new basic manual - riggs autopack manual.pdf · manual handling precautions should be observed when...

Model 1000Semi-Automatic Depositing and Filling machine.

Safety, Installation, Operation&

Spare Parts Manual

IMPORTANT

This manual must be read beforethe machine is Installed or

Operated.

SAFETY NOTICEWARNING

DO NOT dismantle any part ofthe machine, before Isolating the

compressed air supply.

Designers & Manufacturers ofDepositing, Filling and AncillaryEquipment for the Food Industry.

E-mail :- [email protected] :- www.autopack.co.uk

Riggs Autopack LimitedSouthfield Street, Nelson.Lancashire. BB9 0LD England.

Tel :- +44 (0) 1282 440040Fax :- +44 (0) 1282 440041

1




Tel :- +44 (0) 1282 440040Fax :- +44 (0) 1282 440041

INDEX

SECTION DESCRIPTION PAGE

A Safety information…………………………… 3

B Introduction………………………………….. 4, 5

C Installation………….………………………... 6

D Machine specification.……………………… 7

E Material specification.……………………… 8

F Basic machine controls………………………. 9

G Machine settings……………………………… 10

H Depositing volume control…………………… 11

I Calibration chart 1 …………………………… 12

J Calibration chart 2 …………………………… 13

K Machine modes of operation…………………. 14, 15

L Maintenance schedule………………………… 16

M Recommended spares list……………………... 17

N Cleaning………………………………………. 18

O Machine stripdown…………………………… 19, 20, 21, 22

P Assembly drawings…………………………..

Drawing No. Issue

General assembly of machine………………..Motor assembly………………………………” Diameter pump barrel and piston assy..Rotary valve assembly……………………….Ømm Plunger cut off valve assembly…….Rotary valve limit switch assembly…………..Pneumatic circuit……………………………..

2




Tel :- +44 (0) 1282 440040Fax :- +44 (0) 1282 440041

3




Tel :- +44 (0) 1282 440040Fax :- +44 (0) 1282 440041

SAFETY INFORMATION

Incorrect installation, operation, or maintenance of equipment may cause severe personal injury ordeath, and / or equipment damage, and may invalidate the warranty.

This information must be read carefully before beginning installation, operation, or maintenance, andmust be kept with the machine. Only suitably trained or qualified persons must undertake installationand maintenance.

DO NOT OPERATE THE MACHINE IF:-

a) The motor cover is not correctly installed.b) Guards are missing or incorrectly installed.c) The inlet pipe or hopper and outlet pipework is not correctly connected.

DO NOT place fingers, or hands etc into danger zones whilst the machine is inoperation or still connected to the power supply. Severe injury may occur.

Danger Zones :-

a) Product depositing valve. (Cut off valve.)b) Rotary valve.c) Pump barrel.d) Motor.

Some removable parts may be slippery with product or cleaning fluids and careshould be taken when handling these items. The necessary safety clothing andequipment should be used. Ensure that the floor and working surfaces are safe andslip free to prevent risk of injury.

The maximum working pressure for this machine is 100 p.s.i (6,9 bar). Air pressuregreater than this could cause an explosive rupture in any of the air lines or pneumaticcomponents. Failure to adhere to this warning could result in personal injury ordamage to the machine.

When this machine is not in operation, the compressed air supply must bedisconnected at the power isolation point. Failure to disconnect the power supplyfrom the machine creates serious risk of injury. To prevent unauthorised personnelfrom operating this machine secure the lock out valve in the closed position, andattach a padlock through the holes.

Manual handling precautions should be observed when loading product in to the hopper, to prevent risk of injury.

Immediately stop the machine and report any malfunction to the person in charge.

4




Tel :- +44 (0) 1282 440040Fax :- +44 (0) 1282 440041

INTRODUCTION

This machine is manufactured in the UK by Riggs Autopack Ltd. Should you require any informationfor this machine please contact us quoting the machine serial number (TT ????), which can be found onthe CE plate affixed to the machine.

The Model 1000 range of Depositing and Filling Machines comprise of a reciprocating piston pump,fitted with a rotary actuated product valve. This assembly can be supplied as a single unit or may besupplied as a multiple unit for simultaneous operation in use.Ancillary product cut of valves / nozzles may be fitted to the unit(s) via either rigid or flexiblepipework.Product to be deposited or filled can be fed to the unit(s) via hoppers, feed tanks, or in somecircumstances via suitable pipework.The piston pump, rotary valve, and product cut of valves / nozzles are powered by compressed air.Controls for these items may be by air logic valves, electrical circuits or a combination of both.

The Model 1000 machines are designed for the depositing and filling of liquid, semi-liquid, or solids-in-suspension products for the Food Industry, in both Low Risk and High Risk production areas.However these machines are also suitable for filling liquid and viscous products in the Cosmetic andChemical Industries.

This machine is NOT to be used in an environment that has dangerous substances and / or explosiveatmospheres.

The Model 1000 machines may be supplied for:-

A) Semi-Automatic Operation

This requires a machine operator to position a container to be filled or product to be deposited onto,underneath the cut off valve / nozzle. The machine start and deposit cycle is initiated by means of apush button or footswitch or similar device. At the end of the deposit cycle, the container is manuallyremoved from the fill position, by the operator.

B) Automatic Operation

The container will automatically be presented underneath the cut off valve / nozzle, via a conveyor orsimilar means. The machine will accept a suitable external signal to commence an automatic depositing

or filling cycle. At the end of the deposit cycle, the container will automatically be removed from thefill position.

5




Tel :- +44 (0) 1282 440040Fax :- +44 (0) 1282 440041

Fig 1) Pump primed and shown in START / RESET position.

Fig 2) Pump depositing and shown in FORWARD / CALIBRATE position.

6




Tel :- +44 (0) 1282 440040Fax :- +44 (0) 1282 440041

INSTALLATION

1) Installation should be carried out, by a Riggs Autopack Ltd, engineer, or another suitablyqualified person.

2) Fully read this manual and familiarise all personnel necessary, with this manual, the machinecontrols, and SAFE working practices for this machine.

3) The machine weight is greater than 50Kg, and therefore, appropriate lifting arrangementsshould be made.

4) When positioning the machine, ensure there is sufficient space around the machine to allowaccess, for operating, adjustments, stripdown and cleaning, and there is suitable local lightingfor the operator.

5) Ensure the machine is securely fixed in position before switching on. Failure to do this couldcause the machine to become unstable, and lead to risk of injury. The machine should be fixedin one of the following ways :-a) Four 10mm diameter holes, in the support frame, for bolting to a suitable structure or

the floor.b) All levelling feet or lifting jacks should be set to stabilise and level the machine.c) All castors with brakes fitted, should be set in the locked position.

6) Connect the HOPPER or product feed inlet pipework. Note: If the machine is positioned sothat the hopper rim is over 1400mm above ground level, then prior consideration is requiredfor loading. If manual loading is to be carried out, then steps and fixed high level walkwaysetc, may be required. Or load by mechanical means, eg transfer pumps, hoists etc.

7) Connect a clean, dry air supply, using a 3/8” BSP male connector (or ½” BSP for 1000(6.5)machines) , with a supply pressure of 5/6 Bar (75/80 PSI). Ensure that all cables are routed asnot to cause a trip hazard.

NOTES !

A) Maximum air consumption per head, at 6 Bar (80 PSI) is 7Ltr/sec (15ft cube / min.) In normaluse, typical air consumption, at normal operating speeds and air pressure is 3Ltr/sec (5-6ftcube / min.)

B) If product feed, inlet pipework is used, instead of a hopper, then the pipework shouldgenerally not be less than 38mm (1,5”) diameter.

SAFETY NOTICEDISCONNECT THE COMPRESSED AIR SUPPLY, BEFORE DISMANTLING

ANY PART OF THE MACHINE.

7




Tel :- +44 (0) 1282 440040Fax :- +44 (0) 1282 440041

MACHINE SPECIFICATION

Machine Make Model 1000 General Arrangement

Machine Serial No. TT Drawing Number. A00/10/

Date of Manufacture 2008 Issue Level. 1

Mini Fill Standard Fill Maxi Fill

Make Range Make Range Make Range

1000 (26) 3ml – 75ml 1000/1.500 10ml – 170ml 1000/5.125 200ml – 2500ml

1000 (32) 5ml – 110ml 1000/2.285 25ml – 400ml 1000/5.125S 200ml – 3300ml

1000 (38) 10ml – 160ml 1000/2.800 50ml – 600ml 1000/6.500 500ml – 5000ml

1000/4.000 125ml – 1200ml

Equipment supplied with this machine :-

1) Pneumatic drive motor assembly.

2) Pump barrel, piston and rotaryvalve assembly.

3) Filling valve assembly.

4) Pneumatic control unit.

5) Multicycle counter.

6) Foot or Auto control.

7) Secondary machine start control.

8) Product feed tank.

9) Direct product feed connector.

10) Bench mounted frame.

11) Fixed height floor mounted frame.

12) Adjustable height floor mountedframe.

13) Mobile, low mount frame.

14) Adjustable height, filling table.

15) Tank level control unit.

16) Additional interchangeable pumpbarrel, and piston assembly.

Additional information :-

YES

YES

YES

8




Tel :- +44 (0) 1282 440040Fax :- +44 (0) 1282 440041

MATERIAL SPECIFICATION FOR PRODUCTCONTACT PARTS

The following product contact parts have been manufactured from material that conform to the gradesand specifications as listed below, and comply to FDA standards.

COMPONENT MATERIAL GRADE SPECIFICATION

Rotary valve body Stainless steel 316L/316S11 BS. EN 10088Rotary valve end caps Stainless steel 316L/316S11 BS. EN 10088Pump barrel Stainless steel 316L/316S11 BS. EN 10088Front cup support Stainless steel 316L/316S11 BS. EN 10088Rear cup support Stainless steel 316L/316S11 BS. EN 10088Piston boss Stainless steel 316L/316S11 BS. EN 10088Cut off valve - body Stainless steel 316L/316S11 BS. EN 10088Cut off valve - plunger Stainless steel 316L/316S11 BS. EN 10088

Rotor Waukesha NA88 DEW 88 MET

Cut off valve – plungercoated with :- TECHTREX™ 7200

Piston cups P.T.F.E. 100% Virgin white ISO 13000-1

`O’ Rings Nitrile NBR PB80 BS 2571Viton® 75V FluoroelastomerP.T.F.E. Fluolion BS 6564

Tri-Clamp seals EPDM – (Blue) Ethylene Propylene Diene MonomerResistance is good to ketones, alcohol, strong mineral acids and alkalis. Unsuitable for use with oils and hydrocarbons. Temperature range from -50°C to 150°C

Viton® - (Green)Particularly resistant to acids, solvents and most commonly used chemicals in the food industry.Unsuitable for ketones, esters and hot concentrated caustic solutions.Temperature range from -30°C to 250°C

P.T.F.E. - (White) (Teflon)Almost universal chemical inertness.Suffers from cold flow, hence must not be over tightened.Temperature range from -25°C to 250°C

9




Tel :- +44 (0) 1282 440040Fax :- +44 (0) 1282 440041

BASIC MACHINE CONTROLS

A) Compressed air ON / OFF isolation valve.

B) Compressed air, mains pressure regulator.

C) Compressed air emergency stop dump valve.

D) Switch - Manual / Off / Auto

E) Switch – Reset / Off / Flush

F) Button – Emergency Stop

G) Switch – Calibrate On / Off

H) Control panel regulator and gauge.

I) Motor speed controller – Depositing stroke.

J) Motor speed controller – Priming stroke.

K) Calibration lock.

L) Calibration indicator.

M) Calibration handwheel.

N) Foot pedal start switch.

A

BC

N

F

H

G

D

E

M

J

I

L

K

10




Tel :- +44 (0) 1282 440040Fax :- +44 (0) 1282 440041

MACHINE SETTINGS

1) AIR LINE PRESSURE – MAINS.

Set the external filter regulator to 5/6 Bar (75/80 P.S.I)

Set the mains switch, to the ON position.Pull the regulator knob up, to unlock.Turn the regulator knob clockwise to increase the pressure.Turn the regulator knob anti-clockwise to decrease the pressure.Push the regulator knob, back in, to lock.

2) AIR LINE PRESSURE – CONTROL PANEL.

Set the control panel pressure gauge to 2 Bar (30 P.S.I.)

Pull the regulator knob out, to unlock.Turn the regulator knob clockwise to increase the pressure. For highviscosity products, a higher pressure may be required, up to a maximum of6 Bar (80 P.S.I.)

Turn the regulator knob anti-clockwise to decrease the air line pressure. Forlow viscosity products, a lower pressure may be required, down to aminimum of 0,7 Bar (10 P.S.I.)Push the regulator knob, back in, to lock.

3) SPEED CONTROL – PRIMING STROKE.

Set the priming stroke exhaust restrictor to approximately half-open.

Turn the exhaust restrictor clockwise to reduce the speed of the priming stroke. This may help reduce cavitations in the product, when it isbeing drawn into the pump.

Turn the exhaust restrictor anti-clockwise to increase the speed of thepriming stroke.

4) SPEED CONTROL – DEPOSITING STROKE.

Set the depositing stroke exhaust restrictor to approximately half-open.

Turn the exhaust restrictor clockwise to reduce the speed of the dischargestroke. This may help reduce any splashing of the product, caused by fillingthe container too fast.

Turn the exhaust restrictor anti-clockwise to increase the speed of the depositing stroke.

11




Tel :- +44 (0) 1282 440040Fax :- +44 (0) 1282 440041

DEPOSITING VOLUME CONTROL

1) Cycle the machine a few times and check the volume / weight of the product being deposited.

2) To adjust the volume / weight of product deposited, the machine must be set to the“CALIBRATE” mode, ( See MACHINE MODES section. ) The machine will deposit productand then stop in the FORWARD / CALIBRATE position.

3) Release the calibration handwheel lock.

4) Adjust the filling volume accordingly. (See Calibration Charts 1 & 2.)

a) To increase the volume, turn the calibration handwheel clockwise.

b) To reduce the volume, turn the calibration handwheel anti-clockwise.

5) Retighten the calibration handwheel lock.

6) Return the machine to the “CYCLE” mode, ( See MACHINE MODES section. )

7) Cycle the machine a few times and check the volume / weight, and adjust as necessary.

8) Once the machine is depositing the correct volume / weight, make a note of the indicatorreading for future reference.

12




Tel :- +44 (0) 1282 440040Fax :- +44 (0) 1282 440041

CALIBRATION CHART 1

Pump bore = 26mm

Scale readout Displacement (ml) No. of revolutions of handwheel.

750 16.5 151500 33 302250 49.5 453000 66 60

Pump bore = 32mm


750 24 151500 48 302250 72 453000 96 60

Pump bore = 38mm


750 34.5 151500 69 302250 103.5 453000 138 60

Pump bore = 2.285”


750 100 151500 200 302250 300 453000 400 60

NOTE

The amount(s) of displacement shown, are given as a guide only. Any alteration to the depositedvolume / weight, should be checked, prior to a production run.

13




Tel :- +44 (0) 1282 440040Fax :- +44 (0) 1282 440041

CALIBRATION CHART 2



750 150 151500 300 302250 450 453000 600 60



750 300 151500 600 302250 900 453000 1200 60



1500 600 153000 1200 304500 1800 456000 2400 60



1500 960 153000 1920 304500 2880 456000 3840 60

NOTE

The amount(s) of displacement shown, are given as a guide only. Any alteration to the depositedvolume / weight, should be checked, prior to a production run.

14




Tel :- +44 (0) 1282 440040Fax :- +44 (0) 1282 440041

MACHINE MODES

NOTE !

Prior to powering up the machine, ensure that the depositor is correctly coupled to the air supply, andthat all pipework, hopper, and cut off valve are sealed and clamped.

1) EMERGENCY STOP and RESET

On pressing the EMERGENCY STOP button, the compressed air supply to the machine willbe immediately dumped, stopping the depositing machine ONLY. (This EMERGENCY STOPbutton will NOT stop the conveyor or other ancillary equipment.)To restart the depositing machine :- (Clear any fault that may have caused the EMERGENCYSTOP button to be pressed.) On power up, or after an emergency stop, the RESET switchmust be used, to set the machine in the rest/start position (See Fig 1.)

a) Set MAN / OFF / AUTO to ÒFF’.b) Set RESET / OFF / FLUSH to ÒFF’.c) Set CALIBRATE to ÒFF’d) Ensure the EMERGENCY STOP button is released.e) Turn the main, air service unit isolator to ÒN’.f) Turn and hold the RESET switch, until the machine powers up.

OPERATOR / CONTROL PANEL

15




Tel :- +44 (0) 1282 440040Fax :- +44 (0) 1282 440041

2) MANUAL / OFF / AUTO

MANUAL When the switch is turned to “MANUAL”, the machine will cycle once only. ( 1 forward / depositing stoke, and 1 return / priming stroke. ) The switch is sprung loaded and cannot be left in the MANUAL position.

OFF The machine is in the stand by mode, with air power being supplied to the control cabinet.

AUTO When the switch is set in the “AUTO” position, and depositing machine set to accept an air START signal from the conveyor, the machine will automatically deposit product when required. Also use this option whenrequiring to use a foot pedal signal to start the depositing cycle.

3) FLUSH

This will put the machine into a continuous cycle, to allow the product hopper to be emptiedquickly, or to flush the system through with cleaning fluids.NOTE: The plunger in the cut off valve will remain in the open position during this mode.

a) Set MAN / OFF / AUTO, to ÒFF’.b) Set RESET / OFF / FLUSH to ÒFF’.c) Ensure CALIBRATE is set to ÒFF’.d) Ensure the EMERGENCY STOP button is released.e) To activate turn the switch to `FLUSH’.

4) CALIBRATE

This will allow the depositing volume of the machine to be set, by stopping the machine in theforward position of the depositing stroke ( See fig 2. ) Refer to “DEPOSITING VOLUMECONTROL” on how to adjust the amount of product to be deposited.

a) Set MAN / OFF / AUTO to ÒFF’.b) Set RESET / OFF / FLUSH to ÒFF’.c) Ensure the EMERGENCY STOP button is released.d) Set CALIBRATE to “ON”.e) Flick the MANUAL switch once to activate.

16




Tel :- +44 (0) 1282 440040Fax :- +44 (0) 1282 440041

MAINTENANCE SCHEDULE

1) DAILY

Strip down and thoroughly clean all the following parts, after use.

a) Cut off valve.b) Product hopper.c) All product pipework.d) Rotary valve.e) Pump barrel and piston.

Re-assemble, using food quality grease (Riggs Autopack part number:- 111180) on all Ò’rings and pump barrel piston cups / seals. Ensure that the spigot Ò’ rings of the rotary valverotor, and the Ò’ ring of the cut off valve plunger, are well greased.

2) WEEKLY

a) Check the air service unit (A.S.U.) filter bowl for ingress of water, and drain off asnecessary.

Note.

The air service units have a self draining facility. The self draining is activated byturning the air supply to the machine, off and on, at the stop cock attached to theA.S.U.

3) MONTHLY

a) Inspect all Ò’ rings, seals and pump barrel piston cup seals for wear and damage. Replace as necessary.

4) ANUALLY

a) A full inspection and service to be carried out by a RIGGS AUTOPACK Engineer.

17




Tel :- +44 (0) 1282 440040Fax :- +44 (0) 1282 440041

RECOMMENDED SPARES LIST

1) MOTOR

Part Number Description Material Quantity

100864 Poppet valve N/A 2 off

2) PUMP BARREL


Barrel cups P.T.F.E. 2 off

Cup seals Nitrile 2 off

214115-050 Piston Head Seal Viton 1 off

3) ROTARY VALVE


101428 Flange seal Nitrile 1 off

100971 Rotor end cap seal Nitrile 2 off

101427 Rotor spigot seal Silicon 2 off

100863 Roller valve N/A 2 off

5) CUT OFF VALVE


Plunger seal Viton® 1 off

6) PIPEWORK


111005 2” Triclover seal EPDM 1 off

111003 2” Triclover clamp Stainless steel 1 off

111004 1,5” Triclover seal EPDM 2 off

111002 1,5” Triclover clamp Stainless Steel 2 off

18




Tel :- +44 (0) 1282 440040Fax :- +44 (0) 1282 440041

CLEANING

1) Ensure all OPERATORS / CLEANERS are familiar with all controls and safety precautions,prior to using or cleaning the machine.

2) Ensure all OPERATORS / CLEANERS are wearing the necessary personal protectionequipment, prior to using or cleaning the machine.

3) The machine is designed for `OFF LINE’ cleaning and is not suitable for C.I.P. or closedcircuit type cleaning, using caustic soda’s etc.However the machine maybe flushed through with water and / or appropriate cleaning agents.(See `FLUSH’ mode for operation.)

4) To fully detail clean all the product contact components, the machine is required to bedisconnected from the main power supplies, and then stripped down. (See machine strip downsection.)

5) Clean all spillages immediately with the appropriate cleaning methods.

SAFETY NOTICEDO NOT ATTEMPT TO UNBLOCK THE CUT OFF VALVE WHILE THE

MACHINE IS RUNNING, OR STILL CONNECTED TO THE POWER SUPPLY.

(THIS MAY RESULT IN RISK OF INJURY)

19




Tel :- +44 (0) 1282 440040Fax :- +44 (0) 1282 440041

MACHINE STRIP DOWN

Hopper

Pump

Inlet Connection Pump Lockheads

Motor

Outlet Connection

Rotary Valve

Outlet PipeworkActuator Holder

SAFETY NOTICEENSURE THE COMPRESSED AIR IS ISOLATED AND THE HOPPER IS

EMPTY BEFORE STRIPPING THE MACHINE DOWN.

Air Cylinder

TommyBar

INSTRUCTIONS

1) Unfasten the inlet connector and remove the hopper.

2) Disconnect and remove any outlet pipework.

Product CutOff Valve

20




Tel :- +44 (0) 1282 440040Fax :- +44 (0) 1282 440041

(A)

4) Remove the rotary valve actuator (B), and place in the holder, on the frame, if fitted.

(B)

5) Push out the rotor (C) from the valve body. This will automatically remove one of theend caps (D) with it. The other end cap (E) can now be removed.

(C) (D)

(E)

3) Unscrew the clamp knob (A), and remove the clamp

21




Tel :- +44 (0) 1282 440040Fax :- +44 (0) 1282 440041

6) Release the 2 rotary valve lockheads, with the Tommy Bar. Then rotate the valvebody (F), until it can be pulled off, over the lockheads.

7) Remove the pump barrel (G) by releasing the 2 pump lockheads with the Tommy Bar.Then rotate the pump barrel until it can be pulled off over the lockheads. Lift thebarrel slightly to release the coupling (H).

8) The piston assembly (I) can now be pulled out from the pump barrel.

(F)

(G)

(I)

(H)

22




Tel :- +44 (0) 1282 440040Fax :- +44 (0) 1282 440041

PISTON HEAD STRIPDOWN / ASSEMBLY

1) Assembled piston head, with locking pin secured in position.

2) Lift the retaining clip, and pullout the locking pin.

3) Remove the piston cup assembly.

4) Remove the centre stub shaft, from the piston cup assembly.

5) Piston cups, supports and sealswill now come apart.

Assembly of the piston head, isthe reverse of stripping it down.

new basic manual - riggs autopack manual.pdf · manual handling precautions should be observed when...

Documents