User Guide AutoTrans Conveyor Operation & Service
Table of Contents 1 Introduction... 1 2 Specifications, Features & Accessories... 2 2.1 Specifications... 2 2.2 Features... 2 2.3 Accessories... 2 3 Identification of Stations... 3-4 3.1 Filler Station Identification & Component Parts... 5 3.2 Folder Station Identification & Component Parts... 6 3.3 Sealing Station Identification & Component Parts... 7 3.4 Operator Panel... 8 3.5 Touchscreen... 9-10 PLC Inputs & Outputs Charts 11 4 Setup, Preparation, Operation & Maintenance...12 4.1 Setup...12 4.2 Preparation... 12-16 4.3 Operation...17 4.4 Maintenance...17 4.5 Maintenance for Printer Applicator... 18-19 5 Replacement Parts List...20 6 Troubleshooting... 21-23 PLC Inputs & Outputs Description 24 7 One Year Warranty...25 8 Maintenance and Repair History Log...26
1 Introduction Rx Systems, Inc. is very pleased you decided to join the growing number of AutoTrans Conveyor owners. Operating the AutoTrans Conveyor, you will appreciate the basic but efficient design of quality components. With proper care and maintenance you can expect years of trouble free service. This User Guide will make you familiar with the features, operating principals, procedures, necessary maintenance and troubleshooting of the Rx Systems AutoTrans Conveyor. Note: Please keep all packaging materials. REPLACEMENT PACKAGING is EXPENSIVE and REQUIRED for shipping. Page 1
2 Specifications, Features & Accessories 2.1 Specifications Overall Dimensions: Width: 34 (w/o Applicator or Conveyor), 47 (w/applicator & Conveyor) Length: 84 (w/o Applicator or Conveyor), 135 (w/applicator & Conveyor) Height: 50 (w/o Applicator or Conveyor), 70 (w/applicator & Conveyor) Weight: 650 lbs. (machine only) Electrical: 115 volt, 15 amp 2.2 Features Easy Filling, Folding, Sealing and Label Application Low Maintenance Variable Speed Filling Unique design allows fast & easy adjustment for pill sizes with in 1/64 Standard with 30, 31 or 32 count Setup (60, 62 components available) Includes a wide range of Pill dies Temperature, Time & Pressure are controlled for a consistent seal Air cooled outer shell limits access to heat plate for safety Adjustable Seal Time & Temperature Unique trays reduce moisture Safe two-handed operation Emergency Shut-Off Touch screen interface allows for multiple options and settings Stations (Filler, Folder and Sealer) are easily removed for maintenance or replacement. 2.3 Accessories Printer Applicator Conveyor Belt Pre-pack Reorder Cards Brushes Plate Kits Carrier Trays Catch Tray Page 2
3 Identification of Stations 3.1 The AutoTrans Conveyor is comprised of several stations, that each individually has one operation. There are several goals with this type of functionality: Easy to Upgrade / Downgrade to the next generation of machine. Easy to replace single Station if problems arise. With this innovative idea built into this machine, you can expect minimal downtime, and the best operation that fits your pharmacy s needs. Aside from keeping all materials (pill cards and medications) loaded and the collection area clean, the basic form of operating the machine is pressing the two green cycle buttons (on the operator panel) to index the pill card to the next station. Each station will then automatically perform its designed function. Each station is listed below with brief description and its operation. Loading Station: This is where you place a single card ready for packing. Filling Station: This is the module where pills are loaded into the bowl and a pill drop function releases the correct amount of pills into the pill card, based on the count of pill card being used. (ie 30, 60). Page 3
Inspection Station: This is where you visually inspect and correct any miss-filled pills. Folding Station: This is where the lid of the pill card gets closed. This prevents any twist of the card and aids the card into the sealing station. Sealing Station: This is where the sealing of the pill card occurs. The temperature is displayed on top left side of the station and the cooling fan keeps this station cool to the touch. Printer Applicator: This is where the card is labeled. There are two possible locations for this station: 1. Station directly after the sealing station which would label the back side of the pill card. 2. Very last station which would label the front of the pill card while it is on the conveyor belt. Operator Panel: This is where the operator controls the main operations of machine and can turn the machine ON, Cycle the Trays, Enable or Disable the machine. Touch Screen: This is the User Control Screen. Almost all controls for the machine can be adjusted here (Station settings / Adjustments, Label Printing). Conveyor Belt: This is where the card is labeled by the Printer Applicator. This station is optional and is only used if labeling on the front of the pill card is necessary. Page 4
Functions of the Filling Station and its Controls (more information can be found in section 4) Brush Speed Adjustment knob: This knob adjusts the speed in which the brushes spin. You may need to adjust the Brush Speed for different types of medication. Bowl: Locks the filling plates down and helps keep pills in the filling area, during the filling process. Plate Height Adjustment Dial: This dial adjusts the height of the Center Plate in relation to the Base Plate. You may need to adjust this for different types of medication. Brushes: These push the pills around the Filling Station helping them fall into the plates. These should be cleaned with soap and water when transitioning between medications. Push Bar Plunger: This pushes the Center Plate out, aligning the Center Plate with the Base Plate which fills the card with pills. Brush Height Adjustment Knob: Adjust the height of the brushes with this knob. You may need to adjust the brush height for different types of medication. Bowl Locking Ball: This holds the bowl into place. Blister Sensor: This senses if there is a card in the Filling Station. 1. If this sensor is not active the machine will not fill the cards. 2. This sensor sometimes needs to be wiped with a dry towel. Return Push Bar: This pushes the Center Plate back into the ready position. Page 5
Functions of the Folding Station and its Controls Roller Arm: This extends and rolls the lid of the card closed. Hold Down Finger: This holds the card down while the lid is being folded closed. Flapper Assembly: This holds the lid of the card closed after being folded. Page 6
Functions of the Sealing Station and its Controls Watlow Temperature Control: This control regulates the temperature of the Sealing process, much like the thermostat for your house. Cooling Fan: This keeps all sealing components (other than heat plate) cool. Exhaust Vent: Allows a path to circulate the air. Page 7
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Functions of the Touch Screen and its Controls Page 9
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4 Setup, Preparation, Operation & Maintenance 4.1 Setup The AutoTrans Conveyor will automatically Fill, Fold, Seal & Label pill cards at a constant speed and temperature. Initial set-up and one-time adjustments will be installed and completed by an Rx Systems Technician. 4.2 Preparation 1. Plug the AutoTrans Conveyor into a standard 3 prong outlet. It is necessary to use a dedicated 20 amp outlet. a. Plug the Battery Backup into a standard 3 prong outlet. 2. Plug the air line (35 psi) into the quick connect socket for the printer applicator. 3. Turn ON a. AutoTrans Conveyor power switch on right side of Operator Panel b. Computer c. Printer Applicator 4. Allow Heat Sealer to heat up. Your AutoTrans Conveyor sealing temperature is set to 325 degrees Fahrenheit. 5. Open Bartender Label format and test print a label for medication you are packing. a. This should also tell you what plates to select for this medication. b. If not listed, see Filling Plate Selection Understanding the Template System There are three types of templates. Each set of templates has a series of numbers and letters that identify the plate. The plate ID numbers are interpreted below: Top Plates o TP = Top Plate o 30-62 = Hole / Cavity Count o 250-875 = Size of the Plate Opening EXAMPLE: TP 30 562 Top Plate, 30 Cavities,.562 diameter openings Center Plates o CP = Center Plate o 30-62 = Hole / Cavity Count o C, T or V = Capsule, Tablet or Oval o 188-750 = Size of the Plate Opening Page 12
EXAMPLE: CP 32 T 438 Center Plate, 32 Cavities, Tablet,.438 diameter openings Base Plates o BP = Base Plate o 30-62 = Hole / Cavity Count o TN, MD or TK = Thin, Medium or Thick o 348-750 = Size of the Plate Opening EXAMPLE: BP 32 TK 453 Base Plate, 32 Cavities, Thick Plate,.453 diameter openings 6. Install filling plates and adjust height. 7. Enable Machine 8. Test Cycle (without pills) to ensure all stations operational. 9. Load Medication into filling station. Filler Preparation Plate Selection Make sure your plates (Top Plate, Center Plate & Base Plate) are stacked neatly and are clean. Stack the Center Plates (white plates) so that the smallest number is on bottom and the biggest number is on top. Place pill through one of the holes of the Center Plates. Take the last Center Plate that the pill fit through. That will be your Center Plate for tablets. The capsules and caplets will be one or two plates larger. Match up the Center Plate Number on the Filler Plate Chart (Exhibit A), and use the appropriate Top Plate and Base Plate. NOTE: The Plate Chart is only a guide. It is generally correct for most medications. But others may take some experimentation to get the fastest and most thorough filling operation. NOTE: Helpful setup VIDEO can be found at http://youtu.be/ukhfmeusrm0 Height Adjustment o Insert the chosen Base Plate and Center Plate into the filling station. o Place pill through one of the holes on the Center Plate. o Adjust height so the top of the pill cannot be touched by the Top Plate. Take the side of Top Plate and scrape the Center Plate over the area of the inserted pill. If the pill does not move, the height is good. If the pill moves, then increase the height more. Do not adjust the height too high or two pills will try and fill at once. Page 13
Brushes Pressure o Insert the chosen Top Plate o Install the Filler Bowl o Place 30 40 pills into the Filler Station o Lower brushes and turn on so the brushes are moving slowly. o Adjust the brush pressure so the brushes push all of the pills around the bowl and into the holes. And so the brush bristles do not go into the holes. Speed o Set brush speed so the pills have enough time to fall into holes. Place Card into Loading / Inspection Station Load Pills into Filler Section Helpful Hints Be sure pills are whole before loading the filler Remove a brush when smaller pills pop out of the AutoFiller. Long capsules may need XL blisters to clear the base plate. See attached drawings for troubleshooting (Exhibit B) or contact us at 1-800-922-9142 Page 14
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4.3 Operation 1. Load card & blister into Loading Station. 2. Activate the two Green Cycle Buttons on the Operator Panel. 3. Inspect filled card & blister at Inspection Station. 4. Repeat process at Step 1. 4.4 Maintenance The filler bowl, plates and brushes can all be cleaned with warm water and soap. Alcohol can also be used as an antiseptic measure after cleaning with warm water and soap. Monthly, the cover should be removed to check for dirt and dust. AS ALWAYS, THE COVER SHOULD NOT BE REMOVED UNTIL THE MACHINE IS COOL (ABOUT 30 MINUTES AFTER BEING SHUT OFF) AND UNPLUGGED. An air hose or a vacuum cleaner can be used to clean. Always remember to wear the appropriate eye protection. Care should be taken not to disconnect any of the internal wiring. The outside of the AutoTrans Conveyor can be cleaned with a window cleaner or similar product. These maintenance suggestions are just that, suggestions. The volume of your work will dictate how often maintenance should be performed. Page 17
4.5 Maintenance for Printer Applicator Page 18
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5 Replacement Parts List We recommend using Rx Systems parts to insure reliable operation of equipment. Any use of non-rxs approved parts can void your equipment warranty. Page 20
6 Troubleshooting Guide Page 21
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7 One Year Warranty Rx Systems warrants its AutoTrans Conveyor for one year from the original date of purchase. The warranty covers defects in material and workmanship. Within the applicable warranty period, the AutoTrans Conveyor will be repaired or replaced at Rx Systems discretion. Voided Warranty: In the event an AutoTrans Conveyor is returned for warranty work and is improperly packaged, the warranty may be voided. If you need proper packaging, please call Rx Systems, it is available at a cost and required for shipping. An extended warranty may be purchased. Call Rx Systems sales staff for more information. The information contained herein is based upon our research and believed to be accurate, but the accuracy and completeness of our recommendations is not guaranteed. The user shall determine the suitability of the product for their intended use before using the product and the user assumes all risk and liability whatsoever in connection with the use of the product. Neither seller nor manufacturer shall be liable for any injury, loss or damage, direct or consequential, arising out of the use of or inability to use the product. The following is made in lieu of all warranties, express or implied: Seller s and Manufacturer s only obligation shall be to repair, replace or credit such quantity of the product proved to be defective. Page 25
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