40.001.0020 Operating Instructions UniFill G2

Version 0.
7
2020-06-12
Operating Instructions
UniFill
FTSDS-14-4737 | Filltech GmbH| Anton-Böhlen-Str. 25| 34414 Warburg | info@filltech.de

Version
Operating 0.7
Versions
Version Date Changes
0.4 06.03.2020 corrected pressure range and test pressure
0.7 12.06.2020 corrected spare parts / added Information about environment
temperture
Filltech GmbH
Anton Böhlen Straße 25
D-34414 Warburg
Tel.: +49(0)5641 / 7 444 0 - 0
Fax.: +49(0)5641 / 7 444 0 – 21
Email: info@filltech.de
Original Operating Instructions
Copyright ©2020: Filltech GmbH
Subject to Change. Deviations Possible. All rights reserved.
FTSDS-14-4737 | Filltech GmbH| Anton-Böhlen-Str. 25| 34414 Warburg | info@filltech.de | 1

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Table of Contents
EU-DECLARATION OF CONFORMITY............................................................................................................... 4
GENERAL....................................................................................................................................................... 5
TECHNICAL DATA........................................................................................................................................... 6
ALLOWED MEDIA............................................................................................................................................................................................6
DIMENSIONS & WEIGHT................................................................................................................................................................................6
TERMINAL........................................................................................................................................................................................................6
LOAD CELL........................................................................................................................................................................................................6
GENERAL WARNING- AND SAFETY-INSTRUCTIONS......................................................................................... 7
WORKING ENVIRONMENT............................................................................................................................. 9
INTENDED USE............................................................................................................................................. 10
OVERVIEW.....................................................................................................................................................................................................10
Emergency Stop [ESD]-System..................................................................................................................................11
Main Switch...............................................................................................................................................................11
Controller / Terminal.................................................................................................................................................12
THE OPERATOR-TERMINAL (ITX000E)........................................................................................................... 14
STARTING THE TERMINAL............................................................................................................................ 15
USER INTERFACE.......................................................................................................................................... 16
MAIN MENU.................................................................................................................................................................................................16
SIMPLE WEIGHING.........................................................................................................................................................................................17
CYLINDER-FILLING........................................................................................................................................ 18
CYLINDERSELECTION.....................................................................................................................................................................................18
FILLING PROCESS...........................................................................................................................................................................................20
Details..........................................................................................................................................................20
SETTINGS..................................................................................................................................................... 24
GENERAL........................................................................................................................................................................................................24
CYLINDERFILE................................................................................................................................................................................................25
Overview......................................................................................................................................................25
Navigation...................................................................................................................................................25
Cylinder properties.......................................................................................................................................26
Create a new cylinder configuration............................................................................................................28
Step 1(ID)................................................................................................................................................................... 28
Step 2(Data).............................................................................................................................................................. 28
Step 3(Program)........................................................................................................................................................28
LANGUAGES...................................................................................................................................................................................................30
TROUBLESHOOTING..................................................................................................................................... 31
KNOWN MISUSE.......................................................................................................................................... 31
MANUAL VENTING VALVE IN WRONG POSITION........................................................................................................................................31
INSTALLATION............................................................................................................................................. 32
MOUNTING...................................................................................................................................................................................................32
ELECTRICAL INSTALLATION...........................................................................................................................................................................34

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INSTALLATION- UND COMMISSIONING RULES TO REDUCE NOISE AND VIBRATIONS.....................................34
RULES FOR COMMISSIONING AND OPERATING............................................................................................34
TRAINING AND REQUIREMENTS FOR OPERATORS........................................................................................34
RESIDUAL RISKS........................................................................................................................................... 35
MEDIUM........................................................................................................................................................................................................35
PRESSURE......................................................................................................................................................................................................35
NOISE.............................................................................................................................................................................................................35
ELECTRICAL INSTALLATION...........................................................................................................................................................................35
SAFETY RULES.............................................................................................................................................. 36
PSE (PERSONAL SAFETY EQUIPMENT)........................................................................................................... 36
TOOLS......................................................................................................................................................... 36
CONDITIONS UNDER WHICH THE MACHINE MEETS THE REQUIREMENTS FOR STABILITY...............................37
DURING OPERATION.....................................................................................................................................................................................37
DURING INSTALLATION.................................................................................................................................................................................37
DURING DISASSEMBLY..................................................................................................................................................................................37
WHILE OUT OF SERVICE................................................................................................................................................................................37
DURING TESTING..........................................................................................................................................................................................37
IN CASE OF FORESEEABLE FAILURES.............................................................................................................................................................37
SAFETY RULES FOR TRANSPORTATION......................................................................................................... 38
SAFETY RULES FOR STORAGE....................................................................................................................... 39
SAFETY RULES DURING OPERATION............................................................................................................. 39
PROCEDURE FOR ACCIDENTS AND FAILURES................................................................................................ 39
SETUP AND MAINTENANCE OF THE FILLING SYSTEM....................................................................................40
SETUP.............................................................................................................................................................................................................40
PREVENTIVE MAINTENANCE........................................................................................................................................................................40
Maintenance Plan........................................................................................................................................40
INSTRUCTIONS AND SAFETY GUIDELINE FOR THE SAFE INSTALLATION AND MAINTENANCE OF THE SYSTEM...........................................40
SERVICE ADDRESS.........................................................................................................................................................................................41
SPARE PARTS............................................................................................................................................... 41
APPENDIX.................................................................................................................................................... 41
ADM CALIBRATION MANUAL.....................................................................................................................................................................41

TECHNICAL OVERVIEW DRAWING...............................................................................................................................................................41
ELECTRICAL DRAWINGS................................................................................................................................................................................41
EU-DECLARATION OF CONFORMITY...........................................................................................................................................................41

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EU-Declaration of Conformity
A signed version of this document is part of the appendix.

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General
UniFill is a semi-automatic filling system for CO2-Cylinder with a fillweight of 4kg up to 50kg and a
maximum diameter of 300mm. The standard version is delivered with a W24,3 x 1/14” fill adapter, all
other adapters are optional.
The system is controlled by a weighing terminal (IT6000E). It is possible to store up to 50 different

recipies in the controller. The Controller is using the fill weight to observe the automatic fill process.
Whichs includes tare, open and close the valves.
Read and understand this operating instruction before beginning with

the installation and the commissioning of the machine.
Get familiar with the machine and all of its functions before operating
it.
Pay attention to all warning instructions listed in these operating

instructions at all time!
Pay attention to the Do not use the Machine in any other way then described in this
Operating Instructions operating instructions!
This is a new version of the operating instructions. It can be used under some restrictions for older
system as well. Some Functions may not be available for older systems. Some schemas and figures
may also differ.
This symbol marks very important sections of the operating

instructions.
You will find additional information below this symbol.
General
Mandatory-Symbol
This symbol marks very important sections of the operating

instructions. Not following these instructions may cause physical
damage to people or the machine.
You will find additional information below this symbol.
General Warning Symbol

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Technical Data
Power Supply 230V Schuko
16 [A]
1,0 KW
Connections Vacuum 10 [mm]
VSL 10 [mm]
CO2 10 [mm]
Pressure [min.] / [max.] 0 110 [bar]
Test Pressure 125 [bar]
Temperature Media [min.] / [max.] -20 40 [°C]
Temperature Environment [min.] / [max.] 0 40 [°C]
Allowed Media
CO2 Carbon Dioxide
Dimensions & Weight

Dimensions [H x B x T] 1450 x 1025 x 730 [mm]
Weight [ca.] 160 [kg]
Terminal
Systec IT6000E 50 Recipies
Load Cell
Min / Max 20 [g] 250 [kg]
Class MR C3MR

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General Warning- and Safety-Instructions

Note Safety-
Instructions!
Always use an approved Eye Protection while working on the machine.

Malfunctions of the burst discs or of parts of the machine may cause
releases of CO2 under high pressure.
Always use Eye Protection
Only work with approved ear protection.

The system generates an increased noise level.
Always use ear protection
Only work with approved feed protection.

Cylinders may fall down during handling.
Always use toe protection

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Perform Maintenance only if the power supply is disconnected and the

machine is shut down.
Break Power Supply before

Maintenance
Liquid CO2 is very cold this leads to cold piping.
Warning Cold Temperature
Cabinets may be under electrical power.

To open the cabinet is only allowed for trained and qualified personal.
Always shut down the power supply before opening the cabinet!
Warning electrical power
The system will open and close valves automatically after the start
button has been pressed.
If connected the external pumps system will be started after pressing
the pump start button. Ensure everyone is informed and in a save
position before starting the external pump system!
Warning automatic
controlled system

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Working Environment
The operator has to work in an upright position in front of the filling system. He has to handle the
cylinder, open and close the cylinder valves, start the filling process and he has to operate the
manual venting valve.
Only Use as Intended!
FTSDS-14-4737 | Filltech GmbH| Anton-Böhlen-Str. 25| 34414 Warburg | info@filltech.de | 9 /41

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Intended Use
Overview
Controler / Terminal IT6000E
ESD / Reset
Keyboard
Power OK Indicator
Main Switch

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Emergency Stop [ESD]-System

Pressing the red emergency button will activate the ESD-System.
All valves will be in fail safe position.
To deactivate the ESD-System the red emergency button has to be

pulled out and the green Reset button needs to be pressed.
Main Switch
Main Switch in Position [0] / OFF Main Switch in Position [1] / ON
The Main Switch open or closes the main power supply of the filling system.
To power up the filling system the main switch needs to be in Position [1] / ON.
To shut down the filling system the main switch needs to be in Position [0] / OFF.

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Controller / Terminal
The terminal is showing the actual weight on the
scale.
You can enter up to 50 Recipies which can be
used for the filling process.
For further information, like how to calibrate the

scale see the additional ADM-Calibration
Document which is part of the appendix.
Connections
(may differ for different kinds of Unifills)

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Cylinder Fixing System
Scale
Cover Plates

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The Operator-Terminal (ITX000E)
Figure 1: IT9000E (Terminal on the FillUnit may differ but the layout is similar)
1. Switch scale
If more than one scale is connected, the operator can switch between these scales.
2. Set zero
Sets the current scale to zero.
3. Display switch key
Switches between: Tare weight/Gross weight/Gross-Bargraph/calibratable weight storage.
4. Personal tare
Allows the operator to input a manual tare weight
5. Auto-Tare
Simple auto tare
6. Clr (Clear)
Clears the current user input (in input fields)
7. Enter-Key
The enter key is used to confirm user inputs. An equivalent key is located on the keyboard (9).
8. Function-Keys (F1-F6)
The function of each key depends in the ‘position’ within the program
9. Keyboard
Keyboard for user inputs.
10. Number pad
Note: The scale keys 1-5 will be deactivated during the fill process, to prevent the system
from manipulations.

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Starting the Terminal

If you start the terminal and an ‘Emergency stop’ error shows up, make sure the start button is
active. The start button (green) is located near the stop button.
Under normal circumstances the start screen should look like this:
Figure 2: The start screen
It shows information about the connected scales and the free internal memory.
 Calibration
Shows the calibration lock states of the connected scales. Open means the calibration lock of
the scale is not set and Closed means it is set. For further information about the calibration
lock, have a look at the technical manual of the ‘IT9000E’ terminal.
 Free Memory
The free internal memory of the scale.
 State of the Pressure-Transmitters
During the start sequence the system checks the pressure and the weight on the scales. If the system
found something unusual, it starts the ‘Move to Basic Position’ sequence.

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User interface
Main Menu
After a successful start the operator will see the ‘Main Menu’. The figure below shows all possible
user actions.
Figure 3: Main Menu
1. Cylinderfilling
Starts the fill process
2. Simple Weighing
Shows a simple weighing screen
3. Settings
Opens the settings menu.
The operator can use the navigation keys to select an entry and confirm the selection with the ENTER
key. Or he can use the number pad for a quick selection. (e.g.: press ‘1’ for ‘Cylinderfilling)

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Simple weighing
Figure 4: Simple weighing
1. Net (X)
Net (X) is the net weight with a higher resolution. With F1 the Net(X) entry can be enabled or
disabled.
The simple weighing screen shows also the current gross, tare and net values for the selected scale.
Scale actions like “Set Zero”, “Auto tare” and “Manual tare” can be performed with the keys
mentioned in the “The Operator-Terminal (IT9000E)” section of this document.
F6 (Exit) leads the operator back to the Main Menu.

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Cylinder-Filling
CylinderSelection
The first step in the filling process is the “CylinderSelection”. The selection defines the filling setpoint,
the recipe, the tolerances, vacuum level, tare ranges and a few internal values, needed for the filling
process.
Figure 4: Sample list
1. Search field
Allows the operator to search for a specific cylinder-id or cylinder name. This is very useful
for larger cylinder lists. After each change in this search field, the program selects the first
fitting cylinder within the list.
2. Cancel
Leads back to the Main Menu
3. The cylinder list
Each list entry represents a cylinder with ID and name.
Navigation: up, down, left, right; Confirm: ENTER
Left and right are used for paging, this may help to navigate through larger lists.
Use Settings/Cylinderfile to add new cylinder type definitions.

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After the operator has selected a cylinder, a simple confirm screen shows up (5).
Figure 5:ConfirmScreen (Sample CO2/N2 Mix)
This confirm-screen shows information about the selected cylinder type. Amongst others it shows
the target tare- and filling-ranges. The green areas are the target ranges und the red are out of range.
Possible inputs:
 Yes (F1)
Confirms the selection and starts the filling process with the selected cylinder.
 No (F2)
Cancels the selection und leads back to the cylinder selection dialog.
If the operator has not confirmed/disconfirmed this dialog after 5 seconds, the program chooses
‘Yes’ and starts the filling process.
Note: The ConfirmScreen (Figure 5) is just a sample and may differ according to the selected cylinder.

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Filling process
Figure 6 shows an abstract view of the filling process. This is just an overview and doesn’t show all
minor aspects of the filling process.
As figured in the drawing, the “Filling process” can be aborted and stopped. It can be aborted at
almost every point of the filling process, by pressing F6. An emergency stop (local/main) will stop the
complete filling process immediately.
Further details can be found below the following figure.
Figure 6: Filling process
Details:
Following, details for each major step of the filling process. ‘Main Menu’ and ‘Cylinder-Selection’
have already been discussed and can be found in the according sections of this document.
 Input
A simple input dialog for the current batch number and the cylinder barcode(s). At first the
dialog asks for the Batch-Nbr. The operator can confirm his input with the ENTER key.
Then the operator can scan the target cylinder(s).
(The Input-Step is optional and may not be included in your configuration)

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 Place cylinder
At this point, the operator is asked to place a cylinder in the scale
Figure 7: Place Cylinder Screen
 Tare-Check [optional]
According to the cylinder configuration, a tare check will be performed with the vessel which
is placed on the scale.
 Connect cylinder
The operator is asked to connect the cylinder to the fill connector and to open the cylinder
valve (if not done before)
 Fill
The filling starts after pressing the ‘Start Filling’ button. With pressing this button, the
operator confirms the correct execution of the steps mentioned above.
5
2 3
1 6
4
Figure 8:Active filling
1. Progress bar
Visualises the fill progress of the current filling step
2. Fill pressure
3. Pipework pressure (if available)

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4. Valve states: Green (open), Red (closing/closed)

a. Agent 2: Fill valve of the second agent (N2 in this sample)
b. Agent 1: Fill valve of the first agent (CO2 in this sample)
c. VSL: Vent-Valve
5. Fill progress (current/Setpoint)
Shows the current agent and the progress of the current fill step
6. Setpoints
Shows the setpoint of each agent to fill
Possible Problems:
 Awaiting clearance
Another filling module is filling the required agent und this modules has to wait.
 Valves not closed
Not all valves are closed as expected.
 Vent
In this step, the operator has to ensure, that all cylinder valve is closed.
The vent process starts after pressing the external vent button.
 Print label(s)
Figure 9:Print label

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This dialog shows an overview of the filling data. With ‘Reprint’ (F2) the operator can
reprint the current label and ‘Done’ (F1) leads to the next step.
(The Print-Label-step is optional and may not be included in your configuration)
 Remove cylinder(s)
At this point the operator is asked to remove all connected cylinders.
 Special: Emergency Stop

An ‘emergency stop’ (local or main) stops the filling process and all valves are closed. After
the ‘emergence stop’ is released the program will cancel the filling process.

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Settings
The settings menu may be secured with a password. This depends on the password setting at
General/Password.
After access is granted, the operator has 3 options:
 General
 CylinderFile
 Languages
Note: F6 leads back to the main menu
Following, further details for each option and all available properties.
General
 Date
The current date
 Time
The current time
 Always choose [Y, N]
Y=The ‘Select Cylinder’ dialog appears after each filling.
N=After each successful filling, the program starts a new filling-process with the cylinder
selected previously.
 Gas1
Name of the first agent. This name will show up in the UI
 Gas2
Name of the second agent. This name will show up in the UI
 Valve-Delay [Agent1][in Kg, Default: 0,060]
This value is used to compensate the [Agent1] fill-valve close-delay. The filling process will
close the fill valve x Kg before reaching the setpoint. Due to the close-delay, the filling will
still reach its setpoint.
 Valve-Delay [Agent2] [in Kg, Default: 0,060]
This value is used to compensate the [Agent2] fill-valve close-delay. The filling process will
close the fill valve x Kg before reaching the setpoint. Due to the close-delay, the filling will
still reach its setpoint.
 Password
This password is used to secure the settings menu. If not empty, the operator can only access
the settings menu if he/she knows the password.
If the operator presses ‘F6’ this dialog may show up:
Just select ‘Yes’ and confirm with ‘ENTER’

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CylinderFile
The CylinderFile dialog contains all cylinder configurations fillable with this program and can be
extended by the operator.
Overview
Figure 10: CylinderFile dialog
 x/50
x=current cylinder-config count
50=Max. Capacity
In this sample, there is space for 46 more cylinder configurations.
 Print (F2)
Not supported.
 Find (F3)
Shows a list with all available configurations. The operator can select a configuration within
this list, using the up and down key for navigation and the ENTER or F6 key to confirm a
selection.
 Delete (F4)
Deletes the current selected cylinder configuration. Before the final deletion, the operator
has to confirm the deletion.
 Exit (F6)
Leads back to the general settings menu. Every change within the cylinderFile will be applied.
Navigation
For the primary navigation, the navigation keys should be used:
RIGHT/LEFT: Pages through the existing cylinder configurations.

Exception: If a property, with a given value set is selected, the right and left keys are used to select a
value within the value scope.
UP/DOWN: Scrolls through the cylinder properties

Exceptions: If the ‘ID’ field is selected and the operator presses UP, the dialog jumps to the previous
cylinder configuration. The dialog jumps to the next configuration, if the ‘Program’ field is selected
and the operator presses the DOWN key.

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Cylinder properties
 ID
The unique cylinder configuration id. You are free to choose any number, with one
exception: the ID 99999 is used internal and a configuration with this ID will be deleted
automatically.
 Name
A name for the current configuration.
 Scale [1-9, Default: 1]
Defines, which scale will be used for the filling process. It should normally be scale number 1.
Exception: e.g. you have an additional bundle scale.
 Setpoint Gas 1 [in Kg]
The amount of [Agent1] which shall be filled in the cylinder during the filling process. This
also can be zero if only [Agent2] shall be filled.
 Setpoint Gas 2 [in Kg]
The amount of [Agent2] which shall be filled in the cylinder during the filling process. This
also can be zero if only [Agent1] shall be filled.
 Gas1 Tolerance + [in Kg, Default: 0, only available if ‘Setpoint Gas1’ is greater than zero]
Together with the setpoint, the ‘tolerance+’ value defines the upper limit for the cylinder
filling. ‘Tolerance+’ is the maximum positive deviation of the setpoint.
Example: setpoint=10Kg, tolerance+ =0.05kg. The fill procedure will accept a maximum fill
weight of 10.05kg.
 Gas 1 Tolerance – [in Kg, only available if ‘Setpoint Gas1’ is greater than zero]
Together with the setpoint, the ‘tolerance-‘ value defines the lower limit for the cylinder
filling. ‘Tolerance-‘ is the maximum negative deviation of the setpoint.
Example: setpoint=10Kg, tolerance- =0.05kg. The fill procedure will accept a minimum fill
weight of 9.95kg.
 Gas 2 Tolerance + [in Kg, Default: 0, only available if ‘Setpoint Gas2’ is greater than zero]
Together with the setpoint, the ‘tolerance+’ value defines the upper limit for the cylinder
filling. ‘Tolerance+’ is the maximum positive deviation of the setpoint.
Example: setpoint=10Kg, tolerance+ =0.05kg. The fill procedure will accept a maximum fill
weight of 10.05kg.
 Gas 2 Tolerance – [in Kg, only available if ‘Setpoint Gas2’ is greater than zero]
Together with the setpoint, the ‘tolerance-‘ value defines the lower limit for the cylinder
filling. ‘Tolerance-‘ is the maximum negative deviation of the setpoint.
Example: setpoint=10Kg, tolerance- =0.05kg. The fill procedure will accept a minimum fill
weight of 9.95kg.
 TareCheck [Y/N]
If the tare check is active (Y) the tare weight of the placed cylinder will be checked using the
following tare check properties:’ Min. Tare’,’ Max. Tare’ and ‘Tare tolerance’. Is the tare
check not active for this cylinder configuration (N), no tare check will be performed when the
operator chooses this cylinder configuration.
 Min. Tare [in Kg]
Minimum tare weight.
 Max. Tare [in Kg]
Maximum tare weight.

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Note: Is ‘Max Tare’=0, the ’Tare Check’ procedure will only check the min tare weight. If the
result of this check is positive, the tare weight will be set automatically.
 Tare tolerance [in Kg]
This is the maximum difference (negative and positive) between the measured cylinder
weight and the weight given by the operator.
 FlushWeight [in Kg, Default: 0]
if this value is greater than zero, the cylinder will be flushed before the fill process starts
([Agent1] will be used).
 Vacuum level [in Bar, Default: 0.200]
Optional: needed if the cylinder shall be vacuumised.
Defines the lower pressure limit for the vacuum process. If the vacuum pressure drops below
this limit, the vacuum process is done.
 Vacuum cycle time [in Seconds]
Defines the time for each vacuum cycle. This is the duration the program tries to generate a
vacuum before it checks the pressure. If the check fails, it starts again. The program will
repeat these steps until it reaches the defined vacuum pressure.
 Vacuum equal time [in Seconds]
This is the time, the program waits after each vacuum cycle to normalise the pressure.
 Program
The program controls the filling process. Options:
o UniFill Mix
default UniFill Mix programm
o UniFill Mix Vac
UniFill Mix Program that includes all necessary steps to vacuumize the cylinder
Note: Greyed/disabled properties are not necessary for the current cylinder configuration or are not
needed for this filling module.
The F6 key confirms the cylinderFile dialog and leads the operator back to the settings menu. If the
current focus is on the ‘Program’ field, the F6 key will show no response. Just select another field and
try F6 again.

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Create a new cylinder configuration

This is a little How-to that should help to create a new cylinder configuration.
Step 1(ID)
The first thing you need for a new configuration is a free ID. There are multiple ways to find a new ID.
At first you can page to the last cylinder (the one with the highest ID) with the RIGHT key. Then just
add one (+1) to its ID and you have the next free ID. Or you can use trial and error to find a new ID.
Just guess an ID and type it into the ID field (no matter what cylinder is selected) and press ENTER. If
the program shows an existing cylinder configuration (the Name field is not empty) the ID you have
guessed is already in use. Try another guess until you find one with an empty Name field.
Step 2(Data)
After the ID has been found, you can start to fill the other property fields according to the cylinder
type.
 For the Name you can choose a free Text. It is an advantage if the name contains the agents,
the setpoints and for example ‘VAC’ (if the cylinder shall be vacuumised). This just helps to
find the correct cylinder configuration.
(e.g.: 22.5Kg CO2 VAC)
 Scale should be 1. Except you want to use an add-on scale.
 Setpoint and Tolerance+/- should be given
 If you don’t want a tare check choose ‘N’ for ‘TareCheck’ and skip min-/max-Tare and tare
tolerance. Else choose Y for ‘TareCheck’ and set:
o Min-/Max-Tare to an applicable range. If you set Max-Tare to zero, the program will
only check the Min-Tare weight (automatically)
o Tare tolerance is used if the operator has to input the tare weight manually (‘Max-
Tare’ is non-zero). The value depends on the cylinder size and should also be
given.
 If you want to generate a vacuum before filling, you have to fill the vacuum properties. Else
you can skip them.
o For vacuum level you can use the default value: 0.2Bar
o Cycle time and equal time depends on the cylinder size
You also have to use a vacuum program, if you want to generate a vacuum before filling.
(Step 3)
Step 3(Program)
The last thing you have to choose is the program which defines the filling workflow. If you know the
ID of the program you want to use, just type it into the program field and then you are done and can
skip the rest of this how-to.

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Figure 11: CylinderFile (Program)
If the program field has the focus, you can press F3 (Select) and you will see a List with all available
programs (Figure 12).
Note: the list in Figure 12 is just a sample and may differ from the list you will see.
Figure 12: Program list (just a sample)
You can navigate through this list with the UP and DOWN navigation keys. To confirm a selection you
can press OK or ENTER.
After you have selected a program, you are done with this cylinder configuration. Ensure the
program field is no longer selected, and then you can press F6 to quit the CylinderFile dialog.

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Languages
The language menu offers the following options:
1. Select language
Offers a list of all available languages (English, German, Polish, French, Spanish, Swedish).
After the operator has confirmed his selection (ENTER or OK), the program switches to the
new language.
2. Edit texts
After selecting this option, a dialog, similar to the cylinderFile dialog, appears. It allows the
operator to change almost every text, used in this program. The navigation is equal to the
cylinderFile navigation.
3. Export texts (USB)
It might be necessary to export the texts to import the texts at another terminal. This can be
done with this option. Just put in an USB-Storage, choose a file name and press ENTER. After
a few seconds the Languages menu should reappear.
4. Import texts (USB)
To import a previously exported or otherwise given language pack, this option can be used.
Before selecting this option, a USB-Storage with the language pack file should be connected
to the terminal.
If the program finds any usable language pack(s) in the root directory of the USB-Storage, the
operator has the opportunity to select one and confirm his selection with ENTER or OK.
Note: The loading process may take several minutes.

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Troubleshooting
Known Misuse
Manual Venting valve in wrong position

If the manual venting valve is in the wrong position it is not possible to fill the cylinder correctly.
Ensure that the valve is closed for filling and is open to release the pressure after a cylinder is filled.
You will find the contact data at www.filltech.de for any other Issue.

Version
Operating 0.7
Installation
Prepare a base of at least 20 cm concrete to mount the filling system on it. It is possible to install the
Filling System in a pit to have the scale and the floor on the same level. This will be helpful for the
cylinder handling. It is also possible to integrate the filling system into a platform to have the same
level for floor and scale.
Mounting
Remove the cover plates to get to the base f
Mount the base frame to the prepared concr

Version
Operating 0.7
Put the cover plates back

in place.
Connect all hoses like

shown in chapter
connections.
It is also recommended to
install a CO2 decection
and warning system next
to the filling system.

Version
Operating 0.7
Electrical Installation
For more information see the electrical drawings.
Connect the 230V Power plug to a suitable power supply.
Installation- und Commissioning Rules to reduce Noise and Vibrations

 Mount the filling system by using all prepared fixing holes
 Ensure that the pipework is fixed
 Do not remove the cover plates while using the filling system
Rules for Commissioning and Operating

 Ensure that the filling system is correctly installed.
 Ensure that the area is well ventilated before operating the filling system
 Ensure that the power supply is ok
Training and requirements for Operators

Only People that fulfil the following rules are allowed to operate the pump system:
 The operator has to be of age in the country of use and at least 18 years
 The operator must meet all the physical requirements to be able to operate the system.
These include, among others:
o Functionality of arms and hands
o Good eyesight
o Good hearing
 The operator has to be able to operate the system on its own and to react on failures
according the operating instructions.
The following training is required to be able to operate the pump system:
 The operator must have read and understood the operating instructions and he has to sign
and confirm it.
 The operator has to get familiar with all functions of the pump system before starting
operation.
o Very important is the position and the function of the Emergency Stop System

Version
Operating 0.7
Residual Risks
All actions have been taken to minimize the risks arising from the installation. Nevertheless, there are
the following residual risks that must be taken into account when operating the system!
Medium
The used medium is very cold. Wear gloves while operating the system.
There is a risk of life if there is a great amount of CO2 leaking out of the system. It is recommended
to install a gas warning system next to the pump.
Pressure
The system is operating on high pressure. If a hose or pipeline is breaking the operator might be hurt.
Always were the PSE while operating the system.
Noise
Operating the system is causing a high load of noise. Always wear ear protection!
Electrical Installation
Inside the control cabinets, voltage can also be applied in the switched-off state. Control cabinets
may only be opened by skilled personnel who are adequately qualified and trained to perform
electrical work.

Version
Operating 0.7
Safety Rules
The operator has to
 Wear his PSE

 Shut down the system before maintenance
o This also includes removing the cover plates!
PSE (Personal Safety Equipment)

The operator has to wear the following PSE while operating the system:
 Ear protection
 Eye protection
 Feed Protection
 Hand Protection
o Gloves
The PSE has to be certified and authorized for industrial use.
Tools
It is not allowed to add any kind of additional tools to the filling system.
Please ask for optional cylinder adapters.

Version
Operating 0.7
Conditions under which the machine meets the requirements for

stability
For the stability of the installation, a sufficiently fixed floor slab designed for the overall weight of the
installation is required. Use anchors to anchor the system
During Operation
During operation, the system must be anchored to the floor plate at all times. For this purpose, the
bores in the stands must be used. If the system is not properly anchored, the system may be shifted
due to vibrations during operation. It is also important to ensure that the system is aligned
horizontally.
During Installation
During assembly, ensure that the system is in a horizontal position at all times. The base should be
anchored immediately after aligning the unit. Use the holes in the base.
During disassembly
During dismantling, care must be taken that the anchors are not released until all other components,
such as the pipeline, etc., have been removed.
While out of service

If the system has been put out of service and has not been disassembled, care must be taken to
ensure that the anchorages have not been released.
If the system has been disassembled, it may only be transported and stored horizontally on the base.
An additional frame is recommended for storage.
During Testing
For testing ensure that all anchors are properly fastened.
In case of foreseeable failures

Ensure that all anchors are properly fastened.

Version
Operating 0.7
Safety Rules for Transportation

The equipment may always only be lifted by the frame and never by the pressure system or switch
box / cabinet. Before transport the filling system, make sure that the equipment is without load.
During transport, protect the equipment from impact and slipping sideways.
Please note, but not exclusively, the following information: Check Safety Rules for
Transportation!
 Ensure there is no CO2 left inside the pump before disassembly or transportation
 Ensure that all cables and pipe have been removed:
o Liquid supply line
o Ring Return line
o Power supply
o Control wires
 Ensure that the system is adequately protected against tilting and slipping during the
transport. You may use the following approved tools:
o Anti-Slip mats
o Tensioning straps
o Chains
 Ensure that the filling system is protected against dirt and moisture.
 Use only approved lifting devices to lift the filling system.

Version
Operating 0.7
Safety Rules for Storage

For storage, the same safety instructions apply as for transport.
An adequately fixed storage location designed for the weight of the plant is assumed. In addition,
ensure that the storage location is protected against environmental influences such as rain and dirt.
Safety Rules during operation

 Always wear the required PSE.
 Before starting the filling-system ensure that all cover plates are mounted.
 Never open the cover plates during operation.
 Do not climb on the pump.
Procedure for accidents and failures

 Use the ESD-System to stop the system immediately
 If there is any leacking part of the system close all tank / vessel In case of accidents!
valves To stop the CO 2 supply
 In case of leaks ensure that the CO2-Concentration is not getting dangerous.
 Check the display for information about the errors. Solve the errors according the operating
instructions.

Version
Operating 0.7
Setup and Maintenance of the Filling System

Setup
 Check if the Power supply is connected;
 Check if the electrical wiring is ok to start the external pump system.
 Check if all hoses are connected correctly and they are thightened
 Ensure that nothing is blocking the scale
Preventive Maintenance
Most components of the filling system are maintenance free. Anyway, the following parts should be
checked or replaced within the recommended maintenance intervals.
Maintenance Plan
Part Interval
Hoses Daily visual Monthly inspection and tighten of Technical Replace
inspection for leaks connections Checkup hose with
Every 6 a new
Month hose
every 2
Years.
Scale Check every day by Recalibration if required
using a check weight.
Instructions and safety guideline for the safe installation and maintenance
of the system
Work on the pressure system, on the mechanical system and on the electrical system may only be
carried out by people who are qualified and have been specially trained for the respective case of
operation. The respective safety requirements must always be observed.
Before starting to work on the filling system ensure that:
 You have informed the responsible person about the maintenance work
 The filling system is placed at a well-ventilated place
o The venting process may lead to a high concentration of CO2
 The filling system is pressure less. Close all tank valves and vent the filling system completely.
 All remote start functions are disabled
 Before working on the safety devices or pipework ask the manufacture for advises!
o Do not change the release pressure of the safety valves!
 Only use spare parts listed below. At any question contact the service. Contact data is below.
 Always wear the required PSE

Version
Operating 0.7
Service Address
FILLTECH GmbH
Anton – Böhlen – Straße 25
34414 Warburg / Germany
www.filltech.de
Tel.: +49(0)5641/74440-0
Fax.: +49(0)5641/74440-21
Spare Parts
Article Number Version Description
40.015.0003 W21,8 Fill Adapter
40.210.0008 Saftey Belt
40.320.0001 Load Cell K-PW12C 250K
40.323.0005 Analog Scale Connection Module ADM
40.323.0006 Relais Box 8 I/O -RS485 – HS – 24VDC
40.323.0007 Base Module E/A MAI – RS485 – HS -24VDC
40.323.0008 Analog Input ADE 0-20mA / 0-10V
40.323.6001 Scale Controller IT6000 E 110-240 VAC Wall/Table
40.370.0007 Power Supply PSLC243
40.500.0011 Solenoid Valve 2/2 DN8 PN110 IG1/4” 24VDC
40.500.0012 Solenoid Valve 2/2 DN6 PN4 (Vak) IG1/4” 24VDC
40.500.0016 Solenoid Valve 2/2 DN1,5 PN120 IG1/4” 24VDC
40.500.0109 Non Return Valve G1/4 / 10
40.511.0007 Reliefe Valve 5.2 110bar ¼”
40.530.0004 O-Ring 10,8 x 2,62 EPDM 70
40.541.0005 Pressure Gauge 160bar
40.541.0023 Pressure Transmitter abs. 0-160bar 4-20mA G1/4”
40.550.0003 Hose A10 1200 mm
40.550.0010 Hose A10 1000 mm
40.570.0151 M8 x 20mm Residual Gas Pin
Appendix
ADM Calibration Manual
Technical Overview Drawing
Electrical Drawings
EU-Declaration of Conformity

40.001.0020 Operating Instructions UniFill G2

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Version 0.

FTSDS-14-4737 | Filltech GmbH| Anton-Böhlen-Str. 25| 34414 Warburg | info@filltech.de

Anton Böhlen Straße 25

Tel.: +49(0)5641 / 7 444 0 - 0

Fax.: +49(0)5641 / 7 444 0 – 21

Original Operating Instructions

Copyright ©2020: Filltech GmbH

Subject to Change. Deviations Possible. All rights reserved.

FTSDS-14-4737 | Filltech GmbH| Anton-Böhlen-Str. 25| 34414 Warburg | info@filltech.de | 1

GENERAL WARNING- AND SAFETY-INSTRUCTIONS......................................................................................... 7

THE OPERATOR-TERMINAL (ITX000E)........................................................................................................... 14

STARTING THE TERMINAL............................................................................................................................ 15

MANUAL VENTING VALVE IN WRONG POSITION........................................................................................................................................31

FTSDS-14-4737 | Filltech GmbH| Anton-Böhlen-Str. 25| 34414 Warburg | info@filltech.de | 2

RULES FOR COMMISSIONING AND OPERATING............................................................................................34

TRAINING AND REQUIREMENTS FOR OPERATORS........................................................................................34

PSE (PERSONAL SAFETY EQUIPMENT)........................................................................................................... 36

SAFETY RULES FOR TRANSPORTATION......................................................................................................... 38

SAFETY RULES FOR STORAGE....................................................................................................................... 39

SAFETY RULES DURING OPERATION............................................................................................................. 39

PROCEDURE FOR ACCIDENTS AND FAILURES................................................................................................ 39

SETUP AND MAINTENANCE OF THE FILLING SYSTEM....................................................................................40

ADM CALIBRATION MANUAL.....................................................................................................................................................................41

FTSDS-14-4737 | Filltech GmbH| Anton-Böhlen-Str. 25| 34414 Warburg | info@filltech.de | 3

A signed version of this document is part of the appendix.

FTSDS-14-4737 | Filltech GmbH| Anton-Böhlen-Str. 25| 34414 Warburg | info@filltech.de | 4

The system is controlled by a weighing terminal (IT6000E). It is possible to store up to 50 different

Read and understand this operating instruction before beginning with

Pay attention to all warning instructions listed in these operating

This symbol marks very important sections of the operating

This symbol marks very important sections of the operating

General Warning Symbol

FTSDS-14-4737 | Filltech GmbH| Anton-Böhlen-Str. 25| 34414 Warburg | info@filltech.de | 5

Dimensions & Weight

FTSDS-14-4737 | Filltech GmbH| Anton-Böhlen-Str. 25| 34414 Warburg | info@filltech.de | 6

General Warning- and Safety-Instructions

Always use an approved Eye Protection while working on the machine.

Always use Eye Protection

Only work with approved ear protection.

Always use ear protection

Only work with approved feed protection.

Always use toe protection

FTSDS-14-4737 | Filltech GmbH| Anton-Böhlen-Str. 25| 34414 Warburg | info@filltech.de | 7

Perform Maintenance only if the power supply is disconnected and the

Break Power Supply before

Liquid CO2 is very cold this leads to cold piping.

Warning Cold Temperature

Cabinets may be under electrical power.

Warning electrical power

FTSDS-14-4737 | Filltech GmbH| Anton-Böhlen-Str. 25| 34414 Warburg | info@filltech.de | 8

Only Use as Intended!

FTSDS-14-4737 | Filltech GmbH| Anton-Böhlen-Str. 25| 34414 Warburg | info@filltech.de | 9 /41

Controler / Terminal IT6000E

FTSDS-14-4737 | Filltech GmbH| Anton-Böhlen-Str. 25| 34414 Warburg | info@filltech.de | 10

Emergency Stop [ESD]-System

To deactivate the ESD-System the red emergency button has to be

Main Switch in Position [0] / OFF Main Switch in Position [1] / ON

FTSDS-14-4737 | Filltech GmbH| Anton-Böhlen-Str. 25| 34414 Warburg | info@filltech.de | 11

For further information, like how to calibrate the

FTSDS-14-4737 | Filltech GmbH| Anton-Böhlen-Str. 25| 34414 Warburg | info@filltech.de | 12

Cylinder Fixing System

FTSDS-14-4737 | Filltech GmbH| Anton-Böhlen-Str. 25| 34414 Warburg | info@filltech.de | 13

The Operator-Terminal (ITX000E)

FTSDS-14-4737 | Filltech GmbH| Anton-Böhlen-Str. 25| 34414 Warburg | info@filltech.de | 14