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SV 125
4016589

Personnel training

Version 1.0

Instructed

persons

Persons with

technical

qualification

Employee with

electrical

qualification

Superior with

appropriate

competence

Packaging,

transport

Commissioning

Startup

Troubleshooting

Troubleshooting,

mechanical

Troubleshooting,

electrical

Installation,

preparation

Maintenance

Reparation

Switching off,

storage

Summary of Contents for SV 125

Page 1: ...bH Schwaebisch Hall Germany Translation of the original operating manual Operating Manual Fully Automatic Filling And Closing Machine For Syringes SV 125 Customer AP Pharma Inc USA Machine no 4016589 Year of manufacture 2011 ...

Page 2: ...pharma 03 2013 This documentation is protected by copyright All rights reserved No part of this documentation may be translated reproduced stored in a retrieval system or transmitted in any form or by any means graphic electronic or mechanical in cluding photocopying recording taping without the prior permission of the pub lishers The right to make technical modifications is reserved ...

Page 3: ...2 2 Check of safety devices 1 7 1 2 2 1 POWER supply disconnecting device 1 8 1 2 2 2 Compressed air supply disconnecting device 1 8 1 2 2 3 EMERGENCY STOP buttons 1 8 1 2 2 4 Guard doors 1 8 1 2 3 Danger and information signs 1 9 1 2 3 1 Examples of danger signs 1 9 1 3 Duties of the plant operator 1 10 1 3 1 Warranty and liability 1 10 1 3 2 Organizational requirements 1 10 1 3 3 Personnel requi...

Page 4: ...nt operated protective devices RCD 1 18 1 7 1 Mains connection 1 18 1 8 General information about risks 1 19 1 8 1 Residual risk 1 19 1 8 2 Dangers from residual energy 1 20 1 8 3 Informal safety measures 1 20 1 8 4 Personnel training 1 20 1 8 5 Safety measures during normal operating mode 1 21 1 8 6 Harmful fumes 1 22 1 8 7 Noise emission 1 22 2 Transport installation and connection 2 1 2 1 Items...

Page 5: ... EMERGENCY STOP buttons 3 6 3 6 Interfaces and connections 3 7 3 7 Identification of the machine 3 8 3 7 1 Nameplate 3 8 3 8 Technical specifications 3 9 3 8 1 General data 3 9 3 8 2 Power supply 3 9 3 8 3 Formats 3 10 3 8 4 Output 3 10 3 8 5 Ambient conditions 3 10 3 9 Machine accessories 3 11 4 Structure and function 4 1 4 1 General 4 1 4 1 1 Intended use of the machine 4 1 4 1 2 Reasonably fore...

Page 6: ...ling station with vacuum filling 4 12 4 2 10 1 Sensor Syringe too high after filling 4 13 4 2 11 Stopper sorter and stopper lanes 4 14 4 2 11 1 Filling the stopper lanes with stoppers 4 15 4 2 12 Stopper insertion station 4 16 4 2 12 1 Sensors of the stopper insertion station 4 17 4 2 13 Vacuum stopper insertion station 4 18 4 2 13 1 Sensor Syringe too high after stopper insertion 4 20 4 2 14 Evac...

Page 7: ...ty Code screen 1 2 5 12 5 2 9 Security Code screen 2 2 5 13 5 2 10 Security Code function 1 2 5 14 5 2 11 Security Code function 2 2 5 16 5 2 11 1 Security Code help 5 18 5 2 12 Security Parameter 5 19 5 2 13 Security User account 5 20 5 2 14 Security User password 5 23 5 2 14 1 Security User account help 5 25 5 2 15 Main screen 1 5 26 5 2 16 Main screen 2 5 29 5 2 17 Performance 1 2 5 31 5 2 18 P...

Page 8: ... input Pick up station 1 2 5 63 5 2 38 Format input Pick up station 2 2 5 65 5 2 38 1 Format input Pick up station help 5 67 5 2 38 2 Format input Pick up station help 5 68 5 2 39 Format input Piston pumps 1 3 5 69 5 2 40 Format input Piston pumps 2 3 5 71 5 2 41 Format input Piston pumps help 5 74 5 2 42 Format input Piston pumps 3 3 5 75 5 2 43 Format input Filling curve piston pumps 1 2 5 77 5 ...

Page 9: ...5 2 51 1 Format input Stopper setting help 5 113 5 2 52 Format input Stopper setting vacuum 1 3 5 114 5 2 53 Format input Stopper setting vacuum 2 3 5 116 5 2 53 1 Format input Stopper setting vacuum help 5 119 5 2 54 Format input Stopper setting vacuum 3 3 5 120 5 2 54 1 Format input Stopper setting vacuum help 5 123 5 2 55 Format input Tub transfer 1 4 5 124 5 2 55 1 Format input Tub transfer he...

Page 10: ...o axis pump rotation 5 158 5 2 68 1 Teach in servo axis 5 159 5 2 69 Format input Teach servo axis X 5 161 5 2 69 1 Teach in servo axis 5 162 5 2 70 Format input Teach servo axis Y 5 164 5 2 70 1 Teach in servo axis 5 165 5 2 71 Format input Alarm active 5 167 5 2 72 Service Menu 5 169 5 2 73 Service General 5 170 5 2 74 Service Axis 5 173 5 2 75 Service Vacuum 5 175 5 2 76 Operator Menu 5 177 5 2...

Page 11: ...um 2 2 5 199 5 2 94 Information Axis position actual and homestatus 5 200 5 2 95 Batch 5 202 5 2 96 System Password 5 203 5 3 Control and display elements on the machine 5 204 5 3 1 Overview 5 204 5 3 2 Jog cable and jog button 5 205 5 3 3 Air maintenance unit 5 206 5 3 4 Compressed air supply disconnecting device 5 207 5 3 5 Adjustment of vacuum tanks 5 208 5 3 6 Pressure reducer Ventilation vacu...

Page 12: ...rocess 6 9 6 3 3 Transport out nest 6 9 6 3 4 Emptying mode 6 10 6 3 5 EMERGENCY STOP 6 11 6 4 Monitoring operation 6 12 7 Format change 7 1 7 1 Mechanical format change 7 3 7 1 1 Overview 7 3 7 1 2 Dismounting the size parts 7 4 7 1 2 1 Filling needles size part 22 7 4 7 1 2 2 Drive head with shut off needles size part 24 7 5 7 1 2 3 Sorting bowl size part 7 7 7 7 1 2 4 Stopper lanes size part 8 ...

Page 13: ...7 15 7 1 2 16 Tub stopper size part 1 2 3 7 15 7 1 2 17 Suction frame nest pick up station size part 5 5 1 7 16 7 1 3 Mounting the new size parts 7 17 7 1 4 Format settings 7 18 7 1 4 1 Overview 7 18 7 1 4 2 Height adjustment for hold down device 7 19 7 1 4 3 Height adjustment side guide 7 20 7 1 4 4 Installation template side guide 7 21 7 1 4 5 Adjustment vacuum tanks filling and stopper insertio...

Page 14: ... Priming 9 10 9 2 6 1 Priming in Automatic mode 9 10 9 2 6 2 Priming in Setup mode 9 11 9 3 Maintenance and care 9 12 9 3 1 General 9 12 9 3 2 Instructions for procedure 9 13 9 4 Lubrication plan 9 14 9 4 1 Overview of maintenance points 9 15 9 4 2 Maintenance plan interval 8 operating hours 9 16 9 4 2 1 Check compressed air supply 9 16 9 4 3 Maintenance plan interval 40 operating hours 9 17 9 4 3...

Page 15: ...tenance plan interval 1000 operating hours 9 21 9 4 5 1 Lubricate pump drive 9 21 9 4 6 Maintenance plan interval As required 9 22 9 4 6 1 Nest pick up station replace vacuum cups 9 22 9 4 6 2 Replace battery Panel view 9 25 10 Appendix 10 1 ...

Page 16: ...Contents SV 125 4016589 XIV ...

Page 17: ...chine at all times The manual must be ready to hand at all times Danger symbols Symbols identify safety instructions in the operating manual They indicate special dangers for persons property or environment Please observe these instructions Pass on all safety instructions to other users The danger symbols that are used in this operating manual are listed in chapter 1 1 4 page 1 4 General danger El...

Page 18: ...jury Material damage to the machine Information symbols Symbol Signal word Signal color Definition NOTE Blue User tips and other important useful in formation and instructions 1 Next to this symbol you will find an action sequence the order of which must be maintained without fail 1 Numbers next to photos and drawings refer to machine assemblies and ma chine components mentioned in the text These ...

Page 19: ...ent Machine In this operating manual the term machine is identical with plant several machines stations that are combined to one function unit Plant operator Liable person or organisation responsible for machine operation Operator operating personnel Persons who operate the machine or perform operations on the machine Manufacturer Liable person or organisation responsible for the manufacture of th...

Page 20: ...Notes SV 125 4016589 Version 1 0 Page 4 ...

Page 21: ...served by all persons who work on the machine Furthermore the rules and regulations regarding accident prevention valid for the place of installation must be observed 1 1 2 Dangers in handling the machine WARNING A defective or badly maintained machine increases the risk of acci dents Only operate the machine in a technically faultless condition The machine has been built in accordance with state ...

Page 22: ...Signal color Definition Effects DANGER Red Imminent danger Death or severe in jury WARNING Orange Potentially dange rous situation Potential death or severe injury CAUTION Amber Potentially dange rous situation Slight or minor injury Material damage to the machine Information symbols Symbol Signal word Signal color Definition NOTE Blue User tips and other important useful in formation and instruct...

Page 23: ... commissioning operation and maintenance of the ma chine S operation of the machine using defective safety devices or safety and guard devices that have not been properly attached or that are not operable S non compliance with the instructions and information in the operating manual with regard to transport storage installation commissioning opera tion maintenance and setup of the machine S unauth...

Page 24: ...on that raises doubt to safety S Do not climb on or into the machine while the machine is running S Do not make any modifications or conversions to the machine S Keep the work area clean The following designations and symbols might be used in the operating manual Danger Warning Caution Electrical voltage current Danger of burning from warmth and heat Crushing of hands and limbs The machine is not ...

Page 25: ...k of tripping Blade hazard for hands and limbs Entanglement of hands and limbs Entanglement of hands and limbs Automatic start Wear protection goggles Wear gloves Read operating manual NOTE Persons with pacemakers are not allowed in this area Do not drill ...

Page 26: ...6 Incorrect use The machine must only be operated as described in chapter 1 1 5 Intended use Any use that extends beyond this is not allowed danger of injury due to non inten ded use Furthermore the operation of the machine is not allowed S with power sources media or products that are not constituent part of the or der confirmation S with hazardous substances that in any way might have detrimenta...

Page 27: ...onnecting device main switch lockable S Compressed air supply disconnecting device lockable S EMERGENCY STOP buttons S Casings and guard doors S Stacklight 1 2 2 Check of safety devices DANGER Increased danger of accident if the safety devices or protective equip ment are defective or inactive Check all safety devices S after switching the machine on S after each maintenance or repair S at least o...

Page 28: ...ed air supply disconnecting device S Turn off compressed air supply disconnecting device Message Compressed air missing is displayed The machine cannot be started 1 2 2 3 EMERGENCY STOP buttons S Press each EMERGENCY STOP button individually Message EMERGENCY STOP pressed is displayed The machine cannot be started 1 2 2 4 Guard doors S Open each guard door individually Message Guard door open is d...

Page 29: ...igns The danger and information signs on the machine S must not be removed S must be clearly legible Check them regularly NOTE Order missing or illegible danger and information signs via spare parts catalog and attach them to the respective position 1 2 3 1 Examples of danger signs ...

Page 30: ...per handling maintenance or storage of the machine S a non intended use of the machine S non compliance with the instructions and information in the operating manual S changes to or rebuilding of the machine without written authorization of the manufacturer 1 3 2 Organizational requirements The plant operator must train and instruct the operating personnel with the help of this operating manual or...

Page 31: ...erformed only by qualified authorized persons 1 4 Information regarding safety at work WARNING In case of improper use danger to person or damage to property can arise Observe the basic safety instructions about occupational safety 1 4 1 Information regarding operation and work practices S Do not climb on or into the machine S Do not reach over or under protective covers that are open on top or bo...

Page 32: ...e with sound protection Observe the pre scribed breaks and use them for recreation 1 4 2 First aid Observe the local safety instructions for first aid Observe information relating to available facilities like Emergency phone or first aid kit 1 4 2 1 Accident report Immediately inform supervisors and OPTIMA GROUP pharma about accidents and hazard sources If you rapidly inform about hazard sources t...

Page 33: ... reach into the machine subframe while the machine is run ning In case of intervention the respective body parts are crushed DANGER Only trained and qualified personnel are allowed to perform repair work on the machine Company working instructions and operating instructions and relevant accident prevention regulations must be observed DANGER Electric shocks can cause severe burns and life threaten...

Page 34: ...rmed on the machine When replacing large sized subassemblies fasten and secure them carefully to hoists Attach a danger sign prohibiting it from being switched back on Use only original spare parts of the manufacturer The installation of other parts can lead to hazards This excludes any liability of the manufacturer 1 5 1 Constructional changes to the machine Do not carry out any modifications att...

Page 35: ...ine Always comply with the manufacturer s instructions 1 5 3 Disposal of the used substances and materials Handle and dispose of the substances and materials used in the proper manner in particular S when working on lubrication systems and devices and S when cleaning with solvents Always deliver all waste material such as lubricants and detergents to the defined disposal facility Reintroduce recyc...

Page 36: ...6 2 Measures in the event of faults or defects Eliminate any defect on electrical equipment immediately In case of imminent danger do not operate the machine Before starting work ensure that the electrical equipment is de energized If work must be performed on electrically live components S Use insulated tools only 1 6 3 Safety devices WARNING When the POWER supply disconnecting device is turned o...

Page 37: ...r in compliance with the safety regulations 1 6 4 Dangers from electrical power DANGER Electric shocks can cause severe burns and life threatening injuries Have any work on the electrical supply system performed by a certified electrician only Regularly check the electrical equipment of the machine Rectify immediately any loose connections or charred cables DANGER Electric shocks can cause severe ...

Page 38: ...idual current operated protective device RCD is not allowed 1 7 1 Mains connection Connection to mains with residual current operated protective device RCD is only allowed if the residual current operated protective device RCD is triggered by the following earth residual currents S alternating residual currents S intermittent direct residual currents S flat direct residual currents S nearly flat d...

Page 39: ... S live voltages and currents We have minimized this risk through safety engineering and design Respect the danger areas CAUTION During machine operation the motors can become very hot Risk of suffering burns when touching the motors DANGER Through the crushing of jammed objects splinters or product can be uncontrollably flung out in all directions and eyes can be injured If the machine is operate...

Page 40: ... safety measures The operating manual has to be kept next to the machine at all times In addition to the operating manual the generally valid regulations and local regulations con cerning accident prevention and environmental protection must be provided and observed Keep all safety instructions and danger signs on the machine in a legible condition and renew them as necessary 1 8 4 Personnel train...

Page 41: ...otrude from the base mounting e g operator panel chute Before switching the machine on make sure that nobody can be endangered by the machine starting up Inspect the machine for externally detectable damage and for the operability of the safety devices at least once a day On all OPTIMA GROUP pharma machines observe the safety regulations in con formity with the accident prevention regulations Pack...

Page 42: ...ecautions Harmful fumes can escape during operation of the machine Make provision for sufficient exhaust ventilation 1 8 7 Noise emission The continuous acoustic level emitted by the machine amounts to 80 dB A Depending on local conditions a higher acoustic level can occur that causes noise deafness In such case the operating personnel must be safeguarded by means of appropriate protective equipme...

Page 43: ... Transport of the machine to the place of installation has to be effected by means of a pallet lifter or a fork lift truck WARNING Use only lifting gear and suspension devices that have a sufficient load bearing capacity The permissible lifting weight of the lifting device must not be ex ceeded Stipulate a proficient marshalling person for the lifting procedure WARNING Increased risk of accidents ...

Page 44: ...ay Remove all tools and pack them separately Secure all movable and non fastened parts 2 2 3 Center of gravity mark If the center of gravity is not in the center of the transport case a mark is applied on the transport case that indicates the actual center of gravity 2 2 4 Transport with pallet lifter When inserting the tines of the pallet lifter take care not to damage protruding parts handwheel ...

Page 45: ...machine The tines must protrude on the other side of the machine 2 3 Storage and conservation To keep an unused machine operable over a long period of time observe the fol lowing instructions S The storage room must be clean and dry S Do not expose the machine to extreme cold or heat S Place the machine on a flat floor S Do not unpack the machine ...

Page 46: ...ue to electromagnetic compatibility EMC the machine is only al lowed to be operated within the industrial sector Adjust the transfer height to the machines connected to this installation 1 Place a level device on several places of the base mounting and the sub frame of the machine 2 Align the machine horizontally by adjusting the spindle feet Make sure the weight of the machine is evenly distribut...

Page 47: ... cables match those on the sockets on the control cabinet Check that the motors turn in the correct direction Prior to connecting to the power supply system observe the information provided in the wiring diagram installation plan in particular the com patibility with any residual current protection device provided on site Connect media supply NOTE Media supply must be connected by qualified person...

Page 48: ... 2 5 1 Scrapping and disposal Please supply the materials of the used machine to an ecofriendly and expert dis posal Always protect the environment Remove all traces of oils and other environ mentally hazardous substances Deliver hazardous substances such as lubricants or batteries to an authorized disposal facility The machine can be separated into the following material groups S metals S electro...

Page 49: ...SV 125 4016589 Description of the machine Version 1 0 3 1 3 Description of the machine 3 1 Views of the machine Top view ...

Page 50: ...Description of the machine SV 125 4016589 3 2 Version 1 0 3 2 Workplace ...

Page 51: ...f the machine Version 1 0 3 3 3 3 Guard doors NOTE The operator is separated from the danger area of the machine by guard doors and covers Guard door 1 Guard door 2 Guard door 3 Guard door 4 Guard door 5 Guard door 6 Guard door 7 ...

Page 52: ...ion of the machine SV 125 4016589 3 4 Version 1 0 3 4 Danger areas WARNING In the areas marked with this danger sign a danger of crushing exists from moving parts at the machine and at the infeed and discharge ...

Page 53: ...5 DANGER Electric shocks can cause severe burns and life threatening injuries Electrical equipment can be energized Before working on electrical equipment turn off the POWER supply dis connecting device and disconnect the mains supply of the control cab inet ...

Page 54: ...Description of the machine SV 125 4016589 3 6 Version 1 0 3 5 EMERGENCY STOP buttons 1 2 1 On operator panel 2 On machine ...

Page 55: ...SV 125 4016589 Description of the machine Version 1 0 3 7 3 6 Interfaces and connections 1 2 1 Connection power supply 2 Connection compressed air supply ...

Page 56: ...achine SV 125 4016589 3 8 Version 1 0 3 7 Identification of the machine 3 7 1 Nameplate 4016588 TRB 2011 4016588 4016589 SV 125 2011 4016589 NOTE A respective nameplate is also located on the control cabinet of the machine ...

Page 57: ...pecifications 3 8 1 General data Length with TRB approx 4374 mm Width approx 1809 mm Height approx 2110 mm Working height approx 1120 mm 15 mm Weight SV 125 Control cabinet approx 1880 kg approx 365 kg 3 8 2 Power supply Voltage 3x480 V Connected load __ A Frequency 60 Hz 2 ...

Page 58: ...l 100 3 8 4 Output The maximum output of the machine is 10 000 syringes h The output depends on the syringe size on the fill volume and on the specific qualit ies and the viscosity of the product 3 8 5 Ambient conditions Temperature range 10 35 C 50 95 F Relative air humidity 15 80 condensation free ...

Page 59: ...the machine Version 1 0 3 11 3 9 Machine accessories Standard accessories are S Operating manual S Operating manual of sub supplied parts S Spare parts catalog S Wear parts list Check the tools and auxiliary devices for completeness ...

Page 60: ...Description of the machine SV 125 4016589 3 12 Version 1 0 ...

Page 61: ... use of the machine Any damage resulting from non intended use will not be covered by the manufac turer Only products that have been agreed with OPTIMA GROUP pharma may be processed 4 1 2 Reasonably foreseeable misuse The fully automatic filling and closing machine must not be used S to fill and close unspecified packaging containers S to fill hazardous products WARNING Risk of injury through a no...

Page 62: ...me with stainless steel casing S Polycarbonate machine guarding The guard doors are safeguarded by door safety switches S Transport belt S Nest pick up station S Fully automatic X Y table S Dosing station with rotary piston pumps S Filling station S Filling station with vacuum filling S Sorting system S Stopper insertion station S Stopper insertion station with vacuum stopper insertion S Operator ...

Page 63: ...ected to the nest insertion position At the same time another tub arrives at the nest pick up station The X Y table transports the syringes to the filling station for filling Rotary piston pumps dose the quantity of the product that is to be filled The dosage is filled into the syringes via filling station The stoppers are transported in correct position from the sorting bowl into the stop per lan...

Page 64: ...Structure and function SV 125 4016589 4 4 Version 1 0 4 2 Functional description 4 2 1 Overview 1 2 3 14 5 6 7 8 9 11 12 10 4 15 13 ...

Page 65: ... the tub on the infeed chute by hand 4 2 3 Tub support 2 C B In the Tyvek Removal Box the operator has to put the tub manually into the tub sup port B Then the operator pulls off the Tyvek foil manually and removes the Tyvek inlay sheet on the tub Tyvek foil and Tyvek inlay sheet are disposed of through an opening in the machine table C into a waste container ...

Page 66: ...ansport belt 3 D The operator takes the tub out of the Tyvek Removal Box and places it on the trans port belt D The transport belt transports the tubs to the nest pick up station of the SV 125 E Tub stopper 1 infeed gate E separates the tubs on the transport belt ...

Page 67: ... G Tub stopper 2 F stops the tubs at the nest pick up station Sensor Tub present G checks if a tub is present at tub stopper 2 H I Tub stopper 3 H stops the tubs at the nest insertion position Sensor Tub present I checks if a tub is present at tub stopper 3 ...

Page 68: ... pick up station J takes the nest out of the tub and puts it down on the nest centering device of the X Y table When the nest has been taken out of the tub tub stopper 2 releases the tub for further transport and the empty tub is transported on to the nest insertion position via transport belt ...

Page 69: ...insertion station After nest transfer the X Y table performs a shaking movement to fix the syringes The number of shaking movements can be set on the operator panel see chapter 5 2 57 page 5 131 ff 4 2 7 Nest centering device 6 L The nest centering device L positions the syringes for filling and closing and holds them in position during the filling and closing process ...

Page 70: ...s The dosing quantity is adjusted on the operator panel 4 2 8 1 Functional description rotary piston pump When the pump piston moves up filling product is drawn in via the intake hose The continuous rotation of the piston alternately opens the intake inlet and dosing outlet on the pump cylinder Through the following down movement of the pump piston the fill product is pumped to the dosing hose via...

Page 71: ...ling needles N are lowered down into the syringe barrels The syringes are filled in rows Sensor Overload filling needle O checks if a filling needle has been pushed out of the holder The machine stops immediately The cause of the fault must be elim inated Then the respective filling needle must be positioned again ...

Page 72: ... move into the syringes and fill them with the provided product via rotary piston pumps When the filling needles have reached a certain position during the filling process the vacuum valves close after a presettable time After the filling the vacuum chamber is lifted up from the syringes During the lifting process the filling heads of the vacuum chamber are vented via venting valve of the vacuum f...

Page 73: ...g CAUTION Laser class 2 When working with or near the laser wear protection goggles Do not stare into the laser beam R Sensor Syringe too high after filling R checks if a syringe has been pulled up and out of the nest after the filling process As soon as a syringe is detected the machine stops The respective syringe must be positioned correctly by hand ...

Page 74: ...e operator must fill the sorting bowl manually via chute T The stopper lanes U transport the stoppers to the transfer piece Sensors Min accumulation stopper lanes V check if sufficient stoppers are present in the individual stopper lanes If there are not sufficient stoppers present the machine stops As soon as the stopper lanes are filled with stoppers again the machine restarts automatically ...

Page 75: ...stopper lanes and wait for stopper accumu lation S When the stoppers start to accumulate slightly increase the speed of the stopper lanes S Repeat the process gradually increasing the stopper lane speed by 5 to 10 S Only when all stopper lanes and the transfer piece are completely filled with stoppers the originally preset stopper lane speed can be entered NOTE Visually check the correct orientati...

Page 76: ...he insertion tubes The stopper turning device swivels back The hold down device Y is positioned above the syringes The insertion rods press the stoppers to the lower end of the insertion tubes Then the insertion tubes and the stopper insertion rods move into the syringes on insertion position When they have reached insertion position the insertion tubes move up while the stopper insertion rods rem...

Page 77: ...tects an insertion tube the machine stops Afterthe cause of the fault has been eliminated the respective insertion tube must be positioned correctly by hand Sensor Stopper inserted AB checks if stoppers have been inserted in the syr inges Through the stoppers that have been inserted the stopper insertion rod is pressed up If no stopper has been inserted the stopper insertion rod remains in positio...

Page 78: ...tion system with sterile filters and shut off valves In order to largely avoid a reaction of the fill product with the ambient atmosphere and to avoid atmospheric inclusions in the syringe the air is evacuated from the syringes by a vacuum insertion rod holder AC before the stopper insertion pro cess starts For that purpose the vacuum insertion rod holder moves over the syringes seals them and gen...

Page 79: ...od holder is vented to release the filling heads from the syringes Sterile air or nitrogen can be used for venting 2 vacuum sensors are installed in the vacuum pipe system One of these sensors monitors the vacuum in the vacuum tank the second sensor monitors the vacuum in the syringe These sensors continuously check if sufficient vacuum is present If the vacuum falls under a presettable value the ...

Page 80: ...CAUTION Laser class 2 When working with or near the laser wear protection goggles Do not stare into the laser beam AD Sensor Syringe too high after stopper insertion AD checks if a syringe has been pulled up and out of the nest after the stopper insertion process As soon as a syringe is detected the machine stops The respective syringe must be posi tioned correctly by hand ...

Page 81: ...ion 1 0 4 21 4 2 14 Evacuation station 13 AE AF AG AH The vacuum pump for filling AE and the vacuum pump for stopper insertion AF evacuate the respective vacuum tanks Vacuum tank for vacuum stopper insertion AG Vacuum tank for vacuum filling AH ...

Page 82: ...awn out of the syringes and vacuum lines Vacuum sensors AJ monitor the values that have been preset on the operator panel The lower sterile filters AK prevent particles from flowing over the product during venting the upper sterile filters AL prevent particles or product from flowing into the vacuum tanks during the evacuation process ...

Page 83: ...ng plate of the X Y table and on the nest insertion position places the nest in the empty tub Tub stopper 3 AM stops the empty tub at the nest insertion position Sensor Tub present AN checks if a tub is present at the nest insertion position If a tub is present the nest pick up device lowers down and the nest is inserted in the tub After the nest has been inserted in the tub tub stopper 3 releases...

Page 84: ...ansport belt AO transports the tubs on to the downstream machine 4 2 17 Particle counting tube AP The particle counting tubes AP monitor the atmosphere in the machine The cus tomer evaluates the detected values The particle counting tubes are not represented in the overview on page 4 4 ...

Page 85: ...irborne germ collectors AQ The airborne germ collectors that are positioned on the supports AQ monitor the clean room conditions in the machine The customer evaluates the detected val ues The airborne germ collectors are not represented in the overview on page 4 4 ...

Page 86: ...Structure and function SV 125 4016589 4 26 Version 1 0 ...

Page 87: ... It is operated by touching the represented control and input fields 2 EMERGENCY STOP The button serves to stop the machine immediately in event of danger Turn the button to unlock it 3 Key switch setup mode automatic mode The machine can be switched between Setup mode and Automatic mode 4 Control voltage Illuminated push button to switch on the control voltage ...

Page 88: ...16589 5 2 Version 1 0 6 5 5 Interface connection The Ethernet interface connection is located on the bottom side of the oper ator panel 6 Socket for jog cable The socket is located on the bottom side of the operator panel ...

Page 89: ...access rights The values that might be indicated are not representative 5 2 1 1 Changing the values NOTE To enter values a keyboard is automatically displayed on the screen as soon as the operator touches e g an input field When data entry is terminated the keyboard is removed automatically Dependent on the input field the screen keyboard offers keys for purely numeric or alphanumeric data entry ...

Page 90: ...ion The user is logged out Screen Log in is called up Screen Security Menu is called up only possible with the required user access rights Screen Software is called up The machine drive is switched off The system is shut down only possible with the required user access rights Screen Clean screen is called up Clean the screen Do not use solvents or other aggressive substances to clean the screen ...

Page 91: ...SV 125 4016589 Operation Version 1 0 5 5 Function Control field Screen Main screen is called up Screen Info OPTIMA GROUP pharma is called up ...

Page 92: ...Operation SV 125 4016589 5 6 Version 1 0 5 2 3 Info OPTIMA GROUP pharma Address data of the company OPTIMA GROUP pharma GmbH are displayed Control field Function The Start screen is called up ...

Page 93: ...2 4 Clean screen Touch control field on the Start screen The surface of the screen can be cleaned When the cleaning has ended the Start screen is displayed automatically NOTE Do not use solvents or other aggressive substances to clean the screen ...

Page 94: ...oftware Display of the current version of the machine program Display software Display of the current version of the display program Controller Display of the installed controller type Serial number Display of the serial number of the installed controller type Control field Function The machine drive is switched off The previous screen is called up ...

Page 95: ...ssword on the keyboard 6 Touch control field on the keyboard to take over the entry 7 Touch control field to end the log in process After a correct userid and its correct password have been entered message Password ok is displayed on the screen then the screen closes If an incorrect userid has been entered message User not found is dis played and the screen remains on the display If an incorrect p...

Page 96: ...ed message Password ok is dis played on the screen then the screen closes If an incorrect password has been entered message Password incorrect is displayed and the screen remains on the display 8 Touch control field to end the log in process Control field Function Entry of a user name Entry of the password Ends the log in process Change of password only possible with the required user access right...

Page 97: ...ubmenus of the password administration can be selected Control field Function Screen Security Code screen is called up Screen Security Code function is called up Screen Security Parameter is called up Screen Security User account is called up The machine drive is switched off The previous screen is called up ...

Page 98: ...en which should be assigned to another user group With all users the screen can be assigned to all user groups The screen is assigned to a certain usergroup by touching the input field again Afteruser level P the user levels start again from all users 2 Repeat the step for all screens that should be changed Control field Function Screen Security Code help is called up The machine drive is switched...

Page 99: ...the control field of the screen which should be assigned to another user group With all users the screen can be assigned to all user groups The screen is assigned to a certain usergroup by touching the input field again Afteruser level P the user levels start again from all users 2 Repeat the step for all screens that should be changed Control field Function Screen Security Code help is called up ...

Page 100: ...ser groups can be assigned to various functions Shut down operator panel The system is shut down Reset counter production The production counter is reset Reset timer production The operation hour timer is reset Format copy An existing format is copied to be used as a pattern for a new format Format change Another format can be selected ...

Page 101: ... a function 1 Touch the input field next to the function whose assignment should be changed With all users the function can be assigned to all user groups The function is assigned to a certain usergroup by touching the input field again Afteruser level P the user levels start again from all users 2 Repeat the step for all functions that should be changed Control field Function Screen Security Code...

Page 102: ...n screen Security Code function 1 2 The individual user groups can be assigned to various functions Teach in axis Teach in of the axes can be performed Teach in start filling Teach in of the starting point for filling can be performed Teach in step point Teach in of the step points can be performed ...

Page 103: ...he function can be assigned to all user groups The function is assigned to a certain usergroup by touching the input field again Afteruser level P the user levels start again from all users 2 Repeat the step for all functions that should be changed Control field Function Screen Security Code help is called up The machine drive is switched off The previous screen is called up ...

Page 104: ...1 1 Security Code help Touch control field on screens Security Code screen or Security Code function Information about the individual user groups is displayed Control field Function The machine drive is switched off The previous screen is called up ...

Page 105: ...rs of which a password must be composed can be set 3 characters are preset Changing the password minimum length 1 Touch input field 2 Enter the number of characters on the numeric keypad 3 Touch control field on the numeric keypad to take over the entry Control field Function The machine drive is switched off The previous screen is called up ...

Page 106: ... control field on the keyboard to take over the entry 4 Touch input field Full name 5 Enter the full name of the user on the keyboard 6 Touch control field on the keyboard to take over the entry 7 Touch input field User name 8 Enter the user name on the keyboard Log in is performed with this user name 9 Touch control field on the keyboard to take over the entry 10 Activate or deactivate option Cha...

Page 107: ...ng the check box and enter the number of minutes on the input field Touch input field Enter the number of minutes on the keyboard Touch control field on the keyboard to take over the entry 14 If user access should be disabled after a preset number of incorrect pass word entries activate option Disable account at XXX errors by touching the check box and enter on the input field the number of incorr...

Page 108: ...umber and enter the number of the user who should be changed or 1 Touch control field or and select the user who should be changed 2 Change the desired user data The password can only be changed by the user himself Alternatively a new password can be assigned as described in chapter 5 2 14 page 5 23 3 Touch control field to save the changes of the user Control field Function Scrolls the defined us...

Page 109: ...th of the password is defined on screen Security Para meter 3 Touch control field on the keyboard to take over the entry 4 Touch control field 5 Re enter the new password on the keyboard 6 Touch control field on the keyboard to take over the entry After a correct password has been entered message Password ok is dis played on the screen then the screen closes If an incorrect password has been enter...

Page 110: ... 4016589 5 24 Version 1 0 Control field Function Entry of the new password Entry of the new password for confirmation Saves the newly defined password The machine drive is switched off The previous screen is called up ...

Page 111: ...user groups A P are displayed and can be changed Changing the designation of a user group 1 Touch the input field next to the user group whose designation should be changed 2 Enter the new designation on the keyboard 3 Touch control field on the keyboard to take over the entry Control field Function The machine drive is switched off The previous screen is called up ...

Page 112: ...rt screen The following information is displayed Pending error messages Date and time Format Current format number and current format name System System speed as percent of the maximum speed Cycles minute Machine performance in cycles per minute Syringes hour Machine output in syringes per hour ...

Page 113: ...he batch number The display is continuously updated Control field Function Scrolls up the list of error messages Scrolls down the list of error messages The machine drive is switched on The sorting device is switched on or off The transport belts are switched on or off The venting of hoses and pumps Priming is switched on or off Screen Alarm Menu is called up Alarms messages are reset The machine ...

Page 114: ...ion Control field Screen Main Menu is called up The infeed gate is opened or closed The nest processing is completed then the nest is transported out Screen Performance is called up The previous screen is called up Screen Main screen 2 is called up ...

Page 115: ... and time The display is continuously updated Control field Function Scrolls up the list of error messages Scrolls down the list of error messages The machine drive is switched on Function Weighing in is activated 5 syringes are filled Then the nest is transported out The operator can weigh the syringes Normal nest processing continues Screen Alarm Menu is called up ...

Page 116: ...125 4016589 5 30 Version 1 0 Function Control field Alarms messages are reset The machine drive is switched off The processing of the nest is aborted and the nest is transported out The previous screen is called up ...

Page 117: ... control field on the Main screen The working speeds of the following drives are displayed and can be adjusted Speed sorter Speed of the stopper sorting bowl Speed linear track Speed of the stopper infeed rails The speeds are entered as percent value of the maximum speed ...

Page 118: ...ved permanently The speeds of the Format input screen are loaded again at machine restart or after format changeover 4 Touch control field if the speeds should be saved permanently for the selected format Control field Function The entered working speeds are saved permanently for the selected format only possible with the required user access rights The machine drive is switched off Screen Main sc...

Page 119: ... the following drives are displayed and can be adjusted System speed Entry of the speed of the main drive The speeds are entered as percent value of the maximum speed NOTE If the machine is operated with a system speed of 100 it runs with the percent of the speed that is entered in the Format input area see chapter 5 2 35 page 5 59 ...

Page 120: ...eeds are not saved permanently The speeds of the Format input screen are loaded again at machine restart or after format changeover 4 Touch control field if the speeds should be saved permanently for the selected format Control field Function The entered working speeds are saved permanently for the selected format only possible with the required user access rights The machine drive is switched off...

Page 121: ...The submenus for the administration of the error messages can be selected Control field Function Screen Alarm Active is called up Screen Alarm History is called up Screen Alarm Status list is called up The machine drive is switched off The previous screen is called up Screen Main screen is called up ...

Page 122: ... cause of the error message must be eliminated before it can be reset Control field Function The first page of the list of error messages is called up The last page of the list of error messages is called up The previous page of the list of error messages is called up The next page of the list of error messages is called up The previous error message is selected The next error message is selected ...

Page 123: ...SV 125 4016589 Operation Version 1 0 5 37 Function Control field The machine drive is switched off The previous screen is called up ...

Page 124: ...e error messages are sorted according to the frequency of their oc currence Alarm History is completely reset only possible with the required user access rights The first page of the list of error messages is called up The last page of the list of error messages is called up The previous page of the list of error messages is called up The next page of the list of error messages is called up The pr...

Page 125: ...SV 125 4016589 Operation Version 1 0 5 39 Function Control field Alarms messages are reset The machine drive is switched off The previous screen is called up ...

Page 126: ...to switch over the display All alarms All error messages that might occur on the machine are displayed with indication of the frequency of their occurrence Active alarms The current error messages that have not yet been reset are displayed Past alarms All error messages that have occurred on the machine are displayed with indication of the frequency of their occurrence ...

Page 127: ...nly possible with the required user access rights The first page of the list is called up The last page of the list is called up The previous page of the list is called up The next page of the list is called up The previous error message is selected The next error message is selected Alarms messages are reset The machine drive is switched off The previous screen is called up ...

Page 128: ...n be selected Control field Function Screen Counter Production is called up Screen Timer Production is called up Screen Date Time is called up Screen Format Selection is called up Screen Format Copy is called up Screen Format input Menu is called up Screen Service Menu is called up Screen Operator Menu is called up Screen Information Menu is called up ...

Page 129: ...89 Operation Version 1 0 5 43 Function Control field Screen Batch is called up Screen System Password is called up The machine drive is switched off The previous screen is called up Screen Main screen is called up ...

Page 130: ...e ongoing production is displayed The total number of syringes that has been processed by the machine during the ongoing production is displayed Control field Function The counter is reset to 0 only possible with the required user access rights The machine drive is switched off The previous screen is called up Screen Main screen is called up Screen Counter Total is called up ...

Page 131: ...hat has been processed by the machine since machine commissioning is displayed The total number of syringes that has been processed by the machine since ma chine commissioning is displayed The counters cannot be reset Control field Function The machine drive is switched off Screen Main screen is called up The previous screen is called up ...

Page 132: ...e machine has produced and the system time machine has been switched on since production start are displayed Control field Function The timers are reset to 0 only possible with the required user access rights The machine drive is switched off Screen Main screen is called up The previous screen is called up Screen Timer Total is called up ...

Page 133: ...duction On this screen the operation time machine has produced and the system time machine has been switched on since machine commissioning are displayed The timers cannot be reset Control field Function The machine drive is switched off Screen Main screen is called up The previous screen is called up ...

Page 134: ...erator panel and PLC are displayed and can be set Setting date and time 1 Touch the respective input fields New date or New time 2 Enter the new value on the keyboard 3 Touch control field on the keyboard to load the entered value into the memory 4 Touch control field to activate the setting of the new date and or time ...

Page 135: ... 0 5 49 Control field Function The newly entered date and time settings are activated only possible with the required user access rights The machine drive is switched off Screen Main screen is called up The previous screen is called up ...

Page 136: ...ormat is displayed and can be changed Changing the current format 1 Touch control fields or to select a new format or 1 Touch input field Select format Enter the new format on the numeric keypad Touch control field on the numeric keypad to take over the entry 2 Touch control field to load the new format into the memory ...

Page 137: ...at is selected The next format is selected The selected format is loaded into the memory only possible with the required user access rights Screen Format selection Setting is called up The machine drive is switched off Screen Main screen is called up The previous screen is called up ...

Page 138: ...t selection Setting the operator can view format specific data The customer can enter the data on screen Format input Setting The parameters serve for information and do not influence the functionality of the machine Control field Function Screen Main screen is called up The machine drive is switched off The previous screen is called up ...

Page 139: ...0 5 53 5 2 31 Format Copy Touch control field on screen Main Menu An existing format can be copied to be used as a pattern for a new format Source Entry of the number of the source format Destination Entry of the number of the new format ...

Page 140: ...d on the numeric keypad to take over the entry 3 Touch control field to create the new format NOTE Before the copying process starts it is checked if a format with the number of the new format already exists If the format already exists it is only overwritten after confirming the security check Control field Function The new format is created An already existing format is overwritten The copying p...

Page 141: ...rmat input Menu WARNING Only authorized personnel are allowed to perform changes NOTE When screen Format input Menu is called up the machine stops Touch control field on screen Main Menu The submenus for the administration of the formats can be selected ...

Page 142: ... up Screen Format input Piston pumps is called up Screen Format input Filling curve piston pumps is called up Screen Format input Filling curve vacuum piston pumps is called up Screen Format input Stopper setting normal is called up Screen Format input Stopper setting vacuum is called up Screen Format input Tub transfer is called up Screen Format input Main drive virtual is called up The machine d...

Page 143: ...een Format Selection see chapter 5 2 29 page 5 50 is displayed and can be changed Entry of a format name 1 Touch input field Format name 2 Enter the name for the selected format on the keyboard 3 Touch control field on the keyboard to take over the entry Control field Function The machine drive is switched off Screen Main screen is called up The previous screen is called up ...

Page 144: ...w the entered parameters by pressing control field on screen Format Selection The parameters serve for information only and do not influence the functionality of the machine Changing a parameter 1 Touch input field 2 Enter the data 3 Touch control field on the keyboard to take over the entry Control field Function The machine drive is switched off Screen Main screen is called up The previous scree...

Page 145: ...the selected format Speed sorter Speed of the stopper sorting bowl Speed linear track Speed of the stopper infeed rails System speed The speed of the machine is entered The speeds are entered as percent value of the maximum speed NOTE The entered values are automatically taken over on screens Perform ance 1 2 and 2 2 see chapter 5 2 17 page 5 31 and chapter 5 2 18 page 5 33 ...

Page 146: ...eld of the working speed that should be changed 2 Enter the new working speed on the numeric keypad 3 Touch control field on the numeric keypad to take over the entry Control field Function The machine drive is switched off Screen Main screen is called up The previous screen is called up ...

Page 147: ...h Filling system piston pumps is dis played The fact that filling is selected Mode filling normal is displayed The fact that stopper insertion is selected Mode stopper setting normal is dis played Switching stations on or off 1 Touch the respective control field to switch the station on or off When the station is switched on the control field is displayed green When the station is switched off the...

Page 148: ...n or off Sensor Syringe too high after filling is switched on or off The stopper insertion station is switched on or off Multi state control field The stopper insertion mode can be selected here vacuum stopper in sertion The sorting device is switched on or off Sensor Syringe too high after stopper insertion is switched on or off The machine drive is switched off Screen Main screen is called up Th...

Page 149: ...Entry of the upper position of the nest pick up device Upper speed Entry of the speed with which the nest pick up device moves to upper position Wait position mm Entry of the waiting position of the nest pick up device Wait speed Entry of the speed with which the nest pick up device moves to waiting position Pick up nest position mm Entry of the position of the nest pick up device when taking a ne...

Page 150: ...e delay when placing a nest on the nest transport table Changing a parameter 1 Determine the value through teach in see chapter 5 2 60 page 5 137 2 Touch the input field of the parameter that should be changed 3 Enter the determined value on the keyboard 4 Touch control field on the keyboard to take over the entry Control field Function The machine drive is switched off Screen Format input Menu te...

Page 151: ...p XY position mm Entry of the position of the nest pick up device when taking up a nest from the nest transport table Pick up XY speed Entry of the speed with which the nest pick up device moves to pick up position Lay down nest position mm Entry of the position of the nest pick up device when placing a nest in a tub Lay down nest speed Entry of the speed with which the nest pick up device moves t...

Page 152: ... up device moves to waiting position Changing a parameter 1 Determine the value through teach in see chapter 5 2 60 page 5 137 2 Touch the input field of the parameter that should be changed 3 Enter the determined value on the keyboard 4 Touch control field on the keyboard to take over the entry Control field Function The machine drive is switched off Screen Format input Menu teach servo axes is c...

Page 153: ...l field on screen Format input Pick up station 1 2 Information about the moving process of the station is displayed The screen serves for information only No changes can be made Control field Function The machine drive is switched off Screen Main screen is called up The previous screen is called up ...

Page 154: ...l field on screen Format input Pick up station 2 2 Information about the moving process of the station is displayed The screen serves for information only No changes can be made Control field Function The machine drive is switched off Screen Main screen is called up The previous screen is called up ...

Page 155: ...mps 1 3 Touch control field on screen Format input Menu The fill parameters for the rotary piston pumps can be set for the selected format Fill parameter Filling volume ml The fill volume is entered Density g ml The density is entered Filling weight g The weight is entered ...

Page 156: ...rameter that should be changed 2 Enter the value on the keyboard 3 Touch control field on the keyboard to take over the entry Control field Function The machine drive is switched off Screen Main screen is called up The previous screen is called up Screen Format input Piston pumps 2 3 is called up ...

Page 157: ...pumps 1 3 The fill parameters for the rotary piston pumps can be set for the selected format Filling volume ml The fill volume is displayed Filling weight g The fill weight is displayed Density g ml The density is displayed Correction factor The correction factor is entered No of pump stroke The number of pump strokes is entered ...

Page 158: ... is displayed Start dosage ramp The starting point for filling is entered End dosage ramp The stop point for filling is entered Pump diameter mm The diameter of the pump is entered Back absorption distance mm The back absorption is entered Changing a parameter 1 Touch the input field of the parameter that should be changed 2 Enter the value on the keyboard 3 Touch control field on the keyboard to ...

Page 159: ...ield Function The machine drive is switched off Screen Format input Piston pumps help is called up The screen serves for information only Screen Main screen is called up The previous screen is called up Screen Format input Piston pumps 3 3 is called up ...

Page 160: ...rmat input Piston pumps help Touch control field on screen Format input Piston pumps 2 3 This screen visually explains the process Control field Function The machine drive is switched off Screen Main screen is called up The previous screen is called up ...

Page 161: ...on pumps can be set for the selected format Pump rotation Pumping volume ml The pumping volume is entered Pumping speed The speed for pumping is entered Reject after filling stop Max time without filling s Maximum time in case of machine standstill after which the filled product is classi fied as bad No of syringes to reject obj Number of objects that are classified as bad ...

Page 162: ...the input field of the parameter that should be changed 2 Enter the value on the keyboard 3 Touch control field on the keyboard to take over the entry Control field Function The machine drive is switched off Screen Main screen is called up The previous screen is called up ...

Page 163: ... set for the selected format No of filling positions The number of filling positions is entered No of rows filling stopper setting The number of rows between filling and stopper insertion is entered Changing a parameter 1 Touch the input field of the parameter that should be changed 2 Enter the determined value on the keyboard 3 Touch control field on the keyboard to take over the entry ...

Page 164: ...125 4016589 5 78 Version 1 0 Control field Function The machine drive is switched off Screen Main screen is called up The previous screen is called up Screen Format input Filling curve piston pumps 2 2 is called up ...

Page 165: ...red Needle stroke Upper position mm Upper position of the filling needle above the syringe Lower position mm Lowest position of the filling needle Start dosage position inc Position of the filling needle where the dosing station starts the filling process The position must lie between upper and lower position End dosage position inc Position of the filling needle where the dosing station stops the...

Page 166: ...are deleted The needle stroke does not move to the deleted step points any longer Step point no Selection of a step point Step point position mm Entry of the step point position of the selected step point number Segment type Selection of a filling curve for a step point To each step point a segment type can be assigned Either a linear or cubic filling curve can be selected see sketch be low For th...

Page 167: ...nput field of the parameter that should be changed 3 Enter the determined value on the keyboard 4 Touch control field on the keyboard to take over the entry Control field Function Screen Format input Menu teach servo axes is called up A test filling is performed Preparatory operations A spillage tray has been placed under the filling station By touching this control field the pump module automatic...

Page 168: ...sion 1 0 Function Control field Screen Format input Filling curve pump stroke 1 help is called up The screen serves for information only The machine drive is switched off Screen Main screen is called up The previous screen is called up ...

Page 169: ...e syringe on input field Upper position Determine the value through teach in 2 Enter the lowest position of the filling needle inside the syringe on input field Lower position Determine the value through teach in 3 Enter the position where the filling starts on input field Start dosage position 4 Enter the position where the filling ends on input field End dosage position 5 Touch control field to ...

Page 170: ...ontrol field on screen Format input Filling curve piston pumps 2 2 This screen visually explains the process Illustration of the teach in positions for several step points per filling Control field Function The machine drive is switched off Screen Main screen is called up The previous screen is called up ...

Page 171: ...ontrol field on screen Format input Filling curve piston pumps 2 2 This screen visually explains the process Illustration of the teach in positions for several pump strokes per filling Control field Function The machine drive is switched off Screen Main screen is called up The previous screen is called up ...

Page 172: ...step points Dosing start should be 190_ Sketches 1st step point Dosing start 180_ 320_ 190_ 233 55_ 2nd step point 3rd step point 277 11_ 43 55_ Master position approx 2 mm 1st step point 2nd step point 3rd step point We recommend to move the filling needle approx 2mm above fill level after every step point ...

Page 173: ...ve the needle to its lowest position in the syringe by touching control field to move the filling needle to the lowest position in the syringe Note down the value 4 Touch control field The dosing is performed in steps Touch control field and move the needle to the first step point We recommend to move the filling needle approx 2mm above fill level Note down the value For the two remaining step poi...

Page 174: ...er position and enter the upper position of the filling needle above the syringe 7 Enter the noted values for step points 1 through 3 one after the other on input field Step point no Assign to each step point the curve of the fill volume on input field Segment type ...

Page 175: ...filling can be set for the selec ted format No of filling positions The number of filling positions is entered No of rows filling stopper setting The number of rows between filling and stopper insertion is entered Changing a parameter 1 Touch the input field of the parameter that should be changed 2 Enter the determined value on the keyboard 3 Touch control field on the keyboard to take over the e...

Page 176: ... 4016589 5 90 Version 1 0 Control field Function The machine drive is switched off Screen Main screen is called up The previous screen is called up Screen Format input Filling curve vacuum piston pumps 2 4 is called up ...

Page 177: ...n pumps 1 4 The parameters for the needle stroke during vacuum filling can be entered Needle stroke Upper position mm Upper position of the filling needle above the syringe Upper speed Speed with which the filling needle moves to upper position Lower position mm Lowest position of the filling needle Lower speed Speed with which the filling needle moves to lower position ...

Page 178: ...dosing start is between 180 to 250 The dosing range is determined within the area of 180 to 320 No of step points Enter the number of step points If the number of step points is reduced all addi tional step points are deleted The needle stroke does not move to the deleted step points any longer Step point no Selection of a step point Step point position mm Entry of the step point position of the s...

Page 179: ... Pump stroke no Display of the current pump stroke Step point no Display of the current step point NOTE An example for the entry of step points can be found in chapter 5 2 46 1 page 5 95 Changing a parameter 1 Determine the value through teach in see chapter 5 2 60 page 5 137 2 Touch the input field of the parameter that should be changed 3 Enter the determined value on the keyboard 4 Touch contro...

Page 180: ...ally moves to one step point after the other During that process dosing is performed in steps Screen Format input Filling curve vacuum piston pumps help is called up The screen serves for information only Screen Format input Filling curve vacuum pump stroke 1 help is called up The screen serves for information only The machine drive is switched off Screen Main screen is called up The previous scre...

Page 181: ... 3 step points Dosing start should be 190_ Sketches 1st step point Dosing start 180 320 190 233 55 2nd step point 3rd step point 277 11 43 55 Master position approx 2 mm 1st step point 2nd step point 3rd step point We recommend to move the filling needle approx 2mm above fill level after every step point ...

Page 182: ...s in this example 3 3 Call up screen Format input Teach servo axis needle stroke and touch control field to move the filling needle to the lowest position in the syr inge Note down the value 4 Touch control field The dosing is performed in steps Touch control field and move the needle to the first step point We recommend to move the filling needle approx 2mm above fill level Note down the value Fo...

Page 183: ...pillage tray is positioned under the filling station to collect the product that is emerging from the filling needles Mode of procedure 1 Enter the upper position of the filling needle outside the syringe on input field Upper position Determine the value through teach in 2 Enter the lowest position of the filling needle inside the syringe on input field Lower position Determine the value through t...

Page 184: ...um filling can be entered Needle stroke Evacuate position mm Entry of the filling needle position in downward movement where the vacuumvalve is switched on Delay start shaking ms Delay for the shaking of the filling needle Position vacuum off mm Entry of the position where the vacuum is switched off The position is on the up ward movement of the filling needle Shake Upper position mm Upper positio...

Page 185: ...Closing needle CAM ROT position actual Display of the current cam position of the filling needles during pump rotation Closing needle open Entry of the cam parameters when the shut off needles open Changing a parameter 1 Determine the value through teach in see chapter 5 2 60 page 5 137 2 Touch the input field of the parameter that should be changed 3 Enter the determined value on the keyboard 4 T...

Page 186: ...called up The screen serves for information only Screen Format input Filling curve vacuum pump stroke 1 help is called up The screen serves for information only The machine drive is switched off Screen Main screen is called up The previous screen is called up Screen Format input Filling curve vacuum piston pumps 4 4 is called up ...

Page 187: ...on screen Format input Filling curve vacuum piston pumps 2 4 or 3 4 This screen visually explains the process Illustration of the teach in positions dur ing vacuum filling for one pump stroke per filling Control field Function The machine drive is switched off Screen Main screen is called up The previous screen is called up ...

Page 188: ...n screen Format input Filling curve vacuum piston pumps 2 4 or 3 4 This screen visually explains the process Illustration of the teach in positions dur ing vacuum filling for several step points per filling Control field Function The machine drive is switched off Screen Main screen is called up The previous screen is called up ...

Page 189: ...top ms When the entered time has elapsed the evacuation process during filling is abor ted e g in case of leakage Vacuum start filling ms If the entered time has elapsed and the pressure that has been entered on field Vacuum start filling mbar has been reached the vacuum filling starts Vacuum start filling mbar After the indicated pressure and the time that has been set on field Vacuum start filli...

Page 190: ...r the entered time Delay aeration on ms Delay with which aeration is switched on Delay aeration off ms Delay with which aeration is switched off Leaktest limit difference mbar The limit value that the pressure is allowed to drop during leak test is entered Min vacuum tank filling mbar Entry of the required minimum pressure that must be reached in the vacuum tank before the vacuum valve opens Actua...

Page 191: ...uch the input field of the parameter that should be changed 3 Enter the determined value on the keyboard 4 Touch control field on the keyboard to take over the entry Control field Function The leak test during filling is switched on or off The machine drive is switched off Screen Main screen is called up The previous screen is called up ...

Page 192: ...nsertion can be entered No of stopper lanes The number of stopper infeed rails is entered Delay sorter off s When the preset time has elapsed after machine stop the sorter is switched off Changing a parameter 1 Touch the input field of the parameter that should be changed 2 Enter the value on the keyboard 3 Touch control field on the keyboard to take over the entry ...

Page 193: ...n the control field is displayed green When the station is switched off the control field is displayed grey Control field Function The Min accumulation sensor of the indicated stopper lane 1 5 is switched on or off The machine drive is switched off Screen Main screen is called up The previous screen is called up Screen Format input Stopper setting normal 2 3 is called up ...

Page 194: ...tting normal 1 3 The parameters for stopper insertion can be entered Insertion tube Stopper height correction mm The stopper height is entered Stopper setting position mm Entry of the stopper position inside the syringe Master position The position of the master is entered Master position calc The calculated position of the master is displayed ...

Page 195: ... filling mm The stopper insertion position in case of fault during filling is displayed Lower border position stopper setting normal mm Entry of the lower position from the stopper insertion rod to the insertion tube Changing a parameter 1 Touch the input field of the parameter that should be changed 2 Enter the value on the keyboard 3 Touch control field on the keyboard to take over the entry Swi...

Page 196: ...itched on or off Screen Format input Menu teach servo axes is called up Screen Format input Stopper setting help is called up The screen serves for information only The machine drive is switched off Screen Main screen is called up The previous screen is called up Screen Format input Stopper setting normal 3 3 is called up ...

Page 197: ... stopper insertion can be entered Stopper swivel arm Position front The front position of the stopper turning device is entered Position rear The back position of the stopper turning device is entered Changing a parameter 1 Touch the input field of the parameter that should be changed 2 Enter the value on the keyboard 3 Touch control field on the keyboard to take over the entry ...

Page 198: ...d Function Screen Format input Menu teach servo axes is called up Screen Format input Stopper setting help is called up The screen serves for information only The machine drive is switched off Screen Main screen is called up The previous screen is called up ...

Page 199: ...ormat input Stopper setting help Touch control field on screen Format input Stopper setting This screen visually explains the process Control field Function The machine drive is switched off Screen Main screen is called up The previous screen is called up ...

Page 200: ...er insertion can be entered No of stopper lanes The number of stopper infeed rails is entered Delay sorter off s When the preset time has elapsed after machine stop the sorter is switched off Changing a parameter 1 Touch the input field of the parameter that should be changed 2 Enter the value on the keyboard 3 Touch control field on the keyboard to take over the entry ...

Page 201: ...n the control field is displayed green When the station is switched off the control field is displayed grey Control field Function The Min accumulation sensor of the indicated stopper lane 1 5 is switched on or off The machine drive is switched off Screen Main screen is called up The previous screen is called up Screen Format input Stopper setting vacuum 2 3 is called up ...

Page 202: ...or vacuum stopper insertion can be entered Insertion tube Stopper height correction mm The stopper height is entered Stopper setting position mm Entry of the stopper position inside the syringe Plunger Stopper transfer position mm Entry of the stopper transfer position in the insertion tube Stopper setting position mm Entry of the lowest stopper position in the insertion tube ...

Page 203: ...pper setting position error vacuum mm The stopper insertion position in case of vacuum faults is entered Position evacuate mm Display of the position where the evacuation of the syringe starts Position vacuum off mm Entry of the position where the vacuum is switched off Position lower border vacuum mm Entry of the lower position from the stopper insertion rod to the insertion tube Stopper swivel a...

Page 204: ...tion is switched on the control field is displayed green When the station is switched off the control field is displayed grey Control field Function Stopper insertion in case of fault during filling is switched on or off Screen Format input Menu teach servo axes is called up Screen Format input Stopper setting vacuum help is called up The screen serves for information only The machine drive is swi...

Page 205: ...ut Stopper setting vacuum help Touch control field on screen Format input Stopper setting vacuum 2 3 This screen visually explains the process Control field Function The machine drive is switched off Screen Main screen is called up The previous screen is called up ...

Page 206: ...as passed the evacuation process during vacuum stop per insertion is aborted Vacuum start stopper setting ms When the entered time has passed and the pressure that has been entered on field Vacuum start stopper setting mbar has been reached vacuum stopper in sertion starts Vacuum start stopper setting mbar When the entered pressure has been reached and the time that has been set on field Vacuum st...

Page 207: ...lay aeration off ms Delay with which aeration is switched off Leaktest limit difference mbar The limit value that the pressure is allowed to drop during leak test is entered Min vacuum tank stopper mbar Entry of the required minimum pressure that must be reached in the vacuum tank before the vacuum valve opens Actual vacuum tank mbar Display of the current pressure in the vacuum tank Changing a pa...

Page 208: ...eld Function The leak test is switched on for one cycle Screen Format input Stopper setting vacuum help is called up The screen serves for information only The machine drive is switched off Screen Main screen is called up The previous screen is called up ...

Page 209: ... setting vacuum help Touch control field on screen Format input Stopper setting vacuum 3 3 The screen serves for information only No changes can be made Control field Function The machine drive is switched off Screen Main screen is called up The previous screen is called up ...

Page 210: ...s for tub transport can be entered X axis No of syringes Number of syringes per row in X direction 1 stopper row position mm Position of the first stopper row in the nest Last stopper row position mm Position of the last stopper row in the nest Distance nest row mm Display of the row distance in the nest The value is calculated automatically ...

Page 211: ...calculated automatically 2 stopper row 1 syringe mm Position of the 1st syringe in the 2nd stopper row of the nest 2 stopper row 2 syringe mm Position of the 2nd syringe in the 2nd stopper row of the nest Distance 2 nest row mm Display of the syringe distance in the second row The value is calculated automat ically Changing a parameter 1 Determine the values through teach in see chapter 5 2 60 pag...

Page 212: ... input Menu teach servo axes is called up Screen Format input Tub transfer help is called up The screen serves for information only The machine drive is switched off Screen Main screen is called up The previous screen is called up Screen Format input Tub transfer 2 4 is called up ...

Page 213: ...rmat input Tub transfer help Touch control field on screen Format input Tub transfer 1 4 Information about tub transport is displayed Control field Function The machine drive is switched off Screen Main screen is called up The previous screen is called up ...

Page 214: ...ameters for tub transport can be entered X axis Infeed position mm Position of the X Y table on the X axis when a nest is put down Infeed speed Speed with which the X Y table moves on the X axis Y axis Infeed position mm Position of the X Y table on the Y axis when a nest is picked up Infeed speed Speed with which the X Y table moves on the Y axis ...

Page 215: ...iting position Changing a parameter 1 Determine the value through teach in see chapter 5 2 60 page 5 137 2 Touch the input field of the parameter that should be changed 3 Enter the determined value on the keyboard 4 Touch control field on the keyboard to take over the entry Control field Function Screen Format input Menu teach servo axes is called up Screen Format input Tub transfer help is called...

Page 216: ...rmat input Tub transfer help Touch control field on screen Format input Tub transfer 2 4 Information about tub transport is displayed Control field Function The machine drive is switched off Screen Main screen is called up The previous screen is called up ...

Page 217: ...red Y axis No of shake nest Indicates how often the nest is shaken The shaking ensures that the syringes are optimally seated in the nest If shaking is not to be performed enter numeral 0 Shake nest front position mm Front position during nest shaking Shake nest front speed Speed with which the nest is shaken to the front Shake nest rear position mm Rear position during nest shaking ...

Page 218: ...137 2 Touch the input field of the parameter that should be changed 3 Enter the determined value on the keyboard 4 Touch control field on the keyboard to take over the entry Control field Function Screen Format input Menu teach servo axes is called up The machine drive is switched off Screen Main screen is called up The previous screen is called up Screen Format input Tub transfer 4 4 is called up...

Page 219: ...ransport can be entered X axis Y axis Transfer speed Speed with which the X Y table moves on the axis Changing a parameter 1 Determine the value through teach in see chapter 5 2 60 page 5 137 2 Touch the input field of the parameter that should be changed 3 Enter the determined value on the keyboard 4 Touch control field on the keyboard to take over the entry ...

Page 220: ... SV 125 4016589 5 134 Version 1 0 Control field Function Screen Format input Menu teach servo axes is called up The machine drive is switched off Screen Main screen is called up The previous screen is called up ...

Page 221: ...al main drive can be entered Turn speed The speed of the virtual main drive is entered Filling speed The filling speed pump stroke pump rotation needle stroke is entered Changing a parameter 1 Touch the input field of the parameter that should be changed 2 Enter the value on the keyboard 3 Touch control field on the keyboard to take over the entry ...

Page 222: ...Operation SV 125 4016589 5 136 Version 1 0 Control field Function The machine drive is switched off Screen Main screen is called up The previous screen is called up ...

Page 223: ... up NOTE Watch travel movement of axis to avoid collision Control field Function Screen Format input Teach servo axis pick up station nest is called up Screen Format input Teach servo axis plunger is called up Screen Format input Teach servo axis insertion tube is called up Screen Format input Teach servo axis stopper swivel arm is called up Screen Format input Teach vacuum chamber is called up ...

Page 224: ...p Screen Format input Teach servo axis pump stroke is called up Screen Format input Teach servo axis pump rotation is called up Screen Format input Teach servo axis X is called up Screen Format input Teach servo axis Y is called up The machine drive is switched off Screen Main screen is called up The previous screen is called up ...

Page 225: ... nest Touch control field on screen Format input Menu teach servo axes Teach in of the pick up station can be performed Position actual mm The current position of the axis is displayed Position nominal mm Setpoint position to which the axis should move Speed Speed with which the axis should move ...

Page 226: ...ol field on the numeric keypad to take over the entry 3 Touch input field Speed and enter a value 4 Touch control field on the numeric keypad after a value has been entered to take over the entry 5 Touch control field until the axis has moved to the entered setpoint po sition 6 Check position of servo axis and correct it if necessary 7 If the servo axis is correctly positioned read off the current...

Page 227: ...on or off The swivel arm of the pick up station is swivelled into the indicated position The swivel arm of the pick up station is swivelled into the indicated position The swivel arm of the pick up station is swivelled into the indicated position The servo axis is moved It moves as long as the control field is touched The servo axis moves in the indicated direction as long as the control field is ...

Page 228: ...ch control field on screen Format input Menu teach servo axes Teach in of the stopper insertion rod can be performed Position actual mm The current position of the axis is displayed Position nominal mm Setpoint position to which the axis should move Speed Speed with which the axis should move ...

Page 229: ...r a value has been entered to take over the entry 5 Touch control field until the axis has moved to the entered setpoint po sition 6 Check position of servo axis and correct it if necessary 7 If the servo axis is correctly positioned read off the current position 8 Enter the current position on the respective Format input screen Determining the setpoint position by moving the axis directly to the ...

Page 230: ... the control field is touched The servo axis moves in the indicated direction as long as the control field is touched The servo axis moves in the indicated direction as long as the control field is touched Screen Format input Alarm active is called up Alarms messages are reset The previous screen is called up ...

Page 231: ...be Touch control field on screen Format input Menu teach servo axes Teach in of the insertion tubes can be performed Position actual mm The current position of the axis is displayed Position nominal mm Setpoint position to which the axis should move Speed Speed with which the axis should move ...

Page 232: ...r a value has been entered to take over the entry 5 Touch control field until the axis has moved to the entered setpoint po sition 6 Check position of servo axis and correct it if necessary 7 If the servo axis is correctly positioned read off the current position 8 Enter the current position on the respective Format input screen Determining the setpoint position by moving the axis directly to the ...

Page 233: ... the control field is touched The servo axis moves in the indicated direction as long as the control field is touched The servo axis moves in the indicated direction as long as the control field is touched Screen Format input Alarm active is called up Alarms messages are reset The previous screen is called up ...

Page 234: ... arm Touch control field on screen Format input Menu teach servo axes Teach in of the stopper turning device can be performed Position actual The current position of the axis is displayed Position nominal Setpoint position to which the axis should move Speed Speed with which the axis should move ...

Page 235: ...r a value has been entered to take over the entry 5 Touch control field until the axis has moved to the entered setpoint po sition 6 Check position of servo axis and correct it if necessary 7 If the servo axis is correctly positioned read off the current position 8 Enter the current position on the respective Format input screen Determining the setpoint position by moving the axis directly to the ...

Page 236: ...t Value Position nominal for the back position of the stopper turning device is preset The servo axis is moved It moves as long as the control field is touched The servo axis moves in the indicated direction as long as the control field is touched The servo axis moves in the indicated direction as long as the control field is touched Screen Format input Alarm active is called up Alarms messages ar...

Page 237: ...screen Format input Menu teach servo axes The vacuum chamber can be moved Control field Function The vacuum chamber moves into the indicated direction The vacuum chamber moves into the indicated direction Screen Format input Alarm active is called up Alarms messages are reset The previous screen is called up ...

Page 238: ... Touch control field on screen Format input Menu teach servo axes Teach in of the needle stroke axis can be performed Position actual mm The current position of the axis is displayed Position nominal mm Setpoint position to which the axis should move Speed Speed with which the axis should move ...

Page 239: ...r a value has been entered to take over the entry 5 Touch control field until the axis has moved to the entered setpoint po sition 6 Check position of servo axis and correct it if necessary 7 If the servo axis is correctly positioned read off the current position 8 Enter the current position on the respective Format input screen Determining the setpoint position by moving the axis directly to the ...

Page 240: ...ing station The servo axis is moved It moves as long as the control field is touched The servo axis moves in the indicated direction as long as the control field is touched The servo axis moves in the indicated direction as long as the control field is touched Screen Format input Alarm active is called up Alarms messages are reset The previous screen is called up ...

Page 241: ...rol field on screen Format input Menu teach servo axes Teach in of the pump stroke can be performed Position actual mm Display of the current position of the axis Position nominal mm Entry of the setpoint position to which the axis should move Speed Entry of the speed with which the axis should be moved ...

Page 242: ... a parameter has been entered to take over the entry 5 Touch control field until the axis has moved to the entered setpoint po sition 6 Check position of servo axis and correct it if necessary 7 If the servo axis is correctly positioned read off the current position 8 Enter the current position on the respective Format input screen Determining the setpoint position by moving the axis directly to t...

Page 243: ... the control field is touched The servo axis moves in the indicated direction as long as the control field is touched The servo axis moves in the indicated direction as long as the control field is touched Screen Format input Alarm active is called up Alarms messages are reset The previous screen is called up ...

Page 244: ...ontrol field on screen Format input Menu teach servo axes Teach in of the pump rotation can be performed Position actual Display of the current position of the axis Position nominal Entry of the setpoint position to which the axis should move Speed Entry of the speed with which the axis should be moved ...

Page 245: ...er a parameter has been entered to take over the entry 5 Touch control field until the axis has moved to the entered setpoint po sition 6 Check position of servo axis and correct it if necessary 7 If the servo axis is correctly positioned read off the current position 8 Enter the current position on the respective Format input screen Determining the setpoint position by moving the axis directly to...

Page 246: ... The servo axis is moved It moves as long as the control field is touched The servo axis moves in the indicated direction as long as the control field is touched Screen Format input Alarm active is called up Alarms messages are reset The previous screen is called up ...

Page 247: ... Touch control field on screen Format input Menu teach servo axes Teach in of the X axis can be performed Position actual mm The current position of the axis is displayed Position nominal mm Setpoint position to which the axis should move Speed Speed with which the axis should move ...

Page 248: ...r a value has been entered to take over the entry 5 Touch control field until the axis has moved to the entered setpoint po sition 6 Check position of servo axis and correct it if necessary 7 If the servo axis is correctly positioned read off the current position 8 Enter the current position on the respective Format input screen Determining the setpoint position by moving the axis directly to the ...

Page 249: ... the control field is touched The servo axis moves in the indicated direction as long as the control field is touched The servo axis moves in the indicated direction as long as the control field is touched Screen Format input Alarm active is called up Alarms messages are reset The previous screen is called up ...

Page 250: ... Touch control field on screen Format input Menu teach servo axes Teach in of the Y axis can be performed Position actual mm The current position of the axis is displayed Position nominal mm Setpoint position to which the axis should move Speed Speed with which the axis should move ...

Page 251: ...r a value has been entered to take over the entry 5 Touch control field until the axis has moved to the entered setpoint po sition 6 Check position of servo axis and correct it if necessary 7 If the servo axis is correctly positioned read off the current position 8 Enter the current position on the respective Format input screen Determining the setpoint position by moving the axis directly to the ...

Page 252: ...n as long as the control field is touched The servo axis moves in the indicated direction as long as the control field is touched The servo axis moves in the indicated direction as long as the control field is touched Screen Format input Alarm active is called up Alarms messages are reset The previous screen is called up ...

Page 253: ...can be reset The cause of the error message must be eliminated before it can be reset Control field Function The first page of the list of error messages is called up The last page of the list of error messages is called up The previous page of the list of error messages is called up The next page of the list of error messages is called up The previous error message is selected The next error mess...

Page 254: ...Operation SV 125 4016589 5 168 Version 1 0 Function Control field The machine drive is switched off The previous screen is called up ...

Page 255: ... The submenus for the administration of the Service functions can be selected Control field Function Screen Service General is called up Screen Service Axis is called up Screen Service Vacuum is called up The machine drive is switched off Screen Main screen is called up The previous screen is called up ...

Page 256: ...ff 1 Touch the respective control field to switch the function on or off When the function is switched on the control field is displayed green When the function is switched off the control field is displayed grey NOTE Homing of the servo axes control field Homing must be performed S after performing works on the drive chain S if the connection between motor and axis has been cut exchange of motor ...

Page 257: ... is switched on or off The light grid is reset The recording of the batch report is switched on or off When this function is switched on the machine can be operated inde pendently from the batch report Bypass Laminar Flow is switched on or off When this function is switched on the machine can be operated inde pendently from the Laminar Flow unit The Laser sensors are switched on or off The signal ...

Page 258: ...Operation SV 125 4016589 5 172 Version 1 0 Function Control field The sequence chain is reset The machine drive is switched off Screen Main screen is called up The previous screen is called up ...

Page 259: ... Service Menu The brakes of the indicated servo axes can be opened WARNING Before the brake of a vertical servo axis is opened the axis must be supported to protect it from falling down NOTE Before opening a brake press the EMERGENCY STOP button to switch off the control voltage of the machine ...

Page 260: ...e is closed the control field is displayed grey Control field Function The indicated brake is opened or closed The indicated brake is opened or closed The indicated brake is opened or closed The indicated brake is opened or closed The indicated brake is opened or closed The indicated brake is opened or closed The machine drive is switched off Screen Main screen is called up The previous screen is ...

Page 261: ...acuum filling mbar The current pressure of the vacuum chamber during vacuum filling is displayed Actual vacuum tank mbar The current pressure of the vacuum tank during vacuum filling is displayed Vacuum stopper setting Actual vacuum stopper setting mbar The current pressure of the vacuum chamber during vacuum stopper insertion is displayed Actual vacuum tank mbar The current pressure of the vacuum...

Page 262: ...reen When the function is switched off the control field is displayed grey Control field Function Vacuum filling is switched on or off Vacuum stopper insertion is switched on or off The valves of the vacuum system are opened or closed The venting during vacuum filling or vacuum stopper insertion is switched on or off The machine drive is switched off Screen Main screen is called up The previous sc...

Page 263: ...uch control field on screen Main Menu The submenus can be called up Control field Function Screen Operator General is called up Screen Operator Piston pumps is called up Screen Main screen is called up The machine drive is switched off The previous screen is called up ...

Page 264: ...on or off When the function is switched on the control field is displayed green When the function is switched off the control field is displayed grey Control field Function The lamp test is switched on or off When the lamp test is switched on all lamps are blinking for a short time This allows the operator to check all lamps for proper functioning Defective lamps must be replaced immediately The v...

Page 265: ...ssembly of the filling needles during format changeover insertion rod holder filling needle holder and insertion tube holder can be moved to waiting position The lock of the sorting bowl is opened The lock of the sorting bowl is closed Screen Main screen is called up The machine drive is switched off The previous screen is called up ...

Page 266: ...tor Menu The fill weight can be entered The correction factor is calculated by means of the entered weight The correction factor can also be entered directly Correction factor The correction factor is entered Measured weight g The measured fill weight is entered Filling weight g The fill weight is displayed ...

Page 267: ...f the parameter that should be changed 2 Enter the value on the keyboard 3 Touch control field on the keyboard to take over the entry Control field Function The correction factor is calculated Screen Main screen is called up The machine drive is switched off The previous screen is called up ...

Page 268: ...up Control field Function Screen Information Code nest is called up Screen Information Interlock infeed is called up Screen Information Piston pumps is called up Screen Information Vacuum is called up Screen Information Axis position actual and homestatus is called up Screen Main screen is called up The machine drive is switched off The previous screen is called up ...

Page 269: ...d signals the fault that has occurred By touch ing the control field the operator can view the fault The screen serves for information only no changes can be made Control field Function Screen Information Tub error code general is called up Screen Information Tub error code needle stroke is called up Screen Information Tub error code plunger is called up Screen Information Tub error code insertion...

Page 270: ...ation SV 125 4016589 5 184 Version 1 0 Function Control field Screen Main screen is called up The machine drive is switched off The previous screen is called up Screen Information Code nest 2 2 is called up ...

Page 271: ...ub error code general Touch control field on screen Information Code nest 1 2 The cause of the fault is displayed The screen serves for information only no changes can be made Control field Function The machine drive is switched off The previous screen is called up ...

Page 272: ...error code needle stroke Touch control field on screen Information Code nest 1 2 The cause of the fault is displayed The screen serves for information only no changes can be made Control field Function The machine drive is switched off The previous screen is called up ...

Page 273: ...ub error code plunger Touch control field on screen Information Code nest 1 2 The cause of the fault is displayed The screen serves for information only no changes can be made Control field Function The machine drive is switched off The previous screen is called up ...

Page 274: ...rror code insertion tube Touch control field on screen Information Code nest 1 2 The cause of the fault is displayed The screen serves for information only no changes can be made Control field Function The machine drive is switched off The previous screen is called up ...

Page 275: ...error code piston pumps Touch control field on screen Information Code nest 1 2 The cause of the fault is displayed The screen serves for information only no changes can be made Control field Function The machine drive is switched off The previous screen is called up ...

Page 276: ... the nest is displayed If a fault occurs the cause of the fault is displayed The screen serves for information only no changes can be made Control field Function Screen Information Code nest Pick up station nest is called up Screen Information Code nest Y Axis is called up Screen Main screen is called up The machine drive is switched off The previous screen is called up ...

Page 277: ...field on screen Information Code nest 2 2 On this screen the processing status of the nest is displayed If a fault occurs the concerned syringe is indicated The screen serves for information only no changes can be made Control field Function The machine drive is switched off The previous screen is called up ...

Page 278: ...n screen Information Code nest 2 2 On this screen the processing status of the nest is displayed If a fault occurs the concerned syringe is indicated The screen serves for information only no changes can be made Control field Function The machine drive is switched off The previous screen is called up ...

Page 279: ...d Touch control field on screen Information Menu Information about the infeed gate is displayed The screen serves for information only no changes can be made Control field Function Screen Main screen is called up The machine drive is switched off The previous screen is called up ...

Page 280: ...ion Menu Information about the rotary piston pumps is displayed Filling volume ml The fill volume is displayed Density g ml The density is displayed Filling weight g The fill weight is displayed Reject after filling stop s Maximum time in case of machine standstill after which the filled product is classi fied as bad ...

Page 281: ...n 1 0 5 195 Control field Function Function Reject after filling stop is switched off Screen Main screen is called up The machine drive is switched off The previous screen is called up Screen Information Piston pumps 2 2 is called up ...

Page 282: ...ol field on screen Information Piston pumps 1 2 Information about the rotary piston pumps is displayed Fill parameter Correction factor The correction factor is displayed Control field Function Screen Main screen is called up The machine drive is switched off The previous screen is called up ...

Page 283: ...m filling is displayed Vacuum filling Actual vacuum filling mbar The current vacuum during vacuum filling is displayed Actual vacuum tank mbar The current vacuum in the tank is displayed Vacuum filling Start vacuum leaktest mbar The start vacuum of the leak test is displayed End vacuum leaktest mbar The end vacuum of the leak test is displayed ...

Page 284: ...s displayed Last vacuum filling mbar The last vacuum during stopper insertion is displayed Last vacuum tank mbar The last vacuum in the tank is displayed Control field Function The machine drive is switched off Screen Main screen is called up The previous screen is called up Screen Information Vacuum 2 2 is called up ...

Page 285: ...rol field on screen Information Vacuum 1 2 The parameters for vacuum stopper insertion are displayed The screen serves for information only No changes can be made Control field Function The machine drive is switched off Screen Main screen is called up The previous screen is called up ...

Page 286: ...osition actual The current position of the master of the machine MD1 is displayed MD2 position actual The current position of the master for the needle movement MD2 is displayed MD3 position actual The current position of the master for the pump stroke and pump rotation MD3 is displayed PSN position actual mm The current position of the nest pick up station is displayed ROT position actual The cur...

Page 287: ...er insertion rods is displayed TU position actual mm The current position of the insertion tubes is displayed SW position actual The current position of the stopper turning device is displayed X position actual mm The current position of the X axis is displayed Y position actual mm The current position of the Y axis is displayed Control field Function Screen Main screen is called up The machine dr...

Page 288: ...Menu Specifications for the batch protocol are displayed and can be entered Batch no Entry of a batch number Batch name Entry of the batch name Comment Entry of a comment Control field Function Screen Main screen is called up The machine drive is switched off The previous screen is called up ...

Page 289: ...tem Password Touch control field on screen Main Menu The screen is exclusively reserved to the OPTIMA GROUP pharma Service per sonnel Control field Function Screen Main screen is called up The machine drive is switched off The previous screen is called up ...

Page 290: ...Operation SV 125 4016589 5 204 Version 1 0 5 3 Control and display elements on the machine 5 3 1 Overview 7 1 2 5 3 4 6 ...

Page 291: ...ld the 3 position safety switch 1 on its middle position The green LED 2 is lit After a few seconds the machine is ready for operation The machine starts operating when the Start button 3 is pressed If you let go the safety switch or if you press it too hard the red LED 4 is lit The machine is no longer ready for operation Wait a few seconds before you press the safety switch again ...

Page 292: ...by turning the pressure adjusting valve Setting value min 6 bar max 8 bar DANGER For all mechanical maintenance and repair work the compressed air supply disconnecting device must be turned off For all electrical maintenance and repair work the POWER supply dis connecting device on the control cabinet must be set to position OFF 0 and locked to prevent it from being turned back on accidentally ...

Page 293: ...nnecting device to position OFF The ma chine stops immediately Turning on compressed air supply Press in compressed air supply disconnecting device and turn it to position ON DANGER For all mechanical maintenance and repair work the compressed air supply disconnecting device must be turned off For all electrical maintenance and repair work the POWER supply dis connecting device on the control cabi...

Page 294: ...ing screw below the tanks The va cuum pumps evacuate the tank The tank serves as buffer Sensors The preset minimum vacuum draws the air out of the syringes Via sensors the pre set values are detected and can be read off on the operator panel These settings depend on the product The more viscous the product the higher the preset value ...

Page 295: ... gauge vacuum chamber stopper insertion The pressure gauge indicates the preset working pressure The pressure is adjus ted by turning the pressure adjusting valve 5 3 7 Pressure reducer shut off needles 6 Handwheel Pressure gauge The pressure gauge indicates the preset working pressure The pressure is adjus ted by turning the pressure adjusting valve ...

Page 296: ... machine is turned on or off with the POWER supply disconnecting device Position I The power supply is switched on Position 0 The power supply is switched off DANGER For all mechanical maintenance and repair work the compressed air supply disconnecting device must be turned off For all electrical maintenance and repair work the POWER supply dis connecting device on the control cabinet must be set ...

Page 297: ...disconnecting device after 1 minute has elapsed Turning on the POWER supply disconnecting device before 1 min has elapsed could cause S damage to the servo controllers or other electronic components S release of fuses and motor circuit breakers through an increased switch on current ...

Page 298: ...Operation SV 125 4016589 5 212 Version 1 0 ...

Page 299: ...itch on the control cabinet position I The lamps are tested Replace defective lamps immediately 2 Turn on compressed air supply on the compressed air supply disconnecting device 3 Touch control field on the Start screen to log in as a user see chapter 5 2 6 page 5 9 4 Touch control field on the Start screen to call up the Main screen 5 Eliminate any indicated faults and reset with control field 6 ...

Page 300: ...ory operation S The cause for EMERGENCY STOP must be eliminated Mode of procedure 1 Unlock the EMERGENCY STOP button 2 Switch on the control voltage 3 Check error display eliminate any present faults and reset with control field 4 Touch control field and keep it pressed for 3 s to switch on the machine drive ...

Page 301: ... devices do not operate Only personnel who have been trained and instructed in safety regula tions are allowed to operate the machine in Setup mode DANGER Through the crushing of jammed objects splinters or product can be uncontrollably flung out in all directions If the machine is operated in Setup mode with open guard doors the operating personnel must wear protection goggles Mode of procedure 1...

Page 302: ...Only operate the machine with fully functional safety and protection devices Observe safety instructions Mode of procedure 1 Turn the key switch on the operator panel to the left 2 Withdraw key from key switch 3 Switch on the control voltage 4 Check error display eliminate any present faults and reset with control field 5 Touch control field and keep it pressed for 3 s to switch on the machine dri...

Page 303: ... insertion tube holder stopper turning device rotary piston pumps and filling needles must be dismounted before starting Permanent run mode Mode of procedure 1 Dismount the pumps see chapter 9 2 1 page 9 3 2 Turn the key switch on the operator panel to the left 3 Withdraw key from key switch 4 Switch on the control voltage 5 Check error display eliminate any present faults and reset with control f...

Page 304: ...completed then the nest is transported out 3 Touch control field again to switch Emptying mode off again 4 After running the machine empty touch control field to switch off the machine 6 2 5 Standby mode When a preset time has elapsed after machine stop the machine automatically switches to Standby mode In Standby mode the vacuum pump is switched off if no further objects are present in the machin...

Page 305: ...empty 6 2 6 1 Priming in Automatic mode 1 Open guard door 2 Place a spillage tray under the filling needles 3 Close guard door 4 Switch on the control voltage 5 Eliminate any indicated faults and reset with control field 6 Touch control field Priming starts 7 Let the machine pump product until it emerges without air bubbles 8 Touch control field again to switch Priming off 9 Open guard door and re...

Page 306: ...n trained and instructed in safety regula tions are allowed to operate the machine in Setup mode 1 Turn the key switch to the right Connect the jog cable 2 Place a spillage tray under the filling needles 3 Switch on the control voltage on the jog button and keep the button pressed 4 Touch control field on the Main screen 1 to start Priming 5 Let the machine pump product until it emerges without ai...

Page 307: ...lose the infeed gate tub stopper 1 The ma chine continues operating and processes the nest in the machine 2 Touch control field to switch off the machine 6 3 3 Transport out nest 1 Touch control field The machine completes its work cycle and per forms a controlled stop 2 Touch control field 3 Touch control field and keep it pressed for approx 3 s to switch on the machine drive The processing of th...

Page 308: ...1 Do not feed any further tubs with nests 2 Touch control field to switch on Emptying mode The processing of the nest in the X Y table is completed then the nest is transported out 3 Touch control field again to switch Emptying mode off again 4 After running the machine empty touch control field to switch off the machine ...

Page 309: ... Never stop the machine with the EMERGENCY STOP button unless in cases of emergency In event of danger press the EMERGENCY STOP button The machine stops immediately without completing its work cycle When switching off the machine with the EMERGENCY STOP button S the mechanical parts are subject to increased wear S electric and electronic components might get damaged ...

Page 310: ...form the following tasks during machine operation S Visually check the individual machine elements Pay special attention to wear parts S Check sensors for contamination S Watch transport of tubs and nests S Checks tubs nests and syringes for damage S Check machine for unusual noise ...

Page 311: ...en the guard doors are open Turn off the compressed air supply disconnecting device before per forming format changeover on the machine This chapter describes how to adjust the machine for the processing of different formats This chapter describes all the procedures which may be required during format changeover Yet the actual amount of work to be performed depends on the format and might be less ...

Page 312: ...ctually been removed Incorrect size parts may cause damage to the machine Please use only original parts from OPTIMA GROUP pharma We recommend to first dismount all size parts and clean them thoroughly Then mount the new size parts and set the machine to the new format NOTE When format changeover has been terminated jog the machine in Setup mode for 2 3 cycles Thus it can be verified that format c...

Page 313: ...SV 125 4016589 Format change Version 1 0 7 3 7 1 Mechanical format change 7 1 1 Overview 1 2 9 10 11 3 4 5 6 7 8 13 14 12 15 16 17 ...

Page 314: ...ns to their upper hindmost position to ensure an easy dismounting and installation of the size parts 7 1 2 1 Filling needles 1 size part 22 NOTE To prevent product spillage into the machine pull off the filling hoses from the filling needles outside of the machine 1 2 1 Take the filling needles out of the holder 2 Pull off filling hoses ...

Page 315: ...ize part 24 NOTE To prevent product spillage into the machine pull off the filling hoses from the filling needles outside of the machine 1 4 2 3 1 Disconnect the rapid action couplings for the compressed air connections 2 Loosen wing screws 3 Dismount drive head 4 Pull out shut off needles ...

Page 316: ...Format change SV 125 4016589 Version 1 0 7 6 5 7 6 5 Loosen star grip screw 6 Pull safety pusher to the front 7 Dismount filling needles with filling hoses from holder in upward direction ...

Page 317: ... 3 1 Touch control field on screen Operator General to open the lock of the sorting bowl see chapter 5 2 77 page 5 178 2 Unhinge chute 3 Remove sorting bowl in upward direction 4 Touch control field after the installation of the new sorting bowl to close the lock of the sorting bowl ...

Page 318: ...0 7 8 7 1 2 4 Stopper lanes 4 size part 8 9 1 2 Plug sensors into other position 1 Plug sensors into other position 2 Loosen star grip and dismount support rail 3 4 3 Loosen star grips 4 Remove stopper tracks from holder in upward direction ...

Page 319: ...sion 1 0 7 9 7 1 2 5 Stopper turning device 5 size part 11 1 2 1 Loosen hexagon head screw 2 Dismount stopper turning device 7 1 2 6 Stopper holder 6 size part 10 1 2 1 Loosen star grip 2 Dismount stopper holder with hold down device ...

Page 320: ...n 1 0 7 10 7 1 2 7 Stopper transfer bar 7 size part 10 2 1 2 1 Loosen hexagon head screw 2 Dismount stopper transfer bar 7 1 2 8 Insertion rod holder stoppers 8 size part 14 2 1 1 Loosen hexagon head screw 2 Dismount insertion rod holder ...

Page 321: ...1 7 1 2 9 Filling needle holder filling 9 size part 21 2 1 1 Loosen hexagon head screw 2 Dismount filling needle holder 7 1 2 10 Filling needle holder vacuum filling 10 size part 24 2 1 1 Loosen hexagon head screw 2 Dismount filling needle holder ...

Page 322: ...6589 Version 1 0 7 12 7 1 2 11 Vacuum chamber vacuum filling 11 size part 16 2 1 3 4 1 Loosen hexagon head screw 2 Dismount vacuum hose with hose connection 3 Loosen hexagon head screw 4 Dismount vacuum chamber vacuum filling ...

Page 323: ...ion 1 0 7 13 7 1 2 12 Hold down device syringes 12 size part 20 2 1 1 Loosen hexagon head screw 2 Dismount hold down device 7 1 2 13 Insertion tube holder 13 size part 12 2 1 1 Loosen hexagon head screw 2 Dismount insertion tube holder ...

Page 324: ...7 14 7 1 2 14 Insertion tube holder vacuum stopper insertion 14 size part 19 2 1 4 3 1 Loosen hexagon head screw 2 Dismount vacuum hose with hose connection 3 Loosen hexagon head screw 4 Dismount insertion tube holder vacuum stopper insertion ...

Page 325: ... Version 1 0 7 15 7 1 2 15 Centering plate 15 size part 6 1 1 Loosen hexagon head screws 2 screws and remove centering plate 7 1 2 16 Tub stopper 16 size part 1 2 3 1 1 Pull tub stoppers out in upward direction they are plugged in ...

Page 326: ...5 4016589 Version 1 0 7 16 7 1 2 17 Suction frame nest pick up station 17 size part 5 5 1 1 2 2 3 3 1 Loosen hexagon head screws 2 screws and dismount suction frame 2 Loosen hexagon head screws 3 Dismount centering finger ...

Page 327: ...rts When all parts have been removed clean the machine thoroughly Then mount the new size parts NOTE Mount the new size parts in reverse order NOTE Make sure that the installed size parts all bear the same format desig nation Incorrect size parts may cause damage to the machine ...

Page 328: ...Format change SV 125 4016589 Version 1 0 7 18 7 1 4 Format settings NOTE For setting values see format setting sheet 7 1 4 1 Overview 1 2 3 4 ...

Page 329: ...SV 125 4016589 Format change Version 1 0 7 19 7 1 4 2 Height adjustment for hold down device 1 1 2 3 1 Loosen wing screw 2 Adjust the height of the hold down device on the scale 3 Tighten wing screw ...

Page 330: ... 2 3 1 1 3 1 Loosen the hexagon head screws along the side guides 2 Adjust the height of the side guide using the installation template 3 Tighten the hexagon head screws along the side guides NOTE For guide adjustment the installation aid that is included in the delivery must be used ...

Page 331: ...te side guide 3 3 1 1 3 1 Loosen the clamping levers along the side guides 2 Adjust the side guide using the installation template 3 Tighten the clamping levers along the side guides NOTE For guide adjustment the installation aid that is included in the delivery must be used ...

Page 332: ...nd stopper insertion 4 1 1 Adjust the vacuum with the wing screws below the vacuum tanks NOTE The set values are displayed on screens Format input Filling curve vacuum piston pumps 4 4 see chapter 5 2 48 page 5 103 and Format input Stopper setting vacuum 3 3 see chapter 5 2 54 page 5 120 ...

Page 333: ...ent format is displayed and can be changed Changing the current format 1 Touch control fields or to select a new format or 1 Touch input field Select format Enter the new format on the numeric keypad Touch control field on the numeric keypad to take over the entry 2 Touch control field to load the new format into the memory ...

Page 334: ...Format change SV 125 4016589 Version 1 0 7 24 ...

Page 335: ...el are allowed to eliminate faults Observe safety instructions CAUTION Individual stations of the machine are still pressurized even after EMERGENCY STOP or when the guard doors are open Turn off the compressed air supply disconnecting device on the ma chine before eliminating faults on the pneumatic components 8 1 1 Elimination of faults 1 Eliminate the cause of fault 2 Touch control field to res...

Page 336: ...s that are present in the machine are pro cessed according to the information in the shift register The faults are distinguished between S immediate stop S controlled machine stop S controlled machine stop with automatic restart The corresponding alarm messages are displayed on the operator panel In order to be able to eliminate the faults that cause an immediate stop or a con trolled machine stop...

Page 337: ...achine is stopped during production mode through actuation of an EMERGENCY STOP button an immediate stop is triggered and an error message is displayed on the operator panel The object data that have been detected before are saved and the objects that are present in the machine are processed according to these object data at machine restart 8 2 4 Drop of compressed air If the machine is stopped du...

Page 338: ...on the holder Replace defective insertion tube Alarm 12004 Overload filling needle s Cause Action A filling needle does not immerse into the syringe barrel The filling needles are not com pletely inserted into the filling needle holders A filling needle is damaged Sensor is defective or mistadjusted Insert the filling needles into the filling needle holder up to the stopper Check filling needles a...

Page 339: ...n sensor is misadjus ted or defective Eliminate blockage Search and eliminate the cause of lack of compressed air Ensure that the compressed air lines and connections are tight The compressed air manometer must read at least 6 bar Adjust final position sensor and replace it if defective Alarm 30001 Motor protection switch triggered Cause Action The release current of the motor cir cuit breaker is ...

Page 340: ...ped Check fuses Alarm 30009 Compressed air missing Cause Action The pressure switch has been triggered due to lack of compressed air 6 bar Eliminate the cause of lack of com pressed air Ensure that the pressure lines and connections are tight The air pressure gauge must read at least 6 bar Alarm 30016 No control voltage Cause Action Control voltage is missing Unlock the EMERGENCY STOP but ton Clos...

Page 341: ...eleased has been selected in the Format Selection menu Select a released format Alarm 30026 Input parameter not correct Y Axis Cause Action The control unit cannot process the entered parameters The parameters are either too high or too low Enter correct parameters Alarm 30029 Operation requested check all syringes correct in nest Cause Action The operator must check the syr inges in the nest Chec...

Page 342: ...active Cause Action After switching on the machine the lamps are tested When the lamp test has ended reset the message Alarm 30081 Tub missing pick up station Cause Action Tub missing Search and eliminate the cause of fault Alarm 30100 Emergency Stop pressed Cause Action An EMERGENCY STOP button has been pressed Eliminate the cause of fault Unlock the EMERGENCY STOP but ton Switch on the control v...

Page 343: ...ted or wire break Check cabling Locate and eliminate the cause of fault The alarm must be reset If you cannot eliminate this fault please contact the company OPTIMA GROUP pharma Alarm 30404 Orientation wrong stopper in gripper Cause Action Stopper upside down in stopper turn ing device Take stopper manually out of the stop per turning device Check stopper feeding system ...

Page 344: ...ticipant sercos pump stroke Fault BUS participant sercos swivel arm Fault BUS participant sercos X Axis Fault BUS participant sercos Cause Action No communication between indic ated Profibus address and control unit Check lines and plug connections Check module hardware of the de central periphery Turn the POWER supply disconnect ing device off and on again If you cannot eliminate this fault pleas...

Page 345: ...lt cam calculation axis needle stroke Fault cam calculation axis pump rotation Fault cam calculation axis pump stroke Fault cam calculation axis stopper swivel arm Fault cam calculation axis X Axis Fault cam calculation axis Y Axis Cause Action Fault during cam calculation of indic ated axis Reset message Alarm 31032 Operation not active batch Cause Action Batch not started Start batch ...

Page 346: ...n not active safe off mode axis swivel arm Operation not active safe off mode axis x Operation not active safe off mode axis y Cause Action Fault in the safety circuit of the servo controller at the indicated station Check cabling of safety circuit Replace servo controller if defective Alarm 31033 Operation active leak test stopper system Cause Action Leak test active No intervention required The ...

Page 347: ...matically performed at machine restart and after the nest has been transported out Alarm 31039 Fault cam calculation axis insertion rod Fault cam calculation axis insertion tube Fault cam calculation axis main drive 3 Fault cam calculation axis needle stroke Fault cam calculation axis pump rotation Fault cam calculation axis pump stroke Fault cam calculation axis swivel arm Fault cam calculation a...

Page 348: ...light barrier stopper check Monitoring sensor vacuum chamber filling Monitoring sensor vacuum chamber stopper setting Monitoring sensor vacuum tank filling Monitoring sensor vacuum tank stopper setting Cause Action The indicated sensor is contamin ated misadjusted or defective Clean sensor Check sensor and replace it if defect ive Check and adjust sensor Alarm 41000 Vacuum missing pickup station n...

Page 349: ... fault has occurred during vacuum filling at several consecutive syr inges Ensure product supply Check vacuum system Alarm 41700 Consecutive fault stopper setting Cause Action Consecutive fault is reached A fault has occurred during stopper insertion at several consecutive syr inges Check stopper feeding system Alarm 41700 Consecutive fault vacuum stopper setting Cause Action Consecutive fault is ...

Page 350: ...ringe after stopper insertion Cause Action A syringe projects out of the nest Search and eliminate the cause of fault Remove syringe or press it down in the nest manually Alarm 45001 Sorter stoppers not locked Cause Action The stopper sorting bowl is not locked Lock sorter Check control card for Unlock lock sorter ...

Page 351: ... axis swivel arm Position error fault X axis Position error fault Y axis Cause Action The position of the indicated axis is not correct No smooth operation of indicated axis Mechanical problem at indicated axis blockage Acceleration or deceleration of axis is too high Torque of axis is too low Motor current is too low Motor is defective Ensure smooth operation of indicated axis Eliminate mechanica...

Page 352: ...Y axis Cause Action The indicated axis runs to a defined position after a fault has occurred The message is automatically reset when the indicated axis has reached the defined position Alarm 60500 Homing active axis pickup station nest Homing active axis insertion rod Homing active axis insertion tube Homing active axis needle stroke Homing active axis pump rotation Homing active axis pump stroke ...

Page 353: ...e indicated axis Search and eliminate the cause of fault Check servo controller Check motor and cabling Alarm 60700 Module fault axis insertion rod Module fault axis insertion tube Module fault axis needle stroke Module fault axis pickup station nest Module fault axis pump rotation Module fault axis pump stroke Module fault axis swivel arm Module fault X Axis Module fault Y Axis Cause Action Modul...

Page 354: ...ult amplifier axis swivel arm Fault amplifier X Axis Fault amplifier Y Axis Cause Action Fault at the servo controller of the in dicated drive Servo controller is defective Motor is defective Motor is overheated A fuse in the control cabinet has tripped The indicated axis does not operate smoothly Turn main switch off and on again Check motor and servo controller Let motor cool down Check and acti...

Page 355: ...otor of indicated axis Fault at cabling Check servo motor of indicated axis Check cabling Alarm 61000 Feedback noise fault axis insertion rod Feedback noise fault axis insertion tube Feedback noise fault axis needle stroke Feedback noise fault axis pickup station nest Feedback noise fault axis pump rotation Feedback noise fault axis pump stroke Feedback noise fault axis swivel arm Feedback noise f...

Page 356: ...is pickup station nest Software limit switch axis pump stroke Software limit switch axis swivel arm Software limit switch X Axis Software limit switch Y Axis Cause Action The indicated axis is positioned on a software limit switch The indicated axis performs homing Alarm 61400 Waiting for motion group synced PLC Cause Action Axis card not ready Check fiber optic cable Check the connected servo con...

Page 357: ...ifier rack 1 Waiting for amplifier rack 2 Waiting for amplifier X Axis Waiting for amplifier Y Axis Cause Action The message appears when the control voltage has been switched off and on again Wait until the servo controller is ready to operate The waiting time is approx 60 s When the servo controller is ready to operate the message disappears Alarm 65014 Value out of tolerance range vacuum leak t...

Page 358: ...k stopper setting Cause Action Setpoint value not reached at va cuum tank Check parameters Check vacuum tank Alarm 90100 Min accumulation stopper lane 1 Min accumulation stopper lane 2 Min accumulation stopper lane 3 Min accumulation stopper lane 4 Min accumulation stopper lane 5 Cause Action No or not sufficient stoppers in the indicated lane of the stopper feeding system No or not sufficient sto...

Page 359: ...automatically when the tub arrives at the indicated position Alarm 92221 Waiting for downstream machine Cause Action The downstream machine is not ready to operate Startup downstream machine The function can be bypassed in menu Service General function Release downstream machine Alarm 92221 Waiting for I O Communication PLC Cause Action Waiting for the connection between PLC and input output card ...

Page 360: ...Troubleshooting SV 125 4016589 8 26 Version 1 0 ...

Page 361: ...Electrical pneumatic and hydraulic installations require special know ledge Only trained and qualified personnel are allowed to perform servicing work Observe safety instructions WARNING A defective or badly maintained machine increases the risk of acci dents Only operate the machine in a technically faultless condition 9 1 Cleaning 9 1 1 General The plant operator must make provision for complian...

Page 362: ...arings slide bearings or suchlike should not be treated with a high pressure cleaner as this would reduce the service life of the bearing Do not clean painted or anodized machine parts with any hard cleaning objects such as spatulas steel wool or suchlike Also check for loose or damaged machine parts when performing cleaning work 9 1 3 Daily cleaning The cleaning interval is dependent on the produ...

Page 363: ...achine has performed a controlled stop Dismounting 2 3 2 1 1 Loosen clamping connection and dismount intake hose 2 Unscrew threaded bolt 3 Remove the pump from the shaft 4 Remove the pump together with dosing hose and filling needle 5 Repeat steps 1 through 4 for all pumps NOTE Hold the pump during transport so that the piston cannot slip out of the pump ...

Page 364: ...p on a clean and soft surface 3 Dismount dosing hose and filling needle 4 Pull the pump piston 1 out of the pump cylinder 2 5 Unfasten the clamping ring 3 on the pump base 4 and remove it 6 Remove the sealing washer 5 7 Rinse the pump parts with hot WFI water 8 Clean the pump parts in the ultrasonic bath 9 Autoclave the pump parts All pump parts can be autoclaved 10 Lightly grease the running surf...

Page 365: ...face 2 Press the pump base 4 with the sealing ring 6 against the pump cylinder 2 3 Attach clamping ring 3 NOTE The notch 7 of the clamping ring must fit into the groove of the pump base 8 sealing ring 9 and pump cylinder 10 4 Tighten the wing screw of the clamping ring NOTE Hold the pump during transport so that the piston cannot slip out of the pump ...

Page 366: ...ling needle CAUTION Do not use force NOTE Pump cylinder and piston must bear the same number they are paired Do not mix up the pump bases CAUTION When using pumps with small piston diameters 5 7mm connect the intake and filling hoses only when the pump is dismounted Risk of damage to the piston 7 Mount the dosing pump see chapter 9 2 4 page 9 8 ...

Page 367: ...SV 125 4016589 Cleaning and maintenance Version 1 0 9 7 NOTE Hold the pump during transport so that the piston cannot slip out of the pump ...

Page 368: ...ith filling needles are connected NOTE Hold the pump during transport so that the piston cannot slip out of the pump Mounting 2 3 4 5 7 1 Place filling needle in filling needle holder 2 Attach pump base to shaft support 3 Screw in threaded bolt 4 Hinge the piston in at the support bolt 5 Screw in threaded bolt 6 Check the pumps for firm seating and tightness 7 Mount intake hose 8 Repeat steps 1 th...

Page 369: ...g needle from the filling needle holder NOTE Hold the pump during transport so that the piston cannot slip out of the pump 2 At the cleaning place disconnect the product hose from dosing pump and filling needle 3 Clean it with a suitable detergent To avoid detergent residue we recommend to rinse the filling needle parts with purified water WFI water All pump parts can be autoclaved NOTE Mount the ...

Page 370: ...2 6 1 Priming in Automatic mode 1 Open guard door 2 Place a spillage tray under the filling needles 3 Close guard door 4 Switch on the control voltage 5 Eliminate any indicated faults and reset with control field 6 Touch control field Priming starts 7 Let the machine pump product until it emerges without air bubbles 8 Touch control field again to switch Priming off 9 Open guard door and remove spi...

Page 371: ...who have been trained and instructed in safety regula tions are allowed to operate the machine in Setup mode 1 Turn the key switch to the right Connect the jog cable 2 Place a spillage tray under the filling needles 3 Switch on the control voltage on the jog button and keep the button pressed 4 Touch control field on the Main screen to start Priming 5 Let the machine pump product until it emerges ...

Page 372: ...ine can only be ensured if it is also serviced optimally regularly and thoroughly The following maintenance tasks should be carried out S Check the wear parts S Check the control elements for correct functioning S Lubricate S Clean all object conveying parts daily NOTE Because of the machine conception change of grease or oil is not ne cessary Lubricate sparingly Avoid mixing different lubricants ...

Page 373: ...air supply disconnecting device before per forming maintenance and repair work on the machine 1 Run machine empty and switch it off 2 Secure the machine against being turned back on accidentally turn off POWER supply disconnecting device and lock it 3 Secure area of repair 4 Clean the machine if necessary 5 Perform servicing measures 6 Check safety devices e g guards door safety switches or EMERGE...

Page 374: ...avorable usage conditions the lubrication intervals specified in the lubrica tion plan can be altered in accordance with the customer s experience For use in the food and pharmaceutical industries we recommend as lubric ant KlübersynthR UH1 14 151 Class H1 NSF registration number 056354 ...

Page 375: ...SV 125 4016589 Cleaning and maintenance Version 1 0 9 15 9 4 1 Overview of maintenance points 2 5 1 3 6 4 3 4 7 ...

Page 376: ...n interval 8 operating hours 9 4 2 1 Check compressed air supply see position 1 in the Maintenance points overview 2 3 1 Take off machine casing 2 Check the air pressure on the pressure gauge 3 Adjust the air pressure on the adjusting valve if necessary The setting value is 6 bar ...

Page 377: ... interval 40 operating hours 9 4 3 1 Compressed air supply drain condensate see position 1 in the Maintenance points overview 2 4 1 Place a spillage tray under the air maintenance unit 2 Open cap of container 3 Drain condensed water 4 Close cap of container 5 Remove spillage tray ...

Page 378: ...125 4016589 9 18 Version 1 0 9 4 4 Maintenance plan interval 500 operating hours 9 4 4 1 Grease gear wheels see position 2 in the Maintenance points overview 2 1 Take off machine casing 2 Grease toothed wheels slightly with brush ...

Page 379: ...SV 125 4016589 Cleaning and maintenance Version 1 0 9 19 9 4 4 2 Grease guides see position 3 in the Maintenance points overview 2 2 1 Take off machine casing 2 Grease guides slightly with brush ...

Page 380: ...Cleaning and maintenance SV 125 4016589 9 20 Version 1 0 9 4 4 3 Check toothed belts see position 4 in the Maintenance points overview 2 2 1 Take off machine casing 2 Check toothed belts ...

Page 381: ...ntenance Version 1 0 9 21 9 4 5 Maintenance plan interval 1000 operating hours 9 4 5 1 Lubricate pump drive see position 5 in the Maintenance points overview 2 1 Take off machine casing 2 Lubricate lubrication nipple with grease gun ...

Page 382: ...ntenance plan interval As required 9 4 6 1 Nest pick up station replace vacuum cups see position 6 in the Maintenance points overview 1 1 Loosen and screw out hexagon socket screw until the vacuum cup can be taken out of the support 2 2 Take vacuum cup out of support ...

Page 383: ...SV 125 4016589 Cleaning and maintenance Version 1 0 9 23 3 3 Push the hexagon socket screw out of the vacuum cup 4 4 Insert new vacuum cup into support ...

Page 384: ...Cleaning and maintenance SV 125 4016589 9 24 Version 1 0 5 5 Screw in and tighten hexagon socket screw ...

Page 385: ...on in hazardous location installations Be sure that power is removed and the area is nonhazardous before proceeding To replace the battery 1 Disconnect power from the operator panel 2 Place the operator panel display side down on a flat stable surface 3 Detach the communication module if attached from the logic module by re moving the four screws 4 Loosen the six captive screws that attach the log...

Page 386: ...ponents in the logic module 6 Locate the battery on the circuit board Remove battery by lifting up the edge indicated by arrow 7 Remove the battery by lifting up the side of the battery 8 Insert the new battery 9 Attach the logic module by aligning the two connectors on the bottom of the module with the connectors on the operator panel ...

Page 387: ...nd tighten the four screws to a torque of 0 68 Nm NOTE Do not dispose of battery in a fire or incinerator Dispose of used bat teries in accordance with local regulations Store batteries in a cool dry environment We recommend 25 C with 40 60 relative humidity You may store batteries for up to 30 days between 45 to 85 C 49 185 F such as during transportation To avoid possible leakage do not store ba...

Page 388: ...Cleaning and maintenance SV 125 4016589 9 28 Version 1 0 ...

Page 389: ...SV 125 4016589 Appendix Version 1 0 10 1 10 Appendix Personnel training sheet Project drawing Format setting sheets Pneumatic plan vacuum plan ...

Page 390: ...Appendix SV 125 4016589 10 2 Version 1 0 ...

Page 391: ...echnical qualification Employee with electrical qualification Superior with appropriate competence Packaging transport Commissioning Startup Troubleshooting Troubleshooting mechanical Troubleshooting electrical Installation preparation Maintenance Reparation Switching off storage ...

Page 392: ...Personnel training SV 125 4016589 Version 1 0 ...

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