Aesus AESFill AF1 User manual

Aesus Packaging Systems www.aesus.com
188 Oneida Drive Pointe-Claire Montréal, Quebec Canada H9R 1A8
[phone] Fax [phone]
Owner’s Manual
AESFill AF1
Single headgear pump filling machine
**Note—Machine image may not be the same as what was purchased.
Edition Date: 2018-09-04

AESFill AF1C Machine Manual 2/58 Notice Regarding OSHA Regulations
NOTICE REGARDING OSHA REGULATIONS
Sellers shall not be responsible for any failure of compliance which results from the location, operation, use or maintenance of the
equipment or for alterations of the equipment by people other than the seller, or from an option or accessory to the equipment
which was available to the buyer but omitted at the buyer’s direction. Sellers shall not be responsible for designs or instructions
furnished by the buyer or his agents. Seller makes no warranties with respect to noise and will not be responsible for any fines,
penalties, or consequential damages.
Aesus Packaging Systems
Pointe-Claire (Montréal), Québec
Canada

AESFill AF1C Machine Manual 3/58 Table of Contents
Table of Contents
NOTICE REGARDING OSHA REGULATIONS .............................................................................................................................2
Table of Contents....................................................................................................................................................................3
List of Appendix.......................................................................................................................................................................5
List of Tables ...........................................................................................................................................................................5
List of Figures ..........................................................................................................................................................................5
1. Warranty & Terms and Conditions of Sale.....................................................................................................................8
Disclaimer and Limitation of Liability ....................................................................................................................................................9
2. Installation....................................................................................................................................................................10
Unpacking the Machine..........................................................................................................................................................102.1
Installing the Machine ............................................................................................................................................................102.2
2.2.1 Front of AESFill AF1.........................................................................................................................................................10
2.2.2 Rear of AESFill AF1 ..........................................................................................................................................................10
3. General Description......................................................................................................................................................12
4. AESPump ......................................................................................................................................................................13
To assemble the pump ...........................................................................................................................................................144.1
Nozzle .....................................................................................................................................................................................164.2
4.2.1 Standard Nozzles.............................................................................................................................................................16
4.2.2 To assemble the nozzle:..................................................................................................................................................16
4.2.3 Custom Nozzles...............................................................................................................................................................17
Positioning the Equipment .....................................................................................................................................................184.3
4.3.1 Height Adjustments ........................................................................................................................................................18
Connections............................................................................................................................................................................194.4
Air Supply & Lubrication.........................................................................................................................................................204.5
5. Quick Setup ..................................................................................................................................................................21
Quick Setup in 5 Easy Steps ....................................................................................................................................................215.1
5.1.1 Nozzle..............................................................................................................................................................................21
5.1.2 Pump...............................................................................................................................................................................21
5.1.3 Foot switch......................................................................................................................................................................22
5.1.4 Screen Setup ...................................................................................................................................................................22
5.1.5 Container for Filling ........................................................................................................................................................22
Quick & Easy Priming..............................................................................................................................................................225.2
6. Setup for Machine with Conveyor and Gate Indexing System.....................................................................................23
Neck Clamps (Optional)..........................................................................................................................................................236.1
Nozzle Barre Adjustment........................................................................................................................................................246.2
Nozzles Adjustment................................................................................................................................................................246.3
Guide rails adjustments..........................................................................................................................................................256.4
Gates adjustments..................................................................................................................................................................266.5
1st Container Sensor ..............................................................................................................................................................27
6.6
Gap Sensor .............................................................................................................................................................................286.7
Backup Sensor ........................................................................................................................................................................286.8
7. Pump Screens...............................................................................................................................................................29
Home screen / Run screen .....................................................................................................................................................307.1
Fill Setting ...............................................................................................................................................................................307.2
Speed......................................................................................................................................................................................307.3
Repeat Fill...............................................................................................................................................................................317.4
Go to Special Settings .............................................................................................................................................................317.5
Slave .......................................................................................................................................................................................317.6

AESFill AF1C Machine Manual 4/58 Table of Contents
Access continuous pumping ...................................................................................................................................................317.7
Nozzle only .............................................................................................................................................................................327.8
Continuous pumping ..............................................................................................................................................................327.9
Open spout .............................................................................................................................................................................327.10
Close spout .............................................................................................................................................................................327.11
Gating (Optional) ....................................................................................................................................................................337.12
7.12.1 Gap timer ........................................................................................................................................................................33
7.12.2 Gating delay ....................................................................................................................................................................33
7.12.3 Start eye delay ................................................................................................................................................................33
Dive (Optional) .......................................................................................................................................................................347.13
7.13.1 Neck Dive ........................................................................................................................................................................34
7.13.2 Bottom delay...................................................................................................................................................................34
7.13.3 Neck clamp......................................................................................................................................................................34
7.13.4 Full Dive ..........................................................................................................................................................................35
7.13.5 Bottom delay...................................................................................................................................................................35
7.13.6 Neck delay.......................................................................................................................................................................35
7.13.7 Neck clamp......................................................................................................................................................................35
7.13.8 Container height .............................................................................................................................................................36
7.13.9 Neck clearance................................................................................................................................................................36
Profile Filling ...........................................................................................................................................................................377.14
7.14.1 Pump speed at start........................................................................................................................................................37
7.14.2 Slow start duration .........................................................................................................................................................37
7.14.3 Pump speed at end .........................................................................................................................................................37
7.14.4 Slow end duration...........................................................................................................................................................38
Return to RUN SCREEN ...........................................................................................................................................................387.15
8. AF1 Remote Screens (OPTIONAL) ................................................................................................................................39
8.1.1 Remote Screen................................................................................................................................................................39
8.1.2 Main Screen (Run Screen)...............................................................................................................................................39
8.1.2.1 Bottom banner .......................................................................................................................................................39
8.1.2.2 Configuration menu................................................................................................................................................39
8.1.2.3 Alarms Screen.........................................................................................................................................................40
8.1.3 Login Screen ....................................................................................................................................................................40
8.1.4 Dive setup screens ..........................................................................................................................................................40
8.1.5 Gating Setup Screen (Optional) ......................................................................................................................................41
8.1.6 Pump Main Setup Screen................................................................................................................................................41
8.1.6.1 Pump 1 Setup Screen.............................................................................................................................................. 41
8.1.6.2 Pump 2 Setup Screen (Optional) ............................................................................................................................ 42
8.1.6.3 Pump 3 Setup Screen (Optional) ............................................................................................................................ 42
8.1.6.4 Pump 4 Setup Screen (Optional) ............................................................................................................................ 43
8.1.7 Pump 1 Profile Filling Setup Screen ................................................................................................................................43
8.1.7.1 Pump 2 Profile Filling Setup Screen (Optional).......................................................................................................43
8.1.7.2 Pump 3 Profile Filling Setup Screen (Optional).......................................................................................................44
8.1.7.3 Pump 4 Profile Filling Setup Screen (Optional).......................................................................................................44
8.1.8 Profile Lifting Setup Screen.............................................................................................................................................44
8.1.9 Test Screen......................................................................................................................................................................45
9. Feed Tanks....................................................................................................................................................................46
10. Nozzle Types.................................................................................................................................................................47
Exchanging Nozzles & Pumps .................................................................................................................................................4810.1
Cleaning..................................................................................................................................................................................4810.2
10.2.1 Cleaning the Nozzle.........................................................................................................................................................48

AESFill AF1C Machine Manual 5/58 Table of Contents
10.2.2 Cleaning the Pump..........................................................................................................................................................48
11. Changeover ..................................................................................................................................................................49
Simple Changeover.................................................................................................................................................................4911.1
Normal Changeover................................................................................................................................................................4911.2
Determining Volume & Speed................................................................................................................................................4911.3
12. Networking Multiple AF1s Together ............................................................................................................................50
13. Troubleshooting ...........................................................................................................................................................51
General Troubleshooting........................................................................................................................................................5113.1
Inconsistent Fills .....................................................................................................................................................................5213.2
Dripping Nozzle ......................................................................................................................................................................5313.3
14. General Maintenance...................................................................................................................................................54
Before Each Production Run...................................................................................................................................................5414.1
After Each Production Run .....................................................................................................................................................54
14.2
Pneumatic Controls for Shut-Off Nozzles ...............................................................................................................................5414.3
15. Recommended Spare Parts..........................................................................................................................................55
16. Contact Information.....................................................................................................................................................57
17. Some of the other Machinery Manufactured by Aesus Packaging Systems................................................................58
List of Appendix
Appendix 1: Assembly Drawings ....................................................................................................................................................Apdx 1
Appendix 2: Electrical Drawings........................................................................................................................................................Apdx 2
List of Tables
Table 1: Nozzles size ................................................................................................................................................................................47
Table 2: Troubleshooting and quick solutions .........................................................................................................................................51
Table 3: Troubleshooting and quick solution 2 ........................................................................................................................................52
Table 4: Troubleshooting and quick solution 3 ........................................................................................................................................53
Table 5: Recommended spare parts ........................................................................................................................................................55
List of Figures
Figure 2-1: Rating Plate—Example ..........................................................................................................................................................10
Figure 2-2: AESFill AF1 .............................................................................................................................................................................10
Figure 2-3: Rear of AESFill AF1 .................................................................................................................................................................11
Figure 3-1: AF1 Machine ..........................................................................................................................................................................12
Figure 3-2: AESPump................................................................................................................................................................................ 12
Figure 4-1: AESPump body.......................................................................................................................................................................13
Figure 4-2: Pump Assembly ..................................................................................................................................................................... 14
Figure 4-3: Pump Assembly 1................................................................................................................................................................... 14
Figure 4-4: Pump Assembly 2................................................................................................................................................................... 14
Figure 4-5: Pump Assembly 3................................................................................................................................................................... 14
Figure 4-6: Pump Assembly 4................................................................................................................................................................... 14

AESFill AF1C Machine Manual 6/58 Table of Contents
Figure 4-7: Pump Assembly 5................................................................................................................................................................... 14
Figure 4-8: Pump Assembly 6...................................................................................................................................................................15
Figure 4-9: Pump Assembly 7................................................................................................................................................................... 15
Figure 4-10: Standard Nozzle Assembly...................................................................................................................................................16
Figure 4-11: 1 ½“Nozzle ...........................................................................................................................................................................17
Figure 4-12: 1 ½“Custom Nozzle Assembly..............................................................................................................................................17
Figure 4-13: Position of the equipment ...................................................................................................................................................18
Figure 4-14: Pump....................................................................................................................................................................................19
Figure 4-15: Air filter connection ............................................................................................................................................................. 20
Figure 5-1: Fittings ...................................................................................................................................................................................21
Figure 5-2: Nozzles...................................................................................................................................................................................21
Figure 5-3: Flow of the pump...................................................................................................................................................................21
Figure 5-4: Outlet Fittings ........................................................................................................................................................................21
Figure 5-5: Screen ....................................................................................................................................................................................22
Figure 5-6: Priming...................................................................................................................................................................................22
Figure 6-1: Placement bar Adjustment ....................................................................................................................................................23
Figure 6-2: Neck clamps Sideway adjustment 1 ......................................................................................................................................23
Figure 6-3: Neck clamps Sideway adjustment 2 ......................................................................................................................................23
Figure 6-4: Neck clamps Sideway adjustment 3 ......................................................................................................................................24
Figure 6-5: Neck clamps Sideway adjustment 4 ......................................................................................................................................24
Figure 6-6: Nozzle barre adjustment .......................................................................................................................................................24
Figure 6-7: Nozzles adjustment................................................................................................................................................................25
Figure 6-8: Nozzles adjustment 2.............................................................................................................................................................25
Figure 6-9: Guide rails Adjustment ..........................................................................................................................................................25
Figure 6-10: Guide rails Adjustment 2 .....................................................................................................................................................26
Figure 6-11: Bottle placement .................................................................................................................................................................26
Figure 6-12: Gates final position .............................................................................................................................................................. 26
Figure 6-13: Infeed/Outfeed gate adjustment......................................................................................................................................... 26
Figure 6-14: Outfeed gate adjustment ....................................................................................................................................................27
Figure 6-15: Outfeed gate adjustment ....................................................................................................................................................27
Figure 6-16: Outfeed gate adjustment ....................................................................................................................................................27
Figure 6-17: Outfeed gate adjustment ....................................................................................................................................................28
Figure 6-18: Outfeed gate adjustment ....................................................................................................................................................28
Figure 6-19: Outfeed gate adjustment ....................................................................................................................................................28
Figure 7-1: Diagram des Screens..............................................................................................................................................................29
Figure 7-2: Home Screen..........................................................................................................................................................................30
Figure 7-3: Run Screen ............................................................................................................................................................................. 30
Figure 7-4: Fill Screen...............................................................................................................................................................................30
Figure 7-5: Speed Screen .........................................................................................................................................................................30
Figure 7-6: Repeat Fill Screen ..................................................................................................................................................................31
Figure 7-7: Special Screen ........................................................................................................................................................................31
Figure 7-8: Slave Screen...........................................................................................................................................................................31
Figure 7-9: Pumping ................................................................................................................................................................................. 31
Figure 7-10: Nozzle Screen....................................................................................................................................................................... 32
Figure 7-11: Pumping Screen ...................................................................................................................................................................32
Figure 7-12: Spout.................................................................................................................................................................................... 32
Figure 7-13: Close Spout .......................................................................................................................................................................... 32
Figure 7-14: Gating Screen.......................................................................................................................................................................33
Figure 7-15: Gap timer Screen .................................................................................................................................................................33
Figure 7-16: Gating Delay Screen............................................................................................................................................................. 33
Figure 7-17: Start eye delay Screen .........................................................................................................................................................33

AESFill AF1C Machine Manual 7/58 Table of Contents
Figure 7-18: Dive Screen ..........................................................................................................................................................................34
Figure 7-19: Neck dive Screen..................................................................................................................................................................34
Figure 7-20: Bottom Delay Screen ........................................................................................................................................................... 34
Figure 7-21: Neck Clam Screen ................................................................................................................................................................34
Figure 7-22: Full-dive Screen....................................................................................................................................................................35
Figure 7-23: Bottom Delay Screen ........................................................................................................................................................... 35
Figure 7-24: Neck Delay Screen ...............................................................................................................................................................35
Figure 7-25: Neck Clamp Screen .............................................................................................................................................................. 35
Figure 7-26: Container height Screen ...................................................................................................................................................... 36
Figure 7-27: Neck Clearance Screen ........................................................................................................................................................ 36
Figure 7-28: Profile Filling Screen ............................................................................................................................................................ 37
Figure 7-29: Pump Speed Screen .............................................................................................................................................................37
Figure 7-30: Slow start Screen ................................................................................................................................................................. 37
Figure 7-31: Pump Speed Screen 2 ..........................................................................................................................................................37
Figure 7-32: Slow end Screen................................................................................................................................................................... 38
Figure 7-33: Return Screen ...................................................................................................................................................................... 38
Figure 8-1: Remote Screen.......................................................................................................................................................................39
Figure 8-2: Main Screen ...........................................................................................................................................................................39
Figure 8-3: Bottom banner.......................................................................................................................................................................39
Figure 8-4: Configuration menu...............................................................................................................................................................39
Figure 8-5: Alarms screen ........................................................................................................................................................................40
Figure 8-6: Login Menu ............................................................................................................................................................................40
Figure 8-7: Dive Setup Screen ..................................................................................................................................................................40
Figure 8-8: Gating Setup Screen (Optional) .............................................................................................................................................41
Figure 8-9: Pump Main Setup Screen....................................................................................................................................................... 41
Figure 8-10: Pump 1 Setup Screen...........................................................................................................................................................41
Figure 8-11: Pump 2 Setup Screen...........................................................................................................................................................42
Figure 8-12: Pump 3 Setup Screen...........................................................................................................................................................42
Figure 8-13: Pump 4 Setup Screen...........................................................................................................................................................43
Figure 8-14: Pump 1 Profile Filling Setup Screen .....................................................................................................................................43
Figure 8-15: Pump 2 Profile Filling Setup Screen .....................................................................................................................................43
Figure 8-16: Pump 3 Profile Filling Setup Screen .....................................................................................................................................44
Figure 8-17: Pump 4 Profile Filling Setup Screen .....................................................................................................................................44
Figure 8-18: Profile Lifting Setup Screen..................................................................................................................................................45
Figure 8-19: Test Screen ..........................................................................................................................................................................45
Figure 9-1: Tanks......................................................................................................................................................................................46
Figure 10-1: Nozzles.................................................................................................................................................................................47
Figure 10-2: Nozzle 2................................................................................................................................................................................ 48
Figure 10-3: Dissembling pumps.............................................................................................................................................................. 48
Figure 12-1: 5 to 19 Pin Cable .................................................................................................................................................................. 50
Figure 12-2: 19 Pin Automation Kit Connection Cable ............................................................................................................................50

AESFill AF1C Machine Manual 8/58 Warranty, Terms & Conditions of Sale
1. Warranty & Terms and Conditions of Sale
AESUS refers to Aesus Labelling Systems, Aesus Packaging Systems Inc, and DL Tech Inc.
GUARDING: Guarding provided may not suit your local requirements. Additional guarding is available at extra cost and can be provided to meet your requirements.
Please examine the guarding included and advise us immediately should you require any changes.
PERFORMANCE GUARANTEES: The performance of Aesus machinery to do a particular task, at a particular speed, with a customer’s products (caps, containers, labels,
shrink sleeves, etc.) depends on many variables. These variables may also include the ambient temperatures, the environment, the quality of the components, the
quality of the film or the labels, the backing paper, the design of the container, and possibly many other considerations. Aesus in the light of their experience attempt
to provide what Aesus deems is an acceptable and/or affordable solution. Therefore, due to so many possible variables, Aesus cannot positively guarantee all aspects
of performance. Customers are expected to perform a final acceptance test at Aesus’s facility with as many of their components as possible, and Aesus will do their
absolute best to help the customer find a solution to any challenging issues, only charging the customer at Aesus’s cost for the work done in the attempt to find an
acceptable solution.
TESTING: Quotations are always subject to final testing of bulk samples. Changes and additional costs incurred in order to achieve proper operation, or to reach
estimated speeds of the machinery, after testing of bulk samples, will be charged at cost, when not otherwise agreed to in advance. In those cases where bulk
samples are not supplied, equipment will be tested for normal functioning only. Performance on products not submitted whether expressed or implied cannot be
guaranteed.
OTHER MANUFACTURERS: It should be understood that although Aesus will do their best to ensure that coders, vision systems, barcode readers, UV detection
systems, etc., that are manufactured by others but integrated by Aesus, perform appropriately at installations and during FATs (should the customer have
purchased FAT tests at Aesus, or with Aesus in attendance at the customer’s facility), Aesus does not guarantee these items, nor will Aesus be held responsible to
delivery delays caused by deficiencies of such systems. The customer should do their due diligence in the choice of coding and checking systems that are appropriate.
Aesus may facilitate the process by purchasing these items on behalf of the customer, but it is understood that Aesus passes the warranty (ies) of these items to the
customer upon delivery of the machine. If any of these systems fail to perform, the customer should deal directly with the supplier in question, although Aesus will do
their best to help facilitate this process.
An ”Aesus in attendance” run is a test of a duration that is acceptable to both Aesus and the customer (at suitable charges) at an Aesus facility or at the customer’s
facility, with qualified Aesus engineer(s) in attendance for the purpose of qualifying and accepting the machine (FAT).
SAMPLES AND TEST MATERIAL: In order to confirm the order and the estimated time for machine manufactures, representative samples of all materials and
containers to be used on the machine must be available at the factory. Samples, as requested, are to be forwarded free of charge, freight prepaid to the factory by
the customer, indicating minimum values for customs purposes where applicable. All samples will be returned with all the tested machinery. In the case where
returning product will significantly increase the freight costs, the buyer will have the option of paying for proper disposal of their samples.
Normally a 15 minute “production run” of samples of each size bottle (or more), and adequate samples of products, band, or other consumables are required in order
to ensure the proper operation of the machine. Samples must be sent free of charge, freight and duties prepaid to arrive within 30 days of order date. Late delivery of
the samples will result in late delivery of the machine.
MATERIALS AND CONSUMABLES: Aesus assumes no responsibility for materials and consumables purchased by the buyer regardless of testing performed and
recommendations made. Aesus recommends that the customer does not buy considerable quantities of consumables such as film, band, sleeving, caps, labels, etc.
until final satisfactory tests have been conducted to prove suitability of such.
MACHINE ACCEPTANCE: When machinery is complete, the customer will be requested to visit the Factory for machine Acceptance Testing (FAT). All features will be
demonstrated, as well as a five-minute continuous production run on all sizes of samples supplied. Additional charges apply for longer acceptance tests or when more
than 3 product sizes are to be tested. The machine will be deemed to be complete and accepted by the customer when the manufacturer has demonstrated the
machinery operating at the required speeds and quality specified.
ON-SITE ACCEPTANCE TESTING: Customers have the option of having the acceptance tests repeated at their facilities, by contracting for a representative of the
original equipment manufacturer or Aesus to carry out the test on-site, at prevailing rates.
INSTALLATION LABOUR AND TRAINING: Installation of and training on equipment and accessories is not included and can be done by Aesus or by those of Aesus’s
agents and representatives on request at prevailing rates. Note that some equipment such as coders, vision systems, barcode readers, UV detection systems, etc.,
that are manufactured by others (OEMs) but integrated by Aesus, can be complicated and Aesus technicians may not be familiar with many aspects of these items.
Customers should also consider engaging OEM trained technicians for these complicated systems. When equipment is not installed by us, Warranties shall be limited
to replacement of defective parts, FOB supplier factories, supplied prepaid and credited on return of defective parts.
DAMAGE CLAIMS: Great care is taken in packing all machines, parts and accessories. All claims for breakage or damage whether concealed or obvious must be made
to the carrier as soon as possible after receipt of the shipment.

AESFill AF1C Machine Manual 9/58 Warranty, Terms & Conditions of Sale
WARRANTEE: Equipment and Component warranties are in accordance with those of the original equipment supplier, but for Aesus manufactured components shall
be 12 months, based on single shift usage. Wear parts, and those parts found not to be installed according to the equipment manufacturers or Aesus instructions,
abused, not used in accordance with the application originally intended, or modified without prior approval of the original equipment manufacturer or Aesus are
excluded. Labour or travel to replace defective parts is not included.
The foregoing is the only warrantee made by the seller, and the seller specifically disclaim all other warranties, express or implied, including but not limited to, the
implied warranties of marketability and fitness for a particular purpose.
LIMITS OF LIABILITY: Liability of the original Equipment supplier, Aesus’s, its agents, distributors, and representatives, for any damages suffered by the buyer or its
customers, whether in contract or otherwise, shall be limited to the amount paid to the seller by the buyer in reference to the equipment supplied, and in no case
shall a seller be liable for any special, indirect, or consequential damages (including loss of goods, loss of profits, loss of opportunity, replacement costs or other) of
buyers, any customer, or of any third party, even if sellers have been previously advised of the possibility of such damages.
RETURN OF GOODS: In no case can any material or equipment be returned to us without our prior written acceptance.
FORCE MAJEURE : Under no circumstances can Aesus or their representatives be responsible for delays caused by Force Majeure. Force Majeure includes strikes,
wars, riots, floods, fires, earthquakes, and other such eventualities out of the control of Aesus or their representatives.
WAIVER: Our failure to insist upon any of these terms and conditions shall not be deemed a waiver of any rights that Aesus may have, and shall not be deemed a
waiver of any subsequent breach or default in these terms and conditions.
PERMITS: Permits and inspections, when not specified, required for the installation and/or use of the equipment furnished, must be applied for by the buyer at their
own expense.
TAXES, excises, or other charges imposed by any local, state, or federal authority, which have to do with or affect the goods herein ordered, shall be assumed and
paid by the buyer. Bank charges and fees for legalization or certification of documents are not included.
SPECIFICATIONS: Specifications, machine designs, and features are subject to change without notice unless specifically agreed to in advance.
COPYRIGHT: This proposal, specifications, literature material, and all technical details are the property of Aesus and are supplied for the sole purpose of evaluating
equipment to be supplied by Aesus. Any reproduction or redistribution without our prior written consent is strictly prohibited.
CLAIMS: Any claim for consequential or incidental damages and any claims, right of action and demands, regardless of how they are described, whether in law or
equity, shall be interpreted according to the laws of the Province of Quebec, Canada and they shall be pursued solely in the Province of Quebec, Canada.
ACCEPTANCE AND USE OF MACHINERY:
Acceptance and/or use of this packaging machine include acceptance of all terms and conditions included herein.
Disclaimer and Limitation of Liability
IT IS UNDERSTOOD AND AGREED THAT SELLER’S LIABILITY FOR ANY DAMAGES SUFFERED BY BUYERS OR ITS CUSTOMERS, WHETHER
IN CONTRACT, IN TORT, UNDER ANY WARRANTY THEORY, IN NEGLIGENCE OR OTHERWISE, SHALL BE LIMITED TO THE AMOUNT PAID
TO SELLERS BY BUYER PURSUANT TO THE CONTRACT. UNDER NO CIRCUMSTANCES SHALL A SELLER BE LIABLE FOR ANY SPECIAL,
INDIRECT OR CONSEQUENTIAL DAMAGES (INCLUDING LOST PROFITS) OF BUYERS, ANY CUSTOMER, OR ANY OTHER THIRD PARTY,
EVEN IF SELLERS HAS BEEN PREVIOUSLY ADVISED OF THE POSSIBILITY OF SUCH DAMAGES.

AESFill AF1C Machine Manual 10/58 General Description
2. Installation
Unpacking the Machine2.1
The machine is packed in a single crate or box. Small accessories will be packed in separate cartons and included in the main
machine crate. Large accessories, such as a feed tank stand, etc., would be packed in separate crates.
Remove the top and sides of the crate. Place all small packages in a safe area. Carefully remove the main body of the
AESFill AF1.
Carefully inspect the machine for any damage during transport, and if found, notify the carrier immediately.
Installing the Machine2.2
2.2.1 Front of AESFill AF1
The AESFill Body consists of one stainless steel encased unit. This body houses the drive of the AESFill AF1, which is an AC Inverter
system with an exclusive frequency speed control. The machine is supplied to match your voltage but is convertible from 110/60/1
to 220/50–60/1. At this stage, please check the rating plate to see if it correctly matches your supply voltage.
The cabinet consists of the touch screen, the nozzle bar clamp
and the carry handle.
Figure 2-1: Rating Plate—Example
2.2.2 Rear of AESFill AF1
The AF1 is equipped with the below marked items on the rear
of the machine.
1. Exhaust Muffler so that the nozzles close smoothly.
2. Black and blue air hose connectors that connect to the
nozzle with 6 mm hosing.
3. Rating Plate with the AF1 serial number and other
specifications.
4. Air regulator that clean dry air should be attached with a
minimum of 60PSI.
Figure 2-2: AESFill AF1

AESFill AF1C Machine Manual 11/58 General Description
5. As standard the AF1 is equipped with a 12 L/min AESPump. Also available is the 24 L/min pump. The pump can be rotated
360 degrees around its axis.
6. Power cord plug and On/Off Switch. Please check the rating plate for the voltage of your machine.
7. There is a 19 pin communication port and a 5 pin communication port. The 5 pin communication port is for connecting to
the foot pedal as well as networking AF1 machines together. The 19 pin communication port is for communication with
different automation options such as gating and a dive kit. The 19 pin communication port is also used in networking AF1
machines together.
Power Chord Plug
Exhaust Muffler
Black & Blue
Nozzle air
connections
Rating Plate
19 Pin
Communication
Cable Port
On/Off Switch
Figure 2-3: Rear of AESFill AF1
Air Regulator
5 Pin
Communication
Cable Port
AESPump

AESFill AF1C Machine Manual 12/58 General Description
3. General Description
AESFill AF1 is a unique, compact single head liquid filling unit capable of combining with and networking up to 4 heads. Each unit has
a soft touch control screen. As standard, volumes can be entered as low as 1/3 ounces. (10 cc) to volumes greater than 5 Gallons (20
Litres) effortlessly to give repeat fill with an accuracy of up to ±0.5%. Just as easily, the fill speed can be entered to give gentle
foamless filling.
The AESFill AF1 fillers can be networked together to make multi-head liquid filling systems; just plug each unit into power and
connect units to each other with an interface cable, available at time of purchase or through our spare parts department, and they
are networked.
Many units can be networked, but normally up to four units are connected in this manner. Machines with greater than four heads
are usually purchased as AESFill automatic fillers.
If you find that manual filling using the AESFill AF1 fillers is too slow, you can add the automation package and the system can be
automated over any conveyor. There are different options that can be added for different types of products such as neck dive for
cleaner filling or full dive for foamy products. Contact us to learn more about the available options for the AESFill AF1.
The AESPump on the AESFill AF1 can rotate 360 degrees so that you can have your AESPump oriented in any direction. The pump is
fastened onto the machine with sanitary clamp, which makes it very easy to remove while still attached to the nozzle, enabling the
complete liquid contact system to be carried to the clean-up area. With a second pump and nozzle ready to go, changeover to
another product is fast and easy.
Figure 3-1: AF1 Machine

AESFill AF1C Machine Manual 13/58 Installation
4. AESPump
The AESPump consists of 17 pieces:
1. 1 Face Plate
2. 1 O-Ring BunaN (Other materials available)
3. 1 Pump Body
4. 2 Tri-Clover Sanitary Clamps (1–3” Dia. & 1–2” Dia.)
5. 2 Gears
6. 1 Stainless Steel Drive Shaft (4 1/8”, 10.5 cm)
7. 1 Stainless Steel Idler Shaft (2 ½”, 6.4 cm)
8. 1 U-Cup Drive Shaft Seal
9. 1 Stainless Steel Gear Chamber
10. 2 Stainless Steel Bushing Holders
11. 4 Bushings (3 short, 1 long)
1- Pump Face Plat
2- O-Ring
3- Pump Body
4- Tri-Clover Sanitary clamp
6- Drive Shaft
7- Idler Shaft
8- U-Cup Drive Shaft
Seal
9—Gear Chamber
5- Gears
10- Bushing Holders
11- Bushing (3 short/1 Long)
Figure 4-1: AESPump body

AESFill AF1C Machine Manual 14/58 Installation
To assemble the pump4.1
Figure 4-2: Pump Assembly
1. If removed, replace the U-cup drive shaft seal by
inserting the small diameter edge of the seal back into
the drive shaft hole recess.
Figure 4-3: Pump Assembly 1
2. If removed, replace the longer bushing and one of the
smaller bushings into one of the bushing holders.
3. Place this bushing holder into the pump vault making
sure that the longer bushing inserts into the drive shaft
hole recess at the bottom of the pump vault. Both
bushings should be flush with the top of the bushing
holder.
Figure 4-4: Pump Assembly 2
4. Place the drive shaft (longer shaft) through the long
bushing and the shaft seal. The hexagonal section of the
shaft should come up against the end of the bushing
insert.
5. Similarly, place the Idler shaft into the other hole.
Figure 4-5: Pump Assembly 3
6. Slide both gears onto the shafts making sure that they
locate on the hexagonal sections of the shafts.
7. Place the gear chamber into the pump vault on top of the
bushing holder.
Figure 4-6: Pump Assembly 4
8. If removed, insert the two other short bushings into the
second bushing holder. Now slide the second bushing
holder over the two shafts. When this piece is in place, it
should be just above the top flange of the pump body.
Figure 4-7: Pump Assembly 5
9. Place the end cap sealing ring on the top flange of the
pump vault. Place the end cap on top of the seal. Fasten
the 3”(7.5 cm) sanitary clamp and tighten approximately
two turns after contact to seal the end cap to the pump
vault.

AESFill AF1C Machine Manual 15/58 Installation
Figure 4-8: Pump Assembly 6
In order to attach the pump to the docking plate on the filler
you will need to use the smaller 2”(5 cm) sanitary clamp.
There is a circular groove in the bottom of the AESPump and
a matching ridge on the top of the docking plate on the
AESFill AF1.
Place the AESPump on top of the docking plate and use the
sanitary clamp to fasten the two pieces together. No sealing
ring is required for this connection. You can rotate the pump
to any orientation that you need.
Figure 4-9: Pump Assembly 7
Remember, the inlet and the outlets of the pump are
identified by the arrow on the bottom of the pump body.

AESFill AF1C Machine Manual 16/58 Installation
Nozzle4.2
4.2.1 Standard Nozzles
The nozzle consists of 11 pieces:
1. 1 Quick Connect Air Fitting
2. 1 90 degree Quick Connect Air Fitting
3. 1 Air Tubing Duo (Black and Blue)
4. 1 Air Cylinder
5. 1 Nozzle Stem with Set Screw
6. 1 Stem O-Ring Top
7. 1 Stem O-Ring Bottom
8. 1 Nozzle Body
9. 1 Clamp with Handle
10. 1 Nozzle Spout O-Ring
11. 1 Nozzle Spout
12. 1 Nozzle Stem
4.2.2 To assemble the nozzle:
**Note: Before assembly, all O-rings should be wetted with an approved lubricant, or at least with the
product being filled.
1. Install the O-rings (#6 & #7) onto the nozzle stem (#5). Assemble the
plunger onto the air cylinder (#4). The position of the plunger within the
completed nozzle must be adjusted by threading more or less of the air
cylinder into the stem. This is to set the correct closed position of the
nozzle stem.
2. Screw in the small set screw, carefully aligning it with the groove on the air
cylinder, screw it in all the way snug and then loosen it by ¼ turn. The set
screw should be loose, but in far enough so as not to protrude. This way
the stem will hang centrally, and not be forced over to one side.
3. Screw the air cylinder/nozzle stem unit into the nozzle body (#8). Again do
not tighten, leave it a minimum ½ thread loose, at a handy orientation for
the airlines.
4. Place the O-Ring (#10) into the Nozzle Spout (#11) and then slide it onto
the plunger. You may need to push the plunger up so it is easier to get the
nozzle spout on. Now screw the nozzle spout onto the nozzle body.
6-
Stem
O-Ring
Top
11- Nozzle Spout
10- Nozzle Spout
O-Ring
9- Clamp
and
Handle
8- Nozzle Body
7- Stem O-Ring
Bottom
5- Nozzle Stem
Set Screw
4- Air Cylinder
3- Air Tubing
Duo
2–90 Degree Quick Connect Air
Fitting
1- Quick
Connect
Air Fitting
Air Flow Control
12-
Nozzle
Stem
Figure 4-10: Standard Nozzle Assembly

AESFill AF1C Machine Manual 17/58 Installation
4.2.3 Custom Nozzles
The 1 ½“nozzle is comprised of 14 parts.
1. Quick Connect air fitting (Part EDT-75630)
2. Adjustable Handle (Part EDT-88039)
3. Tri-clover Seal (Part EDT-91105B)
4. Tri-clover clamp (Part FIL333)
5. Flow Control (Part FIL66984)
6. Stem Top O ring (Part FIL85948)
7. Stem bottom O ring (Part FIL85949)
8. Spout O ring (Part FIL85955)
100. Air cylinder (Part FIL85951)
200. Nozzle clamp (Part FIL65953)
201. Nozzle stem (Part FIL85898)
500. Nozzle body (Part FIL85953)
501. Nozzle spouts (Part FIL85954)
700. Nozzle stem set screw (Part BOU9102)
Figure 4-11: 1 ½“Nozzle
Figure 4-12: 1 ½“Custom Nozzle Assembly

AESFill AF1C Machine Manual 18/58 Installation
Positioning the Equipment4.3
As shown below, the AESFill AF1 can be positioned on any flat surface to facilitate your filling operation. It is better to position any
infeed tank so that it is at the same level as the pump to make priming easier. If your product is very thick, it may be best to use an
overhead hopper instead of a filling tank.
As shown below, when attaching multiple AESFill AF1s to a holding tank, do not use “tees”or Y-connections. This can result in
inadequate supply volume, causing inconsistent fills, and may cause starvation to a pump, resulting in damage. Each AESFill AF1
should have its own connection to the tank.
Figure 4-13: Position of the equipment
4.3.1 Height Adjustments
You can raise and lower the nozzle bar attached to the AESFill AF1, so that the nozzle is at the appropriate height for the bottles
that you are filling by loosening the black ratchet handle and sliding the nozzle bar up or down.

AESFill AF1C Machine Manual 19/58 Installation
Connections4.4
The AESFill AF1 has 6 connections:
Main Power
The main power inlet is located at the back of the machine. Depending on your requirements, the machine has been configured to
handle either 110 V or 220 V, 50/60 Hz. Check the rating plate to see if it matches your supply. If it does not, call Aesus.
Compressed Air
The air supply should at least be 60 psi. The air inlet is located on the back of the machine to the left side of the air regulator.
Black and blue air connectors while supply air to the nozzle. For IBSO Nozzles, the black hose goes to the top of the nozzle air
cylinder and the blue hose goes to the side of the nozzle air cylinder.
Communication Ports
There are 2 communication ports located on the back of the machine. One is a 5 pin port and the other is a 19 pin port.
5 pin port is used to control a foot pedal as well as daisy chaining / networking multiple AF1 units together.
19 pin port is used to daisy chains / network multiple units together as well as controlling optional automation items such as
gating, diving, neck clamp and a drip tray.
When using an AESFill AF1 on its own, you can connect the foot switch into the 5 pin port.
When multiple AESFill AF1 units are used,
they are connected together via a communication
cable from the 5 pin port to the 19 pin port.
In this case, the foot switch
Would be connected to the unoccupied 5 pin port.
Power Chord Plug
Exhaust Muffler
Black & Blue
Nozzle air
connections
Rating Plate
19 Pin
Communication
Cable Port
On/Off Switch
Air Regulator
5 Pin
Communication
Cable Port
AESPump
Figure 4-14: Pump

AESFill AF1C Machine Manual 20/58 Installation
Air Supply & Lubrication4.5
On the back of the machine there is a filter regulator. The filter cleans the air, the regulator controls the outlet pressure.
The air valve solenoid inside the cabinet controls the air going to the air cylinder. At the appropriate time, when the nozzle needs
to be opened or closed, the air is directed out of one connection or the other.
The Black tagged connector on the rear of the machine connects with the black hose to the top of the nozzle. The blue tagged
connector connects with the blue hose to the side of the nozzle. (Reverse for O.B.S.O. type nozzles.)
The connector installed on the machine is for 6 mm hose. This connector is screwed into the filter/regulator. The filter/regulator
will accept any 1/8 NPT fitting. So from the compressor, either uses a ¼ in or 3/8 inch hose so a BARB adaptor from 1/8 inch NPT to
barb (whatever size the hose ID is) will work correctly.
Periodically you must drain any water or debris that collects in the filter.
**WARNING—DISCONNECT AIR SUPPLY BEFORE SERVICING FILTER**
Figure 4-15: Air filter connection
Connector for the
hose coming from
the compressor
Hose that
connect the
air filter to
the machine.