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WCZY96/84/14Y

Content
chapter 1 general description .....................................................................................6
general safety reference............................................................................6
brief description......................................................................................................12
1 composition of facility ................................................................................12
2 structure feature ........................................................................................13
3 facility operating process .....................................................................14
4 safety device ...............................................................................................18
5 technical paramerer ....................................................................................19
chapter 2 Rinser, Filler & Crowner.....................................................21
overall description..........................................................................................................21
main feature of filler crowner ....................................21
1 Rinser......................................................................................................................22
main feature of rinser.......................................................22
. gripper ..........................................................................................................23
rotary disc....................................................................................................27
distributor and valve on-off device.....................................28
guide rail and protection cover.............................................................33
machine frame and height adjustment device .............................34
water lubrication ........................................................................................36
installation and adjustment ................................................................37
1

Due to the
heavy weight of the machine, therere no spindle feet for fixing on the ground. When installed,
just connect the connecting arm with the base plate of the working table. (The rinser is
adjusted before delivery, so installation on site can be just based on the original positon)..37
. commissioning .............................................................................................37

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. cleaning..........................................................................................................38
. trouble shooting...............................................................................40
. maintenance...............................................................................................41
2 filler.........................................................................................................................44
2.1 structure.........................................................................................................44
22 machine frame ..............................................................................................45
23 revolving machine table.........................................................................46
24 beer inlet device......................................................................47
25 air distributor ......................................................................................53
26 ring bowl and height adjustment device..........................54
All the above piping connect to the
filler via beer inlet pipe..............................................................................................................56
27 lifting cylinder.........................................................................................58

5Lifting cylinder external lubrication: Water


sprayed on the external of the cylinder to lower the temperature due to friction and take
away busting bottle cullets on the shaft (5).....................................................................60
lifting cylinder ...........................................................................................60
28 filling valve.................................................................................................61
When setting time out, vacuum valves
tube close, and the first vacuumization ends. ........................................................................67
CO2 When setting time out, filling valves close, and
CO2 filling ends..............................................................................................................................67
When setting time out, vacuum valves
tube close, and the second vacuumization ends...........................................................................68
2.9 filling valve butterfly............................................................70
2.10 bursting bottle rinsing.............................................................................71
3 Crowner composition...............................................................................74
3.1 running.............................................................................................................75
3.2 height adjustment.....................................................................................78
3.3 crowner head ...............................................................................................79

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3.4 hopper and stirrer of the crowner.......................................81


3.5 cap-stopper..................................................................................................84
3.6 cap turner.....................................................................................................85
4 working table and its transmission..............................................................87
4.1 bottle conveying parts ..............................................................................89
4.2 installation and adjustment of infeed spindle and star
wheel ...............................................................................................................................90
4.3 working table and crowner transmission ...............................95
4.4 working table................................................................................................96
5 piping system .....................................................................................................98
5.1 PID piping system PID drawing...........................................................98
elements that influence the vacuum pump ....................................101
a influence of the work liquid temperature on the pump
capacity .........................................................................................................................101
b influence of the entrance gas humidity on the pump
capacity .........................................................................................................................102
chapter 3 changeover ..........................................................................................104
3.1 safety ....................................................................................................................104
3.2 change format parts....................................................................................105
2.1 change infeed table support........................................................106
2.2 change block starwheel ..............................................................108
2.3 change of star wheel and bottle guiding parts ...................109
2.4 change infeed spindle ................................................................. 110
2.5 change crowning star wheel ....................................................... 111
3.3 height adjustment .......................................................................................... 112
height adjustment steps .......................................................... 112
3.1 steps of height adjustment............................................................ 112
3.2 adjustment of crowner .................................................................. 113
chapter 4 operating instruction ....................................................................... 114
preparation for operation.................................................................... 114
everyday startup................................................................................................... 116

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situation ................................................................................................................ 116


manufacturing monitor .................................................................................. 117
start up.................................................................................................................. 118
chapter5 electrical control ...............................................................................120
51 brief description..................................................................................................120
5.1 facilities display .............................................................................................126
chapter6 cleaning...................................................................................................131
6.1 cleaning foundation and its purpose...............................................131
6.2 limit value of cleaning agent........................................................132
6.3 outer surface of cleaning machine .....................................................134
6.4 usage of high pressure cleaning tool..........................................135
6.5 cleaning of detergent residue.............................................................136
6.6 cleaning plastic monitor on the machine panel ...................136
6.7 compatibility of the material ...................................................................137
6.8 character of sealing material ..............................................................139
chapter7 maintenance ...........................................................................................142
7.1 attention.........................................................................................................142
7.2 rules ......................................................................................................................143
waste disposal.............................................................................................144
treatment of following substances is important
.......................................................................................................................................144
7.3 maintenance table of filler...............................................................145
8 every day or every 8 working hours .......................................145
170 every month or every 170 hours.........................................146
6 1000 every 6 months or every 1000 work hours................147
2000 every year or every 2000 work hours ...............................148
7.4 maintenance of bottle centering ring and bottle sealing
pad ........................................................................................................................................149
7.5 maintenance plan table of crowner ................................................150
8 every day or every 8 working hours .......................................151
40 every week or every 40 working hours.................................151

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170 every month or every 170 working hours ...........................151


1000 twice a year or after every 1000 working hours.....152
2000 every year or every 2000 working hours ......................152
7.6 electrical maintenance ..................................................................................152
switch device.................................................................................................153
motor ....................................................................................................................153
proximity switch and photo cell...................................................153
7.7 pneumatic device maintenance .............................................................154
8 every day or every 8 working hours....................................154
40 every week or every 40 working hours .............................154
chapter 8 lubrication...............................................................................................155
8.1 general description ...............................................................................................155
8.2 star wheel lubrication.....................................................................................159
8.3 crowner lubrication point ......................................................................160
8.4 filler lubrication...........................................................................................161
8.5 manual lubrication..................................................................................162
chapter 9 malfunction analysis and elimination...................................166
9.1 possible..................................................................................166
9.2 meaning of symbols for malfunction elimination.......................168
9.3 cause and elimination of malfunction ....................................168

WCZY96/84/14Y


Chapter 1 brief description
general safety reference

Operating personnel should be aware of


all safety devices and their use method to avoid personal injury and
machine damage.

Safety facilities of machines from GLM2 conform to


regulation of profession association and relevant safety regulation. Only
with proper operation within permitted range will limit danger to the operator
and damage to the machine to the lowest point.


fixed protection cover

Installed in
dangerous place, which dont need contact during daily operation. They are
connected to the machine and are indispensable during the operation of the
machine.

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There

is one or multiple emergency-off switches near the


machine for turning it off.

!
only
use emergency-off in
emergency.

pay
attention to
usage of
emergency
stop.

Emergency-off

switch on the operating table and machine is


used only when operator or machine is in danger.
Generally, dont use it to turn off the machine.

 Dont use
emergency-off for normal turning off.
Emergency-off
switch is automatically locked once started.


Only after elimination of safety


threat to the operator and machine can the
machine be started again.

 storage in midway

If midway storage is
necessary, storage place should meet following needs to prevent any
damage or corrosion of parts sensitive to temperature and humidity.

WCZY96/84/14Y

Keep the machine from dirt, dust or painting molecule. Cover the
machine with plastic film.

10 50 Environment temperature
should be -10to 50.

Good
ventilation is necessary to prevent dew inside and outside the
machine.

There should be
no vapor of solvent, acid fluid and caustic around the machine.

Machine storage place should be horizontal and the weight of the


machine is distributed evenly on each spindle foot.

4-5
PLC

After long time storage (usually 4-5 months), check battery in the
PLC is intact and if all program units still exist. If there is any
question, please consult personnel from GLM2 or personnel
authorized by GLM2.

When following situation


happens, above method is also applicable: program unit partly lose or
completely lose due to long time storage or not enough buffer battery
content.

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during operation, attention should be


paid to:
1.
Dont put bottles, cans, crates, pallets on the
conveyor since there are multiple dangers during operation and stopping.

2.
Dont ever dismantle or move protection device such as
protection cover, baffle and machine case and dont touch any revolving
parts.

3.
Dont open, adjust or turn switch, button, switch, valve,
photocell or other switches and control meter.

4.
Follow safety instruction all the time when working
around dangerous areas. Wear safety helmet, goggles, safety shoes and
protection gloves.

5.Protect operator
from dangerous area with safety device.

6.
Dont operate the
machine when safety device hasnt returned to original place. Only when
changing or repairing in accordance to safety regulation can we open or
remove the safety device.

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7.Dont stay inside the


closed safety bar during operation.
8.One
other person is required for safety protection when some one is working
inside the machine or walking on the machine.


protection measure
aDont dismantle safety device
during the operation of the machine.
bTurn off driving device
during maintenance and repair.
cTurn off
lockable switch on the control box. Dont turn on the switch without
permission.

following information
and warning sign are marked in some area of the machine

danger zone

danger for high voltage

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hot surface

no fire, ignition and


smoke

Dont open it during operation

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General Description
1
Equipment Composition:
Product Model No. WCZY96/84/14

Product Name: Filler and Crowner

Five Main Parts:


 Rinser
 Filler
 Crowner
 Working Table and Drive
 Other
Accessories (including piping system, vacuum system and hot
water system for rinsing etc.)

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2 3 4

13

1 Rinser 2 Filler 3 Crowner 4 Working Table and Drive 5 Other


Accessories

2 structure feature

Main transmission uses system which combines


frequency conversion and speed regulation synchronously.
Transmitting system is an open gear transmission and filling valve is a
built-in mechanical valve. This machine has a double guiding shaft
centering structure with pre-covering function, twice vacuumizing and

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the ability to fill when there are bottles and not to fill when there is no
bottle. It also has the function to rinse broken bottles automatically.
Filler and crowner can adjust their heights automatically and ar easy to
clean due to its reclining hygienic platform. The machines are equipped
with hot water spraying and cleaning system and use fast changing
device for format parts.

3 Equipment Operation Program


CO2
Before operation, ensure
that filling product, cleaning agent, compressed air and CO2 are
delivered to filling equipment through respective feeding pipe and
distributing inlet.

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a) draft beer running process

(1)
(2)(2)(3)

90
90
(5)
(6)(7)

Bottles delivered by infeed conveyor are lined


up into single bottle lane with fix gap by bottle infeed worm (1), then
deliver to infeed star wheel (2). The infeed star wheel (2) convey the
bottles to the rinser (3), of which the gripper heads grip the bottles and
turn them for 90 with the turning cam. The cleaning valves open for
bottle rinsing, then the bottles are sent to the infeed star wheel (7) by the

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discharge star wheel (5) via transit star wheel (6).There bottles are
delivered to lifting cylinders by turning parts. By the lifting motion of
cylinder and centering of centering ring, bottle will be right under filling
parts (filling valves).

During lifting, machine


automatically checks if there is bottle on the bottle lifting device. If there is,
then filling start; If not, then corresponding valves will be close.

CO2

CO2

CO2

910
11

Bottle neck follows the material


distributing exit of the guiding pressed filling valve of the centering device
and under the function of vacuum guiding rail, bottles are vacuumized.
After this vacuumization, open the filling valve and fill in CO2 (short time
so there is no isobaric pressure), then close the filling valve and
vacuumize the second time, in which case very little oxygen is added.
After second vacuumization, open the filling valve, pressurized gas inside
the ring bowl (CO2 gas) can be filled into the bottle until it reaches the
pressure of the ring bowl. Under the influence of spring, filling valve is
open completely and at this time, beer or beverage will flow into the
bottles automatically along with bottle wall. Then gas inside the bottles,
mainly CO2, goes back to the ring bowl. When liquid inside the bottles
reaches certain height (namely, required filling liquid height), liquid will
close gas-returning pipe and then the filling valve will stop filling in beer

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or beverage. Close the filling valve and put it still for some time to release
the pressure inside the bottles and this is the end of filling process. Then
the bottle carrier cylinder lowers and it will be sent via mid star wheel (9)
into the crowner (10) to be capped. After crowning, the bottles are sent
into the discharge star wheel (11) and it will enter discharge conveyor via
discharge star wheel. During this process, use high pressure injection
device depending on the filling situation and to eliminate air in the bottle
neck.

b)
pasteurized beer running process

(1)
(2)(4)
(5)
(6)(7)

Bottles delivered by infeed conveyor are lined


up into single bottle lane with fix gap by bottle infeed worm (1), then
deliver to infeed star wheel (2). With the star wheel (4) guiding parts, the
bottles are sent to the infeed star wheel (7) by the discharge star wheel
(5) via transit star wheel (6).There bottles are delivered to lifting cylinders
by turning parts. By the lifting motion of cylinder and centering of
centering ring, bottle will be right under filling parts (filling valves).

During lifting, machine


automatically checks if there is bottle on the bottle lifting device. If there is,
then filling start; If not, then corresponding valves will be close.

CO2

CO2

CO2

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910
11

Bottle neck follows the material


distributing exit of the guiding pressed filling valve of the centering device
and under the function of vacuum guiding rail, bottles are vacuumized.
After this vacuumization, open the filling valve and fill in CO2 (short time
so there is no isobaric pressure), then close the filling valve and
vacuumize the second time, in which case very little oxygen is added.
After second vacuumization, open the filling valve, pressurized gas inside
the ring bowl (CO2 gas) can be filled into the bottle until it reaches the
pressure of the ring bowl. Under the influence of spring, filling valve is
open completely and at this time, beer or beverage will flow into the
bottles automatically along with bottle wall. Then gas inside the bottles,
mainly CO2, goes back to the ring bowl. When liquid inside the bottles
reaches certain height (namely, required filling liquid height), liquid will
close gas-returning pipe and then the filling valve will stop filling in beer
or beverage. Close the filling valve and put it still for some time to release
the pressure inside the bottles and this is the end of filling process. Then
the bottle carrier cylinder lowers and it will be sent via mid star wheel (9)
into the crowner (10) to be capped. After crowning, the bottles are sent
into the discharge star wheel (11) and it will enter discharge conveyor via
discharge star wheel. During this process, use high pressure injection
device depending on the filling situation and to eliminate air in the bottle
neck.

4 safety device

Operation personnel should be aware of all safety devices and


their usage to avoid personal injury and damage of the machine.

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There is an emergency stop on


the machine operating table.
5 technical parameter
number of rinsing valve96
number of filling valve84
number of crowner14
640ml nominal capacity24000BPH
suitable bottle type height 200350mm
diameter 5282mm
CO2 CO2 consumption 150g/hl(vacuum once)
250g/hl(vacuum twice)
water consumption vacuum pump 1.5m3/h
sweeping

0.5m3/h

AC work voltage
DC control voltage

380V
24V

installed power

30.22kW

1. main motor for filling

5.5kW

2. motor for lifting cylinder

0.75kW

3. main motor for crowner

4.0kW

4. crowner lifting and motor


5. hopper motor

0.55kW

0.37kW

6. vacuum pump motor

15Kw

7. foam injection pump

0.55kW

8. foam injection heater 3.5Kw


9. rinser main drive
10. rinser lifting motor

3 Kw
1.1Kw

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11. rinser hot water pump

20
3 Kw

( ) machine size (including piping)


880072003500
L x W x H
() machine weight

26000 Kg

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Chapter 2 Rinser, Filler & Crowner


General description

Main function and feature of rinser,


filler and crowner

Main transmission uses system


which combines frequency conversion and speed regulation
synchronously. Transmitting system is an open gear transmission. The
rinser is for one medium only- hot water, and rinsing according to
presence of bottles. Filling valve is a built-in mechanical valve. This
machine has a double guiding shaft centering structure with
pre-covering function, twice vacuumizing and the ability to fill when
there are bottles and not to fill when there is no bottle. It also has the
function to rinse broken bottles automatically. Rinser, filler and crowner
can adjust their heights automatically and ar easy to clean due to its
reclining hygienic platform. The machines are equipped with hot water
spraying and cleaning system and use fast changing device for format
parts.

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The filler is for both draft beer and pasteurized beer. When
filling pasteurized beer, the bottles go directly into the filler without
passing through the rinser.

there are four component


groups
a rinser
b filler
b crowner
c

working table and drive

d Other
Accessories (including piping system, vacuum system and hot water
system for rinsing etc.)

1 Rinser

Main feature of Rinser

KHS

KHS
The rinsing
gear motor and the main drive are frequency-converting
synchronized controlled, with the function of no bottles no
rinsing and feedback of lack of bottles. The KHS rinsing
mechanism is adapted to allow a stable and reliable
running. Longtime drying and applicable for various type of

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bottles. The gripper is of advanced KHS mechanism.

components of the rinser


1
gripper
2
rotary disc
3
distributor
4
guide rail and protection
5
machine frame and height
adjustment device
6
water lubrication system

. gripper

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11 31 9 10
12 13 28 30 20 The gripper
consist of plastic clamp 11 & 31, fixing support 9, turning part 10,
support 12, guiding fork 13, pressure spring 28, support block
30 and roller 20.
4 28
20
26
The clamping is done by 4 springs 28. The clamp opens
and moves leftward by a cam via roller 20. The set screw 26

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makes it easier to change the clamp. Just pull out the clamp
when replacing.

turning of the gripper in a rinsing cycle:

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26

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rotary disc

open the cover to


check the small gear
and the gear ring

anti-rotating support for the central tube

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1 2
3 4

Rotary disc is based on the base disc 1. The


motor drives the small gear 2, and then to the gear ring 3, on
which the rotary disc 4 is installed on and driven to rotate. The
rotary disc is made in SS and welded. After artificial aging, its
high strength and anti corrosion enables it to run well under
rinsing condition.

distributor and valve on-off device

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1. nozzle 2 cleaning valve 3 valve


opening device 4 central distributor 5
valve shutting device

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4 4
2 2
1
The cleaning agent flows into central distributor 4 from
external piping, and then be distributed to the cleaning valves
2. The switches of cleaning valves 2 control the cleaning agent
to go to spraying nozzles 1 for rinsing bottles.

nozzle componets

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this device require tight


sealing

cleaning valve

only
maintenance needed for
the sealing, but should
be changed after one
year

central distributor

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32

PLC

the infeed bottle


position is feedback to PLC
for moving calculation to
control the cylinder, enable
no bottle no rinse

valve on/off device

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guide rail and protection cover

18
The turning guide rail turns the bottles to be cleaned
over via the gripper at infeed star wheel and elevates to the
rinsing position for rinsing and drying ( if rinsing with sterile air or
disinfectant, no need to dry), then lowers the bottles, turns over
and conveys to the discharge star wheel to finish the rinsing.
During the upper turning, the bottle month is turned from
upwards to downwards, while in lower turning, the bottle mouth
from downwards to upwards. This part is well adjusted before

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delivery.

The protection cover is to protect operators and to prevent


rinsing liquid from splashing. During maintenance, it can be
taken away following the direction in the diagram. The cover is
high and heavy, pls pay attention when take it away.

machine frame and height adjustment device

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35


1
1 2

Machine frame is the main part supporting the whole


rinser with a height adjustment device. The driving is

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from the motor to the small gear 1, and then the big gear
ring 2. The big gear ring drives four lifting screws 3 to
move the rotary disc upwards or downwards, allowing
bottles of different height to be rinsed.

water lubrication

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Turn on water lubrication before start up the


machine in order to protect the whole guide rail, gripper,
valve opening and closing block. Make sure that all contact
points are not dry will prevent the parts from wearing too
fast.

installation and adjustment

Due to the heavy weight of the machine,


therere no spindle feet for fixing on the ground. When
installed, just connect the connecting arm with the base
plate of the working table. (The rinser is adjusted before
delivery, so installation on site can be just based on the
original position). After that, check if the machines well
fixed.
2.

adjustment
1

Adjust
the rinsing time according Users requirement.
2

Synchronization
adjustment is among the rinser motor, the
working table motor and the filler main motor.

. commissioning

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1


check the electrical performance and the moving
of the parts
2


check connection with exterior pipes including


water ( sterile water and fresh water), air (gas) and
others
3
;
check if the bottle types and bottles enough for
the test
4
check safety
protection device
5

check the inside and outside status of the


machine (should take care of the electrical parts)
6

commissioning (with fresh water)
7
after
commissioning, clean the machine according to
the requirement
.

cleaning

The rinser is for rinsing bottles, so cleaning before and


after production inside and outside the machine is very

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important.
1.



Cleaning agent:
sterile water, disinfectants and chemicals.
2.

Higher
temperature will bring higher cleanness
3. Including
piping interior cleaning and gripper exterior cleaning.
4.


0.2Mpa

Interior piping of the rinser to be cleaned with disinfectant


or sterile water. If there are more than one kind of cleaning
agent, the last rinsing should be with disinfectant. After
cleaning the piping, clean the exterior of the gripper. The
agent pressure for piping cleaning is 0.2Mpa.
5.

Cleaning procedure and cleaning agent


depend on the customer, but should follow sanitary
requirement. The cleaning agent used before and after
production and the cleaning duration depends on
customers job routine.
6.

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If use acid or alkali to


clean, keep low concentration and clean with neutral sterile
water afterwards and drain out, avoid that vapor residue
increase the concentration and damage sealing and other
parts. The exterior rubber hose of the central distributor
should be dismantled and cleaned, if necessary. Please
notice that with high temperature and corrosive media,
rubber hose is easy to get damaged.
7.

Be sure not to use corrosive or strong


caustic agent, sharp tools, C6H6, leaded gas, or
CH3COCH3 to clean.
.
trouble shooting

machine not moving


1.

Cause: low voltage or
improper electrical operation.

Solution: check if phase missing for the motor,


or wrong operation, follow the right procedure.
2.

Cause: synchronized machine stop due to filler or


other equipments stop
incorrect rinsing
1

Cause: infeed sensing not correct



Solution: readjust the sensor to sense the bottle mouth.
2

Cause: valve opening device failure

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Solution: solve the


problem of the valve opening device.
3

Cause: spraying nozzle tilted.

Solution: re-install.
4

Cause: spraying
spreading out, cannot rinse to the bottle bottom.

Solution: check if water pressure enough,


check the nozzle of pipe and clean if necessary.
5

Cause: cleaning valve broken.

Solution: change cleaning valve.


6

cause: electrical or pneumatic


system malfunction.

Solution: check the cause


and solve the problem.
.
maintenance

daily maintenance after


operation
1

Drain out the alkali in the


media pipe.
2

Check the
gripper (guiding part, clamp) and nozzle.
3
Check the
media changeover device and changeover valve.
4

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weekly maintenance
1

Check the plastic part of the


gripper to see the wearing.
2

Check the media distributor.


3

Dismantle and clean the water


inlet and outlet hose.
4

Check the driving gear.


monthly maintenance
1

Maintenance as per
2

Maintenance as per
3

Check all the moving
parts to see the wearing.
4

Check the turning guide
rail and adjust.
5

Check the
moving parts, adjust, fixing or changing parts.
half-year maintenance

Except
for the above maintenance, its suggested to have a fixing
and whole machine adjustment, cleaning or change parts
accordingly every six months or after production peak
season.

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notes
1.

Keep the gears and
bearings away from water during cleaning.
2.

Dont damage the exterior surface,


sealing and nonmetal components while maintaining
the parts.
3.


For those
need to be filled with grease, make sure to
supplement enough grease during maintenance.
Parts like motor reducer should be maintained
following manual and ask for professional
maintenance if necessary.

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2 filler
2.1
structure

1. machine frame

big rotor bearing support revolving parts, namely, revolving of

ring

bowl etc.
2. revolving frame

lifting

cylinder and ring bowl supporting parts


3. inlet pipe

CO2CIP including

alcoholic drink, CO2, compressed air, CIP etc.


4. height adjustment device

for height adjustment when changing different bottle types

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5. lifting cylinder

45

lifting device

6. filling valve

filling units

7. control ring

filling control units

8. protection cover

safety protection

device
9. foam injection device

remove air in

bottle neck
2
2 body frame

12

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Main motor: (1) little driving


gear wheel (2) revolving, little gear wheel drives the especially large
swinging bearing with outer teeth. 3revolves and thus driving the
whole filler to revolve; big and small gear are helical gears, which
guarantee the stable function of the machine. Big rotor bearing is
customized ball bearing with outer teeth circle. This ball bearing is used
for radial and axial spacing of the filler.

2
3 revolving body frame

1
2

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Revolving frame 1 holds


up above the customized big swinging bearing (2) and the revolving
frame is mainly used to support bottle carrier cylinder (3) and filler bowl
and infeed tube etc. The main motor drives the big gear and the revolving
frame via the small gear to complete the filling process. The big gear has
external bevel teeth to stabilize the driving. The bearings are self
lubricating, and the lubricating time depends.

2
4
infeed (alcoholic drinks) tube device

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48

12
1
Substance (bear or drinks) goes through
the infeed tube and enters the infeed tube ((1) at the center of the filler
and the distributor (2) and goes into the ring bowl through the distributor.
The sealing pad of infeed tube (1) doesnt need special maintenance and
only needs to be lubricated with eatable oil during assembling.
CO2 CIP
2

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49

CO2 infeed tube, vacuum, CIP pipe,


electricity invoking source, material infeed tube, collecting discharge tube
inside the central tube are fixed units and connect with corresponding
pipeline through revolving units, namely, distributor (2), and then send all
medium into corresponding tube.

Structure of distributor
is as follows and the distributor is installed under the crossbeam of the
ring bowl.

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50

Distributor mainly includes:


1. distributor fixing seat 4. rotating bearing
2. distributor shell

5.sealer

(star)
3. inner distributor

6.sealer

(star)

Its installed under the crossbeam of


the ring bowl on the filler. All fixed tubes enter from underside and all
discharge pipe are connected with the filling bowl radially.

CO2 CIP
There are 4 disconnected channels in the under
distributor: material channel, CO2 channel, CIP and vacuum channel,
centralizing discharge channel.

function

Distributor is used to connect two disconnected pressure


pipe from fixing parts to revolving parts of revolving platform of the filler.

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51

Fixing parts of distributor is inner


distributor (3) while distributor fixing base (1) and distributor outer shell
revolves with filling bowl.

CIPCO2
Used connect CIP, material, CO2 infeed and centralized discharge
fixing pipe to inner distributor (3).

Material
transporting pipe is connected to distributor fixing seat (1) from center
through inner distributor (3). After that, several spokewise pipes
transfer the material into the filling bowl.

CIP

CIP channel is connected into the inner distributor through the screw
threaded joint and its exits are aligned spokewise here and then

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52

connected to the vacuum chamber of the ring bowl through the pipe
and the vacuum pump vaccumizes the bottles.

CO2
CO2
pipe is connected to the inside of the inner distributor through the screw
threaded joint and its exits are aligned spokewise here and then
connected to the inside of the ring bowl. When operating, the filler will
backpressure the ring bowl.

When filling is finished, beer created by pressure relief will enter


inner distributor through the pipe and will be vacuumized to the outside.

Each pressure room is


protected by two sealing device which separates it with the neighboring
pressure room or bearing base. There is a pressure relief hole which is
connected to air between two sealing devices. If the sealing device is

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53

broken, this can reduce the danger of short circuit between pressure
room.

2
5 air distributor

123
Air distributor mainly includes following parts: electricity invoker (1),
distributor (2), atomized lubricator (3).

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54

The function of electricity invoker is to transfer the electricity and control


signal from fixed parts to the revolving parts of the filler.
A B D
C 3
E 2 air with
different pressure come into air-distributor from A and B respectively. Gas
that comes out of exit D is control gas, which controls pneumatic butterfly
of the ring bowl. Gas comes out from exit C enters atomized lubricator 3.
Gas with oil comes into bottle carrier cylinder from exit E and lubricates
the bottle carrier cylinder.
2
6 ring bowl and height adjustment device

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55

Ring bowl
is designed and constructed according to the requirement of pressure
container and has a solid and reliable structure.

Ring bowl is divided into


product chamber, vacuum chamber and pressure relief chamber.

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56

Products enters ring bowl through distributor


and goes on to filling in filling valve. Liquid level of the ring bowl is
adjusted by level probe through main liquid valve.

CO2 CO2 that


compresses the bottles enters ring bowl through distributor and pipe.

2 CO2 There are 2 discharge


valves on the bowl cover and they are used for pressure relief and CO2
purification.

Cleaning agent goes to ring bowl production chamber, vacuum chamber


and pressure relief chamber through main liquid pipe and vacuum pipe.

Above
pipes are connected to infeed pipe and goes into filling machine through
infeed pipe.

26 Bowl
cover (2) can hold it by revolving the above screw (6) with the hand
shank, which is convenient for inspection and maintenance.
To adapt to different

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57

bottle type, filling machine needs to adjust to different height.


317
45
4489 5
, 5 ,31
Ring bowl (3) and the peripheral control ring (1)
are connected through mark fork (7) and can conduct height adjustment
at the same time and hold the ring-shape bowl above the revolving seat
by the ladder-shaped screw thread shaft (4). Motor (5) drives shaft (4) to
move and the small gear (8) on shaft (4) drives the other 5 small gears
through big gear (9), making the remaining 5 ladder-shaped screw thread
shaft revolve and then ring-shape ring bowl (3) to move upward or
downward with the control ring (1).
17
The control ring (1) separates from the mark fork (7) during
operation and only connects during height adjustment.

Height adjustment motor is connected to the


control cabinet with cable. To ensure safety, socket is inserted into
control cabinet, which cuts off the transmission switch of the filling
machine.

The lifting and descending control button of the ring


bowl is on the control cabinet of the operating front desk. Travel switch
limits the range of height adjustment.

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58

2
7 bottle lifting cylinder

Bottle lifting cylinder is


used to lift the bottles and compress tightly the filling parts. This is a
solely control unit and can be replaced in shortest time if needed.

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59

6
12

3
456
78

Bottle lifting cylinder is


pneumatic-mechanical.

Bottle

lifting

movement

is

realized

by

compressed air and the descending movement is mechanical and


realized by the rolling wheel of the bottle carrier cylinder under the cam
wheel. This can guarantee the equality when ascending and stability
when descending. Bottle carrier cylinder consists of pad plate (1), guiding
pole (2), anti-friction ring(3), bottle carrier seat(4), shaft(5), rolling wheel
(6), discharge screw nut(7) and connectors (8) etc. The friction coefficient
of the anti-friction ring is small with high anti-friction ability, which
guarantees the lubrication of the cylinder and correct function of bottle
carrier cylinder and its life length.
1bar 5 bar Bottle lifting
cylinder pressure should be 1 bar larger than filling pressure but should
not exceed 5 bar.

Compressed air goes through the


air distributor on the filling machine and the pipe inside filling machine
and then enters an oil mist filter. From there it will enter two bottle lifting
tables. The mixture of misted oil and air are distributed to the lifting tables
and at the same time the lubrication cylinder wall and piston.

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60

8 2
Lubrication in the inner part of bottle lifting
cylinder: loosen discharge screw bolt (8), turn on the gas source to allow
compressed air enter bottle lifting cylinder to circulate. When oil drops out
from the base of bottle lifting cylinder, tighten the discharge screw bolt (8)
every two days. The oil mist filter of the compressed air pipe needs to be
oiled on time to make sure that oil mist filter is working with oil.

5Lubrication
for the outside of bottle carrier cylinder: can spray water to the outside of
the bottle carrier cylinder with the muzzle to reduce the temperature
caused by friction and at the same time can take away the cullet sprayed
on shaft (5) because of broken bottles.

Bottle lifting cylinder


2 mmWithout
pressure, the distance between rolling wheel and bottle lowering cam
should be larger than 2mm.

1 - 2 mmWhen bottle carrier platform is lifted to its high-point,


vast plate should be horizontal with bottle sliding rail and the distance
between the 2 should be about 1-2mm.

Bottle

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61

lifting pressure uses corresponding pressure control device of the front


machine to set up. Pressure setup can be shown on the pressure gauge
in the front of the machine. Based on different filling pressure, bottle
lifting pressure should be as the following:
(bar)

(bar)

Filling pressure

Bottle lifting pressure

2-4

2.5 4.5

4 - 10

3.5 - 5

2
8 filling valve

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2.8.1 components and description of filling


valve

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63

filling valve is comprised following parts


1. filling valve butterfly
2. centering device
3. valve body
4. valve seat
5. vent tube

filling valve characteristic

1
Filling valve is of high precision and
equipped

with

non

vacuumization

mechanism

and

non

vacuumization device when there is no bottle.

2
When blowing up or filling, the filling valve will
close automatically and is equipped with automatic cleaning
device due to broken bottles caused by the quality of bottles.

3
All inner sealing parts are of imported seal
material and therefore the sealing parts are reliable and have
long service life.

4
This valve is the most widely
used, most mature and most stable filling valve for bear. It has a
simple structure and is easy and cheap to maintain.

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64

The inside of mechanical filling valve uses mirror


polish and has a smooth surface and simple passway, which is
easy to clean in order to guarantee hygiene.

6
Exact flow-guiding ring structure guarantees stable
liquid incoming and wine closure function and precise liquid
height.

7 Complete valve adopts


modularized design, making it easy to dismantle and maintain.

2
8
2
Operation principle
filling process

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65

( from left to right)


(1)Broken bottle signal

(2)open valve

(5)infeed pressed bottle signal


is bottle

(3)close valve

(6)infeed start to lift

(8)pull down when there is no bottle

(4)open valve

(7) pull when there

a beer

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b vacuum chamber
chamber

first vacuum

66

c pressure relief

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67

Open the vacuum valve


handle and this create a passageway between bottles and vacuum
passageway. Air in the air will get out of the bottle through this
passageway and thus vacuum is created.
When reaching
setting time, vacuumizing valve pole will close, which is the end of the
first vaccumization .
CO2 CO2 pre-fill
CO2 CO2
Air filling valve opens and creates a passageway
between bottles and CO2 space of ring bowl. CO2 enters the filling
bottles through this passageway.

CO2 Reaching setting time,


air filling valve will close and CO2 filling will end.

second vacuum
CO2
Vacuum valve

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68

tube opens, creating a passage way between bottles and vacuum


passageway. CO2 and air mixture in the bottle will expel from the bottle
from this passageway, thus creating vacuum in the bottle.

Reaching the
setting time, vacuum valve pole closes and this is the end of the second
vacuum.

preparation for pressure


CO2
CO2 Open the air filling valve,
which leads to a passageway between the bottle and air-return
passageway. CO2 will enter the bottles from this passageway until CO2
pressure in the bottle equals the pressure in the ring bowl.

filling

CO2

CO2
Open the
liquid valve and between the bottles and the ring bowl there will be
passageway, from which material enters into the bottle. In the mean
time, CO2 in the bottle will flow back to the ring bowl through the

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69

air-returning pipe at the same speed. Until material in the bottle


ascends and overflows the gas-returning pipe, which creates equal
pressure, CO2 compressed in the bottle will block the material from
pouring.
shutting valve

After filling, bottles after stewing for certain time, will


close liquid valve and gas-charge valve and cuts off the passageway
between the ring bowl and the bottles.

air-exhaust

Open an air-exhaust valve to create a passageway between a bottle


and the pressure-relief chamber. Pressure in the bottle will vent out
from this passageway. In the end, the pressure relief process will go on
until the bottles separate from filling parts.

residue blowing

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70

CO2
When filling units are between discharge and infeed star wheel, the
charge valve opens and it will close after the presetting time. In this
case, CO2 in the ring bowl will blow the material that remains in the
air-returning pipe out.

2.9 butterfly for air valve control

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71

1213
Filling valve
star wheel is used to control air valve. By friction braking, the valve
remains closed. There is a groove on Butterfly unit (1). Butterfly unit (1)
can be clamped to the shaft of pressure pole (3) with bolt (2). To ensure
function of the filling valve, the position of the filling valve star wheel is
very important.

2.10 rinsing broken bottles

design

Spraying mechanism is installed on the control ring


pillar and control ring. Its made up of nozzles for spraying filling valve
and the ones for spraying bottle lifting cylinder.

When adjusting the


height of the mechanism, the nozzle for spraying valve can move.

Spraying mechanism
can be connected to sterile water or connected to hot water pipe.

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72

working method

Cullet elimination can


be set to automatic work method on the operating terminal.

When the bottle is broken, broken bottle


signal checking device behind back-pressure can transfer signal to
machine control parts. Machine control system can start the function of
cleaning broken bottles.

When filling machine is


operating under high pressure, there will be occasional broken-bottles.
Therefore, a spraying and rinsing device is provided to rinse filling valve,
bottle centering device and bottle-carrier plate. Under the situation of
broken bottles, sensor will send out signal to automatically turn on the
electromagnetical valve to clean and rinse.

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73

WCZY96/84/14Y

3 Main components of Crowner

Crowner

74

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1. lower parts

75

lifting bottles and

drive the crowner


2. slide way

convey

crown caps to crowner head


3. upper parts

crowning head move

up and down
4. vibrator

vibrate crowner caps

5. assisting support

prevent crowner

from running
6. crowner lifting device
7. cap turner

turn the front side up

8. cap sorting funnel


9. crowner head

move up and down


sort crown caps
crown cap

3.1 operation

Crowner is driven by motor main


transmission
Filled bottles are sent to
crowner with assisting structure (transition star wheel)
Crowner cap go into cap
conveyor slide way through the rotating disc.
Crowner cap slides into cap
conveying slide way to supply to capping parts.
Without bottles, bottle
cap will not go to corresponding capping station.

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76

Crowning cap are sent


to the above of the crowning parts and are attached into capping die by
the magnetic part.

During a rotating
cycle of a crowner, every crowning part goes up and down by the lifting
cam rail. The assisting discharge star wheel conveys the crowned bottles
to bottle discharge conveyor.
Upper height of the
crowner can be adjusted by height adjustment operation.

During the rotation period, capping parts of every open design


will move up or down with the cam rail.
5 mm

Capping parts are equipped with bottle height compensation device.


Bottles whose largest bottle height difference is within 5mm dont need to
adjust the crowning cap tower rotation height. Shrinkable crowning parts
(bottle carrier) can absorb those transitional lifting.

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77

first phase

second

Third phase

Fourth phase Fifth phase

phase
first phase
Bottles are transferred to crowning parts.
second phase
Bottles and crowning parts are finished.
third phase
Crowning process of smallest bottles
fourth phase
Crowning process of largest bottles

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78

fifth phase
Crowning is finished. Bottles discharge.

3.2 height adjustment

Crowner
height adjustment function is to adapt the crowner to different height of
bottles to be crowned.

Height adjustment is achieved by


transmission motor (6) installed on the top of crowner support. Height
adjustment motor is interlocked with the frequency converter main
transmission motor of the driving crowner. Only when button machine on
or off and crowner descends or crowner ascends are pushed at the
same time will the height adjustment motor function. Blocking switch
limits vertical adjustment range of the crowner.

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3.3 crowner head

79

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80

1Cam controls
the upward and downward movement of the crowning head. The cam is
installed on the still part of the upper crowner. Crowning head shaft (1)
revolves drives crowning head to move upward and downward.

32
4
2
4
2
2
When bottles
are transferred from the filler, crowning head has gained a bottle cap
from the cap tank. Crowner head goes down under the influence of the
cam. Bottle cap works under magnetic column (3) and remains in a
suitable position of the material-pushing pole (2). Crowning die inside the
crowner head will lead the bottleneck precisely into the crowning head.
Crowning head, under the influence of spring when it goes downward,
makes the bottle cap and the nozzle of material-pushing pole (2) to touch
and stress downward. With further drop of the crowning head, the bottle
goes into crowning die (4), at which time outside of crowner head is
sealed at the same time, and depth of the bottle will reach the planned
one and the pressure top pole (2) stops. After that during the upward
movement of the crowner head, bottles will be pushed out of the
crowning die under the influence of spring of material-pushing pole (2).
During the process of crowning, height difference of the bottles is
compensated with the crowner head itself.

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81

3.4 hopper and stirrer of the crowner

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82

To ensure normal function of the crowner, only


bottles of precise measurement and height can be used. Crowner head
should stay in dry room.

Hopper
and crowner cap stirrer are installed split. After operation, hopper should
be emptied and crowner head enters stirrer from the hopper. Gyration of
the Stirring wheel of the stirrer is driven by a motor and starting and
closing of their motor are controlled by proximity switch on the slide way
to prevent any bottle cap damage.
(16)(17)(18)
Magnetic stirrer is equipped with independent
transmission device and bottle caps are transferred to the bottle cap slide
way from cap exit through turn table (16) and magnetic iron (17).
Bottle caps are turned
to the right side in the cap-turning pipe for next usage.
(21)
(22)
If there is jam in the cap conveying slide
way, bottle caps go through an inspection elimination switch and will be
lead into a box (21). Then bottle caps slide back to the stirring can from
the box. The number of bottle cap inside stirring can is inspected by
photo electric switch (22) and adjusted by machine.

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83

300 350 Bottle


conveying unit should be adjusted to contain about 300 to 350 bottle cap
inside the stirrer.

There is a photo electric switch inside the bottle cap box of the
magnetic stirrer and when bottle cap inside the box reaches maximum,
photo cell stops bottle cap from entering; when bottle cap inside the box
reaches minimum, photo electric switch starts bottle cap transferring
operation.
(21)(19)

There are 2 proximity switches (19) on the bottle cap transferring slide
way (21) under the direction converting machine. Machine control
inspection turns off the signal and if the proximity switches of the most
above one doesnt find cap, stirring cap motor starts conveying the cap.
Filler and crowner stop working if the lowest proximity switch doesnt find
bottle cap in the slide way.

4
barThere are 2 air pipes on the slide way and they are connected from
the control box to the bottle cap passageway tank and one pipe way
connects to several points of the cap tank to accelerate the flow of bottle
cap inside the tank and the other pipe connects the end of the cap tank to
flow bottle cap from the cap tank passageway to the crowner head.

WCZY96/84/14Y

Pressure of the cap blower should be 4 bar.


3.5 cap-stopper

84

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85

(11)If there
is missing bottle or the crowner stops, the cap-stopper (11) stops
supplying bottle cap.
Cap stopper is controlled
automatically to start or stop with the machine.
3.6 cap turner

When the magnetic stirrer goes through the cap turner, the bottle

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86

cap will be changed to right direction according to their appearance to


send to crowning parts.
Cap
turner is driven to vibrate with a vibrating device to allow bottle caps to
slide.
To prevent bottle
cap from jamming inside the cap-turning pipe, the appearance of the
bottle cap should be intact.
Cap turner can be dismantled to
remove those jammed bottle caps.

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87

4 working table and its transmission

1 infeed spindle

Separate the bottles into equal distance and send them into bottle infeed
star wheel.
2 bottle infeed star wheel

Deliver

the bottles into the rinser.


3 working table and transmission

Drive the working table star wheel


4 transition star wheel

Draft beer

and pasteurized beer change over star wheel.


5 discharge star wheel

Take the

rinsed bottles out of the rinser.


6 transition star wheel

Convey bottles

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7 infeed star wheel

88

Send bottles

to be filled in the filler


8 filler

Fill in the bottles

9 transition star wheel

Take the

bottles into crowner


10 crowner

Crown the caps

11 discharge star wheel

Send capped bottles into conveyor.


12 working table and transmission of the crowner
Drives working table and the crowner.
The machine is
frequency-converting synchronized controlled to allow the machine to
work in a synchronized way.

Rinser, filler and crowner, and the working table are driven respectively
by motor transmission device with transducer.
Discharge star wheel is driven by
a pair of gear of crowner.
Transmission of infeed
spindle is achieved by 2 gearboxes.

Infeed bottle conveyor of the filler is driven by


gleason spiral bevel gear and gear driving flat-top chain and flat-top
chain sprocket drives flat top chain.

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89

4.1 bottle conveying parts


a bottle blocking cylinder part

Bottle blocking cylinder prevents


bottles from entering filler and crowner before machines normal
function and when infeed conveyor has malfunction. It can be
controlled manually or automatically under the automatic working
status. During operation when bottles are not supplied, blocking
cylinder instantly stops bottle blocking star wheel and at the same
time decelerate the speed of the machine.
b Infeed spindle

Infeed
spindle is to separate bottles that come in a sequence to guarantee equal
distance with infeed star wheel to send stable bottles into the star wheel.
Spindle work in this order: constant speed- constant acceleration
speedconstant speed.
c star wheel

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90

Star wheel is the actutating


elements to guarantee the discharge process from the bottles enters the
filler to the completion of crowning.
4.2 installation and adjustment of
infeed spindle and star wheel
infeed spindle

1
2
1
During the
installation of infeed spindle, the center should be parallel with infeed
conveyor and when adjusting the synchronization of infeed spindle,
loosen the tension sleeve (1), revolving screw (2), then wait for the right
position and then lock the tension sleeve (1).

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star wheel device

91

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92

R+1
1.5mm
3 4 3All star
wheels are fixed to the star wheel seat with a bolt through the platen and

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93

the position of the star wheel is guaranteed by the dowel. When installing
bottle guiding plate, pay attention to the gap between star wheels.
Usually the diameter of the bottle is controlled to be about R+11.5mm.
Each pair of star wheel and bottle guiding plate should be on the same
level and when adjusting the synchronization of the star wheel, loosen
tension sleeve 3, turn the star wheel seat 4, and lock tension sleeve 3
after adjusting.
Changeover star wheel

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94

2 1 3
456 5
7
When filling pasteurized beer, take away the
protection sleeve 2, change to changing star wheel 1 and lock the star
handle 3, and then change with corresponding guiding parts 4, 5 and 6.
In that case, the bottles will not go into the rinser but directly to the

WCZY96/84/14Y

95

changing star wheel due to guiding parts 5, after that, go to the discharge
star wheel 7 and normal filling and crowning program starts.
2
When filling draft beer, change to the corresponding
guiding parts and install protection sleeve 2, at the same time lock the set
screw.
4.3 working table and crowner transmission

WCZY96/84/14Y

96

Fixing support
fasten the motor under the working table plate through the bolt and the
dowel. The motor drives the crowner and the star wheel to revolve
through the teeth gear. Forbid direct flush to the motor during cleaning.

4.4 working table

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97

There are infeed table support,


infeed transmission, infeed star wheel, transit star wheel, middle star
wheel, crowner, discharge star wheel, discharge table and protection
device on the working table.

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5 piping system
5.1 PID
piping system PID drawing

98

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5.2 vacuum system

99

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100

vacuum pump
general
(1)
During the process of filling, use vacuum pump (1) to
vacuumize bottles through vacuum passageway of filling bowl of the filler.
function

Vacuum works in the principle of liquid ring. Eccentric


impellor in the pump shell sends driving power to liquid ring, which
operates concentric with the shell. In this case, liquid comes in and out of
the impellor cell like a piston. At the exit of the liquid cycle, impellor cell
sucks air through inhaler. At the entrance of the liquid cycle, air is
compressed and vented.

During operation, there must be constant water supply to the


pump as work liquid to bring away the heat which is produced and to
maintain liquid cycle.

(2)
Usually, a liquid
separator (2) and a water-entrance adjustor are needed. Separate gas
from liquid in the liquid separator. Liquid can be reused as work liquid.
clean and maintain

Clean the vacuum pump when


cleaning the filter.

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101

Vacuum pump can only be cleaned with


cold or hot water.

lubrication

3000
The bearing needs to be cleaned
after about 3000 work hours.
10 Amount: 10g for each bearing
Please follow operating instruction of the
pump manufacturing factory.

elements that influence the vacuum pump


a influence of the work liquid temperature
on the pump capacity
10 12 Temperature of entrance for
vacuum pump cycle liquid is 10-12 degree.
15 Temperature difference of 15 degree will
cause change of the pump.

influence of the work liquid on the pump capacity

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102

1,2

S
SK

13

Process water temperature

15

1,0

17

0,8

0,6

20

Lowest
permissible
intake
pressure

25

30
35
40

45

0,4

30

40

60

80

50

100

200

400

600

800

1000

Intake pressure P1

S = pump content of liquid cycle pump,


working water temperature
SK = Rated pump content of liquid cycle
vacuum pump
S = 15 internal conversion
coefficient of rated pump content at the work temperature difference of
15 degree
SK
b influence of the entrance gas humidity
on the pump capacity
Pump is designed according to the use of
dry air.

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103

If the humidity of infeed


air increases, pump capacity will increase correspondingly.

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104

Chapter 3 changeover
3.1 safety

During changeover, such as star


wheel and bottle guiding units, brewery filling factory
safety principle needs to be followed.

stop

If personnel may face danger, changeover, malfunction


elimination or maintenance should be performed when the power is
turned off and the machine stops working and there will be no accidental
startup of the machine.

For works that cannot be done when machine is off (such as


height adjustment), start the machine when necessary.

When the machine is


working, personnel that are not permitted cannot get close to this
machine.

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105

3.2 change changeover parts

10

11

12

13

If your machine is designed for multiple bottle types, you need to


change following assisting tools according to bottle types

infeed

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table

106

bottle-guiding turning,
transferring star wheel

bottle block star


wheel

infeed worm

crowner
star wheel

10
bottle-guiding turning,
crowner star wheel

infeed star
wheel

bottle-guiding
turning

11 discharge
star wheel
12
bottle-guiding turning,
discharge star wheel

transfer star
wheel

13 Bottle
guider, discharge

2.1 changeover of infeed rack

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12
13
23Loosen the
bolt(1) with a wrench and put in the bottle and then move left or right
bottle guiding unit(2). Move it to the right place and then lock bolt(1); if
necessary, loosen the bolt(3) with a wrench to move the bottle guiding

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parts 2upward or downward until it reaches suitable places and lock


bolt(3); then the adjustment is finished.
2.2 changeover of bottle blocking star wheel

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122
21
Unscrew bolt (1) and take out bottle
blocking star wheel (2). Take out star wheel (2) to the left; then perform
the opposite action.
2.3 change over of star wheel and bottle
guiding parts

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123
3
1Loosen handle(1) and
move part(2) inward to separate it with star wheel(3); at this time star
wheel(3) can be lifted; contrary movement is to change new star wheel
and lock the handle(1).
54
5

Loosen bolt (5), lift part(4); contrary movement is to change new bottle
guiding parts and lock the bolt(5).
2.4 change of infeed screw

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12
3
31
Loosen bolt(1) and get it down and
then move infeed screw stick(2) to the right side and then get infeed
screw stick( dowel (3) remains the same position); contrary movement is
to change new infeed screw stick and put the positioning plate into the
dowel(3) and then lock the bolt(1).
2.5 change of crowning star wheel

12
3

1
4

5
Loosen bolt(1) and get crowning star wheel and
bottle guiding parts(2), (3); contrary movement is to change new
crowning star wheel and bottle guiding parts and lock bolt(1). Common
parts(4), (5) dont need to change except when bottle neck has great
change.

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3.3 height adjustment


The
height of filler and crowner needs to be adjusted when the bottle of
different size is used.
height adjustment steps are as follows
:
attention

When cleaning the filler or when there are bottles remaining in the
filler, height adjustment cannot be performed.
Before height adjustment,
assisting structure parts need to be changed.

When adjusting the height, close all baffle plates


and prevent all people from the danger area of filling towel and
machine.

3.1
adjustment of the filler

When adjusting

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the height of the filler, close button of main machine to ensure safety.

Height
adjustment of filler can be achieved by adjusting the motor by the ring
bowl and controlled by electrical control system.

15mm
Specific height adjusting method: put a
standard bottle under the filling valve (corresponding bottle carrier of this
valve doesnt work under the influence of the cam), use pneumatic bottle
carrier to lift the bottles. Then start ring bowl height adjusting motor and
stop the machine when the height difference between bottle carrier plate
of the pneumatic bottle carrier with bottles and without bottles is 15mm.
then take away test machine and finish adjusting the height.
3.2
adjustment of crowner

Before height
adjustment of the crowner, other buttons need to be turned off to
guarantee safety.

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M20

31.5mm ,

Specific height adjustment method: loosen two


M20 locked bolts on the column and then put a standard bottle on the
bottle carrier plate and move it to the highest point of the crowning cam to
make the distance between the crowning head body bottom of the
crowner head and the upper surface distance of the bottle to be 31.5mm
and then lock the bolt on the column, which is the end of height
adjustment. There are two proximity switches on the column, the function
of which is to limit the height adjusting range of the crowner and to
prevent the height adjusting lead screw separating from or colliding with
the screw.


Chapter 4 operating instruction
preparation for the operation

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before turing on the machine,


please check


nobody is in the
dangerous area of the machine

all protection glass cover and


steel plate are closed

all protection
device, control device and equipments are in a normal working
condition

all guiding device are correctly installed

infeed and all guiding device match bottle types


which are to be processed.

All foreign objects are


cleaned from the machine (tools, rag ect)

All lubricant and working raw


material are filled again.

There is compressed air, water and


power supply available.

During the process of commissioning, manufacturing and


cleaning, the pipe will reach operating temperature and scalding can
happen if anyone touches it.

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If the machine turns off, the temperature of the pipe decreases


very slowly. Therefore, it requires extra attention during maintenance and
repair.

start-up every day


situation


commissioning

1inspection on the performance of


electrical components

2all parts that


involves working with the beverage will conduct leakage test
with water

3
CO2 piping, aseptic air piping and compressed air
piping will undergo sealing test with water

4adjust filler
and capper to suitable position according to bottle type that
is used

5commisioning with water instead of


product

6determine the length of vent


tube of the filling valve

7Clean and sterilize filler


Service personnel from
GLM2 have finished commissioning.

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preparation before operating


1preparation
condition that must be conformed to ( reference for before
operation and inspection)
2 preparation of control cabinet
VVF Please see

manual of VVF filler liquid and air control device

no bottle shortage
There should be enough bottle
supply for at infeed

no bottle jam
Jammed bottle platform and
discharge conveyor need to be cleared.

manufacturing monitor
To detect
malfunction message during manufacturing, following condition
should be checked at a regular time.

filling pressure

filling temperature

bottle cap supply

leakage valve

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if there is abnormal function noise of the


machine

This is precaution to malfunction.

startup
connect control voltage
Turn
control voltage key switch to open.

start usable function

... ...
........
Start corresponding usable function such as
automatic lubrication etc.


selection type.
Adjust height if necessary.

... ...
........ Selection of filling type. If necessary
adjust the height to selected type.
- jogging
- filling
- height adjustment

turn on the filler

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Press gleamy
button turn on the filler.

select and start filling
function mode

... ...
........ activate automatic function of filling to start
filling process

119

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Electrical control system
5
1 brief introduction
PLCVVVF
IMMI
Whole manufacturing process of this filler capping can adopt
electrical control system, which made up of PLC, VVVF and IMMI, which
is the most popular industrial grade HMI, to conduct real time control.
1

working principle

5100 / 10HZ

The speed of motors of main transmission and


infeed conveyor are controlled by transducers and its operating speed
can start from low speed (5100 bottle/hour, corresponding frequency is
10HZ) to necessary production speed with stepless adjustment.
Operating speed of the machine is controlled automatically by the speed
of bottle-flow side switch on the infeed and discharge conveyor.

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PLC

The whole
process of filling and capping is controlled automatically by the PLC and
should belong to operating procedure during normal production. During
operation procedure, the whole production procedure of the machine can
be controlled by PLC in the method of scanner to receive multiple status
signal of entering device and signal from sensor. Then the machine will
complete the whole manufacturing process of filling, rinsing of broken
bottles, spraying of the gas-returning pipe of the ring bowl, high pressure
injection, cap stirring and air blowing for entering cap according to control
signal of task that are specified by programs.

Automatic control during manufacturing


process, machine is controlled based on left shift of the programmable
controller. Work principle is as follows, during operation, machine drives
a metal sensor to move, the lap of revolving of which means position of
one bottle is moved. This sensor flow scans proximity switch, creating a
series of impulse signal, which is the shifting control signal of the
machine. Shifting control data enters signal and the bottle level
inspection switch on the ring bowl is created and to tell whether there is

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bottle on the bottle carrier cylinder. When a bottle enters bottle level
inspection switch sensor and faces with bottle carrier cylinder, metal
parts of corresponding bottle centering ring face their response surface
and there will be discharge signal in the bottle level inspection switch.

When bottle enters the machine, bottle level inspection


switch detects bottle signal, which will shift leftward in order under the
influence of a series of shifting signal created by the pulse accounting
switch. Some bottle spot will send signal to control corresponding
electromagnetic valve to finish the process of filling to capping.
2

control function

There are 3 working mode


1duringsetting process mode

Machine
commission process is mainly used to guarantee the installation place of
bottle level inspection switch and broken bottle inspection switch to make
sure that the machine is functioning accurately from filling to capping and
to adjust the height of filler and capper to adapt to the filling need of
bottles of different height.

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2during operating process mode

Work
speed of machine can be controlled manually or automatically. During
manual operation, operating speed of machine can choose necessary
function speed through speed-adjusting potential device to have
grade-less speed-adjustment; under manual operation, actual operating
speed of the machine can be controlled automatically by bottle-flow
situation of infeed-discharge conveyor.
3During cleaning process mode

Cleaning process is used after machine


finished producing to conduct automatic cleaning. In this time,
electromagnetic valve automatically opens to do cleaning.
3

protection function

1 machine stop protection due to


emergency stop and overload
2 When there
is missing bottle or fallen bottle in machine infeed, bottle stopper will
instantly close to stop incoming of bottles.
3
Safety protection of

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protection door: when the protection door of crowner is not closed,


the machine can not start; or during operation, machine will
instantly stop working when protection door of crowner opens.
4
Protection for jam in discharge: during operation, machine
will instantly stop when there is jam in the discharge.
5
Protection for missing cover of lower
cover groove: during operation, when there is missing cover of
lower cover groove, machine will stop and alarm with light after
short-time delay.

Remarks: after elimination of every malfunction,


malfunction elimination button must be pressed for machine operation
when restarting the machine.
4

interface operation

PLC
PLCPLC
PLC
Interface operation is an interactive work
station designed for PLC and is equipped with the capacity to connect
and monitor PLC. With PLC inner connection point situation, it can
replace old control-interface function. It adopts liquid crystal monitor and
touch button to monitor the operation of self-control system made up of

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PLC.

Remarks: due to different customer requirement, we dont elaborate on


screen design of HMI.
5

control during operation process


a When
filling, bottle neck foam should be checked and use high
pressure jetting device to control foam.
b During

operation, bottle cover needs to be checked constantly and manual


adding cover is necessary.
c See the section for
malfunction elimination if there is malfunction during filling.
d See the section for
malfunction elimination if there is malfunction in cap crowning.
e Cullets need to be blown away if there
is any broken bottle.
6

halt during manufacturing break

Fill all cleaned bottles with beverage and cap them. If


necessary, bottles those are not cleaned need to be sent back to bottle
washer.
ashort time machine-halt step

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1stop bottle
2machine halt
3main drive halt
4vacuum pump halt
5HPI stops
6product pump stops
7infeed conveyor stop
8discharge conveyor stop
9high-pressure pump of HPI stops
10close main switch valve
11 CO2 Close CO2 switch valve
b machine startup after short machine halt
1 CO2 connection of CO2 valve
2open switch valve
3open high-pressure pump of high
pressure jet device
4start the vacuum pump
5start the product pump
6start bottle infeed conveyor
7start bottle discharge coneyor
8open HPI
9turn on main drive
10Release bottle stopping device

5.1 device display


a Home screen

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piping sceen

c
malfunction alarm

127

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d
preparation for filling

e
filling screen

128

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f
height adjustment

g
parameter adjustment

129

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h
central automatic lubrication

130

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131


Chapter 6 cleaning
6.1 cleaning foundation and its purpose

Purpose of
food cleaning process system is to make final production reach quality
standard.

Generally, filling is not conducted in aseptic


environment but it still needs to clean and sterilize to guarantee aseptic
environment to greatest extent.

It will not reach the goal of cleaning and will bring low efficiency if surface
that is not physical cleaning is sterilized.

During physical
cleaning, all paths connecting to products will be cleaned by water or
suitable chemical cleaning agent. When cleaning, high-speed water flow
and all detergent will peel off the foul and clean it.
Then
sterilize pathway that connects the product with hot water, steamer or

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suitable chemical disinfector.


effective cleaning
needs suitable cleaning step and following element

during cleaning, pressure of detergent

flow rate

detergent temperature

chemical detergent concentration

responding time

6.2 limit value of detergent


detergent

Highest

Highest

concentration

Largest

temperature

contact
time

3.0 %

(NaOH) use NaOH

(30,000 ppm*)

detergent

45 min.

80

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(NaOH

2.0 %

133

45 min.

70

45 min.

60

45 min

30

2 hrs

20

16 hrs

30

( NaClO ) (20,000 ppm*)


use
NaOH and NaClO
cleaning agent to conduct
cleaning and sterilization
(pH >11
pH>11 due to chloridion)
(H3PO4)

2.0 %

(HNO3). acidic

(20,000 ppm*)

H3PO4 and HNO3.


detergent
( NaClO )

0.02 %

(pH = 9) NaCLO and

(200 ppm*)

disinfectant(pH=9)
/
50

0.05 %
(500 ppm*)

ppm*
hydrogen peroxide/acetic
peracid disinfectant, used
for process water with 50
ppm* chloride

50 ppm*
iodine disinfectant. Used
for process water with 50
ppm* chloride

0.005 %
(50 ppm*)

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(CLO2)

0.0001 %

(CLO2)cleaning with

(1 ppm*)

134
25

CLO2
clean

45 min.

95

45 min.

110

and sterilize with hot


water
0.5 bar
use 0.5 bar
steam to clean and
sterilize
* ppm = one in a million

At any time, sterilization with oxidant can not exceed limit value in the
tableeg: acetic peracid, Sodium Hypochlorite, since these detergent
will not corrode stainless parts)

6.3 cleaning outer surface of machine

During manufacturing process, all surface of the machine will


possibly be covered by beer residue, leading to increase of germ.
These germs will decrease the
pureness of filling product.

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To prevent such situationoutside of machine


needs to completely clean up on a regular time. During cleaning, all
outside liquid residue needs to be handled. Possibly some parts of the
machine need to be dismantled to clean all important parts.

6.4 usage of high pressure cleaning


tool
pay
attention when cleaning filler and crowner and cleaning with high
pressure squirt gun.

If high pressure
squirt gun is too close to sealing, high pressure water flow will clash the
sealing pad to infilter the water into protection area. And this will lower
service time of relevant faculties and bring other negative effect such as
increase the danger of corrosion.

Humidity in the electrical component cabinet will also accelerate the


corrosion of component and touch point and even have the danger of
short circuit.

Worst function is water mist produced in this method will fill


to the whole machine. At this time, germ of some polluted area will be
diffused to large area including area that will possibly contaminate filling

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product.
20 barIf jetting pressure
exceed 20 bar, this aerial fog will come out in large amount.
20 bar For above
reason, we dont recommend using high pressure water gun higher than
20 bar.

6.5 cleaning detergent residue


Clean remaining detergent on the
surface of the machine with fresh water.
Wipe dry machine parts with fabric
or compressed air.

If the surface of
the machine is not cleaned with fresh water, acid and caustic
concentration will increase gradually due to vaporization and it will
corrode the surface to lead to serious damage.

6.6 plastic monitor of cleaning


machine faceplate
Clean the
monitor with wet cloth or coated abrasive that wets with detergent and
clean with fresh water.

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60 When
cleaning, only use neutral detergent without alcohol or abrasive, such as
soap or household soft detergent. Cleaning temperature can not exceed
60 and can not use solvent that might corrode the surface of the
machine.
No sharp tool such as
shaver to clean the monitor.

6.7 compatibility of the material

Usually material provided by famous producer is reliable


but itll be better to consult producer about the corrosion feature of the
chemical substance. Get certificate of quality since some producers
provide certificate of quality of the material.

Based on our
experience, it would be enough and fine to use caustic or neutral
detergent. Pay special attention to avoid damage if we use acid material.
CKW
H2SO4 H2SO3
Dont use strong inorganic acid, such as
CKW, H2S04 and H2S03 etc if acid chemical substances are used.

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Dont extend sterilizing time, for example, sterilize all night


long, to avoid too high concentration of some part caused by splash or
evaporation.
Complete cleaning
with water is a must if acid substances are used.
50 ppm

pH 10 20
150 ppm

To avoid holes created by corrosion, concentration of acid substances


and chloride in the water should not exceed 50 ppm. Since improper use
of halogen (chlorine, sodium) detergent will easily cause corrosion of the
stainless steel, careful monitor is necessary. Therefore chlorine detergent
with PH value over 10 can not be used over 20 minutes and can only be
soaked cold and the highest concentration of chlorine can not exceed
150 ppm. Then rinsing with fresh water is necessary. Its better to sterilize
with detergent that contains acid or halogen before filling starts.
Plastic parts of filling machine can not
contact acid.
Be aware that
oxidant will have chemical reaction with sealing material, which leads to
leakage.

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6.8 temperament of sealing material




NBR

VMQ and PVMQ

FKM or Viton

EPDM

NBR
feature
 Anti-mineral oil, grease and fuel oil
 flexibility
low-temperature flexibility
anti compression and deformation


-2090

110Fatigue resistance under high


pressure depends on the ingredient of glue and the temperature ranges
from -20 to 90 and can be shortly used in 110 temperature. During
high temperature, the material will become hard.


0.2 ppmsealing can not

prevent ozone and air with ozone with concentration higher than 0.2ppm.

VMQ and PVMQ


Feature
 heat resistant

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140

 low pressure flexibility


 oxygen and ozone resistant


-20130Operating temperature ranges


from -20 to 130

100Strong
acid, caustic substance, water and steam, which exceed
100 ,will damage such material.

FKM or Viton
feature


great chemical stability

great capacity to resist ozone

and humidity and light isolation




great capacity to insulate hot water and

steaming
 -20 150
Working temperature ranges from
-20 to 150
 100

EPDM

feature

Great protection capacity to following substances: hot water, steam,
detergent, oxidation medium, acid and caustic
 Great capacity of resistance to ozone,
humidity and aging

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141

-20130Operating temperature ranges

from -20 to 130.




EPDM EPDM sealing can not

be used for aromatic hydrocarbons and chlorhydrocarbon substance.




EPDM EPDM sealing is not

compatible with mineral oil grease.

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142


Chapter 7 maintenance

7.1 Notes

During
maintenance, inspection and repair, brewery filling plant safety principle
needs to be followed.

Its necessary to have daily maintenance


since operating malfunction due to improper maintenance will cause
high-amount of repair cost and long-time halt of the machine.
Only with
right maintenance will the machine have great performance during
long-time operation.
Maintenance
and repair work can only be executed when machine and facilities are
safe and are not powered on.
Turn off all necessary
switches to eliminate accidental startup of the machine.

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143

Operate according to matters that need attention and


maintenance work is the precondition to guarantee the normal and
longterm performance of the machine.

When replacing spare parts, only parts


made by GLM2 can be used. We draw your attention specifically that
parts and accessories not supplied by us are not checked or identified by
us. We are not responsible for any loss resulting from usage of parts and
accessories that are not supplied by GLM2.
Therefore, we advise you
to maintain the machine according to following maintenance plan.

7.2 rules
effective and
special stipulation in the location of the machine should be followed,
especially instruction and guidance.
- storage, use and handle of relevant
material
- substance harmful to health and
environment

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144

- storage, use and correct handle


of relevant raw material
- operation of electrical system
- Your company regulation

waste disposal

The
disposal of acid liquid and caustic liquid should follow the law. To
guarantee your own safety, special attention is necessary when
handling them. Before neutralization (treatment), they can not be
poured into sewage system directly.

Inspect whether replaced parts or waste created during


maintenance and repair are handled in special way.

Make sure that proper treatment


is done when necessary.

Disposal and treatment of


following items and chemical items are especially important:
- grease and its container( such
as fuel injector, lubricating gun etc)
- cleaning agent, solvent and cooling agent
- battery, CRT and cold red-light lamp
- Plastic

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145

7.3 maintenance plan table for filler


8 maintenance interval referred
to is 8 work days per day

If you turn off the main switch during maintenance,


units of some module still carry electricity, for example:

8
every day or every 8 working hours


filler external Spray machine with water to inspect if there
cleaning

is abrasion on the machine and to clean cullet on the


machine.

filling parts

Check if the vent tube, probe, centering tulip and


crowner are damaged.

distribution

Clean the residue fiber of the filter in the liquid inlet

valve unit

pipe

(CIP)Clean the filler.


filler internal
cleaning

40 every week or every 40 working hours

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146

The height

Height

needs to be adjusted to the highest and lowest at least

adjustment

once respectively.

Water

Check the water separator of the air-adjusting unit. If

separator

necessary, empty it.

Inspect the adjustment


cullet spray
system

of broken-bottle spray system nozzle.

check if
lifting
cylinder

the bottle cylinder has oil and needs to fill in oil on a


regular time.

internal
lubrication

lifting

Check if the lubrication nozzle outside

cylinder

bottle lifting cylinder is working normally. Clean it if

external

there is any problem.

lubrication

air Check air


filter

filter and the filter of ventilation device of the control


cabinet.

170
every month or every 170 work hours

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147

Cleaning pipe and


filth

air-adjusting team piping filter

filter

toothed Check the tension of the toothed belt. If necessary,


belt

adjust the tension of the belt.

inspect following part of the


foam

foam-inducing system:

injection  water flow of the pump


system
 40 barCurrent
pressure of the high pressure filling pipe spraying
( max. 40 bar)

cleaning extra
lifting

lubricating oil when lubricating inside the bottle lifting

cylinder cylinder

6
1000
every 6 months or every 1000 work

hours


lifting

Check if all bottle guiding

cylinder parts are abrasive. Mainly means the wear sleeve and
the corresponding shaft (scratch mark etc)

Check if
supply

compression and lubricating system pipe are leaking.

pipe line

Check if all bottle


bottle

guiding parts are abrasive.

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148

guiding
parts

Check if

switch

carbon brush and silver plating brush on the switch

panel

panel on the sliding ring are abrasive.


Clean deposit sediment
on the switch panel with a piece of cloth.

2000
every year or every 2000 work hours

PLC

buffer
battery

Change buffer battery of PLC controller,


control terminal and filling computer presentably.
important!
PLC
When changing buffer battery of PLC
controller, the main switch must be on.

2000

regular main We recommend a major


maintenance maintenance

or

repair

conducted

by

service

personnel from GLM2 every year or every 2000 work


hours.

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149

7.4 maintenance centering


ring of bottles and sealing of bottle mouth

During filling, bottle mouth retains inside filling valve with centering ring
and sealed by bottle mouth sealing.

These two parts are connected directly


with bottle mouth.

Therefore, pay special attention


to the sanitation situation.

Pay
attention not to have any cullet on these parts since they might fall into
the bottles.

therefore, we recommend following measure to ensure normal function


of the centering ring and bottle mouth sealing.

During filling process of glass bottles, centering ring


and bottle mouth sealing will have cuts, which increase the time for
germs to stay and therefore they are more likely to survive and produce,

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150

thus resulting in contamination of the liquid inside the bottle. If these cuts
are deep, heating time during cleaning is not enough to kill hidden germs.

regular maintenance is
necessary to reduce such risk:

1.

85C 40
Sterilize the centering ring and the bottle mouth sealing inside it
weekly with 85C water for 40 minutes.

2.

1000 3000
Change bottle jaw sealing pad after every 1000 work hours
and change centering ring every 3000 work hours.

Since
the quality of bottles is various, there might be cullet on the bottle mouth
sealing and the centering ring. Probably there will be certain amount of
cullet on the bottle mouth sealing, therefore regular cleaning is
necessary.

7.5 maintenance plan table for the


crowner

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151

8
every day or every 8 work hours

external

Spray the machine with

cleaning

water and check if there is abrasion on the machine and


clean cullet on the machine. Clean all polishing parts with
a piece of rag.
Clean cap stirring

funnel, cover turning device and cap-conveying slide way.

cap
conveying
device

40
every week or every 40 work hours

height

If your machine is equipped with height

adjustment adjustment device, adjust it to the highest and lowest


position at least once respectively.

170
every month or every 170 work hours


crowning
parts

Check if the roller of capping head and press roll are


abrasive. If necessary, it needs to change. Check if the size
of the bottle cap which is to be processed is correct. If any
problem occurs, capping parts need to be changed.

bottle

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152

If there is
abrasion in the bottle support, change it.

support

star Check all star wheel


wheel

and correct if any problems.

1000

Twice a year or after every 1000 working hours

Check magnetic

stirrer and change damaged or worn parts.

Magnetic
stirrer

2000
Every year or after every 2000 work

hours

2000
We recommend an overhaul by

overhaul GLM2 service personnel every year or every 2000 working


hours.

7.6 electrical maintenance

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153

switch facilities

Switch device with mechanical contact point will

Mechanical easily be worn and has certain time of service and rated
on-off time.

switch
device


Electrical switch devices are not

easily worn and maintenance free. But they need to be in

Electrical

proper cool and dry environment.

switch
device

Motor


Three

The cleanness of the cooling air needs to be kept by

phase

the motor and regular check of ball bearing of the motor is

motor

required.

Proximity switch and photo cell

Basic

During the process of manufacturing

requirement and cleaning, attention needs to be paid to prevent light


barrier, optical scanner, electrical and optical facilities

WCZY96/84/14Y

154

from spraying with water.

Before everyday
operation, clean the lens and reflector.

Before
everyday
operation

7.7 maintenance of pneumatic facilities

8
every day or after every 8 working hours

Maintenanc Check if the maintenance unit is working normally. If


e unit

necessary, empty the water separator.

40
every week or every 40 work hours

leakage Check if the hose, hose connector and


connection parts are leaking or damaged. Replace those
have problems!

WCZY96/84/14Y

155


Chapter 8 Lubrication
8.1 general description

Lubrication system is to lubricate all operating organization


of the filler and crowner during operation. It can be divided into 2
categories, one of which is thin oil lubrication system used for lubricating
the lifting cylinder and the second one is grease lubrication system used
for grease lubricating organization and system (such as meshing gear,
drive bearing, sliding, rotation gear etc)

Lubrication system now adopts


concentrating automatic supplying method, namely, a set of lubrication
system provide the same lubricant to multiple lubrication point from one
center-control device. Its feature is to guarantee all guarantee all
lubrication point is even and lubricated and to save time. During
operation, on time lubrication can guarantee and more importantly, no
lubrication link will be missed and also the maintenance cost is low.

WCZY96/84/14Y

156

The working principle of grease lubricating system is as follows;


lubricating grease comes out from lubricating pump and supply to filler,
conveying system and crowners by lubricant-distributor and goes to all
lubrication point from bypass distributor. For lubrication for meshing gear,
usually oil mist spraying method is adopted and it uses compressed air to
spray lubricating grease to the teeth gear through oil mist spray device.
Such method requires little grease and brings great lubricating effect,
namely, grease is even and with great adhesion.

PLC

Lubricating system is controlled by PLC


during operation and its parameter can be set to control the working
status of the lubricating system based on the filler crowners working and
environment requirement. At the same time, pay attention to use one
type of grease, not mixture of multi-grease, which will cause system jam
or damaged lubricating system because of chemical reaction, during the
lubrication process.

WCZY96/84/14Y

157

lubrication system
1 electrical grease pump
main distributor

2 grease-filter

5678 sub-distributor

7
Sub-distributor (7) lubricates the big rotor bearing and its gear pair on the
filler
5
Sub-distributor (5) lubricates the gear pair and driving bearing of the
upper star wheel on the working table.
6
Sub-distributor (6) lubricates the bearing of crowner main shaft, crowning
lifting screw and crowning cam etc.

WCZY96/84/14Y

158

8
Sub-distributor (8) lubricates gear pair of rinser big rotating bearing and
filler big rotating bearing.

WCZY96/84/14Y

8.2 star wheel lubrication

159

8.3

WCZY96/84/14Y

160

lubrication point of the crowner

WCZY96/84/14Y

8.4 lubrication of the filler

161

WCZY96/84/14Y

162

8.5 manual lubrication


1 lubrication of central tube

Lubricate with
specified lubricant through the lubricating nipple on the central tube once
a week.

WCZY96/84/14Y

163

2 lubricate air supply distributor

Lubricate with
specified lubricant through the lubricating nipple on the central tube once
a week.

WCZY96/84/14Y

164

3 lubrication of the lifting and ascending of the ring bowl

Lubricate with general oil monthly.

WCZY96/84/14Y

165

4 Crowner lubrication

Add certain amount of lubricating


grease to the crowner cam surface every month.

WCZY96/84/14Y

166


Chapter 9 malfunction analysis and
elimination
9.1

possible cause of malfunction


1Non-working of the main machine

and driving device doesnt work.


2Speed of the main machine cannot be adjusted.
3Have difficulty in starting the main machine.
4program controller does not work.
5Drive
device work but machine still cannot function. Selection switch is set to
automatically operate.
6No bottles can enter.
7Bottle-stopper is open but no bottles
can enter.
8Unstable bottle infeed.
9Stable bottle flow. Broken
in the infeed and discharge of the ring bowl.
10Broken during the
process of crowning and the cap clamper collide with the bottle mouth.
11Bottle hanging at the discharge of the
crowner.
12Bottle mouth cracking.
13Some or all bottles not

WCZY96/84/14Y

167

capped.
14Crowner does not run.
15Height of the crowner cannot be
adjusted.
16No cap or lack of
cap in the cap funnel and the cap stirring disc.
17Bottle cap cannot pass
successfully in the capping tank.
18Bottle cap
cannot go to the bottle-cap-clamper of the crowning head from the low
cap tank.
19Bottle cap on the bottle mouth inclined.
20 CO2 Cannot fill CO2 in the ring bowl.
21 CO2
Ring bowl is filled with CO2
but no beverage can be filled in.
22Liquid level of the ring bowl is too high.
23Beverage is filled into the
ring bowl but cannot filled in the bottles
24Liquid level of the ring bowl is too low.
25Unstable of liquid level of the ring bowl.
26Liquid overfilled into the bottles.
27Bottles cannot be filled to full
extent or cannot filled at all.
28Less liquid filled into the bottles.
29Serious bubble of the bottles ( spray out)

9.2

WCZY96/84/14Y

168

Meaning of elimination symbol


meaning of the symbol
can be eliminated by operator
must be eliminated by
electrical engineer
must be eliminated by mechanical

engineer

cause of malfunction and

9.3

elimination

malfunction

cause

elimination

remarks

machine

Incorrect startup Read

does not

of driving device,

operation

run and

there must be

procedure for

driving

controlling voltage so

correct startup.

device not

cannot press urgent

work

haut button

WCZY96/84/14Y

169

Despite
correct startup, drive
device still not turns
and malfunction

Close
the protection door.

symbol light is on and


the protection door of
the driving device is
not closed.

Protection door is
closed and the
malfunction signal
light is on. magnet of
the safety switch falls
off or gets out of
control.

Tighten the
magnet and
readjust the magnet
of the magnetic
switch. If the
malfunction light is
still on, check the
electrical road.

Wrong
position of head of

Readjust it

height adjustment

according to the

pole of the filler and

picture.

crowner.

WCZY96/84/14Y

Speed of
machine
cannot be
adjusted.

170

Transducer

Press malfunction

overload.

elimination button.

Bad contact
of speed regulating

Repair, change

potential device or

or reweld.

cold solder.

Find
Overload

the cause and


eliminate

mechanical

malfunction.

Difficult

startup of

main

Wrong setting

machine

value of function

Reset functional

parameter of the

value

transducer such as
torque become
large
4

program

Assistant

contactor

controller

not

cannot

E-stop auto locked.

contacted

or


Change

contactor

or reset the E-stop.

WCZY96/84/14Y

function

24V
24V direct

Disconnect load

current stable without

and to check the

source outlet

stable pressure
power source solely

Close safety

Protection

shielding and

drive device door is not closed and protection door to


works but

safety shielding is not

guarantee enough

machine

shut off.

cap and eliminate

doesnt

malfunction of the

function.

cap tank.

Selection

switch is

adjusted to

Behind the

automatic

machine, bottles on

clean the jammed

control

the conveyor jam and

bottles

malfunction signal
light is on.

171

WCZY96/84/14Y

172


No malfunction

If all

instruction and the

signal lights are on,

machine doesnt

check signal lights

function.

control.

If

some

signal lights are off,


change them.

/
6 Bottle-stop switch

Start

doesnt have

automatic

automatic

operation.

operation/manual
operation.

Bottles are
jammed and
malfunction signal
light is on.

Bottles have fallen or


reversed, malfunction
signal light is on.

Clean
jammed bottles and
start the machine.

Take out the fallen


bottles or turn
bottles to open the
bottle-stopper.

WCZY96/84/14Y

Check compressed
air source in the

cylinder and

change the gas

Bottle

tube if necessary;

stopper doesnt open

check the outer

( in spite of

damage of the

compressed air) no

cylinder and

signal of malfunction.

change the
sealings of the
cylinder; check
whether the
bottle-stopper star
wheel is turning
flexibly and change
it if not; check
electrical device of
the magnetic
valve( choose) or
change the valve.

173

WCZY96/84/14Y

174


Speed too

Find the

fast and cannot turn

malfunction with the

on the bottle stopper.

circuit diagram.

Gap
between bottle
guiding plate and
bottle interval too
narrow.

+3
4mmReadjust the
gap. Read
operation
reference. Bottle
diameter +34mm.


Install wrong Install correct sized
7

sized spare parts.

parts. Read system


table.

Infeed spindle can not


rotate.

If the
tooth belt is loose,
tighten it; if the
tooth belt cracks,
change it. Readjust
infeed screw and
infeed star-shape
wheel.

WCZY96/84/14Y

175

unstable
bottle infeed

Infeed spindle lost


control. Free

Readjust the infeed

movement of the

spindle.

bottle is too much or


not enough.

Install wrong sized


parts or incorrect
spare parts.

Read the
system table if the
size of the installed
parts is correct;
install parts with
correct
appearance.

Bottle
conveyor belt-bottle
slide plate- height
difference between
bottle carrier plate is
not adjusted correctly.

Readjust.

WCZY96/84/14Y

176

Broken Change broken


bottle guiding units

parts of infeed
screw and bottle
guiding plate.

Too low or high of the


ring bowl.

Readjust the
height of the ring
bowl.

Unstable

bottle flow,

Incorrect

broken

installation of infeed

Read system table

bottles in

and discharge star

for correct infeed or

the infeed

wheel and guiding

discharge

and

plate.

star-shape wheel.

discharge of

the ring

bowl

Bottle guiding units

Check the bottle.

(star-shaped wheel

Readjust the bottle

and bending plate) is

guiding units if

too narrow, especially

necessary (the gap

the bending plate of

between bottles

the middle star wheel. must be enough).

WCZY96/84/14Y

Guiding
plate is worn.
Change

guiding plate.

Synchronized

adjustment of infeed

Readjust the

or discharge

adjustable

star-shape wheel and

shaft-connection.

filling valve is wrongly


adjusted.

177

WCZY96/84/14Y

Adjust
centering device for

Bottle mouth
centering device is
not flexible.

Bottle
centering ring is too
small and the bottles
are blocked.

Bottle
centering device is too
high or too low.

Bottle centering
device distorted.

Vent tube bended.

gentle movement.

+0.3mmChange
centering ring or
make the bottle
mouth largest
diameter +0.3mm.

Correctly
adjust bottle jaw
centering device
( read
maintenance for
reference.)

Adjust or
change centering
device.

Change vent tube.

178


10

WCZY96/84/14Y

Incorrect

installation of bottle

Install the guiding

guiding plate.

plate correctly.

Change

broken

Abrasion of bottle

the guiding plate.

bottles and

guiding plate.

collision

between

Incorrect position

Adjust and align

bottle cap

of

bottleneck guiding

clamper

guiding plate.

plate. Read device

of format parts.

Bottle neck guiding

Adjust or

plate is crooked and

change bottle neck

abrasive or has too

guiding plate.

and bottle
mouth
during
capping
process

179

bottle neck

large gap.

Incorrect
adjustment of height

Readjust.

of the crowner.

Incorrect
molding die of cap of
the crowner head.

Install correct cap


molding. Read
device of format
parts according to
operation
instruction.

WCZY96/84/14Y

180

Discharge star wheel,


middle star wheel and Readjust.
crowner star wheel
out of
synchronization.

Damage of
polyurethane disc on
the bottle support
seat.

Incorrect
adjustment of slide
plate and bottle
support seat.
11

Incorrect

adjustment of the

bottle-hangi

height of crowner.

Change
polyurethane disc.

Readjust the
distance between
slide plate and
bottle seat.

Readjust the
height.


ng at the

WCZY96/84/14Y

exit of the

Incorrect

crowner

installation of bottle

Correct

guiding plate.

installation of bottle

guiding plate.


Incorrect position

Adjust

of bottle neck guiding

and align bottle

plate, bottle neck

neck guiding plate

guiding plate is

or change it.

crooked or abrasive.

Change bottle cap

Abrasion of bottle cap

clamper.

clamper.

181

WCZY96/84/14Y

182

Change pressure
spring.

Rupture of
crowner head
pressure spring.

Bottle cap is not


capped tight
enough.

d=26.3+0.3
Readjust the height
of crowner; change
those whose
diameter of crowner
cap column is too
large. Diameter of
bottle mouth should
conform to
international
standard
d=26.3+0.3

12

rupture of
bottle
mouth

Sealing inside the

crown cap does not

qualified

evenly spread and is

caps can be used.

too large.

Only

crowner

WCZY96/84/14Y
GB4544-84

28.4mm

Bottle Check
mouth diameter too

bottle mouth

big.

according to

international

Crowner mould

standard. Crowner

diameter too small.

cap diameter must


not be larger than
28.4mm and
change to qualified
crowner cap.

13

Inside crowner there

Take out broken

will be broken bottle

bottle cap from

some

cap or bottle cap

bottle cap clamper.

bottles are

adhesion.

not capped

Clean

or all the

Embed the bottle

the cap tank.

bottles are

cap inside the cap

not capped.

tank.

183

WCZY96/84/14Y

Too

184

many broken bottles.


Check the bottle
guiding parts and
change them if
necessary.

Too huge load of the Check the


crowner

height adjustment
of the crowner.

14

Incorrect lubrication

Make sure that

leads to heavy

capping can

malfunction

workload of the

happen smoothly

of the

crowner.

under the crowner

crowner

cap cam.

Relubricate
and clean the rust
and tension
transmission belt.
Readjust the
crowner.
Drive
gear broken

Change damaged
gear.

WCZY96/84/14Y

185

Start

15

Incorrect height height adjustment


adjustment
of
the of the crowner

crowner.

correctly.

See

operation
specification.

height

adjustment

of
the
Check
the

Up
and
down
crowner can
electrical
device
journey
switch
is
not
be
and
find
the
connected.
finished.
malfunction
with
the circuit diagram.

Height adjustment Eliminate stick
parts are stick.
16

malfunction.

No or few Fill in
crown caps in the cap crown caps.
stirrer

WCZY96/84/14Y

No or

few

crown

caps in the

Incorrect

cap tank.

startup. See

Crown cap stirrer

operation

doesnt turn.

instruction; check
electrical circuit
and find
malfunction with
circuit diagram.

Transmission

belt of the stirrer

Tension the belt

skids.

and check if the


belt is centering or
not.

Transmission belt

Change broken

of the stirrer is

belt.

damaged.

Speed of bottle cap Adjust the


stirrer is incorrect.

speed with speed


adjustment gear.

186

WCZY96/84/14Y

Wrong revolving Revolving direction


direction of the bottle

of reversal

cap stirrer.

motor .stirrer must


operate
anticlockwise.

Readjust the gap.

Too small or too


large gap between
turntable of the
stirrer and the outer
housing.

Unmoral function
of the turntable of

Check if the

the stirrer

turntable bearing
of the stirrer is
damaged and
change broken
parts if necessary.

187

WCZY96/84/14Y

Incorrect

0.150.2Mpa

adjustment of the

correct air

pressure of the

pressure 0.15

compressed air.

0.2Mpa.

There is

foreign object in the

Take out

stirrer or distorted

foreign object or

bottle cap.

distorted bottle cap


from the stirrer.

Incorrect
installation of spring
piece used for loosen
bottle caps

Installation spring
strip correctly and
guarantee normal
function between
stirrer turntable
and outer housing

Since
the painting of the

bottle cap is stripped

Clean the cap

and accumulated on

tank every week.

the cap passageway,


bottle tank becomes
narrow.

188

WCZY96/84/14Y

Vibration device

Change damaged

damaged.

parts.

Align the

Protection plate of protection plate.


the cap turning device
distorted.

17

bottle
cap cannot

Not

0.15

enough pressure of

0.2Mpaadjust the

cap blowing.

pressure to 0.15
0.2Mpa.


Distortion of the bottle

Remove distorted

cap (there is bur or

bottle cap and

bulged position on the

change to qualified

pass in the side of the cap.


bottle tank.

bottle cap.

Uneven

connection in the

Ensure even joint

cap tank.

between protection
cover and cap
tank.

Change

Abrasion of the

guiding plate.

guiding plate at the


joint place of the cover
tank.

189


18

WCZY96/84/14Y

Crown cap
distorted.

Remove distorted
caps

Eliminate

Bottle cap

distorted bottle

cannot be

Incoordination of

cover. Adjust

sent from

connection joint

correctly the

cap tank to

between the cover

connection place.

cap clamper head clamper of the


of the

bottle cap and the cap

crowner

tank.

head

Not

0.2

enough pressure of

0.3MpaAdjust the

cap blowing.

pressure to 0.2
0.3Mpa.

Nozzle position

Adjust the position

improper.

of the nozzle.

190

WCZY96/84/14Y

191

Not 0.20.3
enough pressure of Mpa. Adjust the
cap blowing.

pressure to 0.2
0.3 Mpa

(19)

No magnet

crown cap

on the cap clamper of Put in suitable

on the bottle the crowner head

magnet and pay

mouth

attention to the

inclined

polarity.

Bottle

cap Change

clamper and crowner cap clamper and


head are worn.

crowner cap.

CO2

CO2

No supply of CO2

Open CO2

20

main switch valve.

CO2

CO2

Not all cleaning

Check the

cannot be

valves are closed.

cleaning valves
and close them.

filled in the
ring bowl.

Exhaust device open.

Close exhaust
device.

WCZY96/84/14Y

192

Filling valve not

0 Use

closed, cause may be:

selection switch to

a.

return the chunk of

Chunk of

pressurization

pressurization control

control device (0

device does not return. position)


b.
Valve-closing
control device does not
work.

Connect
valve-closing
control device to
make it work.

c.
Bearing for the
filling valve butterfly


Readjust
bearing.

not in the right position.


d.
Control ring for the
butterfly does not work.

Change or
maintain.

the

WCZY96/84/14Y

Filling

valve is leaking or

Change sealing.

damaged.

Pressure-reducing

Check why is

valve on the control not effective and


box is broken.

repair or change.
Close the

valve.

Cleaning valve is not


closed.
21
CO2


ring bowl is
filled

with

Open the
Main switch valve not valve.
open.
No
beverage in the sight Ring
glass.

bowl problem
(adjust the

CO2 but no

pressure before

beverage

the valve)

193

WCZY96/84/14Y

can be filled
in.

Membrane valve
cannot be opened.

a.

Close the cleaning


valve if not closed.
b.

0.02
0.03Mpa
Check if
the pressure value
on the pressure
controller is
correct. Actual
pressure of the
ring bowl can only
be 0.020.03Mpa
larger than the set
value to readjust
the adjusting
valve.
c.

Open the
exhaust device to
lower the pressure
of the ring bowl.
When actual value
is below the setting
value, the valve
will open.
d. 2
0.20.3Mpa
Adjust
pressure value of
table 2 to be 0.2
0.3Mpa.

194

WCZY96/84/14Y

Close

Cleaning valve is not the cleaning valve.


closed.

22

liquid level
of the ring

Cleaning valve

Close the

on the ring bowl is not

cleaning valve on

closed.

the ring bowl.

Exhaust device is

Adjust to

bowl is too

not correctly

correct position.

high.

adjusted.

Adjust

Reset

the reset device on

device on the filler

the working

does not work.

position.

195

WCZY96/84/14Y

CO2 CO2
No CO2 into
the ring bowl since the

Open the

valve is not opened.

throttle valve and


CO2 switch valve
to check the flow
meter.

CO2

CO2 pressure not

0.02

enough

0.03MpaAdjust
the pressure to be
0.020.03Mpa
higher than
beverage.

Exhaust device is

Change exhaust

damaged.

device.

Solenoid valve for

Change solenoid

exhaust device

valve.

damaged.

196

WCZY96/84/14Y

0.1MpaLower
Beverage on the
beverage source
front pipe of the
pressure to make it
membrane valve too
0.1Mpa higher
high to keep the valve
than filling
from closing.
pressure.
23

resetting

adjustment

beverage
filled into
ring bowl

Incorrect Correctly adjust


device resetting device.

Switch on all
Slide

rail

for cleaning slide rail.

cleaning is not on.

be filled in

No-contact switch of

Readjust

the bottles

the pressurization

no-contact switch

control isnt well

or change it.

but cannot

adjusted or ineffective.

197

WCZY96/84/14Y

Check

Not all the

pressurization

butterflies for the

control device and

valves are opened.

adjust air valve


butterfly if
necessary.


Selection Set
switch is not adjusted selection switch to
to

the

automatic automatic

program.

operation.

Enough air

Bottle not in alignment

supply should be

with the centering ring

ensured and to

and bottle mouth

adjust air pressure

cannot press on the

correctly. Change

filling valve sealing

lifting cylinder

possibly because of

sealing and adjust

inadequate

the height of the

compressed air

ring bowl if

pressure or bad height

necessary.

adjustment.

198

WCZY96/84/14Y

Beverage Provide
supply stops and the

enough beverage.

membrane valve is
open completely.

24

liquid level
of the ring
bowl is too

Incorrect

Turn

adjustment of

the hand wheel

exhaust float valve.

and correctly
adjust the exhaust

float.

Pressure in the ring

bowl too high.

CO2

low.

Adjust CO2

additional amount

Exhaust device broken according to


adjustment
specification.

Change damaged
parts.

Meter
25

unstable
liquid level
in ring bowl

Correctly adjust

measure mechanism the adjustor.


adjustor is not
adjusted correctly.

Exhaust device is

Change broken

damaged.

parts.

Supply of beverage

Provide normal

199

WCZY96/84/14Y

is not stable.

beverage source.

200

WCZY96/84/14Y

201

Sealing of

Change sealing.

bottle mouth centering


device is damaged.

Vacuum

valve or pressure relief


valve blocked or

leaking.

Get rid of
the cullet to check
if the pressure

26

relief guide rail and

vacuum guide rail

bottle

are correctly

injection is

installed (original

too full.

gradient).

Change

sealing.

Vent

Change vent tube.

tube too short.

Vent

tube bended.

Check infeed
device and
correctly adjust
and change vent
tube.

WCZY96/84/14Y

Valve-closing device Press


is not pressed.

valve-closing
device.

Cleaning guide rail is


not switched out.

Switch out
cleaning guide rail.

Pressure of lifting
cylinder too low.

Correctly
adjust the

Filling
valve is leaking.

pressure in lifting
cylinder.

Check if
the installation of
the filling valve is
proper and change
broken sealings.

202

WCZY96/84/14Y

Air valve

Readjust

butterfly of the filling

and fixate the

valve is not well

butterfly position.

(27)

adjusted.

Liquid level in the

Adjust

Bottle are

ring bowl is too low.

liquid level in the

not filled to

ring bowl with

the fullest

exhaust device.

extent or

cannot be

The feed opening of

Change feed

the filling valve is

opening.

broken.

Change vent tube.

filled in at all

Vent tube too long or


wrongly installed.

203

WCZY96/84/14Y

204

Filling valve is not

Actuate the filling

correctly open.

valve.

Vent

tube bended.

Check
infeed device and
correctly adjust
and change vent

tube.

Vacuum valve
and pressure relief

valve blocked or

leaking.

Get rid of
the cullet to check
if the pressure
relief guide rail and
vacuum guide rail
are correctly
installed (original
gradient).

Change

sealing.

Centering ring
sealing or bottle mouth Change sealing.
damaged.

Remove damaged
bottles.

28

liquid level
in the

WCZY96/84/14Y

Pressure inside the

Correctly

lifting cylinder is too

adjust the

low.

pressure inside the


lifting cylinder.

Bottle

mouth broken.

Check
infeed device and

bottles is
too low.

correctly adjust it.

Reset control device Correctly


is too high.

adjust reset control


device.

205

WCZY96/84/14Y

Beverage

For filling

temperature is too

temperature see

high.

adjustment
chapter.

Filling
pressure is too low.

Correctly adjust
filling pressure.

(29)

foam
spills out
(sprayed
out) from
the bottle

Bottle is Provide clean


not clean.

bottle source.

Liquid
level in the ring bowl Adjust liquid
is too low.

level with a ball


float.

Pressure

relief guide rail or

Enable

valve-closing device

pressure relief

doesnt work.

guide rail or
valve-closing
device.

Spray device

Start the

or vacuum control

spray device or

doesnt work.

vacuum control.

206

WCZY96/84/14Y

Lifting cylinder

Correctly adjust

pressure is too low.

lifting pressure.

Cleaning guide rail is

Switch out the

not switched out.

cleaning guide rail.

Vent tube is

Install correct

wrongly installed.

vent tube.

207