Flexicon PD12IHS Manuel

INSTRUCTION HANDBOOK

PD12IHS / PD12IDH

PD12IHS_PD12IDH IH EN 74-115-181 v2.01

Version: 2.01

Page 1 of 19

PD12 IHS / PD12 IDH

(example; exact model may vary)

This instruction handbook is for the daily users of the equipment.

INSTRUCTION HANDBOOK

PD12IHS / PD12IDH

PD12IHS_PD12IDH IH EN 74-115-181 v2.01

Version: 2.01

Page 2 of 19

Table of Contents

1Introduction................................................................................................................................3

1.1 The peristaltic principle..............................................................................................................3

1.2 Abbreviations in this manual .....................................................................................................3

1.3 Symbols on the machine...........................................................................................................4

1.4 Caution and employee safety....................................................................................................4

1.5 Essential training before daily use.............................................................................................4

1.6 References................................................................................................................................4

2General information...................................................................................................................5

2.1 Unpacking and inspection .........................................................................................................5

2.2 Technical specifications ............................................................................................................5

3Installation.................................................................................................................................6

3.1 Dip-switch settings: ...................................................................................................................7

4Daily Use...................................................................................................................................8

4.1 Starting-up and running.............................................................................................................8

4.2 Placing the product container....................................................................................................8

4.3 Choosing tubes, y-connectors and filling nozzles .....................................................................9

4.4 Assembly of tubes and Y-connectors......................................................................................10

4.5 Mounting of silicone tubes.......................................................................................................11

4.6 Dispensing...............................................................................................................................12

4.6.1 Nature of fill media ..................................................................................................................12

4.6.2 Prime tubes.............................................................................................................................12

4.6.3 Problems with drips.................................................................................................................12

4.6.4 Problems with hard feed..........................................................................................................12

4.6.5 Problems with different volumes from the 2 heads .................................................................12

5Choice of parameters..............................................................................................................13

5.1 Programming principle ............................................................................................................13

5.1.1 Description of PD12 specific functions/parameters.................................................................13

Function 1 –Volume............................................................................................................................13

Function 2 - Tube diameter..................................................................................................................13

Function 3 - Velocity ............................................................................................................................13

Function 4 - Acceleration/deceleration.................................................................................................14

Function 5 - Reversing (back suction) .................................................................................................14

6Cleaning..................................................................................................................................15

6.1 Cleaning Frequency ................................................................................................................15

6.2 Preparations for cleaning ........................................................................................................15

6.3 Cleaning Guidance..................................................................................................................15

6.4 Detergents or cleaning agents ................................................................................................15

7Maintenance & service............................................................................................................16

7.1 Daily maintenance...................................................................................................................16

7.2 Service ....................................................................................................................................16

7.3 Methods and frequency of inspections for safety functions.....................................................16

8Interface and change of voltage..............................................................................................17

8.1 PD12 interface.........................................................................................................................17

8.2 Connecting multiple PD12’s to flexnet.....................................................................................18

8.3 Change of voltage ...................................................................................................................18

9Declaration of conformity.........................................................................................................19

INSTRUCTION HANDBOOK

PD12IHS / PD12IDH

PD12IHS_PD12IDH IH EN 74-115-181 v2.01

Version: 2.01

Page 3 of 19

1 Introduction

This manual covers two models.

PD12 IHS (high speed).

This model fills one bottle at a time.

In the double head the tubes are mounted in pairs of 2 and via y-connectors these are joined into one

tube in order to fill one bottle at a time.

and

PD12 IDH (double head).

This model fills two bottles simultaneously.

In the double head the tubes are mounted in pairs of 2 and via y-connectors each set of tubes are

joined into one tube in order to fill two bottles simultaneously.

In general all sections of the manual cover both models; unless clearly specified.

1.1 The peristaltic principle

PD12 operates with a peristaltic dispenser head (tube pump), where the liquid only comes into

contact with the flexible tube, the tube connections and the filling nozzle. The tubes are usually made

of silicone, but other materials can also be used.

The dispenser head is designed in such a way that sterilized tubes can be mounted in the head

without affecting the sterility.

The dispenser head is self-priming, and the dispenser head itself can stand to be run dry (not

recommended for the sake of the tubes).

The dispenser head on PD12 works with four parallel tubes which are squeezed by rollers mounted

on ball bearings. The rollers in are offset in order to eliminate pulsation.

1.2 Abbreviations in this manual

e.g.

As example

Fig.

Figure

Hertz

i.d.

Internal diameter

IDH

Industrial Double Head

IHS

Industrial High Speed

MC12

Flexicon Master Controller

milli Ampere

msec

milli secunds

o.d.

Outer diameter

PD12

Peristaltic Dispenser

VAC

Volt Alternating Current

VDC

Volts Direct Current

INSTRUCTION HANDBOOK

PD12IHS / PD12IDH

PD12IHS_PD12IDH IH EN 74-115-181 v2.01

Version: 2.01

Page 4 of 19

1.3 Symbols on the machine

Warning against touching

Warning against high voltage

Fig. 1 –Symbols

1.4 Caution and employee safety

This manual should be read before using the PD12.

It is strongly advised that

- Any kind of maintenance or cleaning of the machine not is carried out while power is

connected

- Unauthorised / non-trained personnel should not open the cover of the electrical parts

- The machine is placed in such a way that it is not exposed to high humidity, high temperatures

or other abnormal operating environment.

- The machine is not to be used in explosion hazardous environments.

- When operating the machine make sure that the dispenser heads are closed and that safety

cover is placed above.

- The machine should be used for dosing and filling of liquid fluids, only.

A peristaltic dispenser head is not suitable for viscous products; see section 4.6.1

1.5 Essential training before daily use

Read the section with Daily Use, thoroughly before using the machine.

Protective equipment and protective devices are installed:

The machine is equipped with a safety cover which protects the operator from hazards; the

machine will not run unless the safety cover is placed.

Always respect the symbols on the machine.

Cleaning must be performed as described in section 6.

1.6 References

- MC12 manual

INSTRUCTION HANDBOOK

PD12IHS / PD12IDH

PD12IHS_PD12IDH IH EN 74-115-181 v2.01

Version: 2.01

Page 5 of 19

2 General information

2.1 Unpacking and inspection

Please check that all ordered items have been received and that no items are damaged during

transport. In case of any defects or omissions, please contact W-M Flexicon or your supplier

immediately.

2.2 Technical specifications

Dimensions:

Length: 525 mm

Width: 200 mm

Height: 208 mm (incl. Feet)

Fig. 2 –Dimensions

Buttons:

online

Lights when communicating with MC12.

power

Lights when the machine is on.

prime

Pushbutton for tube priming

Fig. 3 - Buttons on PD12

Other:

Weight: 13 kg

Motor: High Torque Step Motor MST341B02

PD12 Power consumption: max 150 Watt

Mains: 110/230 VAC earthed, 50/60 Hz

INSTRUCTION HANDBOOK

PD12IHS / PD12IDH

PD12IHS_PD12IDH IH EN 74-115-181 v2.01

Version: 2.01

Page 6 of 19

3 Installation

PD12 must be placed on a stable bedplate. All electrical connections are on its rear.

Fig. 4 - Connections

The cable with plug (1) is connected to an earthed switch.

The communication cable from MC12 (type 3) comes fitted with two 4-pin DIN plugs. One is

connected to the "net 1" socket (2) on the PD12, and the other plug is connected to the "net" socket

on MC12.

The terminator supplied with MC12 (4-pin blind DIN plug) is connected to the "net 2" (3) socket on

PD12.

Should the system be operating more than one PD12, the "net 2" socket (3) is to be connected to the

"net 1" socket (2) on the next PD12 by a communication cable (type 3). The terminator is connected

to the last PD12 on the line.

PD12 is now ready to be switched on and to be programmed from the MC12.

If the PD12 is one of several filling stations in a system, none of the stations may have the same

address and it must therefore be changed.

INSTRUCTION HANDBOOK

PD12IHS / PD12IDH

PD12IHS_PD12IDH IH EN 74-115-181 v2.01

Version: 2.01

Page 7 of 19

3.1 Dip-switch settings:

Change of address is performed via a dip-switch

placed underneath the PD12. This change may

only be carried out when the machine is turned

off at the main isolator.

Addresses between 1 and 16 may be chosen,

and the table below shows the various

combinations.

Address "1" is the factory setting of PD12.

This can be changed –see below.

Address

SW1

SW2

SW3

SW4

INSTRUCTION HANDBOOK

PD12IHS / PD12IDH

PD12IHS_PD12IDH IH EN 74-115-181 v2.01

Version: 2.01

Page 8 of 19

4 Daily Use

4.1 Starting-up and running

Installation section must be carried out before this chapter can be performed.

4.2 Placing the product container

In order to build up adequate pressure, it is recommendable to place the product container at the

same level as dispenser head or preferably above the dispenser head level. Placing the container

higher than dispenser head level provides positive product support and may reduce the calibration

interval. It is also recommended to place the container as close as possible to the dispenser on

suction side.

Flexicon

Pump Head

Preferred Placement

of container

Normal Placement

of container

Suction side Pressure side

Fig. 5 - placing the product container

Dispenser head

INSTRUCTION HANDBOOK

PD12IHS / PD12IDH

PD12IHS_PD12IDH IH EN 74-115-181 v2.01

Version: 2.01

Page 9 of 19

4.3 Choosing tubes, Y-connectors and filling nozzles

The filling is carried out by the PD12 which is controlled by the MC12.

The capacity is based on the volume to be dispensed, however a lot of factors can influence on the

obtainable capacity; e.g. choice of tubes and type of product.

These aspects must be considered before choosing the filling settings.

Tubes must be selected according to the application and volume to be filled. Use the table shown

below for choice of tubes according to minimum volume to be filled.

PD12 can operate with different tube dimensions chosen according to the volume to be dispensed.

The tubes are designated by their internal diameters (i.d.) in millimetres. This value is always used as

designation for the individual tube, and this is also the value to be entered in function 2 at the MC12

master controller.

In order to obtain stable and good results, the choice of tubing can be made according to the following

guidelines:

PD12 IHS

Volume

Nozzle

mm i.d.

Tubing

mm i.d.

Y-Connector

i.d.

< 1.00

0.6

0.5

1.2

1.00 –2.00

1.0

0.8

1.2

2.00 –3.40

1.0

1.2

1.8

3.40 –14.0

1.6

1.8

14.0–24.0

3.2

3.6

24.0 –44.0

4.5

4.8

44.0 –70.0

6.0

4.8

>70.0 ml

8.0*

8.0

7.5

* use non-return valve

PD12 IDH

Volume

Nozzle

mm i.d.

Tubing

mm i.d.

Y-Connector

i.d.

< 0.50

0.6

0.5

1.2

0.50 –1.00

1.0

0.8

1.2

1.00 –1.70

1.0

1.2

1.8

1.70 –7.00

1.6

1.8

7.00 –12.0

3.2

3.6

12.0 –22.0

4.5

4.8

22.0 –35.0

6.0

4.8

>35.0 ml

8.0*

8.0

7.5

* use non-return valve

The filling time for a volume of 10.0 ml with a Ø3.2 ID tube is 0.8 seconds with dispenser running in

high speed i.e. 400 in rpm and 100 in acceleration.

INSTRUCTION HANDBOOK

PD12IHS / PD12IDH

PD12IHS_PD12IDH IH EN 74-115-181 v2.01

Version: 2.01

Page 10 of 19

The same volume can be obtained with Ø4.8 ID tube in 0.55 seconds for the same parameters.

The contrast here is outweighed by the fact that Ø3.2 ID tube will in this case yields better accuracy

than the option of using Ø4.8 ID. But as it is indicated the capacity will be higher with Ø4.8 tube since

filling time is shorter.

The above mentioned example should be considered as guidance only, and adjustments should be

done for the individual applications.

4.4 Assembly of tubes and Y-connectors

Before mounting the tubes in the dispenser head

the tubes must be assembled with a Y-connector.

When the Y-connector has been assembled, mount

the tubes in the dispenser head, as shown in 4.5

Each set of tubes and y-connector must be assembled

as this.

PD12 IHS

PD12 IHS (high speed).

This model fills one bottle at a time.

In the double head the tubes must be mounted

in pairs of 2 and via y-connectors these are

joined into one tube.

PD12 IDH

PD12 IDH (double head).

This model fills two bottles simultaneously.

In the double head the tubes must be mounted

in pairs of 2 and via y-connectors each set of

tubes are joined into one tube.

NOTE: To obtain best possible equality of

filling volumes from the 2 heads the tubing

must be of the same type, size, batch and

degree of wear.

(see also 4.6.5)

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