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MAINTENANCE MANUAL

SLICER CCS 5000

with MPS 2

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0. General information

The manual consists of three parts:

1.Operating manual

2.Cleaning manual

3.Maintenance manual

This manual was drawn up for the supervisory and maintenance personnel of the Slicer.

In the event of inquiries refer

Weber GmbH & Co.KG or your local customer service.

Mechanische Fertigung
Formerstraße 3
D-35236 Breidenbach

Tel.: 06465/ 918 - 0

Fax: 06465/ 918 - 100

Type plate

This manual belongs to the Slicer with the following type plate:

Weber GmbH & Co.KG

Mechanische Fertigung
Formerstraße 3, Tel.: 06465/918-0
D-35236 Breidenbach
Typ CCS 5000 Nr.....
400 V 50 Hz 7 kW

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1. TABLE OF CONTENTS

0. GENERAL INFORMATION...........................................................................................................................2

1. TABLE OF CONTENTS .................................................................................................................................3

2. SAFETY INSTRUCTIONS..............................................................................................................................4

3. SAFETY DATA SHEET ..................................................................................................................................5

4. EXPLANATION OF TERMINOLOGY ....................................................................................................... 10

5. TYPOGRAPHY ............................................................................................................................................. 10

6. MACHINE OVERVIEW ............................................................................................................................... 11

7. ASSEMBLING SLICER ................................................................................................................................ 12

7.1 CHANGING LOCATION OF SLICER ...................................................................................................................... 12
7.2 SETTING DROP HEIGHT ..................................................................................................................................... 14
8. MAINTENANCE............................................................................................................................................ 15
8.1 WEEKLY MAINTENANCE WORK ......................................................................................................................... 15
8.1.1 TIGHTENING CONVEYOR WEBBING ................................................................................................................. 15
8.1.2 TIGHTENING TOOTHED BELTS ........................................................................................................................ 15
8.1.3 LUBRICATING CUTTER SHAFT ........................................................................................................................ 16
8.2 MONTHLY MAINTENANCE WORK ...................................................................................................................... 18
8.2.1 LUBRICATING RECIRCULATED BALL SPINDLE .................................................................................................. 18
8.4 HALF-YEARLY MAINTENANCE WORK................................................................................................................. 20
9. PARAMETER DESCRIPTION IN "INFO-PROGRAM.............................................................................. 21

10. TECHNICAL DATA .................................................................................................................................... 23

11. INDEX........................................................................................................................................................... 25

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2. Safety instructions

The following safety instructions must be noted when carrying out maintenance
work on the Slicer:

1. Read the whole maintenance manual before maintaining the Slicer. Follow the manual
exactly in all points. The supervisory personnel must ensure that the maintenance
personnel have fully understood the maintenance manual.

2. Check after maintenance that all protective devices are fully functional. Refer to chapter 3,
"Safety data sheet".

3. Report any defects in protective devices to the supervisory personnel immediately.

4. The supervisory personnel must ensure that the malfunctioning protective devices are
replaced or repaired without delay. Supervisory personnel must provide work instructions
o ensure safe maintenance.

5. The Slicer may only be maintained by trained personnel. Regular refresher courses must be
provided.

6. Observe the instructions given in the operating and cleaning manuals.

7. Protective devices must be checked at least once a year by a specialist for proper
functioning.

8. Never modify the Slicer.

9. Use only Weber spare parts and Weber accessories.

10. If the Slicer is resold, the complete maintenance manual must also be handed over.

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3. Safety data sheet

1 Product base protective cover 8 Operator's panel

2 Gate on cutting edge 9 Operator's panel cover
3 Blade protective cover 10 Switch cabinet door
4 Conveyor belt protective cover 11 Warning sign
5 Conveyor belt 12 Warning sign
6 Cutter head drive 13 Type plate
7 Main switch

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Feed side

Product base protective cover 1

Protective cover has tunnel-form design. Perforated sheet metal 2.0 mm thick, stainless steel,
holes 35 mm diameter.
770 mm Length
660 mm Width
240 mm Distance from product base to lower edge of protective cover.
850 mm Safety margin from cutting edge to end of protective cover.
10 mm Actuator travel at leading edge of protective cover.

Protective cover with gate locked on cutting edge and cutter drive. Gate on cutting edge closes
within 2.0 seconds if protective cover is opened when cutter is running. If the gate does not close
when the protective cover is open, the cutter drive is braked within 2.0 seconds. Blade remains in
resting position. Protective cover closing time 2.0 seconds. Stroke speed is quite safe.
Protective cover on turning bearings, moved pneumatically and held down by a pneumatically
actuated pressurised cylinder. Locking via magnetic switch.
Model: Elobau
Type: 171261 (BWP according to VDE 0660, part 209)
Counterpart: Magnet 30 mm diameter Type: 30420000

Sensor is mounted in machine housing. Counterpart mounted permanently on protective cover

with M4*20 mm screw.

Gate on cutting edge 2

Gate has rectangular design. Sheet metal 3.0 mm thick, stainless steel. Gate guided on both sides
and pneumatically operated.

410 mm Length
120 mm Width
20 mm Height
8 mm Distance between gate upper edge and cutter head housing surface when gate
is closed.

Gate with protective cover locked over product base and cutter drive.
When the gate and protective cover are open the cutter drive cannot be switched on. Locking via
magnetic switch.

Model Elobau
Type: 171261
Counterpart: Magnet 30 mm diameter Type: 30420000

Sensor is mounted in machine housing. Counterpart mounted permanently on slide rod with
M4*20 mm screw.

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Delivery side

Blade protective cover 3

Protective cover has lid-type design. Sheet metal 3.0 mm thick, stainless steel. Fixing with two
M8*50 mm star grip screws. Protective cover on turning bearings with two bolts,
14.5 mm in diameter.

820 mm Length
610 mm Width
55 mm Height
7 mm Actuator travel at outer edge of protective cover.

Protective cover locked with gate and cutter drive. If the protective cover is opened, the cutter
drive brakes within 2.0 seconds. Blade remains in resting position. Protective cover is removable.
Locking via slow-release screw and magnetic switch.

Model: Elobau
Type: 171261
Counterpart: Magnet 30 mm diameter Type: 30420000

Sensor is mounted in machine housing. Counterpart is permanently mounted in protective cover

with M4*20 mm screw.

Conveyor belt protective cover 4

Protective cover has tunnel-form design. Sheet metal 2.0 mm thick, stainless steel.
565 mm Length
380 mm Width
130 mm Distance from conveyor belt to lower edge of protective cover.
360 mm Safety margin from cutting edge to outer edge of protective cover.
10 mm Actuator travel at protective cover.

Protective cover locked with gate and cutter drive. If the protective cover is opened the cutter
drive is braked within 2.0 seconds. Blade remains in resting position. Protective cover on turning
bearings. Locking via slow-release screw and magnetic switch.
Model: Elobau
Type: 171261
Counterpart: Magnet 30 mm diameter Type: 30420000

Sensor and counterpart mounted in machine housing. Counterpart permanently mounted with
M4*20 mm screw.

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Conveyor belt 5

Contact point secured between conveyor belt and deflection roller.

Cutter head drive 6

Driving components on cutter head covered by housing.

Cover plate on front side of housing 5 mm thick, stainless steel. Coverplate fixed with nineteen
M8*20 mm screws and three M8*60 mm screws, which can only be released with a suitable tool.

Cover plate
106 mm Length
620 mm Width

Electrical equipment

Main switch 7

OFF - position: Symbol 0

ON - position: Symbol I

Handle colour: Red, yellow underlay, lockable with cover.

Model: Square D
Type: VC/3-pole
Nominal current: 63A

Control current circuit

24 Volt d.c.

Operator's panel 8

LED red: LED flashes when there is malfunction.

LED green: LED lights up when computer control system is switched on.

Operator's panel cover panel 9

Cover panel: Plexiglass 20 mm thick.

Folds back, attached with two M6*20 mm screws.

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Switch cabinet door 10

Construction: Sheet metal 1.5 mm thick, stainless steel. Mounted with eight casement fasteners
with special key.

955 mm Length
715 mm Width

Warning sign 11

"Turn off main switch before opening housing"

Construction: Plastic, colour: yellow with black lettering.

Warning sign 12

"Discharge time longer than 1 minute"

Construction: Printed on control units.

Colour: Blue background with white lettering.

Type plate 13

Details:

Manufacturer
Type No.....
Mains voltage
Mains frequency
Power intake

Construction: Sheet aluminium, size: 60 mm * 35 mm

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4. Explanation of terminology
Interactive mode: The operator programs the Slicer computer. This is done in
question-answer style. The computer puts the questions to
the operator in plain text on the display. The operator types
in the replies with the keys.

Dimensionless factor: Numerical value without measuring unit.

Display: Readout panel for the operator.

Pressure reducing valve: Valve for setting air pressure.

Eccentric bolt: Bolt outside the turning axis.

Diameter: Diameter of round product

Plain text: Messages are shown on the display with words or

sentences.

Parameter: Reports on a changeable program section.

5. Typography
Letters in bold print refer to a module in the overview diagram.
Example: Slicer CCS 5000 A

Numbers in bold print refer to a component in a diagram.

Example: Compressed air maintenance unit 1

Operator's panel keys are given in square brackets.

Example: [Enter]

Readouts on the display are framed.

Example:

WEBER CCS
READY

Newly entered values appear at the bottom right of the display. If the value is confirmed by
pressing the [Enter] key, it moves to the middle of the display.

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6. Machine overview
Slicer

6 1 2 3

The Slicer CCS 5000 consists of these components:

Cutter head with circular blade 1

Product holder 2
Product base 3
Operator's panel for computer control system 4
Pedestal 5
Conveyor belt 6

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7. Assembling Slicer

The Slicer is assembled by personnel from Weber.

7.1 Changing location of Slicer

1 2 3 4

5
6

9 8 7

Caution!
Switch off the Slicer CCS 5000 as described here.

- Press [STOP] key.

- Turn the main switch handle until it is in the [0] position and attach padlock.

- Take out the mains plug and set the pressure reducing valve on the maintenance unit 6 to 0 bar.

- Cut off compressed air supply at the shut-off valve.

- Take the compressed air hose off the connection 4 on the spindle housing.

- Release the slow-release screw 7 by turning to the right and swing the conveyor belt 9 to the
side.

- Fold up the end of conveyor 1, release the stripper by pulling the star grip 8 at the fixing device
and fold down.

- Take off the webbing and lay to one side.

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- Pull up the stripper and lock in the fixing device by activating the star grip 8.

- Lift up the conveyor belt 9 and dismount the height adjuster 2.

- Grip conveyor belt 9 at the end with both hands, fold up by 90°, take out by lifting out of the
bearing 3 and lay out on a table.

- Swing the conveyor belt back into place and tighten up the slow-release screw 7 by turning to
the right.

- Transport the Slicer to the new location. Use a lifting carriage with at least 1500 kg lifting
capacity. The lifting carriage must be positioned at the side of the cutter head underneath the
pedestal.

- Install the Slicer at the new location and by turning the legs, adjust until it is level.

- Loosen the slow-release screw 7 by turning to the left and swing the conveyor belt to one side.

- Insert the conveyor extension 9 with the end of conveyor 1 facing upwards, fold down by 90°
and put in the height adjuster.

- Release the stripper by pulling the star grip 8 on the fixing device and fold down. Lay out the
webbing, fold down end of conveyor 1, pull up the stripper and engage the fixing device with
the star grip 8.

- Swing the conveyor belt 7 into place and tighten up the slow-release screw by turning to the
right.

- Fit the compressed air hose to connection 4 on the spindle housing and open the shut-off valve.
Set the compressed air to 6 bar at the maintenance unit 6 and insert the plug into the mains
socket.

- Adjust the position of the conveyor belt as required by turning the nuts on the height adjuster 2.

- Remove the padlock from the main switch 5 and turn the handle to position [I ].

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7.2 Setting drop height

Changing the product may also require an adjustment of the drop height.

- Set the distance of the conveyor belt to the cutting edge so that the drop height is sufficient for
the portion.

Note:
Shingled portions minimum distance: 1.5 cm to 2 cm.
Stacked portions minimum distance: pile height

- Turn the main switch handle to the [0] position and attach the padlock.

- Inspect the conveyor belt through the holes in the protective cover 1 and check the drop height.

- Increase the drop height by turning the adjusting screw 2 to the left or reduce it by turning to the
right.

- Remove the padlock from the main switch and turn the handle to the [1] position.

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8. Maintenance
8.1 Weekly maintenance work

8.1.1 Tightening conveyor webbing

- Check conveyor webbing tightness and if necessary re-tension.

1 2

- Fold up the end of conveyor and loosen the nuts 1 on the inside by turning to the left with a
spanner.

- Fold down the end of conveyor and evenly adjust the tensioning screws 2 with a spanner.

- Fold up the end of conveyor and tighten up the nuts on the inside by turning to the right.

- Check that the conveyor is running parallel.

8.1.2 Tightening toothed belts

- Check tightness of toothed belts on portioning conveyor, weighing conveyor and rocker
conveyor and if necessary retighten.

- Loosen the screws on the motor plate by turning them to the left with a screwdriver.

- Move the motor plate and tighten the toothed belts.

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- Tighten the screws on the motor plate by turning to the right with a screwdriver.

8.1.3 Lubricating cutter shaft

2 5 2

4
1

3
4

Maintenance intervals:
Up to 300 slices a minute every 100 hours.
Over 300 slices a minute every 50 hours.

- Lubricate the cutter shaft with the special grease gun and special grease from Weber.

- Wear metal-fibre reinforced gloves.

- Loosen the blade protective cover 1 screws by turning the star grips 2 to the left.

- Swing blade protective cover 1 up and place it on a table.

- Attach the blade holder 3 to the circular blade. The eccentric bolt levers 4 must point to the
middle.

- Insert blade holder 3 with the eccentric bolts 4 into bores of the circular blade. Turn eccentric
levers 4 by 180°. The blade holder 3 is now fixed to the circular blade.

- Release the circular blade fixing screw 5 with a No. 19 ring spanner by turning to the left.

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- Hold the blade holder 3 firmly with one hand and remove the fixing screw 5 with the free hand.
Take out the blade holder 3 with both hands and place on a table.

- Place the grease gun onto the grease nipple inside the cutter bar threaded bore and press five
squirts of grease from the grease gun into the grease nipple.

- With both hands place the blade holder 3 with the circular blade onto the cutter head mounting.
With one hand hold the blade holder 3 firmly and with the free hand tighten the fixing screw 5 by
turning to the right.

- Tighten the circular blade fixing screw 5 with a No. 19 ring spanner by turning to the right.
(Tigthening torque: 80 Nm).

- Turn eccentric lever 4 by 180° and remove the blade holder 3 from the circular blade.

- Swing the blade protective cover 1 back into place. Tighten the screws by turning the star
grips 2 to the right.

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8.2 Monthly maintenance work

8.2.1 Lubricating recirculated ball spindle

- Remove the padlock from the main switch and turn the handle to the [ I ] position

Green LED on computer control system lights up and the following appears on the display:

PRESS START
!

- Press [Start] key.

MPS 2
READY

- Press [Back] key and move the product holder into the middle position. Open the spindle
housing cover with a suitable tool.

- Place the grease gun onto the grease nipple on the nut housing in the spindle housing and press
three squirts of grease from the grease gun into the grease nipple. Close housing cover again.

- Press [INFO] key.

ERROR MESSAGES
(Y/N)?

- Press [-/N] key.

- Press [-->] key until this appears on display:

RETURN
(Y/N)?

- Press [-/N] key.

CODE NUMBER:

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- Enter code number 6821. Press ENTER key

Press [ --> ] key until the following parameter appears:

CARRIAGE RUN-IN
(Y/N)?

- Press (+/Y) key.

CARRIAGE START
(Y/N)?

- Press [+/Y] key.

Run spindle and lubricated nut housing for 15 minute running-in time.

CARRIAGE STOP
(Y/N)?

- Press [+/Y] key.

Spindle drive stops.

- Press [-->] key until this appears on the display:

RETURN
(Y/N)?

- Press [+/Y] key.

Slicing program is called up again.

- Turn the main switch handle to the [0] position and attach the padlock.

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8.4 Half-yearly maintenance work

Half-yearly maintenance work must be carried out by Weber Customer Service.

Firma Weber GmbH & Co. KG

Mechanische Fertigung
Formerstraße 3
D-35236 Breidenbach

Tel.: 06465/ 918 - 0

Fax: 06465/ 918 - 200

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9. Parameter description in "INFO-Program

Error indications Pressing [+/Y] key: Error messages are displayed

(Y/N)? Pressing [-/N] key: Jump to next parameter
P1-version: Program version of processor 1 is displayed
P2-version: Program version of processor 2 is displayed
P1-date: Date of program version 1 is displayed
P2-date: Date of program version 2 is displayed
Set up name: Abbreviated name of set up program is displayed
Set up date.: Date of set up program is displayed
Saved programs Number of saved programs is displayed

Return Pressing [+/Y] key: Return to slicing program

(Y/N)? Pressing [-/N] key: Jump to next parameter
Code number: Enter code number 6821 and press ENTER key

Change gripper Pressing [ 0 ] key: Grippers close manually

Pressing [ 1 ] key: Grippers close automatically
Max. start way (mm) Entry of maximum start distance to find vacuum

Push time gripper (ms) Entry of time from contact being made with product to closing
of grippers
Start delay/ms Gripper delay time before seeking contact

RPM of retreat: Enter RPM of product holder retreat at start

Change language Pressing [+/Y] key: Language can be changed

(Y/N) ? Pressing [-/N] key: Jump to next parameter
Test outputs Pressing [+/Y] key: Outputs can be set
(Y/N) ? Pressing [-/N] key: Jump to next parameter
Read inputs Pressing [+/Y] key: Input status is displayed
(Y/N)? Pressing [-/N] key: Jump to next parameter
Carriage run-in Pressing [+/Y] key: Carriage runs in
(Y/N)? Pressing [-/N] key: Jump to next parameter
Preset RPM Pressing [+/Y] key: Drives can be started
(Y/N) ? Pressing [-/N] key: Jump to next parameter
Running time: Cutter head running time is displayed

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Restart Pressing [+/Y] key: Computer control system restarted

Pressing [-/N] key: Jump to next parameter
Return Pressing [+/Y] key: Return to slicing program
(Y/N)? Pressing [-/N]: Jump to 1st parameter after key number

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10. Technical data

Slicer CCS 5000

Noise emission value

in work place
82 dB (A)
Connection values

Electrical supply 380 V 50 Hz, 32 A, 7 kW

CEE-plug

Mains fusing 32 A

Compressed air 6 bar operating pressure

Cutter head

RPM 500 rpm max

Blade size 460 mm max

430 mm min

Drive Baumüller servomotor

Type DS 100
6.3 kW, 31 A

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Product feed

Drive Baumüller servomotor

Type DS 56
1.9 kW, 8.9 A
Power transmission Precision-recirculated ball spindle

Slice thickness 0.5 mm to 9.99 cm

Product length 1000 mm max

Computer control system

Programming Interactively controlled

Working programs Saveable

Data protection Automatic in the event of power cut

Displays Program parameters

Conveyor belt

Universal stacking/shingling conveyor Type UB 2500

Construction Stainless steel

Conveyor length 2500 mm

Conveyor width 380 mm

Conveyor drive Baumüller servomotor

Type DS 56
1.9 kW, 8.9 A

Design Stepless inclination of sliced goods intake.

Conveyor change by quick action device.

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11. Index
Assembling Slicer 11

Compressed air, releasing 12

Compressed air, feeding in 13

Conveyor belt 12,13

Conveyor webbing, tightening 15

Cutter shaft, lubricating 16

Explanation of terminology 10

Drop height, setting 14

Half yearly maintenance work 20

Location, changing 11,12

Maintenance 15
Machine overview 11
Monthly maintenance work

Recirculated ball spindle, lubricating 19

Safety data sheet 5

Safety instructions 4

Switching off 11

Technical data 21

Toothed belts, tightening 15

Typography 10

Weekly maintenance work 15,16,17

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NOTE!
If necessary also refer to the special cleaning and maintenance manuals.

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