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Model 10 ver 4.2 Operational Manual

1. Valve in full Closed Position Vacuum Port Block Valve in full Open Position Chapter 2 Page 11 of 15 2 5 RECTIFYING FILLING AND CLOSING THE CAPSULES continued 2 5 5 Procedure Rectifying the capsules FATA a A aal RECTIFIER STOP RECTIFIER START VACUUM BYPASS IN OFF POSITION PINCH POINT Set in Position for Capsule Loading hands clear 1 Place the correct sized filling rings cap amp body on the rectifier turntable located on the right and turn them in a clockwise direction until they are seated against the metal drive pin Start the positioning and separation process by pressing the RECTIFIER START button on the front panel The rectifier will correctly position the capsules then drop capsules into each row of the ring set The turntable will automatically stop turning when the rings are filled Qur The RECTIFIER STOP button can be used to interrupt the rectification process When the START button is then pushed processing will continue If the product fill cycle is in process and the rectification process is stopped allow the fill cycle to finish prior to opening the rectifier door NOTE If power is interrupted to the machine during the product fill cycle upon restart it is possible for the fill table to finish the started revolution and revolve one additional complete revolution potentially over filling the ring Verify the product fill weight for any
2. MACHINE STATUS PROXIMITY SENSORS There is a total of 5 proximity sensors installed on the machine but only 4 are monitored FILL HOPPER AT HOME The hopper is at HOME position and ready RING IN CLOSING POSITION Indicates that the ring is in place for closing FILL HOPPER IN PLACE Indicates that the fill hopper is in position over the ring RECTIFIER AT HOME Used to Start Stop the rectifier SOLENOIDS MACHINE AIR ACTIVE Soft Start dump valve indicates air is present RAISE CLOSING STATION When the Ring in closing position prox is ON the solenoid activates which extends to close the capsules FILL HOPPER ADVANCE When The 2 green palm buttons are pressed together the Fill Hopper swings into position RECTIFIER VACUUM ACTIVE Indicates there is vacuum to the Rectifier VACUUM ON VACUUM OFF The vacuum pump may be turned on or aff fram thie erraan MACHINE STATUS haBbCeDdEe Metal CLOSING STATION CLOSING Tano Chapter 5 Page 6 of 12 ALARM SUMMARY B aseocendes gall PER naredi 12 00 00 da E pnm CLOSING STAION RaBbCeDdEe Mad RESET 12345678 uic bibl OFF SHIFT RING COUNTER 123456 r WHEN LIT OKAY RECAP EO DRIVE FREQUENCY BaBbCcDdEe ERE SPEED FILL AUGER MO
3. ONLY NOT A p d CHANGEABLE Loud COMPONET su FEED BLOCK RECTIFIER BLOCK ROTATION MODULE GUIDE CHUTE Rectifier Assembly Chapter 3 Page 5 of 14 3 2 How to Convert the Rectifier Assembly 3 2 2 Procedure Read and understand operation manual prior to operating or servicing this machine Lockout machine prior to service Failure to follow operating instructions could result in personal injury or damage to the equipment Use the following procedure to switch parts on the rectifier assembly 1 Turn the main power disconnect switch OFF Use Lockout Tagout procedure 2 Accessing the Rectifier Assembly Open the rectifier door of the rectifier assembly shown RECTIFIER DOOR SAFETY SWITCH amp LATCH 3 Check the capsule hopper to be sure that all capsules from the last run have been removed If capsules still exist vacuum or dip them out of the hopper 4 Remove the rotation module a remove the air hose from the bottom of the rotation module The tube is removed by pushing the ring of the connection while pulling the tubing b lift the rotation module straight up off the positioning pins and setting it aside ROTATION MODULE AIR HOSE Chapter 3 Page 6 of 14 3 2 How to Convert the Rectifier Assembly 3 2 2 Procedure 5 Remove the two 2 screws from the feed block and lay it aside 6 Remove the two 2 screws fr
4. The filling system consists of the Powder hopper Auger and wiper arm Filling turntable The filling system is diagrammed below 1 5 2 System Diagram POWDER HOPPER WIPER ARM FILLING SHOE CUTOUT FILLING SHOE CAPSULE BODY RING FILL 00 0000 nae TURNTABLE Filling System Chapter 1 Page 13 of 19 1 5 The Filling System 1 5 3 Filling the Capsules The amount of material to be added to the capsules is regulated by the auger speed as well as the turntable speed These are both adjusted with the HMI Touch Screen on the Drive Setup page After the desired material has been placed in the powder hopper and the capsules have been separated the filling process can begin Only the loaded lower body ring is used in the filling process After the rings are separated the cap ring is stored on the cap ring holder and the body ring is placed on the filling turntable When the FILL START button s are pushed the powder hopper automatically swings into place and the auger wiper arm and turntable begin to rotate The powder is forced out of the hopper by the auger filling the capsules while the table rotates continuously at your previously designated speed until all the capsules are filled Filled Capsules Body Ring After one complete rotation the turntable automatically stops and the powder hopper will swing back to its standby position The cap r
5. 2300 MIM ert Note Drive speed indicator and drive reset buttons require Supervisor Rights Pushing any of these buttons will access Nd the LOG ON SCREEN allowing for a SUPERVISOR to Log On ua ELI M Drive Speed RECTIFIER Running Speed PRESET Chapter 2 2 Page 10 of 15 2 5 RECTIFYING FILLING AND CLOSING THE CAPSULES 2 5 4 Adjustments Setting the Vacuum 1 Vacuum Level This is set by the dial on the rear of the vacuum pump which is accessed by the rear door The vacuum level is checked via the gauge in the foot well Note Valve needs to be in the OFF position to set pump See photo below Pump Valve adjustment knob Set to 15inHg max for most applications Valve shown in OFF Position 2 Vacuum Flow The amount of flow at the vacuum port block can be regulated by the valve adjacent to the vacuum gauge As the valve is rotated from the closed position towards the open position filtered air is introduced into the vacuum system reducing the amount of vacuum A setting of 8inHg to 15inHg is suitable for most applications Vacuum higher than 15inHg will require raising the pump pressure accordingly Note The Vacuum can be adjusted anytime the Rectifier Cycle is idle Maximum pump pressure is 24inHg High pressures can shorten pump life e Too much vacuum the capsules will bounce and the caps will fly off e Not enough vacuum will result in poor separation
6. HOPPER RETURN CF 0270 AUGER ONLY CF 2522 BELT AUGER DRIVE CF 2525 BELT AUGER MOTOR CF 3202 MOTOR FILL TABLE hp AC CF 3202 MOTOR AUGER DRIVE 12 HP AC CF 2603 CF 2174 FILLING SHOE BLOCK CF 2675 THRUST WASHER POWDER SWEEP BEARING CF 2515 AUGER SET SCREW SST 32 13 X 1 1 2 CF 2667 POWDER SHOE ADJUSTMENT SET SCREW CF 2676 SHAFT COLLAR 6 3 Closing Assembly Parts CLOSING PRESSURE PLATE GUIDE WASHER CF 2329 CLOSER STOP BLOCK LF 8063 CLOSING SENSOR CF 2633 FLANGE BEARING CF 2210 SHAFT RETAINER CF 2620 SPRING FOR WING CLAMP CF 2504 RETAINER CLIP FOR SPRING CF 2149 RETAINER WASHER FOR SPRING CF 2669 PEG RING SHAFT O RING HARDWARE SST 4 20 X SHCS FOR WINGCLAMP POST BOTTOM HARDWARE SST 10 24 X 3 a LG SHCS FOR UPPER WINGCLAMP POST NN HARDWARE SST 4 20 X LG FHCS HARDWARE SST 10 24 X LG SHCS FOR PEG RING SHAFT BUSHING Chapter 6 3 of 4 6 4 Fuses Partnumber LF 8044 1 AMP FUSE F20 F21 F22 F24 TYPE AGC EX CF 2785 15 AMP FUSE F1 F2 F3 TYPE for 220 VOLT ONLY CF 2727 10 AMP FUSE F4 F5 FNQ TYPE for 220 VOLT ONLY CF 3187 CAN OPEN ETHERNET CABLE CF3188 A C DRIVE CONTROLLER 1 2HP 208 240V 1 CF 3191 CIRCUIT BREAKER 3A CF 3193 CIRCUIT BREAKER 10A CIRCUIT BREAKER 2A 2 AMP FUSE 6 5 ACCESSORIES FOR MODEL 10 3015 CASTERS CF 3229 OPERATION MANUAL CF 2253 POWDER TRAY LH
7. MELIA Li 12 00 00 OO wy 0 No One Logged ON 1 SUPO01 Supervisor 1 4 OP1 Operator 1 2 BACK Button 3 Allow the touch screen to come on it will display the Log On Screen e ouch User Name this will bring up the keypad Key in your user name and push Enter e ouch Password this will bring up the keypad Key in your password and push Enter First Push the Unlock and then the Push the Home button MUST be pushed in this sequence this will take you to the MAIN SCREEN Chapter 2 Page 8 of 15 On screens where there is a BACK button and a MAIN button Pressing the BACK button takes back to the prior screen Pushing the MAIN button takes you to the MAIN SCREEN 2 5 RECTIFYING FILLING AND CLOSING THE CAPSULES 4 Push the Machine Status button to advance to the Machine Status screen Machine Status Screen is only accessible thru the Main Screen MAIN SCREEN MACHINE STATUS SCREEN wy LILI M CLOZIHG STATION FILL HOPPER CLOSING STATION 5 Push the Main Power button on the HMI Human Machine Interface Touch Screen box The Machine Ready Indicator will light Push the Vacuum ON Button to activate air to the machine The MACHINE AIR ACTIVE light should turn green At this time the FILL HOPPER AT HOME and the RECTIFIER AT HOME should be lit NOTE Upon initial Machine Startup or Machine Restart due to emergency stop or door interlock shutdown after the VACUUM ON button
8. a SAFETY LATCH Chapter 4 Page 4 of 22 4 2 How to Clean the Powder Hopper 4 2 2 Procedure probably needs to be repositioned Using the narrow end of the jack handle turn the valve clockwise to jack up the hopper Q NOTE If the jack will not work the release valve at the bottom of the jack INSERT JACK HANDLE HERE TO ADVANCE THE JACK 6 Remove the two 2 large shoulder bolts from the mounting bracket while supporting the filling shoe block with your free hand Chapter 4 Page 5 of 22 4 2 How to Clean the Powder Hopper 4 2 2 Procedure 7 Disconnect the filling shoe block from the hopper and set it aside PLASTIC KNURLED SCREWS FILLING SHOE BLOCK FILLING SHOE Either Powder shown or Pellet 3 ia 8 Loosen the black plastic knurled screws from the top of the hopper and drop the hopper down at an angle to clear the auger POWDER RETURN GASKET Removed Hopper Filling Shoe Pellet Filling Shoe Powder 9 Rinse the hopper with water or alcohol and dry thoroughly The auger wiper arm and filling shoe can be wiped with alcohol Chapter 4 Page 6 of 22 4 2 How to Clean the powder Hopper 4 2 2 Procedure WARNING Use caution when cleaning the auger The sharp points are capable of cutting through skin AUGER CAUTION EDGES amp CORNERS ARE SHARP 10 After the hopper is thoroughly dry reinstall it at an angle under the
9. 6 6 TOOL BOX FOR MODEL 10 3096 PLASTIC STORAGE BOX CF 0664 POWDER TRAY CF 0542 NYLON BRUSH CF 0261 CAPSULE PICK CF 0262 CAPSULE ROD 1 ALLEN WRENCH SET WTERNALFLTER at 1 a CF 2955 INTERNAL FILTER NYLON FEET LF 7079 SCREW DRIVER SECURITY BIT HOLDER PLASTIC FOOT PAD LF 7076 T 10 SECURITY SCREW BIT enclosed in holder LF 7077 T 15 SECURITY SCREW BIT enclosed in holder LF 7078 T 25 SECURITY SCREW BIT enclosed in holder 4 Chapter 6 Page 4 of 4 Upon initial startup of the machine please setup your unique Supervisor Logon Password per the instructions listed below User and passwords are case sensitive As Shipped User is SUPO1 Password sti Please leave the as shipped user and password unmodified USER SETUP Must be Logged on as Supervisor E Access Main Screen e Select USER SETUP o Create a New Supervisor Select Group Select Supervisor Select User Type in new name Select Pwd Type in new password Confirm Pwd retype password i 8722 7 Bv E Press the Face Button to add NEC USER SETUP This screen has a Supervisor security level and is used to setup individual operators The setup table has the following GROUP A drop down list that initially lists three 3 groups Supervisor Operator Guest USER A drop down list that displays operator names PWD An area for adding a password CONFIRM PWD An area t
10. Control System Machine Specifications 1 2 Capsule Information 1 2 1 Size The MODEL 10 is designed to fill capsule sizes sizes 000 through 4 DB A DB B and DB AA The appropriate parts must be installed each time a different capsule size is to be run refer to Section 3 1 2 Orientation positioning of the capsules during processing is important Capsules in the cap up and cap down positions are shown below Capsule positioning rectification is described in Section 1 4 1 2 2 Environmental Conditions The humidity and temperature of the area around the machine will influence the flow of the capsules High humidity especially can promote stickiness in the capsules leading to jams in the rectifying system Chapter 1 Page 7 of 19 1 3 The Capsule Rings 1 3 1 Introduction The capsule rings hold the capsules during the capsule filliing process The capsule ring set consists of a matched pair of rings body and cap rings designed to accommodate a particular size of capsule Because of this only a matched set must be used for the appropriate capsule size Incorrectly matched rings rings for two different capsule sizes will not seat correctly when joined Capsules of one size cannot be processed in a ring set designed for another size 1 3 2 Diagram The capsule ring set is shown in the diagram below SLOSS Sey CAP RING BODY RING Capsule Ring Set 1 3 3 Composition These rings ar
11. Environmental Conditions 7 1 3 The Capsule Rings 8 1 3 1 Introduction 8 1 3 2 Diagram 8 1 93 39 Composition 8 1 4 The Rectifying system 9 1 4 1 Introduction 9 1 4 2 The Capsule Path 1 4 3 Phases of Operation 10 1 4 4 Capsule Entry 10 1 4 5 Capsule Positioning Rectification 10 1 4 6 Capsule Feeding and Separation 12 165 The Filling System 13 1 5 1 Introduction 13 1 5 2 System Diagram 13 1 5 3 Filing the Capsules 14 1 6 The Closing or Closure System 15 1 6 1 Introduction 15 1 6 2 Assembly Diagram 15 1 6 3 Closing the Capsule 15 1 6 4 Capsule Ejection 16 1 7 The Air Vacuum System 16 1 7 1 Introduction 16 1 8 The Computer Control System 17 1 8 1 Introduction 17 1 8 2 Push Buttons Inputs 17 1 8 3 HMI Touch Panel Inputs 17 Table of Contents Page 1 of 4 SECTION 2 2 2 2 1 2 2 2 2 3 2 3 1 2 3 2 2 4 2 4 1 2 4 2 2 5 2 5 1 2 5 2 2 5 3 2 5 4 2 9 9 2 5 6 Lod TITLE Sensor Inputs Controller Outputs Motors Controller Outputs Solenoids Controller Outputs Counter Specifications for Model 10 Dimensions Weight Motors Power Air Vacuum CHAPTER 2 ROUTINE OPERATION Overview Definition Machine Preparation Machine Operation Chapter Contents Warning Labels and Locations Part A MACHINE PREPARATION How to Fill the Powder Hopper Introduction Procedure How to Load the Capsules Introduction Procedure Part B MACHINE OPERATION Overview Three stages Flow of operation Rectifying Filling
12. No vacuum insufficient vacuum Unmatched rings Cap and body rings not aligned Dirty rings oil deposits in cavities Damaged body cap ring Chapter 5 Page 4 of 12 If correct capsules are being processed change to matching sized rings Position the ring clockwise against the pin Replace with new guide block Clear openings of capsule ring Clean vacuum filter see section 4 3 Replace vacuum pump Check that the vacuum valve is opening and adjust air pressure to the valve Adjust vacuum control valve Check and clean replace vacuum filter see section 4 3 Check for obstructions in the vacuum line Replace vacuum pump Be sure the body and cap rings are the same size capsules Be sure the body and cap ring serial numbers match Clean ring cavities amp dry Replace the rings 5 1 2 Troubleshooting Guide Filling Section PROBLEM POSSIBLE CAUSE SOLUTION Capsules damaged Too much product on tables Keep the turntable clean during processing at all times Capsule bodies extend above Always slide your hand over the the body ring during process body ring prior to starting to fill the capsules and push down any protruding capsules Turntable either Proximity switch needs Adjust appropriate switch by continues rotating adjustment referring to Section 4 5 after cycle Auger does not start Proximity switch needs Adjust appropriate switch by after hopper swings adjustment referring to S
13. a d ayy A F Nee FILTER z SPRING VACUUM GASKETS CLIPS CANISTER LID 3 Unlatch the 8 spring clips on the vacuum filter canister and remove the vacuum canister lid Lid has gasket on inside hub DO NOT LOOSE T DO NOT RUN without gaskets in place vacuum pump could be severely damaged 4 Remove the filter from inside the canister inspect and clean or change as required 5 Install the filter and replace the lid Make sure the gaskets are in place latch the 3 spring clips to attach the lid to the canister Close the rear door Chapter 4 Page 9 of 22 4 4 Air and Electrical Diagrams Inside Manual Cover 4 5 How to Adjust Proximity Switches 4 5 1 Introduction Some steps in the machine s processing are dependent on the activation of proximity switches When the switch is activated a step in the process begins or ends There are four 5 proximity switches in the machine The table below gives their names and functions a S 1 Table Home on full rotation of the fill table completed PROX 2 Auger Hopper at Fill Signals the hopper has rotated into position over the Position capsules starts the filling process PROX 3 Closure Unit Ensures drawer with capsule ring set is in closed position Sends a to begin closing process PROX 4 Rectifier Table Home Signals one full rotation completed PROX 5 Auger Hopper at Home Signals the hopper i
14. auger and lift upward until it is positioned in the holding bracket Tighten the four 4 black plastic knurled screws The filling port must be up in the cutout out of the hopper assembly 11 For Powder Make sure the powder return gasket is in position in the filling block mount the powder filling shoe to the filling shoe block with the two 2 locking nuts on the studs and lightly tighten Adjustment procedure for the clearance of the filling shoe to the ring refer to Section 4 11 Slide the filling shoe block onto the bottom of the hopper and reinstall the shoulder bolts Check to be sure the hopper shaft is unobstructed For Pellets Make sure the powder return gasket is in position in the filling block mount the pellet filling shoe to the filling shoe block with the two 2 locking nuts on the studs and lightly tighten Adjustment procedure for the clearance of the filling shoe to the ring refer to Section 4 11 Slide the filling shoe block onto the bottom of the hopper and reinstall the shoulder bolts Check to be sure the hopper shaft is unobstructed T CAUTION Do not over tighten over torque the two 2 locking nuts on the studs This can warp the filling shoe and possible damage the filling rings Chapter 4 Page 7 of 22 4 2 How to Clean the Powder Hopper continued 4 2 2 Procedure 12 Return to the rear of the machine Using the jack raise enough to remove pressure from the safety latch and disengage the
15. breakers have tripped CB2P 1 THRU oe CB2P 4 and CB1P 1 If one has tripped reset the breaker If no electric shock burn breaker has tripped proceed to the next step crt 5 Turn the main power ON If everything is ok and functioning properly system power before servicing proceed to line 7 If the circuit breaker trips a second time STOP and Read and understand 4 manual b tare call customer service at Schaefer Technologies Inc If a fuse has blown Only qualified personnel the blown fuse indicator fuses F1 thru F10 and F20 thru F23 holding He the fuse will indicate the location of the blown fuse Note the fuse number and turn the main power OFF Use Lockout Tagout Procedure Chapter 4 Page 14 of 22 4 6 How To Replace The Fuses and Reset The Circuit Breakers 4 6 2 Procedure 6 Pull the blown fuse and blown fuse indicator straight out Remove the fuse from the indicator and install the new fuse in the indicator Insert the fuse indicator with the new fuse in place into the panel making sure it is properly seated Go Back and repeat set 5 If the fuse blows a second time STOP and call customer service at Schaefer Technologies Inc 7 Turn the main power OFF Use Lockout Tagout procedure Close the electrical box panel and secure it in place by tightening the latch at the top 8 Position the machine s side panel and re install the safety screw and Socket head sc
16. each recipe must be individually deleted e New touch button This is used for setting up additional recipes When selected a new recipe is PRODUCTS made and given a default system name The supervisor can elect to rename the recipe by selecting it from the Recipe drop down list A pop up window will display an alpha numeric keypad used to edit the name Once edits are made the Enter touch button will return to the Recipe Setup screen Three new presets will be inserted into the table and will have a zero value for each Delete Each preset value will need to be changed Select a preset value from the table and a pop up window will display a numeric keypad Each preset has a min max value displayed under the editing window The new value entered must be between the min max values otherwise the value will not be recorded Once the appropriate value is entered select the Enter touch button Perform this sequence for each preset and when finished select the save touch button to record the values for the new recipe in the Recipe Group Chapter 5 Page 11 of 12 Formula Touch buttons e Beads touch button located on the Formula FORMULA HEHU Menu screen is unique when compared to the other formula touch buttons order to protect the RECIPE GROUP drives min max parameters are setup on all the bee 0 M motor drive presets However when the Bead Run touch button is sele
17. is pressed there is a slight delay as the system is allowed to reach full air and vacuum pressure The machine is now ready to operate 6 Press the CLOSING STATION button to access the closing station screen CLOSING STATION SCREEN CLOSING STAION lhaBbCendEe Mae The SHIFT RING COUNTER and the TOTAL RING 1 411 COUNTER may be reset to zero See Chapter 5 for instructions This screen also gives a visual reference for the closing station delay The closing station has the ability to repeat the closing cycle WITHOUT advancing the counter as long as those closing cycles are completed within 7 seconds of the first cycle The counter displayed as 12 now is in seconds and starts at 1 and u 12345678 2345678 YACU M OFF T 123456 23456 RESET counts to 7 During this time the green light is on and the capsule closing cycle may be ran WITHOUT advancing the counter At the end of 7 seconds the Green Light goes out and the closing C WHEN LIT cycle WILL advance the counter OKAY RECAP Chapter 2 9 of 15 2 5 RECTIFYING FILLING AND CLOSING THE CAPSULES 2 5 3 Procedure Machine Startup and Display Settings 7 The Formula Menu Screen allows the Supervisor to create custom menus for the various products that are being filled Gp See Chapter 5 Pg 9 thru 12 for detailed formula and recipe setup instructions Note When the Formula_01 page first comes up the numbers in the Fill Drive Au
18. of your choice previously positioned below the closing station After righting the closure assembly the ring set can then be removed by releasing the wing clamp and lifting straight up and returned to the rectifier turntable to receive the next load of empty capsules CAPSULES BEING EJECTED 1 7 AirNacuum System 1 7 1 Introduction A constant supply of air is introduced into the vacuum air system of the capsule filling machine to provide the following e air to the rectifier manifold powder hopper air cylinder and closing air cylinder e air to operate the vacuum air valve e vacuum for capsule separation at the rectifier feed table Settings for this system are discussed in Section 4 9 How to Adjust the Machine s Air Pressures Chapter 1 Page 16 of 19 1 8 The Computer Control System 1 8 1 Introduction The MODEL 10 operation is controlled by the Telemecanique programmable controller Through its inputs the computer reads in signals and turns on one or more of its outputs based on the logic programmed into the computer memory The input and output functions controlled by the computer include starting and stopping motors turning on solenoids reading sensors and switches These signals during routine operation are described in the sections below 1 8 2 Push Button Inputs The RECTIFIER START button turns on the rectifier turntable to fill a ring with empty capsules The RECTIFIER STOP button stops t
19. screws Chapter 4 Page 19 of 22 4 11 How To Agjust Filling Shoe 4 11 2 Procedure 3 If there is excessive clearance between the filling shoe and the ring the two nuts should be loosened and the set screws tightened Once the clearance is set the two 2 nuts should be snugged up tightened just enough to bring the filling shoe in contact with the adjusting screws at the 003 004 clearance setting the clearance may need to be increased to prevent this The clearance can vary based on pellet size Q Note WHEN FEEDING PELLETS If shearing or crushing of the pellets occurs Q CAUTION Do not over tighten over torque the two 2 locking nuts on the Studs This can warp the filling shoe and possible damage the filling rings 4 fthere is not enough clearance between the filling shoe and the ring the adjusting set screws should be loosened and then the locking nuts tightened snugged up on the two 2 studs 5 Remove the gauge and swing the powder hopper assembly into position over the rest shoe Chapter 4 Page 20 of 22 4 12 Becker Pump Filter Service 4 12 1 4 12 2 Introduction The pumps internal filter needs to be cleaned or replaced after 500 hours of service See service tag photo Procedure 4 12 2 line 6 Procedure Use the following procedure to clean or replace the internal filter 1 Use the procedure in 4 6 2 steps 1 and 2 to remove the panel the back of the machine 2 Remov
20. to the OFF position upon completion Note as a general guideline Flow should be no more than need to persuade the capsules to keep moving Excessive flow can adversely effect the vacuum valve operation Larger capsules require less air flow AIR FILTER BLEED SCREW 5 Position the machine s rear panel with the door to the right in the retaining clips and close the hinged door making sure the interlock is positioned correctly Fasten with one 1 safety screw and two 2 socket head screws Chapter 4 Page 17 of 22 4 10 How to Adjust the Closing Station 4 10 1 Introduction Alignment of the closing station is important for proper capsule closure and Ensure proper switch activation 4 10 2 Procedure 1 Turn the vacuum power switch OFF and the Main Disconnect Switch OFF shown Use Lockout Tagout procedure Open the rear interlocked door 2 Locate the two 2 adjustment bolts at the rear of the closing station ADJUSTMENT BOLTS 3 Move to the front of the machine and secure a matched ring set on the closing station as you would during routine operation 4 Push the closing station completely into the machine again as you would during routine operation 5 Position yourself so that the closing pad and the top of the ring set are at eye level 6 Ifthese do not appear parallel even with each other then the closing station should be adjusted 7 Ifthe closing station is slightly tilted note the direction o
21. 1 16 jam nuts and adjusting the switch up or down Chapter 4 Page 11 of 22 4 5 3 Switch Adjustment Closing Station PROX 3 1 Turn the Master Disconnect Switch OFF Use Lockout Tag out procedure The closing station prox3 switch is adjusted with all power and air supply OFF 2 Loosen the slotted bracket and move to end of slot Towards rear of machine Loosen the jam nuts on the switch body and adjust the switch CCW several turns Place a complete ring set cap and body on the closing station and push the assembly into the machine 4 Adjust the slotted bracket shown below to the middle of the slots and tighten Turn the switch body CW until contact LIGHT contact is made between the switch and ring set and tighten the lock nuts 5 Loosen the bracket and move towards the rear of machine 060 090 inch and tighten bracket Q Caution The switch should be within range to detect the ring 060 090 BUT SHOULD NOT TOUCH THE RING Chapter 4 Page 12 of 22 4 6 How to Replace The Fuses and Reset The Circuit Breakers 4 6 1 Introduction There are nine 9 fuses F1 thru F5 and F20 F21 F22 F24 and seven 7 circuit breakers CB1 thru CB7 in the electrical system They are located in the electrical box inside the right side of the machine The following procedures indicate step by step how to locate and replace the fuses and reset the circuit breakers 4 6 2 Procedure Follow the steps below t
22. 3234102 ay Dui e1sul ains esea d 55 5185 1uaJajJIp os a nsde jo ezis auo ueu 0 aJe sued awos aas ue sy iquiassy 3insopj 91145 E 0 13 00 13 00 72018 T1 vv 8 13 00 13 00 v 8d t oo 00 x20 g paa4 jquiassy 131223 3215 000 31504 19215 jnsdes sued ay 5 Sup AGEL 9215 2 1 59 aq 01 si suo JY Woy 2215 3u2J3jJIp e jo a nsde e Jsnw aJns0 pue 47 sed 2215 pais IINSO D MEJO uoIs 12AU0 2216 Chapter 3 3 of 14 3 1 3 Change Parts Illustrated below are the size dependent parts that must be change when a capsule of a different size from the previous one is to be processed Rectifier Assembly Rotation Module Rectifier Block Assembly Guide Chute Closure Assembly 2 ad b M Peg Ring Closing Pressure Plate Chapter 3 Page 4 of 14 3 2 How to Convert the Rectifier Assembly 3 2 1 Diagram The diagram below shows the changeable parts of the rectifier assembly SHOWN FOR REFERENCE
23. AUGER MOTOR powers the auger for continuous powder distribution into the empty capsule bodies Controller Outputs Solenoids The HOPPER POSITION SOLENOID 5011 controls the air cylinder that owings the powder hopper over the fill table and back to its standby position The RECTIFIER VACUUM SOLENOID SOL2 supplies the vacuum needed to separate the capsules at the rectifier turntable and forced air to the rotation module The SOFT START SOLENOID 5013 controls the air dump valve The CAPSULE CLOSING SOLENOID 5014 controls the air cylinder that reassembles the capsules by pressing with the peg ring the capsule bodies up into the caps See drawing 33982905 for locations Controller Output Counter The RING COUNTER counts the number of completed capsule rings Chapter 1 Page 18 of 19 1 9 Specifications for the STI MODEL 10 Ver 4 2 1 9 1 Dimensions e Height 73 1 4 inches with casters e Width 48 inches e Depth 30 inches This machine requires 36 square feet of floor space 1 9 2 Weight This machine weighs approximately 1 000 Ibs 1 9 3 Motors Horsepower hp Current Assembly Location 1 Rectifier Auger Fill Table Vacuum Pump Drive BECKER 1 9 4 Power e 190 200 208 220 230 380 400 415 440 460 or 480 volt e 50 or 60 cycle e phases e Total load is approximately 2 0 KW 1 9 5 Air e 80psi e 3cfm 5 5 Bar Chapter 1 Page 19 of 19 CHAPTER 2 ROUTINE OPERATION M
24. ES INTO THE MACHINE for the Fill Drive the Auger Drive and the BEADS RUN Pressing for 2 seconds turns the auger off for bead filling formulas Note This setting is modal and will PUSHED BEAD RESET Pressing for 2 seconds turns the auger back STATUS Pressing the Status button brings up the Formula AaBbCcDdEeF f Status Page where the Vacuum Air Flow and Closing FILL DRIVE SPEED FORMULA This display screen allows the operator to select the recipe RECIPE GROUP RECIPES product is selected YOU MUST PRESS THE SEND Rectifier Drive a stay in effect UNTIL THE BEAD RESET BUTTION IS FORMULA STATUS E on for formulas requiring auger fill Station values input and settings are confirmed AUGER DRIVE SPEED Air and Vacuum Settings The ADJUST VACUUM the ADJUST AIR FLOW TO and the ADJUST CLOSING STATION TO gives the operator the Air and Vacuum settings for the eile SSUES calculated formula The operator must adjust these settings ADJUST ADJUST AIR Hus manually FLOW TO STATION TO RECTIFIER ORI E SPEED Recipe Recipe J The FORMULA SETUP SCREEN See Detailed Instructions for Creating and Editing Formulas Snapshot Delete AE naBbCcDdEe Miel Help Screen Pushing the arrow of the category P ERREEN MAINTENANCE Hiii you want help with will call up the information and briefly describe its use m Rec
25. STI MODELI O Ver 4 2 Capsule Filling Machine OPERATION AND MAINTENANCE MANUAL STI MODEL 10 Ver 4 2 SPECIFICATIONS Dimensions 30 deep 55 wide 73 1 4 high with casters Weight Approximately 1 000 pounds Floor space to operate 36 square feet Motors All drive independent units 4 HP AC for rectifier Y HP AC for auger V HP AC for rotary table 1 HP AC 3 phase vacuum pump drive All drives are sealed gear boxes with toothed belt power transmission Oil Less vacuum pump is self contained inside The machine pump requires no water Qualified technical service engineers are available upon request Size changeover 30 minutes or less no realignment required Uses standard Model 8 style filling ring Product run on Model 81M type machine does not require reformulation Uses standard Model 81M type machine auger Designed to fill popular capsule sizes Will operate on 190 200 208 220 230 380 400 415 440 460 or 480 volt three phase power Uses approximately 2 KW Requires 80 psi air service at approximately 3 CFM air flow STI Model 10 Ver 4 2 TABLE OF CONTENTS Chapter 1 Introduction SECTION TITLE PAGE 1 1 Introduction and General Recommendations 2 EC Compliance Statement General Safety Regulations amp Warnings 3 1 11 Overview 1 1 1 Purpose of the Machine 6 1 1 2 Features of this Model 6 1 1 3 Chapter Contents 7 1 2 Capsule Information 7 1 2 1 Size 7 1 2 2
26. TOR rpm 2353 2187 Prezeti312 SO MIN MAX zii 1750 Max EIL IM 1234 1234 1234 E DRIYE STATUS RaBbCeDdEe bel PRESET MP SPEED SPEED 123412 1234 12 1234 12 Fuse RECTIFIER RECTIFIER DIAGHOS TICE AUGER a 123412 8 125412 25412 SPEED 123412 8 125412 1234 12 FILL AMPE ZPEED FILL DIAGNOSTICS ALARMS The alarm screen displays a table that will list machine alarms If an alarm occurs the table indicates the date time and alarm status The alarm shows RED As the alarm condition is corrected the machine status is automatically corrected this does not remove the alarm message from the screen the alarm acknowledgement button must be pushed for each alarm message to remove it from the screen Use the bottom and side scroll bars to allow the display of the complete description and all the alarms CLOSING STATION This screen displays two 2 different types of counters The first Total Ring Counter is a continuous counter used to indicate the total number of rings ran for the history of the machine The second is a shift counter that displays the number of rings ran for a certain shift Both of these have a Reset feature that Requires Supervisor Rights to activate From this screen the SHIFT COUNTER RESET can be used to zero the SHIFT COUNTER 2 second button
27. and Closing the Capsules Definition Prerequisites Procedures Adjustments Setting the Vacuum Rectifying the Capsules Filling the Capsules Closing the Capsules Table of Contents Page 2 of 4 02 0 Co DPD nO C1 O1 O OD SECTION w 3 2 322 3 3 3 3 1 3 3 2 4 1 3 4 2 2 4 8 4 9 4 9 1 4 9 2 4 9 3 CHAPTER 3 CAPSULE SIZE CONVERSION TITLE Overview Size Table Change Parts How to Convert the Rectifier Assembly Diagram Procedure How to Convert the Closure Assembly Diagram Procedure CHAPTER 4 MAINTENANCE AND REPAIR Overview Maintenance Repair Troubleshooting and Repair How to Clean the Powder Hopper Introduction Procedure Powder amp Pellet Shoe Information How to Replace the Vacuum Filter Introduction Procedure Air and Electrical Diagrams How to Adjust the Proximity Switches Introduction Switch Adjustment Rectifier Fill Table Switch Adjustment Hopper Position Switch Adjustment Closing Position How to Replace the Fuses amp Reset Circuit Breakers Introduction Procedure Circuit Breakers and Fuses The Control Box Computer How to Adjust the 5 Air Pressure Introduction Adjustment Knob Location Pressure Adjustments Table of Contents Page 3 of 4 PAGE AON O1 WW CO CO CO SECTION 4 10 4 10 1 4 10 2 4 11 1 4 11 2 4 12 4 12 1 4 12 2 TITLE How to Adjust the Closing Station Int
28. capsules first sit in the rectifier block positioned in both directions cap down Random Positions Rectifier Block Chapter 1 Page 10 of 19 1 4 The System 1 4 5 Capsule Positioning Rectification The rectification of the capsules within the rectifier block by the rectifying blade is shown below Capsule Sitting Cap up blade enters and flips capsule up Capsule Sitting Body up blade enters and flips capsule down Capsules Flipped by Blade The final position orientation of both capsules in the example below are identical the bodies positioned toward the rectifier block exit 2 iN Capsules Positioned for Feeding Chapter 1 Page 11 of 19 1 4 The Rectifying System 1 4 6 Capsule Feeding and Separation When the RECTIFIER START button is pushed capsules are ejected first from the rectifier block by Delrin pins They are pushed into the rotation module and are rotated downward by an air stream through the guide chute and into the ring set The larger sized cap of the capsule is retained in the cap ring as the capsule body is separated from the cap and pulled into the bottom body ring by vacuum originating from below the ring The turntable supporting the ring set rotates continuously until the ring is filled with capsules and then automatically stops Chapter 1 Page 12 of 19 1 5 The Filling System 1 5 1 Introduction
29. cted the Auger motor speed 5 58 set to Zero This is performed using the PLC which monitors the touch button and allows the drive value to be set outside of the min max parameter This Le Ed FORMULA SETUP shuts off the Auger Motor even though the Beads formula has a value Therefore any changes made to the Beads recipe for the Auger preset will be nullified when the Bead Run touch button is selected Note When the Beads formula is used and the Bead Run touch button is selected the Auger drive is turned off and will remain in this state until the Bead Reset button has been pushed Formula Status Screen e When the formula has been selected and the FORMULA STATUS SEND Button must be pressed for 2 AaBbCcDdEeF f GgH x seconds on the Formula Menu Screen FILL DRIVE SPEED pushed Pushing the Status Button will select AUGER DRI E SPEED the Formula Status Screen The Status Screen will display the selected formula s RECTIFIER DRIYE SPEED current drive information AIR amp VACUUM SETTINGS ADJUST e The vacuum air flow and closing station ADAU T AR CLOSING Set IL TATION TO settings are displayed This is an Operator informational area These values DO NOT adjust the machine They must be set by the operator Chapter 5 Page 12 of 12 6 RECOMMENDED SPARE PARTS LISTS Model 10 Ver 4 2 Chapter 6 Page 1 o
30. ded through the cutout in the side of the hopper The step by step procedure can be found in Section 2 2 When this is completed the machine is ready for processing the appropriate sized capsules Chapter 3 Page 14 of 14 4 MAINTENANCE AND REPAIR Model 10 Ver 4 2 Chapter 4 Page 1 of 22 4 MAINTENANCE REPAIR 020 4 1 Overview 411 Maintenance Maintenance consists mainly of keeping the machine clean The tabletops should be cleaned after each run In addition to this cleanup the following procedures are considered routine machine maintenance e Cleaning the powder hopper Section 4 2 e Cleaning and replacing the vacuum filter Section 4 3 e Bleeding the air filter daily and adjusting the air pressure Section 4 9 Filling shoe adjustment sect 4 11 4 1 2 Repair Repair of the machine includes replacing malfunctioning parts such as e Proximity switches e Fuses The diagrams and parts lists in Chapter 6 will be of help if other parts should require replacement 4 1 3 Troubleshooting and Machine Maintenance Chapter 5 Troubleshooting and Machine Maintenance relates to Chapter 4 by including procedure references in the troubleshooting table One of the purposes of the Solution column is to provide replacement procedure locations in Chapter 4 Chapter 4 Page 2 of 22 4 2 How to Clean the Powder Hopper 4 2 1 Introduction This procedure is to be performed whe
31. e machined from aluminum It is important that you handle the rings carefully to prevent nicks in the metal that can cause improper seating of the rings with one another If nicks occur capsules may not be injected properly into the ring set or may fail to separate Chapter 1 Page 8 of 19 1 4 The System 1 4 1 Introduction In order for the capsules to be opened and filled they must all be positioned oriented in the capsule rings in the same direction bodies down This process is called rectification and is performed by the rectifying system 1 4 2 The Capsule s Path The diagram below shows the typical path of a capsule through the rectifying system RECTIFIER ASSEMBLY CAPSULES Capsule Path Chapter 1 Page 9 of 19 1 4 The System 1 4 3 Phases of Operation There are three phases of capsule processing in the rectifier assembly e capsule entry e capsule positioning rectification and e capsule feeding into the ring set 1 4 4 Capsule Entry The capsule hopper at the top of the assembly holds capsules until they are fed by gravity into one of the holes in the upper feed block At this point the capsules are positioned both cap up and cap down As the capsules below them are processed the capsules move down through the holes in the feed block into the rectifier block 1 4 5 Capsule Positioning Rectification As shown below the
32. e rate of flow of capsules from the capsule hopper to the top of the rectifier N be controlled by slightly opening or closing the hopper HOPPER DOOR Chapter 2 Page 6 of 15 Part B MACHINE OPERATION Read and understand operation manual prior to operating or servicing this machine Failure to follow operating instructions could result in personal injury or damage to the equipment 2 4 Overview 2 4 1 Three Stages Once the machine is properly prepared the following procedures are performed by the machine with the operator s assistance e positioning and separating the capsules e filling the capsules e closing and ejecting the capsules 2 4 2 The Flow of Operation The procedures described above always occur in the sequence shown with The machine powered ON throughout The vacuum pump remains ON throughout the procedures as well As you gain more experience you will be able to process capsule rings in two or three stages of operation at the same time The machine is designed to allow a smooth flow through these different stages 2 5 RECTIFYING FILLING AND CLOSING THE CAPSULES 2 5 1 Definition The term rectify means to make unidirectional one direction or set right The rectifier assembly is so named because this is where all capsules are positioned body down to be drawn by vacuum into the capsule filling rings for separation 2 5 2 Pre requisites Before Starting Before the filling proce
33. e the 2 socket head screws holding the shroud in place and set aside ded i ms 2 j qct pe te e NS V lt ese a 22 7 E amp 3 5 SCHEWS dre k 3 Remove the 3 socket head screws that attach the filter housing Pull the filter housing straight out to access the filter SCREWS 4 Use compressed air vacuum or combination of both to clean the filter If filter cannot be cleaned satisfactorily replace the filter Chapter 4 Page 21 of 22 4 12 Becker Pump Filter Service 4 12 2 Procedure FILTER 5 Vacuum to remove any carbon or loose product prior to re assembly 6 Reassemble in the reverse order of the disassembly instructions 7 Position the machine s rear panel with the door to the right in the retaining clips and close the hinged door making sure the interlock is positioned correctly Fasten with one 1 safety screw and two 2 socket head screws Chapter 4 Page 22 of 22 5 TROUBLE SHOOTING AND MACHINE MAINTAINANCE Model 10 Ver 4 2 Chapter 5 Page 1 of 12 CHAPTER 5 TROUBLESHOOTING and MACHINE MAINTENANCE 5 Overview o 5 1 1 Definition Investigating problems encountered during routine operation is called Troubleshooting 5 1 2 Troubleshooting Guide The table in this chapter Section 5 2 offers reasons for and solution to those problems you might encounter du
34. ead and understand operation manual prior to operating or Q o servicing this machine Lockout machine prior to servicing qv Failure to follow operating instructions could result in personal injury or damage to the equipment 2 2 How to Fill the Powder Hopper 2 2 1 Introduction The desired filler material must be placed in the powder hopper before starting the filling process 2 2 2 Procedure Follow this procedure to fill the powder hopper 1 Raise the powder hopper lid and using a scoop add the product THE MAXIMUM POWDER FILL HEIGHT SHOULD BE APPROX 2 INCHES ABOVE WHERE STRAIGHT DIAMETER OF THE HOPPER AND THE TAPERED AREA MEET 2 Fill the hopper according to the number of capsules to be filled As you are operating the machine keep the hopper full enough to maintain the weight required 3 Clean up any spilled material before starting machine operation either by vacuuming brushing to the powder catch tray or wiping with a clean damp cloth Chapter 2 Page 5 of 15 2 3 How to Load the Capsules 2 3 1 Introduction These are the steps in preparing capsules for routine operation Be sure the capsules to be loaded are the correct size for the parts on the machine If a different size is to be used refer to Section 3 before proceeding 2 3 2 Procedure 1 Remove the lid from the capsule container 2 Hand feed scoop the capsules into the top of the capsule hopper CAPSULE HOPPER NOTE Th
35. ection 4 5 into position Blown fuse Replace fuse Section 4 6 Filing shoe dragging Filing shoe not properly Adjust filling shoe body ring on body ring Adjusted clearance Section 4 11 Fill Table not properly cleaned Clean powder from fill table Excessive powder left on top Filling shoe not properly adjusted Adjust filling shoe body ring of ring clearance Section 4 11 Fill weight not consistent Filling shoe not properly adjusted Adjust filling shoe body ring across the ring inside to clearance Section 4 11 outside Hopper stop out of position Adjust position of hopper stop Closing Section Filled capsules fail Bent peg on peg ring Straighten pegs if possible to join properly otherwise replace with new peg ring Cap and body rings not aligned Straighten ring pins or bent ring pins or damaged replace bushings bushings Capsules only partially joined Replace current pad with pad wrong closure pad corresponding to capsule size being processed section 3 1 2 Capsules only partially joined Adjust closing cylinder incorrect air pressure air pressure Closure assembly fails Proximity switch needs Adjust appropriate switch by to operate after adjustment referring to Section 4 5 drawer is closed No ring set in assembly Place ring set on assembly Chapter 5 Page 5 of 12 5 1 4 MACHINE MAINTAINENCE HMI TOUCH SCREENS amp DESCRIPTIONS USER SETUP This screen has a Supervisor security level and is used t
36. eft hand and tilt the assembly away from you When the capsules have dropped into the bin return the assembly to its original upright position Pinch point hazard Keep hands clear 2 Turn the wing clamp to free the wings lift the rings straight up and return to Positioning and Separating the Capsules Section 2 5 to repeat the process QD NOTE The de duster drawer should be emptied when necessary Chapter 2 Page 15 of 15 CHAPTER 3 CAPSULE SIZE CONVERSION Model 10 Ver 4 2 Chapter 3 Page 1 of 14 Chapter 3 CAPSULE SIZE CONVERSION 3 1 Overview 3 1 1 Change Parts Listed below are the size dependent parts that must be changed when A capsule of a different size from the previous one is to be processed Rectifier Assembly e feed block e guide chute e rotation module e rectifier block e capsule ring set Closure Assembly e peg ring e closure pad OQ See 3 1 2 for Capsule Size Conversion Chart for the Rectifier and Closure change parts Where to Find the Procedures The following sections contain procedures for changing the parts affected by using a different sized capsule OR PROCEDURE How to Covert the Rectifier Assembly How to Convert the Closure Assembly How to Change the Powder Product Chapter 3 Page 2 of 14 Capsule Size Conversion Chart 3 1 2 paisi sued jeuonippe anbal osje 000 9215 ajnsde yss azis ajnsde uaym sued
37. f 4 61 Recommended Spare Parts Rectifier Part Number DESCRIPTION CF 2545 CF 2537 RECTIFIER MOTOR DRIVE BELT CF 2538 CF 2200 RECTIFIER BLOCK MOUNTING BOLTS CF 2123 2139 RECTIFIER FLAT COPPER SPRINGS CF 2180 RECTIFIER CAM CF 2182 EJECTOR CAM CF 2240 CRANK ARM CF 2264 RECTIFIER BEARING SPACER CF 2323 VACUUM PORT BLOCK CF 3203 DRIVE MOTOR 4 HP AC CF 2541 CF 2544 MASTER LINK FOR RECTIFIER CRANK ARM CF 2783 CF 2552 CF 2553 EJECTOR ROD COMPRESSION SPRING SIZE 1 THRU 4 CF 2673 2713 2504 RECTIFIER SHAFT SNAP RING RETAINER CF 2503 UPPER CRANK ARM SHOULDER BOLT CF 2632 CF 2502 LOWER CRANK ARM SHOULDER BOLT HARDWARE RECTIFIER DRIVE BELT RECTIFIER TABLE DRIVE BELT ROTATION LOCATOR PIN RECTIFIER SHAFT PILLOW BLOCK SLIDE BEARING 1 LINK FOR RECTIFIER CRANK ARM ROLLER BEARING SHAFT SPRING EJECTOR ROD COMPRESSION SPRING SIZE 000 THRU 0 BRAKE RELAY UPPER CRANK S ARM THRUST WASHER CF 2501 LOWER CRANK ARM SLEEVE BUSHING CF 2500 LOWER CRANK ARM SPACER CF 2641 CRANK ARM EXTENSION SPRING CF 2109 LIFTING PLATE CF 2154 RETAINER BAR BAR CAMS REPLACE AS SET STAINLESS STEEL SHCS 10 24 X 1 LG STAINLESS STEEL SHCS 6 32 X 1 4 LG for CF 2139 HARDWARE STAINLESS STEEL SHCS 8 32 X 1 2 LG for pillow blocks Chapter 6 Page 2 of 4 6 2 Recommended Spare Parts Fill Station Part Number DESCRIPTION REQ D 2186 AUGER SPACER CF 2372 GASKET
38. f the tilt and return to rear of the machine 8 Using a hex wrench loosen the bolts and slide the guide until from the front the closure pad and ring set look parallel to each other Tighten the bolts 9 Close the rear door and remove the ring set from the closing station Chapter 4 Page 18 of 22 4 11 How To Adjust Filling Shoe To Capsule Body Ring Clearance 4 11 1 Introduction Proper ring clearance is required for weight control of filled capsules and to prevent damage to the ring set This procedure is to be performed each time The powder hopper is disassembled for cleaning or maintenance 4 11 2 Procedure For Powder or Pellets 1 With the power OFF and a capsule ring on the fill table swing the powder hopper assembly over the ring set 2 Check the clearance from the filling shoe to the body ring with a standard sheet of notebook paper 0 003 to 0 004 in The paper or feeler gauge if used should slide between the filling shoe and the ring with a slight drag If no drag is felt or the gauge will not slide through adjust the filling shoe by following the rest of this procedure PULL UP STUD 2 PLACES Filling Shoe Powder Filling Shoe Pellet Filling Shoe Over Body Ring There are three 3 set screws and two 2 studs with locking nuts that are used to adjust the filling shoe These three set screws actually adjust the filling shoe while the two studs hold the filling shoe up in contact with the set
39. ger Drive and Rectifier Drive represent the current state last speed ran that the drives are in NOT NECESSARILY what the formula requires 8 Operator e Accesses the Recipe Group and Recipes This displays the list of recipes available to run e Pushing the SEND BUTTON FOR TWO SECONDS THIS WILL CALCULATE AND INSERT THE CORRECT VALUES INTO THE MACHINE for the Fill Drive the Auger Drive and the Rectifier Drive This should be verified on the DRIVE FREQUENCY PAGE e the Formula Menu screen pressing the STATUS Button displays the information for the ADJUST VACUUM the ADJUST AIR FLOW TO and the ADJUST CLOSING STATION TO gives the operator the Air and Vacuum settings for the calculated formula Note These must be manually set by the operator FORMULA MENU FORMULA STATUS PAGE FORMULA MENU E FORMULA STATUS E cack AaBbCcDOdEeF f GgH BACE RECIPE GROUP FILL DRIVE SPEED Dee M AUGER DRIVE SPEED RECTIFIER DRIVE SPEED RECIPES _____ amp VACUUM SETTINGS ADJUST CLOSING STATION TO ADJUST ADJUST MR FLOW TO FORMULA SETUP DRIVE FREQUENCY IEEE l FILL MOTOR NOTE For BEADS the AUGER MOTOR SPEED is set to ZERO 0 AUGER MOTOR SPEED ipm RECT MOTOR SPEED HELP 2225 2157 Prezet1312 SO MIH F100 max
40. gs and information indicated by the following symbols and labels in this manual J Mandatory Danger Read manual Wear eye protection Wear safety gloves wx Electrical Current Specification 220 VOLTS Electrical Voltage Specification PINCH POINT Moving parts below Keep hands clear Caution Pinch Point Pinch point hazard Keep hands Caution Pinch point hazard Keep hands clear Shear hazard Warning Shear hazard Keep hands clear from under blades Turn power om undoing off before servicing Tam power OF before servicing Chapter 1 Page 3 of 19 Rotating parts n inside before servicing Keep hands clear Lackaut Lagaut belore servicing Warning Rotating parts inside Keep hands clear Lockout tagout swe Warning Hazardous Voltage A DANGER Danger Contact may cause Hazardous voltage Contact may cause electric shock or burn Tum et and lock out Turn off and lockout system power before servicing dom ied Read and understand manual before servicing Only qualified personnel should service this panel should service this panel HAZARDOUS VOLTAGE Contact may couse Warning Avoid injury Do not operate with guards removed Replace guards before operating machine For the safety of the operate win guards removes Personal DO NOT modify of remove any of thi
41. he appropriate rectifier block into the front of the module FRONT VIEW KNIFE BLADE CAM EJECTOR ROD ASSEMBLE CAM poring parts KNIFE BLADE EJECTOR ROD Keep hanes clear CAM ROLLEH CAM ROLLER Lockout tagout before servicing 4 HIDDEN HIDDEN o 5 4j BEHIND CAM PES Back View Chapter Page 9 of 14 3 2 How to Convert the Rectifier Assembly 3 2 2 Procedure 12 Return to the rear of the machine place the rectifier block into position Insert the shoulder bolts and while pulling back gently on the block thread the screws through the openings in the bottom and hand tighten Tighten completely with a hex wrench 13 Replace the back panel by positioning it then tightening the two 2 screws over the bar 14 To install the remaining capsule sized parts first install the feed block by inserting the two screws Q NOTE Be sure the retainer bar is on the front side of the springs Pinch point hazard Keep hands clear PROCEDURE 15 FEED BLOCK RETAINER BARS RECTIFIER BLOCK Chapter 3 Page 10 of 14 3 2 How to convert the rectifier assembly 3 2 2 Procedure 15 Atthis point the feed block should be slowly moved down into the rectifier block to verify alignment refer to Section 2 2 5 3 Procedure Machine Startup and Display Settings a Close the rectifier door until the interlock switch is engaged b On the HMI Touch Sc
42. he body ring and lift the two rings from the table Chapter 2 Page 13 of 15 2 5 RECTIFYING FILLING AND CLOSING THE CAPSULES 2 5 7 Procedure Closing the capsules The following procedure is the final stage of capsule processing 1 Place the set of rings containing the filled capsules on the closure assembly adjusting slightly left then right until it is seated securely above the pegs Lock the rings in place by turning the wing of the wing clamp until they lock over the inside of the ring Pinch point hazard Keep hands clear GD Note DO NOT push an empty ring assembly into the capsule closing mechanism and activate 2 When the clamp is secured push the assembly into the machine until the capsule closing mechanism is activated Pinch point hazard Keep hands clear Q Upon closing the Green light is illuminated located on the Closing Station page and stays GREEN for 7 seconds When the light is GREEN You can re close the capsules WITHOUT the counter advancing The RED Ring in Closing Position light is on during the closing cycle Chapter 2 Page 14 of 15 2 5 RECTIFYING FILLING AND CLOSING THE CAPSULES 2 5 8 Procedure Dumping the closed capsules NOTE Before proceeding with this step be sure there is a container under the drawer to receive the closed capsules 1 After the capsules are closed pull the drawer all the way out of the machine grasp the handle in your l
43. he motion of the rectifier only This might be necessary in the event of a capsule jam The FILL START button s turn on the auger and the filling table to fill a ring of empty capsules with product The large red EMERGENCY STOP button will shut down entire machine The Main Power switch turns on power to the machine 1 8 3 HMI Touch Panel Inputs see Chapter 5 1 8 4 Sensor Inputs The RECTIFIER TABLE sensor signals the Programmable Controller that the rectifier table has made one complete revolution The POWDER HOPPER FILL POSITION sensor signals that the powder hopper is in place over the fill table and starts the table and auger rotation automatically The POWDER HOPPER HOME POSITION sensor signals that the powder hopper is in the home position This is required for machine startup The FILL TABLE HOME sensor signals the Programmable Controller that the filling table has made one complete revolution The Closing Unit sensor ensures that the sliding ring drawer with ring is in the closed position and sends the signal to begin the closing process Chapter 1 17 of 19 1 8 The Computer Control System 1 8 5 1 8 6 1 8 7 Controller Outputs Motors The RECTIFIER MOTOR powers the rectifier head and the rectifier turntable as capsules are positioned then inserted into the ring set The FILL TABLE MOTOR turns the turntable beneath the powder hopper as empty capsule bodies are filled with material The
44. hold required The TOTAL RING COUNTER can be set to zero From this screen the TOTAL RING RESET can be used to zero the TOTAL RING COUNTER 2 second button hold required This screen also gives a visual reference for the closing station delay The closing station has the ability to repeat the closing cycle WITHOUT advancing the counter as long as those closing cycles are completed within 7 seconds of the first cycle The counter displayed as 12 now is in seconds and starts at 1 and counts to 7 During this time the green light is on and the capsule closing cycle may be ran WITHOUT advancing the counter At the end of 7 seconds the Green Light goes out and the closing cycle WILL advance the counter on the next closing cycle VACUUM ON VACUUM OFF The vacuum pump may be turned on or off from this screen DRIVE FREQUENCY This display screen is used to adjust the motor speed rpm for each drive controller Modifying these settings requires Supervisor Rights to access Displayed within each heading is the Min Max speed and Preset settings for that particular motor Under each heading is the Speed Reading Display that monitors motor speed A supervisor can adjust these settings by depressing the Speed Reading Display for 2 seconds Located at the bottom of the display is a Preset switch for each of the drives that resets the drive to their original Preset values A Supervisor can activate these settings by depressing
45. ill Preset Fill table speed Aug Preset Auger speed Rec Preset Rectifier speed Note Each preset value when selected uses a numeric keypad for use of editing the preset value Displayed under the editing window is the minimum and maximum settings that can be entered Attempting to enter a value outside the min max is not allowed and the text turns red in the editing window A brief description for each area Drop down Lists he HMI is programmed to perform all recipe searches within the Recipe Group Products No other group is used e Recipe stores the preset and custom recipes Chapter 5 Page 10 of 12 Recipe Group continued Touch buttons Send used whenever a custom recipe is setup or selected from the Recipe drop down menu e Save used to store the values entered for each recipe Note If changes are made to the presets amp the save touch button is not selected before leaving the editing pop up window the recipe values will be lost and will need to be re entered e Snapshot used to take readings from the drives as they run When the Snapshot touch button is selected the values are registered into the presets CD Note The Save touch button must be selected to record those values e Delete Used to delete the displayed recipe Note Once deleted the recipe can not be recovered and must re entered There is mass delete feature
46. ing is then reseated on the body ring and the ring set is placed on the closing station next section where the capsule caps and bodies are rejoined Chapter 1 Page 14 of 19 1 6 The Closing or Closure System 1 6 1 Introduction The separated capsules after being filled must be rejoined to complete the capsule filling process This is accomplished in the closing station located at the left lower portion of the machine 1 6 2 Assembly Diagram CLOSURE PAD The closing station is shown below RING SET WING CLAMP PEG RING LOCATOR PINS C in 1 DEDUSTER a HANDLE The Closing Station 1 6 3 Closing the Capsule The ring set cap and body rings is seated on the locator pins over the peg ring and secured by a wing clamp When ready the drawer the closing station is pushed into the machine until a switch is activated at the rear of the closed drawer Note When the switch is activated closing the capsules the ring counter advances by 1 one If needed the capsules may be closed a second time if done within 7 seconds WITHOUT advancing the ring count IN CLOSING POSITION Chapter 1 Page 15 of 19 1 6 The Closing Closure System 1 6 4 Capsule Ejection The closed capsules are ejected from the ring set by inverting the peg ring ring set module so that the capsules fall out by gravity onto the deduster screen The excess powder is shaken off by the fall and capsules then slide into a receptacle
47. ipes on PGS 10 thru 12 Eig Supervisor allows the Supervisor to create custom menus for pp the various products that are being filled Must be Logged ON Save as Supervisor F Product Recipe Products MACHINE STATLIS ALARMS E DRIVE FREOQUENC CLOSING STATION NEN DRIVE STATLIS LOGIN LOGOUT BEAD SETUP FORMULA i a PEE USER SETUP Chapter 5 Page 9 of 12 Instructions for Creating and Editing Formulas Recipes Supervisor logon is required to set the speeds for the auger fill and rectifier motors E ble e Select Formula Menu from the Main Menu Wird e Listed on the Formula Menu screen the Recipe RECIPE GROUP Group Recipes Bead Run Bead Reset Send Status RecirPesrour and Formula Setup In order to input a new formula the supervisor must be logged in as Supervisor When RECIPES the description box is selected a pop up window PX displays an alpha numeric keypad Type in the name for the formula and select the Enter touch button M DE bus SETUP which saves the name and returns to the Formula Menu screen e To setup a formula select the Formula Setup touch button Recipe Group 1 The following categories are displayed Recipe Group and Recipe pull down areas Touch Buttons Send Save Snapshot and RO Delete There is a table for the setting the motor preset for F
48. latch Then release the jack by placing the narrow end of the jack handle over the release valve and SLOWLY turning the valve counterclockwise This returns the hopper to the normal operating position After the hopper returns to its operating position turn the valve clockwise in preparation for the next hopper cleaning WARNING Turning the release valve too fast will cause hopper to drop dangerously fast 13 After the assembly is in place remove the pin from the bracket swing the cylinder into place and reinstall the pin through the positioning arm Ref Photo Procedure 4 2 2 line 4 Remove the jack handle and return it to its storage area 14 Close the rear panel door 15 Check adjust the clearance of the filling shoe to the ring refer to Section 4 11 WARNING IF FILLING WITH PELLETS Run the Bead Formula this adjusts the auger speed to ZERO RPM 16 Replace finger guard prior to operation FINGER GUARD Chapter 4 Page 8 of 22 4 3 How to Replace the Vacuum Filter 4 3 1 Introduction The condition of the vacuum filter should be checked as needed and cleaned or changed as required Note this will vary lack of capsule separation is an indicator of a clogged filter 4 3 2 Procedure 1 Turn the Master Disconnect Switch OFF Use Lockout Tag out procedure 2 Open the hinged right side door on the back panel CANISTER foo gr as i a T
49. n changing from one filling material to another It also should be performed periodically even though the same filler material is consistently used 4 2 2 Procedure Use the following procedure to clean the powder hopper 1 With the power ON remove any residual powder left in the hopper by activating the FILL START button s without a body ring on the table Usea brush and tray to clean the powder from the fill table and tabletop Warning Keep hands clear of rotating auger inside the hopper shoe Do not use any rags or have loose clothing near the hopper shoe area 2 Shut off the power at the master disconnect switch right side panel 3 Move to the rear of the machine and open the door of the rear panel AIR CYLINDER FOR POWDER HOPPER POSITIONING ARM BRACKET Chapter 4 Page 3 of 22 4 2 How to Clean the Powder Hopper 4 2 2 Procedure 4 Atthe tabletop remove the safety screw from the finger guard and remove it from the base of the hopper post FINGER GUARD SAFETY SCREW 5 Retrieve the handle from its storage area above the jack and insert it into the opening in the jack Jack up the hopper about four 4 inches until SAFETY LATCH can be engaged and the hopper is high enough to be removed Lower the jack until the hopper column rests ON the safety latch T A Lowering the jack until the hopper column rests ON the safety latch prevents the latch from being dislodged accidentally HOPPER COLUMN
50. ng I O Points button brings up the I O screen DRIVE DIAGNOSTICS A diagnostics touch button for each motor drive opens to another page that reveals a graphic image of the drive controller and has several status lamps located to the right used for trouble shooting A status indicator on the graphic image of the drive will appear Green when the drive is ok and Red when the drive has a fault There are 4 indicator lamps used to determine the status of the drive Drive Operational Indicates the drive is ON and functioning Drive Disabled Indicates the drive is Disabled Drive Stopped Indicates the drive is in a Stopped State Drive Fault Indicates the drive has a fault and must be Reset Drive Reset Must be Pushed and Held for 2 seconds to reset Reset Requires a Supervisor Rights FILL MOTOR DIAGNOSTICS FIL AabbCcDdEe es Green COMTROLLER Drive Operational DRIVE OPERATIONAL DRIVE D1 4ELED ray Light Red rdi Drive Disabled 1 PY crave rut Red Drive Inabled but Stopped lt Points Used for Troubleshooting Chapter 5 Page 8 of 12 FORMULA MENU RECIFE GROUP group and access the recipe formulas Formula Setup Supervisor access only Dee qN RECIPES Pushing the down arrow displays a list of products that has been setup by the Supervisor Once the BUTTON AND HOLD FOR TWO SECONDS THIS WILL Eee CALCULATE AND INSERT THE CORRECT VALU
51. o re type the password for confirmation Four 4 Icons at the bottom of the screen allows the supervisor to perform select tasks ICON Face with Plus sign Used to ADD NEW ICON Face with Arrow sign Used to edit user ICON Face with X sign Used to delete user ICON Body to Open Door Exit ADD BUTTON
52. o safely replace fuses and reset circuit breakers 1 Turn the Main Disconnect Switch OFF shown Use Lockout Tagout procedure 2 Move to the right side of the machine Remove the one 1 safety screw and socket head screws Lift the panel clear and lay aside ELECTRICAL BOX BEHIND THIS ACCESS PANEL REMOVE SOCKET HEAD SCREWS and SAFETY SCREW Chapter 4 Page 13 of 22 4 6 How To Replace The Fuses and Reset The Circuit Breakers 4 6 2 Procedure 0 04 i Omn SAFETY RELAY Vacuum Pump Hj Relay and Overload CIRCUIT BREAKERS CB2P 1 THRU CB2P 4 AND CB1P 1 RECTIFIER DRIVE AUGER DRIVE FILL TABLE DRIVE Fuses F1 thru F10 4 F20 thru F23 Control Relay Master CRM 24v Power Supply PROGRAMMABLE CONTROLLER et DANGER an VOLTAGE TRON ACA TENDON OAN MALARDOUS vC tust ID HAZARDOUS VOX TAGE CAMERE USE wu Tov c GEL o erbe iure E Se tmn prononse sort pet ewe Met ce entamar la mot s f eure te Pune 5 pocnaa ve cond neath oc taret nip green cvesro uti bon 25 Mam secet qs 1 i E Power Brake Resistor 3 Open the electrical box by loosening the latch at the top of the panel until DANGER the panel can be freed then swing it down from the top 4 Checkto see if any of the circuit
53. o setup individual operators The setup table has the following GROUP A drop down list that initially lists three 3 groups Supervisor Operator Guest USER A drop down list that displays operator names PWD An area for adding a password CONFIRM PWD An area to re type the password for confirmation Four 4 Icons at the bottom of the screen allows the supervisor to perform select tasks ICON Face with Plus sign Used to ADD NEW ICON Face with Arrow sign Used to edit user ICON Face with X sign Used to delete user ICON Body to Open Door Exit LOG IN This screen is displayed at start up and is used for machine security The screen has two 2 input areas NAME and PASSWORD Directly below the password box is an area that depicts the Current Use At the bottom are three 3 icons HOME BACK and UNLOCK The default user names are as follows SUP01 Supervisor Operator VISITOR for Web Gate access At machine start up after LOG IN the MAIN SCREEN is displayed There are 6 options that the user can select MACHINE STATUS DRIVE FREQUENCY DRIVE STATUS FORMULA MENU USER SETUP LOG OUT Each can be found on the HELP menu that will briefly describe its use LOG OUT In order to LOG OUT the system the user will have to go to the MAIN SCREEN by selecting MAIN located on the upper right side of each screen From there select LOG OUT and hold for 2 seconds
54. odel 10 Ver 4 2 Chapter 2 Page 1 of 15 CHAPTER 2 ROUTINE OPERATION 2 Overview 2 1 1 Definition Routine operation includes the entire process of filling capsules and can be separated into two stages Machine Preparation Part A Machine Operation Part B The flow diagram below presents an overview of the steps in routine Operation of the capsule filling machine MACHINE PREPARATION LOAD THE CAPSULES FILL THE SONDER HOPPER POWER ON um MACHINE PLACE THE RING SET ON RECTIFIER TURNTABLE PRESS THE ee START BUTTON PLACE THE BODY RING T THE FILL TURNTABLE REMOVE E CAP RING PRESS THE O re BUTTONS JOIN THE CAP 5 BODY RINGS PLACE THE RING SET of THE CLOSING STATION PUSH THE SPRTIGNNINTO THE MACHINE RETRIEVE THE ai Gene ASSEMBLY INVERT THE ASSEMBLY DUMP THE CAPSULES Chapter 2 Page 2 of 15 2 1 2 1 2 Machine Preparation As you can see Machine Preparation consists of two procedures e loading the capsules and e filling the powder hopper These are performed by the operator before the capsule filling process begins 2 1 3 Machine Operation The HMI TOUCH SCREEN At any time after Log On you can access the HELP SCREEN by pushing the HELP button MAIN SCREEN MAINTENANCE MACHINE STATUS ALARMS DRIVE FREQUENCY CLOSING STATION DRIVE STATUIS LOGIN LOGOUT NES BEAD SETUP FORMULA MENU USER SETUF As the machine s operator you assist in each stage of the capsule filling p
55. om the guide chute and lay it aside 7 Move to the rear of the machine and remove the rectifier back cover by loosening the two screws on the holding bar then lifting the cover up while pulling it out Lay this panel aside FEED BLOCK FEED BLOCK SCREWS GUIDE CHUTE GUIDE CHUTE SCREWS j 8 From behind the machine free the rectifier block by removing the two 2 shoulder bolts from the top of the rectifier block J SHOULDER BOLTS Rotating parts inside Keep hands clear Lockout tagout before servicing Back View NOTE You will see the block move forward slightly from spring Q action as you remove the screws Chapter 3 Page 7 of 14 3 2 How to Convert the Rectifier Assembly 3 2 2 Procedure 9 Return to the front of the machine and pull the rectifier block straight toward you out of the assembly RECTIFIER BLOCK EJECTOR ROD BRACKET amp RODS NOTE If the ejector rod bracket and ejecting rods do not come out with block Remove them from the machine and while holding the springs on the rods re install them into the rectifier block Chapter 3 Page 8 of 14 3 2 How to Convert the Rectifier Assembly 3 2 2 Procedure 10 Now that all required parts are removed clean the rectifier assembly area with alcohol and blow dry or allow to air dry before installing the parts for the other sized capsules 11 Align the cam rollers to the cams and install t
56. piled by the manufacturer in compliance with the European Directive and defines the machine as safe The manufacturer s declaration will become null and void if the machine is tampered with modified has its fixed and moving protective guards removed or is used for purposes other than those for which it was designed The manufacturer disclaims all responsibility for any accidents or damage that may arise Chapter 1 Page 5 of 19 1 1 1 Overview 1 1 1 Purpose The MODEL 10 capsule filling machine shown above is a semi automated means of filling capsules sizes 000 through 4 DB A DB B and DB AA with powder or pellets 1 1 2 Features of this Model This model provides many helpful features to aid efficiency and productivity in the capsule filling process e capsule feeding from the hopper e automatically stops after one revolution of capsule rings e automatic positioning of powder hopper over the ring set e dedusting screen to promote clean capsule Chapter 1 Page 6 of 19 1 1 Overview 1 1 3 Chapter Contents The following sections introduce the machine and its parts as well as the principle of operation of the various machine systems These systems work together to provide you with an easy to use efficient capsule filling machine The main topic headings are shown below Capsule Information The Capsule Rings The Rectifying System The Filling System The Closing System The Air Vacuum System The
57. reen go to the Drive Setup and adjust the Rectifier to it s slowest setting NOTE By alternately pushing the rectifier start and stop buttons in quick succession you can effectively jog the machine STOP IMMEDIATELY IF THERE APPEARS TO BE AN ALIGNMENT ISSUE c Examine the alignment the rectifier block and the bottom of the feed block should be parallel GUIDE CHUTE SCREWS ROTATION MODULE AIR HOSE Pinch point hazard Keep hands clear 16 Open the rectifier door and install the guide chute with the two 2 screws Check the alignment of the guide chute with the ring and SCrews 17 Install the rotation module onto the positioning pins Install the air hose into the connector 18 Close the rectifier door until the interlock switch is engaged Proceed to the Closure Assembly Replacement next section Chapter Page 11 of 14 3 3 How to Convert the Closure Assembly 3 3 1 Diagram The diagram below shows the changeable parts of the closure assembly CLOSURE PAD LI PEG RING Closure Assembly 3 3 2 Procedure The following is the procedure for changing the peg ring in the closing Assembly 1 Open the wing clamp on the center of the assembly 2 Remove the two 2 screws holding the clamp in place Set aside Chapter 3 Page 12 of 14 3 3 How to Convert the Closure Assembly 3 3 2 Procedure 3 Loosen and remove the center shaft by removing
58. rews 4 7 Control Box 1 The HMI Human Machine Interface Touch Screen allows for the adjustment of and information of the following items Main Screen Gives general machine information The Model Version and the Software program Machine Status Screen Allows the setup of operational settings and has status indicators Drive Setup Allows for the custom settings of the Rectifier Fill Table and Auger Motors or the return to the factory default settings for these motors Closing Station Screen Allows for resetting of the ring counter Alarm Screen Shows active alarms status Diagnostics Screen Has information Amp draw speed and temperature of each drive It also contains the reset buttons for each of the drives Password protected Log On and Log Off for Operators and Supervisor Help Screen 4 8 The Computer Please contact the Schaefer Technologies Inc Service Department for all computer related Issues PLC Controller Chapter 4 Page 15 of 22 4 9 How to Adjust the Machine s Air Pressure 4 9 1 Introduction It s important to keep the air pressure properly adjusted Much of the smooth travel of the capsules depends on the correct airflow pushing them through the rectifier s pathway 4 9 2 Adjustment Knob Locations Will be located on the lower right front of the machine Vacuum Air System VACUUM BYPASS The gauges and valves used to adjust the machine s air pres
59. ring operation of the Model 10 Capsule Filling Machine 5 1 3 Additional Aids Certain replacement procedures are called out within this section s table Parts may be ordered using the parts list in Chapter 6 Also hanging on the side of the rectifier unit is a tool you may find useful if you should encounter a jam in the Rotation Module or Rectifier Block The photographs below show the technique for removing a jammed capsule using two different styles of picks Note that the top of rotation module is hinged for easy access 5 1 4 MACHINE MAINTAINANCE A pick and a brass rod are supplied to help in the removal of capsules that are stuck of jammed in the Rectifier section of the machine Care should be taken when prying out capsules Pinch point hazard Keep hands clear Chapter 5 Page 2 of 12 5 1 2 Troubleshooting Guide General Machine Section PROBLEM POSSIBLE CAUSE SOLUTION NO MOVEMENT STOP OPERATION OF MACHINE BEFORE PARTS START TO BREAK Turn off power and check for broken or jammed parts No Movement Motor controller not powered up or a Check to see that power is on blown fuse Verify fuses are good with continuity tester amp replace if required Rectifier Section PROBLEM POSSIBLE CAUSE SOLUTION Capsules wont feed Obstruction at top of feed block Look for an obstruction at bottom of the hopper and remove it Wrong size upper feed block If the wrong feed block for the capsule
60. ring where the fill cycle has been interrupted and restarted Chapter 2 Page 12 of 15 2 5 RECTIFYING FILLING AND CLOSING THE CAPSULES 2 5 6 Procedure Filling the capsules 1 Remove the ring set from the rectifier station and inspect to ensure that that there is a cap and body in every hole Place the ring set cap and body onto the filling turntable and turn it counterclockwise until it rests against the drive pin Separate the cap ring from the body ring and place the cap ring on the easel to the left side of the machine FAILURE TO DO SO WILL RUN THE CAPSULE HOPPER INTO THE CAP SECTION OF THE RING CAP RING SITTING ON THE CAP RING EASEL HOLDER 2 With the proper material in the powder hopper and the body ring in place start the filling process by pressing the two FILL Start buttons Both buttons must be held in until the ring starts to rotate The filling process will automatically stop after completing a full cycle NOTE If power is interrupted to the machine during the product fill cycle upon restart it is possible for the fill table to finish the started revolution and revolve Q additional complete revolution potentially over filling the ring Verify the product fill weight for any ring where the fill cycle has been interrupted and restarted P Tm vent AAAA e t 6 ute te 3 After the capsules are filled remove the cap ring from the holder on the left side of the machine set it on t
61. rocess This process includes e positioning and separating the capsule filling the capsule e closing and ejecting the capsule Each stage is automated within itself but you initiate each stage through the control panel Control Panel You also provide the transition from one stage to the next maintaining a smooth flow of the entire process 2 1 4 Chapter Contents Step by step procedures for machine preparation and operation Are found in the remaining sections of this chapter Chapter 2 Page 3 of 15 Shear hazard Keep hands clear from under blade Turn power OFF before servicing Avoid injury Do NOT operate with guards removed Replace guarda betore operating machine For the saleby of all personnol DO NOT modify ar Fann Any of this quipment amp guarda safety dario ex warming labels Rotating parts inside Keep hands clear Lockout tagaeut belore servicing PINCH POINT Pinch point hazard Keep hands clear Rotating parts inside Keep hands clear Lockout tagaout belore servicing A 4 DANGER HAZARDOUS VOLTAGE Contact may cause electric shock or burn Turn off and lock oul sysiom power before servicing Read and understand manual before servicing Only qualified personnel should service this panel Chapter 2 Page 4 of 15 Part MACHINE PREPARATION R
62. roduction Procedure How to Adjust the Filling Shoe to Capsule Body Ring Clearance Powder amp Pellet Introduction Procedure Becker Pump Introduction Procedure PAGE 18 18 19 20 21 21 CHAPTER 5 TROUBLESHOOTING amp MACHINE MAINTAINANCE 2 Overview Definition Troubleshooting Guide Additional Aids MACHINE MAINTAINANCE CHAPTER 6 RECOMMENDED SPARE PARTS LISTS Rectifier Station Fill Station Closing Assembly Fuses Tools and Accessories Table of Contents Page 4 of 4 O M no n5 CHAPTER 1 INTRODUCTION to the STI MODEL 10 Ver 4 2 CAPSULE FILLING MACHINE Chapter 1 Page 1 of 19 SCHAEFER TECHNOLOGIES INC STI MODEL 10 Ver 4 2 CAPSULE FILLING MACHINE USER S MANUAL Valid from serial No thru INTRODUCTION AND GENERAL RECOMMENDATIONS INTRODUCTION This User s Manual has been compiled in compliance with Machinery Directive 2006 42 EC and CE Marking Directive 93 68 EEC to provide the user with information about how to use and maintain the machine correctly It is compulsory to read this manual It is our intention that the information contained in this manual will be a valid aid for your work This information is based on data and on our best current knowledge Carefully read this manual including the recommendations and suggestions No part of this manual may be copied or passed to third parties without the prior written consent of Schaefer Technologie
63. s Inc We advise you to carefully read this manual as it is essential to install check and service the machine correctly in order to keep it in a perfectly efficient working order The manual contains tables designs and diagrams which will help you to get to know the machine in detail Please don t hesitate to contact us if you find that an explanation has been omitted or is unclear NAMEPLATE For any servicing or overhaul operations not included in this manual or for any other technical problem which may arise our Technical Personnel are available to provide you with information and to discuss any necessary action to take When contacting us please indicate the data on the machine s nameplate PRELIMINARY REMARKS he drawings and designs which show the system should be considered as reference and not necessarily faithful in every detail e he system dimensions and specifications contained in this manual are not binding and may be changed without warning e The designs and all of the other documents supplied as part of the system are the property of Schaefer Technologies Inc The system is covered by a guarantee and a contract of purchase During the period in which the machine is under guarantee any repairs which have not been authorized by Schaefer Technologies Inc and are carried out on the same machine will automatically make the warranty void Chapter 1 Page 2 of 19 The user must take particular note of the safety warnin
64. s equipments tomar porte soy orem guards Safety devices or warning labels ir labets Avoid injury Warning Read and understand operator s manual before using this and understand Failure to follow operating instructions could result in injury or damage to the equipment Emergency Stop GENERAL SAFETY REGULATIONS e THESE SAFETY REGULATIONS HAVE BEEN DRAWN UP FOR YOUR OWN SAFETY The strict observance of the safety regulations will reduce the risks of accidents for both you and or others e DO NOT attempt to move install or operate the system without having first read and fully understood this manual If in doubt ask your supervisor e Make sure that all of the guards and protective covers are in place BEFORE starting the machine NEVER leave tools mechanical parts or other unsuitable material on or in the machine e Ifa failure should occur push the emergency stop button NEVER WORK ON THE MACHINE WHILE IT IS RUNNING e Pay particular attention even when the main switch is in the OFF position because the electrical power supply cables are still live e BEFORE restarting the production cycle after carrying out maintenance operations or repairs on the machine make sure that all of the guards and protective covers are fitted correctly e Always be cautious remember that your safety and that of fellow workers depend on you e When moving or lifting components of the machine make
65. s in the fully retracted Home Position position Reference drawing 35602904 The switches used on this machine have indicators that light when the switch is activated The body of the switch is threaded with opposing jam nuts to position the switch properly to the metal to be sensed Generally this spacing is 0 060 to 0 090 inches Prox Switch Adjustment Rectifier and Fill Table Index EIS SIGNAL BAR BRACKET J dig GERN Chapter 4 Page 10 of 22 4 5 2 Switch Adjustment Rectifier Fill Table The photograph below shows the location of the Rectifier And Fill Table Switches FILL TABLE SWITCH RECTIFIER TABLE SWITCH Use the following procedure to adjust either the rectifier table or the fill table switches 1 Adjust the switch with the main power ON and the vacuum OFF 2 Remove the back panel of the machine and locate the proximity switch setup 3 Adjust the switch right or left by working with the jam nuts as shown in Section 4 5 1 on the switch body The switch will light when it is in the proper position relative to the signal bar GAP SPACING THE SIGNAL BAR AND PROX SWITCH IS 060 090 INCHES 4 5 3 Switch Adjustment Hopper Position 1 Adjust this switch with the main power ON and the air supply OFF or disconnected 2 Swing the powder hopper out over the fill table 3 First adjust the spacing between the switch and the signal bar by loosening the 1
66. size desired is on the machine change the rectifier parts to accommodate that capsule size Capsules aren t Rotation module air flow set too high Adjust rotation module air flow rate positioned body down or low between 60 100 cfm see section 4 9 Rectifier blade not square with rectifier block Loosen screws holding blade and adjust Retighten screws Upper feed block releasing two 2 capsules at once Straighten capsule retainer bar or replace bar cams Rectifier block has been damaged or worn beyond usable limits Replace with new block Capsules won t feed Wrong size lower guide chute If the desired capsules are in place from rectifying block Replace the lower feed block refer to Section 3 2 Improper rotation module airflow Adjust rotation module airflow to 60 100cfm see section 4 9 Obstruction in rotation module or lower guide chute Open hinged top to clear or remove rotation module and clear Caps bouncing out of Rotation module air flow set too high Adjust rotation module air flow ring during seperation Vacuum set too high Adjust vacuum Chapter 5 Page 3 of 12 Rectifier Section PROBLEM POSSIBLE CAUSE SOLUTION Capsules wont feed from guide chute Capsules won t separate with the rings Wrong size capsule ring set Ring not positioned against pin Guide block is damaged due to wear Ring openings blocked by obstruction No vacuum System clogged No vacuum pump not operating
67. ss can begin the machine must have been properly prepared e Powder hopper filled section 2 2 e Capsules loaded section 2 3 Chapter 2 Page 7 of 15 2 5 RECTIFYING FILLING AND CLOSING THE CAPSULES 2 5 3 Procedure Machine Startup and Display Settings Your assistance in positioning rectifying and separating the capsules consists of the following steps 1 Make sure all interlocked doors are closed and all guards and panels are in place and secured with safety screws Make sure the powder hopper is at its HOME position Turn on the master disconnect switch on the right side of machine 2 Pull out the Emergency Stop button KEY LOCKED BOX MASTER DISCONNECT SWITCH EMERGENCY STOP PUSH PULL Note When the main disconnect is turned ON If there is an alarm issue ie rectifier door open fill hopper not at home position no air to the machine etc the Alarm screen will display instead of the Log On screen As the alarm condition is corrected the machine status is automatically corrected this does not remove the alarm message from the screen the alarm acknowledgement button must be pushed for each alarm message to remove it from the screen When all alarms except for Machine Ready have been satisfied pushing the Back Button will take you to the Log On screen ALARM SCREEN LOG ON SCREEN Alarm Acknowledgement ALARM SUMMARY dE Button pl tre Time Message C U R R E N 5 H
68. sure SWITCH HOPPER SWING AIR FLOW METER CLOSING STATION ROTATION MODULE Vacuum Air System 4 9 3 Pressure Adjustments Follow this procedure to maintain the correct rectifier air pressure in your machine 1 The machine s air supply should be 80 to 100 psi 2 Drain the water from the air filter by loosening the bleed screw on the bottom of the air filter to remove condensation 3 Closing Station Using the air regulators the closing air cylinder pressure should be set at approximately 50 psi this can vary between 30psi and 75 psi based on capsule size Proper pressure is determined by evaluating the capsule after closure Dented capsule pressure set to high Unlocked capsule pressure set too low 4 Setthe hopper position cylinder pressure to for 50 to 100psi avg pressure is set to 65 psi Pressure too low hopper will not swing properly Chapter 4 Page 16 of 22 4 9 How To Adjust The Machine s Air Pressure Continued 4 9 3 Pressure Adjustments 5 Rectifier Make sure the vacuum pump is running You will see a flow meter indicating the rotation module flow rate It should be adjusted with the air regulator to approximately 60 100 cubic feet per hour varies based on customers airflow This adjustment can be made by turning the Vacuum Bypass to the ON position turning the Rotation Module knob to set the desired flow rate shown on the Flow Meter and turn the Vacuum Bypass switch
69. sure that all the regulations for these operations are respected Chapter 1 Page 4 of 19 SPECIAL WARNINGS e The personnel who operate this machine must know and scrupulously observe the general safety regulations If these regulations are not observed this may cause injury to workers and damage components of the machine e The maintenance operations must be carried out with the machine at a standstill Lockout machine prior to servicing Failure to follow operating instructions could result in personal injury or damage to the equipment e The user must make sure that all of the instructions in the manual are followed to the letter Anytampering with the safety systems of the machine done for any reason will be at the user s own responsibility and risk e not ever try to bypass the safety systems or make them ineffective e For the machine smooth operation it is absolutely necessary to observe the speed temperature and tension limits along with all the indications given which the client must in any case respect e Furthermore the environmental conditions must be taken into account for the installation of the machine he national laws governing the use of this type of machine must also be observed WARNING Schaefer Technologies Inc declines any responsibility for damage which may derive from the non compliance with the above mentioned warnings The declaration of conformity enclosed with this manual has been com
70. the desired Preset Button for 2 seconds When the factory Preset value is active the number value display background will turn Green in color VACUUM ON VACUUM OFF The vacuum pump may be turned on or off from this screen DRIVE STATUS This screen monitors motor amperage AMPS Pre set speed and actual speed rom for each drive motor Further monitoring can be achieved by selecting the corresponding Diagnostics touch button for each motor MAINTENANCE touch button changes the display to the Maintenance screen DRIVE DIAGNOSTICS A diagnostics touch button for each motor drive opens to another page that reveals a graphic image of the drive controller and has several status lamps Chapter 5 Page 7 of 12 NAINTEHAHCE mm REC RESET AUGER RESET FILL RESET 23456 DIAGHOSTICS REC RECTIFIER MOTOR CONTROLLER m MG 7 E P 4 DIAGHOSTICS AUG AUGER MOTOR CONTROLLER DRIVE OPERATIONAL DRIVE OF DRIVE STOPPED DRIVE FAULT DRIVE OPERATIONAL f DRIVE DIZABLED T DRE STOPPED Sh 170 POINTS INPUTS OUTPUTS DRIVE FAULT The MAINTENANCE screen displays the run time in HOURS SHIFT and TOTAL HOURS for the Rectifier Motor Auger Motor Fill Motor and Vacuum Pump Motor The HOURS SHIFT meter can be reset to ZERO Requires a Supervisor Rights The TOTAL HOURS meter can be reset to ZERO Requires a STI Service Technician Pushi
71. the top screw while holding the shaft at the bottom The shaft drops down when the screw is removed 4 Remove the peg ring 5 Install the correct size peg ring on the slide then slide the shaft up through the center of the ring from the bottom and install the screw and spacer in the center post WING CLAMP S zm iit x AAR T d s enn eme c PEG RING Closure Assembly 6 Install the wing clamp by inserting the two 2 holding screws at each end of the clamp until they are tight 7 Change the closing pad by a removing the two 2 screws at the underside of the front of the pad and sliding the pad straight out of the drawer area b install the correct pad by sliding it straight back positioning it over the two 2 screws in the rear then installing the two 2 screws in the underside of the front of the pad Chapter 3 Page 13 of 14 3 4 How to Change the powder Filling Material 3 4 1 Introduction When the MODEL 10 is converted to process a different sized capsule a different filling material may also be required If this is the case the hopper should be cleaned thoroughly to remove the original material before adding the new material The procedure for removing and cleaning the powder hopper is found in the Maintenance Chapter Section 4 2 Machine Preparation 3 4 2 Completing the Conversion After the cleaned hopper is in place the desired filling material should be ad

Model 10 ver 4.2 Operational Manual

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