CBE 230 Installation, Operation & Maintenance Instructions Manual Download Page 1

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230 Series Auger Packer

1 OF 115

Customer Name

Project#: INPAK SYSTEMS/CERTIS USA

Customer PO#: 0130369-3

Serial#: 140726

Model: 230 Auger Packer/ Certis USA Project

Controller: Avery ZM405

Electrical Controls: 220/440/ other_

Electrical Motors:

Air Requirements:

Special Features: CLASS 2, Division 2, Group 2 Electrical

Summary of Contents for 230

Page 1: ...ct INPAK SYSTEMS CERTIS USA Customer PO 0130369 3 Serial 140726 Model 230 Auger Packer Certis USA Project Controller Avery ZM405 Electrical Controls 220 440 other_ Electrical Motors Air Requirements Special Features CLASS 2 Division 2 Group 2 Electrical ...

Page 2: ...230 Series Auger Packer 2 OF 115 CBE 230 AUGER PACKER Safety Installation Operation Maintenance _________________________________________________________________ ...

Page 3: ...NSTALLATIONPROCEDURES 16 PNEUMATIC CONNECTIONS 16 ELECTRICALCONNECTIONS 16 FINALIZATION OF INSTALLATION 17 CHAPTER 3 18 PRINCIPLE OF OPERATION 19 SEQUENCE OF OPERATION 19 PHASE ONE 19 PHASE TWO 20 CHAPTER 4 21 MAIN FRAME ASSEMBLY 22 FRONT POST ASSEMBLY 22 AUGER SCREW DRIVE TUBE ASSEMBLY 22 AUGER MOTOR 22 BELT DRIVEASSEMBLY 22 FEED SYSTEMASSEMBLY 22 AUGER BARRELHOUSING 23 AUGER SEAL ASSEMBLY 23 INL...

Page 4: ...APTER 6 34 NON INFLUENCING SPOUT 35 COMPONENTS OF ANON INFLUENCING SPOUT 35 CHANGING THEISOLATOR SEALON AN EXISTINGNON INFLUENCING SPOUT ASSEMBLY 36 DETAILED LAYOUT OF COMPONENTS OFTHEASSEMBLY 37 CHAPTER 7 38 PLC TIMER ADJUSTMENTS 39 PLC SCREEN 39 ADJUSTING THE TIMER 39 PLC 40 INPUT OUTPUT SCREEN 40 VIBRATORY DENSIFIER ON DELAY 40 CHAPTER 8 41 GENERALMAINTENANCE 42 MAINTENACE GUIDE 43 MAINTENANCE ...

Page 5: ...nt Website www choicebagging com IMPORTANTNOTICE 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 ...

Page 6: ...uards are in place and observe all warning signs Be sure electrical equipment is free of any accumulation of water Be sure all personnel are clear of operating mechanisms before connecting air line 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 WHENOPERATINGEQUIPMENT Observe extre...

Page 7: ... normal per new NEMA specifications 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 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 press...

Page 8: ...e 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 ...

Page 9: ...e 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 s...

Page 10: ...e 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 ...

Page 11: ...tator Paddle SS 1 Agitator Spike SS 1 AUGER PER APPLICATION 1 NOZZLE PER APPLICATION 4 DUST SLEEVES PER APPLICATION 1 DROP DOOR PROX 1 Switch Door cleanout 201 008 1 HINGE DOOR SAFETY SWITCH 109 096 2 BEARINGS 4 HOLE FLANGE EPS 2080 1 VFD 240 volt voltage specific PER APPLICATION 1 VFD 480 volt voltage specific PER APPLICATION 1 VALVE PILOT BAG SEAL 145301 OPTIONAL 1 AIR PURGE STUFFING BOX Auger 3...

Page 12: ...230 Series Auger Packer 12 OF 115 CHAPTER 1 RECEIPT OF EQUIPMENT ...

Page 13: ...e 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 It is recommended to install a rubber connection sleeve between bin and hopper to isolate bin vibrations from packers Sleeve not provided with machine Recommend 0...

Page 14: ... machine was ordered from the factory with option equipment this will already be done There is room for only one addition optional feature to be added in the field at a later date Connect all air hoses which were disconnected for shipment All hoses and related fittings are correspondingly color coded and size related for ease of re assembly All hoses on the packer are white for start and black for...

Page 15: ...230 Series Auger Packer 15 OF 115 CHAPTER 2 INSTALLATION ...

Page 16: ... 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 or larger All air line connections should be made using a flexible hose to minimize the transmission of vibration Connect the pneumatic lines using the pneumatic schematic and the color coded end co...

Page 17: ... 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 All gear reducers are sealed They are factory sealed to ensure proper operating temperature and prolonged life Check air pressure at all regulators and set per the pneumatic schematic OPTIONAL Fill all the air l...

Page 18: ...230 Series Auger Packer 18 OF 115 CHAPTER 3 OPERATION ...

Page 19: ...presentative arrangement of the packer is shown below It serves to amplify the following description of a typical TWO PHASE operational sequence for filling a bag It should be noted however that a variety of constructions are optional for the Model 200 The sequences as drawn shows the optional timed powered discharge and timed bag sealer PHASEONE Bulk and Dribble Phase One is the condition the mac...

Page 20: ...ion the machine is in at the beginning of a filling cycle or if the Start or Auto Start pushbutton is pressed This is what occurs The start PB is pressed The bag clamps the empty bag to the fill spout The bag seal inflates inside the valve of the bag Optional The motor drive auger and the agitator start to turn A delay and then the settler turns on Optional Material starts to flow into the bag and...

Page 21: ...230 Series Auger Packer 21 OF 115 CHAPTER 4 COMPONENT DESCRIPTION ...

Page 22: ...or drive belts The delivery auger is supported by two self centering flange bearings which can be adjusted to provide proper auger alignment AUGERMOTOR The delivery auger is powered by a 5 H P TEFC motor and the agitator is powered by a 1 HP 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 produc...

Page 23: ... A movable tapered sleeve cone 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 ...

Page 24: ...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 opened however there is a safety switch which shuts the packer down totally BAGCLAMPASSEMBLY 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 ope...

Page 25: ... 80 PSI Plant air systems are not adequately filtered therefore a filter regulator is installed before all components to assure clean air This is necessary for smooth acting longer lasting components 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...

Page 26: ...attachment Non influencing spout Drop bottom hinged door for cleanout Bag chair settler Tilting bag chair settler for automatic discharge Valve bag sealer for better dust control 12 feed gate to prevent flooding thru the auger Air seal stuffing boxes Auger quick change feed system Auto Start switch will start the fill cycle when the bag is placed on the filling spout Drop door for easy cleanout BA...

Page 27: ...230 Series Auger Packer 27 OF 115 CHAPTER 5 Startup Instructions Adjustments ...

Page 28: ... are clear of machine Pneumatic Control System Open manual valve for incoming high pressure air Adjust pressure regulator to 80 PSIG with power off Electrical control system is on Voltage coming in matches the sticker on the outside of the box Should your packer be equipped with a VFD please be aware that VFD s are voltage specific if voltages do not match it will burn the VFD out PNEUMATICADJUSTM...

Page 29: ...ack the valve sleeve and could damage the bag seal Caution Never start the packer without a bag on the fill spout with the bag seal pressure Always have an empty bag on the spout Damage could and will occur to the bag seal if over inflated without an empty bag on the spout POWEREDBAGCHAIRFLOWCONTROLS Flow controls are located right on the cylinder of the bag chair Take a 3 16 blade screwdriver and...

Page 30: ...ctrical power to machine and lock out 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 Loosen motor and remove belts Take two wrenches and loosen four bolts Move bearing to make correct adjustment to the auger in fill spout When the auger is aligned put the bearings back together Re install all belts Re tighten motor Adjus...

Page 31: ... 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 ...

Page 32: ...nected 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...

Page 33: ... motovibrator is not higher than 40ºC 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 par...

Page 34: ...230 Series Auger Packer 34 OF 115 CHAPTER 6 Non Influencing Fill Spout ...

Page 35: ... wall spout would cause restriction on scale movement and cause weight variance WARNING Only qualified technicians should perform maintenance on the non influencing spout Disconnect the power supply to the 200 Auger Flow during disassembly and re assembly of the non influencing fill spout Maintenance should NEVER be performed with electrical power connected to the machine COMPONENTSOFANON INFLUENC...

Page 36: ...etainer wire and start it in the groove Install retainer wire in until you see it coming out the other side Stop pushing the wire in and pull back til wire disappears on the other side Clip the wire as close as you can on this side Take your pliers or a pointy tool and push the end you just clipped off back in under the retainer ring There should be no wire exposed Reinstall outer spout with 4 nut...

Page 37: ... wire groove Install retainer wire in groove as you did for the inner spout clipping off excess wire so there is no wire exposed This completes the installation See drawing detail A of the spout tip DETAILEDLAYOUTOFCOMPONENTSOFTHEASSEMBLY 3 Outer spout 4 Inner ring 5 Isolator seal 6 Outer retainer wire 7 Inner retainer wire ...

Page 38: ...230 Series Auger Packer 38 OF 115 CHAPTER 7 PLC TIMER ADJUSTMENTS ...

Page 39: ... the levels and timers 1 Choice Bagging Equipment CBE 2 Feed gate toggle Normal gate operation or closes when the packer goes into the dribble mode 3 Reverse 4 Bag Clamp Delay 5 Input Output Screen illuminations ADJUSTINGTHETIMER Use the A or B button to Scroll forward or backward through the Timers Once you reached the desired time press the OK key The timer is able to be edited when the selected...

Page 40: ...reverse at the end of the fill cycle Bag clamp Output 4 Factory default setting 1 5 This is the time the bag clamp remains clamped to the fill spout not letting go of the bag This timer can be used also to add time to allow the bag to settle de aerate so the material does not spill out of the bag INPUT OUTPUTSCREEN The PLC screen displays which inputs and outputs are signaling on and off at any po...

Page 41: ...230 Series Auger Packer 41 OF 115 CHAPTER 8 MAINTENANCE ...

Page 42: ... maintenance adjustments replaced parts and malfunctions These records will assist in several ways they will show 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 cha...

Page 43: ...same loosen the front bolt that go thru the bag post and adjust the flexure up or down to obtain the same dimension between them Check for loose or missing bolts Tighten as required BEAING 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 If rubbing is taking place then the auger...

Page 44: ...ial for cleanliness Replace as required AIR SEAL Check the shaft seals for deterioration and or cracking and proper pressure on regulator Pressure on mini regulator should be 2 3 PSI Adjust air pressure flow and if still leaking replace seal INLET HOPPER ASSEMBLY BEARINGS Check the bearing seals for deterioration and or leaking grease Grease or replace as required Check for excessive vibration wit...

Page 45: ... wear Replace as required Check rod end cushions for smooth operation Adjust as required Check for loose or missing mounting hardware Tighten or replace 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 ELECTRICAL PHOTO EYES Clean all photo eyes and reflectors Check alignment of photo...

Page 46: ...ng 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 As the auger is in operation check the stuffing box The jam nuts should be tightened back to hold the st...

Page 47: ...230 Series Auger Packer 47 OF 115 CHAPTER 9 TROUBLESHOOTING ...

Page 48: ...quipment Ltd see the appropriate Manufacturer s Bulletin TROUBLESHOOTINGGUIDE Issue Weight Variations Possible cause Bag chair position not correct 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 t...

Page 49: ...c Influence Check for possible sources of influence to the weighing system such as hoses or cables product build up loose or missing hardware etc Possible cause Auger Influence Check that the auger is not bent broken or bearings loose or wore out Ensure that the auger is centered in the spout and not rubbing Possible cause Spout Influence Check that the spout and cone are concentric and are not to...

Page 50: ...are sized to small and trips out Damage to exterior wiring Inspect conduit and wiring to and from control panel and motor Damage to interior wiring of motor If repairs are required install replacement units Issue Motor slow to start Possible Cause Overload tripped Inspect for obstruction to belt or in the material flow Possible Cause Pulley Look for frozen or sluggish pulley Possible Cause Bearing...

Page 51: ...le Cause Low line voltage Check line voltage Possible Cause Loss of one of three phases Inspect fuses in control panel and replace as required Issue Excessive noise Possible Cause Insufficient belt tension Properly tension belt then tighten down drive Possible Cause Drive sheaves misaligned Reposition the drive sheaves using a straight edge across the sheave faces Properly tension belt then tighte...

Page 52: ...5 Possible Cause Damaged bearing Replace bearing Possible Cause Loose bearing Tighten or Replace as required Bearings Issue Frozen bearing Replace bearing Issue Damaged or worn bearing Replace bearing Issue Dry bearing Replace bearing ...

Page 53: ...230 Series Auger Packer 53 OF 115 ILLUSTRATED PARTS ...

Page 54: ... Welding Sticker Not Shown 101 113 1 Weight Variation Sticker Not Shown 101 115 1 Yellow Caution Sticker Not Shown 101 118 1 Dust Collector Manifold Not Shown 101 125 1 Serial Plate 4 101 308 1 Load Cell Cover 5 101 309 1 Universal Main Frame 2000 6 101 311 1 Universal Bag Post 7 104 009 1 Load Cell 500 lb S Type 8 104 077 2 Male 1 2 20 Rod Eye 9 104 078 1 Rod Eye Mounting Block For S Load Cell 10...

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Page 57: ...40 1 465 Controller NOT SHOWN 104 041 1 Control Board for 465 NOT SHOWN 109 012 2 End Anchors 3 109 013 3 Terminal 4 109 014 1 Grounding Terminal NOT SHOWN 109 019 1 End Barrier 5 109 301 1 PLC NOT SHOWN 109 118 2 1 2 Cord Grip 6 109 125 2 Narrow Relay Base 7 109 126 2 Narrow Relay NOT SHOWN 109 209 1 Off On Switch NOT SHOWN 109 215 1 Off On Legend 3 4 6 7 5 ...

Page 58: ...SAL TILTING NON POWERED BAG CHAIR ASSEMBLY CBE 106 200 Item PART NUMBER QTY DESCRIPTION 1 145093 1 BAG CHAIR PIVOT PIN 2 145095 2 UNIVERSAL BAG CHAIR CHEEKS 3 145411 1 BAG CHAIR SUPPORT 4 106 001 1 BAG CHAIR BRACKET 5 88066 1 SPRING 1 4 5 3 2 ...

Page 59: ...ay NOT SHOWN 109 030 3 Relay Mounting Socket 7 109 047 1 25 Amp Circuit Breaker NOT SHOWN 109 049 1 2 Pole Center Jumper 8 109 111 1 Overload 1 0 5 0 amps NOT SHOWN 109 297 1 Enclosure 24x20x8 NOT SHOWN 109 298 1 Back Plate for 24x20 9 109 324 1 VFD 7 5 10HP VFD 18A 460V 3PH IN OUT NOT SHOWN 109 328 1 Disconnect Handle 10 109 329 1 Disconnect Shaft 11 109 392 2 Disconnect 32A NOT SHOWN 109 429 3 F...

Page 60: ...ring for CBE 200 301 040 2 6 Stuffing Box Cover 201 021 3 1 200 Spiral Flow Auger Housing M S 201 301 4 1 Bolt on Stuffing Box 201 020 5 1 Agitator Shaft for CBE 200 M S 204 005 6 1 Motor 2HP 60 1 w gear drive KP102215 1 7 1 Blade Style Agitator M S 204 013 8 1 Inspection Door Switch 201 008 9 1 Clean Out Door 201 028 10 1 Weld on Stuffing Box 201 022 ...

Page 61: ...mbly CBE 203 600 Item Part Qty Part Description Not Shown 118 001 1 5 HP Motor 1 201 105 1 Auger Bushing 1 5 SDS 2 903 002 1 1 3 8 Motor Bushing SDS 3 903 001 2 Motor Sheave 4 6 SDS 4 B 38 2 Auger Drive Belt Not Shown 109 088 1 1 2 Sealtite Connector 3 4 2 1 3 3 ...

Page 62: ...ffing Box Assembly CBE 207 100 PARTS LIST ITEM QTY DESCRIPTION PART NUMBER 1 1 Bolt on Stuffing Box 200 900 201 020 2 1 Stuffing Box End Caps 200 900 201 021 3 1 Slinger Ring EPS 255 4 2 Bearing 1 1 2 4 Hole Flange Bearing EPS 2080 1 Waste Packing H 120 ...

Page 63: ...1 Seal Ring for 3 OD Non Influencing 206 505 3 1 3 OD Outer Spout for Non Influencing 206 503 4 1 3 OD Inner Spout for Non Influencing Tapered Spout 206 802 5 1 Auger KP102215 2 Not shown 1 Non Influencing Fill Spout Retaining Wire EPS 2047 Not shown 1 Neoprene Seal 011619315 Not shown 1 Auger Mounting Shaft 212 201 Not shown 1 Quill Auger Spindle Washer 212 202 Not shown 1 Locking Bolt Spindle Wa...

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Page 67: ...230 Series Auger Packer 67 OF 115 CHAPTER 10 WEIGH CONTROLLER ADJUSTMENTS ...

Page 68: ... OF 115 Calibration 1 From the weight mode press and hold the key until 2 The screen will display 3 Enter the passcode 2580 4 Press key to enter the passcode 5 The screen will display busy and then will go into calibration mode ...

Page 69: ...eries Auger Packer 69 OF 115 6 Press to go to calibration menu 7 Press to go to Scale 1 menu 8 Press to calibrate the Zero 9 Press once again and the live weight will display 10 Clear the scale and press key ...

Page 70: ... display press again to accept the value 12 Press key and Zero will display 13 Press and Span will display 14 Press to select the Span menu 15 Key in the value of the test weight and press key 16 The live weight will display place the test weight in the scale ...

Page 71: ...Auger Packer 71 OF 115 17 Press key 18 Press to accept the value 19 Press key three times to go to Save menu 20 Press to select Yes 21 Press key and the controller will reboot and the calibration will be complete ...

Page 72: ...w show o This is changed just like the Target o The Dribble set point is the amount of weight that will be put into the bag at the slower fill speed I E If you set it to 10 lbs the bagger will run in the slow speed for the last 10 lbs of the fill The screen will now show o This is changed just like the Target o It is used to compensate for overweight bags I E If your weight is consistently 2 lbs o...

Page 73: ...you will push the OK key to select that function When the time is selected the numbers will flash on and off When it is not selected blocks will flash over the time Then use the and keys to adjust the timer up and down in 0 1 second increments The Order of the timers 1 Choice Bagging 2 Feed Gate Timer 3 Bag Chair Timer 4 Tube Clean Out Timer Reverse Timer on Auger Packers 5 Input Output Screen ...

Page 74: ... tube into the bag after the fill is over It is adjusted in 0 1 second increments Factory Setting is 1 0 seconds Reverse For 200 Model Packers only Is the time the auger is in reverse at the end of the cycle It is adjusted in 0 1 second increments Factory Setting is 0 5 seconds Adjusting the Timers To adjust the timers you first scroll to the screen of the timer you want to adjust using the A or B...

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