Auto menthol box filling cooling production line

Operation Manual

Of

Auto Menthol/Cream
Hot Filling & Cooling
Production Line
★ Integrity＊Quality＊Service＊Technology ★

Add: 26# Yongtang road, Jintian industry park, Huadong town, Huadu district, Guangzhou,
Guangdong Province, China
Home: http://guanhejx.en.made-in-china.com http://guanhejx.com
Email:kristinna@guanhejx.com Skype: christina09361
Tel: 0086-13570365669 0086-20-37720735 Wechat/whatsapp:0086-13570365669

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 Auto menthol box filling cooling production line
I. Preface

First of all, many thanks for your trust to our factory & purchase of our machines.
The first time u use the machine, pls read carefully the manual; it'll make u familiar
with the functions of main parts, so that u can better & easier to use & maintain it. And
pls stick to the safety rules and operation ways. If any question or problem u meet &
can't solve while using, pls don't hesitate to contact us, and we'll try our best to serve u.

II. Main items

1. Safety: 1)safety rules; 2)safety device
2. Main technical parameter & machine sketch
3. Work principles & machine performance
4. Installation & adjustment
1)adjustment of filling bottles position
2)adjustment of bottle-blocking structure
3)adjustment of bottle-clipping structure
4)adjustment of photoelectricity
5)adjustment of filling dosage
5. Touch screen usage
6. Common malfunction and settlement
7. Circuit diagram（electrical & air circuit）

III. Detailed description

1. Safety notice
1) Safety rules
Pls give a appearance checking before installation in the spot: if there is surface broken
or knocked, if the frame is deformed, if there is any scratch on the acrylic glass hood, or
the control cabinet is damp ect. Pls contact supplier if some parts are not sure.
Do pls make the forklift to put machines in place instead of cable assembly.

To avoid accident, each machine from us is equipped with relative safety device; do pls
obey the following rules.
 Only each safety device is at the normal state, can we start the machine; these
safety device can't be canceled or not work.
 Pls don’t block or interfere the cooling fan of the electrical cabinet; make sure
the normal heat exhaust to prevent the electrical components from being burnt
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 Auto menthol box filling cooling production line
or unstable working resulting from high temp.
 Before starting machine, operator should check all running area to assure no
possible damage or obstacles.
 Do not put hands into filling zone or other running area while filler is
running.
 Do cut off air source & power source before cleaning & maintain the filler.
 If there are some damage or malfunction, the operator must report in time &
solve it.
 During no production period, do cut off air source, power source & material
feeding.
 If emergency occurs during production, press the red button-E-stop on the
panel, and the machine will stop at once, & cut off electricity if needed. After
faults clearance, pls release the button to the previous state.
 Do not use water flush machine appearance directly, to avoid water going
into electrical cabinet. Once there is water in touch screen or electrical cabinet,
do pls cut off power, and ask the professional technical to prepare it.

2) Safety device
A: E-stop button
If emergency occurs, press the red button-E-stop on the panel, and the machine
will stop at once. After faults clearance, pls screw right to recover the button to the
previous state.
B: Safety device checking
 Before starting machine, do pls check if the safety device is all in normal
state.
 The working sate of safety device must be given a yearly check by mechanic.

2. Main structure & technical parameters

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 Auto menthol box filling cooling production line
Technical parameters:
● Power source: about 12KW AC220V 50Hz 3P (cooling machine is converted from
380V 50HZ 3P via equipped electricity tans-former, pls noted the wiring, do pls make it
correct) 12KW
● Air source: 0.6-0.8Mpa 300L/H
● Filling nozzle: 6-nozzle piston filling
● Filling scope: 5-50ml
● Filling error: ±1.5%
● Filling speed: 2800-3600BPH
Cooling temperature's: 0-20℃(adjustable)
Cooling time:5-15mins(adjustable based on material)
Belt material: PVC belt, width customized based on box
Conveying speed:0.5-6/min adjustable
Motor power:1.5kw(frequency-converter)
Cooling set power: 3.75KW* 1 set=3.75KW
Material: frame & appearance SUS304, with heat-persevering system for btter cooling
effect

Mainstructures:

Whole line installation sketch reference

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1- box unscrambling bowl 2- box-entry conveying belt

3- box-pushing cylinder structure 4- hot filling part
5- cooling tunnel with cooling host
6- box-exit cylinder structure 7- box-exit conveying belt

1: box unscrambling part:

Adopting electrically-driven vibrating hopper to unscramble boxes in the bowl, instead
of labor feeding boxes one by one, it’s much faster & more efficient. Boxes will orderly
exit from bowl & come into box conveying belt for next process very smoothly
2: box-entry part
It consists of box-blocking cylinder, box-pushing cylinder, box-blocking plate, and
positioning plates ect. When the system detects 6 boxes, the box-blocking cylinder will
stretch out, & box-pushing cylinder will push the positioned boxes into filling belt.
For different boxes replacement, do pls adjust/change the relative positioning plate.
3 & 4: Filling part
When sensor detects boxes, the filling cylinder auto starts, it fills via the piston dosage
driven by relative cylinder. Each filling set has one separate piston cylinder, single-way
valve & filling nozzle. By adjusting the low limit approach switches to achieve the
filling accuracy adjustment.
The hopper is designed with dual-layer, inner is for liquid, jacket is for water circulating
heating & persevering by water pump & heaters. The filling nozzles r with circulated
water heat-persevering too, ensuring the perfect filling effect. The heating temp can be
controlled easily via temp controller on the electricity cabinet, the liquid temp & jacket
temp.
The jacket water should be added in time if there is water lack through the side sight
pipes.
5: cooling tunnel
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This part mainly consists of heat-insulation 304 hood & cooling unit. The cooling unit
adopts industry cooler & can achieve 5-20 degree temp adjustment; by changing the
conveying belt running speed, the capacity & cooling effect can be achieved
accordingly.
The cooling host units will be installed according to the factory layout, in this machine,
only 1 cooling host, we design to install it nearby the line; anyway u can also install it
outdoors based on actual factory size, just pls ask professional cooling technicians for
extra pipelines connection
6& 7: box-exit part
It consists of box-blocking cylinder, box-pushing cylinder, box-blocking plate, and
positioning plates ect. When the system detects 6 boxes, the box-pushing cylinder will
push the positioned boxes into next conveying belt.
For different boxes replacement, do pls adjust/change the relative positioning plate.

3. Principle & machine performance

1) Working principle
A.This filler mainly adopts cylinders as filling power. It can auto finish bottle-entry,
bottle positioning, hot filling, online cooling, bottle-exit ect.
When piston goes up, the pneumatic one-way valve is between material feeding tube &
filling nozzles, material will be pressed to filling nozzle via tube, & filling nozzle is on
at the same time; when piston goes to the preset position, air valve switches to the
opposite direction of cylinder, then the piston goes down, one-way valve is between
material feeding tube & raw material storage tank, and material will be pumped into
tube, thus achieving qualitative filling.
There are equipped with throttle valves at the inlet & outlet, so the filling speed can be
adjusted based on material viscosity.
B. The cooling speed & temp depends on actual materials.
2) Machine performance
● With PLC to control & touch screen to operate, easy to set parameters;
● With fault self-detecting function, it's clear to know the problems.
● Filling nozzles are equipped with heat-persevering & anti-dripping function,
● Material contacting parts adopt top-quality stainless steel, delicate & durable.
● The hopper above is equipped with auto material feeding device; the machine
designed with labor adding material into hopper time to time considering small filing
volume.
● Easy & quick to adjust filling dosage; touch screen digital shows, easy to adjust.

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 Auto menthol box filling cooling production line
● Most parts are connected with quick-joint, easy to dismantle, clean & install
● No bottle no filling, auto counting with high automation
● Linear bottle in & out, adjusting bottles without tools in several mins without tools.

● All machine is mainly made of SUS304,

● Equipped with voltage transformer to protect the machines.

4. Installation & adjustment

1) Before adjusting machine, pls check if mechanical & electrical parts are normal,
specifically:
● Power socket, voltage & frequency is right or not, also the earth connection condition
● The quick-joint is connected accurately or tightly
● If filling nozzle adjusted vertically well.
● The air source of compressor goes directly via plastic tube with diameter of 12mm to
air tube joint of pressure-adjusting valve; push air slipping valve & make it at on state,
pull up the handle of pressure-adjusting valve & adjust the pressure to about 0.6Mpa,
then press the handle & lock it.

2) Function brief introduction

See II, 2, main structure introduction

3) Main adjustment of separate structure

If u want the cylinder movement of some structure, pls switch to Manual Operation on
the screen, then touch repeatedly at the adjusting item, the relative cylinder moves, &
can be adjusted.
After adjusting, pls try if each part works well in manual state, and go to auto running
after all movement is ok.
Here the machine only 3-part adjustment for different bottles while production shift.

1) The whole position adjustment of filling bottles

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guardrail

Bottle-in blocking
plate with cylinder
Bottle-out
blocking plate

The empty bottles are on the conveyor, approximately under the central position of lifter;
adjust the bottle-blocking cylinders, the block rods of the left & right bottle-blocking
cylinders should be adjusted at the same level, then start conveyor, let the bottle go.
Note: Don't make the guardrails of the conveyor too narrow, & leave the bottle to
guardrail 2mm space & make bottle center at the central of conveyor too.
A: the adjustment of bottle-out blocking plate
This plate functions as positioning the filling bottles.
Adjusting way: After the whole position adjustment of filling bottles, loose the
screws of bottle-blocking plate, slid the whole plate left to right, until the
bottle-blocking plate accurately to the edge of the rightest bottle, then close the screws.
B: the adjustment of bottle-in blocking plate
This plate functions as separating the filling bottles from unfilled bottles. Adjusting
way is the same as the bottle-out plate way.

2) The adjustment of photoelectricity/sensor

Bottle-in Bottle out

sensor sensor
position position

Photoelectrical sensor is used to check & count bottles, also it has function of no
filling while no bottle or no enough bottles. With bottle-in sensor & bottle-out sensor,
when it runs, bottle-out blocking plate stretches out, then bottle-in sensor counts, when
it counts to 4 bottles, the bottle-in blocking plate stretches out, the machine auto finishes
bottle-clipping, filling nozzle inserting into bottles & filling. After filling, bottle-out
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 Auto menthol box filling cooling production line
blocking plate retracts, filled bottles go out one by one, bottle-out sensor counts, when
counts to 4 bottles, bottle-out blocking-plate stretches out. Like this go round & round.
A: Sensor position adjustment
Move sensor stand, aim the sensor probe of back sensor directly to bottle neck next to
the right of back blocking plate; adjust front sensor to bottle neck next to the right of
front blocking plate.
B: Adjustment of probing light intensity
Find the sensor adjusting button, use a small screwdriver to adjust.
Notice: The light intensity should be adjusted too strong, or it'll cause object reflection
from long-distance & result in movement mistakenly.

3) The adjustment of filling dosage

It's a must to re-adjust the filling dosage when change filling different dosages. This
filler adopts touchscreen to adjust dosage. Pls refer the following touch screen operation

5.The usage of touch screen (i will update the correct one soon

tomorrow)
1) Make sure the suitable power connection, then turn on power switch,power indicator is light,
& it comes with welcome picture; appears language option picture.

2) Click relative English language sign on above picture, & the relative auto
operation screen comes out; the operators can start relative buttons & alter data
based on actual production needs.

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1) it means “machine running state”:

There are 3 states, Emergency Stop state, manual state & auto running state.

2) Manual/Auto running option

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3) Auto material refilling switch: Auto material feeding/refilling

starts after auto mode, when material is full in the hopper, auto feeding stops; when
liquid in the hopper reaches upto low-level, auto refilling/feeding starts again.It can be
controlled separately

4) It shows the output of this shift.

Press , the output will be 0.

5) Machine washing setting:

Machine washing times setting

Press for upto 2 seconds, it can start washing.

After pressing the washing on, the piston moves & cylinder comes back one time, it
mean wash one time, after it finishes the preset washing times, it stops washing.

6) the bottle-in delay time for auto mode:

It means the delay time from bottle-in finish to next movement(bottle-in display is the
same as the filling bottles qty)
When bottle-in displays 4, it begins bottle-in delay, when delay time is up, bottle-in
bottle-blocking cylinder moves. Yellow frame is bottle-in delay display, green frame is
the bottle-in delay setting.
This time shouldn’t be set too short, or the bottle-blocking cylinder will stuck bottles
easily when bottles haven’t stopped stably.

7) It means the delay time from filling over to

filling head lifting over, and this delay is the time to continue next movement, it can
avoid material on the filling nozzles dropping on the conveying belt. When filler is
equipped with leakage-collecting device, make bottle-out delay “0” to enhance
efficiency.

8) Liquid refill times, it means at auto state, setting

the moving times of filling cylinder, when it reaches the times, the refilling starts

9) conveying belt speed setting, the running speed is

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 Auto menthol box filling cooling production line
just its running rounds per minute

10) At auto state, when it reaches the

duration time after sensor detects bottles are full on the conveying belt, then it stops the
bottle turntable motor running

11) At auto state, when it reaches the

duration time after sensor doesn’t detect bottles on the conveying belt, then it starts the
bottle turntable motor running

12) 1~4# filling

nozzle dosage setting

13) press it, it comes to Manual operation. It’s often used for
machine readjustment when there is production change & malfunction detection

14) Press this, it comes to PLC input & output check

pictures

4) Press on “Auto Operation", the “Manual Operation"

comes out like following

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 Auto menthol box filling cooling production line

4) Press on “Auto Operation", the “Check picture"

comes out like following, mainly for breakdown checking

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 Auto menthol box filling cooling production line

Input & output is mainly used for monitoring if PLC gets or outputs signals.

Input signals includes switches, sensors & encoders ect.

Output signals is mainly for PLC output controlling equipment, like

solenoid valves, relays, inverters & servo motors

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 Auto menthol box filling cooling production line

4) Encoder pulse & filling volume conversion picture

Press the right corner of the Initial picture above, it can go to the conversion pictures,
like the following

Conversion way:

Press , let the filling cylinder go to the end, it reads encoder

max value, then use this max value divides the max piston volume, for example, if it
reads max value 3456, then the acceptable value 3400/141.3＝24.0622788393489.

So the input value should be 2406 then. When there is big

difference between the touch screen preset filling dosage & the actual filling volume,
it’s ok to alter this value to make the actual filling dosage is close to or equal to the
preset filling dosage.
The encoder reads differently each time because of the match factor of encoder &
machine, generally speaking, the pulse difference around several dozens is common.

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 Auto menthol box filling cooling production line

setting encoder & cylinder stroke display. It doesn’t matter to set or not. If
setting is needed, pls make the encoder max value divide the cylinder stoke, & make the
result integer

5) If emergency occurs during production, pls press Emergency-STOP button, and

see if the electricity should be cut off based on actual condition; when it's solved,
pls adjust 'Emergency-stop' to Release state.

6. Common malfunction & fault-clearance

Malfunction Possible causes & solution
Machine no running Check E-stop switch, air source, power switch, air switch &
power socket are in the normal work state or not
Touch screen black screen No electricity connection or touch screen broken
Make E-stop back to normal state
Operating touch screen, no Touch screen broken
reaction The main power is not on
Check sensor position suitable or not
Adjust the sensor light to suitable intensity
Sensor counting wrongly check machine if the ground connection ok or not
Check if there is sth on sensor probe
check if the indicator of sensor amplifier light or not
If sensor no light: sensor amplifier no voltage input, or amplifier
Sensor no counting is broken
Check if there is sth on sensor probe
Check the sensor position suitable or not
Adjust sensor light intensity to suitable one
Check motor normal or not

Check if speed-adjusting button broken

Check if motor has voltage input
Conveyor no work
Check if conveyor belt is stuck or not

Check motor is stuck or not

Check motor is burnt or not
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 Auto menthol box filling cooling production line
Some work position not in normal state, magnetism switch
doesn't sensor
Machine suddenly no work Check if magnetism switch is broken or magnetism switch not in
suitable position
Check if Emergency-stop switch broken
PLC is interrupted by some strong signal
PLC is broken
Check if the air supply is between 0.4-0.6MPa
Cylinder doesn’t move Check if the air tube is stuck between cylinder & magnetic valves
Check if magnetic valve is broken or if it core is stuck
Check if compressor or compressing valve is on
Check if air switch & power switch is on
Check air pressure up to 0.6Mpa
Piston can't move up & Check if pneumatic valve is installed correctly
down Check O-type ring of piston head is viscous, thus making
piston-head stick tightly to cylinder wall
check if the front & back magnetism switches on the cylinder are
in the inductive position, or if they r broken
the reaction to high-viscous products should be slow;
Filling precision no upto check sealing parts leaking or not
required standard Check if magnetism switch, cylinder & piston are loose or not
Check the material in the filling hopper is enough or not
Check if O-type ring is broken & result in leakage; or there is air
in
Check if material-refilling system works normally
Material in hopper can't be check if the liquid-levels system in the material hopper of filler
provided/refilled in time work or not
if pump material inlet or air calve is stuck or not
Material leakage around air
tube & cylinder joint Check sealing rings & replace if needed
Can't suck material Check if the single-way valve installed exactly & material inlet
valve leakage or not
Bottle fall or bottle-neck Check if the bottle-blocking cylinder touched bottle, if
lean clipping-bottle cylinder stuck bottleneck; or conveyor speed too

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 Auto menthol box filling cooling production line
fast, or 2 bottle-blocking cylinder in the same line or not
Material overflowing from Check if magnetic switch broken or move to other place, or
bottleneck suddenly check if filling nozzle in the central of bottleneck

Check if cylinder throttle valve is adjusted too fast, thus material

filling to fast

7．Machine circuit (pls see the enclosed)

8．Machine vulnerable spare parts

O-ring viton, inner 28*3.55mm 6pcs
O-ring viton, inner 9*1.8mm 6pcs

Y-ring 6-14-6 6pcs

O-ring viton, outer 20*3mm 6pcs
O-ring viton, outer 10*2mm 6pcs
O-ring viton, outer 28*3mm 6pcs
O-ring butyronitrile, outer 110*3.5mm 2pcs
32 quick joint silicon gasket 8pcs
25.4 quick joint silicon gasket 4pcs
19.05 quick joint silicon gasket 6pcs
38.1 quick joint silicon gasket 2pcs

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