This document describes the PowerMax3000™ Slicing System, a computer-controlled machine designed for slicing food products. The manual provides comprehensive information on assembly, operation, disassembly, cleaning, maintenance, and troubleshooting.
Function Description:
The PowerMax3000™ Slicer is designed to efficiently slice various food products. It features a touchscreen operator interface for computer-controlled machine operation and a Backclamp Feed System. The machine can slice 1, 2, 3, or 4 loaves simultaneously, depending on product size, and offers both automatic and manual loading options. It supports variable slicing speeds and various slicing patterns including shingle, stack, bunch, or bulk slicing. The system integrates dynamic scales to weigh sliced portions and adjust slice thickness for weight control, ensuring consistent stack or draft weights. Safety features include interlocks, "MASTER OFF" push buttons, and a safety laser scanner to prevent accidents.
Important Technical Specifications:
- Weight: 6000 lb (2722 Kg)
- Power Rating: 7.2 kVA (10.2 kVA with Knife heater)
- Voltage: 200, 230, 380, 420, 460, 575 Volts, 50/60 Hz, 3 Phase
- Air Requirements: 6.9 bar, 140 L/M (100 PSI, 5 CFM)
- Control System: 24 Volt
- Circuit Breaker: NEMA 4 standard
- Knife Speed: 1500 RPM
- Knife Stop Time: 3 seconds
- Operating Sound Level: 80 dB (A Scale)
- Environmental Operating Conditions: +1°C to +25°C (+34°F to +77°F), installation altitude up to 3000 m (9800 ft) above sea level, non-condensing relative humidity of 20% to 80%. The machine is not intended for use in explosive environments.
- Certifications: U.S.D.A. animal and plant health inspection service accepted, Manufactured to C.E. Specifications.
Usage Features:
The PowerMax3000™ offers a user-friendly touchscreen interface for controlling various aspects of operation.
- Product Codes: Users can select, edit, create, copy, rename, and delete product codes to pre-program machine adjustments and settings, saving setup time for recurring products.
- Run Screen: Displays basic adjustments like blade speed, slice denials, upper infeed pressure, and production rate.
- Adjustments Screen: Provides fine-tuning options for slicing parameters such as orifice clearance, blade backup, slicing start/stop degrees, feed start degrees, stack correction, slice spacing, shaved product move time, shaved product spacing, and slice thickness.
- Weight Data Screen: Shows "Accept/Reject" tolerances, target weight, and percentage of correction for weight control. It also allows dynamic scale checks.
- Loading Product: The Loaf Lift Tray, in conjunction with a safety laser scanner and loaf saddle switch, facilitates safe and efficient product loading. The scanner creates a protective field, stopping operations if an obstruction is detected.
- Slicing Operation: Grippers hold the product and feed it through the shear bar into the knife. The slicing conveyor receives the sliced product, which then transfers to the transfer conveyor and dynamic scale conveyors for weighing and classification.
- Portion Types: Supports "Stack," "Shingle," "Bulk," and "Shaved" modes, each with specific parameters for slice spacing and conveyor movement.
- TS-Max Speed Offset: Controls the speed of product transfer to the packager, allowing adjustment of spacing between stacks or drafts.
- PowerScanner Data: Allows the slicer to use scanner data for density correction, predetermining slice thickness based on product weight and volume.
Maintenance Features:
The manual outlines detailed procedures for daily, weekly, and monthly maintenance, as well as checks every 2000 hours.
- Tooling Care: Emphasizes proper care for the knife, shear bar, and gripper assemblies, including using a knife guard/carrier, keeping the knife sharp, using proper honing techniques, and checking knife clearance.
- Lubrication: Specifies lubrication intervals and recommended food-grade lubricants for various components such as idler roller shafts, gripper guide rails, loaf tray pivot bearings, classifier drive bearings, and structure lift bearings. Gearboxes require oil level checks monthly and oil replacement every 2000 hours.
- Cleaning Instructions: Provides a daily cleaning procedure that includes disassembling components like classifier conveyors, transfer conveyor, dynamic scale conveyors, debris conveyor, gripper drive, grippers, lower infeed conveyors, shear bar, loaf lift tray, slicing conveyor, knife, and side doors. It also details wiping, pre-rinsing, foam cleaning, and sanitization steps.
- Touchscreen Care: Instructions for covering the touchscreen with a plastic bag during cleaning and wiping it with sanitizing solution.
- Safety Precautions: Emphasizes lockout/tagout procedures before any maintenance, not operating the machine with guards open, and ensuring all guards and covers are in place before production.
- Service Screens: Provides access to diagnostic tools such as I/O Monitor, Fault Log, Machine Data, Machine Options, Machine Tests, Programmer Options, Administrator Options, Schematics, and Illustrations for troubleshooting and maintenance.
- Scale Calibration: Detailed steps for calibrating dynamic scales using a 1000-gram weight standard, including setting units to metric, removing weight, setting bias voltage, and performing static checks.
- Component Replacement: Instructions for replacing specific components like motion controllers, active line modules, servo modules, and feedback converters, including safety warnings regarding dangerous voltages.
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