Manual for end user Mini-fill Touch 60/100/230 filling machine
Please keep the original packaging of the Mini-fill filling machine. It must be used for shipping the machine back for repair.
Beldos N.V., Kruiningenstraat 93/95, B-2900, Schoten, Antwerp province, Belgium Phone: +32 3 646 40 48 Fax: +32 3 646 42 46 www.beldos.be Email:
[email protected] Publisher: Beldos N.V. Without permission of the publisher nothing from this folder can be copied. © 01.02.2016
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1. Table of Contents 1.
Table of Contents ................................................................................................................................................. 2
2.
Introduction .......................................................................................................................................................... 3
3.
Declaration of conformity .................................................................................................................................... 4
4.
WARNING & important safety information.......................................................................................................... 5
5.
Filler unit single outlet: assembly, disassembly ................................................................................................... 6
6.
Filler unit double outlet: assembly, disassembly ................................................................................................. 7
7.
Power base: controls and features....................................................................................................................... 8
8.
Operating instructions .......................................................................................................................................... 9 8.1. Start ............................................................................................................................................................... 9 8.2. Deposit modes: single deposit, multiple deposit, continuous .................................................................... 10 8.3 Recipe creation and selection...................................................................................................................... 13 8.4 Update by USB .............................................................................................................................................. 14
9.
Cleaning .............................................................................................................................................................. 15 9.1. Filler unit ...................................................................................................................................................... 15 9.2. Power base .................................................................................................................................................. 15
10.
Maintenance................................................................................................................................................... 16
11.
Wiring diagram ............................................................................................................................................... 21
12.
Trouble shooting............................................................................................................................................. 22
13.
Spare parts...................................................................................................................................................... 24
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2. Introduction Thank you for purchasing Mini-fill filling machine from BELDOS N.V./S.A. You will get years of trouble free use and excellent productivity from your new investment. We strive to manufacture the world’s best single head and multi-head depositors (for depositing, injection, layering and decoration), pumps, cake lines, slicers, etc. BELDOS equipment can be operated in a very easy and efficient way, with a minimum of experience required. We always think together with the customer to find the best solution. BELDOS machines will become the most reliable, easy-to-use and intelligent equipment in your production. Please read this manual to familiarize yourself with the controls, assembly and operating procedure. By carefully following the preventive maintenance indication, your Mini-fill will be your best friend. For any further information concerning your machine or further available options, we always remain at your disposal at the address on the cover of this manual (service contact).
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3.
Declaration of conformity
Name of manufacturer: BELDOS N.V./S.A. Address of manufacturer: Kruiningenstraat 93, B-2900 Schoten, Belgium Name of importer:
………………………………………………………………………..
Address of importer:
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Machine type:
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Model name:
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Serial number:
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Year of construction:
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The undersigned declares that the equipment conforms to the essential health and safety requirements as stated by 2006/42/EG and 2014/35/EU, as a change for 2006/95/EG, directive on machinery and as stated by 2014/30/EU as a change for 2004/108/EG. Signature:
Rudy Van der Linden General Director, Beldos N.V. Date…………………………………………………..
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4. WARNING & important safety information TO REDUCE THE RISK OF FIRE, ELECTRICAL SHOCK, PERSONAL INJURY OR PRODUCT DAMAGE WHEN USING THIS EQUIPMENT, FOLLOW BASIC PRECAUTIONS INCLUDING THE FOLLOWING: TO PROTECT AGAINST RISK OF ELECTRICAL SHOCK, DO NOT PUT POWER BASE IN OR SPRAY WITH WATER OR OTHER LIQUID. UNPLUG THE POWER BASE FROM THE ELECTRICAL OUTLET DURING CLEANING. KEEP HANDS AND FOREIGN OBJECTS OUT OF PUMP INLET AND OUTLET TO AVOID PERSONAL INJURY AND/OR DAMAGE TO EQUIPMENT. DO NOT OPERATE POWER BASE WITH DAMAGED POWER CORD OR PLUG, OR AFTER UNIT HAS BEEN DROPPED OR DAMAGED IN ANY MANNER. DO NOT USE AN EXTENSION CORD WITH THIS UNIT. SUCH USE MAY RESULT IN FIRE, ELECTRICAL SHOCK OR OTHER PERSONAL INJURY. TOUCH SCREEN: ONLY USE FINGERS FOR SELECTING PARAMETERS ON THE TOUCH SCREEN. IT IS FORBIDDEN TO USE KNIVES, SPOONS OR OTHER SHARP OBJECTS FOR SELECTING PARAMETERS ON THE TOUCH SCREEN. ATTENTION THE USER ASSUMES ALL RESPONSIBILITY FOR SAFETY AND ANY USE NOT IN ACCORDANCE WITH THESE INSTRUCTIONS. FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN FIRE, ELECTRICAL SHOCK OR OTHER PERSONAL INJURY.
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5. Filler unit single outlet: assembly, disassembly
1. Place O-ring (1) in Groove of Pump Cover (2). 2. Place Impellers (3, 4) onto Shafts (5, 6). After assembly, verify proper meshing of Impellers by turning them by hand. Impellers must mesh without binding. 3. Place Bearing (7) on Shaft (6). 4. Place Pump Cover (2) with Impellers (3, 4) into Filler Unit (8). 5. Fasten Pump Cover (2) in Filler Unit (8) with Screws (9) and hand tighten only. Make sure that all Screws are tightened evenly. 6. Place O-ring (10) on the required spout and lock it in place with Nut (11). 7. To disassemble Filler Unit, reverse procedure.
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6. Filler unit double outlet: assembly, disassembly
1. Place O-ring (1) in Groove of Pump Cover (2). 2. Place Impellers (3, 4) onto Shafts (5, 6). After assembly, verify proper meshing of Impellers by turning them by hand. Impellers must mesh without binding. 3. Place Bearing (7) on Shaft (6). 4. Place Pump Cover (2) with Impellers (3, 4) into Filler Unit (8). 5. Fasten Pump Cover (2) in Filler Unit (8) with Screws (9) and hand tighten only. Make sure that all Screws are tightened evenly. 6. Place Injection Spouts and turn 1/4 to lock in place. No O-ring required. 7. To disassemble Filler Unit, reverse procedure.
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7. Power base: controls and features
1. Power cord. 2. Power switch - Turns power on and off. 3. Filler Unit. 4. Power base. 5. Safety clamp - Secures filler unit to power base. 6. Trip arm - When depressed it will activate the power base. Suitable for left and right handed operators. 7. Handles - For convenient lifting of the power base. 8. Remote triggering receptacle - Receives a foot switch or other remote triggering devices. 9. Pump driver - Engages filler unit and transmits power to it. 10. Touch screen - Controls all power base functions. 11. Power cord receptacle - Receives detachable power cord.
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8. Operating instructions 8.1. Start 1 2 3 4
Plug Power cord (1) into a GROUNDED electrical outlet. Switch power ON (2). Place the Filler Unit (3) onto the Power base (4). Press HOPPER POSITIONING to bring up the Gear Selection menu.
4.1
OPTIONAL: if using a pneumatic machine, press the AIR button. The light in the corner should go on.
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Choose which hopper is connected. The Pump driver (9) will engage and align the pump shaft with the drive shaft.
5 6 7
Lock the Filler unit (3) on to the Power base (4) with Safety clamp (5). Insert spouts in Filler Unit (3). Lock them in place with the provided nut. Place product in the Filler Unit (3). To ensure consistent dosing, make sure product is free from lumps and air pockets. Use the pressure disk if the product is aerated.
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To prime pump, press VOLUME and select CONTINUOUS , then press and hold Trip Arm (6) until product has begun to exit the Spout(s). Release Trip Arm (6) to stop.
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8.2. Deposit modes: single deposit, multiple deposit, continuous a. SINGLE DEPOSIT
1. Select QUANTITY. 2. Fill in 1 to get one deposit every time you press the handle. 3. Press OK
Volume – select the required deposited volume
Suckback – select the required volume of the suckback to prevent dripping of the product after the deposit Speed – select the speed of depositing
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1. Press VOLUME on the touch screen. 2. Select the required Volume in ml. 3. Press OK
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ATTENTION! This value is an estimate and may not be 100% correct depending on the product used. 1. Press SUCKBACK on the touch screen. 2. Select the required amount (0 – 100). 3. Press OK
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1. Press SPEED on touch screen. 2. Select the desired speed (0 - 100%). 3. Press OK
.
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b. MULTIPLE DEPOSITS
Select ‘multiple deposit’ to get the installed number of deposits every time you press the command. This function is used to relieve the operator from repeatedly pressing the command. It can also be used to deposit product on a moving conveyor. ATTENTION! The operator can start/stop the machine any moment by pressing the handle!
Quantity – select the required number of automatic deposits
1. Press QUANTITY on the touch screen. 2. Select the required amount of deposits.
VOLUME – select the required deposited volume
1. Press VOLUME on the touch screen. 2. Select the required Volume in ml.
SUCKBACK – select the required volume of the suckback to prevent dripping of the product after the deposit WAITING TIME – select the waiting time between each deposit – used only for multiple deposits
3. Press OK
3. Press OK
.
.
ATTENTION! This value is an estimate and may not be 100% correct depending on the product used. 1. Press SUCKBACK on the touch screen. 2. Select the required amount (0 – 100). 3. Press OK
.
1. Press WAITING TIME on the touch screen. 2. Select the required amount. 3. Press OK
.
ATTENTION! This is in 0,1 seconds; 10 = 1 second.
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SPEED – select the speed of the depositing
c. CONTINUOUS DOSING
1. Press SPEED on touch screen. 2. Select the desired speed (0 - 100%). 3. Press OK
.
Select continuous to get a continuous flow of product. Press and keep the handle and the unit will start. Release the command and the unit will stop. To select continuous 1. Press Volume 2. Press the CONTINUOUS
button.
The machine now displays volume 0 and starts counting up while depositing.
ATTENTION – during continuous operation, please leave SUCKBACK and VOLUME at 0 and QUANTITY at 1. SPEED
1. Press SPEED on touch screen. 2. Select the desired speed (0 - 100%). 3. Press OK
.
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8.3 Recipe creation and selection Save current settings as new recipe
1. With the correct settings selected, press SAVE RECIPE. 2. Fill in the desired name and press OK 3. Press ADD 4. Press INSERT 5. Press HOME
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to add the new recipe on the bottom of the list. to add the recipe above the selected recipe. to return to the Main Menu.
Choose recipe from the list
1. Press CHOOSE RECIPE and select the desired recipe from the list.
Change settings of an existing recipe
1. Choose the recipe that needs to be changed (see previous step). 2. Change the Volume, Suckback, Speed, Quantity and Waiting Time as desired. 3. Press SAVE RECIPE.
2. Press HOME
to return to the Main Menu.
4. Optional: choose a different name. Press OK 5. Press UPDATE
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6. Confirm by pressing OK Delete a recipe from the list
.
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7. Press HOME to return to the Main Menu. 1. Press SAVE RECIPE. 2. Skip the name creation by pressing OK . 3. Select the recipe that needs to be deleted. 4. Press DELETE
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5. Confirm by pressing OK 6. Press HOME
.
to return to the Main Menu.
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8.4 Update by USB Update the software
1. Turn off the machine. Put the USB in the USB-port. 2. Turn on the machine. Check the new software version number during booting (date and number). 3. Press Advanced Settings. 4. Press Load From USB. Wait 10 seconds, if no errors appear, you are done.
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9. Cleaning 9.1. Filler unit EMPTY SPOUT/HOSE
Press SUCKBACK on the touch screen and select 100 (maximum). Press OK. Press Volume on the touch screen and select 1. Press the handle to activate the reverse mode and to empty the spout or the handgun hose from the rest of products back into the filler unit.
To disassemble the pump house please refer to articles 4 and 5 of this manual. All parts from the synthetic filler units are dishwasher safe.
9.2. Power base WARNING: To protect against electrical shock unplug Power Base from electrical outlet. Do not place power base in water or any other liquid. Clean exterior of base using a DAMP CLOTH ONLY.
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10.
Maintenance
Power bases are maintenance free. The synthetic single and double fillers units have replaceable shaft seals and nylon support bearings, which after a period of use may have to be replaced. To replace proceed as follows: 1. Remove Clamp (10, 13). 2. Pull out Shaft (6, 7) from Pump Cover (1). 3. Pry out worn Seal (3). Be careful not to damage the Shaft Sealing Surface. Scratches on this surface will shorten seal life. 4. Clean Seal Cavity to remove all foreign material. 5. Slide Washer (4) on Shaft (6, 7). 6. Apply suitable lubricant to the inside diameter of seal only (3). 7. Slide new seal as shown on the drawing (3) over Shaft (6, 7). 8. Slide the Shaft (6, 7) with Washer (4) and Seal (3) into Seal Cavity. 9. Lock the Shaft (6, 7) with Clamp (10, 13). Filler units MFA001033, MFA001034
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1. Remove Clamp (10, 13). 2. Pull out Shaft (8, 7) from Pump Cover (1). 3. Pry out worn Seal (4). Be careful not to damage the Shaft Sealing Surface. Scratches on this surface will shorten seal life. 4. Clean Seal Cavity to remove all foreign material. 5. Slide Washer (5) on Shaft (8, 7). 6. Apply suitable lubricant to the inside diameter of seal only (4). 7. Slide new seal as shown on the drawing (4) over Shaft (7, 8). 8. Slide the Shaft (7, 8) with Washer (5) and Seal (4) into Seal Cavity. 9. Lock the Shaft (7, 8) with Clamp (10, 13). Filler units MFA000075, MFA000174
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1. Remove Clamp (10). 2. Pull out Shaft (8, 7) from Pump Cover (11). 3. Pry out worn Seal (6), be careful not to damage the Shaft Sealing Surface. Scratches on this surface will shorten seal life. 4. Clean Seal Cavity to remove all foreign material. 5. Slide Washer (4, 5) on Shaft (7). 6. Apply suitable lubricant to the inside diameter of seal only (5). 7. Slide new seal as shown on the drawing (5) on Shaft (7). 8. Slide the Shaft (7, 8) with Washer (4) and Seal (5) into Seal Cavity. 9. Lock the Shaft (7) with Clamp (10). Filler units MFA000475, MFA000476
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1. Remove Clamp (11). 2. Pull out Shaft (6, 7) from Pump Cover (1). 3. Pry out worn Seal (4). Be careful not to damage the Shaft Sealing Surface. Scratches on this surface will shorten seal life. 4. Clean Seal Cavity to remove all foreign material. 5. Slide Washer (3) on Shaft (6, 7). 6. Apply suitable lubricant to the inside diameter of seal only (4). 7. Slide new seal as shown on the drawing (4) over Shaft (6). 8. Slide the Shaft (6, 7) with Washer (3) and Seal (4) into Seal Cavity. 9. Lock the Shaft (6) with Clamp (11). Filler units MFA000477, MFA000478
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1. Remove Clamp (11). 2. Pull out Shaft (4, 8) from Pump Cover (1). 3. Pry out worn Seal (7). Be careful not to damage the Shaft Sealing Surface. Scratches on this surface will shorten seal life. 4. Clean Seal Cavity to remove all foreign material. 5. Slide Washer (6) on Shaft (4). 6. Apply suitable lubricant to the inside diameter of seal only (7). 7. Slide new seal as shown on the drawing (7) over Shaft (4). 8. Slide the Shaft (4, 8) with Washer (6) and Seal (7) into Seal Cavity. 9. Lock the Shaft (4) with Clamp (11). Filler units MFA000076, MFA000175
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11.
Wiring diagram
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12.
Trouble shooting
Filler unit single outlet Problem
Cause
Solution
The machine stops and gives a signal, gears/impellers are not turning. The touch screen displays the ERROR message Blocking of the machine while dosing batter with chocolate chips
Product is too viscous or speed is too high
Switch off power to reset overload. Reduce speed OR change viscosity of product. Use a stronger power base (230 W)
Using of wrong impeller system
Use a filler unit with 3 lobe system
Mousse came out clotted
Use of 400 mm extension spout is too long + speed too high
Use a shorter spout 158 mm and reduce speed and start with 40% and go up till e.g 60%
Chocolate mousse is very liquid and dripping
Use of the wrong power base
Use the electro-pneumatic Mini-fill; reverse mode max. 3 and speed starting at 40%
Fruit filling with pieces; pieces were crushed
Wrong impeller and speed too high
Use 3 lobe impeller and reduce speed
Dosing is not accurate
Suck back setting is too high
Reduce the suck back setting
Pastry tip is too big or too small
Try another pastry tip. The product should not drip between deposits
The nozzle or pastry tip touches the product
Do not touch the product with a pastry tip or a nozzle while dosing
The speed is too fast
Reduce the speed
The product is too viscous or not well mixed or with air bubbles
Improve the viscosity of product and make it homogeneous
Product is not smooth and soft enough
Product should be smooth and have room temperature
Not enough pressure to push the product through the impeller system
Use the following plate (stainless steel)
The speed is too fast
Reduce the speed
Using of wrong needles or a wrong impeller system
Use a filler unit with a single outlet and a needle
Filler unit double outlet Dosing is not accurate while injection with nutella (chocopaste)
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of 11,1 mm diameter Generally not accurate dosing (cream)
Speed is too high
Reduce the speed
There is not enough product in the hopper
Fill the hopper completely
No pressure disk used
Use the pressure disk
Viscosity of the product is too high
Do not use products with high viscosity
Wrong pastry tip
Try to dose products without a pastry tip on the nozzle or use another pastry tip
Wrong setting of the Reverse Mode
Do not use the Reverse Mode
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13.
Spare parts
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MFA000075
MFA000174
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MFA000475
MFA000476
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MFA000477
MFA000478
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MFA000076
MFA000175
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Single outlet hoppers
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Double outlet hoppers
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