MacDonald Steel Limited

Transcription

1 DELUXE FILLER / CROWNER MODEL - DFC4 1 REV 00

2 CAUTION / WARNING READ MANUAL BEFORE OPERATING MACHINE DO NOT EXCEED 50 PSI ON Co2 OR BEER LINES DO NOT EXCEED 100 F (35 C) ON Co2 OR BEER LINES DO NOT HOSE OR SPRAY THE FRONT PANEL NEVER PLACE HANDS OR OTHER OBJECTS INTO MACHINE WHILE DOOR IS OPERATING DO NOT LIFT DOOR DURING CYCLE BEFORE SERVICING, DISCONNECT AIR, C02, BEER AND POWER WEAR SAFETY GOGGLES WHILE OPERATING MACHINE HANDLE ALL CLEANING SOLUTIONS ACCORDING TO MANUFACTURERS INSTRUCTIONS AND WEAR PROTECTIVE EQUIPMENT AS REQUIRED. AVOID LOWERING HEADS WITH NO BOTTLE(S) IN PLACE 2 REV 00

3 FEATURES Independent stations, fills one to four bottles Auto level detection, with adjustable fill heights Analog pressure switch control: easy setup of vacuum draw and fobbing Selectable number of evacuation cycles. Auto and manual crowning Monitoring of the fill sequence for easy troubleshooting Preprogrammed cleaning cycles (CIP) Operator interface: 8 color touch screen for setup, cleaning and troubleshooting Adapters are available for filling cans and various size bottles Fill from top nozzles available as an alternative to fill from bottom OPERATING REQUIREMENTS Clean dry air: CFM (min. 3/8 supply line) with necessary adaptor. Oil free recommended. Potable water supply: warm and cold; max temperature 70 F or 21 C C02 at 50 PSI max (3/8 supply line) 120 or 220 VAC, 50-60Hz, 4 AMP, according to local supply. Surge suppression power bar is recommended. Beer supply line to fit sanitary fitting 1/4 line to drain (supplied) 5 gallon (min) pressurized keg for cleaning or other pressurized source 3 REV 00

4 CONTROLS POWER ON/OFF Side panel main power to machine. Circuit breaker(s) are also located directly below the power switch. When tripped a visible red line appears on the breaker button. Also inside the machine on the terminal blocks are fuse(s) which protect the PLC outputs and fuse(s) protecting the 24 VDC power supply. STOP SWITCH (Red) Stops all operations on all heads. All heads lift and shuttle forward. This switch also acts as a master reset switch. At any time if held for 2 seconds, the heads and door will rise, and the shuttles return to the front position. On multi-head machines, there is a stop switch for each head on the Human Machine Interface (HMI), which allows independent heads to be stopped. START SWITCH (Green) When pushed the door will go down and the machine will begin the selected cycle. MANUAL STOP SWITCH: These stop switches are accessed via the HMI display. When the HMI main screen is being displayed, the stop buttons will stop each bottle independently. Pushing the stop button a second time will lift the head immediately. MANUAL CROWN SWITCH: These crown switches are accessed via the operator display. When the HMI main screen is being displayed there is a button for each crowner. ANALOG PRESSURE TRANSDUCERS One for each head, these switches control the pressure for the Co2 pressure and the vacuum draw. VENT CONTROL Stainless steel flow controls, one for each head, located at the lower left side of the machine. These control the rate of pressure released from the bottle and thus the fill rate of beer. AIR REGULATOR Set the regulator to 60 psi as a starting point. The crowning cylinders require the most force and the pressure may have to be increased to ensure a good crown. The vacuum is a venturi style and uses air to achieve vacuum. If you require a deeper vacuum you may have to increase the air pressure as well. The air components in the machine should not be exposed to water or oil, install a good quality filter before the machine. The maximum air pressure should not exceed 90 psi. The lower the pressure the longer life expectancy of the air components. Co2 REGULATOR The Co2 regulator (not supplied) is to be set dependant on the pressure in the beverage supply tank. When the EZ Pressure set up measures the tank pressure the Co2 counter pressure is automatically set to 2 psi higher than the tank reading. The set point value is displayed on the bottom of the pressure screen when the Co2 valve is opened. The Co2 regulator must be able to achieve that value. It is recommended to set the regulator between 5 to 10 psi higher than the tank pressure. Setting the regulator too high could result in false or unstable measurements as the valve opens and Co2 surges into the pressure transducer. 4 REV 00

5 HMI TOUCH DISPLAY This device located on the front panel, allows the operator to change times, starting modes, disable heads, control crowning, monitor and troubleshoot. Using the Display The display offers the operator the ability to easily access the computer (CPU) in the PLC in order to change times, starting modes, disable heads, control crowning, monitor and troubleshoot. It is a good idea to familiarize you with the display functions before beginning to operate the machine. The best way to do this is without bottles in place and to scroll through the various functions as described below. To change values such as crown time, the number (#) of purge cycles, CIP times, etc, when the appropriate screen is displayed touch the button and a cursor numeric key pad displayed to enter the values. When power is first turned on, the following functions automatically return to their start up state. Auto crowning mode is turned off. The heads power up disable off. CIP mode is off, & auto level detect is on. The following remain as they where last set, before power was turned off. Auto level delay times, # purge cycles, auto crown time, start type. WARNING Never spray water or any liquid directly onto the display screen. To clean, wipe the screen with a damp cloth only. 5 REV 00

6 MACHINE SETUP MacDonald Steel Limited After unpacking the machine, the Co2 fitting, fill tubes, and drain fittings must be attached. Installing the air regulator Co2 connection 6 REV 00

7 MACHINE SETUP CIP JUMPER There is a jumper hose with the machine which is used to connect the beer manifold and the Co2 line together for cleaning (CIP). The tee fitting on the jumper has been left blank, attach an appropriate connector to it, depending on the source of your cleaning solution. Water must also run through this jumper to rinse the machine. The CIP jumper hose 7 REV 00

8 MACHINE SETUP LIGHTS Light strips are 24vdc LED s. FILL TUBES The fill tubes must be installed before operating the machine. The fill tubes are designed to reach near the bottom of the bottle when the head is lowered. If filling more than one bottle size, be sure to use the appropriate length fill tube. Failing to use the proper size could result in excess foaming or breaking of the fill tube. Use the Manual Control screen to manually operate the heads. Reduce the air pressure to 5 PSI or less so the heads operate slowly. The fill tubes are threaded on one end. Carefully screw the tube onto the head. Align the tube by slightly bending them if necessary to be centered in the bottle opening. If necessary short fill nozzles are available for fill from top filling, if the displacement of the fill tube is too high. PET BOTTLE HOLDERS If PET bottles are used on the filler, a special adaptor is placed on the filler base instead of the glass bottle holders (pucks). PET bottles are held by the neck to withstand the force applied by the filling head. The PET adaptor is held in place by a plastic plug which locates the adaptor to the filler base (see picture below). Align the hole in the adaptor with the center hole in the machine base. Inserting PET adaptor plug 8 REV 00

9 MACHINE SETUP GLASS BOTTLE HOLDERS MacDonald Steel Limited The filler comes equipped with a two piece plastic base (puck) to hold glass bottles. The bottom piece can be used to hold one size bottle and the second (upper) piece will hold a smaller, second size bottle. The base(s) must be in place to fill glass bottles, do not place a bottle directly on the metal. Two piece glass bottle base small bottle large bottle HEAD TULIPS The filling head has a removable tulip, which is used to center and seal the bottle. The tulip is comprised of three parts; an upper piece which seals against the fill head, a inner rubber seal and a lower piece which acts as a guide to center the bottle. The mouth of the bottle must pass through the lower piece to rest against the rubber seal. On some larger bottles such as growlers the lower tulip piece must be removed in order to seal the bottle during the fill cycle. The lower part of the tulip is threaded; to remove it, simply grasp the piece and twist counterclockwise. 9 REV 00

10 MACHINE SETUP MacDonald Steel Limited VENT TUBES The filling head consists of two metal tubes, one inside of the other. The inner tube is for filling product, while the outer tube is for the C02 pathway, venting pressure out of the bottle and also controls the fill height in the bottle. Both tubes have a screw applying contact to the metal tube, however the inner fill tube is permanently attached, while the outer vent tube is removable. There are wires attached to both screws that provide a signal to the PLC controller. Note: The fill tube is pressed into the fill head and a very small amount of 2 part epoxy is applied to seal and hold in place. This tube is not designed to be removed. The vent tube can be removed by following the instructions below. Removable vent tube If filling more than one size bottle where the neck or other dimensions vary, it may be necessary to change the vent tube so the proper fill height and volume is achieved. To change the vent tube, use the Manual Control menu to manually operate the heads. Reduce the air pressure to 5 PSI or less so the heads operate slowly. With the head in the down position, it may be necessary to rotate the head clockwise to gain access to the screw holding the tube in place. fill head in normal position fill head rotated for access to vent tube screw 10 REV 00

11 MACHINE SETUP MacDonald Steel Limited It will be necessary to hold the wire connector on the vent tube while loosening the locknut on the screw. On some machines this is a knob, while other machines it is a set screw.once the locknut is loose, back off the set screw holding the vent tube in place. Twist and pull down on the tube to remove it from the filling head. Insert the new vent tube into the head and tighten the screw against the vent tube. DO NOT OVERTIGHTEN, contact on the metal tube is all that is required. 3/8 wrench is required Hold the wire in place, loosen locknut Loosen the screw holding vent tube in fill head Vent tube removed from filling head 11 REV 00

12 MACHINE SETUP VENT FLOW CONTROLS These needle valve flow controls are located on the left hand side of the machine, one for each head. C.W. decreases the flow rate, C.C.W. increases flow. Start about ¼ turn C.C.W from fully closed. Gradually increase flow, but do not allow foaming during filling. Flow controls on the DFC4 NOTE During CIP mode, open these controls fully C.C.W. to allow maximum flow of cleaning solutions and rinse water. DRAIN LINES Attach the plastic drain fittings (⅛ NPT x ¼ hose barb) to the vent flow controls on the side of the machine. Using the ¼ hose supplied, cut four lines, one to each of the drain fittings, run these lines to drain. Do not allow the lines to be submersed in liquid; they should be vented to atmosphere. 12 REV 00

13 MACHINE SETUP AIR FLOW CONTROLS The heads, shuttles and door speeds can be affected by the air pressure on the system. There are flow controls on all cylinders that can be adjusted to control the speed of all these actions. If necessary to adjust, set the control so the action is smooth and not too fast, then lock the control using the locknut. Flow control shown on door cylinder, proximity switch is opposite PROXIMITY (REED) SWITCHES There are reed switches mounted on the air cylinders for door closed, head up, shuttle forward and back. These switches close when the cylinder is in its proper position and send that information to the CPU. If a switch fails the machine will not function properly or not at all. To check the switches locate the proper cylinder and observe the small LED mounted on each switch. When properly aligned the LED will be on, if not, loosen the screw located on the switch mounting bracket and move the switch until the LED lights. Tighten screw. Head proximity switches 13 REV 00

14 MACHINE SETUP CROWNING HEAD REPLACEMENT The crowning head on the machine is designed for a 26mm crown. If more than one size crown is to be used, the head must be replaced. If more than one crowning head has been provided, the size of the crowning head is stamped into the side of the head. Use the Manual Control menu to manually operate the crowning heads. Reduce the air pressure to 5 PSI or less so the heads operate slowly. With the head in the down position, use a large wrench and loosen the locknut. Thread the head off the cylinder rod and replace with the new crowning head. Ensure that the magnetic plunger and the spring are in the proper position inside the head before replacing the assembly. Tighten the locknut. The crowning head may have to be adjusted as described below. Changing the crowning head 14 REV 00

15 MACHINE SETUP CROWNING HEAD ADJUSTMENTS The crowning heads have a magnetic plunger enclosed in a plastic housing. This plunger is spring loaded to assist in releasing the bottle from the head after crowning. The spring tension is determined by the position of the head on the crowning cylinder rod, which is held in place by a locknut. On the underside of the crowning assembly is a large set screw which the plunger protrudes through. This screw determines the depth the crown will go into the head, which in turn controls the shape of the finished crown. Adjusting the screw CW into the head allows the crown to go further into the head and results in a tighter crown. If adjusted too deep the bottles will stick in the crowning head. Only make adjustments in small increments at a time. Adjusting the Crown: 1) Loosen the lock nut on the cylinder rod and then loosen the crowning head by rotating CCW. 2) Use a screwdriver as per the picture below and turn the screw CW for a tighter crown and CCW for a looser crown. 3) Rotate the crowning head CCW back onto the cylinder rod until the center plunger has spring tension. You should be able to slightly depress the plunger with one finger pressed against it. 4) Tighten the locknut against the crowning head to hold it in place. NOTE: If after crowning, a noticeable dent is on the top of the crown, the tension may have to be slackened. Loosen the locknut and slowly turn the crown down (C.C.W.) to relief some of the pressure. Adjusting the crown depth 15 REV 00

16 MENU EXPLAINATIONS 1. Manual Control Crown Head Up/Down Fill Head Up/Down Shuttle Control Reed Switch s Counter Door Control OPERATION OF MANUAL CONTROL This screen is used to manually operate the filling heads, crowners and shuttles. The door can also be manually operated. These operations are useful when setting up heads, changing fill tubes, adjusting the crowner and checking the proximity switches. Also, the number of fills per head and the total fills is recorded. To enter this mode press the Manual Control On button. Once in this mode no other operations are possible. A message on the main screens warns of this condition. As the cylinders move from one position to the other the related proximity switches will light showing the cylinder is in position. If the switch does not light it may be necessary to adjust or replace the proximity switch. 16 REV 00

17 MENU EXPLAINATIONS 2. Main Menu Measured Pressure High Pressure Pressure Record Off/On Low Pressure PUSH to Reset High & Low Pressure Zero Pressure Switch Set up Head Lift Pressure Vacuum Set point Purge On/Off Co2 counter pressure value Pressure calibration value To adjust pressure switch to zero Crowner Up/Down Press once to Stop Twice to lift head Cycle & Fill Times Message Display Screen Navigation Bar Pressure Readings The display shows the pressure in each head measured in psi. Pressing the "R" button will record the highest and lowest reading for the head selected. These readings will only change if a higher or lower pressure is measured. The values can be reset by pressing on the reading itself. The vacuum and head lift (fobbing) values can be entered by pressing on the "S/U" button. If the reading on the display shows a value other than "0" when the head is in the raised position the zero value can be calibrated by pressing the "C" button. This will pop up a down and up button along with a numeric display box showing the current zero calibration value. Pushing either of the up or down buttons changes the value for zero. There is a limit hard coded into the computer for this calibration value. If you cannot zero the pressure switch using these buttons the pressure transducer is defective and must be replaced. Whenever the Co2 valve is opened during the purge or counter pressure cycles the set point is displayed in the lower portion of the pressure screen. This value is hard coded to 2 psi higher than the beer open value setting and cannot be changed. The buttons on the pressure screen are maintained style pushbuttons. Pressing once activates the button, pressing a second time deactivates them. 17 REV 00

18 Purge Button Main Menu Each head has a "Purge" button used to manually open the Co2 valve while pressed. This is useful to push beer, foam or water out of the Co2 or vent line. The button is also used to clear a "bridge" of foam or liquid in the fill head. Another function of this button is to check for leaks in the fill head. For more information see the troubleshooting section below. Crowner Down The Crowner Down button is used to manually crown a bottle. This would be used if the crown was not on properly and had to be crowned again. The crowner will only operate as long as the button is held in. For setting up or adjusting the crowner use the "Manual Control" screen. CAUTION: Do not hold onto the bottle while operating the crowners manually. Cycle & Fill Time These timers show the current cycle and fill times and are only used for comparing and maximizing cycle times. Stop Buttons The Stop buttons are used to stop an individual head rather than stopping all four heads by using the main Stop switch. Pressing the button once will stop the current operation, vent the pressure and lift the head. Pressing the button twice will lift the head immediately. Screen Navigation Bar These push buttons are used to move from screen to screen. They are located on each screen. Messages As the machine goes through its cycles, messages appear in the message box explaining what part of the cycle is currently running. If for some reason there is a fault and the cycle cannot be completed a message will appear with the fault description. For details on the fault messages see the troubleshooting section of this manual. Upon pressing the Start Switch the previous messages will clear. 18 REV 00

19 MENU EXPLAINATIONS 3. EZ Setup Crowner On/Off Auto Level On/Off Auto Level Delay Time Enable/disable head Shuttle On/Off Often used for can filling. Crowner Time 1-5 Purges Purge Timeout Simultaneous or Sequential Filling Quick Pressure Setup Level Off/On This button is used to turn the auto level detection off or on. When the level detection is ON, the head will automatically detect the proper level and shut off the beer valve. If the head will not detect the level the setting may be turned to OFF. When the level is turned off the stop switch for that head must be used to turn off the beer valve. Consult the troubleshooting section of this manual for reasons the level detection may not be working. The default is set to ON upon power up. Level Delay This timer is used to delay the beer valve from shutting off once the level has been detected. By increasing the delay time the fill height in the bottle can be increased. The amount of increase is determined by the flow rate as this is a timer. CAUTION: Too much delay time will cause product to flow out of the bottle and into the vent line. This will cause foaming in the next fill cycle as the excess beer is blown back into the bottle during the purge cycle. This in turn will result in the head "bridging" or shorting out the level detectors. Under normal operating conditions set this value to "0". If you cannot achieve the proper level required for your style bottle you may need to change the length of the vent tube. Contact MacDonald Steel for assistance. 19 REV 00

20 Head On / Disabled This button will disable the fill head in case of mechanical or electrical problems that prevent the head from operating properly. By disabling the head the rest of the fill heads can still be used. It is not necessary to place a bottle in the head before disabling it. Shuttle Off / On When the shuttle is turned off it no longer returns to the forward or front position in the machine. This function is useful if you are not crowning your product such as cans, growlers or Champagne style bottles with corks. This reduces the cycle time of the machine by not shuttling back and forth. Crowner Off /On When the machine is first turned on the default setting is crowner off. This allows the operator to set up the machine before crowning. It also allows products that do not require crowns to be filled. Once the crowner is turned on a crown time menu appears. Crown Time Use this menu to set the amount of time the crowner stays in the down time. Set the time to allow a good crown usually about 1.5 seconds. Excess time will increase your overall cycle time. Purges The number of purges for each head is set with this menu. The purge cycle consists of one Co2 pressure and one vacuum draw. Typical number of purges is two. More purge cycles will increase cycle time. Purge Time During the Purge cycle as well as the Counter pressure cycle this timer is used to set the time allowed for the pressure or vacuum set point to be reached. It is also used as a timer to clear a bridge prior to the purge cycle. If the set point cannot be achieved during this time the cycle aborts and the head returns to the up position and the shuttle comes forward. If the Co2 and air regulators are set properly the minimum value of 5 seconds is sufficient to achieve the set points. If filling large bottles such as growlers or 5 liter cans more time is required to achieve the set point especially during vacuum. Setting this value higher allows more time before the cycle aborts. This time value does not control the length of the actual cycle during normal operation. The switching between Co2 pressure and vacuum is controlled by the pressure switch. If for some reason the pressure or vacuum set point cannot be achieved such as a missing, cracked or broken bottle, a bridge in the head or a leaking fill head the higher value will only delay the aborting of the cycle. This value should only be increased when the container being filled cannot reach the set point within the 5 second minimum due to it's large size. Start All / 1 This controls the number of bottles that start once the Start Switch has been pressed. In the "ALL" position, all the bottles start at once. This is the most productive format to use the machine. By selecting the"1" position Head 1 starts first. Once the fill cycle starts, Head 2 starts and the rest of the heads follow. This is sequential filling which is useful when first setting up the machine. It gives the operator time to observe each head and ensure it is operating properly. Due to the sequential starting of each head the overall cycle time in increased. 20 REV 00

21 EZ Pressure Setup This button controls a popup menu used to measure the tank pressure of the product being filled. This in turn sets the counter pressure used during the fill cycle and controls when the beer valve is opened. When the button is pressed the following menu is displayed: This is your Beverage Pressure entering the Filler This Sets the Pressure Set point that the Beverage Valve will Open Pressure differential, between the measured tank pressure and the pressure below that point when the valve opens Used to Calibrate the Pressure Switch (contact MacDonald Steel) Pressure in the bottle being filled should be equal to or slightly less than the pressure in the product tank. This will allow product to flow into the bottle as soon as the product valve opens. The flow should not cause any foaming and should not go up the fill tube or feed line. The menu box Open Below Pressure allows the operator to enter a differential pressure between the counter pressure in the bottle and the pressure in the tank. The value entered into this register is subtracted from the actual tank pressure and this is the pressure at which the beer valve opens as seen in the open=**.* psi menu box. The EZ pressure setup measures the pressure in the tank and automatically counter pressures the bottle to a higher setting. The vent valve then opens allowing pressure to slowly bleed out of the bottle. Once the pressure in the bottle is equal to the open=**.* psi setting, the valve opens allowing product to flow into the bottle. To check the tank pressure, a bottle or can must be placed in the left hand (#1) filling station. The shuttle is moved to the back position and the fill head lowered. Once the Press to Start button is pressed, beer flows into the bottle until the pressure in the bottle is equal to the tank / keg pressure. The pressure reading on the display will stabilize displaying the tank pressure. Press the Set Pressure button and the pressure value is first subtracted from the Open Below Pressure value and then transferred to menu box open = **.* psi. The pressure differential should be between 0 & 2 psi. depending on the conditioning of the beer. Experiment with different values. NOTE: There are several ways to position the bottle to measure the tank pressure. First place a bottle on the shuttle for filling station one. 1) Disable Head 1 with which puts the bottle in the desired position. 2) Another is to power the machine down with a bottle in filling station 1 and power back up again. 21 REV 00

22 3) Use the Manual screen and manipulate the shuttle and head into the proper position. If you select this method be sure to exit the manual mode before trying to measure the pressure, as nothing will operate when the machine is in this mode. The value measured in the pressure setup remains in memory when the power is turned off. The only time another measurement is necessary is if the tank pressure has changed FILLING MODE Before filling, be sure to thoroughly clean and rinse the machine. Turn on the power, connect the Co2, beer and air lines as outlined in the requirements section of this manual. Set up machine via the display, i.e.: # of purges, set start type to sequence (if desired), leave auto crown off. Set beer keg pressure as outlined above. Close the flow controls fully C.W., then open about ¼ turn C.C.W. Place bottles on shuttles and caps in crowners. Push the start switch and adjust each flow control for smooth beer flow, without foaming. Adjust / set bottle release pressure set point for proper fobbing. When bottles fill to proper level and fob, turn on the auto crown. Slowly open the flow controls until maximum flow is achieved without foaming. When setting up the machine sometimes it is helpful to only do one head at a time. Use disable head screen to disable all but the head you are setting up. When all heads have been set up, set all heads to run. The start type sequence could be helpful if trying to draw a deep vacuum. In this start type the bottles purge one at a time instead of all at once as in all start mode. Also during set up it is easier to adjust the bottles one at a time. It may be helpful during fill cycle, as all the beer valves will not open at once thereby reducing turbulence. Note The temperature of the beer should be as cold as possible, near 0 C (32 F), for the best filling results. Also, when first filling, the machine valves and hoses need to cool down. This can be achieved by running a batch of cold water through the machine first, otherwise foaming will occur during the first few cycles. Set the head release set-point so that the bottle fobs and the foam is just starting to overflow the bottle as the crown is applied. This will ensure that minimum air is in the bottle. 22 REV 00

23 MENU EXPLAINATIONS 4. CIP Setup Wash Duration Wash On/Off Rinse Duration Rinse On/Off CIP MODE The filler has a Rinse and a Wash built in, pre-programmed clean-in-place (CIP) cycle. This program ensures all pathways in the machine are cleaned. It is very important that the machine be cleaned after each use. The Rinse cycle is used to rinse the beer manifold and beer pathway to the bottle with water. No connection to the Co2 inlet is necessary. This cycle is used primarily to rinse between different beers or for a quick rinse of the beer pathway. It is not to be used as the main CIP cycle for cleaning the machine. The Wash cycle is for a complete CIP of the machine. The jumper between the beer manifold and the Co2 connection is used. This cycle cleans all pathways in the machine. NOTE: After using the CIP WASH CYCLE with caustic or sanitizer, rinse water must be used during a WASH CYCLE to clear all the pathways in the machine. Using the RINSE CYCLE only rinses the beer manifold and filling line BUT not Co2 lines. Failing to run a WASH CYCLE with water after using caustic could result in caustic remaining in the lines and potentially contaminating the product. 23 REV 00

24 To use the RINSE CYCLE Empty the beer manifold of as much product as possible (if full), by cycling the machine. Connect a water line to the beer manifold. Open the vent flow controls fully C.C.W. Bring shuttles forward to start position. Place bottles on shuttles. Select CIP on display menu. Set a rinse time between 10 to 99 seconds. Push the Rinse button on the screen. Follow on screen instructions for starting, canceling or exiting the cycle. Cycle time can be monitored by staying on the CIP screen. Connect Co2 to the beer manifold and run a short Rinse cycle to clear the water, just before filling operation. Use the "Purge" buttons on the main screen to clear the Co2 lines of water. Note MAXIMUM TEMPERATURE FOR HOSES IS 70 F To use the WASH CYCLE Empty the beer manifold of as much product as possible (if full), by cycling the machine. Connect the beer input and the Co2 input with the CIP jumper hose provided. Connect a caustic line to the input of the jumper. Open the vent flow controls fully C.C.W. Bring shuttles forward to start position. Place bottles on shuttles. Select CIP on display menu. Set a wash time between 1 to 30 minutes. Push the Wash button on the screen. Follow on screen instructions for starting, canceling or exiting the cycle. Cycle time can be monitored by staying on the CIP screen. When the caustic cleaning is completed, connect water to the input jumper and repeat the above steps. Sanitizer can be used in the same way. When finished turn off power, heads will stay down sealing the system. To exit the CIP mode, hold the stop switch until the door opens. Connect Co2 to the beer manifold and run a short Rinse cycle to clear the water, just before filling operation. Use the "Purge" buttons on the main screen to clear the Co2 lines of water. Note MAXIMUM TEMPERATURE FOR HOSES IS 70 F When using the pressurized keg, be sure the keg does not empty before the wash time stops. Typically, the drain hoses are gathered together and placed into an empty keg for collection of the cleaning solution. The contents can then be transferred through the machine again. Stopping the CIP WASH cycle also resets the wash timer, however the machine remains in the CIP mode, to restart push the start switch. The CIP cycle repeats every 20 seconds, therefore selecting several short wash times has no effect on the overall performance. 24 REV 00

25 MENU EXPLAINATIONS 5. Inputs & Outputs This screen can be used to see which inputs and outputs are open or closed on the PLC without having to remove the back cover. Also shown are the Co2, Vacuum and Level set points. This information is used to determine if certain steps in the filling process have been reached. When the input or output is active the "LED" on the screen will change from red to green. 25 REV 00

26 TROUBLESHOOTING - Messages The following is a list of the messages that may appear on the main screen indicating a fault or failure to complete a fill cycle. Head Bridged A bridge occurs when liquid or foam is between the fill tube and vent tube in the filling head while the head is in the up position. The PLC is unable to detect a level when this occurs as it relies on the gap between these two tubes to determine when the bottle is filled to the proper level. When a bridge is sensed while the head is up, the Co2 valve is opened to try and blow the bridge clear. If the bridge is cleared that head will then lower and the fill cycle continues. The maximum time the Co2 valve tries to clear the bridge is determined by the setting of the "Purge Time" as set on the "EZ Setup Menu" screen. If bridging occurs and will not clear automatically, use the "Purge" button on the main screen to try and clear the bridge. Be sure to purge all fill heads after any rinsing or washing cycle. Sometimes drying the head with a hair dryer or heat gun will help. Be careful not to get the head too hot. If the bridge cannot be cleared, turn off the "Auto Level" on the "EZ Setup Menu" screen and use the "Stop" button for that particular head to stop the beer valve at the proper level. The fill head may have to be replaced, contact MacDonald Steel. Failed Co2 set point Co2 counter pressures the bottle to reach the set point on the pressure switch. The set point value is displayed on the bottom of the pressure screen when the Co2 valve is opened. This message appears if the set point is not reached within this time(max time as set in "Purge Time"). Possible causes are Co2 regulator set too low, broken or missing bottle, defective Co2 valve, poor seal at fill head, leaks in fill lines or defective pressure transducer. Check the gauges and the supply to the machine. Failed Vacuum Set point Vacuum is drawn immediately after the Co2 purge and has to reach the set point as entered in the pressure switch setup. This message appears if the set point is not reached within this time (max time as set in "Purge Time"), Possible causes are main air regulator set too low, broken or missing bottle, defective vacuum valve or vacuum venturi, poor seal at fill head, leaks in fill lines or defective pressure transducer. Check the gauges and the supply to the machine. Pressure Loss in Bottle This message appears if the pressure in the bottle drops to the "Head Lift" setting as per the Pressure Switch set up before a proper level has been reached. The head raises and bottle shuttles forward without crowning. Possible causes are the flow control valve is set too high and the supply of product to the machine cannot be maintained, leaks in the fill lines insufficient size of product line to the machine or loss of pressure in the supply line. Try reducing the flow control valve by turning clockwise, increase the size of the product line to the machine and check the pressure in the tank. Head Shorted Before Fill If this message appears the fill head was bridged just before the beer valve opened but after the purge and counter pressure cycles. Try purging the head with Co2. Door Prox Fault The proximity switch on the door cylinder is not being detected. If the heads do not lower the switch must be checked and adjusted or replaced. If the machine cycles then the timing of the shuttles or door is too slow and the flow control on the cylinders must be adjusted. 26 REV 00

27 Shuttle Forward Prox Fault The front proximity switch on the shuttle is not being detected.. If the machine does not start or the crowner will not operate the switch must be checked and adjusted or replaced. If the machine cycles then the timing of the shuttle is too slow and the flow control on the cylinder must be adjusted. Shuttle Back Prox Fault The back proximity switch on the shuttle is not being detected.. If the fill heads will not lower the switch must be checked and adjusted or replaced. If the machine cycles then the timing of the shuttle is too slow and the flow control on the cylinder must be adjusted. Head up Prox Switch The proximity switch on the head cylinder is not being detected.. If the machine does not start or the shuttle will not come forward the switch must be checked and adjusted or replaced. If the machine cycles then the timing of the head cylinder is too slow and the flow control on the cylinder must be adjusted. Head Disabled This message appears when the fill head has been disabled. TROUBLESHOOTING - other Auto Level Detection As noted above in the section "Head Bridged", the fill tube and vent tube are used to determine the proper level. Wires from each tube go from the fill head to the PLC input. Contact between the wires and the tubes are through the set screws in the fill head. These set screws must make contact with the metal tubes. If one of the screws becomes loose or the wiring at the fill head breaks, the level detection will not function. To test the level sensor: - remove the teflon filling tube from the fill head by unscrewing it. - remove the bottle from the shuttle base. - use the manual control screen and lower the fill head. - go to the I/O check screen - use a small screwdriver or other metal object (paper clip etc) and gently short the vent tube and the metal fill tube together. - observe the input "Level Probe" for the appropriate fill head on the I/O screen. If the circuit to the PLC is intact, the LED should turn to green. If circuit is broken the LED will remain red. - If there is no green LED at the fill & vent tubes, then remove the short from the tubes and place it across the two set screws instead. This will check the actual wiring from the fill head to the PLC. - If the LED remains red then the problem is most likely in the wiring. If the LED turns to green with this check, then the problem is lost contact between one of the set screws and one of the tubes. - to determine which set screw has lost contact, short the lower set screw to the fill tube. You may need a piece of wire to perform this test. A red LED indicates contact has been lost at the fill tube (upper) set screw. A green LED indicates lost contact at the vent (lower) set screw. - Once it has been determined which set screw has lost contact, loosen the appropriate lock nuts while holding the set screw with an Allen key and gently turn the set screw CW very slightly. Tightening the set screw too much can damage the tube. Perform the tests again to determine if contact has been made. Tighten the locknut up against the fill head while holding the set screw with an Allen key. 27 REV 00

28 MacDonald Steel Limited Back view of filler showing location of valves Product Valves Vacuum Valves C02 Valves Vent Valves 28 REV 00

29 CAUTION: WEAR SAFETY GOGGLES WHILE OPERATING THIS MACHINE. HANDLE ALL CLEANING SOLUTIONS ACCORDING TO MANUFACTURER S INSTRUCTIONS AND WEAR PROTECTIVE EQUIPMENT AS REQUIRED. NEVER PLACE HANDS OR OTHER OBJECTS INTO MACHINE WHILE DOOR IS OPERATING. DO NOT LIFT DOOR DURING CYCLE; STOP MACHINE FIRST. DO NOT HOLD BOTTLE WHILE MANUALLY CROWNING. DISCONNECT AIR, C02, BEER AND POWER BEFORE SERVICING. 29 REV 00