THOMPSON MEAT MACHINERY - Food Processing & … · THOMPSON MEAT MACHINERY FOREWORD To our valued...

Operation and Maintenance Manual – MK3 Bandsaw © COPYRIGHT – Thompson Meat Machinery 07/2007

THOMPSON MEAT MACHINERY

FOREWORD To our valued Customer, We thank you for your decision to purchase a Thompson Meat Machinery Mk3 BANDSAW. It is a precision built machine, designed to give many years of trouble free service. This Operation and Maintenance Manual makes it easy for you to get to know the Thompson Meat Machinery Mk3 BANDSAW and learn how to use it correctly. This manual contains important information and instructions that, when followed, makes it possible to operate the Mk3 BANDSAW safely, correctly, and economically. It is essential that you become familiar with the contents of this manual to avoid potential hazards, as well as extending the reliability and life-expectancy of the machine. Only authorized and trained personnel should install, operate, clean and maintain the Thompson Meat Machinery Mk3 BANDSAW. The machine should only be operated in a fully maintained and safe condition. The warranty, as stated in our terms and conditions of sale, will become null and void where regular maintenance cannot be substantiated. Only original Thompson Meat Machinery spare parts guarantee quality and exchangeability. We draw your attention to the fact that we assume no liability for damage or operational disturbances resulting from failure to comply with the guidelines and instructions set out in this Operation and Maintenance Manual. Should you have any questions which you believe are not sufficiently answered by this manual, please contact our Customer Service Division or your local Thompson Meat Machinery authorised agent. Prior to operating the machine: It is necessary to become familiar with and comply with all local statutory regulations and industry codes of practice, as well as the Operating Safety Instructions outlined in Section 2 of this manual. The following laws, rules and regulations are a minimum guideline to meeting your obligations: All other commonly valid laws and associated regulations concerning accident prevention and environmental protection must be complied with. Such duties could, for example, concern the handling of hazardous materials or the availability and wearing of personal protective equipment.


ELECTRICAL ISOLATION Refer Appendix C, Illustration A, - page 36 Only qualified persons or authorised persons under their guidance are allowed to service the electrical equipment of the Thompson Meat Machinery Mk3 BANDSAW. When the Thompson Meat Machinery Mk3 BANDSAW is turned off for cleaning and maintenance work, it MUST be electrically isolated from the mains power supply by first TURNING OFF and locking the electrical ISOLATOR switch, retaining the key to the lock on your peson and secondly, if the machine is not hard wired, by unplugging the machine from the power outlet. In the event of a safety concern or a change in the performance of the machine, the operator MUST immediately stop and electrically isolate the machine and report the problem to the responsible person(s). DISCLAIMER No changes, additions or reconstruction of any type that may interfere with the safety or operation of the machine are allowed without the manufacturer’s authorisation in writing. Use of this machine for other than its intended purpose will void all warranties and liabilities held by the manufacturer, unless prior approval, in writing, has been obtained from THOMPSON MEAT MACHINERY. The manufacturer/dealer will not be held responsible for any injury or damage resulting from the improper use of the machine. The operator assumes all risk.


TABLE OF CONTENTS Safety notes – Please read prior to installation. Page 4 Section 1 Installation Page 6 Section 2 Operating Safety Instructions Page 9 Section 3 Bandsaw Assembly / Changing Blades Page 11 3.1 Blade Removal & Refitting Page 11 3.2 Blade Tension Page 11 3.3 Blade Tracking Page 12 3.5 Scraper Blade Adjustment Page 13 Section 4 Operation Page 14 Section 5 Maintenance Page 16 Section 6 Standard Wear Parts Page 21 Section 7 Bandsaw Blade Selection Page 22 Section 8 Conclusion Page 23 Section 9 Options Page 24 Section 10 Specifications Page 25 Section 11 Risk Assessment Procedure Page 26 Section 12 Copyright Page 27 Section 13 Trouble - Shooting Guide Page 28 Appendix A C.E. Declaration Page 29 Appendix B Material Safety Data Sheets Page 30 Cleaning Agents Page 30 Lubricants Page 33 Appendix C Illustrations Page 36 Appendix D Air Gap Adjustment on Motor Brake Page 57 Appendix E Spare Parts & Drawings Page 60


SAFETY NOTES

PLEASE READ PRIOR TO INSTALLATION TO AVOID SERIOUS INJURY AND / OR MACHINE DAMAGE FOLLOW THESE SAFETY GUIDELINES BEFORE INSTALLATION AND PRIOR TO COMMENCING OPERATION. 1) THE MACHINE MUST BE INSTALLED BY A SUITABLY QUALIFIED

PERSON. 2) THE MACHINE MUST BE ON SOLID LEVEL SUPPORT. 3) GUARDS, WHERE FITTED, MUST BE SECURELY IN PLACE OTHERWISE

THE MACHINE WILL NOT START. 4) NEVER OPERATE THE MACHINE WITHOUT TRAINING AND

AUTHORISATION BY YOUR SUPERVISOR. 5. NEVER TAMPER WITH THE SAFETY DEVICES BUILT INTO THE

MACHINE. (Test daily that the machine will not operate with the safety guards open, EXERCISE CAUTION).

5) ONLY USE THE ATTACHMENTS PROVIDED BY THE MANUFACTURER. 7) KEEP HANDS, ARMS, HAIR AND LOOSE CLOTHING CLEAR OF ALL MOVING PARTS. 8) ALWAYS USE QUALITY EAR AND EYE PROTECTION AS A MINIMUM. 9) NEVER TOUCH A ROTATING BLADE OR BLADE WHEELS. 10) ALWAYS USE A FOOD PUSHER, NEVER YOUR HAND. 11) SHOULD MACHINE JAM, TURN THE MACHINE OFF, LOCK-OUT THE

ISOLATOR SWITCH AND IF POSSIBLE, REMOVE PLUG FROM POWER SOURCE, BEFORE CLEARING OBSTRUCTION.

12) ISOLATE THE MACHINE FROM THE ELECTRICAL POWER SOURCE

BEFORE CLEANING, SANITIZING OR SERVICING. 13) ALWAYS EXERCISE CARE WHEN HANDLING THE BANDSAW BLADE.

THESE CAN BE VERY SHARP AND IF HANDLED INCORRECTLY MAY CAUSE PERSONAL INJURY. (IT IS RECOMMENDED THAT STEEL MESH GLOVES BE WORN WHEN CHANGING OR SERVICING THE BLADE).

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The Mk6 BANDSAW has been designed and built with safety as a premium concern. However the machine can be dangerous if it is used by untrained personnel or for uses other than its intended purpose. It is recommended that any person who is involved in the installation, operation or maintaining and cleaning of the machine, will have read this manual prior. Particularly the SAFETY instructions – Section 2 of this manual.


Section 1 - INSTALLATION NOTE: INSTALLATION MUST ONLY BE CARRIED OUT BY COMPETENTLY TRAINED PERSONNEL AND A SUITABLY QUALIFIED ELECTRICIAN. IMPORTANT NOTICE;

Fuse protection and electrical isolation. NOTE: The machine is not supplied with an electrical connection plug. This must be supplied and fitted in accordance with the local electrical standards by a suitably qualified electrician.

Fuse Protection. No protection is supplied for the mains circuit, therefore, the machine owner must ensure suitable provision is made on-site to prevent an over current situation in the main power supply to the machine. A suitable D-Curve Circuit Breaker MUST be installed before the power outlet to the machine. Refer Section 10, Page 26: Technical Specifications. This table shows the maximum current draw for the machine. METHOD OF ISOLATING THE MACHINE To isolate the machine from all energy sources, ensure the power supply is turned off at the wall and disconnected (unplugged). If the machine cannot be unplugged, turn the machine's electrical isolating switch to the OFF position. Fit a safety lockout device of a type approved by your local authority to the lock receiver in the isolating switch, holding the keys to the lock yourself whilst servicing the machine. INSTALLATION 1.1 Ensure that any lifting devices to be used are appropriate and

adequate. Refer Section 10, page 26: Shipping Specifications. 1.2 Move the machine to its designated area (exercise CAUTION on

sloping, uneven or wet surfaces) If the machine is fitted with Castor Wheels, ensure the brakes on the wheels are activated.

1.3 Remove the transportation crate. Please dispose of crate in an

environmentally friendly manner. 1.4 The Thompson Bandsaw is designed as a free standing machine and

therefore does not require bolting down or permanent fixing.

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1.5 CHECK FOR DIRECTION OF ROTATION.

The Bandsaw blade MUST rotate in an Anti-Clockwise Direction, “blade teeth cutting DOWN” towards the Bandsaw table. Refer Appendix C, Illustration D, - page 38

If the direction of rotation is incorrect, have a qualified and authorised electrician change the phase at the power source, in order to correct the direction of rotation.

NOTE: Should the machine be plugged into another power outlet other than the original outlet in which the direction was checked, it is ESSENTIAL that the direction of rotation be checked again before the blade is installed in the new location.

1.6 TEST RUN ALL OPERATING FUNCTIONS. Ensure all safety guards

and doors are in the closed position. (The doors are fitted with electrical safety switches that prevents operation if the doors are opened).

Refer Appendix C, Illustration B and C, - page 37 1.7 STARTING 1.71 Having Completed all the safety checks.

Refer Section 2 – Safety Instructions 1.73 Push the GREEN START button.

Refer Appendix C, Illustration K, - page 45 1.74 Allow time for the machine to accelerate to full speed before

safety testing, or the motor will overheat. If overheating occurs the machine will be automatically stopped by the built in motor protection. Should this occur allow sufficient time for the machine to cool, press the STOP button to reset the overload and then restart the machine with the START button.

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1.8 Safety Testing The installer once satisfied that direction of blade travel is correct and the installation complete should now test the following safety features for correct operation :-

1.81 RED PUSH BUTTON – “OFF” control operates stopping function. 1.82 Kick Stop control operates stopping function. 1.83 Attempting to open top wheel door operates stopping function. 1.84 Attempting to lift table operates stopping function. 1.85 Attempting to open bottom wheel door operates stopping function. 1.9 STOPPING 1.91 To stop the machine push the RED STOP pushbutton on the STOP-

START panel. Refer Appendix C, Illustration K, - page 45

Or; 1.92 Simply kick the KICK STOP block on the base of the machine. Refer Appendix C, Illustration J, - page 44 When satisfied that all safety features are functioning the machine should now be electrically isolated and the machine cleaned and sanitised prior to being placed into production. (See Section 5 – Item 5.7 for cleaning instructions). Although the machine is now ready for operation, PLEASE READ THE OPERATING SAFETY INSTRUCTIONS FIRST!

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Section 2 – SAFETY INSTRUCTIONS Bandsaws are by nature potentially dangerous machines. 2.1 Before installing or operating the Bandsaw, the operator MUST follow these instructions:-

• REMOVE all jewelry from wrists and fingers. • TURN BACK and secure cuffs and loose clothing. • EXERCISE CARE when handling the cutting blade. These can be

very sharp and if handled incorrectly may cause personal injury. It is recommended that steel mesh gloves be worn when handling the blade.

• CHECK that the rotation of the blade is anti-clockwise.

2.2 The Operator MUST :-

• WEAR eye and ear protection at all times, as a minimum. • NEVER leave machine unattended whilst in operation. • ISOLATE the machine from the electrical supply before leaving the machine. • ISOLATE and LOCK OUT the machine from the electrical supply

before removing any covers or making any adjustments. Refer Page 2: Electrical Isolation. (All operator serviceable components are located externally.)

• REPORT all machine or equipment faults immediately to a responsible person or your supervisor.

2.3 Passers-by should never talk to and/or distract the operator

whilst the machine is operating It is recommended that Bandsaws should only be operated by authorised persons over the legal age who have been properly trained and made aware of the relevant dangers and safety precautions. It is advised to post a notice to this effect and also advise other people of the dangers of distraction to the operator. A suggested notice is illustrated below THIS MACHINE SHOULD ONLY BE OPERATED BY SUITABLY TRAINED

PERSONS OF THE REQUIRED LEGAL AGE OR BY PERSONNEL WHO HAVE DEMONSTRATED RECOGNISED PRIOR TRAINING.

DO NOT DISTRACT THE OPERATOR ! 2.7 WARNINGS Failure to follow these operating instructions may result in severe injuries being sustained by the operator or attendant.

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• Severing of fingers or other injuries may occur if fingers

contact the cutting blade. • Serious injuries may be sustained should the Bandsaw topple

over and strike or trap the operator or attendant if moved unsafely.


Section 3 – BANDSAW ASSEMBLY / CHANGING THE BLADE 3.1 CHANGING BLADES & BLADE TENSION AND TRACKING The Blade Tension hand Wheel is situated at the top of the machine. Refer Appendix C, Illustration E, - page 39 Blade Removal 3.11 To remove the blade the hand wheel should be turned in an anti

clockwise direction until the blade is slack. 3.12 Lift the blade from the top wheel and carefully remove from the blade

guides, scrapers and machine. Refer Appendix C, Illustrations P, Q, R and S, - pages 50-53 Blade Re-fitting 3.13 On refitting the blade, position correctly on both wheels, and within

blade guides & scrapers - turn the hand wheel in a clockwise direction. Refer Appendix C, Illustrations P, Q, R and S, - pages 50-53 The blade rear edge should sit 9mm away from the back shoulder flange on the wheels.

Refer Appendix C, Illustration I, - page 43 3.14 When the clutch slips you will hear a "CLUNK'. Three clunks and the

blade will be correctly tensioned. Blade tension 3.2 The blade tension is preset during manufacture of the bandsaw and

it should not be necessary to adjust it. However should it become necessary through wear or age of your machine the following steps should be taken:

3.21 By turning the hand wheel anti clockwise, release the tension on the

blade. Refer Appendix C, Illustration E, - page 39

3.22 Remove the black plastic cap from the top of the tension hand wheel, located underneath the cap you will find an M12 tension adjusting nut. Refer Appendix C, Illustration E, - page 39

3.23 Turn the nut in a clockwise direction to increase the blade tension. half of one full turn will probably be sufficient.

3.24 Retension the blade by turning the hand-wheel in a clockwise direction.

- contd;


Remember not to over tension the blade as doing so may result in the blade breaking.

The correct running position of the bandsaw blade is preset during manufacture. It may be necessary however to adjust the position of the blade after an initial settling in period of two or three days use, and check thereafter when changing blades. Tracking Position 3.3 The correct tracking position of the blade on the band saw is that

the back edge of the blade should run approximately 9mm from the back shoulder of the top wheel. Refer Appendix C, Illustration I, - page 43 The method of adjustment to achieve this is as follows:-

3.31 Loosen the blade tension (refer Section 3.2) by turning the tension

hand wheel anti-clockwise. 3.32 Located behind the top wheel is an M10 “allen key head grub screw

(5mm allen key) locked in position with an M10 lock nut. (17mm spanner). Refer Appendix C, Illustration T, - page 54 Using a 17mm spanner and an allen key unlock the lock nut and adjust the set screw very minutely - the adjustment is very fine - a ¼ of a turn will possibly suffice. By turning the set screw in a clockwise direction the blade will track more to the rear of the wheel. By turning the set screw in an anti-clockwise direction the blade will track toward the front of the machine i.e. towards the operating position. A maintenance button exists for trained technicians only. This button will release the brake on the motor, only when the bottom door is open and the machine is unable to operate. To use this feature, ensure the stop button is latched in the stop position. Open the bottom door, and the yellow button can be seen. Press this button to release the brake, and the wheel can carefully be spun to allow the blade to change to its new tracking position. Use the large holes in the centre of the wheel to spin the wheel. While spinning the blade by hand, extreme caution must be exercised to avoid contact with the blade. Refer Appendix C, Illustration H, - page 43

3.33 Re-tension the blade, exercising due care and caution with regards to the blade teeth. Should it be required - repeat these steps until such time as the blade is tracking in the correct position.

3.34 Ensure that the lock nut is secured before energising the machine !


- contd; These checks and adjustments are extremely important for maximising the life of the wheels and trouble free operation of the machine.

3.4 When fitting a new blade - make sure that the teeth point downwards in the direction the blade will travel. If the teeth point the wrong way, remove the blade from the machine and twist it inside out and refit the blade. 3.5 SCRAPER BLADES Refer Appendix C, Illustration G, - page 41 The

scraper blades should be set so that only the flat section of the band saw blade (i.e. not the teeth ) is in contact with the scraper. If the teeth come into contact with the scraper blades, this may result in blunting the blade prematurely and or result in damage to the scraper blades themselves.


Section 4 – Operation 4.1 STARTING 4.11 Ensure that ALL safety checks have been carried out.

(Refer Sections 2.1 / 2.2 / 2.3) ENSURE BLADE GUARD IS CORRECTLY SET IN POSITION. NEVER OPERATE BANDSAW WITHOUT BLADE GUARD IN POSITION. 4.12 Push the GREEN START button.

Refer Appendix C, Illustration K, - page 45

4.13 Ensure that the Bandsaw blade is rotating in an anticlockwise direction. (Refer Section 3.4)

Allow time for the machine to accelerate to full speed before cutting, or the motor will overheat. 4.2 If overheating occurs the machine will be automatically

stopped by the built in motor protection. Should this occur allow sufficient time for the machine to cool. Press the STOP button to reset the overload and then restart the machine with the green START button.

4.3 CUTTING 4.31 The cutting action should be smooth and rhythmical.

4.32 It is important not to force the meat through the blade.

4.33 Always keep the moveable guide assembly as close to the point of

cutting as possible. Refer Appendix C, Illustration L, - page 46

4.34 When meat being portioned becomes small and the fingers are close to the blade, use another piece of meat or a pusher to push the last portion through.


- contd;

4.4 STOPPING 4.41 To stop the machine push the RED STOP button on the STOP-START

panel Refer Appendix C, Illustration K, - page 45

or; 4.42 Simply kick the KICK STOP block on the base of the machine.

Refer Appendix C, Illustration J, - page 45

4.43 The Thompson Mk 6 Bandsaw is fitted with a Magnetic activated - spring return brake motor. The brake is activated upon the STOP or EMERGENCY STOP command. The motor and bandsaw blade MUST then stop within 4 seconds. If it does not, refer to Appendix D, Air Gap Adjustment on Motor Brake, - Page 56 4.44 OPERATING INSTRUCTIONS THIS MACHINE SHOULD ONLY BE OPERATED BY SUITABLY TRAINED PERSONNEL, OF THE REQUIRED LEGAL AGE OR BY PERSONNEL WHO HAVE DEMONSTRATED RECOGNISED PRIOR TRAINING. 4.45 TO ISOLATE THE MACHINE from all energy sources, ensure power supply is turned off at the wall and disconnected (unplugged). If the machine cannot be unplugged, turn the machine's electrical isolating switch to the OFF position, then fit a padlock to the padlock receiver in the isolating switch, holding the keys to the padlock yourself whilst servicing the machine. Refer Appendix C, Illustration A, - page 36

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Section 5 – MAINTENANCE

5.2 ELECTRICAL SYSTEM MAINTENANCE

Only trained and qualified electricians are permitted to carry out electrical maintenance work on the MK6 Bandsaw. This includes, but is not limited to work on motors, the control circuit, the safety circuit, manual control devices such as buttons and switches and any other item involved in the flow of electric current. To avoid voiding your warranty, it is strongly recommended that only Thompson Meat Machinery or their authorised dealer undertake maintenance work on Thompson machine(s). Any other person(s) should have written authorisation from Thompson Meat Machinery prior to undertaking the service or repair work. MAINTENANCE MUST ALWAYS BE CARRIED OUT WITH THE POWER SOURCE DISCONNECTED AND THE MACHINE ISOLATED ELECTRICALLY. WARNING: Safety circuits and /or fittings are not to be by-passed or rendered ineffective. All safety circuits must be tested for completed operational performance and only after that these safety circuits have been tested may the machine be placed in operation.

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5.3 A GUIDE TO A PREVENTATIVE MAINTENANCE SCHEDULE IS LISTED BELOW BUT IN NO WAY SUGGESTS THAT IS SHOULD BE LIMITED TO THESE MAINTENANCE STEPS ONLY !

Recommended Maintenance Task Recommended Frequency Daily Weekly Monthly or

annually Clean machine • Clean dust collection box • Check condition of Bandsaw blade • Oil moving guide bar & fence bar • CHECK Motor brake is stopping cutting blade within 4 seconds

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Check scraper blades & adjust if necessary

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Table blade guide Every 6 months Top blade guide on blade guard Every 6 months Blade tensioning • Every 6 months Blade tracking • Every 6 months 5.1 Daily Apart from daily cleaning, your Thompson Meat Machinery Bandsaw Mk 6 does not require a lot of maintenance. 5.12 Sliding table tracks (if fitted) should be kept clean and lightly oiled, as should the sliding table wheels to ensure smooth operation. (If fitted). 5.13 Clean dust collection box daily. Refer Appendix C, Illustration O, - page 49 5.14 Check daily before each operation that the MOTOR BRAKE is stopping the Bandsaw blade within 4 seconds following the stop button activation. (If it requires adjustment – refer Appendix D, Air Gap Adjustment on Motor Brake, - Page 56 5.2 Weekly 5.21 The moving guide bar should be lightly oiled weekly and the portion control fence bar should also be lightly oiled once a week. Refer Appendix C, Illustration L, - page 46 5.22 Bandsaw BLADES

Check weekly. Refer to Section 7

5.23 Scraper Blades

Check on re-fitting of a new blade – adjust if required. Periodic replacement as required. Refer Appendix C, Illustration G, - page 41


5.3 Periodic or as Required Blade guides – Periodic replacement as required. Refer Appendix C, Illustration F, - page 40 5.31 Braked Motor Very periodically (dependent on load & use – approx every 6 months) With natural wear of the brake pad the air gap on the braked motor increases gradually affecting the brake performance and hence the stopping time of the motor and the blade. This AIR GAP should be checked and re-adjusted to the manufacturers recommendations – Refer to Appendix D, Air Gap Adjustment on Motor Brake, - Page 56 5.4 BLADE TENSION SETTING The blade tension is preset during manufacture of the band saw and it should not be necessary to adjust it. However should it become necessary through wear or age of your machine the steps in Blade Tensioning in this manual, should be taken: Refer – Section 3, Item 3.2 Remember not to over tension the blade as doing so may result in the blade breaking. 5.5 BLADE TRACKING The correct running position of the bandsaw blade is preset during manufacture. It may be necessary however to adjust the position of the blade after an initial settling in period of two or three days use, and check thereafter when changing blades. Refer – Section 3, Item 3.3

5.51 Re-tension the blade, exercising due care and caution with regards to the blade teeth. Refer – Section 3, Item 3.2 5.52 Ensure that the lock nut is secured before energising the machine. These checks and adjustments are extremely important for maximising the life of the wheels and trouble free operation of the machine. 5.6 BLADE GUIDES AND BLADE SCRAPERS 5.61 BLADE GUIDES – Refer Appendix C, Illustration F, - page 40 Blade guides are standard 'wear parts" and should be adjusted periodically and replaced as necessary. Blade guides must NOT grip the blade or push the blade off its natural running line. The guides should be set close to the blade without touching it. Worn or badly adjusted guides can cause the blade to wander, or can cause the machine to overheat.


5.62 BLADE SCRAPERS – Refer Appendix C, Illustration G, - page 41 Blade scrapers are also standard wear parts". These must be checked and replaced as necessary to ensure clean cutting. 5.63 BLADE SCRAPERS should be set so that only the flat section of the

bandsaw blade (i.e. not the teeth ) is in contact with the scraper. If the teeth come into contact with the scraper blades, this may result in blunting the blade prematurely and or result in damage to the scraper blades themselves.

5.6 CLEANING AND DISINFECTION

Strictly follow the cleaning and disinfectant chemical manufacturer’s directions with regards to chemical concentrations and preventative measures to observe when making up the solutions. Refer Appendix C – Cleaning Agent MSDS

It is strongly recommended that protective gloves be worn when using cleaning detergents, disinfectants and during the whole cleaning process.

BEFORE ANY CLEANING PROCEDURE IS UNDERTAKEN

Electrically isolate the machine from the electrical power Source !

5.71 Stop and electrically isolate the machine. 5.72 Remove the blade taking extreme care handling the blades, protective gloves are recommended. Wash thoroughly using an approved detergent and sanitiser, hot potable water and scrubbing brush. It is recommended the blade is left off the machine overnight, and stored in a safe manner. (See CHANGING BLADES – Section 3) 5.73 Grip the top wheel firmly and lift up. The top wheel assembly will then pull out of the top of the guide ways. 5.74 The sliding table (if fitted), can be removed by removing the butterfly nut and bolt underneath the table. The table can then be withdrawn. 5.75 Empty the bone dust collection box, and clean it thoroughly using an

approved detergent and sanitiser, scrubbing brush and hot potable water.

5.76 Using an approved detergent and sanitiser, scrubbing brush and hot potable water, scrub the Machine, table, wheels and external surfaces thoroughly ensuring all product residue has been removed.

Refer – Appendix B, Cleaning Agents, - Page 30

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5.77 RINSE the whole machine and all accessories thoroughly using hot potable water (50° - 60° C). 5.78 Using an approved sterilized cloth, dry all surfaces thoroughly.


Section 6 – STANDARD WEAR PARTS 6.1 Bandsaw BLADES

Check daily. (Refer to Section 7 – for blade selection)

Apart from keeping a sharp Bandsaw blade to ensure clean cutting, there are other areas that require periodic checking and replacing as follows: 6.2 Blade Scrapers – Refer Appendix C, Illustration G, - page 41

Check on re-fitting of a new blade – adjust if required. Periodic replacement as required, determined by length & wear of Scraper blade.

6.3 Blade guides – Refer Appendix C, Illustration F, - page 40

Periodic replacement as required, determined by wear and clearance of the guide around the blade.


Section 7 – BANDSAW BLADE SELECTION The correct choice of blade for your bandsaw is important to obtain the best performance from your machine for your particular operation. Blades must have a "skip" tooth form and should have 3 or 4 teeth per inch. These are known as 3 skip or 4 skip respectively. As the number of teeth increases 3 ~ 4, the cut becomes finer with less score marks on the meat. However, more teeth means slower cutting. We suggest the following applications: 3 Skip ~ Heavy industrial primal cutting for high production speed. 4 Skip ~ General work on fresh and frozen and hard bone, in factory,

shop or supermarket. The length of the blade should be 3290mm (10 feet 9½ inches). The above are recommendations only and we suggest that you experiment to find the best blade for your particular operation. Remember that in assessing the economics of your bandsaw operation, you must consider the following points:

Waste Surface finish Throughput speed Blade life

All of these points are inter-dependent and you can improve one at the expense of the others. There are several ways of manufacturing band saw blades, but we recommend that you use only blades made by a "milling process" and not "punched" blades. Please contact us at Thompson Meat Machinery or your local authorised Thompson Meat Machinery agent if you are seeking information or advice on blades.


Section 8 – CONCLUSION 8.1 Your Thompson Mk 6 Bandsaw is a precision built machine,

designed to give many years of trouble free service. If these instructions are followed your machine will give you little trouble, if any. If you are in any doubt about any aspect of your Thompson Bandsaw, contact your agent or phone us direct.

8.2 NEVER sit or stand on any part of the Mk 3 Bandsaw.

IMPROPER use of the Thompson machine can cause personal injury or property damage. Thompson Meat Machinery will not be held responsible for any injury or damage resulting from the improper use of the machine. The operator assumes all risk.

Whilst every care has been taken in providing the best available data at the time of publication, Thompson Meat Machinery accepts no liability for the accuracy of information supplied.

8.3 It is the responsibility of the owner and operator to ensure the proper

installation, day to day operation and correct guarding to local health and safety regulations.

8.4 The implementation of a regular maintenance program is highly

recommended by Thompson Meat Machinery and will prolong the life of your Thompson machine. All maintenance work should only be carried out by Thompson Meat Machinery or their authorized Distributor using genuine Thompson machine parts.

8.5 The manufacturer/deliverer will not be held responsible for any injury or damage resulting from the improper use of the machine. The operator assumes all risk.


Section 9 – OPTIONS for the Mk 6 Bandsaw Series 9.1 Stainless Steel Flywheels. 9.2 Sliding cutting table. 9.3 Custom / Modified tables.


Section 10 – SPECIFICATIONS Mk 3 Bandsaw - CE 415V

9.1 General Parameters Table Height: 960 mm Overall height: 2000 mm Footprint: 860 x 900 mm Table size: 750 x 850 mm Mass (weight): 185 kg Shipping mass (weight): 240 kg Shipping crate dimensions: 1000 x 1000 x 2000 H mm 9.2 Electrical Specifications 24V / 415V 50 Hz Drive motor: 1.5 kW / 8 pole 415 V - Braked Starting Current: 45 Amp Run Current: 8 Amp Recommended Circuit: 30 Amp Operating Freq. (Hz, +/-2%) 50 Hz Operating Voltage(V,+/-5%) 415V Control Voltage 24V A.C. Power Supply 3Phase and Earth. Protective System IP56 9.3 The following lubricants are used in Thompson Meat Machinery

Bandsaw Mk 3:- VALVOLINE – FOOD MACHINERY GREASE Used in all areas requiring grease including packing bearings and seals. Refer to Appendix B for the Material Safety Data Sheet. LIGHT FOOD GRADE OIL Used to lubricate the “moving guide slide bar” – Refer Appendix C, Illustration L, - page 46 “portion control guide bar” – Refer Appendix C, Illustration L, - page 46 “sliding table tracks” (if fitted)


Section 11 – RISK ASSESSMENT PROCEDURE The risk of injury through continuous use of this machine can be minimized by adherence to the safety instructions contained within this manual. The Thompson machine has been methodically designed to maximise operator safety without compromising the machine’s endurance. Thompson Meat Machinery continually research to improve the contents of our manuals and further develop our machines. Aspects of our research are;

• Independent assessment of hazards and risks. • Intensive in house testing and continuous audit of all aspects of

design and manufacture. • On site testing and audit of systems. • Feedback for development has been received from:-

o Operators. o End users (management and owners). o Suppliers and agents. o Independent and experienced people within the industry.

As a part of occupational health and safety procedures within a workplace, it is also necessary for you, as the owner or operator of the machine, to conduct and record your own risk assessment prior to using this machine.

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SECTION 12 - COPYRIGHT All users of this specification and the drawings exhibited hereafter are reminded that copyright exists in all Thompson Meat Machinery publications. Except where the Copyright Act otherwise allows, no part of this publication may be reproduced, stored in a retrieval system in any form or transmitted by any means without prior permission in writing from Thompson Meat Machinery. Requests for permission should be directed to Thompson Meat Machinery or a registered agent. Where such requests relate to the reproduction of the whole or a substantial part of any Drawing, permission will be conditional on the appropriate documentation being submitted.


SECTION 13 TROUBLE-SHOOTING GUIDE FAULT POSSIBLE CAUSE REMEDIES Machine will not start on push button. 1. Machine not plugged in to Mains. 1. Plug in to suitable Mains Power outlet. 2. Isolator in OFF position. 2. Check & TURN TO ON POSITION. 3. Safety sensors not activated. 3. Check & close doors / guards / table down 4. Mains circuit breaker OPEN. 4. Reset – CALL SERVICE ELECTRICIAN. 5. Fuse blown. 5. CALL SERVICE ELECTRICIAN. Cutting blade travelling forward or 1. Blade Tracking requires adjustment. 1. Refer Blade Tracking – Manual Index. reverse on wheel and in guide. 2. Fat build up around blade & flywheel. 2. Remove blade / clean and refit & track. Blade not cutting well / cutting rough. 1. Blade wear. 1. Blade requires replacing. 2. Wrong blade for application. 2. Refer Manual – Bandsaw blade selection. Blade continuously breaking. 1. Blade tension set incorrectly. 1. Refer Manual – Bandsaw blade tensioning. Blade loose or slack on fitting. 1. Blade tension set incorrectly. 1. Refer Manual – Bandsaw blade tensioning. Blade traveling / cutting in wrong 1. Blade fitted in reverse. 1. Re-fit blade in correct direction. Direction. Refer Manual – BANDSAW BLADE FITTING. 2. Machine running in reverse. 2. Isolate power / change direction of motor. CALL SERVICE ELECTRICIAN. Machine stalling / stopping on cutting. 1. Faulty overload contactor. 1. CALL SERVICE ELECTRICIAN. 2. incorrect Power Supply. Machine still operates with guards open. 1. Faulty safety switches or circuit. 1. CALL SERVICE ELECTRICIAN. DO NOT OPERATE UNTIL SAFE ! Cutting blade is NOT stopping within 1. Air gap on motor & brake is worn. 1. Adjust air brake. 4 second time frame. CALL SERVICE ELECTRICIAN. Refer to Section 5 in the manual.

A L S O T R A D I N G A S E . L . S A M M O N & C O L E A D I N G M A N U F A C T U R E R S O F M E A T P R O C E S S I N G A C H I N E R Y

134 Magnesium Drive, Crestmead Brisbane, Qld. 4132 Australia Phone 61 (7) 3803 6643 Fax 61 (7) 3803 6635

All correspondence to be addressed to: PO BOX 2163, Crestmead D.C. Qld. 4132 Australia

Email [email protected] ABN 44 680 698 556 Page: 29

Appendix A – CE Declaration DECLARATION OF CE CONFORMITY

We, Thompson Meat Machinery 134 Magnesium Drive Crestmead, Queensland Australia 4132. Ph: 61 7 3803 6643, Fax: 61 7 3803 6635 Declare that the product: THOMPSON MEAT MACHINERY Mk 3 Bandsaw including: MAGNETIC BRAKE, KICK STOPand DOOR SENSORS, complies with the requirements of: DIRECTIVES: MACHINERY DIRECTIVE 98/37/EC Low Voltage Directive 73/23/EEC, 93/68/EEC. Electromagnetic Compatibility Directive 89/336/EEC, 92/31/EEC. STANDARDS: The product complies with the following European standards:- EN 12268:2003 - Food processing machinery. Band saw machines. Safety and hygiene requirements The technical file is maintained at: Thompson Meat Machinery 134 Magnesium Drive, Crestmead, Queensland Australia 4132. Signed: ……………………………………….... Rodney C. Sammon, Chief Executive, Thompson Meat Machinery, 134 Magnesium Drive, Crestmead, Queensland, Australia, 4132 Address of Authorised Representative in the EC: ………………………………………….. …………………………………………..

mailto:[email protected]


Appendix B – Material Safety Data Sheets 1. Detergents & Disinfectants Cleaning Agent Specifications


2. MATERIAL SAFETY DATA SHEETS - LUBRICANTS


Appendix C – Illustrations

ELECTRICAL ISOLATION

Lock the lockable isolator in the OFF position and retain the key on your person.

Unplug the power plug

CAUTION: Only trained and qualified persons are permitted to carry out maintenance work on the Thompson machine. MAINTENANCE MUST ALWAYS BE CARRIED OUT WITH THE POWER SOURCE DISCONNECTED.

Illustration A


SAFETY SENSORS – Doors

Coded Magnetic Switch Coded Magnet

Top Door Safety Sensor

Illustration B


SAFETY SENSORS – Doors

Coded Magnetic Switch Coded Magnet

Bottom Door Safety Sensor

llustration C


MACHINE ROTATION CHECK – Direction of Blade

Direction of Rotation

Blade & Teeth Travel – for correct motor rotation

TO BE CHECKED & CHANGED ONLY BY A QUALIFIED ELECTRICIAN

Illustration D


BLADE TENSION / ADJUSTMENT HAND WHEEL

Hand Wheel – Blade Tensioner

Illustration(s) E

If the Blade Tensioning Requires Adjustment Remove black plastic cap to reveal M12 adjusting nut. To adjust tension refer to – SECTION 3 / Item 3.2

TENSIONING & LOOSENING THE CUTTING BLADE

Turn handwheel CLOCKWISE – to tension blade to factory setting. Handwheel will activate on set point and listen for “clunk” – 3 times.

Turn handwheel ANTI-CLOCKWISE to loosen the blade.


Illustration(s) E BLADE GUIDES

(10mm spanner reqd) Blade Guide on Guard This is a wearing part (6mm Allen Key head bolt)

Blade Guide – on the Table This is a wearing part

Illustration(s) F


BLADE TABLE GUIDE

Blade table guide – removal point

Illustration G

10mm Spanner 8mm Spanner


Blade Scrapers

Blade Scraper Blade Scraper

Adjust Scrapers to scrape Blade surface – BUT NOT the cutting teeth !

Illustration H


TRACKING ADJUSTMENT – Top Wheel Assembly

REFER TO SECTION 3 – ITEM 3.2 “TRACKING” Loosen locking nut Screw Clockwise – Blade travels Back on Wheel Screw Anti-Clockwise – Blade travels Forward on Wheel Tighten locking nut M10 Tracking Adjustment Lock Nut & allen key head grub screw (use 17mm spanner & 5mm allen key)

Maintenance Button

Maintenance button - door coverplate shown opened Illustration I


BLADE RUNNING POSITION on WHEELS

9mm

Correct Blade position on wheel

Illustration J


CONTROL PANEL

STOP / START - Push buttons

Illustration K


SLIDING TABLE CUTTING GUIDE

Lock & Release Pin – Guide Guide Slide Bar & Lock Nut

(light oil Daily)

Illustration L


BLADE GUARD & ADJUSTMENT

Blade Guard Assembly

BANDSAW MUST NEVER BE OPERATED WITHOUT THE BLADE GUARD IN POSITION, AND CORRECTLY FITTED & ADJUSTED.

Illustration M

Locking Screw for BLADE GUARD ADJUSTMENT.

Blade guard should only ever be adjusted to the height of the product being cut – NEVER EXPOSE MORE OF THE BLADE THAN NECESSARY.

WHEN WALKING AWAY FROM THE SAW DROP THE BLADE GUARD TO ITS LOWEST POSITION !

IN OPERATION SET AT PRODUCT HEIGHT ONLY !


BLADE GUARD REMOVAL FOR CLEANING

Remove knurled locking pin to remove blade guard for cleaning

Illustration N


DUST CATCH BOX

Easily removed for Daily cleaning

Illustration O


REMOVING & REPLACING BLADES

STEP 1

STEP 1: Open all covers

MK3 model shown for Illustration purposes

Illustration P


REMOVING & REPLACING CUTTING BLADES STEP 2

Turn blade tensioning hand wheel Anti-clockwise

Blade tension is released Illustration Q



REMOVE BLADE GUARD

MK3 model shown for Illustration purposes Illustration R



Carefully remove blade – DO NOT TOUCH CUTTING TEETH !

Illustration S

REVERSE STEPS 1–4 TO FIT NEW BLADE

On re-fitting the new blade carefully align blade with table and guard guides and scrapers. Adjust scrapers if necessary. Illustration G


TOP WHEEL ASSEMBLY

MK3 model shown for Illustration purposes

Illustration T

Top wheel is hinged and can be removed for cleaning. DO NOT IMMERSE IN WATER.

Blade Tracking bolt


MOTOR AND ELECTRICAL CONTROL BOX

Remove bottom rear panel for full access to electrical box & motor

For full adjustment of air gap on electro-mechanical brake Refer to Appendix D for air gap adjustment procedures on the motor brake

Illustration U

Brake adjustment in motor Manual override on brake


Appendix D – Air Gap Adjustment on Motor Brake Because of the simple construction the brake motors require very little maintenance – basically only a periodical adjustment of the air gap. The brake motors are supplied with an initial factory set air gap (a gap between the armature and frame when the brake coil is energized) of 0.3mm, with a maximum permissible gap of 0.6mm. Due to the natural wear of the lining, the size of the air gap gradually increases without affecting the performance of the brake until it reaches the maximum adjustment value shown on table below. The friction lining is dimensioned such that the brake can be readjusted several times. To adjust the air gap follow this procedure: • Loosen the bolts to allow removal of the fan cover • Remove the protecting band • Measure the air gap at three points near the adjusting bolts using a set of

feeler gauges. If the measurement is equal to or higher than 0.6mm, or the measurements vary excessively, then proceed as follows: 1. Unfasten the nuts and braking bolts 2. Adjust the air gap to 0.3mm by tightening the three bolts equally. The air

gap must be uniform on the three measurements, and it must be such that the feeler gauge set at 0.3mm can penetrate freely in any area. A feeler gauge set at 0.6mm must not be able to be pushed into any point.

3. Tighten the braking bolts to the point where their end seats on the motor end shield. Do not tighten excessively.

4. Tighten the nuts firmly 5. Make a final measurement to ensure the gap is correct as shown in point

2 above 6. Re-install the protection band 7. Re-install the fan cover and tighten bolts. If the above procedure cannot be followed, or the measurements are not within the ranges stated, please contact a Thompson Meat Machinery Service Technician, who can advise the best procedure to follow.


Appendix E – Spare Parts & Drawings Minimum Required – I) Elevation & Plan view showing electrical Isolator. II) Rear shoulder on wheel & blade position.

THOMPSON MEAT MACHINERY - Food Processing & … · THOMPSON MEAT MACHINERY FOREWORD To our valued...

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Transcript of THOMPSON MEAT MACHINERY - Food Processing & … · THOMPSON MEAT MACHINERY FOREWORD To our valued...