REX RKF 130 Configuration guide

RKF 130
General information
Version 1.1 Page 1 of 128
TABLE OF CONTENTS
1. General information ................................................................................................... 7
1.1 Introduction................................................................................................................ 8
1.2 Copyright ................................................................................................................... 9
1.3 Pictographs - Explanations .......................................................................................10
1.4 Basic safety instructions............................................................................................11
1.5 Operating range and danger area for the operating personnel..................................17
2. Description of the machine........................................................................................18
2.1 Brief description for the piston filler ...........................................................................18
2.2 Use...........................................................................................................................19
2.3 Schematic diamgram in case of alternative operation ...............................................21
2.4 Image of the piston filler............................................................................................22
2.5 Safety devices and their safety functions ..................................................................24
3. Transport, setup, installation.....................................................................................25
3.1 Transport ..................................................................................................................25
3.2 Intermediate storage.................................................................................................26
3.3 Installation.................................................................................................................26
3.4 Fuse protection.........................................................................................................26
3.5 Aligning the machine.................................................................................................27
3.6 Space required for operation and maintenance.........................................................27
3.7 Dimensions, weight and technical specifications.......................................................28
3.8 Initial operation..........................................................................................................29
3.9 Safety instructions.....................................................................................................32
4. Operating the piston filler..........................................................................................35
4.1 General safety instructions........................................................................................35
4.2 Operating elements/function .....................................................................................36

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4.3 Description of the touch screen.................................................................................40
4.4 Description of the touch control system.....................................................................44
4.5 Description of the buttons .........................................................................................55
4.6 Setting a straight filling programme...........................................................................58
4.7 Setting a portioning programm..................................................................................61
4.8 Setting a twisting-off programme...............................................................................65
4.9 Special functions.......................................................................................................69
4.10 “Align pipe” special function ......................................................................................70
4.11 Setting the setup mask, language options, time and date .........................................71
4.12 Screen settings.........................................................................................................74
4.13 Recipe management.................................................................................................75
4.14 Note..........................................................................................................................78
4.15 Login.........................................................................................................................79
4.16 Info log......................................................................................................................80
4.17 Service plan..............................................................................................................81
4.18 Status report.............................................................................................................82
4.19 Alarms, faults............................................................................................................83
4.20 Troubleshooting........................................................................................................84
4.21 Emergency programme.............................................................................................86
4.22 Roasting and rotary pistons.......................................................................................87
4.23 Attaching the straight filling pipe and twisting pipe ....................................................89
4.24 Water drain ...............................................................................................................91
4.25 Attaching the twisting pipes and rotating casing holding device ................................92
4.26 Attaching twisting off tubes and rigid casing holding device ......................................96
4.27 Processing instructions for casings.........................................................................100
4.28 Production...............................................................................................................101

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General information
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4.29 End of production....................................................................................................105
5. Maintenance...........................................................................................................106
5.1 Cleaning and cleaning plan.....................................................................................106
5.2 Cleaning the piston filler..........................................................................................107
5.3 Maintenance and servicing .....................................................................................114
5.4 Maintenance and repair work..................................................................................114
5.5 Lubrication..............................................................................................................119
6. Troubleshooting and repair .....................................................................................121
6.1 Check list................................................................................................................121
6.2 Application-technological error, cause and error removal........................................123
7. De-commissioning ..................................................................................................125
7.1 De-commissioning the piston filler...........................................................................125
8. Explanations ...........................................................................................................126
8.1 Delivery explanation................................................................................................126
8.2 CE Declaration of conformity RKF 130....................................................................127
8.3 Notes......................................................................................................................128

RKF 130
General information
Page 4 of 128 Version 1.1
TABLE OF FIGURES
Figure 1: RKF 130 danger area............................................................................................17
Figure 2: Image....................................................................................................................22
Figure 3: Functional elements and their arrangement on the piston filler..............................23
Figure 4: Machine wheels.....................................................................................................25
Figure 5: RKF 130................................................................................................................28
Figure 6: Knee lever switch ..................................................................................................37
Figure 7: Clipper power point................................................................................................39
Figure 8: Main switch ...........................................................................................................39
Figure 9: Pre-cleaning mask.................................................................................................40
Figure 10: Touch screen.......................................................................................................41
Figure 11: Standby mode.....................................................................................................46
Figure 12: Operating elements.............................................................................................48
Figure 13: Searching for a filling programme........................................................................50
Figure 14: Programme name keyboard field.........................................................................51
Figure 15: Changing the default setting with "+" or "-" button................................................52
Figure 16: Changing the default setting directly....................................................................53
Figure 17: Filling the mask ...................................................................................................58
Figure 18: Fill correction mask..............................................................................................59
Figure 19: Portioning mask...................................................................................................61
Figure 20: Portioning correction mask..................................................................................62
Figure 21: Portioning correction mask 2 ...............................................................................63
Figure 22: Twisting-off mask ................................................................................................65
Figure 23: Twisting-off correction mask................................................................................66
Figure 24: Twisting-off correction mask 2.............................................................................67
Figure 25: Information mask.................................................................................................69

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General information
Version 1.1 Page 5 of 128
Figure 26: “Align pipe” special function.................................................................................70
Figure 27: Setup mask .........................................................................................................71
Figure 28: Language options................................................................................................72
Figure 29: Setting the date...................................................................................................73
Figure 30: Setting the time ...................................................................................................73
Figure 31: Screen settings mask..........................................................................................74
Figure 32: Recipe management mask..................................................................................75
Figure 33: Recipe statistics ..................................................................................................76
Figure 34: Favourites mask..................................................................................................77
Figure 35: Note ....................................................................................................................78
Figure 36: Info log ................................................................................................................80
Figure 37: Service plan.........................................................................................................81
Figure 38: Alarm mask .........................................................................................................83
Figure 39: Help mask ...........................................................................................................84
Figure 40: Alarm mask 2 ......................................................................................................85
Figure 41: Alarm mask 3 ......................................................................................................86
Figure 42: Installation sequence for roasting and rotary pistons...........................................87
Figure 43: Attaching straight filling pipe 1.............................................................................89
Figure 44: Attaching straight filling pipe 2.............................................................................90
Figure 45: Water drain..........................................................................................................91
Figure 46: Rotating casing holding device............................................................................92
Figure 47: Rigid casing holding device.................................................................................96
Figure 48: Piston filler control elements..............................................................................101
Figure 49: Cleaning the piston filler ....................................................................................112
Figure 50: Casing holding device’s lubrication point...........................................................119

RKF 130
General information
Page 6 of 128 Version 1.1
© 2010 REX-Technologie GmbH & Co. KG. All copyrights remain property of REX-
Technologie GmbH & Co. KG.
The information or drawings reproduced here may neither be duplicated nor misused nor
communicated to a third party without our prior approval.
Note: the overall documentation for the RKF 130 piston filler comprises the following manual:
1. The operating manual including spare parts documentation, circuit diagram and oil-flow
diagram as well as
2. The CE declaration of conformity and the reply form (machine acceptance log)

RKF 130
General information
Version 1.1 Page 7 of 128
1. GENERAL INFORMATION
MANUFACTURER
REX-Technologie GmbH & Co. KG
Irlachstraße 31
5303 Thalgau
Austria
www.rex-austria.com
OPERATOR
Name
Address
PIN, location
MACHINE MODEL
Type
Machine number
Year of
manufacture
TRAINED PERSONNEL
Name
Name
Name

RKF 130
General information
Page 8 of 128 Version 1.1
1.1 INTRODUCTION
This operating manual contains important information and must be read,
understood and complied with by persons who work with the RKF 130 piston filler
or are responsible for its operation.
The complete operating manual must always be kept close to the RKF 130 piston
filler.
The particularly important details for the operation are referred to in the operating
manual.
Knowledge of and compliance with the operating manual helps to achieve the
degree of security, which can be attained in accordance with the latest
technological developments, and disturbance-free operation when dealing with
this piston filler. Hence, it is very important that this operating manual is made
accessible to the responsible persons and reading of the same is also made
compulsory to this group of people.
Piston fillers subject to official inspection must be inspected before start of
operation. Determining the existence of a national or regional acceptance
obligation is binding for the customer. The manufacturer is excluded from all the
liability claims in case of non-compliance.
We recommend you to carefully read through this operating manual before
operating the piston filler for the first time. The machine manufacturer accepts no
liability for damage and malfunctions which result from non-compliance with the
operating manual.
Please contact our customer service or spare parts department or a
representative who will be glad to help you if any problems crop up.
The images and drawings shows are only for purposes of understanding.
The technical data, descriptions and design details were up-to-date at the time of
printing. Changes in design in the meantime are possible for the sake of an
ongoing further development.

RKF 130
General information
Version 1.1 Page 9 of 128
1.2 COPYRIGHT
Only REX-Technologie GmbH & Co. KG retains the copyright for documents such as
Operating manual
Drawings
Photos
Spare parts lists
Circuit diagram
Programmes etc.
provided by us for using the piston filler. The customer/operator only has the non-
transferable right to use these documents for purposes of assistance for proper operation or
maintenance of the piston filler. Every other use, particularly forwarding, abstraction, re-
recording, duplication or modification is not permissible without prior written approval.
We refuse any liability for damage to property, for financial losses or for
personal injuries if modified or external switching or control programmes
including hardware and software are used as well as if any type of structural
modification is made in the piston filler. Any warranty claim of the operator as
against the machine manufacturer is also inapplicable at the same time.

RKF 130
General information
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1.3 PICTOGRAPHS - EXPLANATIONS
1. Pictograph for "Danger to persons"
2. Pictograph for "Danger to machine"
3. Pictograph for "Qualified electrician/electronic technician required"
4. Pictograph for "Qualified mechanic required"
5. Pictograph for "Lubrication"
6. Pictograph for "Special tool required"
7. Pictograph for "Special instructions for the operating personnel"

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General information
Version 1.1 Page 11 of 128
1.4 BASIC SAFETY INSTRUCTIONS
•Warnings and symbols
Pictographs are used for emphasising important information in the operating manual. They
are shown on the preceding sheet in chapter 1.3 Pictographs - Explanations. These marked
texts are particularly important for the safety of man and machine, for flawless functioning of
the piston filler.
•Basic information for "intended use"
The piston filler has been manufactured in accordance with the latest technological
developments and the recognized safety regulations. Nevertheless, when used, there may
be a risk to the life and limb of the user or third party. It can also have an adverse effect on
the piston filler or other tangible assets. The piston filler may pose dangers if:
- it is not operated by trained personnel,
- it is not operated properly or
- it is not used as directed!
Piston fillers must be in a technically flawless condition and may be used only as
directed and in compliance with the operating manual, while taking into account
safe operation and any possible dangers. Faults in particular, which can affect
the safety adversely, must be immediately eliminated or notified to the
responsible qualified person.
The piston filler is solely meant for filling, portioning and twisting off the filling material, even
in the frozen state, however not colder than -4 °C. Any other use, e.g. filling material that is
colder than -4 °C or for products that contain solid materials or materials having high
toughness such as bones or tendons, is not considered as intended use. The machine
manufacturer shall not assume responsibility for any damage resulting there from. The user
shall assume full responsibility for any such risk.
•Organisational measures
The operating manual must be kept close to the operating site of the piston filler such that it
is handy at all times.
In addition to the operating manual, the knowledge of the general statutory and other binding
regulations for accident prevention and environmental protections should be imparted (e.g.
relevant information about the responsible trade association).
Operating instructions should be added to the chapter 8.3 Notes by documenting instructions
pertaining to the organisation of workflows, personnel employed, maintenance work carried
out for instance. Documents regarding notifiable piston fillers or procedures must be
enclosed with the operating manual.

RKF 130
General information
Page 12 of 128 Version 1.1
The personnel authorised to work with the piston filler must have read the
operating manual before starting the work, basically chapter 4 General safety
instructions. This is particularly important for work that is carried out only
occasionally on the piston filler (retrofitting, maintenance, repairs).
Check at least occasionally that the personnel work in compliance with the
operating manual, while taking into account safe operation and any possible
dangers!
The operating personnel may not wear their long hair open nor wear any loose clothing or
jewellery including rings. These could get caught or pulled into the unit and result in injury.
The operating personnel must be instructed to strictly follow all the safety instructions and
hazard warnings.
The safety instructions and hazard warnings put up on the piston filler must be maintained in
a good, legible condition at all times.
In case of any noticeable changes in the piston filler or its operating behaviour, particularly as
regards safety, the machine operation must be immediately stopped and the changes must
be notified to the responsible person.
No modifications, extensions or reconstructions, which affect the functioning and
safety, must be made to the piston filler without approval from the manufacturer.
Spare parts must fulfil the technical requirements specified by the manufacturer. This is
always ensured if original spare parts are used.
Prescribed deadlines or those specified in the operating manual for maintenance and
inspections must be adhered to. (Refer to chapter 5.4 Maintenance and repair work
)
•Personnel selection and qualification
The personnel, who has been authorised to work with or operate the piston filler, must have
read and understood the operating manual before starting with the work.
The piston filler may be operated only by persons who are clearly suitable for it from the
intellectual and physical point of view. In addition, it can also be expected that they complete
their task reliably. The legally prescribed minimum age must be adhered to!
Persons whose capacity to act is restricted, e.g. due to alcohol, drugs, medicines or the like,
must not operate, maintain, repair or check the piston filler.
Only trained and clearly instructed personnel must be employed. Specify the responsibility
for operation, set-up, maintenance, repairs and settings clearly!

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The person responsible for operating the piston filler must be authorised to
decline a machine operation requested by a third party, which can have an
adverse effect on the safety and functioning.
Allow personnel who are being trained, instructed or who are pursuing a general training
program, to work on the piston filler only under constant supervision of an experienced
person.
Only a qualified electrician may work on electrical equipment of the piston filler
in accordance with the electro-technical regulations.
In case of malfunctions, immediately shut down and secure the piston filler. Get the faults
repaired from qualified technical staff immediately.
•Duties of the operator
All the required safety equipment must be provided to the personnel.
Check regularly that the operating personnel work while taking into account safe operation
and any possible dangers.
All the safety instructions and hazard warnings on the piston filler must be complete and in a
legible condition.
In addition to this operating manual, the general statutory and other binding regulations for
accident prevention and environmental protection must be followed and the personnel must
be instructed regarding the same.
•Duties of the personnel
Follow all the statutory and basic specifications for operational safety and accident
prevention when working.
Follow all the safety instructions and hazard warnings on the piston filler.
In the case of malfunctions, immediately shut down and secure the piston filler. Get the fault
repaired immediately.
Observe the safety regulations applicable for the product when using oils, greases and other
chemical substances. Use the necessary personal safety equipment.

RKF 130
General information
Page 14 of 128 Version 1.1
•Safety instructions for particular stages of operation
- Normal mode
Avoid any working method which is questionable from a safety viewpoint. This is particularly
applicable when using products whose condition does not clearly ensure proper functioning
of the piston filler.
Before starting the work, ensure a working environment that does not give rise to
any obstacles in the operating range and transport sector. Risk of accident!
Operate piston fillers only if all the firmly installed or removable safety equipment, emergency
stop switches, vacuum devices etc. are available and installed.
Check the piston filler at least once per shift for externally recognizable damage
and faults. Immediately report any changes including those in the operating
behaviour to the responsible person/department. Immediately shut down the
machine in case of doubt and secure it against a re-start (switch off the main
switch and lock it).
Before switching on the piston filler ensure that no person can be put at risk by
starting the machine.
- Special work and operation during maintenance, repairs, fault elimination
etc.
Adhere to the setting, maintenance and inspection activities and inspection dates
including the specifications for replacing parts/equipment prescribed in the
operating manual! These activities may be executed only by qualified personnel.
Inform the operating personnel about the planned course of action before starting
the special work. Appoint supervisory staff!
Switch off the piston filler and secure it against unsupervised switching on before
executing the special work. This can be done by switching off the main switch
and locking it. A warning sign must also be put up on the main switch. The key
must be kept safe by the person in-charge.

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General information
Version 1.1 Page 15 of 128
The person in-charge must be informed once the special work is complete. The
person in-charge must ensure that the work has been carried out properly and
that the piston filler can be restarted safely. He/she can unlock the main switch
only after checking and release the machine for operation.
When cleaning the piston filler, the electrical equipment, electric motors, control
cabinets, control panels, command and display devices etc. must not come in
contact with water or steam jet. Penetrating water or temperature of the steam
damage such parts. Hence, they must be cleaned separately and manually using
a mild cleaning agent.
If complete or partial dismantling of the safety equipment was necessary for
executing the special work, it must be ensured that it is re-installed and checked
for functioning immediately after the completion of the work. The person in-
charge is responsible for this.
Make sure that operating and auxiliary materials as well as replacement parts are
disposed in a safe and eco-friendly manner!
•Instructions for special dangers
- Electrical power
Only use original fuses with prescribed currents and correct melting behaviour!
Switch off the piston filler immediately in case of interferences in the electrical
power supply!
Machine and system parts on which inspection, maintenance and repair work is
carried out must be disconnected and this zero potential state must be
maintained till the work is completed! All the disconnected parts must be checked
for their zero potential state before starting the repair work.
Regularly check the electrical equipment of a piston fill. If any faults are found,
e.g. loose connections, braised cables, functionally unreliable relays and
contactors etc., they must be rectified immediately.

RKF 130
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Page 16 of 128 Version 1.1
- Structural modifications
Modifications in or reconstructions of the piston filler or extensions to the machine are
prohibited without prior written approval of REX-Technologie GmbH & Co. KG!
Only original spare and accessory parts of REX-Technologie GmbH & Co. KG may be used.
Otherwise, REX-Technologie GmbH & Co. KG reserves the right to all warranty and
guarantee claims.
- Pneumatics (only in case of accessory units)
Only qualified personnel having special knowledge and experience in the field of
pneumatics may work on pneumatic devices.
Check all lines, hoses and screw connections regularly for leaks and externally
visible damage. Immediately rectify any damage.
- Oils, greases and other chemical substances
Adhere to product-specific safety regulations when using oils, greases and other
chemical substances (cleaning agents)!
Be careful when working with hot operating and auxiliary materials. Risk of
burning!
Dispose of used oil, used grease and other chemical substances in compliance
with the local/regional regulations. Do not dispose of such waste materials in the
normal household or industrial waste at any cost.
Attention: Do not allow used oils to enter the drainage system!

RKF 130
General information
Version 1.1 Page 17 of 128
1.5 OPERATING RANGE AND DANGER AREA FOR THE OPERATING
PERSONNEL
RKF130 has the following danger areas (see Figure 1: RKF 130 danger area):
Operating
range
Danger area
Figure 1: RKF 130 danger area
Type ABCD
RKF 130 1277-1312 1080-1115 773 561

RKF 130
Description of the machine
Page 18 of 128 Version 1.1
2. DESCRIPTION OF THE MACHINE
2.1 BRIEF DESCRIPTION FOR THE PISTON FILLER
Only
- plastically deformable
- compressible
- non-flammable
- non-explosive
filling material may be filled, portioned and twisted off in the piston filler, even in a frozen
state up to maximum -4 °C.
The filling material must also have a certain lubricating effect.
The design of the piston filler is in accordance with the latest regulations of the EU Machinery
Directive. The EU Directive for handling meat and meat products are also complied with.
The compact machine body has a smooth surface and is made completely from stainless
steel. It stands on plastic feet which are adjustable in height and thus runs extremely quietly
and smoothly when working. The height adjustable feet allow balancing on an uneven floor
and you can also comfortably clean the place where the machine stands thanks to clearance
height. The completely flat stainless steel surfaces simplify cleaning and also allow you to
keep a visually attractive and hygienically flawless condition of the piston filler.
Working planes, control knobs and levers for portioning are ergonomically arranged and
ensure low-fatigue work.
The speed of the piston filler is infinitely variable. The piston filler is operated, controlled,
checked and programmed using a lucid, waterproof display. Depending on the equipment,
the machine contains one or two drive units, which are monitored and controlled.

RKF 130
Description of the machine
Version 1.1 Page 19 of 128
2.2 USE
2.2.1 Range of use and intended use
1. This piston filler is designed for filling, portioning and twisting off of organic foodstuffs of
the following type and quality:
- Meat and meat products having a diameter of maximum 45 mm
- Meat and meat products having a diameter of maximum 45 mm and having a
temperature of maximum 40 °C and not colder than -4 °C (attention: the filling
material temperature can drop even lower in case of longer service lives after
cutting.)
- Fish
- Cheese
- soup concentrate etc.
Products fed for human consumption must be in accordance with the local
hygiene regulations.
2. The piston filler can also fill products that are not intended for human
consumptions. However, the machine does not have equipment for preventing
risk of infection, which comes from the processed products. The subsequent
use of the piston filler in accordance with clause 1 is strictly prohibited without
prior implementation of cleaning and disinfection measures!
3. In case of alternate use of the piston filler as per clause 1 and
2, cleaning and disinfection measures must be implemented before every use
of the machine as per clause 1. These measures must be implemented in
accordance with the cleaning schedule in chapter 5. The subsequent rinsing
with warm and cold water having drinking water quality must be carried out
intensively such that all the traces of disinfectants are removed reliably. The
instruction manual of the suppliers of cleansers and disinfectants must be
followed thoroughly.

RKF 130
Description of the machine
Page 20 of 128 Version 1.1
2.2.2 Unauthorised use
This piston filler may not be used for the following purposes:
- Using meat and meat products in blocks having a diameter greater than 45 mm
- Using frozen meat, frozen meat products and other frozen foodstuffs
having a temperature colder than -4 °C
- Using cooked meat or warm meat products, roast meat or other warm foodstuffs,
which are warmer than 40 °C.
Consult the manufacturer first when using materials having a temperature of more
than 40 °C.
Non-compliance with the instructions for “Unauthorised use” can result in the
following damage and dangers:
- Drive elements overload with motor or mechanical defects in the drive
area
- Crack in the roasting or rotary pistons
- Excessive warming up of the transported material and piston filler
- Risk of accident due to unusual machine behaviour and thus an
increased risk potential
This piston filler may not be used for the following purposes without prior cleaning
and disinfection:
-
Using products that are meant for human consumption and which are in
accordance with the hygiene regulations if products have been
processed previously which were not intended for human consumption
or were not in accordance with the local hygiene regulations.
In case of alternative operation of the piston filler with products meant
for human consumption and products that are not in accordance with
the local hygiene regulations or are not meant for human consumption,
a basic cleaning and disinfection must be carried out as per the
cleaning schedule in chapter 5before using the piston filler for products
meant for human consumption. Adhere to the instruction manual of the
disinfectant supplier.
- Using the piston filler for products meant for human consumption after breaks of
more than 1 to 1.5 hours:
See the following schematic diagram for this.