PASSION COMMITMENT QUALITY - Matthiesen Equipmentmatthiesenequipment.com/assets/bagger-manual.pdfPASSION COMMITMENT QUALITY 566 NORTH W.W. WHITE RD. SAN ANTONIO, TEXAS 78219 1-800-624-8635

PASSION COMMITMENT QUALITY

www.matthiesenequipment.com 566 NORTH W.W. WHITE RD. SAN ANTONIO, TEXAS 78219

1-800-624-8635

EQUIPMENT OWNERS MANUAL MATTHIESEN VLS BAGGER

TABLE OF CONTENTS

1) Safety Instruction.....................................................................................3 2) Unpacking Information............................................................................4 3) Warranty Information ..............................................................................5 4) Setup Information ....................................................................................6

5) Blower Adjustments.................................................................................7 6) Volumetric Filler Drum Timing...............................................................7 7) Production Rate.......................................................................................7 8) Start Up ....................................................................................................8 9) Filler Drum Trouble Shooting .................................................................9 10) Bagger Screw Trouble Shooting..............................................................10 11) Blower Trouble Shooting.........................................................................10 12) Ice Bridging Trouble Shooting ................................................................11 13) Ice Bags Trouble Shooting.......................................................................11 14) Lubrication information ...........................................................................12-37

15) Cleaning and Sanitizing ...........................................................................38 16) Electrical Drawings..................................................................................39-40 17) Parts List ..................................................................................................41-43 18) Assembly Drawings .................................................................................44-52 19) Decal Reorder Sheet ................................................................................53-54 20) Inspection Report .....................................................................................55

2

GENERAL SAFETY INSTRUCTION

BE SURE THAT PERSONS USING OR OPERATING THIS EQUIPMENT READ AND UNDERSTAND THESE INSTRUCTIONS BEFORE USE. All equipment developed by Matthiesen has been assembled and fully tested for proper alignment and safe operation, under correct usage, prior to delivery. Many accidents occur from incorrect use or misuse of equipment or tools in all types of work situations. Matthiesen cannot be held responsible for injury or damage resulting from such misuse. Listed below are some general precautions specifically related to ice processing and its environment that should be followed at all times. 1. Only properly trained and qualified personnel should be allowed to operate or service this equipment. 2. Minors must never be allowed to operate or work in close proximity to this equipment. 3. Do not ever attempt to service or clean this equipment while it is operating. Always lock out all power

sources. 4. Observe all posted WARNINGS on equipment and associated systems, to avoid personal or property

damage. Never remove, deface, or cover up any posted “WARNING” or SAFETY markings. 5. Before re-starting any equipment, be certain all personnel and foreign objects are clear of equipment. 6. Do not, under any circumstance insert hands or feet in equipment while operating or equipment is

operational. Lock out all power before servicing. 7. Be certain that proper grounding practices are maintained. Do not remove ground conductor prong from electrical plug provided. 8. Avoid excessive accumulation of ice or water on floor where this and other equipment is in use. 9. Do not operate machine without guards in place! Removal of any safety guards or warning labels shall void

any/all warranties or claims. 10. Do not climb or use machine as a ladder. 11. Equipment should have adequate work area around it to minimize accidents. Confined areas increase chances for accidents. 12. Matthiesen can not and will not be responsible for any loss or damage, including personal injury or property

damage, caused by the acts or omission of parties other than Matthiesen, or in the event of changes or modifications made to the equipment without the knowledge and consent of Matthiesen. Any such changes or modifications shall cause any warranties by Matthiesen to be null and void.

3

UNPACKING EQUIPMENT Upon receiving equipment, it is the responsibility of the customer to check for freight damage or missing parts and report immediately to Matthiesen toll free at 1-800-624-8635. Wash machine free of dirt, grease, or other debris due to shipping and handling. Machine should be sanitized before use, to avoid any contamination of product prior to powering up any and all equipment. Motors are totally fan cooled/wash down available. Electrical is NEMA 12X.

4

WWW.MATTHIESENEQUIPMENT.COM 1-800-624-8635

MATTHIESEN, warrants this equipment to be free from defects in material and workmanship under normal use and service as follows: 90 DAYS WARRANTY ON ALL PARTS: 90 Days from date of purchase to the original purchaser, MATTHIESEN will at it’s election, repair or replace at our factory in San Antonio, Texas, such part or parts found by the manufacturer to be defective. Any part or parts of equipment sent to us for adjustment, repair or replacement, will be shipped with all transportation charges prepaid, and will be returned to the customer with all transportation charges collect. If owner elects to have any malfunctions repaired without the consent of MATTHIESEN during the Warranty Period, MATTHIESEN will exchange only the part or parts found by our factory to be defective with new or factory reconditioned parts. No allowance for labor, transportation or product loss will be allowed. THIS WARRANTY shall not apply to said equipment, or any part thereof, which has been subject to accident, negligence, abuse, misuse, damage by flood, fire, windstorm, or any acts of God. THIS WARRANTY shall not be deemed to place any liability on MATTHIESEN for labor, time loss, and product loss or replacement part purchased by owner without the consent of MATTHIESEN. MATTHIESEN shall be obligated hereby to furnish only the replacement part or parts. MATTHIESEN disclaims all other warranties, express or implied, including warranties of merchantability and of fitness for a particular purpose. Under no circumstances shall MATTHIESEN be liable or responsible for initial or consequential damages caused by any defects in materials, workmanship, or by failure to adhere to any warranties.

MATTHIESEN 566 North W W White Road San Antonio, Texas 78219

www.matthiesenequipment.com Fax: 210-333-1563 1-800-624-8635 Phone: 210-333-1510 02/22/06

5

BAG ADJUSTMENTS STANDARD WICKET HOLDER Bag platform holder has holes across the top for various wicket widths; vertical holes to adjust bag platform for different lengths of bags. A. Place wicket wire through proper hole and push spring-loaded platform holder back beyond downspout lip

and release. B. Place the bag platform at the proper level once bags are correct on wicket.

6

BLOWER ADJUSTMENT & DUST FILTER To start blower, unlock main power source. Turn the on/off switch on the bagger to the on position, then flip toggle switch up. Blower housing has a damper door on inlet to regulate air flow. With bags on wicket, blower must be able to open bag and maintain it open. If damper door is fully open you have maximum air flow. Closed damper door will not open bags properly. Dust filter should be used with blower to keep debris out of bag. Dust filter can be washed with mild soap and water. Clean or replace as needed.

VOLUMETRIC FILLER DRUM TIMING When viewed from the top of the machine, the volumetric filler drum rotates in a counter-clockwise direction to fill the bags with ice. The timing is kept with the triangular cam, which is mounted on top of the filler drum shaft and rotates with it, triggering the limit switch. To make sure the filler drum is properly timed, open the discharge chute door. The inner plate should be centered over the discharge. To adjust, loosen 3/8” hex bolt holding triangular cam and move cam counter-clockwise to delay drum plate position, clockwise to advance.

PRODUCTION RATE Volumetric drum must be free of ice prior to adjustments. Loosen bolt(s) on the side of the filling drum and turn the outer drum shell counter-clockwise to increase volumetric weight, clockwise to decrease. Set desired volume and tighten bolt(s). Drum motor: To adjust turn the crank handle on the motor base clockwise to increase bags per minute. Turn counter-clockwise to decrease. Production rate of your bagger can range from 12 to 45 bags per minute.

7

START-UP Summary of procedures and adjustments for start-up. Unlock all power sources. Bag position set. Turn main on/off switch to on position. Flip blower toggle switch up and open damper door midway. Supply ice to bagger, fill top hopper. Depress foot pedal once to fill drum compartments. Depress foot pedal again to fill bag. If bags are to be filled with amounts greater than the model is designed for, multiple dumps can be made to achieve desired amount. Check volumetric weight and adjust if necessary.

OPTIONAL PROXIMITY SWITCH: Field Installation: When optional proximity switch is purchased and field installed; remove jumper wire at terminal maker 26 & 26a. Install proximity switch wire, according to manufacturer wiring diagrams. Adjusting Proximity Switch Sensitivity: Using a small screwdriver, turn sensitivity screw located at the back of the proximity switch clockwise to increase sensitivity. Turn the sensitivity screw counterclockwise to decrease the sensitivity.

8

TROUBLE SHOOTING FILLER DRUM PROBLEM POSSIBLE CAUSE CORRECTIVE ACTIONS

Drum will not turn Drum breaker Reset breaker or replace Fuse Fuse replacement Foot pedal Check or replace micro switch Wiring or plugs Correct faulty wire connections Drum contactor Repair or replace contactor Overload tripped Reset overload Drum motor Repair or replace motor Drum keeps turning Limit switch frozen Listen for audible click after foot pedal is or worn (no click-replace) released with auto off. Foot pedal micro switch Unplug foot pedal and replace Frozen or worn micro switch * 1983 or earlier Limit switch arm Straighten arm or tighten. Limit switch is loose or bent too Replace if necessary. located directly far away from under drum. pins. * 1984 or later Limit switch frozen Adjust limit switch. Tighten Limit switch is or worn. Timing cam or replace cam. not activating limit switch roller lever Drum motor Motor starter Replace Drum drive chain Repair or replace V-belt Repair or replace

9

TROUBLE SHOOTING BAGGER SCREW PROBLEM POSSIBLE CAUSE CORRECTIVE ACTIONS

Screw not turning Breaker on control box Reset breaker Fuse Replace fuse Limit switch or arm & Check limit switch; or arm & paddle, sensor possibly hanging. Sensor adj. Wiring or plugs Check wiring and connections Screw motor Repair or replace Drive chain Replace chain or broken/ Worn sprocket Screw contactor Replace or repair contactor Overload tripped Reset overload

TROUBLE SHOOTING BLOWER PROBLEM POSSIBLE CAUSE CORRECTIVE ACTIONS

Motor not turning Breaker/Fuse Reset breaker/ Replace Fuse Wiring Check wiring and connections Motor Repair or Replace Blower contactor Repair or Replace contactor Overload tripped Reset overload

10

TROUBLE SHOOTING ICE BRIDGING PROBLEM POSSIBLE CAUSE CORRECTIVE ACTIONS

Bridging at lower Ice level too high Lower ice level Hopper Liner Install optional liner High Ice core temperature Stabilize ice temperature (Wet Ice) Below 30 degrees F

Bridging at top Ice level too high Lower ice level Hopper Liner Install optional liner Wiggler Install optional wiggler Sure Fall Install optional Sure Fall High Ice core temperature Stabilize ice temperature (Wet Ice) Below 30 degrees F

Bridging at Liner Install optional liner Volumetric filler Slapper Install optional Slapper Sure Fall Install optional Sure Fall High Ice core temperature Stabilize ice temperature Below 30 degrees F

TROUBLE SHOOTING ICE BAGS PROBLEM POSSIBLE CAUSE CORRECTIVE ACTIONS

Partial open bags Damper door partially closed Adjust Damper door Filter Clean or Replace filter Bag type Purchase bags with a crimped Lip Bag opener Adjust spring on bag opener to Devent air flow to bag lip

11

LUBRICATION Reducers, bearings and chain are lubricated at the factory. Because of use in wet conditions they should be checked or lubricated periodically. Matthiesen recommends the use of food grade lubricants on all necessary parts. Reducers: Drum – Food grade gear oil Screw – Food grade gear oil Gear motors – Food grade gear oil Refer to provided operating instruction manuals to determine oil level and position of vent. Note: A small amount of grease at frequent intervals is preferable to a large amount at infrequent intervals.

Flange bearings – Food grade bearing grease Matthiesen stocks the following Lubriplate products: STK# PT560 – FMO 9OO AW Food grade gear oil RS035 – FGL –1 Food grade grease RS036 – FMO 350 Food grade spray Flange bearing – There are two 1-1/2” flange bearings on the volumetric drum. One is located on top and one below the machine. Using a grease gun pump, grease through fitting every 100 hours of operation. Chains – Drum and screw chains use spray oil every 20 hours of operation.

PART #BRG016 1 ½” 4 HOLE FLANGED BEARING

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

CLEANING AND SANITIZING INSTRUCTIONS

Equipment: The Matthiesen VLS BAGGER • Materials Required

o Water hose with spray nozzle attached to potable water source. o Pressurized detergent spray unit with application hose and spray nozzle. o Portable, hand operated pressure sprayer (2-3 gallon size). o Auxiliary equipment: Brooms and brushes, sponges, wipes and plastic sheets to cover sensitive

equipment. o Personnel/supplies – plastic or rubber gloves, boots, head cover, aprons/coveralls, eye safety

glasses. o Moderately alkaline detergent (Mix per vendor instructions) o Sanitizer: Quaternary ammonium

• Special Instructions

o Avoid eye and skin contact with chemicals o Maintain adequate ventilation.

• Recommended Frequency of Cleaning

o Recommended weekly or more often, if necessary.

• Procedure 1. Remove residual ice and drain. 2. Shut down and lock out unit (electrical). 3. When essential, hand- clean the motor and controls and cover with plastic sheets. 4. Rinse inside walls, breakers, and exterior with potable water. 5. Spray the detergent solution on all pre-rinsed surfaces with detailed brushing, as required, until

free of debris. 6. Rinse free of detergent with warm water (< 130°F) and inspect for cleanliness. Repeat cleaning

and rinsing until thoroughly clean. Note: It may be necessary to turn on the crusher, applying detergent and rinsing alternatively to obtain thorough cleaning.

7. Spray sanitizer (quaternary ammonium) at 200 ppm on screw and interior housing and allow to dry.

8. Leave unit locked out until the next shift’s operation.

38

39

40

VLS BAGGER PARTS LIST

BAGR 384 1 GALV STL FRAME 35 BAGR 451 1 SS FRAME BAGR 207 1 GALV STL FRAME 510 BAGR 444 1 SS FRAME BAGR 209 1 GALV STL FRAME 815 BAGR 417 1 SS FRAME BAGR 385 1 GALV STL FRAME

1

2025 BAGR 453 1 SS FRAME

2 ALL MODELS BAGR 676 1 ¼” THK HIGH DENSITY BOTTOM PLATE

3 ALL MODELS BAGR 060 1 1/8” THK UHMW DRUM SPACER

35 BAGR 715 1 12 GAUGE SS OUTER DRUM 510 BAGR 394 1 12 GAUGE SS OUTER DRUM 815 BAGR 717 1 12 GAUGE SS OUTER DRUM 4

2025 BAGR 716 1 12 GAUGE SS OUTER DRUM 35 BAGR 652 1 INNER DRUM W/O LINER 510 BAGR 718 1 INNER DRUM W/O LINER 815 BAGR 719 1 INNER DRUM W/O LINER 5

2025 BAGR 720 1 INNER DRUM W/O LINER 35 BAGR 533 1 1/8” THK UHMW INNER DRUM LINER 510 BAGR 522 1 1/8” THK UHMW INNER DRUM LINER 815 BAGR 535 1 1/8” THK UHMW INNER DRUM LINER 6

2025 BAGR 535 1 1/8” THK UHMW INNER DRUM LINER

7 ALL MODELS BRG 016 3 1 ½” 4 HOLE FLANGE BEARING

35, 510, 815 BAGR 097 1 SS TIMING STAR 8

2025 BAGR 098 1 SS TIMING STAR

9 ALL MODELS BAGR 478 1 SS TOP PLATE

10 ALL MODELS PT 388 1 LIMIT SWITCH

BAGR 102 1 GALV STL LIMIT SWITCH BRKT 11 ALL

MODELS BAGR 570 1 SS LIMIT SWITCH BRKT

12 ALL MODELS BAGR 369 1 LIMIT SWITCH W/ARM & PADDLE

BAGR 425 1 GALV STL HOPPER 13 ALL MODELS BAGR 633 1 SS HOPPER

14 ALL MODELS SPR 025 1 DRUM SPROCKET

15 ALL MODELS BSH 043 1 DRUM SPROCKET BUSHING

16 ALL MODELS BAGR 009 1 DRUM DRIVE CHAIN

BAGR 568 1 GALV STL IDLER ARM BRACKET 17

ALL MODELS BAGR 569 1 SS IDLER ARM BRACKET

41

18 ALL MODELS SPR 021 1 IDLER ARM SPROCKET

19 ALL MODELS SPR 012 1 DRUM GEAR REDUCER SPROCKET

20 ALL MODELS MTR 031 1 DRUM REDUCER

21 ALL MODELS MTR 030 1 DRUM MOTOR

22 ALL MODELS MTR 094 1 DRUM MOTOR BASE

23 ALL MODELS PLY 047 2 DRUM GEAR REDUCER PULLEY

24 ALL MODELS VB 056 1 DRUM DRIVE BELT

25 ALL MODELS PLY 061 1 HI LO PULLY

BAGR 006 1 GALV STL BLOWER DAMPER 26 ALL MODELS BAGR 127 1 SS BLOWER DAMPER

BAGR 128 1 SS ASSEMBLY 115-220/1/60 HP3400RPM BAGR 130 1 SS ASSEMBLY 230/3/60 BAGR 100 1 SS WASHDOWN MOTOR (120/1/60) BLOWER ASSEMBLY BAGR 634 1 SS ASSEMBLY (220/1/50) BLOWER BAGR 622 1 GALV STL ½ HP 1 PH 50 HZ BLOWER ASSEMBLY BAGR 459 1 GALV STL ½ HP 1 PH 60 HZ BLOWER COMPLETE ASSEMBLY

BAGR 685 1 GALV STL ½ HP 3 PH 60 HZ BLOWER ASSEMBLY

27

ALL MODELS

BAGR 692 1 GALV STL ¾ HP 3 PH 50 HZ BLOWER

27A ALL MODELS MFBAGR029 1 BLOWER ALUM. FAN WHEEL ONLY

27B ALL MODELS MTR046 1 GALV BLOWER HOUSING 1/3 HP

27C ALL MODELS MTR006 1 SS BLOWER HOUSING 1/3 HP

28 ALL MODELS BAGR 607 1 BLOWER FILTER

BAGR 259 1 GALV STL AIR DUCT 35 BAGR 483 1 SS AIR DUCT BAGR 255 1 GALV STL AIR DUCT 510 BAGR 490 1 SS AIR DUCT BAGR 256 1 GALV STL AIR DUCT

29

815/2025 BAGR 495 1 SS AIR DUCT BAGR 458 1 GALV STL SNOW VISOR 30 ALL

MODELS BAGR 584 1 SS SNOW VISOR

31 ALL MODELS BAGR 686 1 SS BAG OPENER ASSEMBLY

31A ALL MODELS BAGR 618 1 SS ROD

31B ALL MODELS PT646 1 SS SPRING

35 BAGR 721 1 SS DOWN SPOUT 32 510/815 BAGR 487 1 SS DOWN SPOUT

42

2025 BAGR 724 1 SS DOWN SPOUT BAGR 018 1 GALV STL LEFT SIDE SCALE BRKT 33 ALL

MODELS BAGR 564 1 SS LEFT SIDE SCALE BRKT BAGR 017 1 GALV STL RIGHT SIDE SCALE BRKT 34 ALL

MODELS BAGR 565 1 SS RIGHT SIDE SCALE BRKT BAGR 302 1 GALV STL BAG PLATFORM HOLDER 35 ALL

MODELS BAGR 586 1 SS BAG PLATFORM HOLDER BAGR 390 1 GALV STL BAG PLATFORM 36 ALL

MODELS BAGR 585 1 SS BAG PLATFORM

37 ALL MODELS BAGR 433 1 SPRING BAG PLATFORM HOLDER

BAGR 440 1 GALV STL HANGER BRACKET 38 ALL MODELS BAGR 645 1 SS HANGER BRACKET

BAGR 596 1 GALV STL RIGHT HANGER SUPPORT BRKT 39 ALL MODELS BAGR 598 1 SS STL RIGHT HANGER SUPPORT BRKT

BAGR 595 1 GALV STL LEFT HANGER SUPPORT BRKT 40 ALL MODELS BAGR 597 1 SS LEFT HANGER SUPPORT BRKT

BAGR 434 1 GALV STL SCREW AUGER 66 ½” 41 ALL MODELS BAGR 657 1 SS SCREW AUGER 66 ½”

42 ALL MODELS CONV 701 1 1 ½” UHMW AUGER BEARING

BAGR 436 1 GALV STL TROUGH 66 ½” BAGR 779 1 SS TROUGH 66 ½” 43 ALL

MODELS BAGR 659 1 PRE 2004 SS TROUGH 66 ½” BAGR 237 1 GALV STL TROUGH END PLATE 44 ALL

MODELS BAGR 474 1 SS TROUGH END PLATE BAGR 036 1 GALV STL FEED SCREW SUPPORT 45 ALL

MODELS BAGR 559 1 SS STL FEED SCREW SUPPORT BAGR 439 1 GALV STL SCREW SHROUD COVER 46 ALL

MODELS BAGR 505 1 SS SCREW SHROUD COVER BAGR 599 1 GALV STL HANGER ACCESS COVER 47 ALL

MODELS BAGR 600 1 SS HANGER ACCESS COVER BAGR 301 1 GALV STL BOTTOM HOPPER 48 ALL

MODELS BAGR 479 1 SS STL BOTTOM HOPPER

49 ALL MODELS BAGR 457 1 UHMW HOPPER LINER

50 ALL MODELS MTR 041 1 SCREW MOTOR

51 ALL MODELS MTR 040 1 SCREW MOTOR REDUCER

52 ALL MODELS SPR 001 1 1” SCREW MOTOR SPROCKET

53 ALL MODELS SPR 002 1 1 ½” AUGER DRIVE SPROCKET

54 ALL MODELS BAGR 393 1 #60 36” LG SCREW DRIVE CHAIN

BAGR 624 1 GALV STL TOP SCREW CHAIN COVER 55 ALL MODELS BAGR 712 1 SS TOP SCREW CHAIN COVER

BAGR 044 1 GALV STL MIDDLE SCREW CHAIN COVER 56 ALL MODELS BAGR 482 1 SS STL MIDDLE SCREW CHAIN COVER

57 ALL BAGR 625 1 GALV STL END SCREW CHAIN 43

MODELS BAGR 713 1 SS END SCREW CHAIN COVER

58 ALL MODELS PT 369 4 CASTER

59 ALL MODELS PT 794 1 CONTROL BOX

60 ALL MODELS BAGR 405 1 COMPLETE FOOT PEDAL

44

45

46

47

48

49

50

51

52

53

DECAL REORDER SHEET

DECAL NUMBER DECAL IDENTIFICATION

D001...........................................................................................................................

D002.......................................................................................................................................

D003...............................................................................................................

D004...............................................................................................................

D005...................................................................................................................................................

54

DECAL REORDER SHEET

DECAL NUMBER DECAL IDENTIFICATION

D006...............................................................

D007.......................................................................................................................................

D008...............................................................................................................

D009...........................................................................................................................

55

INSPECTION REPORT VISUAL: CLEANLINESS: DRUM OR SCREW PASS FAIL EXTERIOR PASS FAIL

METAL FINISH (UNIFORM) PASS FAIL DECALS: PASS FAIL MECHANICAL: ROTATION OF MOTORS PASS FAIL LIMIT SWITCH PASS FAIL TIMING OF DRUM PASS FAIL MANUAL MODE AND AUTO PASS FAIL CHAIN:

TENSION PASS FAIL ALIGNMENT PASS FAIL

POWER CORD VOLT/AMP SAME AS CONTROL BOX REQ.: PASS FAIL CONFIRM VOLTAGE W/W.O.: PASS FAIL FINAL INSPECTION: DRY TEST RUN PASS FAIL VISUAL PASS FAIL FASTENERS FOR TIGHTNESS PASS FAIL COMMENTS: INSPECTED BY DATE: SERIAL NUMBER G:\equipment manuals\vls\vlsbagger510\inspection report Created by: Ron de Leon Approved by: Pete Ruiz Date: 07/22/06

56