Kalix

Z.A.
de Courtaboeuf n°4
4, avenue du Parana
LES ULIS
91978 Courtaboeuf Cedex France
Tel 33 (0)1 69 18 05 00
Fax 33 (0)1 69 18 05 01
E-mail : commercial @ kalix.fr FILLER
KX 601
TECHNICAL MANUAL
The whole of this document must be read and understood before commissioning the machine.
KX 601
CONTENTS
USE :
- Somery......................................................................................................................................................................... 02
- Machine characteristics........................................................................................................................................... 03
- Handling and installation......................................................................................................................................... 04-05
- Layout space.............................................................................................................................................................. 06-07
- Connection................................................................................................................................................................. 08-09
- Tube circuit................................................................................................................................................................ 10
- Product circuit............................................................................................................................................................ 11
- Control panel.............................................................................................................................................................. 12
- Control panel: Symbols............................................................................................................................................. 13
- Use: Normal running mode...................................................................................................................................... 14-15
Step-by-step running mode / machine stop mode...................................................................................... 16-17
Emergency stop / Restart............................................................................................................................... 18-19
Manual running / Store feeder...................................................................................................................... 20-21
- Absolute encoder programming.............................................................................................................................. 22-23
CHANGE OVER :
- Preparation.................................................................................................................................................................. 24-25
- Tube holder / Plate levelling / Feeder height......................................................................................................... 26-27
- Store feeder................................................................................................................................................................. 28-29
- Presser / Orientation unit / Cleaning device.......................................................................................................... 30-31
- Disassembly of the filling assembly........................................................................................................................ 32
I. Disassembly of the reservoir and injector....................................................................................... 33
II. Disassembly of the shut-off nozzle.................................................................................................. 33
III. Disassembly of the pump, piston, plug valve assembly................................................... ........... 34-35
IV. Disassembly of the plug valve...........................................................................................................34-35
V. Assembly of the filling assembly...................................................................................................... 34-35
- Filling. Injector lifting cam and dose adjustment.................................................................................................. 36-37
THIS DOCUMENTATION IS KALIX PROPERTY. IT CAN NOT BE REPRODUCED OR COPIED WITHOUT ITS AUTHORIZATION.
- Filling. Injector adjustment....................................................................................................................................... 38-39

- Hot-air head................................................................................................................................................................ 40-41
- Ejection........................................................................................................................................................................ 42-43
TECHNICAL DIRECTORY:
- Kinematics.................................................................................................................................................................. 44-45
- Transfer........................................................................................................................................................................ 46
- Cleaning device.......................................................................................................................................................... 47
- Filler.............................................................................................................................................................................. 48-50
- Heating unit................................................................................................................................................................. 51-52
- Adjust temperature regulator.................................................................................................................................... 53
- Tube cutter.................................................................................................................................................................. 54
- Ejection........................................................................................................................................................................ 55
- Console........................................................................................................................................................................ 56-57
- Machine safety devices............................................................................................................................................ 58-59
- Operator safety devices............................................................................................................................................ 60
MAINTENANCE :
- Operator maintenance............................................................................................................................................... 61
- Technician’s maintenance schedule....................................................................................................................... 62
- Technician’s maintenance schedule....................................................................................................................... 63
KX 601 Page 2
Use
MACHINE CHARACTERISTICS
KALIX thanks you for choosing
the “KX 601” model filler.
Maximum production rate: 60 tubes a minute, varying according to the viscosity of the product, tube
diameter, tube skirt length and the options.
Size adjustment: The machine can be adjusted according to the dimensions of the tubes and the physical
properties of the creams. It is suitable for use with PE and coextruded tubes.
Dosing: 1 to 400 ml
Operation: The KX601 only needs one operator, who supplies the machine with empty tubes.
Noise level: Weighted equivalent continuous sound pressure level A, measured at

the work station: 75 dB(A).
Minimum lighting: 400 lux
Important: The machine is not designed to function in a potentially explosive atmosphere.

Limits of components used by the machine
Maximum dimensions
Minimum dimensions 50 mm 50 mm
10 mm
50 mm
230 mm 230 mm
Please contact KALIX for any additional technical or commercial information,

or for any other applications.
KX 601 Page 3
Use
HANDLING AND INSTALLATION
Do not make contact between the

fork uprights and the rear machine
housing.
The forks must project in front
of the machine 700
(minimum fork length 1000 mm)
Insert the truck forks between the
machine support jacks.
KX 601 Page 4
Use
HANDLING AND INSTALLATION
Do the following in order:
Open the crate carefully.

Examine the general condition of the machine (for damage caused by transport, oxidation).
Remove the packaging from around the machine.
Do a full check of any accessories that come with the machine.
Do this check against the delivery note. Tell the carrier and KALIX immediately if there are
any faults, i.e. defective or missing parts.
Lifting the machine:
The forklift truck forks must be located as shown in the diagram above.
Overall machine dimensions (mm):
Footprint: 1110 x 1820

Total height: 2160
Net weight: 700 kg
Machine seating:
When the machine is in its final location, adjust the screw jacks using a spirit level.
Make sure that the machine is stable on the jacks before commissioning.
Clean the whole machine.
KX 601 Page 5
Use
Mini: 1980
Maxi: 2160
Mini: 1810
Maxi: 1990
1110
KX 601
980
1325
980
1820
1110
LAYOUT SPACE
660
Use
800
Ejection outlet
1240
2040
Page 6
1
Lower housings:
by screws
Upper housings:
10
2
Lower housings attached
KX 601
1
76
0
89
8
0 89
90
0
LAYOUT SPACE
Use
1
Page 7
CONNECTION
Isolating switch
220V /60 Hz
6 Bars
Mains water
supply
min :6°C
max :13°C
Drain
Pneumatic stop valve

(padlockable valve)
Water circuit for cooling
the Hot Air unit
- OUTLET
- INLET
Compressed air supply

Necessary pressure 6 bars
KX 601 Page 8
Use
CONNECTION
Connection to mains electricity:

220 volts : use a -G6mm² cable (three-phase + neutre+earth) to connect
to the isolation switch.
Pass the electric cable through the special hole in the machine base plate.
TYPE MACHINE
MACHINE TYPE / MASCHINENTYPE : KX601 N°
TENSION D’ALIMENTATION
SUPPLY VOLTAGE / BETRIEBSSPANNUNG : V HZ
TENSION DE COMMANDE
CONTROL VOLTAGE / STEUERSPANNUNG : 24 V HZ
TENSION DE SIGNALISATION
LIGHTS VOLTAGE / MELDESPANNUNG : 24 V HZ
PUISSANCE INSTALLEE
INSTALLED POWER / INSTALLIERTE LEISTUNG : KVA
PROTECTION AMONT
UPSTREAM SECURITY / ZULEITUNGSSICHERUNG : A
SCHEMA ELECTRIQUE
ELECTRICAL DIAGRAM / SCHALPLAN : DA
NUMERO DE PROGRAMME
PROGRAM NUMBER / PROGRAMMNUMMER :
CONSTRUCTEUR : KALIX
KALIX
Z.A. de Courtaboeuf N°4
DATE
4 avenue du Parana
LES ULIS 91978 TYPE KX601
Courtaboeuf Cedex France
Tél. 33(0)1 69 18 05 00
Fax 33(0)1 69 18 05 01 N°
Pneumatic connection:
Use a 9 x 13 armoured plastic hose.
Necessary pressure: 6 bars.
Flow rate: 50Nm3/h.
Connect the compressed air supply hose to the rear side of the machine.
Air quality (air compressed upstream of the machine): dry, oil-free air.
Dew point: 2.5°C.
Hydraulic connection:
Connect the water supply pipes to the left side of the machine.
Temperature: from 6 to 12°C.
Necessary pressure: mains.
Flow rate: 200 l / h.
Precaution before starting:

Turn the handwheel until the plate has passed at least one unit:
The movement must be smooth and silent. If you feel an abnormal resistance,
find the cause and remedy it.
KX 601 Page 9
Use
TUBE CIRCUIT
«
Hot-air head»
Filling
5 Tube filled
Dépoussiéreur Hot air head
Aspiration of the dust by
Hot air
air blowing with a 6 blown
4
special Venturi System
Orienter
Spot
3 detected
Hot air head
7 Ribbing
Presser
Tube installed
2 in cup
Transfer
Tube transferred
1 from feeder Hot air head
to cup
8 Tube cut
Ejection device
Ejection of the tubes
9 cap ahead
KX 601 Page 10
Use
PRODUCT CIRCUIT
I.
DOSING
II.
START OF FILLING
III.
END OF FILLING
2
4
1 7
8
5
9
3
6
1 Product dosed. (piston moves down).
2 1/4 turn of plug.
3 Injector moves down into tube. 6 Injector moves up gradually. (Filling)
4 Shut-off valve opens. 7 Shut-off valve closes.(End of filling)
5 Shut-off valve opens. 8 1/4 turn of plug.
9 Injector removed from inside tube.
10 Next tube filled.
KX 601 Page 11
Use
CONTROL PANEL
Operator’s
position
GR OU PE S I DEL
VF Fault
Hz
display
Hour OMRON OMRON

OMRON
meter Production
meter
Orientation
on or off
FILLING ORIENTATION SEALING
0 1 SETTING A U T O 0 1
Filling
on or off
Sealing
on or off ON / SETTING BRAKE MOTOR
0 1 0 1
Running/Step-by-step Electronic cams

control box
Machine speed
RGENC adjustment
Main motor ME
STOP START RESET LOADING
A U T O 0 M A N U
Y
E
braked
STOP
Machine
stop
Start Reset after Loading Orientation Emergency stop

faults on or off adjustment
Step-by-step
KX 601 Page 12
Use
CONTROL PANEL: Symbols
MACHINE POWERED
EMERGENCY STOP INDICATOR
HOUSING OPEN INDICATOR
NO AIR INDICATOR
TUBE INCORRECTLY EJECTED INDICATOR

TUBE UPSIDE-DOWN ON TRANSFER UNIT (feeder) INDICATOR
ENCODER FAULT INDICATOR
VF
Hz VARIATOR FAULT INDICATOR
THERMAL FAULT INDICATOR
DECLUTCH MOTOR INDICATOR
KX 601 Page 13
Use
USE : Normal running mode
Isolating switch
Powered
G RO UP E S I D EL
VF
Hz
OMRON OMRON
OMRON
Orientation
on or off
Filling FILLING ORIENTATION SEALING

on or off
Sealing
on or off ON / SETTING BRAKE MOTOR
0 1 0 1
Running/Step-by-step
control
Machine speed
adjustment
RGENC
ME
LOADING
Main motor STOP START RESET A U T O 0 M A N U
Y
E
braked
STOP
Reset after Loading

Start faults on or off
Step-by-step
As the isolating switch does not stop the power supply from the electrical
cabinet, only an authorised person can open the electrical cabinet. Set the
isolating switch to 0 if you want to work in the lower part of the machine.
.
KX 601 Page 14
Use
USE: Normal running mode
Normal running mode
Operation Button
STARTING THE MACHINE
1 è Fill the feeder with tubes. Fill the reservoir with product.
2 è Make sure there is no blockage downstream of the filler.
3 è Open the supply of compressed air to the machine.
Switch on the isolating switch: the

4 F
"POWER" indicator goes on.
NORMAL RUNNING
RESET
1 F Press Reset. x2

Check that the selector switches

2 $
are set to the RIGHT.
ON / SETTING
0 1
Check that the running/adjustment

3 $
selector switch is set to 0.
BRAKE MOTOR
0 1
Check that the brake/motor

4 $
selector switch is set to 0.
$
5 Set the machine production rate.
F
LOADING
A U T O 0 M A N U
Check that the feeder selector

6 $
switch is set to AUTOMATIC.
START
Press "START": the machine

7 F
starts.
KX 601 Page 15
Use
USE: Step-by-step running mode / machine stop mode
Step-by-step remote
control unit.
Button for operating the

machine step-by-step.
GR OU PE S I DEL
VF
Hz
OMRON OMRON
OMRON

ON / SETTING BRAKE MOTOR

0 1 0 1
control
RGENC
ME
A U T O 0 M A N U
Y
E
STOP
Machine stop
KX 601 Page 16
Use
USE: Step-by-step running mode / machine stop mode
Step-by-step running mode

Operation Button
STOPPING THE MACHINE
STOP
Press "STOP" to stop the

1 F machine.
STEP-BY-STEP RUNNING
ON / SETTING LOADING
0 1 A U T O 0 M A N U
Put the key of selector "on setting

mode" on the position 1 and the
1 F loading selector on the "manu"
position.
Press the remote control unit

button. The plate turns one step,
2 F then stops. Release the button,
then press the button again to
repeat a cycle.
Machine stop mode

Operation Button
STOPPING THE MACHINE BY OPENING A HOUSING
Opening only one safety

1 è
housing stops the machine
2 $ The "SAFETY" indicator goes on.
Remove the defective tubes, then

3 è clean the machine before starting
again.
KX 601 Page 17
Use
USE: Emergency stop / Restart
Emergency stop.
G RO UP E S I D EL
VF
Hz
OMRON OMRON
OMRON


0 1 0 1
RGENC
ME
A U T O 0 M A N U
Y
E
STOP
Start Reset after faults Emergency stop
KX 601 Page 18
Use
USE: Emergency stop / Restart
STOPPING THE MACHINE BY OPERATING THE EMERGENCY STOP
RGENC
ME
Y
E
Press "EMERGENCY STOP":
1 F
the machine stops. STOP
RESTARTING THE MACHINE AFTER AN EMERGENCY STOP

RGENC
ME
Turn the emergency stop button
Y
E
1 F
to release it. STOP
RESET
2 F Press "RESET". x2
START
Press "START" to restart the

3 F
machine.
If the filling machine stops, take-out the tube place before the hot air nozzle station,
before restarting the machine.
KX 601 Page 19
Use
USE: Manual running / Feeder
R
G U
O E
P D
I
S L
E
VF
Hz
OMRON OMRON
OMRON
Selector of motor brake 0

FILLING
1
ORIENTATION
SETTING AUTO
SEALING
0 1
ON/SETTING BRAKEMOTOR
0 1 0 1
GEN
MER C
LOADING
STOP START RESET
Machine stop
Y
A U T O 0 M A N U
STOP
Releasing Finger of blocking
Blocking
Mechanical declutching
Front lower housing

The operating handwheel
Sectionneur
KX 601 Page 20
Use
USE: Manual running
MANUAL RUNNING (isolating switch to 0)
STOP
1 F Stop the machine.
Set the isolation switch to 0. The

2 F
mains power supply goes off.
Remove the front lower housing

to get access to the operating
3 F
handwheel and mechnical
declutching.
MANUAL RUNNING (isolating switch to 1)
STOP
1 F Stop the machine.
BRAKE MOTOR
0 1
Place the selector of motor brake

2 F
to the position 1.
Remove the front lower housing

3 F to get access to the operating
handwheel.
Turn the handwheel counterclockwise to move the plate normally.

This operation must be done by an authorised person.
TO ADJUST THE STORE FEEDER
To release the locking finger of

1 F
potentiometer.
To adjust the speed of the

2 F
vibrating
To lock tle locking finger of

3 F
potentiometer.
KX 601 Page 21
Use
ABSOLUTE ENCODER PROGRAMMING
Lit for TEST mode or

PROGRAMME mode
Lit in RUN mode Angle display The "degree" sign

indicates 360° mode
Display of the angle

Number of active cam selected
Cam number during

Angle indicator programming
CHECK
Cam preselection 1 2 3 4 5 6 7 8
number (1 or 2) PV
SV
256
360
Mode indicator OUT N°
Check of recorded
1 2 3 4 5 6 7 8
PRG
STP1ST2 values
TST TCH STEP
Value of rising and falling
RUN MAN
fronts of the current cam Selects or designates
cam number
Programming type ON OFF
Selects
indicator PRGM
TCH preselection (1 or 2)
TEST
Selection of modes RUN MAN - ANGLE + WRITE
PRG = Programme mode CW FAST 256 Selects the rising or
TST = TEST mode ORIGIN CLEAR
ROTATION ANG DSPL falling front of the cam
RUN = RUN mode CCW SLOW 360
Programming mode
Records values
TCH = Machine position
MAN = Manual
Change in direction Deletes recorded values

of rotation
FAST: 60 to 330 rpm 256 or 360 degrees per circle Angle reduction Angle increase
SLOW: less than 60 rpm
To replace starting point
KX 601 Page 22
Use
ABSOLUTE ENCODER PROGRAMMING
POSITION OF SWITCHES FOR

NORMAL OPERATION
SWITCH PRGM/TEST/RUN ON RUN

SWITCH TCH/MAN ON MAN
SWITCH CW/CCW ON CW
SWITCH 256/360 ON 360
PROGRAMMING
a) PUT THE PRGM/TEST/RUN SWITCH ON PRGM

the rise and fall values of cam No. 1 are displayed at the bottom of the screen
b) SELECT THE CAM TO BE CHANGED WITH THE OUT N° KEY
c) SELECT THE RISING OR FALLING FRONT WITH THE
ON OFF KEY
the corresponding symbol flashes and the former value is shown on the angle display
d) CHANGE THIS VALUE WITH THE ANGLE+ AND ANGLE- KEYS
e) PRESS THE WRITE KEY TO RECORD THE NEW VALUE
f) PUT THE SWITCH BACK ON RUN AT THE END OF THE MODIFICATION,
THEN RESET ON THE MACHINE'S CONTROL PANEL.
EXAMPLE OF PROGRAMMING
MODIFICATION OF CAM C3 ( 120° 300°) TO ( 150° 180°)

a) PUT THE SWITCH ON PRGM
the values of cam 1 are displayed
b) PRESS THE OUT N° KEY UNTIL No. 3 IS FRAMED ON THE CAM NUMBER DISPLAY
the values of cam 3 are displayed
c) PRESS THE ON OFF KEY TO SET THE SYMBOL FLASHING
the value of the rise of cam 3 is displayed (120 in this example)
d) PRESS THE ANGLE+ KEY UNTIL THE VALUE 150 IS OBTAINED
e) RECORD THIS VALUE BY PRESSING THE WRITE KEY
f) PRESS THE ON OFF KEY TO SET THE SYMBOL FLASHING
the fall value of cam 3 is displayed (300 in this example)
g) PRESS THE ANGLE- KEY UNTIL THE VALUE 280 IS OBTAINED
h) RECORD THIS VALUE BY PRESSING THE WRITE KEY
i) PUT THE SWITCH BACK TO RUN AND RESET THE MACHINE.
KX 601 Page 23
Use
CHANGE OVER
PREPARATION
Step-by step remote

control unit.
Button for step-by-step

operation of the machine.
GR OU PE S I DEL
VF
Hz
OMRON OMRON
OMRON


0 1
0 1
control
STOP START RESET LOADING RGENC

A U T O 0 M A N U
ME
Y
E
STOP
Machine stop
Page 24
Change over
CHANGE OVER
PREPARATION
Operation Button
STOPPING THE MACHINE

STOP
Press "STOP" to stop the

1 F
machine.
PREPARATION
ON / SETTING
0 1
Put the key switch to the

1 F
"ADJUSTMENT" position.

Set the function selector switches 0 1 SETTING A U T O 0 1
2 F
to the LEFT.
Press the remote control unit

button. The plate turns one step,
3 F then stops. Release the button,
then press the button again to
repeat a cycle.
Open the housings: Remove the

right lower door 1.
Open the lower doors 2.
4 F
Open the upper doors.
The machine is ready for change 2 1
over. 2
Page 25
Change over
CHANGE OVER
TUBE-HOLDER / PLATE LEVELLING / FEEDER
I. TUBE-HOLDER / PLATE LEVELLING:
3 4
5
6
1
2
II. FEEDER:
Clockwise direction =
adjustment for small tubes.
Anticlockwise direction =
adjustment for large tubes.
1
2
Small rule
Marking arrow
Page 26
Change over
CHANGE OVER
TUBE-HOLDER / PLATE LEVELLING / FEEDER HEIGHT
I. TUBE-HOLDER / PLATE LEVELLING:
- Install the tube holders for the new size............

1
- Loosen the small screw...................................... 2
- Release the clamping lever................................ 3
- Let the end stop fall............................................ 4

- Tighten the clamping lever........ ....................... 3
- Put a new tube in its tube holder at the orientation unit..................... 5
6
- Turn the large central nut to put the tube, located under the .............
orienter, against the end stop.
- Release the clamping lever................................. 3

- Lift the end stop.................................................. 4
- Tighten the clamping lever ................................ 3
- Tighten the small screw..................................... 2
II. FEEDER HEIGHT:
1
- Release the loading column locking screw...............................................................
- Adjust the feeder height using the screw. Use a pair of pin pliers
2
for the adjustment; the marking arrow and rule are used to set the ...............
feeder to the required value
Page 27
Change over
CHANGE OVER
STORE FEEDER
4 Final feed guides
7
3
2
1
6
5
10
4mm
11
Précaution: Put the loading Vee in the vertical position (manual running).
Check that the Vee does not touch the tube holder.
In case of contact, go back to the «Feeder height adjustment» step and increase the feeder height.
Page 28
Change over
CHANGE OVER
STORE FEEDER
I. STORE FEEDER :(the operation is to be made when the tube is in its tube holder)
- Loosen the V-block centring screw............................................................................... 1

- Install the V-block for the new size............................................................................... 2
- Loosen the set screws of the final feed guides........................................................... 3
- Set the final feed guides 3 mm from the tube............................................................... 4
- Tighen the set screws..................................................................................................... 3
- Put the V-block in the vertical position........................................................................ 5
- Set the V-block 3mm from the tube (see diagram below)............................................
6
- Tighten the V-block centring screw.............................................................................. 1
- Set the guides with reference to the tube length (3 mm play).................................. 7
8
- Set the guides with reference to the tube diameter (3 mm play).............................
- Move and adjust the right guard with the transfert box (3 mm play)...................... 9
- Unscrew the two screw.................................................................................................. 10
- Put the housing 4 mm above the tube......................................................................... 11
- Lock the two srews......................................................................................................... 10
4
Final
feed guides
3 mm
Tube
Final
feed guides
Vé
4
3 mm
3 mm
6
Page 29
Change over
CHANGE OVER
PRESSER / ORIENTATION UNIT / CLEANING DEVICE
I. PRESSER
II. ORIENTATION UNIT:
3
2
6
1
5 mm
4
III. CLEANING DEVICE:
7 Seal
Page 30
Change over
CHANGE OVER
PRESSER / ORIENTATION UNIT / CLEANING DEVICE
I. PRESSER:
- Release the clamping lever....................................................................................... 1
- Pull down the fixed presser....................................................................................... 2
- Install the fixed presser for the new size................................................................ 2
- Tighten the clamping lever....................................................................................... 1
II. ORIENTATION UNIT:

- Loosen the two screws.................................................................................... 1
- Install the notched base 5 mm below the cup................................................ 2
- Tighten the two screws.................................................................................. 1
- Push the knurled ring and remove the turning presser.................................. 3

- Install the turning presser for the new size.................................................... 4

(automatic engagement)
- Lever for adjusting the distance of the photocell from the spot.................... 5
- Lever for adjusting the height of the photocell from the spot....................... 6
III. CLEANING DEVICE:
- Pull the bottom ........................................................................................................ 7
- Remove the cleaning device nozzle and replace it by the nozzle corresponding
to the size (see set up sheet). Be careful with the joint placed at the extremity of 8
the aspiration axe..............................................................................................................
Page 31
Change over
3
1
2
8
7
5
6
Change over
NOZZLE SLIDE
NOZZLE SHUT-OFF VALVE ROD SLIDE

4
DISASSEMBLY OF THE FILLING ASSEMBLY
10
11
Page 32
I. DISASSEMBLY OF THE RESERVOIR AND INJECTOR:
- Remove the collar. (Plug valve/Reservoir).............................. 1
- Remove the reservoir................................................................ 2
- Remove the collars. (Plug valve/Connecting tube/Injector).... 3
- Remove the connecting tube.................................................... 4
- Put the protection end cap on the nozzle.................................. 5
- Release the clamping lever....................................................... 6
7
- Move the clamp down..............................................................
- Remove the injector.................................................................. 8
II. DISASSEMBLY OF THE SHUT-OFF NOZZLE:
- Loosen the shut-off nozzle nut.................................................... 9
- Pull the nozzle down...................................................................

10
- Pull the shut-off valve rod down for removal............................ 11
Page 33
Change over
4 5 6
Loosen 1/4
turn then pull
Hold
the piston rod
7 8
Page 341 N°9347

Change over
III. DISASSEMBLY OF THE PUMP, PISTON, PLUG VALVE ASSEMBLY:
- Loosen the handle.................................................................. 1
- Remove the clamp.................................................................... 2
- Remove the spacer...................................................................

3
- Pull the plug valve, pump, piston assembly towards ...........

yourself. Hold the piston rod when moving this assembly 4
IV. DISASSEMBLY OF THE PLUG VALVE:
- Unscrew the pump with the piston, turning through a quarter-turn, 5

then pull the assembly...................................................................................
- Remove pump piston............................................................................................. 6
- Screw the handle into the plug............................................................................... 7

- Pull the plug of the valve using handle..................................................................

8
V. ASSEMBLY OF THE FILLING ASSEMBLY:
Proceed in the opposite order to disassembly, taking care to first

position the plug in the valve using the marks provided on the plug
and the plug valve.................................................................................................... 9
Marks for positioning the plug

correctly in the plug valve
Page 35
Change over
CHANGE OVER
FILLING
I. INJECTOR LIFTING CAM AND DOSE ADJUSTMENT:
8 Dose adjustment
4
2 The clamping position
5
3 6
Page 36
Change over
CHANGE OVER
FILLING
I. INJECTOR LIFTING CAM AND DOSE ADJUSTMENT:
- Open the lower housings. (front and left).........................................................................

1
- Move the lever to the clamping position by turning the motor handwheel.....................
2
- Unscrew the clamping screw fixed on the foundry.............................................................

3
- Use the clamping screw to hold the lever in position......................................................

4
- Remove the blocking screw and washer from the cam....................................................

5
- Remove the lifting cam from the injector........................................................................

6
- Install the new cam. Make sure the locating pin is correctly positioned.........................
7
- Put the blocking washer and screw back on the cam.......................................................

5
- Release and remove the clamping screw from the lever................................................. 4
- Put the clamping screw back in its location.....................................................................

3
- Close the lower left housing.............................................................................................

1
- Set the meter to the necessary value using the knob........................................................

8 1 9 71
Page 37
Change over
CHANGE OVER
FILLING
II. INJECTOR ADJUSTMENT:
a) Injector height adjustment:

11
11
Clockwise = injector down.

10
X Z
Contreclockwise =injector up.
Z = from12 mm mini to 52 mm maxi.

1 X = 40 mm variation
Clockwise = lock nut down.
2
Conterclockwise=lock nut up.
Reference face
Small rule
b) Shut-off valve travel adjustment:

Small rule 1
11
11
REMPLISSAGE
0 1
Shut-off valve opening

High position
injector
Shut-off valve closure
2
Low position 10
injector
3
Clockwise = small shut-off
valve opening.
Conterclockwise = large
shut-off valve opening. Marking finger
Small rule
Page 38
Change over
CHANGE OVER
FILLING
II. INJECTOR ADJUSTMENT:
a) Injector height adjustment:

- Unscrew the nut and place the referenced
side on the requested valvue.
............................ 1
- Turn the shaft untill it is in contact with the nut upper part.
Maintain the nut and block the shaft .
2
INJECTOR
Z = from 12 mm mini to 52 mm maxi.

X
X = 40 mm variation
b) Shut-off valve travel adjustment:
REMPLISSAGE
- Position the filling selector on 1. In using the jog, take the injector 0 1
assembly to the low position. At the valve opening, stop using 1

the jog..
- Unscrew the counter nut wheel...................................................................... 2
- In using the nut set the valve opening up.

The mark finger and the rule allow an accurate set up..........................
Maintain the nut an screw the counter nut wheel.
3
Page 39
Change over
CHANGE OVER
HOT-AIR
I. CHANGE HOT AIR NOZZLE AND ADJUST HEIGHT OF HEATING UNIT :
Climber
3
1
4
6
II. CHANGE BATCH NUMBER:

2 1 1
3 3
III. RETAINER BAR AT HEATING UNIT:
2
3mm
Page 40
Change over
CHANGE OVER
HOT-AIR
Caution : Wait the cooling of hot air heating before any change over.
I. CHANGE HOT AIR NOZZLE AND ADJUST HEIGHT OF HEATING UNIT :

- Release the clamping lever...........................................................................
1
- Raise heating unit.......................................................................................... 2
- Tighten the clamping lever...........................................................................

1
- Change hot air nozzle with the climber.........................................................

3
- Place nozzle, making sure it is correctly centred in its housing..................

4
- Release the clamping lever............................................................................

1
- Take the heating unit down........................................................................... 2
- Retighten.......................................................................................................
1
5
- Release the clamping lever............................................................................
6
- Set counter to required value.........................................................................
5
- Tighten the clamping lever........... ...............................................................
II. CHANGE BATCH NUMBER:

- Loosen block fixing screw......................................................................... 1
- Remove plates............................................................................................ 2
- Replace coding digits................................................................................. 3
- Replace plates............................................................................................. 2
- Retighten fixing screw............................................................................... 1
III. RETAINER BAR AT HEATING UNIT:
- Unscrew the locking handle........................................................................... 1
- Place the retainer finger in the required position (3 mm above the cup)........ 2
- Lock the handle............................................................................................... 1
Page 41
Change over
CHANGE OVER
EJECTION
Precaution : Move the ejection rod to the bottom position.
I. ADJUSTING THE EJECTION ROD, RETAINER FINGER, AND PUSHER ARM:

Retainer finger
3
1 1
II. SET UP AND CHANGING OF THE REVERSAL TUNNEL / THE INFEED SYSTEM SET UP :
3
The edge of reference The reversal tunnel
4
Resersal tunnel strip
5 The Strip
The edge of reference
III. SET UP OF THE EJECTION ROD
6 7
Page 42
Change over
CHANGE OVER
EJECTION
Precaution : Move the ejection rod to the bottom position.
I. SET UP OF THE MAINTENING GUIDE:
- Remove the right lower door and open the 2 upper doors .
- Unscrew the clamping lever 1 and place the retainer finger at the required
position (see set up sheet) in using the edge of the retainer finger support and 2
the strip. Lock the lever 1
- Install the new rod changepart...................................................................................... 3
II. SET UP AND CHANGING OF THE REVERSAL TUNNEL / THE INFEED SYSTEM SET UP :
- Unscrew the clamping lever and install the reversal tunnel new change part.
Lock the lever. 4
- Unscrew the clamping lever and adjust the reversal device at the required
position (see set up sheet) in using the strip of the reversal support and the edge 5
of reference.
- Unscrew the tightening key and adjust the ejection chute at the required posi-
tion (see set up sheet) with the strip and the inferior edge of the chute support 6
(= edge of reference).
III. SET UP OF THE EJECTION ROD
- Unscrew the nut 7 and adjust the stroke of the ejection rod to the required
position (see iset up sheet) in using the arrow and the chute system as a reference. 8
- Screw the nut. 7
Caution:
Before the automatic start up, proceed to manual start up. Turn the driving
wheel hill the turntable has made at least one post.
Page 43
Change over
PLUG CONTROL
Y1 CENTRAL SHAFT
Lock
INJECTOR
INSERTION EJECTION
PUMP SHAFT CONTROL
Above table
M1
C5
KINEMATICS
C4 C1
Technical directory
DOSE
ADJUSTMENT
FOUNDRY
FOUNDRY
C3 ORIENTATION C2
M12 ROTATION
CONTROL
Below table
- Pinion
- Tensioner
Page 44
- Roller
C1 C5
Double cam. Double cam.
Controls lifting of orientation rod and Controls the pump shaft.
pusher rod. Figure RM1470B Filling block.
Figure RM1459A Table mechanism.
C2 M1
Double cam.
Main motor.
Controls movement of central shaft.
Figure RM1450B Motorization.
KINEMATICS
Figure RM1456C Plate mechanism.
C3
M12
Single cam.
Controls insertion of injector into tube. Stepped motor for tube rotation and spot
Figure RM1486E Shut-off nozzle control.
Technical directory
detection.
Figure RM1457A Orienter control.
C4
Double cam.
Controls the plug control shaft.
Figure RM1458B Plug release.
Page 45
S01
F01
F02
F04
TRANSFER
S23 2
7
F03 S21 4 2
D01
5 3
Ev7
EV 10
EV 11
EV 1
EV 2
EV 3
EV 4
EV 5
EV 6
EV 7
EV 8
EV 9
1
Technical directory
A 1
33
Not purged Purged
D01
11
Ev0
F01 F02
F04
21 Purged
F03
S01
6 Bar S23 S21

Page 46
S01
F01
F02
CLEANING DEVICE
F04
S23
F03 S21
D01
EV 10
EV 11
EV 1
EV 2
EV 3
EV 4
EV 5
EV 6
EV 7
EV 8
EV 9
Technical directory
A 1
33 33
Not purged Purged
D01
11
Ev0
F01
F02
F04
21 Purged
F03
Ev2
S01
6 Bar S23 S21
Page 47
Pneumatic plate
Valve closing compensation
EV3
Control solenoid valve D3
V2
D3
Distributor 5/2 control V1
Valve control
FILLING ASSEMBLY
V1
Pump/ dosing
piston Valve
opening/closing
Technical directory
BA6 Absolute encoder

Page 48
Inj
va n
ec po
ng itio
tor si
lve
cti os
re- tion
se p
su
er or
cti
int ject
on
In
Pressure indication pressure gauge
INJECTOR 0 VALVE
assisting valve closing.
Injector insertion
control
Pressure control assisting

11
valve closing
FILLING ASSEMBLY
(Compensation actuator V2)
4 6
0 , 4
20, 0 , 6
2 8
0 MPa 0 , 8
(kgf/cm²)
0
10
Electronic
A6 cam box
SC1 Control Ev3
SC5 Control Y1
Technical directory
Y1
Plug
C3 disengagement
Page 49
S01
EV 10
EV 11
EV 1
EV 2
EV 3
EV 4
EV 5
EV 6
EV 7
EV 8
EV 9
Not purged
A 1
Not purged Purged
33
11
D01
Ev0
F01 F01 F02

F04
S01 21 Purged
F03
FILLING ASSAMBLY
6 Bar
F02
S23 S21
F04
S23
F03 S21
D01
V2
R
1
Fast
exhaust
valve
P
Technical directory
V1
Echanger
3
4 2
5 3
Ev3
1
1
Page 50
6 Bar
not purged
Electronic cam box

A6 Rear view of filling
Front
Vue view of de
de face filling
la
unit
remplisseuse SC 4 Control Ev4. unit
HEATING UNIT
Hot-air temperature
controller.
A5
Resistor
R10
Technical directory
B4
Temperature probe VENTURI
On machine stoppage, the heating unit remains in the
Nozzle HA high position.
To prevent the de formation of parts located below the
heating head, it is necessary to evacuate the hot air.
Page 51
The Venturi is used to evacuate the hot air from the

machine.
RETAINER BAR
Hot air evacuation.
Air supply from Venturi
33
(hot air suction).
A
S01 Z
A
R P
D10
F01
Hot air
outlet V3
Limiter
HEATING UNIT
F02
21
(nozzle) 2
1
F04 Limiter
Hold device
S23 4 2 4 2
F03 S21 Ev5

5 3
Ev4
5 3
D01 1 1
EV 10
EV 11
EV 1
EV 2
EV 3
EV 5
EV 6
EV 7
EV 8
EV 9
Technical directory
A 1
Not purged Purged
33
D01
11
Ev0
F01
F02
F04
S01
21 Purged
F03
Page 52
6 Bar
S23 S21
FRONT OF THE REGULATOR: PV Display

Display the process value.
°C PV
SV Display
Display various set values.
SV
ALM1.ALM2
OUT A1M1 A1M2 ALM1.ALM2 Alarm 1 / 2 indicator
OUT Outup indicator Turns on while Alarm 1/2is being outup.
Turns and while the control output is being issued

OMRON E5CJ
ADJUST TEMPERATURE REGULATOR

Down key
Up key
Level key Increments and decrements the set values.When the key is
prossed down for 1 s or more, the numeral changes quickly.
Shifts the display level when pressed for more Display key (ENTER) The set value becomes effective 2 s after releasing Up/Down
than 1 s. Shifts the display mode. key or by pressing Display or Level key.
SET INTERNAL SWITCH POSITIONS SET TEMPERATURE

- Use the and keys to set the required temperature.
SET ALARM:
1 2 3 4 - Press the mode key, .
ON
- Use the and keys to set the value of alarm 1.
OFF - Press the key to confirm.
SW201 If the process temperature appears to diverge from the set temperature, you should run the "AT"
automatic temperature setting routine as outlined below. You do not need to shut down the
system in mid-process.
0 1 2 3 4 5 6 7 8 9
SW202 First of all, check that CP is set to 1 second. To do this, proceed as follows:.
Technical directory
- Press the level key, , for one second.

- Then press the mode key, .
0 1 2 3 4 5 6 7 8 9
PV
SW203 - The display should show:
If it shows a different value, adjust using the
and keys, then press the key for one second to
0 1 2 3 4 5 6 7 8 9 SV comfirm.
SW106
AT ROUTINE
- Press the and keys together until the display starts to blink, then release them.
The display will stop blinking when the AT routine has terminated.
Page 53
Tube cutter control coil
Cuttings blowing pipe
TUBE CUTTER
EV 10
EV 11
EV 1
EV 2
EV 3
EV 4
EV 5
EV 6
EV 7
EV 8
EV 9
Burr
blowing
A 1
Technical directory
Not purged Purged

33
D01
11
Ev0
F01 F02 4 2
F04
S01 21
Ev1 5 3
F03 1
6 Bar
6 Bar S23 S21 Not purged
Page 54
S01
F01
5 3
Ev9
TUBE CUTTER
F02 1
F04
S23
F03 S21
D01
EV 10
EV 11
EV 1
EV 2
EV 3
EV 4
EV 5
EV 6
EV 7
EV 8
EV 9
Technical directory
A 1
Not purged Purged
33
D01
11
Ev0
F01 F02
F04
S01 21 Purged
F03
6 Bar S23 S21

Page 55
Indicator lights
H0 H1 H2 H3 H4 H5 H6 H7 H8 H9
G RO UP E S I D EL
VF
P1
Hz
OMRON OMRON
OMRON
P2
S11
CONSOLE
S10 0
FILLING
1
ORIENTATION
SETTING A U T O
SEALING
0 1
A6
S9
S7 ON / SETTING BRAKE MOTOR

0 1 0 1
R1
Technical directory
RGENC
ME
S12
A U T O 0 M A N U
Y
E
STOP
S6
S3 S4 S5 S8 R2 S1
Page 56
EFFECT Identification Type Function
Emergency stop
S1 push-button
Emergency stop
S3 NC push-button Machine stop
S4 NO push-button Start
Normal running
S5 NO push-button Reset
Potentiometer Machine speed

R1 adjustment
knob
Absolute encoder
A6 Encoder
programming console
2-position key Position 1 housing safety

S7 selector off
Stepped running
CONSOLE
S6 NO push-button Stepped feed
0 no loading
Loading S8 3-position selector 1 loading
2 stey by step loading
0 no filling
S9 2-position selector
1 filling
Filling
0 no agitator
S13 2-position selector
1 agitator
Technical directory
0 no orientation
S10 2-postion selector
1 orientation
Orientation
Mobile contact Orientation offset
R2 potentiometer adjustment
0 hot air head off
Hot air head S11 2-postion selector
1 hot air head on
2-position lighted 0 normal running
Manual running S12 selector 1 manual running
P1 Meter Hour meter

Meter
Page 57
P2 Meter Product meter

M0 Torque limiter
A3
MACHINE SAFETY DEVICES

LH side of filling
assembly
B3
Technical directory
S23 S21
Page 58
MACHINE SAFETY DEVICES

Tripping frequency
Safety for excessive torque A3 Electronic variator
variator if overcurrent
Electric cabinet
M0 Motor-fan unit Electric cabinet cooling
temperature safety
Torque limiter
Machine safety if excessive No cam shaft drive if
torque
B3 &
excessive torque
inductive detector
Compressed air supply
S23 Pressure switch
testing
Compressed air safety
Gradual repressurising
S21 Pressure switch
Technical directory
safety device
Page 59
S2B
OPERATOR SAFETY DEVICES

S2C S2A
S2D
Operator’s position
Technical directory
Front upper housing

S2A Claw-type contact
safety
Rear upper housing
S2B Claw-type contact
safety
Operator safety
S2C Claw-type contact Left lower housing safety
Front lower housing

age 60
S2D Claw-type contact

safety
OPERATOR MAINTENANCE
Switch off the power supply to the machine (isolation switch to 0)

before doing any maintenance work.
FREQUENCY
EVERY THREE MONTHS

EVERY MONTH
JOB N°
EVERY WEEK
EVERY YEAR
EVERY DAY
JOB DESCRIPTION MEANS USED
CLEANING INSTRUCTIONS
Damp cloth (do not
0 Clean the machine housing use alcohol based X
product)
Vacuum cleaner +
1 Clean the tube feeder, and the feeder V-block X
cellulose cloth
Cellulose cloth +
2 Clean inside the tube holders X
distilled water
Clean the lens of the spot reading photocell on the

3 Cellulose cloth X
orientation unit.
Cellulose cloth +
4 Clean off any dirt on the filling nozzle X
distilled water
Clean the smoothing or ribbing jaws (internal and Brush + vacuum
5 external) cleaner
X
INSPECTION OF CONUMABLES AND CRITICAL PARTS
Open ech guard

and ensure that
1 Check operation of guard safety mechanisms machine shuts
X
down (2 guards)
2 Check for leaks on tap unit Visual inspection X
3 Check alignment of heatin g nozzle in housing Visual inspection X
4 Check for leaks on cooling water hoses Visual inspection X
Page 61
Maintenance
TECHNICIAN’S MAINTENANCE SCHEDULE

FREQUENCY
EVERY THREE MONTHS

EVERY MONTH
JOB N°
EVERY WEEK
EVERY YEAR
EVERY DAY
CLEANING INSTRUCTIONS
Remove dust from the upper part of the machine, and Vacuum
1 from the tube holder plate. cleaner
X
Special
Completely clean the filing components (mixer,
2 reservoir, plug, pump, injector) washing X*
product
*For each product change.
CHECKING SENSITIVE or CONSUMABLE ITEMS

1 Make sure the pneumatic circuit is leak tight X
2 Make sure the chains are tensioned correctly X
Make sure the axes and rollers are tight on the connecting rod for
3 X
lifting and lowering the doser piston
4 Make sure the movement drive rollers for the cams are tight. X
5 Check the ball joints of the control rods (for play, tightness) X
6 Check the seals of the plug valve unit (reservoir, plug, pump, injector) X
7 Make sure the force limiter on the main motor operates X

Check condition of pipes and connections on cooling-
8 water circuit X
Page 62
Maintenance
TECHNICIAN’S MAINTENANCE SCHEDULE
Greasing point :
1- Central shaft
2- Dosing connecting rod
1

FREQUENCY
EVERY THREE MONTHS

EVERY MONTH
JOB N°
EVERY WEEK
EVERY YEAR
EVERY DAY
LUBRICATION
1 Grease cams and followers (remove old grease) Grease # X
2 Grease the chains (remove old grease) Grease # X
3 Grease adjustable-dose piston device. Grease # X
4 Grease indexer bevel gears. Grease # X
# NLGI GRADE 2 GREASE (-15°+140°C)
Page 63
Maintenance

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Z.A.

- Filling. Injector adjustment....................................................................................................................................... 38-39

KALIX thanks you for choosing

the “KX 601” model filler.

Noise level: Weighted equivalent continuous sound pressure level A, measured at

Minimum lighting: 400 lux

Important: The machine is not designed to function in a potentially explosive atmosphere.

Limits of components used by the machine

Please contact KALIX for any additional technical or commercial information,

Do not make contact between the

Do the following in order:

Open the crate carefully.

Lifting the machine:

Overall machine dimensions (mm):

Footprint: 1110 x 1820

Lower housings attached

Pneumatic stop valve

Compressed air supply

Connection to mains electricity:

Precaution before starting:

1 Product dosed. (piston moves down).

2 1/4 turn of plug.

3 Injector moves down into tube. 6 Injector moves up gradually. (Filling)

4 Shut-off valve opens. 7 Shut-off valve closes.(End of filling)

5 Shut-off valve opens. 8 1/4 turn of plug.

9 Injector removed from inside tube.

10 Next tube filled.

Hour OMRON OMRON

Running/Step-by-step Electronic cams

Start Reset after Loading Orientation Emergency stop

EMERGENCY STOP INDICATOR

HOUSING OPEN INDICATOR

TUBE INCORRECTLY EJECTED INDICATOR

TUBE UPSIDE-DOWN ON TRANSFER UNIT (feeder) INDICATOR

ENCODER FAULT INDICATOR

THERMAL FAULT INDICATOR

DECLUTCH MOTOR INDICATOR

Filling FILLING ORIENTATION SEALING

Reset after Loading

Normal running mode

Switch on the isolating switch: the

FILLING ORIENTATION SEALING

Check that the selector switches

Check that the running/adjustment

Check that the brake/motor

Check that the feeder selector

Press "START": the machine

Button for operating the

FILLING ORIENTATION SEALING

ON / SETTING BRAKE MOTOR

Step-by-step running mode

Press "STOP" to stop the

Put the key of selector "on setting

Press the remote control unit

Machine stop mode

Opening only one safety

2 $ The "SAFETY" indicator goes on.

Remove the defective tubes, then

FILLING ORIENTATION SEALING