GB - 0300 KUTE LMTEREYTB/BOCRN DC GASES boksy VACUUMASTER Operation and Maintenance Manual «“elby for Wyeth Mexico September, 96 Revision 2 ~ Jason Moxon - Greg Norman Dec 2009 ‘nd Maintenance Manual VTable of Contents 1. INTRODUCTION 2. MACHINE DESCRIPTION AND SPECIFICATIONS. 2 2.1. Mace DescriPrion 2.2. MACHINE SPECIFICATIONS 3. MACHINE LAYOUT DRAWINGS HANDLING AND SHIPPING INFORMATION... 5, ASSEMBLY INSTRUCTIONS. 5.1 INFEED ConvEvOR. 9 Ourrrep Conveyor 10 5.3. CHAMBER Door CVLINDERS. 10 6. INSTALLATION INSTRUCTIONS. 6.1. FINAL POSITIONING AND BOLTING DOWN n 6.2. SERVICE CONNECTIONS " 6.3, ELECTRICAL CONNECTIONS, 2 7. SET-UP PROCEDURI 7.1. COMPRESSED Atk SUPPLY. B 7.2. Door CYLINDER CLEVIS B 73. DooR CYLINDER REED SWITCHES B 7.4, INFEED AND OUTFEED PUSHER SPEED. B INERT GAS INFLOW ir 7.6, CHAMBER VACUUM AND GAS PRESSURE TRANSDUCERS 4 7.7. CHAMBER VACUUM TRANSDUCERS. ry 7.8. Ait INERT Gas AND VACUUM SUPPLY PRESSURE SWITCHES 4 7.9, OVERHEAD PHOTOCELL 4 7.10. INFEED ConvevoR MoTiON DETECTOR. 15 7.11. QUTFEED CoNvEvoR MomON DETECTOR 18 7:12. VacuuM HOLD TIMER 15 7.13. TEST RUN WETHOUT CANS 6 8, SIZE CHANGE PROCEDURE. 9, OPERATING INSTRUCTIONS. 9.1, DESCRIPTION OF ConTROLS. 9.2. MAINTENANCE PUSHUTTON FUNC TIONS 35 9.3, MESSAGE DISPLAY. 2 9.4, CHANGING PRESET VALUES 48 9.5. OPERATING INSTRUCTIONS, 30 10. FAULT FINDING. 37 10.1. TROUBLE SHOOTING GUIDE. 37 10.2. REASONS WHY VACUUMASTER MAY Fall. TO OPERATE 58 11. CLEANING. 9 12. SAFETY PRECAUTIONS. 60 13. MAINTENANCE. “1 13.1, Pertonic CuEck List 6 132 RECOMMENDED LUBRICANT a So by. 38 |Figures FIGURE 4.1; DRAGGING VACUUMASTER TO FRONT OF CONTAINER. 6 FIGURE 4.2 LIFTING END OF THE VACUUMASTER WITH A FORKLIFT TRUCK 6 FIGURE 4.3: DRAGGING THE VACUUMASTER OUT OF THE CONTAINER, 6 FIGURE 44: LIFTING VACUUMASTER CLEAR OF CONTAINER USING CRANE. 7 FIGURE 4 5: MOVING VACUUMASTER CLEAR OF CONTAINER BY ROLLING ON SKATES 7 FIGURE 4,6 DANGERS INVOLVED IN MOVING VACUUMASTER 8 FIGURE 8.1: GUIDE RAIL CLEARANCE. 0 FIGURE 82: IN-LINE PUSHER SHOWING FLAT PUSHER PACKER FOR LEFT TO RIGHT INFEED. 18 FIGURE 8.3: SET PUSHER STROKE SO THAT THE NEXT ROW OF CANS 9 FIGURE 8: POSITION OF STOP COLLARS, 9 FIGURE 8.5; ADJUST REED SWITCHES IN THE DIRECTION OF THE ARROWS. 20 FIGURE 86: POSITION OF REED SWITCH FOR THE FORWARD STROKE. 2» FIGURE 8.7: THE SIDE GUIDES TO BE CHANGED ARE ON THE DOWNSTREAM 21 FIGURE 8.8: THE TRANSFER PLATE SIDE GUIDES TO BE CHANGED ARE ON FIGURE 89: FIXED END STOP ADJUSTMENT WITH FLAT PUSHERS. FIGURE 8.10: FIXED END STOP ADJUSTMENT WITH SCALLOPED PACKERS, FIGURE 8.11: ONE CAN REMAINS ON CAN STOP DURING LOADING FIGURE 8.12: ADIUSTMENTS FOR ROTATING CAN STOP. FIGURE 9.1: VACUUMASTER CONTROL PANEL FIGURE 9.2 PANEL VIEW 550 VACUUMASTER DISPLAY Appendices APPENDIX I ELECTRICAL SCHEMATICS VACUUMASTER APPENDIX Il SUPPLIER TECHNICAL INFORMATION .. APPENDIX IIL COMMISSIONING / TESTING APPENDIX IV. MECHANICAL DRAWINGS. ‘The following conventions are used throughout this manual X Warning: This symbol means that people may be injured if the procedures are not followed. A Caution: This symbol means that equipment may be damaged ifthe procedures are not followed, In the interest of continuing praduct development, Colby Packaging Systems reserves the right o change product specications without noc.INTRODUCTION *VACUUMASTER’ - Fully automatic can gassing system ‘The Vacuumaster evacuates air from a container then introduces an inert gas into the container, to prolong the shelf life of the product in the container. The Vacuumaster uses a batch operation to process the cans. During operation one chamber is loaded and unloaded simultaneously, while the other chambers undergo the evacuation and gassing cycle, The batch method of operation enables longer process cycle times. Cans are delivered to the Vacuumaster chambers by a common infeed conveyor and cans are discharged from the Vacuumaster chambers to a common outfeed conveyor. A pneumatically actuated pusher at the front of each chamber pushes rows of unprocessed cans into the chamber. These cans simultaneously push rows of processed cans through the rear door of the chamber. ‘The number of chambers is dependent upon the residual oxygen level required for the product and the throughput at which this level is to be achieved. The process cycle consists of drawing a vacuum in a chamber to the required level, maintaining the vacuum level for a user definable time and then flushing the chamber with inert gas until the pressure within the chamber is slightly above atmospheric pressure for a fixed time to ensure the replacement cycle is complete.2. MACHINE DESCRIPTION AND SPECIFICATIONS 2A. Machine Description The Vacuumaster employs a number of vacuum/ gas flushing chambers. During, the processing cycle, a chamber is sealed by pneumatically operated sliding doors which are held against the chamber with a positive force. The doors seal the chamber during both the vacuum cycle and the gas flushing cycle and are then retracted to allow loading and unloading of the chamber. Pneumatic pushers on the infeed side of the chamber are used to load cans into the machine. Pushers on the outfeed side of the machine are used to ensure the first row of unprocessed cans after a loading cycle are inside the chamber before the rear door is closed and processing commenced. A pneumatically retractable transfer plate is used to bridge the gap between the Vacuumaster conveyors and the chamber during loading and unloading, ‘The Vacuumaster is controlled by an Allen Bradley SLC 500 programmable logic controller. The operator interface is provided by a PanelView PV 550 display. All operator functions, other than chamber isolation and emergency stop, are performed at the control console, Cans enter the Vacuumaster after the can ends have been fitted at the clincher. ‘There is a gap between the can and the can end after clinching. This allows air to pass from the can and allows an inert gas to enter the can, Dimpled ends are required to produce the required gap. The rate of vacuum pull down is regulated by an orifice plate positioned in the vacuum line above the chamber. A slow rate of vacuum pull down, together with sufficient head space in the can will prevent powder from being drawn into the seam during the vacuum cycle To achieve low residual oxygen levels, it is important to maintain full vacuum on. the cans for a period of time to allow interstitial oxygen removal The gassing cycle is set to suit machine throughput, so that loading does not wait for other chambers to finish gassing. The can ends are sealed to the cans in the seamer which is located immediately downstream of the Vacuumaster. The short time period when the can is exposed. to the atmosphere is not sufficient for significant gas transfer to occur which ‘might raise residual oxygen levels.22, Machine Specifications Project h Model vE Ch ly Aut . Pusher style: Inline Vacuum pump: amps/phase Motors: ‘amps/phase Controls amps, single phase Vacuum pump: Manufacturer: Rietschle Maximum vacuum: 0.5 mbar Vacuumaster Vac. Pump Capacity _Input___ Piping Inert gas consumption (m?/min) The inert gas consumption [Chamber No of chambers figures given in the tableto {size ft _p 3 | the right reflect the "worst [I foos Jou [023 [035 case" conditions. [iT fo12Jo14 [029 [043 Consumption is dependent [iif fo.r7Jo.22|o.as [0.67 on can size (and whether [IV fog Jo.25 Joas lore ballast has been fitted for smaller cans sizes) and the processing rates for which the machine has been set but will generally be significantly lower than the these amounts, Inert gas must be clean, dry and pure. Pipe size: 25 mm (1") N.B. Set inert gas pressure to 500 kPa (5 bar). Compressed Air: 0.9 m/min of re aia 600 KPa (6b) Clean and dry. Pipe size: 25 mm (I") NB.3. MACHINE Layout DRAWINGS Project Drawing No. TitlePOS ey4. HANDLING AND SHIPPING INFORMATION 1, Use a forklift truck and heavy rope to drag the Vacuumaster to the open end of the container as shown in figure 4.1. ([f skates are available, jack up Vacuumaster and place skates under legs, then drag to open end of container) Figure 4.4: Dragging Vacuumaster to front of container, A Caution: Take care that the feet of the Vacuumaster do not dig into the ‘wooden floor of the container, as the frame may be distorted, Place forklift forks under the Vacuumaster frame. Secure the \Vacuumaster to the forklift apron (figure 4.2). Figure 4.2 Liting end of the Vacuumaster with fort truck Liftand drag Vacuumaster to position shown in figure 4.3. Figure 4.3: Dragging the Vacuumaster out of the container POS Ee3. Ifacrane is available: Attach lifting slings to the Vacuumaster in the manner shown in figure 43 below Caution: 1. Slings must pass inside conveyors, or damage will result Spacers or packers must also be used to prevent the chains damaging the top edges of the machine, Use spreader bars so that the slings are approximately vertical during lifting. There is a risk that door seals may ’be damaged if the slings force the doors hard against the chambers, Figure 4.4: Lilting Vacuumaster clear of container using crane, 4. Skates can be placed under the frame to enable the Vacuumaster to be easily moved. ry oft Viera, en Figure 4.5: Moving Vacuumaster clear of container by ring on skates5. When the Vacuumasteris in position, remove the two pieces of angle iron ‘which have been bolted to the bottom of the frame to strengthen it for transport A Caution: Do not attempt to move the machine after the angle iron pieces have been removed Figure 4.6 Dangers involved in moving Vacuumastor Do not move after transport members have been removed. In particular, do not place skates under centre set of legs.5. ASSEMBLY INSTRUCTIONS The Vacuumaster is partially stripped to allow containerisation. The pusher assemblies have to be refitted after the machine is moved into the filling room, and also the door cylinders have to be refitted:- 5. Infeed Conveyor Both conveyors are attached to the machine but the extension pieces will need to be added. The infeed conveyor is the one with pneumatically operated can stops between the chambers, 1. Lift the infeed conveyor extension onto the support leg and adjust jacking screws so that the extension is level with the rest of the conveyor. Bolt the extension to the conveyor. 2, Fit three pusher assemblies (with long pneumatic cylinders) to infeed side of conveyor. Pusher bars must be parallel with conveyor and horizontal 3, Connect air hoses to pusher cylinders. Port B on valve should be piped to rod end of eylinder so that pusher is normally withdrawn, 4. Fit reed switches (2) on each cylinder, Arrange each switch so that the cable connection end faces the Vacuumaster body. ‘The reed switch with the shorter cable should be fitted to the rod. end of the cylinder. See Size Change Procedure for adjustment instructions. 5. Connect hoses to the pneumatic cylinders for the inter-chamber can stops. Port B of the valve should connect to the rod end of the cylinder so that the stop is normally withdrawn. Refer to Size Change Procedure instructions for ean stop location, 6. Fitguide rails to conveyor. 7. Fit the can end present photoelectric sensor brackets to the infeed conveyor (if required), 8, Fit motion detector photoelectric sensor to overhead sensor brackets 9. Connect the motor power to terminals inside the electrical cabinet 27S52. Outfeed Conveyor 1 Lift the outfeed conveyor onto the support leg and adjust jacking screws. The top of the conveying belt should be 1.5 to 2mm below: the top of the wear plate on the chamber floor when bolts are tightened. Do not leave bolts tightened at this stage. Fit bolts through side brackets and into rear of conveyor. “After setting conveyor level and when can transfer is correct ~ tighten side bolts. Fit three pusher assemblies (with short pneumatic cylinders) to side of conveyor. Pusher bars must be parallel with conveyor and horizontal Fit pneumatics as per infeed conveyor instructions. Fit red switches as per infeed conveyor instructions, Fit guide rails to conveyor. Fit motion detector photoelectric sensors (2) to bracket on guide ral, near outfeed end of conveyor. ‘The photo-electric sensor is angled towards the reflector (already mounted), while the proximity sensor reflects directly off the cans, Connect the motor power to terminals inside the electrical cabinet, 5.3, Chamber Door Cylinders Place Cylinder with corresponding chamber and side. (je Chamber [No.1 Infeed Side) Mount into support brackets and tighten shoulder ull pin out of cylinder rod end clevis and attach to door bracket. Ensure all locknuts are tight.6, INSTALLATION INSTRUCTIONS 64. Final Pos ning And Bolting Down 1. Place shim packers (supplied) under Vacuumaster frame base plates to level all chambers (use a dumpy level) 2. Once the Vacuurmaster is accurately located, drill 16 mm diameter holes in the floor and fit M10 masonry anchors (supplied) 3. If the conveyors need height adjustment to suit upstream and downstream equipment, adjust jacking screws to suit. 4. Shorten and/or shim dead plates at ends of conveyors to ensure smooth transfer of cans, 5. Replace plug in top of each conveyor geared motor with vented breather plug, 6. Check oil level in geared motors and top up if necessary. See section 13, Maintenance 62. — Service Connections 1. Run the vacuum pipe to the remote vacuum pump. All joints should be Teak proof. For removable joints, use flanges rather than unions Preferred pipe size is 80 mm (3*) NB with 3" OD plain tube at the end (for connection with a short piece of flexible hose, sealed with silicone sealer and hose clamps). 2. Run the compressed air supply line in 25 mm (1°) STET and finish by welding to weld nipple supplied. The riser can be joined using a short piece of flexible hose sealed with silicone sealer and hose clamps. 3. Run the inert gas supply line in 25 mm (1°) NB pipe and finish by ‘welding to 1” weld nipple supplied. The riser can be joined using a short piece of flexible hose sealed with silicone sealer and hose clamps. Note: The Vacuumaster is supplied with air service equipment for compressed air and inert gas. Nevertheless, it is important to allow a full pressure and volume blow down prior to connection to the air and gas supply. ‘This is to clear the pipe of loose rust or scale particles, oil and excess moisture, x War Take care that the pipe being cleaned is directed away from personnel as the loose particles can reach very high velocity and cause injury63, Electrical Connections. 1 See section 23 for electrical requirements. Wiring terminations are made directly to the top of the main isolating switch terminals Vacuum pump 3 phase power wiring connection is made to terminals in the switchboard (the right most set of terminals). Cable size should be in accordance with local regulations, A controls interlock contact should be provided by the client to stop the Vacuumaster outfeed conveyor, if seamer tums off, or if any accumulation conveyor is full. If a manual seamer is used, a latching button may be connected so that the operator can turn off the conveyor ‘when he is not attending the closer. Connection is made to terminals in the switchboard (terminals numbers ) after first removing the bridging link. A controls interlock contact is provided to turnoff an automatic clincher when the Vacuumaster stops (for any reason) Ifa manaal clincher i= ‘sed, a alarm light may be connected instead so thatthe operator may cease clinching. Connection is made to terminals in the client section (terminal numbers ) ‘Terminals are available for connection of an extemal emergency stop circuit so that remote emergency stop stations can be used for Vacuumaster control (not compulsory), Connection is made to the terminals in the client section (terminal numbers ) after first removing the bridging link. Also, notification of a Vacuumaster emergency stop can be transmitted to the client's emergency stop circuit. Connections are to terminalsSet-Up PROCEDURE ra} 72. 73, 14. Compressed Ar Supply ‘The air supply isolating valve is located on the outside of the machine while the solenoid-operated upper dump valves and filter regulator unit are located in the piping section on the top of the unit. The lower dump valve is located at the bottom of the machine. The dump valves shut off the air supply and vents the machine when power is lost (e.g. when an EMERGENCY sto? pushbutton is pushed). However, air can be supplied directly to the door lift cylinders by manually operating the upper valve in the top of the unit. This allows the doors to be ‘opened for access to chambers when all power is turned oFF All pneumatic components on the Vacuumaster are suitable for use with non- lubricated air. After machine assembly, turn the air supply isolating valve fully on. Set the filter regulator unit to 550kPa. Check pressure reading on digital gauge behind door of control box. Door Cylinder Clevis Each door cylinder rod clevis is factory set, so that the door cylinders do not use their full downward stroke. When closed, the doors are forced down and inwards onto the chamber door seals by the cylinders. This allows slight positive pressurisation to be maintained in the chambers after gassing. All cylinders should be set at the same position on the clevises Door Cylinder Reed Switches ‘Two reed switches are clamped to each door cylinder to indicate to the control system that the doors are fully open or fully closed. With power turned oN, check that the LED on each reed switch illuminates at the appropriate time by manually operating the door with the override switch on the door solenoid valve. Reed switches should contact the cylinder body and be fastened securely to the clamp rail Infeed And Outfeed Pusher Speed a) The forward speed is determined by the setting of the flow controller mounted. on the cylinder. To reduce the speed, the restrictor is screwed inwards. The speed should be set so that the cans are not overpushed. The return speed should be much faster than the forward speed. b) The first forward speed of the infeed pusher is controlled through a flow control silencer located on the 3 port valve. This speed is slower than the normal pushing speed.78, 76. 1. 78, 79. Inert gas Inflow ‘The mixed gas regulator located on the inside of the machine should be set at 500 kPa. Check pressure reading on digital gauge behind the control panel door. The flow control valves are set so that maximum flow is attained without collapsing cans. If the clincher is set properly and cans collapse, then it may be necessary to adjust the flow control valve so that mixed gas flow is reduced. Mixed gas influx should normally take about 15 seconds. Chamber Vacuum and Gas Pressure Transducers ‘The gas pressure transducer on each chamber indicates to the control system that the pressure in the chamber has reached a positive pressure so that the gas solenoid valve can be closed. ‘There is no user adjustment of those transducers Chamber Vacuum Transducers The gas pressure transducers are also used to monitor the vacuum. At -95 kPa gauge, the control system senses that an adequate vacuum has been reached, at which point the Vacuum Hold time commences, The vacuum will continue to increase and, given sufficient time, will achieve the rated ultimate vacuum of the pump. Air, Inert Gas And Vacuum Supply Pressure Switches These switches warn the control system if the compressed air, mixed gas and vacuum levels in the supply piping fall below the minimum level required for correct operation of the machine. An alarm is given and the operation of the machine is stopped if the level falls below the setpoint. All switches are located behind the door of the control panel. Approximate settings are Air supply pressure switch: 350 kPa Mixed gas supply pressure switch: 200 kPa Vacuum supply pressure switch: -55 kPa Overhead Photocell Arreflex photocell is mounted on the infeed door columns at the upstream end of each chamber. It detects the presence of a stationary row of cans in front of the pusher. The sensor is fixed in a position that is suitable for all can sizes.7.40, mm 742. A half second ON-delay timer in the PLC allows the sensor to ignore moving, ‘The sensitivity should be set so that the photocell can see the top of the cans, but not the slat-top belt (about pusher height is best). Focal length of PE can be adjusted and when set should be locked in position. In addition, the sensor should cleactivate between each can, when cans are fed down the conveyor in a "back-to-back" arrangement. Use the smallest height cans for this test. Ifthe sensor does not deactivate, reduce the sensitivity. Once set, the sensitivity should not have to be adjusted for other can sizes (normally factory set). Infeed Conveyor Motion Detector The photocell (with reflector) on the upstream end of the infeed conveyor detects a build up of cans and stops further cans from leaving the clincher. A time delay in the PLC allows the sensor to ignore spaced cans. "Back-to-back" cans, whether moving or stationary, will cause the alarm. Clincher restart is automatic. Outfeed Conveyor Motion Detector The outfeed motion detector employs a proximity sensor and a photo-clectric sensor to distinguish between stationary and moving rows of “back-to-back” cans. The sensor which is aimed at the reflector detects the presence of cans (moving or stationary) The other, an inductive proximity sensor, senses the cans and distinguishes between moving and stationary cans. ‘The sensor range is critical and should be set up using the smallest diameter cans, Adjust the lock screws so that only the side of the can is sensed. The outfeed motion detector interrupts the loading cycle when a build up occurs; restart is automatic. Vacuum Hold Timer The Vacuum Hold timer is used to set the duration of the Vacuum Hold part of the process cycle, A longer Vacuum Hold time will allow a higher ultimate vacuum to be achieved (up to the limit of the pump's capacity). This will result in better residual oxygen levels, the timer should be set long enough to use all the available time between loading cycles for each chamber. Note: In a three chamber Vacuumaster the time available for processing is approximately double the loading time.743, Atypical example: Loading time 60 sec (Closing 10sec ( Bvacuating 25sec Process( Vacuum Hold 60 sec (Gassing 15 sec (Gas Hold 5 sec (Waiting ("Complete") 5 sec ‘Total Process time 120 see It is advisable to keep the Vacuum Hold time long and the Waiting time short. This will reduce the amount of gas required to maintain positive pressure in the chamber during the waiting period. If, in order to achieve a certain residual oxygen level, the Vacuum Hold time has to be increased to the point where loading has to wait for processing to finish, production upstream and downstream of the Vacuumaster will be interrupted periodically. In this case, itis advisable to slow down the filler, clincher etc. until steady production is achieved ie, the chamber will finish processing and wait for loading to commence. Test Run Without Cans Set all front pusher strokes to 150 mm ie pusher does not enter the chamber. Start the machine, Using a can-end, simulate a stationary can beneath the photocell in front of chamber I. (ie hold the can end approximately 25 mm from the photocell head). Alter a slight delay (approximately half a second) the pusher will operate - immediately remove the end. ‘The pusher will travel until the reed! switch signals that the adjustable stroke limit (ie. 150 mm) has been reached. Repeat this for the number of rows set on the row counter. The loading sequence will alternate to chamber 2 and the process cycle will commence in chamber Once all chambers have been tested with this simulated sequence, the ‘Vacuumaster will be ready for trials with clinched cans.8. SIZE CHANGE PROCEDURE ‘The following list and diagram include items which are changed, or adjusted, to suit a change of can size. For the part numbers of parts that need to be changed, refer to diagram AS00772 and Tools required 1. asetof metric Allen keys 2. setof screwdrivers, straight and Philips 3. adjustable spanner Step 1: Infeed and outfeed conveyor guide rails ‘The side guide rails are adjusted for different can diameters. ¥10-20mm A OUTFEED INFEED V3-5mm A Figure 8.1: Guide ral clearance. Procedure: Turn off the conveyor. Place several cans on the conveyors, and offset them towards the chambers 50 that the side of the cans align with the edge of the slattop belts ‘Adjust the rails to allow approximately 3 to 5 mm clearance on the infeed conveyor and 10 to 20 mm on the outfeed. Ensure cans move freely along full length on both infeed and outfeed conveyors. Cans occasionally catch on in-between chamber guides or transfer plate extensions,Stop 2: Front pusher packers For most can sizes a packer is addled to the front of the pusher. The packer may be either scalloped or flat. The flat packers are used for can sizes 154 mm and larger. PUSHER PACKER (FLAT) y 1a + 4 PUSHER EXTENSION PUSHER Figure 6.2: Insine pusher showing at pusher packer fr lef to right infeed. Procedure: The pusher packer is secured to the pusher by 4 screws. Undo screws to remove existing packer, fit new packer and replace Step 3: Font and rear pusher extensions See figure 8.2. For certain combinations of chamber size and can diameter, an extension piece is added to the pusher to lengthen it at the downstream end, Procedure: The pusher packer is secured to the pusher by 2 screws, Undo screws to remove existing packer, fit new packer and replace screws.Step 4: Front pusher stoke ‘The front pusher stroke must be adjusted so that the row of cans leaving the chamber, is pushed fully and squarely onto the outfeed conveyor, leaving the previous row with their seams with 10 mm of the edge of the slattop belt. ‘The adjustment must be after the appropriate pusher packers have been fitted (see # 82), : OUTFEED Figure 8.3: Set pusher stroke so that the next row of cans ‘is lass than 10 mm away from the sia-top belt ‘The rear pusher is set in the same way to push the cans 10 - 15 mm inside chambers, However, the setting should not need adjustment after installation. The stroke of the infeed pusher is determined by the position of stop collars situated on the pusher guide rods, Use a Spanner to loosen the nut so that the collars can be moved to the new position. Re-tighten the nut on the stop collar and confirm the setting is correct by testing with empty cans. \\_ stop COLLARS Figure 8.4: Position of stop cotars.Step: Pusher reed switches Note that when adjusting the position of a reed switch, move the pusher to the desired position and then adjust the position of the reed switches by sliding from the end toward the middle, Fix the position of the reed switch where the LED indicator comes on. Since the plunger in the pneumatic cylinder has a significant thickness, the controls will not operate correctly if the above procedure is not followed eA Ey ‘ Figure 8.5: Adjust eed switches inthe direction ofthe arrows. Only the switch nearest to the pusher requires adjustment. REED SWITCHES Figure 8.6: Position of reed switch for the forward stroke, Procedure: After the stop collars have been adjusted, press the override switch on the pusher solenoid valve, so that that the pusher is fully extended. Move the reed switch as far as possible toward the pusher and then slowly slide back until the LED comes on. Fasten securely. Confirm correct operation by manually operating the pushers with the override switches on the pusher solenoid valve, When Vacuumaster is correctly set and thouroughly tested, a chart should be set up showing the set positions for both the stops and reed switches ‘The chart should list dimensions “A” from both figures 84 and 8.6 for all can sizes being used.Step 6: Chamber side guides ‘These allow an in-line pattern to be maintained in the chamber for various can diameters. The guides on the upstream side of the chambers are fixed, whereas the downstream guide channels are packed, or removed to suit can diameter Some can sizes require spacers. Figure 8.7: The side guides to be changed are on the downstroam ‘sido ofthe chamber. Left tonight infeed shown; right to lof infeed opposite, Procedure: Unscrew, replace the chamber side guides and re-fasten, ‘Stop7: Chamber base plates Note: The chamber base plate can only be changed if the chamber side guides are removed. For can sizes 99 - 127 mm, a ribbed plate is fitted to the chamber floor to guide the cans, For larger sizes, the plate is flat Procedure: After chamber side guides have been removed, undo the screws and lift the plate out of the chamber. Note that 2 people are required to lift the plate, Insert the new plate and replace the screws.Step 8: Transfer pate side guides ‘The hinged transfer plates or dead plates, are fitted with small guide bars at each end, The guide at the downstream end of the infeed conveyor must be changed. to suit can diameter. There is a matching transfer plate side guide for the outfeed conveyor. Both should align with the chamber side guide. > Figure €.8: The transfer pate side guides to be changed are on the downstream side of the chamber. Left o ght infeed shown; right to left infeed opposite. Procedure: Replace the transfer plate side guides and re-fasten. Step®: Fixed end stop The fixed can stop at the end of the infeed conveyor must be adjusted. This adjustment should be made with side guide rails already adjusted and with the infeed conveyor running Fiat pushers Procedure: For the flat faced pusher, the trailing edge of the can which completes the row in front of the pusher, should be aligned with the chamber side guide, on the infeed side of the chamber. END STOP. Set end sto so tha he last can intheow. (ein ine th te Upstream chamber side guide Figure 6.9: Fixed end stop adjustment vith flat pushers.A Caution: Ensure that the end stop is not positioned where it will obstruct the movement of the pusher. When final set position for all can sizes is established, a ‘Sticker’, showing stop locations, is made. Affix sticker to side of conveyor, thus making can change- ‘overs quicker and simpler, as the stop location is permanantly marked. Scalloped pushers Procedure: For the scalloped pusher, the stop is set so that the cans at the centre of the chamber, line up with the centre scallop on the pusher. I, END STOP i. STO} Set end stoo so that the ‘entre can is mine wih the centre scallop of the pusher. Figure 8.40: Fixed end stop adjustment with scalloped packers. A Caution: Ensure that the end stop is not positioned where it will obstruct the movement of the pusher.‘Step 10: nter-chamber can stops ‘The rotating can stops are located on the infeed conveyor between the chambers For large can sizes it is sometimes necessary to leave one can sitting on the conveyor (in contact with the rotating can stop) during the entire loading cycle. This can acts as a stop for cans which are pushed into the chamber, Eventually it will be released and pushed into chamber I, Holding the first can in this position avoids the need to push it backwards with the can stop device. Procedure: Loosen the four bolts securing the rotating can stop to the conveyor. As with the end stop, slide the assembly along the conveyor until 1. the last can in the row is in line with the upstream chamber side guide, if using j flat pushers, or i 2. the centre can is in line with the centre scallop of a scalloped pusher. Check that both reed switches are operating correctly (by manually operating the can stop with the override switch on thecan stop Figure 8.11: One can remains on can solenoid valve) and fastened securely. eee tion and Maintenance ManCAN FLOW ‘TRAVEL LIMITER, -B Lock NUT Figure 8.12: Adjustments for rotating can stop. When Vacuumaster is correctly set and thouroughly tested, a ‘Sticker’ should be made up, showing the set positions for the stops. When final set position for all can sizes is established, a ‘Sticker’, showing stop locations, is made. AMfix sticker to side of conveyor, thus making can change- overs quicker and simpler, as the stop location is permanantly marked, Stop 11; Row counter ‘The number of rows that fit into a chamber should be entered into the PLC using the Panel View PV600 as described in section 9.4. This setting governs the number of strokes of each infeed pusher during a loading cycle The default value for the number of rows, is always set to the minimum number of rows required by the individual client. This is determined by the number of rows required by the largest can size.Can size | No. offows | No.of cans/chamber room owt mw Bap 0 10 | wa 3 ws J 10 1 on on | 6 7 m0 a2 27 se i wl ak BD 90 153 7 7 8 8|2 35 56 of 16s 6 607 Ff om a 176 6 6 7 7 fis ma wo | 5 5 6 61 2 3 3 ws |s 5 6 6] 2» 1 3 Note that if the machine is switched off, the controls Vacuum Hold Time and Number of Rows revert to default values.‘Step 12: Changes for new can height - Chamber ballast packers ‘These 100 x 50 mm bars are inserted into the chambers as required to take up some of the unused space above the cans. Their purpose is to reduce the inert ‘gas consumption when processing short or medium height cans. ‘Three arrangements are possible:- Packer Height Can Heights 100 mm. Up to 130mm, 50 mm, 130 to 180 mm No Packer 180 to 240 mm, Procedure: A large number of bars are placed on their short edge when processing short cans. A smaller number of bars laid over on their Jong edge are used for medium height cans. In the latter case, shorter support angles are used and hooked on to retaining screws, Arrange and fit the ballast packers ensuring that the packers sit wholly within the chambers. A minimum void of approximately 20 mm between cans and packers is recommended for unrestricted air/ gas flow. It may be necessary to adjust the height of the can present PE sensors.9. OPERATING INSTRUCTIONS 9.1. Description Of Controls ‘The control console provides a visual indication of the Vacuumaster's status and. an operator interface with the Vacuumaster control system. From the control console, the operator is able to perform all maintenance and operational functions as described in this manual. The console is also used to adjust the vacuum hold time and the chamber row count parameter. PARAMETERS/ALARMS: wey Figure 9.1: Vacuumaster contro pane!Aova®Five|| Vacuum Hold Time: EHD Sec Fe Number Number Of Rows: ERY Rous Figure 9.2 Panel View 850 Vacuumaster deplay TUTRICEOLES WYETH treo | Tibtboe 422 Cerradora Parada TT Gesu Vacuum Hold Time: JJ Sec z "oes" ||Mumber Of Rows Figure 9.3 New Panel View 600 Vacuumaster alsplayRESET pushbuttonlamp (blue) The RESET button lamp is used to indicate and acknowledge alarm conditions Should an alarm condition occur during the operation of the Vacuumaster, an alarm message appears on the display and the RESET lamp flashes. To acknowledge the alarm condition, the operator must push the Reser button. The alarm can only be reset if the message is currently displayed on the display module, Alarms can be either chamber alarms or general alarms. ‘The location of the fault is indicated by a flashing chamber pushbutton/ lamp in the case of a chamber fault, or by the ce. srarus/accerr pushbutton/lamp in the case of a general fault, To display an alarm on the display module, the operator must push the flashing alarm location indicator. If an alarm is present in more than one location, all relevant locations will be indicated. ‘The reser lamp indicator will also indicate that a warning is current. The lamp is constantly illuminated until either the warning is acknowledged, or the warning, condition is no longer present. ‘The restr button is also used in conjunction with the cycle pushbutton to reset the loading chamber and with a chamber pushbutton to reset the chamber sequence. To operates the lamp test function, where all lamps are illuminated, the Reser is held on for 2 seconds before the machine is started, (while the sror lamp is constantly lit. staat pushbuttonllamp (green) The starr pushbutton is used to commence the Vacuumaster operation. It should. be held on until the staxt lamp latches on. This lamp essentially indicates that the machine is cycling, If the starr lamp is on, the Vacuumaster is functioning normally, or is ready to start, If the starr lamp is flashing, then the clincher has been stopped due to line accumulation (infeed or outfeed), loss of downstream enable from the seamer or due to all chambers being selected off with the chamber isolation switch, For the Vacuumaster to operate, the CONTROLS key-switch must be in the local or remote position, ‘The stakr pushbutton will also start the vacuum pump. To inhibit the display of alarm and warning conditions that may be current on start up, a delay is incorporated in the control system to allow the machine to reach its default position, If an alarm or warning is current after the delay, then it will be displayed. Wyeth10° pushbuttonilamp (red) ‘The sror pushbutton is used to cease operation of the Vacuumaster. There are two modes of stopping the machine: 1. When the sto? pushbutton is pressed for less than 2 seconds, the infeed and outfeed conveyors are stopped, preventing the feed of cans into and out of the Vacuumaster. However, for chambers which are currently processing cans, the vacuum and gassing cycles are continued, This is used when going to lunch, so that processed ‘cans do not spoil. The lamp will flash on and off. ‘The lamp will also start flashing if a fault has developed and the controls have stopped any further operations. 2. When the sro? pushbutton is pressed for 2 seconds afterall chambers Ihave finished processing, then the controls will open all doors, lower the transfer plates and stop the machine cycle. This can be used to clear cans from the chamber at the end of the day but a preferred method of clearing cans out of the chambers is described in section 915, The lamp will be lit continuously. Note that it is not possible to stop the machine completely (je. lamp on constantly) while any chamber is processing cans (messages show COMPLETE, LOADING oF WAITING To LoaD for each chamber). ‘GenewaL staTUS pushbuttonlamp (amber) ‘This lamp is on when the alpha-numeric display is showing information relevant to all chambers, such as an Emergency Stop condition, or Low Air supply. ‘The lamp will flash if there is a General alarm/warning but the display is currently showing information for one particular chamber. To display the message and to stop the light flashing, the operator must press the INERAL STATUS pushbutton, An alarm condition cannot be reset until the message has been displayed. If more than one alarm is current, then the operator may scroll though the messages using the NExT pushbutton. The GENERAL status pushbutton has three functions for the operation of the Vacuumaster: 1. The display can show information for the Vacuumaster as a whole, for for an individual chamber, Pressing the GENERAL STATUS pushbutton, during normal operation, will display all information relevant to the general status of the Vacuumaster. If there are no general wamings/alarms, then the ‘Colby Packaging Sydney - message is displayed as a default. Australi2. The display will continuously show the Vacuum Hold Time and the Row Count, 3. To change the Vacuum Hold Time or the Row Count, the changes key switch must be in the ON position to modify the vacuum hold time. Press Fl on the display keypad and type in the new valve with the keypad, After typing the new valve press the ENTER key To Change the Row Count press 2 and follow the procedure above, Hamer pushbuttonitamps (amber) There is only one alpha-numeric display for all the chambers on the Vacuumaster. Any message shown on the display, specific to an individual chamber, refers to only one chamber. The message may be the process step in progress, or an alarm. To indicate which chamber is being referred to by the message currently on the display, one of the camex lamps will be lit, Only one catamprr lamp will be lit at any given time. ‘The pushbuttons are used to switch the display to one of the other chambers. ‘After the pushbutton is pressed, the lamp for that chamber will be it. ‘AR, MED GAS, VACUUM and MOTOR FAULT lamps (red) These lamps indicate if alarm condition is current for any of the services or motors. During normal operation, none of these lamps should be lit, If the Vacuumaster will not start, check these lamps for a possible cause, The ain indicator light will come on if the air pressure falls below the setpoint of the pressure switch. The ate alk suPPLy alarm message will appear on the display module after approximately 30 seconds, The alarm is current until the air supply is restored to normal, the light will go out. The operator must reset the alarm ‘message to continue normal operation of the Vacuumaster. The vacuu indicator light will come on if the vacuum level in the vacuum piping falls below the setpoint of the vacuum switch, The A17 VACUUM SUPPLY alarm message will appear on the display module after approximately 30 seconds. The alarm is current until the vacuum level is sufficient for normal operation of the Vacuumaster. The operator must reset the alarm message to continue normal operation of the Vacuumaster. POSS oc‘The Gas indicator light will come on ifthe gas level falls below the setpoint of the pressure switch. The a1 Gas supPLy alarm message will appear on the display moclule after approximately 30 seconds. The alarm is current until the mixed gas level is sufficient for normal operation of the Vacuumaster. ‘The operator must reset the alarm message to continue normal operation of the Vacuumaster. ‘The Morok FAULT indicator light indicates that a motor relay has tripped in the electrical cabinet. The thermal overload must be reset for normal operation to continue, Note that alarm conditions may not result in the immediate shutdown of the Vacuumaster. To avoid false alarms, the controls wait for a pre-set time before disabling the machine and displaying the alarm message, cvcte pushbutton The cycte pushbutton is used to initiate processing in the chamber that is currently loading. The operator may initiate the processing of the currently loading chamber only when the chamber is waiting for a full row of cans. The front door will close and the rear pusher will extend to push the last row of cans back into the Vacuumaster. ‘The rear door will close and the evacuation will commence. The Vacuumaster will then commence loading the next available chamber in the sequence. The CYCLE pushbutton must be pressed for 2 seconds before the initiation of the cycle function. There are two situations where the operator is required to use the cycle pushbutton to process cans manually: 1. when insufficient cans are available to complete a chamber cycle, or 2. after an operational delay, where the Vacuumaster been reset and the operator wishes to re-gas cans currently loaded in the Vacuumaster ‘The cvctx pushbutton is also used in several maintenance functions described in section 9.2,next pushbutton With the cHancts key-switch oft, the Next push button is used to scroll through alarm messages on the display module if more than one alarm/ warning is current. Contls OFF! LOCAL! REMOTE Key-switch ‘This machine can be switched "on" either locally or remotely. When the machine is switched "on', either in Local or Remote mode, the operator console is powered up and the Vacuumaster is ready to commence operation. All field devices are active and the Vacuumaster is in the powered default position, with: all doors up, front transfer plates up, rear transfer plates down, pushers are fully retracted and all inter-chamber can stops are retracted, ‘The parameters Vacuum Hold Time and Row Count are reset to their default values of 30 seconds and 8 rows respectively. ‘The machine can be switched "off" either remotely if the remote option is used, or by selecting the Remote position of the key-switch. If the remote option is not used, then all power is removed from the Vacuumaster and the Vacuumaster will return to the unpowered default position with all transfer plates down, It should be noted that any changes made to the parameters while the machine was "on", are lost when the machine is turned oFF. /\ Caution: Note that turning off the machine while the Vacuumaster is in operation, will return the machine to the unpowered default position, This is not advised during operation since a chamber may be under vacuum and the door seal may be damaged as the door iets Son‘CHANGES ON/OFF Key-switeh The cHances key-switch allows the two parameters Vacuum Hold Time and Row Count to be modified To change the Vacuum Hold Time or Row Count, you must press the function keypad button, type in the valve then press ENTER. ‘The function keys are ; FL] To change Vacuum Hold Time F6__| To change Row Count Note: changes can only be made when vacuumaster is stopped. (The red stop light is on and not flashing.) EAIERCENCY STOP pushbutfons (red) The EMERGENCY stor switches are located above the infeed and outfeed doors of the Vacuumaster. If an rencENcy stor is pressed, all power to the Vacuumaster solenoids will drop. All valves will return to their unpowered default position. This will cause the air dump valve to open and isolate the Vacuumaster pneumatically. The mixed gas supply will be removed to any chamber that is processing and all vacuum lines to the chambers will be isolated. As air is removed from the machine, any door that is up will eventually fall. ‘The pushers will remain where they are when the EMERGENCY stor is pressed The display module will show the message A21 EMERGENCY stor. To see this alarm it may be necessary to press the GEN. STATUS/ACCEPT pushbutton. To restart the Vacuumaster it is necessary to pull the emergency stop switch out and to reset the alarm message on the display module, The start pushbutton must be pressed to start operation of the machine after the EMERGENCY sToP has been used ‘The Vacuumaster will start loading the chamber that was loading when the EMERGENCY STOP Was pressed. Auto cycle is disabled during an emergency stop and it is advisable to manually cycle the full chambers to ensure the integrity of the gas flush,ADDITION TO MANUAL FOR GUARD DOORS AND SAFETY = APILZ safely relay is replacing the existing interposing relay, used to drive the ‘emergency stop circuit. The E-Stop Circuit will now have a reset button. In the event ofthe E-Stop button boing pressed, the operator must release the E-Stop and then press the E-Stop reset button, to reset the safety circu An Allen Bradley safety relay is used for a door switch safely circu. - If @ guard door is opened: = The Vacuum Control pump will not run The Panel View 600 wil display an alarm, indicating a guard door is opened = The dump valve will be de-energised +The infeed conveyor will not run = The outfeed conveyor will not run - The guard doors will automatically lock when the start button is pressed, and all guard doors are closed. - The guard door will automatically unlock when the stop button or E-Stop is pressed. = The guard door circuit has a reset button. In the event of a guard door being opened, the operator must close the guard door and then press the guard door reset button, to reset the guard door safety iret. NEW PROCEDURE EMPTYING CHAMBERS AT END OF BATCH To empty chambers manually at the end of a batch ‘© Stop vacuum master to enable doors unlocked © Open required safety doors for emptying chamber © Start vacuum master This procedure will start up the outfeed conveyors whilst the safety doors are open, enabling the operator to push out the remaining cans from chamber at the endl of a batch, ‘To continue operating after the chambers are emptied ; * Stop the vacuum master * Close doors # Reset doors to lock © Reset E-stop © Start vacuum masterEMERGENCY STOP Reset Button (blue) ‘The EMERGENCY STOP RESET button located below the new Panel view 600 mounted on the electrical cabinet. If an EMERGENCY STOP RESET is illuminated , means an EMERGENCY STOP has been activated. Release all EMERGENCY STOP PUSH BUTTONS, then reset the EMERGENCY STOP RESET button. The the button will stop illuminating once reset. ‘SAFETY DOOR LOCK Reset Button (blue) ‘The SAFETY DOOR LOCK RESET button located below the new Panel view 600 mounted on the electrical cabinet. If a SAFETY DOOR is opened / system stopped / or an EMERGENCY STOP, the button will be illuminated. Close all SAFETY DOORS, then reset the SAFETY DOOR LOCK RESET button. ‘The the button will stop illuminating once reset. NB Check all doors are locked and engaged correctly into the switch to allow a successful reset. SAFETY DOOR CYLINDERS ‘The SAFETY DOOR CYLINDERS have an cylinder brake which operates when the air supply is suddenly removed, Slow exhaust of air from the system will not operate the brakes in time, therefore it is recommended to use the stop function and turn off the PLC controls before shutting off the air supply. This will operate the dump valve first - exhausting the air from the machine rapidly. Allowing the brakes to operate straight away. Then turn off the air supply to the machine,92. CHANGER SOLATOR ONOFF switch The CHAMMER ISOLATOR switches are located above the chamber doors. When the switch is selected oN, the chamber is operational When the switch is selected or, the chamber is removed from the operating sequence. If the chamber is processing, it will continue to do so until the cycle is complete, then the doors will lift and the pushers will retract. The front transfer plates will be in the raised position and the rear transfer plate is in the lowered position, The message s11 OFF will appear on the display module if the isolated chamber is being, viewed, If the switch on the loading chamber is selected oft, then the infeed conveyor is automatically stopped and the front/rear pushers are retracted, This feature enables the operator to attend any problems that may be present on the Vacuumaster. Should the operator wish to continue the operation of the Vacuumaster without the chamber that is selected off then itis necessary to reset the loading chamber as described in section 9.2. Maintenance Pushbutton Functions ‘The following pushbutton combinations perform certain maintenance operations which should only be performed by staff with a thorough knowledge of the operations of the Vacuumaster. Note: 1. Where the CYCLE pushbutton is to be used in conjunction with any other pushbutton ensure the other pushbutton is pressed first. This prevents unwanted cycling of the loading chamber. (Chamber Vacuum Break: CHAMBER #+ c¥CLE pushbutton The Vacuum Break function is used to release the vacuum in a chamber. This is achieved by pressing the appropriate cHawmer pushbutton and the Cte pushbutton together. It may be necessary to perform a vacuum break if a machine fault occurs on a chamber which is under vacuum, or if an EMERGENCY sto? pushbutton has been pressed to interrupt the operation of the Vacuumaster. The vacuum break function cannot be initiated if either door on the chamber is not in contact with its lower reed switch, The vacuum break function should not be used on a chamber during normal operationShould it be necessary to release the vacuum in a chamber the following. sequence should be used 1. Turn the CHAMBER ISOLATOR switch to the OFF position. 2. Reset the chamber sequence (CHAMBER # + RESET pushbuttons, see below) to initialise the chamber sequence, 3, Press the CHAMBER pushbutton and then press the CYCLE pushbutton; hold both in together. Do not release the two pushbuttons until the vacuum gauge for the chamber selected reads 4. Release the CYCLE pushbutton then release the CHAMBER pushbutton 5. When the chamber is reset, it will not autocycle and it may be necessary for the operator to CYCLE the chamber to re-gas the cans contained in the chamber. This can only be performed if the chamber is in the loading condition. To avoid the Vacuumaster cycling during the maintenance function, it may be necessary to stop the infeed of cans to the machine. 6. Return the CHAMBER ISOLATOR switch to ON when the chamber is ready ‘Chamber Sequence Reset: cuawoene + Reser pushbuttons ‘The Chamber Reset function allows the operator to reset the cycle of the chamber indicated by the criamnex pushbutton/lamp. The reset function will initialise the sequence of the chamber and return it to the Waiting To Load, or Loading condition Ifa chamber is reset, the PLC controller will assume the chamber is empty of cans and will not autocyce. If there are cans in the chamber and they are left in the chamber for more than 3 minutes, the cans may be exposed to air. ‘The operator should then restart the chamber gassing cycle, using the CxCLE function. The cyctt function will only ‘work if the chamber that has been reset, is the loading chamber. If the chamber is reset and the doors do not open, then there is vacuum in the chamber and a ‘Vacuum Break function should be performed to raise the doors ManualTo reset the chamber the following sequence should be followed 1. Isolate the chamber that is to be reset, by placing the CHAMBER ISOLATOR switch in the OFF position. 2. Look at the vacuum gauge for the chamber to be reset. If the chamber is under vacuum, then it will be necessary to perform a Vacuum Break (CHAMBER # + CYCLE pushbuttons, see above) after the Reset. 3, Press the CHAMBER pushbutton for the chamber to be reset, followed by the RESET pushbutton and hold both pushbuttons together for 2 seconds, 4. Release both pushbuttons. 5. Tum the CHAMBER ISOLATOR switch to the ON position. 6, If thereis vacuum in the chamber, then the doors will not raise. This will generate several alarm conditions, The operator should then perform a Vacuum Break as described in the section above. This will release the vacuum in the chamber and allow the doors to lift. The ‘operator should then reset all the alarms current for the chamber. Resetting the loading chamber: RESET + c¥CLE pushbuttons Resetting the loading chamber is used to select a new chamber to be the loading. chamber. Regardless of which chamber is loading when the Loading Reset function is performed, the controller always looks at chamber 1 first, to see if its CHAMBER ISOLATOR switch is ON. If so, it will be the next chamber to be loaded. even if itis not currently ready. If the switch is ort, the controls will try the next chamber and so on. If there is a problem with the loading chamber the operator can isolate the chamber by turning the CHAMBER IsoLATOR switch to OFF. This will stop the infeed conveyor Should the operator wish to continue to run the Vacuumaster with the chamber isolated while rectification work is carried out it is necessary to perform a loading chamber reset and the Vacuumaster will sequence to an available chamber. The chamber that was the loading chamber will need to be cycled if the cans inside are not gassed, this can only be performed if the chamber that was the loading chamber is again the loading chamber,1, To perform a Loading Reset function the following sequence should be followed 2. Isolate the chamber which is to be taken out of sequence using the (CHAMBER ISOLATOR switch, 3, Press the restr pushbutton, followed by the CYCLE pushbutton and hold both together until a new chamber is selected for loading, 4, Release the CYCLE pushbutton and then release the RESET pushbutton, Set-up Mode to adust the pusher strokes) Set up mode allows the operator to manually cycle the front pushers on the Vacuumaster, without initiating a gassing cycle. ‘This function can be used to set, up the pusher strokes. To enter set-up mode, the operator should set the Row Count to 999 using the procedure used in section 9.4. When the Row Count is set to 999, the software performs the following operations 1. Disables the "Downstream Fault” signal 2. Allows the outfeed conveyor to run without a "Downstream Permit’ signal. 3. Stops the row counter from incrementing each time the front pusher {goes in. Disables Autocycling, Prevents the Cycle function from initiating a gassing cycle. Disables all pusher alarms. In set-up mode, the front pusher stroke for the loading chamber can be verified by blocking the Row Full PLE, for the required time to initiate a front pusher extension. This operation can be repeated indefinitely without causing the chamber to sequence. Itis important that the pushers’ forward reed switch is made at the forward limit, if not the pusher will keep trying to push forward to reach the limit as the alarms have been disabled, To test another chamber using this function it is necessary to make the chamber to be tested the loading chamber using the Reset Loading Sequence function (ciumnascx # + REST pushbuttons) described in the section above, or by using the CYCLE pushbutton to automatically select the next chamber as the loading chamber, Return the row count to the required operating value before the commencement of production.93, Message Display The message display indicates, using descriptive messages, the status of each chamber, warning messages and alarm messages. Alarm messages are preceded by at, warnings by ws and status messages by s#, where # represents the number of the alarm, waming or status message Note : Please quote At, w# or $# when requesting Colby assistance. ‘The message display also shows the Vacuum Hold Time and the Row Count Parameters, Status Messages = St COLBY PACKAGING SYONEY-AUSTRALIA - This is a default message which is displayed when there is no other information to be displayed, ‘82 cLosinG - shows that the chamber has loaded the last row of cans and is closing, the doors to start a process cycle. 59 EVACUATING - shows that the vacuum valve is open and the air in the chamber and cans is being removed but the vacuum is not yet at the desired level ‘s4 VACUUM HOLD - shows that the vacuum has reached the desired level and is being held for a period of time (Preset by the operator) to ensure that all air is, extracted from the cans ‘85 GASSING - shows that the vacuum valve has been closed and the mixed gas valve opened to complete the processing cycle. At this stage the gas level has not reached the desired level ‘86 GAS HOLD - shows that pressure has reached atmospheric pressure and the chamber is being held fractionally above the atmospheric level for a period of time to ensure no residual vacuum remains in the cans, ‘S7 COMPLETE - this signals that the processing cycle is complete with processed, cans waiting in the chamber. ‘The display may change immediately to OPENING if the chamber is the next to load or it may be displayed for some time while the chamber is waiting to be selected for loading again (and unloading of the processed cans). In this latter case the chamber will be periodically gassed to maintain the gas level above atmospheric ‘88 WAITNG TO LOAD - shows that the chamber is empty or has been returned to service after being taken out of sequence and will start loading cans once a preceding chamber has finished loading,‘89 LOADING - shows that the chamber is in the middle of loading cans from the infeed and pushing processed cans onto the outfeed, 10 OPENING - this signals that the chamber is about to start loading cans and is opening the doors. sit“ OFF“ - this message is displayed to show that the chamber is isolated and not selected for loading. The message is cleared by turning the chamber isolating switch on. This allows the chamber to load next time it is selected in the sequence. ‘Chamber Alarms = At FRONT PUSHER JAMMED (EXTENDING) - this alarm message signals that the front pusher has jammed and cannot complete its forward /extend stroke ‘AZ REAR PUSHER JAMMED (EXTENDING) - this alarm message signals that the rear pusher has jammed and cannot complete its forward /extend stroke. 3. FRONT DOOR JAMMED (CLOSING) - this alarm message signals that the front door has jammed and cannot close 'A¢ REAR DOOR JANMED (CLOSING) - this alarm message signals that the rear door has jammed and cannot close AS FRONTIREAR DOOR JAMMED (CLOSING) - this alarm message signals that both doors, have jammed and cannot close. as Not used, [AT FRONT TRANSFER PLATE JAMMED (UP) - This alarm message indicates that the front transfer plate has jammed and cannot complete it's upward stroke. AAS REAR TRANSFER PLATE JAMMED (UP) - This alarm message indicates that the rear transfer plate has jammed and cannot complete it's upward stroke. AS FRONT PUSHER JAMMED (RETRACTING) - this alarm message signals that the front pusher has jammed and cannot complete its reverse / retract stroke. MO. REAR PUSHER JAMMED (RETRACTING) - this alarm message signals that the rear pusher has jammed and cannot complete its reverse / retract stroke. ‘Att FRONT DOOR JAMMED (OPENING) - this alarm message signals that the front door has jammed and cannot open ManualAX? REAR DOOR JAMMED (OPENING) - this alarm message signals that the rear door has jammed and cannot open. [At3 FRONTIREAR OOOR JANMED (OPENING) - this alarm message signals that both doors have jammed and cannot open. ‘Aid FRONT TRANSFER PLATE JAMMED (DOWN) - This alarm message indicates that the front transfer plate has jammed and cannot complete it's downward stroke. [At REAR TRANSFER PLATE JAMMED (OWN) - This alarm message indicates that the rear transfer plate has jammed and cannot complete it’s downward stroke. Note : The above alarms can also be caused by maladjusted reed switches on the cylinders. er ral (Chamber Independent) Alarms: ‘At6 Gas supPLy - this alarm message signals that the pressure of the main gas line is low and the Vacuumaster will not start or continue to operate. ax7 vacuum supPLy - this alarm message signals that the level of vacuum in the ‘main vacuum line is not adequate and the Vacuumaster will not start or continue to operate. ‘asa AiR SUPPLY - this alarm message signals that the pressure in the main air line is low and the Vacuumaster will not operate and stops immediately for safety reasons. [Aig INFEED CONVEYOR OFF- this alarm message signals that the infeed conveyor has stopped due to the motor overload tripping, or the motor contactor failing to operate. The overload must be reset to continue feeding cans through the Vacuumaster. ‘420 OUTFEED CONVEYOR OFF- this alarm message signals that the outfeed conveyor has stopped due to the motor overload tripping, or the motor contactor failing to operate. The overload must be reset to continue feeding cans through the ‘Vacuumaster. 21 EMERGENCY STOP - this alarm message signals that an emergency stop has been pressed and the Vacuumaster has stopped. All power to field devices is off and the air is also turned off. To restart the Vacuumaster, reset the pressed EMERGENCY sto? after the fault is rectified and press the star pushbutton, ‘22 SEAMER OFF - this alarm/warning message signals that the seamer is not running and that the Vacuumaster will not allow the conveyors to operate. When the seamer starts, the Vacuumaster will start or continue to feed cans andthe message cleared. This message may be cleared by the operator at any time by pressing the reser pushbutton to acknowledge the warning, 23 Not used. ‘24 CAN STOP JAMMED - this is an alarm message indicating that one of the can stops is not operating correctly in either direction (reed switch not activated). ‘The problem should be rectified and the fault reset to continue feeding cans {A25 LATA SIN FONDO - Hard end detector missing Hard End ‘828 GUARD DOOR UNLOCKED - this is an alarm message indicates the guard door is not locked. Operator is to check each guard door, to ensure the doors are locked. ‘Chamber Warnings: Wr VacuuM FAIL this warning message signals that the chamber vacuum has not reached the set low level within a certain time (45 sec). This could be caused by either a faulty pressure transducer, a faulty door seal, a blocked vacuum pump filter or a low vacuum supply. Once the vacuum is reached, the message clears and the process cycle continues. This message may also be cleared at any time by pressing the reser pushbutton to acknowledge the warning, W2 GAS FAIL: this warning message signals that the chamber gas pressure has not reached it’s set high level within a certain time (45 sec). This could be caused by either a faulty pressure transducer or a slow gas supply. Once the pressure is, reached, the message clears and the process cycle continues. ‘This message may also be cleared at any time by pressing the riser pushbutton to acknowledge the warning, (Chamber independent warnings Ws INFEED FULL - this warning message signals that the infeed conveyor is full and the clincher has been stopped. When the infeed becomes clear again, the clincher will be restarted and the message cleared. This message may be cleared at any time by pressing the Reser pushbutton to acknowledge the warning, Wa ouTFEED FULL - this warning message signals that the outfeed conveyor is full and the loading of the Vacuumaster has stopped. When the outfeed becomes clear again, the loading of cans will continue and the message cleared. This message may be cleared at any time by pressing the RESET pushbutton to acknowledge the warning, Ws “ALL OFF - this warning message is displayed to show that all of the chambers are isolated and none may be selected for loading. The message is cleared by turning one or more of the chamber isolating switches on and pressing, the star pushbutton again.This message only appears if the operator is displaying the general status when he presses the staxr pushbutton with no CHAMBER ISOLATOR switches on. CHANGES NOT ALLOWED DURING PROCESSING. - This warning message will be displayed if the key-switch marked cHiaNcts is turned on while the conveyors are running, The message will remain as long as the key-switch is in the ON position, or until the conveyors are stopped by momentarily pressing the stop pushbutton. Parameters Status indication - ‘Vacuum Hold Time #8 seconds Number ofRows” a Rows This information displays the current settings for the vacuum hold timer and for the row counter. ‘The row counter determines the number of rows that are pushed into each chamber. The timer and counter values are common to all chambers, This information is displayed at all times. Parameter changing messages (Common for either Vacuum Hold Time or Row Count) Enter Value wae (010 999) The above message allows the operator to change the two values of Vacuum Hold Time and rows pushed. See Section 9.4 for setting instructions, ‘Additional messages - SEARCHING - This message indicates that the system is searching for more alarms. Itis usually only present for a short time after pressing either NEXT or RESET, when alarms are present, FIRST UP ALARM IN CHAMBER 1 - This message will come up on the display if the operator is looking at either chamber 2 or 3 or the general status and the first up alarm occurs in chamber 1. To view the alarm, the operator must press the CH #1 pushbutton (the lamp of which will be flashing to indicate the alarm). FIRST UP ALARM IN CHAMBER 2 - This message is similar to the above but the first up alarm has occurred in chamber 2 in this case and viewing is possible using the cH #2 pushbutton, SoFIRST UP ALARM IN CHAMBER 3 - This message is similar to the above but the first up alarm has occurred in chamber 3 in this case and viewing is possible using the cri ‘#3 pushbutton, FIRST UP ALARM WAS A GENERAL ALARM - This message is similar to the above but the first up alarm was chamber independent and in this case viewing is possible using the GEN.STATUS/ ACCEPT pushbutton. Note: First up alarms generally indicate the alarm which caused a stoppage, hence noting the first up alarm helps maintenance staff locate the cause of problems. Other alarms may be indicated subsequent to the first up alarm but are usually caused by the sequence failure resulting from the first up alarm, Wyeth Operation and Maintenance Manual94, Changing Preset Values ‘The operator has the facility to change two operational parameters. ‘These are Vacuum Hold Time and Row Count. The Vacuum hold time is the duration for which full vacuum is applied to the can during processing and the row count is the number of rows pushed into the Vacuumaster before a loading cycle is complete and processing of the cans commences. ‘The parameters can only be changed when the Vacuumaster is in the full stop position (the stop light is on constantly). Changing Vacuum Hold Time The Vacuum Hold Time is important for achieving the correct R.O. level in the can prior to seaming. The rate at which the Vacuumaster can process cans may be influenced by the Vacuumaster Hold Time. The default for the Vacuum Hold Time is 60 seconds. The default value will be current whenever the Control Console key-switch is turned orF then back oN. To alter the Vacuum Hold Time, the following procedure should be followed: 1. Ensure the machine is in the complete stop condition. If the ‘Vacuumaster is not fully stopped, the Vacuum Hold Time can not be altered. Should the operator attempt to alter the value when the \Vacuumaster is not fully stopped, a warning message will appear on the display module. To bring the Vacuumaster to a complete stop, ‘the operator must press SIOP until the light is constantly on. This can only be done if no chamber is processing cans. 2. Turn the CHANGES key-switch to the ON position. 3, Press the FI Button on the operator interface keypad. The following will appear: = Enter Value #### (010.999) ‘Type desired value on keypad then press ENTER to accept. ‘Turn the CHANGE key switch back to the OFF position. Mexico, Operation and Maintenance Manual Vacuumaster — Sop-98