ZCDYG eye drops filling and capping machine

user's manual

ZCDYG eye drops filling and capping machine

user's manual

File number: ZCDYG-SY

Version number: 2021 (12)

Shanghai Soshine Pharmaceutical Machinery Co., Ltd

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ZCDYG eye drops filling and capping machine
user's manual

Table of contents

1. Introduction
2. Safety precautions
3. Product overview
4. Main technical parameters
5. Main components
6. Installation and commissioning
7. Operation
8. Replacement specifications
9. Maintenance
10. Packaging and Transportation
11. Consumable Parts List
12. Electrical configuration table and circuit diagram

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1. Introduction

Thank you for purchasing ZCDYG eye drops filling, capping and capping machine.

This manual introduces the principle, structure, function, technical parameters, transportation and
installation, operation and use methods and safety precautions of the ZCDYG eye drop filling and capping
machine. Please read before installing and using this equipment so that it can be installed and used correctly.
use.
2. Safety precautions
This machine must be installed, operated, and maintained by professional personnel. Before installation,
operation, maintenance, and inspection, please be sure to read this manual and its attached documents
carefully for correct use. And shall not operate in violation of regulations.
The equipment should be installed, operated, inspected, and maintained only after mastering the relevant
equipment conditions, safety information and precautions.
This manual is divided into two grades of "danger" and "caution" in the column of safety precautions.
DANGER: Disoperation will lead to a dangerous situation, which may cause damage to the machine.
Note: Disoperation will lead to dangerous situations, which may cause moderate or minor injuries, as well as
damage to equipment and objects.
In addition, the items recorded in the attention may also lead to serious consequences depending on the
situation.
The attention and danger signs recorded at the beginning of the article and in the text are important
contents, please strictly abide by them!
I. During installation
Danger
• When hoisting the equipment, do not stand below and do not stand on it. Be careful of collision and injury!
• Wiring must be done by a professional electrician.
• When wiring, please make sure that the power is off to avoid electric shock!
• This machine is not intended for use in potentially explosive environments.
• Be sure to ground reliably to avoid electric shock and fire!
Notice
• The machine should choose a place that is convenient for operation and loading and unloading of materials.
The distance between the machine and the surrounding space shall not be less than 800mm for maintenance
and repair.
• The machine does not need a special concrete installation foundation, but the ground must be flat and must
be able to bear the weight of the machine and moderate vibration. The base must be padded with a 12mm
thick rubber plate.
• The level must be calibrated (adjust the foot screw) when the machine is installed.
• Do wiring after the equipment itself is installed and adjusted.
• The cables entering and exiting the equipment must be protected by protective sheaths.
• When wiring, please confirm that the rated voltage of the power supply is consistent with the requirements of
the device.
• Please use special tools for installation and wiring.
• If the mechanical and electrical parts of the equipment are damaged or damaged, please stop the installation
and contact us in time.

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2. Runtime
Danger
• The machine must be operated by specially trained operators!
• Please lock the door of the control cabinet before power-on, and do not open it during power-on!
• Do not operate various electrical switches, buttons, and touch screens with wet hands to avoid electric
shock!
• When dealing with faults or cleaning up equipment, the power must be cut off! Live maintenance must be
carried out by professionals.
Notice
• The equipment room must maintain a stable temperature and relative humidity during operation.
• Do not open the fixed cover of the moving parts during operation to avoid danger.
• Grease and lubricate each lubricating part according to this manual before starting the machine.
• The operator should pay attention to observe the operation of each part of the machine during the
operation of the machine and is not allowed to leave the post after turning on the machine.
• If a fault occurs during the operation of the equipment, please press the emergency stop button, turn off the
power, and check the cause of the fault. Hard knocking and hard beating are never allowed during repairs, so
as not to damage the machine.
3. During maintenance, inspection, and parts replacement
Danger
• Be sure to cut off the power supply when performing maintenance inspections, replacing specification parts,
and cleaning!
• Live maintenance must be carried out by professionals, and protective measures must be taken!
Notice
• Non-designated personnel are not allowed to maintain and overhaul the equipment.
• Clean and replace all lubrication points and grease in the oil tank every 6-8 months of production.
• The dust inside the machine should be removed in time, and all screws and fasteners should be checked for
looseness and displacement and tightened.
• Regularly check and fasten the screws of each terminal block,
• Regularly check the conditions of all machinery and lubricating parts.
Danger
Do not modify the key parts of this equipment to avoid danger or performance degradation!
3. Product overview
ZCDYG eye drops filling machine is suitable for the packaging process of liquid filling and sealing of 5-15ml
bottles in the pharmaceutical industry. The structure of this model is reasonable, and the whole machine
meets the requirements of GMP. This machine is controlled by two sources of gas and electricity, and the
working surface is protected by stainless steel. The transmission of this machine adopts mechanical
transmission, which has the advantages of accurate and stable transmission, low loss, stable work, and stable
output, and is especially suitable for mass production.
Features:
3.1 The function of automatic feeding and secondary plugging, adopts the method of removing plugs and
covers by manipulators, and the high-precision indexer positions the turntable without gaps, accurate
positioning, and stable transmission.
3.2 It adopts double-head filling, upper cover, upper plug, screw cap, and peristaltic pump or ceramic pump
filling, accurate measurement, adjustable cleaning, and maintenance.
3.3 The high-precision cosine acceleration cam drive makes the capping head more stable; the constant
torque capping and automatic slipping device protects the cap from injury.
3.4 Touch screen full control, PLC intelligent control, simple operation, convenient man-machine dialogue.

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3.5 No bottle, no filling, no inner plug, no inner plug and no outer cover, accurate measurement, simple
operation, etc.;
Main technical parameters
1. Production capacity: ≥80 bottles/min
2. Applicable specifications: 2ml-10ml (change mold)
3. Production qualification rate: not less than 99%
4. Power supply: 220V, 50Hz
5. Total power: 4.0kw
6. Dimensions: 2400mm×1300mm×1700mm
7. Weight: 880kg

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Main components (refer to attached picture)
The main components include bottle feeding station, conveyor belt, filling station, cap unscrambling station,
oscillator (hopper), capping station (inner plug and outer cap), capping station, rack drive, operation control,
etc. part.

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5.1 Bottle unscrambling station:

Prepare enough bottles, put the bottles into the hopper, adjust the knob on the operation panel to control the
bottle unscrambling speed, arrange the bottles in an orderly manner and enter the bottle supply tray, and then
sort out the bottles in an orderly manner through the supply tray. On the conveyor belt, it is transported to the
filling area.

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5.2. Filling station
After turning on the main power and starting the machine, raise the filling needle, start the conveyor belt,
and arrange the bottles one by one; fill when the turntable is intermittent. The liquid medicine is inhaled by the
peristaltic pump controlled by the servo motor, transported by the silicone tube, and filled into the bottle by 4
needle tubes that can automatically move up and down at the filling station. After filling, it is conveyed to the
next station (capping station) by conveyor.

5.3.
Station
for
adding
inner

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plug and outer cover
After filling, the bottles enter the turntable and are sent to the capping station. The inner plug and outer cap are
sorted by the oscillating hopper and transported to the suction cap station and the suction plug station along
the inner plug track and the outer cover track.

The suction plug suction head sucks the inner plug and the outer cap at the same time, and the suction head
that moves up and down presses the inner plug and the outer cap into the bottle respectively.

The bottle with inner plug and outer cap is transferred to the next station (capping station) by the turntable.

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5.4. Capping station
The capping head starts to work, and the capping head rotates continuously above the bottle mouth. When the
bottle stops directly below, the bottle holding cylinder starts to fix the bottle, and the descending capping head
covers the cap to complete the capping action. The capped bottle is then conveyed out of the machine by the
conveyor belt, and enters the next packaging process.

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5.5 Rack transmission station
The frame drive is composed of main motor, reducer, indexer, sprocket, chain, cam, shaft, and signal wheel, as
shown in the figure below

The process flow chart is as follows:

Prepare the bottle, prepare the inner plug, prepare the outer cap, the next process
↓↓↓↑
Bottle input → filling → stoppering → capping → screw cap → bottle output

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6. Installation and commissioning

Take the device out of the packing box, remove the protective film, check whether the machine feet are loose,
and whether the protective cover is damaged. There are instructions for use, inspection report (product
certificate) and other documents in the box, please check according to the documents, if there is any damage to
the equipment or missing accessories, please contact the shipping unit or our company in time, so that it can be
handled properly in time.
6.1 Equipment installation:
The centre of gravity of the device is lower, and it can be placed directly on the ground. When the stand-alone
machine is working, it can be placed according to the position where the operator is facing the power switch, or
it is convenient for the bottle to enter and exit. When connecting the line, align the bottle outlet with the bottle
inlet of the next equipment, and the height should be the same. The chassis needs to be grounded safely.
Installation of the oscillating hopper: During installation, it is only necessary to connect the outlet of the upper
cover hopper with the inlet of the upper cover track. The feeding speed of the hopper is controlled by the knob
switch, the feeding speed should not be too fast, just slightly faster than the bottle-feeding speed.
6.2 Equipment debugging:
6.2.1 Adjustment of machine feet:
Adjust the height of the four machine feet so that the equipment does not tilt or sway. When connecting the
line, by adjusting the height of the four machine feet, the interfaces of the two devices can be matched, so as to
ensure the smooth operation of the whole line.

Adjustment diagram
of machine feet 1

1 Tighten or loosen
to adjust the height of
the machine.

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6.2.2 Adjustment of the conveyor belt:
Loosen the screws as shown in the picture, then the spacing of the tracks can be adjusted.

Conveyor belt adjustment

diagram 1

1 Screw

2 Bars

6.2.3 Adjustment of filling station

As shown in the picture, loosen the screw, then adjust the height of the needle holder to a suitable position and
fix it, then adjust the distance between the filling needle and the bottle mouth, and tighten the screw after
adjustment.
1 Adjustment of filling
station

1 needle Bar
2

2 Screws

6.2.4 Adjustment of the oscillation frequency of unpacking and capping

On the operation panel, you can see the following 1 controller to adjust the frequency and adjust the cap
unscrambling and cap feeding speed.

1 Plug and cover control box

1 Operational Panel

2 Knobs

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6.2.5 Adjustment of the height of the capping head:
As shown in the figure, a splint fixing block fixed by a pair of hexagonal screws and a hexagonal screw can be
seen under the capping station. Loosen the screws to facilitate the adjustment of the capping height as shown
in Figure 2. Then turn the thumb screw to move the capping mechanism up and down as a whole, and then fix it
when it reaches a suitable position, and then fix the capping motor shield.
Adjustment of the height of the screw capping
station

1 Screw cap motor guard

Diagram 1

1、Plywood fixing block

2、Screws

Schematic diagram of cap height adjustment 2

1、Hand screw

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6.2.6 Host speed adjustment
On the operation panel, you can see the contents of the touch screen as follows. After clicking, enter the host
frequency to modify the host speed.

Host inverter

1 Operation panel

2 Enter the host

frequency

6.2.7 Adjustment of conveyor belt speed

The governor for adjusting the conveyor belt is on the side of the machine, and the speed of the conveyor belt
can be adjusted according to the production requirements by rotating the adjusting knob.
conveyor belt
governor

1 governor

2 adjustment knobs

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6.2.8 Filling Volume Adjustment
On the operation panel, the content of the touch screen can be seen as shown in the figure below. After
clicking, enter the value to modify to change the stroke of the metering pump, so as to achieve the purpose of
adjusting the filling volume. Adjust the filling volume of a single pump one by one to achieve the desired
volume.
Filling volume
adjustment diagram 1

1 Operation Panel

2 Single Control
metering Pump Filling
Volume

6.2.9 Install the vibration hopper

Loosen the nuts of the positioning seat as shown in the figure to adjust the four machine feet so that the
oscillator feet can be fixed in without swinging. After the adjustment, tighten the nut of the positioning seat to
fix it.
Oscillator diagram 1

1 Positioning Seat

2 Screws

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Oscillator diagram 2

1 positioning seat

2 screws

6.2.10 Adjustment of the position of the turntable and the bar

As shown in the picture, loosen the screw, and then adjust the position of the turntable and the retaining bar.
Turntable bar adjustment diagram
1 Screws
2 Turntable
3 Bars

6.2.11 Adjustment of the oscillation frequency of unpacking and loading

On the operation panel, you can see the following two controllers for adjusting the frequency, which can be
used to adjust the speed of cap unscrambling and cap feeding.
Riser and lid control box

1 Operation panel

2 knobs

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6.2.12 Replacement method of peristaltic pump hose
When the rubber hose is damaged or its life is reached, it can be replaced as follows. Turn the trigger 180
degrees counter clockwise to open the upper block. Lift up the tube clips on both sides respectively and put the
hose naturally between the roller and the upper pressure block. Turn the trigger lever 180 degrees clockwise to
make the upper pressure block press down in place, and the tube clamp will be firmly clamped to the hose to
prevent the hose from moving when it is working.

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7. Operation
7.1 Operation steps
1. Confirm that the bottle and cap specifications meet the requirements
2. Confirm that the material liquid is well prepared and well connected with the filling head
3. Confirm that the power supply is safe and reliable
4. Confirm whether the inlet and outlet bottles are in place, and whether the inner plug of the oscillating
hopper slideway and the outer cover are in place.
5. Turn on the main power switch and oscillator switch on the operation panel.
6. Click on the main engine to open, the conveying to open, and the cap to open, and the device will run
automatically.
Note: Since there is air in the silicone tube in the pump before filling, it is necessary to fill the silicone tube with
the liquid medicine first and click the test filling option.
7.2 Operating Instructions
7.2.1 Main interface
Turn on the power switch on the filling machine, touch the screen for about 10 seconds and enter the [main
interface], as shown in the figure. In the [main interface], there are options of [manual screen], [automatic
screen], [parameter setting] and [fault screen]. Click the corresponding icon to enter the corresponding screen.

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7.2.3 Automatic screen

After clicking [Automatic Screen], after entering the automatic screen, there are [Output Count], [Output Clear],
[Machine Speed], [System Start], [System Stop], [Bottle Unscramble], [Peristaltic Pump in Use] Function
operation keys. Click to start the corresponding function respectively. This interface is used after debugging the
equipment and adjusting the parameters. As shown in the figure below

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【Output Count】: Here displays the current total filling quantity;

【Host Speed】: Regulate the running speed of the host;
[Output Clear]: After pressing this button, the machine will clear the last production total and start the next
automatic production count;
【System start】: Press start directly after the setting parameters are modified, and the device will run
automatically;
[System Stop]: After clicking, the device will stop and start.
7.2.4 Parameter setting
After clicking [Parameter Setting], after entering the automatic screen, there are [host speed], [1# filling
volume], [2# filling volume], [3# filling volume], [4# filling volume] , 【Filling speed】, 【Back suction volume】,
【Stop without bottle】, 【Start when incoming bottle】, 【Pulse number】,
【Measuring】, 【Actual filling volume】function operation keys. Click to start the corresponding function
respectively. This interface is used to facilitate the automatic operation of the automatic screen after debugging
the device. As shown in the figure below

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【Host Speed】: Regulate the running speed of the host;

【Filling speed】: Regulate the running speed of the filling motor to reach the filling speed;
【Stop without bottle】: adjust the stop time of the machine without bottle, the stop time can be adjusted by
the operator;
[Bottle start]: Adjust the main time for restarting the bottle when there is no bottle;
[Back-suction amount]: Control the servo motor to reverse the roller in the peristaltic pump and suck back the
liquid in the silicone tube.
【1# Filling Volume】, 【2# Filling Volume】, 【3# Filling Volume】, 【4# Filling Volume】: Set the accuracy of
filling volume.
【Pulse Number】: Input the value to measure the filling volume and simulate the filling volume.
【Determination】: Measure the filling volume.
【Actual Filling Volume】: The measured filling volume is the actual filling volume.

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7.2.5 Fault screen
When the device fails, it will be displayed in the [Fault Screen]. After selecting the content of the fault alarm in
the text box, click the button, and then click the [Alarm Clear Confirmation] button to cancel the fault alarm. As
shown in the figure below

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8. Replacement specifications
When producing another batch of bottles with different diameters and heights, it is necessary to change the
specifications of the machine and make appropriate adjustments to the machine. Have tools and specs ready
for replacement: turntable, shaker, shaker track.
After the specifications are changed, the machine needs to be adjusted, and the machine can be adjusted
appropriately by referring to the installation and commissioning of the six parts.
9. maintenance
Correct maintenance and maintenance can better play the performance of the machine and
prolong the life of the machine, so the equipment must be maintained and inspected regularly.
9.1. When the equipment is working, it should be maintained once every three months, and the bearings and
gear transmission parts should be lubricated with grease. It must be lubricated on time. Where there is
reciprocating movement, such as reciprocating shafts and lifting shafts, guide rail oil (N68) should be added
twice a day; where there are rotating parts and swing parts (that is, where there are oil holes or oil cups),
machine oil (N68) should be added once a day. Twice a day; lubricate the cam groove once a half month;
lubricate the oil nozzle once a month.
9.2. The body cover is made of stainless steel. The protective cover can be wiped and cleaned with a cotton cloth
dipped in cleaning solution. The switch control part can be wiped lightly with a dry rag or a little non-
conductive cleaning solution. This cleaning get off work must be done when changing shifts or after work.
After each batch of filling, the equipment must be cleaned, and the production site must be cleaned up.
9.3. Do not use metal tools to scrape or strike when cleaning the molds, parts, and adhesives on the surface of
the equipment, so as not to damage the parts. When cleaning the metering pump: Usually the metering
pump does not need to be disassembled for cleaning, and the cleaning solution can be used instead of the
liquid medicine to start the irrigation. The equipment needs to be thoroughly cleaned before stopping use or
changing the liquid medicine. When cleaning thoroughly, the pump needs to be disassembled. When
disassembling, each set of parts must be numbered to avoid errors during installation. It is not advisable to
start or test the machine for a long time when there is no liquid medicine, so as to avoid damage to the
sealing ring in the metering pump due to dry friction and affect the sealing effect.
9.4. If the equipment is out of service for a long time, it should be lubricated with grease at each transmission
part and bearing part and sealed with waterproof and dustproof materials.
9.5. Do not store any items on the cover of the machine, so as not to damage the smooth and smooth shell.
9.6. The dust inside the machine should be removed regularly, and all screws and fastening parts should be
checked for looseness and displacement and fastened.
9.7. Regularly check and fasten the screws of each terminal block.
9.8. Regularly check whether the lead-out lines of the distribution box (which have been tightened) are loose. If
they are too loose and sagging, they should be tightened again to make them stable, so as not to rub against
the parts, damage the insulating skin, and cause leakage.
9.9. Frequently check the vulnerable parts and replace them in time if any damage is found.
10. Packaging and Transportation
When packing, remove the feet of the machine or make it at the lowest position, and then wrap it with plastic
film to prevent the intrusion of moisture and dust; place it upwards, do not lie down or turn it upside down, and
fix it on the bottom of the packing box. Loose or wobbly conditions.
The machine is packed in a neutral wooden case during transportation. When packing, remove the feet of the
machine or make it at the lowest position, and then wrap it with plastic film to prevent the intrusion of moisture
and dust; place it upwards, do not lie down or turn it upside down, and fix it on the bottom of the packing box.
Loose or wobbly conditions.
When moving, please use a forklift or a crane, and carry it smoothly from the bottom, and pay attention to the
moving icons on the packing box, such as the center of gravity, etc. During hoisting, the hoisting tool should not

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be in direct contact with the product. Four M16X200 bolts should be used to tighten the 4 hoisting screw holes
at the front and rear of the base of the main unit. The hoisting tool should be in contact with the hoisting bolts
for hoisting, and place wooden blocks or other Protective objects in order to avoid damage to the product, if
necessary, you can use the pole to lift smoothly. as shown in the picture
Before unpacking, please check whether the packing box is damaged; if it is damaged, please do not unpack it,
and contact the shipping unit (or individual) immediately. Packing boxes should be opened under the
supervision of transport workers, and check records should be kept.
Take the device out of the packing box, remove the protective film, check whether the machine feet are loose,
and whether the protective cover is damaged. There are attachments and attachment sheets, instruction
manuals, inspection reports (product certificates) and other documents in the box. Please check the
attachments according to the attachment sheets. deal with. If there is no abnormal phenomenon, move the
machine to the place to be installed, and make preparations before installation and commissioning.
For the sake of safety, during transportation, the distance from the bottom of the machine to the ground should
be less than 1m if transported by a forklift, and the distance from the bottom of the machine to the ground
should be 2 to 2.5m if it is hoisted.
11. Vulnerable Parts List
Spare Parts Names Quantity Brand Remarks
Filling Silicon Tube 5M UK Spirax Sparco
Filling Needles 2 Shanghai
Conveyor Cap Box 1M Shanghai
Optical Fibre 1 Shanghai
Optical Fibre Probe 1set Japan
Optical Tools 1set Shanghai

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12. Electrical configuration table and circuit diagram

No. Name Specification/Model Quantity Brand Remarks

1 miniature circuit breaker Easy8 C10 2 Schneider

2 miniature circuit breaker 1C65N C6A 5 Schneider

3 Small relays RXM2LB2BD DC24V 8 Schneider

4 Switching Power Supply LRS-50-24 1 Mean Well

5 Inverter FR-D720S-0.75K-CHT 1 Mitsubishi

8 PLC FX3G-40MT 1 Mitsubishi

9 AC contactor LC1 E09 1 Schneider

10 Sensor FX-100 4 Vision

11 Proximity switch SC1204-N 4 ROKO

12 touch screen SMART700IE 1 Siemens

13 Main motor M2BAX 80MB4 1 ABB

14 Push cover, plug cylinder TN10*20-S 1 AirTAC

15 Bottle holding cylinder TN20*20-S 1 AirTAC

16 Solenoid valve 4V210 08B DC24V 3 AirTAC

17 Reducer WPS60# 1:30 1 Hangzhou

18 Conveyor belt motor 5IK60RGN-CF-J+5GN50KB 1 Shanghai

19 Solenoid valve 4V02508B DC24V 4 AirTAC

20 Vacuum converter VBH12P-66 4 PISCO

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ZCDYG eye drops filling and capping machine certificate

After inspection, all indicators of this machine are qualified, and it is allowed to leave the factory!

Inspection date: year month day

Date of manufacture: year month day
Quality inspector (signature): Zheng Fan

Shanghai Zhuocan Pharmaceutical Machinery Equipment Co., Ltd.

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