Deitz PHARMAFILL CS10 User manual

Model CS10 Cotton Inserter
Operation Manual

Pharmafill Model CS10 Operation Manual
May 2023 Page
2
CONTENTS
1. INTRODUCTION ______________________________________________ 5
2. SPECIFICATIONS ______________________________________________ 7
3. INSTALLATION
A. Unpacking ______________________________________________ 9
B. Commissioning ______________________________________________ 9
C. Compressed Air ______________________________________________ 9
D. Electric _____________________________________________ 10
4. FEATURES
A. General _____________________________________________ 11
B. Operator Interface (Control Panel)_________________________________ 11
C. Safety Enclosure _____________________________________________ 12
D. Turrets _____________________________________________ 12
E. Rollers _____________________________________________ 13
F. Shelf _____________________________________________ 13
G. Air Pressure Controls___________________________________________ 14
H. Bottle Indexing and Bottle Sensors ________________________________ 14
I. Optional Tamper –contact Deitz Co. for availability___________________ 15
J. Lift Platform _____________________________________________ 15
5. OPERATION
A. Control Panel _____________________________________________ 17
B. Insert Cotton ______________________________________________19
Show Values _____________________________________________ 21
C. Adjust Settings _____________________________________________ 22
Cotton Length
Number Of Pieces
Release Time
Dwell Time
D. Change Height _____________________________________________ 24
E. Open Rollers _____________________________________________ 25
F. Clear Tubes _____________________________________________ 27
G. Extend Insert Rods_____________________________________________ 28
H. One Step Index _____________________________________________ 30
I. Index Bottles Only _____________________________________________ 31
J. Set Count To Zero _____________________________________________ 33
K. Options _____________________________________________ 35
L. Technician Only _____________________________________________ 37

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6. SETUP FOR A RUN
QUICKSTART _____________________________________________ 38
A. Start Up _____________________________________________ 39
B. Setup Conveyor _____________________________________________ 39
C. Adjust Settings _____________________________________________ 39
D. Adjust Machine Height _________________________________________ 39
E. Load Cotton Coil _____________________________________________ 39
F. Setup Bottles _____________________________________________ 40
G. This section intentionally left blank ________________________________42
H. Test Cotton Inserting ___________________________________________ 42
7. RUNNING PRODUCTION
QUICKSTART _____________________________________________ 43
A. Start Up _____________________________________________ 44
B. Check Cotton _____________________________________________ 44
C. Check Bottles _____________________________________________ 44
D. Test Operation _____________________________________________ 44
E. Begin Operation _____________________________________________ 44
F. Stopping the Machine Manually___________________________________ 44
G. When the Machine Stops Automatically ____________________________ 44
8. ROUTINE MAINTENANCE
A. Insertion Air Cylinders__________________________________________ 46
B. Compressed Air Filters__________________________________________ 47
C. Cooling Fan Air Filters _________________________________________ 47
D. Lubrication _____________________________________________ 48
E. General Cleaning _____________________________________________ 48
9. TECHNICAL INFORMATION
A. Cycle of Operation_____________________________________________ 49
B. Troubleshooting _____________________________________________ 50
Bottles fall over or jump suddenly.
Plunger crushes or damages the product.
Cotton comes out top of bottle.
Synthetic cotton issues: Rayon and polyester.
Turret not centered on insertion cylinders.
Insertion cylinders extend, then machine stops in extended position.
Insertion cylinders extend, then retract, then machine stops, will not cycle again.
Message: “TURRET ROTATE ERROR”.
Message: “ROLLER TRAVEL ERROR”.
C. Options _____________________________________________ 52
D. Technical Notes/Drawing Index __________________________________ 53
(Technical Notes/Drawings Begin After Last Page)

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Warning
This machine contains moving parts and
operates automatically. This may present a
hazard to personnel.
Never operate this machine with any covers or guards removed or any guard switches or
safety devices removed or bypassed.
Only people who have been correctly trained should operate or clean this machine.
Only people who are correctly qualified and trained should carry out maintenance, installation
or any other service work.
Never clean or service the machine without isolating
the electrical supply and isolating the air supply.
Always test for the presence of voltage before touching or working on electrical components.
Note that there might be other requirements that could apply.
Refer to the manuals supplied by the component manufacturers for further safety instructions.

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Section 1: INTRODUCTION
Thank you for purchasing a Pharmafill Model CS10 Cotton Inserter. We at Deitz Company hope you
will find that the Model CS10 meets or exceeds your expectations and requirements for an
affordable, reliable, and innovative addition to your packaging operation.
Pharmafill products are designed and manufactured by Deitz Company Inc., in Wall, NJ, USA. We
have manufactured machinery for the bottle filling industry since 1966 and began directly marketing
our Pharmafill line in 1993. We are a small (but growing) family-owned business that emphasizes
quality, innovation, and superior customer service.
If you have any questions or comments, please contact us by phone or visit our website. Chances are
someone whose last name is Deitz will handle your inquiry personally.
Deitz Company Inc.
PO Box 1108
1750 Route 34
Wall, NJ, USA 07719
Tel [phone]
Fax [phone]
E-mail [email protected] or
Web site deitzco.com or
pharmafill.com
The operation manual is designed to make it easier for you to know the machine and to make use of
its intended range of operation. It contains important instructions on how to operate the machine
safely, adequately, and economically. Observing these instructions helps to avoid risks, to reduce
cost for repair work and machine downtime, and enhances the machine’s operational reliability and
lifetime.
The operation instructions are to be supplemented by further instructions due to existing national
regulations on accident prevention and environmental protection.
If used in compliance with the instructions contained in this manual and if safety devices are
regularly maintained and properly working, this machine is not dangerous to the operator.
This manual is to be kept accessible to all operators using this machine and it is assumed that before
use the operator will read fully and understand this manual and will follow the instructions stated
within.
As this machine may be used in the packaging of hazardous substances, the operator should be
aware of the precautions required for these substances.

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In addition to the operating instructions and the binding regulations on accident prevention valid in
the country where the machine is being used and at its operational site, the recognized technical rules
on safe and proper working must be observed as well.
These operating instructions and the information contained therein have been compiled with due
care and attention. However, DEITZ COMPANY does not take any responsibility for misprints,
translation errors or other errors and any damage resulting from.
DEITZ COMPANY retains the right to make changes to the described products to improve
functionality, reliability, and design. The measurements or data shown on schematics, sketches and
photos are not binding. They are for description purposes.
The information and drawings found in the operation manual are the intellectual property of DEITZ
COMPANY and may not be copied or given to third parties.

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Section 2: SPECIFICATIONS
MODEL CS10 COTTONER
TYPE AD 1070
TURRET TUBE LENGTH 3, 4 or 5 inches
TURRET TUBE DIAMETER .75 or 1 inch
COTTON TYPE Natural or Synthetic (Rayon, Polyester) Coil
COTTON WEIGHT 6 TO 20 gm
COTTON LENGTH OUTPUT 2 to 9 inches
MAX. OUTPUT SPEED (3” turrets) 180 per minute
MAX. OUTPUT SPEED (4” turrets) 172 per minute
MAX. OUTPUT SPEED (5” turrets) 165 per minute
Maximum output speed will vary with input air pressure, quality of input air and the age and/or
condition of the machine components. Final (actual) output will also depend on the characteristics of
the cotton used and the speed at which cotton, and bottles are fed to the machine.
HEIGHT ADJUSTMENT RANGE 9”
MINIMUM BOTTLE HEIGHT 1” (for standard conveyor height of 36”)
(Continued on next page)
TURRET
LENGTH
TURRET INSIDE
DIAMETER
COTTON
WEIGHT
COTTON
LENGTH MAX
3 inches
.75 inch
6 to 12 gm
5 inches
3
1.00
9 to 20
5
4
.75
6 to 12
7
4
1.00
9 to 20
7
5
.75
6 to 12
9
5
1.00
9 to 20
9

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INPUT REQUIREMENTS
VOLTAGE* 115 VAC
CYCLES 50/60 HZ
PHASE 1
AMPERAGE 20 AMPS
COMPRESSED AIR** 3.0 FT3/MIN AT 80 LB/IN2
ROOM HUMIDITY 85% RH NON-CONDENSING
*Other input voltages are available as factory options if specified at the time of order
** Compressed air must be clean and dry, free of moisture (water) and oil.
PHYSICAL DIMENSIONS
WEIGHT 800 LBS
FLOOR FOOTPRINT 49” WIDE X 40-1/2” DEEP
HEIGHT ADJUSTABLE FROM 56” TO 64” ***
FILLING HEIGHT ADJUSTABLE FROM 37-1/4 TO 45-/14” ***
STANDARD CONVEYOR HEIGHT 36” TO TOP SURFACE ***
BOTTLE HEIGHT FROM 1” TO 9” ***
*** May be adjusted further by adjusting or modifying leveling feet.

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Section 3. INSTALLATION
A. Unpacking
B. Commissioning
C. Compressed Air
D. Electric
3A. Unpacking
❑Carefully remove equipment from crate and remove all packing materials.
❑Inspect all supplied equipment for damage (if any damage is present, please notify DEITZ
COMPANY immediately).
❑Assemble any components such as control panels, etc. using the drawings in this manual as a
guide for mechanical, electrical, and pneumatic assembly.
❑Position the machine on the line and adjust the legs of the machine to level the machine. Note
that the machine is designed for a standard conveyor height of 36 inches from the floor to the
top of the belt.
3B. Commissioning
❑Check that the machine is correctly installed, levelled up and aligned.
❑Check that there are no loose bolts or screws and that all electrical connections are tight.
❑Ensure that the machine isolator (main disconnect switch) is in the OFF position.
❑Do not “megger” the machine (high voltage insulation test) as damage to electronic
components may result.
❑Apply power to the machine and check polarity and voltage of the incoming supply.
❑Check that all emergency stops work correctly.
❑Check that all guard switches operate correctly.
❑Check that the machine operates correctly.
3C. Compressed Air
CONNECT
COMPRESSED
AIR HERE

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❑Compressor must be adequate to meet the specifications (see Section 2).
❑The supply air should be clean and dry, free of condensation and oil.
❑Connect the pneumatic supply.
❑Apply compressed air to the machine and turn both pressure regulators to 80 PSI.
❑Check for air leaks and rectify any leaks found.
3D. Electric
❑Power source must be adequate to meet the specifications (see Section 2).
❑Check the polarity and voltage of the incoming supply.
❑The machine must be solidly earthed.
❑Make sure the Main Disconnect Switch is in the OFF position. If it is not, no action will take
place, but this is good practice.
❑Connect the main electrical supply.
❑Turn the Main Disconnect Switch to the ON position. No action will take place.
❑To confirm that the machine is powered up, the Operator Interface panel should be lit.
❑The machine is now ready for operation.
MAIN
ELECTRICAL
SUPPLY
CORD
GUARD
DOOR
CLOSED
GUARD
DOOR
OPENED
MAIN
DISCONNECT
SWITCH
MAIN
DISCONNECT
SWITCH

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Section 4. FEATURES
A. General
B. Operator Interface (Control Panel)
C. Safety Enclosure
D. Turrets
E. Rollers
F. Shelf
G. Air Pressure Controls
H. Bottle Indexing and Bottle Sensors
I. Optional Tamper –contact Deitz Co. for availability
J. Lift Platform
4A. General
The Model CS10 is an automatic dual station cotton inserter designed to convert continuous cotton
coil to individual pieces and insert them into a bottle or other container at each station. The cotton
coil is cut by the tearing action of two sets of pinch rollers, so that uniform lengths are produced.
The cut piece is then pushed up into a tube, so that it is folded in half to form an inverted-U shape.
The tube is then moved under a sensor to confirm the presence of the cotton piece. If confirmed, the
tube then is moved into position to align with the bottle filling station. If a bottle is present, cotton is
inserted. Because of the inverted-U shape, the ends of the cut piece are inside the bottle and only the
fold is visible at the top. Once a bottle is filled, the machine automatically releases the bottle and
repeats the cycle. These actions are typical of each station.
In addition to the insertion function, there are several secondary functions, which aid in using and
setting up the machine. All functions are detailed in Section 5.
4B. Operator Interface (Control Panel)
The machine operation is controlled with an Operator Interface Panel, or simply a Control Panel.
This is a flat panel device with membrane push buttons, alert indicator lights and a 2-line text display
for input and output. See Section 5 for a full explanation. Next to the Control Panel are two
pushbutton switches labeled “Emergency Stop” and “Start”.
START
EMERGENCY
STOP
CONTROL
PANEL

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4C. Safety Enclosure
The operator is protected from encountering the moving parts of the machine by the safety
enclosure, which is made of clear polycarbonate with a metal and plastic frame. The front of the
enclosure is a hinged door and swings up to provide full access to the components. The Guard Door
contains the Control Panel and has an interlock device, which will prevent the machine from
operating once the door is opened.
4D. Turrets
Each turret assembly transports and inserts the cut cotton pieces. Each turret itself consists of four
clear tubes, arranged vertically, 90 degrees apart, between two discs. A stepper motor rotates the
turret 90 degrees per cycle. The turrets come in different sizes and lengths and are easily changed
over.
There are two sensors built into each turret assembly. On the right is the Turret Sensor (proximity),
which measures and confirms the movement and position of the turret in each cycle. If either turret
fails to rotate, the machine will stop, and an error message will be displayed (see Sec. 9A). On the
left is the Cotton Sensor (fiber optic), which confirms the presence of cotton after each cycle. If
cotton is not detected at the end of each cycle when in automatic mode, the machine will stop, and
an error message will be displayed (see Sec. 9A).
COTTON
SENSOR
TURRET
TURRET
SENSOR
MAIN
DISCONNECT
SWITCH
MAIN
DISCONNECT
SWITCH
GUARD
DOOR
CLOSED
GUARD
DOOR
OPENED

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The lower insertion air cylinder (under the shelf) pushes cut cotton up into the rear tube. At the same
time, the upper insertion air cylinder (on the turret) pushes cut cotton down out of the front tube and
into the bottle. The motion of both air cylinders is confirmed by cylinder sensors (magnetic).
4E. Rollers
Two sets of pinch rollers control the cotton cutting process at the “A” (left) and “B” (right) stations.
At station A, the set of rollers on the left are the feed rollers and the set at the right are the tear
rollers. At station B, the set on the right are the feed rollers and the set at the left are the tear rollers.
Separate stepper motors drive each set. The feed rollers feed an exact length of cotton coil into the
tear rollers, which tear the cotton to length and places the cut piece on the cotton shelf. The amount
of force pressing the rollers together is controlled by air pressure and may be changed. Air pressure
is also used to open the rollers for loading or unloading cotton coil. See Section 5E.
When a new length of cotton is selected, the roller assembly automatically repositions itself to assure
that the cut cotton piece is centered under the rear tube. A stepper motor controls this motion.
4F. Shelf
The Cotton Shelf is where the cut cotton piece is placed prior to being inserted into the rear tube.
The lower insertion air cylinder is mounted under the shelf. The Cotton Stop Blocks are part of each
TEAR
ROLLERS
FEED
ROLLERS
COTTON
STOP BLOCK
COTTON
SHELF
COTTON
PINCHER
STATION “A” SHOWN
STATION “B” IS A
MIRRORED IMAGE

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opposing shelf. These blocks limit the distance the cut piece can travel away from the tear rollers,
assuring correct centering of the piece under the tube. The Cotton Stop Block adjusts automatically
when a new length is selected. Directly above each shelf is a Cotton Pincher assembly. Each has an
air cylinder and two moving arms that hold the cotton in place as it is inserted into the rear tube.
4G. Air Pressure Controls
There are two air regulators with gauges that control pressure to two separate air circuits in the
machine. Air Pressure Control 1 controls the insertion of air cylinders and the pincher mechanisms.
Air Pressure Control 2 controls the bottle stops and pinch roller pressure.
4H. Bottle Indexing and Bottle Sensors
____
The machine controls the bottle flow on the conveyor by using air-controlled bottle indexing. This
system uses two bottle-stop air cylinders at each station, mounted on the conveyor rail, which can be
adjusted manually side to side. The air cylinder pushes a finger out to stop the bottle. The first stop is
positioned to center the bottle under the filling tube. The second stop is positioned to allow one
bottle to move past the filling point.
There are three sensors (fiber-optic) that detect the presence of bottles. The first two are the START
BOTTLE sensors, which are positioned ahead of station A and B. In automatic mode, whenever the
AIR
PRESSURE
GAUGE 1
AIR
PRESSURE
CONTROL 1
START BOTTLE B
SENSOR
BOTTLE STOP B1
BACKUP
SENSOR
BOTTLE STOP B2
AIR
PRESSURE
CAUGE 2
AIR
PRESSURE
CONTROL
2
BOTTLE STOP B1
STATION “B” SHOWN
STATION “A” IS
SIMILAR

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sensors detect a bottle (and if all other conditions are correct), the machine will perform an insertion
cycle at that station. The third one is the BACKUP sensor, which is positioned down line after
station B. If a downline process stops, bottles will accumulate on the conveyor. When this sensor
detects a bottle, it stops automatic or manual insertion. Once the bottle backup is cleared, insertion
will resume without operator intervention.
4I. Optional Tamper - contact Deitz Co. for availability
4J. Lift Platform
The machine incorporates an electrically operated lift platform, which is used to adjust the height of
the filling tube over the conveyor. The height must be set by visual observation, as there is no
feedback or digital readout of relative height. There is also a manual override feature in case of an
electrical problem. A manual crank handle is stored inside the machine, accessible through the rear
access door.
VERTICAL
ADJUSTMENT
BAR
HORIZONTAL
ADJUSTMENT
BAR
SECONDARY
TAMPER
ATTACH
MANUAL
CRANK
HANDLE
HERE

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Section 5. OPERATION
A. Control Panel
B. Insert Cotton
Show Values
C. Adjust Settings
Cotton Length
Number Of Pieces
Release Time
Dwell Time
D. Change Height
E. Open Rollers
F. Clear Tubes
G. Extend Insert Rods
H. One Step Index
I. Index Bottles Only
J. Set Count To Zero
K. Options
L. Technician Only
(Section begins on next page)

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Section 5A: CONTROL PANEL
This is the operator interface for control functions and message display.
5. From the top menu, press
MENU to select the mode of
operation. At any time press
the CLEAR to return to the top
menu.
1. Note the locations of the
EMERGENCY STOP button,
the START button, and the
CONTROL PANEL.
2. When “STOPPED- Press
Start” is displayed, twist and
release the STOP button then
press the START button.
4. When the “find home”
routine is complete, you will
see the top menu. The
machine is now ready to
operate.
START
CONTROL
PANEL
EMERGENCY
STOP
3. The machine will now
initialize, and the turrets will
execute the “find home”
routine. The guard door must
be down.

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Section 5A: CONTROL PANEL (Continued)
6. Press a menu option or press
CLEAR/EXIT to return to the
top menu. The choices are
explained in the following
sections.
(End 5-A)
7. The PLC/IO button will
access the Inputs and Outputs
on the PLC in real time. This
will be explained further in the
Troubleshooting section.
END Section 5A

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Section 5B: INSERT COTTON
This function controls the inserting process.
2. Press INSERT COTTON.
1. Press MENU.
3. To start a single insertion
cycle, press MANUAL.
4. Press Side A or Side B. The
machine will make one
complete cycle, including
indexing the bottles.
5. To cycle continuously,
press and hold Side A or Side
B arrow.

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Section 5B: INSERT COTTON
(Continued)
6. Press MANUAL again to
return to SELECT screen.
10. If either of the COTTON
SENSORS fails to detect
cotton in the left-hand tubes,
the machine will stop and
display the message “NO
COTTON IN TUBE A /
TUBE B”. Insertion will not
resume automatically.
7. To start fully automatic
operation, press AUTO
ON/OFF. If all conditions are
correct, cotton will be inserted
(cotton present in tube, bottle
present, no backup).
8. If the BACKUP SENSOR
detects a bottle downline of
station B, the machine will
pause and display “BOTTLE
BACKUP DOWNSTREAM”.
Once the backup clears,
insertion will BEGIN.
9. If there is no bottle at one
or both BOTTLE SENSORS,
the machine will pause and
display the message “Waiting
For Bottle... Side A / Side B”.
As soon as bottles are
detected at both sensors,
insertion will begin.