Page 2 Disclaimer of Liability Tipper Tie shall not be liable to any person for any defects or damages to persons or property resulting directly or indirectly from: (1) any neglect, misuse or abuse of the equipment, including, but not limited to, improper or inadequate maintenance of the equipment or improper modification or alteration thereto, or (2) any use of the equipment which contravenes any of the instructions set forth in this manual.
Page 3: Table Of Contents
RS4203 Manual Contents Contents Publication History ........................... 7 Terms and Conditions for Use ....................... 9 Chapter 1 – Machine Description and Specifications ..............11 1.1 Description ........................11 1.2 Operation ......................... 11 1.3 Name Plate and Specifications ..................13 1.4 Control System ........................ 15 1.5 Layout and Dimensions ....................
Page 4 RS4203 Manual Contents 4.4 Air Filter/Regulator ......................30 4.5 Main Lubricator ........................ 30 4.6 Conveyor Air Motor Lubricator..................31 4.7 Voider Rotary Actuator Lubricator .................. 31 Chapter 5 – Operator Interface ....................33 5.1 Interface Display Unit ...................... 33 5.2 Control Panel ........................34 5.3 Remote Heat Seal Control ....................
Page 5 RS4203 Manual Contents 10.1 Clipper Description ......................61 10.2 Clipper Operation ......................61 10.3 Crimp Control Layout ....................62 10.4 Crimp Control Adjustment .................... 63 10.5 Punch Pressure Regulator ................... 64 10.6 Voider Closed Position Iris Opening ................65 10.7 Clipper Slack Fill Adjustment ..................66 10.8 Looper Setup and Adjustments ..................
Page 6 RS4203 Manual Contents 14.3 Moisture and Corrosion Control ................... 86 14.4 Air Prep Maintenance ....................86 14.5 Air Lubricators ....................... 87 14.6 Conveyor Maintenance ....................88 14.7 Mechanical Lubrication ....................88 14.8 Daily Preventive Maintenance ..................93 14.9 Weekly Preventive Maintenance .................. 96 14.10 Quarterly Preventive Maintenance ................
Page 7: Publication History
RS4203 Manual Publication History Publication History The publication history summarizes major changes to this document. Each update of this manual is a new revision (Rev) in the first column (for example, Rev 02). An update that applies only to the drawings is listed on the Assembly Drawings PDF as a sub-revision (for example, Rev 02.01, Rev 02.02, etc.).
Page 8 RS4203 Manual Publication History Revision Description of changes Issue date Revised FRL content and graphics for new modules. Updated ECN January 2, 2008 drawings. Added water separator to conveyor motor lubricator / water separator February 2, 2008 assembly. Updated ECN drawings. Revised cleaning sections and deleted cleaning appendix.
Page 9: Terms And Conditions For Use
RS4203 Manual Terms and Conditions For Use Terms and Conditions for Use Warranty. Limitation of Liability. Tipper Tie, Inc. warrants the Products will, upon delivery to Customer, conform to the description and specifications set forth herein and will be free from defects in material and workmanship.
Page 10 RS4203 Manual Terms and Conditions For Use Security Interest. Customer hereby grants Tipper Tie, Inc. a security interest in the Product and proceeds thereof, to secure Customer’s obligation hereunder. Customer hereby appoints Tipper Tie, Inc. its attorney-in-fact to execute financing statements to perfect such security interest. General.
Page 11: Chapter 1 - Machine Description And Specifications
Chapter 1 – Machine Description and Specifications 1.1 Description The Tipper Tie RS4203 is a multi-purpose, automated double clipper with a user-friendly programmable touch screen user interface. The RS4203 handles soft and hard emulsions as well as whole muscle meat products ranging in size from 2 to 7 inches (50 to 180 mm) in diameter and up to 64 inches (162 cm) in length.
Page 12 RS4203 Manual Chapter 1 - Machine Description and Specifications When the operating parameters have been set to the desired values, the operator uses the Cycle Start pushbutton to begin the operation. In the automatic mode, the stuffing and clipping cycle automatically restarts at the end of each clip cycle until all of the casing has been used.
Page 13: Name Plate And Specifications
RS4203 Manual Chapter 1 - Machine Description and Specifications 1.3 Name Plate and Specifications The machine’s name plate is affixed to the top of the electrical control box. The name plate shows important production data and specifications and is similar to the one shown below. The RS4203 is available in low voltage (115 VAC) or high voltage (230 VAC) versions.
Page 14 RS4203 Manual Chapter 1 - Machine Description and Specifications The following name plate is for the high voltage RS4203. RS4203 Model Machine Family xxxxxxxx Serial Number xx/xx/xxxx Production Date 1220 lbs. (553,4 Kg.) Machine Weight (6,2 bar) 90 PSI Max Allowable Air Pressure 63-4216 Pneumatic Schematic Number 230 VAC, 1-phase...
Page 15: Control System
RS4203 Manual Chapter 1 - Machine Description and Specifications 1.4 Control System • Operator interface: CTC P1 Touchscreen Machines built or upgraded after Feb. 21, 2011 will use a CTC PA2 touchscreen. • PNP proximity sensors • Programmable Controller (PLC) – source input and source output •...
Page 16: Layout And Dimensions
RS4203 Manual Chapter 1 - Machine Description and Specifications 1.5 Layout and Dimensions 33 inches 83.8 cm 120 inches 304.8 cm 68 inches 172.7 cm Machine weight: 1,220 pounds (553,4 Kg) Shipping weight: 1,700 pounds (771,1 Kg) Rev 32, 01/11/13 Copyright ©...
Page 17: Major Components
RS4203 Manual Chapter 1 - Machine Description and Specifications 1.6 Major Components The layout and major components of the RS4203 are shown in the following illustration. Remote Looper Station Reel pans for Spool reel-fed clips 40”, 48” or 72” Conveyor Assembly Guard Assembly...
Page 19: Chapter 2 - Safety Instructions
RS4203 Manual Chapter 2 - Safety Instructions Chapter 2 – Safety Instructions 2.1 General Precautions These safety instructions comply with the European Union Declaration of Conformity. To prevent possible serious injury, it is extremely important that you understand and follow these safety precautions: •...
Page 20: Safety Symbols
RS4203 Manual Chapter 2 - Safety Instructions 2.2 Safety Symbols Throughout this manual, you will see a variety of safety symbols, each of which denotes a specific type of warning or caution. The purpose of each safety symbol is described in the following illustrations. •...
Page 21: Capital Equipment Safety Circuit Overview
RS4203 Manual Chapter 2 - Safety Instructions 2.4 Capital Equipment Safety Circuit Overview Note: Existing machines that use a programmable logic controller (PLC) adhere to the statements in this section although previous issues of this manual do not contain these statements. Tipper Tie equipment that uses a PLC also contains an independent safety circuit, which is either a programmable safety module or safety relay.
Page 22: Safety Illustrations
RS4203 Manual Chapter 2 - Safety Instructions Caution: Do not attempt to install, setup or operate this machine before you have read and understood this manual and any accompanying suppliers’ manuals. 2.6 Safety Illustrations Emergency Stop Buttons Push the Emergency Stop button on the control panel or on the remote to immediately stop the machine. Control Panel O perator Interface P O W E R...
Page 23 RS4203 Manual Chapter 2 - Safety Instructions Control Box Door The electrical control box door (shown below) contains the electrical disconnect and lock-out (the large red knob). Always turn off and lock out the electrical disconnect before performing any service or maintenance on the machine.
Page 24 RS4203 Manual Chapter 2 - Safety Instructions Air Supply Shut-Off and Lock-Out Valve The machine’s main air supply shut-off and lock-out valve (red knob in the photo below) is located alongside the air prep assembly, underneath the conveyor, on the outside of the electrical and pneumatic control box.
Page 25 RS4203 Manual Chapter 2 - Safety Instructions Clipper SAFETY INSTRUCTIONS Clipper Assembly KEEP Keep hands fingers AND F and clothes clear of the punch, gate, die CLEAR and knife areas PUNC GATE “Punch down” proximity switch ”PUNCH DOWN” PROXIMITY SWITCH GATE Gate ACTUATOR...
Page 26 RS4203 Manual Chapter 2 - Safety Instructions Knife Assembly Knife KNIFE BLOCK block W ARNING: KEEP FINGERS Warning: Keep AND HANDS hands and fingers CLEAR OF clear of CUT-OFF cut-off knife assembly KNIFE ASSEMBLY Knife blade KNIFE BLADE Knife KNIFE COVER cover Knife Blade Assembly KNIFE BLADE ASSEMBLY...
Page 27: Chapter 3 - Delivery And Setup
RS4203 Manual Chapter 3 - Delivery and Setup Chapter 3 – Delivery and Setup 3.1 Delivery Upon delivery of your machine, inspect the shipping container and equipment for damages due to shipping and handling. If damage is found or suspected, contact the shipping agent immediately. The carrier must have an opportunity to inspect the damage to properly verify claims.
Page 28: Main Circuit Breaker
RS4203 Manual Chapter 3 - Delivery and Setup 3.3 Main Circuit Breaker When shipped, the main circuit breaker in the control box is in the OFF position. Turn the breaker ON. 3.4 Stuffer Connection Connect the stuffer cable to the stuffer plug (shown at right) at the input end of the machine.
Page 29: Chapter 4 - Air Connections, Lubrication And Adjustments
RS4203 Manual Chapter 4 - Air Connections, Lubrication and Adjustments Chapter 4 – Air Connections, Lubrication and Adjustments 4.1 Installation of Main Air Supply A 25 feet (6.7 meters) length of 3/4” diameter (19 mm) Nylobrade hose is supplied to connect the machine to the plant air supply.
Page 30: Air Pressure Adjustment
RS4203 Manual Chapter 4 - Air Connections, Lubrication and Adjustments 4.3 Air Pressure Adjustment System air pressure is displayed on the pressure gauge (shown on the lower right in the illustration). Adjust the air pressure by rotating the black knob on top of the air filter/regulator module. To increase the air pressure, rotate the adjustment knob clockwise.
Page 31: Conveyor Air Motor Lubricator
RS4203 Manual Chapter 4 - Air Connections, Lubrication and Adjustments 4.6 Conveyor Air Motor Lubricator The conveyor air motor has a separate water separator/ lubricator assembly (as shown at right) which is mounted on the left end of the machine just above the system air pressure gauge and behind the air pressure lockout valve.
Page 33: Chapter 5 - Operator Interface
RS4203 Manual Chapter 5 - Operator Interface Chapter 5 – Operator Interface 5.1 Interface Display Unit The RS4203 has an easy-to-use interface display unit with a touch screen on the control panel, which provides a simple and useful means of communication between the operator and the machine’s processing unit.
Page 34: Control Panel
RS4203 Manual Chapter 5 - Operator Interface 5.2 Control Panel The control panel is used to operate the RS4203. The diagram below shows the control panel with a description of the pushbutton controls. Control Panel Operator Interface POWER TOUCH TOUCH SCREEN SCREEN CYCLE...
Page 35: Remote Heat Seal Control
RS4203 Manual Chapter 5 - Operator Interface 5.3 Remote Heat Seal Control Utilizing the Handshaking Signals to Remotely Control the Operation of the Heat Seal: The RS4203 clipping machine incorporates the heat seal handshaking signals to allow the operator to remotely control the heat seal while standing at the clipping machine.
Page 36: Touch Screen
RS4203 Manual Chapter 5 - Operator Interface 5.4 Touch Screen The interactive, programmable touch screen is the heart of the user interface and is used to set and change the machine’s operating parameters, to monitor machine operations, and to assist in troubleshooting problems that may arise.
Page 37: Chapter 6 - Machine Operation
RS4203 Manual Chapter 6 - Machine Operation Chapter 6 – Machine Operation 6.1 Preparation Before operating the machine, check all air connections. If they have become disconnected, reassemble as shown in the pneumatic schematic. Adjust the incoming air to a pressure of 80 to 90 PSI (5,4-6,2 bar), and check for any air leakage.
Page 38 RS4203 Manual Chapter 6 - Machine Operation 5. Following a successful start up, the RUN screen appears on the CTC touch screen of the user interface panel (an example of the RUN screen is shown at left). The touch screen allows the operator to select a running mode or to change operating parameters.
Page 39: Loading Clips - Stick Clips
RS4203 Manual Chapter 6 - Machine Operation 6.3 Loading Clips – Stick Clips Tipper Tie stick clips are easily loaded for dispensing. Clips are held in place within the clip rail and guided towards the punch by means of a clip weight. Position the clips so that they slide down the rail, and gently guide them down the rail.
Page 40: Loading Clips - Reel Clips
RS4203 Manual Chapter 6 - Machine Operation 6.4 Loading Clips – Reel Clips Tipper Tie machines often use two clip reel pans instead of one. But loading clip reels is the same procedure, whether your machine uses one or two reel pans. On many Tipper Tie machines, operators will require a step ladder to load the clip reels.
Page 41 RS4203 Manual Chapter 6 - Machine Operation Guide the clips onto the clip rail, fitting them onto the rail. Guide and gently push the clips all the way down the rail until they can go no further into the clipper. The clips are now in place to be used for clipping.
Page 43: Chapter 7 - Recipe Descriptions
RS4203 Operating Manual Chapter 7 - Recipe Descriptions Chapter 7 – Recipe Descriptions The touch screen uses a series of recipes to provide the operator with the ability to set or modify a variety of operating parameters and features. This section describes the recipes, the valid range of the settings, and the default system setting.
Page 44 RS4203 Operating Manual Chapter 7 - Recipe Descriptions Operating Item Parameters/Features Description Valid Range Default PIECES/SHIRR (COUNTER) Used to enable the pieces/shirr counter. On or Off If OFF, allows the punch to extend more quickly. If ON, provides an air cushion to PUNCH CUSHION (ON/OFF) On or Off slow the extension of the punch.
Page 45 RS4203 Operating Manual Chapter 7 - Recipe Descriptions Operating Item Parameters/Features Description Valid Range Default Enabling this option causes the conveyor to stop when the RS4203 clip cycle STOP CONVEYOR DURNG activates. If set to OFF, the conveyor Yes or No CLIP? (YES/NO) continues to run at the stuff-speed while clipping.
Page 46 RS4203 Operating Manual Chapter 7 - Recipe Descriptions Operating Item Parameters/Features Description Valid Range Default This Timer is used to adjust a DWELL on the PUNCH when it is fully extended into 26 PUNCH DWELL (SEC) 0.00s to 1.00s 0.20s the clip and die.
Page 47 RS4203 Operating Manual Chapter 7 - Recipe Descriptions Operating Item Parameters/Features Description Valid Range Default A timer which will not allow signals SHORTER than the time specified to be accepted as registration Indicator mark detection. The wider the Indicator mark, 37 EYE-MARK FILTER WIDTH 0.00s to 10.00s 0.02s...
Page 49: Chapter 8 - Touch Screen
RS4203 Manual Chapter 8 - Touch Screen Chapter 8 – Touch Screen The following sections describe the user interface touch screen menus. 8.1 Run Screen Upon start up of the machine, the interactive touch screen displays the RUN screen. This screen provides information about current settings and the status of the current machine operation.
Page 50: Home Screen
RS4203 Manual Chapter 8 - Touch Screen 8.2 Home Screen The HOME screen provides access to the INPUT and OUTPUT screens; the RUN, RECIPE, and SEQ (sequence) screens; the PLC error screen; the KEYENCE calibration screen; and the CHANGE USER module.
Page 51: Recipe Screen
RS4203 Manual Chapter 8 - Touch Screen 8.3 Recipe Screen The recipe screen is used to setup or modify operating parameters and menus. Use the up or down arrows to select the menu item. The item will then be highlighted. Press the EDIT key.
Page 52: Calibrate Screen
RS4203 Manual Chapter 8 - Touch Screen 8.4 Calibrate screen The calibrate screen is used to record and store background and target data for registration I-marks. Background/target data for up to eight different color combinations may be recorded and stored for future recall.
Page 53: Sequence Screen
RS4203 Manual Chapter 8 - Touch Screen 8.5 Sequence Screen The sequence (SEQ) screen indicates the PLC status at the current step in the sequence of a clip cycle. The sequence screen indicates the current step of the PLC during a clip cycle. Should a fault occur, the sequence screen displays a fault message in place of the step indicator.
Page 54: Input Screens
RS4203 Manual Chapter 8 - Touch Screen 8.6 Input Screens The input screens indicate the current state of all inputs. Rev 32, 01/11/13 Copyright © 2013, Tipper Tie, Inc., All rights reserved...
Page 55: Output Screens
RS4203 Manual Chapter 8 - Touch Screen 8.7 Output Screens The OUTPUT screens indicate the current state of all outputs. Rev 32, 01/11/13 Copyright © 2013, Tipper Tie, Inc., All rights reserved...
Page 56: Help Screens
RS4203 Manual Chapter 8 - Touch Screen 8.8 Help Screens The RS4203 user interface provides item-specific HELP screens for many of the touch screen functions. Press the HELP button on any screen to access additional information about that screen. The sequence help screen and the PLC error help screen are shown.
Page 57: Output Test Mode Screen
RS4203 Manual Chapter 8 - Touch Screen 8.9 Output Test Mode Screen The output test mode screen, which can be accessed from any of the OUTPUT screens, allows a technician to directly control the machine’s outputs and is intended for use only by Tipper Tie technicians. Caution: The output test mode disables all software inhibited outputs (i.e., any output may be activated regardless of the potential...
Page 59: Chapter 9 - Product Specification Worksheet
RS4203 Manual Chapter 9 - Product Specification Worksheet Chapter 9 – Product Specification Worksheet A master copy of the product specification worksheet is included on the next page. Use the master copy to make copies and use it to record recipe settings. Rev 32, 01/11/13 Copyright ©...
Page 60 RS4203 Manual Chapter 9 - Product Specification Worksheet RS4203 Product Specification Worksheet (Recipes) Depending on program revision levels and specific machine model, some of the parameters below may not be present or functional. Product No. Product Name (Size) & (Weight) Horn Size Coupled To Chub...
Page 61: Chapter 10 - Clipper And Looper Operation And Adjustments
RS4203 Manual Chapter 10 - Clipper and Looper Operation and Adjustments Chapter 10 – Clipper and Looper Operation and Adjustments 10.1 Clipper Description The RS4203 offers two clipper options, depending on the customer’s needs. The Z4270M clipper uses Z400 stick clips. The Z4270RP clipper uses ZR400 reel-fed clips for use with longer runs. The clip size is determined by product or closure size.
Page 62: Crimp Control Layout
RS4203 Manual Chapter 10 - Clipper and Looper Operation and Adjustments 10.3 Crimp Control Layout Refer to section 10.4 for details on adjusting the crimp control. Clip rail Clip rail “Punch down” proximity switch Crimp control locking knob Rotate clockwise to lock knob Rev 32, 01/11/13 Copyright ©...
Page 63: Crimp Control Adjustment
RS4203 Manual Chapter 10 - Clipper and Looper Operation and Adjustments 10.4 Crimp Control Adjustment The clips should always form a tight, permanent seal around the product. The tightness or crimp of the clip can be adjusted by rotating the crimp control adjustment ring. Before making an adjustment, loosen the crimp control locking knob located at the far side of the support plate.
Page 64: Punch Pressure Regulator
RS4203 Manual Chapter 10 - Clipper and Looper Operation and Adjustments 10.5 Punch Pressure Regulator The machine is designed to operate with the air pressure from the main regulator set at 90 PSI (6,2 bar). To ensure the maximum life expectancy of the clipper, do not exceed the recommended air pressure. In addition to the crimp control in the previous section, clip tightness is also related to the air pressure on the punch cylinder.
Page 65: Voider Closed Position Iris Opening
RS4203 Manual Chapter 10 - Clipper and Looper Operation and Adjustments 10.6 Voider Closed Position Iris Opening The closed position voider opening is adjustable. This feature controls the amount of residual product that is left in the tail portion of the package. This adjustment allows for various diameters of products to be run on the same machine.
Page 66: Clipper Slack Fill Adjustment
RS4203 Manual Chapter 10 - Clipper and Looper Operation and Adjustments 10.7 Clipper Slack Fill Adjustment The clipper can vary the amount of slack filled casing on each package. This is accomplished by varying the extend direction of the movable voider plates, which are extended by the voider spread cylinder. The voider drive shaft is coupled to the voider spread cylinder.
Page 67: Looper Setup And Adjustments
RS4203 Manual Chapter 10 - Clipper and Looper Operation and Adjustments 10.8 Looper Setup and Adjustments The optional Looper system automatically applies a string loop under the clip for hanging products. 10.8.1 Installing Loops on the Looper This section provides detailed instructions on installing the loop spool and routing the loop tape. The sections that follow provide instructions for adjusting the looper system.
Page 68 RS4203 Manual Chapter 10 - Clipper and Looper Operation and Adjustments When you install the loop spool on the spool shaft, ensure that one white delrin spacer is behind the spool and one delrin spacer is in front of the spool. If the spacers are not in place both in front of and behind the spool, you will have either too much tension or not enough tension on the loop spool.
Page 69: Looper Settings And Adjustments
RS4203 Manual Chapter 10 - Clipper and Looper Operation and Adjustments Feed casing onto the horn and pull it through the voiders. Then, push the clip and loop button. This will feed the first loop into the die support. The machine is ready to start running product. When the machine first runs, watch the looper closely, keeping an eye on where the loop knot is positioned.
Page 70 RS4203 Manual Chapter 10 - Clipper and Looper Operation and Adjustments Adjusting Loop Insertion Distance To adjust the loop insertion distance, refer to Detail “B” for the initial setup. Loosen roller handle H, and center it in its slot. Tighten roller handle H. Loosen knurled handle G. Pull the index sprocket wheel towards you to loosen it on the tapered shaft.
Page 71 RS4203 Manual Chapter 10 - Clipper and Looper Operation and Adjustments Detail “C” Looper Adjustments Adjusting Loop Idler Arm Tensioning Spring To adjust the tension on the Loop Idler Arm spring loosen bolt U as shown on Detail “B”. Raise the spring block to increase the tension on the loop idler arm.
Page 72 RS4203 Manual Chapter 10 - Clipper and Looper Operation and Adjustments Upper Loop Strip Plate Adjustment The Upper Loop Strip Plate is positioned as shown in Detail “E” below. In the up position, it is flush with the bottom of the Tape Backup Plate, and in the down position it meets the Lower Loop Strip Plate. To change the position, adjust clevis Q on the Upper Loop Strip Plate Cylinder as shown in Detail “C”.
Page 73 RS4203 Manual Chapter 10 - Clipper and Looper Operation and Adjustments Loop Brake and Lower Loop Strip Plate Feed Position Adjustment The Loop Brake and the Lower Loop Strip Plate are positioned as shown in Detail “D” on the previous page.
Page 75: Chapter 11 - Conveyor Assembly Operation And Adjustments
RS4203 Manual Chapter 11 – Conveyor Assembly Operation and Adjustments Chapter 11 – Conveyor Assembly Operation and Adjustments 11.1 Conveyor Assembly Layout The layout of the conveyor assembly is shown in the illustration on the right. Note the location of the conveyor air motor lubricator at the lower right side of the illustration behind the incoming air supply quick-disconnect and above the air pressure gauge.
Page 76: Trip Paddle
RS4203 Manual Chapter 11 – Conveyor Assembly Operation and Adjustments Check the oil level in the lubricator each day and refill as necessary. Do not overfill the lubricator. Use a high quality SAE #10 pneumatic lubrication oil. Note: The use of oil with a higher viscosity will result in machine failure.
Page 77: Chapter 12 - Programmable Controller
RS4203 Manual Chapter 12 - Programmable Controller Chapter 12 – Programmable Controller 12.1 Description The electronic programmable controller (PLC) provides precise control of machine functions and rapid clip cycle time. The system is operator friendly and very reliable. To ensure proper operation of the PLC, follow these important guidelines: •...
Page 78: Battery Replacement
RS4203 Manual Chapter 12 - Programmable Controller Installation 1. Turn off the power to the programmable controller. 2. Remove the cover from the memory installation unit. 3. Connect the memory cassette to the connector, carefully inserting the pins. Removal 1. Turn off the power to the programmable controller. 2.
Page 79 RS4203 Manual Chapter 12 - Programmable Controller The user interface touchscreen provides specific information about the PLC and battery functions. The following examples show the PLC error help screen followed by low battery voltage error screen. The programmable controller should provide years of trouble-free performance if these operating instructions and precautions are followed.
Page 81: Chapter 13 - Cleaning Procedures
RS4203 Manual Chapter 13 - Cleaning Procedures Chapter 13 – Cleaning Procedures 13.1 Cleaning Overview After the machine has been used or serviced, it must be cleaned to remove all food or other residue from the food contact zone – the clipper, punch, die, gate, knife assembly and all other contact surfaces. Check all other machine surfaces and surrounding work stations for contamination.
Page 82: Cleaning Procedures
RS4203 Manual Chapter 13 - Cleaning Procedures 13.3 Cleaning Procedures 1. Turn off and lock out the electrical power (ensure the electrical cabinet is securely closed). 2. Turn off the factory air, and use the quick disconnect to remove the air supply from the machine. 3.
Page 83 RS4203 Manual Chapter 13 - Cleaning Procedures Disassembling the Knife Assembly Knife cylinder assembly Knife assembly 3/32 x 3/4 long spring pin (press fit) M5 x 16 mm long hex head bolt Knife block 35 degree Knife block assembly angle shown disassembled for daily cleaning Knife...
Page 84 RS4203 Manual Chapter 13 - Cleaning Procedures Disassembling the Pivot Rotor Assembly The pivot rotor assembly should be cleaned daily. Disassembly of the unit is shown in the following illustration. Rev 32, 01/11/13 Copyright © 2013, Tipper Tie, Inc., All rights reserved...
Page 85: Chapter 14 - Maintenance Guide
RS4203 Manual Chapter 14 – Maintenance Guide Chapter 14 – Maintenance Guide 14.1 General Guidelines For proper machine function and continued satisfaction with your finished product, it is essential that your machine be properly maintained. This means that a preventive maintenance (PM) schedule should be established and followed.
Page 86: Maintenance Precautions
RS4203 Manual Chapter 14 – Maintenance Guide 14.2 Maintenance Precautions After performing any service or maintenance, before returning the machine to operation, always check for and tighten any loose screws, bolts, nuts, connectors and hoses. Inspect all safety components. Closely follow all safety warnings and notes to avoid serious injury and potential damage to the machine.
Page 87: Air Lubricators
RS4203 Manual Chapter 14 – Maintenance Guide Air Pressure Adjustment Adjust the operating air pressure using the black knob on top of the filter/regulator module. To increase the pressure, turn the adjustment knob clockwise. The recommended pressure is 90 PSI (6,2 bar). Warning: Do not set the air pressure above 90 PSI (6,2 bar).
Page 88: Conveyor Maintenance
RS4203 Manual Chapter 14 – Maintenance Guide To add oil to a lubricator, follow these steps: 1. Ensure that the air supply is shut off and locked out and remove the filler plug. 2. Fill with oil to the level mark and replace the plug. 3.
Page 89 RS4203 Manual Chapter 14 – Maintenance Guide Daily Clipper Pivot Clevis Daily Clipper Swing Eccentric Daily Voider Main Shaft Right End Bearing Block Rev 32, 01/11/13 Copyright © 2013, Tipper Tie, Inc., All rights reserved...
Page 90 RS4203 Manual Chapter 14 – Maintenance Guide On left: Daily Voider Main Shaft Moveable Voider Hub On right: Daily Voider Main Shaft Stationary Voider Hub On left: Weekly Voider Rotary Shaft Bearing Caution: Do not over-grease this fitting On right: Daily Voider Eccentric On top left: Daily...
Page 91 RS4203 Manual Chapter 14 – Maintenance Guide Daily Voider guide shaft blocks (1 fitting on each block) On left: Weekly Conveyor Idler Roller (2 fittings - 1 in front and 1 on back of roller) Caution: Do not over-grease this fitting On right: Daily Conveyor Shuttle Roller...
Page 92 RS4203 Manual Chapter 14 – Maintenance Guide Periodic Maintenance Procedures The following sections provide step-by-step periodic maintenance procedures that are required on a daily, weekly, quarterly, semi-annual, and annual basis. To help you track scheduled maintenance activities, a sample of a machine maintenance log has been included in Appendix 2. Make copies of the sample (or use your own form) to record all service and maintenance activities and to track your PM program.
Page 93: Daily Preventive Maintenance
RS4203 Manual Chapter 14 – Maintenance Guide 14.8 Daily Preventive Maintenance Prior to any maintenance or repair, use the following lockout and tag-out procedures: • Disconnect the main power and electrical supplies. • Attach power and electrical lockout devices. • Tag-out the machine before beginning any maintenance work.
Page 94 RS4203 Manual Chapter 14 – Maintenance Guide 14.8.3 Grease working surfaces ___ Apply grease to all external working surfaces of the voider main shaft and drive shafts. Also grease the voider plates and exposed shaft surfaces of the skin brake shuttle cylinder. ___ Ensure sufficient grease was used in the assembly of the horn and rotor assembly.
Page 95 RS4203 Manual Chapter 14 – Maintenance Guide 14.8.9 Run the machine Investigate and repair any mechanical or electrical faults or leaks. Run the machine for at least one complete cycle. During this step, ensure the horn properly engages the skin brake and the housing floats on the horn. ___ Observe for proper tracking of conveyor belt, and adjust length of tension belt bolts if needed.
Page 96: Weekly Preventive Maintenance
RS4203 Manual Chapter 14 – Maintenance Guide 14.9 Weekly Preventive Maintenance Before completing the lockout and tag-out procedures for weekly preventive maintenance, put the machine into TEST mode. Both voider pairs should be together and closed to allow inspection of the voider orifice ratio (opening) between the voider plates.
Page 97 RS4203 Manual Chapter 14 – Maintenance Guide ___ Check voider eccentric and crank assemblies for excessive wear. Replace if necessary. ___ Ensure mounting bolts for voider pivot blocks are tight. Apply Loctite and retighten as required. ___ Check for any loose components on the coarse and fine adjustments of the slack-fill adjustment blocks.
Page 98 RS4203 Manual Chapter 14 – Maintenance Guide 14.9.8 Inspect for safety Re-activate the machine by applying both air and electrical power to the machine. ___ Inspect and close each guard and ensure proper powering up of the machine by pressing and resetting the Emergency Stop button.
Page 99: Quarterly Preventive Maintenance
RS4203 Manual Chapter 14 – Maintenance Guide 14.10 Quarterly Preventive Maintenance Prior to any maintenance or repair, use the following lockout and tag-out procedures: • Disconnect the main power and electrical supplies. • Attach power and electrical lockout devices. • Tag-out the machine before beginning any maintenance work.
Page 100 RS4203 Manual Chapter 14 – Maintenance Guide 14.10.6 Inspect condition of keys and keyed shafts Inspect the condition of keys, keyed shafts and crank assemblies of clippers and voiders. Also inspect both adjuster block bushings for the movable voider plates. If worn, replace with appropriate parts. ___ Crank, yoke and bushing assemblies inspected.
Page 101: Semiannual Preventive Maintenance
RS4203 Manual Chapter 14 – Maintenance Guide 14.11 Semiannual Preventive Maintenance Prior to any maintenance or repair, use the following lockout and tag-out procedures: • Disconnect the main power and electrical supplies. • Attach power and electrical lockout devices. • Tag-out the machine before beginning any maintenance work.
Page 102 RS4203 Manual Chapter 14 – Maintenance Guide ___ Movable voiders extend or separate away from fixed voiders. ___ Clipper swings down in between both pairs of voiders. ___ Clipper gate closes. ___ Clipper punch extends down and knife is fired. ___ Clipper gate opens, clipper swings back, and both voiders open.
Page 103: Annual Preventive Maintenance
RS4203 Manual Chapter 14 – Maintenance Guide 14.12 Annual Preventive Maintenance Prior to any maintenance or repair, use the following lockout and tag-out procedures: • Disconnect the main power and electrical supplies. • Attach power and electrical lockout devices. • Tag-out the machine before beginning any maintenance work.
Page 104 RS4203 Manual Chapter 14 – Maintenance Guide ___ Movable voiders retract towards and flush with fixed voiders. ___ Both pairs of voiders close. ___ Movable voiders extend or separate away from fixed voiders. ___ Clipper swings down in between both pairs of voiders. ___ Clipper gate closes.
Page 105: Chapter 15 - Troubleshooting Guide
RS4203 Manual Chapter 15 - Troubleshooting Guide Chapter 15 – Troubleshooting Guide If you are having trouble with your machine, before you call for assistance, try to resolve the problem through the following troubleshooting steps. Find your problem from the list of symptoms in the left column, then try each of the solutions in the right column until the problem is resolved.
Page 107: Chapter 16 - Troubleshooting By Product Appearance
RS4203 Manual Chapter 16 – Troubleshooting by Product Appearance Chapter 16 – Troubleshooting by Product Appearance This chapter provides a guide to troubleshooting by product appearance. UNIFORM END CENTERED CLIP Check for reliable tight, uniform undamaged closure PROBLEMS SOLUTIONS Clip applied off center end of Conveyor height must be set up so that product is fully supported by chub conveyor as it is being filled.
Page 108 RS4203 Manual Chapter 16 – Troubleshooting by Product Appearance CHECK FOR CLEAN CASING ENDS OR TAILS. SOME RESIDUAL PRODUCT IS EXPECTED. Adjust voider orifice wheel if needed. Turn wheel clockwise to loosen or increase the orifice. Turn wheel counterclockwise to tighten or reduce the orifice. Note: a small adjustment can make a large difference in the orifice opening.
Page 109 RS4203 Manual Chapter 16 – Troubleshooting by Product Appearance Always check manufacturer’s recommended stuff diameter and proper soaking and preparation procedures. Correct or acceptable final stuffed diameter PROBLEMS SOLUTIONS Product diameter undersized Check and increase Skin Brake tightness. Confirm proper functioning of the Skin Brake.
Page 110 RS4203 Manual Chapter 16 – Troubleshooting by Product Appearance Clip slippage or blow-off may result from the following PROBLEMS SOLUTIONS Inadequate air pressure to Check punch regulator and adjust if needed. punch cylinder Check power air supply for fluctuation. Check and adjust punch dwell if needed. Turn off punch cushion option in the recipe for this product.
Page 111: Chapter 17 - Spare Parts Lists
RS4203 Manual Chapter 17- Spare Parts Lists Chapter 17 – Spare Parts Lists Important: When ordering parts for optional assemblies or for assemblies with multiple equipment options (such as rotors and conveyors), please refer to the part numbers on the relevant assembly drawing in Chapter 18 to ensure you order the correct part for your application and equipment.
Page 112 RS4203 Manual Chapter 17- Spare Parts Lists 17.5 Recommended Horn Sizes for Various Casings Casing finished diameter Nominal Actual O.D. at lip From: 40 mm diameter 64 mm diameter 1 inch 1 1/16 diameter (27 mm)* 65 mm diameter 98 mm diameter 1 1/2 inch 1 9/16 diameter (39,7 mm) 84 mm diameter...
Page 113: Chapter 18 - Assembly Drawings
RS4203 Manual Chapter 18 - Assembly Drawings Chapter 18 – Assembly Drawings Important: When ordering parts for optional assemblies or for assemblies with multiple equipment options (such as rotors and conveyors), refer to the part numbers on the relevant assembly drawing to ensure you order the correct part for your application and equipment.
Page 114: Controls
RS4203 Manual Chapter 18 - Assembly Drawings 18.4 Controls 00-1731 Din Rail A 00-1732 Din Rail B 00-1733 Din Rail C 00-1734 Din Rail D 00-1735 Din Rail E 00-2147 Touch Screen Cover 00-2204 Enclosure, Heater/Fan 73-0052 Panel 73-0053 Enclosure 73-0054 RS4203 Control Box Assembly Complete 73-0055...
Page 115: Guarding
RS4203 Manual Chapter 18 - Assembly Drawings 00-1587 Rotary Actuator/ 3-Way Valve-with Tee 00-1588 Rotary Actuator/ 3-Way Valve-with Elbow 15-0302 Main Voider Shaft 18.7 Guarding 00-1770 Horn 00-2050 RS4203 Guarding Assembly 00-2051 Clipper 00-2052 Conveyor 00-2053 Horn Guard Assembly 00-2054 Left Lower Door 00-2055 Right Lower Door...
Page 116: Schematics
RS4203 Manual Chapter 18 - Assembly Drawings T10 Single Belt Dump Conveyors (Used on machines after October 2004): 00-2206 Nose Tray Roller Assembly (also used in standard conveyors, above) 00-2208 Hitch Bar Assembly (also used in standard conveyors, above) 00-2280 Drive Roller Assembly 00-2282 Paddle Mount –...
Page 117 RS4203 Manual Chapter 18 - Assembly Drawings Water Separator Retrofit Kits 00-2746 RS4203 Water/Mist Separator Kit (for Air Prep) 00-2877 RS4203 Adding Water Separator to the Conveyor Air Motor Kit Rev 32, 01/11/13 Copyright © 2013, Tipper Tie, Inc., All rights reserved...
Page 119: Appendix 1 - Noise Level Tests
RS4203 Manual Appendix 1 - Noise Level Tests Appendix 1 – Noise Level Tests Sound levels: The sound and noise level tests were conducted under the European Norm Number 31201, Noise Emitted by Machinery & Equipment Standards for Emission of Both Peak & Continuous Sound Levels at a Work Station.
Page 121: Appendix 2 - Maintenance Log
RS4203 Manual Appendix 2 - Maintenance Log Appendix 2 – Maintenance Log Make copies of this maintenance log (or use your own form) and use the log to record all preventive maintenance and unscheduled service activities. Use the log to identify and isolate adverse trends. Date Technician Maintenance Performed...

Dover Tipper Tie RS4203 User Manual

Chapter 1 - Machine Description and Specifications

Chapter 2 - Safety Instructions

Chapter 3 - Delivery and Setup

Chapter 4 - Air Connections, Lubrication and Adjustments

Chapter 5 - Operator Interface

Chapter 6 - Machine Operation

Chapter 7 - Recipe Descriptions

Chapter 8 - Touch Screen

Chapter 9 - Product Specification Worksheet

Chapter 10 - Clipper and Looper Operation and Adjustments

Chapter 11 - Conveyor Assembly Operation and Adjustments

Chapter 12 - Programmable Controller

Chapter 13 - Cleaning Procedures

Chapter 14 - Maintenance Guide

Chapter 15 - Troubleshooting Guide

Chapter 16 - Troubleshooting by Product Appearance

Chapter 17 - Spare Parts Lists

Chapter 18 - Assembly Drawings

Appendix 1 - Noise Level Tests

Appendix 2 - Maintenance Log

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Summary of Contents for Dover Tipper Tie RS4203

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