Filler Maintenance

Technical Documentation

Maintenance Procedures Manual

FILLER COMBI MATRIX SF300 FM 144/24 (SRMB0119)

Original instructions

All figures and photographs are for information only

Publication Date: 25/06/2013 SIDEL S.p.A. - Via La Spezia, 241/A - (43100), Parma ITALY Tel.: +39 0521 9991 - Fax: +39 0521 959009

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NON CONTRACTUAL DOCUMENT: if

any constructive or commercial requirement should occur, the supplier society reserves the right to modify the machine, under no obligation to timely update this manual.

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SERVICECATALOGUEPRESENTATION

PARTA

MAINTENANCEPLAN

PARTB

MECHANICALINTERVENTIONPROCEDURES

PARTC

ELECTRICALMAINTENANCEPROCEDURES

PARTD

TABLE OF CONTENTS SERVICE CATALOGUE PRESENTATION..................................................................................................................... Part A

General presentation .........................................................................................................................................................A-1 MAINTENANCE PLAN ................... ...................... ..................... ...................... ..................... ..................... ..................... Part B

Maintenance plan...............................................................................................................................................................B-1 MECHANICAL INTERVENTION PROCEDURES ..................... ...................... ..................... ..................... .................... Part C .

Cleaning/control procedures list.........................................................................................................................................C-1 Removal/replacement procedures list................................................................................................................................C-2 Lubrication/greasing procedures list ..................................................................................................................................C-3 ELECTRICAL MAINTENANCE PROCEDURES............................................................................................................ Part D

List o cleaning/control procedures .................................................................................................................................... !-1 List o removal/replacement procedures............................................................................................................................!-2

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Parte A


ASSISTANCECATALOGUEPRESENTATION

PARTA

MAINTENANCEPLAN

PARTB

MECHANICALMAINTENANCEPROCEDURES

PARTC


PARTD

TABLE OF CONTENTS MAIN PRESENTATION ...................... ..................... ...................... ..................... ..................... ...................... ..................... A-1 ......

Foreword .......................................................................................................................................................................... A-1-1 General safety information................................................................................................................................................ A-1-2 Using the assistance card catalogue ................................................................................................................................ A-1-3 Tightness values............................................................................................................................................................... A-1-4 u!ricant"grease s#ecification .......................................................................................................................................... A-1-$

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Parte A

A-1 MAIN PRESENTATION

A-1-1

Foreword

Prerequisites:

A-1-2

You must carefully read the “User Manual” before starting any maintenance procedures.

General safety information

The Maintenance Procedure Manual includes all preventive maintenance procedures. General safety conditions during maintenance: 1.

Machine maintenance must only be performed by qualified and authorised personnel.

2.

Always wear the personal protection equipment required for each maintenance operation.

3.

Always inform other operators of your intentions before making repairs or performing maintenance on the machine.

4.

All operations performed inside the perimeter marked by the safety doors must be undertaken with the machine switched OFF, empty of bottles and in one of the following operating conditions: -

Mains power supply disconnected

-

JOG control ON

5.

Use ORIGINAL SPARE PARTS only.

6.

Before starting the machine, make sure that:

-

Any guards removed during maintenance are refitted and operating correctly.

-

All foreign objects (cloths, tools, etc.) are removed from the machine.

All spare parts are fitted correctly and locked in position.

Machine parts reach very high temperatures during sterilisation and CIP: burn hazard. Operators must NOT access the inside of the machine until the temperature indicated on the o perator panel is less th an 40°C.

Do NOT perform maintenance inside the perimeter marked by the safety doors during sterilisation and/or CIP operations. During sanitisation the machine hoses transfer toxic liquids which are a health hazard in the event of contact.

WARNING: In the event of checks running programmable logic (PLC) installed directly on the control panel (or inside the electrical cabinet which does not have a front door – e.g. in the control room), the person assigned to electrical maintenance must be sure to discharge any staticor electricity build-up beforeToapproaching PLC to perform maintenance operations even simple tests. do this, atheportable maintenance kit for static electricity discharge must be utilized. This kit is comprised of a metal band to be applied around the wrist and a pad made of conductive material. This kit must be connected to the same reference potential (earth) that the PLC body is connected to.”

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Parte A


WARNING: During maintenance involving the machine base, take care of the surface which may be slippery.

WARNING: Tampering with or removing safety devices is strictly prohibited. The manufacturer cannot be held responsible for the consequences of tampering with or removal of safety devices. In ”JOG” mode, the operator must be careful to the position of the cord to the portable pushbutton panel in order to prevent crushing it. Conduct that does not conform to the safety instructions given for the use of this machine could be fatal or cause serious injury or damage to persons and or property.

A-1-3

Using the assistance card catalogue

How are the procedures classified? •

Maintenance procedures are classified into two areas:

- mechanical procedures (F_M) - electrical procedures (F_E) •

Information included on the control bar:

Minimum operator level required for the procedure

Name procedure

Symbol procedure

•

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Number pages Procedure classification and progressive number

Control bar list:

1

Mechanical checking / cleaning procedures from 001 to 999

FNM - xxx

1/1

1

Mechanical removal / substitution procedures from 001 to 999

FDM - xxx

1/1

1

Mechanical greasing / lubrication procedures from 001 to 999

FGM – xxx

1/1

1

Electrical checking / cleaning procedures from 001 to 999

FNE - xxx

1/1

1

Electrical removal / substitution procedures from 001 to 999

FDE - xxx

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Maintenance Procedures Manual •

Parte A

Operator levels

-level 1: -level 2: - level 3: - level 5:

generic operator: maintenance mechanic/electrician customer maintenance supervisor Sidel S.p.A. technician

What do the maintenance procedures describe?

- The exact position where the operation is required - Reference to general safety precautions to be taken - Reference to safety precautions specific to the procedure - Specific operating instructions (machine emptying, rinsing, etc.) - Specific tools to use - Lubricant/s to use - Standard operating procedure How are the maintenance procedures used? The procedures in this manual assume the machine is fully installed and connected correctly to services (air, water, mains power and process liquids). The following are described below:

-

general safety precautions; operator level required of personnel performing maintenance; correct tools and equipment to be used for the operation; correct lubricants to use (for lubrication procedures).

Before starting the operation, read the entire procedure to:

- identify the exact position on the machine where the operation is to be performed; - obtain the correct standard equipment (e.g. rags, brushes, gauges, etc.); - be aware of all specific instructions; - refer to all other procedures which may be required. Always complete each step of the operation in the order listed in the procedure : At the end of the procedure, clean the area carefully making sure the machine can restart production as normal, no tools or size parts have been left inside the machine and the machine does not represent a hazard for personnel. Make sure of compliance with all machine hygiene conditions.

Terminology used The meaning of some specific terms is given below to clarify the terminology used in the procedures: Overhaul Check

total dismantling of a component and if necessary substitution of worn or damaged parts. visual inspection and/or checks using equipment of a component and dismantling if necessary.

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Parte A

A-1-4


Tightness values

Tri-clamp setting Clamp 1” e 1 ½”

Clamp ½” e ¾”

Clamp 4”

Clamp 3”

Clamp 2 ½”

Clamp 2”

Clamp 6”

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Parte A


Screw torque wrench settings Class of resistance 10.9

12.9

8.8

Area Starting Starting Starting Threading Yield Tightening Yield Tightening Yield Tightening mm2 clamping clamping clamping point torque point torque point torque strenght strenght strenght M 3x0.5 M 4x0.7

5.03 8.78

kfg 563 983

kfg 394 688

kfg - cm 17 40

kfg 482 842

kfg 338 589

kfg - cm 15 34

kfg 328 573

kfg 230 401

kfg - cm 10 23

MM5x0.8 6x1 M 8x1.25 M 10x1.5 M 12x1.75 M 14x2 M 16x2 M 18x2.5 M 20x2.5 M22x2.5 M24x3

14.2 20.1 36.6 58 84.3 115 157 192 245 303 353

1590 2251 4099 6496 9442 12880 17584 21504 27440 33936 39536

1113 1576 2869 4547 6609 9016 12039 15053 19208 23755 27675

81 138 334 663 1160 1840 2870 3950 5600 7620 9680

1362 1928 3510 5562 8084 11029 15056 18413 23496 29058 33853

953 1349 2457 3894 5659 7720 10539 12889 16447 20340 23697

69 118 286 567 990 1580 2460 3380 4790 6520 8290

927 1313 2390 3787 5505 7510 10252 12922 16489 20392 23757

649 919 1673 2651 3853 5257 7176 9045 11542 14274 16630

47 80 195 386 674 1070 1670 2370 3360 4580 5820

The values in the table are approximate and for reference only.

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Parte A


A-1-5

Lubricant/grease specifications

Refer to specific maintenance cards for the specifications of lubricants and greases.

WARNING: Do NOT use lubricants/greases with viscosity index other than those indicated as this may cause overheating and early wear of components.

-

When topping up/substituting lubricants, make sure the new lubricant has the same composition and viscosity characteristics. Mixing lubricants with different basic compositions can cause irreparable damage to reduction gears and/or machine components.

-

Do NOT use grease with a consistency value greater then 2 for automatic lubrication control units. Failure to do this may result in ungreased parts requiring lubrication and damage to the grease dosing and distribution pump.

Terminology Contact SIDEL or the machine supplier if you have any doubts concerning the type of lubricant to use. Resistance that the molecules of a liquid apply when sliding against each other. This resistance is also known as internal friction. Derives from the contact friction of the sliding surfaces when the lubricating film is Wear missing. Mineral oil Oil obtained through processing of crude oil. Oil obtained by synthesising chemical substances with low molecular weight – Synthetic oil hydrocarbon or silicon composites. Unit of measure to assess grease consistency. The depth of penetration into the Grease penetration grease of a normalised cone is measured on a scale of 10-1 mm. Viscosity

NLGI consistency class Drop point H1 approval

The NLGI number indicates the depth of penetration of a grease measured using the penetration meter after a fixed processing cycle . The temperature at which the external soapy structure of the grease releases the oil contained therein. H1 is the code for Food grade lubricants, i.e. lubricants which can be used on all friction points on machines used in food processing where occasional contact between the food and lubricant is possible.

It is recommended the Safety Cards provided by the supplier are to hand to identify:

-

hazards; protection devices; first aid requirements; fire prevention measures; action in the event of accidental leaks; physical and chemical properties; stability and reactivity; toxicological information; ecological information; disposal information; shipping information.

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Parte A

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Part B



PARTA

MAINTENANCEPLAN

PARTB


PARTC


PARTD

TABLE OF CONTENTS MAINTENANCE PLAN ................... ...................... ..................... ...................... ..................... ..................... ..................... .......... B-1

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B-1

Part B

MAINTENANCE PLAN

2/2

CodMacchina SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119

Location All modules Ele-Electricalmaingroup Ele-Electricalmaingroup VFiller valve V-Fillervalve VFiller valve V-Fillervalve V-Fillervalve V-Fillervalve V-Fillervalve V-Fillervalve V-Fillervalve V-Fillervalve V-Fillervalve V-Fillervalve V-Fillervalve V-Fillervalve AFiller AFiller A-Filler A-Filler Filler A AFiller A-Filler AFiller A-Filler A-Filler A-Filler A-Filler

Position CodID ID Component 0 MAINT2559 Services 0 MAINT6042E mergencystopbutton 0 MAINT6043E lectricalconnections 1000 MAINT1163B odyvalve 1000 MAINT1165B odyvalve 1000 MAINT1166 Bodyvalve 1000 MAINT1172F illingvalves 1005 MAINT1163F illingvalveinletpart 1005 MAINT1172F illingvalveinletpart 1010 MAINT1163F illingvalvedistributorgroup 1010 MAINT1165F illingvalvedistributorgroup 1010 MAINT1172F illingvalvedistributorgroup 1020 MAINT1165G roupbell 1020 MAINT1172G roupbell 1025 MAINT1172D ummybottlegroup 1060 MAINT1172F illingvalvegrip 1075 MAINT1181P ilotvalve 2020 MAINT2269S lewingring 2020 MAINT2273 Slewingring 2035 MAINT1178C arouselcontrol 2035 MAINT1182F illercontrolpinion 2035 MAINT2266 Engine 2035 MAINT2273 Piniongear 2035 MAINT2274F illergearboxoillevel 2035 MAINT2278 Engine 2500 MAINT1171U ppermanifold 1W. 2500 MAINT1183E lectricmanifoldrotating 2502 MAINT1170L owermanifold 2510 AVF201 MAINT1175T ankblow-offvalve

Operation Period HoursC CT Control 0 CT-Control Weekly 125 2 CT-Control Quarterly 1500 20 CTControl Daily 24 0 CT-Control Weekly 125 2 CTControl Weekly 125 2 RP-Replacement Annual 6000 60 CT-Control Daily 24 0 RP-Replacement Annual 6000 60 CT-Control Daily 24 0 CT-Control Weekly 125 2 RP-Replacement Annual 6000 60 CT-Control Weekly 125 2 RP-Replacement Annual 6000 60 RP-Replacement Annual 6000 60 RP-Replacement Annual 6000 60 RP-Replacement Conditional 0 0 CTControl Quarterly 1500 20 CTControl Annual 6000 80 RP-Replacement Twoyears 12000 160 RP-Replacement Conditional 0 0 CT Control Monthly 500 7 CTControl Annual 6000 80 GR-Greasing Twoyears 12000 160 RPReplacement Conditional 0 0 RP-Replacement Sixmonths 3000 40 RP-Replacement Conditional 0 0 RP-Replacement Annual 6000 40 RP-Replacement Annual 6000 80

ycleL evel Time 1 FNE059 1 3min FNE030 33 0min FNE031 2 2min FNM240 2 1,5min FNM244 2 3min FNM245 5 7min FDM380 2 2min FNM240 5 7min FDM380 2 2min FNM240 2 1,5min FNM244 57 min FDM380 2 1,5min FNM244 5 7min FDM380 5 7min FDM380 5 7min FDM380 3 5min FDM395 3 10min FNM252 5 30min FNM253 5 480min FDM391 5 60min FDM396 35 min FNM249 5 30min FNM253 2 20min FGM034 5 60min FDM394 5 120 FDM378 3 60min FDM397 5 480min FDM377 3 60min FDM385

SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119

A-Filler A-Filler A-Filler A-Filler A-Filler A-Filler A-Filler A-Filler A-Filler A-Filler A-Filler A-Filler A-Filler A-Filler A-Filler A-Filler A-Filler A-Filler A-Filler A-Filler B Base B-Base BBase B-Base B-Base B-Base B-Base B-Base Base B B-Base B-Base B-Base B-Base

2510 2510 2510 2510 2510 2510 2510 2510 2510 2510 2510 2510 2510 2512 2518 2518 2522 2525 2525 2575 3000 3020 3023 3032 3063 3063 3065 3065 4000 4016 4018 4020 4033

AVF202 MAINT1175T ankblow-offvalve AVF203 MAINT1175T ankblow-offvalve AVF204 MAINT1175T ankblow-offvalve AVF205 MAINT1175T ankblow-offvalve AVF207 MAINT1175T ankblow-offvalve AVF208 MAINT1175T ankblow-offvalve AVF254 MAINT7003T hrottlegaskets LSF203HM AINT7004L evelprobe LSF202HM AINT7004L evelprobe LSF201HM AINT7004L evelprobe LSF204HM AINT7004L evelprobe TTF201 MAINT7016T emperatureprobe PTF204 MAINT7049P ressureswitchgaskets MAINT1170F eedingpiping MAINT1173F lowmeter MAINT6044F lowmeter MAINT1170P roductdistribution MAINT2271C ouplingproductfeeding PTF203 MAINT7049P ressureswitchgaskets MAINT1168V alvepneumaticconnections MAINT2260 Capper base MAINT2578O utputtapeOVERHEAD(beltdrive) MAINT2272O utputtape MAINT1492S tarwheelcontrol MAINT1177 Devicesinthebottlebody(outputSOCKETNECK) MAINT1483O utputSOCKETNECKguide MAINT1167O utputstarwheel(phasing) MAINT1177 Devicesinthebottlebody(outputSOCKETNECK) MAINT2260 Filler base MAINT1492S tarwheelcontrol720 MAINT1492S tarwheelcontrol720 MAINT1492S tarwheelcontrol1080 MAINT1179D ummybottle

RP-Replacement Annual 6000 RP-Replacement Annual 6000 RP-Replacement Annual 6000 RP-Replacement Annual 6000 RP-Replacement Annual 6000 RP-Replacement Annual 6000 RP-Replacement Annual 6000 CL-Cleaning Annual 6000 CL-Cleaning Annual 6000 CL-Cleaning Annual 6000 CL-Cleaning Annual 6000 CT-Control Fouryears 24000 RP-Replacement Annual 6000 RP-Replacement Annual 6000 RP-Replacement Annual 6000 RP-Replacement Conditional 0 RP-Replacement Annual 6000 RP-Replacement Sixmonths 3000 RP-Replacement Annual 6000 CT-Control Monthly 500 CL Cleaning Daily 24 RP-Replacement Twoyears 12000 RPReplacement Annual 6000 RP-Replacement Twoyears 12000 RP-Replacement Annual 6000 CT-Control Weekly 125 CT-Control Weekly 125 RP-Replacement Annual 6000 CL Cleaning Daily 24 RP-Replacement Twoyears 12000 RP-Replacement Twoyears 12000 RP-Replacement Twoyears 12000 RP-Replacement Twoyears 12000

3 60min FDM385 3 60min FDM385 3 60min FDM385 3 60min FDM385 3 60min FDM385 3 60min FDM385 2 15min FDM185 2 5min FNM119 2 5min FNM119 2 5min FNM119 2 5min FNM119 3 10min FNM042 2 10min FDM448 5 480min FDM377 3 5min FDM383 3 5min FDE044 5 480min FDM377 3 30min FDM379 2 10min FDM448 2 5min FNM251 15 min FNM238 31 80min FDM749 3 60min FDM382 5 30min FDM750 35 min FDM387 2 5min FNM475 2 12,5min FNM247 35 min FDM387 15 min FNM238 5 30min FDM750 5 30min FDM750 5 30min FDM750 3 15min FDM393


B-Base BBase B-Base B-Base B-Base B Base B Base B-Base B-Base B-Base B-Base B-Base B-Base B-Base B-Base C-Safeguard C-Safeguard C-Safeguard C-Safeguard C-Safeguard C-Safeguard C-Safeguard C-Safeguard CSafeguard C-Safeguard Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit

4034 4034 4034 4034 4034 4035 4036 4037 4037 4039 4044 4044 4061 4061 4061 5000 5000 5004 5004 5005 5005 5020 5020 5040 5040 6000 6000 6000 6000 6000 6000 6000 6000

AVB223 AVE234 AVB222 AVB221 AVS219 AVB233

MAINT1185S tarwheelcontrolpinion MAINT2266 Starwheelengine MAINT2274S tarwheelcontrolgearboxoillevel MAINT2278S tarwheelengine MAINT2585B asegearbox MAINT2583 Phasesensor MAINT2584 Photocell MAINT2265B ottleejectorpiston MAINT2277B ottleejectorpiston MAINT2281C oolingbottlenozzles MAINT2579B elt-COMBItransmissionunit MAINT2580B elt-COMBItransmissionunit MAINT1162N eckhandlingtweezers MAINT1167G ripassembly(phasing) MAINT1176N eckhandlingtweezers MAINT6041D oorssensor(COMBIbase) MAINT6045D oorssensor(COMBIbase) MAINT6041D oorssensor(outletbase) MAINT6045D oorssensor(outletbase) MAINT6041D oorssensor(filler) MAINT6045D oorssensor(filler) MAINT2581G ALVANIFilter MAINT2582G ALVANIFilter MAINT2262 Safetyplates MAINT2263D oorssafetyplates MAINT7000T RI-clampgaskets MAINT7001D INgaskets MAINT7003T hrottlegaskets MAINT7003T hrottlegaskets MAINT7003T hrottlegaskets MAINT7003T hrottlegaskets MAINT7003T hrottlegaskets MAINT7003T hrottlegaskets

RP-Replacement Conditional 0 0 CTControl Monthly 500 7 GR-Greasing Twoyears 12000 160 RP-Replacement Conditional 0 0 RP-Replacement Twoyears 12000 160 CT Control Weekly 125 CL Cleaning Weekly 125 CT-Control Monthly 500 7 RP-Replacement Twoyears 12000 160 CL-Cleaning Monthly 500 7 RP-Replacement Twoyears 12000 160 CT-Control Quarterly 1500 20 CT-Control Daily 24 0 CT-Control Weekly 125 2 RP-Replacement Annual 6000 80 CT-Control Daily 24 0 RP-Replacement Conditional 0 0 CT-Control Daily 24 0 RP-Replacement Conditional 0 0 CT-Control Daily 24 0 RP-Replacement Conditional 0 0 RP-Replacement Annual 6000 80 CL-Cleaning Quarterly 1500 20 CTControl Daily 24 0 CT-Control Daily 24 0 RP-Replacement Annual 6000 RP-Replacement Annual 6000 RP-Replacement Annual 6000 RP-Replacement Annual 6000 RP-Replacement Annual 6000 RP-Replacement Annual 6000 RP-Replacement Annual 6000 RP-Replacement Annual 6000

SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119

Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit

6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000

AVB232 AVB235 AVS232 AVS230 AVF212 AVF215 HVF209 AVF209 AVF238 AVF220 AVS204 AVF221 AVG217 AVG252 AVF227 AVF240 AVF228 AVF226 AVF266 AVF206 AVS203 AVG251 AVS202 AVB284 RVG205 RVF201 RVG202

MAINT7003T hrottlegaskets MAINT7003T hrottlegaskets MAINT7003T hrottlegaskets MAINT7003T hrottlegaskets MAINT7003T hrottlegaskets MAINT7003T hrottlegaskets MAINT7003T hrottlegaskets MAINT7003T hrottlegaskets MAINT7003T hrottlegaskets MAINT7003T hrottlegaskets MAINT7003T hrottlegaskets MAINT7003T hrottlegaskets MAINT7003T hrottlegaskets MAINT7003T hrottlegaskets MAINT7003T hrottlegaskets MAINT7003T hrottlegaskets MAINT7003T hrottlegaskets MAINT7003T hrottlegaskets MAINT7003T hrottlegaskets MAINT7003T hrottlegaskets MAINT7003T hrottlegaskets MAINT7003T hrottlegaskets MAINT7003T hrottlegaskets MAINT7003D iaphragmvalvegaskets MAINT7003D iaphragmvalvegaskets MAINT7003M odulatingvalvegaskets MAINT7003M odulatingvalvegaskets

RP-Replacement RP-Replacement RP-Replacement RP-Replacement RP-Replacement RP-Replacement RP-Replacement RP-Replacement RP-Replacement RP-Replacement RP-Replacement RP-Replacement RP-Replacement RP-Replacement RP-Replacement RP-Replacement RP-Replacement RP-Replacement RP-Replacement RP-Replacement RP-Replacement RP-Replacement RP-Replacement RP-Replacement RP-Replacement RP-Replacement RP-Replacement

Annual Annual Annual Annual Annual Annual Annual Annual Annual Annual Annual Annual Annual Annual Annual Annual Annual Annual Annual Annual Annual Annual Annual Annual Annual Annual Annual

6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000

80 80 80 80 80 80 80 80 80 80 80 40 80 0 40 40 80 7 0 80 160 80 2 80 0 160 160 160 160

5 60 FDM411 3 5min FNM249 22 0min FGM034 5 60min FDM394 3 480min FDM753 1 15min FNE067 2 15 min FNE068 2 2min FNM248 3 15min FDM392 2 5min FNM261 36 0min FDM751 3 15min FNM477 2 5min FNM239 2 12,5minF NM247 3 15min FDM386 1 3min FNE029 35 min FDE045 1 3min FNE029 3 5min FDE045 1 3min FNE029 3 5min FDE045 2 10min FDM752 2 15min FNM478 1 3min FNM241 1 3min FNM242 2 5min FDM088 2 5min FDM089 2 15min FDM185 2 15min FDM185 2 15min FDM185 2 15min FDM185 2 15min FDM185 2 15min FDM185 2 15min 2 15min 2 15min 2 15min 2 15min 2 15min 2 15min 2 15min 2 15min 2 15min 2 15min 2 15min 2 15min 2 15min 2 15min 2 15min 2 15min 2 15min 2 15min 2 15min 2 15min 2 15min 2 15min 21 5min 21 5min 21 5min 21 5min

FDM185 FDM185 FDM185 FDM185 FDM185 FDM185 FDM185 FDM185 FDM185 FDM185 FDM185 FDM185 FDM185 FDM185 FDM185 FDM185 FDM185 FDM185 FDM185 FDM185 FDM185 FDM185 FDM185 FDM185 FDM185 FDM185 FDM185

ProcSheet

Comments Preliminary operations

Timeforsinglecomponent Timeforsinglecomponent Timeforsinglecomponent Timeforsinglecomponent Timeforsinglecomponent Timeforsinglecomponent Timeforsinglecomponent Timeforsinglecomponent Timeforsinglecomponent Timeforsinglecomponent Timeforsinglecomponent Timeforsinglecomponent Timeforsinglecomponent

Timeforsinglecomponent Timeforsinglecomponent Timeforsinglecomponent Timeforsinglecomponent

Timeforsinglecomponent Timeforsinglecomponent

Timeforsinglecomponent

Timeforsinglecomponent Timeforsinglecomponent Timeforsinglecomponent

Timeforsinglecomponent Timeforsinglecomponent Timeforsinglecomponent Timeforsinglecomponent Timeforsinglecomponent Timeforsinglecomponent


SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119

Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit

6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000


Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit Y-CIP/SIPUnit

6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6010 6010 6010 6010 6010 6010 6010

SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119 SRMB0119

A-Filler A-Filler A-Filler A-Filler A-Filler A-Filler A-Filler A-Filler A-Filler AFiller -

7000 7000 7000 7022 7022 7022 7022 7022 7022 7075

RVG203 AVF298 AVF241 AVS225 OG212 OG213 OG211 OG210 OS201 OE201 OB201 LSF206L LSF209L LSF205L PTF208 FF200 FF201 FF202 PPF201 PPS200 OF220 OF228 EB200 TTB206 TTS201 FG202 FG207 FF207

MAINT7003M odulatingvalvegaskets MAINT7003M IXPROOFvalvegaskets MAINT7003M IXPROOFvalvegaskets MAINT7003M IXPROOFvalvegaskets MAINT7003N on-returnvalvegaskets MAINT7003N on-returnvalvegaskets MAINT7003N on-returnvalvegaskets MAINT7003N on-returnvalvegaskets MAINT7003N on-returnvalvegaskets MAINT7003N on-returnvalvegaskets MAINT7003N on-returnvalvegaskets MAINT7004L evelprobe MAINT7004L evelprobe MAINT7004L evelprobe MAINT7005T anklevelprobe MAINT7008C O2sterielfilter MAINT7009V alvepositioncontroller MAINT7010F iltercartridge MAINT7010F iltercartridge MAINT7010F iltercartridge MAINT7011P umpgasket MAINT7011P umpgasket MAINT7012S peculumgaskets MAINT7012S peculumgaskets MAINT7014H eatexchanger MAINT7016T emperatureprobe MAINT7016T emperatureprobe MAINT7018Y filtergaskets MAINT7018Y filtergaskets MAINT7020O utletfilter

FG201 MAINT7022Y filter FG207 MAINT7022Y filter FF207 MAINT7024O utletfilter FF202 MAINT7010F iltercartridge FF201 MAINT7010F iltercartridge FF200 MAINT7010F iltercartridge PCG203 MAINT7028 Pressurereducergaskets PSG204 MAINT7049P ressureswitchgaskets PSG203 MAINT7049P ressureswitchgaskets PSG202 MAINT7049P ressureswitchgaskets PTF200 MAINT7049P ressureswitchgaskets PTF209 MAINT7049P ressureswitchgaskets PTS201 MAINT7049P ressureswitchgaskets PTE201 MAINT7049P ressureswitchgaskets MAINT7068I nletairpressions MAINT7069P neumaticsystemconnections FB200 MAINT7070W ashingsolutionfilter FB200 MAINT7077W ashingsolutionfilter FSS200 MAINT7080F lowmetergaskets FTB209 MAINT7080F lowmetergaskets FSE201 MAINT7080F lowmetergaskets OF210 MAINT7082A irstreamtrap MAINT7091S olenoid AVF298 MAINT7098M IXPROOFvalve AVS225 MAINT7098M IXPROOFvalve AVF241 MAINT7098M IXPROOFvalve AVB229 MAINT7003T hrottlegaskets AVB230 MAINT7003T hrottlegaskets AVB226 MAINT7003T hrottlegaskets AVB231 MAINT7003T hrottlegaskets LSB221HM AINT7004L evelprobe LSB222L MAINT7004L evelprobe PPB220 MAINT7011P umpgasket MAINT2269A utomaticcentralisedlubrication MAINT2279L ubricationautomaticpump MAINT2280L ubircationautomaticdistributor AVE213 MAINT7003D iaphragmvalvegaskets AVB208 MAINT7003T hrottlegaskets AVE201 MAINT7003T hrottlegaskets AVE202 MAINT7003T hrottlegaskets AVE203 MAINT7003T hrottlegaskets AVE214 MAINT7003T hrottlegaskets MAINT2267P neumaticsystem

RP-Replacement Annual 6000 RP-Replacement Annual 6000 RP-Replacement Annual 6000 RP-Replacement Annual 6000 RP-Replacement Annual 6000 RP-Replacement Annual 6000 RP-Replacement Annual 6000 RP-Replacement Annual 6000 RP-Replacement Annual 6000 RP-Replacement Annual 6000 RP-Replacement Annual 6000 CL-Cleaning Annual 6000 CL-Cleaning Annual 6000 CL-Cleaning Annual 6000 CL-Cleaning Annual 6000 RP-Replacement Annual 6000 CT-Control Annual 6000 RP-Replacement Annual 6000 RP-Replacement Annual 6000 RP-Replacement Annual 6000 RP-Replacement Annual 6000 RP-Replacement Annual 6000 RP-Replacement Annual 6000 RP-Replacement Annual 6000 RP-Replacement Conditional 0 CT-Control Fouryears 24000 CT-Control Fouryears 24000 RP-Replacement Annual 6000 RP-Replacement Annual 6000 RP-Replacement Annual 6000 CL-Cleaning Monthly CL-Cleaning Monthly CL-Cleaning Weekly RP-Replacement Annual RP-Replacement Annual RP-Replacement Annual RP-Replacement Annual RP-Replacement Annual RP-Replacement Annual RP-Replacement Annual RP-Replacement Annual RP-Replacement Annual RP-Replacement Annual RP-Replacement Annual CT-Control Daily CT-Control Monthly CL-Cleaning Monthly RP-Replacement Conditional RP-Replacement Annual RP-Replacement Annual RP-Replacement Annual CL-Cleaning Annual RP-Replacement Conditional CT-Control Sixmonths CT-Control Sixmonths CT-Control Sixmonths RP-Replacement Annual RP-Replacement Annual RP-Replacement Annual RP-Replacement Annual CL-Cleaning Annual CL-Cleaning Annual RP-Replacement Annual

500 500 125 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 24 500 500 0 6000 6000 6000 6000 0 3000 3000 3000 6000 6000 6000 6000 6000 6000 6000

CT-Control Quarterly RP-Replacement Conditional CL-Cleaning Conditional RP-Replacement Annual RP-Replacement Annual RP-Replacement Annual RP-Replacement Annual RP-Replacement Annual RP-Replacement Annual CT-Control Monthly

1500 0 0 6000 6000 6000 6000 6000 6000 500

80 80 80 80 80 80

80 80 80 80 0

80 80 80 7 7

80 80 80 80 80 80 80 80 0 7 7 0 80 80 80 80 0 40 40 40

80 80 80 20 0 0

7

21 5min 21 5min 21 5min 21 5min 21 5min 21 5min 21 5min 21 5min 21 5min 21 5min 21 5min 2 5min 2 5min 2 5min 2 40min 2 15min 1 2min 2 30min 2 30min 2 30min 2 60min 2 60min 2 10min 2 10min 3 30min 3 10min 3 10min 2 10min 2 10min 2 5min

FDM185 FDM185 FDM185 FDM185 FDM185 FDM185 FDM185 FDM185 FDM185 FDM185 FDM185 FNM119 FNM119 FNM119 FNM145 FDM183 FNM112 FDM174 FDM174 FDM174 FDM173 FDM173 FDM092 FDM092 FDM176 FNM042 FNM042 FDM175 FDM175 FDM095

2 5min FNM055 2 5min FNM055 2 5min FNM111 2 30min FDM174 2 30min FDM174 2 30min FDM174 21 0min FDM098 21 0min FDM448 21 0min FDM448 21 0min FDM448 21 0min FDM448 21 0min FDM448 21 0min FDM448 21 0min FDM448 1 1min FNM106 2 10min FNM107 2 10min FNM108 21 5min FDM178 21 0min FDM184 21 0min FDM184 21 0min FDM184 2 15min FNM118 2 3min FDE028 2 3min 2 3min 2 3min 2 15min FDM185 2 15min FDM185 2 15min FDM185 2 15min FDM185 2 5min FNM119 2 5min FNM119 2 60min FDM173 3 10min FNM252 3 30min FDM410 3 20min FNM260 2 15min FDM185 2 15min FDM185 2 15min FDM185 2 15min FDM185 2 15min FDM185 2 15min FDM185 2 5min FNM250

Timeforsinglecomponent Timeforsinglecomponent Timeforsinglecomponent Timeforsinglecomponent Timeforsinglecomponent




Timeforsinglecomponent Timeforsinglecomponent Timeforsinglecomponent Timeforsinglecomponent


Part C



PARTA

MAINTENANCEPLAN

PARTB


PARTC


PARTD

TABLE OF CONTENTS CONTROL/CLEANING PROCEDURES LIST.......................................................................................................................... C-1

REMOVAL/REPLACEMENT PROCEDURES LIST ...................... ..................... ...................... ..................... ..................... C-2 ......

LUBRICATION/GREASING PROCEDURES LIST .................................................................................................................. C-3

. A . p . S l e d i S ©

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C-1

CONTROL/CLEANING PROCEDURES LIST Control/cleaning procedures


Part C

Number

Check the calibration of the temperature sensor Clean the Y filter Check the air supply pressure Check the pneumatic system connections Clean the washing solution filter Clean the delivery side filter Check the valve position controller Clean the air condensate discharge valve Clean the level sensor Clean and check the level sensor Product tank Cleaning the outside of the base Checking the bottle neck gripper Checking for leaks from membranes, actuators and seals Checking the presence and condition of safety signage Checking the presence of safety signage on doors Checking the filling valve seal Checking filling valves are secure Checking equipment timing - Conveyor unit Checking the bottle ejector pneumatic piston unit

FNM – 042 FNM – 055 FNM – 106 FNM – 107 FNM – 108 FNM – 111 FNM – 112 FNM – 118 FNM – 119 FNM – 145 FNM – 238 FNM – 239 FNM – 240 FNM – 241 FNM – 242 FNM – 244 FNM – 245 FNM – 247 FNM – 248

Check the noise levels and inspect the drive Cleaning and checking the pneumatic system for leaks Checking filling valve pneumatic connections Checking automatic greasing systems Cleaning the automatic greasing distributors Checking and cleaning the bottle cooling nozzles Checking the bottle infeed neck guide Belt wear – COMBI transmission unit Clean the GALVANI laminar flow powered ventilation unit filters

FNM – 249 FNM – 250 FNM – 251 FNM – 252 FNM – 260 FNM – 261 FNM – 475 FNM – 477 FNM – 478

Refer to the clearing procedures depicted in the “User Manual”.

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Part C

C-2


REMOVAL/REPLACEMENT PROCEDURES LIST Removal/replacement procedures

Number

Substituting the TRI-clamp seals Substituting the DIN seals Substitute the inspection window seals Substitute the delivery side filter Substitute the pressure reducer seals Substitute the centrifugal pump seal Substitute the filter cartridge Substitute the Y filter seals Substitute the heat exchanger Substitute the washing solution filter Substitute the CO2 sterile filter Substitute the flow switch seal Substitute the valve seals Substituting product infeed seal Overhauling the outfeed belt Substituting the filling valve FLOWMETER seals Tank breather valve overhaul Bottle body equipment overhaul Bottle ejector pneumatic piston overhaul

FDM – 088 FDM – 089 FDM – 092 FDM – 095 FDM – 098 FDM – 173 FDM – 174 FDM – 175 FDM – 176 FDM – 178 FDM – 183 FDM – 184 FDM – 185 FDM – 379 FDM – 382 FDM – 383 FDM – 385 FDM – 387 FDM – 392

Dummy bottle extractor overhaul Substituting the pilot valve Substitute the electric rotary manifold Substituting worn components on the automatic greasing pump Substitute the pressure switch seal Overhauling the tilting outfeed belt (chain drive) Substituting the COMBI transmission unit belts Overhaul of GALVANI laminar flow powered ventilation unit filters Overhauling the base gear motor

FDM – 393 FDM – 395 FDM – 397 FDM – 410 FDM – 448 FDM – 749 FDM – 751 FDM – 752 FDM – 753

. A . p . S l e d i S ©

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C-3

Part C

LUBRIFICATION/GREASING PROCEDURES’ LIST Lubrication/Greasing procedures’ list Changing the reduction gear oil

Number FGM – 034


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Part D



PARTA

MAINTENANCEPLAN

PARTB


PARTC


PARTD

TABLE OF CONTENTS CONTROL/CLEANING PROCEDURES LIST.......................................................................................................................... D-1

REMOVAL/REPLACEMENT PROCEDURES LIST ...................... ..................... ...................... ..................... ..................... D-2 ......

. A . p . S l e d i S ©

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D-1

CONTROL/CLEANING PROCEDURES’ LIST Control/Cleaning procedures’ list Checking the front door sensors Checking the emergency stop buttons Checking the filling valve and carousel connections Switching off the power supplies Checking the timing sensors Checking the photocells


Part D

Number FNE – FNE – FNE – FNE – FNE – FNE –

029 030 031 059 067 068

Refer to the clearing procedures described in the “User Manual”.

2/4

Parte D

D-2


REMOVAL/REPLACEMENT PROCEDURES LIST

Removal/Replacement procedures list Substitute a solenoid valve Substituting the filling valve FLOWMETER Substituting the front/rear door sensors

Number FDE – 028 FDE – 044 FDE – 045

. A . p . S l e d i S ©

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Part D

Page voluntarily left white

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2

Check the calibration of the temperature sensor

Follow health and safety guidelines (see “USER Manual”).

OPERATION SAFETY: Compulsory PPE:

Gloves

Safety footwear

Helmet

Overalls

Goggles

MACHINE CONDITIONS:

- Machine with the following power and product supplies switched OFF:

-



air



mains power



process liquids

Product filling system drained.

MATERIAL REQUIRED: Consumables: - Clean and dry rags. Equipment: - Thermometer

FNM - 042

1/2


2

Check the calibration of the temperature sensor

FNM - 042

DESCRIPTION OF OPERATIONS: Preliminary operations 1) Drain the system by selecting the DRAINING mode on the operator panel (see User manual). A 2) Disable the compressed air supply: Switch off the compressed air supply at the knob (A). 3) Remove the guards preventing access to the operating area. (Open the doors or detach the panels fixed with screws).

Before you start this operation, read the instructions in the component manufacturer's use and maintenance manual.

Checking calibration 4) Unscrew and remove the temperature sensor (B) from its seat.

5) To check that the temperature sensor is measuring correctly, proceed as follows:

-

Measure the temperature of the test fluid with a master thermometer. Note this temperature. Immerse the temperature probe in the test fluid and note its temperature reading.

-

Check that the two readings are the same. B If the readings are substitute the sensor.

not

the

same,

Final operations 8) When you have finished, refit the temperature sensor and screw it into its seat. 9) Close the guard doors and refit the guard panels 10) Return the filler to service.

2/2


2

Clean the Y filter



Gloves

Safety footwear

Helmet

Overalls

Goggles

MACHINE CONDITIONS:


-



air



mains power



process liquids


MATERIAL REQUIRED: Consumables:

-

Clean and dry rags.

FNM - 055

1/3


2

Clean the Y filter

FNM - 055

DESCRIPTION OF OPERATIONS: Preliminary operations 1) Drain the system by selecting the DRAINING mode on the operator panel (see User manual).

2) Disable the services: You must switch off the power and product supplies before you start work: Hazard. Components under pressure. Chemical products may be present.

A

Switch OFF the mains electrical power supply by moving the main switch lever to 0 “OFF” (A).

Padlock the main ON-OFF switch in the OFF (0) position. Keep the key on your person or keep it in place where access is restricted to authorised persons. This is safety precaution designed to prevent accidental start-up.

Switch OFF the(B). compressed air supply using the knob

3) Remove the guards preventing access to the operating area. (Open the doors or detach the panels fixed with screws).

B

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2

Clean the Y filter

FNM - 055

3/3

Cleaning the filter 4) Unscrew the clamping Allen screw (C).

D

5) Remove the filter (D) inside. 6) Wash the filter with running water and products certified as safe for use with food products.

Final operations 7) When you have washed the filter (D), refit it to its seat. During dismantling and fitting, ensure that the seal is not removed from its seat. 8) Tighten the Allen screw (C).

9) Close the guards removed previously. (Close the doors or refit the fixed panels). 10) Return the filler to service.

C


1

Check the air supply pressure



Gloves

Safety footwear

Helmet

Overalls

Goggles

MACHINE CONDITIONS: Check (1) - Machine rotating. Check (2) - machine stopped in STANDBY status with access doors open; services OFF: 

air



mains power



process liquids

MATERIAL REQUIRED: Consumables: - Clean and dry rags. Equipment: - Access ladder.

FNM - 106

1/3


1


FNM - 106

DESCRIPTION OF OPERATION:

(1) Checking pressures 1) Check the supply operating pressure of pneumatic system on the pressure gauges (A):

- Minimum pressure - Maximum pressure

= =

A

the A

6 bar 8 bar

If you obtain other pressure readings, substitute the filter cartridges.

2) Check the general pressure of the filler on the pressure gauge (B):

-

Pressure

=

6 bar

If you obtain other pressure readings, adjust the general pressure by turning the reducer regulator knob. B

3) Check the jack pressure (where fitted) from the operator panel.

-

Pressure = 1 bar higher than the filler pressure measured on the filler tank. Ensure that there are containers on the carousel when you are checking the values.

2/3


1


FNM - 106

(2) Checking the pressures of the filler carousel (where present) 4) Stop filling machine rotation from the control panel. 5) Enable opening of the mobile guard doors (see User Manual). 6) Open the rear doors to access the operation area.

On systems fitted with a safety lockout or a safety keylock. Before you start work, remove the key and keep it on your person for the entire period when you are inside the guards. This is a safety precaution to prevent someone from inadvertently closing a guard door and starting the machine. 7) Switch OFF the electrical power supply:

C

Move the main ON-OFF switch lever to 0 “OFF” (C).


8) Climb on to the carousel using the ladder supplied. 9) Check the filling valve (D) pressures inside the pneumatic panel: - Pressure = 5.5 bar

If you obtain other pressure readings, substitute the filter cartridges.

Final operations 10) When you have finished the checks, close the doors and return the keys to their storage position. 11) Return the filler to service.

D

3/3


2

Check the pneumatic system connections



Gloves

Safety footwear

Helmet

Overalls

Goggles

MACHINE CONDITIONS:

-

-

Machine with the following power and product supplies switched OFF: 

air



mains power



process liquids


MATERIAL REQUIRED: Consumables: - Clean and dry rags.

FNM - 107

1/2


2

Check the pneumatic system connections

FNM - 107

2/2


A

2) On the battery limit valves, shutdown the process liquid supply. To check the pneumatic system for leaks the electrical and compressed air supplies must be ON. 3) Remove the machine guards to enable access to the working area (open the mobile doors and release the fixed panels by removing the their screws).

Checking for leaks 4) Check the entire pneumatic system for leaks. Check at the following points: A. Pneumatic system piping and connections.

B

B. Pressure reducers. C. Pneumatic valve control stations. Check the pneumatic system as follows: -

Wet the pneumatic connections with soapy water. The formation of bubbles indicates the presence of leaks.

-

Listen for whistling sounds which may indicate air leaks.

If you find any faults, substitute the faulty parts.

Final operations 5) Close the guards removed previously. (Close the doors or refit the fixed panels).

C

6) Return the filler to service.

C


2

Clean the washing solution filter



Gloves

Safety footwear

Helmet

Overalls

MACHINE CONDITIONS:

-

Machine stopped with power and product supplies OFF:  air  mains power  process liquids

-



FNM - 108

1/3


2


DESCRIPTION OF OPERATIONS: Preliminary operations 1) Drain the system by selecting the DRAINING mode on the operator panel (see User manual). 2) On the battery limit valves, shutdown the process liquid supply. To check the pneumatic system for leaks the electrical and compressed air supplies must be ON. 3) Remove the guards preventing access to the operating area. (Open the doors or detach the panels fixed with screws).

Cleaning the filter 4) Close the manual infeed valve (A). 5) Open the drain valve (B) and drain off any remaining liquid into the container (C). Before you start to use chemical products, obtain the relevant “Safety Data Sheets” provided by the supplier. The SDS indicate the following:

-


A

B

Chemicals and dirty rags must be disposed of by specialist companies in accordance with current legislation in the country of use.

C

FNM - 108

2/3


2


FNM - 108

3/3

6) Release the locking collar (D) and remove the filter (E) from inside. 7) Wash the filter with running water and products certified as safe for use with chemical products.

E

D

Final operations 8) When you have washed the filter (E), refit it to its seat. During dismantling and fitting, ensure that the seals remain in place. 9) Tighten the locking collar (D). 10) Close the drain valve (B) and open the manual infeed valve (A).

11) Close the guards removed previously. (Close the doors or refit the fixed panels). 12) Return the machine to service.


2

Clean the delivery side filter



Gloves

Safety footwear

Helmet

Overalls

Goggles

MACHINE CONDITIONS:

-

Machine stopped with power and product supplies OFF:  air  mains power  process liquids

-


MATERIAL REQUIRED: Consumables: - Clean and dry rags. Components: - New seals.

FNM - 111

1 /3


2


FNM - 111


2) Switch off the services: You must switch off the power and product supplies before you start work: Hazard. Components under pressure. Chemical products may be present.

A


Padlock the main ON-OFF switch in the OFF (0) position. Keep the key on your person or keep it in place where access is restricted to authorised persons. This is safety precaution designed to prevent accidental start-up. Switch OFF the compressed air supply using the knob (B).


B

2 /3


2


FNM - 111

Cleaning the filter 4) Release the 2 locking collars (C) and dismantle the filter body. 5) Remove filter (D) from inside the body. 6) Wash the filter with running water and products certified as safe for use with chemical products.

D

C

C

Final operations 7) When you have washed the filter (D), refit it to its seat. Substitute and fit the seals ensuring that they are correctly seated. 8) Tighten the locking collars (C).


3 /3


1

Check the valve position controller

FNM - 112



Gloves

Safety footwear

Helmet

Overalls

Goggles

MACHINE CONDITIONS:

- Machine operating.

DESCRIPTION OF OPERATIONS: Checking procedure 1) Check the condition of the valve position indicator (A) of the electrical connections. If the indicator (A) does not operate, check the electrical connections and the configuration of the electrical connections (see the Use and Maintenance manual for this item). If the problem persists, substitute the component at the first opportunity when the machine is out of service.

A

1 /1


2

Clean the air condensate discharge valve



Gloves

Safety footwear

Helmet

Overalls

MACHINE CONDITIONS:

-


-



FNM - 118

1 /3


2


FNM - 118



A






B

2 /3


2


FNM - 118

Cleaning the discharge valve 4) Unscrew the air condensate discharge valve (C) and detach it from the filter unit. 5) Clean the discharge valve with the recommended products.

Substitute faulty discharge valves.

C

Final operations 6) When you have finished cleaning the air condensate discharge valve, refit this item by following the procedures described above in reverse order. 7) Close the guards (close the mobile doors and screw up the fixed panels). 8) Return the machine to service.

3 /3


2

Clean the level sensor



Gloves

Safety footwear

Helmet

Overalls

MACHINE CONDITIONS:


-



air



mains power



process liquids



FNM - 119

1/3


2


FNM - 119



A






B

2/3


2


FNM - 119

3/3

Cleaning 4) Unscrew and remove the level sensor (C).

C

5) Using a damp cloth, carefully clean the sensor. Check the condition of the level sensor: If the external sheath of the sensor is damaged, substitute the sensor.

Final operations 6) When you have finished cleaning, refit the level sensor following the procedure described above in reverse order.

D

Align the sensor with the piping: The marking (D) must be facing in the direction of flow. Substitute the seal. Fit the new seal in its seat. Example picture

7) Close the guards (close the mobile doors and screw up the fixed panels). 8) Return the filler to service.


2

Clean and check the level sensor Product tank



Gloves

Safety footwear

Helmet

Overalls

Goggles

Template

MACHINE CONDITIONS: Cleaning the sensor


-



air



mains power



process liquids


Checking the sensor

-

Machine stopped in stand-by condition with the following power and product supplies OFF: 

air



mains power



process liquids

FNM - 145

1/4


2


FNM - 145


- Cleaning cloth. Equipment:

- New seals. Ladder.


2) Disable the services: You must switch off the power and product supplies before you start work:

A

Hazard. Components under pressure. Chemical products may be present. Switch OFF the mains electrical power supply by moving the main switch lever to 0 “OFF” (A).



B

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2


FNM - 145

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Cleaning the level sensor Ensure that the product tank is empty and depressurised before performing the operations described below. E

E

F

C

4) Using the ladder, go to the level sensor. 5) Disconnect the level sensor connector (C). 6) Detach the sensor from its mounting (flange, Triclamp, DIN). Example: Clamp (D). 7) Remove the complete sensor from the tank. 8) Unscrew and remove the screws (E). 9) Remove the upper body (F) of the probe from its lower body (G). 10) Substitute the seals (H) and (I).

H

G

11) Using a damp cloth, carefully clean the sensor. Check the condition of the level sensor: If the external sheath of the sensor is damaged, substitute the sensor.

12) When you have finished cleaning, refit the level sensor following the operations described above in reverse order.

When tightening the clamp (D), use adjustable pliers (p) to keep the two ends close together. By hand, tighten the trigger (J) as indicated on the card “Torque wrench settings” (Part A1-4). Do NOT force the hold of the pliers on the collar to prevent damage to the new seal.

J

p

D

D

I


2


Checking the level sensor 13) Switch on the electrical power supply to the machine. 14) Check the efficiency of the sensor as follows: Check that the level value (expressed as a percentage) measured by the sensor and displayed on the operator panel matches the actual level of the liquid in the tank as indicated on the inspection window.

If this is not the case, substitute the sensor.

Final operations 15) Close the guards (close the mobile doors and screw up the fixed panels). 16) Return the filler to service.

FNM - 145

4/4


1

Cleaning the outside of the base


OPERATION SAFETY: Compulsory PPE: Gloves Safety footwear

Goggles

Helmet Overalls

MACHINE CONDITIONS: Machine stopped: 

System drained



Guard doors open



Electrical power supply OFF



Compressed air supply OFF

(see “Switching off power supplies” operation sheet)

PERSONS INVOLVED

-

One maintenance technician (mechanical)


FNM - 238

1 /2


1

Cleaning the outside of the base

DESCRIPTION OF OPERATIONS: 1) Remove any crushed or fallen bottles from along the bottle path.

Before you start cleaning, check there are no people inside the maintenance area of the machine. 2) Clean the base using compressed air. Set the compressed air pressure to the maximum (6 to 8 bar).

3) Rinse the base to remove any product residues.

Final operations

4) Close the guard doors. 5) Return the filler to service.

FNM - 238

2 /2


3

Checking the bottle neck gripper



Goggles

Helmet Overalls

MACHINE CONDITIONS: Machine stopped with the JOG MODE enabled: 

System drained



Guard doors open








PERSONS INVOLVED

-



FNM - 239

1 /2


3

Checking the bottle neck gripper

FNM - 239

DESCRIPTION OF OPERATIONS:

Checking the grippers 1) Check that there are no bent grippers (A). 2) Check the state of the rollers (B) and springs (C). 3) Check that the distance between the upper and lower gripper is:

B

C

In the event of inconsistency or components worn / damaged, to restore the optimal conditions (adjustments or replacements). To check the less accessible grippers, rotate the transfer starwheels. For this operation, use the MAINTENANCE CONTROL PANEL in the JOG mode. Before you move the carousel, make sure there are no physical obstructions preventing rotation.

Final operations 1) When you have finished the check, close the guard doors. 2) Return the filler to service.

A

2 /2


2

Checking for leaks from membranes, actuators and seals



Goggles

Helmet Overalls


System drained



Guard doors open








PERSONS INVOLVED

-



FNM - 240

1 /2


2

Checking for leaks from membranes, actuators and seals


Checking for leaks 1) Check for leaks of air or process gas from the filling valve by running your hand under, above and around the valve. Perform this operation for the valves accessible from the area of intervention.

2) Move your hands away from the filling valves and rotate the machine using the JOG control until there is a new set of valves in front of you ready for checking. Before rotating the carousel make sure there are no physical obstructions preventing rotation. Use the MAINTENANCE CONTROL PANEL in the JOG mode. 3) Repeat the procedure until the check has been performed for the entire carousel. If you find any leaks, note the number of the valve and the fault so the problem can be rectified during the next maintenance stop.

Final operations 4) When you have finished the checks, close the mobile guard doors. 5) Return the filler to service.

FNM - 240

2 /2


1

Checking the presence and condition of safety signage

Follow health and safety guidelines (see “USER Manual”). OPERATION SAFETY: Compulsory PPE: Gloves Safety footwear

Helmet

MACHINE CONDITIONS:

- machine rotating. DESCRIPTION OF OPERATION: Check that the safety signage is present at the points indicated. Refit missing signage. Substitute any signage which has become illegible. The following mandatory and warning signs must be present: Wear safety gloves

Wear safety footwear

Wear safety eyewear Hazard warning: Live electrical components Hazard warning: Corrosive substances Hazard warning: Do not walk on roof. Hazard warning: Hot surfaces

Warning: No unauthorised access.

Warning: Do not remove safety devices Warning: Do not clean, lubricate or repair moving components.

FNM - 241

1 /3


1


FNM - 241

2 /3


1


FNM - 241

3 /3


1

Checking the presence of safety signage on doors



Helmet

MACHINE CONDITIONS:

- machine rotating.

PERSONS INVOLVED

-

One maintenance technician (general)

LEGEND: Rear doors Front doors

FNM - 242

1 /2


1

Checking the presence of safety signage on doors

FNM - 242

2 /2


Checking the door signs 1) Check the the safety signage (A) is present on all machine access doors. Wear safety eyewear

Wear safety footwear

Wear safety gloves

Change any safety signs (A) which are damaged or have become illegible. Replace missing signs.

A


2

Checking the filling valve seal



Goggles

Helmet Overalls

MACHINE CONDITIONS: Machine rotating and in CIP mode 

System drained



Guard doors open








PERSONS INVOLVED

-



FNM - 244

1 /2


2

Checking the filling valve seal

FNM - 244

2 /2

DESCRIPTION OF OPERATIONS: Valve seal check

1) Check for any leaks during hot washing. Check that the tank is at the correct pressure and that the filling valves are open in the recirculating mode on the dummy bottle. Perform the check FROM OUTSIDE THE FRONT SAFETY DOORS.

2) Under these operating conditions, watch the rotation of the filling carousel and check for leaks of liquid from the valve in the areas (A).

If you find any leaks, note the valves involved. When CIP has been completed, drain the machine and switch it to the STANDBY state. Perform the maintenance necessary to return the components to full operating efficiency.

A

A

A

A


2

Checking filling valves are secure



Goggles

Helmet Overalls


System drained



Guard doors open








PERSONS INVOLVED

-



FNM - 245

1 /2


2

Checking filling valves are secure

FNM - 245

2 /2


Checking for leaks 1) Check the valve securing screws (A) are tightened correctly. Tighten any loose screws.

Perform this operation for the valves accessible from the area of intervention.

2) Move your hands away from the filling valves and rotate the machine using the JOG control until there is a new set of valves in front of you ready for checking. Before rotating the carousel make sure there are no physical obstructions preventing rotation. Use PANELthe in theMAINTENANCE JOG mode.

CONTROL

A

3) Repeat the procedure until the check has been performed for the entire carousel. A

If you find any leaks, note the number of the valve and the fault so the problem can be rectified during the next maintenance stop.

A

Final operations 4) When you have finished the checks, close the mobile guard doors. 5) Return the filler to service. A


2

Checking equipment timing - Conveyor unit



Gloves Safety footwear Helmet Overalls

MACHINE CONDITIONS: - Machine stopped with the JOG MODE enabled:  System drained 

Guard doors open






Compressed air supply OFF (see “Switching off power supplies” operation sheet)

PERSONS INVOLVED: 1 maintenance technician

MATERIAL REQUIRED: Consumables: - clean and dry rags. Equipment: - test bottle.

FNM - 247 1/13


2


FNM - 247 2/13


The machine is timed correctly when: the bottles are conveyed perpendicularly to the transfer surface; the bottles are free to rotate on their own axis in the starwheel to starwheel and starwheel to carousel transfer points; Checking the timing C

1) Stop filling machine rotation from the control panel. 2) In the manual mode from the operator panel, open the bottle block so that the first bottle is loaded on to the machine infeed starwheel and then close the bottle block.

B

D A

E F

3) Enable opening of the guard doors and then open the guard doors to access the maintenance area (see “Switching off power supplies” operation sheet”). 4) Enable carousel rotation using the JOG control and check the timing in the transfer areas by watching the movement of the bottle loaded on the machine.

C

Before you move the carousel make sure there are no physical obstructions preventing rotation. Use the MAINTENANCE CONTROL PANEL in JOG mode.

A

A

D E F

Setting the timing

If timing is not as described above, proceed to set machine timing in the areas indicated with the starting point being the area of transfer between the capper infeed starwheel (D) and the capper starwheel (E) then working backwards towards the machine infeed. E F

Areas for checking/maintenance

D

A

C

A. Machine infeed starwheel B. Rinser infeed starwheel C. Filler infeed starwheel

E

D. Filler outfeed starwheel. E. Capper starwheel F. Capper outfeed starwheel

C

D F

B

C A A

A

D F

E


2


1. Capper infeed starwheel timing 7) Working from the control panel, release the motor brake (see the User Manual).

8)

Working by hand, rotate the capper infeed starwheel unti the grippers on the starwheel are concentric with the capper compartments and the fixed grippers on the filling valve.

9)

Working from the control panel, obtain the starwheel offset position (see the User Manual) and lock the brake.

FNM - 247 3/13


2


2. Filler carousel timing 10) In the JOG mode rotate the carousel until the fixed grippers of the filling valves are concentric with the filler infeed starwheel grippers.

11) Working from the control panel, obtain the offset position (see the User Manual) and lock the brake.

3. Filler infeed starwheel timing 12) Working from the control panel, release the motor brake (see the User Manual).

13) Working by hand, rotate the filler infeed starwheel until the grippers on the starwheel are concentric with the filling valve fixed grippers.

14) Working from the control panel, obtain the starwheel offset position (see the User Manual) and lock the brake.

A

FNM - 247 4/13


2


4. Rinser timing (only for BLOCKRINSER bases)

15) In the JOG mode, rotate the carousel until the fixed grippers of the rinser carousel are concentric with the grippers of the rinser infeed starwheel.

16) position Working(see fromthe the control panel, thebrake. offset User Manual) andobtain lock the

5. Rinser infeed starwheel BLOCKRINSER bases)

timing

(only

17) Working from the control panel, release the motor brake (see the User Manual).

18) Working by hand, rotate the rinser infeed starwheel until the grippers on the starwheel are concentric with the fixed grippers of the rinser.


for

FNM - 247 5/13


2


6. Transfer starwheel timing (only COMBI bases)


21) Working by hand, rotate the transfer starwheels until the grippers on the starwheels are concentric with the grippers on the filler infeed starwheel.


FNM - 247 6/13


2


7. Machine infeed starwheel timing BLOCKRINSER and STANDALONE)

(only

for


Filler / Rinser infeed starwheel

Transfer infeed starwheel

24) Working by hand, rotate the m achine infeed starwheel until the compartments and grippers are concentric with the bottle.


FNM - 247 7/13


2


8. Capper outfeed starwheel timing

The capper unit can be fitted with four different types of starwheel: BODY PICKUP MULTIBODY STANDARD NECK PICKUP GRIPPER NECK PICKUP BODY PICKUP 26) Loosen the 6 securing screws of the capper outfeed starwheel. 27) Rotate the capper outfeed starwheel until the compartment is concentric with the bottle and the capper compartment on the straight line between the starwheel centre and the capper centre.

1 6

2 5

3 4

28) When the capper outfeed starwheel timing is correct, block the position by tightening the 6 securing screws.

FNM - 247 8/13


2


MULTIBODY 29) Loosen the 6 securing screws of the capper outfeed starwheel. 30) Rotate the capper outfeed starwheel until the compartment is concentric with the bottle and the capper compartment on the straight line between the starwheel centre and the capper centre.

Adjust the play between the starwheel compartment and the bottle to 1 mm.

1 6

2 3 4 5

31) Turn the knob (K) to set the mobile guide (L) of the bottle descender guide.

K

L


FNM - 247 /13


2


FNM - 247 1!/1

33) Turn the knob (M) to set the height of the bottle descender chute (N).

Adjust the distance between the chute and the bottle bottom to approx. 5-6 mm.

M

N

STANDARD NECK PICKUP 34) Loosen the 6 securing screws of the capper outfeed starwheel. 35) Rotate the capper outfeed starwheel until the compartment is concentric with the bottle and the capper compartment on the straight line between the starwheel centre and the capper centre.

1

2 3

6 5

4


2


FNM - 247 11/1


GRIPPER NECK PICKUP 37) Loosen the 6 securing screws of the capper outfeed starwheel. 38) Rotate the capper outfeed starwheel until the compartment is concentric with the bottle and the capper compartment on the straight line between the starwheel centre and the capper centre.

1

2 3

6 5


4


2


Checking the bottle rotation and the passage play 40) Using a plug gauge with the same diameter as the bottle neck, check the play between the compartment and the guide (O).

P

O

41) Unscrew the stop screws on the guides (P) and precision adjust the distance between the cavity and the guide.

Checking the bottle rotation height. 42) Go to the carousel infeed/outfeed starwheels.

The next check must be performed with air in the filling valves.

43) The filler outfeed starwheel must be 0.5 – 1 mm lower than the filling valve bracket. 44) The filler infeed starwheel must be 0.5 - 1 mm higher than the filling valve bracket.

FNM - 247 12/1


2


The next check must be performed without air in the filling valves.

45) Check that the radial play between the filling valve bracket and the guide is approx. 1 mm.

46) Check that the play between the roller and the cam is 1-2mm.

To facilitate the infeed and outfeed of the bottles to and from the filler carousel, adjust as follows: - At the infeed: align the lowest point of the starwheel with the filling valve bracket; this means that the bottles will always travel downwards to the other points. - At the outfeed: align the highest point of the starwheel with the filling valve bracket; this means that the bottle will always drop downwards towards the other points.

Final operations 47) When you have finished timing, close the guard doors. 48) Return the filler to service.

FNM - 247 13/1


1

Checking the bottle ejector pneumatic piston unit



Goggles

Helmet Overalls


System drained



Guard doors open








PERSONS INVOLVED

-



FNM - 248

1 /2


1

Checking the bottle ejector pneumatic piston unit


Check 1) Check the following ejector unit components:

-

Check the sliding surface of the roller on the cam (A).

-

By hand, check that the pneumatic piston ( B)

-

can slide freely. Check that the play between the sliding bushes (C) and pins is no greater than 0.4 mm.

Substitute components.

worn

or

damaged

A

B

C

Final operations 2) doors. When you have finished, close the mobile guard 3) Return the filler to service.

FNM - 248

2 /2


3

Check the noise levels and inspect the drive



Goggles

Helmet Overalls

MACHINE CONDITIONS: Checking noise levels: - Machine stopped: 

System drained



Guard doors open








Visual inspection of critical points: - Machine stopped with the JOG MODE enabled: 

System drained



Guard doors open








PERSONS INVOLVED

-


FNM - 249

1 /2


3

Check the noise levels and inspect the drive

2 /2

FNM - 249

DESCRIPTION OF OPERATIONS: The procedure consists of 2 steps: - Checking operating noise level. - Visual inspection of critical points on the drive.

B

Checking operating noise level 1) Start filler rotation at production speed. 2) Go to zone A and stop the filler with an emergency stop at the same time checking for any unusual noise.

A

C

3) Repeat this operation at zones B and C checking for unusual noises during the emergency stop. Perform this check two or three times to check for any faults and then proceed to the next step.

B

Visual inspection of critical points on the drive

A

4) Operate the machine using the JOG control. Listen for excessive noise at the points indicated. Excessive noise may indicate the presence of the following faults:

C

- loose bolts; - excessive play or wear. C Before you move the carousel make sure there are no physical obstructions preventing rotation. Use the MAINTENANCE CONTROL PANEL in the JOG mode. A

5) Restore the correct operating conditions in the event of any anomalies: - tighten any loose bolts;

- substitute worn components.

B

B

B

C

Final operations 6) When you have finished the checks, close the guard doors. 7) Return the filler to service.

A

C


3

Cleaning and checking the pneumatic system for leaks



Helmet

Overalls


System drained



Guard doors open








PERSONS INVOLVED

-


MATERIAL REQUIRED: Consumables: - Clean and dry rags. Equipment: - Ladder

Pneumatic system

FNM - 250

1 /2


3

Cleaning and checking the pneumatic system for leaks

FNM - 250

2 /2

DESCRIPTION OF OPERATIONS: Checking the pneumatic system for leaks 1) Check the entire pneumatic system for leaks or deposits of condensate or oil in the following areas: A. Carousel shaft B. Filler outfeed starwheel bottle ejector C. Capper

D

D. Bottle block

A B C

If you identify any functioning faults, restore the correct functioning conditions by substituting any nonconforming parts in accordance with the relevant maintenance cards or by draining/cleaning the parts with any fluid inside.

A

Before you start to use oils, greases and lubricants, obtain the relevant “Safety Data Sheets” provided by the supplier. The SDS indicate the following:

-

B C

Hazards. Protection devices. First aid requirements. Fire prevention measures. Action in the event of accidental spillage and leaks. Physical and chemical properties. Stability and reactivity. Toxicological information. Ecological information. Disposal information. Shipping information.

A C

B D

Oil, lubricants and dirty rags must be disposed of by specialist companies in accordance with current legislation in the country of use.

A

B

A

B

Final operations 2) When you have finished all checks cleaning, close the mobile guard doors. 3) Return the filler to service.

and C

D

C


2

Checking filling valve pneumatic connections



Helmet

Overalls


System drained



Guard doors open








PERSONS INVOLVED

-


MATERIAL REQUIRED: Consumables: - Clean and dry rags. Equipment: - Ladder

FNM - 251

1 /2


2

Checking filling valve pneumatic connections

FNM - 251


Checking the connections 1) Climb on to the carousel using the ladder supplied. Identify the pneumatic connections to be checked.

A

2) Check for leaks of valve control air from the connectors (A) and from the connection hoses (B).

In the event of any leaks, note the damaged components and substitute any non-conforming parts in accordance with that stated on the relevant maintenance cards.

Final operations 3) When you have finished the check, close the guard doors. 4) Return the filler to service.

B

2 /2


3

Checking automatic greasing systems



Helmet

Overalls

MACHINE CONDITIONS: Step A: - Machine stopped in STANDBY state: 

System drained



Guard doors open








Step B: - Machine stopped: 

System drained



Guard doors open








PERSONS INVOLVED

-


LEGEND: Filler greasing area (filler rack – capper – rinser) Position of the main greasing pump (1)

FNM - 252

1 /2


3

Checking automatic greasing systems

2 /2

FNM - 252

DESCRIPTION OF OPERATIONS: The procedure for the general greasing system consists of the following steps: A. Check the automatic operation of the greasing system B. Visual inspection for leaks of grease at critical points

Step A: Check that there is grease inside the general greasing pump (A).

B

B

A

B

1) Press the automatic greasing button on the operator panel.

B

2) Wait for the end of the automatic greasing cycle. 3) Check for any alarms at the end of the greasing cycle and, if necessary, restore correct functioning conditions to clear the alarms. 4) greasing Repeat system. the procedure

for

each

automatic

Step B:

A

B

A

B

5) Go inside the machine to the filler / rinser (where present) / capper rack. 6) Check for the presence of new, wet grease in the areas (B) indicated.

Final operations

B

A

B

B

7) When you have finished the checks, close the mobile guard doors. 8) Return the filler to service. B A

B

Greasing circuit


3

Cleaning the automatic greasing distributors



Helmet

Overalls


System drained



Guard doors open








PERSONS INVOLVED

-


MATERIAL REQUIRED: -Consumables: Clean and dry rags.


FNM - 260

1 /2


3

Cleaning the automatic greasing distributors

DESCRIPTION OF OPERATIONS: Substituting the pump components Clean the distributors as instructed in the relevant operation and maintenance manual.


-



Final operations 1) When you have finished the maintenance work, close the guard doors. 2) Return the filler to service.

Greasing circuit

FNM - 260

2 /2

Maintenance Procedure Manual

2

Checking and cleaning the bottle cooling nozzles


OPERATION SAFETY: Compulsory PPE: Gloves

Safety footwear

Goggles

Helmet Overalls

MACHINE CONDITIONS:

Check - Machine rotating. Cleaning - Machine stopped: 

System drained



Guard doors open








PERSONS INVOLVED

-



FNM - 261

1 /2


2

Checking and cleaning the bottle cooling nozzles


Checking the nozzles 1) Activate the "bottle bottom cooling system" in MANUAL mode from the operator panel. 2) Visually check the spray from all the nozzles (A). If a nozzle is blocked, make a note of its position and clean it at the first opportunity when the machine is STOPPED AND POWERED DOWN (see section below.

A

Cleaning the nozzles 3) Go to the bottle cooling unit and unscrew the blocked nozzle (A). 4) Clean the nozzle using compressed air. Set the compressed air pressure to the maximum (6 to 8 bar). 5) Clean the nozzle (A) then screw it back in to the bottle cooling manifold. Substitute damaged nozzles.

Final operations 6) When you have finished, close the mobile guard doors. 7) Return the filler to service.

FNM - 261

2 /2


2

Checking the bottle infeed neck guide



Goggles

Helmet Overalls


System drained



Guard doors open








PERSONS INVOLVED

-



FNM - 475

1 /2


2

Checking the bottle infeed neck guide

FNM - 475

Check the outfeed guide 1) Visually inspect the machine outfeed neck guide (A). Check for wear. Substitute any guides which are cut, damaged or bent. (see the “Bottle body equipment overhaul” maintenance sheet).


A

2 /2


3

Belt wear – COMBI transmission unit



Goggles

Helmet Overalls


System drained



Guard doors open








PERSONS INVOLVED

-


MATERIAL REQUIRED: Equipment: - Binder frequency meter

FNM - 477

1 /3


3


FNM - 477

Checking the belts Checking of the belts is divided into two steps: a. Visual inspection to check for belt wear b. Belt tensioning check

a.

Visual inspection to check for belt wear

1) Check the side (A) and the teeth (B) of the belt for cuts, fraying or any other signs of a possible belt breakage.

Substitute the belt if damaged. B

A

b. Belt tensioning check 2) Position the Binder frequency meter (C) at a distance of 5 mm under the belt. 3) Vibrate the belt and press the red button until a value is displayed on the meter display.

The correct tension value is: approximately 30 Hz

C

2 /3


3


3 /3

FNM - 477

4) If the belt is not tensioned correctly, adjust the nuts on the tensioner (D) until the correct tension is obtained.

Make sure the tension is not too high. Excessive tension will cause rapid belt wear.

D

Final operations 5) Close the guard doors. 6) Return the filler to service.


Clean the GALVANI laminar flow powered ventilation unit filters

2



Goggles

Helmet Overalls


System drained



Guard doors open








PERSONS INVOLVED

-


MATERIAL REQUIRED: Consumables: - Clean and dry rags. Equipment: - Ladder conforming prevention regulations.

to

current

accident

FNM - 478

1 /6


2


DESCRIPTION OF OPERATIONS: Cleaning the standard filter The filter consists of two parts: - Pre-filter (on fan inlet) - Fine filter (on fan outlet) Cleaning the pre-filter 1) Using a ladder which complies with accident prevention regulations, go to the powered ventilation unit. DO NOT climb onto the roof to substitute the pre-filter. The roof is not designed to support the weight of persons. 2) Raise the pre-filter (A) and remove it from its seat.

A

3) Clean with compressed air taking care not to damage the component. Set the compressed air pressure to the maximum (6 to 8 bar).

4) Refit the pre-filter to its seat. Take care not to crush the filter during positioning. Slowly and carefully guide the filter into position until it reaches its final position.

FNM - 478

2 /6


2


FNM - 478

Cleaning the fine filter 5) Disconnect the electrical connections (B) of the powered ventilation unit.

B B

6) Unscrew the countersunk screws (C) on both sides of the powered ventilation unit. 7) Using theventilation handles unit (D) until provided, lift the powered it reaches thetilting end of its travel.

D

C

3 /6


2


8) Raise the filter (E) and remove it from its seat.

E

9) Clean with compressed air taking care not to damage the component. Set the compressed air pressure to the maximum (6 to 8 bar).

10) Refit the filter making sure that it is positioned in the direction of the arrow (fr). Take care not to crush the filter during positioning. Slowly and carefully guide the filter into position until it reaches its final position.

11) Grip the handles (D) and slowly guide the tilting element into its closed position. Take care not to crush the filter. Slowly guide the tilting element into position.

12) Tighten the screws (C) to secure the tilting element in its seat. 13) Reconnect the electrical connections (B).

fr

FNM - 478

4 /6


2


FNM - 478

Cleaning the vertical filter (RFA only) 14) Go to the powered ventilation unit. 15) Remove the guard cover (F) by lifting it and pulling it outwards in the direction of the arrow as shown in the figure. 16) Raise the pre-filter (G) and remove it from its seat.

F G

17) Remove the metal fram e by unscrewing the retaining screws (H) on the sides of the framework. 18) Loosen the four screws (I) securing the fan (J).

H I

J

5 /6


2


19) Remove the fan unit (K) and the fine filter (L) outwards.

K

L

20) Clean the pre-filter (G) and the filter (L) with compressed air. Take care not to damage the elements. Set the compressed air pressure to the maximum (6 to 8 bar).

21) Refit the filters following the instructions given above in reverse order. Take care not to crush the filter elements during positioning. Slowly and carefully guide the filter into position until it reaches its final position. 22) Refit the guard cover (F) slowly guiding it back into its closed position. Crushing hazard. Slowly guide the guard cover (F) back into position.

Final operations 23) When you have completed the operations described above, return the filler to service.

FNM - 478

6 /6


2

Substituting the TRI-clamp seals



Gloves Safety footwear

Helmet

Overalls Goggles

MACHINE CONDITIONS:


-



air



mains power



process liquids



FDM - 088

1/3


2


FDM - 088

DESCRIPTION OF OPERATIONS: Preliminary operations 1) Drain the system by selecting the DRAINING mode on the operator panel ( see User manual). 2) Disable the services: You must switch off the power and product supplies before you start work: Hazard. Components under pressure. Chemical products may be present.

A




B

2/3


2


FDM - 088

Operations to substitute the seals

C

Substitute ALL THE TRI-clamp seals on the machine.

4) Unscrew the trigger (C) and release it from its seat by tilting it as shown in the figure. 5) Open the collar and remove the TRI-clamp. 6) Remove and substitute the seal (D).

On units fitted with a DIAPHRAGM in addition to the seals, you must also substitute the diaphragm. Proceed as follows: Remove the diaphragm and measure the diameter of the hole. New diaphragms are supplied blanked off.Take a new diaphragm and make a hole with the same diameter. Fit the new diaphragm.

D

Final operations 7) When you have finished refit the TRI-clamp by securing the collar using adjustable pliers (p) to keep the 2 ends (E) close together . Do NOT force the hold of the pliers on the collar to prevent damage to the new seal. C

8) By hand, tighten the trigger (C) as indicated on the card “Torque wrench settings” (Part A-1-4).

p 9) Close the guards (close the mobile doors and screw up the fixed panels). 10) Return the filler to service.

E

3/3


2

Substituting the DIN seals




Helmet

Overalls Goggles

MACHINE CONDITIONS:


-



air



mains power



process liquids


MATERIAL REQUIRED: Consumables: - Clean and dry rags. Components: - New seals. Equipment: - Universal ring nut spanner.

FDM - 089

1/3


2


FDM - 089

DESCRIPTION OF OPERATIONS: Preliminary operations 1) Drain the system by selecting the DRAINING mode on the operator panel (see User manual). 2) Disable the services: You must switch off the power and product supplies before you start work: Hazard. Components under pressure. Chemical products may be present.

A




B

2/3


2


FDM - 089

3/3


Substitute ALL THE DIN seals on the machine.

1) Remove the ring nut (C) by unscrewing it using the special wrench (p).

p

2) Remove and substitute the seal (D). C Make sure you insert the seal in the correct direction (asymmetrical seal).

Final operations 3) When you have finished tighten the ring nut (C) using the wrench (p). 4) Close the guards (close the mobile doors and screw up the fixed panels). 5) Return the filler to service.

D


2

Substitute the inspection window seals




Helmet

Overalls Goggles

MACHINE CONDITIONS:

- Machine with the following power and product supplies switched OFF: 

air



mains power



process liquids

- Product filling system drained.


FDM - 092

1/3


2


FDM - 092


A




B

2/3


2


FDM - 092

3/3

Operations to substitute the seals 4) Detach the inspection window (C) and remove the seals as follows: a. For inspection windows with a flange fitting, unscrew the screws (D). b. For inspection windows with a clamp fixing, detach the pin (E) and open the collar (F). E

b

a

D F

C

D

C

5) Remove the inspection window (C) and substitute the seal.

Substitute the seals on both inspection windows following this procedure.

Substitute the seal ensuring that it is correctly positioned in its seat.

Final operations 6) When you have finished, fit the new seals and refit the inspection windows (E) following the instructions given above in reverse order. When you refit the inspection windows, check that there are no obstructions in the piping which might interfere with the efficiency of the machine. 7) Close the guards (close the mobile doors and screw up the fixed panels). 8) Return the filler to service.


2

Substitute the delivery side filter



Gloves

Safety footwear

Helmet

Overalls

Goggles

MACHINE CONDITIONS:

-


-



FDM - 095

1/3


2


FDM - 095



A




B

2/3


2


FDM - 095

Substituting the filter 4) Release the 2 locking collars (C) and dismantle the filter body. 5) Remove filter (D) from inside the body.

D

C

C

Final operations 6) Fit a new filter (D) in the filter seat. Substitute the seals taking care to ensure that they fit correctly in their seats. 7) Tighten the locking collars (C).


3/3


2

Substitute the pressure reducer seals



Gloves

Safety footwear

Helmet

Overalls

Goggles

MACHINE CONDITIONS:


-



air



mains power



process liquids



FDM - 098

1/3


2


FDM - 098



A




B

2/3


2



Before you start this operation, read the instructions in the component manufacturer's use and maintenance manual. 4) Detach the pressure reducer (C) from the infeed and outfeed piping by removing the fittings. Substituting the seals

C

C 5) Take the pressure reducer to the workbench and proceed to substitute the seals (see the instructions in the related use and maintenance manual).

Final operations 6) When you have finished, refit the reducer following the dismantling procedure in reverse order.

During reassembly, check that there are no extraneous objects inside the unit which might reduce the efficiency of reducer operation. 7) Close the guards (close the mobile doors and screw up the fixed panels). 8) Return the filler to service.

FDM - 098

3/3


2

Substitute the centrifugal pump seal




Helmet

Overalls Goggles

MACHINE CONDITIONS:


air



mains power



process liquids



FDM - 173

1/3


2


FDM - 173

2/3


A



B


Substituting the pump seal 4) Detach the centrifugal pump from the inlet (C) and outlet (D) connections. D

C Remove and substitute the seals.


2


Before you start to use chemical products, obtain the relevant “Safety Data Sheets” provided by the supplier. The SDS indicate the following:

- hazards; - protection devices; - first aid requirements; - fire prevention measures; - action in the event of accidental leaks; - physical and chemical properties; - stability and reactivity; - toxicological information; - ecological information; - disposal information; - shipping information.

Chemicals and dirty rags must be disposed of by specialist companies in accordance with current legislation in the country of use. Perform this maintenance operation following the instructions given in the component manufacturer's use and maintenance manual.

Final operations 5) When you have finished, refit the pump to the inlet and outlet pipes. 6) Close the guards (close the mobile doors and screw up the fixed panels). 7) Return the filler to service.

FDM - 173

3/3


2

Substitute the filter cartridge




Helmet

Overalls Goggles

MACHINE CONDITIONS:

- Machine with the following power and product supplies switched OFF:  air  mains power  process liquids


MATERIAL REQUIRED: Consumables: - Clean and dry rags. Components: - New seals. - New filter cartridge.

FDM - 174

1/3


2


FDM - 174

DESCRIPTION OF OPERATIONS: Preliminary operations 1) Drain the system by selecting the DRAINING mode on the operator panel (see User Manual). 2) Switch off the services: You must switch off the power and product supplies before you start work: Hazard. Components under pressure. Chemical products may be present.

A

Switch off the mains electrical power supply by moving the main switch lever to 0 “OFF” (A).

When you have switched off the electrical power supply, padlock the main ON-OFF switch in the OFF (0) position. Keep the key on your person or keep it in a place where access is restricted to authorised persons. This is a safety precaution designed to prevent accidental start-up. Switch OFF the compressed air supply using the knob (B).


B

2/3


2


FDM - 174

3/3

Substituting the filter cartridges 4) Operate the drain valve (C) on each filter to discharge any residues remaining in the housing. 5) Unscrew the clamp (D). 6) Remove the housing (E). 7) Remove and substitute the filter cartridge (F). D Substitute the seal (G) ensuring that it is correctly positioned in its seat. G

F

If the sterile water filter cartridge is changed (bottle and cap handling), run the CIP sanitisation procedure on the processing piping downstream of the second filter and the housing of the filter itself before the filter is refitted. The quality of the treatment water must

E

comply with specification CDC004.18 and specifically the Silt Density Index must be < 1.

C Final operations 8) When you have finished, refit the filter following the operations described above in reverse order. 9) Fix the clamp collar (H) using adjustable pliers (p) to keep the two ends together. I Do NOT force the hold of the pliers on the collar to prevent damage to the new seal. 10) By hand, tighten the trigger (I) as per the instructions given on the card “Tightening torque values” (Part A1-4). p 11) Close the guards (close the mobile doors and screw up the fixed panels). 12) Return the machine to service.

H


2

Substitute the Y filter seals



Gloves

Safety footwear

Helmet

Overalls

Goggles

MACHINE CONDITIONS:


-



air



mains power



process liquids



-

Clean and dry rags.

FDM - 175

1/3


2


FDM - 175



A






B

2/3


2


FDM - 175

3/3

Operations to substitute the seals 4) Unscrew the clamping Allen screw (C).

D

5) Remove and substitute the seals (D) inside.

Final operations 6) Fit the new seal (D) in its seat. During fitting of the new seal, check that there are NO obstructions inside the filter which might interfere with efficient operation. 7) Tighten the Allen screw (C).

8) Close the guards removed previously. (Close the doors or refit the fixed panels). 9) Return the filler to service.

C


2

Substitute the heat exchanger




Helmet

Overalls

Goggles

MACHINE CONDITIONS:

-


-



FDM - 176

1 /3


2


FDM - 176

DESCRIPTION OF OPERATIONS: Preliminary operations 1) Drain the system by selecting the DRAINING mode on the operator panel (see User manual). 2) Switch off the services:

A

You must switch off the power and product supplies before you start work: Hazard. Components under pressure. Chemical products may be present. Switch OFF the mains electrical power supply by moving the main switch lever to 0 “OFF” (A).

Padlock the main ON-OFF switch in the OFF (0) position. Keep the key on your person or keep it in place where access is restricted to authorised persons. This is safety precaution designed to prevent accidental start-up. Switch OFF the compressed air supply using the knob (B). 3) Remove the guards preventing access to the operating area. (Open the doors or detach the panels fixed with screws).


B

2 /3


2


FDM - 176

Substituting the heat exchanger D 4) Detach the plate heat exchanger (C) by unscrewing the 4 couplings (D). 5) Remove and substitute the heat exchanger (C).

C

D

Final operations 6) When you finished, refit the inheat exchanger following thehave dismantling procedure reverse order. During reassembly, check that there are no extraneous objects inside the unit which might reduce the heat exchanger efficiency. 7) Close the guards (close the mobile doors and screw up the fixed panels). 8) Return the machine to service.

3 /3


2

Substitute the washing solution filter



Gloves

Safety footwear

Helmet

Overalls

MACHINE CONDITIONS:

-

Machine stopped with power and product supplies OFF:  air  mains power  process liquids

-



FDM - 178

1 /3


2


DESCRIPTION OF OPERATIONS: Preliminary operations 1) Drain the system by selecting the DRAINING mode on the operator panel (see User manual). 2) On the battery limit valves, shutdown the process liquid supply. To check the pneumatic system for leaks the electrical and compressed air supplies must be ON. 3) Remove the guards preventing access to the operating area. (Open the doors or detach the panels fixed with screws).

Substituting the filter 4) Close the manual infeed valve (A). 5) Open the drain valve (B) and drain off any remaining liquid into the container (C). Before you start to use chemical products, obtain the relevant “Safety Data Sheets” provided by the supplier. The SDS indicate the following:

-


Chemicals and dirty rags must be disposed of by specialist companies in accordance with current legislation in the country of use.

A

B

C

FDM - 178

2 /3


2


FDM - 178

3 /3

6) Release the locking collar (D). 7) Remove and substitute the filter (E) inside.

E

D

Final operations 8) Fit the new filter (E) in its seat. During dismantling and fitting, ensure that the seals remain in place. 9) Tighten the locking collar (D). 10) Close the drain valve (B) and open the manual infeed valve (A).



2

Substitute the CO sterile filter 2



Gloves

Safety footwear

Helmet

Overalls Goggles

MACHINE CONDITIONS:

-



MATERIAL REQUIRED: Consumables: - Clean and dry rags. Components: - New seals. - New filter cartridge. Equipment: - Universal ring nut spanner.

FDM - 183

1

/3


2


FDM - 183

DESCRIPTION OF OPERATIONS: Preliminary operations 1) Drain the system by selecting the DRAINING mode on the operator panel (see User manual). 2) Switch off the services: You must switch off the power and product supplies before you start work: Hazard. Components under pressure. Chemical products may be present.

A




B

2

/3


2


FDM - 183

Substituting the filter

3

D

4) Operate the drain valve (C) on each filter to discharge any residues remaining in the housing. 5) Disconnect the IN and OUT connections (D). 6) Remove the fixings (E). Substitute the filter.

E When you substitute the filter also substitute the filter seal. Ensure that the seal is correctly seated.

E

Final operations 7) When you have finished, refit the filter following the operations described above in reverse order. 8) Tighten the fixings (E) as per the instructions given on the card “Tightening torque values (Part A-1-4). 9) Close the guards (close the mobile doors and screw up the fixed panels). 10) Return the machine to service.

C

/3


2

Substitute the flow switch seal




Helmet

Overalls Goggles

MACHINE CONDITIONS:


air



mains power



process liquids



FDM - 184

1/3


2


FDM - 184


A




B

2/3


2


FDM - 184

3/3

Substituting the seals 4) Unscrew the clamping nut (C) and remove the flow switch from its seat. 5) Remove and substitute the seal (D).

C

D

Final operations 6) When you have finished, refit the flow switch following the instructions given above in reverse order. 7) Close the guards (close the mobile doors and screw up the fixed panels). 8) Return the filler to service.


2

Substitute the valve seals

FDM - 185

1/3


Example picture


Gloves

Safety footwear

Helmet

Overalls

Goggles

MACHINE CONDITIONS:


-



air



mains power



process liquids




2


FDM - 185



A





Before you start to use chemical products, obtain the relevant “Safety Data Sheets” provided by the supplier. The SDS indicate the following:

- hazards; - protection devices; --

first aid requirements; fire prevention measures; action in the event of accidental leaks; physical and chemical properties; stability and reactivity; toxicological information; ecological information; disposal information; shipping information.

B

2/3


2



Before you start this operation, read the instructions in the component manufacturer's use and maintenance manual. Perform this maintenance operation on one valve at a time. This will ensure that you do not inadvertently confuse the positions of the valves.

4) Disconnect any compressed air connections to the valve. 5) Detach the valve from the piping by removing any fittings. Substituting the seals

6) Take the valve to the workbench and proceed to substitute the seals (see the instructions in the

related use and maintenance manual).

Final operations 7) When you have finished, refit the valve following the dismantling procedure in reverse order. During reassembly, check that there are no extraneous objects inside the unit which might reduce the efficiency of reducer operating efficiency. 8) Close the guards (close the mobile doors and screw up the fixed panels). 9) Return the filler to service.

FDM - 185

3/3


3

Substituting product infeed seal



Goggles

Helmet Overalls


System drained



Guard doors open








PERSONS INVOLVED

-



FDM – 379

1 /3


3


FDM – 379

DESCRIPTION OF OPERATIONS: Substituting the seals 1) Unscrew the screws (A) with an appropriate tool. 2) Lower the feed piping (B) using the feet (C) if necessary.

B

C

A

3) Unscrew the screws (D) with an appropriate tool. 4) Remove the coupling (E). Dismantle the coupling at the workbench.

D

E

2 /3


3


FDM – 379

5) Unscrew the M8 hex head screws (F) together with their nuts (G). 6) Dismantle the flanges (H). Remove and substitute the seal (I).

F

H

I

Final operations 7) Reassemble the unit following the instructions given above in reverse order. 8) Close the guard doors. Refit any guards removed earlier. 9) Return the filler to service.

H

G

3 /3


3

Overhauling the outfeed belt



Helmet Overalls


System drained



Guard doors open








PERSONS INVOLVED

-



FDM – 382

1 /2


3

Overhauling the outfeed belt

FDM – 382

DESCRIPTION OF OPERATIONS: Overhauling the belt

B

D

Guide profile 1) Unscrew the 4 securing screws (A) (2 on each side) and remove the sprocket guard (B). 2) Remove a joint link from the chain. Remove the

C A

outfeed belt chain (C). 3) Unscrew the fixing screws (D) and substitute the two guide profiles. The new guide profiles must be cut and drilled to ensure alignment with the previous securing points.

F

E

Outfeed belt idle sprocket 4) Rotate the idle sprocket (E) until the two securing screws (F) are accessible. 5) Unscrew the screws (F) and substitute the two halves of the sprocket (E).

J

UCF support bearings 6) Unscrew the screws (I).

H G

7) Remove the plate (G) from the shaft (J). 8) Remove and substitute the bush (H). I

Final operations 9) When you have finished, refit the outfeed belt unit following the operations described above in reverse order. 10) Close the guard doors. 11) Return the filler to service.

2 /2


3

Substituting the filling valve FLOWMETER seals



Goggles

Helmet Overalls


System drained



Guard doors open








PERSONS INVOLVED

-



FDM – 383

1 /2


3

Substituting the filling valve FLOWMETER seals

FDM – 383

2 /2

DESCRIPTION OF OPERATIONS: Substituting the flowmeter seals 1) Climb onto the carousel and identify the flowmeter (A) requiring substitution. 2) Disconnect the connector (B). 3) Unscrew the tri-clamp (C). 4) Remove the flowmeter (A) with the hose (D) still connected. 5) Place the flowmeter on the bench, remove the triclamp (E) and remove the hose (D). 6) Substitute the 2 seals (F). C

F B

A E

F

D

Final operations 7) Refit the flowmeter following the instructions given above in reverse order. The tightness of the tri-clamps must match the reference given in the “General Information” table. 8) When you have finished, close the mobile guard doors. 9) Return the filler to service.


3

Tank breather valve overhaul



Goggles

Helmet Overalls


System drained



Guard doors open








PERSONS INVOLVED

-



FDM – 385

1/3


3


FDM – 385

2/3

DESCRIPTION OF OPERATIONS: Tank breather valve overhaul

1) Go to the work area. 2) Identify the rotary tank breather valve (A).

A

3) Loosen and remove the screws (B). 4) Remove the breather valve (A).

A

B


3


5) Overhaul the breather valve by (A) substituting the following components:

FDM – 385

G

D

3/3

E

C. spring D. bush E. stop ring F. pin membrane G. seal

H

H. O-Ring

C

Final operations

6) When you have finished, refit the valve following the operations described above in reverse order.

Grease the work side lip and fit the seal (G). 7) Return the filler to service.

F


2

Bottle body equipment overhaul



Goggles

Helmet Overalls


System drained



Guard doors open








PERSONS INVOLVED

-



FDM – 387

1 /3


2


FDM – 387

Bottle body equipment overhaul The bottle body equipment overhaul procedure consists of checking and substituting the following: machine outfeed starwheel guides machine outfeed starwheel body* (* only on the version with the standard neck pickup)

A. Overhauling the guides 1) Check the state of wear on the bottle body guides. Substitute any guides which are cut, damaged or bent.

B

2) Unscrew the nuts (A) and remove the damaged bottle guides (B). 3) Substitute the guides (B).

4) Unscrew the nuts (A).

A

2 /3


2


FDM – 387

B. Overhaul the neck pickup starwheel body 5) Check the state of wear on the bottle body starwheels. Substitute starwheels which are cut or otherwise damaged. D

6) Unscrew the nuts (C) and remove the components of the bottle body starwheel (D). 7) Substitute the damaged starwheel (D) parts.

8) Unscrew the nuts (C).


C

3 /3


3

Bottle ejector pneumatic piston overhaul



Goggles

Helmet Overalls


System drained



Guard doors open








PERSONS INVOLVED

-



FDM – 392

1 /3


3


FDM – 392

2 /3

DESCRIPTION OF OPERATIONS: Overhauling the ejector The overhaul procedure is divided into 3 steps: ejector unit dismantling ejector unit overhaul on a bench refitting the ejector after overhaul 1) Disconnect the 3 pneumatic connections (A). Mark the position of the bolts relative to the support plate so as not to lose the timing. 2) Unscrew the 3 securing bolts (B). A

3) Remove the bottle ejector unit upwards.

B B

4) Unscrew the nut (C) and remove the piston (D). 5) Unscrew the 2 couplings (E).

E

6) Substitute the piston (D). Fit the couplings (E) on the new piston (D) using LOCTITE thread locker.

C

D


3


FDM – 392

7) Unscrew the 2 bolts (F) and remove the guide pins (G). 8)

Remove the bushes substitute them.

(H)

sideways

and

H

F H

Final operations 9) When you have finished re-assemble the bottle ejector unit by following the operations described above in reverse. Make sure the timing of the bottle ejector unit is correct by tightening the 3 bolts securing the support plate in the positions marked at the beginning of the operation.

10) Close the mobile guard doors. 11) Return the filler to service.

G

3 /3


3

Dummy bottle extractor overhaul



Goggles

Helmet Overalls


System drained



Guard doors open








PERSONS INVOLVED

-



FDM – 393

1 /3


3


FDM – 393

2 /3

DESCRIPTION OF OPERATIONS: Overhauling the extractor 1) Disconnect the pneumatic connections (A).

A

F

2) Unscrew the screws (B) securing the piston. 3) Remove and substitute the Rilsan tube (C). 4) Remove the cotter pins (D) and remove the pin (E). 5) Remove the pneumatic cylinder (F). D E

D

C B

6) Make sure that the cylinder (N) measurements shown in the figure:

has

the 164 mm

197 mm (STROKE= 60 mm) F


3


7) Unscrew the nut (G) and the screw (H). 8) Remove the dummy bottle extractor cam (I).

H

9) Remove and substitute the spacer (J).

I

J G

Final operations 10) When you have finished, refit the dummy bottle extractor assembly following the instructions given above in reverse order.


FDM – 393

3 /3


3

Substituting the pilot valve



Goggles

Helmet Overalls


System drained



Guard doors open








PERSONS INVOLVED

-



FDM – 395

1 /2


3

Substituting the pilot valve

FDM – 395

2 /2

DESCRIPTION OF OPERATIONS: Substituting the pilot valve 1) Go to the PILOT VALVE (A) to be substituted. 2) Disconnect the connectors (B) from the pilot valve. 3) Unscrew the screws (C) and substitute the pilot valve (A) which is faulty.

If you need to substitute a pilot valve (A) which you cannot reach from the maintenance zone, proceed as follows: Move your hands away from the filling valves and rotate the machine using the JOG control until the pilot valve to be substituted is in front of you in the

A

B

maintenance zone. Before rotating the carousel make sure there are no physical obstructions preventing rotation. Use the MAINTENANCE CONTROL PANEL in the JOG mode.

C

Final operations 4) Refit the pilot valve (A) following the instructions given above in reverse order.

Make a note of the serial number marked on the pilot valve. You will need this later during initialisation (see “User Manual”). 5) When you have finished, close the mobile guard doors. 6) Return the filler to service.


3

Substitute the electric rotary manifold



Goggles

Helmet Overalls


System drained



Guard doors open








PERSONS INVOLVED

-



FDM – 397

1 /3


3


FDM – 397

2 /3

DESCRIPTION OF OPERATIONS: Substituting the seals 1) Climb on to the filling carousel to access the electric rotary manifold (A). 2) Disconnect the connections of the electric rotary manifold (B). 3) Unscrew the three screws (C) securing the electric rotary manifold. 4) Remove the electric rotary manifold assembly (A). B

A

C

C

5) Unscrew the screws (D) and remove the flange (E). 6) Substitute the ELECTRIC ROTARY MANIFOLD (F).

D F D

E


3


FDM – 397

Final operations 7) When you have finished, refit the electric rotary manifold by performing the operations described above in reverse order. Position the electric rotary manifold (F), ensuring that the pin (p) is inserted in the hole provided on the clamping bracket. Reconnect the cabling by following the indications given in the wiring diagram.


F

p

3 /3


Substituting worn components on the automatic greasing pump

3



Helmet

Overalls


System drained



Guard doors open








PERSONS INVOLVED

-


MATERIAL REQUIRED: -Consumables: Clean and dry rags.


FDM – 410

1 /2


Substituting worn components on the automatic greasing pump

3

FDM – 410

2 /2

DESCRIPTION OF OPERATIONS: Substituting the pump components Substitute any worn components in the automatic greasing pump (A) as instructed in the relevant operation and maintenance manual.


-

A


A


Final operations

A

A

1) When you have finished the maintenance work, close the guard doors. 2) Return the filler to service.

A

Greasing circuit


2

Substitute the pressure switch seal




Helmet

Overalls

Goggles

MACHINE CONDITIONS:

-




FDM - 448

1 /3


2


FDM - 448

DESCRIPTION OF OPERATIONS: Preliminary operations 1) Drain the system by selecting the DRAINING mode on the operator panel (see User manual). 2) Switch off the services: You must switch off the power and product supplies before you start work: Hazard. Components under pressure. Chemical products may be present.

A




B

2 /3


2


FDM - 448

3 /3

Substituting the seal


4) Unscrew the clamping nut (C) and remove the pressure switch from its seat. 5) Remove and substitute the seal (D). Substitute the seal (D) and ensure that it is correctly seated. C

D

Final operations 6) When you have finished, refit the pressure switch following the instructions given above in reverse order. During reassembly, check that there are no extraneous objects inside the unit which might reduce the pressure switch efficiency. 7) Close the guards removed previously. (Close the doors or refit the fixed panels). 8) Return the machine to service.


Overhauling the tilting outfeed belt (chain drive)

3



Safety eyewear Helmet Overalls


System drained



Guard doors open







(see “Switching off power supplies” operation sheet”)

PERSONS INVOLVED:

-


MATERIAL REQUIRED: Consumables: - Clean and dry rags. Equipment: - Lifting equipment (min. capacity 500 kg). - Trestle to support the belt.

FDM – 749

1/6



3

FDM – 749

2/6

Overhauling the belt 1) Position the trestle (A) under the tilting belt (B). 2) Unscrew the securing screws (C). Detach the tilting belt (B) from the filler belt (D) 3) Detach and remove the chain from the belt. C

D

B

A

4) Unscrew the fixing screws (E) of the neck guide support. By hand, remove the guide support (seethe maintenancecard“Overhaulthebottlebodyfittings ).

E

E

(example picture)


3


FDM – 749

3/6

5) Before you remove the belt, positiontheforksofa forklift truck or similar lifting equipment under the belt. To lift and transport the belt, use a fork lift truck or similar equipment with a minimum load bearing capacity of 500 Kg. Exercise extreme caution during lifting and handling. Take care not to damage the belt components. Keep all personnel away from the operating area of the lifting device. Only the operator trained to use the device should be in the area.

6) Using an Allen key, unscrew the countersunk screws (F). 7) With the aid of the lifting device positioned previously, lift and remove the belt (D).

D

F

F

F


3


FDM – 749

8) Turn the handwheel (G) to remove the feed screw (H) from the lead nut (I). 9) Remove the belt support sleeve. 10) Change the scraper ring (K).

J

H

K

I

G

L

M

11) Unscrew the screws (L). 12) Remove the bracket and the handwheel (M) from the reduction gear drive shaft.

L

4/6


3


FDM – 749

13) Remove a link from the chain (N) and remove the chain. Check chain (N) wear. Substitute worn chains. 14) Remove the sprockets (P) from the two jacks (O). 15) Unscrew the screws (Q) and slide the jack unit (O) out and down to the floor. Go to the work bench. Overhaul the jacks (O) following the instructions in the manufacturer’s manual.

Q S

Q

R

R

T

T

U

O

16) Unscrew the screws (R). Remove the flange (S).

O

P

V

V

17) Unscrew the screws (T). Remove the flange (U). 18) Unscrew the screws (V). 19) Lift and remove the hub (W).

W

20) Substitute the seal (X).

X

5/6


3


Final operations 21) When you have finished dismantling and substituting wear parts, reassemble the unit by performing the operations described above in reverse order. 22) Close the guard doors. Close the guards. 23) Return the filler to service.

FDM – 749

6/6


3

Substituting the COMBI transmission unit belts



Goggles

Helmet Overalls


System drained



Guard doors open








PERSONS INVOLVED

-


MATERIAL REQUIRED: Equipment: - Binder frequency meter

FDM – 751

1 /2


3

Substituting the COMBI transmission unit belts

2 /2

FDM – 751

Substituting the belt 1) Loosen the belt using the nuts on the tensioner (A). 2) When the belt is loose, slide the belt off the pulleys.

A

3) Fit a new belt by wrapping it around the pulleys as shown in the diagram. 4) Position the Binder frequency meter (B) at a distance of 5 mm under the belt. 5) Vibrate the belt and press the red button until a value is displayed on the meter display. 6) Adjust the nuts on the tensioner (A) until the following value is shown on the meter: approximately 30 Hz Make sure the tension is not too high. Excessive tension will cause rapid belt wear.


B


2

Overhaul of GALVANI laminar flow powered ventilation unit filters Follow health and safety guidelines (see “USER Manual”).


Goggles

Helmet Overalls


System drained



Guard doors open








PERSONS INVOLVED

-


MATERIAL REQUIRED: Consumables: - Clean and dry rags. Equipment: - Ladder conforming to prevention regulations.

current

accident

FDM – 752

1 /6


2

Overhaul of GALVANI laminar flow powered ventilation unit filters

DESCRIPTION OF OPERATIONS: Overhauling the standard filter The filter consists of two parts: - Pre-filter (on fan inlet) - Fine filter (on fan outlet)

Overhauling the pre-filter 1) Using a ladder which complies with accident prevention regulations, go to the powered ventilation unit. DO NOT climb onto the roof to substitute the pre-filter. The roof is not designed to support the weight of persons. 2) Raise the pre-filter (A) and remove it from its seat.

A

3) Substitute the pre-filter. Fit the new pre-filter in its seat. Take care not to crush the filter during positioning. Slowly and carefully guide the filter into position until it reaches its final position.

FDM – 752

2 /6


2


FDM – 752

Overhauling the fine filter 4) Disconnect the electrical connections (B) of the powered ventilation unit.

B B

5) Unscrew the countersunk screws (C) on both sides of the powered ventilation unit. 6) Using theventilation handles unit (D) until provided, lift the powered it reaches thetilting end of its travel.

D

C

3 /6


2


7) Raise the filter (E) and remove it from its seat.

E

8) Substitute the filter. Fit the new filter making sure that it is positioned in the direction of the arrow (fr). Take care not to crush the filter during positioning. Slowly and carefully guide the filter into position until it reaches its final position.

9) Grip the handles (D) and slowly guide the tilting element into its closed position. Take care not to crush the filter. Slowly guide the tilting element into position.

10) Tighten the screws (C) to secure the tilting element in its seat. 11) Reconnect the electrical connections (B).

fr

FDM – 752

4 /6


2


FDM – 752

Overhauling the vertical filter (RFA only) 12) Go to the powered ventilation unit. 13) Remove the guard cover (F) by lifting it and pulling it outwards in the direction of the arrow as shown in the figure. 14) Raise the pre-filter (G) and remove it from its seat.

F G

15) Remove the metal fram e by unscrewing the retaining screws (H) on the sides of the framework. 16) Loosen the four screws (I) fixing the fan (J).

H I

J

5 /6


2


17) Remove the fan unit (K) and the fine filter (L) outwards.

K

L

18) Substitute the pre-filter (G) and the filter (L) by following the instructions given above in reverse order.

Take care not to crush the filter elements during positioning. Slowly and carefully guide the filter into position until it reaches its final position.

19) Refit the guard cover (F) slowly guiding it back into its closed position. Crushing hazard. Slowly guide the guard cover (F) back into position.

Final operations 20) When you have completed the operations described above, return the filler to service.

FDM – 752

6 /6


5

Overhauling the base gear motor



Goggles

Helmet Overalls


System drained



Guard doors open








PERSONS INVOLVED

-


MATERIAL REQUIRED: Consumables: - Clean and dry rags. Equipment: - Lifting device (minimum load capacity 500 kg).

FDM – 753

1/4


5


2/4

FDM – 753

DESCRIPTION OF OPERATIONS: Preliminary operations 1) To to the base drive unit. Any piping obstructing movement should be removed after you have drained the pipes (see “USER Manual”). 2) Before you remove the drive unit, position the forks of a transpallet or similar lifting equipment under the unit. To lift and transport the drive unit, use a transpallet or lifting equipment with the following characteristics: - minimum load bearing capacity 500 Kg - low enough to pass under the filler base. Take care not to damage the drive unit components during lifting and moving. Do not modify the machine stopped position.

C

Overhauling the gear motor 3) Remove the motor guard by unscrewing its retaining screws. 4) Disconnect the connectors (A) from the motor. 5) Unscrew the screws (B) from the 4 stud bolts (C) holding the reduction gear mounting plate.

A

B

6) Using the lifting equipment positioned previously, remove the base drive unit and take it to the bench.

B


5


3/4

FDM – 753

7) Unscrew the screws (D). 8) Remove the brushless motor (E) from the reduction gear. F

F G

D

I

J D

E K L M

9) Unscrew the screws (F) and their nuts (f). 10) Remove the gears (G). 11) Unscrew the screw (H) and remove the shaft (I). 12) Remove the tab (J) by unscrewing the screws. Check the tab. Substitute if damaged. 13) Remove the flange (K).

N

14) Remove and substitute: - the seal (L) - the ring (M) 15) Unscrew the screws (N) and remove the plate (O).

O

Q P

16) Unscrew the screws (P) and remove the fixing flange (Q). 17) Remove the reduction gear (P)

P Q

Q

Refer to the reduction gear manual provided by the manufacturer and proceed as follows: - check the play of the outfeed shaft; - substitute the seal rings; - change the oil. P f f H


5


Final operations 18) When you have finished, refit the drive unit following the operations described above in reverse order. Check and carefully clean all components during re-assembly. Substitute all the seals.

the

Make sure that the connection is as specified on the electrical diagram. The oil removed from the gears must be collected in a container and forwarded to a specialist disposal company in accordance with current legislation in the country of use. Reconnect any piping dismantled during maintenance to improve access.

19) Close the doors. Refit the guards. 20) Return the filler to service.

FDM – 753

4/4


Changing the reduction gear oil

2



Goggles

Helmet Overalls


System drained



Guard doors open








PERSONS INVOLVED

-


MATERIAL REQUIRED: Consumables: - Clean and dry rags. - Special oil for reduction gears (see table below). Equipment: - Oil filling pump.

FGM – 034

1 /4



2

FGM – 034

2 /4

DESCRIPTION OF OPERATIONS: Greasing the bearings Before you start to use oils, greases and lubricants, obtain the relevant “Safety Data Sheets” provided by the supplier. The SDS indicate the following:

-

Hazards. devices. Protection First aid requirements. Fire prevention measures. Action in the event of accidental spillage and leaks. Physical and chemical properties. Stability and reactivity. Toxicological information. Ecological information. Disposal information. Shipping information.


B

1) Align the used oil container with the oil drain plug (A).

2) Remove the drain plug (A) and allow the oil to run into the used oil container positioned previously.

3) Remove the filler cap (B) to facilitate draining.

4) When you have drained all the oil from the reduction gear, refit and tighten the drain plug (A) complete with a new seal. Remove the used oil container and dispose of the oil in accordance with current legislation in the country of use. A

5) Fill the reduction gear with the oil specified. Fill at the filling point (B). Use the filling pump (see oil table). Gear motor type

80.81

100

125

140

160

180

200

Capacity (litres)

2

3.8

7

8.3

13

15.3

24



2

3 /4

FGM – 034

6) After 30 seconds check the level using the level plug (C).

B

The CORRECT LEVEL (a) is between the halfway point and the bottom point of the level glass. The minimum oil level must NOT fall below the MINIMUM LEVEL (b). 7)

Top up the oil in the reduction gear until the level is correct (a).

8)

When filling is complete, refit the filling cap (B) complete with a new seal.

C

a

b

Final operations Clean the reduction gear using a clean and dry rag. 9) When you have finished changing the oil, close the guard doors. 10) Return the filler to service.

Oil table USE

APPLICATION AREA

Gears

Gears

SYMBOL

ISO VG VISCOSITY CLASS (DIN 51519)

MAKE

220

Klüber

320

NAME

KINEMATIC VISCOSITY AT 40°C (min-max) mm2/s

FOOD SAFE SAFETY APPROVAL H1 (USDA/NSF)

Klübersynth GH 6-220

220

-

Klübersynth UH1 6-220

232

H1


320

-


320

H1

Klüber

Reduction gears* Gears

460

Gears

680


460

-


450

H1

Klüber


680

-


680

H1

Klüber

Pneumatic system lubrication

Pneumatic system lubricators, tank lifting air motor

32

Klüber

Klüber Summit HYSYN FG 32

33

H1

Pneumatic systems

Jack lubrication tank

15

Klüber


15

H1

Pneumatic systems

Bluestar and Newcanfill filling valves

32

Klüber


33

H1

* The reduction gear specifications are given in the “Reduction gear lubrication specification table”



2

FGM – 034

4 /4

Reduction gear lubrication specification table Reduction gear size 32, 40, 50, 63, 64, 80, 81

100

125, 126, 160, 161

Rossi reduction gears 200, 250

Screw speed rpm

ISO VG

= 280

680

Design type B3

B6

B7

B8

V5

V6

> 280

320

2800 - 1400

320

1400 - 710 710 - 355

320 460

355 - 180

680

< 180

680

Reduction gear size

B3

2800 - 1400

320/220*

32

0.2

0.25

0.2

0.2

1400 - 710

320

40

0.32

0.4

0.3 2

0.32 0.5

Quantity of oil (litres) B6, B7 B8

V5, V6

710 - 355

460

50

0.5

0.7

0.5

355 - 180

680/460**

63, 64

1

1.3

1

1

< 180

680

80, 81

1.5

2.5

2

1.5 3.3

2800 - 1400

220

100

2.1

6.3

4.5

1400 - 710

320/220*

125, 126

3.8

11.6

8.8

6.3

710 - 355

460/320***

160, 161

6.5

20.8

16.5

11.2

355 - 180

460

200

10.4

38

31.5

21.2

< 180

320

250

18.3

67

53

35.7

* Use ISO 320 oil for reduction gears B3,V5, V6 and ISO 220 oil for B6, B7, B8. ** Use ISO 680 oil for reduction gears B3, V5, V6 and ISO 460 oil for B6, B7, B8. *** Use ISO 460 oil for reduction gears B3, V5, V6 and ISO 320 oil for B6, B7, B8.

Right-angle gear-boxes

Angular output speed rpm

ISO VG

> 710 SIZE 80, 100, 125

710 - 280

*

280 - 90 < 90

SIZE 160, 200, 250, 320

*

> 710

150

710 - 280

220

280 - 90

320

< 90

460

Right-angle gearboxes sizes 80 to 125 do not require lubrication because they are supplied complete with synthetic grease for lifetime greasing.


1

Checking the front door sensors



Helmet

Overalls

MACHINE CONDITIONS: Check 1 - Machine rotating. Check 2 - Machine stopped in STANDBY state: 

System drained



Guard doors open







PERSONS INVOLVED

-



LEGEND: Front doors fitted with interlocked sensors and door lock Rear doors fitted with interlocked sensors and door lock

FNE - 029

1 /2


1

Checking the front door sensors

FNE - 029

2/2


Check 1 1) During a production cycle, check on the operator panel that the opening of all doors is DISABLED. 2) With the machine rotating, try to open the doors. Check that the following condition is present: - It must NOT be possible to open the doors when the machine is operating. If this is not the case, check the alignment of the keys (A) with the interlocked sensors (B).

Check 2 3) Stop filling machine rotation from the control panel. Enable opening of the front mobile guard doors (see the “Switching off power supplies” operation sheet).

4) Open ONE door and try to start the machine from the operator panel. It should not be possible to start the machine and an alarm message indicating that a door is open will appear on the operator panel. 5) Close the door. Repeat the check on ALL the front mobile guard doors.

If this is not the case, check the alignment of the keys (A) with the interlocked sensors (B).

If the alignment is correct but the fault persists this indicates that the sensor is damaged. Substitute the faulty sensor.

Final operations 8) When you have finished the checks, close the guard doors. 9) Return the filler to service.

A

B


1

Checking the emergency stop buttons



Gloves

Safety footwear

Helmet

MACHINE CONDITIONS:

-

Machine rotating without bottles.

DESCRIPTION OF OPERATIONS: 1) During production, press the emergency stop button and check the following conditions:

-

Immediate machine stop (i.e. control voltage is cut to the electric motor contactors; the PLC, adjustment tools, the monitors and the main compressed air solenoid valve and pressure switch remain powered up).

-

Red light on signal light column switched ON flashing.

-

Actuation of buzzer.

To restart the machine, release the emergency stop button (rotate in a clockwise direction) and press the reset button.

Check the functioning of all emergency stop buttons on the filler.

the

FNE - 030

1/1


Checking the filling valve and carousel connections

1



Helmet

Overalls


System drained



Guard doors open







PERSONS INVOLVED

-

One maintenance technician (electrical)


FNE - 031

1/2


1

Switching off the power supplies



Gloves

Safety footwear

Helmet Overalls

MACHINE CONDITIONS: Depending on the maintenance operation required, perform the following operations in the order shown: 

Drain the system.



Open the guard doors.



Switch off the mains power supply.



Switch off the compressed air supply.

DESCRIPTION OF OPERATIONS: Draining the system 1) Drain the system by selecting the DRAINING mode on the operator panel (see User Manual).

FNE - 059

1 /2


1

Switching off the power supplies

FNE - 059

Opening the guard doors. 2) With the machine stopped, enable opening of the mobile guard doors (see User Manual). 3) Open the guard doors to access the maintenance area.

On systems fitted with a safety lockout or a safety keylock. Before you start work, remove the key and keep it on your person for the entire period when you are inside the guards. This is a safety precaution to prevent someone from inadvertently closing a guard door and starting the machine.

Switching off the mains power supply. Do NOT perform any work on the machine until the services are switched off and locked out. Crushing hazard in the event of inadvertent start-up.

Switch off the mains electrical power supply by moving the main switch lever to 0 “OFF” (A).

A

When you have switched off the electrical power supply, padlock the main ON-OFF switch in the OFF (0) position. Keep the key on your person or keep it in place where access is restricted to authorised persons. This is safety precaution designed to prevent accidental start-up.

Switching off the compressed air supply. Switch OFF the compressed air supply using the knob (B).

With the electrical power supply ON: When you have switched off the compressed air supply, padlock the knob in the OFF (0) position. Keep the key on your person or keep it in a place where access is restricted to authorised persons. This is safety a precaution designed to prevent accidental start-up.

B

2 /2


1

Checking the timing sensors



Goggles

Helmet Overalls


System drained



Guard doors open







PERSONS INVOLVED

-



FNE - 067

1/2


1

Checking the timing sensors

FNE - 067


Checking the sensors 1) Clean the timing sensors (A). 2) Check that the timing sensors are correctly fixed.

Use the references (B) to align the timing sensors.

A

B


2/2


1

Checking the photocells



Helmet

Overalls


System drained



Guard doors open







PERSONS INVOLVED

-




Checking the photocells 1) Clean the projector (emitter) with a clean, dry cloth. Final operations 2) Close the guard doors. 3) Return the filler to service.

FNE - 068

1/1


2

Substitute a solenoid valve




Helmet

Overalls

MACHINE CONDITIONS:


air



mains power



process liquids

MATERIAL REQUIRED: Consumables: - Clean and dry rags. Components: - New solenoid valves.

FDE - 028

1/2


2

Substitute a solenoid valve

FDE - 028

DESCRIPTION OF OPERATIONS: Preliminary operations 1) Stop the machine and switch off the power and product supplies.

A

You must switch off the power and product supplies before you start work: Hazard. Components under pressure. Chemical products may be present. Switch OFF the mains electrical power supply by moving the main switch lever to 0 “OFF” (A).



Substituting a solenoid valve

Substitute the solenoid valve following the instructions in the related User and Maintenance Manual.

Final operations 3) When you have completed maintenance, close the guards removed previously. (Close the doors or refit the fixed panels). 4) Return the filler to service.

B

2/2


3

Substituting the filling valve FLOWMETER



Goggles

Helmet Overalls


System drained



Guard doors open








PERSONS INVOLVED

-



FDE - 044

1/2


3

Substituting the filling valve FLOWMETER

FDE - 044

2/2

DESCRIPTION OF OPERATIONS: Substituting the flowmeter seals 1) Climb onto the carousel and identify the flowmeter (A) requiring substitution. 2) Disconnect the connector (B). 3) Unscrew the tri-clamp (C). 4) Remove the flowmeter (A) with the hose (D) still connected. 5) Place the flowmeter on the bench, remove the triclamp (E) and remove the hose (D). 6) Substitute the flowmeter (A). Substitute the seals (F) before fitting the flowmeter. Mount the seals without using grease or oil. C

F B

A E

F

D

Final operations 7) Refit the flowmeter following the instructions given above in reverse order. The tightness of the tri-clamps must match the reference given in the “General Information” table. 8) When you have finished, close the mobile guard doors. 9) Return the filler to service.


3

Substituting the front/rear door sensors



Helmet

Overalls


System drained



Guard doors open







PERSONS INVOLVED

-


MATERIAL REQUIRED: Consumables: - Clean and dry rags. Equipment: - Ladder conforming to current accident prevention regulations. - Triangular socket spanner

LEGEND: Front doors fitted with interlocked sensors and door lock Rear doors fitted with interlocked sensors and door lock

FDE - 045

1/2


3

Substituting the front/rear door sensors

2/2

FDE - 045

DESCRIPTION OF OPERATIONS: Substituting the front door sensors 3) Open the operator door which has the faulty sensor. C

If the door remains locked you must release it mechanically. To do this, use the triangular socket spanner provided.

A

4) Unscrew the screws (A). 5) Disconnect the electric cable (B). 6) Substitute the sensor (C).

7) Fit the new sensor (C) following the instructions given above in reverse order. A

B

D

Substituting the rear door sensors 8) Using a ladder which conforms to applicable safety standards, go to the sensors to be substituted. 9) Disconnect the electric cable (D). 10) Remove the two pins (E) securing the sensors in place (one per sensor) using a thin punch. 11) Remove both the sensors (F), as shown in the figure. 12) Substitute the sensors (F).

13) Fit the new sensors (F), reversing the steps described above. F1

F2

Final operations 14) Close the guard doors.

F

15) Return the machine to service. E

Filler Maintenance

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