AUTO-FILL 900 SERIES SINGLE HEAD/BAG-IN-BOX FILLER Scholle Corporation 19500 JAMBOREE ROAD IRVINE, CALIFORNIA 92612-2457 U.S.A. TOLL FREE SERVICE LINE 1 (877) AUTO-FILL (1 (877) 288-6345 ) PHONE: 1 (949) 955-1750 FAX: 1 (949) 476-2967AUTO-FILL 9 DVT OPERATION / SERVICE GUIDE TABLE OF CONTENTS IMPORTANT USER INFORMATION ...... 2... 20-22 0c css eee see eeeeeeeeeeeeeenes iv WARNINGS GENERAL DESCRIPTION . SERVICE REQUIREMENTS BASIC MACHINE SPECIFICATIONS . MACHINE DIMENSIONS .. INSTALLATION .........45 CONTROLS DESCRIPTION .... 9D CONTROL PANEL DTAM - EXPLANATION . TIMER/COUNTER EXPLANATION . HIGH SPEED COUNTER PROGRAMMING DTAM FUNCTIONS, PROGRAMMING FUNCTIONS AF 9DVT BACK UP POWER FOR RAM .. EEPROM INSTALLATION - SLC500 . NO CAP/NO FILL PRESSURE SENSOR . CAP SENSOR DESCRIPTION SENSOR ADJUSTMENT CONTROL DEVICES CONTROL SOLENOIDS .. PRESSURE REGULATORS we 2d July 24, 1998, ‘SCHOLLE CORPORATION Page iAUTO-FILL 9 DVT BASIC FILLER OPERATIONS........+..-0000005 pee CLEAN IN PLACE / SANITATION PROCEDURE . FILLING BAGS ..... Rte aft FILLING SEQUENCE . CAN FILL OPERATION . CLEANING AND MAINTENANCE ....... FILL HEAD MAINTENANCE ...... REMOVAL AND DISASSEMBLY . RE-ASSEMBLY AND INSTALLATION PRODUCT VALVE REMOVAL AND DISASSEMBLY . ASSEMBLY AND INSTALLATION MECHANICAL ADJUSTMENTS ..... CAPPER / HEAD ADJUSTMENT . PRODUCT VALVE ADJUSTMENT . REED SWITCH ADJUSTMENT ..... LUBRICATION AND MAINTENANCE SCHEDULE ............0.0.00005 60 TROUBLE SHOOTING TROUBLESHOOTING - Example DTAM FUNCTION -7 FAULT CODE LIST . TROUBLE SHOOTING TABLES .... PLC VO LISTING ......... noes TYPICAL PROCESS-AUTOMATIC FLOW METER . TURBINE FLOW METER DISASSEMBLY . TURBINE FLOW METER ASSEMBLY .. PLC LOGIC LISTING (Insert) July 24, 1998 ‘SCHOLLE CORPORATION. Page iiAUTO-FILL 9 DVT PARTS LISTS . BILL OF MATERIALS - AF 9-DVT ,,. SHIPPING CHECKLIST - AF 9-DVT .... . 82 . 82 . 88 SPARE PARTS - DOMESTIC - AF 9-DVT . -89 SPARE PARTS - OVERSEAS - AF 9-DVT ..... 2.200... 0 cece eee eee e ee eeaee 1 DRAWING LIST .......cccetetecccenet ee eetene eee csene eset eeneteeseensteeee 93 July 24, 1998) ‘SCHOLLE CORPORATION Page iiAUTO-FILL 9 DVT IMPORTANT _ Because of the variety of uses for the product described in this publication, those responsible for the application and USER use of this equipment must satisfy themselves that all necessary steps have been taken by them to assure that INFORMATION each application and use meets all of their performance and safety requirements, including any applicable laws, regulations, codes, and standards. Mlustrations, charts, tables, images, and layout examples shown in this guide are intended solely for purposes of example. Since there are many variables and requirements associated with any particular installation, Scholle Corporation does not assume any responsibility or liability for actual use or application thereof, or for any results obtained. All warranties are disclaimed, including, without limitation, the implied warranties of FITNESS FOR A PARTICULAR PURPOSE, and MERCHANTABILITY. Reproduction of the contents of this publication, in whole or in part, without expressed, written, permission of Scholle Corporation, is prohibited. eee eee Cee ATTENTION! This symbol identifies information about practices or circumstances that can lead to personal injury or death, na | property damage or economic loss. July 24, 1998 ‘SCHOLLE CORPORATION Page ivAUTO-FILL 9 DVT WARNINGS! SECURELY CLOSE ALL CABINET DOORS AND COVERS DURING WASH DOWN AND FILLING OPERATIONS. THIS MACHINE IS CONTROLLED BY ELECTRONIC EQUIPMENT THAT WILL BE DAMAGED BY WATER, CAUSTIC, AND PRODUCT!!! IT 1S IMPERATIVE THAT, DURING CLEAN UP OPERATIONS, EXTREME CARE MUST BE TAKEN TO INSURE THAT NO WATER OR CLEANING SOLUTION OF ANY KIND ARE ALLOWED TO ENTER THE CABINET OR ENCLOSURE. DO NOT POINT HIGH PRESSURE WASHING EQUIPMENT DIRECTLY TOWARDS AND UNDER ELECTRONIC DEVICES OR CABINETS. FAILURE TO OBSERVE THIS WARNING MAY RESULT IN DAMAGE TO EQUIPMENT OR HARM THE OPERATOR. HIGH VOLTAGE INSIDE. PLEASE CONTACT OUR FIELD SERVICE DEPARTMENT FOR SPECIAL INSTRUCTIONS PRIOR TO ANY WELDING ON OR AROUND THE FILLER, July 24, 1998 ‘SCHOLLE CORPORATION Page VvAUTO-FILL 9 DVT PLC CONTROLLED EQUIPMENT IS SENSITIVE TO EMF AND MUST BE ISOLATED TO PROTECT AGAINST UNEXPECTED ELECTRICAL SURGES. NOTE: THIS PUBLICATION IS PROVIDED AS A GUIDE FOR THE TRAINED TECHNICIAN FOR INSTALLING, ASSEMBLING, f) REPAIRING, AND SERVICING THE SCHOLLE AUTO FILL. ye REPAIR OR ADJUSTMENT BY UNAUTHORIZED PERSONS MAY poi VOID ANY, OR ALL, WARRANTIES, AND, OR, ANY GUARANTEES OF PERFORMANCE. THE SELECTED INDIVIDUAL MUST BE FAMILIAR WITH STANDARD TERMS USED TO IDENTIFY PARTS. APPLICATION AND DESCRIPTIONS. ORDERING INFORMATION Itis most important that the correct part number is used when ordering replacement, or repair, parts. Parts orders are machine processed, using only the part number and quantity provided. Parts orders are not edited, or verified, to determine if the part number, description, and application agree. For this reason, orders must be placed sing the original Bill of Material, and Spare Parts Lists placed in the back of this guide for your convenience. SCHOLLE CORPORATION RESERVES THE RIGHT TO MAKE REFINEMENTS OR CHANGES TO THE EQUIPMENT AND THIS PUBLICATION WITHOUT NOTIC! July 24, 1998 ‘SCHOLLE CORPORATION Page viAUTO-FILL 9 DVT | INTRODUCTION The information in this guide has been compiled to assist properly trained personnel in their understanding of the Scholle AF 9-DVT filling machine. Because basic operating principles are discussed here, this manual is considered mandatory reading by anyone involved with the day to day running, maintenance, and servicing of the machine. Optimum machine operation can only be achieved with a basic understanding of the operating sequences, coupled with the electro/mechanical disciplines involved. An understanding of the functions of the control panel switches and indicators is vital. Optimum machine operation and efficiency can only be achieved if the operator becomes familiar with the daily routine of running the machine. The person operating this equipment has responsibility that includes, but should not be limited to, cleaning the machine, checking mechanical operation, ordering repairs and arts, calibrating and adjusting the fill volume, and checking production quality. On installation, our Field Service Technician will be available for the purpose of providing training to the extent of self-sufficiency. As the operator has daily contact and, thus, familiarity with the machine, he/she should notify the maintenance personnel should something out of the ordinary become evident. This may avoid major breakdowns and down time. July 24, 1998, ‘SCHOLLE CORPORATION Page 7AUTO-FILL 9 DVT This guide contains information on the operation and maintenance of the filler, as well as a technical overview of the operating functions. The sections on the adjustment and operation of the machine details setting up of the machine by the service technician or maintenance personnel and explains how to run the machine in manual step cycle as well as running in automatic mode. Although every effort has been made to list possible problems that could arise with the machine, problems could still eventuate from a source external to the machines environment which cannot be foreseen and diagnosed. Equipment maintenance is always critical. Machines need administration; without it, they are seen as being unreliable, WARNING! PERSONNEL PERMITTED TO MAKE ADJUSTMENTS OR SERVICE FOR THIS TYPE OF ADVANCED EQUIPMENT MUST BE CAPABLE OF INTERPRETING TECHNICAL TERMS, DESCRIPTIONS, AND MUST POSSESS, AT MINIMUM, A BASIC UNDERSTANDING OF TROUBLE SHOOTING ELECTRO-MECHANICAL PNEUMATIC DEVICES. July 24, 1998 ‘SCHOLLE CORPORATION. Page 2AUTO-FILL 9 DVT a GENERAL DESCRIPTION Your Auto-Fill 9-DVT is a single head hand-fed automatic bag filler. Included in the advanced features are, an Allen-Bradley PLC (Programmable Logic Control) unit, that eliminates electro-mechanical devices, such as relays, cam timers, et cetera, as well as the most advanced solenoid directional control valves, reed switches, and related industrial hardware available today. Your filler uses one of several product metering systems specifically selected for this application. The selected metering system consists of a sensing instrument to provide output to an accumulation device coupled to the PLC that controls accurate, repetitious, dispensing of product to a preset value. In most cases, a turbine flow meter is used. See the appropriate section of this guide for detailed information regarding turbine flow meters, or the manufacturers catalogs of other devices, Briefly described, as product is pushed through the flow meter, the flow meter impeller reacts and begins to turn. As the impeller turns, the vanes pass in close Proximity to an external pickup, in this case, a transducer mounted to the meter body. The transducer produces a DC, ON - OFF signal representing movement through the pipe. This electrical representation is registered at the input device and accumulated to a preset value that represents movement of product through the pipe, The package size may be adjusted by changing the “PRESET value” at the DTAM controller (Data Table Access Module). See the section for DTAM setup and procedures, July 24, 1998 SCHOLLE CORPORATION Page 3AUTO-FILL 9 DVT a SERVICE REQUIREMENTS BASIC MACHINE SPECIFICATIONS: POWER REQUIREMENTS... (5 AMPS)... 110/220 ** VAC ** CAUTION: See special instructions in the INSTALLATION section AIR SUPPLY... (4 CFM)... 80 P.S.I. (min) MACHINE DIMENSIONS: HEIGHT... 76 INCHES... 2" VERTICAL ADJUSTMENT WITH STAND PIPE... 120 INCHES (Ceiling clearance) 43 INCHES WITH TABLE 22 INCHES 38 INCHES WITH SIDE UNLOAD TABLE REAR EGRESS / INGRESS FRAME FOOTPRINT 30” 20°W x 28"D July 24, 1998 ‘SCHOLLE CORPORATION. Page 4AUTO-FILL 9 DVT LL INSTALLATION A REMOVE any strapping tape and packing material from the filling head. Check that all the bolts and nuts on the filler are tight. Also, check that all electrical connections and air line fittings are tight. B. PLACE the filler in its location - The filler can be leveled by adjusting the ball feet ‘on the lower frame. . PROVIDE POWER - The standard filler requires 110/220 V.A.C., 50 or 60 hertz, 5 amps, and is furnished with a power cord. (220 VAC may also be used if required.) NOTE: When 220 VAC is used, the input wiring to the internal DC power supply must be changed BEFORE applying power. See Electrical schematic for detail. D, SUPPLY COMPRESSED AIR - Provide a minimum of 80 psi at 4 cfm. (100 psi is recommended) E. Place the bag box on the conveyor in front of the filler. Adjust the table height so that the lip is just above the box. The edge of the table should be located about one haif inch to the inside of the box. This will allow the bag to fall into the container and clear the rear corners. The filler should be secured so that it will not move from this. adjusted location. July 24, 1998 ‘SCHOLLE CORPORATION Page 5AUTO-FILL 9 DVT F, After setting the table height to the box, adjust the auto head height, to accommodate a five gallon Scholle bag. Holding the auto head; loosen the four 1/4-20 bolts on the u-clamp holding the auto head to the auto head support U-CLAMP post. Move the auto head so that the bottom of | the spout holder is five inches above the table. Tighten the bolts. SPOUT “~ HOLDER G. Install the product line connection. The filling head may have to be adjusted up or down once the filler is in operation. This adjustment will change the position of the product line connection, so make allowances for this in the product line installation. H. When fabricating a rigid C.I.P. (CLEAN IN PLACE) return loop, use the following Procedure to set up the machine for piping alignment: 1. Turn the selector switch SS1 to the “OFF” position 2. Main power on 3. Air on, and the FILL CYCLE STOP switch pushed IN July 24, 1998 SCHOLLE CORPORATION Page 64, Insert the C.I.P. adapter into the spout holder. Hold the adapter in position and turn the selector switch SS1 to the “CIP” position. A: Pull out the FILL CYCLE STOP button. The cap holder will move up and rotate outward, and the product valve will move down to the C.I.P. adaptor. B: Install the necessary plumbing to connect the C.|.P. adapter to the C.LP. return line, Try to use the standpipe in this connection. This insures the standpipe is removed during clean up and will also eliminate the need to hand wash. Disconnect the C.I.P. adapter from the C.I.P. return line. Turn the selector switch, SS1, to the “OFF” po! It is suggested that the C.I.P. return be made from 1" - 1.5" stainless steel tubing, with brackets mounted to the process system framework, and a shut-off valve (butterfly) installed at the lowest point, July 24, 1998 ‘SCHOLLE CORPORATION Page 7AUTO-FILL 9 DVT a CONTROLS DESCRIPTION The Scholle filler is controlled by an Allen Bradley PLC (programmable logic controller). Operator controls are provided in the form of pushbuttons, selector switches and pilot light indicators, and, on some equipment, operator terminals. Filler configuration and diagnostics are provided at the operator terminal. The following sections describe the filler controls in more detail. July 24, 1998 ‘SCHOLLE CORPORATION Page 81 SS-3 MAIN POWER - This ON/OFF switch turns the power on, or off at the filler. 2. MAIN POWER INDICATOR - This light, when illuminated, indicates that main power is turned on. 3. SS-1 CIP/ OFF / RUN - A three position selector switch that turns the filler OFF, to C.LP., or the RUN mode. 4. PB-1 FILL CYCLE STOP - Maintained pushbutton switch - when pushed in before fill, will not allow the filler to operate. Also used as the EMERGENCY STOP. When pushed in during a fill, it latches an emergency stop bit, immediately closing the Product valve and dropping air to the MAIN CYLINDER and EJECTOR solenoids. The capper will return to the top of the spout, where the operator can push the cap back on ‘and pull the bag free. There is no EMERGENCY STOP push button on this equipment. ‘The FILL CYCLE STOP INDICATOR will FLASH when a fault occurs. July 24, 1998 SCHOLLE CORPORATION Page 9DTAM - EXPLANATION DTAM Module The Allen-Bradley Data Table Access Module is a device Overview utilized on some Scholle fillers to access, and modify, data file information, monitor, and clear processor faults. For further information on operation, utilization, and other applications, refer to the User Manual included with this Operation Guide. July 24, 1998 ‘SCHOLLE CORPORATION Page 10CONFIGURE DTAM To configure the DTAM; the jumper wire at the back of the DTAM must be between terminals 1 & 2. 1 is the bottom terminal and 2 is the middle terminal. With the power on; the green led light (COMM) will be flashing. You are now in the modify mode. Start by pushing [7] and [INC] simultaneously, holding until the display reads: MODIFY SETUP CONFIRM? Then release and push [ENTER] The display reads: SELECT LANGUAGE ENGLISH Push [INC}to toggle. Stop at ENGLISH, push [ENTER]. The display reads: SELECT DTAM ADDR 0 Address will be 0 - push [ENTER] The display reads: SELECT BAUD RATE 19200 Push [INC] to toggle, stop at 19200 and push [ENTER]. The display reads: SET AUTO ATTACH ON July 24, 1998 ‘SCHOLLE CORPORATION Page 11Push [INC] to toggle on, push [ENTER]. The display reads: ‘SET BACKLIGHTING | ON Push [INC] to toggle on, push [ENTER] The display reads: Push [INC] to toggle on, push [ENTER] The display reads: Push [ENTER]. The dtam performs a self test. Upon completion of the test the display reads: Configur ion procedure is complete. July 24, 1998, ‘SCHOLLE CORPORATION Page 12AUTO-FILL 9 DVT TIMER/COUNTER EXPLANATION The following examples show the keystrokes necessary to change the presets of the programmable timers and counters. The functions of these timers have been established as ‘user definable’ and user access is allowed in order to ‘fine tune’ the setting. Only properly trained personnel should be permitted to access and adjust these settings. The example below illustrates setting the vacuum timer (FUNCTION 5). All other timer Presets may be changed in the same manner; just enter the appropriate function key number and the desired preset value. An explanation of the other user timers and presets will follow. TIMER VALUES ARE SET IN “HUNDREDTHS OF A SECOND” EXAMPLE: 5 0=1/2SECOND 1 0 0=1SECOND VACUUM TIMER - Function 5. PUSH: F5 THE DISPLAY READS (.5 SECONDS) = % SECOND TO INCREASE THE TIME TO 1.0 (ONE) SECOND: PUSH: 10 0 PUSH: ENTER IF DONE PROPERLY THE DISPLAY SHOULD READ (1.00 SECOND) PUSH: ESC July 24, 1998, SCHOLLE CORPORATION Page 13AUTO-FILL 9 DVT eS DTAM PROGRAMMABLE FUNCTIONS FUNCTION ILL COUNTER PRESET (HIGH SPEED INTER: As product is pushed through the flow meter, a stream of pulses is sent to the programmable logic controller (PLC) High Speed Counter. Each pulse represents movement through the product pipe, or meter body. Counting these pulses to a preset value in the controlling device, the Product Valve is closed, shutting off product flow at the correct count. This process repeats to a high degree of accuracy and repeatable measurement is achieved. Example: Approximately 300 counts on the DTAM equals one US gallon of water on a 1.5" turbine flow meter. Enter 1500 counts on the DTAM; this should equal about five US gallons of water. Weights vary from product to product due to. density properties. Using a five gallon Scholle bag, start with 1500 counts on the DTAM. Fill the bag with product and weigh the filled bag on a scale. Increase or decrease the counts on the DTAM to reach the desired weight of the product in the bag. FUNCTION 1 - COUNTER ACCUMULATOR NO SETTING ON THIS COUNTER - This function is used to display the accumulating counts during a fill. FUNCTION 2 - BAG COUNTER RESET BAG COUNTER - this function is to reset the bag counter to zero (0) after a production run. BAG COUNTER OPERATION Each time the fill counter reaches it preset, one count is added to the bag counter. The value should be checked, recorded, and reset at the start and end of each product run. July 24, 1998 ‘SCHOLLE CORPORATION Page 14AUTO-FILL 9 DVT eS FUNCTION 4 - CRUSH TIMER The CRUSH TIMER is started when the MAIN CYLINDER EXTEND solenoid is energized and the MAIN CYLINDER EXTEND reed switch turns ON during recapping of the Auto Fill Cycle. The MAIN CYLINDER EXTEND solenoid remains energized until the timer reaches it preset. This timer is especially important when using two position, or Dust Cover, caps. These caps need over-travel during recapping to be fully capped and may require more time on this timer. FUNCTION 5 - VACUUM TIMER The vacuum valve is opened when the MAIN CYLINDER RETRACT reed switch turns ON during the uncapping of the Auto Fill Cycle. This removes air that may have entered the bag during the uncapping cycle. The vacuum valve stays open for the amount of time entered at the DTAM. FUN IN_7 - FAULT CODE DI: Y. This is used to display a list of Fault Codes, See the TROUBLESHOOTING section of this guide for more information. FUNCTION 8 - CAN FILLER MODE This is used to set the filler up to allow filling into open top cans. July 24, 1998 ‘SCHOLLE CORPORATION Page 15AUTO-FILL 9 DVT PROGRAMMING DTAM FUNCTIONS DELAY BEFORE EJECT TIMER _14:4.PRE NOTE: THIS TIMER IS NOT A DTAM (F-X) FUNCTION BUT MAY BE ACCESSED MANUALLY FROM THE DTAM. When the crush timer ends, the main cylinder de-energizes (becomes neutral) and this timer is started, At this time the cap holder will rebound up due to the crush spring. When this timer has reached its preset, the SPOUT EJECT OPEN solenoid will energize and eject the cap and spout. CAUTION! This timer is designed to reduce the stress on the spout ejector plate bushing, Careful observation of filler operation before and after adjusting this timer is REQUIRED to prevent damage or excessive wear to the ejector bushing. This time is variable depending on the cap and spout combir The timer should be set and REMAIN FIXED once the proper time is established. tion you are using. TO SET THE TIMER, PRESS : SHIFT T 4 ‘SHIFT : 4 SHIFT PRE ENTER This will display the current time in the timer. To change this time, enter the new time on the display using the numeric keys and press [ENTER]. ie : 50 = % SECOND, 100 = 1 SECOND. TO EXIT PROGRAMMING, PRESS [ESC]. July 24, 1998 ‘SCHOLLE CORPORATION Page 16AUTO-FILL 9 DVT a PROGRAMMING FUNCTIONS AF 9DVT Use the following guide to program the functions into the DTAM. This should only be necessary if a new DTAM is installed on the filler. FUNCTION - 0_HIGH SPEED COUNTER (N7:0) SHIFT N 7 SHIFT : ENTER SHIFT FOF oo ENTER FUNCTION - 1_ COUNTER ACCUMULATOR (C5:0.ACC! SHIFT c 5 ‘SHIFT : 0 SHIFT ACC ENTER SHIFT F F 1 ENTER FUNCTION - 2_BAG COUNTER (C5:1.ACC. ‘SHIFT c¢ 5 — SHIFT : 1 SHIFT ACC ENTER SHIFT F oF 2 ENTER FUNCTION - 4_CRUSH TIME (T4:6.PRE) SHIFT T 4 SHIFT : 6 SHIFT PRE ENTER SHIFT F F 4 ENTER FUNCTION - 5 _ VACUUM (T4:0.PRE) SHIFT T 4 SHIFT 7 0 SHIFT PRE ENTER SHIFT Bae: ENTER FUNCTION - 7 FAULT CODE (B12:0) SHIFT Bo4 2 SHIFT : 0 ENTER SHIFT FOF 7 ENTER FUNCTION - 8 CAN FILLER MODE (B3/11 SHIFT B 3 SHIFT / 1 1 ENTER ‘SHIFT FO oF 8 ENTER July 24, 1998 'SCHOLLE CORPORATION Page 17AUTO-FILL 9 DVT ny BACK UP POWER FOR RAM PROGRAM BACK-UP Back-up power for RAM is provided by a capacitor that will retain the contents of the RAM for a period of 5 to 30 days. For applications requiring memory back-up for a longer period of time a replaceable battery is required (Scholle part number P03820, 1747-BA). The lithium battery provides back-up for approximately five years. A red BATTERY LOW LED turns on when the lithium battery voltage has fallen below a preset threshold level. Once the BATTERY LOW LED turns on, do not remove processor power or your program may be lost. Replace the battery as soon as possible, See the SLC500 manual for battery replacement procedures. Scholle Corporation provides an EEPROM with the program for your filler. With the EEPROM installed, the SLC500 processor will automatically load the program from the EEPROM each time the processor is powered-up. After restoring the program to RAM, remove power from the SLC500 processor and store the EEPROM in a safe place. The RAM memory will then be retained each time the SLC500 is powered-up, as explained above. Due to the high probability that program changes are made during the installation, it is highly recommended to have the current program saved on this EEPROM. Program changes or updates must be “burned” to the EEPROM by Scholle Corporation. EEPROM changes and updates must be requested from the Control Systems Department at Scholle Corporation. See the following manual section for EEPROM installation and removal. July 24, 1998 ‘SCHOLLE CORPORATION. Page 18AUTO-FILL 9 DVT a EEPROM INSTALLATION - SLC500 TO PREVENT POSSIBLE DAMAGE TO THE EEPROM OR CAUSE CPU FAULTS, TURN OFF POWER TO THE PROCESSOR BEFORE INSERTING OR REMOVING THE EEPROM. 1. Remove the door on the processor. 2. Locate the EEPROM socket on the PC board as the drawing indicates, 3. The EEPROM is keyed, Position the EEPROM in the socket and press firmly in place. 4. Restore power to the processor. The EEPROM will automatically down load its memory into the processor memory, 5. The EEPROM should be removed from the processor and stored in a secure place. 6. _ Place the door on the processor. July 24, 1998 SCHOLLE CORPORATION Page 19AUTO-FILL 9 DVT NO CAP / NO FILL PRESSURE SENSOR CAP SENSOR DESCRIPTION The cap sensing system uses back pressure in an open ended circuit to determine the presence of an object in the sensing/holding device. Clean dry regulated air flows out to an orifice in the capper plate at a rate determined by the flow control valve. A change in the volume of air passing through the bleed hole on the capper will cause a rise in back pressure. When this back pressure is sensed, the sensor switches ON its output allowing the fill cycle to begin. SHC pestuienieToH July 24, 1998 SCHOLLE CORPORATION. Page20AUTO-FILL 9 DVT a SENSOR CONTROLS The SMC pressure sensor incorporates an LCD display and the following controls: MOMENTARILY PUSHED, TOGGLES THE LCD DISPLAY SET KEY: AS FOLLOWS- — - INCOMING PRESSURE - - LOW ALARM VALUE - - HIGH ALARM VALUE - When pushed for one second or longer - First - the configuration display is shown - then - The set key may then be pushed momentarily to toggle the configuration screens for UNIT and OUTPUT selection. UPKEY:a. Increases the numerical value. Also changes the unit or output selection. DOWN KEY: ¥ Decreases the numerical value, Also changes the unit or output selection. RESET: a+ TO CLEAR THE DISPLAY AND RESET ERRORS Arrow buttons pushed simultaneously will clear the display and RESET any errors in the unit. July 24, 1998 SCHOLLE CORPORATION Page2tAUTO-FILL 9 DVT SENSOR ADJUSTMENT 1. UNIT AND OUTPUT MODE SETTING @. Push the SET button for one second or longer - the UNIT SELECTION will begin flashing. b. UNIT SELECTION: Use the DOWN button to select “psi”, ¢. Momentarily push the SET button. d. _ OUTPUT SELECTION: Use the DOWN button to select “P”. e. Momentarily push the SET button. f. UNIT and OUTPUT MODE SETTING completed. DATA SETTING a, Momentarily push the SET button. b. Pt will be displayed on the left; use the UP/DOWN button to select 6. ¢. Momentarily press the SET button. 4. P2will be displayed on the left; use the UP/DOWN button to select 4. . _ Momentarily press the SET button. Incoming pressure is displayed. f. DATA SETTING completed. July 24, 1998 SCHOLLE CORPORATION Page22AUTO-FILL 9 DVT a 3. PRESSURE SENSOR AIR FLOW ADJUSTMENT a. Turnon the air supply to the filler. b. Push in the FILL CYCLE STOP pushbutton. ¢, Loosen the lock nut on the cap sensor flow control and open it completely. (counterclockwise) d. Remove the cap and spout from the capper/spout holder and adjust regulator R-7 until the sensor display reads 14-15 PSI. e. Turn the flow control in (clockwise) until the sensor display reads 3-4 PSI. f. Tighten the lock nut on the flow control. ‘ When a cap is not in the cap holder, the LED should be OFF, the input to the PLC should be OFF. The display should read approximately 2-3 PSI. ¢ When a capis in the cap holder, the LED should turn ON and the input to the PLC should turn ON. The display should read approximately 7-10 PSI. July 24, 1998 SCHOLLE CORPORATION. Page23AUTO-FILL 9 DVT CONTROL DEVICES CONTROL SOLENOIDS SOLENOID CYLINDER AIR LINE ADDRESS SOL-1A MAIN CYLINDER RETRACT #2 SOL-1B MAIN CYLINDER EXTEND #1 | SOL-6A —TevecTor SOLENOID OPEN 47 SOL-6B EJECTOR SOLENOID CLOSE. #6 SOL-5A PRODUCT VALVE OPEN #4 SOL-4A VACUUM VALVE OPEN #8 PRESSURE REGULATORS INCOMING SUPPLY REGULATOR MAIN CYLINDER 80 PSI (MIN.) 50 PSI R-5* ‘SPOUT EJECTOR FORK .) | POPPET CONTROL (OPTION) (U.BR.) | AIRLESS FILL PAD 50 PSI 50 PSI_ (As Req'd) | 50 40 PSI (As Req'd) R-6* R7 NOTE: NOTE: BYPASS / DIVERT VALVE 45 PSI (MAX.) NO CAP NO FILL SENSOR PUFF/VAC SHUTTLE 9 PSI 50 PSI U.B.R. is an SMC Under Base Regulator mounted under the controlling solenoid. Asterisk refers to optional equipment July 24, 1998 ‘SCHOLLE CORPORATION Page24AUTO-FILL 9 DVT eS BASIC FILLER OPERATIONS July 24, 1998 SCHOLLE CORPORATION. Page25AUTO-FILL 9 DVT aS CLEAN IN PLACE / SANITATION PROCEDURE The filler must be flushed and hand cleaned after every production run. The filler is designed to allow the circulation of cleaning solutions through the product line, the product valve, the vacuum valve, through the C..P. adapter and to the return line. NOTE: THE PRODUCT VALVE WILL OPEN AND CLOSE DURING THE C.I.P. PROCESS. IF PIPING HAMMER IS EVIDENT, IT MAY BE NECESSARY TO REMOVE THE BOTTOM 0-RING ON THE PLUNGER. THIS WILL BE SUBJECT TO INDIVIDUAL APPLICATIONS AND THE SCHOLLE FIELD SERVICE TECHNICIAN WILL BE ABLE TO DETERMINE IF THIS STEP SHOULD BE TAKEN. 1. Turn OFF the air supply to the vacuum pump on the vacuum tank, 2. DRAIN the product line and valve. Push ‘IN’ PB1 - FILL CYCLE STOP. A. Insert the C.|.P. adapter with the return hose connected, Water or product may be captured in this manner. B. Turn selector switch to “C.I.P.” position. Pull out the FILL CYCLE STOP push button and product line will drain. When finished - push IN the FILL CYCLE STOP push button E. Remove the C.LP. adaptor with the hose and proceed, July 24, 1998) SCHOLLE CORPORATION Page26AUTO-FILL 9 DVT a NOTE: As a SAFETY precaution, disconnect the air lines, #4 and #5, to the product valve at the quick connects on the cabinet. NOTE: STEPS 3 AND 4 ARE REQUIRED ONLY IF A VITON O-RING IS USED 3. REMOVE the 1 1/2" Tri-Clover clamp connecting the product pipe to the product valve body. Lower the valve body and remove. 4. Use an O-ring tool and remove the Viton O-ring from the vacuum valve plunger. Put the valve body back on the valve adapter making sure the gasket is seated properly. Clamp the two together with the 2" clamp. Insert the line gasket into the product pipe. Connect the product pipe to the valve body with the 1 1/2" tri clover clamp. NOTE: STEPS 3 AND 4 ARE ONLY REQUIRED IF REQUIRED BY THE PIPING SYSTEM INSTALLATION. 5. Re-connect the #4 and #5 air lines to the quick connects on the cabinet. 6. Remove the clamp holding the standpipe to the tee. Remove the clamp holding the end cap to the standpipe. Place the cap with gasket on the tee where the stand pipe was removed and clamp. Position the stand pipe in the C.LP. return connection. This ensures the standpipe is removed and , REDUCING the need to hand wash it. cleaned during C. July 24, 1998) ‘SCHOLLE CORPORATION Page27AUTO-FILL 9 DVT 7. Atthe DTAM, push counter function “FO" and set the counter to run 5 gallons of cleaning solution. When the counter reaches its preset, the product valve will close for 1.5 seconds, then open. This helps clean the product valve. NOTE: THESE CONDITIONS MUST BE MET BEFORE STARTING C.I.P... THE PUSHBUTTON, PB1 FILL CYCLE STOP, MUST BE PULLED OUT. THE SELECTOR SWITCH, SS1, MUST BE IN THE “OFF” POSITION. THE CAP HOLDER MUST BE IN THE DOWN POSITION CLOSING THE CONTACTS OF THE MAIN CYLINDER EXTEND REED SWITCH (RS-3). 8. Inspect and lubricate the O-ring in the C.I.P. adapter. 9 Disconnect the vacuum line at the vacuum tank and connect to a drain or C.LP. return line. 10. Slide the C.I.P. adapter into the spout plate. Close the cap jaws. Turn the selector switch SS1 to the “CIP” position. The ejector close solenoid energizes locking in the C.I.P. adapter. The main cylinder retract solenoid energizes and the capper moves up. When the middle reed switch is passed the air spring solenoid is energized causing the product valve to. seat against the c.i, . adapter. July 24, 1998 SCHOLLE CORPORATION. Page28AUTO-FILL 9 DVT eS 11. Connect the C.I.P. return line to the C.I.P. adapter. Check the product pipe connections for gaskets and tight clamps. NOTE: WHEN A TURBINE FLOW METER IS USED A LIQUID CLEANER RATHER THAN A POWDERED CLEANER SHOULD BE USED FOR C.I.P. UNDISSOLVED POWDER MAY ACT AS AN ABRASIVE AND DAMAGE THE FLOW METER. PUMPING THE ‘SOLUTION AT RATES GREATER THAN 2 GALLONS PER SECOND MAY CAUSE ACCELERATED WEAR ON THE FLOW METER. 12, When the FILL CYCLE STOP pushbutton is pulled out, the product valve will open. The vacuum valve solenoid is also energized, opening the vacuum valve (poppet). The vacuum valve will remain open during C.L.P. Start the CLP, circulation pump. The product valves is pulsed (closed momentarily for 1.5 seconds) each time the fill counter preset (function “F0") is reached. Set “FO" to AROUND 1500 counts. WARNING! THE C.I.P. PUMP MUST BE SHUT DOWN BEFORE STOPPING THE FLOW OF CLEANING SOLUTION AT THE FILLER. IF THE PRODUCT VALVE O-RING HAS BEEN REMOVED THE FLOW WILL NOT STOP COMPLETELY. THE C.I.P, PUMP MUST BE SHUT DOWN. July 24, 1998 ‘SCHOLLE CORPORATION Page29AUTO-FILL 9 DVT | 13, After the cleaning solution has been circulated for the required time, turn the C.L.P. circulating pump off. ALLOW THE SYSTEM TO DRAIN. 14. When the system has drained, push IN the FILL CYCLE STOP pushbutton, the product valve and vacuum valve will close. Disconnect the C..P. return line from the C.|.P. adapter. 15. Turn the selector switch SS1 to the “OFF” position. The Main Cylinder retract ‘solenoid and the Air Spring solen: ll de-energize. The Product Valve will move out of the C.L.P, adapter and the Capper will relax. If the Capper does not move down completely, push it down by hand. The Spout Holder solenoid is also de-energized, allowing the C.I.P, adapter to be removed, Remove the C.I.P. adapter and store for subsequent use. 16. At the end of PRODUCTION, the Product Valve must be disassembled, cleaned, and inspected. Follow the Product Valve disassembling and assembling procedures. Visually inspect the standpipe for cleanliness and clamp it on the tee. 17. With the vacuum tank cleaned and drained, connect the tubing from the Vacuum Valve to the Vacuum Tank. Prepare the filler for the next process. Eg: shut down & maintenance, or BAG FILLING. July 24, 1998 ‘SCHOLLE CORPORATION Page30ILL9 DVT | FILLING BAGS The Auto Fill Operator must be aware that the automatic cycle begins as soon as a bag is inserted into the SPOUT HOLDER, If all conditions are correct, the filler product into the bag, and place the cap onto the bag spout, will uncap, applying the proper amount of over-stroke to re-seal the cap and the spout. After the bag has been re-capped it will be ejected from the spout holder. The automatic cycle will only operate when SS-1 is in the “RUN” position and the FILL CYCLE STOP pushbutton is pulled out. NOTE: IF THE FILL CYCLE STOP PUSHBUTTON IS PUSHED DURING A FILL, THE PRODUCT VALVE WILL CLOSE AND THE AUTO FILL CYCLE WILL BE DISABLED. THE MAIN CYLINDER, SPOUT HOLDER AND AIR SPRING SOLENOIDS ARE DE-ENERGIZED. AT THE SAME TIME, THE AIR IS EXHAUSTED AT THE SPOUT HOLDER AND MAIN CYLINDER, AND RESTORED TO THE AIR SPRING BLOCK. THIS RAISES THE PRODUCT VALVE UP OUT OF THE BAG. THE BAG WILL REMAIN UNTIL RE-CAPPED BY HAND AND PULLED FROM THE SPOUT HOLDER BEFORE THE NEXT AUTO FILL CYCLE. In order for the Auto Fill Cycle to begin, the following conditions must be met: 1. The FILL CYCLE STOP push button must be pulled out. 2. The selector switch must be in the “RUN” position. The cap holder must be down in the ‘HOME" position. The MAIN CYLINDER EXTEND reed switch must be ON. The spout ejector must be pulled OUT (open). The EJECTOR CLOSED reed switch must be OFF. The MAIN CYLINDER RETRACT reed switch must be OFF. NP ap wo July 24, 1998 ‘SCHOLLE CORPORATION Page3tAUTO-FILL 9 DVT A FILLING SEQUENCE 1. Turn the power selector switch to the ON position. The green power light will turn ON. The DTAM will turn ON. 2. Set the fill counter function - “F 0" - for the desired fill count. Reset the bag counter to zero (function F2). 3. Turn selector switch SS1 to the “RUN” position and pull out the FILL CYCLE STOP push-button. 4. _ Insert a new Scholle bag of the desired package size into the spout holder. The Scholle bag will be uncapped, filled, recapped, and ejected automatically. July 24, 1998 SCHOLLE CORPORATION PageS2AUTO-FILL 9 DVT a AUTOMATIC FILL SEQUENCE DESCRIPTION The Auto Fill Cycle starts when the cap and spout are inserted into the Spout Holder/Capper Plate. The following describes, step-by-step, the actions of the Auto-Fill. This may also serve as a diagnostic step description of the Auto Fill Cycle in the unlikely event trouble-shooting is ever required: The following is a description of the Auto Fill Cycle: 1. The Auto Fill Cycle is started when the cap and spout are inserted into the spout holder/capper, and the EJECTOR CLOSED reed switch turns ON, and the cap ‘sensor air switch turns ON. 2. The EJECTOR CLOSE solenoid is energized, locking the spout into the spout holder. The MAIN CYLINDER RETRACT solenoid is energized causing the capper to move up and remove the cap from the bag. 3. When the magnet of the main cylinder passes the AIRSPRING DUMP (middle) reed switch, the AIR SPRING solenoid is energized, releasing the air from the air spring block, When the alr is released, the main cylinder will continue to retract and the product valve will move down into the bag spout. 4, When the magnet of the main cylinder reaches the MAIN CYLINDER RETRACT reed switch, the vacuum timer is started, This energizes the vacuum valve Poppet, removing most of the air in the bag. When the vacuum timer reaches its preset, the vacuum solenoid will de-energize and the product valve will open. duly 24, 1998, SCHOLLE CORPORATION Page33AUTO-FILL 9 DVT NOTE: TO CLOSE THE PRODUCT VALVE IN AN EMERGENCY PUSH THE FILL CYCLE STOP PUSH-BUTTON. 5. When the fill counter preset is reached, the product valve will close and the main cylinder extend delay timer will start. This allows the product valve to close before it is removed from the spout. 6. After the main cylinder extend delay timer times out, the AIR SPRING and MAIN CYLINDER RETRACT solenoids de-energized, causing air to be put on the air spring block, moving the product valve up. The MAIN CYLINDER EXTEND solenoid is then energized causing the capper to move down, placing the cap on the spout of the bag. 7 Once the magnetic plunger of the main cylinder meets the MAIN CYLINDER EXTEND reed switch, the crush timer is started. When the crush timer reaches it preset, the MAIN CYLINDER EXTEND solenoid is de-energized, relieving the Pressure on the cap. At this time the SPOUT EJECT DELAY timer is started. 8. When the SPOUT EJECT DELAY timer reaches its preset, the SPOUT EJECTOR OPEN solenoid is energized, ejecting the filled bag. When the EJECTOR OPEN timer reaches its preset, the SPOUT EJECTOR OPEN solenoid is de-energized and the Auto Fill Cycle is reset. AFTER PRODUCTION REFER TO THE BEGINNING OF THIS SECTION FOR CLEANING / SHUT DOWN INSTRUCTIONS. July 24, 1998 ‘SCHOLLE CORPORATION PageddAUTO-FILL 9 DVT CAN FILL OPERATION Turn selector switch SS1 to the OFF position. Push in the red FILL CYCLE STOP button on the control panel. Push in the red stop button on the air switch at the can filler valve. 2. Insert the can filler adapter in to the spout plate. 3, Hold the adapter and hose in place and turn the selector switch SSi to the CIP position. The spout ejector will lock the adapter in place and the product valve will be inserted into the adapter. 4. Disconnect the “no cap/no fill” air line at the pneumatic cabinet and connect the air switch air line for the can fill valve to this connector. 5. To switch to the CAN FILL mode, push [F 8] on the DTAM. The DTAM screen will show “B3/11 0" . push [1], a flashing “'1" will appear on the screen. Push ENTER, the “1" will stop flashing. The filler is now in the CAN FILL mode. Push [ESC] to return to the main menu. 6. Set the fill counter, DTAM “FO”. 7. Place the can filler tube in the can to be filled. July 24, 1998 SCHOLLE CORPORATION Page35Note: 10. 11, NOTE: 12. 13. Pull the red FILL CYCLE STOP button on the control panel out. Push in the green start button on the air switch on the can fill valve. The fill valve will open and the can will start to fill with product. When the counter reaches its preset, the valve will close. The fill can be stopped at any time during the fill cycle by pushing in the red stop button on the air switch on the can fill valve. To resume filling, push in the green start button on the air switch on the can fill valve. This will not effect the counter accumulation. After the can has been filled, slowly lift the can fill tube up and allow it to drain before moving it to the next can, Push in the red stop button on the air switch at the can filler valve. This resets the filler to do the next can. Pushing the FILL CYCLE STOP pushbutton on the control panel resets the counter accumulator to zero (0). Continue to fill the cans in this matter. After the production run has been completed, push in the red stop button on the air switch on the can fill valve. Then push in the FILL CYCLE STOP. button on the control panel. July 24, 1998, SCHOLLE CORPORATION. Page36AUTO-FILL 9 DVT 14, Turn the selector SS1 to the OFF position. 15. Holding the can fill hose, turn off the CAN FILL mode at the DTAM. Push IF 8]. The DTAM screen will show “B3/11 1". Push [0], a flashing 0 will show on the screen. Push ENTER. The product valve will move up from the can fill adapter. When the product valve is all the way up, the spout ejector will release the adapter. The CAN FILL mode is now shut off. Push [ ESC ] to return to the main menu, 16. Disconnect the air switch air line for the can fill valve at the pneumatic cabinet and re-connect the “no cap/no fill” air line to this connector. July 24, 1998 ‘SCHOLLE CORPORATION Page37AUTO-FILL 9 DVT CLEANING AND MAINTENANCE MAIN CYLINDER AIR SPRING BLOCK PRODUCT VALVE CAPPER, SPOUT HOLDER July 24, 1998 ‘SCHOLLE CORPORATION Page38AUTO-FILL 9 DVT FILL HEAD MAINTENANCE USE ASSEMBLY DRAWING THIS PUBLICATION IS PROVIDED AS A GUIDE FOR THE TRAINED TECHNICIAN FOR INSTALLING, ASSEMBLING, REPAIRING, AND SERVICING THE SCHOLLE AUTO FILL. PRACTICAL KNOWLEDGE AND COMMON SENSE MAY BE USED TO PREVENT ACCIDENTS OR DAMAGE TO EQUIPMENT. REPAIR OR ADJUSTMENT BY UNAUTHORIZED PERSONS MAY VOID ANY, OR ALL WARRANTIES AND, OR ANY GUARANTEES OF PERFORMANCE. THE SELECTED INDIVIDUAL MUST BE FAMILIAR WITH STANDARDIZED TERMS USED TO IDENTIFY PARTS APPLICATION AND DESCRIPTIONS. REMOVAL AND DISASSEMBLY 1. Remove the product valve assembly from the air spring block. (4 bolts) and set aside. 2. Remove the Dust Cover adjuster and Spout Clamp Assembly. 3. Remove the Cam Follower Pin, Capper assembly and Uncapper Slide from the Uncapper Shaft. Inspect the Cam Follower Pin and Uncapper Slide for wear or defects. Re-install using new O-rings. July 24, 1998 ‘SCHOLLE CORPORATION Page39AUTO-FILL 9 DVT 4 Disconnect the air lines #,1 #2, #3, and reed switches #1, #2, #3, from the Main Cylinder/AirSpring Block. 5. Remove the 1/4-20 bolts from the Main Cylinder and pull up on the cylinder and remove with the uncapper shaft. v Replace O-rings on Slug Collar and Cylinder Block Cap. v Check the Thrust Washer I-glide for wear or damage. Replace as needed. v Re-pack the Thrust Bearing and Washers with 111 food grade grease, v Verify the Uncapper Shaft clearance - this should be 16-3/4" from the bottom of the Cylinder Block Cap to the top of the Cam Flow Pin hole. Make correction as needed. 6. Lower the Air Spring Block and remove the 3/4" Guide Pin jam nuts and Uncapper Post retaining ring. Slide the Air Spring Block up and off of the Uncapper Post. A Inspect the Air Spring Block, check the Cylinder Block Bushing and Pin Guide Bushing for excessive wear or defects. B. Replace the O-ring in the Cylinder Block Bushing and lube with 111 food grade grease. July 24, 1998 SCHOLLE CORPORATION Page40