Related Manuals for ALL-FILL 500 Series
Summary of Contents for ALL-FILL 500 Series
- Page 1 AFI Publication Model 585b Piston Filler User Manual | Issue: Preliminary | October 2020 Model 585b Piston Filler User Manual All-Fill 418 Creamery Way Exton, PA 19341 USA 610.524.7350 www.all-fill.com...
- Page 2 DO NOT OPERATE THE MACHINE WITHOUT THE HOPPER (OR BULK SUPPLY) AND SHUT OFF NOZZLE(S) CORRECTLY FITTED. KEEP HANDS CLEAR OF THE ROTARY VALVE AND ALL OTHER MOVING PARTS WHEN THE MACHINE IS OPERATING. DO NOT OPERATE MACHINE WITHOUT ALL SAFETY GUARDS AND COVERS IN PLACE. All-Fill 585b Filling Machine...
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Page 3: Table Of Contents
Contents Introduction ........................A-1 All-Fill 500 Series Filling Machines .................. A-2 Getting to know the Filling System Components ............. A-3 Control Cabinet ......................A-3 Power Cylinder / Main Drive Cylinder ................. A-3 Filling Volume Adjustment ..................A-4 Stroke Indicator ......................A-4 Recharge Speed Adjustment .................. - Page 4 Gating Initiation Sensor Assembly (Dwg 1201d) ............G-16 Gating Initiation Sensor Parts List................. G-17 Rotary Nozzle Assembly (Dwg 9226g) ................. G-18 Rotary Nozzle Parts List ....................G-19 Universal Nozzle Assembly (Dwg 1691f) ..............G-20 Universal Nozzle Parts List ................... G-21 All-Fill 585b Filling Machine...
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Page 5: Introduction
Introduction This section presents general introductory material about your All-Fill 500 Series Filling System and should be read before proceeding with any actual installation, operation, or servicing. Included in this section are: • All-Fill 500 Series Filling Machines A general description of the filler Filling System Components •... -
Page 6: All-Fill 500 Series Filling Machines
The unit is manufactured to strict hygiene standards and can easily be disassembled when in-place cleaning is not applicable. The All-Fill range includes various single and multiple head volumetric and gravimetric fillers, capable of accurately metering quantities from 0.5ml to 200 litres or more. -
Page 7: Control Cabinet
Filling System Components The following major components and equipment are used on the All-Fill 500 Series Filling Machines. Drawings supplied in the Assembly Drawings and Parts Lists section can be used to identify or locate particular parts and assemblies on the machine. -
Page 8: Filling Volume Adjustment
Activate (push in) the Emergency Stop before making any adjustments STROKE INDICATOR The All-Fill 500 Series Filler includes a graduated scale on the side of the main cover which displays the Percentage of Stroke that the Power Cylinder is operating at. This indicator, as well as the Metering Cylinder Set size, is used to determine how much product is dispensed per single fill cycle. -
Page 9: Rotary Valve
SIDE SHIFT ASSEMBLY All-Fill 500 Series Filling Machines can include a Side Shift Assembly to move the filling nozzles away from the tops of the containers and over a drip tray at the end of a filling cycle. This allows any drips to be contained and/or prevent overfilling with certain types of products. -
Page 10: Conveyor
Typical Filler Operation The All-Fill Piston Fillers operate by means of a compressed air power source to dispense metered amounts of liquids and other products to medium viscosity into containers. The combination of a metering cylinder/piston set and rotary valve accurately dispenses product contained in a hopper mounted on the filler, or connected to a bulk product supply. -
Page 11: Safety Considerations
Safety Considerations Use the following general guidelines and instructions with your All-Fill Filling Equipment to prevent accidents, personal injury, or damage to the machine and equipment. INSTALLATION • Use proper lifting equipment to position the machine. Refer to shipping records for machine weight and select equipment accordingly. -
Page 12: Filling Machine Specifications
Frame Type: Standard Options: Ethernet capable PLC Waukesha Rotary Valve Core Ø1.0” Teflon lined S/S braided flexible hoses and fittings to nozzles Auto gating mechanism Nozzle side shift with drip tray Secondary speed control Ancillary Equipment: All-Fill 585b Filling Machine... -
Page 13: Warranty Information
STANDARD WARRANTY All-Fill, Inc. warrants each item of its manufacture to be free from defects for a period of 90 days from start up. Equipment within this warranty will be repaired free of charge and returned to the point of original sale provided that: ●... - Page 14 AFI Publication Model 585b Piston Filler User Manual | Issue: Preliminary | October 2020 A-10 All-Fill 585b Filling Machine...
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Page 15: Installation
Installation This section contains information, procedures, and recommendations concerning the installation of the All-Fill 500 Series Filling Machine. Included in this section are: • Inspection and Unpacking For use when you initially receive the equipment Site Requirements • That can be used to plan for the proper location to install and operate your machine Tools and Materials •... -
Page 16: Inspection And Unpacking
Upon receipt of your equipment, you should initially inspect the shipping container(s) for any damage that may have occurred in transit. If damage is apparent, notify the transport carrier in writing immediately describing the damage. All-Fill, Inc. should also be notified about any damage that may have occurred in shipping. -
Page 17: Electrical Requirements
The hoisting equipment is used to position the filling machine. Consult shipping weight records for appropriate tonnage equipment. The All-Fill 500 Series Filling Machine requires oil for the pneumatic (air) supply filled in a lubricator at the Air Service Unit. Appropriate types of lubrication are listed below. -
Page 18: Installation Procedures And Recommendations
AFI Publication Model 585b Piston Filler User Manual | Issue: Preliminary | October 2020 Installation Procedures & Recommendations Correct and careful installation of the All-Fill Piston Filler will result in proper, accurate filling production, lower maintenance, and reduced risk of machine down time due to equipment failure. -
Page 19: Setup And Operation
Setup and Operation The following section presents the typical setup and operating procedures used with the All-Fill 500 Series Filling System, including: Filler Setup • Outlines the procedure to setup and operate the All-Fill 500 Series Piston Filler. Container Gating Setup •... -
Page 20: Filler Setup Procedure
If necessary, adjust the Filler Volume and repeat steps 14 and 15 until the correct volume/weight is achieved. Your All-Fill 500 Series Filling System should now be ready for continuous use. It is recommended that product volume/weight be checked regularly during automatic operation. -
Page 21: Metering Cylinder Volumes (Graph
Metering Cylinder Volumes All-Fill 585b Filling Machine... -
Page 22: Container Gating System (Dwg 5500M
AFI Publication Model 585b Piston Filler User Manual | Issue: Preliminary | October 2020 Container Gating System 418 Creamery Way Exton, PA 19341 P: (610) 524 -7350 E: info@allfill.com All-Fill 585b Filling Machine... -
Page 23: Container Gating Configurations
Two different configurations are provided in the programming of the PLC, a 300 Series and a 500 Series configuration (refer to previous drawing). Use of either configuration will vary according to your filling application, product characteristics, and/or container types. -
Page 24: Container Gating Setup Procedure
Determine which configuration best suits your application. (Refer to previous page) If 500 Series: Position Cylinder “B,” color-coded yellow, immediately between the fourth and fifth Filling Nozzles, and cylinder “A,” color-coded red, immediately before the container under the first nozzle. Containers should center directly under each nozzle when the pins are extended. - Page 25 Notes All-Fill 585b Filling Machine...
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Page 26: Control Panel Layout
AFI Publication Model 585b Piston Filler User Manual | Issue: Preliminary | October 2020 Control Panel Layout 418 Creamery Way Exton, PA 19341 P: (610) 524 -7350 E: info@allfill.com All-Fill 585b Filling Machine... -
Page 27: Control Functions
PRESSURE GAUGE Indicates the current working pressure of the filler. The normal operating pressure of the All-Fill 500 Series is 80 psi (550kPa). NOTE: The gauge only indicates working pressure when the Emergency Stop is inactive RED POWER ON INDICATOR A red indicator light / reset push-button switch combo. - Page 28 The flow regulator located under the power unit controls the rate at which the metering cylinders are recharged with product after a filling cycle. NOTE: Set at a rate no faster than that required to recharge the metering cylinders before the next group of containers is in position C-10 All-Fill 585b Filling Machine...
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Page 29: Home Screen
(continued) PANELVIEW C400 HMI TOUCHSCREEN The Touchscreen Control Panel is the main Control Interface of the All-Fill 500 Series Filler. It is used to put the Filler into the various operating modes, view and adjust operating timers and counters, and diagnose problems with the machine. -
Page 30: Operating Modes
The Home Screen will now also display the Stroke Counters. To adjust and set the multi-stroke counter, press the (stroke value) button next to Number of Strokes Req: (an on-screen keyboard will be displayed) key in the new value and press the enter C-12 All-Fill 585b Filling Machine... -
Page 31: Settings Menu
GATE MODE SELECTOR This button is used to switch the filler between the two Gating Modes. The button will display Gate Mode 500 when in 500 Series Gating Mode, or Gate Mode 300 when in 300 Series Gating Mode. C-13... -
Page 32: Misc Parameters
The Slow Start Dwell Timer is used to set the duration of the slow filling rate at the beginning of the fill cycle. Container Present Timer The Container Present Dwell Timer controls the time delay between containers being detected by the Container Sensor and the fill cycle being initiated. C-14 All-Fill 585b Filling Machine... -
Page 33: Typical Settings For Automatic Operation
Before Fill Settle Time Container dependant Container dependant Gap Time Container dependant Gate Time Container dependant After Fill Settle Time Gate Mode Gate Test 0.20 sec Misc Parameters Slow Start Time Container Present Time 3.00 sec C-15 All-Fill 585b Filling Machine... -
Page 34: Typical Operating Sequence
AFI Publication Model 585b Piston Filler User Manual | Issue: Preliminary | October 2020 Typical Operating Sequence The following procedure describes the typical operating sequence of the All-Fill 500 Series Filling System. Actual operating procedures may differ, however, depending on specific procedures and methods used at your facility. -
Page 35: Maintenance And Servicing
Maintenance and Servicing This section presents information about cleaning, maintaining and servicing your All-Fill Series 500 Filling System. Included in this section are: • General Cleaning Guidelines Information containing guidelines on cleaning your All-Fill 500 Series Filling System as well as the procedure for removing the rotary valve core. -
Page 36: General Cleaning Guidelines
It is recommended that the machine be set to maximum stroke before cleaning in place, as this will minimize the area behind the piston; it will also help to stop any product which has leaked past the piston from hardening, and possibly damaging the seal(s). All-Fill 585b Filling Machine... -
Page 37: Removing And Installing The Rotary Valve Core
13. Refit the change over lever and the change over cylinder. Manually check the operation of the rotary valve. The rotary valve core should turn freely in the rotary valve body when the main air is switched off. All-Fill 585b Filling Machine... - Page 38 AFI Publication Model 585b Piston Filler User Manual | Issue: Preliminary | October 2020 Removing and Installing the Rotary Valve Core (continued) 418 Creamery Way Exton, PA 19341 P: (610) 524 -7350 E: info@allfill.com All-Fill 585b Filling Machine...
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Page 39: Preventative Maintenance
Following a regular pattern of daily and monthly preventative maintenance will assure continued, reliable operation of your All-Fill Filler. Establishing procedures to perform maintenance will assist you in keeping your filling equipment in proper operating condition, as well as allowing you to recognize potential problems that could lead to a machine breakdown. - Page 40 Check nozzle O-ring seals, pneumatic fittings and hoses, cap and insert sealing Weekly surfaces for condition and functionality. Replace worn or damaged seals as required. • Check product hoses and S/S clamps for condition and functionality. All-Fill 585b Filling Machine...
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Page 41: Corrective Maintenance
Check seals for wear or damage. Any Seals leakage of product beyond seals is an indication of worn or damaged seals. Check for leaks or restrictions. Product Inlet (if hopper not used) Recharge Speed May be set too high. Re-adjust. All-Fill 585b Filling Machine... -
Page 42: Plc Troubleshooting
Before requesting service assistance record the PLC Program Steps as displayed in the Diagnostics Screen and the status of all inputs as shown on the Input Devices Screen. This will ensure prompt diagnosis of any problem. All-Fill 585b Filling Machine... -
Page 43: Returns And Repairs Procedure
All-Fill, Inc. can repair or replace failed equipment and components of fillers. Components and equipment of All-Fill Piston Fillers still covered under warranty will be repaired or replaced under the terms of All-Fill, Inc.’s standard warranty (refer to Warranty Information). Items no longer under warranty will be repaired or replaced according to the standard Terms and Conditions supplied with the Machine at time of purchase. -
Page 44: Filler Electrical Circuit (Dwg 12223B
AFI Publication Model 585b Piston Filler User Manual | Issue: Preliminary | October 2020 Filler Electrical Circuit 418 Creamery Way Exton, PA 19341 P: (610) 524 -7350 E: info@allfill.com All-Fill 585b Filling Machine... -
Page 45: Filler Rail And Junction Box Terminals Layout (Dwg 12224B
Filler Rail and Junction Box Terminals Layout All-Fill 585b Filling Machine... -
Page 46: Plc I/O Allocation
O:1/0 Side Shift Cylinder Valve Solenoid 6 O:1/1 Slow Down Valve Solenoid 7 O:1/2 Spare Valve Solenoid 8 O:1/3 Conveyor Motor Control Relay 1 O:1/4 Spare Output O:1/5 Spare Output O:1/6 Spare Output O:1/7 Spare Output All-Fill 585b Filling Machine... - Page 47 Notes All-Fill 585b Filling Machine...
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Page 48: Pneumatic Circuit (Dwg 9550L
AFI Publication Model 585b Piston Filler User Manual | Issue: Preliminary | October 2020 Pneumatic Circuit All-Fill 585b Filling Machine... -
Page 49: Pneumatic Circuit Parts List
Festo S/S Lock Nut BM16x1.5 DIN 439:V2A IFM Efector100 Inductive Proximity Sensors IFC246 IFM Ecomat400 Right Angled Cable - 5m EVC005 SMC Double Acting Cylinder CG5BN25SR-25 SMC Double Acting Cylinder CG5BN25SR-50 HFS S/S Cylinder Brackets 2452d All-Fill 585b Filling Machine... - Page 50 AFI Publication Model 585b Piston Filler User Manual | Issue: Preliminary | October 2020 585bc Filler General Assembly 418 Creamery Way Exton, PA 19341 P: (610) 524 -7350 E: info@allfill.com All-Fill 585b Filling Machine...
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Page 51: 585B Filler Parts List
HFS S/S Control Cabinet Mast 3476g HFS S/S Filler Mounting Post 9241f SMC Double Acting Cylinder CG5BN25SR-50 SMC Double Acting Cylinder CG5BN25SR-25 HFS S/S Gating Cylinder Mounting Bracket 2452d HFS Initiation / Backlog Sensor Assembly 1201d All-Fill 585b Filling Machine... -
Page 52: Control Panel Component Layout (Dwg 12259A
AFI Publication Model 585b Piston Filler User Manual | Issue: Preliminary | October 2020 Control Panel Component Layout 418 Creamery Way Exton, PA 19341 P: (610) 524 -7350 E: info@allfill.com All-Fill 585b Filling Machine... -
Page 53: Control Panel Parts List
Selectlok Cam Lock 200-9043 Selectlok Key 5mm 204-0108 Allen Bradley Panel View C400 2711C-T4T Allen Bradley Connector Cable 1761-CBL-PM02 HFS S/S Control Panel 12259c Festo Flow Control GR-1/8-B Festo Flow Control GR-3/8-B Southco Nylon Inline Knuckle Hinge 96-50-300-11 All-Fill 585b Filling Machine... -
Page 54: Control Cabinet Component Layout (Dwg 12259B
AFI Publication Model 585b Piston Filler User Manual | Issue: Preliminary | October 2020 Control Cabinet Component Layout 418 Creamery Way Exton, PA 19341 P: (610) 524 -7350 E: info@allfill.com All-Fill 585b Filling Machine... -
Page 55: Control Cabinet Parts List
ARO 1/2" B.S.P Male Air Fitting 300-405 Festo Elbow Fitting LJK-1/2 Festo Air Service Unit FRC-1/2-D-MIDI Festo Dump Valve HEE-D-MIDI-24 Festo Socket With Cable` KMEB-1-24-2.5-LED Festo Silencer U-1/4 Festo Manual Override AHB-MEB Festo Multiple Distributor Fitting QSLV3-1/2-12 All-Fill 585b Filling Machine... -
Page 56: Filler Height Adjuster Assembly (Dwg 4560
AFI Publication Model 585b Piston Filler User Manual | Issue: Preliminary | October 2020 Filler Height Adjuster Assembly 418 Creamery Way Exton, PA 19341 P: (610) 524 -7350 E: info@allfill.com All-Fill 585b Filling Machine... -
Page 57: Filler Height Adjuster Parts List
HFS Gear Locating Collar HFS Threaded Bevel Gear NTN Ball Bearing 6204-2-RS HFS Adjustment Handle Hex Bolt S/S M6 x 35.0 HFS Bevel Gear Shaft HFS Keyed Bevel Gear HFS Adjustment Screw Rod HFS Universal Stand Mast 5214 All-Fill 585b Filling Machine... -
Page 58: Ø5.0" Power Cylinder Assembly (Dwg 5010K
AFI Publication Model 585b Piston Filler User Manual | Issue: Preliminary | October 2020 Ø5.0" Power Cylinder Assembly G-10 All-Fill 585b Filling Machine... -
Page 59: Ø5.0" Power Cylinder Parts List
HFS Nylon Piston Buffer 5106-2 Piston Seal MU500 HFS S/S Power Piston Rod 6149-1 Gland Seal SU100150250DI HFS Bronze Gland Nut 2638-1 HFS S/S Tie Rods 2103 S/S Nut HFS S/S Stroke Adjustment Spanner 220a G-11 All-Fill 585b Filling Machine... - Page 60 AFI Publication Model 585b Piston Filler User Manual | Issue: Preliminary | October 2020 Rotary Valve & Metering Cylinders Assembly G-12 All-Fill 585b Filling Machine...
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Page 61: Rotary Valve And Metering Cylinders Parts List
S/S Metric Cap Screws M8 x 20.0 Festo Proximity Sensors SME-8M-DS-24V-K-2,5-OE Festo S/S Lock Nut BM16x1.5 DIN 439 Igus Female Rod End (M16) KBRM-16x1.5-MH HFS S/S C/O Cylinder Rod End Bolt 7358c HFS S/S Tie Rods 9237 G-13 All-Fill 585b Filling Machine... -
Page 62: Side Shift Assembly (Dwg 12272
AFI Publication Model 585b Piston Filler User Manual | Issue: Preliminary | October 2020 Side Shift Assembly G-14 All-Fill 585b Filling Machine... -
Page 63: Side Shift Parts List
Festo S/S Lock Nut BM16x1.5 DIN 439 S/S Metric Capscrews M8 x 35.0 HFS S/S Mounting Arm 8143g S/S Metric Capscrews M12 x 30.0 HFS S/S Post Clamp 230c S/S Metric Capscrews M12 x 35.0 G-15 All-Fill 585b Filling Machine... -
Page 64: Gating Initiation Sensor Assembly (Dwg 1201D
AFI Publication Model 585b Piston Filler User Manual | Issue: Preliminary | October 2020 Gating Initiation Sensor Assembly G-16 All-Fill 585b Filling Machine... -
Page 65: Gating Initiation Sensor Parts List
IFC246 IFM Ecomat400 Right Angled Cable - 5m EVC005 HFS S/S Initiation Bracket HFS S/S Rail Clamp - Sensor 134b HFS Initiation Swivel Assembly S/S Bar Ø 5/8” x 470 Aluminium Wand Arm Ø 1/8” G-17 All-Fill 585b Filling Machine... -
Page 66: Rotary Nozzle Assembly (Dwg 9226G
AFI Publication Model 585b Piston Filler User Manual | Issue: Preliminary | October 2020 Rotary Nozzle Assembly G-18 All-Fill 585b Filling Machine... -
Page 67: Rotary Nozzle Parts List
HFS S/S Nozzle Actuating Bar 4759h-4 HFS Aluminium Nozzle T-Slot Mounting Bar 4759h-1 HFS S/S T-Slot Clamps 4759h-3 (48mm Long) HFS Aluminium Nozzle Clamp Blocks 6169-2 Glacier DU Bushes 16DU24 HFS S/S Nozzle Drive Gears 5999-1 G-19 All-Fill 585b Filling Machine... -
Page 68: Universal Nozzle Assembly (Dwg 1691F
AFI Publication Model 585b Piston Filler User Manual | Issue: Preliminary | October 2020 Universal Nozzle Assembly 418 Creamery Way Exton, PA 19341 P: (610) 524 -7350 E: info@allfill.com G-20 All-Fill 585b Filling Machine... -
Page 69: Universal Nozzle Parts List
HFS S/S T316 Ø12.0mm Nozzle Cap 810b-6 HFS S/S T316 Cap Insert 810b-6 Festo Push-In Air Fittings QS-1/8-4 O-Rings Nitrile Imperial O-Ring 010N70 Nitrile Imperial O-Ring 023N70 Viton Imperial O-Ring 020V Viton Imperial O-Ring 016V Nitrile Imperial O-Ring 024N70 G-21 All-Fill 585b Filling Machine... - Page 70 THIS PAGE INTENTIONALLY LEFT BLANK...
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