CCE-07ND-Gateway Filler Volume 1 - System Overview, Operation and Routine Maintenance
Draft release
Project : 1954
Copyright Copyright © 2013 PLF International. All rights reserved worldwide. All information in this manual and any drawings and technical descriptions which have been made available by us, remain our intellectual property and may not be duplicated in any way, transferred or made known to a third party without first obtaining written permission from PLF International.
Contact information PLF International Ltd. Riverside House, Iconfield, Parkeston Harwich, Essex CO12 4EN England Tel: +44 (0) 1255 552994 Fax: +44 (0) 1255 552995 E-mail: [email protected] Website: http://www.plfinternational.com
Contents
1 About this manual 1-1 1.1 Scope ...... 1-1 1.1.1 Equipment covered by this manual ...... 1-1 1.2 Manual structure ...... 1-2 1.3 Manual Amendment Record ...... 1-2 1.4 Associated documentation ...... 1-3
2 Safety information 2-1 2.1 Standards for safety ...... 2-1 2.2 Responsibility for safety ...... 2-1 2.3 Personnel training ...... 2-1 2.4 System use disclaimer ...... 2-1 2.5 General safety ...... 2-1 2.6 Operational safety ...... 2-2 2.7 Maintenance safety ...... 2-2 2.8 Gassing system safety ...... 2-2 2.8.1 Gassing environment safety ...... 2-3 2.8.2 Compressed gas safety ...... 2-3 2.9 Startup checks ...... 2-3 2.10 System safety features ...... 2-3 2.10.1 Emergency stops ...... 2-3 2.10.2 Power isolators ...... 2-4 2.10.3 Vacuum system isolator ...... 2-6 2.10.4 Compressed air isolators...... 2-7 2.10.5 Nitrogen isolators ...... 2-8 2.10.6 Interlocked doors and panels ...... 2-8 2.10.7 Fixed covers ...... 2-9 2.11 End of life treatment ...... 2-9
3 System overview 3-1 3.1 System functions ...... 3-1 3.2 Line layout ...... 3-1 3.3 Production process ...... 3-2 3.3.1 Infeed conveyor ...... 3-2 3.3.2 Powder filling ...... 3-2 3.3.3 Powder hoppers ...... 3-2 3.3.4 Check weigh ...... 3-2 3.3.5 Container sealing ...... 3-2 3.3.5.1 Seal press ...... 3-2 3.3.5.2 Sealer ...... 3-2 3.3.6 Container rejection ...... 3-3 3.3.7 Code printing ...... 3-3 3.3.8 Gassing ...... 3-3 3.4 Production control ...... 3-4 3.4.1 Machine recipes ...... 3-4 3.4.2 Line sensors ...... 3-4
4 Operation 4-1 4.1 Control Station Overview ...... 4-2 4.1.1 Controls and indicators ...... 4-2 4.1.2 Status beacons ...... 4-3 4.1.3 Powering up ...... 4-3 4.1.4 Logging on ...... 4-4 4.1.5 Overview screen ...... 4-5 4.1.5.1 Status diagram ...... 4-6
4.1.5.2 Function buttons ...... 4-9 4.1.5.3 Navigation bar ...... 4-12 4.1.5.4 Vacuum status ...... 4-12 4.1.5.5 Filler speed ...... 4-12 4.1.5.6 Fill weight ...... 4-13 4.2 Operation ...... 4-14 4.2.1 Preparing the system to run ...... 4-14 4.2.2 Starting and stopping the system ...... 4-14 4.2.3 Using emergency stops ...... 4-15 4.2.4 Jogging the filler ...... 4-15 4.2.5 Resetting lift tables ...... 4-16 4.2.6 Emptying the filler hopper...... 4-16 4.2.7 Clearing containers ...... 4-16 4.2.8 Priming the filler hopper ...... 4-17 4.2.9 Responding to alarms ...... 4-17 4.2.10 Resetting a table up alarm ...... 4-17 4.2.11 Controlling the powder feed ...... 4-18 4.2.12 Sampling filled containers ...... 4-19 4.2.13 Gassing operation ...... 4-20 4.2.13.1 Gas Overview Screen ...... 4-20 4.2.13.2 Gassing the system ...... 4-21 4.2.13.3 Degassing the system - 1954 specific ...... 4-21 4.2.14 Working with recipes ...... 4-22 4.2.14.1 Creating and editing recipes ...... 4-22 4.2.14.2 Using stored recipes ...... 4-26 4.3 Screen descriptions...... 4-27 4.3.1 Overview screen ...... 4-27 4.3.2 Gas Overview screen ...... 4-28 4.3.3 Gas calibration screen ...... 4-28 4.3.4 Head data screens ...... 4-29 4.3.5 Lift height screen ...... 4-30 4.3.6 Sample screen - 1954 specific ...... 4-31 4.3.7 Select recipe ...... 4-31 4.3.8 Enter recipe screen ...... 4-32 4.3.9 Settings ...... 4-32 4.3.9.1 Settings - Delays and Gassing ...... 4-33 4.3.9.2 Settings - Powder feed ...... 4-34 4.3.9.3 Settings - Speeds ...... 4-35 4.3.9.4 Settings - Encoder ...... 4-36 4.3.9.5 Settings - Sealer Generator Power ...... 4-39 4.3.9.6 Settings - Sealer Setup ...... 4-39 4.3.10 Diagnostics...... 4-39 4.3.10.1 Diagnostics 1 ...... 4-40 4.3.10.2 Diagnostics 2 ...... 4-40 4.3.10.3 Diagnostics 3 ...... 4-41 4.3.10.4 Diagnostics 4 ...... 4-41 4.3.10.5 Diagnostics 5 ...... 4-42 4.3.10.6 Diagnostics 6 ...... 4-43 4.3.11 Jog ...... 4-43 4.3.12 Powder feed ...... 4-44 4.3.13 Alarms ...... 4-44 4.3.14 Events ...... 4-44
5 Cleaning and routine maintenance 5-1 5.1 Safety during maintenance ...... 5-1 5.1.1 Returning the system to use...... 5-1 5.2 Jogging the filler machine ...... 5-1 5.3 Cleaning and purging ...... 5-2 5.3.1 General cleaning ...... 5-2 5.3.2 Cleaning the powder filler ...... 5-2 5.3.2.1 Cleaning filler nozzles ...... 5-2 5.3.2.2 Cleaning nozzle clamps ...... 5-7 5.3.2.3 Clearing nozzle gauzes ...... 5-8 5.3.2.4 Cleaning filler hopper, lids and seals ...... 5-9 5.3.2.5 Cleaning hopper cones ...... 5-11
5.3.2.6 Cleaning the central vacuum system ...... 5-12 5.3.3 Cleaning the feed hoppers ...... 5-21 5.3.4 Cleaning the sealer ...... 5-21 5.3.5 Cleaning the gas extraction system ...... 5-22 5.3.6 Cleaning line control sensors ...... 5-23 5.4 Maintenance ...... 5-24 5.4.1 Maintenance schedule ...... 5-24 5.4.2 Vacuum pump ...... 5-25 5.4.3 Clearing the central vacuum tube ...... 5-25 5.4.4 Testing sensors and interlocks ...... 5-25 5.4.4.1 Set up for tests ...... 5-25 5.4.4.2 Testing line control sensors ...... 5-25 5.4.4.3 Testing machine sensors ...... 5-26 5.4.4.4 Testing interlocks ...... 5-28 5.4.4.5 Testing emergency stops ...... 5-29
CCE-07ND-Gateway Filler
C H A P T E R 1 1 About this manual
This manual provides information required to operate the CCE-07ND-Gateway powder filling system 1954 safely and correctly. We recommend that a copy of the guide is made permanently available to all system operators. The information provided deals mainly with the functions controlled from the filler operator control station, but it also gives general instructions for operating other aspects of the system. Some of the information is generic in nature and applies to all PLF filling systems. Consequently, some of the illustrations may not exactly match the screens displayed. Where relevant, however, the information is specific to the system with which it is supplied.
WARNING: INCORRECT OPERATION OF THE SYSTEM OR FAILURE TO OBSERVE SAFETY INSTRUCTIONS MAY RESULT IN SERIOUS INJURY OR DEATH.
Caution: Incorrect operation of the system may result in damage to the filler or associated equipment.
All personnel must be familiar with the safety and other information contained in this manual before attempting to operate the system. In addition, anyone involved in product changeover and/or maintenance must be familiar with the information provided in the associated system maintenance information.
1.1 Scope This manual has been specifically produced for the system identified on the front cover. It must not be used for any other system. The supplied documentation does not cover general rules for the prevention of accidents, or other binding rules or laws for the prevention of accidents and protection of the environment.
1.1.1 Equipment covered by this manual . Powder filling machine . Feed hopper control system . Cap press . Sealer . Gassing system . Electrical/control system . Pneumatic system
1-1 CCE-07ND-Gateway Filler About this manual
1.2 Manual structure The complete manual for powder filling system 1954 comprises three volumes: Volume 1 Line Overview, Operation and Maintenance
This contains information required by line operators for normal day-to-day operation and maintenance of the filling line. It provides: . essential safety information which must be understood and followed by anyone operating or working on the filling line; . a brief introduction to the filling line for the benefit of new operators; . instructions for operating the filling line for normal production runs; . instructions for cleaning and for performing the routine maintenance needed to ensure efficient and hygienic operation of the filling line.
Volume 2 Line Description This contains information required for a more detailed understanding of the filling line. It is intended for use by personnel with responsibility for line maintenance, fault location and repair. It provides descriptions of: . the overall filling line and its principles of operation and control; . the individual systems and items of equipment comprising the filling line. Where relevant, it refers to the parts lists, drawings and schematics in Volume 3, and to other equipment manufacturers' documentation (page 1-3).
Volume 3 Parts lists, Assembly Drawings and System Schematics This contains parts lists, mechanical assembly drawings and system schematics (electrical, pneumatic, etc.) for all PLF-supplied equipment.
1.3 Manual Amendment Record
Revision Nature of Change Date Signature 1 Original 2012 KCL
2
3
4
5
6
7
1-2 CCE-07ND-Gateway Filler About this manual
1.4 Associated documentation
System Manufacturer Documentation Seamer Fords packaging Rejector Heuft Checkweigher Garvens Slip ring Trolex Air con unit Rittall Vacuum valve Parker conveyors Autarky pneumatics Festo VC500 Vac pump Rietschle Encoder Hengstler Encoder Lika level probe Endress & Hauser Inverter AB Powerflex
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C H A P T E R 2 2 Safety information
2.1 Standards for safety CE-marked machines have been designed and manufactured to comply with the essential health and safety requirements of the European Union Directives. Machines that are not required to be CE marked are built to a similar level of safety or to alternative regulations, as required.
2.2 Responsibility for safety Every care has been taken in the design and manufacture of the equipment to ensure that it meets all relevant safety requirements. However, any person operating or working on any equipment is personally responsible for: . their own safety and that of any other people who may be affected by their actions. . performing all operating, maintenance or repair procedures correctly, in accordance with this manual and all associated documentation. . compliance with all applicable local safety regulations or legislation that may exist. PLF International cannot be held responsible for any injury, death or damage to equipment arising from the failure of any personnel to fulfill these responsibilities, or to comply with any other safety information and procedures given in this manual.
2.3 Personnel training PLF International training programs enhance the operational capabilities of the equipment, and reduce downtime. An investment in training assures maximum productivity from the equipment. PLF International recommends that all Operators and Maintenance personnel are trained to the required competency by PLF International before they attempt to operate or maintain the equipment. PLF International are pleased to offer this service to our customers. A typical training course would cover the following topics: . Safety . Principles of operation . Equipment set-up . Changeover procedures . Cleaning routines . Routine maintenance and lubrication . Fault finding
2.4 System use disclaimer This powder filling system is intended for filling containers with the powder type(s) specified at the time of purchase. It is not suitable for any other purpose. Any use of the equipment other than for its intended purpose may result in injury to personnel and/or damage to the equipment.
2.5 General safety . The powder filling system must be used only when all equipment is in perfect working order. In the event of any fault or abnormal condition such as unusual noises, smoke or signs of overheating: . shut down the affected equipment . isolate all electrical, vacuum and compressed air supplies to the equipment . take appropriate steps to have the equipment tested and any faults rectified before putting the equipment back into service
2-1 CCE-07ND-Gateway Filler Safety information
. Do not attempt to bypass, disconnect or remove any system safety switches or interlocks or other safety devices. . Check daily that all equipment door and access panel interlocks, and all emergency stop buttons are operating correctly. . Do not modify or redesign the equipment in any way without the prior consent of PLF International. Unauthorised alterations may make the equipment unsafe. . Spare parts must conform to the specifications issued by relevant equipment manufacturers. To ensure this, we recommend that all spare or replacement parts are obtained from the original equipment manufacturer.
2.6 Operational safety The system must not be operated by anyone who has not been trained in the safe and proper use of the system and of the individual items of equipment. Before operating the system: . Read and understand the procedures and instructions provided in this manual. . Do not operate the system if you are under the influence of drugs or alcohol, or are suffering from any illness or condition that might affect your ability to operate the system safely. . Make sure that you know the locations of emergency stop buttons and safety isolators so that you can operate these rapidly in the event of an emergency. . Ensure that there are no other people in the vicinity of the system whose safety may be affected by any of your actions. . Provide adequate warnings to all relevant personnel before starting any of the system equipment. When operating the system: . Do not attempt to operate the equipment unless all access doors are closed and all access panels and safety guards are correctly fitted and secured. . Except in the event of an emergency, never use emergency stop buttons or isolator switches to stop equipment. This can be dangerous and may cause damage. In normal operating conditions, always stop equipment from the relevant operator control panel(s), using the correct stop/shut-down procedures. . Wear appropriate protective clothing and equipment, including: . Industry-approved safety glasses . Industry-approved hearing protection . Suitable protective clothing for the product powders being run . Non-skid, protective footwear . Do not wear loose clothing, long hair or loose jewellery such as necklaces or bracelets. . Never attempt to perform any cleaning or maintenance while the equipment is in operation. . Keep the areas around all machines clear and free of obstacles. . Do not place any items on the machines or conveyors.
2.7 Maintenance safety Before starting maintenance on any part of the system, follow the safety procedures (page 5-1) given in the Cleaning and routine maintenance section.
2.8 Gassing system safety
Nitrogen (N2) and/or carbon dioxide (CO2) are used to create a low-oxygen environment within the gassed areas of the filling line. Exposure to this environment can cause asphyxiation due to lack of oxygen.
Cylinders of compressed N2 and/or N2/CO2 mix may be included in the system for calibration of gas analysers. These cylinders can be hazardous if not handled correctly. . In addition to the safety rules given in this manual, all relevant local and national regulations related to the use of these gases and of compressed gas cylinders must be observed. . All personnel working with, or in the vicinity of, the gassing system should be suitably trained in respect of: . Safe operation of the gassing system . Recognition of system alarms, and familiarity with safety/evacuation procedures in the event of alarms . Recognition of the symptoms of asphyxiation
2-2 CCE-07ND-Gateway Filler Safety information
. Basic first-aid measures for dealing with victims of asphyxiation
2.8.1 Gassing environment safety For operator safety, all access doors into the gassed area are locked and sealed when the atmosphere inside is not safe to breathe. The filler HMI Gas Overview screen shows when the gassing zones are safe or not safe.
Safety rules . Before attempting to open any enclosure doors, always check on the GAS OVERVIEW screen that the relevant Zone(s) is/are safe. . Do not attempt to open the doors by force. . Do not try to gain access to the gassed enclosure by any other means. . Do not attempt to override the door interlocks. . If the audible/visible room atmosphere alarms are triggered, leave the room immediately. The gassing system will shut down and de-gas automatically, so there is no need to do this manually. . If you notice any damage to door seals or access gloves, do not attempt to start the gassing system. If the system is on, shut it down and de-gas the zones. . Ensure that the door seals, air vents and other gassing enclosure components are checked and maintained as specified in the routine safety checks and maintenance schedule (page 5-24). . Do not modify the gassing enclosures or any of the associated systems in any way without first consulting PLF International.
2.8.2 Compressed gas safety Compressed gas cylinders can be dangerous if handled or stored incorrectly. They can explode if exposed to excessive heat or impact, and may be projected around at very high speed if punctured. If calibration gas cylinders are used on the system: . Read and follow the safety information supplied with, and on, the gas cylinders. . Observe all national, state and local regulations pertaining to the storage, use and disposal of compressed gasses. . When replacing cylinders, always secure them properly in the cylinder clamps and fit the protective cover.
2.9 Startup checks Before starting the filling line, perform the following safety checks. Check: . that conveyors and machines are clear of all items other than containers. . that there are no fallen containers on the line. . that all access passageways are clear. . that all machine guarding doors and covers are closed. . that there are no personnel in the vicinity who could suffer injury as a result of equipment starting up. . that notifications and warnings are given to personnel in accordance with the relevant safety regulations.
2.10 System safety features
2.10.1 Emergency stops The system is fitted with emergency stop buttons at the locations illustrated below.
2-3 CCE-07ND-Gateway Filler Safety information
Pressing any emergency stop button on the powder filler or sealer will immediately stop both machines and the associated conveyors. Pressing either of the emergency stops on the cap press stops only the cap press.
Emergency stop locations
1 Powder filler 2 Sealer 3 Cap press
2.10.2 Power isolators Electrical power isolators are provided at the locations indicated below. Each isolator enables the associated equipment to be shut off and locked out using a padlock or personalised tag.
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Power isolator locations
Isolator Function 1 Main filler system isolator. Location: front of system main control panel CP01 (not illustrated) 2 Infeed conveyor motor 3 Filler and sealer main drive motor 4 Checkweigher 5 Outfeed conveyor motor 6 Reject conveyor motor 7 Cap press autosplicer motor 8 Cap press main motor (Location: in base of machine) 9 Sealer head heating power supplies (4 isolators)
2-5 CCE-07ND-Gateway Filler Safety information
2.10.3 Vacuum system isolator The vacuum system isolator is a manually-operated valve located near the base of the powder filler.
Valve port Function A To vacuum pump
B To filler vacuum reservoir = Vacuum path
C To atmosphere = Port closed
The valve has three positions shown above:
Position Operating state 1 On Normal operating position. The filler vacuum reservoir is connected to the vacuum pump. 2 Off The filler is isolated from the vacuum pump, and the filler vacuum reservoir is vented to atmosphere. 3 Isolated The filler vacuum reservoir is port is shut so that the reservoir vacuum is maintained. The vacuum pump is opened to atmosphere. Note: If the isolator valve is going to be left in this position for more than about three to four minutes, the vacuum pump should be switched off.
Vacuum system isolator location
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2.10.4 Compressed air isolators All compressed air supplies to the system include manually-operated on/off valves which can be used to isolate the system air distribution panels from the factory air supply. In some cases, the isolators are fitted on the air distribution panels, and can be operated only when the panel cover is open. A typical isolator is indicated below.
In other cases, isolators are fitted to the outside of machine enclosures, enabling them to be operated without special access. The specific locations of the system air on/off valves are shown below.
Compressed air isolator locations
Isolator Function 1 Filler air systems 2 Sealer air systems 3 Cap press air systems
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2.10.5 Nitrogen isolators All nitrogen supplies to the gassing system include manually-operated on/off valves which can be used to isolate the nitrogen conditioning and distribution panels from the factory supply. In some cases, the isolators are fitted in the nitrogen conditioning panels, and can be operated only when the panel cover is open. A typical isolator is shown below. In other cases, isolators are fitted to the outside of machine enclosures, enabling them to be operated without special access.
The specific locations of the system nitrogen valves are shown below.
Nitrogen isolator locations
2.10.6 Interlocked doors and panels All opening doors, and various access panels in the machine enclosures are fitted with electronically-operated interlocks. These prevent the doors and panels from being opened until the machines have been stopped and the gas extracted from the gassing enclosures. Machines cannot be started when any of these doors or panels are open. When any interlocked door or panel is open, its status and location are shown on the operator control station OVERVIEW screen (page 4-6).
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2.10.7 Fixed covers Fixed covers are fitted in various locations, such around the around the bases of the filler and other system machines, and on electrical and pneumatic control panels. A special key is required to open these panels. These panels: . must be opened ONLY by trained personnel. . must NOT be opened while the machines are running. . must NOT be opened before the relevant power, air or vacuum supplies have been isolated. . MUST be replaced before starting the machines.
2.11 End of life treatment Please contact PLF International (page 1-2) to discuss disposal options.
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C H A P T E R 3 3 System overview
3.1 System functions The Powder Filling System is configured for filling plastic tubs with food powders and sealing them in a modified atmosphere packaging (MAP) environment. The system provides the facilities required to:
. receive prepared plastic tubs from upstream equipment
. receive product powder into pre-gassing feed hoppers
. control powder flow from the hoppers into the powder filling machine
. create and monitor the modified atmosphere environment (nitrogen gassing)
. accurately fill and check-weigh plastic tubs
. apply foil seals to the plastic tubs
. automatically eject under-weight plastic tubs from the production line
. recycle product powder from underweight containers
The following sections show the overall layout of the filling line equipment and provide brief descriptions of the individual machine and system functions. Please refer to the relevant documentation for details of each system.
3.2 Line layout
1 Infeed conveyor 2 Powder filler 3 Operator control station 4 Checkweigher
5 Checkweigher control panel 6 Seal press 7 Seal conveyor 8 Sealer 9 Outfeed conveyor 10 Reject station 11 Reject holding conveyor 12 Recycle bin 13 Gas extraction system
3-1 CCE-07ND-Gateway Filler System overview
3.3 Production process This section gives brief descriptions of each stage of the filling process covered by this manual. For information on any other part of the production line, refer to the relevant manufacturer's documentation.
3.3.1 Infeed conveyor The infeed conveyor transports prepared containers from upstream equipment on the filling line and delivers them to the infeed scroll of the powder filler. The conveyor is fitted with a minimum queue sensor (page 3-5) as part of the overall line control system.
3.3.2 Powder filling The filler machine takes empty containers in a continuous stream from the infeed and passes them to multiple filling stations on a rotating turret. The containers are filled with a precise weight of product powder as they pass through the machine, and are then transferred to the machine outfeed. The individual filling stations are continually adjusted by the line control system to ensure consistent filling accuracy throughout the production run. The filler machine has an integral powder hopper, which is filled from a factory powder feed system and delivers product powder directly to each of the filling stations. It holds enough product powder to ensure an uninterrupted supply for the continuous filling process. Powder level in the hopper is monitored by sensors and controlled automatically.
3.3.3 Powder hoppers Before entering the filling machine hopper, product powder is held in three external feed hoppers which enable it to be immersed in a nitrogen atmosphere. This improves the shelf-life of the packaged product by minimising oxidation in the containers. The three hoppers are filled from the factory bulk supply, and then feed powder in sequence to the filler hopper. At any time: . one hopper is being filled from the factory supply; . another hopper is full and the contents are being pre-gassed with nitrogen; . the third hopper is emptying pre-gassed powder to the filler hopper. The sequence of filling, gassing and emptying is controlled automatically.
3.3.4 Check weigh Immediately after leaving the filler, containers are individually checked for filling accuracy by an in-line check weigher. The weight values are passed to the line control system which then continually adjusts the filler machine to maintain the correct fill weight.
3.3.5 Container sealing The filled containers are hermetically sealed with aluminium foil caps. The process involves two machines - the cap press and the rotary sealer.
3.3.5.1 Seal press The cap press forms individual container sealing caps from a continuous strip of aluminium foil. The caps are passed via a guide channel to the sealer, where they are applied to the containers.
3.3.5.2 Sealer The sealer receives filled product containers on an infeed conveyor, and pre-formed container caps from the cap press. The caps are applied to the containers by multiple sealing heads on a rotary turret, and are bonded to the containers by an induction-heating process. The sealed containers are then returned to the production line conveyor.
3-2 CCE-07ND-Gateway Filler System overview
3.3.6 Container rejection Containers are ejected from the production line if they are either: . identified by the check weigher as underweight, or; . identified by sensors as they leave the sealer as having missing or mis-aligned seals The information from the check weigher or sensors allows these containers to be tracked by the line control system and to be diverted onto a reject conveyor by an ejector system. Rejected containers are held temporarily on the reject conveyor for reprocessing. A sensor (page 3-5) is mounted on the reject conveyor to detect when it is full.
Powder recovery Product powder from rejected underweight containers is emptied manually into a powder recycle bin. From here it is returned by a vacuum system to the filler hopper for re-use.
3.3.7 Code printing The system is equipped with two ink jet printers with remote print heads located near the outfeed conveyor from the sealer. The two printers print duplicate information so that containers continue to be correctly coded in the event of one printer failure. The containers are printed with two items of information: . Every container leaving the sealer rotor is marked with the number of the relevant sealer head. This helps with finding the cause of any poorly-sealed containers. . Any container leaving the sealer with a missing or mis-aligned foil seal is marked with the sealer head number and the letter R to indicate 'reject'. These containers are automatically diverted onto the reject conveyor.
3.3.8 Gassing The purpose of the gassing system is to ensure maximum shelf-life of the final packed product by reducing exposure of the product powder to atmospheric oxygen during and after the filling process. This is achieved by: 1 saturating the product powder in the product feed hoppers with nitrogen 2 flooding the sections of the filling line carrying filled but un-sealed containers with nitrogen The area covered by the gassing system is protected by guarding enclosures with interlocked gas-tight access doors. A gas-monitoring and safety system prevents the area from being gassed until all doors are closed and sealed. It then prevents doors from being opened unless the gassing system is shut down and concentration of gas in the enclosed areas is reduced by extractors to a safe level. When required, the gassed area is cleared of gas by an extraction system. This can be started manually from the filler control station, or automatically in the event of a leak or other error.
3-3 CCE-07ND-Gateway Filler System overview
Gassed areas The gassed areas are shown in yellow below. They comprise: . Powder filler 1, sealer 2 and connecting enclosures . Feed hoppers 3 located on Level 4500
3.4 Production control The filling system has two principal means of production control: . machine recipes that define the setup of machines for any given production run. . line sensors that monitor container flow on the line, and automatically start and stop machines.
3.4.1 Machine recipes A recipe is a pre-defined set of instructions for a particular type of production run. The system can be programmed with a number of recipes for selection on the filler control station as required. The creation and use of recipes is fully described in the Operation section of this manual (page 4-22).
3.4.2 Line sensors Sensors are positioned at appropriate points on the line to control individual machines and conveyor sections. Understanding the effects of the sensors is useful for identifying and clearing the causes of any filler line problems. Brief descriptions of their functions is given below.
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Line control sensor locations
No. Sensor ID Name/Function 1 PEC03201 Minimum Queue : Inhibits or stops the machine unless there enough containers at the infeed to cover this sensor. Provided the machine has been set to start by the operator, it will start, or re-start, automatically when the sensor detects containers present. 2 PROX03106 Container present in starwheel : Detects individual containers missing from the starwheel, and prevents the filler from attempting to fill the missing container. No operator action is needed. 3 PROX10402 Sealer head position : Detects the leading edge of each container to increment the head number printed by the code printer.
4 PROX10401 Sealer head 1 pulse : Sends a signal to the control system when head 1 passes this position. This enables the correct head number to be printed (page 3-3) on each container as it leaves the machine. 5 See Fords Sealer Container present at sealer infeed : Checks for a container in each manual pocket of the sealer infeed starwheel. If any container is missing, the relevant sealer head is inhibited.
6 See Fords Sealer Seal missing : Checks for missing seals on incoming containers. manual When a container is detected without a seal: . the relevant sealer head is inhibited. . the code printer is triggered to mark the container with a reject code. . the container is diverted onto the reject conveyor. 7 PEC040A02 Seal alignment sensors : This is an array of six fibre-optic sensors on to PEC040A07 a single plate mounted above the sealer outfeed. They identify containers with mis-aligned seals so that they can be ejected from the production line. The sensors are arranged around the outside edge of the correct seal position to detect mis-aligned seals.
8 PEC02701 First gate sensor : Provides an accurate position reference for reject containers, enabling the reject unit to operate at the correct time, and also for triggering the code printers.
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9 PEC00301 Second gate sensor : Confirms the position of reject containers just before the reject unit. Also buildback from reject
10 PEC00302 Reject confirmation : Checks that reject containers have actually left the production line. If not, the system goes into an amber warning state and the line is stopped. It must be restarted manually after the reject container has been removed. 11 PEC03203 Reject conveyor full : When containers build back to this sensor, the filler and sealer ramp down, and then stop completely after a configurable time delay if containers are not removed from the reject conveyor. 12 PEC03202 Buildback : Detects a build-back of containers resulting from downstream delays (e.g. a stopped machine). It stops the filler and sealer to prevent additional build-back. The machines return automatically to normal speed when the build-back is eliminated.
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C H A P T E R 4 4 Operation
This section provides instructions for actions required to operate the powder filling system covered by this manual (page 1-1). For information on operating any equipment used in the production process which is outside of the scope of this manual, please refer to the appropriate equipment documentation.
Caution: The information here is not intended as a substitute for proper operator training. Procedures in this section assume that the operator has received appropriate training.
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4.1 Control Station Overview
4.1.1 Controls and indicators Before operating the system, you should familiarise yourself with the control station functions.
Control Function 1 Touch screen Displays system status and information, and provides touch-sensitive machine controls. 2 GASSING This key-switch enables or disables the gassing system. (page 4-21) ON/OFF 3 GAS EXTRACT Stops the filler (if running) and starts the gas extraction system to remove gas from one or more zones. 4 JOG When Jog mode is selected on the touch screen, the filler can be run slowly by pressing and holding the Jog button. (page 4-15) 5 START Starts the system running normally, provided it is in a condition to do so - i.e. there are no error conditions, containers are present, etc. (page 4-14) 6 STOP Stops the system from the running condition. (page 4-14) 7 RESET This button flashes when there is a current system error. After rectifying the condition that caused the error, pressing this button will clear the error and allow the system to be restarted.
8 EMERGENCY Immediately stops the filler system and conveyors. (page 4-15) STOP
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4.1.2 Status beacons The three-colour beacon towers mounted above machine control stations provide indications and warnings of the machine status.
Indicator Indicates Red A fault condition is present and the associated machine is stopped. Amber The associated machine is stopped temporarily in response to an operating condition that will normally clear automatically, such as shortage of containers or a container build-back. Green The machine is running normally. Audible sounder Not used
4.1.3 Powering up 1 Before applying power to the filler and any associated conveyors or machines, take the following precautions. . Ensure all personnel are clear. . Ensure all doors and guards are closed. 2 Set all system power isolators to ON (page 2-4).
There is normally a master isolator on the front of the main electrical control panel, and individual isolators on the filler, conveyors and any associated machines. When the power to the filler is on, the system will perform a number of self-checks and display relevant messages on the filler control station screen. A Startup screen similar to the following will then be displayed, showing the specific machine number.
3 Touch anywhere on the screen to display the OVERVIEW screen (page 4-5).
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4.1.4 Logging on The operator control station has a number of password-controlled permission levels.
. Default . Operator . Supervisor . Administrator When the system is first powered up, or the control station has been idle for some time, the permission level is automatically set to Default. This allows access to all screens except those shown below.
To access these screens, you need to log on with at least the indicated minimum permission level.
Screen Minimum required permission level SELECT RECIPE Operator ENTER RECIPE Supervisor SETTINGS Administrator
Logging On A Log on window and touch-screen keypad will automatically appear when you attempt to select a restricted screen.
If you do not know the appropriate user name and/or password, refer to your system administrator. 1 Touch the User and Password fields in turn and use the keypad to enter your user name and password. 2 Touch OK. Note: After logging on, the system will remain in your permission level as long as the restricted screen remains displayed, even if there is no control panel activity. If you want it to return to the default level, select any unrestricted screen. The permission level will then return to Default if the control panel is idle for a short period.
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4.1.5 Overview screen The OVERVIEW screen is the main working screen for monitoring and operating the filler system. It provides a comprehensive real-time view of the system status, using colours to show which components are running, paused or stopped. It also shows error messages and alarm conditions to enable you to take appropriate actions, when necessary. The screen also contains buttons for performing specific functions, and for selecting other operating and monitoring screens.
Note: On systems where the filler control station interacts with equipment on other parts of the filling line, there may be an associated Line Overview screen to provide relevant status information. In these cases, a description of the Line Overview screen will be included in the main Screen Descriptions section. (page 4-27)
1. Screen title Identifies the displayed screen, corresponding to the currently-selected Menu button. 2. Status diagram This shows a representation of the system machines and conveyors, and uses colours and icons to show the running status of the system components. (page 4-6) 3. Function buttons Each button initiates an immediate system action, such as starting or stopping the conveyors. (page 4-9) 4. Navigation bar This is displayed on all screens enabling selection of any required screen. (page 4-12) 5. Notifications Notifications are messages that appear giving information about self-clearing conditions, such as lack of containers at the filler infeed. These do not generally require any operator action. Notifications are highlighted in yellow. 6. Warnings Warnings are messages that appear giving information about conditions that stop the system and require some operator action, such as open guard doors or activated emergency stops. Warnings are highlighted in red. 7. Alarm banner This appears on most screens and lists current alarms. Alarms are caused by various machine fault conditions such as a jammed starwheel or a lift table fault.
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8. Vacuum status These fields show the current system vacuum levels, which are essential to the accuracy of the powder filling process. (page 4-12) As a general rule, numeric fields with yellow background are for information only. They do not allow the values to be changed. 9. Filler speed Shows the current speed of the filler, in containers per minute. The speed can be changed by touching the SPEED field. (page 4-12) As a general rule, numeric fields with a blue background allow the value to be changed. 10. Fill weight This shows the actual weight of product in each container, as measured by the check weigher. (page 4-13)
4.1.5.1 Status diagram The status diagram is a simplified outline of the filler system equipment and conveyors, as viewed from above.
1. Filling machine 2. Seal press 3. Sealer 4. Top-up station 5. Conveyor 6. Scroll 7. Starwheel 8. Filler rotor 9. Checkweigher The status diagram allows you to see immediately: . which parts of the system are running normally . which parts, if any, are paused or stopped . the conditions causing any machine pause or stop The individual status indications work as described in the following sections.
Note: the following illustrations are to show principles only and may not match your system.
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4.1.5.1.1 Machines and conveyors Colours are used to indicate the status of the machine parts and conveyors.
Green When the system is running normally, all parts are shown in green.
Yellow Any part of the system that is shown in yellow has been stopped by a non-fault error condition. An icon and/or messages will indicate the cause of the error and any action required to re-start the system. For example, this shows the filler is stopped because there are no containers at the infeed. When containers arrive, the filler will re-start automatically.
This shows the filler stopped because a guard door is open. The messages indicate that a manual reset and machine start are required after the door been closed.
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Red Any part of the system that is shown in red has been stopped by a fault condition. One or more alarm messages will indicate the fault and any action required to re-start. For example, this shows the outfeed starwheel in fault condition - probably due to a jammed container. The messages identify the fault, and indicate that a manual reset and machine start are required after the fault has been cleared.
4.1.5.1.2 Icons The following icons are used to indicate error conditions on the status diagram.
Guard door open Open guard doors are shown as a diagonal red line.
Filler hopper lid open Open hopper lids are shown as red sections on the filler top.
Emergency stop active Active emergency stops are shown as a yellow circle with a red centre. The position of the indicator on the status diagram shows the location of the active emergency stop.
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4.1.5.2 Function buttons Function buttons are arranged down the left-hand side of the OVERVIEW screen. All buttons have a toggle action. Touching a button repeatedly cycles through all of its states. The button backgrounds change to indicate their current state. Details of the individual buttons are given below.
4.1.5.2.1 Stop Vacuum The STOP VACUUM button is used to stop the vacuum pump during production - typically to allow cleaning and maintenance operations on the central vacuum system, such as emptying the powder receiver jar (page 5-12). The button has four states:
State Colour Meaning RUNNING Green Pump running normally
STOPPED Yellow Pump has been stopped using this button STARTING Yellow Pump has been started but vacuum has not reached working level
FAULT Red A pump fault has occurred. The specific fault is shown on the fault alarm banner and the alarm list (page 4-17)
Stopping the pump Selecting the STOP VACUUM function immediately stops the vacuum pump. The button background will change to yellow while the pump is stopped. If the filler is running, it will continue until the vacuum level falls too low for correct filling and then stop automatically.
Starting the pump To re-start the vacuum pump it is necessary to press the green START button below the touch screen. The pump will start immediately, but the filling machine will not start until the vacuum pump has been running long enough to establish the correct system vacuum levels. During this period the message VACUUM PUMP STARTING is displayed in the message banner at the top of the Overview screen.
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4.1.5.2.2 Powder Feed The function of the POWDER FEED is to stop or start the powder feed into the filler hopper. It is typically used when you want to empty the filler completely of product powder for cleaning, maintenance or product change. The button has two states:
State Colour Meaning AUTO Green Powder feed is in the normal production mode. It will stop and start automatically under control of the powder level sensors. OFF Yellow Powder feed to the hoppers is stopped. The low powder sensor is overridden, allowing the filler to continue running, if required.
After emptying the hopper, it is necessary to prime the hopper and nozzles (page 4-17).
4.1.5.2.3 Conveyors When the filler is stopped by pressing the STOP pushbutton the filler conveyors and check weigher continue to run. They can be stopped when required by selecting the CONVEYORS function button. The button has two states:
State Colour Meaning AUTO Green Conveyors running normally. They will stop and start automatically under control of the line sensors. OFF Yellow The conveyors have been stopped using this button.
The conveyors and check weigher will restart if the filler START button is pressed.
4.1.5.2.4 Containers The CONTAINERS function button is generally used to remove all containers from the filler. The button has two states:
State Colour Meaning AUTO Green Container flow into the filler is in normal running mode. As long as there are containers on the infeed, they will enter the machine. OFF Yellow A container-stop mechanism on the infeed conveyor is activated to stop the flow of containers into the filler.
Provided there are containers on the infeed conveyor to cover the minimum queue sensor (page 3-4), the filler and conveyors will continue to run. Any containers already in the filler or the infeed scroll will be filled normally. Powder filling will be inhibited as the containers are emptied from the machine.
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4.1.5.2.5 Empty Containers Normally, the filler will stop as soon as there are not enough containers on the infeed conveyor to cover the minimum queue sensor. (page 3-4) This means that the filler will not process the last few containers on the infeed or those already on the lift tables. The EMPTY CONTAINERS function is typically used at the end of a production run to fill all remaining containers on the line. The button has two states:
State Colour Meaning ON Green The minimum queue sensor is overridden. The filler will continue to run and fill containers even when the infeed is empty. As the filler runs out of containers, it will continue running but the powder filling is inhibited.
OFF Yellow This is normal production mode. The filler will stop and start according to the supply of containers, under control of the minimum queue sensor.
4.1.5.2.6 Reset lifts After applying power to the filler, the machine cannot be run until the lift tables are reset to a known position using the RESET LIFTS button. Until this is done a LIFTS NOT RESET warning message is displayed on the overview screen and you will not be able to start the filler. The button has three states:
State Colour Meaning Not active No Lifts positions are either currently known or in the process of resetting. See Resetting background below.
Error Red Not possible to reset the lifts. See below.
When the RESET LIFTS button is pressed, the message LIFTS RESETTING is displayed on the screen until the process is complete. If the lifts cannot be reset an appropriate message is displayed below the RESET LIFTS button, highlighted in red. The lifts cannot be reset if one or more of the following conditions is present. . Emergency stop pressed. . Guard open. . Low air pressure. . Filler running. The lifts can also be reset from the SELECT RECIPE and ENTER RECIPE screens.
4.1.5.2.7 Base light This simply switches working lights in the base of the filler on or off.
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4.1.5.3 Navigation bar The navigation bar is displayed along the bottom of all screens, enabling selection of any required screen.
Where a selected button accesses more than one display, a secondary navigation bar is displayed.
If you select a screen with restricted user access, you will be required to logon as a user with appropriate permissions before the screen will be displayed. (page 4-4)
The alarm banner is displayed on a number of screens, including the OVERVIEW. It lists all current alarms that have not yet been acknowledged and cleared.
For further information, refer to Responding to alarms. (page 4-17)
4.1.5.4 Vacuum status These fields show the current vacuum levels in the three vacuum systems that are essential to the accurate operation of the filler. They are for information only and cannot be adjusted from the OVERVIEW screen.
Value Adjustment FILL VACUUM These are the values set in the currently-selected recipe. CLAMP VACUUM There should be almost no fluctuation in these values during production. HIGH VACUUM This is the un-regulated vacuum created by the vacuum pump. It cannot be changed.
4.1.5.5 Filler speed This shows the current speed of the filler machine in containers per minute (CPM). The speed is set in the product recipe, but it can be adjusted here by touching the field and using the displayed keypad.
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4.1.5.6 Fill weight This shows the actual weight of product in each container, as measured by the check weigher. (page 4-13)
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C H A P T E R 5
4.2 Operation
4.2.1 Preparing the system to run The exact procedure for preparing any filling line to run product will depend on the overall configuration of the line and the machines involved. The following provides a general checklist of actions which should be adapted as necessary. 1 Clear the line of any previous containers and product powder. . Empty the filler hopper (page 4-16). . Clear all containers from the filler (page 4-16). . Remove all containers from the other machines and conveyors. 2 If you are running a different sized container, fit the appropriate change parts. Refer to the filler main manual for information. 3 Check that all machine guard doors are closed and all emergency stop buttons are released. 4 Power up the filler and other machines. 5 Select the correct product recipe on the filler control station. 6 Press the RESET LIFTS button on the OVERVIEW screen to reset the lift tables (page 4-16). 7 Load the correct containers onto the filling line. 8 Before starting any machines or conveyors, perform safety checks (page 2-3). 9 Prime the filler hopper (page 4-17). The system is now ready to run.
4.2.2 Starting and stopping the system
Starting 1 If the system includes gassed (modified atmosphere) areas, start the gassing system (page 4-21). 2 Start all machines on the filling line other than the filler according to their manufacturers' instructions. 3 If there are any error or fault messages (e.g. NO CONTAINERS, NO POWDER, GUARD OPEN, etc.) displayed on the filler control station OVERVIEW screen, correct the associated condition. 4 Press the green START button. Note: If the system includes gassing, the START button will flash and the filler will not start until the gassing of the enclosures reaches the correct level for production. At this point the filler will start automatically.
Stopping normally . Press the red STOP button on the control station. If the system includes gassing, it must be degassed before any guard doors can be opened.
Stopping in an emergency . Press any Emergency Stop button. Caution: Do not use emergency stop buttons except in an emergency (page 4-15).
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4.2.3 Using emergency stops Emergency stops (e-stops) are fitted on the filler control station and at various points on the system. (page 2-4) Pressing any e-stop will immediately stop the filler system and associated conveyors.
Caution: Emergency stop buttons should be used ONLY in the case of an emergency. The emergency stop procedure causes stress to machine drive components and must not be used routinely for stopping the system.
When an emergency stop is active, the following indications are shown on the control station OVERVIEW screen:
Shows the location of the active e-stop.
Provides an e-stop warning. ESTOP PRESSED
Indicates that a reset is required before the system will start. RESET REQUIRED
Button is lit to show that it must be pressed before the system will RESET start.
To stop the system in an emergency . Press any emergency stop button.
To restart after an emergency stop 1 Rotate the e-stop button in either direction to release it. 2 Press the blue RESET button. 3 Press the START button.
4.2.4 Jogging the filler Whenever you need to run the filler very slowly or in small increments, use the Jog facility.
Note: The full system safety conditions apply when using Jog. It will operate only when all interlocked guard doors and panels are closed.
Black JOG buttons are normally fitted: . Below the touch screen on the operator control station . On one or more sides of the filler enclosure . On the top of the filler
JOG
To use Jog: 1 If necessary, press the STOP button to stop the system. 2 Where relevant, de-gas the system. 3 On any screen, select DIAG/JOG on the navigation bar, and then JOG on the secondary bar. The screen will display a large JOG SELECTED banner. 4 Use any JOG button: . Press and hold to run the machine slowly. . Press repeatedly to move the machine in small increments.
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5 When you have finished with Jog mode, select any other screen to cancel it.
4.2.5 Resetting lift tables After applying power to the filler, the machine cannot be run until the lift tables are reset to a known position. Until this is done a LIFTS NOT RESET warning message is displayed on the overview screen and you will not be able to start the filler. 1 Power up the filler and display the OVERVIEW screen. 2 If the RESET LIFTS button has a red background with the message NOT POSSIBLE, check: . that all emergency stops are released. . that all guard doors are closed. . that the compressed air supply pressure to the filler is adequate (typically around 6 bar as shown on the air conditioning panel). 3 Touch the RESET LIFTS button. The message LIFTS RESETTING is displayed on the screen until the process is complete.
Note: The lifts can also be reset from the SELECT RECIPE and ENTER RECIPE screens.
4.2.6 Emptying the filler hopper This procedure required the filling system to be capable of running normally, i.e. with all doors closed, gassing on (where relevant), no error conditions, etc. 1 Ensure that there is a supply of containers to the filler infeed. 2 On the control station OVERVIEW screen, touch the POWDER FEED button. The button should be highlighted in yellow. In this condition no powder is fed into the filler hopper but the low powder sensors are ignored so that the machine can continue running and filling containers. 3 Run the filler until the hopper and filler nozzles are essentially empty. 4 Stop the filler and de-gas the system, where relevant. Any remaining powder can now be removed from the hopper by vacuum suction or other means. The hopper must be primed (page 4-17) before the filler will run.
4.2.7 Clearing containers The procedures below can be used to empty containers from the filler only, or from the filler and infeed conveyors.
Clearing the filler only 1 Run the machine normally. 2 On the OVERVIEW SCREEN, set the CONTAINERS button to OFF (yellow). A container-stop mechanism on the infeed conveyor is activated to stop the flow of containers into the filler. Provided there are containers on the infeed conveyor to cover the minimum queue sensor (page 3-4), the filler and conveyors will continue to run. Any containers already in the filler or the infeed scroll will be filled normally. Powder filling will be inhibited as the containers are emptied from the machine.
Clearing the filler and infeed 1 Run the machine normally. 2 On the OVERVIEW SCREEN, set the CONTAINERS button to AUTO (green) 3 Set the EMPTY CONTAINERS button to ON (green). The filler will continue to run and fill containers even when the infeed is empty. As the filler runs out of containers, it will continue running but the powder filling is inhibited.
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4.2.8 Priming the filler hopper Priming is the process of filling the filler hopper and nozzles with product powder, usually after the machine has been emptied for product change and/or cleaning. The filler will not run normally until priming is complete because the powder level sensors will indicate a low- or no-powder condition.
1 Fit the supplied nozzle bungs to all nozzles. 2 Check that the powder supply to the filler hopper is on. 3 Remove any containers from the filler infeed scroll and starwheel, and prevent further containers from reaching infeed. For example: . If there are CONTAINER and EMPTY CONTAINERS buttons on the control station, select both buttons. or: . Stop the machine immediately upstream from the filler, and cover the minimum queue sensor on the filler infeed conveyor. This will allow the filler to run without containers. 4 Close all machine guard doors. 5 If relevant, gas the system (page 4-20). 6 Press START. The filler will run for a short time and then stop, with a message showing LOW POWDER 7 Repeat the last step until the LOW POWDER message stops appearing and the filler continues to run. 8 Stop the filler, and de-gas it if necessary. 9 Remove the nozzle bungs. 10 Cancel the actions taken in step 3. The filler can now be started and run normally.
4.2.9 Responding to alarms When a filler system fault occurs, an alarm is generated which results in several indications on the operator control station: . A red alarm message is displayed as an immediate notification of the condition. . A description of the latest alarm is added to the alarm banner displayed above the navigation buttons on most screens. . The same description is added to an active alarm list, viewable on the ALARM screen. . The ALARMS button on the navigation bar flashes red on and off. In addition, an entry is made in a permanent alarm log. Most alarm conditions will stop the system, and so must be cleared before production can continue. The general procedure is: 1 Using the description shown in the alarm banner or on the ALARMS screen, identify the cause of the condition and rectify it. 2 Press the blue RESET button. The alarm is removed from the alarm banner and from the ALARMS screen.
Note: A permanent list of all cleared and uncleared alarms can be viewed by touching the EVENTS button on the ALARMS screen.
4.2.10 Resetting a table up alarm The system constantly checks to make sure the lift tables are in the fully-down position prior to reaching the outfeed of the powder filling. If a lift table stays up for any reason the machine is stopped and a message similar to this is displayed on the OVERVIEW screen.
If this occurs reset the table down fault, as follows. 1 Touch the Table Up Reset Required message.
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This will display a Table Up Reset screen containing a warning message and a table reset button:
CAUTION: Do not press the main Reset button below the touch screen. If you do, you may cause an impact between the lift table and the starwheel, resulting in serious damage. 2 Check whether there is any physical reason for the lift table approaching the outfeed being in the up position - e.g. jammed by a fallen container. If so, remove the obstacle. 3 After clearing any obstacles, touch the RESET TABLE UP button on the screen (shown above). This should drive all lift tables fully down. 4 Check whether all tables are down and do one of the following. . If any tables are not fully down, there is a fault on the machine which must be rectified before it can continue with the production run. In this case, request technical assistance and do not proceed with the following actions. . If all lift tables are down press the RESET button. The machine should re-start. Any containers that are not correctly filled as a result of the error will be rejected. New containers entering the machine should be filled normally. If the machine stops again and displays a Table UP error message, there is a continuing fault. Request technical assistance. 5 Press the Overview button at the bottom of the TABLE UP RESET screen to return to the OVERVIEW screen.
4.2.11 Controlling the powder feed
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4.2.12 Sampling filled containers The SAMPLE facility enables containers to be selectively removed for quality control according to one of several sampling strategies. Sampled containers are diverted from the production conveyor to a holding area.
To sample containers: 1 Touch the SAMPLE button on the navigation bar. 2 Using the information below, choose a sample strategy and initiate sampling. Sample Operation FILLER SAMPLE Diverts all containers filled by a selected filler head to the sample area. (selected head) . Touch the HEAD field and enter the required head number. . Touch START to start sampling, and again to stop sampling. FILLER SAMPLE Diverts either a single container or three consecutive containers from any filler head(s) (random containers) to the sample area.
FILLER CONSECUTIVE Diverts all containers from all filler heads to the sample area. TUBS . Touch START to start sampling, and again to stop sampling. SEALER SAMPLE Diverts all containers processed by a selected sealer head to the sample area. . Touch the HEAD field and enter the required head number. . Touch START to start sampling, and again to stop sampling. SEALER Diverts all containers from all sealer heads to the sample area. CONSECUTIVE TUBS . Touch START to start sampling, and again to stop sampling.
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4.2.13 Gassing operation
4.2.13.1 Gas Overview Screen The GAS OVERVIEW screen shows many of the same elements as the MACHINE OVERVIEW screen (page 4-5) including the status diagram, navigation bar and alarm/warning messages. In addition, it provides indications of the gassing status in each of the gassing zones and individual gassed areas of the system.
Gas indicators
2 1 FILLER 3 O2 00.0 % START 4 NOT SAFE 5
1. Sample point Indicates the location of the gas sample point. 2. Gas type Identifies the specific gas monitored at this point. Note: On some systems, there may be more than one gas type field, showing oxygen and carbon dioxide, for example. 3. Concentration Shows the current concentration of the monitored gas as a percentage of the total sample. This is updated continuously by the associated gas analyser. 4. Filler start/stop When the monitored gas is at its working concentration, this shows START to indicate that the filler is either running or can be started. START When the gas concentration is outside the working limits, the indicator changes to STOP STOP, showing that the filler has been stopped.
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5. Safety status When gas has been extracted from the gassing enclosure and the atmosphere at the sampling point is safe to breathe, this shows SAFE. In this state, the SAFE enclosure doors seals are released. Provided the machine is stopped, the doors NOT SAFE may be opened. When the atmosphere is not safe to breathe, the indicator changes to NOT SAFE. In this state, the enclosure doors are sealed and locked.
4.2.13.2 Gassing the system This procedure assumes that the gassing system has been stopped and all gas extracted. 1 Select the GAS OVERVIEW button. 2 On the GAS OVERVIEW screen, check for any open door indicators.
If any open doors are indicated, close them securely. 3 If the gassing area is divided into zones, open all sluice gates to allow full circulation of the gas. The gates are shown on the status diagram.
Yellow = closed; Green = open. 4 Press the blue RESET button. The button should stop flashing, and the RESET REQUIRED indicator on the screen should be removed. 5 Set the GASSING OFF/ON keyswitch to ON. The gassing enclosure doors will be locked and sealed, and the gassing system will then start. 6 Observe the gas status indicators. FILLER O2 20.1 % STOP SAFE
Within a short period, the gas concentration readings will move towards their operating levels, and the SAFE indicator will change to NOT SAFE. When the concentrations reach their operating levels, the STOP indicators will change to START. At this point, the filling line may be started for normal production.
4.2.13.3 Degassing the system - 1954 specific 1 Stop the filling line. 2 On the filler control station, press the yellow GAS EXTRACT button below the touch screen. Note: This action will stop the filling line if it is not already stopped. The gassing system will be stopped and the gas extraction system started. 3 Observe the gas status indicators on the GAS OVERVIEW screen. When the extraction is complete the gas indicators (page 4-20) change from to
In this condition, the gassing area is safe to enter and the doors in all zones will be released. 4 Set the GASSING OFF/ON keyswitch on the filler control station to OFF.
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4.2.14 Working with recipes Recipes are stored and named sets of parameters that define the filler setup for running any particular product. They specify the required filler speed (containers per minute), the container dimensions, product target fill weight, and a range of associated machine settings. Recipes are created and stored using the filler operator control station. Once they have been created, they can be recalled and loaded at any time to re-apply the defined setup for another production run. Access to the screens used to create and load recipes may be controlled by user permissions. If these have been activated, you will need to know the relevant user names and passwords to use the screens.
4.2.14.1 Creating and editing recipes
When the screen is selected, it will display the parameters of the currently loaded recipe.
Note: you cannot create a new recipe by recalling and modifying an existing one, and then saving it under a new name and number.
To enter a new recipe: 1 Touch ENTER RECIPE on the Navigation Bar to display the ENTER RECIPE screen. 2 Use the down arrow in the PRODUCT CODE LIST to scroll to a blank entry. 3 Touch the blank product code field and use the keyboard mimic to enter the required recipe code/name. 4 Touch each of the blue fields under FILLER SELECTED RECIPE in turn and use the displayed keypad to enter the required values. Use the information below to determine the appropriate values. 5 Touch SAVE. To modify an existing recipe: 1 Display the ENTER RECIPE screen. 2 Use the up and/or down arrows to select the recipe you wish to modify. 3 Touch any of the blue fields in the FILLER SELECTED RECIPE section and use the displayed keypad to enter new values. 4 Touch SAVE. If you want to use the new or modified recipe for a production run, use the SELECT RECIPE screen (page 4-31) to recall it as the current recipe.
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4.2.14.1.1 Recipe parameters
Parameter Function Range Product code An alphanumeric recipe name. Up to XX alphanumeric characters FILLER SPEED Use this to set the required number of containers to be 10 to 120 CPM filled per minute. This will set the running speed of the (containers per filler. minute) TARGET WEIGHT Enter the required product fill weight. 0 to 999.9g For average-weight filling, set for the declared final weight. For minimum-weight filling, use a starting figure of about 2% over the declared final weight. CONTAINER HEIGHT Enter the container height. 1 to 9999.9mm CORRECTION RANGE Sets the upper and lower limits of fill weight adjustment. 0 - 999.9 This is used to prevent the filler from attempting to adjust for major weight errors resulting from abnormalities such as damaged containers or a blocked nozzle. Example: TARGET WEIGHT 200g; CORRECTION RANGE 50g. The filler will correct for containers weighing only between 150g and 250g. Any containers outside this will be ignored and the message ‘OUT’ will be displayed against the relevant head on the HEAD DATA screen. Note: If OUT is shown for all heads on the HEAD DATA screen, check the START LIFT HEIGHT value (see below). CORRECTION Sets the minimum deviation from the target weight for 0 to 9.9 DEADBAND which the filler will attempt a correction. If the deviation is less than the dead band value, no adjustment is made. CORRECTION GAIN This sets the size of each fill-weight adjustment as a 0 to 100% proportion of the measured error. For example if a filled container is measured as 10g underweight and the CORRECTION GAIN value is 50% the relevant head is adjusted by 5g on the next fill. If the correction gain is set too low, fill weight errors will take a relatively long time to correct. If it is set to high the system may over-correct, causing the fill weight to oscillate either side of the target. A value of 20-30% is normally appropriate. FILL VACUUM Sets the filling vacuum level. Around 12mbar is a good mbar starting point. This should be adjusted, in combination with VACUUM ON TIME, up to a maximum of 20mbar to produce a complete and compact fill. VACUUM ON TIME Sets the on-time duration of the fill vacuum when a 0 to 9.9s container is being filled. This should be adjusted, in combination with FILL VACUUM, to produce a complete and compact fill. Typical values for two container sizes: 400g, 1s; 900g, 1.5s Note: The initial values for vacuum level and vacuum on time are normally determined by practical tests with each specified product powder during system test and commissioning. These may need to be repeated for any new product powder. Please contact PLF International for assistance, if necessary. START LIFT HEIGHT This sets an initial amount by which lift tables are raised. 0 to 260mm See About lift heights (page 4-24) for more information.
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MAXIMUM LIFT HEIGHT The MAXIMUM LIFT HEIGHT setting prevents the 0 to 260mm automatic lift height adjustment from attempting to raise the nozzle clamp beyond its physical limit. See About lift heights (page 4-24) for more information.
MINIMUM LIFT HEIGHT The MINIMUM LIFT HEIGHT setting prevents the 0 to 260mm automatic lift height adjustment from attempting to lower the lift table too far for proper contact between container and the nozzle vacuum seal. See About lift heights (page 4-24) for more information.
4.2.14.1.2 About lift heights The term 'lift height' refers to the amount by which the product container tables are raised during the filling process. Each recipe contains adjustable settings for three important lift height values: . START LIFT HEIGHT . MINIMUM LIFT HEIGHT . MAXIMUM LIFT HEIGHT These settings must be determined individually for each particular combination of filler nozzle, container size and product powder that is used on the machine. The general processes are described below.
START LIFT HEIGHT The amount of product powder placed in each container is controlled by the height to which the container is lifted during the filling process. The START LIFT HEIGHT is calculated as a starting point to give an approximately correct fill at the start of a production run. The filled containers are then weighed as they leave the filler, and the filler control system automatically adjusts the lift heights from the starting value until the correct fill weight is reached. This automatic adjustment continues throughout the production run. If the START LIFT HEIGHT is close to the correct running value, the correct fill weight will be reached quickly at the start of the run. General calculation procedure:
1 Estimate the ullage (a) for a correctly-filled container. 2 With a container on a lift table, measure the gap (b) between the top edge of the container and the face of the nozzle container seal. 3 Add the estimated ullage to this measurement (a+b). Use this as the initial START LIFT HEIGHT value. b After the machine has run a number of containers a using the calculated start lift height value, the system will have adjusted the actual lift heights to achieve the correct fill weight. The average adjusted height is displayed on the LIFT HEIGHT screen (page 4-30).
4 When the AVERAGE LIFT HEIGHT has stabilised, touch the SAVE START LIFT HEIGHT button. This will save the displayed average as a new START LIFT HEIGHT value in the recipe.
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MINIMUM LIFT HEIGHT Containers must be lifted high enough during the filling process to press against the nozzle container seal. Otherwise, a vacuum cannot be formed in the container, and this will stop it from being filled correctly. The MINIMUM LIFT HEIGHT setting prevents the automatic lift height adjustment from attempting to lower the lift table too far for proper contact between container and the seal. If the system tries to lower the lift table below the minimum lift height value, the message 'DOWN' will be displayed against the relevant head on the HEAD DATA screen. General calculation procedure:
1 Place a container on a lift table. 2 Measure the gap (b) between the top edge of the container and the face of the nozzle container seal. 3 Add 5mm to this measurement. Use this as the initial MINIMUM LIFT HEIGHT value.
b a
MAXIMUM LIFT HEIGHT The nozzle clamp (1) slides up the body of the nozzle as the container is raised by the lift table. The MAXIMUM LIFT HEIGHT setting prevents the automatic lift height adjustment from attempting to push the clamp beyond its physical limit. If the system tries to raise the lift table above the maximum lift height value, the message 'UP' will be displayed against the relevant head on the HEAD DATA screen.
Note: If the maximum height setting is wrong and the nozzle clamp is pushed to its physical stop, this will not cause any damage to the machine.
General calculation procedure:
1 Place a container on a lift table. 1 2 Measure the gap (a) between the top edge of the container and the face of the nozzle container seal.
On most nozzles, the clamp has a movement b range (b) of 65mm. If necessary, raise the clamp to its top limit and measure the range. (You may need to remove the vacuum pipe from the rear of a the clamp to achieve this.) 3 Calculate the MAXIMUM LIFT HEIGHT value as: (a + b) - 5mm.
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4.2.14.2 Using stored recipes Previously-stored recipes are recalled and loaded as required for a new production run using the SELECT RECIPE screen.
To select and load a recipe: 1 Display the SELECT RECIPE screen. 2 Do one of the following: . Use the up and/or down arrows in the PRODUCT CODE LIST section to scroll through the stored recipes until the required one is highlighted. . If you know the number of the required recipe, touch the field to the left of the RECALL RECIPE button and then use the keypad mimic to enter the recipe number. 3 Touch RECALL RECIPE. The stored recipe name and settings will be displayed in the FILLER LOAD RECIPE section. 4 If you want to change any settings before using the recipe, touch any of the blue fields and use the displayed keypad to enter new values, then touch LOAD RECIPE. Note: These changes will apply to the current production run only. They will not be saved in the stored recipe. If you want to make permanent changes, use the ENTER RECIPE screen instead. 5 If you want to load the stored the recipe without change, touch LOAD RECIPE. In either case, the recipe will be loaded as the current running recipe, and the settings will be shown in the FILLER RUNNING RECIPE section.
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C H A P T E R 6
4.3 Screen descriptions This section provides system-specific descriptions of all operator control station screens, including the screen functions and parameter fields. Where relevant. references are made to the Operation section for further information on using the screens.
4.3.1 Overview screen The OVERVIEW screen is the main working screen for monitoring and operating the filler system. Please refer to the Control Station Overview section (page 4-5) for a detailed description.
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4.3.2 Gas Overview screen The GAS OVERVIEW screen shows the status of the gassing (modified atmosphere) system. Please refer to the Gassing Operation section (page 4-20) for a detailed description.
4.3.3 Gas calibration screen For calibration, it is necessary to apply a calibration gas source to the gas analyser inputs in place of the normal zone sampling input. This screen is used to switch individual analyser inputs to the relevant calibration sources.
Only one analyser at a time can be set for calibration.
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4.3.4 Head data screens The HEAD DATA screen provides real-time filling weight values for each individual filling head. The screen is for information only. You cannot adjust any of the displayed values.
Where the system includes a PLF automatic topup unit, there are two head data screens. . HEAD DATA : INTERMEDIATE displays the filling weights measured by the intermediate check weigher before top-up. . HEAD DATA : FINAL displays the filling weights measured by the final check weigher after top-up. For each filler head, the screen shows:
Field Function Net Wt g The actual weight of product in each container, as measured by the check weigher. Av Wt g The average product weight, calculated over the last eight weights from each head. S Dev g The standard deviation from the target fill weight, calculated over the last eight weights from each head. The red message field for each head is used to indicate when the lift table reaches limits set in the current recipe as follows.
Message Meaning
UP The system has tried to move the lift table above the MAXIMUM LIFT HEIGHT value set in the recipe. DOWN The system has tried to move the lift table below the MINIMUM LIFT HEIGHT value set in the recipe. OUT The filled weight of a container is outside the CORRECTION RANGE value set in the recipe.
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4.3.5 Lift height screen The LIFT HEIGHT screen allows the lift table height for the filler heads to be adjusted during a production run to correct the filling weight either for individual heads or all heads.
For each filler head, the screen shows:
Field Function Net Wt g The actual weight of product in each container, as measured by the check weigher immediately after the filler outfeed. Av Wt g The average product weight, calculated over the last eight weights from each head. Lift Height The height of the lift table for each filling operation.
Using manual lift height adjustments The manual adjustment facilities are normally used for one the following purposes. . To reduce time taken to reach the target fill weight at the start of production If the start lift height (page 4-24) set in the recipe is significantly too high or too low, the filler may take some time to reach the target fill weight by automatic lift-height adjustment alone. This can result in a lot of rejected containers at the start of a production run. If this is happening, you can speed up the adjustment by repeatedly pressing the INCREASE WEIGHT or DECREASE WEIGHT buttons while watching the average weight (Av wt g) fields. When the weights have adjusted to the correct values and have been stable for a reasonable period, It is a good idea to touch the SAVE START LIFT HEIGHT button. This will save the current average lift height as a new start value in the recipe, which should speed up the automatic adjustment to target weights on subsequent production runs. . To compensate temporarily for partially blocked nozzles Individual filler heads can occasionally become partially blocked during production, preventing them from achieving the correct fill weight. To avoid having to stop production to clear the head, you may be able compensate temporarily by manually adjusting the associated lift height. To do so, touch the relevant blue Lift Height field and enter a value on the displayed keypad. Bear in mind that this is only a temporary work-around. The blockage may clear spontaneously, in which case you may need to remove your temporary setting. Alternatively, it could get worse to the point where you cannot apply enough compensation.
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4.3.6 Sample screen - 1954 specific This screen is used to sample filled containers from the production line for quality control. (page 4-19)
4.3.7 Select recipe The select recipe screen is used to recall a previously stored recipe and load it for the current production run. Where required, parameters of the recalled recipe can be adjusted before the recipe is finally loaded. (page 4-26)
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4.3.8 Enter recipe screen This screen is used to create and save new product recipes and to modify existing ones. (page 4-22)
When the screen is selected, it will display the parameters of the currently loaded recipe.
4.3.9 Settings The settings screens are used to define fundamental aspects of the machine setup. The settings are configured during system installation and commissioning, and do not normally need further adjustment.
CAUTION: Changing settings may prevent the filler from operating correctly, and could even result in damage to the machine. Consequently, changes should be made only after consulting PLF International for advice.
All settings screens have restricted user access to prevent unauthorised use.
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4.3.9.1 Settings - Delays and Gassing
This screen defines settings for sensor delay and for gassing system parameters as described below.
Sensor delays Each of the fields in the left-hand column sets a delay in the response to the associated sensor being covered or uncovered. For example, the tub present sensor must be covered for the specified ON delay period before the filler will start, and uncovered for the OFF period before the filler stops. Range, all fields : 0 to 99.9s
Gassing settings The fields in the right-hand column define gassing system parameters as follows.
Parameter Function Range FILLER HOPPER GASSING These set the maximum allowable atmospheric oxygen 0 - 99.9%
START LEVEL (O2) level in the specified gassed areas for normal (O2 level) production. FILLER GASSING START LEVEL The filling line will not start until the O2 level is reduced by gassing to these values, and will stop automatically if the CHECK WEIGHER any level rises above this value during production. GASSING START LEVEL SEALER GASSING START LEVEL
FILLER HOPPER GASSING These set the O2 threshold level for purge/trickle switching 0 - 99.9%
TRICKLE LEVEL in the gassing system. (O2 level) FILLER GASSING TRICKLE When gassing is first started, the gas flow to the specified LEVEL areas is set to purge (high volume) to reduce the O2 levels
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SEALER GASSING TRICKLE quickly.
LEVEL When the O2 levels reach the values set here, the gas flow is switched to trickle (low volume). This is sufficient most of the time to compensate for normal nitrogen loss from the gassed areas.
If the O2 levels rise above the values set here, gas flow is switched temporarily back to purge. GAS EXTRACTION VENTS Extraction vents allow the entry of normal atmosphere into 0 - 99.9s ON TIME DELAY the gassing enclosures during gas extraction. This field sets a delay in opening the vents after gas extraction is started to prevent escape of gas when the vents are opened. GAS EXTRACTION VENTS This sets a delay in closing the extraction vents after the 0 - 99.9s OFF TIME DELAY atmosphere in the enclosure reaches the 'safe' condition. GAS EXTRACTION DOOR This sets a delay in deflating the enclosure door seals 0 - 99.9s DEFLATE ON TIME DELAY after the atmosphere in the enclosure reaches the 'safe' condition. Doors cannot be opened until the seals deflate.
4.3.9.2 Settings - Powder feed
Parameter Function Range TIME TO POWDER FEED Sets the time after low powder level has been detected in 0 - 99.9s the filler hopper before the filler requests powder. POWDER FEED OVERUN Sets the time after high powder level has been detected in 0 - 99.9s the filler hopper before the filler stops requesting powder. TIME TO LOW POWDER Sets the time delay before the LOW POWDER message 0 - 99.9s is displayed on the overview screen after low level is detected in the filler hopper. TIME TO NO POWDER Sets a wait time after display of the LOW POWDER 0 - 99.9s message. If the powder level continues to be low after this time, the NO POWDER message is displayed. The machine will then stop after the time set for RUN FILLER WITH NO POWDER .
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RUN FILLER WITH NO Sets the amount of time the filler will continue to run 0 - 99.9s POWDER after the NO POWDER message is displayed. POWDER ROTARY VALVE 0 - 100%
4.3.9.3 Settings - Speeds
Each of these parameters defines the speed of the associated device as a direct proportion to the filler speed. Range, all fields : 10% - 200%
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4.3.9.4 Settings - Encoder
Parameter Function Range CONTAINER IN The encoder value when a container that will go onto 0 to 171 STARWHEEL filling head one has been detector by the container in starwheel sensor. HEAD 1 POINT The encoder value at which the system resets the head 0 to 4095 counter and the data on the HEAD DATA screen. This is normally set so that the reset occurs a short time after head 1 passes the home point on each revolution. A typical value is 100. COUNT SYNC HEAD A number which synchronises the data on the HEAD Equal to the DATA screen with the check weigher output. number of filler heads. READ WEIGHT POINT LIFT HEAD 1 (RAISE) The encoder value at which head 1 lift table will be raised. 0 to 4095 Usually just after the lift table has cleared the infeed star wheel. LIFT HEAD 1 (LOWER) The encoder value at which head 1 lift table will start to be 0 to 4095 lowered. HEAD CLAMP 1 The encoder value at which the clamp vacuum for head 0 to 4095 one will be turned ON. VACUUM HEAD 1 The encoder value at which fill vacuum for head one will 0 to 4095 be turned ON. This usually just after the container has been lifted to the nozzle. FILLER STANDSTILL VACUUM BOOST ENCODER VALUE This displays the current encoder value to enable other 0 to 4095 values to be entered. (read only)
Button Function
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SET HOME POINT Sets the ENCODER VALUE to 0000. This is the basic timing parameter for the filler. SET HOME POINT must be applied while filler head 1 is positioned at the front dead centre of the machine - i.e. directly over the centre line of the centre plough. CAN IN STARWHEEL Normally, lift tables and nozzle vacuum are operated only if containers are OVERRIDE detected by the can in starwheel sensor. This button overrides the sensor, allowing the machine to run normally even when there are no containers present. This is generally used for test purposes. CAUTION: USING THIS OVERRIDE ON A MACHINE FITTED WITH EITHER VOLUMETRIC NOZZLES OR SHROUDED VACUUM NOZZLES MAY CAUSE LARGE QUANTITIES OF PRODUCT POWDER BEING DISCHARGED INTO THE FILLER ENCLOSURE.
4.3.9.4.1 Defining encoder settings
CAUTION: INCORRECT SETTINGS ON THIS SCREEN MAY RESULT IN SERIOUS DAMAGE TO THE MACHINE. BEFORE MAKING ANY CHANGES, CONTACT PLF INTERNATIONAL FOR ADVICE.
Set home point 1 Jog the filler until head 1 is positioned at the front dead centre of the machine. 2 Touch SET HOME POINT. The ENCODER VALUE field will now show 0000.
Container in starwheel 1 Place containers on the infeed conveyor. 2 Jog the machine until head 1 is just before the front dead centre. 3 Visually assess which container in the starwheel will go into head 1. 4 Display the DIAGNOSTICS screen showing the status of system sensors. 5 Jog the machine until the CONTAINER IN STARWHEEL sensor changes to green, and then note the ENCODER VALUE reading. 6 Display the encoder SETTINGS screen and enter the noted encoder reading into the CONTAINER IN STARWHEEL field.
This an arbitrary value which is normally set so that the head counter and the data reset occurs a short time after head 1 passes the home point on each revolution. A typical value is 100.
Count sync head 1 Place a heavily-weighted container on the infeed. 2 Run the machine slowly and note which head the container goes into. 3 Note which head number the heavy reading appears against on the HEAD DATA screen. 4 Enter a COUNT SYNC HEAD number to move the reading to the correct head. Example: if the weighted container goes into head 8 but the reading appears against head 3, the COUNT SYNC HEAD value would need to be 5.
Lift head 1 The RAISE and LOWER fields together define proportion of a whole filler rotor revolution for which the lift tables are in the raised position, and are generally set to provide the maximum possible filling time. The procedures for setting them are given below.
Note: If a complete fill cannot be achieved after setting the raise and lower values as described, please contact PLF International for advice and assistance.
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Lift head 1 Raise CAUTION: If this procedure is not followed correctly, it may result in damage to the lift table and or change parts.
As a general rule, the lift tables should start to rise as soon as possible after they clear the infeed starwheel. This is normally when they are about three pitches (table positions) from front dead centre. 1 Remove the starwheels and plough guides. 2 Check that the home point is set correctly (page 4-37). 3 Calculate a starting value using: (4095/number of filler heads) x 3 E.g. for a 16-head machine: (4095/16) x 3 = 768 (to nearest whole number) 4 Enter this value in the RAISE field. 5 Set the LOWER value to 2500. (This is only a safe temporary value.) 6 Jog the machine to the point where a lift table just starts to rise. Note the associated head number. 7 Fit the infeed start wheel and check that the table noted above is clear of the starwheel. Ideally, the clearance should be about 10 - 20mm. 8 If necessary, adjust the RAISE value and repeat steps 5 and 6 to achieve this clearance. Do not run the machine with change parts fitted until the RAISE point is correct. 9 Now set the LOWER encoder value. (page 4-38)
Lift head 1 Lower Ideally, the lift tables should remain raised as long as possible to provide the maximum filling time. However, they must be fully down before they reach the 'table up' sensor or the machine will stop immediately to prevent collision between the tables and the outfeed starwheel. Because the tables drop at a constant rate, the point at which they need to start lowering depends on the maximum speed at which the filler will be run. This can be determined as follows. 1 Check that the RAISE point is set correctly (page 4-38), and that the LOWER value is set to around 2500. 2 Fit the starwheels and plough guide. 3 Run the filler at the intended maximum production speed. 4 Gradually increase the LOWER value until the filler is stopped by a FILLER TABLE UP alarm condition. 5 Reset the table up condition. (page 4-17) 6 Return to the SETTINGS - ENCODER screen and decrease the head 1 LOWER value by 50. 7 Run the filler again. 8 If it is stopped again by a table up condition, repeat steps 5 through 7 until the filler runs normally.
Vacuum head 1 On This determines the point at which the fill vacuum is applied to the filler nozzles. To provide the maximum filling time the vacuum should be switched on as soon as possible after the containers have been raised to make contact with the nozzle seal.
Note: This set-up should be done with no powder in the machine to avoid powder spillage if the vacuum is switched on too early.
1 Set the Lift Head 1 Raise value. (page 4-38) 2 Add 200 to this value and enter the result as a starting point for the Vacuum Head 1 ON setting. 3 Run the filler, with containers, at the intended maximum production speed. 4 With the machine running, listen carefully for the application of the fill vacuum. . If the vacuum switches on before the container seals with the nozzle you will hear a definite hissing sound. In this case increase the vacuum ON value. . If the vacuum switches on significantly after the container seals with the nozzle, reduce the ON value to minimise the delay.
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4.3.9.5 Settings - Sealer Generator Power
4.3.9.6 Settings - Sealer Setup
4.3.10 Diagnostics The diagnostics screens provide a means of checking the status and operation of various system devices such as photo-electric sensors, proximity switches and vacuum valves.
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4.3.10.1 Diagnostics 1
4.3.10.2 Diagnostics 2 This screen shows the current state of proximity and photo-electric sensors. The relevant sensor ID, as used on the sensor labels and system schematics, is shown alongside each indicator.
To test any sensor, simply operate it as appropriate (e.g. trip out a starwheel, cover/uncover a photo-electric sensor) and check that the associated indicator changes colour.
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4.3.10.3 Diagnostics 3
4.3.10.4 Diagnostics 4 This screen provides status indication for each of the head updates.
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BOTTOM LIMIT These are the bottom limit proximity sensor indicators. They should change colour when the lift tables are lowered during normal operation. TOP LIMIT These are the top limit proximity sensor indicators. The lift table does not go to the top limit in normal operation. The sensor can be tested by observing the TOP LIMIT indicator and having an assistant place a metal object against the sensor. DRIVE OK These show the status of the stepper drives and should be green when the machine is on. LIFT STATE These indicate the state of the drive signals to the pneumatic solenoids that switch compressed air to the lift table cylinders.
4.3.10.5 Diagnostics 5
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4.3.10.6 Diagnostics 6
4.3.11 Jog Selecting the JOG button from the diagnostics screen displays the JOG screen.
With this displayed, the filler can be run at slow speed by pressing and holding the JOG button below the touch-screen, or one of the JOG buttons on the sides of the machine. If any of the machine guard doors are opened while in jog mode, it may be necessary to press the blue RESET button before the filler can be re-started. In this case, the RESET button will flash and a RESET REQUIRED message will be displayed.
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4.3.12 Powder feed
4.3.13 Alarms The ALARMS screen displays a list of all currently active alarms, with the latest alarms at the top.
As alarms are cleared (page 4-17), they are removed from the ALARMS screen.
4.3.14 Events The EVENTS screen displays the contents of the alarm log, which is a permanent list of all cleared and uncleared alarms.
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C H A P T E R 7 5 Cleaning and routine maintenance
5.1 Safety during maintenance
CAUTIONS: Maintenance work must be performed only by suitably trained personnel familiar with all applicable safety requirements and machine safety systems. Do not attempt to override any machine safety system or door guard/interlocks.
TO AVOID RISK OF INJURY, THE FOLLOWING ACTIONS MUST BE PERFORMED TO MAKE THE SYSTEM SAFE WHENEVER CARRYING OUT ANY MAINTENANCE WORK ON THE MACHINE. Before starting work on any part of the system: . Notify everyone in the vicinity that you intend shutting down any part of the system. . Shut down the relevant machine(s). . If the work requires access to anything within the gassing area, extract the gas and then shut off and lock the nitrogen isolators (page 2-8). . Shut off and lock the relevant compressed air isolator(s) (page 2-7), and then dump air pressure on the associated air panels. . Switch off and lock the relevant electrical power isolators (page 2-5). . Before working on any part of the filler vacuum system: . On the filler control station, select the Overview page and touch the STOP VACUUM button to stop the vacuum pump. . Set the vacuum pump electrical isolator to Off and attach a lock or tag. . Set the vacuum isolator to the Off position (page 2-6). . Always refer to the relevant cleaning or maintenance procedure prior to starting any work, to ensure you are completely familiar with all aspects of the process.
5.1.1 Returning the system to use Use the following general procedure to return the system to normal use. 1 Visually check to make sure that no loose components, tools or other items have been left in the machines or on conveyors. 2 Make sure that all access covers have been replaced and properly secured. 3 Notify everyone in the vicinity that the system is about to be started. 4 Close all guard doors. 5 Remove locks from electrical, air and nitrogen isolators, and set the isolators to their On positions. 6 Set the manual vacuum isolator to the On position. 7 Refer to the Operating Instructions and re-start the system.
5.2 Jogging the filler machine In several maintenance and cleaning procedures, it is necessary to run the machine very slowly to position the nozzles as required for access. To do this, use the Jog facility: 1 Close all guard doors. 2 On the filler control station, press the blue RESET button. Note: The next step may vary slightly from one system to another. 3 On the control station touch screen, typically: . touch the JOG button, or; . touch the DIAG/JOG button and then the JOG button. The JOG SELECTED screen should be displayed. 4 Press the black JOG button on the control station to turn the machine rotor to the required position. Note: One or more additional black JOG buttons may be fitted on the side and/or rear of the filler frame to enable it to be jogged from these locations.
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To leave jog mode, select any other display on the touch screen.
5.3 Cleaning and purging This section provides cleaning information for the filling system covered by this manual, including general surface cleaning, and deep cleaning involving the complete removal of product powder from the system. For information on cleaning any other part of the powder storage, handling or delivery system, please refer to the appropriate factory documentation.
5.3.1 General cleaning The general cleaning procedures for production machines and container handling equipment will depend on your application. Surfaces should be cleaned and de-sanitised in accordance with your standard operating procedures and all relevant local regulations, taking account of the following. . Do not clean machine surfaces with water. . Use vacuum cleaning to remove powder and loose material. . Clean the clear plastic guard doors and door seals with a damp cloth ONLY. DO NOT use chemical or abrasive cleaners which may damage the doors or seals. DO NOT use a dry cloth as this may cause a build-up of static charge.
5.3.2 Cleaning the powder filler
5.3.2.1 Cleaning filler nozzles To clean the nozzles effectively, they must be dismantled completely as described in this section.
CAUTION: The filler nozzles are high-precision units designed to be assembled with care. Follow the illustrated steps carefully. DO NOT USE FORCE. If you need to use force at any stage, you are doing something wrong and your actions will probably result in costly damage.
5.3.2.1.1 Nozzle removal and replacement This procedure describes a method for removing all nozzles for cleaning or other purposes.
WARNING: During this procedure, the compressed air supply to the filler nozzle clamps remains on. Consequently, there is a possible risk of injury if the procedure is not followed correctly.
Removal 1 Empty the hopper of product. 2 Press the STOP button on the HMI to stop the machine. 3 If the filler is part of a gassed (modified atmosphere) system, extract the gas. 4 Open one or more guard doors and remove all accessible nozzles. For each nozzle:
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. Disconnect the air hose 1 from the nozzle. Do not disconnect the two hoses 2 from the nozzle clamp.
. Turn the locking control 3 adjacent to the nozzle clamp counter-clockwise to the red position.
CAUTION: Nozzles are heavy - typically up to 20kg
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. Grip the nozzle tightly with both hands and slide it out of the clamp.
WARNING: Do not place fingers or any other part of your body in a nozzle clamp after the nozzle is removed. Because the compressed air supply is on, there is a possible danger of crushing. 5 When all accessible nozzles are removed, do the following: . Close all guard doors. . Jog the machine rotor (page 5-1) until more nozzles are accessible. . Open the guard doors and remove further nozzles. . Repeat these steps for any remaining nozzles.
Replacement 1 Repeat the process given above to gain access to nozzle clamps and replace groups of nozzles. Ensure that the nozzle locating pins are properly aligned with the holes in the nozzle clamps.
As each nozzle is replaced its clamp, immediately turn the associated locking control to the green position to lock it in place.
CAUTION: If this is not done, there is a possibility that nozzles could slide out of the clamps when the rotor is jogged, causing serious damage. 2 Re-connect the air hoses to the nozzles.
5.3.2.1.2 Nozzle strip-down 1 For each nozzle, disconnect all hoses from the nozzle and remove it from the machine. 2 Remove the nozzle components in the order indicated in the strip-down sequence below. 3 Clean and de-contaminate all components in accordance with your standard procedures. For example, use compressed air, a vacuum cleaner, a soft brush and/or alcohol wipes. Do not clean with water. 4 Inspect all O-ring seals and U seals for wear or damage and obtain new ones if necessary. 5 After cleaning, refer to the reassembly procedure (page 5-6).
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Strip-down sequence
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5.3.2.1.3 Nozzle reassembly 1 Assemble the nozzle components as indicated in the reassembly sequence below. Do not use force at any stage. If components are aligned carefully, they will fit together easily. 2 After reassembly, refit the nozzle in the machine and reconnect all hoses.
Reassembly sequence
In step 7, turn the ring (A) slightly, if necessary, to insert the tube (B) the last few mm. The end of the tube must be flush with the nozzle body as shown (C).
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In step 10, note the alignment of the locating pin (A) and the vacuum fitting hole (B). Use one of the fixing screws as shown to align the assembly accurately.
In step 12, note the alignment of the two fitting holes (A).
5.3.2.2 Cleaning nozzle clamps 1 Empty the hopper (page 5-11) and cone of product. 2 Remove the relevant nozzle (page 5-2). WARNING: Do not place fingers or any other part of your body in a nozzle clamp after the nozzle is removed. Until the compressed air supply is switched off in the next step, there is a possible danger of crushing. 3 Set the filler compressed air On/Off control to Off and attach a lock or tag to the control.
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4 Roll the silicone rubber sleeve at the top 1 and bottom 2 of the cone away from the hopper and the nozzle tubes respectively.
5 Remove the cone. 6 Remove all product powder from the inside of the clamp using a soft brush and/or compressed air. 7 Clean and sanitise the inside of the clamp according to factory procedures.
5.3.2.3 Clearing nozzle gauzes To maintain the accuracy of filling weight, nozzle gauzes must be kept clear of compacted powder. This is done by routine clearing at the intervals recommended in the Maintenance Schedule (page 5-24).
Note: The tendency for gauzes become blocked varies with different product powders and atmospheric conditions. Consequently, these intervals may need to be adjusted in the light of experience.
Is this true? It seemed plausible when I thought of it. Either at the defined routine intervals, or if the powder filling accuracy has declined: 1 On the control station OVERVIEW screen, select the CONTAINER STOP button. 2 Allow all containers currently in the filler to clear the outfeed starwheel and then stop the filler. 3 If the system is gassed, extract the gas. 4 Using a soft brush, brush the accumulated product powder from the gauze in every nozzle. Note: this can normally be done without removing nozzles from the machine. Jog the machine as necessary to access all nozzles.
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5.3.2.4 Cleaning filler hopper, lids and seals This procedure removes all necessary parts for cleaning the hopper. The individual parts should be cleaned in accordance with factory procedures.
1 Empty the hopper (page 5-11) of product.
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2 Remove all nozzles (page 5-2). 3 Remove all hopper cones (page 5-11). 4 On each of the three hopper lid sections incorporating a powder inlet tube: . Remove the powder level probe 1 from the powder inlet tube 2, and set it aside, taking care to place it where it will not be damaged. . Remove the two clamps 3 and slide the powder feed coupling tube out and remove it from the machine. . Remove the powder inlet tube fixings 4. . Withdraw the powder inlet tube assemblies from their lid section seals. 5 Disconnect the tube from the gas sampling filter 5. 6 Remove the hopper vent filter and pipes 6. 7 Undo the clamps and remove the gas inlets 7 fitted in three lid sections. 8 Slacken the lid clamps 8 on all segments and move them through 90° to lay flat. 9 Make a note of the position of each lid section, and remove all lid sections. 10 Remove the lid sealing strips 9. 11 Lift the outer 10 and inner 11 lid-sealing sections out of their channels.
12 From each of the sections, remove the plug 12 and seal energiser 13, and then remove the wear strip 14. Use a suitable tool to push the plug up and out of the quadrant; a hole is provided underneath.
13 Thoroughly clean inside, and all around the hopper in accordance with the applicable procedures. Dry thoroughly, if necessary. 14 Clean the plugs, seal energisers and wear strips, inspecting them for wear and damage. Fit them back into the sealing sections and refit to the hopper. 15 Refit the lid sealing strips. 16 Clean the powder level probes. 17 Away from the machine: . Clean the gas sampling filter 5.
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. Unscrew the lid of the filter 6 and remove the filter cartridge. Clean the filter cartridge and housing and the rest of the lid section, then replace the cartridge. . Clean the powder inlet tube seals. . Clean the remaining lid sections. 18 Re-fit the lid sections in their correct positions. 19 Re-fit the filler powder inlet tube assemblies. 20 Re-fit the level probes, ensuring that the sensor blades are vertical (narrow side up). 21 Re-fit the hopper vent filter and pipes. 22 Clean the hopper cones and sleeves. 23 Clean the nozzle clamps. 24 Re-fit the cones. 25 Re-fit the nozzles.
5.3.2.4.1 Emptying the filler powder hopper This procedure required the filling system to be capable of running normally, i.e. with all doors closed, gassing on (where relevant), no error conditions, etc. 1 Ensure that there is a supply of containers to the filler infeed. 2 On the control station OVERVIEW screen, touch the POWDER FEED button. The button should be highlighted in yellow. In this condition no powder is fed into the filler hopper but the low powder sensors are ignored so that the machine can continue running and filling containers. 3 Run the filler until the hopper and filler nozzles are essentially empty. 4 Stop the filler and de-gas the system, where relevant. Any remaining powder can now be removed from the hopper by vacuum suction or other means. The hopper must be primed (page 4-17) before the filler will run.
5.3.2.5 Cleaning hopper cones 1 Empty the hopper (page 5-11) of product. 2 Jog the machine (page 5-1) to gain access to each cone, as necessary. 3 Tap the outside of the cone to dislodge any remaining powder. 4 Roll the silicone rubber sleeve at the top 1 and bottom 2 of the cone away from the hopper and the nozzle tubes respectively.
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5 Remove the cone.
5.3.2.6 Cleaning the central vacuum system The central vacuum system creates the low vacuum which is used to draw product powder through the filling nozzles into the containers. Inevitably, a small quantity of product powder is continually sucked into the vacuum system, and will form a residue within the components of the system. To maintain hygienic conditions, the parts of the central vacuum system listed below should be routinely removed and cleaned in accordance with the maintenance schedule (page 5-24). Powder receiver jar (page 5-12) Vacuum receiver jar (page 5-15) Vacuum reservoirs (page 5-17) Central vacuum tube (page 5-18) Vacuum supply tube and valve (page 5-20) Vacuum relay valves (page 5-15) Unless stated otherwise in the instructions, after removing vacuum system components they should be cleaned and sanitised in accordance with relevant local procedures and regulations.
Note: The illustrations in this section show typical parts and assemblies, and may differ in detail from the parts on any particular machine. This should not affect the procedures involved.
5.3.2.6.1 Cleaning the powder receiver jar
CAUTIONS: If you are using a vacuum cleaner it should be an Atex approved version. Powder receiver component parts are heavy. Take great care when lifting them to avoid injury.
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Emptying the jar 1 Stop the filler. 2 On the filler control station, select the MACHINE OVERVIEW page and touch the STOP VACUUM button to stop the vacuum pump. 3 Set the vacuum pump electrical isolator to Off and attach a lock or tag. 4 Set the vacuum isolator to the Off position.
5 Loosen the door knob and open the inspection door 1.
6 Reach up inside of the jar and shake the nylon filter socks to dislodge any powder dust accumulated on the filters. 7 Remove any residual powder from the jar using a soft brush or vacuum cleaner. 8 Close the inspection door, and tighten the door knob. 9 Restart the vacuum pump. 10 Check the vacuum gauge: when the machine is in operation, it should read 8-12 inches of mercury. If this value is not reached, or if the vacuum fluctuates, there may be a vacuum leak or repair may be necessary.
Cleaning the jar and filters 1 Switch the vacuum pump off. 2 Disconnect the vacuum input pipe 2 at a convenient union. 3 The top cover 3 is fastened with quick release latches. Press the button in the middle and lift the latch. 4 Remove the top cover.
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5 Check the top cover sealing ring for damage. Replace if necessary.
6 With two people, lift the filter ring assembly 4 from the jar. 7 The top half of the jar 5 is fastened with quick release latches: press the button in the middle, and lift the latch. 8 With two people, remove the top half of the jar.
9 Clean the jar using compressed air, a vacuum cleaner, a soft brush and/or alcohol wipes. Do not clean the jar with water. 10 Check the sealing rings 6 for damage. Replace if necessary. 11 Replace the top half. 12 Remove the filter socks from the filter ring and remove the weight from each sock. 13 Check each sock for damage. Replace if necessary. 14 Clean the socks. 15 Replace the sock weights. 16 Attach the socks to the filter ring. 17 With two people, replace the filter ring. 18 Replace the top cover. 19 Reconnect the vacuum input pipe and tighten the union fixings. 20 Restart the vacuum pump. 21 When the machine is in operation, check the vacuum gauge reads its normal operating level. If this value is not reached, or if the vacuum fluctuates, there may be a vacuum leak or repair may be necessary.
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5.3.2.6.2 Cleaning the vacuum receiver jar
CAUTIONS: If you are using a vacuum cleaner it should be an Atex approved version. Vacuum receiver component parts are heavy. Take great care when lifting them to avoid injury.
The procedures for cleaning the vacuum receiver jar and filters are basically the same as those for the powder receiver jar. Follow the instructions provided (page 5-13), substituting the vacuum receiver jar components as applicable. Under normal circumstances there should be no residual powder in the vacuum receiver jar. However, if powder is present, check the powder receiver jar as its filters may have been damaged, or may have detached from the filter ring. Avoid powder spillage in this area if possible, also avoid excessive disturbance of the powder causing a dust cloud in the area.
5.3.2.6.3 Cleaning vacuum relay valves Vacuum relay valves must be dismantled and cleaned periodically. The following cleaning periods are recommended:
Relay Cleaning frequency Clamp Monthly Filler Weekly
3.6.2.3.5.1 Removing valves from the machine Each vacuum relay assembly comprises two separate relay valves - a clamp valve 1 and a filler valve 2. 1 Isolate (page 5-1) the filler vacuum and compressed air systems. 2 Make a note of the flexible vacuum tube connections to the clamp vacuum relay valve 1 and the filler vacuum relay valve 2, then disconnect the tubes. 3 Uncouple the tube 3 from the filler relay valve by pushing it towards the vacuum reservoirs 4 in the direction arrowed, and then withdrawing it from the machine.
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4 Rotate the tube 5 through 180 degrees until the machined flat is at the bottom. Push it towards the vacuum reservoirs and then withdraw it from the machine.
5 Remove clamp relay valve by rotating the body of the valve through 90 degrees and withdrawing from the nozzle rotor. The lower air connector 6 may also have to be rotated to allow removal.
6 Remove filler relay valve by withdrawing it from the nozzle rotor in the direction shown. It is advisable to hold onto the clamp connecting tube 7 to prevent it falling during removal.
Both relay valves are similar in construction, so only the clamp relay valve is illustrated below. 1 Remove the vacuum relay valves (page 5-15) from the machine. 2 Dismantle each valve by unscrewing the knurled rings 5 from both ends of the valve body. 3 Remove the internal components: . 1 - Diaphragm . 2 - Diaphragm support . 3 - Spring
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. 4 - End cap
4 Check the condition of the diaphragms. They should be flat and perfectly circular, and should fit inside the knurled ring with only a small clearance (about 1mm). If they show any sign of damage, distortion or stretching, replace them with a new ones. 5 Clean the valve body and all components. If you are re-using the diaphragms, clean them with distilled water only and dry thoroughly before reassembling. 6 Inspect the O-rings fitted to the vacuum tube connections for damage or wear and replace if necessary. 7 Reassemble the valves, making sure that the components are in the correct order as shown above. 8 Ensure the knurled rings are tightened firmly.
5.3.2.6.4 Cleaning vacuum reservoirs 1 Make the vacuum system safe.
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2 Remove sufficient nozzles from the filler to provide access the vacuum reservoirs in the centre of the machine, and space to remove them.
3 Remove the upper clamp 1 and lower the reservoir tank as far as possible onto the central vacuum tube flange 3. Retain the sealing ring. 4 Remove the lower clamp 2. 5 Carefully slide the upper section 4 out and remove it from the machine. Retain the sealing ring. 6 Lift the lower section 5 upwards and remove it from the machine.
5.3.2.6.5 Filler central vacuum tube 1 Remove the vacuum reservoirs (page 5-17). 2 Remove the four bolts securing the central vacuum tube flange to the rotor base. 3 Lift the central vacuum tube up and out of the machine. 4 Carefully prise out and remove the two U-seals 1 from the central vacuum tube flange noting their orientation.
5 Clean all removed parts thoroughly. 6 Inspect the following for damage or wear and replace if necessary:
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. the two reservoir sealing rings . the central vacuum tube flange U-seals 1 . the central vacuum pipe sealing O-ring 2 fitted in the rotary joint. The cross-section view below shows its location:
. the sealing rings 3 fitted to vacuum supply tube clamps
7 Refit the U-seals into the central vacuum tube flange ensuring they are fitted the correct way up.
8 Clean the inside of the passage in the centre of the machine through which the central vacuum tube passes. 9 Clean the inside of the rotary joint. 10 Refit the rotary joint, central vacuum supply tube and reservoirs using the reverse of the removal procedures.
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5.3.2.6.6 Cleaning the vacuum supply tube and valve This procedure removes the complete vacuum supply tube and the rotary joint that connects it to the filler vacuum reservoirs. 1 Remove the vacuum reservoirs (page 5-17). 2 Remove the central vacuum tube (page 5-18). 3 Undo the two vacuum valve nuts 1 and remove the valve 2 from the vacuum tubes.
4 Remove filler base cover panels as necessary to gain access to the vacuum supply tube components underneath the machine. 5 If the vacuum supply tube is fitted with a vacuum sensor 3, undo the tri-clamp 4 and remove the sensor.
6 Remove all tri-clamps from the two parts of the vacuum supply tube and remove the tube sections. Retain all sealing rings from the tube joints.
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7 Slide the rotary vacuum joint 5 out of the support plate 6, and then remove the elbow tube 7 from the rotary joint.
8 Clean the rotary joint and elbow. Re-attach the elbow tube and slide the rotary joint back into the support plate 9 Clean all of the vacuum supply tube components and reassemble the tube sections. Take care to ensure that the joint sealing rings are fitted correctly and all of the tri-clamps are tight. 10 Unscrew the lid of the vacuum valve, clean the inside of the valve and then reassemble. 11 Detach the vacuum tube from the vacuum pump. Clean the tube and then re-attach it. 12 Re-attach the vacuum valve to the supply tubes.
5.3.3 Cleaning the feed hoppers Please refer to the Guerin powder feed system documentation.
5.3.4 Cleaning the sealer For sealer cleaning instructions, please refer to the Fords Seamer manual (page 1-3).
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5.3.5 Cleaning the gas extraction system The gas extraction system must be examined and cleaned at regular intervals to prevent the build-up of product powder and other contaminants in the extraction ducts and filters. The rate of powder build-up will depend on the nature of the product powder and production volume. Consequently, the appropriate cleaning frequency must be established by experience during the initial period of system operation.
Note: The illustration below shows a typical gas extraction assembly for the sake of example.
At regular intervals: 1 Check the in-line filters: . Remove the filter cover 1. . Remove and examine the filter element 2. Replace it with a new one if necessary. . Replace and secure the cover. 2 Dismantle and clean the extraction ducts: . Before dismantling, check that all balancing valve lock nuts 3 are tight. It is important that these valves remain in the positions set during system set-up. . Make a note of the locations in the system of each balancing valve 4 and butterfly isolating valve 5 so that they can be replaced in the same locations after cleaning. . Remove all tube clamps 6 and the associated tube sections. . Remove the joint sealing rings. . Clean and sanitise all tube sections, balancing valves and butterfly isolating valves in accordance with factory procedures. Important: before cleaning each balancing valve, note the position of its control handle. After cleaning, return it to the same position and tighten the lock nut. 3 Reassemble the tube sections. . Fit the valves in their original locations. . Ensure that all sealing rings are fitted correctly.
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5.3.6 Cleaning line control sensors Most line control sensors (page 3-4) are optical units consisting of a transmitter/receiver head 1 mounted on one side of the container path and a reflector 2 mounted on the other.
These should be cleaned regularly with a clean damp cloth to remove any build-up of product powder.
The array of seven fibre-optic Seal present, and seal alignment sensors (page 3-4) located near the outfeed of the sealer should be cleaned with a soft brush and/or a soft dry cloth.
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C H A P T E R 8
5.4 Maintenance
5.4.1 Maintenance schedule
Note: The following maintenance schedule is for general guidance only. Depending on the powders in use, production hours, etc., the need for routine maintenance may vary.
Every 4 hours . Inspect the powder receiver jar (page 5-12), and empty it if necessary. . Clear accumulated powder from all nozzle gauzes (page 5-8).
At the end of every shift . Clear the central vacuum tube (page 5-25).
Weekly . Perform the daily maintenance checks. . Check the oil in the vacuum pump. (Refer to the pump manufacturers documentation (page 1-3).) . Clean the filters in the powder receiver (page 5-12) and vacuum receiver (page 5-15) jars. . Clean the vacuum relay valves (page 5-15). . Clean and check or test: . Interlocks (page 5-28) . Emergency stops (page 5-29) . Machine sensors (page 5-26) . Conveyor and general machine parts . Line control sensors (page 5-25) . Hopper seal and breather (page 5-9)
Monthly . Perform the weekly maintenance checks. . Clean the machine vacuum reservoirs (page 5-17).
Every three months . Perform the weekly maintenance checks. . Perform the monthly maintenance checks. . Clean and check the vacuum receiver jar (page 5-15). . Do a visual check on all timing and drive belts.
Caution: use extreme care when checking running machine
Every year . Perform the weekly maintenance checks. . Perform the monthly maintenance checks. . Perform the three-monthly maintenance checks. . Lubricate the bottom rotor bearing. . Perform the vacuum pump annual service in accordance with the manufacturers documentation (page 1-3). . Replace the diaphragms in the relay valves (page 5-15). . Replace the jar seals, door seal and filter socks in the powder receiver jar. . Replace the diaphragm in the main vacuum regulator valve. . Replace the filters in the powder receiver (page 5-12) and vacuum receiver (page 5-15) jars. . Replace the filters in the pneumatic system components. . Replace the inner and outer hopper lid seals and wear strips. . Replace the top and bottom cone rubbers.
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5.4.2 Vacuum pump Maintenance of the vacuum pump should be carried out according to the manufacturer's maintenance manual. Particular attention should be paid to: . filters . wearing parts
5.4.3 Clearing the central vacuum tube To prevent build-up of product powder in the central vacuum tube, the vacuum isolation valve should be opened momentarily about every eight hours of filler running time. 1 Move the valve control quickly to about half way between the On (1) and Off (2) positions and immediately back to On. 2 Repeat once.
5.4.4 Testing sensors and interlocks
5.4.4.1 Set up for tests To test safety interlocks and control sensors you should first set up the system to be able to run without product powder or containers. 1 On the operator control station, press the STOP button to stop the filler. 2 Select the OVERVIEW screen. 3 Select the CONTAINER STOP and POWDER FEED buttons. When these overrides are on, the buttons are highlighted in red. 4 If the system includes gassing, set the GASSING OFF/ON keyswitch to Off. At the end of tests, deselect the CONTAINER STOP and POWDER FEED buttons to return them to their normal operating condition (green).
5.4.4.2 Testing line control sensors Line control uses a mixture of optical sensors and proximity sensors. They can all be tested by operating the sensors and observing their status on the control station DIAGNOSTICS screens. 1 Refer to the sensor information (page 3-4) and identify the location and type of each sensor. . Optical sensors have IDs starting PEC. . Proximity sensors have IDs starting PROX. 2 On the control station, select the DIAGNOSTICS screen that shows some or all of the sensors. 3 Test each optical (PEC) sensor by covering and uncovering either the transmitter/receiver or the reflector and observing the status on the DIAGNOSTICS screen. This should be: Sensor state Diagnostics status Covered Grey Uncovered Green
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4 Test each proximity (PROX) sensor by placing the appropriate item (e.g. product container) in front of the sensor. Where the sensor is intended to detect a moving machine component, it may be necessary to jog the machine to position and remove the component. 5 Check the status on the diagnostics screen. Remove the detected item and check that the status changes. Sensor state Diagnostics status Detected item in place Green Detected item removed Grey
5.4.4.3 Testing machine sensors Check the following machine sensors for correct operation.
Hopper level probes These are ultrasonic vibrating-fork sensor located in the powder feed tubes on the hopper lid. When it is covered by product powder the fork vibrations are damped and the sensor provides a signal to shut off the powder feed. The probe can be tested by manually damping the fork vibration. 1 Empty the powder hoppers (page 5-11). 2 Set the system up for tests (page 5-25). 3 Release the clamp 1 and carefully remove the level probe 2 from the powder feed tube.
4 Unscrew and remove the cover 3 on the rear of the level probe. This will reveal a yellow LED which indicates the state of the probe. When the probe fork is not covered by product powder, the LED should be off. 5 Place your hand on both prongs of the level fork inside the powder feed tube, and check that the yellow LED is lit. Check that it goes off when you remove your hand. 6 Replace the probe in the feed tube and tighten the fixing clamp. 7 Replace the cover on the rear of the probe and ensure that it is fully tightened. WARNING: THERE IS A DANGER OF EXPLOSION IF THIS COVER IS NOT REPLACED AND TIGHTENED CORRECTLY.
Table down sensor The table down sensor is located a number of table positions before the outfeed starwheel, to check that the tables have returned to the down position by this point in the filling cycle. This check simulates a jammed table fault. Do the following for one table. 1 Set the system up for tests (page 5-25). 2 Remove the starwheels and centre plough guide completely from the machine. This is a very important precaution to avoid damaging the machine.
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3 Obtain two small blocks of a hard plastic material (e.g. Delrin or PTFE), approximately 2.5cm (1 inch) thick. 4 If there are no containers in the machine, select the EMPTY MACHINE option on the operator control station. This will allow the lift tables to operate in the absence of containers. 5 Run the machine for a few revolutions and then stop it. 6 Open the rear doors of the machine guard. 7 Place the two plastic blocks under one of the raised tables, close to the table lift shaft.
8 Run the machine slowly. 9 Check that the sensor trips and stops the machine. TABLE UP RESET REQUIRED warning will display on the control panel OVERVIEW screen, and blue RESET button will flash. 10 Remove the plastic blocks. 11 Press the screen RESET button. 12 On the next screen view, a large RESET button will be displayed. Press to reset. 13 Check test table is down. If OK press the blue RESET button. CAUTION: never press the blue RESET button unless all tables are down from the table down sensor to the outfeed starwheel. 14 Replace the starwheels and centre plough guide.
Starwheel torque limiter sensors The infeed and outfeed starwheel torque limiters are equipped with proximity sensors to detect a limiter trip. If a sensor is activated, the condition is shown on the control station and needs to be reset. To check these sensors: 1 Set the system up for tests (page 5-25). 2 Turn the starwheels by hand until you feel the torque limiters trip and the starwheels turn freely. The torque limiter should trip with just moderate pressure. 3 Check the control station diagnostics screen for indications of the tripped condition. 4 Turn the starwheels until the torque limiters re-engage and check that the trip condition can be reset on the control station.
Scroll torque limiter sensor The scroll drive torque limiter is equipped with a proximity sensor to detect a limiter trip. If the sensor is activated, the condition is shown on the control station and needs to be reset. To check this sensor: 1 Set the system up for tests (page 5-25). 2 Turn the scroll by hand until you feel the torque limiter trip and the scroll turns freely. 3 Check the control station diagnostics screen for indications of the tripped condition. 4 Turn the scroll until the torque limiter re-engages and check that the trip condition can be reset on the control station.
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5.4.4.4 Testing interlocks Interlocks (page 2-8) are fitted to all enclosure doors and to the removable sections of the filler hopper lid. These should be cleaned, inspected and checked for correct operation at weekly intervals or more often if required by factory procedures.
WARNING: IF ANY OF THE CHECKS OR TESTS DESCRIBED BELOW INDICATE INTERLOCK DAMAGE OR MALFUNCTION THE MACHINE MUST NOT BE USED UNTIL THE RELEVANT PARTS HAVE BEEN REPLACED AND FULLY TESTED.
1 Press the STOP button on the operator control station to stop the filler. 2 Extract the gas. 3 Set the system up for tests (page 5-25). 4 Clean and check the filler hopper lid and enclosure door interlocks as described below.
5.4.4.4.1 Filler hopper lid interlocks
Filler hopper lid interlocks 1 Remove one of the filler hopper lid sections fitted with interlocks.
If necessary, refer to the section on cleaning the hopper (page 5-9) for information on removing lid sections. 2 Clean all product powder from the lid interlocks with a soft brush and compressed air. Pay particular attention to the locking tabs (fixed to the lid section) and the tab receptacles. 3 Carefully inspect the interlock casings and the cable entry glands for damage or signs tampering. Of particular importance is damage which causes loss of sealing at the lid or conduit entry. WARNING: THERE IS A DANGER OF EXPLOSION IF THE INTERLOCKS ARE NOT COMPLETELY SEALED. 4 While the lid section is removed, check that the MACHINE OVERVIEW screen on the operator control station shows a 'lid open' indicator.
If this is displayed, the interlock is working correctly and this would prevent the machine from being started. 5 Replace and secure the lid section and check that the 'lid open' indicator has been removed from the Overview Screen. 6 Repeat these steps for all other lid sections fitted with interlocks.
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5.4.4.4.2 Enclosure door interlocks
Enclosure door interlocks 1 With the system stopped, open each enclosure door and clean all product powder from the door interlocks with a soft brush and compressed air. Pay particular attention to the locking tabs (fixed to the enclosure doors) and the tab receptacles. 2 Carefully inspect the interlock casings and the cable entry glands for damage or signs tampering. Of particular importance is damage which causes loss of sealing at the lid or conduit entry. WARNING: THERE IS A DANGER OF EXPLOSION IF THE INTERLOCKS ARE NOT COMPLETELY SEALED. 3 Close all enclosure doors. 4 Now open each door in turn and check that the MACHINE OVERVIEW screen on the operator control station shows a 'door open' indicator.
If this is displayed, the interlock is working correctly and this would prevent the machine from being started. 5 Close all doors and check that all 'door open' indicators have been removed from the Overview screen. 6 Make sure the system is still set up to run without containers or product (page 5-25), and then start the filler. 7 Physically check that all enclosure doors are locked and cannot be opened. CAUTION: Do not use excessive force when testing the doors.
5.4.4.5 Testing emergency stops Stopping the system by pressing emergency stop buttons causes stress to the machine drive components and should generally be avoided except in the case of an emergency. This procedure allows the emergency stop buttons to be tested without actually running and stopping the system. 1 Set the system up for tests (page 5-25). 2 On the operator control station, select the MACHINE OVERVIEW screen. 3 Press any one of the emergency stop buttons and check that the screen on the operator control station shows an 'E-stop pressed' icon and a banner message.
If these are displayed, the emergency stop is working correctly and would stop the machine if it was running. 4 Reset the emergency stop button and press the RESET button on the operator control station. 5 Check that the icon and message are removed. 6 Repeat these steps for all emergency stop buttons.
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Emergency stop locations
1 Powder filler 2 Sealer 3 Cap press
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