KWT-8000FM AUTO FILLING MACHINE 37-161000 OPERATION MANUAL KWT MACHINE SYSTEMS CO., LTD. No. 21, Taiping 21 Street, Taiping City, Taichung Hsien 411, Taiwan TEL : 886-4-22773390 FAX : 886-4-22773412 E-MAIL: sales@kwt.com.tw 0
General index 1.0. General 1.1 Chapter Index 3 1.2 General Safety Instructions 4 1.3 Machine Dimension 7 1.4 Specification 8 1.5 Equipment Lay-out 9 1.6 Machine Identification 10 1.7 Location of Warning Labels 11 2.0. Installation 2.1. Chapter Index 14 2.2 Setting The Machine & Choosing Base 15 2.3 Transporting 16 2.4 Position of Connection 18 2.5 Mechanic Installation Step 20 2.6 Utility Tie-in Point 21 2.7 Drain Point 22 2.8 Wire Installation 23 2.9 Pneumatic Installation 25 3.0. Machine Operation 3.1. Chapter Index 26 3.2. Line Components 27 3.3. Filler Operating Principle 31 3.3.1 Measuring Principle of the Flow Meter 3.3.2 Measuring Process 3.3.3 Operation Steps Before Filling 3.3.4 Filling Logical Steps 3.4 Operating and Control Devices 39 3.4.1. Push Button Map 3.4.2. Sensor Map 3.4.3. Proximity Map 3.4.4. Flow Meter Map 3.4.5. Servo Motor Map 3.5 Over Safety Map 44 3.6 Pneumatic Circuit 49 4.0. Adjustment and Set-up 4.1 Chapter index 52 1
4.2 Centerlines 53 4.2.1 Sensor Reflector With Filler Lane 1 4.2.2 Sensor Reflector With Filler Lane 2 4.2.3 Filler Lane 1 Panel Operation Condition 4.2.4 Filler Lane 2 Panel Operation Condition 4.3 Flow Meter Calibration 62 4.4 Manifold Test Report 95 5.0. Electrical Devices Identification 5.1 Chapter Index 103 5.2 Electrical Devices 104 5.2.1 Control Panel Lane 1 5.2.2 Control Panel Lane 2 6.0. Size Change Over 106 7.0. How to Order Spare Parts 7.1 Chapter Index 108 7.2 Procedure 109 7.3 Recommended Spare Parts List 110 7.4 Complete Components List 115 7.3.1 Conveyor Assembly 7.3.2 Slide Gate Assembly 7.3.3 Drip Tray and Neck Grabber Assembly 7.3.4 Manifold Assembly 7.3.5 Up and Down Movement Assembly 7.3.6 Safety Guard Assembly 7.3.7 Sensor Assembly 7.3.8 Conveyor Driving Assembly 7.3.9 Windowssembly 7.3.10 Support Assembly 7.3.11 Electrical Components Part List 8.0. Component Life Span 140 9.0. Maintenance 9.1 Chapter Index 141 9.2 Lubrication Points 142 9.3 Tool List 144 10.0. Cleaning Procedure 146 11.0. Trouble Shooting 147 12.0. Electrical Drawings 148 2
1.0 General 1.1 Chapter Index 1.0. General 1.1 Chapter Index 3 1.2 General Safety Instructions 4 1.3 Machine Dimension 7 1.4 Specification 8 1.5 Equipment Lay-out 9 1.6 Machine Identification 10 1.7 Location of Warning Labels 11 3
1.2 General Safety Instructions Using Restriction: The KWT-8000FM is suitable for non-explosive, non-flammable mild liquids that need to be filled into bottle, it is forbidden to try low-flash point, poison, irritant, oily, fermentative, sticky and fibrous materials. Read instruction manual before operating the machine for your safety. Person(s) who operate the machine must be trained, read and understood to use the safety measures, and possess the ability to obey and execute the regulation stated in this manual. Ground all machines. A terminal for the connection of the external ground conductor is provided in the vicinity of the associated phase conductor terminals with marked PE. It should make sure the PE terminal being connection before power supply. Supply voltage and source frequency: 0.9-1.1 nominal supply voltage and 0.99-1.01 nominal frequency. Verify the main power is stable before connecting it to the equipment. If not, use a voltage regulator. Ambient temperature: 5 0 C - 40 0 C. Altitude: shall be at altitudes up to 1000m above mean sea level. Relative humidity: not exceed 50% at 40 0 C. Electrical equipment shall withstand the effects of transportation and storage temperature within a range of -25 to 55 and for short periods not exceeding 24 hours at up to +70. Atmosphere: Free from excessive dust, acid fume, corrosive gases and salt. The power supply should be away from humidity and properly grounded. Avoid exposing to direct sunlight or heat rays which can change the environmental temp. Avoid exposing to abnormal vibration. Electrical connection shall be installed by a professional electrician. Keep guards in place and working area clean and dry. Keep working area well lighted and ventilation. No loose clothing, neckties, rings bracelets, or other jewelry to get caught in moving parts. Wear protective hair covering to contain long hair. Watch what you are doing. Do not operate machine when you are tired. Please stand in front of machine for proper position operation. SHUT OFF the power, removed the products, and isolated energy before leaving the machine. Shut off the power and carried out only when the machine is stationary before inspection, maintenance, adjustment and cleaning. Have your machine repaired by a qualified person. Repairs should only be carried out by qualified persons using original spare parts, otherwise this may result in considerable danger to the user. Not to attempt to carry out any repairs, e.g. electrical or mechanical, unless properly authorized. 4
Disposing wasted material and wasted lubricating oil shall obey the local regulation and be deeply careful. The possibility is very low: the ignition of material happens in the working area. However, the user can install a fire detector on the top of production line by self, and connecting to the specified terminals in the wiring system for buzzer warning, see the circuit diagrams, please. The workshop of user shall be with the fire extinguisher or other devices according to the local safety regulations and be deeply careful. If ancillary equipment is removed the original grounds or safety devices shall be replaced. The connection of ancillary equipment including any necessary modification of the guarding of the machine shall not afford unprotected access to danger areas of the machine. Never attempt to change the setting and design of all protective devices without consulting with KWT. When the machine is out of order while running, shut it down and turn to serviceman for help as soon as possible. Make sure switches of control panel are OFF position before operating main disconnector. Never leave machine running unattended. Turn power off from the main disconnector. Don t leave machine until it comes to a complete stop. This machine is provided eight emergency buttons. They are self-latching push-buttons on the control panel and other easy access positions. The emergency button is colored red and yellow background. After emergency stop, follow the normal stop procedure and suitable operation to obviate the hazard. Please see the circuit diagram to connect emergency stop circuit by qualified engineer. Safety related components which shall not be changed by user. ( e.g. safety relay module, interlock switch ) Please wear plastic-gloves and gauze mask (mouth-muffle) to operate the machine. Install the machine on a flat and vibration free floor / foundation. The machine has to be mounted on a level surface. Never clean electrical components with water. Operation and technical adjustments are only to be done by trained technical engineers. Never open electric box or connect cables without a permit. Never clean the equipment by using an aggressive agent such as acid or caustic liquid. The machine was designed for certain application only. We strongly recommend that this machine NOT be modified and / or used for any application other than for which it was designed. I you have any questions relative to its application DO NOT use the machine until you have had detail instruction from your dealer. Keep away from moving machine parts while machine is in operation. The training of the user / operator should be carried out by our authorized agent or service engineer in an oral / practical in site of the ordered machine, including protective device explanation, mechanism, personal protective equipment, operation / use. Not to access the machine at any time without first isolating the relevant power supply and having ensured that those movable parts of the machine which can be accessed are at rest. Not to remove guards from the machine unless properly authorized. Not to use unauthorized or improvised means of gaining access to parts of the machine which are not normally accessible. For a responsible person to carry out regular inspections to verify that all guards and covers are secure 5
properly in position and that all safety devices are functioning correctly. Pay attention on setting, clean and maintenance the merging conveyor since it may cause the accident. Pay attention to operate the machine since finger may be crushed by the gate control cylinder. Be careful while operate the machine since cap striper and bottle transportation may cause the accident by non-smooth running surface. Mop the floor immediately when the filling materials or lubricants splash or leak out. Keep the working area well-ventilated and with appropriate lighting Follow the maintenance instructions to wipe the machine periodically to prevent from the hazards caused by the presence of pathogenic bacteria Check all safety relevant functions, like EMS, interlocking guards, flash& audile warning signs daily, stop to operate this machine if anyone of those safety functions is out of order. Keep MSDS of filling materials available at anytime. 6
1050 1512 490 2089 1400 420 490 2835 2503 1.3 Machine Dimension EQUIPMENT BLOCK DIMENSION LENGTH/mm WIDTH/mm HEIGHT/mm Infeed Conveyor 3791 133/lane 1050 Filler 2204 2089 2835 6085 2978.6 812.4 3016.4 2204 3791 3791 2204 7
1.4 Specification Model KWT-8000FM Products Total power consumption Electrical supply Pneumatic supply Pre-formed container size Conveyor Height Servo Motor Conveyor with inverter Filler for pre-formed rigid container 4kW 3~, 220V±10%, 50/60Hz±1% 6 bar H: 180-380mm / W: 70-210mm / T: 20-160mm 950mm±5% 750W x 2 = 1.5kW 375W x 2 = 0.75kW Filling nozzle 10 x 2 = 16 Speed Air Consumption 45-50 BPM/Lane (based on bottle size) 370 L/min Remark: Specifications su0bject to change without prior notice Airborne noise emitted by machine: measured according to EN ISO 3746: 1995 A-weighted sound pressure level: [dba] 77.0 db A-weighted sound power level: [dba] 95.4 8
1.5 Equipment Layout In-Feed Conveyor Filler 9
1.6 Machine Identification The machine identification plate is placed. In case of requests for assistance, change parts or information on the machine, please mention the machine serial number printed on the relevant identification plate. KWT Type: Auto Filling Machine Series No.: 37-161000 Designation: KWT- 8160FM Pneumatic pressure: 6 bar Rated Power: 5 kw Mfg. Date: Apr.2011. Power supply: 3~220V, 50Hz Machine weight: 4000 kg Full load current: 30A Document No.: 2810 Short-circuit current: 5 KA KWT Machine System Co., Ltd. No. 21, Taiping 21 Street, Taiping City, Taichung Hsien 411, Taiwan TEL: 886-4-22773390 FAX: 886-4-22773412 Website: http://www.kwt.com.tw OOO Manufacture Company Address: xxxxxxxxxxxxxx TEL: xxxxxxxxxxxx 10
1.7 Location of Warning Labels 11
Dangerous area and Working Environment Dangerous Location Mold clamping/ Moving area Precaution Rolling, Keep hands clear. Marking Label Machine Moving down could press your hands. (Keep hands clear) HIGH VOL TAGE! Shut OFF the Power, and isolated energy before leaving and any service. Please wearing plastic gloves for protecting your hands. 12
Machine moving down could hit your head. (keep head clear) Machine moving forward could stab your hands. (keep hands clear) Warning on the electrical Cabinet and terminal box. 13
2.0 Installation 2.1 Chapter Index 2.0. Installation 2.1. Chapter Index 14 2.2 Setting The Machine & Choosing Base 15 2.3 Transporting 16 2.4 Position of Connection 18 2.5 Mechanic Installation Step 20 2.6 Utility Tie-in Point 21 2.7 Drain Point 22 2.8 Wire Installation 23 2.9 Pneumatic Installation 25 14
2.2 Setting the Machine & Choosing Base 1. The site for machine construction should be equipped with appropriate spacing. 2. In accordance with the drawing, along the machine, extra clearing must be provided to permit efficient maintenance and assembly. 3. For detail information regarding space required to run the machine, please refer to dimension drawing below. 4. Assembly site must be able to afford machine weight and vibration. A B Height 28090mm 4569mm 4000mm 15
2.3 Transporting The machine shall be moved by persons who are qualified. Other than the worker, people who are unrelated are not allowed to stay in the work area during machine transportation. 1. Please refer to instruction manual in specifications and machine weight for handling equipment arrangement. Be sure to use suitable forklift for machine lifting. 2. Forklift can be used in handling and shall be operated by qualified driver. 3. Before handling, make sure all movable parts are secured in their positions and all movable accessories should be removed from machine. 4. Make sure that the strength of forklift is sufficient to handle machine. 5. During handling, people are strictly prohibited from entering into the path of machine movement. 6. While transporting, pay attention to the balance of machine. 7. Please be careful of the forklift position and the fork length shall be 2/3 machine width length. 16
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2.4 Position of Connection All machine blocks are numbered with a sticker on each of their end so that parts can be easily recognized and installed properly. The sketch below summarizes the stickers position/number applies through the complete line. 18
Item Position No. Description Photo 1 L1A Infeed Conveyor Connection 2 L1B Outfeed Conveyor Connection 3 L2A Infeed Conveyor Connection 4 L2B Outfeed Conveyor Connection 19
2.5 Mechanic Installation Step Step. P. No. Description Workers Time Tools 1 P1 P3 Combine in-feed conveyor based on filler's level plane. 2 0.5 Hr. FOKLIFT HAND TOOLS 2 P2 P4 Place the Filler at appropriate location and adjust foot pad to required height. 3 1 Hr. FOKLIFT HAND TOOLS 20
2.6 Utility Tie-in Point 21
2.7 Drain Point 22
2.8 Wire Installation CABLE NO. FROM TO CABLE SPECIFICATION WIRE NO. T/B POSITION CONNECT DEVICE TB24-2-4 L1D TB24-2-8 A LANE1 PANEL LANE2 PANEL 14AWG/4C L2D TB24-2-9 L3D TB24-2-10 R3 TB24-2-22 B LANE1 PANEL LANE2 PANEL 14AWG/4C T3 TB24-2-23 R TB24-2-20 C LANE1 PANEL LANE2 PANEL 14AWG/4C T TB24-2-21 D LANE1 PANEL LANE2 PANEL OPTICAL FIBER E LANE1 PANEL LANE2 PANEL ETHERNET ET2 HMI2 A1 TB22-1-3 F LANE1 PANEL LANE2 PANEL 18AWG/4C B3 TB22-1-34 DN21 PLC2 DN22 PLC2 G LANE1 PANEL LANE2 PANEL DEVICENET DN23 PLC2 DN24 PLC2 DN25 PLC2 1704 TB23-2-18 1706 TB23-2-20 1707 TB23-2-21 1714 TB23-2-22 1716 TB23-2-24 H LANE1 PANEL LANE2 PANEL 18AWG/12C 1802 TB23-2-27 1804 TB23-1-28 1812 TB23-2-33 1814 TB23-1-34 1823 TB23-2-38 1824 TB23-2-39 OF03 B1 US02 RX TB22-1-13 OF02 A3 US02 TX TB22-1-27 KWT MACHINE SYSTEMS CO., LTD. Page 23
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2.9 Pneumatic Installation 25
3.0 Machine Operation 3.1 Chapter Index 3.0. Machine Operation 3.1. Chapter Index 26 3.2. Line Components 27 3.3. Filler Operating Principle 31 3.3.1 Measuring Principle of the Flow Meter 3.3.2 Measuring Process 3.3.3 Operation Steps Before Filling 3.3.4 Filling Logical Steps 3.4 Operating and Control Devices 39 3.4.1. Push Button Map 3.4.2. Sensor Map 3.4.3. Proximity Map 3.4.4. Flow Meter Map 3.4.5. Servo Motor Map 3.5 Over Safety Map 44 3.6 Pneumatic Circuit 49 26
3.2 Line Components 27
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1. Foot pad: Adjust the height of machine. 2. Solenoid valve: Adjust actions for the cylinder of in-feed /out-feed gate and front / back neck grabber. 3. Light Beacon: Color Position Specific Use Red Top Flashing indicates abnormal stop or fault Orange 2nd From Top Flashing Indicates Alarm Green Bottom Solid Indicates Normal Operation, Running Product Horn: Horn will activate for about 30 seconds at start up. Then, the machine will be ready for operation. 4. Slide Gate: Stop bottle movement on conveyor. 5. Drip-tray: Height adjustment for drip tray, which collects drips from the nozzles to prevent them from dripping onto bottles and machine. 6. Sensor: The slide gate will open and the bottle transportation activates once the in-feed sensor detects adequate bottles, and the out-feed sensor will extend to halt the bottles for filling. 7. Manifold: Contains filling liquid. 8. Hand Wheel for the height of back neck grabber: Adjust the height of back neck grabber according to the bottle size. 9. Air cylinder: To assist filler assembly up and down. 10. Filler servo motor: Control up and down movements of filling nozzles. 11. Door interlock: Enhance safeness to work with the machine when doors are open. 12. Slide: To be used for moving filler up and down assembly. 13. Magnetic flow meter: Controls filling volume. 14. LCD touch screen: Gives order and control the whole line. 15. Emergency stop switch: Stops machine immediately and release compressed air from the equipment. 16. Stop button: Stop the filler conveyor and de-energize the filler. 17. Start button: Start the filler conveyor and energize the filler. 18. Reset button: Start the motor power and air after the trouble shooting or turn on the power. 19. Transformer: Change voltage to which is suitable for machine. 20. Filling nozzle bracket: Fix filling nozzles (Adjustable). 21. Front neck grabber: Can be adjusted to fit different bottle size. 22. Drip-tray: Height adjustment for drip tray, which collects drips from the nozzles to prevent them from dripping onto bottles and machine. 23. Back neck grabber. 24. Back neck grabber: Can be adjusted to fit different bottle size. 25. Electrical panel. 30
3.3 Filler Operating Principle The filler is an in-line equipment with 16 filling heads. The filler fills into the containers the pre-set amount of product by means of inductive magnetic flow meters. The filling heads move up and down by means of a servo motor. The start height, diving height, down and up speeds are all programmable. Those parameters can be set using the HMI, and are called by the program when entering the product code. 3.3.1 Measuring Principle of the Flow Meters Faraday s law of induction states that a voltage is induced in a conductor moving in a magnetic field. In electromagnetic measuring, the flowing medium (min. conductivity 5 Micro Siemens/cm) corresponds to the moving conductor. The induced voltage is proportional to the flow velocity and is detected by two measuring electrodes and transmitted to the amplifier. Flow volume is computed on the basis of the pipe's diameter. The constant magnetic field is generated by a switched direct current of alternating polarity. 31
3.3.2 Measuring Process Each flow meter send pulses to a high speed counter card. This card operates with a scan time of the order of 1 millisecond. The counter card totalizes pulses from the flow meter until it reaches the cutoff set-point. When it reaches the set-point, the high speed counter card provides the DC signal to the high speed solenoid valve to open / close the filling nozzle. Via PLC messaging, the PLC: - downloads a new cutoff set-point (in counts) to the high speed counter card whenever the set-point changes, - tells the high speed counter card to begin filling, Note: The PLC performance is not critical. The high speed counter card has multiple counter inputs AND multiple discrete outputs. 32
3.3.3 Operation Steps Before Filling Step Description Comments & photos 1 Turn on power supply The filler is provided power for operation after turning on power supply on Control Panel. 2 Turn on Safety Disconnect switch Safety Disconnect is on Control Panel. 3 Turn on Air Disconnect Before turning on Air Disconnect, the indicator shows zero in green color. This means no air for Filler currently. After turning on Air disconnect, the indicator shows digital data in red color. This means the air can enter into Filler. 33
4 Verify two Emergency Buttons are both pulled up. The Filler can t work without pulling up Emergency Button. One of Emergency Buttons is on the side machine frame (nearby outfeed conveyor). Another Emergency Button is on HMI. 5 Shut Filler s door with Door Interlock. The Filler can t work if the door is opening. 6 Press Reset Button on HMI The Filler can t work if Reset Button is not pressed. 34
7 Press the button of Main on the LCD screen. Press Main button for entering Main Screen 8 Press Auto, button afterward, press System OK button on the LCD screen. If Installation and Adjustment have been completed before, just press Auto button and then System OK button. 9 Press Start button on HMI. Press Start button to run the filling line. 35
3.3.4 Filling Logical Steps When there is sufficient accumulation in front of the filler, the opening gates are opened and 4 bottles are allowed to enter the filler. After a certain time, the neck centering plates are loaded to position the bottles neck under the filling nozzles. When it is ready, the drip trays are retracted, the filling nozzles come down and the filling process starts. The product is fed into the bottles while the filling nozzles are lift upward. When the fill process is completed, the drip trays are positioned under the fill nozzles. If there is space on the filler out-feed accumulation conveyor, then the out-feed gates are opened. When the bottles are out of the filler, the out-feed gates are closed, and the in-feed gates are opened for a new cycle. In case a bottle has fallen on the conveyor, that bottle is not seen by the out-feed counting device and after a time delay an alarm is raised. It is possible to change the value of the number of bottles that come out before the in-feed gate is opened, in order to increase the machine output. In that case, a fallen bottle will not be detected before the next cycle, and product will be fed on the conveyor. The parameters can be set using the HMI, and are called by the program when entering the product code. Step Description Conditions to Start Step Comments 1 Verify that there is enough bottles accumulated in front of the filler 2 Start delay Infeed Time 3 Verify that bottles are exiting the filler 4 Open the in-feed gate AND start counting of bottle. 5 Index in, 10 empty bottles into the lane by counting bottles 6 Start delay infeed stop, on each lane separately. 7 Close the in-feed gate, on each lane separately. 8 Start delay neck press on each lane separately 9 Load the neck centering plate in position each lane separately AND Start delay Wait for Neck Close, on each lane separately. 10 Generate an emergency alarm and stop the line. 11 Retract drip trays, on each lane separately. 12 Lower fill head to start fill position AND Photocell Sensor (SN) detects a bottle for a set time. Delay Infeed Time expired, AND Discharge count SP equal to set value. 10 bottles are counted on the lane Each lane Photocell counts 10 bottles separately Delay Infeed stop expired In-feed gate is closed Delay timer neck press expired Delay Wait for Neck Close expired The neck centering plates is in loaded position Drip tray is confirmed retracted on each lane Use filler in-feed accumulation photocell If the photocell is set for the accumulation of 10 bottles with the biggest side to side dimension, the photocell position doesn t need to be changed. In this case the accumulation will always be 10 bottles or more. This is done via the photocell at the exit of the filler that counts bottle coming out. The number of bottles that needs to come out of the filler before the infeed gate opens can be set under the Discharge Count SP panel view parameter. Use filler in-feed bottle counting photocell. Infeed stop is the time between the count of 10 bottles is completed and the infeed gate is closed. Photocell sees bottle neck. Need time for the full bottle to pass the in-feed gate Use filler in-feed gate cylinder proximity switch Time to allow bottle to travel to end position The neck centering plate could not move to final position Use neck centering plate cylinder proximity switch. Use drip tray cylinder proximity switch. 36
during all this operation servomotor torque does not exceed a set value, if it does, generate emergency alarm and stop line. 13 Download new set-point Cutoff SP for nozzles 1-10 to counter card if changed. 14 Start filling bottle by enabling counter card which opens output to solenoid. 15 Start delay Start Pos Wait to Fill. 16 Raise filling heads to stop Fill position at preset velocity & acceleration AND during all this operation servomotor torque does not exceed a set value, if it does, generate emergency alarm and stop line. 17 Stop filling heads uplift movement 18 Counter card closes output to solenoid valve for each head. Stop filling bottle per nozzle when fill level is reached 19 Generate error if any head fails to complete fill cycle. 20 Start Dwell After Fill Comp timer on each nozzle. 21 Raise filling heads to wait position at calculated velocity AND during all this operation servomotor torque does not exceed a set value, if it does, generate emergency alarm and stop line. 22 Retract the neck centering plate, on each lane separately. 23 Index out the filled bottles, each lane separately, by counting bottles.. separately Delay Start Pos Wait To Fill expired Delay Start Pos Wait to Fill expired Servo reports heads at Stop fill position. Nozzle set point Cutoff SP reached Dwell After Fill Comp timer expired on each nozzle Delay Discharge Count SP expired Start Pos Wait to Fill is the time between the servo has reached its start fill position and it starts to go up. Checks that there is not a mechanical interference in the movement. Checks that product flows at expected rate. Stops line if flow of any head is under expected minimum rate Index 1 is the time between the filling is completed and the nozzles start to go to their wait position. Checks that there is not a mechanical interference in the movement. Gives enough time for the drip tray to come under the nozzles, to avoid drips on bottles. Use filler out-feed bottle counting Photocell 24 Generate emergency All bottles did not come out or there is a fallen bottle. 37
alarm, do not stop the line. 25 Start delay timer Wait For OutFeed Gate Extend Dwell. 26 Close the filler out-feed gate, on each lane separately, AND OutFeed Time. 27 Generate emergency alarm 8 bottles indexed out. Delay timer OutFeed Time expired OutFeed Time AND filler out-feed gate not in closed position Filler out-feed counting photocell located at out-feed gate, looks at neck. Time is required for bottle to pass gate. Use filler out-feed gate proximity switch. 38
3.4 Operating and Control Devices 3.4.1 Push Button Map 39
3.4.2 Sensor Map 40
3.4.3 Proximity Map 41
3.4.4 Flow Meter Map 42
3.4.5 Servo Motor Map 43
3.5 Over Safety map Emergency Stop Switch Pushing on any one of the emergency stops provided along the line will immediately stop all equipment and bleed compressed air. E-stop Description Lane Photo 1 Machine Frame Emergency Stop 1 2 HMI Emergency Stop 1 3 Machine Frame Emergency Stop 2 4 HMI Emergency Stop 2 44
Safety Disconnect Enhance safeness to work with the machine. When doors are open, the switch can be locked off with a personal lock. No Description Lane Photo 1 Filler Safety Disconnect 1 2 Filler Safety Disconnect 2 45
Air Disconnect Enhance safeness to work with the machine. When doors are open, the valve can be locked off with a personal lock. No Description Lane Photo 1 Main Air Disconnect 1 2 Main Air Disconnect 2 46
Air Receiptor Enhance safeness to work with the machine. When doors are open, the valve can be locked off with a personal lock. No Description Lane Photo 1 Air Receiptor 1 2 Air Receiptor 2 47
Door Interlock No Description Lane Photo 1 Filler Center Door 1 2 Filler Center Door 2 48
3.6 Pneumatic Circuit 49
item Position Part Hose No. Hose Size ( mm ) Pressure ( Bar ) Part No. Supplier 1 H1 Start Valve HE-D-MIDI FESTO 2 W1 Service Unit FRC-1/2-D-O-MIDI-A FESTO 3 PE1 Pressure Sensor ( 0 ~ 10 Bar ) 6~8 SPAB-P10R-R18-2N-K1 FESTO 4 H3 start valve 00 10 M56-SV-1/2-D-10V24-SD-MP1-WPB FESTO 5 H4 start valve 01 10 HE-1/2-D-MIDI FESTO 6 HS01 Solenoid valve A1 A2 8 PME-613JB MAC 7 HS02 Solenoid valve A3 A4 8 PME-613JB MAC 8 HS03 Solenoid valve A5 A6 8 PME-613JB MAC 9 HS04 Solenoid valve A7 A8 8 PME-613JB MAC 10 HS05 Solenoid valve A9 A10 8 PME-613JB MAC 11 HS06 Solenoid valve A11 A12 8 PME-613JB MAC 12 HS07 Solenoid valve A13 A14 8 PME-613JB MAC 13 HS08 Solenoid valve A15 A16 8 PME-613JB MAC 14 W2 Pressure regulator C0 10 LR-1/4-7-MINI FESTO 15 SV1 Compressed Air Reservoir C1 C2 10 5 CRVZS-5 (5L) FESTO 16 SOL12 Solenoid valve C3 8 5 CPE-14-M1BH-3GL-1/8 FESTO 17 PE2 Pressure Sensor ( 0 ~ 10 Bar ) C5 C4 8/6 5 SPAB-P10R-R18-2N-K1 FESTO 18 SC1 Semi-Rotary Drive C6 8 5 DGC-25-800-G-PPV-A FESTO 19 SC2 Semi-Rotary Drive C7 8 5 DGC-25-800-G-PPV-A FESTO 20 K2 Manifold strip (4) B0 10 CPE14-PRS-3/8-4 FESTO 21 SOL1 Solenoid valve B1 B2 6 CPE14-M1BH-5L-1/8 FESTO 22 SOL2 Solenoid valve B3 B4 6 CPE14-M1BH-5L-1/8 FESTO 23 SOL3 Solenoid valve B5 B6 6 CPE14-M1BH-5L-1/8 FESTO 24 SOL4 Solenoid valve B7 B8 6 CPE14-M1BH-5L-1/8 FESTO 25 W3 Pressure regulator B2 6 1~2 LR-1/4-7-MINI FESTO 26 SB1 Standard cylinder B1 B2 6 DSNU-25-80-P-A FESTO 27 SB2 Standard cylinder B3 B4 6 DSNU-25-80-P-A FESTO 28 SB3 Standard cylinder B5 B6 6 DSNU-25-50-P-A FESTO 29 SB4 Standard cylinder B7 B8 6 DSNU-25-50-P-A FESTO 30 H5 start valve 00 M56-SV-1/2-D-10V24-SD-MP1-WPB FESTO 50
31 H6 start valve 00 01 HE-1/2-D-MIDI FESTO 32 W4 Pressure regulator E E1 LR-1/4-7-MINI FESTO 33 SOL60 Solenoid valve E2 E3 CPE14-M1BH-5L-1/8 FESTO 34 K3 Manifold strip (6) A 10 CPE14-PRS-3/8-6 FESTO 35 SOL61 Solenoid valve A1 A2 8 CPE14-M1BH-5L-1/8 FESTO 36 SOL64 Solenoid valve A3 A4 6 CPE14-M1BH-5L-1/8 FESTO 37 SOL66 Solenoid valve A5 A6 4 CPE14-M1BH-5L-1/8 FESTO 38 SOL68 Solenoid valve A7 A8 6 CPE14-M1BH-5L-1/8 FESTO 39 SOL62 Solenoid valve A9 A10 6 CPE14-M1BH-5L-1/8 FESTO 40 SOL63 Solenoid valve A11 A12 6 CPE14-M1BH-5L-1/8 FESTO 41 SB1 Standard cylinder A1 A2 8 DSNU-32-80-PPV-A FESTO 42 SB4 Standard cylinder A3 A4 6 DSNU-10-10-P-A FESTO 43 SB6 Standard cylinder A5 A6 4 DGC-18-100-G-PPV-A FESTO 44 SB0 Standard cylinder A7 A8 6 DSNU-25-80-P-A FESTO 45 SB2 Standard cylinder A9 A10 6 DSNU-25-40-P-A FESTO 46 SB3 Standard cylinder A11 A12 6 DSNU-25-40-P-A FESTO 47 W5 Pressure regulator B B0 LR-1/4-7-MINI FESTO 48 SOL65 Solenoid valve B0 B1 8 1~5 CPE14-M1BH-5L-1/8 FESTO 49 SOL67 Exhaust Valve C M56-SV-1/2-D-10V24-SD-MP1-WPB FESTO 50 W6 Pressure regulator D D1 10 5 LR-1/4-7-MINI FESTO 51 SV2 Compressed Air Reservoir D1 D2 10 CRVZS-510(10L) FESTO 52 SOL52 Solenoid valve D5 8 CPE-14-M1BH-3GL-1/8 FESTO 53 PE400 Pressure Sensor ( 0 ~ 10 Bar ) D4 6 SPAB-P10R-R18-2N-K1 FESTO 54 SD2 Semi-Rotary Drive D3 8 DGE-40-300-ZR-RF-LK-RB-GK FESTO 51