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):


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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.

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

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.

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.
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

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