LFA RTP 10i User Manual
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LFA RTP 10i User Manual

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RTP 10i® Tablet Press User Manual
We don't just sell machines—
we provide service.
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Summary of Contents for LFA RTP 10i

  • Page 1 RTP 10i® Tablet Press User Manual We don’t just sell machines— we provide service.
  • Page 2 Copyright Notice © LFA Machines Oxford Limited, published in 2020 by LFA Machines Oxford Limited 2020. Registered in England and Wales, company number 08428898, registered office for service Demar House 14 Church Road East Wittering, Chichester, West Sussex, PO20 8PS.

  • Page 3: Personal Protection

    • Keep fingers away from all moving parts. For personal protection while transporting the • Ensure that it is securely against the RTP 10i®, abide by these actions: workspace surface. • Use a forklift to lift the machine. • Inspect machine before use.

  • Page 4: Symbols

    This signals potential risk for electrical shock. CAUTION This signals potential risk for damage to the machine or other parts. Modes for Stopping In the case of an emergency during automatic operation, immediately unplug the RTP 10i® and/ or push the Emergency Stop button:...

  • Page 5: Table Of Contents

    In the case of an emergency during operation, immediately push the Emergency Stop button. Important Safety Information Symbols Modes for Stopping RTP 10i® Components RTP 10i® Electrical Components (front) RTP 10i® Electrical Components (back) Preface Training On-Site/Off-Site Training Training via Video Chat/Phone...

  • Page 6: Rtp 10I® Components

    RTP 10i® Components 1. Hopper 5. Lower Tracking 2. Upper Roller Cam 6. Lower Roller Cam 3. Upper Tracking Key 7. Machine Panel Door (Back) 4. Main Turret 8. Worm Gear 9. Electric Mounting Board...

  • Page 7: Rtp 10I® Electrical Components (Front)

    RTP 10i® Electrical Components (front) WARNING Only qualified electricians should work with these controls. 1. Solenoid switches for Motor, Vacuum, (HMI) and Force Feeder 3. Force Feeder Controller 2. Programmable Logic Controller 4. AC to 12 V DC power converter...

  • Page 8: Rtp 10I® Electrical Components (Back)

    RTP 10i® Electrical Components (back) WARNING Only qualified electricians should work with these controls. 1. Breaker 3. Solenoid switches for Vacuum and 2. Variable frequency drive (for motor Force Feeder speed) 4. Fuses...

  • Page 9: Preface

    With a fast 2.2 kW motor and ten sets of Tooling, the RTP 10i® has the ability to make up to 12,000 tablets an hour. Particularly popular in the pharmaceutical, chemical, food, and electronic industries, the RTP 10i® has been designed for fast production with an emphasis on safety and ease of use.

  • Page 10: Training

    Using an online video chat system, an LFA technician can interact face-to-face with you and assist with your understanding of the machine. Or, if you prefer, LFA can provide training via phone for all customers who call the office. To set up a training, call or email your local LFA office:...

  • Page 11: Installation

    Installation Tools and Materials Needed Before you install and operate the RTP 10i®, it is best to have the following tools and materials on hand for general operation and maintenance: • Forklift • Lifting strap • Level • Crowbar • Hammer •...
  • Page 12 The shipping crate will contain the following: 1. The assembled RTP 10i® 2. The Tooling (already installed)
  • Page 13 3. Toolkit including: Note: Door keys not needed for RTP 10i®. • Die Installation/Removal Bar • Grease guns • Crosshead screwdriver • Flathead screwdriver • Wrenches • Allen key set...

  • Page 14: Assembly

    1.1 Note: Make sure that the eyelet bolt is securely tightened. 2. Feed the lifting straps through the eyelet bot. 3. Position the forks of a forklift truck over the top of the RTP 10i and securely attach the lifting straps.

  • Page 15: Controls

    Controls Basic Components Hopper Upper Roller Cam Upper Pre-Pressure Roller Cam Turret Lower Pre-Pressure Lower Roller Roller Cam A description of the principal components follows: • The Hopper holds the dry materials that will be compressed. • The Force Feeder distributes the dry materials into the Die bores and its Take-Off Blade pushes tablets into the Tablet Chute (not pictured above).
  • Page 16 Control Console To watch a video of of an introduction to the RTP 10i's digital screen controls, go to https://www. lfatabletpresses.com/rtp10i-screen-introduction 1. Adjusts Turret speed. 2. Runs/jogs the Force Feeder and/or Vacuum. 3. Shows how long the machine has been running, how many tablets have been produced, and the pressure levels during production.
  • Page 17 RTP 10i® Process The basic mechanism of the RTP 10i® involves filling the Tooling (Dies, Upper Punches, and Lower Punches) with powder, compressing the powder, and ejecting the tablets. Filling the Tooling with Powder The dry materials are poured into the Hopper and funneled into Force Feeder via the connecting pipe.
  • Page 18 • Disposable latex/rubber gloves (for food grade products and to protect hands from grease) • Hairnet and/or beard net (food grade products only) • Sterile shoe covers (food grade products only) WARNING: To prevent any potential personal injury, unplug the RTP 10i® from the electrical outlet when manually operating the machine. Instructions Note: Wear latex/rubber gloves (and appropriate food grade attire if applicable) during this process.

  • Page 19: Settings And Adjustment

    Settings and Adjustment The RTP 10i®’s settings can be adjusted. Tuning the machine can help with changing the tablets’ characteristics. Fill Depth At times, a tablet will be too small or too large, and its weight must change. This simple adjustment determines the tablet’s weight.
  • Page 20 • Disposable latex/rubber gloves (for food grade products and to protect hands from grease) • Hairnet and/or beard net (food grade products only) • Sterile shoe covers (food grade products only) WARNING: To prevent any potential personal injury, unplug the RTP 10i® from the electrical outlet. Instructions Note: Wear latex/rubber gloves (and appropriate food grade attire if applicable) during this process.
  • Page 21 5. Loosen the Force Feeder Height Adjustment Base with an Allen key. 6. Adjust the three Force Feeder Height Adjusters with a wrench/by hand. 6.1 Note: To raise the Force Feeder Adjustment Base, turn counterclockwise. To lower the Force Feeder, turn clockwise. 7.
  • Page 22 Force Feeder Speed There is a variable speed control on the lefthand side of the RTP 10i®'s console to adjust the Force Feeder's speed. The Force Feeder's speed can be increased to address any flow issues with the powder. Tools and Materials Needed •...
  • Page 23 • Disposable latex/rubber gloves (for food grade products and to protect hands from grease) • Hairnet and/or beard net (food grade products only) • Sterile shoe covers (food grade products only) WARNING: To prevent any potential personal injury, unplug the RTP 10i® from the electrical outlet. Instructions Note: Wear latex/rubber gloves (and appropriate food grade attire if applicable) during this process.
  • Page 24 • Disposable latex/rubber gloves (for food grade products and to protect hands from grease) • Hairnet and/or beard net (food grade products only) • Sterile shoe covers (food grade products only) WARNING: To prevent any potential personal injury, unplug the RTP 10i® from the electrical outlet. Instructions Note: Wear latex/rubber gloves (and appropriate food grade attire if applicable) during this process.
  • Page 25 Tight Upper Punches and Lower Punches can be an indication of not enough oil. Adjusting the flow of the RTP 10i®'s oil wick well (located at the top of the machine) can help with these lubrication issues.
  • Page 26 • Disposable latex/rubber gloves (for food grade products and to protect hands from grease) • Hairnet and/or beard net (food grade products only) • Sterile shoe covers (food grade products only) WARNING: To prevent any potential personal injury, unplug the RTP 10i® from the electrical outlet. Instructions Note: Wear latex/rubber gloves (and appropriate food grade attire if applicable) during this process.
  • Page 27 • Disposable latex/rubber gloves (for food grade products and to protect hands from grease) • Hairnet and/or beard net (food grade products only) • Sterile shoe covers (food grade products only) WARNING: To prevent any potential personal injury, unplug the RTP 10i® from the electrical outlet. Instructions Note: Wear latex/rubber gloves (and appropriate food grade attire if applicable) during this process.

  • Page 28: Maintenance

    Maintenance To ensure that the RTP 10i® will have a long operational life, maintenance is essential. This section includes methods for replacing parts, troubleshooting solutions, and how often to grease and clean your machines to keep its performance optimal. General Maintenance Prescriptions •...
  • Page 29 2. Remove the Upper Punches and Lower Punches. 2.1 For additional assistance, please refer to the Tooling replacement instructions on page 3. Lubricate the heads of the Upper Punches and Lower Punches with NLGI Grade 1 grease. 4. Lubricate the barrels of the Upper Punches and Lower Punches with SAE 10 oil. 5.
  • Page 30 6. Lubricate the Upper Roller Cam's grease nipple with NLGI Grade 2 grease. 7. Pull off the righthand side panel door. 8. Lubricate the Lower Roller Cam's grease nipple with NLGI Grade 2 grease.
  • Page 31 Lubrication Schedule LFA recommends the following RTP 10i® parts to be lubricated according to the following frequency: Part Location Image Frequency Type of Lubricant Visually inspect through Mounted above the the eye glass and apply Main Worm Gear Motor in the lower WA 460 Oil (0.55 L)

  • Page 32: Dismantling For Repair And Replacement

    Dismantling for Repair and Replacement Eventually due to wear and tear, some parts of the RTP 10i® will need to be removed for repair and replacement. To prevent any delays in your tablet production, it is best practice to keep extra parts just in case.

  • Page 33: Wear Parts And Causes Of Damage

    Cause of Damage Tooling The Tooling can become chipped or broken. Lead times for a new set of Tooling can take as long as 6-8 weeks, so LFA recommends having a spare set or two. Force Feeder On the RTP 10i®, the Force Feeder is used to spread the powder over the Die Table and into the Die bores.

  • Page 34: Tooling

    If you want to change the shape and diameter of the tablet, or if any of the Upper Punches, Lower Punches, and/or Dies you currently have are damaged, it is necessary to change the Tooling. To watch a video of an RTP 10i® Tooling change, go to https://www.lfatabletpresses.com/rtp10i-...
  • Page 35 4. Unscrew and remove the Force Feeder's 17 mm bolts with a wrench or by hand. 5. Pull up the Force Feeder and remove it from the RTP 10i®. 6. Remove the entire Upper Tooling Shroud with a crosshead screwdriver.
  • Page 36 11. Repeat steps 9-10 until all Upper Punches are removed. 12. Remove the Lower Tooling Shroud with an Allen key. 13. Push up the the Lower Punch Retaining Puck underneath the Lower Punches and remove it from the RTP 10i®.
  • Page 37 14. Rotate the Hand Wheel until a Lower Punch is aligned with where the Lower Punch Retaining Puck was previously. 15. Gently pull on the Lower Punch's head through the hole. 15.1 Note: Be sure to have a firm hold on the Lower Punch so that it does not fall and become damaged.
  • Page 38 19. Insert the Die Removal Bar up through the hole where the Lower Punch Retaining Puck was previously. 20. Tap the Die with the Die Removal Bar until it pops up from the Turret. 20.1 Note: If Die is difficult to remove, tap the end of the Die Removal Bar with a rubber mallet.
  • Page 39 Note: To help ensure that the Dies are inserted correctly, LFA recommends using an Insertion Ring. You can order the Die Seat Cleaner and Insertion Ring on our website at https://www. lfatabletpresses.com/die-seat-cleaner-insertion-ring Replace the Tooling 22. Position the new Die on the Turret.
  • Page 40 29. Rotate the Hand Wheel until the next new Lower Punch can be inserted. 30. Repeat steps 28-29 until all the new Lower Punches are inserted into the Turret. 30.1 Note: Manually turn the RTP 10i® Turret for a couple of rotations to ensure that the new Lower Punches are situated correctly.
  • Page 41 34. Rotate the Hand Wheel until the next new Upper Punch can be inserted. 35. Repeat steps 32-34 until all the new Upper Punches are inserted into the Turret. 35.1 Note: Manually turn the RTP 10i® Turret for a couple of rotations to ensure that the new Upper Punches are situated correctly.
  • Page 42 37. Reassemble the Lower Tooling Shroud and insert it back on the RTP 10i® with an Allen key. 38. Resecure the Upper Tooling Shroud back on the RTP 10i® with a crosshead screwdriver. 39. Place the Force Feeder on the RTP 10i® base's key and align it with the bolts' holes.

  • Page 43: Force Feeder Wear Plate

    Force Feeder Wear Plate The Force Feeder channels the dry materials into the Die bores. This part has a brass plate designed to wear to avoid damaging the Tooling and/or Turret, so it may need to be replaced. Tools and Materials Needed •...
  • Page 44 4. Unscrew and remove the Force Feeder's 17 mm bolts with a wrench or by hand. 5. Pull up the Force Feeder and remove it from the RTP 10i®. 6. Remove the Force Feeder Wear plate with a crosshead screwdriver.
  • Page 45 7. Attach the new Force Feeder Wear Plate to the Force Feeder with a crosshead screwdriver. 8. Place the Force Feeder on the RTP 10i® base's key and align it with the bolts' holes. 9. Screw in the Force Feeder's 17 mm bolts.

  • Page 46: Take-Off Blade And Force Feeder Scraper

    Take-Off Blade and Force Feeder Scraper The Take-Off Blade and Force Feeder Scraper are attached to the Force Feeder. They help keep the powder flowing into the Dies' bores and aid in tablet ejection. Tools and Materials Needed • Crosshead screwdriver •...
  • Page 47 4. Unscrew and remove the Force Feeder's 17 mm bolts with a wrench or by hand. 5. Pull up the Force Feeder and remove it from the RTP 10i®. 6. Remove the Force Feeder Scraper with a crosshead screwdriver.
  • Page 48 7. Remove the Take-Off Blade from the Force Feeder with a crosshead screwdriver. Replace the Take-Off Blade and Force Feeder Scraper 8. Loosely attach the Take-Off Blade to the Force Feeder.
  • Page 49 9. Loosely attach the Force Feeder Scraper to the Force Feeder. 10. Place the Force Feeder on the RTP 10i® base's key and align it with the bolts' holes.
  • Page 50 11. Screw in the Force Feeder's bolts. 11.1 Note: Please refer to the Force Feeder Height adjustment instructions on page 20 for calibration or watch the following video: https://www.lfatabletpresses.com/rtp10i-force-feeder- calibration 12. Adjust the Force Feeder Scraper so that it is flush against the Die Table. 13.

  • Page 51: Adjustment Knobs

    Adjustment Knobs The adjustment knobs are located on the lefthand side of the RTP 10i® and control the tablet's thickness and weight as well as the Pre-Pressure Roller Cam compression level. Tools and Materials Needed • New Adjustment Knob part •...
  • Page 52 Replace the Adjustment Knob 3. Insert the new Adjustment Knob onto the keyed shaft. 3.1 Note: Ensure that the keyed shaft is in the upward position. 4. Rotate the inner knob clockwise until the new Adjustment Knob is secure.

  • Page 53: Troubleshooting

    Troubleshooting Sometimes unavoidable issues will occur while operating the RTP 10i®. Fortunately, there are several methods to remedy these issues. Common Machine/Part Issues Symptom Possible Cause Possible Solution Regularly oil and grease all the Grease point areas are dry. Grease Nipples and high friction areas.
  • Page 54 The Tooling is damaged. Upper Punches, Lower Punches, and Dies). If the machine is able to make tablets with LFA's Firmapress®, then the There are flowing issues with the mix. problem is your mix. Adjust your formulation. If still an issue, contact...

  • Page 55: Common Tablet Issues

    If the machine is able to make tablets There are problems with the with LFA's Firmapress®, then the formulation of the granules and problem is your mix. Adjust your ingredients. formulation. If still an issue, contact LFA for support.

  • Page 56: De-Jamming The Rtp 10I

    De-Jamming the RTP 10i® There are several reasons why a RTP 10i® might jam such as: • The fill depth is set too low and the pressure is set too high. At its highest punch pressure force, the machine will automatically cut off.

  • Page 57: Cleaning

    Cleaning During the RTP 10i®’s operation, excess powder will find its way into parts of the machine, particularly in the Tooling and Force Feeder. It is important to clean the RTP 10i® thoroughly to prevent rusting and cross contamination. LFA recommends that the machine be cleaned after each operation.
  • Page 58 Pull out the Force Feeder Adjustment Base Discharge Plate to release excess powder. Reinsert the Force Feeder Adjustment Base Discharge Plate and secure its screw with a crosshead screwdriver. Remove and Clean the Parts 5. Remove the Hopper, the Force Feeder, and the Tooling. 5.1 Note: Please refer to the replace Tooling instructions on page 33 for further assistance.
  • Page 59 Dismantle and Clean the Force Feeder 10. Remove the screws on the outside of the Force Feeder with a crosshead screwdriver. 11. Pull up the top of the Force Feeder from the bottom. 12. Spray the Force Feeder's bottom with a cleaner, particularly where the propellers come into contact with powder.
  • Page 60 15. Remove the Force Feeder's paddles with an Allen key. 15.1 Note: Hold onto one of the paddles while removing the other to keep it from moving. 15.2 Note: If paddles are difficult to remove, insert a flathead screwdriver underneath it for leverage.
  • Page 61 26. Vacuum the entire area inside the bottom part of the panel door encasement. 26.1 Note: Be sure to vacuum both levels and all corners of the RTP 10i® base. Note: LFA recommends using our Die Seat Cleaner. You can order...

  • Page 62: Storing The Rtp 10I

    After its thorough cleaning, the RTP 10i® needs to be stored in the proper conditions. It is important to store it in an environment in which the machine is safe from rusting. The RTP 10i®’s high traction areas and the Tooling need to be lubricated separately before you store them.
  • Page 63 Lubricating the Grease Points and High-Traction Parts 1. Pull off all of the lower panel doors from the RTP 10i®. 2. Remove the Hopper and raise all the Perspex Casing's doors. 3. Lubricate the Upper Roller Cam's oil well's wick on top of the machine with a grease gun.

  • Page 64: Appendix

    The adjustable amount of force that is used to Punch pressure press tablets. LFA trademarked term for rotary tablet press. RTP® Enables a tablet press to form tablets. It Tooling consists of a Die, Upper Punch, and Lower...

  • Page 65: Description Of Rtp 10I® Parts

    Description of RTP 10i® Parts Tooling Take-Off Blade and Force Feeder Scraper The Tooling consists of the Dies, the Upper The Force Feeder Scraper (nonmetal) helps Punches, and the Lower Punches. They all work keep the powder flowing into the Dies' bores, as a set and compress the powder into tablets.
  • Page 66 Hopper Perspex Casing Door The Hopper contains the powder and allows it The Perspex Casing Doors (4) make up to flow into the Force Feeder and into the Dies' an enclosure that covers the Turret and bores. Order at https://www.lfatabletpresses. Force Feeder.
  • Page 67 Ejection Cam The Ejection Cam pushes the Lower Punches up through the Die bores to eject the tablets from the press. Order at https://www.lfatabletpresses. com/ejection-cam-rtp-10i Fill Cam The Fill Cam pulls down the Lower Punches into the Die bores, which allows powder to enter. Order at https://www.lfatabletpresses.com/rtp- 10i-fill-cam...
  • Page 68 Upper Pre-Pressure Roller Cam Hopper to Force Feeder Connecting Pipe The Upper Pre-Pressure Roller Cam provides the The Hopper to Force Feeder Connecting Pipe initial compression force to the Upper Punches. allows powder to be transferred from the Order at https://www.lfatabletpresses.com/pre- Hopper to the Force Feeder.
  • Page 69 Force Feeder Adjustment Base The Force Feeder Adjustment Base is seated Force Feeder Height Adjustment Nut underneath the Force Feeder. It can be moved The Force Feeder Height Adjustment Nut is to adjust the height of the Force Feeder, which moved to change the Force Feeder's height affects powder flow.
  • Page 70 Force Feeder. It is made of Front Panel Electrical Door brass and meant to wear. Order at https://www. The Front Panel Electrical Door can be opened lfatabletpresses.com/rtp-10i-force-feeder-wear- to reveal the RTP 10i®'s electrical components. plate Order at https://www.lfatabletpresses.com/rtp- 10i-front-panel-electrical-door Lower Punch Retaining Puck...
  • Page 71 Perspex Casing Door Hinge The Perspex Casing Door Hinge connects two Perspex Casing Doors together. Order at https:// www.lfatabletpresses.com/rtp-10i-perspex- Adjustment Knob casing-door-hinge The Adjustment Knobs control the RTP 10i®'s punch pressure, pre-pressure, and the tablet's fill depth. Order at https://www.lfatabletpresses. com/rtp-10i-adjustment-knob...
  • Page 72 Upper Punches. Order at https://www. lfatabletpresses.com/rtp-10i-upper-shroud Tablet Chute Stand The Tablet Chute Stand supports the Tablet Chute up against the RTP 10i®'s base. Order at Vacuum-Turret Connection https://www.lfatabletpresses.com/rtp-10i-tablet- The Vacuum-Turret Connection joins the chute-stand vacuum to the Turret. Order at https://www.

  • Page 73: Food Grade Point Of Contact Parts

    Food Grade Point of Contact Parts Contact Part Material Turret Cast iron 250 Ejection Tray SUS304 Hopper SUS304 Tooling User specified (Upper Punches, Lower Punches, and Dies) Fill Tray Tin bronze QSN-6-3 Force Feeder Scraper and Take-Off Blade Bakelite and copper coat Zn Technical Specifications Tooling Specification D Tooling...

  • Page 74: Maintenance Checklist

    Maintenance Checklist Before Operation □ Visually inspect the tablet press and the parts. □ Ensure all locking nuts are tight. □ Visually inspect grease nipples and regrease where necessary. □ Manually rotate the machine without powders to ensure that it is not jammed □...

  • Page 75: Diagrams

    Diagrams RTP 10i® Upper Tooling and Die Dimensions A - A...
  • Page 76 RTP 10i® Lower Tooling Dimensions...
  • Page 77 RTP 10i® Exploding Diagram Drawing RTP-10i Exploded View 1 Name Product RTP-10i Name Version V1.0 Provided Mark Burchell www.lfamachines.com...
  • Page 78 RTP 10i® Wiring Diagram 1...
  • Page 79 RTP 10i® Wiring Diagram 2...
  • Page 80 RTP 10i® Wiring Diagram 3...

  • Page 81: Resources

    Warranty LFA Machines YouTube Channel For information regarding the warranty policy of Our YouTube videos provide you an opportunity the RTP 10i® and other LFA products, please to see demonstrations of how to use our tablet visit https://www.lfatabletpresses.com/warranty presses, common troubleshooting tips, and...
  • Page 82 LFA MACHINES Copyright © 2020 by LFA Machines www.lfamachines.com Germany Taiwan United Kingdom United States Business Parc Am Unit 4B 955 N Sylvania Ave 403, Section 2, 2號 Trippelsberg 92 Murdock Road Fort Worth Taiwan Boulevard Düsseldorf Bicester Texas Taichung City...

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