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User Manual
FILLER
COMBI MATRIX
SF300 FM 144/24K
(SRMB0119)
Coca-Cola Bottlers Philippines, Inc.
Original instructions
SF300 Filler
User Manual / Table of Contents
Sidel S.p.A.
II
Matrix Filler
User Manual / Table of Contents
PART I
SAFETY STANDARDS
PART II
TECHNICAL DATA
PART III
INSTALLATION
PART IV
OPERATION
PART V
OPERATING INSTRUCTIONS
PART VI
SIZE CHANGEOVER
PART VII
MAINTENANCE SCHEDULE
PART VIII
DIAGNOSTICS
PART IX
APPENDICES
PART X
TABLE OF CONTENTS
Sidel S.p.A.
SF300 Filler
User Manual / Table of Contents
Sidel S.p.A.
IV
Matrix Filler
User Manual / Table of Contents
4.5
4.6
4.7
Sidel S.p.A.
SF300 Filler
User Manual / Table of Contents
6.7
6.8
6.9
Sidel S.p.A.
APPENDICES ..............................................................................................................................................................Part IX
10.1 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
VI
PART I
Sidel S.p.A.
Part I
Matrix Filler
User Manual / General regulations and warnings
1.1
I-1
Matrix Filler
User Manual / General regulations and warnings
1.1
Part I
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.
Sidel S.p.A.
The conditions of the warranty are specified in the agreements stipulated between the parties when the
contract is drafted.
I-2
1.1
Matrix Filler
User Manual / General regulations and warnings
Part I
1.2
1.2.1
Foreword
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
Sidel S.p.A.
1.2.3
1.1
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Matrix Filler
User Manual / General regulations and warnings
1.3
Part I
REFERENCE STANDARDS
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)
Sidel S.p.A.
I-4
1.1
Matrix Filler
User Manual / General regulations and warnings
Part I
1.3.1
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:
Sidel S.p.A.
(1)
1.1
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Matrix Filler
User Manual / General regulations and warnings
1.3.2
Part I
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
8
9
10
4
11
(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
Sidel S.p.A.
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Matrix Filler
User Manual / General regulations and warnings
Part I
1.3.3
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:
Sidel S.p.A.
(1)
1.1
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User Manual / General regulations and warnings
Part I
Sidel S.p.A.
(1)
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User Manual / General regulations and warnings
Part I
1.3.4
The plates are attached to the pressurised tanks of the machine and show the main features of the system.
Example:
2
3
7
2
3
4
8
Sidel S.p.A.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
1.1
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User Manual / General regulations and warnings
1.3.5
Sidel S.p.A.
(1)
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1.1
Part I
Matrix Filler
User Manual / General regulations and warnings
Part I
1.3.6
Plate 1 is attached to the electrical cabinet of the machine and shows the main features of the electrical
system.
Example:
6
1
8
9
10
4
11
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
Sidel S.p.A.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
12
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User Manual / General regulations and warnings
Part I
Plate 2 is attached to the pressurised tank of the machine and shows the main features of the system.
Example:
2
3
7
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Sidel S.p.A.
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Matrix Filler
User Manual / General regulations and warnings
Part I
1.4
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.
Sidel S.p.A.
1.1
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User Manual / General regulations and warnings
1.5
Part I
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:
-
Sidel S.p.A.
For more information about our Customer Technical Assistance Service, www.sidel.com.
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Matrix Filler
User Manual / General regulations and warnings
Part I
1.6
The customer is responsible for purchasing original 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) 05219991
Fax (+39) 0521959009
The following information should be provided with each request to ensure safe and rapid identification of
spare parts:
-
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
Sidel S.p.A.
Servizio Ricambi: fax number +39 0521 999530, telephone number +39 0521 999295
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Matrix Filler
User Manual / General regulations and warnings
1.7
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.
The following symbols are used throughout this manual to indicate special instructions and hazard warnings:
Strictly prohibited.
Sidel S.p.A.
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Matrix Filler
User Manual / General regulations and warnings
Part I
1.7.3
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.
Clean-In-Place (CIP) - a system for cleaning a line or an item of
equipment in a closed cycle.
CIP/SIP UNIT
CLEANING
CONTACT SURFACES
All equipment surfaces which come into contact with the product either
intentionally or unintentionally (e.g. through splashing).
DISINFECTANT
DISINFECTION
FILLING NOZZLE
FILLING VALVE
A fluid control system which feeds the fluid into a container through the
filler nozzle.
FORESEEABLE
CONDITIONS OF USE
ISOLATOR
JOG UNIT
MANIFOLD
A manifold collects fluid coming from one or more pipes and distributes it
to one or more units.
MANUAL CLEANING
All exposed surfaces except those which may potentially come into
contact with the product.
OP
Operator
P&I
PAA
Peracetic acid.
Sidel S.p.A.
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User Manual / General regulations and warnings
PAA/SW UNIT
PAM - MP
Machine parameters.
PAR - RP
Recipe parameters
PAT
Technical parameters
PID
RESIDUE
ROTARY COUPLING
SANITIZER
SANITIZING
SOLUTION
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
SW
Sterile Water.
Sidel S.p.A.
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Part I
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Matrix Filler
User Manual / General regulations and warnings
Part I
1.8
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.
Sidel S.p.A.
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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User Manual / General regulations and warnings
1.8.3
Part I
Operation
References
Description
BOTTLE INFEED (empty bottles)
Sidel S.p.A.
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User Manual / General regulations and warnings
Part I
1.9
MAIN UNITS
10
3
7
15
12
13
9
4
11
16
Reference
Description
Reference
Description
Central manifold
10
SKID
Carousel
11
Guards
Ring manifold
12
Base
13
Lubrication
Drive units
14
Bottle conveyor
15
Filling valve
16
Blower*
Operator interface
17
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User Manual / General regulations and warnings
Part I
10
15
17
13
11
14
Reference
Description
Reference
Description
Central manifold
10
SKID
Carousel
11
Guards
Ring manifold
12
Base
13
Lubrication
Drive units
14
Rinser
Bottle conveyor
15
Filling valve
16
Operator interface
17
Sidel S.p.A.
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Matrix Filler
User Manual / General regulations and warnings
Part I
1.9.1
Central manifold
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)
Sidel S.p.A.
1.1
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User Manual / General regulations and warnings
1.9.2
Part I
Carousel
1.9.3
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
Sidel S.p.A.
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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Matrix Filler
User Manual / General regulations and warnings
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.
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).
Sidel S.p.A.
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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Part I
2
2
References
1.9.6
Description
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 OUTFEED
The bottle outfeed module (1) conveys the bottles onto the outfeed conveyor.
Sidel S.p.A.
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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
Description
Adjuster handwheel
Sidel S.p.A.
References
1.1
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User Manual / General regulations and warnings
References
Description
Adjustable belt motor
Adjuster handwheel
Sidel S.p.A.
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Part I
Matrix Filler
User Manual / General regulations and warnings
Part I
Description
Adjustable guides
Sidel S.p.A.
References
1.1
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User Manual / General regulations and warnings
1.9.7
Part I
Filling valve
2
1
1
1
2
5
2
5
4
References
Description
Filling valve body
Fluid distributor
Bell unit
Dummy bottle
Pilot valve
CIP unit
Sidel S.p.A.
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User Manual / General regulations and warnings
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.
Sidel S.p.A.
1.1
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User Manual / General regulations and warnings
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.
Sidel S.p.A.
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Matrix Filler
User Manual / General regulations and warnings
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
Sidel S.p.A.
Product infeed
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User Manual / General regulations and warnings
Product storage
Sidel S.p.A.
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Part I
Part I
Matrix Filler
User Manual / General regulations and warnings
Bottle
bottom
cooling
circuit
management, distribution and recycling
(optional)
Pneumatic distribution
Sidel S.p.A.
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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.
Sidel S.p.A.
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Part I
Part I
Matrix Filler
User Manual / General regulations and warnings
Sidel S.p.A.
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 guards are designed using gates made from tempered glass fitted near to the front and rear of the
machine.
Options:
-
B.
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.
Sidel S.p.A.
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 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.
Sidel S.p.A.
The base and filling area are fitted with reduced guards and the rinsing area is fitted with a cover.
1.1
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Part I
Sidel S.p.A.
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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User Manual / General regulations and warnings
Part I
References
Description
Fixed structure.
Mobile carousel.
Sidel S.p.A.
1.1
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Matrix Filler
User Manual / General regulations and warnings
Part I
Distribution of processes:
8
References
Description
References
Description
Mixer.
Valves.
Pressure transducers.
Sidel S.p.A.
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.
I - 42
1.1
PART II
SAFETY STANDARDS
Sidel S.p.A.
Part II
Matrix Filler
User Manual / Safety standards
1.1
II - 1
Matrix Filler
User Manual / Safety standards
2.1
Part II
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:
-
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 original spare parts when changing faulty or worn parts. Original spare parts are covered by the
manufacturers 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.
Sidel S.p.A.
DO NOT wear clothing, personal jewellery or other items which might become trapped in moving parts.
II - 2
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Matrix Filler
User Manual / Safety standards
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.
Sidel S.p.A.
Maintenance involving the central carousel must be performed using the special platform. Personnel must
use a safety harness (PPE).
1.1
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User Manual / Safety standards
2.2
Part II
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 CO2 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 manufacturers 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:
-
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.
Sidel S.p.A.
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
Sidel S.p.A.
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 operators attention to the problem.
1.1
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User Manual / Safety standards
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.
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.
Sidel S.p.A.
Operators must not approach the area in front of the signal when this sign is displayed.
II - 6
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Part II
Mandatory sign: wear safety eyewear. This is located on the columns of the front mobile guards.
Operators must wear safety glasses before intervening on the machine when this sign is
VAA316 displayed.
Mandatory sign: wear safety gloves. This is located on the columns of the front mobile guards.
Operators must wear safety gloves before intervening on the machine when this sign is
VAA312 displayed.
Mandatory sign: wear safety footwear. This is located on the columns of the front mobile guards.
Sidel S.p.A.
Operators must wear safety footwear before intervening on the machine when this sign is
VAA311 displayed.
1.1
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User Manual / Safety standards
2.5
Part II
PERSONNEL
Sidel S.p.A.
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.
II - 8
1.1
Part II
2.6
Matrix Filler
User Manual / Safety standards
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):
Sidel S.p.A.
1.1
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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
(Example picture)
Sidel S.p.A.
Legend:
Light beacon
Operator area
JOG unit
Operator position
II - 10
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User Manual / Safety standards
Part II
Wide Area Protection:
(Example picture)
Legend:
Light beacon
Operator area
JOG unit
Operator position
Sidel S.p.A.
Emergency handle
1.1
II - 11
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User Manual / Safety standards
2.7.2
Rear doors
Front doors
Sidel S.p.A.
II - 12
1.1
Part II
Matrix Filler
User Manual / Safety standards
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.
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:
To change the Combi interface panel, under safe conditions access the panel through the
blower doors. If necessary temporarily move / remove the guides / starwheels.
Sidel S.p.A.
IMPORTANT: Do not open the panel during a production cycle or during a sanitizing cycle.
1.1
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User Manual / Safety standards
C.
Part II
Rear doors
Sidel S.p.A.
IMPORTANT: Do not open the doors during a production cycle or during a sanitizing cycle.
II - 14
1.1
Matrix Filler
User Manual / Safety standards
Part II
Wide Area Protection
7
2
6
4
1
5
3
(Example picture)
1
2
3
4
5
6
7
8
Sidel S.p.A.
1.1
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User Manual / Safety standards
Part II
Sidel S.p.A.
In the event of power failure, use the emergency handle (8) to exit the chamber (see below).
II - 16
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User Manual / Safety standards
Part II
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.
Sidel S.p.A.
(Example picture)
1.1
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Matrix Filler
User Manual / Safety standards
D.
Part II
Front doors
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)
The automatic controls will move the filling valves to the home position.
The brake will be actuated.
The bottle block will remain in its current position.
The 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.
Sidel S.p.A.
II - 18
1.1
Part II
E.
Matrix Filler
User Manual / Safety standards
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:
-
Sidel S.p.A.
1.1
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User Manual / Safety standards
F.
Part II
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)
50
Sidel S.p.A.
Connector
10,5
1.1
Matrix Filler
User Manual / Safety standards
Part II
Emergency handle (if present)
G.
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
The emergency handle is used to exit the chamber in the event of accidental closure of the rear doors
and during power failures.
H.
2-way selector:
-
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.
Sidel S.p.A.
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I.
Part II
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.
Sidel S.p.A.
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.
The air ON-OFF valve switches the supply of air to the machines 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.
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.
Sidel S.p.A.
ON-OFF valve
1.1
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M.
Part II
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.
Sidel S.p.A.
The machine is fitted with ON/OFF valves for the chemical solutions used to sanitize the filling circuit.
II - 24
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Part II
O.
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
P.
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
Sidel S.p.A.
Golfare
1.1
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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
Sidel S.p.A.
II - 26
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User Manual / Safety standards
Part II
2.9
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.
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.
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.
During sanitization when corrosive products such as acids and alkaline lyes are used.
To reduce this hazard:
-
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.
When the operator lifts machine components during transport, handling and maintenance.
Sidel S.p.A.
Exercise extreme caution when performing these operations. Use appropriate PPE and safety equipment in
compliance with local health and safety regulations.
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User Manual / Safety standards
e.
Part II
When the operator comes into contact with hot machine components during the sanitization process.
To reduce this hazard:
-
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.
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.
h.
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.
To reduce this hazard:
-
Sidel S.p.A.
II - 28
1.1
PART III
TECHNICAL DATA
Sidel S.p.A.
Part III
Matrix Filler
User Manual / Technical Data
1.1
III - 1
Matrix Filler
User Manual / Technical Data
3.1
Part III
DIMENSIONS
Sidel S.p.A.
The dimensions are shown in the drawing in PART X APPENDICES, section 10.1.1 Layout and
connections.
III - 2
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User Manual / Technical Data
Part III
3.2
MACHINE CONFIGURATION
3.2.1
Technical data
Project
SMMM3084
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
24
Capper manufacturer
AROL
EURO PK
400V
50Hz
Specifications
Consumption
Flow rate
Production
speed (bph)
Bottle volume
(lt)
Beverage type
Production
(lt/h)
P01QD023-005
36.000
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
COKE
48.000
11060292-01
44.000
0.33
VIVA
13.200
11060326-01
44.000
0.5
VIVA
22.000
11026397-04
36.000
VIVA
36.000
X-Z00-11-6928
44.000
0.3
COKE
13.200
11060349-01
44.000
0.5
WILKINS
22.000
Sidel S.p.A.
Bottle design
1.1
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User Manual / Technical Data
3.3
3.3.1
Part III
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:
-
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.
Sidel S.p.A.
Two sockets have been included to connect the jog mobile pushbutton panel to facilitate machine setup and
maintenance.
III - 4
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User Manual / Technical Data
Part III
3.3.2
Storage temperature: 10 C to + 60 C.
Ambient operating temperature: 10 C to 45 C.
Electric power cabinet temperature: < 45 C.
Vibrations
Sidel S.p.A.
The machine is designed and manufactured in compliance with current directives and the permitted level of
vibrations.
1.1
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User Manual / Technical Data
3.4
PERFORMANCE LEVELS
3.4.1
Speed variations
Production
Jog control
Sanitization or rinsing
Sidel S.p.A.
production mode
Speed = 4000 up to max. b/h value
jog mode
Speed = 4000 6000 b/h
sanitization mode
Speed = 4000 8000 b/h
III - 6
1.1
Part III
Matrix Filler
User Manual / Technical Data
Part III
3.5
3.5.1
3.5.2
Tanks
7 bar
Volume (V)
1030 litres
+95 C
Minimum temperature
-10 C
1 (Sanitizing) IN SANITIZATION
2 (beverage, CO2) IN PRODUCTION
Manifold tank:
Maximum pressure (PS)
3 bar
Volume (V)
146 litres
+95 C
Minimum temperature
-10 C
1 (Sanitizing) IN SANITIZATION
2 (beverage, CO2) IN PRODUCTION
3.5.3
Piping
Refer to the relevant parts lists for the dimensions of the following pipes:
3.5.4
Calibration pressure
7 bar
Type of fluid
Gas
1000 m/h
1.1
Sidel S.p.A.
III - 7
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User Manual / Technical Data
3.6
WEIGHTS
Base
Filler carousel
Rinser carousel*
Sidel S.p.A.
* If fitted
III - 8
1.1
Part III
Matrix Filler
User Manual / Technical Data
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:
-
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
Meter used:
Reference standards:
DIN 45635
Sidel S.p.A.
1.1
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User Manual / Technical Data
Sidel S.p.A.
III - 10
1.1
Part III
Matrix Filler
User Manual / Installation
Part IV
INSTALLATION
Sidel S.p.A.
PART IV
1.1
IV - 1
Matrix Filler
User Manual / Installation
4.1
4.1.1
Type of packaging
Part IV
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
IMPORTANT: Unless otherwise stated in the sales contract, customers are responsible for
unloading the machinery.
Sidel S.p.A.
Standard pictograms are attached to the crates and packages. The pictograms give instructions
concerning how to handle the crates and packages.
IV - 2
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User Manual / Installation
Part IV
4.1.4
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.
1.1
Sidel S.p.A.
A detailed list of each crate / pallet is included in the installation dossier in the possession of the site
manager.
IV - 3
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User Manual / Installation
4.1.6
Part IV
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.
Sidel S.p.A.
IV - 4
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User Manual / Installation
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.
Sidel S.p.A.
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.
1.1
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Matrix Filler
User Manual / Installation
4.3
4.3.1
Part IV
The facility receiving the equipment must have already prepared the following:
-
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
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
The following instructions should be followed carefully to ensure safe movement of the machine:
1.
2.
3.
Sidel S.p.A.
4.
IV - 6
Move the unpacked machine as close as possible to the installation area then unpack the machine
making sure the contents of the crates and packages match that specified on the delivery document.
Remove the cover and then all the dismantled components and accessories.
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.
1.1
Matrix Filler
User Manual / Installation
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)
b)
4.3.4
Crate: take hold of the crate in the positions indicated using the chain pictogram and keep it in the
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.
Sidel S.p.A.
If the customer has requested special protective greases for the machine then the customer is responsible
for removing them before assembly.
1.1
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User Manual / Installation
4.3.5
Part IV
Sidel S.p.A.
IV - 8
1.1
Part IV
Matrix Filler
User Manual / Installation
Sidel S.p.A.
Adjust the feet support bar to level the machine with the
floor and the line.
1.1
IV - 9
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User Manual / Installation
Part IV
4.3.6
Sidel S.p.A.
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.
IV - 10
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Part IV
4.4
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
The electrical connection is made in compliance with general regulations for installing, preparing and putting
into service industrial electrical systems.
4.4.2
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
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.
Sidel S.p.A.
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.
1.1
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4.4.5
Part IV
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
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:
-
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.
Sidel S.p.A.
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.
IV - 12
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Part IV
4.5
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.
Sidel S.p.A.
1.1
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User Manual / Installation
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:
-
Sidel S.p.A.
Check that there are no leaks of substances which might harm the environment. Repair any
leaks immediately.
IV - 14
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User Manual / Installation
Part IV
4.5.3
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.
Sidel S.p.A.
1.1
IV - 15
Matrix Filler
User Manual / Installation
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
Only use appropriate equipment to clean the areas inside the machine. Change damaged cleaning
equipment.
4.5.6
Safety warning
Sidel S.p.A.
Check that there are no leaks of substances which might harm the environment. Repair any
leaks immediately.
IV - 16
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User Manual / Installation
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
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
In order to prevent errors and accidents, the machine is connected up to the customers 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.
Sidel S.p.A.
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:
-
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 customers
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.
Sidel S.p.A.
For instructions on positioning and connecting up the machine in its new position, see the related section of
this manual.
IV - 18
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User Manual / Installation
Part IV
4.7
The activities described in this section must only be performed by the following qualified personnel:
-
4.7.1
Disposal of packaging
Plastic packing
Plastic components can be recycled to produce new resources in the sector of origin 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.
1.1
IV - 19
Sidel S.p.A.
Separating packing waste enables a vast range of waste materials to be reused ensuring significant
economic and environmental advantages.
Matrix Filler
User Manual / Installation
4.7.2
Part IV
The machine will require dismantling if it is sold, installed in a new position or stored in the customers
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.
Sidel S.p.A.
IV - 20
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User Manual / Installation
Part IV
4.7.3
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.
During disposal, implement the local waste disposal and recycling regulations.
Sidel S.p.A.
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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.
Sidel S.p.A.
For disposal instructions about filling products, contact your local health authority and read the safety data
sheets for each product.
IV - 22
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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.
Sidel S.p.A.
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
Sidel S.p.A.
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.
IV - 24
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Part IV
Matrix Filler
User Manual / Installation
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).
1)
2)
3)
4)
5)
6)
IV - 25
Sidel S.p.A.
Matrix Filler
User Manual / Installation
7)
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).
Sidel S.p.A.
8)
IV - 26
Part IV
1.1
Matrix Filler
User Manual / Operation
Part V
OPERATION
Sidel S.p.A.
PART V
1.1
V-1
Matrix filler
User Manual / Operation
5.1
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
WATER
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:
-
INERT GASES
Optimum filling gas consumption is achieved by complying with the following prescriptions:
-
Sidel S.p.A.
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.
V-2
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User Manual / Operation
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
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.
Sidel S.p.A.
1.1
V-3
Matrix filler
User Manual / Operation
5.3
OPERATING DESCRIPTION
5.3.1
Filling processes
Part V
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.
Sidel S.p.A.
V-4
Spraying
Dripping
1.1
A
B
Part V
2.
Matrix Filler
User Manual / Operation
Filling
3.
Capping
4.
Sidel S.p.A.
The bottles leave the machine and enter the process cycles
of the machines located downstream.
1.1
V-5
Matrix filler
User Manual / Operation
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 machines 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).
Gas
Decompression
Product
Reference
Description
Filler carousel
Bottle
Feed pipes
Filling valve
Tank
Sidel S.p.A.
V-6
1.1
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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.
A
D
Description
Reference
Description
Pneumatic unit
Valve body
1.1
Sidel S.p.A.
Reference
V-7
Matrix filler
User Manual / Operation
5.3.3
Part V
Filling steps
Bottle infeed.
Bottle centring.
Pressurisation with CO2.
Filling.
End of filling.
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.
Sidel S.p.A.
V-8
1.1
Part V
2.
Matrix Filler
User Manual / Operation
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
Sidel S.p.A.
1.1
V-9
Matrix filler
User Manual / Operation
3.
Part V
The valve (1) opens and the CO2 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
Valve position
during the step
shown here.
Sidel S.p.A.
V - 10
1.1
Part V
4.
Matrix Filler
User Manual / Operation
Filling
At this point the valve (1) opens and filling of the bottle (2) starts.
Valve position
during the step
shown here.
Sidel S.p.A.
1.1
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5.
Part V
End of filling
When the product inside the bottle (1) reaches the required level, filling stops.
Valve position
during the step
shown here.
Sidel S.p.A.
V - 12
1.1
Part V
6.
Matrix Filler
User Manual / Operation
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.
Valve position
during the step
shown here.
Sidel S.p.A.
1.1
V - 13
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User Manual / Operation
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).
Valve position
during the step
shown here.
Sidel S.p.A.
V - 14
1.1
Part V
5.4
Matrix Filler
User Manual / Operation
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.
1.0
Sidel S.p.A.
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:
V - 15
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5.5
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.
Sidel S.p.A.
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.
V - 16
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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.
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.
Sidel S.p.A.
If you have any doubts concerning the use of detergents or sanitizing products, contact Sidel S.p.a. or
the supplier.
1.0
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5.5.3
Part V
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:
-
hardness in fH
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.
Sidel S.p.A.
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.
V - 18
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Part V
5.5.4
Use
PRODUCT
TEMPERATURE
(MAX)
CONCENTRATION
DURATION
(MAX)
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
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)
30 mins.
DISINFECTION WITH
CHLORINE
SOLUTIONS
(200 ppm max chloride
in water and pH>6<8 in
CIP solution)
Do not exceed 30 C
20 mins.
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
Sidel S.p.A.
CLEANING IN PLACE
1.0
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Use
PRODUCT
TEMPERATURE
(MAX)
CONCENTRATION
Part V
DURATION
(MAX)
EXTERNAL CLEANING
Ambient temperature
2 to 4% (w/v)
depending on foam
consistency required
30 mins.
FOAMING ACID
SOLUTIONS OF
DESCALING
PRODUCT
Ambient temperature
2 to 4% (w/v)
depending on foam
consistency required
30 mins.
FOAMING
DISINFECTANT
SOLUTION OF
PEROXYACETIC ACID
Ambient temperature
2 to 4% (w/v)
depending on foam
consistency required
30 mins.
DISINFECTION WITH
CHLORINE
SOLUTIONS
(200 ppm max
chloride in water e
pH>6.5<8 in
CIP solution)
Ambient temperature
30 mins.
OTHER
SANITIZATION WITH
STEAM
NOT PERMITTED
OZONATED RINSING
WATER
30 C
1.0 ppm
Continuous
BOTTLED OZONATED
WATER*
30 C
0.6 ppm
Continuous
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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:
SUBSTANCE
IRCH
n. d.
29
n. d.
33
PERACETIC ACID
80
NITRIC ACID
110
PHOSPHORIC ACID
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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User Manual / Operation
V - 22
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Part V
PART VI
OPERATING INSTRUCTIONS
Sidel S.p.A.
Part VI
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User Manual / Operation
1.1
V,- 1
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User Manual / Operating Instructions
6.1
Part VI
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.
Sidel S.p.A.
6.1.2
VI - 2
Layout of components
Two-way key selector to implement size changeover (machines for glass bottles).
Three-way key selector with return to central position: adjusts the position of the tank
or capper rinser (machines for glass bottles).
1.1
Matrix Filler
User Manual / Operating Instructions
Part VI
A filling test pushbutton panel is installed on the rear guards of the filling machine:
Filling test selector (located on the HMI when not on the pushbutton panel).
6.1.3
jog speed.
Operator panel
TECHNICAL SPECIFICATIONS
The operator panel (OP) consists of the following:
-
Internal peripherals
-
Ethernet card.
External peripherals
MASTER card.
Sidel S.p.A.
Software installed
-
1.1
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6.1.4
Part VI
Sidel S.p.A.
Description of areas:
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.
1.1
Matrix Filler
User Manual / Operating Instructions
Part VI
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
A
required to start rotation. When the machine is running, press the button to stop rotation.
B
JOG mode: press this button to enable/disable jog mode on the machine.
Unlock doors: press this button to enable/disable unlocking of the front doors.
Unlock doors: press this button to enable/disable unlocking of the front transfer doors (if fitted).
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.
Coupling: press this button to enable/disable coupling of the filler with the blower.
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).
Sidel S.p.A.
1.1
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Part VI
The general information area (2) is always displayed and used to access the following functions:
A
Counter: the number of bottles which have entered the machine 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.
Sidel S.p.A.
The main functions area (3) is always displayed and used to access the following functions:
VI - 6
Changeover: the interface for the CIP system/Auxiliaries in remote system is displayed.
1.1
Matrix Filler
User Manual / Operating Instructions
Part VI
A
B
D
E
F
G
1.1
Sidel S.p.A.
The main navigation bar (4) is always displayed and used to access the following functions:
VI - 7
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User Manual / Operating Instructions
Sidel S.p.A.
VI - 8
1.1
Part VI
Matrix Filler
User Manual / Operating Instructions
Part VI
-
Command and control page: contains diagrams, controls and navigation buttons.
Page change area: this area contains navigation buttons used to access further sub-pages:
Type of buttons:
Button to access functional sub-page.
Sidel S.p.A.
1.1
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User Manual / Operating Instructions
6.1.5
Part VI
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
Sidel S.p.A.
Display showing the level of acidity of the CIP solution present in the circuit.
VI - 10
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User Manual / Operating Instructions
Part VI
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.
If the icon of the sensor or the digital device appears as shown below:
Grey on orange background
Sidel S.p.A.
This indicates that the operating cycle is waiting for the digital device to changed state.
1.1
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User Manual / Operating Instructions
Part VI
Valve body:
Controlled actuator
N.O.
Normally Open
N.C.
Normally Closed
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.
Controlled actuator
Sidel S.p.A.
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.
VI - 12
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User Manual / Operating Instructions
Part VI
Valve body:
Controlled actuator
N.O.
Normally Open
N.C.
Normally Closed
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.
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
VI - 13
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Matrix Filler
User Manual / Operating Instructions
Part VI
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.
Sidel S.p.A.
VI - 14
Press this button to switch the component to OFF in the manual mode.
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.
1.1
Matrix Filler
User Manual / Operating Instructions
Part VI
A.
B.
C.
A.
B.
A.
B.
Three-way selector:
Two-way selector:
Sidel S.p.A.
Start/Stop button
VI - 15
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Part VI
Adjustment tools
1.
A.
B.
C.
A
B
This display shows the current value read from the device and the set-point value.
2.
A.
B.
C.
D.
A.
B.
C.
D.
A
B
3.
A
B
Sidel S.p.A.
VI - 16
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Part VI
PID control pop up
A
B
C
D
Output: PID adjustment control output, this is the flow valve opening value, the motor control
reference, etc.
Use this to set the Set-Point manually and activate the adjustment.
Sidel S.p.A.
4.
1.1
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User Manual / Operating Instructions
5.
Part VI
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.
Sidel S.p.A.
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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User Manual / Operating Instructions
Part VI
6.2
6.2.1
Main functions
PASSWORD PAGE
Function to access the Password page.
A
B
D
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.
Alarm reset
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
1.1
X
X
X
X
X
X
X
X
X
Sidel S.p.A.
X
X
X
X
Exit application
X
X
X
X
Machine configuration
Language selection
X
X
X
X
Recipe review
0
1
4
10
Password level
op
ins
dir
sa
User ID
Operator
Inspector
Supervisor
Sidel
Manual adjustments
(valves, pumps, etc.)
Name
VI - 19
Matrix Filler
User Manual / Operating Instructions
A
B
C
D
E
Sidel S.p.A.
VI - 20
Project version.
Serial number.
Project name.
1.1
Part VI
Matrix Filler
User Manual / Operating Instructions
Part VI
ALARM PAGE
L
K
J
All
Machine
Operator
Filler
Crown capper
Capper
Rinser
Power supplies
External
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.
1.1
VI - 21
Sidel S.p.A.
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.
Matrix Filler
User Manual / Operating Instructions
6.2.2
Part VI
Reception
Function to access the Reception page.
A
B
Sidel S.p.A.
A.
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.
VI - 22
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User Manual / Operating Instructions
Part VI
6.2.3
Piping circuit
Function to access the Piping page.
Sidel S.p.A.
1.1
VI - 23
Matrix Filler
User Manual / Operating Instructions
Control area
Three-way selector: Valve opening control
Sidel S.p.A.
VI - 24
1.1
Part VI
Matrix Filler
User Manual / Operating Instructions
Part VI
Page change area
Use this page to start, stop and interrupt the production, rinsing and sanitization cycles of the filler.
A
A
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.
2.
3.
4.
5.
6.
7.
GAS FLUSHING PRODUCTION: Starts production with CO2 flushing and bleeding of
valves.
FAST PRODUCTION: Starts rapid production.
TANK FLOODING PRODUCTION: Starts production with bleeding of valves and tank
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.
The Abort sequences button is used to quit any of the machine phases and return to the
STANDBY step.
1.1
Sidel S.p.A.
1.
VI - 25
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User Manual / Operating Instructions
6.2.4
Part VI
Machine components
Sidel S.p.A.
VI - 26
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User Manual / Operating Instructions
Part VI
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.
Analogue values (temperatures and levels).
Solenoid valves.
Pressure switches.
Flow gauges.
Chlorine concentration
pH values.
Sidel S.p.A.
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.
1.1
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Part VI
Pumps.
Pneumatic valves.
Analogue values (temperatures and levels).
Control area
Two-way selector: water cooling control.
Sidel S.p.A.
VI - 28
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Part VI
FOAMER SUBPAGE
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
Sidel S.p.A.
1.1
VI - 29
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User Manual / Operating Instructions
Sidel S.p.A.
VI - 30
1.1
Part VI
Matrix Filler
User Manual / Operating Instructions
Part VI
Sidel S.p.A.
Navigation button: display of cap safety device and crown capper starwheel safety device
subpage.
1.1
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User Manual / Operating Instructions
Part VI
AROL EQUATORQUE
B
Sidel S.p.A.
VI - 32
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User Manual / Operating Instructions
Part VI
AROL EQUATORQUE
D
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
B
Parameters Upload button
Encoder: Reading encoder position with zero-setting button:
C
Encoder zero-setting button
Sidel S.p.A.
1.1
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Part VI
Calibration area:
D
E
-
Sequencer: Reading current values (A) of the motor during calibration with the head not loaded
and with the clutch installed during calibration.
Sidel S.p.A.
VI - 34
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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.
1.1
Sidel S.p.A.
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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.
Sidel S.p.A.
VI - 36
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User Manual / Operating Instructions
Part VI
AROL EQUATORQUE Size Change
Central guide
Bottle body pad
Extractor pad (Bottle Outfeed)
Press this button to move the selected motor to the Home position (initial).
Sidel S.p.A.
1.1
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Part VI
Positioning:
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.
Sidel S.p.A.
VI - 38
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Part VI
CAPPER SUBPAGE
Sidel S.p.A.
1.1
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User Manual / Operating Instructions
Part VI
Control area
Three-way selector: ventilator start control
Sidel S.p.A.
VI - 40
1.1
Sidel S.p.A.
Part VI
Matrix Filler
User Manual / Operating Instructions
1.1
VI - 41
Matrix Filler
User Manual / Operating Instructions
Part VI
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
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.
Sidel S.p.A.
A.
B.
C.
D.
VI - 42
Alarms
Actual heights
Messages
Heights from recipe
1.1
Part VI
Matrix Filler
User Manual / Operating Instructions
Control area
Three-way selector: Size changeover selection Manual Automatic - Disabled.
Sidel S.p.A.
1.1
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User Manual / Operating Instructions
Part VI
Control area
Two-way selector: Rinser manual lifting selection.
Sidel S.p.A.
VI - 44
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User Manual / Operating Instructions
Part VI
EXTERNAL FOAMING SUBPAGE
Control area
Two-way selector to enable manual or satellite launch.
Sidel S.p.A.
1.1
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User Manual / Operating Instructions
Part VI
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.
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.
Sidel S.p.A.
VI - 46
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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.
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).
Sidel S.p.A.
Scroll button.
1.1
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User Manual / Operating Instructions
6.3
Part VI
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 Force Filling Time subpage (only displayed if a flow meter is
configured as a measuring device)
Sidel S.p.A.
VI - 48
1.1
Sidel S.p.A.
Part VI
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User Manual / Operating Instructions
1.1
VI - 49
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Part VI
POSITION TX SUBPAGE
Read-only page:
Sidel S.p.A.
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.
VI - 50
1.1
Displays the current firmware version installed on the majority of the slave
cards fitted on 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.
Sidel S.p.A.
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1.1
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Part VI
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
Sidel S.p.A.
VI - 52
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Part VI
Bottle pressurised
Bottle not pressurised
Valve disabled or pressure control by pressure sensor or not
configured.
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).
Sidel S.p.A.
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).
1.1
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Part VI
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).
Flow rate OK
Low flow rate
alarm indicator:
Temperature in [C] of the product detected by the card (operates if temperature sensor
configured otherwise disabled).
Temperature OK
Low temperature
alarm indicator:
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.
Sidel S.p.A.
Last
filling
operation trigger
indicator:
VI - 54
Trigger OK
Trigger not reached
Valve disabled
1.1
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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
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.
Sidel S.p.A.
The button is only enabled when the Filling Master Card is phased.
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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.
Sidel S.p.A.
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.
Sidel S.p.A.
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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.
Sidel S.p.A.
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.
Sidel S.p.A.
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Read-only page:
Sidel S.p.A.
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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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.
Sidel S.p.A.
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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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.
Sidel S.p.A.
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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Sidel S.p.A.
Read-only page:
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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).
-
Sidel S.p.A.
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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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.
Sidel S.p.A.
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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.
Sidel S.p.A.
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.
Sidel S.p.A.
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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
(disabled status).
page turn grey
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.
Sidel S.p.A.
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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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
(disabled status).
indicators on the diagnostics page turn grey
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.
Sidel S.p.A.
The button is only enabled when the Filling Master Card is phased.
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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
(disabled status).
on the diagnostics page turn grey
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.
Sidel S.p.A.
The button is only enabled when the Filling Master Card is phased.
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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
(disabled status).
indicators on the diagnostics page turn grey
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.
Sidel S.p.A.
The button is only enabled when the Filling Master Card is phased.
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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
(disabled status).
page turn grey
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.
Sidel S.p.A.
The button is only enabled when the Filling Master Card is phased.
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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.
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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Sidel S.p.A.
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.
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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
(disabled).
and turn grey
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.
Sidel S.p.A.
Only accessible if the Manual Filling Test selector is enabled ON or manual filling
is in progress.
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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.
Sidel S.p.A.
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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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.
Sidel S.p.A.
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].
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].
Sidel S.p.A.
Graph displaying the instant pressure detected by the sensor installed on the valve in [mbar] and [ms].
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Click this button to return to the page displaying both graphs which are also redrawn.
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.
Sidel S.p.A.
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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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.
Sidel S.p.A.
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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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.
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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Sidel S.p.A.
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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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.
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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Sidel S.p.A.
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.
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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).
Sidel S.p.A.
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.
Sidel S.p.A.
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.
Sidel S.p.A.
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).
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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Sidel S.p.A.
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.
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User Manual / Operating Instructions
Part VI
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 the button when you wish to reset fully all the network nodes by forcing the exit of the nodes from all
enabled modes or commands (OPER., manual test, etc.).
Sidel S.p.A.
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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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.
Sidel S.p.A.
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.
Sidel S.p.A.
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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Selection page
Sidel S.p.A.
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
Card Diagnostic subpage) only in OPER. mode when the filler is
incorrect sequence is programmed i.e. the sum of phase times
revolution, the sequence is stopped when the valve moves away
starwheel.
Sidel S.p.A.
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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FMC DIAGNOSTIC SUBPAGE
Selection page
Sidel S.p.A.
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
Part VI
RECIPES
B
P
C
D
E
A.
B.
Press this button to edit any recipe i.e. compile all available parameters.
C.
D.
E.
F.
Sidel S.p.A.
G.
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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.
Sidel S.p.A.
H.
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D
This page shows data for the bottle used in the recipe.
GENERAL
A.
B.
C.
CAPPER
Cap type: numeric value representing the type of cap used for this size (see legend).
Sidel S.p.A.
D.
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A
B
C
D
E
GENERAL
A.
B.
C.
TEMPERATURE CONTROL
D.
E.
F.
G.
H.
I.
J.
Sidel S.p.A.
K.
L.
M.
N.
O.
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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.
Positioning of Motors.
Central guide
Bottle body pad
Extractor pad (Bottle Outfeed)
2.
Sidel S.p.A.
1.
-
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CLOSING DATA
Head lowering start angle from which the rotation of the motor head starts.
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 of closing cycle angle, represented by the position in which it lifts from the closed
bottle.
Lock Mode:
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.
Sidel S.p.A.
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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:
Percentage of the final closing speed to consider the cap closed with LockMode =
"No Speed".
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".
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").
Sidel S.p.A.
Slow Torque:
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Contains the data required by PID adjustment for the tank level.
F.
G.
H.
I.
J.
K.
A.
B.
C.
D.
E.
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G
H
Sidel S.p.A.
I.
J.
K.
L.
M.
N.
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A.
B.
C.
D.
E.
F.
G.
H.
I.
J.
K.
L.
M.
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Sidel S.p.A.
Contains the data required by PID adjustment for the tank pressure.
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Part VI
A
B
C
D
E
F
Sidel S.p.A.
A.
B.
C.
D.
E.
F.
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A
B
C
D
E
F
G
H
Contains the data required by PID adjustment for the foamer temperature and pressure.
H.
Sidel S.p.A.
A.
B.
C.
D.
E.
F.
G.
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A
B
C
D
E
F
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.
Sidel S.p.A.
D.
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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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 Pressure Burst Control parameter is configured).
Burst: Max Pressure Variation: maximum pressure variation value expressed in [mbar]; the bottle
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.
Sidel S.p.A.
M.
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B
A
A.
Sidel S.p.A.
B.
Preclosing Time: the filling pre-closing time. This parameter is sent by the Filling Master Card to the
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 on the internal memory of the electronic card. 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 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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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.
Sidel S.p.A.
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6.4.1
Layout
Function to access the Layout page.
No bottles at infeed.
No bottles at outfeed.
Bottle block.
Lubrication alarm.
Greasing alarm.
Sidel S.p.A.
Operator guards.
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Double neck.
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.
Displays the window showing the data required for the burst bottle test procedure.
Displays the window showing burst bottle diagnostics (glass bottle machines).
Sidel S.p.A.
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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H
A
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.
Sidel S.p.A.
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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
Meaning
Grey
no burst detected
Red
burst detected
Orange
Yellow
Green
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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Sidel S.p.A.
The Burst Reset Button (C) resets all the counters (colour display only) by turning them back to the colour
grey.
Matrix Filler
User Manual / Operating Instructions
6.4.2
Graphics
Function to access the Graphics page.
Control area
Sidel S.p.A.
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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.
Control area
Two-way selector: jack air discharge control.
Sidel S.p.A.
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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).
Sidel S.p.A.
The Program State window displays the states of the Syncposs card during synchronisation of the two
machines.
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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.
E.
Press this to display the "Trend" window. Showing the frequency, current, power and
torques.
Sidel S.p.A.
Press this to display the values read from the driver for the parameters/data selected in
zone #3.
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Sidel S.p.A.
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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B
C
D1
D
D2
D3
A.
B.
C.
D.
Sidel S.p.A.
E.
F.
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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.
Sidel S.p.A.
A.
B.
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A
A.
B.
Area showing the preset values for greasing laps and greasing cycles.
Area showing the actual values for greasing laps and greasing cycles.
Sidel S.p.A.
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Area showing the preset values for lubrication times and lubrication cycles.
Area showing the actual values for lubrication pause and operating cycles.
Sidel S.p.A.
A.
B.
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Parameters
PAM
PAT
PAS
Sidel S.p.A.
6.4.4
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PAM
Main navigation buttons
B.
Sidel S.p.A.
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C.
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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:
Sidel S.p.A.
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D.
E.
Sidel S.p.A.
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F.
G.
H.
I.
Sidel S.p.A.
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L.
Sidel S.p.A.
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User Manual / Operating Instructions
Part VI
PAT
Main navigation buttons
A.
Sidel S.p.A.
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B.
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Part VI
C.
Matrix Filler
User Manual / Operating Instructions
D.
E.
F.
Sidel S.p.A.
1.1
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G.
I.
Sidel S.p.A.
H.
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Part VI
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User Manual / Operating Instructions
Part VI
PAS
Main navigation buttons
A
A.
B.
Sidel S.p.A.
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C.
D.
Sidel S.p.A.
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Part VI
E.
F.
Sidel S.p.A.
1.1
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G.
H.
Sidel S.p.A.
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1.1
Part VI
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User Manual / Operating Instructions
Part VI
6.4.5
Services
Navigation page: This page displays buttons for opening the following submenus. The submenus available
depend on the machine specifications or options:
Sidel S.p.A.
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Part VI
Navigation page: This page displays buttons for opening the following submenus. The submenus available
depend on the machine specifications or options:
Sidel S.p.A.
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
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.
1.1
VI - 143
Sidel S.p.A.
Screen cleaning
Matrix Filler
User Manual / Operating Instructions
Part VI
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:
Sidel S.p.A.
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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Part VI
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.
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.
CIP SUBPAGE
Function to access the CIP page.
Sidel S.p.A.
1.1
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Part VI
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.
RINSING SUBPAGE
Function to access the Rinsing page.
Sidel S.p.A.
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
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.
Sidel S.p.A.
The operator must hold the mobile control unit in order to control movements.
1.1
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6.6
Part VI
6.6.1
1.
2.
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.
Sidel S.p.A.
3.
Preliminary checks
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Part VI
6.6.2
Starting
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.
-
Sidel S.p.A.
1.
-
1.1
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Part VI
Use the special selector to enable the compressed air supply for the jacks.
Press the jack air selector on the Maintenance page:
Sidel S.p.A.
VI - 150
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Part VI
Matrix Filler
User Manual / Operating Instructions
3.
On the pressure reducer, set the CO2 tank supply pressure to approx. 1 bar above the filling pressure.
4.
5.
Sidel S.p.A.
Allow the machine to run in noload conditions until all the filling valves have closed.
1.1
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Part VI
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.
Sidel S.p.A.
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9.
10.
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
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.
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.
Sidel S.p.A.
1.
1.1
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6.7
6.7.1
Part VI
6.7.2
When the Stop button is pressed, the machine stops with bottles inside.
Or:
1.
2.
Wait until all the bottles are fed out of the machine.
3.
4.
Sidel S.p.A.
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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.
3.
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.
Sidel S.p.A.
1.1
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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.
3.
Press:
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.
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).
Sidel S.p.A.
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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1.1
PART VII
SIZE CHANGEOVER
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Part VII
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User Manual / Size Changeover
1.0
VII - 1
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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.
Sidel S.p.A.
In the event of a fault to the lifting motor, see section 7.4 Removing size changeover parts.
VII - 2
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User Manual / Size Changeover
Part VII
7.2
Reference
Description
Reference
H
Sidel S.p.A.
Description
Bottle bottom spacers (where fitted)
1.0
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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.
Sidel S.p.A.
VII - 4
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Part VII
7.4
Matrix Filler
User Manual / Size Changeover
1.
A
2.
D
Unscrew the threaded knob F. Remove
and substitute the starwheel G.
Sidel S.p.A.
3.
1.0
VII - 5
Matrix Filler
User Manual / Size Changeover
4.
Part VII
I
5.
6.
Sidel S.p.A.
VII - 6
1.0
Part VIII
Matrix Filler
User manual / Maintenance Schedule
Sidel S.p.A.
1.0
VIII - 1
Matrix Filler
User manual / Maintenance Schedule
8.1
Part VIII
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
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:
Every 24 hours or after three shifts.
Weekly
Monthly
Yearly:
Every 50 weeks.
Sidel S.p.A.
Daily
VIII - 2
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Part VIII
Therefore, the estimated intervals are:
Interval
Daily
24
Weekly
125
Monthly
500
1500
20
3000
40
4500
60
Yearly
6000
80
12000
160
18000
240
24000
320
Variable (*)
(*)
(**)
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).
Sidel S.p.A.
Failure to follow this advice can lead to injury to persons or damage to machine.
1.0
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Part VIII
8.1.1
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.
Sidel S.p.A.
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:
VIII - 4
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Part VIII
8.1.2
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.
Sidel S.p.A.
The use of Safety Data Sheets translated into the language of the country of use is
recommended.
1.0
VIII - 5
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User manual / Maintenance Schedule
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
customers 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.
Sidel S.p.A.
The use of Safety Data Sheets translated into the language of the country of use is
recommended.
VIII - 6
1.0
Part VIII
8.2
Matrix Filler
User manual / Maintenance Schedule
MAINTENANCE SCHEDULE
Sidel S.p.A.
1.0
VIII - 7
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User manual / Maintenance Schedule
Sidel S.p.A.
VIII - 8
1.0
Part VIII
Matrix Filler
User Manual / Diagnostics
Part IX
DIAGNOSTICS
Sidel S.p.A.
PART IX
1.0
IX - 1
Matrix Filler
User Manual / Diagnostics
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.
Sidel S.p.A.
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.
IX - 2
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Part IX
9.1.1
Problem
The machine does not start
when the START button is
pressed or the machine stops
during normal operation.
9.1.2
Cause
Solution
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.
Cause
Solution
Change the
necessary.
1. Outfeed
starwheel
timed
incorrectly relative to the crown
capper.
1.0
solenoid
valve
if
Sidel S.p.A.
Problem
IX - 3
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User Manual / Diagnostics
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.
Sidel S.p.A.
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.
IX - 4
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Part IX
NO FILLING
Problem
Cause
1. No seal between the bottle and
the centring bell.
No filling
Some filling valves.
No filling
All filling valves.
Solution
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.
Cause
Solution
control
Problem
Insufficient filling.
All filling valves.
Insufficient filling.
Some filling valves.
Sidel S.p.A.
INSUFFICIENT FILLING
1.0
IX - 5
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User Manual / Diagnostics
Part IX
EXCESSIVE FILLING
Problem
Cause
Solution
Cause
Solution
4. Decompression
stage
not
performed
due
damaged
electronic card output.
Excessive filling.
FOAMING
Problem
Foaming
Some filling valves.
Foaming
All filling valves.
Sidel S.p.A.
IX - 6
1.0
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User Manual / Diagnostics
Part IX
9.1.4
Capping
SCREW CAPS
In general capping problems can divided into two groups:
-
Cause
Solution
Problem
1.0
IX - 7
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Bent caps.
9.1.5
2. Worn balls.
2. Faulty probe.
Sidel S.p.A.
IX - 8
Part IX
1.0
Matrix Filler
User Manual / Appendices
PART X
APPENDICES
Sidel S.p.A.
PART X
1.0
X-1
Matrix Filler
User Manual / Appendices
10.1
DOCUMENTATION ENCLOSED
Sidel S.p.A.
X-2
1.0
PART X
PART X
Matrix Filler
User Manual / Appendices
Sidel S.p.A.
1.0
X-3
Sidel S.p.A.
Matrix Filler
User Manual / Appendices
X-4
1.0
PART X
PART X
Matrix Filler
User Manual / Appendices
Sidel S.p.A.
1.0
X-5
Sidel S.p.A.
Matrix Filler
User Manual / Appendices
X-6
1.0
PART X
RICAVATO DA:
19
55
02
9
10
57
5111
57
11
DETTAGLIO B
B DETAIL
SCALA 1:10
SCALE 1:10
10
02
11
7404
DETTAGLIO C
C DETAIL
SCALA 1:10
SCALE 1:10
2
2
Gruppi
Groups
Peso Totale
Kg
Total Weight
13600
300
F
25.08.2011
G.A
316745
01
11.10.2012
G.M
Sostituito pos 10
365871
02
Ind Maj
Ind Min
3
7
ECO
DETTAGLIO A
A DETAIL
Rugosit :
(senza indicazione contraria)
Surface condition
(Unless otherwise stated)
Massa / Mass = g
Data di Rilascio
Disegnato da / Drawn by
MALPELI
This Drawing is SIDEL property and contains or may contain SIDEL confidential information, including trade secrets. This drawing and all
the information contained therein shall be kept strictly confidential by the recipient and shall not be disclosed to any third party without
SIDEL's express consent. This drawing shall not be used directly or indirectly by the recipient except for the specific purpose for which this
drawing is disclosed by SIDEL. All Intellectual Property Rights, including Copyright, are reserved by SIDEL. No representation or warranty,
express or implied, is made by SIDEL with respect to the truth, accuracy, sufficiency or absence of defect of the information contained in this
drawing or with respect to third party intellectual property rights.
Numero / Number :
Scala / Scale
11.10.2012
1:15
42879659- 02
a
1
Size
Sheet
A2 1/1
N 10664182
Trattamento / Treatement :
Denominazione / Description :
SCALA 1:10
SCALE 1:10
Specifiche materiale
/ Specification sheet :
Sidel S.p.A.
Via La Spezia 241/A
43100 PARMA - ITALY
Materiale / Material :
4
DETTAGLIO / DETAIL X
SCALA / SCALE 1 : 5
2377,7
DETTAGLIO / DETAIL Y
SCALA / SCALE 1 : 5
2217,7
7
608,4
768,4
2387,7
ATTENZIONE!
DOPO LA REGOLAZIONE IN ALTEZZA
RIPOSIZIONARE LA COPIGLIA DI SICUREZZA
CAUTION!
AFTER HEIGHT REGULATION REPOSITION
THE SAFETY SPLI SPIN
494,3
334,3
02
a
3
Y
02
a
2487,7
2327,7
134,2
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979,1
294,2
24.10.2011
B.B
324002
01
16.07.2012
A.M
PART. 3; 9
355129
02
ECO
Ind Maj
Ind Min
Materiale / Material :
Specifiche materiale
/ Specification sheet :
N 10664182
Trattamento / Treatement :
Rugosit :
(senza indicazione contraria)
Surface condition
(Unless otherwise stated)
Massa / Mass = g
2497,7
Data di Rilascio
Disegnato da / Drawn by
MALETTI
This Drawing is SIDEL property and contains or may contain SIDEL confidential information, including trade secrets. This drawing and all
the information contained therein shall be kept strictly confidential by the recipient and shall not be disclosed to any third party without
SIDEL's express consent. This drawing shall not be used directly or indirectly by the recipient except for the specific purpose for which this
drawing is disclosed by SIDEL. All Intellectual Property Rights, including Copyright, are reserved by SIDEL. No representation or warranty,
express or implied, is made by SIDEL with respect to the truth, accuracy, sufficiency or absence of defect of the information contained in this
drawing or with respect to third party intellectual property rights.
Numero / Number :
16.07.2012
1:20
42891959- 02
Scala / Scale
Size
Sheet
A1 1/1
A
DETTAGLIO/DETAIL A
SCALE 1 : 5
1
B
1945,62
ATTENZIONE !
DOPO LA REGOLAZIONE IN ALTEZZA
RIPOSIZIONARE LA COPIGLIA DI SICUREZZA
CAUTION !
AFTER HEIGHT REGULATION REPOSITION
THE SAFETY SPLI SPIN.
8
754,67
E
1080,46
F
18.03.2013
B.B
Ind Min
Specifiche materiale
/ Specification sheet :
N 10664182
Rugosit :
(senza indicazione contraria)
Surface condition
(Unless otherwise stated)
Massa / Mass = g
Data di Rilascio
Disegnato da / Drawn by
BSPROGETTI
This Drawing is SIDEL property and contains or may contain SIDEL confidential information, including trade secrets. This drawing and all
the information contained therein shall be kept strictly confidential by the recipient and shall not be disclosed to any third party without
SIDEL's express consent. This drawing shall not be used directly or indirectly by the recipient except for the specific purpose for which this
drawing is disclosed by SIDEL. All Intellectual Property Rights, including Copyright, are reserved by SIDEL. No representation or warranty,
express or implied, is made by SIDEL with respect to the truth, accuracy, sufficiency or absence of defect of the information contained in this
drawing or with respect to third party intellectual property rights.
Numero / Number :
Scala / Scale
18.03.2013
1:20
43000833- 01
c
1
Size
Sheet
A2 1/1
H
8
Ind Maj
Materiale / Material :
Trattamento / Treatement :
Denominazione / Description :
Sidel S.p.A.
Via La Spezia 241/A
43100 PARMA - ITALY
ECO
01
385204
PART X
Matrix Filler
User Manual / Appendices
Sidel S.p.A.
1.0
X-7
Sidel S.p.A.
Matrix Filler
User Manual / Appendices
X-8
1.0
PART X
PART X
Matrix Filler
User Manual / Appendices
10.1.4 Equipment
Sidel S.p.A.
PART VII REMOVING SIZE CHANGEOVER PARTS in section 7.4 Removing size changeover parts
1.0
X-9
Sidel S.p.A.
Matrix Filler
User Manual / Appendices
X - 10
1.0
PART X
PART X
Matrix Filler
User Manual / Appendices
Sidel S.p.A.
10.1.5 Recipes
1.0
X - 11
Sidel S.p.A.
Matrix Filler
User Manual / Appendices
X - 12
1.0
PART X
14/07/2011
DIVERSEY PRODUCTS
STEP
FLUID
TEMPERATURE
RINSING
QUALITY WATER*
Ambient
VE3-Enduro Super
Ambient to 40 C
RINSING
QUALITY WATER*
Ambient
VE10-Enduro Cid
Ambient to 40 C
RINSING
QUALITY WATER*
Ambient
CONCENTRATION
DURATION
10 min
2%
6 cycles x 10 mi n***
5 min**
2%
MS
1/7
SIDEL PROCESS
14/07/2011
DIVERSEY PRODUCTS
STEP
FLUID
TEMPERATURE
RINSING#
QUALITY WATER*
Ambient
DISINFECTION
VT70-Diverfoam Active
Ambient
RINSING
QUALITY WATER*
Ambient
CONCENTRATION
DURATION
5 min
2%
3 cycles x 10 min***
20 min**
MS
2/7
SIDEL PROCESS
14/07/2011
DIVERSEY PRODUCTS
STEP
FLUID
TEMPERATURE
RINSING
QUALITY WATER*
Ambient
ALKALINE CLEANING
VE3-Enduro Super
Ambient to 40 C
RINSING
QUALITY WATER*
Ambient
CONCENTRATION
DURATION
5 min
2%
10 min***
2 cycles x 5 min**
MS
3/7
SIDEL PROCESS
14/07/2011
DIVERSEY PRODUCTS
STEP
FLUID
TEMPERATURE
RINSING#
QUALITY WATER*
Ambient
DISINFECTION
VT70-Diverfoam Active
Ambient
RINSING
QUALITY WATER*
Ambient
CONCENTRATION
DURATION
5 min
2%
10 min***
2 cycles x 10 min**
MS
4/7
SIDEL PROCESS
14/07/2011
DIVERSEY PRODUCTS
5 DESCALING FOAM WEEKLY (DAILY if Filling Water Hardness > 200 ppm CaCO3 ( 20F))
STEP
FLUID
TEMPERATURE
CONCENTRATION
DURATION
VE10-Enduro Cid
Ambient to 40 C
2%
10 min***
RINSING
QUALITY WATER*
Ambient
2 cycles x 5 min**
MS
5/7
SIDEL PROCESS
14/07/2011
DIVERSEY PRODUCTS
STEP
FLUID
TEMPERATURE
RINSING
QUALITY WATER*
Ambient
VE3-Enduro Super
Ambient to 40 C
RINSING
QUALITY WATER*
Ambient
VE10-Enduro Cid
Ambient to 40 C
RINSING
QUALITY WATER*
Ambient
CONCENTRATION
DURATION
5 min
2%
2 cycles x 10 mi n***
5 min**
2%
MS
6/7
SIDEL PROCESS
14/07/2011
DIVERSEY PRODUCTS
7 WATER QUALITY
Parameter
Limit
Microbial Load
<100 CFU/ml
Hardness
Chlorides
Chlorine
Ph
6.5/7.5
Iron
< 1 ppm
Manganese
Suspended Solid
None
Smell or taste
None
10
Dissolved solids
E.coli or thermotolerant coliform
bacteria
11
MS
7/7
SIDEL PROCESS
16/04/2012
FLUID
TEMPERATURE
RINSING
QUALITY WATER
ambient
ALKALINE SOLUTION
80C **
RINSING
QUALITY WATER
ambient
ACID CLEANING
NITRIC ACID***
40C **
RINSING
QUALITY WATER
ambient
ALKALINE SOLUTION
80C **
RINSING
QUALITY WATER
ambient
SOLUTIONS
ALKALINE
ACID 1
Pure Chemical
NaOH
HNO3
MS
1/11
CONCENTRATION
DURATION
5 min
4%
30 min
5 min*
5%
30 min
10 min*
1%
30 min
15 min*
Diversey
VC13-Diverspray
VA5-Pascal
Ecolab
P3-mip CIP
P3-horolith FL
SIDEL PROCESS
16/04/2012
(ALTERNATIVE TO RECIPE # 3)
FLUID
TEMPERATURE
RINSING
QUALITY WATER
ambient
DISINFECTION
45 C *
RINSING
QUALITY WATER
ambient
SOLUTIONS
Pure Chemical
CONCENTRATION
DURATION
10 min
10 min
20 min**
Diversey
Hydrogen peroxide
VT6-Divosan Forte
+ peracetic acid
Ecolab
Oxonia Aktiv 30
MS
2/11
SIDEL PROCESS
16/04/2012
(ALTERNATIVE TO RECIPE # 2)
STEP
FLUID
TEMPERATURE
CONCENTRATION
RINSING
QUALITY WATER
ambient
10 min
QUALITY WATER***
85 C **
40 mi n
COOLING RINSE
QUALITY WATER
ambient
5/10 min
DURATION
** Temperature on return line to CIP. Temperature must not drop below 80C 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
SIDEL PROCESS
16/04/2012
FLUID
TEMPERATURE
RINSING
QUALITY WATER
ambient
ALKALINE SOLUTION
75C *
COOLING/RINSING
QUALITY WATER
ambient
SOLUTIONS
ALKALINE
Pure Chemical
NaOH
MS
4/11
CONCENTRATION
DURATION
5 min
2%
15 min
10 min*
Diversey
VC13-Diverspray
Ecolab
P3-mip CIP
SIDEL PROCESS
16/04/2012
FLUID
TEMPERATURE
RINSING
QUALITY WATER
ambient
ALKALINE SOLUTION
85C **
COOLING/RINSING
QUALITY WATER
ambient
SOLUTIONS
ALKALINE
Pure Chemical
NaOH
CONCENTRATION
DURATION
5 min
2%
30 min
5/10 min*
Diversey
VC13-Diverspray
Ecolab
P3-mip CIP
** Temperature on return line to CIP. Temperature must not drop below 80C
anytime during the sanitize cycle. If so the hot sanitize cycle must restart.
MS
5/11
SIDEL PROCESS
16/04/2012
STEP
FLUID
TEMPERATURE
CONCENTRATION
DURATION
FLOODING MACHINE
20 C
500 ppm
see note *
SOLUTIONS
MS
6/11
Pure Chemical
Diversey
Hydrogen peroxide
VT6-Divosan Forte
+ peracetic acid
Ecolab
Oxonia Aktiv 30
SIDEL PROCESS
16/04/2012
FLUID
TEMPERATURE
RINSING
QUALITY WATER
ambient
ALKALINE SOLUTION
80C **
RINSING
QUALITY WATER
ambient
ACID SOLUTION
50C **
RINSING
QUALITY WATER
ambient
SOLUTIONS
ALKALINE
ACID 1***
ACID 2
ACID 3***
Pure Chemical
NaOH
HNO3
H3PO4
HNO3+H3PO4
MS
7/11
CONCENTRATION
DURATION
5 min
2%
30 min
5 min*
1%
15 min
10 min*
Diversey
VC13-Diverspray
VA5-Pascal
VA3-Alwash
VA4-Superdilac
Ecolab
P3-mip CIP
P3-horolith FL
P3-Horolith PA
P3-Horolith V
SIDEL PROCESS
16/04/2012
8 CLEANING and SANITIZATION - MONTHLY OR AFTER HEAVY MAINTENANCE - (5 Step Cleaning and Hot Sanitization)
ALKALINE CHEMICAL MUST BE AVAILABLE
STEP
FLUID
TEMPERATURE
RINSING
QUALITY WATER
ambient
ALKALINE SOLUTION
80C **
RINSING
QUALITY WATER
ambient
5 min*
QUALITY WATER***
85 C **
20 mi n
COOLING RINSE
QUALITY WATER
ambient
5/10 min
SOLUTIONS
ALKALINE
Pure Chemical
NaOH
CONCENTRATION
DURATION
5 min
2%
Diversey
VC13-Diverspray
30 min
Ecolab
P3-mip CIP
** Temperature on return line to CIP. Temperature must not drop below 80C
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
SIDEL PROCESS
16/04/2012
FLUID
TEMPERATURE
RINSING
QUALITY WATER
ambient
ACID SOLUTION
50C **
RINSING
QUALITY WATER
ambient
SOLUTIONS
ACID 1***
ACID 2
ACID 3***
Pure Chemical
HNO3
H3PO4
HNO3+H3PO4
MS
9/11
CONCENTRATION
DURATION
5 min
1%
15 min
10 min*
Diversey
VA5-Pascal
VA3-Alwash
VA4-Superdilac
Ecolab
P3-horolith FL
P3-Horolith PA
P3-Horolith V
SIDEL PROCESS
16/04/2012
10 WATER QUALITY
MS
Parameter
Limit
Microbial Load
<100 CFU/ml
Hardness
Chlorides
Chlorine
Ph
6.5/7.5
Iron
< 1 ppm
Manganese
Suspended Solid
None
Smell or taste
None
10
Dissolved solids
11
10/11
SIDEL PROCESS
16/04/2012
ML
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
Not Available
Not Available
Not Available
11/11
SIDEL PROCESS
Matrix Filler
User Manual / Appendices
PART X
Description
Command Execution
18
Abort
18
oH
Recipe Download
Burst
13
0.
Snift/Decompression
1 + Rotation
Start Filling
C + Rotation
CIP Active
MMM
h + Rotation
14
Start Sequencer
17
Command Error
Valve Posit > Exit Filling Cam PAS but Fill Not Completed or
Timeout Communication Broadcast Force Centering Cup Up
21
23
N.
22
At every start up on display appears Node actual setting in slave card encoded using led segments
Sidel S.p.A.
Led segments:
1.0
X - 13
Matrix Filler
User Manual / Appendices
Sidel S.p.A.
X - 14
1.0
PART X
Sidel S.p.A.
SF300 Filler
User Manual / Appendices
Montageanleitung / Bettiger
AZM 161
1/2
Hinweis
Verwenden Sie als Sicherung gegen unbefugtes Lsen Sicherheitsschrauben mit Einwegschlitz (als Zubehr erhltlich). Bei Befestigung, z.B. durch Nieten oder Schweien, ist darauf zu achten,
dass sich die Eintauchtiefe des Bettigers nicht ndert.
Es stehen verschiedene Bettigerformen zur Verfgung: Vorzugsweise
fr verschieb- und abnehmbare Schutzeinrichtungen der Bettiger
AZM 161-B1 und AZM 161-B1E. Fr drehbare Schutzeinrichtungen
der Bettiger AZM 161-B6.
AZM
AZM
AZM
AZM
AZM
AZM
AZM
AZM
AZM
Einstellschraube
Werkseitig ist der Bettiger AZM 161-B6 auf den kleinsten Radius
eingestellt. Bei greren Radien erfolgt die Einstellung durch Drehen
der Einstellschrauben a + b mit einem Innensechskant-Schlssel
SW 2,5 mm.
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.
franais
Remarque
Pour viter tout dmontage intempestif, utiliser les vis tte fraise
avec vissage unidirectionnelle (peut tre fourni comme accessoire).
En cas de fixation selon un mode diffrent, par exemple par rivetage
ou soudage, veiller ce que la profondeur de plonge de l'acionneur
ne varie. Different formes dactionneurs sont disponibles. Les
actionneurs AZM 161-B1 et AZM 161-B1E sont recommands pour
les protecteurs coulissants et amovibles. Dans le cas de protecteurs
pivotants, nous vous conseillons lactionneur AZM 161-B6.
161-B1
161-B1-1747
161-B1-2024
161-B1-2053
161-B1-2177
161-B1E
161-B1F
161-B1S
161-B1ES
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
AZM 161-B6
AZM 161-B6-2177
AZM 161-B6S
95
95
95
11
17
95
95
95
11
17
Legende
Legend
Lgende
R min.
x
R min.
x
Einstellschraube
Set screw
Vis de rglage
Montage
Lors du montage sur des protecteurs pivotants, veiller ce que
l'axe de rotation se trouve dans le plan de la surface de l'interrupteur de scurit dans laquelle l'actionneur plonge (voir table).
Vis de rglage
Le rglage de base AZM 161-B6 est tabli en fonction du plus petit
rayon. Dans le cas de rayons plus grands, modifier le rglage en
tournant la vis de rglage a + b l'aide d'une cl 6 pans de
2,5 mm sur plats.
Der Drehpunkt des Scharniers und Oberkante des Sicherheitsschalters mssen zuzglich x mm eine Ebene bilden. Die Grundeinstellung ist auf den kleinsten Radius Rmin 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
Rmin [mm] x [mm]
Montage
Bei der Montage an drehbaren Schutzeinrichtungen ist darauf
zu achten, dass der Drehpunkt in der Ebene der Oberflche des
Sicherheitsschalters liegt, in die der Bettigungsbgel eintaucht
(s. Tabelle).
english
R min.
R min.
Bettigungsradien
Actuator radii
Rayons d'actionnement
deutsch
AZM 161
2/2
italiano
Avvertenza
Per evitare uno smontaggio non autorizzato o manomissioni
utilizzare viti di sicurezza con intaglio antisvitamento (disponibili
come accessori). Durante il fissaggio, ad esempio mediante rivetti o
saldatura, assicurarsi che la profondit di inserimento dell'attuatore
non venga alterata.
Sono disponibili diversi tipi di attuatori: per protezioni traslabili e
amovibili sono da preferirsi gli attuatori AZM 161-B1 e AZM 161-B1E,
per protezioni a cerniera lattuatore AZM 161-B6.
Raggi d'azionamento
Radios de accionamiento
AZM
AZM
AZM
AZM
AZM
AZM
AZM
AZM
AZM
Vite di regolazione
L'attuatore AZM 161-B6 tarato sul raggio minimo. Per raggi
maggiori modificare la taratura agendo sulle viti di regolazione
a + b con una chiave a brugola da 2,5 mm.
161-B1
161-B1-1747
161-B1-2024
161-B1-2053
161-B1-2177
161-B1E
161-B1F
161-B1S
161-B1ES
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
AZM 161-B6
AZM 161-B6-2177
AZM 161-B6S
95
95
95
11
17
95
95
95
11
17
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 funcin del radio mnimo, Rmin.
Legenda
Leyenda
Tornillo de regulacin
La regulacin de base del AZM 161 B6 se establece en funcin del
mnimo radio de giro. En caso de mayores radios de giro, modificar
el reglaje girando los tornillos de regulacin a + b mediante una llave
hexagonal de 2,5 mm entre caras.
R min.
x
R min.
x
Vite di regolazione
Tornillo de regulacin
K. A. Schmersal GmbH
Industrielle Sicherheitsschaltsysteme
Mddinghofe 30, D - 42279 Wuppertal
Postfach 24 02 63, D - 42232 Wuppertal
Telefon
Telefax
E-Mail:
Internet:
Informacin
Se debe asegurar contra desmontajes no autorizados mediante la
utilizacin de los tornillos de seguridad con la cabeza fresada (suministrados como accesorios) que solo permiten el apriete. En caso
de utilizar un modo de fijacin distinto, por ejemplo por remaches o
por soldadura, hay que asegurarse que la profundidad de penetracin sea la misma. Existen distintas versiones de actuador disponibles, dependiendo de cada aplicacin. 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.
Montaje
En caso de montajes en protecciones pivotantes, hay que asegurarse
de que el eje de giro se encuentre en el plano de la superficie del interruptor de seguridad en el cual penetra el actuador (ver tabla).
Montaggio
Durante il montaggio su dispositivi di sicurezza con cerniere, assicurarsi che lasse di rotazione si trovi sul piano della superficie dellinterruttore di sicurezza nella quale si inserisce lazionatore (vedi tabella).
espaol
R min.
R min.
x
+49 - (0)2 02 - 64 74 - 0
+49 - (0)2 02 - 64 74 - 1 00
info@schmersal.com
http://www.schmersal.com
27
Azionatore CST 34
27
27
27
97,2
108,2
97,2
27
97,2
108,2
27
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