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Table top-Mobile-Power lift

INSTRUCTIONS AND SPARE PARTS

Manual Part # CT-Ins-UK 12/08/2010 From serial number 8989

Translation from the Original Instructions

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Table of Contents

SAFETY INSTRUCTIONS AND WARNINGS..................................................................................................................4

INTRODUCTION ..............................................................................................................................................................5

CONTACTING UNIFILLER ..............................................................................................................................................5

MACHINE DESCRIPTION................................................................................................................................................6

COMPACT POWER LIFT ...................................................................................................................................................6 COMPACT MOBILE ..........................................................................................................................................................7 COMPACT TABLE TOP .....................................................................................................................................................7

SERIAL NUMBER LOCATION ........................................................................................................................................8

POWER REQUIREMENTS ..............................................................................................................................................9

AIR REQUIREMENTS ........................................................................................................................................................9

ASSEMBLY AND OPERATION.....................................................................................................................................10

HOPPER SAFETY PLUG .................................................................................................................................................10 DEPOSITING ACCESSORIES SET UP ................................................................................................................................11 PRIMING / PREPARING TO DEPOSIT ................................................................................................................................11 DEPOSIT SPEED CONTROL ............................................................................................................................................12 VOLUME ADJUSTMENT ..................................................................................................................................................12 WORKING WITH THE DEPOSITOR....................................................................................................................................13

DISASSEMBLY FOR SANITIZING................................................................................................................................14

GENERAL .....................................................................................................................................................................14

CLEANING AND SANITIZING.......................................................................................................................................16

CLEANING.....................................................................................................................................................................16 SANITIZING ...................................................................................................................................................................17 RE ASSEMBLY ..............................................................................................................................................................17

MAINTENANCE .............................................................................................................................................................18

O RING CARE ...............................................................................................................................................................19 DAILY ...........................................................................................................................................................................19 WEEKLY .......................................................................................................................................................................19 3 MONTHS ....................................................................................................................................................................19 O RING AND GASKET PART NUMBERS ............................................................................................................................19

SPARE PARTS ..............................................................................................................................................................20

PRODUCT CYLINDER SIZES ...........................................................................................................................................20

PARTS IDENTIFICATION..............................................................................................................................................21

UNI BLOCK...................................................................................................................................................................21 RH SIDE CONNECTIONS................................................................................................................................................22 BASE COMPONENTS LH ................................................................................................................................................22 BASE COMPONENTS RH................................................................................................................................................23 POWER LIFT LOWER FRAME ..........................................................................................................................................26 POWER LIFT UPPER FRAME...........................................................................................................................................27 POWER LIFT UPPER FRAME (BOTTOM SECTION) .............................................................................................................28 TABLE TOP FRAME........................................................................................................................................................28 MOBILE FRAME .............................................................................................................................................................30 DEPOSITING WITH HOT PRODUCT ..................................................................................................................................31

PNEUMATIC SCHEMATICS..........................................................................................................................................32

TROUBLESHOOTING ...................................................................................................................................................33

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PISTON RETURN SPEED CONTROL.................................................................................................................................35

CE MARK .......................................................................................................................................................................36

SOUND LEVEL MEASUREMENT .................................................................................................................................37

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Safety Instructions and Warnings

These safety instructions must be read prior to operating, sanitizing or servicing the equipment. All machines have a risk of personal injury wherever moving parts are involved in their operation. UNIFILLER has taken all possible precautions to reduce and wherever possible eliminate the dangers associated with moving parts. Having all operators of this equipment read and abide by the instructions in this manual will further reduce the risk of personal injury.

Turn air off and remove supply line from machine before attempting to clean, dismantle, or service the machine. Keep fingers and hands away from all mechanical moving parts including the hopper inlet and deposit nozzle outlet. Do not try to service the Air regulator / Water filter with the air supply line connected. For servicing or technical support please contact UNIFILLER directly or one of its authorized suppliers or dealers. Do not run product or water, with temperatures exceeding 140 deg F (60 Deg C), through the machine. For Product Temperatures that exceed 140 deg F (60 Deg C) up to 180 deg F (82 Deg C), please use HOT changeover parts on the machine. Operating Air pressure should not be adjusted to exceed 80 P.S.I. (551 kPa /5.52 Bar) on the Air regulator / Water filter pressure gauge. Always wash out the machine after use, dismantle and lubricate all the seals (As per cleaning instructions in this manual). Follow the enclosed instructions carefully before operating the machine for the first time, or maintenance. Before use ensure that the locks on the wheels are engaged. Unifiller Systems recommends the use of personal protection equipment approved by the safety regulators in the country of use. IMPORTANT: All stainless steel parts are coated with a protective coating at the factory and therefore any stainless steel parts that may come into contact with product must first be washed in hot water and detergent.

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Introduction Thank you for purchasing Unifiller Equipment. We are sure you will get years of trouble free use and excellent productivity from your new investment. Please take a few minutes to read this manual and familiarize yourself with the layout of the controls, and the set up and operating procedure. If you have any questions regarding the setting up, or operation of your equipment please contact us.

Contacting Unifiller

OR Contact your local authorized Unifiller dealer. Please see our website for dealer contact information @. www.unifiller.com Please remember to supply your company name, telephone number, email and a contact name when ordering parts.

Manufacturer Unifiller Systems Incorporated, 7621 Macdonald Road Delta, B.C. V4G 1N3 Telephone Main: 604-940-2233 Toll Free: 1-888-733-8444 Fax : 604-677-5844 Email: parts@unifiller.com

EU Contact Barclay – Phelps, Atlantic House, High Road Wood Green London N22 8HH

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Machine Description The Compact is an air operated positive displacement depositor.

Intended uses Non intended uses Batter for cakes, muffins, etc Dry goods Fruit fillings Large chunks

Icings, frostings and toppings Liquids Jams and jellies Stiff non settling products Creams, custards and mousse Anything that can be squeezed through a pastry bag

Compact Power Lift

# Description 1 Up / Down Control Valve 2 Air Connection 3 Volume Adjustment 4 Deposit Speed Control 5 Air Regulator / Filter

6 On / Off Adjust Switch 7 Product Cylinder 8 Table Lock 9 Work Table

10 Hopper Safety 11 UNI Block Air Cylinder 12 UNI Block

13 14 Gallon / 52 Lt Hopper

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Compact Mobile

Compact Table Top

# Description 1 Air Regulator / Filter

2 Air Connection 3 Deposit Speed Control 4 On / Off Adjust switch 5 Table Lock 6 Hopper Safety 7 Product Cylinder

8 Work Table 9 UNI Block Air Cylinder

10 UNI Block 11 14 Gallon / 52 Lt Hopper 12 Volume Adjustment 13 Depositor Height Adjustment

Clamp (not shown)

# Description 1 Air Regulator / Filter

2 Air connection 3 Deposit Speed Control 4 Volume Adjustment 5 On / Off Adjust Switch 6 Hopper Safety 7 Table Lock 8 Work Table

9 UNI Block Air Cylinder 10 UNI Block 11 14 Gallon / 52 Lt Hopper 12 Product Cylinder

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Serial Number location Quote this number when ordering spare parts. It is located as shown, stamped into the side of the base. .

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l

Power Requirements

Air Requirements

Important: • It is recommended that the compressed air supplied to the depositor be run through an air

dryer before connecting to the machine. Please contact Unifiller for details.

• Use an airline with a minimum inside diameter of 3/8” (10mm)

• Set the air pressure gauge on the machine to 80 P.S.I. (6 Bar). Connect your supply air hose that comes from your compressor (not supplied) to the quick connector (1) which is located as follows: Power lift - On the main upright of the frame on. Mobile - On the Air pressure regulator for the. Table top - At the end of the air line from the Air regulator . Set the air pressure gauge on the machine to 80 P.S.I. (6 Bar) by pulling up the knob (1), adjusting the air pressure, and then pushing the knob down to lock it.

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Assembly and operation NOTE: Before filling the hopper, ensure the machine is assembled correctly with seals in place, and that the correct depositing outlet attachment is fitted and all clamps are tightened.

Hopper Safety Plug Some versions of the Compact may not have the hopper safety plug feature. If installed the machine will not operate until the Hopper Safety plug (1) is connected to the quick disconnect on the side of the base.

Warning: Compact Power Lift only.

To avoid possible tipping of the machine, keep the area under the work table clear.

• To raise the machine, move and hold the Black lever in the up position(1). The machine will stop if the lever is released.

• To lower the machine, move and hold the lever in the down position (2). The machine will stop if the lever is released.

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Depositing Accessories set up The Depositing Nozzle and the foot pedal airlines are connected to the ports located on the side of the base If using a Hand held nozzle, the four lines will connect to the foot pedal port and accessories port. Remove the cap (5) if fitted.

If the foot pedal is being used with an attachment that does not have an Air cylinder i.e. (injection needles) connect the cap (5) on to the male fitting (3) of the accessories quick disconnects to prevent air loss.

Priming / Preparing to Deposit

• After sanitizing (See sanitizing section), fill the hopper.

• Connect the depositing attachment and or foot pedal to the machine using the appropriate clamps and quick disconnects.

• Connect the air supply.

• Depress foot pedal or hand held nozzle trigger until product flows from outlet.

# Description

1 and 2 Foot pedal or external signal connection

3 and 4 Nozzle / Accessory connection

5 Cap

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Deposit Speed Control The deposit speed (1) controls the speed at which the product is placed into the target area. Turn clockwise = decrease deposit speed Turn counter clockwise = increase deposit speed

Important: If a deposit speed adjustment is made after the volume has been set, the volume may change slightly, so be sure to re-adjust the deposit volume if required.

Volume Adjustment

• Press the pedal or trigger on the hand held nozzle once and 1 measured amount will be deposited.

• For continuous deposits press and hold.

• Run the machine 2 or 3 cycles, check the weight of the last deposit.

• Adjust size of deposit by turning the switch on the side to OFF / ADJUST position.

• Unlock the handle on the side of the machine by turning it counter clockwise and slide the handle to the desired setting.

• Re lock the handle, then turn the switch back to ON.

• Make 2 or 3 deposits into a container and check the weight, adjust the volume again if required.

# Description 1 Volume % scale. 2 Control switch set to

“OFF/ADJUST”. 3 Volume locking handle.

Shown in the ‘Lock” position.

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Working with the Depositor If you experience splashing of the product when depositing, slow down the deposit speed as described previously. If the product is deposited too slowly increase the deposit speed. Keep the hopper more than ½ full to avoid air pockets and inconsistent deposits / portions.

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Disassembly for Sanitizing

General

• Sanitizing requires that the machine must be disassembled.

• Turn air off and remove supply line from machine.

• Scrape down the inside of the hopper.

• Reconnect supply line and turn Air on.

• Keep depositing until nothing more comes out of the outlet nozzle.

• Turn air off and remove supply line from machine.

• Pour warm water (maximum 140 deg, F 60 deg C) into the hopper and wipe the inside of the hopper clean.

• Reconnect supply line and turn Air on.

• Reduce deposit speed.

• Cycle the rest of the water out of the machine.

• Repeat the above procedure.

• Turn air off and remove supply line from machine.

• Disconnect attachment airlines from machine.

• Connect the red and black quick connects together. This will stop water from entering the air cylinders during cleaning.

DO NOT SUBMERGE THE AIR CYLINDERS IN WATER.

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• Remove Hopper and place top downwards on a sanitary surface.

• Unclamp depositing attachment.

• Remove the UNI-block insert, by removing the clamp and pulling the assembly out.

• Slide Air cylinder out of slot.

• Pull the Red safety pin out from the side.

• Remove the UNI-block by: 1. Tilt up the UNI block (1). 2. Slide UNI block forward (2),over tab (3)

• Remove the product cylinder by sliding forward.

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• Remove the product piston.

• NOTE: Use O-Ring tool to remove all O-Rings

Cleaning and Sanitizing

Cleaning Clean and sanitize the parts shown, and any attachment parts.

• Mix 1 to 4 ounces (30-120ml) of Zep F.S. PROCESS CLEANER (green) per gallon (4ltr) of water. Immerse the parts in the solution. Clean all food residues with a cloth or a non-metallic scrubbing pad/brush. Rinse thoroughly with potable water. For the hopper, spray the same solution on to the Hopper surface.

Item Description 1 Clamp 2 Product Cylinder 3 Product piston O

Ring 4 Product Piston 5 Safety Pin

6 Hopper Gasket 7 Product Cylinder O

Ring 8 Uni Block 9 Uni Valve O Rings

10 Uni Valve

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Sanitizing • Mix 1 ¼ oz’s (120ml) of Zep F.S. SUPERMARKET SANITIZER (red) per gallon (4ltr) of

water. Immerse all parts that were previously in the cleaner in the new solution for 1-2 minutes. Rinse thoroughly with potable water.

Re Assembly

• Inspect all ‘O’ rings and seals for damage or wear; replace if required. Re-lubricate all O rings with food quality grease (as supplied with your machine).

• Re-assemble in the reverse order taking care to center the stainless steel pin of the Air cylinder with the cutout in the UNI valve assembly,

• Re-connect all the airlines The rest of the machine can be wiped down or washed with a mild detergent.

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Maintenance

Turn air off, and remove air supply line from machine before any maintenance is performed.

IMPORTANT SAFETY NOTES: Any maintenance to the pneumatics system will require the top cover to be opened and removed. Turn air off and remove air supply line from machine before opening the cover. If top cover is removed beware of pinch points Maintenance personnel will require a Phillips screwdriver to open the cover. The top cover is held in place with 2 screws’ (1 and 2) as shown in the pictures. Remove both screws and lift cover off.

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O Ring Care The most important components of the machine are the O rings. These must be inspected and maintained daily. All O rings should be high quality Viton as supplied by Unifiller, or your authorized Unifiller dealer. Signs of wear include: Flatness, Abrasions, Cracks, and Cuts

Daily After parts have been cleaned, lubricate all O rings, seals and moving parts with food grade grease.

Weekly With the air disconnected. Check the air filter/regulator bowl and if necessary clean the bowl and empty any accumulated water.

3 Months With the air disconnected. Check the condition of the White filter in the Air regulator / Water filter, and replace if contaminated.

O Ring and Gasket Part numbers

Description Part Number Quantity Required Hopper Gasket 01250-00 1 11/2” Clamp Gasket 01251-00 1 Uni Valve O ring V0222-00 2 Product Cylinder O Ring V0222-00 1 per Cylinder 1” (25.4 mm) Product Piston O Ring V0115-00 1 per Piston

1 ½” (38.1 mm) Product Piston O Ring V0216-00 1 per Piston 2” (50 mm) Product Piston O Ring V0223-00 1 per Piston 2 ½” (63.5 mm) Product Piston O Ring V0227-00 1 per Piston 3” (76.2 mm)Product Piston O Ring V0230-00 1 per Piston

The following parts are available from Unifiller or one of its authorized representatives.

Part Number Description Item 21052-00

O ring lubricant. 4 oz tube Lubri-film plus.

22049-00

O-ring pick tool.

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Spare Parts

Product Cylinder Sizes To obtain the most accurate deposit volume, 5 different sizes of product cylinder and product piston are available. See chart following. To maintain portion accuracy, it is recommended that the % volume setting for the machine be set between 12 to 80% of the scale, this will ensure optimum machine performance.

Size Piston and Cylinder Kits Part Numbers

Volume (Oz) Volume (ml)

1” (25.4 mm) 15031-00 0.3 –1.7oz 10 – 48 ml 1.5” (38.1 mm) 15032-00 0.4 – 4.1oz 12 – 122 ml 2” (50 mm) 15047-00 0.8 – 7.6oz 23 – 226 ml 2.5” (63.5 mm) 15033-00 1.2 – 12.3oz 36 – 363 ml 3” (76.2 mm) 15034-00 1.8 – 18.0oz 53 – 532 ml

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Parts Identification It is highly recommended to carry a complete spare set of ‘O’ rings and seals, as these are vital to the accuracy of the machine. See O ring care section for a full list.

UNI Block

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RH Side Connections

Base Components LH

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Base Components RH

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Underside Pneumatic Components

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Adjustable Table (Power lift and Mobile)

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Power Lift Lower Frame

27

Power Lift Upper Frame

28

Power Lift Upper Frame (bottom section)

Table Top Frame

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Adjustable Table-Table Top

30

Mobile Frame

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Depositing with Hot Product

The depositor is supplied with standard product piston and Uni valve, used for products up to 60°

C/140° F.

For products above 60° C/140° F and up to 82° C /180°F, a hot product piston and Uni valve should be used. Contact Unifiller customer service for details. Hot UNI valve part number: 00501-03 For hot product piston part numbers see page 16. The “HOT” versions of both parts are identified by the word “HOT” stamped into the end of each one.

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Pneumatic Schematics

Pow

er Lift

Mob

ile

Tab

le Top

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Troubleshooting IMPORTANT SAFETY NOTE: The machine will not operate until the Red handled block pin is fully inserted.

Problem Cause Remedy Machine will not cycle.

Low air pressure.

Check air supply for correct operation. Also check pressure regulator setting (80 psi/5.5bar).

Air on/off rotary switch is in the “Off/Adjust” position.

Turn rotary switch to the “On” position.

Rear pilot valve has loosened from its mount bracket or is damaged.

Check rear pilot valves that they are secure. Replace if necessary.

Incomplete piston stroke caused by solid object in product cylinder

Remove product cylinder and check for obstruction.

Volume adjustment set too low. Increase volume setting. Deposit speed set too low. Adjust deposit speed.

Kinked air lines. Check air lines to make sure they are not kinked.

Product being deposited is too hot. Ensure product temperature does not exceed 140 deg F (60 deg C) unless HOT valves are in place.

Red Uni block pin is not inserted Insert pin fully. Inconsistent deposits

Air leakage past product piston seal, possibly worn or damaged.

Replace ‘O’ ring. Use ‘O’ ring template at the back of this manual.

Hopper almost empty and sucking air.

Fill hopper or scrape down.

Large air pocket in product mix. Use product mix as soon as it comes off the mixer.

Product inconsistent. Supply smooth product mix and inspect seals and O-Rings for wear.

Deposit return speed too fast.

Turn air off and remove supply line from machine before opening the cover.

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Adjust piston return speed control to slow down back stroke. See page 35

Air leakage past loose clamps. Check all clamps and ensure all flat seals are in place and in good condition. Replace seals or tighten clamps as required.

Deposit speed set too high. Reduce deposit speed

Fluctuating air supply pressure. Check setting of air regulator / water filter.

Water build up in air lines and valves.

Drain air compressor regularly to remove build up of water.

Thick product mix. Reduce deposit piston speed.

Machine cycles but will not deposit

Hopper is loose or beveled seal is missing.

Check that the beveled seal is in place and is not damaged. Re tighten hopper nut.

Air quick connects are not secure. Check all air connections are securely attached.

Product valve piston jammed. (Positive cut off nozzle only).

If the product you are depositing is over 150 Deg F (60 Deg C), change the product valve to the high temperature version).

Product piston ‘O’ Ring worn or missing.

Replace ‘O’ Ring.

Product leakage Clamps not tight. Check all clamps for tightness.

Flat seal missing or damaged. Check that the flat seals are in place and are not damaged.

Product piston ‘O’ Rings worn or damaged.

Replace ‘O’ Rings.

Product tails from nozzle. (Positive cut off nozzle).

Deposit speed set too low.

Increase deposit speed adjust deposit setting using adjuster located on the top cover

Product splashes Deposit speed set too fast. Decrease deposit speed adjust deposit setting using adjuster located on the top cover

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Piston Return Speed Control This is a factory setting and should not normally need to be adjusted. (See trouble shooting section under inconsistent deposits).

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CE Mark

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Sound Level Measurement All sound level readings taken at 1m from the front of the machine and 1.6m from the floor level. All readings are “A” weighted emission sound pressure level.

Machine Sound level dB Compact Depositor 79.4 Uni1000i 72.9 Pro 1000i 72.9 Pro 2000 78.7

Spot 87.5 XL2 81 COM Servo 72.9 Deco Mate 78.0 Hopper Topper 72.0 Hopper Topper Max 82.5 Multi 87