MacDonald Steel Limited HDP Deluxe DFC4 User manual

MacDonald Steel Limited
BREWERY SYSTEMS DIVISION
1 REV 00
DELUXE FILLER / CROWNER
MODEL - DFC4

MacDonald Steel Limited
BREWERY SYSTEMS DIVISION
2 REV 00
CAUTION / WARNING
READ MANUAL BEFORE OPERATING MACHINE
DO NOT EXCEED 50 PSI ON Co2 OR BEER LINES
DO NOT EXCEED 100°F (35°C) ON Co2 OR BEER LINES
DO NOT HOSE OR SPRAY THE FRONT PANEL
NEVER PLACE HANDS OR OTHER OBJECTS
INTO MACHINE WHILE DOOR IS OPERATING
DO NOT LIFT DOOR DURING CYCLE
BEFORE SERVICING, DISCONNECT AIR, C02,
BEER AND POWER
WEAR SAFETY GOGGLES WHILE OPERATING MACHINE
HANDLE ALL CLEANING SOLUTIONS ACCORDING TO
MANUFACTURERS’ INSTRUCTIONS AND WEAR
PROTECTIVE EQUIPMENT AS REQUIRED.
AVOID LOWERING HEADS WITH NO BOTTLE(S) IN PLACE

MacDonald Steel Limited
BREWERY SYSTEMS DIVISION
3 REV 00
FEATURES
•Independent stations, fills one to four bottles
•Auto level detection, with adjustable fill heights
•Analog pressure switch control: easy setup of vacuum draw and fobbing
•Selectable number of evacuation cycles.
•Auto and manual crowning
•Monitoring of the fill sequence for easy troubleshooting
•Preprogrammed cleaning cycles (CIP)
•Operator interface: 8” color touch screen for setup, cleaning and troubleshooting
•Adapters are available for filling cans and various size bottles
•Fill from top nozzles available as an alternative to fill from bottom
OPERATING REQUIREMENTS
Clean dry air: 90 psi @ 2.5 CFM (min. 3/8” supply line) with necessary adaptor. Oil free recommended.
Potable water supply: warm and cold; max temperature 70°F or 21°C
C02 at 50 PSI max (3/8” supply line)
120 or 220 VAC, 50-60Hz, 4 AMP, according to local supply. Surge suppression power bar is
recommended.
Beer supply line to fit sanitary fitting
1/4” line to drain (supplied)
5 gallon (min) pressurized keg for cleaning or other pressurized source

MacDonald Steel Limited
BREWERY SYSTEMS DIVISION
4 REV 00
CONTROLS
POWER ON/OFF
Side panel – main power to machine. Circuit breaker(s) are also located directly below the power
switch. When tripped a visible red line appears on the breaker button. Also inside the machine on
the terminal blocks are fuse(s) which protect the PLC outputs and fuse(s) protecting the 24 VDC
power supply.
STOP SWITCH
(Red) Stops all operations on all heads. All heads lift and shuttle forward. This switch also acts
as a master reset switch. At any time if held for 2 seconds, the heads and door will rise, and the
shuttles return to the front position.
On multi-head machines, there is a stop switch for each head on the Human Machine Interface
(HMI), which allows independent heads to be stopped.
START SWITCH
(Green) When pushed the door will go down and the machine will begin the selected cycle.
MANUAL STOP SWITCH:
These stop switches are accessed via the HMI display. When the HMI main screen is being
displayed, the stop buttons will stop each bottle independently. Pushing the stop button a second
time will lift the head immediately.
MANUAL CROWN SWITCH:
These crown switches are accessed via the operator display. When the HMI main screen is
being displayed there is a button for each crowner.
ANALOG PRESSURE TRANSDUCERS
One for each head, these switches control the pressure for the Co2 pressure and the vacuum
draw.
VENT CONTROL
Stainless steel flow controls, one for each head, located at the lower left side of the machine.
These control the rate of pressure released from the bottle and thus the fill rate of beer.
AIR REGULATOR
Set the regulator to 60 psi as a starting point. The crowning cylinders require the most force and
the pressure may have to be increased to ensure a good crown. The vacuum is a venturi style
and uses air to achieve vacuum. If you require a deeper vacuum you may have to increase the
air pressure as well. The air components in the machine should not be exposed to water or oil,
install a good quality filter before the machine. The maximum air pressure should not exceed 90
psi. The lower the pressure the longer life expectancy of the air components.
Co2 REGULATOR
The Co2 regulator (not supplied) is to be set dependant on the pressure in the beverage supply
tank. When the EZ Pressure set up measures the tank pressure the Co2 counter pressure is
automatically set to 2 psi higher than the tank reading. The set point value is displayed on the
bottom of the pressure screen when the Co2 valve is opened. The Co2 regulator must be able to
achieve that value. It is recommended to set the regulator between 5 to 10 psi higher than the
tank pressure. Setting the regulator too high could result in false or unstable measurements as
the valve opens and Co2 surges into the pressure transducer.

MacDonald Steel Limited
BREWERY SYSTEMS DIVISION
5 REV 00
HMI TOUCH DISPLAY
This device located on the front panel, allows the operator to change times, starting modes,
disable heads, control crowning, monitor and troubleshoot.
Using the Display
The display offers the operator the ability to easily access the computer (CPU) in the PLC in order to
change times, starting modes, disable heads, control crowning, monitor and troubleshoot.
It is a good idea to familiarize you with the display functions before beginning to operate the machine.
The best way to do this is without bottles in place and to scroll through the various functions as described
below.
To change values such as crown time, the number (#) of purge cycles, CIP times, etc, when the
appropriate screen is displayed touch the button and a cursor numeric key pad displayed to enter the
values.
When power is first turned on, the following functions automatically return to their “start up” state. Auto
crowning mode is turned off. The heads power up “disable” off. CIP mode is off, & auto level detect is on.
The following remain as they where last set, before power was turned off. Auto level delay times, # purge
cycles, auto crown time, start type.
WARNING Never spray water or any liquid directly onto the display screen. To
clean, wipe the screen with a damp cloth only.

MacDonald Steel Limited
BREWERY SYSTEMS DIVISION
6 REV 00
MACHINE SETUP
After unpacking the machine, the Co2 fitting, fill tubes, and drain fittings must be attached.
Installing the air regulator
Co2 connection

MacDonald Steel Limited
BREWERY SYSTEMS DIVISION
7 REV 00
MACHINE SETUP
CIP JUMPER There is a jumper hose with the machine which is used to connect the beer manifold and
the Co2 line together for cleaning (CIP). The ‘tee’ fitting on the jumper has been left
blank, attach an appropriate connector to it, depending on the source of your cleaning
solution. Water must also run through this jumper to rinse the machine.
The CIP jumper hose

MacDonald Steel Limited
BREWERY SYSTEMS DIVISION
8 REV 00
MACHINE SETUP
LIGHTS
Light strips are 24vdc LED’s.
FILL TUBES
The fill tubes must be installed before operating the machine. The fill tubes are designed to reach near
the bottom of the bottle when the head is lowered. If filling more than one bottle size, be sure to use the
appropriate length fill tube. Failing to use the proper size could result in excess foaming or breaking of
the fill tube.
Use the “Manual Control” screen to manually operate the heads. Reduce the air pressure to 5 PSI or less
so the heads operate slowly. The fill tubes are threaded on one end. Carefully screw the tube onto the
head. Align the tube by slightly bending them if necessary to be centered in the bottle opening.
If necessary short fill nozzles are available for “fill from top” filling, if the displacement of the fill tube is too
high.
PET BOTTLE HOLDERS
If PET bottles are used on the filler, a special adaptor is placed on the filler base instead of the glass
bottle holders (pucks). PET bottles are held by the neck to withstand the force applied by the filling head.
The PET adaptor is held in place by a plastic plug which locates the adaptor to the filler base (see picture
below). Align the hole in the adaptor with the center hole in the machine base.
Inserting PET adaptor plug

MacDonald Steel Limited
BREWERY SYSTEMS DIVISION
9 REV 00
MACHINE SETUP
GLASS BOTTLE HOLDERS
The filler comes equipped with a two piece plastic base (puck) to hold glass bottles. The bottom piece
can be used to hold one size bottle and the second (upper) piece will hold a smaller, second size bottle.
The base(s) must be in place to fill glass bottles, do not place a bottle directly on the metal.
Two piece glass bottle base small bottle large bottle
HEAD TULIPS
The filling head has a removable tulip, which is used to center and seal the bottle. The tulip is comprised
of three parts; an upper piece which seals against the fill head, a inner rubber seal and a lower piece
which acts as a guide to center the bottle. The mouth of the bottle must pass through the lower piece to
rest against the rubber seal. On some larger bottles such as growlers the lower tulip piece must be
removed in order to seal the bottle during the fill cycle. The lower part of the tulip is threaded; to remove
it, simply grasp the piece and twist counterclockwise.

MacDonald Steel Limited
BREWERY SYSTEMS DIVISION
10 REV 00
MACHINE SETUP
VENT TUBES
The filling head consists of two metal tubes, one inside of the other. The inner tube is for filling
product, while the outer tube is for the C02 pathway, venting pressure out of the bottle and also
controls the fill height in the bottle. Both tubes have a screw applying contact to the metal tube,
however the inner fill tube is permanently attached, while the outer vent tube is removable. There
are wires attached to both screws that provide a signal to the PLC controller.
Note: The fill tube is pressed into the fill head and a very small amount of 2 part epoxy is applied
to seal and hold in place. This tube is not designed to be removed. The vent tube can be
removed by following the instructions below.
Removable vent tube
If filling more than one size bottle where the neck or other dimensions vary, it may be necessary
to change the vent tube so the proper fill height and volume is achieved. To change the vent
tube, use the “Manual Control” menu to manually operate the heads. Reduce the air pressure to
5 PSI or less so the heads operate slowly. With the head in the down position, it may be
necessary to rotate the head clockwise to gain access to the screw holding the tube in place.
fill head in normal position fill head rotated for access to vent tube screw

MacDonald Steel Limited
BREWERY SYSTEMS DIVISION
11 REV 00
MACHINE SETUP
It will be necessary to hold the wire connector on the vent tube while loosening the locknut on the
screw. On some machines this is a knob, while other machines it is a set screw.Once the locknut
is loose, back off the set screw holding the vent tube in place. Twist and pull down on the tube to
remove it from the filling head. Insert the new vent tube into the head and tighten the screw
against the vent tube. DO NOT OVERTIGHTEN, contact on the metal tube is all that is required.
3/8” wrench is required Hold the wire in place, loosen locknut
Loosen the screw holding vent tube in fill head Vent tube removed from filling head

MacDonald Steel Limited
BREWERY SYSTEMS DIVISION
12 REV 00
MACHINE SETUP
VENT FLOW CONTROLS
These needle valve flow controls are located on the left hand side of the machine, one for each
head. C.W. decreases the flow rate, C.C.W. increases flow. Start about ¼ turn C.C.W from fully
closed. Gradually increase flow, but do not allow foaming during filling.
Flow controls on the DFC4
NOTE During CIP mode, open these controls fully C.C.W. to allow maximum flow of cleaning
solutions and rinse water.
DRAIN LINES Attach the plastic drain fittings (⅛NPT x ¼ hose barb) to the vent flow controls on the
side of the machine. Using the ¼” hose supplied, cut four lines, one to each of the drain
fittings, run these lines to drain. Do not allow the lines to be submersed in liquid; they
should be vented to atmosphere.

MacDonald Steel Limited
BREWERY SYSTEMS DIVISION
13 REV 00
MACHINE SETUP
AIR FLOW CONTROLS
The heads, shuttles and door speeds can be affected by the air pressure on the system. There
are flow controls on all cylinders that can be adjusted to control the speed of all these actions. If
necessary to adjust, set the control so the action is smooth and not too fast, then lock the control
using the locknut.
Flow control shown on door cylinder, proximity switch is opposite
PROXIMITY (REED) SWITCHES
There are reed switches mounted on the air cylinders for door closed, head up, shuttle forward
and back. These switches close when the cylinder is in its proper position and send that
information to the CPU. If a switch fails the machine will not function properly or not at all. To
check the switches locate the proper cylinder and observe the small LED mounted on each
switch. When properly aligned the LED will be on, if not, loosen the screw located on the switch
mounting bracket and move the switch until the LED lights. Tighten screw.
Head proximity switches

MacDonald Steel Limited
BREWERY SYSTEMS DIVISION
14 REV 00
MACHINE SETUP
CROWNING HEAD REPLACEMENT
The crowning head on the machine is designed for a 26mm crown. If more than one size crown
is to be used, the head must be replaced. If more than one crowning head has been provided,
the size of the crowning head is stamped into the side of the head. Use the “Manual Control”
menu to manually operate the crowning heads. Reduce the air pressure to 5 PSI or less so the
heads operate slowly. With the head in the down position, use a large wrench and loosen the
locknut. Thread the head off the cylinder rod and replace with the new crowning head. Ensure
that the magnetic plunger and the spring are in the proper position inside the head before
replacing the assembly. Tighten the locknut. The crowning head may have to be adjusted as
described below.
Changing the crowning head

MacDonald Steel Limited
BREWERY SYSTEMS DIVISION
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MACHINE SETUP
CROWNING HEAD ADJUSTMENTS
The crowning heads have a magnetic plunger enclosed in a plastic housing. This plunger is
spring loaded to assist in releasing the bottle from the head after crowning. The spring tension is
determined by the position of the head on the crowning cylinder rod, which is held in place by a
locknut. On the underside of the crowning assembly is a large set screw which the plunger
protrudes through. This screw determines the depth the crown will go into the head, which in turn
controls the shape of the finished crown. Adjusting the screw CW into the head allows the crown
to go further into the head and results in a tighter crown. If adjusted too deep the bottles will stick
in the crowning head. Only make adjustments in small increments at a time.
Adjusting the Crown:
1) Loosen the lock nut on the cylinder rod and then loosen the crowning head by rotating CCW.
2) Use a screwdriver as per the picture below and turn the screw CW for a tighter crown and
CCW for a looser crown.
3) Rotate the crowning head CCW back onto the cylinder rod until the center plunger has spring
tension. You should be able to slightly depress the plunger with one finger pressed against it.
4) Tighten the locknut against the crowning head to hold it in place.
NOTE: If after crowning, a noticeable dent is on the top of the crown, the tension may have to be
slackened. Loosen the locknut and slowly turn the crown down (C.C.W.) to relief some of the
pressure.
Adjusting the crown depth

MacDonald Steel Limited
BREWERY SYSTEMS DIVISION
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MENU EXPLAINATIONS
1. Manual Control
OPERATION OF MANUAL CONTROL
This screen is used to manually operate the filling heads, crowners and shuttles. The door can
also be manually operated. These operations are useful when setting up heads, changing fill
tubes, adjusting the crowner and checking the proximity switches. Also, the number of fills per
head and the total fills is recorded. To enter this mode press the “Manual Control On” button.
Once in this mode no other operations are possible. A message on the main screens warns of
this condition. As the cylinders move from one position to the other the related proximity switches
will light showing the cylinder is in position. If the switch does not light it may be necessary to
adjust or replace the proximity switch.
Crown Head
Up/Down
Fill Head
Up/Down
Shuttle Control
Reed Switch’s
Counter
Door Control

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BREWERY SYSTEMS DIVISION
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MENU EXPLAINATIONS
2. Main Menu
Pressure Readings
The display shows the pressure in each head measured in psi. Pressing the "R" button will record the
highest and lowest reading for the head selected. These readings will only change if a higher or lower
pressure is measured. The values can be reset by pressing on the reading itself. The vacuum and head
lift (fobbing) values can be entered by pressing on the "S/U" button. If the reading on the display shows a
value other than "0" when the head is in the raised position the zero value can be calibrated by pressing
the "C" button. This will pop up a down and up button along with a numeric display box showing the
current zero calibration value. Pushing either of the up or down buttons changes the value for zero.
There is a limit hard coded into the computer for this calibration value. If you cannot zero the pressure
switch using these buttons the pressure transducer is defective and must be replaced. Whenever the
Co2 valve is opened during the purge or counter pressure cycles the set point is displayed in the lower
portion of the pressure screen. This value is hard coded to 2 psi higher than the beer open value setting
and cannot be changed. The buttons on the pressure screen are maintained style pushbuttons. Pressing
once activates the button, pressing a second time deactivates them.
Measured
Pressure
Zero
Pressure
Switch
High
Pressure
Low
Pressure
Set up
Head Lift
Pressure
Vacuum
Set point
Purge
On/Off
Press once to Stop
Twice to li
ft head
Crowner
Up/Down
To adjust
pressure
switch to
zero
Pressure
Record
Off/On
Screen Navigation BarMessage
Display
PUSH to Reset
High & Low
Pressure
Co2
counter
pressure
value
Pressure
calibration
value
Cycle &
Fill Times

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BREWERY SYSTEMS DIVISION
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Main Menu
Purge Button
Each head has a "Purge" button used to manually open the Co2 valve while pressed. This is useful to
push beer, foam or water out of the Co2 or vent line. The button is also used to clear a "bridge" of foam
or liquid in the fill head. Another function of this button is to check for leaks in the fill head. For more
information see the troubleshooting section below.
Crowner Down
The Crowner Down button is used to manually crown a bottle. This would be used if the crown was not
on properly and had to be crowned again. The crowner will only operate as long as the button is held in.
For setting up or adjusting the crowner use the "Manual Control" screen.
CAUTION: Do not hold onto the bottle while operating the crowners manually.
Cycle & Fill Time
These timers show the current cycle and fill times and are only used for comparing and maximizing cycle
times.
Stop Buttons
The Stop buttons are used to stop an individual head rather than stopping all four heads by using the
main Stop switch. Pressing the button once will stop the current operation, vent the pressure and lift the
head. Pressing the button twice will lift the head immediately.
Screen Navigation Bar
These push buttons are used to move from screen to screen. They are located on each screen.
Messages
As the machine goes through its cycles, messages appear in the message box explaining what part of the
cycle is currently running. If for some reason there is a fault and the cycle cannot be completed a
message will appear with the fault description. For details on the fault messages see the troubleshooting
section of this manual. Upon pressing the Start Switch the previous messages will clear.

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BREWERY SYSTEMS DIVISION
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MENU EXPLAINATIONS
3. EZ Setup
Level Off/On
This button is used to turn the auto level detection off or on. When the level detection is ON, the head will
automatically detect the proper level and shut off the beer valve. If the head will not detect the level the
setting may be turned to OFF. When the level is turned off the stop switch for that head must be used to
turn off the beer valve. Consult the troubleshooting section of this manual for reasons the level detection
may not be working. The default is set to ON upon power up.
Level Delay
This timer is used to delay the beer valve from shutting off once the level has been detected. By
increasing the delay time the fill height in the bottle can be increased. The amount of increase is
determined by the flow rate as this is a timer.
CAUTION: Too much delay time will cause product to flow out of the bottle and into the vent line. This
will cause foaming in the next fill cycle as the excess beer is blown back into the bottle during the purge
cycle. This in turn will result in the head "bridging" or shorting out the level detectors. Under normal
operating conditions set this value to "0". If you cannot achieve the proper level required for your style
bottle you may need to change the length of the vent tube. Contact MacDonald Steel for assistance.
Simultaneous or
Sequential Filling
Auto Level On/Off
Enable/disable head
Shuttle On/Off
Often used for can
filling.
Crowner On/Off
1-5 Purges
Purge
Timeout
Quick Pressure Setup
Crowner Time
Auto Level
Delay Time

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BREWERY SYSTEMS DIVISION
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Head On / Disabled
This button will disable the fill head in case of mechanical or electrical problems that prevent the head
from operating properly. By disabling the head the rest of the fill heads can still be used. It is not
necessary to place a bottle in the head before disabling it.
Shuttle Off / On
When the shuttle is turned off it no longer returns to the forward or front position in the machine. This
function is useful if you are not crowning your product such as cans, growlers or Champagne style bottles
with corks. This reduces the cycle time of the machine by not shuttling back and forth.
Crowner Off /On
When the machine is first turned on the default setting is crowner off. This allows the operator to set up
the machine before crowning. It also allows products that do not require crowns to be filled. Once the
crowner is turned on a crown time menu appears.
Crown Time
Use this menu to set the amount of time the crowner stays in the down time. Set the time to allow a good
crown usually about 1.5 seconds. Excess time will increase your overall cycle time.
Purges
The number of purges for each head is set with this menu. The purge cycle consists of one Co2 pressure
and one vacuum draw. Typical number of purges is two. More purge cycles will increase cycle time.
Purge Time
During the Purge cycle as well as the Counter pressure cycle this timer is used to set the time allowed for
the pressure or vacuum set point to be reached. It is also used as a timer to clear a bridge prior to the
purge cycle. If the set point cannot be achieved during this time the cycle aborts and the head returns to
the up position and the shuttle comes forward. If the Co2 and air regulators are set properly the minimum
value of 5 seconds is sufficient to achieve the set points. If filling large bottles such as growlers or 5 liter
cans more time is required to achieve the set point especially during vacuum. Setting this value higher
allows more time before the cycle aborts. This time value does not control the length of the actual cycle
during normal operation. The switching between Co2 pressure and vacuum is controlled by the pressure
switch. If for some reason the pressure or vacuum set point cannot be achieved such as a missing,
cracked or broken bottle, a bridge in the head or a leaking fill head the higher value will only delay the
aborting of the cycle. This value should only be increased when the container being filled cannot reach
the set point within the 5 second minimum due to it's large size.
Start All / 1
This controls the number of bottles that start once the Start Switch has been pressed. In the "ALL"
position, all the bottles start at once. This is the most productive format to use the machine. By selecting
the"1" position Head 1 starts first. Once the fill cycle starts, Head 2 starts and the rest of the heads
follow. This is sequential filling which is useful when first setting up the machine. It gives the operator
time to observe each head and ensure it is operating properly. Due to the sequential starting of each
head the overall cycle time in increased.
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