Nassenheider Fill Up 2 User manual

Fill up 2
Manual

Fill up 2
© FILL-Systems GmbH, 22.08.2019

3Table of contents
Table of contents
1 Foreword 5
2 Manufacturer 6
3 About this manual 7
4 General safety instructions 8
5 Delivery 9
95.1 Scope of delivery
105.2 Content control
6 Technical details of the machine 11
116.1 Intended use
116.2 Technical data
126.3 Fuses
136.4 Connections and controls on the driving module
7 Putting into operation 14
147.1 Unpacking and installation
157.2 Cleaning
167.3 Adjustment to the jar height and size
177.4 Suctioning of the medium
187.5 Pump head
18Gear wheel pump head L 20Changing shaft seals 227.6 Filling nozzles
237.7 External switches
23Microswitch 23Foot switch 24Float switch
8 Processing of honey 25
258.1 Preparing the machine for filling
278.2 Preparation of the honey for the filling
288.3 Pumping to make creamy honey
9 Operation 29
299.1 Operating the keypad
309.2 Operating modes
31Manual mode 32Auto mode/dosage 35Time switch 369.3 Setup Menu

Table of contents4
10 Maintenance and Support 38
3810.1 Maintenance
3910.2 Possible irregularities
4010.3 Support
4110.4 Transport and storage
4110.5 Disposal of the old machine
11 Warranty 42
12 EC declaration of conformity according to
the machinery directive 2006/42/EC, annex
II a 43

Foreword 5
1 Foreword
Congratulations,
with the FILL-Systems product Fill up 2 you have chosen a proven and robust machine
from our high-quality product line for filling technology. The decision to include a
machine from FILL-Systems in your equipment fleet will facilitate the filling of your
products significantly and measurably increase productivity.
For many years now, all machines and devices bearing the NASSENHEIDER®product
brand name have been developed, designed and built exclusively by us in Dresden with
an international team. With passion and specialist engineering expertise, we adhere to
high quality objectives for our unique products and consistently integrate all the
current requirements set forth by the safety and environmental regulations into our
manufacturing processes. On the basis of quality, reliability and closeness to our
customers, we have developed into a leading global technology company with great
innovative strength and enjoy a high level of trust.
Sustainability and maximum efficiency are two of our most important principles.
All our machines are extremely energy-efficient and work without compressed air-
supported systems that unnecessarily increase energy consumption. Any maintenance
and extension of the machines can be very easily implemented due to our intelligent
modular system. When production volume increases, your machine park grows through
meaningful system extensions and extension options from FILL-Systems without any
problems.
Should a defect occur, each machine part can be repaired or replaced promptly and
with pinpoint accuracy. Likewise, the durability of our machine designs on the basis of
the long-term supply guarantee for spare parts has shown itself to be effective
thousands of times and all over the world. Moreover, we have the necessary
components / parts manufactured by partners in the region according to our quality
standards. This means that transportation routes are short while we are simultaneously
strengthening regional economic cycles.
In the interests of maximum functionality of our developments we do not use
unnecessary or superfluous features, in order to maintain the serviceability and
reliability of our products at the highest possible level.
Our website will provide you with all product-related information and a variety of
options relating to enhancements and innovations. We are also available for personal
consultation.
We thank you for your confidence in us and look forward to a long and happy
collaboration with you, wishing you every success with your new FILL-Systems
product.
Your FILL-Systems team from Dresden.

Manufacturer6
2 Manufacturer
FILL-Systems GmbH
Leipziger Str. 33
01097 Dresden
Germany
Office: [phone]
Technical support: [phone]
Fax: [phone]
Email:
• Office: [e-mail]
• Technical support: [e-mail]
Website: www.fill-systems.com
NASSENHEIDER®is a registered trademark and property of Stefan Weiland, Dresden.
The company FILL-Systems GmbH has a licence to use this trademark.
District court Dresden: HRB 38264
VAT No.: DE 320 995 937

About this manual 7
3 About this manual
This manual contains important information and is therefore an essential part of your
new FILL-Systems product. To ensure an optimal and safe use of your product, read
this manual carefully before putting into operation and the use of the product.
If you have any technical questions or doubts regarding the details given in the
explanations, our support team will be glad to help you via email or over the phone.
You can find the relevant contact details in the chapter Manufacturer. We always
welcome and appreciate comments and suggestions for improvement, too.
For quick help, we have provided a wide selection of helpful answers on our website
under the menu item Service: Answers to frequently asked questions FAQ.
Please note that the figures contained in this manual are schematic diagrams. Due to
the continuous advancement of our devices, photos and details may differ from the
design of your device.
Definitions
The term viscosity refers to the resistance of the product to flow. The thicker (lower
flowability) the product, the higher the viscosity (highly viscous). The thinner
(greater flowability) the product, the lower the viscosity (slightly viscous). For
example: honey is highly viscous, while water is slightly viscous.
The products to be filled (honey, syrup, etc.) are called product or products in this
manual.
The containers to be filled (bottles, glasses, etc.) are called jars in this manual.
The keys to be pressed are shown in square brackets, e.g. [+] and [-], or as small
symbols, e.g. .
Article numbers (Art. 012345, for example) indicated in this manual refer to our
company's internal article numbers.
Symbols
The following symbols are used in this manual:
Important information and helpful tips for correct use.
Warning about situations posing a hazard to personal safety
and/or to the product.
Warning about electric shocks.
Warning about injuries.
Note on damage resulting from external devices.

General safety instructions8
4 General safety instructions
The safety instructions generally apply to all FILL-Systems products.
Danger of hand injuries
Make sure that during operation of the machine, your hands (as well
as hair, clothing, etc.) do not get caught in rotating parts (gears,
driving shafts) or other moving parts.
In case of dismantling (e.g. when removing the pump head) or
cleaning, turn the power off and unplug from the power supply.
Risk of injury from electrical current
Protect the electronic connections to the power adapter against
moisture. Please ensure that all electrical cables / wires are installed
in such a way they cannot be damaged, crushed or can impair the
insulation.
Never open the driving module, the power adapter or a plug.
In the case of disassembly (e. g. when removing the pump head) or
cleaning, the device must be disconnecte from the mains!
Risk of contamination of the product by damaged wear parts
Carry out a subsequent cleaning and visual inspection of the following
components after each finished filling process (or at least once daily):
1. gears / impeller rotor / hoses of the pump head
2. filling nozzles
3. gaskets
4. seals
5. hoses.
Damaged parts must be replaced immediately.
Special comments
This type of machine is electronically controlled by a microcomputer.
Faults / malfunctions during further operation under the influence of
strong electrical or electromagnetic fields cannot be ruled out
completely even though such events are highly unlikely.
Should this happen, please proceed as follows:
- turn off the machine,
- wait at least 10 seconds,
- restart the machine,
- if necessary perform a factory reset.

Delivery 9
5 Delivery
5.1 Scope of delivery
Fig. 1: Scope of delivery
Art. 301001
Item
Quantity
Description
Art.
Wear part
1
1 pc.
Driving module Fill up 2/100
(inc. item 4)
301002
2
1 pc.
Gear pump head L, with pair of gears;
individual parts, see chapter Putting into
Operation: Pump head
302001
x
3
4 m
priming hose Ø 40 x 3 mm
304002
x
4
1 pc.
Power adapter 230 V, AC primary: 230 V,
50/60 Hz, secondary: 24 V DC/10 A,
unregulated
or optional: 115 V/24 V (Art. 307044)
307127
or:
307044
5
2 pc.
Wedge nozzle, hard
306015
x
6
1 pc.
Conical filling nozzle, hard
306002
x
7
1 pc.
Support for conical filling nozzle
306005
x

Delivery10
8
1 pc.
Filling nozzle, flat
306001
x
9
1 pc.
Limitation cross for flat filling nozzle
306006
x
10
1 pc.
Combination wrench, SW 10 mm
307007
11
2 pc.
Micro fuse, 8A, medium time lag, inscription:
M8/250
307009
x
12
2 pc.
Gasket for clamping flange
307004
x
13
1 pc.
Clamping flange Ø 37 for filling nozzles,
preassembled
306007
14
3 pc.
Hose clamp, for hose Ø 40 mm, size 48
304066
15
1 pc.
Check valve for hose Ø 40 mm (inkl. item 14)
306038
16
1 pc.
Pipe bend 90°, bended aside, for pumping, for
hose Ø 40 mm (incl. item 12, 14)
304001
17
1 pc.
Network cable/power cord, EU plug
307022
18
1 pc.
Microswitch, 5-pin plug
307039
19
1 pc.
Y-bracket
307034
20
1 pc.
Pipe bend 90°, for hose Ø 40 mm (incl. item
12, 14)
304034
21
1 pc.
Set of seals (replacement for pump head)
307043
x
22
1 pc.
Stand 50 cm (incl. item 19)
303012
Without exception, wear parts are not covered by the warranty.
All wear parts must be checked regularly for damage and wear and
replaced if necessary. Porous, leaking or worn parts must be replaced
immediately. Operation with defective parts can be harmful to the life,
electronics, mechanics and functionality of the machine as well as to
the quality of your product to be filled.
Among other things, the service life of the wear parts depends on the
respective products to be filled, the duration and nature of use and
on environmental conditions (temperature, corrosive fumes etc.).
The inactivity of the machine can also negatively affect the service
life of the wear parts due to the different ageing processes of
individual components.
5.2 Content control
During our outgoing controls, all our deliveries are carefully checked for completeness
and intactness. Nevertheless, we recommend that, after unpacking the machine, you
check the delivery immediately for completeness according to your delivery note and
using Fig. 1.
In case of missing or damaged parts, please inform the company FILL-Systems GmbH
immediately in writing, at the latest within two working days after receiving the
delivery. We request you to note that upon expiry of this deadline, we can no longer
guarantee any replacement/subsequent delivery of parts at the company's expense.

Technical details of the machine 11
6 Technical details of the machine
6.1 Intended use
The Fill up 2 is designed for the filling of honey.
With additional accessories it is also possible to fill propolis and royal jelly.
Decisive for an accurate filling is the viscosity of the product.
When filling non-flowable products, the pump head and the
driving module can be damaged. The manufactuere assumes no
liability for this.
The Fill up 2 ist designed for single-shift operation.
6.2 Technical data
Nominal voltage
24 V DC
Rated current
2,0 A
Power consumption motor
approx. 200 VA
Motor/pump speed
14-100/min (regulated with the rotary knob
righthandside of the machine)
Tightening torque
90 Nm
Nominal torque
9,5 Nm
Noise emission
< 70 dB
Set up area
width = 33 cm x depth = 32 cm
Overall height
50-100 cm (according to design)
Height below filling nozzle
5-30 cm, stand 50 cm (Art. 303012)
5-50 cm, stand 70 cm (Art. 303006)
5-80 cm, stand 100 cm (Art. 303023)
Weight
approx. 16 kg (basic configuration)
Dosing quantities
5 ml - 65 l or 5 g - 32.5 kg
Repeat accuracy/ filling accuracy
approx. 1-2 g (depending on dosing
quantity, viscosity and filling speed, up to
a jar size of 500 g)
Pumping data for honey
Max. priming height
up to 4.9 ft / 1.5 m
Max. conveyor height pressure side
up to 13 ft / 4.0 m
Max. pump capacity per hour
up to 420 kg/h, 300 l/h

Technical details of the machine12
6.3 Fuses
Software
To protect the mechanics and the motor, the machine is equipped with an overload
protection. If there is a blockage in the mechanical part, the machine switches off and
the message Overpump appears on the display.
In this event, it is absolutely necessary to find the root cause of
the blockage and to remove it.
If the root cause is rectified, the machine can be put into operation by confirming with
the key.
Electrics
The electronic parts and power supply are protected via a micro fuse in the form of a
melting-fuse type (see chapter Delivery: Scope of delivery). The fuse acts on short-
circuit/over voltage in the power supply and becomes defective after it has fulfilled its
function and can no longer be used. After the source of the fault has been identified
and rectified, the micro fuse must be replaced.
To do this, the fuse holder is unscrewed, the defective micro fuse is removed and the
fuse holder is inserted again with a new micro fuse (see chapter Technical Details of
the Machine: Connections and controls on the driving module). Normally, the
machine can now be restarted.
Never attempt to repair a fuse or bypass - danger to life.
There are two replacement fuses among the components
included in the delivery.
If the newly installed micro fuse breaks immediately, please
contact our Technical Support.
Electronics
If the machine is exposed to an extreme, continuous load due to unfavourable
conditions (high room or outside temperature), a thermal fuse is activated when a
temperature of the motor of approx. 70 °C is reached. In this case, the machine
switches off to protect against overheating, and the message T-Error appears on the
display. After a cool-down phase of approx. 15 minutes, the machine can be put into
operation mode again by pressing the key. For a faster cool-down leave the machine
switched on that the fan accelerates the cool-down phase.

Technical details of the machine 13
6.4 Connections and controls on the driving module
Fig. 2: Right side of the driving
module
Fig. 2:
1- Rotary knob for stepless speed regulation
2- ON/OFF toggle switch/main switch (without LED)
3- 3-pin socket connector for 24 V power supply
4- Fuse holder (contains the micro fuse)
Fig. 3: Left side of the driving
module
Fig. 3:
5- Blank cover for optional installation of a port for additional devices
6- 3-pin port for connecting a turntable
7- 5-pin port for external switches/sensors

Putting into operation14
7 Putting into operation
7.1 Unpacking and installation
Fig. 4: Removing the
protective cover
After unpacking remove the protective cover
from the stainless steel sheets (see Fig. 4).
To ensure optimum operation of your machine
we recommend:
- placing the machine on a table or a stable worktop
- a room temperature between 15 °C and 35 °C
- allowing the machine to acclimatize prior to putting
it into operation for about 1 hour to prevent damage
caused in the electronics by condensation (e.g. due
to high temperature or climatic differences during
transport)
- operating the machine only with tested and proper
power connections.
The machine must neither be operated nor stored in places with
unfavorable environmental conditions such as high humidity,
water vapor, aggressive or acidic vapors, extreme heat,
extremly dusty air etc.

Putting into operation 15
7.2 Cleaning
For hygienic reasons, we recommend that all parts coming in
direct contact with the product should be cleaned before first
use and after each use. The parts can be cleaned by hand or in
the dishwasher. For cleaning by hand, you can use commercial
dishwashing detergent.
Cleaning these parts after each use is important and necessary
to maintain the proper functioning of the machine.

Putting into operation16
7.3 Adjustment to the jar height and size
The height below the filling nozzle can be adjusted between 5 and 30 cm for the stand
50 cm. For filling taller jars, a high stand can be purchased, if required (see chapter
Technical details of the machine: Technical data). The height adjustment takes
place by means of the locking lever at the driving module (see Fig. 5).
When releasing the lever, the driving module
must be held tightly in place from below, so that
it does not slip suddenly downwards on the
stand rod (see Fig. 5).
Fig. 5: Height
adjustment
Generally, the filling nozzle should be fitted as tightly as possible over the jar opening.
Fig. 6: Y-bracket and microswitch
Installation and adjustment of Y-bracket
and microswitch, see Fig. 6:
1. By means of the star grip and the guide plate,
the Y-bracket is attached to the stand and
positioned so that an adjacent jar is located
centrally under the filling nozzle.
2. By means of the knurled nut, the microswitch
is positoned that a pressed on jar actuates
the microswitch.

Putting into operation 17
7.4 Suctioning of the medium
To prime in the product into the pump head and fill it into the jar, proceed as follows:
1.
Fill the pump head with 2-4 table spoons of the product, depending on the viscosity
(see Fig. 7). In this way, the pump head is greatly vented, sealed and lubricated,
and the product can be primed.
2.
Replug the pipe bend, including the priming hose, into the top opening of the
pump head.
3.
Place a collection container under the filling nozzle.
4.
Prime the product until it emerges from the filling nozzle without bubbles.
- Operation mode used: Manual mode – Forward interval
- using the black rotary knob on the right side of the driving module
set the motor speed (filling speed) to maximum (100/min)
- fill up until the hose and pump head are filled with the product without bubbles.
Fig. 7: Filling the pump
head
The product should have reached the pump head after 15
seconds. If this does not occur, the pump head should again be
filled with product and the hose connections checked for leaks.
Prolonged priminging without further addition of product to
lubricate the gears can destroy the pump head.

Putting into operation18
7.5 Pump head
7.5.1 Gear wheel pump head L
Fig. 8: Gear pump head L
(Art. 302001)
Fillable products
The gear pump head L is designed for the filling of honey.
To prevent temperature differences and segregations, we strongly recommend that the
product is thoroughly stirred.Honey should not be heated above 40 °C.
The volume flow of the gear pump head L is approx. 5 liters/minute at the maximum
delivery rate.
Cleaning
In order to clean the pump head, it (we recommend including pipe bend and priming
hose) can be removed from the driving module and be disassembled.
To do this, proceed as follows (see Fig. 9):
- empty the pump head as far as possible
- remove the pump head from the driving module by unscrewing the two
wing screws M6 x 90 mm (2)
- remove the pipe bend and the clamping flange including the filling nozzle and the
flange seal by unscrewing the nuts (8) at the top and the bottom of the
pump head
- remove the cover (3) by unscrewing the wing screws M6 x 20 mm (1)
- remove the cover gasket (7) from the groove and the pair of gears (4) from the
housing (9)
Attention: The pair of gears sit tightly on the shafts due to their
very precise fitting. To facilitate removal, these can be lifted with a flat
screwdriver through the openings for the nozzles.
- Strictly avoid force and scraping etc.
Attention! Do not lose small parts.
Pump head housing (incl. shafts), pair of gears and cover can now be cleaned, e.g. in
the sink by hand (small parts) or in the dishwasher. Recesses can be brushed out or
wiped with a small brush or a sponge respectively. Only commercially available dish
washing / cleaning agents should be used for this purpose.
The assembly then takes place in reverse order.

Putting into operation 19
The ball bearing of the driving shaft is pressed into the housing.
A thorough cleaning is also possible without its dismantling.
When assembling the pump head it is important to fix the wing
screws (1, 2) and the nuts (8) only hand-tight.
Fig. 9: Pump head L, exploded view drawing
Item
Number
Description
Art.
1
4 pc.
Wing screws M6 x 20 mm
307063
2
2 pc.
Wing screws M6 x 90 mm
3
1 pc.
Cover
307092
4
1 pc.
Pair of gears, helical cut
302017
5
1 pc.
Shaft seal, red/blue
307026
6
1 pc.
Shaft seal, green/blue
307027
7
1 pc.
Cover gasket
307003
8
4 pc.
Nut M6
307002
9
1 pc.
Pump head housing with passive shaft
10
1 pc.
Driving shaft with ball bearing
307079
11
1 pc.
Plastic ring
The shaft seals (5 and 6, either red and green or both blue) are generally to be
replaced after 20,000 kg, at least once a year. For the exchange of all seals on the
pump head, we offer seal sets in different materials: Art. 307043 (food grade), Art.
307061 (chemical-resistant).
The pump head must never be operated in a dry state, i.e.
without product. Without the lubricating effect of the product,
the synthetic gears would rub against one another and could
thereby be damaged or destroyed.
On the other hand, no lubrication is necessary with all other
parts of the filling equipment.

Putting into operation20
7.5.2 Changing shaft seals
Be careful when changing the shaft seals, not to damage any part of the pump head.
The shaft seals for the exchange may both be blue. In this case pay attention only to
the installation direction.
Fig. 10: Gear pump head L,
disassembled
Disassemble the gear pump head as
described in chapter Putting into
Operation: Pump head (see Fig. 10).
Fig. 11: Knock out the driving
shaft
Knock the hexagonal driving shaft
(including ball bearing) and the white
plastic ring out of the housing with a
suitable rubber hammer (see Fig. 11).
Fig. 12: Remove the red/blue
shaft seal
Remove the red/blue and the green/blue
seal shaft after each other with a suitable
tool from the housing
(see Fig. 12 and Fig. 13).
Fig. 13: Remove the green/blue
shaft seal