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accu-max™

Two Stream Blending System

OPERATING MANUAL
MODEL: AM-25

Coca-Cola Bottling Durham


Durham, North Carolina
Project 24-152

Cadence Technologies Inc.


1006 Windward Ridge Pkwy Rev. 00/00/01
Alpharetta, GA, 30005 USA
Cadence Technologies, Inc.
1006 Windward Ridge Pkwy
Alpharetta, GA, 30009 USA
(800) 352-1828

Cadence Technologies Inc.


1006 Windward Ridge Pkwy Rev. 00/00/01
Alpharetta, GA, 30005 USA
Table of Contents
Table of Contents................................................................................................ 3
Overview........................................................................................................................... 6
Accu-Change Flavor Change Over .......................................................................................... 6
Accu-Change Timeline ............................................................................................................. 8
Accu-change Illustration ........................................................................................................... 9

Screens ............................................................................................................................ 27
Screen Navigation ..................................................................................................................... 27
Indicators ................................................................................................................................... 28
Module Status Indicator ............................................................................................................ 29
Home Screen ............................................................................................................................ 30
Simplified Screen ...................................................................................................................... 31
Simplified Screen ...................................................................................................................... 32
Side Bar Menu ........................................................................................................................... 33
Recipe Screen ........................................................................................................................... 34
Machine Command Screen ....................................................................................................... 35
Machine Commands ................................................................................................................. 36
Machine Command Glossary .................................................................................................... 36
Syrup Port Command Glossary ................................................................................................ 39
Blending Operations Screen ..................................................................................................... 39
Blending Operations Command Screen.................................................................................... 41
Implied Syrup Brix ..................................................................................................................... 42
Accu-brix Function .................................................................................................................. 42
Change Over Screen................................................................................................................. 43
Change Over Screen Color Meaning ........................................................................................ 44
Production Record Screen ........................................................................................................ 45
Change Over Tally Screen ........................................................................................................ 46
Machine Cycle Screen .............................................................................................................. 47
Trend Screen ............................................................................................................................. 47
Trend Mass Flow Screen .......................................................................................................... 49
CIP Screen ................................................................................................................................ 50
CIP Program Screen ................................................................................................................. 51
Alarm Screen ............................................................................................................................. 53
Alarm Indicators ........................................................................................................................ 54
Alarm Messages ........................................................................................................................ 55
Blender Screen .......................................................................................................................... 66
Blender Screen Indicators ......................................................................................................... 68
Blender Command Screen ........................................................................................................ 69
Deaeration Unit Screen ............................................................................................................. 69
Gas Injector Screen................................................................................................................... 71
Gas Injector Command Screen ................................................................................................. 72
Product Tank Screen................................................................................................................. 73
Product Tank Screen Indicators ................................................................................................ 74
Product Tank Command Screen ............................................................................................... 75
Product Tank Refrigeration Screen ........................................................................................... 76
Product Tank Refrigeration Screen Indicators .......................................................................... 76
Filler Screen .............................................................................................................................. 78
Filler Screen Indicators.............................................................................................................. 79

Cadence Technologies Inc.


1006 Windward Ridge Pkwy Rev. 00/00/01
Alpharetta, GA, 30005 USA
Filler Command Screen............................................................................................................. 81
Special Filler Functions ............................................................................................................. 81
Syrup Port Screen ..................................................................................................................... 83
Syrup Port Status Matrix ........................................................................................................... 84
Syrup Port “READY” and “CONNECTED”: ............................................................................... 85
Syrup Port Command Screen ................................................................................................... 86
Syrup Port Ready Screen ......................................................................................................... 87
Syrup Port Utilities Screen ........................................................................................................ 87
Syrup Line Purge Screen .......................................................................................................... 89
Maintenance Screen ................................................................................................................. 90
Maintenance PID Screen .......................................................................................................... 91
PID Control Devices and Available Parameters ....................................................................... 92
Maintenance Setup Screen ....................................................................................................... 94
Maintenance Change Over Screen ........................................................................................... 97
Maintenance Vacuum Pump Screen......................................................................................... 99
Maintenance Meter Setup ....................................................................................................... 100
Maintenance Meter Setup – Syrup Reservoir Calibration ....................................................... 101
Maintenance Meter Proving .................................................................................................... 102
Maintenance Force Screens ................................................................................................... 103

Recipes........................................................................................................................... 107
Recipe Items ........................................................................................................................... 108
Active and Next Recipes ......................................................................................................... 111
Viewing Active and Next Recipes ........................................................................................... 112
Next Recipe Selection ............................................................................................................. 115
Syrup Port ............................................................................................................................... 116
Next Syrup Port Selection ....................................................................................................... 117
Run Out Type .......................................................................................................................... 118
Next Run Out Type Selection .................................................................................................. 119
Setting Up an Active Recipe ................................................................................................... 121

Recipe Manager................................................................................................ 122


Recipe Manager Screen ......................................................................................................... 123
Recipe Viewing ........................................................................................................................ 124
Recipe Editing ......................................................................................................................... 124
Modifying the Selected Recipe Item........................................................................................ 125
Recipe Editor Page 2 .............................................................................................................. 127
Saving the Recipe ................................................................................................................... 128
Copying A Recipe.................................................................................................................... 129
Recipe Name Modification ...................................................................................................... 129
Recipe Deleting ....................................................................................................................... 132

Operation ..................................................................................................................... 136


Utilities Check .......................................................................................................................... 136
E-Stop Check .......................................................................................................................... 136
Morning Start Up ..................................................................................................................... 137
Flavor Change Preparation ..................................................................................................... 139
Flavor Change ......................................................................................................................... 140
Filler Run Out Completion ....................................................................................................... 140
End of Day Shutdown.............................................................................................................. 141
Packaging Change .................................................................................................................. 142
Product Proportioning Adjustment .......................................................................................... 143
Product Tank Pressure Adjustment ........................................................................................ 144

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Gas Injector Set Point Adjustment .......................................................................................... 145
CIP........................................................................................................................................... 146

Frequently Asked Questions .......................................................... 148


Question - Low Syrup Density Alarm Fault on startup ............................................................ 149
Question - foam in my Syrup Reservoir during a Syrup Reservoir Runout ............................ 149
Question – My Syrup Reservoir is High and I can blend no more .......................................... 149

Cheat Sheet............................................................................................................. 151


START UP ............................................................................................................................... 152
FLAVOR CHANGE.................................................................................................................. 153
END OF PRODUCTION.......................................................................................................... 154

Appendix....................................................................................................................... 154
Capacitance Probe Calibration ............................................................................................... 155
INTRODUCTION ................................................................................................................ 155
OPERATING ELEMENTS .................................................................................................. 155
SWITCHES ......................................................................................................................... 155
PUSHBUTTONS ................................................................................................................. 155
CALIBRATION .................................................................................................................... 156
STEP by STEP ................................................................................................................... 156
RTD Calibration ....................................................................................................................... 156
RTD Calibration ....................................................................................................................... 157
Modem Set Up ........................................................................................................................ 158

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OVERVIEW

ACCU-CHANGE Page 6 of 159

Overview
Accu-Change
 Flavor Change Over

The accu-change™ fast flavor change-over option can significantly reduce operating cost. This capability
will add more productive uptime to line operation and boost output. It allows line personnel to execute a 5
to 7 minute change-over with ease. This translates to fewer overtime shifts and reduced operating costs.
It also provides greater short-run flexibility, permitting you to run more products over the course of a day.
In operation, the accu-change™ system coordinates the entire change-over process. At end-of-run, all
syrup is transferred to the blender. The amount of product that can be made is calculated and converted
to empty containers required. This information is transmitted to the depalletizer operator who sends the
required sweeps to the line. No product or containers are wasted. The syrup line, blender, and filler are
concurrently rapid-rinsed and dried for the next product.

In operation, the Operator selects desired recipe from touch screen, which loads target brix and CO2
settings. Operator then pushes START button which rinses and dries system. Concurrently, separate
routines rinse and dry syrup line and filler. When both operations are completed, the syrup cut-off tank
fills, and blending begins. Precision flow meters measure actual syrup, water and CO2 flow-rates. PLC
logic compares actual flow rates against target flow rates and adjusts the syrup pump speed and the CO2
control valve to maintain target flow rates. Initial settings are automatically adjusted to compensate for

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OVERVIEW

ACCU-CHANGE Page 7 of 159

residual water and provide a no-dump start. At end of run, gas pushes all syrup from syrup line into the
syrup cut-off tank. When syrup level reaches low point in the cut-off tank, water is added to tank to push
in-spec product to carbonator tank. When carbonator empties, the entire system is rinsed and prepared
for next flavor.

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OVERVIEW

ACCU-CHANGE Page 8 of 159

Accu-Change
 Timeline

In order to provide the fastest flavor change over possible the system is partitioned into modules that
allow concurrent operations. The timeline above illustrates the accu-change flavor change sequences
for each module. Each module is identified on the left, while each machine function timing and length is
shown on grid in increments of 5 seconds. The total Filler down time is shown at the bottom in black.

Reviewing the timeline one can observe the benefit of partitioning the system into modules, while
producing the benefit of concurrent machine functions, that save change over time.

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OVERVIEW

ACCU-CHANGE Page 9 of 159

Accu-change
 Illustration

The following pages illustrate an accu-change flavor change over each machine function is illustrated and
also described in the upper right hand machine status box.

The change over starts when the syrup in the syrup line is pushed into the Syrup Reservoir with a CO2
gas purge.

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OVERVIEW

ACCU-CHANGE Page 10 of 159

After the syrup in the syrup line is purged into the Syrup Reservoir the container stop at the filler is
automatically pulled in to pack the empty side to a known container count. Concurrently the syrup line is
rinsed and drained.

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ACCU-CHANGE Page 11 of 159

Once the operator confirms that the empty is packed, the container stop is opened allowing containers to
be filled again, and the system calculates the number of sweeps required at the depalletizer to place the
entire volume of product in the system into containers, and notifies the depalletizer operator.

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ACCU-CHANGE Page 12 of 159

As the system runs out the Syrup Reservoir, the syrup line is prepared for the next production.

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ACCU-CHANGE Page 13 of 159

The Syrup Reservoir is still running out the syrup, and the syrup line is ready for the next production run.

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OVERVIEW

ACCU-CHANGE Page 14 of 159

When the level in the Syrup Reservoir reaches bottom of the vessel, water is used to push the remaining
syrup through the syrup mass flow meter. At the end of the Syrup Run Out water push a Mix Line Run
Out pushes all the product in the Mix Line into the Product Tank with water, and a Syrup Reservoir Rinse
starts.

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When the Mix Line Run Out finishes, the Product Tank Run Out will provide the filler with product at
pressure. Concurrently the Syrup Reservoir is drained and the Mix Line is rinsed in preparation of next
production.

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ACCU-CHANGE Page 16 of 159

The Syrup reservoir is primed concurrently, while the Mix Line is rinsed and drained.

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The Mix Line is drained concurrently during a Syrup Reservoir Prime and a Product Tank Run Out.

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The Syrup Reservoir has finished priming, the Mix Line drain and Product Tank Run Out continue.

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ACCU-CHANGE Page 19 of 159

After the Mix Line Drain, a Mix Line Prime is initiated by the system to pack the Mix Line with product for
the next production run. Concurrently the Product Tank Run Out continues with the current production
run.

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ACCU-CHANGE Page 20 of 159

When the level of product in the Product Tank reaches bottom of the tank, a Filler Run Out is initiated by
the system. At the same time a Product Tank is rinsed and drained. The Filler Run Out uses the
remaining product in the Filler Bowl to fill the remaining containers.

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ACCU-CHANGE Page 21 of 159

When the entire volume product in the Filler Bowl has been consumed, the operator acknowledges the
end of production, and the system initiates draining of the Filler. Concurrently the Product Tank is
draining. No containers are filled, thus down time starts to be recorded.

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ACCU-CHANGE Page 22 of 159

After the initially draining the Filler, the Filler Bowl is rinsed with it’s own water supply and drained in
preparation of the next production. Concurrently the Product Tank Prime fills the Product Tank with
product for the next production run.

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ACCU-CHANGE Page 23 of 159

Product is ready in the Product Tank. The Filler is finishing draining itself.

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ACCU-CHANGE Page 24 of 159

Before bringing product into the Filler, the Filler Bowl must be pressurized. This is done automatically by a
Filler Charge function.

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ACCU-CHANGE Page 25 of 159

After the Filler Charge pressurizes the Filler Bowl, the system will automatically initiate a Filler Prime,
which will gently bring the product into the filler bowl in order to minimize product disturbance.

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ACCU-CHANGE Page 26 of 159

After the Filler Prime has brought the product into the Filler Bowl, the container stop is opened and
production starts again.

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SCREENS

HOME Page 27 of 159

Screens
Screen Navigation

The machine is equipped with a touch screen as a main operator interface. The only pushbuttons in the
machine operating area are an E-Stop pushbutton and a Reset pushbutton. All adjustments to the system
and screen navigation are made through the touch screen operator interface by using your finger.

On the screens there are different styles of buttons, that are described below. Each has a special
purpose.

Button Style Purpose


Example
Square buttons with a graphic within, are Screen Navigation Buttons. Screen
Navigation Buttons change the existing screen to a new screen.

Rectangular buttons with text within, and a colored rectangular indicator on top, are
Machine Command Buttons. When these buttons are pressed a Machine Function
is initiated. Care should always be taken when pressing a Machine Command
Button. The colored rectangular bar on the top of the button indicates the state of
the Machine Function.
Red means the machine Function is inactive. Yellow means that the Machine
Function is waiting on some condition to be satisfied before, the function will start.
Green means that the Machine Function is active and running.
A Screen Navigation Button with a graphic of a house within, will always change
the screen to the Home Screen.

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SCREENS

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Indicators

Colors are used on the screens to indicate the state of valves and pumps, and machine functions. The
table below shows the different colors used on the screens and their meanings.

Color Meaning
The function is not running. (OFF)

The function is waiting for some condition, before it will start executing.

The function is running (ON)

The function has run already during this change over (DONE)

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SCREENS

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Module Status Indicator

On many screens you will see a one or more Module Status Bars. Below is a Module Status Indicator for
the Syrup Reservoir Module. There are Module Status Indicators for the Syrup Room, Syrup Port,
Blender, Mix Line, Product Tank, and Filler. The purpose of the Module Status Indicator is to convey to
the operator what the system is doing, and perhaps what the system is waiting for before it can proceed
to the next step.
Progress Bar

Module’s Machine Function Machine Function’s Operation

The three elements of a Module Status Indicator are described in the table below.

Element Description
Module’s The Module’s Machine Function indicates the current Machine Function that the module is
Machine running, such as Rinse, Priming, Draining, and Blending among others.
Function

Machine The Machine’s Function Operation indicates the current operation, which the Machine
Function’s Function is performing, such as In Progress, Waiting for Tank Pressure, Blowing Through
Operation Filling Valves, or Waiting for Tank to Empty for example.

Progress The Progress Bar indicates the progression of the execution of a function. The Progress
Bar Bar fills with a green bar from left to right as the Machine Function proceeds through it’s
execution.

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SCREENS

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Home Screen

The Home Screen is the pivotal main screen where all other screens are accessed. In the center is a
representational process diagram for the system. The process diagram is broken into the following
modules Syrup Line, Deaeration Unit, Blender, Gas Injector, Product Tank, and Filler. A modules screen
Can be moved to by touching the module on the process diagram.

Along the right side of the Home Screen is the Side Bar Menu where pushbutton icons, represent (in
order) Recipe Screen, Machine Command, Blender Operations, Change Over, Trends, CIP, Maintenance
and Alarms screens. Pressing the associated icon pushbutton will change the screen.

Time and
Date

Press
here to go
to the
Simplified
Screen

Press one
of the
modules
to change
the
screen

Press one
of the
pushbutton
icon to
change the
screen

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To the right of the Active and Next Recipe display, are status lights that indicate the state of some basic
machine functions.
Automatic Change Change Over in
Over Enabled Progress Indicator
Indicator

Forces Active
Blender Status Indicator

Accu-Brix
Enabled Indicator
CIP Indicator

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SCREENS

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Simplified Screen

The Simplified Screen provides the operator a view of the simplified version of the process, while
displaying basic information of operator interest, such as Syrup Port status, Syrup Reservoir Level,
Product Tank Level, and Product Tank Outlet Valve status.

Step Action
1. To view the Simplified Screen follow the links below from the home screen

Home 
2. The Simplified Screen will display as shown below:

Syrup
Port
Product
Status
Setpoint
Target
Syrup
Reservoir Gas
Level Injector
Target
Syrup
Reservoir
Product
Volume
Tank
Pressure
Target
Syrup Meter
Mass Flow
Filler
Rate
Container
Water Stop
Meter Status
Mass Tank
Flow Rate

Product Tank Outlet Blender Control Status


Valve status for Filler Container Stop
Output

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Side Bar Menu

The Side Bar Menu is on the right hand side of the Home Screen and the Simplified Screen. The menu
provides access to specific screens as outlined below.

Recipe Screen

Machine Command

Blending Operations Screen

Change Over Screen

Trend Screen

CIP Screen

Maintenance Screen

Alarm Screen

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OPERATIONS

SCREENS (RECIPE) Page 34 of 159

Recipe Screen

The Recipe Screen provides the operator a view of Recipe Names, Run Out Parameters, and Operator
Assigned Syrup Port for the Active and next Recipes. Access is also given for the Active Recipe Screen,
the Next Recipe Screen, and The Recipe Manager.

Step Action
1. To view the Recipe Screen follow the links below from the home screen

Press
here to go
Home  to the
2. The Recipe Screen will display as shown below: Active
recipe

Active Recipe Press


Name here to go
to the
Active
recipe

Press
here to go
to the
Active
recipe
Run Out
Length
Next Recipe
Name
Run Out
Type

Operator
Selected
Syrup Port

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Machine Command Screen

The Machine Screen provides the operator the ability to initiate the machine functions.

Step Action
1. To view the Recipe Screen follow the links below from the home screen

Home 
2. The Recipe Screen will display as shown below:

Other
Screens
Machine
Command
Screens

Change
Over
Screen

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OPERATIONS

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Machine Commands

Machine Command Glossary

The Machine Command Screen provides the operator the ability to initiate the machine functions.

Pushbutton / Action
Indicator
AUTO When the AUTO function is enabled, the system will automatically sequence
through the change over process without operator intervention.
BLEND The BLEND function, requests syrup from the Active Syrup Port, requests
water from the deaerator, proportions water, syrup and gas, controls the
Product Tank Pressure, and provides product to the filler.
BLEND PAUSE The BLEND PAUSE function halts the BLEND function.
END OF DAY The END OF DAY function provides a means to stop the system at the end
of the production day. It kills every other running function.
FILLER BLOW The FILLER BLOW function removes the residual water from the filler, by
using a gas blow from the bottom of the filler. This automated function opens
drain valves and the filling valves in a sequence.
FILLER CHARGE The FILLER CHARGE function pressurizes the filler bowl in preparation to
receive product. Having the filler bowl pressurized as product first enters the
filler, minimizes the velocity in which the product enters the filler, thus
minimizing the change of carbonation to the product.
FILLER COLD The FILLER COLD RINSE function provides cold water to the filler. Water
RINSE pumped from the deaerator through the Product Chiller and Product Tank,
and then delivered to the filler.
FILLER DRAIN The FILLER DRAIN function removes product from the in preparation for a
FILLER RINSE. The product is removed by opening the filling valves and the
Filler Drain Valve.
FILLER PRIME The FILLER PRIME function provides a means to bring the product into the
filler after a FILLER CHARGE. The function opens the Product Tank Outlet
Valve (Filler Inlet Valve) and monitors the level probes on the filler line. At the
end of the FILLER PRIME the Container Stop is released.
FILLER RINSE The FILLER RINSE function uses treated water to flush the filler, after a
flavor change. The Filler Rinse Valve injects water directly into the filler line,
where it moves through the filler line up into the filler bowl. The filling valves
are automatically opened.
FILLER RUNOUT The FILLER RUNOUT function maintains the filler in a state in which it can
deliver the remaining useable product in the filler bowl to containers. The
FILLER RUNPOUT is initiated after a PRODUCT TANK RUNOUT. The
Product Tank Outlet (Filler Inlet) valve is closed, thus the only product that
remains is in the filler bowl.
MIX LINE PRIME The MIX LINE PRIME function packs the Mix Line with product. This is done
in preparation to then move product into the product tank. During a MIX LINE
PRIME, a drain at the top end of the Mix Line is opened, product is then
proportioned for a volume that equals the volume of the Mix Line.
MIX LINE RINSE The MIX LINE RINSE function flushes the Mix Line with water from the
Deaerator, the water is pushed out a drain at the top end of the Mix line.
MIX LINE RUNOUT The MIX LINE RUNOUT function pushes the contents of the Mix Line into the
Product Tank. A volume of water from the Deaerator, equal to the volume of
the Mix Line, is used to push the remaining product in the Mix Line into the

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Product Tank.
PRODUCT TANK The PRODUCT TANK DRAIN function removes the left over rinse water from
DRAIN the Product Tank during a flavor change over. Pressure is maintained on the
Product Tank while drain valves are opened at the bottom. The Product Tank
Empty probe is used to determine that the Product Tank is empty.
PRODUCT TANK The PRODUCT TANK PRESSURE function maintains pressure in the
PRESSURE Product Tank at the Product Tank Pressure Target. While monitoring the gas
pressure via the Product Tank Pressure Transducer, the Product Tank Gas
Supply Control Valve is used to supply gas to the Product Tank and the
Product Tank Pressure Relief Valve is used to exhaust the gas from the
Product Tank. The two valves work in opposition to maintain the pressure
target setpoint.
PRODUCT TANK The PRODUCT TANK PRIME function is used to bring product into the
PRIME product tank for the first time after a flavor change over. The function controls
the target pressure for the product tank as the Product Tank is filled with
product. The function runs for a finite volume of product. During the
execution of the function the Target Product Tank Pressure is first set to
Initial Product Tank Pressure Recipe Item value and then ramped up to the
Product Tank Pressure Recipe Item value as the volume of product enters
the product tank. The function is completed once the finite volume of product
enters the Product Tank.
PRODUCT TANK The PRODUCT TANK RINSE function flushes the Product Tank with water
RINSE from the Dearator. Pressure is maintained to the Product Tank and when the
Product Tank Empty probe indicates the presence of water. The Product
Tank Drain opens, thus draining the water to the floor. This function runs for
a finite volume of water. The function terminates upon meeting the water
volume requirements for the rinse.
PRODUCT TANK The PRODUCT TANK RUNOUT function is used to provide the filler with the
RUNOUT remaining product in the product tank during a flavor change over. The
PRODUCT TANK RUNOUT is initiated after a MIX LINE RUNOUT. During a
PRODUCT TANK RUNOUT, pressure is maintained on the Product Tank
and the Product Outlet Valve is left open until the Product Tank Empty Probe
indicates the absence of product, which then the function is terminated.
RUN OUT START The RUNOUT START function initiates a flavor change over. The function
checks the system to confirm that a flavor change is possible and then
initiates a SYRUP RUNOUT.
STARTUP The STARTUP function initiates a sequence of functions which prepare the
system for production. When the STARTUP function begins, it confirms that
the Product Tank and the Syrup Reservoir are empty. If the tanks are not
empty the STARTUP function stops, and the operator must first drain the
tanks before attempting the STARTUP again. When the confirmation
indicates that the tanks are empty, then the function initiates a SYRUP
RESERVOIR RINSE, MIX LINE RINSE, PRODUCT TANK RINSE and a
FILLER RINSE.
SYRUP RESV The SYRUP RESERVOIR DRAIN function empties the contents of the Syrup
DRAIN Reservoir to the floor.
SYRUP RESV The SYRUP RESERVOIR PRIME function is used to fill the Syrup Reservoir
PRIME with syrup and recirculate the syrup through the mass flow meter in
preparation for blending. The function opens the Active Syrup Port to deliver
the syrup to the Syrup Reservoir, fills the Syrup Reservoir until the level
reaches above the recirculation pipe inlet, and then uses the syrup to push

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the contents (usually water) of the Syrup Mass Meter to drain. When the
Syrup Meter contents is purged the drain is closed and the recirculation valve
opens in order to recirculate the syrup through the Syrup Reservoir and the
Syrup Mass Meter.
SYRUP RESV The SYRUP RESERVOIR RINSE function flushes water from the Deaerator
RINSE through the Syrup Reservoir, in order to remove the residual previous flavor
syrup and/ or CIP solution.
SYRUP RESV The SYRUP RESERVOIR RUNOUT function is used to delivery terminate
RUNOUT the delivery of syrup to the Syrup Reservoir and blend the remaining syrup
into the Product Tank. When the Syrup Reservoir syrup level reaches the
bottom of the Syrup Reservoir, the remaining syrup is pushed through the
Syrrup Mass Flow Meter with water from the Syrup Reservoir CIP Spray
Valve.

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OPERATIONS

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Syrup Port Command Glossary

The Machine Screen provides the operator the ability to initiate the machine functions.

Pushbutton / Action
Indicator
SYRUP LINE The SYRUP LINE AUTO PREP function automatically sequences the Syrup
AUTO-PREP Line through a SYRUP LINE RINSE, SYRUP LINE DRAIN, and places the
syrup line a SYRUP LINE READY state.
SYRUP LINE The SYRUP LINE DRAIN function, removes liquid from the Direct syrup line,
DRAIN by using is a gas blow at the highest point the line, and opening the drain
valves.
SYRUP LINE The SYRUP LINE CLOSE DIVERT function will close the Direct Line Syrup
CLOSE DIVERT Shutoff Valve. This function can only be used if the Direct Line is being used
for production, otherwise this function is inhibited.
PORT A The PORT A CONNECTED function toggles the “CONNECTED” state of the
CONNECTED Syrup Port A
PORT B The PORT A CONNECTED function toggles the “CONNECTED” state of the
CONNECTED Syrup Port B
SYRUP LINE The DIRECT LINE PRIME function is used to prepare the Syrup Line for
PRIME production by packing the Syrup Line with syrup. The function opens a path
through the Syrup Line to drain, in order provide a pressure relief for the
syrup brought into the Syrup Line in the syrup room. This function is timed,
and will stop after running approximately 5 seconds.
SYRUP LINE The DIRECT LINE READY function toggles the “READY” state of the Direct
READY Syrup Port
SYRUP LINE The DIRECT LINE RINSE function flushes the Direct syrup line with water, in
RINSE order to remove syrup and CIP residue. The source of the water is
automated by a valve behind the syrup room divert panel.
SYRUP LINE The SYRUP LINE PURGE function is used to push the syrup out of the
PURGE active Syrup Line. When this function is running the Syrup reservoir Level
Control Valve opens 100% to allow all the syrup in the syrup line to be
pushed into the Syrup Reservoir.
SYRUP LINE Not Applicable
RUNOUT

Blending Operations Screen

The Blending Operations Screen provides the operator the ability view blender proportioning, and
gas injection flow rates and totals, along with Recipe and operator adjusted set points..

Step Action
1. To view the Blending Operation Screen follow the links below from the home screen

Home 
2. The Blending Operations Screen will display as shown below:

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SCREENS

BLENDING OPERATIONS Page 40 of 159

Accu-Brix
Status Blending
Operations
Command
Screen

Blender
Status
Indicator

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Blending Operations Command Screen

The Blending Operations Command Screen provides the operator the ability to adjust the
proportioning and gas injection set points, along with enabling the accu-brix control function.

Step Action
1. To view the Blending Operation Command Screen follow the links below from the home
screen

Home  
2. The Blending Operation Command Screen will display as shown below:

Accu-Brix
Enable/
Disable
Pushbutton

Operator
Adjustments

Blender
Status
Indicator

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Implied Syrup Brix

The system calculates the (implied) syrup brix from the measured syrup density and measured
syrup temperature. The accu-brix function uses the Implied Syrup Brix in calculating the
percent syrup used in proportioning.

Accu-brix
 Function

The accu-brix function provides the ability to automatically adjust the percent syrup
proportioned, based on the brix of the syrup delivered to the blender. Without the accu-brix
function enabled, the system uses the value of the Syrup Brix from the recipe to calculate the
percent syrup proportioned. With accu-brix function enabled, the system uses the Implied
Syrup Brix to calculate the percent syrup proportioned. This allows the system to produce
consistant quality of product independent of small variations in the incoming syrup brix.

Follow the steps below to enable the accu-brix function.

Step Action
1. Follow the links below from the home screen

Home  
2. Pressing the accu-Brix pushbutton will toggle the accu-brix enable/disable status. See
pushbutton below.:

Enabled/
Disabled
Status
Indicator

Indicator Meaning
Color
Red The accu-brix function is disabled

Green The accu-brix function is enabled, and operating.


Yellow The accu-brix function is enabled, but not operating, because the Active Recipe
is a Diet Recipe.

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SCREENS (CHANGE OVER) Page 43 of 159

Change Over Screen

The Change Over Screen provides the operator the ability to view the current steps of the flavor change
over functions. The status of each function is displayed by the color of the indicator, and the flow of the
change over is indicated by arrows.

Step Action
1. To view the Change Over Screen follow the links below from the home screen

Home 
2. The Change Over Screen will display as shown below:

Change
Over Flow
Indication

Function
Status
Indicator

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Change Over Screen Color Meaning

The Change Over Screen has a colored block for each function in the change over. The colored block
indicated the state of each function in the current change over.

Color Meaning
The function is not running. (OFF)

The function is waiting for some condition, before it will start executing.

The function is running (ON)

The function has run already during this change over (DONE)

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Production Record Screen

The Production Record Screen displays information on the last ten production runs.

Step Action
1. To view the Production Record Screen follow the links below from the home screen

Home  
2. The Production Record Screen will display as shown below:

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Change Over Tally Screen

The Change Over Tally Screen displays for the current container cut off. Information regarding the
amount of syrup and product in the system is used to calculate the number of depalletizer sweeps
required to use all the product available.

Step Action
1. To view the Change Over Tally Screen follow the links below from the home screen

Home  
2. The Change Over Tally Screen will display as shown below:

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Machine Cycle Screen

The Machine Cycle Screen displays the different modules of the system and the Machine Function and
Function Status for each module.

Step Action
1. To view the Machine Cycle Screen follow the links below from the home screen

Home  
2. The Machine Cycle Screen will display as shown below:

Progress
Bar

Machine Function
Function Status
Trend Screen

The Trend Screen provides the operator the ability to choose one of seven realtime-trend displays that
are available.

Step Action

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MACHINE COMMANDS

MACHINE COMMAND Page 48 of 159

1. To view the Trend Screen follow the links below from the home screen

Home 
2. The Machine Cycle Screen will display as shown below:

Select a trend display by


pressing one the seven
pushbuttons

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Trend Mass Flow Screen

The Trend Mass Flow Screen displays a real-time trend of the water and syrup, target and actual mass
flow

Step Action
1. To view the Trend Mass Flow Screen follow the links below from the home screen

Home  
2. The Trend Mass Flow Screen will display as shown below:

Target flow rate Actual flow rate

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CIP Screen

The CIP Screen provides the operator the ability to CIP the system.

Step Action
1. To view the CIP Screen follow the links below from the home screen

Home 
2. The CIP Screen will display as shown below:

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CIP Program Screen

The CIP Screen provides the operator the ability to select one of five different CIP Programs. Each CIP
step for the selected program is listed.

Step Action
1. To view the CIP Screen follow the links below from the home screen

Home 
2. The CIP Screen will display as shown below:

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ALARM Page 52 of 159

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Alarm Screen

The Alarm Screen displays the status of the machine Alarms and prvides the operator access to the
Alarm Status Screen and the Alarm History Screen.

Step Action
1. To view the Alarm Screen follow the links below from the home screen

Home 
2. The Alarm Screen will display as shown below:

Use these buttons to go to the Alarm Press this button to reset all alarms
Status or Alarm History Screens

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Alarm Indicators

In the center of the Alarm Screen are four indicators, which change from black to a color, when a
condition exists as described below.

Alarm Indicator Descriptions

Indicates that an alarm occurred, which has stopped the machine (faulted out)

Indicates that an alarm occurred that will not stop the machine, but the condition of the
machine should be reviewed by the operator.

Indicates that the machine is blending normally.

Indicates that the system is in a flavor change over, and has pulled in the container stop,
waiting for the operator to confirm a line back up.

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Alarm Messages

The table below gives a description of each Alarm Message.

Alarm Message Why and When Meaning


51 ACCU-BRIX This alarm occurs if the difference The accu-brix function is used to adjust
CALCULATION between the Recipe Syrup Brix the syrup proportioning within a
OUT OF RANGE and the accu-brix Implied Syrup reasonable syrup brix variation.
Brix calculation is more than 3.0 Variations outside the norm are alarmed
Brix. to bring the attention to the operator that
the syrup may be for a different flavor.

79 ACCU-BRIX This alarm occurs when Accu-Brix An invalid reading from the Syrup Meter
SYRUP DENSITY is operating and if the Syrup Density output may be caused by one of
TOO HIGH Density rises above the High the following: 1) Syrup Flow Meter
Syrup Density Limit for the Transducer Failure. 2) Analog Input
Implied Syrup Brix Calculation. Failure. 3) Incorrect Syrup.
80 ACCU-BRIX This alarm occurs when Accu-Brix An invalid reading from the Syrup Meter
SYRUP DENSITY is operating and if the Syrup Density output may be caused by one of
TOO LOW Density falls below the Low Syrup the following: 1) Syrup Flow Meter
Density Limit for the Implied Transducer Failure. 2) Analog Input
Syrup Brix Calculation. Failure. 3) Incorrect Syrup.
77 ACCU-BRIX This alarm occurs when Accu-Brix An invalid reading from the Syrup
SYRUP is operating and if the Syrup Temperature Transducer may be caused
TEMPERATURE Temperature rises above the High by one of the following: 1) Syrup
TOO HIGH Syrup Temperature Limit for the Temperature Transducer Failure 2)
Implied Syrup Brix Calculation. Analog Input Failure. 3) Incorrect Syrup.
78 ACCU-BRIX This alarm occurs when Accu-Brix An invalid reading from the Syrup
SYRUP is operating and if the Syrup Temperature Transducer may be caused
TEMPERATURE Temperature falls below the Low by one of the following: 1) Syrup
TOO LOW Syrup Temperature Limit for the Temperature Transducer Failure 2)
Implied Syrup Brix Calculation. Analog Input Failure. 3) Incorrect Syrup.
34 Active Recipe: This alarm occurs if the Active If the Active Recipe Number is not within
Invalid Recipe Recipe Number is not between 1 a valid range the system will not proceed.
to 100. The Active Recipe should be checked.
Reloading the recipe may be required.
35 Active Recipe: This alarm occurs if the Operator The Operator Selected Syrup Port must
Syrup Ports Do Not Selected Active Syrup Port does match the Recipe Syrup Port. This
Match not match the Active Recipe redundancy minimizes the possibility of
Syrup Port. Not: If the Active opening the incorrect Syrup Port.
Recipe Syrup Port is “Any Port”,
the Operator Selected Active
Syrup Port may be any valve,
except for “None”.

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Alarm Message Why and When Meaning


64 AIR PRESSURE This alarm occurs when the Air Typically an air supply of 100psi is
LOW (FAULT) Pressure switch located in the required to the blender. The Air Supply is
Blender pneumatic panel senses regulated to 90psi typical, by an internal
a Low Air Supply. regulator in the Blender pneumatic panel.
Low Air Supply Pressure may be caused
by one of the following: 1) Low incoming
air pressure and or volume from plant air
system. 2) A failed Air Supply Regulator
inside the Blender pneumatic panel. 3) A
failed Air Supply Pressure Sensor,
located inside the Blender pneumatic
panel.
42 AUTO START UP This alarm occurs when the Conditions which inhibit the AUTO
NOT STARTED operator presses the AUTO START button are: 1) BAD NEXT
(CHECK SYSTEM) START button, and the conditions RECIPE. 2)
for initiating Auto Start Up are not SYRUP PORT IS CONNECTED. 3)
valid. SYRUP RESERVOIR IS NOT EMPTY
4) FILLER NOT READY FOR START UP
5) AUTO NOT ENABLED
15 BLEND, SYRUP This alarm occurs when the Syrup The Syrup Stream Zero Balance can be
STREAM HIGH Stream Zero Balance has out of viewed from the Trend Screen.
(OUT OF range, delivering too much syrup Conditions which may cause a High
CONTROL) for 6 seconds. Syrup Stream are: 1) Poor Water Stream
control caused by Product Flow Control
Valve not responding. 2) Syrup
Proportioning Pump not responding to a
speed adjustment sent by the PLC. 3)
Syrup Flow sensor or transmitter
malfunction. 4) Water Flow sensor or
transmitter malfunction
16 BLEND, SYRUP This alarm occurs when the Syrup The Syrup Stream Zero Balance can be
STREAM LOW Stream Zero Balance has out of viewed from the Trend Screen.
(OUT OF range, delivering not enough Conditions which may cause a Low
CONTROL) syrup for 6 seconds Syrup Stream are: 1) Poor Water Stream
control caused by Product Flow Control
Valve not responding. 2) Syrup
Proportioning Pump not responding to a
speed adjustment sent by the PLC. 3) A
total Syrup Proportioning Pump
malfunction. 4) Syrup Flow sensor or
transmitter malfunction. 5) Water Flow
sensor or transmitter malfunction
27 CIP This alarm occurs when the 4- This alarm can be caused; 1) Electrical
CONDUCTIVITY 20ma signal on the transducer failure of the device itself. 2) Faulty
TRANSDUCER transmitter is significantly below wiring. 3) Failure of the PLC analog
FAILURE 4ma or greater than 20ma. input.

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Alarm Message Why and When Meaning


50 CIP RETURN This alarm occurs if the PLC This alarm can be caused by: 1) Tripped
PUMP HAS output to the pump is turned on, overload protection. 2) Faulty motor
FAILED and the auxiliary feedback on the starter. 3) Faulty wiring to motor starter.
pump contactor does not indicate 3) Faulty feedback wiring from auxiliary
the pump is running within 3 contact on motor starter to PLC input.
seconds.
13 CIP SUPPLY This alarm occurs when the 4- This alarm can be caused; 1) Electrical
TEMPERATURE 20ma signal on the transducer failure of the device itself. 2) Faulty
TRANSMITTER transmitter is significantly below wiring. 3) Failure of the PLC analog
FAILURE 4ma or greater than 20ma. input.
65 CIP This alarm occurs during CIP if The steam is disabled if this alarm
TEMPERATURE the Product Temperature, Syrup occurs.
HIGH ALARM Temperature or Water
(STEAM Temperature exceeds 92 degrees
DISABLED) C.
9 CIP This alarm occurs when the 4- This alarm can be caused; 1) Electrical
TEMPERATURE 20ma signal on the transducer failure of the device itself. 2) Faulty
TRANSMITTER transmitter is significantly below wiring. 3) Failure of the PLC analog
FAILURE 4ma or greater than 20ma. input.
6 DC POWER This alarm occurs when the PLC This alarm can be caused; 1) Electrical
FAILURE no longer senses the presence of failure of the DC Power Supply. 2) Faulty
the DC power supply voltage. wiring. 3) Failure of the PLC digital input.
1 ESTOP PRESSED This alarm occurs if the PLC does This alarm can be caused by: 1) The
not sense the presence of voltage operator pressing the E-Stop Button on
from the E-Stop circuit. Indicating the operator panel. 2) E-Stop circuit
that the circuit has been broken, power loss.
by an E-Stop being pressed or a
power failure.
82 FILLER - This alarm occurs when the This alarm can be caused by Remote IO
BLENDER handshake signal sent back and wiring problems, Remote IO
COMMUNICATION forth over the remote IO Communication Card problems, or power
S FAILURE communication network, between failure on either end of the network.
the Blender and the Filler fails
over a 4 second period.
71 FILLER BLOW - This alarm occurs during a Filler This alarm indicates that something is
NOT REACHING Blow, if the sequence waits more wrong with the pressure source under
HIGH PRESSURE than 150 seconds for the Bowl the filler, or that there may be a leak in
pressure to reach high pressure. the filler, which is keeping the filler bowl
from pressurizing. This alarm may also
be caused by a Filler Bowl Pressure
Transducer failure.
70 FILLER BLOW - This alarm occurs during a Filler This alarm indicates that either the valve
NOT REACHING Blow, if the sequence waits more opener of the filler is not working
LOW PRESSURE than 100 seconds for the Bowl properly. This alarm may also be caused
pressure to reach low pressure. by a Filler Bowl Pressure Transducer
failure.

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Alarm Message Why and When Meaning


61 FILLER FILLING This alarm occurs if the blender This alarm indicates that either the valve
VALVES NOT sends a signal to the filler to open opener of the filler is not working
RESPONDING the filling valves, and the filler fails properly, or that there may be something
to signal back that the filling wrong with the blender-filler
valves are open. communications. This alarm may also be
caused by the Filler Valve Opener being
in a manual/hand mode, rather than an
Automatic type mode. Review messages
on filler operating console or call filler
manufacturer.
57 FILLER NOT This alarm occurs during a Filler During an automated change over, after
EMPTY Charge, when either the Filler a Filler Blow, the Filler Product line
Empty Point Probe or the Filler should be dry. If the system detects
Operating Point Probe indicates water a Filler Charge, the system will not
the presence of a liquid (water). bring in the product into the Filler, by not
performing a Filler Prime automatically.
59 FILLER NOT This alarm occurs if the Filler is During an automated change over the
ROTATING FOR not rotating during a Filler Rinse, Filler must rotate in order to implement
CHANGEOVER Filler Drain, or Filler Blow. the correct sequences. Review
messages on filler operating console or
call filler manufacturer.
10 FILLER This alarm occurs when the signal This alarm can be caused; 1) Electrical
PRESSURE 4-20ma signal from the failure of the device itself. 2) Faulty
TRANSDUCER transducer is out of range. wiring. 3) Failure of the PLC analog
FAILURE input.
62 FILLER This alarm occurs if the Filler is During an automated change over the
ROTATING TOO not rotating at a minimum rate Filler must rotate at a minimum rate in
SLOW during a Filler Rinse, Filler Drain, order to implement the correct
or Filler Blow. sequences.
73 FILLER SPEED This alarm occurs if the Filler During an automated change over the
CONTROL MUST speed control is not in Automatic Filler speed setpoint is sent to the Filler
BE IN AUTO mode during a Filler Rinse, Filler for optimum rinsing and draining. Poor
Drain, or Filler Blow. product quality may result if the Filler is
not running at optimum speed. Review
messages on filler operating console or
call filler manufacturer.
74 FILLER VALVE This alarm occurs if the Filler During an automated change over the
OPENER Valve Opener control is not in Filler Valve Opener must be under the
CONTROL MUST Automatic mode during a Filler control of the blender in order to
BE IN AUTO Rinse, Filler Drain, or Filler Blow. implement the correct sequences. Poor
product quality may result if the Filler is
not under the control of the blender
during the change over sequences.
Review messages on filler operating
console or call filler manufacturer.
12 GAS FLOW This alarm occurs when the 4- This alarm can be caused; 1) Electrical
TRANSMITTER 20ma signal on the transducer failure of the device itself. 2) Faulty
FAILURE transmitter is significantly below wiring. 3) Failure of the PLC analog
4ma or greater than 20ma. input.

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Alarm Message Why and When Meaning


81 GAS This alarm occurs if the gas- This alarm can be caused by: 1) Gas
PROPORTIONING proportioning valve stays open Proportioning Valve not being able to
VALVE AT 100% 100% for 6 seconds while trying open. 2) Inadequate gas supply
to proportion the correct amount pressure. 3) Gas Flow Transmitter
of gas. This signals that the gas failure.
proportioning valve is unable to
maintain the proper gas flow while
in an operating range in which the
valve can sustain control.
17 GAS INJECTOR This alarm occurs if the gas This alarm can be caused by: 1) Gas
STREAM HIGH proportioning delivers too much Proportioning Valve not being able to
(OUT OF gas and does not compensate seat itself closed. 2) Gas Flow
CONTROL) within 6 seconds, during Transmitter failure.
Blending.
18 GAS INJECTOR This alarm occurs if the gas This alarm can be caused by: 1) Gas
STREAM LOW proportioning does not deliver Proportioning Valve not being able to
(OUT OF enough gas and does not open. 2) Inadequate gas supply
CONTROL) compensate within 6 seconds, pressure. 3) Gas Flow Transmitter
during Blending. failure.
40 INVALID This alarm occurs when the It is required that the Operator Selected
CONTAINER TYPE Operator Selected Container Container Type be chosen for every
Type is not a valid selection. production run.
52 MIX LINE PRIME, This alarm occurs if the syrup The Syrup Stream Zero Balance can be
SYRUP STREAM proportioning delivers too much viewed from the Trend Screen.
HIGH (OUT OF syrup and does not compensate Conditions which may cause a High
CONTROL) within 6 seconds, during a Mix Syrup Stream are: 1) Poor Water Stream
Line Prime. control caused by Product Flow Control
Valve not responding. 2) Syrup
Proportioning Pump not responding to a
speed adjustment sent by the PLC. 3)
Syrup Flow sensor or transmitter
malfunction. 4) Water Flow sensor or
transmitter malfunction
53 MIX LINE PRIME, This alarm occurs if the syrup The Syrup Stream Zero Balance can be
SYRUP STREAM proportioning does not deliver viewed from the Trend Screen.
LOW (OUT OF enough syrup and does not Conditions which may cause a Low
CONTROL) compensate within 6 seconds, Syrup Stream are: 1) Poor Water Stream
during a Mix Line Prime. control caused by Product Flow Control
Valve not responding. 2) Syrup
Proportioning Pump not responding to a
speed adjustment sent by the PLC. 3) A
total Syrup Proportioning Pump
malfunction. 4) Syrup Flow sensor or
transmitter malfunction. 5) Water Flow
sensor or transmitter malfunction

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Alarm Message Why and When Meaning


47 MIX PUMP HAS This alarm occurs if the PLC This alarm can be caused by: 1) Tripped
FAILED output to the pump is turned on, overload protection. 2) Faulty motor
and the auxiliary feedback on the starter. 3) Faulty wiring to motor starter.
pump contactor does not indicate 3) Faulty feedback wiring from auxiliary
the pump is running within 3 contact on motor starter to PLC input.
seconds.
32 Next Recipe: This alarm occurs if the Next
Invalid Recipe (5 Recipe Number is not between 1
Min. Warning) to 100, 5 minutes before a non-
operator triggered run out.
33 Next Recipe: Syrup This alarm occurs if the Next
Ports Do Not Match Recipe Operator Selected Next
(5 Min. Warning) Syrup Port does not match the
Recipe Syrup Port. If the Next
Recipe Syrup Port is “Any Port”,
the Operator Selected Next Syrup
Port may be any valve, except for
“None”.
67 NO CIP FLOW This alarm occurs during a CIP, if A minimum flow is required during a CIP.
ALARM - SYRUP the Syrup Mass Flow is less than Check valves and pumps for proper
SIDE the minimum allowable CIP flow operation. This alarm can be caused by a
limit. number of reasons; 1) Syrup
Proportioning Pump failure 2) Failure of a
valve to open upstream of the Syrup
Reservoir. 3) Loss of water upstream of
the Syrup Reservoir. 4) Air supply failure.
5) Syrup Flow sensor or transmitter
failure.
66 NO CIP FLOW This alarm occurs during a CIP, if A minimum flow is required during a CIP.
ALARM - WATER the Water Mass Flow is less than Check valves and pumps for proper
SIDE the minimum allowable CIP flow operation. This alarm can be caused by a
limit. number of reasons; 1) Insufficient water
supply 2) Failure of a valve to open
upstream of the Water Flow meter. 3) Air
supply failure. 5) Water Flow sensor or
transmitter failure.
48 PRODUCT PUMP / This alarm occurs if the PLC This alarm can be caused by: 1) Tripped
CIP DELIVERY output to the pump is turned on, overload protection. 2) Faulty motor
PUMP HAS and the auxiliary feedback on the starter. 3) Faulty wiring to motor starter.
FAILED pump contactor does not indicate 3) Faulty feedback wiring from auxiliary
the pump is running within 3 contact on motor starter to PLC input.
seconds.
56 PRODUCT TANK This alarm occurs during blending This alarm indicates that there may be a
GAS INLET VALVE if the Tank Pressure Source problem with tank pressure gas source,
AT 100% Modulating Valve is required to or Tank Pressure Source Modulating
be opened at 100% for more than Valve. Check gas source pressure and
20 seconds. volume, and check Tank Pressure
Source Modulating Valve operation.

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Alarm Message Why and When Meaning


43 PRODUCT TANK This alarm occurs if the Product This alarm keeps the Product Tank from
IS LOW Tank Low Level Sensor does not running dry. This alarm can occur if the
sense a product for delivery to the Blender is having trouble keeping up with
Filler. Typically the container stop the Filler demand.
will be disabled.
11 PRODUCT This alarm occurs if the Product This alarm indicates that the product is
TEMPERATURE Temperature rises above the warm, and perhaps there is a
HIGH ALARM Recipe Maximum Product refrigeration issue.
Temperature value.
44 PRODUCT TANK This alarm occurs when the 4- This alarm can be caused by; 1)
LEVEL 20ma signal on the transducer Electrical failure of the device itself. 2)
TRANSMITTER transmitter is significantly below Faulty wiring. 3) Failure of the PLC
FAILURE 4ma or greater than 20ma. analog input.
(ANALOG)
11 PRODUCT This alarm occurs when the This alarm can occur from; 1) The filler
TEMPERATURE Product Temperature rises above remaining idle for extended periods,
HIGH ALARM the Maximum Product where the product is then warmed from
Temperature setpoint in the the ambient air. 2) Refrigeration system
Active Recipe. failure
7 PRODUCT This alarm occurs when the 4- This alarm can be caused by; 1)
TEMPERATURE 20ma signal on the transducer Electrical failure of the device itself. 2)
TRANSDUCER transmitter is significantly below Faulty wiring. 3) Failure of the PLC
FAILURE 4ma or greater than 20ma. analog input.
68 REFRIGERATION This alarm occurs when the This alarm can be caused by; 1)
NOT RUNNING blender is not receiving the signal Refrigeration System not turned on. 2)
(ALARM) from the Refrigeration system, Refrigeration System failure. 3) Faulty
when the blender is calling for wiring. 4) Failure of the PLC digital output
Refrigeration. or input.
31 SYRUP This alarm occurs when the 4- This alarm can be caused; 1) Electrical
CONDUCTIVITY 20ma signal on the transducer failure of the device itself. 2) Faulty
TRANSDUCER transmitter is significantly below wiring. 3) Failure of the PLC analog
FAILURE 4ma or greater than 20ma. input.
41 SYRUP DENSITY This alarm occurs if the syrup The syrup density is constantly checked
LOW FAULT density measured by the mass to confirm that the quality of the syrup
flow meter is less than the Recipe has not been inadvertently compromised
Item Syrup Density Low value. by the syrup room delivery or the wrong
syrup being delivered to the blender.
54 SYRUP DENSITY This alarm occurs when a Diet Syrup delivery errors are possible, when
TOO HIGH FOR recipe is active and the syrup performing tank changes in the syrup
DIET density measured by the syrup room. This alarm is check for those
mass flow meter, is greater than errors.
1.10 g/cc.
8 SYRUP DENSITY This alarm occurs when the 4- This alarm can be caused by; 1)
TRANSMITTER 20ma signal on the transducer Electrical failure of the device itself. 2)
FAILURE transmitter is significantly below Faulty wiring. 3) Failure of the PLC
4ma or greater than 20ma. analog input.
36 SYRUP FLOW This alarm occurs when the 4- This alarm can be caused by; 1)
TRANSMITTER 20ma signal on the transducer Electrical failure of the device itself. 2)
FAILURE transmitter is significantly below Faulty wiring. 3) Failure of the PLC
(ANALOG) 4ma or greater than 20ma. analog input.

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SCREENS

ALARM Page 62 of 159

Alarm Message Why and When Meaning


3 SYRUP LEVEL This alarm occurs when the 4- This alarm can be caused by; 1)
TRANSDUCER 20ma signal on the transducer Electrical failure of the device itself. 2)
FAILURE transmitter is significantly below Faulty wiring. 3) Failure of the PLC
4ma or greater than 20ma. analog input.
49 SYRUP POSITIVE This alarm occurs when the syrup
DISPLACEMENT pump variable frequency drive
PUMP HAS sends a fault signal to the system
FAILED PLC.
22 SYRUP This alarm occurs when the Syrup This alarm indicates either a problem
PROPORTIONING Proportioning pump is required by with the Syrup Proportioning Pump or a
PUMP AT 100% the control algorithm to run at problem with the syrup delivery to the
100%, in order to maintain flow.. Syrup Proportioning Pump.
21 SYRUP This alarm indicates that liquid This alarm is used to inhibit the
RESERVOIR HIGH has been detected by the Syrup possibility of over flowing the Syrup
(OVERFLOW!) Reservoir Reservoir do to a level control failure.
This alarm can be overridden by pressing
and holding the BLEND button down, in
order to blend syrup out of the Syrup
Reservoir.
72 SYRUP This alarm occurs when blending, When this alarm occurs, the system will
RESERVOIR if the Syrup Reservoir level drops signal the container stop to close. This
LEVEL LOW below the minimum level required will safe guard the amount of
ALARM to run out the containers on the product/syrup to run out the empty
empty side. containers on the line.
38 SYRUP This alarm occurs when the Syrup This alarm is a safe guard against
RESERVOIR Reservoir Prime pushes the rinse pushing too much syrup to drain. If this
PRIME water to drain before it detects alarm occurs, check 1) That the correct
EXCEEDED good syrup, and the total amount syrup has been delivered to the blender.
MAXIMUM pushed to drain exceeds the 2) That the syrup delivered to the blender
VOLUME - CHECK maximum volume limit. is not diluted.
SYRUP!
23 SYRUP This alarm occurs when the Syrup This alarm is used to detect the possible
RESEVOIR Reservoir Capacitance Probe failure of the Syrup Reservoir Empty
EMPTY PROBE indicates a level in the Syrup Probe.
FAILURE Reservoir, but the Syrup
Reservoir Empty Probe does not
sense any liquid.
2 SYRUP This alarm occurs when the 4- This alarm can be caused by; 1)
TEMPERATURE 20ma signal on the transducer Electrical failure of the device itself. 2)
TRANSDUCER transmitter is significantly below Faulty wiring. 3) Failure of the PLC
FAILURE 4ma or greater than 20ma. analog input.
69 SYRUP ROOM - This alarm occurs when the This alarm can be caused by 1) Syrup
BLENDER blender does not receive a Room PLC malfunction. 2) Syrup Room
COMMUNICATION handshake reply from the Syrup or Blender Communications channel
S FAILURE Room PLC within 4 seconds. failure. 3) Faulty wiring.
(ALARM) Which indicates that the two
devices are no longer
communicating.

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SCREENS

ALARM Page 63 of 159

Alarm Message Why and When Meaning


55 TANK PRESSURE This alarm occurs during blending This alarm is a warning that there may be
LOW TOLERANCE when the Product Tank Pressure some difficulty controlling the tank
RANGE WARNING is 1.0 psi lower or less than the pressure during the present operation.
setpoint for 20 seconds. This alarm can be caused by; 1) Low
supply pressure from gas source. 2)
Problem with the Product Tank Gas
Source valving. 3) Rapid loss of product
level, which can make it difficult to
maintain tank pressure..
83 TANK PRESSURE This alarm occurs during blending This alarm is a warning that there may be
HIGH when the Product Tank Pressure some difficulty controlling the tank
TOLERANCE is 1.0 psi or more higher than the pressure during the present operation.
RANGE WARNING setpoint for 20 seconds. This alarm can be caused by; 1)
Problems with the Product Tank Gas
Exhaust valving. 3) Rapid increase of
product level, which can make it difficult
to relieve the tank pressure..
4 TANK PRESSURE This alarm occurs when the 4- This alarm can be caused by; 1)
TRANSDUCER 20ma signal on the transducer Electrical failure of the device itself. 2)
FAILURE transmitter is significantly below Faulty wiring. 3) Failure of the PLC
4ma or greater than 20ma. analog input.
39 TREATED WATER This alarm occurs if the PLC This alarm can be caused by: 1) Tripped
PUMP HAS output to the pump is turned on, overload protection. 2) Faulty motor
FAILED (FAULT) and the auxiliary feedback on the starter. 3) Faulty wiring to motor starter.
pump contactor does not indicate 3) Faulty feedback wiring from auxiliary
the pump is running within 3 contact on motor starter to PLC input.
seconds.
24 VACUMM This alarm occurs if the Water The Water condenser ensures that no
DEAERATOR Condenser on the suction of the liquid water enters the Vacuum Pump
CONDENSER HAS Vacuum Pump detects the and subsequently damages it. This alarm
BEEN PURGED presence of liquid. When it does, may happen once a day. If this alarm
an automated sequence is occurs more than a day, an investigation
initiated, which purges the of the Water Condenser system on the
contents of the Condenser. Vacuum Deaerator should be undertaken
by Maintenance. This alarm can be
caused by; 1) General build up of water
mist in the Water Condenser. 2) The
water level in the Vacuum Deaerator
being to high, and traveling down the
Vacuum Line, in which the Level Control
Probe or the Level Control Valve may
have failed.

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SCREENS

ALARM Page 64 of 159

Alarm Message Why and When Meaning


25 VACUUM This alarm occurs when the level A capacitance probe and a modulating
DEAERATOR of the Vacuum Deaerator rises valve control the level of the Vacuum
HIGH WATER above 65%. Dearator. If the level rises too high, water
LEVEL may travel down the vacuum line towards
the Vacuum Pump, creating a potentially
damaging situation for the Vacuum
Pump. This alarm can be caused by; 1)
Failed open water inlet modulating valve.
2) Capacitance probe failure.
60 VACUUM This alarm occurs when the This alarm is used to detect the possible
DEAERATOR Vacuum Deaerator Level failure of the Vacuum Deaerator Empty
LEVEL OR POINT Capacitance Probe indicates a Probe.
PROBE FAILURE level in the Vacuum Deaerator,
but the Vacuum Deaerator Empty
Probe does not sense any liquid.
63 VACUUM This alarm occurs when the 4- This alarm can be caused by; 1)
DEAERATOR 20ma signal on the transducer Electrical failure of the device itself. 2)
LEVEL transmitter is significantly below Faulty wiring. 3) Failure of the PLC
TRANSMITTER 4ma or greater than 20ma. analog input.
FAILURE
(ANALOG)
26 VACUUM This alarm occurs when the This alarm can be caused by; 1) Vacuum
DEAERATOR vacuum level in the Vacuum pump failure. 2) Vacuum transducer
PRESSURE TOO Dearator Vessel is insufficient to failure. 3) a valve in the Vacuum system,
LOW (ALARM dearate the water. The system sticking closed.
WAIT) will stop blending until a proper
vacuum is achieved.
30 VACUUM This alarm occurs when the This alarm can be caused by; 1) Vacuum
DEAERATOR vacuum level in the Vacuum pump failure. 2) Vacuum transducer
VACUUM Dearator Vessel is not optimum in failure. 3) a valve in the Vacuum system,
PRESSURE LOW order to dearate the water. This is sticking closed.
(ALARM) a warning type alarm.
58 VACUUM This alarm occurs when the level A capacitance probe and a modulating
DEAERATOR of the Vacuum Deaerator falls valve control the level of the Vacuum
WATER LEVEL IS below 10%. Dearator. If the level rises too high, water
LOW may travel down the vacuum line towards
the Vacuum Pump, creating a potentially
damaging situation for the Vacuum
Pump. This alarm can be caused by; 1)
Failed closed water inlet modulating
valve. 2) Capacitance probe failure.
46 VACUUM This alarm occurs if the PLC This alarm can be caused by: 1) Tripped
DEAERATOR output to the pump is turned on, overload protection. 2) Faulty motor
WATER PUMP and the auxiliary feedback on the starter. 3) Faulty wiring to motor starter.
HAS FAILED pump contactor does not indicate 3) Faulty feedback wiring from auxiliary
the pump is running within 3 contact on motor starter to PLC input.
seconds.

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SCREENS

ALARM Page 65 of 159

Alarm Message Why and When Meaning


29 VACUUM This alarm occurs when the 4- This alarm can be caused by; 1)
PRESSURE 20ma signal on the transducer Electrical failure of the device itself. 2)
TRANSDUCER transmitter is significantly below Faulty wiring. 3) Failure of the PLC
FAILURE 4ma or greater than 20ma. analog input.
45 VACUUM PUMP This alarm occurs if the PLC This alarm can be caused by: 1) Tripped
HAS FAILED output to the pump is turned on, overload protection. 2) Faulty motor
and the auxiliary feedback on the starter. 3) Faulty wiring to motor starter.
pump contactor does not indicate 3) Faulty feedback wiring from auxiliary
the pump is running within 3 contact on motor starter to PLC input.
seconds.
28 VACUUM PUMP This alarm occurs when the over The temperature of the Vacuum Pump
TEMPERATURE temperature switch on the system is an temperature sensor located
TOO HIGH vacuum pump indicates an over in the vacuum pump, and cooling water
temperature. delivered through a heat exchanger,
located on top of the vacuum pump. This
alarm can be caused by; 1) Loss of
cooling water supply. 2) Temperature
transducer failure. 3) Cooling water ball
valve failure.
14 VACUUM PUMP This alarm occurs when the 4- This alarm can be caused by; 1)
TEMPERATURE 20ma signal on the transducer Electrical failure of the device itself. 2)
TRANSDUCER transmitter is significantly below Faulty wiring. 3) Failure of the PLC
FAILURE 4ma or greater than 20ma. analog input.
84 VACUUM PUMP This alarm occurs when the The Vacuum Pump is required to have
OIL CHANGE Vacuum Pump Hour timer the oil change periodically. Once the oil
REQUIRED SOON exceeds the Vacuum Pump Oil has been changed, the Vacuum Pump
Change Warning Timer Limit. Hour must be reset from the Vacuum
Pump Maintenance Screen.
85 VACUUM PUMP This alarm occurs when the The Vacuum Pump is required to have
OIL CHANGE Vacuum Pump Hour timer the oil change periodically. Once the oil
REQUIRED NOW exceeds the Vacuum Pump Oil has been changed, the Vacuum Pump
Change Alarm Timer Limit. Hour must be reset from the Vacuum
Pump Maintenance Screen.
37 WATER FLOW This alarm occurs when the 4- This alarm can be caused by; 1)
TRANSMITTER 20ma signal on the transducer Electrical failure of the device itself. 2)
FAILURE transmitter is significantly below Faulty wiring. 3) Failure of the PLC
(ANALOG) 4ma or greater than 20ma. analog input.
19 WATER STREAM This alarm occurs if water flow The water flow has to be within range.
HIGH (OUT OF control is delivering more than The Mix Throttling Valve and water
CONTROL) 100 kg/min higher than the target delivery system to the blend skid can
flow. effect the water flow.
20 WATER STREAM This alarm occurs if water flow The water flow has to be within range.
LOW (OUT OF control is delivering less than 100 The Mix Throttling Valve and water
CONTROL) kg/min lower than the target flow. delivery system to the blend skid can
effect the water flow.
5 WATER This alarm occurs when the 4- This alarm can be caused by; 1)
TEMPERATURE 20ma signal on the transducer Electrical failure of the device itself. 2)
TRANSDUCER transmitter is significantly below Faulty wiring. 3) Failure of the PLC
FAILURE 4ma or greater than 20ma. analog input.

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SCREENS

ALARM Page 66 of 159

Alarm Message Why and When Meaning


84 VACUUM PUMP This alarm message is a warning This alarm message is a warning to the
OIL CHANGE that is activated when the operator that an oil change of the
REQUIRED SOON Vacuum Pump Hour Timer Vacuum Pump is required in the near
exceeds the Warning Hours future.
parameter value, set in the
Maintenance Vacuum Pump
Screen.
85 VACUUM PUMP This alarm is activated when the This alarm indicates to the operator that
OIL CHANGE Vacuum Pump Hour Timer an oil change of the Vacuum Pump is
REQUIRED NOW exceeds the Alarm Hours past due.
parameter value, set in the
Maintenance Vacuum Pump
Screen.

Blender Screen

The Blender Screen provides the operator the ability to view the Blender Module valve position,
pump speed, flow rates and current Machine Function.

Step Action
1. To view the Blender Screen follow the links below from the home screen

Home 
2. The Blender Screen will display as shown below:

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SCREENS

BLENDER Page 67 of 159

Press Here to Go
To Syrup Room
Press
Graphic
Here to
Go To
Deox
Graphic

Press Here
to Go To
Injector
Graphic

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SCREENS

BLENDER Page 68 of 159

Blender Screen Indicators

There are a number of colored indicators on the Blender Screen, which show the state of the
level of the syrup in the Syrup Reservoir.

LP201 Syrup
Reservoir Level High
Probe. Green means
syrup level is high.
Red means the syrup
level is below the
high level.

LP203 Syrup Reservoir


Level Low Probe. Green
means product is present
at the bottom of the Syrup
Reservoir. Red means the
CT201 Syrup Line
Syrup Reservoir is empty.
Conductivity
Transmitter.
Indicates
conductivity of
Syeup in the Syrup
LP200 Syrup Line – Syrup Line feeding the
Detection Probe. Green blender.
indicates. Syrup or Water
(liquid) is present in the
syrup Line. Red indicates
the Syrup Line is empty.

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SCREENS

BLENDER Page 69 of 159

Blender Command Screen

The Blender Command Screen provides the operator the initiate Blender Module Machine
Commands and make operator adjustments to the proportioning.

Step Action
1. To view the Blender Command Screen follow the links below from the home screen

Home  
2. The Blender Command Screen will display as shown below:
Use the Up/Down arrows
to change the Operator
Adjusted Brix

Deaeration Unit Screen

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SCREENS

DEAERATION UNIT Page 70 of 159

The Deaeration Unit Screen provides the operator the ability to view the Deox (Vacuum
Deaeration unit) valve position and pump status.

Step Action
1. To view the Deaeration Unit Screen follow the links below from the home screen

Home 
2. The Deaeration Unit Screen will display as shown below:

Press Here to
go to CIPSkid

Press Here to
go to Blender
Graphic

Indicates number of Press here to


seconds left in warm up go to enable
or warm down. Vacuum

Press Here to
to enable
Dearator

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SCREENS

GAS INJECTOR Page 71 of 159

Gas Injector Screen

The Gas Injector Screen provides the operator the ability to view the position and status of the valves on
the Gas Injector Module.

Step Action
1. To view the Gas Injector Screen follow the links below from the home screen

Home 
2. The Gas Injector Screen will display as shown below:

Press here to go
to Product Tank
Graphic

Press here to go
to Blender
Graphic

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SCREENS

GAS INJECTOR Page 72 of 159

Gas Injector Command Screen

The Gas Injector Command Screen provides the operator the ability to adjust the Gas Injector set point.

Step Action
1. To view the Gas Injector Command Screen follow the links below from the home screen

Home  
2. The Gas Injector Command Screen will display as shown below:

Use Up/Down
arrows to adjust
the Gas Injector
Set point,

Press Here to go
to Product Tank
Graphic

Press here to go
to Blender
Graphic

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SCREENS

PRODUCT TANK Page 73 of 159

Product Tank Screen

The Product Tank Screen provides the operator the ability to view the position and status of the valves on
the Product Tank Module.

Step Action
1. To view the Product Tank Screen follow the links below from the home screen

Home 
2. The Product Tank Screen will display as shown below:

Press here to got


to Injector
Graphic

Press here to got


to Filler Graphic

Press here to got


to Injector
Graphic

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SCREENS

PRODUCT TANK Page 74 of 159

Product Tank Screen Indicators

There are a number of colored indicators on the Product Tank Screens, which show the state of the level
of the product in the Product Tank.

Indicator Description
Beverage When the blender has sufficient level of product in the Product Tank for delivery to the
Available Filler, this indicator will turn green.

LP401 Product Tank


Empty Probe. Green
means product is
present at the bottom
of the Product Tank.
Red means the
Product Tank is
empty.

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SCREENS

PRODUCT TANK Page 75 of 159

Product Tank Command Screen

The Product Tank Command Screen provides the operator the ability to adjust the Product Tank pressure
and the product temperature set points.

Step Action
1. To view the Product Tank Command Screen follow the links below from the home screen

Home  
2. The Product Tank Command Screen will display as shown below:

Use Up/Down
arrows to adjust Use Up/Down
the Product arrows to adjust
Temperature if the Product Tank
Accu-Temp  Pressure
Option is
installed

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SCREENS

PRODUCT TANK Page 76 of 159

Product Tank Refrigeration Screen

The Product Tank Command Screen provides the operator the ability to adjust the Product Tank pressure
and the product temperature set points. This screen is available with the Accu-Temp
 option.

Step Action
1. To view the Product Tank Command Screen follow the links below from the home screen

Home  
2. The Product Tank Command Screen will display as shown below:

Accu-temp BPRV
control variables

Product Tank Refrigeration Screen Indicators

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847-882-0690
SCREENS

PRODUCT TANK Page 77 of 159

There are a number of colored indicators on the Product Tank Refrigeration Screen, which show the
status of the Product Refrigeration.

BPRV Position
LS231H indicates
a high ammonia V232 BPRV (Back
level in the surge Pressure Regulating
tank. Valve) maintains a
constant pressure on the
Ammonia Surge Tank,
in order to maintain a
constant temperature.

LS231O indicates
that the ammonia
level is a the
operating level of V230 Ammonia
the surge tank Liquid Line
Solenoid Valve.
Sources liquid
ammonia into the
surge tank.

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SCREENS

FILLER Page 78 of 159

Filler Screen

The Filler Screen provides the operator the ability to view the position and status of the valves on the
Filler Module.

Step Action
1. To view the Filler Screen follow the links below from the home screen

Home 
2. The Filler Screen will display as shown below:

Astirix (*) indicates valves are normally open. Valve


is open when red, closed when green.

LP402 Filler Line LP403 Filler Line


Full Probe
Empty Probe

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SCREENS

FILLER Page 79 of 159

Filler Screen Indicators

There are a number of colored indicators on the Filler Screens, which show the state of the interface
between the Blender and the Filler.

The STATUS indicators are actual feed back from the Filler to the Blender.

Status Description
Indicators
Container Indicates the actual status of the Filler Container Stop. The Container Stop is open
Stop (allowing containers to pass through the filler) when the indicator is green. The Container
Stop is closed (containers are blocked from passing through the filler) when the indicator
is red.
Valve Indicates the actual status of the Filler Valve Opener. The Valve Opener is open, when the
Opener indicator is green. The Valve Opener is closed, when the indicator is red.
Rotating Indicates when the Filler drive control is active, in order to rotate the Filler. Many Filler
Machine Functions require that the Filler rotate in order to execute.

The OUTPUTS indicators are commands sent to the Filler from the Blender.

Output Description
Indicators
Container During a Flavor Change Over or when certain Alarm Faults occur, the blender signals the
Stop Filler to inhibit containers from passing through the Filler. When this indicator blinks green,
the Container Stop will block the containers.
Valve During certain Filler Machine Functions (rinses, drains, and blows) the Blender will signal
Opener the Filler to open the Valve Opener. When this indicator is green the Filler will open the
Valve Opener.

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SCREENS

FILLER Page 80 of 159

The following indicators show the status of the availability of beverage from the blender, and the request
for beverage from the Filler.

Indicator Description
Beverage When the blender has sufficient level of product in the Product Tank for delivery to the
Available Filler, this indicator will turn green.

Beverage When the Filler is ready to accept product, it requests beverage through this signal. Even
Request if the Blender has “Beverage Available” the Product Outlet Valve will not open until the
Filler makes a “Beverage Request”

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SCREENS

FILLER Page 81 of 159

Filler Command Screen

The Filler Command Screen provides the operator the ability to initiate the available Filler functions.

Step Action
1. To view the Filler Command Screen follow the links below from the home screen

Home  
2. The Filler Command Screen will display as shown below:

Press here to end


the Filler Run Out
during a Flavor
Change

Special Filler Functions Press here to manually


to toggle the Beverage
Request signal to the
Output Indicators Description Blender
Filler Runout Done. This button is used to end a Runout of the
production. This button is active when the Product Tank Runout or the
Filler Runout are in progress, and will complete both of them. If this button

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SCREENS

FILLER Page 82 of 159

is pressed during a Filler Runout, the automatic changeover is initiated by


completing the Filler Runout and initiating a Filler Drain. If this button is
pressed while a Product Tank Runout is in progress, the Filler starts a
Filler Drain, and the Product Tank will initiate a Product Tank Empty,
which will release all the product in the Product Tank to Drain.
Enable Product Pump. When enabled, the Product Pump is used to
deliver product to the filler.

Hold Auto Prime. When enabled, a Filler Prime will not be initiated
automatically during a Filler Change Over. The Filler Prime will have to be
manually initiated. This button is used to hold off the automatic initiation of
the Filler Prime, in instances, where the operator may be required to
perform some maintenance on the Filler. (ie changing a valve)

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OPERATIONS

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Syrup Port Screen

The Syrup Port Screen provides the operator the ability to view the Syrup Port status and valve position
of the syrup manifold.

Step Action
1. To view the Syrup Port Screen follow the links below from the home screen

Home 
2. The Syrup Port Screen will display as shown below: Press Here to
Go to Blender
Green indicates Syrup Graphic
Pump is running. Red
indicates Syrup Pump Is
not running.
Syrup
Port
Status
Matrix

Press here to
go to Syrup
Room
Commands
Screen

Press here to go to Deox Indicates if the Syrup Pump is being


Graphic Screen requested to run by the blender.

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Syrup Port Status Matrix

Displayed on the Syrup Port Screen and other screens, is the Syrup Port Status Matrix. The Syrup Port
Status Matrix indicates the condition and current operation each syrup port.

PORT A
PORT B

State or
Operation

Each column of the matrix represents one of the syrup lines (ala DIRECT LINE, DIET LINE, FLAVOR
LINE, or CLASSIC LINE. Note in some installations only one syrup line is indicated). Each row indicates a
specific state or operation.

State or Description
Operation
Active When green, this indicates that the Syrup Port is selected in the Active Recipe.
Next When green, this indicates that the Syrup Port is selected in the Next Recipe.
Ready When green, this indicates the Syrup Port is ready for production.
Connected When green, this indicates that syrup is connected in the Syrup Room to the Syrup Port.
Rinse When green, this indicates that the Syrup Port is being rinsed.
Drain When green, this indicates that the Syrup Port is being drained.
Prime When green, this indicates that the Syrup Port is being primed.

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Syrup Port “READY” and “CONNECTED”:

The Syrup Port states “CONNECTED” and “READY” are set by the operator, as confirmation to the
Blender, as to the status of the Syrup Port. This redundancy is used to minimize the possibility of opening
the wrong Syrup Port through operator error. The following also applies.
• In order for the Syrup Inlet valve for the Syrup Port to open the Syrup Port must be
“CONNECTED” and be “READY”. The blender will wait until the Syrup Port is “CONNECTED”
and “READY” before it will start a Syrup Reservoir Prime, Mix Line Prime or Blending.
• The Syrup Port can only be Primed if the Syrup Port is “CONNECTED” and is “READY”.
• The Syrup Port cannot be Rinsed, Drained, or CIPed if the Syrup Port is “READY”. The logic in
the system software will inhibit this.
• The Syrup Port “CONNECTED” state is set to false during a Run Out. Therefore the Syrup Port
will require the “CONNECTED” state to be set to true again, when the Syrup Port is needed in the
future.

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Syrup Port Command Screen

The Syrup Port Command Screen provides the operator the ability to initiate commands that affect the
Syrup Ports.

Step Action
1. To view the Syrup Port Command Screen follow the links below from the home screen

Home  
2. The Syrup Manifold Screen will display as shown below:

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Syrup Port Ready Screen

The Syrup Port ready Screen allows the provides the operator the ability to initiate commands, that affect
the Syrup Ports.

Step Action
1. To view the Syrup Port Command Screen follow the links below from the home screen

Home    Syrup Port Ready


2. The Syrup Manifold Screen will display as shown below:

Syrup Port Utilities Screen

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The Syrup Port ready Screen allows the provides the operator the ability to initiate commands, that affect
the Syrup Ports.

Step Action
1. To view the Syrup Port Command Screen follow the links below from the home screen

Home    Syrup Port Utilities


2. The Syrup Manifold Screen will display as shown below:

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Syrup Line Purge Screen

The Syrup Port ready Screen allows the provides the operator the ability to initiate commands, that affect
the Syrup Ports.

Step Action
1. To view the Syrup Port Command Screen follow the links below from the home screen

Home    Syrup Line Purge


2. The Syrup Manifold Screen will display as shown below:

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Maintenance Screen

The Maintenance Screen a pivotal screen, where all the screens that pertain to machine setup,
performance, component testing and calibration are accessed.

Step Action
1. Access the Maintenance Screen by following the links below from the home screen

Home  Maintenance
2. The Maintenance Screen will display as shown below:

Press here to
enable the forcing
of machine
components.

Press a
button
button to
access
the sub-
screen

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Maintenance PID Screen

The Maintenance PID Screen displays to the available PID parameter adjustment screens for the system.
The PID parameters control the dynamics of how a control point is maintained to a set point.

Step Action
1. Access the Maintenance PID Screen by following the links below from the home screen

Home  Maintenance  Maintenance PID


2. The Maintenance PID Screen will display as shown below:

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PID Control Devices and Available Parameters

Each PID Maintenance Screen is used to adjust the dynamics of a specific control point. Refer to the
table below regarding the Control points input device, out put device, and available parameters that can
be adjusted.

Screen Input Device Output Device Available Parameters


Syrup Syrup Meter (FT201) Syrup Proportioning Pump Feed Forward Scale
Blending and Water Meter (P201) Feed Forward Offset
(FT101) Gain
Integral
Derivative
Product Flow Water Meter (FT101) Mix Line Throttling Valve Feed Forward Scale
(Product Modulating Valve) Feed Forward Offset
(V404) Gain
Integral
Derivative
Reservoir Syrup Reservoir Syrup Reservoir Level Control Gain
Level Capacitance Probe Valve (V204) Integral
(LT201) Derivative
Tank Product Tank Pressure Product Tank Gas Inlet Valve Gain
Pressure Transducer (PT401) (V323) and Product Tank Gas Integral
Outlet Valve (V326) Derivative
CO2 Injection Gas Mass Flow Meter Gas Injector Modulating Valve Feed Forward Scale
(FT301) (V306) Feed Forward Offset
Gain
Integral
Derivative
CIP Supply CIP Return Steam Control Valve (V001) Gain
Temperature Temperature Integral
Transducer (RTD001) Derivative
Vacuum Vacuum Deaerator Vacuum Deaerator Water Level Gain
Deaerator Capacitance Probe Control Valve (V102) Integral
Level (LT101) Derivative

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Press up
arrow to
increase Press down
arrow to
parameter
increase
value.
parameter
value.

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Maintenance Setup Screen

The Maintenance PID Screen displays to the available PID parameter adjustment screens for the system.
The PID parameters control the dynamics of how a control point is maintained to a set point.

Step Action
1. Access the Maintenance Setup Screen by following the links below from the home screen

Home  Maintenance  Setup


2. The Maintenance Setup Screen will display as shown below:

Parameter Description
Syrup Reservoir Volume at 100% This parameter is used to scale the Syrup Reservoir
Capacitance Probe analog input to the conversion to
volume (in liters). The value entered here should be the
volume of the Syrup reservoir when the reservoir is at
100%.

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Syrup Reservoir Volume at 0% This parameter is used to scale the Syrup Reservoir
Capacitance Probe analog input to the conversion to
volume (in liters). The value entered here should be the
volume of the Syrup Reservoir when the reservoir is at 0%.
Analog In High Alarm This parameter is used as an upper threshold for a valid
analog input current reading in milliamps. If an analog input
rises above this valve, a Transducer Failure Alarm is
generated.
Analog In Low Alarm This parameter is used as an lower threshold for a valid
analog input current reading in milliamps. If an analog input
falls below this valve, a Transducer Failure Alarm is
generated.
Water Brix This parameter is used in the internal calculations the
system performs toward the determination of percent syrup
of a Non-Diet product dependent upon Recipe values of
Syrup Brix and Product Brix. This value should be the
apparent brix of the water used by the blending system.
Water TA/% This parameter is used in the internal calculations the
system performs toward the determination of percent syrup
on a Diet product dependent upon Recipe values of Syrup
Brix and Product Brix. This value should be the apparent TA
of the water used by the blending system.
Residual Water Mass This value is used in calculating the initial blend during the
initial blend of a product. Blending at a lower ratio during the
initial blend of a product corrects for the residual water left
after a rinse and drain of the system. The unit of this
parameter is in kilograms.
Blend Sweet Mass This value is used to determine the amount of mass of
product is blended at a lower blend ratio during the initial
blend of a product. Blending at a lower ratio corrects for the
residual water left after a rinse and drain of the system. The
unit of this parameter is in kilograms.

Metric Mass Display This parameter determines if the units of the mass display
values (flow rates and totals) are displayed in metric
(kilograms and gallons) or Imperial Units (pounds/min and
liters).
Metric Non-Mass Display This parameter determines if the units of the non-mass
display values (temperature and pressures ) are displayed
in metric (kilograms) or Imperial Units (pounds/min).
Auto Start Auto Brix This parameter determines if the Accu-Brix control algorithm
is started automatically when a new product starts up.
CIP Pressure This parameter provides the Setpoint for the Product Tank
Pressure during a CIP. Typical value is 0, for an
atmospheric tank CIP.
Accu-Temp Offset The parameter provides the value of the split across the
Product Chiller in degrees C. Typical for PHE is 1.0C and
for Carbo-Cooler is 3.0 C.
Vacuum Low This parameter determines the low threshold for the
Vacuum Pressure Low Warning

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Vacuum Too Low This parameter determines the low threshold for the
Vacuum Pressure Low Alarm. Blending cannot continue
below this level.

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Maintenance Change Over Screen

The Maintenance Change Over Screen gives the operator the ability to adjust parameters pertaining to
the volumes metered during certain functions.

Step Action
1. Access the Maintenance Change Over Setup Screen by following the links below from the
home screen

Home  Maintenance  Change Over


2. The Maintenance Change Over Screen will display as shown below:

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Parameter Description
Syrup Line Volume This parameter provides the system information regarding
the amount of syrup volume is held in a packed sysrup line.
This value is used to determine the amount of syrup
available in the system.

Syrup Reservoir Push Volume This parameter provides the system with information
regarding the volume of syrup held in the syrup metering
line from the bottom of the Syrup Reservoir all the way up to
the Mix Line. The value is used during a Syrup Reservoir
Runout. When the level of the syrup reaches the bottom of
the Syrup Reservoir, the Syrup is metered until the volume
metered reaches this value.
Mix Line Prime Volume This parameter provides the system with information
regarding the volume of the Mix Line Prime. During a Mix
Line Prime, the amount of liquid (rinse water) is metered to
drain, exceeds this value; the product is then diverted into
the Product Tank afterwards.
Mix Line Runout Push Volume This parameter provides the system with information
regarding the volume of the Mix Line for the Mix Line
Runout. During a Mix Line Runout, the amount of product
that is pushed with water into the Product Tank is metered.
When the amount of metered water exceeds this value, the
Mix Line Runout is terminated.
Product Tank Volume This parameter provides the system with the volume of the
Product Tank in liters when the Product Tank capacitance
probe reads 100%.
Filler and Line Volume This parameter provides the system with information
regarding the volume of the Filler and Filler Line, during
normal product operation. This value is used in determining
the container cutoff value.
Syrup Reservoir Rinse Volume This parameter is used by the system to determine the
amount rinse water volume should be metered during a
Syrup Reservoir Rinse.
Syrup Reservoir Prime Drain This parameter provides the system with information
pertaining to the amount of rinse water to meter to drain,
before a recirculation is initiated during a Syrup Reservoir
Prime. This value should be the volume of the syrup meter
line from the bottom of the Syrup Reservoir to the Syrup
Meter Drain.

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Maintenance Vacuum Pump Screen

The Maintenance Change Over Screen gives the operator access to Vacuum Pump hour counter alarm
set points and the ability to reset the hour counter.

Step Action
1. Access the Maintenance Vacuum Pump Screen by following the links below from the
home screen

Home  Maintenance  Vacuum Pump


2. The Maintenance Vacuum Pump Screen will display as shown below:

Press here to
reset the hour
counter, after you
have changed the Press up or down
oil in the Vacuum arrow to
Pump increment or
decrement the
parameter value.

The Vacuum Deaerator provided with the system requires an oil change periodically. This Maintenance
Vacuum Pump Screen is used to set the number of hours that an oil change is absolutely required (Alarm
Hours) and to set the number of hours for a reminder message (Warning Hours). This screen is also used
by the operator to reset the hour counter one the oil has been changed.

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Maintenance Meter Setup

The Maintenance Meter Setup Screen provides access to each meter’s maximum value at 20 milliamps,
and whether the water meter is a volumetric type or a mass meter. The screen also provides the ability to
calibrate the Syrup Reservoir.

Step Action
1. Access the Maintenance Meter Setup Screen by following the links below from the home
screen

Home  Maintenance  Maintenance Meter Setup


2. The Maintenance Meter Setup Screen will display as shown below:

Press here to
toggle between a
Mass Meter or a
Volumetric Meter.

Press up or down
arrow to
increment or
decrement the
parameter value.

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Maintenance Meter Setup – Syrup Reservoir Calibration

The Maintenance Meter Setup Screen also provides a means to calibrate the Syrup Reservoir
Capacitance Probe. With the buttons shown below, the qualified operator can fill the Syrup Reservoir with
water from the Deaerator by pressing the “Fill Syrup Reservoir” button, and then when complete, start
totalizing the amount of sysrup in the Syrup Reservoir by pressing “Syrup Totalize”. The value of the
current Syrup Volume metered and the current level are also shown.

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Maintenance Meter Proving

The Maintenance Meter Proving Screen provides the OEM technician with the ability to prove the blender
meters. A qualified OEM technician should only undertake this.

Step Action
1. Access the Maintenance Meter Proving Screen by following the links below from the home
screen

Home  Maintenance  Maintenance Meter Setup


2. The Maintenance Meter Proving Screen will display as shown below:

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Maintenance Force Screens

In order to test individual machine components, it may be required by a Qualified Operator to activate a
specific machine component. This “Forcing” capability is provided through the “Force Screens”. The
Maintenance Screen provides access to a number of “Force” Screens, located in the “Force Screen
Area”.

Force Enable
Force Screen Button
Area

Do not attempt to Force a component while the system is performing a function or operation. To enable
“Forcing”, press the Force Enable Button. A green indicator means that Forcing is enabled.

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Inside the “Force Screen Area”, are a number of Force Screens, which provide access to Forcing
Components based on the location in the System. Below is an example of a typical Force Screen for the
Vacuum Deaerator. A green indicator means the item is activated. A red indicator means the item is
deactivated.

Press Up / Down
arrows to move
Selected item to selection.
be activated.

Indicator

Press Enter Button


to activate /
deactivate selected
item.

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Analog outputs, to such devices as driver speeds and I/P transducers are forced on the Maintenance
Analog Table, shown below. Press Up / Down arrows to
increment or decrement
item analog out from 0 to
100%.

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RECIPE

RECIPES Page 107 of 159

Recipes
A Recipe is a list of variables used by the blender to formulate the ingredients for the correct end product.
The system allows up to 100 different recipes to be developed. A Typical recipe displayed by the Recipe
Viewer is shown below.

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Recipe Items

Each Recipe Item has it’s own description with an associated value, The definition of each Recipe Items
is described below.

Recipe Item Definition


Syrup Brix /TA/Percent This is the target value of the Finished Syrup that is being
delivered to the blender. This number, along with the Product
Brix/TA/Percent Recipe Item value determines the blending ratio
for proportioning water and syrup. The value of this Recipe Item
depends on how the end Product is measured, which
corresponds to value and units of the Product Brix/TA/Percent
Recipe Item value.

• If the end Product is measured in Brix from a


Refractometer or a Densitometer, Then specify this value
as the Target Syrup Brix for this flavors syrup batching.
• If the end Product is measured by a titration (which
typically determines product acidity), Then specify this
value as the measurement of the Titration of a full
strength Finished Syrup batch. Typically this value is the
blending ratio plus one times Target Product Titration
value (ie Syrup TA = {Ratio +1} * Product Titration).
• If the end Product is measured by another means as a
percentage, where 100% is the Target for the Product
Then enter this value a the blending ratio plus one times
Target Product Percentage (ie Syrup Percent = {Ratio
+1} * Product Percent).
Syrup Density This is the Nominal Finished Syrup Density in units of grams per
cubic centimeter. Typical for sugared (sweet) beverages is in the
range of 1.12 to 1.3 g/cc. Typical for diet beverages is in the
range 1.0 to 1.09 g/cc. This number is used explicitly in for a diet
beverage for calculation of the percent syrup by mass for
blending.
Syrup Density Low This value determines the low measured density for alarming
purposes. If during a production run, the measured Syrup Density
is less than this value, an Alarm Fault will occur and blending will
be stopped immediately. Typical for sugared (sweet) beverages
is 0.02 less than the Nominal Syrup Density. Typical for diet
beverages is in the range 0.998 to 1.001 g/cc
Product Brix/TA/Percent This is the target value of the Finished Product that is to be
produced by the blender. This number, along with the Syrup
Brix/TA/Percent Recipe Item value determines the blending ratio
for proportioning water and syrup. The value of this Recipe Item
depends on how the end Product is measured.
• If the end Product is measured in Brix from a
Refractometer or a Densitometer, Then specify this value
as the Target Product Brix for this flavor.
• If the end Product is measured by a titration (which
typically determines product acidity), Then specify this

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Recipe Item Definition


value as the measurement of the Titration of sample of
the Target Product.
• If the end Product is measured by another means as a
percentage, where 100% is the Target for the Product
Then enter this 100% as the value.

Product Temperature This is the Target Product Temperature for delivery to the filler,.
This number is used as a Setpoint to control the Product
Temperature with the Accu-Temp option, otherwise it is used only
for reference.
Product Temperature Maximum This value determines the Product Temperature threshold for
alarming, that the Product Temperature is high, which therefore
indicates to the operator to review the temperature control
hardware for problems.
Product Flow Rate (cpm) This is the Target Product Flow rate in containers per minute. The
blender will proportion product at this rate.
Pungifity
Tank Pressure This is the target operating pressure for this flavor.
Initial Tank Pressure This is the intial pressure, when the Product Tank is first being
filled with product, during a Product Tank Prime. This value is
typically less than the Tank Pressure value in order to minimize
any saturated gas pickup while filling the Product Tank for the
first time. As product continues entering the Product Tank during
a Product Tank Prime the Target Product Tank Pressure Setpoint
is ramped from the Initial Tank Pressure value to the Tank
Pressure value. Typically the Intial tank Pressure value is 10 to
15 psi less than the Tank Pressure value.
Gas Injector This is the Target Gas Volumes for the Gas Injector.
Initial Gas Injector This is the Target Gas Volumes for the Gas Injector during a
Product Tank Prime. This value is typically less than the Gas
Injector value in order to minimize any saturated gas pickup while
filling the Product Tank for the first time.
Injector Factor This number determines the Gas Injection efficiency for this flavor
based on 1.95g/ liter / volume. This number is typically in the
range of 1.0 to 1.1 for DIET beverages and 0.85 to 1.0 for Non
DIET beverages.
Saturator Factor This number specifies the efficiency of the Product Tank as a
Saturator, and determines the amount of gas volume pickup
during normal operating conditions. Typical values for a
Satuarator only system is 0.6. Typical values for a Gas Injector
only system is 0.03.
Diet Beverage A value of YES means this beverage is a DIET beverage. A value
of NO means this is not a DIET beverage (it is a sweet drink).
Refrigeration Required A value of YES, specifies that refrigeration is required during
production of this beverage, and that refrigeration will be
requested from the plant’s refrigeration system. A value of NO,
specifies that no refrigeration is required, and that refrigeration
will not be requested from the plant’s refrigeration system.
Nitrogen Required A value of YES, indicates that a Nitrogen is used as the gas
source, for Injection and Pressurizing the Product Tank. In this

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Recipe Item Definition


specific application, this value is unused, and should be set to
NO.
Container This value specifies the Container Type and Size for the
production run. This value and the Product Flow Rate value
determines the production ate of the blender.
Only Use Syrup Port This value specifies the Syrup Port that is to be only for this
beverage. A value ANY PORT will allow this recipe to use any
port to obtain syrup. An assignment of a specific syrup port, will
only allow this recipe to obtain syrup from that specific port. A
value of not assigned will generate a alarm fault.
Product Brix Offset The Product Brix Offset number is used to offset the entered
recipe value of the Product Brix/TA/Percent/Ratio. A positive
number will make the blending more rich (more syrup). A
negative number will make the blending less rich (less syrup).
Syrup Brix Offset The Syrup Brix Offset number is used to offset syrup brix as
calculated by the system from the syrup density and syrup
temperature. The number serves as a correction to the calculated
syrup brix, where ingredients in the syrup may scew the result.

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Active and Next Recipes

Recipes are developed and modified using the Recipe Manager as described in this manual. Once the
recipe is satisfactorily developed, it can be selected for use. The current recipe that the system is using to
formulate the beverage is called the Active Recipe. The Active Recipe is essentially a copy of one of the
recipes developed by the Recipe Manager. Once a specific recipe has been selected and copied into the
Active Recipe, the values of the Recipe Items are used for blending.

Like the Active Recipe, the Next Recipe is a copy of one of the recipes developed by the Recipe
Manager, but to be used for the next flavor’s production run after a flavor change over. During an
automatic flavor change over, the Next Recipe is moved into the Active Recipe, and the Next Recipe then
is Empty. This feature allows the operator to pre-select the next flavor to be run, along with syrup port
selection, in order that no operator intervention is required during the actual change over.

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Viewing Active and Next Recipes

Step Action
1. To view the Next Recipe follow the links below from the home screen

Home  Recipe  Next Recipe


2. The Next Recipe Screen will display as shown below:

Press here to
edit the Next
Recipe

Press here to
modify the
Next Runout
Type and
Length, or
the selected
Syrup Line

Press here to
select the
Next Recipe

Press
here to
Edit the
Next
Recipe

Run Out and Syrup Line Selection


Recipe Items

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The Next Recipe screen gives access to the next recipe that will be loaded automatically on the next
flavor changeover. This screen provides;

• A means to view the Next Recipe – Recipe Item values


• An option to Select a new Next Recipe by pressing the Next Recipe Select button
• An option to modify the Next Runout Type and Length
• A means to select the Next Syrup Line
• An option to edit the Next Recipe

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Step Action
1. To view the Active Recipe follow the links below from the home screen

Home  Recipe  Active Recipe


2. The Active Recipe Screen will display as shown below, with the associated values.

Selected Recipe Location, which Active Recipe Name


Active Recipe came from

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Next Recipe Selection

Step Action
1. To view the Next Recipe follow the links below from the home screen

Home  Recipe  Next Recipe Select


2. The Next Recipe Selection Screen will display as shown below:

Recipe Selection

Press Up-
Down Buttons
To Move
Recipe
Selection
Cursor Press
Selected SELECT
Recipe after
moving
UP/DOWN
arrows to
Recipe the
Selection required
Cursor recipe.

Press Left Arrow to Press right arrow


go back a page. Page Selection to move forward a
Indicator page.

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Syrup Port

In many situations, syrup used for blending may come from multiple sources. The sources may have
automated valving, which controls the delivery of syrup into the blender. In order to minimize the possible
error of delivering the wrong syrup, the system provides a level of redundancy to prevent this.

There are two variables that determine which syrup port is to be used. One is the Syrup Port selection
called “Only Use Syrup Port” in the recipe itself, the other is an operator confirmed selection called Syrup
Port made when setting up the Next Recipe.

These are pointed out below, and must match. If these two values do not match an alarm fault will occur,
and no syrup will be delivered. One exception is, when the “Only Use Syrup Port” value is “Use Any Port”,
this allows any syrup port to be selected.

These selections must match, if


“Only Use Syrup Port” does not
have a value of “Any Port”

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Next Syrup Port Selection

Step Action
1. To select the Next Syrup Port follow the links below from the home screen

Home  Recipe  Next Recipe  Next Syrup Port


2. The Next Syrup Port Screen will display as shown below:

Use the UP/DOWN arrows


to change the Syrup Port
Selection
During a flavor change over, the Next Recipe is moved into the Active Recipe. The Next Recipe is made
“EMPTY” and the Syrup Port is made “NOT ASSIGNED”. This makes it necessary for the operator to
Select the Next Syrup Port, or the blender will alarm if the selection is “NOT ASSIGNED”.

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Run Out Type

The Run Out type allows the operator to choose how long and how the end of production for the
production run will be initiated.

Run Out Type

Run Out Length

The table below defines the different Run Out Types

Run Out Type Definition


By Operator Specifies that the operator pressing the “Start Run Out” button will initiate the end of
production Run Out.
By Time Specifies that the end of production Run Out will be initiated by the expiration of time,
in units of minutes. The Run Out Length sets the expiration time.
By Syrup Specifies that the blender consuming a Syrup Volume will initiate the end of
Volume production Run Out. The Run Out Length sets the Syrup Volume threshold, in units
of liters.
By Containers Specifies that the blender producing enough beverage to fill a quantity of containers
will initiate the end of production Run Out. The Run Out Length sets the number of
containers, in units of containers.

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Next Run Out Type Selection

Step Action
1. To select the Next Syrup Port follow the links below from the home screen

Home  Recipe  Next Recipe  Next Run Out


2. The Next Syrup Run Out Screen will display as shown below:

Indicates
current
selection.

Use the UP/DOWN


arrows to change the Use the UP/DOWN arrows for
Run Out Type each digit to change the Run
Out Units

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Setting Up a Next Recipe

In order to set up a Next Recipe the following steps must be taken. All the individual steps and have been
described above.

Step Action
1. Select the Next Syrup Port

Home  Recipe  Next Recipe  Next Syrup Port


2. Select the Next Recipe

Home  Recipe  Next Recipe  Next Recipe Select


3 Select the Next Run Out Type and Run Length

Home  Recipe  Next Recipe  Next Run Out

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Setting Up an Active Recipe

Under normal operating circumstances, setting up an Active Recipe is not required, since the Active
Recipe is automatically loaded from the Next Recipe during a flavor change. The system does provide the
capability for Active Recipe Selection, Active Syrup Port Selection, and Active Run Out Selection. The
links to perform these actions are provided for reference below.

Step Links
Active
Recipe
Selection
Home  Recipe  Active Recipe  Active Recipe Select
Active
Syrup
Port
Home  Recipe  Active Recipe  Active Syrup Port
Selection
Active
Run Out
Selection
Home  Recipe  Active Recipe  Active Run Out

The procedure for Active Recipe Selection, Active Syrup Port Selection, and Active Run Out Selection are
much the same as for the Next Recipe. Refer to the above for details.

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RECIPE

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Recipe Manager
The Recipe Manager allows the operator to VIEW, EDIT, CHANGE NAME, and DELETE and. A total of
100 Recipes can be developed. The 100 recipes are displayed in 10 pages of 10 recipes each.

All the recipe values are stored in the PLC (Programmable Controller), which keeps the recipes safe from
hard disk crashes and operating system corruption. This also makes the automatic loading of recipes
seamless, because there are not any communication lags like other MMI based recipe systems.

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Recipe Manager Screen

Step Action
1. Access the Recipe Manager Screen by following the links below from the home screen

Home  Recipe  Recipe Manager


2. The Recipe Manager Screen will display as shown below:

Selected Recipe Selected Recipe Name


Location
Available
Operations

Press Up-
Down Buttons
To Move
Recipe
Selection
Cursor
Selected
Recipe

Recipe
Selection
Cursor

Press Left Arrow to Page Selection Press right arrow


go back a page. Indicator to move forward a
page.
The pages are navigated by pressing the up and down arrows to move the Page Selection Cursor, to the
desired page, and then pressing the enter key to display the selected page.

A recipe can then be selected by moving the Recipe Selection Cursor to the desired recipe location.

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Recipe Viewing

Step Action
1. To use the Recipe Manager Recipe Viewer, choose the
page the desired recipe is on by using the page selection
buttons illustrated on the left.

2. Select the desired recipe by using the up-down arrows to move the Recipe
Selection Cursor to the desired recipe.

3. Now press the VIEW RECIPE button to view the selected recipe.

4. The Recipe Viewer display as shown below:


Viewed Recipe
Name

Viewed Recipe
Location

Recipe Editing

The Recipe Editor is used to modify the contents of the recipe location.

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Step Action
1. To use the Recipe Manager Recipe Editor, choose the
page the desired recipe is on by using the page selection
buttons illustrated on the left.

2. Select the desired recipe by using the up-down arrows to move the Recipe
Selection Cursor to the desired recipe.

3. Now press the EDIT RECIPE button to view the selected recipe.

4. The Recipe Editor display as shown below:

Recipe
Item
Selection
Cursor Use
keypad to
change
Press Up- the value
Down of the
Buttons to Selected
Move Recipe
Recipe Item Item.
Selection
Cursor

Press here to go to
Page 2 of Recipe
Editor

Modifying the Selected Recipe Item


Press here to SAVE
Step Action
modified recipe

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1. Use the Up-Down Buttons to Move Recipe Item Selection Cursor to the desired
recipe Item to be modified.

2. Use the Digital keypad to enter in a new value for the Selected
Recipe Item.

3. Press ENTER to move the new value into the item’s value.

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Recipe Editor Page 2

Step Action
1. In order to access Page 2 of the Recipe Editor, press the Recipe Editor Page
2 button on the bottom the the Recipe Editor Screen.

2. The Recipe Manager Screen will display as shown below:

Press here to modify the


YES or NO status of item.

Use up-down arrows to modify


Use up-down arrows to modify
selected Syrup Port. selected Container Size.
The value of the Only Use Syrup Port Recipe Item determines what Syrup Port will only be allowed to
used for this recipe. A value of ANY will allow any Syrup Port to be used.

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Saving the Recipe

Step Action
1. In order to save the modifications made to by the Recipe Editor, press the
SAVE button on the bottom the the Recipe Editor Screen.

2. The button will flash yellow for 3 seconds and display “SAVING”.

2. After 3 seconds the button will return to it’s normal state. The Recipe has
been saved.

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Copying A Recipe

Step Action
1. In order to obtain a copy of a recipe from another location.Press the GET
COPY button on the top of the the Recipe Editor Screen.

2. The Recipe Get Copy screen will be displayed as shown below:

Step Action
3. Press the GET ACTIVE or GET NEXT pushbuttons, or enter in the location of the recipe
you want to copy into the Recipe Editor.
4. Press the RETURN button to move back to the Recipe Editor .

Recipe Name Modification

Step Action

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1. To use the Recipe Manager to change the name of a


Recipe Location, choose the page the desired recipe is
on by using the page selection buttons illustrated on the
left.

2. Select the desired recipe by using the up-down arrows to move the Recipe
Selection Cursor to the desired recipe.

3. Now press the CHANGE NAME button to view the selected


recipe.

4. The Recipe Name Editor screen will display as shown below:

Step Action

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5. Use the displayed keyboard by pressing the appropriate


keys to enter in the modified name for the Selected recipe
Location.

2. Complete the modification by pressing the Enter Key on the bottom right
hand corner of the keyboard.

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Recipe Deleting

Deleting a recipe clears the recipe location’s values and renames the recipe to “EMPTY RECIPE”.

Step Action
1. To Delete a Recipe Location, choose the page the
desired recipe is on by using the page selection buttons
illustrated on the left.

2. Select the desired recipe by using the up-down arrows to move the Recipe
Selection Cursor to the desired recipe.

Selected Recipe
Name

Selected Recipe
Location

Press DELETE
button to Delete
Selected Recipe

Step Action
3. Now press the DELETE button to view the selected recipe.

4. The Recipe Editor display as shown below: This is a confirmation screen, which ask the
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operator to confirm that the selected recipe is to be deleted. If the information is incorrect,
then the operator should press NO, and the screen will change back to the RECIPE
MANAGER screen. If the information is correct, the operator should press YES.

Selected Recipe Name

Press YES
to Delete
the
Selected
Recipe

Press NO to
Return to
the RECIPE
MANAGER
SCREEN

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Step Action
5. If the operator presses YES, the YES button will turn yellow and the
text will change to DELETING. This indicates that the Recipe
Deletion is in progress. The process will take approximately 3
seconds, as illustrated below.

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Step Action
6. After Deleting the Selected Recipe Location. The screen will automatically change back to
the Recipe Manager screen. The Selected Recipe Location will now indicate that the
location is an “EMPTY RECIPE”, as illustrated below.

Recipe
Location Is
Now EMPTY
RECIPE

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OPERATIONS

MORNING START UP Page 136 of 159

Operation
Utilities Check

On the main control panel are several gauges, which measure the pressure set point for the regulators.
Before attempting to initiate any action on the system, each gauge should be checked and compared with
the requirements outlined in the table below.

Gauge Requirement
Plant Air Regulator 90 to 110 psi
Main Gas Pressure Regulator Gas Injection Capable - 220 psi to 300 psi
No Gas Injection – 120 psi minimum
Product Tank Gas Pressure Regulator 180 psi
Gas Injector Pressure Regulator 100 psi
Control Air Pressure Regulator 25 psi
Blow Gas Pressure Regulator 40 psi

E-Stop Check

Below the touch screen on the main control panel is an E-Stop pushbutton and a green Reset
pushbutton. In emergency situations the E-Stop pushbutton can be pressed by the operator in order to
stop all machine functions.

The green Reset pushbutton will be illuminated if the system is not in an E-Stop condition. Before
initiating any action on the system, the E-Stop circuit will need to be checked by confirming that the green
Reset button is illuminated. If the green Reset pushbutton is not illuminated, the operator can reset the E-
Stop condition by pressing the Reset pushbutton.

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Morning Start Up

After extended down time or CIP, the system will require the operator to initiate a Start Up procedure. The
table below lists the Start Up procedure.

While a Filler Cold Rinse is running the operator can set up the Next Recipe and Syrup Ports. When the
Filler Cold Rinse is complete. The operator must confirm the Syrup Reservoir and the Product Tank are
empty, and drain if required. Once the tanks are empty the operator can initiate an automated start up,
by pressing the Start Up Machine Command button.

The table below outlines the steps and screen links to follow to perform a Morning Start Up.

Step Action
1. Perform a Filler Cold Rinse

Home  Recipe  Next Recipe  Active Recipe Select


2. Select Next Syrup Port

Home  Recipe  Next Recipe  Next Syrup Port


3. Select the Next Run Out Type and Run Length

Home  Recipe  Next Recipe  Next Run Out


4. Select the Next Recipe

Home  Recipe  Next Recipe  Next Recipe Select


5. Connect Syrup Port

Home  
6. Confirm Syrup Line is Ready

Home    Syrup Port Ready

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Step Action
7. Check Syrup Reservoir Level

Home 
8. Check Product Tank Level

Home 
9. Place the system in Auto, so the system sequences automatically.

Home  
10. Initiate Start Up

Home  

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Flavor Change Preparation

Before initiating a Flavor Change Over (Initiating a Run Out), the Next Recipe and Syrup Port will need to
be set up. The operator may set up the Next Flavor, anytime after the current flavor (Active Recipe) has
started production (ie. at the end of Filler Prime).

The table below outlines the steps required to prepare for a Flavor Change.

Step Action
1. Select Next Syrup Port

Home  Recipe  Next Recipe  Next Syrup Port


2. Select the Next Run Out Type and Run Length

Home  Recipe  Next Recipe  Next Run Out


3. Select the Next Recipe

Home  Recipe  Next Recipe  Next Recipe Select


4. Connect Syrup Port

Home  
5. Confirm Syrup Line is Ready

Home    Syrup Port Ready

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Flavor Change

With the Accu-Change system, flavor changes are very simple. Flavor changes are initiated by a single
machine command called Run Out Start.

Step Action
1. Initiate Start Up

Home  

Filler Run Out Completion

At the end of a flavor change, when the Filler Run Out has finished filling all the containers, the operator
must acknowledge that the containers have all been filled, by pressing the Filler Run Out Done
pushbutton.

Step Action
1. Initiate Start Up

Home   

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End of Day Shutdown

With the Accu-Change system, flavor changes are very simple. Flavor changes are initiated by a single
machine command called Run Out Start.

Step Action
1. Initiate Start Up

Home  
2. After the Filler Run Out has completed press the End of Day Machine Command

Home  

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OPERATIONS

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Packaging Change

When changing the package, it becomes necessary to provide carbonated water to the filler. The table
below outlines the steps and screen links required to provide carbonated water to the filler. First a Filler
Cold Rinse is initiated to produce carbonated water in the to the filler. Once the Product Tank has
adequate level of water, the Filler Cold Rinse can be terminated, and a Product Tank Run Out can be
initiated to maintain Product Tank Pressure to push the carbonated water to the Filler. A Beverage
Request must come from the Filler in order for the Product Tank Run Out to open the Product Outlet
Valve.

Step Action
1. Take the system out of Auto.

Home  
1. Initiate a Filler Cold Rinse

Home   Rinse and Drains


2. When the Product Tank has adequate level for the test, terminate the Filler Cold Rinse

Home   Rinse and Drains


2. Initiate a Product Tank Run Out

Home   Run Outs


2. Initiate a Beverage Request from the Filler, by pressing the Filler Product Request
Machine Command.

Home   

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Product Proportioning Adjustment

The set point for the Product Proportioning is in units of Brix for sweet (Non-diet) drinks and in TA or
Percent for diet drinks. The set point for the Product Proportioning is determined by adding the Operator
Adjust to the Recipe Set Point. Where small adjustments are required the operator should modify the
Operator Adjust set point. There are two locations that the Operator Adjust set point for Product
Proportioning. These two methods are outlined in the steps below.

Method 1:
Step Action
1. Go to the Blender Command Screen by following the links below from the home screen

Home  
2. Use the Up/Down arrows connected to the Operator Adjust, shown below.

Method 2:
Step Action
1. Go to the Blending Operation Command Screen by following the links below from the
home screen

Home  
2. Use the Up/Down arrows connected to the Operator Adjust, shown below.

Note that “Brix” is displayed when non-diet (sweetdrink) recipe is active, and TA/% is displayed when diet
recipe is active.

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OPERATIONS

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Product Tank Pressure Adjustment

The Target set point for the Product Tank Pressure is determined by adding the Operator Adjustment,
and the Accu-SAT adjustment to the Recipe Setpoint. Where small adjustments are required the
operator should modify the Operator Adjust set point. Follow the steps below to modify the Operator
Adjust for the Product Tank Pressure

Step Action
1. Go to the Product Tank Command Screen, follow the links below from the home screen

Home  
2. Use the Up/Down arrows connected to the Operator Adjust, shown below

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Gas Injector Set Point Adjustment

The set point for the Gas Injector is in units of Volumes. The target set point for the Gas Injector is
determined by adding the Operator Adjust to the Recipe Gas Inj. Vol. Where small adjustments are
required the operator should modify the Operator Adjust set point. There are two locations that the
Operator Adjust set point for Gas Injector. These two methods are outlined in the steps below.

Method 1:
Step Action
1. Go To the Gas Injector Command Screen follow the links below from the home screen

Home  
2. Use the Up/Down arrows connected to the Operator Adjust, shown below.

Method 2:
Step Action
1. Go to the Blending Operation Command Screen by following the links below from the
home screen

Home  
2. Use the Up/Down arrows connected to the Operator Adjust, shown below.

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CIP

Follow the steps outlined in the table below in order to perform a CIP of the system.

Step Action
1. Confirm air supply connection to Product Tank.

2. Behind the filler there are two valves. The CIP Return valve to the Deox / Product Tank skid must be
open. The Filler Vent Valve must be closed.

3. Confirm CIP CAM is moved into place.

4. All CIP Channel Drain Valves must be closed on the bottom of the Filler Bowl.

5. All CIP Return Valves on top of the Filler Bowl must be opened.

6. CIP Cups on filler must be installed.

7. Go To the CIP Program Screen by following the links below from the home screen

Home   CIP Program


8. Use the Up/Down to select one of five different CIP programs.

9. Go To the CIP Screen by following the links below from the home screen

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Step Action

Home 
10. Press the ENABLE button to initiate the CIP Process.

The button will turn green when the CIP is in progress.

11. Based on the program selected the system will step through the program. Observe the indicators shown
below to observe what type of step the system is executing.

12. When the CONNECTED button begins to blink, Chemicals are required to be connected to the system..

Connect the chemicals and press the button to confirm.


13. Press the NEXT button in order to skip to the next Step.

Or Press the HOLD button to hold the system in its current Step.

14. When the CIP has completed all the programmed steps ENABLE button will turn RED, Indicating that the
CIP has stopped.

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Step Action

Frequently Asked Questions

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SCREENS

ALARM Page 149 of 159

The following are frequently asked questions and our response.

Question - Low Syrup Density Alarm Fault on startup


During a startup on a Sweet product the density of the syrup was so low that the blender gave me a
“Low Syrup Density Alarm Fault”. I keep on resetting the alarm, but the alarm keeps on coming back
up.

Response
When too much water is present in the syrup, the density drops below the value of Syrup Density Low
parameter in the Recipe, and the “Low Syrup Density Alarm Fault” occurs.
1) The first decision that needs to be made is whether the syrup is good enough to blend, and
that it is not tainted in any way. A Qualified Operator should take a Syrup Brix measurement
of the current syrup in the Syrup Reservoir.
2) If the Syrup is OK to blend, then a Qualified Operator must edit the Syrup Density Low
parameter in the Active Recipe. The value should be changed to less than the currently
displayed Syrup Density on the Blender Graphic Screen.
3) Also, adjust the Syrup Brix parameter in the Active Recipe to match the value of the Syrup
Brix measurement taken in step 1.
4) Reset the alarm, and monitor the blending operation.

Question - foam in my Syrup Reservoir during a Syrup Reservoir Runout


I have foam in my Syrup Reservoir during a Syrup Reservoir Runout and one of the following alarms
keep me from blending Low Syrup Density Alarm, Syrup Flow Transmitter Failure, or Syrup Density
Transmitter Failure.

Response
You cannot blend foam. The meters will not measure it properly
1) Determine if your Syrup Reservoir indeed is full of foam.
2) If it is full of foam. You can terminate the Syrup Reservoir Runout and continue to the next
change over step, by going to the Runout Command Screen and press Syrup Reseroir
Runout Kill.
3) This will step the system to the next steps (Syrup Reservoir Rinse and Mix Line Runout)

Question – My Syrup Reservoir is High and I can blend no more


My Syrup Reservoir level became too high and the Blender Pauses on High Syrup Reservoir Level,
and keeps on pausing when ever I reset the alarm to re-initiate blending.

Response

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SCREENS

ALARM Page 150 of 159

The Syrup Reservoir generates a High Syrup Reservoir Level Alarm Fault, when the High Point
probe on the Syrup Reservoir detects a liquid.
1) Before resetting the alarm, inquire why the alarm was generated and repair.
2) Reasons for failure
a. During a Syrup Line Runout someone did not disconnect the syrup source.
b. The High Point Probe was splashed with syrup during a blow from the syrup room
c. The Syrup Reservoir Level Capacitance probe failed.
3) You can resume blending by resetting the alarm fault and pressing the BLEND PAUSE
button on the Blender Graphic Screen to un-pause the blender.
4) If for some reason the level is too high, and you want the blender to run continuously without
it faulting, you can press and hold either the BLEND or BLEND PAUSE buttons on the
Blender Graphic Screen.

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CHEAT SHEET

Page 151 of 159

Cheat Sheet

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CHEAT SHEET

Page 152 of 159

Blender Cheat Sheet bturig 5/14/2003

Note: Think twice, press once

START UP

Syrup Preparation

1) Bring good syrup all the way to divert panel in syrup room

• 2) Wait for "Prime Waiting" indicator on Syrup Room Display

3) Open valves from Syrup Tank supply line to blender syrup line, with Syrup Tank Pump on.

4) Press "Port A Connected" on Syrup Room Display, to indicate to blender that syrup is connected

Blender Preparation

1) Vacuum Deaeration Unit must be running (15 minute warm up)

2) Filler
• must be rotating
• filling valves must be in automatic
• speed control must be in automatic

3) Turn on Refrigeration Chiller from control panel on Chiller.

4) If need to do a Cool Down. Turn Auto Off, and manually perform a “Filler Cold Rinse”.

5) Blender
• Syrup Reservoir must be empty, drain if necessary.

6) Syrup Room (Syrup Prep)


• Syrup Port Connected indication on Syrup Room Display must be off (Not Connected)

7) Select Next Recipe

8) Place blender in Auto

9) Upper Bar on "Start Up" button will be illuminated. If not review Steps 2 through 4.

10) Press "Start Up"

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CHEAT SHEET

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FLAVOR CHANGE

Syrup Preparation

1) Enable a Syrup Line Purge from Syrup Room Display

2) Purge from Syrup Tank and/or from Divert Panel

3) Close Divert Panel hand valves

4) Press RunOut Start from Syrup Room Display

5) Bring in good NEXT syrup all the way to divert panel in syrup room

6) Wait for "Prime Waiting" indicator on Syrup Room Display

7) Open valves from Syrup Tank supply line to blender syrup line, with Syrup Tank Pump on.

8) Press "Port A Connected" on Syrup Room Display, to indicate to blender that syrup is connected

Blender Preparation

1) Filler container stop must be in automatic

2) Blender must be in Auto

3) Select Next Recipe

Filler Preparation

1) Filler Container Stop must be in automatic

2) When Syrup Reservoir reaches Back Up Level, container stop will pull in for Empty Side Backup

3) Confirm containers are backed through conveyor and rinser.

4) Wait for Depal Operator to release Container Stop by pressing Container Stop Release

5) Run Out Product in System

7) When finished running out remaining product in system, make sure filler is rotating, with filling valves
and speed in automatic and then Press Filler RunOut Done on blender operator interface. Filler will dump
remaining contents in Filler and Product Tank if not empty.

8) Filler will automatically rinse, drain and bring in Next product when available from system.

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CHEAT SHEET

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Depal Display Login

1) Press LOGIN

2) Enter 3333

3) Press Depal

Depal Operation

1) Change Over Indicator indicates when Change Over has started. (Do not cut bottles yet)

2) Back Up Indicator will illuminate when Syrup Reservoir on Blender drops down to the Back Up Level
(30%). The Filler Container Stop is automatically pulled in by the blender.

3) Depal operator must verify that the empty side completely filled to the depal.

4) Note number of Sweeps to add from Depal Display.

5) Press “Container Stop Release” on Depal Display to open the Container Stop at filler and continue
running out the line.

6) Add sweeps as noted in Step 4, when line was backed up.


Note: VALUE OF SWEEPS INDICATED “CHANGE OVER SWEEPS CALLED FOR” DOES NOT
COUNT DEPAL SWEEPS AUTOMATICALLY, DEPAL OPERATOR MUST COUNT ON OWN.

END OF PRODUCTION

Blender Preparation

1) Do not enter a Next Recipe

2) After Filler RunOut is Done, Press End OF Day.

Appendix

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Schaumburg, IL 60173 USA
APPENDIX E01.01

Calibration of the FEC 12 Electronic Transmitter Page 155 of 159

Capacitance Probe Calibration

INTRODUCTION

The FEC 12 electronic insert is a transmitter for capacitive level measurement. It converts
changes in capacitance resulting from changes in level into a capacitance-proportional impressed
current. In vessels with a uniform cross section, the level or quantity (volume) can be thus
displayed as a percentage of full level.

OPERATING ELEMENTS

A cover protects the operating elements of the FEC 12. Inserting a small screwdriver into a slit at
the edge can raise this. The inside of the cover has symbols printed on it that serves as a quick
operating manual.

SWITCHES
The left hand switch selects whether
the linearization is to be carried out
remotely with the hand held terminal
or locally with the FEC 12 operating
elements. If linearization at the FEC
12 is required, then one of two
linearization modes in the electronic
insert is activated (vertical vessel with
linear characteristics) at the right hand
switch.

PUSHBUTTONS
Calibration, locking and reset to
factory-set values are carried out at
the FEC 12 by using the four
pushbuttons.
BASIC OPERATION:
The pushbuttons marked with plus (+) increase current and those marked minus (-) decrease
current. Punching the pushbuttons produces a step-wise change. The smallest resolution
possible is 0.014mA. If the pushbutton is depressed continuously, then the current also changes
continuously until the pushbutton is released. The change begins slowly and gradually increases
in speed and so quickly passes through a wide range. Just before reaching the value required,
the pushbutton should be released and the procedure completed by punching the pushbutton for
fine resolution. If the value desired is overrun then correct for it by punching the pushbutton for
the other direction.

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APPENDIX E01.01

Calibration of the FEC 12 Electronic Transmitter Page 156 of 159

CALIBRATION

Two types of linearization can be selected:


• Vessel characteristics as linear.
• Vessel characteristics as horizontal cylinder.

Use the left hand switch to select whether linearization is to be carried out at the electronic insert
or by the handheld terminal. If the left hand switch is moved to the right, then linearization is
carried out at the electronic insert. If the left hand switch is moved to the left, then linearization
must be carried out with the hand held terminal and the switch on the right remains inactive.
• Move the left hand switch to the right.
Select the type of linearization for local calibration using the right hand switch. When it is moved
to the left, then the level (output current) is proportional to volume, i.e., the cross-section of the
vessel should be constant over its entire length. When it is moved to the right, then linearization
is set for a horizontal cylinder, and the measured value supplied corresponds directly to a percent
of full volume.
• Move the right hand switch to the left.

With the vessel completely empty (0%), both pushbuttons on the left minus (-) and plus (+) are
depressed simultaneously in order to set the signal current to the 4mA lower value. The green
LED lights up to acknowledge that the setting has been accepted. Only when the green LED
goes out is the correct value of 4mA shown on the ammeter.

With the vessel full (just touching the high level probe), both pushbuttons on the right minus (-)
and plus (+) are depressed simultaneously in order to set the signal current to the 20mA higher
value. The green LED lights up to acknowledge that the setting has been accepted. Only when
the green LED goes out is the correct value of 20mA shown on the ammeter.

STEP by STEP

1. Move the left hand switch to the right.


2. Move the right hand switch to the left.
3. With the vessel completely empty push both left (+) and (-) pushbuttons. The green
LED lights up to acknowledge that the setting has been accepted.
4. With the vessel completely full push both right (+) and (-) pushbuttons. The green
LED lights up to acknowledge that the setting has been accepted.

The Vessel / Capacitive probe is now calibrated.

RTD Calibration

The RTD should be checked quarterly to maintain accuracy, using the verification procedure
below:

The following tools will be required to perform this procedure:


• a small flat head screwdriver.
• an ammeter.

Step Action

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APPENDIX E02.01

RTD Calibration Page 157 of 159

1. Locate the RTD.


2. Remove the cover on the RTD and check for the red led operation.
3. If the red led is not on, replace the RTD and continue this procedure
4. Remove the black wire from the terminal on the RTD.
Using the ammeter, apply the probes to the terminal and the wire that was removed from
the terminal.
5. Record the reading from the ammeter
6. Using a thermometer from the QC lab, measure the product temperature in degrees F.

7. Using a thermometer from the QC lab, measure the product temperature in degrees F.
8. Insert the temperature into the following equation to calculate the mA signal (mA = (16 *
deg.F / 250) + 4).
9. If the value calculated and the reading recorded from the ammeter are within +/- 0.128
mA, then the RTD is good.

10. If it is not within +/0.128 mA, replace the RTD.

RTD Calibration

RTD’s work on the principle that


there is a positive correlation
between the electrical resistance
of a metal conductor and changes
in temperature.

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Schaumburg, IL 60173 USA
APPENDIX E05.01

MODEM SET-UP Page 158 of 159

Modem Set Up

1. Using the serial port on a computer, establish a connection with the modem.

2. Set the dip switches on the back of the modem as follows:

Switch 1 - down - DTR override


Switch 2 - up - verbal result codes
Switch 3 - down - display result codes
Switch 4 - up - echo offline commands
Switch 5 - up - auto answer on first ring
Switch 6 - up - carrier detect normal
Switch 7 - up - load NVRAM defaults
Switch 8 - down - smart mode

3. Issue the following commands to the modem:

“AT &R1” - sets modem to ignore RTS


“AT &N10” - sets modem to negotiate baud rate at 19200 bps only
Note: (AT &N6 9600 baud at &N3 2400 baud)
“AT &WO” - writes current configuration to NVRAM 0
“AT &W1” - writes current configuration to NVRAM 1

4. Issue the following command to the modem: “AT I4”.

5. The following table of information is displayed on the computer for verification:

BO E1 F1 M1 Q0 V1 X4 YO
BAUD=19200 PARITY=N WORDLEN=8
DIAL=HUNT ON HOOK
&A3 &B1 &C1 &D0 &G0 &H1 &I0 &K1 &M4 &N10
&P0 &R1 &S0 &T5 &U0 &Y1
S00=001 S01=000 S02=043 S03=013 S04=010 S05=008 S06=002
S07=060 S08=002 S09=006 S10=014 S11=070 S12=050 S13=000
S15=000 S16=000 S18=000 S19=000 S21=010 S22=017 S23=019
S25=005 S27=000 S28=008 S29=020 S30=000 S31=128 S32=002
S33=000 S34=000 S36=014 S38=000

Please Note: The registers displayed above must match exactly with the registers as displayed once
configuration is completed. Should they not, please correct using AT commands. When complete,
perform Step #3 once more and then verify.

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Cadence Technologies Inc.
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