CUTTING STATION

PRIMUS III – PW0589

- OPERATIVE INSTRUCTION –
ASSEMBLY AND MAINTANANCE
FOR THIS MACHINE

Supplier: Sales&Service
C.N.C. Srl VARIOVAC PS SystemPack GmbH
41012 Carpi (Mo) Ernst-Litfass-Strasse 3 und 5
ITALY D-19246 Zarrentin am Schaalsee
Tel.: +39 059 697746 Tel.: +49 (0) 38851-823 0
Fax: +39 059 641797 Fax: +49 (0) 38851-823 520
E-mail: cnc.carpi@cnc-carpi.com E-Mail: dokumentation@variovac.de
Contents

1 - In General

1.1 How to use this manual .................................................................. Pag.2

1.2 Where to store this manual ............................................................. Pag.2
1.3 Manual updates .............................................................................. Pag.2
1.4 Safety symbols ............................................................................... Pag.3
1.5 Terminology frequently used .......................................................... Pag.4
1.6 Personnel qualification .................................................................... Pag.4
1.7 Warranty Terms & conditions ......................................................... Pag.5

2 - Technical Specification / Installation / Functions

2.1 Machine’s ID ................................................................................... Pag.6

2.2 Appropriate/Inappropriate Applications of the Machine .................. Pag.7
2.3 Environmental Condition ................................................................. Pag.7
2.4 Transport and Packaging .............................................................. .Pag.8
2.5 Technical Data ................................................................................ Pag.9
2.6 Cutting Station Description ............................................................ Pag.10
- Dimensions .................................................................................. Pag.11
- Description Parts ......................................................................... Pag.12
2.7 Assembling .................................................................................... Pag.13
2.8 Knives Sharpening ......................................................................... Pag.15
2.9 Cleaning and Maintenance ............................................................ Pag.18
2.10 Disposal Instructions ...................................................................... Pag.19

3 – Pneumatics - Assembly - Parts List

Pneumatics ............................................................................................. Pag.20

Pneumatic Outline PW0589 .................................................................... Pag.22
Cutting Station Assembly PW0589 ......................................................... Pag.23
Cutting Station Assembly PW0589 (Upper) ............................................ Pag.24
Cutting Station Assembly PW0589 (Lower) ............................................ Pag.25
Cutting Station Parts-List PW0589 ......................................................... Pag.26

Declaration of Incorporation
(2006/42 CEE Directive, attachment 2, paragraph 1, subparagraph B) .................... Pag.29

Declaration Concerning the Parts of the Station ..................................... Pag.30

1
 1 – IN GENERAL

TO ASSURE A GOOD FUNCTIONALITY AND PERFORMANCE OF OUR SYSTEM, WE ENPHESIZE THE

CORRECT APPLICATION TO ALL THE INSTRUCTIONS CONTAINED IN THIS MANUAL
 As an attachment to this document you can find the certification:
Declaration of Incorporation
(2006/42 CEE Directive, attachment 2, paragraph 1, subparagraph B)

Declaration Concerning the Parts of the Station

1.1 How to Use the Manual

This manual is for authorised personnel only who use this system.
 It must be available to all the personnel authorised in the usage of this system.
This document is essential to:
 To the responsible personnel of the plant/installation personnel;
 To the operators;
 To the maintenance crew

1.2 Where to Store this Operative Manual

The Operative Manual must be kept in a suitable place and must be always available to all the
authorized personnel.
If you lose the Operative Manual, or it become unreadable, the documentation will be sent again
upon request to the SUPPLIER indicating the ID number of the machine.

1.3 Manual Update

This manual contains information and instructions appropriate at the time of the issue of this
system. It complies to all the legislation and law requirements at the time of issue. It cannot be
considered inadequate if the system will be upgraded after the delivery.
Any changes or updates to the system herewith intended, will not oblige the supplier to intervene
on the system. Any integrations/updates to the manual will be sent by the supplier at his
discretion. Any new pages sent by the supplier must be inserted in the manual as instructed.

2
1.4 Safety Symbols

SIMBOLS
Below you can find symbols used in this document and the explanation of these safety symbols.

DANGER: this symbol refer to a dangerous situation that could cause irreversible
damages or death

WARNING: this symbol refer to a dangerous situation that could cause irreversible
damages or very serious injuries.

ATTENTION: this symbol refer to a dangerous situation that could cause some
damages or injuries

IMPORTANT NOTE: this symbol refer to important information for the proper
functionality of the machine.

Wear safety gloves

Wear safety goggles

Wear safety shoes

Caution: high voltage – Danger to your life!

Warning: possible damages to your hands – squeezing or cutting!

3
1.5 Terminology Frequently Used in this Manual

Q.E: electric panel

Operator: operator, authorised personnel for the usage and maintenance of the machine.
Exposed person: a person within a danger area.

Danger Area: area inside or near the machine that constitutes a risk to the health and safety of
operator or authorized personnel.

D.P.I. : Individual Protection Device

C.A.T. : Technical Assistance Centre

1.6 Personnel Qualification

Below you find a list of the qualification for the operators who will work with our system.
Each qualified personnel will work on the machine with different roles (they must be trained
and informed). The description below for each qualification will define the role of the
operator to work on the machine safety.

Level 1 operator: not qualified, he/she will be able to perform very simple operations on the
machine as turn on the machine.

Level 2 operator: not qualified, he/she will be able to perform simple operations as level 1
plus simple setting

Level 3 operator (maintenance) : qualified technician who is able to perform operation level
1 and 2 and to intervene on the mechanical parts and pneumatic system as finding and resolving
faults, setting and eventual cleaning of the machine.

Maintenance personnel: qualified technician who is able to intervene on the electric panel
and other electrical parts for: connections, repairs, faults.

Level 4 operator: qualified technician from the supplier who is able to intervene on the
system on faults and find resolutions.

4
1.7 Warranty – Terms & Conditions

Our system is defined as an “almost machine” as per the Machine Directives law
(art. 2 com. g 2006/42/EC), for this reason can only be functioning when mounted on pre-existing line. The
mounting and start- up of the system must be performed only by specialized personnel provided by the
supplier and after reading very carefully the instructions herewith which is also a precondition for the validity
of the warranty. We will not be held responsible if the system is malfunctioning after a long period of inactivity
of the machine.

The warranty has the duration of 1 year, starting at the delivery of the system. Warranty and liability claims
in respect of damage or injury to persons or property are excluded if they are caused by one or all the
following conditions:

• No observance of the manual’s information in respect of transportation, mounting,

repair or maintenance of the machine;
• Unauthorized alterations carried by a third party.
• The supplier will be responsible for any faulty parts and replace them free ex works.
• The client will be responsible and charged accordingly for travel and expenses for the
supplier’s technician visit.
• For any material the manufacture will be responsible as per the warranty contract. For
any further details we will refer to the sale contract agreed by both parties.

5
 2 - Technical Specification / Installation / Functions

2.1 Machine ID
The “complete cutting system” is identified by plates with the specific information placed on the
machine. The plates MUST NOT be removed or altered in any way!

Should you accidentally scratch or lose the plates, please contact immediately the supplier.

PRODUCT NAME: CUTTING STATION

MODEL: 038-20 – PW0589
ID NUMBER: 660-640-2.2
CONSTRUCTION YEAR: 2020

6
2.2 Appropriate / Inappropriate Applications of the Machine

The “CUTTING STATION” is a component of an existing line and must be mounted in the
thermoforming machine for packing food products. Once mounted (following the given instructions
herewith), the system can be only used for the final cut of the packs and out-fed on the conveyor
belt supplied by us.

INAPPROPRIATE APPLICATIONS:

 No observance on the manual’s instructions;

 Malfunction of the electric supply;
 Applications by unqualified personnel;
 Repair or changes by unqualified personnel not authorised by the supplier;
 Install not original spare parts;
 Improper application of the cutting station to activities different from the one specified in the;
 Damages caused by major forces as unpredictable events not related to the machine.

It is not allowed to make changes to the system

or to the safety devices.

2.3 Environmental Conditions

The environment condition for the machine must have the following characteristics:

 Temperature +10°C / +30°C

 Humidity max 90% max.
 Light min 200 lux min.

7
 2.4 Transport / Packaging

The Cutting station weight Kg. 1200.

(Punches Frame Group 440 Kg – Die Frame Group 270 Kg)

 It is forbidden to try and lift the station by hand;

 Use a fork lift with an appropriate weight load and position it on the points as indicated in
the picture below (2.4.1). During the transport to position the station, personnel not
involved must keep a proper distance from the area;
 Use the D.P.I. during this activity;

Fig. 2.4.1

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2.5 Technical Data
Dimension: See drawing (2.6.2)

Energy Supply Volt 380/400

Frequency Hz 50
Power KW 2
Phases 3+N+T

9
 2.6 Cutting Station Description

The “CUTTING STATION” is a component of an existing line PRIMUS III and must be mounted in
the thermoforming machine for packing food products. Once mounted (following the given
instructions herewith), the system can be only used for the final cut of the packs. (Fig.2.6.1)

Fig.2.6.1

10
Dimensions

Fig. 2.6.2

11
 Description Parts

Frame

Conveyor Belt

Fig.2.6.3

Pos. Descrizione
1 Bottom Part with Knee-Lever Motion Connection
2 Cutting Die Group
3 Top Part with Punches Group
4 Motor + Worm Gear
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2.7 Assembling

The cutting station must be mounted in the production line as follow:

 Disconnect all the electric and pneumatic connections;
 Conveyor-Belt Line without, remove the chains (1) which are in the line of the positioning of
the cutting station and lift the bottom frame of the Station (2) on the ground through the
Machine’s Line Frame (3) and fix the bottom frame (2) by the attachments (4). (Fig.2.7.1)

 Fix the lower parts of the station (5) to the Eyebolts (6), lift the station and carefully place it
on the frame support (2) through the Machine’s Line Frame (3) and fix by the regulation
blocks (7) and (8). (Fig.2.7.2)

13
  Fix the Conveyor-Belt and lift the Die Group (9) by the Eyebolts (6) on the spacer blocks (10)
and fix by the collar spacer (11). (Fig.2.7.3a). Fix the chains (1) in original position and lifting to
the station the Punches Group and the upper part of the station (12) to the Eyebolts (6), with
carefully place it by the main columns (13) and spacer (14). (Fig.2.7.3b) (Fig.2.7.3c)

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2.8 Knives Sharpening

To SHARPEN the blades, the following part must be dismounted:

 Disconnect the top part of the equipment from the pneumatic and electric connection;
 Remove the extractor pads (15) with suckers (16) and take out the extractor group
(12b) and the Punches Group (12a) by the Eyebolt (6) (Fig.2.8.1)

15
  Take out the stripper plate (17) by removing the collar screws (18) and springs (19).
Take out the punches (20) by removing the screws (21) and pins (22). (Fig.2.8.2)

 Take out the Dies (23) by the Eyebolts (6) , after removing of the Rubber Caps (24), the
Screws (25) and the pins (26).

16
 PRELOADED and TIGHTENING TORQUE TABS

WARNING : Tightening of the Screws by Torque Meter Wrench (Fig.2.8.3)

17
 2.9 Cleaning and Maintenance

The CUTTING STATION must be cleaned and lubricated regularly.

 All the cleaning and maintenance operations must be conducted after turning off the
electricity;
 Lubricate periodically, using the grease class listed below the (A), the columns, the flexible
connections and the recirculating ball nut;
 Brush with grease the visible parts of the guide columns of the cutting system (B);
 Control regularly the correct evacuation of the side strips hopper;
 Control regularly the wear or damage to the suctions cups;
 Do not use cleaning agents too strong;

Pos. Description Period

A N°1 - Lubrication of the recirculating ball nut – Grease NLGI 2 6 Months
A N°2-3 - Guide Columns Knee-Lever connection – Grease NLGI 2 1 Months
B Guide Columns of the Cutting Station – PTFE-BASED GREASE 1 Months
C Cutting Die – Kluberoil 4 – UH1-1500 N Spray (ES) - KLUBER Lubrification TURN END

1
3
3
1

Fig. 2.9.1

A 3
A

A 2 1

Fig. 2.9.2a Fig.2.9.2.b

18
 B

Fig. 2.9.3

Fig. 2.9.4

2.10 Disposal Instructions

Even for machines that is used in a working environment, it is necessary to dispose properly of the
electrical and electronics as per EC regulations.
The EC regulation impose that the above material should be disposed following specific
procedures. Before disposing any part of this system, please consult the supplier to check if there
are any collecting procedures.

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 3 - Pneumatics
Maintanance Pneumatics
The pneumatic system does not require particular maintenance except for:
Pos. Description Supplier Code
1.01 Pressure Regulator (Tar.3 bar) Pneumax 17112B.C
1.02 Pressure Regulator (Tar.3 bar) Pneumax 17112B.C
1.05 Cylinder (Support) SMC C55-B50-125
1.07 Block Valve Pneumax 6.09.18.U
1.09 Acting Cylinder CNC CNC-TRC-013
1.11 Grip Suction Cylinder Festo ADN-50-5-I-P-A ISO-21287
1.13 Suction Cups Gama Art. VSUM35L D.35 1/8”
1.15 Pneumatic Cylinder (Release Product) Festo DSBC-63-220-D3-PPV-A-N3
1.17 Speed Controller with Piloted Valve SMC ASP-430-F-02-08S (1/4”)
1.19 Speed Controller SMC AS-22-01-F-02-08-SA (3/8”)
1.21 Sensor SME-8-S-LED-24 - Upper Festo 150-857 + 541332
+ Cable NEBU-M8G3-K-10-LE3
1.22 Sensor SME-8-S-LED-24 - Lower Festo 150-857 + 541332
+ Cable NEBU-M8G3-K-10-LE3
1.25 Sensor SME-8-S-LED-24 Festo 150-857 + 541332
+ Cable NEBU-M8G3-K-10-LE3
- Check that the calibration for the Pressure Regulator is 4 bar for SMC C55-B50-125
Cylinders, and 3.5 bar for CNC-TRC-013 Cylinders. (Fig.3.1 – Fig.3.4)

1.01

1.02

1.07

Fig.3.1

1.19
1.21

1.15

1.22
1.17

Fig.3.2
20
 1.11

1.25

Fig.3.3

1.05

1.09

Fig.3.4

1.13

Fig.3.5

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22
Cutting Station Assembly PW0589

23
 Cutting Station Assembly PW0589 (Upper)

24
Cutting Station Assembly PW0589 (Lower)

25
 Cutting Station Parts-List PW0589

26
27
28
Declaration of Incorporation
(2006/42 CEE Directive, attachment 2, paragraph 1, subparagraph B)

The undersigned CNC srl company, located in Carpi (MO, Italy) at Via Emilia Romagna n. 7

DECLARE

Under its sole exclusive responsibility that the following PARTLY-COMPLETED MACHINERY

CLASSIFICATION: CUTTING STATION

MODEL: PW0589
SERIAL NUMBER: TR 038 20
YEAR OF PRODUCTION: 2020

in compliance with the ATTACHMENT VII (subparagraph B of the Directive 2006/42/CE), is

compliant with the requests of the following ESSENTIALS SAFETY REQUIREMENT applied:

1.1.1, 1.1.2, 1.1.3, 1.1.5, 1.1.6, 1.1.7, 1.3.1, 1.3.2, 1.3.3, 1.3.4, 1.5.4, 1.6.1, 1.6.5, 1.7.1, 1.7.1.1,
1.7.2, 1.7.3, 1.7.4.

The company undertakes to convey, in response to a pertinent request adequately justified

made by national authorities, the pertinent information concerning the present Partly-
completed Machinery, under the agreed times and conditions.
CNC forbid to set in motion the Partly-completed Machinery until the Machine in which
it will be inserted, will be declared compliant with the instructions of the 2006/42/CE
Directive.

Place and date: Carpi, February the 7th, 2020

The legal representative (name and last name)
Corrado Cantarelli

29
 Declaration Concerning the Parts of the Station

The undersigned CNC srl company, located in Carpi (MO, Italy) at Via Emilia Romagna n. 7

DECLARE

Under its sole exclusive responsibility that the device

CLASSIFICATION: CUTTING STATION

MODEL: PW0589
SERIAL NUMBER: TR 038 20
YEAR OF PRODUCTION: 2020

Is made of the following parts:

 Reinforcement crossbar of bottom frame in C40 steel;

 Punch holder top frame in C40 steel;
 Die holder frame C40 steel;
 Cutting punches in steel K340;
 Cutting die in steel K340 steel treated with Nicasil Process;
 Guiding system ø 32 with columns and bushings in 1.7131 16MnCr5
 Mobile plate in anodized Al7075 Ergal.

Place and date: Carpi, February the 7th, 2020

The legal representative (name and last name)

Corrado Cantarelli

30