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Third Edition, Nov 2016

ACS V4.2

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9

Section C. ACS Operations Overview

Section C.

ACS Operations Overview

C.1

System Operation Walkthrough

This section details the steps and procedures you’ll need to familiarize yourself with in order to operate the ACS. This
includes all functions and the effect of every switch and button on the machine. The following is a brief breakdown of the
line’s operation. Beginning at can in feed and following through to finished product out feed.



The conveyer belt carries cans to the first gate. The gate, just after the fill head, has a dual function, A) stopping
and holding cans under the fill head, and B) opening just long enough to allow the five filled cans to pass after fill
cycle.



The fill head waits for ten cans to accumulate underneath it before lowering. The first set of five cans are filled
with beer. The second set of five cans are purged with CO2. When the beer level reaches the sensors the fill stops,
the head rises, and the gate opens to allow the 5 filled cans through and stops the 5 purged cans under the raised
fill tubes.



The filled cans leave the gate, pass under the lid dispenser where the leading edge of each can grabs a lid as it
passes under the slide, pulling a lid onto the top of each can. The area immediately under the lid dispenser and
the dome under the can lid are purged with CO2 during the process.



Cans then stop at the block before the #1 push cylinder. This block acts both to stop the flow, and trigger the
cylinder to push the can onto the seamer lift table. This sensor also triggers the lid dispenser to drop another lid
into the lid slide tray.



Once on the lift table the can is raised into the chuck, which rotates the can. The #1 die pushes into chuck making
the first seaming operation, followed by #2 which completes the seam, then the lift table lowers.



The lowered can is pushed off the lift table by the oncoming can and deposited in front of the #2 push cylinder,
which pushes it onto the out feed conveyer which carries it through the washer/dryer (if installed), after which
the final product is carried to the end of the process, the collection table.

C.2

Controllers

C.2.1

HMI Panel – Main Page

Main screen to start the seamer motor and the belt. Also, controlling CIP, Top Up, Foam Valves, Lid Dispenser. Main Screen
has integrated timers for better production monitoring while filling.

Figure 7 HMI Panel – Main Page screenshot

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Summary of Contents for ACS V4.2

Page 1: ... Free 1 800 661 8443 Direct 1 403 640 4677 Fax 1 403 640 4680 e mail info cask com Technical Service Support Parts Order 1 800 661 8443 Option 4 1 800 661 8443 Option 4 support cask com parts cask com Official supplier of Ball Corporation for the supply of printed aluminum cans to our customers cask com ...

Page 2: ...ncluded set of instructions and descriptions are accurate for the Cask Brewing Systems Inc Automated Canning System Version 4 2 ACS V4 2 in its stock condition as supplied by Cask Brewing Systems Inc at the time of this manual s production However subsequent products and manuals are subject to change without notice Therefore Cask Brewing Systems Inc assumes no liability for damages incurred direct...

Page 3: ... Expanded Frequently Asked Questions section Third Edition November 2016 ACS V4 2 Formatting update Can Seam Evaluation videos added Updated Parts List Expanded Can Table Height Adjustment section Future Updates As we evolve future iterations of this Manual we will post the most recent versions and updates on line at our website www cask com customer login Password CaskCustomer Note you will also ...

Page 4: ...on Motors 20 Section D ACS System Operations 22 D 1 Initial Start up Adjustments Settings 22 D 2 Pre Start Checklist 22 D 3 Startup Operation 23 D 4 Clean in Place CIP System 23 D 5 ACS Post Operation Shutdown Checklist 24 D 6 System Periodic Maintenance 25 D 7 Parts List 25 D 8 Adjustment Troubleshooting 27 D 9 Frequently Asked Questions 32 Section E Seam Measurement 37 E 1 Can Seam Evaluation Tr...

Page 5: ...6 ACS V4 2 Page 4 Section A Before You Begin Section A Before You Begin A 1 Unit Diagram Figure 1 Automated Canning System Unit Diagram A 2 System Requirements Figure 2 Top View Canning System Requirements all hookups except drain on backside of unit ...

Page 6: ...sk ACS Inspect crate exterior and document any damage incurred in transit Cut metal bands and remove from exterior of crate Use pry bars to remove plywood covering each end Figure 4 Step 1 Next remove plywood skin from top of crate Figure 4 Step 2 Leave end supports and remove all top cross supports with hammer Brace sides or have someone hold them in place and remove last top cross supports Gentl...

Page 7: ...close to welded joints as possible to prevent bending cross supports Slide lifting forks under lower supports centered on balance fulcrum of unit which is located on center of the machine Figure 5 Forklift moving Cask ACS into position B 4 Initial Adjustments Settings Your Cask canning line has been factory tested prior to shipping to allow for trouble free installation by a Cask Technical Represe...

Page 8: ...0psi from plant system connected to machine with 3 8 barbed fitting Drainage Drainage is required from the canning table to drain standard 1 waste pipe connection Beer 1 5 2 beer line from dispense tank Beer supplied to machine at a temperature of 32 to 35 6 F 0 to 2 C Forklift To unload the equipment on arrival Table 1 ACS Machine Specifications B 5 Unloading Cans The cans come stacked up to 8 9 ...

Page 9: ...www cask com 1 800 661 8443 Third Edition Nov 2016 ACS V4 2 Page 8 Section B Unit Setup Figure 6 Forklift carrying your printed cans A and a pallet of can lids or ends B B A ...

Page 10: ...ed cans leave the gate pass under the lid dispenser where the leading edge of each can grabs a lid as it passes under the slide pulling a lid onto the top of each can The area immediately under the lid dispenser and the dome under the can lid are purged with CO2 during the process Cans then stop at the block before the 1 push cylinder This block acts both to stop the flow and trigger the cylinder ...

Page 11: ...clean in place function on or off Top Up Indicator Switch Auto Lights up when top up is running Turn top up on or off depending on position Top Up Timer Auto Sets the amount of time the top up will last for Foam Valves Indicator Switch Auto Lights up when foam valves running Turn foam on or off depending on position Foam Valve Timer Auto Sets the amount of time the foam valves will be on for Start...

Page 12: ... or stops the conveyer depending on position Lid Purge Manual Opens under lid gas purge Filler Cylinder Button Manual When held down the fill head will lower fill head into the down position when released the fill head will return up Pre rinse Manual Opens pre rinse water supply All Can Fill Button Manual Opens all 5 fill stations Table 3 HMI Panel Filler Page Button Functions C 2 3 HMI Panel Seam...

Page 13: ...0 Emergency Stop and Power Buttons Button Switch Manual Auto Function Emergency Stop Button Both Immediately stops the system from operating and pneumatics return to their rest positions Main Switch behind machine Both Main power supply switch Table 5 Manual buttons located below the touchscreen C 3 HMI Control Panel Operations There are two different operating modes that the ACS can operate in an...

Page 14: ...Top up button to allow you to turn top up on and off and control the duration of the top up timer 3 Foam valves to allow you to turn foaming on and off and control the duration of the foam creation with the timer 4 Fill stop to allow you to stop filling while continuing to seam remaining cans filler will continue to fill cans that are in the filler but will not begin the next fill cycle cans will ...

Page 15: ...www cask com 1 800 661 8443 Third Edition Nov 2016 ACS V4 2 Page 14 Section C ACS Operations Overview Figure 12 Variable Frequency Drives VFD s 1 for main conveyor motor and 2 for seamer motor 1 2 ...

Page 16: ...ER MOTOR 5 START DRYER SOLENOID 6 WASHER SOLENOID 7 PRE RINSE SOLENOID 8 CO2 PURGE LID DISPENSER 9 CO2 PURGE CANS 10 BEER VALVE 1A 11 BEER VALVE 2A 12 BEER VALVE 3A 13 BEER VALVE 4A 14 BEER VALVE 5A 15 BEER VALVE 1B 16 BEER VALVE 2B 17 BEER VALVE 3B 18 BEER VALVE 4B 19 BEER VALVE 5B 20 FOAM VALVE 1 21 FOAM VALVE 2 22 FOAM VALVE 3 23 FOAM VALVE 4 24 FOAM VALVE 5 Figure 13 Relay wiring diagram ...

Page 17: ... will fail to open In Figure 14 you can see the two sets of five supply lines that are connected to the valves in the fill head as well as the single supply line from the tank Best practise is to install a temperature and pressure gauge on the end of the beer manifold to allow monitoring of temperature and pressure of the beer at the delivery point to the machine Figure 14 Beer Manifold C 4 3 Fill...

Page 18: ... com 1 800 661 8443 Third Edition Nov 2016 ACS V4 2 Page 17 Section C ACS Operations Overview Figure 15 Can Gate downstream of fill head Figure 16 ACS fill head showing fill sensors foam tube and fill tube Gate ...

Page 19: ...urbulence created as the beer flows into the filled can to beers that foam too much when the foam valves are used To operate turn the foam valve on when the fill heads are at rest Set the timer to 0 25 seconds Run a few can fill cycles to gauge the effect Increase the time interval as required Note When setting interval on top up timer be sure that beer valves are not still open verify visually du...

Page 20: ...sed beneath the lid to purge air from the top of can A new lid is dropped into the tray for every can that comes into contact with the position sensor at 1 push cylinder Lids can be manually dispensed using the Lid Dispense button on the Seamer Panel see Figure 9 on Page 11 For more information regarding adjustment and troubleshooting refer to Section D 8 1 Lid Dispenser Adjustment Troubleshooting...

Page 21: ...em at the primary regulator Figure 19 The primary regulator is located outside of the back cabinet and should be set to 90 PSI All of the devices and cylinders are controlled through the actuator bank Each actuator has two air lines coming out of it and into the front and back of an individual air cylinder on the system The rate of flow through each cylinder is controlled by an airflow control scr...

Page 22: ...tion Nov 2016 ACS V4 2 Page 21 Section C ACS Operations Overview There should be no adjustments needed to any of these motors after initial installation Figure 20 The ACS has two motors to drive the seamer and the main conveyor MOTORS 1 2 ...

Page 23: ...gulator 0 5 2 PSI CO2 delivery Check and verify CO2 dispenses from purge tubes and lid dispenser slide Water inlet valve is open The regulator should read 22 PSI applies to models with rinser dryer and or pre rinser Beer header input pressure and head pressure on the tank should be within 1 to 2 PSI differential pressure of each other to ensure consistent fill levels Conveyor guides Cans travel fr...

Page 24: ... should be checked frequently once every three to five minutes throughout production Production should be stopped if there is a change of more than 2 1000 on either dimension A full seam tear down should be performed to determine the cause of the change and the adjustments required The procedure for checking the quality of your seams is a Can Seam Tear Down This enables you to make various measure...

Page 25: ... fill valve coils to cool before cycling on again This will prevent the coils from overheating and potentially burning out This sequence will be repeated for 30 minutes until the stop button is pushed Notes on CIP Pressure when flushing the system with water or cleaning solutions it is important to keep pump pressures below 24 PSI The fill valves will not open at pressures higher than this level I...

Page 26: ... 7 mm inlet on fill valve R 990704 N 1 O ring small for tap spout inside R 990015 N 2 O rings large for tap spout outside FES DSNU2599PPVAMQQTXT Festo Can Push 1 Air Cylinder 99mm FES SMT8MANS24VE03M Air Cylinder Proximity Limit SENSOR CBS NOZ PRERINSE Plastic nozzles adj mist spray for ACS rinser 100pcs bag SETSCR SEAM ROLL Seam roller adjust set screw w nylon tip FES ADVUL 40 25 P A Festo seam t...

Page 27: ...view of 2 seaming roll 1 2 A B C D E A Can Ball Top B Bearing C External Retainer Ring D Can Ball Top Male E Can Ball Top Female 1 A B C E D A Pivot Shaft Spindle B Bearing C Internal Retainer Ring D Internal Shim E Adjuster Block 1 2 A B C D E F A B C D E A Spindle Housing Bearing Retainer B Bearing C Inner Bearing Spacer D Outer Bearing Spacer E Spindle Housing F Seamer Spindle A Seaming Roll B ...

Page 28: ...ptoms Lid not releasing from bottom of slide correctly Lids not catching can Lids not automatically refilling Adjustment Points If cans tip over after lid application loosen rubber band tension If can lids drop frequently with no cans in place tighten rubber band Figure 23 shows set bolts for adjustment of can lid dispense height Set screws under the retaining bars Figure 23 Setting bolts to adjus...

Page 29: ...ition of the hopper and tray It should be positioned as below in Figure 24 Figure 24 Ideal lid dispense hopper and tray configuration D 8 1 3 Problem 3 Symptoms Lids miss the can fail to grab the can as it passes by on the conveyor Adjustment Points Check for proper height of Lid Dispenser Slide see Figure 25 If height is found to be incorrect Loosen Bolts and carefully adjust to suitable height t...

Page 30: ...2016 ACS V4 2 Page 29 Section D ACS System Operations Figure 25 Ideal can lid dispensing diagram The Can Lid should look as pictured in a full rest position This enables the lip of the can to catch the Can Lid and drag it off of the Can Slide Table ...

Page 31: ...s if no cracks are found go to the air bank and depress the corresponding actuators button to manually override the corresponding pneumatic cylinder If you are unable to manually override the air bank this is possibly a result of a bad malfunctioning partition of the bank itself To test a possible bad partition remove and swap with a mating partition If the problem moves to the swapped out part yo...

Page 32: ...g either of these screws in a clockwise direction will slow the stroke Dialling counter clockwise will speed up the stroke Turning the flow control clockwise will close the airflow control thereby slowing motion down Conversely counter clockwise will open the airflow control speeding motion up All of the solenoids are labeled as to which cylinder they control This becomes important when setting up...

Page 33: ...ere should be no detectable bump i e the slide table should be at the same height as the top of the conveyor belt Adjust the height of the slide table by loosening the nuts on top Figure 29 Photo 1 and raising or lowering as required the nuts on the bottom Figure 29 Photo 2 Retighten the top nuts If the stumble is occurring at the can lift table it may be necessary to adjust the height of the heig...

Page 34: ... assembly D 9 1 2 Cans misfeed and crush against chuck during seaming Problem Symptoms The can appears to load crooked lopsided or incompletely and is not centered when the can lift table rises resulting in the can crushing against the chuck as it rises Solutions Check the alignment and position of Push Cylinder 1 If extensive can jamming has occurred or the push cylinder has been bumped by an ope...

Page 35: ...sensor is at rest the back sensor light should be illuminated If it is not the sensor has been misaligned and it needs to be shifted forward or backward on the cylinder body until the light stays illuminated Figure 31 Proximity Sensor D 9 1 4 Push arm 1 does not retract Problem Symptoms Push arm loads a can on but then stays in the fully extended position won t retract Solutions In manual mode pre...

Page 36: ...y can that touches the sensor at the end of the line If you start with too many lids in the lid slide it can overfill which will cause a jam at the top ALWAYS count the lids in the slide prior to restarting after a can misfeed D 9 2 4 Cans stick in lid slide or do not fully descent Lids miss the can Problem Symptoms Cans stick in lid slide do not fully descend or lids miss the can altogether Solut...

Page 37: ...or may be defective and require replacement D 9 3 4 More than 5 cans exit the filler after a fill cycle Problem More than 5 cans exit the filler after a fill cycle Solution The count out sensor is miscounting cans One of two possible adjustments or a combination of the two may be required Adjust the position of the front guide rail of the conveyor so that it is closer to the back rail The two must...

Page 38: ...mining the results of both the first and second operation seaming rolls The first die has a wider roll that creates the initial loose fold This operation puts the hooks in place but does not seal it The second die is narrower pressing the seam into itself and actually sealing the can Figure 32 Visualization of a double seam in 3D E 1 Can Seam Evaluation Training Videos There are three detailed Can...

Page 39: ...eading a micrometer of any kind is not as hard as some may think If you can simply add and subtract you can read a Micrometer Below are a few simple pointers to get you started Each Tick Thimble Sleeve is equal to 0 025 25 Thousandths of an inch therefore 0 025 x 4 Ticks 0 100 and so on Each Tick on the Thimble is equal to 0 001 1 Thousandth of an inch therefore on complete revolution from 0 back ...

Page 40: ...at 0 the total was 0 250 as it is here but The 2 002 is in line with the Thimble Sleeve so we need to add that to the 0 250 0 250 0 002 0 252 If the 24 on the Thimble was in Line with the Thimble Sleeve we would take the read of above 0 250 and add the in line 24 0 024 0 274 overall Figure 35 Seam Micrometer 0 1 Example 3 E 4 Seam Measurement Seams should be checked on a regular basis in order to ...

Page 41: ...s and fractures of the seam itself E 4 2 Seam Height If the can passes a basic visual inspection and there are no obvious problems you can move on to more precise measurements with your can seam micrometer It is best to check the seam height and width before opening or cutting the can For best results use a can seam micrometer for measuring seam width It s design enables you to get consistent meas...

Page 42: ... section of the seam off of the can from the lip Then using a pair of needle nosed pliers or some other similar tool pull the body hook away from the cover hook and unfold the cover hook from itself in order to be able to see it Refer to Page 35 of the Darex Evaluating and Controlling Double Seams Manual that you received with your system This video also shows the process of a Manual Can Teardown ...

Page 43: ... Long Body Hook Lift table set too high Die 1 set too far from the chuck Short Cover Hook Lift table set too high Die 1 set too far from the chuck Long Cover Hook Die 1 set too close to the chuck Table 9 Common seam issues and problem resolution Figure 37 Seam roll process first and second operation seams E 6 Seam Specifications Ball Can Seam Specifications These specifications will vary depending...

Page 44: ...Operation compresses the seam creating a tight seal 5 Once both seaming operations are complete the lift table will drop bringing the can back down Figure 38 Can seaming station F 1 Seamer Adjustment Troubleshooting Good seams start with The proper base plate pressure see F 1 3 Can Table Height on Page 46 The proper first operation seam roll thickness generally 0 076 0 002 o This dimension is for ...

Page 45: ...ays within specifications the following adjustments can be made Can Platform Height Set Screw on back of table Can Platform Height Adjust CW DOWN CCW UP Turn clock wise to raise seam wheel Seam Roll Height Set Screw Seam Roll Height Set Screw Turn counter clock wise to lower seam wheel Seam Wheel Lock Nut Seam Wheel Proximity Adjustor CW In CCW Out ...

Page 46: ...Rotating the piston on the First Op Seaming Roll in a clockwise direction will move the seaming wheel CLOSER to the chuck Observe the gap between the seaming wheel and the chuck as you turn the piston Once the gap has been adjusted retighten the set bolt Figure 40 Seaming Wheel Proximity F 1 2 Seaming Wheel Height Adjustment The height of each seaming wheel relative to the chuck can be adjusted as...

Page 47: ...ont of the can platform With the unit in manual mode actuate the can lift button so that the can platform is extended Loosen the can seam height set bolt 2 or 3 turns Grasp the middle section indicated above by the red arrow in Figure 42 not the top section on which the can rests Turn clock wise to increase the height counter clock wise to lower it For initial set up raise the platform until there...

Page 48: ...nd long seaming cycle can also affect the final seam specifications This speed is controlled by the flow controls on air valves which control the flow of air to the air cylinders that move the seaming wheels and the can platform Refer to Section D 8 2 1 Air Cylinder Speed Adjustment on Page 31 for details on how to adjust the air cylinders F 2 Seamer Troubleshooting Testing the First Operation Sea...

Page 49: ...earing slide onto Spindle and into Spindle Housing 4 Spindle Housing Bearing Spacer 5 Spindle Bearing Spacer 6 Bearing slide onto Spindle and into Spindle Housing 7 Bearing Retainer Ring 4 Bolts 8 Lock washer Spanner Nut 1 2 3 4 5 6 7 6 5 4 3 2 1 1 Can table top 2 Slide Bearing onto Shaft 3 Install Snap Ring Retainer into Groove 4 Slide Second Bearing onto Shaft 5 Insert bearings and Can Table Top...

Page 50: ...ent damage to your feet from possible falling debris NEVER wear Gloves of any kind when operating Machinery Moving parts can catch the gloves and pull you into the machine resulting in possible injury There are many moving parts on Casks Machinery Please use caution when operating any component keep note that any moving part is a potential hazard Compressed Air is used in many components of this M...

Page 51: ... thereto Cask Brewing Systems Inc shall not be liable for any claim of lost revenues products or profit resulting from any defect which is the subject of a proper warranty claim If more than one Canning System shall be purchased by the Purchaser at one time a warranty claimable defect found in one system shall not entitle the Purchaser to refuse payment or delivery or to claim a set off in respect...

Page 52: ...00 64 Ave SE Calgary Alberta T2C 4V3 CANADA Toll Free 1 800 661 8443 Direct 1 403 640 4677 Fax 1 403 640 4680 Email info cask com Website www cask com Technical Service Support Toll Free 1 800 661 8443 Option 4 Direct 1 403 640 4677 Option 4 support cask com Parts Order Toll Free 1 800 661 8443 Option 4 Direct 1 403 640 4677 Option 4 parts cask com www cask com ...

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