INSTRUCTIONS FOR ADJUSTING

FILLING HEIGHT
COMPATIBLE TO MACHINES: 2257 / 2216 / 2265

Machinentyp: FS 910 / BA10 (BA2)

Customer: Nestlè Dolce Gusto (CH, ES, UK, DE)

Rychiger AG, Alte Bernstrasse 135, 3613 Steffisburg, Switzerland

T +41 33 439 68 68 / F +41 33 439 68 88 / www.rychiger.com
History

Revision Date Comment Editor

Instructions for adjusting 14.04.2014 First version Philippe Lehmann

filling height

Changing Text in Chapter 16.10.2014 Version r02 BMU

2 and 3.

This document is confidential and is intended only for internal use. This is a Rychiger AG publication which is
protected by copyright. No part of this document may be photo-copied, reproduced, or translated to another
language without the prior written consent of Rychiger AG. The information contained in this documentation is
subject to change without notice.

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TABLE OF CONTENTS

1 SAFETY AND PREPARATION .......................................................................................................... 4

1.1 PREVENTION OF PERSON AND MATERIAL DAMAGE .................................................................. 4
1.2 PREPARATION FOR ADJUSTING FILLING HEIGHTS .................................................................... 4
1.2.1 Needed material .................................................................................................................................. 4
1.2.2 Cleaning .............................................................................................................................................. 4

2 ADJUSTING FILLING HEIGHT RYAG-FILLER ................................................................................ 5

2.1 CHECK HOME POSITION, INSTALLING GAUGES .......................................................................... 5
2.2 CHANGES FOR RYAG FILLER ON PLC AND HMI .......................................................................... 7
Main PLC ............................................................................................................................................ 7
Servo PLC ........................................................................................................................................... 7
HMI ...................................................................................................................................................... 8
2.3 MEASURING ...................................................................................................................................... 9
2.4 ADJUSTING ...................................................................................................................................... 10

3 ADJUSTING FILLING HEIGHT ALLFILL-FILLER .......................................................................... 12

3.1 CHECK HOME POSITION, INSTALLING GAUGES ........................................................................ 12
3.2 CHANGES FOR ALLFILL FILLER ON PLC AND HMI ..................................................................... 13
Main PLC .......................................................................................................................................... 13
Servo PLC ......................................................................................................................................... 13
HMI .................................................................................................................................................... 14
3.3 MEASURING .................................................................................................................................... 15
3.4 ADJUSTING ...................................................................................................................................... 16

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1 SAFETY AND PREPARATION

1 SAFETY AND PREPARATION

1.1 PREVENTION OF PERSON AND MATERIAL DAMAGE
In case of lack of clarity and uncertainties as to hazard areas and prevention of accidents,
please read chapter "Safety" in Operating Instructions of machines no. 2257-xxx or 2216-
xxx or 2265-xxx.
Only correspondingly trained industrial mechanics may carry out the following described
work. Mastering the machine operating is indispensable to do this (Chapter “Machine
Operation” in manuals 2257-xxx or 2216-xxx or 2265-xxx).

Principally no hard tools and abrasive cleaning agents must be used. Exceptions are
specified in the corresponding passages of the operating instructions (2257-xxx or 2216-
xxx or 2265-xxx).

1.2 PREPARATION FOR ADJUSTING FILLING HEIGHTS

1.2.1 Needed material

Gauge Funnel 10 Pieces 00127806 665110

Gauge cup holder 10 Pieces 00127807 665111
Gauge 50 mm 1 Pieces 665112
Kröplin 1 Pieces 665113
Bolt 6Kt- M5x10 40 Pieces 104698
Bolt In 6-Kt M6x80 10 Pieces 104988

1.2.2 Cleaning
1. Empty machine.
2. Stop machine.
3. Take out the hopper.
4. Clean hopper and filler area
with soft brush and vacuum
cleaner.

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2 ADJUSTING FILLING HEIGHT RYAG-FILLER

2 ADJUSTING FILLING HEIGHT RYAG-FILLER

2.1 CHECK HOME POSITION, INSTALLING GAUGES

1. Check home position acc-

ording Rychiger Operating
instructions, Chapter 9.6.
Home of crankshaft is -80°
on the block.
2. If home position is not okay
adjust according to manual.
3. Dismount aluminum plate.
The plate is mounted with
6x M6 screws.
4. Dismount all funnels.
5. Dismount all augers.
6. Take out the acrylic gas
cover under the hopper. Funnels 6 screws Aluminium plate

7. Remove all center screws of

the cup holders.

Cup
holder

8. Mount gauges 665111 onto

the cup holders. Make sure,
the bolts do not protrude. Gauges

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2 ADJUSTING FILLING HEIGHT RYAG-FILLER

9. Pending on junction of funnel

to hopper, use the gauge as
shown on the pictures.

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2 ADJUSTING FILLING HEIGHT RYAG-FILLER

2.2 CHANGES FOR RYAG FILLER ON PLC AND HMI

Main PLC
Export Routine (Control_Lift_Height) from Base Project.
(PLC_Rychiger_Main_Rychiger_Filler_Date_2014_04_03.ACD) and import to your project.

Servo PLC
Export Routine (Manual_JOGMove_Handler) from Base Project.
PLC_Rychiger_Servos_Rychiger_Filler_Date_2014_043_03.ACD) and import to your project.

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2 ADJUSTING FILLING HEIGHT RYAG-FILLER

HMI
Open up Baseproject and your Project in the english language.
Copy the «Filling Height », «Inch To Fill Pos » and « Filling Hight Correction » Button from base
Project (TS_2216_with_AllFill Filler-apa) to your Project page 305.

New Buttons

Filling Height

Inch To Fill Pos

Filling Height Correction

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2 ADJUSTING FILLING HEIGHT RYAG-FILLER

2.3 MEASURING

1. Login as admin, to have

access to the page 305.
2. Set filling height to 10 mm.

3. Bring gauge in position as

shown in picture.
4. Drive the crank shaft up
carefully till you reach 0 mm
on the gauge.
5. Move the gauge to the next
lane and measure all 10
lanes.
6. Maximal difference for
evenness should not be
higher than 0.5 mm.
7. Calculate the mean of all the
differences from the 10
lanes.

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2 ADJUSTING FILLING HEIGHT RYAG-FILLER

2.4 ADJUSTING

Adjusting of actual position, notice this axes is on a crankshaft, this means the offset in height is
not linear.

3. Adjust the offset to

actual position with the
button FILLING HEIGHT
CORRECTION.

1. The actual position shows 2. Offset to theoretical Current filling height

the angel in degrees. filling height.

α° offset [mm] S [mm]

24.10 1.31 8.6887
24.20 1.27 8.7341
24.30 1.22 8.7796
24.40 1.17 8.8253
24.50 1.13 8.8712
24.60 1.08 8.9172
24.70 1.04 8.9634
24.80 0.99 9.0098
24.90 0.94 9.0563
25.00 0.90 9.1030
25.10 0.85 9.1499
25.20 0.80 9.1969
25.30 0.76 9.2441
25.40 0.71 9.2915
25.50 0.66 9.3390
25.60 0.61 9.3867
25.70 0.57 9.4346
25.80 0.52 9.4826
25.90 0.47 9.5308
26.00 0.42 9.5792
26.10 0.37 9.6278

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2 ADJUSTING FILLING HEIGHT RYAG-FILLER

α° offset [mm] S [mm]

26.20 0.32 9.6765
26.30 0.27 9.7253
26.40 0.23 9.7743
26.50 0.18 9.8235
26.60 0.13 9.8729
26.70 0.08 9.9224
26.80 0.03 9.9721
26.90 -0.02 10.0220
27.00 -0.07 10.0720
27.10 -0.12 10.1221
27.20 -0.17 10.1725
27.30 -0.22 10.2230
27.40 -0.27 10.2737
27.50 -0.32 10.3245
27.60 -0.38 10.3755
27.70 -0.43 10.4266
27.80 -0.48 10.4779
27.90 -0.53 10.5294
28.00 -0.58 10.5810
28.10 -0.63 10.6328
28.20 -0.68 10.6848
28.30 -0.74 10.7369
28.40 -0.79 10.7891
28.50 -0.84 10.8416
28.60 -0.89 10.8942
28.70 -0.95 10.9469
28.80 -1.00 10.9998
28.90 -1.05 11.0529
29.00 -1.11 11.1061
29.10 -1.16 11.1595
29.20 -1.21 11.2130
29.30 -1.27 11.2667
29.40 -1.32 11.3206
29.50 -1.37 11.3746
29.60 -1.43 11.4288

1. Double check the measurements, to make sure you did not make any mistake
2. Take out the gauge and jigs
3. Reassembly funnels according product card
4. Check filling height on HMI Settings according product card
5. All the Product Card for this Product must be changed

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3 ADJUSTING FILLING HEIGHT ALL FILL FILLER

3 ADJUSTING FILLING HEIGHT ALLFILL-FILLER

3.1 CHECK HOME POSITION, INSTALLING GAUGES

1. Check home position acc-

ording Rychiger Operating
instructions, Chapter 9.9.
Cup
2. If home positions is not okay
holder
adjust according manual
3. Remove all center screws of
the cup holders lift.

4. Mount gauges 665111 onto

the cup holders. Make sure,
the bolts do not protrude.

Gauges

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3 ADJUSTING FILLING HEIGHT ALL FILL FILLER

3.2 CHANGES FOR ALLFILL FILLER ON PLC AND HMI

Main PLC
Export Routine (Control_Lift_Height) from Base Project.
(PLC_Rychiger_Main_Allfill_Filler_Date_2014_04_03.ACD) and import to your project.

Servo PLC
Export Routine (Manual_JOGMove_Handler) from Base Project.
PLC_Rychiger_Servos_Allfill_Filler_Date_2014_043_03.ACD) and import to your project.

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3 ADJUSTING FILLING HEIGHT ALL FILL FILLER

HMI
Open up Baseproject and your Project in the english language.
Copy the «Filling Height», «Inch To Fill Pos» and «Filling Hight Correction» Button from base
Project (TS_2216_with_AllFill Filler-apa) to your Project page 305.

New Buttons

FILLING HEIGHT

INCH TO FILL POS

FILLING HEIGHT CORRECTION

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3 ADJUSTING FILLING HEIGHT ALL FILL FILLER

3.3 MEASURING

1. Login as admin to have

access to page 306.
2. Set filling height to 80 mm.

3. Install the lower gauge.

4. Drive the lifter up till you
Lower gauge
have 0mm on the gauge.
5. Move the gauge to the next
lane.
6. Measure all 10 lanes. Max
difference for evenness
should not be higher than
0.5 mm.
7. Calculate the mean of all the
differences form the 10
lanes.

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3 ADJUSTING FILLING HEIGHT ALL FILL FILLER

3.4 ADJUSTING

Adjusting of actual position, notice this axes in on a linear lifting system, the offset will be linear.

1. To get the filling height correction, calculate as follows

Filling Height Correction = -57.5 + (Actual position)

2. Set the calculated value with the button FILLING HEIGHT CORRECTION.

1. Double check the measurements, to make sure you did not make any mistake
2. Take out the gauge and jigs
3. Reassembly funnels according product card
4. Check filling height on HMI Settings
5. All the Product Card for this Product must be changed

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