Fillflex™ Split Wall Operating and Service Manual
Contents
1. 109 42 10 8002 WNLVG M3SAV N3ONINONY 138 78 S1304 A3 Wniva i d xaqda avia AV AV 5399 av XIT ulds 0055 S3ANDNSONINLIMS W3ANDNSL38NV uu 086 uu yz uu 0 ug JS wu 091 the 3 N31108 7K i E 3 N 6 4 AHA a X Pung OZW Pung SEW X Z 3 3 4 ZA IW DDYTIIL 149 A A us e ww z 9 Ole ww 006 uu 096 WWwO9 5 5 5 918 4 19 a pany oy J JL 203 51614 i 3 S L 420 SL 0 JO x XM Ste x Joy Jejd juou 7 LH 4 3 E Duiube 18H 1580 in za a E Sng x y 3 pl 42 5 A iggl 3 a o o TH U i U VLL uuggc ww 99s 2 6 1103 2 Fillflex Split Wall Connections and operating panel 109 42 10 8002 uorjextjDadsiarJa e WNLWG NSIS M3SAV N3ONINONY 138 51303 A38 WnLiva 10S dW ua N d 8 AYLIN S399Y lONVH gv 313 11 xg a l ids 00352. 47 10 8002 ewaysssbulupuiguo4 244A WNLVd NSIS MJSAV N39NIMONY 138 H S1MOJ A34 Wniva 106 dW uaJBAN d B avig AW OvLI AV 9399 av xmi xg lz I i H ulds 00551 YAWWNNSONINLIY M3NADnNSL38NV D dyxs1vuvddv 1 a 3d ONINTTASNALLOG Lz u 3 ZA i NY i L DDYN LAYLNOJ INS IVIIN3IOd N i oz ONINTIAS TYNOISddOLS NH3DG 9 N 602 4 dyxs1vavddv 1 VONVIS WNddO f N t 34 ONINTIAS 74 Lz 6 TLNIALINOWW LA i NL i 8 TILNGASONINTIAd m goz 1 30 1 1 UD 0 t LOZ 3d NOQ NINLQTISNY 44015 1 L 113838804 9 DDYN 3d 902 9 t Jd Y S O OVA OEZ Lee zl ibe TWNOISHV I 3 3 N T al Ls UZ T38VNISNY JYVAIDSINd LSD t4 Le 74 S OXZX4 t H I YOLOWdWNd LoS l 1 j LV LNOOWYSL 4 4 6 rE TWNOISLUVIS 1 p 34 T J L TWNOISUY DH ed t4 Lc M 5 l 0 uz 138vX SNV uU010Ndhd Ls A S 1X AN l n in q 99y 9 E EOZ uc 3d 34 RII VILN3IOd Y N L C SE TILSAT x f N Li ONINTIAJ IVNOIS L4V 1S NH31X3 N J T SNINL VH 3 N 2x IX y
3. Fillflex Split Wall Programme steps and custom settings Progr Display Default Batch B1 Batch B2 Batch B3 Batch B4 Batch B5 Batch B6 Batch B7 Batch B8 steps in red 1 Pulse 48 2 Pulse Out 1 Ratio Input 001 3 Stop 0 10s Detect 4 Flow gt gt gt Direction 5 Autostart No Yes Next fill 6 Extern Count start Imp 7 Paus time 5 00s next fill 8 Reversing No Yes 9 Reversing 0000 pulses 10 Revering 020 speed 11 Compen Yes sation No Present Value 12 Pulse 1 000 Multi Factor 13 Choice of P Units 14 Pump 0 00 s Start Delay 15 Value 0 00 s Close Delay 16 Value Of Yes Close Af ter Stop 17 Speed RPM Unit 18 Batch No Comp 19 Adjust 001 ment of pulses 20 Batch 0 00 max adjust ment The table continues on next page gt 1103 5 15 5 E The control system and its functions and programme steps Fillflex Split Wall Progr Display Default Batch B1 Batch B2 Batch B3 Batch B4 Batch B5 Batch B6 Batch B7 Batch B8 steps in red 21 Quantity 000 delay comp 22 Ext Input No Adj To Zero 23 Pre Filling No Yes 24 Pre Filling 02096 speed 25 Pre Filling 02096 amount 26 End Fil No Yes ling 27 End 020 Filling speed 28 End Fil 080 ling start 29 Filling No Yes From Bot tom 30 Time in 1 00s bottom pos 31 System Yes Ready Signal 32
4. 2 10 1103 2 E Connections and operating panel Fillflex Split Wall 2 11 1103 Fillflex Split Wall quick stop shut off starter switch 1103 electric and pneumatic connections 3 Installation and connection of new machine 3 Installation and con nection of new machine The Fillflex Split Wall can be used for both 3 1 Manually started filling the filling process is started by an operator or 3 2 Mechanically started filling the filling process is started by a signal from a conveyor belt or similar equipment The machine may have been delivered with different types of equipment depending on its intended use e g pump different types of ejector pneumatic valves pneumatic pedal etc Check that the equipment is complete before installation and connection 3 1 Manually started filling The machine is delivered with a suitable pump The machine can always be quick stopped with the red quick stop button on top of the machine 1 Mount and connect the control cabinet according to instructions inside cabinet 2 Install the pump and connect the suction line or filling hopper if the pump is to be equipped with one to the inlet side of the pump The gear pump works equally well in both directions and has no preset direction of flow The inlet and outlet sides can therefore be chosen as desired Should the pump be found to go the wrong way the direction of flow is altered as in paragrap
5. Possible values 1 255 Example If the value 255 is selected the control programme will count 1 control pulse only after 255 motor revolution pulses have been counted P03 Time between two motor revolution pulses before stop is confirmed Function To enable the control programme to know if the pump has stopped or is about to stop Possible values 0 01 9 99 s seconds Example If the time is long e g 1 00 s the motor has stopped If the time is short e g 0 10 s the motor has not 5 5 5 E The control system and its functions and programme steps Fillflex Split Wall P04 FLOW DIRECTN gt gt gt POS AUTO START NEXT P06 5 6 PILE NO EXTERN START CONT stopped completely If 8 pulses rev see P01 has been selected and 0 10 between two pulses has been selected the stop indication will come at 75 rpm 60 divided by stop time between two pulses x pulses rev P04 Changing direction of flow Function Change of direction of flow direction of rotation of motor Possible values or P05 Automatic start after change of packing P05 is used with P06 and P07 Function Automatic start after the time which is set on 07 Used for example to enable a large number of packages to be filled more quickly The operator then has the time set under P07 to change the package Filling then starts automatically without a new start signal needing to be given Possible values YES
6. 020 Bae A single quick press raises the value in steps if is kept pressed the value rises continuously at a constant speed which increases after 3 seconds A m Setting of value in display under PRESET A single quick press lowers the value in steps if is kept pressed the value falls continuously at a constant speed which increases after 3 seconds ON Start of filling process during continuous manual or automatic operation OFF Stopping of filling process during continuous operation During manual operation filling is stopped by releasing ON on automatic it is stopped by the control unit BATCH With BATCH one of the stored programmes up to eight in number is selected After the machine has been started or has been dead for some reason the programme B1 is shown Repeated pressing of the BATCH button moves the display from B1 up to B8 and then begins again with B1 The programmes set may be quite different for example B1 may be a small package which is to be filled slowly B2 a larger package to be filled quickly etc As the machine always shows B1 when starting it may be appropriate to store the smallest filling quantity in position B1 065 SPEED SPEED 1173RPM Alternate between operating mode and speed mode The display shows the word SPEED and the pump speed in revolutions per minute RPM The filling speed can be increased and reduced step
7. 5 7 P11 5 The control system and its functions and programme steps Fillflex Split Wall COMPENSATION PRESET VALUE YES P12 PULSE MULTI FACTOR 1 000 Pesce p OPES OI UNITS KG P11 Compensation for difference in PRESET and VALUE Function When doing the first filling after shut off the pump stops when PRESET and VALUE are the same which means that the pump rotates after one or more additional pulses depending on the speed The values PRESET and VALUE must be the same all the time By selecting YES at P11 continuous compensation is obtained for differences between PRESET and VALUE both upwards and downwards PRESET and VALUE then remain the same all the time Possible values YES or NO YES If YES is selected the stop signal in the next filling will come as many pulses earlier as the excess number in the preceding filling If NO is selected the stop signal will come when PRESET and VALUE are equal P12 Constant between pulses and volume Function Constant by which the number of pulses is multiplied to enable the value of PRESET and VALUE to agree with the numerical value for volume or weight in the package which is being filled Possible values 0 001 9 999 Example If a filled volume of 650 ml gives a numerical value of 400 pulses the factor will be 650 400 1 625 By setting the constant 1 625 under P12 the numerical value on the display will show the
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9. Ready 0 0 s Signal Time Delay 33 Restart No Yes From Zero 34 Connect Yes Sensor Fault 35 BC5500 1 6 Version If you change this program step diffrent program steps could appear afterwards If you feel uncertain read the manual before you change Fore more information contact Fillflex AB 1103 Fillflex Split Wall 6 CE Certificate EC DECLARATION OF CONFORMITY We hereby declare that the following machinery conforms to the machinery directive 89 392 EEC Product name Fillflex filling machines Type Serial Number Other Applicable Directive 73 23 EEC and 89 336 EEC Fillflex AB Karl Johansgatan 158 414 51 Gothenburg Sweden Signed NS Date Name Sture Olsson Position Managing Director 1103
10. YIWWNANS NINLIY N3AWnNSL388V S 0XZX 94 uz S 1X AN uz X313113 AV A21 3uvdivadnr1 SA 33 9 0501 ONIYOSWONIDL LOWS YA XIT AV A31 8 TLNJAL3ND VA A XIT AV A31 5 E TJLNIALINDYW LA SE 1S TM 3 X 9 J V18 N 74M NVTIaM 1N 1d X NAM 3 1NId X 44015 aou 20LZV S8Z 7 SEZ 3 23 3131 4 2 1 5 l q 1uV1S NOUS LEWOMV SEZ EEEMV SEZ 300NV23N3131 ddVIDDDAHL div LH LS J 00554 Y41731 1081N00H21V8 Iv J 3 AIT 3 0 13843 Yd 831 S3v2283 37 31 QuNQNY LS 0 0 vin l XIT AV MISL 0 gZ 3783 321 39 804 05 3 384 in l j MOEZ LW0L603 121 3n0INV23W3131 SO LV NOM D z DDYTIIL z 33 9 0501 ONISQHON39 110S XJI AV A3 30V1138VT1A3N31108 5 3uv LAYSWOYLSHIAUL XSLLVIQ3Nd 49 g X34 AV A1 1815 YSILYWNINd UV LAYSWOYLSHIAUL XSILVIQ3Nd 1d9 SWOLLNM 43943891M 9v LONVH139A8 LLISLSOU 092X007X08E E0ZLS6 01SN3 dYJSLYYYddY DuiuxJeuuy ejeq d feylsge4 uoijxunj u o Buluweuag 1504 Y 1103 2 7 2 Connections and operating panel Fillflex Split Wall LOL 72 10 8002 78 S1304 A3 Wniva 109 dW uaJBAN d avid AV QVLld AV S399Y IONVH YSWWNNSONINLIY YSWWNNSLASYV 91155 91 gY x3147114 Hds 00551 Wniva NSIS YASAV N39NI
11. new start of next filling 07 is used if YES has been chosen at P05 Function Used to select the time the operator needs to change packing Possible values 0 01 9 99 s seconds 08 Reversing of direction of flow at end of filling process P08 is used with PO9 and P10 Function Reversing of direction of flow of gear and lobe pumps to reduce the dripping tendency when filling with viscous products The filling process is completed when the pump runs in the opposite direction with the number of pulses given at P08 after which the product remaining outside the filling nozzle is withdrawn slightly If a hose is used for filling and reversing is not used the product will come out through the filling nozzle when the pump stops and the hose returns to its original diameter Possible values YES or NO P09 Number of pulses for which pump reverses at P08 09 is used if YES has been selected at P08 Function The number of pulses which the pump runs in the reverse direction reversing begins when stop is detected at P03 The number of pulses for which the pump is run in the opposite direction of flow has to be repeated by the pump in the forward direction at the next filling before the volume begins to count Possible values 0 999 P10 Speed of reversing at P08 P10 is used if YES has been chosen at P08 Function The speed with which reversing proceeds as of maximum speed Possible values 0 100
12. number of ml The value obtained is then combined with the units in P13 P13 Choice of units Function To give the right unit for the value after setting in P12 Possible values P pulses litres dl cl ml kg hg and g Example compare P12 If ml is selected the display will show 650 ml 1103 Fillflex Split Wall P14 PUMP START DELAY 0 005 P15 VALVE CLOSE DELAY 0 00s P16 VALVE CLOSE AFTER STOP 1103 YES 5 The control system and its functions and programme steps L P14 Delay of pump start Function Used if the filling machine is equipped with a pneumatically controlled outlet valve Delay of pump start is used when the shut off valve is connected in order to be able to give the valve time to open before the pump starts In this way there is no build up of pressure before the valve opens if the valve opens with pressure in the pipe there may be splashing Possible values 0 00 9 99 s seconds P15 Delay of valve closure after filling Function Used if the filling machine is equipped with a pneumatically controlled outlet valve Delay of valve closing after filling to avoid the pressure in the pump system remaining in the pipe after stopping if there is pressure in the pipeline at the next filling there may be splashing Possible values 0 00 9 99 s seconds P16 Synchronization of valve closure and pump stop Function Used if the filling machine i
13. preservatives yoghurt mayonnaise honey washing liquid shampoo degreasers hand cream paint acid oil and other substances Containers The machine can be easily adapted to suit many different types of container everything from 10 ml bottles to dishes jars barrels drums and vats It is simplicity itself to alter or adjust the chosen filling volume Up to 8 pre selected options can be stored 1 1 1103 Fillflex Split Wall 1103 1 This is Fillflex Split Wall L Power connection 230 V or 400 V TF machine features connectors for external start up and communication with a conveyor system etc Dimensions Fillflex Split Wall cabinet Length 260 mm Width 400 mm Height 380 mm Construction The Fillflex system features a simple and robust design The pump is driven by an electric motor and filler speed rotating speed is controlled by a separate control All settings for portion size filling speed and automatic manual operation take place via the control unit and can quickly and easily be altered by the filling operator Various types of installations and connections with Fillflex Split Mobile and Fillflex Split Wall Fillflex Split Mobile gives a very high filling capacity On the Fillflex Split Mobile the control cabinet and motor pump unit are sepa rated both compo nents are on wheels With the Fillflex Split Mobile you can use larger motors and pumps giving you very high filling capaci
14. system programme steps 5 5 Programme steps and custom settings 6 CECertificate 1103 Fillflex Split Wall Warning symbols General warning Dangerous voltage A Corrosive substances 1103 Safety regulations L Safety regulations All warnings are summarized below Follow the directions carefully to avoid any injury or damage Installation operating and service personnel must possess ade quate knowledge of the machine Always begin by reading the manual Installation Always study the technical data A Only qualified electricians may open the cover of the electric equipment Never insert fingers into pump connections or any shut off valve Operation Always study the technical data Never touch a pump or piping containing hot liquids Never start the machine before the pump unit is properly assembled A Always handle hazardous fluids with great caution Never insert fingers into pump connections or any shut off valve Maintenance Always study the technical data Disconnect electrical connections and any air connection before servicing Servicing must never be carried out while the pump is hot The pump and pipes must not be under pressure during servicing Never insert fingers into pump connections or any shut off valve 1 E This is Fillflex Split Wall Fillflex Split Wall 1 This is Fillflex Split Wall Fillflex Split Wall is the latest ge
15. Bele 0 000 1 Place an empty container under the ejector D uak oer EI 2 Press the MAN button Zero VALUE if it does not already show zero 3 Press the ON button and keep it pressed until the desired 3 333 0 000 volume is obtained the ON button may be released P MAN HLT B1 causing HLT to be shown on the display and pressed again the control system then continuing from the value it had when stopped 3 933 2 2272 The reading under VALUE begins to count up as filling P MAN OFF B1 proceeds 4 Read off the current value e g 2 222 under VALUE and set the same value under PRESET with the aid of the 205300755 29021217 buttons and P MAN OFF B1 5 Press OFF HLT will change to OFF Then press AUTO Next time ON is pressed the desired volume will be filled Note however After the first filling VALUE will be rather too high The machine automatically compensates at the second filling and VALUE will then be the same as under PRESET 1103 m N Fillflex Split Wall 065 SPEED 1173RPM E g Speed is 1 173 rpm which represents 6596 of maximum 1103 4 Daily operation L 4 5 Fine adjustment of filling volume If the filling volume set under PRESET needs fine adjustment somewhat too little or too much in the package this is done as follows 1 Adjust the value under PRESET with or 2 Atthe next filling the adjusted volume will be fil
16. Fillflex Split Wall Operating and Service Manual quM rm Prog Mode Shift le Shi Cont Man Auto que ncm on WWw fillflex com Fillflex Split Wall Model F5500SW Control system version 1 6a Operating and Service Manual the flexible filling machines Fillflex AB S dra L ngebergsgatan 26 B SE 421 32 Vastra Fr lunda info fillflex com Tel 46 31 14 58 40 Fax 46 31 14 58 43 www fillflex com 1103 N Contents Fillflex Split Wall Contents Safety regulations 1 Thisis Fillflex Split Wall Brief description of the Fillflex system 2 Connections and operating panel 2 1 Control shroud och operating panel 2 2 Electrical connections for external communication 2 3 Wiring diagrams 3 Installation and connection of new machine 3 1 Manually started filling filling controlled by operator 3 2 Mechanically started filling filling controlled by e g conveyor belt 4 Daily operation 4 1 Emergency stop 4 2 Start up 4 3 Shut off and cleaning 4 4 Setting of filling volume 4 5 Fine adjustment of filling volume 4 6 Adjustment of filling speed 4 7 Storing a filling programme in the memory 4 8 Using a stored filling programme 4 9 Adjusting a stored filling programme 5 Control system and its functions and programme steps 5 1 General information on control system 5 2 Control system functions on the operating panel 5 3 Sensor fault indication 5 4 Control
17. HONY 138 xa AOECXE YOLOWAdWNd TIv1SsQdv is ONINLVW 30NVAWOXMNI e 9 a S 1X dd M hf 41 M3SL O Hun 38VH303H0 AYNIY in SISIL Ly tis 80 10L 18 9 3d VO LOL 18 9 VO LOL ia lt SL 0 08 51 2 S1 I8VAS 2 8 1103 2 Fillflex Split Wall Connections and operating panel 106 42 10 8002 euayrssyauy NSIS YaSAV N39NIMNONY 138 8 51804 A3 Wniva LOL dW U2JD N d i 71 11 avi QVLIM AV S399Y0NVH gv XJT xg Iz ulds 00551 S3ANDNSOSNINLIMS N3ANWDNSL38NV am amp QUAL s 31 10 Er VONVLS VNddO FAD da 9NINTIA4N31108 ONINTIAS seit ra 3 3 JYYWYOIWOSNIAYIY x 95vmii v 1 mmm n Lex 3d LX 6 1X Id LX amp 4 STETI 2x Uy 39V11 NIA NOG
18. ay to the operating mode 10 The machine is now ready for setting of the filling volume see section 4 4 3 2 Mechanically started filling Installation and connection take place in the same manner as with manually started filling but with the difference that the machine receives a starting signal from the conveyor belt Paragraph 4 in section 3 1 now becomes Connect the communication from the conveyor at the communication connection Connecting instructions on page 2 3 and 2 4 electric and pneumatic connections 3 2 1103 Fillflex Split Wall X XXX P AUTO OFF The display after the starter switch has been pressed the last value set is shown at X XXX 1103 Preset r Prog Mode Shift Cont uto VS l 0S0 Bsa www fillflex com 0 004 4 Daily operation L 4 Daily operation 4 1 Quick stop Fillflex Split Wall can always be quick stopped with the red quick stop button on top of the machine Motor and pump and the pneumatic valve on the outlet pipe if one is fitted will then stop immediately When the reason for the quick stop has been dealt with the machine is restarted with the green starter switch 4 2 Start up For daily use the machine is started as follows 1 Fit the pump and pneumatic valve if applicable if these have been removed and cleaned 2 Connect where applicable the compressed air to the pneumatic valve 3 Connect the earthed plug 4 Pre
19. en selected at P31 Function Used to delay ready signal for example to wait for other equipment or to avoid dripping in wrong place Possible values 0 00 9 99 s seconds P33 Restart from zero Function Used for restart from zero at next start if external stop signal has stopped filling before the set volume has been reached Possible values YES or NO P34 Connection and disconnection of sensor fault indication Function Connects or disconnects indication of sensor fault YES Indicates and shuts off the machine in case of fault Function disconnected This position is normally used only for running in and special operation which is usually carried out by specialist personnel See also 5 3 Sensor fault indication Possible values YES or NO P35 Type and version of control unit 5 13 5 M The control system and its functions and programme steps Fillflex Split Wall Notes Batch 1 Value Speed Batch 2 Value Speed Batch 3 Value Speed Batch 4 Value SDOBU aea Batch 5 Value aes scien Batch 6 Value Speed Batch 7 Value Speed Batch 8 Value Speed 5 14 1103 5 The control system and its functions and programme steps L
20. er Used for filling foaming products or to avoid splashing Possible values NO FINISHED or TIME FINISHED At the start signal for filling the filling lance goes down to its bottom position When the control unit receives the signal that the lance is in position filling starts and the filling lance remains in the bottom position until filling is complete Then the filing lance is drawn up again quickly TIME As above but the filling lance remains in the bottom position only for the time set at P30 after which it slowly rises to allow the liquid to flow out under the surface When filling is complete the filling lance rises quickly for the remaining distance P30 Time for filling lance in bottom position P30 is used if TIME has been selected at P29 Function Determines the time that the filling lance stays in the bottom position before being slowly raised Possible values 0 00 9 99 s sec P31 Ready signal via auto ready signal relay P31 is used together with P32 Function Gives ready signal via auto ready signal relay Usually used for filling on conveyor belt Possible values YES or NO 1103 5 Fillflex Split Wall The control system and its functions and programme steps L P32 READY SIGNAL TIME DELAY 0 00s P33 RESTART FROM ZERO NO P34 CONNECT SENSOR FAULT YES P35 BC 5500 VERSION 1 6 1103 P32 Delay of ready signal via auto ready signal relay P32 is used if YES has be
21. h 7 3 Connect the outlet and pneumatic valve if the machine is equipped with one to the outlet side of the pump 4 Connect any external communication electrical or pneumatic 5 Turn on the power by pressing the green starter switch on the machine The lamp in the switch and the display on the operating panel will come on 3 1 3 p Installation and connection of new machine Fillflex Split Wall 6 Check the direction of flow by pressing MAN on the operating panel Then press ON briefly the pump works as long as ON is kept in www fillflex com POT PULSE REV If the pump is going the wrong way the direction of 0 1 rotation is altered as follows Press OFF on the operating panel Press PROG Step forward to position P04 with Press MODE Turn the flow arrows by pressing Press MODE Display at 04 NS Press PROG Display after pressing PROG The pump will now rotate in the other direction 8 Fill the system pump hose and pipe by pressing MAN on the operating panel Then press ON The pump will Em go as long as the button is pressed in The system must be entirely free from air before filling can begin 9 The speed can be increased to make it easier for the pump mii to suck The speed is adjusted by pressing SPEED and increasing reducing with or Then press SPEED again to return the displ
22. inuous operation the pump works continuously until OFF is pressed This mode of operation is selected by pressing CONT Filling is then controlled only with ON and OFF without considering any preset stop value This mode can be used for transport washing circulation or setting a large filling volume 2 Manual operation MAN When on manual operation the pump works as long is ON is pressed This mode is selected by pressing MAN Filling is then controlled only with ON This mode is used for start up filling the system and setting the filling volume 3 Automatic operation AUTO When on automatic operation the machine does a complete filling process according to the chosen settings volume speed 5 1 5 E The control system and its functions and programme steps Fillflex Split Wall cautious initial filling etc after ON has been pressed Then the machine stops and waits for ON to be pressed again The starting impulse can also come from a hand held switch pneumatic pedal automatic conveyor belt etc This mode is selected by pressing AUTO and is usually the normal operating mode for the machine 5 2 Control system functions on the operating panel AUTO When starting 1 the current reading is zeroed on the display under VALUE 2 the display shows ON 3 the pump starts 4 filling begins and 5 the sensor emits pulses The current VALUE counts up
23. l has tripped shut off the machine and restart The pump rotates but VALUE does not change on the display Action Contact your machine supplier or Fillflex AB 1103 Fillflex Split Wall P01 EU REV 0 1 P02 PULSE RATIO OUT 1 INPUT 001 P03 STOP DETECT PULLS PUES 1103 1 005 5 The control system and its functions and programme steps L 5 4 All the steps in the control programme The programming mode is obtained as follows 1 Press PROG on the operating panel 2 Step forward to the desired programme step with Note that inapplicable programme steps are omitted For example P06 and 07 are not shown unless YES has been selected under P05 3 Press MODE The step is now adjustable 4 Make the changes and 5 Leave the step by pressing MODE 6 Select a new programme step or leave the programming mode by pressing PROG 7 Custom Settings on the panel could be noted in in table at page 5 14 5 15 P01 Number of pulses per revolution of motor Function Value for number of pulses per revolution of the motor To see the speed of the motor in rpm Possible values 1 99 02 Number of pulses received before the control programme counts a control pulse Function The number of pulses received from the motor per control pulse counted in the control programme Used to reduce large numbers of pulses so that the working range of the machine will be adequate
24. led 4 6 Adjustment of filling speed 1 Press SPEED on the operating panel 2 Adjust the 96 value speed as of maximum by pressing a n a n or 3 Press SPEED to return to the main menu The pump will now work at the new filling speed When adjusting the filling speed fine adjustment of the filling volume may be necessary see 4 5 4 3 4 4 4 Daily operation Fillflex Split Wall 4 7 Store a filling programme in the memory This is how the memory works The machine can store up to eight different filling programmes in its memory They are named B1 B2 etc up to B8 and are selected with BATCH All the adjustments which are made e g change of the filling volume speed etc are automatically stored in the filling programme which has been selected If the machine is in the AUTO position it always works to one of the filling programmes B1 to B8 The machine always starts in the same batch programme that was used when it was shut down Custom batch can be noted on pages 5 14 5 15 This is how a filling programme is stored in the memory 1 Select the desired position B1 B8 by pressing BATCH The position must always be selected before programming 2 Make the desired settings e g filling volume see section 4 4 speed see section 4 6 or other parameters see section 5 3 Do a filling 4 The desired programme is now stored in the selected progra
25. lessly with the buttons and 1103 5 3 5 E The control system and its functions and programme steps Fillflex Split Wall P05 AUTO START NEXT FILL NO ISENSOR FAULT 5 4 PROG Alternate between operating and programming mode To go up and down the programme steps the buttons and are used When the machine has been dead step P01 is always shown in the programming mode If for example programme step P05 is shown when returning to the operating mode P05 will come up at the next change from operating to programming mode MODE Change to alteration of the programme step which is displayed An arrow is shown before the value or the text which may be altered To increase or reduce the value or alternate between two or Hn more fixed choices e g YES NO the buttons and are used SHIFT Spare button 5 3 Sensor fault indication If YES has been selected at programme step P34 the control programme will alarm and switch off the machine if the signal from the sensor is incorrect An incorrect signal is when the time between two motor revolution pulses set on programme step P03 is longer than the time an extra second which has been set at P03 In addition filling should be in progress The pump does not rotate Possible causes action The pump is blocked remove the blockage Speed set too low increase the filling speed see 4 6 The frequency contro
26. mme position 4 8 Using a stored filling programme 1 Select the desired programme position B1 B8 by pressing BATCH 2 Press AUTO 3 The programme is now ready for use 4 9 Change a stored filling programme 1 Select the programme position B1 B8 which it is desired to change by pressing BATCH 2 Make the desired adjustments 3 Do a filling 4 The changes are now stored in the selected programme position 1103 Fillflex Split Wall 1103 5 The control system and its functions and programme steps L 5 The control system and its functions and programme steps 5 1 General information on the control system The Fillflex control system counts the pulses it receives from the motor and their speed The pulses correspond to the speed revolutions or part revolutions of the motor and therefore also the quantity of filling material which has passed the pump By counting the pulses during filling and comparing them with the set values the machine can control the filling process There are three operating modes 1 Continuous operation CONT 2 Manual operation MAN 3 Automatic operation AUTO During automatic operation the filling process can be varied according to the filling material and the container volume speed cautious initial filling etc The adjusted filling process BATCH is stored in the memory of the control unit 1 Continuous operation CONT When on cont
27. neration of our renowned Fillflex filling machines It is compact versatile and economical and its design is different to that of the traditional piston driven filler The machine is fitted with a pump suitable for the filled media The machine is very easy to use By simply pressing keys on a panel the operator can conveniently increase or decrease the volume and filling speed and equally easily store the new readings in one of the 8 pre selector options Since filling volumes can be altered infinitely the same machine can be used for filling small retail size 10 ml bottles as well as large wholesale size drums or vats The containers to be filled can be fed either manually one at a time or in a fully automatic process for large scale operation using conveyor belts Fillflex Split Wall can also handle traditionally difficult media such as highly viscous foodstuffs and cleaning agents or detergents which froth easily Adjustment of the operating parameters is simplicity itself If you need to increase production simply keep your machine and add a conveyor system and other peripheral equipment The machine is available with a wide range of pumps ejectors valves and accessories for a variety of products and applications Products Fillflex Split Wall can handle virtually all types of fluid including highly viscous and frothing liquids It is used for filling jam and marmalade marzipan custard sauce pat dressing
28. o reduce filling speed at the end of filling Used to give the product time to run out into the whole package any foam must have time to settle in whole or part or to reduce the speed when filling packages which narrow at the top The function is also used to reduce the effect of differences in stop and shut off times Possible values NO or YES P27 Speed of slow top filling at end of filling process P27 is used if YES has been selected at P26 Function Used to give the speed after the quantity of total filling set at P28 Possible values 0 100 of max speed P28 Proportion of slow top filling at end of filling process P28 is used if YES has been selected at P26 Function Used to specify the proportion of total filling after which the slower end filling is to start When this quantity has been filled the speed changes from the basic speed set in the SPEED mode to the end filling speed set at P27 Possible values 0 100 of total filling amount 5 11 5 E The control system and its functions and programme steps Fillflex Split Wall P29 FILLING BOTTOM NO P30 TIME IN FROM BOTTOM POS 00 0s P31 SYSTEM READY SIGNAL YES P29 Bottom filling with filling lance P29 is used together with P30 Function Used if the filling machine is equipped with pneumatically controlled filling lance The speeds for movement up and down are set with separate throttle valves on the pneumatic cylind
29. on the cable and mount it on the cabinet so that the X plug hangs outside the cabinet Then plug the cable back to the respective terminals N B When installing the X2 plug do not forget to remove the jumper inside the cabinet that sits between 207 208 Installation of X contacts at fixed installation of F5500T W 1 Note the color stuck into the terminals before disconnecting them 2 Then connect your own cable on each terminal 1103 2 4 2 Fillflex Split Wall Connections and operating panel 107 47 10 8002 Buiuxpa J10JsBuiu Jt WNLVG N9IS W3SAV N3ONIMONY 138 5 A34 Wniva LOL dw uaJb N d 5 avia AV AV S399Y l ONVH gv XJT 1 1 E ids 0055 YAWWNNSONINLIY M3NADnNSL38NV 39NVUO VTIVINONIS 38LLA NYEJ 3OV IVH SVS L33SDNTID3UHOJ vig HOSISWI80J 8VSIJEXAIS O08 HOSISTIXYA 80J 8VS 3XUALS D TUVAS HOSISWTSJTH 80 BVSL UNL IVE yasnn JUVOITIVELNIN 38YO31500JUS 1 702 09 N3 SS LOVING 48398V4SDNINO31 j E S J o S UO o6 o N 0 Sc 06 VWSIHISSONINGNIGYOS 3411 q M N OL VWSHISSL3Y m S 09 VWSHISSLIYMGNANH 0S NOIL VMIJID23dS 11341 VA SUN 07 D LIYSONIGSIV Id J ONINMIFLYOASONIN LIY q V OL 6 8 9 S 7 t 1103 2 5 2 Connections and operating panel Fillflex Split Wall
30. or NO P06 Selection of start and stop method with automatic start 06 is used if YES has been chosen on P05 Function Choice of starting and stopping method with automatic starting Possible values CONT or IMP CONT As long as an external sensor e g pedal is active depressed a new start signal will come automatically after the time set on P07 When the external sensor becomes inactive pedal released the filling which has started will be completed after which automatic filling stops until the external sensor is activated again The display shows ON all the time until the signal for automatic start stops the pedal is released IMP A short pulse one push on the pedal from an external sensor starts the automatic start function with the pause time set on P07 When the external sensor is activated again new pressure on the pedal the filling which has been started will be completed after which the automatic filling stops until the external sensor is activated again The display shows ON all the time after the first external start impulse is given until the next external signal for automatic start comes The display then shows OFF 11 Fillflex Split Wall P07 PAUSE TIME NEXT FILL 5 00s P08 REVERSING NO P09 REVERSING PULSES 000 P10 REVERSING 1103 SPEED 020 5 The control system and its functions and programme steps L P07 Setting of pause time from stop to
31. rating panel Fillflex Split Wall 2 2 Electrical connections for external communication When are the X contacts used X plugs are used when external communications of different kind are to be connected with F5500T W X plugs are always pre installed inside the cabinet at delivery of a F5500T W The X1 plug is used when communication for external start stop function is connected to F5500T W Examples of such communication is when a conveyor is connected and used with the F5500T W The X2 plug is used in communication between F5500T W and a status indicator that is attached to a valve that open inwards This is because the pump not should work against a closed valve An example of such communication is when our conevalve TFV20101 is used with F5500T W X1 i ready signal external start signal max 230V 1A gt NOY start ready signal x2 status indicator 55 valve in position 2 3 1103 2 Fillflex Split Wall Connections and operating panel L Installation of X contacts at a F5500T W 1 Note the color stuck into the terminals before disconnecting them 2 Installation of X1 plug Disconnect X1 plug terminals 202 203 204 amp 206 Take the screw located on the cable and mount it on the cabinet so that the X plug hangs outside the cabinet Then plug the cable back to the respective terminals 3 Installation of X2 plug Disconnect X2 plug terminals 207 208 Take the screw located
32. s equipped with a pneumatically operated outlet valve To obtain the optimum setting between valve closure and pump stop As the pump does not stop immediately because of the speed of rotation when the control system signals stop filling continues for a short time To prevent dripping it is possible to select to shut the pneumatic valve at the same time as the pump stops or after the pump stops If NO is selected the valve closes and the pump stops at the same time If YES is selected the valve closes after the pump has stopped The time between the pump stopping and the valve closing can be determined by a setting or two settings 5 9 Ui P17 z o P23 5 The control system and its functions and programme steps SPEED UNIT RPM P18 BATCH COMP PRE FILLING z o P24 PRE FILLING 10 SPEED 020 Fillflex Split Wall 1 The time which has been selected under P03 the time after which the control programme will by definition think that the pump has stopped At this point the valve is closed if P15 is O 2 If in addition a delay time has been set under P15 this time is added to the time under P03 For example if 0 5 sec has been selected under P03 and 1 2 sec has been selected under P15 the valve closes 1 7 sec after the pump has received its stop signal Possible values NO or YES P17 Selection of unit to be shown in SPEED position Function Selection of desired unit
33. ss the green starter switch on the machine The lamp in the switch and the display on the operating panel will come on 5 Fill the system pump hose and pipe by pressing MAN on the operating panel Then press ON The pump will run as long as ON is pressed in 6 When the whole system is free from air filling can begin For setting of filling volume selection of preset programme etc see below 4 1 4 E Daily operation Fillflex Split Wall 4 3 Shut off and cleaning The procedure for daily shutdown is as follows 1 Flush out the system pump hose and pipe with suitable Pros Mode Shi rinsing agent by pressing MAN on the operating panel 3 Sk The pump will run as long as ON is pressed in Alternatively CONT may be selected The pump is then started with ON and shut off with OFF in this case the operator can leave the machine during flushing 2 Press the red quick stop shut off button on top of the machine The lamp in the green starter switch and the display on the operating panel will go out and the machine is now off 3 Remove the earthed plug Switch off the compressed air if applicable 4 Dismantle the pump and pneumatic valve if fitted for cleaning 3 333 3 333 4 4 Setting of filling volume P AUTO OFF B1 When starting after shut off the machine always begins with the filling programme B1 Any previous setting is shown under PRESET e g 3 333
34. to be shown in SPEED position Possible values RPM 9 l m litres per minute or similar according to the unit chosen at P13 P18 P22 Automatic compensation for external factors Programme steps P18 P22 are intended for compensation and setting of compensation For more information contact Fillflex AB P23 Slow prefilling at start of filling P23 is used together with P24 and P25 Function Used to avoid foaming and splashing and to increase the total filling speed Possible values NO or YES P24 Speed for slow prefilling at start of filling P24 is used if YES has been selected at P23 Function Used to give the speed of the amount of prefilling set at P25 Possible values 0 10096 of max speed 1103 Fillflex Split Wall P25 PRE FILLING P26 p P28 END 1103 AMOUNT 020 END FILLING NO END FILLING SPEED START 020 FILLING 080 5 The control system and its functions and programme steps L P25 Proportion of slow prefilling at start of filling P25 is used if YES has been selected at P23 Function Used to indicate the proportion of the total filling which is to proceed more slowly After this amount has been filled the speed changes to the basic speed set in the SPEED mode Possible values 0 100 96 of filling amount P26 Slow top filling at end of filling process P26 is used together with P27 and P28 Function Top filling end filling t
35. ty The mobile version also enables you to take the filler to the product instead of vice versa Fillflex Split Wall controls the pro cess from a diffe rent position Fillflex Split Wall has the control cabinet separated from the motor pump unit and can be placed where ver convenient 1 2 2 M Connections and operating panel Fillflex Split Wall 2 Connections and operating panel 2 1 Control shroud och operating panel Fillflex Split Wall control shroud quick stop shut off operating panel starter switch electric and pneumatic connections 2 1 1103 2 Fillflex Split Wall Connections and operating panel L Operating panel Shift Display Cont reserve Continuous switch operation Mode Change in programme Man Manual operation Prog Changeover between working and pov IE ci program Prog Mode Shift Cont Man Auto Auto ming mode Q e A Automatic x Batch operation and Increase reduce volu www fillflex com me filling speed and values when Speed On Off program Setting of fil Start Stop ming ling speed Batch Choice of preset filling programme ON on the operating panel has the same function as exter nal control via the electrical and pneumatic connections For further explanation of the operating panel functions see 5 2 Control system functions on the operating panel 1103 2 2 2 M Connections and ope
36. until it is equal to the preset value under He Ses PRESET after which filling stops and the display shows OFF The machine can be stopped in the middle of a filling process with the OFF button The display then shows HLT When the start button ON is pressed the control system continues from the value reached when the machine was stopped Preset www fillflex com To begin from 0 with a new filling after a manual stop press the AUTO button MAN Filling is manual and the pump only works as long as the start button ON or pedal or similar is pressed in The current VALUE is not zeroed if the start button ON is pressed It is zeroed by first pressing the OFF button and then the MAN button This mode of operation is used for start up filling the system and setting the filling quantity CONT The machine is operated only with the start and stop buttons ON and OFF without taking into account any preset stop value This mode of operation can for example be used for transport washing circulation or setting a high filling quan tity VALUE Current real value Shows the number of pulses from the last zero setting 5 2 1103 5 Fillflex Split Wall The control system and its functions and programme steps L PRESET Preset desired value Shows the value at which stop occurs when running on AUTO aoa Setting of value on display under PRESET
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