Formax PowerMax 3000 - Safety System Overview

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031914 1-5

SAFETY SYSTEM OVERVIEW

SAFETY ZONES FUNCTION BRANCH CONTACTOR

Main Guard Function Stops all motions KA1/KA2

Clean Function Allows clean motions only:

Structure

KA3/KA4

Safety Laser Scanner Inhibits Motions:

Product Lift Tray

KA7/KA8

KM2

CONTACTOR

KM3

CONTACTOR

KA1/KA2 KA3/KA4 KA5/KA6

Main Page

Table of Contents7
Safety15
Safety Information15
Safety Sign Locations16
Safety System Overview19
Lockout/Tagout20
Theory of Operation21
Introduction21
Clean-Up Position21
Infeed Structure Lift21
Knife Cover21
Move to Ready Position22
Loaf Lift Tray23
Safety Laser Scanner23
Loaf Tray Lift Cylinders24
Load Loaf Saddle Switch24
Loaf Gate25
Loaf Length Sensors25
Gripper Drives26
Lower Infeed Conveyors26
Grippers26
Upper Infeed Hold down Assembly28
Shear Bar28
Knife29
Knife Motor29
Knife Retract Actuator29
Slicing Conveyor30
Debris Conveyor30
Transfer Conveyor31
Transfer Alignment Actuator31
Dynamic Scale Conveyors32
Classifier Conveyors33
Touchscreen Controls35
Introduction35
Page 3-2 "Home" Screen35
Page 3-3 "Run" Screen35
Page 3-4 "Product Codes" Screen35
Page 3-5 "Production Data" Screen35
"Service" Screen40
Tooling43
Tooling Care43
Shear Bar Care44
Classifier Conveyors47
Transfer Conveyor49
Gripper Drive54
Shear Bar58
Loaf Lift Tray59
Slicing Conveyor61
Side Doors63
Power on64
Operation65
Introduction65
Assemble the Machine65
Power on66
Login66
Select Product Code68
Cycle Start68
Load Product69
Start Feed70
Stopping the Machine70
Remove Product70
Machine Adjustments71
Adjustments Screen81
Production Data Screen99
Weight Data Screen100
Product Code Parameters103
Introduction103
Selecting a Product Code103
Editing a Product Code104
Creating a Product Code106
Keyboard Buttons107
Copy an Existing Product Code108
Rename an Existing Product Code109
Delete a Product Code110
Programming Product Code Parameters111
Disassembly and Cleanup139
Raise Classifier Conveyors139
Power off140
Remove the Knife141
Cover Touchscreen142
Disassemble Slicing Conveyor142
Remove Shear Bar145
Remove the Infeed Conveyors145
Remove Grippers147
Disassemble the Gripper Drive Assembly148
Disassemble the Loaf Lift Tray150
Disassemble the Classifier Conveyors151
Disassemble the Dynamic Scale Conveyors152
Disassemble the Transfer Conveyor154
Cleaning Instructions158
Lubrication171
Introduction171
Procedures172
Daily173
Weekly176
Monthly177
Service Screens183
Introduction183
Monitor I/O184
Chart Recorder188
Profibus Network192
Scales193
Fault Log196
Maintenance196
Machine Data197
Machine Options197
Machine Tests198
Programmer Options212
Administrator Options212
Schematics216
Illustrations216
Motion Control/Servo Drive System217
Introduction217
Computer217
Profibus Network218
Modbus Network218
Motion Control Module218
Active Line Module220
Servo Drive Modules220
Servo Motor221
Resolver Feedback System221
Feedback Converters222
Servo Motor Cables223
U3 Active Line Module: Electrical Overview227
Motion Control Modules232
Servo Drive System247
Servo Drive Modules251
Servo Motors262
Resolver Feedback Converter Modules263
Motion Controller Replacement (U11)267
Active Line Module Replacement271
Servo Module Replacement275
Feedback Converter Replacement U0279
Electrical - Electronic285
Introduction285
Electrical Precautions285
Electrical/Electronic System Overview288
Computer288
Electrical Overview (3-Phase AC Supply Voltage)301
System Overview - A4 Safety Laser Scanner329
Pneumatic Supply365
Infeed Housing Manifold366
Mainframe Manifold367
Scale Manifold368
Pressure Switch369
Replace Scale Assembly372
Scale Calibration375
Transfer Conveyor Repair379
Seal and Bearing Replacement379
Honing the Knife385
Maintenance and Lubrication394
Honing the Knife397
Maintenance and Lubrication406
Formax H1 Gear Oil407

Formax PowerMax 3000 - Safety System Overview

Table of Contents