monofil Aerosol-Abfullgerat D-2014 User manual

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01 INTRODUCTION 4
1.1 Explanation of symbols and notes 4
1.2 Safety definitions 4
1.3 Machine terms 5
1.4 Scope of delivery 5
1.5 Safety check 5
1.6 Unauthorised modifications and spare parts 6
1.7 Monitoring 6
1.8 Staff training 6
02 GENERAL SAFETY NOTES 7
2.1 Intended use 7
2.2 Special operator obligations 7
03 SPECIAL SAFETY NOTES 8
3.1 Safety devices 8
3.2 Special personal protective equipment 8
3.3 Special dangers at the machine –source of danger 8
3.4 Special dangers caused by the product 8
3.5 Behaviour in case of danger 9
3.6 Rescue, First Aid 9
3.7 Firefighting 9
04 TRANSPORT 9
4.1 Safety regulation 9
4.2 Requirements on the executing staff 9
4.3 Technical data 9
05 DESIGN & FUNCTION 10
5.1 Installation 10
5.2 Technical data 11
5.3 Safety and monitoring devices 11
5.4 Controls and Displays 11
5.4.1 Arrangement and designation 11
06 BRINGING INTO SERVICE 12
6.1 Requirements on the executing staff 12
6.2 Mounting / Assembly 12
6.2.1 Requirements 12
6.2.2 First use 12
6.2.3 Cleaning 13
6.3 Initial operation 13
07 OPERATION 14
7.1 Safety Notes 14
7.2 Operating the filling machine 14
7.2.1 Setup, adjust, equip 14
7.2.2 Check before switching on 14
7.2.3 Preparations 14
7.2.4 Use of standard dosing jar (with cleaning) 16
7.2.5 Use of a clean-free jar 18
7.2.6 Use of a Clean-Free Adapter ECO+ Set 20
7.2.7 Switching off 24
7.2.8 Changeover / retrofitting 24

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08 DYSFUNCTION, CAUSE OF FAILURE / TROUBLESHOOTING 25
09 MAINTENANCE 25
10 REPAIR 25
11 SPARE-PARTS & ACCESSORIES 26
12 DISPOSAL 28
12.1 Safety regulations 28
12.2 Requirements on the executing staff 28
12.3 Operating materials / materials 28
13 EC DECLARATION OF CONFORMITY FOR FILLING MACHINE 29
14 EC DECLARATION OF CONFORMITY FOR FILLING MACHINE (ATEX) 30
15 NAMEPLATE 31
15.1 Filling machine in standard design 31
15.2 Filling machine in ATEX design 31

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01 INTRODUCTION
Before using the unit for the first time, please read these operating instructions carefully and follow the instructions. Keep
this manual easily accessible at any time.
Personal injuries caused by failure to comply with the operating instructions are not covered by the product liability law.
MONOFIL assumes no liability for damages to the machine caused by non-compliance with the instructions in this
manual.
Safety instructions are intended to warn of hazards and to help prevent personal injuries and material damages. For your
own safety, compliance with the safety instructions in this manual is absolutely essential.
The corresponding national and international occupational safety regulations must be observed. Each operator is solely
and entirely responsible for complying with the regulations that apply to him and must independently get the latest
regulations.
1.1 Explanation of symbols and notes
General information for operators and maintenance staff
Detailed information for maintenance staff
This symbol is used to indicate that inaccurate following or failure to follow instructions may result in
injury to persons or damage tot he machine.
This symbol means that special technical knowledge is required to check or troubleshoot the described
problems in order to ensure a proper and safe operation of the system.
1.2 Safety definitions
The design and implementation was carried out according tot he following guidelines:
(see declarations of conformity)

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1.3 Machine terms
1manometer
2piston
3dosing jar
4valve
5height adjustment adapter for
400ml cans
6T-handle
7cam latch
8protection door
1.4 Scope of delivery
Included in delivery:
- filling machine for aerosol cans
- dosing jar incl. Lindal –adapter and injection nozzle
- bolt for fixing the filling machine on the erection area (see chapter 7)
- connection kit for compressed air supply (coupling connection is not included and must be ordered separately!)
- height adjustment adapter for Clean-Free jar
1.5 Safety check
To ensure the operator’s safety, the machine has to be bolt securely to the worktop. Check that the machine is standing
on a safe (not loose) worktop and is firmly fixed to it.
All housing parts of the machine serve as protection devices and must therefore not be removed in whole or in part
during the operation. Operation with removed or defective housing is not allowed.
The filling process is started by actuating the door latch. The door must be completely closed. When opening the door
latch, the piston moves upwards.
This mechanism has to be checked at regular intervals (or before each use) with the door closed and the dosing jar
inserted.
If necessary, the machine must be sent for repair.

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Daily check all:
- safety devices
- fixation of the unit on the worktop
- housing parts
- pneumatic system parts for leaks
1.6 Unauthorised modifications and spare parts
Conversion or modifications of the machine are only permitted after written agreement and approval by MONOFIL. Only
use original spare parts and accessories authorised by the manufacturer. The use of other spare parts annuls the liability
for the resulting consequences.
1.7 Monitoring
Our aim is to continue to offer you safe, state-of-the-art products in the future.
Please inform us immediately about:
- Faults in the safety devices
- Faults in machine operation
- Changed settings
- Problems in handling the machine
- Accidents or near-accidents
1.8 Staff training
- Only trained personnel may operate the machine.
- The responsibilities of the personnel are to be clearly defined for operation, changeover and maintenance.
Instructed
persons
Persons with
technical training
Transport
X
X
Starting
X
X
Operation
X
X
Troubleshooting
X
X
Fault repair
mechanic
–
X
Maintenance
–
X
Repair
–
X
Disposal
–
X

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02 GENERAL SAFETY NOTES
2.1 Intended use
The operational safety of the supplied system is only guaranteed if it is used in accordance with its
intended purpose.
- The machine supplied is intended exclusively for filling pre-filled aerosol spray cans.
- Only undamaged aerosol cans are allowed to be filled. Check the cans for damages, especially for bulging.
- The recommended filling quantity (100 ml for a 400 ml aerosol can) must not be exceeded.
- Only fill aerosol cans that are intended exclusively for subsequent filling.
- Do not fill more than once.
- Only fill with approved substances. Approved substances are paints, primers and related substances such
as hardeners, converters or thinners.
The system may only be operated if it is in perfect working order.
- In case of malfunctions of the compressed air system, switch off the machine immediately, disconnect it from the
pneumatic supply and secure it against uncontrolled restarting. Immediately report and repair all faults and damages
displayed by the system or otherwise detected.
The following are not permitted:
- Operating the system in a defective condition
- Changing the connection requirements, operating conditions and performance data defined in the technical
documentation
- Changing or modifying the machine without prior approval by MONOFIL
- Smoking, eating or drinking while operating the machine
- Installed safety devices must be in place, properly installed and fully functional. They must not be changed in
their position, bypassed or disabled.
- Safety components such as limit switches, valeves and other control components must not be disabled.
- Persons under influence of alcohol, other drugs or medication that affect their ability ro react must not operate
or maintain the machine.
We strictly forbid improper use. In the event of damage, the responsibility remains with the operator
and cannot be transferred to the manufacturer.
2.2 Special operator obligations
- Every operator must prepare operating instructions.
- In accordance with BGV A3, the operator must ensure that the machine and the operating materials are
repeatedly inspected to maintain its proper condition.
- A qualified person is responsible for carrying out the inspections properly.

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03 SPECIAL SAFETY NOTES
3.1 Safety devices
Never manipulate the following:
- Safety locks
- Pressure releases
- Protection door
- all other safety devices
3.2 Special personal protective equipment
- Protective glasses
- Respiratory protection
- Protective gloves
- Observe the safety instructions of the operator
3.3 Special dangers at the machine - source of danger
3.4Special dangers caused by the product
Source of danger
Instructed persons
Persons with technical training
Loose pipes (whipping)
Risk of injury due to whipping pipes
Initial operation made by specialist at the
manufacturer
Uncontrolled actuation of
the piston
Danger of crushing
Initial operation made by specialist at the
manufacturer
Machine falls down
Risk of personal injury
The machine must be mounted on a secure
and stable surface.
Spillage of liquids
Danger of slipping
Immediately remove and disposed of spilled
liquids in a professional manner.
Source of danger
Danger
Prevention
Symbol
Bursting can
Risk of personal injury
Check can for damage (e.g. deformation)
before filling.
Occuring vapours
Danger by poisoning/
suffocation
Wear respiratory protection
Source of Danger
Danger
Prevention
Symbol

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3.5 Behaviour in case of danger
Shut down the machine by disconnecting it from the pneumatic supply. Further measures are to be specified by the
operator.
3.6 Rescue, First Aid
Follow the company health and safety instructions.
3.7 Firefighting
Observe the company firefighting procedure.
04 TRANSPORT
4.1 Safety regulation
When transporting the unit, the protection door can move freely due to its own weight.
Provide transport lock.
4.2 Requirements on the executing staff
(see chapter 1.8Staff training)
4.3 Technical data
External dimensions (L x W x H): 650 x 300 x 300 mm
Gross weight / Net weight: 20 kg
Liquid spraying out
Risk of the operator
Wear suitable protective clothing and safety
googles
Contact with substances
to be filled
Depending on the substances
to be filled
Avoid contact by wearing suitable protective
clothing and gloves.
Fire and explosion
hazard
Depending on the substances
to be filled
Observe the safety instructions oft he substance
manufacturer! Have suitable estinguishing media at
hand.

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05 DESIGN AND FUNCTION
5.1 Installation
1Manometer
2Piston
3Dosing jar
4Valve
5Height adjustment for 400ml
aerosol cans
6T-handle
7Cam latch
8Protection door
1Compressed air supply
2Condensate drain

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5.2 Technical data
Dimensions:
Height 615 mm
Width 225 mm
Depth 225 mm
Weight:
approx. 18 kg
Pressure (dry and oil-free compressed air):
max: 10 bar
min: 7 bar
5.3 Safety and monitoring devices
Protection door
Protects the user from possible leaking media.
Cam latch
The door valve is installed in a way that it can only be actuated by the cam latch.
Manometer
The pressure gauge indicates the set pressure.
5.4 Controls and Displays
5.4.1 Arrangement and designation
T-handle
The cam latch is moved by the door handle. When the cam latch is turned to the right as far as it will go, it actuates the
door valve and the piston moves downwards.
Pressure regulator
The operational pressure is pre-set at the factory and can be read on the pressure gauge.
Door „CLOSED“
Piston moves downwards
Door „OPEN“
Piston moves upwards

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06 BRINGING INTO SERVICE
6.1 Anforderungen an das ausführende Personal
see chapter 1.8Staff training
6.2 Mounting / Assembly
6.2.1 Requirements
- Dry and oil-free compressed air
- Clean and stable installation location
- Ensure ergonomic working height
- Room temperature: 15 –30 °C
See also 6.3 measures to be taken before initial operation
Required space/ space requirements 1 x 1 x 2 m (LxWxD)
Install the machine on a safe (not loose) worktop and ensure that it is firmly fixed to the worktop.
6.2.2 First use
- Remove the unit from its packaging
- Open the protection door
- Remove the dosing jar
- Securely screw the unit to the worktop with the screw (1) (through the bottom of machine (2))

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Connect the compressed air supply with
the enclosed connection set.
Place the collecting vessel under the
condensate drain.
Check the operating pressure on the manometer.
Pre-set: 8 bar
6.2.3 Cleaning
After finishing the filling process, clean the unit immediately, as dried residues are difficult to remove.
Wipe the piston with a cloth soaked in solvent, place the dosing jar into a solvent bath when finished and use a brush to
clean it.
6.3 Initial operation
The initial operation has been carried out by the manufacturer.

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07 OPERATION
Operation means the entirety of all activities executed on the machine and on similar working equipment from the
takeover of the machine until it’s decommissioning.
This chapter informs you about:
- Safe operation
- Exploiting the full potential of the machine
- Economic operation of the machine
7.1 Safety Notes
- See also chapter 2 General Safety Notes
- See also chapter 3 Special Safety Notes
- Check safety devices daily before switching on!
- When carrying out set-up and adjustment works in manual mode, act appropriately to secure the system
against unauthorised operation.
- If necessary, work should only be carried out by two persons.
- If the machine is not in filling mode, or if the responsible personnel is leaving the working area, the machine
must “always” be disconnected from the pneumatic air supply and secured against unauthorised restarting.
7.2 Operating the filling machine
7.2.1 Setup, adjust, equip
- Close the protection door
- Connect the device to the compressed air supply
7.2.2 Check before switching on
- Check the piston for tight fit
- Check the piston for wear (e.g. scoring)
7.2.3 Preparation
- Remove the safety cap from the aerosol can.
- Remove the spray head.

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Adapt base to spray can used.
1Rim
2base
The top and bottom of the base can be used for two different types of cans. In order to adapt the base to the cans used,
the base can be turned or an additional adapter can be used.

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For cans with 250 ml / 300 ml content a
height adjustment adapter (sold separately,
see spare parts list chapter 11) can be used.
1Height adjustment adapter
7.2.4 Use of standard dosing jar (with cleaning)
Ensure that the correct piston is mounted.
Place the dosing jar on the spray can.

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- Make sure that the dosing jar and can are
assembled without any gaps (arrow).
- Fill 100 ml of the material to be filled into the
dosing jar, i.e. up to approx. 5 mm below the
bevel on the upper edge of the dosing jar.
- Push the can with attached dosing jar into the
machine as far as it will go.
- Adjust the height to the correct can size.
Adjust the base by revolving until it butts
against the bottom of the can.
Close the protection door again and turn the T-handle to the right as far as it will go. This activates the circuit breaker and
releases the air supply.
Door „CLOSED“
Piston moves downwards
Door „OPEN“
Piston moves upwards

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- To purge the dip tube and valve of the spray can, turn the door handle back a little until the piston has
audibly moved completely upwards again. Then turn the door handle again all the way to the right and
carry out a complete up and down movement of the piston.
- After the piston has reached its upper position, you can open the door and the remove the can with the dosing jar.
- Remove the dosing jar from the spray can.
- If necessary, clean the valve with a cloth.
- Replace the spray head and the cap.
7.2.5 Use of a clean-free jar (old design model until december 2020)
- Ensure that the correct piston is mounted.
- Place the dosing jar on the spray can.

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- Insert the Clean-Free jar in the dosing jar.
(Clean-Free-Adapter-Set is sold separately,
see accessories)
- Fill 100 ml of the material to be filled into the
dosing jar, i.e. up to approx. 5 mm below the
bevel on the upper edge of the dosing jar.
- Close the filling jar with the lid.
- Place the height adjustment adapter for
Clean-Free jar.
- Push the can with attached dosing jar
into the machine.
- Fix the bottom plate.
- Close the door.
- Adjust the height to the correct can size.
Adjust the base by revolving until it butts
against the bottom of the can.

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Close the protection door again and turn the T-handle to the right as far as it will go. This activates the circuit
breaker and releases the air supply.
- After the piston has reached its upper position, you can open the door and the remove the can with the dosing jar.
- Remove the dosing jar from the spray can.
- If necessary, clean the valve with a cloth.
- Replace the spray head and the cap.
7.2.6 Use of the Clean-Free Adapter ECO + Sets (new design model since January 2021)
The Clean-Free Adapter ECO+ Set consists of three parts:
Piston
Filling cap holder
Spacer
Door „CLOSED“
Piston moves downwards
Door „OPEN“
Piston moves upwards