Operating Manual
`
`Slicer
`CCS 904
`
`CCS-904_06_2006-07-01_GB / T-07_2005-11-10
`
`Weber EX1005
`IPR2020-01557
`U.S. Patent No. 10,639,812
`
`
`
`Slicer
`CCS 904
`
`CCS-904_06_2006-07-01_GB / T-07_2005-11-10
`
`Weber EX1005
`IPR2020-01557
`U.S. Patent No. 10,639,812
`
`
`
`...or your WEBER Customer Service:
`
`WEBER contact addresses
`
`Please direct all queries to:
`
`WEBER Maschinenbau GmbH & Co. KG
`Günther-Weber-Strasse 3
`35236 Breidenbach
`Germany
`www.weber-net.de
`
`Customer service hotline:
`Tel: +49 (0) 6465 918-213
`Fax: +49 (0) 6465 918-203
`
`E-mail: service@weber-net.de
`
`Company stamp
`
`WEBER Maschinenbau GmbH Neubrandenburg
`Feldmark 11
`17034 Neubrandenburg
`Germany
`www.weber-net.de
`
`Customer service hotline:
`Tel: +49 (0) 395 4506-214
`Fax: +49 (0) 395 4506-220
`E-mail: info@weber-net.de
`
`Spare parts orders:
`Tel: +49 (0) 6465 918-209 or -219
`Fax: +49 (0) 6465 918-203
`E-mail: service@weber-net.de
`
`© WEBER Group
`Without the written authorisation of the WEBER Group, neither the operating manual nor any portion
`thereof may be reproduced or transferred in any way. The user may copy the operating manual for in-
`ternal use or print it from CD.
`Technical modifications received after the copy deadline are not included in the operating manual.
`
`– page 2 of 288 pages –
`Operating Manual Slicer CCS 904
`CCS-904_06_2006-07-01_GB / T-07_2005-11-10
`
`
`
`Table of contents
`1 Machine overview .........................................................................................10
`1.1 Areas of the Slicer............................................................................................10
`Loading area/infeed area .......................................................................... 10
`1.1.1
`1.1.2 Slicing area............................................................................................ 11
`1.1.3 Discharge area ....................................................................................... 12
`1.2 Operating positions ......................................................................................... 13
`1.2.1 Touch-Screen operating position ................................................................ 13
`1.2.2 Operating position/loading position ............................................................. 14
`1.3 CCS 904 (product length up to 1200 mm) ......................................................... 15
`1.4 CCS 904 (product length exceeding 1200 mm).................................................. 17
`1.5 Controls ......................................................................................................... 19
`1.6 Assemblies/components.................................................................................. 20
`Involute blade......................................................................................... 20
`1.6.1
`1.6.2 Product bed conveyor (product length up to 1200 mm) ................................... 21
`1.6.3 Upper product guide ................................................................................ 22
`1.6.4 Product holder........................................................................................ 23
`1.6.5 Blank holder (product length exceeding 1200 mm) ......................................... 24
`1.6.6 Product conveyor and timing belt (product length up to 1200 mm) ..................... 25
`1.6.7 Product conveyor (product length exceeding 1200 mm) .................................. 26
`1.6.8 End piece ejection flap (product length exceeding 1200 mm) ........................... 27
`1.6.9 End piece removal conveyor (product length up to 1200 mm)........................... 28
`1.6.10 End piece chute/end piece removal conveyor (product length
`exceeding 1200 mm) ............................................................................... 29
`1.6.11 Shear bar/product-section guide................................................................. 30
`1.7 Safety devices ................................................................................................ 31
`1.8 Main switch and compressed air supply for the Slicer......................................... 34
`1.9 EMERGENCY STOP ...................................................................................... 35
`1.10 Type plate ...................................................................................................... 36
`2 Functions .........................................................................................................37
`2.1 Intended use ...................................................................................................37
`2.2 Predictable incorrect use ................................................................................. 38
`2.3 Centre of discharge and discharge height ..........................................................38
`2.4 Operational sequence for Slicers with a loading device up to 1200 mm ............... 39
`Loading procedure .................................................................................. 39
`2.4.1
`Semi-automatic loading by the operator........................................ 39
`2.4.1.1
`Automatic loading by a module connected upstream ....................... 39
`2.4.1.2
`Loading procedure .................................................................................. 40
`2.4.2
`2.4.3 Slicing process ....................................................................................... 40
`2.4.4 Ejection of the end pieces ......................................................................... 40
`
`– page 3 of 288 pages –
`Operating Manual Slicer CCS 904
`CCS-904_06_2006-07-01_GB / T-07_2005-11-10
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`
`
`2.5 Operational sequence for Slicers with a loading device exceeding 1200 mm........ 41
`Loading procedure .................................................................................. 41
`2.5.1
`Loading procedure .................................................................................. 41
`2.5.2
`2.5.3 Slicing process ....................................................................................... 41
`2.5.4 Ejection of the end pieces ......................................................................... 42
`
`3 Residual risks .................................................................................................43
`3.1 Residual risk due to moving components ...........................................................43
`3.2 Residual risk due to sharp-edged and pointed components ................................ 46
`
`4 Operation .........................................................................................................48
`4.1 Slicer operating modes.................................................................................... 49
`4.1.1 Standby mode ........................................................................................ 49
`4.1.2 Slicing mode .......................................................................................... 49
`Idle cut mode ......................................................................................... 49
`4.1.3
`4.1.4 Cleaning mode ....................................................................................... 49
`“Malfunction” operating mode .................................................................... 50
`4.1.5
`4.1.6 Service mode ......................................................................................... 50
`4.1.7 Detecting the operating mode/status of the slicing line (optional)....................... 51
`4.2 Start-up...........................................................................................................52
`4.2.1 Start-up for adjustment work...................................................................... 53
`4.2.2 Start-up for slicing ................................................................................... 53
`4.2.3 Checking components.............................................................................. 54
`4.2.4 Checking the safety devices ...................................................................... 56
`4.2.5 Putting the Slicer into operation.................................................................. 66
`4.3 Opening and modifying programs..................................................................... 67
`4.4 Loading the Slicer ........................................................................................... 68
`4.5 Starting the slicing procedure............................................................................68
`4.6 Switching the slicing line to idle cut mode.......................................................... 69
`4.7 Cancelling idle cut mode...................................................................................69
`4.8 Stopping the slicing process .............................................................................69
`4.9 Blade change ................................................................................................. 70
`4.9.1 Removing the involute blade ..................................................................... 71
`Installing the involute blade ....................................................................... 72
`4.9.2
`4.10 Setting up the Slicer ........................................................................................ 73
`4.10.1 Preparing to set up the Slicer..................................................................... 73
`4.10.2 Adjusting the product clearance height and total product width ......................... 74
`4.10.2.1 Moving the blade head housing vertically...................................... 74
`Adjusting the cutting position of the blade ..................................... 75
`4.10.2.2
`Adjusting the total product width ................................................. 75
`4.10.2.3
`Completing the set up of the Slicer .............................................. 76
`4.10.2.4
`
`– page 4 of 288 pages –
`Operating Manual Slicer CCS 904
`CCS-904_06_2006-07-01_GB / T-07_2005-11-10
`
`
`
`4.11 Shut down...................................................................................................... 77
`4.11.1 Switching off sequence ............................................................................ 77
`4.11.2 Stopping slicing ...................................................................................... 78
`4.11.3 Shutting down the Slicer ........................................................................... 79
`
`5 Disassembly and assembly .......................................................................80
`5.1 Safe disassembly/assembly............................................................................. 81
`5.2 Releasing/connecting the compressed air supply............................................... 82
`5.2.1 Releasing compressed air ports ................................................................. 83
`5.2.2 Connecting the compressed air ports .......................................................... 83
`5.3 Safety devices .................................................................................................84
`5.3.1 Opening the safety device......................................................................... 84
`Opening the left-hand door of the safety device.............................. 84
`5.3.1.1
`Opening the right door of the safety device.................................... 85
`5.3.1.2
`Opening the rear door of the safety device .................................... 85
`5.3.1.3
`5.3.1.4
`Opening the door of the safety device above the CCU
`portioning unit ......................................................................... 86
`Opening the door of the safety device above the timing belt.............. 87
`5.3.1.5
`5.3.2 Closing the safety device .......................................................................... 88
`Closing the left door of the safety device....................................... 88
`5.3.2.1
`Closing the right door of the safety device..................................... 88
`5.3.2.2
`Closing the rear door of the safety device ..................................... 89
`5.3.2.3
`5.3.2.4
`Closing the door of the safety device above the CCU
`portioning unit ......................................................................... 90
`Closing the door of the safety device above the timing belt ............... 91
`5.3.2.5
`5.3.3 Blade safety cover................................................................................... 93
`Opening the blade safety cover .................................................. 93
`5.3.3.1
`Closing the blade safety cover.................................................... 94
`5.3.3.2
`5.3.4 Housing covers and switch cabinet covers ................................................... 96
`Disassembling the housing cover ................................................ 96
`5.3.4.1
`Assembling the housing cover .................................................... 96
`5.3.4.2
`Opening the switch cabinet covers .............................................. 97
`5.3.4.3
`Closing the switch cabinet covers................................................ 98
`5.3.4.4
`5.4 Collecting trays (optional) .................................................................................99
`5.4.1 Moving the collecting trays out ................................................................... 99
`5.4.2 Pushing in the collecting tray ................................................................... 101
`5.5 CCU portioning unit........................................................................................103
`5.6 Timing belt (product length up to 1200 mm) .................................................... 104
`5.6.1 Disassembling the timing belt .................................................................. 104
`Removing the side limit stops ................................................... 104
`5.6.1.1
`Disassembling the centre separation bars (optional)...................... 105
`5.6.1.2
`Releasing and removing the conveyor belt .................................. 107
`5.6.1.3
`
`– page 5 of 288 pages –
`Operating Manual Slicer CCS 904
`CCS-904_06_2006-07-01_GB / T-07_2005-11-10
`
`
`
`5.6.2 Assembling the timing belt ...................................................................... 108
`Mounting and tensioning the conveyor belt.................................. 108
`5.6.2.1
`Inserting the side limit stops ..................................................... 110
`5.6.2.2
`Adjusting the side limit stops .................................................... 111
`5.6.2.3
`Assembling the centre separation bars (optional).......................... 114
`5.6.2.4
`5.7 Product holder ...............................................................................................116
`5.7.1 Preparing assembly/disassembly ............................................................. 116
`5.7.2 Releasing compressed air ports ............................................................... 117
`5.7.3 Releasing and removing the product holder ................................................ 117
`5.7.4 Fitting and fastening the product holder ..................................................... 118
`5.7.5 Connecting the compressed air ports ........................................................ 119
`5.7.6 Adjusting the product holder .................................................................... 121
`5.8 Blank holder (product length exceeding 1200 mm)............................................125
`5.8.1 Disassembling the blank holder................................................................ 126
`5.8.2 Assembling the blank holder.................................................................... 127
`5.8.3 Adjusting blank holders .......................................................................... 128
`5.9 Product conveyor and its variants................................................................... 129
`5.9.1 Product conveyor (product length up to 1200 mm) ....................................... 129
`Disassembling the product conveyor.......................................... 129
`5.9.1.1
`Assembling the product conveyor.............................................. 135
`5.9.1.2
`5.9.2 Product conveyor (product length exceeding 1200 mm) ................................ 142
`Disassembling the product conveyor.......................................... 142
`5.9.2.1
`Assembling the product conveyor.............................................. 147
`5.9.2.2
`5.10 End piece ejection flap (for product length exceeding 1200 mm) ........................156
`5.10.1 Removing the side limit stop of the end piece ejection flap (optional) ............... 156
`5.10.2 Disassembling the plastic rollers of the end piece ejection flap ....................... 157
`5.10.3 Assembling the plastic rollers of the end piece ejection flap ........................... 159
`5.10.4 Assembling the side limit stop of the end piece ejection flap (optional) ............. 160
`5.11 End piece removal conveyor.......................................................................... 161
`5.11.1 Preparing disassembly/assembly ............................................................. 161
`5.11.2 Disassembling the end piece removal conveyor .......................................... 162
`5.11.3 Assembling the end piece removal conveyor .............................................. 166
`5.12 Product bed conveyor and its variants ............................................................ 170
`5.12.1 Product bed conveyor (product length up to 1200 mm) ................................. 170
`Disassembling the product bed conveyor.................................... 171
`5.12.1.1
`Assembling the product bed conveyor........................................ 174
`5.12.1.2
`5.12.2 Product bed conveyor for CCI Interleaver (optional) ..................................... 179
`Disassembling the product bed conveyor.................................... 180
`5.12.2.1
`Assembling the product bed conveyor........................................ 183
`5.12.2.2
`5.12.3 Standard product bed conveyor (product length exceeding 1200 mm).............. 186
`Disassembling the product bed conveyor.................................... 187
`5.12.3.1
`Assembling the product bed conveyor........................................ 191
`5.12.3.2
`
`– page 6 of 288 pages –
`Operating Manual Slicer CCS 904
`CCS-904_06_2006-07-01_GB / T-07_2005-11-10
`
`
`
`5.13 Upper product guide.......................................................................................195
`5.13.1 Disassembling the support frame (without conveyor belt) .............................. 195
`5.13.2 Disassembling the support frame (with conveyor belt) (optional) ..................... 197
`5.13.3 Assembling the support frame (with conveyor belt) (optional) ......................... 201
`5.13.4 Assembling the support frame (without conveyor belt) .................................. 206
`5.14 Involute blade ................................................................................................207
`5.14.1 Disassembling the involute blade ............................................................. 209
`5.14.1.1 Opening the blade safety cover ................................................ 209
`Assembling the blade guard..................................................... 210
`5.14.1.2
`Removing the involute blade .................................................... 210
`5.14.1.3
`Setting the involute blade down safely........................................ 212
`5.14.1.4
`5.14.2 Cleaning the involute blade ..................................................................... 213
`5.14.3 Storing the involute blade ....................................................................... 214
`5.14.4 Assembling the involute blade ................................................................. 215
`Assembling the blade guard..................................................... 216
`5.14.4.1
`Installing the involute blade...................................................... 216
`5.14.4.2
`Disassembling the blade guard................................................. 218
`5.14.4.3
`Closing the blade safety cover.................................................. 219
`5.14.4.4
`5.15 Shear bar/product-section guide......................................................................220
`5.15.1 Disassembling the shear bar/product-section guide...................................... 221
`5.15.2 Assembling the shear bar/product-section guide.......................................... 223
`5.16 Checking and adjusting the cutting gap............................................................225
`5.16.1 Adjusting the shear bar/product-section guide ............................................. 226
`5.16.1.1 Manual or automatic adjustment of the cutting gap?...................... 226
`5.16.1.2 Manual adjustment of the shear bar/product-section guide ............. 227
`Automatic adjustment of the shear bar/product-section guide (optional)....
`5.16.1.3
`228
`[Cutting gap setting (mm)] parameter ......................................... 229
`5.16.1.4
`5.16.2 Checking the cutting gap manually ........................................................... 231
`5.16.3 Adjusting the cutting gap manually............................................................ 234
`5.17 Moving and adjusting axes ............................................................................ 235
`5.18 Moving the blade head housing.......................................................................236
`5.18.1 Moving the blade head housing vertically ................................................... 236
`5.18.2 Moving the blade head housing horizontally................................................ 236
`5.19 Moving the infeed unit horizontally...................................................................237
`5.20 Moving and adjusting the upper product guide..................................................238
`
`6 Cleaning .........................................................................................................239
`6.1 Preparations for cleaning................................................................................239
`6.1.1 Using guard plates to protect the light barriers from splashing water ................ 239
`6.2 Performing interim cleaning ........................................................................... 240
`
`– page 7 of 288 pages –
`Operating Manual Slicer CCS 904
`CCS-904_06_2006-07-01_GB / T-07_2005-11-10
`
`
`
`6.3 Preparations for regular cleaning.................................................................... 241
`6.3.1 Shutting down the Slicer ......................................................................... 241
`6.3.2 Disassembling components for regular cleaning .......................................... 241
`6.4 Performing regular cleaning ........................................................................... 246
`6.5 Completing regular cleaning ...........................................................................246
`6.5.1 Assembling components after regular cleaning............................................ 246
`6.5.1.1
`Assembling components/assemblies
`(product length up to 1200 mm) ................................................ 246
`Assembling components/assemblies
`(product length exceeding 1200 mm) ......................................... 247
`6.6 Completing cleaning...................................................................................... 248
`6.6.1 Removing the guard plates from the light barriers ........................................ 248
`6.6.2 Switching on the slicing line..................................................................... 248
`
`6.5.1.2
`
`7 Maintenance ..................................................................................................250
`7.1 Maintenance intervals ....................................................................................250
`7.2 Preparations for maintenance work ................................................................ 251
`7.2.1 Shutting down the Slicer ......................................................................... 251
`7.2.2 Overview of the assemblies/components to be maintained ............................ 252
`7.3 Daily maintenance ........................................................................................ 254
`7.3.1 Maintenance of the involute blade ............................................................ 254
`7.3.2 Completing daily maintenance ................................................................. 254
`7.4 Weekly maintenance..................................................................................... 255
`7.4.1 Timing belt (product length up to 1200 mm) ................................................ 255
`Checking the conveyor belt...................................................... 255
`7.4.1.1
`Replacing the conveyor belt ..................................................... 256
`7.4.1.2
`7.4.2 Product conveyor (product length up to 1200 mm) ....................................... 257
`Checking conveyor belts and toothed belts.................................. 257
`7.4.2.1
`Replacing the conveyor belt ..................................................... 258
`7.4.2.2
`7.4.3 Product conveyor (product length exceeding 1200 mm) ................................ 259
`Checking the conveyor belts and toothed belts............................. 259
`7.4.3.1
`Replacing the conveyor belts.................................................... 259
`7.4.3.2
`7.4.4 Product bed conveyor ............................................................................ 260
`Checking conveyor belts ......................................................... 260
`7.4.4.1
`Replacing conveyor belts......................................................... 261
`7.4.4.2
`Checking the plastic rollers (optional)......................................... 261
`7.4.4.3
`Replacing plastic rollers .......................................................... 261
`7.4.4.4
`7.4.5 End piece ejection flap ........................................................................... 262
`Checking the plastic rollers ...................................................... 262
`7.4.5.1
`Replacing the plastic rollers ..................................................... 262
`7.4.5.2
`
`– page 8 of 288 pages –
`Operating Manual Slicer CCS 904
`CCS-904_06_2006-07-01_GB / T-07_2005-11-10
`
`
`
`7.4.6 End piece removal conveyor ................................................................... 263
`Checking the conveyor belt...................................................... 263
`7.4.6.1
`Replacing the conveyor belt ..................................................... 264
`7.4.6.2
`Checking the deflection roller ................................................... 264
`7.4.6.3
`Replacing the deflection roller................................................... 264
`7.4.6.4
`7.4.7 Upper product guide .............................................................................. 265
`Checking the conveyor belts .................................................... 265
`7.4.7.1
`Checking the deflection rollers.................................................. 266
`7.4.7.2
`Replacing the deflection rollers ................................................. 266
`7.4.7.3
`Replacing the conveyor belts.................................................... 266
`7.4.7.4
`7.4.8 Blank holder (product length exceeding 1200 mm) ....................................... 267
`Checking the plastic rollers ...................................................... 267
`7.4.8.1
`Replacing the plastic rollers ..................................................... 267
`7.4.8.2
`7.4.9 Completing weekly maintenance .............................................................. 268
`7.5 Monthly maintenance .................................................................................... 269
`7.5.1 Components to be lubricated ................................................................... 269
`7.5.2 Using the correct grease gun................................................................... 270
`7.5.3 Using the correct grease......................................................................... 270
`7.5.4 Preparations for monthly maintenance....................................................... 271
`Disassembling the housing cover .............................................. 271
`7.5.4.1
`Lubricating the ball screw spindle and guide carriage of the carriage drive ........ 273
`Ball screw spindle .................................................................. 273
`7.5.5.1
`Guide carriage ...................................................................... 274
`7.5.5.2
`Lubricating the trapezoidal spindles in the carriage housing ........................... 275
`7.5.6.1
`Trapezoidal spindles for the horizontal movement
`of the carriage housing ........................................................... 275
`Trapezoidal spindles for the vertical movement
`of the “upper product guide” ..................................................... 276
`Lubricating the trapezoidal spindles of the spindle stroke drive ....................... 277
`Lubricating the trapezoidal spindle............................................. 278
`7.5.7.1
`7.5.8 Changing the air filter element of the ventilation system ................................ 279
`Opening the suction channel .................................................... 279
`7.5.8.1
`Replacing the air filter element.................................................. 280
`7.5.8.2
`Closing the suction channel ..................................................... 280
`7.5.8.3
`7.5.9 Completing monthly maintenance............................................................. 281
`Assembling the housing cover .................................................. 281
`7.5.9.1
`Running in lubricated components............................................. 282
`7.5.9.2
`
`7.5.5
`
`7.5.6
`
`7.5.6.2
`
`7.5.7
`
`8 Malfunctions .................................................................................................283
`
`9 Technical data ..............................................................................................286
`
`10Index ................................................................................................................288
`
`– page 9 of 288 pages –
`Operating Manual Slicer CCS 904
`CCS-904_06_2006-07-01_GB / T-07_2005-11-10
`
`
`
`1
`
`Machine overview
`
`1
`
`Machine overview
`1
`This chapter describes the most important components of the module and their functions. The basic de-
`sign of the different versions of the Slicer is almost identical. The positions of the components and as-
`semblies of the Slicer CCS 904 is shown and described in the following for a carriage up to 1200 mm.
`
`Areas of the Slicer
`1.1
`This chapter looks at the areas products pass through when going through the Slicer. These areas are
`referred to repeatedly in the operating manual.
`
`1.1.1
`
`Loading area/infeed area
`
`1
`
`2
`
`3
`
`4
`
`5
`
`6
`
`Fig. 1
`
` Loading area/infeed area
`
`The loading and infeed area of the Slicer consists of assemblies that are used to move the products to
`the slicing area.
`
`These assemblies include the following:
`
`– Product bed conveyor (1)
`– Upper product guide (2)
`– Blank holder (only for the version for product lengths exceeding 1200 mm) (3)
`– Product holder (4)
`– Product conveyor (5)
`– Timing belt (only for the version for product lengths up to 1200 mm) (6)
`
`– page 10 of 288 pages –
`Operating Manual Slicer CCS 904
`CCS-904_06_2006-07-01_GB / T-07_2005-11-10
`
`
`
`1
`
`Machine overview
`
`1
`
`1.1.2
`
`Slicing area
`
`1
`
`2
`
`Fig. 2
`
` Slicing area
`
`The slicing area of the Slicer consists of assemblies that are used directly to slice the product.
`
`These assemblies include the following:
`
`– Blade (1)
`– Shear bar/product-section guide (2)
`
`– page 11 of 288 pages –
`Operating Manual Slicer CCS 904
`CCS-904_06_2006-07-01_GB / T-07_2005-11-10
`
`
`
`1
`
`Machine overview
`
`1
`
`1.1.3
`
`Discharge area
`
`1
`
`2
`
`Fig. 3
`
` Discharge area
`
`The Slicer's discharge area consists of assemblies and modules used to transport the sliced portions
`further or for discharging first slices or end pieces.
`
`These include the following assemblies and modules:
`
`– CCU portioning unit (1)
`– End piece removal conveyor (2).
`
`Depending on the configuration of the slicing line, the position and design of the end piece removal con-
`veyor may deviate. The end piece removal conveyor version illustrated above is installed on Slicers with
`CCI 904 Interleaver (optional).
`
`– page 12 of 288 pages –
`Operating Manual Slicer CCS 904
`CCS-904_06_2006-07-01_GB / T-07_2005-11-10
`
`
`
`1
`
`Machine overview
`
`1
`
`Operating positions
`1.2
`During operation of the slicing line, the operator may only assume the specified operating positions.
`
`Caution!
`Risk of injury due to moving components during operation of the slicing line.
`A number of drives and components are in motion during operation of the slicing line.
`Reaching into these dangerous area
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