Fillflex™ 5500 Compact Filling machine Installation and user manual
Contents
1. Preset DSO Bza www fillflex com 141128 3 Automatic operation AUTO When on automatic operation the machine does a complete filling process according to the chosen settings volume speed cautious initial filling etc after ON has been pressed Then the machine stops and waits for ON to be pressed again The starting impulse can also come from a hand held switch pneumatic pedal automatic conveyor belt etc This mode is selected by pressing AUTO and is usually the normal operating mode for the machine 5 2 Control system functions on the operating panel AUTO When starting 1 the current reading is zeroed on the display under VALUE 2 the display shows ON 3 the pump starts 4 filling begins and 5 the sensor emits pulses The current VALUE counts up until it is equal to the preset value under PRESET after which filling stops and the display shows OFF The machine can be stopped in the middle of a filling process with the OFF button The display then shows HLT When the start button ON is pressed the control system continues from the value reached when the machine was stopped To begin from 0 with a new filling after a manual stop press the AUTO button MAN Filling is manual and the pump only works as long as the start button ON or pedal or similar is pressed in The current VALUE is not zeroed if the2. the direction of flow is altered as in paragraph 7 3 Connect the outlet and pneumatic valve if the machine is equipped with one to the outlet side of the pump 4 Connect any external communication electrical or pneumatic 5 Turn on the power by pressing the green starter switch on the machine The lamp in the switch and the display on the operating panel will come on www fillflex se 3 1 Fillflex 5500 Compact Filling machine 3 Installation and connection of new machine 6 Check the direction of flow by pressing MAN on the operating panel Then press ON briefly the pump works as long as ON is kept in Preset an Prog Mode Shift Con Auto Ss aani aaa peo Gre www fillflex com If the pump is going the wrong way the direction of P01 PULSE SREY rotation is altered as follows 01 Press OFF on the operating panel Press PROG Step forward to position P04 with Press MODE Turn the flow arrows by pressing Press MODE Press PROG Display after pressing PROG Display at P04 The pump will now rotate in the other direction 7 Fill the system pump hose and pipe by pressing MAN on the operating panel Then press ON The pump will go as long as the button is pressed in Preset The system must be entirely free from air before filling can begin Prog Mode Shift Cont Man Auto
3. No Sensor Fault 35 BC 5500 1 6 Version If you change this program step diffrent program steps could appear afterwards If you feel uncertain read the manual before you change Fore more information contact Fillflex AB 141128 www fillflex se 5 18 Fillflex 5500 Compact Filling machine 6 CE Certificate EC DECLARATION OF CONFORMITY OF THE MACHINE We the undersigned Manufacture FILLFLEX AB Adress S dra L ngebergsgatan 26B Country Sweden Contact T 46 31 14 58 40 F 46 31 14 58 43 E post info fillflex com Declares under its sole responsibility that the product Fillflex filling machine TY PEE sisane enn rr Serial nr ceeeeeeee To which this Declaration is in conformity with the following standards or other regulatory documents and meet that all applicable provisions under the terms of Directive 2006 42 EC and EMC Directive 2004 108 EC 2007 LVD Directive 2006 95 EC 2007 G teborg 2014 06 25 Par Nygren FILLFLEX 141128 www fillflex se 6 1
4. Batch Batch Batch Batch Batch Batch Batch Batch gram i r tt B1 B2 B3 B4 B5 B6 B7 B8 steg 1 Pulse 48 2 Pulse Out 1 Ratio Input 001 3 Stop 0 10s Detect 4 Flow gt gt gt Direction 5 Autostart No Yes Next fill 6 Extern Count start Imp 7 Paus time 5 00s next fill 8 Reversing No Yes 9 Reversing 0000 pulses 10 Revering 020 speed 11 Compen Yes sation No Present Value 12 Pulse 1 000 Multi Factor 13 Choice of P Units 14 Pump 0 00 s Start Delay 15 Value 0 00 s Close Delay 16 Value Of Yes Close Af ter Stop 17 Speed RPM Unit 18 Batch No Comp 19 Adjust 001 ment of pulses 20 Batch 0 00 max adjust ment 141128 www fillflex se 5 17 Fillflex 5500 Compact Filling machine 5 The control system and its functions and programme steps Pro Display Default Batch Batch Batch Batch Batch Batch Batch Batch gram i r tt B1 B2 B3 B4 B5 B6 B7 B8 steg 21 Quantity 000 delay comp 22 Ext Input No Adj To Zero 23 Pre Filling No Yes 24 Pre Filling 020 speed 25 Pre Filling 020 amount 26 End No Yes Filling 27 End 020 Filling speed 28 End 080 Filling start 29 Filling No Yes From Bottom 30 Time in 1 00s bottom pos 31 System Yes Ready Signal 32 Ready 0 0s Signal Time Delay 33 Restart No Yes From Zero 34 Connect Yes
5. Fillflex 5500 Compact Filling machine Safety regulations Warning symbols AN General warning AN Dangerous voltage A Corrosive substances 141128 Safety regulations All warnings are summarized below Follow the directions carefully to avoid any injury or damage Installation operating and service personnel must possess adequate knowledge of the machine Always begin by reading the manual Installation AN Always study the technical data AN Only qualified electricians may open the cover of the electric equipment AN Never insert fingers into pump connections or any shut off valve Operation AN Always study the technical data AN Never touch a pump or piping containing hot liquids AN Never start the machine before the pump unit is properly assembled A Always handle hazardous fluids with great caution AN Never insert fingers into pump connections or any shut off valve Maintenance AN Always study the technical data A Disconnect electrical connections and any air connection before servicing AN Servicing must never be carried out while the pump is hot AN The pump and pipes must not be under pressure during servicing AN Never insert fingers into pump connections or any shut off valve www fillflex se ll Fillflex 5500 Compact Filling machine 1 This is Fillflex Compact 1 This is Fillflex Compact Fillflex Compact is the latest generation of our renowned Fillflex filling mach
6. after which the product remaining outside the filling nozzle is withdrawn slightly If a hose is used for filling and reversing is not used the product will come out through the filling nozzle when the pump stops and the hose returns to its original diameter Possible values YES or NO www fillflex se 5 8 Fillflex 5500 Compact Filling machine 5 The control system and its functions and programme steps P09 REVERSING PULSES 000 P10 REVERSING SPEED 020 P11 COMPENSATION PRESET VALUE YES 141128 PO9 Number of pulses for which pump reverses at P08 P09 is used if YES has been selected at P08 Function The number of pulses which the pump runs in the reverse direction reversing begins when stop is detected at P03 The number of pulses for which the pump is run in the opposite direction of flow has to be repeated by the pump in the forward direction at the next filling before the volume begins to count Possible values 0 999 P10 Speed of reversing at P08 P10 is used if YES has been chosen at P08 Function The speed with which reversing proceeds as of maximum speed Possible values 0 100 P11 Compensation for difference in PRESET and VALUE Function When doing the first filling after shut off the pump stops when PRESET and VALUE are the same which means that the pump rotates after one or more additional pulses depending on the speed The values PRESE
7. rather too high The machine automatically compensates at the second filling and VALUE will then be the same as under PRESET 141128 www fillflex se 4 2 Fillflex 5500 Compact Filling machine 4 Daily operation 065 SPEED 1173RPM Ex Speed is 1 173 rpm which represents 65 of maximum 141128 4 5 Fine adjustment of filling volume If the filling volume set under PRESET needs fine adjustment somewhat too little or too much in the package this is done as follows 1 Adjust the value under PRESET with or 2 At the next filling the adjusted volume will be filled 4 6 Adjustment of filling speed 1 Press SPEED on the operating panel 2 Adjust the value speed as of maximum by pressing oyu u n or 3 Press SPEED to return to the main menu The pump will now work at the new filling speed When adjusting the filling speed fine adjustment of the filling volume may be necessary see 4 5 www fillflex se 4 3 Fillflex 5500 Compact Filling machine 4 Daily operation 4 7 Store a filling programme in the memory This is how the memory works The machine can store up to eight different filling programmes in its memory They are named B1 B2 etc up to B8 and are selected with BATCH All the adjustments which are made e g change of the filling volume speed etc are automatically stored in the filling programme which has been selec
8. start button ON is pressed It is zeroed by first pressing the OFF button and then the MAN button This mode of operation is used for start up filling the system and setting the filling quantity www fillflex se 5 2 Fillflex 5500 Compact Filling machine 5 The control system and its functions and programme steps Preset DSO Bra www fillflex com 141128 CONT The machine is operated only with the start and stop buttons ON and OFF without taking into account any preset stop value This mode of operation can for example be used for transport washing circulation or setting a high filling quan tity VALUE Current real value Shows the number of pulses from the last zero setting PRESET Preset desired value Shows the value at which stop occurs when running on AUTO Lh Setting of value on display under PRESET A single quick press raises the value in steps if is kept pressed the value rises continuously at a constant speed which increases after 3 seconds HX Setting of value in display under PRESET A single quick press lowers the value in steps if is kept pressed the value falls continuously at a constant speed which increases after 3 seconds ON Start of filling process during continuous manual or automatic operation OFF Stopping of filling process during continuous o
9. 00T W and a status indicator that is attached to a valve that open inwards This is because the pump not should work against a closed valve An example of such communication is when our conevalve TFV20101 is used with F5500T W X1 X2 ZON ZON O ready signal o i external start signal 7 max 230V 1A 5 status indicator OZ NOY start ready signal valve in position X5 ZON O ready signal NPN indicator external stop signal o max 230V 1A 0 30 VDC stop ready signal start signal 141128 www fillflex se 2 3 Fillflex 5500 Compact Filling machine 2 Connections and operating panel Installation of X contacts at a F5500T W 1 Note the color stuck into the terminals before disconnecting them 2 Installation of X1 plug Disconnect X1 plug terminals 202 203 204 amp 206 Take the screw located on the cable and mount it on the cabinet so that the X plug hangs outside the cabinet Then plug the cable back to the respective terminals 3 Installation of X2 plug Disconnect X2 plug terminals 207 208 Take the screw located on the cable and mount it on the cabinet so that the X plug hangs outside the cabinet Then plug the cable back to the respective terminals N B When installing the X2 plug do not forget to remove the jumper inside the cabinet that sits between 207 208 Installation of X contacts at fixed installation of FS500T W 1 Note the color stuck into the terminals before disconnecting them 2 Then conne
10. Fillflex 5500 Compact Filling machine Fillflex 5500 Compact Filling machine Installation and user manual Model T5500C Control system version 1 6b FILLFLEX the flexible filling machines Fillflex AB S dra L ngebergsgatan 26 B SE 421 32 Vastra Fr lunda Sweden info fillflex com Tel 46 31 1458 40 Fax 46 31 14 58 43 www fillflex se 141128 Fillflex 5500 Compact Filling machine Contents Contents Safety regulations 1 This is Fillflex Compact Brief description of the Fillflex system 2 Connections and operating panel 2 1 Control shroud och operating panel 2 2 Electrical connections for external communication 3 Installation and connection of new machine 3 1 Manually started filling filling controlled by operator 3 2 Mechanically started filling filling controlled by e g conveyor belt 4 Daily operation 4 1 Quick stop 4 2 Start up 4 3 Shut off and cleaning 4 4 Setting of filling volume 4 5 Fine adjustment of filling volume 4 6 Adjustment of filling speed 4 7 Storing a filling programme in the memory 4 8 Using a stored filling programme 4 9 Adjusting a stored filling programme 5 Control system and its functions and programme steps 5 1 General information on control system 5 2 Control system functions on the operating panel 5 3 Sensor fault indication 5 4 Control system programme steps 5 5 Programme steps and custom settings 6 CE Certificate 141128 www fillflex se
11. Possible values 0 01 9 99 s seconds Example If the time is long e g 1 00 s the motor has stopped If the time is short e g 0 10 s the motor has not stopped completely If 8 pulses rev see P01 has been selected and 0 10 between two pulses has been selected the stop indication will come at 75 rpm 60 divided by stop time between two pulses x pulses rev P04 Changing direction of flow Funktion Function Change of direction of flow direction of rotation of motor Possible values lt lt lt or gt gt gt P05 Automatic start after change of packing P05 is used with P06 and P07 Function Automatic start after the time which is set on P07 Used for example to enable a large number of packages to be filled more quickly The operator then has the time set under P07 to change the package Filling then starts automatically without a new start signal needing to be given Possible values YES or NO P06 Selection of start and stop method with automatic start P06 is used if YES has been chosen on P05 Function Choice of starting and stopping method with automatic starting Possible values CONT or IMP CONT As long as an external sensor e g pedal is active depressed a new start signal will come automatically after the time set on P07 When the external sensor becomes inactive pedal released the filling which has started will be completed after which automatic filling stops
12. T and VALUE must be the same all the time By selecting YES at P11 continuous compensation is obtained for differences between PRESET and VALUE both upwards and downwards PRESET and VALUE then remain the same all the time Possible values YES or NO YES If YES is selected the stop signal in the next filling will come as many pulses earlier as the excess number in the preceding filling NO If NO is selected the stop signal will come when PRESET and VALUE are equal www fillflex se 5 9 Fillflex 5500 Compact Filling machine 5 The control system and its functions and programme steps P12 PULSE MULTI FACTOR 1 000 Piles VCHIO PCE Our UNITS P P14 PUMP START DELAY 0 00s P15 VALVE CLOSE DELAY 0 00s 141128 P12 Constant between pulses and volume Function Constant by which the number of pulses is multiplied to enable the value of PRESET and VALUE to agree with the numerical value for volume or weight in the package which is being filled Possible values 0 001 9 999 Example If a filled volume of 650 ml gives a numerical value of 400 pulses the factor will be 650 400 1 625 By setting the constant 1 625 under P12 the numerical value on the display will show the number of ml The value obtained is then combined with the units in P13 P13 Choice of units Function To give the right unit for the value after setting in P12 Possi
13. ble values P pulses litres dl cl ml kg hg and g Example compare P12 If ml is selected the display will show 650 ml P14 Delay of pump start Function Used if the filling machine is equipped with a pneumatically controlled outlet valve Delay of pump start is used when the shut off valve is connected in order to be able to give the valve time to open before the pump starts In this way there is no build up of pressure before the valve opens if the valve opens with pressure in the pipe there may be splashing Possible values 0 00 9 99 s seconds P15 Delay of valve closure after filling Function Used if the filling machine is equipped with a pneumatically controlled outlet valve Delay of valve closing after filling to avoid the pressure in the pump system remaining in the pipe after stopping if there is pressure in the pipeline at the next filling there may be splashing Possible values 0 00 9 99 s seconds www fillflex se 5 10 Fillflex 5500 Compact Filling machine 5 The control system and its functions and programme steps P16 VALVE CLOSE AFTER STOP YES P17 SPEED UNIT R PM P18 BATCH COMP NO 141128 P16 Synchronization of valve closure and pump stop Function Used if the filling machine is equipped with a pneumatically operated outlet valve To obtain the optimum setting between valve closure and pump stop As the pump does not stop immediat
14. ct your own cable on each terminal 141128 www fillflex se 2 4 Fillflex 5500 Compact Filling machine 3 Installation and connection of new machine starter switch quick stop shut off pneumatic connections connection for any external electrical or pneumatic control 141128 3 Installation and con nection of new machine The Fillflex Compact can be used for both 3 1 Manually started filling the filling process is started by an operator or 3 2 Mechanically started filling the filling process is started by a signal from a conveyor belt or similar equipment The machine may have been delivered with different types of equipment depending on its intended use e g pump different types of ejector pneumatic valves pneumatic pedal etc Check that the equipment is complete before installation and connection 3 1 Manually started filling The machine is delivered with a suitable pump The machine can always be quick stopped with the black quick stop button on top of the machine 1 Mount and connect the control cabinet according to instructions inside cabinet 2 Install the pump and connect the suction line or filling hopper if the pump is to be equipped with one to the inlet side of the pump The gear pump works equally well in both directions and has no preset direction of flow The inlet and outlet sides can therefore be chosen as desired Should the pump be found to go the wrong way
15. ely because of the speed of rotation when the control system signals stop filling continues for a short time To prevent dripping it is possible to select to shut the pneumatic valve at the same time as the pump stops or after the pump stops If NO is selected the valve closes and the pump stops at the same time If YES is selected the valve closes after the pump has stopped The time between the pump stopping and the valve closing can be determined by a setting or two settings 1 The time which has been selected under P03 the time after which the control programme will by definition think that the pump has stopped At this point the valve is closed if P15 is 0 2 If in addition a delay time has been set under P15 this time is added to the time under P03 For example if 0 5 sec has been selected under P03 and 1 2 sec has been selected under P15 the valve closes 1 7 sec after the pump has received its stop signal Possible values NO or YES P17 Selection of unit to be shown in SPEED position Function Selection of desired unit to be shown in SPEED position Possible values RPM l m litres per minute or similar according to the unit chosen at P13 P18 P22 Automatic compensation for external factors Programme steps P18 P22 are intended for compensation and setting of compensation For more information contact Fillflex AB www fillflex se 5 11 Fillflex 5500 Compact Fill
16. ey eS SS ey SY SS Chee Gi date 07 8 The speed can be increased to make it easier for the pump to suck The speed is adjusted by pressing SPEED and increasing reducing with or Then press SPEED again to return the display to the operating mode www fillflex com 9 The machine is now ready for setting of the filling volume see section 4 4 3 2 Mechanically started filling Installation and connection take place in the same manner as with manually started filling but with the difference that the machine receives a starting signal from the conveyor belt Paragraph 4 in section 3 1 now becomes Connect the communication from the conveyor at the communication connection Connecting instructions on page 2 3 and 2 4 electrical connection for external signal from conveyor belt etc 141128 www fillflex se 3 2 Fillflex 5500 Compact Filling machine 4 Daily operation No i X XXX 0 000 P AUTO OFP B The display after the starter switch has been pressed The last value set is shown at X XXX The last chosen filling program number is shown at Preset sa Prog Mode Shift Coi uto VS Ss No O aza www fillflex com 141128 4 Daily operation 4 1 Quick stop Fillflex Compact can always be quick stopped with the black quick stop button on top of the machine Motor and pump and the pneumatic valve on the outlet pipe if one is fitted wi
17. fillflex se 2 1 Fillflex 5500 Compact Filling machine 2 Connections and operating panel Mode Change in programme Prog Changeover between working and programming mode och Increase reduce volu me filling speed and values when program ming 141128 Shift Display Cont reserve Continuous switch operation Man Manual operation aa oe Prog Mode Shift Cont Man Auto Auto ee ed Automatic R e Batch Off operation a www fillflex com Speed On Off Setting of Start Stop filling speed Batch Choice of preset filling programme ON on the operating panel has the same function as external control via the electrical and pneumatic connections For further explanation of the operating panel functions see 5 2 Control system functions on the operating panel www fillflex se 2 2 Fillflex 5500 Compact Filling machine 2 Connections and operating panel 2 2 Electrical connections for external communication When are the X contacts used X plugs are used when external communications of different kind are to be connected with F5500T W X plugs are always pre installed inside the cabinet at delivery of a FS500T W The X1 plug is used when communication for external start stop function is connected to F5500T W Examples of such communication is when a conveyor is connected and used with the F5500T W The X2 plug is used in communication between F55
18. fillflex se 5 12 Fillflex 5500 Compact 5 The control system Filling machine and its functions and programme steps P27 END FILLING P27 Speed of slow top filling at end of SPEED 020 filling process P27 is used if YES has been selected at P26 Function Used to give the speed after the quantity of total filling set at P28 Possible values 0 100 of max speed P28 END FILLING P28 Proportion of slow top filling at end of START 080 filling process P28 is used if YES has been selected at P26 Function Used to specify the proportion of total filling after which the slower end filling is to start When this quantity has been filled the speed changes from the basic speed set in the SPEED mode to the end filling speed set at P27 Possible values 0 100 of total filling amount P29 FILLING PROM P29 Bottom filling with filling lance BOTTOM NO P29 is used together with P30 Function Used if the filling machine is equipped with pneumatically controlled filling lance The speeds for movement up and down are set with separate throttle valves on the pneumatic cylinder Used for filling foaming products or to avoid splashing Possible values NO FINISHED or TIME FINISHED At the start signal for filling the filling lance goes down to its bottom position When the control unit receives the signal that the lance is in position filling starts and the filling lance remains in the bottom posit
19. for filling jam and marmalade marzipan custard sauce pat dressing preservatives yoghurt mayonnaise honey washing liquid shampoo degreasers hand cream paint acid oil and other substances Containers The machine can be easily adapted to suit many different types of container everything from 10 ml bottles to dishes jars barrels drums and vats It is simplicity itself to alter or adjust the chosen filling volume Up to 8 pre selected options can be stored 141128 www fillflex se 1 1 Fillflex 5500 Compact Filling machine 1 This is Fillflex Compact Power connection 230 V or 400 V TF machine features connectors for external start up and communication with a conveyor system etc Dimensions Fillflex Compact cabinet Length approx 400 mm Width 260 mm Height approx 400 mm Construction The Fillflex system features a simple and robust design The pump is driven by an electric motor and filler speed rotating speed is controlled by a separate control All settings for portion size filling speed and automatic manual operation take place via the control unit and can quickly and easily be altered by the filling operator Various types of installations and connections with Fillflex Split Mobile and Fillflex Compact 141128 Fillflex Compact basic version Fillflex can be provided with different types of ejector for for example viscous media where there is a risk of dripping Pedal s
20. ine The lamp in the green starter switch and the display on the operating panel will go out and the machine is now off 3 Remove the earthed plug Switch off the compressed air if applicable 4 Dismantle the pump and pneumatic valve if fitted for cleaning 4 4 Setting of filling volume 3 333 37 333 When starting after shut off the machine begins with the last P AUTO OFF B chosen filling programme Any previous setting is shown under PRESET e g 3 333 1 Place an empty container under the ejector 3 333 0 000 2 Press the MAN button Zero VALUE if it does not P MAN OFF B already show zero 3 Press the ON button and keep it pressed until the desired volume is obtained the ON button may be released Jad 0 000 causing HLT to be shown on the display and pressed P MAN HLT B again the control system then continuing from the value it had when stopped The reading under VALUE begins to count up as filling 3 333 2 ADD proceeds P MAN OFF B 4 Read off the current value e g 2 222 under VALUE and set the same value under PRESET with the aid of the buttons and 2 222 2 22 5 Press OFF HLT will change to OFF Then press Pe OFF B AUTO Next time ON is pressed the desired volume will The last chosen filling program be filled number is shown at Note however After the first filling VALUE will be
21. ines It is compact versatile and economical and its design is different to that of the traditional piston driven filler Fillflex Compact is very easy to use By simply O pressing keys on a panel the operator gt can conveniently increase or decrease the volume and filling speed and equally easily store the new readings in one of the 8 pre selector options It is very easy to clean the pump can even be dismantled without tools The entire machine is made of stainless materials and is easily washed and cleaned Since filling volumes can be altered infinitely the same machine can be used for filling small retail size 10 ml bottles as well as large wholesale size drums or vats The containers to be filled can be fed either manually one at a time or in a fully automatic process for large scale operation using conveyor belts Fillflex Compact can also handle traditionally difficult media such as highly viscous foodstuffs and cleaning agents or detergents which froth easily Adjustment of the operating parameters on Fillflex Compact is simplicity itself If you need to increase production simply keep your machine and add a conveyor system and other peripheral equipment The machine is available with a wide range of ejectors valves and accessories for a variety of products and applications Products Fillflex Compact can handle virtually all types of fluid including highly viscous and frothing liquids It is used
22. ing machine 5 The control system and its functions and programme steps P23 PRE FILLING NO P24 PRE FILLING SPEED 020 P25 PRE FILLING AMOUNT 020 P26 END FILLING NO 141128 P23 Slow prefilling at start of filling P23 is used together with P24 and P25 Function Used to avoid foaming and splashing and to increase the total filling speed Possible values NO or YES P24 Speed for slow prefilling at start of filling P24 is used if YES has been selected at P23 Function Used to give the speed of the amount of prefilling set at P25 Possible values 0 100 of max speed P25 Proportion of slow prefilling at start of filling P25 is used if YES has been selected at P23 Function Used to indicate the proportion of the total filling which is to proceed more slowly After this amount has been filled the speed changes to the basic speed set in the SPEED mode Possible values 0 100 of filling amount P26 Slow top filling at end of filling process P26 is used together with P27 and P28 Function Top filling end filling to reduce filling speed at the end of filling Used to give the product time to run out into the whole package any foam must have time to settle in whole or part or to reduce the speed when filling packages which narrow at the top The function is also used to reduce the effect of differences in stop and shut off times Possible values NO or YES www
23. ion until filling is complete Then the filing lance is drawn up again quickly TIME As above but the filling lance remains in the bottom position only for the time set at P30 after which it slowly rises to allow the liquid to flow out under the surface When filling is complete the filling lance rises quickly for the remaining distance 141128 www fillflex se 5 13 Fillflex 5500 Compact Filling machine 5 The control system and its functions and programme steps P30 TIME IN BOTTOM POS 00 0s P31 SYSTEM READY SIGNAL YES P32 READY SIGNAL TIME DELAY 0 00s P33 RESTART FROM ZERO NO P34 CONNECT SENSOR FAULT YES 141128 P30 Time for filling lance in bottom position P30 is used if TIME has been selected at P29 Function Determines the time that the filling lance stays in the bottom position before being slowly raised Possible values 0 00 9 99 s sec P31 Ready signal via auto ready signal relay P31 is used together with P32 Function Gives ready signal via auto ready signal relay Usually used for filling on conveyor belt Possible values YES or NO P32 Delay of ready signal via auto ready signal relay P32 is used if YES has been selected at P31 Function Used to delay ready signal for example to wait for other equipment or to avoid dripping in wrong place Possible values 0 00 9 99 s seconds P33 Restart from zero Function Used for restart from zero at next s
24. lected under P05 3 Press MODE The step is now adjustable 4 Make the changes and 5 Leave the step by pressing MODE 6 Select anew programme step or leave the programming mode by pressing PROG 7 Custom Settings on the panel could be noted in in table at page 5 14 5 15 P01 PULSE REV P01 Number of pulses per revolution of motor 01 Function Value for number of pulses per revolution of the motor To see the speed of the motor in rpm Possible values 1 99 P02 PULSE RATIO P02 Number of pulses received before the OUT 1 INPUT 001 control programme counts a control pulse Function The number of pulses received from the motor per control pulse counted in the control programme Used to reduce large numbers of pulses so that the working range of the machine will be adequate Possible values 1 255 Example If the value 255 is selected the control programme will count 1 control pulse only after 255 motor revolution pulses have been counted 141128 www fillflex se 5 6 Fillflex 5500 Compact Filling machine 5 The control system and its functions and programme steps P03 STOP DETECT PULS PULS 1 00s P04 FLOW DIRECTN gt gt gt POS AUTO START NEXT FILL NO P06 EXTERN START CONT 141128 P03 Time between two motor revolution pulses before stop is confirmed Function To enable the control programme to know if the pump has stopped or is about to stop
25. ll then stop immediately When the reason for the quick stop has been dealt with the machine is restarted with the green starter switch 4 2 Start up For daily use the machine is started as follows 1 Fit the pump and pneumatic valve if applicable if these have been removed and cleaned 2 Connect where applicable the compressed air to the pneumatic valve 3 Connect the earthed plug 4 Press the green starter switch on the machine The lamp in the switch and the display on the operating panel will come on 5 Fill the system pump hose and pipe by pressing MAN on the operating panel Then press ON The pump will run as long as ON is pressed in 6 When the whole system is free from air filling can begin For setting of filling volume selection of preset programme etc see below www fillflex se 4 1 Fillflex 5500 Compact Filling machine 4 Daily operation 4 3 Shut off and cleaning The procedure for daily shutdown is as follows 1 Flush out the system pump hose and pipe with suitable Prog Mode Shift rinsing agent by pressing MAN on the operating panel a 5 Ga The pump will run as long as ON is pressed in Alternatively CONT may be selected The pump is then wwwillflex com started with ON and shut off with OFF in this case the operator can leave the machine during flushing kS 2 Press the black quick stop shut off button on top of the mm mach
26. ore fixed choices e g YES NO the buttons and are used SHIFT Spare button www fillflex se 5 4 Fillflex 5500 Compact Filling machine 5 The control system and its functions and programme steps PESENSOR FAULT 141128 5 3 Sensor fault indication If YES has been selected at programme step P34 the control programme will alarm and switch off the machine if the signal from the sensor is incorrect An incorrect signal is when the time between two motor revolution pulses set on programme step P03 is longer than the time an extra second which has been set at P03 In addition filling should be in progress The pump does not rotate Possible causes action The pump is blocked remove the blockage Speed set too low increase the filling speed see 4 6 The frequency control has tripped shut off the machine and restart The pump rotates but VALUE does not change on the display Action Contact your machine supplier or Fillflex AB www fillflex se 5 5 Fillflex 5500 Compact 5 The control system Filling machine and its functions and programme steps 5 4 All the steps in the control programme The programming mode is obtained as follows 1 Press PROG on the operating panel 2 Step forward to the desired programme step with Note that inapplicable programme steps are omitted For example P06 and P07 are not shown unless YES has been se
27. peration During manual operation filling is stopped by releasing ON on automatic it is stopped by the control unit BATCH With BATCH one of the stored programmes up to eight in number is selected The machine always starts in the same batch programme that was used when it was shut down www fillflex se 5 3 Fillflex 5500 Compact Filling machine 5 The control system and its functions and programme steps 065 SPEED 1173RPM P05 AUTO START NEXT FILL NO 141128 Repeated pressing of the BATCH button moves the display up to B8 and then begins again with B1 SPEED Alternate between operating mode and speed mode The display shows the word SPEED and the pump speed in revolutions per minute RPM The filling speed can be increased and reduced steplessly with the buttons and PROG Alternate between operating and programming mode To go up and down the programme steps the buttons and are used When the machine has been dead step P01 is always shown in the programming mode If for example programme step P05 is shown when returning to the operating mode P05 will come up at the next change from operating to programming mode MODE Change to alteration of the programme step which is displayed An arrow is shown before the value or the text which may be altered To increase or reduce the value or alternate between two or m
28. tart if external stop signal has stopped filling before the set volume has been reached Possible values YES or NO P34 Connection and disconnection of sensor fault indication Funktion Function Connects or disconnects indication of sensor fault YES Indicates and shuts off the machine in case of fault NO Function disconnected This position is normally used only for running in and special operation which is usually carried out by specialist personnel See also 5 3 Sensor fault indication Possible values YES or NO www fillflex se 5 14 Fillflex 5500 Compact Filling machine 5 The control system and its functions and programme steps P35 BC 5500 VERSION 1 6 141128 P35 Type and version of control unit www fillflex se 5 15 Fillflex 5500 Compact 5 The control system Filling machine and its functions and programme steps Notes Batch 1 Value oss Speed oon Batch 2 Value ss Speed n Batch 3 Value oss Speed ss Batch 4 Value oss Speed once Batch 5 Value an SPC once Batch 6 Value n Speed ss Batch 7 Value oss Speed oss Batch 8 Value nn SPEC onssas 141128 www fillflex se 5 16 Fillflex 5500 Compact Filling machine 5 The control system and its functions and programme steps Programme steps and custom settings Pro Display Default
29. tarted Fillflex Compact with feed hopper Fillflex with a hopper that is filled from above and discharges at the bottom This is a suitable arrangement for viscous media Fillflex Compact and automatic operation The standard version Fillflex is prepared for fully automatic operation This makes it easy to increase output The starting signal comes from the conveyor www fillflex se Fillflex Compact with bottom filler Fillflex can be com bined with a pneu matic bottom filler for foaming liquids etc The bottom filler is fully controlled by the Fillflex control programme Fillflex Compact on wheels Fillflex equipped with wheels and standing on the floor The machine starts and stops itself and the operator need only move the ejector between the receptacles Fillflex Compact and automatic operation with bottom filler Here automatic filling has been supplemen ted with a bottom filler for foaming liquids The starting signal comes from the conveyor Fillflex 5500 Compact Filling machine 2 Connections and operating panel 2 Connections and operating panel 2 1 Control shroud och operating panel Fillflex Compact control shroud Quick stop shut off Starter switch Operating panel Pneumatic connections Electrical connection for external signal from conveyor belt etc look at page 2 3 Pump Pneumatic connection for external control by pedal etc 141128 www
30. ted If the machine is in the AUTO position it always works to one of the filling programmes B1 to B8 The machine always starts in the same batch programme that was used when it was shut down Custom batch can be noted on pages 5 14 5 15 This is how a filling programme is stored in the memory 1 Select the desired position B1 B8 by pressing BATCH The position must always be selected before programming 2 Make the desired settings e g filling volume see section 4 4 speed see section 4 6 or other parameters see section 5 3 Doa filling 4 The desired programme is now stored in the selected programme position 4 8 Using a stored filling programme 1 Select the desired programme position B1 B8 by pressing BATCH 2 Press AUTO 3 The programme is now ready for use 4 9 Change a stored filling programme 1 Select the programme position B1 B8 which it is desired to change by pressing BATCH 2 Make the desired adjustments 3 Doa filling 4 The changes are now stored in the selected programme position 141128 www fillflex se 4 4 Fillflex 5500 Compact 5 The control system Filling machine and its functions and programme steps 5 The control system and its functions and programme steps 5 1 General information on the control system The Fillflex control system counts the pulses it receives from the motor and their speed The p
31. ulses correspond to the speed revolutions or part revolutions of the motor and therefore also the quantity of filling material which has passed the pump By counting the pulses during filling and comparing them with the set values the machine can control the filling process There are three operating modes 1 Continuous operation CONT 2 Manual operation MAN 3 Automatic operation AUTO During automatic operation the filling process can be varied according to the filling material and the container volume speed cautious initial filling etc The adjusted filling process BATCH is stored in the memory of the control unit 1 Continuous operation CONT When on continuous operation the pump works continuously until OFF is pressed This mode of operation is selected by pressing CONT Filling is then controlled only with ON and OFF without considering any preset stop value This mode can be used for transport washing circulation or setting a large filling volume 2 Manual operation MAN When on manual operation the pump works as long is ON is pressed This mode is selected by pressing MAN Filling is then controlled only with ON This mode is used for start up filling the system and setting the filling volume 141128 www fillflex se 5 1 Fillflex 5500 Compact Filling machine 5 The control system and its functions and programme steps
32. until the external sensor is activated again www fillflex se 5 7 Fillflex 5500 Compact Filling machine 5 The control system and its functions and programme steps P07 PAUSE TIME NEXT FILL 5 00s P08 REVERSING NO 141128 The display shows ON all the time until the signal for automatic start stops the pedal is released IMP A short pulse one push on the pedal from an external sensor starts the automatic start function with the pause time set on P07 When the external sensor is activated again new pressure on the pedal the filling which has been started will be completed after which the automatic filling stops until the external sensor is activated again The display shows ON all the time after the first external start impulse is given until the next external signal for automatic start comes The display then shows OFF P07 Setting of pause time from stop to new start of next filling P0O7 is used if YES has been chosen at P05 Function Used to select the time the operator needs to change packing Possible values 0 01 9 99 s seconds PO8 Reversing of direction of flow at end of filling process PO8 is used with P09 and P10 Function Reversing of direction of flow of gear and lobe pumps to reduce the dripping tendency when filling with viscous products The filling process is completed when the pump runs in the opposite direction with the number of pulses given at P08
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