Page 1. M4 & M6 BOTTLE FILLING MACHINE. OPERATING MANUAL. “R” SERIES. 12/10/14. Page 2. 2. TABLE OF CONTENTS. GENERAL .
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2 TABLE OF CONTENTS GENERAL .. .. .. .. . 3 CONTROL PANEL .. .. .. . 3 SAFE OPERATION OF THE BOTTLING MACHINE .. .. . 5 PROCEDURE FOR CLEANING AND SANITIZING .. .. 5 OPERATING SUMMARY .. .. .. . 6 SANITIZING .. .. .. .. 7 BOTTLING .. .. .. .. 8 AUTO FILLING .. .. .. 9 AUTO CLEANING .. .. .. .. 1 3 CLEANING .. .. .. .. 1 5 MANUAL OVERRIDE .. .. .. .. 1 6 RUN LEAK TEST .. .. .. . 1 7 ADJUSTMENTS OF THE MACHINE .. .. . 1 8 BOTTLE INDEXING & FILL HEAD ALIGNMENT .. . 1 8 CAP FEED .. .. .. . 1 8 COMPUTER .. .. .. .. . 1 9 TROUBLESHOOTING .. .. .. .. 20 PRESSURE SENSOR CHECK .. .. .. .. 2 2 LUBRICATION & MAINTENANCE .. .. .. 2 2 FILL MANIFOLD & TUBING MAINTENANCE .. .. . 2 3 BOTTLE DETECTION SYSTEM /INDEX PLATE ADJUSTMENT .. . 2 5 BOTTLE DETECTION BY – PASS .. .. .. 2 6 BOTTLE INDEXING SPEED ADJ USTMENT .. .. 2 6 WARNING AS WITH ALL MECHANICAL EQUIPMENT, CARE MUST BE TAKEN TO AVOID INJURY FROM MOVING PARTS WHICH OPERA TE WITH CONSIDERABLE FORCE AND WITHOUT WARNING. MEHEEN MANUFACTURING SHALL NOT BE HELD LIABLE FOR INJURY OR DAMAGE RESULTING FROM THE INAPPROPRIATE USE OF THIS MACHINE OR FROM NORMAL OPERATION WITHOUT REGARD TO NORMAL SAFETY CONSIDERATIONS. MEHEEN MANUFA CTURING SHALL BE HELD HARMLESS IN THE CASE OF INJURY RELATED TO THE USE OF THIS MACHINE REGARDLESS OF THE CIRCUMSTANCES AND OPERATING PROCEDURES USED.
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3 GENERAL The M4 & M6 automated bottling machine s are designed with quality and portability in mind. An onboard computer controls all automated functions including bottle fill levels and pressures. Standard automated feature s include sanitizing, cleaning, filling and crowning. The M4 & M6 are specifically designed for bottling carbonated beverages , under c old counter pressure conditions , directly from the bottling tank. Generally optimum bottling conditions are cold (30 – 3 4 0 F) and 2.0 – 3.0 volumes dissolved CO 2 . A compressed air source that can provide 100psi + is required to operate the M4 and M6, as well as 110 volt AC electrical power and a regulated CO 2 source. Meheen Manufacturing suggests the use of an oil sump, reciprocating type air compressor with a min of 15scfm@90psi rating. DO NOT use a home – style, direct drive oil – less compressor. Regulated a ir pressure on the machine itself needs to be 95 – hose or less and larger for longer runs. Also all devices restricting air flow, such as regulators and moisture traps should be removed betwe en the air compressor and the bottling machine. CONTROL PANEL The control panel of the M4 and M6 bottling machine s consist of the operator interface shown above and a large red mushroom switch which is located near the bottom center of the panel. The opening screen gi ves information about the M4 and M6 machine s , such as Brewery Name, Serial#, interface and computer program version . This screen appears each time the machine is turned on. To access the main operating screen, simply touch the wizard an d the screen will change to the main operating screen.
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4 On/Off : Main power to the machine is turned on by pulling the red mushroom button out, and turned off by pushing it in. Main Screen : The main operating screen shown below allows you to choose the func tion needed. Display options are Imperial units as default or change to Metric by pressing the Display button. You may ret urn to the main operating screen from any of the operati ng screens by pressing the Reset k ey and then the main button with the wiz ard pictured on it. Auto Filling, Clean, Sanitize and Manual Override : These operations are entered from the Main screen show n above by pressing the desired button. When any of these buttons are pressed the screen will change to that operation. Note : T he Reset k ey must be pressed before starting a ny operational mode except the m anual override functions. Reset : The Reset button is used any time the machine has been stopped, paused, or about to be s tarted in a new mode. The Reset always returns the machine to its starting conditions for each mode. Reset must be used each time the machine enters a new operation before the machine will start any program functions and before pressing the Main screen button. CAUTION : If the bottling machine is paused a nd rapidly Reset during a time when the machine has pressure in the bottle (i.e., filling) , pressure in the bottles will be released r apidly without warning. Rapid release of pressure can be hazardous due to glass breakage and liquid spray.
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5 SAFE OPERAT ION OF THE BOTTLING MACHINE D uring normal operation of the M4 and M6 several very powerful moving parts are utilized that could cause serious injury if proper precautions are not taken. Even though bottles are designed for much higher pressures than util ized by the bottling machine, manufacturing defects can exist which can cause bottle failure resulting in breakage and potentially flying glass. Meheen Manufacturing recommends the following safety precautions be observed while operating the M4 and M6 : 1. Always wear safety glasses or other eye protection. 2. Avoid loose fitting clothing which could become caught in moving parts of the machine. 3. Keep hands and face away from moving parts of the machine at all times when air pressure is connected to th e machine. 4. Do not exceed 40 psi CO 2 to the machine at any time, damage to the pressure sensor will occur. 5. Avoid direct water spray on the control panel and electrical parts. 6. Components located inside the control panel operate on 24VDC , high volta ge (100 – 220 Volts AC) energy is converted by a power supply located on the cord. DO NOT open the control panel or power supply when plugged in. 7. Service of electrical components should be referred to qualified personnel only. PROCEDURE FOR CLEANING A ND SANITIZING Even though the products mentioned in this procedure are supplied by B irko Corporation any brand can be used. Birko products can be purchased from: 1. Dissolve four ounces (one – half cup or about 125 grams) of Birko CELL – R – M A STR in 5 g allons of 120 – 130 0 F water. 2. For light – duty cleaning, circulate the CELL – R – MASTR solution through the machine for a minimum of 2 – 4 minutes. For heavily soiled machines, circulate the solution through the machine until clean. Do this by operating the mach ine in the Sanitize mode as many times as needed. 3. Drain CELL – R – MAST R solution, and then rinse the machine with ambient or warm water until the pH of the rinse water is the same as the pH of the tap water. For final rinse, operate the machine in the Clea n mode to blow out the tubing before storing the machine. Birko Corporation 9152 Yosemite Street Henderson, CO 80640 – 8027 (800) 525 – 0476
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6 4. Prior to bottling, sanitize using an appropriate no – rinse sanitizer such as Chlorine Dioxide (ClO 2 ) or Peracetic Acid (PAA). Operate the machine in the Sanitize mode. To remove beer stone (Calciu m Oxalate) deposits, the use of an acid product such as Acid Brite No.2 (Phosphoric/Nitric blend) is recommended. Run 1 ounce (30ml) of acid per gallon of warm (120 0 F) water for a minimum of 2 – 4 minutes prior to CELL – R – MASTR . OPERATING SUMMARY
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8 6. Place three rows of bottles on the bo ttle runway at the base of the bottle feed ramp. When the bottling machine is started it will automatically index the bottles to the filling and crowning stations. 7. Press the Reset System is Reset at the bottom of the screen . 8. Place the sanitizing pump into the bucket of sanitizing solution and plug it in. 9. Press the Sanitize Off/On button to begin the sanitizing cycle. The button will change color from red to green and the green RUN light wi ll illuminate at the top of the screen. machine will automatically perform two 1 minute sanitizing cycles then stop Illuminating the PAUSE light and display in the message . CAUTION: The bottle filling head will come up without w arning to index the next row of bottles . Keep hands and face away from moving parts at all times. 10. Bottle caps in the cap feed ramps will automatically feed into the capping head each time the capping head cycles to the up position. The cap feed ramps hold enough caps for 2 – 3 cases of bottles . More caps can be added to the cap feed ramps at any time. 11. The machine automatically stops at the end of the second san itizing cycle with the fill ing heads down. The amber PAUSE light in the center of the interface will be lit when the c ycle . Press the S anitize but ton to turn the prog ram off. The button will turn r ed and the message display Do not remove bottles filled with sanitizing solution from the bottling machine as they will be needed for weight to provide proper bottle feeding when starting the automatic bottling cy cle. When the Sani tize cycle is complete, unplug the pump to stop solution still being pumped through the liquid pressure sensor hose. image to return to the Main Operation M enu. 12. Allow the liquid pressure sensor hose from the beer distribution to drain before connecting to the control panel. Af ter the pressure sensor hose is drained , reinstall it on the bottling machine by pushing the hose firmly into the fittings on the sensor and beer manifold. Note : The tubing is often difficult to push into the fittings. You should feel the tube slide into the fitting and seat when it is installed properly. Bottling : 1. Connect the hose used for the sanitizing cycle from the distribution manifold of the ma chi ne to the product dispensing tank. Be sure to clamp both ends of the hose securely. Open the dispensing tank valve very slowly when first charging the line. If the tank valve is opened too fast, severe damage may occur to the beer line pressure senso r.
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9 2. Connect the CO 2 supply to the CO 2 inlet on the top of the bottling machine and adjust the pressure to 25 psi. This CO 2 source is used to purge the bottles, bring them to counter pressure and pulse the full bottles. DO NOT EXCEED 40 psi to avoid da mage to pressure sensors on the machine. 3. Adjust the CO 2 pressure applied to the head space of the dispensing tank 1 – 2 psi above the tank equilibrium pressure or an adequate level to dispense the product into the bottles. 4. Place 4 – 5 rows of bottles o n the sloped bottle feed ramp to begin the bottling process. The full bottles from the sanitizing cycle should remain on the machine until enough full bottles have accumulated on the machine to keep the bottle feeding system operating properly. As full b ottles accumulate on the exit portion of the machine , more bottles can be added to the bottle feed ramp. The full bottles provide the needed friction for the bottle gravity feed system to operate properly, and keep the bottles being indexed from sliding t oo far and misfeeding. Once the machine is operating in the bottling mode, at least 6 rows of full bottles must be maintained on the exit portion of the machine. Auto Filling :
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10 5. The Auto Filling screen is show n above and consists of three slide ba rs, two pressure meters , manifold temperature display and Auto Off/On, Res e t , Pulse , Evac/Purge , Liquid psi Control buttons and Liquid psi arrow key adjustment with pressure display . The first time the machine is turned on , l eveling will be at 0.0 which i ndicates no leveling time after bottles have been detected full. To add leveling time, slide the leveling slide bar up to the desired time. T he Fill Sensor will be in the Auto mode and the slide for the Manual mode . This is q uite sensitive for fill detection at low filling speeds. When the Fill S ensor is in the Auto mode, it will automatically adjust to changing pouring conditions and is not adjustable by the operator. Should the Auto Fill Detection fail to work properly , it may be change d to Manual adjustment by pressing the selector button at the top of the Fill Sensor. The color of the button will change from green to blue and the text will change to Manual indicating the mode change for Fill Detection. As filling speeds are increase d in the Manual mode , the Fill Sensor will need heads are raise d, or the pressure at which the Pulse will occur. It is generally recommended to operate the Low Pressure as low as possible and still maintain a 1 second or less time from when the filling valve closes until the filling heads are raised from the bottles. If t he filling heads remain in the bottle more than 1 second after the
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11 filling valve has closed, you need to raise the Low Pressure until the 1 second has been met. The two pressure bars simply display incoming product pressure to the machine and the pressure in the bottle . It can be used for adjustments to the machine or trouble shooting . 6. The M4 and M6 control panel s also display temperature in the product manifold located at the top of the machine. This temperature display simply lets the operator observe the incoming temperature of the product and can be used to help with determining prop er pressures in the liquid tank. 7. A (LpC ) is located in the upper right hand portion of the display. T his button turns on and off the controls to adjust CO 2 dispensing pressure in the head space of the tank based on liquid manifold pressure at the machine. This function is optional and intended to help resolve di spensing pressure drops that can occur when using manual style regulators. To utilize this feature, an independent CO 2 source , different from the one used for the bottling machine , is connected to the control valve inlet (see photo). T he inlet pressure s hould be set at 30 – 35 psi from the CO 2 source. A hose will need to be connected between the control valve and head space of the dispensing t ank. How LpC works, is when connected to a CO 2 source and the head space of the dispensing tank and the system records the static liquid pressure at the manifold and displays that pressure as the set point above the adjusting arrow keys. Using the arrow keys you can adjust this set p oint up or down as needed. Each cycle , before the product valve opens the computer , will sample the manifold pressure and turn the CO 2 control valve on or off as needed. NOTE: This system is limited to a maximum control pressure of 14.9 psi and only op erates when the filling process is running. It does not function when the machine is paused. 8. Press the Reset button on the operator interface and the message display should read uto Filling to start the machine in its automat ic filling and capping mode. The message display will display , the Run light will be illuminated and the Auto Filling button will change from red to green . To adjust the Low Pressure and Fill Sensor simply move the slide bars to the d esired amount . Adjusting the Fill Sensor to a higher value makes it less sensitive and a lower value makes it more sensitive.
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