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HHooppppeerr TTooppppeerr INSTRUCTIONS AND SPARE PARTS
Manual Part # HT-Ins-UK 12/08/2010 V7
From serial number 8775 -
Translation from the Original Instructions
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TABLE OF CONTENTS
SAFETY INSTRUCTIONS AND WARNINGS............................................................................. 4
INTRODUCTION ........................................................................................................................ 5
CONTACTING UNIFILLER ........................................................................................................ 5
MACHINE DESCRIPTION.......................................................................................................... 6
HOPPER TOPPER POWER LIFT ....................................................................................................... 6 HOPPER TOPPER MAX ................................................................................................................... 7 HOPPER TOPPER ECONO ............................................................................................................... 8
SERIAL NUMBER LOCATION................................................................................................... 9
RECEIVING ................................................................................................................................ 9
POWER REQUIREMENTS ...................................................................................................... 10
AIR REQUIREMENTS..................................................................................................................... 10 ELECTRICAL REQUIREMENTS ........................................................................................................ 10
ASSEMBLY AND OPERATION ............................................................................................... 11
OUTLET PIPE CONNECTION – POWER LIFT AND MAX ...................................................................... 11 OUTLET HOSE CONNECTION - ECONO ............................................................................................ 11
OPERATING INSTRUCTIONS................................................................................................. 12
OPERATING THE HOPPER TOPPER POWER LIFT AND MAX.............................................................. 12
HEIGHT ADJUSTMENT ........................................................................................................... 13
OPERATING THE HOPPER TOPPER ECONO....................................................................... 14
PHOTO SENSOR HOPPER LEVEL CONTROL.................................................................................... 15 FOOT PEDAL ............................................................................................................................... 16 DEPOSIT SPEED ADJUSTMENT...................................................................................................... 16
OPERATING THE HOPPER TOPPER WITH DEPOSIT CONTROL ....................................... 17
POSITIVE CUT OFF NOZZLE .......................................................................................................... 18 XL POSITIVE CUT OFF NOZZLE..................................................................................................... 19
DISASSEMBLY AND CLEANING............................................................................................ 20
CLEANING ................................................................................................................................... 24 SANITIZING ................................................................................................................................. 24 RE-ASSEMBLY ............................................................................................................................ 24
OPTIONAL FLAPPER VALVE VERSION................................................................................ 25
MAINTENANCE........................................................................................................................ 26
O RING CARE ............................................................................................................................. 26
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DAILY ......................................................................................................................................... 26 WEEKLY ..................................................................................................................................... 26 3 MONTHS .................................................................................................................................. 26 O RING AND GASKET PART NUMBERS ........................................................................................... 27
LEVEL CONTROL CIRCUIT DIAGRAM .................................................................................. 28
120V AC NORTH AMERICA........................................................................................................... 28 LEVEL CONTROL SPARE PARTS .................................................................................................... 29 240V AC EUROPE ....................................................................................................................... 29
PARTS IDENTIFICATION ........................................................................................................ 30
FRAME ASSEMBLY HOPPER TOPPER POWER LIFT.......................................................................... 30 FRAME ASSEMBLY HOPPER TOPPER ECONO ................................................................................. 31 PUMP ARM ASSEMBLY ................................................................................................................. 31 UPPER FRAME ASSEMBLY HOPPER TOPPER MAX ......................................................................... 32 LOWER FRAME ASSEMBLY HOPPER TOPPER MAX.......................................................................... 32 HOPPER TOPPER POWER LIFT AND MAX AIR REGULATOR............................................................... 33 HOPPER TOPPER ECONO AIR REGULATOR .................................................................................... 33 PUMP HOPPER TOPPER POWER LIFT AND ECONO .......................................................................... 34 PUMP HOPPER TOPPER MAX........................................................................................................ 35 CONTROL BOX HOPPER TOPPER POWER LIFT AND ECONO............................................................. 36 CONTROL BOX HOPPER TOPPER MAX........................................................................................... 37 CONTROL BOX HOPPER TOPPER MAX........................................................................................... 38 OUTLET PIPE WORK HOPPER TOPPER POWER LIFT....................................................................... 39 OUTLET PIPE WORK HOPPER TOPPER MAX .................................................................................. 39 OUTLET PIPE WORK HOPPER TOPPER ECONO .............................................................................. 40
PNEUMATICS DIAGRAMS ...................................................................................................... 41
HOPPER TOPPER POWER LIFT..................................................................................................... 41 HOPPER TOPPER ECONO ............................................................................................................ 42 HOPPER TOPPER MAX ................................................................................................................. 43 HOPPER TOPPER POWER LIFT WITH DEPOSIT CONTROL................................................................ 44 HOPPER TOPPER ECONO WITH DEPOSIT CONTROL ....................................................................... 45
TROUBLE SHOOTING ............................................................................................................ 46
CE MARK ................................................................................................................................. 47
SOUND LEVEL MEASUREMENT............................................................................................ 48
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Safety Instructions and Warnings
These safety instructions must be read prior to operating, sanitizing or servicing the equipment. All machines have a risk of personal injury wherever moving parts are involved in their operation. UNIFILLER has taken all possible precautions to reduce and wherever possible eliminate the dangers associated with moving parts. Having all operators of this equipment read and abide by the instructions in this manual will further reduce the risk of personal injury.
Turn air off and remove supply line from machine before attempting to clean, dismantle, or service the machine. Keep fingers and hands away from all mechanical moving parts including the hopper inlet and deposit nozzle outlet. Do not try to service the Air regulator / Water filter with the air supply line connected. For servicing or technical support please contact UNIFILLER directly or one of its authorized suppliers or dealers. Do not run product or water, with temperatures exceeding 140 deg F (60 Deg C), through the machine. For Product Temperatures that exceed 140 deg F (60 Deg C) up to 180 deg F (82 Deg C), please use HOT changeover parts on the machine. Operating Air pressure should not be adjusted to exceed 80 P.S.I. (551 kPa /5.52 Bar) on the Air regulator / Water filter pressure gauge. Always wash out the machine after use, dismantle and lubricate all the seals (As per cleaning instructions in this manual). Follow the enclosed instructions carefully before operating the machine for the first time, or maintenance. Before use ensure that the locks on the wheels are engaged. Unifiller Systems recommends the use of personal protection equipment approved by the safety regulators in the country of use. IMPORTANT: All stainless steel parts are coated with a protective coating at the factory and therefore any stainless steel parts that may come into contact with product must first be washed in hot water and detergent.
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Introduction Thank you for purchasing UNIFILLER Equipment. We are sure you will get years of trouble free use and excellent productivity from your new investment. Please take a few minutes to read this manual and familiarize yourself with the layout of the controls, and the set up and operating procedure. If you have any questions regarding the setting up, or operation of your equipment please contact us.
Contacting Unifiller
OR
Contact your local authorized Unifiller dealer. Please see our website for dealer contact information @. www.unifiller.com
Please remember to supply your company name, telephone number, email and a contact name when ordering parts. Provide the serial number of your machine when ordering spares.
Manufacturer Unifiller Systems Incorporated. 7621 Macdonald Road Delta, B.C. V4G 1N3 Telephone Main: 604-940-2233 Toll Free: 1-888-733-8444 Fax : 604-677-5844 Email: [email protected]
EU Contact Barclay – Phelps, Atlantic House, High Road Wood Green London N22 8HH
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Machine Description The Hopper Topper is an air operated transfer pump.
Intended uses Non intended uses Batter for cakes Dry goods Fruit fillings Liquids Icings, frostings and toppings Stiff non settling products Jams and jellies Creams, custards and mousse Soups, Meat sauce Mashed potato
Hopper Topper Power Lift
# Description 1 Outlet tube. 2 Pump speed control 3 “Continuous run” jumper ports 4 Pump body 5 Product inlet 6 Locking wheels 7 Air regulator and filter 8 Air connection 9 Power lift and Pump control
10 Height adjustment clamp 11 Control box
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Hopper Topper Max
# Description 1 Outlet tube. 2 Pump speed control 3 Quick exhaust 4 “Continuous run” jumper ports 5 Pump body 6 Product inlet 7 Locking wheels 8 Air connection 9 Air regulator and filter
10 Power lift and Pump control 11 Muffler 12 Height adjustment clamp 13 Control box
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Hopper Topper Econo
# Description 1 Hopper clamp 2 Pump speed control 3 “Continuous run” jumper ports 4 Height adjustment clamp 5 Air regulator and filter 6 Air connection 7 Locking wheels 8 Product inlet 9 Pump body
10 Control box 11 Outlet tube.
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Serial Number location Quote this number when ordering spare parts It is located as shown, stamped into the top of the arm.
Receiving Remove all packaging and shipping materials from the crate. Remove the spare parts kit from the shipping box. Store in a safe place Assemble the bottom frame assembly to the main post using the supplied fasteners.
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Power Requirements
Air Requirements Important: It is recommended that the compressed air supplied to the depositor be run through an air dryer before connecting to machine. Please contact Unifiller for details. The supply airline must have a minimum inside diameter of 3/8” (10mm) Connect your supply air hose that comes from your compressor (not supplied) to the quick connector (1) which is located on the main upright of the frame. Set the air pressure gauge on the machine to 80 P.S.I. (5.5 Bar) by pulling up the knob (2), adjusting the air pressure, and then pushing the knob down to lock it.
Electrical Requirements Photo sensor level control 120 or 240 volt A.C. For 240 volt operation an appropriate plug will have to be attached.
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Assembly and Operation
Outlet Pipe connection – Power Lift and Max A clamp connects the outlet tube to the main body. Check the condition of the gasket when assembling and replace if damaged.
Outlet hose connection - Econo When connecting outlet hose check the condition of the swivel joint (1), O ring (2).
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Operating Instructions
Operating the Hopper Topper Power Lift and MAX The main lever located above the air filter / regulator has 3 functions.
To raise the pump. Move the lever to the Up position and press the Green push button.
To lower the pump. Move the lever to the Down position and press the Green push button
To pump. 1. Move lever to the PUMP position. If the Hopper Topper
is in the raised position, pressing the Green push button will lower the Hopper Topper while pumping, when a signal from external source or “continuous run” jumper is installed.
NOTE: The Hopper Topper will not operate in pump position until a signal source is connected i.e. a “continuous run” jumper, or a photo sensor hopper level control.
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Height Adjustment
• With the Hopper Topper in the down position
• Place a mixing bowl next to the Hopper Topper in the down position.
• Adjust the arm by releasing height adjusting clamp (1) and moving the arm, so that the end of the pump body is approximately 6” above the bottom of the bowl. (This will ensure that the suction tube does not hit the bowl when lowered down from its top position).
• Raise the Hopper Topper Power Lift to its top position.
• Place the mixing bowl underneath the product inlet.
• Lower the power lift to its low position and move height adjustment clamp until it touches the bottom of the bowl. Tighten clamp to secure arm.
• Plug in the Power Cord for photo level control to 120/240V outlet.
• Place level control on hopper, or install “continuous run” jumper / optional foot pedal.
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Operating the Hopper Topper Econo
• Adjust arm to desired height by releasing clamp (1) and moving arm to desired height and tighten.
• Place mixing bowl of product to be pumped underneath Hopper Topper Econo by tilting pump arm up.
• Plug in the Power Cord for the level control to 120/240V outlet.
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• Place level control on hopper, or install “continuous run” jumper. NOTE: The Hopper Topper will not operate until a signal source is connected i.e. a “continuous run” jumper, or a Photo Sensor Hopper Level Control.
Photo Sensor Hopper Level Control Automatically controls the level of product in the hopper of a depositor. Connection point: Male and Female quick disconnects located on main control box. The level control unit is dual voltage 120/240 volt A.C. NOTE: If the sensor is used on 240 Volt use the appropriate plug for your country.
Wiring colors. North America Green = Ground/Earth White = Neutral Black = Live Europe Green/Yellow = Ground/Earth Brown = Live Blue = Neutral
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Foot Pedal (Optional accessory) Use: Allows manual operation (one press of pedal gives one stroke of pump.) Connection point: Remove “continuous run” jumper, and connect the two airlines from the foot pedal, to the Male and Female quick disconnects located on main control box.
Deposit Speed Adjustment The speed of the deposit can be adjusted by turning the adjustment knob (1)
Power lift and Econo Max
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Operating the Hopper Topper with Deposit Control (This option is factory installed and is not field installable.)
• Connect the foot pedal to the “foot pedal / Signal” quick connects on the control box.
• Connect the depositing nozzle air lines to the “Accessory / Nozzle” quick connects.
Hopper Topper Power lift only Move the control lever to the “Pump” position. By depressing the foot pedal the following will happen.
1. The Hopper Topper will operate. 2. The depositing nozzle will open.
Upon release of the foot pedal, the depositing nozzle will close, and the Hopper Topper will return to its start position. If the foot pedal is not being used, connect the attached cap onto the male fitting.
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Positive Cut off Nozzle
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XL Positive Cut Off Nozzle
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Disassembly and Cleaning
• Disconnect the electrical supply.
• Disconnect the air lines from the control box.
• Remove the photo sensor level control from hopper.
• Fill a mixing bowl with hot water (max. 140 F.) and pump water through Hopper Topper until it runs clear.
• Remove product hose bracket from hopper (Econo).
• Remove air supply from air regulator.
• Remove swivel hose connector from Hopper Topper Econo and hang product hose to air dry.
• For Power lift and Max, remove pipe work
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• Unfasten bottom clamp that holds top and bottom of Hopper Topper together.
• Pull piston coupling downwards, and slide piston shaft sideways out of coupling.
•••• Remove Clamp Gasket Check condition of Gasket (1)
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Important Maintenance Note
• Remove white bushing (with U-cup and O-ring seals) from the lower tube
• Use O ring removal tool and check condition of U-Cup seal and O ring. Replace if worn.
• When reassembling make sure the lips of the U-Cup are facing down (1).
• Remove piston from body.
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•••• Remove bottom nut and remove lower check valve (1).
•••• Remove o-ring from piston and check O Ring and Ball for wear (1).
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Cleaning
• Mix 1 to 4 ounces (30-120ml) of Zep F.S. PROCESS CLEANER (green) per gallon (4ltr) of water. Immerse all product contact parts in the solution. Clean all food residues with a cloth or a non-metallic scrubbing pad/brush. Rinse thoroughly with potable water
Sanitizing • Mix 1 ¼ oz’s (120ml) of Zep F.S. SUPERMARKET SANITIZER (red) per gallon (4ltr) of
water. Immerse all parts that were previously in the cleaner in the new solution for 1-2 minutes. Rinse thoroughly with potable water.
Re-Assembly
• Inspect all ‘O’ rings and seals for damage or wear; replace if required. Re-lubricate all O rings with food quality grease Pt# 21052-00 (as supplied with your machine).
• Re-assemble in the reverse order
• Re-connect all the airlines The rest of the machine can be wiped down or washed with a mild detergent.
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Optional Flapper Valve version (Available for HT Power lift and HT Econo only) Your Hopper Topper may have an optional “Flapper” type piston shaft, disassemble as shown.
• Remove piston as shown previously for ball version.
• Remove the mechanical flapper by removing the cross pin.
• Undo the large nut at the bottom of the main tube.
• Remove lower check valve assembly.
• Remove flapper retaining pin and stainless flapper.
• Check all parts for wear and damage. Replace if necessary.
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Maintenance
Turn air off, and remove air supply line from machine before any maintenance is performed.
O Ring Care The most important components of the machine are the O rings. These must be inspected and maintained daily. All O rings should be high quality Viton as supplied by Unifiller, or your authorized Unifiller dealer. Signs of wear include: Flatness, abrasions, cracks, and cuts
Daily After parts have been cleaned, lubricate all O rings, seals and moving parts with food grade grease.
Weekly With the air disconnected. Check the air filter/regulator bowl and if necessary clean the bowl and empty any accumulated water. Check condition of flappers. Replace if required.
3 Months With the air disconnected. Check the condition of the White filter in the Air regulator / Water filter, and replace if contaminated.
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O Ring and Gasket Part Numbers
Description Power lift Quantity Max Quantity Econo Quantity Outlet pipe work Gasket or O ring
01253-00 01252-00
1 2
01253-00 3 V0230-00 1
Piston shaft O ring and cup seal
00130-00 V0206-00
1 1
00130-00 V0206-00
1 1
00130-00 V0206-00
1 1
Piston V0229-00 1 V0238-00 1 V0229-00 1 Delrin top bushing
01253-00 1 97965-00 1 01253-00 1
The following parts are available from Unifiller or one of its authorized representatives.
Part Number Description Item 21052-00
O ring lubricant. 4 oz tube Lubri-film plus.
22049-00
O-ring pick tool.
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Level Control Circuit Diagram
120v AC North America Pneumatic Solenoid valve Power Supply Fuse and Fuse Holder
Line Voltage color Type Black Line White (Black dashed line) Neutral Green / Yellow Ground
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Level Control Spare Parts
240v AC Europe
# Description Part Number Quantity 1 Pneumatic solenoid valve 80060-00 1 2 5 Amp fuse 80036-00 1 3 Fuse holder 81291-00 1 4 Sensor 80604-00 1 5 Power supply 80024-00 1
Line Voltage color Type Brown Line (240Vac) Blue Neutral (0Vac) Green / Yellow Ground
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Parts Identification
Frame Assembly Hopper Topper Power Lift
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Frame Assembly Hopper Topper Econo
Pump Arm Assembly
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Upper Frame Assembly Hopper Topper MAX
Lower Frame Assembly Hopper Topper Max
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Hopper Topper Power lift and Max Air Regulator
Hopper Topper Econo Air Regulator
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Pump Hopper Topper Power lift and Econo
35
Pump Hopper Topper Max
36
Control Box Hopper Topper Power Lift and Econo
37
Control Box Hopper Topper Max
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Control Box Hopper Topper Max
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Outlet Pipe Work Hopper Topper Power Lift
Outlet Pipe Work Hopper Topper Max
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Outlet Pipe Work Hopper Topper Econo
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Pneumatics Diagrams
Hopper Topper Power Lift
P
A
A
P
14
24
12
51
3
1P
4B
2A
42
31
5
12
42
14
P
A
A
P
Hopper Topper Econo
43
Hopper Topper Max
2A
4B
1P
P
A
A
P
14
24
12
51
3
44
Hopper Topper Power Lift with Deposit Control
PEA
NA
EB
B
1P
4B
2A
P
A
P
A
5
14
1
412
3
2
45
Hopper Topper Econo with Deposit Control
PEA
NA
EB
B
P
A
P
A
5
14
1
412
3
2
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Trouble shooting
Problem Cause Remedy Pump stops operating No air pressure Check for compressed air.
Set Air regulator to 80 PSI (5.5 Bar)
No signal Remove level sensor or foot pedal and replace with “continuous run” jumper. If machine operates check level control.
Roller switch 01659-00 not operating
Check condition of roller switch, located inside control box. Check that it operates freely. Adjust or replace if defective.
Pump operates but does not move product
Product to thick, or product not flowing in to inlet (tunneling) .
Thin product.
Product is visible coming out of slots of the main body
White Bushing missing, or O ring for Bushing missing or damaged. Check condition of cup seal in bushing
Check parts are in place, and replace if necessary.
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CE Mark
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Sound Level Measurement All sound level readings taken at 1m from the front of the machine and 1.6m from the floor level. All readings are “A” weighted emission sound pressure level.
Machine Sound level dB Compact Depositor 79.4 Uni1000i 72.9 Pro 1000i 72.9 Pro 2000 78.7 Spot 87.5 XL2 81 COM Servo 72.9 Deco Mate 78.0 Hopper Topper 72.0 Hopper Topper Max 82.5 Multi 87