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Motor and Drive Parts
TIMING BELT REPLACEMENT
1, Power source must be connected to machine and turned on. Turn the power disconnect/lockout switch to the “O” (OFF) position and lock out. Allow machine to come to a complete stop, then press the “I” (START) button and hold for two seconds to verify that the machine will not start.
2, After the green guard locking switch status light illuminates (when all rotating parts are idle) rotate the latch handle on the gear compartment door and open the gear door.
3, Remove the belt guard by removing the hand knob that holds the guard (inside the gear compartment).
4, Loosen the two pinch fasteners in the jack shaft spindle assembly (Figure 50).
5, Loosen the motor mounting fasteners and slide the motor to release belt tension. Remove the belts (Figure51).
Figure 50—Loosen pinch fasteners in jack shat spindle assembly (1) Pinch Fasteners,(2) Jack Shaft Spindle Assembly
Figure 51 – Timing Belts(1)
TIMING BELT TENSION
1, Use the motor tension wrench to slide the motor and apply tension to the timing belts. The pin on the wrench fits in a hole on the support housing(Figure52). The pinch fasteners in the jack shaft spindle assembly must be properly tension both belts. Tighten the motor mounting fasteners, and then tighten the pinch fasteners in the jack shaft spindle assembly.
Figure 52 – Using the motor to apply belt tension. (1) Motor Tension Wrench
2, Replace belt guard and tighten with the hand knob.
3, Close and rotate latch handle connecting the gear compartment door and support housing.
Electrical Assembly
INSPECTION
WARNING: In the event of an electrical problem, only a qualified electrician should inspect or repair the fault. Voltages dangerous to life exist in the starter enclosure! The power disconnect/lockout switch must be in the “O”(OFF) position. Live voltages are still present in the box even though disconnect is off. Always disconnect and lock out power source before beginning electrical inspection or repair.
The electrical assembly must be in good working condition before operating this machine. For a description of the amplifier and safety switch operation and method for checking this system. Electrical schematics are located in the starter enclosure. Refer to Figures53 and 54 and inspect the following:
Figure 53 – Starter enclosure interior with variable frequency drive. (1) Disconnect Switch, (2) Guard Locking Switch Power Disconnect, (3) Main Fuses, (4) Earthing Terminals, (5) Transformer, (6) Transformer Fuses Block, (7) Variable Frequency Drive, (8) Contactor, (9) Standstill Monitor, (10) Control Relay
Figure 54 – Starter enclosure interior, across-the-line start. (1) Disconnect Switch, (2) Guard Locking Switch Power Disconnect, (3) Main Fuses, (4) Earthing Terminals, (5) Transformer, (6) Transformer Fuse Block, (7) Overload Relay, (8) Contactor, (9) Standstill Monitor, (10) Control Relay
Starter enclosure: Inspect interior of starter enclosure for corrosion. If a significant amount of water accumulates in the bottom of the starter enclosure, check the breather drain. Breather drain should be free from obstruction. Excess water could also indicate an opening or loose fitting that allows water to enter the enclosure. Check all access points to the enclosure. Check gasket around door and window. Inspect push/pull stop button, “I” (START) push button assemblies, selector switches and pilot light assembly for damage or corrosion. Replace rubber boots and pilot light lens if damaged.
NOTE: Electrical components that fail due to water or chemical contamination are not covered under the warranty.
Fuses: Remove transformer fuses, located in the transformer fuse blocks. Check with an ohmmeter or continuity light. If one fuse is replaced, all others of that type fuse should also be replaced.
Machines equipped with variable frequency drive(VFD):The drive currently in use is the GPD315/V 7. If the digital display on the drive is not illuminated when the machine is energized, contact Urschel Laboratories.
Standstill monitor: Terminals should be tight and free from corrosion. Monitor must be replaced if damaged.
Power line filter (CE compliant machine with VFD): See the electrical assemblies illustrations in the “Parts” section of this manual for part locations.
Guard locking switches: Replace or straighten actuator key if it is damaged or bent. Check cords for cuts or abrasions. If the green guard locking switch status light does not illuminate when power to the machine is connected, contact Urschel Laboratories. Switch must be replaced if it has been forced open while locked. Use only new screws that are supplied with the switch. Manual release must be in “l(fā)ock” position when removing and replacing lid( Figure 55).
Figure 55 – Guard Locking Switch. (1) Green Guard Locking Switch Status Light, (2) Guard Locking Switch Manual Release
Green status light must be inside the lens when replacing the lid. To maintain watertight features, securely tighten the seven screws for the lid until there is no gap between lid and switch assembly. Do not over tighten.
NOTE: The two screws located under the lid on the guard locking switch act as special dowel pins locking the switch assembly into place and must not be substituted.
Interrupt switch: Terminals should be tight and free from corrosion. Recommended torque is 5.0 inch pounds (80 inch ounces) or 0.56 Newton-meters. Check sensor, actuator and cord for damage. Switch should be replaced if any defect or damage is defected. Check switch alignment. Actuator must be aligned and within 1/32 (8mm) of sensor to complete safety switch circuit (Figure 56).
WARNING: Always perform the guard locking/interrupt switch system test before operating the machine.
Figure 56 – Interrupt switch sensor and actuator must be aligned and within 1/32” (8mm). (1) Sensor, (2) Actuator
VARIABLE FREQUENCY DRIVE PROGRAMMING
A replacement variable frequency drive must have frequencies programmed after the drive has been installed into the electrical enclosure. Refer to the “Speed Chart” on your machine or on page 30 in this manual and program the replacement unit according to the following procedure.
WARNING: Starter enclosure must be energized in order to program the drive. Voltages dangerous to life exist when equipment is open and energized! Only a qualified electrician should inspect, install, or program variable frequency drive.
1, Turn power disconnect/lockout switch to “O” (OFF). Open starter enclosure door. Operate the power disconnect/lockout switch mechanism in the enclosure to turn power on.
2, Set the selector switches to the first drive frequency to be programmed. The frequency drive has a digital operator with a display (Figure 57). The display for the GPD 315/V7 drive will read the lowest setting allowed.
Figure 57 – FPD 315 Drive, digital operator. (1) Digital Display,(2) Numeral Change Key, (increase), (3) Numeral Change Key, (decrease), (4) Read/Write Key
3, Enter the speed in the display in hertz. Increase or decrease the value with the “numeral
change” keys. See the chart for frequency settings.
CAUTION: Do not attempt to over speed the motor! Over speeding could create a safety hazard and cause excessive wear on machine parts. Under speeding will cause the motor to overheat.
4, With the value correctly displayed and flashing, press the “DATA/ENTER” or
“ENTER” key. The display will stop flashing, indicating that the value has been entered.
NOTE: Altering preprogrammed speeds will permanently change these values. To return to original settings, follow steps 1-4.
5, Operate the power disconnect/lockout switch mechanism in the enclosure to turn power off. Close and lock starter enclosure door.
Knife Care
KNIFE CARE GUIDELINES
Knives should be inspected and sharpened or replaced at regular intervals depending upon operating conditions, type of product and hours of operation. Follow these guidelines for best results:
1, Do not attempt to remove all defects from the knife edge by sharpening. This practice results in shortened knife life. Small defects will not affect knife performance.
2, New knives should not be installed beside worn knives. This arrangement may result in poor quality cuts. Keep all the knives from one spindle in a set and sharpen them together. Periodically check knife width or diameter to make sure all the knives in a set are the same size.
3, Recommended minimum dimensions: The following minimum dimensions are intended to give satisfactory results for most applications. However, each customer must look at the quality of cut on his product to determine at what point knives are resharpened beyond usefulness. The minimum dimensions stated are intended to give satisfactory results for most applications. Some customers may be able to give satisfactory results from knives ground smaller, but some may notice a deterioration in quality of out before the minimum size is reached. Measure crosscut knives from the cutting edge to the back of the knife unless otherwise noted; measure the diameter of circular knives unless otherwise noted.
Type of knife
Knife No.
Minimum Size
CROSSCUT
42281
595” (15.1mm)
42446
1.125”(28.6mm)
42460
223” (5.7mm)
CIRCULAR
42265
Bottom of serrations
SLICING,(straight,replaceadle)
53178
1.249 (31.7mm)
SLICING,(straight)
see page 77
3.750” (95.3 mm)
SHARPENING EQUIPMENT
Urschel Laboratories manufactures machines to quickly and efficiently sharpen knives. The following machine are available;
Model WG honing machine is used to sharpen slicing knives and crosscut knives (straight cut only). For the Model DC, use workrest 33224 for 42281 and 42446 crosscut knives and slicing knife insert .Use workrest 33225 for 42460 crosscut knives. Use workrest 33256 for all other slicing knives.
Model CKG honing machine is used to place the best possible edge on circular knives. The Model CKG can be purchased from the factory ready to sharpen 3-1/2” circular knives for the Model DC. Honers that are not set up to sharpen 3-1/2” circular knives must have certain parts installed. Use the following procedure:
WARNNING: Honers place an extremely sharp edge on knives; handle knives with care!
1, Make sure the honer is unplugged from the power source.
2, Install hone assembly, knife holder hub and edge roller stud for 3-1/2’’circular knives (Figure 58). The hone assembly (part number 33083) contains the hone bracket and internal parts, the shield and the honing wheel. The stud on the hone bracket is installed in the second hole from the motor shaft (4” knife position). The knife holder hub (part number 33081) is installed with the raised diameter facing out. The edge roller stud (part number 33023) is installed with the set screw in the second spot drilled hole from the outside end (Note that this part number has remained the same but the part has been modified. The stud should have four spot drilled holes.)
3, Position the hone shield in as far as possible by loosening the screw and sliding the shield. Retighten the screw.
4. Pull the knife clamp hub out of the clamping position. Hold a knife against the knife holder hub. Loosen the set screw in the motor shaft hub and slide the hub and knife on the motor shaft until the knife just touches the honing wheel. Tighten the set screw.
5, Adjust the knife clamp if necessary. The knife clamp should hold the knife against the hub tight enough so that it cannot be rotated yet not so tight that it drives the motor back and distorts the base (the brake arm assembly must be properly adjusted to test for knife rotation). To adjust the knife clamp, loosen the two locking nuts and move the clamp in or out.
6, Place a knife in the honer and sharpen in the normal manner (see the Model CKG instruction manual for more information). If too much of the knife edge is removed, readjust the hub. If insufficient metal is removed, loosen the screw on the hone shield and slide the hone slightly forward against the knife edge.
BUFFING
WARNING: Only qualified trained personnel should buff knives. Use adequate eye and respiratory protection, and a properly guarded buffing wheel. Hold knife securely. Never attempt to catch a dropped knife! Should you drop a knife during the buffing operation, move away and let it tall.
When crosscut knives are sharpened by grinding, filing or honing, a slight wire edge may be produced. Buffing will remove this wire edge.
Install two to four 10" (254 mm) diameter buffing wheels side by side between flanges at least2" (51 mm) in diameter. Buffing wheels and bars of buffing compound are available from Urschel Laboratories (see “Tools", page67).
Turn on the buffer (3600RPM) and hold the bar of buffing compound firmly against the outside diameter of the buffing wheels to apply alight coating of compound. Apply compound frequently to obtain sharp edges quickly.
NOTE: If excess compound is applied, the wheel will harden, making it ineffective.
Should this occur, Use a buffing wheel rake, available from an industrial supplier, to soften the wheel.
When holding knives, be cautions and use a firm grip. Hold the knife firmly with the bevel side up, parallel with and just below the center line of the shaft of the buffer (Figure 58). Push the knife edge into the buffing wheel, penetrating the wheel 1/16"-1/8"(1.5-3mm). Move the knife endwise and buff the entire edge across the buffing wheel with a steady rapid movement in each direction. Several rapid passes are better than one or two slow ones. Do not hold the knife in one area of the buffing wheel too long as the edge may heat and burn. If a burr or wire edge remains, turn the knife over and buff with the bevel side down. Continue buffing, switching from side to side, until wire edge or burr is gone.
Sharpen all sides of crinkle knife edges by tipping the knife endwise at a slight angle, first in one direction and then in the other. Next, the knife is held straight and level to buff the remainder of the cutting edge.
With bevel side up, sharpen side surface of crinkle knife edge by tipping the knife endwise at a slight angle, first in one direction and then in the other. Next, the knife is held straight and level to buff the remainder of the cutting edge.
Figure 58 – Model CKG honing machine set to sharpen 3-1/2” circular knives (1) Hone Bracket, (2) Mounting Position for Hone Assembly, (3) Knife Holder Hub, (4) Set Screw,(5) Edge Roller Stud (set screw seats in second hole), (6) Hone Shield, (7) Screw, (8) Knife Clamp Hub, (9) Locking Nuts, (10) Honing Wheel
Failure to obtain sharp edges by buffing may be caused by the following:
1, Edges may be too dull or blunt. Blunt edges must always be ground or filed to restore a bevel width and angle similar to that found on a new knife.
2, Knives must be correctly held against the buffing wheel (Figure 59).
3, Too little or too much buffing compound on the wheel.
4, Undersize buffing wheels. Discard the buffing wheels when they are worn to8-3/4" (222 mm) diameter.
Figure 59 – Correct position (top) and incorrect position (bottom) for knife during buffing .(1) Knife, (2) Buffing Wheel
Troubleshooting
PROBLEM
CAUSE
CORRECTION
Machine Does
Not Start
Power disconnect lockout switch is in the "O"(OFF)position
Turn power disconnect lockout switch to the "I"(ON) position.
Manual release on either of the guard locking switches is in the "unlock" position
Turn manual release to the "lock" position on both switches, page 17.
Guard locking switch power disconnect is in the "O"(OFF)position
Turn guard locking switch power disconnect to the "I"(ON) position, page 54.
Push/pull stop button is not pulled out after being pushed
Pull push/pull stop button out, page 28.
Covers and guards not securely closed
Make certain covers and guards are securely closed. Check for bent or twisted brackets that will prevent switches from lining up. See "Covers and Guards", pages34-35.
VFD fault or warning
Not error code displayed on VFD. Turn disconnect off. Correct fault or warning (refer to VFD manual).Turn disconnect on. If error code is still displayed, contact Urschel Laboratories.
VFD failure; no display on digital operator when machine is energized
Contact Urschel Laboratories.
Actuator key is bent or broken
Straighten or replace the actuator key.
Blown fuses
Check main and transformer fuses. See "Inspection", pages 54-55.
Electrical system malfunction
Inspect electrical system. See “Inspection", pages 54-55.
Overload relay tripped (across-the-line start)
Wait 5 minutes. Press “RESET" button. See "Motor Overload", page31.
Feed Cover or Gear Compartment Door Will Not Open(Guard locking Switch Status Lights Not Illuminated)
Guard locking switch power disconnect (located inside starter enclosure) is in the “O”(OFF) position.
Turn guard locking switch power disconnect to the “1”(ON) position, page 54
Guard locking switch solenoid failure
Replace guard locking switch.
Power source not connected to machine and turned on
Connect power source to machine and turn power source on.
Power failure
Turn the guard locking switch to the “unlock” position using the manual release, page 14.
Blown transformer fuse
Replace transformer fuse, page 54.
Feed Cover or Gear Compartment Door Will Not Open (Guard Locking Switch Status Lights Are Illuminated
Feed Cover door draw latch is unlatched before guard locking switch status light illuminates causing actuator key to hang up
Push feed cover door completely closed before opening, page 34.
Gear compartment door latch handle is rotated before guard locking switch status light illuminates causing actuator key to hang up
Push gear compartment door completely closed before opening, page 34.
Guard locking switch malfunction
Contact Urschel Laboratories.
Motor Frequently becomes Overloaded
Machine overload or jam
See “Correcting Machine Overload or Jam”. Page 31.
Feed rate too high
See “Feeding Method”, page 29.
Dull knives
Sharpen or replace as required, pages 68-69.
Power source too low
Incoming power must be at least 95% of specified voltage.
Motor problem
Contact Urschel Laboratories for location of nearest authorized motor service center.
Product Jams in Dicing Unit
Crosscut knives installed backwards
Install crosscut knives correctly. See “Reassembly”, page 49 or “Replacement of Crosscut Knives”, page 40.
Product Jams Between Stripper Plate and circular knives
Stripper plate area not thoroughly clean
When cleaning machine with hose, make sure all fines are cleared from stripper plate area.
Poor Quality Cuts
Crinkle case used with flat lid, or flat case used with crinkle lid
Use crinkle case with crinkle lid and straight lid with straight case.
Crosscut knives installed backwards
Install crosscut knives correctly. See “Reassembly”, page 49 or “Replacement of Crosscut Knives”, page 40.