microcanner M1000

OPERATING INSTRUCTION MANUAL

Version 1.0 Date 03/21/18

microcanner MC1000

WARNING!

OPERATING AUTOMATED EQUIPMENT IS DANGEROUS. DO NOT OPERATE

THE MC1000 CANNING SYSTEM UNTIL YOU HAVE READ THIS MANUAL AND

HAVE RECEIVED PROPER TRAINING. PRECAUTIONS MUST BE TAKEN TO

SAFEGUARD OPERATORS. OPERATORS MUST BE TRAINED AND AWARE OF

DANGER POINTS, IF SOMEONE FAILS TO FOLLOW SAFETY RULES, INJURY

OR DEATH COULD RESULT.

IMPORTANT SAFTEY PRACTICES

• Conveyors are dangerous and present entanglement hazards. Loose clothing,

hair, and jewelry should be avoided at all costs. Never place hands near or inside

of a moving conveyor.

• NEVER permit children, or un-trained operators anywhere near an operating

machine.

• In the event of an emergency, hit the E-stop. • Never preform adjustments without being in E-Stop mode, or unplugging.

• Never plug into an outlet that is not GFCI. Water and electricity do not mix. • Never open the control panel while powered up / plugged in. • Keep clear of all moving parts. • Clear machine jams only when in E-stop mode or fully powered down.

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• It is recommended that you wear safety glasses anytime during operation of the

MC1000 canning system.

TABLE OF CONTENTS

1 INTRODUCTION………………………………………………………….... 4

2 MACHINE REQUIREMENTS……………………………………………...4

3 GENERAL MACHINE SERVICE………………………………………….5

4 START UP PROCEDURE………………………………………………….7

5 SEAM SETUP GUIDE……………………………………………….…….11

6 CHANGE OVER PROCEDURE………………………………………...16

7 HMI OPERATIONS…………………………………………………..…...20

8 TIPS FOR A SUCCESSFUL RUN………………………………….…..26

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1 INTRODUCTION

• Thank you for purchasing a microcanner MC1000 canning system. This manual is

written for your benefit to help you fully understand how to operate and service your

machine. With proper operation and service your machine will offer you years of

service.

• The MC1000 canning system is designed to run 12 or 16oz cans with a few simple

changeover steps. The machine will run up to 68 cases per hour, this will vary from

product to product based on carbonation and/or specific gravity.

2 MACHINE REQUIREMENTS

• For safety purposes you should plug your machine into a 110v 20 amp GFCI outlet.

Please note that the motors use a V.F.D. (variable frequency drive) to convert 110v

single phase to 220 volt, 3 phase power. The type of GFCI commonly purchased in a

big box store will not work. A licensed electrician with experience in motor control

should to be contracted to perform the work.

• Clean dry air supply to the machine. Below is one we would suggest. o http://www.smcusa.com/products/idfb-refrigerated-air-dryer.aspx o Model IDF

B3E-11N should be adequate. Consult your local SMC representative prior to

purchase.

o Failure to provide dry air will destroy valves and void the warranty.

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o Air Regulator at the machine is to be set at 80 P.S.I. If your pressure needle

jumps around during operation, you will need to supply a surge tank near the

machine.

• CO 2 delivery system that is regulated to 10 P.S.I. This line should have a standard

quick connect for hooking up to the filler head.

• Water supply for rinse tunnel, and pre-rinse if applicable. Simple garden hose

connection.

• 1 ½ Tri-clamp product supply line from brite tank, preferably insulated • 34°F product @ 2.64 Co2 @ 11 PSI head pressure (head pressure will vary and a

longer line set may be required when running high gravity, high IBU double IPA beer)

• 1 ¹⁄�” Tri-clamp with sanitizer to rinse filler valves (pump kit is supplied)

3 GENERAL MACHINE SERVICE

Like any other piece of equipment, new car or tractor, your canning

machine needs to be cleaned, lubricated and periodically serviced. Screws

loosen, Filters plug up with contaminates, sensors vibrate out of adjustment and

seam tooling wears. It is important to assign a technician to learn the system and

take good care of it.

• Prior to each use, all screws and sensors should be checked for tightness. • During each use seams should be checked at least every 200 cans to assure

that bad cans are not being made due to worn out or loose tooling.

• Drain beer from fill line and run sanitizer through it after use. Thoroughly clean

fill level sensors and spray with alcohol.

• Following each use, the entire machine should be hosed off (no pressure

washers). A bucket of warm water and dawn soap should be prepared, and the

machine be scrubbed with a soft plastic bristled bush. All water spots should be

polished off using vinegar and rags.

• After cleaning a food grade zero weight grease

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( https://www.mcmaster.com/1445K41/ ) needs to be applied to all conveyor

bearing zerk fittings. There are 3 conveyor bearings on the main line.

• Grease must also be applied to 1 st operation and 2 nd operation tooling. While

greasing, spin the form wheel. Stop pumping when you just start to notice the

rpm of the wheel drop from the grease contact.

• Prior to running the machine check to see if any water has accumulated in the

catch bowl of the filter regulator to the right, or the water separator to the left.

o To empty the catch bowl, push down on the grey thumb slide, then turn and

pull down to take the bowl off. Empty the bowl of any water.

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o Look through the sight glass of the water separator and open the relief

valve on the bottom to clear any water. The separator is designed to auto

drain when air is powered down.

4 START UP PROCEDURE

1. Put machine into desired location.

2. With a bubble level on the bed of the conveyor, raise the machine by lowering the

threaded foot pads by hand until the machine is completely level.

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3. Place and level add-on rinse / feed system, if applicable

a. Start by adjusting foot pads to adjust until rinse platform and print track are

aligned.

b. Connect the proximity cable sensor and put the 3/8” black air supply tube in

the t-fitting located on the main line

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4. Verify that the machine is setup to run desired cans, 12 or 16 oz. If not see

change over manual

5. Verify that the cap shedder is at the appropriate running height. Run a can by

hand under the shedder to verify the end catches and falls on top of the can.

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6. Plug in the machine power, rotary feed table power, hook up the air supply,

connect Co2 on the quick connect fitting located behind the filler head, attach cold

water supply to both the line and the rotary feed / rinse package, and attach

supply of sanitizer to the filling station.

7. With the machine on, e-stop button off, and the fill station raised, put the machine

into paused mode. On the fill station screen (7.4) on the HMI hit the on/off button

to open the valves and let the sanitizer flow completely through the fill lines.

a. During this process leave 4 cans under the filling station so they will fill with

sanitizer.

b. Make sure sanitizer has fully made it through the system.

c. Using the fill station screen, lower the fill station so that the fill tubes and float

switches can be soaked with sanitizer.

d. On the HMI turn the fill valves off.

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e. Let sit for desired amount of time.

f. Raise the fill station.

g. Remove the 4 cans filled with sanitizer.

h. Fully purge system with product.

8. Load ends into cap feeder station.

9. Turn machine to automatic mode.

10.Engage the “hold back cans” button on the first screen.

11. Load cans

*Be sure to check the seam dimensions (5.4) on the first few cans, and

periodically throughout the run.

5 SEAM SETUP GUIDE

5.1 GETTING STARTED

• Prior to getting started review seam setup dimensions (7.3) and controls (7.6)

in the HMI operations section (7).

• Your machine will be setup prior to shipment, but you will want to verify that

the seams are still in spec prior to every run, and periodically while running.

5.2 GENERAL SEAMING INFORMATION

• There are 3 main components to the operation.

1. The center chuck is what the can is pressed into and holds the can in

place for seaming.

2. The 1 st operation form tool is to the right of the chuck, and starts the seam

by curling the end around the lip of the can.

3. The 2 nd operation form tool is to the left of the chuck, and acts more as an

anvil to flatten and seal the seam

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• Check out http://www.doubleseam.com/ for a wealth of great information.

5.3 HOW TO ADJUST SEAM FORM TOOLING

1. You should read this section 5.3 and the next 5.4 to get a good

understanding of the necessary steps required to properly setup your tool

prior to adjusting any tooling.

2. It is recommended that any step in this section 5.3 be done with the air

powered down, turned off, and the seaming arms moved manually to verify fit

and function. Failure to follow this step could result in damage to tooling and

voiding warranty of the tooling.

3. Unless your chuck becomes loose, or a bearing fails, there is never

any need to adjust it.

4. When setting up the 1 st and 2 nd op form tools you want to have about a

paper thickness of air gap (.003”) between the shoulder of the chuck, and the

shoulder of either form tool.

5. To adjust the height on either form tool you first need to loosen the 2

jam nuts, then the two set screws that lock the threads of the form tools.

Never use a set screw that is not brass or brass tipped as you risk damaging

the threads of the form rolls. You then turn the form tools clockwise to raise

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the tool, or counter-clockwise to lower the tool. Once in position, retighten

the 2 set screws, and jam nuts. Take care to make sure the form tools do not

move while retightening the clamp screws.

6. To adjust the depth of the 1 st op form tool you will need to first loosen

the jam nut on the cylinder rod on the rear of the cylinder. Then put a wrench

on the rod of the cylinder and turn the wrench clockwise to increase depth,

and counter-clockwise to reduce depth. Retighten the jam nut once in desired

position.

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7. Adjusting the 2 nd op form tool is the same except you turn the wrench in

the opposite direction. Counter-clockwise to increase depth, and clockwise

to reduce depth.

5.4 HOW TO TEST AND MEASURE SEAMS

1. Prior to make sure to complete the steps in section 5.3 to roughly position the seam

tooling to avoid damage to the tooling.

2. Start with the machine on, and in manual mode. (reference 7.2 for manual mode)

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3. Take a can and fill it with water to give it structural rigidity. The can will get crushed

without fluid in it running through the seaming station.

4. Place an end on the can, and place it on the conveyor prior to the seaming station

5. The following steps will be done using the seam setup controls screen (7.6).

6. Index the can into position.

7. Lift can.

8. Motor on.

9. Press and hold the 1 st operation button for 2 seconds.

10. Drop can

11. Motor off

12. Index can (make sure the can dropped before hitting index)

13. Measure the seam and compare to seam dimensions. If dimensions are out of

tolerance adjust the 1 st op form tooling until within spec.

14. Repeat steps 3-12 until you have a seam that is within spec.

15. After your first seam is set and in tolerance, repeat steps 3-8 and proceed as follows

16. Press and hold the 2 nd operation button for 2 seconds.

17. Drop can.

18. Motor off.

19. Index can.

20. Measure the seam and compare to seam dimensions. If dimensions are out of

tolerance adjust the 2 nd op form tooling until within spec.

21. Repeat steps 3-19 as necessary to get a seam within spec. You can skip steps 9-13

after the first operation seam is satisfactory.

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6 CHANGE OVER PROCEDURE

6.1 ADJUSTING THE FILLER

1. Fill 4 cans with water or product to the desired volume/weight, and place

them under the filling station.

2. Go the filling station screen on your HMI panel, and lower the filling station

so that the fill tubes and float switches are inside the cans.

3. Loosen the screws on the switch plate. Move the plate up or down until

the sensor light is activated on the HMI screen. Then tighten the screws.

4. Use the HMI screen to raise the fill station.

5. Remove setup cans so the machine will be ready to run.

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6.2 ADJUSTING THE MAIN HEAD

1. The 3 bolts clamping the head assembly will need to be loosened to set

the height for 12 or 16 oz. Cans.

2. Use an unseamed can without an end on the conveyor and raise or lower

the main head using the height adjustment bolt until caps catch on the

can.

3. Retighten the 3 bolts.

4. Run can through by hand to verify height. Repeat as necessary.

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6.3 ADJUSTING THE CAP HOLD DOWN

1. Place a can on the conveyor with a lid on it.

2. Using the slotted adjustment set the foam plate about .01 inch above the

can and lid assembly

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3. Once the rail height is set, put a can with an end on it under the cap in

place sensor. This is the sensor directly above the next can waiting to go

into the seam station.

4. With a can and end directly under the cap in place sensor press and hold

the teach button until it turns solid yellow. From time to time this sensor

will need to be retaught its position. Repeat this step whenever necessary.

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7 HMI OPERATIONS

7.1 HMI BASIC OPPERATIONS

• There are 5 menu screens on your HMI F1-F5, which we will get into in this

section. You navigate through each screen by pushing the corresponding

button on the right.

• Most menu screens have buttons on the touch screen that perform certain

tasks, that will be described in the sections below.

• Below the touch panel, you will see a red emergency stop button. This E-stop

button will shut the entire machine off, and is a vital piece of safety

equipment. Familiarize yourself with this button and its operations prior

to running the machine.

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7.2 F1: MAIN SCREEN

• The numbers on the picture below correspond with the numbering in this

section

1. Main Reset: This is the main reset button for the machine. If something

is not acting right, power off, power on, push reset, then put the machine

back into running mode

2. Pause (II): This button pauses the entire machine. It can be used as a

brief stop of the machine. It should not be used to do machine

maintenance. Always press the e-stop button prior to doing any

maintenance.

3. Running/Paused Icon: This is not a button, but is shown to display if you

are in running or paused mode.

4. Missing Cap Pause (II): This button should be used when a can with a

missing end has made it under the cap in place sensor. If this button is not

pushed before placing an end on the can, the machine may actuate early

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and send a can into the seaming station. After replacing a missing end, hit

the button again to unpause the machine.

5. Run Counter Reset: This button resets the run counter. You can reset

this counter prior to each run.

6. Run Counter: Displays the amount of cans run per session.

7. Hold Back: Use this button to run cans out while holding new ones from

entering the fill station. This is helpful while setting fill weights or when

taking a break.

7.3 F2: SEAM SETUP DIMENSIONS

• These dimensions are for LOE can end. You can also consult your supplier for

manufacturer specific dimensions.

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7.4 F3: FILL STATION SETUP

• This screen is to be used for the sanitation of the machine before and after

running product through the machine, and also to set the float valves on the

filling station if they ever need to be adjusted.

• Reference step 7 of startup procedure for sanitation procedure

• Reference section 6.1 on how to adjust the filler.

• There are only two buttons on the fill station setup screen

1. Fill Valves on/off: Turns the fill valves on or off.

2. Co2 sanitizer: Use to force sanitizer through the gas vales

3. Fill Lifter: Raises or lowers the fill station.

• There are 4 icons at the bottom of the screen that will light up when the

corresponding float valve on the filling station is activated. This is a visual cue

used to set the fill level in each can.

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7.5 F4: TOP OFF MODE

• This screen can be used if at any time an additional amount of product needs

to be added to any individual can.

• If you are standing at the front of the machine at the HMI V1 controls the

valve closest to you, or farthest left, and V6 controls the valve farthest from

you, or farthest right.

• Each button push will add an additional 1/16 of a second. The number

displayed is in milliseconds, where 1000=1 second.

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7.6 F5: SEAM SETUP CONTROLS

• This screen is a simple way to be able to run a single can through the

seaming station to test and measure seams.

• Reference the seam setup guide (5) on how to test and measure seams.

• Below is a quick over of the buttons and how they function.

1. Lift Can: Either lifts or lowers the lift puck depending on the position it is

already in.

2. Motor on/off: Turns the seam chuck motor on or off.

3. Index Can: Indexes the rotary actuator that will let you feed a can in or

out of the seaming station.

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4. Opp 1: Extends the 1 st operation tooling. This button needs to be held to

keep the form tooling in position.

5. Opp 2: Extends the 2 nd operation tooling. This button needs to be held to

keep the form tooling in position.

8 TIPS FOR A SUCCESSFUL RUN • When canning you want the temperature of your product to be as close to 32°

as possible for your first run. The key to low dissolved oxygen levels is to

have

a perfect marshmallow of foam when the cans leave the fill head. To

achieve this, tank pressure, temperature and carbonation rates must be

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experimented with on each beer until this desired condition is met. When

starting out, only can the beer you know will sell in a couple of weeks.

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