WGJ-1 单头灌装机

WGJ-1 full-auto single head aseptic filler

使用说明书
Operation Manual

上海承欢轻工机械有限公司

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 目录
1 各部件及其功能简介 1
1 Introduction for function and each section 1
1.1 灌装头 1
1.1 Filling head 1
1.2 盖夹持器： 1
1.2 The lid holder: 1
1.3 物料阀： 2
1.3 Material valve: 2
2 操作规程 3
2 Operation Regulation 3
2.1 开机前的准备 3
2.1 Preparation before startup 3
2.2 触摸屏页面 3
2.2 Touch screen(HMI) page 4
2.2.1 主页面 4
2.2.1 Main Page 4
2.2.2 设定页面 7
2.2.2 Setting page 7
2.2.3 温度页面 13
2.2.3 Temperature page 13
2.2.4 报警页面 14
2.2.4 Alarm page 14
2.3 操作面板 14
2.3 Operating Panel 14
2.3.1 面板上的按钮 15
2.3.1 Button on the panel 15
2.3.2 操作盒上的按钮 15
2.3.2 Button on the operation box 15
2.4 手动调试 16
2.4 Manual commissioning 16
2.5 操作流程 19
2.5 Operating procedure 19

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 2.5.1 杀菌 19
2.5.1 Sterilizing 19
2.5.2 灌装 21
2.5.2 Filling 21
2.5.3 清洗 23
2.5.3cleaning 23
3 故障及维护 24
3Malfunction and maintenance 24

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1 各部件及其功能简介

1 Introduction for function and each section

WGJ-1 全自动单头无菌灌装机由灌装头、操作系统、控制系统、供排气系统和工作台
等部件组成。
WGJ-1 full-auto single head aseptic filler is composed by filling head, operation system,
controlling system, air supply and exhaust system and work table.

1.1 灌装头

1.1 Filling head

灌装头由灌装室、盖夹持器、物料阀和蒸汽管道等组成。
Filling head is composed by filling chamber, clamp, material valve and steam tubes.
灌装室：是一个圆形的腔体，由上盖板、下底板和灌装室壳体组成。下底板上有装袋口和
卡住袋子（或杀菌头、清洗头）用的下卡爪。每次生产前要对灌装室进行杀菌，杀菌完成后 ，灌
装室内通入适量蒸汽，保持灌装室的合适温度（≥ 95℃）和适量的正压，使灌装室处于无菌状态 。
拔下盖子、灌装物料和压上盖子的工作都在无菌的灌装室内进行，由计算机控制自动完成。
Filling Chamber: filling chamber is a circular chamber, and is composed by upper
lid、bottom board and filling chamber container. Bottom board has a bag filler mouth and a lower
clamp for fasten bags (or sterilize head 、washing head). Before each production cycle, sterilize
the filling chamber. After sterilized, fill optimal steam into the filling chamber, and keep suitable
temperature (≥95℃) and optimal positive pressure within the filling chamber, making the filling
chamber in an aseptic condition. The working steps which include unplugging lid, filling material
and putting on lid are all done in aseptic filling chamber, and are controlled automatically by
computer.

1.2 盖夹持器：

1.2 The lid holder:

由上卡爪、上卡板、凸轮轴和气缸等组成。当袋子装好后 ，按启动按纽 ：上卡爪下降 ，接
着上卡爪合上，卡住无菌袋的盖子，然后上卡爪上升拔起盖子，之后上卡爪夹着盖子向后摆动，
到位后，灌装室上升，这时物料阀的灌装口插入已拔掉盖子的袋口内，物料阀打开，开始灌装；待
灌装完毕后，物料阀关闭，灌装室下降恢复原位，上卡爪向前摆动复位，使盖子正对袋口，上卡爪
下降，把盖子压入袋口，上卡爪张开并上升 ，恢复原位 （上卡爪的开合由气缸带动凸轮轴完成 ）；
下卡爪张开，装满物料并已盖好盖子的无菌袋脱离灌装头。以上所有动作都是由计算机自动
控制、气缸执行完成的。
The lid holder is composed of upper clamp, upper board, cam shaft and cylinder. After fixed
the bags, press the start button: the upper clamp falls down and then close which holds the lid of
aseptic bag. After the upper clamp pull out the lid, it moves backward with the lid to the
designated position, and the filling chamber is raised up. At this time, the filling port of the
material valve pulls into the bag mouth which the lid had been pull-out and the material valve
opens, then the filling begins; after filling finished, the material valve close and the filling
chamber is back the normal position. The upper clamp swings ahead, making the lid just over the
bag mouth. Then the upper clamp declines to press the lid into the bag mouth, where after it opens
and raise up back to normal (the open and close of upper clamp in done by cam shaft which is
controlled by cylinder); the lower clamp opens, the aseptic bag which had filled with material and
covered with lid is separating from the filling head. The behaviors above are controlled
automatically by computer and done by cylinder.

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1.3 物料阀：
主要由阀杆、灌装口、气缸和支架等组成。当灌装室上升，袋口对准灌装口后，计算机自
动控制阀杆打开，物料在压力作用下进入无菌袋。当灌装量达到设定数值时 ，阀杆自动关闭 ，
停止灌装。阀杆上共有三道 O 型密封圈，最下面的一道密封圈用于密封物料——当阀杆向下
运动到位时，它将灌装口密封住，阻止物料滴落；上面的两道密封圈尺寸相同，它们之间的腔体
是蒸汽密封带——防止当阀杆上下运动时，细菌穿过密封圈进入物料管内，污染物料。

1.3 Material valve:

Material valve is composed of valve stem, filling port, cylinder and frames. When the filling
chamber is raise up and the bag mouth is just over the filling port, the valve stem is opened
automatically by computer and material is pressed into the aseptic bag. After the filling rises to
required amount, the valve stem closes automatically to stop filling. There are three “O” ring seals
on the valve stem, the bottom one is used to seal material after the valve stem moves downward to
position, it seals the filling port to prevent material spattering; the upper two “O” rings have the
same size and the chamber between them is steam seal area to avoid virus contamination
happening in material tube through “O” rings when the valve stem moves up and down.
阀杆关闭时 ，阀杆底端要伸出灌装口 1mm 左右。这便于阀杆关闭时将灌装口处的物料
完全推进无菌袋，避免残留的物料污染灌装室或无菌袋的盖子。
When the valve stem closed, the valve stem bottom should be about 1mm extend from the
filling port, which helps to completely push the material into the aseptic bag when the valve stem
is closed, to avoid the rudimental material pollutes the filling chamber or lid of aseptic bag.
每次手工清洗时一定要拆下阀杆检查密封圈是否磨损或损坏。
Each time when manual washing, the valve stem should be disassembled to check if the
sealing ring wore or damaged.

2 操作规程

2 Operation Regulation
2.1 开机前的准备

2.1 Preparation before startup

2.1.1 电 压：三相 220V，60Hz；
2.1.1 Voltage: 3-phase 220V, 60Hz;
2.1.2 压缩空气：0.7MPa，20m3/h；
2.1.2 Compressed air: 0.7MPa, 20m3/h;
2.1.3 蒸 汽：≥0.3MPa；
2.1.3 Steam: ≥0.3MPa;
2.1.4 灌装头为自动工作状态。
2.1.4 Filling head is in automatic working condition.
2.1.5 设备外围地方禁止有干扰光电开关的物品。
2.1.5 All the stuff which could interfere the photoelectric switch are forbidden in the equipment
peripheral places
上述条件有一条不满足时，禁止开机！
Warning: If one of the conditions above is not fulfilled, start up
is forbidden.

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2.2 触摸屏页面
灌装机的控制系统主要有 PLC 和触摸屏组成，触摸屏是操作人员完成操作、设定和监控
的主要工具。触摸屏主要可以分为主页面、设定页面、温度页面和报警页面四个部分，下面
依次介绍各个页面的主要功能。

2.2 Touch screen(HMI) page

The filler control system is made up of PLC and touch screen(HMI), the touch screen(HMI)
is the operator’s main tool for operating、setting and monitoring. The touch screen(HMI) mainly
include four parts: main page 、 setting page 、 temperature page and alarm page, we are
introducing the main function for each page sequentially in below.

2.2.1 主页面

2.2.1 Main Page

操作人员通过主页面可以完成对灌装机工作状态、灌装室温度、压力、主要阀门状态
等参数的监控。

图 1 主页面
The operator use the main page to monitoring the parameter such as filler working
condition、filling chamber temperature、pressure、main valve condition etc.

图 1 Main page
主页面由灌装头、工作台和公共阀门 （ AV3、AV12、JV1）三部分构成。通过触摸屏可

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以方便对灌装室温度、蒸汽密封温度、各个阀门的状态进行监控。工作台是自动进灌装桶
的装置。公用阀门是灌装头进料和清洗管道上的控制阀门。
The main page is made up of filling head 、 working table 、 public
valves（AV3、AV12、JV1）．The filling chamber temperature、steam sealing temperature、every
valve condition can be easily monitored by the touch screen. The working table is automatic
filling barrel entry device, The public valve is the control valve for the filling head handling
material and washing pipe.

，灌装机在清洗状态时打开，清洗和杀菌时关闭。打开状态为 。

, opening under the filler washing condition, closing under washing and sterilizing
condition. This is the opening state.

，灌装机在灌装状、清洗态时打开，杀菌时关闭。打开状态为 。
, opening under the filler filling 、 washing condition, closing under sterilizing
condition. This is the opening state.
，杀菌进蒸汽阀门，杀菌时随温度变化而变化，当灌装室温高于设顶温度时，JV1 关闭
当室温低于设定温度时，JV1 打开。
， Sterilizing steam input valve, during sterilizing, it changes with the temperature
change, when the filling chamber temperature higher than setting temperature, JV1 close, when
filling chamber temperature lower than setting temperature, JV1 open.

，蒸汽密封，是对灌装头在动作时，相对运动或者连接处，通蒸汽，防止空
气进入无菌环境。蒸汽密封温度一般设定为 97℃。

Steam sealing is when the filling head are moving, relative movement or
connection location, supply steam to prevent the air into the aseptic environment. The steam
sealing temperature normally setting at 97℃.

，灌装室温度，在灌装时温度一般设定在 97℃，杀菌时设定为 122℃，清

洗时为室温。

Filling chamber temperature normally setting at 97℃ during filling,

setting at 122℃ during sterilizing, setting at room temperature during washing.

，隔膜泵和抽水角阀，主要是来抽在生产过程中累积在灌装室中的冷凝水。只有
在灌装状态手动打开或者关闭，通过在设定界面中的开关控制。

Diaphragm pump and pump angle valve are used to pump condensate water which
was accumulated in the filling chamber during production. It only can be manual open or close
under filling condition, controlled by the switch in the setting page.

， 喷气阀门 ， 在灌装时 ， 在拔盖和压盖时对袋口进行喷蒸汽消毒 ， 喷气时间

（秒)可以在操作页面中设定。

Spray steam valve, blasting steam to sterilize the bag mouth when the lid been
plug out and press down. The lasting time (second) can be set in the operation page.

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 ，灌装室温阀，用来控制灌装室内部的温度。在灌装时，根据灌装室温设定的数
值，控制灌装室温阀的开启，当实际温度高于设定值 2℃时，阀门关闭，当实际温度低于设定值
2℃时，阀门打开。

Filler room temperature valve used to control the filling chamber inner
temperature. During filling, the opening of the valve is controlled by the filling chamber
temperature setting data. When the actual temperature above setting data 2℃, this valve close,
when the actual temperature lower than setting data 2℃, this valve open.

2.2.2 设定页面

2.2.2 Setting page

设定页面主要功能是完成对杀菌机工艺参数、工作状态选择、手自动控制等指令的设
定。设定页面包括两页，如下图所示：

图 2 设定页面

The main function of the setting page are: set the filler processing data 、 chose working
condition 、 manual automatic control. The setting page include two pages, as below picture
showed

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 图 2 Setting page

2.2.2.1 灌装室温度设定

灌装时温度为 97℃，杀菌时温度为 122℃，清洗时温度为 30℃。温度随着状态的变换

自动跳转，也可以手动设定。在灌装状态时，如果灌装室温度比设定温度低 3℃，物料阀杆将
关闭，同时报警页面会产生一条报警信息，待温度升高后，打开。

2.2.2.1 Setting the filling chamber temperature

Filling temperature 97℃, sterilizing temperature 122℃, washing temperature 30℃. The
temperature is automatically jumping with the conditions change，it also can be manual set. Under
filling condition, if the filling chamber temperature is 3℃ lower than setting temperature, the
material valve will close, and the alarm page will show an alarm message, when the temperature
rising, the material valve open.

2.2.2.2 蒸汽喷袋口时间设定

在灌装状态时，拔盖和压盖时对袋口进行蒸汽喷射，对袋口进行消毒。

2.2.2.2 Bag mouth steam spurting time setting

Under filling condition, spraying steam to the bag mouth for sterilization when the lid been
plug out and press down.

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2.2.2.3 灌装头再次杀菌时间设定。

当灌装机处于灌装状态时，如果有一个灌装头受到污染需要重新杀菌，可以将灌装室温度
手动设定为 122℃，装上杀菌头，再次杀菌时间通常设定为 30Min，当室温达到 122℃后，开始计
时 30 分钟，下面的杀菌时间是显示已经开始杀菌的时间，到达 30Min 后，将灌装室温度手动设
定为 97℃，待温度低于 100℃后，取下杀菌头，继续灌装。

2.2.2.3Filling head re-sterilizing time setting.

Under the filling condition, in case anyone filling head contaminated then need to do the
sterilization again. Manual set the filling chamber temperature as 122℃, fix the filling head, the
re-sterilizing time normally be set as 30Min, when the room temperature goes to 122℃, start time
counting 30Min, the sterilization time is showing the time already sterilized. After 30Min, manual
set the filling chamber temperature as 97℃, take off the filling head till the temperature goes
below 100℃, continue filling.

2.2.2.4 灌装机自动\手动状态选择。

当灌装机处于自动状态时，灌装机才能完成杀菌、灌装、清洗功能，当灌装机处于手动状
态时，操作者主要完成对灌装机动作的调试工作，操作者通过灌装机面板上的步进\步退按钮
逐步对灌装机动作进行调试，在下面章节中将重点说明手动调试的过程。

2.2.2.4Choose the filler Automatic/Manual motion.

Under the automatic condition, the filler can complete the sterilizing 、 filling 、 washing
function, under the manual condition, the operator mainly is complete the debugging of the filler
motion, the operator debugging the filler by the stepping /step back switch on the filler panel, the
below chapter will explain the manual debugging procedure.

2.2.2.5 蒸汽密封温度设定

蒸汽密封温度在灌装和杀菌状态下都设定为 97℃，在灌装状态下，如果实际蒸汽密封温
度低于设定温度 3℃，灌装阀杆将关闭，待温度升高后，打开。

2.2.2.5 Temperature setting of steam sealing.

The steam sealing temperature should be setting at 97℃ both under filling and sterilizing
condition. Under filling condition, if the actual steam seal temperature is 3℃ lower than setting
temperature, the filling valve stem will close. It will open until the temperature rising.

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2.2.2.6 复位按钮。

主要用于自动状态下由于突然断电或者机械动作故障引起的动作卡死情况。在自动状
态下，机械动作卡死，首先要把灌装机自动\手动状态切换到手动状态下，然后点击 Reset，灌装
头会顺序的回到初始状态。注：当灌装头恢复到初始状态后，要把点击 Finished 结束复位，否
则会处于一直复位状态，影响下一步动作。

2.2.2.6 Reset button.

It is mainly used for motion stuck caused by sudden power shutdown or mechanical problem.
Under automatic condition, the mechanical motion stuck, need to swift the filler automatic/manual
condition to manual condition, then press Reset, the filling head will return to initial condition
consequently. Notice: when the filling head return to initial condition, need to press Finished to
finish the reset, otherwise the reset condition will lasting，and affecting next motion.

2.2.2.7 抽水泵的开关。

抽水泵只有在灌装的状态下才能受控，当抽水完毕后，关闭抽水泵，防止抽水太长，造成室
温下降。

2.2.2.7 Condensate pump On/Off.

The condensate pump can only be controlled under filling condition, after pumping,，close the
pump to avoid room temperature decrease.

2.2.2.8 灌装头磁性开关、位置传感器状态显示页面。

图 2 传感器状态显示页面
灌装头上的磁性开关包括灌装管上位、灌装管下位、上卡爪上位、上卡爪下位、上卡
爪前位、上卡爪后位、物料阀开启、上卡爪开启 8 个磁性开关。 灌装头完成依次灌装由上
卡爪关闭、上卡爪上移、上卡爪后摆、灌装管下移、物料阀打开、灌装物料、物料阀关闭
灌装管上移、上卡爪前摆、上卡爪下移压盖 10 步主要动作完成 ，每一步都对应不同的磁性
开关位置，如果磁性开关没有检测到气缸的位置，则会出现不动作或者误动作等现象，所以在
手动调试时，要找到正确的磁性开关位置，并固定好，防止由于灌装头的震动引起磁性开关的
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松动或者脱落。在手动调试章节中将重点介绍如果确定磁性开关的正确位置。

2.2.2.8 Filling head magnetic switch、position sensor display page.

图 2 Sensor status display pages

The filling head magnetic switch including：filling pipe up、filling pipe down、upper clamp
up 、 upper clamp down 、 upper clamp fore 、 upper clamp rear 、 material valve open 、 upper
clamp open. The filling head complete the filling consequently by these 10 motions: upper clamp
close 、 upper clamp up 、 upper clamp rear 、 filling pipe down 、 material valve open 、 filling
material、material valve close、filling pipe up、upper clamp fore、upper clamp down press lid.
Every motion has corresponding magnetic switch position, if the magnetic switch can’t detect the
cylinder position, it may happen the no motion or wrong motion phenomenon. So when do manual
debugging, need to find the correct magnetic switch position, and fix it, in case the filling head
vibration causing the magnetic switch loosing or lost. In the manual debugging chapter, the
magnetic switch correct position will be introduced in detail.

2.2.3 温度页面

图 3 温度页面

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2.2.3 Temperature page

图 3 Temperature page
温度页面是对灌装室、灌装头上移动部件和法兰蒸汽密封温度、AV3 及 AV12 蒸汽密
封的记录，主要用于监测各个温度参数是否到达所需的工艺温度。温度分为两组，可以根据下
面的按钮选择需要查看的温度趋势，温度页面可以查询从当前时间起 5 分钟内的温度曲线。
The temperature page is to record the filling chamber、filling head moving components and
flange steam seals temperature 、 AV3 and AV12 steam seals, mainly used to monitor each
temperature data reached the required processing temperature. The temperature are divided into
two group, using the below button to chose to see the temperature trend, the temperature page can
check the temperature curve from current time till 5 5Min.

2.2.4 报警页面

2.2.4 Alarm page

报警记录是对当前存在的报警点的说明，报警分为警告和危险两种状态，警告报警是提醒
操作者目前的关键点，防止误操作，比如工作状态、杀菌计时开始、杀菌计时到等 ，危险报警
是出现了会严重影响产品质量的事件，比如灌装温度低、压缩空气低等，当出现此类报警时应
及时查明原因，迅速解决。此类报警还会伴随报警灯打开，提醒操作者。
The alarm record is the explanation to the current existing alarm point, the alarm include
warning and danger two condition, warning alarm is to remind the operator the current key points,
to prevent from wrong operation, such as working condition 、 sterilization time counting
start 、 sterilization time counting end etc, danger alarm is when the accident happen which can
severely affecting the production quality, such as low filling temperature 、 compressed air
pressure low etc. When the alarm happening, need to checking the alarm reason, settle it
immediately. This alarm will come with the alarm light open, to remind the operator.

2.3 操作面板

2.3 Operating Panel

灌装机除了可以在触摸屏进行参数设定和监控，操作人员在生产过程中主要通过面板和
机架上的操作和来完成对灌装机的操作。
The filler not only setting the data and monitoring on the touch screen, the operator can
operates the filler through the panel and frame.

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2.3.1 面板上的按钮

2.3.1 Button on the panel

电源指示：当灌装机处于带电状态时，指示灯亮。
Power: when the filler is in the charged condition, this indication light turns on.
报警：当灌装机有报警信息时，指示灯亮，同时在触摸屏报警页面会出现相应的报警信息。
Alarm: when the filler has alarm massage, the indication light turns on, at the same time, the
corresponding alarm message will be showing at the touch screen alarm page.
杀菌\灌装\清洗：三位选择开关，杀菌、灌装、清洗状态的转换。
Sterilizing\filling\cleaning: three-position selection switch, changing the condition of
sterilizing、filling、washing.

步进\步退：二位选择开关，用于手动调试。灌装机处于手动状态时，利用前进或者后退可
以完成整个灌装动作。
Stepping\step back: two-position selection switch，used for manual debugging. When the filler
is in manual condition, use the stepping forward or stepping backward to complete the whole
filling motion.
上卡爪卡开\关 上卡爪上\下 上卡抓前\后 灌装管上\下 物料阀开\关，每一个动作
都可以进行前后循环。
Upper clamp open/close upper clamp up\down upper clamp fore/rear filling pipe
up\down material valve open\close, each motion can be forth back circulating.

2.3.2 操作盒上的按钮

2.3.2 Button on the operation box

急停：灌装过程中如果发生紧急情况，按下急停按钮，灌装阀杆会自动关闭，防止物料充满
灌装室，造成灌装室玻璃爆裂或者污染灌装室。注：在正常工作状态，急停不要按下。
Emergency ； Emergency shutdown: when the emergency situation happens during filling
procedure, pressing this button the filling valve stem will close automatically, to prevent material
filled in the filling chamber, causing the filling chamber glass explosion or filling chamber
contamination. Notice: do not pressing this button under normal working condition.
灌装头升/降：两位选择开关，手动控制灌装头的升降。
Filling head up/down: two-position selection switch ，used to manual control the filling head
raising and descending.
启动：灌装室，手动夹上无菌袋后 ，按下启动自动完成灌装动作。如果在灌装过程中强制
停止灌装，手动按下急停按钮，点击启动，完成压盖动作。
Start: filling chamber, manually fixed the aseptic bag, press Start button to complete the
filling motion automatically. If need to compulsory stop the filling motion during filling
procedure, manually press emergency stop button, press Start button, complete the lid pressing
motion.
下爪开关:手动控制下卡爪，用于夹无菌袋、杀菌头和清洗软管。
clamp switch: manually control the lower clamp, using to clamp the aseptic bag 、sterilizing
head and washing soft pipe.

2.4 手动调试

2.4 Manual commissioning

手动调试是手动控制灌装机的动作，不能实现真正灌装，通过手动调试可以调整机械部分，
实现动作的连贯、顺畅。通过步进、步退旋钮可以完成灌装头的手动调试，手动调试按顺序
依次为上卡爪关，上卡爪上，上卡爪后摆，灌装管下，物阀开，灌装管上，上卡爪前摆 ，上卡爪下，上
卡爪开，完成一个循环动作，以上也是在自动状态完成一个灌装流程所经过的动作。以上每一

14
个动作都可以通过步进和步退进行重复。
Manual commissioning is the manual motion to control the filler. It can’t realize real filling,
it is adjusting mechanical part through manual commissioning, to realize the motion’s coherent
and smoothing. Complete the filling head commissioning by the stepping and step back buttons.
Manual commissioning consequently are upper clamp close 、 upper clamp up 、 upper clamp
rear、filling pipe down、material valve open、filling pipe up、upper clamp fore、upper clamp
down、upper clamp open to finish a circulating motion, the above are also the motion to complete
a filling procedure under automatic condition. The above every motion can be repeated by the
stepping and step back buttons.

具体调试过程。点击触摸屏上的 按钮，将灌装状态切换到
手动状态下。灌装头气缸动作是否到位通过磁性开关来判断的，如果相应磁性开关不到位，气
缸无法进行下一步动作，结合磁性开关的位置说明各个动作，各磁性开关的状态可以通过触摸
屏上灌装头磁性开关页面监控。

Clicking the button on the touch screen, change the filling

condition to manual condition. Whether the filling head cylinder motion is in place is judged by
the magnetic switch, if the corresponding magnetic switch is not in place, the cylinder con not
doing next motion, combine with the magnetic switch position to explain each motion, the
condition of every magnetic switch can be monitored by the filling head magnetic switch page on
the touch screen.
初始位置是灌装机通电后，所有气缸的默认的位置。
The initial position is all the cylinder default position as the filler been charged.
初始状态到位的磁性开关：管上位、卡爪下位、卡爪前位、卡爪开、物料阀关。
The magnetic switch when initial position in place: pipe up 、 clamp down 、 clamp
fore、clamp open、material valve close.
2.4.1 在初始状态下点击步进，上卡爪气缸动作，上卡爪关闭，完成夹盖动作。
2.4.1 Clicking the stepping button, upper clamp cylinder act, upper clamp close, clamp lid
motion completed.
此时应到位的磁性开关：管上位、卡爪下位、卡爪前位、卡爪关、物料阀关。
Now the magnetic switch in placed are: pipe up 、 clamp down 、 clamp fore 、 clamp
close、material valve close.
2.4.2 继续点击步进，上卡爪上移，完成拔盖动作。
2.4.2 Continue clicking the stepping button, upper clamp move upwards, complete pulling
out the lid.
此时应到位的磁性开关：管上位、卡爪上位、卡爪前位、卡爪关、物料阀关。
Now the magnetic switch in placed are: pipe up 、 clamp up 、 clamp fore 、 clamp
close、material valve close.
2.4.3 继续点击步进，上卡抓后摆。
2.4.3 Continue clicking the stepping button, upper clamp move backwards.
此时应到位的磁性开关位：管上位、卡爪上位、卡爪后位、卡爪关、物料阀关。
Now the magnetic switch in placed are: pipe up 、 clamp up 、 clamp rear 、 clamp
close、material valve close.
2.4.4 继续点击步近，灌装管下移，灌装口对准袋口。
2.4.4 Continue clicking the stepping forward button, filling pipe descends, filling head aim at
bag mouth.
此时应到位的磁性开关位：管下位、卡爪上位、卡爪后位、卡爪关、物料阀关。
Now the magnetic switch in placed are: pipe down 、 clamp up 、 clamp rear 、 clamp
close、material valve close.
2.4.5 继续点击步近，物料阀打开。
2.4.5 Continue clicking the stepping button, material valve open.
此时应到位的磁性开关位：管下位、卡爪上位、卡爪后位、卡爪关、物料阀开。
Now the magnetic switch in placed are: pipe down 、 clamp up 、 clamp rear 、 clamp
close、material valve open.
此时完成了灌装的过程，可以点击上一步按钮，逐步复位。
Now the filling procedure completed, click the previous step button, reset step by step.
2.4.6 继续点击步退，物料阀关闭。
2.4.6 Continue clicking the step back button, material valve close.
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 此时应到位的磁性开关位：管上位、卡爪上位、卡爪后位、卡爪关、物料阀关。
Now the magnetic switch in placed are: pipe up 、 clamp up 、 clamp rear 、 clamp
close、material valve close.
2.4.7 继续点击步退，灌装管上移。
2.4.7 Continue clicking the step back button, filling pipe move upwards.
此时应到位的磁性开关位：管上位、卡爪上位、卡爪后位、卡爪关、物料阀关。
Now the magnetic switch in placed are: pipe up 、 clamp up 、 clamp rear 、 clamp
close、material valve close.
2.4.8 继续点击步退，上卡爪前摆。
2.4.8 Continue clicking the step back button, upper clamp move forward.
此时应到位的磁性开关：管上位、卡爪上位、卡爪前位、卡爪关、物料阀关。
Now the magnetic switch in placed are: pipe up 、 clamp up 、 clamp fore 、 clamp
close、material valve close.
2.4.9 继续点击步退，上卡爪下移，完成压盖动作，在手动调试下因为没有小行程，因此盖子
不能被压到位。
2.4.9 Continue clicking the step back button, upper clamp descends, press lid motion
completed, there are no short stroke under manual debugging, so the lid can not be pressed in
place.
此时应到位的磁性开关位：管上位、卡爪下位、卡爪前位、卡爪关、物料阀关。
Now the magnetic switch in placed are: pipe up 、 clamp down 、 clamp fore 、 clamp
close、material valve close.
2.4.10 继续点击步退，上卡爪开，回到原位。
2.4.10 Continue clicking the step back button，upper clamp open，back to original position.
此时应到位的磁性开关位：管上位、卡爪下位、卡爪前位、卡爪开、物料阀关。
Now the magnetic switch in placed are: pipe up 、 clamp down 、 clamp fore 、 clamp
open、material valve close.
注意：在以上 10 步动作中，每一步都可以通过步进和步退按钮重复操作。如果手动和自
动发生灌装中某一个动作不到位，或者无法行下一步动作，请检查相应状态的磁性开关是否正
常、机械结构卡死或者不到位，此时应到初始位置，逐步调整相应机械位置后再恢复自动生产。
Notice: The above 10 step of motion, every motion can be operated repeatedly through the
stepping and step back buttons. If during filling, a motion is not in place manually or
automatically, or can’t do the next motion, please check the corresponding magnetic switch is
normal or not 、 mechanical component is stuck or not in place, now should go back to initial
position, adjust corresponding mechanical position gradually, then recover automatic producing.

2.5 操作流程

2.5 Operating procedure

灌装机操作正常操作流程为杀菌、灌装、清洗。杀菌是在高温状态下保持一定时间，将
管道和灌装室内的细菌杀死，创造无菌环境。灌装是灌装机主要工序，包括进托盘、灌装单桶、
灌装头移动、出桶等步骤。清洗是灌装机在完成灌装后，对灌装机进行 CIP 清洗。
The filler normal operating procedure is sterilizing 、 filling 、 washing. Sterilizing is under
the high temperature for a period of time to kill the bacteria in the pipe and filling chamber, create
the aseptic environment. Filling is the main procedure for filler, include pallet entering 、filling
single barrel 、 filling head moving 、 barrel output etc. Washing is when the filler complete the
filling, to do the CIP wash to the filler.

2.5.1 杀菌

2.5.1 Sterilizing
2.5.1.1 打开蒸汽排放阀，排放冷凝水，
2.5.1.1.Open the steam exhaust valve, releasing the condensate water.
2.5.1.2 打开电源开关，将灌装头调至自动工作状态。
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 2.5.1.2.Open power switch, change the filling head to the automatic working condition.
2.5.1.3 打开压缩空气供给阀，将两联体调压阀的压力调至 0.6MPa。
2.5.1.3 Open compressed air supply valve, adjust the doublet pressure regulating valve to
0.6MPa.
2.5.1.4 检查气控柜内其它气路压力。
2.5.1.4 Inspect the other path pressure in the electric control cabinet.
2.5.1.5 按住下卡爪开关按钮，打开下卡爪，装上杀菌头，杀菌头的针阀不要关严，防止灌装
室内压力过高，产生危险！！！
2.5.1.5 Press the lower clamp switch button, open lower clamp respectively, fix the sterilizing
head, the sterilizing head needle valve do not close too tight, prevent the filling chamber pressure
from too high, causing danger!!!
2.5.1.6 打开蒸汽供给球阀，将蒸汽调压阀的压力调至 0.2～0.3MPa，杀菌过程中不要敲打
观察视窗，防止意外发生！
2.5.1.6 Open steam supply ball valve, adjust the steam pressure regulating valve to 0.2-
0.3Mpa, do not knock the view window during sterilizing, preventing any accident from
happening!
2.5.1.7 开启灌装头的蒸汽密封和 AV3、AV4 的蒸汽密封的针阀，调节排泄针阀，使排汽
量不要太大。
2.5.1.7 Open the steam seal for filling head and the needle valve for AV3、AV4 steam seal,
adjust the exhaust needle valve, to limit the exhaust amount.
2.5.1.8 在面板上的旋转开关旋转至杀菌状态，这时的灌装室温度设置自动跳转到
122℃，蒸汽密封温度自动跳转到 97℃。物料阀杆打开，急停按钮确保不要按下。
2.5.1.8 Turn the knob on the panel to sterilizing condition, at this time the filling chamber
temperature set automatically jump to 122℃, steam seal temperature automatically jump to 97℃.
Open the material valve , make sure do not press the emergency button.
2.5.1.9 蒸汽角阀自动打开，且受灌装室温度控制，当灌装室温度低于设定温度 2℃时，蒸汽
阀开，如果灌装室温高于设定温度 2℃时，蒸汽阀关闭。 手动打开针阀和角阀旁的球阀，自杀
菌程序开始。打开蒸汽排放针阀，当各点温度上升到 100℃以上后，关小相应的排放阀。
2.5.1.9 Steam angle valve open automatically, and also controlled by the filling chamber
temperature, when filling chamber temperature 2℃ lower than the setting temperature, the steam
valve open, when filling chamber temperature 2℃ higher than setting temperature, the steam
valve close. Manually open the needle valve and ball valve besides the angle valve, self sterilizing
program start. Open the steam exhaust needle valve, when every point temperature higher than
100℃, turn down the corresponding exhaust valve.
2.5.1.10 当灌装头的温度达到 122℃以上后，开始计时， 触摸屏显示杀菌时间， 30 分钟后，
杀菌程序结束。(若在计时过程中，如果有任何一点的温度低于 122 度，计时则会清零，待温度
达到 122 度时再重新开始计时。再重新计时 30 分钟）。
2.5.1.10 When filling head temperature higher than 122℃, start time counting, the touch
screen showing the sterilizing time, after 30Min, sterilizing procedure completed. During the time
counting, every if any temperature control point is lower than 122℃, the counting will be zero
clearance, wait until the filling head temperature reached 122℃, do the time counting again,
recount the time for 30Min.
2.5.1.11 杀菌完毕后，将旋钮转换到灌装，温度设置自动跳转到 97℃，温度低于这个设
定值会有报警。
2.5.1.11 When the sterilization complete, turn the knob to filling, temperature setting jump to
97℃ automatically, there will be alarming when temperature lower than this setting data.
2.5.1.12 待灌装室的温度下降至 100℃ 以下，杀菌头排放阀不再有压力的情况下，分别按
住下卡爪开关按钮，打开下卡爪，取下杀菌头，等待灌装。
2.5.1.12 Wait until the filling chamber temperature lower than 97℃, and the sterilizing head
exhaust valve do not have pressure, hold the clamp switch button respectively, open lower clamp,
take off the sterilizing head, wait for filling.
注意：（在等待灌装时一定要看好灌装室温度不要低于 95℃）
Notice: (Make sure the filling chamber temperature should not be lower than
97℃during wait for filling).

17
2.5.2 灌装

2.5.2 Filling
每次灌装，将灌装头上升至上位，随着灌装量的增加，手动降低灌装头至低位，注意在这个
过程中，无菌袋不要受力太大，防止撕裂。
根据需要，定时灌装样袋，以便化验室做理化分析及无菌检测
灌装量在计数器上设定，如脉冲当量（一个脉冲代表的体积，可以修改）设定值是 10 毫克，
则一公斤为 100 个脉冲，200 公斤为 20000 个脉冲。
每次灌装的前几桶要用电子秤算出净重，再修正计数器的脉冲值。

2.5.2.1 手动按下爪开关按钮，加上无菌袋，确定加牢固后，松开下抓开关按钮，然后用夹袋
器加上袋子的两边。
2.5.2.1 Press the lower clamp switch button manually, fix the aseptic bag, make sure tighten,
loose the lower clamp switch button, then use the clamp-bag machine to clamp the two sides of
the bag.
2.5.2.2 按启动按钮，灌装头自动完成拔盖子、上卡爪摆动到后位、灌装管下，物料阀杆开
（此时急停不能在按下的状态），开始灌装。
2.5.2.2 Press the start button, filling head automatically complete pull out lid 、upper clamp
move backward、filling pipe down、material valve stem open ( now the emergency button can
not be in the press down condition), start filling.
注意:
Notice：
1 在灌装过程中，物料阀会受到蒸汽密封温度、灌装室温度的控制，如果两者有一个低于
设定温度，物料阀会自动关闭，待温度上升后，自动开启。
1 During filling procedure, the material valve can be controlled by the steam seal
temperature、filling chamber temperature, if any one of these two temperature lower than
setting temperature, the material valve will close automatically, and it will start
automatically till the temperature raising.
2 在拔盖子和压盖子的时候，会对袋口进行喷蒸汽消毒，时间可在触摸屏设定。
2 When pull out the lid or press the lid, it will spurt steam to the bag mouth for
sterilizing, time can be set on the touch screen.
2.5.2.3 当灌装量达到设定值后，压盖完成，手动按下爪开关 ，使袋口落下 ，并且手动松开夹
带器，此时标志这一桶已经灌装完毕。按下头升/降按钮，灌装头自动上升，当上升到上位后，按
下下爪开关，重复上袋子的步骤。
2.5.2.3 When filling amount reached the setting data, complete press the lid, manually press
the clamp switch button, make the bag mouth fall, and manually loosen the clamp-bag machine,
now is the symbol for the filling completion of this barrel. press the raise/down button, the filling
head move upward , when it raises into upper position, press the clamp switch button, repeat the
fix bag procedure.
注意：
Notice：
在灌装过程中要保持蒸汽的正常供给，防止温度持续下降，影响产品质量。
The steam supply should be keeping during filling procedure, to prevent product
quality be affected from temperature descending.
2.5.2.4 灌装头杀菌
2.5.2.4filling head sterilizing
如果在生产过程中，灌装室被污染，要立即停止灌装生产，对该侧灌装头进行清洗后单独
杀菌。灌装头的杀菌过程如下： 1、把杀菌头装上； 2、在触摸屏上手动将温度设定到 122 ℃，
时间 30 分钟。当触摸屏上的温度达到 120℃以后，开始计时，连续保持 30 分钟后，杀菌过程结
束。
If in working process, the filling chamber is polluted, the filling production should be stopped
immediately and sterilize the filling head of this side . The steps of filling head sterilizing is as
follows: 1 、fix the sterilizing head; 2 、Manually setting on the touch screen fortemperature to
122℃, time 30Min. when the temperature on the touch screen reached 120℃, the counting
18
begins. After 30 min, the sterilizing procedure completed.
（若在计时过程中，各温度控制点任何一点有低于 120℃的现象，在重新达到 120 后，再重
新计时 30 分钟）。
( when in the counting process, if any temperature control points is below 120℃, after
the temperature rises to 120℃ again, do counting to 30 min again.)
计时完毕后，待灌装室的温度下降至 100℃以下，排放阀不再有压力的情况下，按住下卡爪
开关按钮，打开下卡爪，取下杀菌头，可以开始灌装。
After the time counting completed, wait until the filling chamber temperature lower than
100℃, and the exhaust valve do not have pressure, hold the lower clamp switch button, open
lower clamp, take off the sterilizing head, can start filling.

2.5.3 清洗

2.5.3washing
一批物料灌装结束后，设备需要清洗，以备下次使用。由于灌装机自身没有清洗泵，需要
借用从杀菌机过来的清洗液进行清洗，步骤如下：
After one patch material filling completed, machine needs washing for production next time.
Filler has no washing pump. Therefore, filler can use washing liquid from sterilizer to do washing,
process as following:
2.5.3.1 关闭蒸汽供给总阀。
2.5.3.1 Close steam supply main valve
2.5.3.2 按住下卡爪开关按钮，打开下卡爪，装上清洗头。
2.5.3.2 Hold down the clamp switch button, Open lower clamp . Fix washing head.
2.5.3.3 将面板选择开关旋至清洗状态，按下启动按钮，开始清洗程序。
2.5.3.3 Turn the selection switch on the panel to washing condition, Press the start button
start the washing procedure.
2.5.3.4 当杀菌机用酸碱液清洗时，可按以上步骤冲洗几次后，按下急停按钮，让碱液（或酸
液）浸泡主管道，直至杀菌机打来清水时，再用清水反复清洗，直至干净为止。
2.5.3.4 When use acid liquid and alkali liquid to wash sterilizer, press the emergency button
after doing above steps for several times. Let main tube dip into alkali liquid (or acid liquid) till
sterilizer sending clean water. Then wash it by clean water repeatedly.
2.5.3.5 清洗完毕后，再按急停按钮，启动按钮，灌装管上升、上卡抓摆至前位，结束清洗工
作。
2.5.3.5 After the washing completed, Press the emergency button again, Press the start
button, filling pipe raising、upper clamp move forwards, finish washing process.
2.5.3.6 按住下卡爪开关按钮，开下卡爪，卸下清洗头。
2.5.3.6 Press the clamp switch button, Open left/right lower clamp separately ， Discharge
washing head.
2.5.3.7 关闭压缩空气供给总阀，关闭设备电源。
2.5.3.7Close compressed air supply main valve. Turn off the power.

3 故障及维护

3 Malfunction and maintenance

3.1 上卡爪向后摆动到位，灌装室上不去。
3.1 Upper clamp swing backward to right position, filling chamber cannot rise enough.
3.1.1 检查固定在摆动气缸尾部的磁性开关，其指示灯是否熄灭，同时检查固定在摆动气
缸头部的磁性开关，其指示灯是否亮，若位置不正确，松开固定螺钉，调整到正确位置后紧固即
可。
3.1.1 Check magnetic switch fixed on the end of swing cylinder, and check if the pilot lamp
is light or not. At the same time, check the magnetic switch on top of swing cylinder, and if the
pilot lamp is light or not. If the position is wrong, loosen the fixing screw, and regulate it to
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correct position and fasten it again.
3.1.2 检查控制灌装室上下的气缸，看气路是否正确，电磁阀是否工作正常。
3.1.2 Check the cylinder which control filling chamber to move up and down. check the path
is correct or not, and magnetic valve can work well or not.
3.1.3 检查是否有机械碰卡现象。
3.1.3 Check if there is mechanical collision.
3.1.4 检查控制灌装室上下的气压是否在 0.5MPa 以上。
3.1.4 Check if the air pressure is above 0.5Mpa, which control filling chamber to move up
and down.
3.2 设备杀菌时，灌装室温度上不去
3.2 During sterilizing, temperature in filling chamber isn’t high enough.
3.2.1 蒸汽减压阀的压力表显示是否达到 0.2～0.3MPa。
3.2.1 If the steam pressure reducing valve’s pressure gauge display reached 0.2--0.3Mpa.
3.2.2 灌装室的蒸汽供给、排放管路有无堵塞现象（拆下管路，清理堵塞物）。
3.2.2 If there is block in steam supply、exhaust pipe in filling chamber (Discharge pipes and
clean the block).
3.3 物料阀关闭时，从灌装口漏料
3.3 When the material valve closed, there is leakage from filling mouth.
3.3.1．阀杆下端密封圈被损坏，更换即可。
3.3.1. If valve stem lower part of sealing ring is damaged, change it.
3.3.2．旁路阀 AV3 端面密封垫被损坏或松动，更换密封垫或拧紧螺钉。
3.3.2.If by-pass valve AV3 end face sealing gasket is damaged or loose, change sealing
gasket or fasten screw.
3.3.3 灌装杆未上到位。
3.3.3 The filling valve stem is not in place.
3.4 上卡爪卡不住盖子或盖不上盖子
4.4 Upper clamp cannot hold lid or the lid cannot cover it.
3.4.1 上卡爪拉簧脱落，重新装上。
3.4.1 If extension spring of upper clamp is fall off, install it again.
3.4.2 上卡爪摆动位置不正确，调节上卡爪摆动拨板，使上卡爪对准物料袋。
3.4.2 If swing position of upper clamp is not correct, regulate swing shift panel of upper
clamp, and make upper clamp aim at material bag.
3.4.3 上卡爪向上或向下运动不到位，调到合适位置。
3.4.3 If upper clamp cannot move up and down to correct position, regulate it to suitable
position.
3.4.4 上卡板压盖子的定心元件松动，拧紧即可。
3.4.4 If centering components are loose which press the lid of upper clamp, fasten it.
3.4.5 上卡爪开合位置不正确，松开上卡爪拨叉上的 M5 紧固螺钉，将控制上卡爪开合的气
缸推到缸杆缩回的极限位置，使上卡爪完全合上，再拧紧上卡爪开合拨叉上的 M5 紧固螺钉。
3.4.5 If open and close position of upper clamp is not correct, loose M5 fasten screw of upper
clamp shift fork, and then make cylinder which control upper clamp close and open. Upper clamp
close completely, then fasten M5 fasten screw of upper clamp close/open shift fork.
3.5 上卡爪上下动作不灵活
3.5 Upper clamp cannot move up and down smoothly.
3.5.1 气缸与上卡爪的运动轴不同心，松开气缸固定螺母，将两个运动轴调至同心，再拧紧
螺母。
3.5.1 Cylinder and upper clamp motion shaft is not concentric, loose cylinder fixing nut.
Regulate two motion shafts to concentric, and then fasten the nut.
3.5.2 上卡爪蒸汽密封圈被损坏，更换即可。
3.5.2 If steam sealing ring of upper clamp is damaged, change it.
3.6 灌装室上下动作不灵活
3.6 Filling chamber cannot move up and down smoothly.
3.6.1 控制灌装室上下运动的气缸与其运动导轨不同心，松开紧固螺钉，调至两者同心后
再拧紧。
3.6.1. If the cylinder, which control filling chamber move up and down, and its moving guide
rails are not concentric, loose fixing screws. Regulate the cylinder and the guide rail to concentric,
and then fasten the screw.
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 3.6.2 灌装室上下蒸汽密封圈被损坏，更换即可。
3.6.2 Upper and lower steam sealing rings in filling chamber are broken. Change them.
3.6.3 控制灌装室上下气缸的气压小，调至 0.5MPa。
3.6.3 Pressure which controls filling chamber upper and lower cylinders is low. Adjust it to
0.5MPa.
3.6.4 快插调节阀调节不合适，重新调节即可。
3.6.4 Adjustment of inverted intercept valve is not proper. Adjust it again.
3.7 无菌袋中有气体
3.7 Air bubbles in aseptic bags.
3.7.1 检查灌装室排放管路是否通畅、排放阀是否打开。
3.7.1 Check if the exhaust path in filling chamber is stuffed or not and exhaust valve is open
or not.
3.7.2 阀杆中间一道密封圈被损坏，更换即可。
3.7.2 Sealing ring in the middle of valve stem is broken. Change it.
3.7.3 灌装口没插进无菌袋的袋口内，调整灌装室高度及上卡爪高度。
3.7.3 Filling mouth isn’t inserted in aseptic bag. Adjust the height of filling chamber and
upper clamp.
3.7.4 旁路阀（AV3）蒸汽密封圈被损坏，更换即可。
3.7.4 Bypass valve (AV3) Steam sealing ring is broken. Change it.
3.7.5 无菌袋的袋口与灌装口不匹配，更换无菌袋。
3.7.5 Aseptic bag mouth doesn’t match with filling mouth. Change aseptic bag.
3.7.6 计量误差较大
3.7.6 Too much metering error
3.7.8 请重新标定电子称。
3.7.8 Please recalibrate the electronic balance.
3.9 控制系统故障判断及排除
3.9 Controlling system malfunction and solution
指挥灌装机工作的 PLC 正常工作时主机板上绿灯亮，电源指示红灯亮，按钮指示灯闪亮，
各输入输出模板有信号端子的指示灯亮。
When PLC that controls the filler works normally, green lamp on main board is light; red
lamp of power supply is light; button pilot lamp blinks; and pilot lamps of signal terminals on
every input and output panels are light.
3.9.1 如果开机后电源指示灯不亮，则应查找交流电压有无输入、电源保险是否被损坏。
3.9.1 If pilot lamp of power supply isn’t light after startup, AC shall be checked if it has input
or not and power insurance device shall be checked if it is broken or not.
3.9.2 在交流电源输入低于 185V 时，PLC 将自动保护，不能工作。
3.9.2 When AC input is lower than 185V, PLC will be protected automatically and cannot
work.
3.9.3 在交流模板上，若某点有输入信号，则对应的指示灯亮，若不亮，必有故障。
3.9.3 On AC panel, when there is an input signal, the corresponding lamp shall be light;
otherwise, there must be an error.
3.9.4 在交流输出模板上，若某点有信号输出而无电压输出，指示灯也不亮，说明该板可能
有问题。当上端保险指示灯亮时，说明该路的内部保险已烧坏，需要更换。
3.9.4 On AC output panel, if there is a signal output but no voltage output and the lamp is not
light, it means that there is something wrong with the panel. When insurance lamp above is light,
it means that the inner insurance is burnt and need to be change.
3.9.5 多功能输入板，在开机时指示灯亮，等待主机板“ RUN”指示灯亮了以后，它应该立即
熄灭，如果该灯一直亮，则该模板有故障。
3.9.5Multi-functional input panel, when pilot lamp is light after startup, it shall be off
immediately when “RUN” lamp on main panel is light; otherwise, there is something wrong with
the panel.
3.10 温度显示偏差大
3.10 Too much deviation of displayed temperature
3.10.1.检查灌装室温控角阀是否打开；电磁阀是否有问题。
3.10.1 Check the filling chamber temperature control angle valve is open or not; the magnetic
valve is well or not.
3.10.2 温度测量是由传感器将信号送往指示仪表，若发生故障，首先应该检查温度传感器
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是否被损坏，通过测量它的电阻值可以判断是好是坏，它的铂电阻值在常温下大约在 100Ω 左
右，其次检查引线是否短路或断路，最后再检查仪表，以判断故障所在。
3.10.2 Temperature measurement signal is sent to indication meter through sensors. If there is
an error, temperature sensor shall be check first if it is broken or not. Measuring its resistor value
to see if it is good or not. The Pt resistor value is about 100Ω under room temperature. Then check
the lead wire if it is short circuit or shutoff. Finally check the meters to find out the error.
3.11 滚道故障及排除
3.11 Roller malfunction and solution
3.11.1 如滚道到位不停；检查滚道上的行程开关未回位或损坏；检修或更换。
3.11.1. If the roller do not stop when arrived it’s position; inspect the stoke switch on the
roller is not return or damaged; maintenance it or change.
3.11.2 滚道不管手动还是自动都不动；检查小车电机和链条；或电机继电器是否吸合。
3.11.2. If the roller does not move whether manual or automatic; inspect the trolley electric
motor and chain; or the motor relay is operating or not.
3.12 设备维护
3.12Equipment maintenance
设备需要进行经常性的维护，才能满足大量的、长时间的工作要求，避免在生产过程中出
现故障，影响生产，造成浪费，同时还可以延长设备的使用寿命。
Regular equipment maintenance is needed to satisfy the requirement of large quantity and
long time working in order not to have breakdown, influence production, and lead to material
waste at the same time, lift time of the equipment can also be prolonged.
具体做法如下：
Detail methods as following:
3.12.1 经常在各个运动部位加注润滑油（硅脂）；定期拆卸灌装室，把上卡爪转轴、物料阀 、
下卡爪等清洗干净，并涂抹润滑油（硅脂）后再重新装好；经常检查各处密封圈，如有损坏，及时
更换。
3.12.1Lubricant (or grease) shall be added to every moving positions regularly: disassemble
filling chamber regularly, clean the upper clamp, rotation shaft, material valve and lower clamp,
and re-install after smear lubricant (or grease). If anything is broken, it shall be changed in time.
3.12.2 经常检查个电机，链条的润滑油，及时添加，涂抹。
3.12.2 Check the lubricant oil of the electric motor, chain, keep adding and daubing in time.
切记：任何故障先检查前一步工作是否正常（尤其是相应电磁阀开关和光电开关是否正常亮
灭）。
Remember: when any accident happened, check the previous procedure is right or not
(especially the light of the corresponding magnetic valve switch and photoelectric switch are
normally turned on and off).

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