ProSys

4 Head Filling System

SERIAL NUMBER S1142
OPERATING INSTRUCTION MANUAL
for
Prodo Pak
TABLE OF CONTENTS PAGE
FOR PROSYS PARTS AND SERVICE CONTACT:........................................................................................... IV 
PROSYS SPARE PARTS ORDERING POLICY ................................................................................................... V 
PROSYS PATENTED PARTS ................................................................................................................................ VI 
PARTS ORDER FORM.......................................................................................................................................... VII 
CHAPTER 1................................................................................................................................................................. 1 
SAFETY CONSIDERATIONS ................................................................................................................................ 1 
LOCATE THE FILLING MACHINE FOR SAFETY ............................................................................................ 1 
PREPARE FOR SAFETY ..................................................................................................................................... 1 
FILLING MACHINE SAFETY FEATURES ......................................................................................................... 1 
SAFETY PRACTICES - GENERAL...................................................................................................................... 2 
SAFETY PRACTICES - ELECTRICAL ................................................................................................................ 3 
CHAPTER 2................................................................................................................................................................. 5 
MACHINE UTILITY REQUIREMENTS ................................................................................................................ 5 
IMPORTANT INSTALLATION NOTES ............................................................................................................... 5 
ELECTRICAL SUPPLY ....................................................................................................................................... 5 
Connection ........................................................................................................................................................................ 5 
COMPRESSED AIR SUPPLY .............................................................................................................................. 5 
Connection ........................................................................................................................................................................ 6 
TAKE AWAY SYSTEM ......................................................................................................................................... 6 
CHAPTER 3................................................................................................................................................................. 7 
FILLER FUNCTION OVERVIEW .......................................................................................................................... 7 
ProSys FILLING MACHINE................................................................................................................................ 7 
CHAPTER 4................................................................................................................................................................. 9 
FILL STATION ........................................................................................................................................................ 9 
FILL STATION OVERVIEW ................................................................................................................................ 9 
FILL STATION OPERATING SEQUENCE ......................................................................................................... 9 
AIR IN THE FILL SYSTEM.................................................................................................................................. 9 
VOLUME vs. WEIGHT ...................................................................................................................................... 10 
NOZZLE BLAST................................................................................................................................................. 11 
DISPENSE HEAD .............................................................................................................................................. 12 
FILL PURGE FEATURE ................................................................................................................................... 12 
METERING / MATERIAL FEED RATE ADJUSTMENT ................................................................................... 12 
When using a press: ........................................................................................................................................................ 13 
FILL STATION DISASSEMBLY AND ASSEMBLY............................................................................................ 13 
FILL VALVE / METERING REMOVAL............................................................................................................. 14 
ROTARY FILL VALVE DISASSEMBLY, MAINTENANCE AND ASSEMBLY ................................................... 14 
Fill Valve Porting Verification........................................................................................................................................ 17 
METERING PACKAGE DISASSEMBLY, MAINTENANCE AND ASSEMBLY ................................................. 17 
Standard Metering Package............................................................................................................................................. 17 
FILL VALVE / METERING INSTALLATION .................................................................................................... 18 
DISPENSE HEAD DISASSEMBLY, MAINTENANCE AND ASSEMBLY .......................................................... 18 
NOZZLE PACKAGE .......................................................................................................................................... 20 
DISPENSE HEAD PURGE ................................................................................................................................ 21 
HUMAN / MACHINE INTERFACE UNIT FUNCTIONS .................................................................................. 22 
Station Select .................................................................................................................................................................. 22 
Selector Switches ....................................................................................................................................................... 22 
Fill Purge................................................................................................................................................................... 23 
Status .............................................................................................................................................................................. 24 
Setup ............................................................................................................................................................................... 24 
Load / Matl Feed ....................................................................................................................................................... 24 
Fill #1 Setup .............................................................................................................................................................. 26 
Fill #2 Setup .............................................................................................................................................................. 29 

Page ii
 ALARM MESSAGES .......................................................................................................................................... 32 
Optional Fill Station Alarm Messages ............................................................................................................................ 35 
CHAPTER 5............................................................................................................................................................... 37 
MAINTENANCE ................................................................................................................................................... 37 
PREVENTATIVE MAINTENANCE.................................................................................................................... 37 
DAILY: ........................................................................................................................................................................... 37 
WEEKLY: ...................................................................................................................................................................... 37 
QUARTERLY: ............................................................................................................................................................... 37 
MAINTENANCE NOTES ................................................................................................................................... 38 
SEAL AND O-RINGS ......................................................................................................................................... 38 
METHODS OF CLEANING .............................................................................................................................. 38 
SPARE PARTS ................................................................................................................................................... 38 
TOOLS REQUIRED ........................................................................................................................................... 38 
OTHER MATERIALS REQUIRED FOR MAINTENANCE OF THREADS ....................................................... 39 
CHAPTER 6............................................................................................................................................................... 40 
PROSYS BILLS OF MATERIALS .......................................................................................................................... 40 

Page iii
 FOR PROSYS PARTS AND SERVICE CONTACT:

ProSys Innovative Packaging Equipment

422 East 17th Street
Webb City, MO 64870

Phone: 800-231-3455 or 417-673-5551

Fax: 417-673-7971

For us to better serve you:

Ask for “ProSys PARTS and SERVICE Department”.

If have a problem with your ProSys equipment you need technical assistance with
your ProSys equipment please tell the service department receptionist your
company name, machine serial number and a brief description of the problem you
are having with your ProSys equipment.

If you need to order parts please have the ProSys part number and / or the
manufacturer’s part number of the part(s) you need to order. If you do not have the
ProSys part number or manufacturer part number, please have the drawing number
of the assembly the part is used in and a good description of the part.

Fax orders are encouraged and may be faxed in at any time. Faxed orders will be
handled promptly. You may copy and use the "Parts Order Form" in the front of
this manual for your convenience.

If you have an inquiry about an open order please have the purchase order number,
ProSys part number of the part(s) in question and the date ordered.

Please refer to the machine serial number and model number when needing parts or
service.

Our business hours are Monday through Friday from 8:00 AM to 4:30 PM Central
Standard Time.

Page iv
 PROSYS SPARE PARTS ORDERING POLICY
A) MINIMUM ORDER = $50.00

B) SHIPPING SCHEDULE:

Order received Ship* Expedite Charge

8:00 a.m. - 3:00 p.m. same day n/c

3:00 - 4:30 p.m. same day Fed Ex $15.00 -- requires special handling
3:00 - 4:30 p.m. following day n/c
(Central time)

* when part is in stock

C) PARTS RESTOCKING POLICY: 20% restocking charge

1) No returns under $15.00 total.

2) We issue RMA # (Return Merchandise Authorization #) to customer.
3) No returns accepted without RMA #.
4) Credit issued after inspection of unused-resalable part.
5) Credit will be issued on customers account for future orders.
6) Custom/Nonstock parts are returnable at our discretion.

D) PARTS WARRANTY POLICY:

1) Replacement part is shipped on a new P.O. #.

2) Defective part must be returned on an RMA #.
3) Account will be credited upon return and inspection of defective part.
4) We will ship replacement part Next Day at no charge.
5) If the “defective” part is good & resalable, customer will be invoiced for freight only.
If the “defective” part is good & not resalable, the customer will be invoiced for the
part + shipping, and the part returned to the customer.

NOTE: New Machine Warranty is not covered by this policy.

Don Sonntag
ProSys Division Manager
02/06/97

Page v
 PROSYS PATENTED PARTS

The equipment described in this instruction manual was designed and

manufactured by ProSys Innovative Packaging Equipment.

Information provided in this manual contains proprietary data on patented

materials and systems. This information is furnished for the use of the customer to
install, maintain, repair and operate the equipment.

The equipment described in this instruction manual is protected under one or more
of the following patents:

U.S. patent number 4,974,755

U.S. patent number 5,350,233

U.S. patent number 5,551,493

Canadian patent number 2,014,993

Canadian patent number 2,145,186

Other U.S. and foreign patents pending

It is a violation of patent law to copy or reproduce any patented component for any
reason.

Page vi
 PARTS ORDER FORM
ProSys Innovative Packaging Equipment 422 East 17th Street
Division of Reagent Chemical & Research, Inc. Webb City, MO 64870
Phone: 417-673-5551
Fax: 417-6737971

Date Ordered:______________ Purchase Order No:___________________

Date Needed:_______________ Machine Serial No:___________________

Order Taken By:______________________

Ship to:
Company Name:________________________________________________________

Street:________________________________________________________________

City:_____________________ State:_______ Zip:___________

Telephone:_____________________Fax:________________________________

Attention:______________________________________________________________

Ship via: __FedEx Priority Over Night __FedEx Standard Over Night __FedEx
Economy 2 Day __UPS Ground __UPS Red __UPS Blue
QTY. ProSys PN. Mfg.No. Description
__________________________________________________________
__________________________________________________________
__________________________________________________________
__________________________________________________________
__________________________________________________________
__________________________________________________________
__________________________________________________________
__________________________________________________________
__________________________________________________________
To place a parts order via fax, fill this form out as completely as possible and fax to our Parts
and Service department at 417-673-7971.

Page vii
 CHAPTER 1: SAFETY CONSIDERATIONS

CHAPTER 1
SAFETY CONSIDERATIONS

Filling machines can cause serious injury if the operator is untrained or

careless. Do not attempt to operate or service this machine unless you are trained and
experienced and have read and understand the instructions in this manual.
These safety procedures are to be used in conjunction with the installation, operation, and
maintenance instructions in this manual. Since actual working environments vary greatly, it is
impossible to mention all precautions that should be taken in a particular situation. The
information contained in this manual does not relieve the operating and maintenance personnel
of the responsibility to exercise good judgment in the operation and maintenance of this
equipment.
LOCATE THE FILLING MACHINE FOR SAFETY
Position the machine so that access to electrical components is provided. Maintenance and
service personnel will perform more safely when they have unobstructed access.
Electrically ground the machine. This will ensure that the machine will not be a source of
electrical shock that could be fatal.
PREPARE FOR SAFETY
An operator should never attempt to run or maintain the machine without first attaining the
appropriate skills. The lack of proper operating procedures, care, and attention, increases the
potential hazards around the filling machine. Be sure all operators are individually and
thoroughly trained on the kinds of filling machines they will be attending.
FILLING MACHINE SAFETY FEATURES
Lockout-Tagout devices are provided for both
electrical and pneumatic energy sources. The
lock-outs should be used whenever maintenance
is performed. The pneumatic supply to the filler
has a shut off valve with a provision for lockout.
The electrical supply to the filler has a
disconnect switch with a provision for a lockout.

Warning and caution labels are provided to alert the operator to potentially hazardous conditions
that may exist at various locations around the filling machine.

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 CHAPTER 1: SAFETY CONSIDERATIONS

The manual itself is safety instructive and is

meant to be kept with the filling machine for
continuous study by operators.

SAFETY PRACTICES - GENERAL

All personnel should learn and practice the
following rules.
Note that the words "filling machine", "equipment", and "machine" used in this text are meant to
apply to the total filling equipment provided by ProSys.
The machine should never be operated without proper
training, experience, and authority.
The machine should never be operated at unsafe speeds.
The machine should never be operated from any awkward
or unsafe position.
Safety devices on the machine are to protect the
operator from harm and to protect the equipment
from damage. Never defeat or bypass any mechanical
or electrical safety device or interlock. They are for
your safety and should be functional at all times.

Guards and protective covers should never be

opened when the equipment is running nor should
the equipment be operated without the guards and
covers properly installed. Never open or remove
protective guards or machine parts that are secured
by wrench-type fasteners unless the electrical power
to the machine and/or air supply is locked out.
Moving parts of the machine should never be
touched while running.

Lockouts and hazard identification tags must always be

applied to the main power disconnect and/or pneumatic
air supply when any heavy maintenance or service is
being performed. And although the "ON/OFF" button
prevents operation of the filling machine the "ON/OFF"
should never be substituted for lockouts and tags. Tags
identify the individual who locked the system as well as
their location and activity. Lockouts must disconnect all

2
 CHAPTER 1: SAFETY CONSIDERATIONS

sources of energy including electrical, and pneumatic when operations are performed that are not
protected by standard guarding.
Do not use improper tools to work on the machine. Always use the appropriate tools.
Tools, oil cans, supplies, rags, or any other materials used in maintenance or production should
never be left standing on the machinery or in the aisles. Unrestrained
objects may fall into the machinery and cause damage.
Never lean against the machine or prop your hands or feet on it.
Clothing is always a potential safety hazard around machinery.
Personnel should exercise good judgment in the selection of clothing
and avoid any type that could become caught in the machinery and
cause a serious injury. Items that should not be worn around operating
equipment are neckties, long sleeves, rings, or dangling jewelry (neck
chains, medallions, bracelets, watches, etc.).
Long hair is also potentially dangerous around moving machines and
therefore should be covered or contained to prevent entanglement in
the equipment.
Stop the machine before clearing jams or cleaning.
Do not touch heated surfaces.
DO NOT OPERATE THE MACHINE IN A MANNER FOR WHICH IT IS NOT INTENDED.
SAFETY PRACTICES - ELECTRICAL
All maintenance procedures that involve removing or replacing equipment on the filling machine
or expose personnel to hazardous moving mechanisms require that lockouts and tags be used on
the power disconnects for all types of power involved. On some filling machines lockouts may
be required on more than one power source due to the various kinds of equipment involved.

High Voltages are present when incoming AC power is connected. Make

all changes to the equipment with the electrical power off and locked out. Failure to
follow this procedure may cause serious personal injury, death, and/or equipment
damage. Some machines have multiple disconnects which should each be locked off.
Filling machines should be installed, adjusted, and serviced by qualified
electrical maintenance personnel familiar with the operation of the equipment and
potential hazards. Failure to follow this practice may cause serious personal injury, death,
and/or equipment damage.
Observe the safety procedures listed here, national electrical code
recommendations, and plant procedures when working on equipment. Disregarding these
requirements may cause serious personal injury, death, and/or equipment damage.
Disregarding these requirements may cause serious personal injury, death, and/or equipment
damage.

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 CHAPTER 1: SAFETY CONSIDERATIONS

Never make adjustments to the electrical system until you are sure all personnel are clear of
rotating and moving parts.
Safety devices should never be jumped or defeated in any way. These devices are designed to
protect personnel and equipment.
There are symbols used throughout the manual to draw particular attention to the user. They are
as follows:

Statements advising the user of procedures, hints and instructions that

are of particular interest.

Statements to identify a condition or practice, if not avoided, could

possibly result in damage to the equipment or in minor or moderate personal injury.

Statements to identify a condition or practice, if not avoided, could

result in serious personal injury or loss of life.

Statement to identify a condition or practice that will result in death or

serous injury.

4
 CHAPTER 2: MACHINE UTILITY REQUIREMENTS

CHAPTER 2
MACHINE UTILITY REQUIREMENTS
These installation instructions are intended to provide the customer with the following
information:
 Setting the equipment in place.
 Electrical and compressed air utility requirements and their connection for the equipment
provided by ProSys.
 Connection of any peripheral equipment provided by ProSys.
 Product feed requirements to the ProSys filler.
IMPORTANT INSTALLATION NOTES
The quality and consistency of the utilities to the ProSys filler have a direct effect on how well
the machine performs. The electrical and compressed air supply to the ProSys filler must meet
the minimum and maximum requirements outlined for the machine to operate satisfactorily. A
letter and approval drawing was sent to Prodo Pak prior to the filler being built. This letter and
drawing outlined the utility requirements for the filler. Refer to drawing S1142 in these
installation instructions. The drawing shows the layout of the filler. Considerations must be made
for ease of access to the machine.
ELECTRICAL SUPPLY
The electrical voltage must be within plus or minus 10% of the nominal voltage specified. If
electrical “spikes, dips or brownouts” occur an appropriate constant voltage transformer and line
conditioner should be installed or other appropriate action taken to ensure the voltage remains
within the specified range.
CONNECTION
The control system is to be provided by the customer. The controls for the metering adjust motor
provided requires 240Vac, three phase, 60HZ, 40AMP electrical power with a ground.

Only qualified personnel should perform electrical installation. Damage to

the equipment or severe injury may result if improper electrical connections are made.
COMPRESSED AIR SUPPLY
The consistency of the pressure and flow and the quality of the compressed air supply to the
filler is extremely important to maintain performance of the filler and extend the service life of
the pneumatic components. The air should be dry and free of contaminants. Moisture in the air
may cause the machinery to not function properly and fail prematurely. An air dryer may be
required to remove moisture. If there is excessive oil form the air compressor, a coalescing filter
should be installed to remove excess compressor oil from the air to the filler. Air born particles
can cause the solenoid valves to stick and cause undue wear on all pneumatic components.
The pneumatic system on the filler is intended to operate “dry” with no additional lubrication. If
lubrication is to be used, the proper type of lubricants must be used and applied in the proper
manner. Contact ProSys for recommendations.
The maximum and minimum air pressures specified must be maintained for the filler to operate
properly. Many factors can affect the air supply to the filler. The pressure at the compressed air

5
 CHAPTER 2: MACHINE UTILITY REQUIREMENTS

source may not be the same as the pressure at the filler. Compressed air pipe size, distance, and
number of elbows or bends in the line all affect the pressure at the end of the line. If other
equipment that uses compressed air is operating from the same compressor source, it must be
considered in the overall scope of the compressed air supply. It is recommended that a pressure
gauge be installed in the line close to the filler to monitor compressed air supply. The air
pressure can be monitored to verify if there are supply issues.
Please contact ProSys with any questions on the electrical or compressed air supply.
CONNECTION
This filler station was built with the intent of a customer supplied dry clean air system with 10
SCFM @ 80 PSI MINIMUM 120PSI MAXIMUM. A 1-inch minimum inside diameter supply
line is recommended.
TAKE AWAY SYSTEM
The means to handle the containers after they are filled from the ProSys filler is to be provided
by the customer.

6
 CHAPTER 3: FILLER FUNCTION OVERVIEW

CHAPTER 3
FILLER FUNCTION OVERVIEW

The ProSys Filler is four head filler designed for metering flow able materials into a form / fill /
seal type bag. Bags are sealed with a customer supplied sealer.
The machine is electric/pneumatic operated, designed for operation in a NON-HAZARDOUS
location. The pneumatic devices are controlled by customer supplied air solenoid valves and
regulators.

PROSYS FILLING MACHINE

The fill station is to be secured to the customer supplied bag form and seal machine.

7
 CHAPTER 3: FILLER FUNCTION OVERVIEW

The fill station uses a positive displacement-metering cylinder to measure the volume of the
material to dispense into the bags. A rotary style valve controls the porting for the material
metering and dispense.

8
 CHAPTER 4: FILL STATION

CHAPTER 4
FILL STATION
FILL STATION OVERVIEW
The fill station uses a positive
displacement-metering cylinder to
measure the volume of the material
to dispense into the pouches. A rotary
style valve controls the porting for
the material metering and dispense.
When the valve is in the retracted
position, the port is open from the
material feed to the metering
cylinder. As the piston inside the
metering cylinder is drawn back, the
material flows into the metering
cylinder from the feed. When the
valve is in the extended position, the
port is open from the metering
cylinder to the dispense nozzle and
closed from the material feed to the
metering cylinder. As the metering
piston extends, material is displaced
from the metering cylinder out the
dispense nozzle.
FILL STATION OPERATING SEQUENCE
When a pouch is formed at the fill station, the dispense nozzle has an internal shut off that
opens while dispensing and closes to prevent material from dripping after dispensing. The
shut off is hollow to provide an air blast to clean the dispense nozzle tip if necessary. When
the dispense nozzle is in the bottom of the pouch, the fill valve rotates to the dispense position
and the nozzle shut off opens. When the valve is “Open” and the dispense nozzle is in
position, the metering piston extends to displace the material from the metering cylinder out
the dispense nozzle.
AIR IN THE FILL SYSTEM
The ProSys filler uses a, positive displacement filling system. It is absolutely essential that the
material to be filled is free of entrapped air and that air is not introduced in the process of
delivering the material to the ProSys filler. Air entrapped in the material will compress in the
system, giving inconsistent fill volumes and “popping” at the dispense nozzle as the air escapes.
If material with entrapped air is introduced into the system, it must be removed.
The operator must remove the material from the customer’s delivery system and the filler until a
steady flow of material with no “popping” is seen.

9
 CHAPTER 4: FILL STATION

VOLUME VS. WEIGHT

The ProSys filler is designed to fill by volume so it is important to understand the difference
between volume and weight when filling containers. The volume of material to be dispensed into
the container is measured in the metering cylinder on the ProSys fill station. The metering
cylinder has a fixed diameter and the piston inside the cylinder travels the determined distance
on each stroke. The diameter of the cylinder and the stroke of the piston determine the volume of
material that can be filled.
Volume is defined as the amount of space occupied by a three-dimensional object as measured
in cubic units. Typical units of measure used for volume with their common abbreviations are as
follows:
Fluid ounces – fl oz
Cubic inches – cu in or in3
Cubic centimeters – cc
Milliliters – ml
When relating to pouch filling Volume refers to the capacity of a pouch. Volume may refer to
liquids or solids.
Weight is defined as the force with which a body is attracted toward the earth by gravitation and
which is equal to the product of the mass and the gravitational pull. Since gravity on earth is
relatively constant, weight refers to the mass or density of a material.
Typical units of measure used for weight with their common abbreviations are as follows:
Ounce - oz
Pound - lb
Milligrams – mg
Grams – g
Kilograms - kg
When relating to pouch filling Weight refers to the weight of the material in the pouch as
measured on a scale.
Different materials can occupy the same volume and weigh differently, hence the analogy a
pound of feathers vs. a pound of lead. They both weigh the same, but a pound of feathers will
occupy a much larger volume than a pound of lead.
Since the ProSys filler is designed to fill by volume, if the amount of material in the container is
being measured by weight and if the density of the material changes, the weight will change as
well, even though the same volume of material is in the pouch. The change in weight is not a
function of the ProSys filler, but the change in the density of the material.

10
 CHAPTER 4: FILL STATION

NOZZLE BLAST
The nozzle blast is intended to help clean the nozzle
after each fill. The blast feature is used only with
certain styles of nozzles. The nozzle has a hollow
stopper rod that extends to the dispensing end of the
nozzle.
The nozzle blast occurs after all of the material has
been dispensed into the pouch. The signal for the
blast is given when the metering stroke is complete.
The blast is accomplished by a directing a volume of
air through the hollow stopper rod inside the nozzle.
The blast may be adjusted by changing the pressure on
the nozzle blast air regulator.

Timers accessible from the HMI determine when the

blast occurs and the duration of the blast. The nozzle
blast timers will be discussed in detail later in this
section.
The blast may not be needed for thinner materials. If
the material is thin and the blast is set too high, the
blast may splatter the material back onto the nozzle.
To disable the blast, set the air pressure at the
regulator to “0”, disconnect the blast air line at the top
of the nozzle stopper air cylinder and install a push in
plug in the fitting.

11
 CHAPTER 4: FILL STATION

DISPENSE HEAD

FILL PURGE FEATURE

The fill station is programmed with a FILL PURGE feature that
allows the operator to cycle the fill station independent of all
other operations. Reference the HMI section of this chapter for
complete instructions.

METERING / MATERIAL FEED RATE ADJUSTMENT

Material must be able to flow to the fill valve at a sufficient rate to ensure full loading of the
metering cylinder as it charges. If the metering cylinder moves up (recharge) at too slow of a
rate, the machine cycle rate will be decreased. Inconsistent fills are usually the result of one of
three conditions:
 Air entrapped in the material or in the fill system.

12
 CHAPTER 4: FILL STATION

 Product not flowing to the metering cylinder at a sufficient rate from the material feed tank.
 Worn or damaged seals in the metering or fill valve.
If the fill weights are inconsistent, refer to the action described below for the type of material
feed system being used. A reliable test to determine if the material feed is the cause of the
inconsistency is described as follows:
 A run of pouches will be made in the automatic mode and in the manual mode. The two runs
must be kept track of separately to compare.
 Select the “Manual” mode of operation so the machine will only index 1 time when the cycle
start button is pressed.
 Fill one set of pouches then wait a full 10 seconds.
 After 10 seconds, press the cycle start button to fill another set of pouches.
 Repeat for at least 5 to 10 set of pouches.
 Weigh the pouches ran in the manual mode and record the weight of each.
 Select the “Auto” mode of operation and run 5 to 10 consecutive sets pouches.
 Weigh the pouches run in the automatic mode and record the weight of each in the order they
were run. It is important to keep the pouches in the order they were filled!
 If the weights run in the automatic mode decrease in the order they were run and / or the
pouches run in the manual mode are consistent, then the material is not being fed into the fill
valve and metering at an adequate rate.
WHEN USING A PRESS:
If it is determined that product is not being delivered at a sufficient rate from the press, increase
the pressure on the press system. DO NOT EXCEED 200 PSI to the fill valve inlet.
If the press pressure is at the maximum, it may be necessary to reduce the fill speed. Reducing
the fill speed will reduce the metering speed in both directions of travel. Reducing the metering
recharge stroke speed will allow the material more time to flow into the metering cylinder
ensuring a full charge and consistent fill volume.

If the material viscosity is very high, it may not be possible to obtain the
maximum cycle rate of the filler. Product flow is one factor in that may affect machine
cycle rate.
FILL STATION DISASSEMBLY AND ASSEMBLY

REMOVE ALL FORMS OF POWER AND FOLLOW PROPER

LOCKOUT AND TAG OUT PROCEDURES BEFORE PROCEEDING WITH THE
FOLLOWING MAINTENANCE.

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 CHAPTER 4: FILL STATION

FILL VALVE / METERING REMOVAL

If applicable, remove the material feed per the
instructions above.
 If desired, remove the air lines for
the dispense head and nozzle blast.
Remove the four bolts releasing the
dispense head from the valve.
 Remove the Allen screws that retain
the valve and metering assembly to the
base plate.
 Remove the clamp that connects the
drive to the metering assembly.
 Lift the assembly away from the
valve drive actuator to remove. The
valve drive actuator is keyed into the
valve core. The assembly may need to
be “worked” out gradually.

DO NOT move the

valve stop block. The block determines the correct position of the valve in relation to
the drive air cylinder.
 Remove the bolts on the Top Cap and remove from the Fill
Valve.
ROTARY FILL VALVE DISASSEMBLY, MAINTENANCE AND ASSEMBLY
The fill valve is a three-way valve mechanism providing a means for controlling the material
flow for the filling operation. Only two ports are open at any time during the valve operation.
When the valve is in the “normal” position, the porting is open between the material inlet and the
metering cylinder to allow the metering cylinder to be charged with the desired amount of
material. The port to the dispense nozzle is closed. When the valve core rotates to the dispense
position, the porting is open between the metering cylinder and the dispense nozzle. The port to
the material inlet is closed.
Refer to drawing and the Sanitary Valve graphic below. The valve core slides into the valve
body. The core is supported by two ball bearings. The fit of the ball bearings to the body and the
core is a very close tolerance slip fit. Take care not to dent, scratch or otherwise damage the
inside diameter of the valve body or the outside diameter of the valve core. The bearing retaining
washers fit between the ball bearings and the core. The washers serve to retain the o-rings on the
core and provide a means to load the inner race of the ball bearing. The o-rings fit onto the small
“step” on the valve core and provide the means to seal the product pressure inside the valve
assembly. The bearings, bearing retaining washers, o-rings and valve core all “sandwich”
together to make up the internal parts of the valve assembly. The core with, bearings, retaining
washers and o-rings, slide into the valve body at the assembly.

14
 CHAPTER 4: FILL STATION

Note that there are holes through the valve body that intersect the inner
bore. These are bleed ports for material that may leak by the o-rings when worn. If
material is present in the bleed ports, the o-rings should be replaced and the valve
assembly inspected for wear and /or damage. If the operation is continued with the
valve o-rings leaking, product will likely migrate to the bearings and damage the
bearings.
The o-rings in the valve will need to be replaced as they wear with use and are considered
normal wear items.

To disassemble the valve, proceed as follows:

 Place close attention to the orientation of the valve body with respect to how it is mounted on
the machine and the valve core with respect to how it oriented inside the valve body.
 Loosen the locking handles and swivel the eccentric clamp plate to access the valve core.
 Tighten the locking handles to secure the clamp plate in place.
 Using the handle on the valve core, pull the valve core free from the valve body.
 It is not necessary to remove the end retainer plate but may be desired to make cleaning
easier.
 As the core is removed from the valve body, the bearings, bearing retaining washers and o-
rings will be pushed from the body.
 One bearing may remain in the body when the core is pushed out. Wipe material from the
inside of the body, and then push the bearing out of the body.
 Remove the bearings from the core and / or body.
 Remove the two retaining washers from the core.
 Remove the two o-rings from the core.

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 CHAPTER 4: FILL STATION

 The valve key adapter need not be removed, if removed it is critical that the valve key
adapter be installed back in the same location due to the design of the valve core. The cutout
in the end of the valve core for the valve key adapter is offset from the centerline of the valve
core. If the valve key adapter is installed improperly, the valve key adapter will not align
properly with the rotary actuator key causing the assembly to bind and not function in an
acceptable manner.
 Clean all parts immediately being careful not to scratch or damage the valve body and the
core. Inspect the valve core and inside diameter of the valve body for scratches, scoring or
other signs of wear or damage. The parts are precision machined with very fine finishes,
scratches or scoring on these surfaces is signs of problems and parts should be reworked or
replaced.
 Do not immerse the bearings in water or solvents when cleaning the valve. Wipe away any
material from the bearings. The bearings are sealed for incidental contact with foreign
materials. Some solvents may attack the bearing seal material.
 Inspect the bearings for wear or contamination. Turn the bearing by hand to ensure the
bearing is free and smooth. If there is doubt to the condition of the bearing, it should be
replaced.
 The valve core o-rings are a standard o-ring dash number 327. The o-ring material may vary
according to the application. Viton is the standard material. Check for compatibility of the o-
ring material with the products to be filled. One exception to the size is if Teflon
encapsulated o-rings are used, then the next larger size, 328 is used.
To assemble the valve, proceed as follows:
 Place the o-rings onto the small step on the valve core.
 Place a small amount of o-ring lubricant or grease on the o-rings to aid installation.
 Place the retaining washers onto each end of the core. Note the orientation of the small step
on the washers. The step must face away from the o-rings.
 Slide the bearings onto each end of the core. The bearings should slide freely onto the core
by hand.
 If the end retainer was removed, reinstall with the two ¼-20 screws.
 Carefully slide the valve core assembly into the bore in the valve body. Be very careful not to
pinch the o-rings as they enter the body.
 Push the core in until the core assembly is fully seated in the valve body. Note the valve
core should be reinstalled into the valve body with the valve key adapter end of the
valve core entering first. The valve key adapter should protrude thru the end retainer.
 Unlock the locking handles and swivel the clamp plate to secure the core assembly in the
valve. Tighten the locking handles when complete.
 Use a 5/8” open-end wrench on the valve key adapter to turn the core. The core should turn
easily with the wrench.
 Turn the core so the porting is open and evenly aligned from the inlet (top) and metering
(bottom). The port to the dispense nozzle (side) should be completely closed. The valve core
will need to be in this position to be installed. The valve adapter key is rectangular (5/8” X
1”) and will only slide into the fill stand if oriented correctly.

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 CHAPTER 4: FILL STATION

FILL VALVE PORTING VERIFICATION

The fill valve porting should be verified after the valve is assembled. With the valve in
the “home” position, the porting must be open from the material feed to the metering
cylinder. The port to the dispense head must be completely blocked by the core.
With the valve in the “extend” position, the porting must be open from the metering to
the dispense head. The port to the material feed must be completely blocked by the core.
METERING PACKAGE DISASSEMBLY, MAINTENANCE AND ASSEMBLY
Refer to the change charts for the correct metering package to use with the desired container
size.

STANDARD METERING PACKAGE

For disassembly of the metering package, refer to drawing.
 Remove the metering package from the valve block by removing the clamp. Note the O-
ring on the flange.
 Hold the metering package over a container and push the rod toward the cylinder to
push most of the material out of the metering cylinder.

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 CHAPTER 4: FILL STATION

 Remove cylinder clamp from metering cylinder.

 Remove the clamp from the metering cylinder cap.
 Pull the metering rod and seal assembly from the cylinder
 Remove the seal from the metering cylinder. IF THERE IS ANY DOUBT TO THE
CONDITION OF THE SEAL, REPLACE IT. Inspect the bore of the bronze bushing for
excessive wear and replace if needed.
 Clean all parts immediately being careful not to scratch or damage the bore in the metering
cylinder and the metering rod. Inspect the metering rod and metering cylinder bore for
scratches, scoring or other signs of wear or damage. The parts are precision machined with
very fine finishes, scratches or scoring on these surfaces are signs of problems and parts
should be reworked or replaced.
 Reverse the disassembly procedure to assemble.
 Replace the seals as needed. Note the orientation of the lip of the seal when installing.
 Be careful not to damage the seal when inserting rod.
 Be sure to install the Teflon gasket between the cylinder flange weldment and the metering
cylinder before installing the sanitary clamp.
 Secure the metering package to the valve body.
FILL VALVE / METERING INSTALLATION
 Refer to the Fill Station drawing.
 Slide the assembly into the fill stand. The valve body should sit on the locating pins on the
base plate at the Fill Station. The valve core is keyed into the rotary actuator. The core and
key must be oriented correctly for the valve to slide into the stand.
 The assembly may need to be “worked” in gradually. DO NOT force the assembly into
place. NEVER use a hammer, similar object or excess force to get the metering and
valve assembly into the stand. If there is a problem, ensure the valve core and actuator
block are in the correct position.
 Once it is assured the assembly is set correct, install the bolts and tighten to the base plate.

The valve must be positioned correctly in relation to the air cylinder or it

will not operate properly. There should be no material or debris on the top of the valve block.
Also, there should be no material or debris on the mounting plate or the stop block the valve
rests against. The valve must set against the stop block and pull up to the mounting plate to be
properly aligned.
 After the assembly is secured in place, install the clamp to connect the metering rod to
the drive assembly.
 Assemble the dispense head assembly by securing with the bolts.
 Connect the air lines to the nozzle stopper air cylinder on the dispense head. The air
line slips into the fittings for easy installation.
DISPENSE HEAD DISASSEMBLY, MAINTENANCE AND ASSEMBLY
The dispense head incorporates the filling nozzle and the nozzle stopper mechanism. The
nozzle clamps to the block in which the product is fed. There is an air cylinder to actuate
the nozzle stopper mechanism.

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 CHAPTER 4: FILL STATION

There is a seal around the air cylinder extension rod to hold the product pressure. The seal
is considered a normal wear item and will need to be replaced if leaking, worn or
damaged. For maintenance of the dispense head seals, remove the nozzle as outlined below
refer to t h e D i s p e n s e H e a d A s s e m b l y drawing. Before disassembling, note the
orientation of the air fittings when installing the air cylinder onto the dispense block.
DISASSEMBLY
For seal maintenance, remove the nozzle as outlined below, proceed as follows:
 Remove the three air lines to the nozzle stopper air cylinder on the dispense head. The air
fittings do not need to be unscrewed the air line slips out of the fittings. To remove the air
line, hold the sleeve surrounding the air line in and pull the air line out. You must hold the
sleeve in while you are pulling on the air line.
 Remove the air fitting from the nozzle stopper so the stopper rod can be removed.
 Remove the anti-rotate pin from the stopper rod. It is a push to lock pin system. **HINT:
It may be easier to push the pin and then push from the front of the pin to remove.
 Remove the t w o socket cap screws and pull the stopper air cylinder and air cylinder
m o u n t b l o c k u p and of the bearing/seal assembly.
 Remove the sanitary clamp and gasket from the nozzle.
 Lower the Stopper Rod straight down, ensure not to bend the stopper rod.
 Use the Seal Removal Rod, per the Change parts drawing, and push the seal and bearing
out of the housing.
 Clean all parts thoroughly being careful not to scratch or damage the air cylinder
rod, bushing. Inspect these parts for scratches, scoring or other signs of wear or damage.
The air cylinder extension is precision machined with a very fine finish. If the rod is
scratched or scored the part should be polished or replaced.
 Make sure the bore through the air cylinder rod and air cylinder extension is clean.
The nozzle blast air passes through this bore and it is important to keep clean to ensure
proper operation of the nozzle blast.

DO NOT immerse the air cylinder in solvent or other fluids,

including water. Keep solvents away from where the rod enters the air cylinder to
prevent the air cylinder seals from being damaged.
 Inspect the seal and the o-ring for wear or damage and replace if necessary. If there is
any doubt to the condition of the seal, it is best to replace it now.
ASSEMBLY
 Place the Stopper Rod through the Inlet Fitting
 Replace the Nozzle
 Replace the sanitary clamp and gasket for the nozzle.
 Install the seal into the dispense head body. Note the orientation of the seal lip in
the drawing. Be very careful not to damage the lip on the seal when installing the in the
body. It is recommended you use an appropriate lubricant when installing seals and O-
rings.
 Install the bearing over seal and seat the seal in the housing so the bearing is flush with the
housing.

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 CHAPTER 4: FILL STATION

 Orient the stopper rod so the double holes are facing the front of the machine
 Install the two socket cap screws through the holes in the air cylinder mount,
threaded into the Dispense Head Body. Note the orientation of the air fittings.
 Tighten all bolts
 Pin starting with the middle air cylinder first then outside ends
 Install the air fitting in the nozzle blast.
 Connect the airlines
NOZZLE PACKAGE
Refer to the Nozzle Package drawings for the nozzle provided with this machine.
Note that the nozzle package has a rod that runs through the length of the nozzle. This rod
seats at the tip of the nozzle to cut off the material at the end of the nozzle. The positive
shut off nozzle stopper rod is hollow to accommodate the nozzle blast. The nozzle blast is
covered in the first part of this section of the manual. To disassemble the fill nozzle proceed
as follows:
 Unclamp the nozzle body from the adapter. Note the o-ring between the nozzle and the
dispense head.
 Carefully lower the nozzle down until free of the stopper.
 Pull the stopper rod anti-rotate pin.
 Remove the air lines for the nozzle blast. Then remove the air line fitting from the stopper
rod.
 Unscrew the stopper rod from the dispense head extension. Use the wrench flats on the
stopper rod, DO NOT use channel locks, vice grips or similar tools. There are wrench flats
on the top portion of the air cylinder shaft to hold with a ½” wrench while unscrewing the
nozzle stopper.
 Unscrew the nozzle tip from the nozzle body.
 Clean the stopper rod. Be very careful not to bend the stopper rod or damage the end
that seats into the nozzle tip. Be certain the hole through the center of the stopper is clean
and completely free of product or obstructions to ensure proper operation of the nozzle blast.
 Inspect the bevel seat area of the nozzle tip.
 Inspect the bevel seat area of the nozzle stopper rod.
 If the bevel seat is worn or damaged, the nozzle stopper will not seal off satisfactorily. The
nozzle stopper tip and nozzle tip are considered normal wear items and will need to be
replaced when worn to the point the seat is compromised.
 Assemble by reversing the above procedures.
 When installing the nozzle tip, it is recommended to put one wrap of a Teflon thread sealing
tape onto the male threads of the nozzle body.

DO NOT use channel locks, vice grips or similar pliers on the nozzle
body bottle or nozzle tip. If these parts are squeezed, they will become “egg” shaped
and the parts will not assemble or disassemble.

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 CHAPTER 4: FILL STATION

Be careful not to over-tighten the stopper or the threaded portion

of the stopper may break. If the threaded portion needs replaced, order ProSys
part number 19592.
DISPENSE HEAD PURGE
Refer to the Change parts drawing for the nozzle provided with this machine. To purge
all of the material from the dispense head before use open valves on the dispense head and cycle
the Fill Station. When product flow from the port, close.

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 CHAPTER 4: FILL STATION

HUMAN / MACHINE INTERFACE UNIT FUNCTIONS

There is access to menus for options to select as well as access to timers and counters for set up
purposes. Follow the on screen prompts to determine the buttons to press for the desired feature.
There is access to menus for options to select as well as access to timers and counters for set up
purposes. Follow the on screen prompts to determine the buttons to press for the desired feature.
STATION SELECT
There are selector screens for the various stations, material feed, and fill purge. Each screen is
shown below:

Selector Switches

FILL STATION OFF/ON

Pressing this button toggles the fill station operation off and on. The fill station should be on for
normal operation. When the fill station is selected “ON” the fill station will operate so the tube is
lifted, filled and set into the index dial. When selected “OFF”, the fill station will not operate and
tubes will not be filled. When the button is pressed so the fill station is “ON” the button will be
highlighted.
HOPPER ON / SURGE TANK ON / RESERVOIR ON / MATERIAL FEED OFF
Pressing this button will toggle the hopper, reservoir, or surge tank level sensor on or the
material feed relay off. When the selector is on the signal will be given to fill the tank when the
level sensor is met the product feed will stop filling. When the low level is sensed the product
will fill the tank. When the selector is off, no signal will be given to fill the tank.

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 CHAPTER 4: FILL STATION

Fill Purge
The fill station is programmed with a FILL PURGE feature that allows the operator to cycle the
fill station independent of all other operations. This allows a material purge, flush out, or
removal of material with entrapped air from the fill station to minimize waste and down time.
When the machine is in the purge mode, only the fill station will operate and the dial will not
index. The fill lift mechanism is disabled when using the fill purge feature, allowing the operator
to set a container on the dial, under the fill nozzle to catch the purged material. The fill purge on
/off selection is made on the station select screen of the HMI terminal.

Before entering the purge mode:

1. Turn the load station off and allow the dial to index until all tubes are clear of the fill
station. DO NOT manually remove tubes from under the fill nozzle to purge!
1. Place a container under the fill nozzle to catch the material before setting the machine to
the purge mode.
2. Select the FILL PURGE to the desired stroke.
The fill purge mode is enabled and operation of the dial is disabled. When the CYCLE START
push button is pressed, the fill station will perform one cycle and stop. Continue to press the
cycle start button one time for each cycle.
When the fill purge mode is selected, this message will be displayed:
FILL STATION PURGE SELECTED

Remove the container after leaving the purge mode.

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 CHAPTER 4: FILL STATION

When finished with the fill purge mode:

1. Remove the container after leaving the purge mode.
2. Select the fill purge mode to “Off”.
STATUS
Refer to chapter 4 of this manual for instruction on these screen.
SETUP
The “SETUP” button on the main screen will take you to a screen to access the following
settings, then press the Fill #1 or Fill #2 tabs for the variables for the fill station.
Load / Matl Feed

HOPPER LOW LEVEL ALARM

This counter determines how many fill cycles are completed before the hopper is considered too
low to continue filling. The counter starts after the signal for the hopper to fill is given. If the
counter reaches the preset before the hopper is completely filled and the full sensor is made, the
message “RESERVOIR IS LOW, AUTO MODE IS DISABLED” will be displayed. The counter
should be tuned to work with the material feed system. The counter should be set so the hopper
is filled before the counter reaches the preset and still allow the material feed system to catch up
and replenish the hopper. The total of the reservoir low level and the reservoir high level should
not exceed the volume of the reservoir.
RESERVOIR LEVEL
The volume of the reservoir is approximately 10 gallons (1,280 fluid ounces). The material feed
fill counter determines how many fill cycles are completed before giving the signal to fill the
reservoir. The counter starts after the material level has fallen out of range of the reservoir full

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 CHAPTER 4: FILL STATION

sensor. The counter should be tuned to work with the feed system. Ideally the counter should be
set so as much material as possible is used out of the reservoir before the material feed system is
turned on and still allow the material feed system to catch up and replenish the reservoir. If the
counter is set low, the filler will function fine, but the material feed pump may cycle on and off
more than needed causing undue wear on those components. If the counter is set too high, the
material feed pump may not be able to keep up with the demand and the reservoir low message
may stop the filler. If in doubt, it is better to set the counter on the low side. The total of the
reservoir level and the reservoir low counter should not exceed the volume of the reservoir. For
example if 5-ounce tubes are being run. The amount of material being used out of the reservoir
for each fill is 5 fluid ounces 5 per cycle. The maximum volume of the reservoir in fluid ounces
is 1,280.
How many fill cycles can be made with the 1,280 ounces in the reservoir?
1,280 ÷ 5= 256
It would take 256 fill cycles when filling 5 ounce tubes to completely empty the reservoir. If you
were to figure 1/3 of the reservoir volume to be used prior to refilling, first you must figure how
many cycles that will take. [256 ÷ 3 = 85.33333 (86 rounded off)]
This means 86 fill cycles would use roughly 1/3 of the reservoir volume. This means the
reservoir fill counter could potentially to be set to 86. The actual value depends on the capacity
of the customer’s material feed system
RESERVOIR LOW ALARM
The material feed low counter determines how many fill cycles are completed before the level in
the reservoir is considered too low to continue filling. The counter starts after the signal for the
material feed to turn on is given. If the counter reaches the preset before the reservoir is filled,
the machine will be stopped and the “RESERVOIR LOW” message will be displayed. The
counter should be tuned to work with the customer’s material feed system. The counter should be
set so the reservoir is filled before the counter reaches the preset and still allow the pump to catch
up and replenish the reservoir. The total of the reservoir low counter and the reservoir fill counter
should not exceed the volume of the reservoir. Refer to the example above for the reservoir fill
counter. We are completing 86 fill cycles before the customer’s material feed system comes on
to refill the reservoir. We want the material feed low counter to be set so the machine stops
before the reservoir is completely empty. Assuming the worst case of NO material coming into
the reservoir when the material feed comes on (someone turns pump off for example) how much
material can we use before the reservoir is empty? Remember we can complete 64 fill cycles
before completely emptying the reservoir:
256 – 86 = 170
This means we could potentially fill 170 tubes after the material feed system comes on to re-fill
the reservoir if the pump was not working. We could set the low counter to 170. It is
recommended not setting the low counter to the 170 though to allow for some error. A value of
165 would be recommended to give a margin of 5 fill cycles. It is best to set the value lower if in
doubt.
RESERVOIR FULL ALARM

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 CHAPTER 4: FILL STATION

The material feed full counter determines the number of cycles the fill will run with the reservoir
full sensor “ON”. It is recommended to set this at about the same value as the reservoir fill
counter.
Fill #1 Setup

FILL VOLUME (mL)

This button is used to enter the desired volume dispensed. Changing the fill volume will change
the distance the fill metering actuator strokes. If a change is made in the fill volume, the fill lift
will automatically follow at the preset ratio. Refer to the table below for values to convert from
common units of measure of volume. Refer to the discussion of weight versus volume in the first
part of the fill station section of the manual.

Volume converter
cubic
Variable Number cubic fluid centimeters /
Volume Unit Type of units inches ounces milliliters
fluid ounces 1 1.80 1 29.58
cubic inches 1 1 0.55 16.39
cubic centimeters 1 0.06 0.03 1
METERING I.D.
Use this button to enter the diameter of the metering piston being used on the fill station. This
value should equal the diameter of the piston for the metering cylinder assembly to be used.
Refer to the assembly drawing for the metering cylinder assembly to reference the inside

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 CHAPTER 4: FILL STATION

diameter. The value must be entered in inches. This value is used in conjunction with the tube
diameter, and fill volume to calculate the stroke of the metering actuator and the ratio of the lift
drop to the metering actuator stroke.
If your machine has more than one metering cylinder assembly, you must be certain the correct
assembly is installed for the tube to be run. Reference the change parts drawing for the tube to be
run. The change parts drawing will indicate the metering package to use. If in doubt about
choosing a metering assembly, refer to the table below as a general guide. As a rule, you should
choose a metering assembly that has no more than 3 times the maximum volume of the tube
volume you want to fill. Reference the table below. For example if you have a tube that is 1 fluid
ounce, you could use a 0.750” diameter metering package up to a 1.125” diameter metering
package. If a larger diameter metering package is used, the metering stroke gets very short to
achieve the desired fill.
Metering
Cylinder Inside Maximum Fill
Diameter in Volume in Fluid
Inches Ounces

0.500 0.598
0.625 0.935
0.750 1.346
0.875 1.832
1.000 2.393
1.125 3.029
1.250 3.739
1.375 4.525
1.500 5.385
1.625 6.320
1.750 7.329
1.875 8.414
2.000 9.573
2.250 12.116

TUBE I.D.
Use this button to enter the inside diameter of the tube being filled. The value must be entered
in inches. This value is used in conjunction with the metering diameter, and fill volume to
calculate the stroke of the metering actuator and the ratio of the lift drop to the metering actuator
stroke.
TUBE LENGTH (inch)
Use this button to enter the length of the body of tube being filled. The body of the tube is the
portion that will be filled with material and excludes any nozzles or caps. The value must be
entered in inches. This value is used to calculate the stroke of the fill lift actuator and the ratio of
the lift drop to the metering actuator stroke.
DIAL HEIGHT

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 CHAPTER 4: FILL STATION

This value determines the location of the fill lift axis home position. The value should be equal to
the value shown on the dial height scale. Enter up to a 5-digit number to the nearest decimal
from the scale reading on the dial post. This value needs to be adjusted any time the dial height
has been adjusted.

See the section of this manual covering the index dial. Reference the
instructions on the dial height.
DISPENSE SPEED
The metering dispense speed is how fast the metering actuator drives up and down during the
fill. The speed of the metering drive motor may be changed from 10% to 100% of the maximum
drive speed.
RECHARGE SPEED
The metering recharge speed is the speed the metering moves down after the fill to recharge the
metering cylinder. The speed of the drive motor may be changed from 10% to 100 % of the
maximum drive speed.
FILL LIFT CLEARANCE
Use this button to enter the desired value equal to the distance between the end of the fill nozzle
and the bottom of the tube when the tube is lifted to fill. This distance is the fill lift clearance.
The value must be entered in inches. This distance will need to be adjusted as needed for the
material viscosity and flow characteristics.
FILL RATIO
The fill ratio determines the rate between the metering dispense and the fill lift moving the tube
“down” while filling. The ratio must be changed when changing over between container sizes.
Also, the ratio may be varied slightly if a container of a slightly different diameter is to be run or
to allow for different material flow rates. The maximum and the minimum values that may be
entered are restricted. The number displayed is the rate or the lift compared to the rate of the
metering. Increasing the number will make the lift drop away faster in relation to the rate of the
metering. This would be needed if a slightly smaller diameter container were run.

Decreasing the number will make the lift drop away slower in relation to the rate of the metering.
This would be needed if a slightly larger diameter container were run.
The ratio can also be used to compensate for the compressibility of a product. If a product is
compressible, some of the movement of the metering will occur before the material compresses
to a point that it flows at a steady rate. If the product is compressible, then a lower ratio would be
desired.
When changing the ratio it is recommended to change in increments of 0.005 or less. A slight
change can make a considerable difference in the fill quality. This parameter may be changed
“on the fly” while the machine is filling. The change will not take effect until the next fill cycle
after the change was made.
SUGGESTED FILL RATIO
This is the suggested fill ratio based on the parameters for the fill metering and the tube to be
run.

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 CHAPTER 4: FILL STATION

Fill #2 Setup

LIFT UP SPEED (First Move)

This speed of the fill lift during the “up” portion of the movement may be changed if desired.
The value is a percentage of the maximum speed of the fill lift mechanism ranging from 25% to
100%. It is recommended to set the speed as low as possible while still maintaining the fill
station cycle speed needed.
LIFT DOWN SPEED
The entry controls the speed at which the fill lift will move down the remaining distance after the
tube is filled, to set the tube back into the index dial. The value entered is a percentage of the
maximum speed of the lift.
This can be an advantage for thinner products to help eliminate the potential for the product
“splashing” as the tube and holder is set back into the index dial. If the lift is slowed on the down
stroke the tube and holder will hit the index dial with less impact and reduce the chance of the
product splashing into the seal area or out of the tube.
The value of the lift return speed may change automatically if the parameters entered for stroke,
speed etc. are beyond the limits of the fill lift drive. If the system calculated that the drive can not
move as fast as the value entered, a new value for a rate that are within the limits of the drive will
automatically move into the setting.
LIFT DISPENSE DELAY
The lift dispense delay allows the metering actuator to move the entered time before the lift start
to move the tube down at the calculated ratio. This allows some product to be dispensed into the

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 CHAPTER 4: FILL STATION

bottom of the tube before the lift starts moving down. This can be an advantage with thicker
materials to ensure a solid fill. Also if the material is compressible the delay can be used to
compensate for the compressibility of the material. As a rule, start with a value of “0” for the lift
dispense delay. The value entered is in 1/100s of a second.
LIFT RETURN DELAY
The timer controls when the fill lift starts to move DOWN after the fill is complete. This time
can be used with the nozzle blast delay to create a dwell time for the blast to occur within the
tube.
An increase in time will cause the blast to occur closer to the material in the tube. If the blast is
occurring too close to the material in the tube, the blast will “splatter” the material into the seal
area of the tube and onto the nozzle, start to decrease the timer. If timer is set at “0” and the blast
is still “splattering” material, start increasing the nozzle blast delay. A significant increase in this
time value may affect the fill station cycle time and slow the overall output rate of the filler. The
value entered is in 1/100s of a second.
NOZZLE OPEN DELAY
The fill nozzle open timer controls when the stopper rod in the nozzle opens to allow product to
dispense. With no delay, the signal for the fill lift to move up and the nozzle stopper to open are
given at the same time. By inserting a delay, you can allow the nozzle to be at a lower point in
the tube before the stopper opens.
NOZZLE CLOSE DELAY
The timer controls when the dispense nozzle stopper closes after the fill. The timer may be used
to delay the stopper closing, ensuring that the pressure in the dispense nozzle is relieved and the
flow stopped. Closing the nozzle stopper against pressure or flow may result in a “spurt” of
material onto the tube.
NOZZLE BLAST DELAY
The timer to control when the dispense
nozzle blast occurs AFTER the fill is
complete. An increase in time will cause
the blast to occur further from the material
in the tube. If the blast is occurring too
close to the material in the tube, the blast
will “splatter” the material into the seal
area of the tube and onto the nozzle
The blast delay and lift return delay can be
used together to create the correct timing
for the blast. If the blast is occurring as the
nozzle is exiting the tube, start to decrease
the nozzle blast time. If the timer is at “0”
and the blast is still outside the tube, start
increasing the lift return delay or the lift
return offset to create a dwell period for
the blast to occur.

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 CHAPTER 4: FILL STATION

The graphic to the right illustrates the tube inside diameter, tube length, fill volume, lift return
offset and fill lift clearance. The graphic is intended as an aid in understanding the relationship of
the adjustable fill station parameters and how they affect the fill.
NOZZLE BLAST ON TIME
The timer how long the nozzle blast solenoid stays on, determining the duration of the nozzle
blast. The duration can be set as desired to help clean the end of the fill nozzle. Too short of a
duration may not clean the fill nozzle adequately. A long duration will help clean the fill nozzle
but may be such that the blast occurs outside of the tube or splatters in the seal area. The nozzle
blast delay and fill lift return delays can be used to help keep the blast within the tube.

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ALARM MESSAGES
The alarm messages pertaining to the fill station are as follows:
FILL VALVE IS NOT CLOSED
There are two sensors that verify the fill valve rotary actuator is at each end of its stroke. There is
a limit switch on each end of the actuator. The valve extend solenoid is not energized and the
valve “home” limit switch was not made within the preset time. The valve should be open from
the product inlet to the metering.
 The valve air cylinder has insufficient air pressure. Check the air pressure at the regulator.
 The limit switch needs repositioned.
 The valve core may be jammed or seized due to cured product or foreign material.
 Make sure the valve assembly is in the cradle against the stop block and the valve block is tight
against the cradle end plate.
 Check that the connector for the limit switch cable is secure
FILL VALVE IS NOT OPEN
There are two sensors that verify the fill valve rotary actuator is at each end of its stroke. There is
a limit switch on each end of the actuator. The valve extend solenoid is energized and the valve
“extend” limit switch was not made within the preset time. The valve should be open from the
metering to the nozzle.
 The valve air cylinder has insufficient air pressure. Check the air pressure at the regulator.
 The limit switch needs repositioned or has failed.
 The valve rotary core may be jammed or seized due to cured product or foreign material.
 Make sure the valve assembly is in the cradle against the stop block and the valve block is tight
against the cradle end plate.
 Check that the connector for the limit switch cable is secure
METERING SERVO DRIVE FAULT
The servo drive that operates the fill metering has a fault present. Go to the status screen for the
fill metering in the HMI and observe / note the fault code being displayed before taking any
action to clear the fault. The fault code with be displayed with an “S” then a two digit number
code, such as “S10”. Note the most likely cause of the fault is trying to push a thick material too
fast or a restricted flow path for the material. Clear the fault as described below. If there is no
apparent blockage for the material flow, reduce the metering speed by ½ and see if the fault
returns.
If an error code is encountered, check the following:
 There are no obstructions between the metering drive and metering cylinder.
 Check to see if the metering seal is leaking – if so the dried material may be creating
excessive drag and load.
 Verify the product flow path from the metering cylinder to the fill nozzle is free and
unobstructed. A foreign object in the material could cause a flow restriction and added
load to the metering drive.
To clear the alarm message / fault, proceed as follows:
 After all machine operations have completed, press the emergency stop button.
 Go to the status screen for the fill metering in the HMI.

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 Press the button “Servo Fault Reset”.

 Pull out the emergency stop button and press the RESET button to enable the filler.
 Press the RESET push button again to clear the message from the human/machine
interface terminal.
 If the servo drive fault cleared, the metering actuator will home. Watch for the movement
of the fill metering actuator when you re-enable the filler.
 Refer to the trouble shooting section of the manufacture’s manual for the servo drive for
possible causes and remedies for the fault code or contact ProSys for assistance.
 If there is no definite indication of the problem after reading the fault code, turn the main
disconnect switch off to remove electrical power. Leave the power off for one full
minute, then turn the disconnect switch “On” to restore power.
 Enable the filler and check the status of the drive and human/machine interface terminal.
Only qualified persons should open the electrical enclosure, perform
electrical troubleshooting or maintenance functions.
METERING ACTUATOR WILL NOT HOME
There is a proximity sensor mounted on the channel rail that detects the metering. The proximity
sensor is used for the servomotor to determine the “home” position for the metering. If this
message appears, the metering servo motor is moving to “find” the home proximity sensor, but
the “home” proximity sensor has not been made.
 Verify the position of the metering.
 Check the coupling at the drive shaft and metering housing. This coupling may have
slipped or broke.
 Check, that the face of the proximity sensor is within 1/16” from the target.
 Check that the cable for the proximity sensor is connected and secure.
FILL STATION PURGE SELECTED
When the fill purge mode is selected, this message will be displayed. Refer to Fill Station section
for information on this message.
PREVENTIVE MAINTENANCE REQUIRED ON THE METERING ACTUATOR,
GOTO MACHINE STATUS (PREV. MAIN. ALARM RESET) TO CLEAR ALARM
Once the fill station has completed “one million cycles”, this message will appear. The message
can only be reset by accessing the “Preventative Maintenance Reset” pushbutton located in the
“Machine Status” screen. This screen can only be accessed by a user logged in under
“maintenance” or “supervisor”. Refer to the fill station section of this manual for the
maintenance requirements.
METERING ACTUATOR WILL REQUIRE SERVICE IN 90,000 CYCLES
There is a counter built in to track the number of cycles of the fill metering servo actuator. A
message will be displayed after 910,000 cycles of the fill metering actuator. Messages will be
displayed intervals of 30,000 cycles until 1,000,000 (one million) fill metering actuator cycles
have been reached. The messages will read “METERING ACTUATOR WILL REQUIRE
SERVICE IN 90,000 FILL CYCLES” then 60,000 cycles and 30,000 cycles of the fill metering
servo actuator. These messages will not stop the operation of the filler and will be cleared if the
“Reset” button is pressed while the message is displayed.

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When the fill metering actuator cycle counter reaches one million cycles,
the load will be disabled, the dial will empty and the filler will stop. The message
Preventive Maintenance Required On The Metering Actuator, Goto Machine Status
(Prev. Main. Alarm Reset) To Clear Alarm will appear. Once the fill station has
completed “one million cycles”, this message will appear. The message can only be reset
by accessing the “Preventative Maintenance Alarm Reset” pushbutton located in the
“Misc. Functions Setup” screen.
REDUCE FILL VOLUME AND/OR FILL RATIO
The entered “Fill Ratio” or “Fill Volume” have exceeded the metering actuator stroke; reduce
either the “Fill Ratio” or the “Fill Volume”.
MAXIMUM METERING STROKE EXCEEDED, CONFIRM / REDUCE FILL VOLUME
The entered “Fill Volume” has exceeded the maximum metering servo actuator stroke; reduce
the “Fill Volume” entry. If the maximum metering stroke has been reached, then to achieve a
larger fill volume a larger diameter metering cylinder assembly would have to be installed.
Verify the correct metering cylinder assembly is installed for the container being filled.
REDUCE DISPENSE SPEED
This message will appear only if the calculated fill station cycle time has exceeded the time for
the fill station to cycle without receiving an interrupt message. If the container is filling properly
and the nozzle cut off is good, then the machine speed will need to be reduced.
REDUCE TUBE LENGTH
The entered “Tube Length” has exceeded the maximum “Fill Lift Stroke”; reduce the “Tube
Length”.
MAX. MACHINE SPEED HAS BEEN EXCEEDED, REDUCE MACHINE SPEED OR
EDIT FILL PARAMETERS
This message will appear only if the calculated fill station cycle time has exceeded the time for
the fill station to cycle without receiving an interrupt message. The fill station parameters that
affect this message:
 Fill Lift Stroke
 Fill Lift Return Stroke
 Lift Return Speed
 Fill Meter Stroke
 Fill Lift Drop Delay
If the container is filling properly and the nozzle cut off is good, then the fill lift return stroke, lift
return speed or lift drop delay are the parameters that could likely be reduced and still maintain
the fill and cut off. If reducing these parameters is not feasible, then the machine speed will need
to be reduced to match what is displayed at the “Maximum Machine Cycle Rate” data
displayed in the operator interface terminal.
REDUCE RECHARGE SPEED
The entry controls the speed at which the metering will move down after the tube is filled. The
value entered is a percentage of the maximum speed of the metering.

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The value of the metering speed may change automatically if the parameters entered for stroke,
speed etc. are beyond the limits of the metering drive. If the system calculated that the drive
cannot move as fast as the value entered, a new value for a rate that are within the limits of the
drive will automatically move into the setting.
ABORTED TUBE AT THE FILL STATION - REMOVE
The emergency stop push button or an access door was opened before the fill station completed
the cycle. The tube may not be filled correctly. The operator should inspect the tube and may
remove the tube if desired; otherwise, the tube will be unloaded from the filler.
FILL STATION INDEXER INTERRUPT
The index dial is running and it was detected that the fill lift is not in the down position as the
dial was ready to move. The index dial was immediately stopped to prevent potential damage to
the lift.
 The fill station parameters require the machine to be run at a slower rate, reduce the
machine speed.
 The fill lift servo has faulted.
OPTIONAL FILL STATION ALARM MESSAGES
The following alarms are programed in the filler and depend on the additional
options purchased with the basic filler package.
RESERVOIR LOW, LOAD DISABLED IN AUTO MODE
The reservoir is selected “ON”, and the full sensor has not been detected after the preset number
of fill cycles. The level in the reservoir may be close to empty. The load station is disabled to
prevent partially filled or empty pouches from being packaged. If the reservoir is selected "OFF"
the machine may be run, but the pouches may not be filled properly.
SURGE TANK LOW, LOAD DISABLED IN AUTO MODE
The material feed is selected “ON”, and the surge tank level is low enough that the “low”
proximity sensor was made. The level in the surge tank may be close to empty. The load station
is disabled to prevent partially filled or empty pouches from being packaged. If the material feed
is selected "OFF" the machine may be run, but the pouches may not be filled properly.
RESERVOIR FULL TOO LONG
If the material feed is selected “ON”, the fill station has cycled a preset number of times and the
material feed full sensor is still “ON,” the load station will be disabled. The level in the material
feed container is uncertain and pouches may not fill properly.
 The full sensor may have product on it. Check and clean.
 Check the “material full too long counter” preset value. The value should be a number
that is greater than the number of fill cycles required for the product in the reservoir to
fall below the range of the reservoir full proximity sensor. This value will need to vary if
the fill volume of the pouches is changed significantly.
 The setup of the material feed full proximity sensor may be too high so that the input is
on even when the material feed is not full. Set the sensor as described above in the fill
station section of this manual.
HOPPER LOW, LOAD DISABLED IN AUTO MODE

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 CHAPTER 4: FILL STATION

The hopper is selected “ON”, and the full sensor has not been detected after the preset number of
fill cycles. The level in the hopper may be close to empty. The load station is disabled to prevent
partially filled or empty pouches from being packaged. If the hopper feed is selected "OFF" the
machine may be run, but the pouches may not be filled properly.

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 CHAPTER : MAINTENANCE

CHAPTER 5
MAINTENANCE

PREVENTATIVE MAINTENANCE

Filling machines can cause serious injury if the operator and/or

maintenance personnel are untrained or careless. Do not attempt to service this machine
unless you are trained and experienced and have read and understand the instructions in
this manual. A SAFETY section is included in the front of this manual. This should be
read and understood before working on the machine.

For information on auxiliary equipment not manufactured by ProSys, refer to the manuals
provided by the manufacturer.
Routine maintenance will keep the machine running in peak condition and will avoid costly
repairs and down time. To prevent deterioration of machine performance, ProSys recommends
that a routine maintenance schedule be established and followed. Below is a general guide for
establishing a preventive maintenance. The type of products run, the environment the filler is run
in and the number of cycles the filler is run are all factors in determining when preventative
maintenance should be done. ProSys highly recommends creating a maintenance log to
document the type of maintenance, the date and the reason for maintenance on the filler. This
information can be used to help establish a more comprehensive preventative maintenance
program and to establish the type and quantity of spare parts to keep on hand.
DAILY:
 Visually inspect the fill station components and plumbing for any material leaks. Correct the
cause of the leak. Material leaking from around the fill valve core or from the bottom of the
metering cylinder is a definite sign that seals need replaced.
 Check the overall condition of the machine for loose or broken parts, signs of wear, etc.
 KEEP ALL MOVING PARTS CLEAN! Keeping the machine clean in general will aid in
operation, reduce down time in the long run and prolong the life of the equipment. If there is
a spill clean it up immediately. Product or any foreign material on moving parts can greatly
affect the operation and service life of the parts.
Note these particular areas to keep clean:
 Fill nozzle.
 Check the fill station nozzle blast to make sure the lines are clear.

WEEKLY:
 Inspect air cylinders, air tubing and air fittings for signs of wear or air leaks and replace
as needed.
 Inspect the machine for loose or missing fasteners and tighten or replace as needed.
QUARTERLY:
 Completely clean all machine parts and inspect operational functions and adjustments.
Some disassembly of stations may be required.

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 CHAPTER : MAINTENANCE

MAINTENANCE NOTES
The intervals for maintenance listed above are based on the equipment running a single eight-
hour shift, five days per week. If the equipment is to be run beyond a standard forty-hour week,
adjustments in the Preventative Maintenance schedule should be considered accordingly.
Conditions and environments vary and should be considered in the Preventative Maintenance
schedule. Additional procedures other than those listed above may need to be implemented.
SEAL AND O-RINGS
Seals and o-rings in the fill station are considered normal wear items and will need to be replaced
on a regular basis. There are many variables the seals and o-rings are exposed to that may affect
the service life and ProSys makes no claims or guarantees as to service life of seal and o-rings.
With the information provided, we match a seal and o-ring configuration that will give a
reasonable service life at a reasonable expense.
METHODS OF CLEANING
Use of Scotch-brite® pads is recommended for cleaning metal parts on the filler, including the
fill valve and metering parts. DO NOT use steel wire brushes to clean fill station components.
DO NOT use putty knives or steel scrapers on fill station or other components.
Nylon brushes are recommended for ease of cleaning some fill station components as well as
nylon bottlebrushes.

SPARE PARTS
Machine down time can be minimized if a reasonable inventory of seals, o-rings, and electrical
and mechanical spare parts is established and maintained. ProSys provides a recommended spare
parts list with this manual. This list is intended as a general guide and in no way can cover all
parts that may be needed over the service life of the equipment. Check stock often and replenish
as needed. Spare parts are available from ProSys. The bill of material in this manual provides the
ProSys part number as well as the manufacturer and manufacturer’s part number, if applicable,
so the customer can source the parts independently if desired.
TOOLS REQUIRED
A collection of basic hand tools will be needed to adjust, maintain and do bag size changes on
the filling machine. There should be no “specialty” tools required for normal adjustment and
maintenance on the filler. The correct size and type of tool needs to be used to prevent damage to
machine parts and fasteners. The use of adjustable “crescent” wrenches and channel lock type
pliers is NOT recommended.
A list of tools follows below. This list is a basic list and additional tools may help with time and
ease of adjustments and maintenance. All of the tools listed are “inch” sets unless specifically
noted.
 Socket wrench set and ratchet, 3/8” drive. Sockets should range from ¼” through 1” in at
least the following increments. ¼, 9/32, 5/16, 11/32, 3/8, 7/16, ½, 9/16, 5/8, 11/16, ¾, 13/16,
7/8, 15/16, 1”.
 Combination box / open-end wrench set from ¼” through 1” in the same increments as the
sockets listed above.
 Standard straight blade screwdriver set. A small 1/8” wide, thin blade screwdriver is needed
for adjusting some flow controls.

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 CHAPTER : MAINTENANCE

 Phillips screwdriver set.

 Hex key set for inch Allen bolts. A standard set of 1/16” through 3/8” is needed. We
recommend the ball end style for ease of access to some fasteners. A set of Bondhus® BLXB
wrenches is highly recommended. The most commonly uses hex key sizes are 3/16 and 5/32
inch. Extra wrenches of this size may be considered.
The following are tools that are not required for normal maintenance and adjustments but are
recommended:
 Hook and pick set for seal and o-ring removal. A suitable set would include McMaster Carr
part numbers 3842A21, 3842A25 & 3842A26.
 Soft face or rubber dead blow hammer.
 “T” handle style Allen wrench set.
 Strap wrench with reinforced rubber strap. This is useful for removal of round parts with out
damage such as the fill nozzle tips.
OTHER MATERIALS REQUIRED FOR MAINTENANCE OF THREADS
When installing some fasteners it is recommended that a service removable thread retaining
compound be used. Use of Loctite® 242 or an equivalent is recommended. Follow the
manufacturer recommendations for cleaning, application and types of metals to use retaining
compounds with. The fill station valve, metering and dispense head assemblies are an exception.
The relative frequency these are disassembled do not lend to using retaining compounds.
When the threaded stainless steel components of the fill station are assembled, use of an anti
seize compound is recommended to prevent “galling” between the two parts.

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 CHAPTER : ProSys BILLS OF MATERIALS

CHAPTER 6
PROSYS BILLS OF MATERIALS
The bill of materials lists the parts of each assembly on the machine by assembly number. The
bill of materials is intended to give the customer the assembly number the part is used in, the
ProSys part number, a brief description of the part, the manufacturer of the part, the
manufacturer’s part number if applicable and the quantity used in an assembly.

The bill of materials along with assembly drawings and schematics are intended to help the
customer find the correct part when ordering. Having the correct ProSys part number ready will
greatly speed up the parts ordering process and ensure the customer gets the parts they need.

There may be up to four different bills of material for a single machine.

The bill of material has the parent item of SXXX, where XXX is the machines’ three-digit serial
number. The bill of material includes all of the parts on the machine.

Within the bill of material are the miscellaneous parts bill, with the parent item XXXM, and the
controls bill of material with the parent item number of CXXX where XXX is the machines’
three-digit serial number.
The miscellaneous parts bill includes parts that may change from the “basic” filler according to
the specifications. This commonly includes seals, o-rings, etc. that are different from filler to
filler because of the material to be run on the machine. The change parts may also include
additional parts that are required for the customer to run a variety of bags specified.
The controls bill lists all of the control components such as the PLC, indexer or servo drive, etc.
as well as limit switches, photo eyes, proximity sensors, relays, switches, etc. The controls bill
also list solenoids, air fittings, flow controls, solenoids, etc. The bill is broken down by the
mechanical assemblies the electrical components are used on, or the electrical enclosure number
that the parts are located in.
The recommended spare parts bill with the parent item number of XXXSP, where XXX is the
machine three-digit serial number. The recommended spare parts bill is intended a basic guide
for the parts that should be kept on hand to maintain the operation of the machine. The list
includes normal wear items, items that may tend to get damaged through repeated maintenance
or change-over and items with normally long lead times.

The bill of materials is “indented” which means if an assembly contains a smaller sub-assembly,
the sub-assembly is indented below the main assembly. The “relative level” column shows the
level of indention.
The sequence number column corresponds to the sequence number on the actual assembly
drawing. If the letters “AS” appear in the sequence number column, the number shown is an
assembly drawing number.

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 CHAPTER : ProSys BILLS OF MATERIALS

The component item no./ description column shows the ProSys part number for the parts, a brief
description, the manufacturer of the part and the manufacturer’s part number if applicable.

If the item is a part designed and manufactured by ProSys there will be no manufacturer part
number.

The next unlabeled column is the ProSys bin location and is intended for use by ProSys only.

The qty. per column shows the quantity used in that particular assembly. The same part may be
used several times in other assemblies throughout the machine.

41