Getinge Castle MTP 1975 Series User manual

SERIES 1975
AUTOMATIC BOTTLE
FILLING SYSTEM
USER MANUAL
61301604293 Rev. A

SERIES 1975
AUTOMATIC BOTTLE
FILLING SYSTEM
USER MANUAL
Getinge/Castle, Inc.
1777 East Henrietta Road
Rochester, New York 14623-3133
Phone: [phone] USA
Facsimile: [phone]

USER MANUAL 61301604293
Rev. A (10/31/2000)
Related Publications:
Service Data Manual 61301604052
Customer Manual—keyed to the customer’s specific serial number
DESCRIPTION OF SYMBOLS & NOTES IN MANUAL
The following symbols with related notes appear in this manual.
“Warning” notes alert the user to the possibility of personal injury.
“Caution” notes alert the user to the possibility of damage to the equipment.
“Notes” alert the user to pertinent facts and conditions.
This manual contains proprietary information of Getinge/Castle, Inc. It shall
not be reproduced in whole or in part without the written permission of Get-
inge/Castle, Inc.
and are registered trademarks of Getinge/Castle, Inc.
Copyright ©2000 by Getinge/Castle, Inc.
WARNING
NOTE
CAUTION
NOTE
Castle
®

61301604293 iii
Table of Contents
SPECIAL SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . vii
WARNINGS SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . viii
Section 1 General Description
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1
Construction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2
Standard Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2
Optional Standards and Codes . . . . . . . . . . . . . . . . . . 1–2
Optional Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
Accessory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
STANDARD FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
All Stainless Steel Construction. . . . . . . . . . . . . . . . . . 1–3
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
Stainless Steel Transport Cart. . . . . . . . . . . . . . . . . . . 1–3
Filling Head System . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3
ACCESSORY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4
Additional Transport Carts . . . . . . . . . . . . . . . . . . . . . . 1–4
Section 2 The Control Panel
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1
CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2
Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2
Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3
Cycle Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3
Section 3 Operating Instructions
GENERAL MACHINE OPERATION. . . . . . . . . . . . . . . . . . 3–1
DAILY CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1
USING THE BOTTLE FILLER . . . . . . . . . . . . . . . . . . . . . . 3–3
Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3
Fill the Bottles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3
Remove the Cart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3
SETTING THE TIMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–4
Adjusting the Fill Time
(units with proportioner). . . . . . . . . . . . . . . . . . . . . 3–4
Setting The Fill Timer
(option—units without proportioner) . . . . . . . . . . . 3–5

iv
END OF DAILY OPERATION . . . . . . . . . . . . . . . . . . . . . . 3–6
EDSTROM BOTTLE FILLING PROPORTIONER SYSTEM
(Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–7
Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . 3–7
EMERGENCY OPERATION . . . . . . . . . . . . . . . . . . . . . . . 3–8
Emergency Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . 3–8
Section 4 Maintenance
GENERAL MAINTENANCE SCHEDULE . . . . . . . . . . . . . 4–1
ROUTINE MAINTENANCE SCHEDULE—STANDARD . . 4–2
When Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2
Daily. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2
Every Six Months. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2
RECOMMENDED SPARE PARTS LIST . . . . . . . . . . . . . . 4–3
Consumable Stock . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–3
Recommended Spare Parts . . . . . . . . . . . . . . . . . . . . 4–3
Section 5 Troubleshooting
Section 6 Installation Instructions
INSTALLATION OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . 6–1
UNCRATING & EQUIPMENT INSPECTION. . . . . . . . . . . 6–1
INSTALLATION/ASSEMBLY CHECKLIST . . . . . . . . . . . . 6–2
Equipment Location. . . . . . . . . . . . . . . . . . . . . . . . . . . 6–2
Utilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–2
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–2
START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3
CHECK-OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–4

61301604293 v
Section 7 Options
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1
MOST COMMON OPTIONS . . . . . . . . . . . . . . . . . . . . . . . 7–1
Water Pressure Reducing Station . . . . . . . . . . . . . . . . 7–1
Bottle Filling Proportioner System . . . . . . . . . . . . . . . . 7–1
Water Pressure Gauges . . . . . . . . . . . . . . . . . . . . . . . 7–2
Freight to Job Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–2
Stainless Steel Type 304 Components . . . . . . . . . . . . 7–2
Stainless Steel Type 316L Components . . . . . . . . . . . 7–2
pH Monitor System . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–2
Selectable Head Filling . . . . . . . . . . . . . . . . . . . . . . . . 7–2
Selectable Filling Water Types . . . . . . . . . . . . . . . . . . 7–2
Selectable Bottle Types . . . . . . . . . . . . . . . . . . . . . . . . 7–2
Index

vi

Series 1975 Feeder Bottle Fillers
61301604293 vii
SPECIAL SAFETY INSTRUCTIONS
THE FOLLOWING SAFETY INSTRUCTIONS APPEAR WITHIN THIS
MANUAL. READ THEM CAREFULLY BEFORE OPERATING THE UNIT.
“Warning”notes alert the user to the possibility of personal
injury.
Warnings Summary p. viii
FALL HAZARD: Areas located immediately around the filler may become a
fall hazard due to water dripping from the plumbing components. For a safe
environment, insure floor is kept clean and dry.
SHOCK HAZARD: Prior to any service or maintenance on the bottle filler, all
utilities should be disconnected and the lockout/tagout procedures should
be followed to insure safety and prevent accidental shock.
PERSONAL HAZARD AND EQUIPMENT DAMAGE: Safe and efficient
operation of this equipment requires scheduled preventative maintenance.
Routine adjustments and replacement of parts by other than authorized ser-
vice technicians may cause personal injury or the equipment to perform less
than its capabilities.
Emergency Operation p. 3-6
The Control Panel ON/OFF Switch turns the power OFF to the controls only;
it does not remove all power from the filler.
Routine Maintenance Schedule-Standard p. 4-2
ELECTRIC SHOCK HAZARD: Only an electrician should perform this test!
WARNING

viii
WARNINGS SUMMARY
SPECIAL SAFETY INSTRUCTIONS FOLLOW .
READ THEM CAREFULLY BEFORE OPERATING THE UNIT, AND
FOLLOW THE INSTRUCTIONS.
•FALL HAZARD: Areas located immediately around the filler
may become a fall hazard due to water dripping from the
plumbing components. For a safe environment, insure floor is
kept clean and dry.
•SHOCK HAZARD: Prior to any service or maintenance on the
bottle filler, all utilities should be disconnected and the
lockout/tagout procedures should be followed to insure safety
and prevent accidental shock.
•PERSONAL HAZARD AND EQUIPMENT DAMAGE: Safe and
efficient operation of this equipment requires scheduled
preventative maintenance. Routine adjustments and
replacement of parts by other than authorized service
technicians may cause personal injury or the equipment to
perform less than its capabilities.
WARNINGS

61301604293 1–1
Section 1 General Description
INTRODUCTION
Figure 1–1. 1975 FEEDER BOTTLE FILLER
The 1975 Series units are automatic, food grade, filling systems used to
transport and fill feeder bottles mounted in stainless steel baskets. The
filling header and transport cart can be adapted to various types of bottles
and configurations.
See Table 1–1 for the 1975 SERIES FEEDER BOTTLE FILLERS size
specifications.
A04052-1

General Description
1–2
Models and dimensions are listed in Table 1–1.
Construction PROCESSING SYSTEM
The system consists of the fill header, sanitary filling system when stainless
steel is specified, an autoclaveable transport cart, and an electrical control
system.
ELECTRICAL CONTROL SYSTEM
The processing systems consists of a main electrical power panel. The
panel is connected to the electrical supply, within the building, and contains
all components required to operate and power the total processing system.
The operator control terminal, contains all control functions necessary for
the operator to easily operate and monitor the process.
Standard Features •All Stainless Steel Construction
•Automatic Operation —Including a timer, a solenoid valve, and a stain-
less steel enclosure complete with a control panel to regulate the filling
time and rate.
•Stainless Steel Transport Cart
•Filling Head System
Optional Standards and
Codes
Bottle fillers can meet the applicable requirements of:
•UL standards —Main Control Panel is fully inspected and labeled
in accordance with UL standards.
•Seismic requirements per California Administrative Code
Table 1–1. 1975 SERIES FEEDER BOTTLE FILLERS
SIZE (W in. X. H in. X. L in. [cm])
MODEL BASKET SIZE
(in. [cm])
NUMBER
OF
BASKETS
OVERALL MACHINE SIZE
(in. [cm])
OVERALL
CART SIZE
(in. [cm])
With Header in
Down Position
With Header in
Up-Right Position
1975
4x6
12½x 13.5 x18.5
[31.8 x 34.3 x 47]
4 37 x 59 x 60
[94 x 150 x 152.4]
without Cart
12 x 85 x 60
[30.5 x 216 x152.4]
without Cart
28 x 42 x 40
[71x106.7x101.6]
1975
5x5
17 x 12 x 17
[43.1x30.5x43.1]
4 46 x 59 x 60
[116.8x150x152.4]
without Cart
12 x 95 x 60
[30.5x249x152.4]
without Cart
37.5x42x37.5
[95.2x106.7x95.2]

Series 1975 Feeder Bottle Fillers
61301604293 1–3
Optional Features For additional information about the following optional features, see
“Options”on page 7-1.
•Water Pressure Reducing Station
•Bottle Filling Proportioner System
•Water Pressure Gauges
•Stainless Steel Type 304 Components
•Stainless Steel Type 316L Components
•pH Monitor System
•Selectable Head Filling
•Selectable Filling Water Types
•Selectable Bottle Types
Accessory •Additional Transport Carts
STANDARD FEATURES
All Stainless Steel
Construction
The fill header and transport cart is fabricated from 304 stainless steel for
use with acidified drinking water. Type 316 stainless steel can be provided
on the Series 1975 model.
Control Panel The filler is equipped with a control panel that monitors and controls the
filling sequence. The system is activated by the transport cart when it is
moved into the filling position.
Stainless Steel Transport Cart The system is supplied with one (1) transport cart fabricated from 304
stainless steel. The cart is equipped with a removable wire basket for
holding and processing stoppers and sipper tubes through a tunnel or batch
type washer. Located below the bottle baskets is a splash drain pan that
collects any water run off from the baskets during the filling process. The
cart discharges the water run off into a collection pan on the filler. The cart
collection pan is equipped with a manual shutoff to eliminate water dripping
onto the floor during transporting. The cart is supplied with four (4) stainless
steel autoclaveable casters, two (2) with brakes. Additional carts are
available.
Filling Head System The header system and control panel are mounted on the wash room wall.
A stainless steel guard is supplied to protect the header and its components
when in the upright (non-filling) position. The header system can be lowered
for filling and raised out of the way when inserting the stoppers. Safety
systems are in place to stop filling if the cart is moved from the filling
position or if the header is raised to the upright position. The header is
supplied with brass jets and fill piping. Stainless steel jets and fill piping are
available.

General Description
1–4
ACCESSORY
Additional Transport Carts Stainless steel transport carts are provided to transport baskets to and from
the filler. The transport cart interfaces with the filler opening to permit easy
transfer of baskets into and out of the filler.
Transport cart sizes include:
Model Width (in.) Height (in.) Length (in.)
4x6284240
5 x 5 37.5 42 37.5

61301604293 2–1
Section 2 The Control Panel
INTRODUCTION
The Control Panel on this Washer provides the operator with an interface
linked to the Programmable Logic Controller (PLC) located in the Control
Box. Using this panel, the operator is able to:
•Power the equipment ‘ON’and “OFF”
•Select the header configuration for a fill cycle
•Select a fill cycle for eight- or sixteen-ounce bottles
•Start a processing cycle

The Control Panel
2–2
CONTROLS
Control Panel
Switches ON/OFF (controls only — does not disconnect equipment from AC voltage)
To operate the bottle filler, set ON/OFF to ON.
#1–#4 HEADER ON/OFF
Before pressing START, set each switch to ON to fill the bottles in its
respective basket location (see “Cycle Programming”on page 2–3).
BOTTLE Size Selector
All bottles must be the same size.
Set the switch to “8 OZ”position to fill 8 oz. bottles or to “16 OZ”to fill 16 oz.
bottles.
START
Press START to start the filling cycle.
Cold Water/Processed Water (Option, not shown)
When cold water or processed water is required in the bottles, set the switch
to COLD WATER or PROCESSED WATER.
NOTE

Series 1975 Feeder Bottle Fillers
61301604293 2–3
Indicator POWER
A white bezel power lamp is lit when power is supplied to the Control Panel.
Cycle Programming It is important to know which headers to activate in order to fill the bottles as
they are arranged on the cart.
On the control panel the #1–#4 HEADER ON/OFF switches control header
#1, #2, #3, and #4. These switches activate sections of the header which
correspond to the areas of the cart shown below.
# 3 # 4
# 1 # 2
HEADER HEADER
HEADERHEADER
8 OZ
16 OZ
START
# 3
# 1
# 4
# 2
OFF ON
POWER
ON ON
ONON
OFF OFF
OFFOFF
TOP VIEW
CART A04052- 2

The Control Panel
2–4

61301604293 3–1
Section 3 Operating Instructions
GENERAL MACHINE OPERATION
The operator places up to four baskets on the transport cart. The stoppers
are removed and set aside, typically on the lower cart tray.
Before moving the cart into position, the operator makes two decisions:
The operator positions the cart, lowers the header, and presses START. The
bottle filler fills the bottles with water. The operator then raises the header to
replace the stoppers into the bottles. The operator uses the cart to move the
bottles to the animal rooms.
DAILY CHECKLIST
To prepare the bottle filler for daily operation, do the following at
the beginning of the day:
1. Check that the water line is supplying water to the bottle
filler.
2. Apply power to the bottle filler from the main circuit breaker
box.
The operator decides and then he selects
The number of baskets containing bottles to
be filled
one, two, three, or four headers
The size of bottles to be filled 8 OZ or 16 OZ

Operating Instructions
3–2
BOTTLE FILLER COMPONENTS
HEADER
DRAIN LEVER
GUIDE
CONTROL
PANEL
CART
BASKET BOTTLE
GUIDE
A04293-A