maintenance, spare parts and user’s handbook is-028/028s - baaderbaader.is/pdf/manual/is-028 r02...

Maintenance, spare parts and user’s handbook

IS-028/028s

Hafnarbraut 25 200 Kopavogur

Iceland

Tel: +354 520 6900 Fax: +354 520 6911

[email protected] www.baader.is

http://www.baader.is/

IS-28/28s

Baader Ísland ehf, Hafnarbraut 25, Kopavogur, IcelandTel: +354 520 6900 Fax: +354 520 6911

[email protected] / www.baader.is

2

PREFACE

The manual presents the machine and its proper usage for users. It contains

important information about its installation as well as safe, reliable and efficient

usage. It is intended for:

- Machine operators who usually operate and clean the machine daily

- Technicians responsible for the installation, preparation for production and

maintenance of the machine.

Read the manual and precaution instructions carefully. Do not operate the machine

before reading the manual and before the manual instructions are understood.

The manual must be always readily available where the machine is used. It must be

supplemented by the operator with additions and current directives of the respective

country concerning accident prevention and emission control.

This manual is part of the machine.

The manual must be included when the machine is purchased!

The manual must neither be copied nor accessible to a third party or misused without

our written consent!

The company Baader Ísland Ltd. is not responsible for any damage due to the failure

to comply with the manual, inadequate training of the personnel, unusual usage of

the machine as well as its usage for a different purpose than the one specified in this

manual!

Observe the current safety and legal procedures concerning machines in food

industry.

It is the responsibility of the machine’s owner that all the personnel operating the

machine receive training in the machine usage.

When dismounting, supplementing machine parts or making changes to the machine

on your own initiative without our consent, our declaration of accordance (EB-

Directive/CE) will expire.

Use only spare parts from BAADER!

Caution! In order to show better the machine’s functionality the protective parts have

been opened and removed. All protective parts must be in place when operating.

Otherwise it can lead to serious damage to health or death.

mailto:[email protected]%20/%20www.baader.is

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3

CONTENTS

PREFACE ..................................................................................................................................... 2

CONTENTS .................................................................................................................................. 3

WARNING ................................................................................................................................... 5

CAUTION SIGNS .......................................................................................................................... 6

SAFETY MEASURES ..................................................................................................................... 7

SAFETY INSTRUCTIONS ............................................................................................................... 8

PROTECTIVE PARTS ..................................................................................................................... 9

PROTECTIVE PARTS SENSORS ................................................................................................... 12

SAFETY MARKING ON THE MACHINE ....................................................................................... 13

GENERAL INFORMATION ON THE MACHINE ........................................................................... 14

DESCRIPTION OF EFFICIENCY ................................................................................................... 14

TECHNICAL INFORMATION IS-028............................................................................................ 15

TECHNICAL INFORMATION IS-028S .......................................................................................... 16

DIMENSIONS DRAWING IS-28 .................................................................................................. 17

WORK AREA IS-28 ..................................................................................................................... 18

DIMENSIONS DRAWING IS-28S ................................................................................................ 19

WORK AREA IS-28S ................................................................................................................... 20

KNIVES ...................................................................................................................................... 21

WORK CONDITIONS .................................................................................................................. 22

ELECTRICAL CONNECTION ........................................................................................................ 23

WATER CONNECTION ............................................................................................................... 24

COMPRESSED AIR CONNECTION .............................................................................................. 25

TRANSPORTATION .................................................................................................................... 26

Information on transportation ............................................................................................. 26

Preparation for transportation ............................................................................................. 26

Transportation by ship .......................................................................................................... 26

Transportation by airplane ................................................................................................... 27


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Moving the machine ............................................................................................................. 28

Certified transport equipment ............................................................................................. 28

Moving the machine with a forklift ...................................................................................... 28

Moving the machine with a trolley....................................................................................... 28

INSTALLATION OF THE MACHINE ............................................................................................. 29

BEFORE STARTUP ..................................................................................................................... 30

STARTUP ................................................................................................................................... 31

THE MACHINE TAKEN OUT OF SERVICE ................................................................................... 32

THE MACHINE READY FOR STORAGE ....................................................................................... 32

STARTING THE MACHINE ......................................................................................................... 33

FEEDING THE MACHINE ........................................................................................................... 33

UPPER AND LOWER FIN FISHER ............................................................................................... 34

PLATES ...................................................................................................................................... 34

SPIKE PRESS .............................................................................................................................. 35

OTHER CONTROLLERS .............................................................................................................. 35

DE-HEADING ............................................................................................................................. 36

OPTIONAL EQUIPMENT ............................................................................................................ 36

ROTARY KNIVES INSTALLED ...................................................................................................... 37

UPPER ROTARY KNIFE IS-28/28S .............................................................................................. 38

LOWER DE-HEADING KNIFE IS-28 ............................................................................................. 40

LOWER DE-HEADING KNIFE IS-28S ........................................................................................... 41

ADJUSTMENTS OF THE MACHINE ............................................................................................ 43

Gap between knives ............................................................................................................. 43

Adjusting backplates ............................................................................................................. 44

Adjusting plates .................................................................................................................... 45

Movement of the knife part ................................................................................................. 46

Adjustment of eye spikes ..................................................................................................... 47

Adjustment of head bar ........................................................................................................ 47

CONTROL PANEL ....................................................................................................................... 48

Switch box ............................................................................................................................. 48

Air board ............................................................................................................................... 50

Water board.......................................................................................................................... 50


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The Main Switch ................................................................................................................... 51

MAINTENANCE ......................................................................................................................... 52

Inspection and maintenance plan ........................................................................................ 53

Lubrication ............................................................................................................................ 54

Lubrication areas .................................................................................................................. 55

CLEANING ................................................................................................................................. 56

Cleaning at work breaks and pre-cleaning before the main cleaning .................................. 58

Main cleaning ....................................................................................................................... 59

Detergents and disinfectants (from Henkel) ........................................................................ 61

Lubricants and protection substances .................................................................................. 63

Grease and oils mixed together............................................................................................ 64

Miscibility types grease and oils ........................................................................................... 65

WARNING

In the manual of BAADER machines you can find chapters on particular dangers or

special conditions. They are identified by words of warning and caution signs in

accordance with the Machinery Directive

(2006/42/EB) and Norm IEC 82079-1 as well as Norm ANSI Z-535.2 and Z-535.3.

Words of warning are always structured in the following manner:

WARNING

Danger!

Description of consequences if applicable

- -Preventing the danger


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CAUTION SIGNS

Instruction

Caution, Warning, if the instructions are not observed, it can cause a personal injury or machine failure

Danger, high risk of serious injury

Risk of high voltage


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7

SAFETY MEASURES

The machine operators, repair technicians or cleaning personnel must read,

understand and observe the manual when performing all the necessary actions.

Safety instructions

- Misusage and wrong operation of the machine can cause serious health

and physical damage.

- It is forbidden to short-circuit, change or remove safety equipment from the

manufacturer.

- Security marking on the machine must be always noticeable and legible.

Faulty or worn-out safety marking must be immediately replaced.

- Read the manual before operating the machine.

- It is forbidden for untrained personnel to deploy and operate the machine.

- Wear tight body workwear, especially covering the arms.

- Tie long hair together and cover it.

- Do not wear watches, rings, bracelets, etc.

- Do not interfere with the machine while it is running.

- Do to place any objects on the machine.

- Do not step on or use conveyor belts for storage of heavy objects.

- Bacterial infections in cut injuries can cause complications (e.g. blood

poisoning). It is impossible to eliminate these consequences even if the

machines are thoroughly cleaned and disinfected! Therefore observe the

following:

o Clean the machine thoroughly and disinfect it before the installation,

the end of operation, maintenance and repair.

o Wear protective gloves while working on machine parts or tools with

sharp edges.

o Never run a check on the bit of the cutting edge on the skin.

o Seek medical assistance immediately in case of cut injuries!

- It is forbidden to spray any substance into the electrical switch box and the

switching device; fire and explosion risk!

- Do not let the machine run unattended.

- Turn the machine off, put the main switch in 0-position and lock it:

o in case of disruptions in the processing flow

o before cleaning

o before the installation and end of operation

o before maintenance and repair work

o before lubrication

o before leaving the machine area

- Maintenance and repair work may only be performed when the machine is

at rest. Make sure it is impossible to turn the machine on and an

appropriate warning sign is in place.

- To make sure it is impossible to turn the machine on, the main switch must

be padlocked.


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SAFETY INSTRUCTIONS

Before activating the machine:

Check if all protective parts are in place

Check if all the safety equipment works

The running machine must be stopped...

… when the EMERGENCY stop is

pressed (fig. 1, pos. 1)

… when the stop button is activated (fig.

1, pos. 2)

… when the EMERGENCY-bar switch is

activated (fig. 1, pos. 3)

… when a protective part is put up or put

in the open position (fig. 1 and 2, blue

protective parts)

2

1

2

3

1


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PROTECTIVE PARTS

All flip-up protective parts of the machine are kept closed with a pump. No locks need

to be opened manually or with tools.

To open the machine it is enough to grasp the handle and pull it. The pump also

keeps the protective parts in the open position. It is good to hold the cover when

opening and closing.

Protective parts closed

Flip-up protective parts are specified

in fig. 5 and 6 in green. (IS-028s

shown)

5

6


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Protective parts open

Flip-up protective parts are

specified in fig. 7 and 8 in green.

(IS-028s shown)

7

8


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COVER AND SAFETY LIGHTS ON CONTROLLER BOX

On the control box there are 6 lights that indicate which safety sensor is activated if

the safety circuit is not complete.

3

1

2

4

6

5

3

2

1

6

5

4


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PROTECTIVE PARTS SENSORS

There are 6 protective parts

sensors in the machine (fig. 9

and 10 in yellow). Under various

conditions they can be

connected incorrectly

- If a protective part is

opened very little and

closed.

- If a protective part

bounces when being

closed.

- If a protective part is opened and

closed very quickly.

There are two ways of correcting the

connection.

- Open the protective part

in question and close it

again slowly.

- Hold the button on the

white light on the control

panel for 3 sec. and reset

all protective parts

sensors.

Sensors must be set in such a

way so that the longer sides

face each other (fig. 11)!

9

10

11


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13

SAFETY MARKING ON THE MACHINE

It is forbidden to spray into the machine

- Explosion risk!

- Order number of stickers: 37601110

- Sticker on the switch box (fig. 5, pos. 1)

Warning of dangerous voltage!

- Order number of sticker: 37601104

- Sticker on the switch box (fig. 5, pos. 2)

Warning of stinging injury

Warning of cut injury

Warning of bruise injury

Warning of bruise injury

- Order number of sticker: 37601129

Use suitable protective gloves


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GENERAL INFORMATION ON THE MACHINE

Figure 12

1 - Tray 5 – Production area

2 – Electricity, air and water control 6 – Heads out

3 – Control panel 7 – Headless fish out

4 – Feed-in area

DESCRIPTION OF EFFICIENCY

IS-28 and IS-28s remove heads along with the collar bone of whitefish

Bear in mind that the machine is not designed for living and frozen

fish or fish in rigor mortis.

2

1

4 5

6

7

3

12


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15

TECHNICAL INFORMATION IS-028

Species of fish :Whitefish

Condition of fish :Gutted fish

Size range :4 – 13kg

Output of the machine (1) :fish per min.

Power requirements of the

machine

:2,5 kW

Water requirements of the

machine

- Usage

- Pressure

- Connection

- Type

:12,5 l/min at 2 bars 20 l/min at 5 bars

:2 to 5 bars

:1/2" Hose nozzle

:Drinking water

Air Pressure :4-8 bars

Volume

Dimensions - Length

- Breadth

- Height

:3150 mm

:1700 mm

:2130 mm

Weight :850 kg

Operation :1 person

Noise limits :82dB(A) – Wear Ear Protection.

1) The machine is made for the above-mentioned size and output ranges.

Nevertheless, due to the influence of the fish ratio and quality (depending on the time

of year, fishing ground, freshness, etc.) on the above-mentioned ranges, they can, in

fact, vary. It is not possible to process fish in rigor mortis or frozen fish.

2) The usage is restricted to clean water! Dirty water causes blockages.

3) Noise measurement (estimated pursuant to DIN EN ISO 11201)


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TECHNICAL INFORMATION IS-028S

Species of fish :Whitefish

Condition of fish :Gutted fish

Size range :1 – 8kg

Output of the machine (1) :fish per min.

Power requirements of the

machine

:2,5 kW

Water requirements of the

machine

- Usage

- Pressure

- Connection

- Type

:12,5 l/min at 2 bars 20 l/min at 5 bars

:2 to 5 bars

:1/2" Hose nozzle

:Drinking water

Air -Pressure :4-8 bars

-Volume

Dimensions - Length

- Breadth

- Height

:2300 mm

:1370 mm

:2104 mm

Weight :800 kg

Operation :1 person

Noise limits :82dB(A) – Wear Ear Protection.

1) The machine is made for the above-mentioned size output ranges. Nevertheless,

due to the influence of the fish ratio and quality (depending on the time of year,

fishing ground, freshness, etc.) on the above-mentioned ranges, they can, in fact,

vary. It is not possible to process fish in rigor mortis or frozen fish.

2) The usage is restricted to clean water! Dirty water causes blockages.

3) Noise measurement (estimated pursuant to DIN EN ISO 11201)


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DIMENSIONS DRAWING IS-28


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WORK AREA IS-28

The machine must be accessible on both sides for maintenance and adjustment.

Space for the operator must be secured next to the tray on the side of the machine

where the knives are and the platform must be on the right side of the machine to

enable easy replacement of knives.


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DIMENSIONS DRAWING IS-28S


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20

WORK AREA IS-28S

The machine must be accessible on both sides for maintenance and adjustment.

Space for the operator must be secured next to the tub on the side of the machine

where the knives are and the platform must be on the right side of the machine to

enable easy replacement of knives.


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21

KNIVES

Name Quantity Dimensions Sharpening Number

Fish head knives

2 pieces

94010161_028


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22

WORK CONDITIONS

Floor surface

The load bearing capacity of floors must be suitable for the weight of the machine not

to make impressions on the surface of the floor. The floor surface around the

machine must be even at an adequate radius from it for the operators of the machine

and maintenance personnel to work unobstructed. The slope of the floor surface may

be at most 1°; in case of bigger deviations, appropriate measures must be taken. The

floor surface must be even to ensure the best possible feed-in of fish into the work

area and the right positioning of fish when de-heading.

Space requirements

The operators and maintenance personnel must have ready access to the whole

system installed. The dimensions are specified in the technical information.

Working space for the operator of the machine

Working space for the operator of the machine is next to the tray.

Lighting

Adequate lighting in working with the machine is important depending on how well

one needs to see. Here we should bear in mind the following aspects (see also

Norm EN 12464-1):

- candle power 500 (500 lx)

- light direction and shadow

- colour light

- limited visibility

- preventing from distractive reflections.


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23

ELECTRICAL CONNECTION

The machine must be connected to an electrical power distribution system in

accordance with the wiring diagram, taking into account the provisions of the local

electrical power distribution company. Also, legal safety provisions must be observed,

e.g.:

- Europe / Germany: DIN/EN 60204-1 / VDE 0100

- BNA: NEC

- Canada: CEC

WARNING

Risk of electroshock!

The electrical equipment of the machine connected to the

mains contain dangerous, unprotected conductive parts,

mobile parts or rotating parts when the main switch is on

and the machine running.

- It is forbidden to remove the available protective

parts!

- Wrong operation or inadequate maintenance can

cause serious health and physical damage!

The personnel responsible for the safety of the machine must therefore

observe that...

…only the authorised personnel may work with the machine,

…this personnel must always have access to the included manual and all other

necessary documents in connection with the work and also that they commit

themselves to adhere completely to all the information included in the above

mentioned documents.

…it is forbidden for any unauthorised personnel to work with the machine or in the

vicinity of it.

WARNING

Risk of explosion!

- It is forbidden to spray any

substances into the electric

switch box and the switching device.


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Mains plug

The machine is supplied with a 5 m of Ölflex 191 5 G 2.5

cable compatible with the 416P6 plug with IP44 splash

protection which meets the requirements IEC 60 309-2.

CHECK

The machine does not start!

The phases must be connected correctly to start the machine. See

phase items on the electric blueprint.

The necessary voltage and Hertz frequency are specified on the power shield of the

machine and on the wiring diagram (see in detail in chapter 7.4.1 Electrical

Connection)

WATER CONNECTION

Water supply connectors are in the toolbox under the intake on the top.

- Push the hose up onto the hose

nozzle (fig. 19, in yellow)

- Fasten the hose firmly on the

nozzle with a hose clasp

- Turn on the tap

Water supply connectors are designed for 19 mm internal diameter hoses (1/2“). The

hose must be fastened firmly onto the nozzle with a clasp. The tap is turned on and

off with a cut-off tap. Use the stopcock for daily usage.

WARNING

Risk of motor damage!

- Make sure water is always available

when the machine is running

because motors are water-cooled.

19


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25

INSTRUCTION

Dirty water can cause blockage in the magnet valve and

spray nozzle of the machine!

- Only clean water is allowed to be used.

INSTRUCTION

The machine is not protected or can be responsible

for the water supplied.

- The operator must take all the measures concerning

the inspection of the water and the treatment of

category 5 fluids pursuant to DIN EN 1717 (existence

of disease causing bacteria and viruses).

COMPRESSED AIR CONNECTION

Compressed air connectors are in the tool box. Air distribution to the machine is done

in the toolbox.

Push an 8 mm hose into the coupler (fig.

20, in yellow)

INSTRUCTION

Dirt blocks the pressure

regulator and causes precipitation in the cylinder!

- The compressed air must be in

accordance with definition ISO 8573-1, category 7.4.3

(chapter 17). The intake is not allowed to exceed the

peak pressure, see ‘Technical Information’!

20


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26

TRANSPORTATION

WARNING!

Risk of heavy weights!

- Be careful when transporting!

- Use only the transportation

equipment included or other comparable and certified

one

- Bear in mind the weight of the machine (see

‘Technical Information’)

- Bear in mind the centre of gravity of the machine (see

‘Dimensions Drawings’)

- Do not step or hold underneath when it is in the air

Current provisions of the concerned country on transportation must be observed!

When lifting and moving the machine, observe the valid safety procedures on

handling of heavy weights!

Information on transportation

Bear in mind the centre of gravity of the machine while transporting. Weights and

dimensions of the machine are specified in technical information. (See ‘Technical

Information’ and ‘Dimensions drawing’.)

Preparation for transportation

- by ship: in containers designed for seagoing

- by airplane: a wooden frame on special flight legs

- by lorry: a wooden frame

Transportation by ship

The machine is placed on a wooden frame keeping it steady and firm in the

container. A forklift is used to move the machine. It is possible to lift it longitudinally

with the frame but to move it transversely you must insert the forks into the fork

drawers on the machine.


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27

Transportation by airplane

Legs on the machine must be changed

before flight

- Flight legs must be

fastened on the machine

(fig. 21, in yellow) in the

appropriate holes.

- The machine is lifted on

the forklift drawers welded

to the transport legs.

- The original legs are

disassembled (fig. 22)

- The machine is placed on

a pallet underneath and

bolted firmly (fig. 23).

To assemble the machine after flight the

above steps must be followed in the

reverse order.

DANGER!


- It is necessary to use a trestle

under the machine when

changing the legs. Do not rely

solely on the forklift.

21

22

23


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28

Moving the machine

Certified transport equipment

- Forklift

- Trolley for indoor transportation/installation of the machine

Moving the machine with a

forklift

The machine has fixed drawers for

forklifts (fig. 24, in yellow). Always bear

in mind the centre of gravity of the

machine.

Moving the machine with a

trolley

If it is necessary to move the machine

through a narrow door or area, you can

place it on a trolley using wooden beams

(fig. 25).

WARNING


- Take all the necessary precautions

when moving the machine with a

trolley and especially bear in mind the centre of gravity

of the machine.

24

25


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INSTALLATION OF THE MACHINE

Before installing the machine it is mandatory for trained professionals to check all the

wiring to and from the parts for the raw material, processed products and waste, as

well as the connectors to other machines and the installation of the necessary input

wiring. Especially bear in mind the lighting and noise protection.

The operators and maintenance personnel must have ready access to the machine

from all the sides after the installation.

The machine installed on adjustable

spindles

Tools and materials

- 17 mm spanner

- 4 pieces of adjustable spindles

- 4 pieces of 100 mm footings

- 4 pieces of 24 mm nuts

Procedure

1. Move the machine to the

installation area (see

‘Transportation’)

2. Place adjustable spindles in all 4 footings of the machine (fig. 26, pos. 1)

3. Place a footing under each adjustable spindle (fig. 26, pos. 2)

4. Place the machine down until the adjustable spindles are on the footings.

5. Adjust the machine until it is positioned correctly

6. Place nuts on the adjustable spindles and tighten them (fig. 26, pos. 3)

Finishing

- Remove all the accessory equipment used in transportation, if applicable.

- Undo fastenings holding the flip-up protective parts firmly in place

- Fasten the platforms and install the footboard

WARNING!

Risk of machine falling down/worker falling over!

If the machine is elevated, its centre of gravity changes

accordingly. Take measures to prevent the machine from

falling down, especially if the platform is fixed to the

machine.

- Bolt the machine to the floor

- Install a handrail for the worker to prevent the

risk of falling.

1

2

3

26


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BEFORE STARTUP

1. Remove protection substances from all the parts in contact with the product to

be manufactured:

- with water, max. 60°C

- from above and underneath

- with low pressure, max. 30 bars

2. Lubricate the machine


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STARTUP

DANGER!

Risk of serious damage!

- It is forbidden to short-circuit,

change or remove the safety

equipment from the

manufacturer.

- For accident and damage prevention observe the

safety instructions earlier in the manual (chapter

2).

Preparation

Start the engine

1. Make sure all the doors and protective parts are in the closed position.

2. Turn the main switch to the I-position. The machine is turned on.

3. Turn on the tap with a handle on it (fig. 56, pos. 1).

4. Press the Start button.

The machine is started.

The safety equipment checked

Follow the following steps with all the safety equipment (see ‘Safety equipment’):

5. Start the machine, if applicable

6. Activate the safety equipment (e.g. press the EMERGENCY-STOP bar

or open a protective part)

The machine must stop!

7. Place the safety equipment back in the operating position (e.g. put the

protective part down again)

8. If the safety equipment did not stop the machine when moved:

-Press the Stop button

-Find the cause and adjust

-Check the safety equipment again

To turn the machine off

9. Press the Stop button


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The machine stops.

THE MACHINE TAKEN OUT OF SERVICE

Water system emptied

If the machine is not used, the water system must be drained, in case of any risk of

frost, to prevent any damage:

1. Disconnect form the source of water (chapter 7.4.2)

2. Pull the hose off

3. Loosen the water supply connectors from the knives motors

4. Blow the water out of the water pipe and knives motors with high

pressure

WARNING!

Risk of freezing damage!

- Especially make sure the motors are

emptied of water

- It may be necessary to unfasten them to empty them

completely

THE MACHINE READY FOR STORAGE

INSTRUCTION

- If the machine is not used for a longer time, protection substances

must be applied on it that are harmless to people!

Recommended protection substances

- Protection substance spray BKS-P; best. No. 51100205 (400 ml can)

- Protection substance fluid BKS; best. No. 51100200 (5 litre container)

These protection substances are standardised according to NSF-H1.

The machine should preferably be stored in a frost-free area. In case of risk of frost in

the storage area or installation area, the water system must be emptied and

especially bear in mind the water-cooled knives motors.


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STARTING THE MACHINE

a. Press the Start button

b. Check daily after the first startup of the machine if all safety equipment

works properly, see ‘Safety Equipment’

FEEDING THE MACHINE

WARNING!

Risk of cut injury, stinging and jamming!

During feeding bear in mind especially:

- The conveyor belt

- Eye spikes

- To wear appropriate protective gloves

- To use ear protectors

Feeding the machine

1. The fish is taken from the tray and placed on the conveyor belt, with its

back onto the back of the drawer (the stomach facing the processing

area).

2. The operator pulls the fish by its snout towards himself with the left hand

and places the lower eye on the eye spike.

The eye spike pierces the fish through both eyes to gain most control of the

fish.

3. Check the result and adjust the

machine if needed


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34

UPPER AND LOWER FIN

FISHER

The upper and lower fin fishers

(fig. 13, in yellow) catch the

pectoral fins and ensure that the

collar bone moves on the

correct side of the plates.

PLATES

Plates (fig. 14, in yellow) direct

the collar bone of the fish to the

correct side of the knives. They

are pressed together with the

plates system controlled with

compressed air. The plates

settings are explained in chapter

‘Installation and Finishing,

Plates Adjustments’

13

14


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35

SPIKE PRESS

Spike press (fig. 15, in

yellow) ensures the

pressure on the eye pins

while they move along

the knife. The pressure

is kept up by air jacks

and is controlled with the

pressure regulator in the

toolbox (see ‘Control Panel, Air Board’).

OTHER CONTROLLERS

On the way to the processing area there

are controllers (fig. 16 and 17)

positioning the fish correctly. These

controllers must be correctly adjusted

with appropriate air pressure on the jack

(see ‘Control Panel, Air Board’).

1

15

16

17


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DE-HEADING

In the processing area the head

and pectoral fin bone are cut off

with two de-heading knives (fig. 18,

in yellow). The knives must always

be well sharpened and controllers

are properly installed.

OPTIONAL EQUIPMENT

Head press

It is possible to get a head press enabling piercing through both eyes with the eye

spike by pressing on the head before it comes to the processing area.

Length measurement

In case of significant differences in fish sizes, it may be necessary to use a length

measurement opening pectoral fin bones for the head in case the fish exceeds a

specified size.

Footboard

A footboard enables elevating the platform making it easier for the operators to

operate the machine. The footboard is made of a rack and platform to be placed on

various cogs of the rack.

Platform

A platform can be included with the machine enabling access to the knives system.

The platform is bolted to the machine.

DANGER!

Risk of the machine falling down/worker falling over!

If the machine is elevated, the centre of gravity changes

accordingly. Take measures to prevent the machine from

falling down, especially if the platform is fastened to the

machine.

- Bolt the machine to the floor

18


IS-28/28s



37

- Install a handrail to prevent the worker from

falling over.

ROTARY KNIVES INSTALLED

WARNING!

Risk of cut injury caused by sharp knife edges!

Bacterial infections in cut injuries caused by knives

can lead to complications (e.g. blood poisoning).

This possibility cannot be eliminated in case of

cut injury even on thoroughly cleaned and

disinfected machines.

- Wear protective gloves when working with knives

or in the vicinity of them!

- Seek medical assistance in case of accident!

- Never run a check of the bit of the cutting edge

on the skin!

WARNING!

When damaged de-heading knife is broken, it

creates a risk of accident due to objects scattered

around!

- Check the de-heading knives

daily!

- Cracked and chipped de-heading knives must

be replaced. It is forbidden to use them!

INSTRUCTION!

You can find one pair of protective gloves among the tools of

the machine. Use part no. 52100196 when ordering more

gloves. (Part number refers to 1 glove!)


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38

Prerequisites for working with knives

- The machine must be thoroughly cleaned,

see ‘Cleaning’

- The main switch in the 0-position and locked,

see ‘Safety’

Bear in mind especially the direction of

rotation of knife nuts and axes. Left-handed

nuts are identified with notches on the edges

(fig. 25).

UPPER ROTARY KNIFE IS-28/28S

Movement direction

The knife rotates with the movement

direction of fish (fig. 26, white arrow)

Type of thread

Right-handed

Position

The phase knife rotates towards the

drawers (fig. 27)

Assembled and disassembled

Hold the knife axis firmly with a 36 mm

spanner and loosen or tighten the knife nut

with a 36 mm spanner.

WARNING!

If the knife nut is suddenly loosened, it can cause injury to

the hands on the cutting-edge.

26

25

27


IS-28/28s



39

- Always squeeze spanners together to get a grip on

them!

- Never pull spanners in separate ways when

tightening or loosening knife nuts!

- Always use knife

gloves!

-


IS-28/28s



40

-

LOWER DE-HEADING KNIFE IS-28

Movement direction


direction of the fish (fig. 28, white arrow)

Type of thread

Left-handed (knife nut with a notch)

Position

The phase knife rotates towards the drawers (fig. 28)

Assembled and disassembled

Hold the knife axis firmly with a 36 mm spanner and loosen or tighten the knife nut


WARNING!

If the knife nut is suddenly loosened, it can cause injury to the

hands on the cutting edge

- Always squeeze

spanners together to get

a grip on them!

- Never pull spanners in

separate ways when

tightening or loosening the knife nut!

- Always use knife gloves!

28


IS-28/28s



41

LOWER DE-HEADING KNIFE IS-28S

Movement direction


direction of the fish (fig. 29, white

arrow)

Type of thread

Left-handed (knife nut with a notch)

Position

The phase knife rotates towards the drawers

Remove the middle table

- Take the set screw off

with a screwdriver (fig.

30, in red)

- It is not necessary to

loosen the other two

screws (fig. 30, in blue)

- Slide the middle table

along the machine and

then lift it (fig. 30, in

yellow)

It is possible, if needed, to remove two drawers

- Adjust the machine to the slowest speed (see chapter 8)

- Start the machine (chapter 7.6) until the drawers with lock holes face the

operator. Stop and lock the machine. Loosen the screws and push the

drawers until the screws come out through the lock holes. Remove the

drawers.

- Let the machine run until the waste comes to the processing hole.

29

30


IS-28/28s



42

Place the knife in the machine

Hold the knife’s axis firmly with a 36 mm spanner and tighten/loosen the knife nut


Perform in the reverse order to prepare the machine for processing.

WARNING



can lead to complications (e.g. blood poisoning). This

possibility cannot be eliminated in case of cut injury

even on thoroughly cleaned and disinfected

machines.





on the skin

WARNING

Retraction and risk of cut injury caused by mobile

parts of the machine!

If the machine is on while adjusting, it can cause serious

injury.

- If not stated otherwise, turn the main switch to

the 0-position and lock it!


IS-28/28s



43

ADJUSTMENTS OF THE MACHINE

Gap between knives

- Loosen the bolt through the eccentric

(fig. 31, in yellow) with a 19 mm

spanner.

- Turn the eccentric (fig. 31, in red) with

a 26 mm spanner until the gap

between the knives is 2 mm

- Tighten the bolt again

- Move the knives to check if they are in

contact with an object

31

32


IS-28/28s



44

Adjusting backplates

Remove the knives

- Loosen the bolts (fig. 33, in red)

- Place the edge of the backplate

(fig. 33, in yellow) be as close to

the knives as possible

- If the plate moves away from the

knives, there is a larger gap further

away from the knife centre

- Tighten the bolts

- Move the knives to check if the

backplate touches them

Distance from the centre

- Loosen the nuts (fig. 35, in red)

- Remove the backplate (fig. 35, in

yellow) if needed

- Tighten the bolts

- Move the knives to check if the

backplate touches them

33

34

35


IS-28/28s



45

Adjusting plates

Distance from the knives

- Loosen the bolts (fig. 36, in

red)

- Slide the plates (fig. 36, in

blue) forward until the edge of

plates (fig. 36, in yellow),

which is in contact with the

fish, touches the knife

- Tighten the bolts

- Move the plates up and down

and move the knives to check

if the plates touch the knives

Gap between the plates

- Loosen the nuts (fig. 37, in

red)

- Turn the bolt (fig. 37, in blue)

to change the gap between

the plates (fig. 37, in yellow) if

needed

- Tighten the nuts

- Move the knife to check if

there is contact

36

37


IS-28/28s



46

Free-play plates

The gap between the spring (fig. 38, in

blue) and the locknut (fig. 38, in green)

enables light movement of plates. A

small opening of the plates is then

lighter than a large one.

Adjusting free-play plates

- Move the locknut (fig. 38, in

green) away from the spring to

secure more free-play.

Movement of the knife part

It is necessary to inhibit movement of

the knife part so knives do not collide.

- Loosen set nuts

- First move one bolt (fig. 39, in

red) while the knife part (fig. 39,

in yellow) is in contact with it

- Move as much as possible

without the knives colliding.

- Fasten the bolt.

- Repeat in the other direction.

38

39

40


IS-28/28s



47

Adjustment of eye spikes

It is necessary to adjust the position of eye spikes

as to the size and species of fish.

- Open the protective part at the back

- Loosen 3 bolts (fig. 41, in yellow) with a

19 mm bit on the extension

- Move the eye spike if needed (fig. 42)

- Tighten the bolts again

- Close the protective

part.

Adjustment of head bar

The head bar’s function is to direct the

head and keep it down. It must come as

close to the knife as possible. Make sure

it is free to turn a little.

- Loosen the nut (fig. 43, in red)

- Take hold of the bearing case (fig.

43, in blue) and screw it up.

- Adjust the head bar (fig. 43, in

yellow) so that it is parallel to the plate as close to the knife as possible

- Tighten the nut

- Turn the head bar to check if it can touch the knife.

41

42

43


IS-28/28s



48

CONTROL PANEL

The control equipment of the machine is divided into 4 parts:

- The switch box where the machine is started, stopped and speed of the

drawers controlled

- The air board where air pressure on the jack is controlled

- The water board where water volume in every place is controlled

- And the main switch box where the machine is turned on

Switch box old

Figure 44

1.

a) Light. When the light is on, the machine is on and the safety system is closed.

This means that all the protective parts are closed, the phases in the motors

are correct and the main switch is in the I-position.

b) The restart button for the safety switch, when pressed for 3 seconds, is used

only if the safety switch is connected incorrectly.

2. Speed adjustment. It controls the speed of drawers.

3. The Start button. It starts the machine when pressed on it.

4. The Stop button. It stops the machine.

It is also possible to activate the Stop button by pressing on the cover of the

protective part above the switch box.

1 2

3 4

44


IS-28/28s



49

Switch box new

(Explanation of fig. 44b)

1. Emergency stop. Activated once it is pressed and inhibits the operation of the machine. It is necessary to turn the emergency stop push button clockwise in order to reset the safety circuit and start the machine.

2. i) White light. When the light is on the machine is turned on and the safety

circuit is closed. This implies that all the covers are closed, motor phases are correct, and the main switch is on (set on I).

ii) Push button that resets the safety circuit once it is pressed, only necessary to press if the safety circuit was not closed. Resetting takes 8 seconds, if the button is pressed again before the machine resets the resetting process restarts.

3. Push button starts the machine if the safety circuit is closed. 4. Push button stops the machine. 5. Lights that indicate which protection sensor is disconnected if the safety circuit is

not closed. 6. Push Button increases the speed of the conveyor. Must be pressed repeatedly,

cannot be held down. 7. Push button decreases the speed of the conveyor. Must be pressed repeatedly,

cannot be held down.

1

2

3

4

5

6

7

44 b


IS-28/28s



50

Air board

A 8 mm coupler for the machine Otherwise a 6 mm coupler Figure 45

1. 1-4 bars precise pressure regulator. It controls the pressure on the

spike press.

2. 1-4 bars precise pressure regulator. It controls the pressure on plates.

3. 1-8 bars pressure regulator. It controls the pressure on the pressure

wheel

4. 1-8 bars pressure regulator. It controls the pressure in the joystick.

Water board

An 8 mm coupler for water

system

Figure 46

1. Cooling in knives motors. The drain runs under the machine to rinse the

drawers

2. Lower knife rinse

3. Upper knife rinse

4. Unused

1

3

2

4

45

1 2 3 4

46


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51

The Main Switch

It turns the machine on and off

- Turned on when in the I-

position

- Turned off when in the O-

position

47


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52

MAINTENANCE

WARNING!

Risk of wrong maintenance!

Wrong maintenance can cause serious injury and machine

failure.

- Continual maintenance must be performed only by

trained personnel after receiving required guidance!

- Protective parts with a fixture that can be lost (e.g.

screws) can only be removed by trained service

personnel. After maintenance work is finished, the

whole fixture that has been lost needs to be

installed.

WARNING

Risk of explosion!

- It is forbidden to spray all types of

substances into the electric

switch box and switching device.

WARNING

Retraction and risk of cut injury caused by mobile

objects of the machine!

- If the machine is turned on during

maintenance work, it can cause serious injury.

- If not stated otherwise, turn the main switch into the 0-

position and lock it!


IS-28/28s



53

WARNING

Risk of dirt!

- When the maintenance and service

work is completed the respective

areas must be left in an impeccable state.

WARNING

Risk of dirt!

During the maintenance and service work the workers are

probably in contact with areas that are less often cleaned.

- Clean these areas thoroughly before other work is

done there

Inspection and maintenance plan

d = daily, v = weekly, m = monthly, á = yearly

Tasks to do d v m a

Inspect if all jacks work properly x

Check if all springy parts of the machine work properly x

Check the switching device and safety equipment x

Check damages in de-heading knives x

Replace and sharpen new knives x

Lubricate according to the lubrication plan x

Check the waterflow and pressure x

Inspect if water hoses and connectors are tight x

Check if safety marking/warning signs are in place on the machine and legible x

Check if grease cups and grease pipe work properly (grease is pressed out) x

Check if a detailed, legible and updated manual is available x


IS-28/28s



54

Lubrication

Lubricate the machine daily.

The machine must always be lubricated after cleaning; this way unwanted water is pressed out of the

bearings.

The machine is lubricated with BAADER-Spezialfett GLS 380/N3. This grease is accredited in

accordance with USDA-H1.

INSTRUCTION

If other lubricants are used (see table 15), it may cause

disturbances in operation of the machine!

- Use only clean lubricants! Therefore all

the lubrication equipment (grease cup,

grease can’s nozzle, manual spray gun

and clutch, if applicable) must be free of dirt!

- The pressure limit of lubricants at the grease can’s

nozzle must not exceed 150 bars!

- For hygienic reasons all the excess of all lubricants

must be cleaned on all grease cups and lubrication

areas!

Information on lubricants

- Lubrication time: 8 running hours

- Lubricants: Hochlastfett GLS 380 N. This lubricant is accredited in accordance

with NSF-H1.


IS-28/28s



55

Lubrication areas

Open the protective part above

the knives system

There are 10 grease cups

(yellow) altogether in three areas

in the machine

8 pieces on the lubrication

board

1 piece on the left plate’s

arm

1 piece on the lower

plate’s arm


IS-28/28s



56

CLEANING

WARNING!



can lead to complications (e.g. blood poisoning). This

possibility cannot be eliminated in case of cut injury

even on thoroughly cleaned and disinfected

machines.





on the skin

Clean the machine every 8 working hours.

WARNING!

Wrong treatment and risk of damage!

- Do not use the high-pressure

equipment

- Do not direct the water jet (max. 30 bars) straight

at bearings or gaps and seals of the tool box.


IS-28/28s



57

Prerequisites for all cleaning work

- -No breakdowns

- The main switch in the 0-position and locked

- All protective parts are opened

and the tray put up


IS-28/28s



58

Cleaning at work breaks and pre-cleaning before the main cleaning

WARNING!

Risk of water high-pressure!

Water splashes and product left-overs can be sprayed into

eyes.

- Wear protective clothes (e.g. protective goggles).

1. Remove the waste and rinse the machine on all the sides with a high-pressure

water jet (max. 30 bars)

- with water, max. 60°C

- from the top and down

- with low-pressure, max. 30 bars

2. Clean the control component, if needed


IS-28/28s



59

Main cleaning

Preparing the machine

- Carry out pre-cleaning

Cleaning the machine

WARNING!

Risk of detergents and disinfectants!

Wear protective clothes while cleaning and disinfecting.

- Observe the local regulations

on the usage of detergents and disinfectants

Clean the machine according to the instructions in the cleaning plan

Work arrangement Detergent 2) Device/method Comments Main cleaning 2 - 5% P3-topax

17 (Henkel) 1)

Apply foam with a foam device

From the bottom to the top. Leave it for 15 min.

To get rid of calcium precipitation use 2-5% P3-topax 56 (Henkel) foam detergent 1 per

week instead of P3-topax 17

Water, max. 60°C Rinse with low-pressure max. 30 bars

Thoroughly from the top to the bottom

Inspection Visual

Disinfection 1% P3-topax 91 (Henkel)

Spray with low-pressure max. 30 bars

From the top to the bottom. Leave for 15 min. Depends on viruses: see product description document

Rinse Water, c.a. 20°C With low-pressure max. 30 bars

Rinse thoroughly afterwards

1) To avoid white residue apply P3-topax 17-foam on hot spots.

2) You can find names of specified detergents for different countries in chapter ‘Detergents and

disinfectants (from Henkel)‘


IS-28/28s



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61

Detergents and disinfectants (from Henkel)

Country

Product

P3-topax

12

P3-topax

17

P3-topax

56

P3-

topax

68

P3-topax

99

P3-topax

91

Brazil Quorum

Pink II Quorum

Pink II Quorum

Purple Quorum

Amber Quorum

Clear Ster-Bac

Canada Quorum

Pink II Quorum

Pink II Quorum

Purple Quorum

Amber Quorum

Clear Ster-Bac

France P3-topax

12 P3-topax

C 80 P3-topax M

acid

P3-

topax

M55

P3-

sterylmouss P3-triquart

Germany P3-topax

12 P3-clint RI P3-topax 56

P3-zinnfest

flüssig

P3-topax

99 P3-topax

91

Greece P3-topax

12 P3-topax

17 P3-topax 56

P3-

topax 68 P3-topax

99 P3-topax

91

Italy P3-topax

12 P3-topax

17 P3-topax

L54 P3-

topax 68 P3-topax

SAN P3-topax

91

Japan P3-topax

12 P3-topax 56

P3-

topax 68 P3-topax

99 P3-triquart

Namibia Quorum

Pink II Quorum

Pink II Quorum

Purple Quorum

Amber Quorum

Clear Ster-Bac

Netherlands P3-topax

12 P3-topax

17 P3-topax 56

P3-

topax 68 P3-topax

99 P3-triquart

Norway TP 12 TP 17 TP 56 TP 68 TP 99 Triquart

AP

Poland P3-topax

12 P3-topax

17 P3-topax 56

P3-

topax 68 P3-topax

99 P3-topax

91

Russia P3-topax


P3-zinnfest

flüssig

P3-topax

99 P3-topax

91

South

Africa Quorum

Pink II Quorum

Pink II Quorum

Purple Quorum

Amber Quorum

Clear Ster-Bac

Spain P3-topax

12 P3-topax

17 P3-topax 56

P3-

topax 68 P3-topax

99 P3-topax

91


IS-28/28s



62

United

Kingdom P3-FBC

foam P3-rik P3-topax 56

P3-

topax 68 P3-triquart

Ukraine P3-topax


P3-zinnfest

flüssig

P3-topax

99 P3-topax

91

USA Quorum

Pink II Quorum

Pink II Quorum

Purple Quorum

Amber Quorum

Clear Ster-Bac

Authorised dealers Henkel:

Information at any time are provided at www.ecolab.com


http://www.ecolab.com/

IS-28/28s



63

Lubricants and protection substances

Substance NLGI ISO-VG

... Colour Reference/categ. Volume Product number

Grease

Bearing grease GLS 380/N3

2 ...68 White USDAH-1 400 g box

515500103 18 kg bucket (+) 51500102

Floating grease GLS 367/N000

0 ...200 Brown,

transparent NSF-H1

5 kg bucket 51500151

+ +

Grease for heavy work VP 873

2 ...460 White worn NSF-H1 400 g box 51500117

5 kg bucket (+) 50500116

Grease spray can FLC 65-P 1)

2 ...155 Yellowish NSF-H1 400 ml can 51100187

- -

Oil

Gear oil LFC 3068 / CLP 68

- ...68 Transparent NSF-H1 5 l barrel 51100146

+ +

Gear oil LFC 3460 / CLP 460


+ +

Hydraulic oil LFC 3068 / HLP 68


+ +

Oil for air tools LFC 3015


1 l can 51100142

Stabilisers

Spray BKS-P 1)

- - - NSF-H1 400 ml can 51100205

-

Fluid BKS

- - - NSF-H1 5 l barrel 51100200

-

+ different volume according to inquiry 1) Pump spray in no high-pressure containers (harmless product)

INSTRUCTION!

Do not mix grease and oil together or grease types and oil types

together.

There is a risk of chemical degradation!


IS-28/28s



64

Grease and oils mixed together

- Legal provisions concerning certification forbid mixing different H1-products together in

order to obtain new lubricants!

- What is shown here is based on lubricant mixtures with unavoidable residues of original

lubricants.

- The miscibility of lubricants must be especially checked if different types of thickening

agents and/or types of base oils are available when changing lubricants.

- Due to different additives in lubricants always change oils completely once a year.

INSTRUCTION!

Chemical reactions of these mixtures can cause hardening or

softening of the mixture!

We bear no liability for these instructions on miscibility; they

need to be checked in every single case!

Miscibility of thickening agents

Types of thickening agents in

BAADER-lubricants

Types of thickening agents, others

Polyurethane Calcium blends

Lithium blends Bentonite

Aluminium blend

GLS 380 N3 Aluminium blends yes no yes no yes

GLS 367 N000 Bentonite yes no no yes no

VP 873 Polyurethane yes yes yes yes yes


IS-28/28s



65

Miscibility types grease and oils

Basic types, others BAADER-basic types

Types of grease 1) Oils 2)

Paraffin oil yes yes

Polyalfaolefins yes yes

Polyglicon no no

Natural ester yes yes

Artificial ester yes yes

Alkyn benzene * *

silicon oil methylamine no no

silicon oil ethylamino yes yes

Polyester * * 1) Types of lubricants: GLS 380/N3, GLS 367/N000 and VP 873

2) Oils: LFC 3068, LFC 3460 and LFC 3015

Explanation:

- yes = both oil and thickening agents are in most cases miscible; we bear

no liability concerning the above. Check miscibility in every separate case.

- no = these oil and thickening agent do not mix together.

- *= not applicable


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