Alfalaval HS-LA FILLER Manual

Ver. 01
Original instructions
Operations & Maintenance Manual
HS-LA FILLER
Machine Serial No. : 2016-094
Project No. : 21R60.BA 0180

GENERAL INDEX
HS-LA FILLER_IM_E I
GENERAL INDEX
1 INTRODUCTION .................................................................................................1
1.1 WARNING ..................................................................................................................1
1.2 CHOICE AND QUALIFICATION OF THE OPERATOR.............................................2
1.2.1 GENERIC OPERATOR:......................................................................................2
1.2.2 MECHANICAL MAINTENANCE:.........................................................................2
1.2.3 ELECTRICAL MAINTENANCE:..........................................................................2
1.2.4 ALFA LAVAL TECHNICIAN: ................................................................................2
1.3 GUARANTEE.............................................................................................................3
1.3.1 SCOPE OF THE GUARANTEE ..........................................................................3
1.3.2 DURATION OF THE GUARANTEE ....................................................................3
1.3.3 APPLICATION OF THE GUARANTEE ...............................................................4
1.3.4 EXCLUSIONS AND LIMITS ................................................................................4
1.3.5 HOW TO RETURN THE DEFECTIVE MATERIAL..............................................4
1.4 TEST AND RESPONSIBILITY ..................................................................................5
1.5 SOFTWARE LICENCE ..............................................................................................6
1.6 TECHNICAL REFERENCE STANDARDS ................................................................7
2 GENERAL INFORMATION .................................................................................1
2.1 SAFETY .....................................................................................................................1
2.1.1 WARNINGS.........................................................................................................1
2.1.2 PERSONAL PROTECTIVE EQUIPMENT ..........................................................2
2.1.3 THE OPERATOR SHOULD ................................................................................4
2.1.4 THE OPERATOR SHOULD NEVER...................................................................4
2.1.5 THE OPERATOR SHOULD ALWAYS .................................................................5
2.1.6 DANGEROUS AREAS – WORKING AREAS ....................................................6
2.1.7 SAFETY SYMBOLS............................................................................................8
2.1.8 SAFETY SYMBOLS POSITION ....................................................................... 11
2.1.9 RESIDUAL RISKS DANGER SOURCE AREA .................................................26
2.1.10 IDENTIFICATION OF THE MACHINE ..............................................................31

GENERAL INDEX
HS-LA FILLER_IM_E
II
2.2 RECEPTION AND CONTROL OF THE MACHINE ................................................32
2.2.1 TRANSPORT ....................................................................................................32
2.2.2 ADOPTION OF PROTECTION DEVICES ........................................................34
2.2.3 PACKING OF THE MACHINE...................................................... 35
2.2.4 HANDLING AND LIFTING OF THE PACKING .................................................37
2.2.5 UNPACKING AND INITIAL INSPECTION.........................................................40
2.2.6 PACKAGING DISPOSAL ..................................................................................41
2.3 STOCKING / STORAGE..........................................................................................41
2.3.1 STORAGE BEFORE INSTALLATION...............................................................41
2.4 DEMOLITION AND DISPOSAL ..............................................................................42
2.4.1 INTRODUCTION...............................................................................................42
2.4.2 PROCEDURE ...................................................................................................43
2.4.3 DEMOLITION MATERIALS............................................................................... 43
2.4.4 INSTRUCTIONS FOR SUITABLE TREATMENT OF WASTE .........................45
2.4.5 INSTRUCTIONS FOR SUITABLE TREATMENT OF WASTE
ELECTRICAL AND ELECTRONIC EQUIPMENT (WEEE) ...............................45
3 TECHNICAL DATA..............................................................................................1
3.1 MAIN DESCRIPTION.................................................................................................1
3.1.1 INTENDED USE AND REASONABLY FORESEEABLE USE ............................ 6
3.1.2 MAIN COMPONENTS ........................................................................................7
3.1.3 OVERALL DIMENSIONS AND WEIGHTS.......................................................... 9
3.1.4 WEIGHT AND DIMENSION .............................................................................. 11
3.1.5 PRESSION AND CONSUMPTION ................................................................... 11
3.1.6 FEATURES OF THE CIRCUITS AT MACHINE BOARD................................... 11
3.1.7 PRODUCTION TYPE........................................................................................12
3.1.8 VIBRATIONS ....................................................................................................12
3.1.9 WATER STANDARD .........................................................................................12
4 INSTALLATION ...................................................................................................1
4.1 INTRODUCTION ........................................................................................................1
4.2 ENVIRONMENTAL CONDITIONS OF USE...............................................................1
4.3 USE OF PERSONAL PROTECTIVE EQUIPMENT...................................................2
4.4 POSITIONING THE MACHINE PARTS - SEE LAYOUT CHAPTER 8.....................2

GENERAL INDEX
HS-LA FILLER_IM_E III
4.5 MACHINE LEVELLING..............................................................................................6
4.5.1 LEVELLING CHECK POINTS.............................................................................7
4.6 MACHINE ASSEMBLING ..........................................................................................9
4.6.1 LIGHT TOWER INSTALLATION .......................................................................10
4.7 CONNECTIONS ....................................................................................................... 11
4.7.1 CONNECTION TO UTILITIES AND PRODUCTION LINE................................ 11
4.7.2 ELECTRIC CONNECTIONS............................................................................. 11
4.8 ROTATION OF ELECTRIC MOTORS......................................................................13
5 INSTRUCTIONS FOR THE OPERATOR ............................................................1
5.1 CHECKING BEFORE STARTING .............................................................................2
5.2 PUSH BUTTON BOARD DESCRIPTION..................................................................4
5.3 STARTING PROCEDURE .........................................................................................6
5.3.1 OPERATOR’S POSITION...................................................................................6
5.3.2 START-UP...........................................................................................................6
5.3.3 MANUAL BAGS STRIP LOADING......................................................................7
5.3.4 MANUAL BAGS STRIP UNLOADING ..............................................................14
5.3.5 LOADING AND UNLOADING DISINFECTANT ................................................15
5.4 OPERATOR PANEL USE - HOME - ........................................................................17
5.4.1 PROCESS LAY OUT.........................................................................................19
5.4.2 MOTION LAY OUT............................................................................................27
5.4.3 ASEPTIC TANK HMI REMOTE CONTROL...................................................... 31
5.4.4 CONVEYOR BELTS LAY OUT .........................................................................31
5.4.5 ACTIVE MAINTENANCE WARNINGS .............................................................32
5.4.6 ACTIVE MANUAL COMMANDS .......................................................................32
5.4.7 ACTIVE ALARM ...............................................................................................33
5.4.8 DATA RECORDER............................................................................................33
5.4.9 MOTION RECIPES DATABASE .......................................................................34
5.4.10 CONTROL PANEL ............................................................................................34
5.4.11 USER LOGIN ....................................................................................................42
5.4.12 RECIPE MENU .................................................................................................42
5.4.13 USING THE DEVICE SYMBOLS......................................................................60
5.4.14 COLOURS ........................................................................................................60
5.4.15 DEVICE SYMBOLS ..........................................................................................61

GENERAL INDEX
HS-LA FILLER_IM_E
IV
5.5 CRITICAL CONTROL POINTS ...............................................................................62
5.6 OPERATIVE PHASES DESCRIPTION....................................................................63
5.6.1 PRODUCTION ..................................................................................................63
5.6.2 SIP ....................................................................................................................63
5.6.3 CIP ....................................................................................................................64
5.7 ALARMS ..................................................................................................................65
5.8 GUARDS SAFETY SWITCHES BYPASS ...............................................................69
5.9 FORMAT CHANGING..............................................................................................71
5.10 EMERGENCY STOP................................................................................................74
5.11 RESTARTING THE MACHINE AFTER IT HAS STOPPED.....................................75
5.12 MACHINE STANDSTILL FOR OVER THREE MONTHS ........................................75
6 MAINTENANCE INSTRUCTIONS ......................................................................1
6.1 MAINTENANCE .........................................................................................................1
6.1.1 GENERALS.........................................................................................................1
6.2 ORDINARY MAINTENANCE OPERATIONS ............................................................3
6.2.1 MAINTENANCE OPERATIONS FOR FILLER’S VALVE BODY. ........................ 3
6.2.2 RECOMMENDED CLEANING PROCEDURES ................................................. 4
6.2.3 MAINTENANCE OPERATIONS FOR CIP / SIP PLATE GASKET.................... 21
6.2.4 AX103 – DECAPPER CLAMP LIFT..................................................................22
6.2.5 AX102 AND AX105 – DECAPPER CLAMP ROTATION AND CLOSURE ........24
6.2.6 AX150 AND AX151 – BAG LOADER CLAMPS ................................................ 34
6.2.7 AX107 – FILLING VALVE STEM.......................................................................36
6.2.8 AX106 – FILLING VALVE LIFT .........................................................................37
6.2.9 ORDINARY MAINTENANCE TABLE ................................................................38
6.3 NOT-ORDINARY MAINTENANCE ..........................................................................41
6.3.1 MOBILE HEAD MOTORS REPLACEMENT.....................................................41
6.3.2 STERILE FILTER MAINTENANCE...................................................................48
6.3.3 DISINFECTANT TANK MAINTENANCE...........................................................49
6.3.4 BATTERIES ......................................................................................................50
6.4 CLEANING...............................................................................................................51
6.5 LIST OF MAINTENANCE CARRIED OUT ..............................................................52

GENERAL INDEX
HS-LA FILLER_IM_E V
7 SUGGESTED SPARE PARTS ............................................................................1
7.1 SPARE PART LIST ....................................................................................................1
7.2 SPARE PARTS TABLE ............................................................................................. 8
7.2.1 INTRODUCTION.................................................................................................8
7.2.2 DESCRIPTION OF CONTENTS OF SPARE PART TABLES ............................8
7.2.3 HOW TO INTERPRET THE SPARE PART TABLES ..........................................9
7.2.4 FILLING VALVE ASSEMBLY - 70-57-003-02....................................................10
7.2.5 VALVE STEAM DIFFUSER ASSEMBLY - 70-57-005-01 ................................. 12
7.2.6 UNCAPPER MOVEMENT ASSEMBLY - 04-02-0022-01.................................. 14
7.2.7 UNCAPPER ASSEMBLY - SMURFIT SCREWCAP - 04-02-101-00................. 16
7.2.8 ASEPTIC FILLING HEAD ASSEMBLY - 70-51-001-01.....................................18
7.2.9 PRESENCE CAP - 70-51-002-00 .....................................................................22
7.2.10 UNCAPPER ASSEMBLY - 70-56-001-01..........................................................24
7.2.11 VALVE HANDLING ASSEMBLY - 70-57-002-02...............................................27
7.2.12 STEM LIFTING ASSEMBLY - 70-57-001-01.....................................................30
7.2.13 LOADER GROUP ASSEMBLY - 70-55-001-01.................................................32
7.2.14 BAG FEEDER CLAMP ASSEMBLY - 70-61-001-02.........................................35
7.2.15 BAG FEEDER CLAMP 150 ASSEMBLY - 70-61-002-00..................................39
7.2.16 FLAT UNCAPPER KIT - 70-61-004..................................................................44
7.2.17 WASHING PLATE GROUP ASSEMBLY - 70-58-001-02 ..................................46
7.2.18 CLAMP SUPPORT ASSEMBLY - 70-68-001-01 ............................................... 50
7.2.19 CUTTER ASSEMBLY - 70-60-001-02...............................................................52
7.2.20 TANK ASSEMBLY - 21-06-335-01 ....................................................................54
7.2.21 VENTURI GROUP ASSEMBLY - 70-66-010-01................................................56
7.2.22 STERILIZED AIR HEATER ASSEMBLY - 70-66-022-01...................................58
7.2.23 EJECTION STEAM BARRIER PIPING ASSEMBLY - 70-69-026-01 ................60
7.2.24 SUCTION EJECTOR ASSEMBLY - 21-01-090-00............................................62
7.2.25 DISPENSER TANK - 21-06-338........................................................................64
7.2.26 VENTURI GROUP ASSEMBLY - 70-66-010-01................................................66

GENERAL INDEX
HS-LA FILLER_IM_E
VI
7.3 HOW TO ORDER SPARE PARTS .......................................................................... 68
7.3.1 USE OF THE CATALOGUE .............................................................................. 68
7.3.2 TO ORDER SPARE PARTS..............................................................................68
7.3.3 CARD FOR SPARE PARTS ORDERING .........................................................69
8 LAYOUT - FLOW SHEET - ELECTRIC AND PNEUMATIC DIAGRAM..............1
8.1 LAYOUT 01.00.1908-00 .............................................................................................1
8.2 P&ID 05.04.1330-02...................................................................................................3
8.2.1 LIST OF COMPONENTS..................................................................................17
8.3 ELECTRIC AND PNEUMATIC DIAGRAM ..............................................................21
8.3.1 INTRODUCTION...............................................................................................21
8.3.2 HOW TO INTERPRET THE WIRING DIAGRAM .............................................21
8.3.3 ELECTRICAL AND PNEUMATIC ..................................................................... 21
9 COMPONENTS AND CERTIFICATES................................................................1
9.1 LIST OF ATTACHMENTS ..........................................................................................1
10 UPDATINGS ........................................................................................................1
10.1 MANUAL UPDATINGS ..............................................................................................1

CHAPTER 1 INTRODUCTION
HS-LA FILLER_IM_E 1
1 INTRODUCTION
1.1 WARNING
The instructions accompanying the machine should be “original instuctions” or a “translation of
the original instructions”. In this case, you should attach a copy of the original instructions to the
translation.
These INSTRUCTIONS FOR USE & MAINTENANCE are part of the machine and should accom-
pany it throughout its useful life until disposed of INSTRUCTIONS.
Before starting ANY operation, consult the relevant Section of these INSTRUCTIONS.
Make sure that nobody has access to the machine before getting thoroughly acquainted with these
INSTRUCTIONS.
The only operations allowed are those described in these INSTRUCTIONS.for any operation other
than these, contact Alfa Laval’s Customer Service.
!
ATTENTION!
Do not attempt tampering the calibration of any component or part of the
plant unless expressly authorized in writing by Alfa Laval.
Any calibration carried out by Alfa Laval at the time of testing has the
purpose of ensuring the plants safety and trouble free operation:
Any unauthorized tampering will entail the forfeiture of the guarantee.
Furthermore, the tampering of any safety device may undermine the safe
use of the equipment, thereby Alfa Laval shall not be held liable for damages
in case of accidents resulting from such unauthorized tampering.
This manual must always be accessible to the operators in charge of the
machine/plant and its operation, as well as all persons working near the
machine, although autonomously.
Keep these INSTRUCTIONS FOR USE AND MAINTENANCE at operator’s
reach and make sure that their place of storage is suitable to protect them
from accidental damage.
You should furtherly consider to update it any time you intervene with
relevant modications to the plant and to transmit it to other users or
following owners.

CHAPTER 1 INTRODUCTION
HS-LA FILLER_IM_E
2
PURPOSES OF THE HANDBOOK
The purpose of this manual is to supply:
The operators the most complete manual , instructing them on the functioning of the machine at
the best safety conditions.
The maintenance operators a detailed plan on which and how many services you need for reliable
operation.
For this purpose we will quote in the chapters which need it, the specic indication of WHO and
WITH WHICH QUALIFICATION should operate and intervene in that determined situation.
1.2 CHOICE AND QUALIFICATION OF THE OPERATOR
We classify the personnel assigned to the plant according to the specialization and to the task
they should carry out.
The operators are qualied as follows:
1.2.1 GENERIC OPERATOR:
Personnel not specialized ready to rule the plant by acting on the push buttons placed on the
control panel, able to succeed in charging or discharging materials used during production cycle
and learn about simple functions such as starting or restarting the production after forced pauses.
1.2.2 MECHANICAL MAINTENANCE:
Technician qualied to rule the plant during its standard running, able to succeed in size changing
and in operating on the mechanical parts for adjustments, maintenance and repairing. He is not
allowed to operate on the electric system with tension connected.
The operator has the skills to operate properly and safely when using forklifts, bridge cranes and
other equipment necessary to handle and lift machines with or without packaging.
1.2.3 ELECTRICAL MAINTENANCE:
Technician qualied to operate the plant during its standard running and charged with all the elec-
trical adjustments, maintenance and repairing. They are allow to operate inside the control cabinet
and the connector block with tension connected.
1.2.4 ALFA LAVAL TECHNICIAN:
Qualied technician supplied by Alfa Laval for complex services.