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ACASIS PI-3300 Operation Manual

Piston filler machine
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OPERATION MANUAL
PISTON FILLER MACHINE
MODEL PI-3300
CLIENT: SIGMA EQUIPMENTS
SERIAL # 2947
ALL OPERATORS MUST READ AND UNDERSTAND THIS MANUAL BEFORE
THEY CAN USE THE MACHINE
th
7085 NW 46
Street, Miami, FL 33166 - USA. Telephone: 305-8058533 Fax: 305-8058535
www.acasi.com
PI-3100 Page #
1

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Summary of Contents for ACASIS PI-3300

  • Page 1 OPERATION MANUAL PISTON FILLER MACHINE MODEL PI-3300 CLIENT: SIGMA EQUIPMENTS SERIAL # 2947 ALL OPERATORS MUST READ AND UNDERSTAND THIS MANUAL BEFORE THEY CAN USE THE MACHINE 7085 NW 46 Street, Miami, FL 33166 - USA. Telephone: 305-8058533 Fax: 305-8058535 www.acasi.com...
  • Page 2 ALL PROPOSAL, QUOTATIONS AND ORDERS ARE SUBJECT TO THE FOLLOWING TERMS AND CONDITIONS Quoted Prices are FOB point of shipment (Miami, FL), freight collect or prepaid. The contents of all quotations are subject to change without notice. Brochures and literature are subject to constant design improvements and are not binding in detail. ACASI MACHINERY INC.
  • Page 3 Date Revision Edited Approved Comments 06/2014 I. Possin First version 7085 NW 46 Street, Miami, FL 33166 - USA. Telephone: 305-8058533 Fax: 305-8058535 www.acasi.com PI 3300 Page # 3...

  • Page 4: Table Of Contents

    INDEX INTRODUCTION ....................6 RECEIPT OF THE MACHINE ................7 III. PLACEMENT AND INSTALLATION OF THE FILLER MACHINE ....8 SYSTEM REQUIREMENTS FOR STARTING UP THE MACHINE ....11 V. GENERAL AND PREVENTIVE MAINTENANCE ..........12 GETTING FAMILIAR WITH THE MACHINE ..........14 Control Panel ......................
  • Page 5 INDEX FIGURE Figure 1: Mounting the Conveyor to the Machine and Leveling ........7 Figure 1A ........................8 Figure 1B ........................9 Figure 1C ........................10 Figure 2: Frontal view of the control panel ..............14 Figure 3: Internal View of the Control Panel..............16 Figure 4: Location of the Sensors on the Machine............

  • Page 6: Introduction

    Following the instructions listed in this manual will also increased the life span of your PI-3300 piston filler. Please, do not hesitate to contact Acasi Machinery if you require further information or assistance with this machine.

  • Page 7: Receipt Of The Machine

    RECEIPT OF THE MACHINE If your machine is equipped with a feed tank (optional part), the hoses will be disconnected from the valve system for easier transportation, please use the supplied hose clamps to fasten the tubing to the valves. In the machine was purchased with a conveyor installed (optional part).

  • Page 8: Placement And Installation Of The Filler Machine

    III. PLACEMENT AND INSTALLATION OF THE FILLER MACHINE Decide the machine location according to the dimensions shown in the following images. Figure 1A 7085 NW 46 Street, Miami, FL 33166 - USA. Telephone: 305-8058533 Fax: 305-8058535 www.acasi.com PI 3300 Page # 8...
  • Page 9 Figure 1B 7085 NW 46 Street, Miami, FL 33166 - USA. Telephone: 305-8058533 Fax: 305-8058535 www.acasi.com PI 3300 Page # 9...
  • Page 10 Figure 1C 7085 NW 46 Street, Miami, FL 33166 - USA. Telephone: 305-8058533 Fax: 305-8058535 www.acasi.com PI 3300 Page # 10...

  • Page 11: System Requirements For Starting Up The Machine

    These next steps will assist the operator in starting up the machine and tuning the filler: a) Once the conveyor has been mounted in place on the machine, place the machine in the working location and level the conveyor by adjusting of the four (04) large screws (GI3100-01-090, shown in figure 1) on the bottom frame rails.

  • Page 12: General And Preventive Maintenance

    GENERAL AND PREVENTIVE MAINTENANCE Acasi Machinery highly recommends implementing a consistent maintenance plan, based on the following recommendations. The life span and the performance of this machine will certainly increase with proper scheduled maintenance. The air being fed to the machine must be dry, or have the least amount of water content possible.
  • Page 13 General Lubrication: All bushings, bearings, and lubrication points must be lubricated weekly with good quality grease. All of the threaded rods and adjustment screws must be lubricated monthly with light grease. These parts must also be lubricated after each cleaning or full wash down.

  • Page 14: Getting Familiar With The Machine

    GETTING FAMILIAR WITH THE MACHINE Control Panel All the electrical functions of the machine are controlled through the electric panel; a brief description of these components is given below: Figure 2: Frontal view of the control panel 7085 NW 46 Street, Miami, FL 33166 - USA.

  • Page 15: Electrical System

    Stops the machine EMERGENCY STOP immediately START BUTTON Energizes the machine From this HMI, all the TOUCHSCREEN controls and processes of the machine are set up Electrical system The electrical system controls all the functions of the machine, based on the information that is received from the sensors installed throughout the filler.
  • Page 16 Figure 3: Internal View of the Control Panel PLC: This is the brain of the machine. It receives information through the inputs, interprets this information, and sends signals through the outputs to execute the various functions and control the filling process. Power Supply: This component converts 220V AC to 24V DC power to run all of the components in the control panel.
  • Page 17 Relay: This component allows the PLC to control the movement (start and stop) of the conveyor. Magnetic Switches: These sensors are located on the back of the main air cylinder. They should be placed over the body of the pneumatic cylinder (one at the bottom & one at the desired nozzle height).

  • Page 18: Use Of The Filler

    Figure 4: Location of the Sensors on the Machine VII. USE OF THE FILLER Setting up the main options in the HMI Follow the steps below to start the set up the conditions of work for your filler: 1. Turn the safety lockout switch on the side of the control panel to ON (if necessary).
  • Page 19 Figure 5: Main Screen 4. Set the number of the speed at which the conveyor works by pressing the blue button in the upper left corner of the main screen (see Figure 5). A numeric keypad appears on the screen to enter the number (see figure below). A numeric keypad appears on the screen to enter the number (see Figure 6).
  • Page 20 5. Set the number of containers to be filled in the machine by pressing the blue button on the right side of the main screen, called (INSTALLED) (see figure below). A numeric keypad appears on the screen to enter the number. Figure 7: Setting number of bottles 6.

  • Page 21: Additional Settings And Other Options

    Additional settings and other options Figure 9: Additional settings Nozzles 1. In the screen shown in the following figure, the times are adjusted before and after filling. Figure 10: Screen additional settings (Nozzles) 2. Selecting any of the options represented by the buttons to the right of the screen (see Figure 10), a numeric keypad appears on the screen to enter the number (see Figure 11).

  • Page 22: Drip Tray C. Guide

    Figure 11: Filling time setting Drip Tray C. Guide Figure 12: Setting screen centering and drip tray 3. Set the activation time of the centering or the drip tray by pressing the button in the center of the screen (see Figure 12). A numeric keypad appears on the screen to enter the number (see Figure 13).

  • Page 23: Entry Cylinder

    Figure 13: Set the activation time of the centering and the drip tray iii. Entry cylinder Figure 14: Main screen of setting the time for the retract operation input 4. Set the time for retraction of the inlet cylinder to give a greater or lesser separation between each production (see Figure 14).

  • Page 24: Exit Cylinder

    Figure 15: Set the entry cylinder retraction time Exit cylinder Figure 16: Main screen of setting the time for the retract operation input 5. Set the time of retraction of the exit cylinder (see Figure 16). A numeric keypad appears on the screen to enter the number (see Figure 17). 7085 NW 46 Street, Miami, FL 33166 - USA.

  • Page 25: Conveyor

    Figure 17: Set the exit cylinder retraction time Conveyor Figure 18: Main screen setting time to reach the desired speed 6. Adjust the times to reach the desired speed, acceleration or deceleration (see Figure 18). A numeric keypad appears on the screen to enter the number (see Figure 19), this will happen by selecting any of the options.

  • Page 26: Additional Setting 2

    Figure 19: Setting time to reach the desired speed iii. Additional Setting 2 7. For setting more options, press the blue button located in the lower right corner, this is located in all settings options (see Figure 20 as an example) Figure 20: Example button more settings 7085 NW 46 Street, Miami, FL 33166 - USA.

  • Page 27: Pneumatic Flow Controls

    Figure 21: Additional Settings 2 In this screen (Figure 20), toggle the options (just one can be active at the time) depending on the desired operation mode. The last option allow setting a delay to control de bottom up movement, values are shown in seconds. VIII.

  • Page 28: Nozzles

    • One flow control to regulate the retraction speed of the entrance cylinder • One flow control to regulate the retraction speed of the exit cylinder Optional Configuration: If movements requiring more consistent speeds are required, we can install hydraulic flow controls to regulate speeds more accurately. Please call Acasi Machinery to obtain specific details regarding this upgrade.

  • Page 29: Pistons For Filling

    Figure 22: Flow Control Locations PISTONS FOR FILLING The pistons used for filling the product are fabricated in different capacities (from 2.5 oz. to 1 gallon). All these pistons are made of stainless steel class 316L, and utilize Teflon seals. We offer both standard (thread together) and sanitary (compression fit) type pistons.

  • Page 30: Starting Up The Filler

    Figure 23: Entry & Exit Cylinder Location For sanitary applications we recommended using Teflon Spring Seals that have the spring area (exposed on standard seals) filled in with sanitary silicone. These seals help avoid product retention between the seal and the spring, which will also make cleaning and piston maintenance easier.

  • Page 31: Adjusting The Height And Stroke Of The Nozzles

    Adjusting the Height and Stroke of the Nozzles a) Without the machine connected to an electrical supply. Hook up the air line and adjust the pressure coming from the tank to between 80 and 100 PSI. Once this is done, open the emergency cut-off valve (See Figure 25) and set the regulator on the machine to the same pressure (80-100 PSI).

  • Page 32: Adjusting The Nozzle Spacing And Setting The Position Of The Entry And Exit

    Figure 24: Location of the Nozzle Bar Stops Adjusting the Nozzle Spacing and Setting the Position of the Entry and Exit Cylinders to Control the Containers If you are about to start these steps, the adjustment of the height and stroke of the nozzles should be completed.

  • Page 33: Adjusting The Optical Sensors At The Entry And Exit Of The Machine

    but also so that it does not contact the guide rails upon extension or retraction (see Figure 25). e) Set the guide rails so that there is roughly 1/16 in. to 1/8 in. of clearance on each side of the container to prevent the containers from getting stuck as they travel down the conveyor.

  • Page 34: Piston Adjustment: Fill Volume, Fill Speed, And Charge Speed

    Figure 25: Exit Cylinder, Guide Rail, and Nozzle Adjustment Piston Adjustment: Fill Volume, Fill Speed, and Charge Speed a) The quantity of product being filled is determined by the stroke of the piston. To increase or decrease the fill volume, turn the hand wheel (PI3100-01-059), which raises or lowers the proximity sensor.
  • Page 35 screws be set at the upper most position, and backed out until the desired volume is achieved. This will allow for the maximum amount of adjustment. Figure 26: Entry & Exit Sensor Setup c) To change the fill speed of the pistons, open or close the flow control valve (See Figure 22).

  • Page 36: How The Machine Works

    Figure 27: Adjusting Filling Volume. XII. HOW THE MACHINE WORKS For the description below we will assume that the machine will be setup using the “Down” type fill cycle, and with just one stroke per fill cycle. a) When the air feed for the machine is connected, the nozzles should go up until the nozzle bar reaches the upper stops.
  • Page 37 c) The exit cylinder must be extended and the entry cylinder retracted (See Figure 23). d) When the containers are moving down the machine’s conveyor, they should be traveling without problems until they stop at the exit cylinder (See Figure 25). e) Once all of the containers are in position (# of containers in the filling area = # of nozzles).

This manual is also suitable for:

2947

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