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Installation Manual -EL2


Doc. No.: 2028232 Machine Model: A-2160301, EL2 Installation Manual Original Instructions

Installation Manual

IM

EL2

Doc. No.: 2028232 Machine Mo

del: A-2160301, EL2 Installation Manual Original Instructions

Installation Manual

IM

EL2

Copyright ? 2011 Ecolean R&D A/S. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means without the prior written permission of Ecolean R&D A/S. Please note that the content of this publication is intended for informational use only, is subject to change without notice, and should not be considered as a commitment by Ecolean R&D A/S. ECOLEAN? is a trademark of Ecolean R&D A/S. ECOLEAN? Air, EL2, the Ecolean logotype, and the phrase “A lighter approach to packaging” are brand names of Ecolean R&D A/S. For copyright issues, please contact Ecolean R&D A/S, Holbergsgade 14, 2 sal, t v, DK-1057 Copenhagen K, Denmark. Phone +45 33 91 40 95. Fax +45 33 91 40 95. E-mail: info@ecolean.dk. For technical issues, concerning this manual or other Ecolean machinery, please contact Ecolean AB. See below for contact details.

Issue: April 4, 2011

Ecolean AB Kielergatan 48 ? SE-252 32 Helsingborg ? Sweden Phone +46 42 450 45 00 ? Fax +46 42 260 745 E-mail: info@ecolean.se www.ecolean.com

Table of Contents

1 Introduction
1.1 About this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 Filling Machine Purpose . . . . . . . . . . . . . . . . . . . . . . . . 1.3 About the P-Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3.1 Purpose of the P-Kit . . . . . . . . . . . . . . . . . . . . . . . 1.3.2 Wear Parts and Operation-Critical Parts . . . . . . . . . . . 1.3.3 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 The ECOLEAN? Packages . . . . . . . . . . . . . . . . . . . . . . . 1.5 Machine Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5.1 Machine Overview (Filling Machine) . . . . . . . . . . . . . . 1.5.2 Machine Overview (Filling Machine with Straw Applicator) 1.5.3 Machine Identi?cation . . . . . . . . . . . . . . . . . . . . . . 1.5.4 Main Power Switch . . . . . . . . . . . . . . . . . . . . . . . . 1.5.5 Main Air Pressure Valve . . . . . . . . . . . . . . . . . . . . . 1.5.6 Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5.7 Unwinding Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5.8 Transport Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5.9 Cutting Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5.10 Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5.11 Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5.12 Filling Station. . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5.13 Sealing Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5.14 Output Conveyor . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . .

1-2 1-3 1-4 1-4 1-4 1-4 1-5 1-6 1-6 1-9 1-12 1-12 1-13 1-14 1-15 1-16 1-17 1-18 1-19 1-20 1-21 1-22

2 Safety Precautions
2.1 Safety Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2 Safety Symbols and Terms . . . . . . . . . . . . . . . . . . . . . . 2.3 Personnel Requirements . . . . . . . . . . . . . . . . . . . . . . . . 2.3.1 Personnel Skills . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.2 Personal Protection . . . . . . . . . . . . . . . . . . . . . . . 2.4 Electrical Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 Main Power Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 Main Air Pressure Valve . . . . . . . . . . . . . . . . . . . . . . . . 2.7 Emergency Stop and Safety Systems . . . . . . . . . . . . . . . . 2.7.1 Emergency Stop Buttons . . . . . . . . . . . . . . . . . . . . 2.7.2 Resetting an Emergency Stop Button and Restarting the Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.3 Door Safety System . . . . . . . . . . . . . . . . . . . . . . . 2.7.4 Testing the Safety Systems . . . . . . . . . . . . . . . . . . . 2.8 Noise Emission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 Machine Spare Parts and Consumables . . . . . . . . . . . . . . 2.9.1 Machine Spare Parts . . . . . . . . . . . . . . . . . . . . . . . 2.9.2 Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9.2.1 Detergents . . . . . . . . . . . . . . . . . . . . . . . . 2.9.2.2 Lubricants . . . . . . . . . . . . . . . . . . . . . . . . 2.9.2.3 Date Unit Ink . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . .

2-2 2-3 2-6 2-6 2-7 2-8 2-9 2-11 2-12 2-12 2-15 2-15 2-15 2-16 2-17 2-17 2-17 2-17 2-18 2-18

. . . . . . . . . .

i

Table of Contents 2.9.2.4 Solvent/Make-Up Fluid. 2.10 Emergency Situations . . . . . . . . . 2.10.1 Harmful Substances . . . . . . 2.10.2 Fire Protection . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-18 2-19 2-19 2-19

3 Crate Handling
3.1 Crate Data . . . . . . . . . . . . . . . 3.1.1 Filling Machine . . . . . . . . 3.2 Storing the Crate . . . . . . . . . . . 3.2.1 Filling Machine . . . . . . . . 3.3 Unloading and Moving the Crate .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2 3-2 3-3 3-3 3-4

4 Installing the Filling Machine
4.1 Opening the Crate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 Unpacking the Filling Machine . . . . . . . . . . . . . . . . . . . . . 4.3 Moving the Filling Machine . . . . . . . . . . . . . . . . . . . . . . . 4.3.1 Long Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.2 Short Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4 Levelling the Filling Machine Chassis . . . . . . . . . . . . . . . . 4.5 Installing the Support Arm and Alarm Beacon . . . . . . . . . . . 4.6 Installing the Accumulator and Connecting the Product Supply 4.7 Installing the Reel Table . . . . . . . . . . . . . . . . . . . . . . . . . 4.8 Connecting the CIP Return Pipe . . . . . . . . . . . . . . . . . . . . 4-2 4-3 4-5 4-5 4-5 4-6 4-7 4-9 4-12 4-13

5 General Installation
5.1 5.2 5.3 5.4 5.5 5.6 Connecting the Compressed Air and Water Supply . Connecting the Power Supply . . . . . . . . . . . . . . Drain Connections . . . . . . . . . . . . . . . . . . . . . . Foam Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . Conveyor Belt Connection Options . . . . . . . . . . . Pneumatic Settings . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2 5-3 5-5 5-6 5-7 5-8

6 Decommissioning
6.1 Decommissioning the Machine . 6.2 Dismantling the Machine . . . . . 6.3 Disposing the Machine . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2 6-3 6-4

7 Technical Speci?cations
7.1 General Speci?cations . . . . 7.1.1 Machine Requirements 7.1.2 Pneumatic Settings . . . 7.1.3 Machine Performance .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-2 7-2 7-3 7-4

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Table of Contents 7.1.4 Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . 7.2 Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . 7.3 Consumables Speci?cations . . . . . . . . . . . . . . . . . . . . 7.3.1 Lubricant Speci?cations . . . . . . . . . . . . . . . . . . . . 7.3.2 Detergent Speci?cations . . . . . . . . . . . . . . . . . . . . 7.3.3 Date Unit Ink and Solvent/Make-Up Fluid Speci?cations .
. . . . . . . . . . . .

7-4 7-5 7-6 7-6 7-6 7-7

iii

Table of Contents

iv

CHAPTER

INTRODUCTION

Introduction

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1.1 About this Manual
This Installation Manual describes necessary measures to be undertaken at the customer site prior to the reception of the machine, as well as machine installation procedures. Please read this manual carefully, and make sure that you understand the information provided before attempting to install and/or operate the machine.

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1.2 Filling Machine Purpose
The purpose of this Ecolean ?lling machine is to package ?uid foodstuffs, e.g. milk, fruit juices etc. The packages used are the ECOLEAN? packages, which along with the Ecolean machinery compose the ECOLEAN? Packaging System. The ?lling machine is fully automatic and the operator need only to replace the package reel when depleted. In practice, one operator is able to operate several machines. The ?lling machine is intended for packaging of ?uid foodstuffs only and may not be used for any other purposes.

Introduction

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1.3 About the P-Kit
1.3.1 Purpose of the P-Kit
Upon delivery, the ?lling machine is supplied with a P-kit, containing wear parts and operation-critical parts. The purpose of the P-kit is to provide the customer with an initial supply of spare parts. This is to ensure that ? ? Start-up of machine operations will run as trouble-free as possible The customer is given time to establish routines for spare parts supply

The parts in the P-kit are not intended to last for any given time period or amount of produced packages.

1.3.2 Wear Parts and Operation-Critical Parts
Typical wear parts included in the P-kit are listed below: ? ? ? ? ? ? Cutting edges All soft parts made of e.g. rubber, silicon, etc. Gaskets Hoses Transmission belts Heating jaws and heating cartridges

Operation-critical parts are parts that will not break under normal conditions but might do so due to unexpected incidents.

1.3.3 Warranty
Wear parts cannot be claimed during the warranty period unless the parts have manufacturing errors, or they are damaged by other malfunction in/caused by the machine. Operation-critical parts may be claimed during the warranty period. Parts used from the P-kit will be replaced at no cost if the claim is accepted. Contact your local Ecolean representative for assistance in this matter.

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1.4 The ECOLEAN? Packages
The ECOLEAN? Packaging System combines the ECOLEAN? packages of different sizes and shapes with economical ?lling machines. This EL2 machine, with a production capacity of 5400 packages/hour (200/250 ml) or 5000 packages/hour (450 ml), supports the ECOLEAN? Air packages of sizes 200 ml, 250 ml and 450 ml.

Ecolean Air 200 ml

?

Ecolean Air 250 ml

?

Ecolean Air 450 ml

?

The Air Handle (1) of the ECOLEAN? Air Package (2) is in?ated through the Air Channel Opening (3).

3 1 2
Ecolean? Air 250 ml

1 2 3

Air Handle ECOLEAN? Air Package Air Channel Opening

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1.5 Machine Overview
1.5.1 Machine Overview (Filling Machine)
The different machine parts and their locations (front view):

1 2

3

4

10

9

8

7

6
6 7 8 9 10

5
Machine Covers Transport Unit Filling System HMI Panel Conveyor

1 2 3 4 5

Accumulator Electrical Cabinet Unwinding Unit Reel Holder Date Unit Cabinet

(Continued)

1-6

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(Continued) View from the rear:

11 12
11 12 Electrical Cabinet Pneumatic System

(Continued)

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(Continued) This manual uses the following de?nitions of machine orientation. The ?gure shows the machine from above. ? ? ? ? ? ? ? A indicates the front side of the machine B indicates the rear side of the machine C indicates the right side of the machine D indicates the left side of the machine E indicates the input region of the machine F indicates the output region of the machine E and F indicate the direction of the package ?ow through the machine

F

D

A

B

C E

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1.5.2 Machine Overview (Filling Machine with Straw Applicator)
The different machine parts and their locations (front view):

1

2

3

4

5

11
1 2 3 4 5 6

10

9

8

7
7 8 9 10 11

6
Machine Covers Transport Unit Filling System HMI Panel Conveyor

Accumulator Electrical Cabinet Unwinding Unit Straw Applicator Reel Holder Date Unit Cabinet

(Continued)

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(Continued) View from the rear:

12
12 13

13

Electrical Cabinet Pneumatic System

(Continued)

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(Continued) This manual uses the following de?nitions of machine orientation. The ?gure shows the machine from above. ? ? ? ? ? ? ? A indicates the front side of the machine B indicates the rear side of the machine C indicates the right side of the machine D indicates the left side of the machine E indicates the input region of the machine F indicates the output region of the machine E and F indicate the direction of the package ?ow through the machine

F

D

A

B

C E

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1.5.3 Machine Identi?cation
The machine plate is attached on the side of the electrical cabinet of the ?lling machine and is used for identi?cation of the machine. When inquiries about a particular machine are made to Ecolean, the information given on the plate must be stated, together with production data and running hours.

1.5.4 Main Power Switch
The Main Power Switch (1) is located on the side of the electrical cabinet. Before starting any work (maintenance etc.) on the machine, make sure that the main power switch is OFF.

1

1

Main Power Switch

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1.5.5 Main Air Pressure Valve
The Main Air Pressure Valve (1) is located on the pneumatic panel behind the rear doors. Before starting any work (maintenance etc.) on the machine, make sure that the main air pressure valve is closed.

1

1

Main Air Pressure Valve

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1.5.6 Operator Panel
The Operator Panel (1) is attached to the Arm (2) of the ?lling machine. The operator panel features the HMI Panel (3), the Arrow Up and Arrow Down Buttons (4), the Acknowledgement Button (5), and an Emergency Stop Button (6). The HMI panel is a touch screen used to operate the machine, adjust the settings, view the machine status, and handle generated alarms. NOTE: The emergency stop button is only allowed to be used in the case of emergency.

2 1 3 4 5

6

1 2 3 4 5 6

Operator Panel Arm HMI Panel Arrow Up and Arrow Down Buttons Acknowledgement Button Emergency Stop Button

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1.5.7 Unwinding Unit
The unwinding unit serves to provide the machine with empty packages for ?lling. The Package Reel (1) is loaded on the Reel Table (2). The packages are fed through the Bottom Opener (3), around the Infeed Roller (4), the Drive Roller (5), the Feeding Roller (6), and the Guide Roller (7), before it continues into the separator. The Web End Sensor (8) indicates when it is time to change to a new package reel.

4 3 8 2 1

5 7 6
1 2 3 4 5 6 7 8 Package Reel Reel Table Bottom Opener Infeed Roller Drive Roller Feeding Roller Guide Roller Web End Sensor

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1.5.8 Transport Unit
The package web is transported in the machine by the Carrier (1). The carrier consists of two parallel bars, equipped with pistons indexing the package web forward. The Package Guide (2) and the Lower Guide (3) support the web during the movement. Air pressure activates the pistons holding the package web during the movement. Four packages at a time are indexed forward and aligned below the ?lling pipes by the Optical Sensor (4).

1

4 2

3
1 2 3 4 Carrier Package Guide Lower Guide Optical Sensor

1-16

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1.5.9 Cutting Unit
The cutting unit serves to cut off the top strip of each package before ?lling. The packages are provided sealed upon delivery and must therefore be opened prior to ?lling. In order to open the packages, a thin strip at the top of each package is cut off by two rotary knives. The strip is dismissed into a waste pipe leading down to the bucket at the bottom of the machine.

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1.5.10 Separator
The separator cuts the package web vertically, separating the packages from each other. The cutting sequence is executed in two steps. First, the cutting plates make sure that the web is ?xed. Second, the punching stroke of the cutting knives causes two packages to separate from each other.

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1.5.11 Accumulator
The Accumulator (1) serves to maintain a controlled product pressure during the ?lling sequence. A great and instant product supply is required during the ?lling sequence, which causes the product pressure to drop. The accumulator is pressurised, and by keeping a constant air pressure in the accumulator, the variations in product pressures are reduced. When the ?lling valves are opened, the product is squeezed out of the accumulator by the higher pressure, and a prolonged product pressure is maintained. The accumulator pressure must, however, be slightly lower than the pressure in the product line to allow a product ?ow into the accumulator. For more information, refer to the Operator Manual. The product volume contained in the hose inside the accumulator is slightly larger than the volume consumed during one ?lling sequence. At the end of each ?lling sequence, the hose is almost emptied and ?attened. The product is then again accumulated in the hose, during the short period of time new packages are fed into the ?lling station.

1

1

Accumulator

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1.5.12 Filling Station
Four packages at a time are opened with the assistance of pneumatic pistons before the ?lling procedure. The pneumatic pistons, equipped with suction cups, press against the top sections of the packages, and vacuum in the suction cups serves to open the packages. When the packages are open, a vertical movement lowers the Filling Nozzles (1) into the packages, and the packages are ?lled. When ?lling has been completed, the nozzles are pulled up again. Above the ?lling nozzles, the liquid product is carried in Flexible Hoses (2). Flowmeters and servomotors regulate the product ?ow by opening and closing dosing valves allowing accurate ?lling of the packages, with small margins of error.

2

1
1 2 Filling Nozzles Flexible Hoses

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1.5.13 Sealing Unit
After the ?lling, the packages are sealed just below the line where the strip was cut earlier by a pair of pneumatically driven Heating Jaws (1). The packages are sealed by contact heat generated by electrical heating elements. The temperature is kept constant via a built-in thermal transmitter and an external regulator. The surface of each heating jaw is coated with Te?on (polytetra?uoroethylene) to prevent the packages from sticking. The blow unit ?lls the air handle with air. The blow unit and the air handle unit are built into the same unit.

1
1 Heating Jaws

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1.5.14 Output Conveyor
The ?lled and sealed packages are dropped onto the Output Conveyor (1) by the carrier, and are transported out from the machine by the output conveyor.

1

1

Output Conveyor

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Introduction

CHAPTER

SAFETY PRECAUTIONS
To ensure maximum safety, always read this section carefully before making any adjustments or carrying out any work on the machine. Important!

Safety Precautions

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2.1 Safety Regulations
The machine complies with health, environment, safety and other relevant safety regulations of the European Community and European Economic Area. In many cases, accidents are not caused by the machinery, but by human error. Safety awareness and a well-maintained machine make a safe, ef?cient and pro?table combination.

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2.2 Safety Symbols and Terms
This manual uses the following symbols and terms to identify important information related to the correct and safe operation of the machine.
Symbol Description

Risk of electrical shock! Indicates a potentially hazardous situation due to high voltage inside a unit or machine part.

Risk of cutting! Indicates sharp-edged machine parts and a potential risk of cutting both when these are rotating and standing still.

Risk of cutting! Indicates sharp-edged machine parts and a potential risk of cutting both when these are moving and standing still.

Risk of crushing! Indicates moving machine parts and a potential risk of crushing.

Risk of burns! Indicates hot component and a potential risk of burn injuries. Wait until part cools down.

Risk of entanglement! Indicates moving machine parts and a potential risk of entanglement.

Important! This symbol is of a more general nature. It could indicate risk of personal injury, be a warning or an important note.

(Continued)

Safety Precautions

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(Continued)
Symbol Description Corrosive! Indicates that the solution used could be highly corrosive. Always read the supplier’s Material Safety Data Sheet before handling. Use hand protection, eye protection, and take necessary precaution measures.

Risk of falling! Indicates the risk of falling or slipping.

Overhead load! Heavy load hanging down from the ceiling implies a hazard if the suspension device breaks. Keep out of the loading area.

Flammable! Indicates the risk of ?re due to ?ammable substances.

Eye protection! Indicates that eye protection must be worn during exposure to ?ying particles, liquid chemicals, acids or caustic liquids.

Hearing protection! Indicates that hearing protection must be worn during exposure to hazardous noise levels.

(Continued)

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(Continued)
Symbol Description

Hand protection! Indicates that chemical-resistant and/or heat-resistant hand protection must be worn when working with chemicals and/or hot substances.

No smoking! Indicates that it is forbidden to smoke inside or near the ?lling machine.

Before carrying out certain service and other types of maintenance work on the machine, it is important to: ? turn the main power switch off to shut OFF the power to the machine and/or ? close the main air pressure valve to turn OFF the compressed air to the machine

These requests are indicated by the following table in the beginning of the chapters concerned:
Machine Status Power Compressed air OFF OFF

Safety Precautions

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2.3 Personnel Requirements
2.3.1 Personnel Skills
Personnel Machine operators Requirements to Ful?l Only trained/quali?ed personnel are allowed to operate the equipment. The machine operator must be trained on Ecolean machinery, and have the required knowledge based on existing manuals in order to operate the machine. Only trained/quali?ed technicians are allowed to work on the machine. The technicians must be trained on Ecolean machinery, and have the required knowledge based on existing manuals, in order to carry out work on the machine. Service technicians may be: ? ? Electricians Technicians employed by Ecolean Technicians employed by the customer

Service technicians

Electricians must: ? ? ? ? Be certi?ed according to local regulations Have experience of similar types of installations Have proven skills in reading and working from drawings and cable lists Have knowledge in local safety regulations concerning electrical power supplies and automation

NOTE: If further questions regarding the machine operation and maintenance remains after consulting the manuals, contact an Ecolean representative.

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2.3.2 Personal Protection

Wear hearing protection when the equipment is running. Hearing protection!

Wear eye protection when cleaning the machine.

Eye protection!

Wear chemical-resistant and/or heat-resistant hand protection when working with chemicals and/or hot substances. Avoid contact with eyes and skin. Hand protection!

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2.4 Electrical Cabinet

The high voltage inside the electrical cabinet can be harmful. Only electricians or service technicians may perform electrical work inside the electrical cabinet. Risk of electrical shock!

The main electrical cabinet is placed on the back side of the ?lling machine next to the unwinding unit.

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2.5 Main Power Switch

Risk of electrical shock!

Sometimes the main power switch must be ON during service and other types of maintenance work carried out on the machine. Take every precaution in those situations since the machine then carries high tension voltage.

The main power switch is located on the side of the electrical cabinet of the ?lling machine.

(Continued)

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(Continued)

Risk of electrical shock!

Turning the main switch OFF does not disconnect the electrical power supply to the machine. The Cable (1) and the Main Power Switch (2) will still carry electricity.

1 2

1 2

Cable Main Power Switch

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2.6 Main Air Pressure Valve

Before the start of any service or maintenance work, make sure that the machine is not pressurised. Important!

When the main power switch is turned OFF, the machine automatically also loses its compressed air pressure. Furthermore, opening any of the doors will also result in loss of compressed air pressure. The main air pressure valve is located on the pneumatic panel behind the rear doors. Turn the Handle (1) clockwise to close the main air pressure valve.

1

1

Handle

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2.7 Emergency Stop and Safety Systems
The ?lling machine safety system consists of several emergency stop buttons and a door safety system.

2.7.1 Emergency Stop Buttons
The machine is equipped with three emergency stop buttons. When pushing an emergency stop button, both the electrical power supply and the compressed air supply to the machine will be disrupted. In case of danger to people, or the risk of damage being caused to the machine, push one of the emergency stop buttons.

NOTE: The emergency stop buttons are not allowed to be used to stop the machine under normal conditions. Use the Arrow Down button to stop the machine under normal conditions. NOTE: The emergency stop buttons do not disconnect the electrical power supply to the machine. The location of the emergency stop buttons are given on the following pages.

(Continued)

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(Continued) One Emergency Stop Button (1) is placed on the operator panel of the ?lling machine.

1

1

Emergency Stop Button

The second Emergency Stop Button (2) is placed on the door of the electrical cabinet at the back of the ?lling machine.

2

2

Emergency Stop Button

(Continued)

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(Continued) The third Emergency Stop Button (3) is placed on the side of the conveyor. This emergency stop button is mobile within a limited range. All other emergency stop buttons are ?xed and cannot be moved.

3

3

Emergency Stop Button

Alternatively, the third Emergency Stop Button (4) may be placed on the rear side of the machine.

4

4

Emergency Stop Button

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2.7.2 Resetting an Emergency Stop Button and Restarting the Production
1 2 Pull out the pushed emergency stop button to reset it. Restart the production. For more information, refer to the Operator Manual.

2.7.3 Door Safety System
The EL2 ?lling machine is provided with a door safety system that will stop the machine if a machine door is opened during operation. When a door is opened during production, the compressed air supply will be disrupted, and there will be electric power supply only to the servo drivers. NOTE: It is strictly forbidden to bypass the door magnetic switches or any other emergency stop function by any means.

2.7.4 Testing the Safety Systems
Test all emergency stop buttons and all door magnetic switches daily. The machine needs only to be in Machine Status Zero to perform the tests. 1 Test each emergency stop button by pushing the button. If an alarm "Emergency stop" is generated on the HMI panel and the alarm beacon lights orange, the emergency stop button is working properly. Reset the emergency stop button and the generated alarm and test the other emergency stop buttons. NOTE: If any of the emergency stop buttons do not work properly, contact Ecolean personnel. 3 Test each magnetic switch by opening the corresponding door. If an alarm "Door is open" is generated on the HMI panel and the alarm beacon lights orange, the door magnetic switch is working properly. Close the door, reset the generated alarm and test the other door magnetic switches. NOTE: If a magnetic switch does not work properly, it must be replaced. For more information, refer to the Maintenance Manual.

2

4

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2.8 Noise Emission
The sound level from the machine is LAeq < 80 dB, measured in accordance with the EC Machinery Directive. The sound levels have been measured 1.5 m above the ?oor and 1 m away from the machine. The results are shown in the table below.
Measurement Point A B C D Sound Level (dB) 78.5* 72.0* 78.0* 78.8*

*) The measurements were made on an EL2 ?lling machine with a straw applicator. Thus, without a straw applicator the sound levels could be a bit lower. ? ? ? ? A: 1 m in front of the machine B: 1 m behind the machine C: 1 m to the right of the machine D: 1 m to the left of the machine

D

A

B

C

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2.9 Machine Spare Parts and Consumables
2.9.1 Machine Spare Parts
To ensure proper function of the ?lling machine and to prevent risks of e.g. personal injuries, only spare parts provided by Ecolean should be used.

2.9.2 Consumables
Consumables are e.g. detergent solutions, lubricants and date unit ink. It is strongly recommended to use the consumables suggested by Ecolean. However, if consumables manufactured by other companies are used, make sure that the products have similar speci?cations as the products recommended by Ecolean.

2.9.2.1 Detergents

For Material Safety Data Sheets for detergents, please refer to the supplier. If using other detergents than those recommended by Ecolean, make sure to have the corresponding material safety data sheets as enclosed documentation. Important!

For a list of recommended detergents, refer to 7.3.2 Detergent Speci?cations.

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2.9.2.2 Lubricants

For Material Safety Data Sheets for lubricants, please refer to the supplier. If using other lubricants than those recommended by Ecolean, make sure to have the corresponding material safety data sheets as enclosed documentation. Important!

For a list of recommended lubricants, refer to 7.3.1 Lubricant Speci?cations.

2.9.2.3 Date Unit Ink

For Material Safety Data Sheets for date unit ink, please refer to the supplier. If using other types of date unit ink than those recommended by Ecolean, make sure to have the corresponding material safety data sheets as enclosed documentation. Important!

For a list of recommended types of date unit ink, refer to 7.3.3 Date Unit Ink and Solvent/Make-Up Fluid Speci?cations.

2.9.2.4 Solvent/Make-Up Fluid

For Material Safety Data Sheets for solvent/make-up ?uid, please refer to the supplier. If using other types of solvent/make-up ?uid than those recommended by Ecolean, make sure to have the corresponding material safety data sheets as enclosed documentation. Important!

For a list of recommended types of solvent/make-up ?uid, refer to 7.3.3 Date Unit Ink and Solvent/Make-Up Fluid Speci?cations.

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2.10 Emergency Situations
2.10.1 Harmful Substances
Inside the machine, there are several harmful substances such as detergents, lubricants, date unit ink, solvent and make-up ?uid. In case of possible emission or leakage of these substances, refer to the Material Safety Data Sheets obtained from the suppliers.

2.10.2 Fire Protection

It is forbidden to smoke inside or near the ?lling machine.

No smoking!

NOTE: In case of ?re, an appropriate type of ?re extinguisher must be used. Depending on the location of the ?re, the electrical components inside the machine must be considered, and the ?re extinguisher must have the proper classi?cation.

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CHAPTER

CRATE HANDLING

Crate Handling

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3.1 Crate Data
3.1.1 Filling Machine
The ?lling machine is delivered in a wooden crate, with the following dimensions:
Crate Dimensions Length Width Height Weight 4700 mm 1160 mm 2230 mm 2000 kg

A standard forklift truck with a minimum capacity of 2500 kg is recommended to lift the crate. Make sure that the fork length is longer than the crate width. The space required for storage of the crate is found in 3.2.1 Filling Machine.

The spare parts and other accessories are also delivered in a wooden crate, with the following dimensions:
Crate Dimensions Length Width Height Weight 3300 mm 1150 mm 1080 mm 600 kg

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3.2 Storing the Crate
3.2.1 Filling Machine
If the crate must be stored before the installation of the ?lling machine, the storage area must have the approximate dimensions of (length, width, height):
6000 x 2000 x 3500 mm

These dimensions allow about 1000 mm of free space around the crate for access and ventilation.
Recommended Storage Environment Temperature range Humidity range from +2 °C to +40 °C from 20 % to 80 % relative humidity

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3.3 Unloading and Moving the Crate

Under no circumstances may the machine be unloaded without the supervision of an Ecolean service technician. Important!

Moving the crate always involves risks of personal injury. Take necessary precautions to eliminate the risks. Risk of crushing!

Upon reception of the machine, a standard forklift truck with a minimum capacity of 2500 kg is recommended to unload the crate. The forklift truck must be provided at site by the customer. Make sure that the fork length is longer than the crate width. Unload the crate in accordance with the centre of gravity markings on the crate. The customs inspection panel is placed on the rear side of the machine. Move the crate carefully and always make sure that it remains stable on the forklift truck. Move slowly to the ?nal destination. Lower down the crate and ensure that it is steadily and ?rmly supported on the ground.

3-4

Crate Handling

CHAPTER

INSTALLING THE FILLING MACHINE

Installing the Filling Machine

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4.1 Opening the Crate

Moving the crate/?lling machine always involves risks of personal injury. Take necessary precautions to eliminate the risks. Important!

NOTE: Under no circumstances may the ?lling machine be unpacked without the supervision of an Ecolean service technician. Remove the top of the crate followed by the front side. If the ?lling machine is to be returned or sent forward, save the crate.

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4.2 Unpacking the Filling Machine
NOTE: Under no circumstances may the ?lling machine be unpacked without the supervision of an Ecolean service technician. The crate contains the ?lling machine and seven loose Lower Covers (1). The seven lower covers (four belonging to the front of the ?lling machine, and three belonging to the back of the ?lling machine) are placed under the ?lling machine. The smaller crate that comes along with the larger crate contains: the accumulator, spare parts kit, two package reels with material, operator panel, waste buckets, date unit, air and water guns.

1
1 Lower Covers

1

1 2

Remove the loose covers from inside the crate. Remove the straps and scantlings that have secured the ?lling machine inside the crate.

(Continued)

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(Continued) 3 Use a standard forklift truck with a minimum capacity of 2500 kg to remove the ?lling machine from the crate. Make sure that the fork length is longer than the ?lling machine width. NOTE: Remove loose covers from underneath the ?lling machine. NOTE: All covers (front and back) must be unmounted when moving the ?lling machine.

4

The fork of the forklift truck must be positioned correctly in order to preserve machine stability above the ground. The left fork prong must be positioned as close to the next left-most Machine Foot (2) as possible.

2
2 Machine Foot

5

Lift the ?lling machine carefully and always make sure that it remains stable on the forklift truck. Move slowly to the ?nal destination.

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4.3 Moving the Filling Machine
4.3.1 Long Side
It is important to remove the lower front ?lling machine covers before placing the forklift under the ?lling machine.

4.3.2 Short Side
If the ?lling machine is transported alongside, it is necessary to use two forklifts (one on each short end). The lower covers on the short sides must be removed before placing the forklifts under the ?lling machine.

Installing the Filling Machine

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4.4 Levelling the Filling Machine Chassis
The ?lling machine must have a slight slope to the rear left-hand corner of the ?lling machine to allow for proper drainage. Adjust each machine foot individually using a 30 mm and a 17 mm spanner. The normal height range is 115±25 mm. It is recommended to adjust the machine feet so that the rear left-most foot is 20 mm shorter than the front right-most foot.

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4.5 Installing the Support Arm and Alarm Beacon

DANGER! Danger of personal injury. It is strictly forbidden to step or walk on top of the machine due to the risk of falling. Use a staircase with platform for access. Risk of falling!

NOTE: It is recommended that two persons perform the installation of the support arm together. The support arm and alarm beacon are found inside the crate. 1 Position a staircase with platform on the backside of the ?lling machine.

(Continued)

Installing the Filling Machine

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(Continued) 2 Assemble the Support Arm (1) and Alarm Beacon (2) and install on top of the ?lling machine.

2 1

1 2

Support Arm Alarm Beacon

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4.6 Installing the Accumulator and Connecting the Product Supply

DANGER! Danger of personal injury. It is strictly forbidden to step or walk on top of the machine due to the risk of falling. Use a staircase with platform for access. Risk of falling!

The accumulator is heavy (20 kg). Be careful when handling it! Primarily, an overhead crane should be used when lifting the accumulator. If an overhead crane is not available, two persons should lift the accumulator according to the description below. Important!

If pipe welding is necessary, it is strongly recommended to use protection gas inside the pipes. Make sure that the servo drivers are disconnected prior to welding. Never connect the ground cable of the welding unit to, or nearby, the machine electrical cabinet. Important!

NOTE: It is strongly recommended to install the accumulator in a place where it will not be exposed to strong sunlight or strong UV illumination. If the accumulator tank is exposed to this kind of strong illumination, there is a risk that the hard plastic will crack.

(Continued)

Installing the Filling Machine

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(Continued) 1 Position a staircase with platform on the backside of the ?lling machine.

2 3

Install the Holder (1) on top of the ?lling machine. Place the Accumulator Tank (2) on top of the ?lling machine. NOTE: It is recommended that two persons lift up the accumulator tank together.

4 5 6

Step up on the staircase. Place the accumulator tank in its holder. Install the Clamps (3) and (4).

(Continued)

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(Continued) 7 8 Install the Pipe Supports (5) and (6). Install the Product Valve (7) and tighten the Clamps (8) and (9). NOTE: It is very important to tighten all ?lling system connections well. Otherwise there is the risk of air being sucked into the system causing foaming. Use required tools to tighten the connections. Tightening by hand is not enough. 9 10 Connect the compressed air supply hose of the accumulator. Connect the product valve to the dairy pipeline system using a 2-inch ISO clamp.

7 8 5

2 9 6

3

4

1
1 2 3 4 5 Accumulator Tank Holder Clamp Clamp Pipe Support 6 7 8 9 Pipe Support Product Valve Clamp Clamp

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4.7 Installing the Reel Table
1 Assemble the Holder (1) and install the Reel Table (2).

1 2

1 2

Holder Reel Table

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4.8 Connecting the CIP Return Pipe
If pipe welding is necessary, it is strongly recommended to use protection gas inside the pipes. Make sure that the servo drivers are disconnected prior to welding. Never connect the ground cable of the welding unit to, or nearby, the machine electrical cabinet. Important!

1

Connect the machine CIP Return Pipe (1) to the dairy CIP return using a 2-inch ISO clamp.

1
1 CIP Return Pipe

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4-14

Installing the Filling Machine

CHAPTER

GENERAL INSTALLATION

General Installation

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5.1 Connecting the Compressed Air and Water Supply
1 2 Connect a 3/4 inch reinforced compressed air hose to the Nipple (1) on the top of the ?lling machine. Secure the hose using a suitable clamp. Connect a 1/2 inch reinforced water connection to the Nipple (2) on the top of the ?lling machine. Secure the connection using a suitable clamp.

2 1

1 2

Air Hose Nipple Water Connection Nipple

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5.2 Connecting the Power Supply

Make sure that the phase and zero-voltage cables are connected correctly. Ensure that all connections are made according to the electrical diagram. Risk of electrical shock!

1

Connect the electrical power supply cable from the top of the ?lling machine through the Cable Gland (1) to the Main Circuit Switch (2).

1 2

1 2

Power Supply Cable Gland Main Circuit Switch

2

The power source must be rated at 400 V (AC), 50 Hz (L1, L2, L3, N, PE) and 4 kW.

(Continued)

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(Continued) 3 Connect the main switch connection points. Connect the L3 Cable (3) to the position marked “5” on the main switch block. 4 5 6 7 Connect the L2 Cable (4) to the position marked “3” on the main switch block. Connect the Neutral Cable (5) to the position marked “N” on the main switch block. Connect the L1 Cable (6) to the position marked “1” main switch block. Connect the Ground Cable (7) to position marked with the ground symbol ) on the main switch block. (

If it is only a four- (4) wire connection, make sure to bridge between Neutral (3) and Ground (5). Important!

8

If the component A001 in the electrical cabinet is showing a red light, switch cable positions (L1, L2 and L3) until the right sequence is found and the red light disappears. However, if A001 is still showing a red light after testing all combinations, check that the power source provides 400 V.

3

4

5

6

7

3 4 5 6 7

L3 Cable L2 Cable Neutral Cable L1 Cable Ground Cable

5-4

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5.3 Drain Connections
The wastewater pipe and drain hose, at each end of the ?lling machine, facilitate drainage of the ?lling machine. 1 Connect the Wastewater Pipe (1) to the dairy wastewater system using a 1.5 inch ISO clamp.

1

1

Wastewater Pipe

2

The Drain Hose (2) is to be connected to the sewer in the ?oor under the ?lling machine. For more information, refer to the preinstallation document (Ecolean Technical Service).

2
2 Drain Hose

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5.4 Foam Unit
1 Install the Plastic Can (1) with the foaming agent. Connect the Hose (2), partially fed through a stiff pipe to help stabilise the hose inside the can. Finally, make sure that the Valves (3) and (4) are open.

4 3

1
Foam

2
20 L

1 2 3 4

Plastic Can Hose Valve Valve

5-6

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5.5 Conveyor Belt Connection Options
The Output Conveyor Belt (1) is positioned approximately 1000 mm above the ground. However, the distance might vary due to the setting of the machine chassis level.

1

1

Output Conveyor Belt

The conveyor belt connection options are: ? ? ? A dairy conveyor belt in the same direction as the machine conveyor belt. A dairy conveyor belt at a 90° angle to the machine conveyor belt. A rotation table.

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5.6 Pneumatic Settings
1 Switch ON the main power and adjust the pneumatic regulators according to the recommended settings presented in 7.1.2 Pneumatic Settings.

5-8

General Installation

CHAPTER

DECOMMISSIONING

Decommissioning

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6.1 Decommissioning the Machine

Before decommissioning the machine, it is very important to ensure that there is no main power leading into the machine. Risk of electrical shock!

Before decommissioning the machine, it is very important to ensure that there is no compressed air or water supply leading into the machine. Important!

NOTE: Please contact Ecolean for consultation or assistance in the procedure of decommissioning. 1 2 3 Turn the main power switch OFF. For more information, refer to 1.5.4 Main Power Switch. Close the main air pressure valve. For more information, refer to 1.5.5 Main Air Pressure Valve. Disconnect the electrical power supply cable from the top of the ?lling machine. Follow the steps in 5.2 Connecting the Power Supply in the reversed order. Disconnect the dairy pipeline system from the product valve. Follow the steps in 4.6 Installing the Accumulator and Connecting the Product Supply in the reversed order. Disconnect the compressed air supply and water supply. Follow the steps in 5.1 Connecting the Compressed Air and Water Supply in the reversed order. Disconnect the CIP return pipe. Follow the steps in 4.8 Connecting the CIP Return Pipe in the reversed order. Disconnect the waste pipe and drain hose. Follow the steps in 5.3 Drain Connections in the reversed order. Remove the can containing the foaming agent.

4

5

6 7 8

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6.2 Dismantling the Machine
1 2 Remove the accumulator from the top of the ?lling machine. Remove the support arm with the HMI panel and the alarm beacon from the top of the ?lling machine. Follow the steps in 4.5 Installing the Support Arm and Alarm Beacon in the reversed order. Remove the holder and the reel table.

3

Decommissioning

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6.3 Disposing the Machine
After disposing the machine, assort the different components by material and recycle the material after local regulations. Possible recycling areas: ? ? ? Metals (aluminium, stainless steel) Plastics Electrical components

6-4

Decommissioning

CHAPTER

TECHNICAL SPECIFICATIONS

Technical Speci?cations

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7.1 General Speci?cations
7.1.1 Machine Requirements
Power Speci?cations Main connection Power consumption Water Speci?cations Connection Pressure Consumption 400 V AC 50 Hz (L1, L2, L3, N, PE) 4 kW

Temperature Compressed Air Speci?cations Connection Pressure Consumption Compressed air quality

? inch hose 3 bar (recommended) 20 l/min (maximum) NOTE: Based upon Injector LP manual plus (14 l/min) plus 6 l/min for extra washing hoses. 70 °C (maximum)

? inch hose 6 bar (minimum), 12 bar (maximum) 610 Nl/min (average), 1100 Nl/min (maximum) DIN ISO 8573-1 NOTE: The quality classes for oil content, particle size and water content are speci?ed below. Oil content: class 2 Particle size: class 3 Water content: class 2

Product Speci?cations Product line Connection Pressure Nominal ?ow

Type

Temperature CIP Speci?cations Connection CIP in Connection CIP out Pressure Flow velocity Flow capacity

2 inch pipe between product pump and ?lling machine 2 inch TriClamp welding ?ange Constant value between 1.2 and 1.4 bar 1080 l/h (200 ml) 1350 l/h (250 ml) 2250 l/h (450 ml) Liquid food products NOTE: Product particles with maximum dimensions of 3x3x3 mm. Veri?cation of ?lling performance must be made with relevant product and product supply. 2–45 °C

same connection as for product 2 inch TriClamp welding ?ange 3.0 bar (maximum) (?lling hose burst limit) 1.8 m/s (minimum) 3700 ml/s = 13320 l/h (minimum) (Continued)

7-2

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(Continued) Temperature 90 °C (maximum). For complete information on the CIP cycle, refer to the Operator Manual. NOTE: It is strictly forbidden to use steam during the disinfection cycle due to the risk of explosion of hoses.

Drain Speci?cations Connection Operation Temperature

1 ? inch TriClamp welding ?ange

The machine is designed to operate in a temperature range from +2 °C to +40 °C. Humidity The machine is designed to operate in a relative humidity range from 20 % to 80 %.

7.1.2 Pneumatic Settings
Regulator Main regulator Denomination Settings 6.0 bar 5.0 bar 4.0 bar 5.0 bar 1.0 bar 3.0 bar 0.5 bar 1.8 bar 1.0 bar (Slightly (~0.2 bar) below the product line pressure.) 3.0 bar 3.5 bar 2.3 bar 5.5 bar 3.0 bar 0.5 bar (Initial value set. Refer to the Operator Manual.)

Suction cup unit/Ejector pressure U1001 Air grip move Air grip seal Air grip blow Carrier Blow pistol Feeding roller Accumulator pressure Pneumatic disc brake Air grip preblow Filler lift Filler lift Gripping (if EP2 available) Foam unit U1002 U1003 U1004 U1005 U1006 U1007 U1008 U1009 U1010 U1011 U1012 U2000 -

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7.1.3 Machine Performance
Product Speci?cations Filling volume 200 ml 250 ml 450 ml Standard deviation 3 ml. The standard deviation is in accordance with the European directive 76/211/EEC. NOTE: Filling accuracy is based on applications such as standard milk using a product supply recommended by Ecolean. Inferior product supply and/or ?lling products with particles may affect the ?lling accuracy.

Filling accuracy

Packaging Material Type Volume

ECOLEAN? Air packages 200 ml 250 ml 450 ml

Machine Capacity Product

5400 packages/hour (200/250 ml) 5000 packages/hour (450 ml) Machine capacity is based on applications such as standard milk.

7.1.4 Machine Dimensions
Overall Dimensions – Filling Machine Length 6395 mm Width 1110 mm Height 3090 mm (at product line connection) Weight 1700 kg Overall Dimensions – Crate with Filling Machine Length 4700 mm Width 1160 mm Height 2230 mm Weight 2000 kg

7-4

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7.2 Declaration of Conformity
We, the undersigned, declare under our sole responsibility that,
Machine Type Drawing No. EL2 2160301

A. To which this declaration relates is in conformity with the following standards or other normative documents. EN 12100-1:2003, EN 12100-2:2003, EN ISO 14121-1:2007. B. Following the provisions of EC Directives: ? ? ? ? 98/37/EC on the approximation of the laws of the Member States relating to machinery; 89/336/EEC on the approximation of the laws of the Member States relating to electromagnetic compatibility; 73/23/EEC on the harmonisation of the laws of the Member States relating to electrical equipment designed for use within certain voltage limits; 1935/2004 on materials and articles intended to come into contact with food and repealing Directives 80/590/EEC and 89/109/EEC.

C. Miscellaneous. All material that are in direct contact with food have FDA and 3A approval.

Helsingborg, Sweden 2011

....................................................................................................
Bengt-Arne Olofsson / Sales Administration Manager

Person authorised to compile the technical ?le: Bengt-Arne Olofsson, Sales Administration Manager, Ecolean AB, Kielergatan 48, SE-252 32 Helsingborg, Sweden, tel. +46 42 450 45 00

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7.3 Consumables Speci?cations
7.3.1 Lubricant Speci?cations
The following commercially available lubricants are recommended:
Lubricant Shell Cassida RLS 00 Shell Cassida RLS 1 Shell Cassida RLS 2 Shell Cassida HDS 2 Regular Grade Ecolean Number 80133-006 80133-005 80133-002 80133-007 80133-004 Purpose Ball screw inside the drive unit in the ?lling unit. Pistons in the transport carrier, suction cup unit and sealing unit. General purpose. Spline shaft and female spline in the drive unit in the ?lling unit. Heating elements in the heating jaws in the sealing unit.

7.3.2 Detergent Speci?cations
The different detergent solutions, and their required speci?cations, needed for external cleaning and CIP are given in the table below.
External Foam Cleaners Alkaline Speci?cation Aluminiumfriendly Acid Aluminiumfriendly CIP Alkaline Acid

The following commercially available detergent solutions are recommended:
External Foam Cleaners Alkaline Acid CIP Alkaline Superquest VC82 Acid Descale VA1

JohnsonDiversey Safefoam VF9L NP Freefoam VF11

NOTE: The names of the products mentioned above might vary slightly between different countries. NOTE: Detergent solutions provided by other companies can also be used. However, make sure that they ful?l the required speci?cations.

7-6

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7.3.3 Date Unit Ink and Solvent/Make-Up Fluid Speci?cations
The following commercially available types of date unit ink and solvent/make-up ?uid are recommended:
Company Videojet Linx Hitachi Willett Ink V569-C Linx Black mixed base ink 3103 JP-K72 201-0001-601 Solvent/Make-Up Fluid V810 D Linx mixed base solvent 3501 TH-18 201-0001-701, 201-0001-417 Cleaning Solution V904-Q – – 201-0001-702

NOTE: There may be local discrepancies of what kind of ink to use. Please contact Ecolean if further information is needed. NOTE: Laser printers must NOT be used.

Technical Speci?cations

7-7


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