Fillflex™ Compact Operating and Service Manual
Contents
1. 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 Compact 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 E P07 Setting of pause time from stop to new start of next filling P07 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 P08 Reversing of direction of flow at end of filling process PO8 is used with P09 and P10 Function Reversing of direction of flow of gear and lobe pumps to reduce the dripping tendency when filling with viscous products The filling process is completed when the pump runs in the opposite direction with the number of pulses given at P08 after which the product remaining outside the filling nozzle is withdrawn slightly If a hose is used for filling and r2. 100 of max speed P28 Proportion of slow top filling at end of filling process P28 is used if YES has been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 K The control system and its functions and programme steps Fillflex Compact 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 cylinder Used for filling foaming products or to avoid splashing Possible values NO FINISHED or TIME FINISHED At the start signal for filling the filling lance goes down to its bottom position When the control unit receives the signal that the lance is in position filling starts and the filling lance remains in the bottom 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
3. NO Function disconnected This position is normally used only for running in and special operation which is usually carried out by specialist personnel See also 5 3 Sensor fault indication Possible values YES or NO P35 Type and version of control unit 5 13 5 he The control system and its functions and programme steps Fillflex Compact Notes Batch 1 Value occ Speed oc Batch 2 Value occ Speed ce Batch 3 Value occ Speed ce Batch 4 Value once SPEC e Batch 5 Values occ SPEC erener Batch 6 Value ccc Speed ce Batch 7 Value once Speed oc Batch 8 Value occ Speed occ 5 14 1103 Fillflex Compact 5 The control system and its functions and programme steps 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 A
4. 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 Big 3 SE 0 000 1 Place an empty container under the ejector BML Ore Bt 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 I 3383 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 2 29 I DIF 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
5. hand cream paint acid oil and other substances Containers Fillflex Compact 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 Power connection 230 V single phase earthed standard earthed socket no permanent connection is required It features connectors for external start up and communication with a conveyor system etc 1103 Fillflex Compact 1103 Dimensions 1 This is Fillflex Compact Length approx 400 mm Width 260 mm Height approx 400 mm Weight approx 25 kg Construction Fillflex Compact features a simple and robust design The pump is driven by an electric motor installed inside the shroud 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 installation and connection Fillflex Compact basic version Fillflex can be pro vided with different types of ejector for for example viscous media where there is a risk of dripping Pedal started Fillflex Compact with feed hopper Fillflex with a hop per that is filled from above and discharges at the bottom This is a sui
6. increase or reduce the value or alternate between two or uon 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 control has tripped shut off the machine and restart The pump rotates but VALUE does not change on the display Action Contact your machine supplier or Fillflex AB 1103 Fillflex Compact P01 PULSE REV 01 P02 PULSE RATIO OUT 1 INPUT 001 P03 STOP DETECT PULLS PUES 1103 1 00s 5 The control system and its functions and programme steps E 5 4 All the steps in the control programme The programming mode is obtained as follows 1 Press PROG on the operating panel 2 Step forward to the desired programme step with Note that inapplicable programme steps are omitted For example P06 and P07 are not shown unless YES has been selected under
7. machine automatically compensates at the second filling and VALUE will then be the same as under PRESET 1103 D N Fillflex Compact 065 SPEED 1173RPM Ex Speed is 1 173 rpm which represents 65 of maximum 1103 4 Daily operation 4 5 Fine adjustment of filling volume If the filling volume set under PRESET needs fine adjustment somewhat too little or too much in the package this is done as follows 1 Adjust the value under PRESET with or 2 At the next filling the adjusted volume will be filled 4 6 Adjustment of filling speed 1 Press SPEED on the operating panel 2 Adjust the value speed as of maximum by pressing a uw a 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 Compact 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 the machine always w
8. ALUE both upwards and downwards PRESET and VALUE then remain the same all the time Possible values YES or NO YES If YES is selected the stop signal in the next filling will come as many pulses earlier as the excess number in the preceding filling NO If NO is selected the stop signal will come when PRESET and VALUE are equal P12 Constant between pulses and volume Function Constant by which the number of pulses is multiplied to enable the value of PRESET and VALUE to agree with the numerical value for volume or weight in the package which is being filled Possible values 0 001 9 999 Example If a filled volume of 650 ml gives a numerical value of 400 pulses the factor will be 650 400 1 625 By setting the constant 1 625 under P12 the numerical value on the display will show the number of ml The value obtained is then combined with the units in P13 P13 Choice of units Function To give the right unit for the value after setting in P12 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 Compact P14 PUMP START DELAY 0 00s P15 VALVE CLOSE DELAY 0 00s P16 VALVE CLOSE AFTER STOP 1103 YES 5 The control system and its functions and programme steps E P14 Delay of pump start Function Used if the filling machi
9. Fillflex Compact Operating and Service Manual P Fillflex Compact Model T5500C Control system version 1 6b Operating and Service Manual FILLFLEX the flexible filling machines Fillflex AB S dra L ngebergsgatan 26 B SE 421 32 Vastra Fr lunda info fillflex com Tel 46 31 1458 40 Fax 46 31 14 58 43 www fillflex com 1103 Contents Fillflex Compact Contents Safety regulations 1 This is Fillflex Compact Brief description of the Fillflex system 2 Connections and operating panel 2 1 Control shroud och operating panel 2 2 Electrical connections for external communication 3 Installation and connection of new machine 3 1 Manually started filling filling controlled by operator 3 2 Mechanically started filling filling controlled by e g conveyor belt 4 Daily operation 4 1 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 system programme steps 6 CE Certificate 1103 Fillflex Compact Warning symbols AN General warning AN Dangerous voltage A Corrosi
10. 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 P02 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 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 be The control system and its functions and programme steps Fillflex Compact P04 FLOW DIRECTN gt gt gt POS AUTO START NEXT P06 5 6 PILE NO EX
11. P24 is used if YES has been selected at P23 Function Used to give the speed of the amount of prefilling set at P25 Possible values 0 100 of max speed 1103 Fillflex Compact P25 PRE FILLING P26 P27 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 E P25 Proportion of slow prefilling at start of filling P25 is used if YES has been selected at P23 Function Used to indicate the proportion of the total filling which is to proceed more slowly After this amount has been filled the speed changes to the basic speed set in the SPEED mode Possible values 0 100 of filling amount P26 Slow top filling at end of filling process P26 is used together with P27 and P28 Function Top filling end filling to reduce filling speed at the end of filling Used to give the product time to run out into the whole package any foam must have time to settle in whole or part or to reduce the speed when filling packages which narrow at the top The function is also used to reduce the effect of differences in stop and shut off times Possible values NO or YES 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
12. TERN 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 lt lt lt or gt gt gt P05 Automatic start after change of packing P05 is used with P06 and P07 Function Automatic start after the time which is set on P07 Used for example to enable a large number of packages to be filled more quickly The operator then has the time set under P07 to change the package Filling then starts automatically without a new start signal needing to be given Possible values YES or NO P06 Selection of start and stop method with automatic start P06 is used if YES has been chosen on P05 Function Choice of starting and stopping method with automatic starting Possible values CONT or IMP CONT As long as an external sensor e g pedal is active depressed a new start signal will come automatically after the time set on P07 When the external sensor becomes inactive pedal released the filling which has started will be completed after which automatic filling stops 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
13. closed valve An example of such communication is when our conevalve TFV20101 is used with F5500C X1 X2 ZON ZON external start signal es Liat IA status indicator XOY NOS start ready signal valve in position X5 ZOS Ge ready signal NPN indicator SKER stop signal o max 230 V 1A 0 30 V DC XO stop ready signal start signal 2 3 1103 Fillflex Compact starter switch quick stop shut off pneumatic connections connection for any external electrical or pneumatic control 1103 3 Installation and connection of new machine 3 Installation and con nection of new machine Fillflex Compact can be used for both 3 1 Manually started filling the filling process is started by an operator or 3 2 Mechanically started filling the filling process is started by a signal from a conveyor belt or similar equipment The machine may have been delivered with different types of peripheral equipment depending on its intended use e g pneumatic pedal different types of ejector pneumatic valves etc Check that the equipment is complete before installation and connection 3 1 Manually started filling Fillflex Compact is delivered with a suitable pump and a conventional tube ejector as an outlet pipe and a hose connection for the suction line These instructions apply to machines equipped in this manner Fillflex Compact can always be quick stopped with the red quick stop button on top of the machine S
14. d 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 steplessly with the buttons and 1103 5 3 5 be The control system and its functions and programme steps Fillflex Compact 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
15. et up the machine on a stable foundation 2 Connect the suction line or filling hopper if the machine is 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 paragraph 7 3 Connect the outlet and pneumatic valve if the machine is equipped with one to the outlet side of the pump 4 Connect any external communication electrical or pneumatic 5 Connect the machine to a 230 V earthed socket 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 Compact 7 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 P0O1 PULSE REV If the pump is going the wrong way the direction of 01 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 7 Press MODE Display at P04 Ea Press PROG Display after pressing PROG The pump will now rotate in t
16. eversing 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 PO9 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 5 7 P11 5 The control system and its functions and programme steps Fillflex Compact COMPENSATION PRESET VALUE YES P12 PULSE MULTI FACTOR 1 000 Biles CHOICE OF 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 V
17. ex Compact cautious initial filling etc after ON has been pressed Then the machine stops and waits for ON to be pressed again The starting impulse can also come from a hand held switch pneumatic pedal automatic conveyor belt etc This mode is selected by pressing AUTO and is usually the normal operating mode for the machine 5 2 Control system functions on the operating panel AUTO When starting 1 the current reading is zeroed on the display under VALUE 2 the display shows ON 3 the pump starts 4 filling begins and 5 the sensor emits pulses The current VALUE counts up until it is equal to the preset value under 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
18. f 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 The control system and its functions and programme steps Fillflex Compact 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 020 speed 25 Pre Filling 020 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 Ready 0 0s Signal Time Delay 33 Restart No Yes From Zero 34 Connect Yes No Sensor Fault 35 BC 5500 1 6 Version If you change this program step diffrent program steps could appear afterwards If you feel uncertain read the manual before you change Fore more information contact Fillflex AB 1103 Fillflex Compact 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 Fil
19. he other direction 8 Fill the system pump hose and pipe by pressing MAN on the operating panel Then press ON The pump will pen go as long as the button is pressed in The system must be entirely free from air before filling can begin poas 9 The speed can be increased to make it easier for the pump e to suck The speed is adjusted by pressing SPEED and increasing reducing with or Then press SPEED wepenliien ccm again to return the display 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 plug X1 electrical connection for external signal from conveyor belt etc 3 2 1103 4 Fillflex Compact Daily operation 4 Daily operation 4 1 Quick stop Fillflex Compact 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 ay 5 nm 4 2 Start up For daily
20. lflex AB Karl Johansgatan 158 414 51 Gothenburg Sweden Signed Rud ba Date Name Sture Olsson Position Managing Director 1103
21. nd the valve closing can be determined by a setting or two settings 5 9 vI P17 a Oo P23 5 The control system and its functions and programme steps SPEED UNIT RPM P18 BATCH COMP PRE FILLING Oo P24 PRE FILLING 10 SPEED 020 Fillflex Compact 1 The time which has been selected under P03 the time after which the control programme will by definition think that the pump has stopped At this point the valve is closed if P15 is 0 2 If in addition a delay time has been set under P15 this time is added to the time under P03 For example if 0 5 sec has been selected under P03 and 1 2 sec has been selected under P15 the valve closes 1 7 sec after the pump has received its stop signal Possible values NO or YES P17 Selection of unit to be shown in SPEED position Function Selection of desired unit to be shown in SPEED position Possible values RPM l m litres per minute or similar according to the unit chosen at P13 P18 P22 Automatic compensation for external factors Programme steps P18 P22 are intended for compensation and setting of compensation For more information contact Fillflex AB 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
22. ne 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 is equipped with a pneumatically operated outlet valve To obtain the optimum setting between valve closure and pump stop As the pump does not stop 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 a
23. nel Shift Display Cont reserve Continuous switch operation Mode Change in programme Man Manual operation Prog Changeover between working and pe ENN program Prog Mode Shift Cont Man Auto Auto ming mode VY Vd LY LT Automatic Speeal Cn 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 E Connections and operating panel Fillflex Compact 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 F5500C X plugs are always pre installed outside the cabinet at delivery of a F5500C The X1 plug is used when communication for external start stop function is connected to F5500C Examples of such communication is when a conveyor is connected and used with the F5500C The X2 plug is used in communication between F5500C and a status indicator that is attached to a valve that open inwards This is because the pump not should work against a
24. orks to one of the filling programmes B1 to B8 The machine always starts in the same batch programme that was used when it was shut down Custom batch can be noted on pages 5 14 5 15 This is how a filling programme is stored in the memory 1 Select the desired position B1 B8 by pressing BATCH The position must always be selected before programming 2 Make the desired settings e g filling volume see section 4 4 speed see section 4 6 or other parameters see section 5 3 Doa filling 4 The desired programme is now stored in the selected programme position 4 8 Using a stored filling programme 1 Select the desired programme position B1 B8 by pressing BATCH 2 Press AUTO 3 The programme is now ready for use 4 9 Change a stored filling programme 1 Select the programme position B1 B8 which it is desired to change by pressing BATCH 2 Make the desired adjustments 3 Doa filling 4 The changes are now stored in the selected programme position 1103 Fillflex Compact 1103 5 The control system and its functions and programme steps E 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
25. quantity of filling material which has passed the pump By counting the pulses during filling and comparing them with the set values the machine can control the filling process There are three operating modes 1 Continuous operation CONT 2 Manual operation MAN 3 Automatic operation AUTO During automatic operation the filling process can be varied according to the filling material and the container volume speed cautious initial filling etc The adjusted filling process BATCH is stored in the memory of the control unit 1 Continuous operation CONT When on continuous operation the pump works continuously until OFF is pressed This mode of operation is selected by pressing CONT Filling is then controlled only with ON and OFF without considering any preset stop value This mode can be used for transport washing circulation or setting a large filling volume 2 Manual operation MAN When on manual operation the pump works as long is ON is pressed This mode is selected by pressing MAN Filling is then controlled only with ON This mode is used for start up filling the system and setting the filling volume 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 K The control system and its functions and programme steps Fillfl
26. 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 Compact The control system and its functions and programme steps PRESET Preset desired value Shows the value at which stop occurs when running on AUTO aoa Setting of value on display under PRESET 020 Bae www tillfl x com 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 u n 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 selecte
27. table arrang ement for viscous media Fillflex Compact and automatic operation The standard version Fillflex is prepared for fully automatic operation This makes it easy to increase output The starting signal comes from the conveyor Fillflex Compact with bottom filler Fillflex can be com bined with a pneu matic bottom filler for foaming liquids etc The bottom filler is fully controlled by the Fillflex control programme Fillflex Compact on wheels Fillflex equipped with wheels and standing on the floor The machine starts and stops itself and the operator need only move the ejector bet ween the receptacles Fillflex Compact and automatic operation with bottom filler Here automatic filling has been supplemen ted with a bottom filler for foaming liquids The starting signal comes from the conveyor 1 2 2 E Connections and operating panel Fillflex Compact 2 Connections and operating panel 2 1 Control shroud och operating panel Fillflex Compact control shroud Quick stop shut off Operating Starter switch panel Pneumatic connections M Electrical connection for external signal from conveyor belt etc Pneumatic connection for external control by pedal etc The electrical and pneumatic connections for external control give the same function as ON on the operating panel 2 1 1103 2 Fillflex Compact Connections and operating panel Operating pa
28. 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 Compact The control system and its functions and programme steps E 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 been selected at P31 Function Used to delay ready signal for example to wait for other equipment or to avoid dripping in wrong place Possible values 0 00 9 99 s seconds P33 Restart from zero Function Used for restart from zero at next 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
29. use the Fillflex Compact is started as follows 1 Fit the pump and pneumatic valve if applicable if these have been removed and cleaned 2 Connect where applicable the compressed air to the pneumatic valve 3 Connect the earthed plug 4 Press the green starter switch on the machine The lamp in the switch and the display on the operating panel will come on e 1 wane X XXX 0 008 P AUTO OFF The display after the starter switch has been pressed the last value set is shown at X XXX 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 Prog Mode Shift Go Gr 6 When the whole system is free from air filling can begin Jie C eeh For setting of filling volume selection of preset programme etc see below Preset www fillflex com 1103 4 1 4 E Daily operation Fillflex Compact 4 3 Shut off and cleaning The procedure for daily shutdown of the machine is as follows 1 Flush out the system pump hose and pipe with suitable Prog Mode Shift rinsing agent by pressing MAN on the operating panel ome Gia The pump will run as long as ON is pressed in Alternatively CONT may be selected The pump is then www iliflex com 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
30. ve substances 1103 Safety regulations m 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 AN Always study the technical data A Only qualified electricians may open the cover of the electric equipment A Never insert fingers into pump connections or any shut off valve Operation AN Always study the technical data AN Never touch a pump or piping containing hot liquids AN Never start the machine before the pump unit is properly assembled A Always handle hazardous fluids with great caution AN Never insert fingers into pump connections or any shut off valve Maintenance AN Always study the technical data AN Disconnect electrical connections and any air connection before servicing AN Servicing must never be carried out while the pump is hot AN The pump and pipes must not be under pressure during servicing AN Never insert fingers into pump connections or any shut off valve 1 1 1 This is Fillflex Compact Fillflex Compact 1 This is Fillflex Compact Fillflex Compact is the latest generation 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 Fillflex Compact is ver
31. y 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 It is very easy to clean the pump can even be dismantled without tools The entire machine is made of stainless materials and is easily washed and cleaned Since filling volumes can be altered infinitely the same machine can be used for filling small retail size 10 ml bottles as well as large wholesale size drums or vats The containers to be filled can be fed either manually one at a time orina fully automatic process for large scale operation using conveyor belts Fillflex Compact can also handle traditionally difficult media such as highly viscous foodstuffs and cleaning agents or detergents which froth easily Adjustment of the operating parameters on Fillflex Compact is simplicity itself If you need to increase production simply keep your machine and add a conveyor system and other peripheral equipment The machine is available with a wide range of ejectors valves and accessories for a variety of products and applications 0 G Products Fillflex Compact 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 preservatives yoghurt mayonnaise honey washing liquid shampoo degreasers
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