CHANTLAND 4190 - Choice Bagging Equipment · Chantland 4190 Auger Packer Rev. A 2010 2 OF 54 FOREWARD This manual has been prepared to assist you with your Choice Bagging Equipment,

Chantland 4190 Auger Packer Rev. A 2010 1 OF 54

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CHANTLAND 4190

Safety - Installation - Operation – Maintenance


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!

mailto:[email protected]

http://www.findtherightbagger.com/


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 ………………………………………………………….…..............…. 14 2. Pneumatic Connections …………………………………………………………………....….. 14 3. Electrical Connections …………………………………………………………………..…...… 14 4. Finalization of Installation …………………………………………………….….............…….. 14

CHAPTER 3 – COMPONENT DESCRIPTION

1. Main Frame Assembly ...……………………………………………….……………….….….. 18 2. Front Post Assembly …………………………………………………………….……….......... 18 3. Auger Screw Drive Tube Assembly ……………………………………...........................…… 18 4. Auger Motor ……………………………………………………………………………….……. 18 5. Belt Drive Assembly ……………………………………………………………………………. 18 6. Feed System Assembly ………………………………………………………………..….…… 18 7. Auger Barrel Housing …………………………………………………………….…..………... 19 8. Auger Seal Assembly …………………………………………………...……………………… 19 9. Inlet Hopper Assembly ……………………………………………………………….………… 20 10. Hopper Seal Assembly ………………………………………………….…………………….. 20 11. Belt Guard Assembly …………………………………………………………….……………. 20 12. Bag Clamp Assembly ……………………………………………...………………………….. 20 13. Bag Chair Assembly ……………………………………………………………….………….. 20 14. Dust Collections Assembly …………………………………………....................…………... 20 15. Pneumatic Controls ………………………………………………………………..….………. 20 16. Electrical Controls ………………………………………………………………….………….. 21

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 ............................................................... 28 2. Auger Adjustment …………………………................................................................................ 28 3. Bag Chair Positioning ................................................................................................................ 29 4. Motovibrator Bag Settling Chair ................................................................................................ 29

A. Operation & Maintenance of Motovibrator ................................................................. 30 B. Adjusting the Intensity of Vibrations ............................................................................ 30

C. Noise Level ……….. .................................................................................................... 30 D. Maintenance ................................................................................................................. 31 E. Lubrication ……………………………………………….……………..…..….……….. 31 F. Non-Influencing Spout …………………………………..……………..……..……….. 31


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 …………………………………………………………………………….…………… 40 2. Troubleshooting Guide ………………………………………………….…………………….. 40

2.1 Weight Variations ……………………………………………………………………. 40 A. Bag Chair Height ……………………………………………………………….. 40 B. Bag Size Check ………………………………………………………….……… 40 C. Vibration ……………………………………………………………….………… 41 D. Misc. Influence ……………………………………………………….…...…….. 41 E. Auger Influence ………………………………………………………….……… 41 F. Spout Influence ……………………………………………………………......... 41

2.2 Motors A. Motor will not start ……………………………………………………....….. ….. 41 B. Motor slow to start …………………………………………………….…........... 41 C. Repeated Stalling …………………………………………………….…............ 41 D. Motor Runs Hot ……………………………………………………….….……... 41 E. Excessive Noise ………………………………………………………..………. 41

2.3 Bearings A. Frozen Bearing …………………………………………………………..……… 42 B. Excessive Noise ……………………………………………………….……….. 42

APPENDIX A: ASSEMBLY DRAWINGS / PART NUMBERS...................................................... ……… 43 APPENDIX B: LAYOUT DIAGRAMS AND WIRING SCHEMATICS......................................................


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


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


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.



CHAPTER 1

RECEIPT

AND ASSEMBLY_____


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. (512-

352-3694) 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


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.



CHAPTER 2

INSTALLATION

_______


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 sub-

assembly 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


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.



CHAPTER 3

COMPONENT DESCRIPTION

_______________


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


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 pre-

condition 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 free-

flowing 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


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


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.



CHAPTER 4

OPERATION

_____


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 starting product flow from the housing, through the fill spout, and into the bag.

4. The material is weighed in the bag until the desired net weight is reached.

5. When the bag comes to weight, the "Stop" circuit energizes and the condition in Phase One is in effect.


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.



CHAPTER 5

START-UP INSTRUCTIONS

AND

ADJUSTMENTS _______


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


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: 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. Sewn Bags: 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


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


WARNING: Maintenance must be performed ONLY by qualified technicians, with the power supply disconnected.

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 non-influencing 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.



CHAPTER 6

MAINTENANCE

____________


WARNING: Maintenance must be performed ONLY by qualified technicians, with the power

supply disconnected.

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


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


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


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.



CHAPTER 7

TROUBLESHOOTING

_


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


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 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.

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


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


Appendix A: Assembly Drawings









Appendix B Layout Diagrams

& Wiring Schematics



Documents

CHANTLAND 4190 - Choice Bagging Equipment · Chantland 4190 Auger Packer Rev. A 2010 2 OF 54 FOREWARD This manual has been prepared to assist you with your Choice Bagging Equipment,