Chapter 1 - NORMS AND GENERAL INFORMATION
NEXTSTEP FC100+MONO-PACK
Serial n° 655/09
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1.1 - LIST OF THE SAFETY PLATES
This paragraph contains all the safety and machine identification plates. Always keep
these signs in good conditions in order to ensure their readability.
The machine identification and safety signs belong to the safety system therefore for this
reason they haven’t to be dismounted or detached from the same machine.
MACHINE IDENTIFICATION PLATE
This plate showing the EEC mark is mounted on the front side of the machine.
It shows the machine name, the serial number, the manufacturing year, the weight, the air
and the electrical supply data.
Refer to these data when you ask information by the constructor or when you have to
order some spare parts.
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SAFETY SIGNS
They have been mounted on the machine where there is the possibility of residual risks for
the operator.
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1.2 - DECLARATION OF CONFORMITY
The Firm
OPEM S.p.A.
Via G. Mercalli, 16/A Area Ind. SPIP
43100 Parma (Italy)
On behalf of:
Mr. Fabio Binacchi
President
STATES
Under his own responsibility that
The new
POD MAKING AND PACKAGING MACHINE
Mod:
CL100/S + Monopack
with serial no.:
655/09
referred to this documentation,
CONFORMS TO
The laws transposing the Directions:
• 98/37/CE “MACHINES DIRECTIVE”
• 2004/108/CE “ELECTROMAGNETIC COMPATIBILITY”
• 2006/95/CE “ELECTRICAL MATERIALS DESTINED TO BE USED WITHIN PARTICULAR
TENSION LIMITS”
• 89/109/CE “MATERIALS AND THINGS DESTINED TO BE INCONTACT WITH FOOD
PRODUCTS”
and/or the subsequent modifications and integrations.
Parma, on: Signed by
(Fabio Binacchi)
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1.3 - TESTING AND GUARANTEE
1.3.1 Testing
The machine testing is carried out by Opem technicians or by the personnel authorized by
our Firm. The testing terms are shown in the sale agreement.
At the end of the testing, the Customer takes on the machine operation.
Therefore, at the end of the testing either positive or negative the involved technician will
fill the testing form, as the one illustrated below.
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1.3.2 Guarantee
The sale agreement contains the guarantee terms.
The improper use of the machine and the replacement of parts with others not in
conformity with the OPEM specifications, found on trade or not supplied by OPEM even if
as per drawing, will lose the guarantee.
We suggest you to ask the intervention of an OPEM inspector if you desire to transfer the
machine in other areas prior to restart it.
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1.4 - REFERENCE NORMS
- DPR 547/1955 ACCIDENT PREVENTION AND SANITARY REGULATIONS
- D.L. 277/1991 CHAP. IV: PERSONNEL PROTECTION AGAINST NOISE RISKS
DURING THE WORK .
- Annexed VI : CRITERIA FOR NOISE MEASUREMENT.
- DIRECTION 86/188/CEE RISKS COMING FROM THE NOISE EXPOSURE (CONCEIVED IN
ITALY WITH D.L. 277/1991).
- MACHINE DIRECTIVE 89/392/CEE - 91/368/CEE - 93/44/CEE - 93/68/CEE
- UNI - EN 292-1 Nov. 1992 MACHINE SAFETY RULES – RISK EVALUATION
- UNI - EN 292-2 Nov. 1992 MACHINE SAFETY RULES – SPECIFICATIONS AND TECHNICAL
PRINCIPLES
- Pr EN 954-1 Dic. 1992 MACHINE SAFETY RULES – GENERAL DESIGN PRINCIPLES
- EN 60204 Ott. 1992 MACHINERY ELECTRICAL EQUIPMENT -
and CEI 44-5 Sett. 1993 GENERAL REQUIREMENTS
- UNI 7712 - ISO 3746 WORK ENVIRONMENT NOISE MEASUREMENT
- UNI - EN 418 Ott. 1992 EMERGENCY AND SHUTDOWN DEVICES, DESIGN PRINCIPLES
- UNI - EN 294 Lug. 1993 SAFETY DISTANCES TO PREVENT ARMS FROM CONTACTING
DANGEROUS ZONES
- UNI - EN 349 Giu. 1994 MINIMAL DISTANCES TO AVOID HEAD CRUSHING
- DIRECTIVE 73/23/CEE SAFETY RULES FOR LOW VOLTAGE ELECTRICAL MATERIALS
- DIRECTIVE 89/109/CEE CONCERNING MATERIALS AND PARTS COMING IN CONTACT
WITH FOODSTUFFS
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1.5 – AT CUSTOMER’S CHARGE
The customer has the following charges and responsibilities:
- Civil engineering (preparation of leveled floor, ground and air anchorages).
Floor capacity for the machine installation: 3 Kg/[Link].
- Discharge and machine positioning on installation site.
For the capacity of the crane and other unloading and handling equipment,
see paragraph 3.2.
- Compressed air connection.
For capacity, connection point and dimensions see lay out drawing
6L.806.090 supplied by OPEM.
- Compressed air pressure: 6 bars – from plant network.
- electr. Supply connection.
For power and connection point see lay out drawing 6L.806.090 supplied by
OPEM
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1.6 - INSTRUCTIONS FOR INTERVENTION REQUEST
Phone or fax our Customer service to obtain any kind of intervention.
Our Customer service will help you to solve the problems in the min. shortest time.
OPEM S.p.A.
UFFICIO ASSISTENZA CLIENTI
Phone: +390521607501
Fax: +390521607509
E-mail: info@[Link]
1.7 - SPARE PART ORDERING INSTRUCTIONS
Using the furnished Spare Part catalogue you can find the machine spare parts easily.
This document made of drawings and bills of materials permits you to find the mechanical
part and the corresponding code. The form for the spare part request is at the end of the
catalogue.
The electrical component requiring a spare can be found on the wiring schematics. On the
wiring schematics, you will find the components referred to the schematic with the
corresponding code.
Send (also by fax) your spare part orders to OPEM SPARE PART DEP’T specifying the
serial number on every request.
OPEM S.p.A.
UFFICIO RICAMBI
Phone: +390521607501
Fax: +390521607509
E-mail: info@[Link]
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Chapter 2 - TECHNICAL DATA
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2.1 - PLANT DIMENSIONS
Refer to layout n° 6L.806.090 for dimensions
2.2 - POWER AND CONSUMPTION
MACHINE CL100/S
Electric Energy:
Volt See EC plate
Hz See EC plate
Total kW See layout
Control Circuit 24 V dc
Pneumatic Energy See EC plate
Maximum Air Consumption See layout
2.3 - PERFORMANCE
approx.
Product weight Pod type Bag type
output
Round pod in special Stamped doubled heat-sealing
format film - 4 seals 80 - 90
Ground coffee 7 g.
int.Ø 76 - ext.Ø 87 dimensions: 110 x 105 pieces/min.
(see diag. 6C.802.419) (see diag. 6C.151.176)
production is indicative and bound to the kind of film and used products
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2.4 - MACHINE DESCRIPTION
The “CL100” packaging machine produces pods containing ground coffee made
from reels of filter paper (A1 and A2), and inserts them in single dose packs, made
from a reel of thermal retractable film (B). Inert gas is added to the single dose
packs. The pods are formed on small dies on a catenary (C) where the auger
dosing unit (E) deposits a measured amount on the lower filter paper. Next to the
dosing unit there is a pre-forming pad (D) which is lowered onto the paper to shape
it. After being deposited on the filter paper the coffee dose is passed under pad (F)
and pressed. In the following stations the pod is sealed (G) and cut (H). The
finished pods are collected from the dies by a pneumatic system and individually
weighed by a loading cell (I): those outside a determined weight tolerance are
discarded. After the forming cycle, the pods are inserted in single dose packs. The
film used for creating the bag is sealed vertically (L) and horizontally (M). Before the
completed bag can drop it is stopped by a bag-blocking pad (N) and placed on the
delivery belt (O), which transports it to the belt elevator (P). Off-cuts from the above
procedure, for producing pods for single dose packs, are sucked up by a special
suction pump. The work cycle is managed by PLC with alphanumeric interface
display and self-test function, manual commands and work program selection Some
groups are controlled by electronic starters or frequency changers to obtain smooth
stops and starts and speed variations.
E F G
A1
CL 100
I
A2 O
M
N
P
A2
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2.5 - NOISE LEVEL MEASUREMENT
The airborne noise produced by the machine has been measured as per norms ISO 3746.
Its value corresponds to:
_
LpA= <85 dB (A)
ATTENTION:
The employer has to inform the personnel about the risks for the hearing and must
adopt the necessary safety measures in conformity with the rules.
Aspirators must be used when carrying out machine operations. These do not have
to be compulsorily positioned near the machine but must be located in soundproof
areas. The Customer is responsible for providing suitable soundproof structures to
prevent any consequent damage caused by overall machine noise. If the user is
unable to position the aspirators in suitable areas then he must provide operators
with protection as required under the law.
2.6 - ENVIRONMENTAL CONDITIONS
The machine environmental operating conditions must comply with the following
requirements:
Temperature: from 0°C to +50°C
Humidity from 10% to 90% (not condensed).
The machine must be located in a place sheltered from the rain and the sand.
The presence of environmental conditions different from those shown can cause great
damage to the machines, especially to the electronic equipment.
The mounting of the machine when made in environments different from those suggested
WILL LOSE YOU THE GUARANTEE for the parts to replace.
The storage of the machine, when out of service, allows a temperature range within
-10°C and +70°C, being unchanged the other precautions.
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Chapter 3 - INSTALLATION
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3.1 - MACHINE TRANSPORTATION
The machine is divided into the following groups for easy transportation:
A) Group: CL100/S
Dimensions (mm): See layout
Weight (Kg): See EC plate
B) Packages Delivery Belt
Dimensions (mm): See layout
Peso (Kg): 100
3.2 - LOADING UNLOADING AND GROUP TRANSFER
For loading, unloading and transfer of the groups, it’s necessary to comply with the
schematic instructions supplied on the attached drawings.
As lifting points, the operator can use the main frames (sides or beams). The cranes, the
hoists and the lifting truck represent the means required for the unloading.
All the groups equipped with eyebolts or points showing their application must be raised in
the marked points. The ropes must be steadily hooked to the eyebolts and to the hook of
the crane or hoist. For the groups without eyebolts or not foreseen for this application it’s
allowed the use of lifting bands to balance the weight.
ATTENTION:
Make sure vehicles and logistic structures comply with the requested use and are in
their best conditions.
Keep away from suspended loads.
Make sure ropes and lifting bands are in their best conditions and have been
adequately inserted in the proper hooks.
During the operation, remember to use safety gloves, safety shoes and helmet.
WARNING:
During the eyebolt lifting to ensure the sealing let an angle between the eyebolt and
the band (chain or rope) equal to
α = >45°°
Stretch the ropes slowly and verify that any component not related to the
lifting (as electrical components, raceways a.s.o.) hasn’t been involved in the
operation.
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3.2.1 Handling CL100/S
Insert the lifting hooks in the eyebolts on the upper part of
the structure to lift and move the structure (as shown in
the figure).
Slightly tighten the belts, before lifting and moving the
group, to ensure that it is completely disconnected from
the rest of the plant.
Dimensions (mm): See layout
Weight (Kg): See EC plate
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3.2.2 Handling of the Packages Delivery Belt
To lift and move the machine, do as follows:
1) Disconnect the belt from the rest of the system.
2) Pass the lifting belts under the base of the delivery belt and slightly incline it, as
shown in the figure, to aid stability.
3) Slightly tighten the lifting belts, before lifting and moving the delivery belt, to
ensure that no parts unable to bear weight are involved.
Dimensions (mm): See layout
Weight (Kg): 100
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3.3 - POSITIONING OPERATION DESCRIPTION
The right positioning of the machine helps the best operating conditions, an easy cleaning
and routine maintenance . It’s necessary to keep free an area all around the machine in
relation to the machine dimensions to permit the activity of the personnel during the
installation operations.
For the dimensions refer to the lay out measurements.
WARNING:
Be sure that the floor used for the machine installation is able to bear the weight of
the machine.
After the measurement control, level all the machine members.
Check if the machine rests on its support feet firmly and on the contrary adjust the feet.
The height adjustments must be made acting on the adjusting nuts of the support feet, as
follows:
1) unloose the upper nuts blocking the adjustable feet by a wrench.
2) Set the height from the ground screwing or unscrewing the bottom nuts by a wrench
then level the machine taking as reference the top surface of the same.
3) Check if all the feet bear the machine weight.
4) Lock the upper nuts to fasten the machine in the right position.
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3.4 - AIR AND ELECTRICAL ASSEMBLY
Electrical connections
The control board supply line must be sized on the ground of the length of the laying of the
room temperature, the nature of the load and however it must comply the laws in force in
the installation country .
The user is responsible for the sizing of the supply line and ground wire up to the machine,
also the choice of the safety devices against the short circuit and the contact voltage.
About the electrical machine requirements and the connections refer to the wiring
schematics.
The machine has been designed and built in order to eliminate by the grounding the
possible risks due to the build-up of electrostatic charges and to prevent any risk due to
the electric energy.
ATTENTION
DANGER!
These operations have to be carried out by qualified personnel only and when the
power is off.
1) The machine wiring takes place in accordance with the regulations in force in the
country foreseen for the installation therefore operator has just to plug the machine in
the mains supply.
2) Check if the line voltage corresponds to the one shown on the motor plate.
3) Connect the three-phase voltage, the ground and the neutral.
4) Turn on the power setting the main disconnector on “I” and check the rotation direction
of the motors as described in the following paragraph.
The connection work is easier if operator refers to the attached wiring schematics.
Motor rotation direction
Inspections must comply with the safety rules since when checking motors operators are
obliged to enter moving parts.
Prior to start the motors be sure that only the installation personnel is in proximity to the
machine and however nobody is in contact with the machinery.
The rotation direction must be the one shown by the arrow marked on the motor.
Reverse two phases If the rotation direction is wrong.
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Air and gas connections
To connect the air and gas supply pipes to their
respective fittings in the filter-reducer-lubricator
groups insert the power supply using the special
attachment, as shown in the photo.
For the power pressure required consult the
supplied lay-out.
Electric connections
The electric cable is in the upper part of the machine switchboard.
Insert the plug in the special electrical socket.
For the power required consult the supplied lay-out.
Connection of pumps and packages delivery belt
To connect the pumps and the belt insert the connections in their respective sockets as
shown in the photo. For connections consult the wiring diagrams.
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3.5 - DESCRIPTION OF SETTING UP AND INITIAL STARTING
OPERATIONS
These operations must be exclusively carried out by an OPEM technician.
Otherwise, OPEM declines all responsibility for the machine.
3.6 - REINSTALLATION
The operation can be carried out by a qualified technician of the User following the
instructions given in paragraphs 3.1, 3.2, 3.3, 3.4.
Machine start-up can only be carried out by an OPEM technician.
Otherwise, OPEM declines all responsibility for the system.
3.7 - DISMANTLING AND SCRAPPING
Dismantling can be carried out by qualified technicians, mechanics and electricians of the
User following the instructions given in paragraphs 3.1, 3.2, 3.3, 3.4.
Scrapping does not require any particular provisions, as the machine is not built with
harmful substances.
You must however follow the legislation in effect in the country of installation.
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Chapter 4 - SAFETY DATA
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4.1 - INTENDED USE AND APPLICATIONS
4.1.1 Intended use of the machine
The machine has been designed to package single doses of ground coffee in pods of filter
paper.
4.1.2 Machine applications
Machine type: CL100/S
Serial n°: 655/09
has been designed and equipped to form the packages described in the table below
approx.
Product weight Pod type Bag type
output
Round pod in special Stamped doubled heat-sealing
format film - 4 seals 80 - 90
Ground coffee 7 g.
int.Ø 76 - ext.Ø 87 dimensions: 110 x 105 pieces/min.
(see diag. 6C.802.419) (see diag. 6C.151.176)
production is indicative and bound to the kind of film and used products
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4.2 - ALLOWED USE, FORESEEN USE, NOT ALLOWED USES
4.2.1 Allowed use
The machine is equipped and programmed to work with the products listed at paragraph
4.1.2 "Machine application".
OPEM refuses any responsibility in case of malfunction, failures or accidents due to the
use of products or materials different from those mentioned at paragraph “Machine
application".
4.2.2 Foreseen use
The machine could also work with products different but similar to those listed at
paragraph 4.1.1 concerning "Machine purpose", if suitably equipped and programmed.
This tooling and programming can be carried out by OPEM only. Otherwise OPEM refuses
any responsibility on the plant.
4.2.3 Not allowed uses
Other uses, not foreseen on paragraphs “Machine purpose” and “Machine application”
aren’t allowed.
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4.3 - DANGEROUS ZONES
All the dangerous zones have been enclosed by fixed or mobile guards.
4.4 - RISKS, DANGERS AND UNREMOVABLE RISKS
There are zones with residual risks.
4.4.1 Control box
If it’s necessary to enter the control box when the power is on, the intervention has to be
made by qualified personnel trained for this work.
The doors mounted on the control box are equipped with safety switches that release the
main cutout switch at the opening of the doors. These doors are provided with locks and
the keys are kept by qualified electricians.
ATTENTION
DANGER !
The inside parts are hot under a voltage of 380 Volt.
The wiring part connecting the RST supply terminals remains under the grid
voltage.
4.4.2 Handling for unloading and positioning
During the handling of several groups as well for unloading as for positioning it can occur
the breakage of the lifting bands.
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4.5 - ADOPTED SAFTEY DEVICES
Personnel in charge of running and maintaining the machines, must be instructed on how
to use the guards: how to open and replace them and how to free themselves if trapped. If
using factory equipment, follow the instructions given in the specific paragraphs of this
Operations and Maintenance Manual.
4.5.1 Fixed and opening guards
The machine have guards to isolate the danger zones.
Two types of guard are used:
- Fixed guards
Guards fixed to the machine body by screws or bolts which can only be removed by
wrenches. This may be necessary when carrying out exceptional maintenance work
requiring the intervention of a mechanical technician.
ATTENTION:
Fixed guards can only be removed with the machine in standstill, the general
electric switch off and with no pressure in the pneumatic circuit.
Never use the machine without the guards assembled and locked.
- Opening guards
These guards are mounted on hinges or rails. Each guard has a safety micro-switch which
intervenes whenever a guard is opened, causing an emergency stop.
The micro-switches used are shown in the photo.
ATTENTION:
Do not eliminate the safety limit switch by electrical or
mechanical alterations.
Never use the machine without the guards assembled
and locked.
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4.5.2 Motorization guards
All motorization has metal sheeting or mesh protection.
4.5.3 Emergency stop buttons
These buttons are red with mushroom-heads in conformance with current
regulations. Four are installed on the machine in easily accessible positions.
When a button is pressed it immediately stops the automatic cycle and all motors.
RED MUSHROOM -HEAD BUTTON ON YELLOW BACKGROUND
Installed on control panel.
RED MUSHROOM -HEAD BUTTON ON YELLOW BACKGROUND
Installed next to electrical cabinet, near the CE plate.
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RED MUSHROOM -HEAD BUTTON ON YELLOW BACKGROUND
Installed on the left side of the electrical cabinet, near the rolls of filter paper.
4.5.4 Electric cutout box safety
The general switch is a door locking switch; opening the door cuts the power off.
The box has a warning hooter to signal machine start-up
ATTENTION:
The wiring connecting the RST feed clamp to the mains switch remains under
voltage.
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4.5.5 Key selector switches
These selectors can only be operated by the key holder.
This prevents anyone else cutting out the safety device.
They are located on the machine command panel.
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4.5.6 PLC buffer battery
In the control box there is a buffer battery that permits to the CPU of the PLC the continuity
of the storage in case of lack of supply. This battery is guaranteed for 1-year life. It’s
recommended on the ground of the purchase date and of the machine working hours to
replace the buffer battery with another similar to the one formerly installed by us. The
replacement of the buffer battery has to take place when the CPU is fed.
ATTENTION:
the buffer battery is a lithium battery and CAN’T BE RECHARGED.
Explosion danger.
The exhausted batteries have to be eliminated as special waste.
In case of missing replacement of the buffer battery the CPU will lose the content of
the inside memory every time the power will be cut from the control box therefore it
will be necessary to reload the program into the Control Process Unit.
ALL THE DESCRIBED OPERATIONS HAVE TO BE MADE BY QUALIFIED
PERSONNEL.
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