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Component Maintenance Item

Part Number

Inspection

Maintenance Required

Year
1

Year
2

Year
3

Year
4

Year
5

Year
6

Year
7

Year
8

Year
9

Year
10

Ducting

GASKETS

11-0184/11-0186

Weekly

Ducting

DUCT CLAMPS AND
HOSE CLAMP

14-0036/14-
0070/23010124A/23-
10125A/23-10129A

Weekly

Summary of Contents for T-ZERO

Page 1: ...T ZERO Maintenance and Cleaning Manual 21 10098A_REV00 Version 1 0 March 2020...

Page 2: ...n on the Conveyor 25 Adjusting Conveyor Sidewall Height 25 Disassembling the T ZERO 27 Reassembling the T ZERO 34 Cleaning the T ZERO 36 Cleaning Conveyors 38 Cleaning the Cyclone and Ducting 39 Inspe...

Page 3: ...s Low 67 Product is Sticking to the Inside of the Tumbler 68 Tumbler is Bouncing Around While Rotating 69 Appendix 70 Product Specifications 70 Material Specifications 71 Air Requirements Pulse Jet 72...

Page 4: ...llation Improper electrical connection Improper maintenance Neglect Normal wear Unapproved modifications Keirton assumes no risk and shall be subject to no liability for damages or loss resulting from...

Page 5: ...g the T ZERO DO NOT OPERATE UNDER THE INFLUENCE OF ALCOHOL OR DRUGS Follow routine maintenance schedule DO NOT REMOVE SAFETY LABELS REPLACE SAFETY LABELS IF THEY BECOME DAMAGED OR OBSCURED Lock out po...

Page 6: ...er 15 of NFPA 69 Standard on Explosion Prevention Systems EQUIPMENT SHOULD BE PROPERLY ANCHORED TO THE GROUND WITH A SUITABLY SIZED CONCRETE ANCHOR AND ADHERE TO LOCAL CODES AND REGULATIONS BEFORE CLE...

Page 7: ...6 SYSTEM OVERVIEW DISCLAIMER Keirton reserves the right to make design changes and or improvements in the products they manufacture at any time Specifications are subject to change without notice...

Page 8: ...7 TRIMMER OVERVIEW...

Page 9: ...8...

Page 10: ...9 HORIZONTAL CYCLONE OVERVIEW...

Page 11: ...10 HEPA FILTER STACK HFS OVERVIEW...

Page 12: ...11 CONVEYOR OVERVIEW...

Page 13: ...alled Engineering Mode To enable Engineering Mode 1 From Automatic Mode tap the Advanced Mode button highlighted below 2 From Advanced Mode tap the Engineering Mode button highlighted below 3 Enter us...

Page 14: ...G MODE FUNCTIONS Water Sprayer Settings The water sprayer feature automatically applies water to the brush to help lubricate the tumbler and keep the machine clean while trimming wet The buttons benea...

Page 15: ...ation see technical support details at back of manual Automatic Reset The Auto Drive Error Acknowledgement button resets the motor drive This feature will not solve all motor errors To remove other er...

Page 16: ...starting in the following order 1 Vacuum motor 2 Blades 10 seconds after the Vacuum Motor 3 Tumbler 18 seconds after the Vacuum Motor 4 Feed Conveyor 22 seconds after the Vacuum Motor 5 QC Conveyor 2...

Page 17: ...erate to 48 5 RPM decelerate to 44 5 RPM and then return to 46 5 RPM in a period of 10 seconds Air Lock Settings The Airlock blasts compressed air inside the rotors to help clean the rotor pockets out...

Page 18: ...otors off when pressed After being pressed the STANDBY button will read OFFLINE and the corresponding motor will disappear from the Advanced Mode screen Motor Presets The readings in line to the right...

Page 19: ...CTED BY TECHNICAL SUPPORT Exit Program This button returns the operator to the PLC start up screen System Info This button takes the operator to the System Information page shown on following page The...

Page 20: ...19...

Page 21: ...ING THIS FEATURE MUST BE UNLOCKED EACH TIME IT IS USED AND SAFETY PRECAUTIONS MUST BE TAKEN BEFORE OPERATING THE LIFT Note The powered lifting feature is interlocked with all the motors requiring all...

Page 22: ...sure no one or anything is near it 4 Make sure both conveyors are at least 6 away from the machine and all cables are clear of the lifting feet 5 Tap the Tilt Lock button to activate the Raise and Low...

Page 23: ...ates what angle the machine is currently at When loading a recipe adjust the machine until the ACTUAL reading matches the SETPOINT reading to set the trimmer at the correct angle 10 Re align the conve...

Page 24: ...t 2 Once conveyor is at desired height retighten knobs IMPORTANT SAFETY INFORMATION o The conveyor motor is heavy Always use at least two people for the following tasks o Always move the conveyors awa...

Page 25: ...e ADJUSTING FEED CONVEYOR CHUTE The chute will need to be adjusted if the conveyor belt or sidewalls are adjusted To adjust the conveyor chute 1 Loosen the nuts on the sidewall just enough so the chut...

Page 26: ...may need to be readjusted to fit snug around the conveyor belt 2 Turn the conveyor to ensure the belt stays in the center of the conveyor a If the belt moves to one side the rollers are not parallel...

Page 27: ...26 3 Check the chutes to ensure they are not interfering with the conveyor belt or tumbler after adjustment...

Page 28: ...pull the infeed and QC conveyors away from the T ZERO You may need to re level the conveyors before pulling them away ENSURE CHUTES STAY CLEAR OF THE TUMBLER AND MACHINE WHEN REMOVING CONVEYORS 4 Lif...

Page 29: ...28 5 Loosen the tumbler lid knobs and lift the tumbler lids...

Page 30: ...lts and place them between the tumblers see diagram at top of next page 7 Remove the tumbler see diagram at top of next page IMPORTANT SAFETY INFORMATION TUMBLERS ARE HEAVY ALWAYS LIFT WITH TWO PEOPLE...

Page 31: ...30 8 Repeat steps 5 to 7 to remove the second tumbler 9 If vacuum bars are installed pull them to remove...

Page 32: ...ur vacuum shrouds a Release the two vacuum shroud knobs on the bottom DO NOT REMOVE FULLY b Release the toggle clamps on the shrouds c Slide the shroud out d Repeat on the front shroud and then opposi...

Page 33: ...n the plastic centre piece b Slide the ring to one side and pull out the plastic coupling c Release the bed knife pins with a 5 8 wrench two bolts per blade IMPORTANT SAFETY INFORMATION DO NOT TAMPER...

Page 34: ...33 d Carefully flip up the blades 4 IMPORTANT SAFETY INFORMATION BEWARE OF CUTTING HAZARDS WITH THE BED KNIVES AND HELIX BLADES WEAR GLOVES BED KNIVES AND BLADES CAN BE VERY SHARP...

Page 35: ...shroud c Once front and rear plenums are installed and seated properly lock the two vacuum shroud knobs on the bottom AN IMPROPERLY INSTALLED VACUUM SHROUD WILL CAUSE AIR LEAKS WHICH WILL AFFECT THE M...

Page 36: ...and close the main lid 7 Reposition the Feed and QC conveyors ENSURE THE CONVEYOR BELTS AND CHUTES ARE NOT RUBBING ON THE TUMBLER 8 Close the rear doors 9 Reconnect the ducting to the T ZERO 10 Reinst...

Page 37: ...essure washing the on board electrical box and motors It is ok for these components to get wet but HIGH PRESSURE WATER CAN DAMAGE THE SEALS c Pressure wash from the top of the machine down being mindf...

Page 38: ...HANDING THE SHROUDS AND THE TUMBLER TO PREVENT DAMAGE 6 Reassemble the T ZERO see Reassembling the T Zero on page 34 Note Take care when removing transporting cleaning and reinstalling the tumbler Alw...

Page 39: ...provides easy access to clean underneath the belt 3 Clean the entire conveyor using the Twister Cleaning Method for more details see Cleaning the T ZERO on page 36 4 Wipe down belts or clean with low...

Page 40: ...39 CLEANING THE CYCLONE AND DUCTING To clean the cyclone and inlet ducting 1 Remove bin and bin lid hose see diagrams below...

Page 41: ...tering the HEPA Filter Stack 4 Inspect cyclone to trimmer ducting to ensure there isn t excessive debris on the sidewalls or caught in elbows IF EXCESSIVE DEBRIS IS FOUND REMOVE DUCTING AND CLEAN USIN...

Page 42: ...d to be cleaned periodically using a shop vacuum DO NOT USE ANY SOLID TOOLS TO SCRAPE THE FILTERS DOING SO COULD POKE HOLES OR CAUSE DAMAGE REDUCING FILTER LIFE 10 Use compressed air to remove any poo...

Page 43: ...you hear a ting sound i Try to locate the contact point and bend the tumbler clear of the interference ii If required adjust the lower rollers up to eliminate any contact see Adjusting the Rollers on...

Page 44: ...t the edges to make sure the top edge of the rear vacuum shroud is flush on the blade cartridge ANY GAPS AROUND THE SHROUDS WILL DECREASE VACUUM SUCTION AND REDUCE PERFORMANCE 9 Check blade belt is te...

Page 45: ...gs 1 Remove bearing caps 2 Manually clean out as much grease as possible 3 WEARING NITRILE GLOVES pack new grease into the bearing with thumb 4 Fill bearing cap cavity 50 60 full DO NOT FILL BEARING C...

Page 46: ...r prolonged use the filters will need to be replaced The HFS includes two pressure gauges located next to the primary filter access door that measure differential pressure across the filter media The...

Page 47: ...re 4 Open the Primary Filter Access Door and check for any holes or damage to the filters IF THERE IS EXCESS DUST BUILD UP CLEAN WITH A SOFT BRUSH AND SHOP VACUUM WHEN REMOVING THE FILTERS ALWAYS CHEC...

Page 48: ...ning the grey fitting at the bottom towards O 8 Remove the inlet ducting and check for material buildup on the duct walls If there is excess build up clean the ducts to improve airflow 9 Upon reinstal...

Page 49: ...cyclone and trimmer a Check all gaskets for cracking and wear b Ensure the orange silicone is properly seated in the groove of the clamp c Ensure ducting is free of dents or cracks especially at the c...

Page 50: ...THE BELT STOPS SLIPPING 3 Check sidewall height ensuring there is at least a 1 8 gap between the belt and the wall a Turn the conveyor on and apply a vertical force on the sidewall to ensure there is...

Page 51: ...image at the top of the next page has rollers numbered 1 10 which are mirrored on the other side The numbers on each roller correspond to the order of adjustment in this procedure Purpose of Each Rol...

Page 52: ...xperiencing interference between the tumbler and blades skip to step 1 of To reset Lower and Upper Radial Rollers 1 Raise all the axial rollers to align the tumbler with the motor and pulleys A 12 poi...

Page 53: ...gled face of the tumbler Ensure the sub lid clamps are fully tightened during this step Note These instructions assume the right side of the image is the feed side of the machine If feeding from the l...

Page 54: ...e tumbler is aligned rotate the tumblers by hand to find the high spot on the feed side 6 Once the minimum gap is found place a 060 shim between roller C and the tumbler then tighten it Repeat for rol...

Page 55: ...1 4 hex wrench in the center of the roller Note a torque wrench product 14 10126 and offset socket adapter product 24 10165A can be purchased from Keirton 2 Take the top roller alignment tool and plac...

Page 56: ...ler is contacting the blades place a shim between the tool and blade to set the roller higher right image above 7 After re adjusting the rollers re install the tumblers and check for interference or e...

Page 57: ...by hand to find the point where the tumbler is closest to the roller 3 Use a 010 015 shim to tighten roller where the minimum gap is found 4 Repeat steps 2 and 3 on all remaining rollers The upper rad...

Page 58: ...should only touch briefly at the high spots 6 Confirm the Upper Radial Rollers are set at the high spot by rotating both tumblers by hand Each roller should only touch briefly at the high spot then be...

Page 59: ...on is required 1 Remove the Tumblers and Blade Couplings for instructions see Disassembling the T ZERO on page 27 2 Spin each blade by hand cutting paper along the length to determine which side needs...

Page 60: ...e CLOSER to the helix blade start by backing off the screws on the rear of the machine Then tighten front screw to push the blade down MAKE SURE TO COUNT THE ROTATIONS WHEN BACKING OFF THE SCREW Less...

Page 61: ...adjustment If the blades can spin by hand the blades are correctly adjusted ADJUSTING THE BLADE BELT TENSION To adjust the blade tension 1 Remove the tumbler and blade belt cover to gain access to the...

Page 62: ...ADJUSTING THE TUMBLER BELT TENSION Before adjusting the tumbler belt ensure the pulley grooves on the tumblers are in line with the lower pulleys Do this adjustment with the tumblers and belts install...

Page 63: ...e angle sensor has drifted since the last calibration Adjust any recently saved recipes by this value and resave 2 Use the leveling feet to level the machine Note a high precision level is ideal for t...

Page 64: ...to get into program mode 2 Use the up and down arrows to adjust the setpoints 3 Press the SET button repeatedly to toggle through each parameter The order of parameters is as follows a High Alarm Set...

Page 65: ...ght to open the box 2 Push and hold the dial in the center until Pr9 is displayed on the screen 3 Rotate the knob to toggle between parameters 4 Then press in the knob to select a parameter to adjust...

Page 66: ...acity of the air compressor for more details see Air Requirements Pulse Jet on page 72 ALL OTHER PARAMETERS WILL BE SET BY KEIRTON CONTACT TECHNICAL SUPPORT IF THERE IS A NEED TO ADJUST ANY OTHER PARA...

Page 67: ...the HEPA Filter Stack fan on to the operating setting and verify that the differential pressure is still within the acceptable range 5 W C for the primary filter and 2 for the HEPA filter IF THE DIFF...

Page 68: ...tact If the contact is isolated to a single or a couple locations it is likely caused by damage to the tumbler If it is consistent around the perimeter is it likely caused by misaligned rollers or bla...

Page 69: ...are tight with seals in place and there are no blockages anywhere in the ducting 9 Ensure that the filters are within acceptable operating range 10 Ensure that the HEPA Filter Stack doors are all clo...

Page 70: ...UND WHILE ROTATING If tumbler is bouncing around while rotating 1 Ensure the sub lid is secured 2 Ensure the rollers are at the correct height and not damaged 3 IF DAMAGED HAVE SERVICE TEAM READJUST T...

Page 71: ...460VAC 3 Phase Cutting system Belt drive quad blade system Tumbler ID 13 5 Effective cut length 64 Vacuum airflow 5000 CFM Trim separation Horizontal Cyclone Separator Primary filtration 99 99 partic...

Page 72: ...anti seize Meets FDA 21 Tumbler lid bushings Food grade oil embedded flanged sleeve bearing Brush CNN 6 12 nylon and 304 stainless steel Sheet metal parts 304 Stainless steel Tumbler rollers Food grad...

Page 73: ...EMENTS PULSE JET HEPA Filter Stack Air Consumption 90 105psi recommended On time 0 15 seconds Off time seconds Air Consumption CFM 5 27 6 10 13 8 15 9 2 20 6 9 25 5 5 30 4 6 35 4 40 3 5 45 3 1 50 2 8...

Page 74: ...ure Qty Reason for Recommendation 02 10000A T ZERO STANDARD SLOT TUMBLER ASSEMBLY PACKAGED EA 2 Processing 11 0184 GASKET TRIM BIN TO FLANGE SILICONE FDA APPROVED EA 1 Service 11 0186 GASKET CYCLONE T...

Page 75: ...NO NC T ZERO EA 2 Service 19 0022 FLANGE BEARING 2 BOLT STAINLESS STEEL T ZERO EA 2 Service 19 0034 BELT V BELT HIGH CAPACITY 95 CIRCUMFERENCE TUMBLER T ZERO EA 2 Service 19 0035 BELT V BELT HIGH CAPA...

Page 76: ...rvice 11 10005A BEDKNIFE T ZERO EA 2 Service 13 0454 SCREW SET HOLLOW LOCK T ZERO EA 1 Service 13 0467 SCREW SET FLAT TIP T ZERO EA 2 Service 13 0477 SCREW SET CUP T ZERO EA 1 Service 14 0037 STAINLES...

Page 77: ...immer FLANGE BEARING PLUNGERS 19 0022 13 0212 Weekly R R R R R Trimmer BEDKNIVES 11 10005A Weekly R R R R R Trimmer HELIX BLADES 24 0652 24 0671 Weekly R R R R R Trimmer AXIAL TUMBLER ROLLERS 24 10014...

Page 78: ...REPLACE AS REQUIRED Trimmer VACUUM BAR 11 0195 Weekly REPLACE AS REQUIRED Trimmer ELECTRICAL BOX CONNECTIONS Weekly Trimmer BLADE COUPLINGS 13 0222 Weekly R R Trimmer TUMBLER BELT SHEAVES 11 0111A We...

Page 79: ...14 10155 Weekly Cyclone TRIM BIN GASKET 14 0037 Weekly Cyclone INLET OUTLET HATCH Weekly Cyclone CYCLONE DOOR GASKET Weekly Conveyors FEED BELT 26 10004A Weekly R R Conveyors QC BELT 26 10005A Weekly...

Page 80: ...ntenance Required Year 1 Year 2 Year 3 Year 4 Year 5 Year 6 Year 7 Year 8 Year 9 Year 10 Ducting GASKETS 11 0184 11 0186 Weekly R R R R R R R R R R Ducting DUCT CLAMPS AND HOSE CLAMP 14 0036 14 0070 2...

Page 81: ...82 CONTACT US Keirton Technical Support is available at 1 888 254 3204 between 7 a m and 7 p m Pacific Time seven days a week...

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