Operating Manual Tablet Counting and Filling Machine Model IMC-16-1 -
CONTENTS 1. Precautions 2. Introduction to the machine 3. Relevant Technical Data 4. Working environment 5. Introduction to the control system 6. Introduction to major parts 7. Preparation before turning on machine 8. Operate machine 9. Matters needing attention during operation 10. Maintenance Direction 11. Safety Guide 12. Hoist and installation 13. Failure Solution 14. Conditions 15. Illustration 16. Circuit Diagram - 2 -
1. Precautions Remove all temporary fixtures (Noted on machine) in machine before connecting to power supply. There are three fix screws on the bottom of vibrator cabinet which holds the vibrators for transportation, please take them off before turning on the machine; otherwise it will damage the vibrator. (Refer to picture) Fix screw for transportation Please check and make sure the machine is placed on a level surface. Make sure all the connection points are ideally fixed and no parts are loose. Do not place anything on the top of the machine especially liquid items. Avoid putting your hand into the machine whilst operating as it will cut off it off Set the speed according to the type of tablets and bottles you want to arrange. Make sure the power supply and compressor air supply is stable. DO NOT open the cover of the machine to avoid powder and dust distribution - 3 -
2. Introduction to the machine IMC-16 tablet counting and filling machine adopts advanced vibration and multi-channel feeder, computer control, dynamic scan counting, automatic transfer of bottle, automatic system test, with error alarm, automatic stop and other advanced technology. This machine is designed to GMP standards. Compose light and electric machinery to one set, which is suitable for tablet, capsule counting and filling for pharmaceutical or food industry. The machine could be widely used for all kinds of different tablets, capsule, pill in different shapes and sizes. The speed and accuracy of counting and filling is able to meet advanced levels. The specification of the machine as follows: Vibration feeder: 3 grade vibration. 16 passages. ( 8 passages per head) Running dependability: Works smoothly with very little noise. Counting accuracy: The ability to fill bottle less than national standard. Working continuity: Feeding continuity, switching of bottles without stopping vibrator. Dual channel filling system: Increase filling bottle speed. Related function: System alarm and automatic machine stop when there is an error. Self check and alarm of sensor. Easy to operate: Adopt the intellectual design. Trained operator can operate machine. Easy to clean and change parts, no need for more tools to adjust. 3. Relevant Technical Data Tablet and capsule to be counted:φ7~14mm, transparency NOT higher than 80%. Bottles to filled: customized Range of counting and filling: 20~999 adjustable Counting and filling speed: 2000-4000 pieces (sample as normal tablet Φ8 5mm)/minute, 50-80 BPM (according to the material, size of tablet or capsule, filling number of each bottle) Counting error: 1 pieces - 4 -
4. Working environment Voltage: 220V, 50HZ 1000W Weight: 400Kg Size of Machine (L*W*H) : 1800 1500 1650mm Ambient: Indoor, Temperature 0 ~30, Humidity 80%,No shake and highlight. Compressed air: 6 Kgs/cm 2 5. Introduction to the control system Control panel and its function Start screen Enter the main page after turning on the machine. Screen displays as follows Touching button In this page user can access different pages by pressing the relevant button on the screen: Press to go to Work Monitor page Press to go to login page Press to go to Test screen page - 5 -
Press to go to Help screen page Press the highlighted text Welcome Enter to go to menu page The user can access any page by pressing the relevant button on the screen in this page. Caution: pressing Menu Screen in above page, will result in going back to the Manu page directly. The user will be required to enter the user name and password before entering the System para. Setting, Screen adjust and Exit system screen/menus. - 6 -
Password screen The original user name and password as follows: User name: ADMIN Password: 900 In this page, user can change the language between English and Chinese by pressing Language switch - 7 -
Screen adjust User can adjust the screen in this page. You will need to enter user name and password before entering this page. Contrast up and Contrast down can adjust the contrast of screen. Adjust touch can adjust the precise touch point on the screen. The user can automatically clear the screen by pressing the Clear screen. Exit you will return to menu page. - 8 -
Test screen In this page, user can test the counting accuracy of each channel. The system will count the number of tablets/capsules the user has dropped into each channel. The value will display on the screen. Press the to go to Equipment action test 1 page as follows: In this page, user can test the action of gate at the end of channel. For example, press the button - 9 -
of 1#, the gate of 1# will close, and press the button again, the gate will open again. Press the to go to Equipment action test 2 page as follows: In this page, press the button of Put bottle Test 1#, Put bottle Test 2#, Cylinder Test 1#1, Cylinder Test 1#2, Cylinder Test 2#1 and Cylinder Test 2#2 to test the action of cylinder on the bottle feeding system. Press the Conveyor Test to start or stop running the conveyor. Press the Machine Up and Machine Down to test the elevator on the machine which controls the height of dropper. User can put one piece of capsule into channel 1 after pressing sense of Sensor. (Note: only channel 1 has test function.) The system will indicate the induction speed of sensor based on the size of capsule. - 10 -
System work para. Setting In this page, 1# means the feeder 1, 2# means the feeder 2. (The same as following page) - 11 -
Brief parameter setting according to following chart Time of Sensor to How much time it takes from tablet passing the counting sensor to the Gate gate. Time of Gate to The time it takes for tablet to pass the gate to the conveyor Conveyor Time of changing Time it takes for that a bottle to be filled pass by. bottle Delay-time of put The delay time of bottle holding bar 2 Vs action of bottle holding bar 1. bottle If the setting is same as bottle pass time, when first bottle pass, gate of conveyor will open while next bottle arrives. If the setting is less than bottle pass time, bottle arrives after gate of Time of Harmonize conveyor is open. (To increase the production) If the setting is more than bottle pass time, gate of conveyor will open after bottle arrives. (Try this setting when tablets is drop out of bottle) The system will stop the vibrator if there is no bottle at the bottom of Vibrator delay time dropper over the delay time. Time of Sensor If machine is miscounting for clear soft gel, try to change this setting shield Set value of vibrator Control the power of vibrator 1 1 Set value of vibrator Control the power of vibrator 2 2-12 -
In the System para. Setting 2, user can enter to Recipe Screen which can store or restore the pre-setting parameter in the system by pressing the button Recipe Screen page 1 In this page, double click the item, such as Recipe record 1 user can go to Recipe Screen page 2. Press go to Recipe Screen page 3. Recipe Screen page 2 In this page, user can set the relevant parameter separately. Press back to Recipe Screen page 1. Press go to Recipe Screen page 3. - 13 -
Recipe Screen page 3 New means to build new group parameters. Delete means to delete existing group parameters. Save As means to save the group parameters with new name. To PLC means to restore the group parameters to PLC as current parameter. From PLC means to save the current parameter to RAM system. Back means to go back to Recipe Screen page 1. Open means to go to Recipe Screen page 2. - 14 -
Alarm screen This page displays some detailed information if the machine stops working or cannot run in normal state. If the machine alarm goes off, press the mark to clear the warning mark once the problem has been solved, otherwise the warning mark will remain on the screen. Press the alarm screen to return to the menu page. - 15 -
Alarm on screen Reason Solution Outer or inner channel lack bottle then system stop vibration Over setting of buffer, stop. Over setting, stop. There is not enough bottles on the conveyor The actual value of buffer is over the value of buffer setting The actual value of counting is over the value of setting, Put more bottles on the conveyor 1. Set the max number of each passage again, if over the setting, the vibrator will stop. 2. Clear out the tablet in the channel and restart the machine Modify the set value of vibrator in order to slow down the tablet feeding Help screen - 16 -
In these two screens (above), user can obtain helpful information about the machine. Press the highlighted text Help Screen 1 or Help Screen 2 to go back to menu page. Work Monitor PV means actual number SV means preset number which user wants to fill into bottle. - 17 -
Buffer : Set the max number of each passage, if over the setting, the vibrator will stop. When the bottles passes by, the vibrator will start again. The function of this setting is to avoid too many tablets in the passage, which might cause tablets to jam in the track or passages. Press the Running to start the machine, press the Stop to stop the machine, press the Reset to clear up the PV setting. 6. Introduction to major parts The machine includes Vibrating Feeder, Counting System, Bottle Feeding System, Cabinet, and Controlling System. (See Illustration of the machine.) 6.1. Vibrating Feeder This part is made up of Tablet Hopper, Vibrator, Tablet Feeding Track, Dust Cap. Tablet Hopper: This is for storing and loading the tablest to be counted. There is an adjustable baffle at the exit of tablet hopper, which can be adjusted to output the volume of tablets. The hopper can be taken off to make it easier to clean. Vibrator and Tablet Feeding Track: The machine adopts 3 grades vibrations, which is made of vibrator 1 (long corrugated board), vibrator 2 (short corrugated board) and vibrator 3 (flat board which is close to hopper). The tablet feeding track has 16 passages. By setting the parameters on parameter setting page, you can adjust the vibration of vibrator 1 and 2. There is a knob (with a vibrator label) on the side of the control box, which is to adjust the vibration speed of vibrator 3, this controls the flow of tablets. - 18 -
There is a 2mm small gap in front of the tablet feeding track. Whilst operating the dust and powder will fill into the dust collector after vibration. User must clean the collector from time to time. Dust Cap: Dust cap is made of Perspex, which prevents dust and make it easy to watch the state of tablet feeding. - 19 -
6.2. Counting System The machine adopts dual dropper and double track conveyor separately. The counting system includes a tablet guide plate, counting heads, dropper. Guide plate: The guide plate is customized according to the tablet range provided by user. Counting Heads: The counting heads are made of highly sensitive sensors. The Sensors will count the numbers of tablet while they pass by, and displays this the on control screen by sending a signal to the control system. Dropper: For this Model there are two filling droppers, which fills the bottles with tablets once counted. The Dropper must to match the diameter of bottle mouth. The dropper position can adjusted on the right top of bottle mouth, there s a fix screw to adjust the dropper. 6.3. Bottle feeding system: Feeding system: Under the tablet dropper, which is made up of a transmission part, conveyor, bottle hold bar etc. Transmission part: This part includes transmission shaft, which drives the motor. Conveyor: The conveyor is made by a chain-plank, which links the tension pulley at the beginning and end of the conveyor. The conveyor will assist bottles in feeding them in right direction within a suitable speed. There is a division board in the middle of the chain-plank, which divides the conveyor into 2 sections in order to deliver two bottles at the same time. Bottle Hold Bar and electromagnet: User can adjust the space between railings on the conveyor according to the diameter of bottles. The distance between the bottle hold1 & the bottle hold 2 should be the same as the diameter of the bottle. Above the bottle hold, there s a bottle inspection sensor, and when there is no bottles in this section, the system will alarm and the vibrator will stop automatically. - 20 -
6.4. Cabinet The cabinet consists of cabinet case, screw on pillar, adjustable pillar. There are four mounting screws on the pillars which can be adjusted. Adjust the height of machine to the same level to link to other machines. 6.5. Controlling system: Most of the electrical components are inside the cabinet or control box, and can be controlled at the PLC s. The power supply plug is on the right hand side of the cabinet. 7. Preparation before turning on machine 7.1. Inspection on outlook: As there might be loose connections after transportation and installation, please make sure all the electrical connections are connected and tighten any loose items 7.2. Check if all the tablet feeding tracks are in line with the counting tracks. Put on the cover with plexiglass. 7.3. Check the power supply: The machine requires a 220V±5V, 50 Hz alternating current. The plug is 3 heads. The electrical outlet the user use, must be of a good quality and earthed. 8. Operate machine 8.1. Filling the tablet: Filling tablets into the hopper on the top of machine. 8.2. Adjustment on space between the end of tablet hopper and vibrator 3 (flat board) based on the size of tablet. 8.3. Adjust the railing on conveyor, height of dropper according to the diameter and height of bottles. - 21 -
8.3.1. Adjustment on railing space -- Loosen the fixed screw on bottle feeding system, adjust the distance between two railings on conveyor (about 2mm bigger than the diameter of bottle), and fix the railing. 8.3.2. Adjustment on height of dropper: Adjust the height of the dropper until it s about 2mm higher than the height of bottle. Turn the Up and Down knob (light on), Up button means up, and Down means down, after adjustments, turn off the knob in time. Controlling knobs as follows: Dropper should be on the right top of the bottle mouth: To turn the knob on the two sides of dropper, adjust the position of dropper till on the right top of bottle mouth. Looses the fixed screw on railing, adjust the bottle holding bar, to ensure the dropper is on the top of all bottles. - 22 -
9. Matters needing attention during operation 9.1. The speed and accuracy of tablet feeding is the key to accurate counting performance. Please ensure average distance between tablets or capsules on feeding track and no overlapping tablet. 9.2. End of feeding track should aim at the tablet counting passage, the entrance of counting passage is1-2mm lower than the feeding tracking, to avoid jamming. 9.3. Give correct and quick response when machine alarm sounds and stop processing. Fix the issue according to guide, and restart the machine. 9.4. If there is a bottle in the dropper, but machine alarm shows NO BOTTLE, this means the bottle inspection sensor is not in the right position, please adjust it. 10. Maintenance Direction 10.1 If he counting sensor is polluted by the dust. Please use absorbent cotton or silk fabric to clean the dust on the glasses in the counting sensor. 10.2 Regularly clean the dust collector below the vibrator. 10.3 Regularly keep the machine clean. When cleaning the dust, take off the cover gently.. 10.4 You MUST NOT put any other contents besides tablets to be counted on the feeding track or conveyor to avoid scratching. 10,5 After stopping the machine, please clean the dust in hopper, dropper and tablet feeding track, then close the cover. 10.6 The electric board has been adjusted. Please DO NOT Adjust at random. 10.7 Please change the fuse to correct specification. - 23 -
11. Safety Guide 11.1 The machine should be placed on a flat surface. 11.2 The power should be earthed. When changing the plug, pull out the pin should which will cut off power supply first. 11.3 Keep the machine and it surroundings clean. When cleaning the machine the power must be off. If cleaning the vibrator or feeding track, don t let the cleaning liquid spray into the electrical parts. 11.4 While performing maintenance on the machine, you MUST NOT at wiring. The pin must be taken out slightly, to avoid breaking the electric wire. 12. Hoist and installation 12.1 Hoisting and Opening Case 12.1.1 Use an appropriate vehicle to transport the machine in a wooden case. DO NOT let the wooden case lean. The machine must remain upright whilst transporting. 12.1.2 The machine must only be removed from the box in the area where the machine will be placed for operating. Open the wooden case from the top at first, then open the sides. 12.1.3 User should inspect the outside of the machine when opening the wooden case. Inspect each item according to the packing list. 12.1.4 Carry the machine whilst in wooden case from bottom of the box. 12.1.5 The incline angle should not be less than 15 when the machine is hoisted. 12.2 Installation 12.2.1 The machine should be installed on a hard and flat concrete floor. The surface must be smooth. - 24 -
12.2.2 Start to install the machine by loosening the bolt at the bottom of the wooden case. Use the forklift (Based on the sketch map) raise the machine. Make bottom wooden board separate with the forklift. At same time settle the bottom bolt, then carry the machine to a suitable place. 12.2.3 After the machine is settled, adjust the bottom bolt to the suitable height. Screw down the bolt after placing the machine on a flat surface. 12.2.4 Clean the surface dust after settle finished. Caution: It is important to take off the mounting screw for transportation which is under the bottom of vibrator plate before testing the machine. Mounting screw for transportation - 25 -
13. Failure Solution Fault Reason Precaution and solution Tablet jam-up The bottle place is not lining up Error on counting and filling bottle The tablet drops out of the bottle The speed is too high The timing of the bottle The dropper is not line up with the little bottle mouth The space between railings on conveyor is too big The counting time and end time is not correct The distance between filling dropper mouth and bottle mouth is too long. Adjust vibration of vibrator and feeding track. Adjust the data on control panel Adjust the station of the dropper Adjust space between railings. Leave about 2mm at bottle to holding bar. To the settle page.adjust the channel (inner block is 1,the outside block is 2,)photoelectric gate time (the unit is millisecond ),if the bottle in front is more than, and the second is slower,then reduce the time. Alternatively add time if in reverse. Adjust the height of filling dropper to the distance between filling dropper mouth and bottle mouth to less than the diameter of tablet or capsule. - 26 -
The bottle falls down when passing by the hold The counting sensor stops working Alarm The opening time of bottle hold is too long. There is some dust on the counting sensor The sensitivity of counting sensor is out of proper scope No bottle The white bottle have strong light The sensitivity of sensor due to dust Adjust the time of bottle pass in the parameter setting page Clean the sensor Adjust the small adjusting knob on the counting sensor circuit board until the sensor starts working (The method of adjusting sensor refer to pic1 and pic2 ) Supply the bottle Keep out the light Clean the sensor 14. Conditions 14.1 This machine is photoelectric and is customized to IMC and customer agreed specifications. IMC will not warranty machine if: 14.1.1 The condition can t reach the requirement. 14.1.2 The materials (tablet/capsules/bottles) used are different to that used when manufacturing and commissioning of the machine. 14.1.3 Machine (or parts) have been changed or tampered with. 14.1.4 Operator has not followed instructions as per operating manual. 14.2 All faults must be communicated to our company. 14.3 Only IMC parts must be used in the machine. - 27 -
14.4 Our company reserves the right to change parts and appearance of this model machine. 15. Illustration Front and Side View - 28 -
Top view of the bottle feeding system - 29 -
16. Circuit Diagram - 30 -
1L 0.0 0.1 0.2 0.3 2L 0.4 0.5 0.6 0.7 1.0 3L 1.1 1.2 1.3 1.4 1.5 1.6 1.7 N L1 6ES7 216-2AF22 1M 0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 1.0 1.1 1.2 1.3 1.4 2M 1.5 1.6 1.7 2.0 2.1 2.2 2.3 2.4 2.5 2.6 2.7 M L+ - 31 -
RECOMMENDED SPARE PARTS LIST No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Machine Part HMI Model SIEMENS PLC SIEMENS LAN SIEMENS Solid state relay ORMON Conveyor motor Coil for Vibrator Timing motor Cylinder Bottle inspection sensor Fibre-optic cable Counting circuit board NS Valve for bottle bar Supply wire Speed controller Lamp house Gas adaptor Chain-plank Short Bracket Battery Vibration controller SIEMENS Photo