Egli Precision Engineering

Egli Precision Engineering

F1 CONSTANT HEAT PACKAGING MACHINE

User Manual

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Table of Contents

▪ Introduction ▪ Safety Instructions ▪ Machine Details ▪ Transportation and Installation ▪ Operation:

- Start Up

- Panel - HMI Screens - Cleaning / Maintenance

▪ Technical: - Machine Settings - HMI Screens - HMI Settings - Filling Systems - Trouble Shooting - Maintenance Schedule

▪ Spare Parts ▪ Electrical Drawings

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Introduction

Egli is a premium manufacturer of packaging and food processing machines. Egli has produced over 400 vertical form, fill and seal and baling machines to date, and more than 200 maize snack extrusion lines to customers all over SA and throughout Africa.

Egli pride's its self on quality workmanship and reliable products. All spares are manufactured using the latest technology CNC machines. Strict quality standards and highly qualified technicians make sure our customers keep coming back. Our design and development department utilises Solidworks (state of the art 3D design software) to ensure new products are industry leaders. A continuous improvement design methodology is applied at all levels to achieve best results from all our current products.

Gus Egli is the founder of Egli Engineering and he has built a solid business with a strong reputation over the past 40 years. His sense of perfection and innovation has been the cornerstone of Egli’s success and growth.

It is our aim to become Africa’s leading manufacturer in our industry.

Congratulations on your purchase of an Egli machine! We trust you will enjoy many years of good service from it. Please study this manual closely to ensure you achieve the maximum performance and reliability from your machine. Please ensure all operators study the safety and operations sections thoroughly before use. Please feel free to contact our friendly staff on the details below. They will be happy to assist you with any spares requests or technical related queries you might have.

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Safety Instructions

▪ Machine installation and start-up:

• Machine electricity supply is only to be installed and connected by a qualified electrician.

• Machine must be set up and commissioned by an Egli technician or an approved and qualified technician.

• Machine is to be set up on a level surface and in a clean and dry environment.

• Exposure to excessive dust and/or moisture should be avoided.

• Don't allow unqualified or untrained personnel to operate or maintain the machine at any time. Ensure this manual has been thoroughly studied before engaging with the machine.

• All doors must be closed and guards in place before machine is started.

• Machine and surrounding area should be inspected before use to ensure operation will commence safely.

• Before any doors or panels are opened or any maintenance work is carried out, ensure machine is switched off and correctly isolated.

▪ Safety points to remember:

• The sealing jaws are equipped with heating elements which reach high temperatures. Always be aware and do not touch these jaws while machine is on or for a time period after machine has switched off.

• The concealed blade on the front jaw is sharp and dangerous.

• Do not stand or sit on any part of the machine or any surrounding equipment.

• Do not operate the machine if any doors, panels or covers are missing or damaged.

• Do not at any time place your hands under the front doors of the machine to pull packaging material down while in operation. Rather stop the machine and correct.

• Always use the “STOP” option on the front of the machine to stop production. The emergency stop is only for use in emergency situations. Shutting the machine down in the correct sequence, prevents damaged product and spillage when starting up again.

• Never over-ride safety features.

▪ Safety features

Red “E-STOP” button will shut the machine down in case of emergency.

Red main isolator switch. Must be in “off” position with lock to ensure machine is safely isolated.

Main pneumatic control valve. Will shut off pressure to machine in case of emergency.

Door proximity sensor. Will not allow machine to start if front doors are open.

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▪ Warning Stickers Take note of the warning stickers below. These highlight potential areas of danger on and around your FFS packing machine. These are not to be removed and should be understood by all who are responsible for operating, cleaning and maintaining the machine.

Jaws and all connected plates get very hot while running. These retain their heat for some time after stopping. Allow sufficient time to cool before any work is carried out on sealing mechanisms.

There is various moving part on the machine. Attention should always be paid to moving parts as these could cause severe injury should one get a limb or item of clothing caught in the machine.

Near the unwind section of the packaging film and at the draw down area there are pint points and risk of entanglement. Hands should be kept clear at all times while running.

The electrical panel houses various electrical components that could cause electrical shock if handled incorrectly. Only qualified electricians should have access to electrical panel and should only work on the panel when machine is securely locked out.

One of the most dangerous sections of the machine is the Horizontal/Cross Sealing assembly. The knife is extremely sharp and could severely harm a limb if it got caught in the jaw. Hands should be kept out of the sealing area during production.

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Machine Details

▪ Dimensions

▪ Specifications

• Description: Vertical form fill and seal packaging machine (FFS1 constant)

• Filling options: o multihead weigher; o auger dosing; o rotary volumetric; o basculating volumetric

• Max speed: 100 bags per minute

• Max reel width: 400mm (520mm on BUV)

• Power connection: 220V

• Power consumption: 20A

• Compressed air supply: 6bar

• Air consumption: 220 L/min

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▪ Main Machine Components

Main Machine Components

1 In-feed (not shown)

2 Forming Shoulder and Pipe

3 Draw-down and Vertical/Impulse Seal

4 Controls

5 De-coiler (not shown)

6 Horizontal/Cross Seal

7 Exit conveyor (not shown)

1

2

3

4

5

6

7

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1. In-feed The gateway for product to enter the working area of the machine is through one of three in-feed systems: A) Volumetric doser B) Volumetric doser C) Multihead weigher D) Auger doser A) B) C) D)

2. Forming Shoulder and Pipe

Volumetric Doser

This system uses specific size cups to achieve an accurate and consistent product volume. Unit is calibrated to achieve desired result by opening and closing the cup sizes.

Multihead Weigher

This system uses integrated load cells to weigh product. Each head has a linear vibrator and catchment chute to apply correct weight of product as required.

The function of the forming shoulder is to continuously direct the foil to the pipe. The shoulder then causes the foil to surround the pipe and creating a vertical, cylindrical shape with an overlap. Th is shape is then ready to be sealed and receive the product. The pipe acts as a conduit for the product to flow from the in-feed system into the bag. The pipe is equipped with a hopper to receive the product.

Auger Doser

This system uses a purpose-made screw to accurately meter set amounts of product. Usually used with powder type products.

Basculating Volumetric Doser

This system has a basculating chute which flips side to side. This diverts product into cups on either side which hold a set volume. These cups are adjusted together or individually to achieve a desired weight.

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3. Draw-down and Vertical/Seam Seal

4. Control Panel

5. De-coiler

The draw-down belt assembly runs against the vertical pipe and is used to pull the packaging film from the reel.

The vertical sealing assembly applies heat to the over-lapped section of the film, at the vertical pipe, and creates a seal.

The control panel houses all electrical, electronic and pneumatic components required to run the machine. This should remain securely closed at all times and should only be opened and worked on by qualified personnel. Outside the panel are the various buttons, dials, gauges and touch screen used for general operating of the machine. Operation of these will be discussed later in the manual. Also located on the panel are plug points, for the exit conveyor and any auxiliary equipment, and a regulator to manage air pressure coming into the machine and filter moisture from in-coming air.

Please refer to the electrical and pneumatic schematic diagrams (found later in this manual) before any maintenance work is carried out on the machine.

The de-coiler assembly is located at the rear of the machine frame. It consists of various rollers, a frame, de-coiler bar and braking system. Its function is to manage the unwinding of the roll of packaging film, to ensure an even and centralised feed to the shoulder. It does this through controlling the film tension and horizontal tracking.

A photo-eye is added to the assembly to assist with graphic alignment and more accurate bag lengths.

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6. Horizontal/Cross Seal

7. Exit Conveyor

The rear and front horizontal jaws close on the bag. The jaws apply heat and simultaneously create the top seal for the filled bag and the bottom seal for the next bag to be filled.

Located inside the front jaw is a blade that cuts off the filled and sealed package.

The exit conveyor will transport the completed bags. It is placed below the horizontal jaws and takes the packaged goods away from the machine to where they can be handled safely.

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Transport and Installation NOTE: Transport and installation must only be carried out by trained professionals. Machine weighs roughly 600kgs and so lifting equipment rated 1t or higher should be used to move your FFS packing machine. NOTE: Electrical connection of your machine should only be carried out by a qualified electrician.Special care should be taken when doing this to ensure no injuries or damage to the machine occur. For transport, moving and positioning of machine use pallet trolley of forklift and lift using locations highlighted below:

When moving and positioning your FFS machine remember the following important points:

• Forks on forklift should be set as wide as is possible.

• Ensure no pipes or cable get caught and crushed between the forks and square tube of the frame.

• Lift the machine only as much as is needed to clear the floor. Lifting too much could cause the machine to become unstable.

• When correctly placed into position, use a 24mm spanner to adjust the 4 mounting feet to get the machine level. Check using a spirit level and ensure no “rocking” occurs when pushing on each corner of the machine.

• Lock all feet with M16 lock nut.

Side View Front View

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Operation – Start Up The following steps must be carried out every time machine is started:

1. A general examination of the machine and surrounding environment must be carried out. Things to look out for are:

• Any misplaced objects on or around the machine,

• Loose covers/guards,

• Exposed wires,

• Damaged or leaking pneumatic pipes,

• Excessive moisture build up in the air regulator,

• Any foreign objects/dirt in the in-feed hopper Should anything be out of place, contact your supervisor before proceeding with the start up. These checks should be performed daily.

2. Following the general checks listed above, more specific checks below should be done:

• Forming shoulder Check that forming shoulder is correctly fitted in position. There should be no dirt or debris in the slide preventing it from locating correctly. Lock clamping plates down securely.

• Back stop Behind the forming shoulders pipe is a back stop. This prevents the pipe from flexing excessively when the seam is formed.

- Loosen the locking handle,

- adjust the stop until it just touches the pipe,

- slacken it back approximately 1mm or just until there is no resistance to packaging material sliding down the pipe.

- Tighten the locking handle securely.

• Draw down belts

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Using a clean cloth, apply a small amount of methylated spirits (or equivalent solvent) to the belts and wipe clean. Ensure all dirt or excess material is removed to prevent belt slippage.

• Teflon tape Check the quality of the Teflon tape on the shoulder and pipe. Special attention should be given to the tape located on the sides of the pipe on which the draw-down belts run. Replace if necessary.

3. Place packaging material roll on decoiler bar. Using a ruler to measure, check that the roll is centralised on bar. Use nuts to adjust if required and ensure nuts are well tightened.

4. Ensure the packaging film is fed through the machine as per the web diagram below. Also ensure it is correctly fed through the registration mark sensor bracket.

5. Check all safety doors are closed and then switch the main isolator switch to the ON position.

6. Check that the E-STOP is deactivated and that the DOSER switch is in off position.

7. Check HMI that there are no faults showing. Clear any faults if required.

8. Check the draw down belt engage lever is in CLOSE position.

9. Switch heaters to ON position. Wait for jaws to reach operating temperature set point.

Current temperature value

Raise set value

Temperature set point

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10. Push the START button. Machine will begin running empty bags. Observe machine running a few bags and check the following:

a) Seals are correctly made with no leaking of air; b) Bags are correct length and starting/ending in correct position; c) Packaging film is centralised on forming shoulder; d) Knife is working correctly separating bags

If any of the above conditions are not met then use the trouble shooting table below or call a technician to assist with troubleshooting.

Problem Possible Solution Horizontal seal leaking check for excessive build up on the jaws – clean if necessary

adjust temperature up or down as needed

request a technician to check jaw alignment

Vertical/seam seal leaking check for build-up on the sealer bar

check tracking and that correct overlap is being made (see below for tracking adjustment)

adjust temperature up or down as needed

request a technician to check seam seal alignment

Bags incorrect length check film is correctly fed through eye mark sensor bracket

request technician to check draw-down settings

Bags not starting / ending in correct position

check film is correctly fed through eye mark sensor bracket

request technician to “teach” photo eye sensor

Packaging film is not centralised on shoulder

check roll is centralised on decoiler bar

adjust the carriage position using the adjustor handle

check shoulder position and ensure it is correctly located and locked in place

Bags are not separated check condition of knife (be very careful of hot jaws and sharp knife), look for build-up on knife and material stuck in between slot on front and back jaws.

request technician to replace knife

Reduce set value

Watch forming shoulder while adjusting tracking. Remember that while adjusting on the run, material takes a second or two to respond to adjustment.

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11. Once happy with the bag condition, switch the doser switch to allow bags to start being filled.

The machine will run according to the following sequence: The machine will operate according to the following cycle:

i. Doser gives a signal (when doser is activated). ii. After a set delay the horizontal jaws close and when closed the jaw closed sensor is met. iii. At the same time the seam seal closes to create the seam.

It is important that the seam seal on-time isn’t longer than the horizontal seal on-time. iv. Once the jaw closed sensor is met, a delay will be triggered after which the knife will move to

the out position (also for a set on time), cutting and separating the incoming and outgoing bag. It is important that the knife on time is as short as possible to ensure the knife has retracted before the horizontal jaw opens.

v. Once the jaw closed sensor is met, the printer is also triggered. vi. After the horizontal jaws have been closed for a set on time, they will open. vii. As the horizontal jaws open, a delay will be triggered after which the draw down belts will run

for a set on-time. It is important to note when using a registration mark sensor, that the draw down on time should be set such that if the registration mark was not seen, the bag would be longer than it should be. The sensor should interrupt the draw down on-time.

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Operation – Panel

1] HMI touch-screen panel: Human – machine – interface (see next chapter).

2] START button: When pressed will run through machine cycle as laid out in previous chapter. 3] PRODUCT toggle switch: Activates in-feed system to allow product flow. Stops product flow when setting up packets.

4] EMERGENCY STOP BUTTON: (see safety features chapter).

5] Belt pressure gauge: Shows pressure applied by the draw-down belt against the pipe 6] BELT PRESURE regulator: Belt pressure adjustment. 7] Main isolator switch: (see safety features chapter).

8] STOP button: Completes current cycle and then stops machine.

9] Temperature controllers: Manages jaw heat settings.

10] HEATERS toggle switch: Starts jaw heating elements.

11] Belt engage hand-lever: Sets draw-down belts to OPEN or CLOSED.

11] Belt engage hand-lever 6] BELT PRESSURE regulator

5] Belt pressure gauge

4] EMERGENCY STOP button

10] HEATERS toggle switch

9] Temperature controllers

4] Main isolator switch

3] DOSER toggle switch

8] STOP button 2] START button

1] HMI touch-screen panel

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Operation – HMI The FFS1 uses a DELTA HMI (Human-Machine-Interface) touch screen controller. This touch screen communicates with the PLC and enables interaction with the equipment. Production statistics can be viewed, machine functions monitored and various adjustments made. These adjustments are controlled by using various keys which out outlined below. Two levels of access allow changes at different levels. Operator access allows for operational changes to be made in the machine. Technician access requires a unique password and allows settings to be made and modified at a higher level on the machine. This password should only be issued to trained and qualified staff members. Operator HMI screens:

Machine status – Shows what mode the machine is currently in. If machine is in fault, will show what the current fault is.

2] Production figures and log.

Current product in production.

1] Product recipes – saved settings for each different product to be run.

Live bag count. Reset count to start at 0.

Current date and time.

Current machine speed – in BPM.

4] Activation of various functions.

1] RECIPES page

Technician level access required.

3] Operator settings. Resets fault indicator once fault

has been corrected.

RECIPES page is used to save setting up of machine for different products and weights. On this page these can be activated during change over or saved when setting up new products or when settings have been changed on existing products.

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PRODUCTION figures show current machine speed and bag count figures. These can be used to track shift performance. The TOTAL count can be used to schedule maintenance and daily, weekly or monthly performance.

2] STATS page

The EVENT LOG shows specific events by date and time. This can be used to monitor machine reliability and to tie up with the counts to review shift performance.

3] OPERATOR page

The OPERATOR page hosts the main operational functions needed. Date and time and passwords can be set up through this page. FUNCTION TESTS and MATERIAL ROUTE pages are shown below. DOSER WEIGHT ADJUST will increase or decrease (+ -) the volume (on a volumetric filler) or the amount of rotation (on an auger filler). This is a fine adjustment to get exact weights. During production, weights should be checked at set intervals and these settings adjusted to allow for change in bulk density of the product. This can occur automatically if a check weigher is in place.

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This is the material route map as shown in “START UP”. This page is a reminder on the HMI to show how to feed the packaging material through the machine after a roll change.

MATERIAL ROUTE page

FUNCTION TESTS - MAIN page

The TESTS pages are used to manual actuate individual functions. VALVES operates pneumatic cylinder functions and MOTORS operates electric motor functions. These tests are used in fault finding, setting up machine and jogging or actuating when cycle has been incorrectly stopped before sequence is complete. 4] ENABLES page

As the name suggests, the ENABLES screen is used to enable of disable certain functions. These can be used when setting up the machine or under various abnormal running conditions. The INFEED SYSTEM is in relevant in some applications where the doser unit is automatically fed by another system.

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Operation – Cleaning / Maintenance A good cleaning schedule is critical for sustained machine reliability. The following cleaning tasks should be considered preventative maintenance and must be a priority in an operator’s responsibilities. These tasks are to be carried out in addition to the items listed in “machine start-up”. NOTE: Be sure to refer to the chapter on “Safety Instructions”. Machine must be appropriately locked out before any cleaning or maintenance work is carried out.

Daily Cleaning / Maintenance

Task Notes

Blow off machine Using the pneumatic spray gun supplied with the machine, blow dust off all services on entire machine. Focus on removing any debris or dirt around sealing areas. NOTE: Use safety glasses when using pneumatic spray gun.

Wipe down machine Use a dry, clean cloth to wipe off any remaining dirt after blowing. Be sure to wipe clean linear shafting on horizontal jaw assembly.

Drain water trap This is located on the regulator at the rear side of the control panel. Unscrew the bottom nut until water and air spray out. Close the nut again when all the water has drained.

Clean draw-down belts Using a clean cloth, apply a small amount of methylated spirits (or equivalent solvent) to the belts and wipe clean. Ensure all dirt or excess material is removed to prevent belt slippage.

Weekly Cleaning / Maintenance

Task Notes

Clean sealing jaws Using a wire brush, clean off any build-up that may have occurred on any of the jaws. Be careful not be burnt on hot jaws while cleaning.

Check knife Ensure the cavity on the jaw opposite the knife is clean and clear of any excess material. Check sharpness of knife by inspecting packets end quality. Should the knife be showing signs of wear alert a maintenance technician to have this replaced.

Inspect wiring/piping Should any wire or pneumatic pipe be showing signs of wear and tear, call maintenance personnel to have this replaced before a leak or short occurs.

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Technical – Machine Settings There are various mechanical adjustments that can be made to your FFS machine. It is important to remember that every machine is tested before leaving the Egli factory so little to no adjustment should be needed to be done for some time. However, there will be general wear and tear on the FFS machine and some adjustments and setting may need to be carried out after running for a period of time. All these settings should be checked on a weekly basis. They are not listed in any particular order.

Horizontal/Cross Sealing Jaw The horizontal jaws can become loose over time and move out of alignment. This will be seen in cross seals not being formed correctly. To set this follow the steps below:

Vertical/Seam Sealing Jaw

• Turn the machine off and lock it out so it can be safely worked on.

• Loosen front and rear jaw mounting bolts.

• Close the jaws by hand, so they are touching each other without anything between them. The grooves on both jaws should mesh with each other and pull them into alignment with each other.

• Feel along the top of touching planes of both jaws to ensure they are correctly aligned.

• Tighten all mounting bolts securely.

• Open and close jaw again to ensure correct alignment was achieved.

• After setting jaw alignment check mounting bolt tightness after a day or two of running.

Should the operator report seam seals not correctly made, the first step is to reduce heat settings if the seal is burning and to increase the heat is the seal is not made. If there are still issues the seam seal jaw assembly could have moved out of alignment. To set this follow the step below:

Bracket Alignment:

• Turn the machine off and lock it out so it can be safely worked on.

• Loosen both jaw assembly mounting bolts slightly – just enough to allow movement in the assembly. • Brush your fingers between the two aluminium mounting plates to feel for misalignment. • Tap the assembly up or down to get both surfaces lined up with each other. • Tighten mounting bolts securely. • After setting jaw alignment check mounting bolt tightness after a day or two of running.

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Photo-eye / Registration Mark Sensor If the operator reports issues big bag length or issues relating to the photo-eye, there may be two settings to correct: the photo eye bracket positioning or teaching the photo-eye.

To move the bracket position, simply loosen the two brass clamping screws. The photo-eye has up / down; left / right and rotational adjustments. This will allow you to find the exact position so the packaging film can run through the slot.

To teach the sensor and ensure it’s reading the reg. mark. Carry out the following procedure:

• Stop machine.

• Hold STATIC button on the sensor controller until LED’s flash.

• Move packaging material to ON condition. Press STATIC button.

• Move packaging material to OFF condition. Press STATIC button.

• Check set up is working correctly.

Sealer Bar Alignment and Spacing:

• Look at the seam seal sealer bar from the side of the machine checking if it is parallel to the forming pipe. (Use a ruler to measure the distance from the top tip of the sealer bar to the shoulder and then do the same on the bottom).

• Should the bar be misaligned, first check both springs are in place. If not, replace spring.

• Turn top and bottom adjustors to set angle of sealer bar.

• Once sealer bar is parallel, measure distance from sealing edge to pipe.

• The bar should be roughly 5mm from the pipe when open. If distance is less or more the, seam seal assembly can be adjusted closer to, or further from the pipe.

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Technical – HMI Screens In addition to the operator screens discussed previously, the following SETTINGS screens are only available to those with a technician level password.

1]

2]

4] 3]

6]

5]

7]

1] MACHINE SPEED Machine speed is rated in bags per minute. This setting does not affect all other delays but rather it changes the cycle time. This means these settings affect the frequency of the complete sequence. It is important that this master setting is not faster than what the other accumulated delays and on-time settings allow for.

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2] DATE CODER Basic delay and on-time settings for the date coder as shown in the machine sequence on page 14.

3] CROSS SEAL Basic delay and on-time settings for the horizontal/cross seal jaw and knife as shown in the machine sequence on page 14.

4] MACHINE FAULT SETUP Activate and disable various faults. Use these to run the machine in isolation or to run out product left in a machine after a run.

5] DOSER The machine will give off a drop signal to the doser according to the current set machine frequency. There is an adjustable delay after which the doser will drop the next batch of product. Doser weight adjust will increase or decrease (+ -) the volume (on a volumetric filler) or the amount of rotation (on an auger filler). This is a fine adjustment to get exact weights.

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7] SEAM SEAL Basic delay and on-time settings for seam seal.

6] DRAW DOWN SYSTEM Draw delay – This is the delay after jaws open before draw down starts. Draw length – This is a rough guide as to how should the bag should be if it is not interrupted by the photo-eye. Delay to enable photo-eye – This is a de-bounce function to prevent the photo-eye reading the same registration mark twice. Draw down belt speed – This is a percentage of the maximum belt speed set on the servo drive.

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Technical – HMI Settings Below is a table to keep record of all settings as shown on HMI. It is important to keep track of settings and to record any changes made. This should be carried out for each recipe.

Page Setting Description

Value 1 Value 2 Value 3 Value 4 Value 5

Machine Speed

Empty bags per minute

Full bags per minute

Cross Seal Jaws delay

Jaws on time

Knife delay

Knife on time

Seam Seal Seal delay

Seal on time

Date Coder On delay

On time

Doser Delay after drop signal

Draw Down System

Draw delay

Draw length (mm)

Delay to enable photo-eye

Draw down belt speed (0% - 100%)

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Filling Systems Below is some technical details around the Egli filling systems as described in Main Machine Components. This includes setting, maintenance and trouble shooting. Dedicated parts lists are included at the end of the manual.

Auger Doser

Introduction: The Egli Auger Doser or Screw Filler is a volumetric dosing system. A very accurate vertical screw turns a set number of times to transfer a repeatable, consistent amount of fine granular or powdered product. The most important consideration when using the auger doser is to keep the dosing screw fully charged at all times to ensure repeatability. This is done using the rotary agitator and a level control. There will usually be an additional cross feeding screw to supply product into the dosing hopper and sometimes a set of end flaps at the outlet to prevent dribble when not dosing.

Basic Layout:

Adjustments and Fault Finding: There are not many mechanical settings that are needed on the Auger Doser. Every unit is tested with relevant product before being dispatched from Egli. The two areas that may require adjustment are the level control sensor (height and distance from the clear polycarbonate viewing area) and the agitator (rotational adjustment setting distance from side and centre shaft). The following problems could occur at some stage and the suggested solutions should be attempted before carrying out further fault finding:

Problem Possible Solution Not achieving consistent weights from doser

• Check agitator is turning. Adjust agitator speed up or down to get better flow of product.

• Empty hopper, release clamp holding doser pipe, unclip toggle clamps and open front half of dosing hopper. Check for the following:

- Ensure hopper is clean inside and that there is no build up of old or hardened product, especially near the outlet of the dosing hopper.

Inlet (no cross feed shown)

Dosing Hopper

Dosing Pipe

Outlet with End-flaps

Level Control Sensor

Agitator

Dosing Screw

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- Check agitator arms are correctly positioned so that one arm is as near to the side wall of the hopper as possible without touching, and the other should be positioned tangentially to the outer diameter of the dosing screw. These arms prevent building up along the sides and pushes product into the area of dosing.

Agitator or doser drive tripping

• First listen for any scraping sound coming from the hopper or dosing pipe that could imply the screw or agitator arm could be touching the sides restricting movement. A scraping noise could also point to a foreign object inside the dosing area causing a blockage.

• Also listen for any noise comping from the drive area on top of the doser or in the bearing housing between the drive area and the hopper top plate. Noises here could point to an issue in the drive train.

• Empty hopper, release clamp holding doser pipe, unclip toggle clamps and open front half of dosing hopper. Check agitator arms and dosing screw above. Turn dosing screw and agitator arms by hand. There will be resistance on the agitator due to the gearbox ratio but it should turn. Check drive train as above.

Doser hopper not filling • First check infeed device is working and that there is no blockage on inlet to doser hopper.

• Check there is power to hopper level sensor.

• If there is a build up of product less than 10mm deep inside hopper window, DO NOT CLEAN. Use the opportunity to ensure the sensor is in the correct position and then teach it to see the hopper as empty with some build up.

• If the build us is excessive clean and check agitator is set up correctly to ensure smooth flow of product.

Rotary Volumetric Filler Introduction: The Egli rotary volumetric filler has a set of equal volume cups that rotate at a set speed. This is used to dose granular products of consistent bulk density. The cups are open on the top and there is a stationary plate closing the bottom. At the start of the rotation is a stationary hopper that by gravity fills the cup as it rotates past. After the cup moves through half a rotation, there is an opening in the bottom plate that allows the portioned product to drop into the pipe chute of the FFS machine. The cups are made up of two halves, an inner and outer that are adjusted out or in to get more or less volume in the cup. Since all the cups are of an even volume, the filler will consistently drop the same volume of product as it rotates.

Basic Layout:

Hopper

Inner Cup

Outer Cup

Outlet

Stationary Bottom Plate

Manual Adjustment

Motorised Adjustment

Drive Motor Pipe Chute

Rotational Speed Sensor

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Adjustments and Fault Finding: There is some adjustment available on the rotary volumetric doser. Every unit is tested with relevant product before leaving Egli. There could, however, be some setting required as parts wear over time. The following problems could occur at some stage and the suggested solutions should be attempted before carrying out further fault finding:

Problem Possible Solution Consistent but under weights supplied from doser

• Look into doser from top while running. If cups are not being filled completely, check for the following:

- Slow doser down and see if speed is limiting filling height. If speed is the cause then adjust cup open and check if you are able to achieve target weight.

- Drain hopper and check for any blockages or build up that could cause resistance to flow.

Consistent but over weights supplied from doser

• Check hopper silicon scraper strip is in place and is levelling product from the top of the cup.

• Adjust cups together to close the holding volume.

• Check that product level is kept fairly constant in the doser hopper.

Inconsistent weights supplied from doser

• Remove all cups and clean thoroughly. Look out for any damage or excessive build up inside any cup. Replace cups and test.

• Check bags to see if there are one or two cups in particular that are giving out of spec weights. Check bottom plate for straightness and ensure top and bottom plates are parallel.

• Check if product has consistent bulk density.

Main drive tripping • Check inside doser for any parts that may have come loose or any foreign objects that could cause a blockage.

• Look out for shuddering of doser during running.

- This could point to building up of product between bottom plate and stationary plate.

- It could also point to inner scrapers (that run on stationary plate) are set to tight.

• Check for heat or noise coming from main bearing housing.

Height adjust drive tripping

• Check there is no hardened product inside cups or bottom plate and stationary plate.

• Check nut can move freely. Look for any damaged threads.

Basculating Volumetric Filler Introduction: A basculating filler has side-by-side volumetric cups that are filled by a basculating chute. This chute indexes from side to side diverting product flow from hopper into one cup and then the next. The cup outlet has a flap which stays closed to allow product to fill up to a set level. The flap opens while the next cup is being filled, discharging the product into the pipe inlet chute. The height adjustment system moves the cups together up and down to increase and decrease the volume. The cups can be individually adjusted relative to each other for fine tuning. A gate closes off the hopper from the filler. Doors prevent dust from leaving the machine when running and prevent access to the machine which could cause injury.

[29]

Basic Layout:

Adjustments and Fault Finding: There is some adjustment available on the basculating volumetric doser. Every unit is tested with relevant product before leaving Egli. There could, however, be some setting required as parts wear over time. The following problems could occur at some stage and the suggested solutions should be attempted before carrying out further fault finding:

Problem Possible Solution Both cups supplying equal but under weight

• Adjust cups down to increase volume.

• Slow doser speed down and see if speed is limiting filling height. If speed is the cause then adjust cups down/open and check if you are able to achieve target weight.

• Check through path of product though chute and cups for any cause for restricted product flow.

Both cups supplying equal but over weight

• Adjust cups up to decrease volume.

• Check that inner plates are fitted to prevent over and uneven filling of cups.

Inconsistent weights supplied from doser

• Check that inner plates are fitted to prevent over and uneven filling of cups.

• Check weights coming from each cup.

- If weights are consistent but different between each cup, use manual adjustor screw to increase or decrease volume to even the weight out.

- If weights are varying first check product for consistency and uniform bulk density.

• Slow doser speed down and check for any incorrect or inconsistent timing or movement of flaps and chute.

• Check through path of product though chute and cups for any cause for uneven product flow.

Hopper

Hopper gate

Door

Basculating chute

Cups

Cup flap

Pipe chute

Cup height adjustment

Chute drive cylinder

[30]

Technical – Trouble-shooting When performing fault finding of any kind, always have this user manual at hand for reference purposes. Below is a list of all fault codes that could appear on the machine status bar on the main page of the HMI.

Fault Description Location of Fault Possible Solution

Air pressure low Air pressure inlet to packing machine

• Check pressure regulator on back end of panel – turn anti-clockwise to open.

• Check for any leaks in supply line.

Infeed conveyor drive fault (only relevant in some applications)

Drive located in panel • If drive reads “OL 1”, motor is being over-loaded. Check any mechanical blockages on conveyor.

• Refer to drive manual for other faults.

Draw-down drive fault

Servo drives located in panel (x2)

• If drive reads “ERROR 16.0”, motor is being over-loaded. Check for excessive draw-down belt pressure.

• Refer to drive manual for other faults.

Safety door open Front machine door • Check front door, front top plate, side inspection door and bulk feeder doors are closed.

• Check safety switches are correctly fitted.

Jaw obstruction Obstruction to horizontal jaw

• Check for any obstruction to horizontal jaws closing.

• Clean jaws if excessive build up has occurred.

• Check sensor has not moved out of position. Sensor should be activated when jaws closed with no obstruction.

Date coder fault Inside main body of machine

• Refer to printer manual.

Stopped by next machine (only relevant in some applications)

Other machine in packing line

• Carry out fault finding on relevant machine.

E Stop pressed Estops on front panel • Check that all is clear and release Estop.

Reg mark sensor error

De-coiler carriage • Confirm sensor position is aligned with foil.

• Check foil condition and replace is excessive damage has occurred to foil roll.

End of roll De-coiler carriage • Roll of foil has finished and requires changing.

[31]

It is important to consistently review sample bags during production and look out for the following faults.

Fault Probable Cause/s Action

Vertical seal opening/rupturing

▪ Burnt seal ▪ Not sufficient heat

✓ Check temperature ✓ Poor overlap – set tracking

Horizontal seal opening/rupturing

▪ Burnt seal ▪ Not sufficient heat ▪ Knife blunt ▪ Seal bar alignment

✓ Check temperature ✓ Check for damaged thermo

couple ✓ Check for failed element ✓ Replace knife ✓ Maintenance staff to

centralise sealer bar in jaw

Inconsistent bag length ▪ Foil roll loose on mandrel ▪ Draw down belt slipping

▪ Photo eye out of position

✓ Tighten foil locking nuts ✓ Clean belts with solvent ✓ Replace belts if worn ✓ Replace Teflon on pipe if

worn ✓ Re-teach photo eye

Product trapped in seals

▪ Jaw timer too short ▪ Delay from multi-head too

long

✓ Set jaw delay ✓ Re-set delay on doser

Varying bag weights ▪ Oscillating product bulk density

▪ Build-up in dosing system

▪ Weigher out of calibration

✓ Adjust doser +- to achieve correct weight

✓ Install check weigher ✓ Stop production and clean

doser ✓ Carry out calibration on

weigher

For technical assistance or to arrange on-site training or maintenance from one of our technicians, please use the contact details below:

Arnold Worthmann (Works Manager) Mobile: +27 82 8229173 Email: [email protected] Mark Payne (Head of Electrical) Mobile: +27 82 4618236 Email: [email protected] Johnathan Schmidt (Head of Automation) Mobile: +27 76 9063941 Email: [email protected] Reece Morrison (Technician) Mobile: +27 71 8857299 Email: [email protected] Aiden Manikum (Technician) Mobile: +27 63 6915089 Email: [email protected]

mailto:[email protected]





[32]

Technical – Maintenance Schedule The following maintenance tasks should be carried out on a weekly basis. This is in addition to the strict cleaning/maintenance schedule that should be carried out by operations (see page 19). If the maintenance and cleaning tasks are not carried out timeously and consistently it can unnecessarily result in serious machine failure and extended down time. NOTE: Ensure machine is turned off and correctly locked out before any maintenance work is carried out.

Task Notes

Review operations tasks

• Check general machine and specifically sealing bars and draw down belts are clean and free from build-up.

• Check knife

• Check Teflon tape

• Check water trap has been drained. NOTE: if this is being drained often it shows there is excessive moisture in the pneumatic lines and the system should be reviewed. Excess moisture in the line can lead to reduction in pneumatic component service life.

Inspect wiring/piping Run through complete machine. Gently tug on all pneumatic and electrical connections. Resolve any loose connections or terminals, frayed wires and leaking pneumatic pipes. Replace any fittings that aren’t functioning correctly. Ensure all safety items are functioning correctly. Focus specifically on parts of machine where wiring and piping move with components like sealing jaw assemblies.

Check sealing assemblies for wear

Cross seal

• Check all linear bearings and shafting. Look for any obvious visual signs of wear and tear.

• Gently apply pressure to jaw assemblies and take note of play. If play is excessive linear bearings and liners may need replacing. If there is wear or damage to the hard-chromed linear shafting, this may also need to be replaced.

• With air switched off, open and close the cross seal jaw assembly by hand. This should move freely. If it feels like there is excessive resistance to movement, check liners and shafting.

Seam seal

• Check seam seal assembly for excessive play. Bearings or bushings may need replacing.

• Also check seam seal bar springs to ensure bar is centralising itself. Also check arm locking spring to ensure that seam seal assembly is secure when in closed position.

NOTE: if worn bearings and bushes are not replaced timeously, more severe damage could occur to other components.

Check rollers Check all carriage rollers are free running. If any are not moving freely, adjust side screws or, if need-be, replace bush ends.

[33]

Grease all lubrication points

As shown below, there are various greasing points. Apply one or two pulls of grease at each highlighted location and wipe away any excess grease.

Check fastener tightness

Run through complete machine and check tightness on all screws. Special attention must be given to cross seal and draw down assemblies.

Test functions When all other maintenance is complete, switch machine back on. Run through all test functions and ensure each process is working correctly.

[34]

Spare Parts The following critical spares are in stock and available on order. Quantities are suggested minimum quantities to keep on hand. For additional spares on your Egli machine or assembly information, please review the complete parts list. Use contact details below to place your order: TEL: +27 (33) 3868578 EMAIL: [email protected] NOTE: For some spares (eg. Shoulder and pipe, volumetric cups and plates etc.) you will be required to supply information such as product type; bag size and bag material and size.

Critical Spares

Item Part

Number Description Quantity

1 PR-0001-E FFS1 Constant Heat jaw set complete with cables (1x vertical seal, 1x horizontal front, 1x horizontal rear)

1

2 EC-0002-L Element 10 x 280 (Seam Seal) 1

3 EC-0003-L Element 10 x 200 (Cross Seal) 1

4 EC-0001-L Thermo-couple 6 x 50 1

4 PT-0001-B Draw-down belt 25 x 240L 2

5 ME-0001-E T-knife 2 x 204 1

Consumables

Part

Number Description

PR-0002-E Teflon tape 30mm x 30m roll

PR-0003-E Teflon tape 60mm x 30m roll

Critical Panel Spares

Part Number Description Qty

700 HLT 1224 Slim line relay (AB) 1

E5CB-R1TC/ED2 Temperature controller (Omron) 1

Solid state relay (Omron) 1

MD-24VDC-PA 24V DC valve solenoid coil (FESTO) 1


[35]

Parts List Complete

[36]

ITEM NO.

PART NUMBER

DESCRIPTION QTY.

1 MA-0001-E Frame complete FFS1 1

2 MA-0011-E Forming shoulder complete (product

dependant) 1

3 MA-0006-E Draw-down complete FFS1 1

4 MA-0002-E Decoiler complete FFS1 1

5 MA-0007-E Horizontal jaws complete FFS1 1

6 MA-0013-E Exit conveyor 240 x 2000 1

[37]

MA-0001-E Frame Complete FFS1

[38]

ITEM

NO.

PART

NUMBERDESCRIPTION QTY.

ITEM

NO.

PART


1 TC-0012-E Magnet washer MS Chromed 2 20 WC-0024-E Front door RH FFS1 1

2 TC-0013-B Washer 20 x 30 x 4 4 21 MA-0067-E Main1 panel complete FFS1 1

3 TC-0014-B Eccentric bush 1 22 BR-0002-B Bearing 6003 4

4 TC-0015-B Mounting bush 3 23 ME-0004-E Bullet hinge bolt-on 4

5 TC-0054-T Washer M6 x 20 x 3 6 24 ME-0005-E Bullet hinge male slotted 2

6 TC-0055-T Roller de-coiler 2 25 ME-0006-E Mounting foot 100mm 4

7 MC-0052-A Magnet holder 2 26 ME-0007-E Magnet round 25 x 3 2

8 MC-0053-A Magnet holder side door 2 27 ME-0008-E Door handle std. 3

9 MC-0054-A Shoulder clamp 4 28 FR-0005-W Washer flat M5 9

10 LC-0021-E Shoulder upper plate 1 29 FR-0006-Y Nut nyloc M6 2

11 LC-0034-D Frame top plate FFS1 1 30 FR-0510-C Cap screw M5 x 10 29

12 LC-0035-E Pneumatic mounting plate FFS1 1 31 FR-0510-K CS cap screw M5 x 10 2

13 LC-0037-E Side door LH FFS1 1 32 FR-0525-C Cap screw M5 x 25 2

14 LC-0038-E Brace side door LH FFS1 1 33 FR-0540-C Cap screw M5 x 40 4

15 LC-0210-E Front1 door adjustment plate 1 34 FR-0660-C Cap screw M6 X 60 2

16 LC-0218-E Cover Plate FFS1 1 35 FR-0620-B BH cap screw M6 x 20 2

17 WC-0001-E Frame body FFS1 1 36 FR-0816-C Cap screw M8 x 16 19

18 WC-0022-E Frame side panel FFS1 1 37 FR-0825-C Cap screw M8 x 25 8

19 WC-0023-E Front door LH FFS1 1 38 FR-0840-C Cap screw M8 x 40 4

MA-0001-E Frame Complete

[39]

MA-0006-E Draw-down complete FFS1

[40]

ITEM

NO.

PART


ITEM

NO.

PART


1 TC-0001-H Guide rod vertical jaw FFS1 2 44 MC-0019-A Belt mounting draw-down FFS1 1

2 TC-0002-H Guide rod draw-down FFS1 2 45 MC-0020-A Belt mounting1 draw-down FFS1 1

3 TC-0003-A Bearing housing FFS1 draw down 2 46 MC-0022-A Mounting pipe support 1

4 TC-0003-H Jaw mounting pin seam seal 1 47 MC-0164-A Vertical1 jaw FFS1 1

5 TC-0004-ABearing housing slide draw down

FFS14 48 MC-0198-A Vertical seal lock block 1

6 TC-0004-B Bush pivot lock FFS1 draw down jaw 1 49 MA-0066-E Vertical guide block 1

7 TC-0004-C Stop pipe support 1 50 ME-0003-P Spring rotary 40x4 3 coil 1

8 TC-0005-A Idler pulley draw-down 2 51 ME-0004-P Spring compress 8x1x35 2

9 TC-0005-BBush1 pivot lock FFS1 draw down

jaw1 52 PC-0001-A Str. Fitting 8mm 3/8" 2

10 TC-0006-A 20 tooth draw-down pulley 2 53 PC-0001-C Compact cylinder 32 x 10 1

11 TC-0006-B Jaw element sleeve 1 54 PC-0001-V Single acting flow control 1/8" 2

12 TC-0007-B Jaw element nut 1 55 PC-0002-A Elbow fitting 6mm M5 4

13 TC-0008-B Spring retainer vertical jaw 2 56 PC-0002-C DSNU cylinder 15 x 50 2

14 TC-0009-B Nut spring retainer vertical jaw 2 57 BR-0002-L Linear bearing 16x26x26 8

15 TC-0016-T Drive shaft FFS1 draw down 2 58 RM-0001-E Omron R88M G75030 2

16 TC-0019-T Pivot pin arm vertical jaw FFS1 1 59 BR-0001-B Bearing 6005 2

17 TC-0020-T Pivot pin lock vertical jaw FFS1 1 60 BR-0003-B Bearing 6002 - 2RS 4

18 TC-0021-T Washer M6 x 25 x 4 1 61 PT-0001-B Draw-down belt 25 x 240L 2

19 TC-0023-TMounting rod pivot arm vertical jaw

FFS12 62 BR-0004-B Bearing 6203 - 2RS 2

20 TC-0024-T Shaft draw-down pulley 2 63 BR-0001-L Linear bearing 10x19x29 2

21 TC-0025-T Washer M16 2 64 EC-0001-L Thermo-couple 6 x 50 1

22 TC-0026-T Washer M6x35 CSK 2 65 EC-0002-L Element 10 x 280 1

23 TC-0027-T Pipe support rod 1 66 BR-0004-R Needle roller bearing HK1010 2

24 TC-0209-T Pivot arm lock pin FFS1 1 67 FR-0001-P Roll pin M4 x 18 4

25 LC-0004-D Flange mount DSNU 12/16 2 68 FR-0006-W Washer flat M6 6

26 LC-0005-DPlate draw-down belt support

mount2 69 FR-0008-W Washer flat M8 4

27 LC-0009-E Handle FFS1 draw down arm lock 1 70 FR-0010-W Washer flat M10 1

28 MC-0001-C Handle draw-down jaw lock 1 71 FR-0012-W Washer flat M12 2

29 MC-0001-L Mounting bracket jaw cable 1 72 FR-0016-R Cir-clip ext. 16 2

30 MC-0002-C Belt support draw-down 2 73 FR-0516-C Cap screw M5 x 16 5

31 MC-0003-E Insulating plate seam seal FFS1 2 74 FR-0608-G Grub screw M6 x 8 7

32 MC-0005-AMain mounting plate FFS1 draw-

down1 75 FR-0616-C Cap screw M6 x 16 1

33 MC-0006-AAdaptor plate servo motor FFS1

draw-down2 76 FR-0620-C Cap screw M6 x 20 4

34 MC-0007-ASupport vertical jaw arm FFS1 draw-


35 MC-0009-AMounting1 vertical jaw FFS1 draw-



down1 79 FR-0630-K CS cap screw M6 x 30 8







40 MC-0014-A Mounting arm vertical jaw FFS1 1 83 FR-1240-C Cap screw M12 x 40 2

41 MC-0015-A Mounting arm1 vertical jaw FFS1 1 84 FR-1045-C Cap screw M10 x 45 2

42 MC-0016-APivot arm vertical jaw FFS1 draw-


43 MC-0018-A Slide draw-down FFS1 2

MA-0006-E Draw-down complete FFS1

[41]

MA-0002-E De-coiler complete FFS1

[42]

ITEM

NO.

PART


ITEM

NO.

PART


1 TC-0001-C Bush decoiler swing-arm 2 29 WC-0004-E Swing-arm de-coiler FFS1 1

2 TC-0002-A Pulley FFS1 decoiler brake 1 30 WC-0005-E Brake-arm de-coiler FFS1 1

3 TC-0002-B Sett ing FFS1 decoiler 1 31 WC-0006-E Spring guide rod de-coiler FFS1 1

4 TC-0002-T Shaft FFS1 decoiler swing-arm 1 32 WC-0007-E Photo-eye mounting rod FFS1 1

5 TC-0003-E Spike FFS1 decoiler roller M4 SS thrd bar 4 33 FC-0004-P Plate 5 25x30 1

6 TC-0004-EBearing housing FFS1 decoiler MS and

chromed1 34 MA-0003-E Roller complete decoiler FFS1 7

7 TC-0004-T Pin FFS1 decoiler brake-arm 1 35 MA-0004-ELocking screw adjustment FFS1

photo-eye2

8 TC-0005-E Sett ing FFS1 decoiler M10 SS thrd bar 1 36 MA-0005-E Spring mounting FFS1 brake arm 1

9 TC-0005-T Spacer washer FFS1 decoiler brake-arm 1 37 ME-0001-P Spring compress 20x2x55 1

10 TC-0007-T Spigot1 FFS1 decoiler brake-arm spring 1 38 ME-0002-P Spring compress 14x1.2x75 2

11 TC-0008-T Bush retainer FFS1 decoiler spring 2 39 CC-0001-R Proximity sensor M8 brass 1

12 TC-0010-T Pin FFS1 decoiler brake-arm pivot 1 40 BR-0001-B Bearing 6005 2

13 TC-0011-T Rod FFS1 photo-eye mount 1 41 FR-0005-W Washer flat M5 3

14 TC-0012-T Sleeve FFS1 decoiler roller 6 42 FR-0006-W Washer flat M6 14

15 TC-0013-T Shaft FFS1 decoiler unwind 1 43 FR-0008-W Washer flat M8 3

16 TC-0014-C Nut locking decoiler 1 44 FR-0008-E E-clip 8mm 1

17 TC-0014-T Spacer bush FFS1 decoiler unwind 1 45 FR-0010-N Nut M10 30

18 TC-0015-T Washer counter bored M8 1 46 FR-0010-W Washer flat M10 6

19 TC-0015-C Nut1 locking decoiler 1 47 FR-0510-C Cap screw M5 x 10 5

20 MC-0001-A Arm decoiler FFS1 mounting 1 48 FR-0610-C Cap screw M6 x 10 10

21 MC-0002-A Arm1 decoiler FFS1 mounting 1 49 FR-0616-C Cap screw M6 x 16 3

22 MC-0002-E Block brake-arm decoiler FFS1 Bakerlite 1 50 FR-0620-C Cap screw M6 x 20 1

23 MC-0004-A Block mounting FFS1 photo-eye 1 51 FR-0625-C Cap screw M6 x 25 5

24 LC-0006-E Bracket FFS1 photo-eye 1 52 FR-0640-C Cap screw M6 x 40 1

25 LC-0007-E Bracket1 FFS1 photo-eye 1 53 FR-0820-C Cap screw M8 x 20 1

26 LC-0008-E Bracket2 FFS1 photo-eye 1 54 FR-0825-C Cap screw M8 x 25 1

27 LC-0209-E Bracket decoiler FFS1 mounting arm 4 55 FR-0830-C Cap screw M8 x 30 2

28 WC-0003-E Frame de-coiler FFS1 1

MA-0002-E De-coiler complete FFS1

[43]

MA-0007-E Horizontal jaw complete FFS1

[44]

ITEM

NO.

PART


ITEM

NO.

PART


1 TC-0004-H Rotary arm cylinder mounting pin 1 32 MC-0161-A Jaw box cross member 3 (Pnuematic) 1

2 TC-0005-H Jaw pivot pins for bearing type FFS1 2 33 MC-0162-A cylinder clevis M16x1.5 1

3 TC-0006-B Jaw element sleeve 4 34 MC-0163-A Jaw drive link arm front 2

4 TC-0006-H Horizontal jaw guide rod FFS1 HC 2 35 WC-0010-E Horizontal jaw cover 1

5 TC-0007-A Slide plate bearing housing 2 36 WC-0008-E Jaw crank shaft FFS1 1

6 TC-0007-B Jaw element nut 4 37 WC-0113-E Actuator rotary arm horizontal jaw 1

7 TC-0008-A Jaw box plate bearing housing 4 38 MA-0065-E Jaw box cross member Hub bearing type 2

8 TC-0009-A Positioning bush rotary arm 1 39 ME-0001-E Knife 2x204 1

9 TC-0028-T Jaw position bush 1 40 LC-0011-E Proxy mounting bracket 1

10 TC-0030-T Rotary arm pin horizontal jaw 2 41 BR-0003-R Niddle roller bearing NKI20/16 inner ring 3

11 TC-0031-T Washer M10 4 42 PC-0003-C DNC cylinder 63 x 50 1

12 TC-0032-T Bearing retainer jaw box 1 43 PC-0003-A ZNCM 63 trunion mount 1

13 TC-0033-B Crank spacer 4 44 PC-0002-V Non return flow control 3/8" 8mm 2

14 TC-0034-B Spacer 2 45 PC-0005-A Elbow fitting 8mm 3/8" 2

15 TC-0035-T Pillar knife cylinder 4 46 EC-0001-L Thermo-couple 6 x 50 1

16 TC-0036-T Mounting horizontal jaw knife 1 47 EC-0003-L Element 10 x 200 4

17 TC-0200-T Niddle roller bearing NKI20/16 inner ring 3 48 BR-0008-B Bearing 6006 - 2RS 1

18 MC-0001-L Mounting bracket jaw cable 2 49 BR-0010-B Bearing 6204 - 2RS 2

19 MC-0002-T Rotary arm boss shaft key 1 50 BR-0009-B Bearing 6004 - 2RS 1

20 MC-0004-E Backing plate horizontal jaw FFS1 2 51 BR-0001-G Igus sleeve JUM 01-20 8

21 MC-0023-A Jaw box main plate FFS1 1 52 CC-0002-R Proximity sensor M12 1

22 MC-0024-A Jaw box support plate FFS1 1 53 ME-0036-E Grease Nipple M6 3

23 MC-0025-A Jaw box rear plate FFS1 1 54 FR-0006-W Washer flat M6 6

24 MC-0026-A Jaw box slide plate rear FFS1 1 55 FR-0020-R Cir-clip ext. 20 6

25 MC-0029-A Link arm mounting 4 56 FR-0510-C Cap screw M5 x 10 2

26 MC-0031-A Jaw box slide plate support 1 57 FR-0525-C Cap screw M5 x 25 4

27 MC-0032-A Front jaw 1 58 FR-0620-C Cap screw M6 x 20 33

28 MC-0033-A Rear jaw 1 59 FR-0625-C Cap screw M6 x 25 16

29 MC-0034-A Jaw box slide plate centre FFS1 1 60 FR-0820-C Cap screw M8 x 20 4

30 MC-0036-A Jaw box slide plate front FFS1 1 61 FR-0825-C Cap screw M8 x 25 34

31 MC-0160-A Jaw box cross member 2 (Pnuematic) 1

MA-0007-E Horizontal jaw complete FFS1

[45]

MA-0013-E Exit conveyor 240 x 2000

[46]

ITEM

NO.

PART


ITEM

NO.

PART


1 TC-0015-T Washer counter bored M8 2 23 WC-0026-E Side plate exit conveyor 2m 2

2 TC-0050-T Washer 25 x 40 x 5 4 24 WC-0027-E Mounting plate conveyor bearing 2

3 TC-0051-T Shaft idler 240 conveyor 1 25 WC-0028-E Exit conveyor chute 240 1

4 TC-0052-T Shaft drive 240 conveyor 1 26 GB-0003-M VF44 0.37kW 1:25 1

5 TC-0053-T Spacer bar 240 conveyor 4 27 BR-0001-U Bearing unit 25 sq flange cbore 1

6 TC-0061-T Washer M8 x 20 x 4 1 28 BR-0002-U Bearing unit 25 sq flange cbore special 1

7 TC-0062-T Washer M6 x 30 x 3 CSK 2 29 BR-0007-B Bearing 6205 - 2RS 2

8 TC-0063-T Bush spacer 8.5 x 30 x 34 1 30 PT-0002-T Plastic 12 tooth sprocket 2

9 LC-0023-E Conveyor tensioner plate 2 31 PT-0003-T Plastic 12 tooth drive sprocket 2

10 LC-0025-E Conveyor tensioner plate2 2 32 ME-0006-E Mounting foot 100mm 4

11 LC-0027-E Torque arm conveyor bearing 1 33 FR-0008-N Nut M8 7

12 LC-0029-E Backing plate conveyor 240 x 2m 1 34 FR-0008-W Washer flat M8 37

13 LC-0030-E Torque arm VF49 P1 1 35 FR-0010-N Nut M10 3

14 LC-0032-E Mounting plate conveyor pivot 2 36 FR-0010-W Washer flat M10 2

15 LC-0034-E Mounting T plate conveyor pivot 2 37 FR-0025-R Cir-clip ext. 25 2

16 LC-0047-E Conveyor lower guide 2m 2 38 FR-0510-K CS cap screw M5 x 10 2

17 FC-0003-R Pipe 32x25.4x93 AL 1 39 FR-0610-C Cap screw M6 x 10 8

18 FC-0004-R Pipe 32x25.4x79.6 AL 2 40 FR-0812-C Cap screw M8 x 12 2

19 MC-0003-T Sprocket key 2 41 FR-0820-C Cap screw M8 x 20 10

20 ME-0001-B Conveyor belt std 225 x 2m 1 42 FR-0825-C Cap screw M8 x 25 31

21 WC-0020-E Conveyor tensioner 2 43 FR-0860-C Cap screw M8 x 60 1

22 WC-0021-E Stand conveyor 240 x 2m 1

MA-0013-E Exit conveyor 240 x 2000

[47]

MA-0077-E Auger Doser

[48]

ITEM

NO.

PART


ITEM

NO.

PART


1 PT-0007-B Timing belt 255L x 12 1 27 ME-0042-E Seal 47x25x7 1

2 PT-0009-PTiming pulley 26 tooth 25mm

taperlock1 28 LC-0243-E

Inner Bearing housing base plate

Auger doser1

3 PT-0006-B Drive chain Auger Doser 1 29 TC-0213-T Screw feeder shaft 1

4 TC-0223-T Motor adjusment slide 4 30 MC-0200-A Screw feeder clamp 1

5 LC-0257-E Flate plate 121.70x6x139.70 1 31 WC-0151-E Mounting frame Auger doser 1

6 PT-0010-PTiming pulley 12 tooth 16mm pilot

bore1 32 MC-0202-A Main mounting plate 1

7 TC-0227-T Spacer 16x30x2 1 33 MC-0208-A Flange 85x119x10 1

8 ME-0040-E Side cover plate 220x55x5 2 34 WC-0157-E Screw1 with agitator 150 x 1700 1

9 MA-0078-E Drive chain cover 1 35 WC-0153-E Back hopper1 1

10 PT-0010-T Sprocket 15 tooth 10 bore 1 36 MC-0207-A Hopper top mount ring 1

11 TC-0224-T Gearbox adjustment slide 4 37 FC-0028-P Dust cover ring 1

12 TC-0225-T Sprocket spacer 1 38 LC-0080-D Bearing housing cap 1

13 TC-0220-T Mounting cover pillar 4 39 LC-0265-E Spacer plate 1

14 LC-0254-E Spacer plate 120x3x120 1 40 GB-0017-M C12 0.37kW 1:47.6 1

15 MC-0201-A Screw feeder main plate 1 41 RM-0001-E Omron R88M G75030 1

16 WC-0155-E Infeed cup 1 42 TC-0218-T Screw feeder shaft link bush 1

17 TC-0215-T Spacer bush 1 43 TC-0216-T Screw feeder link shaft 1

18 BR-0001-B Bearing 6005 2 44 TC-0217-T Screw feeder link bush 1

19 ME-0039-E M65x2 Bearing nut 1 45 WC-0159-E Agitator2 1

20 PT-0011-T Sprocket 15 tooth 65 bore 1 46 WC-0158-E Agitator1 1

21 TC-0226-T Spacer 25x35x6 1 47 CC-0010-R Capacitive sensor 1

22 TC-0041-B Spacer 65x75x6.5 1 48 WC-0156-E Capacitive sensor mount 1

23 BR-0013-B Bearng 6013 - 2RS 2 49 TC-0214-T Hub pillar Auger doser 8

24 TC-0212-T Agitator drive shaft 1 50 LC-0246-E Toggle clamp plate 1

25 WC-0152-E Main bearing hub Auger doser 1 51 WC-0154-E Front hopper1 1

26 ME-0041-E Seal 100x65x10 1

MA-0077-E Auger Doser

[49]

MA-0091-E Basculating Filler

[50]

ITEM

NO.

PART


ITEM

NO.

PART


1 TC-0051-B Volumetric cup adjustment bush 1 1 35 LC-0310-E Volumetric cup side plate 4

2 TC-0052-B Volumetric cup adjustment bush 2 1 36 LC-0311-E Mounting bracket 5

3 TC-0053-B Pivot bush housing 4 37 LC-0312-E Cylinder mounting bracket 4

4 TC-0054-B Knob knurled 2 38 LC-0313-E Volumetric cup plate 1.5 2

5 TC-0255-T Hopper mounting pillar FFF 4 39 LC-0314-E Volumetric cup lid 2 2

6 TC-0256-T Cylinder pin 8x32L 5 40 LC-0315-E Cover flip flop filler 1

7 TC-0257-TVolumetric cup hight adjustment

shaft 1 41 LC-0316-E Bearing retainer plate 1

8 TC-0258-T Product diverter shaft 1 42 LC-0317-E Front bracing plate 1

9 TC-0259-T Keyway shaft 1 43 LC-0318-E Product deflecor 77x1.5x125 2

10 TC-0260-T Pivot bush volumetric lid FFF 4 44 FC-0015-A Angle 40x40x6x220 SP 1

11 TC-0261-T Washer M14 x 40 x 5 2 45 FC-0015-E Thrd bar M12 x 80 2

12 MC-0007-C Positioning block 1 1 46 WC-0172-E Sq. to round hopper FFF 1

13 MC-0008-C Positioning block 2 1 47 WC-0173-E Product Diverter 1

14 MC-0024-E Strip plate 25x3x350 4 48 WC-0174-E Hopper Sq. pipe 100x2x260L 1

15 MC-0025-E Transparent back cover 1 49 BR-0002-B Bearing 6003 1

16 MC-0219-A Main mounting plate FFF 1 50 PC-0011-A SGS M8 rod eye 5

17 MC-0220-A Flange plate FFF LH 1 51 PC-0016-C DSNU cylinder 20 x 40 1

18 MC-0221-A Flange plate FFF RH 1 52 PC-0017-C DSNU cylinder 20 x 20 PPS 4

19 MC-0222-A Slide guide FFF 4 53 GB-0024-M MVF44 0.18kW 1:28 1

20 MC-0223-A Slide guide mounting plate FFF 1 54 CC-0013-R PNP sensor NC M1-B3 2

21 MC-0224-A Centre plate FFF 1 55 FR-0005-W Washer flat M5 8

22 MC-0225-A Slide guide mounting plate 2 FFF 1 56 FR-0006-W Washer flat M6 36

23 MC-0226-A Sensor plate FFF 1 57 FR-0006-N Nut M6 8

24 MC-0227-A EGLI brand plate 1 58 FR-0006-Q Retaining clip M6 10

25 MC-0228-A Horizontal pillar plate FFF 1 59 FR-0008-W Washer flat M8 8

26 MC-0229-A Mounting block 2 60 FR-0410-K CS cap screw M4 x 10 17

27 MC-0231-AVolumetric cup slide guide side

plate RH1 61 FR-0525-C Cap screw M5 x 25 2

28 MC-0230-AVolumetric cup slide guide side

plate LH 1 62 FR-0540-C Cap screw M6 x 25 6

29 MC-0232-A Crank arm M16 1 63 FR-0620-C Cap screw M6 x 20 24

30 MC-0233-A Main shaft plate 1 64 FR-0625-C Cap screw M6 x 25 16

31 MC-0234-A Guide sleeve 26.7x5.5x350L 2 65 FR-0630-C Cap screw M6 x 30 11

32 LC-0011-E Proxy mounting sensor bracket 2 66 FR-0830-C Cap screw M8 x 30 17

33 LC-0308-E Flip flop filler top plate 1 67 FR-0840-C Cap screw M8 x 40 6

34 LC-0309-EVolumetric cup hight adjustment

plate 2

MA-0091-E Basculating Filler

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MA-0008-E Volumetric Filler VF1

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ITEM

NO.

PART


ITEM

NO.

PART


1 TC-0001-L Scraper lower pivot washer 4 44 FC-0011-P Volumetric hopper pipe 1

2 TC-0001-N Volumetric adjustment nut 1 45 LC-0014-E Proxy mounting bracket 1

3 TC-0002-N Thrust bearing race 1 46 LC-0019-E Scraper holder plate 2

4 TC-0003-N Scraper ring volumetric cup lower 4 47 LC-0020-E Scraper plate lower 4

5 TC-0010-B Volumetric clamp bush 12 48 LC-0220-E Volumetric hoper kidney 1

6 TC-0011-B Volumetric clamp washer 12 49 FC-0026-P Chute volumetric plate 2.0 1

7 TC-0012-B Volumetric seal spring adjustor 8 50 WC-0011-E Volumetric main bearing housing 1

8 TC-0039-T Volumetric main drive shaft 1 51 WC-0012-E Volumetric centre hub 1

9 TC-0042-T Anti-rotate pin 2 52 WC-0014-E Volumetric upper hub 1

10 TC-0043-T Washer M5 x 25 2 53 WC-0015-E Volumetric chain guard 1

11 TC-0044-T Washer M12 x 40 2 54 WC-0016-E Volumetric mounting bracket 1

12 TC-0045-T Volumetric sensor shaft 1 55 WC-0017-E Volumetric hopper1 1

13 TC-0046-T Drive shaft volumetric adjuster 1 56 WC-0018-E Volumetric scraper holder 2

14 TC-0047-T Bush volumetric scraper 2 57 WC-0025-E Volumetric chain tensioner 1

15 TC-0048-T Lower scraper pivot pin 4 58 PT-0001-T Sprocket 17 tooth 20 bore 1

16 TC-0056-T Washer M6 x 16 x 3 8 59 GB-0001-M W75 0.75kW 1:60 1

17 MC-0001-N Scraper guide ring 1 60 GB-0002-M VF44 0.37kW 1:14 1

18 MC-0005-E Volumetric scraper lower block 8 61 BR-0005-B Bearing 6012 - 2RS 2

19 MC-0037-A Thrust bearing plate outer 1 62 ME-0006-P Spring compress 9x0.5x17 8

20 MC-0038-A Volumetric lower plate 1 63 ME-0012-P OD10 x1mm x20long seal adj spring 12

21 MC-0039-A Volumetric centre plate 1 64 CC-0002-R Proximity sensor M12 2

22 MC-0040-A Clamping jaw 4 65 FR-0006-Y Nut nyloc M6 6

23 MC-0041-A Volumetric top plate 1 66 FR-0006-W Washer flat M6 10

24 MC-0042-A Volumetric clamp 12 67 FR-0008-W Washer flat M8 1

25 MC-0043-A Motor mount volumetric adjust 1 68 FR-0010-N Nut M10 4

26 MC-0044-A Volumetric sensor mount 1 69 FR-0010-W Washer flat M10 8

27 MC-0045-A Volumetric sensor tab 2 70 FR-0012-N Hexagon NNut M12 4

28 MC-0048-A Volumetric hopper mount base 1 71 FR-0012-W Washer flat M12 4

29 MC-0049-A Volumetric hopper mount gusset 2 72 FR-0410-K CS cap screw M4 x 10 36

30 MC-0050-A Volumetric hopper mount arm 1 73 FR-0510-C Cap screw M5 x 10 6

31 MA-0009-EVolumetric lower cup complete

1kg4 74 FR-0616-C Cap screw M6 x 16 8

32 MA-0010-EVolumetric upper cup complete

1kg4 75 FR-0620-B BH cap screw M6 x 20 6

33 MA-0015-E Chain idler volumetric 1 76 FR-0620-C Cap screw M6 x 20 19

34 FC-0003-E Volumetric scraper wear strip 2 77 FR-0625-C Cap screw M6 x 25 2

35 FC-0005-P Chute volumetric plate 1.2 1 78 FR-0630-C Cap screw M6 x 30 1

36 FC-0006-F Flat bar 40x6x40 2 79 FR-0820-K CS cap screw M8 x 20 8

37 FC-0006-P Lower ring volumetric plate 1.5 1 80 FR-0825-C Cap screw M8 x 25 1

38 FC-0007-P Upper ring volumetric plate 1.6 1 81 FR-0830-C Cap screw M8 x 30 4

39 FC-0009-E Stud thrd bar M12 x 35 4 82 FR-0860-C Cap screw M8 x 60 1

40 FC-0017-P Volumetric dust cover ring FFS1 1 83 FR-0890-C Cap screw M8 x 90 2

41 LC-0008-D Volumetric large sprocket 1 84 FR-1025-C Cap screw M10 x 25 6

42 LC-0009-D Volumetric lower plate cover 1 85 FR-1030-C Cap screw M10 x 30 10

43 LC-0010-D Volumetric upper plate cover 1


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Electrical Drawings Following is a set of electrical drawings for an FFS1 Constant Heat. Some details may vary depending on the filling system fitted on your machine:

Egli Precision Engineering

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