Professional Documents
Culture Documents
FAMIX Manual #1711+1713
FAMIX Manual #1711+1713
S. 1 Contents
S. 2 Erection and assembly
S. 3 Preparation and start-up
S. 5 Cleaning and disinfection
S. 6 Ratio controller
S. 8 CO2 Adjustment
S. 9 Alarms
S. 10 CO2 controller
S. 14 Brix and CO2 control
S. 28 Operation and alarm displays
1
Erection and assembly
It must be exactly aligned at the installation point by means of the spindles and
floor plates provided, using a spirit level.
1.) Treated water direct to the mains, inlet pressure 3 bar minimum.
4.)Air for CO2 controller, inlet pressure 6 bar, operating pressure 2.5 bar, set at
the fitted reducing valve.
Caution
Before connecting to the installation, newly laid pipes must be thoroughly rinsed
or blown through. The installation has undergone a trial run, cleaning and
rinsing at the factory. However, it is absolutely essential to rinse, clean and
disinfect it again before starting production.
2
Preparation and start-up :
The treated water is connected to the water inlet of the vacuum tank with a
minimum supply pressure of 3 bar. The vacuum tank is under 98 % vacuum.
The air is sucked out of the tank by the vacuum tank and the tank is filled with
deaerated water. The level in the tank is controlled by probes.
In the standard version the machine has a one step deaeration which achieves
a deaeration efficiency of 85 - 90 %.
To reach a greater efficiency we recommend our two step deaeration.
Now also this part of the plant is ready for production and water can be
carbonated. The machine starts if switch is in position 'Production'.
If soft drinks are produced the syrup part has to be supplied with syrup. To do
this first all water has to be drained out of the pipes and the sight glass as far a
possible.
Then allow the syrup to flow in. If a syrup supply pump is installed switch
selector switch external syrup pump to position "Hand" to do so.
3
Anyway a certain amount of water is drained by the syrup first so that the syrup
drain valve needs to be open until pure syrup arrives. Then close the drain
valve and open the vent valve. Wait until the sight glass is filled totally with
syrup and it flows out at the vent valve, then close this valve.
Take care that the syrup contains absolutely no air when it is pumped to the
plant.
Make sure that all manual valves for spray balls are closed and that the valve in
the vacuum pipe is open.
Switch the water pump and the metering pump on, and switch the external
syrup pump to automatic.
Start a product in the BMS7 TouchPanel and make sure that the correct CO2
pressure and the correct blending ratio are adjusted.
To start the mixer switch the main selector switch to position "Production". The
plant starts.
When you see syrup in the sight glass on top of the syrup pipe switch to
position "O".
Drain the first water and syrup mixture from the beverage tank.
Then switch on again and run the machine for 15 - 30 sec. before you switch
off.
Switch the sample pump on so that you can read the Brix result and take a
sample at the sample valve. The sample pump will only run if there is enough
product in the tank i.e. the minimum probe in the tank is covered.
To push all remaining water out of the pipe between the mixer and the filler the
pipe and the filler should be flooded with product. To do so open the beverage
outlet valve slowly. After the flooding close it again.
If the Brix of the sample is correct the FAMIX is switched on again and runs until
the level control switches off automatically.
4
Check if the filler is pressurized correctly, the minimum pressure on the filler
should be the beverage pressure on the FAMIX. Then open the beverage outlet
valve slowly and switch on the beverage booster pump.
When the filler vessel is filled and the inlet valve closes bottling can be started.
On low level of water, syrup or CO2 the plant switches off and the alarm is
shown on the TouchPanel.
All motors are protected by overload relays. If one relay is actuated the whole
plant stops and the alarm ís shown on the display.
In case of an alarm find out what the reason for the alarm was and push the
reset button on the overload relay and the "Quit" button on the FAMIX.
To empty the product tank wait until the booster pump stops because the low
level probe is reached. Then raise CO2 pressure 1 - 2 bar above the adjusted
pressure and push beverage tank and filler empty.
The FAMIX is suitable for all kinds of cleaning and disinfection processes :
For all types of cleaning the cleaning agents are supplied through the syrup
pipe and the swing bend at the water inlet is connected to the CIP inlet.
All tanks are sprayed and flooded so that they are totally filled.
Do this as described before and take care that all switches are in the correct
positions.
If CIP cleaning is used the CIP pump should supply minimum 20 - 30 m³/h at a
pressure of 4 bar to ensure a high flowrate. Only the CIP pump pumps the
cleaning agent. All pumps on the FAMIX are switched off but should be run from
time to time.
5
All sample and vent valves should be slightly open.
The cleaning circuit is completed by the pipe to the filler, the filler and the return
pipe to the CIP plant.
The contact time for disinfection with hot water of 85° C should be at least 30
minutes.
For disinfection with steam a pressure of 0,5 bar is enough to push through the
whole system. Please make sure that all sample, vent and flooding valves are
slightly open.
After each cleaning process the plant has to be rinsed and flooded with water
as described earlier.
The controller operates as a sequence controller with the water as master flow
W and syrup as the slave flow X.
As the water starts to flow the water flowmeter send pulses to the W input of the
controller. With these pulses the controller forms, together with the set ratio X:W
an output signal of 4 - 20 mA for the frequency inverter of the syrup metering
pump.
The syrup flow is also measured with a flowmeter which sends pulses, to the X
input of the controller.
By this means it is possible to control and monitor the adjusted ratio
continuously as the incoming pulses of water flow and syrup flow have always
to be in the adjusted set ratio.
The water and the syrup flow rate can be seen on the Touch Panel display.
To check the correct functioning of the controller you can divide the water
flowrate by the set ratio and the result should be the syrup flowrate shown.
E.g. if the water flowrate shows 300 l/min and the ratio is 1 : 5 (= 20 %) the
syrup flowrate should read 60 l/min.
6
Adjustment of the ratio at the controller
The ratio between water and syrup is adjusted in percent with two decimals in
the product memory of the Touch Panel.
When you start a product at the BMS7 TouchPanel as described later on the
ratio is automatically set from the product memory.
e.g.:
A ratio of 1:5 (1 part syrup, 5 parts water) means that 1/5 or 20 % (100/5) of the
water has to be added as syrup. So you have to adjust 20.00 % as the ratio.
The ratio 1:5.5 is adjusted as 100/5.5 = 18.18 %, and the ratio 1:4.4 as 100/4.4
= 22,72 %.
If the Brix in the syrup is correct the Brix in the beverage will be very close to
the standard with these adjustments. To adjust the ratio to the exact Brix
standard only the two decimals should be changed. A higher figure for the ratio
causes a higher Brix in the product and a lower figure a lower Brix.
For a ratio of 20.00 % and a Brix in the product of 10.00 each second decimal
will change the Brix x/- 0.005 and each first decimal +/- 0.05.
7
Mixer CO2 Adjustment
The CO2 content in the product is depending on the product temperature and
the carbonation pressure.
To find the correct setting for the carbonation pressure proceed as follows :
Read the product temperature on the CO2 controller display. Find by means of
a CO2 chart or slide rule the necessary CO2 pressure according to the desired
CO2 content. Add 0.5 - 1 bar to this pressure and adjust the result as the
carbonation pressure.
Example : Desired gas volume : 4 vol, product temperature 15°C; the CO2 chart
reads 2.7 bar so a pressure between 3.2 and 3.7 has to be adjusted.
To enter the carbonation pressure set the CO2 value on the display to a figure
that gives the desired pressure.
When the filler has been started, check the CO2 content in the bottle or can and
correct the carbonation pressure if necessary. When the filler is running at the
rated speed another sample has to be taken to check the gas volume. Then you
do the fine adjustment of the carbonation pressure :
CO2 content too low : adjust a higher pressure
CO2 content too high : adjust a lower pressure
The setting for the carbonation pressure is stored in the product memory. So
when you start the product next time the carbonation pressure will be adjusted
correctly. Be aware that the pressures are different if the product temperature
varies. For further details see also the description of the FAMIX CO2 pressure-
temperature ratio controller.
To find the exact CO2 content in the bottle please proceed as follows :
Take a bottle from the conveyor.
Turn over the bottle 2-3 times.
Place the bottle and wait until the product has calmed down again i.e. no
bubbles are moving in the bottle.
Connect the pressure tester.
Push the tester through the capsule and release the head pressure.
Shake the bottle or start an automatic tester until the pressure is not increasing
any more.
Read the pressure and measure the temperature in the bottle.
With temperature and pressure you can read the CO2 gas volume from a chart
or a slide rule.
Only as described above you are able to do an exact measurement of the CO2
volume in the bottle.
8
Alarms
Low levels of water, syrup and CO2 will switch off the plant and show a
message on the display.
In case of an alarm find out first what the reason for the alarm was and repair
the fault. Then push Quit to restart the plant. The machine will never restart
automatically.
If the same alarm comes up again immediately please do not start the plant
several times but check what the reason for the lack of water, syrup or CO2 is
and make sure that all ingredients are supplied correctly. Otherwise we cannot
quarantee a correct function of the ratio control.
If the ratio controller cannot maintain the adjusted ratio the plant will also switch
off show a corresponding message.
If the controller has switched off the plant first check the syrup supply to the
mixer.
To restart the metering pump switch can be switched off and on again to reset
the controller. This clears the memory of the controller and resets the alarm.
Then the plant can be started again. If the controller switches off again check
the syrup pump and make sure that there is absolutely no air in the syrup pipe.
For a low level alarm of beverage terminals to connect an alarm signal are
provided.
Plants with automatic Brix, CO2, or conductivity control will also give an alarm if
the product is out of the entered standards. This is only done the monitoring is
active.
With a potential free contact the bottle stopper of the filler can be activated or
the whole plant can be switched off.
General remark
9
FAMIX CO2 pressure-temperature ratio controller
1. Functional description
For the production of soft drinks the product water or the product is carbonated
with CO2 gas. To maintain a constant CO2 content in the product a precise and
quick control system is required.
The FAMIX BMS7 CO2 control system reads the carbonation pressure and the
temperature of the product and compares it with the setpoint for the CO2
content. Using a high accurate control valve the carbonation pressure is
controlled automatically and the CO2 content in the product is maintained
independent of the product temperature.
Layout drawing :
The following drawing shows the scope of supply of the FAMIX CO2 controller
comprising of the sensors, valves, and electronic control :
S7
Regler
Controller
Druck
Pressure
4 - 20 mA
CO2 24 V DC
Regelventil
Druck- Überdruckventil
Control valve
behälter Overpressure valve
Pressure
tank
Temperatur
CO2
As variations of the temperature will modify the CO2 content the carbonation
pressure is automatically controlled in relation to the temperature so that the
CO2 content remains constant.
10
So the BMS7 CO2 control system guarantees a constant CO2 carbonation
independent of temperature variations and stops and starts of the plant.
A display shows the actual pressure and temperature and also the setpoint for
the control.
From these readings a theoretical CO2 content is calculated which can be
calibrated to the result in the bottle using a correction factor.
If required a printer can be activated to print all data in a time interval of your
choice. So you will get the necessary recordings for quality control
The FAMIX CO2 control system can be used for every mixer using a pressure-
temperature depending carbonation system. It is easy to install also on older
systems.
Using the seriell data interface interface the controller can also be linked to an
operation data processing unit.
To read the carbonation pressure and the product temperature a pressure and
a temperature sensor have to be installed in the mixer.
The pressure sensor should be installed in the gas room on top of the
carbonation tank .
The temperature sensor has to be installed into the product tank or a product
pipe.
The necessary fittings to connect the sensors are supplied with them.
Please take care of the instructions supplied with the sensors and the above
installation drawing.
The CO2 control valve has to be installed into the CO2 supply. It should be as
close as possible to the carbonation point and the CO2 supply pressure to the
valve should be 10 - 15 bar.
To release high pressure from the carbonation tank the overpressure valve
should be installed in the gas head room of the tank using an existing pipe.
11
3. Wiring of the controller
All signals should be wired with shielded wire. Further details you find in the
enclosed wiring diagramme.
a) 230 V AC supply
This supply is only required if the mixer does not have a 24 V DC supply.
Please use a 3 x 1.5 mm² oilflex cable and make sure that the supply is secured
with a 6 A fuse.
In case the machine has a 24 V DC rectifier the controller can be connected
directly to this.
4. Technical data
12
5. Trouble shooting
13
FAMIX Brix and CO2 control BMS7
Start-up
Switch mains switch and control voltage on and wait until the Start display is
shown :
This display gives access to the following functions which are described in detail
later on. It shows also the product temperature and the carbonation pressure
and the CO2 setting for the carbonation pressure.
General :
The colour of a display shows its status :
Blue : Monitoring is not active
Green : Monitoring is active - no alarm
Red : Monitoring is active - alarm
Alarms are shown as text messages in the first line. To reset a message press
the Quit button after the alarm has been repaired.
14
Start Production
Touch the green Start key in the start display. The production start display
appears :
Touch the ▼-key next to the data record name line and a window will
open which shows all products stored in the product memory.
Touch the desired product. The name is shown in the data record name
line.
Touch the key with the PLC symbol to transfer the data to the PLC.
Please make sure that you always enter a data record name, even if there is
already one shown in the line.
15
Production display
After the start the production display is shown allowing the following functions :
CO2 controller: Shows the setting for the CO2 pressure. To change it touch
the figure and a numeric keyboard appears. Enter a new value and touch
return.
To keep this modification in the product memory it has to be downloaded in the
memory as described later.
Syrup cotroll.: Show the setting for the syrup ratio. To change it touch the
figure and a numeric keyboard appears. Enter a new value and touch return.
To keep this modification in the product memory it has to be downloaded in the
memory as described later.
Also this display shows all information about the product, like Brix, CO2,
temperature and carbonation pressure, and the flow of water and syrup.
You can call the graphs, bar graphs and parameters.
To calibrate Brix and CO2 results you have to touch the CO2 or Brix Act. figure
and the correction display will be shown.
16
The second page allows the following functions :
Control On/Off : This activates the monitoring of Brix and CO2. After the start
the monitoring is off i.e. the measuring results are shown but there is no alarm if
they are out off the limits.
When the values have reached the standard the monitoring can be switched on
by touching the key.
In case of an alarm it has to be switched off before you can quit the alarm.
Meter Zero : This key is used to reset the counters of the flow meters to 0.
Stop production : Stops the measurement and the start display is shown
again.
17
Correction display
To calibrate the Brix or CO2 display touch the figure and enter the result you
have measured with your quality control equipment. Then touch the Store
button. The control calculates a correction factor and changes the display
corresponding to the quality control result.
This will not influence the quality of the product but only calibrate the display !
To store this correction in the product memory call the name of the product in
the data record name line, touch the upload symbol and then store it with the
disk symbol.
18
Parameter
Alarm delay : The time the control waits before it will alarm out.
19
CO2 Parameter
Product temperature
Carbonation pressure
Hysteresis Overpressure : The allowed pressure over the carbonation pressure
before the overpressure valves opens (standard 0.1)
CO2 unit : g/l or vol.
20
Syrup Parameter
21
Bar graphs
This display can be used to observe easily the status of the measuring results.
22
Graphs
This display show a graph of the measuring results over the time.
The actual value is the yellow line. The high and low limit are shown as red
lines.
With the arrow keys you can select another time period.
23
Product memory
In the product memory is stored all data of the products. Only if the products are
stored they can be called in the production start display.
To enter a new product or modify an existing one please proceed as follows :
Upload a product
If you want to store the product which is running in production in the moment
you can use the upload function.
Call the name of the product in the data record name line, touch the upload
symbol and then store it with the disk symbol.
24
Special functions
Clean Touch : Touch this key before you clean the display with a moist tissue.
For 30 sec it will not react on touches.
PC Menu : For service purposes only. Give access to the Windows CE level of
the display.
25
Operation and alarm displays
Message Hints
Swing bend water at CIP. You want to start production but the swing
bend is not in correct position
Swing bend water not at You want to start CIP but the swing
production bend is not in correct position
Valve vacuum pipe closed The valve in the vacuum pipe is closed for
production. Open the valve
Valve vacuum pipe not closed The valve in the vacuum pipe is not closed
for CIP. Close the valve
Valve sprayball vacuum tank The valve for the sprayball vacuum tank is
closed closed for CIP. Open the valve
Valve sprayball vacuum tank The valve for the sprayball vacuum tank is
not closed not closed for production. Close the valve
Valve sprayball product tank The valve for the sprayball product tank is
closed closed for CIP. Open the valve
Valve sprayball product tank The valve for the sprayball product tank is
not closed not closed for production. Close the valve
26
Low level syrup No syrup in the sight glass.
Low level CO2 CO2 is under low limit. Switch monitoring off
raise CO2 setting and quit alarm.
High level CO2 CO2 is over high limit. Switch monitoring off
lower CO2 setting and quit alarm
Low level Brix Brix is under low limit. Switch monitoring off
raise syrup controller setting and quit alarm.
High level Brix Brix over high limit. Switch monitoring off
lower syrup controller setting and quit alarm
27