manual x-c efc diversey namthip_en

Manual

X-Controller

EFC

Diversey Germany Services OHG Mallaustrae 50 56 D-68219 Mannheim

Tel.: +49 (0) 621 - 8757 0

V0.0.0.1 01.10.2012

Manual X-Controller EFC

technical changes reserved Seite - 2 - Version 0.0.0.1 Stand 01/13



1 INSTALLATION GUIDANCE ............................................................................................................................................. 5 2 CONFIGURATION ............................................................................................................................................................... 5

2.1 FUNCTION ............................................................................................................................................................................................. 5 2.2 CLEANING PROGRAMS ............................................................................................................................................................................ 5 2.3 GENERAL TERM EXPLANATIONS .............................................................................................................................................................. 7 2.4 BASE-IMAGE .......................................................................................................................................................................................... 8 2.5 SETTINGS .............................................................................................................................................................................................. 8 2.5.1 GLOBAL ................................................................................................................................................................................................. 9 2.5.2 PRODUKTS .......................................................................................................................................................................................... 15 2.5.3 AREA RECIPES ..................................................................................................................................................................................... 21 2.5.4 SEGMENT GROUPS ............................................................................................................................................................................... 23 2.5.5 IO-TEST .............................................................................................................................................................................................. 25

3 STATISTIC .......................................................................................................................................................................... 28 4 PASSWORD-LEVEL ......................................................................................................................................................... 29 5 START ................................................................................................................................................................................. 30

5.1 AUTOMATIC: ........................................................................................................................................................................................ 30 5.2 SEMI-AUTOMATIC: ................................................................................................................................................................................ 31 5.3 MANUAL: ............................................................................................................................................................................................. 33

6 VISUALISATION ............................................................................................................................................................... 34 7 ERRORS ............................................................................................................................................................................. 35



1 Installation guidance

2 Configuration

2.1 Function

* Controller for foam/gel/disinfection-cleaning OPC; (e.g. filler, rinser, capper and conveyor-CIP).

* Up to 16 area valves (standard) or 32 valves (advanced) can be controlled during cleaning-process. Up to 2 zones (standard) or 4 zones (advanced) can be used.

* Coupling different segmentvalves into segment-groups in different procedures.

* Up to 15 different area-recipes can be couple with segment-groups.

* Free settable parameters per recipe and segment-group like: concentration, flow, pressure, time, etc.

* Easy parameter-settings via touch-panell.

* Password-protection over different levels.

* Statistic about consumptions and number of cleanings with or without Error.

Reasons of the area division:

* different concentrations in different zones (e.g. filler, conveyor).

* different placed (e.g.: filler 1, filler 2).

* Reducing the cleaning-times.

* If the foam-flow is at limit in a segment-group, then must be used an additional segment-valve.

2.2 Cleaning programs

Each of the 15 area recipes can be started in 9 different cleaning programs (program modes):



step

n

um

ber

Pro

gram

m

ode

1

(only

rin

se)

Pro

gram

m

ode

2

(foam

al

calin

e) Pr

ogr

am m

ode

3

(alka

linel

y+di

sin

fect

ion

) Pr

ogr

am m

ode

4

(disi

nfe

ctio

n)

Pro

gram

m

ode

5

(foam

ac

idic

) Pr

ogr

am m

ode

6

(acid

ic+

disi

nfe

ctio

n)

Pro

gram

m

ode

7

(alca

line+

acid

ic+

disi

n.)

Pro

gram

m

ode

8

(alca

line+

acid

ic)

Pro

gram

m

ode

9

(hotw

ater

)

1 Pre-rinse 1 1 1 1 1 1 1 2 Foam alcaline 1 1 1 1 3 Reaction time alcaline 1 1 1 1 4 Rinse off foam 1 1 1 1 5 Foam acidic 1 1 1 1 6 Reaction time acidic 1 1 1 1 7 Rinse off foam 1 1 1 1 8 Disinfektion 1 1 1 1 9 Reaction time disinfection 1 1 1 1

10 Final rinse 1 1 1 1 1 11 Emptying 1 1 1 1 1 1 1 1 12 Blow air 1 1 1 1 1 1 1 1 13 Hotwater 1 14 Program end 1 1 1 1 1 1 1 1 1



2.3 General term explanations

a) Zone: A racking plant with filler and Rinser or conveyor-CIP.

b) Recipe: A cleaning range within a zone, which can be summarized some segment-valves. It has a defined structure which can be edit by the parameters.

c) Segments: Is one single valve, mounted for delivering the liquid to a defined part in the filler.

d) Segment-Groups: One or more segments can be combined and become into a group then at the same time headed for. The recipe works from group 1 till group x (x in global configuration).

e) Products: Water, foam, gel, disinfection;

f) Procedure: Rinse water, alcaline, acid, disinf., blow air, hotwater;

g) Fill System: There is no separate filling-step, so if wanted, then must be used segment-group 1. Filling-step: delivers the liquid to the valve-distributor / valve-knot.

h) Emptying: All segment-valves, which are configured via segment-group in a receipe will be opend for a time to drain the liquid out of the cleaning-pipe-system. After emptying there can be done a blow air.

i) Loop / repeats: Every procedure (group 1 till group x) can be repaeted during a receipe. Up till 9 times.

j) Hotwater: Herefore the unit uses a seperate water-suppy (hot) for flushing special areas in the filler with hotwater. Additioned can be regulated the temperature.

k) ClO2 Flushing: Instead of the seperate water supply can be used a CLO2-solution for flushing special areas in the filler.



2.4 base-image

In the top-line there are global informations: Level: active level (by password) Status: status of the cleaning process Controller: the loaded software

or shows if the controller do have an Error or not. Versionnr.: Version-number of the loaded software. Date/Time: actuelle time

In the bottom-line (menue-selection): settings: (configuration); statistic (consumptions and number of cleanings with or without Error); login/logout: (different levels); start: start of following modes: (automatic, semi-autom., manual) and open visualisation!

2.5 settings



2.5.1 global

Select language: german, english, french, italian, spanish, portuguese, turkish;

Water mode: Selecting if the control variable for water by flow or pressure.



Profibus: Inactiv: Controlling X-Controller by panel or kabel-interface (INT) from filler (see start filler 1). Here is only 1 filler possible to controll. Interface by hardware. Selection of Interface at start filler 1 and button digital (s.b.) By selecting panel release-signal DI27 necessary. By selecting INT the DI19 till DI29 must be connect. Activ: Controlling/communication of X-Controller by profibus. (Signal-listing see below). Here its possible to clean 2 fillers. Filler 1 can be started by panel or interface. Interface can be hardware (cable) or signals via profibus. Filler 2 can be started by panel or interface via profibus.

Segment groups: Number of max. activ segment-groups in the cleaning-programm. (For both filler total).

Injector type: Type L: Lhrke-injector installed as mixing-unit with the possibility to rinse the injector-system. (rinse time injector will be activ in all rinse-procedures at the beginning only once). Type S: Systemcleaners-injector installed. (no injector-rinsing neccesary)

Feedback. SV1: Feedback-signal of savety-valve 1 can be selected with a delaytime (TCO).

Start filler 1: Panel: Start-Stop of the cleaning via panel X-Controller. Here only release-signal from filler to XCon necessary. (By cable digital input 27). INT: Interface via cable or profibus (if profibus is selected). Via cable: can be communicate by BCD-code or single signals. (selecting by button digital). BCD-code is fix. Single signals can be set free. Herefore in the Configuration Profibus must be selected to int. filler 1: HW (hardware). Via profibus the interface-signlas are fixed in a list (see below).

Feedback. SV2: Feedback-signal of savety-valve 2 can be selected with a delaytime (TCO).

Start filler 2: Only by panel or DP-Coupling possible! (s.o. Profibus Aktiv)



Analogue: Configuration of the analogue inputs and outputs. Choose the measuring-signal 0-20mA or 4-20mA and the physical end-value of measuring range (for 20mA).

Digital: Only available if filler 1 is configured to SST or profibus filler 1 selected to HW. In the follwing 4 pictures are the possible communications shown:



Program-mode selection via BCD-code: the list above shows the signal combinations for selcting the different program-modes. Digital inputs (23 -26). This signal structure is fixed and cannot be changed.

Program-mode selection via single signal: max 4 program-modes can be free selected. Digital inputs (23 -26).



Program-number selection via BCD-code: the list above shows the signal combinations for selcting the different program-modes. Digital inputs (19 -22). This signal structure is fixed and cannot be changed.

Program-number selection via single signal: max 4 programs can be free selected. Digital inputs (19 -22).



Profibus: DP-coupler typ: K1 using for coupling to Krones-filler; K2 using for coupling to KHS-filler; master adresse X-Controller setting; int. fller 1: can be selected to hardware (cabel oder panel) or to DP with setting the DP-adress; int. fller 2: only per DP-connection possible with setting the DP-adress; segments 116: choosing if the segment-valves 1..16 are connected via hardware (HW) means directly to X-Controller, or valve-cluster (DP to Festo or Brkert) with setting the DP-adress; segments 1732: choosing if the segment-valves 17..32 are connected via hardware (HW) means directly to X-Controller, or valve-cluster (DP to Festo or Brkert) with setting the DP-adress; Hygiene-Center: choosing if the hc-valves are connected via hardware (HW) means directly to X-Controller, or valve-cluster (DP to Festo or Brkert) with setting the DP-adress;



System: Set system time; Ethernet parameters;

2.5.2 Produkts



Water - set:

controlled: If no flowmeter is installed, then cero must be set in all fields. If flowmeter installed, setting for flowmeter rate and if wanted a flow deviation and delay time for error.



regualted: addition to controlled there are 2 settings (Kp and Ti) for the automatic software regulator water. (can be eg. regulator valve or frequency-controller)

air - set: controlled: no settings necessary. regulated: settings (Kp and Ti) for the automatic software regulator air.



alcaline: select if dosing activ (OFF/ON); alcaline - set:

passiv: injector-application. If no flowmeter in dosing-pipe installed, then 0 must be set in all fields. If flowmeter installed, setting for flowmeter rate and if wanted a flow deviation and delay time for error.

stroked: dosing-pump-stroked. If no flowmeter in dosing-pipe installed, then 0 must be set in field flowmeter-rate.



If flowmeter installed, setting for flowmeter rate and if wanted a flow deviation and delay time for error. Field density the density of the alcaline product. Stroke time is the time, where the digital output is active, to start one puls at the dosing-pump. Stroke pulse value is clculated by max flow of the pump and max pulses the pump can work.

Time controlled: dosing-pump-timed. If no flowmeter in dosing-pipe installed, then 0 must be set in field flowmeter-rate. If flowmeter installed, setting for flowmeter rate and if wanted a flow deviation and delay time for error. Field density the density of the alcaline product. Max flow of the dosing-pump. Every time periode the dosing pump starts. Depending of the max flow the needed dosing-time (during time periode) will be calculated.

acid: equivalent to configuration alcaline.

disinfektion: equivalent to configuration alcaline.

hotwater: select if activ (OFF/ON);



Controlled: If no flowmeter in dosing-pipe installed, then 0 must be set in all flow fields. If flowmeter installed, setting for flowmeter rate and if wanted a flow deviation and delay time for error If no temperature sensor installed, then 0 must be set in all temp. fields. If temperature sensor installed, setting max deviation and delay time for error.

regualted: addition to controlled there are 2 settings (Kp and Ti) more for the automatic software regulator temperature water.



2.5.3 area recipes

Select recipe 1 to 15;

general:



Choosing a recipe name. recipe switching activ by button activ/inactiv; assign one, two ore both zone-valves (max.2 per filler); line delay water: for filling the main-pipe from HC to filler with water, will be done at the end of an dosing-step that function. Means eg. At the end of step dosind alcaline will be submitted water instead of alcaline, for that given time to pre-fill the main-pipe with alcaline. line delay alcaline: for filling the main-pipe from HC to filler with alcaline, will be done at the end of the pre-rinse-step that function. Means eg. At the end of step pre-rinse will be submitted alcaline instead of water, for that given time to pre-fill the main-pipe with water. line delay acid: for filling the main-pipe from HC to filler with acid, will be done at the end of the previous rinse-step that function. Means eg. At the end of step rinse alcaline will be submitted acid instead of water, for that given time to pre-fill the main-pipe with water. line delay disinfection: for filling the main-pipe from HC to filler with disinf., will be done at the end of the previous rinse-step that function. Means eg. At the end of step rinse acid will be submitted disinf. instead of water, for that given time to pre-fill the main-pipe with water. concentration: setpoint for the different concentrations of the different chemicals. retention: retention-time for the different chemicals. air: air dosing ON/OFF for the different chemicals.

repeats:



Almost all procedures can be repeat (eg. rinse foam), including a break-time between the loops if needed. Additioned must be selected if during the repeats segment-group 1 shoud be repeated. If using segment-group 1 as filling-step it doesnt have to repeat!

2.5.4 segment groups



Choose procedure.

Select segmentgroup and assign the segments. Segments V1..V8 are virtuel segments and used for DP-bus. These can be used eg. for valves which are installed and controlled at filler- or capper-unit.



Via button para the setpoints for each segment-group and each procedure shoud be set. And setting the recipe where that segment-group shoud be activ.

2.5.5 IO-Test



IO-test analogue: all analogue-inputs can be checked and analogue-outputs can be forced for testing (eg.start-up).



IO-test digital: all digital-inputs can be checked and digital-outputs can be forced for testing (eg.start-up). Also counters and savety-valves 1/2.



IO-test profibus: 6 byte digital-outputs can be forced and 6 byte digital-inputs can be checked for testing (eg.start-up). Profibus.

3 statistic

Select area recipe.



It shows the numbers ofn every recipe. With DEL the listing can be deleted. T means total and D means daily. OK or ERR gives information, if the program was running without (OK) or with error (ERR). At the right side the consumptions are listet total and per day.

4 password-level

The unit do have 3 paword-levels: administrator-level, service-level, user-level User-level: automatic: start/stop/reset of the programs; service-level: user plus: configuration of the controller, manual and semi-manual functions.



Administrator-level: access at all levels plus system-functions.

5 start

starting: automatic, aemi-automatic, manual or show visualisation!

5.1 automatic:



Selecting a recipe (area);

Selectin the mode;

If disinfection is selcted, there are addition modes for disinf. With or without pre-rinse and with or without final rinse. Now Start-button and the program starts (if release is activ).

5.2 semi-automatic:



Selecting a recipe (area);

Selecting a single step of a procedure;



Selecting a segment-group. Only time must be set. All other parameters are take from the recipe. Now Start-button and the program starts (if release is activ).

5.3 manual:

Selecting a segment-group. The assigned segments will be taken from the recipe. All other parameters must be set manual (zone-valve, conc., time, air-pr. And water-flow. Now Start-button and the program starts (if release is activ). Mit Start-taste aktivieren! Danach spring Anzeige in Visu-bild; Bedingung zum Starten ist Freigabesignal!



6 visualisation

Visualisation of hygienig-center; Button Stop stops the program;

button forward:

Visualisation of segmentvalves at filler;



7 errors

In the main-picture or in the visualisation-pictures the error-symbol is shown. Touching the error-symbol will open next window:

Here error can be confirmed

Error during cleaning:



Error during cleaning allowes 3 scopes: Cancel: the cleaning will be interrupted directly; Rinse off foam: the cleaning jumps into the rins-steps to rinse the filler; Continue: the cleaning will continue.

Errors:

Str_Alarm01 no release from mashine Str_Alarm02 LA- foam alcaline 1 Str_Alarm03 LA- foam acid 1 Str_Alarm04 LA- disinfection 1 Str_Alarm05 flow too high water Str_Alarm06 flow too low water Str_Alarm07 flow too low foam alcaline 1 Str_Alarm08 flow too low foam acid 1 Str_Alarm09 flow too low disinfection 1 Str_Alarm10 flow too low hot water / ClO2 Str_Alarm11 temperature too low hot water / ClO2 Str_Alarm12 no feedback safety valve 1 Str_Alarm13 EMERGENCY STOP Str_Alarm14 no communication between touch panel and PCB Str_Alarm15 user reset Str_Alarm16 air pressure too low at Hygiene Center Str_Alarm17 no feedback pressure pump Str_Alarm18 no feedback pump foam alcaline 1 Str_Alarm19 no feedback pump foam acid 1 Str_Alarm20 no feedback pump disinfection 1 Str_Alarm21 Keine Kommunikation Profibus Fller 1 Str_Alarm22 Keine Kommunikation Profibus Fller 2

Warnings:

Str_Warn01 LA- foam alcaline 1 Str_Warn02 LA- foam acid 1



Str_Warn03 LA- disinfection 1 Str_Warn04 flow too high foam alcaline 1 Str_Warn05 flow too high foam acid 1 Str_Warn06 flow too high disinfection 1

manual x-c efc diversey namthip_en

Documents

installation guidance

general term explanations

cleaning programs

area recipes

segment groups