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accu-max™ Two Stream Blending System
OPERATING MANUAL MODEL: AM-25 Coca-Cola Bottling Durham Durham, North Carolina Project 24-152
Cadence Technologies Inc. 1006 Windward Ridge Pkwy Alpharetta, GA, 30005 USA
Rev. 00/00/01
Cadence Technologies, Inc. 1006 Windward Ridge Pkwy Alpharetta, GA, 30009 USA (800) 352-1828
Cadence Technologies Inc. 1006 Windward Ridge Pkwy Alpharetta, GA, 30005 USA
Rev. 00/00/01
Table of Contents Table of Contents................................................................................................ 3 Overview........................................................................................................................... 6 Accu-Change Flavor Change Over .......................................................................................... 6 Accu-Change Timeline ............................................................................................................. 8 Accu-change Illustration ........................................................................................................... 9
Screens ............................................................................................................................ 27 Screen Navigation ..................................................................................................................... 27 Indicators ................................................................................................................................... 28 Module Status Indicator ............................................................................................................ 29 Home Screen ............................................................................................................................ 30 Simplified Screen ...................................................................................................................... 31 Simplified Screen ...................................................................................................................... 32 Side Bar Menu ........................................................................................................................... 33 Recipe Screen ........................................................................................................................... 34 Machine Command Screen ....................................................................................................... 35 Machine Commands ................................................................................................................. 36 Machine Command Glossary .................................................................................................... 36 Syrup Port Command Glossary ................................................................................................ 39 Blending Operations Screen ..................................................................................................... 39 Blending Operations Command Screen.................................................................................... 41 Implied Syrup Brix ..................................................................................................................... 42 Accu-brix Function .................................................................................................................. 42 Change Over Screen................................................................................................................. 43 Change Over Screen Color Meaning ........................................................................................ 44 Production Record Screen ........................................................................................................ 45 Change Over Tally Screen ........................................................................................................ 46 Machine Cycle Screen .............................................................................................................. 47 Trend Screen ............................................................................................................................. 47 Trend Mass Flow Screen .......................................................................................................... 49 CIP Screen ................................................................................................................................ 50 CIP Program Screen ................................................................................................................. 51 Alarm Screen ............................................................................................................................. 53 Alarm Indicators ........................................................................................................................ 54 Alarm Messages ........................................................................................................................ 55 Blender Screen .......................................................................................................................... 66 Blender Screen Indicators ......................................................................................................... 68 Blender Command Screen ........................................................................................................ 69 Deaeration Unit Screen ............................................................................................................. 69 Gas Injector Screen................................................................................................................... 71 Gas Injector Command Screen ................................................................................................. 72 Product Tank Screen................................................................................................................. 73 Product Tank Screen Indicators ................................................................................................ 74 Product Tank Command Screen ............................................................................................... 75 Product Tank Refrigeration Screen ........................................................................................... 76 Product Tank Refrigeration Screen Indicators .......................................................................... 76 Filler Screen .............................................................................................................................. 78 Filler Screen Indicators.............................................................................................................. 79 Cadence Technologies Inc. 1006 Windward Ridge Pkwy Alpharetta, GA, 30005 USA
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Filler Command Screen............................................................................................................. 81 Special Filler Functions ............................................................................................................. 81 Syrup Port Screen ..................................................................................................................... 83 Syrup Port Status Matrix ........................................................................................................... 84 Syrup Port “READY” and “CONNECTED”: ............................................................................... 85 Syrup Port Command Screen ................................................................................................... 86 Syrup Port Ready Screen ......................................................................................................... 87 Syrup Port Utilities Screen ........................................................................................................ 87 Syrup Line Purge Screen .......................................................................................................... 89 Maintenance Screen ................................................................................................................. 90 Maintenance PID Screen .......................................................................................................... 91 PID Control Devices and Available Parameters ....................................................................... 92 Maintenance Setup Screen ....................................................................................................... 94 Maintenance Change Over Screen ........................................................................................... 97 Maintenance Vacuum Pump Screen......................................................................................... 99 Maintenance Meter Setup ....................................................................................................... 100 Maintenance Meter Setup – Syrup Reservoir Calibration ....................................................... 101 Maintenance Meter Proving .................................................................................................... 102 Maintenance Force Screens ................................................................................................... 103
Recipes........................................................................................................................... 107 Recipe Items ........................................................................................................................... 108 Active and Next Recipes ......................................................................................................... 111 Viewing Active and Next Recipes ........................................................................................... 112 Next Recipe Selection ............................................................................................................. 115 Syrup Port ............................................................................................................................... 116 Next Syrup Port Selection ....................................................................................................... 117 Run Out Type .......................................................................................................................... 118 Next Run Out Type Selection .................................................................................................. 119 Setting Up an Active Recipe ................................................................................................... 121
Recipe Manager................................................................................................ 122 Recipe Manager Screen ......................................................................................................... 123 Recipe Viewing ........................................................................................................................ 124 Recipe Editing ......................................................................................................................... 124 Modifying the Selected Recipe Item........................................................................................ 125 Recipe Editor Page 2 .............................................................................................................. 127 Saving the Recipe ................................................................................................................... 128 Copying A Recipe.................................................................................................................... 129 Recipe Name Modification ...................................................................................................... 129 Recipe Deleting ....................................................................................................................... 132
Operation ..................................................................................................................... 136 Utilities Check .......................................................................................................................... 136 E-Stop Check .......................................................................................................................... 136 Morning Start Up ..................................................................................................................... 137 Flavor Change Preparation ..................................................................................................... 139 Flavor Change ......................................................................................................................... 140 Filler Run Out Completion ....................................................................................................... 140 End of Day Shutdown.............................................................................................................. 141 Packaging Change .................................................................................................................. 142 Product Proportioning Adjustment .......................................................................................... 143 Product Tank Pressure Adjustment ........................................................................................ 144 Accurate Metering Systems, LLC. 1651 Wilkening Road Schaumburg, IL 60173 USA
Rev. 00/00/01
Gas Injector Set Point Adjustment .......................................................................................... 145 CIP........................................................................................................................................... 146
Frequently Asked Questions .......................................................... 148 Question - Low Syrup Density Alarm Fault on startup ............................................................ 149 Question - foam in my Syrup Reservoir during a Syrup Reservoir Runout ............................ 149 Question – My Syrup Reservoir is High and I can blend no more .......................................... 149
Cheat Sheet............................................................................................................. 151 START UP ............................................................................................................................... 152 FLAVOR CHANGE.................................................................................................................. 153 END OF PRODUCTION.......................................................................................................... 154
Appendix....................................................................................................................... 154 Capacitance Probe Calibration ............................................................................................... 155 INTRODUCTION ................................................................................................................ 155 OPERATING ELEMENTS .................................................................................................. 155 SWITCHES ......................................................................................................................... 155 PUSHBUTTONS ................................................................................................................. 155 CALIBRATION .................................................................................................................... 156 STEP by STEP ................................................................................................................... 156 RTD Calibration ....................................................................................................................... 156 RTD Calibration ....................................................................................................................... 157 Modem Set Up ........................................................................................................................ 158
Accurate Metering Systems, LLC. 1651 Wilkening Road Schaumburg, IL 60173 USA
Rev. 00/00/01
OVERVIEW ACCU-CHANGE
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Overview Accu-Change Flavor Change Over
The accu-change™ fast flavor change-over option can significantly reduce operating cost. This capability will add more productive uptime to line operation and boost output. It allows line personnel to execute a 5 to 7 minute change-over with ease. This translates to fewer overtime shifts and reduced operating costs. It also provides greater short-run flexibility, permitting you to run more products over the course of a day. In operation, the accu-change™ system coordinates the entire change-over process. At end-of-run, all syrup is transferred to the blender. The amount of product that can be made is calculated and converted to empty containers required. This information is transmitted to the depalletizer operator who sends the required sweeps to the line. No product or containers are wasted. The syrup line, blender, and filler are concurrently rapid-rinsed and dried for the next product. In operation, the Operator selects desired recipe from touch screen, which loads target brix and CO2 settings. Operator then pushes START button which rinses and dries system. Concurrently, separate routines rinse and dry syrup line and filler. When both operations are completed, the syrup cut-off tank fills, and blending begins. Precision flow meters measure actual syrup, water and CO2 flow-rates. PLC logic compares actual flow rates against target flow rates and adjusts the syrup pump speed and the CO2 control valve to maintain target flow rates. Initial settings are automatically adjusted to compensate for Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
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residual water and provide a no-dump start. At end of run, gas pushes all syrup from syrup line into the syrup cut-off tank. When syrup level reaches low point in the cut-off tank, water is added to tank to push in-spec product to carbonator tank. When carbonator empties, the entire system is rinsed and prepared for next flavor.
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
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Accu-Change Timeline
In order to provide the fastest flavor change over possible the system is partitioned into modules that allow concurrent operations. The timeline above illustrates the accu-change flavor change sequences for each module. Each module is identified on the left, while each machine function timing and length is shown on grid in increments of 5 seconds. The total Filler down time is shown at the bottom in black. Reviewing the timeline one can observe the benefit of partitioning the system into modules, while producing the benefit of concurrent machine functions, that save change over time.
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
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Accu-change Illustration The following pages illustrate an accu-change flavor change over each machine function is illustrated and also described in the upper right hand machine status box.
The change over starts when the syrup in the syrup line is pushed into the Syrup Reservoir with a CO2 gas purge.
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA 847-882-0690
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After the syrup in the syrup line is purged into the Syrup Reservoir the container stop at the filler is automatically pulled in to pack the empty side to a known container count. Concurrently the syrup line is rinsed and drained.
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA 847-882-0690
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Once the operator confirms that the empty is packed, the container stop is opened allowing containers to be filled again, and the system calculates the number of sweeps required at the depalletizer to place the entire volume of product in the system into containers, and notifies the depalletizer operator.
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA 847-882-0690
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As the system runs out the Syrup Reservoir, the syrup line is prepared for the next production.
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA 847-882-0690
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The Syrup Reservoir is still running out the syrup, and the syrup line is ready for the next production run.
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA 847-882-0690
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When the level in the Syrup Reservoir reaches bottom of the vessel, water is used to push the remaining syrup through the syrup mass flow meter. At the end of the Syrup Run Out water push a Mix Line Run Out pushes all the product in the Mix Line into the Product Tank with water, and a Syrup Reservoir Rinse starts.
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA 847-882-0690
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When the Mix Line Run Out finishes, the Product Tank Run Out will provide the filler with product at pressure. Concurrently the Syrup Reservoir is drained and the Mix Line is rinsed in preparation of next production.
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA 847-882-0690
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The Syrup reservoir is primed concurrently, while the Mix Line is rinsed and drained.
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA 847-882-0690
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The Mix Line is drained concurrently during a Syrup Reservoir Prime and a Product Tank Run Out.
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA 847-882-0690
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The Syrup Reservoir has finished priming, the Mix Line drain and Product Tank Run Out continue.
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA 847-882-0690
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After the Mix Line Drain, a Mix Line Prime is initiated by the system to pack the Mix Line with product for the next production run. Concurrently the Product Tank Run Out continues with the current production run.
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA 847-882-0690
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When the level of product in the Product Tank reaches bottom of the tank, a Filler Run Out is initiated by the system. At the same time a Product Tank is rinsed and drained. The Filler Run Out uses the remaining product in the Filler Bowl to fill the remaining containers.
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA 847-882-0690
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When the entire volume product in the Filler Bowl has been consumed, the operator acknowledges the end of production, and the system initiates draining of the Filler. Concurrently the Product Tank is draining. No containers are filled, thus down time starts to be recorded.
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA 847-882-0690
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After the initially draining the Filler, the Filler Bowl is rinsed with it’s own water supply and drained in preparation of the next production. Concurrently the Product Tank Prime fills the Product Tank with product for the next production run.
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA 847-882-0690
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Product is ready in the Product Tank. The Filler is finishing draining itself.
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA 847-882-0690
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Before bringing product into the Filler, the Filler Bowl must be pressurized. This is done automatically by a Filler Charge function.
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA 847-882-0690
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After the Filler Charge pressurizes the Filler Bowl, the system will automatically initiate a Filler Prime, which will gently bring the product into the filler bowl in order to minimize product disturbance.
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA 847-882-0690
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After the Filler Prime has brought the product into the Filler Bowl, the container stop is opened and production starts again.
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA 847-882-0690
Cover Page.doc1 Rev. 00/00/01
SCREENS HOME
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Screens Screen Navigation The machine is equipped with a touch screen as a main operator interface. The only pushbuttons in the machine operating area are an E-Stop pushbutton and a Reset pushbutton. All adjustments to the system and screen navigation are made through the touch screen operator interface by using your finger. On the screens there are different styles of buttons, that are described below. Each has a special purpose.
Button Style Example
Purpose Square buttons with a graphic within, are Screen Navigation Buttons. Screen Navigation Buttons change the existing screen to a new screen.
Rectangular buttons with text within, and a colored rectangular indicator on top, are Machine Command Buttons. When these buttons are pressed a Machine Function is initiated. Care should always be taken when pressing a Machine Command Button. The colored rectangular bar on the top of the button indicates the state of the Machine Function. Red means the machine Function is inactive. Yellow means that the Machine Function is waiting on some condition to be satisfied before, the function will start. Green means that the Machine Function is active and running. A Screen Navigation Button with a graphic of a house within, will always change the screen to the Home Screen.
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
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Indicators Colors are used on the screens to indicate the state of valves and pumps, and machine functions. The table below shows the different colors used on the screens and their meanings. Color
Meaning The function is not running. (OFF)
The function is waiting for some condition, before it will start executing.
The function is running (ON)
The function has run already during this change over (DONE)
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
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Module Status Indicator On many screens you will see a one or more Module Status Bars. Below is a Module Status Indicator for the Syrup Reservoir Module. There are Module Status Indicators for the Syrup Room, Syrup Port, Blender, Mix Line, Product Tank, and Filler. The purpose of the Module Status Indicator is to convey to the operator what the system is doing, and perhaps what the system is waiting for before it can proceed to the next step. Progress Bar
Module’s Machine Function
Machine Function’s Operation
The three elements of a Module Status Indicator are described in the table below. Element Module’s Machine Function
Description The Module’s Machine Function indicates the current Machine Function that the module is running, such as Rinse, Priming, Draining, and Blending among others.
Machine Function’s Operation
The Machine’s Function Operation indicates the current operation, which the Machine Function is performing, such as In Progress, Waiting for Tank Pressure, Blowing Through Filling Valves, or Waiting for Tank to Empty for example.
Progress Bar
The Progress Bar indicates the progression of the execution of a function. The Progress Bar fills with a green bar from left to right as the Machine Function proceeds through it’s execution.
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
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Home Screen The Home Screen is the pivotal main screen where all other screens are accessed. In the center is a representational process diagram for the system. The process diagram is broken into the following modules Syrup Line, Deaeration Unit, Blender, Gas Injector, Product Tank, and Filler. A modules screen Can be moved to by touching the module on the process diagram. Along the right side of the Home Screen is the Side Bar Menu where pushbutton icons, represent (in order) Recipe Screen, Machine Command, Blender Operations, Change Over, Trends, CIP, Maintenance and Alarms screens. Pressing the associated icon pushbutton will change the screen.
Time and Date
Press here to go to the Simplified Screen
Press one of the modules to change the screen
Press one of the pushbutton icon to change the screen
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
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To the right of the Active and Next Recipe display, are status lights that indicate the state of some basic machine functions. Automatic Change Over Enabled Indicator
Change Over in Progress Indicator Forces Active Indicator
Blender Status
Accu-Brix Enabled Indicator CIP Indicator
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
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Simplified Screen The Simplified Screen provides the operator a view of the simplified version of the process, while displaying basic information of operator interest, such as Syrup Port status, Syrup Reservoir Level, Product Tank Level, and Product Tank Outlet Valve status. Step 1.
Action To view the Simplified Screen follow the links below from the home screen
2.
Home The Simplified Screen will display as shown below:
Syrup Port Status
Product Setpoint Target
Syrup Reservoir Level
Gas Injector Target
Syrup Reservoir Volume
Product Tank Pressure Target
Syrup Meter Mass Flow Rate
Filler Container Stop Status Tank
Water Meter Mass Flow Rate
Product Tank Outlet Valve status
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
Blender Control Status for Filler Container Stop Output
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Side Bar Menu The Side Bar Menu is on the right hand side of the Home Screen and the Simplified Screen. The menu provides access to specific screens as outlined below.
Recipe Screen
Machine Command
Blending Operations Screen
Change Over Screen
Trend Screen
CIP Screen
Maintenance Screen
Alarm Screen
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
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OPERATIONS SCREENS (RECIPE)
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Recipe Screen The Recipe Screen provides the operator a view of Recipe Names, Run Out Parameters, and Operator Assigned Syrup Port for the Active and next Recipes. Access is also given for the Active Recipe Screen, the Next Recipe Screen, and The Recipe Manager. Step 1.
2.
Action To view the Recipe Screen follow the links below from the home screen Press here to go to the Active recipe
Home The Recipe Screen will display as shown below:
Active Recipe Name
Press here to go to the Active recipe
Press here to go to the Active recipe Run Out Length
Next Recipe Name
Run Out Type
Operator Selected Syrup Port
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
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Machine Command Screen The Machine Screen provides the operator the ability to initiate the machine functions. Step 1.
Action To view the Recipe Screen follow the links below from the home screen
2.
Home The Recipe Screen will display as shown below:
Other Screens Machine Command Screens
Change Over Screen
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
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Machine Commands Machine Command Glossary The Machine Command Screen provides the operator the ability to initiate the machine functions. Pushbutton / Indicator AUTO BLEND
BLEND PAUSE END OF DAY FILLER BLOW
FILLER CHARGE
FILLER COLD RINSE FILLER DRAIN
FILLER PRIME
FILLER RINSE
FILLER RUNOUT
MIX LINE PRIME
MIX LINE RINSE MIX LINE RUNOUT
Action When the AUTO function is enabled, the system will automatically sequence through the change over process without operator intervention. The BLEND function, requests syrup from the Active Syrup Port, requests water from the deaerator, proportions water, syrup and gas, controls the Product Tank Pressure, and provides product to the filler. The BLEND PAUSE function halts the BLEND function. The END OF DAY function provides a means to stop the system at the end of the production day. It kills every other running function. The FILLER BLOW function removes the residual water from the filler, by using a gas blow from the bottom of the filler. This automated function opens drain valves and the filling valves in a sequence. The FILLER CHARGE function pressurizes the filler bowl in preparation to receive product. Having the filler bowl pressurized as product first enters the filler, minimizes the velocity in which the product enters the filler, thus minimizing the change of carbonation to the product. The FILLER COLD RINSE function provides cold water to the filler. Water pumped from the deaerator through the Product Chiller and Product Tank, and then delivered to the filler. The FILLER DRAIN function removes product from the in preparation for a FILLER RINSE. The product is removed by opening the filling valves and the Filler Drain Valve. The FILLER PRIME function provides a means to bring the product into the filler after a FILLER CHARGE. The function opens the Product Tank Outlet Valve (Filler Inlet Valve) and monitors the level probes on the filler line. At the end of the FILLER PRIME the Container Stop is released. The FILLER RINSE function uses treated water to flush the filler, after a flavor change. The Filler Rinse Valve injects water directly into the filler line, where it moves through the filler line up into the filler bowl. The filling valves are automatically opened. The FILLER RUNOUT function maintains the filler in a state in which it can deliver the remaining useable product in the filler bowl to containers. The FILLER RUNPOUT is initiated after a PRODUCT TANK RUNOUT. The Product Tank Outlet (Filler Inlet) valve is closed, thus the only product that remains is in the filler bowl. The MIX LINE PRIME function packs the Mix Line with product. This is done in preparation to then move product into the product tank. During a MIX LINE PRIME, a drain at the top end of the Mix Line is opened, product is then proportioned for a volume that equals the volume of the Mix Line. The MIX LINE RINSE function flushes the Mix Line with water from the Deaerator, the water is pushed out a drain at the top end of the Mix line. The MIX LINE RUNOUT function pushes the contents of the Mix Line into the Product Tank. A volume of water from the Deaerator, equal to the volume of the Mix Line, is used to push the remaining product in the Mix Line into the
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
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OPERATIONS SCREENS
PRODUCT TANK DRAIN
PRODUCT TANK PRESSURE
PRODUCT TANK PRIME
PRODUCT TANK RINSE
PRODUCT TANK RUNOUT
RUN OUT START
STARTUP
SYRUP RESV DRAIN SYRUP RESV PRIME
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Product Tank. The PRODUCT TANK DRAIN function removes the left over rinse water from the Product Tank during a flavor change over. Pressure is maintained on the Product Tank while drain valves are opened at the bottom. The Product Tank Empty probe is used to determine that the Product Tank is empty. The PRODUCT TANK PRESSURE function maintains pressure in the Product Tank at the Product Tank Pressure Target. While monitoring the gas pressure via the Product Tank Pressure Transducer, the Product Tank Gas Supply Control Valve is used to supply gas to the Product Tank and the Product Tank Pressure Relief Valve is used to exhaust the gas from the Product Tank. The two valves work in opposition to maintain the pressure target setpoint. The PRODUCT TANK PRIME function is used to bring product into the product tank for the first time after a flavor change over. The function controls the target pressure for the product tank as the Product Tank is filled with product. The function runs for a finite volume of product. During the execution of the function the Target Product Tank Pressure is first set to Initial Product Tank Pressure Recipe Item value and then ramped up to the Product Tank Pressure Recipe Item value as the volume of product enters the product tank. The function is completed once the finite volume of product enters the Product Tank. The PRODUCT TANK RINSE function flushes the Product Tank with water from the Dearator. Pressure is maintained to the Product Tank and when the Product Tank Empty probe indicates the presence of water. The Product Tank Drain opens, thus draining the water to the floor. This function runs for a finite volume of water. The function terminates upon meeting the water volume requirements for the rinse. The PRODUCT TANK RUNOUT function is used to provide the filler with the remaining product in the product tank during a flavor change over. The PRODUCT TANK RUNOUT is initiated after a MIX LINE RUNOUT. During a PRODUCT TANK RUNOUT, pressure is maintained on the Product Tank and the Product Outlet Valve is left open until the Product Tank Empty Probe indicates the absence of product, which then the function is terminated. The RUNOUT START function initiates a flavor change over. The function checks the system to confirm that a flavor change is possible and then initiates a SYRUP RUNOUT. The STARTUP function initiates a sequence of functions which prepare the system for production. When the STARTUP function begins, it confirms that the Product Tank and the Syrup Reservoir are empty. If the tanks are not empty the STARTUP function stops, and the operator must first drain the tanks before attempting the STARTUP again. When the confirmation indicates that the tanks are empty, then the function initiates a SYRUP RESERVOIR RINSE, MIX LINE RINSE, PRODUCT TANK RINSE and a FILLER RINSE. The SYRUP RESERVOIR DRAIN function empties the contents of the Syrup Reservoir to the floor. The SYRUP RESERVOIR PRIME function is used to fill the Syrup Reservoir with syrup and recirculate the syrup through the mass flow meter in preparation for blending. The function opens the Active Syrup Port to deliver the syrup to the Syrup Reservoir, fills the Syrup Reservoir until the level reaches above the recirculation pipe inlet, and then uses the syrup to push
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
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OPERATIONS SCREENS
SYRUP RESV RINSE SYRUP RESV RUNOUT
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the contents (usually water) of the Syrup Mass Meter to drain. When the Syrup Meter contents is purged the drain is closed and the recirculation valve opens in order to recirculate the syrup through the Syrup Reservoir and the Syrup Mass Meter. The SYRUP RESERVOIR RINSE function flushes water from the Deaerator through the Syrup Reservoir, in order to remove the residual previous flavor syrup and/ or CIP solution. The SYRUP RESERVOIR RUNOUT function is used to delivery terminate the delivery of syrup to the Syrup Reservoir and blend the remaining syrup into the Product Tank. When the Syrup Reservoir syrup level reaches the bottom of the Syrup Reservoir, the remaining syrup is pushed through the Syrrup Mass Flow Meter with water from the Syrup Reservoir CIP Spray Valve.
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
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Syrup Port Command Glossary The Machine Screen provides the operator the ability to initiate the machine functions. Pushbutton / Indicator SYRUP LINE AUTO-PREP SYRUP LINE DRAIN SYRUP LINE CLOSE DIVERT PORT A CONNECTED PORT B CONNECTED SYRUP LINE PRIME
SYRUP LINE READY SYRUP LINE RINSE SYRUP LINE PURGE
SYRUP LINE RUNOUT
Action The SYRUP LINE AUTO PREP function automatically sequences the Syrup Line through a SYRUP LINE RINSE, SYRUP LINE DRAIN, and places the syrup line a SYRUP LINE READY state. The SYRUP LINE DRAIN function, removes liquid from the Direct syrup line, by using is a gas blow at the highest point the line, and opening the drain valves. The SYRUP LINE CLOSE DIVERT function will close the Direct Line Syrup Shutoff Valve. This function can only be used if the Direct Line is being used for production, otherwise this function is inhibited. The PORT A CONNECTED function toggles the “CONNECTED” state of the Syrup Port A The PORT A CONNECTED function toggles the “CONNECTED” state of the Syrup Port B The DIRECT LINE PRIME function is used to prepare the Syrup Line for production by packing the Syrup Line with syrup. The function opens a path through the Syrup Line to drain, in order provide a pressure relief for the syrup brought into the Syrup Line in the syrup room. This function is timed, and will stop after running approximately 5 seconds. The DIRECT LINE READY function toggles the “READY” state of the Direct Syrup Port The DIRECT LINE RINSE function flushes the Direct syrup line with water, in order to remove syrup and CIP residue. The source of the water is automated by a valve behind the syrup room divert panel. The SYRUP LINE PURGE function is used to push the syrup out of the active Syrup Line. When this function is running the Syrup reservoir Level Control Valve opens 100% to allow all the syrup in the syrup line to be pushed into the Syrup Reservoir. Not Applicable
Blending Operations Screen The Blending Operations Screen provides the operator the ability view blender proportioning, and gas injection flow rates and totals, along with Recipe and operator adjusted set points.. Step 1.
Action To view the Blending Operation Screen follow the links below from the home screen
2.
Home The Blending Operations Screen will display as shown below:
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
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SCREENS BLENDING OPERATIONS
Page 40 of 159
Accu-Brix Status
Blending Operations Command Screen
Blender Status Indicator
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
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SCREENS BLENDING OPERATIONS
Page 41 of 159
Blending Operations Command Screen The Blending Operations Command Screen provides the operator the ability to adjust the proportioning and gas injection set points, along with enabling the accu-brix control function. Step 1.
2.
Action To view the Blending Operation Command Screen follow the links below from the home screen
Home The Blending Operation Command Screen will display as shown below:
Accu-Brix Enable/ Disable Pushbutton
Operator Adjustments
Blender Status Indicator
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
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SCREENS BLENDING OPERATIONS
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Implied Syrup Brix The system calculates the (implied) syrup brix from the measured syrup density and measured syrup temperature. The accu-brix function uses the Implied Syrup Brix in calculating the percent syrup used in proportioning. Accu-brix Function The accu-brix function provides the ability to automatically adjust the percent syrup proportioned, based on the brix of the syrup delivered to the blender. Without the accu-brix function enabled, the system uses the value of the Syrup Brix from the recipe to calculate the percent syrup proportioned. With accu-brix function enabled, the system uses the Implied Syrup Brix to calculate the percent syrup proportioned. This allows the system to produce consistant quality of product independent of small variations in the incoming syrup brix. Follow the steps below to enable the accu-brix function. Step 1.
Action Follow the links below from the home screen
2.
Home Pressing the accu-Brix pushbutton will toggle the accu-brix enable/disable status. See pushbutton below.: Enabled/ Disabled Status Indicator
Indicator Color Red
Meaning
Green Yellow
The accu-brix function is enabled, and operating. The accu-brix function is enabled, but not operating, because the Active Recipe is a Diet Recipe.
The accu-brix function is disabled
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
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OPERATIONS SCREENS (CHANGE OVER)
Page 43 of 159
Change Over Screen The Change Over Screen provides the operator the ability to view the current steps of the flavor change over functions. The status of each function is displayed by the color of the indicator, and the flow of the change over is indicated by arrows. Step 1.
Action To view the Change Over Screen follow the links below from the home screen
2.
Home The Change Over Screen will display as shown below:
Change Over Flow Indication
Function Status Indicator
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
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OPERATIONS SCREENS (CHANGE OVER)
Page 44 of 159
Change Over Screen Color Meaning The Change Over Screen has a colored block for each function in the change over. The colored block indicated the state of each function in the current change over. Color
Meaning The function is not running. (OFF)
The function is waiting for some condition, before it will start executing.
The function is running (ON)
The function has run already during this change over (DONE)
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
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OPERATIONS SCREENS (CHANGE OVER)
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Production Record Screen The Production Record Screen displays information on the last ten production runs. Step 1.
Action To view the Production Record Screen follow the links below from the home screen
2.
Home The Production Record Screen will display as shown below:
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
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OPERATIONS SCREENS (CHANGE OVER)
Page 46 of 159
Change Over Tally Screen The Change Over Tally Screen displays for the current container cut off. Information regarding the amount of syrup and product in the system is used to calculate the number of depalletizer sweeps required to use all the product available. Step 1.
Action To view the Change Over Tally Screen follow the links below from the home screen
2.
Home The Change Over Tally Screen will display as shown below:
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
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OPERATIONS SCREENS (CHANGE OVER)
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Machine Cycle Screen The Machine Cycle Screen displays the different modules of the system and the Machine Function and Function Status for each module. Step 1.
Action To view the Machine Cycle Screen follow the links below from the home screen
2.
Home The Machine Cycle Screen will display as shown below:
Progress Bar
Machine Function Trend Screen
Function Status
The Trend Screen provides the operator the ability to choose one of seven realtime-trend displays that are available. Step
Action
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
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MACHINE COMMANDS MACHINE COMMAND
Page 48 of 159
1.
To view the Trend Screen follow the links below from the home screen
2.
Home The Machine Cycle Screen will display as shown below:
Select a trend display by pressing one the seven pushbuttons
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
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MACHINE COMMANDS MACHINE COMMAND
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Trend Mass Flow Screen The Trend Mass Flow Screen displays a real-time trend of the water and syrup, target and actual mass flow Step 1.
Action To view the Trend Mass Flow Screen follow the links below from the home screen
2.
Home The Trend Mass Flow Screen will display as shown below: Target flow rate
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
Actual flow rate
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SCREENS CIP
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CIP Screen The CIP Screen provides the operator the ability to CIP the system. Step 1.
Action To view the CIP Screen follow the links below from the home screen
2.
Home The CIP Screen will display as shown below:
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
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SCREENS CIP
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CIP Program Screen The CIP Screen provides the operator the ability to select one of five different CIP Programs. Each CIP step for the selected program is listed. Step 1.
Action To view the CIP Screen follow the links below from the home screen
2.
Home The CIP Screen will display as shown below:
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
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SCREENS ALARM
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
Page 52 of 159
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SCREENS ALARM
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Alarm Screen The Alarm Screen displays the status of the machine Alarms and prvides the operator access to the Alarm Status Screen and the Alarm History Screen. Step 1.
Action To view the Alarm Screen follow the links below from the home screen
2.
Home The Alarm Screen will display as shown below:
Use these buttons to go to the Alarm Status or Alarm History Screens
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
Press this button to reset all alarms
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SCREENS ALARM
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Alarm Indicators In the center of the Alarm Screen are four indicators, which change from black to a color, when a condition exists as described below. Alarm Indicator Descriptions
Indicates that an alarm occurred, which has stopped the machine (faulted out)
Indicates that an alarm occurred that will not stop the machine, but the condition of the machine should be reviewed by the operator. Indicates that the machine is blending normally.
Indicates that the system is in a flavor change over, and has pulled in the container stop, waiting for the operator to confirm a line back up.
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
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SCREENS ALARM
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Alarm Messages The table below gives a description of each Alarm Message. Alarm Message ACCU-BRIX CALCULATION OUT OF RANGE
Why and When This alarm occurs if the difference between the Recipe Syrup Brix and the accu-brix Implied Syrup Brix calculation is more than 3.0 Brix.
Meaning The accu-brix function is used to adjust the syrup proportioning within a reasonable syrup brix variation. Variations outside the norm are alarmed to bring the attention to the operator that the syrup may be for a different flavor.
79
ACCU-BRIX SYRUP DENSITY TOO HIGH
80
ACCU-BRIX SYRUP DENSITY TOO LOW
77
ACCU-BRIX SYRUP TEMPERATURE TOO HIGH
78
ACCU-BRIX SYRUP TEMPERATURE TOO LOW
34
Active Recipe: Invalid Recipe
This alarm occurs when Accu-Brix is operating and if the Syrup Density rises above the High Syrup Density Limit for the Implied Syrup Brix Calculation. This alarm occurs when Accu-Brix is operating and if the Syrup Density falls below the Low Syrup Density Limit for the Implied Syrup Brix Calculation. This alarm occurs when Accu-Brix is operating and if the Syrup Temperature rises above the High Syrup Temperature Limit for the Implied Syrup Brix Calculation. This alarm occurs when Accu-Brix is operating and if the Syrup Temperature falls below the Low Syrup Temperature Limit for the Implied Syrup Brix Calculation. This alarm occurs if the Active Recipe Number is not between 1 to 100.
35
Active Recipe: Syrup Ports Do Not Match
An invalid reading from the Syrup Meter Density output may be caused by one of the following: 1) Syrup Flow Meter Transducer Failure. 2) Analog Input Failure. 3) Incorrect Syrup. An invalid reading from the Syrup Meter Density output may be caused by one of the following: 1) Syrup Flow Meter Transducer Failure. 2) Analog Input Failure. 3) Incorrect Syrup. An invalid reading from the Syrup Temperature Transducer may be caused by one of the following: 1) Syrup Temperature Transducer Failure 2) Analog Input Failure. 3) Incorrect Syrup. An invalid reading from the Syrup Temperature Transducer may be caused by one of the following: 1) Syrup Temperature Transducer Failure 2) Analog Input Failure. 3) Incorrect Syrup. If the Active Recipe Number is not within a valid range the system will not proceed. The Active Recipe should be checked. Reloading the recipe may be required. The Operator Selected Syrup Port must match the Recipe Syrup Port. This redundancy minimizes the possibility of opening the incorrect Syrup Port.
51
This alarm occurs if the Operator Selected Active Syrup Port does not match the Active Recipe Syrup Port. Not: If the Active Recipe Syrup Port is “Any Port”, the Operator Selected Active Syrup Port may be any valve, except for “None”.
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
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SCREENS ALARM
Alarm Message AIR PRESSURE LOW (FAULT)
Why and When This alarm occurs when the Air Pressure switch located in the Blender pneumatic panel senses a Low Air Supply.
42
AUTO START UP NOT STARTED (CHECK SYSTEM)
This alarm occurs when the operator presses the AUTO START button, and the conditions for initiating Auto Start Up are not valid.
15
BLEND, SYRUP STREAM HIGH (OUT OF CONTROL)
This alarm occurs when the Syrup Stream Zero Balance has out of range, delivering too much syrup for 6 seconds.
16
BLEND, SYRUP STREAM LOW (OUT OF CONTROL)
This alarm occurs when the Syrup Stream Zero Balance has out of range, delivering not enough syrup for 6 seconds
27
CIP CONDUCTIVITY TRANSDUCER FAILURE
This alarm occurs when the 420ma signal on the transducer transmitter is significantly below 4ma or greater than 20ma.
64
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
Page 56 of 159
Meaning Typically an air supply of 100psi is required to the blender. The Air Supply is regulated to 90psi typical, by an internal regulator in the Blender pneumatic panel. Low Air Supply Pressure may be caused by one of the following: 1) Low incoming air pressure and or volume from plant air system. 2) A failed Air Supply Regulator inside the Blender pneumatic panel. 3) A failed Air Supply Pressure Sensor, located inside the Blender pneumatic panel. Conditions which inhibit the AUTO START button are: 1) BAD NEXT RECIPE. 2) SYRUP PORT IS CONNECTED. 3) SYRUP RESERVOIR IS NOT EMPTY 4) FILLER NOT READY FOR START UP 5) AUTO NOT ENABLED The Syrup Stream Zero Balance can be viewed from the Trend Screen. Conditions which may cause a High Syrup Stream are: 1) Poor Water Stream control caused by Product Flow Control Valve not responding. 2) Syrup Proportioning Pump not responding to a speed adjustment sent by the PLC. 3) Syrup Flow sensor or transmitter malfunction. 4) Water Flow sensor or transmitter malfunction The Syrup Stream Zero Balance can be viewed from the Trend Screen. Conditions which may cause a Low Syrup Stream are: 1) Poor Water Stream control caused by Product Flow Control Valve not responding. 2) Syrup Proportioning Pump not responding to a speed adjustment sent by the PLC. 3) A total Syrup Proportioning Pump malfunction. 4) Syrup Flow sensor or transmitter malfunction. 5) Water Flow sensor or transmitter malfunction This alarm can be caused; 1) Electrical failure of the device itself. 2) Faulty wiring. 3) Failure of the PLC analog input.
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SCREENS ALARM
50
13
65
9
6
Alarm Message CIP RETURN PUMP HAS FAILED
CIP SUPPLY TEMPERATURE TRANSMITTER FAILURE CIP TEMPERATURE HIGH ALARM (STEAM DISABLED) CIP TEMPERATURE TRANSMITTER FAILURE DC POWER FAILURE
1
ESTOP PRESSED
82
FILLER BLENDER COMMUNICATION S FAILURE
71
FILLER BLOW NOT REACHING HIGH PRESSURE
70
FILLER BLOW NOT REACHING LOW PRESSURE
Why and When This alarm occurs if the PLC output to the pump is turned on, and the auxiliary feedback on the pump contactor does not indicate the pump is running within 3 seconds. This alarm occurs when the 420ma signal on the transducer transmitter is significantly below 4ma or greater than 20ma. This alarm occurs during CIP if the Product Temperature, Syrup Temperature or Water Temperature exceeds 92 degrees C. This alarm occurs when the 420ma signal on the transducer transmitter is significantly below 4ma or greater than 20ma. This alarm occurs when the PLC no longer senses the presence of the DC power supply voltage. This alarm occurs if the PLC does not sense the presence of voltage from the E-Stop circuit. Indicating that the circuit has been broken, by an E-Stop being pressed or a power failure. This alarm occurs when the handshake signal sent back and forth over the remote IO communication network, between the Blender and the Filler fails over a 4 second period. This alarm occurs during a Filler Blow, if the sequence waits more than 150 seconds for the Bowl pressure to reach high pressure.
This alarm occurs during a Filler Blow, if the sequence waits more than 100 seconds for the Bowl pressure to reach low pressure.
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
Page 57 of 159
Meaning This alarm can be caused by: 1) Tripped overload protection. 2) Faulty motor starter. 3) Faulty wiring to motor starter. 3) Faulty feedback wiring from auxiliary contact on motor starter to PLC input. This alarm can be caused; 1) Electrical failure of the device itself. 2) Faulty wiring. 3) Failure of the PLC analog input. The steam is disabled if this alarm occurs.
This alarm can be caused; 1) Electrical failure of the device itself. 2) Faulty wiring. 3) Failure of the PLC analog input. This alarm can be caused; 1) Electrical failure of the DC Power Supply. 2) Faulty wiring. 3) Failure of the PLC digital input. This alarm can be caused by: 1) The operator pressing the E-Stop Button on the operator panel. 2) E-Stop circuit power loss.
This alarm can be caused by Remote IO wiring problems, Remote IO Communication Card problems, or power failure on either end of the network.
This alarm indicates that something is wrong with the pressure source under the filler, or that there may be a leak in the filler, which is keeping the filler bowl from pressurizing. This alarm may also be caused by a Filler Bowl Pressure Transducer failure. This alarm indicates that either the valve opener of the filler is not working properly. This alarm may also be caused by a Filler Bowl Pressure Transducer failure.
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SCREENS ALARM
Alarm Message FILLER FILLING VALVES NOT RESPONDING
Why and When This alarm occurs if the blender sends a signal to the filler to open the filling valves, and the filler fails to signal back that the filling valves are open.
57
FILLER NOT EMPTY
This alarm occurs during a Filler Charge, when either the Filler Empty Point Probe or the Filler Operating Point Probe indicates the presence of a liquid (water).
59
FILLER NOT ROTATING FOR CHANGEOVER
This alarm occurs if the Filler is not rotating during a Filler Rinse, Filler Drain, or Filler Blow.
10
FILLER PRESSURE TRANSDUCER FAILURE FILLER ROTATING TOO SLOW
This alarm occurs when the signal 4-20ma signal from the transducer is out of range.
61
62
This alarm occurs if the Filler is not rotating at a minimum rate during a Filler Rinse, Filler Drain, or Filler Blow. This alarm occurs if the Filler speed control is not in Automatic mode during a Filler Rinse, Filler Drain, or Filler Blow.
73
FILLER SPEED CONTROL MUST BE IN AUTO
74
FILLER VALVE OPENER CONTROL MUST BE IN AUTO
This alarm occurs if the Filler Valve Opener control is not in Automatic mode during a Filler Rinse, Filler Drain, or Filler Blow.
12
GAS FLOW TRANSMITTER FAILURE
This alarm occurs when the 420ma signal on the transducer transmitter is significantly below 4ma or greater than 20ma.
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
Page 58 of 159
Meaning This alarm indicates that either the valve opener of the filler is not working properly, or that there may be something wrong with the blender-filler communications. This alarm may also be caused by the Filler Valve Opener being in a manual/hand mode, rather than an Automatic type mode. Review messages on filler operating console or call filler manufacturer. During an automated change over, after a Filler Blow, the Filler Product line should be dry. If the system detects water a Filler Charge, the system will not bring in the product into the Filler, by not performing a Filler Prime automatically. During an automated change over the Filler must rotate in order to implement the correct sequences. Review messages on filler operating console or call filler manufacturer. This alarm can be caused; 1) Electrical failure of the device itself. 2) Faulty wiring. 3) Failure of the PLC analog input. During an automated change over the Filler must rotate at a minimum rate in order to implement the correct sequences. During an automated change over the Filler speed setpoint is sent to the Filler for optimum rinsing and draining. Poor product quality may result if the Filler is not running at optimum speed. Review messages on filler operating console or call filler manufacturer. During an automated change over the Filler Valve Opener must be under the control of the blender in order to implement the correct sequences. Poor product quality may result if the Filler is not under the control of the blender during the change over sequences. Review messages on filler operating console or call filler manufacturer. This alarm can be caused; 1) Electrical failure of the device itself. 2) Faulty wiring. 3) Failure of the PLC analog input.
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SCREENS ALARM
81
Alarm Message GAS PROPORTIONING VALVE AT 100%
17
GAS INJECTOR STREAM HIGH (OUT OF CONTROL)
18
GAS INJECTOR STREAM LOW (OUT OF CONTROL)
40
INVALID CONTAINER TYPE
52
MIX LINE PRIME, SYRUP STREAM HIGH (OUT OF CONTROL)
53
MIX LINE PRIME, SYRUP STREAM LOW (OUT OF CONTROL)
Why and When This alarm occurs if the gasproportioning valve stays open 100% for 6 seconds while trying to proportion the correct amount of gas. This signals that the gas proportioning valve is unable to maintain the proper gas flow while in an operating range in which the valve can sustain control. This alarm occurs if the gas proportioning delivers too much gas and does not compensate within 6 seconds, during Blending. This alarm occurs if the gas proportioning does not deliver enough gas and does not compensate within 6 seconds, during Blending. This alarm occurs when the Operator Selected Container Type is not a valid selection. This alarm occurs if the syrup proportioning delivers too much syrup and does not compensate within 6 seconds, during a Mix Line Prime.
This alarm occurs if the syrup proportioning does not deliver enough syrup and does not compensate within 6 seconds, during a Mix Line Prime.
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
Page 59 of 159
Meaning This alarm can be caused by: 1) Gas Proportioning Valve not being able to open. 2) Inadequate gas supply pressure. 3) Gas Flow Transmitter failure.
This alarm can be caused by: 1) Gas Proportioning Valve not being able to seat itself closed. 2) Gas Flow Transmitter failure. This alarm can be caused by: 1) Gas Proportioning Valve not being able to open. 2) Inadequate gas supply pressure. 3) Gas Flow Transmitter failure. It is required that the Operator Selected Container Type be chosen for every production run. The Syrup Stream Zero Balance can be viewed from the Trend Screen. Conditions which may cause a High Syrup Stream are: 1) Poor Water Stream control caused by Product Flow Control Valve not responding. 2) Syrup Proportioning Pump not responding to a speed adjustment sent by the PLC. 3) Syrup Flow sensor or transmitter malfunction. 4) Water Flow sensor or transmitter malfunction The Syrup Stream Zero Balance can be viewed from the Trend Screen. Conditions which may cause a Low Syrup Stream are: 1) Poor Water Stream control caused by Product Flow Control Valve not responding. 2) Syrup Proportioning Pump not responding to a speed adjustment sent by the PLC. 3) A total Syrup Proportioning Pump malfunction. 4) Syrup Flow sensor or transmitter malfunction. 5) Water Flow sensor or transmitter malfunction
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SCREENS ALARM
47
Alarm Message MIX PUMP HAS FAILED
Why and When This alarm occurs if the PLC output to the pump is turned on, and the auxiliary feedback on the pump contactor does not indicate the pump is running within 3 seconds. This alarm occurs if the Next Recipe Number is not between 1 to 100, 5 minutes before a nonoperator triggered run out. This alarm occurs if the Next Recipe Operator Selected Next Syrup Port does not match the Recipe Syrup Port. If the Next Recipe Syrup Port is “Any Port”, the Operator Selected Next Syrup Port may be any valve, except for “None”. This alarm occurs during a CIP, if the Syrup Mass Flow is less than the minimum allowable CIP flow limit.
32
Next Recipe: Invalid Recipe (5 Min. Warning)
33
Next Recipe: Syrup Ports Do Not Match (5 Min. Warning)
67
NO CIP FLOW ALARM - SYRUP SIDE
66
NO CIP FLOW ALARM - WATER SIDE
This alarm occurs during a CIP, if the Water Mass Flow is less than the minimum allowable CIP flow limit.
48
PRODUCT PUMP / CIP DELIVERY PUMP HAS FAILED
56
PRODUCT TANK GAS INLET VALVE AT 100%
This alarm occurs if the PLC output to the pump is turned on, and the auxiliary feedback on the pump contactor does not indicate the pump is running within 3 seconds. This alarm occurs during blending if the Tank Pressure Source Modulating Valve is required to be opened at 100% for more than 20 seconds.
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
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Meaning This alarm can be caused by: 1) Tripped overload protection. 2) Faulty motor starter. 3) Faulty wiring to motor starter. 3) Faulty feedback wiring from auxiliary contact on motor starter to PLC input.
A minimum flow is required during a CIP. Check valves and pumps for proper operation. This alarm can be caused by a number of reasons; 1) Syrup Proportioning Pump failure 2) Failure of a valve to open upstream of the Syrup Reservoir. 3) Loss of water upstream of the Syrup Reservoir. 4) Air supply failure. 5) Syrup Flow sensor or transmitter failure. A minimum flow is required during a CIP. Check valves and pumps for proper operation. This alarm can be caused by a number of reasons; 1) Insufficient water supply 2) Failure of a valve to open upstream of the Water Flow meter. 3) Air supply failure. 5) Water Flow sensor or transmitter failure. This alarm can be caused by: 1) Tripped overload protection. 2) Faulty motor starter. 3) Faulty wiring to motor starter. 3) Faulty feedback wiring from auxiliary contact on motor starter to PLC input. This alarm indicates that there may be a problem with tank pressure gas source, or Tank Pressure Source Modulating Valve. Check gas source pressure and volume, and check Tank Pressure Source Modulating Valve operation.
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SCREENS ALARM
43
Alarm Message PRODUCT TANK IS LOW
11
PRODUCT TEMPERATURE HIGH ALARM
44
PRODUCT TANK LEVEL TRANSMITTER FAILURE (ANALOG) PRODUCT TEMPERATURE HIGH ALARM
11
7
68
31
41
PRODUCT TEMPERATURE TRANSDUCER FAILURE REFRIGERATION NOT RUNNING (ALARM)
SYRUP CONDUCTIVITY TRANSDUCER FAILURE SYRUP DENSITY LOW FAULT
54
SYRUP DENSITY TOO HIGH FOR DIET
8
SYRUP DENSITY TRANSMITTER FAILURE
36
SYRUP FLOW TRANSMITTER FAILURE (ANALOG)
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Why and When This alarm occurs if the Product Tank Low Level Sensor does not sense a product for delivery to the Filler. Typically the container stop will be disabled. This alarm occurs if the Product Temperature rises above the Recipe Maximum Product Temperature value. This alarm occurs when the 420ma signal on the transducer transmitter is significantly below 4ma or greater than 20ma.
Meaning This alarm keeps the Product Tank from running dry. This alarm can occur if the Blender is having trouble keeping up with the Filler demand.
This alarm occurs when the Product Temperature rises above the Maximum Product Temperature setpoint in the Active Recipe. This alarm occurs when the 420ma signal on the transducer transmitter is significantly below 4ma or greater than 20ma. This alarm occurs when the blender is not receiving the signal from the Refrigeration system, when the blender is calling for Refrigeration. This alarm occurs when the 420ma signal on the transducer transmitter is significantly below 4ma or greater than 20ma. This alarm occurs if the syrup density measured by the mass flow meter is less than the Recipe Item Syrup Density Low value.
This alarm can occur from; 1) The filler remaining idle for extended periods, where the product is then warmed from the ambient air. 2) Refrigeration system failure This alarm can be caused by; 1) Electrical failure of the device itself. 2) Faulty wiring. 3) Failure of the PLC analog input. This alarm can be caused by; 1) Refrigeration System not turned on. 2) Refrigeration System failure. 3) Faulty wiring. 4) Failure of the PLC digital output or input. This alarm can be caused; 1) Electrical failure of the device itself. 2) Faulty wiring. 3) Failure of the PLC analog input. The syrup density is constantly checked to confirm that the quality of the syrup has not been inadvertently compromised by the syrup room delivery or the wrong syrup being delivered to the blender. Syrup delivery errors are possible, when performing tank changes in the syrup room. This alarm is check for those errors.
This alarm occurs when a Diet recipe is active and the syrup density measured by the syrup mass flow meter, is greater than 1.10 g/cc. This alarm occurs when the 420ma signal on the transducer transmitter is significantly below 4ma or greater than 20ma. This alarm occurs when the 420ma signal on the transducer transmitter is significantly below 4ma or greater than 20ma.
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
This alarm indicates that the product is warm, and perhaps there is a refrigeration issue. This alarm can be caused by; 1) Electrical failure of the device itself. 2) Faulty wiring. 3) Failure of the PLC analog input.
This alarm can be caused by; 1) Electrical failure of the device itself. 2) Faulty wiring. 3) Failure of the PLC analog input. This alarm can be caused by; 1) Electrical failure of the device itself. 2) Faulty wiring. 3) Failure of the PLC analog input. Cover Page.doc1 Rev. 00/00/01
SCREENS ALARM
3
49
22
Alarm Message SYRUP LEVEL TRANSDUCER FAILURE SYRUP POSITIVE DISPLACEMENT PUMP HAS FAILED SYRUP PROPORTIONING PUMP AT 100%
21
SYRUP RESERVOIR HIGH (OVERFLOW!)
72
SYRUP RESERVOIR LEVEL LOW ALARM
38
SYRUP RESERVOIR PRIME EXCEEDED MAXIMUM VOLUME - CHECK SYRUP! SYRUP RESEVOIR EMPTY PROBE FAILURE
23
2
69
SYRUP TEMPERATURE TRANSDUCER FAILURE SYRUP ROOM BLENDER COMMUNICATION S FAILURE (ALARM)
Why and When This alarm occurs when the 420ma signal on the transducer transmitter is significantly below 4ma or greater than 20ma. This alarm occurs when the syrup pump variable frequency drive sends a fault signal to the system PLC. This alarm occurs when the Syrup Proportioning pump is required by the control algorithm to run at 100%, in order to maintain flow.. This alarm indicates that liquid has been detected by the Syrup Reservoir
This alarm occurs when blending, if the Syrup Reservoir level drops below the minimum level required to run out the containers on the empty side. This alarm occurs when the Syrup Reservoir Prime pushes the rinse water to drain before it detects good syrup, and the total amount pushed to drain exceeds the maximum volume limit. This alarm occurs when the Syrup Reservoir Capacitance Probe indicates a level in the Syrup Reservoir, but the Syrup Reservoir Empty Probe does not sense any liquid. This alarm occurs when the 420ma signal on the transducer transmitter is significantly below 4ma or greater than 20ma. This alarm occurs when the blender does not receive a handshake reply from the Syrup Room PLC within 4 seconds. Which indicates that the two devices are no longer communicating.
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
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Meaning This alarm can be caused by; 1) Electrical failure of the device itself. 2) Faulty wiring. 3) Failure of the PLC analog input.
This alarm indicates either a problem with the Syrup Proportioning Pump or a problem with the syrup delivery to the Syrup Proportioning Pump. This alarm is used to inhibit the possibility of over flowing the Syrup Reservoir do to a level control failure. This alarm can be overridden by pressing and holding the BLEND button down, in order to blend syrup out of the Syrup Reservoir. When this alarm occurs, the system will signal the container stop to close. This will safe guard the amount of product/syrup to run out the empty containers on the line. This alarm is a safe guard against pushing too much syrup to drain. If this alarm occurs, check 1) That the correct syrup has been delivered to the blender. 2) That the syrup delivered to the blender is not diluted. This alarm is used to detect the possible failure of the Syrup Reservoir Empty Probe.
This alarm can be caused by; 1) Electrical failure of the device itself. 2) Faulty wiring. 3) Failure of the PLC analog input. This alarm can be caused by 1) Syrup Room PLC malfunction. 2) Syrup Room or Blender Communications channel failure. 3) Faulty wiring.
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SCREENS ALARM
Alarm Message TANK PRESSURE LOW TOLERANCE RANGE WARNING
Why and When This alarm occurs during blending when the Product Tank Pressure is 1.0 psi lower or less than the setpoint for 20 seconds.
83
TANK PRESSURE HIGH TOLERANCE RANGE WARNING
This alarm occurs during blending when the Product Tank Pressure is 1.0 psi or more higher than the setpoint for 20 seconds.
4
TANK PRESSURE TRANSDUCER FAILURE
39
TREATED WATER PUMP HAS FAILED (FAULT)
24
VACUMM DEAERATOR CONDENSER HAS BEEN PURGED
This alarm occurs when the 420ma signal on the transducer transmitter is significantly below 4ma or greater than 20ma. This alarm occurs if the PLC output to the pump is turned on, and the auxiliary feedback on the pump contactor does not indicate the pump is running within 3 seconds. This alarm occurs if the Water Condenser on the suction of the Vacuum Pump detects the presence of liquid. When it does, an automated sequence is initiated, which purges the contents of the Condenser.
55
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
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Meaning This alarm is a warning that there may be some difficulty controlling the tank pressure during the present operation. This alarm can be caused by; 1) Low supply pressure from gas source. 2) Problem with the Product Tank Gas Source valving. 3) Rapid loss of product level, which can make it difficult to maintain tank pressure.. This alarm is a warning that there may be some difficulty controlling the tank pressure during the present operation. This alarm can be caused by; 1) Problems with the Product Tank Gas Exhaust valving. 3) Rapid increase of product level, which can make it difficult to relieve the tank pressure.. This alarm can be caused by; 1) Electrical failure of the device itself. 2) Faulty wiring. 3) Failure of the PLC analog input. This alarm can be caused by: 1) Tripped overload protection. 2) Faulty motor starter. 3) Faulty wiring to motor starter. 3) Faulty feedback wiring from auxiliary contact on motor starter to PLC input. The Water condenser ensures that no liquid water enters the Vacuum Pump and subsequently damages it. This alarm may happen once a day. If this alarm occurs more than a day, an investigation of the Water Condenser system on the Vacuum Deaerator should be undertaken by Maintenance. This alarm can be caused by; 1) General build up of water mist in the Water Condenser. 2) The water level in the Vacuum Deaerator being to high, and traveling down the Vacuum Line, in which the Level Control Probe or the Level Control Valve may have failed.
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SCREENS ALARM
Alarm Message VACUUM DEAERATOR HIGH WATER LEVEL
Why and When This alarm occurs when the level of the Vacuum Deaerator rises above 65%.
60
VACUUM DEAERATOR LEVEL OR POINT PROBE FAILURE
63
VACUUM DEAERATOR LEVEL TRANSMITTER FAILURE (ANALOG) VACUUM DEAERATOR PRESSURE TOO LOW (ALARM WAIT)
This alarm occurs when the Vacuum Deaerator Level Capacitance Probe indicates a level in the Vacuum Deaerator, but the Vacuum Deaerator Empty Probe does not sense any liquid. This alarm occurs when the 420ma signal on the transducer transmitter is significantly below 4ma or greater than 20ma.
25
26
30
58
46
VACUUM DEAERATOR VACUUM PRESSURE LOW (ALARM) VACUUM DEAERATOR WATER LEVEL IS LOW
VACUUM DEAERATOR WATER PUMP HAS FAILED
This alarm occurs when the vacuum level in the Vacuum Dearator Vessel is insufficient to dearate the water. The system will stop blending until a proper vacuum is achieved. This alarm occurs when the vacuum level in the Vacuum Dearator Vessel is not optimum in order to dearate the water. This is a warning type alarm. This alarm occurs when the level of the Vacuum Deaerator falls below 10%.
This alarm occurs if the PLC output to the pump is turned on, and the auxiliary feedback on the pump contactor does not indicate the pump is running within 3 seconds.
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Meaning A capacitance probe and a modulating valve control the level of the Vacuum Dearator. If the level rises too high, water may travel down the vacuum line towards the Vacuum Pump, creating a potentially damaging situation for the Vacuum Pump. This alarm can be caused by; 1) Failed open water inlet modulating valve. 2) Capacitance probe failure. This alarm is used to detect the possible failure of the Vacuum Deaerator Empty Probe.
This alarm can be caused by; 1) Electrical failure of the device itself. 2) Faulty wiring. 3) Failure of the PLC analog input.
This alarm can be caused by; 1) Vacuum pump failure. 2) Vacuum transducer failure. 3) a valve in the Vacuum system, sticking closed.
This alarm can be caused by; 1) Vacuum pump failure. 2) Vacuum transducer failure. 3) a valve in the Vacuum system, sticking closed. A capacitance probe and a modulating valve control the level of the Vacuum Dearator. If the level rises too high, water may travel down the vacuum line towards the Vacuum Pump, creating a potentially damaging situation for the Vacuum Pump. This alarm can be caused by; 1) Failed closed water inlet modulating valve. 2) Capacitance probe failure. This alarm can be caused by: 1) Tripped overload protection. 2) Faulty motor starter. 3) Faulty wiring to motor starter. 3) Faulty feedback wiring from auxiliary contact on motor starter to PLC input.
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SCREENS ALARM
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45
Alarm Message VACUUM PRESSURE TRANSDUCER FAILURE VACUUM PUMP HAS FAILED
Why and When This alarm occurs when the 420ma signal on the transducer transmitter is significantly below 4ma or greater than 20ma. This alarm occurs if the PLC output to the pump is turned on, and the auxiliary feedback on the pump contactor does not indicate the pump is running within 3 seconds. This alarm occurs when the over temperature switch on the vacuum pump indicates an over temperature.
28
VACUUM PUMP TEMPERATURE TOO HIGH
14
VACUUM PUMP TEMPERATURE TRANSDUCER FAILURE VACUUM PUMP OIL CHANGE REQUIRED SOON
This alarm occurs when the 420ma signal on the transducer transmitter is significantly below 4ma or greater than 20ma. This alarm occurs when the Vacuum Pump Hour timer exceeds the Vacuum Pump Oil Change Warning Timer Limit.
85
VACUUM PUMP OIL CHANGE REQUIRED NOW
This alarm occurs when the Vacuum Pump Hour timer exceeds the Vacuum Pump Oil Change Alarm Timer Limit.
37
WATER FLOW TRANSMITTER FAILURE (ANALOG) WATER STREAM HIGH (OUT OF CONTROL)
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20
WATER STREAM LOW (OUT OF CONTROL)
This alarm occurs when the 420ma signal on the transducer transmitter is significantly below 4ma or greater than 20ma. This alarm occurs if water flow control is delivering more than 100 kg/min higher than the target flow. This alarm occurs if water flow control is delivering less than 100 kg/min lower than the target flow.
5
WATER TEMPERATURE TRANSDUCER FAILURE
This alarm occurs when the 420ma signal on the transducer transmitter is significantly below 4ma or greater than 20ma.
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Meaning This alarm can be caused by; 1) Electrical failure of the device itself. 2) Faulty wiring. 3) Failure of the PLC analog input. This alarm can be caused by: 1) Tripped overload protection. 2) Faulty motor starter. 3) Faulty wiring to motor starter. 3) Faulty feedback wiring from auxiliary contact on motor starter to PLC input. The temperature of the Vacuum Pump system is an temperature sensor located in the vacuum pump, and cooling water delivered through a heat exchanger, located on top of the vacuum pump. This alarm can be caused by; 1) Loss of cooling water supply. 2) Temperature transducer failure. 3) Cooling water ball valve failure. This alarm can be caused by; 1) Electrical failure of the device itself. 2) Faulty wiring. 3) Failure of the PLC analog input. The Vacuum Pump is required to have the oil change periodically. Once the oil has been changed, the Vacuum Pump Hour must be reset from the Vacuum Pump Maintenance Screen. The Vacuum Pump is required to have the oil change periodically. Once the oil has been changed, the Vacuum Pump Hour must be reset from the Vacuum Pump Maintenance Screen. This alarm can be caused by; 1) Electrical failure of the device itself. 2) Faulty wiring. 3) Failure of the PLC analog input. The water flow has to be within range. The Mix Throttling Valve and water delivery system to the blend skid can effect the water flow. The water flow has to be within range. The Mix Throttling Valve and water delivery system to the blend skid can effect the water flow. This alarm can be caused by; 1) Electrical failure of the device itself. 2) Faulty wiring. 3) Failure of the PLC analog input.
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SCREENS ALARM
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85
Alarm Message VACUUM PUMP OIL CHANGE REQUIRED SOON
VACUUM PUMP OIL CHANGE REQUIRED NOW
Why and When This alarm message is a warning that is activated when the Vacuum Pump Hour Timer exceeds the Warning Hours parameter value, set in the Maintenance Vacuum Pump Screen. This alarm is activated when the Vacuum Pump Hour Timer exceeds the Alarm Hours parameter value, set in the Maintenance Vacuum Pump Screen.
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Meaning This alarm message is a warning to the operator that an oil change of the Vacuum Pump is required in the near future.
This alarm indicates to the operator that an oil change of the Vacuum Pump is past due.
Blender Screen The Blender Screen provides the operator the ability to view the Blender Module valve position, pump speed, flow rates and current Machine Function. Step 1.
Action To view the Blender Screen follow the links below from the home screen
2.
Home The Blender Screen will display as shown below:
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
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SCREENS BLENDER
Press Here to Go To Deox Graphic
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Press Here to Go To Syrup Room Graphic
Press Here to Go To Injector Graphic
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SCREENS BLENDER
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Blender Screen Indicators There are a number of colored indicators on the Blender Screen, which show the state of the level of the syrup in the Syrup Reservoir. LP201 Syrup Reservoir Level High Probe. Green means syrup level is high. Red means the syrup level is below the high level.
LP203 Syrup Reservoir Level Low Probe. Green means product is present at the bottom of the Syrup Reservoir. Red means the Syrup Reservoir is empty.
LP200 Syrup Line – Syrup Detection Probe. Green indicates. Syrup or Water (liquid) is present in the syrup Line. Red indicates the Syrup Line is empty.
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
CT201 Syrup Line Conductivity Transmitter. Indicates conductivity of Syeup in the Syrup Line feeding the blender.
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SCREENS BLENDER
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Blender Command Screen The Blender Command Screen provides the operator the initiate Blender Module Machine Commands and make operator adjustments to the proportioning. Step 1.
Action To view the Blender Command Screen follow the links below from the home screen
2.
Home The Blender Command Screen will display as shown below: Use the Up/Down arrows to change the Operator Adjusted Brix
Deaeration Unit Screen
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SCREENS DEAERATION UNIT
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The Deaeration Unit Screen provides the operator the ability to view the Deox (Vacuum Deaeration unit) valve position and pump status. Step 1.
Action To view the Deaeration Unit Screen follow the links below from the home screen
2.
Home The Deaeration Unit Screen will display as shown below:
Press Here to go to CIPSkid
Press Here to go to Blender Graphic
Indicates number of seconds left in warm up or warm down.
Press here to go to enable Vacuum
Press Here to to enable Dearator
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SCREENS GAS INJECTOR
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Gas Injector Screen The Gas Injector Screen provides the operator the ability to view the position and status of the valves on the Gas Injector Module. Step 1.
Action To view the Gas Injector Screen follow the links below from the home screen
2.
Home The Gas Injector Screen will display as shown below:
Press here to go to Product Tank Graphic
Press here to go to Blender Graphic
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SCREENS GAS INJECTOR
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Gas Injector Command Screen The Gas Injector Command Screen provides the operator the ability to adjust the Gas Injector set point. Step 1.
Action To view the Gas Injector Command Screen follow the links below from the home screen
2.
Home The Gas Injector Command Screen will display as shown below:
Use Up/Down arrows to adjust the Gas Injector Set point,
Press Here to go to Product Tank Graphic Press here to go to Blender Graphic
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SCREENS PRODUCT TANK
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Product Tank Screen The Product Tank Screen provides the operator the ability to view the position and status of the valves on the Product Tank Module. Step 1.
Action To view the Product Tank Screen follow the links below from the home screen
2.
Home The Product Tank Screen will display as shown below:
Press here to got to Injector Graphic
Press here to got to Filler Graphic Press here to got to Injector Graphic
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
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SCREENS PRODUCT TANK
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Product Tank Screen Indicators There are a number of colored indicators on the Product Tank Screens, which show the state of the level of the product in the Product Tank.
Indicator Beverage Available
Description When the blender has sufficient level of product in the Product Tank for delivery to the Filler, this indicator will turn green.
LP401 Product Tank Empty Probe. Green means product is present at the bottom of the Product Tank. Red means the Product Tank is empty.
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SCREENS PRODUCT TANK
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Product Tank Command Screen The Product Tank Command Screen provides the operator the ability to adjust the Product Tank pressure and the product temperature set points. Step 1.
Action To view the Product Tank Command Screen follow the links below from the home screen
2.
Home The Product Tank Command Screen will display as shown below:
Use Up/Down arrows to adjust the Product Temperature if Accu-Temp Option is installed
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
Use Up/Down arrows to adjust the Product Tank Pressure
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SCREENS PRODUCT TANK
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Product Tank Refrigeration Screen The Product Tank Command Screen provides the operator the ability to adjust the Product Tank pressure and the product temperature set points. This screen is available with the Accu-Temp option. Step 1.
Action To view the Product Tank Command Screen follow the links below from the home screen
2.
Home The Product Tank Command Screen will display as shown below:
Accu-temp BPRV control variables
Product Tank Refrigeration Screen Indicators
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA 847-882-0690
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SCREENS PRODUCT TANK
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There are a number of colored indicators on the Product Tank Refrigeration Screen, which show the status of the Product Refrigeration.
BPRV Position LS231H indicates a high ammonia level in the surge tank.
LS231O indicates that the ammonia level is a the operating level of the surge tank
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA 847-882-0690
V232 BPRV (Back Pressure Regulating Valve) maintains a constant pressure on the Ammonia Surge Tank, in order to maintain a constant temperature.
V230 Ammonia Liquid Line Solenoid Valve. Sources liquid ammonia into the surge tank.
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SCREENS FILLER
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Filler Screen The Filler Screen provides the operator the ability to view the position and status of the valves on the Filler Module. Step 1.
Action To view the Filler Screen follow the links below from the home screen
2.
Home The Filler Screen will display as shown below:
Astirix (*) indicates valves are normally open. Valve is open when red, closed when green.
LP402 Filler Line Empty Probe
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
LP403 Filler Line Full Probe
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SCREENS FILLER
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Filler Screen Indicators There are a number of colored indicators on the Filler Screens, which show the state of the interface between the Blender and the Filler. The STATUS indicators are actual feed back from the Filler to the Blender.
Status Indicators Container Stop
Valve Opener Rotating
Description Indicates the actual status of the Filler Container Stop. The Container Stop is open (allowing containers to pass through the filler) when the indicator is green. The Container Stop is closed (containers are blocked from passing through the filler) when the indicator is red. Indicates the actual status of the Filler Valve Opener. The Valve Opener is open, when the indicator is green. The Valve Opener is closed, when the indicator is red. Indicates when the Filler drive control is active, in order to rotate the Filler. Many Filler Machine Functions require that the Filler rotate in order to execute.
The OUTPUTS indicators are commands sent to the Filler from the Blender.
Output Indicators Container Stop Valve Opener
Description During a Flavor Change Over or when certain Alarm Faults occur, the blender signals the Filler to inhibit containers from passing through the Filler. When this indicator blinks green, the Container Stop will block the containers. During certain Filler Machine Functions (rinses, drains, and blows) the Blender will signal the Filler to open the Valve Opener. When this indicator is green the Filler will open the Valve Opener.
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
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SCREENS FILLER
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The following indicators show the status of the availability of beverage from the blender, and the request for beverage from the Filler.
Indicator Beverage Available
Description When the blender has sufficient level of product in the Product Tank for delivery to the Filler, this indicator will turn green.
Beverage Request
When the Filler is ready to accept product, it requests beverage through this signal. Even if the Blender has “Beverage Available” the Product Outlet Valve will not open until the Filler makes a “Beverage Request”
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
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SCREENS FILLER
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Filler Command Screen The Filler Command Screen provides the operator the ability to initiate the available Filler functions. Step 1.
Action To view the Filler Command Screen follow the links below from the home screen
2.
Home The Filler Command Screen will display as shown below:
Press here to end the Filler Run Out during a Flavor Change
Special Filler Functions
Output Indicators
Press here to manually to toggle the Beverage Request signal to the Description Blender Filler Runout Done. This button is used to end a Runout of the production. This button is active when the Product Tank Runout or the Filler Runout are in progress, and will complete both of them. If this button
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SCREENS FILLER
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is pressed during a Filler Runout, the automatic changeover is initiated by completing the Filler Runout and initiating a Filler Drain. If this button is pressed while a Product Tank Runout is in progress, the Filler starts a Filler Drain, and the Product Tank will initiate a Product Tank Empty, which will release all the product in the Product Tank to Drain. Enable Product Pump. When enabled, the Product Pump is used to deliver product to the filler. Hold Auto Prime. When enabled, a Filler Prime will not be initiated automatically during a Filler Change Over. The Filler Prime will have to be manually initiated. This button is used to hold off the automatic initiation of the Filler Prime, in instances, where the operator may be required to perform some maintenance on the Filler. (ie changing a valve)
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
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OPERATIONS SYRUP PORT
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Syrup Port Screen The Syrup Port Screen provides the operator the ability to view the Syrup Port status and valve position of the syrup manifold. Step 1.
Action To view the Syrup Port Screen follow the links below from the home screen
2.
Home The Syrup Port Screen will display as shown below: Green indicates Syrup Pump is running. Red indicates Syrup Pump Is not running.
Press Here to Go to Blender Graphic
Syrup Port Status Matrix
Press here to go to Syrup Room Commands Screen
Press here to go to Deox Graphic Screen
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
Indicates if the Syrup Pump is being requested to run by the blender.
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OPERATIONS SYRUP PORT
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Syrup Port Status Matrix Displayed on the Syrup Port Screen and other screens, is the Syrup Port Status Matrix. The Syrup Port Status Matrix indicates the condition and current operation each syrup port. PORT A PORT B
State or Operation
Each column of the matrix represents one of the syrup lines (ala DIRECT LINE, DIET LINE, FLAVOR LINE, or CLASSIC LINE. Note in some installations only one syrup line is indicated). Each row indicates a specific state or operation. State or Operation Active Next Ready Connected Rinse Drain Prime
Description When green, this indicates that the Syrup Port is selected in the Active Recipe. When green, this indicates that the Syrup Port is selected in the Next Recipe. When green, this indicates the Syrup Port is ready for production. When green, this indicates that syrup is connected in the Syrup Room to the Syrup Port. When green, this indicates that the Syrup Port is being rinsed. When green, this indicates that the Syrup Port is being drained. When green, this indicates that the Syrup Port is being primed.
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
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OPERATIONS SYRUP PORT
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Syrup Port “READY” and “CONNECTED”: The Syrup Port states “CONNECTED” and “READY” are set by the operator, as confirmation to the Blender, as to the status of the Syrup Port. This redundancy is used to minimize the possibility of opening the wrong Syrup Port through operator error. The following also applies. • In order for the Syrup Inlet valve for the Syrup Port to open the Syrup Port must be “CONNECTED” and be “READY”. The blender will wait until the Syrup Port is “CONNECTED” and “READY” before it will start a Syrup Reservoir Prime, Mix Line Prime or Blending. • The Syrup Port can only be Primed if the Syrup Port is “CONNECTED” and is “READY”. • The Syrup Port cannot be Rinsed, Drained, or CIPed if the Syrup Port is “READY”. The logic in the system software will inhibit this. • The Syrup Port “CONNECTED” state is set to false during a Run Out. Therefore the Syrup Port will require the “CONNECTED” state to be set to true again, when the Syrup Port is needed in the future.
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OPERATIONS SYRUP PORT
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Syrup Port Command Screen The Syrup Port Command Screen provides the operator the ability to initiate commands that affect the Syrup Ports. Step 1.
Action To view the Syrup Port Command Screen follow the links below from the home screen
2.
Home The Syrup Manifold Screen will display as shown below:
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OPERATIONS SYRUP PORT
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Syrup Port Ready Screen The Syrup Port ready Screen allows the provides the operator the ability to initiate commands, that affect the Syrup Ports. Step 1.
Action To view the Syrup Port Command Screen follow the links below from the home screen
2.
Home The Syrup Manifold Screen will display as shown below:
Syrup Port Ready
Syrup Port Utilities Screen
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OPERATIONS SYRUP PORT
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The Syrup Port ready Screen allows the provides the operator the ability to initiate commands, that affect the Syrup Ports. Step 1.
Action To view the Syrup Port Command Screen follow the links below from the home screen
2.
Home The Syrup Manifold Screen will display as shown below:
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
Syrup Port Utilities
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OPERATIONS SYRUP PORT
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Syrup Line Purge Screen The Syrup Port ready Screen allows the provides the operator the ability to initiate commands, that affect the Syrup Ports. Step 1.
Action To view the Syrup Port Command Screen follow the links below from the home screen
2.
Home The Syrup Manifold Screen will display as shown below:
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
Syrup Line Purge
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OPERATIONS SCREENS (HOME)
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Maintenance Screen The Maintenance Screen a pivotal screen, where all the screens that pertain to machine setup, performance, component testing and calibration are accessed. Step 1.
Action Access the Maintenance Screen by following the links below from the home screen
2.
Home Maintenance The Maintenance Screen will display as shown below:
Press here to enable the forcing of machine components.
Press a button button to access the subscreen
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OPERATIONS SCREENS (HOME)
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Maintenance PID Screen The Maintenance PID Screen displays to the available PID parameter adjustment screens for the system. The PID parameters control the dynamics of how a control point is maintained to a set point. Step 1.
Action Access the Maintenance PID Screen by following the links below from the home screen
2.
Home Maintenance Maintenance PID The Maintenance PID Screen will display as shown below:
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OPERATIONS SCREENS (HOME)
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PID Control Devices and Available Parameters Each PID Maintenance Screen is used to adjust the dynamics of a specific control point. Refer to the table below regarding the Control points input device, out put device, and available parameters that can be adjusted. Screen Syrup Blending
Input Device Syrup Meter (FT201) and Water Meter (FT101)
Output Device Syrup Proportioning Pump (P201)
Product Flow
Water Meter (FT101)
Mix Line Throttling Valve (Product Modulating Valve) (V404)
Syrup Reservoir Capacitance Probe (LT201) Product Tank Pressure Transducer (PT401)
Syrup Reservoir Level Control Valve (V204)
Reservoir Level Tank Pressure CO2 Injection
Gas Mass Flow Meter (FT301)
CIP Supply Temperature
CIP Return Temperature Transducer (RTD001) Vacuum Deaerator Capacitance Probe (LT101)
Vacuum Deaerator Level
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA 847-882-0690
Product Tank Gas Inlet Valve (V323) and Product Tank Gas Outlet Valve (V326) Gas Injector Modulating Valve (V306)
Steam Control Valve (V001)
Vacuum Deaerator Water Level Control Valve (V102)
Available Parameters Feed Forward Scale Feed Forward Offset Gain Integral Derivative Feed Forward Scale Feed Forward Offset Gain Integral Derivative Gain Integral Derivative Gain Integral Derivative Feed Forward Scale Feed Forward Offset Gain Integral Derivative Gain Integral Derivative Gain Integral Derivative
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OPERATIONS SCREENS (HOME)
Press up arrow to increase parameter value.
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Press down arrow to increase parameter value.
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Maintenance Setup Screen The Maintenance PID Screen displays to the available PID parameter adjustment screens for the system. The PID parameters control the dynamics of how a control point is maintained to a set point. Step 1.
Action Access the Maintenance Setup Screen by following the links below from the home screen
2.
Home Maintenance Setup The Maintenance Setup Screen will display as shown below:
Parameter Syrup Reservoir Volume at 100%
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA 847-882-0690
Description This parameter is used to scale the Syrup Reservoir Capacitance Probe analog input to the conversion to volume (in liters). The value entered here should be the volume of the Syrup reservoir when the reservoir is at 100%. Cover Page.doc1 Rev. 00/00/01
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Syrup Reservoir Volume at 0%
Analog In High Alarm
Analog In Low Alarm
Water Brix
Water TA/%
Residual Water Mass
Blend Sweet Mass
Metric Mass Display
Metric Non-Mass Display
Auto Start Auto Brix CIP Pressure
Accu-Temp Offset
Vacuum Low
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This parameter is used to scale the Syrup Reservoir Capacitance Probe analog input to the conversion to volume (in liters). The value entered here should be the volume of the Syrup Reservoir when the reservoir is at 0%. This parameter is used as an upper threshold for a valid analog input current reading in milliamps. If an analog input rises above this valve, a Transducer Failure Alarm is generated. This parameter is used as an lower threshold for a valid analog input current reading in milliamps. If an analog input falls below this valve, a Transducer Failure Alarm is generated. This parameter is used in the internal calculations the system performs toward the determination of percent syrup of a Non-Diet product dependent upon Recipe values of Syrup Brix and Product Brix. This value should be the apparent brix of the water used by the blending system. This parameter is used in the internal calculations the system performs toward the determination of percent syrup on a Diet product dependent upon Recipe values of Syrup Brix and Product Brix. This value should be the apparent TA of the water used by the blending system. This value is used in calculating the initial blend during the initial blend of a product. Blending at a lower ratio during the initial blend of a product corrects for the residual water left after a rinse and drain of the system. The unit of this parameter is in kilograms. This value is used to determine the amount of mass of product is blended at a lower blend ratio during the initial blend of a product. Blending at a lower ratio corrects for the residual water left after a rinse and drain of the system. The unit of this parameter is in kilograms. This parameter determines if the units of the mass display values (flow rates and totals) are displayed in metric (kilograms and gallons) or Imperial Units (pounds/min and liters). This parameter determines if the units of the non-mass display values (temperature and pressures ) are displayed in metric (kilograms) or Imperial Units (pounds/min). This parameter determines if the Accu-Brix control algorithm is started automatically when a new product starts up. This parameter provides the Setpoint for the Product Tank Pressure during a CIP. Typical value is 0, for an atmospheric tank CIP. The parameter provides the value of the split across the Product Chiller in degrees C. Typical for PHE is 1.0C and for Carbo-Cooler is 3.0 C. This parameter determines the low threshold for the Vacuum Pressure Low Warning
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Vacuum Too Low
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This parameter determines the low threshold for the Vacuum Pressure Low Alarm. Blending cannot continue below this level.
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Maintenance Change Over Screen The Maintenance Change Over Screen gives the operator the ability to adjust parameters pertaining to the volumes metered during certain functions. Step 1.
2.
Action Access the Maintenance Change Over Setup Screen by following the links below from the home screen
Home Maintenance Change Over The Maintenance Change Over Screen will display as shown below:
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Parameter Syrup Line Volume
Description This parameter provides the system information regarding the amount of syrup volume is held in a packed sysrup line. This value is used to determine the amount of syrup available in the system.
Syrup Reservoir Push Volume
This parameter provides the system with information regarding the volume of syrup held in the syrup metering line from the bottom of the Syrup Reservoir all the way up to the Mix Line. The value is used during a Syrup Reservoir Runout. When the level of the syrup reaches the bottom of the Syrup Reservoir, the Syrup is metered until the volume metered reaches this value. This parameter provides the system with information regarding the volume of the Mix Line Prime. During a Mix Line Prime, the amount of liquid (rinse water) is metered to drain, exceeds this value; the product is then diverted into the Product Tank afterwards. This parameter provides the system with information regarding the volume of the Mix Line for the Mix Line Runout. During a Mix Line Runout, the amount of product that is pushed with water into the Product Tank is metered. When the amount of metered water exceeds this value, the Mix Line Runout is terminated. This parameter provides the system with the volume of the Product Tank in liters when the Product Tank capacitance probe reads 100%. This parameter provides the system with information regarding the volume of the Filler and Filler Line, during normal product operation. This value is used in determining the container cutoff value. This parameter is used by the system to determine the amount rinse water volume should be metered during a Syrup Reservoir Rinse. This parameter provides the system with information pertaining to the amount of rinse water to meter to drain, before a recirculation is initiated during a Syrup Reservoir Prime. This value should be the volume of the syrup meter line from the bottom of the Syrup Reservoir to the Syrup Meter Drain.
Mix Line Prime Volume
Mix Line Runout Push Volume
Product Tank Volume
Filler and Line Volume
Syrup Reservoir Rinse Volume
Syrup Reservoir Prime Drain
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Maintenance Vacuum Pump Screen The Maintenance Change Over Screen gives the operator access to Vacuum Pump hour counter alarm set points and the ability to reset the hour counter. Step 1.
2.
Action Access the Maintenance Vacuum Pump Screen by following the links below from the home screen
Home Maintenance Vacuum Pump The Maintenance Vacuum Pump Screen will display as shown below:
Press here to reset the hour counter, after you have changed the oil in the Vacuum Pump
Press up or down arrow to increment or decrement the parameter value.
The Vacuum Deaerator provided with the system requires an oil change periodically. This Maintenance Vacuum Pump Screen is used to set the number of hours that an oil change is absolutely required (Alarm Hours) and to set the number of hours for a reminder message (Warning Hours). This screen is also used by the operator to reset the hour counter one the oil has been changed.
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Maintenance Meter Setup The Maintenance Meter Setup Screen provides access to each meter’s maximum value at 20 milliamps, and whether the water meter is a volumetric type or a mass meter. The screen also provides the ability to calibrate the Syrup Reservoir. Step 1.
2.
Action Access the Maintenance Meter Setup Screen by following the links below from the home screen
Home Maintenance Maintenance Meter Setup The Maintenance Meter Setup Screen will display as shown below:
Press here to toggle between a Mass Meter or a Volumetric Meter.
Press up or down arrow to increment or decrement the parameter value.
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Maintenance Meter Setup – Syrup Reservoir Calibration The Maintenance Meter Setup Screen also provides a means to calibrate the Syrup Reservoir Capacitance Probe. With the buttons shown below, the qualified operator can fill the Syrup Reservoir with water from the Deaerator by pressing the “Fill Syrup Reservoir” button, and then when complete, start totalizing the amount of sysrup in the Syrup Reservoir by pressing “Syrup Totalize”. The value of the current Syrup Volume metered and the current level are also shown.
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Maintenance Meter Proving The Maintenance Meter Proving Screen provides the OEM technician with the ability to prove the blender meters. A qualified OEM technician should only undertake this. Step 1.
2.
Action Access the Maintenance Meter Proving Screen by following the links below from the home screen
Home Maintenance Maintenance Meter Setup The Maintenance Meter Proving Screen will display as shown below:
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Maintenance Force Screens In order to test individual machine components, it may be required by a Qualified Operator to activate a specific machine component. This “Forcing” capability is provided through the “Force Screens”. The Maintenance Screen provides access to a number of “Force” Screens, located in the “Force Screen Area”.
Force Screen Area
Force Enable Button
Do not attempt to Force a component while the system is performing a function or operation. To enable “Forcing”, press the Force Enable Button. A green indicator means that Forcing is enabled.
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA 847-882-0690
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Inside the “Force Screen Area”, are a number of Force Screens, which provide access to Forcing Components based on the location in the System. Below is an example of a typical Force Screen for the Vacuum Deaerator. A green indicator means the item is activated. A red indicator means the item is deactivated.
Selected item to be activated.
Press Up / Down arrows to move selection.
Indicator
Press Enter Button to activate / deactivate selected item.
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Analog outputs, to such devices as driver speeds and I/P transducers are forced on the Maintenance Analog Table, shown below. Press Up / Down arrows to increment or decrement item analog out from 0 to 100%.
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Recipes A Recipe is a list of variables used by the blender to formulate the ingredients for the correct end product. The system allows up to 100 different recipes to be developed. A Typical recipe displayed by the Recipe Viewer is shown below.
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Recipe Items Each Recipe Item has it’s own description with an associated value, The definition of each Recipe Items is described below.
Recipe Item Syrup Brix /TA/Percent
Definition This is the target value of the Finished Syrup that is being delivered to the blender. This number, along with the Product Brix/TA/Percent Recipe Item value determines the blending ratio for proportioning water and syrup. The value of this Recipe Item depends on how the end Product is measured, which corresponds to value and units of the Product Brix/TA/Percent Recipe Item value. If the end Product is measured in Brix from a Refractometer or a Densitometer, Then specify this value as the Target Syrup Brix for this flavors syrup batching. • If the end Product is measured by a titration (which typically determines product acidity), Then specify this value as the measurement of the Titration of a full strength Finished Syrup batch. Typically this value is the blending ratio plus one times Target Product Titration value (ie Syrup TA = {Ratio +1} * Product Titration). • If the end Product is measured by another means as a percentage, where 100% is the Target for the Product Then enter this value a the blending ratio plus one times Target Product Percentage (ie Syrup Percent = {Ratio +1} * Product Percent). This is the Nominal Finished Syrup Density in units of grams per cubic centimeter. Typical for sugared (sweet) beverages is in the range of 1.12 to 1.3 g/cc. Typical for diet beverages is in the range 1.0 to 1.09 g/cc. This number is used explicitly in for a diet beverage for calculation of the percent syrup by mass for blending. This value determines the low measured density for alarming purposes. If during a production run, the measured Syrup Density is less than this value, an Alarm Fault will occur and blending will be stopped immediately. Typical for sugared (sweet) beverages is 0.02 less than the Nominal Syrup Density. Typical for diet beverages is in the range 0.998 to 1.001 g/cc This is the target value of the Finished Product that is to be produced by the blender. This number, along with the Syrup Brix/TA/Percent Recipe Item value determines the blending ratio for proportioning water and syrup. The value of this Recipe Item depends on how the end Product is measured. • If the end Product is measured in Brix from a Refractometer or a Densitometer, Then specify this value as the Target Product Brix for this flavor. • If the end Product is measured by a titration (which typically determines product acidity), Then specify this •
Syrup Density
Syrup Density Low
Product Brix/TA/Percent
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Recipe Item
Definition value as the measurement of the Titration of sample of the Target Product. • If the end Product is measured by another means as a percentage, where 100% is the Target for the Product Then enter this 100% as the value.
Product Temperature
This is the Target Product Temperature for delivery to the filler,. This number is used as a Setpoint to control the Product Temperature with the Accu-Temp option, otherwise it is used only for reference. This value determines the Product Temperature threshold for alarming, that the Product Temperature is high, which therefore indicates to the operator to review the temperature control hardware for problems. This is the Target Product Flow rate in containers per minute. The blender will proportion product at this rate.
Product Temperature Maximum
Product Flow Rate (cpm) Pungifity Tank Pressure Initial Tank Pressure
Gas Injector Initial Gas Injector
Injector Factor
Saturator Factor
Diet Beverage Refrigeration Required
Nitrogen Required
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
This is the target operating pressure for this flavor. This is the intial pressure, when the Product Tank is first being filled with product, during a Product Tank Prime. This value is typically less than the Tank Pressure value in order to minimize any saturated gas pickup while filling the Product Tank for the first time. As product continues entering the Product Tank during a Product Tank Prime the Target Product Tank Pressure Setpoint is ramped from the Initial Tank Pressure value to the Tank Pressure value. Typically the Intial tank Pressure value is 10 to 15 psi less than the Tank Pressure value. This is the Target Gas Volumes for the Gas Injector. This is the Target Gas Volumes for the Gas Injector during a Product Tank Prime. This value is typically less than the Gas Injector value in order to minimize any saturated gas pickup while filling the Product Tank for the first time. This number determines the Gas Injection efficiency for this flavor based on 1.95g/ liter / volume. This number is typically in the range of 1.0 to 1.1 for DIET beverages and 0.85 to 1.0 for Non DIET beverages. This number specifies the efficiency of the Product Tank as a Saturator, and determines the amount of gas volume pickup during normal operating conditions. Typical values for a Satuarator only system is 0.6. Typical values for a Gas Injector only system is 0.03. A value of YES means this beverage is a DIET beverage. A value of NO means this is not a DIET beverage (it is a sweet drink). A value of YES, specifies that refrigeration is required during production of this beverage, and that refrigeration will be requested from the plant’s refrigeration system. A value of NO, specifies that no refrigeration is required, and that refrigeration will not be requested from the plant’s refrigeration system. A value of YES, indicates that a Nitrogen is used as the gas source, for Injection and Pressurizing the Product Tank. In this Cover Page.doc1 Rev. 00/00/01
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Recipe Item
Container
Only Use Syrup Port
Product Brix Offset
Syrup Brix Offset
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Definition specific application, this value is unused, and should be set to NO. This value specifies the Container Type and Size for the production run. This value and the Product Flow Rate value determines the production ate of the blender. This value specifies the Syrup Port that is to be only for this beverage. A value ANY PORT will allow this recipe to use any port to obtain syrup. An assignment of a specific syrup port, will only allow this recipe to obtain syrup from that specific port. A value of not assigned will generate a alarm fault. The Product Brix Offset number is used to offset the entered recipe value of the Product Brix/TA/Percent/Ratio. A positive number will make the blending more rich (more syrup). A negative number will make the blending less rich (less syrup). The Syrup Brix Offset number is used to offset syrup brix as calculated by the system from the syrup density and syrup temperature. The number serves as a correction to the calculated syrup brix, where ingredients in the syrup may scew the result.
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Active and Next Recipes Recipes are developed and modified using the Recipe Manager as described in this manual. Once the recipe is satisfactorily developed, it can be selected for use. The current recipe that the system is using to formulate the beverage is called the Active Recipe. The Active Recipe is essentially a copy of one of the recipes developed by the Recipe Manager. Once a specific recipe has been selected and copied into the Active Recipe, the values of the Recipe Items are used for blending. Like the Active Recipe, the Next Recipe is a copy of one of the recipes developed by the Recipe Manager, but to be used for the next flavor’s production run after a flavor change over. During an automatic flavor change over, the Next Recipe is moved into the Active Recipe, and the Next Recipe then is Empty. This feature allows the operator to pre-select the next flavor to be run, along with syrup port selection, in order that no operator intervention is required during the actual change over.
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Viewing Active and Next Recipes Step 1.
Action To view the Next Recipe follow the links below from the home screen
2.
Home Recipe Next Recipe The Next Recipe Screen will display as shown below:
Press here to edit the Next Recipe Press here to modify the Next Runout Type and Length, or the selected Syrup Line Press here to select the Next Recipe Press here to Edit the Next Recipe
Run Out and Syrup Line Selection
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Recipe Items
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The Next Recipe screen gives access to the next recipe that will be loaded automatically on the next flavor changeover. This screen provides; • • • • •
A means to view the Next Recipe – Recipe Item values An option to Select a new Next Recipe by pressing the Next Recipe Select button An option to modify the Next Runout Type and Length A means to select the Next Syrup Line An option to edit the Next Recipe
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Step 1.
Action To view the Active Recipe follow the links below from the home screen
2.
Home Recipe Active Recipe The Active Recipe Screen will display as shown below, with the associated values. Selected Recipe Location, which Active Recipe came from
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Active Recipe Name
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Next Recipe Selection Step 1.
Action To view the Next Recipe follow the links below from the home screen
2.
Home Recipe Next Recipe Select The Next Recipe Selection Screen will display as shown below: Recipe Selection
Press UpDown Buttons To Move Recipe Selection Cursor Selected Recipe
Press SELECT after moving UP/DOWN arrows to the required recipe.
Recipe Selection Cursor
Press Left Arrow to go back a page.
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Page Selection Indicator
Press right arrow to move forward a page.
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Syrup Port In many situations, syrup used for blending may come from multiple sources. The sources may have automated valving, which controls the delivery of syrup into the blender. In order to minimize the possible error of delivering the wrong syrup, the system provides a level of redundancy to prevent this. There are two variables that determine which syrup port is to be used. One is the Syrup Port selection called “Only Use Syrup Port” in the recipe itself, the other is an operator confirmed selection called Syrup Port made when setting up the Next Recipe. These are pointed out below, and must match. If these two values do not match an alarm fault will occur, and no syrup will be delivered. One exception is, when the “Only Use Syrup Port” value is “Use Any Port”, this allows any syrup port to be selected.
These selections must match, if “Only Use Syrup Port” does not have a value of “Any Port”
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Next Syrup Port Selection Step 1.
Action To select the Next Syrup Port follow the links below from the home screen
2.
Home Recipe Next Recipe The Next Syrup Port Screen will display as shown below:
Next Syrup Port
Use the UP/DOWN arrows to change the Syrup Port Selection During a flavor change over, the Next Recipe is moved into the Active Recipe. The Next Recipe is made “EMPTY” and the Syrup Port is made “NOT ASSIGNED”. This makes it necessary for the operator to Select the Next Syrup Port, or the blender will alarm if the selection is “NOT ASSIGNED”.
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Run Out Type The Run Out type allows the operator to choose how long and how the end of production for the production run will be initiated.
Run Out Type Run Out Length The table below defines the different Run Out Types Run Out Type By Operator By Time By Syrup Volume By Containers
Definition Specifies that the operator pressing the “Start Run Out” button will initiate the end of production Run Out. Specifies that the end of production Run Out will be initiated by the expiration of time, in units of minutes. The Run Out Length sets the expiration time. Specifies that the blender consuming a Syrup Volume will initiate the end of production Run Out. The Run Out Length sets the Syrup Volume threshold, in units of liters. Specifies that the blender producing enough beverage to fill a quantity of containers will initiate the end of production Run Out. The Run Out Length sets the number of containers, in units of containers.
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Next Run Out Type Selection Step 1.
Action To select the Next Syrup Port follow the links below from the home screen
2.
Home Recipe Next Recipe The Next Syrup Run Out Screen will display as shown below:
Next Run Out
Indicates current selection.
Use the UP/DOWN arrows to change the Run Out Type
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Use the UP/DOWN arrows for each digit to change the Run Out Units
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Setting Up a Next Recipe In order to set up a Next Recipe the following steps must be taken. All the individual steps and have been described above. Step 1.
Action Select the Next Syrup Port
2.
Home Recipe Select the Next Recipe
3
Home Recipe Next Recipe Select the Next Run Out Type and Run Length
Home
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Recipe
Next Recipe
Next Recipe
Next Syrup Port
Next Recipe Select
Next Run Out
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Setting Up an Active Recipe Under normal operating circumstances, setting up an Active Recipe is not required, since the Active Recipe is automatically loaded from the Next Recipe during a flavor change. The system does provide the capability for Active Recipe Selection, Active Syrup Port Selection, and Active Run Out Selection. The links to perform these actions are provided for reference below. Step Active Recipe Selection Active Syrup Port Selection Active Run Out Selection
Links
Home
Recipe
Active Recipe
Active Recipe Select
Home
Recipe
Active Recipe
Active Syrup Port
Home
Recipe
Active Recipe
Active Run Out
The procedure for Active Recipe Selection, Active Syrup Port Selection, and Active Run Out Selection are much the same as for the Next Recipe. Refer to the above for details.
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Recipe Manager The Recipe Manager allows the operator to VIEW, EDIT, CHANGE NAME, and DELETE and. A total of 100 Recipes can be developed. The 100 recipes are displayed in 10 pages of 10 recipes each. All the recipe values are stored in the PLC (Programmable Controller), which keeps the recipes safe from hard disk crashes and operating system corruption. This also makes the automatic loading of recipes seamless, because there are not any communication lags like other MMI based recipe systems.
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Recipe Manager Screen Step 1.
Action Access the Recipe Manager Screen by following the links below from the home screen
2.
Home Recipe Recipe Manager The Recipe Manager Screen will display as shown below:
Selected Recipe Location
Selected Recipe Name Available Operations
Press UpDown Buttons To Move Recipe Selection Cursor Selected Recipe
Recipe Selection Cursor
Press Left Arrow to go back a page.
Press right arrow to move forward a page. The pages are navigated by pressing the up and down arrows to move the Page Selection Cursor, to the desired page, and then pressing the enter key to display the selected page. Page Selection Indicator
A recipe can then be selected by moving the Recipe Selection Cursor to the desired recipe location.
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Recipe Viewing Step 1.
Action To use the Recipe Manager Recipe Viewer, choose the page the desired recipe is on by using the page selection buttons illustrated on the left.
2.
Select the desired recipe by using the up-down arrows to move the Recipe Selection Cursor to the desired recipe.
3.
Now press the VIEW RECIPE button to view the selected recipe.
4.
The Recipe Viewer display as shown below:
Viewed Recipe Name
Viewed Recipe Location
Recipe Editing The Recipe Editor is used to modify the contents of the recipe location. Cadence Technologies Inc. 1006 Windward Ridge Pkwy Alpharetta, GA, 30005 USA
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Step 1.
Action To use the Recipe Manager Recipe Editor, choose the page the desired recipe is on by using the page selection buttons illustrated on the left.
2.
Select the desired recipe by using the up-down arrows to move the Recipe Selection Cursor to the desired recipe.
3.
Now press the EDIT RECIPE button to view the selected recipe.
4.
The Recipe Editor display as shown below:
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Recipe Item Selection Cursor
Use keypad to change the value of the Selected Recipe Item.
Press UpDown Buttons to Move Recipe Item Selection Cursor
Press here to go to Page 2 of Recipe Editor
Modifying the Selected Recipe Item Step
Action
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Press here to SAVE modified recipe
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1.
Use the Up-Down Buttons to Move Recipe Item Selection Cursor to the desired recipe Item to be modified.
2.
Use the Digital keypad to enter in a new value for the Selected Recipe Item.
3.
Press ENTER to move the new value into the item’s value. .
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Recipe Editor Page 2 Step 1.
Action In order to access Page 2 of the Recipe Editor, press the Recipe Editor Page 2 button on the bottom the the Recipe Editor Screen.
2.
The Recipe Manager Screen will display as shown below:
Press here to modify the YES or NO status of item.
Use up-down arrows to modify selected Syrup Port.
Use up-down arrows to modify selected Container Size. The value of the Only Use Syrup Port Recipe Item determines what Syrup Port will only be allowed to used for this recipe. A value of ANY will allow any Syrup Port to be used.
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Saving the Recipe Step 1.
Action In order to save the modifications made to by the Recipe Editor, press the SAVE button on the bottom the the Recipe Editor Screen.
2.
The button will flash yellow for 3 seconds and display “SAVING”.
2.
After 3 seconds the button will return to it’s normal state. The Recipe has been saved.
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Copying A Recipe Step 1.
Action In order to obtain a copy of a recipe from another location.Press the GET COPY button on the top of the the Recipe Editor Screen.
2.
The Recipe Get Copy screen will be displayed as shown below:
Step 3.
Action Press the GET ACTIVE or GET NEXT pushbuttons, or enter in the location of the recipe you want to copy into the Recipe Editor.
4.
Press the RETURN button to move back to the Recipe Editor .
Recipe Name Modification Step
Action
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RECIPE RECIPE MANAGER
1.
To use the Recipe Manager to change the name of a Recipe Location, choose the page the desired recipe is on by using the page selection buttons illustrated on the left.
2.
Select the desired recipe by using the up-down arrows to move the Recipe Selection Cursor to the desired recipe.
3.
Now press the CHANGE NAME button to view the selected recipe.
4.
The Recipe Name Editor screen will display as shown below:
Step
Action
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RECIPE RECIPE MANAGER
5.
Use the displayed keyboard by pressing the appropriate keys to enter in the modified name for the Selected recipe Location.
2.
Complete the modification by pressing the Enter Key on the bottom right hand corner of the keyboard.
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RECIPE RECIPE MANAGER
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Recipe Deleting Deleting a recipe clears the recipe location’s values and renames the recipe to “EMPTY RECIPE”. Step 1.
Action To Delete a Recipe Location, choose the page the desired recipe is on by using the page selection buttons illustrated on the left.
2.
Select the desired recipe by using the up-down arrows to move the Recipe Selection Cursor to the desired recipe.
Selected Recipe Name
Selected Recipe Location
Press DELETE button to Delete Selected Recipe Step 3.
Action Now press the DELETE button to view the selected recipe.
4.
The Recipe Editor display as shown below: This is a confirmation screen, which ask the
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RECIPE RECIPE MANAGER
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operator to confirm that the selected recipe is to be deleted. If the information is incorrect, then the operator should press NO, and the screen will change back to the RECIPE MANAGER screen. If the information is correct, the operator should press YES.
Selected Recipe Name
Press YES to Delete the Selected Recipe Press NO to Return to the RECIPE MANAGER SCREEN
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Step 5.
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Action If the operator presses YES, the YES button will turn yellow and the text will change to DELETING. This indicates that the Recipe Deletion is in progress. The process will take approximately 3 seconds, as illustrated below.
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RECIPE RECIPE MANAGER
Step 6.
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Action After Deleting the Selected Recipe Location. The screen will automatically change back to the Recipe Manager screen. The Selected Recipe Location will now indicate that the location is an “EMPTY RECIPE”, as illustrated below.
Recipe Location Is Now EMPTY RECIPE
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OPERATIONS MORNING START UP
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Operation Utilities Check On the main control panel are several gauges, which measure the pressure set point for the regulators. Before attempting to initiate any action on the system, each gauge should be checked and compared with the requirements outlined in the table below. Gauge Plant Air Regulator Main Gas Pressure Regulator Product Tank Gas Pressure Regulator Gas Injector Pressure Regulator Control Air Pressure Regulator Blow Gas Pressure Regulator
Requirement 90 to 110 psi Gas Injection Capable - 220 psi to 300 psi No Gas Injection – 120 psi minimum 180 psi 100 psi 25 psi 40 psi
E-Stop Check Below the touch screen on the main control panel is an E-Stop pushbutton and a green Reset pushbutton. In emergency situations the E-Stop pushbutton can be pressed by the operator in order to stop all machine functions. The green Reset pushbutton will be illuminated if the system is not in an E-Stop condition. Before initiating any action on the system, the E-Stop circuit will need to be checked by confirming that the green Reset button is illuminated. If the green Reset pushbutton is not illuminated, the operator can reset the EStop condition by pressing the Reset pushbutton.
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OPERATIONS MORNING START UP
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Morning Start Up After extended down time or CIP, the system will require the operator to initiate a Start Up procedure. The table below lists the Start Up procedure. While a Filler Cold Rinse is running the operator can set up the Next Recipe and Syrup Ports. When the Filler Cold Rinse is complete. The operator must confirm the Syrup Reservoir and the Product Tank are empty, and drain if required. Once the tanks are empty the operator can initiate an automated start up, by pressing the Start Up Machine Command button. The table below outlines the steps and screen links to follow to perform a Morning Start Up. Step 1.
Action Perform a Filler Cold Rinse
2.
Home Recipe Select Next Syrup Port
Home Recipe Next Recipe Select the Next Run Out Type and Run Length
Next Syrup Port
3.
Home Recipe Select the Next Recipe
Next Recipe
Next Run Out
4.
Home Recipe Connect Syrup Port
Next Recipe
Next Recipe Select
5.
Home Confirm Syrup Line is Ready
6.
Home
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
Next Recipe
Active Recipe Select
Syrup Port Ready
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OPERATIONS MORNING START UP
Step 7.
Action Check Syrup Reservoir Level
8.
Home Check Product Tank Level
9.
Home Place the system in Auto, so the system sequences automatically.
Home Initiate Start Up
10.
Home
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OPERATIONS MORNING START UP
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Flavor Change Preparation Before initiating a Flavor Change Over (Initiating a Run Out), the Next Recipe and Syrup Port will need to be set up. The operator may set up the Next Flavor, anytime after the current flavor (Active Recipe) has started production (ie. at the end of Filler Prime). The table below outlines the steps required to prepare for a Flavor Change. Step 1.
Action Select Next Syrup Port
Home Recipe Next Recipe Select the Next Run Out Type and Run Length
Next Syrup Port
2.
Home Recipe Select the Next Recipe
Next Recipe
Next Run Out
3.
Home Recipe Connect Syrup Port
Next Recipe
Next Recipe Select
4.
Home Confirm Syrup Line is Ready
5.
Home
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Syrup Port Ready
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Flavor Change With the Accu-Change system, flavor changes are very simple. Flavor changes are initiated by a single machine command called Run Out Start.
Step 1.
Action Initiate Start Up
Home
Filler Run Out Completion At the end of a flavor change, when the Filler Run Out has finished filling all the containers, the operator must acknowledge that the containers have all been filled, by pressing the Filler Run Out Done pushbutton. Step 1.
Action Initiate Start Up
Home
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OPERATIONS MORNING START UP
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End of Day Shutdown With the Accu-Change system, flavor changes are very simple. Flavor changes are initiated by a single machine command called Run Out Start.
Step 1.
Action Initiate Start Up
2.
Home After the Filler Run Out has completed press the End of Day Machine Command
Home
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OPERATIONS MORNING START UP
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Packaging Change When changing the package, it becomes necessary to provide carbonated water to the filler. The table below outlines the steps and screen links required to provide carbonated water to the filler. First a Filler Cold Rinse is initiated to produce carbonated water in the to the filler. Once the Product Tank has adequate level of water, the Filler Cold Rinse can be terminated, and a Product Tank Run Out can be initiated to maintain Product Tank Pressure to push the carbonated water to the Filler. A Beverage Request must come from the Filler in order for the Product Tank Run Out to open the Product Outlet Valve.
Step 1.
Action Take the system out of Auto.
1.
Home Initiate a Filler Cold Rinse
2.
Home Rinse and Drains When the Product Tank has adequate level for the test, terminate the Filler Cold Rinse
2.
Home Rinse and Drains Initiate a Product Tank Run Out
2.
Home Run Outs Initiate a Beverage Request from the Filler, by pressing the Filler Product Request Machine Command.
Home
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OPERATIONS MORNING START UP
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Product Proportioning Adjustment The set point for the Product Proportioning is in units of Brix for sweet (Non-diet) drinks and in TA or Percent for diet drinks. The set point for the Product Proportioning is determined by adding the Operator Adjust to the Recipe Set Point. Where small adjustments are required the operator should modify the Operator Adjust set point. There are two locations that the Operator Adjust set point for Product Proportioning. These two methods are outlined in the steps below. Method 1: Step Action 1. Go to the Blender Command Screen by following the links below from the home screen
2.
Home Use the Up/Down arrows connected to the Operator Adjust, shown below.
Method 2: Step Action 1. Go to the Blending Operation Command Screen by following the links below from the home screen
2.
Home Use the Up/Down arrows connected to the Operator Adjust, shown below.
Note that “Brix” is displayed when non-diet (sweetdrink) recipe is active, and TA/% is displayed when diet recipe is active.
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OPERATIONS MORNING START UP
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Product Tank Pressure Adjustment The Target set point for the Product Tank Pressure is determined by adding the Operator Adjustment, and the Accu-SAT adjustment to the Recipe Setpoint. Where small adjustments are required the operator should modify the Operator Adjust set point. Follow the steps below to modify the Operator Adjust for the Product Tank Pressure Step 1.
Action Go to the Product Tank Command Screen, follow the links below from the home screen
2.
Home Use the Up/Down arrows connected to the Operator Adjust, shown below
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OPERATIONS MORNING START UP
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Gas Injector Set Point Adjustment The set point for the Gas Injector is in units of Volumes. The target set point for the Gas Injector is determined by adding the Operator Adjust to the Recipe Gas Inj. Vol. Where small adjustments are required the operator should modify the Operator Adjust set point. There are two locations that the Operator Adjust set point for Gas Injector. These two methods are outlined in the steps below. Method 1: Step Action 1. Go To the Gas Injector Command Screen follow the links below from the home screen
2.
Home Use the Up/Down arrows connected to the Operator Adjust, shown below.
Method 2: Step Action 1. Go to the Blending Operation Command Screen by following the links below from the home screen
2.
Home Use the Up/Down arrows connected to the Operator Adjust, shown below.
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OPERATIONS MORNING START UP
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CIP Follow the steps outlined in the table below in order to perform a CIP of the system. Step 1.
Action Confirm air supply connection to Product Tank.
2.
Behind the filler there are two valves. The CIP Return valve to the Deox / Product Tank skid must be open. The Filler Vent Valve must be closed.
3.
Confirm CIP CAM is moved into place.
4.
All CIP Channel Drain Valves must be closed on the bottom of the Filler Bowl.
5.
All CIP Return Valves on top of the Filler Bowl must be opened.
6.
CIP Cups on filler must be installed.
7.
Go To the CIP Program Screen by following the links below from the home screen
8.
Home CIP Program Use the Up/Down to select one of five different CIP programs.
9.
Go To the CIP Screen by following the links below from the home screen
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OPERATIONS MORNING START UP
Step
Action
10.
Home Press the ENABLE button to initiate the CIP Process.
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The button will turn green when the CIP is in progress.
11.
Based on the program selected the system will step through the program. Observe the indicators shown below to observe what type of step the system is executing.
12.
When the CONNECTED button begins to blink, Chemicals are required to be connected to the system..
13.
Connect the chemicals and press the button to confirm. Press the NEXT button in order to skip to the next Step.
Or Press the HOLD button to hold the system in its current Step.
14.
When the CIP has completed all the programmed steps ENABLE button will turn RED, Indicating that the CIP has stopped.
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OPERATIONS MORNING START UP
Step
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Action
Frequently Asked Questions
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SCREENS ALARM
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The following are frequently asked questions and our response. Question - Low Syrup Density Alarm Fault on startup During a startup on a Sweet product the density of the syrup was so low that the blender gave me a “Low Syrup Density Alarm Fault”. I keep on resetting the alarm, but the alarm keeps on coming back up.
Response When too much water is present in the syrup, the density drops below the value of Syrup Density Low parameter in the Recipe, and the “Low Syrup Density Alarm Fault” occurs. 1) The first decision that needs to be made is whether the syrup is good enough to blend, and that it is not tainted in any way. A Qualified Operator should take a Syrup Brix measurement of the current syrup in the Syrup Reservoir. 2) If the Syrup is OK to blend, then a Qualified Operator must edit the Syrup Density Low parameter in the Active Recipe. The value should be changed to less than the currently displayed Syrup Density on the Blender Graphic Screen. 3) Also, adjust the Syrup Brix parameter in the Active Recipe to match the value of the Syrup Brix measurement taken in step 1. 4) Reset the alarm, and monitor the blending operation.
Question - foam in my Syrup Reservoir during a Syrup Reservoir Runout I have foam in my Syrup Reservoir during a Syrup Reservoir Runout and one of the following alarms keep me from blending Low Syrup Density Alarm, Syrup Flow Transmitter Failure, or Syrup Density Transmitter Failure.
Response You cannot blend foam. The meters will not measure it properly 1) Determine if your Syrup Reservoir indeed is full of foam. 2) If it is full of foam. You can terminate the Syrup Reservoir Runout and continue to the next change over step, by going to the Runout Command Screen and press Syrup Reseroir Runout Kill. 3) This will step the system to the next steps (Syrup Reservoir Rinse and Mix Line Runout)
Question – My Syrup Reservoir is High and I can blend no more My Syrup Reservoir level became too high and the Blender Pauses on High Syrup Reservoir Level, and keeps on pausing when ever I reset the alarm to re-initiate blending.
Response
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SCREENS ALARM
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The Syrup Reservoir generates a High Syrup Reservoir Level Alarm Fault, when the High Point probe on the Syrup Reservoir detects a liquid. 1) Before resetting the alarm, inquire why the alarm was generated and repair. 2) Reasons for failure a. During a Syrup Line Runout someone did not disconnect the syrup source. b. The High Point Probe was splashed with syrup during a blow from the syrup room c. The Syrup Reservoir Level Capacitance probe failed. 3) You can resume blending by resetting the alarm fault and pressing the BLEND PAUSE button on the Blender Graphic Screen to un-pause the blender. 4) If for some reason the level is too high, and you want the blender to run continuously without it faulting, you can press and hold either the BLEND or BLEND PAUSE buttons on the Blender Graphic Screen.
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CHEAT SHEET Page 151 of 159
Cheat Sheet
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CHEAT SHEET Page 152 of 159
Blender Cheat Sheet
bturig 5/14/2003
Note: Think twice, press once START UP Syrup Preparation 1) Bring good syrup all the way to divert panel in syrup room •
2) Wait for "Prime Waiting" indicator on Syrup Room Display
3) Open valves from Syrup Tank supply line to blender syrup line, with Syrup Tank Pump on. 4) Press "Port A Connected" on Syrup Room Display, to indicate to blender that syrup is connected Blender Preparation 1) Vacuum Deaeration Unit must be running (15 minute warm up) 2) Filler • must be rotating • filling valves must be in automatic • speed control must be in automatic 3) Turn on Refrigeration Chiller from control panel on Chiller. 4) If need to do a Cool Down. Turn Auto Off, and manually perform a “Filler Cold Rinse”. 5) Blender • Syrup Reservoir must be empty, drain if necessary. 6) Syrup Room (Syrup Prep) • Syrup Port Connected indication on Syrup Room Display must be off (Not Connected) 7) Select Next Recipe 8) Place blender in Auto 9) Upper Bar on "Start Up" button will be illuminated. If not review Steps 2 through 4. 10) Press "Start Up"
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CHEAT SHEET Page 153 of 159
FLAVOR CHANGE Syrup Preparation 1) Enable a Syrup Line Purge from Syrup Room Display 2) Purge from Syrup Tank and/or from Divert Panel 3) Close Divert Panel hand valves 4) Press RunOut Start from Syrup Room Display 5) Bring in good NEXT syrup all the way to divert panel in syrup room 6) Wait for "Prime Waiting" indicator on Syrup Room Display 7) Open valves from Syrup Tank supply line to blender syrup line, with Syrup Tank Pump on. 8) Press "Port A Connected" on Syrup Room Display, to indicate to blender that syrup is connected Blender Preparation 1) Filler container stop must be in automatic 2) Blender must be in Auto 3) Select Next Recipe Filler Preparation 1) Filler Container Stop must be in automatic 2) When Syrup Reservoir reaches Back Up Level, container stop will pull in for Empty Side Backup 3) Confirm containers are backed through conveyor and rinser. 4) Wait for Depal Operator to release Container Stop by pressing Container Stop Release 5) Run Out Product in System 7) When finished running out remaining product in system, make sure filler is rotating, with filling valves and speed in automatic and then Press Filler RunOut Done on blender operator interface. Filler will dump remaining contents in Filler and Product Tank if not empty. 8) Filler will automatically rinse, drain and bring in Next product when available from system.
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CHEAT SHEET Page 154 of 159
Depal Display Login 1) Press LOGIN 2) Enter 3333 3) Press Depal Depal Operation 1) Change Over Indicator indicates when Change Over has started. (Do not cut bottles yet) 2) Back Up Indicator will illuminate when Syrup Reservoir on Blender drops down to the Back Up Level (30%). The Filler Container Stop is automatically pulled in by the blender. 3) Depal operator must verify that the empty side completely filled to the depal. 4) Note number of Sweeps to add from Depal Display. 5) Press “Container Stop Release” on Depal Display to open the Container Stop at filler and continue running out the line. 6) Add sweeps as noted in Step 4, when line was backed up. Note: VALUE OF SWEEPS INDICATED “CHANGE OVER SWEEPS CALLED FOR” DOES NOT COUNT DEPAL SWEEPS AUTOMATICALLY, DEPAL OPERATOR MUST COUNT ON OWN. END OF PRODUCTION Blender Preparation 1) Do not enter a Next Recipe 2) After Filler RunOut is Done, Press End OF Day.
Appendix Accurate Metering Systems, LLC. 1651 Wilkening Road Schaumburg, IL 60173 USA
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APPENDIX E01.01 Calibration of the FEC 12 Electronic Transmitter
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Capacitance Probe Calibration INTRODUCTION The FEC 12 electronic insert is a transmitter for capacitive level measurement. It converts changes in capacitance resulting from changes in level into a capacitance-proportional impressed current. In vessels with a uniform cross section, the level or quantity (volume) can be thus displayed as a percentage of full level. OPERATING ELEMENTS A cover protects the operating elements of the FEC 12. Inserting a small screwdriver into a slit at the edge can raise this. The inside of the cover has symbols printed on it that serves as a quick operating manual. SWITCHES The left hand switch selects whether the linearization is to be carried out remotely with the hand held terminal or locally with the FEC 12 operating elements. If linearization at the FEC 12 is required, then one of two linearization modes in the electronic insert is activated (vertical vessel with linear characteristics) at the right hand switch. PUSHBUTTONS Calibration, locking and reset to factory-set values are carried out at the FEC 12 by using the four pushbuttons. BASIC OPERATION: The pushbuttons marked with plus (+) increase current and those marked minus (-) decrease current. Punching the pushbuttons produces a step-wise change. The smallest resolution possible is 0.014mA. If the pushbutton is depressed continuously, then the current also changes continuously until the pushbutton is released. The change begins slowly and gradually increases in speed and so quickly passes through a wide range. Just before reaching the value required, the pushbutton should be released and the procedure completed by punching the pushbutton for fine resolution. If the value desired is overrun then correct for it by punching the pushbutton for the other direction.
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APPENDIX E01.01 Calibration of the FEC 12 Electronic Transmitter
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CALIBRATION Two types of linearization can be selected: • Vessel characteristics as linear. • Vessel characteristics as horizontal cylinder. Use the left hand switch to select whether linearization is to be carried out at the electronic insert or by the handheld terminal. If the left hand switch is moved to the right, then linearization is carried out at the electronic insert. If the left hand switch is moved to the left, then linearization must be carried out with the hand held terminal and the switch on the right remains inactive. • Move the left hand switch to the right. Select the type of linearization for local calibration using the right hand switch. When it is moved to the left, then the level (output current) is proportional to volume, i.e., the cross-section of the vessel should be constant over its entire length. When it is moved to the right, then linearization is set for a horizontal cylinder, and the measured value supplied corresponds directly to a percent of full volume. • Move the right hand switch to the left. With the vessel completely empty (0%), both pushbuttons on the left minus (-) and plus (+) are depressed simultaneously in order to set the signal current to the 4mA lower value. The green LED lights up to acknowledge that the setting has been accepted. Only when the green LED goes out is the correct value of 4mA shown on the ammeter. With the vessel full (just touching the high level probe), both pushbuttons on the right minus (-) and plus (+) are depressed simultaneously in order to set the signal current to the 20mA higher value. The green LED lights up to acknowledge that the setting has been accepted. Only when the green LED goes out is the correct value of 20mA shown on the ammeter. STEP by STEP 1. Move the left hand switch to the right. 2. Move the right hand switch to the left. 3. With the vessel completely empty push both left (+) and (-) pushbuttons. The green LED lights up to acknowledge that the setting has been accepted. 4. With the vessel completely full push both right (+) and (-) pushbuttons. The green LED lights up to acknowledge that the setting has been accepted. The Vessel / Capacitive probe is now calibrated. RTD Calibration The RTD should be checked quarterly to maintain accuracy, using the verification procedure below:
The following tools will be required to perform this procedure: • a small flat head screwdriver. • an ammeter. Step
Action
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APPENDIX E02.01 RTD Calibration
1. 2. 3. 4.
5. 6. 7. 8. 9.
10.
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Locate the RTD. Remove the cover on the RTD and check for the red led operation. If the red led is not on, replace the RTD and continue this procedure Remove the black wire from the terminal on the RTD. Using the ammeter, apply the probes to the terminal and the wire that was removed from the terminal. Record the reading from the ammeter Using a thermometer from the QC lab, measure the product temperature in degrees F. Using a thermometer from the QC lab, measure the product temperature in degrees F. Insert the temperature into the following equation to calculate the mA signal (mA = (16 * deg.F / 250) + 4). If the value calculated and the reading recorded from the ammeter are within +/- 0.128 mA, then the RTD is good. If it is not within +/0.128 mA, replace the RTD.
RTD Calibration
RTD’s work on the principle that there is a positive correlation between the electrical resistance of a metal conductor and changes in temperature.
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APPENDIX E05.01 MODEM SET-UP
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Modem Set Up 1. Using the serial port on a computer, establish a connection with the modem. 2. Set the dip switches on the back of the modem as follows: Switch 1 - down - DTR override Switch 2 - up - verbal result codes Switch 3 - down - display result codes Switch 4 - up - echo offline commands Switch 5 - up - auto answer on first ring Switch 6 - up - carrier detect normal Switch 7 - up - load NVRAM defaults Switch 8 - down - smart mode 3. Issue the following commands to the modem: “AT &R1” - sets modem to ignore RTS “AT &N10” - sets modem to negotiate baud rate at 19200 bps only Note: (AT &N6 9600 baud at &N3 2400 baud) “AT &WO” - writes current configuration to NVRAM 0 “AT &W1” - writes current configuration to NVRAM 1 4. Issue the following command to the modem: “AT I4”. 5. The following table of information is displayed on the computer for verification: BO E1 F1 M1 Q0 V1 X4 YO BAUD=19200 PARITY=N WORDLEN=8 DIAL=HUNT ON HOOK &A3 &B1 &C1 &D0 &G0 &H1 &I0 &K1 &M4 &N10 &P0 &R1 &S0 &T5 &U0 &Y1 S00=001 S01=000 S02=043 S03=013 S04=010 S05=008 S06=002 S07=060 S08=002 S09=006 S10=014 S11=070 S12=050 S13=000 S15=000 S16=000 S18=000 S19=000 S21=010 S22=017 S23=019 S25=005 S27=000 S28=008 S29=020 S30=000 S31=128 S32=002 S33=000 S34=000 S36=014 S38=000 Please Note: The registers displayed above must match exactly with the registers as displayed once configuration is completed. Should they not, please correct using AT commands. When complete, perform Step #3 once more and then verify.
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OPERATING MANUAL MODEL: AM-25 Coca-Cola Bottling Durham Durham, North Carolina Project 24-152
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Table of Contents Table of Contents................................................................................................ 3 Overview........................................................................................................................... 6 Accu-Change Flavor Change Over .......................................................................................... 6 Accu-Change Timeline ............................................................................................................. 8 Accu-change Illustration ........................................................................................................... 9
Screens ............................................................................................................................ 27 Screen Navigation ..................................................................................................................... 27 Indicators ................................................................................................................................... 28 Module Status Indicator ............................................................................................................ 29 Home Screen ............................................................................................................................ 30 Simplified Screen ...................................................................................................................... 31 Simplified Screen ...................................................................................................................... 32 Side Bar Menu ........................................................................................................................... 33 Recipe Screen ........................................................................................................................... 34 Machine Command Screen ....................................................................................................... 35 Machine Commands ................................................................................................................. 36 Machine Command Glossary .................................................................................................... 36 Syrup Port Command Glossary ................................................................................................ 39 Blending Operations Screen ..................................................................................................... 39 Blending Operations Command Screen.................................................................................... 41 Implied Syrup Brix ..................................................................................................................... 42 Accu-brix Function .................................................................................................................. 42 Change Over Screen................................................................................................................. 43 Change Over Screen Color Meaning ........................................................................................ 44 Production Record Screen ........................................................................................................ 45 Change Over Tally Screen ........................................................................................................ 46 Machine Cycle Screen .............................................................................................................. 47 Trend Screen ............................................................................................................................. 47 Trend Mass Flow Screen .......................................................................................................... 49 CIP Screen ................................................................................................................................ 50 CIP Program Screen ................................................................................................................. 51 Alarm Screen ............................................................................................................................. 53 Alarm Indicators ........................................................................................................................ 54 Alarm Messages ........................................................................................................................ 55 Blender Screen .......................................................................................................................... 66 Blender Screen Indicators ......................................................................................................... 68 Blender Command Screen ........................................................................................................ 69 Deaeration Unit Screen ............................................................................................................. 69 Gas Injector Screen................................................................................................................... 71 Gas Injector Command Screen ................................................................................................. 72 Product Tank Screen................................................................................................................. 73 Product Tank Screen Indicators ................................................................................................ 74 Product Tank Command Screen ............................................................................................... 75 Product Tank Refrigeration Screen ........................................................................................... 76 Product Tank Refrigeration Screen Indicators .......................................................................... 76 Filler Screen .............................................................................................................................. 78 Filler Screen Indicators.............................................................................................................. 79 Cadence Technologies Inc. 1006 Windward Ridge Pkwy Alpharetta, GA, 30005 USA
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Filler Command Screen............................................................................................................. 81 Special Filler Functions ............................................................................................................. 81 Syrup Port Screen ..................................................................................................................... 83 Syrup Port Status Matrix ........................................................................................................... 84 Syrup Port “READY” and “CONNECTED”: ............................................................................... 85 Syrup Port Command Screen ................................................................................................... 86 Syrup Port Ready Screen ......................................................................................................... 87 Syrup Port Utilities Screen ........................................................................................................ 87 Syrup Line Purge Screen .......................................................................................................... 89 Maintenance Screen ................................................................................................................. 90 Maintenance PID Screen .......................................................................................................... 91 PID Control Devices and Available Parameters ....................................................................... 92 Maintenance Setup Screen ....................................................................................................... 94 Maintenance Change Over Screen ........................................................................................... 97 Maintenance Vacuum Pump Screen......................................................................................... 99 Maintenance Meter Setup ....................................................................................................... 100 Maintenance Meter Setup – Syrup Reservoir Calibration ....................................................... 101 Maintenance Meter Proving .................................................................................................... 102 Maintenance Force Screens ................................................................................................... 103
Recipes........................................................................................................................... 107 Recipe Items ........................................................................................................................... 108 Active and Next Recipes ......................................................................................................... 111 Viewing Active and Next Recipes ........................................................................................... 112 Next Recipe Selection ............................................................................................................. 115 Syrup Port ............................................................................................................................... 116 Next Syrup Port Selection ....................................................................................................... 117 Run Out Type .......................................................................................................................... 118 Next Run Out Type Selection .................................................................................................. 119 Setting Up an Active Recipe ................................................................................................... 121
Recipe Manager................................................................................................ 122 Recipe Manager Screen ......................................................................................................... 123 Recipe Viewing ........................................................................................................................ 124 Recipe Editing ......................................................................................................................... 124 Modifying the Selected Recipe Item........................................................................................ 125 Recipe Editor Page 2 .............................................................................................................. 127 Saving the Recipe ................................................................................................................... 128 Copying A Recipe.................................................................................................................... 129 Recipe Name Modification ...................................................................................................... 129 Recipe Deleting ....................................................................................................................... 132
Operation ..................................................................................................................... 136 Utilities Check .......................................................................................................................... 136 E-Stop Check .......................................................................................................................... 136 Morning Start Up ..................................................................................................................... 137 Flavor Change Preparation ..................................................................................................... 139 Flavor Change ......................................................................................................................... 140 Filler Run Out Completion ....................................................................................................... 140 End of Day Shutdown.............................................................................................................. 141 Packaging Change .................................................................................................................. 142 Product Proportioning Adjustment .......................................................................................... 143 Product Tank Pressure Adjustment ........................................................................................ 144 Accurate Metering Systems, LLC. 1651 Wilkening Road Schaumburg, IL 60173 USA
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Gas Injector Set Point Adjustment .......................................................................................... 145 CIP........................................................................................................................................... 146
Frequently Asked Questions .......................................................... 148 Question - Low Syrup Density Alarm Fault on startup ............................................................ 149 Question - foam in my Syrup Reservoir during a Syrup Reservoir Runout ............................ 149 Question – My Syrup Reservoir is High and I can blend no more .......................................... 149
Cheat Sheet............................................................................................................. 151 START UP ............................................................................................................................... 152 FLAVOR CHANGE.................................................................................................................. 153 END OF PRODUCTION.......................................................................................................... 154
Appendix....................................................................................................................... 154 Capacitance Probe Calibration ............................................................................................... 155 INTRODUCTION ................................................................................................................ 155 OPERATING ELEMENTS .................................................................................................. 155 SWITCHES ......................................................................................................................... 155 PUSHBUTTONS ................................................................................................................. 155 CALIBRATION .................................................................................................................... 156 STEP by STEP ................................................................................................................... 156 RTD Calibration ....................................................................................................................... 156 RTD Calibration ....................................................................................................................... 157 Modem Set Up ........................................................................................................................ 158
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Overview Accu-Change Flavor Change Over
The accu-change™ fast flavor change-over option can significantly reduce operating cost. This capability will add more productive uptime to line operation and boost output. It allows line personnel to execute a 5 to 7 minute change-over with ease. This translates to fewer overtime shifts and reduced operating costs. It also provides greater short-run flexibility, permitting you to run more products over the course of a day. In operation, the accu-change™ system coordinates the entire change-over process. At end-of-run, all syrup is transferred to the blender. The amount of product that can be made is calculated and converted to empty containers required. This information is transmitted to the depalletizer operator who sends the required sweeps to the line. No product or containers are wasted. The syrup line, blender, and filler are concurrently rapid-rinsed and dried for the next product. In operation, the Operator selects desired recipe from touch screen, which loads target brix and CO2 settings. Operator then pushes START button which rinses and dries system. Concurrently, separate routines rinse and dry syrup line and filler. When both operations are completed, the syrup cut-off tank fills, and blending begins. Precision flow meters measure actual syrup, water and CO2 flow-rates. PLC logic compares actual flow rates against target flow rates and adjusts the syrup pump speed and the CO2 control valve to maintain target flow rates. Initial settings are automatically adjusted to compensate for Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
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residual water and provide a no-dump start. At end of run, gas pushes all syrup from syrup line into the syrup cut-off tank. When syrup level reaches low point in the cut-off tank, water is added to tank to push in-spec product to carbonator tank. When carbonator empties, the entire system is rinsed and prepared for next flavor.
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Accu-Change Timeline
In order to provide the fastest flavor change over possible the system is partitioned into modules that allow concurrent operations. The timeline above illustrates the accu-change flavor change sequences for each module. Each module is identified on the left, while each machine function timing and length is shown on grid in increments of 5 seconds. The total Filler down time is shown at the bottom in black. Reviewing the timeline one can observe the benefit of partitioning the system into modules, while producing the benefit of concurrent machine functions, that save change over time.
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Accu-change Illustration The following pages illustrate an accu-change flavor change over each machine function is illustrated and also described in the upper right hand machine status box.
The change over starts when the syrup in the syrup line is pushed into the Syrup Reservoir with a CO2 gas purge.
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After the syrup in the syrup line is purged into the Syrup Reservoir the container stop at the filler is automatically pulled in to pack the empty side to a known container count. Concurrently the syrup line is rinsed and drained.
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Once the operator confirms that the empty is packed, the container stop is opened allowing containers to be filled again, and the system calculates the number of sweeps required at the depalletizer to place the entire volume of product in the system into containers, and notifies the depalletizer operator.
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As the system runs out the Syrup Reservoir, the syrup line is prepared for the next production.
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The Syrup Reservoir is still running out the syrup, and the syrup line is ready for the next production run.
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When the level in the Syrup Reservoir reaches bottom of the vessel, water is used to push the remaining syrup through the syrup mass flow meter. At the end of the Syrup Run Out water push a Mix Line Run Out pushes all the product in the Mix Line into the Product Tank with water, and a Syrup Reservoir Rinse starts.
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When the Mix Line Run Out finishes, the Product Tank Run Out will provide the filler with product at pressure. Concurrently the Syrup Reservoir is drained and the Mix Line is rinsed in preparation of next production.
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The Syrup reservoir is primed concurrently, while the Mix Line is rinsed and drained.
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The Mix Line is drained concurrently during a Syrup Reservoir Prime and a Product Tank Run Out.
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The Syrup Reservoir has finished priming, the Mix Line drain and Product Tank Run Out continue.
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After the Mix Line Drain, a Mix Line Prime is initiated by the system to pack the Mix Line with product for the next production run. Concurrently the Product Tank Run Out continues with the current production run.
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When the level of product in the Product Tank reaches bottom of the tank, a Filler Run Out is initiated by the system. At the same time a Product Tank is rinsed and drained. The Filler Run Out uses the remaining product in the Filler Bowl to fill the remaining containers.
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When the entire volume product in the Filler Bowl has been consumed, the operator acknowledges the end of production, and the system initiates draining of the Filler. Concurrently the Product Tank is draining. No containers are filled, thus down time starts to be recorded.
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After the initially draining the Filler, the Filler Bowl is rinsed with it’s own water supply and drained in preparation of the next production. Concurrently the Product Tank Prime fills the Product Tank with product for the next production run.
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Product is ready in the Product Tank. The Filler is finishing draining itself.
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Before bringing product into the Filler, the Filler Bowl must be pressurized. This is done automatically by a Filler Charge function.
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After the Filler Charge pressurizes the Filler Bowl, the system will automatically initiate a Filler Prime, which will gently bring the product into the filler bowl in order to minimize product disturbance.
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After the Filler Prime has brought the product into the Filler Bowl, the container stop is opened and production starts again.
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Screens Screen Navigation The machine is equipped with a touch screen as a main operator interface. The only pushbuttons in the machine operating area are an E-Stop pushbutton and a Reset pushbutton. All adjustments to the system and screen navigation are made through the touch screen operator interface by using your finger. On the screens there are different styles of buttons, that are described below. Each has a special purpose.
Button Style Example
Purpose Square buttons with a graphic within, are Screen Navigation Buttons. Screen Navigation Buttons change the existing screen to a new screen.
Rectangular buttons with text within, and a colored rectangular indicator on top, are Machine Command Buttons. When these buttons are pressed a Machine Function is initiated. Care should always be taken when pressing a Machine Command Button. The colored rectangular bar on the top of the button indicates the state of the Machine Function. Red means the machine Function is inactive. Yellow means that the Machine Function is waiting on some condition to be satisfied before, the function will start. Green means that the Machine Function is active and running. A Screen Navigation Button with a graphic of a house within, will always change the screen to the Home Screen.
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Indicators Colors are used on the screens to indicate the state of valves and pumps, and machine functions. The table below shows the different colors used on the screens and their meanings. Color
Meaning The function is not running. (OFF)
The function is waiting for some condition, before it will start executing.
The function is running (ON)
The function has run already during this change over (DONE)
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Module Status Indicator On many screens you will see a one or more Module Status Bars. Below is a Module Status Indicator for the Syrup Reservoir Module. There are Module Status Indicators for the Syrup Room, Syrup Port, Blender, Mix Line, Product Tank, and Filler. The purpose of the Module Status Indicator is to convey to the operator what the system is doing, and perhaps what the system is waiting for before it can proceed to the next step. Progress Bar
Module’s Machine Function
Machine Function’s Operation
The three elements of a Module Status Indicator are described in the table below. Element Module’s Machine Function
Description The Module’s Machine Function indicates the current Machine Function that the module is running, such as Rinse, Priming, Draining, and Blending among others.
Machine Function’s Operation
The Machine’s Function Operation indicates the current operation, which the Machine Function is performing, such as In Progress, Waiting for Tank Pressure, Blowing Through Filling Valves, or Waiting for Tank to Empty for example.
Progress Bar
The Progress Bar indicates the progression of the execution of a function. The Progress Bar fills with a green bar from left to right as the Machine Function proceeds through it’s execution.
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Home Screen The Home Screen is the pivotal main screen where all other screens are accessed. In the center is a representational process diagram for the system. The process diagram is broken into the following modules Syrup Line, Deaeration Unit, Blender, Gas Injector, Product Tank, and Filler. A modules screen Can be moved to by touching the module on the process diagram. Along the right side of the Home Screen is the Side Bar Menu where pushbutton icons, represent (in order) Recipe Screen, Machine Command, Blender Operations, Change Over, Trends, CIP, Maintenance and Alarms screens. Pressing the associated icon pushbutton will change the screen.
Time and Date
Press here to go to the Simplified Screen
Press one of the modules to change the screen
Press one of the pushbutton icon to change the screen
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To the right of the Active and Next Recipe display, are status lights that indicate the state of some basic machine functions. Automatic Change Over Enabled Indicator
Change Over in Progress Indicator Forces Active Indicator
Blender Status
Accu-Brix Enabled Indicator CIP Indicator
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Simplified Screen The Simplified Screen provides the operator a view of the simplified version of the process, while displaying basic information of operator interest, such as Syrup Port status, Syrup Reservoir Level, Product Tank Level, and Product Tank Outlet Valve status. Step 1.
Action To view the Simplified Screen follow the links below from the home screen
2.
Home The Simplified Screen will display as shown below:
Syrup Port Status
Product Setpoint Target
Syrup Reservoir Level
Gas Injector Target
Syrup Reservoir Volume
Product Tank Pressure Target
Syrup Meter Mass Flow Rate
Filler Container Stop Status Tank
Water Meter Mass Flow Rate
Product Tank Outlet Valve status
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Blender Control Status for Filler Container Stop Output
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Side Bar Menu The Side Bar Menu is on the right hand side of the Home Screen and the Simplified Screen. The menu provides access to specific screens as outlined below.
Recipe Screen
Machine Command
Blending Operations Screen
Change Over Screen
Trend Screen
CIP Screen
Maintenance Screen
Alarm Screen
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Recipe Screen The Recipe Screen provides the operator a view of Recipe Names, Run Out Parameters, and Operator Assigned Syrup Port for the Active and next Recipes. Access is also given for the Active Recipe Screen, the Next Recipe Screen, and The Recipe Manager. Step 1.
2.
Action To view the Recipe Screen follow the links below from the home screen Press here to go to the Active recipe
Home The Recipe Screen will display as shown below:
Active Recipe Name
Press here to go to the Active recipe
Press here to go to the Active recipe Run Out Length
Next Recipe Name
Run Out Type
Operator Selected Syrup Port
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Machine Command Screen The Machine Screen provides the operator the ability to initiate the machine functions. Step 1.
Action To view the Recipe Screen follow the links below from the home screen
2.
Home The Recipe Screen will display as shown below:
Other Screens Machine Command Screens
Change Over Screen
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Machine Commands Machine Command Glossary The Machine Command Screen provides the operator the ability to initiate the machine functions. Pushbutton / Indicator AUTO BLEND
BLEND PAUSE END OF DAY FILLER BLOW
FILLER CHARGE
FILLER COLD RINSE FILLER DRAIN
FILLER PRIME
FILLER RINSE
FILLER RUNOUT
MIX LINE PRIME
MIX LINE RINSE MIX LINE RUNOUT
Action When the AUTO function is enabled, the system will automatically sequence through the change over process without operator intervention. The BLEND function, requests syrup from the Active Syrup Port, requests water from the deaerator, proportions water, syrup and gas, controls the Product Tank Pressure, and provides product to the filler. The BLEND PAUSE function halts the BLEND function. The END OF DAY function provides a means to stop the system at the end of the production day. It kills every other running function. The FILLER BLOW function removes the residual water from the filler, by using a gas blow from the bottom of the filler. This automated function opens drain valves and the filling valves in a sequence. The FILLER CHARGE function pressurizes the filler bowl in preparation to receive product. Having the filler bowl pressurized as product first enters the filler, minimizes the velocity in which the product enters the filler, thus minimizing the change of carbonation to the product. The FILLER COLD RINSE function provides cold water to the filler. Water pumped from the deaerator through the Product Chiller and Product Tank, and then delivered to the filler. The FILLER DRAIN function removes product from the in preparation for a FILLER RINSE. The product is removed by opening the filling valves and the Filler Drain Valve. The FILLER PRIME function provides a means to bring the product into the filler after a FILLER CHARGE. The function opens the Product Tank Outlet Valve (Filler Inlet Valve) and monitors the level probes on the filler line. At the end of the FILLER PRIME the Container Stop is released. The FILLER RINSE function uses treated water to flush the filler, after a flavor change. The Filler Rinse Valve injects water directly into the filler line, where it moves through the filler line up into the filler bowl. The filling valves are automatically opened. The FILLER RUNOUT function maintains the filler in a state in which it can deliver the remaining useable product in the filler bowl to containers. The FILLER RUNPOUT is initiated after a PRODUCT TANK RUNOUT. The Product Tank Outlet (Filler Inlet) valve is closed, thus the only product that remains is in the filler bowl. The MIX LINE PRIME function packs the Mix Line with product. This is done in preparation to then move product into the product tank. During a MIX LINE PRIME, a drain at the top end of the Mix Line is opened, product is then proportioned for a volume that equals the volume of the Mix Line. The MIX LINE RINSE function flushes the Mix Line with water from the Deaerator, the water is pushed out a drain at the top end of the Mix line. The MIX LINE RUNOUT function pushes the contents of the Mix Line into the Product Tank. A volume of water from the Deaerator, equal to the volume of the Mix Line, is used to push the remaining product in the Mix Line into the
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OPERATIONS SCREENS
PRODUCT TANK DRAIN
PRODUCT TANK PRESSURE
PRODUCT TANK PRIME
PRODUCT TANK RINSE
PRODUCT TANK RUNOUT
RUN OUT START
STARTUP
SYRUP RESV DRAIN SYRUP RESV PRIME
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Product Tank. The PRODUCT TANK DRAIN function removes the left over rinse water from the Product Tank during a flavor change over. Pressure is maintained on the Product Tank while drain valves are opened at the bottom. The Product Tank Empty probe is used to determine that the Product Tank is empty. The PRODUCT TANK PRESSURE function maintains pressure in the Product Tank at the Product Tank Pressure Target. While monitoring the gas pressure via the Product Tank Pressure Transducer, the Product Tank Gas Supply Control Valve is used to supply gas to the Product Tank and the Product Tank Pressure Relief Valve is used to exhaust the gas from the Product Tank. The two valves work in opposition to maintain the pressure target setpoint. The PRODUCT TANK PRIME function is used to bring product into the product tank for the first time after a flavor change over. The function controls the target pressure for the product tank as the Product Tank is filled with product. The function runs for a finite volume of product. During the execution of the function the Target Product Tank Pressure is first set to Initial Product Tank Pressure Recipe Item value and then ramped up to the Product Tank Pressure Recipe Item value as the volume of product enters the product tank. The function is completed once the finite volume of product enters the Product Tank. The PRODUCT TANK RINSE function flushes the Product Tank with water from the Dearator. Pressure is maintained to the Product Tank and when the Product Tank Empty probe indicates the presence of water. The Product Tank Drain opens, thus draining the water to the floor. This function runs for a finite volume of water. The function terminates upon meeting the water volume requirements for the rinse. The PRODUCT TANK RUNOUT function is used to provide the filler with the remaining product in the product tank during a flavor change over. The PRODUCT TANK RUNOUT is initiated after a MIX LINE RUNOUT. During a PRODUCT TANK RUNOUT, pressure is maintained on the Product Tank and the Product Outlet Valve is left open until the Product Tank Empty Probe indicates the absence of product, which then the function is terminated. The RUNOUT START function initiates a flavor change over. The function checks the system to confirm that a flavor change is possible and then initiates a SYRUP RUNOUT. The STARTUP function initiates a sequence of functions which prepare the system for production. When the STARTUP function begins, it confirms that the Product Tank and the Syrup Reservoir are empty. If the tanks are not empty the STARTUP function stops, and the operator must first drain the tanks before attempting the STARTUP again. When the confirmation indicates that the tanks are empty, then the function initiates a SYRUP RESERVOIR RINSE, MIX LINE RINSE, PRODUCT TANK RINSE and a FILLER RINSE. The SYRUP RESERVOIR DRAIN function empties the contents of the Syrup Reservoir to the floor. The SYRUP RESERVOIR PRIME function is used to fill the Syrup Reservoir with syrup and recirculate the syrup through the mass flow meter in preparation for blending. The function opens the Active Syrup Port to deliver the syrup to the Syrup Reservoir, fills the Syrup Reservoir until the level reaches above the recirculation pipe inlet, and then uses the syrup to push
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SYRUP RESV RINSE SYRUP RESV RUNOUT
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the contents (usually water) of the Syrup Mass Meter to drain. When the Syrup Meter contents is purged the drain is closed and the recirculation valve opens in order to recirculate the syrup through the Syrup Reservoir and the Syrup Mass Meter. The SYRUP RESERVOIR RINSE function flushes water from the Deaerator through the Syrup Reservoir, in order to remove the residual previous flavor syrup and/ or CIP solution. The SYRUP RESERVOIR RUNOUT function is used to delivery terminate the delivery of syrup to the Syrup Reservoir and blend the remaining syrup into the Product Tank. When the Syrup Reservoir syrup level reaches the bottom of the Syrup Reservoir, the remaining syrup is pushed through the Syrrup Mass Flow Meter with water from the Syrup Reservoir CIP Spray Valve.
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Syrup Port Command Glossary The Machine Screen provides the operator the ability to initiate the machine functions. Pushbutton / Indicator SYRUP LINE AUTO-PREP SYRUP LINE DRAIN SYRUP LINE CLOSE DIVERT PORT A CONNECTED PORT B CONNECTED SYRUP LINE PRIME
SYRUP LINE READY SYRUP LINE RINSE SYRUP LINE PURGE
SYRUP LINE RUNOUT
Action The SYRUP LINE AUTO PREP function automatically sequences the Syrup Line through a SYRUP LINE RINSE, SYRUP LINE DRAIN, and places the syrup line a SYRUP LINE READY state. The SYRUP LINE DRAIN function, removes liquid from the Direct syrup line, by using is a gas blow at the highest point the line, and opening the drain valves. The SYRUP LINE CLOSE DIVERT function will close the Direct Line Syrup Shutoff Valve. This function can only be used if the Direct Line is being used for production, otherwise this function is inhibited. The PORT A CONNECTED function toggles the “CONNECTED” state of the Syrup Port A The PORT A CONNECTED function toggles the “CONNECTED” state of the Syrup Port B The DIRECT LINE PRIME function is used to prepare the Syrup Line for production by packing the Syrup Line with syrup. The function opens a path through the Syrup Line to drain, in order provide a pressure relief for the syrup brought into the Syrup Line in the syrup room. This function is timed, and will stop after running approximately 5 seconds. The DIRECT LINE READY function toggles the “READY” state of the Direct Syrup Port The DIRECT LINE RINSE function flushes the Direct syrup line with water, in order to remove syrup and CIP residue. The source of the water is automated by a valve behind the syrup room divert panel. The SYRUP LINE PURGE function is used to push the syrup out of the active Syrup Line. When this function is running the Syrup reservoir Level Control Valve opens 100% to allow all the syrup in the syrup line to be pushed into the Syrup Reservoir. Not Applicable
Blending Operations Screen The Blending Operations Screen provides the operator the ability view blender proportioning, and gas injection flow rates and totals, along with Recipe and operator adjusted set points.. Step 1.
Action To view the Blending Operation Screen follow the links below from the home screen
2.
Home The Blending Operations Screen will display as shown below:
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Accu-Brix Status
Blending Operations Command Screen
Blender Status Indicator
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
Cover Page.doc1 Rev. 00/00/01
SCREENS BLENDING OPERATIONS
Page 41 of 159
Blending Operations Command Screen The Blending Operations Command Screen provides the operator the ability to adjust the proportioning and gas injection set points, along with enabling the accu-brix control function. Step 1.
2.
Action To view the Blending Operation Command Screen follow the links below from the home screen
Home The Blending Operation Command Screen will display as shown below:
Accu-Brix Enable/ Disable Pushbutton
Operator Adjustments
Blender Status Indicator
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
Cover Page.doc1 Rev. 00/00/01
SCREENS BLENDING OPERATIONS
Page 42 of 159
Implied Syrup Brix The system calculates the (implied) syrup brix from the measured syrup density and measured syrup temperature. The accu-brix function uses the Implied Syrup Brix in calculating the percent syrup used in proportioning. Accu-brix Function The accu-brix function provides the ability to automatically adjust the percent syrup proportioned, based on the brix of the syrup delivered to the blender. Without the accu-brix function enabled, the system uses the value of the Syrup Brix from the recipe to calculate the percent syrup proportioned. With accu-brix function enabled, the system uses the Implied Syrup Brix to calculate the percent syrup proportioned. This allows the system to produce consistant quality of product independent of small variations in the incoming syrup brix. Follow the steps below to enable the accu-brix function. Step 1.
Action Follow the links below from the home screen
2.
Home Pressing the accu-Brix pushbutton will toggle the accu-brix enable/disable status. See pushbutton below.: Enabled/ Disabled Status Indicator
Indicator Color Red
Meaning
Green Yellow
The accu-brix function is enabled, and operating. The accu-brix function is enabled, but not operating, because the Active Recipe is a Diet Recipe.
The accu-brix function is disabled
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
Cover Page.doc1 Rev. 00/00/01
OPERATIONS SCREENS (CHANGE OVER)
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Change Over Screen The Change Over Screen provides the operator the ability to view the current steps of the flavor change over functions. The status of each function is displayed by the color of the indicator, and the flow of the change over is indicated by arrows. Step 1.
Action To view the Change Over Screen follow the links below from the home screen
2.
Home The Change Over Screen will display as shown below:
Change Over Flow Indication
Function Status Indicator
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
Cover Page.doc1 Rev. 00/00/01
OPERATIONS SCREENS (CHANGE OVER)
Page 44 of 159
Change Over Screen Color Meaning The Change Over Screen has a colored block for each function in the change over. The colored block indicated the state of each function in the current change over. Color
Meaning The function is not running. (OFF)
The function is waiting for some condition, before it will start executing.
The function is running (ON)
The function has run already during this change over (DONE)
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
Cover Page.doc1 Rev. 00/00/01
OPERATIONS SCREENS (CHANGE OVER)
Page 45 of 159
Production Record Screen The Production Record Screen displays information on the last ten production runs. Step 1.
Action To view the Production Record Screen follow the links below from the home screen
2.
Home The Production Record Screen will display as shown below:
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
Cover Page.doc1 Rev. 00/00/01
OPERATIONS SCREENS (CHANGE OVER)
Page 46 of 159
Change Over Tally Screen The Change Over Tally Screen displays for the current container cut off. Information regarding the amount of syrup and product in the system is used to calculate the number of depalletizer sweeps required to use all the product available. Step 1.
Action To view the Change Over Tally Screen follow the links below from the home screen
2.
Home The Change Over Tally Screen will display as shown below:
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
Cover Page.doc1 Rev. 00/00/01
OPERATIONS SCREENS (CHANGE OVER)
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Machine Cycle Screen The Machine Cycle Screen displays the different modules of the system and the Machine Function and Function Status for each module. Step 1.
Action To view the Machine Cycle Screen follow the links below from the home screen
2.
Home The Machine Cycle Screen will display as shown below:
Progress Bar
Machine Function Trend Screen
Function Status
The Trend Screen provides the operator the ability to choose one of seven realtime-trend displays that are available. Step
Action
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
Cover Page.doc1 Rev. 00/00/01
MACHINE COMMANDS MACHINE COMMAND
Page 48 of 159
1.
To view the Trend Screen follow the links below from the home screen
2.
Home The Machine Cycle Screen will display as shown below:
Select a trend display by pressing one the seven pushbuttons
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
Cover Page.doc1 Rev. 00/00/01
MACHINE COMMANDS MACHINE COMMAND
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Trend Mass Flow Screen The Trend Mass Flow Screen displays a real-time trend of the water and syrup, target and actual mass flow Step 1.
Action To view the Trend Mass Flow Screen follow the links below from the home screen
2.
Home The Trend Mass Flow Screen will display as shown below: Target flow rate
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
Actual flow rate
Cover Page.doc1 Rev. 00/00/01
SCREENS CIP
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CIP Screen The CIP Screen provides the operator the ability to CIP the system. Step 1.
Action To view the CIP Screen follow the links below from the home screen
2.
Home The CIP Screen will display as shown below:
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
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SCREENS CIP
Page 51 of 159
CIP Program Screen The CIP Screen provides the operator the ability to select one of five different CIP Programs. Each CIP step for the selected program is listed. Step 1.
Action To view the CIP Screen follow the links below from the home screen
2.
Home The CIP Screen will display as shown below:
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
Cover Page.doc1 Rev. 00/00/01
SCREENS ALARM
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
Page 52 of 159
Cover Page.doc1 Rev. 00/00/01
SCREENS ALARM
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Alarm Screen The Alarm Screen displays the status of the machine Alarms and prvides the operator access to the Alarm Status Screen and the Alarm History Screen. Step 1.
Action To view the Alarm Screen follow the links below from the home screen
2.
Home The Alarm Screen will display as shown below:
Use these buttons to go to the Alarm Status or Alarm History Screens
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
Press this button to reset all alarms
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SCREENS ALARM
Page 54 of 159
Alarm Indicators In the center of the Alarm Screen are four indicators, which change from black to a color, when a condition exists as described below. Alarm Indicator Descriptions
Indicates that an alarm occurred, which has stopped the machine (faulted out)
Indicates that an alarm occurred that will not stop the machine, but the condition of the machine should be reviewed by the operator. Indicates that the machine is blending normally.
Indicates that the system is in a flavor change over, and has pulled in the container stop, waiting for the operator to confirm a line back up.
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
Cover Page.doc1 Rev. 00/00/01
SCREENS ALARM
Page 55 of 159
Alarm Messages The table below gives a description of each Alarm Message. Alarm Message ACCU-BRIX CALCULATION OUT OF RANGE
Why and When This alarm occurs if the difference between the Recipe Syrup Brix and the accu-brix Implied Syrup Brix calculation is more than 3.0 Brix.
Meaning The accu-brix function is used to adjust the syrup proportioning within a reasonable syrup brix variation. Variations outside the norm are alarmed to bring the attention to the operator that the syrup may be for a different flavor.
79
ACCU-BRIX SYRUP DENSITY TOO HIGH
80
ACCU-BRIX SYRUP DENSITY TOO LOW
77
ACCU-BRIX SYRUP TEMPERATURE TOO HIGH
78
ACCU-BRIX SYRUP TEMPERATURE TOO LOW
34
Active Recipe: Invalid Recipe
This alarm occurs when Accu-Brix is operating and if the Syrup Density rises above the High Syrup Density Limit for the Implied Syrup Brix Calculation. This alarm occurs when Accu-Brix is operating and if the Syrup Density falls below the Low Syrup Density Limit for the Implied Syrup Brix Calculation. This alarm occurs when Accu-Brix is operating and if the Syrup Temperature rises above the High Syrup Temperature Limit for the Implied Syrup Brix Calculation. This alarm occurs when Accu-Brix is operating and if the Syrup Temperature falls below the Low Syrup Temperature Limit for the Implied Syrup Brix Calculation. This alarm occurs if the Active Recipe Number is not between 1 to 100.
35
Active Recipe: Syrup Ports Do Not Match
An invalid reading from the Syrup Meter Density output may be caused by one of the following: 1) Syrup Flow Meter Transducer Failure. 2) Analog Input Failure. 3) Incorrect Syrup. An invalid reading from the Syrup Meter Density output may be caused by one of the following: 1) Syrup Flow Meter Transducer Failure. 2) Analog Input Failure. 3) Incorrect Syrup. An invalid reading from the Syrup Temperature Transducer may be caused by one of the following: 1) Syrup Temperature Transducer Failure 2) Analog Input Failure. 3) Incorrect Syrup. An invalid reading from the Syrup Temperature Transducer may be caused by one of the following: 1) Syrup Temperature Transducer Failure 2) Analog Input Failure. 3) Incorrect Syrup. If the Active Recipe Number is not within a valid range the system will not proceed. The Active Recipe should be checked. Reloading the recipe may be required. The Operator Selected Syrup Port must match the Recipe Syrup Port. This redundancy minimizes the possibility of opening the incorrect Syrup Port.
51
This alarm occurs if the Operator Selected Active Syrup Port does not match the Active Recipe Syrup Port. Not: If the Active Recipe Syrup Port is “Any Port”, the Operator Selected Active Syrup Port may be any valve, except for “None”.
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
Cover Page.doc1 Rev. 00/00/01
SCREENS ALARM
Alarm Message AIR PRESSURE LOW (FAULT)
Why and When This alarm occurs when the Air Pressure switch located in the Blender pneumatic panel senses a Low Air Supply.
42
AUTO START UP NOT STARTED (CHECK SYSTEM)
This alarm occurs when the operator presses the AUTO START button, and the conditions for initiating Auto Start Up are not valid.
15
BLEND, SYRUP STREAM HIGH (OUT OF CONTROL)
This alarm occurs when the Syrup Stream Zero Balance has out of range, delivering too much syrup for 6 seconds.
16
BLEND, SYRUP STREAM LOW (OUT OF CONTROL)
This alarm occurs when the Syrup Stream Zero Balance has out of range, delivering not enough syrup for 6 seconds
27
CIP CONDUCTIVITY TRANSDUCER FAILURE
This alarm occurs when the 420ma signal on the transducer transmitter is significantly below 4ma or greater than 20ma.
64
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
Page 56 of 159
Meaning Typically an air supply of 100psi is required to the blender. The Air Supply is regulated to 90psi typical, by an internal regulator in the Blender pneumatic panel. Low Air Supply Pressure may be caused by one of the following: 1) Low incoming air pressure and or volume from plant air system. 2) A failed Air Supply Regulator inside the Blender pneumatic panel. 3) A failed Air Supply Pressure Sensor, located inside the Blender pneumatic panel. Conditions which inhibit the AUTO START button are: 1) BAD NEXT RECIPE. 2) SYRUP PORT IS CONNECTED. 3) SYRUP RESERVOIR IS NOT EMPTY 4) FILLER NOT READY FOR START UP 5) AUTO NOT ENABLED The Syrup Stream Zero Balance can be viewed from the Trend Screen. Conditions which may cause a High Syrup Stream are: 1) Poor Water Stream control caused by Product Flow Control Valve not responding. 2) Syrup Proportioning Pump not responding to a speed adjustment sent by the PLC. 3) Syrup Flow sensor or transmitter malfunction. 4) Water Flow sensor or transmitter malfunction The Syrup Stream Zero Balance can be viewed from the Trend Screen. Conditions which may cause a Low Syrup Stream are: 1) Poor Water Stream control caused by Product Flow Control Valve not responding. 2) Syrup Proportioning Pump not responding to a speed adjustment sent by the PLC. 3) A total Syrup Proportioning Pump malfunction. 4) Syrup Flow sensor or transmitter malfunction. 5) Water Flow sensor or transmitter malfunction This alarm can be caused; 1) Electrical failure of the device itself. 2) Faulty wiring. 3) Failure of the PLC analog input.
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SCREENS ALARM
50
13
65
9
6
Alarm Message CIP RETURN PUMP HAS FAILED
CIP SUPPLY TEMPERATURE TRANSMITTER FAILURE CIP TEMPERATURE HIGH ALARM (STEAM DISABLED) CIP TEMPERATURE TRANSMITTER FAILURE DC POWER FAILURE
1
ESTOP PRESSED
82
FILLER BLENDER COMMUNICATION S FAILURE
71
FILLER BLOW NOT REACHING HIGH PRESSURE
70
FILLER BLOW NOT REACHING LOW PRESSURE
Why and When This alarm occurs if the PLC output to the pump is turned on, and the auxiliary feedback on the pump contactor does not indicate the pump is running within 3 seconds. This alarm occurs when the 420ma signal on the transducer transmitter is significantly below 4ma or greater than 20ma. This alarm occurs during CIP if the Product Temperature, Syrup Temperature or Water Temperature exceeds 92 degrees C. This alarm occurs when the 420ma signal on the transducer transmitter is significantly below 4ma or greater than 20ma. This alarm occurs when the PLC no longer senses the presence of the DC power supply voltage. This alarm occurs if the PLC does not sense the presence of voltage from the E-Stop circuit. Indicating that the circuit has been broken, by an E-Stop being pressed or a power failure. This alarm occurs when the handshake signal sent back and forth over the remote IO communication network, between the Blender and the Filler fails over a 4 second period. This alarm occurs during a Filler Blow, if the sequence waits more than 150 seconds for the Bowl pressure to reach high pressure.
This alarm occurs during a Filler Blow, if the sequence waits more than 100 seconds for the Bowl pressure to reach low pressure.
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
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Meaning This alarm can be caused by: 1) Tripped overload protection. 2) Faulty motor starter. 3) Faulty wiring to motor starter. 3) Faulty feedback wiring from auxiliary contact on motor starter to PLC input. This alarm can be caused; 1) Electrical failure of the device itself. 2) Faulty wiring. 3) Failure of the PLC analog input. The steam is disabled if this alarm occurs.
This alarm can be caused; 1) Electrical failure of the device itself. 2) Faulty wiring. 3) Failure of the PLC analog input. This alarm can be caused; 1) Electrical failure of the DC Power Supply. 2) Faulty wiring. 3) Failure of the PLC digital input. This alarm can be caused by: 1) The operator pressing the E-Stop Button on the operator panel. 2) E-Stop circuit power loss.
This alarm can be caused by Remote IO wiring problems, Remote IO Communication Card problems, or power failure on either end of the network.
This alarm indicates that something is wrong with the pressure source under the filler, or that there may be a leak in the filler, which is keeping the filler bowl from pressurizing. This alarm may also be caused by a Filler Bowl Pressure Transducer failure. This alarm indicates that either the valve opener of the filler is not working properly. This alarm may also be caused by a Filler Bowl Pressure Transducer failure.
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SCREENS ALARM
Alarm Message FILLER FILLING VALVES NOT RESPONDING
Why and When This alarm occurs if the blender sends a signal to the filler to open the filling valves, and the filler fails to signal back that the filling valves are open.
57
FILLER NOT EMPTY
This alarm occurs during a Filler Charge, when either the Filler Empty Point Probe or the Filler Operating Point Probe indicates the presence of a liquid (water).
59
FILLER NOT ROTATING FOR CHANGEOVER
This alarm occurs if the Filler is not rotating during a Filler Rinse, Filler Drain, or Filler Blow.
10
FILLER PRESSURE TRANSDUCER FAILURE FILLER ROTATING TOO SLOW
This alarm occurs when the signal 4-20ma signal from the transducer is out of range.
61
62
This alarm occurs if the Filler is not rotating at a minimum rate during a Filler Rinse, Filler Drain, or Filler Blow. This alarm occurs if the Filler speed control is not in Automatic mode during a Filler Rinse, Filler Drain, or Filler Blow.
73
FILLER SPEED CONTROL MUST BE IN AUTO
74
FILLER VALVE OPENER CONTROL MUST BE IN AUTO
This alarm occurs if the Filler Valve Opener control is not in Automatic mode during a Filler Rinse, Filler Drain, or Filler Blow.
12
GAS FLOW TRANSMITTER FAILURE
This alarm occurs when the 420ma signal on the transducer transmitter is significantly below 4ma or greater than 20ma.
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
Page 58 of 159
Meaning This alarm indicates that either the valve opener of the filler is not working properly, or that there may be something wrong with the blender-filler communications. This alarm may also be caused by the Filler Valve Opener being in a manual/hand mode, rather than an Automatic type mode. Review messages on filler operating console or call filler manufacturer. During an automated change over, after a Filler Blow, the Filler Product line should be dry. If the system detects water a Filler Charge, the system will not bring in the product into the Filler, by not performing a Filler Prime automatically. During an automated change over the Filler must rotate in order to implement the correct sequences. Review messages on filler operating console or call filler manufacturer. This alarm can be caused; 1) Electrical failure of the device itself. 2) Faulty wiring. 3) Failure of the PLC analog input. During an automated change over the Filler must rotate at a minimum rate in order to implement the correct sequences. During an automated change over the Filler speed setpoint is sent to the Filler for optimum rinsing and draining. Poor product quality may result if the Filler is not running at optimum speed. Review messages on filler operating console or call filler manufacturer. During an automated change over the Filler Valve Opener must be under the control of the blender in order to implement the correct sequences. Poor product quality may result if the Filler is not under the control of the blender during the change over sequences. Review messages on filler operating console or call filler manufacturer. This alarm can be caused; 1) Electrical failure of the device itself. 2) Faulty wiring. 3) Failure of the PLC analog input.
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SCREENS ALARM
81
Alarm Message GAS PROPORTIONING VALVE AT 100%
17
GAS INJECTOR STREAM HIGH (OUT OF CONTROL)
18
GAS INJECTOR STREAM LOW (OUT OF CONTROL)
40
INVALID CONTAINER TYPE
52
MIX LINE PRIME, SYRUP STREAM HIGH (OUT OF CONTROL)
53
MIX LINE PRIME, SYRUP STREAM LOW (OUT OF CONTROL)
Why and When This alarm occurs if the gasproportioning valve stays open 100% for 6 seconds while trying to proportion the correct amount of gas. This signals that the gas proportioning valve is unable to maintain the proper gas flow while in an operating range in which the valve can sustain control. This alarm occurs if the gas proportioning delivers too much gas and does not compensate within 6 seconds, during Blending. This alarm occurs if the gas proportioning does not deliver enough gas and does not compensate within 6 seconds, during Blending. This alarm occurs when the Operator Selected Container Type is not a valid selection. This alarm occurs if the syrup proportioning delivers too much syrup and does not compensate within 6 seconds, during a Mix Line Prime.
This alarm occurs if the syrup proportioning does not deliver enough syrup and does not compensate within 6 seconds, during a Mix Line Prime.
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
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Meaning This alarm can be caused by: 1) Gas Proportioning Valve not being able to open. 2) Inadequate gas supply pressure. 3) Gas Flow Transmitter failure.
This alarm can be caused by: 1) Gas Proportioning Valve not being able to seat itself closed. 2) Gas Flow Transmitter failure. This alarm can be caused by: 1) Gas Proportioning Valve not being able to open. 2) Inadequate gas supply pressure. 3) Gas Flow Transmitter failure. It is required that the Operator Selected Container Type be chosen for every production run. The Syrup Stream Zero Balance can be viewed from the Trend Screen. Conditions which may cause a High Syrup Stream are: 1) Poor Water Stream control caused by Product Flow Control Valve not responding. 2) Syrup Proportioning Pump not responding to a speed adjustment sent by the PLC. 3) Syrup Flow sensor or transmitter malfunction. 4) Water Flow sensor or transmitter malfunction The Syrup Stream Zero Balance can be viewed from the Trend Screen. Conditions which may cause a Low Syrup Stream are: 1) Poor Water Stream control caused by Product Flow Control Valve not responding. 2) Syrup Proportioning Pump not responding to a speed adjustment sent by the PLC. 3) A total Syrup Proportioning Pump malfunction. 4) Syrup Flow sensor or transmitter malfunction. 5) Water Flow sensor or transmitter malfunction
Cover Page.doc1 Rev. 00/00/01
SCREENS ALARM
47
Alarm Message MIX PUMP HAS FAILED
Why and When This alarm occurs if the PLC output to the pump is turned on, and the auxiliary feedback on the pump contactor does not indicate the pump is running within 3 seconds. This alarm occurs if the Next Recipe Number is not between 1 to 100, 5 minutes before a nonoperator triggered run out. This alarm occurs if the Next Recipe Operator Selected Next Syrup Port does not match the Recipe Syrup Port. If the Next Recipe Syrup Port is “Any Port”, the Operator Selected Next Syrup Port may be any valve, except for “None”. This alarm occurs during a CIP, if the Syrup Mass Flow is less than the minimum allowable CIP flow limit.
32
Next Recipe: Invalid Recipe (5 Min. Warning)
33
Next Recipe: Syrup Ports Do Not Match (5 Min. Warning)
67
NO CIP FLOW ALARM - SYRUP SIDE
66
NO CIP FLOW ALARM - WATER SIDE
This alarm occurs during a CIP, if the Water Mass Flow is less than the minimum allowable CIP flow limit.
48
PRODUCT PUMP / CIP DELIVERY PUMP HAS FAILED
56
PRODUCT TANK GAS INLET VALVE AT 100%
This alarm occurs if the PLC output to the pump is turned on, and the auxiliary feedback on the pump contactor does not indicate the pump is running within 3 seconds. This alarm occurs during blending if the Tank Pressure Source Modulating Valve is required to be opened at 100% for more than 20 seconds.
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
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Meaning This alarm can be caused by: 1) Tripped overload protection. 2) Faulty motor starter. 3) Faulty wiring to motor starter. 3) Faulty feedback wiring from auxiliary contact on motor starter to PLC input.
A minimum flow is required during a CIP. Check valves and pumps for proper operation. This alarm can be caused by a number of reasons; 1) Syrup Proportioning Pump failure 2) Failure of a valve to open upstream of the Syrup Reservoir. 3) Loss of water upstream of the Syrup Reservoir. 4) Air supply failure. 5) Syrup Flow sensor or transmitter failure. A minimum flow is required during a CIP. Check valves and pumps for proper operation. This alarm can be caused by a number of reasons; 1) Insufficient water supply 2) Failure of a valve to open upstream of the Water Flow meter. 3) Air supply failure. 5) Water Flow sensor or transmitter failure. This alarm can be caused by: 1) Tripped overload protection. 2) Faulty motor starter. 3) Faulty wiring to motor starter. 3) Faulty feedback wiring from auxiliary contact on motor starter to PLC input. This alarm indicates that there may be a problem with tank pressure gas source, or Tank Pressure Source Modulating Valve. Check gas source pressure and volume, and check Tank Pressure Source Modulating Valve operation.
Cover Page.doc1 Rev. 00/00/01
SCREENS ALARM
43
Alarm Message PRODUCT TANK IS LOW
11
PRODUCT TEMPERATURE HIGH ALARM
44
PRODUCT TANK LEVEL TRANSMITTER FAILURE (ANALOG) PRODUCT TEMPERATURE HIGH ALARM
11
7
68
31
41
PRODUCT TEMPERATURE TRANSDUCER FAILURE REFRIGERATION NOT RUNNING (ALARM)
SYRUP CONDUCTIVITY TRANSDUCER FAILURE SYRUP DENSITY LOW FAULT
54
SYRUP DENSITY TOO HIGH FOR DIET
8
SYRUP DENSITY TRANSMITTER FAILURE
36
SYRUP FLOW TRANSMITTER FAILURE (ANALOG)
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Why and When This alarm occurs if the Product Tank Low Level Sensor does not sense a product for delivery to the Filler. Typically the container stop will be disabled. This alarm occurs if the Product Temperature rises above the Recipe Maximum Product Temperature value. This alarm occurs when the 420ma signal on the transducer transmitter is significantly below 4ma or greater than 20ma.
Meaning This alarm keeps the Product Tank from running dry. This alarm can occur if the Blender is having trouble keeping up with the Filler demand.
This alarm occurs when the Product Temperature rises above the Maximum Product Temperature setpoint in the Active Recipe. This alarm occurs when the 420ma signal on the transducer transmitter is significantly below 4ma or greater than 20ma. This alarm occurs when the blender is not receiving the signal from the Refrigeration system, when the blender is calling for Refrigeration. This alarm occurs when the 420ma signal on the transducer transmitter is significantly below 4ma or greater than 20ma. This alarm occurs if the syrup density measured by the mass flow meter is less than the Recipe Item Syrup Density Low value.
This alarm can occur from; 1) The filler remaining idle for extended periods, where the product is then warmed from the ambient air. 2) Refrigeration system failure This alarm can be caused by; 1) Electrical failure of the device itself. 2) Faulty wiring. 3) Failure of the PLC analog input. This alarm can be caused by; 1) Refrigeration System not turned on. 2) Refrigeration System failure. 3) Faulty wiring. 4) Failure of the PLC digital output or input. This alarm can be caused; 1) Electrical failure of the device itself. 2) Faulty wiring. 3) Failure of the PLC analog input. The syrup density is constantly checked to confirm that the quality of the syrup has not been inadvertently compromised by the syrup room delivery or the wrong syrup being delivered to the blender. Syrup delivery errors are possible, when performing tank changes in the syrup room. This alarm is check for those errors.
This alarm occurs when a Diet recipe is active and the syrup density measured by the syrup mass flow meter, is greater than 1.10 g/cc. This alarm occurs when the 420ma signal on the transducer transmitter is significantly below 4ma or greater than 20ma. This alarm occurs when the 420ma signal on the transducer transmitter is significantly below 4ma or greater than 20ma.
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
This alarm indicates that the product is warm, and perhaps there is a refrigeration issue. This alarm can be caused by; 1) Electrical failure of the device itself. 2) Faulty wiring. 3) Failure of the PLC analog input.
This alarm can be caused by; 1) Electrical failure of the device itself. 2) Faulty wiring. 3) Failure of the PLC analog input. This alarm can be caused by; 1) Electrical failure of the device itself. 2) Faulty wiring. 3) Failure of the PLC analog input. Cover Page.doc1 Rev. 00/00/01
SCREENS ALARM
3
49
22
Alarm Message SYRUP LEVEL TRANSDUCER FAILURE SYRUP POSITIVE DISPLACEMENT PUMP HAS FAILED SYRUP PROPORTIONING PUMP AT 100%
21
SYRUP RESERVOIR HIGH (OVERFLOW!)
72
SYRUP RESERVOIR LEVEL LOW ALARM
38
SYRUP RESERVOIR PRIME EXCEEDED MAXIMUM VOLUME - CHECK SYRUP! SYRUP RESEVOIR EMPTY PROBE FAILURE
23
2
69
SYRUP TEMPERATURE TRANSDUCER FAILURE SYRUP ROOM BLENDER COMMUNICATION S FAILURE (ALARM)
Why and When This alarm occurs when the 420ma signal on the transducer transmitter is significantly below 4ma or greater than 20ma. This alarm occurs when the syrup pump variable frequency drive sends a fault signal to the system PLC. This alarm occurs when the Syrup Proportioning pump is required by the control algorithm to run at 100%, in order to maintain flow.. This alarm indicates that liquid has been detected by the Syrup Reservoir
This alarm occurs when blending, if the Syrup Reservoir level drops below the minimum level required to run out the containers on the empty side. This alarm occurs when the Syrup Reservoir Prime pushes the rinse water to drain before it detects good syrup, and the total amount pushed to drain exceeds the maximum volume limit. This alarm occurs when the Syrup Reservoir Capacitance Probe indicates a level in the Syrup Reservoir, but the Syrup Reservoir Empty Probe does not sense any liquid. This alarm occurs when the 420ma signal on the transducer transmitter is significantly below 4ma or greater than 20ma. This alarm occurs when the blender does not receive a handshake reply from the Syrup Room PLC within 4 seconds. Which indicates that the two devices are no longer communicating.
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
Page 62 of 159
Meaning This alarm can be caused by; 1) Electrical failure of the device itself. 2) Faulty wiring. 3) Failure of the PLC analog input.
This alarm indicates either a problem with the Syrup Proportioning Pump or a problem with the syrup delivery to the Syrup Proportioning Pump. This alarm is used to inhibit the possibility of over flowing the Syrup Reservoir do to a level control failure. This alarm can be overridden by pressing and holding the BLEND button down, in order to blend syrup out of the Syrup Reservoir. When this alarm occurs, the system will signal the container stop to close. This will safe guard the amount of product/syrup to run out the empty containers on the line. This alarm is a safe guard against pushing too much syrup to drain. If this alarm occurs, check 1) That the correct syrup has been delivered to the blender. 2) That the syrup delivered to the blender is not diluted. This alarm is used to detect the possible failure of the Syrup Reservoir Empty Probe.
This alarm can be caused by; 1) Electrical failure of the device itself. 2) Faulty wiring. 3) Failure of the PLC analog input. This alarm can be caused by 1) Syrup Room PLC malfunction. 2) Syrup Room or Blender Communications channel failure. 3) Faulty wiring.
Cover Page.doc1 Rev. 00/00/01
SCREENS ALARM
Alarm Message TANK PRESSURE LOW TOLERANCE RANGE WARNING
Why and When This alarm occurs during blending when the Product Tank Pressure is 1.0 psi lower or less than the setpoint for 20 seconds.
83
TANK PRESSURE HIGH TOLERANCE RANGE WARNING
This alarm occurs during blending when the Product Tank Pressure is 1.0 psi or more higher than the setpoint for 20 seconds.
4
TANK PRESSURE TRANSDUCER FAILURE
39
TREATED WATER PUMP HAS FAILED (FAULT)
24
VACUMM DEAERATOR CONDENSER HAS BEEN PURGED
This alarm occurs when the 420ma signal on the transducer transmitter is significantly below 4ma or greater than 20ma. This alarm occurs if the PLC output to the pump is turned on, and the auxiliary feedback on the pump contactor does not indicate the pump is running within 3 seconds. This alarm occurs if the Water Condenser on the suction of the Vacuum Pump detects the presence of liquid. When it does, an automated sequence is initiated, which purges the contents of the Condenser.
55
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
Page 63 of 159
Meaning This alarm is a warning that there may be some difficulty controlling the tank pressure during the present operation. This alarm can be caused by; 1) Low supply pressure from gas source. 2) Problem with the Product Tank Gas Source valving. 3) Rapid loss of product level, which can make it difficult to maintain tank pressure.. This alarm is a warning that there may be some difficulty controlling the tank pressure during the present operation. This alarm can be caused by; 1) Problems with the Product Tank Gas Exhaust valving. 3) Rapid increase of product level, which can make it difficult to relieve the tank pressure.. This alarm can be caused by; 1) Electrical failure of the device itself. 2) Faulty wiring. 3) Failure of the PLC analog input. This alarm can be caused by: 1) Tripped overload protection. 2) Faulty motor starter. 3) Faulty wiring to motor starter. 3) Faulty feedback wiring from auxiliary contact on motor starter to PLC input. The Water condenser ensures that no liquid water enters the Vacuum Pump and subsequently damages it. This alarm may happen once a day. If this alarm occurs more than a day, an investigation of the Water Condenser system on the Vacuum Deaerator should be undertaken by Maintenance. This alarm can be caused by; 1) General build up of water mist in the Water Condenser. 2) The water level in the Vacuum Deaerator being to high, and traveling down the Vacuum Line, in which the Level Control Probe or the Level Control Valve may have failed.
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SCREENS ALARM
Alarm Message VACUUM DEAERATOR HIGH WATER LEVEL
Why and When This alarm occurs when the level of the Vacuum Deaerator rises above 65%.
60
VACUUM DEAERATOR LEVEL OR POINT PROBE FAILURE
63
VACUUM DEAERATOR LEVEL TRANSMITTER FAILURE (ANALOG) VACUUM DEAERATOR PRESSURE TOO LOW (ALARM WAIT)
This alarm occurs when the Vacuum Deaerator Level Capacitance Probe indicates a level in the Vacuum Deaerator, but the Vacuum Deaerator Empty Probe does not sense any liquid. This alarm occurs when the 420ma signal on the transducer transmitter is significantly below 4ma or greater than 20ma.
25
26
30
58
46
VACUUM DEAERATOR VACUUM PRESSURE LOW (ALARM) VACUUM DEAERATOR WATER LEVEL IS LOW
VACUUM DEAERATOR WATER PUMP HAS FAILED
This alarm occurs when the vacuum level in the Vacuum Dearator Vessel is insufficient to dearate the water. The system will stop blending until a proper vacuum is achieved. This alarm occurs when the vacuum level in the Vacuum Dearator Vessel is not optimum in order to dearate the water. This is a warning type alarm. This alarm occurs when the level of the Vacuum Deaerator falls below 10%.
This alarm occurs if the PLC output to the pump is turned on, and the auxiliary feedback on the pump contactor does not indicate the pump is running within 3 seconds.
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
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Meaning A capacitance probe and a modulating valve control the level of the Vacuum Dearator. If the level rises too high, water may travel down the vacuum line towards the Vacuum Pump, creating a potentially damaging situation for the Vacuum Pump. This alarm can be caused by; 1) Failed open water inlet modulating valve. 2) Capacitance probe failure. This alarm is used to detect the possible failure of the Vacuum Deaerator Empty Probe.
This alarm can be caused by; 1) Electrical failure of the device itself. 2) Faulty wiring. 3) Failure of the PLC analog input.
This alarm can be caused by; 1) Vacuum pump failure. 2) Vacuum transducer failure. 3) a valve in the Vacuum system, sticking closed.
This alarm can be caused by; 1) Vacuum pump failure. 2) Vacuum transducer failure. 3) a valve in the Vacuum system, sticking closed. A capacitance probe and a modulating valve control the level of the Vacuum Dearator. If the level rises too high, water may travel down the vacuum line towards the Vacuum Pump, creating a potentially damaging situation for the Vacuum Pump. This alarm can be caused by; 1) Failed closed water inlet modulating valve. 2) Capacitance probe failure. This alarm can be caused by: 1) Tripped overload protection. 2) Faulty motor starter. 3) Faulty wiring to motor starter. 3) Faulty feedback wiring from auxiliary contact on motor starter to PLC input.
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SCREENS ALARM
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45
Alarm Message VACUUM PRESSURE TRANSDUCER FAILURE VACUUM PUMP HAS FAILED
Why and When This alarm occurs when the 420ma signal on the transducer transmitter is significantly below 4ma or greater than 20ma. This alarm occurs if the PLC output to the pump is turned on, and the auxiliary feedback on the pump contactor does not indicate the pump is running within 3 seconds. This alarm occurs when the over temperature switch on the vacuum pump indicates an over temperature.
28
VACUUM PUMP TEMPERATURE TOO HIGH
14
VACUUM PUMP TEMPERATURE TRANSDUCER FAILURE VACUUM PUMP OIL CHANGE REQUIRED SOON
This alarm occurs when the 420ma signal on the transducer transmitter is significantly below 4ma or greater than 20ma. This alarm occurs when the Vacuum Pump Hour timer exceeds the Vacuum Pump Oil Change Warning Timer Limit.
85
VACUUM PUMP OIL CHANGE REQUIRED NOW
This alarm occurs when the Vacuum Pump Hour timer exceeds the Vacuum Pump Oil Change Alarm Timer Limit.
37
WATER FLOW TRANSMITTER FAILURE (ANALOG) WATER STREAM HIGH (OUT OF CONTROL)
84
20
WATER STREAM LOW (OUT OF CONTROL)
This alarm occurs when the 420ma signal on the transducer transmitter is significantly below 4ma or greater than 20ma. This alarm occurs if water flow control is delivering more than 100 kg/min higher than the target flow. This alarm occurs if water flow control is delivering less than 100 kg/min lower than the target flow.
5
WATER TEMPERATURE TRANSDUCER FAILURE
This alarm occurs when the 420ma signal on the transducer transmitter is significantly below 4ma or greater than 20ma.
19
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Page 65 of 159
Meaning This alarm can be caused by; 1) Electrical failure of the device itself. 2) Faulty wiring. 3) Failure of the PLC analog input. This alarm can be caused by: 1) Tripped overload protection. 2) Faulty motor starter. 3) Faulty wiring to motor starter. 3) Faulty feedback wiring from auxiliary contact on motor starter to PLC input. The temperature of the Vacuum Pump system is an temperature sensor located in the vacuum pump, and cooling water delivered through a heat exchanger, located on top of the vacuum pump. This alarm can be caused by; 1) Loss of cooling water supply. 2) Temperature transducer failure. 3) Cooling water ball valve failure. This alarm can be caused by; 1) Electrical failure of the device itself. 2) Faulty wiring. 3) Failure of the PLC analog input. The Vacuum Pump is required to have the oil change periodically. Once the oil has been changed, the Vacuum Pump Hour must be reset from the Vacuum Pump Maintenance Screen. The Vacuum Pump is required to have the oil change periodically. Once the oil has been changed, the Vacuum Pump Hour must be reset from the Vacuum Pump Maintenance Screen. This alarm can be caused by; 1) Electrical failure of the device itself. 2) Faulty wiring. 3) Failure of the PLC analog input. The water flow has to be within range. The Mix Throttling Valve and water delivery system to the blend skid can effect the water flow. The water flow has to be within range. The Mix Throttling Valve and water delivery system to the blend skid can effect the water flow. This alarm can be caused by; 1) Electrical failure of the device itself. 2) Faulty wiring. 3) Failure of the PLC analog input.
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SCREENS ALARM
84
85
Alarm Message VACUUM PUMP OIL CHANGE REQUIRED SOON
VACUUM PUMP OIL CHANGE REQUIRED NOW
Why and When This alarm message is a warning that is activated when the Vacuum Pump Hour Timer exceeds the Warning Hours parameter value, set in the Maintenance Vacuum Pump Screen. This alarm is activated when the Vacuum Pump Hour Timer exceeds the Alarm Hours parameter value, set in the Maintenance Vacuum Pump Screen.
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Meaning This alarm message is a warning to the operator that an oil change of the Vacuum Pump is required in the near future.
This alarm indicates to the operator that an oil change of the Vacuum Pump is past due.
Blender Screen The Blender Screen provides the operator the ability to view the Blender Module valve position, pump speed, flow rates and current Machine Function. Step 1.
Action To view the Blender Screen follow the links below from the home screen
2.
Home The Blender Screen will display as shown below:
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
Cover Page.doc1 Rev. 00/00/01
SCREENS BLENDER
Press Here to Go To Deox Graphic
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Press Here to Go To Syrup Room Graphic
Press Here to Go To Injector Graphic
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SCREENS BLENDER
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Blender Screen Indicators There are a number of colored indicators on the Blender Screen, which show the state of the level of the syrup in the Syrup Reservoir. LP201 Syrup Reservoir Level High Probe. Green means syrup level is high. Red means the syrup level is below the high level.
LP203 Syrup Reservoir Level Low Probe. Green means product is present at the bottom of the Syrup Reservoir. Red means the Syrup Reservoir is empty.
LP200 Syrup Line – Syrup Detection Probe. Green indicates. Syrup or Water (liquid) is present in the syrup Line. Red indicates the Syrup Line is empty.
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
CT201 Syrup Line Conductivity Transmitter. Indicates conductivity of Syeup in the Syrup Line feeding the blender.
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SCREENS BLENDER
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Blender Command Screen The Blender Command Screen provides the operator the initiate Blender Module Machine Commands and make operator adjustments to the proportioning. Step 1.
Action To view the Blender Command Screen follow the links below from the home screen
2.
Home The Blender Command Screen will display as shown below: Use the Up/Down arrows to change the Operator Adjusted Brix
Deaeration Unit Screen
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SCREENS DEAERATION UNIT
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The Deaeration Unit Screen provides the operator the ability to view the Deox (Vacuum Deaeration unit) valve position and pump status. Step 1.
Action To view the Deaeration Unit Screen follow the links below from the home screen
2.
Home The Deaeration Unit Screen will display as shown below:
Press Here to go to CIPSkid
Press Here to go to Blender Graphic
Indicates number of seconds left in warm up or warm down.
Press here to go to enable Vacuum
Press Here to to enable Dearator
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SCREENS GAS INJECTOR
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Gas Injector Screen The Gas Injector Screen provides the operator the ability to view the position and status of the valves on the Gas Injector Module. Step 1.
Action To view the Gas Injector Screen follow the links below from the home screen
2.
Home The Gas Injector Screen will display as shown below:
Press here to go to Product Tank Graphic
Press here to go to Blender Graphic
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Cover Page.doc1 Rev. 00/00/01
SCREENS GAS INJECTOR
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Gas Injector Command Screen The Gas Injector Command Screen provides the operator the ability to adjust the Gas Injector set point. Step 1.
Action To view the Gas Injector Command Screen follow the links below from the home screen
2.
Home The Gas Injector Command Screen will display as shown below:
Use Up/Down arrows to adjust the Gas Injector Set point,
Press Here to go to Product Tank Graphic Press here to go to Blender Graphic
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
Cover Page.doc1 Rev. 00/00/01
SCREENS PRODUCT TANK
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Product Tank Screen The Product Tank Screen provides the operator the ability to view the position and status of the valves on the Product Tank Module. Step 1.
Action To view the Product Tank Screen follow the links below from the home screen
2.
Home The Product Tank Screen will display as shown below:
Press here to got to Injector Graphic
Press here to got to Filler Graphic Press here to got to Injector Graphic
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SCREENS PRODUCT TANK
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Product Tank Screen Indicators There are a number of colored indicators on the Product Tank Screens, which show the state of the level of the product in the Product Tank.
Indicator Beverage Available
Description When the blender has sufficient level of product in the Product Tank for delivery to the Filler, this indicator will turn green.
LP401 Product Tank Empty Probe. Green means product is present at the bottom of the Product Tank. Red means the Product Tank is empty.
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SCREENS PRODUCT TANK
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Product Tank Command Screen The Product Tank Command Screen provides the operator the ability to adjust the Product Tank pressure and the product temperature set points. Step 1.
Action To view the Product Tank Command Screen follow the links below from the home screen
2.
Home The Product Tank Command Screen will display as shown below:
Use Up/Down arrows to adjust the Product Temperature if Accu-Temp Option is installed
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
Use Up/Down arrows to adjust the Product Tank Pressure
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SCREENS PRODUCT TANK
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Product Tank Refrigeration Screen The Product Tank Command Screen provides the operator the ability to adjust the Product Tank pressure and the product temperature set points. This screen is available with the Accu-Temp option. Step 1.
Action To view the Product Tank Command Screen follow the links below from the home screen
2.
Home The Product Tank Command Screen will display as shown below:
Accu-temp BPRV control variables
Product Tank Refrigeration Screen Indicators
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA 847-882-0690
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SCREENS PRODUCT TANK
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There are a number of colored indicators on the Product Tank Refrigeration Screen, which show the status of the Product Refrigeration.
BPRV Position LS231H indicates a high ammonia level in the surge tank.
LS231O indicates that the ammonia level is a the operating level of the surge tank
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA 847-882-0690
V232 BPRV (Back Pressure Regulating Valve) maintains a constant pressure on the Ammonia Surge Tank, in order to maintain a constant temperature.
V230 Ammonia Liquid Line Solenoid Valve. Sources liquid ammonia into the surge tank.
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SCREENS FILLER
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Filler Screen The Filler Screen provides the operator the ability to view the position and status of the valves on the Filler Module. Step 1.
Action To view the Filler Screen follow the links below from the home screen
2.
Home The Filler Screen will display as shown below:
Astirix (*) indicates valves are normally open. Valve is open when red, closed when green.
LP402 Filler Line Empty Probe
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
LP403 Filler Line Full Probe
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SCREENS FILLER
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Filler Screen Indicators There are a number of colored indicators on the Filler Screens, which show the state of the interface between the Blender and the Filler. The STATUS indicators are actual feed back from the Filler to the Blender.
Status Indicators Container Stop
Valve Opener Rotating
Description Indicates the actual status of the Filler Container Stop. The Container Stop is open (allowing containers to pass through the filler) when the indicator is green. The Container Stop is closed (containers are blocked from passing through the filler) when the indicator is red. Indicates the actual status of the Filler Valve Opener. The Valve Opener is open, when the indicator is green. The Valve Opener is closed, when the indicator is red. Indicates when the Filler drive control is active, in order to rotate the Filler. Many Filler Machine Functions require that the Filler rotate in order to execute.
The OUTPUTS indicators are commands sent to the Filler from the Blender.
Output Indicators Container Stop Valve Opener
Description During a Flavor Change Over or when certain Alarm Faults occur, the blender signals the Filler to inhibit containers from passing through the Filler. When this indicator blinks green, the Container Stop will block the containers. During certain Filler Machine Functions (rinses, drains, and blows) the Blender will signal the Filler to open the Valve Opener. When this indicator is green the Filler will open the Valve Opener.
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
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SCREENS FILLER
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The following indicators show the status of the availability of beverage from the blender, and the request for beverage from the Filler.
Indicator Beverage Available
Description When the blender has sufficient level of product in the Product Tank for delivery to the Filler, this indicator will turn green.
Beverage Request
When the Filler is ready to accept product, it requests beverage through this signal. Even if the Blender has “Beverage Available” the Product Outlet Valve will not open until the Filler makes a “Beverage Request”
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
Cover Page.doc1 Rev. 00/00/01
SCREENS FILLER
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Filler Command Screen The Filler Command Screen provides the operator the ability to initiate the available Filler functions. Step 1.
Action To view the Filler Command Screen follow the links below from the home screen
2.
Home The Filler Command Screen will display as shown below:
Press here to end the Filler Run Out during a Flavor Change
Special Filler Functions
Output Indicators
Press here to manually to toggle the Beverage Request signal to the Description Blender Filler Runout Done. This button is used to end a Runout of the production. This button is active when the Product Tank Runout or the Filler Runout are in progress, and will complete both of them. If this button
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Cover Page.doc1 Rev. 00/00/01
SCREENS FILLER
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is pressed during a Filler Runout, the automatic changeover is initiated by completing the Filler Runout and initiating a Filler Drain. If this button is pressed while a Product Tank Runout is in progress, the Filler starts a Filler Drain, and the Product Tank will initiate a Product Tank Empty, which will release all the product in the Product Tank to Drain. Enable Product Pump. When enabled, the Product Pump is used to deliver product to the filler. Hold Auto Prime. When enabled, a Filler Prime will not be initiated automatically during a Filler Change Over. The Filler Prime will have to be manually initiated. This button is used to hold off the automatic initiation of the Filler Prime, in instances, where the operator may be required to perform some maintenance on the Filler. (ie changing a valve)
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
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OPERATIONS SYRUP PORT
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Syrup Port Screen The Syrup Port Screen provides the operator the ability to view the Syrup Port status and valve position of the syrup manifold. Step 1.
Action To view the Syrup Port Screen follow the links below from the home screen
2.
Home The Syrup Port Screen will display as shown below: Green indicates Syrup Pump is running. Red indicates Syrup Pump Is not running.
Press Here to Go to Blender Graphic
Syrup Port Status Matrix
Press here to go to Syrup Room Commands Screen
Press here to go to Deox Graphic Screen
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
Indicates if the Syrup Pump is being requested to run by the blender.
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OPERATIONS SYRUP PORT
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Syrup Port Status Matrix Displayed on the Syrup Port Screen and other screens, is the Syrup Port Status Matrix. The Syrup Port Status Matrix indicates the condition and current operation each syrup port. PORT A PORT B
State or Operation
Each column of the matrix represents one of the syrup lines (ala DIRECT LINE, DIET LINE, FLAVOR LINE, or CLASSIC LINE. Note in some installations only one syrup line is indicated). Each row indicates a specific state or operation. State or Operation Active Next Ready Connected Rinse Drain Prime
Description When green, this indicates that the Syrup Port is selected in the Active Recipe. When green, this indicates that the Syrup Port is selected in the Next Recipe. When green, this indicates the Syrup Port is ready for production. When green, this indicates that syrup is connected in the Syrup Room to the Syrup Port. When green, this indicates that the Syrup Port is being rinsed. When green, this indicates that the Syrup Port is being drained. When green, this indicates that the Syrup Port is being primed.
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
Cover Page.doc1 Rev. 00/00/01
OPERATIONS SYRUP PORT
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Syrup Port “READY” and “CONNECTED”: The Syrup Port states “CONNECTED” and “READY” are set by the operator, as confirmation to the Blender, as to the status of the Syrup Port. This redundancy is used to minimize the possibility of opening the wrong Syrup Port through operator error. The following also applies. • In order for the Syrup Inlet valve for the Syrup Port to open the Syrup Port must be “CONNECTED” and be “READY”. The blender will wait until the Syrup Port is “CONNECTED” and “READY” before it will start a Syrup Reservoir Prime, Mix Line Prime or Blending. • The Syrup Port can only be Primed if the Syrup Port is “CONNECTED” and is “READY”. • The Syrup Port cannot be Rinsed, Drained, or CIPed if the Syrup Port is “READY”. The logic in the system software will inhibit this. • The Syrup Port “CONNECTED” state is set to false during a Run Out. Therefore the Syrup Port will require the “CONNECTED” state to be set to true again, when the Syrup Port is needed in the future.
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Cover Page.doc1 Rev. 00/00/01
OPERATIONS SYRUP PORT
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Syrup Port Command Screen The Syrup Port Command Screen provides the operator the ability to initiate commands that affect the Syrup Ports. Step 1.
Action To view the Syrup Port Command Screen follow the links below from the home screen
2.
Home The Syrup Manifold Screen will display as shown below:
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OPERATIONS SYRUP PORT
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Syrup Port Ready Screen The Syrup Port ready Screen allows the provides the operator the ability to initiate commands, that affect the Syrup Ports. Step 1.
Action To view the Syrup Port Command Screen follow the links below from the home screen
2.
Home The Syrup Manifold Screen will display as shown below:
Syrup Port Ready
Syrup Port Utilities Screen
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OPERATIONS SYRUP PORT
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The Syrup Port ready Screen allows the provides the operator the ability to initiate commands, that affect the Syrup Ports. Step 1.
Action To view the Syrup Port Command Screen follow the links below from the home screen
2.
Home The Syrup Manifold Screen will display as shown below:
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
Syrup Port Utilities
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OPERATIONS SYRUP PORT
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Syrup Line Purge Screen The Syrup Port ready Screen allows the provides the operator the ability to initiate commands, that affect the Syrup Ports. Step 1.
Action To view the Syrup Port Command Screen follow the links below from the home screen
2.
Home The Syrup Manifold Screen will display as shown below:
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
Syrup Line Purge
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OPERATIONS SCREENS (HOME)
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Maintenance Screen The Maintenance Screen a pivotal screen, where all the screens that pertain to machine setup, performance, component testing and calibration are accessed. Step 1.
Action Access the Maintenance Screen by following the links below from the home screen
2.
Home Maintenance The Maintenance Screen will display as shown below:
Press here to enable the forcing of machine components.
Press a button button to access the subscreen
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OPERATIONS SCREENS (HOME)
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Maintenance PID Screen The Maintenance PID Screen displays to the available PID parameter adjustment screens for the system. The PID parameters control the dynamics of how a control point is maintained to a set point. Step 1.
Action Access the Maintenance PID Screen by following the links below from the home screen
2.
Home Maintenance Maintenance PID The Maintenance PID Screen will display as shown below:
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OPERATIONS SCREENS (HOME)
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PID Control Devices and Available Parameters Each PID Maintenance Screen is used to adjust the dynamics of a specific control point. Refer to the table below regarding the Control points input device, out put device, and available parameters that can be adjusted. Screen Syrup Blending
Input Device Syrup Meter (FT201) and Water Meter (FT101)
Output Device Syrup Proportioning Pump (P201)
Product Flow
Water Meter (FT101)
Mix Line Throttling Valve (Product Modulating Valve) (V404)
Syrup Reservoir Capacitance Probe (LT201) Product Tank Pressure Transducer (PT401)
Syrup Reservoir Level Control Valve (V204)
Reservoir Level Tank Pressure CO2 Injection
Gas Mass Flow Meter (FT301)
CIP Supply Temperature
CIP Return Temperature Transducer (RTD001) Vacuum Deaerator Capacitance Probe (LT101)
Vacuum Deaerator Level
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA 847-882-0690
Product Tank Gas Inlet Valve (V323) and Product Tank Gas Outlet Valve (V326) Gas Injector Modulating Valve (V306)
Steam Control Valve (V001)
Vacuum Deaerator Water Level Control Valve (V102)
Available Parameters Feed Forward Scale Feed Forward Offset Gain Integral Derivative Feed Forward Scale Feed Forward Offset Gain Integral Derivative Gain Integral Derivative Gain Integral Derivative Feed Forward Scale Feed Forward Offset Gain Integral Derivative Gain Integral Derivative Gain Integral Derivative
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OPERATIONS SCREENS (HOME)
Press up arrow to increase parameter value.
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA 847-882-0690
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Press down arrow to increase parameter value.
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OPERATIONS SCREENS (HOME)
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Maintenance Setup Screen The Maintenance PID Screen displays to the available PID parameter adjustment screens for the system. The PID parameters control the dynamics of how a control point is maintained to a set point. Step 1.
Action Access the Maintenance Setup Screen by following the links below from the home screen
2.
Home Maintenance Setup The Maintenance Setup Screen will display as shown below:
Parameter Syrup Reservoir Volume at 100%
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA 847-882-0690
Description This parameter is used to scale the Syrup Reservoir Capacitance Probe analog input to the conversion to volume (in liters). The value entered here should be the volume of the Syrup reservoir when the reservoir is at 100%. Cover Page.doc1 Rev. 00/00/01
OPERATIONS SCREENS (HOME)
Syrup Reservoir Volume at 0%
Analog In High Alarm
Analog In Low Alarm
Water Brix
Water TA/%
Residual Water Mass
Blend Sweet Mass
Metric Mass Display
Metric Non-Mass Display
Auto Start Auto Brix CIP Pressure
Accu-Temp Offset
Vacuum Low
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This parameter is used to scale the Syrup Reservoir Capacitance Probe analog input to the conversion to volume (in liters). The value entered here should be the volume of the Syrup Reservoir when the reservoir is at 0%. This parameter is used as an upper threshold for a valid analog input current reading in milliamps. If an analog input rises above this valve, a Transducer Failure Alarm is generated. This parameter is used as an lower threshold for a valid analog input current reading in milliamps. If an analog input falls below this valve, a Transducer Failure Alarm is generated. This parameter is used in the internal calculations the system performs toward the determination of percent syrup of a Non-Diet product dependent upon Recipe values of Syrup Brix and Product Brix. This value should be the apparent brix of the water used by the blending system. This parameter is used in the internal calculations the system performs toward the determination of percent syrup on a Diet product dependent upon Recipe values of Syrup Brix and Product Brix. This value should be the apparent TA of the water used by the blending system. This value is used in calculating the initial blend during the initial blend of a product. Blending at a lower ratio during the initial blend of a product corrects for the residual water left after a rinse and drain of the system. The unit of this parameter is in kilograms. This value is used to determine the amount of mass of product is blended at a lower blend ratio during the initial blend of a product. Blending at a lower ratio corrects for the residual water left after a rinse and drain of the system. The unit of this parameter is in kilograms. This parameter determines if the units of the mass display values (flow rates and totals) are displayed in metric (kilograms and gallons) or Imperial Units (pounds/min and liters). This parameter determines if the units of the non-mass display values (temperature and pressures ) are displayed in metric (kilograms) or Imperial Units (pounds/min). This parameter determines if the Accu-Brix control algorithm is started automatically when a new product starts up. This parameter provides the Setpoint for the Product Tank Pressure during a CIP. Typical value is 0, for an atmospheric tank CIP. The parameter provides the value of the split across the Product Chiller in degrees C. Typical for PHE is 1.0C and for Carbo-Cooler is 3.0 C. This parameter determines the low threshold for the Vacuum Pressure Low Warning
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Vacuum Too Low
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This parameter determines the low threshold for the Vacuum Pressure Low Alarm. Blending cannot continue below this level.
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Maintenance Change Over Screen The Maintenance Change Over Screen gives the operator the ability to adjust parameters pertaining to the volumes metered during certain functions. Step 1.
2.
Action Access the Maintenance Change Over Setup Screen by following the links below from the home screen
Home Maintenance Change Over The Maintenance Change Over Screen will display as shown below:
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Parameter Syrup Line Volume
Description This parameter provides the system information regarding the amount of syrup volume is held in a packed sysrup line. This value is used to determine the amount of syrup available in the system.
Syrup Reservoir Push Volume
This parameter provides the system with information regarding the volume of syrup held in the syrup metering line from the bottom of the Syrup Reservoir all the way up to the Mix Line. The value is used during a Syrup Reservoir Runout. When the level of the syrup reaches the bottom of the Syrup Reservoir, the Syrup is metered until the volume metered reaches this value. This parameter provides the system with information regarding the volume of the Mix Line Prime. During a Mix Line Prime, the amount of liquid (rinse water) is metered to drain, exceeds this value; the product is then diverted into the Product Tank afterwards. This parameter provides the system with information regarding the volume of the Mix Line for the Mix Line Runout. During a Mix Line Runout, the amount of product that is pushed with water into the Product Tank is metered. When the amount of metered water exceeds this value, the Mix Line Runout is terminated. This parameter provides the system with the volume of the Product Tank in liters when the Product Tank capacitance probe reads 100%. This parameter provides the system with information regarding the volume of the Filler and Filler Line, during normal product operation. This value is used in determining the container cutoff value. This parameter is used by the system to determine the amount rinse water volume should be metered during a Syrup Reservoir Rinse. This parameter provides the system with information pertaining to the amount of rinse water to meter to drain, before a recirculation is initiated during a Syrup Reservoir Prime. This value should be the volume of the syrup meter line from the bottom of the Syrup Reservoir to the Syrup Meter Drain.
Mix Line Prime Volume
Mix Line Runout Push Volume
Product Tank Volume
Filler and Line Volume
Syrup Reservoir Rinse Volume
Syrup Reservoir Prime Drain
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Maintenance Vacuum Pump Screen The Maintenance Change Over Screen gives the operator access to Vacuum Pump hour counter alarm set points and the ability to reset the hour counter. Step 1.
2.
Action Access the Maintenance Vacuum Pump Screen by following the links below from the home screen
Home Maintenance Vacuum Pump The Maintenance Vacuum Pump Screen will display as shown below:
Press here to reset the hour counter, after you have changed the oil in the Vacuum Pump
Press up or down arrow to increment or decrement the parameter value.
The Vacuum Deaerator provided with the system requires an oil change periodically. This Maintenance Vacuum Pump Screen is used to set the number of hours that an oil change is absolutely required (Alarm Hours) and to set the number of hours for a reminder message (Warning Hours). This screen is also used by the operator to reset the hour counter one the oil has been changed.
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Maintenance Meter Setup The Maintenance Meter Setup Screen provides access to each meter’s maximum value at 20 milliamps, and whether the water meter is a volumetric type or a mass meter. The screen also provides the ability to calibrate the Syrup Reservoir. Step 1.
2.
Action Access the Maintenance Meter Setup Screen by following the links below from the home screen
Home Maintenance Maintenance Meter Setup The Maintenance Meter Setup Screen will display as shown below:
Press here to toggle between a Mass Meter or a Volumetric Meter.
Press up or down arrow to increment or decrement the parameter value.
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Maintenance Meter Setup – Syrup Reservoir Calibration The Maintenance Meter Setup Screen also provides a means to calibrate the Syrup Reservoir Capacitance Probe. With the buttons shown below, the qualified operator can fill the Syrup Reservoir with water from the Deaerator by pressing the “Fill Syrup Reservoir” button, and then when complete, start totalizing the amount of sysrup in the Syrup Reservoir by pressing “Syrup Totalize”. The value of the current Syrup Volume metered and the current level are also shown.
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Maintenance Meter Proving The Maintenance Meter Proving Screen provides the OEM technician with the ability to prove the blender meters. A qualified OEM technician should only undertake this. Step 1.
2.
Action Access the Maintenance Meter Proving Screen by following the links below from the home screen
Home Maintenance Maintenance Meter Setup The Maintenance Meter Proving Screen will display as shown below:
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Maintenance Force Screens In order to test individual machine components, it may be required by a Qualified Operator to activate a specific machine component. This “Forcing” capability is provided through the “Force Screens”. The Maintenance Screen provides access to a number of “Force” Screens, located in the “Force Screen Area”.
Force Screen Area
Force Enable Button
Do not attempt to Force a component while the system is performing a function or operation. To enable “Forcing”, press the Force Enable Button. A green indicator means that Forcing is enabled.
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Inside the “Force Screen Area”, are a number of Force Screens, which provide access to Forcing Components based on the location in the System. Below is an example of a typical Force Screen for the Vacuum Deaerator. A green indicator means the item is activated. A red indicator means the item is deactivated.
Selected item to be activated.
Press Up / Down arrows to move selection.
Indicator
Press Enter Button to activate / deactivate selected item.
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Analog outputs, to such devices as driver speeds and I/P transducers are forced on the Maintenance Analog Table, shown below. Press Up / Down arrows to increment or decrement item analog out from 0 to 100%.
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Recipes A Recipe is a list of variables used by the blender to formulate the ingredients for the correct end product. The system allows up to 100 different recipes to be developed. A Typical recipe displayed by the Recipe Viewer is shown below.
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Recipe Items Each Recipe Item has it’s own description with an associated value, The definition of each Recipe Items is described below.
Recipe Item Syrup Brix /TA/Percent
Definition This is the target value of the Finished Syrup that is being delivered to the blender. This number, along with the Product Brix/TA/Percent Recipe Item value determines the blending ratio for proportioning water and syrup. The value of this Recipe Item depends on how the end Product is measured, which corresponds to value and units of the Product Brix/TA/Percent Recipe Item value. If the end Product is measured in Brix from a Refractometer or a Densitometer, Then specify this value as the Target Syrup Brix for this flavors syrup batching. • If the end Product is measured by a titration (which typically determines product acidity), Then specify this value as the measurement of the Titration of a full strength Finished Syrup batch. Typically this value is the blending ratio plus one times Target Product Titration value (ie Syrup TA = {Ratio +1} * Product Titration). • If the end Product is measured by another means as a percentage, where 100% is the Target for the Product Then enter this value a the blending ratio plus one times Target Product Percentage (ie Syrup Percent = {Ratio +1} * Product Percent). This is the Nominal Finished Syrup Density in units of grams per cubic centimeter. Typical for sugared (sweet) beverages is in the range of 1.12 to 1.3 g/cc. Typical for diet beverages is in the range 1.0 to 1.09 g/cc. This number is used explicitly in for a diet beverage for calculation of the percent syrup by mass for blending. This value determines the low measured density for alarming purposes. If during a production run, the measured Syrup Density is less than this value, an Alarm Fault will occur and blending will be stopped immediately. Typical for sugared (sweet) beverages is 0.02 less than the Nominal Syrup Density. Typical for diet beverages is in the range 0.998 to 1.001 g/cc This is the target value of the Finished Product that is to be produced by the blender. This number, along with the Syrup Brix/TA/Percent Recipe Item value determines the blending ratio for proportioning water and syrup. The value of this Recipe Item depends on how the end Product is measured. • If the end Product is measured in Brix from a Refractometer or a Densitometer, Then specify this value as the Target Product Brix for this flavor. • If the end Product is measured by a titration (which typically determines product acidity), Then specify this •
Syrup Density
Syrup Density Low
Product Brix/TA/Percent
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Recipe Item
Definition value as the measurement of the Titration of sample of the Target Product. • If the end Product is measured by another means as a percentage, where 100% is the Target for the Product Then enter this 100% as the value.
Product Temperature
This is the Target Product Temperature for delivery to the filler,. This number is used as a Setpoint to control the Product Temperature with the Accu-Temp option, otherwise it is used only for reference. This value determines the Product Temperature threshold for alarming, that the Product Temperature is high, which therefore indicates to the operator to review the temperature control hardware for problems. This is the Target Product Flow rate in containers per minute. The blender will proportion product at this rate.
Product Temperature Maximum
Product Flow Rate (cpm) Pungifity Tank Pressure Initial Tank Pressure
Gas Injector Initial Gas Injector
Injector Factor
Saturator Factor
Diet Beverage Refrigeration Required
Nitrogen Required
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This is the target operating pressure for this flavor. This is the intial pressure, when the Product Tank is first being filled with product, during a Product Tank Prime. This value is typically less than the Tank Pressure value in order to minimize any saturated gas pickup while filling the Product Tank for the first time. As product continues entering the Product Tank during a Product Tank Prime the Target Product Tank Pressure Setpoint is ramped from the Initial Tank Pressure value to the Tank Pressure value. Typically the Intial tank Pressure value is 10 to 15 psi less than the Tank Pressure value. This is the Target Gas Volumes for the Gas Injector. This is the Target Gas Volumes for the Gas Injector during a Product Tank Prime. This value is typically less than the Gas Injector value in order to minimize any saturated gas pickup while filling the Product Tank for the first time. This number determines the Gas Injection efficiency for this flavor based on 1.95g/ liter / volume. This number is typically in the range of 1.0 to 1.1 for DIET beverages and 0.85 to 1.0 for Non DIET beverages. This number specifies the efficiency of the Product Tank as a Saturator, and determines the amount of gas volume pickup during normal operating conditions. Typical values for a Satuarator only system is 0.6. Typical values for a Gas Injector only system is 0.03. A value of YES means this beverage is a DIET beverage. A value of NO means this is not a DIET beverage (it is a sweet drink). A value of YES, specifies that refrigeration is required during production of this beverage, and that refrigeration will be requested from the plant’s refrigeration system. A value of NO, specifies that no refrigeration is required, and that refrigeration will not be requested from the plant’s refrigeration system. A value of YES, indicates that a Nitrogen is used as the gas source, for Injection and Pressurizing the Product Tank. In this Cover Page.doc1 Rev. 00/00/01
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Recipe Item
Container
Only Use Syrup Port
Product Brix Offset
Syrup Brix Offset
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Definition specific application, this value is unused, and should be set to NO. This value specifies the Container Type and Size for the production run. This value and the Product Flow Rate value determines the production ate of the blender. This value specifies the Syrup Port that is to be only for this beverage. A value ANY PORT will allow this recipe to use any port to obtain syrup. An assignment of a specific syrup port, will only allow this recipe to obtain syrup from that specific port. A value of not assigned will generate a alarm fault. The Product Brix Offset number is used to offset the entered recipe value of the Product Brix/TA/Percent/Ratio. A positive number will make the blending more rich (more syrup). A negative number will make the blending less rich (less syrup). The Syrup Brix Offset number is used to offset syrup brix as calculated by the system from the syrup density and syrup temperature. The number serves as a correction to the calculated syrup brix, where ingredients in the syrup may scew the result.
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Active and Next Recipes Recipes are developed and modified using the Recipe Manager as described in this manual. Once the recipe is satisfactorily developed, it can be selected for use. The current recipe that the system is using to formulate the beverage is called the Active Recipe. The Active Recipe is essentially a copy of one of the recipes developed by the Recipe Manager. Once a specific recipe has been selected and copied into the Active Recipe, the values of the Recipe Items are used for blending. Like the Active Recipe, the Next Recipe is a copy of one of the recipes developed by the Recipe Manager, but to be used for the next flavor’s production run after a flavor change over. During an automatic flavor change over, the Next Recipe is moved into the Active Recipe, and the Next Recipe then is Empty. This feature allows the operator to pre-select the next flavor to be run, along with syrup port selection, in order that no operator intervention is required during the actual change over.
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Viewing Active and Next Recipes Step 1.
Action To view the Next Recipe follow the links below from the home screen
2.
Home Recipe Next Recipe The Next Recipe Screen will display as shown below:
Press here to edit the Next Recipe Press here to modify the Next Runout Type and Length, or the selected Syrup Line Press here to select the Next Recipe Press here to Edit the Next Recipe
Run Out and Syrup Line Selection
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Recipe Items
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The Next Recipe screen gives access to the next recipe that will be loaded automatically on the next flavor changeover. This screen provides; • • • • •
A means to view the Next Recipe – Recipe Item values An option to Select a new Next Recipe by pressing the Next Recipe Select button An option to modify the Next Runout Type and Length A means to select the Next Syrup Line An option to edit the Next Recipe
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Step 1.
Action To view the Active Recipe follow the links below from the home screen
2.
Home Recipe Active Recipe The Active Recipe Screen will display as shown below, with the associated values. Selected Recipe Location, which Active Recipe came from
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Active Recipe Name
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Next Recipe Selection Step 1.
Action To view the Next Recipe follow the links below from the home screen
2.
Home Recipe Next Recipe Select The Next Recipe Selection Screen will display as shown below: Recipe Selection
Press UpDown Buttons To Move Recipe Selection Cursor Selected Recipe
Press SELECT after moving UP/DOWN arrows to the required recipe.
Recipe Selection Cursor
Press Left Arrow to go back a page.
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Page Selection Indicator
Press right arrow to move forward a page.
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Syrup Port In many situations, syrup used for blending may come from multiple sources. The sources may have automated valving, which controls the delivery of syrup into the blender. In order to minimize the possible error of delivering the wrong syrup, the system provides a level of redundancy to prevent this. There are two variables that determine which syrup port is to be used. One is the Syrup Port selection called “Only Use Syrup Port” in the recipe itself, the other is an operator confirmed selection called Syrup Port made when setting up the Next Recipe. These are pointed out below, and must match. If these two values do not match an alarm fault will occur, and no syrup will be delivered. One exception is, when the “Only Use Syrup Port” value is “Use Any Port”, this allows any syrup port to be selected.
These selections must match, if “Only Use Syrup Port” does not have a value of “Any Port”
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Next Syrup Port Selection Step 1.
Action To select the Next Syrup Port follow the links below from the home screen
2.
Home Recipe Next Recipe The Next Syrup Port Screen will display as shown below:
Next Syrup Port
Use the UP/DOWN arrows to change the Syrup Port Selection During a flavor change over, the Next Recipe is moved into the Active Recipe. The Next Recipe is made “EMPTY” and the Syrup Port is made “NOT ASSIGNED”. This makes it necessary for the operator to Select the Next Syrup Port, or the blender will alarm if the selection is “NOT ASSIGNED”.
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Run Out Type The Run Out type allows the operator to choose how long and how the end of production for the production run will be initiated.
Run Out Type Run Out Length The table below defines the different Run Out Types Run Out Type By Operator By Time By Syrup Volume By Containers
Definition Specifies that the operator pressing the “Start Run Out” button will initiate the end of production Run Out. Specifies that the end of production Run Out will be initiated by the expiration of time, in units of minutes. The Run Out Length sets the expiration time. Specifies that the blender consuming a Syrup Volume will initiate the end of production Run Out. The Run Out Length sets the Syrup Volume threshold, in units of liters. Specifies that the blender producing enough beverage to fill a quantity of containers will initiate the end of production Run Out. The Run Out Length sets the number of containers, in units of containers.
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Next Run Out Type Selection Step 1.
Action To select the Next Syrup Port follow the links below from the home screen
2.
Home Recipe Next Recipe The Next Syrup Run Out Screen will display as shown below:
Next Run Out
Indicates current selection.
Use the UP/DOWN arrows to change the Run Out Type
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Use the UP/DOWN arrows for each digit to change the Run Out Units
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Setting Up a Next Recipe In order to set up a Next Recipe the following steps must be taken. All the individual steps and have been described above. Step 1.
Action Select the Next Syrup Port
2.
Home Recipe Select the Next Recipe
3
Home Recipe Next Recipe Select the Next Run Out Type and Run Length
Home
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Recipe
Next Recipe
Next Recipe
Next Syrup Port
Next Recipe Select
Next Run Out
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Setting Up an Active Recipe Under normal operating circumstances, setting up an Active Recipe is not required, since the Active Recipe is automatically loaded from the Next Recipe during a flavor change. The system does provide the capability for Active Recipe Selection, Active Syrup Port Selection, and Active Run Out Selection. The links to perform these actions are provided for reference below. Step Active Recipe Selection Active Syrup Port Selection Active Run Out Selection
Links
Home
Recipe
Active Recipe
Active Recipe Select
Home
Recipe
Active Recipe
Active Syrup Port
Home
Recipe
Active Recipe
Active Run Out
The procedure for Active Recipe Selection, Active Syrup Port Selection, and Active Run Out Selection are much the same as for the Next Recipe. Refer to the above for details.
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Recipe Manager The Recipe Manager allows the operator to VIEW, EDIT, CHANGE NAME, and DELETE and. A total of 100 Recipes can be developed. The 100 recipes are displayed in 10 pages of 10 recipes each. All the recipe values are stored in the PLC (Programmable Controller), which keeps the recipes safe from hard disk crashes and operating system corruption. This also makes the automatic loading of recipes seamless, because there are not any communication lags like other MMI based recipe systems.
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Recipe Manager Screen Step 1.
Action Access the Recipe Manager Screen by following the links below from the home screen
2.
Home Recipe Recipe Manager The Recipe Manager Screen will display as shown below:
Selected Recipe Location
Selected Recipe Name Available Operations
Press UpDown Buttons To Move Recipe Selection Cursor Selected Recipe
Recipe Selection Cursor
Press Left Arrow to go back a page.
Press right arrow to move forward a page. The pages are navigated by pressing the up and down arrows to move the Page Selection Cursor, to the desired page, and then pressing the enter key to display the selected page. Page Selection Indicator
A recipe can then be selected by moving the Recipe Selection Cursor to the desired recipe location.
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Recipe Viewing Step 1.
Action To use the Recipe Manager Recipe Viewer, choose the page the desired recipe is on by using the page selection buttons illustrated on the left.
2.
Select the desired recipe by using the up-down arrows to move the Recipe Selection Cursor to the desired recipe.
3.
Now press the VIEW RECIPE button to view the selected recipe.
4.
The Recipe Viewer display as shown below:
Viewed Recipe Name
Viewed Recipe Location
Recipe Editing The Recipe Editor is used to modify the contents of the recipe location. Cadence Technologies Inc. 1006 Windward Ridge Pkwy Alpharetta, GA, 30005 USA
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Step 1.
Action To use the Recipe Manager Recipe Editor, choose the page the desired recipe is on by using the page selection buttons illustrated on the left.
2.
Select the desired recipe by using the up-down arrows to move the Recipe Selection Cursor to the desired recipe.
3.
Now press the EDIT RECIPE button to view the selected recipe.
4.
The Recipe Editor display as shown below:
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Recipe Item Selection Cursor
Use keypad to change the value of the Selected Recipe Item.
Press UpDown Buttons to Move Recipe Item Selection Cursor
Press here to go to Page 2 of Recipe Editor
Modifying the Selected Recipe Item Step
Action
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Press here to SAVE modified recipe
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1.
Use the Up-Down Buttons to Move Recipe Item Selection Cursor to the desired recipe Item to be modified.
2.
Use the Digital keypad to enter in a new value for the Selected Recipe Item.
3.
Press ENTER to move the new value into the item’s value. .
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Recipe Editor Page 2 Step 1.
Action In order to access Page 2 of the Recipe Editor, press the Recipe Editor Page 2 button on the bottom the the Recipe Editor Screen.
2.
The Recipe Manager Screen will display as shown below:
Press here to modify the YES or NO status of item.
Use up-down arrows to modify selected Syrup Port.
Use up-down arrows to modify selected Container Size. The value of the Only Use Syrup Port Recipe Item determines what Syrup Port will only be allowed to used for this recipe. A value of ANY will allow any Syrup Port to be used.
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Saving the Recipe Step 1.
Action In order to save the modifications made to by the Recipe Editor, press the SAVE button on the bottom the the Recipe Editor Screen.
2.
The button will flash yellow for 3 seconds and display “SAVING”.
2.
After 3 seconds the button will return to it’s normal state. The Recipe has been saved.
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Copying A Recipe Step 1.
Action In order to obtain a copy of a recipe from another location.Press the GET COPY button on the top of the the Recipe Editor Screen.
2.
The Recipe Get Copy screen will be displayed as shown below:
Step 3.
Action Press the GET ACTIVE or GET NEXT pushbuttons, or enter in the location of the recipe you want to copy into the Recipe Editor.
4.
Press the RETURN button to move back to the Recipe Editor .
Recipe Name Modification Step
Action
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1.
To use the Recipe Manager to change the name of a Recipe Location, choose the page the desired recipe is on by using the page selection buttons illustrated on the left.
2.
Select the desired recipe by using the up-down arrows to move the Recipe Selection Cursor to the desired recipe.
3.
Now press the CHANGE NAME button to view the selected recipe.
4.
The Recipe Name Editor screen will display as shown below:
Step
Action
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5.
Use the displayed keyboard by pressing the appropriate keys to enter in the modified name for the Selected recipe Location.
2.
Complete the modification by pressing the Enter Key on the bottom right hand corner of the keyboard.
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RECIPE RECIPE MANAGER
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Recipe Deleting Deleting a recipe clears the recipe location’s values and renames the recipe to “EMPTY RECIPE”. Step 1.
Action To Delete a Recipe Location, choose the page the desired recipe is on by using the page selection buttons illustrated on the left.
2.
Select the desired recipe by using the up-down arrows to move the Recipe Selection Cursor to the desired recipe.
Selected Recipe Name
Selected Recipe Location
Press DELETE button to Delete Selected Recipe Step 3.
Action Now press the DELETE button to view the selected recipe.
4.
The Recipe Editor display as shown below: This is a confirmation screen, which ask the
Cadence Technologies Inc. 1006 Windward Ridge Pkwy Alpharetta, GA, 30005 USA
Rev. 00/00/01
RECIPE RECIPE MANAGER
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operator to confirm that the selected recipe is to be deleted. If the information is incorrect, then the operator should press NO, and the screen will change back to the RECIPE MANAGER screen. If the information is correct, the operator should press YES.
Selected Recipe Name
Press YES to Delete the Selected Recipe Press NO to Return to the RECIPE MANAGER SCREEN
Cadence Technologies Inc. 1006 Windward Ridge Pkwy Alpharetta, GA, 30005 USA
Rev. 00/00/01
RECIPE RECIPE MANAGER
Step 5.
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Action If the operator presses YES, the YES button will turn yellow and the text will change to DELETING. This indicates that the Recipe Deletion is in progress. The process will take approximately 3 seconds, as illustrated below.
Cadence Technologies Inc. 1006 Windward Ridge Pkwy Alpharetta, GA, 30005 USA
Rev. 00/00/01
RECIPE RECIPE MANAGER
Step 6.
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Action After Deleting the Selected Recipe Location. The screen will automatically change back to the Recipe Manager screen. The Selected Recipe Location will now indicate that the location is an “EMPTY RECIPE”, as illustrated below.
Recipe Location Is Now EMPTY RECIPE
Cadence Technologies Inc. 1006 Windward Ridge Pkwy Alpharetta, GA, 30005 USA
Rev. 00/00/01
OPERATIONS MORNING START UP
Page 136 of 159
Operation Utilities Check On the main control panel are several gauges, which measure the pressure set point for the regulators. Before attempting to initiate any action on the system, each gauge should be checked and compared with the requirements outlined in the table below. Gauge Plant Air Regulator Main Gas Pressure Regulator Product Tank Gas Pressure Regulator Gas Injector Pressure Regulator Control Air Pressure Regulator Blow Gas Pressure Regulator
Requirement 90 to 110 psi Gas Injection Capable - 220 psi to 300 psi No Gas Injection – 120 psi minimum 180 psi 100 psi 25 psi 40 psi
E-Stop Check Below the touch screen on the main control panel is an E-Stop pushbutton and a green Reset pushbutton. In emergency situations the E-Stop pushbutton can be pressed by the operator in order to stop all machine functions. The green Reset pushbutton will be illuminated if the system is not in an E-Stop condition. Before initiating any action on the system, the E-Stop circuit will need to be checked by confirming that the green Reset button is illuminated. If the green Reset pushbutton is not illuminated, the operator can reset the EStop condition by pressing the Reset pushbutton.
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
Cover Page.doc1 Rev. 00/00/01
OPERATIONS MORNING START UP
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Morning Start Up After extended down time or CIP, the system will require the operator to initiate a Start Up procedure. The table below lists the Start Up procedure. While a Filler Cold Rinse is running the operator can set up the Next Recipe and Syrup Ports. When the Filler Cold Rinse is complete. The operator must confirm the Syrup Reservoir and the Product Tank are empty, and drain if required. Once the tanks are empty the operator can initiate an automated start up, by pressing the Start Up Machine Command button. The table below outlines the steps and screen links to follow to perform a Morning Start Up. Step 1.
Action Perform a Filler Cold Rinse
2.
Home Recipe Select Next Syrup Port
Home Recipe Next Recipe Select the Next Run Out Type and Run Length
Next Syrup Port
3.
Home Recipe Select the Next Recipe
Next Recipe
Next Run Out
4.
Home Recipe Connect Syrup Port
Next Recipe
Next Recipe Select
5.
Home Confirm Syrup Line is Ready
6.
Home
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
Next Recipe
Active Recipe Select
Syrup Port Ready
Cover Page.doc1 Rev. 00/00/01
OPERATIONS MORNING START UP
Step 7.
Action Check Syrup Reservoir Level
8.
Home Check Product Tank Level
9.
Home Place the system in Auto, so the system sequences automatically.
Home Initiate Start Up
10.
Home
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
Page 138 of 159
Cover Page.doc1 Rev. 00/00/01
OPERATIONS MORNING START UP
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Flavor Change Preparation Before initiating a Flavor Change Over (Initiating a Run Out), the Next Recipe and Syrup Port will need to be set up. The operator may set up the Next Flavor, anytime after the current flavor (Active Recipe) has started production (ie. at the end of Filler Prime). The table below outlines the steps required to prepare for a Flavor Change. Step 1.
Action Select Next Syrup Port
Home Recipe Next Recipe Select the Next Run Out Type and Run Length
Next Syrup Port
2.
Home Recipe Select the Next Recipe
Next Recipe
Next Run Out
3.
Home Recipe Connect Syrup Port
Next Recipe
Next Recipe Select
4.
Home Confirm Syrup Line is Ready
5.
Home
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
Syrup Port Ready
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OPERATIONS MORNING START UP
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Flavor Change With the Accu-Change system, flavor changes are very simple. Flavor changes are initiated by a single machine command called Run Out Start.
Step 1.
Action Initiate Start Up
Home
Filler Run Out Completion At the end of a flavor change, when the Filler Run Out has finished filling all the containers, the operator must acknowledge that the containers have all been filled, by pressing the Filler Run Out Done pushbutton. Step 1.
Action Initiate Start Up
Home
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
Cover Page.doc1 Rev. 00/00/01
OPERATIONS MORNING START UP
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End of Day Shutdown With the Accu-Change system, flavor changes are very simple. Flavor changes are initiated by a single machine command called Run Out Start.
Step 1.
Action Initiate Start Up
2.
Home After the Filler Run Out has completed press the End of Day Machine Command
Home
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
Cover Page.doc1 Rev. 00/00/01
OPERATIONS MORNING START UP
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Packaging Change When changing the package, it becomes necessary to provide carbonated water to the filler. The table below outlines the steps and screen links required to provide carbonated water to the filler. First a Filler Cold Rinse is initiated to produce carbonated water in the to the filler. Once the Product Tank has adequate level of water, the Filler Cold Rinse can be terminated, and a Product Tank Run Out can be initiated to maintain Product Tank Pressure to push the carbonated water to the Filler. A Beverage Request must come from the Filler in order for the Product Tank Run Out to open the Product Outlet Valve.
Step 1.
Action Take the system out of Auto.
1.
Home Initiate a Filler Cold Rinse
2.
Home Rinse and Drains When the Product Tank has adequate level for the test, terminate the Filler Cold Rinse
2.
Home Rinse and Drains Initiate a Product Tank Run Out
2.
Home Run Outs Initiate a Beverage Request from the Filler, by pressing the Filler Product Request Machine Command.
Home
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
Cover Page.doc1 Rev. 00/00/01
OPERATIONS MORNING START UP
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Product Proportioning Adjustment The set point for the Product Proportioning is in units of Brix for sweet (Non-diet) drinks and in TA or Percent for diet drinks. The set point for the Product Proportioning is determined by adding the Operator Adjust to the Recipe Set Point. Where small adjustments are required the operator should modify the Operator Adjust set point. There are two locations that the Operator Adjust set point for Product Proportioning. These two methods are outlined in the steps below. Method 1: Step Action 1. Go to the Blender Command Screen by following the links below from the home screen
2.
Home Use the Up/Down arrows connected to the Operator Adjust, shown below.
Method 2: Step Action 1. Go to the Blending Operation Command Screen by following the links below from the home screen
2.
Home Use the Up/Down arrows connected to the Operator Adjust, shown below.
Note that “Brix” is displayed when non-diet (sweetdrink) recipe is active, and TA/% is displayed when diet recipe is active.
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
Cover Page.doc1 Rev. 00/00/01
OPERATIONS MORNING START UP
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Product Tank Pressure Adjustment The Target set point for the Product Tank Pressure is determined by adding the Operator Adjustment, and the Accu-SAT adjustment to the Recipe Setpoint. Where small adjustments are required the operator should modify the Operator Adjust set point. Follow the steps below to modify the Operator Adjust for the Product Tank Pressure Step 1.
Action Go to the Product Tank Command Screen, follow the links below from the home screen
2.
Home Use the Up/Down arrows connected to the Operator Adjust, shown below
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
Cover Page.doc1 Rev. 00/00/01
OPERATIONS MORNING START UP
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Gas Injector Set Point Adjustment The set point for the Gas Injector is in units of Volumes. The target set point for the Gas Injector is determined by adding the Operator Adjust to the Recipe Gas Inj. Vol. Where small adjustments are required the operator should modify the Operator Adjust set point. There are two locations that the Operator Adjust set point for Gas Injector. These two methods are outlined in the steps below. Method 1: Step Action 1. Go To the Gas Injector Command Screen follow the links below from the home screen
2.
Home Use the Up/Down arrows connected to the Operator Adjust, shown below.
Method 2: Step Action 1. Go to the Blending Operation Command Screen by following the links below from the home screen
2.
Home Use the Up/Down arrows connected to the Operator Adjust, shown below.
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
Cover Page.doc1 Rev. 00/00/01
OPERATIONS MORNING START UP
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CIP Follow the steps outlined in the table below in order to perform a CIP of the system. Step 1.
Action Confirm air supply connection to Product Tank.
2.
Behind the filler there are two valves. The CIP Return valve to the Deox / Product Tank skid must be open. The Filler Vent Valve must be closed.
3.
Confirm CIP CAM is moved into place.
4.
All CIP Channel Drain Valves must be closed on the bottom of the Filler Bowl.
5.
All CIP Return Valves on top of the Filler Bowl must be opened.
6.
CIP Cups on filler must be installed.
7.
Go To the CIP Program Screen by following the links below from the home screen
8.
Home CIP Program Use the Up/Down to select one of five different CIP programs.
9.
Go To the CIP Screen by following the links below from the home screen
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
Cover Page.doc1 Rev. 00/00/01
OPERATIONS MORNING START UP
Step
Action
10.
Home Press the ENABLE button to initiate the CIP Process.
Page 147 of 159
The button will turn green when the CIP is in progress.
11.
Based on the program selected the system will step through the program. Observe the indicators shown below to observe what type of step the system is executing.
12.
When the CONNECTED button begins to blink, Chemicals are required to be connected to the system..
13.
Connect the chemicals and press the button to confirm. Press the NEXT button in order to skip to the next Step.
Or Press the HOLD button to hold the system in its current Step.
14.
When the CIP has completed all the programmed steps ENABLE button will turn RED, Indicating that the CIP has stopped.
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
Cover Page.doc1 Rev. 00/00/01
OPERATIONS MORNING START UP
Step
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Action
Frequently Asked Questions
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
Cover Page.doc1 Rev. 00/00/01
SCREENS ALARM
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The following are frequently asked questions and our response. Question - Low Syrup Density Alarm Fault on startup During a startup on a Sweet product the density of the syrup was so low that the blender gave me a “Low Syrup Density Alarm Fault”. I keep on resetting the alarm, but the alarm keeps on coming back up.
Response When too much water is present in the syrup, the density drops below the value of Syrup Density Low parameter in the Recipe, and the “Low Syrup Density Alarm Fault” occurs. 1) The first decision that needs to be made is whether the syrup is good enough to blend, and that it is not tainted in any way. A Qualified Operator should take a Syrup Brix measurement of the current syrup in the Syrup Reservoir. 2) If the Syrup is OK to blend, then a Qualified Operator must edit the Syrup Density Low parameter in the Active Recipe. The value should be changed to less than the currently displayed Syrup Density on the Blender Graphic Screen. 3) Also, adjust the Syrup Brix parameter in the Active Recipe to match the value of the Syrup Brix measurement taken in step 1. 4) Reset the alarm, and monitor the blending operation.
Question - foam in my Syrup Reservoir during a Syrup Reservoir Runout I have foam in my Syrup Reservoir during a Syrup Reservoir Runout and one of the following alarms keep me from blending Low Syrup Density Alarm, Syrup Flow Transmitter Failure, or Syrup Density Transmitter Failure.
Response You cannot blend foam. The meters will not measure it properly 1) Determine if your Syrup Reservoir indeed is full of foam. 2) If it is full of foam. You can terminate the Syrup Reservoir Runout and continue to the next change over step, by going to the Runout Command Screen and press Syrup Reseroir Runout Kill. 3) This will step the system to the next steps (Syrup Reservoir Rinse and Mix Line Runout)
Question – My Syrup Reservoir is High and I can blend no more My Syrup Reservoir level became too high and the Blender Pauses on High Syrup Reservoir Level, and keeps on pausing when ever I reset the alarm to re-initiate blending.
Response
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
Cover Page.doc1 Rev. 00/00/01
SCREENS ALARM
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The Syrup Reservoir generates a High Syrup Reservoir Level Alarm Fault, when the High Point probe on the Syrup Reservoir detects a liquid. 1) Before resetting the alarm, inquire why the alarm was generated and repair. 2) Reasons for failure a. During a Syrup Line Runout someone did not disconnect the syrup source. b. The High Point Probe was splashed with syrup during a blow from the syrup room c. The Syrup Reservoir Level Capacitance probe failed. 3) You can resume blending by resetting the alarm fault and pressing the BLEND PAUSE button on the Blender Graphic Screen to un-pause the blender. 4) If for some reason the level is too high, and you want the blender to run continuously without it faulting, you can press and hold either the BLEND or BLEND PAUSE buttons on the Blender Graphic Screen.
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
Cover Page.doc1 Rev. 00/00/01
CHEAT SHEET Page 151 of 159
Cheat Sheet
Accurate Metering Systems, LLC. 1651 Wilkening Road Schaumburg, IL 60173 USA
Cover Page.doc1 Rev. 00/00/01
CHEAT SHEET Page 152 of 159
Blender Cheat Sheet
bturig 5/14/2003
Note: Think twice, press once START UP Syrup Preparation 1) Bring good syrup all the way to divert panel in syrup room •
2) Wait for "Prime Waiting" indicator on Syrup Room Display
3) Open valves from Syrup Tank supply line to blender syrup line, with Syrup Tank Pump on. 4) Press "Port A Connected" on Syrup Room Display, to indicate to blender that syrup is connected Blender Preparation 1) Vacuum Deaeration Unit must be running (15 minute warm up) 2) Filler • must be rotating • filling valves must be in automatic • speed control must be in automatic 3) Turn on Refrigeration Chiller from control panel on Chiller. 4) If need to do a Cool Down. Turn Auto Off, and manually perform a “Filler Cold Rinse”. 5) Blender • Syrup Reservoir must be empty, drain if necessary. 6) Syrup Room (Syrup Prep) • Syrup Port Connected indication on Syrup Room Display must be off (Not Connected) 7) Select Next Recipe 8) Place blender in Auto 9) Upper Bar on "Start Up" button will be illuminated. If not review Steps 2 through 4. 10) Press "Start Up"
Accurate Metering Systems, LLC. 1651 Wilkening Road Schaumburg, IL 60173 USA
Cover Page.doc1 Rev. 00/00/01
CHEAT SHEET Page 153 of 159
FLAVOR CHANGE Syrup Preparation 1) Enable a Syrup Line Purge from Syrup Room Display 2) Purge from Syrup Tank and/or from Divert Panel 3) Close Divert Panel hand valves 4) Press RunOut Start from Syrup Room Display 5) Bring in good NEXT syrup all the way to divert panel in syrup room 6) Wait for "Prime Waiting" indicator on Syrup Room Display 7) Open valves from Syrup Tank supply line to blender syrup line, with Syrup Tank Pump on. 8) Press "Port A Connected" on Syrup Room Display, to indicate to blender that syrup is connected Blender Preparation 1) Filler container stop must be in automatic 2) Blender must be in Auto 3) Select Next Recipe Filler Preparation 1) Filler Container Stop must be in automatic 2) When Syrup Reservoir reaches Back Up Level, container stop will pull in for Empty Side Backup 3) Confirm containers are backed through conveyor and rinser. 4) Wait for Depal Operator to release Container Stop by pressing Container Stop Release 5) Run Out Product in System 7) When finished running out remaining product in system, make sure filler is rotating, with filling valves and speed in automatic and then Press Filler RunOut Done on blender operator interface. Filler will dump remaining contents in Filler and Product Tank if not empty. 8) Filler will automatically rinse, drain and bring in Next product when available from system.
Accurate Metering Systems, LLC. 1651 Wilkening Road Schaumburg, IL 60173 USA
Cover Page.doc1 Rev. 00/00/01
CHEAT SHEET Page 154 of 159
Depal Display Login 1) Press LOGIN 2) Enter 3333 3) Press Depal Depal Operation 1) Change Over Indicator indicates when Change Over has started. (Do not cut bottles yet) 2) Back Up Indicator will illuminate when Syrup Reservoir on Blender drops down to the Back Up Level (30%). The Filler Container Stop is automatically pulled in by the blender. 3) Depal operator must verify that the empty side completely filled to the depal. 4) Note number of Sweeps to add from Depal Display. 5) Press “Container Stop Release” on Depal Display to open the Container Stop at filler and continue running out the line. 6) Add sweeps as noted in Step 4, when line was backed up. Note: VALUE OF SWEEPS INDICATED “CHANGE OVER SWEEPS CALLED FOR” DOES NOT COUNT DEPAL SWEEPS AUTOMATICALLY, DEPAL OPERATOR MUST COUNT ON OWN. END OF PRODUCTION Blender Preparation 1) Do not enter a Next Recipe 2) After Filler RunOut is Done, Press End OF Day.
Appendix Accurate Metering Systems, LLC. 1651 Wilkening Road Schaumburg, IL 60173 USA
Cover Page.doc1 Rev. 00/00/01
APPENDIX E01.01 Calibration of the FEC 12 Electronic Transmitter
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Capacitance Probe Calibration INTRODUCTION The FEC 12 electronic insert is a transmitter for capacitive level measurement. It converts changes in capacitance resulting from changes in level into a capacitance-proportional impressed current. In vessels with a uniform cross section, the level or quantity (volume) can be thus displayed as a percentage of full level. OPERATING ELEMENTS A cover protects the operating elements of the FEC 12. Inserting a small screwdriver into a slit at the edge can raise this. The inside of the cover has symbols printed on it that serves as a quick operating manual. SWITCHES The left hand switch selects whether the linearization is to be carried out remotely with the hand held terminal or locally with the FEC 12 operating elements. If linearization at the FEC 12 is required, then one of two linearization modes in the electronic insert is activated (vertical vessel with linear characteristics) at the right hand switch. PUSHBUTTONS Calibration, locking and reset to factory-set values are carried out at the FEC 12 by using the four pushbuttons. BASIC OPERATION: The pushbuttons marked with plus (+) increase current and those marked minus (-) decrease current. Punching the pushbuttons produces a step-wise change. The smallest resolution possible is 0.014mA. If the pushbutton is depressed continuously, then the current also changes continuously until the pushbutton is released. The change begins slowly and gradually increases in speed and so quickly passes through a wide range. Just before reaching the value required, the pushbutton should be released and the procedure completed by punching the pushbutton for fine resolution. If the value desired is overrun then correct for it by punching the pushbutton for the other direction.
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
Cover Page.doc Rev. 00/00/01
APPENDIX E01.01 Calibration of the FEC 12 Electronic Transmitter
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CALIBRATION Two types of linearization can be selected: • Vessel characteristics as linear. • Vessel characteristics as horizontal cylinder. Use the left hand switch to select whether linearization is to be carried out at the electronic insert or by the handheld terminal. If the left hand switch is moved to the right, then linearization is carried out at the electronic insert. If the left hand switch is moved to the left, then linearization must be carried out with the hand held terminal and the switch on the right remains inactive. • Move the left hand switch to the right. Select the type of linearization for local calibration using the right hand switch. When it is moved to the left, then the level (output current) is proportional to volume, i.e., the cross-section of the vessel should be constant over its entire length. When it is moved to the right, then linearization is set for a horizontal cylinder, and the measured value supplied corresponds directly to a percent of full volume. • Move the right hand switch to the left. With the vessel completely empty (0%), both pushbuttons on the left minus (-) and plus (+) are depressed simultaneously in order to set the signal current to the 4mA lower value. The green LED lights up to acknowledge that the setting has been accepted. Only when the green LED goes out is the correct value of 4mA shown on the ammeter. With the vessel full (just touching the high level probe), both pushbuttons on the right minus (-) and plus (+) are depressed simultaneously in order to set the signal current to the 20mA higher value. The green LED lights up to acknowledge that the setting has been accepted. Only when the green LED goes out is the correct value of 20mA shown on the ammeter. STEP by STEP 1. Move the left hand switch to the right. 2. Move the right hand switch to the left. 3. With the vessel completely empty push both left (+) and (-) pushbuttons. The green LED lights up to acknowledge that the setting has been accepted. 4. With the vessel completely full push both right (+) and (-) pushbuttons. The green LED lights up to acknowledge that the setting has been accepted. The Vessel / Capacitive probe is now calibrated. RTD Calibration The RTD should be checked quarterly to maintain accuracy, using the verification procedure below:
The following tools will be required to perform this procedure: • a small flat head screwdriver. • an ammeter. Step
Action
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
Cover Page.doc Rev. 00/00/01
APPENDIX E02.01 RTD Calibration
1. 2. 3. 4.
5. 6. 7. 8. 9.
10.
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Locate the RTD. Remove the cover on the RTD and check for the red led operation. If the red led is not on, replace the RTD and continue this procedure Remove the black wire from the terminal on the RTD. Using the ammeter, apply the probes to the terminal and the wire that was removed from the terminal. Record the reading from the ammeter Using a thermometer from the QC lab, measure the product temperature in degrees F. Using a thermometer from the QC lab, measure the product temperature in degrees F. Insert the temperature into the following equation to calculate the mA signal (mA = (16 * deg.F / 250) + 4). If the value calculated and the reading recorded from the ammeter are within +/- 0.128 mA, then the RTD is good. If it is not within +/0.128 mA, replace the RTD.
RTD Calibration
RTD’s work on the principle that there is a positive correlation between the electrical resistance of a metal conductor and changes in temperature.
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
Cover Page.doc Rev. 00/00/01
APPENDIX E05.01 MODEM SET-UP
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Modem Set Up 1. Using the serial port on a computer, establish a connection with the modem. 2. Set the dip switches on the back of the modem as follows: Switch 1 - down - DTR override Switch 2 - up - verbal result codes Switch 3 - down - display result codes Switch 4 - up - echo offline commands Switch 5 - up - auto answer on first ring Switch 6 - up - carrier detect normal Switch 7 - up - load NVRAM defaults Switch 8 - down - smart mode 3. Issue the following commands to the modem: “AT &R1” - sets modem to ignore RTS “AT &N10” - sets modem to negotiate baud rate at 19200 bps only Note: (AT &N6 9600 baud at &N3 2400 baud) “AT &WO” - writes current configuration to NVRAM 0 “AT &W1” - writes current configuration to NVRAM 1 4. Issue the following command to the modem: “AT I4”. 5. The following table of information is displayed on the computer for verification: BO E1 F1 M1 Q0 V1 X4 YO BAUD=19200 PARITY=N WORDLEN=8 DIAL=HUNT ON HOOK &A3 &B1 &C1 &D0 &G0 &H1 &I0 &K1 &M4 &N10 &P0 &R1 &S0 &T5 &U0 &Y1 S00=001 S01=000 S02=043 S03=013 S04=010 S05=008 S06=002 S07=060 S08=002 S09=006 S10=014 S11=070 S12=050 S13=000 S15=000 S16=000 S18=000 S19=000 S21=010 S22=017 S23=019 S25=005 S27=000 S28=008 S29=020 S30=000 S31=128 S32=002 S33=000 S34=000 S36=014 S38=000 Please Note: The registers displayed above must match exactly with the registers as displayed once configuration is completed. Should they not, please correct using AT commands. When complete, perform Step #3 once more and then verify.
Accurate Metering Systems, Inc. 1651 Wilkening Road Schaumburg, IL 60173 USA
Cover Page.doc Rev. 00/00/01
Cadence Technologies Inc. 1006 Windward Ridge Pkwy Alpharetta, GA, 30005 USA
Rev. 00/00/01
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