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Deitz PHARMAFILL CS10 Operation Manual

Cotton inserter
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Model CS10 Cotton Inserter
Operation Manual

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Summary of Contents for Deitz PHARMAFILL CS10

  • Page 1 Model CS10 Cotton Inserter Operation Manual...
  • Page 2 _____________________________________________ 13 F. Shelf _____________________________________________ 13 G. Air Pressure Controls ___________________________________________ 14 H. Bottle Indexing and Bottle Sensors ________________________________ 14 I. Optional Tamper – contact Deitz Co. for availability ___________________ 15 J. Lift Platform _____________________________________________ 15 5. OPERATION A. Control Panel _____________________________________________ 17 B.

  • Page 3: Table Of Contents

    Pharmafill Model CS10 Operation Manual 6. SETUP FOR A RUN QUICKSTART _____________________________________________ 38 A. Start Up _____________________________________________ 39 B. Setup Conveyor _____________________________________________ 39 C. Adjust Settings _____________________________________________ 39 D. Adjust Machine Height _________________________________________ 39 E. Load Cotton Coil _____________________________________________ 39 F.
  • Page 4 Pharmafill Model CS10 Operation Manual Warning This machine contains moving parts and operates automatically. This may present a hazard to personnel. Never operate this machine with any covers or guards removed or any guard switches or safety devices removed or bypassed. Only people who have been correctly trained should operate or clean this machine.
  • Page 5 Pharmafill Model CS10 Operation Manual Section 1: INTRODUCTION Thank you for purchasing a Pharmafill Model CS10 Cotton Inserter. We at Deitz Company hope you will find that the Model CS10 meets or exceeds your expectations and requirements for an affordable, reliable, and innovative addition to your packaging operation.
  • Page 6 The measurements or data shown on schematics, sketches and photos are not binding. They are for description purposes. The information and drawings found in the operation manual are the intellectual property of DEITZ COMPANY and may not be copied or given to third parties.
  • Page 7 Pharmafill Model CS10 Operation Manual Section 2: SPECIFICATIONS MODEL CS10 COTTONER TYPE AD 1070 TURRET TUBE LENGTH 3, 4 or 5 inches TURRET TUBE DIAMETER .75 or 1 inch COTTON TYPE Natural or Synthetic (Rayon, Polyester) Coil COTTON WEIGHT 6 TO 20 gm COTTON LENGTH OUTPUT 2 to 9 inches TURRET...
  • Page 8 Pharmafill Model CS10 Operation Manual INPUT REQUIREMENTS VOLTAGE* 115 VAC CYCLES 50/60 HZ PHASE AMPERAGE 20 AMPS COMPRESSED AIR** 3.0 FT /MIN AT 80 LB/IN ROOM HUMIDITY 85% RH NON-CONDENSING *Other input voltages are available as factory options if specified at the time of order ** Compressed air must be clean and dry, free of moisture (water) and oil.
  • Page 9 3A. Unpacking Carefully remove equipment from crate and remove all packing materials. ❑ Inspect all supplied equipment for damage (if any damage is present, please notify DEITZ ❑ COMPANY immediately). Assemble any components such as control panels, etc. using the drawings in this manual as a ❑...
  • Page 10 Pharmafill Model CS10 Operation Manual Compressor must be adequate to meet the specifications (see Section 2). ❑ The supply air should be clean and dry, free of condensation and oil. ❑ Connect the pneumatic supply. ❑ Apply compressed air to the machine and turn both pressure regulators to 80 PSI. ❑...
  • Page 11 F. Shelf G. Air Pressure Controls H. Bottle Indexing and Bottle Sensors I. Optional Tamper – contact Deitz Co. for availability J. Lift Platform 4A. General The Model CS10 is an automatic dual station cotton inserter designed to convert continuous cotton coil to individual pieces and insert them into a bottle or other container at each station.
  • Page 12 Pharmafill Model CS10 Operation Manual 4C. Safety Enclosure GUARD GUARD MAIN DOOR MAIN DOOR DISCONNECT CLOSED DISCONNECT OPENED SWITCH SWITCH The operator is protected from encountering the moving parts of the machine by the safety enclosure, which is made of clear polycarbonate with a metal and plastic frame. The front of the enclosure is a hinged door and swings up to provide full access to the components.
  • Page 13 Pharmafill Model CS10 Operation Manual The lower insertion air cylinder (under the shelf) pushes cut cotton up into the rear tube. At the same time, the upper insertion air cylinder (on the turret) pushes cut cotton down out of the front tube and into the bottle.
  • Page 14 Pharmafill Model CS10 Operation Manual opposing shelf. These blocks limit the distance the cut piece can travel away from the tear rollers, assuring correct centering of the piece under the tube. The Cotton Stop Block adjusts automatically when a new length is selected. Directly above each shelf is a Cotton Pincher assembly. Each has an air cylinder and two moving arms that hold the cotton in place as it is inserted into the rear tube.
  • Page 15 B. If a downline process stops, bottles will accumulate on the conveyor. When this sensor detects a bottle, it stops automatic or manual insertion. Once the bottle backup is cleared, insertion will resume without operator intervention. 4I. Optional Tamper - contact Deitz Co. for availability VERTICAL ADJUSTMENT...
  • Page 16 Pharmafill Model CS10 Operation Manual Section 5. OPERATION A. Control Panel B. Insert Cotton Show Values C. Adjust Settings Cotton Length Number Of Pieces Release Time Dwell Time D. Change Height E. Open Rollers F. Clear Tubes G. Extend Insert Rods H.
  • Page 17 Pharmafill Model CS10 Operation Manual Section 5A: CONTROL PANEL This is the operator interface for control functions and message display. 1. Note the locations of the EMERGENCY STOP button, EMERGENCY the START button, and the CONTROL STOP PANEL CONTROL PANEL. START 2.
  • Page 18 Pharmafill Model CS10 Operation Manual Section 5A: CONTROL PANEL (Continued) 6. Press a menu option or press CLEAR/EXIT to return to the top menu. The choices are explained in the following sections. (End 5-A) 7. The PLC/IO button will access the Inputs and Outputs on the PLC in real time.
  • Page 19 Pharmafill Model CS10 Operation Manual Section 5B: INSERT COTTON This function controls the inserting process. 1. Press MENU. 2. Press INSERT COTTON. 3. To start a single insertion cycle, press MANUAL. 4. Press Side A or Side B. The machine will make one complete cycle, including indexing the bottles.
  • Page 20 Pharmafill Model CS10 Operation Manual Section 5B: INSERT COTTON (Continued) 6. Press MANUAL again to return to SELECT screen. 7. To start fully automatic operation, press AUTO ON/OFF. If all conditions are correct, cotton will be inserted (cotton present in tube, bottle present, no backup).
  • Page 21 Pharmafill Model CS10 Operation Manual Section 5B: INSERT COTTON (Continued) 11. Inserting cotton will only occur in AUTO mode or MANUAL mode, not both. 12. To exit automatic operation, press AUTO ON/OFF... or press CLEAR/EXIT. END Section 5B May 2023 Page 21...
  • Page 22 Pharmafill Model CS10 Operation Manual Section 5C: ADJUST SETTINGS This function sets the values for length of cotton and other parameters. 1. Press MENU. 2. Press ADJUST SETTINGS. 3. Current Values are displayed. Ranges for each setting appear in numeric keypad upon selection of each setting.
  • Page 23 Pharmafill Model CS10 Operation Manual Section 5C: ADJUST SETTINGS (Continued) 7. “Release Time” ranges from 0.10 to 2.00 seconds. This is the time delay the bottle indexing mechanism allows for a filled bottle to move out of either of the filling positions, before starting a new cycle.
  • Page 24 Pharmafill Model CS10 Operation Manual Section 5D: CHANGE HEIGHT This function raises or lowers the machine height over the conveyor. 1. Press MENU. 2. Press CHANGE HEIGHT 3. Press ENTER. Exercise caution and common sense to not cause personal injury and to not damage any equipment.
  • Page 25 Pharmafill Model CS10 Operation Manual Section 5E: OPEN/CLOSE ROLLERS This function separates the pinch rollers to allow the cotton coil to be fed in 1. Press MENU. 2. Press OPEN/ CLOSE ROLLERS. 3. Press ENTER. Exercise caution and common sense to not cause personal injury and to not damage any equipment.
  • Page 26 Pharmafill Model CS10 Operation Manual Section 5E: OPEN ROLLERS (Continued) 6. Feed the cotton coil through the optional cotton box top (if equipped), then through the 1st cotton guide loop. 7. Feed the cotton through the 2nd and 3rd cotton guide loops and then the first pair of rollers, stopping just before the second set of...
  • Page 27 Pharmafill Model CS10 Operation Manual Section 5F: CLEAR TUBES This function empties the cotton from the tubes. 1. Press MENU. 2. Press CLEAR TUBES. 3. Press ENTER. 3. You will now see the CLEAR TUBES options. Press CLEAR SIDE A (left) or the CLEAR SIDE B (right).
  • Page 28 Pharmafill Model CS10 Operation Manual Section 5G: TEST RODS This function extends the insertion air cylinder rods for setup purposes. 1. Press MENU. 2. Press TEST RODS. 3. Press ENTER. 4. Press OPERATE SIDE A to cause the insertion air cylinders at station A (left) to extend fully and hold in that position or press the OPERATE...
  • Page 29 Pharmafill Model CS10 Operation Manual Section 5G: EXTEND RODS (Continued) 5. With the rod in the fully extended position, you may test a filled bottle to see that the contents are not being crushed by the cotton Rod in EXTEND insertion action.
  • Page 30 Pharmafill Model CS10 Operation Manual SECTION 5H: ONE STEP INDEX This function jogs the bottle indexing mechanism for setup purposes. 1. Press MENU. 2. Press ONE STEP INDEX. 3. Press ENTER 4. Press INDEX SIDE A to cause the bottle gating mechanism at station A (left) to switch to the release position and hold...
  • Page 31 Pharmafill Model CS10 Operation Manual Section 5I: INDEX BOTTLES ONLY This function cycles the bottle gating mechanism without inserting cotton. 1. Press MENU. 2. Press INDEX BOTTLES ONLY 3. Press ENTER. 4. To start a single insertion cycle, press MANUAL. 5.
  • Page 32 Pharmafill Model CS10 Operation Manual Section 5I: INDEX BOTTLES ONLY (Continued) 7. Press MANUAL again to return to SELECT screen. 8. To start automatic indexing operation, press AUTO ON/OFF. If all conditions are correct, the machine will automatically execute one bottle index cycle at each station each time a bottle is detected by the bottle sensor.
  • Page 33 Pharmafill Model CS10 Operation Manual Section 5J: SET BATCH TO ZERO This function will reset the internal batch counter value to zero. 1. Press MENU. 2. Press SET BATCH TO ZERO 3. Press ENTER. 4. The current machine cycle count will be displayed.
  • Page 34 Pharmafill Model CS10 Operation Manual Section 5J: SET BATCH TO ZERO (Continued) 5. Press RESET. Note: The count value is now ZERO. 6. Press CLEAR to exit this function and return to the top menu. END Section 5J May 2023 Page 34...
  • Page 35 Pharmafill Model CS10 Operation Manual Section 5K: OPTIONS This function will allow the operator to use Both sides, only Side A or only Side B. 1. Press MENU. 2. Press OPTIONS. 3. Press ENTER. 4. Enable Both Sides? Press NEXT to advance screen.
  • Page 36 Pharmafill Model CS10 Operation Manual Section 5K: OPTIONS (Continued) 7. If no options are selected, press CLEAR/EXIT and no changes will take place. 8. To select an option, press ACCEPT. 9. Press CLEAR to exit this function and return to the top menu.
  • Page 37 Pharmafill Model CS10 Operation Manual Section 5L: TECHNICIAN ONLY THIS FUNCTION SHOULD ONLY BE ACCESSED BY A QUALIFIED TECHNICIAN 1. Press MENU. 2. Press TECHNICIAN ONLY. 3. Press and hold ENTER. 4. Technicians should refer to the Technical Notes at the end of this manual.

  • Page 38: Setup For A Run

    Pharmafill Model CS10 Operation Manual Section 6. SETUP FOR A RUN QUICK START A. Start Up ❑ B. Setup Conveyor ❑ C. Adjust Settings ❑ D. Adjust Machine Height ❑ E. Load Cotton Coil ❑ F. Setup Bottles ❑ G. This Section intentionally left blank ❑...
  • Page 39 Pharmafill Model CS10 Operation Manual DETAILED EXPLANATION 6A. Start Up Lift open the Guard Door. ❑ Turn the Main Disconnect Switch ON. ❑ Close the Guard Door. ❑ Press the STOP Button. ❑ Twist and release the STOP Button. ❑ Press the START Button.
  • Page 40 Pharmafill Model CS10 Operation Manual 6F (a). Setup Bottles – Station “A” (see technical drawing Sec. 9E) Turn on conveyor, set to operating speed. ❑ BOTTLE STATION A STOP A1 SHOWN With several bottles on the conveyor, adjust Stop A1 (normally extended) so the first ❑...
  • Page 41 Pharmafill Model CS10 Operation Manual Position the station START BOTTLE “A” sensor so it is centered on an empty bottle. ❑ This bottle may be the one directly under the filling tube or any bottle upstream of the filling position. It is recommended that the sensor be positioned at least 3 bottles upstream.

  • Page 42: This Section Intentionally Left Blank

    Pharmafill Model CS10 Operation Manual Set Stop 2 so that the third bottle is centered under the front tube, or just 1/8 to 1/4 ❑ inch upstream from centered position. Alternately extend the stops several times using the One Step Index function to see if ❑...

  • Page 43: Running Production

    Pharmafill Model CS10 Operation Manual Section 7. RUNNING PRODUCTION QUICK START A. Start Up ❑ B. Check Cotton ❑ C. Check Bottles ❑ D. Test Operation ❑ E. Begin Operation ❑ F. Stopping the Machine Manually ❑ G. When the Machine Stops Automatically ❑...
  • Page 44 Pharmafill Model CS10 Operation Manual 7A. Start Up Lift open the Guard Door. ❑ Turn the Main Disconnect Switch ON. ❑ Close the Guard Door. ❑ Press the STOP Button. ❑ Twist and release the STOP Button. ❑ Press the START Button. The turrets will “find home”. ❑...
  • Page 45 Pharmafill Model CS10 Operation Manual If the bottles begin to backup from the downline direction of station B, the Backup ❑ Sensor will cause the machine to pause and display the message “BOTTLE BACKUP DOWNSTREAM”. Once the backup is cleared, automatic operation will resume immediately.

  • Page 46: Routine Maintenance

    Pharmafill Model CS10 Operation Manual Section 8. ROUTINE MAINTENANCE A. Insertion Air Cylinders B. Compressed Air Filters C. Cooling Fan Air Filters D. Lubrication E. General Cleaning 8A. Insertion Air Cylinders NOTE: Do not add lubrication to the air cylinders or air supply. Cylinders are pre-lubricated. If the lubrication fails, the cylinder has reached the end of its life and must be re-built.
  • Page 47 Pharmafill Model CS10 Operation Manual 8B. Compressed Air Filters There are two replaceable filters in the compressed air system, one for the incoming air filter and one for the exhaust filter. They are found at the lower rear of the machine. INCOMING EXHAUST AIR FILTER...

  • Page 48: Lubrication

    Pharmafill Model CS10 Operation Manual 8D. Lubrication There are no lubrication points on the machine. All bearings are permanently lubricated and/or are sealed. Feed screws for the roller carriage travel (one, behind turret assembly inside upper cabinet) and lift platform (two, inside lower cabinet) may occasionally need to be coated with any common grease.

  • Page 49: Technical Information

    Pharmafill Model CS10 Operation Manual Section 9. TECHNICAL INFORMATION A. Cycle of Operation B. Troubleshooting C. Options D. Technical Notes/Drawing Index 9A. Typical machine cycle (insertion process sequence of operations) TO START CYCLE - Press MENU, press INSERT COTTON, press ENTER... Press MANUAL (to cycle once) or press AUTO ON/OFF (for continuous insertion).

  • Page 50: Troubleshooting

    ❑ occupy. Cotton is best inserted below the shoulder, not only within the neck of the container. Install the optional Tamper Assembly – contact Deitz Co. for availability. ❑ 3. Synthetic cotton issues: Rayon and polyester Pure cotton coil always runs best. It cuts most easily and consistently.

  • Page 51: Message: "Roller Travel Error

    Pharmafill Model CS10 Operation Manual Message: “ROLLER TRAVEL ERROR” Roller carriage drive electronic components may be defective or becoming defective. ❑ Stop the machine and try again. If it continues to occur, contact a technician. May 2023 Page 51...

  • Page 52: Options

    Pharmafill Model CS10 Operation Manual 9C. Options Cotton Box Cover Assembly (center draw, no breaks) AD1035-1 CS10 Secondary Tamper Assembly AD1029-4 Cotton Feed Reject (CFR) System AD1271-5 May 2023 Page 52...

  • Page 53: Technical Notes/Drawing Index

    Pharmafill Model CS10 Operation Manual 9D. Technical Notes/Drawing Index (Technical Notes/Drawings Begin After Last Page) Number Title No. of Pages TECH NOTES TN0076 Using ***Technician Only*** Menu TN0075-3 CS10 Service Parts List DRAWINGS 2006-19 CS10 Dimensional Drawing 2006-22 CS10 Bottle Gating Setup - No Tamper SC1007 CS10 Wiring Schematic SC1008...
  • Page 54 Deitz Company Inc. Wall, NJ 07719 USA (TEL) 732-681-0200 July 2023 Using the ***TECHNICIAN ONLY*** Menu Item 1A. Explanation This function allows the qualified technician to access some settings within the PLC that can be used to fine-tune the characteristics of the machine’s operation. This function should never be used by the operators or by any personnel who are not authorized to service the machine.
  • Page 55 Deitz Company Inc. Wall, NJ 07719 USA (TEL) 732-681-0200 July 2023 - TURRET TIME: To maximize the top speed of the machine, the insertion plunger will begin its motion before the turret has come to rest. This value sets the time delay between the start of turret rotation and the action of the insertion plunger.
  • Page 56 Deitz Company Inc. Wall, NJ 07719 USA (TEL) 732-681-0200 July 2023 Section 1B: TECHNICIAN ONLY This function adjusts special values in the PLC control program. 1. Press MENU. 2. Press TECHNICIAN ONLY 3. Press and hold ENTER for three (3) seconds.
  • Page 57 Deitz Company Inc. Wall, NJ 07719 USA (TEL) 732-681-0200 July 2023 7. FEED LENGTH FACTOR MAX: 15.0 MIN: 5.0 Normal value is 10. Factory default is 10. 8. TEAR LENGTH ADDER MAX: 1500 MIN: 500 Factory default is 800. 9. TURRET TIME MAX: 0.99...
  • Page 58 Deitz Company Inc. Wall, NJ 07719 USA (TEL) 732-681-0200 July 2023 12. GATING “A” DELAY MAX: 1.00 MIN: 0.00 MAX LENGTH is based on the size of the Turret Tube. This setting can only be changed by changing the TURRET TUBE HEIGHT setting.
  • Page 59 Deitz Company, Inc. Wall, NJ 07719 USA (Tel) 732-681-0200 Rev 10JUN05 Call Quan Part Number Description Type Used Prices Where Used AD1071-1 CS2/10 Cylinder Rebuild Kit WEAR Incl. (1) FM3283F, (2) P0156, (2) P0157 AD1085-3 CS10 Spare Fuse Kit WEAR...
  • Page 60 Deitz Company, Inc. Wall, NJ 07719 USA (Tel) 732-681-0200 Rev 10JUN05 Call Quan Part Number Description Type Used Prices Where Used P0418 Belt, Gear - 150T SPARE Carriage drive assembly P1822-1 Step Motor Driver/Translator, Small SPARE SMDT1, 2 Electronics panel, top...
  • Page 61 Deitz Company, Inc. Wall, NJ 07719 USA (Tel) 732-681-0200 Rev 10JUN05 Call Quan Part Number Description Type Used Prices Where Used FM3031 LP Bevel Gear REPAIR Lift Platform FM3155-1 Turret Disc Upper REPAIR Turret tube assembly FM3155-2 Turret Disc Lower...
  • Page 62 Deitz Company, Inc. Wall, NJ 07719 USA (Tel) 732-681-0200 Rev 10JUN05 Call Quan Part Number Description Type Used Prices Where Used P0337 Bearing Mounted, 1 Flange Type #1A399 REPAIR Lift platform P0338 Bearing Mounted .50 #1A396-9 REPAIR Main frame (2 per) & Lift platform (6 per) P0347 Bearing Frelon Lined-Open 1/2"...

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