The document provides technical details and instructions for an AF-3 filling machine. It includes: - An overview of the machine components and operation procedures. - Safety guidelines for transport, installation, operation and maintenance. - Mechanical drawings of the major assemblies - load cell & drum clamp, nozzle, and structure - with part lists. - Electrical & pneumatic diagrams showing connections, wiring and functions. - Parameter settings for the weighing indicator and maintenance instructions.

1. USER’S MANUAL
CM SPECIALIST PTE LTD

2. TABLE OF CONTENT
TECHNICAL DATA OF THE MACHINE Pg 2–Pg 4
TRANSPORT AND INSTALLATION Pg 5-Pg 6
CHAPTER
1. INTRODUCTION TO AF-3 Pg 7- Pg 16
2. INDICATOR DESCRIPTION Pg 17
3. CALIBRATION & FUNCTION SETTING Pg 21
4. SETTING FILLING WEIGHT Pg 25
5. INSRTUCTION IN CASE OF MALFUNCTION Pg 27
MECHANICAL DRAWING
- GENERAL ASSEMBLY (DWG NO: GA)
- LOAD-CELL & DRUM CLAMP ASSEMBLY (DWG NO: LB00)
- NOZZLE ASSEMBLY (DWG NO: NC00)
- NOZZLE HOLDER ASSEMBLY (DWG NO: NH00)
- STRUCTURE ASSEMBLY (DWG NO: SA00)
- MECHANICAL DRAWING PART LIST
ELECTRICAL & PNEUMATIC DRAWING
- ELECTRICAL CIRCUIT CONNECTION (DWG NO: E00)
- ELECTRICAL PANEL DIAGRAM (DWG NO: E01)
- PLC FPX0-L30R INPUT CONNECTION (DWG NO: E02)
- PLC FPX0-L30R OUTPUT CONNECTION (DWG NO: E03)
- PANEL SWITCHES (DWG NO: E04)
- PANEL SWITCHES WIRING (DWG NO: E05)
- INDICATOR I/O FUNCTION (DWG NO: E06)
- LOAD-CELL CONNECTION (DWG NO: E07)
- INSTALL POSTION OF SENSOR (DWG NO: E08)
- PROGRAMMABLE LOGIC CONTROLLER (DWG NO: E09)
- PNEUMATIC DIAGRAM (DWG NO: P00)
- PNEUMATIC LAYOUT (DWG NO: P01)

3. PART LIST
- STANDARD PART LIST
- ELECTRICAL & PNEUMATIC PART LIST
APPENDIX
- WEIGHING INDICATOR FUNCTION PARAMETER

4. TECHNICAL DATA OF THE MACHINE
1
TECHNICAL DATA OF THE MACHINE
Specification
Machine
Length : 860 mm
Width : 1700 mm
Height : 3100 mm
Electrical Supply
Operating volt : 230VAC+/- 10%, 1 phase
Control volt : 24VDC
Amp supply : 6A
Pneumatical Supply
Connection : dia 12mm pneumatic fitting
Operate pressure : 6 to 7 kg/sq.cm at o.2 cu.m/min
Quality : oil free, dried and filtered.
Product Inlet
Connection : stainless steel 304 ANSI-SO 150# Flange
Size : dia 2”
Supply Pressure Feed
: < 0.8 kg/sq.cm
Ambient Temperature
: -5 deg C to 40 deg C
Operating Humidity
: < 85% RH (non-condensing)
Structure
: mild steel. Stainless steel 304 for product contact part

5. SAFETY MEASURES BY THE USER
2
SAFETY MEASURES BY THE USER
Take note of the remark in the instruction manual
Please read the instruction manual especially the safety-instruction prior setting the machine
into operation. The instruction manual contains the most important remarks how to run the
machine according to safety standards. It has to be reminded by all the persons who work
with the machine. This specially effects all safety instruction.
Further on the current safety relevant directions and preventions of accidents in the
installation area have to be considered.
Dangers in operating with the machine
In spite of this there may occur dangers of life or body to the user or a third person, resp.
infringement of the machine or other material values, when the machine is running.
Obligations of user
The user is obliged only to let persons work with the machine who
 Have read and understand this instruction manual especially the safety and warning
hints.
 Have been instructed how to operate the machine.
 Are familiar with the basic current instruction of accident prevention and labor.
The user has to check in regular turns the safety and dangers relevant working of the
personnel in consideration of the instruction manual as well as the statutory instruction about
safety-safety and prevention of accident.
Obligations of the personnel
All persons who work with the machine are obliged before starting their work to:
 Read and remind the safety and warning remarks of this instruction manual.
 To remind the basic current instruction of the prevention of accident and labor safety.
Organizational measures
 The instruction manual has to be placed permanently ready to reach at the operation
area of the machine.
 General valid statutory and other binding regulation for prevention of accidents and
environment protection has to be allocated and reminded.

6. SAFETY MEASURES BY THE USER
3
 The user has to care for personnel protection equipment.
 All remarks concerning safety and dangers have to be kept up completely in a legible
status.
Protection device
 All existing safety devices have to check in regular turns.
 Before each starting up of the machine all protection devices have to be installed
correctly and have to be functional.
 Protection devices may only be recovered when the machine is on hold and protected
against unexpected restart.
Training of the personnel
 Only reliable personnel are permitted to carry out works on the machine.
 Only trained and instructed personnel should operate the machine.
 The responsibility of the personnel for the opening, starting up, maintenance and
repair duties have be fixed clearly.
 Personnel to be trained or to be instructed only should work on the machine under
permanent supervision of an experienced person.
Machine controlling
 It is not permitted to carry out program changes with the software.
 Only trained personnel with the adequate knowledge of the subject is permitted to
work with the control unit.
Safety measures in standard mode
 Machine should only be run in case that all protection devices and safety relevant
installation are available and functional.
 Before starting and running the machine it has to be ensured that nobody will be
threatening by the starting machine.
 At least once per shift, the machine has to be checked regarding visual outer damage.
 In case of malfunction the machine has to be stopped and protect immediately.
Failures have to be settled without and duly.
Maintenance and service

7. SAFETY MEASURES BY THE USER
4
 Set-up, maintenance and inspection works, prescribed in instruction manual have to
be carried out in time.
 Operators have to be informed before starting of maintenance works.
 In case of maintenance and service works the machine has to be switched off
completely and secured against unexpected restart by following means:
 Closed main switch and pull off key.
 Installing a warning sign at the main switch to avoid switching on
 All line components, working before or after the machine, have to be secured against
unexpected restart.
 Disconnect machine from external air supply and secure closing valve on
maintenance unit against unexpected restart.
 Retighten carefully loosened screw-connection and check solid tightness.
 Check the function of all safety devices after terminating maintenance works.
Constructional modifications / changes
 Changes or modifications on the machine may not be carried out without permission
of the producer.
 All modifications have to be confirmed by CM SPECIALIST PTE LTD
 Use only genuine replacement parts.
 In case of using foreign part, it cannot be guaranteed that they are according to the
producer’s technical specifications.
Dangers caused by electrical energy
 Electrical qualified personnel may only carry out works on the electrical equipment.
 The electrical equipment of machine has to be checked in regular turns. Inaccuracies
like loose connection or scorched cables have to be removed immediately.
 If works on voltage carrying parts are necessary, a second person has to be there in
order to switch off the main switch in case of emergency.
Cleaning and services of the machine
Used material and stuff should always be handled correctly.
 When handling oil, grease or other chemical substances, the safety instructions for the
very product have to be considered. It should especially be considered when cleaning
is done with solvents.
 Used material and stuff should be disposed nonpolluting.

10. CHAPTER 1 - INTRODUCTION TO AF-3
7
INTRODUCTION TO AF-3
Start-Up Final Check
 Set air pressure 5 to 6 bar.
 Check entire machine for broken, worn or missing components, loose nut or bolts.
 When air and the electrical supply are supplied to the machine, the lance will raise
automatically to the original home position. (Upper position)
Connecting to Air Supply
- To adjust the pressure, pull the pressure controller.
- Turn the controller to clockwise (+) to increase the pressure.
- Turn the controller to counter-clockwise (-) in case to decrease the pressure.
- Push the controller to lock the air service unit.
* Pressure range: 5-6 bar
Incoming air
supply
Air supply to machine
( tubing 12mm )
Air service unit
Pressure controller

11. CHAPTER 1 - INTRODUCTION TO AF-3
8
Connecting to Power Supply
- Please do the connections as this diagram.
- Brown / Red (Live) L
Blue (Neutral) N
Green (Earth) E
Electrical panel

12. CHAPTER 1 - INTRODUCTION TO AF-3
9
Nozzle
Drum Clamp
Load cell
Cylinder Nozzle
Cylinder Lance
Up/down
Electrical &
Pneumatic Panel
Machine View
Figure 1(a): Filling Machine (front)

13. CHAPTER 1 - INTRODUCTION TO AF-3
10
Switch Description (Operator Panel)
Figure 1(b): Operator Panel

14. CHAPTER 1 - INTRODUCTION TO AF-3
11
When depressed [START] button, it will start filling operation in auto.
START
TOP
Top mode is mean when the filling action start the lance descends to “MIDDLE” position
(under bunghole) until final weight reached.
BOTTOM
Bottom mode is mean when the filling action start the lance descends to “BOTTOM”
position of drum. While the optional prelim weight is reached, the lance will ascend to
“MIDDLE” position (under bunghole).
When switched ‘ON’, the switch is illuminated and power is applied to the MCB (switched
‘ON’). The 230V AC power has applied to weighing indicator and 24V DC power supply.
POWER
OFF ON
MODE
TOP BOTTOM
NET
MAN GROSS
MAN
This is manual mode when operator depressed [START] button, the lance will descends
down to position. Then depressed and hold the [START] button, the nozzle and ball valve
will open. When [START] button is released, the nozzle and ball valve will close. If [E-
STOP] button depressed, the lance will ascends to “UP” or “HOME” position.
NET
This is “NET” fill with auto tare. When empty drum placed into the weighing platform, the
weighing indicator will register the empty drum weight. When in this mode after depressed
the [START] button, the indicator will tare the empty drum weight and display will return
to 0.0KG but it is at “NET” reading.
GROSS
This is “GROSS” fill without tare. The empty drum weight is not tare and the display is at
“GROSS” reading.

15. CHAPTER 1 - INTRODUCTION TO AF-3
12
In case of emergency, when depressed [E-STOP] button, entire machine will stop all the
operation. The nozzle and ball valve will close; the lance will retract back to “UP” or
“HOME” position.
E - STOP
DRUM CLAMP
When depressed [DRUM CLAMP] button, the drum clamp device will clamp the
bunghole of drum.

16. CHAPTER 1 - INTRODUCTION TO AF-3
13
Operation Procedures
 With nothing on the weighing platform, the digital weighing indicator should indicate
0.0kg. If the display is not at 0.0kg, press the [ZERO] button on the weighing indicator
to get 0.0kg.
 Operator preset on weighing indicator for desired “ZERO BAND”, “OPTIONAL
PRELIM”, “PRELIM”, “FINAL” and “FREE FALL” (if needed) value for filling.
 When the empty drum placed into the weighing platform, the operator will depress
[DRUM CLAMP] button to locate the bunghole position. Then press [START] button.
If bottom mode, the lance will descend to “BOTTOM” position or if top mode, the
lance will descends to “MIDDLE” position. If the operation in “GROSS” modes, the
empty drum wills not tare and indicator display is at “GROSS” reading. If the
operation in “NET” mode, the empty drum weight will auto tare to 0.0kg before start
filling, but it is “NET” reading.
 At the top mode, the filling operation start fill product into drum, while the lance
descends to “MIDDLE” position which is approx. 50mm below the bunghole.
 At the bottom mode, the filling operation start fill product into drum, while the lance
descends to bottom position of the drum, and raise to middle position, when the
optional prelim weight was reach.
 When the “PRELIM” weight is reached, the ball valve will close and slow fill will be
activated to reduce the flow rate.
 When the “FINAL” weight is reached, the nozzle will close completely. And the lance
device will ascend back to “UP” or “HOME” position.

17. CHAPTER 1 - INTRODUCTION TO AF-3
14
OPERATION FLOWCHART
SEMI-AUTO MODE
SWITCH POWER ON
SWITCH TO NET MODE SWITCH TO GROSS MODE
SWITCH TO BOTTOM MODE SWITCH TO TOP MODE
PRESS DRUM CLAMP BUTTON PRESS DRUM CLAMP BUTTON
PRESS START BUTTON PRESS START BUTTON
START FAST FILLSTART FAST FILL
REACHED OP. PLIM WEIGHT
REACHED PRELIM WEIGHT
Put in the empty
drum
Ready for
Start Fill
Nozzle and ball valve
will activated
Lance move until bottom
level
Nozzle and ball valve
will activated
Lance move until middle
level
Lance move upward
until middle level
Drum clamp down Drum clamp down
A
Ball valve close and start
slow fill

18. CHAPTER 1 - INTRODUCTION TO AF-3
15
REACHED FINAL WEIGHT
END CYCLE
* NET MODE = Filling process will start from 0.0 kg
GROSS MODE = Filling process will start from drum weight
Nozzle closed & lance move
upward until top level then
drum clamp release
A

19. CHAPTER 1 - INTRODUCTION TO AF-3
16
MANUAL MODE
SWITCH POWER ON
SWITCH TO MAN MODE
SWITCH TO BOTTOM MODE SWITCH TO TOP MODE
PRESS DRUM CLAMP BUTTON PRESS DRUM CLAMP BUTTON
PRESS THE START BUTTON PRESS THE START BUTTON
PRESS THE START BUTTON PRESS THE START BUTTON
RELEASED THE START BUTTONRELEASED THE START BUTTON
PRESS THE STOP BUTTON
Ready for
Start Fill
Nozzle and ball valve
will closed
Lance move upward until top level
& drum clamp release
END CYCLE
Lance move until bottom
level
Lance move until middle
level
Put in the empty
drum
Nozzle and ball valve
will activated
Nozzle and ball valve
will activated
Nozzle and ball valve
will closed
Drum clamp down Drum clamp down

32. MECHANICAL
DRAWING

38. CM SPECIALIST PTE LTD
APPROVED :
MACHINE MODEL : AF-3 MODULES : DATE : 3/8/2015
ITEM DRAWING NO: / SPECIFICATION DESCRIPTION PART NO. QTY MATERIAL MECHANICAL WELDING FABRICATION S.YUNG TREATMENT POLISH REMARK
LB00
1 LB01 PLATFORM STRUCTURE 1
2 LB02 CDF-3 CONVEYOR 1
3 LB03 CDF-3 CONVEYOR COVER 1
4 LB04 PLATFORM STRUCTURE PLATE 1
5 LB05 RING ARM 1
6 LB06 DRUM CLAMP RING 1
7 LB07 CLAM SLIDE ROD 2
8 LB08 RING ARM MOUNT 1
9 LB09 CLYLINDER MOUNTING PLATE 1
10 LB10 CLAMP TOP PLATE 1
11 LB11 CLAMP BOTTOM PLATE 1
12 LB12 BASE STAND 2
13 LB13 BASE STAND PLATE 2
14 NC00
15 NC01 NOZZEL MOUNTING 1
16 NC02 SPRING LOCATION NUT 1
17 NC03 COMPRESSION SPRING 1
18 NC04 CYLINDER SPRING LOCATOR 1
19 NC05 CYLINDER MOUNTING PLATE 1
20 NC06 TOP PLATE 1
21 NC07 BOTTOM PLATE 1
22 NC08 COVER 1
23 NC09 JOINT BRACKET 1
24 NC10 ADJUST NUT 1
25 NC11 ROD 2
26 NC12 TEE JOINT 1
27 NC13 LANCE 1
28 NC14 CUP 2
29 NC15 LANCE FLANGE 1
30 NC16 SEAL 1
31 NC17 LANCE SHAFT 1
32 NC18 LOCKNUT TEFLON 1
33 NC19 NUT 1
34 NC20 SEAL CUP 1
35 NC21 TOP CHUCK 1
36 NC22 TEFLON CHUCK 1
37 NC23 LANCE TIP 1
38 NH00
39 NH01 TOP PLATE 1
40 NH02 BOTTOM PLATE 1

39. 41 NH03 SLIDER BASE PLATE 1
42 NH04 ARM 2
43 NH05 SHAFT 2
44 NH06 BLOCK 1
45 NH07 CONTROL PANEL MOUNTING PLATE 2
46 NH08 SLOT PIN 18
47 NH09 BRAKE HOLDER 1
48 NH10 CABLE CHAIN BKT 1
49 NH11 SENSOR HOLDER 3
50 NH12 SENSOR BKT 1
51 NH13 GUIDE ROD 1
52 NH14 BRACKET 2
53 NH15 WHIPPER BUSH 1
54 NH16 DRIP TIP 1
55 NH17 CONTROL PANEL 1
56 NH18 WHIPPER HOUSING 1
57 NH19 DRIP TRAY 1
58 NH20 TRAY BRACKET 1
59 NH21 HOLLOW 1
60 SA00
61 SA01 BASE 1
62 SA02 STAND 1SET
63 SA03 BALL VALVE BRACKET 1
64 SA04 PLC CONTROL BOX 1
65 SA05 INDICATOR PANEL 4401 1
66 SA06 CONTROL BOX ARM 1
67 SA07 CHAIN BRACKET 1
68 SA08 STUB"1 1
69 SA09 STAND 1
70 SA10 LEG STUB'1 1
71 SA11 2" SCH40 PIPE 1
72 SA12 2" FLEXIBLE HOSE ADAPTOR 1
73 SA13 2" SCH40 PIPE 1
74 SA14 CONTROL BOX BRACKET 1

54. CM SPECIALIST PTE LTD PRODUCTION PART LIST
LABOUR MATERIAL
01 LM16-LUU BEARING LETROMAX 2
02 60X600RL GRAVITY ROLLER ROKONMA 8
03 AMSA32X150-S CYLINDER AIRTAC AIRTAC 1
04 DGC-50-1000-G PPV A FESTO CYLINDER FESTO FESTO 1
05 LM20-LUU BEARING LETROMAX 4
06 HSP0320 CHAIN HSC AIM INDUSTRY 50
07 ASUD63X40 CYLINDER AIRTAC AIRTAC 1
08 27X5TXL111XC11 COMPRESSION SPRING RIVETECH 1
09 2"X90 ELBOW HUP SENG 1
10 2" PLANGE HUPSENG 1
11 2" BALL VALVE ACTUATOR SIRCA VALVE STORE 1
12 KP-8-350 CYLINDER BRAKE FESTO FESTO 1
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
DATE ORDER DELIVERY
DATE
TREATMENT VENDOR QTY
IN-HOUSE
REMARKSITEM MODEL NO. DESCRIPTION
BRAND /
MATERIAL
PROJECT TITLE : STD COMPONENT TECH. ASST.: CHECKED : DATE : 3/8/2015
MACHINE MODEL : AF-3 MODULES : PREPARED : APPROVED :

55. CM SPECIALIST PTE LTD PRODUCTION PART LIST
QTY
01 FPX0-L30R PLC PANASONIC IAC 1
02 LAY5-BD25 2 WAY SELECTOR SWITCH TECH AVE 2
03 LAY5-BD33 3 WAY SELECTOR SWITCH TECH AVE 1
04 LAY5-BA31 GREEN PUSH BUTTON TECH AVE 1
05 LAY5-BA51 YELLOW PUSH BUTTON TECH AVE 1
06 LAY5-BS542 E-STOP BUTTON TECH AVE 1
07 NBB5-18GM50-E0 INDUCTIVE PROXIMITY SENSOR P&F P&F 3
08 LRS 50-24 24VDC POWER SUPPLY MEAN WELL OSA 1
09 NGP061C 1 POLE MCB (6KA) EPS OSA 1
10 AD4401 WEIGHING INDICATOR A&D AF 1
(S.N:K4452421)
11 LC4204-K600 LOAD CELL A&D AF 1
12 302901 TERMINAL BLOCK SUPU OSA 50
13 AW30-03-A AIR SERVICE UNIT SMC SMC 1
14 SY7320-5G-02 SOLENOID VALVE SMC SMC 1
15 SY7120-5G-02 SOLENOID VALVE SMC SMC 4
16 SS5Y7-20-05 MANIFOLD SMC SMC 1
17 VT317-5G-02 SOLENOID VALVE SMC SMC 1
18 QJSC6-01(B) SPEED CONTROLLER ATC ATC 1
19 QJSC10-02(B) SPEED CONTROLLER ATC ATC 2
20 QPC12-04 AIR FITTING ATC ATC 1
21 QPC8-03 AIR FITTING ATC ATC 2
22 QPC8-02 AIR FITTING ATC ATC 6
23 QPC6-02 AIR FITTING ATC ATC 2
24 QPL12-04 AIR FITTING ATC ATC 1
25 QPL12-02 AIR FITTING ATC ATC 1
26 QPL10-03 AIR FITTING ATC ATC 2
27 QPL10-02 AIR FITTING ATC ATC 1
28 QPL6-M5 AIR FITTING ATC ATC 1
29 B2 BRASS FITTING ATC ATC 5
30 SL-02 SILENCER ATC ATC 2
31 RRSL-02 SILENCER ATC ATC 1
32 FSL-01 SILENCER ATC ATC 1
DELIVERY
DATE
REMARKS
MODULES :
TECH. ASST.:
BRAND /
MATERIAL
SUPPLIERITEM MODEL NO. DESCRIPTION
PREPARED : APPROVED :
CHECKED : DATE :
MACHINE MODEL : AF-3
PROJECT TITLE : ELECTRICAL & PNEUM
DATE ORDER

57. (A) WEIGHING INDICATOR FUNCTION PARAMETER
CALF- DESCRIPTION SETTING
VALUE
F01 Weighing Unit 2
F02 Decimal Point Position 1
F03 Minimum Division 0.1
F04 Capacity 300.00
F05 Set Zero Range 10
F10 Tare and Zero at Unstable Weight Value 1
F11 Tare at Negative Gross 1
F14 Weighing Mode 1
FNCF- DESCRIPTION SETTING
VALUE
F02 Capabilities of [F] Key 0
F04 Display Content of Subdisplay Section 4
INF- DESCRIPTION SETTING
VALUE
INF-02 Capabilities of Input Terminal A2 2
INF-03 Capabilities of Input Terminal A3 9
INF-04 Capabilities of Input Terminal A4 10
CALIBRATION RELATED FUNCTION SETTING VALUE
BASIC CAPABILITIES FUNCTION RELATED SETTING VALUE
CONTROL I/O INPUT RELATED SETTING VALUE

58. OUTF- DESCRIPTION SETTING
VALUE
OUTF-01 Capabilities of Output Terminal B1 1
OUTF-02 Capabilities of Output Terminal B2 4
OUTF-03 Capabilities of Output Terminal B3 5
OUTF-04 Capabilities of Output Terminal B4 6
CONTROL I/O OUTPUT RELATED SETTING VALUE