Operation and Maintenance Manual for Semi-Automatic Shaping Device

OPERATION AND MAINTANCE
DOCUMENTATION OF THE
SEMI-AUTOMATIC DEVICE FOR FINAL
SHAPING OF SHIRRED STICKS
USER MANUAL
Model: P 160
Type: Nikelman
Serial Number: III-92/187
Year of manufacture: 2019
Operation and maintance documentatnion of semi-automatic device for final shaping of shirred sticks NIKELMAN P160 1/42
TABLE OF CONTENTS
1 DESCRIPTION OF THE DEVICE AND INTENDED USE.......................................................4
2 TECHNICAL DATA OF THE DEVICE......................................................................................5
3 ASSEMBLY OF THE DEVICE, CONNECTION AND PREPARATION FOR OPERATION......6
3.1 Unloading......................................................................................................................... 6
3.2 Setting and installation.....................................................................................................6
3.3 Connecting the electrical supply and compressed air system..........................................6
3.4 Trial Run........................................................................................................................... 6
4 THE COMPONENTS OF THE DEVICE...................................................................................7
4.1 List of components........................................................................................................... 7
4.2 Supporting structure ........................................................................................................9
4.3 Mechanism for carrying calibration bars........................................................................10
4.4 Replacement of the calibration bars..............................................................................11
4.5 Drying tunnel.................................................................................................................. 13
4.6 Blowing........................................................................................................................... 13
4.6.1 Blowing components...............................................................................................13
4.6.2 Operating principle of the airflow system................................................................14
4.7 Cooling the formed sticks...............................................................................................15
4.8 Pressure mechanism......................................................................................................15
4.8.1 Replacement of the pressure pad...........................................................................16
4.9 Welding device.............................................................................................................. 17
4.9.1 Replacing the Welding Cone..................................................................................17
5 ELECTRICAL INSTALLATION..............................................................................................18
5.1 Electrical documentation...............................................................................................18
5.2 Operation of the operator panel - settings of operating parameters...............................19
5.2.1 Acknowledgement of the message (warning).........................................................20
5.2.2 Main Screen............................................................................................................ 20
5.2.3 Parameter setting (Parameter setting mode)..........................................................20
5.2.4 Tunnel temperature setting.....................................................................................21
5.2.5 Tunnel humidity setting...........................................................................................21
5.2.6 Setting the fan parameters in the drying tunnel.......................................................22
5.2.7 Setting the parameters of the welding device.........................................................23
5.2.8 Working time counter..............................................................................................23
5.2.9 ''WORK" mode, "STOP" mode................................................................................24
6 DESCRIPTION OF THE USE OF THE EQUIPMENT............................................................25
6.1 Work cycle activities during arming of the unit................................................................25
6.2 Operation of the work cycle after the device is fully armed.............................................26
7 INTERCHANGEABLE ELEMENTS (DEPENDING ON THE ORDERED SET)......................28
8 SPARE PARTS...................................................................................................................... 29
9 FOR OPERATING PERSONNEL..........................................................................................30
10 ACTIVITIES FORBIDDEN TO THE EMPLOYEE.................................................................32
11 OCCUPATIONAL HEALTH AND SAFETY RULES.............................................................33
Technical and operational documentation operating instructions a table-top dryer NIKELMAN P160 2.0 2/42
12 TERMS OF THE GUARANTEE...........................................................................................35
13 INTERMEDIATE PERIODIC INSPECTION OF THE DEVICE.............................................36
13.1 The pressure pads.......................................................................................................36
13.2 Cables.......................................................................................................................... 36
13.3 Pins.............................................................................................................................. 37
13.4 Rings............................................................................................................................ 37
13.5 Main disc drive unit ......................................................................................................37
13.6 Formed sticks ejector assembly .................................................................................37
14 PERIODIC INSPECTION OF THE DEVICE.........................................................................38
15 MAINTENANCE AND LUBRICATION OF THE DEVICE.....................................................38
16 SERVICE INSPECTION......................................................................................................38
17 THE SAFETY OF THE OPERATOR....................................................................................39
18 HEALTH AND SAFETY LABELLING...................................................................................40
1 DESCRIPTION OF THE DEVICE AND INTENDED USE
The device is responsible for the operations to be performed after the shirring
process – forming and drying and the shirred casing sticks, along with the possibility of
manual welding of one tip to prevent spontaneous expansion using special device.
The control of individual processes is pneumatic and electric. The device has a
regulation of humidity and temperature, which allows to control these parameters for
each type of casing.
The device is adapted to compress and dry casing sticks with diameters from Ø
17 to Ø 32 for a length of 250, 300 or 320 mm.
The equipment includes a set of interchangeable calibration bars and
subassemblies for each casing diameter.
ATTENTION!
Operators and maintenance personnel should be trained by manufacturer service

personnel to make the most of the capabilities of the Nikelman P-160 semi-
automatic device for final forming and drying shirred casing sticks.
If you do not operate the device in accordance with these instructions, you may
damage the device components and do not accept any complaints.
The device should only be operated by appropriately trained and qualified
personnel.
2 TECHNICAL DATA OF THE DEVICE
Number of bars 160 pcs.. In two rows 80 pcs. each
Number of crescents with bars 8 pcs.
Total length of the calibration bars 360mm
Length of formed sticks 250, 300, 320 mm
Diameter of formed casings min Ø 17 max Ø 32 mm
Diameter of drying tunnel 1290 mm
Powerful heater 9 kW,
Ventilator power 0,255 kW

Maximum stick shaping efficiency
(depends on the number of meters
from 6.500 up to 9.500 meters per hour
in the stick and the forming time
cycle )
Supply voltage 400 V, 60 Hz
Stick tip welder
Temperature range Regulation up to 250 oC
Power supply 230/400 V
Compresed air 0,6-0,8 MPa
Dimensions of the device (length x
1970 mm x 2065 mm x 1778 mm
height x width)
Total weight 700 kg
Colour Silver-Blue
3 ASSEMBLY OF THE DEVICE, CONNECTION AND PREPARATION
FOR OPERATION.
3.1 Unloading
Unloading the device and delivering it to the place of assembly without unpacking
the crates is done by the buyer. During unloading and transportation, the machine
elements must be protected against damage. All parts must be stored in a place free
from moisture and dirt until installation.
3.2 Setting and installation
The device can be assembled at manufacturer's Plant to allow preliminary

commissioning and to check the operation of the device, its individual components and
used drives.
The device may only be installed by persons who have been trained by
manufacturer personnel. However, please note that individual components that cannot
be disassembled or assembled as a component may not be disassembled or modified
for personal use without the knowledge and consent of the manufacturer of the
equipment. The ease of movement of the assembled device allows it to adapt to any
possible configuration in the production hall.
3.3 Connecting the electrical supply and compressed air system
At the place of installation, the following connections must be prepared: electrical

supply - required for operation of the machine (3x400 V; 60 Hz); 11.5 kW; protected by
40A per phase switch), pneumatic (technological specification of air preparation), fresh
air intake channel.
3.4 Trial Run
The customer is obliged to make the device available for initial commissioning in
the presence of a person from the manufacturer service. A report is drawn up on the
commissioning of the device and signed by both parties.
4 THE COMPONENTS OF THE DEVICE
4.1 List of components
Semi-automatic device for final forming the shirred casing consists of the following
components:
1. Supporting structure;
2. Rotary disc;
3. Ejection system;
4. Drying tunnel;
5. Blowing system;
6. Clamping mechanism;
7. Disck lock;
8. Tappet;
9. Stick tip welding device
10. Control cabinet;
11. Crescents with calibration bars.
The individual assemblies, listed above, consist of the components and elements
described in this user manual.
Fig. 1: Supporting structure
Fig. 2: Rotary disc Fig. 3: Ejection system
Fig. 4 Drying tunnel Fig. 5 Blower fan
Fig. 6 Clamping mechanism Fig 7. Disc lock
Fig. 8 Tappet without guard Fig. 9: Welding device
Fig.10 armed device
4.2 Supporting structure

The main construction is the frame of the device. It is made of steel sections and
a support plate, on which is mounted a system for carrying shirred casing sticks.
The supporting structure is a fixed element. Do not make any structural changes
to the supproting structure.
To the frame is attached the blowing system, housing, control cabinet, thermal
instalation (separating the controls from the blowing system), a cylinder pushing out
ready sticks and two supported shelfs for cartons. On support plate is mounted a
drying tunnel with accessories, a pressure mechanism, control buttons, a knife to
cut off the casing excess after making a knot and control panel. The supproting
structure is a fixed element to which a supporting plate is welded.
In the carrier plate there are holes made through which the blowing hoses are led
out. Such a solution makes the whole structure compact without any elements
outside the working area.
4.3 Mechanism for carrying calibration bars

1. The following elements are the components of the bar handling mechanism:
2. Mainboard divided into 8 parts with cronical bars of the desired diameter
depending on the formed casing caliber, so-called crescents,
3. The main disc, which is designed to move the casings attached to the bars in the
drying tunnel,
4. Blocking of the main rotary disc (main disc positioning),
5. Actuator locks
6. Actuator with Tappet
Fig. 11 Main disc with bars Fig.12 Crescent with a set of calibration bars
The main disc is a moving element on which the crescents and calibration bars
with shirred casing are transported. Depending on the transfer of the required diameter
of the casings, the crescent moons and calibration bars are replaced.
4.4 Replacement of the calibration bars
All steps for the disassemble and assembly of the crescent moons are described
Below. Calibration bars are dismantled by unscrewing the mounting screws shown in
Figure 13. The crescent should be dismantled after unscrewing the pressure cube.
The crescents are assembled and disassembled as follows:

− using the crescent wrench, unscrew the three fastening screws ( shown in
Figure 13.)
− to disassemble the crescent.
− preset a new crescent.
− pre-tighten the three fastening screws leaving mounting clearance, to
position the crescent.
− tighten the srcews.
Then we proceed in the same way as the other crescents. The disc is replaced
after the rotation of the disc by an appropriate distance.
Figure 13: Removal of the crescent moon.
Figure 14: Disassembly of the crescent .
The rotary disck lock mechanism remains in the extended position even after the
air is cut off. If free rotation is required, the system can be locked mechanically by using
a wrench or a screw plugged into the lock.
Blockade
Fig. 15: Main rotary disc position lock
The purpose of the actuator locking mechanism is to prevent accidental displacement of

the main disc drive element and to establish itself in the position of the disc drive seat.
Thrust pin
Unit cover Pusher

plate
Pneumatic
cylinder
Pneumatic lock
cylinder
Figure 16: Main rotary disc pushing mechanism

with pneumatic cylinder lock and pusher plate
4.5 Drying tunnel
The drying tunnel ensures proper air circulation. The temperature inside the tunnel is
controlled by a sensor.
Fig. 17 Drying tunnel
4.6 Blowing
4.6.1 Blowing components

The blowing system consists of three basic elements: a throttle, a fan and a
heater. All the elements are to ensure proper (required) efficiency of the drying
chamber.
To ensure this, an electric throttle is used, which provides an appropriate mix of
used, return air from the drying tunnel, with additional fresh air supplied from
outside the room in which the device is located.
In addition, the blowing system is equipped with an outlet switch that distributes
the heated air to the individual points in the drying tunnel.
The individual elements of the blowing system are shown in Figure 18.
1. Throttle
2. Canal fan
3. Heater with outlet switch
Fig 18. Blowing system
4.6.2 Operating principle of the airflow system
The purpose of the blowing system is to supply a sufficient amount of heated air to
the drying tunnel chamber, which takes place as follows:
1. fresh air flows from the duct (ventilation grille in the customer's production hall)
to the air inlet (1)
2. the air used from the drying chamber is supplied to the inlet (6),
3. the wind media are mixed in the damper (5) depending on the signal provided by
the temperature and humidity sensor installed in the drying tunnel chamber, by
means of a stepper motor controlled by the device controller,
4. the damper allows one of the media to be isolated in such a way that either fresh
air or used air (closed circuit) can be supplied to the fan or mixed to ensure
optimum drying conditions,
5. the one-phase motor fan (3) pumps the air mixture to the heater (4), where the
temperature of the heated medium can be controlled automatically,
6. then properly prepared air is delivered to the outlet ports and then transported to
the drying tunnel.
There is a possibility of programmable settings, both the heating power obtained on

the heater and the fan speed (speed/slow speed).
Fig. 19. Principles of operation of the blower system
4.7 Cooling the formed sticks
The machine is additionally equipped with a formed sticks cooler. It is equipped
with a fan, which after starting is designed to cool the hot, formed and dry casing sticks.
Fig. 20 Cooler fan
4.8 Pressure mechanism
The clamping mechanism is shown in Figure 21. The mechanism is equipped

with a rod for adjusting the stroke of the clamping mechanism. By adjusting the nuts we
determine the correct actuator stroke needed for its proper clamping. The jump depends
on the length of the shirring bar (holes for pin pins in rods).
Fig. 21: Assembleod the clamping mechanism
The pressure value is adjusted by shifting the adjusting nuts to the position in
which the desired extension of the pressure block will take place.
Clamping length
adjusting screw
Fig. 22 Sticklength adjustment
4.8.1 Replacement of the pressure pad
If the crescent and calibration bars are replaced, the preassure pad \ clamping block
must be replaced with a suitable one for the calibration set. To do this, loosen the lock
nut of the old cube. Turn the piston rod to remove the piston rod from the block. Lower
the block to the bottom of the bars. Turn the main dial so that the old pressure block can
be removed.
The assembly of the new preassure pad (changeover to a different diameter of the
dried bars) takes place in the following way:
1. Apply a new preassure pad (next to the actuator handle).

2. Turn the main disc so that the new preassure pad is under the piston rod of the
actuator. NOTE: The main disc with the bars should be placed in the
position to compress the sticks.
3. Lift the pad to the piston rod.
4. Turn the piston rod and screw it into the cube.
5. Lower the actuator
6. When turning clamping adjustment screw, adjust the distance between the
pressure pad (its lower surface) and the upper surface of the main disc to 289 1
mm.
7. Tighten the lock nut NT-03.
4.9 Welding device
The main elements of the welding device are:
1. Pipeline heater
2. Teflon-coated sealing insert
3. Teflon cone
Fig. 23: Fold in the welding machine
4.9.1 Replacing the Welding Cone
When replacing the caliber of the casing, replace the insert in the welding device.
Select the Insert corresponding to the diameter of the selcted casing. For replacement,
unscrew the Insert using the supplied tool. Replace it with a disc of the appropriate
diameter.
Note: Special care must be taken when replacing the welding insert.
The machine should not be switched off and the time between the last welding
and replacement should be min. 20 minutes (the heater must cool down).
5 ELECTRICAL INSTALLATION
The most important components of the electrical installation:

- Switch cabinet - photo 24
- control panel - photo 25
- control buttons (in the top of the device) - photo 26
- blowing system (heater, fan, throttle) - photo 27
- stick tip welder - photo 23
Photo 24 - Switch cabinet Photo 25 - Control panel
Photo 26 - START control buttons Photo 27 - Blowing system
5.1 Electrical documentation
Electrical documentation is an integral part of this manual.
ATTENTION! Do not make any changes to the electrical installation of the

machine. This may result in electric shock or damage to the machine.
5.2 Operation of the operator panel - settings of operating
parameters
The panel consists of an LDC display, 4 function keys F1 – F4, arrow buttons
▲, ►, ▼, ◄ and buttons ESC i OK (fig. 28.).
ENTER
Figure 28 - Appearance of the operator panel of a stick shaper device
Use of buttons:
− F1 – switching on the operating mode (switching to the edition of the next

parameter in the parameter setting mode)
− F2 – deactivation of operating mode (switch on/off devices in parameter setting
mode)
− F3 – switching on/off the parameter setting mode
− F4 – switching on/off the timer mode (switching to the previous parameter edition
in the parameter setting mode)
− ESC – activating/disabling parameter selection mode in parameter setting mode
− ENTER – acknowledge warnings (enable/disable parameter edit mode,
remembering parameter settings - in parameter setting mode)
− ► or ◄ – selection of the digit position of the value of the parameter whose

setting we want to change
− ▲ or ▼ – decreasing (increasing) the value of the parameter digit value
5.2.1 Acknowledgement of the message (warning).
Every time you start the device and press the emergency button, a message will
appear on the control panel screen (fig. 29). This warning will be displayed until the
fault is rectified, the emergency button is released and the RESET button on the
back of the unit is pressed. After all these steps have been completed, the warning
can be deleted (confirmed) by pressing the ENTER button.
Figure 29 - Message about the pressed emergency button
5.2.2 Main Screen

If no emergency situation has occurred and the initial message has been
acknowledged, the start screen should appear on the panel screen (fig. 26).
Figure 30 - Initial screen
5.2.3 Parameter setting (Parameter setting mode).
Before commencing operation, set the desired operating parameters of the device.
This is done by pressing the F3 button. You can set the following parameters:
● Drying tunnel temperature and operation of the tunnel heater
● Drying tunnel humidity and throttle operation
● Rotation of the tunnel fan
● Sealer temperature
Parameters are switched by pressing F1 or F4. Exiting the parameter edit mode is
done by pressing the F3 button.
5.2.4 Tunnel temperature setting
The first parameter to be set is the temperature of the drying tunnel

(Figure 27).
Figure 31 - Drying tunnel temperature settings
To set the tunnel temperature, press and hold (for about 2-3 seconds) ESC then
ENTER. By means of ► and ◄ buttons select the position of the temperature setting
digit digit, and then by means of ▲ or ▼ buttons set the desired temperature value from
0 to 60 degrees Celsius.
The heater operation can be switched on/off using the F2 button
5.2.5 Tunnel humidity setting
In order to go to the tunnel's (relative) humidity setting (fig. 28), press F4 button
(marked on the screen) when the temperature setting screen is displayed (Fig. 28).
as ►).
Figure 32 - Dryer tunnel humidity settings
To set the desired tunnel humidity, press and hold (for about 2-3 seconds) the
ESC button then the ENTER button. By means of ► and ◄ buttons select the position
of the temperature setting digit digit, and then by means of ▲ or ▼ buttons set the
desired humidity value from 0 to 100%.
The throttle (humidity control device) can be turned on/off using the F2 button.
5.2.6 Setting the fan parameters in the drying tunnel
To go to the fan settings in the tunnel (fig. 29) press F4 button (marked on the
screen as ►) when the humidity setting screen is displayed.
Figure 33 - Settings of the fan parameters in the drying tunnel
The fan in the drying tunnel can operate in three modes:

● „0” - Off
● „1” – idle rotations
● „2” - fast rotations
The transition between the modes shall be made by pressing button F2 (marked:
0►1, 1►2, 2►0 respectively).
Activation of the fan is necessary to start the heater and the damper in the drying
tunnel.
5.2.7 Setting the parameters of the welding device
In order to switch to the sealer settings (fig. 30), press F4 button (marked on the
screen as ►) while the fan settings screen is displayed in the tunnel.
Figure 34 - Welding parameter settings
To set the desired sealer temperature, press and hold (for approximately 2-3
seconds) the ESC button then the ENTER button. By means of ► and ◄ buttons select
the position of the temperature setting digit digit, and then by means of ▲ or ▼ buttons
set the desired temperature value from 0 to 250°C.
The operation of the welder can be switched on/off using the F2 button.
The parameter setting mode can be ended with F3 button.
5.2.8 Working time counter
The device is equipped with a programmed working hours counter (working

hours counter). To read it (fig. 31), press the F4 button on the start screen (fig. 26).
Fig. 35 - Example of an operating time counter display
The device informs us about the total time (hours and minutes) of being
connected to the mains. It is not possible to reset the working time counter.
Exiting from the reading of the working time counter is done after pressing the F4
button.
5.2.9 ''WORK" mode, "STOP" mode
In order to activate the devices of the dryers whose parameters have been set
earlier, press the F1 button. The device then enters the "WORK" state, during which it is
possible to achieve the desired drying parameters and perform the bar crushing cycle.
Readiness for work is indicated by highlighting both green START buttons located on
the device's top.
During the dryer operation, it is possible to switch off its devices by pressing the
F2 button. The device then goes into the "STOP" state, then switches off the heater, the
throttle valve and the sealer immediately, and the fan in the tunnel is delayed. Only from
the "STOP" mode it is possible to switch to the "PARAMETER SETTINGS" mode or to
read the operating time counter.
Figure 36 – Example of a WORK mode display
In screen mode we can find the following information:

 temperature in the drying tunnel
 humidity (relative) in the drying tunnel
 fan speed
 sealer temperature
6 DESCRIPTION OF THE USE OF THE EQUIPMENT
One qualified person - the operator - is assigned to operate the unit. The first
start of the unit (unarmed unit) starts with the main power switch on the control cabinet.
6.1 Work cycle activities during arming of the unit.
Placing the shirred sticks is done manually on two axially placed calibration bars
indicated (red) in fig. 37. Placing the sleeves on the placed sticks and pressing them
manually so that the sleeve does not fall of from the calibration bar (the sleeves are
taken from the container; in the figure 37 shown with the blue arrows). After placing the
first shirred sticks, start the work cycle by pressing the cycle START buttons (green
buttons) with two hands. After each application of shirred sticks and sleeves, start the
cycle.
Fig. 37. Inserting the first sticks
When the first sticks are compressed, insert the safety pin shown in Figure 38
(highlighted in red, take the pins from the container). The pin must pass through two
calibration bars and must not interfere with the drying tunnel.
Figure 38: Inserting the first sticks
6.2 Operation of the work cycle after the device is fully armed.
After the device is fully armed (fig. 39.), after the drying cycle of the casings in the
drying tunnel, remove the pin from the shaped bars (red) and put it into the bars
squeezed before the process of forming. Place the freshly shirred sticks on the
calibration bars (as shown in Fig. 37) and then place the crushing sleeves from the
emptied rods on top of them. Remove individually dried bars pushed out by the pushing
mechanism (blue). At this point the operator binds one end of the casing and cuts off its
excess on the knife located on the left side of the dryer, and welds the other side, on the
heating device located also on the right side of the dryer (purple). After this treatment,
the casing is packed in a carton standing on a shelf next to the cutting and welding
components.
After all the above mentioned actions have been completed, start the next work
cycle by pressing the START buttons with two hands.
Fig.39. Bar pulling
ATTENTION:
In case of any irregularities in the operation of the machine, it is possible to
manually switch it off by the operator by means of an emergency stop button
located on the front cover of the machine.
7 INTERCHANGEABLE ELEMENTS (DEPENDING ON THE ORDERED
SET)
The device is equipped with replaceable elements. Replacement elements are

included:
Amo
Lp. Name of the component/ part/other Overview figure
unt
Crescents with Ø9,3 diameter rods (rods/semi-

1 160/8
moons)
Crescents with Ø 10,9 diameter rods (rods/semi-

2 160/8
moons)
Crescents with Ø 12 diameter rods (rods/semi-

3 160/8
moons)
Crescents with Ø 13 diameter rods (rods/semi-

4 160/8
moons)
Crescents with Ø14,7 diameter rods (rods/semi-

5 160/8
moons)
Crescents with Ø20 diameter rods (rods/semi-

6 160/8
moons)
7 Pushing out ring for rods Ø 12 160
7 Pushing out for rods Ø 13 160
11 Pushing out no. 2 for rods Ø 12 160
14 Pushing out No. 2 for rods Ø 18 160
15 Pushing outno. 2 for rods Ø 20 160
16 Pressure pad fi 16 1
17 Pressure fad fi 21 1
18 Welding element 01 1
21 Scalpel nr 24 1
8 SPARE PARTS.
The device can be supplied with spare parts on request :
• rods of the desired diameter - (depending on the diameter of casings)

that are not part of the device,
• Gaskets for inlet and outlet ports,
• Welding elements - (depending on the diameter of casings)
that are not part of the device,
• Brushes for sealing the drying tunnel,
• Other not mentioned.
9 FOR OPERATING PERSONNEL.
- GENERAL INSTRUCTIONS ON HEALTH AND SAFETY
The servant in charge of the dryer should :

- start working on time, being rested for the specific PSYCHOFIASIC AFFAIRS,
properly dressed (work clothes or overalls, work boots, work gloves, headgear if
necessary),
- hear the professional instructions given by their immediate superior concerning
the tasks to be performed on the working day in question and the professional
and safe operation of the dryer,
- check the condition of the dryer,
- make sure that:
a/ All control levers and buttons that operate the machine are in the zero position
(switched off),
b/ there is no visible damage to the electrical installation
Perform the following steps:

- remove all unnecessary objects (tool materials, etc.) from the workstation.
impairing the normal operation of the machine
- illuminate the entire workstation correctly,
- if you notice any deficiencies or hazards, make your comments to your
immediate supervisor so that they can be remedied quickly and, after you are
sure that they have been remedied, proceed with the operation of the dryer.
ESSENTIAL ACTIVITIES DURING THE PERFORMANCE OF WORK:
● always use safe working methods without posing any risks to yourself, your
colleagues or the environment,
● after ensuring the correct ambient temperature, set the machine to the specified
duty cycle.
● when working with the dryer for several people, switch the dryer on and off with
the knowledge of other employees,
● only operate the dryer with proper lighting of the entire workstation and the
machine,
● only use the machine for the intended purpose.(in technology) of tools and
workshop assistance,
● ensure that the machine and its components are kept clean throughout the entire
process cycle,
● in the event of a machine failure or a power failure, switch off the machine
(emergency stop red on the control panel and main switch in the control cabinet).
● carry out the work entrusted to you thoroughly, focusing all your attention on
what you are doing,
● place tools, workshop aids in the designated areas,
● store waste and scrap in special containers,
● report every accident at work immediately to your immediate supervisor,
● when an accident at work occurs, leave the place of its occurrence in the same
condition as the accident occurred until the arrival of the post-accident team,
● if you have any doubts about the professional and safe operation of the dryer,
ask your line manager for guidelines and instructions for further work.
10 ACTIVITIES FORBIDDEN TO THE EMPLOYEE
It is forbidden for any operator of the machine to:

● use dangerous working methods when operating a dryer that pose a risk to
yourself and others
● disregard of the principles and guidelines given in the technology,
● Ensure that the machine is dirty, polluted
● Allow the workplace to be slippery, wet,
● Terrace and obstruct passageways, roads, access to fire-fighting equipment,
● Maintenance of the machine after repair or inspection without checking its
technical condition,
● Remove or open covers,
● Allow unauthorized persons to operate the machine,
● Use of tools and workshop aids that are damaged, inappropriate, inconsistent
with technology,
● drinking alcohol at the workplace or on the premises of the company, taking part
in it in dangerous "games" or "jokes" that pose a threat to co-workers
CATEGORICALLY
PROHIBITED
● Use loose sleeves and gloves when handling rotating equipment,
● Clean all components on the moving machine,
● Lubrication of gearboxes during machine operation.
11 OCCUPATIONAL HEALTH AND SAFETY RULES
Occupational health and safety notes and warnings
Always follow the general rules for the use of the equipment and the instructions
in this manual.
Use the device only in good working order and in accordance with its intended
use. Malfunctions that may impair safety must be rectified at all times!
ATTENTION: Operation not in accordance with the instructions in these

operating instructions may result in damage to machine components and reject any
complaints.
The manufacturer does not take responsibility for the
consequences of using the device in a manner inconsistent with its
intended use..
The appliance is not equipped with any parts which could be harmful to the life or
health of the operator. Interruption or change of the power supply, whether accidental or
controlled, does not result in hazardous situations.
If you notice any safety-relevant changes in the operation of the unit, stop them
immediately and report them to the supervisor!
Keep these operating and safety instructions with the machine at all times!
Work on the machine may only be carried out by trained or instructed personnel.
The competence of the personnel to operate and maintain the machine must be clearly
defined.
During maintenance and repair work, switch off the machine by means of the
main switch. Check the de-energized components first, check for live parts, then ground
and short-circuit them and isolate any live parts adjacent to them!
Inspect and check the electrical equipment of the machine regularly. Any noticed
faults must be rectified immediately.
If it is necessary to carry out work on live parts, a second person must be called
in to start the machine if necessary.
Emergency stop button or main switch. Only use tools with voltage-insulated
insulation!
The ambient temperature must not exceed +40°C or drop below
+5°C. Relative humidity at the installation site must not exceed 50% at +40°C
and 90% at +20°C.
Modifications of the device without agreement with the manufacturer are
forbidden for safety reasons and result in the loss of warranty.
Before starting work, it is essential that all personnel working

on the machine or performing any other activity on the
machine read the operating manual, in particular the chapter
"Operator safety".
Compliance with this point is particularly important for
persons who only work with the machine from time to time,
e.g. when setting up and maintaining the machine in good
working order.
OPERATOR SAFETY - WARNINGS
● Personal hearing protection is recommended (i.e. earplugs or earmuffs).
● Never turn on the appliance until the accessories are in place.
● Keep your hands, pencils, screwdrivers and other small objects away from the
various moving parts of the device while it is in operation.
● Only authorized personnel may have access to electrical cabinets. No one should
come into contact with electrical equipment other than authorized personnel.
● When you want to repair or change an accessory, make sure the safety switch is
pressed in, just to be sure, wait one minute until all electrical equipment is
switched off.
● Do not use gloves when working on the machine, fasten loose parts of clothing,
put on the headgear.
● Do not leave any materials near the machine.
● Never clean and lubricate the machine in motion
● Do not allow untrained persons to operate the unit.
● Use only good, appropriate tools
12 TERMS OF THE GUARANTEE
Warranty service is not performed in accidents:
● The installation and commissioning of the Equipment must not be carried out by
the Seller or by persons authorized by the Seller.
● Note any failure to comply with any of the "Installation conditions" points in the
protocol.
● Incompatible serial number and model of the device with the numbers on the
sales invoice of the device.
● Failure to inform the Seller within 7 calendar days of the occurrence of failures,
which are remedied under warranty service.
● Breach of warranty seals and marking inside the device.
● Detection of traces of repairs to the Equipment carried out by the Buyer or third
parties.
● Non-observance (violation) of operating, transport and safety rules.
● Use of the machine for purposes other than its intended purpose or in permitted
operating modes (not specified in the technical documentation and operating
instructions).
● Modification, modification or alteration in any way of the Equipment without the
consent of seller
● Use of cables, cords and wires of improper quality for connection to/from the
device.
● Operation in rooms that do not meet the standards for humidity, temperature,
vibration, dust, vapour and alkaline substances.
● Detection of traces of mechanical damage, as well as damage caused by contact
with water, fire or caustic agents.
● Detection of traces of electrical or other damage caused by changes in the
parameters of the electrical network.
● Damage caused by the ingress of foreign objects, materials, liquids and living
organisms.
● Damage caused by the product:
● force majeure (elements, fires, etc.),
● intentional actions on the part of the Buyer or third parties.
● Damage caused by the use of non-standard spare parts and production
materials, cleaning materials, as well as damage caused by failure to comply with
technical and periodic inspection periods and deadlines, if required for the
Equipment.
● Assembly (replacement) by the Buyer of spare parts other than those described
in the technical documentation of the Device, without the consent of the seller
● If work on the machine is carried out by untrained or instructed persons. Specify
the competence of the personnel to operate and maintain the machine.
● If the machine is equipped with Internet connection options, ensure that this
connection is available for correct operation and service diagnosis of the
machine. If there is no internet connection, the manufacturer does not provide full
service.
13 INTERMEDIATE PERIODIC INSPECTION OF THE DEVICE.
The following components must be inspected periodically for proper operation:

● The pressure block
● Blower pipe connections from the drying unit and the exhaust air
extraction unit
● Safety pins
● sleeves
● The main rotation disc pushing unit with position lock,
● calibtarion bar on which shirried sticks are placed,
● The ejection unit .
All the above mentioned elements directly influence the correctness of the drying
process and should take place each time the device is started up.
13.1 The pressure pads

Periodic inspection of the pressure pads should be carried out during the change
of the pads depending on the diameter of the casing. If change occurs more frequently
than once every 3 months, the inspection should be performed before the next drying
cycle is started, before the start of the operator's work. The inspection should be carried
out on the basis of checking the correctness of stick compression, i.e. the shirred stick
should be placed on the bar and the work cycle should be completed. If the stick is
compressed and you can insert a pin in the place on the pad, you can start work. Such
operations should be performed organoleptically, no additional devices and instruments
are needed for this purpose.
NOTE: If the cube blocks the crushing of bars, unevenly descends down, cracks
are visible, the pin cannot be inserted, the machine should be immediately
switched off (stop button) and the settings adjusted using the screws of the
Clamping Mechanism assembly fastening. However, this operation should be
consulted with manufacturer service. If any inconvenience persists after this
operation, contact the service center of the machine manufacturer.
13.2 Cables
The cables connecting the blower system with inlet ports are subject to periodic
inspection. The fastening clamps at the inlet ports should be inspected by checking that
all clamps are tightened and that there are no leaks. Whole pipes should also be
inspected and visually inspected for cracks. All faults must be rectified. The inspection is
carried out once every 6 months.
NOTE: Any noticeable reduction in drying performance or leakage is subject to

immediate inspection of connections and wiring and must be made immediately.
If you notice any interruptions in the inlet lines, replace them with new ones. If
there is no significant improvement after this operation, call manufacturer
Service.
13.3 Pins
The safety pins should be checked during the drying process.
NOTE: If it is found that the pin is bent, replace it immediately with a new one.
13.4 Rings
The sleeves are made of polyamide and are subject to periodic inspection every
6 months. However, when replacing the rods with other diameters, they should be
wiped with a cloth in order to remove any dirt that may arise during the drying process.
NOTE: Periodic inspection should include checking the degree of wear of the
sleeves and in case of gross defects, i.e. cracks, chipping, it should be replaced
with a new one.
13.5 Main disc drive unit

The blade shifting assembly is subject to periodic inspection. Before starting the
drying process, the mechanism should be checked for proper functioning. For this
purpose, start the device and check whether the pusher actuator moves the disc and
whether there are no additional disturbances in the area of pressure, i.e. dirt, elements
occurring between the pusher arm which extends out.
Additionally, it should be checked whether the disc is stopped after one cycle in
the correct position allowing for crushing of shirring bars.
NOTE: If the travel actuator does not work or the bar disc does not rotate, turn off
the unit. Check all connections for correctness. If you find that there are no
irregularities and the machine still cannot be started, contact manufacturer
Service immediately..
13.6 Formed sticks ejector assembly

Periodic inspection of the ejector unit of a dried bar is subject to periodic inspection,
which should be carried out not less frequently than once a month of operation of the
device.
Moreover, the operation of the ejector should be checked each time before starting the
drying cycle. The inspection should be carried out through the opening on the front part
of the casing.
NOTE: If the ejection unit does not work properly (it is not possible to eject a
dried bar), immediately immobilize the device and contact the manufacturer's
service department.
14 PERIODIC INSPECTION OF THE DEVICE
All device should be subject to periodic full inspection at least once every 6
months.
For this purpose, the process must be interrupted and all machine components
must be inspected to ensure that they function correctly.
For this purpose, the machine must be started up and all components of the
machine checked for correct operation without any shirred sticks. Check the correct
functioning of the blowing system even though it is controlled by the controller, clean all
devices and safety sensors, check the correctness and condition of the connections of
the components.
In addition, check the condition of the individual components inside the machine.
For inspection, remove the front and side housings of the unit and inspect the individual
components on the off-loaded machine.
If there is any problem with the drying temperature, check that the heater and
blower are working properly. In the event of failure of these components, they are
replaced by new modules or regenerated.
NOTE: Please note that it is not allowed to interfere with the base components
without the manufacturer's consent and any incompatibilities found should be
consulted with the manufacturer's service department.
15 MAINTENANCE AND LUBRICATION OF THE DEVICE
The external components of the device are subject to maintenance, which should
be carried out after the device is switched off. Maintenance should be carried out every
month, taking care of the cleanliness of the external parts of the machine and it should
be carried out with agents that are safe for the food industry.
NOTE: Do not use solvent-based cleaning agents to clean the unit, which may
cause damage to the movement and safety components.
All components of which the device is made do not require lubrication, but only the
raceway elements are prelubricated during assembly at the manufacturer's premises
and should be made only during the inspection of the machine as specified by the
manufacturer.
16 SERVICE INSPECTION
The service inspection is performed by manufacturer service and is performed at

the request of the customer (after the expiry of the warranty period with a fee), or once a
year during the warranty period of the device specified by the manufacturer.
17 THE SAFETY OF THE OPERATOR
The device is equipped with sensors that are designed to limit the consequences
of accidental, unintentional damage to the machine and thus, are a safety feature for the
user.
For the correct and safe use of the device, the new operator is instructed by the
manufacturer to avoid unforeseeable random events. In addition, the machine is
equipped with two cycle switches (to avoid unforeseeable spontaneous start-up of the
machine), and an emergency stop switch (STOP), which completely switches off the
machine.
Note: When using the machine, special attention should be paid to the bar tip
welding system and the bar crushing system.
Do not put your hands into the working area of the pressure bar. The safety
feature is a double-clicking system for the machine cycle.
Do not lean against the mainboard on which the bars are moving during the
operation of the machine.
The rest of the safety notes are included in the description of the technical and
operational documentation above and consist of them:
● To get the most out of your table dryer, operators and maintenance
personnel should be trained by manufacturer service personnel. If you do
not operate the dryer in accordance with these instructions, you may
damage the components of the dryer and will not accept any complaints.
● The inlet pipes must be installed on the switched off unit and can only be
installed by unscrewing the side cover of the unit.
● When installing new members, pay special attention to the positioning of
pin 4 so that it can move freely through the two openings of the adjacent
members.
● Take special care when replacing the welding cone. The machine should
not be switched on and the time between the last welding and
replacement should be min. 20 minutes.
Before starting work, it is essential that all personnel

working on the machine or performing any other
activity on the machine read the operating manual, in
particular the chapter "Operator safety".
Compliance with this point is particularly important

for persons who only work with the machine from
time to time, e.g. when setting up and maintaining the
machine.
Personal hearing protectors (i.e. earplugs or earmuffs) are

recommended.
18 HEALTH AND SAFETY LABELLING
Labelling on the device

Nr. Lebal HSL Description NOTE:
A requirement to
1
work with shields.
Attention! Risk of
2
hand jamming.
Attention! Risk of
3
cutting off hands.
Warning of electric
4
shock
5 Emergency stop
Main power-off
6
switch.
General sign Note.

7
Other dangerous.
Attention! High
8
temperature.
NOTES

Operation and Maintenance Manual for Semi-Automatic Shaping Device

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Operation and Maintenance Manual for Semi-Automatic Shaping Device

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OPERATION AND MAINTANCE

Operators and maintenance personnel should be trained by manufacturer service

Number of bars 160 pcs.. In two rows 80 pcs. each

Number of crescents with bars 8 pcs.

Total length of the calibration bars 360mm

Length of formed sticks 250, 300, 320 mm

Diameter of formed casings min Ø 17 max Ø 32 mm

Diameter of drying tunnel 1290 mm

Powerful heater 9 kW,

Ventilator power 0,255 kW

3.2 Setting and installation

The device can be assembled at manufacturer's Plant to allow preliminary

3.3 Connecting the electrical supply and compressed air system

At the place of installation, the following connections must be prepared: electrical

3.4 Trial Run

4.1 List of components

Fig. 1: Supporting structure

Fig. 4 Drying tunnel Fig. 5 Blower fan

Fig. 6 Clamping mechanism Fig 7. Disc lock

Fig.10 armed device

4.2 Supporting structure

4.3 Mechanism for carrying calibration bars

The crescents are assembled and disassembled as follows:

Figure 13: Removal of the crescent moon.

Figure 14: Disassembly of the crescent .

Fig. 15: Main rotary disc position lock

The purpose of the actuator locking mechanism is to prevent accidental displacement of

Unit cover Pusher

Figure 16: Main rotary disc pushing mechanism

Fig. 17 Drying tunnel

4.6.1 Blowing components

Fig 18. Blowing system

There is a possibility of programmable settings, both the heating power obtained on

Fig. 19. Principles of operation of the blower system

Fig. 20 Cooler fan

4.8 Pressure mechanism

The clamping mechanism is shown in Figure 21. The mechanism is equipped

Fig. 21: Assembleod the clamping mechanism

Fig. 22 Sticklength adjustment

4.8.1 Replacement of the pressure pad

1. Apply a new preassure pad (next to the actuator handle).

Fig. 23: Fold in the welding machine

4.9.1 Replacing the Welding Cone

The most important components of the electrical installation:

Photo 24 - Switch cabinet Photo 25 - Control panel

Photo 26 - START control buttons Photo 27 - Blowing system

5.1 Electrical documentation

Electrical documentation is an integral part of this manual.

ATTENTION! Do not make any changes to the electrical installation of the

Figure 28 - Appearance of the operator panel of a stick shaper device

− F1 – switching on the operating mode (switching to the edition of the next

− ► or ◄ – selection of the digit position of the value of the parameter whose

Figure 29 - Message about the pressed emergency button

5.2.2 Main Screen

Figure 30 - Initial screen

5.2.3 Parameter setting (Parameter setting mode).

The first parameter to be set is the temperature of the drying tunnel

Figure 31 - Drying tunnel temperature settings

The heater operation can be switched on/off using the F2 button

5.2.5 Tunnel humidity setting

Figure 32 - Dryer tunnel humidity settings

5.2.6 Setting the fan parameters in the drying tunnel