Horizontal
filling machine
Single/Double head liquid
filling machine
(Model:G1WY/G2WY)
1 、 Principle, performance, models and technical parameters…… 1 - 2
2 、 C a u t i o n s a n d f a c t o r s a f f e c t e d b y w o r k ……………2-3
3、Installation and commissioning: liquid filling machine … … 3
4、Filling machine speed, accuracy and adjustment … … … … … 4 - 5
5、Point and automatic operation…………………………………………5
6、Use of emergency stop switch……………………………………… …5
7、Daily maintenance………………………………………… ………… …5
8
、Filling machine schematic part name ……………………………… 6
9、Filling machine diagram………… ……………………………………6-7
10、Common faults and troubleshooting……………………………… 7-9
Filling machine
Contents
1
Filling machine
1 、 Principle, technical parameters and performance
1.1 Working principle: This series of filling machines are semi-automatic piston
filling machines. The cylinder drives a piston to suck and eject the material. The
one-way valve is used to control the material flow. The magnetic switch is used to
control the stroke of the cylinder to adjust the filling amount.
1.2 Technical Parameters：
Technical
Parameters
content
Parameters
Voltage
220V/50Hz（ ） 110V/60Hz（ ）
current
1A
power
10W
Rated air
pressure
0.4-0.6MPa
Filling
speed
Single head 10-30 bottles per minute
Double head 20-60 bottles per minute
Filling
accuracy
±0.5 % -±1%
Filling
range
Equipment
abbreviated
model
Filling range
（ml）
Optimal filling
range（ml）
Model of the
machine
100 型
2-130
10-100
300 型
5-320
30-300
500 型
10-540
50-500
1000 型
80-1100
100-1000
3000 型
300-3500
500-3000
5000 型
1500-5200
1000-5000
2
1.3 Performance: The semi-automatic piston filling machine produced by
our company is based on the company's filling machine series, introducing
foreign advanced filling machine technology, and carried out a series of
transformations and innovations. Its structure is simpler and more reasonable.
Higher accuracy, easier cleaning, and easier operation. The contact areas with
the material are made of 304 stainless steel, which meets the requirements of
GMP. The sealing parts are made of PTFE and silicone materials. They have
corrosion resistance, aging resistance, high temperature resistance, and
sealing. Good and other advantages, ideal for filling equipment in food,
pharmaceutical, chemical, daily chemical, oil, pesticide and other industries。
2 、 C a u t i o n s an d fa c t o r s a f f e c t e d b y wo r k
Safety Precautions：This series of filling machine is only suitable for
filling liquid, low concentration paste can not be used for other purposes.
To ensure safe production, please read the following precautions carefully:
1. Use a power supply and air source that conforms to the requirements of
this machine (see the technical parameters of the machine in this book for
details). The stability of the air source must be maintained under continuous
working conditions.
2. Before disassembling, washing or repairing this machine, please be sure
to turn off the air source and power supply first.
3. The rear half of the machine (near the control buttons) and the lower part
of the machine frame are equipped with electrical control components. Under
no circumstances should the body be washed directly with water, otherwise there
will be danger of electric shock and damage to the electrical control
components.
4. After the power switch is turned off, there is still voltage in some
circuits in the electrical control of this machine. When repairing the control
circuit, please be sure to unplug the power cord.
5. Do not keep your eyes close to the filling head during work, pay attention
to personal safety.
6. Do not put your hand on the central axis of the cylinder during the work
process, pay attention to pinching your hands.
7. Before using materials for filling, it is best to clean the machine with
detergent first, and then clean it with clean water, so as to avoid oil stains
or foreign materials and materials mixing, which will lead to waste of materials
and damage to the machine.
Cover the hopper of the paste filling machine when it is not working to prevent
dust or other debris from entering the hopper, resulting in wasted materials
and damage to the machine.
Affected by the following factors at work
1.The factors that affect the filling accuracy are: the stability of the
compressed air, the uniformity of the material, the filling speed, etc.
Filling machine
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2.The factors that affect the filling speed are: the viscosity of the
material, the stroke of the cylinder, the size of the cylinder, the size
of the discharge nozzle, the proficiency of the operator, etc.
3. This machine has two methods, foot switch filling and continuous
automatic filling; the two filling methods can be switched arbitrarily.
It is recommended to use the foot switch for filling at the beginning.
3 、 Installation and commissioning: liquid filling machine
(Reference diagram)
Filling machine
1、1、Install the three-way control valve (1), install the three-way
inlet connector (2), and then connect the feed hose to the connector (the
three-way clamp and the hose buckle must be locked);
2、Adjust the height of the filling head (18) according to the height
of the items to be filled;
3、 Confirm the position of the movable (4) and fixed (5) magnetic
switches on the cylinder (the position of the cylinder magnetic switch
(5) is fixed and cannot be moved).
4、 Insert the feed hose (3) into the storage bucket or connect to
the storage bucket. (Before using the material filling, it is best to first
clean the machine with cleaning detergent, and then clean it with water,
so as to avoid oil contamination or foreign matter and material mixing,
resulting in wasted materials and damage to the machine);
5、 Plug in the power cord (6) and turn on the power switch . (No such
step for explosion-proof filling machine);
6、 Connect the inlet air pipe to the air source and quickly pass (8)
to the air source, turn on the air source switch (9), push the air source
switch is on, and pull out the air source switch is off. The pressure can
be adjusted by pulling out the upper part of the pressure regulating filter
(29) and fixing the pressure according to the carry;
7、Switch the working mode of the selection switch (10) to "electric";
8、Electric foot switch until material flows out of the filling head;
9、Rotate the filling machine speed adjustment throttle (12) and the
filling interval adjustment throttle (13) to adjust the appropriate
pumping speed to adjust the throttle (12) slowly (do not make the filling
There are materials or bubbles flushing out of the bottle during the
process).
10、According to your filling needs, adjust the position of the movable
magnetic switch (4) on the cylinder through the hand wheel (14) on the
right side of the filling machine to determine the required filling amount.
After the filling amount is determined, the movable magnetic switch (4)
on the cylinder is locked and the filling is officially started. (The
farther the moving magnetic switch (4) and the fixed magnetic switch (5)
are from each other, the larger the filling volume, and the smaller the
filling volume);
11、After skilled operation, you can switch the working mode to "Auto".
Filling machine
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4、Filling machine speed, accuracy and adjustment
Filling speed and adjustment
The filling speed is determined by the following 5 factors:
1、Suction speed: Depending on the viscosity of the product, the length
of the liquid suction tube (3).
2、Filling speed: It depends on the size of the replaceable nozzle (19)
of the filling head, and the filling speed is fast if the diameter is large;
3、Bubble speed of the product: The filling speed of the product with high
foam should be slowed down;
4、How much is the filling amount: the slower the filling amount is;
5、Filling accuracy: the higher the accuracy requirement, the slower the
filling speed;
The adjustment operation is as follows: loosen the lock nut of the filling
speed adjustment throttle (12) and the filling interval adjustment throttle
(13);
1、Twist the handle of the filling speed adjustment throttle (12) clockwise
to slow down the forward speed of the cylinder and slow down the loading speed;
2、Turn the handle of the throttle (12) counterclockwise to adjust the speed
of the throttle valve (12).
3、Turn the handle of the throttle (13) clockwise to adjust the filling
interval clockwise to slow down the cylinder's backward speed and the suction
speed.
4、Turn the handle of the throttle (13) counterclockwise to adjust the
filling interval to widen the speed of the cylinder and speed up the suction
speed.
Filling accuracy and adjustment
Liquid filling machine
1、 The filling error of the liquid filling machine is mainly caused by the
filling volume, filling speed, three-way control valve (1) opening and
closing valve speed, filling head (18) opening and closing valve speed, and
cylinder piston ( 23) Or the silicone O-ring (24) on the piston and the air
in the feeding hose;
2、The switching speed of the three-way control valve (1) and the filling
head (18) is related to the viscosity of the product. The higher the
viscosity, the slower the valve opens and closes;
3、 Adjust the three-way control valve (1) The switching speed of the valve
mainly adjusts the spring pressure in the valve. As the spring pressure
increases, the valve opens and closes faster. Adjust the spring pressure
in the three-way control valve (1) and the experience of the operator to
determine the filling measurement;
4、The opening and closing speeds of the two three-way valves (1) of the
double-head liquid filling machine are not necessarily the same. It is
determined according to the experience of the on-site production and
operators;
Filling machine
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5、The speed of the upper and lower valve switches of the two filling
heads (18) of the double-head liquid filling machine mainly adjusts the two
throttle valves (21) on the thin cylinder (20) on the filling head;
6、The speed of the upper and lower valve opening and closing of the two
slap filling head (18) of the double-head liquid filling machine is not
necessarily the same, which is determined according to the experience of the
field production and operator;
7、The filling accuracy mainly depends on the wear of the cylinder piston
(23) or the silicone O-ring (24) on the piston, as well as the wear of all
the O-rings and all flat seals on it;
8、Minimize the air in the feeding leather tube as much as possible.
5、Point and automatic operation
The jog and automatic selection switch (10) is mainly set for debugging
or measurement. Whenever the new machine is commissioned, or the product is
changed, or the filling volume is changed, or the equipment is cleaned, it
is recommended to use the jog gear to debug. When the commissioning is
completed and the product filling volume is normal, the automatic gear works.
You can switch between jog and automatic without shutting down.
6、Use of emergency stop switch
The safety switch is also called emergency stop switch (25). In normal
work, the safety switch is turned off. When the material is lost due to
improper operation, the safety switch can be pressed to avoid material waste
and keep the workshop clean.
7、Daily maintenance1.
1、In order to keep the fuse tube frame (27) smooth and clean, do not
scrape its surface with sharp or hard sharp tools. If there is any stain,
wipe it with alcohol;
2、The cylinder (26) has been lubricated at the factory. Do not disassemble
the cylinder or add any lubricant.
3、Stainless steel tee (1), material tank (22), filling head (18), O-ring,
seal ring, etc. can be easily removed and washed.
4、When cleaning is needed, turn on the machine and let the machine work
automatically until cleaning. It is best to use hot water for cleaning.
5、If the machine is not used for a long time, the stainless steel tee,
material tank, filling head, 0-ring, sealing ring and other parts in contact
with the material can be removed and cleaned to prevent the material from
drying and corrosion. For future use.
Filling machine
9 、 S I n g l e h e a d f i l l i n g m a c h i n e d i a g r a m
D o u b l e h e a d f i l l i n g m a c h i n e d i a g r a m
6
8 、 F i l l i n g m a c h i n e s c h e m a t i c p a r t n a m e
( 1 ) T h r e e - w a y c o n t r o l v a l v e ( 2 ) F e e d p o r t c o n n e c t o r ( 3 )
L e a t h e r t u b e ( 4 ) M o v a b l e m a g n e t i c s w i t c h ( 5 ) F i x e d m a g n e t i c
s w i t c h ( 6 ) P o w e r c o r d ( 7 ) P o w e r s w i t c h ( 8 ) A i r s o u r c e
q u i c k - i n s t a l l s t r a i g h t - t h r o u g h s o c k e t ( 9 ) A i r s o u r c e s w i t c h
( 1 0 ) S e l e c t s w i t c h ( 1 2 ) C a n n e d s p e e d a d j u s t m e n t t h r o t t l e ( 1 3 )
C a n n e d i n t e r v a l a d j u s t m e n t t h r o t t l e ( 1 4 ) H a n d w h e e l ( 1 8 )
C a n n e d h e a d ( 1 9 ) R e p l a c e a b l e n o z z l e ( 2 0 ) T h i n c y l i n d e r ( 2 1 )
T h i n c y l i n d e r t h r o t t l e v a l v e ( 2 2 ) M a t e r i a l c y l i n d e r ( 2 3 )
M a t e r i a l c y l i n d e r p i s t o n ( 2 4 ) P i s t o n O - t y p e s i l i c o n e s e a l ( 2 5 )
E m e r g e n c y s t o p s w i t c h ( 2 6 ) C y l i n d e r ( 2 7 ) F r a m e ( 2 8 ) T w o
F i v e - w a y s o l e n o i d v a l v e ( 2 9 ) p r e s s u r e r e g u l a t o r f i l t e r ( 3 0 )
b a r o m e t e r ( 3 1 ) f o o t s w i t c h c o n n e c t i o n l i n e ( 3 2 ) c l a m p ( 3 3 )
l e a t h e r t u b e b u c k l e ( 3 4 ) p i s t o n r o d
Filling machine
10、Common faults and troubleshooting
7
Filling machine
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Filling machine
十一、常见故障及排除
Failure
pheno
menon
Failure analysis
Troubleshooting
Cylinder does not work
1. Confirm that the barometer (30) shows
whether the air pressure meets the
requirements and whether the air source has
entered the machine;
This machine can only be used with air
pressure, please refer to the technical
parameters of this machine before connecting
the air source
2. Check whether the power switch (7) is on.
Turn on the power switch (not available in
explosion-proof filling machines)
3. Check if the air source switch (9) is on.
Turn on the air source switch
4. Confirm the position of the fixed magnetic
switch (5)
The rear magnetic switch must be fixed at the
rear of the cylinder so that the cylinder can
work and cannot be moved
5. Confirm whether the emergency stop
switch (25) is pressed.
Turn the emergency stop switch to return it to
its original position
6. Confirm the insurance management (11)
If the fuse is broken, replace it with a new
one.
7. Confirm whether the cylinder piston (23) is
stuck.
Replacing the piston
8. Confirm whether the O-ring silicone ring
(24) of the cylinder piston is sticky, which will
cause the piston to jam.
Replace O-shaped silicone ring
9. Check if the position of the movable
magnetic switch (4) exceeds the maximum
filling amount
Turn the active magnetic switch back
10. Check if the active magnetic is intact
If damaged, replace it with a new one
Inaccurate or unfilled filling
1. Check if the movable magnetic switch (4)
is loose.
The front magnetic switch is locked after each
adjustment of the filling volume
2. Confirm whether the canned speed throttle
(12) and the canned interval throttle (13) are
closed.
Throttle valve cannot be closed
3. Check if the filling speed is too fast
Adjust the canning speed by adjusting the
throttle valve (12) to reduce the canning
speed
4. Confirm if there is any foreign matter in the
quick-install three-way control valve (1) or
control rotary valve (16)
If necessary
9
Failure
phenomeno
n
Failure analysis
Troubleshooting
5.Make sure that all clamps, hose clamps, air
pipe joints, etc. are properly sealed.
Everything must be locked and sealed so that no
air leaks can occur. If the flat silicone seal of the
clamp is damaged, it needs to be updated
6. Check if the air pressure is stable
When the air pressure cannot be high or
low, it must be consistent
7.Confirm whether there is enough
material in the storage bucket or hopper
Materials cannot be more or less, must be
consistent
Filling machine
