MacDonald Steel Limited HDP Deluxe DFC4 Manual
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MacDonald Steel Limited HDP Deluxe DFC4 Manual

Filler/crowner
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MacDonald Steel Limited
BREWERY SYSTEMS DIVISION
DELUXE FILLER / CROWNER
MODEL - DFC4
REV 00
1

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Summary of Contents for MacDonald Steel Limited HDP Deluxe DFC4

  • Page 1 MacDonald Steel Limited BREWERY SYSTEMS DIVISION DELUXE FILLER / CROWNER MODEL - DFC4 REV 00...

  • Page 2: Caution / Warning

    MacDonald Steel Limited BREWERY SYSTEMS DIVISION CAUTION / WARNING READ MANUAL BEFORE OPERATING MACHINE DO NOT EXCEED 50 PSI ON Co2 OR BEER LINES DO NOT EXCEED 100° F (35° C) ON Co2 OR BEER LINES DO NOT HOSE OR SPRAY THE FRONT PANEL...

  • Page 3: Operating Requirements

    MacDonald Steel Limited BREWERY SYSTEMS DIVISION FEATURES Independent stations, fills one to four bottles • Auto level detection, with adjustable fill heights • Analog pressure switch control: easy setup of vacuum draw and fobbing • Selectable number of evacuation cycles.
  • Page 4 MacDonald Steel Limited BREWERY SYSTEMS DIVISION CONTROLS POWER ON/OFF Side panel – main power to machine. Circuit breaker(s) are also located directly below the power switch. When tripped a visible red line appears on the breaker button. Also inside the machine on the terminal blocks are fuse(s) which protect the PLC outputs and fuse(s) protecting the 24 VDC power supply.
  • Page 5 MacDonald Steel Limited BREWERY SYSTEMS DIVISION HMI TOUCH DISPLAY This device located on the front panel, allows the operator to change times, starting modes, disable heads, control crowning, monitor and troubleshoot. Using the Display The display offers the operator the ability to easily access the computer (CPU) in the PLC in order to change times, starting modes, disable heads, control crowning, monitor and troubleshoot.

  • Page 6: Machine Setup

    MacDonald Steel Limited BREWERY SYSTEMS DIVISION MACHINE SETUP After unpacking the machine, the Co2 fitting, fill tubes, and drain fittings must be attached. Installing the air regulator Co2 connection REV 00...
  • Page 7 MacDonald Steel Limited BREWERY SYSTEMS DIVISION MACHINE SETUP CIP JUMPER There is a jumper hose with the machine which is used to connect the beer manifold and the Co2 line together for cleaning (CIP). The ‘tee’ fitting on the jumper has been left blank, attach an appropriate connector to it, depending on the source of your cleaning solution.
  • Page 8 MacDonald Steel Limited BREWERY SYSTEMS DIVISION MACHINE SETUP LIGHTS Light strips are 24vdc LED’s. FILL TUBES The fill tubes must be installed before operating the machine. The fill tubes are designed to reach near the bottom of the bottle when the head is lowered. If filling more than one bottle size, be sure to use the appropriate length fill tube.
  • Page 9 MacDonald Steel Limited BREWERY SYSTEMS DIVISION MACHINE SETUP GLASS BOTTLE HOLDERS The filler comes equipped with a two piece plastic base (puck) to hold glass bottles. The bottom piece can be used to hold one size bottle and the second (upper) piece will hold a smaller, second size bottle.
  • Page 10 MacDonald Steel Limited BREWERY SYSTEMS DIVISION MACHINE SETUP VENT TUBES The filling head consists of two metal tubes, one inside of the other. The inner tube is for filling product, while the outer tube is for the C02 pathway, venting pressure out of the bottle and also controls the fill height in the bottle.
  • Page 11 MacDonald Steel Limited BREWERY SYSTEMS DIVISION MACHINE SETUP It will be necessary to hold the wire connector on the vent tube while loosening the locknut on the screw. On some machines this is a knob, while other machines it is a set screw.Once the locknut is loose, back off the set screw holding the vent tube in place.
  • Page 12 MacDonald Steel Limited BREWERY SYSTEMS DIVISION MACHINE SETUP VENT FLOW CONTROLS These needle valve flow controls are located on the left hand side of the machine, one for each head. C.W. decreases the flow rate, C.C.W. increases flow. Start about ¼ turn C.C.W from fully closed.

  • Page 13: Air Flow Controls

    MacDonald Steel Limited BREWERY SYSTEMS DIVISION MACHINE SETUP AIR FLOW CONTROLS The heads, shuttles and door speeds can be affected by the air pressure on the system. There are flow controls on all cylinders that can be adjusted to control the speed of all these actions. If necessary to adjust, set the control so the action is smooth and not too fast, then lock the control using the locknut.
  • Page 14 MacDonald Steel Limited BREWERY SYSTEMS DIVISION MACHINE SETUP CROWNING HEAD REPLACEMENT The crowning head on the machine is designed for a 26mm crown. If more than one size crown is to be used, the head must be replaced. If more than one crowning head has been provided, the size of the crowning head is stamped into the side of the head.
  • Page 15 MacDonald Steel Limited BREWERY SYSTEMS DIVISION MACHINE SETUP CROWNING HEAD ADJUSTMENTS The crowning heads have a magnetic plunger enclosed in a plastic housing. This plunger is spring loaded to assist in releasing the bottle from the head after crowning. The spring tension is determined by the position of the head on the crowning cylinder rod, which is held in place by a locknut.
  • Page 16 MacDonald Steel Limited BREWERY SYSTEMS DIVISION MENU EXPLAINATIONS 1. Manual Control Fill Head Crown Head Up/Down Up/Down Shuttle Control Reed Switch’s Counter Door Control OPERATION OF MANUAL CONTROL This screen is used to manually operate the filling heads, crowners and shuttles. The door can also be manually operated.
  • Page 17 MacDonald Steel Limited BREWERY SYSTEMS DIVISION MENU EXPLAINATIONS 2. Main Menu PUSH to Reset High & Low Pressure Zero Pressure Record Pressure Measured High Off/On Switch Pressure Pressure Pressure counter pressure value Set up Pressure Head Lift calibration Pressure value...
  • Page 18 MacDonald Steel Limited BREWERY SYSTEMS DIVISION Main Menu Purge Button Each head has a "Purge" button used to manually open the Co2 valve while pressed. This is useful to push beer, foam or water out of the Co2 or vent line. The button is also used to clear a "bridge" of foam or liquid in the fill head.
  • Page 19 MacDonald Steel Limited BREWERY SYSTEMS DIVISION MENU EXPLAINATIONS 3. EZ Setup Crowner On/Off Auto Level On/Off Crowner Time Auto Level Delay Time 1-5 Purges Enable/disable head Purge Shuttle On/Off Timeout Often used for can filling. Simultaneous or Sequential Filling Quick Pressure Setup Level Off/On This button is used to turn the auto level detection off or on.
  • Page 20 MacDonald Steel Limited BREWERY SYSTEMS DIVISION Head On / Disabled This button will disable the fill head in case of mechanical or electrical problems that prevent the head from operating properly. By disabling the head the rest of the fill heads can still be used. It is not necessary to place a bottle in the head before disabling it.
  • Page 21 MacDonald Steel Limited BREWERY SYSTEMS DIVISION EZ Pressure Setup This button controls a popup menu used to measure the tank pressure of the product being filled. This in turn sets the counter pressure used during the fill cycle and controls when the beer valve is opened.

  • Page 22: Filling Mode

    MacDonald Steel Limited BREWERY SYSTEMS DIVISION 3) Use the “Manual” screen and manipulate the shuttle and head into the proper position. If you select this method be sure to exit the manual mode before trying to measure the pressure, as nothing will operate when the machine is in this mode.
  • Page 23 MacDonald Steel Limited BREWERY SYSTEMS DIVISION MENU EXPLAINATIONS 4. CIP Setup Wash Duration Wash On/Off Rinse Duration Rinse On/Off CIP MODE The filler has a “Rinse” and a “Wash” built in, pre-programmed clean-in-place (CIP) cycle. This program ensures all pathways in the machine are cleaned. It is very important that the machine be cleaned after each use.
  • Page 24 MacDonald Steel Limited BREWERY SYSTEMS DIVISION To use the RINSE CYCLE Empty the beer manifold of as much product as possible (if full), by cycling the machine. Connect a water line to the beer manifold. Open the vent flow controls fully C.C.W.
  • Page 25 MacDonald Steel Limited BREWERY SYSTEMS DIVISION MENU EXPLAINATIONS 5. Inputs & Outputs This screen can be used to see which inputs and outputs are open or closed on the PLC without • having to remove the back cover. Also shown are the Co2, Vacuum and Level set points. This information is used to determine if certain steps in the filling process have been reached.

  • Page 26: Troubleshooting - Messages

    MacDonald Steel Limited BREWERY SYSTEMS DIVISION TROUBLESHOOTING - Messages The following is a list of the messages that may appear on the main screen indicating a fault or failure to complete a fill cycle. Head Bridged A bridge occurs when liquid or foam is between the fill tube and vent tube in the filling head while the head is in the up position.

  • Page 27: Troubleshooting - Other

    MacDonald Steel Limited BREWERY SYSTEMS DIVISION Shuttle Forward Prox Fault The front proximity switch on the shuttle is not being detected. . If the machine does not start or the crowner will not operate the switch must be checked and adjusted or replaced. If the machine cycles then the timing of the shuttle is too slow and the flow control on the cylinder must be adjusted.
  • Page 28 MacDonald Steel Limited BREWERY SYSTEMS DIVISION Back view of filler showing location of valves Product Valves Vacuum Valves Valves Vent Valves REV 00...
  • Page 29 MacDonald Steel Limited BREWERY SYSTEMS DIVISION CAUTION: WEAR SAFETY GOGGLES WHILE OPERATING THIS MACHINE. HANDLE ALL CLEANING SOLUTIONS ACCORDING TO MANUFACTURER’S INSTRUCTIONS AND WEAR PROTECTIVE EQUIPMENT AS REQUIRED. NEVER PLACE HANDS OR OTHER OBJECTS INTO MACHINE WHILE DOOR IS OPERATING.

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