Promix Operation Manual - Hermosillo

Process Technology
Promix Blending System

Operation Manual
Manual Number: MAN-PMX-7.5-07461

Model Number: Promix
Customer: Coca-Cola Company / ARCA
Serial Number: 07461
Issue: August, 2008
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Promix Blending System

Operation Manual
Document Number: MAN-PMX-7.5-07461
Issue Date: August, 2008
Customer: Coca-Cola ARCA
Location: Hermosillo, Tamaulipas, Mexico
Model Number: Promix
Serial Number: 07461
Process Technology
Copyright 2008 © KHS USA
This manual is furnished for informational and instructional use only and is subject to
changes without notice. No part of this publication may be reproduced, stored in a
retrieval system, or transmitted in any form or by any means without the prior written
permission of KHS USA.
KHS, Inc.
880 Bahcall Court

Waukesha, WI 53186
Phone: 262-797-7200
Fax: 262-797-0025
www.KHS.com
Process Technology
Table of Contents
Chapter 1: Introduction
Overview................................................................................................................................ 1-1
Blender Specifications ........................................................................................................... 1-2
Text Notes and Explanations ................................................................................................. 1-3
Warnings .........................................................................................................................1-3
Important .........................................................................................................................1-3
Electrical Information .....................................................................................................1-3
Notes ...............................................................................................................................1-3
Graphics ................................................................................................................................. 1-4
Claims .................................................................................................................................... 1-5
Chapter 2: Safety
General Information............................................................................................................... 2-1
Precautions............................................................................................................................. 2-2
Hazards .................................................................................................................................. 2-3
Spare and Wear Parts ............................................................................................................. 2-4
Disconnection Considerations ............................................................................................... 2-4
Chapter 3: Installation
Receiving ............................................................................................................................... 3-1
Field Welding ........................................................................................................................ 3-1
Transport ................................................................................................................................ 3-2
Installation ............................................................................................................................. 3-2
Accessory Parts Box .............................................................................................................. 3-3
Piping Considerations ............................................................................................................ 3-3
General Piping ................................................................................................................3-3
Water Piping ...................................................................................................................3-4
Syrup Piping/CIP Piping .................................................................................................3-4
Compressed Air Piping ...................................................................................................3-4
Electrical ................................................................................................................................ 3-5
Electrical Enclosures .......................................................................................................3-5
Control System Power ....................................................................................................3-5
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Operation Manual
Chapter 4: Machine Description

Deaerator................................................................................................................................ 4-2
Deaeration .......................................................................................................................4-2
CO2 Injection (Sparge) ...................................................................................................4-3
Pump Seal Water ............................................................................................................4-3
Water or CIP Inlet ...........................................................................................................4-4
Vacuum Pump .................................................................................................................4-4
Syrup Tank............................................................................................................................. 4-6
Blender................................................................................................................................... 4-7
Water Stream ..................................................................................................................4-7
Syrup Stream ...................................................................................................................4-7
Product Mix Pump ..........................................................................................................4-8
CO2 Injection ..................................................................................................................4-8
Product Chiller ................................................................................................................4-9
In-Line Carbonator .......................................................................................................4-10
Carbonation ...................................................................................................................4-11
Output Stage .................................................................................................................4-11
Product Buffer Tank .....................................................................................................4-11
Syrup Interface Module ................................................................................................4-12
Chapter 5: Screen Navigation and Blender Operation

Main Menu............................................................................................................................. 5-1
Main Menu Upper and Lower Sections ..........................................................................5-1
Logging In.............................................................................................................................. 5-3
Logging Out ....................................................................................................................5-4
User Accounts and Access/Security ...............................................................................5-4
Overview Screen.................................................................................................................... 5-5
Blender Screen ....................................................................................................................... 5-6
Deaerator .........................................................................................................................5-7
Syrup Interface Module ..................................................................................................5-8
Product Tank Screen .......................................................................................................5-9
Graphic Display Elements/Control Device Piping .............................................................. 5-10
Control Device Operating States ..................................................................................5-10
Flow Meters ..................................................................................................................5-11
Pressure Transmitters ....................................................................................................5-11
Tanks .............................................................................................................................5-11
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Operation Manual
Manual Operation ................................................................................................................ 5-12

Automatic Valve (AV) ..................................................................................................5-12
Flow Control Valve (FCV) ...........................................................................................5-13
Pump (P) .......................................................................................................................5-13
Recipe Screen ...................................................................................................................... 5-14
Selecting a Recipe .........................................................................................................5-14
Selecting a Container ....................................................................................................5-14
Brix and Diet Recipe Values ........................................................................................5-14
Loading and Unloading Recipes ...................................................................................5-15
Container Definition ............................................................................................................ 5-16
Containers Per Minute ..................................................................................................5-16
Containers Per Layer ....................................................................................................5-16
OZ .................................................................................................................................5-17
Layers ............................................................................................................................5-17
Blender Information............................................................................................................. 5-18
Changeover and Production Times ...............................................................................5-19
Production Rate, Product Tank Pressure ......................................................................5-20
Brix Target, Diet Ratio, CO2 Volumes, Chiller Temperature ......................................5-20
Blender Information Table ............................................................................................5-21
CIP Control .......................................................................................................................... 5-22
Utilities Screen..................................................................................................................... 5-23
Screen Clean Utility ......................................................................................................5-24
Legend Screen ...............................................................................................................5-25
Stacklight Beacon .........................................................................................................5-26
System Language Interface and Units of Measurement ...............................................5-26
Alarm History ...................................................................................................................... 5-27
Trend Screens ...................................................................................................................... 5-28
Trend Screen Information .............................................................................................5-29
Navigating Trend Screens .............................................................................................5-29
Stream Tuning...................................................................................................................... 5-30
Proportional Control .....................................................................................................5-30
Integral Control .............................................................................................................5-30
Recipe Edit........................................................................................................................... 5-31
Entering the Edit Menu .................................................................................................5-31
Forcing Screens.................................................................................................................... 5-33
Output Force Screen .....................................................................................................5-33
Input Force Screen ........................................................................................................5-34
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Analog Force Screen .....................................................................................................5-35

Start Up Adjustments Screen ............................................................................................... 5-36
Utilities Screens Reserved for KHS Use ............................................................................. 5-37
Operating the Blender: Overview ........................................................................................ 5-38
Operating Instructions ...................................................................................................5-39
Load Recipe or Start CIP ..................................................................................................... 5-39
Selecting a Recipe .........................................................................................................5-40
Start Rinse and Send Syrup ................................................................................................. 5-41
Rinse Cycle ...................................................................................................................5-41
Syrup Send ....................................................................................................................5-42
System Prime ....................................................................................................................... 5-45
Production ............................................................................................................................ 5-47
End of Run ........................................................................................................................... 5-49
Continue Here for Container Cut ..................................................................................5-50
Complete End of Run ...................................................................................................5-51
Starting a New Process ........................................................................................................ 5-52
Syrup Interface Module ....................................................................................................... 5-52
Chapter 6: Maintenance
Machine Maintenance Overview ........................................................................................... 6-1
Maintenance Schedule ........................................................................................................... 6-2
Machine Maintenance Instructions ........................................................................................ 6-5
Lines, Seals, and Gaskets ................................................................................................6-5
Pneumatics ......................................................................................................................6-5
Butterfly Valve Maintenance ..........................................................................................6-6
Butterfly Valve Rebuild ..................................................................................................6-7
Flow Control Valves .......................................................................................................6-7
Level Probes (Capacitance Type) ...................................................................................6-8
Centrifugal Pumps ..........................................................................................................6-8
Deaerator Vacuum Pump ..............................................................................................6-10
Electrical Cabinet................................................................................................................. 6-12
Operator Console Screen ..............................................................................................6-12
Programmable Logic Controller (PLC) and Associated Cards .....................................6-13
Volume Setup Points for Blender System Values ............................................................... 6-14
Syrup Room Pipe Volume (Syrup Room 1 or 2) ..........................................................6-15
Syrup Tank Quantity .....................................................................................................6-15
Level Probe Calibration ................................................................................................6-16
iv MAN-PMX-7.5-07461
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Chiller Quantity (Used with an Off-Skid Chiller) ........................................................6-18

Product Tank Quantity ..................................................................................................6-18
Filler Bowl Quantity .....................................................................................................6-19
Chapter 7: Alarms and Troubleshooting

Troubleshooting Guidelines................................................................................................... 7-1
Troubleshooting Alarm Faults ............................................................................................... 7-2
Viewing Alarms ..............................................................................................................7-2
Troubleshooting Shutdown Alarms ................................................................................7-3
Troubleshooting Warning Alarms ..................................................................................7-8
Troubleshooting Production Problems (No Fault Message)................................................ 7-10
Chapter 8: Parts Lists and Drawings

Introduction............................................................................................................................ 8-1
Deaerator Spare Parts ......................................................................................................8-4
Deaerator Rebuild Parts ..................................................................................................8-5
Syrup Inlet Spare Parts ...................................................................................................8-6
Syrup Inlet Rebuild Parts ................................................................................................8-7
Blender Spare Parts .........................................................................................................8-8
Blender Rebuild Parts .....................................................................................................8-9
Carbonation Spare Parts ................................................................................................8-10
Carbonation Rebuild Parts ............................................................................................8-11
Pneumatics Spare Parts .................................................................................................8-12
Pneumatics Rebuild Parts .............................................................................................8-13
Seal Water Spare Parts ..................................................................................................8-14
Seal Water Rebuild Parts ..............................................................................................8-15
SIM Spare Parts List .....................................................................................................8-16
SIM Available Rebuild Parts ........................................................................................8-17
Glycol Chiller Spare Parts ............................................................................................8-18
Glycol Chiller Rebuild Parts .........................................................................................8-19
Chapter 9: P&ID and Layout Drawing Supplement
Chapter 10: Electrical Schematics
MAN-PMX-7.5-07461 v
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vi MAN-PMX-7.5-07461
Operation Manual
CHAPTER 1 Introduction
1.1 — Overview
This manual contains information for the safe, efficient, and accurate use of the KHS promix
blender. Understanding and observing this information will reduce repair downtime, increase
reliability, and ensure safe operation.
Where applicable, this manual will be complemented by valid safety and environmental
regulations specific to the country where the machine is in use.
Please review Chapter 2 — Safety.
NOTE: This manual must be reviewed by all personnel responsible for the operation
and maintenance of the KHS promix blender machinery. It must be available at all
times in a known location near the machine.
Your KHS promix blender includes the following features:

• Automatic changeover, syrup chase, and CIP
• Improved accuracy through use of mass flow meters
• Blending capacity to 7,500 gallons per hour
• Intuitive system alarms
MAN-PMX-7.5-07461 1-1
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Introduction
1.2 — Blender Specifications
BLENDER SPECIFICATIONS
Nominal Capacity 7,500 gph finished product
Meter Accuracy ± 0.10% by weight (mass)
Brix Accuracy ± 0.01% Brix
CO2 Accuracy ± 0.05 volumes
CO2 Range 1.0 to 4.5 volumes
CO2 / Nitrogen Requirements 1,000 lb./hr.
Blend Ratios 4:1 to 6:1
Water Requirements 100 gpm at 50 psig for 7,500 gph
Syrup Requirements 70 gpm at 60 psig for 7,500 gph
Seal Water Requirements 1 gpm @ 20 psig
Electrical Requirements 480V / 60Hz / 150 amps
Process Connections Tri-clamp
Gasket Material EPDM
Shipping Weight 9,000 lbs.
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Operation Manual
Introduction
1.3 — Text Notes and Explanations
Throughout the manual certain tables and symbols appear:
1.3.1 — Warnings
WARNING: Warnings are accompanied by a red alert symbol, and they
!
provide information that will help prevent the possibility of injury, or
damage to the machine.
1.3.2 — Important
IMPORTANT: To alert the reader to pay careful attention, these signs
! are placed near important information. Alerts indicate that the machine
could possibly sustain damage if instructions are not followed carefully.
1.3.3 — Electrical Information
This symbol alerts the reader to important information about electrical components
or procedures involving electrical components.
1.3.4 — Notes
NOTE: Notes highlight important information that will ensure smooth machine
operation, and prevent possible injury to personnel or damage to the machine.
MAN-PMX-7.5-07461 1-3
Operation Manual
Introduction
1.4 — Graphics
Wherever possible, graphics, charts, tables, and photographs have been included to help
identify, explain, and demonstrate the components, machine areas, and procedures involved
with the operation of the promix machinery.
However, installation options and other differences exist between models. Not all of the
graphics in this manual will exactly represent the full variety of possible machine
configurations.
FIGURE 1-1. Promix (Typical)
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Introduction
1.5 — Claims
KHS is committed to continuous improvement in the development of all of its machines.

Therefore, the design, technology, and equipment are subject to modification without notice.
No claims can be made based upon the information in this manual.
MAN-PMX-7.5-07461 1-5
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Introduction
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CHAPTER 2 Safety
2.1 — General Information
The safety devices mounted on the machine by the manufacturer are only precautionary
safeguards. The ultimate responsibility for safe, accident-free operation rests with the owner
of the machine and the personnel operating and maintaining the machine. Do not attempt to
set up or operate the machinery until all safety information has been reviewed and understood.
In addition to the precautions explained in this chapter, observe safety information and
regulations from all of the following:
• Local, company, and department safety rules and codes, including all tagout/lockout
procedures
• Other KHS and vendor documentation supplied
• State and federal safety laws and guidelines
WARNING: To safeguard against injury, follow any and all company
!
tagout/lockout procedures developed for the facility, as they apply.
MAN-PMX-7.5-07461 2-1
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Safety
2.2 — Precautions
This manual is an integral component of the machinery, and must be available to properly
trained operating and maintenance personnel. Machine operators and maintenance personnel
must understand that an obligation to consistent day-to-day safety procedures is a vital part of
their job, and that all precautionary measures must be followed.
Only properly trained and authorized personnel should be allowed to work on or near the
machine components.
ALWAYS OBSERVE THE FOLLOWING:

• Be alert to the presence of others on or near the machine.
• Check the area around the machinery before any button is pushed.
• Lockout and tagout the machine in the Off position for maintenance, repair, or when-
ever it is necessary for personnel to service the machine.
• Use the appropriate personal protective equipment and wear appropriate clothing.
• Keep all operating elements — levers, grips, steps, platforms, etc. — free of dirt and
grease to prevent slipping.
• Keep the machine free of items that may obstruct or impede operation.
• Know where the Stop buttons are located in case of an emergency.
• Be attentive, during operation, to excessive vibration, unusual sounds, or anything
that may indicate problems requiring immediate action.
• Inform KHS about any change in the machinery that might affect safety.
WARNING: Operating a malfunctioning machine could cause serious
!
physical injury to operators and/or serious damage to the machine. It is
the responsibility of the owner of the machine to ensure that machine
operators and maintenance personnel have received instruction specific
to the safe operation of the machine.
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Safety
NEVER DO THE FOLLOWING:

• Never manually operate or bypass devices or components during normal production
operations unless these procedures have been specified for your machine by KHS.
• Do not lean on, climb on or under, or reach over or through the machinery while it is
running.
• Never operate the machinery with safety guards, shields, barriers, covers, alarms, or
other protective devices disconnected, removed, or bypassed.
• Do not use non-original KHS parts or accessories.
• Do not engage in horseplay or behavior that may compromise safety.
2.3 — Hazards
Machine operators and maintenance personnel must be on guard for possible dangers.
BE ALERT FOR THE FOLLOWING HAZARDS:

• For safety and hygiene purposes, observe guidelines for the proper handling and dis-
posal of oils and lubricants.
• Do not wear neckties, scarves, gloves, or loose-fitting clothing.
• Do not wear jewelry. This includes bracelets, watches, rings, or necklaces.
• Wear a hairnet, hat, or protective headgear to restrain long hair.
• The key that unlocks the switch cabinet must be entrusted only to authorized
personnel.
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Operation Manual
Safety
2.4 — Spare and Wear Parts
Spare parts and accessories not supplied by KHS have not been tested and approved by KHS.
The use of non-KHS parts and accessories could seriously damage the machine.
IMPORTANT: KHS does not accept liability for any injury to
!
personnel or damage to the machine resulting from the use of non-
original KHS parts and accessories.
For spare parts mounting, dismounting, and starting, please request a skilled KHS
representative or consult with our service department.
Only proper tools and testing/measuring equipment should be used for repair and/or
maintenance procedures.
2.5 — Disconnection Considerations
To ensure safety, before any cleaning, maintenance, or repair work, the machine
must be disconnected. To disconnect the machine, perform the following steps:
1. Stop the machine and follow tagout/lockout procedures.

2. Switch off the pneumatic equipment as follows:
• Close the shutoff valve.
• Release all spring-loaded and compressive-loaded systems. De-aerate the machine at the
operator/pneumatic unit.
3. Close all electric switch cabinet doors to protect it from water, vapor, and dust.
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Operation Manual
CHAPTER 3 Installation
3.1 — Receiving
KHS recommends that the equipment be thoroughly checked on delivery. Any damaged or
destroyed equipment should be immediately reported to KHS. This will expedite repair or
replacement if required. All freight is FOB point of origin, unless specified otherwise.
Damaged goods are the responsibility of the carrier, and claims are generally handled through
the carrier's insurance company.
3.2 — Field Welding
WARNING: Never perform any welding on any part of the system
!
while it is powered up. Serious damage to flow meters, transmitters,
level probes, and other electronic equipment can occur. Do not weld any
structural support to the frame. Please consult KHS before any welding
is performed.
If welding is necessary, disconnect the 480 VAC power, pull out all PLC cards, and pull out
the fuses in the main terminal block.
MAN-PMX-7.5-07461 3-1
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Installation
3.3 — Transport
All KHS equipment comes skid-mounted and can be moved by using a forklift rated for the
weight of the machine. Extreme care should be taken when placing the forks underneath the
skid. Under most circumstances, the center of gravity is usually in the middle of the skid.
Placing the forks underneath the frame in the center of the skid is the preferred location, but
professional judgment should be exercised at all times.
For extremely large skids, a single forklift is not sufficient. The skid will flex and possibly
damage the piping or fracture the frame welds. Unloading the skid from the truck may require
two forklifts or a professional rigging crew. To transport the skid to its final location, machine
dollies should be used.
3.4 — Installation
If any questions arise during installation with regard to placement of the equipment, please
contact a KHS engineer. Be sure to provide adequate space around the system components for
service and maintenance needs. Maintain a minimum of 36 inches around each unit for access.
Clearance above each unit should be 48 inches minimum. Consideration should also be given
to the process needs and any material handling requirements. Since the placement of the
machine will affect machine performance, we request that you consult KHS for any potential
problems. As a standard, KHS creates a suggested installation drawing for each piece of
equipment, and will recommend piping sizes for all interconnecting piping.
The floor should be able to support the weight of each machine when flooded. Any drainage
requirements should be based upon the approximate discharge rates of the unit. If applicable,
this discharge rate is specified on the drawings.
IMPORTANT: Final equipment installation must be leveled across
! frame tubing. Be sure that leveling tools and methods used satisfy
technical standards, to comply with your facility’s guidelines.
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Installation
3.5 — Accessory Parts Box
A wooden crate is typically shipped along with your system. This crate contains all
disassembled and loose parts, as well as supplemental installation and operation information.
It should be removed, checked, and secured before and during installation to avoid lost
accessories. A complete packing slip will accompany the accessory parts box. Verify that all
items noted on the packing slip are included within the shipment. Any discrepancies between
the list and the actual contents should be reported to KHS immediately.
3.6 — Piping Considerations
For more specific information, refer to the P&IDs and piping drawings in this manual. The
piping contractor should have advance notice of the proposed equipment installation to assure
that tie-in points and existing utilities are adequate.
3.6.1 — General Piping
Ingredient and utility piping flow rates are identified on the P&IDs. A rectangular box
describes the service, flow rate, pressure, and line size required. It will also describe where the
piping is coming from or going to.
Piping between multiple skids is normally described with a flow arrow box. The flow box
describes the service, flow rate, pressure, and line size required. It will also describe where the
piping is coming from or going to.
Above the boxes or within, there is normally a note labeled “customer piped” at all points
where the contractor is required to connect piping. Any piping that is pre-fabricated at KHS is
labeled “pre-piped”.
MAN-PMX-7.5-07461 3-3
Operation Manual
Installation
3.6.2 — Water Piping
The customer is responsible for connecting a water source that will supply a minimum of 45-
psig and a maximum of 65-psig continuous water pressure at the flow rates specified. It is
essential that the blender and associated equipment receive stable water pressure. Varying
water pressure decreases the performance of the blender dramatically, and can lead to water
hammer and equipment failure. Spring or air loaded pressure regulators and/or pressure relief
valves should be installed by the customer if this condition becomes apparent. KHS does not
provide these devices as a standard.
If pre-chilled water will be used, the piping should be fully insulated to prevent condensation
and help maintain consistent water supply temperatures. KHS does not provide insulation.
This must be provided by the customer.
3.6.3 — Syrup Piping/CIP Piping
It is very important to take adequate measures to provide the necessary CIP circuits for the
syrup system. CIP pipeline velocities, pump CIP capabilities, and tank CIP flow rate
requirements are all very important factors, and should not be overlooked. If requested, KHS
can recommend pumps, line sizes, and pipeline circuit layouts that are suitable for the
appropriate process and cleaning requirements. Whether or not KHS designs this aspect of the
project, please notify KHS of the selections made.
3.6.4 — Compressed Air Piping
The promix uses compressed air for the pneumatics system and line-blow purposes. The
customer is responsible for supplying compressed air at 85 psig minimum to 100 psig
maximum at 70o F to 90o F. The compressed air supplied should be clean and dry. A pressure
regulator inside the pneumatics cabinet of the blender will regulate the pressure as needed for
controls. A compressed air filter, mounted at the blender, is shipped standard with all
equipment requiring compressed air.
WARNING: Do not support any field piping from the blender piping.
!
Ensure that all field piping is self-supported.
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Installation
3.7 — Electrical
For more information, refer to the layout schematic in the manual. The electrical contractor
should have advance notice of the proposed equipment installation to ensure that power
facilities are adequate.
3.7.1 — Electrical Enclosures
The electrical system is enclosed to protect electrical components from moisture

and dirt. Avoid making unnecessary holes in the enclosure. Holes in the roof of the
cabinet (other than those installed at the factory) are not recommended.
Do not make any holes over or near the PLC processor rack. A leak in this area could cause
serious damage.
3.7.2 — Control System Power
The customer is responsible for supplying the required control power. Operator consoles
provided with an un-interruptible power system (UPS) must be supplied by a separate source.
The customer is responsible for materials and labor required to interconnect all independent
system components in accordance with KHS electrical diagrams.
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3-6 MAN-PMX-7.5-07461
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CHAPTER 4 Machine Description
The promix is a precision multi-stream continuous blend process system combining water
deaeration, meter-based blending, and carbonation into one comprehensive processing unit.
The meter-based carbonation unit automatically adjusts blend and carbonation rates to meet
production demand. The carbonator meters by weight, rather than by volume, enabling the
system to operate in direct proportion to product flow. Principal components of the promix
blend system are shown below.
Carbonation/ Syrup Tank Deaerator Tank

Product Buffer
Tank
P200 Syrup
P1100 Mix P2 H20

Pump Discharge
P1101 P1 H20
Inline Recirculation
Carbonator
Booster
P3 Vacuum
P2400 CIP
Booster
FIGURE 4-1. Machine Overview
MAN-PMX-7.5-07461 4-1
Operation Manual
Machine Description
4.1 — Deaerator
The promix deaeration system

consists of the following Water/CIP Inlet
components:
Deaerator
• Water and CIP inlet Tank
valves
• Compartmented deaera- Seal Water Heat
tion tank Exchanger
• Vacuum, recirculation,
and outfeed pumps
• Associated piping, con- Water Separator
trols, and valves
P3 Vacuum
P1 H20
Recirculation
P2 H20
Discharge
FIGURE 4-2. Deaerator Circuit
4.1.1 — Deaeration
The deaerator uses two-stage vacuum diffusion combined with CO2 injection, and is capable
of achieving dissolved oxygen contents of less than 0.5 ppm in the final process water.
Water is sprayed through a diffusion tube into the lower chamber of the deaeration tank. The
vacuum pump removes trapped air from the water. The recirculation pump returns water to
the upper tank compartment for a second deaeration stage. Deaerated water is pumped from
the upper tank downstream, as needed.
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Machine Description
4.1.2 — CO2 Injection (Sparge)

MV-4 Needle Valve
The deaeration process is aided by Adjustment Knob
the injection of CO2 as water enters
the upper tank compartment. CO2
injection normally turns on and off
with the vacuum pump.
The flow indicator should be set

between 4 and 6 scfm, through
needle valve MV4.
FIGURE 4-3. CO2 Stream
4.1.3 — Pump Seal Water
The pumps require seal water to keep the seals cool, and to create the vacuum seal on the
vacuum pump. An integrated tube heat exchanger cools the seal water supply to the vacuum
pump. If flow switch FS-1 indicates low seal water flow, a shut-down alarm will sound to
prevent damage to the pump seals.
Seal Water Heat

Exchanger
Flow Switch FS-1
FIGURE 4-4. Pump Seal Water Circuit and Flow Switch
MAN-PMX-7.5-07461 4-3
Operation Manual
Machine Description
4.1.4 — Water or CIP Inlet
The deaerator tank maintains a

level in the bottom section
using a level probe LT1. 100
percent full scale on the probe
is referenced at the bottom of
the hole in the side of the tank
to which the probe is mounted. FCV-1
The tank level is then
controlled by opening or AV-12
closing the inlet flow control
valve FCV1 based on the level
CIP Inlet
reading from the probe. An
operation range between 25
percent and 50 percent of the
AV-11
level is normal. This range will
keep the holes on the diffuser
inside the tank from being LT-1
covered by liquid. The inlet
FCV1 will be 100 percent Water Inlet
open at 25 percent level or
lower and 0 percent open at 50
percent or higher level.
FIGURE 4-5. Water/CIP Inlet
4.1.5 — Vacuum Pump
The vacuum pump uses water to form the liquid seal needed to draw a vacuum. Seal water is
supplied from the process water line, and is passed through the seals of each centrifugal pump.
It then ends up being used as the sealing water for the vacuum pump. The flow through the
pumps is approximately 0.5 gallons per minute. The vacuum pump itself needs 3 to 4 gallons
per minute to maintain its seal. Because of this, the water exhausted from the pump is pushed
into a water separator that is attached to the pump's output. Water from the separator is pulled
through a heat exchanger and back to the inlet of the vacuum pump. The heat exchanger
reduces the temperature of the water, which gets heated by the pumps. If the seal water to the
pump exceeds 85° F, the vacuum created by the pump will decrease.
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Machine Description
H20 Separator
P3 Vacuum
Pump
FIGURE 4-6. Vacuum Pump
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Machine Description
4.2 — Syrup Tank
The syrup tank is used to store a ready supply of syrup at the blender, and to aid in container
or syrup cuts. It also allows for better syrup Brix on start up.
Syrup tank level is maintained during production within a 10 gallon range. This level is based
upon how much syrup is needed at the end of run to use up all of the containers between the
filler and the depalletizer. A pump at the outlet of the tank is used to supply the syrup stream
on the blender.
Level Probe LT-200
AV-212
Syrup/CIP Inlet
AV-211
AV-210
AV-215
AV-213
P200 Syrup Pump
FIGURE 4-7. Syrup Tank
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Machine Description
4.3 — Blender
4.3.1 — Water Stream
Water is pumped from the deaerator directly to the water stream, which is metered by a mass
flow meter FT-100. The flow through the water stream is based on how far open FCV1100 is.
Mass Flow
Meter FT-100
FIGURE 4-8. Water Stream
4.3.2 — Syrup Stream

FCV-200
Syrup from the syrup tank
enters the syrup stream piping,
and is measured for flow and
density at FT-200. Flow
control valve FCV-200
modulates as necessary to
maintain syrup flow at the
calculated setpoint. The
setpoint of the syrup stream is Mass Flow
Meter FT-200
based upon the water stream
flow rate. This is called a
master/slave control strategy.
As the water stream flow rate
changes, the syrup stream flow
rate will change to match it.
FIGURE 4-9. Syrup Stream
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Machine Description
4.3.3 — Product Mix Pump
The blended product flows P1100 Mix

through the product mix, or as Pump
it may also be referred to, the
product boost pump.
This pump raises the product’s

pressure high enough to
carbonate it efficiently in the
small carbonation loop.
FIGURE 4-10. Product Mix Pump
4.3.4 — CO2 Injection
The first stage of the carbonation process is to inject CO2 into the product stream through a
specialized injection/dispersion nozzle. The setpoint is calculated using the product flow rate
and the CO2 recipe value in volumes. Flow control valve FCV-300 modulates as necessary to
maintain the setpoint.
Mass Flow Meter

FT-300
Flow Control
Valve FCV-300
FIGURE 4-11. CO2 Injection
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Machine Description
4.3.5 — Product Chiller
The product chiller uses a plate and frame design. The plate and frame heat exchanger consists
of a series of thin, corrugated plates that are gasketed, welded together (or any combination of
these), or brazed together depending on application. The plates are then compressed together
in a rigid frame to create an arrangement of parallel flow channels. One fluid travels in the odd
numbered channels, while the other travels in the even channels, transferring heat from the
product to the glycol being circulated on one side of the channels.
The promix will monitor the product temperature at the product return from the glycol chiller.
Then it will control the glycol flow control valve FCV-5000 to allow more or less glycol to
flow through the heat exchanger if the temperature is different than the target temperature.
The glycol flow through the heat exchanger will increase if the product is above the target
temperature, and it will decrease if the temperature is below the target.
The bypass valve AV-5000

will remain closed during
normal operation, and it will
open when the glycol flow
control valve is closed. As a
precautionary step, the glycol Flow Control
pressure through the heat Valve FCV-5000
exchanger should be lower
than the pressure of the
product flowing through the
same heat exchanger. This is
in case of leakage, so that the
Bypass Valve
product flows into the glycol AV-5000
stream and not the opposite.
FIGURE 4-12. Glycol Chiller
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Machine Description
4.3.6 — In-Line Carbonator
The in-line carbonator is a

pump-driven, continuous-flow
system. It takes chilled,
blended product, pressurizes it,
and then injects a measured CO2
quantity of carbon dioxide into Injection
it before sending the completed
beverage to the product tank
for storage.
The ILC system encompasses

several different processes,
including the following:
• Pressurization
• CO2 injection
• Static mixing
FIGURE 4-13. In-Line Carbonator
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Machine Description
4.3.7 — Carbonation
Dual in-line static mixers PT-2400
FE1101 facilitate the absorption
of CO2 into the product. A mix Dual In-line
pump is added to help the Static Mixers
Inside Pipes
absorption CO2 at low blender
speeds.
4.3.8 — Output Stage

FCV1100 modulates based upon
two factors: the flow rate
setpoint, entered on the
Information screen, and the level
in the product tank. The flow
rate setpoint is displayed in
containers per minute. The
promix takes this value and
multiplies it by the volume per
container to calculate the
blender’s speed in gallons per
minute. The second item is the
product tank level. Once the
level reaches 230 gallons, the
blender will start to slow to
compensate for a reduced
demand from the filler. The
slowest the blender will flow is FCV-1100 CO2 Injection
30 percent of the maximum flow
rate for which it was sold.
FIGURE 4-14. Carbonation
4.3.9 — Product Buffer Tank

The product tank's CO2 pressure is controlled within a 3 psi range. A pressure transducer
PT2400 is used to monitor the tank pressure, and two plug valves are used to add or blow off
pressure as needed.
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Machine Description
4.3.10 — Syrup Interface Module

The Syrup Interface Module (SIM), has two main functions, as follows:
1. It reduces delay and production downtime by automating changeover from one batch tank
to another.
2. Production efficiency is increased. Using push water instead of blow down to move syrup
to the promix reduces the amount of wasted syrup.
The operator can use the SIM screen in the HMI software to open one of the two batch tank
valves AV-222 or AV-224, to select syrup. See Figure 4-15 for batch tank valve locations.
NOTE: Configuration of the SIM may vary slightly, according to the installation
requirements at your facility.
Batch Tank Valves
FIGURE 4-15. SIM
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CHAPTER 5 Screen Navigation and Blender

Operation
5.1 — Main Menu
The Main Menu is a navigational interface that always appears at the top of the touchscreen.
The Main Menu provides information updates and displays, but it is primarily designed to be
the operator’s central input point, providing access to all other software functions.
5.1.1 — Main Menu Upper and Lower Sections
The Main Menu screen is divided into two parts:

1. The top part of the Main Menu (below) gives the operator input for the login/access func-
tion, key operation screens, the specific recipe that is currently loaded, and – during pro-
duction – the container size and container cut information.
• Pressing the Access button allows the user to log in. Each session must be started by log-
ging in.
• Pressing the Overview, Recipe, Info, CIP, Utilities, and Alarm buttons on the Main Menu
will display those screens.
FIGURE 5-1. Upper Half of the Main Menu
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Screen Navigation and Blender Operation
2. The lower section of the Main Menu screen is used for system control. The left side of the
Main Menu display contains the Start and Stop buttons for the following:
• Syrup Send
• System Prime
• Production
• Final End of Run
FIGURE 5-2. Lower Half of the Main Menu
3. Blender sequence operations are also accessible through the lower half of the Main Menu.
The currently enabled blender sequence position (POS) is displayed just to the right of the
Start or Stop buttons.
• POS is the sequencer current step in the process.
• 0 is the “home step” where no operation is being performed.
4. A brief description of the current blender function being performed is displayed under
Description. Or, as in the view above, if no operation is selected, the description provides
information on starting an operation sequence.
5. The lower right-hand portion of the Main Menu is used for starting or stopping the
Blender and Filler Rinse, End of Run, and Container Cut functions.
• The Rinse, Start or Stop buttons, which are displayed during the beginning of the
blender's startup process, initiate Blender and Filler Rinse functions.
• The End of Run button, which is displayed after
blender production has commenced, is used to start
the final run out process.
• Other controls are displayed after blender startup, as
needed.
FIGURE 5-3. Blender Control Buttons
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5.2 — Logging In
A user name and password are required in order to use the blender. To log in to the system:
1. Press the Access button at the top right corner of the Main Menu.
2. The Login window appears:
3. Press User to call up the Alphanumeric keypad:
4. Type in your user name and press Enter .
5. Press Password and type your password. Press Enter .
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6. Press Enter on the Login window to log in to the system.
7. Press ESC to exit the Login window without logging in.
5.2.1 — Logging Out
1. Press the Exit: Default button on the Main Menu.
2. Always remember to log out of the system when finished. This not only prevents unautho-
rized access to the equipment, it may also help to identify production variables or incon-
sistencies that may be related to individual operators.
5.2.2 — User Accounts and Access/Security
Contact KHS to establish new user accounts, make changes to existing accounts, or to
prioritize or restrict login/security levels.
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5.3 — Overview Screen

This screen displays a blending system schematic view incorporated into the total process
system:
• The Overview screen gives access to more detailed views of the various blend system
components.
• Pressing any button highlighted in yellow brings up a detailed information screen corre-
sponding to that circuit, providing greater detail and more control options.
• To access the Deaerator, Syrup Tank, Blender, or Product Tank screens, touch the appro-
priate yellow button on the Overview screen display.
• The total number of gallons of product in the blending system is displayed in the lower
right corner of the Overview screen. This includes the amount of product capable of
being made from the syrup in the syrup line, from the syrup room, and the syrup tank.
• The Filler Enable button on the Overview screen is used to close the product tank.
FIGURE 5-4. Overview Screen
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5.4 — Blender Screen
The Blender screen displays the following:

• A graphic representation of system piping and instrumentation
• Flow information for each stream
• The status of all control devices
FIGURE 5-5. Blender Screen
As with the Overview screen, pressing any button highlighted in yellow brings up a detailed
information screen for that circuit, providing greater detail and more control options.
Arrows on buttons or piping indicate the direction of flow.
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5.4.1 — Deaerator
The deaerator tank system provides all process water to the blender.
• The Deaerator screen indicates real time valve, pump, and circuit actuation.
• All valves, pumps, and analog devices can be controlled manually by selection.
• The yellow buttons allow for navigation to connecting process displays.
FIGURE 5-6. Deaerator Screen
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5.4.2 — Syrup Interface Module
The Syrup Interface Module is used to reduce downtime by automating changeover from one
batch tank to another. Valve selection buttons appear only after a recipe has been loaded.
FIGURE 5-7. Syrup Interface Module
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5.4.3 — Product Tank Screen
The product tank system is the surge tank between the blender and the filler.
• The Product Tank screen indicates real time valve, pump, and circuit actuation.
• All valves, pumps, and analog devices can be controlled manually by selection.
• The yellow buttons allow for navigation to connecting process displays.
• The Filler Enabled button can be toggled by selection, and will turn white to indicate
that the supply of product to the filler is disabled.
FIGURE 5-8. Product Tank Screen
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5.5 — Graphic Display Elements/Control Device Piping
Control devices (for example, diverter valves, flow control valves, or pumps) are an active
part of the Blender screen. They are also active displays on other control screens.
• Each control device is identified by a device number (e.g. AV100, FCV200).
• Each device's current status can be read in three places: in the display screen text above
the device symbol, in the device's force popup window, and on the I/O Force screen.
(See Section 5.16 — Forcing Screens.)
FT200
3.9 %Solids
2.04 GPM
66.2 Degs F
OK
FIGURE 5-9. Control Devices Displayed In Circuit
• All automatic valves are air-to-open

(on) and spring-to-close (off) unless Automatic Valve Pump Flow Control Valve
indicated otherwise on the P&IDs. AV200 P200 FCV200
A valve display indication On is in
an open position.
• Flow control valve symbols indicate
the value (amount open 0 to 100
percent) that the control program is
requesting for the valve’s position.
FIGURE 5-10. Control Devices Displayed Out of Circuit
5.5.1 — Control Device Operating States
All control devices can function in any of the following four operating states:
• Auto On
• Auto Off
• Forced On
• Forced Off
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5.5.2 — Flow Meters
The information window above each flow

meter symbol shows the following: Brix FT200
50.9 %Solids
• Brix in percentage of solids Flow Rate 0.00 GPM
• The current flow rate in gallons per 66.2 Degs F
minute Temperature OK
• The temperature in degrees Fahrenheit
Meter Status
• Flow meter status
FIGURE 5-11. Flow Meter Display Data
5.5.3 — Pressure Transmitters
Transmitters PT100 and PT200 indicate supply pressure as

indicated in psi.
FIGURE 5-12. Gauge Icon
5.5.4 — Tanks
Tank level is displayed in a graph, and the product quantity is

displayed in number of gallons. The product tank also shows tank Product
Tank
pressure.
LT2400
201 Gallons
PT2400
21 Psi
FIGURE 5-13. Product Tank
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5.6 — Manual Operation
Pressing the screen symbol for a Control Device (for example – AV-100 FCV-200
AV-100 or FCV-200, at right) opens the force popup window
for that device. From the force popup window, a device can be
placed in manual operating mode. This feature overrides the
control program’s automation.
FIGURE 5-14. Control Devices
Each force popup window includes the device's identification number, the device description,
PLC address, and the current status (Auto On, Auto Off, Forced On, or Forced Off).
IMPORTANT: The manual control option is intended mainly for use
!
during maintenance and troubleshooting. Operating the blender with
devices in manual is not recommended, and can adversely affect your
process.
5.6.1 — Automatic Valve (AV)
Press the Force On and Force Off buttons to manually force the valve on or off. Press the Auto
button to return the valve to automatic mode.
FIGURE 5-15. AV 2403 Manual Pop-up Window
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5.6.2 — Flow Control Valve (FCV)
Press the Force On button to enter a numeric value (valve percent open) in the Percent Out
window.
FIGURE 5-16. FCV-1100 Manual Pop-up Window
5.6.3 — Pump (P)
The Force On and Force Off buttons manually force the pump on or off. Press the Auto button
to return the pump to automatic mode.
FIGURE 5-17. P1 100 Manual Pop-up Window
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5.7 — Recipe Screen
The Recipe screen simplifies loading all of the parameters needed to blend a specific product
into a specific size container.
5.7.1 — Selecting a Recipe
Recipe names are listed at the right side of the Recipe screen. If the
required recipe is not visible in the list, touch the screen where the
list is displayed to bring up the remainder of the available selections.
Note the number preceding the recipe name.
1. Touch the number box to the left of the Recipe Number text.
2. A numeric entry pad will pop up.
3. Select the number that corresponds to the desired recipe and press the Enter button.
5.7.2 — Selecting a Container
If containers of different sizes are available, and the value displayed

doesn’t match the container required for production, touch the entry
box preceding the current container size.
• Starting with number 1, the number in the box corresponds to the container size.
• Select the container size loads, the production rate in containers per minute, and all the
values needed for the container cut.
• These values were established at the time the blender was commissioned.
5.7.3 — Brix and Diet Recipe Values
The left side of the screen displays recipe data. If the recipe being selected is a Brix product,
Final Product Brix and Product Tank PSI will show displayed values when that recipe is
loaded.
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If the product is a
diet recipe, Water /
Syrup Ratio and
Product Tank PSI
will display values
once the recipe is
loaded.
FIGURE 5-18. Recipe Screen
5.7.4 — Loading and Unloading Recipes
When all recipe values being displayed on the screen are correct (recipe, container, etc.), press
the Load Recipe button at lower left.
Following completion of the production run, when all product

has been exhausted from the product tank, press the Unload
Recipe button.
NOTE: Pressing the Unload Recipe button clears all information for the run, and
allows another filler rinse to run. This can also be used as a system reset button.
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5.8 — Container Definition
The Container Definition screen provides the operator with all of the available
data that pertains to the currently selected production container, including size,
production rate, and palletizing values. This information is used to control the
container cut at the end of the run. To observe the information on this screen,
press the button on the Recipe screen marked Container Definition.
FIGURE 5-19. Container Definition
5.8.1 — Containers Per Minute
Below Containers Per Minute, the value displayed should correspond to the filler’s maximum
speed for that specific container size. This ensures that the blender won’t run out of product
during this run.
5.8.2 — Containers Per Layer
Below Containers Per Layer, enter the number of containers in one layer of a pallet. This
value is used in calculating the container cut during the End of Run process.
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5.8.3 — OZ
Below OZ, enter the number of ounces of product in one container. This value is used to
calculate blender speed, and is used in the End of Run process.
5.8.4 — Layers
Enter the number of containers needed to fill the conveyor from the filler to the depalletizer.
This value is used during the End of Run process.
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5.9 — Blender Information
The Blender Information screen is used to make adjustments to operating parameters, and to
monitor basic information in the blending operation.
• The values displayed in yellow text are from the current downloaded recipe.
• Adjustments can be made to any of these recipe values during production, but these
changes are not saved to the recipe.
• Values in yellow can be changed for the current production run.
• The Reset Totals button is only visible when not in production and the recipe is
unloaded.
FIGURE 5-20. Blender Information Screen
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5.9.1 — Changeover and Production Times
FIGURE 5-21. Changeover and Production Times Screen
• Time in Production — This displays the amount of time the promix is blending.
• Total Change Over Time — This field displays the time elapsed between loading the
recipe and restarting after the lab test has been conducted.
• Load Recipe > Start Syrup Send through Change Over Time not Including Lab Test —
These fields show a step-by-step amount of time the system takes to change over.
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5.9.2 — Production Rate, Product Tank Pressure
The production rate is set in containers per minute (CPM). This

value is supplied from the Container Definition screen. To
change the production rate, touch the yellow CPM value to pop
up the numeric keypad. Enter the value desired for the
maximum filler speed in CPMs.
NOTE: The new value will only affect the current run. The
containers per minute rate will not change for the next run
using this container size.
The product tank pressure is set in psi. To change the value, use
the numeric keypad.
FIGURE 5-22. Numeric Keypad
5.9.3 — Brix Target, Diet Ratio, CO2 Volumes, Chiller Temperature
The values for each process – Brix Target, Diet Ratio, CO2, and Chiller Temperature – are
adjusted using an increment/decrement window, such as those shown below.
NOTE: Changes to process values are

updated as screen values are refreshed,
following a brief delay. INC DEC INC DEC
CO2
BRIX
VOLUME
ADJUSTMENT ADJUSTMENT
CLOSE CLOSE
FIGURE 5-23. Fixed Window Process Adjustments
Each press of the button will increase or decrease the value by a fixed amount. The change to
the recipe value will register in the appropriate window in yellow. There is a delay between
when the button is pressed and the actual value change.
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5.9.4 — Blender Information Table
This table in the Blender Information screen displays data for each blender stream:
FIGURE 5-24. Blender Information Table
• Total Actual — This column displays the number of gallons used for water and syrup.
CO2 is displayed in pounds (lbs.) used. This data is useful for inventory control.
• Density — Micro Motion flow meters calculate the current density. This is converted by
the blender's processor into a Brix value for the syrup.
• Actual Flowrate — These values are supplied directly from the Micro Motion flow
meters.
• Temp — Temperature values are supplied directly from the Micro Motion flow meters.
The Reset Totals button is used to clear the Total Actual data. This can be
done to track production per shift, if required. Reset Totals can only be
initialized if the blender is stopped.
NOTE: This button is located on the bottom left side of the Information screen, and is
only visible when the syrup send is completed.
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5.10 — CIP Control
The CIP Setup screen allows user input during the CIP process.
FIGURE 5-25. CIP Setup Screen
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5.11 — Utilities Screen
The Utilities screen provides inputs for non-critical phases of normal operation. The screen is
separated into three different access levels.
• Operator Level Access — This level is available to all users.
• Manager — This level is password-controlled. Access is most often provided to QA
managers, maintenance technicians, or other fully-trained, experienced personnel.
• KHS — This level is available only to KHS service personnel during initial setup and
testing of the blending equipment.
FIGURE 5-26. Utility Access Levels
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5.11.1 — Screen Clean Utility
The Screen Clean utility allows the user to clean the touchscreen surface.
Press the Screen Clean button to access this utility.
Before cleaning the area around the Exit button, place the index finger from your other hand
on a different screen location. This prevents the curser from pointing to the Exit button. When
finished cleaning, touch the Exit button to return to the Utilities screen.
FIGURE 5-27. Screen Clean Utility
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5.11.2 — Legend Screen
The promix stacklight beacon’s signals are color-coded, providing an indicator of the
blender’s operating status that is always active and always on. The Legend screen provides an
interface between the stacklight beacon and the operating software.
FIGURE 5-28. Legend Screen
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5.11.3 — Stacklight Beacon
The stacklight beacon is a highly visible interface located on top of the electrical cabinet that
is used to inform the operator of general machine status as follows:
• A solid green light indicates that the system is running. The blender is in production
mode and operating properly.
• A flashing green light indicates that a device
Solid Lights Flashing Lights
is in manual mode. A valve or pump is
forced in the On or Off position. The light
will flash until the device is returned to auto-
matic mode.
• A flashing red light indicates that a warning
alarm is active. The blender will operate, but
there is a condition that requires operator
attention.
• A solid red light indicates that a shutdown
alarm is active. The blender will not operate.
FIGURE 5-29. Stacklight Beacon Signals
5.11.4 — System Language Interface and Units of Measurement
Two buttons at the lower left corner of the Utilities screen are always accessible to every level
of password protection.
• The upper button allows the operator to switch the language of the
operator interface from English to a second language. The second
language currently available is Spanish.
• The second control button allows the operator to switch between
standard and metric units of measurement.
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5.12 — Alarm History

The Alarm History screen is useful for advanced troubleshooting. This screen displays all
historical alarms, beginning with the most recent and including the last 512 alarms. When the
list of stored alarms reaches 512, the alarm history begins to overwrite its memory, erasing the
oldest files.
FIGURE 5-30. Alarm History Screen

• Alarm Time — This field indicates the time the alarm occurred.
• Message — This field indicates the type of alarm.
• Acknowledge Time — This field indicates the time when the alarm was acknowledged.
• 0 Forced Off — This indicates that the output has been manually forced off.
• 0 Forced On — This indicates that the output has been manually forced on.
Scroll keys at the bottom of the screen move the cursor through the complete, stored history.
Each screen lists approximately 20 events. Any time the HMI program is restarted, the alarm
history is cleared.
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5.13 — Trend Screens
Three types of Trend screens — Water, Syrup, and CO2 — all provide a real-time display of
each stream's flow rate. Across the bottom of these graphs, the (horizontal) X-axis displays
time. Current time is at the far right. The (vertical) Y-axis displays flow rate in pounds per
hour (PPH). PPH is the chosen value, rather than gallons per minute (gpm), as flow trending
from the Micro Motion meters is output more precisely in PPH.
Values are defined so that evaluation and adjustment of PID loops will be as accurate as
possible. FCV-200 indicates that the screen shown below is a Syrup Stream Trend screen.
FIGURE 5-31. Syrup Stream Trend Screen
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5.13.1 — Trend Screen Information
Information displayed on the Trend screen is as follows:

• Actual Flow — This indicates the actual flow rate is displayed in pounds per hour
(PPH). The corresponding line is green. The actual flow rate should actively attempt to
match the desired flow rate.
• Desired Flow — This shows the setpoint calculated by the processor to deliver the
amount of syrup that will produce the required product, within specifications. The corre-
sponding line is red. The calculated value is determined by the recipe settings and the
flow rate of the water stream. The water stream is the master stream.
• FCV200 — This shows the output position sent to the flow control valve as a percentage
(0 to 100 percent) of the fully open valve.
• Total Actual — This shows the actual total in pounds of syrup used.
• Total Desired — This is the calculated total of syrup in pounds based on the recipe and
water total.
• Difference — This shows the error or difference between the Total Desired and Total
Actual pounds produced. This error value is used to make corrections to the flow control
valve's open position.
IMPORTANT: If more than 15 seconds elapse with no correlation
!
between the stream's actual flow and desired flow, a flow deviation alarm
is activated.
5.13.2 — Navigating Trend Screens

• Use the left and right arrow keys to scroll through a stream's time line.
• Press directional buttons to move the timeline in the direction the arrow is pointing.
• Each push advances the timeline by one minute.
• Push the center key to return the trend display to the present time.
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5.14 — Stream Tuning
In order to maintain a stream's flow rate at the desired setpoint, the blender uses a closed-loop
Proportional Integral Derivative (PID) control strategy, implemented in the PLC program.
• The process variable measured by the mass flow meter is
sent to the PLC. (PV = actual flow rate.)
• Based on the input PV and the current setpoint, an error
term e = SP - PV is generated. (SP = desired flow rate.)
• The PLC solves the PID equation, and creates an output
which is sent to the flow control valve. When properly
tuned, the PID loop will drive the error term toward zero, thereby ensuring that the
actual flow tracks tightly to the desired flow at all times.
5.14.1 — Proportional Control
Proportional control multiplies the error term by a constant pressure coefficient (Kp). The
resulting change in control output is proportional to the magnitude of the error. Proportional
control can improve rise time (the time it takes for the process to respond to a change in error).
Increase the P value to correct a lag (slow rise time) in actual flow.
5.14.2 — Integral Control
Integral control is used to make small changes to the PV when close to the setpoint. If the PV
response is lagging, increase the value to bring the PV into line more quickly.
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5.15 — Recipe Edit

This screen is provided to edit or delete existing recipes, or to add new ones to the available
menu. Move your finger up or down to scroll through the recipes.
FIGURE 5-32. Recipe Edit Screen
5.15.1 — Entering the Edit Menu

1. Press the recipe number display box.
2. From the number pad, enter the recipe number to be edited or the recipe location for a new
recipe, and press Enter.
3. Press the Recipe Edit button to access parameters to be edited, and to open
the Recipe Edit screen.
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Adjustable parameters of the Recipe Edit screen are as follows:

• Recipe Name — Touch the top line to bring up a keypad. Type in the desired recipe
name and press Enter.
• Water-Syrup Ratio (Diet Products) — Touch the yellow number to bring up the keypad.
Enter a new value to change the ratio.
• Final Product Brix (Brix Products) — Touch the yellow number to bring up the keypad.
Enter a new value to change the ratio.
• Volume Carbonation — This is the target volume of CO2. Touch the yellow number to
bring up the keypad. Enter a new value for required volume.
• Product Tank — Touch the yellow number to bring up the keypad. Enter a new value to
vary pressure.
• Chiller Enable — This allows the chiller to be selected for operation. The chiller is nor-
mally off for non-carbonated beverages, and it is on for carbonated beverages. When the
chiller is off, the button color is red; when the chiller is on, the button color is green.
• Normal Blend — All regular Brix and diet syr-
ups use the Normal Blend feature, enabling the
blender's Syrup Detection and Elevated Syrup
Prime functions. Flavored water products with
the same density as water require this button to
be selected.
• Use Syrup Line — This toggles the use of the
syrup line for carbonated and non-carbonated
beverages.
• Save Change — Press this button to save the
changes to the recipe.
• Close Window — Press this button to go on to
the next screen.
• Chiller Temperature — Touch the yellow num-
ber to bring up the keypad. Enter the value for
the required chiller temperature.
FIGURE 5-33. Recipe Edit Screen
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5.16 — Forcing Screens
There are three screens (available from the Utilities screen) that show the
state of the blender's valves and pumps. An all-in-one view of these
components is provided. This saves the operator from having to scroll
repetitively through a succession of screens, checking valves and pumps, to
see what might be forced.
Device states can be changed from within Forcing screens. See Section 5.6
— Manual Operation for more information on changing device states.
5.16.1 — Output Force Screen
This screen displays all pumps, valves, and outputs controlled by the blender.
FIGURE 5-34. Output Force Screen
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5.16.2 — Input Force Screen
This screen displays feedback from the blender's pumps or valves, as well as interlock signals
from plant locations such as the filler or CIP skid.
NOTE: When any of the buttons are selected on these screens, the pop up dialog box that
shows the Man/Off/Auto control for each selection is the same as the pop up that appears
when valves are selected on the diagram display screens.
FIGURE 5-35. Input Force Screen
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5.16.3 — Analog Force Screen
This screen displays analog input and output information to or from the blender's tank
pressure, line pressure, or tank level sensors. It also displays outputs that regulate the blender's
flow control valves.
FIGURE 5-36. Analog Force Screen
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5.17 — Start Up Adjustments Screen
This screen is accessible by pushing the Start Up Adjustments button in the

right half of the Utilities screen, just above the System Shutdown button.
• This utility permits offset adjust-
ments that compensate for trapped
water between the blender and the
filler.
• It also allows the customer to make
offset adjustments that prevent CO2
over-saturation during the initial
product transfer to the filler.
• Tank pressure setpoint adjustments
are permitted to make sure that the
product is not over-carbonated when
sent to the filler for the first time.
FIGURE 5-37. Start Up Adjustment Utility
Adjustable parameters on the Start Up Adjustments screen are as follows:

• Product % Diet Offset — This offsets the diet syrup by this percentage during the prime
sequence to compensate for trapped water.
• Product Brix Offset — This offsets the Brix syrup by this value during the prime
sequence to compensate for trapped water.
• Product Tank Low Carbonation Setpoint — This sets the product tank pressure value
used during the prime sequence for a low carbonation beverage.
• Product Tank High Carbonation Setpoint — This sets the product tank pressure value
used during the prime sequence for a high carbonation beverage.
• Low Carbonation Maximum Setpoint — This is the dividing point between low and high
carbonation products. Products with a CO2 recipe value below this setting will use low
carbonation tank pressure settings. Products with a CO2 recipe value at or above this set-
ting use high carbonation tank pressure settings.
• Product Tank Pressure Setpoint Offset — This is the reduction of the normal recipe set-
point used during the priming of the product tank during blender start-up. After the
product tank is primed, the product tank pressure will be set to the normal operating
pressure.
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5.18 — Utilities Screens Reserved for KHS Use
The controls at the far right of the Utilities screen are reserved for KHS service personnel.
Unless the person logging in has appropriate access, these utilities remain hidden.
FIGURE 5-38. KHS Utilities
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5.19 — Operating the Blender: Overview
Blender operation is set up to lead the operator through operating steps with on-screen
prompts, status information, and other visual or verbal cues. For example, in the Overview
screen shown below, with no recipe loaded, the Mode field informs the operator that the
blender is idle. The operator can choose to start production (load a recipe), or start a CIP
cycle.
• Color is used to show the operating status of control buttons and blender processes.
• The color yellow is used in text fields to background highlight navigation/scroll-through
options.
• The lower half of the Main Menu has text guides or cues, operator responses, and input.
FIGURE 5-39. Blender Overview Screen
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5.19.1 — Operating Instructions

IMPORTANT: In the sections that follow, all steps requiring an action
!
or input from the operator are numbered. Elsewhere, bullets (•) indicate
that the operation requires no direct input from the operator. Examples
include the following:
• Actions already programmed into the software, which update or occur automatically
• Actions performed at other locations, where the controls involved are not on the promix
blender
5.20 — Load Recipe or Start CIP

1. To start the process of system operation, press the Recipe button on the Main
Menu. The Recipe Screen opens up to enable the start of production.
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5.20.1 — Selecting a Recipe
From the Recipe screen, you can start a production

run sequence.
1. Choose the recipe: Press the numeric value in
the Recipe Number box to pop up the Numeric
keypad. Enter the required recipe number. The
recipe name, ingredient amounts, and tank
pressure setting will appear on the screen.
NOTE: If the required recipe is not included in

the first list of 50 recipes, touch the middle of
the screen to list the next 50 recipes.
2. Choose a container: Press the yellow numeric

value in the Container box. The parameters for
blender speed and container cut off values, cor-
responding to that container, will be entered.
NOTE: If using the same container as the last

run, it is not necessary to enter a new value.
3. Select a recipe: Press the Load Recipe button

to choose a recipe.
4. Syrup room module (optional): With a syrup room module included in your system, there
are extra buttons available on the left-hand side of the screen. Push the button that will
open the valve supplying syrup. The button turns green after being selected.
5. Press the Overview button at the top right corner of the Main Menu to
return to the Overview screen. OVERVIEW
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5.21 — Start Rinse and Send Syrup
At the start of every production run, the following two operations are normally performed at
about the same time, in separate parts of the blender system piping circuit:
• The water piping rinse is initiated.

• Piping and/or other required connections to syrup room piping are verified and made
ready.
Green buttons on the lower half of the Main Menu indicate available options. Because a
complete rinse of the blender and filler may take more than five minutes, the Start button is
normally selected after syrup is sent.
1. Check the displayed values against the required interval duration.
FIGURE 5-42. Start Rinse and Send Syrup Message
5.21.1 — Rinse Cycle
Start the filler rotating. Open the filler valves.

1. If a change in the filler rinse cycle time is needed, enter a new value for rinse time. At the
Main Menu, enter the time required for the rinse. Touch the yellow number (time in sec-
onds) displayed in the rinse block. The screen shown below indicates a setting for 100 sec-
onds, but this interval can be changed to any value within the range of 0 to 9999 seconds.
Other values displayed in yellow may also be adjusted.
2. Press the Rinse Start button. The display on the right side of the touchscreen changes to
indicate that the Filler Rinse is active. The status message, button color, and wording are
updated to reflect the new status.
FIGURE 5-43. Syrup Send Message
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3. This is now in the Rinse Status screen. The time displayed in the rinse block counts down
to show how many seconds are left for the rinse. If there is any reason to pause or stop the
rinse, it can be stopped by pressing the red Rinse Stop button.
• During the rinse/drain operation, the product tank is charged with CO2. The product
tank, the product lines, and the filler are purged in this process, which is referred to as a
“blow.” The number of blows to be completed is displayed on the right side of the slash,
and the number of blows already completed is indicated on the left side of the slash. The
rinse/drain timer counts down from whatever value has been entered to 0.
• When the rinse/drain/purge operation has been completed, the right half of the Main
Menu goes black, and the blender automatically goes into production mode.
IMPORTANT: If the filler is not rotating during the drain and blow
!
cycle, it is likely that the first bottle may be low on CO2 and Brix.
The rinse portion of the Main Menu updates when the blender goes into production mode.
5.21.2 — Syrup Send
Be sure that syrup is connected from the syrup room. The syrup room horn will sound. Then
(as the rinse cycle is counting down), press the Hook Up Ack push-button in the syrup room.
• The rinse countdown is visible only as long as this process takes to complete.
• Press the Syrup Visual OK button for manual control to prevent syrup from draining in
the event of overflow. See the note below, and the photo on the following page.
NOTE: If you have the optional syrup room module, the syrup send process is
normally connected before the new recipe is loaded.
FIGURE 5-44. Waiting for Brix Message
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During this process, the following actions are performed automatically:

• System Check Brix (Low): The blender drains water to the floor.
The operator should check the Brix as the syrup flows through the
Micro Motion flow meter. Scroll back to the Overview screen or the
Blender screen and look at the values at FT200. Normal values for
diet recipes are about 4 Brix, and for sugar, 10 Brix.
NOTE: If the water to syrup change is not caught by the blender, and syrup is seen
going to the drain for a long period, press the ACK button to manually trigger the
switch.
• Re-circulate to 50 Gallons: The syrup tank inlet valve will open. The blender will con-
tinue re-circulating the syrup from the bottom of the syrup tank through the meter and
back to the syrup tank until the tank reaches a minimum of 50 gallons. During this time
the Brix in the syrup meter continues to rise.
NOTE: 50 gallons is a minimum requirement for initial product to be within specified

tolerances.
Syrup Send Complete: When this process is completed, the Main Menu changes to show the
system prime process.
FIGURE 5-45. Prime Blender System Option
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Operation Manual
The operator should be aware of syrup coming out of the drain pipe during the System Check
Brix process. Have an assistant stand behind the blender, or monitor the FT200 value
displayed on the Overview screen if operating the blender alone.
Drain Pipe
FIGURE 5-46. Drain Location Reference Photo
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5.22 — System Prime
When the Start Rinse and Send Syrup processes are completed, the Main Menu displays the
Prime Blender option:
1. Press the green Start button to prime the blender system.

2. After the filler stops dripping from the rinse cycle, close the filler valves.
3. Pressurize the filler to 2 psi
less than the start up pressure.
The value for the start up pres-
sure is based on the Start Up
Adjustment screen. This
applies to both high carbon-
ation and low carbonation
products.
NOTE: The Start Up

Adjustments screen is only
available through the Manager
access level or higher from the
Utilities Menu.
FIGURE 5-47. Start Up Adjustments Utility
After the System Prime process has begun, a sequence of informational messages for the
operator is displayed in the following order:
• Hold for Syrup and Water Pressure — The blender requires a short delay interval to
allow water pressure and syrup pressure to build to minimum required levels.
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Operation Manual
• Hold for Product Tank Pressure — A delay interval is also required to build tank pres-
sure up to the prime value.
• Blend to Fill the System — The blender fills the system through the chiller. During this
blend process, the product recipe is based on the offset value from the Start up Adjust-
ment screen to raise the amount of syrup.
• Blend to Preset Gallons — The drain valve closes, the carbonator starts, and the blender
begins to produce product up to the amount specified (in gallons), not exceeding the vol-
ume available in the product tank.
• Blender Preparing for Production Mode — The blender is stopped when the timer fin-
ishes. The outlet valve on the product tank opens, releasing the product to the filler.
When all priming processes have completed, the blend sequencer moves to production mode.
IMPORTANT: While the blender is priming, the filler should be
!
charged to the running setpoint in preparation for receiving product.
Incorrect filler pressure might cause blowback or problems with product
carbonation.
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5.23 — Production
Before starting production, a delay may be required for testing the product.
FIGURE 5-48. Production
When you are ready to begin the production run, press the green Start button.
After the production process has begun, a sequence of informational messages for the operator
is displayed, in the following order:
• Hold for Low Level in Product Tank — The blender requires a brief delay interval until
the product tank reaches the low level used for restart.
• Hold for Water, Syrup and Tank Pressure — The blender checks the minimum of the
water pressure and the syrup pressure. The product tank has to be within 5 psi of the set-
point.
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• Ramping Up to Production Rate — The blender starts at 30 percent of the production

rate, and spends 10 seconds ramping up to the setpoint of GPH based on the CPM value
set in the Information screen.
• In Production, Monitor Tank Levels — The blender monitors the product tank level.
When the high level is reached, the blender moves on to the next step in the production
sequence.
• Stopping Production, Ramping Down — The blender will spend 10 seconds ramping
down from its current production rate to 30 percent of the blender’s maximum capabil-
ity.
• Production Standby — The blender continues to total meters for four extra seconds to
accommodate any delay that could occur in receiving signals from the meters.
• Restarting Production Sequencer — The blender returns the production sequence back
to the first step, holding for low level in the product tank.
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5.24 — End of Run
When all of the syrup in the tank in the syrup room has just about run out, or the last pallets of
bottles are being loaded on the conveyor, the End of Run sequence can be started.
1. The default end of run is a syrup cut, which means that you have more containers on hand
than syrup with which to fill them. If you’re going to run out of syrup first, press the EOR
START button and continue with the next step. If you need to end production according to
an exact number of containers filled, press the Cut Off Select button and go to Section
5.24.1 — Continue Here for Container Cut.
FIGURE 5-49. End of Run
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Operation Manual
2. Press EOR Start for a syrup cut. A small popup window with the message Are You Sure?
will ask you to verify.
3. Press the Begin End Of Run button and press Close Screen.
The syrup inlet valve on the syrup tank will close, and the
blender will continue to run. The Water On ACK button will
appear. The operator will connect a water line to the syrup
supply to the blender and then press the Hook Up ACK but-
ton. The water will start to push the syrup from the syrup
room to the blender, bypassing the syrup tank. When the
Micro Motion meter detects the change in solids, the syrup
will start to come from the blender syrup tank again.
4. The blender continues until the Req. Layers In Depal reaches zero. This closes the con-
tainer stop at the filler, allowing the conveyor to fill to the depalletizer.
5. The depal operator will inform the filler operator that the table is full. The
filler operator will press the ACK button in the depal room to open the bottle ACK
stop and run out the rest of the product.
5.24.1 — Continue Here for Container Cut

6. If you are going to run out of containers before syrup runs out, press the Cut Off Select
button. The bottle stop will close.
7. Contact the depal operator and ask for the count of layers left on the pallets before the
depal and in the chute. Enter that value in the Layers Left In Depal box by pressing the
yellow number to open the numeric keypad.
NOTE: The value entered must be greater than the required layers in depal.
• The container stop will open at the filler, and production will continue when the value is
entered.
• When the Layers Until Cut display shows zero, the syrup tank inlet will close. The Water
On ACK button will appear. The operator will connect a water line to the syrup supply to
the blender and then press the Hook Up ACK button in the syrup room. Water will push
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Operation Manual
the syrup from the syrup room to the blender, bypassing the syrup tank. When the Micro
Motion meter detects the change in solids, the syrup will come from the blender syrup
tank again. The system will continue until all product and containers are complete.
The following operations are common to both types of production run outs (syrup and
container):
• End Production Run — The blender goes to this step when all of the syrup in the syrup
tank is used up.
• Final Syrup Push From Syrup Room — The blender closes the syrup tank outlet valve,
opens the syrup bypass valve, and continues blending, pushing with water until the
syrup reaches low density.
• Water Push Blender Lines — The blender keeps the water line open, running for a spec-
ified number of gallons of water. This pushes the product from the blender to the product
tank, then stops.
• Rinse Syrup Tank for Brix (Low) — The syrup tank starts the rinse process through the
syrup meter. When the syrup Brix drops below the minimum setpoint, the blender goes
on to the next step.
• Rinse Syrup Tank for 90 Sec. — The syrup tank rinses to drain for 90 seconds.
• Drain Syrup Tank to Low Level — The syrup tank is drained (below) until the level in
the tank is below five percent.
• Drain Syrup Tank for 60 Sec. — The syrup tank is drained for a specified interval (60
seconds).
5.24.2 — Complete End of Run
1. To unload the recipe after a completed production run, press the Recipe button at the top
of the Main Menu.
2. Press the Unload Recipe button.
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5.25 — Starting a New Process

• If a rinse is all that is needed, because the last product run is going to be run again, press
the Rinse Start button.
• If a new recipe is going to be loaded, press the Recipe button at the top of the Main
Menu to return to the Load Recipe option.
5.26 — Syrup Interface Module
The Syrup Interface Module (SIM) is used to reduce downtime by automating changeover
from one batch tank to another. Valve selection buttons appear only after a recipe has been
loaded.
NOTE: SIM design configurations may vary, depending on facility site requirements.
FIGURE 5-50. SIM Screen
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AV-222
AV-224
FIGURE 5-51. SIM
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CHAPTER 6 Maintenance
6.1 — Machine Maintenance Overview
A carefully followed preventative maintenance program helps to ensure accurate, optimum

performance, increase the service life of components, and deliver reliable, trouble-free
operation.
The recommended service schedule for periodic, regular maintenance is based on information
provided by the manufacturers of KHS system equipment, and on KHS direct experience.
The maintenance instructions listed in this section do not include normal, everyday cleaning
— which should be performed on a routine, periodic basis — or any service or procedures
required by your facility’s quality assurance staff, or which are mandated by any
governmental, regulating body or industry association. Compliance with all maintenance
requirements is the responsibility of the user.
NOTE: Use only factory authorized KHS replacement machine parts when
performing maintenance or repair work. Use of non-authorized parts will void any
warranty.
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Maintenance
6.2 — Maintenance Schedule
Suggested intervals for recommended maintenance procedures are summarized in these

schedule tables. Not all promix installations include all of the equipment listed in the
schedule. Some assemblies are optional.
Daily Maintenance
Component Action
Lines, Seals, and Gaskets Check integrity.
Pneumatics Enclosure Check regulators.
Check for air leaks.
Glycol Chiller Drain oil trap.
Operator Control Screen Clean.
Monthly Maintenance
Component Action
Line Clamps Check and tighten.
Electrical Enclosures Check interior and door seals.
Operator Control Console Check air flow.
Emergency Stop Button Check light and clean.
Pneumatics Enclosure Check interior.
Quarterly Maintenance
Component Action
Vacuum Separator Check for sediment.
Motors (US Electric) Lubricate.
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Maintenance
Semi-Annual Maintenance
Component Action
Vacuum Pump Lubricate motor.
Motors Lubricate.
Annual Maintenance
Component Action
Uninterruptible Power Systems Check battery.
Centrifugal Pumps Check seals, O-rings.
Regulators Check and calibrate.
Line Seals, Gaskets Replace.
Pressure Sensors Check zero/span.
Check gaskets.
Level Probes Check.
Vacuum Sensor Check.
Flow Control Valves Replace valve lip seals.
Clean actuator air release filters; replace if
necessary.
Check zero/span.
Check gaskets.
Automatic Valves Test.
Check actuator exhaust.
Check Valves Test.
Manual Valves Test.
Mixproof Valves Test.
Vacuum Pump Check impeller chamber for sediment.
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Maintenance
Annual Maintenance
Component Action
Process Lines Check line pitch.
I/P Regulator Calibrate.
Two-Year Maintenance
Component Action
All Pumps Rebuild.
All Valves Rebuild.
Mass Flow Meters Check prove streams.
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Maintenance
6.3 — Machine Maintenance Instructions

The general information summary that follows is intended to supplement specific instructions
in vendor equipment manuals.
6.3.1 — Lines, Seals, and Gaskets

• Lines should be checked for integrity.
• Where applicable, check lines for correct line pitch. This is typically a slight downslope
(1/16” per foot), which facilitates manual drain, if needed.
• Replace line seals and gaskets annually.
6.3.2 — Pneumatics
• Clean, dry control air and CO2 are necessary for the blender to function properly.
• Check the filters and regulators whenever filter manual drains are purged.
NOTE: In high ambient humidity conditions, filters require more frequent attention.
• Replace the filter elements when necessary.
• The solenoids require no periodic service, but can be replaced in the event of failure.
CO2 Inlet Control Air

Valve, Inlet Valve,
Regulator Regulator
Gauge, and Gauge, and
Filter Filter
Manual
Drains
FIGURE 6-1. Pneumatic Panel
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Operation Manual
Maintenance
6.3.3 — Butterfly Valve Maintenance
A rebuild is recommended for all automatic valves every two years. Rebuild kits are available
from KHS. Consult the applicable vendor manuals for valve maintenance procedures.
Periodic maintenance instructions are as follows:
1. Check for disc shaft wear. The valve position indicator must be 90 degrees to the shaft and
not twisted or skewed.
2. Check seals, bushings, and sanitary gaskets.
3. Check electrical and pneumatic connections.
4. Inspect the valve for leakage and verify mechanical operation.
Overhead View
Position Indicator
90°
Straight Valve Position Disc Shaft

Edge Indicator Coupling
FIGURE 6-2. Black Plastic Valve Position Indicator
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Maintenance
6.3.4 — Butterfly Valve Rebuild

The valve disassembly sequence is as follows:
1. Shut off the fluid stream to the valve.
2. Allow the valve to cool down if necessary.
3. Have a valve rebuild kit on hand.
4. Remove and label the air lines from the actuator.
5. Remove the valve from the stream.
6. Drain the valve of any remaining liquid.
The valve reassembly sequence is as follows:
1. Install the valve on the stream.
2. Connect the air lines to the actuator.
3. CIP the system before running product.
6.3.5 — Flow Control Valves

A rebuild is recommended for all
automatic valves every two years.
Rebuild kits are available from
KHS.
• Check for leakage and verify
smooth operation. Replace the
valve lip seals and clean the
actuator air filters annually.
• Replacement of actuator rubber
seals is recommended after five
years of service.
• Periodically check valve zero
and span.
Valve Diaphragm Between the Piping Positioner Diaphragm

Manifold and the Valve Block
FIGURE 6-3. Flow Control Valve Diaphragm Seal Locations
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Maintenance
6.3.6 — Level Probes (Capacitance Type)
Check the probe insulation for any evidence of damage, cracks or wear. If there is any reason
to suspect that the probe is giving inaccurate readings, perform the following steps:
1. Drain the tank.
2. Remove the probe.
3. Check the discoloration and material buildup on the probe surface.
• Deposit buildup can throw off the reading accuracy.
4. Clean the probe by wiping off the buildup with a wet, clean, soft rag.
• Any time the probes are removed from the tank for any reason, wipe them clean.
FIGURE 6-4. Level Probe
6.3.7 — Centrifugal Pumps

• Check seals and O-rings for any visible evidence of external wear or damage.
• Verify that the pump is operating without excessive vibration.
• Rebuild pumps every two years.
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Maintenance
P-1100 P-2400 CIP P-1101 Inline P-200 P-2 H20 P-1 H20 P-3 Vacuum
Mix Pump Booster Carbonator Syrup Discharge Recirculation
Booster Pump
FIGURE 6-5. Pump Usage
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Operation Manual
Maintenance
The pump disassembly sequence is as follows:

1. Shut off/lock out the pump fluid stream.
2. Open/lock out the motor disconnect switch.
3. Allow the motor, pump, and associated piping to cool down if necessary.
4. Have replacement parts on hand, including rebuild kits and tri-clamp seals.
5. Disconnect and label the seal water piping.
6. Drain the pump of any remaining liquid.
7. If motor service is required, remove and label the motor wiring.
The pump reassembly sequence is as follows:

1. Install the pump and motor on the skid.
2. Connect the seal water piping to the seals.
3. Install the piping on the pump.
4. Connect the motor wiring to the motors and run a CIP.
6.3.8 — Deaerator Vacuum Pump
Because it is designed to move gas rather than liquids, the vacuum pump assembly requires
maintenance that is specific to this pump design. Verify that the pump is running smoothly,
without excessive vibration or noise. A noisy vacuum pump could indicate the following:
• Seal water is flooding the pump.
• The level sensor is not working and/or the pump is taking on water.
• CO2 injection is off; the pump is pulling in too great a vacuum.
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Maintenance
FIGURE 6-6. P3 Vacuum Pump
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Maintenance
6.4 — Electrical Cabinet
The promix cabinet is designed for maintenance-free service, but it should be inspected at
least annually for corrosion or damage. Check doors, seals, hinges, and latches. Inspect the
interior for signs of contamination. If cleaning is required, use only clean, fresh water or mild
non-abrasive cleaners. Do not use pressure washers or chemical sanitizers.
NOTE: Be sure to fully latch all clips on the enclosure after inspection. Fluid may
leak inside the cabinet and damage electrical components if not properly closed.
FIGURE 6-7. Electrical Cabinet
6.4.1 — Operator Console Screen
The touch-screen panel contains no user-serviceable parts. Clean the display daily using a
procedure approved for computer monitors. The HMI program includes a Screen Clean utility
for this purpose. See Section 5.11.1 — Screen Clean Utility.
6-12 MAN-PMX-7.5-07461
Operation Manual
Maintenance
6.4.2 — Programmable Logic Controller (PLC) and Associated Cards
The PLC chassis contains no user-serviceable parts. Under normal circumstances, no

preventative maintenance is required for the controller or associated cards. Check the air flow
through the top of the PLC chassis on a monthly basis.
NOTE: Never set anything on top of the PLC cooling grille, as this may cause the
PLC to overheat and malfunction.
PLC Cooling Grille
FIGURE 6-8. PLC Unit
MAN-PMX-7.5-07461 6-13
Operation Manual
Maintenance
6.5 — Volume Setup Points for Blender System Values
All volume setups require the highest level of password access, and are normally completed at
the time of installation. However, if changes or updates to the equipment at your facility
require re-routing or replacing major components in the filling circuit, one or more of the
setup procedures that follow might need to be verified or reset. You may also need to check
volume setup points following removal or replacement of blender components. Each point in
the system needs an accurate value, in gallons of syrup, for the volume of product in the
system.
The values that may require verification or reset are as follows:

• Syrup From Syrup Room 1
• Syrup From Syrup Room 2
• Chiller Quantity
• Filler Bowl Quantity
The screen below shows volume setup points for the blender. This screen is accessible to KHS
personnel through the Utility Screens Menu.
FIGURE 6-9. Volume Setup Points for Blender System Values
6-14 MAN-PMX-7.5-07461
Operation Manual
Maintenance
6.5.1 — Syrup Room Pipe Volume (Syrup Room 1 or 2)

1. Load a syrup proving recipe.
2. Fill the pipe from the syrup room to the blender with water.
3. Force closed AV210, AV213, and P200. Force open AV211.
4. Load a syrup proving recipe in the blender.
5. Set the flow rate at 1000 lbs. per hour and desired lbs. at 30.
6. Connect a Brix syrup at the syrup room.
7. Start the blender.
8. When the blender stops, write down the actual lbs. that flowed through the system.
Change the flow rate to 5,000 lbs. per hour, and increase the desired total to 10,000.
9. Connect the water back at the syrup room.
10. Go to the Overview screen and start the blender.
11. Watch the Brix at the syrup meter. When the Brix starts to climb, press the Stop button.
12. Go to the Information screen, look at the total gallons for FT200, and enter that number in
at Syrup from Syrup Room.
13. If there is a second syrup room, repeat the procedure (steps 8 through 12), and enter that
value.
14. Put all forced valves back in Auto mode.
6.5.2 — Syrup Tank Quantity

1. Syrup tank quantity is entered at the System Setup 0 screen.
2. Open AV215 and AV213. Make sure that all of the water is drained from the syrup tank.
3. Put AV215 and AV213 in automatic.
4. Open the cover on the level probe at the top of the syrup tank LT200, and press the two
buttons under the empty tank.
• Refer to the blowup inside the photo in Figure 6-10 for button location.
• A green LED at the lower left corner of the panel will turn on when the calibration is
“zeroed,” or complete.
MAN-PMX-7.5-07461 6-15
Operation Manual
Maintenance
6.5.3 — Level Probe Calibration
The level probe calibration summary is as follows:

• Unscrew the level probe cover and flip up the access panel.
• Press the two buttons at the left to span the probe with an empty tank.
• Press the two buttons at the right to span the probe with a full tank.
• The LED at lower left will turn green when calibration is complete.
LED Left Buttons Right Buttons
FIGURE 6-10. Level Probe Calibration
6-16 MAN-PMX-7.5-07461
Operation Manual
Maintenance
To fully calibrate the level probe, follow these steps:

2. Set the flow rate at 5,000 lbs. per hour and desired lbs. at 10,000 lbs.
3. Force closed AV201, AV202, AV210 and AV212. Force open AV214. Reset the totalizer.
4. Go to the Overview screen and start the blender.
5. Watch the level in the syrup tank. When the level reaches the bottom of the probe, the dis-
played value will start to fluctuate. Press the Stop button.
6. Go to the Information screen. Look at the total gallons for FT200, and enter that number at
Below Syrup Tank Probe to Blender.
7. Press the Reset Totalizer button.
8. Remove the overflow pipe on the side of the syrup tank.
9. Press the Start button to fill the syrup tank. It will take a while because you are using a
half-inch line to fill it.
10. When the water starts to come out of the overflow on the side of the syrup tank, press the
Stop button.
11. Go to the Information screen, and look at the total gallons for FT200. Go to the System
Setup 0 screen, and go down to the device named CH2: SCALE. On the Min. Scale Factor,
enter 0. On the Max Scale Factor, enter the number of gallons derived from the equation.
buttons under the full tank.
• A green light will turn on when the calibration is “spanned”, or complete.
13. Put all forced valves back in auto.
NOTE: If a replacement probe is installed in the system, always zero the probe with
the tank empty. Then fill tank to the overflow level, and span the probe. Recalibrating
the tank is not required.
MAN-PMX-7.5-07461 6-17
Operation Manual
Maintenance
6.5.4 — Chiller Quantity (Used with an Off-Skid Chiller)

1. Open all drain valves from the blender to the product tank. Once drained, put these valves
in automatic.
2. Remove the clamp from FCV1100 valve and turn it up so the water will come out of the
top.
3. Force open FCV1100.
5. Force closed AV210, AV213, and P200 off. Force open AV211.
7. When the water starts to come out of FCV1100, stop the blender.
8. Go to the Information screen. Look at the total gallons for FT200, and enter that number at
Chiller Quantity.
9. Put all pumps and valves back in automatic.
10. Connect FCV1100 back to the tank.
6.5.5 — Product Tank Quantity

1. Force closed AV210, AV213, and P200. Force open AV211. Force FCV1100 to 100 per-
cent.
2. Remove PT2400 from the product tank.
WARNING: Before removing the transducer from the side of the tank,
!
make sure that there is less than five psi in it.
3. Load a syrup proving recipe in the blender.

5. Open the cover on the level probe of the product tank LT2400, and press the two buttons
under the empty tank. A green light will turn on when the zero is done.
7. Go the Overview screen and watch the level for the product tank. When the level starts to
move above zero, stop the blender.
8. Record the total gallons in the Below Product Tank Probe parameter.
6-18 MAN-PMX-7.5-07461
Operation Manual
Maintenance
9. Go to the Information screen and press the Zero button.

11. Fill until the water comes out of the pressure transducer port.
12. Stop the blender.
13. Go to the Information screen and look at the total gallons for FT200. Go to the System
Setup 0 screen, and go down to the device named CH3: SCALE. On the Min. Scale Factor,
enter 0. On the Max Scale Factor, enter the number of gallons from the Information
screen.
buttons under the full tank.
• A green light will turn on when the calibration is “spanned” or complete.
15. Remove all forces.
6.5.6 — Filler Bowl Quantity

1. Force closed AV210, AV213, and P200. Force open AV211 and AV2407. Load a syrup
proving recipe in the blender.
4. Go to the Overview screen. When the level reads 100 gallons, stop the blender.
5. Charge the product tank with 30 psi by opening AV2405. Put the valve back in auto.
6. Charge the filler with water until it reaches operating level for production.
7. Subtract the current level from the level before the product was sent to the filler, and enter
the gallon amount in Filler Bowl Quantity.
8. Remove all forces.
MAN-PMX-7.5-07461 6-19
Operation Manual
Maintenance
6-20 MAN-PMX-7.5-07461
Operation Manual
CHAPTER 7 Alarms and Troubleshooting
7.1 — Troubleshooting Guidelines
Analyze the situation, evaluate all possible alternatives, and take logical steps to resolve the
condition.
1. Assemble reference materials and data. Use this manual and the additional support infor-
mation that is provided with some components as a reference when troubleshooting.
Check Chapter 3 for specific procedures, adjustment, and setup information.
2. Isolate potential root causes. Carefully analyze each problem to identify all factors. Do not
consider only the symptoms of a malfunction — solve the problem that is creating the
symptoms. Consult the KHS service department.
3. Address potential root causes as a logical sequence of possible test steps. Break down the
best options for testing root causes by isolating one system, or one assembly, at a time.
Compile a list of possible test steps for each of those systems, or assemblies, before you
begin. Evaluate those testing options in logical sequence, to avoid redundant trial-and-
error tests.
4. Complete and evaluate each logical sequence of possible tests, one step at a time. Make
only one correction or adjustment at a time and observe the results before proceeding to
another adjustment. If the adjustment does not correct the situation, restore the original
setting before making another adjustment. Also, consider the effect of any adjustment
upon related settings.
NOTE: The troubleshooting tables are not all-inclusive, but they do provide a good
basis for investigating machine malfunctions. Use these tables as your starting point.
MAN-PMX-7.5-07461 7-1
Operation Manual
Alarms and Troubleshooting
7.2 — Troubleshooting Alarm Faults
Alarm functions alert the operator to conditions that may result in non-conforming product, or
loss of data.
There are two types of alarms: Shutdown and Warning:

• A Shutdown alarm stops the system. Immediate attention is required.
• A Warning alarm indicates a condition requiring immediate attention, but allows the
operator to continue operating the blender.
NOTE: A Warning alarm may also close the container stop on the filler.
7.2.1 — Viewing Alarms
The Active Alarms screen opens automatically when an alarm occurs.

• The alarm time and a brief description are displayed.
FIGURE 7-1. Alarm Screen (Typical)
• The Alarm Acknowledge (Auto Close) button resets the alarm(s) and
ALARM
returns the operator back to the previous screen. ACKNOWLEDGE
(Auto Close)
• The Silence Alarms button acknowledges all active

alarms, and turns off the alarm horn. This button gives SILENCE ALARMS
you the opportunity to acknowledge the alarms with-
out closing the screen. Alarms must be acknowledged
before they can be cleared from the system.
7-2 MAN-PMX-7.5-07461
Operation Manual
7.2.2 — Troubleshooting Shutdown Alarms
Shutdown Alarm Possible Causes Action to Take

FT100 High Flow There had been previous Low The blender will try to make up the
Deviation: Flow syrup alarms. difference.
The actual flow During end of run there is a Decrease the water push pressure by
rate is higher than water push out. If the water using a water regulator. Decrease the
the desired flow pressure is too high, the syrup water pressure by turning off the
rate for more than valve will remain too far open. syrup supply pump in the syrup room.
15 seconds. Once the problem has been corrected,
check the actual and desired total
pounds of syrup on the Syrup Trend
screen. If the difference is more than
three pounds, press the Total Reset
button on the Information page and
restart the blender.
FT100 Low Flow At start up, there is a low flow If running a Brix recipe, is the syrup
Deviation: alarm. Brix close to what is coming out of
the tank in the syrup room? If not
check what is in the tank. The blender
can only compensate for a 20% differ-
ence before it would have to be
slowed down.
The actual flow • The supply pressure should Check the recipe value for the correct
rate is lower than be greater than 50 psi. ratio or Brix.
the desired flow • The pump may not be pro- Once the problem has been corrected,
rate for more than ducing the required pres- check the actual and desired total
15 seconds. sure, may be turning the pounds of syrup on the Information
wrong direction, or the flow screen. If the difference is more than
control valve may not be three pounds, press the Total Reset
functioning correctly. button on the Information page and
MAN-PMX-7.5-07461 7-3
Operation Manual

FT200 High Flow There had been previous Low The blender will try to make up the
Deviation: Flow syrup alarms. difference.
The actual flow During end of run there is a Decrease the water push pressure by
rate is higher than water push out. If the water using a water regulator. Decrease the
the desired flow pressure is too high, the syrup water pressure by turning off the
rate for more than valve will remain too far open. syrup supply pump in the syrup room.
15 seconds. Once the problem has been corrected,
check the actual and desired total
pounds of syrup on the Syrup Trend
screen. If the difference is more than
three pounds, press the Total Reset
button on the Information page and
FT200 Low Flow At start up, there is a low flow If running a Brix recipe, is the syrup
Deviation: alarm. Brix close to what is coming out of
the tank in the syrup room? If not
check what is in the tank. The blender
can only compensate for a 20% differ-
ence before it would have to be
slowed down.
The actual flow • The supply pressure should Check the recipe value for the correct
rate is lower than be greater than 50 psi. ratio or Brix.
the desired flow • The pump may not be pro- Once the problem has been corrected,
rate for more than ducing the required pres- check the actual and desired total
15 seconds. sure, may be turning the pounds of syrup on the Information
wrong direction, or the flow screen. If the difference is more than
control valve may not be three pounds, press the Total Reset
functioning correctly. button on the Information page and
7-4 MAN-PMX-7.5-07461
Operation Manual

FT300 CO2 High The actual and desired flow are Tune the PID loop.
Flow Deviation: not matching on the Trend
screen.
The actual flow The flow control valve is not Re-zero the valve.
rate is higher than zeroed correctly.
the desired flow
rate for more than
15 seconds.
FT300 CO2 Low • The line pressure is inade- • Check the supply pressure. If not
Flow Deviation: quate. high enough, increase the regulator
• The tank pressure has been pressure.
raised. • Increase the regulator pressure.
The actual flow • The actual and desired flow • Tune the PID loop.
rate is lower than are not matching. • Check the fuse.
the desired flow • No flow shows on the flow • Make sure that the isolation valves
rate for more than meter. are opening.
15 seconds.
FT100, FT200, The sensor sends a fault code. • One fault sent could be slug flow.
FT300 Meter This is caused by a mixture of gas
Sensor Fault: and liquid going through the meter.
Find the source of gas if this is a
liquid meter. If this is a gas meter,
there may be a problem with the
CO2 evaporator.
• There may be an issue with the
meter. Call a technician.
The sensor stops • Check the fuse for the meter.
communicating. • Check the wiring to the Prosoft
card.
MAN-PMX-7.5-07461 7-5
Operation Manual

LT200 Syrup The syrup supply tank in the Select another syrup tank or start End
Tank Level Low: syrup room is empty. of Run.
The syrup tank
level is below
operating level but
higher than cut off
level.
LT2400 Product The filler has pushed back Lower the pressure in the filler bowl
Tank High Level: product so the level has gone so the product will return.
The product tank too high.
goes over 90% for
over 3 seconds.
PT2400 Product The CO2 inlet valve is in man- Put the valve in Automatic mode.
Tank High ual open.
Pressure:
The product tank The CO2 inlet valve is stuck • Check the solenoid valve to make
pressure is over 90 open. sure that it is not forced on.
psi for 3 seconds. • Check the solenoid valve to see if it
is stuck open.
• Check the inlet valve to see if the
seat is bad.
PT2400 Product Low pressure when no product Close the product outlet valve.
Tank Low is in the tank.
Pressure:
The CO2 vent valve is in man- Put vent valves in Automatic mode.
ual open.
• Low pressure when product Check the vent valve to see if the seat
is in the tank. is bad.
• The CO2 vent valve is stuck
open.
7-6 MAN-PMX-7.5-07461
Operation Manual

Water Stream The water pump starter is • Reset the water pump starter.
Low Pressure: tripped.
The water pres- Deaerator tank level is low. • Check the water supply.
sure is lower than • Check the tank level control and
25 psi for more valve.
than 3 seconds.
E-Stop: The E-stop has been activated. Reset.
MAN-PMX-7.5-07461 7-7
Operation Manual
7.2.3 — Troubleshooting Warning Alarms
Warning Alarm Possible Causes Action to Take

Outputs in Manual: One or more con- Check each process screen (Blender,
trol devices are in Deaerator, Syrup Tank, Product Tank) for
Manual mode. a Forced On or Forced Off indication.
Return the device to Automatic control.
(See Section 5.6 — Manual Operation.)
LT200 Syrup Tank One of the valves on Place this valve in Automatic mode.
High Level: the syrup tank
(AV212, AV210, or
AV211) is in man-
ual open.
The seal on AV210, Replace the seal.
AV211, or AV212
is bad.
LT2400 Product The blender is off. Restart the blender.
Tank Low Level:
The blender is not On the Information screen, check the pro-
keeping up with the duction rate CPM setpoint against the
filler. CPM current flow. If they are equal, and
the blender is not keeping up, increase the
CPM setpoint to match the filler speed.
If the current flow rate is not keeping up
with the setpoint, check the water flow
control valve on the Blender screen to see
if the water valve is open to 100%. If so,
make sure of the following:
• The product tank pressure is not too
high.
• The mix pump check valve did not fail.
• The mix pump motor is not tripped.
7-8 MAN-PMX-7.5-07461
Operation Manual
Warning Alarm Possible Causes Action to Take

TT2400 Product The chiller is not Check the refrigeration system.
Tank High cooling.
Temperature:
NOTE: This temperature is checked at the product tank outlet 30 seconds after the
blender starts operating.
VS1 Deaerator There is not enough • Check the seal water supply and make
Vacuum Switch: seal water going to sure that it is on.
the vacuum pump. • Check the seals on the pumps prior to
NOTE: This the vacuum pump to make sure one is
alarm is set if not leaking.
the deaerator
has less than The seal in the vac- Rebuild the pump.
15” of vacuum uum pump is bad,
for more than and too much air is
30 seconds. flowing past.
The flow of sweep The flow of this gas should be set at 6
gas going into the scfm.
deaerator is too
high.
The water level in • Make sure that the water inlet valve is
the deaerator is too not forced open.
high, and the vac- • Make sure that the valve zero is
uum pump has shut adjusted correctly.
down. • Check the seal on the valve.
Low Layer: The system is in The depal operator should fill the line
End of Run and the with containers until full, and advise the
syrup cut is initi- blender operator. This can be done with a
ated. radio or by pressing the button on the
Required Layers in depal switch box received with the blend-
Depal counts down ing system.
to zero.
MAN-PMX-7.5-07461 7-9
Operation Manual
7.3 — Troubleshooting Production Problems (No Fault Message)
Problem Action to Take

Product Brix/Assay on • Ensure that the recipe is correct for the syrup chosen.
Startup Low • Check to see if the filler was turning during the drain and
blow of the filler after rinse.
• Check to see if the filler valves were open during and after
the blow so that all of the water drained.
• Check to see if the filler product valve was open 100% (when
applicable) during the rinse and filler blow.
• If product is diet, check to see if the syrup that was sent to the
syrup tank was up to specification when the switch was made
to the syrup tank, from the push out to drain.
• If product is diet, check to see if the syrup made in the syrup
room was at target range or below target range. If it was
below, it could make start up product out of specification.
• Diet or Brix is slightly out of specification. Adjust the offset
at start up on the Maintenance screen.
Product Brix/Assay on • Ensure that the recipe is correct for the syrup chosen.
Startup High • If product is diet, check to determine if the syrup made in the
syrup room was at target range or above target range? If it
was above, it could make start up product out of specifica-
tion.
• If it is a Brix syrup, there may be excess air in the syrup.
Product Brix/Assay • Check the syrup stream trend. If the actual flow is not match-
Varying During Nor- ing the desired flow, the P&ID loop needs to be tuned. This
mal Production will most likely appear during starts or stops.
• The product chiller is icing up due to running refrigeration
too cold.
• There may be seal water leaking into the syrup pump.
7-10 MAN-PMX-7.5-07461
Operation Manual

Product Brix/Assay • The water was connected after the syrup ran out, but the End
Varying at End of Run of Run push button on the screen was not pushed. Water got
in the syrup tank and diluted the syrup.
• There may be a bad seal on the spray ball or the syrup tank
inlet valve. Replace the seal.
• If a plate and frame chiller is in the system, the product push-
out gallon amount may be too high. Adjust at the mainte-
nance screen.
CO2 Variation During If the CO2 is low, one or more of the following may apply:
Startup • There may be excess water in the system. Normally the syrup
is also low.
• The filler was not charged high enough at start up. (See filler
charge instructions.)
• A nitrogen product was the last product run, and the tank was
not purged.
If the CO2 is high, one or more of the following may apply:

• The filler pressure was charged over the pressure of the car-
bonation tank, so gas blew back into the product tank.
• The filler was charged higher than the filler charge proce-
dure.
CO2 Variation During • The temperature is not stable. Look at the temperature trend.
Production • If the CO2 is high, the blender is starting and stopping too
often.
• Product tank pressure is varying more than 2 psi.
No Flow — System Check the gauge on the back pressure regulator on the glycol
Includes a Plate and vapor line. If this reads below 30°, the chiller may be frozen.
Frame Chiller Stop the system, increase the chiller temperature, and run warm
water on the chiller until the pressure gauge reads 40°. Restart
the blender.
MAN-PMX-7.5-07461 7-11
Operation Manual

No Flow • Visually check each valve on the screens to see which ones
are open, then check the valves on the blending system to see
if they are physically open. There is an arrow on each valve
showing the direction of flow.
• Go to the Blender screen. Look at the percentage that each
flow control valve is open. With no flow, the water valve
should be open to 100%. Go to the water flow control valve
and check to see if it is open 100% on the scale. If closed, go
to flow control valve testing.
• Go to the Blender screen. Look at the percentage that each
flow control valve is open. If the water valve is closed and
says 0%, look at the Brix on the syrup meter (if blending a
Brix product). Check to see if this has dropped below the tar-
get syrup Brix. Check to see if there is water in the syrup.
Reduced Flow — • Go to the Information screen and check the setpoint flow
Blender not Keeping against the actual flow. If equal, calculate the gph needed for
up with Filler the container running, and increase the flow so it is equal to
105% of what is needed.
• Check the water supply. Check to see if the deaeration system
is running out of water.
• The product tank pressure has been increased higher than
what the blender is capable to overcome. Check the water
flow control valve; it should be showing 100% open.
7-12 MAN-PMX-7.5-07461
Operation Manual
CHAPTER 8 Parts Lists and Drawings
8.1 — Introduction
The following lists include mechanical parts and available rebuild and kit parts. To order
parts, call the KHS parts department at 262-797-7200. Please note that KHS can schedule
same day shipment if required.
Note:
Parts identified in the following tables inside a circle —

indicate spare parts.
Parts identified in the following tables inside a box —

indicate rebuild and kit parts.
MAN-PMX-7.5-07461 8-1
Operation Manual
Parts Lists and Drawings
Table of Contents
Deaerator Spare Parts ...................................................................................................... 8-3
Deaerator Rebuild Parts .................................................................................................. 8-4
Syrup Inlet Spare Parts ................................................................................................... 8-5
Syrup Inlet Rebuild Parts ................................................................................................ 8-6
Blender Spare Parts ......................................................................................................... 8-7
Blender Rebuild Parts ..................................................................................................... 8-8
Carbonation Spare Parts .................................................................................................. 8-9
Carbonation Rebuild Parts ............................................................................................ 8-10
Pneumatics Spare Parts ................................................................................................. 8-11
Pneumatics Rebuild Parts ............................................................................................. 8-12
Seal Water Spare Parts .................................................................................................. 8-13
Seal Water Rebuild Parts .............................................................................................. 8-14
SIM Spare Parts List ..................................................................................................... 8-15
SIM Available Rebuild Parts ........................................................................................ 8-16
CIP Discharge Spare Parts List ..................................................................................... 8-17
CIP Discharge Rebuild Parts ........................................................................................ 8-18
CIP Return Spare Parts List .......................................................................................... 8-19
CIP Return Rebuild Parts .............................................................................................. 8-20
CIP Steam Condensate Spare Parts List ....................................................................... 8-21
CIP Steam Condensate Rebuild Parts ........................................................................... 8-22
CIP Pump Suction Spare Parts List .............................................................................. 8-23
CIP Pump Suction Rebuild Parts .................................................................................. 8-24
Glycol Chiller Spare Parts ............................................................................................ 8-25
Glycol Chiller Rebuild Parts ......................................................................................... 8-26
8-2 MAN-PMX-7.5-07461
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MAN-PMX-7.5-07461 8-3
Operation Manual
8.1.1 — Deaerator Spare Parts
8-4 MAN-PMX-7.5-07461
Operation Manual
8.1.2 — Deaerator Rebuild Parts
MAN-PMX-7.5-07461 8-5
Operation Manual
8.1.3 — Syrup Inlet Spare Parts
8-6 MAN-PMX-7.5-07461
Operation Manual
8.1.4 — Syrup Inlet Rebuild Parts
MAN-PMX-7.5-07461 8-7
Operation Manual
8.1.5 — Blender Spare Parts
8-8 MAN-PMX-7.5-07461
Operation Manual
8.1.6 — Blender Rebuild Parts
MAN-PMX-7.5-07461 8-9
Operation Manual
8.1.7 — Carbonation Spare Parts
8-10 MAN-PMX-7.5-07461
Operation Manual
8.1.8 — Carbonation Rebuild Parts
MAN-PMX-7.5-07461 8-11
Operation Manual
8.1.9 — Pneumatics Spare Parts
8-12 MAN-PMX-7.5-07461
Operation Manual
8.1.10 — Pneumatics Rebuild Parts
MAN-PMX-7.5-07461 8-13
Operation Manual
8.1.11 — Seal Water Spare Parts
8-14 MAN-PMX-7.5-07461
Operation Manual
8.1.12 — Seal Water Rebuild Parts
MAN-PMX-7.5-07461 8-15
Operation Manual
8.1.13 — SIM Spare Parts List
8-16 MAN-PMX-7.5-07461
Operation Manual
8.1.14 — SIM Available Rebuild Parts
MAN-PMX-7.5-07461 8-17
Operation Manual
8.1.15 — Glycol Chiller Spare Parts
8-18 MAN-PMX-7.5-07461
Operation Manual
8.1.16 — Glycol Chiller Rebuild Parts
MAN-PMX-7.5-07461 8-19
Operation Manual
8-20 MAN-PMX-7.5-07461
Operation Manual
CHAPTER 9 P&ID and Layout Drawing

Supplement
MAN-PMX-7.5-07461 9-1
Operation Manual
P&ID and Layout Drawing Supplement
9-2 MAN-PMX-7.5-07461
Operation Manual
CHAPTER 10 Electrical Schematics
MAN-PMX-7.5-07461 10-1
Operation Manual
Electrical Schematics
10-2 MAN-PMX-7.5-07461
Operation Manual

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Promix Operation Manual - Hermosillo

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Process Technology

Promix Blending System

Manual Number: MAN-PMX-7.5-07461

Promix Blending System

Document Number: MAN-PMX-7.5-07461

Issue Date: August, 2008

Customer: Coca-Cola ARCA

Location: Hermosillo, Tamaulipas, Mexico

Model Number: Promix

Serial Number: 07461

Copyright 2008 © KHS USA

880 Bahcall Court

Chapter 4: Machine Description

Chapter 5: Screen Navigation and Blender Operation

Manual Operation ................................................................................................................ 5-12

Analog Force Screen .....................................................................................................5-35

Chiller Quantity (Used with an Off-Skid Chiller) ........................................................6-18

Chapter 7: Alarms and Troubleshooting

Chapter 8: Parts Lists and Drawings

Chapter 9: P&ID and Layout Drawing Supplement

Chapter 10: Electrical Schematics

Please review Chapter 2 — Safety.

Your KHS promix blender includes the following features:

1.2 — Blender Specifications

1.3 — Text Notes and Explanations

Throughout the manual certain tables and symbols appear:

WARNING: Warnings are accompanied by a red alert symbol, and they

IMPORTANT: To alert the reader to pay careful attention, these signs

1.3.3 — Electrical Information

FIGURE 1-1. Promix (Typical)

KHS is committed to continuous improvement in the development of all of its machines.

2.1 — General Information

WARNING: To safeguard against injury, follow any and all company

ALWAYS OBSERVE THE FOLLOWING:

WARNING: Operating a malfunctioning machine could cause serious

NEVER DO THE FOLLOWING:

BE ALERT FOR THE FOLLOWING HAZARDS:

2.4 — Spare and Wear Parts

IMPORTANT: KHS does not accept liability for any injury to

2.5 — Disconnection Considerations

1. Stop the machine and follow tagout/lockout procedures.

3.2 — Field Welding

WARNING: Never perform any welding on any part of the system

IMPORTANT: Final equipment installation must be leveled across

3.5 — Accessory Parts Box

3.6 — Piping Considerations

3.6.1 — General Piping

3.6.2 — Water Piping

3.6.3 — Syrup Piping/CIP Piping

3.6.4 — Compressed Air Piping

3.7.1 — Electrical Enclosures

The electrical system is enclosed to protect electrical components from moisture

3.7.2 — Control System Power

CHAPTER 4 Machine Description

Carbonation/ Syrup Tank Deaerator Tank

P1100 Mix P2 H20

The promix deaeration system

FIGURE 4-2. Deaerator Circuit

4.1.2 — CO2 Injection (Sparge)

The flow indicator should be set

FIGURE 4-3. CO2 Stream

4.1.3 — Pump Seal Water

Seal Water Heat