Bottling technology nassenheider www.nassenheider.com nassenheider fill up Bottling machine Fill up 2 visco basic configuration for honey Manual nassenheider fill up Manual Fill Up 2 Contents 1 Foreword 2 2 Manufacturer 3 3 Reading and application of the manual 3 4 Security instructions 4 5 Technical details 4 5.1 Intended use 5 5.2 Technical data 6 5.3 Safeguards 6 5.4 Connections on the drive module 6 6 7 8 9 Preparations for use 7 6.1 General instructions 8 6.2 Components included in delivery (basic configuration for honey, Art.No. 301001) 8 6.3 Unpacking and set up 9 6.4 Adjustment of the jar height 10 6.5 Transport and storage 10 Processing of honey 10 7.1 Suction out of a container 11 7.2 Connection to a container with valves 12 7.3 Preperation of the honey 12 7.4 Dosage 13 7.5 Transference of honey between containers/ creamed honey 13 Processing of other liquids (apart from honey) 13 8.1 14 Pre-settings Assembly, dismantling and cleaning 14 9.1 15 filling nozzles 10 Operation 16 10.1 Membrane keyboard and display 16 10.2 General use of the keyboard 17 10.3 Modes of operation 17 © Stefan Weiland 15.11.2012 Page 1 nassenheider fill up Manual Fill Up 2 10.4 SETUP menu 23 10.5 External switches 24 11 Maintenance, troubleshooting and reparation 25 11.1 Maintenance 25 11.2 Update of the software 25 11.3 Troubleshooting 26 11.4 Support and reparation 27 11.5 Disposal of your old machine 27 12 Warranty 27 13 CE - DECLARATION OF CONFORMITY 28 © Stefan Weiland 15.11.2012 Page 2 nassenheider fill up 1 Manual Fill Up 2 Foreword Dear Customer, Thank you for purchasing our filling machine "Nassenheider fill up 2 visco" Your new appliance is specially designed and aimed to serve the requirements of small to medium size apiaries and consumer goods manufacturers. It will save you valuable time and work as well as having cost benefits. We have developed a modular filling system, which enables the bottling of a variety of liquids and soft mediums at a reasonable price. We always research new technologies to improve our products and develop additional components for the filling process. This way we are able to continously broaden the spectrum of our product line-up. Beside the standard gear-pumphead we offer various pumpheads like the impeller-pumphead, two different peristaltic-pumpheads, hoses and hoppers in many different shapes and sizes. In this way particular attention has been paid to providing the largest possible compatibility and options for adding additional, modern and energy saving parts. Please ask your local dealer for more information or have a look at our homepage. If your company grows, our machine can grow, too! Additional parts like automatic turntables, conveyor-belts or a weighing-module will make your work even more effective. A future update of the appliance-software by means of an USB adaptor and PC is also possible. NASSENHEIDER-machines are developed and assembled in our own workshop in Dresden, Germany. Therefore we can provide full technical support and there is always the safety of getting qualified support and spare-parts for many years. The manufacturing-process is done under consideration of the latest safety- and environmental laws and guidelines. We use electricity which is 100% made from renewable energies and our machines are easy to maintain and to repair for a long life. This sustainable production and the energy-saving design of our machines is our current small contribution to prepare our planet for the future generations. We work towards having a long term partnership with you and wish you a lot of fun and economic success with your new filler. Your Nassenheider team 2 Manufacturer Contact data of the manufacturer for support: Stefan Weiland Produktservice Leipziger Str. 33 01097 Dresden Germany Sales: Support: Fax: +49 (0) 351-896691-01 +49 (0) 351-896691-05 +49 (0) 351-896691-99 E-mail: Homepage: [email protected] www.nassenheider.com © Stefan Weiland 15.11.2012 Page 3 nassenheider fill up 3 Manual Fill Up 2 Reading and application of the manual The manual is an important component of the product. Therefore we ask that you read it thoroughly before use. This will allow the optimum and safe use if the machine. You can use the „quickstart-manual“ for your everyday filling work. In the service section of our website www.nassenheider.com you are provided with manuals in different languages. 4 Security instructions There is a danger of injuring hands in the rotating gear wheels and motor axis. For this reason, before assembly or dismantling, turn off the machine and ensure that the power-plug of the transpormer is disconnected from the power network. There is a danger of injury through electrical current! For this reason, - always ensure that the power supply (transformer) is protected from moisture. - do not open or disassemble the driving-module of the machine, the transformer or any of the plugs There is a danger of worn out parts polluting your filling mediums! That is why you should always check the assembly parts of the pumphead, the nozzles and the hoses for their cleanliness and their condition. Clean dirty parts and replace broken or worn out parts immediatly! Important: This equipment is electronically steered by a microcomputer. Although unlikely, malfunctions can occur through the effect of strong electrical or electromagnetic fields. If this were to happen, please reload the factory pre-sets again (RESET of the software). Troubel shooting: see page 32. © Stefan Weiland 15.11.2012 Page 4 nassenheider fill up 5 Manual Fill Up 2 Technical details © Stefan Weiland 15.11.2012 Page 5 nassenheider fill up 5.1 Manual Fill Up 2 Intended use The bottling-machine ʺNASSENHEIDER fill up 2 viscoʺ is desgned for the dosing and pumping of the following liquids and creams: Dynamic viscosity: (depending on the pumphead and equipment) 10³ bis 106 mPa*s (thick oils, sirup, mayonnaise, honey, shampoo, yoghurt, fresh cheese, quark, handcreme etc.) Temperature range for filling: - from 32°F/ 0°C to 104 °F/ 40°C (gearpump standard version) - from 104°F/ 40°C to 194°F/ 90°C (gearpump with wheels for hot filling Nr. 302021 or 302022) - from 32°F/ 0°C to 209°F/ 95°C (impeller- and peristaltic pumphead) Never bottle any explosive or flammable liquids or liquids containing solvents! Before using the machine, possible incompatibilities of the filling product and the parts of the machine have to be clarified (solvents and abrasiv components). Therefore all products that have to be filled (except honey) are to be approved by the manufacturer beforehand seperately for each product. If not approved, the manufacturer is not liable for any following damage or injuries! 5.2 Technical data Nominal voltage drive module: No load current: Power consumption motor: Revolutions per minute: Starting torque: Nominal torque: Noise emission: Set up area: Overall height: Lower filling nozzle: Weight: pumping data for honey: Max. suction height: Max. conveyor height pressure side: Max. pump capacity per hour: 5.3 UN = 24 V DC I0 = 2,5 A P = approx. 100 VA 14-100 rpm (regulated with a control knob righthandside of the machine) MA = 90 Nm MN = 9,5 Nm <70 dB. width = 350 mm x depth = 320 mm 520 to 1200 mm (according to model) 50-300 mm (standard stand 500 mm, Art.No. 303012) 50-500 mm (stand 700 mm, Art.No. 303006) 50-800 mm (stand 1000 mm, Art.No. 303023) approx. 40 lbs/ 18 kg incl. transformer up to 3.3 ft/ 1,3 m up to 13 ft/ 4 m up to 926 lbs/ 420 kg ≙ 300 l/h Safeguards Motor protection An electronic overload protection guard is built into the system. Should the pump head become blocked, a warning sign “overload” will appear on the screen. After acknowledging the blockage by pressing the -key, work can be continued. Micro fuse In the power supply and the drive mudule: 8 A, medium time lag, Art.No.. 307009 © Stefan Weiland 15.11.2012 Page 6 nassenheider fill up 5.4 Manual Connections on the drive module Right side: A - Control knob for speed regulation B - On/ Off toggle switch/ main switch (no lighting) C - Connection socket for 24V power supply (24 V DC by power supply Art.No. 307014 or 24V attachment cable Art.No. 303003) D - Fuse holder (contains micro fuse 8 A, medium time lag, Art.No. 307009) Fill Up 2 fig. 2.4 right side left side 15-100/min n assenh eid er fill up DS 20 000 Left side: E - USB port for updating of appliance software F - Port for external switch (Flat switch, Art.No. 307006 or Foot switch, Art.Nr. 303001) G - Blank port (optional port for additional connections) © Stefan Weiland 15.11.2012 1000213 2010 A B C D E F G Page 7 nassenheider fill up 6 Manual Fill Up 2 Preparations for use © Stefan Weiland 15.11.2012 Page 8 nassenheider fill up 6.1 Manual Fill Up 2 General instructions When unpacking, please make sure that the machine: - has not been damaged - is complete according to the following depiction If this is not the case, please get in contact with your local reseller or the manufacturer: STEFAN WEILAND PRODUKT SERVICE within two weeks, either verbally or in writing. 6.2 Components included in delivery (basic configuration for honey, Art.No. 301001) (components may vary, if your machine is not meant for honey) More components are available; please ask for catalogues and price lists! © Stefan Weiland 15.11.2012 Page 9 nassenheider fill up 6.3 Manual Unpacking and set up Fill Up 2 fig. 3.3 - set up in a closed, dry area - room temperature : 15 - 35°C/ 59 - 95°F - before use, please allow allow about an hour for the the appliance to become acclimatized to the room; this prevents damage from condensation When unpacking please take care of the following: - Take the protective plastic film off the stainless steel parts - Clean the pieces that come in contact with the honey or other filling products with commercial dish washing Assembly should take place on a table or hanging from a barrel or with the hanger, Art.No. 303002. 6.4 Adjustment of the jar height The filling nozzle should always be as fitted as tightly as possible over the jar opening. The vertical adjustment takes place by means of locking levers. The drive module must be held tightly in place, so that it does not slip downward on the column. The height below the filling nozzle can be adjusted between approx. 50 mm - 280 mm (also see chapter 5.2). 6.5 fig. 3.4 Transport and storage Transport and storage should only take place in the original packaging in order to protect the equipment from contamination and damage. Always protect from moisture and vibrations. © Stefan Weiland 15.11.2012 Page 10 nassenheider fill up 7 Manual Fill Up 2 Processing of honey © Stefan Weiland 15.11.2012 Page 11 nassenheider fill up 7.1 Manual Fill Up 2 Suction out of a container Assembly of the hose using a bent pipe - dip the hose and the bent pipeto hot water (approx. 95°C / 203°F) (fig. 4.1) - after assembly immediatly pull the hose clamp tight, making sure that the hose does not get damaged fig. 4.1 Attach check valve to the other end (fig. 4.2) - ensures that the honey does not flow back out of the hose - ensures that the opening does not adhere to the container bottom, position (A) Honey suction - before assembly of the upper bent pipe, pour approx. 2 tablespoons of honey into the pumphead, position (C) - this way the pumphead becomes sealed and coated and able to draw the air out of the hose fig. 4.2 When set up in the way described above, the machine is in position to fill honey into jars, to a suction height of 1.5 m and without air bubbles. Attention: The honey should be aspired into the pumphead after about 15 seconds. If not, check the hose-connections because of airleaks. A longer motion of the gears without or with only little honey may destroy the pumphead due to too little greasing by the honey! Suction of other mediums Other mediums like mustard, ketchup, sauces etc. have to be drawn with thinner hoses. For this we offer hoses and bent pipes with a diameter of 25 mm and 15 mm. Please don't hesitate to ask, since we will be glad to counsel you! Mediums, like e.g. creams usually cannot be drawn from below, but have to be poured from above. For this case we offer various containers, hoppers and hose connections. leakages while drawing honey: When there are suction problems, use additional honey to seal the machine in the folowing places (fig 4.2): - connection intake - suction hose, position (A) - sealing ring on top of the pump head, position (C) - sealing ring on bent pipe, position (B) In case of the reverse flow of liquid honey and simultaneous suction of air through the filling nozzle - use the check valve - fill liquid honey at the coolest temperature possible (approx. 15-20°C/ 59-68 °F) - place container as high as possible suction problems with honey that is too tough - remove flange and membrane from check valve, but don't remove the screws and wing nuts © Stefan Weiland 15.11.2012 Page 12 nassenheider fill up 7.2 Manual Fill Up 2 Connection to a container with valves - Direct connection by means of a connection pipe (Art.No. 304013 - 304015) and disk valve (Art.No. 304010 or 304012). The container should then be raised accordingly. - Connection by hose with hose nozzle and swivel nut (Art.No. 304011) and disk valve (Art.No. 304010 or 304012). For more information about these components please check our website. 7.3 Preperation of the honey - Filter wax from honey in a cleaning basin Honey must be in liquid form Honey must be freshly stirred, in order to prevent possible temperature differences (= density variations) in the container. Dichteunterschiede verursachen Ungenauigkeiten bei der Abfüllung! Processing temperatures of the honey - liquid honey freshly extracted: 20-25°C/ 68-77°F - Creamed honey with low water content: 26-35°C/ 79-95°F - Maximum temperature: 40°C/ 104°F Using the machine at higher temperatures can clog the gear whels due to an expansion in the pumphead. Attention: If the honey is colder during the bottling, the machine could be damaged - for that we assume no liability! 7.4 - 7.5 Dosage programming of the nominal filling amounts in the SETUP menu. Operating mode "AUTO" Choose dosage amount according to jar size (10 g - 32,5 kg/ 1 oz – 71 lbs) do the fine tuning (calibration of the filling amounts) the accuracy between each filling-process is ± 3g / 0,1 oz (without air-bubbles) Transference of honey between containers/ creamed honey (with bent pipe, Art.No. 304001), our recommendation: the ʺpumpʺ or ʺtime switch clockʺ modes inject honey with creamed honey and/ or wait for crystalization process transference between containers at a rate of 5-8 times per day Attention: Never operate the pumphead dry, i.e. without honey! Without the lubricating effect of honey between the gear wheels the plastic pump module can be damaged, even destroyed © Stefan Weiland 15.11.2012 Page 13 nassenheider fill up 8 Manual Fill Up 2 Processing of other liquids (apart from honey) Each medium that is put through the machine requires a special selection of our components according to the unit assembly system. You can choose from different gear wheels, pump heads like the impeller module and peristaltic modules as well as from different filling nozzles. We can configure the machine to your special medium and can supply it pre-assembled. The basis for this is our application form on our homepage: http://abf.nassenheider.com/anfrags/index_en The answers to the questions asked help us to determine the perfect solution for your filling premise. 8.1 Pre-settings In the configuration menu you can do your own pre-setting, in order to adapt your filling machine to your own special medium. This requires the following: - Unit display: grams (g), milliliter (ml), ounce (oz) Thickness of liquid: oil (0,9 g/cm³), water 1,0 g/cm³), honey (1,4g/cm³), or any numeric value between 0,8-1,8 g/cm³ Pump head Gear-1: Gear wheel pump head, small, stainless steel (Fill up Liquid) Gear-2: Gear wheel pumphead, large, plastic (Fill up 2) Impeller: Impeller pump head for liquid, slightly chunky mediums Peris-1: Peristaltic pump head, small, for liquids (filling amount 1 ml - 500 ml) Peris-2: Peristaltic pump head,big, for liquids (filling amount 250 ml - 1000 ml) As far as possible, we configure the special settings of the machine in our factory. These can however be lost while loading the factory pre-sets (RESET) and may need to be reset. © Stefan Weiland 15.11.2012 Page 14 nassenheider fill up 9 Manual Fill Up 2 Assembly, dismantling and cleaning © Stefan Weiland 15.11.2012 Page 15 nassenheider fill up 9.1 Manual filling nozzles Depending on the medium used, we provide suitable filling nozzles. The correct assembly of the nozzles is described below. Fill Up 2 fig. 6.9 a Wedge nozzle 22 mm Wedge nozzle 22 mm soft (Art.No. 306014), hard (Art.No. 306015) (fig. 6.9 a): Put directly into.the pump head with a clamping flange. Application: hard implementation: for filling honey soft implementation: for liquid honey, mustard and soft pastes Wedge nozzle 10 mm soft (Art.No. 306011), hard (Art.No. 306032) and wedge nozzle 17 mm soft (Art.No. 306012), hard (Art.No. 306013) (fig. 6.9 b): Always assemble together with appropriate filling pipe (10 or 15mm) and sealing gasket at the bottom pump head. The side of the sealing gasket with the rounded edges always faces towards the filling pipe (downward). fig. 6.9 b Wedge nozzle with filling pipe Application: for liquid mediums (oil, sauces etc.) Filling pipe without filling nozzle Ø 10 mm (Art.No. 306008), Ø 15 mm ( Art.No. 306009), Ø 25 mm immer ohne Düse (Art.No. 306010) (fig. 6.9 c): Assemble with flange sealing gasket at the bottom of the pump head. The side of the sealing gasket with the rounded edges always faces towards the filling pipe (downward). fig. 6.9 c Filling pipe Application: for non dripping pastes like creams, cream cheese, curd Conical filling nozzle with cover (Art.No. 306002) (fig. 6.9 e): - insert conical filling nozzle into the pump head - put the cover on the filling nozzle - fasten the clamping flange with nuts - screw the pump head to the pumping mudule fig. 6.9 e Conical filling nozzle with cover Application: especially for liquid honey and smaller jar size © Stefan Weiland 15.11.2012 Page 16 nassenheider fill up Manual Fill Up 2 10 Operation 10.1 Membrane keyboard and display Do not use the keys with you fingernails! Do not use aggressive detergents! 10.2 General use of the keyboard 10.3 Modes of operation The operation modes are chosen in the main menu. 10.3.1 Operation mode HAND/PUMP Pump (with bent pipe Art.No. 304001): The pumping mode of operation is used for the self-priming, i.e. filling the hose and the pump-head, for continuous pumping as well as to stirr creamy honey. For the stirring of creamy honey, the mode of operation "time switch clock" can also be used. Self-priming: In order for the pump to draw in the honey, the following measures are necessary - apply 3 teaspoons of honey, to the gear wheels from above - connect the bent pipe to the pump head - place an empty jar below the filling nozzle (approx. 350 ml/ 500g) - turn speed up to 100/min (max) with the turning knob on the right side - draw the honey in, using PUMP mode, until the pump head is filled without any bubbles. Attention: The honey should be aspired into the pumphead after about 15 seconds. If not, check the hose-connections because of airleaks. A longer motion of the gears without or with only little honey may destroy the pumphead due to too little greasing by the honey! © Stefan Weiland 15.11.2012 Page 17 nassenheider fill up Manual Fill Up 2 You can select the pumping direction by marking the arrow with the key and adjusting it by means of the keys. Confirm again with the key. Here you can select the following options: Forward continously A short press of the -key, sets the honey in motion, a second press terminates this motion. The product is pumped from above downward (forward). Forward interval The forward motion of the honey remains unaffected while the is pressed. When letting go the motor stops. The product is pumped from above downward (forward). -key Backward continously A short press of the -key, sets the honey in motion, a second press terminates this motion. The product is pumped from below upward (backwards). Backward intervall The forward motion of the honey remains unaffected while the is pressed. When letting go the motor stops. The product is pumped from below upward (backwards). -key The filling nozzle (Art.No. 306015) must be removed each time continuous pumping is carried out. To not do so would cause too much resistance in the tubing witch may could damage the motor by overloading the machine. Use of the Niveau switch(Accessory Art.No. 303004) Pumping freshly turned honey from the cleaning basin into a larger container (e.g. onto a shelf) can be regulated with the niveau switch. For more information see chapter ʺexternal switchesʺ The Mode of Operation to be selected is: PUMP → INTERVAL → FORWARD or BACKWARD 10.3.2 Automatic dosage operation This mode of operation is used for the filling of jars and/or other containers with the desired quantity. General Operation: 1. Choice of nominal filling quantity of the contents (jar size, programmed in the SETUP menu) 2. Filling of a jar 3. Weighing of the jar's contents 4. Correction (calibration) of the weight 5. Possible repetition of the points 2-4 6. filling of the desired number of jars © Stefan Weiland 15.11.2012 Page 18 nassenheider Manual fill up Fill Up 2 Choice of the nominal quantity/ jar size Most nominal quantities (jar sizes) are pre-programmed by the manufacturer. They appear in the first line of the AUTO-menu and can be selected as follows: - Selection of a line with the - Marking of this line with the - keys - key and adjustment of the value by means of the - Confirm afterwards with the - keys - key Programming of new nominal quantities If a desired jar size has not yet been stored, it can be programmed in: CHOICE → SETUP → FILLING Possible selection: - a pre-programmed nominal size can be changed, or: - new nominal sizes can be added to the spaces labeled ʺ0ʺ - Selection of a line with the - Marking of this line with the - keys - key and adjustment of the value by means of the Confirm afterwards with the © Stefan Weiland 15.11.2012 - keys - key Page 19 nassenheider fill up Manual Fill Up 2 Filling Pushing the - key (or microswitch/ foot switch) once and a jar will be filled. After replacement of the jar press again to fill it. Selecting the density of the medium The machine has no in-built scale; it measures the volume of the medium to be filled by way of counting the revolutions of the gear wheels. The weight on the display is calculated by the control with the help of the density of the medium to be filled. The density can be preset in the SETUP menu: Select → Setup → Density Standard setting for honey is preset (Density 1.4 kg/l), or a numeric value can be entered. Correction/ calibration of the contents Different honey types/batches have different densities. Before the filling of each new batch or before the use of a new jar size, a calibration of the contents need to be made with the help of a calibrated scale. - Empty jar will be weighed by an electronic scale, press TARA/0 (or with a mechanical scale note the jar weight) - Select nominal weight (e.g. 20 g) and fill the jar - After filling, the newly filled jar is then reweighed - If the new honey weight differs from the nominal weight, it needs to be calibrated (note a accuracy of ± 3 g!): - Select line: with the - keys - Here you will see the nominal weight. Highlight this with and change the amount exactly to the weighed amount as shown on the scale (e.g. 26 g) by using the - keys. and confirm with . - now that the machine displays the nominal weight again (e.g. 20g), the control calculates the exact density of the medium and fills the jar with 6 g less the next time. Now we can start the filling process again. In case of large deviations from the desired contents it may be necessary to repeat this procedure. Variations in weight of the glass jars do not influence the weight of the filling amount. At the very first use of the machine, the actual filling weight might differ from the nominal filling weight. We therefore recommend the selection of a small quantity (e.g. 125 g), with a large jar (500 g) for the initial calibration. © Stefan Weiland 15.11.2012 Page 20 nassenheider fill up Manual Fill Up 2 Drawback The motor moves a little backwards immediately after stopping. This happens in order to ensure a drip-free filling process. This motion draws the last drop of liquid back from the nozzle and at the same time, closes the filling nozzle. The backwards motion is adjustable, and is slowed down depending upon the viscosity of the medium. Therefore it needs to be adjusted depending on the nozzle and the medium. If it is too short, the nozzle will drip, if too long, air will be drawn in from below and create air bubbles during the next filling. Here are some approximate values: 0-1: liquid mediums such as oil or aqueous solutions 2-3: liquid, freshly extracted honey, mustard, thick sauces 4-5: creamy honey Please obtain your own optimum value with the medium that you use (fig. 7.1): The two surfaces on the filling nozzle should meet exactly, to cut off the flow of the medium. This prevents dripping or taking in of any air. fig. 7.1 Different types of filling nozzles We can deliver filling nozzles of two different hardnesses (see illustration on the right). Below some approximate values: Hard nozzle: - creamed honey - liquid honey Soft nozzle: - very liquid, freshly extracted or very warm honey - mustard, ketchup, sauces - creams, fats with air pockets, drips Trouble shooting - dripping nozzle: Make sure that you have inserted all the seals on the pump head and that all screws (on the cover and on the bent tube) have been tightly fastened. withour air pockets, closed © Stefan Weiland 15.11.2012 Page 21 nassenheider fill up Manual Fill Up 2 10.3.3 Time switch/ making creamed honey Another possible application of the filling machine is to stir honey in order to make creamed honey. For this, the use of the built in time switch is recommended. While stirring, the temperature of the honey should be around 20 - 25°C/ 68 - 77°F. Procedure: - Add approximately 5-10% fine-crystalline honey (briefly mixed by hand) to the honey to be stirred, or wait until the honey automatically begins to crystallize. - Replace the filling nozzle (Art.No. 306015) and clamping flange (Art.No. 306007) with an additionally available bent pipe (Art.No. 304001, bent to the side) with an attached pressure hose (Art.No. 304002, available in any desired length) - Insert the pressure hose into a second honey container - Pump the honey into the second container (during the pumping procedure the crystals are reduced to small fragments that are finely distributed throughout). - Leave for one day, then pump the honey back again. - One can also pump the honey into a large container that is circulated: the honey is drawn from below and returned from above). However, there is a danger that part of the honey gets out of the circulation cycle. - the pumping process should be carried out approx. 3-8 times a day with break of a few hours up to one day between procedures To obtain a creamy texture, the honey should not become warmer than 40°C / 104 F, otherwise the crystals will dissolve and the honey will become liquid again. A single pumping or filling with our machine does not change the structure of the honey in any way. Using the time switch: Pump forwards inside the pumphead (from above, downwards) Pump backwards inside the pumphead (from below, upwards) Pump in both directions (cycle alternates from above down wards, the next cycle from down upwards) START Setting of the time between the pumping cycles (in Hours: Minutes: Seconds) ON Setting the running time of the motor in the cycle (in Minutes: Seconds) When the start button is pressed, the pump begins to run immediately until the ON time is completed. The display indicates the remaining time. © Stefan Weiland 15.11.2012 Page 22 nassenheider fill up Manual Fill Up 2 10.4 SETUP menu ABC: Select language FILLING: List of the pre-programmed filling amounts, different quantities can be added or existing ones changed: select an empty storage location with the -keys, mark with -key save with the -key It is also possible to change the preset quantities. RETRACT: Programming the length of retraction after the motor stopps UNIT: Choose Unit: Grams g, Milliliter ml, Ounce oz DENSITY: Preset the density of the Medium to be used PUMP: Selection of the pump head Gear-1: small gear pump head for liquids (Fill up Liquid) Gear-2: big gear pump head for honey etc. (Fill up 2) IMPELLR:impeller pump head Peris-1: peristaltic pump head small Peris-2: peristaltic pump head big ACCESSR: Selection of the attached accessories: TURN-1: turntable small (speed not adjustable) TURN-2: turntable big (speed adjustable, default 15%) more information in the documents of the turn tables SCALE: scale module RESET: Reset to the factory settings INFO: top counter: shows the overall amount filled/ pumped with the machine; this cannot be reset This display is only approimate value, because different calibrations are not taken into account during the calculation bottom counter: daily counter, can be changed using the -keys © Stefan Weiland 15.11.2012 Page 23 nassenheider fill up Manual Fill Up 2 10.5 External switches All external switches are inserted into the 5-pin socket on the left side of the driving module. The microswitch (Art.No. 307006, fig. 7.2 a) is adjusted in such a way that it releases the renewed filling procedure when placing the next jar into the yframe. This switch is only used in AUTO mode. fig. 7.2 a Bügelschalter The foot switch (Accessory Art.No. 303001, fig. 7.2 b) is connected in all modes of operation, parallel to the - key of the keyboard, witch has thus exactly the same functions. It can be ordered as an accessory. To avoid any unintentional filling up procedure, microswitch or foot switches should only be attached when all preparation (suction and calibration) has been finalized, before filling. fig. 7.2 b Fußschalter Niveau switch (Accessory Art.No. 303004, fig. 7.2 c) Moving freshly extracted honey from the cleaning basin into a larger tank (e.g. onto a shelf) can be controlled by the float switch.The switch can be hung with the mounting plate onto a container. The metal strip may need to be shortened. Used as in (A): - With rising level of liquid the motor is switched on. - Use in the cleaning basin after the honey extractor - Motor always starts, when sufficient honey has run out of the centrifuge Used as in (B): - With rising level of liquid the motor is switched off - Used in the tank to be filled (prevention of tank to be filled overflowing) fig. 7.2 c Schwimmerschalter The mode of operation to be chosen here is: PUMP → INTERVAL FOREWARD or BACKWARD Microswitches, foot-switches and niveau-switches are waterproof (Protection level IP 67) and can be immersed into water for cleaning. (A): (B): © Stefan Weiland 15.11.2012 Page 24 nassenheider fill up Manual Fill Up 2 11 Maintenance, troubleshooting and reparation 11.1 Maintenance The filling machine is generally maintenance-free. In the pump module, honey acts as a lubricant. The ball bearing is lubricated maintenance-free and totally enclosed. In order to prevent pollutants getting into the honey, ensure no part of the filling machine is lubricated with machine oil or the like. A thorough cleaning after each use is important (after long breaks, before renewed use) in order to keep abrasive particles away from the plastic pump module and to thus increase its life span. The life span of the motor and pump module is aproximately amount of 120,000 kg of pumped honey. A replacement of individual components is always possible. Change of the shaft seal rings After approx. 5-8 tons workload the shaft seal rings of the pump heads have to be changed. Therefore we offer our sealing set (Art.-No. 307043) including a manual on how to change them. Attrition of the shaft seal rings results in liquids leaking at the back of the pump head. If this liquid soiles the motor behind, the motor might be damaged. Worn out shaft seal rings also result in air invading the pump head, which results in inaccurate filling and air pockets inside the filling product. That is why you should change the shaft seal rings at the latest when you see air bubbles coming in from the back of the pump head. Opening of the drive module should only be carried out by specialists. Within the guarantee period, equipment may only be opened by specialists assigned by the manufacturer; otherwise all warranty claims become invalid. 11.2 Update of the software The filling machine is equipped with a USB interface. This allows the updating of the software by means of a PC. Please inquire, on our homepage www.nassenheider.com or by phoning us directly, about the availability of a new software-version. This will be provided for downloading and includes an installation guide. We will also gladly send this software as a CD version. The current software version is found on the entry menu, after switching the machine on. © Stefan Weiland 15.11.2012 Page 25 nassenheider Manual fill up Fill Up 2 11.3 Troubleshooting Error Reason Malfunction of the software effect of strong electromagnetic fields (mobile phone, cordless telephones, or another motor was not screened off from the agitator) The medium is filled with Some large air bubbles in the honey air bubbles cannot be completely removed because the honey stream enters the jar in concentric circles and so allows large air bubbles in. Retract is too long, so that some air bubbles are always sucked back into the fill nozzle during retraction (applies mainly to liquid honey) Leakages in the suction connections Pump motor is turned on, but does not turn easily, or does not turn at all. Fault warning: overload Blockage of the gear wheels with hardened honey or some other foreign object: motor protection is activated. Can happen after long filling breaks (e.g. over night): - Honey is too cold - Honey has crystallized Solution Reset to factory settings Menu SETUP → RESET → Place the equipment as far down as possible, so that the filling nozzle is very close to the edge of the jar and fill the honey as liquid as possible (warm). reduce retraction period. Rule of thumb: 0-1: liquid medium such as oil or other liquid solutions 2-3: liquid, freshly extracted honey, mustard, thick sauces 4-5: creamed honey Check the bolt connections, sealing rings and sensitive places at the problem area before applying with a honey coating (see Fig. 4.2, page 12). Remove cause (clean machine, place in warm room etc.). Acknowledge with , when machine is working again If there is a foreign object in the pump head, the gear wheels are blocked (e.g. nuts.) Inaccuracies when filling Air pockets See above Medium cannot flow through suction hose and bent pipe fast enough (especially a problem with rapehoney). You can see this, when tiny vacuum pockets are building up in the upper part of the pump head (easily visible through the transparent pump head cover). Use bigger suction hose-Ø and bent pipe Reduce viscosity of the medium (e.g. through raise of temperature of the honey to 25 – 30°C/ 77 - 86°F) Keep the suction hose as short as possible Slow down motor speed to approx. 40/min. That way the machine is adjusted to the rate of flow of the honey inside the hose. More tips and tricks: see our homepage www.nassenheider.com at Service → FAQ. At the service page you can also find other technical documents and manuals in serveral languages © Stefan Weiland 15.11.2012 Page 26 nassenheider fill up Manual Fill Up 2 11.4 Support and reparation If there are any problems that could not be solved by the troubleshooting, please contact your local reseller our support team via telephone, e-mail or fax. We will counsel you about the next steps. Our customer service: sales: 0351- 89 66 91- 01 support: 0351- 89 66 91- 05 fax : 0351- 89 66 91- 99 e-mail: [email protected] Please do not send the machine back without first having contacted us! Returns have to be done in the original packaging to prevent damage on the return way! 11.5 Disposal of your old machine The filling machine is designed for a long-term and sustainable use. All components can be replaced individually, even after many years. Therefore you will be able to rely on your NASSENHEIDER filling machine for many years. When the time has finally come for your machine, we will take it back for disposal, free of charge. Electronic equipment and batteries should not be disposed of with household waste but must be returned to a collection point for recycling. This prevents potential damage to the environment and human health. Follow the local guidelines that you can get from the responsible authority of your community,at a waste disposal company or the retailer where you purchased the product. You may also turn directly to "Stefan Weiland Product Service". Do not try to remove fixed battery packs by yourself. Fixed batteries are to be removed by a waste treatment facility or a trained service technician. The disposal of the packaging follows the same way as waste paper. However, we recommend to keep the packaging in storage for the possibility of a return for reperation. 12 Warranty The guarantee for the filling machine is 24 months starting from the delivery date or expires with 30.000 l filling volume, depending on which limit is reached first. Guarantee is limited to damage and faults which are based on workmanship. Wearing parts are excluded from this liability. The company ʺStefan Weilandʺ is not responsible for damages caused by inappropriate treatment, unintended usage, (see chapter 5.1), wrong assembly or maintenance by unqualified personnel or unauthorized electrical, electronic or mechanical interferences of any kind in the drive module or the pump head. The warranty covers only damage to the filling machine. The manufacturer can not take responsability for consequentional damages. Worn parts are excluded from this liability. The repairs should will be carried out by the manufacturer (or representatives) and will cover spare parts and workmanship. The return of the machine should only take place after consulting the manufacturer. If you find, after purchase of the machine and checking the contents that individual parts are missing, this must be communicated to the company Weiland within two weeks of the purchase date, either verbally or in writing. © Stefan Weiland 15.11.2012 Page 27 nassenheider fill up Manual Fill Up 2 13 CE - DECLARATION OF CONFORMITY We, Stefan Weiland Produktservice Leipziger Str. 33 01097 Dresden Deutschland hereby declare in our own responsibility, that our bottling machine NASSENHEIDER fill up 2 is designed and assembled in conformity with the following harmonized standards: EN 262-1 und 292-2 EN 50081-1/1992; EN 55014; EN 61000-3-2/3 EN 50082-1/1997; EN 55014-2 (EN 61000-4-2/-3/-4/-5/-6/-11) According to the regulations of the following EU directives: 2006/42/EG (machinery directive) 2004/108/EG (electromagnetic compliance) 2006/95/EG (low voltage directive) 01.01.2013 © Stefan Weiland 15.11.2012 Stefan Weiland Page 28 www.nassenheider.com Produktservice Stefan Weiland Leipziger Str. 33 01097 Dresden Germany Sales: +49(0)351-89 66 91-01 Support: +49(0)351-89 66 91-05 Fax: +49(0)351-89 66 91-99 PRO E-Mail: [email protected] Website: www.nassenheider.com n Stefa d n a il e W E RVIC SE DUKT
