CASK ACS V4.2 User manual

Automated Canning
System V4.2 Manual
CASK BREWING SYSTEM INC.
Third Edition, November 2016
ACS V4.2
Toll Free: 1-800-661-8443 Direct: [phone] Fax: [phone] e-mail: [e-mail]
Technical Service & Support Parts Order
1-800-661-8443 Option #4 1-800-661-8443 Option #4
[email protected] [email protected]
Official supplier of Ball Corporation for the supply of printed aluminum cans to our customers
cask.com

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Confidential
Automated Canning System (ACS) V4.2 Manual
Third Edition, September 2016
Copyright
© 2016 Cask Brewing Systems Inc. All rights reserved.
Disclaimer
The information presented in this manual has been reviewed and validated for accuracy. The included 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 directly or indirectly from errors, omissions, or discrepancies between any subsequent or altered
products and this manual.

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Revision History & Document Control
Manual
Version
Release
Date
System
Updates
First Edition
August
2011
ACS V4.0
Initial Manual Release.
Second Edition
February
2014
ACS V4.1
Updated electrical section for new V4.1 panel design.
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 require the below username to download the PDF version of the manuals.
Username: CaskCanning123

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Table of Contents
Section A. Before You Begin............................................................................................................................................. 4
A.1 Unit Diagram ........................................................................................................................................................... 4
A.2 System Requirements ............................................................................................................................................. 4
Section B. Unit Setup ....................................................................................................................................................... 5
B.1 Uncrating Requirements ......................................................................................................................................... 5
B.2 Uncrating Procedure ............................................................................................................................................... 5
B.3 Packing List / Loose Parts ........................................................................................................................................ 6
B.4 Initial Adjustments & Settings................................................................................................................................. 6
B.5 Unloading Cans ....................................................................................................................................................... 7
Section C. ACS Operations Overview ............................................................................................................................... 9
C.1 System Operation Walkthrough ............................................................................................................................. 9
C.2 Controllers............................................................................................................................................................... 9
C.3 HMI Control Panel Operations .............................................................................................................................. 12
C.4 Electrical Panel Overview...................................................................................................................................... 13
C.5 Can Filling .............................................................................................................................................................. 18
C.6 Lid Dispenser ......................................................................................................................................................... 19
C.7 Parts in Motion: Pneumatics................................................................................................................................. 19
C.8 Parts in Motion: 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 Training Videos................................................................................................................... 37
E.2 Manual Seam Evaluation Process ......................................................................................................................... 38
E.3 Reading a Seam Micrometer................................................................................................................................. 38
E.4 Seam Measurement.............................................................................................................................................. 39
E.5 Seam Troubleshooting .......................................................................................................................................... 42
E.6 Seam Specifications .............................................................................................................................................. 42
Section F. Can Seamer ....................................................................................................................................................... 43
F.1 Seamer Adjustment & Troubleshooting ............................................................................................................... 43
F.2 Seamer Troubleshooting....................................................................................................................................... 47
F.3 Bearing Replacement ............................................................................................................................................ 47
Section G. Safety ............................................................................................................................................................ 49
Section H. Warranty Information ................................................................................................................................... 50
Section I. Company Information ....................................................................................................................................... 51

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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

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Section B. Unit Setup
Section B. Unit Setup
B.1 Uncrating Requirements
Recommended Tools
Bolt cutters or large pair of wire cutters to remove metal bands
Pry bar (recommend 2)
Claw hammer
Freestanding 10’ Ladder
Forklift
Cordless drill with Robertson/Phillips bit
B.2 Uncrating Procedure
Refer to Figure 4 Uncrating your new Cask 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
Gently fold sides of crate down to the floor (Figure 4 –Step 3)
You now have unfettered access to contents
Figure 4 Uncrating your new Cask ACS
Figure 3 In case you’ve never seen a crate before
1
2
3

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Section B. Unit Setup
B.3 Packing List / Loose Parts
Inside the container you’ll find the following items packed along with the main machine
Lid Cage
Conveyer Catch Tray
Tool kit
Twist rinser (if ordered)
Spare parts package (if ordered)
Darex Manual “Evaluating and Controlling Double Seams Manual”
B.3.1 Moving Unit into Position
After removing bands and holding blocks securing canning machine to pallet base, use forklift (lift truck) to move
main unit into position (refer to unit footprint Figure 2 for clearances).
Protect stainless finish by placing wood on lifting forks to prevent metal-on-metal contact.
Spread forks so lifting points are as 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
Representative at your site.
Your warranty period will also commence at the date of installation and commissioning by a Cask Technical Rep.
Prior to arrival of your Cask Technical Rep, you should complete the following initial machine setup:
•Inspect overall machine shipping damage.
•Level machine in final production position.
•Have qualified electrician connect the machine to plant power (refer to C.4 Electrical Panel ).
•Connect machine to compressed air supply (see Table 1).
•Connect machine to plant CO2 system (see Table 1).

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Section B. Unit Setup
•Connect machine to cold water supply (see Table 1
•Also recommended to have hot water access nearby machine for cleaning.
B.4.1 Machine Specification Sheet
Your Cask ACS will require the following utilities.
Power
208/230 volts, 50/60 Hz, 40 amps, 3 phase
Electrical connection to be hardwired inside panel by certified electrician
Compressed Air
18 cfm at 125 psi
Require a 7.0 peak HP, 50 gal/200L tank c/w refrigerated dryer and autofloat drain for Depal
and ACS combined operation.
Cask recommend compressor is CompAir L05 FS –200 (23.66 CFM-0.67 mᶟ/min).
Water Supply
½” cold water line – garden hose connection (testing)
½” hot water line – nearby machine (CIP)
CO2Supply
20psi from plant system connected to machine with 3/8” barbed fitting
Drainage
Drainage is required from the canning table to drain (standard 1 ¼” 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” high on Pallets (Figure 6 - A).
The cans are very fragile and are subject to denting and damage in handling so be very careful.
Verify straps are undamaged before moving full pallet.
Resist impulse to touch stack or cans as damage will result.
Each pallet footprint is 44” x 56”.
A single truck load of cans contains up to 25 pallets of cans.
Storage –Can be stacked 4 high, height permitting. One container load of cans on pallets require roughly 374
square feet of floor space.
The lids for an entire container load of cans are on a single pallet (Figure 6 - B).

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Section B. Unit Setup
Figure 6 Forklift carrying your printed cans (A) and a pallet of can lids or ends (B)
B
A

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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