Filler User Manual

Technical Documentation

User Manual

FILLER

COMBI MATRIX SF300 FM 144/24K (SRMB0119) Coca-Cola Bottlers Philippines, Inc.

Original instructions

All figures and photos are for information purposes only.

Publication date: 28/06/2013

SIDEL S.p.A. - Via La Spezia, 241/A - (43126), Parma ITALY Tel.: +39 0521 9991 - Fax: +39 0521 959009

SF300 Filler

User Manual / Table of Contents

Page intentionally left blank

. A . p . S l e d i S © II

Matrix Filler


GENERALREGULATIONSAND WARNINGS

PARTI

SAFETYSTANDARDS

PARTII

TECHNICALDATA

PARTIII

INSTALLATION

PARTIV

OPERATION

PARTV

OPERATINGINSTRUCTIONS

PARTVI

SIZE CHANGEOVER

PARTVII

MAINTENANCESCHEDULE

PARTVIII

DIAGNOSTICS

PARTIX

APPENDICES

PARTX

TABLE OF CONTENTS GENERAL REGULATIONS AND WARNINGS ............................................................................................................... Part I

1.1 1.2

1.3

1.4 1.5 1.6 1.7

1.8

1.9

Testing and warranty .............................................................................................................................................. 2 Warnings and personnel ......................................................................................................................................... 3 1.2.1 Foreword .................................................................................................................................................... 3 1.2.2 Reproduction rights and copyright.............................................................................................................. 3 1.2.3 Documents supplied with the machine ....................................................................................................... 3 Reference standards .............................................................................................................................................. 4 1.3.1 EC declaration of conformity with machinery directive............................................................................... 5 1.3.2 Identification and CE marking plate............................................................................................................ 6 1.3.3 EC Declaration of conformity as per Pressure Equipment Directive (PED) ............................................... 7 1.3.4 Plates certifying conformity to Pressure Equipment Directive (PED) ......................................................... 9 1.3.5 Quality certificate (countries not in the EEA).............................................................................................. 10 1.3.6 Identification plates (countries not in the EEA)........................................................................................... 11 Setup provided by the customer ............................................................................................................................. 13 Technical assistance request procedure ................................................................................................................ 14 Instructions for ordering spare parts ....................................................................................................................... 15 Consulting this manual ........................................................................................................................................... 16 1.7.1 General information .................................................................................................................................... 16 1.7.2 Symbols used in this manual...................................................................................................................... 16 1.7.3 Terminology used in this manual................................................................................................................ 17 Description of the machine ..................................................................................................................................... 19 1.8.1 Intended use............................................................................................................................................... 19 1.8.2 General description .................................................................................................................................... 19 1.8.3 Operation.................................................................................................................................................... 20 Main units ............................................................................................................................................................... 21 1.9.1 Central manifold ......................................................................................................................................... 23 1.9.2 Carousel ..................................................................................................................................................... 24 1.9.3 Rotary product manifold ............................................................................................................................. 24 1.9.4 Base ........................................................................................................................................................... 24 1.9.5 Drive units .................................................................................................................................................. 25 1.9.6 Bottle conveyor........................................................................................................................................... 26 1.9.7 Filling valve................................................................................................................................................. 30 1.9.8 Operator interface ...................................................................................................................................... 31 1.9.9 Bottle closing .............................................................................................................................................. 32 1.9.10 SKID ........................................................................................................................................................... 33 1.9.11 Guards........................................................................................................................................................ 38 1.9.12 Bottle cooling (if fitted) ................................................................................................................................ 40 1.9.13 Automatic centralised lubrication system ................................................................................................... 40 1.9.14 Rinser (only BLOCKRINSER fillers) ........................................................................................................... 41 III

SF300 Filler


1.9.15 Filling valve drainage tank (HOTFILL optional) .......................................................................................... 42 SAFETY STANDARDS......................................................................................................................................................

2.1 2.2 2.3 2.4 2.5 2.6 2.7

2.8 2.9

2.7.2 Characteristics and operation of safety devices ........................................................................................ 12 Hazardous areas........................................................................................................................................................ 26 2.8.1 Hazard zones ............................................................................................................................................. 26 Residual risks and hazards ........................................................................................................................................ 27

TECHNICAL DATA.........................................................................................................................................................

3.1 3.2 3.3

3.4 3.5

3.6 3.7

Part II

General safety information ......................................................................................................................................... 2 Notes on using the system......................................................................................................................................... 4 Definition of safety terms ........................................................................................................................................... 5 Safety signage ........................................................................................................................................................... 6 Personnel................................................................................................................................................................... 8 Personal protective equipment (PPE) ........................................................................................................................ 9 Operator safety .......................................................................................................................................................... 10 2.7.1 Operator guard and protection devices ...................................................................................................... 10

Part III

Dimensions ................................................................................................................................................................ 2 Machine configuration ................................................................................................................................................ 3 3.2.1 Technical data ............................................................................................................................................ 3 Machine and environmental characteristics ............................................................................................................... 4 3.3.1 Man - machine interface ............................................................................................................................. 4 3.3.2 Ambient installation conditions ................................................................................................................... 5 Performance levels .................................................................................................................................................... 6 3.4.1 Speed variations......................................................................................................................................... 6 Power and consumption ............................................................................................................................................ 7 3.5.1 Installed voltage and power........................................................................................................................ 7 3.5.2 Tanks.......................................................................................................................................................... 7 3.5.3 Piping ......................................................................................................................................................... 7 3.5.4 Pressurised tank safety valves (if fitted) ..................................................................................................... 7 Weights ...................................................................................................................................................................... 8 Noise levels................................................................................................................................................................ 9

INSTALLATION............................................................................................................................................................. Part IV

4.1

4.2 4.3

4.4

. A . p . S l e d i S © IV

Packaging and shipping.......................................................................................................................................... 2 4.1.1 Type of packaging ...................................................................................................................................... 2 4.1.2 Incoterm® requirement............................................................................................................................... 2 4.1.3 Moving the packed machinery.................................................................................................................... 2 4.1.4 Receiving the material ................................................................................................................................ 3 4.1.5 List of components ..................................................................................................................................... 3 4.1.6 Storage conditions for packed machinery .................................................................................................. 4 Foundations ............................................................................................................................................................ 5 Movement and positioning ...................................................................................................................................... 6 4.3.1 Delivery to the customer's premises........................................................................................................... 6 4.3.2 Tooling supplied with the machine. ............................................................................................................ 6 4.3.3 Unpacking and hoisting .............................................................................................................................. 6 4.3.4 Removal of scrap material.......................................................................................................................... 7 4.3.5 Moving and positioning the machine .......................................................................................................... 8 4.3.6 Hook positioning table ................................................................................................................................ 10 Connections and cabling ........................................................................................................................................ 11 4.4.1 Electrical connection (responsibility of the manufacturer) .......................................................................... 11 4.4.2 Compressed air connection (responsibility of the customer)...................................................................... 11 4.4.3 Earthing system.......................................................................................................................................... 11 4.4.4 Connection for liquid waste disposal .......................................................................................................... 11 4.4.5 Connection for disposal of fumes ............................................................................................................... 12 4.4.6 Accidental spillage of substances harmful to the environment................................................................... 12

Matrix Filler


4.5

4.6 4.7

Setting up and first startup ...................................................................................................................................... 13 4.5.1 Pre-startup settings .................................................................................................................................... 13 4.5.2 Pre-startup checks ..................................................................................................................................... 14 4.5.3 Cleaning and general inspection ................................................................................................................ 15 4.5.4 General cleaning ........................................................................................................................................ 16 4.5.5 Cleaning products and equipment.............................................................................................................. 16 4.5.6 Safety warning............................................................................................................................................ 16 4.5.7 First startup ................................................................................................................................................ 17 4.5.8 Sanitizing the system ................................................................................................................................. 17 4.5.9 Setting up and first startup ......................................................................................................................... 17 Re-installation ......................................................................................................................................................... 18 Decommissioning and disposal .............................................................................................................................. 19 4.7.1 Disposal of packaging ................................................................................................................................ 19 4.7.2 Dismantling and removing the machine ..................................................................................................... 20 4.7.3 Disposal of the machine ............................................................................................................................. 21

OPERATION.................................................................................................................................................................. Part V

5.1

5.2 5.3

5.4 5.5

Permitted use. Improper use. Energy reduction ..................................................................................................... 2 5.1.1 Design use ................................................................................................................................................. 2 5.1.2 Operational criteria to reduce consumption................................................................................................ 2 Production limits ..................................................................................................................................................... 3 5.2.1 Instructions in the event of a fire ................................................................................................................ 3 operating description .............................................................................................................................................. 4 5.3.1 Filling processes......................................................................................................................................... 4 5.3.2 Filling .......................................................................................................................................................... 6 5.3.3 Filling steps ................................................................................................................................................ 8 Washing step (if available)...................................................................................................................................... 15 Machine cleaning and sanitization .......................................................................................................................... 16 5.5.1 Introduction................................................................................................................................................. 16 5.5.2 General information .................................................................................................................................... 17 5.5.3 5.5.4

Use of chemical products to remove limescale deposits from external surfaces....................................... 18 Limits to using detergents and sanitisation products.................................................................................. 19

OPERATING INSTRUCTIONS....................................................................................................................................... Part VI

6.1

6.2

6.3 6.4

6.5

6.6

Control panel, warning lights and pushbuttons ....................................................................................................... 2 6.1.1 Foreword .................................................................................................................................................... 2 6.1.2 Layout of components ................................................................................................................................ 2 6.1.3 Operator panel ........................................................................................................................................... 3 6.1.4 Operator interface main structure............................................................................................................... 4 6.1.5 Operator panel operations.......................................................................................................................... 10 Description of individual interfaces ......................................................................................................................... 19 6.2.1 Main functions ............................................................................................................................................ 19 6.2.2 Reception ................................................................................................................................................... 22 6.2.3 Piping circuit ............................................................................................................................................... 23 6.2.4 Machine components ................................................................................................................................. 26 Electronic filling valves (Mastercard) ...................................................................................................................... 48 Recipes ................................................................................................................................................................... 94 6.4.1 Layout......................................................................................................................................................... 110 6.4.2 Maintenance Graphics ..................................................................................................................................................... 114 6.4.3 ............................................................................................................................................... 115 6.4.4 Parameters ................................................................................................................................................. 125 6.4.5 Services...................................................................................................................................................... 141 Operating mode selection ....................................................................................................................................... 147 6.5.1 Automatic operation ................................................................................................................................... 147 6.5.2 Manual operation........................................................................................................................................ 147 Machine startup and production ............................................................................................................................. 148 6.6.1 Preliminary checks ..................................................................................................................................... 148 6.6.2 Starting ....................................................................................................................................................... 149 6.6.3 Procedures for standard operation ............................................................................................................. 153

V

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6.7

6.8 6.9

Stop and emergency stop modes ........................................................................................................................... 154 6.7.1 Machine emergency stop ........................................................................................................................... 154 6.7.2 Machine stop during production ................................................................................................................. 154 Rinsing.................................................................................................................................................................... 155 Sanitization ............................................................................................................................................................. 156

SIZE CHANGEOVER..................................................................................................................................................... Part VII

7.1 7.2 7.3 7.4

General precautions ............................................................................................................................................... 2 Description of the size change parts....................................................................................................................... 3 Machine cleaning .................................................................................................................................................... 4 Removing size changeover parts (where fitted) ..................................................................................................... 5

MAINTENANCE SCHEDULE....................................................................................................................................... Part VIII

8.1

8.2

General information about maintenance................................................................................................................. 2 8.1.1 Maintenance operation times ..................................................................................................................... 4 8.1.2 Greasing machine parts ............................................................................................................................. 5 8.1.3 Preventive maintenance ............................................................................................................................. 6 8.1.4 Extraordinary maintenance ........................................................................................................................ 7 Maintenance schedule ............................................................................................................................................ 8

DIAGNOSTICS............................................................................................................................................................. Part IX

9.1

Troubleshooting ...................................................................................................................................................... 2 9.1.1 General machine operation ........................................................................................................................ 3 9.1.2 Bottle conveyor........................................................................................................................................... 3 9.1.3 Filling .......................................................................................................................................................... 4 9.1.4 Capping ...................................................................................................................................................... 7 9.1.5 Product level in static tank (if fitted)............................................................................................................ 8

APPENDICES.............................................................................................................................................................. Part IX

10.1

. A . p . S l e d i S © VI

Documentation enclosed ........................................................................................................................................ 2 10.1.1 Layout and connections ............................................................................................................................. 3 10.1.2 Moving the machine ................................................................................................................................... 4 10.1.3 Flow circuit diagram ................................................................................................................................... 5 10.1.4 Equipment .................................................................................................................................................. 6 10.1.5 Description of slave card display unit controls ........................................................................................... 7 10.1.6 Appendices for commercial equipment ...................................................................................................... 8

Matrix Filler

Part I

PART I

User Manual / General regulations and warnings

GENERAL REGULATIONS AND WARNINGS

1.1

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1.1

Part I

TESTING AND WARRANTY

The filling machine is shipped to the customer ready for installation following factory testing performed by the manufacturer, in compliance with current legislation. During the period of warranty the manufacturer is bound to resolve faults and defects as long as the machine has been operated correctly in compliance with that stated in the use and maintenance manuals. Any consumables, including those supplied by the dealer together with the machine, are not covered by the warranty. The conditions of the warranty are specified in the agreements stipulated between the parties when the contract is drafted.

. .A .p lS e id S ©

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Part I

1.2

WARNINGS AND PERSONNEL

1.2.1

Foreword

This manual is an integral part of the machine. This manual was written in the manufacturer’s language and then translated into the language of the country where the machine will be installed and operated. The photos, figures and diagrams in this manual refer to a standard machine. The configurations shown in the figures may differ from those on the machine in your possession. The functions remain identical. These manual and the technical documentation must be readily available to all users of the machine. This manual has been written for the following persons: -

The installation manager. The operators starting and operating the machine. The maintenance technicians.

This manual provides the following general information: -

A description of the machine operating units and sub-assemblies. Operating and use instructions. Maintenance procedures.

This manual contains: -

Technical data about the machine, its functions, its components and their operation. Information about receiving, unpacking and handling the machine. Instructions on connecting up the various electrical cabinets and the power systems to the external supplies.

The machine is commissioned and started for the first time by qualified technicians from SIDEL. Commissioning includes the following: 1.2.2

Final setting up and adjustment. Levelling. Assembly of all sub-components. Adjustment and testing of machine functions. Production with the sizes to be used on the machine. Reproduction rights and copyright

All rights reserved. Translation rights, electronic storage rights, reproduction and adaptation rights, partial or complete, using any means (including microfilm and photocopies) are reserved for all countries.

1.2.3

-

Documents supplied with the machine

User Manual. Maintenance manual. Parts manual (list of components with SIDEL codes and overall drawings). Wiring diagram.

1.1

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1.3

Part I

REFERENCE ST ANDARDS All SIDEL machines are designed and manufactured in compliance EU standards.

The documents supplied to the customer vary in accordance with the country of destination of the SIDEL machine: -

The following are supplied for countries in the European Economic Area (EEA): -

-

CE declaration of conformity with machinery directive Identification and CE marking plate Declaration of conformity as per Pressure Equipment Directive (PED) (pressure systems) CE marking plate as per Pressure Equipment Directive (PED) (pressure systems)

The following are supplied for other countries: Quality certificate Identification plates


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Part I 1.3.1

EC declaration of conformity with machinery directive

The declaration is given to the customer when the machine is put into service and after the presence of the user instructions and safety device operating instructions has been verified. Example:

1

(1)

See the machine identification data on the cover of this manual.

1.1

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1.3.2

Part I

Identification and CE marking plate

The plate is attached to the electrical panel of the machine and shows the CE marking, the name of the manufacturer SIDEL, machine identification, the year of manufacture and the main features of the electrical system. Example:

6 1

7

2

8 9

3

10 4

11

5 (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12)

12

Machine name Model Type Serial number Year of manufacture Nominal power rating Maximum current absorbed Number of phases Power supply voltage Frequency Short circuit current Wiring diagram identification Do not remove or tamper with the identification plate.


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Part I 1.3.3

EC Declaration of conformity as per Pressure Equipment Directive (PED)

The customer is given 2 declarations (one for the tank and one for the assembly of pressurised components) when the machine is put into service. The declarations are drafted following testing at the SIDEL manufacturing facility. Example:

1

(1)


1.1

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Part I


1

(1)



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Part I 1.3.4

Plates certifying conformity to Pressure Equipment Directive (PED)

The plates are attached to the pressurised tanks of the machine and show the main features of the system. Example:

5 1

6

2 3 7

4

5

1

6

2 3 4 8

(1)

Identification of the tank or assembly

(2) (3) (4) (5) (6) (7) (8)

Design pressure Hydrostatic test pressure Design temperature (Min - Max) Identification of notified test body (if applicable) Year of manufacture Nominal capacity Identification of safety valve Do not remove or tamper with the identification plates.

1.1

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1.3.5

Quality certificate (countries not in the EEA)

The certificate is given to the customer when the machine is delivered. Example:

1

(1)



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1.1

Part I

Matrix Filler


Part I 1.3.6

Identification plates (countries not in the EEA)

There are 2 identification plates for countries not in the EEA: -

Plate 1 is attached to the electrical cabinet of the machine and shows the main features of the electrical system.

Example:

6 1

7

2

8 9

3

10 4

11

5

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12)

12

Machine name Model Type Serial number Year of manufacture Nominal power rating Maximum current absorbed Number of phases Power supply voltage Frequency Short circuit current Wiring diagram identification

1.1

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Part I


-

Plate 2 is attached to the pressurised tank of the machine and shows the main features of the system.

Example:

5

1

6

2 3 7

4

(1) (2) (3) (4) (5) (6)

Identification of the tank or assembly Design pressure Hydrostatic test pressure Design temperature (Min - Max) Identification of notified test body (if applicable) Year of manufacture

(7)

Nominal capacity

Do not remove or tamper with the identification plates.


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1.1

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Part I

1.4

SETUP PROVIDED BY THE CUSTOMER

The following connections must be provided by the customer: -

Mains water. Treated water (if applicable). Compressed air. Gas (CO2 − Sterile air − etc.). Sanitising agent.

-

Mains power. Product. Water drainage. Conveyance of emissions in the atmosphere.

The following must also be provided by the customer: -

Earth connection. Consumption materials. Further information concerning the operations required to make the connections can be found in section 3.5 “CONNECTIONS AND CABLING” in this manual.

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1.5

Part I

TECHNICAL ASSISTANCE REQUEST PROCEDURE

Requests for the intervention of the customer technical assistance service must be sent by fax to the following address: Sidel S.p.A. Via La Spezia, 241/A - (43126), Parma ITALY Servizio Assistenza Tecnica Clienti: fax number +39 0521 999530

Please state: -

Machine type, Serial Number, Year of installation. Description of the fault(s). Exact address of the production facility where the machine is installed. The name of a contact person.

For more information about our Customer Technical Assistance Service, www.sidel.com.


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Matrix Filler


Part I

1.6

INSTRUCTIONS FOR ORDERING SPARE PARTS

The customer is responsible for purchasing srcinal spare parts to ensure maintenance operations which keep the machine safe and efficient. The list of spare parts required, precise instructions for identifying them and the procedure to order them are shown in detail in the enclosed spare parts catalogue. The dismantling and reassembly operations must be performed in compliance with the instructions provided by the manufacturer. Requests for spare parts must be sent by fax to the following address: Sidel S.p.A. Via La Spezia, 241/A 43126 Parma, Italy Tel. (+39) 0521−9991 Fax (+39) 0521−959009

The following information should be provided with each request to ensure safe and rapid identification of spare parts: -

Machine type and serial number.

-

Drawing number and the position of the part on the drawing. Description of the part. Part code specified on the parts list. Quantity required.

Please also specify whether the request is an executive order or a request for parts, the requested delivery date, the delivery address, invoicing address and any specific shipping instructions. The name, telephone number and fax number of the person who shall be the contact with Sidel for the supply of spare parts must be provided. When your order has been received, you will be sent an order confirmation including prices, delivery date and supply conditions. The address of the spare parts centre is as follows: Sidel S.p.A. Via La Spezia, 241/A - (43126), Parma ITALY Servizio Ricambi: fax number +39 0521 999530, telephone number +39 0521 999295

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1.7

CONSULTING THIS MANUAL

1.7.1

General information

Part I

All users must read this manual in its entirety. Users must be fully aware of and understand the instructions contained in this manual. This manual is a reference and consultation document containing instructions and procedures. The manual should be available at all times to all personnel responsible for operating or maintaining the machine. The manual is designed to enable quick reference and to ensure that you can rapidly find all the information you need about operation, control and maintenance. The following features are designed to help users find the information they need quickly: -

1.7.2

There is a table of contents at the start of the manual and a table of contents at the start of each part detailing the topic covered in that part. The manual is divided into parts and sections for each main topic. The header of each part indicates the exact position inside the manual. Symbols are used to identify different types of information. A glossary which explains the technical terms used in the manual.

Symbols used in this manual

The following symbols are used throughout this manual to indicate special instructions and hazard warnings:

Strictly prohibited.

Warning – Please read carefully.

Prohibition sign: No persons with pacemaker

Mandatory sign: Read the manual

Notes and comments on the results of an operation.

Indications for protecting the environment.


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Part I 1.7.3

Terminology used in this manual

In the interests of clarity we provide a glossary explaining some of the technical terms used in this manual. This glossary has been prepared for all the machines we manufacture. Not all of the terms refer to the machine in your possession and it is possible therefore that some of the terms may not appear in your manual.

CIP INTERNAL CLEANING

Clean-In-Place (CIP) - a system for cleaning a line or an item of equipment in a closed cycle.

CIP/SIP UNIT

A Clean-In-Place (CIP) or a Sanitize-In-Place (SIP) unit.

CLEANING

Removal of food residues, dirt, grease or any unwanted material.

CONTACT SURFACES

All equipment surfaces which come into contact with the product either intentionally or unintentionally (e.g. through splashing).

COP EXTERNAL CLEANING

Clean-Out of-Place (COP) - a system for the external cleaning a line or an item of equipment in a closed cycle.

DISINFECTANT

A chemical product used after cleaning to eliminate a part or a type of microorganism remaining on surfaces.

DISINFECTION

The use of chemical agents or physical methods to reduce the number of microorganisms to a level which does not endanger the safety or suitability of foodstuffs.

FILLING NOZZLE

End part of the valve which sprays in the filling fluid.

FILLING VALVE

A fluid control system which feeds the fluid into a container through the filler nozzle.

FORESEEABLE CONDITIONS OF USE

The reasonably foreseeable conditions of use, including cleaning, under which the machine will operate. These conditions set the limits for the variables such as time, temperature and concentration.

ISOLATOR

An area where the environment is controlled by an overpressure cascade between the various zones (e.g. between the white zone and the grey zone).

JOG UNIT

An item of equipment used to operate the machine in the manual mode at low speed.

MANIFOLD

A manifold collects fluid coming from one or more pipes and distributes it to one or more units.

MANUAL CLEANING

Removal of residues by hand when the equipment is partially or completely disassembled.

NON PRODUCT CONTACT SURFACES

All exposed surfaces contact with the product.except those which may potentially come into

OP

Operator

P&I

Functional diagram of the line complete with the part codes.

PAA

Peracetic acid.

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PAA/SW UNIT

The unit for storing peracetic acid and sterile water.

PAM - MP

Machine parameters.

PAR - RP

Recipe parameters

PAT

Technical parameters

PID

Proportional Integral Derivative.

RESIDUE

Any material remaining in the equipment or in the process area. Residues may or may not contain microorganisms.

ROTARY COUPLING

A component which enables a fluid to pass from a fixed pipe to a rotating pipe.

SANITIZER

A substance which reduces the microbial contaminants on inanimate surfaces to within levels considered safe for public health.

SANITIZING

A process applied to a clean surface to reduce the number of resistant human pathogenic agents. Mechanical or manual methods can be used for sanitizing using hot water, steam or an approved disinfectant.

SOLUTION

Water or homogeneous mixtures of cleaning agents or disinfectants and water used for the flow, cleaning, rinsing and disinfection.

SPLASHED CONTACT SURFACES

Surfaces not in contact with the product which during normal use accumulate residues which must be cleaned away at regular intervals to prevent these residues entering the product or the main container.

STERILISATION

A process aimed at removing or killing all forms of microorganism including bacterial spores.

SW

Sterile Water.


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Part I

1.1

Matrix Filler


Part I

1.8

DESCRIPTION OF THE M ACHINE

1.8.1

Intended use

The machine is designed to fill returnable and disposable PET bottles with collar with still and/or fizzy (CO2 added) soft beverages.

1.8.2

General description

This manual refers to the rotary filler for bottling and capping containers at high speed. Each machine is manufactured by Sidel S.p.A., PARMA (ITALY) and is designed using the latest techniques for bottling and capping at high speed. The machine is able to achieve high production rates. This together with good resistance to corrosive environments, low maintenance, high reliability and easy size changeover are all features which make this a safe, versatile and reliable machine suitable for practically any application. All machine movements are powered by electric motors controlled by a PLC. The cables to the electrical equipment are suitably dimensioned and are housed inside special trunking and cableways which enable easy inspection of the cables. The electrical cabinet houses the low tension circuits for the control and programming equipment. It also houses the power contactors. The operator-machine interface consists of a local pushbutton panel complete with real time displays of machine states and the controls for operating the machine in the manual mode.

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1.8.3

Part I

Operation

The containers are filled and capped inside the machine. This section identifies the main machine units which are then described in more detail in the sections that follow. The figure below shows the machine operating process. The containers are conveyed inside the machine using a starwheel train. In the filling unit the containers are filled by following the technical filling criteria (see section 5.4.2 “Filling”). The capper / crown capper if fitted with the closing device. At the end of these operations the containers are conveyed to the next processing stage using conveyor belts.

References

Description

1

BOTTLE INFEED (empty bottles)

2

FILLER (bottle filling)

3

CAPPER CROWN / CAPPER (bottle capping)

4

BOTTLE OUTFEED (bottles ready for the next processing stage)


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Part I 1.9

MAIN UNITS

COMBI filler main units

10 3 7 15 12

5

2

13

1

9 4

11

6

8

16

Reference

Description

Reference

Description

1

Central manifold

10

SKID

2

Carousel

11

Guards

3

Ring manifold

12

Bottle cooling (if fitted)

4

Base

13

Lubrication

5

Drive units

14

-

6 7

Bottle conveyor Filling valve

15 16

HotFill Filling valve drainage tank (where fitted) Blower*

8

Operator interface

17

-

9

Capper / Crown capper

(*) not included in the documentation

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Part I


BLOCKRINSER filler main units

10

3

7

15

17

5

2

13

4

11

9

8

5

14

1

6

Reference

Description

Reference

Description

1

Central manifold

10

SKID

2

Carousel

11

Guards

3

Ring manifold

12

-

4

Base

13

Lubrication

5

Drive units

14

Rinser

6

Bottle conveyor

15

HotFill Filling valve drainage tank (where fitted)

7

Filling valve

16

-

8

Operator interface

17

Hema* pulp (if fitted)

9

Capper / Crown capper

(*) not included in the documentation


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Part I 1.9.1

Central manifold

UPPER CENTRAL MANIFOLD

The upper central manifold (1) supplies the carousel with the following: -

Compressed air for the pneumatic valves and the jacks (where installed). Electrical signals for solenoid valves and probes. Sanitizing solutions for COP (with COP and reduced laminar flow)

1

LOWER CENTRAL MANIFOLD

The lower central manifold (2) supplies the carousel with the following: -

Product. CO2/N2 (if applicable) Sanitizing solution for use during the CIP process. Decompression.

2

1.1

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1.9.2

Part I

Carousel

This consists of two parts: 1. 2.

1.9.3

A fixed part to support the structure. A rotary part including the support for the filling valves and the product manifold.

Rotary product manifold

The rotary product manifold on the filling machine has a ring design to connect the product infeed pipes and the sanitization recycling pipes from the central manifold.

1.9.4

Base

This contains the drive transmission components for the filler carousel, belts, bottle conveyor starwheels, capping units and any other connected machinery.


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Part I 1.9.5

Drive units

All the rotary mechanical components are powered independently by their own brushless motors (1) which are electronically synchronised. One of the motors, the master, provides the reference speed used for synchronisation. In the event of a power failure, any mistiming caused by the different inertias of the rotating masses as they come to a stop is prevented by an DC energy generating circuit.

1

2

The carousels are driven by the reduction gearbox shaft (2) located under the filler carousel. This shaft drives the drive shaft and the pinion (3) which engages directly with the rack (4).

4

3

In the base, the drive is transmitted to the reduction gearbox located inside the base. The gearbox drives a gear train which rotates all the bottle handling parts and the capping units.

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Matrix Filler

Part I

User Manual / General regulations and warnings COMBI Filler Drive Units

BLOCKRINSER Filler Drive Units

1

1

3

2 2

References

1.9.6

Description

1

filler carousel drive motor

2

bottle conveyor starwheel drive gear motor

3

rinser drive gear motor

Bottle conveyor

The bottles are conveyed into and out from the filling carousel using transfer starwheels and guides. The path followed by the bottles through the machine is as follows: 1. 2. 2. 3. 4.

Bottle infeed starwheel/s. Rinser (where fitted) Filling carousel. Capper/Crown capper. Bottle outfeed belt.

BOTTLE OUTFEED

The bottle outfeed module (1) conveys the bottles onto the outfeed conveyor. 1


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Part I

A pit (2) positioned after the outfeed module stops the machine in the event that the conveyor belt circuit downstream from the filler jams or is blocked. 2

The height adjustable belt (3) picks up the bottles arriving from the last starwheel of the machine; the belt picks up the bottles by their bottoms. An inclined belt enables connection to the conveyor belt line. A safety system stops the machine in the event that the conveyor belt circuit downstream from the filler jams or is blocked. 3

4 References

Description

1

Bottle outfeed module

2

Clogged bottle outfeed pit

3

Adjustable outfeed belt

4

Adjuster handwheel

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Matrix Filler


Belt with automatic adjustment (optional)

The height of the belt is adjusted automatically by a motor (5). In the event of a motor fault, the height can be adjusted using the handwheel (6).

6

5

References

Description

5

Adjustable belt motor

6

Adjuster handwheel


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Matrix Filler


Part I

Guides with automatic adjustment (optional)

The width of the guides (7) is adjusted automatically by a motor (8).

7

8

References

Description

7

Adjustable guides

8

Adjustable guide motor

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Matrix Filler

Part I


1.9.7

Filling valve

Depending on the type of filler, different types of valves are used: Alcohol and still product valve

Fizzy product valve

6

Hot product valve

6

6

2 1 1

7

1 2

5 2

7

3 4

5

5

4 4

References

Description

1

Filling valve body

2

Fluid distributor

3

Bell unit

4

Bottle support with gripper

5

Dummy bottle

6

Pilot valve

7

CIP unit


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Part I 1.9.8

Operator interface

The operator interface includes a part with traditional controls (buttons, selectors, knobs), and another part integrated into the operator panel.

Pushbutton control panel

The control panel includes all the electric control and warning devices.

Pneumatic control and adjustment panel

The control panel includes all the devices used to control and adjust the compressed air and CO2.

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1.9.9

Part I

Bottle closing

The capping tower consists of a series of capping heads on a carousel and a pick-and-place unit (a cap distribution starwheel). The cap is transferred to the pick-and-place unit only when a bottle to be capped is present. The screwing heads (1) perform two movements: rotation on their own axes at a variable angular speed; axial travel controlled by a cam. The combination of these two movements during rotation of the capper enables the capping heads to perform the following sequence of operations. The capping heads pick up the caps from the distribution system, position them on the bottles, screw them on, tighten them and then disengage from the bottle (see the manual supplied by the manufacturer of the capper). For further information refer to the manual supplied by the manufacturer of the bottle closing unit.

1


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Part I


1.9.10 SKID PROCESS SKID

This is a process unit acting as an interface between the filler infeed and outfeed fluids and also as a device to store and manage the product used for filling. If the SKID unit is not fitted, the components described below are part of a sanitizing machine called COREBLEND (see the specific manual).

SKID composition:

Product delivery

Product infeed

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Matrix Filler


Product storage

Gas treatment (compressed air, CO2)

CIP infeed and recycling (optional)

Bottle rinsing circuit infeed (optional)


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Matrix Filler

Part I


Bottle bottom cooling circuit management, distribution and recycling (optional)

Foaming control unit for COP external washing (optional)

Pneumatic distribution

Atmospheric and pressurised drainage

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Matrix Filler


ICS (optional)

Electrical cabinet

The machine is equipped with a main electrical cabinet containing the following safety components: Main ON/OFF switch on the filler. Emergency stop pushbutton. Before switching on the electrical cabinet for the first time, proceed as follows: Check the customer’s power supply. Check the connections inside the electrical cabinet. Check that the emergency stop pushbutton is OFF. Rotate the main ON/OFF switch to power up the electrical cabinet.


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Part I

Matrix Filler

Part I


PAA SKID (where fitted)

This system is used to prepare the solution of water with added PAA at a concentration of 50 ppm at room temperature. The system is fitted with a mixing tank with a capacity of 400 litres, a pump to keep the solution circulating and a counter-pressure valve to regulate the pressure in the circuit. Dosing is performed using an electric membrane pump and a flow meter installed on the recycled water inlet. The flow meter generates a pulse each time a set quantity of water transits through the pump; for each pulse the dosing pump performs a dosing operation so that the correct volume of water is dosed to produce the concentration required.

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Part I

1.9.11 Guards

The machine has 3 types of perimeter guards: A.

Tight Area Protection

Tight area guards are designed using gates made from tempered glass fitted near to the front and rear of the machine. Options: -

Cover for the dynamic air over-pressure system. Gutter around the base of the front table

B.

Wide Area Protection

Wide are guards are designed using fixed panels made from Lexan and gates made from tempered glass fitted near to the front but far from the rear of the machine. Options: Glass for fixed panels (laminated glass) Cover for the dynamic air over-pressure system. Gutter around the base of the front table


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Part I

C.

Reduced Filling Area

Reduced filling area guards are designed using gates made from tempered glass fitted near to the machine, collection trays under the filling carousel and gutters around the base. The base and filling area are fitted with reduced guards and the rinsing area is fitted with a cover.

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Part I

1.9.12 Bottle cooling (if fitted)

The cooling unit nozzles direct jets of cold water on to the bottom of the bottles as they move on the machine infeed starwheels (at blower outfeed), thus cooling the bottles before they enter the filling carousel.

1.9.13 Automatic centralised lubrication system

The automatic centralised lubrication system is designed to supply a series of “users” (i.e. components requiring greasing) with the appropriate amount of grease at regular intervals during machine operation without any direct intervention by the operator. The minimum grease level sensor triggers an alarm displayed on the operator panel. The operator panel has a pushbutton for starting the lubrication cycle in the manual mode. Use this button to run a test lubrication cycle or to run a greasing cycle when starting the machine after a long stoppage.


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Part I

1.9.14 Rinser (only BLOCKRINSER fillers)

The rinser unit rinses the empty bottles just before they are filled. The structure of the machine is designed to ensure high standards of hygiene and to enable cleaning during work and sanitizing cycles. The design also ensures easy access to all zones for scheduled and extraordinary maintenance. The fixed structure (1) of the rinser consists of the carousel transmission and raising components, cam support, collection channel and rack; the bottles are rinsed in carousel ( 2). Depending on the configuration, bottle washing/cleaning is performed as follows: -

-

Treatment with water only. Treatment with air only. Treatment with water and air. Treatment with sanitizer, draining and rinsing.

2

1

References

Description

1

Fixed structure.

2

Mobile carousel.

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Matrix Filler

Part I


Distribution of processes: 8

4

1

References

2

3

Description

5

References

6

7

Description

1

Air ring manifold.

5

Mixer.

2

Air ring manifold.

6

Air + water pipe.

3

Central rotary distributor.

7

Bottle tipping gripper unit.

4

Valves.

8

Pressure transducers.

1.9.15 Filling valve drainage tank (HOTFILL optional)


The filling valve drainage tank collects the product before the filling cycle during the valve preparation stage, when sufficient product is released to completely fill the valve stem. During this operation, the drainage tank moved forward under the valve to recover any excess product. When the valve is ready, the product is blocked and the drainage tank moves back to its home position.

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Part II

PART II

Matrix Filler User Manual / Safety standards

SAFETY STANDARDS

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Part II

GENERAL SAFETY INFORMATION

Carefully read all the safety instructions and regulations described here. They are designed to prevent injury to persons, damage to property and pollution of the environment. These should become part and parcel of your daily routines when operating and maintaining this equipment. Do not attempt to start the machine until you fully understand how it functions. If you still have any doubts after carefully reading this manual, do not hesitate to contact the Customer Assistance Service at Sidel S.p.A. Ensure that all the personnel operating, cleaning and maintaining the equipment are fully aware of the safety precautions and procedures described in this manual. Before starting the machine, the operator must: -

Read and understand this manual. Be fully aware of the functions and positions of the STOP and the EMERGENCY stop buttons. Inspect the machine and its safety devices for any visible defects. Inform Sidel S.p.A. immediately if the inspection reveals any clear signs of structural or functional faults.

Before you start the machine, warn any persons in the vicinity and advise them to move away from the area.

DO NOT disable, bypass, remove or modify the safety devices on the machine. The manufacturer declines all liability for damage or injury caused by tampering with, bypassing or removing safety devices. During maintenance, adjustment and repair it may be necessary to disable some of these safety devices. This operation must only be performed by authorised and specialist personnel. The number of persons involved in the operations and their qualification is indicated on the relevant maintenance sheets. Safety and warning signage must be kept in perfect condition. Damaged or illegible signage must be substituted immediately. Only use srcinal spare parts when changing faulty or worn parts. Original spare parts are covered by the manufacturer’s warranty. DO NOT implement risky solutions! Before starting the machine remove any extraneous objects left in the machine work area. DO NOT operate the machine in the automatic mode with the fixed or mobile guards removed. DO NOT under any circumstances attempt to work on moving parts. DO NOT attempt to free moving parts which are jammed. DO NOT wear clothing, personal jewellery or other items which might become trapped in moving parts. . A . .p S l e id S ©

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Part II


Keep the floor and platforms around the machine clean, dry and free of obstructions. All technicians must wear the personal protective equipment (PPE) specified in the regulations for the country of installation. Pay the maximum attention to the hazard warning, mandatory or other signage on and around the machine. Do not walk or stand on the cover above the base (where fitted). Walking or standing on the cover could cause breakage of the cover resulting in a falling hazard and serious injury to the operator. Maintenance involving the central carousel must be performed using the special platform. Personnel must use a safety harness (PPE).

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2.2

Part II

NOTES ON USING THE SYSTEM

The machine must only be used for the purposes for which it was designed. These purposes are specified contractually with Sidel S.p.A.

DO NOT USE THE MACHINE FOR PURPOSES OTHER THAN THOSE SPECIFIED IN THIS MANUAL. DO NOT USE THE MACHINE TO PROCESS PRODUCTS OR CONTAINERS WHICH ARE DIFFERENT FROM THOSE SPECIFIED IN THIS MANUAL. DO NOT INCREASE THE SPEED OF THE MACHINE OVER THE LIMIT VALUE SPECIFIED IN THIS MANUAL. Improper use of the machine can cause hazards for machine operators and can damage the machine. For any problems which may occur during the life cycle of the machine and which are not covered in the technical documentation, contact our Customer Assistance Service for a rapid solution to the problem.

The CO 2 pressure must not exceed the maximum permitted operating pressure (refer to the technical specifications) and the pressure must not be set at a higher value. Hazard warning Acid burns The sanitizing products (acids and alkaline lyes) are corrosive. Implement the safety precautions and the handling instructions indicated in the manufacturer’s Safety Data Sheets. The type of products filled, the containers used and the machine performance are specified in detail in section 3 “Technical Data”

THE FOLLOWING ARE STRICTLY FORBIDDEN: -

Modifying the machine cycle. Processing products other than those specified. Substituting machine components. Modifying the speed of components. Using non-srcinal spare parts. Modifying electrical connections in order to bypass safety devices. Removing or modifying guards. Using the machine in explosive or corrosive atmospheres. Using products with alcoholic strength greater than 18%.

Before you make any modification to the machine, you must contact Sidel S.p.A. to obtain the necessary authorisation.

PERMITTED USE The machine can be used to process products and containers of shapes and sizes other than those specified in the manual. In this case the machine requires refitting and reprogramming. These operations must be performed by Sidel S.p.A. technicians or when authorisation has been received from Sidel S.p.A. Failure to do this shall result in Sidel S.p.A. declining all responsibility for any injury or damage caused.

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NON-PERMITTED USE Non-permitted (or improper) uses are defined as all the uses not described in this section.

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Part II

2.3

DEFINITION OF SAFETY TERMS

The following safety terms are used in this manual:

Exposed person: Any person who is partially or totally inside a hazard zone.

Operator: A person authorised to install, operate, adjust, maintain, clean, repair or transport parts of the machine or who is authorised to perform any other activity required to operate the machine.

Safety components: A component specially designed by the manufacturer to perform safety functions; the component may be marketed separately from the machine. A safety component is therefore any mechanism whose failure to operate may endanger the safety of exposed persons.

Hazardous areas: Any areas of the machine where there are potential hazards during standard operating and maintenance operations.

Operator positions: These are the workstations occupied by operators supervising the machine during standard operating cycles.

Supervision: The supervision zones are outside the hazard zone and do not therefore present hazards to the operator. The machine does not require continuous supervision by an operator. In the event of a fault the machine siren will sound calling the operator’s attention to the problem.

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2.4

Part II

SAFETY SIGNAGE

Warning signs regarding operator safety are positioned in clearly visible positions around the machine.

PROHIBITION SIGNS Sign indicating no access for unqualified personnel. This is located on the rear guard doors and on the fixed guards of the base. VAA317

Unqualified personnel are forbidden from accessing areas where this sign is displayed. Sign indicating safety devices must not be removed. This is located on the rear guard doors and on the fixed guards of the base.

VAA327

Operators must not remove safety devices with the machine running and connected to the power supplies when this sign is displayed. Prohibition sign: do not clean, lubricate, repair or adjusting moving parts. This is located on the rear guard doors and on the fixed guards of the base.

VAA328

Operators must not perform maintenance on moving parts but must wait until the machine has stopped before intervening when this sign is displayed.

HAZARD WARNING SIGNS Hazard warning: container fragments. This is located on the front mobile guards.

VAA318

Operators must only approach the machine when all fragments of glass have been removed from the relevant area when this sign is displayed. Wear protective gloves at all times. Burn hazard: located on the product infeed and sanitizer return piping, on the heater, on the foamer nozzles.

VAA314 VAA315

Operators must only approach the machine when all the hot components have cooled sufficiently when this sign is displayed. Wear protective gloves at all times.

Electric shock hazard: positioned on the cableways, junction boxes, inside the electrical cabinet, on the machine cabinet, inside the upper guards. EEQ992

Operators must only approach the machine when it is disconnected from the mains power supply when this sign is displayed. Wear protective gloves at all times.

Do not walk on the cover: located on fillers fitted with covers and on the roof of the base.

Operators must not approach the area in front of the signal when this sign is displayed.

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Part II

Warning sign in various languages indicating circuits which remain powered up even when the main ON-OFF switch is off.

EEQ988/EEQ530/EEQ529

MANDATORY WARNING SIGNS IMPORTANT: Personnel operating the line must wear suitable personal protective equipment (PPE) such as safety eyewear, gloves, overalls and safety footwear with non-slip, non-piercing soles).

Mandatory sign: wear safety eyewear. This is located on the columns of the front mobile guards. VAA316

Operators must wear safety glasses before intervening on the machine when this sign is displayed. Mandatory sign: wear safety gloves. This is located on the columns of the front mobile guards.

VAA312

Operators must wear safety gloves before intervening on the machine when this sign is displayed. Mandatory sign: wear safety footwear. This is located on the columns of the front mobile guards.

VAA311

Operators must wear safety footwear before intervening on the machine when this sign is displayed.

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2.5

Part II

PERSONNEL

Operators are classified as follows:

Generic operator: Non-specialist person who knows how to operate the machine using the controls on the control panel, knows how to load and unload production material, knows how to perform simple operations such as starting and restarting production after a forced interruption.

Maintenance technician (mechanical): Qualified technician who knows how to operate the machine in standard conditions, to perform a size changeover and to adjust, maintain and repair mechanical components. Technicians at this level are not allowed to work on electrical equipment which is powered up.

Maintenance technician (electrical): Qualified technician who knows how to operate the machine in standard conditions and to adjust, maintain and repair electrical components. This technician is also authorised to modify the operating cycle of the machine using the programmer case. This technician is authorised to work inside electrical cabinets and junctions boxes when the machine is powered up.

Sidel S.p.A. technician: Qualified technician provided by Sidel S.p.A. or by an agent of Sidel S.p.A. This technician is authorised to perform complex operations.

External technician: Qualified technician made available by the manufacturer (Siemens, Sew−Eurodrive, etc.) or by the distributor of widely consumed commercially available components authorised to modify, repair and change these components.

QUALIFIED PERSONNEL are all personnel who have attended specialist training courses and have experience with the installation, putting into service and maintenance of the equipment. This personnel must also be fully conversant with the accident prevention regulations. Qualified personnel must also be trained in first aid procedures in the event of an accident.

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2.6

PERSONAL PROTECTIVE EQUIPMENT (PPE)

The employer must provide personnel with information concerning the following safety issues when using the machine: -

Accident hazards. Operator safety devices. Accident prevention regulations stipulated in international directives and legislation in the country where the machine is installed.

Operators must know the layout and function of the controls and the characteristics of the machine before starting work. Operators must read all of this manual and any related manuals.

Operators must: Pay the maximum attention to the hazard warning, mandatory or other signage on and around the machine. Use safety gloves for maintenance operations and when handling tin strip or glass containers. Wear safety footwear, ear protectors and any other PPE in the areas where these are required. Use all the personal protective equipment (PPE) specified in the manuals. Apply safety precautions and ensure that others do so, too. If you have any doubts, read this manual again before continuing. When indicated on machine safety signage or in manuals, personnel must wear the following personal protective equipment (PPE): Mandatory sign: Helmet must be worn

Mandatory sign: Safety gloves must be worn.

Mandatory sign: Safety footwear must be worn.

Mandatory sign: Safety eyewear must be worn.

Mandatory sign: Overalls must be worn.

Mandatory sign: Safety harness must be worn.

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2.7

Part II

OPERATOR SAFETY

The machine is fitted with fixed guards and opening guard doors around the operating area of the machine. These limit access to the machine are are designed to protect the safety of the operator. The machine is also fitted with electro-mechanical safety devices including emergency stop pushbuttons, microswitches and warning lights. These devices stop the machine or prevent it from being started, display a fault message on the control panel and light up the red section (flashing) on the signal light column. To restart, trace and remove the cause of the stoppage and then press the Reset button.

IMPORTANT: Tampering with or removing safety devices is strictly prohibited. The manufacture declines all liability for damage or injury caused by tampering with, bypassing or removing safety devices.

2.7.1

Operator guard and protection devices

Tight Area Protection - ReducedFilling Area:

(Example picture)

Legend:

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Light beacon

Operator area

Front access area

JOG unit

Operator position

Rear access area

Emergency stop button

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Part II Wide Area Protection:

(Example picture)

Legend: Light beacon

Operator area

Front access area

JOG unit

Operator position

Rear access area

Emergency stop button Emergency handle

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2.7.2

Characteristics and operation of safety devices

Safety devices fitted on the machine:

A

Fixed guards

B

COMBI interface protection panel

C

Rear doors

D

Front doors

E

Mushroom-head emergency stop buttons

F

JOG pushbutton panel

G

Emergency handle (if present)

H

JOG production mode selector

I

Main ON-OFF switch

J

Valve position sensors

K

Air ON-OFF valve

L

CO2 ON-OFF valve (only CSD)

M

Tank safety valve (if fitted)

N

ON-OFF valves for chemical solutions

O

Signal light column with siren

P

Eye bolts to secure operator safety harness

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Part II A.

Fixed guards

The machine is fitted with fixed guards to protect the machine areas which do not need to be accessed during operation (guards, grills, etc.).

B.

COMBI interface protection panel

The COMBI interface protection panel is interlocked and separates the machine infeed from the blower outfeed. A different panel must be fitted depending on whether the machine is no production or sanitization:

1

2

1

Panel OPEN - machine in PRODUCTION Only the bottles are allowed to pass by reducing to a minimum the area of contamination with the blower.

2

Panel CLOSED - machine in SANITIZATION The panel is completely closed.

To change the Combi interface panel, under safe conditions access the panel through the blower doors. If necessary temporarily move / remove the guides / starwheels.

IMPORTANT: Do not open the panel during a production cycle or during a sanitizing cycle.

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C.

Part II

Rear doors

Tight Area Protection and Reduced Filling Area These guards are fitted with safety microswitches (1) and have a mechanical lock opened with a safety key (2). The safety key must be managed and kept by the person authorised to manage the equipment. Access to the rear of the machine is for authorised, qualified personnel only. The machine must not be operated in the production mode with the rear guard doors open. In the JOG2 production mode all machine movements will be preceded by an acoustic warning. In the JOG sanitizing mode you may enter through the rear doors to insert the dummy bottles. The acoustic warning will sound. The procedure is as follows: a) b) c) d) e)

Set the machine to the sanitizing mode. Select the operating mode using the mode selector on the operator interface. Check that all the rear doors are closed. Open one of the doors using the key provided. Enter the machine taking the JOG2 button panel and the safety key with you.

1

2

IMPORTANT: Do not open the doors during a production cycle or during a sanitizing cycle. . A . .p S l e id S ©

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Part II Wide Area Protection

These guards have electro-mechanical microswitches with electrical safety locks.

2

7

8

6

4

8

7 2

6 4

1 5 3 (Example picture)

1

Production – Jog selector

5

Safety device reset button

2

Lock – unlock selector

6

Safety device reset buttons

3

Front JOG control socket

7

Production – Jog internal selector

4

Rear JOG control sockets

8

Emergency handle

There are two different procedures to open the doors, as follows:

Access procedure without use of jog control a) Stop the machine. b) Insert the key in one of the Lock - Unlock selectors (2) and turn it to unlock. If the machine is stopped the guards are unlocked (green light ON), thus allowing access inside the machine. Remove the key from the selector and keep it on your person. c)

Open the door using the handle (8) and enter.

When you have finished: d) Make sure nobody is inside the machine, close the guards, insert the key in the Lock - Unlock selector (2) and turn it to lock. This action locks the guards. Remove the gear and keep it on your person. e) Press the safety device reset button (5) and then the machine start button.

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Part II

Access procedure with use of jog control a) Stop the machine. b) Move the Production – Jog selector (1) to jog. c) Remove the jog control panel from the front socket (3) and keep it on your person. d) Insert the key in one of the Lock - Unlock selectors (2) and turn it to unlock. If the machine is stopped the guards are unlocked thus allowing access inside the machine. Remove the key from the selector and keep it on your person. e) Open the door using the handle (8), enter and then close the door. f) Insert the plug of the jog control panel in one of the rear sockets (4) and insert the key removed from the selector (2) in the internal Production – Jog selector (7). Turn the key to Jog. g) Press the safety device reset button (6) and then move the machine forward slowly using the jog control panel.

The operations inside the cabin must be performed by a single person only. If another person enters the cabin when an operator is already inside, the machine is stopped under safe conditions and cannot be started. When you have finished: h) Check that nobody is inside and turn the internal Production – Jog selector (7), previously turned to jog, back to production. i) Remove the key and remove the jog control panel from the socket. j) Exit the cabin and close the guards. k) Insert the key on one of the two selectors (2) and turn the key to lock. This action locks the guards. Remove the key and keep it on your person. l) Turn the Production – Jog selector (1) to production. m) Insert the jog control panel in the front socket (3). Press the safety device reset button (5) and then the machine start button. In the event of power failure, use the emergency handle (8) to exit the chamber (see below).

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Option with wide area protection interlocked keys With the interlocked keys option, proceed as follows to open the doors: a) b) c) d) e)

Stop the machine. Turn the key selector to open on the main control panel. When the machine is stopped, the ON/OFF switch 1 is disabled. This releases a key which must be inserted in the key holder 2. Insertion of this key in the key holder 2 releases two other keys used to open the locks 3 and 4 located on the guard uprights. When the keys, released from the key holder 2, are inserted in the locks 3 and 4, a key is released which the operator must keep on their person during maintenance operations inside the rear chamber.

When you have finished, repeat the operations described above in reverse order. If one of the keys from the locks 3 and 4 is missing then the key, destined for the key holder 1, cannot be released from the key holder 2, and therefore the machine cannot be started.

4

3

1

2 (Example picture)

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D.

Part II

Front doors

These guards have electro-mechanical microswitches with electrical safety locks. To open these doors, proceed as follows: a) b) c)

Stop the machine. Turn the key selector to open on the main control panel. When the machine has stopped, open the door required.

To restart, close the doors, return the key selector switch to the Close position and then start the machine. To enter inside the filler in a safe condition, proceed as follows: a) b)

Open the door. Hold the JOG pushbutton panel with the emergency stop pressed down.

Opening the doors will have the following effect: a) b) c) d)

The The The The

automatic controls will move the filling valves to the home position. brake will be actuated. bottle block will remain in its current position. power supply to the main motor contactor will be powered down by hardware.

In some cases in addition to the keyswitch on the main control panel there is also a keyswitch on the upright close to the outfeed belt.

DO NOT use the machine with the guards disabled.

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Part II E.


Mushroom-head emergency stop buttons

The machine is fitted with mushroom-head emergency stop buttons. The buttons are red on a yellow background. Press one of these buttons to stop the machine immediately by overriding all other operations. These safety devices must be used: -

In the event of an imminent hazard or mechanical accident. When the machine has already been stopped after a brief period of time to ensure the machine remains stopped.

The buttons must be kept pressed in the event of: Maintenance. Operations requiring the presence of the operator inside the hazardous area.

To restart the machine after an emergency stop, press the ALARM RESET button and then the START button. DO NOT USE THE EMERGENCY STOP BUTTON FOR NORMAL OPERATING STOPS.

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F.

Part II

JOG pushbutton panel

In addition to the main control panel on the console, on board the machine there is also a MAINTENANCE PUSHBUTTON PANEL with three connectors for plugging into and selecting the intervention zone. a) b) c)

Front connector, for front access to the base. Rear connector, for access to the rear of the machine (filler carousel). Side connector, reserved for the side accesses of the base.

The pushbutton panel has a JOG button. The intervention zones are selected by using the selector on the main control panel and by plugging the JOG unit into the connector of the zone required. The button panel is mobile and has a coiled connecting cable 1.5 metres long which extends to 4.5 metres.

Joystick pushbutton panel:

Press the button for machine start. Release or fully press the button for machine stop.

Two hands pushbutton panel:

Ø50

10,5 Connector . A . .p S l e id S ©

Press the buttons at the same time for machine start. Release at least one button for machine stop. II - 20

1.1


Part II G.

Emergency handle (if present)

The machine is fitted with an emergency handle located on the rear guard doors. The external handle (silver) can be used to open and close the door. The internal handle (red) can be used to open the door only. The door cannot be closed from the inside. When the door is open, the red handle moves but the door cannot be closed.

-

A

B

A

Handle open position

B

Handle closed position

The emergency handle is used to exit the chamber in the event of accidental closure of the rear doors and during power failures.

H.

JOG-AUTO mode selector

2-way selector: -

JOG pushbutton panel. Automatic operation.

This is a key selector switch which can be locked in either of the positions by simply removing the key. In the interests of safety, the key should be removed from the selector and kept by the person authorised to manage the equipment. This selector is on the control panel.

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I.

Part II

Main ON-OFF switch

The main ON-OFF switch is on the machine electrical cabinet. It can be padlocked. Before you start any maintenance on the machine, switch off and lock out the main ON-OFF switch on the electrical cabinet. Remove the key and keep it on your person. When you have finished maintenance, return the switch to the I (ON) position.

J.

Valve position sensors

These sensors check that the CIP and production automatic valves on the CIP and production piping are in the correct position. Their purpose is to ensure that the flow of product and sanitizer is taking place efficiently.

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Part II K.

Air ON-OFF valve

The air ON-OFF valve switches the supply of air to the machine’s pneumatic circuits ON and OFF. The valve can be padlocked. Before you start any maintenance, switch off and lock out this valve. Remove the key and keep it on your person. When you have finished maintenance, reopen the air ON-OFF valve. To restart the machine, close the guards and hold the RESET button pressed down for approx. 15 to 20 seconds. This will pressurise the air system, reset the pressure switch and reset the ON-OFF solenoid valve.

Padlocked valve

L.

CO2 ON-OFF valve (only CSD)

The CO2 ON-OFF valve switches the supply of carbon dioxide to the machine ON and OFF. Before you start any maintenance, switch off this valve.

ON-OFF valve

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M.

Part II

Tank safety valve (if fitted)

The safety valve on the tank pressure circuit is calibrated to trigger when the circuit pressure reaches the limit value defined in the system design.

IMPORTANT: Carbon dioxide is heavier than air. If the safety valve triggers it will discharge CO2 through the exhaust pipe towards the ground. This does not constitute a hazard to the operator. However, the concentration of CO2 above certain limits in the area around the machine can be harmful to the health of exposed persons. The machine should therefore be installed in wellventilated surroundings where a ventilation system ensures a regular, assisted change of air. IMPORTANT: During normal operation the safety valves do not operate. We recommend that you check the efficiency of these valves at regular intervals and check that the valve is not stuck in its seat. To do this, lift the lever until the valve starts to discharge carbon dioxide.

N.

ON-OFF valves for chemical solutions

The machine is fitted with ON/OFF valves for the chemical solutions used to sanitize the filling circuit.

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Part II O.

Signal light column with siren

The signal light column lights up to indicated various machine operating conditions. The siren sounds to indicate that the machine is starting in a particular condition. During production when the machine is electronically interlocked and stopped with other machines the siren will sound just before restarting.

Red

Yellow

Green

Siren

Green light

Normal start

Flashing yellow light

Bottle block due to external sources

Flashing red light

Stopped under safe conditions

P.

Eye bolts to secure operator safety harness

The eye bolts fitted on the filler carousel column are designed for securing the safety harness worn by mechanical operators during maintenance on the carousel.

Golfare

Golfare

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2.8

HAZARDOUS AREAS

2.8.1

Hazard zones

Part II

Hazard zones are any areas of the machine where there are potential hazards during standard operations. These zones are protected by the guard devices listed in the previous section.

Combi

BlockRinser

Electrical hazard zones Crushing hazard zones High-temperature hazard zones Chemical hazard zones

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Part II

2.9

RESIDUAL RISKS AND H AZARDS

The system has been designed and manufactured to ensure the highest standards of protection for operator health and safety. While every effort has been taken to reduce risks, the following residual risks remain:

a.

Residual crushing hazard:

When an operator enters a hazard zone to perform adjustment or maintenance and another operator attempts to start the machine.

To reduce this hazard: -

b.

Follow the procedure for accessing hazard zones. Keep the access door open throughout the entire operation. After an “Emergency stop pressed” alarm, check that there is no-one inside the hazard zone before restarting the machine.

Residual falling or slipping hazard:

Hazard for the operator during maintenance or repairs at the top of the machine. Exercise extreme caution when accessing these components. Use appropriate PPE and safety equipment in compliance with local health and safety regulations. This hazard increases when working on surfaces which are very slippery, for example during emptying of the crown capper when the operator support surface is wet.

c.

Residual burn hazard due to acid:

During sanitization when corrosive products such as acids and alkaline lyes are used.


Follow general safety guidelines and the specific instructions of the manufacturer when using these products. Avoid contact with the skin and especially the eyes. Wear protective clothing, safety glasses and safety footwear. During the sanitization cycle do not stand near emptying or drainage piping or near to the filling area.

In the event of accidental contact with acid, rinse the area of the body affected using running hot water. In the event of prolonged contact, seek immediate medical assistance at the nearest accident and emergency department making sure you have with you the toxicology sheet for the product.

d.

Residual falling load hazard:

When the operator lifts machine components during transport, handling and maintenance. Exercise extreme caution when performing these operations. Use appropriate PPE and safety equipment in compliance with local health and safety regulations. . A . .p S l e id S ©

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e.

Part II

Residual burn hazard:

When the operator comes into contact with hot machine components during the sanitization process.


f.

Wear protective clothing, safety glasses and safety footwear. During the sanitization cycle do not stand near emptying or drainage piping or near to the filling area. Allow the hot surfaces to cool naturally. This should take approximately 10-30 minutes. Do not cool the surfaces artificially to ensure more rapid intervention as this may cause damage to machinery and injury to personnel.

Residual suffocation hazard:

During production, nitrogen is fed into the tank to create an inert, non-oxidising atmosphere which protects the filling product. The flow of nitrogen saturates the space inside the tank and as a result eliminates any oxygen present.

IMPORTANT: Suffocation hazard. The lack of oxygen inside the tank constitutes a residual risk of suffocation for operators who work inside the tank during maintenance operations. To reduce this hazard: -

Maintenance operations which involve dismantling of the upper manifold of the tank either alone or with other components are to be performed by Sidel specialist personnel only. OTHER PERSONS ARE NOT AUTHORISED FOR THESE OPERATIONS AND MUST NOT PERFORM SUCH OPERATIONS.

g.

Residual flying material hazard.

h.

Hazard for persons with pacemakers:

The optional stirrer fitted to the tank is magnetic. The manufacturer warns that there is a residual risk for the wearers of pacemakers. Wearers of pacemakers must not approach this equipment.


HAZARD WARNING. NO PACEMAKERS. There is a residual risk to wearers of pacemakers. Wearers of pacemakers are forbidden to approach the tank stirrer. Users must read all the machine manuals before proceeding with any operation on the machine.

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Part III

PART III

User Manual / Technical Data

TECHNICAL DATA

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3.1

Part III

DIMENSIONS

The dimensions are shown in the drawing in PART X “APPENDICES”, section 10.1.1 “Layout and connections”.


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Part III

3.2

MACHINE CONFIGURATION

3.2.1

Technical data

Project

SMMM3084

Serial number - WBS

SRMB0119

Description note

Matrix SF300

Machine family

Matrix

Year of manufacture

2013

Bottle type

PET

Filling temperature

Water: Ambient COKE: 18 °C SPRITE: 18 °C RTO: 18 °C

No. of capper heads

24

Capper manufacturer

AROL EURO PK

Line power voltage Line power frequency

400V 50Hz Specifications

Consumption

Flow rate

Bottle design

Production speed (bph)

Bottle volume (lt)

Beverage type

Production (lt/h)

P01QD023-005

36.000

1

COKE

36.000

11034160-01

36.000

1.5

SPRITE

54.000

11034200-01

36.000

1.5

RTO

54.000

11034102-01

36,000

1.5

COKE

54,000

11034161-01

24.000

2

COKE

48.000

11060292-01 11060326-01

44.000 44.000

0.33 0.5

VIVA VIVA

13.200 22.000

11026397-04

36.000

1

VIVA

36.000

X-Z00-11-6928

44.000

0.3

COKE

13.200

11060349-01

44.000

0.5

WILKINS

22.000

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3.3

MACHINE AND ENVIRONMENTAL CHARACTERISTICS

3.3.1

Man - machine interface

Part III

Movement and control system interface

This includes: -

Display unit. Standard controls.

-

Filling valve test pushbutton panel. Removable jog pushbutton panel and two front and rear connection sockets.

Display unit

The display unit is used to run non-critical control operations such as response time, that is to say: -

Operating mode setup (sanitization, jog), etc. Control operations not included in the standard controls for each operating mode. Transmission of parameters to the PLC.

The following are also implemented: -

Summary diagram. Diagnostics.

Standard controls Some standard controls have been included to ensure quick and safe intervention by the operator, for example: Machine stop. Machine start. Bottle block. Etc. Filling valve test pushbutton panel

A specific pushbutton panel is used to check the efficiency of each filling valve (see section 6.1.2). Jog pushbutton panel

Two sockets have been included to connect the jog mobile pushbutton panel to facilitate machine setup and maintenance.


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Part III 3.3.2

Ambient installation conditions

Airing the room

The machine must be installed in a working environment with suitable fresh air circulation. Ambient temperature

The machine should be installed in a room within the following temperature limits to ensure good operation and safety: --

Storage temperature: −10 °C to +1060°C°C. Ambient operating temperature: to 45 °C. Electric power cabinet temperature: < 45 °C.

Vibrations

The machine is designed and manufactured in compliance with current directives and the permitted level of vibrations.

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3.4

PERFORMANCE LEVELS

3.4.1

Speed variations

The machine has three operating modes: -

Production Jog control Sanitization or rinsing

The speeds which can be selected are as follows: -

production mode Speed = 4000 − up to max. b/h value jog mode Speed = 4000 − 6000 b/h sanitization mode Speed = 4000 − 8000 b/h


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Part III

Matrix Filler


Part III

3.5

POWER AND CONSUMPTION

3.5.1

Installed voltage and power

See PART X “APPENDICES”, section 10.1.1 “Layout and connections”

3.5.2

Tanks

External static tank (if fitted)

Maximum pressure (PS)

7 bar

Volume (V)

1030 litres

Maximum temperature (TS)

+95 °C

Minimum temperature

-10 °C 1 (Sanitizing) – IN SANITIZATION 2 (beverage, CO2) – IN PRODUCTION

Fluid unit fitted

Manifold tank:

Maximum pressure (PS)

3 bar

Volume (V)

146 litres

Maximum temperature (TS)

+95 °C

Minimum temperature

-10 °C 1 (Sanitizing) – IN SANITIZATION 2 (beverage, CO2) – IN PRODUCTION

Fluid unit fitted

3.5.3

Piping

Refer to the relevant parts lists for the dimensions of the following pipes: -

3.5.4

Product feed pipe. Product manifold. Product infeed pipe. CO2 infeed / outfeed pipe. Sanitizer infeed pipe. Sanitizer return pipe.

Pressurised tank safety valves (if fitted)

Calibration pressure

7 bar

Type of fluid

Gas

Minimum discharge flow rate

1000 m³/h

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3.6

WEIGHTS

Base

See PART X “APPENDICES”, section 10.1.1 “Layout and connections”

Filler carousel

“

SKID + Electrical cabinet

“

Rinser carousel*

“

* If fitted


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Part III

3.7

NOISE LEVELS

The machine is fitted with special devices for limiting the noise emitted at source. The noise level of the machine, as well as depending on the movement of moving parts, also depends on the working environment where the machine is installed and the type of filling containers used on the system. The noise levels measured in the operator position are as follows: -

Mean continuous acoustic pressure level A1 LAeq = 72 dB(A). Maximum mean instantaneous acoustic pressure value C1 Lpc < 80 dB(C).

The measurement conditions were as follows: Product dimensions: -

length width height

20 m 10 m 8m

Installation environment: -

floors covers walls

Coefficient for environments:

smooth concrete tiles with side glass panels the

type

of

Ô = 0.15 (environments with lots of installations and smooth walls)

Meter used:

Bruel & Kjaer mod. 2221 Class 1.

Reference standards:

DIN 45635

IMPORTANT: If the machine is installed in a reverberating environment or in the presence of other sources of noise and the level of daily exposure is greater than 87db(A), there is a potential hazard and employers must supply PPE (ear muffs, ear plugs) to personnel to protect their hearing.

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1.1

Part III

Matrix Filler

User Manual / Installation

Part IV

PART IV

INSTALLATION

1.1

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4.1

PACKAGING AND SHIPPING

4.1.1

Type of packaging

Part IV

Given their large size, Sidel machines are shipped dismantled. Given the modes of transport used for shipping, SIDEL has designated three levels of packaging to ensure optimum protection of the various machine components for the entire duration of shipping.

Level 1: Light protection suitable for road transport. Usually a casing to protect against flying objects. Level 2: Protection suitable for shipping at sea. This is a sealed cover with an air pocket to protect all

components at risk of corrosion. All components outside of the profile are shipped inside wooden crates. Level 3: Reinforced protection suitable for combined shipping at sea and by road with multiple handovers.

All components are packed in wooden crates and protected inside the crates by a sealed cover with an air pocket. Further details concerning these types of packaging are available from SIDEL on request.

4.1.2

Incoterm® requirement

The Incoterm defines the risks associated with shipping. The Incoterm is specified in the machine sales contract. Whatever the Incoterm, customers must inform hauliers of any visible issues with the crates when they are unloaded on their premises. Management of damage in relation to insurance policies is the responsibility of either the customer or SIDEL depending on the Incoterm.

4.1.3

Moving the packed machinery

IMPORTANT: Unless otherwise stated in the sales contract, customers are responsible for unloading the machinery.

Standard pictograms are attached to the crates and packages. The pictograms give instructions concerning how to handle the crates and packages.


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Part IV 4.1.4

Receiving the material

IMPORTANT: When the material is unloaded the customer must thoroughly check all the crates and packages and inform the haulier of any doubts concerning degradation of the crates or packages.

Photographic evidence is useful to document the state in which the materials were received. Degraded packaging must be kept for inspection by personnel from Sidel or the insurer.

4.1.5

List of components

A packing list is included with the delivery documents. See example (A). This packing list indicates the main components contained in each crate.

A detailed list of each crate / pallet is included in the installation dossier in the possession of the site manager.

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4.1.6

Part IV

Storage conditions for packed machinery

As soon as the crates are unloaded, all machinery must be stored in a closed, clean and dry room protected against freezing temperatures until the SIDEL site manager arrives. The floor of the building must be strong enough to withstand the weight of the entire machine inside the crate and allow movement of equipment used to move the machinery. IMPORTANT: SIDEL accepts no responsibility in the event of failure to comply with these storage requirements.

IMPORTANT: Do not cover the machine with waterproof sheets as this prevents water evaporation. IMPORTANT: Do not expose the machine to sunlight.


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Part IV

4.2

FOUNDATIONS

The machine does not require special foundations. You should check that the foundations provided can bear the load of the machine. IMPORTANT: The machine must be positioned on a floor surface with the load bearing capacity specified by the machine manufacturer and given in section 3.

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4.3

MOVEMENT AND POSITIONING

4.3.1

Delivery to the customer's premises

Part IV

The facility receiving the equipment must have already prepared the following: -

The installation space. Equipment for unloading and positioning the equipment (crane, fork-lift trucks, transpallets).

Receipt, unloading and handling of the machine must be supervised by the manager authorised. The manager is responsible for supervising unloading and checking that the material delivered matches that on the delivery/shipping note. The manager must check for missing or damaged parts. IMPORTANT: Check that the slings, fork-lift trucks and handling equipment have an appropriate load bearing capacity. IMPORTANT: The lifting equipment supplied with the machine (chains, slings, lifting bars and arms) must be used for handling this machine. The lifting equipment is provided solely for handling the machine with which it is supplied and described in this manual. All other uses including use on similar machines is strictly prohibited and constitutes improper use. SIDEL declines all responsibility for improper use and failure to comply with this instruction.

4.3.2

Tooling supplied with the machine.

The machine is delivered together with a series of tools required for movement and assembly. The list of tools is as follows: 1. 2. 3. 4. 5. 6.

4.3.3

Complete set of Allen keys. Set of spanners from 7 to 22. Plate spanner. Special wrench (to be used for the expansion pulleys). Grease gun. Pin punch.

Unpacking and hoisting

The following instructions should be followed carefully to ensure safe movement of the machine: 1.

Move the unpacked machine as close as possible to the installation area then unpack the machine

2.

making the contents of the crates and packages matchand thataccessories. specified on the delivery document. Removesure the cover and then all the dismantled components Free very carefully all the material used to package the machine. Separate the base of the machine from the machine surface by removing, if present, the wooden side securing plugs or securing screws inserted under the support surface. Lift the components using the eye bolts, where fitted, or the points indicating where the eye bolts should be secured. Attach the cables securely to the eye bolts and the hook of the crane or overhead crane. Units not fitted with eye bolts or on which eye bolts cannot be secured must be lifted using straps positioned so that the weight is balanced.

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Part IV 5.

When lifting the machine using a forklift truck with flat forks, make sure the forks are at least as long as the machine.

IMPORTANT: When lifting the machine take up the slack on the straps slowly and make sure that components unable to withstand the weight of the unit, such as electrical parts, conduits, rollers, etc., are not affected by the lifting process. IMPORTANT: The customer is responsible for disposing of packaging material in compliance with legislation in the country where the machine is installed. Check that the slings, fork-lift trucks and handling equipment have an appropriate load bearing capacity.

The machine is fitted with eye bolts and anchoring points to facilitate movement operations.

The nominal load bearing capacity of a forklift truck is not the same as the actual capacity which varies in accordance with height at which the operation is performed and the barycentre of the load relative to the spine of the forks. a)

Crate: take hold of the crate in the positions indicated using the chain pictogram and keep it in the

b)

position indicated by the pictograms. Machine: Lifting must be done with care to prevent damage to the machine caused by the forklift truck clamps, straps or lifting hooks of the crane.

4.3.4

Removal of scrap material

If the customer has requested special protective greases for the machine then the customer is responsible for removing them before assembly.

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4.3.5

Part IV

Moving and positioning the machine

Move and position the machine in the following order: 1st blower 2nd transfer table 3rd filling carousel and crown capper

The machine, consisting of the filler, bases and the Skid (if present), must be moved and positioned as follows:

The filler block with(yellow). holes to which the lifting equipment must is befitted secured The hooks of the chain must be secured to the special eye bolts (see photo) so that the filling carousel is balanced.

The bases are fitted with holes to which the lifting equipment must be secured (yellow). The hooks of the chain must be secured to the special eye bolts (see photo) so that the base is balanced.


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Part IV


Before positioning, make sure the plates used for shipping are free from the base of the shipping crate.

Position the machine feet securing plates in compliance with the system layout drawing. The plates must be bolted to the floor when the correct position has been identified.

Position the machine in compliance with the system layout drawing making sure the feet are resting on the plates bolted to the floor earlier.

Adjust the feet support bar to level the machine with the floor and the line.

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Part IV


Place a spirit level on the special supports to check the level. This should be done on all the machine supports.

After positioning and levelling of the machine, remove the plates used to move the machine (A) by unscrewing the bolts (B).

A

A

B

Start the machine and wait for it to stabilise. IMPORTANT: Do not start the machine if it is not perfectly level.

When stabilisation is complete, weld the feet of the machine to the plates bolted to the floor in compliance with the layout shown alongside (see PART X “APPENDICES”, section 10.1.2 “Moving the machine”).

4.3.6

Hook positioning table

IMPORTANT: The machine must be positioned by securing the special lifting equipment to the attachment points of the frames (fitted with eye bolts) indicated in the table shown in PART X “APPENDICES”, section 10.1.2 “Moving the machine”.


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Part IV

4.4

CONNECTIONS AND CABLING

Connections and cabling for the electric, hydraulic and compressed air systems must be able to withstand the maximum machine absorption values, as indicated in the technical data table (section 3.2.1). IMPORTANT: Only QUALIFIED personnel are permitted to perform the activities described in this section.

4.4.1

Electrical connection (responsibility of the manufacturer)

The electrical connection is made in compliance with general regulations for installing, preparing and putting into service industrial electrical systems.

4.4.2

Compressed air connection (responsibility of the customer)

The machine must be supplied with dry air which is not lubricated. Damp air and air with lubricating fluid cause the pneumatic parts to stop operating immediately and usually these parts are blocked as well.

4.4.3

Earthing system

The metal structures of the machine are earthed using insulated conductors connected to the earth bar of the electrical cabinet (supplied by the manufacturer). The earthing system and the connection of the main earth terminal in the electrical cabinet with the earth bar of the distribution panel must be implemented in compliance with the general regulations for industrial electrical systems.

4.4.4

Connection for liquid waste disposal

IMPORTANT: Liquid waste may contain substances which are not very biodegradable or even harmful for the environment. This waste must be purified before disposal.

In the event of disposal into sewer systems or surface water (rivers, lakes sea), authorisation may be required in compliance with current legislation concerning environmental protection in the country of use. If drain points are connected to tanks then this waste must be treated as liquid waste by following the procedures described in section 4.7 “Decommissioning and Disposal” in this manual and in compliance with current legislation concerning environmental protection in the country of use.

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4.4.5

Part IV

Connection for disposal of fumes

IMPORTANT: All fumes should be conveyed outside the working area or the fumes should be purified before being recycled into the working area to protect the health and safety of the workforce.

If fumes are conveyed outside the working area, authorisation may be required in compliance with current legislation concerning environmental protection in the country of use.

4.4.6

Accidental spillage of substances harmful to the environment

Substances harmful to the environment cannot be released from the machinery during normal operation because the machinery is designed to store processing liquids internally. Leaks can be classified as accidental events. Hazardous substances include: -

Oils and greases. Sanitizing products.

OILS AND GREASES IMPORTANT: During maintenance check the devises used to close the lubrication circuits are fitted, tightened correctly and that they do not leak. Check there are no leaks or spillages around seals. In the event of spillages the lubricant must be collected and disposed of in compliance with current legislation in the country of use. Clean any parts affected by the spillage.

SANITIZING PRODUCTS IMPORTANT: Accidental leaks of sanitizing liquid can occur throughout the circuits used to convey the filling product and the gas used for filling. Leaks from the circuits can occur around couplings and in all those areas where seals or gaskets are fitted. If the liquid which has leaked risks being conveyed towards systems used for disposal into sewer systems or surface water, authorisation may be required in compliance with current legislation concerning environmental protection in the country of use. Alternatively the user must install collection and conveying systems in the areas at risk so any spillages can be treated as liquid waste, by following the procedures described in section 4.7 “Decommissioning and Disposal” in this manual and in compliance with current legislation concerning environmental protection in the country of use.


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Part IV

4.5

SETTING UP AND FIRST STARTUP Carefully read all the manuals before you proceed with the operations described below.

The operations described below must only be performed by a SIDEL technician or under the supervision of this technician.

4.5.1

Pre-startup settings

The machine must only be started by appropriately qualified personnel working in compliance with all the safety regulations.

The machine has been designed and constructed to operate with the power sources and ratings specified. If the user modifies the machine or changes the power source or rating this could damage the machine.

List of components and units to be adjusted

Machine in order of operation: -

Customisation for the production installed.

--

Guard installed. All the covers operating and workstation safety devices. Visually inspect the machine for faults. Before startup, check that all components are synchronised as specified.

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4.5.2

Part IV

Pre-startup checks

The tests and checks must be performed by suitably qualified and trained personnel working in accordance with the procedures of the country where the machine is installed. Electrical and safety checks

Before you start the machine for the first time, proceed as follows: -

-

Check that all the guards and guard doors are fitted to the machine. Check that the main ON-OFF switches are ON. Check that the power supply line to these switches is ON. Check that the rating of the power supply line to the machine matches the SIDEL S.p.A. specifications. Check that all the safety equipment (fuse holders, overload switches) are efficient and ready to operate. Power up all the service units to the machine. Switch on the main ON-OFF switches on the electrical cabinets. Using a voltmeter, test that power is arriving at the terminals of the safety devices (overload switches, fuses). Follow the instructions in the electrical part of the manual. Close the safety devices again, one by one. Check the efficiency of the emergency stops. Check that when an emergency stop is pressed that this shuts down the electrical and pneumatic power supplies and stops the machine immediately. Check the efficiency of the electrical safety devices by checking that the appropriate LED lights up.

Mechanical checks

Connect up the circuits for compressed air, cleaning products, products, steam, water, nitrogen and valve opening and then proceed as follows: -

Check the pneumatic connectors and connections. Check for leaks. Check the liquid connectors and connections. Check for leaks. Check the steam connectors and connections. Check for leaks. Check the product circuit connectors and connections. Check for leaks. Check that all mechanical components are positioned correctly and firmly secured. Check that there are no extraneous objects or obstructions inside the machine.

Checking the supply lines Electrical power supply: Check that the rating of the power supply line to the machine matches the SIDEL S.p.A. specifications. Compressed air supply: Open the valves of the compressed air system. Check that the pressure is as

specified. Cleaning and sanitizing products: Open the supply valve for the cleaning products. Product: Open the product supply valve. Steam: Open the steam supply valve. Check that the steam temperature and pressure are as specified. Water: Open the water supply valve. Check that the water pressure is as specified. During these checks, wear a face mask/visor, safety footwear, overalls, safety gloves and a helmet. Check that there are no leaks of substances which might harm the environment. Repair any leaks immediately.


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Matrix Filler


Part IV 4.5.3

Cleaning and general inspection

Do not use high-pressure water jets to wash the machine. Water under high pressure will damage electrical equipment. Before you use the machine, check that it has been sanitized and cleaned. Sanitize the machine and clean the machine completely. This will ensure compliance with standard hygiene regulations.

If you are using chemical substances, check the Safety Data Sheets provided by the manufacturer to identify any safety and environmental hazards for the chemical used. Safety Data Sheets indicate the following: -

Hazards. Personal protective equipment and general protections required. First aid instructions. 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 and handling information.

The use of Safety Data Sheets translated into the language of the country of use is recommended.

Main operations

-

Fill the soap and disinfectant dispensers. Fill the mask, paper and glove dispensers. Empty and disinfect the waste baskets in the production area. Remove all extraneous or unused objects from the production area. Thoroughly clean the platform. Fill the manual spray jets.

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Matrix Filler


4.5.4

Part IV

General cleaning

The machine must be cleaned immediately after the end of production. The purpose of cleaning is to prevent the risk of contamination and to remove all product residues from the machine. Daily cleaning is not related to production cycles. General cleaning consists of implementing the standard hygiene procedures and includes the following: -

Supply a sufficient amount of overalls, masks and gloves in the changing rooms. Keep the work area clean. Remove any dropped containers. Soiled paper or rags must be disposed of in accordance with waste disposal regulations in the country where the machine is installed.

4.5.5

Cleaning products and equipment

Only use appropriate equipment to clean the areas inside the machine. Change damaged cleaning equipment.

4.5.6

Safety warning

During all cleaning operations wear gloves, a mask and overalls. Check that there are no leaks of substances which might harm the environment. Repair any leaks immediately.


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Part IV 4.5.7

First startup

Check that you have sufficient caps, capsules and bottles to complete the production cycle which is about to be started. The first startup procedure must be performed before the machine is put into service. The first startup procedure must also be performed if the machine has been out of service for a long period.

4.5.8

Sanitizing the system

After installation run a sanitizing cycle on the machine to remove any machining waste, swarf, dirt and other contaminants. (For instructions, see the CIP and COP sanitizing sections).

4.5.9

Setting up and first startup

In order to prevent errors and accidents, the machine is connected up to the customer’s electrical, water and compressed air supplies by SIDEL S.p.A specialist technicians. Only SIDEL S.p.A. personnel are authorised to perform the activities described in this section. Check that all connecting components (couplings, solenoid valves, pumps and piping) are tightened as per specifications. We recommend that you perform a complete cycle using water so as to show up any leaks.

Perform the pre-first start up checks and check for any damage resulting from shipping, handling and positioning. When you have completed installation, check the machine timing. Check that all safety devices are correctly fitted and are fully efficient. Check that there are no leaks of substances which might harm the environment. Repair any leaks immediately.

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4.6

Part IV

RE-INSTALLATION IMPORTANT: The dismantling, reassembly and re-installation of the machine as described in this section must only be performed by the following qualified personnel: -

SIDEL S.p.A. technicians assisted by local personnel. Skilled technician who has attended specialist training courses and has experience with the installation, putting into service and maintenance of the equipment. This person must also be fully conversant with the accident prevention regulations.

Refer to that stated in the first section for details of the procedure used to request the technical assistance of Sidel S.p.A. personnel. The machine will require dismantling if it is sold, installed in a new position or stored in the customer’s premises. The general dismantling procedure is as follows: a) b) c) d) e)

f) g) h)

Decide how the machine is to be broken down into its component parts. This decision depends on the size of the transport vehicle(s) to be used and the number of component parts. Position moving parts in the most favourable position for shipping. Number the joins of all the parts to be separated. This will make reassembly quicker and easier. Disconnect the electrical and compressed air supplies to the machine. Disconnect all the electrical cables as follows: - Disconnect the cables in the electrical cabinet. - Pull these cables out of the cableways up to the unit to which they are connected. Disassemble the machine into the component parts decided previously. Any parts which might move or slide during transport must be mechanically clamped, fixed or tied down. On gear motors where there is a likelihood of oil leaks during transport, substitute the vented caps with caps without vent holes. IMPORTANT: See section 4.7 “Decommissioning and Disposal” for details of how to manage waste.

For instructions on positioning and connecting up the machine in its new position, see the related section of this manual.


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Part IV

4.7

DECOMMISSIONING AND DISPOSAL

The activities described in this section must only be performed by the following qualified personnel: -

SIDEL S.p.A. technicians assisted by local personnel. Skilled technician who has attended specialist training courses and has experience with the

installation, putting into service and maintenance of the equipment. This person must also be fully conversant with the accident prevention regulations.

4.7.1

Disposal of packaging

Packaging complies with standards or current applicable legislation. Customers are advised that they are under an obligation to dispose of packing materials in accordance with local waste disposal regulations. See this section entitled DECOMMISSIONING AND DISPOSAL.

In order to reduce environmental impact, packing should wherever possible be re-used, recycled or sent for energy recovery treatment. Disposing of packing waste in other ways should be considered as a last resort and should be reserved for materials that cannot be recycled or treated. RE-USE OF PACKING

Some packing items such as wooden pallets and filling can be re-used for their srcinal purpose. This lengthens the life cycle of these items, reduces the amount of raw materials used for packing and reduces the amount of packing waste. SEPARATE WASTE COLLECTION. RECYCLING

Separating packing waste enables a vast range of waste materials to be reused ensuring significant economic and environmental advantages. -

Plastic packing

Plastic components can be recycled to produce new resources in the sector of srcin or to produce heat and energy through incineration. This ensures that at the end of their lifecycle, these components do not become a burden on the environment as a result of disposal at a landfill site. Polyethylene (PE), polypropylene (PP), polyethylene terephthalate (PET), polyvinyl chloride (PVC) are some examples of recyclable polymers. -

Paper, card and cardboard packing

Packing made from paper, card and cardboard can be reused in the papermaking industry. The conventional papermaking process requires the felling of trees, large amounts of energy, large amounts of water (which is returned polluted to the environment), various chemical substances and the use of machinery and vehicles which are also a source of pollution. Recycling paper reduces all this, reduces waste requiring disposal and reduces the work of purification plant. -

Wooden packing

Wooden packing waste can be reused for: the production of wood composites (widely used in the furniture industry); the production of cellulose pulp for the papermaking industry; the production of composts following incineration in heat and electrical energy generation plant.

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4.7.2

Part IV

Dismantling and removing the machine

The machine will require dismantling if it is sold, installed in a new position or stored in the customer’s premises. The general dismantling procedure is as follows: -

Decide how the machine is to be broken down into its component parts. This decision depends on the size of the transport vehicle(s) to be used and the number of component parts. Position moving parts in the most favourable position for shipping. Number the joins of all the parts to be separated. This will make reassembly quicker and easier. Disconnect the electrical and compressed air supplies to the machine. Disconnect all the electrical cables as follows: Disconnect the cables in the electrical cabinet. Pull these cables out of the cableways up to the unit to which they are connected. Disassemble the machine into the component parts decided previously. Any parts which might move or slide during transport must be mechanically clamped, fixed or tied down. On gear motors where there is a likelihood of oil leaks during transport, substitute the vented caps with caps without vent holes.

For instructions on positioning and connecting up the machine in its new position, see the related section of this manual. The dismantling, reassembly and re-installation of the machine as described in this section must only be performed by the following qualified personnel: -

SIDEL S.p.A. technicians assisted by local personnel. Skilled technician who has attended specialist training courses and has experience with the installation, putting into service and maintenance of the equipment. This person must also be fully conversant with the accident prevention regulations.


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Part IV 4.7.3

Disposal of the machine

Only skilled, qualified personnel are authorised to dismantle this machine. These persons must comply with all the applicable health and safety regulations. At the end of the machine life cycle the plant user must decommission and dispose of the machine in accordance with current regulations. Decommissioning primarily involves emptying lubricants from the machine, complete general cleaning of the machine and then breaking the machine down into its component parts. Once the machine has been dismantled according to the procedure described above, the plant user must separate the component materials by type in compliance with the regulations of the country where disposal is to take place. The machine does not contain hazardous substances or components requiring special dismantling procedures.

MATERIALS COMPRISING THE MACHINE

The materials comprising the machine are not hazardous and are as follows: -

Stainless steel 300 and 400 series. Polyethylene plastic, loaded and not loaded. Adiprene plastic. Elastomers. Gearbox oil. Gear motor oil. Electric motors. Electric cables with sheathing. Electronic control and actuating devices. Support feet and rubber based materials.

During disposal, implement the local waste disposal and recycling regulations. Store polluting materials such as oils and solvents in metal containers.

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Part IV

CONSUMABLES

Consumables must be disposed of as follows: Sanitizing products

Do not discharge sanitizing products into the public drainage system. For information about local disposal regulations, contact your local health authority or factory inspectorate. If you are using chemical substances, check the Safety Data Sheets provided by the manufacturer to identify any safety and environmental hazards for the chemical used. Safety Data Sheets indicate the following: -

Hazards. Personal protective equipment and general protections required. First aid instructions. 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 and handling information.

The use of Safety Data Sheets translated into the language of the country of use is recommended. Batteries

The PLC battery must be substituted by a maintenance electrician. Used batteries must be separated from ordinary waste and delivered to an authorised disposal centre. Reject bottles and caps

Reject bottles and caps must be treated according to their type and classification and in compliance with local waste disposal regulations. Product remaining

Some products must not be discharged into the public drainage system. For disposal instructions about filling products, contact your local health authority and read the safety data sheets for each product.


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Part IV


Reduction gear oil Dispose of old oil, oily residues and objects soaked with oil in compliance with local waste disposal regulations.

Dispose of dirty, oily or greasy paper and cleaning rags in accordance with local waste disposal regulations. In the case of lubricating oils, check the Safety Data Sheets provided by the manufacturer to identify any safety and environmental hazards for the lubricants used. Safety Data Sheets indicate the following: Hazards. Personal protective equipment and general protections required. First aid instructions. 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 and handling information. The use of Safety Data Sheets translated into the language of the country of use is recommended.

Waste products from the pneumatic system

Condensate discharged by the system may contain oil and must not be disposed of in the environment. It must be collected and treated in compliance with the environmental protection legislation and standards of the country where the machine is used.

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Part IV

SEPARATE WASTE COLLECTION. RECYCLING

The machine is designed using materials which can be easily recycled and used as materials for other production processes. Separating waste enables a vast range of waste materials to be reused ensuring significant economic and environmental advantages. Plastics

Plastic components can be recycled to produce new resources in the sector of srcin or to produce heat and energy through incineration. This ensures that at the end of their lifecycle, these components do not become a burden on the environment as a result of disposal at a landfill site. This material should be sorted and separated by type in order to facilitate efficient recycling. Iron and steel

Scrap iron and steel can be sent to steelworks and foundries for use in the production of other metal products. Once again, this material should be sorted and separated by type in order to facilitate efficient recycling. The machine consists almost entirely of stainless steel (non ferromagnetic). Painted components are made from ferromagnetic steel. Gears and gear motor bodies are made from cast iron. Brass parts are easy to identify by their characteristic yellow colour.

PROCEDURE FOR DISMANTLING THE MACHINE

Before you start to decommission the machine, you should check local regulations regarding the following: -

Compulsory notification and registration with control authorities. Environmental protection regulations. Waste and scrap disposal regulations. Health and safety in the workplace regulations.

To dismantle the machine, proceed as follows: 1) 2) 3) 4) 5) 6)

Disconnect the machine from the electrical, water and compressed air supply networks. Empty the lubricant tanks. To do this, remove the drain plugs and collect the lubricant in a suitable container. Do not mix different or incompatible types. Dismantle the units containing grease (racks, couplings, controls). Clean these units. Empty washing agents from the system. Collect the washing agents in a suitable container. Do not mix different or incompatible types. Proceed with dismantling of the machine. Sort and separate the various components by type as indicated in the section “Separate waste collection. Recycling”. Store and dispose of waste and recyclable material as indicated in this section and in compliance with local regulations.


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Matrix Filler

Part IV


WASTE MANAGEMENT

General instructions about waste management

Identify and classify waste in accordance with the current regulations in the country where the machine is used. Do not dump waste in the environment. Waste must be collected, separated and disposed of in a systematic, controlled manner. Do not discharge waste liquids into surface or underground water. Do not mix types of waste. Deliver waste to accredited local agencies authorised to collect, transport and treat wastes. Prepare the administrative documentation required by local regulations (production, storage and disposal registers, transport documents). Complete any administrative procedures required (keeping registers, preparing documentation). General instructions for collecting and storing waste

1)

2)

3)

4)

5)

6)

Waste must be sorted and separated by homogeneous types. Waste must be collected and stored by homogeneous type because this is the only way of: Preventing the risk of chemical-physical incompatibility between waste products. Ensuring correct final treatment and enabling the most efficient, least hazardous recycling method. It is important therefore not to mix types of waste. Appropriate containers should be used for handling and stocking waste. Waste containers must be resistant to the chemical-physical properties of the substances they contain and must be appropriate to the hazards posed by those substances. (Example: Acid substances must be kept in plastic containers or in suitably treated metal containers). Container labelling. During storage inside the company, containers must be marked with labels or plates enabling rapid identification of the waste type and related hazards. The labels can be on the containers themselves or in the storage areas. The waste containers must be marked with details of the type of waste they contain and the related health, safety and environmental hazards. Handling waste inside the company. During handling, ensure that the containers are completely closed. When moving containers, avoid routes with drains and gulleys. This precaution is to prevent waste from entering the public and rainwater drainage systems in the event of an accidental spillage. You should provide suitable material and equipment in the handling area for absorbing waste in the event of an accidental spillage. Storing liquid waste (oil, acid). In order to prevent spillage, containers holding liquids should be stored inside container basins. The minimum capacity of these basins must be as great as the largest container to be held in the basin. Liquid containers must have closures designed to prevent leakage. Containers must be fitted with lifting systems enabling safe and easy handling. Containers must be fitted with overflow prevention systems. (If the overflow prevention system includes an overflow pipe, ensure that the overflow is channelled in such a way that it does not constitute a health, safety or environmental hazard). Storing solid waste in heaps. In order to prevent soil pollution, bulk waste stored in heaps must be stored on a resistant base such as a paved flooring. Do not heap bulk waste on unprotected ground surfaces. 1.1

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-

7)

8)

Bulk waste stored in heaps must be protected from the action of rainwater. Rainwater washout from the heap can pollute ground water. Storing incompatible wastes (e.g. acids and bases). Wastes which are incompatible with each other must be stored so there is no possibility of contact between them. Contact between incompatible wastes can cause hazardous reactions, fire and toxic emissions and generate large amounts of heat. Handling empty drums which previously contained hazardous waste. Drums which previously contained hazardous waste may be used to contain the same type of waste. In all other cases these drums must be decontaminated. It is important therefore that drums are marked with details of the substances they contain or contained (if empty).


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Part IV

1.1

Matrix Filler User Manual / Operation

Part V

PART V

OPERATION

1.1

V-1

Matrix filler User Manual / Operation

5.1

PERMITTED USE. IMPROPER USE. ENERGY REDUCTION

5.1.1

Design use

Part V

The filling machine is designed and manufactured to fill and cap bottles at high speed. Uses other than the one for which the machine is explicitly designed and described in this manual are not permitted. The manufacturer denies all responsibility in the event of incorrect machine use.

5.1.2

Operational criteria to reduce consumption

WATER Optimum water consumption is achieved by complying with the following prescriptions: -

Washing cycles should be brief and frequent. Do not adjust the settings made after startup. Routinely check the circuits for leaks.

-

Use cold water for recycling in the liquid loop of the vacuum pump (if fitted). Dispose of waste washing water in compliance with legislation in the country of installation.

POWER Optimum power consumption is ensured by routinely checking power absorption during normal machine operation using the inverter interface fitted in the electrical cabinet. Increases in the consumption of absorbed power indicate a fault or wear. In this case: -

Check components are lubricated correctly. Check the racks and the structures of the carousel and capper for wear.

-

Make sure the control gears under the base are clean. Make sure there are no leaks of oil from the reduction gears.

-

Check the teeth of the gears under the base for wear.

INERT GASES Optimum filling gas consumption is achieved by complying with the following prescriptions: -

Avoid frequent machine stops and restarts. Normal machine operation should be as constant as possible. Use the machine at the maximum nominal operating capacities.

-

Use pure gas (≥ 99.9%). Do not use filling pressures greater than the ones required to ensure the correct balance of the

-

product. Check the condition of the containers before filling. Broken containers result in greater consumption.

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V-2

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Part V

5.2

PRODUCTION LIMITS IMPORTANT: The machine must be used in compliance with the limits relating to strokes, dimensions, supported loads, materials and productivity specified in this manual.

Equipment must comply with that indicated in section 3 of this document and in Volume II − Spare Parts Catalogue. The equipment indicated is specifically designed by the manufacturer for the machine. The manufacturer denies all responsibility for failure to comply with these safety instructions.

5.2.1

Instructions in the event of a fire

In the event of a fire involving the electrical cabinet, the equipment or parts of the cabling on board the machine, proceed as follows: -

Switch off the electrical power supply upstream from the electrical cabinet. Fight the fire with a suitable extinguisher (powder, CO and other gases).

IMPORTANT: Do not use water. IMPORTANT: Plant users must install their pressurised systems in surroundings where there is no risk of fire. This is because pressurised systems which have been in contact with fire cannot be used again.

1.1

V-3


5.3

OPERATING DESCRIPTION

5.3.1

Filling processes

Part V

The bottle filling process consists of the four steps: 1.

Infeed of empty bottles

COMBI Filler The empty bottles coming from the blower are conveyed, hung by their necks, to the filler infeed starwheel.

BLOCKRINSER Filler The empty bottles arrive from the rinser on an air conveyor and are fed to a starwheel which spaces them apart. The spacing is exactly the same as the centre-to-centre distance of the rinser grippers and the filling valves of the filler. The bottles are centred under the pickup grippers by a starwheel and a guide which holds the bottles by the neck.

A lever arm sliding on a twist turns the bottles over onto the spraying nozzles.

The rinsing cycle starts with spraying followed by dripping. Next, the twist returns the bottles to their srcinal upright position. The bottles leave the rinser and are conveyed hung by their necks to the filler infeed starwheel. . A . .p S l e id S ©

A. B.

V-4

Spraying Dripping

1.1

A

B

Part V 2.


Filling

The filler infeed starwheel positions the empty bottles on the forks of the filling valves. The filling cycle begins.

3.

Capping

The filled bottles are now transferred to the capper and aligned with the capper heads. After capping, the bottles, assisted by a guide, are transferred to the starwheel and from here to the outfeed belt.

4.

Outfeed of filled, capped bottles.

The bottles leave the machine and enter the process cycles of the machines located downstream.

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V-5


5.3.2

Part V

Filling

The filling module fills bottles (2) with the product stored in the tank (5). This machine employs the isobarometric filling method. The machine’s complete filling cycle is described in the following pages. The filling carousel (1) fills the bottles (2). A series of pipes (3) feed product to the filling valve (4).

4

4

2

1

3

Gas Decompression Product Reference

Description

1

Filler carousel

2

Bottle

3

Feed pipes

4

Filling valve

5

Tank

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1.1

2

5


Part V FILLING VALVE OPERATION

The ring storage tank (1) feeds product to the filling nozzle (3). The ring tank has the following components: -

A pressure transducer. A thermometer. Level sensors.

The chamber (2) feeds CO2 to the filling nozzle (3). The chamber (4) is used to decompress the bottle. The various chambers are fed through pipes from a central manifold which distributes the various service fluids and power. The product flows into the bottle under the force of gravity. The filling stop is controlled by the pump located between the external tank and the filler carousel.

1

A

2

E

B

C

4

A

D

3

Reference

Description

Reference

Description

A

Filling step controller unit

D

Product feed and gas return spout

B

Valve opening/closing unit

E

Pneumatic unit

C

Valve body

1.1

V-7


5.3.3

Part V

Filling steps

The machine’s complete filling cycle is described in the following pages. For each main step there is a drawing and a description. The main filling steps are: 1. 2. 3. 4. 5.

Bottle infeed. Bottle centring. Pressurisation with CO2. Filling. End of filling.

6. 7.

Decompression. Bell upstroke.

1.

Bottle infeed

In the first step the bottle (1) is transferred from the infeed by the infeed starwheel directly to the bottle pickup unit.

Valve position during the step shown here.

1

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1.1

Part V 2.


Bottle centring

After these steps the centring bell (3) travels downwards so that its seal makes contact with the mouth (2) of the bottle (1).

Valve position during the step shown here. 4

3 2

1

1.1

V-9


3.

Part V

Pressurisation with CO2

The valve (1) opens and the CO 2 flows from the chamber (3) into the bottle (2). The pressure inside the bottle (2) reaches the same pressure as that inside the chamber (3).

1 3


2

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1.1

Part V 4.


Filling

At this point the valve (1) opens and filling of the bottle (2) starts.


1

2

1.1

V - 11


5.

Part V

End of filling

When the product inside the bottle (1) reaches the required level, filling stops.


1

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1.1

Part V 6.


Decompression

The valve (1) opens to decompress the gas contained inside the bottle (2). Before decompression starts there is a short delay to allow the product to stabilise.


1

2

1.1

V - 13


7.

Part V

Bell upstroke

At the end of the cycle, the bell travels upwards. The mouth of the bottle (2) detaches from the valve (1).


1 2

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Part V

5.4

WASHING STEP (IF AVAILABLE)

This consists of washing ramps which uses water under pressure to remove any residues of accidental product leaks. When available, the washing step has three different configurations, as follows: -

BOTTLE WAY The washing system consists of a series of fixed nozzles directed on to the filling valves and the bottle neck at machine outfeed.

-

AMBIENT COP (with reduced laminar flow) The washing system consists of a series of mobile nozzles designed to clean the entire bottle line.

-

WITH DOOR WASHING The washing system cleans the bottle line and the inside of the doors using nozzles.

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5.5

MACHINE CLEANING AND SANITIZATION

5.5.1

Introduction

Part V

This section describes the procedures required to clean and sanitize the machine internally and externally.

INTERNAL washing operations: -

-

Pre-washing: Washing with lots of water (not recycled) to remove product residue from inside the machine. The internal surfaces (conduits, valves, tank) are flooded and rinsed using non-recycled water for approximately 5-10 minutes. Washing: A detergent and water solution is used to remove traces of product residues and to clean the internal surfaces and all machine parts in contact with the product.

-

Sanitisation: Hot water, steam or a chemical solution is used to sanitize all machine conduits involved in production. This process sterilises all the internal surfaces in contact with the product. As with the washing procedure, the machine is set up to use dummy bottles so that the filling valves are also cleaned and sanitized by the detergent and sanitizing solutions.

-

Rinsing: Washing with lots of water (not recycled) to remove any deposits of detergent or sanitizer from inside the conduits. The internal surfaces are flooded and rinsed using non-recycled water for

-

approximately 5-10 minutes. Draining: Any water remaining inside the machine and infeed manifold is drained. The filling valves are opened so that any water remaining in the conduits is able to drain.

EXTERNAL washing operations: External washing of the machine is vital to remove from the transfer components, base and all external components any traces of dirt, product residues and any chemical product limescale resulting from the internal washing processes. External washing can be performed using water, a foamy detergent and water solution or a low concentration alkaline solution. In the latter two cases washing must be followed by rinsing with lots of water to remove any residues of detergent or alkaline solution. NOTE: Make sure any painted parts as well as electrical and electronic components are suitably protected during external washing.

IMPORTANT: At the end of the process, dispose of the water, sanitizer and acid substances in compliance with the local waste disposal regulations. Do not discharge this type of waste into water courses or the public drainage system. This type of waste requires pre-treatment before final disposal.

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1.0


Part V 5.5.2

General information

IMPORTANT: The chemical products used to clean, disinfect and sanitize may cause corrosion of some of the materials used to manufacture the filling machines and systems used to prepare beverages. Carefully follow all the instructions in this section of the manual to prevent problems related to corrosion.

-

The use of products manufactured by renowned companies is recommended. Follow the user instructions carefully for each product.

-

Some types of acid such as: - hydrochloric acid (HCl) - sulphurous acid (H2SO3) - sulphuric acid (H2SO4) are particularly aggressive towards the steels normally used to manufacture Sidel machines. These

-

acids or similar chemical products must not be used. Before using any corrosive products, check the compatibility with the materials used to manufacture the machinery.

If necessary seek the advice of Sidel S.p.A. or the supplier of the chemical products. -

If the commercial name or the information provided by the manufacturer does not enable identification of the chemical agents contained in the product then corrosion tests must be performed. The corrosion index of detergents also depends on the quality and concentration of chlorine in the water used to prepare the solution.

This value must not exceed 25 ppm. -

All halogens (bromine, iodine, chlorine) can cause punctiform corrosion, intercrystalline corrosion and stress corrosion cracking.

High local concentrations of these chemicals caused by the formation of drips or evaporation must be avoided. Rinsing with lots of water is vital after all external cleaning and sanitization. The duration of rinsing must be established using the analysis method. There must be no traces of the products used once rinsing is complete. High concentrations of the chemical solutions used, caused by evaporation of the water in the solution, not only cause corrosion of metal parts but can also irreparably damage plastic components and rubber seals. Do not perform the disinfecting procedure when the machine is stopped and therefore flooded with chemical agents. Do not leave sanitizing products to act over long periods.

If you have any doubts concerning the use of detergents or sanitizing products, contact Sidel S.p.a. or the supplier.

1.0

V - 17


5.5.3

Part V

Use of chemical products to remove limescale deposits from external surfaces

The hardness of water used in industrial processes can have negative effects in many applications. Hard water, specifically when used at high temperatures, can cause chalky deposits. Furthermore, when mixed with hard water, many substances combine with the calcium and magnesium salts to form insoluble compounds. The hardness of water is expressed in conventional degrees which take into consideration not the individual salts but their equivalent quantities. Three units of measure are used as follows: French degrees, German degrees and English degrees. French degrees express hardness as the number of grams of calcium carbonate per 100 litres of water; German degrees express hardness as the number of grams of calcium oxide per 100 litres of water; English degrees express hardness as the number of grains of calcium carbonate per gallon of water (1 degree = 0.064 grams; 1 gallon = 4.453 litres). The values are converted as follows: -

1 German degree = 0.56 French degrees. 1 English degree = 1.18 French degrees.

hardness in ºfH

hardness in mmol/l

Indication

0-7

0-0.7

very soft

> 7-15

> 0.7-1.5

soft

> 15-25

> 1.5-2.5

not hard

> 25-32

> 2.5-3.2

moderately hard

> 32-42

> 3.2-4.2

hard

> 42

> 4.2

very hard

Products used to reduce calcium levels in water can be divided into three groups, as follows: very aggressive, aggressive, slightly aggressive. The level of aggressiveness is determined by the percentage of nitrogen and phosphorous contained in the chemical composition. The presence of these two elements, and specifically nitrogen, makes these type of products extremely corrosive. Therefore, make sure the appropriate concentration of product is used. Make sure suitable protection is provided for electronic and electrical components, filling valve seals and any painted, zinc-plated or bronze components. The use of only slightly aggressive products, consisting mainly of inorganic acids and tensioactive agents, is recommended. These types of product are recommended to remove, not only deposits derived from water hardness, but also inorganic contamination residues caused by food processing. The products do not represent an excessive corrosion hazard for the machine components.

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Part V 5.5.4

Limits to using detergents and sanitisation products

For filling machines and beverage preparation systems: IMPORTANT: When using Oxonia during sanitization procedures, make sure the concentration of chlorine in the water used does not exceed 25 ppm.

Use

PRODUCT

TEMPERATURE (MAX)

CONCENTRATION

DURATION (MAX)

WASHING AND DISINFECTION

E C A L P N I

ALKALINE SOLUTIONS OF SODIUM HYDROXIDE (NaOH) > 30% w/w

85 °C

1.5 to 4% (w/v)

30 mins.

ACID SOLUTIONS OF NITRIC ACID (HNO3) > 30% w/w

60 °C

0.5 to 1.5% (w/v)

15 mins.

ACID SOLUTIONS OF PHOSPHORIC ACID (H3PO4) > 30% w/w

60 °C

0.8 to 2% (w/v)

15 mins.

DISINFECTANT SOLUTION OF PEROXYACETIC ACID

Ambient (max. 40 °C)

50 to 500 ppm as PAA

30 mins.

G N I

DISINFECTION WITH CHLORINE

N A E L C

SOLUTIONS (200 ppm max chloride in water and pH>6<8 in CIP solution)

Do not exceed 30 °C

Max. 40 ppm as free Chlorine

20 mins.

Chlorine Dioxide ClO2

Ambient temperature

5 ppm

20 mins.

Sodium Hypochlorite NaClO

Ambient temperature

10 to 40 ppm

1 hour

SANITIZATION WITH HOT WATER (TREATED F_<10)

98 °C

/

30 mins.

SANITIZATION WITH STEAM

NOT PERMITTED

1.0

V - 19


Use

PRODUCT

TEMPERATURE (MAX)

CONCENTRATION

Part V

DURATION (MAX)

WASHING AND DISINFECTION

G N IN A E L C L A N R E T X E

FOAMING ALKALINE SOLUTIONS OF SODIUM HYDROXIDE

Ambient temperature

2 to 4% (w/v) depending on foam consistency required

30 mins.

FOAMING ACID SOLUTIONS OF DESCALING PRODUCT

Ambient temperature


30 mins.

FOAMING DISINFECTANT SOLUTION OF PEROXYACETIC ACID

Ambient temperature


30 mins.

DISINFECTION WITH CHLORINE SOLUTIONS (200 ppm max chloride in water e pH>6.5<8 in CIP solution)

Ambient temperature

Max 10 ppm as free Chlorine

30 mins.

SANITIZATION WITH STEAM R E H T O

OZONATED RINSING WATER BOTTLED OZONATED

NOT PERMITTED 30 °C

1.0 ppm

Continuous

30 °C

0.6 ppm

Continuous

WATER* * 0.4 ppm max in bottle (FDA 21 CFR 184.1563) 0.5 ppm max (EU DIRECTIVE 2003/40/EC).

. A . .p S l e id S ©

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Part V

IMPORTANT: The following table is enclosed to provide important information concerning the environmental impact of the various sanitizing products:

INDEX OF ENVIRONMENTAL HARM SUBSTANCE UTN

IRCH

CAUSTIC SODA (NaOH)

n. d.

29

SODIUM HYPOCHLORITE (NaOCl)

n. d.

33

PERACETIC ACID

1

80

NITRIC ACID

8

110

PHOSPHORIC ACID

5

50

The IRCH index compares various substances to assess their impact on human health, ecosystems and the environment in general. It is an index of risk (from 0 to 200) based on a calculation algorithm which takes into consideration the ecological impact on water, air, soil (waste) and the atmosphere (ozone, greenhouse effect, etc). The impact in the various areas also takes into consideration the effects on human health (source: Indiana Pollution Prevention and Safe Materials Institute at Purdue University - EPA Project - 1996). The UTN index (from 0 to 100) compares different substances in terms of their toxicity for organisms living in water- and land-based ecosystems (source: G. Davis et al. - EPA/600/R-94/177 - 1996). IMPORTANT: If you are using hazardous substances, check the Safety Data Sheets to identify any safety and environmental hazards for the chemical used. The safety data sheets identify: -

Hazards.

-

Personal protective equipment and general protections required. First aid instructions.

-

Fire prevention measures. Action in the event of accidental spillage and leaks of hazardous substances. Chemical and physical properties.

-

Stability and reactivity. Toxicological information. Environmental information. Disposal information.

-

Shipping and handling information.

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. A . .p S l e id S ©

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Part V

Matrix Filler

Part VI

PART VI

User Manual / Operation

OPERATING INSTRUCTIONS

1.1

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Part VI

User Manual / Operating Instructions

6.1

CONTROL PANEL, WARNING LIGHTS AND PUSHBUTTONS

1

2

3 4

6.1.1

Foreword

The operator interface includes a part with traditional controls (selectors, knobs), and another part integrated into the operator panel.

6.1.2 1

Maintained mushroom head emergency stop button.

2

Two-way key selector to implement size changeover (machines for glass bottles).

3

4


VI - 2

Layout of components

Three-way key selector with return to central position: adjusts the position of the tank

or capper rinser (machines for glass bottles). Monitor: displays machine status, messages and control menus.

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Part VI

A filling test pushbutton panel is installed on the rear guards of the filling machine:

5

6

7

8

5

Bottle feed button.

6

Filling stop button.

7

Filling start button.

8

Filling test selector (located on the HMI when not on the pushbutton panel).

The mobile pushbutton panels have only one button: -

6.1.3

jog speed.

Operator panel

TECHNICAL SPECIFICATIONS

The operator panel (OP) consists of the following: -

Touch panel with WINDOWS CE operating system (24 V DC power supply). Touch–screen monitor.

Internal peripherals

-

Ethernet card.

External peripherals

-

MASTER card.

Software installed

-

The operator interface uses ZENON software on the OP.

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Part VI


6.1.4

Operator interface main structure

The operator interface can be divided into the following areas: 2

3

5

4

1

Description of areas: 1 2 3 4

5


VI - 4

Main controls: this area contains the main operator controls. This area is displayed on all

the interface pages. General information: this area contains general information concerning machine operation

and the interface. This area is displayed on all the interface pages. Main functions: this area contains the buttons to enable the main interface functions. This

area is displayed on all the interface pages. Main navigation bar: use this area to navigate the pages making up the interface. This

area is displayed on all the interface pages. Page area: this contains the functions for the page selected using the main navigation bar.

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Part VI

DESCRIPTION OF MAIN CONTROLS (1)

A

1

B

C

D

E

F

G

H

I

L

The main control area (1) is always displayed and used to access the following functions: Machine Start/Stop: when the machine is stopped, press and hold this button for the time B

required to start rotation. When the machine is running, press the button to stop rotation. JOG mode: press this button to enable/disable jog mode on the machine.

C

Bottle block: press this button to enable/disable bottle block.

D

Bottle release: press this button to enable/disable bottle release.

E

Unlock doors : press this button to enable/disable unlocking of the front doors.

F

Unlock doors : press this button to enable/disable unlocking of the front transfer doors (if fitted).

A

G H

Enable actuators: press this button to enable/disable manual control of actuators (valves,

motors, etc.). Enable controls: press this button to enable/disable manual control of the operator control

selectors on the pages.

I

Coupling: press this button to enable/disable coupling of the filler with the blower.

L

Alarm reset: press this button to reset all the alarms in the log (if cause of alarm removed).

All the buttons have the following colours depending on their status: Button not enabled: cannot be pressed (grey).

Button not active: control not running (light blue).

Button pressed: control sent to PLC (blue).

Button active: control running (light red).

Button pressed: control requested (dark red).

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Part VI


DESCRIPTION OF GENERAL INFORMATION (2) 2

A

F

E

C

B

G

D

H

The general information area (2) is always displayed and used to access the following functions: A

Machine speed: current machine speed displayed in bottles/hour.

B

Counter: the number of bottles which have entered the machine is displayed.

C

Hours: machine operating hours are displayed.

D

Active recipe: name of the recipe currently being processed is displayed.

E

User: current active user is displayed.

F

Level: the active level is displayed.

G

Machine: current machine status is displayed. PLC – HMI communication status: communication status between the PLC and operator

panel is displayed. If the icon is orange then communication is active; if it is grey then the operator panel is not communicating correctly with the PLC.

H

DESCRIPTION OF MAIN FUNCTIONS (3)

A

3

B

C

D

The main functions area (3) is always displayed and used to access the following functions:


VI - 6

A

Login: used to set the user and operating level.

B

Info: the system information window is displayed.

C

Alarms: the alarm window is displayed.

D

Changeover: the interface for the CIP system/Auxiliaries in remote system is displayed.

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Part VI

DESCRIPTION OF THE MAIN NAVIGATION BAR (4) 4

A B

C

D E

F G

H

I

L

M The main navigation bar (4) is always displayed and used to access the following functions: A

Reception: displays the main page.

B

Piping circuit: displays the tank page.

C

Machine components : displays the component navigation page.

D

Electronic filling valve: displays the electronic valve navigation page.

E

Recipe: displays the recipe navigation page.

F

Efficiency: page reserved for SIDEL operators.

G

Layout: displays the machine summary page.

H

Bar graph: displays the trend page.

I

Maintenance: displays the maintenance functions page.

L

Parameters: displays the machine step navigation page.

M

Services: displays the services and general parameters navigation page.

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Matrix Filler


DESCRIPTION OF THE PAGE AREA (5)

There are two main types of page area: -


VI - 8

Navigation page: contains only navigation buttons to recall sub-pages.

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Part VI -

Command and control page: contains diagrams, controls and navigation buttons.

C

B

A

The command and control page (5) is divided into: Summary area: depending on the machine specifications and/or options installed, this area A B C

displays a summary to enable a quick and complete overview of the assembly. Control area: this area contains buttons and selectors used to perform various actions involving the machine equipment. Page change area: this area contains navigation buttons used to access further sub-pages:

Type of buttons: Button to access functional sub-page.

Button for more page detail.

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Matrix Filler


6.1.5

Part VI

Operator panel operations

The following pages describe how the operator panel may be used to monitor and control the various components of the system during operation of the machine. In order to make the text which follows easier to understand, in this section we describe some of the conventions used in the description of the operator panel. Physical size display

Two pieces of information are displayed for each physical size controlled by the program, as follows: the size “set point” value, i.e. the value desired for the size itself during machine operation, and the size “actual value”, i.e. the value actually assumed by the size in real time. The set point value is orange and the actual value is blue. Modulating valve opening display

Display showing the opening (as a percentage) of the regulating valve. Press the button on the valve to specify the opening percentage required: 0% = closed 100% = open Motor/Pump speed display ( if controlled by an inverter)

Display showing the speed of the actuator as a percentage. Press this button on the motor/pump to adjust the speed.

Temperature display

Display showing the temperature of the product / CIP solution present in the circuit in °C.

Pressure display

Display showing the pressure of the product / CIP solution present in the circuit in bar.

Level display

Display showing the level of the product / CIP solution present in the circuit in mm.

Speed display

Display showing the speed of the product / CIP solution present in the circuit in mc/h.

pH display

Display showing the level of acidity of the CIP solution present in the circuit.


VI - 10

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Part VI

DISPLAY OF ANALOGUE CONTROL DEVICES

Display showing analogue control devices. To set the operating values of these analogue control devices, press the related icon. When the alarm is disabled, the surround of the icon flashes and is coloured fuchsia.

In the event of a fault, the alarm is enabled and the probe surround changes to red. If the display box is orange then the operating cycle is waiting for the analogue device to reach the set point value.

DISPLAY OF SENSORS OR DIGITAL DEVICES

Display showing sensors or digital devices. List of devices: -

Fs: flow switch. Ls: level switch. B: Photocells / detector sensors.

The icon for a digital device can display up to 2 items of information. OFF (grey) ON (green)

If the icon of the sensor or the digital device appears as shown below: Grey on orange background This indicates that the operating cycle is waiting for the digital device to changed state.

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Part VI


DISPLAY OF SINGLE ON-OFF VALVE STATES Valve logic state:

Valve actuator state:

Valve body:

Subject to automatic control

Controlled actuator

N.O. Normally Open

Subject to manual control (both ON and OFF)

Actuator without control

N.C. Normally Closed

Valve in alarm condition

Alarm OFF.

To change the valve state backwards and forwards between open and closed, press the valve icon shown on the displays in the “Modify component state” section.

DISPLAY OF THE STATE OF MIXPROOF VALVES


Valve logic state:



Controlled actuator




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Part VI

DISPLAY OF THE STATE OF REGULATING VALVES Valve logic state:


Valve body:


Controlled actuator

N.O. Normally Open



N.C. Normally Closed

Valve in alarm condition

Alarm OFF.


DISPLAY OF MOTOR AND PUMP STATES

Display showing the motors and pumps and their state during machine operation.

Motor / Pump green: automatic control ON

Motor / Pump green: automatic control OFF

Motor / Pump red: alarm present

Motor / Pump yellow: Manual control (ON and OFF).

Motor / Pump pink: Alarm OFF.

Press the icon to change the state manually (from manual ( ON – OFF) to automatic and back again) using the displays shown in the “Modify component state” section.

1.1

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Part VI


DISPLAY OF CONTROL CAM STATES

Display showing control cams and their state during machine operation.

Cam actuator green: automatic control

Cam actuator yellow: manual control (ON and OFF).

Press the valve icon to change the state manually (from manual (ON – OFF) to automatic and back again) using the displays shown in the “Modify component state” section.

MODIFY THE STATE OF COMPONENTS Types of controls:

B

A

C

D

Device control with feedback

Press this button to switch the component to ON in the manual mode.

B

Press this button to enable operation of the component in automatic mode.

C

Press this button to switch the component to “OFF” in the manual mode.

C

Press this button to disable/enable the component position alarm (where present): When the alarm is disabled, the surround of the component flashes and is coloured fuchsia. In the event of a fault, the alarm is enabled and the component surround changes to red.

VI - 14

B

Device control without feedback

A

D


A

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Part VI

A.

Sets device actuation to manual.

B.

Sets device management to automatic.

C.

Sets device disabling to manual.

A.

Switches the device ON.

B.

Switches the device OFF.

A.

Starts the device

B.

Stops the device.

A

B

C

Three-way selector:

A

B

Two-way selector:

A

B

Start/Stop button

Press to execute the command. Single button 1.1

VI - 15

Matrix Filler


Adjustment tools 1.

Analogue device pop-up without totalizer:

A.

Process Value adjustment zone.

B.

Set Point adjustment zone.

C.

Alarm enable/disable button.

A B

C

This display shows the current value read from the device and the set-point value. 2.

Analogue device pop-up with totalizer:

A.

Actual Value Control Area

B.

Totalizer Control Area

C.

Totalizer Reset Button

D.

Alarm enable/disable button.

A B

D

3.

C

Fixed analogue device reference pop-up

A.

Zone for displaying the reference value.

B.

Button to modify the reference manually.

C.

Zone for setting the reference value.

D.

Button to open the parameter setting popup.

A

B

C D . .A .p lS e id S ©

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Part VI

4.

PID control pop up E

F

H

A B C D

G

A

Actual value: Actual process value.

B

Actual set-point : Actual set-point value.

C

Feed Forward: Disturbance parameter to be entered in the PID setting.

D

Output: PID adjustment control output, this is the flow valve opening value, the motor control

reference, etc.

E

Use this to set the Set-Point manually and activate the adjustment.

F

Use this to set the output manually.

G

Display zone for the regulation trend.

H

Opens the parameter setting page.

1.1

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Matrix Filler

Part VI


5.

Parameter setting pop-up:

A

B

A

Min Out: Output minimum value.

B

Max Out: Output maximum value.

You can set a component manually to any user-defined state. Exercise great care when performing operations in the manual mode. Manual operations performed incorrectly can seriously damage production and the sanitizing procedure and can also create hazards for operators working close to the machine. To enable manual commands, you must be logged on as “Inspector” and the device functioning mode on the synoptic page must be set to “Manual”. When you press any valve or pump icon on the synoptic page, the manual setting menu for that device will appear.


VI - 18

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Matrix Filler


Part VI

6.2

DESCRIPTION OF INDIVIDUAL INTERFACES

6.2.1

Main functions

PASSWORD PAGE

Function to access the “Password” page. A B D

C

A

Field to enter user name.

B C

Field to enter password. Button to confirm the data entered.

D

Button for operator login.

Simply press button 4 for access to the lowest operator login level. To start using the operator panel, enter your user name and password. The user level for using the operator panel depends on the user name and password that you enter. Displaying the access security level

e m a N

Operator Inspector Supervisor Sidel

ID r sU e

op ins dir sa

l e v le d r o w ss a P

0 1 4 10

s n to t u b r e filt m r la A

X X X X

X X X X

n tico e l e s

n o tic e l e s

e g a u g n a L

cy le c IP C

X X X X

P I C \ p to \st r ta S

X X X X

d n a m m o ce cyl C

p to s r ze z u b g in n r a W

t se e r ra m l A

X X X X

X X X X

1.1

n o i ct e l se e n li P I C

X X X X

st n e m st ju a d l a u n a M

X X X

sr e t e m a r a p e l yc / e n i h c a M

.)c t e s, p m u p s, ve l a v(

X X

l o tr n co n o iit so p vle a V

X X

n o it a r u g if n o ce n i h c a M

w e vi re

ss a yp b

e ip c e R

X X

X

n tio ca li p p a ti x E

X

VI - 19

Matrix Filler


SYSTEM INFORMATION PAGE System information page access function.

A B C D E

Use this tool to retrieve system information such as:


VI - 20

A

Free disk space.

B

Free memory space.

C

Project version.

D

Serial number.

E

Project name.

1.1

Part VI

Matrix Filler


Part VI ALARM PAGE

Function to access the “Alarms” page. A

B

C

D

F

E

G

H

I

L K J

Use this page to identify any alarms triggered during functioning. The following are displayed for each alarm: date and time alarm triggered, description of the alarm, the variable symbol linked to the alarm and the group of alarms to which it belongs. Select one of the Tab windows to display a specific group of alarms. A

All

B

Machine

C

Operator

D

Filler

E

Crown capper

F

Capper

G

Rinser

H

Power supplies

I

External

J

Specific alarm class selection

K

Filter removal from classes

L

Switch from current alarms triggered page to alarm log page.

The recognition of alarms takes place by pressing the Reset button, this makes the alarm disappear if the reasons that caused it have been removed, and at the same time it makes the messages from the alarm page disappear.

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Matrix Filler


6.2.2

Part VI

Reception

Function to access the “Reception” page.

A B

C

This is the home page displaying the main machine data:


A.

Use this button to set maximum machine speed during production.

B.

Use this button to zero-set the counter for the number of bottles which have been fed into the machine. Display area showing information concerning the status of the main probes on the machine such as temperature and pressure.

C.

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Part VI 6.2.3

Piping circuit

Function to access the “Piping” page.

COMMAND AND CONTROL PAGE

Summary diagram area

This page shows all the information required to monitor machine operation: flow rates, opening of modulating vales, On/Off valves, pumps and analogue values. The panel shows the following components: -

Motors. Pneumatic valves. Flow meters. Levels. Analogue values. Solenoid valves. Powered modulating valves Adjustment tool: Area to access display/entry of data to adjust levels or

modulating valve pressures.

Three-way selector: Area to access the manual open, manual closed and

automatic control for the filling valves. This is only possible when the operating mode of the devices is set to manual.

Three-way selector: pump control

Display of sanitizing information.

Display of production end information.

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Matrix Filler


Control area Three-way selector: Valve opening control

Three-way selector: Valve bleed control.

Two-way selector: Tank drainage control

Two-way selector: Ring storage tank drainage.

Two-way selector: Co2 bleed bleeding.

Two-way selector: Conductivity meter control.

Start/Stop button Pump control.

Three-way selector: Shaker control.


VI - 24

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Part VI

Matrix Filler


Part VI Page change area

Displays relevant sub-page (Level, Pasteuriser, CIP).

Navigation button: display of Start-up sub-page.

Use this page to start, stop and interrupt the production, rinsing and sanitization cycles of the filler.

A A

B

C

D

External consent and filler signals must be ready to start any of the machine phases. The start sequences button is enabled when one of the functions from 1 to 7 is selected. 1.

GAS FLUSHING PRODUCTION: Starts production with CO2 flushing and bleeding of

valves. B

2. 3.

FAST PRODUCTION: Starts rapid production. TANK FLOODING PRODUCTION: Starts production with bleeding of valves and tank

4. 5. 6. 7.

washing with product. DRAIN: Starts the machine drain sequence. RINSE: Starts the rinse sequence. RINSE WITH DUMMY BOTTLE: Starts machine filling with dummy bottles. CIP: Starts machine sanitization.

C

The Stop sequences button interrupts the current sequence.

D

The Abort sequences button is used to quit any of the machine phases and return to the STANDBY step.

1.1

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Matrix Filler


6.2.4

Part VI

Machine components

Function to access the “Machine components” page. Navigation page: This page displays buttons for opening the following submenus. The submenus available

depend on the machine specifications or options:

Displays Rinsing subpage.

Displays Bottle cooling subpage.

Displays Foamer subpage.

Displays Capper subpage:

Displays Crown Capper subpage:

Displays Clean room subpage.

Displays Size changeover subpage.

Displays External foaming subpage.


VI - 26

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Part VI RINSER SUBPAGE

Select this to open the Rinser subpage.

This page shows all the information required to monitor rinser operation: On/Off valves, pumps and analogue values. The panel shows the following components: -

Pumps. Pneumatic valves.

--

Analoguevalves. values (temperatures and levels). Solenoid Pressure switches. Flow gauges.

-

Chlorine concentration

-

pH values.

Three-way selector: first rinsing treatment control.

Two-position selector: rinsing sanitization treatment enabling control.

Use this button to start the automatic production, drain, rinse and sanitization sequences of the rinsers which run a repeat treatment process using chlorine. This operation is run specifically on machines used for hot filling such as RAD.

This area displays the first and second treatment sequence messages.

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Matrix Filler


Part VI

BOTTLE COOLING SUBPAGE

Select this to open the Bottle cooling subpage.


This page shows all the information required to monitor operation of the bottle cooling unit: On/Off valves, pumps and analogue values. The panel shows the following components: -

Pumps. Pneumatic valves. Analogue values (temperatures and levels).

Control area

Two-way selector: water cooling control.

Three-way selector: bottle cooling control

Page change area

Navigation button: Displays bottle cooling temperature safety values.


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Part VI FOAMER SUBPAGE

Select this to open the Foamer subpage.


This page shows all the information useful for monitoring operation of the foamer: PID regulator and adjustment pressures/temperatures.

Area to access display of the set point value and process value for foamer water temperature.

Area to access display of the set point value and process value for foamer water pressure.

Control area

Three-way selector: foamer control

Two-way selector: foamer water heater control.

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Matrix Filler


CROWN CAPPER SUBPAGE

Select this to open the Crown capper subpage.


This page shows all the information useful for monitoring operation of the crown capper. Control area

Two-way selector: cap on starwheel safety device control.

Two-way selector: UV lamp control.

Two-way selector: cap emptying control.

Two-way selector: cap belt control.

Two-way selector: steam on caps enabling control.

Two-way selector: cap buffer lifting enabling control.

Two-way selector: cap buffer emptying control.

Three-way selector: cap release control.

Three-way selector: hopper control

Three-way selector: bottle neck ring washing control. . .A .p lS e id S ©

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Part VI

Three-way selector: Buffer mode selection - Emptying – Production – Delay.

Three-way selector: Operating mode selection - Jog – Automatic – Stop.

Three-way selector: jog selection.

Size changeover enable button.

Encoder reset button.

Page change area

Navigation button: display of cap safety device and crown capper starwheel safety device subpage.

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Part VI


AROL EQUATORQUE B

C

E

A


VI - 32

D

F

A

Maintenance: Gives access to the crown capper maintenance page.

B

General Information: Gives access to the crown capper control page.

C

Measuring devices: Reading Equatorque motor temperature probe 1.

D

Measuring devices: Reading Equatorque motor temperature probe 2.

E

Measuring devices: Reading crown capper encoder position.

F

Size changeover Gives access to the size changeover control page.

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Part VI AROL EQUATORQUE D

A

B

E

C

F

G

H

Parameterization area: Parameters: This area accesses the maintenance parameters of the capper head selected in

zone 8. All the parameters may be modified by the operator and transferred to the head using the special button: A

-

Parameters “Download” button Enable/Disable: Head Enabling and Disabling Torque: Torque Real KT: Motor Torque Constant (Motor and Current) Torque Correction: Torque Correction Percentage (if necessary) Parameters: The parameters of the capper head selected in zone 8 may be read in this area. The data is read by pressing the special button:

B

-

Parameters “Upload” button

Encoder: Reading encoder position with zero-setting button: C -

Encoder zero-setting button

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Calibration area: D

Sequencer: Reading calibration progress status. Sequencer: Reading calibration data.

-

Calibration Offset: Current correction offset Current: Motor current Torque Load: Motor torque applied in calibration Motor Torque: Measured motor torque

The head calibration is started with the special button. E

-

Calibration start button.

Head rotation button. This button rotates the head for a “rotation test” if the calibration is not being performed. F

G

Sequencer: Reading current values (A) of the motor during calibration with the head not loaded

and with the clutch installed during calibration. Sequencer: Reading calibration progress percentage. Sequencer: Area for selecting the head to be parameterized.

H


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Part VI AROL EQUATORQUE Feed-Back

Crown capper control:

This page displays the torque values of each capping motor corresponding to the respective head and any feedback alarms (heads 1 to 10): No Load (SlowTorque not reached): Minimum torque not reached. No Closure (EndMainAngle reached before ClosureTorque reached): Closure angle reached before

closure torque. In Torque (EndMainAngle reached before end of In Torque state): Closure angle reached before

necessary time. CapTurns (no. of turns specified by Cap Turns not reached): Rotation angle no reached. Following (Head following error): Following error. Bad Closure (closure torque reached, but stop speed not reached): Closure torque reached but

stopping speed not detected.

No Position (position not reached): No unscrewing.

Press this button to access the next control page:

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AROL EQUATORQUE Feed-Back

This page displays the torque values of each capping motor corresponding to the respective head and any feedback alarms (heads 11 to 20): No Load (SlowTorque not reached): Minimum torque not reached. No Closure (EndMainAngle reached before ClosureTorque reached): Closure angle reached before

closure torque. In Torque (EndMainAngle reached before end of In Torque state): Closure angle reached before

necessary time. CapTurns (no. of turns specified by Cap Turns not reached): Rotation angle no reached. Following (Head following error): Following error. Bad Closure (closure torque reached, but stop speed not reached): Closure torque reached but

stopping speed not detected. No Position (position not reached): No unscrewing.

Press this button to return to previous page.


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Part VI AROL EQUATORQUE Size Change

A

B

1

Select motor to be checked:

-

Central guide Bottle body pad Extractor pad (Bottle Outfeed)

C

D

The boxes display the current position of the motors. The motor selected is shown in yellow. Based on the selection, the following operations may be performed: 2

Home Position

Press this button to move the selected motor to the Home position (initial).

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Positioning:

A predetermined position may be entered for the selected motor. This is useful for defining recipe positions based on the size.

Press buttons “+” and “-” to move the selected motor in the desired direction. The current position of the selected motor is always displayed.

4

Brake:

Press this button to release the brake of the selected motor (for manual movements), which will be displayed in the following manner in zone 1.

Press this button to reset the brake of the selected motor.


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Part VI CAPPER SUBPAGE

Select this to open the Capper subpage.


This page shows all the information needed to monitor functioning of the capper: Control area

Two-way selector: capper safety device control.

Three-way selector: channel 1 cap block control.

Three-way selector: channel 2 cap block control.

Three-way selector: capper 1 hopper control.

Three-way selector: Capper 2 hopper control.

Three-way selector: extractor unit cleaning control

Three-way selector: capper washing control.

Channel fault rest button.

Navigation button: displays capper safety device.

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CLEAN ROOM SUBPAGE

Select this to open the Clean room subpage.


This page shows all the information useful for monitoring operation of the clean room: ventilator motor control and display of clean room pressure values.

Control area

Three-way selector: ventilator start control

Control to switch ON internal lighting divided by ventilation areas.


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Ventilator speed control. Press this button to display a window to read the current speed of the ventilators and to adjust the speed manually.

Fan status display page.

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SIZE CHANGEOVER SUBPAGE

Select this to open the Size changeover subpage.

A page for automatic size changeover management or a page for manual size changeover is available depending on the type of machine. Automatic size changeover


This page shows all the information needed to monitor the size changeover: current position and adjustment position of the rinser, filler, cam, capper and crown capper.

A

B

D

C

A. Alarms B. Actual heights C. D.


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Control area

Three-way selector: Size changeover selection – Manual – Automatic - Disabled.

Two-way selector: Rinser manual lifting selection.

Two-way selector: Filler manual lifting selection.

Two-way selector: Cam manual lifting selection.

Two-way selector: Capper manual lifting selection.

Two-way selector: Crown capper manual lifting selection.

Button: START automatic size changeover.

Button: confirm the size selected.

Button: STOP automatic size changeover.

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Manual size changeover Summary diagram area

This page shows all the information needed to monitor the size changeover: current position and adjustment position of the rinser, filler, cam, capper and crown capper.

Control area

Two-way selector: Rinser manual lifting selection.

Two-way selector: Filler manual lifting selection.

Two-way selector: Capper manual lifting selection.

Two-way selector: Crown capper manual lifting selection.


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Part VI EXTERNAL FOAMING SUBPAGE

Select this to open the External foamer subpage.


This page shows all the information useful for monitoring operation of the external foamer. Valves, pumps and process recipes.

Control area

Two-way selector to enable manual or satellite launch.

Two-way selector to enable recipe in manual.

Area to select and display the foaming recipe to be processed using manual control.

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This area is used to configure enabling of the foaming recipe during the various processing phases. For example, before inserting the dummy bottles and after CIP has been performed. Single button: START recipe selected.

Single button: STOP recipe selected.

Area displaying the name and number of the recipe being processed. Area displaying the preset time and recipe currently being processed. Area displaying the name and number of the phase in progress. Area displaying the preset time and and actual phase in progress.

Navigation button: Displays internal piping of the foaming control unit.

Function to access the “Foaming recipes” page.


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Part VI Summary diagram area

This page shows all the information needed to set the foaming recipe: times, pressures, washing areas. A

B A. B. C. D. E.

C

D

E

Select recipe to be edited. Phase type selection. Phase time setting. Control unit outfeed pressure setting. Selection of branches/sections to be enabled during the individual phases.

Control area

Recipe Save: save the recipe data in the archive (enabled for users with “Supervisor” access level).

Recipe Read: update the data displayed with the data of the recipe present in archive (enabled for users with “Supervisor” access level). Scroll button.

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ELECTRONIC FILLING VALVES (MASTERCARD) Button to access the “Electronic Filling Valves” page. The version of the installed FMC child project is displayed top left.

Navigation page:

Depending on the type of filler and the optional devices configured, various buttons are displayed giving access to specific subpages:

Button to access the “ Position TX” subpage

Button to access the “Filling Instruments Measure Data” subpage

Button to access the “Force Filling Time” subpage (only displayed if a flow meter is configured as a measuring device)

Button to access the “Filling Valves Data Pressurize” subpage

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Button to access the “Statistical Analysis Filling Valves” subpage.

Button to access the “Filling Master Card Diagnostic #1” subpage

Button to access the “Disable Filling Valves” subpage

Button to access the “Manual Filling Test” subpage

Button to access the “ Filling Valves Maintenance” subpage

Button to access the “Test Outputs Filling Valves” subpage

Button to access the “Sequencer Outputs Filling Valve #1 subpage

Button to access the “B&R Diagnostic” subpage

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POSITION TX SUBPAGE

Button to access the “ Position TX” subpage

Read-only page:

This page displays read-only data showing the control software positions and the number of the valves currently present in these positions. On the basis of the rotation direction of the filler (anti-clockwise in the figure above) and the infeed of empty bottles, the following control software positions can be identified: Filling in Production Start, Burst Control, Filling Area Outfeed and Data Collection . The number of the valve currently at a tangent to the filler inlet starwheel ( Valve in tang on inlet starwheel ) is also shown. This information is useful for technicians during start-up/testing to search for correct synchronisation of the electronic filling system with the real mechanical position of the valves (see “PAS Filler Tx Step - Filling Master Card” page). The number of the valve currently in the Manual Filling Start position is also displayed. This valve is ready to receive the filling command sent from the remote pushbutton control panel (where fitted). The duration of the various phases of the recipe in operation (flushing, pressurisation, filling, snift, etc.) are displayed in the coloured circular graph and numerically in steps in the legend top right. Calculation of the steps is dynamic and varies according to real machine speed. This data can be analysed to assess whether the recipe set is correct and whether all available steps are used. The message “Steps Recipe Error!” is displayed instead of “Steps Recipe OK!” if the number of usable steps is exceeded.

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Displays the current software version of the Filling Master Card.

Displays theoncurrent firmware version installed on the majority of the slave cards fitted the filler. Button to simulate a bottle burst on valve no. 1. The button is displayed in the event of configuration of the burst test using a pressure sensor on the valve or the burst test using flow variation (if a flow meter is configured). This button can also be used to test operation of the washing ramps (if configured) and the bottle ejector if synchronised correctly. Simulation does not increase the burst counter on valve no. 1 and no alarms are displayed on the panel. Button accessible only with Filling Master Card phases, OPER mode enabled, no selectors enabled and filler rotating with bottles being filled. For safety reasons it is disabled in the CIP/RINSE mode. Washing ramp start-up indicator (only displayed if washing ramps configured). Only used on glass bottle filling machines with the ramps managed internally by the Filling Master Card. Selector to enable valve bleeding in the middle of the starwheels. The selector is only displayed on the panel if configured. The selector is disabled when the bleed time of phase 15 of the recipe is set to zero. Valve bleed control indicator (only displayed if configured). Green only when the bleed control selector is enabled and passage of a valve, which has already completed filling, occurs.

Legend of colours for the various phases of the filling recipe. The duration of the phases is expressed in steps taking into account any fractions. “Angle Available”: expresses the effective size of the filling angle on the basis of the steps set on the “PAS - Filler Tx Step - Filling Master” page.

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FILLING INSTRUMENTS MEASURE DATA SUBPAGE

Button to access the “Filling Instruments Measure Data” subpage

Read-only page:

These pages display the filling values received from the electronic cards after the switch from the Data Collection position. These values show the result of the most recent filling operation performed by the valve with the bottle present. A legend is shown on the right of the page to facilitate understanding of the coloured indicators. The meaning of the various columns is described below:

Number of the electronic card (slave card), matches the number of the filling valve on the filler. The green tick

to the left of the valve number indicates the bottle is present.

Filling completed without alarms, bottle OK Filling completed with at least one alarm, bottle not OK Result of most recent filling operation:

Valve in CIP/RINSE mode Filling completed with pre-closing, bottle not OK Valve in recirculation process (only displayed if recirculation option configured) Valve disabled

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If the background box is blue then the slave card is processing a recipe transferred manually and not the recipe currently active on the filler. In the absence of bottle OK (green bullet), the bottle is not capped. A burst, snift, pressurisation, etc. alarm, depending on the type of filler, will result in the bottle OK signal not being given. For further details concerning the most recent filling operation, open the specific subpage called “Filling Valve Data Details”. Most recent bottle pressurisation status, check performed using the pressure sensor installed on the valve (only operates if pressure sensor configured, otherwise displayed as disabled): Bottle pressurised Last fillingbottle operation pressurisation indicator:

Bottle not pressurised Valve disabled or pressure control by pressure sensor or not configured.

Bottle bursts on individual filling valve counter; the counter is incremental. The counter increases in the event of bursts detected by the control made on the pressure using the sensor installed on the valve (if configured) and bursts detected by control of the flow variation (if configured) using a flow meter. Good bottle Last filling operation burst bottle indicator:

Burst bottle Valve disabled or burst control using pressure sensor disabled or burst control using flow variation and pressure sensor not configured and not fitted

Product set point volume in [ml] set in the recipe currently active on the filler (present if a flow meter is fitted as a measuring device).

Delay time in [ms] after the probe trigger; filling is complete when the delay expires. This value is set in the recipe currently active on the filler (present if a resistive probe is fitted as a measuring device)

Probe trigger in [mV] detected by the card during the last filling operation when the product comes into contact with the resistive probe (present if a resistive probe is fitted as a measuring device).

Effective product volume in [ml] counted by the slave card during the last filling operation (present if a flow meter is fitted as a measuring device).

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Effective filling time in [ms] calculated by the slave card during the last filling operation This time period only concerns product valve opening in all recipe phases i.e. pressurisation, flushing and filling.

Mean flow rate in [ml/s] calculated by the card during the last second of control of the opening valve (present if a flow meter is fitted as a measuring device).

Low flow rate alarm indicator:

Flow rate OK Flow rate lower than the set point limit requested Valve disabled

Temperature in [°C] of the product detected by the card (operates if temperature sensor configured otherwise disabled). Temperature OK Low temperature alarm indicator:

Temperature lower than the set point threshold requested Valve disabled or temperature sensor disabled

Tail Time in [ms] calculated by the slave card during the closing transition of the last filling operation. Transit time of the Tail Volume (present if a flow meter is fitted as a measuring device).

Tail Volume in [ml] calculated by the slave card during the closing transition of the last filling operation. The volume of product transiting during the Tail Time (present if a flow meter is fitted as a measuring device).

Non-dimensional Tail K constant [-] calculated by the slave card taking into consideration the closing transition of the last filling operations and the previous ones. This constant is used by the card to calculate the advanced closing to be used in the next filling operation (present if a flow meter is fitted as a measuring device).

Filling trigger alarm on individual valve counter; the counter is incremental. Failure to reach the probe trigger (if resistive probe fitted) or the set point trigger (if flow meter fitted) increases this counter. Last filling operation trigger indicator:

Trigger OK Trigger not reached Valve disabled

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Counter for transmission alarms between individual slave card and Filling Master Card; the counter is incremental.

Last transmission result indicator:

Last transmission OK Last transmission error Valve disabled

Filling valve scroll button (up)

Filling valve scroll button (down)

Reset Data button with confirmation pop-up window. Press this button to zero-set all the filling data on the page (alarm counters, logic states and filling values) except for the Rcp[ml] or Rcp[ms] column. This button can be pressed at any time (e.g. during production or CIP cycles) without causing any problems. The button is only enabled when the Filling Master Card is phased.

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FILLING VALVE DATA DETAILS SUBPAGE

Click the box corresponding to the valve required to open a subpage called Filling Valve Data Details for the last filling operation performed by the valve. This page displays detailed information received from the slave cards in the Data Collection position. As well as the end of filling data shown on the previous pages, detailed diagnostics is shown for the errors and logic states of the individual cards. Refer to the colours in the legend shown on the right of the page to identify the meaning of each alarm and logic state indicator. Depending on the type of filler and the optional devices configured, different indicators are shown on the page. Read-only page:

A brief description is given below of the indicators displayed on the screen page: Manual Recipe status indicator: grey valve disabled; white OFF; blue manual recipe active on

the slave card transferred with filling command in manual. The manual filling command can be sent from the panel or the remote pushbutton panel (if fitted). CIP Mode status indicator: grey valve disabled; white OFF; blue CIP/RINSE mode enabled. Parameter alarm indicator: grey valve disabled; green valve parameterised; red valve not parameterised. In this case you must run the Download Parameters and Check command from the Filling Valves Maintenance or FMC PAS page.

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Pressure Sensor alarm indicator: grey valve disabled; green pressure sensor OK; red

pressure sensor installed on filling valve not functioning correctly. In this case, to prevent triggering of alarms caused by incorrect sensor measurement, disable the corresponding burst, snift and vacuum alarms on the Disable Filling Valves page. This indicator is only present if the pressure sensor option is configured. Flow Meter or Vortex or Mass Flow or Ultra Sonic Sensor (depends on the type of flow

rate measuring device configured). Alarm indicator: grey valve disabled; green measuring device OK; red measuring device not functioning correctly. The electronic card generates this alarm when no pulses are counted for a period of one second when the product valve is open. Before substituting the device, make sure the valve is opening correctly, check the product is moving in the pipe and the device is connected to the corresponding slave card. This indicator is only present if a flow meter is configured as a measuring device.

Probe alarm indicator: grey valve disabled; green probe functioning OK; red probe not

functioning correctly. This indicator is only present if a resistive probe is configured as a measuring device.

PWM alarm indicator: grey valve disabled; green PWM OK; red PWM of the electronic card

used to actuate the the digital outputs of the latter not functioning correctly.

Pressurization alarm indicator: grey valve disabled or burst check using pressure sensor

disabled or not configured; green bottle pressurisation correct; red bottle not pressurised. In the latter case the bottle is not OK and therefore is not capped. The pressure detected by the pressure sensor installed on the valve is not equal to the pressure in the tank; therefore the isobaric condition is missing. Correct pressurisation of the bottle ensures no foam during filling. With a cracked or damaged PET bottle, failed pressurisation causes filling to be stopped. Similarly, filling of glass bottles is stopped if the bottle is not gripped perfectly. This indicator is present only on fillers with the pressure sensor optional installed on the filling valve. This indicator is only present if the pressure sensor option is configured. Vacuum alarm indicator: grey valve disabled or vacuum check using pressure sensor

disabled or not configured; green vacuum in bottle OK; red vacuum in bottle less than the threshold set in the recipe. In the case of bottles which are cracked, damaged or not gripped perfectly, a missing vacuum does not cause filling to be stopped; however the bottle is not OK and is not capped. This indicator is only present if the pressure sensor option is

configured.

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Burst alarm indicator: grey valve disabled or burst check using pressure sensor disabled or

burst check using flow rate variation and pressure sensor not present; green good bottle; red burst bottle. In the latter case the bottle is not OK and therefore the cap is not released. Burst bottles often occur during pressurisation when there is a bottle defect (e.g. cracks). If the card detects, using the sensor installed on the on the valve, a sudden pressure variation or a difference in pressure between the bottle and the tank greater than the limit values set in the recipe, filling is stopped and in the event of a glass filler the washing ramps are actuated (if present and configured). On PET fillers with a flow meter, the burst check is also performed by checking the flow variation. This indicator is only present if the pressure sensor option or the flow variation check are configured. Set Point Trigger alarm indicator: grey valve disabled; green recipe set point trigger in [ml] reached; red recipe set point trigger in [ml] not reached. In this case the bottle is not OK and

therefore is not capped. In the event of timed filling (mode which can be set if there is a fault on the flow meter), the set point is when the time set is reached. This indicator is only present if a flow meter is configured as a measuring device. Probe Trigger alarm indicator: grey valve disabled; green recipe trigger in [mV] reached; red recipe trigger in [mV] not reached. In the latter case the bottle is not OK and therefore is not

capped. This indicator is only present if a resistive probe is configured as a measuring device. Snift alarm indicator: grey valve disabled or snift check using pressure sensor disabled or not

configured; green snift or bottle decompression OK; red snift or bottle decompression unsuccessful. In the latter case, as a result of failed decompression, the bottle is not OK and therefore is not capped. The pressure detected by the pressure sensor installed on the valve is greater than the threshold set in the recipe. This indicator is only present if the pressure sensor option is configured. Fill Running status indicator: grey valve disabled; white OFF filling sequence not enabled;

blue sequence enabled filling in progress.

Fill End status indicator: grey valve disabled; white OFF filling not completed or in progress;

green filling completed.

Bottle Burst Control with Pressure Sensor status indicator: grey valve disabled or burst

control disabled; blue burst control performed using pressure sensor installed on the filling valve actuated. This indicator is only present if the burst control using the pressure sensor option is configured.

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Bottle Vacuum Control with Pressure Sensor status indicator: grey valve disabled or

vacuum control disabled; blue vacuum control performed using pressure sensor installed on the filling valve actuated. This indicator is only present if the vacuum control using pressure sensor option is configured. Bottle Snift Control with Pressure Sensor status indicator: grey valve disabled or snift

control disabled; blue snift control performed using pressure sensor installed on the filling valve actuated. This indicator is only present if the snift control using pressure sensor option is configured. Displays the tail values calculated by the card during the last filing operation. This indicator is only present if a flow meter is configured as a measuring device.

Displays the flow rate values (present only if a flow meter is configured as a measuring device) and the temperature values (present only if the temperature sensor is configured).

Displays the current firmware version installed on the slave card selected.

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FORCE FILLING TIME SUBPAGE

Button to access the “Force Filling Time” subpage (only displayed if a flow meter is configured as a measuring device) Read-only page:

Use this page to force timed filling on a maximum of four valves. If a flow meter is not functioning correctly, production can be continued by forcing timed filling on the individual valve. The time used as the filling set point is the mean filling time of all the valves fitted on the filler. An adjustment time can be added to or subtracted from this mean time for each individual valve. This page is only present on fillers with flow meters. In the case of fillers with a resistive probe, the recipe already contains the Filling Timeout parameter. This is an emergency operating mode to be used only under exceptional circumstances until the faulty flow meter is substituted. The precision and repeatability of filling are not guaranteed.

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FILLING VALVES DATA PRESSURIZE SUBPAGE

Button to access the “Filling Valves Data Pressurize” subpage

Read-only page:

This page displays the filling values received from the electronic cards after the switch from the Data Collection position. These values show the result of the most recent filling operation performed by the valve with the bottle present. A legend is shown on the right of the page to facilitate understanding of the coloured indicators. Most of the indicators on the page have already been described on the “Filling Instruments Measure Data” subpage in this manual to which the reader is referred. Only the indicators not already described are detailed below. Pressure value [mbar] detected by the sensor installed on the valve during the last filling operation. A total of six pressure measurements can be taken during filling. The phases in which pressure is measured during filling must be selected in the recipe (manual or automatic); see the “Pick Pressure” parameter. This indicator is only present if the pressure sensor option is configured. Some of the status indicators shown above may not be displayed on the panel if the corresponding optionals are not configured of if they are not part of the design for the type of filler selected.

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FILLING VALVE DATA PRESSURIZE DETAILS SUBPAGE

Click the box corresponding to the valve required to open a subpage called Filling Valve Data Pressurize Details for the last filling operation performed by the valve. This page displays detailed information received from the electronic card in the Data Collection position. As well as the end of filling data shown on the previous pages, detailed diagnostics is shown for the errors and logic states of the individual cards. Refer to the colours in the legend shown on the right of the page to identify the meaning of each alarm and logic state indicator. Depending on the type of filler and the optional devices configured, different indicators are shown on the page. Read-only page:

For the description of the indicators present on the pages above, refer to the “Filling Instruments Measure Data”, “Filling Valve Data Details” and “Filling Valves Data Pressurize” subpages in this manual. Some of the status indicators shown above may not be displayed on the panel if the corresponding optionals are not configured of if they are not part of the design for the type of filler selected.

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STATISTICAL ANALYSIS FILLING VALVES SUBPAGE

Button to access the “Statistical Analysis Filling Valves” subpage.

Read-only page:

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FILLING MASTER CARD DIAGNOSTIC #1 SUBPAGE


Diagnostic page:

Use this page and the ones that follow to check operation of the Filling Master Card by analysing the various status indicators. The filling system should be considered as a module to run commands (see “FMC CMD”) which depend on specific operating conditions and references received as inputs (see “FMC DATA IN” and “FMC HW INPUT”); in turn the system is able to supply status, consent and value signals as outputs and to create events (see “FMC ACK”, “FMC DATA OUT” ,”FMC HW OUTPUT”, “FMC EVENTS”). -

“FMC CMD”: Requests to the Filling Master Card to run commands. “FMC ACK”: Running status of the commands sent or process logic states performed by the Filling

Master Card. -

“FMC DATA IN”: Signal logic states or reference values as inputs to the Filling Master Card. “FMC DATA OUT”: Functional signals or values calculated and sent back by the Filling Master Card.

Some of the status indicators shown above may not be displayed on the panel if the corresponding optionals are not configured of if they are not part of the design for the type of filler selected.

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Filling master card diagnostic #2 subpage


Diagnostic page:

-

“FMC EVENTS”: Events generated by the Filling Master Card as a result of specific operating

conditions. An event is linked to an action, e.g. bottle block or triggering of an alarm signal or display of a message on the filler alarm page.

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Diagnostic page:

-

“FMC SETTING”: Display of Filling Master Card configuration settings currently enabled. On the basis

-

of the options configured, the various options available on the filler are displayed/disappear with the relevant status indicators and control parameters (e.g.: purge command, temperature sensor etc.). N.B. The settings on this page are read-only and cannot be modified. “EXP FMC SETTING”: Button to export FMC configuration file to a USB memory stick.

The configuration parameters displayed on this page are set in the FMC_Setting.csv file housed on the memory card of the Filling Master Card and cannot be modified using the operator panel; this configuration file is read during each restart. To change these parameters, you must open and modify the file located on the flash card using Excel. Connect a memory stick to a USB port of the Filling Master Card to export (but not import) the configuration file. At the end of testing this file must be saved and stored with the machine documentation. The file exported onto the memory stick is unequivocally form that filler, i.e. it contains the name of machine serial number e.g. FMC_Setting SRMB0102.csv. Some of the status indicators shown above may not be displayed on the panel if the corresponding optionals are not configured or if they are not part of the design for the type of filler selected.

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Diagnostic page:

-

-

-

-

“FMC HW INPUT”: Cabled Hardware inputs (fast signals). These inputs are not displayed on the panel

if the Filling Master Card SW module is integrated in the B&R PLC which also manages the filler. However they are displayed in the case of an external PLC (Siemens, Allen Bradley, B&R etc.) dedicated to management of the filler and from which fast signals such as Presence or Preclosing can be received. “FMC HW OUTPUT”: Hardware outputs cabled for fast signals. These outputs are not displayed on the panel if the Filling Master Card SW module is integrated in the B&R PLC which also manages the filler. However they are displayed in the case of an external PLC (Siemens, Allen Bradley, B&R etc.) dedicated to management of the filler and to which fast signals such as Burst or Fill OK can be sent. “FMC BUFFER TX”: Total counters for the transmissions performed and in error, for each individual buffer, by the Filling Master Card to the slave cards of the network. The operating status of the RS485 network can be diagnosed from here. Two buttons are also displayed to reset the Tx counters. “FMC CLOCK PHASING”: clock time, clock delay, delay time between clock and valve no. 1 sensor. Some of the status indicators shown above may not be displayed on the panel if the corresponding optionals are not configured of if they are not part of the design for the type of filler selected.

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FILLING VALVE DISABLE SUBPAGE

Button to access the “Disable Filling Valves” subpage

Selection page

Use this page to disable the individual electronic filling valves by making a simple selection. The disabled valves do not receive the filling during production command when they move away from the opening position. When the selections are made, the corresponding alarm and status indicators on the diagnostics page turn grey (disabled status).

Button with confirmation pop-up window, deselects all the selections made on the page. The button is only enabled when the Filling Master Card is phased. Button with confirmation pop-up window, selects all the possible selections on the page. The button is only enabled when the Filling Master Card is phased.

WARNING: no valves can be disabled if CIP/RINSE mode is enabled. In this case the FMC removes all the disable modes set on the panel.

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BURST BOTTLE CONTROL USING PRESSURE SENSOR DISABLE SUBPAGE

Button to access the Burst Bottle Control Using Pressure Sensor Disable subpage

Selection page

Use this page to disable the burst bottle control of the individual electronic filling valves by making a simple selection. The valves with the control disabled do not perform the burst bottle control during filling in production. This selection is useful, if the pressure sensor installed on the valve is not operating correctly, to prevent bottle rejects at outfeed. This page is present only on fillers with both the pressure sensor and burst bottle control optionals configured. When the selections are made, the corresponding alarm and status indicators on the diagnostics page turn grey (disabled status).


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Vacuum Control Using Pressure Sensor Disable Subpage

Button to access the Vacuum Control Using Pressure Sensor Disable subpage

Selection page

Use this page to disable the vacuum control of the individual electronic filling valves by making a simple selection. The valves with the control disabled do not perform the vacuum control during filling in production. This selection is useful, if the pressure sensor installed on the valve is not operating correctly, to prevent bottle rejects at outfeed. This page is present only on fillers with both the pressure sensor and vacuum control optionals configured. When the selections are made, the corresponding alarm and status indicators on the diagnostics page turn grey (disabled status).


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Snift Control Using Pressure Sensor Disable Subpage

Button to access the Snift Control Using Pressure Sensor Disable subpage

Selection page

Use this page to disable the snift control of the individual electronic filling valves by making a simple selection. The valves with the control disabled do not perform the snift control during filling in production. This selection is useful, if the pressure sensor installed on the valve is not operating correctly, to prevent bottle rejects at outfeed. This page is present only on fillers with both the pressure sensor and snift control optionals configured on the filling valve. When the selections are made, the corresponding alarm and status indicators on the diagnostics page turn grey (disabled status).


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TEMPERATURE SENSOR DISABLE SUBPAGE

Button to access the “Disable Sensors Temperature” subpage

Selection page

Use this page to disable the individual temperature sensors on the electronic filling valves by making a simple selection. Disabled sensors are ignored by the Filling Mater Card and therefore temperature alarms are not triggered by these sensors. This page is present only on fillers with the temperature sensor configured. When the selections are made, the corresponding alarm and status indicators on the diagnostics page turn grey (disabled status).


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Part VI MANUAL FILLING TEST SUBPAGE

Button to access the “Manual Filling Test” subpage

Selection page

Use this page to select a valve and send a command to the valve for filling start with a suitably configured manual recipe. WARNING: when you have performed a filling operation in this mode, you must reload the production

recipe currently enabled on the filler otherwise the valve continues to perform filling operations using the recipe sent in manual mode. Refer to the production recipe pages for an explanation of manual recipe parameters. You must enable the “Manual Filling Test” mode using the two-position selector shown below to perform manual filling operations. Remember that this selector can only be enabled if the filler selectors on the operator panel toolbar are released. Button with pop-up confirmation window to command manual filling in step by step mode. To enable the button, select the check mark located to the left before pressing the manual opening command button on the control panel. Each programmed step in the manual recipe sequence is performed only after this button is pressed. This operation is useful to perform filling in sequenced mode to observe better the various phase transitions. Only accessible if the “Manual Filling Test” selector is enabled ON, the filler is stopped, bullet to the left of the button is selected and manual filling is not in progress.

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”Manual Filling Test” two-position selector enabled ON. When this selector is enabled

ON, the buttons located on the right of the page are released. A bottle block warning message (info) is displayed on the alarm page to indicate the ON status of the selector. To restart production in automatic mode at the end of manual filling operations, set the selector to OFF or remove the filler selectors release function on the operator panel toolbar If you wish to perform manual filling by sending the start filling command from the remote pushbutton panel (if fitted), the ”Manual Filling Test” selector on this page must always be enabled beforehand. The selector can only be enabled when the filler selector release is enabled, the Filling Master Card is phased, OPER. or IDLE mode enabled and “Manual Test Enable OK” signal from the filler in green ON status (cumulative signal for doors closed, safety devices enabled, etc.) For safety reasons it cannot be enabled in CIP/RINSE mode or simultaneously with other selectors of the Filling Master Card. Field to enter the number of the valve for which manual filling is required. Type in the number directly or scroll through the valve numbers using the arrows. By selecting the check marks for the individual burst bottle, vacuum and snift controls, the corresponding controls can be disabled during manual filling. By enabling the check marks on the “Manual Filling Valve Data Details” page, the corresponding status and indicators and turn grey (disabled). Button with confirmation pop-up window to load the recipe values currently present in the enabled production recipe and transfer them to the values of the manual recipe. Only accessible if the “Manual Filling Test” selector is enabled ON and manual filling is not in progress. Button with pop-up confirmation window to command manual filling start. The manual recipe is sent to the valve currently selected on the control panel and filling begins. At the same time as this operation, recording of the instantaneous values for flow rate, pressure or probe voltage (depending on the options installed) begins; the values are also displayed in graph format. Only accessible if the “Manual Filling Test” selector is enabled ON, the filler is stopped and manual filling is not in progress. If an opening command is sent using the remote pushbutton panel (if fitted), the command is sent to the valve located at the step set on the “FMC PAS” page and not to the number of the valve selected on this page. Manual filling cannot be performed on all the valves in the section between the outfeed starwheel and the infeed starwheel. Button with pop-up confirmation window to stop manual filling. The electronic card immediately stops manual filling by returning to the status of waiting for the initial command. Only accessible if the “Manual Filling Test” selector is enabled ON or manual filling is in progress.

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Part VI Graph filling instant data subpage

Button with pop-up confirmation window to access the “Graph Filling Instant Data” subpage Only accessible if the “Manual Filling Test” selector is enabled ON and manual filling is not in progress. Read-only page:

The Instant graph displays the data archived by the Filling Master Card during the last filling operation performed in manual mode. These values are sampled on the basis of a preset time in the recipe called Scope T. Sample Instant. This data archiving mode is only enabled during filling operations performed in manual mode.

Contrary to Storage, the type of data to be sampled does not have to be indicated beforehand; therefore the voltage of the resistive probe (if fitted) or the product flow value (if flow meters are fitted) and the pressure detected by the sensor (if fitted) are always sampled during each manual filling command. Press the button above the GetIData.csv file with the data archived by the Filling Master Card to recover the data from the Filling Master and display it in graph format on the panel. If another filling valve is selected, a new filling operation must be performed beforehand by pressing the manual opening button to generate a new file. This file can also be exported to a USB memory stick and analysed on a PC. The type of graph, filler serial number, the recipe currently enabled on the machine as well as the filler date and time are always displayed at the top of each graph (see pages below). If a USB memory stick is inserted in one of the two ports of the Filling Master Card and the last valve to have performed manual filling is interrogated to obtain the instant data graphs, the GetIData.csv file is also automatically copied on to the USB stick so it can be analysed on a PC. Each exported graph is copied into a sub-folder of a folder with a name which is identical to the machine serial number. The sub-folder is named using the valve number, date and time (e.g.: n94_Y11M03D24h11m13s05)

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Machine type with pressure sensor and/or flow meter

The individual graphs can be enlarged to full-screen size by clicking on the corresponding magnifying glass icon. Note how this page and successive ones can be used to send a new manual opening command, to modify the valve selection, redraw the graph, display filling details and stop the manual filling operation currently in progress.

By clicking on the upper magnifying glass icon:

Graph displaying the instant flow rate of the filling valve in [ml/s] and [ms].

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Graph displaying the instant pressure detected by the sensor installed on the valve in [mbar] and [ms].

Machine type with pressure sensor and/or resistive probe

The individual graphs can be enlarged to full-screen size by clicking on the corresponding magnifying glass icon. Note how this page and successive ones can be used to send a new manual opening command, to modify the valve selection, redraw the graph, display filling details and stop the manual filling operation currently in progress.

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Graph displaying the instant voltage of the filling valve probe in [mV] and [ms].


Graph displaying the instant pressure detected by the sensor installed on the valve in [mbar] and [ms].

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Description of buttons on graph pages:

The following buttons can be found on the Graph Filling Instant Data pages and the Graph Filling Storage Data pages.

Click this button to return to the page displaying both graphs which are also redrawn.

Click this button to zoom in on the graph displayed in full-screen mode.

Click this button to zoom out of the graph displayed in full-screen mode.

Click this button to scroll to the right the graph displayed in full-screen mode.

Click this button to scroll to the left the graph displayed in full-screen mode.

Click this button to redraw the graph by highlighting the values actually sampled by the card during manual filling. The graph displayed is the result of a spline interpolation of the points sampled.

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Graph Filling Storage Data subpage

Button to access the “Graph Filling Storage Data” subpage Only accessible if the “Manual Filling Test” selector is enabled ON and manual filling is not in progress. Read-only page:

The Storage graph, contrary to the Instant graph displays the data archived in the internal memory of the electronic card during the last filling operation. Once an initial delay, called Scope T. Delay Storage has elapsed, values are sampled on the basis of a preset time in the recipe called Scope T. Sample Storage. The internal sampling buffer of the slave card has 100 values. Contrary to Instant , you must first decide which type of value to sample i.e. the voltage of the resistive probe (if fitted), the product flow rate (if a flow meter is fitted) or the pressure of the sensor (if fitted). This method of archiving data is always enabled during each filling operation in manual mode (see manual recipe) and in production (see production recipe).

Press the button shown above to command the Filling Master Card to recover the data from the slave card and create an archive file called GetSData.csv which is shown in graph format on the panel. This file can also be exported to a USB memory stick and analysed on a PC. If a new filling valve is selected, press the button above again to recover the data for this new valve. The type of graph, filler serial number, the recipe currently enabled on the machine as well as the filler date and time are displayed at the top of each graph (see pages below). If a USB memory stick is inserted in one of the two ports of the Filling Master Card and a valve is interrogated to display the storage data in a graph, the GetSData.csv file is also automatically copied on to the USB stick so it can be analysed on a PC. Each exported graph is copied into a sub-folder of a folder with a name which is identical to the machine serial number. The sub-folder is named using the valve number, date and time (e.g.: n94_Y11M03D24h11m13s05)

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Machine type with flow meter

This page displays the graph in [ml/s] and [ms] for the flow rate sampled and archived in the internal memory of the electronic slave card during the last filling operation performed. Note how this page and successive ones can be used to send a new manual opening command, to modify the valve selection, redraw the graph, display filling details and stop the manual filling operation currently in progress. Machine type with pressure sensor

This page displays the graph in [mbar] and [ms] for the pressure sampled and archived in the internal memory of the electronic card during the last filling operation performed. Note how this page and successive ones can be used to send a new manual opening command, to modify the valve selection, redraw the graph, display filling details and stop the manual filling operation currently in progress.

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Machine type with resistive probe

This page displays the graph in [mV] and [ms] for the resistive probe data sampled and archived in the internal memory of the electronic card during the last filling operation performed.

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Manual filling valve data details subpage

Button with pop-up confirmation window to display a detailed subpage called “Manual Filling Valve Data Details” for the last filling operation performed by the valve selected. Detailed diagnostics is shown for the errors and logic states of the individual slave card. Refer to the colours in the legend shown on the right of the page to identify the meaning of each alarm and logic state indicator. Depending on the type of filler, different indicators are shown on the page. Only accessible if the “Manual Filling Test” selector is enabled ON and manual filling is not in progress. Read-only page: Machine type with flow meter and pressure sensor

These values show the result of the most recent filling operation performed by the valve in manual or in production. The data for the valve selected is updated automatically when the page is opened. If another filling valve is selected, press the button again to update the data on the page. For the description of the indicators present on the pages above, refer to the “Filling Instruments Measure Data”, “Filling Valve Data Details”, “Filling Valves Data Pressurize” and “Filling Valve Data Pressurize Details” subpages in this manual. Some of the status indicators or fields to insert data shown above may not be displayed on the panel if the corresponding optionals are not configured or if they are not part of the design for the type of filler selected.

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FILLING VALVES MAINTENANCE SUBPAGE

Button to access the “Filling Valves Maintenance” subpage Selection page: can only be accessed and used by those with supervisor access level authority Read-only page:

Use this page to perform the following maintenance operations on the filling valve electronic-pneumatic units ( slave cards): -

slave card addressing with allocation of the new node using the serial number; verification of the node set on a slave card using the serial number; verification of the serial number of a slave card using the node; slave card firmware updating; firmware writing; firmware for archive file importation/exportation from/to USB memory stick backup recipes: importation/exportation from/to USB memory stick of archive file; sending the abort command to all the slave cards in the network (“Abort Valves”); loading of configuration parameters on the slave cards with verification of the firmware installed (“Check Valves”). Some of these operations can only be performed when the corresponding two-position selectors are enabled and when the filler selectors on the operator panel toolbar are released.

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“Filling Valves Addressing” two-position selector When this selector is enabled ON, the buttons located in

the selector box are released. A bottle block warning message (info) is displayed on the alarm page to indicate the ON status of the selector. To restart production in automatic mode, set the selector to OFF or remove the filler selectors release function on the operator panel toolbar. The selector can only be enabled when the filler selector release is enabled, the filler is empty and OPER. or IDLE mode are enabled. For safety reasons it cannot be enabled in CIP/RINSE mode or simultaneously with other selectors of the Master Card.

Button with confirmation pop-up window to display “Read Serial Number by Address”. Enter the node number of the electronic-pneumatic unit you wish to interrogate in the “Valve Number” field and press the corresponding button; the Filling Master Card sends a command to this card which responds with its own serial number and the firmware version currently loaded. If the card interrogated is disconnected or not programmed with this node number, the reply fields “Serial Number” and “Version” remain set to zero. Communication faults may occur in the reply if two cards parameterised with the same node number are connected to the network (both reply simultaneously thus creating a conflict). In the event of Tx errors, refer to the transmission alarm counter diagnostics pages and the valve alarm page. Node numbering is unequivocal.

Button with pop-up confirmation window, “Set Address by Serial Number”. This function is used if an entire valve control electronic-pneumatic unit must be substituted. Enter the serial number printed on the valve control unit in the “Serial Number” field and the node number you wish to assign in the “Valve Number” field and press the corresponding button to command the Filling Master Card card to send a broadcast to all the slave cards connected to the network. Given that the serial numbers of the control units

are unequivocal, only one node will reply to the command by making the node number sent its own. When you have parameterised the slave card with a new node, perform a check by interrogating the node you have just configured using the serial number or the node itself to ensure the serial number is correct.

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Button with pop-up confirmation window, “Read Address by Serial Number”. Enter the serial number of the electronic-pneumatic unit you wish to interrogate in the “Serial Number” field and press the corresponding button to command the Filling Master Card card to send a broadcast to all the slave cards connected to the network. Given that the serial number of the control unit is unequivocal, only one node will reply to the command with its own number. If the slave card interrogated is disconnected or there is no match for the serial number requested, the “Valve Number” reply field remains set to zero. Communication faults may occur in the reply if two slave cards parameterised with the same serial number are connected to the network (both reply simultaneously thus creating a conflict). In the event of Tx errors, refer to the transmission alarm counter diagnostics pages and the valve diagnostics alarm page.

The button to the left is only enabled when a USB memory stick is connected to one of the two USB ports present on the Filling Master Card. If a memory stick is connected the colour of the indicator top left is green. Press the button to the left to display the “Copy File Firmware MOT” pop-up window. Use this window to decide whether to copy the “Filling_Valve.mot” file containing the firmware to be updated on the control units from the USB memory stick to the Filling Master Card or vice versa. If the file is copied correctly, the indicator top left is green otherwise it is red to indicate a fault. Press the button top right “Start Firmware Compile”, with confirmation pop-up window, to compile the firmware; this operation requires several minutes for completion and must be performed before any updating is performed. If the firmware is not compiled, the indicator in the top left corner of the button is red. The indicator is green when the firmware is compiled. The compilation process can be started under any conditions. If there is no MOT file to compile then the button cannot be accessed. Read the diagnostics messages displayed in the “Messages Diagnostic” field.

Each time the “Filling_Valve.mot” file containing the firmware to be updated is copied and overwritten on the one present on the Filling Master Card, you must recompile the firmware before proceeding to update the control units. The firmware must also be recompiled if the voltage is cut to the master card. Compilation should also be performed before each firmware updating operation. If the firmware is not compiled the message “WARNING Filling_Valve.mot – Not Compile” is displayed in the field “Messages Diagnostic”.

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The button opens the pop-up window shown below. The upper and lower buttons are used to copy from and to the USB memory stick and are only enabled when a memory stick is connected to one of the two USB ports on the Filling Master Card. The middle button starts the procedure to create the RcpBackup_XXX.csv file on the flash card of the Filling Master Card; XXX indicates the serial number of the machine e.g.: RcpBackup_SRMB0102.csv . Creation of this file requires at least 20 minutes during which time all the buttons are disabled, the middle one is red and the warning “ Creating File RcpBackup.csv – Please Wait ” is displayed in the “Messages Diagnostic” window. The backup process can be started at any time when the machine is in production or CIP. However once the process has begun it cannot be interrupted. Wait for the process to finish. If at least one recipe backup file has been created and is present on the flash card, then the file can be exported to the USB memory stick connected by pressing the lower button in the pop-up window. Recipe backup files previously saved can also be imported from the USB memory stick by pressing the button in the upper part of the pop-up window. The import process requires approximately twenty minutes, just like the backup process. Any faults occurring during transfer or creation of the file are signalled in the “Messages Diagnostic” window. A recipe backup file can only be imported if the serial number contained in the name of the file matches the name set in the “Filler Serial Number” parameter (see the “FMC_Setting.csv” file).

”Firmware Update” two-position selector. When this selector is enabled ON, the “Start Firmware Update” button with confirmation window and the “From Valve” and “To Valve” data fields contained in the selector

box are released. A bottle block warning message (info) is displayed on the alarm page to indicate the ON status of the selector. To restart production in automatic mode, set the selector to OFF. The selector can only be enabled if the firmware present on the Filling Master Card has been compiled. Note the “Faults Counter” field showing the faults occurring during the firmware update operation. Also read the diagnostics messages displayed in the “Messages Diagnostic” field. The selector can only be enabled when the firmware is compiled, the filler is empty and OPER. or IDLE mode is enabled. For safety reasons it cannot be enabled in CIP/RINSE mode or simultaneously with other selectors of the Filling Master Card. This selector is not linked to the status of the selector release button located on the filler control toolbar.

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“Check Valves” button with confirmation pop-up window. Press this button to send to the control units the configuration parameters set on the “FMC PAS” page where a button identical to this one is displayed.

The firmware version currently loaded on the valve control unit is also checked. The button is only enabled when the machine is empty. A bottle block warning message (info) is displayed on the alarm page to indicate the running status of the command. This button must be pressed following the physical substitution of a valve control unit. This button must also be pressed after modification of one of the configuration parameters on the “FMC PAS” page where a button identical to this one is displayed. Furthermore after each restart caused by a voltage cut, the system performs a filler phasing operation (search for the sensor of valve no. 1) and then automatically recalls this parameterisation function.

An abort command is sent to all the slave cards present in the network when this button is pressed. Only press themodes buttonorwhen you wish to reset fully alltest, the network enabled commands ( OPER ., manual etc.). nodes by forcing the exit of the nodes from all The command is always accepted except when the the “Filling Valves Addressing” or “Firmware Update” selectors are enabled or with “CIP/RINSE” mode enabled.

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MANUAL TEST FILLING VALVE OUTPUTS SUBPAGE

Button to access the “Test Outputs Filling Valves” subpage

Selection page

“Manual Test Filling Valve Outputs” two position selector enabled ON.

When this selector is enabled ON, the direct commands of the individual outputs located on the right of the page are enabled. A bottle block warning message (info) is displayed on the alarm page to indicate the ON status of the selector. To restart production in automatic mode after the manual test, set the selector to OFF or remove the filler selectors release function on the operator panel toolbar. This operation also disables OFF all the forced operations enabled on the filling valve outputs. The selector can only be enabled when the filler selector release is enabled, the Filling Master Card is phased, OPER. or IDLE mode enabled and “Manual Test Enable OK” signal from the filler in ON status (cumulative signal for doors closed, safety devices enabled, etc.) For safety reasons it cannot be enabled in CIP/RINSE mode or together with other selectors of the Filling Master Card. Field to enter the number of the valve for which manual testing is required. Type in the number directly or scroll through the valve numbers using the arrows.

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Button with forcing enabled. The corresponding electrical output of the filling valve currently selected is forced to OFF status. Button with forcing disabled. The corresponding electrical output of the filling valve currently selected is forced to OFF status. Button with forcing inhibited.

Some of the status indicators or fields to insert data shown above may not be displayed on the panel if the corresponding optionals are not configured or if they are not part of the design for the type of filler selected.

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SEQUENCER OUTPUTS FILLING VALVE #1 SUBPAGE


Selection page

Sequencer outputs filling valve #2 subpage


Selection page

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Use this page to program the Rinse Sequence, Flushing Sequence, Drain Sequence and Priming Sequence. These sequences are fixed (there are no recipes) and involve, for each individual output, programming of eight timed phases during which the command logic status can be defined (ON or OFF of the individual outputs). There is also a sequence start delay parameter expressed in machine steps relative to the command send position which matches the Filling Start position. These sequences can be enabled on request (see FMC CMD and FMC ACK on the first “Filling Master Card Diagnostic” subpage) only in OPER. mode when the filler is rotating and there are no bottles. If an incorrect sequence is programmed i.e. the sum of phase times exceeds the time needed for a filler revolution, the sequence is stopped when the valve moves away from the tangent position on the inlet starwheel. The sequences are not performed if the Master Card is in CIP/RINSE or IDLE mode. Their use is strictly linked to the type of machine (glass, cans, plastic, still water, etc.) in that they enable running of alternative sequences to filling not linked to product or bottle presence.

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Part VI FMC DIAGNOSTIC SUBPAGE

Button to access the “ FMC Diagnostic” subpage

Selection page

Filling Master Card diagnostics page. The Web Server integrated in the B&R PLC can be used to monitor the operating status of the PLC by checking for example use of the CPU, allocation of the memory, hardware status, etc. The page is read-only. If you wish to monitor operating status directly from your own PC, open Internet Explorer and enter the TCP/IP address of the Filling Master Card, e.g.: http://10.1.20.17/sdm (the system asks for a plug-in to be installed).

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6.4

RECIPES

Function to access the “Recipes” page. H

I

K

J

L

M

N

O

A

G

B P

C

D E

F

A.

Press this button to access the active recipe selected.

B.

Press this button to edit any recipe i.e. compile all available parameters.

C.

Press this button to download a recipe.

D.

Press this button to upload a recipe.

E.

Press this button to cancel the recipe selected.

F.

Press this button to copy the recipe required.

G.

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Recipe status display: red = ON-LINE green = OFF-LINE

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H.

Select this menu to access the recipe index page showing all the available OFF-LINE (inactive) and ON-LINE (active) recipes.

I.

Select this menu to access the general recipes and product pages.

J.

Select this menu to access the recipe page dedicated to tank level control.

K.

Select this menu to access the recipe page dedicated to pressure controls.

L.

Select this menu to access the recipe page dedicated to the rinser, specifically setting of the times applied to air and water treatment.

M.

Select this menu to access the first part of the production recipe relating to the filling valves.

N.

Select this menu to access the second part of the production recipe relating to the filling valves.

O.

Select this menu to access the part of the production recipe concerning the filling Set Point of the filling valves.

P.

List of recipe names.

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GENERAL DATA WINDOW

A

B

C

D

This page shows data for the bottle used in the recipe. GENERAL A. B. C.

Bottle Size: the size in mm of the bottle used in the recipe. Machine Speed: maximum machine speed for this size. Outfeed Conveyor Motor 1 KS: ratio constant between machine speed and outfeed belt speed.

CAPPER D.

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Cap type: numeric value representing the type of cap used for this size (see legend).

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GENERAL DATA WINDOW FOR HOT MACHINES

A B C

D E

K

F

L

G

M

H

N

I

O

J

GENERAL A.

Bottle Size: the size in mm of the bottle used in the recipe.

B. C.

Machine Speed: maximum machine speed for this size. Outfeed conveyor motor 1 KS: ratio constant between machine speed and outfeed belt speed.

TEMPERATURE CONTROL D. E. F. G. H. I. J.

Infeed tank - Set Point 1: Product tank temperature Set Point. Infeed tank - Low temp. alarm: Product delivery low temperature alarm threshold. Infeed tank - High temp. alarm: Product delivery high temperature alarm threshold. Recycling tank - Set Point 1: Recycling tank temperature Set Point. Recycling tank - Low temp. alarm: Product return low temperature first alarm threshold. Recycling tank - Very low temp. alarm: Product return low temperature second alarm threshold. Recycling tank - High temp. alarm: Product return high temperature alarm threshold.

WASHING WITH HOT WATER K. L.

Set point: steam temperature Set Point value. Proportional gain: Gain parameter for PID regulation.

M. N. O.

Integral time: Integral parameter for PID regulation. Derivation time: Derivative parameter for PID regulation. Feed - Forward: feed forward parameter value for PID adjustment corresponds to opening of the modulating valve when the machine is operating at speed (maximum speed, full of bottles).

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General data window for machines with AROL Equatorque crown capper

A

Contains the data relative to the sizes of the AROL Equatorque crown capper. 1.

Positioning of Motors.

--

Centralbody guide Bottle pad Extractor pad (Bottle Outfeed)

2.

Access to page to enter closing data.

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CLOSING DATA

Contains the data relative to the AROL Equatorque capper: Press this button to Upload the capper data contained in the PLC or to load the default operating data. Start Main Angle:

Closing cycle start angle from which the motor head is activated with rigid axis. Position always before the Down Main Angle.

Down Main Angle:

Head lowering start angle from which the rotation of the motor head starts.

Close Main Angle:

Angle in which the head starts the actual closing of the bottle; this position must normally occur before that in which the cap starts to interfere with the neck of the bottle.

End Main Angle:

End of closing cycle angle, represented by the position in which it lifts from the closed bottle.

Lock Mode:

Type of closing algorithm used: 0. Torque: 1. Torque + No Speed. 2. 50.

Unwarp + No Speed. Position

Closure Torque:

Final closing torque (Nm). Indicates the torque for the final tightening of the bottle.

Gearing Ratio:

Ratio between the carousel speed and the initial rotation speed of the motor head.

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Slow Torque:

Slowing torque (Nm), after which the head slows down before the final part of the closing.

Gearing Holding:

Angle relative to the measurement position of the first threshold for maintaining the rotation of the heads in Gearing mode with the capper speed.

Closure Speed:

Rotation speed (rpm) for the final tightening; it must be sufficiently low to limit the inertia effect.

Closing Acceleration:

Acceleration limit (head revs/s2) during the closing phase.

Stop Factor Speed:

Percentage of the final closing speed to consider the cap closed with LockMode = "No Speed".

Blind Input Angle:

Angle relative to "Close Main Angle" for measuring the first threshold.

Torque Time:

This is the time for maintaining the cap torque at the end of the closing phase.

Unwrap Angle:

Cap unscrewing angle before low speed closing with LockMode = "Unwrap". Screwing takes place with a negative value.

Unwrap Speed:

Cap closing speed before low speed closing with LockMode = "Unwrap".

Unwrap Acceleration:

Acceleration limit (head revs/s2) during any reopening phase with LockMode = "Unwrap".

Unwrap Blind Main Angle:

Angle of carousel before which no unscrewing is performed.

Cap Turn Not Reached:

Rotation angle.

Fault Enable – Not In Torque:

Enabling "Not In Torque” alarm (Cycle ended during the Torque phase).

Fault Enable – Bad Closure:

Enabling "Bad Closure" alarm (Torque applied but speed above "Stop Factor Speed").

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Part VI


LEVEL DATA WINDOW A B C D E F G H I J K

Contains the data required by PID adjustment for the tank level. A.

Set Point: percentage value of tank level to be adjusted.

B. C. D. E.

Proportional gain: Gain parameter for PID regulation. Integral time: Integral parameter for PID regulation. Derivation time: Derivative parameter for PID regulation. Feed Forward: feed - forward parameter value for PID adjustment corresponds to opening of the

F.

G.

H.

modulating valve when the machine is operating at speed (maximum speed, full of bottles). Ramp speed: Feed - Forward percentage value added until the maximum or minimum (zero) “Feed Forward” parameter is reached. Used during transitions (machine filling / emptying). This parameter sets the opening / closing speed of the modulating valves during transitions. FF increase ramp delay steps: the delay in machine steps (bottles) before the Feed Forward increase ramp starts (from zero to the value set). This matches approximately the number of steps between the opening command and filling start i.e. the number of steps required for vacuum / pressurisation (by the filling valve recipe). FF decrease ramp delay steps: the delay in machine steps (bottles) before the Feed Forward decrease increase ramp starts (from the current value to zero). This matches approximately the number of steps between the opening command and filling start (by the filling valve recipe).

I.

Maximum level: the percentage level above which the product infeed modulating valve is forced closed by the safety valve (not the same value as the Set Point).

J.

Minimum level: percentage level below which the machine, if in production, is stopped in alarm status

K.

(absolute value). Level OK: percentage hysteresis relative to the Set Point which, when reached, is considered the set point value (not the same value as the Set Point).

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LEVEL DATA WINDOW FOR HOT MACHINES

A

I

B

J

C

K

D

L

E

M

F

N

G H

Product tank level A. B. C.

Set point: percentage value of level to be adjusted. Maximum level: maximum level alarm. Minimum level: minimum level alarm.

D. E. F. G. H.

Level OK: correct level off set reached. Shaker speed: shaper operating speed. Spray ball infeed time ON: tank infeed with spray balls ON time. Spray ball infeed time OFF: tank infeed with spray balls OFF time. Enable spray ball infeed: Product infeed by spray ball enabling.

Recycling tank level I. J. K. L. M. N.

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Set point in CIP: percentage value of level to be adjusted during sanitization. Pump start level in CIP: percentage value to enable pump start during sanitization. Set point in production: percentage value of level to be adjusted during production. Pump start level in production: percentage value to enable pump start during production. Minimum level: minimum level alarm. Maximum level: maximum level alarm.

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PRESSURE DATA WINDOW A B C D E F G H I J K L M

Contains the data required by PID adjustment for the tank pressure. A. B. C. D. E. F.

G.

H.

I.

Set Point: percentage value of tank level to be adjusted. Proportional gain: Gain parameter for PID regulation. Integral time: Integral parameter for PID regulation. Derivation time: Derivative parameter for PID regulation. Feed Forward: parameter value for PID adjustment corresponds to opening of the modulating valve

when the machine is in loading transition (bottle feed starts). Ramp speed: Feed - Forward percentage value added until the maximum or minimum (zero) “Feed Forward” parameter is reached. Used during transitions (machine filling / emptying). This parameter sets the opening / closing speed of the modulating valves during transitions. FF increase ramp delay steps: the delay in machine steps (bottles) before the Feed Forward increase ramp starts (from zero to the value set). This matches approximately the number of steps between the opening command and pressurisation start i.e. the number of steps required for vacuum (by the filling valve recipe). FF decrease ramp delay steps: the delay in machine steps (bottles) before the Feed Forward decrease increase ramp starts (from the current value to zero). This matches approximately the number of steps between the opening command and vacuum end (by the filling valve recipe). FF change delay time: the time during which the Feed Forward value is maintained before the decease ramp to Feed Forward value 2. Matches approximately pressurisation time (by the filling valve recipe).

J. K. L. M.

Feed Forward 2: feed - forward parameter value for PID adjustment corresponds to opening of the

modulating valve when the machine is operating at speed (maximum speed, full of bottles). Maximum breather pressure: the pressure at which the breather valves are enabled (not the same value as the Set Point). Maximum breather hysteresis: the pressure hysteresis at which the breather valves are disabled (not the same value as the Set Point). Minimum pressure in production: pressure value below which the machine, when in production, is stopped in alarm status (not the same value as the Set Point).

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HOT PRESSURE DATA WINDOW

A B C D E F

A. B. C.

Set point: filling value in mm corresponding to the pressure on the bottle. Proportional gain: Gain parameter for PID regulation. Integral time: Integral parameter for PID regulation.

D. E. F.

Derivation time: Derivative parameter for PID regulation. Set Point 50%: bottle filling value in mm with machine speed at 50% of the nominal value. Machine stopped recycling percentage: Product recycling percentage when the machine is stopped.

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FOAMER DATA WINDOW

A B C D E F G H

Contains the data required by PID adjustment for the foamer temperature and pressure. A. B.

Set Point: percentage value of tank level to be adjusted. Proportional gain: Gain parameter for PID regulation.

C. D. E. F. G.

Integral time: Integral parameter for PID regulation. Derivation time: Derivative parameter for PID regulation. Maximum temperature: Maximum temperature parameter for PID adjustment. Minimum temperature: Minimum temperature parameter for PID adjustment. Feed Forward: feed forward parameter value for PID adjustment.

H.

This type of control predicts how the system will perform in the future and makes adjustments based on this estimate. These corrections are used to correct the mean instantaneous error enabling the PID to correct the error thus improving the performance of the system. Pressure: display of filling speed with relative pressure.

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RECIPE PRODUCTION WINDOW Machine type with purge option and pressure sensor

A B C

D E F

J

G

M

H

L

I K

These pages contain the recipe data needed to command the filling valves during production. The recipe is divided into 14 phases as well as the preliminary flushing (present if configured) and valve spout purge (present if configured) zero phase. During each phase it is possible to decide which solenoid valves to open, for how long and where the set point trigger or probe trigger should be set. Some of the status indicators or fields to insert data shown above may not be displayed on the panel if the corresponding optionals are not configured or if they are not part of the design for the type of filler selected. DESCRIPTION OF ELECTRONIC VALVE OUTPUTS ON THE BASIS OF THEIR USE: A.

B. C.

D.

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Fast Filling: solenoid valve used to pressurise the bottle (with the Opening valve closed) or to fill at

higher speed (with Opening valve open) by removing the CO2 inserted during filling from a larger passage. Opening: solenoid valve used to open the valve shutter to allow product infeed into the bottle. Slow Filling: solenoid valve used to pressurise the bottle (with the Opening valve closed) or to fill at reduced speed (with Opening valve open) by removing the CO2 inserted during filling from a smaller passage. Snift/Decompress: solenoid valve used to open the bottle decompression circuit at the end of filing.

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Part VI


Controls which can only be set with the pressure sensor configured: E.

F.

G.

H.

I.

J.

Control Burst: used to indicate during which phase of the recipe the burst bottle control is to be

performed using the pressure sensor installed on the valve (visible if the “Presence Pressure Burst Control” parameter is configured). Pick Pressure: used to indicate during which phase of the recipe the pressure should be detected using the pressure sensor installed on the valve. A maximum of 6 pressure value can be detected during a single filling operation (visible if the “Presence Sensor Pressure” parameter is configured). Max Delta Press Tank-Bottle: maximum pressure differential value expressed in [mbar] between the tank and the bottle; the bottle burst alarm is triggered if this limit is exceeded during filling (visible if the “Presence Burst Control” maximum parameter pressure is configured). variation value expressed in [mbar]; the bottle Burst: MaxPressure Pressure Variation: burst alarm is triggered if this limit is exceeded during filling (visible if the “Presence Pressure Burst Control” parameter is configured). Burst: Control Time: burst bottle control time expressed in [ms]; indicates the frequency with which the check on pressure variation indicated in the previous parameter is performed (visible if “Presence Pressure Burst Control” parameter is configured). Snift: Max Pressure: maximum pressure value in [mbar] above which the snift operation performed on the bottle at the end of filling is considered incorrect and a bottle snift alarm is triggered (visible if the “Presence Pressure Snift Control” parameter is configured).

Parameters which can only be set with the flow meter configured: K.

L.

Burst: Max Flow Variation: maximum flow rate variation value expressed in [mbar]; the bottle burst

alarm is triggered if this limit is exceeded during filling (visible if the “Presence Flow Var. Burst Control” parameter is configured). Trigger Set Point: Phase Wait: recipe phase during which the set point trigger is reached in [ml] (if flow meter configured) or in [ms] (if no flow meter configured) set on the “Set Point” recipe subpage.

Decompression/dynamic snift parameters:

Each individual slave card calculates automatically the advance in steps (compared to the outfeed position) when the final dynamic snift sequence begins. To make this calculation the slave cards receive during each machine step the real speed of the filler in [bott/min/10] (see parameters relating to filling steps on the “FMC PAS” page). M.

Snift Dynamic: Phase Start: recipe phase in which the dynamic snift operation on the bottle begins and the snift control becomes operative (only if the “Presence Pressure Snift Control ” is configured).

If the Snift/Decompress outlet is set to ON during the recipe 14 phase, this stays open at the end of the set dynamic decompression time. The phase 14 time may also be set to zero [ms].

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RECIPE PRODUCTION WINDOW

B A

A.

Preclosing Time: the filling pre-closing time. This parameter is sent by the Filling Master Card to the

B.

slave card with the valve opening command when a valve must be pre-closed and therefore a bottle must be under-filled and rejected at outfeed. It is not present in the still product fillers. Data acquisition parameters for the “Storage” graph. The values sampled during the last filling operation are housed the internal memory of the electronic card.ofOnce an initial hasonelapsed, values are sampled on the basis a preset time delay, in the called recipe Scope called T. Delay Storage Scope T. Sample Storage. The internal sampling buffer of the card has 100 values. You must first decide which type of value to sample i.e. the voltage of the resistive probe (if fitted), the product flow rate (if a flow meter is fitted) or the pressure of the sensor (if fitted). This method of archiving data is always enabled during each filling operation in manual mode (see manual recipe) and in production (see production recipe). The internal buffer of the card is filled with the data collected on the basis of the parameterisation received with the last recipe.

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Part VI SET-POINT WINDOW

Use this page to set for each individual filling valve the volume set point expressed in [ml] (if flow meter fitted), the time set point expressed in [ms] (if no measuring device is fitted), or the delay time expressed in [ms] for valve closing to be counted after intervention of the trigger (if resistive probe fitted).

This is the field for entering the value you wish to add to or subtract from all the fields on the page.

Button to increase the values of all the fields on the page

Button to decrease the values of all the fields on the page

Button to reset all the values on the page

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6.4.1

Layout

Function to access the “Layout” page.


Displays the overall layout of the machine with the relevant warning icons, such as: No auxiliaries.

No bottles at infeed.

No bottles at outfeed.

Bottle block.

Gripper released on rinser. No caps in crown capper starwheel. Outfeed pit.

Reject outfeed clogged.

Outfeed belt control.

Lubrication alarm.

Greasing alarm.

Operator guards.

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Part VI

Emergency stop buttons.

Double neck.

No bottles at filler outfeed.

Access to the subpage to enter the value (% of CO2) for the safety threshold in the filling chamber. Access to the subpage used to display the system designed to count repeat consecutive errors and total accumulated errors by the photocells used to check bottle presence at machine infeed and outfeed. A preset value for the errors can also be set (only on COMBI version machines).

Control area

Button: press to enable the burst bottle test procedure.

2-way selector: conveyor start authorisation.

Displays the window showing the data required for the burst bottle test procedure.

Two-way selector: chamber light ON control.

Displays the window showing burst bottle diagnostics (glass bottle machines).

Button to reset the errors accumulated by the photocells used to detect bottle presence at machine infeed and outfeed (only on COMBI version machines).

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Page change area

Press this to display the “Conveyors” window. H A

I

B

J

C

K

D

L

E

M

F

N

G O P Q R S T

This page displays the status of the signals exchanged between the filler and bottle conveyors. Signals for conveyors A. Machine ready. B. Bottle block open. C. Conveyors in automatic mode. D. Machine empty. E. Outfeed conveyor running. F. Machine speed. G. Conveyor speed. Signals from conveyors H. Outfeed conveyor ready. I. Bottle block from outfeed belts. J. Maximum speed from outfeed conveyors. K. Rejects clogged. L. Outfeed: FBI fault. M. Outfeed: FBI too many rejects. N. Infeed conveyors ready. O. Bottle block from infeed belts. P. Speed reduction from infeed conveyors. Q. Maximum speed from infeed conveyors. R. Restart in automatic. S. Speed from labeller. T. Line speed reference.

Displays the status of the signals exchanged between the filler and bottle conveyors.

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Part VI

Displays the “Burst Bottle Diagnostics”.

A

B

C

D

E F

This page displays the status of the filling valves in terms of burst bottles. System description:

On the Operator Panel a “Counter with variable colour background” (F) is displayed for each valve, indicating bottle burst status and the number of burst bottles for the same valve. The colour depends on the code written inside the Byte related to the valve: Use the ”Info” key (E) to display a description of the colour code in compliance with the following table: Code

Colour

0

Grey

no burst detected

Meaning

1

Red

burst detected

2

Orange

Preclosing cycles in progress

3

Yellow

End of preclosing cycles

4

Green

End of preclosing and washing cycles

With the Yellow or Green colour the bottles are blocked. With the Green colour the machine is stopped with the valve positioned at the outfeed of the third washing ramp (after a complete emptying cycle). The Operator checks the cleanliness of all the Green valves and then presses the Reset Button ( B) that turns the green counters back to the colour grey. The machine can re-start only after a command from the Reset Button. The “Burst Reset Button” ( C) resets all the counters (colour display only) by turning them back to the colour grey. If the Machine Stop selector ( A) is disabled, it does not block the bottles and does not stop the machine (the counters stay in the relative colour) The “Counter Reset Button” ( D) resets all the counters (numeric display only) by setting them at 0 (zero).

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6.4.2

Graphics

Function to access the “Graphics” page.

Control area

Select the trend to be displayed.

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Part VI 6.4.3

Maintenance

Function to access the “Maintenance” page.

Navigation page: Use this page to activate various commands regarding maintenance of the machine so as

to keep it in good working order and efficient over time. This page displays buttons for opening the following submenus. The submenus available depend on the machine specifications or options: Summary diagram area

Displays “Machine Drives” subpage.

Displays “Brushless Machine Drives” subpage.

Displays “Machine Greasing” subpage.

Displays “Manifold Lubrication” subpage.

Displays “Filter Sterilization” subpage.

Displays “Jack Lubrication” subpage.

Displays “Profibus Diagnostics” subpage.

Control area

Two-way selector: jack air discharge control.

Two-way selector: filling valve air discharge control.

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Three-way selector: external washing control.

Two-way selector: burst bottle machine stop control.

Two-way selector: inspector safety device override.

Two-way selector: bottle encoder control.

Two-way selector: filling valve release enabling control.

Three-way selector: filling valve roller washing control.

Button: press to enable the burst bottle test procedure.

Two-way selector: burst bottle machine stop enable.

Two-way selector: Nitrogen doser enable.

Two-way selector: Flushing pad enable.

Two-way selector: Enable supplementary breather process actuated automatically when the bottles pass through the machine.

Three-way selector: Bottle shower at outfeed control.

Two-way selector: Enable bottle size changeover.

Two-way selector: Enable machine washing.

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MACHINE DRIVES SUBPAGE

Select this to open the Machine Drive subpage.

Navigation page: Use this page to access the various subpages for the motors controlled by an inverter

fitted on the machine. This page displays buttons for opening the subpages for the profibus node for the motor selected. The subpages available depend on the machine specifications or options. Summary diagram area (only for machine motors on the Combi version)

This page shows all the information needed to monitor functioning of the machine motor selected:

This window displays the states of the frequency converter of the main motor of the filler. The analogue values of the encoders of the main motor of the Filler (X55-SLAVE) and of the Blower (X56MASTER). The Program State window displays the states of the Syncposs card during synchronisation of the two machines.

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Part VI

Summary diagram area (for machine motors in the standard version + all other motors)

This page shows all the information needed to monitor functioning of the motor selected: E

A

B

C

D

A. Number and type of alarm present on the driver. B. Driver status. C. Select the parameter to be displayed in this section. D. Values of selected parameters. E. In data values being read from the driver.

Press this to display the "Trend" window. Showing the frequency, current, power and torques. Press this to display the values read from the driver for the parameters/data selected in zone #3.

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MACHINE BRUSHLESS MOTOR SUBPAGE

Select this to open the Machine Brushless Motor subpage.


This page shows all the information needed to monitor the operation of the brushless motors on the machine.

This page displays the states and operating modes of the MAX4 controller. It also shows the position, status, absorbed power and enabling of the motors present on the filler.

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Press this to open the “Brushless Motor Maintenance" page.

B C

A

D1 D D2 D3

E

F

A. B. C. D.

E. F.

Two-position selector: Enable rinser motor control. Two-position selector: Enable base motor control. Two-position selector: Enable filler motor control. Two-position selector: Position at the distance selected. D.1 Area to enter the rinser positioning offset. D.2 Area to enter the base positioning offset. D.3 Area to enter the filler positioning offset. Button: “Home” control (machine in phase). Two-position selector: Enable brake release control.

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Part VI

MACHINE GREASING SUBPAGE

Select this to open the Machine Greasing subpage.


This page shows all the information useful for monitoring and performing machine greasing.

A

A. B.

B

Area showing the preset values for greasing times and greasing cycles. Area showing the actual values for greasing times and greasing cycles.

Press this to display the "Trend" window. Showing the frequency, current, power and torques.

Press this to display the values read from the driver for the parameters/data selected in zone #3.

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MANIFOLD LUBRICATION SUBPAGE

Select this to open the Manifold Lubrication subpage.


This page shows all the information useful for monitoring and performing manifold lubrication.

A A. B.

B

Area showing the preset values for greasing laps and greasing cycles. Area showing the actual values for greasing laps and greasing cycles.

Displays window used to set manifold greasing/lubrication data.

Button: manifold greasing manual start control.

Button: manifold greasing manual stop control.

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JACK LUBRICATION SUBPAGE

Select this to open the Jack Lubrication subpage.


This page shows all the information useful for monitoring and performing filler jack lubrication.

A A. B.

B

Area showing the preset values for lubrication times and lubrication cycles. Area showing the actual values for lubrication pause and operating cycles.

Displays window used to set filler jack lubrication data.

Button: filler jack lubrication manual start control.

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PROFIBUS DIAGNOSTIC SUBPAGE

Select this to open the “Profibus Diagnostic” subpage.


This page displays information concerning the status of each individual node on the filler profibus network.

Displays the information page for node faults.

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Part VI 6.4.4

Parameters

Function to access the “Parameters” page.

Displays the machine parameter pages.

PAM

Displays the pages used to enter machine technological parameters.

PAT

Displays the pages used to enter machine steps.

PAS

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PAM

Main navigation buttons

B

A

A.

C

D

E

F

G

H

I

L

DISPLAYS MACHINE SPEED SUBPAGE

Use this page to set the data for the machine speed: Speed in sanitization: this is the fixed speed of the machine during sanitization or rinsing (bottles/hour). Slowing down percentage: this is the slower speed of the machine (expressed as a percentage of production speed) when the Bottle Block is active (i.e. when the machine is empty) (%). External foaming speed: this is the fixed speed of the machine when the external foaming cycle is enabled (%). Bleeding speed: this is the fixed speed of the machine during bleeding of the filling valves (bottles/hour). PAM list displayed:

B.

DISPLAYS UTILITY SUBPAGE

Displays “Valve Washing” subpage.

PAM list displayed:

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Displays “Machine Greasing” subpage.

PAM list displayed:

Displays “Machine Lubrication” subpage.

PAM list displayed:

C.

DISPLAYS FILLER SUBPAGE

Displays “CIP Parameters” subpage. Use this page to set the data for CIP: PRESSURE

-

Maximum pressure during CIP: maximum pressure permitted inside the tank during sanitization. Opening: fixed opening value for pressure modulation during the sanitization sequence.

LEVEL

-

Opening: fixed opening value for level modulation during the sanitization sequence.

TIMES

-

Times for sanitization of the product pipes, filling valves and pressurisation unit are displayed.

PAM list displayed:

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Displays “Rinsing Parameters” subpage.

Use this page to set the data for rinsing: LEVEL

-

Opening: fixed opening value for level modulation during the rinsing sequence.

PRESSURE

-

Opening: fixed opening value for pressure modulation during the rinsing sequence. Number of cycles: the rinsing sequence is repeated for the number of cycles set.

-

Number of cycles with filling valves open: the number of machine cycles with the filling valves open to rinse the valves.

PAM list displayed:

Displays “Draining Parameters” subpage.

Use this page to set the data for draining: PRESSURE

-

Opening: fixed opening value for pressure modulation during the draining sequence. Set Point: pressure set point value to be controlled during the draining sequence.

LEVEL

-

Opening: fixed opening value for level modulation during the draining sequence. Number of cycles: the draining sequence is repeated for the number of cycles set.

PAM list displayed:

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Displays “Startup Parameters” subpage.

Use this page to set the data for machine Startup during the Startup sequence: LEVEL

-

Opening: fixed opening value for level modulation during the startup sequence.

PRESSURE

-

Opening: fixed opening value for pressure modulation during the startup sequence.

TEMPERATURE (hot machine)

-

Times for heating the machine and draining the filling valves are displayed. A machine heating bypass button is fitted.

PAM list displayed:

Displays “Production Parameters” subpage.

Use this page to set the data for production end: Tank volume: fixed value showing the capacity of the tank (litres). Pipe volume: fixed value showing the capacity of the pipes before the tank (litres). PAM list displayed:

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D.

DISPLAYS “ELECTRONIC FILLING VALVE / FILLING MASTER CARD” SUBPAGE

Displays “Electronic Filling Valve / Filling Master Card” subpage. PAM list displayed:

E.

DISPLAYS “CAPPER / CROWN CAPPER’’ SUBPAGE

Displays “Crown Capper Parameters” subpage.

PAM list displayed:

Displays “Capper Parameters” subpage. PAM list displayed:

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Part VI

F.

DISPLAYS BOTTLE COOLING PARAMETERS SUBPAGE

PAM list displayed:

G.

DISPLAYS PRODUCT PUMP PARAMETERS SUBPAGE

PAM list displayed:

H.

DISPLAYS BOTTLE SIZE PARAMETERS SUBPAGE

PAM list displayed:

I.

DISPLAYS FOAMER PARAMETERS SUBPAGE

Displays “CIP” subpage.

PAM list displayed:

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Displays “Rinsing” subpage.

PAM list displayed:

Displays “Draining” subpage.

Displays “Production” subpage.

PAM list displayed:

L.

DISPLAYS CLEAN ROOM PARAMETERS SUBPAGE

PAM list displayed:

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Part VI PAT Main navigation buttons

B

A

A.

C

E

D

F

G

H

I

DISPLAYS “FILTER STERILIZATION” SUBPAGE

Displays “Air Filter” subpage

PAT list displayed:

Displays “Nitrogen Filter” subpage

PAT list displayed:

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B.

DISPLAYS STEAM BARRIER SUBPAGE

Displays “Aseptomag Steam Barrier” subpage

PAT list displayed:

Displays “Product Pump Steam Barrier” subpage

PAT list displayed:

Displays “Upper Rotary Manifold Steam Barrier ” subpage PAT list displayed:

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C.


DISPLAYS FILLER SUBPAGE

PAT list displayed:

D.


PAT list displayed:

E.

DISPLAYS BOTTLE COOLING SUBPAGE

F.

DISPLAYS PIPE TREATMENT SUBPAGE

PAT list displayed:

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G.

DISPLAYS HYDRAULIC SEAL SUBPAGE

PAT list displayed:

H.

DISPLAYS BOTTLE SIZE SUBPAGE

I.

DISPLAYS CLEAN ROOM SUBPAGE

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Part VI

PAS

Main navigation buttons

B

A A.

C

E

D

F

G

H

DISPLAYS “RINSING” SUBPAGE

PAS list displayed:

B.

DISPLAYS “FILLER/FILLER WASHING” SUBPAGE

Displays “Filler” subpage

PAS list displayed:

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Displays “Filler Washing” subpage

PAS list displayed:

C.

DISPLAYS FOAMER STEPS SUBPAGE

PAS list displayed:

D.

DISPLAYS “TX TRANSMITTER STEPS” (Mastercard) SUBPAGE

PAS list displayed:

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Part VI E.


Displays “Crown Capper Parameters” subpage.

PAS list displayed:

Displays “Capper Parameters” subpage. PAS list displayed:

F.

DISPLAYS MACHINE STEPS SUBPAGE

PAS list displayed:

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G.

DISPLAYS DRIVE STEPS SUBPAGE

PAS list displayed:

H.

DISPLAYS PULP DOSER STEPS SUBPAGE

PAS list displayed:

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Part VI 6.4.5

Services

Function to access the “Services” page.

Navigation page: This page displays buttons for opening the following submenus. The submenus available


Displays “HMI Management” subpage.

Displays “Rinser” subpage.

Displays “Capper” subpage.

Displays “Crown Capper” subpage.

Displays “Filler” subpage.

Displays “Filler TX Steps” subpage.

Displays “Motor” subpage. (Available on machines with brushless motors).

These pages are reserved for SIDEL technicians.

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HMI MANAGEMENT SUBPAGE

Function to access the “HMI” page.

Navigation page: This page displays buttons for opening the following submenus. The submenus available


Displays “Language change” page.

Displays “Project information” page.

Displays “Date and time settings” page.

Displays “Screen cleaning” page

Language change page

Use this page to change the language used for the operator interface by selecting the flag for the language required.

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Part VI Project information A B C D E

Use this tool to retrieve system information such as: A. Free disk space. B. Free memory space. C. Project version. D. Serial number. E. Project name. Date and time setting page

Screen cleaning

On this page the touch-screen remains disabled for the time shown on the counter (in seconds) to enable cleaning of the screen. When the time elapses (1 minute), the Reception page is displayed automatically.

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Part VI

EXPORT DATA PAGE

Use the EXPORT DATA page to save all the machine parameters onto an external memory using a USB connection.

MACHINE SPEED SUBPAGE

Function to access the “Machine speed” page.

Use this page to set the data for the machine speed: Speed in sanitization: this is the fixed speed of the machine during sanitization or rinsing (bottles/hour). Slowing down percentage: this is the slower speed of the machine (expressed as a percentage of production speed) when the Bottle Block is active (i.e. when the machine is empty) (%). External foaming speed: this is the fixed speed of the machine when the external foaming cycle is enabled (%). Bleeding speed: this is the fixed speed of the machine during bleeding of the filling valves (bottles/hour).

FLUSHING SUBPAGE

Function to access the “Flushing” page.

Use this page to set the data for machine flushing during the Startup sequence: PRESSURE Set Point: pressure set point value to be controlled during the gas flushing sequence (bar). Number of cycles: the gas flushing sequence is repeated for the number of cycles set.

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PRODUCT Set Point: level set point value to be controlled during the product flushing sequence (bar). Opening: fixed opening value for level modulation during the product flushing sequence (%). Number of cycles: the product flushing sequence is repeated for the number of cycles set.

PRODUCTION STARTUP SUBPAGE

Function to access the “Startup” page.

Use this page to set the data for machine Startup during the Startup sequence: LEVEL Opening: fixed opening value for level modulation during the startup sequence. PRESSURE Opening: fixed opening value for pressure modulation during the startup sequence. TEMPERATURE (hot machine)

-

Times for heating the machine and draining the filling valves are displayed. A machine heating bypass button is fitted.

PRODUCTION END SUBPAGE

Function to access the “Production” page.

Use this page to set the data for production end: Tank volume: fixed value showing the capacity of the tank (litres) Pipe volume: fixed value showing the capacity of the pipes before the tank (litres)

CIP SUBPAGE

Function to access the “CIP” page.

Use this page to set the data for CIP: PRESSURE -

Maximum pressure during CIP: maximum pressure permitted inside the tank during sanitization. Opening: fixed opening value for pressure modulation during the sanitization sequence.

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LEVEL Opening: fixed opening value for level modulation during the sanitization sequence. TIMES

-

Times for sanitization of the product pipes, filling valves and pressurisation unit are displayed.

DRAINING SUBPAGE

Function to access the “Draining” page.

Use this page to set the data for draining: PRESSURE Opening: fixed opening value for pressure modulation during the draining sequence. Set Point: pressure set point value to be controlled during the draining sequence. LEVEL Opening: fixed opening value for level modulation during the draining sequence. Number of cycles: the draining sequence is repeated for the number of cycles set.

RINSING SUBPAGE

Function to access the “Rinsing” page.

Use this page to set the data for rinsing: LEVEL Opening: fixed opening value for level modulation during the rinsing sequence. PRESSURE Opening: fixed opening value for pressure modulation during the rinsing sequence. Number of cycles: the rinsing sequence is repeated for the number of cycles set. Number of cycles with filling valves open: the number of machine cycles with the filling valves open

to rinse the valves.

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Part VI

6.5

OPERATING MODE SELECTION

6.5.1

Automatic operation

This mode should be maintained during the production phase to allow the machine to fill the product containers and apply the cap continuously. The machine must be monitored during this phase. The machine can be operated by a generic machine operator who controls the operating states using the operator interface.

6.5.2

Manual operation

Before performing any manual operations, make sure there are no physical obstructions preventing the movement required. Manual operation requires use of the MAINTENANCE PUSHBUTTON PANEL to run the machine in JOG mode. The operator must hold the mobile control unit in order to control movements.

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6.6

Part VI

MACHINE STARTUP AND PRODUCTION WARNING: at the start of each shift and before starting up production, perform a preliminary check on the efficiency of the safety systems.

To start the machine, proceed as follows: 6.6.1

1. 2.

3.

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Preliminary checks

Make sure the Combi “open” interface panel is fitted between the machine infeed and blower outfeed (see section 2.7.2). Check the equipment is adjusted correctly for the bottles to be filled. Check that the handling parts are perfectly timed. Check the timing by running one or more bottles all the way through the machine at low speed using the jog mode.

Make sure the crowns or caps match the product and bottles to be used. Check that a sufficient quantity of crowns or caps is available.

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Part VI 6.6.2

Starting

1. -

Power up the machine pneumatic circuit. Close all the operator guards. Open the manual supply valve.

-

Press and hold the reset button until the no pressure warning message is cleared from the monitor.

-

At this point the entire pneumatic system has reached the pressure value set at infeed.

2. -

Adjust the air pressures. Supply the carousel controls at 6 bar.

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-

Supply the jacks at 4 bar. Check these values on the pressure gauges whenever necessary during a filling cycle or when adjusting the regulators.

-

Use the special selector to enable the compressed air supply for the jacks. Press the jack air selector on the “Maintenance” page:

-

Disable the component so the jacks are able to pressurise.

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3.

On the pressure reducer, set the CO2 tank supply pressure to approx. 1 bar above the filling pressure.

4.

Set the bottle block selector to automatic.

5.

Press the Start/Stop pushbutton.

Allow the machine to run in no−load conditions until all the filling valves have closed.

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6.

On the Recipe page select the recipe for the type of production and press the button to enable the recipe:

7.

Set the 2 “Enable Actuators” and “Enable Controls” buttons to automatic and make sure all the threeway selectors for valves and motors switch to AUT.

8.

Press one of the following icons on the filler “Startup” page (see section 6.2.3.):

Fast startup.

Startup with gas flushing (optional).

Startup with product flushing (optional).

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9.

Press the button to start the production sequence.

10.

Set the bottle stop selector to the automatic position.

The bottle stop opens, the bottles enter the machine and the filling process starts. 11. If necessary select the machine speed using the special field on the “Reception” page (section 6.2.2).

6.6.3

Procedures for standard operation

During the cycle check that the parameters remain constant at the set values. Check the bottle filling level and the closures. If the machine is stopped by the tripping of an internal safety device, trace and remove the cause. Check for part damage before restarting the machine. Restarting a production cycle after a stoppage requires the presence of an operator. 1. 2. 3.

When processing carbonated products, check the extent and formation of foam during the filling step. When filling beer, regulate the pressures to optimise the efficiency of the foamers. Monitor the supply and level of crown caps and caps in the hoppers. Fill by hand where necessary. Check and regulate the machine temperatures, pressures and speeds to obtain the highest production rates which are compatible with the production quality standards specified.

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6.7

STOP AND EMERGENCY STOP MODES

6.7.1

Machine emergency stop

Part VI

This operation must only be performed when there is a genuine EMERGENCY. When the emergency stop button is pressed on the control panel, the machine stops under safe conditions with bottles inside. Rotate the button to release it. The emergency stop button is red on a yellow background.

6.7.2

Machine stop during production

When the ”Stop” button is pressed, the machine stops with bottles inside.

Or:

1.

Block the bottles at infeed.

2.

Wait until all the bottles are fed out of the machine.

3.

Press the Start / Stop button:

4.

Press STOP on the filler “Startup” page:

The machine ends production by completely emptying the tank.

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Part VI

6.8

RINSING

The rinsing step can be enabled using the filler “Startup” page (see section 6.2.3.). 1.

Make sure the Combi “closed” interface panel is fitted between the machine infeed and blower outfeed (see section 2.7.2).

2.

Start the machine

3.

Press the icon to switch the machine to the rinsing mode.

4.

Press:

-

The power supply to the jacks is disabled and the jacks are depressurised. All the machine valves are set to rinsing mode (see section 5 for further details). Rinsing of the internal machine parts begins.

The filling valves open automatically when flooding is complete. Rinsing is completed by automatic draining assisted by CO2 flow into the filler. Rinsing can be performed before and after production.

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6.9

Part VI

SANITIZATION

The sanitization step can be enabled using the filler “Startup” page (see section 6.2.3.). 1.

Make sure the Combi “closed” interface panel is fitted between the machine infeed and blower outfeed (see section 2.7.2).

2.

Press the icon to switch the machine to the sanitizing mode.

3.

Press:

-

The jacks are depressurised.

4.

The machine stops and a message is displayed on the monitor requesting the insertion of dummy bottles. Enable the rear JOG control and insert the dummy bottles manually. Once finished (the machine checks that all the dummy bottles have been fitted), disable the JOG and start the machine.

5.

Start the sanitizing the inside ofand the consists machine.of sanitizing with a chemical product, a rinse and The sanitizing cyclecycle runsfor automatically final drainage.

6.

To stop and leave the sanitizing mode, press the icon (Stop mode):

-

The machine displays a message instructing you to remove the dummy bottles.

7.

Enable the rear JOG control and start to remove the dummy bottles in order to end this operating mode. (The machine will check that the dummy bottles have been removed).

SANITIZATION FOR MACHINES WITH AUTOMATIC DUMMY BOTTLES

Machines with a system for automatically inserting and removing the dummy bottles do not require operator intervention. The machine is not set to JOG mode. On these machines the dummy bottles are inserted and removed automatically.

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Part VII

PART VII

User Manual / Size Changeover

SIZE CHANGEOVER

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7.1

Part VII

GENERAL PRECAUTIONS

Size changeover operations must be performed without any bottles inside the machine. If the machine has just come out of service, check that the piping is not hot. When you have completed a size changeover, check that you have not left any tools or other extraneous objects inside the machine. Before you start a production cycle, test that the size change is OK by running one or two bottles through the machine at slow speed. Cordon off the area around the machine. Place warning signs around the machine indicating that maintenance work is in progress. Prevent unauthorised persons from entering the area. A size changeover may require you to move the carousel. You must only use the JOG control to do this. Do not stay inside the machine. Do not stand close to moving parts. The size changeover must be performed by one person only using the JOG control. Some operations may require the assistance of a second person. In this case, only one person is permitted to use the JOG control. Before using the JOG control this person must check that the second person is not in the hazard zone.

Size changeover operations are quick and easy. This section details the areas involved in size changeover. The size changeover operations described in this section must be performed by QUALIFIED personnel.

Cordon off the area around the machine during size changeovers. Keep all unauthorised persons away from the machine. Fix a Work in Progress warning sign to the control panel. For each bottle type the manufacturer supplies a set of tooling and equipment (size changeover kit) for mounting on the machine (see Vol. II Spare Parts Catalogue). The size changeover kits for each bottle type are marked in our works with an unique identifier letter. Unauthorised modification or substitution of size changeover parts can cause an accident hazard. The manufacturer declines all liability for damage or injury caused by unauthorised modifications or substitutions.

AUTOMATIC SIZE CHANGEOVER

The sequence and adjustments for the automatic size changeover are shown on the operator panel. There are therefore no drawings. In the event of a fault to the lifting motor, see section 7.4 “Removing size changeover parts”.


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Part VII

7.2

DESCRIPTION OF THE SIZE CHANGE PARTS

COMBI Filler Equipment C

D

E

A

F

B

BLOCKRINSER Filler Equipment C

E

A

F

B

D

G

Reference

Description

A

Crown capper infeed guide (if fitted)

B

Crown capper starwheel (if fitted)

C D

Internal outfeed guide (if fitted) External outfeed guide (if fitted)

E

Crown capper external guide (if fitted)

F

Machine outfeed starwheel (if fitted)

G

Machine infeed guide (where fitted)

Bottle bottom spacers (HOTFILL optional)

H

Reference H

Description

Bottle bottom spacers (where fitted)

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7.3

Part VII

MACHINE CLEANING

Clean the machine thoroughly before you start the size changeover. Clean the area which will receive the size changeover parts with a jet of compressed air. Remove any deposits present. Clean the machine surface with a damp cloth.


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Part VII

7.4


REMOVING SIZE CHANGEOVER PARTS (WHERE FITTED) Refer to the size changeover diagram in PART X “APPENDICES”, section 10.1.4 “Size change parts”.

1.

Remove the pins A. Rotate the clamps. Remove and substitute the guide B and the starwheel C.

B

C

A 2.

Remove the pin D. Rotate the clamp. Remove and substitute the guide E.

D 3.

E

Unscrew the threaded knob F. Remove and substitute the starwheel G.

G

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4.

Remove the pin H. Rotate the clamp. Remove and substitute the guide I.

I 5.

6.

Loosen the nuts J. Remove and substitute the guide K.

J

Adjust the tipping belt L to match the height of the bottle to be processed.

Automatic size changeover:

L

In the event of lifting motor failure, use the handwheel M.


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Part VIII

PART VIII

User manual / Maintenance Schedule

MAINTENANCE SCHEDULE

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8.1

Part VIII

GENERAL INFORMATION ABOUT M AINTENANCE

The “Maintenance” section is the main reference with instructions on how best to maintain your machine. The section has been written to assist maintenance technicians to optimise maintenance operations. All technicians working on the machine should be fully conversant with the General Safety Information in section 1.1 and the Maintenance Levels described in this manual. This chapter is a maintenance guide providing details of the general maintenance schedule, the lubrication sheets and the maintenance instructions (with details of maintenance level). MACHINE OPERATING SYSTEMS

This section indicates the various operations to be performed on the machine, its assemblies and components. This section also indicates the maintenance operations to be performed on these components. SIZE CHANGEOVER

The Size Changeover section provides instructions on changing over between bottle sizes and between product types. On some pages in this manual there is an icon on the right-hand side. This icon indicates that there is also relevant maintenance procedure in the Maintenance Procedure Manual.

Icon

Indicates the existence of a procedure for:

Cleaning. Checking of electrical or mechanical components and checking fluids. Removing or repairing electrical or mechanical components and changing fluids. Lubrication and greasing.

Before you start work on the machine, check once again which part of the machine requires maintenance. Check that all the personnel involved in these operations have read the safety instructions. The maintenance intervals in this manual are intended as a guide only. The intervals are based on the average time needed for the operations to be performed on the machine, including setup: Daily

Every 24 hours or after three shifts.

Weekly

Every five days.

Monthly

Every four weeks.

Yearly:

Every 50 weeks. One cycle of 3 hours every 72 hours of continuous machine production.

Machine cleaning and sterilisation interval: . .A .p lS e id S ©

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Therefore, the estimated intervals are: Machine operation periods (including setup) Interval

Hours

Machine production cycles (**)

Daily

24

-

Weekly

125

2

Monthly

500

7

Every three months

1500

20

Every six months

3000

40

Every nine months

4500

60

Yearly

6000

80

Every two years

12000

160

Every three years

18000

240

Every four years

24000

320

-

-

Variable (*) (*) (**)

Maintenance necessitated by component failure, damage or malfunction. 1 cycle = sanitizing + production + cleaning.

In practice machine usage is closely linked to production schedules and the type of beverage processed. This means that the intervals in the table should be understood as: “Whenever an interval (Interval, Hours or Machine Production Cycles) is reached, maintenance must be performed. Examples: The machine has already worked for over 6000 hours but the Yearly interval has not yet elapsed. In this case the maintenance operation indicated must be performed. The machine has already completed 160 work cycles but the Every Two Years interval has not yet elapsed. In this case the maintenance operation indicated must be performed. The machine has already worked for over Two Years but has not yet completed 160 cycles. In this case the maintenance operation indicated must be performed. The general maintenance table, the greasing table and the electrical and mechanical maintenance tables refer to and indicate maintenance procedure numbers. Operations at level 5 do not have written procedures. For details of all the other operations not described in the general maintenance table, contact SIDEL S.p.A. Customer Service. Follow the safety instructions. Perform the procedures as described. Perform the procedures at the specified intervals. Use the recommended materials (oils, greases, tools). Failure to follow this advice can lead to injury to persons or damage to machine.

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State of the machine before and after a maintenance operation: Maintenance procedures start from the assumption that the machine has been installed correctly, that it has stopped normally (i.e. not because of a fault) and that it is connected to the electrical power supply, to the water supply and to the low- and high-pressure compressed air supply. Other conditions are specified on the maintenance procedure sheets. At the end of the procedure: thoroughly clean the area; make sure that the machine can restart production normally; check that no tools or size parts have been left inside the machine; check that the machine does not constitute a hazard for personnel. Before you restart the machine, perform all the sterilisation and cleaning procedures.

8.1.1

Maintenance operation times

The time needed for a maintenance operation is the theoretical time needed to perform a single maintenance operation by skilled operators working on individual machine assemblies or components. This time is provided as a guide only. SIDEL S.p.A. cannot guarantee the accuracy of this value. Each operation time refers to a single machine assembly or component and is to be understood as the total time necessary for the operation calculated as follows. The operation refers to the machine units “z” (position on the synoptic panel or a quantity). The operation requires “n” number of persons, an intervention time of “itime” and an effective time “etime” to complete the operation. Thus:


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Part VIII 8.1.2

Greasing machine parts

Only certified food contact grease may be used to lubricate machine parts. Parts which come into contact with the product or containers must only be lubricated with H1 (USDA, NFS) food contact grease. Grease the grease points with the amount of grease specified and at the frequency specified in the maintenance schedule. At the end of the process, dispose of the water, sanitizer and acid substances in compliance with the local waste disposal regulations. Do not discharge this type of waste into water courses or the public drainage system. This type of waste requires pre-treatment before final disposal. Dispose of dirty, oily or greasy paper and cleaning rags in accordance with local waste disposal regulations. Hazard warning. The products used in the CIP SYSTEM ARE IRRITANT AND TOXIC. Use the appropriate PPE. If you are using chemical substances, check the Safety Data Sheets provided by the manufacturer to identify any safety and environmental hazards for the chemical used. Safety Data Sheets indicate the following: -

Hazards. Personal protective equipment and general protections required. First aid instructions. 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 and handling information.


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8.1.3

Part VIII

Preventive maintenance

In order to ensure a long, efficient life cycle for SIDEL S.p.A machines, we recommend that you follow the preventive maintenance procedures specified by SIDEL S.p.A at the intervals indicated and using the parts and methods indicated. On this type of plant, component wear and seal condition require particular attention. Good maintenance also requires a system for documenting maintenance operations which matches the customer’s needs. Maintenance personnel must be suitably trained and authorised to perform maintenance. Any liquid removed may contain oil and must not be disposed of in the environment. It must be collected and treated in compliance with the environmental protection legislation and standards in the country where the machine is used. Dispose of dirty, oily or greasy paper and cleaning rags in accordance with local waste disposal regulations. Hazard warning. The products used in the CIP SYSTEM ARE IRRITANT AND TOXIC. Use the appropriate PPE. If you are using chemical substances, check the Safety Data Sheets provided by the manufacturer to identify any safety and environmental hazards for the chemical used. Safety Data Sheets indicate the following: -

Hazards. Personal protective equipment and general protections required. First aid instructions.

-

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 and handling information.



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8.2


MAINTENANCE SCHEDULE

Check the maintenance schedule in the Maintenance procedures manual

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Matrix Filler

User Manual / Diagnostics

Part IX

PART IX

DIAGNOSTICS

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9.1

Part IX

TROUBLESHOOTING

Troubleshooting is vital to restore the filler to full operation when faults occur. A step-by-step systematic approach to machine diagnostics significantly increases the chances of identifying the causes of faults. The list below is a general one designed to facilitate identification of the cause of a fault and then solve the problem. Identifying faults

Before any attempt is made to resolve operating faults, as much information as possible should be procured about the fault. Carefully observe the fault and seek the assistance of the operator to assess machine performance. Take note of the frequency and type of events. Resolving the effects of the fault does not solve the problem. The aim must be to find and eliminate the causes of the fault. Identify the position of the fault

Faults on the filler machine can usually be traced to one or two of the six machine areas, as follows: -

Drive units. Bottle conveyor. Product distribution. Container cleaning. Filling. Capping.

Follow an investigative procedure

Make corrections and adjustments in a logical sequence i.e. starting from the most likely cause and proceeding to the most unlikely one. A flurry of blind activity is not only likely to be a waste of time but may even aggravate the problem. Proceed step by step

Make only one correction at a time and observe the results before making any other corrections. After maintenance

When you think you have solved the problem, monitor the machine carefully to obtain confirmation that maintenance has been successful. If production demands dictate a temporary solution, make note of the problem and then implement a definitive solution during scheduled maintenance.


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Part IX 9.1.1

General machine operation

Problem

The machine does not start when the START button is pressed or the machine stops during normal operation.

9.1.2

Cause

Solution

1. Main switch not in the ON position.

Turn ON the main switch on the electrical cabinet.

2. Safety device triggered.

Remove the cause, press RESET and restart the machine.

Bottle conveyor

This section assumes the bottles used are of good quality and match the specifications permitted for the machine. It also assumes correct bottle infeed and pressure in the system. Problem

The bottle block is not operating (Standalone only).

The bottles are guided badly in the rinser infeed area.

The bottles are guided badly in the filler infeed area.

The bottles are guided badly in the carousel outfeed area.

The bottles are guided badly at the crown capper outfeed.

Cause

Solution

1. Solenoid valve not working.

Check the controls and cables connected to the solenoid valves.

2. Air infeed pipes damaged or loose.

Check and tighten or change the air infeed hoses.

3. Faulty solenoid valve operation.

Change the necessary.

4. Bottle block damaged.

Check the bottle block.

1. Rinser infeed starwheel timed incorrectly relative to the bottle pickup grippers.

Set the timing of the rinser infeed starwheel relative to the grippers.

1. Filler infeed starwheel timed incorrectly relative to the filling carousel.

Set the timing of the filler carousel.

2. Filling valve bottle support forks at incorrect height relative to the infeed starwheel.

Check the height of all the forks making sure the height is 0.5mm lower than the starwheel.

1. Filler infeed starwheel timed incorrectly relative to the outfeed starwheel.

Set the timing of the filler carousel relative to the starwheel.

2. Filling valveheight. bottle support forks at incorrect

Check the height of all the forks.

1. Outfeed starwheel timed incorrectly relative to the crown capper.

Set the timing of the crown capper with the starwheel.

2. Bottle outfeed guide from the crown capper sized incorrectly.

Change the guide.

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valve

if

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9.1.3

Part IX

Filling

In general faults related to filling can be divided into four types as follows: -

No filling. Insufficient filling. Excessive filling. Foaming.

The first step to solving this type of problem is to assess whether the fault is with all the filling valves or only one of them. The causes and solutions vary in accordance with the size of the problem. Filling problems are often difficult to solve because of the vast range of components and systems affecting the filling process. Operation of the filling valve, the product distribution system, the bottle conveyor system, the product mixing system and other factors, such as the quality of the bottle to be filled, can affect the filling process. Another factor to be taken into consideration when solving filling problems is that different faults can have the same base cause but on different levels. For example, many filling problems can be caused by a degrading of the filling valve seal. However, excessive filling can be caused by slight degradation of the seal, insufficient filling by slightly more degradation and no filling by the complete degradation of the seal. IMPORTANT: If the sanitizing process is run, you should check the condition of all the rubber seals on the filling valves every 6 months and, if necessary, change them.


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Part IX NO FILLING Problem

Cause

Solution

1. No seal between the bottle and the centring bell. No filling Some filling valves.

No filling All filling valves.

2. Valve not enabled on the control panel.

Check the mouth of the bottle is not chipped or faulty. Check the filling seal for faults. Check the position of the seal. Make sure there are no foreign bodies on the centring bell. Enable the valve by following the procedure described on the filling valve ENABLE / DISABLE page.

3. Transmission error between the master and the electronic filling valve.

Change the electronic card of the filling valve in question.

1. Filling valve opening pneumatic system fault.

Check correct operation of the control rod membranes. Check correct operation of the bottle presence sensor.

2. No product in the tank.

Fill the tank.

3. Transmission error between the master and the electronic filling valves.

Change the electronic transmission card.

Cause

Solution

1. The carousel rotates too quickly (only Standalone).

Set a lower carousel speed.

2. Product code selected for a different size.

Select the correct product code.

1. Faulty filling valve.

Dismantle and check the filling valve.

2. Rubber filling seal damaged.

Change the centring bell and filling valve seals.

3. Filling set point too low.

Correct the valve filling set point.

control

INSUFFICIENT FILLING Problem

Insufficient filling. All filling valves.

Insufficient filling. Some filling valves.

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Part IX

User Manual / Diagnostics EXCESSIVE FILLING Problem

Cause

Solution

1. Liquid seal fault.

Change the liquid seal.

2. Rod seals broken.

Change the seals.

3. Flow meter not connected to the

Check the connection between the

Excessive filling. electronic card.

flow meter and the electronic card.

4. Flow meter damaged.

Change the flow meter.

Cause

Solution

1. Calibrated decompression hole blocked.

Clean the nozzle.

2. Rubber bell seal damaged or worn.

Change the seal.

3. Faulty filling valve.

Remove and check the valve.

4. performed Decompressiondue stage not damaged electronic card output.

Change the electronic control or pilot valve.

1. Insufficient pressure in the tank.

Adjust the pressure.

FOAMING Problem

Foaming Some filling valves.

2. Product temperature too high.

Foaming All filling valves.

Adjust the pressure.

3. Too many carousel stops and starts which agitate the product. Check flushing and the temperature of cooling water.

4. Bottles too hot. 5. Dirty bottles. 6. Incorrect decompression stage due to incorrect product recipe.


IX - 6

1.0

Upload the correct product recipe.

Matrix Filler


Part IX 9.1.4

Capping

SCREW CAPS In general capping problems can divided into two groups: -

Cap infeed fault. Poor capping quality. The caps must be in good condition and within the tolerance limits. Irregular caps can be considered a possible cause of any faults relating to the cap infeed system during production and storage.

Problem

The caps are not fed out of the hopper (if fitted).

Cause

Solution

1. Too many caps in the hopper.

Remove the excess caps. Adjust the cap level sensor.

2. Too few caps in the hopper. Cap descent channel empties.

1. Caps blocked in the automatic ejector (unit with paddle wheel and ejection piston) (if fitted).

Too many upturned caps in the channel.

1. Cap selection device not set correctly. 1. End section of the channel at incorrect height relative to the pick and place unit sliding plate.

Cap block at pick and place system infeed. 2. Insufficient air jet flow.

Caps not screwed up correctly.

Adjust the cap level sensor. Check the efficiency of the system feeding caps to the hopper. Remove the caps from the ejector and check for missing or damaged seals. Check the height of the support bridge and the position of the cap support tab. The cap should be supported by 1-2 mm and should fall freely when upturned. Adjust the height of the channel and specifically make sure it is not too low relative to the plate. Make sure the air jets are not blocked. Adjust the flow, pressure and direction of the air jets to ensure correct cap sliding.

1. Non-conforming caps or bottles.

Check the bottle and cap thread for any faults.

2. Bottles rotate during capping.

See the previous point and make sure the toothed collars are clean.

3. Speed controller rpm not set correctly (if the problem only occurs at high speed). 4. Insufficient torque wrench setting. 5. Temperature too low.

Increase the rpm of the speed controller. Increase the torque wrench setting. Check the internal and external temperature of the machine. . A . .p S l e id S ©

1.0

IX - 7

Matrix Filler

Part IX


Bottles rotate on the toothed anti-rotation collars.

Bent caps.

External cap damage. Falling caps during transfer from the pick and place unit to the bottle.

1. Teeth damaged or worn.

Change the collars.

2. Not enough head compression and guide set too high.

Check and adjust the compression and check the guide setting.

1. Non-conforming caps and bottles.

Check the diameters of the bottle necks and caps are compatible and within the tolerance limits.

2. Screwer cone not compatible with caps.

Check and if necessary change the screw cones.

3. Caps not picked up correctly by the heads on the pick and place system plate.

Adjust the timing of the starwheel relative to the capping piston.

4. Bottle not vertical or too much play between the starwheel and bottle body.

Change the starwheel so the bottle is guided correctly.

1. Incompatible screwer cone or non-conforming caps.

Check the diameter and profile of the cap teeth.

1. Cap holding ball compression spring broken.

Change the spring if damaged.

2. Worn balls.

Change any worn balls.

Cap thread skips bottle thread.

1. Torque wrench setting too high (if a general problem with all bottles) or non-conforming cap. 2. Torque wrench setting too high (if a problem only on one head) or non-conforming cap.

Caps deformed on the bottles (thread too evident on the outside).

1. Torque wrench setting too high.

9.1.5

all the heads. Adjust the torque wrench setting and, if necessary, loosen the grub screw. Reduce the torque wrench setting. This problem can also arise when the ambient temperature is too high).

Product level in static tank (if fitted)

1. Incorrect level parameters. Incorrect or unstable tank level.

Set new homogeneous parameters. Check, dry and secure the probe

2. Faulty probe. 3. Too much foam in the tank.


IX - 8

Adjust the torque wrench setting on

1.0

correctly or change it. Drain the product from the tank and repeat the tank filling procedures.

Matrix Filler

User Manual / Appendices

PART X

PART X

APPENDICES

. A . .p S l e id S ©

1.0

X-1

Matrix Filler


10.1

DOCUMENTATION ENCLOSED

10.1.1 Layout and connections 10.1.2 Moving the machine 10.1.3 Flow circuit diagram (if present) 10.1.4 Equipment (if present) 10.1.5 Recipes 10.1.6 Description of slave card display unit controls 10.1.7 Appendices for commercial equipment


X-2

1.0

PART X

Matrix Filler

PART X


10.1.1 Layout and connections

PART III “TECHNICAL DATA” in section 3.1 “Dimensions”

. A . .p S l e id S ©

1.0

X-3

Matrix Filler



X-4

1.0

PART X

Matrix Filler

PART X


10.1.2 Moving the machine

PART IV “INSTALLATION” in section 4.3.6 “Hook positioning table”

. A . .p S l e id S ©

1.0

X-5

Matrix Filler



X-6

1.0

PART X

8

7

65

4321

RICAVATO DA: A

9 02

A

9 1

10

5 5

° 57

11

7 5

°

1 1 1 5

B

B

DETTAGLIO B

B DETAIL SCALA 1:10

B

SCALE 1:10

10

02 C

C

11 7404

9

C D

D

4 DETTAGLIO C

C DETAIL

3 5

SCALA 1:10

SCALE 1:10

3

8 E

E

2 2

Gruppi

2

Groups

PesoTotale

Kg

TotalWeight

13600

Peso struttura sollevamento Weight Lift Structure

6

300

ACCOPPIAMENTI FILETTATI: 100120231 SCREWED COUPLINGS: 100120231

F

F 25.08.2011

G.A

Creazione disegno / Drawing creation

316745

11.10.2012

G.M

Sostituito pos 10

365871

02

ECO

Ind Maj Ind Min

01

3 7

Data/date Nome/name Descrizione modifica/Change Description ENGINEERING & PACKAGING SOLUTIONS

G

SidelS.p.A. Via La Spezia 241/A

1

Rugosit à : (senza indicazione contraria)

SCALA 1:10

ARRANGE CHAINS IN ORDER TO HAVE MINIMUM ANGLE EQUAL 45° DURING THE LEFTING

7

Surfacecondition (Unlessotherwisestated)

SOLLEVAMENTO RIEMPITRICI CZA270 F-M9004

( g

LIFTING RIEMPITRICI CZA270 F-M9004

= ss a /M This Drawingis SIDELpropertyand contains ormaycontainSIDELconfidentialinformation,includingtrade s ecrets .This drawingandall a s s a M

8

G

N° 10664182

Trattamento/ Treatement :

Denominazione/Description:

SCALE 1:10

H

General tolerances according to specification : (unless otherwise stated)

/ Specificationsheet :

DETTAGLIO A

A DETAIL

DISPORRE LE CATENE DURANTE IL SOLLEVAMENTO CON UN ANGOLO MINIMO DI 45°

Tolleranze generali in accordo con la specifica : (senza indicazione contraria)

Mat eriale / Material :

Specifiche materiale

43100 PARMA - ITALY

a

theinformationcontainedthereins hallbekept s trictlyconfidentialbytherecipientand s hallnotbe dis clos edtoanythird partywithout SIDEL's expres s cons ent.This drawings hall notbeus ed directlyorindirectlybythe recipientexceptforthes pecificpurpos eforwhich this drawingis dis clos edbySIDEL.All IntellectualPropertyRights ,includingCopyright,areres ervedbySIDEL.Norepres entationorwarranty, expres s orimplied,is madeby SIDELwithres pecttothe truth,accuracy,s ufficiencyorabs enceof defectoftheinformationcontainedin this drawingorwithres pectto thirdpartyintellectualpropertyrights .

2

Data di Rilascio Disegnat o da /Drawnby

MALPELI Numero /Number:

)

/ Release date : 11/10/2012 Dat a /Date

Scala /Scale

11.10.2012 1:15 Ind Maj Ind min

42879659 - 02

a 1

Size

Sheet

A2 1/1

H

N

O

P

M

K

L

J

I

H

F

G

D

E

C

A

B

RICAVATO DA / DRAWN FROM: 04284405501 BASAMENT O COME IN FIGURA = 2575 KG ALTEZZA DA TERRA BARICENTRO = 1165 mm

8

BASE AS SHOWN = 2575 KG HEIGHT CENTER OF GRAVITY = 1165 mm

8

4

DETTAGLIO / DETAIL X SCALA / SCALE 1 : 5 6

2377,7

DETTAGLIO / DETAIL Y SCALA / SCALE 1 : 5

5

2217,7 7

7 7

7

8 6

4,

6

8 0

4 ,

COLONNA REGOLABILE IN ALTEZZA ADJUSTABLE HEIGHT COLUMN 3

6 , 4

, 4 9 4

02

2387,7

6

ATTENZIONE! DOPO LA REGOLAZIONE IN ALTEZZA RIPOSIZIONARE LA COPIGLIA DI SICUREZZA CAUTION! AFTER HEIGHT REGULATION REPOSITION THE SAFETY SPLI SPIN 3

3 3

a

X

3 Y

5

5

1 BASAMENTO COMPLETO DI PROTEZIONI = 3375 KG ALTEZZA DA TERRA BARICENTRO = 1280 mm BASE WITH PROTECTION = 3375 KG HEIGHT CENTER OF GRAVITY = 1280 mm

4

4

02

9

2487,7

a

2327,7

3

2

3 8

9

9 7

,1 1 8

9

2 , 4

24.10.2011

B.B

CREAZIONE DISEGNO / NEW DRAWING

324002

16.07.2012

A.M

PART. 3; 9

355129

02

ECO

Ind Maj Ind Min

01

3 1

2

b

2

2 , 4

Data/date Nome/name Descrizione modifica/Change Description 9 2

ENGINEERING & PACKAGING SOLUTIONS Sidel S.p.A. Via La Spezia 241/A 43100 PARMA - ITALY Denomina zione/Description:

Mat eriale

Tolleranze generali in accordo con la specifica: (senza indicazione cont raria)

/Material:

Generaltolerances according tospecification : (unlessotherwisestated)

Specifiche mat eriale /Specificationsheet :

N° 10664182

Trat t ament o/Treatement :

Rugosit à : (senza indicazione cont raria)

SOL L E VAME NTO BASAME NTO COMBI 7 STE L L E

Surfacecondition (Unlessotherwisest ated)

2497,7 LIFTING BASAMENTO COMBI 7 STELLE

g

= ssa /M ThisDrawingisSIDELproperty andcontainsormaycontainSIDELconfidentialinformation,includingtradesecrets.Thisdrawing andall

1

a s s a M

P

O

N

M

L

K

F

E

theinformationcontainedthereinshallbekeptstrictlyconfidentialbyther ecipientandshallnotbedisclosedtoany thirdpartywithout SIDEL'sexpressconsent.Thisdrawingshallnotbeused directlyorindirectlybytherecipientexceptfor thespecificpurposeforwhichthis drawingisdisclosedbySIDEL.All IntellectualPropertyRights,includingCopyright,arereservedbySIDEL.Norepresentationorwarranty, expressorimplied,ismadeby SIDELwithrespecttothetruth,accuracy,sufficiencyorabsenceof defectoftheinformationcontainedinthis drawingorwith respecttothirdpartyintellectualpropertyrights.

D

C

Dat a di Rilascio Disegna to da/Drawnby

MALETTI Numero /Number:

/Release date: 17/7/20 12 Da ta /Date

B

Sca la/Scale

1

16.07.2012 1:20 Ind Ma j Ind min

42891959- 02

b

Size

Sheet

A1 1/1 A

8

7

65

4321

RICAVATO DA: 04285434802 A

A

DETTAGLIO/DETAIL A SCALE 1 : 5

1 B

B

A

3

5 C

C

COLONNA REGOLABILE IN ALT EZZA ADJUSTABLE HEIGHT COLUMN 2 6 , 5 4 9 1

9

6

2

4 7 D

D

ATTENZIONE ! DOPO LA REGOLAZIONE IN ALTEZZA RIPOSIZIONARE LA COPIGLIA DI SICUREZZA CAUTION ! AFTER HEIGHT REGULATION REPOSITION THE SAFETY SPLI SPIN.

8 754,67

E

E

F

F

6 4 , 0 8 0 1

18.03.2013

B.B

CREAZIONE DISEGNO / DRAWING CREATION

Data/date Nome/name Descrizione modifica/Change Description ENGINEERING & PACKAGING SOLUTIONS

G

SidelS.p.A. Via La Spezia 241/A

7

c

Tolleranze generali in accordo con la specifica : (senza indicazione contraria)

Mat eriale / Material :

General tolerances according to specification : (unless otherwise stated)

/ Specificationsheet :

G

N° 10664182 Rugosit à : (senza indicazione contraria) Surfacecondition (Unlessotherwisestated)

GRUPPO SOLLEVAMENTO BASAMENTO CAPS 960

( g

GROUP BASE LIFTING CAPS 960

= ss a /M This Drawingis SIDELpropertyand contains ormaycontainSIDELconfidentialinformation,includingtrade s ecrets .This drawingandall a s s a M

8

Ind Maj Ind Min

Trattamento/ Treatement :

Denominazione/Description:

H

01

ECO

Specifiche materiale

43100 PARMA - ITALY

PESO TOTALE = 3480 KG BASAMENTO = 880 KG CASPULATRICE =2600 KG TOTAL WEIGHT = 3480 KG BASE = 880 KG CAPPER STRUCTURE = 2600 KG

385204

theinformationcontainedthereins hallbekept s trictlyconfidentialbytherecipientand s hallnotbe dis clos edtoanythird partywithout SIDEL's expres s cons ent.This drawings hall notbeus ed directlyorindirectlybythe recipientexceptforthes pecificpurpos eforwhich this drawingis dis clos edbySIDEL.All IntellectualPropertyRights ,includingCopyright,areres ervedbySIDEL.Norepres entationorwarranty, expres s orimplied,is madeby SIDELwithres pecttothe truth,accuracy,s ufficiencyorabs enceof defectoftheinformationcontainedin this drawingorwithres pectto thirdpartyintellectualpropertyrights .

2

Data di Rilascio

BSPROGETTI Numero /Number:

)

/ Release date : 19/3/2013

Disegnat o da /Drawnby

Dat a /Date

Scala /Scale

18.03.2013 1:20 Ind Maj Ind min

43000833 - 01

c 1

Size

Sheet

A2 1/1

H

Matrix Filler

PART X


10.1.3 Flow circuit diagram

. A . .p S l e id S ©

1.0

X-7

Matrix Filler



X-8

1.0

PART X

Matrix Filler

PART X


10.1.4 Equipment

PART VII “REMOVING SIZE CHANGEOVER PARTS” in section 7.4 “Removing size changeover parts”

. A . .p S l e id S ©

1.0

X-9

Matrix Filler



X - 10

1.0

PART X

Matrix Filler

PART X


10.1.5 Recipes

. A . .p S l e id S ©

1.0

X - 11

Matrix Filler



X - 12

1.0

PART X

14/07/2011

COPSuggestRecipes(Diversey)1.3_EN

DIVERSEY PRODUCTS

STANDARD CIP RECIPES - EXTERNAL CLEANING/FOAMING Sidel s.r.l. - Via La Spezia 241/A - 43100 Parma - Italy

1 CLEANING FOAM TREATMENT BEFORE COMMISSIONING

STEP

TEMPERATURE

FLUID

1

RINSING

QUALITY WATER*

Ambient

2

ALKALINE CLEANING (degreasing)

VE3-EnduroSuper

Ambientto40°C

3

RINSING

QUALITY WATER*

Ambient

4

ACID CLEANING (descaling)

5

RINSING

VE10-EnduroCid QUALITY WATER*

Ambientto40°C Ambient

CO NCENTR ATIO N

DURATION

10 min 2%

6cyclesx10mi n***

2%

3cyclesx10min *** 10 min**

min** 5

* Recommanded Twh 50< ppm/l as CaC03 (see Tab. 6) ** Check Ph surface are neutral *** Last area Contact Time

MS

1/7

PROCES SIDEL

14/07/2011


DIVERSEY PRODUCTS


2 SANITIZATION FOAM BEFORE COM MISSIONING

STEP 1

RINSING#

2

DISINFECTION

3

R

INSING

FLUID

TEMPERATURE

QUALITY WATER*

CO NCENTR ATIO N

Ambient

VT70-Diverfoam Active QUALITY WATER*

Ambient Ambient

DURATION

min 5 2%

3 cycles x 10 min*** 20 min**

# Not necessary after previous cleaning * Recommanded Twh 50< ppm/l as CaC03 (see Tab. 6) ** Check surfaces whit Peracetic Test Strips *** Last area Contact Time

MS

2/7

PROCES SIDEL

14/07/2011


DIVERSEY PRODUCTS


3 CLEANING FOAM AFTER PRODUCTION

STEP

TEMPERATURE

FLUID

RINSING

QUALITY WATER*

Ambient

2

ALKALINE CLEANING

5

RINSING

VE3-EnduroSuper QUALITYWATER*


1

CO NCENTR ATIO N

DURATION

min 5 2%

10min*** 2cyclesx5min**

* Recommanded Twh 50< ppm/l as CaC03 (see Tab. 6) ** check Ph surface are neutral *** Last area Contact Time

MS

3/7

PROCES SIDEL

14/07/2011


DIVERSEY PRODUCTS


4 SANITIZATION FOAM BEFORE PRODUCTION - DAILY

STEP 1

RINSING#

2

DISINFECTION

3

R

INSING

TEMPERATURE

FLUID

QUALITY WATER*

CO NCENTR ATIO N

Ambient

VT70-Diverfoam Active QUALITYWATER*

Ambient Ambient

DURATION

min 5 2%

10 min*** 2cyclesx10min**

# Not necessary after previous cleaning * Recommanded Twh 50< ppm/l as CaC03 (see Tab. 6) ** check surfaces whit Peracetic Test Strips *** Last area Contact Time

MS

4/7

PROCES SIDEL

14/07/2011


DIVERSEY PRODUCTS


5 DESCALING FOAM WEEKLY (DAILY if Filling Water Hardness > 200 ppm CaCO3 ( 20° F))

STEP 1

ACID CLEANING (descalant)

2

RINSING

TEMPERATURE

FLUID

VE10-EnduroCid QUALITYWATER*


CO NCENTR ATIO N

2%

DURATION

10min*** 2cyclesx5min**


MS

5/7

PROCES SIDEL

14/07/2011


DIVERSEY PRODUCTS


6 CLEANING - MONTHLY OR AFTER HEAVY MAINTENANCE

STEP

TEMPERATURE

FLUID

1

RINSING

2


VE3-EnduroSuper

3

RINSING

QUALITY WATER*

Ambient

4

ACID CLEANING (descaling)

5

RINSING

VE10-EnduroCid QUALITYWATER*


QUALITY WATER*

CO NCENTR ATIO N

Ambient Ambientto40°C

DURATION

min 5 2%

2cyclesx10mi n***

2%

1cyclesx10min *** 2cyclesx5min**

min** 5


MS

6/7

PROCES SIDEL

14/07/2011


DIVERSEY PRODUCTS


7 WATER QUALITY P a r a me t e r

Microbial Load

<100 CFU/ml

2

Hardness

< 50 ppm CaCO3 (< 5°F)

3

Chlorides

< 40 ppm (as NaCl)

4

Chlorine

< 1 ppm (as free Chlorine)

5

Ph

6.5/7.5

6

Iron

< 1 ppm

7

Manganese

< 0.5 ppm

8

Suspended Solid

None

9

Smell or taste

None

10

Dissolved solids E.coli or thermotolerant coliform bacteria

< 700 mg/l Must not be detectable in any 100-ml sample

11

MS

Limit

1

7/7

PROCES SIDEL

16/04/2012

WP001-CIPSuggestedRecipes-C SDorSoftDrink1.1_EN.xls

STANDARD CIP RECIPES ( CSD - SOFT DRINK - JUICE ) Sidel s.p.a. - Via La Spezia 241/A - 43100 Parma - Italy

1 CHEMICAL TREATMENT BEFORE COMM ISSIONING ALKALINE AND ACID CHEMICALS MUST BE AVAILABLE STEP 1

R

INSING

2


3

RINSING

4

ACID CLEANING

5

RINSING

6

ALKALINE CLEANING (neutralization)

7

RINSING

* start time when <0,1 % of caustic/acid ** temperature on return line to CIP *** only with fillers manufactured after 2004

MS

FLUID

TEMPERAT URE

QUALITY WATER ALKALINE SOLUTION QUALITY WATER

CO NCENTRAT ION

ambient 80°C **

min 5 4%

ambient

NITRIC ACID*** QUALITY WATER

40°C **

QUALITY WATER

80°C **

30 min min* 5

5%

ambient

ALKALINE SOLUTION

DURATION

30 min 10 min*

1%

ambient

30 min 15 min*

SOLUTIONS

PureChemical

ALKALINE

NaOH

VC13-Diverspray

P3-mip CIP

ACID 1

HNO3

VA5-Pascal

P3-horolith FL

1/11

Diversey

Ecolab

PROCE SIDEL

16/04/2012



2 DISINFECTION BEFORE COMMISSI ONING

(ALTERNATIVE TO RECIPE # 3)

PEROXYACETIC CHEMICAL MUST BE AVAILABLE STEP

FLUID

TEMPERAT URE

1

RINSING

QUALITY WATER

2

DISINFECTION

PAA(peroxyaceticacid)

3

R

INSING

QUALITY WATER

SOLUTIONS

* temperature on return line to CIP

CO NCENTRAT ION

ambient 45°C*

PAA (peroxyacetic acid)

1500ppm***

ambient

PureChemical

DURATION

10 min 10min 20 min**

Diversey

Hydrogen peroxide VT6-Divosan Forte + peracetic acid

Ecolab

Oxonia Aktiv 30

** rinsing efficiency control. New rinsing if necessary *** PAA dosed after water has reached 45 °C

MS

2/11

PROCE SIDEL

16/04/2012



3 SANITIZATION BEFORE COM MISSIONING

STEP 1

RINSING

(ALTERNATIVE TO RECIPE # 2)

FLUID

TEMPERAT URE

QUALITY WATER

2

HOTWATERSANITIZATION

QUALITYWATER***

3

COOLING RINSE

QUALITY WATER

ambient 85°C** ambient

CO NCENTRAT ION

DURATION

10 min 40mi n 5/10 min

** Temperature on return line to CIP. Temperature must not drop below 80°C anytime during the sanitize cycle. If so the hot sanitize cycle must restart. *** Recommanded Twh 50< ppm/l as CaC03 (see Tab. 8)

MS

3/11

PROCE SIDEL

16/04/2012



4 CLEANING BEFORE PRODUCTION - DAILY - ( 3 Step Cleaning) ALKALINE CHEMICAL MUST BE AVAILABLE STEP 1

R

INSING

2

ALKALINE CLEANING (Detersion)

3

COOLING/RINSING

* start time when <0,1 % of caustic/acid

MS

FLUID

TEMPERAT URE

QUALITY WATER ALKALINE SOLUTION QUALITYWATER

CO NCENTRAT ION

ambient 75°C *

min 5 2%

ambient

SOLUTIONS

PureChemical

ALKALINE

NaOH

4/11

DURATION

15 min 10min*

Diversey

VC13-Diverspray

Ecolab

P3-mip CIP

PROCE SIDEL

16/04/2012



5 CLEANING and SANITIZATION BEFORE PRODUCTION - (3 Step Caustic Sanitization) ALKALINE CHEMICAL MUST BE AVAILABLE STEP 1

R

INSING

2


3

COOLING/RINSING

FLUID

TEMPERAT URE

QUALITY WATER ALKALINE SOLUTION QUALITYWATER

85°C **

PureChemical

ALKALINE

NaOH

DURATION

min 5 2%

ambient

SOLUTIONS


CO NCENTRAT ION

ambient

30 min 5/10min*

Diversey

VC13-Diverspray

Ecolab

P3-mip CIP

** Temperature on return line to CIP. Temperature must not drop below 80°C anytime during the sanitize cycle. If so the hot sanitize cycle must restart.

MS

5/11

PROCE SIDEL

16/04/2012



6 LONG STOPS (WEEK END AND HOLIDAYS) - Flooding PEROXYACETIC CHEMICAL MUST BE AVAILABLE STEP 1

FLOODINGMACHINE

* drain and refill every 2/3 days

FLUID

TEMPERAT URE

PAA(peroxyaceticacid) SOLUTIONS

PureChemical

PAA (peroxyacetic acid)

MS

20°C

6/11

CO NCENTRAT ION

500ppm Diversey

Hydrogen peroxide VT6-Divosan Forte + peracetic acid

DURATION

seenote* Ecolab

Oxonia Aktiv 30

PROCE SIDEL

16/04/2012



7 CLEANING - MONTHLY OR AFTER HEAVY MAINTENANCE - (5 Step Cleaning) ALKALINE AND ACID CHEMICALS MUST BE AVAILABLE STEP 1

R

INSING

2


3

RINSING

4

ACID CLEANING (Descaling)

5

RINSING

* start time when <0,1 % of caustic/acid **temperatureonreturnlinetoCIP *** only fillers manufactured after 2004

FLUID

TEMPERAT URE


80°C **

ACID SOLUTION QUALITY WATER

50°C **

SOLUTIONS

PureChemical

NaOH HNO 3 H3PO4 HNO3+H3PO4

7/11

30 min min* 5

1%

ambient

ALKALINE ACID 1*** ACID 2

DURATION

min 5 2%

ambient

ACID 3***

MS

CO NCENTRAT ION

ambient

15 min 10 min*

Diversey

VC13-Diverspray VA5-Pascal VA3-Alwash VA4-Superdilac

Ecolab

P3-mipCIP P3-horolithF L P3-Horolith PA P3-Horolith V

PROCE SIDEL

16/04/2012



8 CLEANING and SANITIZATION - MONTHLY OR AFTER HEAVY MAINTENANCE - (5 Step Cleaning and Hot Sanitization) ALKALINE CHEMICAL MUST BE AVAILABLE STEP 1

R

INSING

2


3

RINSING

FLUID

TEMPERAT URE


4

HOTWATERSANITIZATION

QUALITYWATER***

5

COOLING RINSE

QUALITY WATER

80°C **

min 5

20mi n

ambient

PureChemical

NaOH

30 min min* 5

85°C**

ALKALINE

DURATION

2%

ambient

SOLUTIONS


CO NCENTRAT ION

ambient

5/10 min

Diversey

VC13-Diverspray

Ecolab

P3-mip CIP

** Temperature on return line to CIP. Temperature must not drop below 80°C anytime during the sanitize cycle. If so the hot sanitize cycle must restart. *** Recommanded Twh 50< ppm/l as CaC03 (see Tab. 10)

MS

8/11

PROCE SIDEL

16/04/2012



9 DESCALING - MONTHLY OR HARDNESS WATER >15° F - (3 St ep Acid Cleaning ) ACID CHEMICAL MUST BE AVAILABLE STEP 1

R

INSING

2

ACID CLEANING (Descaling)

3

RINSING

* start time when <0,1 % of /acid **temperatureonreturnlinetoCIP *** onlyfillers manufactured after 2004

MS

FLUID

TEMPERAT URE

QUALITY WATER ACID SOLUTION QUALITY WATER

CO NCENTRAT ION

ambient 50°C **

min 5 1%

ambient

SOLUTIONS

PureChemical

ACID1*** ACID 2 ACID 3***

HNO 3 H 3PO4 HNO3+H3PO4

9/11

DURATION

15 min 10 min*

Diversey

VA5-Pascal VA3-Alwash VA4-Superdilac

Ecolab

P3-horolithF L P3-Horolith PA P3-Horolith V

PROCE SIDEL

16/04/2012



10 WATER QUALITY

Parameter

MicrobialLoad

<100CFU/ml

2

Hardness

<50ppmCaCO3(<5°F)

3

Chlorides

<40ppm(asNaCl)

4

Chlorine

<1ppm(asfreeChlorine)

5

Ph

6

Iron

7 8 9

MS

L i mi t

1

Manganese SuspendedSolid Smell or taste

6.5/7.5 ppm 1< <0.5ppm None None

10

Dissolvedsolids E.coli or thermotolerant coliform

<700mg/l Must not be detectable in any 100-ml

11

bacteria

sample

10/11

PROCE SIDEL

16/04/2012



11 FEASIBLE RECIPES WITH THE VARIOUS SIDEL CIP SYSTEMS

ML

CSD - SOFT DRINK - JUICE Recipes

ML Standard (PAA+Caustic)

2-3-4-5-6-8

ML 3°Chemicals (PAA+Caustic+Descalant)

1-2-3-4-5-6-7-8-9

ICS

MS

ICS Standard (PAA)

Not Available

ICS 2°Chemicals (PAA+Caustic)

Not Available

ICS 3°Chemicals (PAA+Caustic+Descalant)

Not Available

11/11

PROCE SIDEL

Matrix Filler


PART X

10.1.6 Description of slave card display unit controls Slave Display

Description

.

Slave Card in Tangent at Inlet Starwell

18

A

Abort

18

P

Check and Download Parameters

7

oH

Recipe Download

8

b

Burst

13

-

Wait Phase Start Dynamic Snift/Decompression

1

0

Fillling Execution Completed SetPoint Not OK

1

0.

Filling Execution Completed SetPoint OK

1

d

Snift/Decompression

1

1 + Rotation

Start Filling

1

C + Rotation

CIP Active

2

F

Start Flushing (only in FLAT)

3

MMM

User Program Mode

6

h + Rotation

Start Filling in Manual

14

S

Start Sequencer

3

U

Manual Step by Step Active

17

E

1

4

Command Error Valve Posit > Exit Filling Cam PAS but Fill Not Completed or Timeout Communication Broadcast Force Centering Cup Up Start Purge Volume (only in FLAT)

5

Start Purge Time (only in FLAT)

5

2

Read Serial by Node

21

6

Read Node by Serial

23

N.

Set Node by Serial

22

Ξ.

Slave Card Not Communication with Master

t

Command Execution

4

At every start up on display appears Node actual setting in slave card encoded using led segments Led segments:

. A . .p S l e id S ©

1.0

X - 13

Matrix Filler


10.1.7 Appendices for commercial equipment


X - 14

1.0

PART X

SF300 Filler


. A . p . S l e d i S ©


Montageanl eitung / Betätiger

AZM 161

Mounting instruct ions / Actuators Instructions de montage / Actionneurs

1 /2

deutsch

english

Set screw The basis setting of actuator AZM 161-B6 provides a minimum radius. For larger radii, the angle has to be adjusted correspondingly by turning the set screws a + b, using an hexagonal key wrench 2.5 mm A/F.

français

Rmin [ m m ] x [ m m ]

180 150 150 150 150 180 180 180 180

5 5 5 5 5 5 11 – –

150 150 150 150 150 150 150 150 150

5 5 5 5 5 5 11 – –

95 95 95

11 17 –

95 95 95

11 17 –

The axis of the hinge must be x mm above and in a parallel plane to the top surface of the safety switch. The basis setting provides a minimum radius of R min. L'axe de rotation de l'articulation et la face supérieure de l’interrupteur de sécurité doivent se situer dans deux plans parallèles distants de x mm. Le réglage de base est établi en fonction du plus petit rayon, R . min

Legende Legend Légende

Remarque Pour éviter tout démontage intempestif, utiliser les vis à tête fraisée avec vissage unidirectionnelle (peut être fourni comme accessoire). En cas de fixation selon un mode différent, par exemple par rivetage Einstellschraube ou soudage, veiller à ce que la profondeur de plongée de l'acionneur Set screw ne varie. Different formes d’actionneurs sont disponibles. Les Vis de réglage actionneurs AZM 161-B1 et AZM 161-B1E sont recommandés pour les protecteurs coulissants et amovibles. Dans le cas de protecteurs pivotants, nous vous conseillons l’actionneur AZM 161-B6.

R min . x

R min . x

Radien über die breite Seite des Betätigers Radii over the wide edge of the actuator Rayons d'actionnement sur le grand côté de l'actionneur Radien über die schmale Seite des Betätigers Radii over the small edge of the actuator Rayons d'actionnement sur le petit côté de l'actionneur

b

a

Montage Lors du montage sur des protecteurs pivotants, veiller à ce que l'axe dede rotation se dans trouve dans lel'actionneur plan de la surface de l'interrupteur sécurité laquelle plonge (voir table).

Vis de réglage Le réglage de base AZM 161-B6 est établi en fonction du plus petit rayon. Dans le cas de rayons plus grands, modifier le réglage en tournant la vis de réglage a + b à l'aide d'une clé 6 pans de 2,5 mm sur plats.


Der Drehpunkt des Scharniers und Oberkante des Sicherheitsschalters müssen zuzüglich x mm eine Ebene bilden. Die Grundeinstellung ist auf den kleinsten Radius R min eingestellt.

Notice Please ensure this is fitted the correct way round, and tighten the actuator with one-way screws (available as accessory), to prevent deliberate removal. Please ensure with welding or riveting of the actuator, that the insertion depth of the actuator is not altered. There are different actuator types available, depending on the application. The actuator AZM 161-B1 and AZM 161-B1E are designed for sliding and removable safety guards, while AZM 161-B6 is recommended for hinged safety guards. Mounting Please note, that the centre of rotation must be in the same plane as the upper edge of the safety switch (see table).

x

x

AZM 161-B6 AZM 161-B6-2177 AZM 161-B6S

Einstellschraube Werkseitig ist der Betätiger AZM 161-B6 auf den kleinsten Radius eingestellt. Bei größeren Radien erfolgt die Einstellung durch Drehen der Einstellschrauben a + b mit einem Innensechskant-Schlüssel SW 2,5 mm.

R min .

R min .

Hinweis Betätigungsradien Verwenden Sie als Sicherung gegen unbefugtes Lösen SicherheitsActuator radii schrauben mit Einwegschlitz (als Zubehör erhältlich). Bei BefestiRayons d'actionnement gung, z.B. durch Nieten oder Schweißen, ist darauf zu achten, dass sich die Eintauchtiefe des Betätigers nicht ändert. Es stehen verschiedene Betätigerformen zur Verfügung: Vorzugsweise für verschieb- und abnehmbare Schutzeinrichtungen der Betätiger AZM 161-B1 AZM 161-B1 und AZM 161-B1E. Für drehbare Schutzeinrichtungen AZM 161-B1-1747 der Betätiger AZM 161-B6. AZM 161-B1-2024 AZM 161-B1-2053 AZM 161-B1-2177 Montage Bei der Montage an drehbaren Schutzeinrichtungen ist darauf AZM 161-B1E zu achten, dass der Drehpunkt in der Ebene der Oberfläche des AZM 161-B1F Sicherheitsschalters liegt, in die der Betätigungsbügel eintaucht AZM 161-B1S (s. Tabelle). AZM 161-B1ES

a

b

Istruzioni di montaggio / Attuatori

AZM 161

Instrucciones de montaje / Actuadores

2 /2

italiano

español

Avvertenza Raggi d'azionamento Per evitare uno smontaggio non autorizzato o manomissioni Radios de accionamiento utilizzare viti di sicurezza con intaglio antisvitamento (disponibili come accessori). Durante il fissaggio, ad esempio mediante rivetti o saldatura, assicurarsi che la profondità di inserimento dell'attuatore non venga alterata. Sono disponibili diversi tipi di attuatori: per protezioni traslabili e AZM 161-B1 amovibili sono da preferirsi gli attuatori AZM 161-B1 e AZM 161-B1E, AZM 161-B1-1747 per protezioni a cerniera l’attuatore AZM 161-B6. AZM 161-B1-2024 AZM 161-B1-2053 AZM 161-B1-2177 Montaggio Durante il montaggio su dispositivi di sicurezza con cerniere, assicuAZM 161-B1E rarsi che l’asse di rotazione si trovi sul piano della superficie dell’interAZM 161-B1F ruttore di sicurezza nella quale si inserisce l’azionatore (vedi tabella). AZM 161-B1S AZM 161-B1ES Vite di regolazione L'attuatore AZM 161-B6 è tarato sul raggio minimo. Per raggi AZM 161-B6 maggiori modificare la taratura agendo sulle viti di regolazione AZM 161-B6-2177 AZM 161-B6S a + b con una chiave a brugola da 2,5 mm.

R min .

R min . x

x


180 150 150 150 150 180 180 180 180

5 5 5 5 5 5 11 – –

150 150 150 150 150 150 150 150 150

5 5 5 5 5 5 11 – –

95 95 95

11 17 –

95 95 95

11 17 –

Il fulcro della cerniera ed il bordo superiore dell'interruttore di sicurezza devono essere su due piani paralleli distanti fra loro x mm. Al montaggio la taratura è fissata sul raggio minimo R min.

Información Se debe asegurar contra desmontajes no autorizados mediante la utilización de los tornillos de seguridad con la cabeza fresada (suministrados como accesorios) que solo permiten el apriete. En caso de utilizar un modo de fijación distinto, por ejemplo por remaches o por soldadura, hay que asegurarse que la profundidad de penetración sea la misma. Existen distintas versiones de actuador disponibles, dependiendo de cada aplicación. Los actuadores AZM 161B1 y AZM 161 – B1E, han sido previstos para puertas deslizantes o desmontables, mientras que AZM 161- B6 se recomienda para las puertas protectoras de seguridad pivotantes.

El eje de giro de la bisagra, y la cara superior del interruptor de seguridad deben situarse en dos planos paralelos, separados por x mm. El reglaje de base viene establecido en función del radio mínimo, R min.

Montaje En caso de montajes en protecciones pivotantes, hay que asegurarse Legenda de que el eje de giro se encuentre en el plano de la superficie del inte- Leyenda rruptor de seguridad en elcual penetra el actuador (vertabla). Tornillo de regulación La regulación de base del AZM 161 –B6 se establece en función del mínimo radio de giro. En caso de mayores radios de giro, modificar el reglaje girando los tornillos de regulación a + b mediante una llave hexagonal de 2,5 mm entre caras.

R min . x

R min . x

Raggio sul lato lungo dell'attuatore Radios de accionamiento en el lado mayor del actuador

Raggio sul lato corto dell'attuatore Radios de accionamiento en el lado menor del actuador

b

Vite di regolazione Tornillo de regulación E e b a g s u

a

A / 0 0 9 V 1 6 1 6 1 0 5 Z B / 8 9 0 8 4 1 1 .r N e li e T / 8 .0 7 0 / . .A v / 0 0 0 x

a

K. A. Schmersal GmbH Industrielle Sicherheitsschaltsysteme Möddinghofe 30, D - 42279 Wuppertal Postfach 24 02 63, D - 42232 Wuppertal

Telefon Telefax E-Mail: Internet:


+49 - (0)2 02 - 64 74 - 0 +49 - (0)2 02 - 64 74 - 1 00 [email protected] http://www.schmersal.com

b

Sensore elettronico di sicurezza CSS 34 Sensore CSS 34

27

Sensore CSS 34F0/F1

27

27

Azionatore CST 34

27 27

2 , 7 9

2 , 8 0 1

2 , 8 0 1

2 , 7 9

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M 12x1

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                 

 CSS 34F0            CSS 34F1          

Certificazioni

Certificazioni





Dati per l‘ ordine

D at i pe r l ‘ or di ne

Certificazioni   

D at i pe r l ‘ or di n e

     

     

  

N r.

N r.

N r.



I n s er i r e 

 



 

   

12

D e s cr i z i o n e

                               

7 , 1 0 1

2 , 7 9

M 12x1

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27



I n se r i r e 

D es c r i z i on e

                                             

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

I n se r i r e 

D e sc r i z i o n e

        

Sensore elettronico di sicurezza CSS 34 Dati tecnici

Dati tecnici



                                           Colleg amento in se rie: max. 31 di sposi tivi            Distanze azionamento sec. EN 60947-5-3:                         Uscite di sicurezza Y1/Y2:                                                                 Cavo:                                                       Uscite di diagnosi:    Connettore:               Condizioni ambientali:                                                                          Classif. di sicurezza:                           Dati elettrici: 

                                                           

Note                         

   

                 

Diagnosi Requisiti per la diagnosi                                                                     

13

Sensore elettronico di sicurezza CSS 34 Spostamento assiale laterale Azionamento laterale   

Cablaggio Cablaggio del CSS 34 con cavo di collegamento (ordinare -L)

S Sa r

S [mm]

SOFF

15

S e n s o r eco n u sc i t a d i d i a g n o si

S e n so r ec on d i a g n os i se r i a l e

C ol o r ic a v o ( or di n ar e - L )

                            

                           

                

SON

13

Sa o 10

V1 V2

5

0 - 19

-15

-10

-5

0

5

10

V [mm]

15 19

   V2



Cablaggio di CSS 34 e CSS 34F0/F1 con connettore (ordinare -ST)                         S e n s o r eco n S e n so r ec on u sc i t a d i d i a g n o si d i a g n os i se r i a l e *

V1



Azionamento sulla testina    S

                            

Sa r S [mm] 13

SOFF SON

10 Sa o

5

                          

6

5

7 1

4 8 3 2

C on f i g .P I N C ol o r i con net tor e ca vo                                        

0 -1 0

-5

0

5

10

V [mm]

  

S

V





Spostamento assiale laterale                                            

                              6 5 4 8 3 7      1 2      S e n s o r e co n S e n so r e c on C on f i g . P I N C ol o r i u sc i t a d i d i a g n o si d i a g n os i se r i a l e * con net tor e ca vo                             

                           

               

Direzioni di azionamento                       Legenda                                               

14

               

SON < SH < SOFF

          

1

MODULO DI MONITORAGGIO VELOCITA’ DI ROTAZIONE

2

3

Filler User Manual

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