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EQUIPMENT : SEMI-AUTO BULK FILLING LINE

1 & 5 USG

SR. NO. : M233/2022-23

P.O. No. & DATE : PO/2022-23/027 DT.16-08-2022

MFRS. : CADETRONICS
NAVI MUMBAI - 400701

CUSTOMER : RAJ ENTERPRISE, MUMBAI

CADETRONICS brings Computer Aided Designs

 I N D E X

DESCRIPTION PAGE
NO.
1. General Instructions 1

2. Technical Specifications 2-5

3. System Description 6

4. System Operations 7

5. Operating Instructions 8

6. Push Button & Functions 9-10

7. Pre-Operations Check List 11-22

8. Alarm List 23

9. PLC Input & Output List 24-25

10. Drive Setting Chart 26

11. Maintenance sheet 27

12. Spares List 28

Drawing No.

13. G.A. Drawing CD 9913

14. Electrical Drawings CW 3272

15. Pneumatic Drawings CW 4182

CADETRONICS brings Computer Aided Designs

 GENERAL INSTRUCTION

AS IN THE CASE WITH EVERY AUTOMATIC MACHINE, REGULAR

CLEANING AND LUBRICATION IN ADDITION TO CAREFUL MAINTENANCE,
ARE QUITE ESSENTIAL FOR OBTAINING GOOD RESULTS OVER A LONG
PERIOD.

A MACHINE OF THIS TYPE INTENDED FOR HANDLING FOOD, PAINTS,

COSMETICS, AND CHEMICALS PRODUCTS ETC. SHOULD ALWAYS BE
KEPT HYGIENICALLY CLEAN AND FREE FROM DUST.

THE INSTRUCTION GIVEN IN THE FOLLOWING PAGES SHOULD BE

CAREFULLY STUDIED AND FOLLOWED.

THE MACHINE IS ADJUSTED AND TESTED PRIOR TO DELIVERY BUT

FINAL ADJUSTMENT MAY BE NECESSARY TO PUT IT ON PRODUCTION -
CYCLE.

CAUTION

THIS IS HIGH SPEED, ACCURATE DISPENSING MACHINE. USE STANDARD

SCALES / MEASURES FOR VERIFICATION OF QUANTITY FILLED.

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 CADETRONICS
TECHNICAL SPECIFICATION FOR
SEMI-AUTO BULK FILLING LINE 1 & 5 USG

Ref. Drg. CD 9913

Product : Water Base Emulsion Paints

Sp. Gravity:- 1.3
Viscosity: - 3000-7000CPS

Pack Size : 1 & 5 USG

(5 Ltr, 15Ltr and 18Ltr)
(Dimensional List Enclosed in data folder)
Open Mouth Plastic Pails
of specified Dimensions

Type : Weighmetric (FLP)

With 3 Nozzle
Gross Weight Filling

Operation : Electro – Pneumatic

Filling Speed : 8-9 Fills Per Min. for 1 USG

6-7 Fills Per Min. for 5 USG

Accuracy : ± 0.7% for 1 USG Pack

± 0.2% for 5 USG Pack
at S.O.P. & S.O.C.

Change Over Time : 10-15 Min.

Electric supply : 230 V AC, Single Phase

Power Consumption : 2.5 HP Approx.

Air supply : @ 6 kg/cm2 at Air Inlet

Air Consumption : 80-100 LPM

Man Power requirement : 2 Nos.

Space requirement : As per GA Drg.

… Contd. 2.

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 CADETRONICS
TECHNICAL SPECIFICATION FOR
SEMI-AUTO BULK FILLING LINE 1 & 5 USG
…2…
THE MACHINE INCORPORATES FOLLOWING COMPONENTS

1. CAN INFEED
The operator will manually Place Empty Can on Conveyor.

2. TRACK INDEXING CONVEYOR

Purpose - Transferring the Cans from one station to
other stations for further automated
operations like, Filling, Lid Pressing etc.
Construction - Dodge type, Twin Chain Indexing System
Track width - 400 mm
Guide Rails - Adjustable
Drive - 2 HP Motor (Hindustan Make) with
Gear Box (Bonfiglioli Make)
General Construction - Body Frames MS Powder coated/Painted
and covering of S.S. / M.S.
3. FILLER
Type - Weighmetric)
With 3 Nozzle
Gross Weight Filling
General Construction - Robust M.S. Framework with
Powder Coated/Painted
Loadcell Capacity - 100 Kg. (Mettler Toledo Make)
Scale Capacity - 50 Kg.
Least Count - 5 gram
Product Tank - A storage tank made out of 2 mm
S.S.304 sheet, having 80 Ltr. capacity
With 80 mm Infeed Valve and Pneumatic
Float Type Level Switch for automatic
Level control
Cut off Valve - Flange mounted Two-way Valve
made out of S.S. 304 with drip free cut-off
Bowl & Ball 50 mm-2 Nos.
Bowl & Ball 40 mm-1 Nos.
System Output - Ethernet
Height Adjustment - By Rotating Hand Wheel

4. LID PLACEMENT

Manual operation operator needs to place Lids on Pails Manually.

… Contd. 3.
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 CADETRONICS
TECHNICAL SPECIFICATION FOR
SEMI-AUTO BULK FILLING LINE 1 & 5 USG

…3…

5. LID PRESSER

Type - Split Pressure Plate type

Operation - Pneumatic
Lidpress Cylinder - 2 x 100 NB
Height Adjustment - By Rotating Hand Wheel

6. IDLER ROLLER CONVEYOR

Length - 1500 mm
Width - 400 mm
Entry Ht. - 600 mm ± 25 mm
Discharge Ht. - 580 mm ± 25 mm
Rollers - 40 mm dia at 60 mm pitch
Painting - Frame powder coating
General - Guide Rails on side
and stopper plate at end.

(Note: Offer Is Inclusive Of Nozzle Adaptors With Flexible Pipe For Cleaning Of
Filling Tank And Nozzles Using Solvent.)

**********************************

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HARDWARE & PROGRAM REF:

ITEM SPECS MAKE

Program Ref CA-130C
Control Panel FLP SSPL
PLC TM221CE24T Schneider
HMI HMIGXU3512 Schneider
VFD 2 HP Single Phase Drive Reputed Make
Loadcell 100KG Mettler
Weight Module Precia Molen
Level Sensor Pneumatic Float Switch Revati
Infeed Actuator 80 [3”] Ball valve Actuator Micro Pneumatics
M.C.B. Schneider, Siemens,
L&T
Relay Card 8-ch Relay card Aventek
Rotary Switches Kaycee / Teknic
IR Sensor MIAD9W Banner
Proxy sensor NJ8-18GM-N-5M P&F
Accumulation Sensor P&F
Solenoid Valves Festo
Cylinders Festo/Duncle/SMC
FR Units Janatics/Festo
Motors 2HP FLP Motor Hindustan
Gear Box Bonfiglioli

**********************************

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 SYSTEM DESCRIPTION

The High Speed Paint Packing Line is an automatic integrated paint filling
and packing system engineered to provide reliable and trouble free
performance resulting in high quality packs. It is the product of a team of
highly specialized engineers at CADETRONICS, Navi-Mumbai.

The design of this system emphasizes the effective use of simple techniques to
achieve the automation desired, resulting in easy to learn operation.
Procedures detailed in the following pages, carefully followed, will provide the
material needed by the operator to master the machine in a short
time through training and practice.

The system consists of functional stations, which are detailed separately one
by one. But first let us note the integrated function of these operational units
with regard to interface between consecutive units by following the path of
and operations on a double can from beginning to end.

The Packing Line having Three Head construction in that first are empty can
loading station & 3rd prefill stations based on timing and 2nd 3rd head is
loadcell based for top up the remain weight. It will provide high speed high
accuracy and smooth packing operation for following functions.

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 SYSTEM OPERATIONS

Buckets are placed manually on the dodge conveyor, on dodge entry sensor
sensing takes the transfer to next station.

Next most important station is FILLER. It is time and weigh fill Type which is
highly reliable and accurate. Filling is done as per time set in prefill station
and remaining filling is done by gravity that is load cell based station.

The next station is LID PRESS which is pressure split type. Can aligns to this
station and Pneumatic Cylinder is operated. Hence Lid is pressed on filled
Can. The output of this Dodging Conveyor goes to exit table.

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 OPERATING INSTRUCTIONS

The machine is provided with PVC Pipe for Compressed Air Supply
connections.

1. Connect the single phase 3 wire power supply.

2. Connect Air Supply to the equipment. (@ 6-7 kg/cm 2 pressure) Check

Air pressure on the pressure gauges provided on regulator units.

PRECAUTION

i) Ensure that the desk is clear.

ii) Check filler height, Lid press height and railings are set correctly.

iii) Check for In-feed Actuator Valve Operations.

iv) Before starting fill, check for successful working of all stations.

v) Confirm accurate operator settings, weight settings in Hmi.

vi) Confirm transfer operation by Manual Transfer button on HMI.

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 PUSH BUTTONS AND FUNCTIONS

FUNCTION KEYS

PREV : To move on previous page.

NEXT : To move on next page.

DEL : To enter the password.

LEFT : To move in RUN page.

INC : Used for increment the value.

DEC : Used for decrement the value.

RIGHT : Used to go to the production counter.

UP : Used to scroll Upward.

DOWN : Used to scroll downward.

ENTER : directly moved to the run parameter setting page.

ERROR ACK: This push button is used to acknowledge fault messages and
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fault lamp.

SHIFT : Used to change the base while entering password/dly data.

Base 1,10,100,1000.

E.M. STOP: on press of this button all operation will stop.

To restart, unlock this push button by rotating clock wise little using key &
press cycle start push button

CYCLE START: to start the system first need to put at run mode then need
to press cycle start push button.

NOTE: after putting run - off switch in run mode on first time. Press of cycle
start the conveyor will run. So, do not put hands or any obstacle in the way
of conveyor.

RUN: RUN –ON is used for activate the plc.

CONVEYOR TRANSFER AUTO/MANUAL SW:

A] AUTO – In AUTO mode, if the can is present at the entry of conveyor & all
units completed its operations then conveyor will take transfer
automatically.

B] MANUAL: In MANUAL mode, if the can is present at the entry of conveyor

& all units completed its operations then conveyor will not take transfer
automatically. For conveyor to take transfer need to press manual p.b.

END OPERATION ON-OFF SW:

When the cans on can feeder & Orientor conveyor gets over & cans are
present only at dodge conveyor but not at the entry of the dodge conveyor
then to take out these cans from end of the dodge conveyor with completing
all operations in between, END OPERATION is used.

 If there is no can at entry of conveyor & manual transfer command is

given then dodge conveyor will not take transfer if End operation sw is
in OFF mode.

 If there is no can at entry of conveyor & manual transfer command is

given then dodge conveyor will take transfer if End operation sw is in
ON mode.

NOTE: When End Operation sw is in ON mode, Can Feeder & Orientor

conveyor will stop automatically & also pusher will not operate.
POWER ON LAMP: This Green lamp is incorporated to indicate whether m/c
power is on or not.

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FAULT LAMP: This Red lamp is incorporated to indicate the fault.

Pre-Operations Check List

Select RUN page from below HOME screen then NEXT key

RUN PARA SCREEN will appear.

PASSWORD ENTER PASSWORD SCREEN will appear.
Operator Password: 1234
Engineer Password: 2468
COUNT PRODUCTION COUNTER SCREEN will appear.
REPORT SCREEN will appear.

Operator Password: 1234

Filling Weight settings:

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In the Above screen on press of Filler Packsize selection page will appear.
Here Selection of Pack size done. After selection of Pack size suppose we have
selected 10L then we have to press at 10L for further weight and time settings.

Suppose 5L selected then below screen will appear

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On press of Next Prefill time page for Particular Packsize open.

Suppose 18L selected then below screen

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On press of Next Prefill time page for Particular Packsize open.

After The above weight settings next step will be tare the empty bucket on loadcell
platform.

After that required set parameter as target weight so use SET key for set weight
parameter

Bypass screen: on press of bypass following screen will appear. Here we can
bypass lid press and stoppage of conveyor on high weight.

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Engineering login:
Password 24:

HOME PAGE SCREEN

RUN PARA SCREEN will appear.

PASSWORD ENTER PASSWORD SCREEN will appear.
COUNT PRODUCTION COUNTER SCREEN will appear.
REPORT SCREEN will appear.

ENTER PASSWORD SCREEN

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ENGINEERING SET PARA SCREEN will appear.
FORCE OUTPUT SCREEN will appear.
OUTPUT STATUS SCREEN will appear.
INPUT STATUS SCREEN will appear.

INPUT STATUS SCREEN 1

INPUT STATUS SCREEN 2

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 INPUT STATUS SCREEN 3

INPUT STATUS SCREEN 4

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 INPUT STATUS SCREEN 5

OUTPUT STATUS SCREEN 1

OUTPUT STATUS SCREEN 2

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 FORCE OUTPUT STATUS SCREEN 1

FORCE OUTPUT STATUS SCREEN 2

PRODUCTION COUNTER SCREEN

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 ENGG PARAMETER SET SCREEN-1

ENGG PARAMETER SET SCREEN-2

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 ENGG PARAMETER SET SCREEN-3

ENGG PARAMETER SET SCREEN-4

REPORT SCREEN 1

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 REPORT SCREEN 2

RUN PARAMETER SCREEN 1

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 RUN PARAMETER SCREEN 2

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 ALARAM LIST

SR.NO ALARM TO DO

1 EMERGENCY Release EMERGENCY

STOP PRESSED STOP, run off the
display panel, manual
transfer it, in order to
attain the pack size
position, then cycle
start & continue the
machine.

2 LOW WEIGHT If low weight is

AT detected at any head
CHECKWARE then press error
acknowledge push
button on HMI then
top up window will
appear. Press top up
tab to start fill again
to reach the target
weight.

HIGH WEIGHT If high weight is

3 AT detected on any head
CHECKWARE then machine will
stop, press error
acknowledges to take
transfer so that cycle
will start again.
Stopping of m/c on
high weight can be
bypassed from
bypass setting. If it is
bypassed then m/c
will not stop on high
weight alarm.

AIR PRESSURE If air pressure is low

OK/LOW than machine stops,
6 check air supply then
restart machine.

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 PLC INPUT LIST

PLC INPUTS
I0.0 TOP UP
I0.1 LID PRESS CAN SENSOR
I0.2 CONVEYOR BOTTOM SENSOR 5L
I0.3 CONVEYOR BOTTOM SENSOR 15L
I0.4 CONVEYOR BOTTOM SENSOR 18L
I0.5 ERROR ACK
I0.6 RUN ON
TM221CE24R
I0.7 CYCLE START
I0.8 EM STOP
I0.9 CAN SENSOR AT DODGE ENTRY
I0.10 PRESSURE SW
I0.11 ACCUMULATION SENSOR
I0.12 LID PRESS UP MSW
I0.13 PREFILL CAN SENSOR#1
I1:0 ENTRY KEY
I1:1 DOWN KEY
I1:2 INCREMENT KEY
I1:3 DECREMENT KEY
I1:4 LEFT KEY
I1:5 RIGHT KEY
I1:6 ESCAPE KEY
I1:7 DELETE KEY
TM3DI16
I1:8 PREVIOUS PAGE KEY
I1:9 NEXT PAGE KEY
I1:10 MANUAL TRANSFER
I1:11 UP KEY
I1:12 AUTO/MANUAL
I1:13 END OPERATION SW
I1:14 SHIFT
I1:15 Fill OFF

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 PLC OUT-PUTS

PLC OUTPUTS
%Q0.0 AL0 RL1:1:O
%Q0.1 AL1 RL1:2:O
%Q0.2 AL2 RL1:3:O
%Q0.3 PREFILL SOL COIL#1 RL1:4:O
%Q0.4 LID PRESS SOL #2 RL1:5:O
TM221CE24R
%Q0.5 DODGE CONV FWD RL1:6:O
%Q0.6 DODGE CONV STP RL1:7:O
%Q0.7 DODGE CONV REV RL1:8:O
%Q0.8 SPEED SEL 15 LTR RL2:1:O
%Q0.9 SPEED SEL 18LTR RL2:2:O
%Q1.0 ACTUATOR RL2:3:O
%Q1.1 BECON LAMP GREEN RL2:4:O
%Q1.2 BECON ORANGE RL2:5:O
%Q1.3 WEIGHT MODULE ZERO RL2:6:O
TM3DQ8R
%Q1.4 BECON LAMP RED RL2:7:O
%Q1.5 SPARE RL2:8:O
%Q1.6 SPARE
%Q1.7 SPARE

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 DRIVE SETTING CHART

Parameter DODGE CONVEYOR

SET ACC 0.7
DEC 0.7
LSP 0.0
HSP 40
SP2 25.0
SP3 25.0
SP4 20.0
SP5 --
SP6 --
SP7 --
SP8 --
DRC TUN
I-O TCC 3C
FUN SA1
PSS PS2 LI4
PS4 LI5
PS8 NO
PS16 NO
JOG LI6

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 MAINTENANCE SHEET

Sr.no ACTIVITY FREQUENCY

CONVEYORS
1 Clean the dodge conveyor dodges weekly
2 Clean railing & sensor, stopper bracket for any deposition of daily
paint.
3 Clean sensor head for any deposition of paint daily

4 Clean the spillage on conveyor immediately. daily

5 Greasing of chains 15 days

PRODUCT TANK & FILLING AREA
1 Clean the product tank after end of day immediately daily
2 Clean Seating portion bowl of each head to avoid dripping weekly
from fill valves.
3 Clean any deposition on plunger rods to avoid jamming of weekly
rods & oil the bush for smooth operation
4 Tighten the locknuts & Locking pins of plungers weekly
5 Clean float ball for any heavy deposition for easy float daily
operation & to avoid overflow
6 Clean & grease the height adjustment screws, bevel gears & weekly
guide rods.
7 Drain waret (moisture) from filter unit daily
8 Loadcell platform cleaning, do not scratch it. Daily

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 SPARE LIST

Sr.
No. DESCRIPTION QTY.
1 Loadcell Cap. 100 Kg. MT1241-100 1 Nos.
2 Dodge Assy. 5 Nos.
3 IRD Sensor FLP Banner MIAD9W 2 Nos.
4 Proxi Controller for Sensor Turck IM1-22EX-R 2 Nos.

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CADETRONICS brings Computer Aided Designs
 STORAGE

CAUTION

BEFORE COMMISSIONING STORE THESE EQUIPMENT CASES

AS PER THE ARROW MARKED, IN A CLEAN, WELL-LIGHTED /
VENTILATED, DUST FREE, DAMP PROOF, COVERED ROOM.

DAMPNESS MAY EFFECT DEVICE PERFORMANCE / MATERIAL,

AND CAUSE RUST.

DOCUMENTATION FEEDBACK:

Your comments will help us serve your documentation needs better. If you have any
suggestions on how to improve this document, please write to us on the following
email ID’s:

1. info@cadetronics.com

2. service@cadetronics.com

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