Nassenheider Fill Up 2 Manual

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Fill up 2

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Summary of Contents for Nassenheider Fill Up 2

Page 1 Manual Fill up 2...
Page 3: Table Of Contents
Table of contents Table of contents 1 Foreword 2 Manufacturer 3 About this manual 4 General safety instructions 5 Delivery 5.1 Scope of delivery 5.2 Content control 6 Technical details of the machine 6.1 Intended use 6.2 Technical data 6.3 Fuses 6.4 Connections and controls on the driving module 7 Putting into operation 7.1 Unpacking and installation...
Page 4 Table of contents 10 Maintenance and Support 10.1 Maintenance 10.2 Possible irregularities 10.3 Support 10.4 Transport and storage 10.5 Disposal of the old machine 11 Warranty 12 EC declaration of conformity according to the machinery directive 2006/42/EC, annex II a...
Page 5: Foreword
Foreword Congratulations, with the FILL-Systems product Fill up 2 you have chosen a proven and robust machine from our high-quality product line for filling technology. The decision to include a machine from FILL-Systems in your equipment fleet will facilitate the filling of your products significantly and measurably increase productivity.
Page 6: Manufacturer
• Technical support: support@fill-systems.com Website: www.fill-systems.com ® NASSENHEIDER is a registered trademark and property of Stefan Weiland, Dresden. The company FILL-Systems GmbH has a licence to use this trademark. District court Dresden: HRB 38264 VAT No.: DE 320 995 937...
Page 7: About This Manual
About this manual About this manual This manual contains important information and is therefore an essential part of your new FILL-Systems product. To ensure an optimal and safe use of your product, read this manual carefully before putting into operation and the use of the product. If you have any technical questions or doubts regarding the details given in the explanations, our support team will be glad to help you via email or over the phone.
Page 8: General Safety Instructions
General safety instructions General safety instructions The safety instructions generally apply to all FILL-Systems products. Danger of hand injuries Make sure that during operation of the machine, your hands (as well as hair, clothing, etc.) do not get caught in rotating parts (gears, driving shafts) or other moving parts.
Page 9: Delivery
Fig. 1: Scope of delivery Art. 301001 Item Quantity Description Art. Wear part 1 pc. Driving module Fill up 2/100 301002 (inc. item 4) 1 pc. Gear pump head L, with pair of gears; 302001 individual parts, see chapter Putting into Operation: Pump head priming hose Ø...
Page 10: Content Control
Delivery 1 pc. Filling nozzle, flat 306001 1 pc. Limitation cross for flat filling nozzle 306006 1 pc. Combination wrench, SW 10 mm 307007 2 pc. Micro fuse, 8A, medium time lag, inscription: 307009 M8/250 2 pc. Gasket for clamping flange 307004 1 pc.
Page 11: Technical Details Of The Machine
Technical details of the machine Intended use The Fill up 2 is designed for the filling of honey. With additional accessories it is also possible to fill propolis and royal jelly. Decisive for an accurate filling is the viscosity of the product.
Page 12: Fuses
Technical details of the machine Fuses Software To protect the mechanics and the motor, the machine is equipped with an overload protection. If there is a blockage in the mechanical part, the machine switches off and the message Overpump appears on the display. In this event, it is absolutely necessary to find the root cause of the blockage and to remove it.
Page 13: Connections And Controls On The Driving Module
Technical details of the machine Connections and controls on the driving module Fig. 2: Right side of the driving module Fig. 2: 1 - Rotary knob for stepless speed regulation 2 - ON/OFF toggle switch/main switch (without LED) 3 - 3-pin socket connector for 24 V power supply 4 - Fuse holder (contains the micro fuse) Fig.
Page 14: Putting Into Operation
Putting into operation Putting into operation Unpacking and installation After unpacking remove the protective cover from the stainless steel sheets (see Fig. 4). To ensure optimum operation of your machine we recommend: - placing the machine on a table or a stable worktop - a room temperature between 15 °C and 35 °C - allowing the machine to acclimatize prior to putting it into operation for about 1 hour to prevent damage...
Page 15: Cleaning
Putting into operation Cleaning For hygienic reasons, we recommend that all parts coming in direct contact with the product should be cleaned before first use and after each use. The parts can be cleaned by hand or in the dishwasher. For cleaning by hand, you can use commercial dishwashing detergent.
Page 16: Adjustment To The Jar Height And Size
Putting into operation Adjustment to the jar height and size The height below the filling nozzle can be adjusted between 5 and 30 cm for the stand 50 cm. For filling taller jars, a high stand can be purchased, if required (see chapter Technical details of the machine: Technical data).
Page 17: Suctioning Of The Medium
Putting into operation Suctioning of the medium To prime in the product into the pump head and fill it into the jar, proceed as follows: 1. Fill the pump head with 2-4 table spoons of the product, depending on the viscosity (see Fig.
Page 18: Pump Head
Putting into operation Pump head 7.5.1 Gear wheel pump head L Fig. 8: Gear pump head L (Art. 302001) Fillable products The gear pump head L is designed for the filling of honey. To prevent temperature differences and segregations, we strongly recommend that the product is thoroughly stirred.Honey should not be heated above 40 °C.
Page 19 Putting into operation The ball bearing of the driving shaft is pressed into the housing. A thorough cleaning is also possible without its dismantling. When assembling the pump head it is important to fix the wing screws (1, 2) and the nuts (8) only hand-tight. Fig.
Page 20: Changing Shaft Seals
Putting into operation 7.5.2 Changing shaft seals Be careful when changing the shaft seals, not to damage any part of the pump head. The shaft seals for the exchange may both be blue. In this case pay attention only to the installation direction.
Page 21 Putting into operation Fig. 14: Insert the green/blue, Fig. 15: Insert the red/blue, greased shaft seal greased shaft seal Lubricate the new shaft seals with food First the green/blue shaft seal with the grade grease (e.g. vaseline) and insert groove downwards, then the red/blue one them into the housing with the groove upwards.
Page 22: Filling Nozzles
Putting into operation Filling nozzles Wedge nozzle outside Ø 26 mm, hard (Art. 306015) (see Fig. 17) Put directly into the pump head with a the clamping flange. Application: for highly viscous honey Fig. 17: Wedge nozzle on pump head Conical filling nozzle with support (Art.
Page 23: External Switches
Putting into operation External switches 7.7.1 Microswitch Fig. 20: Microswitch (Art. 307039) The microswitch is to be adjusted at the Y-bracket so that it triggers the filling process when the jar is pressed. It is active only in Auto mode. The key can also be used instead of the microswitch.
Page 24: Float Switch
Putting into operation 7.7.3 Float switch Optionally available as accesory. Fig. 22: Float switch (Art. 303004) The float switch is used for pumping from one container to another one. For this purpose, the switch is fixed to a container with the help of the vertically-adjustable bracket.
Page 25: Processing Of Honey
Processing of honey Processing of honey Preparing the machine for filling Assemble of the hose using a bent pipe - put the hose clamp onto the priming hose - dip the end of the hose and the bent pipe into hot water (approx.
Page 26 Processing of honey Assembly suggestions for filling Fig. 27: Table filling Fig. 28: Filling out of a deep standing container Fig. 30: Flat filling nozzle for pressure Fig. 29: Direct connection to a honey reduction container, possible variety Direct connection to a honey container (see Fig. 29 and Fig. 30): - recommended: installation of a disk valve (3) - if the honey drips from the filling nozzle, the flat filling nozzle (1) is inserted for pressure recuction (see chapter Putting into operation: Filling nozzles)
Page 27: Preparation Of The Honey For The Filling
Processing of honey priming problems are solved as follows: Leaks In the case of priming problems, honey can also be sealed at the following parts (see Fig. 27): - gasket for clamping flange (1) - connection between pipe bend and hose (2) - connection between check valve and hose (3) - filling nozzle.
Page 28: Pumping To Make Creamy Honey
Processing of honey Pumping to make creamy honey Preparation - instead of the clamping flange and the filling nozzle the pipe bend (bended aside) for pumping with priming hose is installed at the bottom of the pump head: - put the hose clamp onto the priming hose - heat the end of the priming hose and the pipe bend, after assembly immediatly pull the hose clamp tight, making sure that the hose does not get damaged - insert the gasket for the clamping flange into the pump head and mount the...
Page 29: Operation
Operation Operation Operating the keypad Display and keypad should not be operated with fingernails or hard objects as this could cause scratches and surface damage. Moreover, aggressive cleaning agents or abrasives should never be used. Fig. 31: Keypad and display Fig.
Page 30: Operating Modes
Operation Operating modes In the main menu, two operating modes and the setup menu are available: Manual mode - priming / pumping of the product AUTO Auto Mode - automatic fine dosing Time switch - time-controlled pumping/making creamy honey SETUP Setup Menu - settings.
Page 31: Manual Mode
Operation 9.2.1 Manual mode This mode of operation is used to prepare for the filling (to prime the product in order to fill the priming hose and the pump head) and for continuously pumping (e.g. pumping from one container to another one). Forward continuously Pressing the key briefly will start the filling prozess.
Page 32: Auto Mode/Dosage
Operation 9.2.2 Auto mode/dosage The Auto mode (dosing) is used to repeatedly fill a fixed quantity (batch filling). General procedure: 1. select nominal filling quantity (jar size) - Select from the settings (see Fig. 32) - this can be specifically programmed in the setup menu 2.
Page 33 Operation - Press TARE/0 (or in case of mechanical scales, note the weight or the mass of the empty jar). - Select nominal filling quantity (e.g. 20 g) on the machine and fill the jar. - Weigh the jars just filled. - If the weighed quantity deviates from the adjusted nominal filling quantity.
Page 34 Operation During the very first use of the machine, the actual filling quantity may differ significantly from the nominal filling quantity. Therefore, for initial calibration, the selection of a small nominal filling quantity (e.g. 125 g) in a much larger jar (e.g. 500 g) is recommended to prevent overflowing.
Page 35: Time Switch
Operation 9.2.3 Time switch The time switch is very suitable to stir honey in order to make creamed honey (see chapter Processing of honey: Stirring to make creamy honey). Operating the time switch Pump forwards inside the pump head (from above, downwards) Pump backwards inside the pum phead (from below, upwards) Pump into both directions (cycle alternates from above down wards, the next cycle from down upwards)
Page 36: Setup Menu
Operation Setup Menu Here the basic settings of the machine can be made for the filling (see Fig. 38). These include language, jar sizes (nominal filling quantities), accessories (e.g. turntable) or the used pump head. Where possible, the individual settings of the machine will already have been made in our factory.
Page 37 Operation Selection of connectable accessories. The accessory works only in Auto mode. WITHOUT Select this when not using an accessory. TURN 1 1: Sensor type (PNP is the standard for the sensors supplied by us) 2: Delay drip (Pause after filling, before restarting the turntable) 3: Stop delay (Pause after stopping of the turntable, before filling)
Page 38: Maintenance And Support
Maintenance and Support Maintenance and Support 10.1 Maintenance In the pump head, the product undertakes the functions of lubrication and sealing. The built-in ball and slide bearings, however, are basically maintenance-free, as they are lubricated separately and sealed against the fluid-handling components. Regular cleaning after each filling batch or once daily of all product-touching parts is necessary to keep abrasive particles away from the pump head to maintain its efficiency and maintain the warranty and guarantee claims.
Page 39: Possible Irregularities
Maintenance and Support 10.2 Possible irregularities Error Possible reason Solution Malfunction Effect of strong electromagnetic fields Reset to factory settings of the (mobile phone, cordless telephones, or Menu SETUP: RESET software another motor was not screened off from the agitator) The product Some large air bubbles in the honey Place the driving module as far...
Page 40: Support
Maintenance and Support 10.3 Support In the case of faults that can neither be resolved using this manual nor by our FAQs, please contact our technical support by phone, fax or email. We would be happy to support you. If a problem cannot be solved in this way, our send-in-service will help you after consultation with our technical support.
Page 41: Transport And Storage
10.5 Disposal of the old machine The FILL-Systems product Fill up 2 has been designed for long-term and sustainable use. All individual components can be replaced even after many years. Of course, we will take back your old disused machine free of charge and guarantee professional and environmentally friendly disposal in accordance with the legal requirements.
Page 42: Warranty
Warranty The warranty period for the functionality of the FILL-Systems product Fill up 2 is 24 months from the date of delivery when used properly in accordance with this manual. The warranty is limited to damage and disruption that are caused by defective workmanship on our part.
Page 43: Ec Declaration Of Conformity According To The Machinery Directive 2006/42/Ec, Annex Ii A
EC declaration The manufacturer/distributor FILL-Systems GmbH Leipziger Str. 33 01097 Dresden hereby declares that the following product Product designation: Fill up 2 Model name: Fill up 2/100 Year of manufacture: 2019 Description: Machine for filling honey The following additional EU directives have been applied:...