ACASIS PI-3300 User manual

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PI-3100 Page # 1
OPERATION MANUAL
PISTON FILLER MACHINE
MODEL PI-3300
CLIENT:SIGMA EQUIPMENTS
SERIAL # 2947
ALL OPERATORS MUST READ AND UNDERSTAND THIS MANUAL BEFORE
THEY CAN USE THE MACHINE

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PI 3300 Page # 2
ALL PROPOSAL, QUOTATIONS AND ORDERS ARE SUBJECT TO
THE FOLLOWING TERMS AND CONDITIONS
1. Quoted Prices are FOB point of shipment (Miami, FL), freight collect or prepaid. The contents of all quotations are
subject to change without notice.
2. Brochures and literature are subject to constant design improvements and are not binding in detail.
3. ACASI MACHINERY INC. warrants that the subject goods and equipment are manufactured in conformity with the
specifications pertaining thereto. THIS WARRATY IS EXPRESSELY IN LIEU OF ANY AND ALL WARRANTIES
EXPRESS OR IMPLIED. THERE IS NO WARRANTY THAT THE GOODS AND EQUIPMENT ARE
MERCHANTABLE OR FIT FOR A PARTICULAR PURPOSE.
4. Stock subject to prior sale, order will be entered and delivery will be after credit approval.
5. All orders are subject to final acceptance from ACASI MACHINERY INC, quoted Prices are subject to final
confirmation at the time that the order is placed.
6. By acceptance of this quotation, through the purchase of the goods or equipment described herein. Buyer agrees to
hold harmless and indemnify ACASI MACHINERY INC. against any claim cost, lost of profit or expense, including,
by way of illustration, not limitation, consequential damages, attorneys fees, court costs and all other losses incurred
by any person or entity by reason of use, operation, maintenance, ownership or possession of the subject goods or
equipment.
7. Shipments dates are not guaranteed and are subject to delays due to causes beyond the seller control. The seller shall
not be liable for late or non-delivery due to accident, strike, fire any Act of God or other causes beyond shipper’s
control.
8. Orders are not subject to cancellation except with seller’s consent and upon terms indemnifying seller against loss.
9. Sales use, excise, property or similar taxes relating to this order are not included. The Seller shall have right at any
time to bill Buyer for any such tax, which Seller may be called upon to pay.
10. No modification shall be affected by the acknowledgement or acceptance of purchase order containing different
conditions.
11. None of the terms and conditions contained herein may be added to, modified superseded or otherwise altered
except by written consent from ACASI MACHINERY INC.
12. This document and any obligations arising hereunder shall de construed and understood under FLORIDA law only.
13. Until full payment is made by the purchaser-customer, title to any goods or equipment sold hereunder shall remain,
for repossession purposes with the seller. Purchaser-customer agrees to insure the goods or equipment against any
loss or liability.
Company : _________________________________________________________________________________________________
Company Representative: ___________________________________________________________________________________
Title: ______________________________________ Date: ______________________________________
Signature _________________________________________________

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PI 3300 Page # 3
Date
Revision
Edited
Approved
Comments
06/2014
I. Possin
First version

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PI 3300 Page # 4
INDEX
I. INTRODUCTION...................................................................................................6
II. RECEIPT OF THE MACHINE ...............................................................................7
III. PLACEMENT AND INSTALLATION OF THE FILLER MACHINE.................8
IV. SYSTEM REQUIREMENTS FOR STARTING UP THE MACHINE................11
V. GENERAL AND PREVENTIVE MAINTENANCE.............................................12
VI. GETTING FAMILIAR WITH THE MACHINE.................................................14
i. Control Panel......................................................................................................14
ii. Electrical system.................................................................................................15
VII. USE OF THE FILLER........................................................................................18
i. Setting up the main options in the HMI...............................................................18
ii. Additional settings and other options ..................................................................21
i. Nozzles ...........................................................................................................21
ii. Drip Tray C. Guide......................................................................................22
iii. Entry cylinder..............................................................................................23
iv. Exit cylinder................................................................................................24
v. Conveyor.....................................................................................................25
iii. Additional Setting 2.........................................................................................26
VIII. PNEUMATIC FLOW CONTROLS................................................................27
IX. NOZZLES..........................................................................................................28
X. PISTONS FOR FILLING......................................................................................29
XI. STARTING UP THE FILLER............................................................................30
i. Adjusting the Height and Stroke of the Nozzles..................................................31
ii. Adjusting the Nozzle Spacing and Setting the Position of the Entry and Exit
Cylinders to Control the Containers...........................................................................32
iii. Adjusting the Optical Sensors At The Entry And Exit Of The Machine...........33
iv. Piston Adjustment: Fill Volume, Fill Speed, and Charge Speed.......................34
XII. HOW THE MACHINE WORKS........................................................................36

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PI 3300 Page # 5
INDEX FIGURE
Figure 1: Mounting the Conveyor to the Machine and Leveling.......................................7
Figure 1A........................................................................................................................8
Figure 1B ........................................................................................................................9
Figure 1C ......................................................................................................................10
Figure 2: Frontal view of the control panel ....................................................................14
Figure 3: Internal View of the Control Panel..................................................................16
Figure 4: Location of the Sensors on the Machine..........................................................18
Figure 5: Main Screen ...................................................................................................19
Figure 6: Conveyor speed adjustment............................................................................19
Figure 7: Setting number of bottles................................................................................20
Figure 8: Button on or off the conveyor.........................................................................20
Figure 9: Additional settings..........................................................................................21
Figure 10: Screen additional settings (Nozzles) .............................................................21
Figure 11: Filling time setting........................................................................................22
Figure 12: Setting screen centering and drip tray ...........................................................22
Figure 13: Set the activation time of the centering or the drip tray .................................23
Figure 14: Main screen of setting the time for the retract operation input.......................23
Figure 15: Set the entry cylinder retraction time ............................................................24
Figure 16: Main screen of setting the time for the retract operation input.......................24
Figure 17: Set the exit cylinder retraction time...............................................................25
Figure 18: Main screen setting time to reach the desired speed ......................................25
Figure 19: Setting time to reach the desired speed..........................................................26
Figure 20: Example button more settings.......................................................................26
Figure 21: Additional Settings 2....................................................................................27
Figure 22: Flow Control Locations................................................................................29
Figure 23: Entry & Exit Cylinder Location....................................................................30
Figure 24: Location of the Nozzle Bar Stops..................................................................32
Figure 25: Exit Cylinder, Guide Rail, and Nozzle Adjustment.......................................34
Figure 26: Entry & Exit Sensor Setup............................................................................35
Figure 27: Adjusting Filling Volume.............................................................................36

7085 NW 46th Street, Miami, FL 33166 - USA. Telephone: [phone] Fax: [phone]
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PI 3300 Page # 6
I. INTRODUCTION
This manual is an important guide that shows how to operate the filling machine. Getting
familiar with this manual and following the instructions given in it will help avoid
problems that could affect production. Following the instructions listed in this manual
will also increased the life span of your PI-3300 piston filler.
Please, do not hesitate to contact Acasi Machinery if you require further information or
assistance with this machine.
REMEMBER, IF A PROBLEM OCCURS WHILE THE MACHINE IS IN
OPERATION, BE SURE TO DISCONNECT ALL PNEUMATIC AND
ELECTRICAL SUPPLIES BEFORE TRYING TO FIX THE PROBLEM.

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PI-3100 Page # 7
II. RECEIPT OF THE MACHINE
If your machine is equipped with a feed tank (optional part), the hoses will be
disconnected from the valve system for easier transportation, please use the supplied hose
clamps to fasten the tubing to the valves.
In the machine was purchased with a conveyor installed (optional part). The conveyor
may be sent separately for easier transportation. To mount the conveyor to the filler, lay
the conveyor across the supports on the front of the machine, and use the supplied
mounting hardware to secure the conveyor in place. See Figure 1 (Mounting the conveyor
to the machine and leveling) for further detail.
Figure 1: Mounting the Conveyor to the Machine and Leveling

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III. PLACEMENT AND INSTALLATION OF THE FILLER MACHINE
Decide the machine location according to the dimensions shown in the following images.
Figure 1A

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PI 3300 Page # 9
Figure 1B

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PI 3300 Page # 10
Figure 1C

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These next steps will assist the operator in starting up the machine and tuning the filler:
a) Once the conveyor has been mounted in place on the machine, place the machine in
the working location and level the conveyor by adjusting of the four (04) large screws
(GI3100-01-090, shown in figure 1) on the bottom frame rails.
b) After the filler has been leveled, check to be sure that all of the switches on the
control panel are in the OFF position.
c) Connect the main power cord to an electrical supply with 220VAC (1 phase, 1 neutral
and ground feeder), 60Hz. Make sure the Emergency Stop button is depressed at this
time.
d) Connect an airline to the quick connect fitting on the filler’s regulator (right side of
control panel). Make sure the emergency disconnect is stopping the flow of air to the
machine at this time.
e) At this time, the machine should be ready to run. However, before putting the
machine into production. We highly recommend cleaning the filler and all
components thoroughly, prior to operation. After cleaning, it is also recommended
that any filler components that will come in direct contact with the product be cured
with the product being filled prior to starting a production run.
IV. SYSTEM REQUIREMENTS FOR STARTING UP THE MACHINE
•Electrical requirements: 220 VAC, 20A (the main plug must have a solid ground
connection).
•Pneumatic requirements: 20 CFM @80 PSI

7085 NW 46th Street, Miami, FL 33166 - USA. Telephone: [phone] Fax: [phone]
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PI 3300 Page # 12
V. GENERAL AND PREVENTIVE MAINTENANCE
Acasi Machinery highly recommends implementing a consistent maintenance plan, based
on the following recommendations. The life span and the performance of this machine
will certainly increase with proper scheduled maintenance.
The air being fed to the machine must be dry, or have the least amount of water content
possible. The presence of water in the air supply will not affect the normal functioning of
the machine, but it will decrease the life span of the internal components and valves.
DO NOT, UNDER ANY CIRCUMSTANCES, CLEAN THIS MACHINE WITH
BLEACH OR ACIDIC SOLUTIONS. These products will react with, and attack, the
sanitary stainless steel components.
Air filter:
The air filter must be checked frequently to extract any water or dirt that has been
retained.
Lubricating the Linear Bearings and Calibrated Shafts:
These bearings and shafts (Figure 24, GI3100-01-006) must be lubricated weekly, or after
every full wash down, with good quality grease.
Pneumatic Cylinder Lubrication:
Even though these cylinders come pre-lubricated from the factory, we recommend
lubricating the interior of the cylinder body monthly. For this, use a couple drops of
pneumatic oil (SAE 10 for compressors).
Oil Tank:
The minimum level of oil in the holding tank must not be less than 1 inch (read via sight
glass tube on side of tank). The oil used is ISO 46 for high pressures hydraulic systems
HM type. (See Figure 22).

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PI 3300 Page # 13
General Lubrication:
All bushings, bearings, and lubrication points must be lubricated weekly with good
quality grease. All of the threaded rods and adjustment screws must be lubricated
monthly with light grease. These parts must also be lubricated after each cleaning or full
wash down.
Conveyor Motor:
These bearings are sealed and pre-lubricated for their life span.
The motor brushes must be periodically checked to insure proper operation. These
brushes have an initial length of 1.25 inches. When the brushes reach 0.375 inches long,
they must be replaced. The average life span of the brushes is around a year and a half.
PLC:
The PLC has a lithium battery that has a maximum life span of about 5 years. We
recommend replacing this battery every 4 years.

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PI 3300 Page # 14
VI. GETTING FAMILIAR WITH THE MACHINE
i. Control Panel
All the electrical functions of the machine are controlled through the electric panel; a
brief description of these components is given below:
Figure 2: Frontal view of the control panel

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PI 3300 Page # 15
EMERGENCY STOP
Stops the machine
immediately
START BUTTON
Energizes the machine
TOUCHSCREEN
From this HMI, all the
controls and processes of
the machine are set up
ii. Electrical system
The electrical system controls all the functions of the machine, based on the information
that is received from the sensors installed throughout the filler. With this information the
PLC controls the various functions and processes. A basic layout of the primary electrical
components (except sensors and motors) housed in the control panel is illustrated in
Figure 3.

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Figure 3: Internal View of the Control Panel
PLC: This is the brain of the machine. It receives information through the inputs,
interprets this information, and sends signals through the outputs to execute the various
functions and control the filling process.
Power Supply: This component converts 220V AC to 24V DC power to run all of the
components in the control panel. This power supply has a capacity of 30W.
Fuses: There are two fuses located in the control panel, one 5A for the conveyor motor
and one 2A for the PLC.

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Relay: This component allows the PLC to control the movement (start and stop) of the
conveyor.
Magnetic Switches: These sensors are located on the back of the main air cylinder. They
should be placed over the body of the pneumatic cylinder (one at the bottom & one at the
desired nozzle height). They inform the PLC of the position of the nozzles (See Figure 4).
Sensors of filling point: These are proximity sensors placed on the adjusting filling bar
(pieces PI3100-01-060 and PI3100-01-062, see figure 4) they are activated when the
pneumatic filling cylinder is extended or retracted.
Solenoid Valves: These are signaled by the PLC to control the pneumatic functions of
the machine, by activating the pneumatic cylinders placed throughout the machine:
•Main Cylinder Movement (Nozzles Up and Down)
•Entry Gate
•Exit Gate
•Filling Process (Piston Charge & Discharge)
There are also a few optional solenoids that may be installed on your machine, depending
on the application requirements:
•Nozzle Opening & Closing (Pneumatic Cut-off)
•Centering Guide
•Drip Tray

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Figure 4: Location of the Sensors on the Machine
VII. USE OF THE FILLER
i. Setting up the main options in the HMI
Follow the steps below to start the set up the conditions of work for your filler:
1. Turn the safety lockout switch on the side of the control panel to ON (if
necessary).
2. Release the emergency stop button by turning it (if necessary).
3. Press the start button in the control panel, DO NOT PLACE ANY
CONTAINERS ON THE CONVEYOR YET

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Figure 5: Main Screen
4. Set the number of the speed at which the conveyor works by pressing the blue
button in the upper left corner of the main screen (see Figure 5). A numeric
keypad appears on the screen to enter the number (see figure below). A
numeric keypad appears on the screen to enter the number (see Figure 6).
Figure 6: Conveyor speed adjustment

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5. Set the number of containers to be filled in the machine by pressing the blue
button on the right side of the main screen, called (INSTALLED) (see figure
below). A numeric keypad appears on the screen to enter the number.
Figure 7: Setting number of bottles
6. Set the conveyor ON or OFF by pressing the button in the center of the main
screen, the color of the button will change depending on the state of the
conveyor (see Figure 8).
Figure 8: Button on or off the conveyor