KWT-860R

Six Nozzle Filler

Operation Manual
 Preface
Thank you for purchasing and using our machines.

Our filling machine feature PLC control and digital

touch screen. With the device of setting parameters

in filling speed, our machine offer excellent and

stable filling quality. The large LCD touch screen

clearly shows various filling parameters without the

defects of misunderstanding and easy to breakdown

which are usually happened to on / off switch device

or mechanical diaphragm-type keyboard. We do

not care about high cost and just want to share with

you the technology advancement.

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 CONTENTS
A：GENERAL SPECIFICATIONS
1). Machine Specification and Layout …………….……………….3
2). Parts Identifications……………………………………………....5
3) Panel Layout……………………………………………………...11
4). Instruction of three-point generator and functions of
solenoid valve. Air pressure meter and air pressure detector.12

B：SAFETY REGULATIONS
1). General Safety Regulations……………………………………...12
2). Notice…………………………………………………...................12

C：INSTRUCTION OF USE CONTROL PANEL

1). Human/Machine Interface LCD Displays Controller ………...14
2). Preparation and notice of installment ………………………....24
3). Operation ………………………………………………………....25

D：TROUBLE SHOTING ………………………………………….26

E： Motor / Magnetic Switch list................................................27

F：Circuit Diagram attached......................................................29

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A : GENERAL SPECIFICATIONS
1.) Machine Specification and Layout

Specification：
Model No. KWT-860R Six Nozzle FillerMachine
Dimension L. 4885 * W.2010 * H.2295 mm
Machine Weight 1200Kgs
Power Source 380V, 50Hz, Three Phase
Filling Volume Adjustment Variable Adjustment
Filling Speed Adjustment Invert
Filling Speed 0-30 pcs/per minute
Tank Capacity 150 Liter
Optional Accessories 1.Turn Table 2. Pump
3.Conveyor Extension
Control System MITSUBISHI PLC Control System and
Digital Touch Screen

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2). Parts identifications :
1. Power :
Main Power Switch
2. Emergency Stop Button :
For stopping machine in case of emergency.
3. Conveyor 1 Speed Inverter :
For adjustment the conveyor speed by top △ and down ▽ key.
4. LCD Touch Screen Control Panel :
For digital adjustment to ensure filling accuracy and quality.
5. Filling Pump Speed Inverter :
For adjustment the pump speed by top △ and down ▽ key.
6. Reed Switch :
Control the delay time of large air cylinder and fixed level filling time,
divided into three parts: Up, Middle, Low.
7. Large Air Cylinder :
Filling nozzle dipping into bottle when filling to ensure filling speed smoothly
and quickly.
8. Bottle Holding Speed Inverter :
For adjustment bottle holding speed by knob.
9. Aluminum Alloy Guide Rail :
For separating the dual conveyor.
10. Conveyor 1 Motor :
Driven for conveyor 1.
11. Liquid Supplying Hole:
For supplying liquid into the liquid tank.
12. Storage Tank :
For storing the liquid.
13. Outlet Sensor :
For detecting the filled bottle after filling.
14. Inlet Sensor :
For detecting the empty bottles before filling.
15. Run-Out Switch :
Open the switch to run out the liquid from the liquid tank. Close the switch
after cleaning the liquid tank.
16. Air Gate 1 :
The gate will open and allow 6 empty bottles entering the filling station.
17. Air Gate 2 :

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 The gate will open after filling and it will close after 6 filled bottles passing
through.
18. Ball Valve Switch:
Combine with large LCD and electric-magnetic valve to volumetric control
when ball valve filling.
19. Air Cylinder for Filling Nozzle Assembly :
Filling nozzles are moved forward and backward by air cylinder in order to
fill the dual lane.
20. Filling Nozzle Assembly :
Filling nozzle assembly dive into bottles, and then start filling.
21. Drip Tray :
For collection the liquid drip down from filling nozzle. Drip tray will back
when start filling. There are internal and external drip tray
22. Air Cylinder for Neck Holder :
For fixing the bottle mouth. There are internal and external.
23. Rotary Filling Pump :
For filling the liquid into the bottle.
24. Backlog Sensor：
Fiiling will stop while bottle is jammed.

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 3).Panel Layout

4 5 6
8

9
3

2 16

10-15

17
17

18
21
22
20

1. HMI (Touch Screen) 10-15. Filling motor driver

2. Start/ Stop switch 16. Power Supply A. B.
3. Emergency switch 17. Power Supply A3. B3
4. PLC (FX2N-32MR) 18. Conveyor motor driver
5. PLC (FX0N-8EYR) 19. Motor driver connection cable
6. PLC (FX2N-8EYR) 20. Liquid level controller
7. Realy 21. Magnetic contactor CN-35
8. Fuse 22. No-Fuse Breaker 50A
9. Fan

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4).Instruction of three-point generator and functions of solenoid valve air pressure
meter and air pressure detector
1. Manual Locking Switch for Air Supply.

2. Air Pressure Adjustment Knob: the pressure meter must be at 5-6 Kgf/cm2

3. Water Discharge Switch: The hydrosphere will damage of machine, this

switch will automatically eliminate the hydrosphere from compressed air.

4. Lubricant Storage Tube: for lubricating cylinder. Turn anti-clockwise and

remove it. Fill the lubricant # RS32 into the tube.

5. Air Pressure Detector: Air pressure is required at 3-4 Kgf/cm2, otherwise the
machine will shut down automatically.

6. Solenoid Valve: Control the injection and ejection of the compressed air.

7. Lubricant Slot: Use flat screw driver to remove the screw to supply lubricant.

8. Lubricant Adjust Button: Turn left for feeding more lubricant, turn right then less.

1. Air Pressure Adjustment Knob

2. Manual Locking Switch for air supply
3.Air Pressure Meter
4.Water Filter Tube
5.Water Discharge Switch
6. Lubricant Storage Tube
7. Air Pressure Detector
8. Air Pressure Meter
9. Solenoid Valve
10.Lubricant Supplying Hole
11.Lubricant Adjustment Knob

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B. SAFETY REGULATIONS

1). General Safety Regulations

1. Check to verify that power source meets machine requirement.
2. Be ensure the main power is fixed stable before connecting it to power box.
3. Never connect improper power voltage to power box.
4. The power should be away from humidity and properly grounded.
5. Power outlets must be installed by a professional electrician.

2). Notice
Please study he observe the following safety regulations.

Read this operation before installing the machine.

1. Be ensure the correct voltage for machine. Never use the long or slim extended cable
wire. Use a voltage regulator if local electronic current is not stable.
2. The machine should not be installed location high temperature or wet areas.
3. Technical adjustments are only to be done by a trained technical engineer and never
open electric box or connect cable without permit.
4. Never clean machine by using the aggressive, acid, caustic liquid.
5. Keep away from moving machine parts while machine is in operation.
6. Push the red emergency stop button to stop machine immediately in the event of any
machine malfunction.
7. Never clean electrical components with water.

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C. INSTRUCTION OF USE CONTROL PANEL

Human / Machine Interface Control Panel :

Turn on the main power switch, the LCD touch screen will show following job selection.

1. PLC BATT CHANGE : The light of PLC BATT CHANGE key will illuminate while low battery.
You may contact with us to get a new battery for placement.
2. MAIN SCREEN : Press the key to enter main screen.
3. MEMORY NUMBER : Press the key to enter memory number.
4. OPERATION SCREEN : Press the key to enter operation screen.

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Main Screen:

Press MAIN SCREEN key, LCD display will show 10 different windows for function selection.

1. I/O TABLE : Press to check the status of input and output.

2. FILLING TIME SET 1, 2 : Press the key to set the filling time.
3. MANU SCREEN 1, 2 : Press the key to enter manual operation screen.
4. MEMORY NUMBER : Press the key to enter memory number, set and recall job memory.
5. OPERATION SCREEN : Press the key to enter the operation screen.
6. TIME SET : Press the key to adjust the up/down delay time of the large air cylinder.
7. QUANTITY : Output in total.
8. STATUS : When the machine don’t work abnormally, please enter the key to check which
mechanism has problems.
9. FILLING SET : Press the key to choice the required filling nozzle.

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Operation Screen

Press the OPERATION SCREEN key to start operation.

AIR PRESS：The light will turn off once the compressed air is sent to three-point generator .

EMG1-2：Unscrew the EMERGENCY STOP BUTTON when this key illuminate. Unscrew the
button clockwise direction shows on EMG STOP button. The EMG1-2 will be off after
turn off the Emergency Stop Button.

START/STOP：Press it and filling machine will run automatically under AUTO mold.

AUTO/MANU：Enter automatic status when the key is pressed on. Light on for AUTO mold. Light
off for MANU mold.

CONVEYOR RUN/STOP：Press the key, when filling area stop. Conveyor will run after ending
filling.

CONV：Press the key and conveyor will run. The conveyor will stop when the light off.

BOTTLE HANDLE : Because one bottle have two messages, so have to press this key.

LQ LOWER : To warn the liquid is lower than minimum.

FEED：To Start the material feeding motor pump.

NOT CHECK LEVEL：When liquid is lower than minimum, do not need to check level.

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Time Set

1. SET KEY : Press it and start to adjust the time. Press it again after adjustment.

2. Time Adjustment Keys from right to left side : RST / -1 / +1 / +10

RST : To erase figure.
-1 : Press it minus one. +1: Press it plus one. +10 : Press it plus ten each time.

3. UP TIME SET : The time for filling nozzle lift up from the bottle during filling cycle.
4. OPEARTION DELAY TIME: Bottle into the filling then accumulate sensor illuminate the
bottle through all second bottle than filling action.
5. SECOND SLOW SPEED TIME SET: The required time of the final filling section.
(The time for the second filling section - slow speed filling).
6. FIRST SLOW SPEED TIME SET : The required time of the first filling section.
(The time for first section filling section - slow speed filling).

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QUANTITY : The total amount of production quantity.

Press RESET key, the figure will be cleared. Press MAIN SCREE key, then back Main Screen.

MEMORY SET:

To place new job setting into memory or to recall job setting from memory.
1. Press the SET KEY .
2. Press the CLR key to CLAER memory number set.
3. Press the number that you want to save into the job memory number.
4. Press ENT key for final confirm.
5. Press the SET KEY to save the job setting data into job memory.

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FILLING TIME SET 1：
1. Time Adjustment Keys from right to left side : RST / -1 / +1 / +10
RST : To erase figure.
-1 : Press it minus One. +1: Press it plus One. +10 : Press it plus Ten each time.

2. SET key : Press it and start to adjust the time. Press it again after adjustment.
3. FILLING TEST : Press it and enter the filling test screen.
4. H1 TIME : If you need filling more or less , you can adjustment keys.
5. H2 ~H4 TIME : The same method like as you did for H1 .

FILLING TIME SET 2：

1. SET key : Press it and start to adjust the time. Press it again after adjustment.
2. Time Adjustment Keys from right to left side : RST / -1 / +1 / +10
RST : To erase figure.
-1 : Press it minus One. +1: Press it plus One. +10 : Press it plus Ten each time.
3. FILLING TEST : Press it and enter the filling test screen.
4. H5 TIME : If you need filling more or less , you can adjustment keys.
5. H6 TIME : The same method like as you did for H5 .

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FILLING TEST :

1. Press the FILLING TEST key for testing.

2. Press H1 key and start to test.
3. If the filling volume is more (or less) than expected filling volume after test,
Press FILLING TIME ADJ key to adjust the filling volume that you want.
4. Press H2 ~ H6 key and start to test. The same method like as you did for H1 .

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MANU 1 SCREEN：

1. H1 JOG ~ H8 JOG : Press the keys to fill the liquid into pipes before
running. To remove the air from the pipes and ensure the filling quality.
2. Press UP to arise the large cylinder or press DOWN to depress it.
3. STOP 1 STOP 2 : for holding the bottle while filling.
4. DRIP TRAY : Press the key, the drip tray will move forward and backward.
Press the key, the bottle holding device will move backward.
5. PRESS BOTTLES : The air cylinder for holding bottles while filling.
Press the key, the gate will move backward.

MANU 2 SCREEN

1. Press SWITCH VALVE 1 or SWITCH VALVE 6 for testing ball valve is normal or not.
2. Press H1 DSB ~ H6 DSB then filling nozzle 1 ~ 6 start filling separately.

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CLEARING : For cleaning the filling pipes.

Press H1 to clear the filling pipe for filling head 1.

Press H2 to clear the filling pipe for filling head 2.
Same procedure for the other filling pipe 3 , 4.

FILLING SET : To choice the filling nozzle.

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I/O TABLE 1 :

This screen is designed for electricians for inspection of circuit situation purpose only.

I/O TABLE 2 :

This screen is designed for electricians for inspection of circuit situation purpose only.

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2.Preparation and notice of installment :
 Check to verify that power source meets machines requirements and the machine must
be properly grounded.

 Set compressed air pressure at requirement figure, weak air pressure will cause on
performing and incorrect filling volume.

 Open the liquid inlet of spiral filling pump and fill the liquid fully. The hose also need to be
filled with liquid fully. The spiral filling pump will be damaged badly while no liquid inside it
and keep it rotating continuously. Only fill the liquid into the storage tank fully
if above optional item is available.

 Press the POWER button and JOG button, the liquid will fill the hose soon.

 Adjust the filling speed and filling time. The faster rotating the shorter filing time will be
required . The longer rotating, the longer filling time will be required. The filling time and
filling speed shall be adjusted properly depending on the liquid viscosity.

 Reset the COUNTER to zero.

 Check the lubricate on a regular time schedule.

 Stop operating the machine while no liquid. The spiral filling pump will damage
in case of no liquid inside of the filling pump while machine is running condition.

 AUTO is available when having long been familiar with operation.

 Set level pads on a flat and vibration free floor /foundation properly.
(shown as following diagram 1)

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3. Operation

 Filler
1. Connect air pipe from air compressor and push manual locking switch for air supply.

2. Turn on power source, press MANU1, enter PRESS BOTTLE, and then air cylinder
stretches out. Please adjust guide rail and filling nozzles in this period, in order to the bottle
mouths aim at the filling nozzle.

3. Press STOP 1, the air cylinder stretches out , then adjusting air gate position until touch first
bottles.

4. Adjusting outlet sensor position. Next, please examine when each bottles go through the outlet
sensor, the light is able to on and off once. And bottles have already passed STOP 2 when the
sensor light off.

5. Press STOP 2, the air cylinder stretch out, then adjusting air gate position until touch bottles
between eighth and ninth.

6. Adjusting the position of in-feed sensor. Next, please examine when each bottles go through
the in-feed sensor, the light is able to on and off once. And the in-feed sensor continually
illuminate the ninth bottle.

7. Press MANU1, enter UP and DOWN, the large air cylinder will up and down. Please fix the
reed switch on up, middle, low position.

8. Enter MANU2, press H1DSB ~ H6DSB, and then filling nozzles will work, but not fill.

9. Enter OPERATION SCREEN, press AUTO/MANU, START/STOP and CONVEYOR. Next,

place bottles on the conveyor, check all of actions work smoothly or not. If there are not any
problems, please go head next steps.

10. Press MANU1, enter H1JOG~H8JOG. Please wait for liquid flow from filling nozzles.

11. Press MANU2, enter CLEARING, then press H1~H6. This function is used for sweeping
away air from flexible hose.

12. Press FILLING TIME SET1 FILLING TIME SET2 and set filling time for each filling nozzles.
Then press FILLING TEST to examine filling volume. If filling volumes don’t reach your required,
please back 1~4TIME SET , 5~6TIME SET and reset it

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D： Trouble Shooting

Problem Caused by To Repair

Air compressor does not work. Start air pump.
Air pressure insufficient. Change a suitable air pump.

Manual valve switch is locked. Push in the manual valve.

The machine does not fill The pressure of air pressure Adjust the pressure to 3-4kg
detector is too high.
The pressure of 3-ponint
Adjust the valve to 5-6kg
generator is too low.
The emergency stop button is Lax the emergency stop
tight. button.

Fuse is broken. Change new fuse.

Dark screen Plug the wire into right
Wire mistakenly plug in. power position and make
sure if the fuse is broken.
Adjust the reed switch to
Solenoid Valve Switch is lax. the shine of signal lamp
Front / back stop and lock it tight.
cylinder and drip –trap Check the magnetic valve
cylinder do not work. Solenoid Valve Switch signal switch is broken or not if the
lamp is OFF. signal lamp is off during
adjustment.
Fixed-point delay and Solenoid Valve Switch unfixed. Fix it to right position.
down-press delay do not Solenoid Valve Switch signal Change it if the signal lamp
work. lamp is OFF. does not light.

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E. Motor / Magnetic Switch list
Motor list

NO. PART NO. Q’TY DESCRIPTION

17 GH22-750-7S 2 Motor

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 Reed Switch list

NO. PART NO. Q’TY DESCRIPTION

6 LN-01B 1 Control cylinder working.
Control the delay time of large
air cylinder and fixed level filling
7 LN-03A 3
time, divided into three parts:
Up, Middle, Low.

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 R1

T1

R1 30
GND
IN5 IN6 31 IN0
M0

U5 V5 W5 U6 V6 W6
U0V0 W0

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M5 M6 M0
30
31
32
COM2 Y24 Y25 Y26 Y27 Y30 Y31 Y32 Y33 Y34 Y35 Y36 Y37
Y34 Y35 Y36 Y37
Y24 Y25
IN6 GND
Y30 Y31 Y32 Y33
IN5 GND
COM7
IN6M0 IN6M3 IN5M0 IN5M3
5 6 7 8