COMAC Keg Cleaner - Filler Manual

Via G.
Garibaldi, 34N - 24040 Bonate Sotto (BG) Italy

Tel. +39 035 499 4211 - Fax +39 035 993 090 - info@comacitalia.it - www.comacitalia.it
Smart kegger K2 SS
Mod. 2TSA NS-C+HW
Instruction manual
Philter Brewing Pty Ltd

This page has been intentionally left blank
2
Contents
Contents
Chapter 1: General information ........................................................................................ 7
1.1. Instruction manual ........................................................................................................... 7
1.2. Proprietary information ................................................................................................... 7
1.2.1. Symbols ....................................................................................................................................... 8
1.3. Manufacturer identification data ..................................................................................... 9
1.4. Machine identification data ............................................................................................. 9
1.5. Use of the machine ........................................................................................................ 10
1.5.1. Proper use.................................................................................................................................. 10
Machine purpose .................................................................................................................................. 10
Environment .......................................................................................................................................... 10
Space required for machine installation................................................................................................ 10
1.5.2. Improper use .............................................................................................................................. 10
1.6. Description of the machine ........................................................................................... 11
1.6.1. Main components ....................................................................................................................... 11
Chapter 2: Safety information ......................................................................................... 13
2.1. Introduction .................................................................................................................... 13
2.2. Safety criteria applied .................................................................................................... 14
2.2.1. Safety measures ........................................................................................................................ 14
Fixed guards ......................................................................................................................................... 14
Mobile safety devices ........................................................................................................................... 14
Emergency stops .................................................................................................................................. 14
2.2.2. Further protections and safety devices ...................................................................................... 14
2.3. Personnel........................................................................................................................ 15
2.4. Health and safety information ....................................................................................... 15
2.5. Safety system reset ....................................................................................................... 17
2.5.1. Emergency button reset ............................................................................................................. 17
2.5.2. Reset of safety limit switches ..................................................................................................... 17
2.6. Protection from contact with energized elements ....................................................... 18
2.6.1. Direct .......................................................................................................................................... 18
2.6.2. Indirect ....................................................................................................................................... 18
2.7. Visual/acoustic warnings .............................................................................................. 19
Chapter 3: Machine characteristics................................................................................ 21
3.1. Technical specifications ................................................................................................ 21
3.1.1. Nominal output ........................................................................................................................... 21
3.1.2. Overall dimensions .................................................................................................................... 21
3.1.3. Utilities required ......................................................................................................................... 21
3.1.4. Consumption .............................................................................................................................. 21
3.2. Constructional characteristics ...................................................................................... 22
3.3. Switchboard ................................................................................................................... 23
3.4. Cabling............................................................................................................................ 24
Chapter 4: Installation ..................................................................................................... 25
4.1. General information ....................................................................................................... 25
4.2. Loading and transport ................................................................................................... 26
4.3. Lifting operations ........................................................................................................... 27
4.4. Unloading and inspection ............................................................................................. 30
4.5. Installation ...................................................................................................................... 31
4.5.1. Storage conditions ..................................................................................................................... 31
4.5.2. Tips on installation ..................................................................................................................... 32
3
Contents
4.5.3. Utilities at customer's charge ..................................................................................................... 33

4.5.4. Connection to the power supply ................................................................................................ 34
4.5.5. Connection to the earthing system ............................................................................................ 35
4.6. Commissioning .............................................................................................................. 36
4.6.1. Testing ....................................................................................................................................... 37
Chapter 5: Use ................................................................................................................. 39
5.1. Operating principle ........................................................................................................ 39
5.1.1. Washing head diagram (head 1) ............................................................................................... 40
Washing head cycle .............................................................................................................................. 41
5.1.2. Filling head diagram (head 2) .................................................................................................... 42
Filling head cycle .................................................................................................................................. 43
Sanitization cycle .................................................................................................................................. 44
5.2. Automatic start-up ......................................................................................................... 45
5.3. Manual start-up .............................................................................................................. 46
5.4. Machine use ................................................................................................................... 47
5.4.1. Filling head C.I.P. cycle ............................................................................................................. 47
Installation of the CIP cap for sanitization ............................................................................................ 48
5.4.2. Preparation for production ......................................................................................................... 49
5.4.3. Production cycle ......................................................................................................................... 50
Production ............................................................................................................................................. 50
Chapter 6: Controls and instrumentation ...................................................................... 51
6.1. Controls .......................................................................................................................... 51
6.1.1. Control push-button station ........................................................................................................ 51
6.1. Operator panel Asem HMI30.......................................................................................... 53
General features ................................................................................................................................... 53
Data modification .................................................................................................................................. 54
Access to protected pages or data ....................................................................................................... 55
6.1.1. Home page................................................................................................................................. 56
6.1.2. System pages ............................................................................................................................ 57
Remote assistance ............................................................................................................................... 58
6.1.3. Parameter menu ........................................................................................................................ 59
“Operation” page ................................................................................................................................... 60
“Selections” page .................................................................................................................................. 61
“Changeover” page ............................................................................................................................... 62
“Recipe” page ....................................................................................................................................... 63
“Counters” pages .................................................................................................................................. 64
“General times” page ............................................................................................................................ 66
“Times head 1” pages ........................................................................................................................... 67
“Times head 2” pages ........................................................................................................................... 71
“Pressure” page .................................................................................................................................... 73
“Filling” page ......................................................................................................................................... 74
“Acid solution tank” page ...................................................................................................................... 75
“Caustic solution tank” page ................................................................................................................. 76
Manual control menu ............................................................................................................................ 77
Head 1 manual controls ........................................................................................................................ 78
Head 2 manual controls ........................................................................................................................ 80
Presser and table manual controls ....................................................................................................... 81
6.1.4. Alarm page ................................................................................................................................. 82
Alarm historical report page .................................................................................................................. 83
6.2. Alarms............................................................................................................................. 84
6.3. Troubleshooting ............................................................................................................. 87
Chapter 7: Maintenance .................................................................................................. 89
7.1. Maintenance and spare parts ........................................................................................ 89
7.2. Routine maintenance ..................................................................................................... 90
7.3. Maintenance of mechanical and pneumatic components ........................................... 92
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Contents
7.3.1. Pneumatic system ...................................................................................................................... 92

Mains air pressure adjustment .............................................................................................................. 93
7.3.2. Pneumatic operated valve control ............................................................................................. 94
7.3.3. Lubrication and cleaning of pneumatic valves ........................................................................... 95
7.3.4. Pneumatic cylinder adjustment .................................................................................................. 97
7.3.5. Maintenance of pneumatic cylinders ......................................................................................... 98
7.3.6. Maintenance of linear guides ..................................................................................................... 99
7.3.7. Maintenance of the adjustable discharge regulator ................................................................. 100
Adjustable discharge regulator calibration procedure ........................................................................ 101
7.4. Maintenance of electrical parts ................................................................................... 102
7.4.1. Bero proximity switches ........................................................................................................... 102
7.4.2. Cylinder position sensor ........................................................................................................... 103
How to replace a pneumatic cylinder sensor ...................................................................................... 103
How to adjust the position of a pneumatic cylinder sensor ................................................................ 103
7.4.3. Solenoid valves ........................................................................................................................ 104
7.4.4. Pressure controllers ................................................................................................................. 105
7.4.5. Pressure analog sensors ......................................................................................................... 106
7.4.6. Dual threshold thermostats ...................................................................................................... 107
7.4.7. Ultrasonic level limit switch for liquids ...................................................................................... 108
7.4.8. Liquid presence detection probes by impedance spectroscopy .............................................. 109
7.4.9. Electromagnetic flow-meters.................................................................................................... 110
7.5. Maintenance of washing and filling heads ................................................................. 111
7.5.1. Washing head exploded view .................................................................................................. 112
7.5.2. Filling head exploded view ....................................................................................................... 113
Assembling of the filling head valves .................................................................................................. 114
Assembling of the filling probe group.................................................................................................. 115
7.5.3. Position of the head gaskets .................................................................................................... 116
Washing head ..................................................................................................................................... 116
Filling head .......................................................................................................................................... 117
7.5.4. How to separate the rod from the head ................................................................................... 118
7.5.5. How to assemble the rod ......................................................................................................... 119
How to install the seals ....................................................................................................................... 120
7.5.6. How to replace the plunger ...................................................................................................... 122
7.5.7. How to replace the top seal ..................................................................................................... 123
Chapter 8: Dismantling.................................................................................................. 125
8.1. Deactivation of the machine ........................................................................................ 125
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Contents
6
General information
Chapter 1: General information

1.1. Instruction manual
Machine: ........................................................................................................... Smart kegger K2 SS
Version: ....................................................................................................................................... 1.0
Printed: .............................................................................................................................. July 2020
Code: .............................................................................................................................. 14691MAN
1.2. Proprietary information

This manual contains proprietary information. All rights are reserved. Users shall not copy or
reproduce this documentation, in whole or in part, without a prior written permission from Co.Mac.
The use of this document is permitted only to the user who receives it as an integral part of the
machine and only for the purposes of installation, use and maintenance of the relevant machine.
Co.Mac declares that the information contained in this manual corresponds to the technical and
safety specifications of the machine it refers to. The manufacturer declines all responsibility for any
damage to people, things or domestic animals caused as a result of improper use of either the
manual or the machine.
Each chapter consistently sets out all information necessary for the user.
All technical data included in this manual is subject to modifications without prior notice due to
possible interventions on the machine aimed at improving its performances. Co.Mac may amend
its documentation without any obligations for prior notice.
REMARK
Notwithstanding the exhaustiveness of the present manual, Comac does not exempt itself from the duty of
assistance and guarantees a prompt intervention of its qualified technicians whenever required.
7
General information
1.2.1. Symbols
REMARK
These windows contain important information concerning the relevant text.
WARNING
These windows contain indications concerning procedures which must be strictly complied with. Failure to
comply with these procedures may cause damages to the machine or the equipments connected to it.
DANGER
These windows contain indications concerning procedures which may cause injuries to the operator or
impair his health in case they are not strictly complied with.
MACHINE
This word refers to the equipment specified in the paragraph "1.4 Machine identification data".
CIP
Acronym that stands for the phrase “Cleaning In Place” it refers to the machine cleaning cycle.
8
General information
1.3. Manufacturer identification data
Via Garibaldi, 34N – 24040 Bonate Sotto (BG) Italy

Tel. +39 035 4994211 - Fax +39 035 993090
http://www.comacitalia.it - Email:info@comacitalia.it
1.4. Machine identification data

The machine is provided with an identification plate which contains the essential identification data.
Model
Indicates the model
Serial Number
Indicates the serial number of the machine
Diagram
Indicates the electrical diagram number
Year
Indicates the year of manufacture
Voltage
Indicates the machine operating voltage
Frequency
Indicates the machine operating frequency
Power
Indicates the operating power of the machine
WARNING
It is strictly forbidden to remove or tamper with the machine identification plate.
9
General information
1.5. Use of the machine

1.5.1. Proper use
Machine purpose
Internal pre-washing and washing of stainless steel kegs, pressurization with CO2 and filling with
product.
Environment
The machine has been designed and manufactured for use in industrial environment. It must be
kept sheltered from weather.
Space required for machine installation

The machine must be installed in a place where installation, changeover, use and maintenance
operations can be carried out easily and safely.
1.5.2. Improper use

It is strictly forbidden to use the machine for purposes which are not expressly indicated in Chapter
1, General information, paragraph 1.5.1 Proper use.
In particular, use of the machine is forbidden:
✓ In explosive atmospheres.
✓ In flammable atmospheres.
DANGER
You are strongly recommended to install fire extinguishers near the line, in an easily accessible location.
10
General information
1.6. Description of the machine

1.6.1. Main components
1) Keg presser assembly
2) Washing head
3) Filling head
4) Keg lifting group
5) Switchboard
6) Operator panel
7) Process valves
8) Acid solution tank
9) Caustic solution tank
10) Pneumatic valves
9 10 1 5 1 6
8 7 4 2 4 3 4
11
General information
12
Safety information
Chapter 2: Safety information

2.1. Introduction
Although the equipment has been designed in accordance with the most advanced technology in
order to be used by skilled and trained personnel in safe conditions, your personnel must be
properly trained on the general safety rules of the country and the specific rules of the local plant
where the equipment is installed.
we remind that lack of attention, excessive confidence in one’s own knowledge of operational and
maintenance procedures, non-observance of safety rules and lack of experience may result in
damages to property and injuries to people.
Before using the machine, operators and maintenance technicians must:

• read and understand this instruction manual and documentation annexed,
• no safety system or recommendation can guarantee total safety, if you do not interact with the
equipment with seriousness, attention and professionalism.
REMARK
Co.Mac declines all responsibility for damages or injuries caused by non-observance of:
• content of the Instruction manual
• rules on conduct and behaviour related to the use of the equipment as per Co.Mac instructions
• rules on conduct and behaviour related to the use of the equipment as per Total Quality Manager or
other professional profile, in compliance with the regulations of the Country where the equipment is
used
• applicable safety regulations
• Instructions provided by sub suppliers of machine components
13
Safety information
2.2. Safety criteria applied

This machine complies with the safety requirements indicated in the Machinery Directive
2006/42/EC and subsequent modifications.
REMARK
Co.Mac declines all responsibility for any damage to people, domestic animals or things caused as a
result of non-compliance of the safety regulations and recommendations indicated in the documentation
supplied.
2.2.1. Safety measures

Fixed guards
A system of fixed guards limits access to the mechanical parts in movement. Removal of fixed
guards or part of them must be carried out by authorized personnel exclusively and with the
machine disconnected from its energy sources.
Mobile safety devices

A series of doors controlled by safety limit switches restricts access to the machine. The opening of
one of these doors causes the immediate stop of the machine.
Emergency stops
The machine is equipped with a switch isolator and emergency push-buttons; both disconnect the
power circuits of the machine.
Because of their purpose, these devices belong to class “0” of the IEC EN60204-1 standard.
2.2.2. Further protections and safety devices

Besides the safety measures mentioned above, the equipment is also provided with:
• devices for the detection of failures or anomalies that may occur during operation, and for the
generation of the relevant alarms and error messages;
• main power supply selector, that can be locked in its “0” position;
• visual and acoustic warning devices;
• clear indications concerning the function of all controls available.
All safety measures and devices must be maintained and kept in perfect conditions, in order to
guarantee their effectiveness.
At regular intervals, check and make sure that fixed protections are in place and safety systems
are working properly.
14
Safety information
2.3. Personnel
The equipment can be handled by qualified and properly trained personnel only. Any maintenance
or repair operation, both mechanical and electrical, must be carried out exclusively by technicians
who have been trained for the purpose and are provided with the proper protective equipment. The
type of technician required for the handling and maintenance of the machine is as follows:
Generic operator: Handles the machine basic controls for the machine start-up and normal
operation and resumes production after a stop. He can only perform his duty with all the safety
measures working properly.
Mechanical maintenance technician: A qualified technician, who can handle the equipment even
when the safety systems are disconnected. He can carry out maintenance operations, adjustments
and repairs on the mechanical components but is not allowed to operate the electrical equipment.
Electrical maintenance technician: A qualified technician who can handle the equipment even
when the safety systems are disconnected. He has a perfect knowledge of the electrical system
and the machine operation. He is in charge of maintenance operations, adjustments and repairs of
electrical components. He can perform his duties even when the machine is connected to the
power supply.
2.4. Health and safety information

A strict observance of the safety measures indicated hereunder is important in order to guarantee
the physical integrity of the personnel in charge of maintaining and handling the machine.
During machine operation:
A single operator is in charge of handling the machine; make sure everybody else keeps a
safety distance from the machine.
The operators in charge of the machine must have a perfect knowledge of its operation and
be aware of the importance of the emergency stops.
Before starting the machine, the operator shall make sure that the safety devices are
working properly.
It is forbidden to disconnect safety devices and emergency stops during production.
The operator must keep his concentration and alertness during the whole of his working
shift. If not, he should stop working and inform the shift supervisor immediately.
15
Safety information
During maintenance or repairs:
Disconnect the main switch and lock it.
Always wear personal protective equipment.
Before starting the machine, make sure nobody is in the machine area.
Make sure the safety devices are disconnected or removed only by authorized personnel
before carrying out maintenance operations and repairs that require the protections to be
disabled. Besides, make sure to prevent any damage to people and machines. The
interventions must be carried out slowly and carefully.
Do not touch the heating system pipes unless you are sure they are cold. Lock the steam
valve when you close it for maintenance operations.
Do not wear rings or necklaces that could get caught into the machine parts. Tie long hair
back and wear a hair net.
Maintenance and repairs on the electrical system must be carried out only by authorized
and specially trained technicians. The instruments and equipments used must be in perfect
conditions in order to avoid electrocution. In case of tests to be carried out with the machine
connected to the power supply, it is mandatory to comply with the relevant regulations.
The personnel working at height must be secured to the machine by means of safety belts
and must always move with caution.
Do not carry out lubrication and maintenance operations when the machine is in operation.
Furthermore, it is strictly forbidden to:

• Open the safety guards during machine operation.
• Inspect the machine while in operation.
• Lean against the machine while in operation.
• Sit on the machine components.
• Sit on the safety guards of the machine.
• Use the machine for purposes which are not indicated in this manual.
• Modify any part of the machine.
• Install further devices on the machine.
• Allow interventions on the machine by technicians who are not qualified or have a qualification
which is different from the one required (cfr. 2.3)
WARNING
Co.Mac declines all responsibility in case the customer does not carry out completion and insulation
works or implement the safety measures at his charge agreed upon as per contract.
16
Safety information
2.5. Safety system reset

2.5.1. Emergency button reset
By pressing one of the mushroom head push buttons shown in the drawing on the previous page,
the entire machine stops and all controls are disabled immediately (EMERGENCY condition); the
light of the auxiliary circuit enabling button goes off, signalling that the 24V circuits are deactivated.
To resume the machine operation, turn the mushroom head in the sense indicated by the arrows,
till it is released.
Before resetting an emergency, make sure the causes that generated it have been removed. Only
after resetting the emergency push-button, it is possible to reactivate the auxiliary circuits.
To reset safety systems after an emergency stop, proceed as follows:

• search for the cause of the emergency stop and remove it, making sure you comply with safety
procedures.
• Make sure there is nobody around the dangerous areas of the machine.
• Release the mushroom head button that has been pressed, by turning it in the sense indicated
by the arrow till you hear it click.
• Press the auxiliary circuit push-button to enable the 24V circuits.
2.5.2. Reset of safety limit switches

Access to all dangerous parts of the machine is restricted by means of safety limit switches, that
make sure access doors are properly locked.
Whenever an access door secured by safety limit switches is opened, the machine is immediately
stopped. The safety device reset push-button blinking light warns that a safety device has tripped.
To reset the safety systems after an access door has been opened, proceed as follows:
• Close the door that has been opened, causing the safety system to trip.
• Press the safety device reset push-button on the control push-button station; the button light
goes off, confirming the reset.
17
Safety information
2.6. Protection from contact with energized elements

2.6.1. Direct
In order to avoid accidental contacts with live elements located in the switchboards, access doors
of all cabinets are locked; the relevant key must be entrusted to the maintenance engineer.
In any case, access to the components inside the electrical cabinets must be permitted to skilled
and trained personnel only.
Access to inner components of junction boxes, push-button stations, etc. installed on the
machines, is secured by means of keys or special tools.
All keys and tools that give access to live parts must be entrusted to the maintenance engineer.
2.6.2. Indirect
To avoid any indirect electrical contact that might occur due to a failure of the insulation between
the live element and the earthing system, the earth is connected to the equipotential protection
circuit; besides, a protection device guarantees the automatic interruption of the power supply in
case of insulation failure.
All metallic parts of the machine are electrically connected to one another so that the whole system
is connected to the PE terminal.
WARNING
Checks on the equipotential protection circuit efficiency must be carried out at regular intervals.
18
Safety information
2.7. Visual/acoustic warnings

According to the model, a visual/acoustic warning column may be installed on the machine in order
to warn the operators and maintenance technicians about the machine status.
REMARK
Both operators and maintenance technicians must read carefully and fully understand the meaning of the
status signalled by the acoustic/visual warning system.
The visual/acoustic warning system can consist of various signalling modules, depending on the
specific functions of the machine. In this case, the warning system consists of the following
modules:
VISUAL/ACOUSTIC WARNINGS
Image Device Machine status warning
• It emits an intermittent sound whenever an alarm status occurs.

The sound stops as soon as the operator presses the reset push-
Acoustic button.
warning
• It emits a sound that lasts about one second each time the
operator presses the machine start push-button.
• Fixed light: It indicates that the operator has silenced the acoustic
warning after checking the nature of an alarm generated by the
machine.
Warning light • Blinking light: it indicates that the machine has generated an alarm.
- The light goes on blinking till the operator presses the alarm reset
red push-button to acknowledge the alarm.
• Off: It indicates that the operator solved the cause of the alarm and
kept the alarm reset push-button pressed until the light turned off.
The machine is now ready to resume operation.
19
Safety information
20
Machine characteristics
Chapter 3: Machine characteristics

3.1. Technical specifications
3.1.1. Nominal output
32 kph with 50 litre kegs
3.1.2. Overall dimensions

• Width about ............................................................................ 1750........................................ mm
• Length about .......................................................................... 1850........................................ mm
• Height about ........................................................................... 2200........................................ mm
• Weight about .......................................................................... 600............................................ Kg
3.1.3. Utilities required

For the correct operation of the plant, the following utilities are required:
• Air pressure for pneumatic circuit ........................................... 6.0............................................ bar

• Filtered air pressure ............................................................... 5.0............................................ bar
• Mains water pressure ............................................................. 3.0............................................ bar
• CO2 pressure.......................................................................... 4.0............................................ bar
• Steam pressure ...................................................................... 8.0............................................ bar
• Product pressure .................................................................... 2 .............................................. bar
• Product temperature ............................................................... 3 ............................................... °C
• Product flow rate .................................................................... 6 ............................................ m3/h
3.1.4. Consumption
• Mains air................................................................................. 40 ....................................... Nm3/h
• Treated water ......................................................................... 1 ............................................ m3/h
• Steam..................................................................................... 120......................................... kg/h
• CO2 ........................................................................................ 15 .......................................... Kg/h
21
3.2. Constructional characteristics

• Framework in AISI 304 stainless steel, sandblasted with microscopic glass beads and treated
with thermo-protective varnish. The framework is provided with height adjustable supports.
• Cleaning solution storage tank, with a capacity of 200 litres and complete with centrifugal pump,
water loading manual valve, overflow discharge pipe, inspection and cleaning manhole, liquid
level detection sensor.
• Acid solution storage tank, with a capacity of 200 litres and complete with centrifugal pump,
water loading manual valve, overflow discharge pipe, inspection and cleaning manhole, liquid
level detection sensor.
• Detergent solution heating system, which consists in a coil placed inside the tank, a steam
infeed valve, a steam trap and a digital thermostat for temperature control.
• Keg lifting system, controlled by a pneumatic cylinder.
• Special presser, controlled by a pneumatic cylinder, which blocks the kegs onto the
washing/filling head.
• Washing/filling head in AISI 316L stainless steel, provided with EPDM seals in order to ensure
maximum hygiene.
• N.C. pneumatic valves in AISI 316L for flow control during washing and filling cycles.
• Filling control system by either conductivity probe or flow-meter.
• Product inlet pipe, provided with:
✓ manual shut-off valve;
✓ Pressure indicator
✓ sampling valve;
✓ sight glass;
✓ non return valve.
• Electrical system for the connection of the different equipment. Cables are laid in cable trays for
an easy inspection.
• Stainless steel cable trays, dimensioned according to the quantity of cables they contain.
• Control switchboard in painted steel, programmable by PLC and provided with all relevant
power equipment and transformers.
• Push-button station in stainless steel, complete with operator panel and all relevant controls.
22
3.3. Switchboard
The switchboard complies with the following specifications:
• It is made of a stainless steel sheet, protection level IP 54.
• It is provided with a power connector for computers.
• Their dimensions guarantee an easy access to the components and allow for future
enlargements.
• The logic section (PLC) is separated from the power section (remote control switches,
magnetothermal switches, contactors).
• Doors, frame, panel and generally all those parts that can be disconnected mechanically are
connected to the grounding terminal.
• Possible modifications to the switchboard (holes or slots for instrumentation) do not alter its
rating.
• Cables are introduced from beneath the board.
• Each piece of equipment installed onto the board is provided with a clear and permanent coding
in order to make identification easier.
• Every control and warning device is provided with a permanent plate indicating its function.
• Every single terminal has only one wire connected to it.
• All terminals are numbered and the bridges consist of special connecting bars.
• The sections with different potential are separated by means of special spacers and retainers.
• The power supply input is marked and protected by means of a special protection plate.
• Every cable is numbered and connected with a terminal clamp.
• Control circuits are protected by means of magnetothermal switches.
• The power calculated for CC and AC transformers and feeders guarantees their performance
and prevents overheating.
• The control circuit voltages comply with the applicable regulations on equipment installation
environments.
• All cables comply with the relevant legislation on sheath sections and colours, according to the
circuit they belong to.
• The PLC is provided with memory, spare inputs and outputs for possible future modifications.
• The colours of the devices comply with the standards in force.
• The emergency stops are perfectly visible and easy to reach.
REMARK
The electrical diagram contains dimensions, cabling and position of components and terminal strips,
besides the list of materials.
23
3.4. Cabling
The electrical connection cables comply with the standards in force, that is, the IEC 20 and 22 and
IEC 20.37.
The cables subject to twisting or bending are highly flexible and comply with the above-mentioned
standards.
The cable sections of both power and control circuits and auxiliary circuits are in accordance with
the applicable standards.
The data and analogue signal transmission cables are shielded.
All equipment fittings are watertight and provided with cable gland and seals.
The electrical connection cables are laid in cable trays, stainless steel pipes, jackets or cable
holder chains with adequate sections.
24
Installation
Chapter 4: Installation
4.1. General information
To make transport and re-erection in its final destination easier, the machine is subdivided into
main parts before shipment.
Transport and installation of the machine must be carried out by skilled personnel, provided with
the necessary personal protective equipment as per prescriptions below.
The unloading, handling and transportation operations must be performed by skilled personnel,
authorized to use fork lift trucks, cranes or overhead cranes.
WARNING
The area included between the mean of transport parking area and the machine installation area must be
previously identified and inspected in order to detect the possible presence of “DANGEROUS ZONES”.
WARNING
Pay special attention to electrical lines and pipes in which corrosive fluids or gases flow at high pressure
and temperatures. If similar lines or pipes exist on the route, it is MANDATORY to isolate them, in
compliance with the local rules and provisions, making sure there's no energy accumulations of any kind.
WARNING
All transportation and handling operations must be performed with the maximum care and attention, using
suitable lifting equipment. Besides, while lifting or handling the machine, make sure there is nobody in the
area who might get hurt. Nobody is allowed to pass underneath or close to the machine during handling,
transportation and lifting.
25
Installation
4.2. Loading and transport

The machine can be packed in different ways, depending on the customer's needs:
• in a wooden crate or cage: the machine parts are fastened inside the container in order to
prevent sudden movements or impacts during transport and handling.
• Transport without any special packaging: the machine is secured by means of ropes fixed to the
strongest points, indicated by the people in charge of the installation.
Wooden crate ready for shipment Fig. A
The drawing in figure A shows the symbols visibly marked on the crate. The arrows indicate the
points where the ropes must be fixed in order to lift the crate. These points are indicated by means
of two chains drawn on the crate (see fig. A) and guarantee a balanced lifting thanks to the uniform
distribution of the machine weight.
It is essential that the ropes or chains used to lift the machine are strong enough to bear the overall
weight of the charge. Handle the charge with maximum care in order to avoid injuring people or
damaging the machine.
After loading, the crate must be securely fastened to the mean of transport to prevent movements
or vibrations during transport.
WARNING
Before moving the machine, the personnel in charge of transportation must be informed about the risks of
injuries involved in the transportation of the equipment.
They shall be properly trained on the correct use of the lifting systems, in order to guarantee the safety of
the people exposed to danger.
The security management must train the personnel in charge of transportation on the performance of
these operations and make sure safety procedures are strictly complied with.
26
Installation
4.3. Lifting operations

To lift the big components of the machine, the use of suitable lifting equipment is mandatory.
On the contrary, a fork lift truck can be used to lift small and light packaging materials containing
ancillary parts of the machine.
WARNING
During lifting operations, make sure none of the machine components falls to the ground or hits
something.
To lift the machine and its components, use bands, ropes or metallic chains whose loading
capacity is suitable for the weight of the part to be lifted and that must be arranged as indicated.
Besides, make sure the lifting bands do not damage the machine parts and surfaces they are in
contact with.
Check and make sure all machine components are correctly balanced before lifting them;
otherwise, adjust the harness till obtaining a perfect balance.
WARNING
It is strictly forbidden to use the machine components to hook up the load, in order to avoid deformation or
damages to any delicate parts.
To protect both the personnel and the integrity of the machine components, the following rules
must be complied with during lifting and transportation operations:
• make sure the packaging is in good conditions and guarantees stability during transportation.
• transport the machine only after lifting it by means of suitable lifting equipment.
Lifting operations must be carried out with the maximum care in order to hurt people, pipes or other
machines installed in the area.
27
Installation
Depending on the conditions of use, the loading capacity of a lifting device can vary.
The picture shows, for example, the force lifting systems

(such as ropes, bands or chains) are subject to during lifting
operations, according to the various inclination angles
applied.
In case of machine components whose dimensions prevent 30°
the use of bands or chains converging in a single point, we

suggest the use of spreader beams provided with lifting
chains on both sides, as shown in the picture below.
60°
500 Kg
517 Kg
577 Kg
90°
707 Kg 75° 90°
60°
45°
1000 Kg 120°
30°
1932 Kg 150° 15°
1000 Kg
If the load cannot be equally distributed on the bands, it is essential that one of them bears the
whole weight, while the others will be used to stabilize it.
Do not overlap or cross two lifting means

(ropes, chains or bands) on the same hook
(see picture).
if you do, just one of the two ropes will work
correctly; besides, the point in which they
overlap will tend to move downwards.
WARNING
It is strictly forbidden to:
• Use worn out lifting devices (ropes, chains or bands);
• Shorten lifting devices drawing knots in them;
• Use worn out hooks.
28
Installation
When the load surface is rough or presents sharp edges that might damage the lifting bands or
chains used, place small wooden or rubber pieces between the load the lifting mean so as to
prevent damages, as indicated in the figure below.
After loading, the crate must be securely fastened to the mean of transport to prevent movements
or vibrations during transport.
29
Installation
4.4. Unloading and inspection

Unload the crate bearing in mind the suggestions contained in the previous paragraph,
summarized hereunder:
• Use bands that can bear the charge to be lifted
• Place the bands as indicated on the crate
• Unload the machine with maximum care in order to avoid injuring people or damaging the
machine
• Follow all the instructions described in the paragraph above concerning lifting operations.
When removing the packaging, use a hammer to bend any nails that may protrude from the wood,
in order to avoid getting injured.
WARNING
We suggest you should wear safety gloves before bending and removing nails from the crate, and pay
maximum attention in order not to get hurt.
• Make sure the various parts of the machine don't show any visible damage.
Check the machine thoroughly in order to detect any possible damage or missing parts. In
particular:
• Make sure that the protection guards are free of dips and crushing: otherwise remove them and
verify that the covered parts haven't suffered damages.
• Make sure none of the machine components has been damaged.
• Make sure in the control cabinets there are no loose components due to shocks or excessive
vibrations.
• Make sure that the parts that are not painted are not oxidized.
• Make sure all buttons, levers, selectors and hand-grips on the push-button stations are in good
conditions.
• Make sure all external cables for the connection of the various appliances (motors, limit
switches, etc.) to the control cabinet are not damaged or bent.
• Make sure pneumatic actuators do not present any sign of damage.
REMARK
In case of damages to or loss of ancillary parts, stop immediately the installation procedures and inform
Co.Mac. S.r.l. It is advisable that you take pictures of the damaged parts and provide them to Co.Mac.
30
Installation
4.5. Installation
Clean the machine, remove all dust and dirt accumulated during transport. with compressed air
and clothes moistened with water.
WARNING
Clean all plastic parts with water. Do not use any solvent.
The installation environment must comply with the following characteristics:

Space surrounding the machine: ................................................................................................ 1 meter min.
Bearing plane loading capacity: ................................................................................................... >2000 kg/m2
Specific resistance to bearing plane compression: ..................................................................... >10 kg/cm2
Ambient light conditions: ................................................................................................ from 300 to 500 lux
Acceptable temperature range: ......................................................................................... from 5°C to +35°C.
Acceptable relative humidity: .............................................................................................. from 30% to 95%.
DANGER
The place where the machine is installed must comply with the fire regulations in force.
4.5.1. Storage conditions

All those parts of the machine that may be subject to oxidation (roller pins, sliding guides,
processed parts, etc.) are greased and protected by means of sprays before shipment, in order to
prevent oxides from forming on them due to environmental conditions.
If you need to store the machine for a short period of time, make sure you store it in a dry place,
protected against humidity, after checking out the packaging for damages or wet parts. The
protections to the various connections foreseen in the factory must not be removed.
If you need to store the machine for a longer period of time, besides the prescriptions mentioned
above, the following measures need to be taken: Spread a further layer of grease on all those parts
that are subject to the formation of oxides.
Furthermore, place Silica gel satchels in the switchboard, in order to absorb humidity. Replace the
satchels at regular intervals, bearing in mind the humidity rate, in order to guarantee the integrity
and efficiency of the electrical and electronic circuit.
In case of storage, make sure there is enough space around the machine for the authorized
personnel to circulate and handle it easily and safely.
WARNING
It is forbidden to place any object on the machine or its components.
31
Installation
4.5.2. Tips on installation

• Remove the package only when the machine is as close as possible to the place of installation,
so as to contain vibrations and avoid damaging the electrical and mechanical components.
• After removing the packaging materials, check whether the adjustable support feet have been
disassembled; fix them in their proper seat as shown in the attached drawings.
• Place the machines complying with the dimensions shown in the general lay-out.
• Level and assemble the different parts of the equipment following the indications shown in the
lay-out.
• Install the pipes for the connection of the different machines according to the flow chart and the
tag numbers printed on the pipe joints.
• Install the cable trays on the machine in accordance with the number of the different joints and
follow the indications for the cabling shown in the electrical diagram.
• Check whether the mechanical components (pipes, screws, cylinders, etc…) are properly
tightened or got loosened during transport.
• Arrange the supply lines of the various fluids (air, steam, backpressure gas, water, product,
power supply, etc…). Before carrying out the final connections, make sure the pipes have been
cleaned perfectly and are therefore free from any deposit or dirt. This check guarantees that no
foreign body deposit inside the machine components, thus avoiding damages to the equipment.
Pay attention so as to avoid excessive backpressure in the manifolds that could impair the
machine performances.
• Connect the power supply cable terminals to the terminals in the switchboard (access to the
terminals is possible through the special passages provided with cable glands at the bottom of
the electrical cabinet; otherwise, make use of the general cable duct, observing the applicable
regulations concerning electric lines).
• Connect the earth conductor (PE) and coordinate the interventions of the safety devices
upstream of the panel, according to the EN 60204-1 standard.
32
Installation
4.5.3. Utilities at customer's charge
REMARK
Before connecting the machine, pay special attention to the technical specifications concerning the supply
of the different utilities; in particular, check that microbiological conditions, pressures, flow rates and
temperatures (see technical data) are strictly complied with and remember that the aforesaid conditions
must be kept constant during operation.
Water supply
Before connecting to the water supply, make sure the piping system is properly dimensioned. After
starting the machine, check that the required conditions are complied with even in case of
maximum consumption.
Water hardness must be checked also.
The water must be bacteria free.
Air supply
Dimension the pipes so as to avoid pressure drops during operation. Air must be dry and oil-free.
Product supply
The beer delivery system must be projected and developed with special care. Please note that
pressure, flow and temperature variations are far more critical than in the case of the other fluids.
Steam supply
A steam trap on the steam line is recommended (specially if the line is very long) in order to avoid
water hammers. Anyway, the steam must be dry.
Backpressure gas supply for filling

Check that the pressure is not higher than 10 bars, otherwise, provide the machine with an
additional pressure reducer.
Power supply
See specifications in the electrical diagram. Connect the earthing system following the procedure
described in paragraph 4.5.5.
All the connection points are provided with an identification plate. Notwithstanding, look up the
connection points of the different utilities in the plant lay-out, in case some of them require to be
connected to more than one point.
WARNING
The steam valve must always be opened gradually, in order for the pipes to be pressurized slowly, so as
to avoid water hammers.
33
Installation
4.5.4. Connection to the power supply

Before starting the machine, connect the power supply cable to the special terminal strip in the
switchboard.
DANGER
Connections must be carried out by authorized personnel.
Depending on the type of switchboard, it is possible that the power supply cable must be
connected either to a dedicated terminal strip or directly to the main switch. The input hole of the
power supply cable is located in the lower panel of the switchboard, where you can see the
relevant cable gland.
Direct connection to the main switch:
N R S T R S T
PE PE
3-phase + neutral + earth power supply 3-phase + earth power supply
Connection to a dedicated terminal strip:
R R
S S
T T
N PE
PE
3-phase + neutral + earth power supply 3-phase + earth power supply
WARNING
It is essential to check the tightening of the terminals in the switchboard at regular intervals. Poor
inspections may be the cause of serious damages to the components in the switchboard.
34
Installation
4.5.5. Connection to the earthing system

Grounding of the metal components of the machine is obtained by means of isolated conductors
connected to the switchboard earth bar.
In each appliance, the grounding system for the protection of all the relevant parts and circuits
must be connected to a single grounding system.
Make sure the materials used for the grounding system are robust and their mechanical protection
is adequate.
The connection to the main grounding system must be as short as possible and the conductors
mustn't be subject to mechanical stress or risk of corrosion.
To guarantee the safety of both people and appliance, it is essential to comply with the following
rules:
• Check the power supply characteristics and make sure they are coherent with the technical
characteristics of the appliance.
• Power cables and switchboard connection cables must be tightly and properly connected to the
relevant terminals of the appliance.
The table below provides useful indications to define the correct dimension of the grounding
conductors, in relation to the section of the phase conductors:
Section of the phase conductors of the Minimum section of the relevant grounding
appliance conductors
S [mm2] Sp [mm2]
S10 Sp=S
16<S35 Sp=16
S>35 Sp=S/2
35
Installation
4.6. Commissioning
The table below shows a list of items to be checked before commissioning.
REMARK
Before requiring our intervention for the start-up, make sure all the items listed hereunder have been
checked by your personnel.
Check YES NO
Machine positioning and levelling.
Presence of shut-off valves on the inlet of the various fluid supplies. Otherwise,
install them.
Connection of the water line to the relevant points.
Connection of the steam line to the relevant points.
Connection of the compressed air line to the relevant points.
Connection of the product line to the relevant points.
Connection of the backpressure gas line to the relevant points.
Connection of the switchboard to the power supply, as per technical specifications

listed in the electrical diagrams.
36
Installation
4.6.1. Testing
It consists of a series of inspections and tests to be carried out according to a definite programme.
• Inspection of the cable routes, with regard to alignment, centre distance between supports,
distance from heat sources.
• Test on access to hazardous live parts and safety devices, in compliance with the standards in
force.
• Test on conductor tightness in the relevant cable glands.
• Inspection of all fittings and junction boxes, which must be in perfect conditions upon receipt of
the equipment.
• Inspection of the connections on the terminal strip and connections to the electrical equipment
terminals.
• Check on the correct execution of all mechanical, pneumatic, hydraulic and electrical cabling.
• Inspection of the electrical isolation of motors, switchboards and supply cables; earthing system
resistance measurement.
• Check on load distribution balance.
• Inspection of the cable terminal tag numbers.
• Tightness test on pneumatic connections, making sure there is no obstruction or throttling in the
pipes.
• Check on the presence of power supply upstream of the general switch located in the
switchboard.
• Connection to the power supply, setting the main switch of the switchboard to position “1”.
• Check on the tension of all phases of the power supply line.
• Check on the rotation sense of the electrical motors.
• Performance test of all safety devices and emergency stops.
• Performance test of all mechanical and electrical components of the distribution panel, as
relays, switches, contactors, safety devices, etc...
• Check of conformity of the equipment to the applicable regulations in force.
DANGER
These operations must be performed by skilled personnel, suitably equipped and informed on the risks
implied in them.
37
Installation
38
Use
Chapter 5: Use
5.1. Operating principle
DANGER
Before using the machine for internal cleaning and filling, we suggest cleaning or sanitizing the filling head
and the product infeed pipe. The cleaning operation is executed sending off hot water or the cleaning
solution normally used for the sanitization to the product infeed pipe. In any case, we suggest that a
complete CIP cycle be carried out at least once a week in order to prevent microbiological problems.
After loading a keg onto the washing head table, press the two cycle start buttons at the same time
to start the working cycle.
Upon starting, the table and the presser lower and fix the keg onto the washing head. The washing
head working cycle begins.
As soon as the working cycle finishes, table and presser lift and release the clean keg.
Remove the keg from the washing head table and place it on the filling head table. Place another
keg on the washing head and press the first head cycle start buttons at the same time. Then, press
the second head cycle start buttons simultaneously.
Tables and pressers lower and fix the kegs onto the washing and filling heads. The washing cycle
and the filling cycle start.
When the cycles come to an end, tables and pressers lift and release both the clean and the filled
keg.
The operator can now unload the keg from the filling head, move the washed keg to the filling head
table and load a new keg onto the washing head table.
Press the two cycle start buttons of both heads in order to start a new cycle.
WARNING
In order to ensure the operators safety, the machine program requires the two cycle start buttons of each
head to be pressed simultaneously and kept pressed until the washing and filling cycles have started. If
one of the two buttons is released beforehand, pressers and kegs return to the rest position preventing
the working cycle from starting.
A detailed description of the working cycle of each head is described hereafter.
39
Use
5.1.1. Washing head diagram (head 1)
LS06201
PT06701
PV01701
PV01301
PV01101
CAUSTIC SOLUTION CAUSTIC SOLUTION
PV01401 PV02601
ACID SOLUTION CAUSTIC SOLUTION
PV01001 PV02801
MAINS WATER ACID SOLUTION
PV02001 PV04301
STEAM
DISCHARGE
PV00301
AIR
PV01701 FULL/REDUCED FLOW VALVE

PV01101 CAUSTIC SOLUTION INLET
PV01401 ACID SOLUTION INLET
PV01001 MIXED WATER INLET
PV02001 FILTERED STEAM INLET
PV00301 FILTERED AIR INLET
PV01301 COUNTERCURRENT CAUSTIC SOLUTION INLET
PV02601 CAUSTIC SOLUTION RETURN
PV02801 ACID SOLUTION RETURN
PV04301 RESIDUE DISCHARGE
PT06701 ANALOGUE PRESSURE SENSOR
LS06201 LIQUID DETECTION PROBE
40
Use
Washing head cycle

1. Keg manual loading onto the head;
2. Lowering of presser and table in order to fix the keg onto the head;
3. Check on correct coupling between keg and head by means of pressurization of the head with
filtered air*;
4. Introduction of the plunger;
5. Check on residual pressure inside the keg*;
6. Discharge of all residue from inside the keg by means of a blow of sterile air;
7. Keg depressurization;
8. Keg pre-washing with mains water;
9. Ejection of the pre-washing water by means of filtered air;
11. Internal washing with flow of caustic solution, full and reduced alternatively;
12. Counter current washing with caustic solution;
13. Recovery of caustic solution from inside the keg by means of a blow of sterile air;
15. Internal washing with flow of mains water, full and reduced alternatively;
16. Discharge of the mains water by means of a blow of sterile air;
18. Internal washing with flow of acid solution, full and reduced alternatively;
19. Counter current washing with acid solution
20. Recovery of acid solution from inside the keg by means of a blow of sterile air;
22. Internal washing with flow of hot water, full and reduced alternatively;
23. Ejection of the hot water by means of a blow of filtrate steam;
24. Steam sterilization of the keg;
25. Extraction of the plunger;
26. Head residual pressure discharge;
27. Lifting of presser and table in order to release the keg.
* Remark: Each one of these two phases is performed only if the other has been disabled.
Thus, the check on coupling between head and fitting is performed only if the residual
pressure control has been disabled.
41
Use
5.1.2. Filling head diagram (head 2)
PRODUCT"
PI
FT05401
PV01801 PV05101
LS06201
PT06701
PV00601
CO2
PV02001
STEAM
PV04001
CO2 DISCHARGE
DISCHARGE
PV01801 PRODUCT INLET VALVE RESIDUE DISCHARGE

PV05101 RESIDUE LIMITATION VALVE
PV00601 CO2 INLET VALVE
PV02001 STEAM INLET VALVE
PV04001 CO2 REGULATED DISCHARGE
LS06201 LIQUID DETECTION PROBE
PT06701 ANALOGUE PRESSURE SENSOR
FT05401 FLOWMETER
42
Use
Filling head cycle

1. Lowering of presser and table in order to fix the keg onto the head;
2. Check on keg position onto the head by means of pressurization of the head with CO2;
3. Head depressurization;
4. Introduction of the plunger;
5. Keg steaming with pulsed discharge;
6. Condensate discharge by means of a blow of CO2;
7. Pressurization of the keg with CO2;
8. Overpressure discharge for filling;
9. Opening of the product valve;
10. Opening of regulated discharge and start of the filling stage;
11. End of filling and subsequent closing of product valve and regulated discharge valve;
12. Extraction of the plunger;
13. Discharge of the residues of product by means of a blow of CO2;
14. Steam sterilization of the head and keg spear fitting;
15. Head depressurization;
16. Lifting of presser and table in order to release the keg.
43
Use
Sanitization cycle
Before performing a sanitization cycle, the operator must install the dummy keg onto the filling
head.
1. Check on dummy keg position onto the head by means of pressurization of the head with CO2;
2. Opening of the product valve;
3. Intermittent opening of the discharge valve;
4. Waiting time before the operator presses the filling head exclusion push-button (or the stop
push-button) in order to finish the C.I.P. cycle. (see remarks below);
5. Closure of the product valve;
6. Opening of the discharge valve;
7. Waiting time during discharge;
8. Closing of the discharge valve;
9. Lifting of pressers and tables.
Now the operator can remove the dummy keg from the filling head.
REMARK
The filling head exclusion push-button stops the C.I.P. cycle and depressurizes the head. To prepare the
machine for production, press the stop push-button, prepare the tank from the cellar and press the start
push-button to fill the pipes with product.
44
Use
5.2. Automatic start-up
DANGER
Before starting the machine in automatic mode, make sure nobody is working on it. Before carrying out
any operation on the machine, turn off and lock the main switch in the switchboard.
In order to start the machine in automatic mode, the following operations must be carried out:
1. Turn on the main switch.
2. Open the shut-off valves of the various fluids (compressed air, water, CO2, etc…).
3. Release the emergency push-button, if it has been pressed.
4. Press the auxiliary circuit connection push-button.
5. Select the correct cycle in the operator panel.
6. In the operator panel, select the recipe that corresponds to the product you want to use for
production.
7. Press the start push button during 1 second approximately: the fixed light indicates that the
machine is in automatic operation.
8. After treatment on the washing head, move the keg onto the filling head. Place a new keg on
the washing head.
9. Press the two washing head cycle start buttons at the same time and keep them pressed until
the lights come on, indicating that the working cycle has started.
10. Press the two filling head cycle start buttons at the same time and keep them pressed until the
lights come on, indicating that the working cycle has started.
The machine will carry out all the operations required for the execution of the selected working
cycle automatically.
45
Use
5.3. Manual start-up

In order to start the machine in manual mode, the following operations must be carried out:
1. Turn on the main switch.
2. Open the shut-off valves of the various fluids (compressed air, water, CO2, etc…).
3. Release the emergency push-button, if it has been pressed.
4. Press the auxiliary circuit connection push-button.
5. Select the manual operation mode in the operator panel.
6. Select the manual operations to be executed by the machine in the relevant pages of the
operator panel.
DANGER
Carry out the manual operations only after making sure nobody is in the machine radius of action.
46
Use
5.4. Machine use

5.4.1. Filling head C.I.P. cycle
The C.I.P. cycle (Cleaning In Place) must be performed both before and after a production cycle,
or for the weekly cleaning of the system. The machine must be empty.
During this cycle, the cleaning solution normally used for the sanitization is sent to the product
infeed pipe.
In order to prepare the machine for the C.I.P. cycle, perform the following operations:
• Set the product infeed pipes so that the cleaning solutions may reach the filling head.
• Install the dummy keg on the filling head (see next page).
• Press the white illuminated circuit activation push button.
• Select the “Sanitization” cycle in the operator panel.
• Press the start push button to start the cycle.
The duration of cleaning and sanitization is up to the user who may interrupt the cycle or let it go
on for as long as he wants.
Please remember that, after a weekly C.I.P. cycle, an abundant rinsing with (preferably hot) water
must be performed in order to ensure that no trace of sanitizing solution is left into the circuit.
To bring the sanitization cycle to an end:

• Press the head exclusion push-button and wait for the machine to stop.
After pressing the head exclusion button, the machine opens the discharge valve and the CO2
infeed valve in order to discharge any possible liquid residue from the head. After a few seconds,
the CO2 infeed valve closes, while the discharge valve keeps open for some more seconds in
order to depressurize the head.
WARNING
We recommend the client to execute, at each beginning of the production, some microbiological tests on
all the first kegs produced. This will allow the user to detect immediately any microbiological problems due
to an insufficient cleaning of the components of the machine and avoid to sale a not compliant product.
If some microbiological problems are found, we recommend to increase the duration of the sanitization
cycles and verify the quality of the disinfectant solutions in order to guarantee an in-depth cleaning of the
components that are normally in contact with the product.
47
Use
Installation of the CIP cap for sanitization

To install the CIP cap properly, proceed as follows:
Whenever not in use, the CIP cap must be stored in Turn the bracket CCW and remove it.
its seat; unscrew the handgrip to unlock the fastening
bracket.
Take the CIP cap. Place the CIP cap on the filling head.
Introduce the fastening bracket into the special Screw the bracket handgrip on the CIP cap till it is
connections and turn it CW. completely locked in place; at this point it is possible
to proceed with the sanitization cycle.
To remove the CIP cap, perform the operations listed above in reverse order.
After removing the cap from the head, store it in its seat.
48
Use
5.4.2. Preparation for production

Before starting production, discharge the rinsing water remained in the pipes after the sanitization
cycle. The machine must be empty and set for the sanitization cycle.
Unless a C.I.P. cycle is in progress, perform the following operations:

• Set the product infeed pipes so that the cleaning solutions may reach the filling head.
• Install the dummy keg on the filling head.
• Press the white illuminated circuit activation push button;
• Select the sanitization cycle in the operator panel;
• Press the start push button;
• Wait for the C.I.P. system to complete the cleaning cycles;
• Follow the instructions provided hereafter.
In case a C.I.P. cycle is in progress, perform the following operations as soon as it comes to an
end:
• Press the stop push button (not the filling head exclusion push button);
• Prepare the piping so that the product proceeding from the cellar reaches the machine inlet
pipe;
• Press the start push button to resume the C.I.P. cycle;
• Wait for the product to reach the machine and flow over the discharge pipe;
• After discharging all water residues, as soon as you are sure that product only is flowing
through the pipes, press the filling head exclusion push button.
After pressing the head exclusion button, the machine opens the discharge valve and the CO2
infeed valve in order to discharge any possible liquid residue from the head. After a few seconds,
the CO2 infeed valve closes, while the discharge valve keeps open for some more seconds in
order to depressurize the head.
The machine stops automatically when the residue discharge valve closes; at that moment, the
operator can remove the dummy keg from the filling head.
49
Use
5.4.3. Production cycle

During the production cycle, kegs are submitted to the internal cleaning on the first head and
subsequent filling with product on the second.
Production
In order to start production with stainless steel kegs, proceed as follows:
• Make sure you have removed the dummy keg from the filling head.
• Press the white illuminated circuit activation push button;
• Select the “Production” cycle in the operator panel;
• Select the recipe for stainless steel kegs in the operator panel and transfer it to the PLC;
• Make sure there is product in the buffer tank and that the delivery pressure is correct;
• Press the start push button;
• Place the kegs on the two heads (keg filling on the second head must be performed only after
internal cleaning on the first);
• Press the two cleaning head cycle start push buttons at the same time;
• Press the two filling head cycle start push buttons at the same time.
Kegs are cleaned and filled according to the sequences indicated in the paragraph “Operating
principle”.
50
Controls and instrumentation
Chapter 6: Controls and instrumentation

6.1. Controls
WARNING
It is strictly forbidden to change the location of the machine controls; in no case shall the controls inside
the machine protected areas be relocated. Co.Mac. S.r.l. declines all responsibility for any damage to
people, animals or things caused as a result of changes made to controls or their location.
6.1.1. Control push-button station

The machine is provided with the following controls:
102S1 Mushroom head emergency push button: emergency stop

This button completely stops the machine. Use exclusively in case of emergency.
102S2 Auxiliary circuit activation neutral illuminated push-button

Used to activate the auxiliary circuits; a fixed light comes on. Press the emergency
push button to disconnect the circuit.
300S1 Yellow push-button: head 1 cycle start (washing)

300S2 Yellow push-button: head 1 cycle start (washing)
After setting the machine for automatic operation, selecting the production cycle and
pressing the start push-button, press these two push-buttons at the same time to start
the washing cycle for the keg placed on the first head. Keep the two push-buttons
pressed until the washing cycle starts (the keg support table and keg presser must
complete their stroke). It one or both push-buttons are released too early, the washing
cycle won't start and the keg support table and presser will go back to their rest
position.
300S1 Yellow push-button: head 2 cycle start (filling)

300S2 Yellow push-button: head 2 cycle start (filling)
After setting the machine for automatic operation, selecting the production cycle and
pressing the start push-button, press these two push-buttons at the same time to start
the filling cycle for the keg placed on the second head. Keep the two push-buttons
pressed until the filling cycle starts (the keg support table and keg presser must
complete their stroke). It one or both push-buttons are released too early, the filling
cycle won't start and the keg support table and presser will go back to their rest
position.
51
Position of controls on the machine push-button station:
300S1 102S1 300S1

Cycle start Emergency Cycle start
head 1 stop head 2
300S2 ASEM 102S2 300S2

Cycle start HMI30 Auxiliary Cycle start
head 1 circuits head 2
REMARK
The push buttons 300S1 and 300S2 must be pressed simultaneously in order to start the washing cycle
(head 1).
The push buttons 300S1 and 300S2 must be pressed simultaneously in order to start the washing cycle
(head 2).
52
6.1. Operator panel Asem HMI30
General features
The terminal ASEM HMI30 allows the user to analyse the process parameters and control the
actuators by means of the touch screen and the additional function keys.
By pressing the function keys or the data entry fields on the display, the operator can solve all kind
of problem. This user-friendly terminal has been designed to be used as an interface in a large
series of applications.
It can be handled even by unskilled operators; indeed, its extremely clear icons make its use very
easy and immediate.
It is rather small, 175x145 mm., and it weighs 900 grams approximately. It is provided with a 7"
LCD TFT display, 800x480 pixel resolution, 16 millions of colours, with LED back light that
guarantee a minimum of 80,000 hours useful life. Analogue-resistive touch screen.
It is provided with a 1GHz ARM Cortex A8 processor, with 400 MHz memory bus, a 1GB RAM
DDR3-800 memory for the execution of the programs and a 4GB eMMC memory for projects and
applications.
Windows Embedded Compact 7 Pro operating environment.
Besides, it is also provided with two communication ports Ethernet RJ45 (100 Mbps + 10/100
Mbps), two USB ports and one RS232/422/485 serial port.
WARNING
In accordance with the model, the operator panel may be provided of a storage device (memory card SD,
flash drive USB or CF card).
If the storage device is present, it is necessary that, at intervals of one month and only with the machine
off, the storage device is extracted from the operator panel to execute a copy of backup of the data
contained in the computer.
Reinstall the storage device in the operator panel before turning on the machine.
53
Data modification
Press directly onto push-buttons and switches on every page displayed on the panel in order to
activate them.
Press onto the relevant field on the display to set (or modify) data; a digital keyboard is shown on
the display where new data can be entered:
“ENTER” key
Confirm the data entered and remove the keyboard by pressing “Enter” on the keyboard.
A numeric or alphanumeric keyboard will appear on the screen, depending on the type of data to
be entered. Use the relevant buttons to shift from numeric to alphanumeric keyboard and
viceversa.
Numeric keyboard Alfanumeric keyboard
54
Access to protected pages or data

In order to prevent accidental modifications to data that are extremely important for the correct
operation of the installation, a set of passwords for different levels have been introduced. Each
level password allows entering modifications to definite data groups.
Higher level passwords allow the access to data protected by lower level passwords.
Whenever the operator tries to gain access to a protected page or to make modifications to
protected data, a window requiring the password appears:
The "User name" field in the connection window enables the operator to enter the user
identification code; the "Password" field allows entering the password connected to the user
identification code.
Press the button , located on the right of the fields “User Name” and “Password”, to open the
keyboard required to insert the data in the relevant fields. The data introduced by means of the
keyboard must be confirmed, using the "Enter" key on the same keyboard.
After introducing all the data required, tag the box "Change Password after login", located at the
bottom, to be enabled to modify the user password.
Press "OK" in the access window to enable the user.
Press “Cancel” to disable the login function.
For further safety, the connection is automatically deactivated after the time set for every user.
55
6.1.1. Home page

Upon switching on the panel, the program is charged and carried out automatically. The following
frame appears:
The two fields per each head, located in the centre of the page show the work phase in progress
and the rejection cause (in case of rejection), in real time.
The fields at the left bottom of the page, show the work phase in progress in the acid solution tank
and caustic solution tank.
The two fields in the bottom right side of the page show the pressure values detected by the
sensors of the two heads, in real time.
The bottom bar, common to all pages, contains a series of push-buttons that give access to the
menu pages, where you find the machine controls and can set the operation parameters.
The upper bar is common to all pages as well, and allows the user to check the machine operation
status, working cycle in progress and recipe currently selected, in real time.
Press the field on the right of the logo to gain access to machine operation mode setting page.
In all the pages visualized on the screen, the button at the bottom bar takes back to the
previous page.
56
6.1.2. System pages
Press in the bottom bar to gain access to the following frame::
This page shows the controls for the service operations; the left column contains the following
controls:
Press this push button to display the window for the access to protected information
by logging in with username and password.
Press this push button to deactivate the active user: the protected information are
not accessible any longer till a new login session.
Press this push button to terminate the program of the operator panel. Access to the
functions of this button is only permitted to Co.Mac technicians.
Press the push button "Remote assistance" to gain access to the page where the operator can
enable the remote service provided by Comac after-sales department.
The central frame containing the two fields with date and time, allows the user to modify the date
and time in the operator panel. Press "Confirm" to enable the modifications made.
In the column on the right of the screen, press the push-buttons with the flags to modify the
language of the texts displayed on the operator panel screen.
57
Remote assistance
Press “Remote assistance” in the "Setup" page to gain access to the following frame:
When remote assistance is requested, Comac technicians get connected to the machine and are
therefore able to perform checks and control the machine from remote.
The push-button "ON" can be pressed by the operator (or by Comac technician from remote) to
generate the alarm that warns that remote control of the machine has been enabled; a blinking
light remains on as long as teleservice is active.
The push-button "OFF" must be pressed by the operator (or by Comac technician from remote)
when the teleservice is completed and remote assistance is no longer required. Upon pressing the
push-button, the alarm disappears.
DANGER
During remote assistance, the operator must make sure nobody is in the machine working area.
The operator himself must keep away from the machine action area.
The machine safety devices remain active as long as teleservice is on.
58
6.1.3. Parameter menu
Press in the bottom bar to gain access to the following frame:
The push-buttons in this page give access to the various pages that contain the main operation
parameters of the plant.
A detailed description of all the pages that can be accessed by means of these push-buttons is
provided hereafter.
59
“Operation” page
Press “Operation” in the parameter menu to gain access to the following frame:
The buttons in this page allow the user to select the machine operation mode and the work cycle to
be performed.
Press the push-buttons of the frame “Filler" in the left part of the screen to select the machine
operation mode:
Manual: This selection sets the machine in manual control.
0: This selection disables the machine and prevents any operation, both manual
and automatic.
Automatic: Press to set the machine for the automatic control.
The active operation mode is displayed in the field on top of the group of push-buttons.
The two push-buttons in the right part of the screen allow selecting the work cycle the machine
must carry out when set in automatic operation:
Production: The plant is set for the automatic execution of the production cycle.
CIP: The plant is set for the execution of the sanitization of all those parts which get in contact with
the product.
After the selection, a message is displayed in the field “Production” on top of the push-buttons,
which shows the selected cycle. Before selecting a work cycle you must necessarily press the stop
push-button.
Upon pressing the button "CIP", another button appears on the screen called "Tanks management
during CIP". This button allows the operator to disable the operation of the tanks during the
execution of the sanitization cycle at the end of production (to save energy), or to enable the
operation of the tanks in order to anticipate their preparation during the sanitization cycle,
performed before production.
60
“Selections” page
Press “Selection” in the parameter menu to gain access to the following frame:
The commands in this page allow enabling and disabling some specific functions of the machine:
The buttons named “Residual pressure control” allow enabling or disabling the keg inner residual
pressure control function for the first head.
If the residual pressure control function is disabled, the machine only checks the coupling between
head and keg.
The push-buttons “Head 2 pressurization only” enable and disable the function of pressurization
with CO2 only; when this function is enabled, the filling phases are excluded.
61
“Changeover” page
Press “Changeover” in the parameter menu to gain access to the following frame:
This page allows the user to load the recipe of the product he intends to process and send it to the
PLC.
The dropdown box shows all the available recipes. Press the required recipe to select it; press
"ACTIVATE" to transfer the relevant data to the PLC.
The field underneath the pull-down box displays the recipe transfer status.
As indicated by the warning at the bottom of the screen, a new recipe can be transferred only after
pressing the stop push-button. Otherwise, the new data won't be sent to the PLC for the execution.
62
“Recipe” page
Press “Recipes” in the parameter menu to gain access to the following frame:
The machine operation parameters for each type of keg or product to be processed can be stored
in recipes, each one with a different name and easy to access. This way, the user doesn't need to
set all the parameters again at every changeover. The pull down box in the upper part of the
screen allows selecting the recipe whose parameters you want to modify. In the box, you can enter
the name of the recipe you want to create.
The central window contains the list of process parameters; in this area, data can be modified
before they are sent to the PLC or stored in a new recipe. The push-buttons on the page bottom
allow the operator to create, store or delete recipes.
Press "Write" to transfer data from the recipe to the PLC.
Press "Read" to transfer data from the PLC to the recipe.
Press "Save" to store a recipe after modifying the relevant parameters.
Press "Delete" to delete the selected recipe.
Press "Copy" to copy in memory the data of the selected recipe.
Press "Paste" to paste in the selected recipe the data copied by the push-button "Copy".
Press "Import" to import in the selected recipe the data stored
Press "Export" to export the data of the selected recipe into an external file.
63
“Counters” pages
Press “Counters” in the parameter menu to gain access to the following frame:
The page contains the production counters (partial and total) of the first head:
The fields “H1 – Partial rejected” show the number of kegs rejected by the machine during
production.
The fields “H1 – Partial produced” show the number of kegs correctly produced by the machine.
The fields “H1 – Partial processed” show the number of kegs introduced into the machine for
production.
Press "Reset partial" to reset the production partial counters.
The fields “H1 – Total rejected” show the total number of kegs rejected by the machine during
production.
The fields “H1 – Total produced” show the total number of kegs correctly produced by the
machine.
The fields “H1 – Total processed” show the total number of kegs introduced into the machine for
production.
Press "Reset total" to reset the production total counters.
The arrows on top of the page allow the operator to move through the various pages of analysis of
the production counters.
64
Press the right arrow in the previous page to gain access to the following frame:
The page contains the production counters (partial and total) of the second head:
The fields “H2 – Partial rejected” show the number of kegs rejected by the machine during
production.
The fields “H2 – Partial produced” show the number of kegs correctly produced by the machine.
The fields “H2 – Partial processed” show the number of kegs introduced into the machine for
production.
Press "Reset partial" to reset the production partial counters.
The fields “H2 – Total rejected” show the total number of kegs rejected by the machine during
production.
The fields “H2 – Total produced” show the total number of kegs correctly produced by the
machine.
The fields “H2 – Total processed” show the total number of kegs introduced into the machine for
production.
Press "Reset total" to reset the production total counters.
The arrows on top of the page allow the operator to move through the various pages of analysis of
the production counters.
65
“General times” page

Press “General times” in the parameter menu to gain access to the following frame:
This page allows checking and setting the general working times of the washer/filler:
CIP - Valve OFF time: it defines how long the valves that open and close at regular intervals
during the CIP cycle (flip-flop) remain open.
CIP - Valve ON time: it defines how long the valves that open and close at regular intervals during
the CIP cycle (flip-flop) remain closed.
Head 1 - Table descent delay: It defines the delay after which the keg support table of the first
head must start its descent; this parameter allows synchronizing the keg support table and keg
presser cylinder descent cycle, in order to deposit the keg onto the head without jerking
movements.
Head 2 - Table descent delay: It defines the delay after which the keg support table of the second
head must start its descent; this parameter allows synchronizing the keg support table and keg
presser cylinder descent cycle, in order to deposit the keg onto the head without jerking
movements.
Time-out recovery solution: It defines the maximum time within which the phases of recovery of
liquids at the end of the various washing phases must be completed.
Time-out solution discharge: it defines the maximum time within which the various liquids must be
discharged.
The working times indicated above can be set in the fields of the “Set” column, while the column
“Act” displays the times actually set in real time.
The arrows on top of the page allows the operator to move through the various pages for the
working time setting.
66
“Times head 1” pages

Press “Head 1 times” in the parameters menu to gain access to the following frame:
In this page, the user can analyse and set the first part of the working times of the first head of the
washer/filler:
Coupling control: it defines the duration of the check of the coupling between keg and head,
carried out by means of filtered air.
Residual pressure control time-out: it defines the maximum time within which the correct
residual pressure value must be detected inside the keg.
Time-out residue ejection: It shows the maximum time within which the residues must be
discharged from inside the keg.
Inner pressure discharge time-out: It defines the maximum time within which the keg must be
depressurised after the phase of ejection of all liquids by means of air.
Prewashing with mains water: It defines the duration of the keg internal prewashing phase with
mains water.
Liquid discharge time-out: It shows the maximum time within which the water must be ejected
from the keg after the washing phase.
The working times indicated above can be set in the fields of the “Set” column, while the columns
“Act” display the times actually set.
The fields with a blue contour line only display values, that can be edited in the general time page.
67
In this page, the user can analyse and set the third part of the working times of the first head of the
washer/filler:
N° of pulsed washings with caustic solution: It defines the number of pulses to use during the
pulsed washing with caustic solution.
Full flow washing with caustic solution: it defines the duration of the pulsed washing phase with
full flow of caustic solution.
Low flow washing with caustic solution: it defines the duration of the keg pulsed washing phase
with reduced flow of caustic solution.
Caustic recovery time-out: It shows the maximum time within which the recovery of the caustic
solution at the end of the washing phase must be completed.
N° of pulsed intermediate washings: It defines the number of pulses that compose the pulsed
intermediate washing with mains water.
Pulsed washing with water: It defines the duration of the keg internal washing phase with pulses
of mixed water.
Water pulsed recovery: it defines the duration of the phase of discharge of the water from the keg
after the pulsed washing.
68
In this page, the user can analyse and set the second part of the working times of the first head of
the washer/filler:
N° of pulse washings with acid solution: It defines the number of pulses that compose the
pulsed washing with acid solution.
Full flow washing with acid solution: it defines the duration of the pulsed washing phase with full
flow of acid solution.
Low flow washing with acid solution: It defines the duration of the pulsed washing with reduced
flow of acid solution.
Acid recovery time-out: It shows the maximum time within which the recovery of the acid solution
at the end of the washing phase must be completed.
69
In this page, the user can analyse and set the second part of the working times of the first head of
the washer/filler:
N° of pulse washings with hot water: It defines the number of pulses that compose the pulsed
washing with hot water.
Full flow washing with hot water: It defines the duration of the pulsed washing phase with full
flow of hot water.
Low flow washing with hot water: It defines the duration of the pulsed washing with reduced flow
of hot water.
Hot water recovery time-out: It shows the maximum time within which the recovery of the hot
water at the end of the washing phase must be completed.
Final head pressure discharge: It defines the time required for the depressurization of the head
after the working cycle.
Residue ejection time-out for keg rejection: It shows the maximum time within which the
residues must be completely evacuated from inside a rejected keg..
70
“Times head 2” pages

Press “Head 2 times” in the parameters menu to gain access to the following frame:
In this page, the user can analyse and set the first part of the working times of the second head of
the washer/filler:
Coupling control: it defines the duration of the check of the coupling between keg and head,
carried out by means of filtered air.
Sterilization: It defines the duration of the steam sterilization phase.
Pressure reached time-out: it defines the maximum time within which the correct pressure value
must be detected in the keg during the steam sterilization phase.
Condensate discharge: It defines the duration of the condensate ejection phase after sterilization.
Pressurization with CO2 time-out: It defines the maximum time within which the correct pressure
value must be detected in the keg during the pressurization with CO2.
Filling minimum time: It defines the minimum time required for a proper filling of the keg with product.
Filling time-out: it defines the maximum time within which the phase of filling with product must
end.
71
In this page, the user can analyse and set the second part of the working times of the second head
of the washer/filler:
Residue discharge: It defines the duration of the product residue discharge phase from the head after
filling.
Keg neck steaming: it defines the duration of the fitting and head steam sterilization phase.
Final head pressure discharge: it defines the time required to depressurized the head.
Residue ejection time-out for keg rejection: It shows the maximum time within which the
residues must be completely evacuated from inside a rejected keg.
72
“Pressure” page
Press “Pressures” in the parameter menu to gain access to the following frame:
In this page, the operator can see and set the pressure values that must be detected on the heads
of the washer/filler during the working cycles.
The fields are arranged in columns: the column “Set” contains the pressure values used as
reference during operation. A tick in the columns “Head 1 - Head 2" marks off the head that makes
use of each parameter.
The line "Actual" displays the pressure values detected in real time by the sensors installed on
each head of the washer/filler, while in the other lines the following parameters can be set:
Coupling: it defines the pressure value that must be detected during the check on the coupling
between keg and head.
Residual: it defines the minimum pressure value that must be detected during the keg residual
pressure control.
Inner pressure discharge: it defines the pressure value below which the keg depressurization
stage comes to an end.
Sterilization: it defines the minimum pressure value that must be detected during the sterilization
of the keg with steam.
CO2 pressurization: It defines the pressure value that must be reached during the pressurization
of the keg with carbon dioxide.
Min.press. washing liquids: it defines the minimum pressure value that must be detected during
the washing phases.
73
“Filling” page
Press “Filling” in the parameter menu to gain access to the following frame:
This page allows the user to check and set the parameters that control the filling phase when
controlled by flowmeter.
Full keg: It defines the volume of product (in gallons) that must be introduced in the kegs during
the filling phases controlled by means of flow-meter.
Hysteresis: it defines the volume of product (gallons) that, once reached, allows the system to
close the product valve in time so as not to exceed the volume set point at the end of the filling
phase.
Flow-rate: It shows the product flow-rate, expressed in gallons/second, detected by the flow-meter
during the filling phases in real time.
The working parameters indicated above can be set in the fields of the “Set” column, while the
column “Act” displays the values set in real time.
74
“Acid solution tank” page

Press “Acid solution tank” in the parameter menu to gain access to the following frame:
In this page it is possible to check the operation parameters system of the caustic solution dosing
system.
Set kegs for acid solution renewal: It defines the number of kegs to be processed before the
machine warns the operator that the acid solution needs to be renovated.
The indicator "Working temperature" changes from white to green when the working temperature
threshold for the acid solution is reached.
The indicator "Minimum temperature" changes from blinking white/red to green when the minimum
temperature threshold for the acid solution is reached.
The temperature thresholds must be set directly on the ring nuts of the dual threshold thermostat
installed in the tank.
In the bottom part of the page are shown the manual control push-buttons available for each
actuator; the push-buttons are active provided that the machine is set for manual mode.
It is possible to gain access to this screen also by pressing the push-button "Acid" in the manual
control menu.
75
“Caustic solution tank” page

Press “Caustic solution tank” in the parameter menu to gain access to the following frame:
In this page it is possible to check the operation parameters system of the caustic solution dosing
system.
Set kegs for caustic solution renewal: It defines the number of kegs to be processed before the
machine warns the operator that the caustic solution needs to be renovated.
The indicator "Working temperature" changes from white to green when the working temperature
threshold for the caustic solution is reached.
The indicator "Minimum temperature" changes from blinking white/red to green when the minimum
temperature threshold for the caustic solution is reached.
The temperature thresholds must be set directly on the ring nuts of the dual threshold thermostat
installed in the tank.
In the bottom part of the page are shown the manual control push-buttons available for each
actuator; the push-buttons are active provided that the machine is set for manual mode.
It is possible to gain access to this screen also by pressing the push-button "Acid" in the manual
control menu.
76
Manual control menu
The push-buttons in this page give access to the various pages that contain the manual controls of
the machine actuators.
A detailed description of all the sub-pages is provided hereafter.
77
Head 1 manual controls

Press “Head 1” in the manual control menu to gain access to the following frame:
This page contains the first part of commands for the manual control of the actuators belonging to
the first head of the machine.
The frame contains the manual control push-buttons available for each actuator; the push-buttons
are active provided the machine is set for manual mode.
The fields between the description of the actuator and the control push-buttons indicate the status
of the sensors installed on the actuator itself.
The push-button "Presser-Table" doesn't activate the manual controls but gives access to a
separate page dedicated to manual control (see page 80).
The arrows in the upper corners of the screen allow the user to move through the pages of manual
controls.
78
This page contains the rest of commands for the manual control of the actuators belonging to the
first head of the machine.
controls.
79
Head 2 manual controls

Press “Head 2” in the manual control menu to gain access to the following frame:
This page contains the commands for the manual control of the actuators belonging to the second
head of the machine.
The push-button "Presser-Table" doesn't activate the manual controls but gives access to a
separate page dedicated to manual control (see page 80).
controls.
80
Presser and table manual controls

Press “Presser-Table” in the washing and filling head manual control pages to gain access to the
following frame:
This page contains the push-buttons that allow setting the machine pressers and tables for manual
control.
For each actuator the push-buttons “UP” e “DOWN” allow for the ascent and descent of the
relevant actuator; the activation of one push-button deactivates automatically the other one.
After activating the push-buttons of the two actuators, it is possible to steer them by pressing the
two work start push-buttons at the same time. This system allows to control the two actuators at
the same time.
81
6.1.4. Alarm page
The page contains a list of the alarms that warn about the troubles occurred during the normal
operation of the machine.
To delete the list of alarms, the operator must solve the problems that caused them.
Press the button on the operator panel to reset the alarms and resume operation.
Press to gain access to the "Alarm historical report" page, where the last 1000 alarms
occurred during the machine operation are listed in order of appearance.
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Alarm historical report page
Press the push-button in the top right-hand corner of the previous page to gain access to
the following frame:
This page shows a chronological list of the latest 100 alarms occurred during the machine operation.
Press the symbol to update the list including the alarms that have occurred after the opening of
the page.
Press the symbol to gain access to the search filter window; the parameters contained in the
window permit to filter and display only the alarms corresponding to the parameters indicated and
modify the display order.
83
6.2. Alarms
A list of alarms is provided hereunder together with some useful indications concerning possible
solutions for the relevant problems. The alarms have been divided in homogeneous groups. The
descriptions are the same as those displayed on the operator panel.
0001 - =00101+001-YV07401A/R - Keg presser head out of position ........................................................1

0002 - =00101+001-YV07501A/R - Table out of position .............................................................................2
0004 - =00101+002-YV07401A/R - Keg presser head out of position ........................................................4
0005 - =00101+002-YV07501A/R - Table out of position .............................................................................5
0026 - =00101+002-PV01801A/R - Product inlet out of position...............................................................26
0027 - =00101+002-PV05101A/R - Residue limitation out of position .....................................................27
These alarms are generated whenever an actuator does not reach the right position within the guard time
after the relevant command sent by the PLC. Make sure no foreign body prevents the actuator from
moving; check the actuator position sensors and the operation of the relevant control solenoid valves.
0003 - =00101+001-YV07601A/R - Plunger out of position .........................................................................3

0006 - =00101+002-YV07601A/R - Plunger out of position .........................................................................6
These alarms are generated whenever the plunger is not correctly introduced into the keg within the guard
time after the relevant command sent by the PLC. Make sure the keg valve is not defective and that no
foreign body prevents the plunger from moving. Check the relevant position sensor and control solenoid
valves.
0033 - =00101+QG1-100K1 - Auxiliary circuits off .....................................................................................33

This alarm is generated in case of lack of response from the safety relay of the auxiliary circuits; make sure
the emergency button on the control board hasn't been pressed. Check the safety relay operation. Reset
the correct conditions and start the machine.
0034 - =00101+JB1-300S7 - Emergency pressed on panel ......................................................................34

The emergency button located on the machine control board has been pressed. In order to reset the correct
working conditions, release the emergency button, activate the auxiliary circuits, reset the alarms and restart
the machine.
0035 - =00101+QG1-70Q3 - Aboard machine 24Vdc automatic switch tripped .....................................35

This alarm is generated whenever the thermal circuit breaker of the specific 24V circuit trips. Make sure no
component is shorted; open the switchboard, reset the thermal circuit breaker and restart the machine.
0036 - =00101+PB-PS08301 - Mains air failure ...........................................................................................36

This alarm is generated by a drop of pressure of the pneumatic circuit mains air. In order to restore the
operating conditions, make sure the air adjustment assembly valve has been opened, the pressure
controller is working properly and the mains pressure is sufficient. Reset the alarm and start the machine.
0037 - Coupling in CIP failed.........................................................................................................................37

This alarm warns the operator that the CIP cap position does not guarantee the correct coupling for the
execution of the CIP cycle. Make sure the CIP cap is correctly installed on the head, that the head gasket is
in good condition and no foreign object is preventing a correct coupling between the filling head and CIP
cap.
84
0038 - Recipe transfer failed! ........................................................................................................................38

This alarm is generated whenever the transfer of a recipe takes longer than the maximum time set. Make
sure the connections of the cables between operator panel and PLC are in perfect conditions. Repeat the
recipe transfer operation.
0039 - Head 1 rejected keg ............................................................................................................................39

0040 - Head 2 rejected keg ............................................................................................................................40
This alarm warns the operator that the keg currently present on the head has been rejected. Check the
status of the keg spear fitting and, in case of consecutive rejections, make sure the machine sensors and
valves are in perfect conditions. Eventually, check the working parameters set in the operator panel.
0041 - Cleaning tanks not ready...................................................................................................................41

This alarm warns the operator that the cleaning solution tanks do not communicate to the PLC that they are
ready for the working cycles. If the preparation phase is still in progress, wait until it ends. Make sure the
tanks are working.
0049 - =00101+QG1-20K4/20Q4 - =00401+024-PU01401 - Acid solution delivery pump no

feedback ..........................................................................................................................................................49
0065 - =00101+QG1-20K1/20Q1 - =00401+020-PU01101 - Caustic solution delivery pump no
feedback ..........................................................................................................................................................65
This alarm is generated either whenever the magnetothermal switch for the protection of the centrifugal
pump power circuit opens, or when the power remote control switch doesn't open or close after the relevant
command. Open the switchboard and reset the tripped protection thermal circuit breaker. Check the remote
control switch coil operation and make sure the remote control switch hasn't got stuck. Pay special attention
when performing the above mentioned operations as some of the internal parts remain live in spite of being
protected. In case the thermal circuit breaker should trip more than once, check that it is adjusted in
compliance with the data indicated in the motor identification plate and that the relevant motor is working
properly.
0051 - =00401+024-TS08301 - Acid solution tank low temperature.........................................................51

0067 - =00401+020-TS08301 - Caustic solution tank low temperature ...................................................67
This alarm appears if the temperature of the solution in the tank drops below the minimum temperature set
point set in the operator panel. Make sure the steam manual valve is open and the steam pressure is
correct. Check the efficiency of the steam valve and relevant temperature sensor and, eventually, the
parameters set in the operator panel.
0056 - =00401+024-LS06001 - Acid solution tank low level ......................................................................56

0072 - =00401+020-LS06001 - Caustic solution tank low level.................................................................72
This alarm appears whenever the level of the solution in the tank indicated doesn't reach the control probe
within the maximum time set. Make sure the manual valve is open, check the efficiency of the water loading
valve and control the level sensor to make sure it is not dirty or covered with scale deposits.
0059 - Acid solution inlet low pressure .......................................................................................................59

0075 - Caustic solution inlet low pressure..................................................................................................75
These alarms appear whenever the pressure of the fluid specified drops below the minimum threshold.
Make sure the fluid delivery pressure is correct and the manual shut-off valves are open; eventually, check
the efficiency of the pressure control sensor.
85
0063 - Renewal acid solution........................................................................................................................63

0079 - Renewal caustic solution ..................................................................................................................79
These alarms warn the operator that the indicated solution must be renovated. Stop the machine and
empty the detergent solution tank. Restart the machine and pour concentrate in the tank while it is being
filled with water.
0116 - Attention remote assistance in progress!!!!! ............................................................................... 116

This alarm appears after the operator confirms the connection for remote control during teleservice. The
alarm remains active during the whole teleservice session.
0121 - =00101+001-PT06701 - Pressure analog instrument error......................................................... 121

0125 - =00101+002-PT06701 - Pressure analog instrument error......................................................... 125
This alarm is generated whenever the PLC detects a value lower than 4 mA on one or more inlets of the
analogue cards. It is possible that one of the sensors or one of the analogue cards is defective; make sure
these components work properly and replace them if necessary.
0122 - =00101+001-PT06701 - Pressure analog instrument misadjusted............................................ 122

0126 - =00101+002-PT06701 - Pressure analog instrument misadjusted............................................ 126
This alarm is generated whenever the specified sensor detects values that are not consistent with the type
of measuring in progress. Check the sensor parameters and make sure it works properly.
0128 - =00101+002-FT05401 - Flow meter sensor in alarm.................................................................... 128

This alarm appears in case of failure of the flow-meter. Check the failure cause on the display of the
instrument. Make reference to the relevant instruction manual.
86
6.3. Troubleshooting
A list of possible failures and relevant causes is provided hereunder together with the checks to
perform in order to resume operation after a machine stop or fault.
FAILURE POSSIBLE CAUSE
The production cycle has been

 The program selected is not correct.
selected but the machine does not
 The temperature of the cleaning solution in the tank is not correct.
start.
 The backpressure gas pressure value is not correct (it must be

approximately 0.2 bar lower than the product pressure).
Excessive number of kegs rejected  The sterile air pressure is not sufficient.
during production.  The steam pressure is not sufficient.
 The product pressure is not sufficient.
 The cleaning solution pressure is not sufficient.
The machine stops suddenly during  The mains air pressure has dropped or is completely missing.
operation.  One of the cylinder position sensor is broken and must be replaced.
 Excessive quantity of residues inside the keg; the residue evacuation

maximum time set is not sufficient.
 The liquid detection probe is either dirty or covered with deposits. Remove
Excessive number of kegs rejected and clean the probe.
on the first head during the residue  The liquid detection probe is not working properly. Make sure the
discharge phase. connector is properly connected.
 The steam or sterile air pressure are not sufficient.
 The valves do not open properly; check the efficiency of the valves and
relevant control solenoid valves.
 The liquid detection probe is either dirty or covered with deposits. Remove
and clean the probe.
Excessive number of kegs rejected  The liquid detection probe is not working properly. Make sure the
on the first head during the liquid connector is properly connected.
introduction phase.  The steam or sterile air pressure are not sufficient.
The introduction of the plunger into  The plunger position sensor is not in the correct position. Adjust it.
the spear fitting is not detected.  The plunger position sensor is not working properly. Replace it.
Excessive number of kegs rejected

 The pressure value set in the operator panel is too high.
during the check of the coupling
 The pressure control sensor is not working properly and must be replaced.
between head and keg.
87
FAILURE POSSIBLE CAUSE
 The pressure value set in the operator panel is not correct.

Excessive number of kegs rejected  The pressure control sensor is not working properly and must be replaced.
during keg pressurization with  Either the gas pressure is not sufficient or the manual valve is closed.
backpressure gas.  The valves do not open properly; check the efficiency of the valves and
 The backpressure gas pressure value is not correct (it must be

approximately 0.2 bar lower than the product pressure).
Kegs are not properly filled during  The liquid detection conductivity probe is either dirty or covered with
filling regulated by means of deposits. Remove the probe and clean it.
conductivity probe.  The connections of the conductivity probe are defective.
 The regulator installed on the regulated discharge pipe is not properly

Keg filling is too slow. adjusted. Adjust the backpressure gas discharge speed and the filling
speed by means of the regulator.
 The liquid detection conductivity probe is either dirty or covered with

During filling controlled by means of
deposits. Remove the probe and clean it.
conductivity probe, excessive
 The connections of the conductivity probe are defective.
quantities of product overflow from
the regulated discharge.
88
Maintenance
Chapter 7: Maintenance
7.1. Maintenance and spare parts
DANGER
The customer must make sure the personnel in charge of maintenance has a perfect knowledge of the
information provided in this manual and has been properly trained on the dangers arising from lack of
attention,
disregard for the use of personal protective equipments and for safety standards (see chapter 2).
All maintenance, cleaning, lubrication and repair activity must be carried out only after disconnecting the
machine from its sources of energy. The main switch must be set in off position and locked. Before
performing operational tests, it is mandatory to check that all tools and replaced parts have been removed
from the machine. Furthermore, check that nobody is working on the machine.
All tests must be carried out slowly and carefully. Make sure they do not endanger people health or impair
the machine integrity.
Do not perform any adjustment on the machine components when the machine is in operation. Keep at a
safety distance and do not touch any parts in motion, neither with your hands nor with any tool, while
checking the machine operation.
Maintenance consists in a schedule of operations to be carried out on the machine in order to

guarantee its most effective operation and longest useful life.
It deals mainly with:
• Checking that the different parts of the machine work properly;
• Solving or removing faults and events that could cause major problems in case of deterioration,
although they do not represent an immediate source of danger or cause of technical failure.
These operations are periodical and must be carried out at regular intervals.
A constant and accurate maintenance, together with the relevant analysis, is essential in order to
guarantee the machine performances as per constructional characteristics.
REMARK
All the pictures contained in this chapter are merely a rough guide to show the components installed on
the machine; they might slightly differ from the components actually installed.
WARNING
During any maintenance operation described hereafter, use the supplied or, in any case, appropriate
tools. Pay extreme attention in order not to damage the delicate machine components, such as seal
gaskets, guide bands, etc.
To get the codes of the spare parts, please refer to the tables supplied with the technical documentation
on digital support. To order spare parts, please send an email to the address spare.parts@comacitalia.it
WARNING
Use the document attached to check the compatibility between lubricant and gasket materials.
89
Maintenance
7.2. Routine maintenance

All the machine components require regular inspections and maintenance. The table hereunder
indicates the frequency recommended by the manufacturer for the execution of all essential
inspections and maintenance operations:
WARNING
Incompliance of the maintenance intervals indicated by Co.Mac implies the immediate cancellation of the
machine warranty.
Co.Mac will not replace under warranty those components that are damaged or broken as a result of
negligence.
The table below shows, in red color, the interventions included in the Co.Mac's Preventive
Maintenance Program.
FREQUENCY OF INSPECTIONS AND MAINTENANCE

AREA ITEM TO BE CHECKED METHOD TOOLS FREQUENCY
Observation, Sight, brush
1 Machine framework General cleaning
cleaning if necessary and water
Weekly
Check whether the mechanical Observation,

2 Machine framework components screws are properly tightening if Sight, wrenches Annually
tightened necessary
Adjustment of CO2 pressure
3 Process components Observation Sight Daily
reducer
Check on pressure gauge
4 Process components
operation
Observation Sight Daily
Observation and
Check on leakage on centrifugal replacement of the
pumps relevant seals if
Sight, wrenches Weekly
necessary
Check on valve and electronic
sensor tightness
Observation Sight Monthly
7 Process components Check on valve leakage Observation Sight Monthly
Check on cleaning and integrity Observation,

8 Process components of the self-cleaning filter internal replacement if Sight, wrench 6 Monthly
components (if present) necessary
Observation,
Check on analog sensor
adjustment
adjustment if Computer Annually
necessary
Observation; clean
Check on the presence of dirt or Sight, descaling
scale deposits from the pipes
with descaling
solution
Annually
solution if necessary
Check on plunger position
11 Washing/filling head
sensor operation
Observation Sight Daily
12 Washing/filling head Check on filling probe operation Observation Sight Daily

13 Washing/filling head General cleaning
cleaning if necessary and water
Weekly
Observation,
14 Washing/filling head Check on ring nut wear replacement if Sight, wrench Monthly
necessary
Observation,
15 Washing/filling head Check on head seal wear replacement if Sight, wrench Monthly
necessary
Check on plunger pneumatic
cylinder operation
17 Washing/filling head Check on rod/cylinder joint Observation Sight Monthly
90
Maintenance
FREQUENCY OF INSPECTIONS AND MAINTENANCE

AREA ITEM TO BE CHECKED METHOD TOOLS FREQUENCY
18 Washing/filling head Check on head leakage Observation Sight Monthly
Observation,
Check on plunger rod seals and
replacement if required
replacement if Sight, wrench Annually
necessary
Check on plunger pneumatic Observation,
20 Washing/filling head cylinder and replacement if replacement if Sight, wrench Annually
required necessary
Observation,
Check on lubrication of the Sight, grease
21 Keg support table
shifting guides
lubrication if
gun
Monthly
necessary
Check the joint sealing cylinder-
22 Keg support table
frame is properly tightened
Observation Sight, wrench Monthly
Check on wear and tear of the Observe,

23 Keg support table high density polyethylene Observation replace if Annually
(polizene) plate necessary
Check on wear and tear of the Observe,
24 Keg support table high density polyethylene Observation replace if Annually
(polizene) adjustable supports necessary
Check the joint sealing cylinder-
25 Keg presser
presser is properly tightened
Observation Sight, wrench Monthly
Observation,
Control wear of the polizene
26 Keg presser
rubber edge
replacement if Sight, wrench 6 Monthly
necessary
Check on pneumatic connection
27 Pneumatic circuit
and pneumatic cylinder integrity
Check on pressure regulator Observation. Empty

and filter the filter if necessary
Sight Monthly
Check on cylinder rod tip

clearance
Check on solenoid valve

operation
Check on operation and position

31 Pneumatic circuit of the sensors on the pneumatic Observation Sight Monthly
cylinders
32 Electrical cabinets Cleaning of filters
cleaning if necessary and air
Monthly
Check the tightness of the cable

33 Electrical cabinets
glands
Observation Manual Annually
Check on air conditioner

34 Electrical cabinets
operation
Observation Sight Annually
Observation,
35 Electrical cabinets Check on terminal tightness tightening if Sight, wrenches Annually
necessary
36
37
38
39
40
91
Maintenance
7.3. Maintenance of mechanical and pneumatic components

7.3.1. Pneumatic system
The compressed air purity is fundamental in order to guarantee performances, useful life and
reliability of all pneumatic components. The air treatment system consists of the following
elements:
• Shut-off valve on the compressed air inlet.
• Filter for the removal of all impurities and condensate from the air.
• Outlet pressure regulator, for the supply of air to the pneumatic components.
• Pressure gauge displaying the outlet pressure.
• Pressure controller for the detection of possible drops or lack of pressure.
Air treatment system can be combined differently, according to the machine where it is installed.
The drawing hereunder shows a standard air treatment system showing several of its components:
Pressure
Shut off valve regulation
Air inlet Air outlet
Pressure switch
Pressure gauge
Filter
Filter drain
Valve: It shuts off the compressed air supply to the machine pneumatic system. By closing the
valve, the system depressurizes the pneumatic equipment connected to the outlet.
Filter: It consists of a diffuser and a wing deflector. The air is conveyed in a centrifugal movement
so that the liquid and solid impurities are projected towards the cup walls and settle at the bottom.
The air then passes through a cartridge for a final filtration.
The cup must be emptied at regular intervals so as to remove all impurities.
92
Maintenance
Regulator: Used to keep the outlet pressure constant in spite of any possible inlet pressure
variation. The outlet pressure is adjusted by means of a position locking cylinder which controls a
spring. The spring regulates the opening of a valve, thus keeping the outlet pressure constant.
Pressure gauge: Shows the pressure value detected at the regulator outlet on a graduated scale.
Pressure controller: Used to detect possible drops or lack of pressure on the regulator output
line. It consists of a pressure-driven electrical contact - The pressure set point can be regulated by
means of the pressure controller. We recommend periodical checks on the pressure controller
efficiency and adjustment.
Mains air pressure adjustment
Lift up the handgrip Rotate the handgrip counter- Lower the handgrip
until it clicks clockwise until the value of 6 until it clicks
bar is displayed on the
pressure gauge
93
Maintenance
7.3.2. Pneumatic operated valve control

It is absolutely essential to inspect the wear and tear parts as seal gaskets, o-rings, diaphragms
etc. on a regular basis.
Check the operation of the valves making use of both mechanical and electrical manual controls.
In case the electrical controls are not available, it is possible to check the valve operation by
pressing directly onto the solenoid valves (with a screwdriver of adequate dimensions) in the points
indicated in the picture below.
A red pin on the upper part of the pneumatic valve shows that it has been activated (see picture
below).
Valve open Valve closed
94
Maintenance
7.3.3. Lubrication and cleaning of pneumatic valves

Disassemble and clean all pneumatic valves at regular intervals and replace their worn parts in
order to prevent them from getting blocked.
Lubricate preferably with minimum quantities of silicone grease.
The pictures below show a pneumatic valve. Leakage may be caused either by wear or excessive
deposits on the seal.
Pressurize the control bushing in order to keep the valve open. Make sure the red pin is visible in
the upper part of the valve. It is now possible to disassemble the instrument safely and easily.
Unscrew the instrument at the point indicated by the arrow in fig. 1 using a wrench and carefully
clean the internal part of the valve. Check if the seal (indicated by the arrow in fig.2) is in good
conditions and remove the residues.
Open/closed state
indicator
Unscrew
here
Fig. 1 Fig. 2 Fig. 3
Assemble the valve taking care not to spoil the seal or leave any dirt between the seal and its seat.
Lubricate the actuator thread with silicone grease (as indicated in picture 3) before screwing it back
onto the valve body. If the gasket (indicated in picture 2) is damaged and needs replacing, proceed
as indicated in the next page.
Cross sectional view of a pneumatic valve
For further information, see the relevant technical documentation.
95
Maintenance
To replace the gasket of the valve indicated on the previous page, proceed as follows:
Unscrew the transparent cover of the valve indicator and
1
remove it from its seat.
Block the valve in a bench vice as indicated in the picture.

2
Remove the elastic ring located under the valve body

3
using a plier. Open the bench vice very carefully, as the
springs contained in the valve body are still under tension.
Separate the two sections of the valve body paying

4 attention not to lose the spring or spot the internal
components.
After removing the valve body, remove the damaged

5
gasket using two wrenches.
Perform the above mentioned operations in reverse order
to reassemble the valve.
96
Maintenance
7.3.4. Pneumatic cylinder adjustment

The cylinders control the movable parts of the machine. In order to avoid jerking movements, these
elements must be controlled properly. The speed of the movements can be controlled by means of
special chokes (Fig. A) and movement can be prevented using blockers (Fig. B). Furthermore, the
cylinder stroke can be slowed both at the start and at the end by means of special brakes (Fig. C).
The chokes (Fig. A) regulate the cylinder air flow. Adjust the flow by
means of the screw indicated by the arrow. The adjusting screw is
usually locked by means of a nut. Loosen the nut to adjust the screw
and tighten it again after the intervention.
Fig. A
The blockers prevent the air from entering the cylinder until some air at
the correct pressure is introduced into the unlocking bush indicated by
the arrow in Fig. B.
These components are used to prevent unexpected movements of the
machine.
Fig. B
Loosen or tighten the screws indicated by the Braking adjustment screws

arrows in Fig. C to slow the cylinder end of
stroke. A proper adjustment prevents jerking
movements.
Remember to adjust the braking screws
whenever you replace or maintain a cylinder.
Air fittings
Fig. C
In order to perform a good adjustment of the cylinders, make use of the manual controls available
in the operator panel and test their movement.
DANGER
Carry out the above-mentioned operations with maximum care, making sure nobody is too close to the
machine.
97
Maintenance
7.3.5. Maintenance of pneumatic cylinders

All the cylinder parts must be inspected at regular intervals and worn components shall be
replaced. The pictures below show an assembled cylinder (Fig. A) and a set of spare seals (Fig.
B).
1 2 3 4 5
Fig. A Fig. B
1 3 5 2 4 4 5 3
Fig. C
The drawing (Fig. C) shows the position of the seals (Fig. B) in the cylinder, the spare kit also
includes a bag of lubricating grease.
In order to replace the cylinder seals, proceed as follows:
Loosen the screws of the 4 tie rods, remove the front and rear base and extract the rod. Access to
all seals is now possible.
Remove all seals paying attention not to damage their seat. Clean the seats carefully and apply a
thin layer of grease. Insert the new seals and lubricate them, taking care not to damage either the
seals or their seats.
Lubricate the internal part of the cylinder and the rod. Assemble the cylinder with care, following
the above-mentioned steps in reverse order. Screw the tie rods.
Install the cylinder on the machine and carry out the adjustments as described in the previous
paragraph.
98
Maintenance
7.3.6. Maintenance of linear guides

The linear guides, installed on the keg support table lifting systems, must be inspected and
lubricated at regular intervals, in order to guarantee their useful life and correct operation.
In the picture, the arrow shows one of the two linear
guides installed in the machine.
During inspection, make sure there's no dirt
accumulated or poor lubrication that, due to the
increased friction, might cause damages or wear and
tear of the guides where they are in contact with the
balls.
Besides, make sure the guides are steadily fastened
onto the machine support frame; misalignments of the
guides may jeopardize the correct operation of the lifting
system and increase the guide wear and tear, due to a
higher load.
Lubricate the guides every six months (or 100 km of
operation or, again, 480,000 manoeuvres), using lithium
grease of a medium texture (grease for bearings). The
grease must be distributed on the guide and interstices
of the cage that contains the balls.
Before proceeding with the lubrication, clean the guides thoroughly in order to remove all possible
accumulation of dirt.
99
Maintenance
7.3.7. Maintenance of the adjustable discharge regulator

To dismount the various components of the flow regulator, proceed as indicated below:
Use curved nose pliers to loosen Unscrew the regulator cover Clean the adjusting screw groove
the regulator cover. completely, then remove it. with care.
Use a suitable screwdriver to Extract the seat located in the Remove the gasket from the seat
unscrew and remove the centre of the regulator body. and replace it with a new one if
adjustment screw located in the necessary.
centre of the cover.
Check the integrity of the gaskets installed on the regulator cover and adjustment screw; replace
them if damaged.
To remount the regulator components, follow the dismounting procedure in reverse order.
While reassembling the components, take care not to damage the sealing gaskets.
100
Maintenance
Adjustable discharge regulator calibration procedure

The regulator, located on the regulated discharge of the washer/filler, allow controlling the keg
filling speed, preventing the formation of foam.
The following procedure allows for a correct calibration of the regulator:
1. Close the adjustment screw of the regulator completely.
2. Place a keg onto the filling head and use the manual commands to pressurize it with CO2 at
the pressure normally used during production.
3. Use the manual commands to open the regulated discharge valve.
4. Open the adjustment screw of the regulator slowly; the pressure inside the keg must go to 0 in
about 3 seconds.
5. At the end of the adjustment, use the manual commands to close the regulated discharge
valve.
After calibrating the regulator, make sure that, during the fast filling phases, the regulated
discharge valve remains always open. If the valve closes temporarily, it means that the discharge
phase is too fast; in that case, close the regulator slightly.
The regulator is correctly set when the regulated discharge valve remains open during the whole of
the fast filling phase, without closing.
101
Maintenance
7.4. Maintenance of electrical parts

For a proper and effective operation, the electrical parts of the machine must be in perfect
conditions. This chapter provides indications concerning maintenance of the electrical system.
WARNING
Maintenance of electrical components must be carried out only by qualified personnel. Make sure the
machine is disconnected from its energy sources.
7.4.1. Bero proximity switches

This type of proximity switch is used to detect the position of mechanical parts in motion.
Their readable area depends on the model. To get a reliable value, place the sensor at a distance
shorter than the readable area from the element to be detected.
In the bero proximity switches with threaded body (see pictures below) there are two ring nuts for
both fixing and adjustment of the sensor; close to the connection plug you can also see a LED
signalling the output status.
Sensitive part
Connector
LED
Threaded part for

adjusting rings
Bero sensor Connector with pin configuration and diagram
To replace a proximity switch, unscrew and remove the connector, then unscrew the adjustment
ring nuts to release the sensor. Install the new sensor adjusting the ring nuts; once the best
position of the sensor has been found, carry out some manual tests to check that the sensor is
working properly. Make sure the PLC receives the signal; if it doesn't, check the sensor position
and the condition of the connection cable.
102
Maintenance
7.4.2. Cylinder position sensor

If there is a failure with one of these sensors, the machine stops in the position controlled by the
same sensor. The PLC waits for the sensor response to each movement: if it doesn't receive a
response, either the sensor is broken or faulty or it is not in the correct position.
How to replace a pneumatic cylinder sensor
• Turn off the main switch and lock it to cut off the switchboard power supply.
• Remove the connection cable connector
• Unscrew the fastening screw of the sensor
• Separate the sensor support from the pneumatic cylinder
• Pull out the sensor from the support and replace it with a new one of the same model
• Mount the sensor support on the pneumatic cylinder
• Screw the sensor fastening screw back in place
In order to mount the replacement sensor, carry out the following operations:
How to adjust the position of a pneumatic cylinder sensor
• Move the cylinder towards the sensor by means of the manual controls
• Loosen the fastening screw of the sensor
• Move the sensor horizontally in both directions in order to find the two points delimitating the
readable area of the sensor; a LED lights up on the sensor indicating the reading point.
• Place the sensor in between the two points defined in the previous step.
• Tighten the fastening screw of the sensor
Follow the above-mentioned procedure to position

the sensor so as to obtain the best operating area
and ensure a correct response to each movement of
the pneumatic cylinder.
The picture shows two sensors mounted onto a
cylinder. The arrows show how to move the sensor
in order to find the correct reading position.
103
Maintenance
7.4.3. Solenoid valves

Solenoid valves control the movement of cylinders and open/close pneumatic valves. Failure of a
solenoid valve may be due to a break of either its control coil or the valve.
Fig. A Fig. B
Check the solenoid valve operation by means of the relevant control in the operator panel; if the
solenoid valve doesn't react, try with a screwdriver on the mechanical control. Before replacing a
faulty solenoid valve, disconnect the power supply and close the mains air manual valve. Unscrew
the fastening screws on the defective solenoid valve (see fig. A).
Now it is possible to remove the solenoid valve and replace it with a new one of the same type.
Fig. B shows the group of solenoid valves with the faulty valve set apart.
Assemble the group following the above-mentioned steps in reverse order.
Check the solenoid valve group operation by means of the manual controls in the operator panel.
104
Maintenance
7.4.4. Pressure controllers

Pressure controllers ensure that air pressure doesn't drop below the minimum set point. The figure
below shows a Festo programmable pressure controller type SDE5 installed on a compressed air
adjustment and filtration assembly. In figure A you can see the pressure controller and its support
base.
Switching pressure adjustment:
• Connect the voltage supply;
• Open the mains air valve;
• Adjust the mains air pressure according to the operation set point;
• Press “Edit” on the pressure controller until the led starts blinking (Fig.B);
• Release the “Edit” push button in order to store the switching value;
• Check that the pressure controller switches over the electrical contact properly, according to the
air pressure variations.
Fig. A Fig. B
In case the pressure controller doesn't change the state even if mains air pressure and electrical
connections are correct, replace the controller.
Pressure controller replacement:
• Disconnect the mains air and power supply
• Remove the air pipe and unscrew the connector from the pressure controller
• Remove the pressure switch from its support base by means of a screwdriver
• Replace the controller with a new one of the same type
• Connect the air pipe and screw the connector on the pressure controller
• Connect the mains air and voltage supply
• Adjust the instrument
• Make sure the pressure controller switches over the electrical contact properly and the relevant
input in the PLC receives the signal
105
Maintenance
7.4.5. Pressure analog sensors

These precision instruments measure the pressure of liquids or gases in different points of the
plant. The output current (4-20mA) is proportional to the pressure detected. The pictures show a
Endress+Hauser PMP23 pressure sensor and its connection diagram:
Cerabar PMP23 E+H pressure sensor Connections
The minimum output current is 4mA. In case of failure, the current is absent or definitely lower than
4mA. This value is constantly controlled by an analogue card in the PLC. If any failures are
detected, the PLC immediately generates an alarm.
In order to replace a faulty pressure sensor, cut off the switchboard power supply, make sure no
pressurized liquids or gases reach the converter, unscrew the fastening screw of the connector
and remove the connector. Unscrew the handle of the sensor fastening clamp and remove it from
its seat.
Install the new sensor following the above-mentioned steps in reverse order. To prevent leakages,
check the integrity of the o-ring joint inside the instrument fastening clamp and replace it if
damaged.
If the sensor is placed horizontally, block it in such a way that the connector cable inlet is oriented
downwards. This way, no liquid can penetrate inside the connector.
106
Maintenance
7.4.6. Dual threshold thermostats

This type of thermostat is provided with two different tripping thresholds, that allow the automation
to react in a different way whenever the relevant temperature values are reached in the pipes or
tanks of the plant.
The thermostat is provided with a regulation ring nut for each one of the two thresholds; rotate the
ring nuts to modify the threshold that causes the relevant contact to close whenever the
temperature value set is reached.
A third ring nut allows locking the other two after setting the thresholds.
Ring nut for Set 1
Ring nut for Set 2
LED Set 1
LED Set 2
Fastening ring nut
Fig. A Fig. B
Fig. A shows the thermostat, with the regulation ring nuts (orange) and locking ring nut. Fig. B
shows the thermostat connector connections.
During operation, two yellow LEDs come on whenever the two tripping thresholds are reached.
To replace a temperature sensor, proceed as follows:

• Disconnect the switchboard power supply;
• Empty the pipe or tank where the thermostat is installed;
• Unscrew the ring nut of the connector in order to separate it from the thermostat;
• Unscrew and remove the thermostat from its seat, using a suitable wrench;
• Introduce the new thermostat in the seat, screw it and orient it so that, when the connector is
introduced, the cable input is oriented downwards;
• Tighten the thermostat with care, using a suitable wrench;
• Introduce the connector in the thermostat and screw the ring nut;
• Perform some tests to make sure the thermostat works properly.
For further information, see the relevant documentation.
107
Maintenance
7.4.7. Ultrasonic level limit switch for liquids

It detects the presence of liquids in pipes. Being a very delicate device, the relevant maintenance
operations shall be carried out with special care. Failure of this type of probe may be due either to
an actual break or, more often, to an excess of scale deposits on the sensitive elements (fork)
submerged in the liquid.
Clean the probe with a brush, rubbing the fork delicately.
In order not to damage the probe:
• Do not use hammers or any similar object to remove scale deposits
• Do not try to enlarge, close or bend the fork
• Do not try to lengthen, shorten or cut the fork
• Handle the probe holding the body and not the fork
During operation, the fork vibrates symmetrically in its resonant frequency. The frequency changes
when the probe is submerged in the liquid. An electronic circuit detects the frequency change and
actuates the switch. In case of failure or lack of power supply, the switch remains open. Two LEDs
on the probe body show the operating state. The tables show the status of the two LEDs in the
different operating modes.
Green LED: the probe is powered.
Red LED: the electronic switch is open.
Remark: It is possible to switch over the output status by simply approaching a magnet to the
probe body.
In order to replace a faulty level probe, cut off the switchboard power supply, empty the tank where
the probe is installed, unscrew the fastening screw of the connector and remove the connector.
Unscrew the instrument and remove it from its seat using a proper wrench. Install the new probe
following the above-mentioned steps in reverse order. Wrap several turns of Teflon around the
threaded part or the instrument in order to prevent leakages. Fix the instrument in position so that
the connector input is oriented downwards. This way, no liquid can penetrate the connector.
For further information see the documentation annexed to the present manual.
108
Maintenance
7.4.8. Liquid presence detection probes by impedance spectroscopy

It detects the presence of liquids in pipes. Being a very delicate device, the relevant maintenance
operations shall be carried out with special care. Failure of this type of probe may be due either to
an actual break or, more often, to an excess of scale deposits on the sensitive element (fork)
submerged in the liquid.
Clean the probes using a cloth (with descaling solution in case of presence of scale deposits),
rubbing the sensitive element delicately.
Do not use hammers or similar tools to remove scale deposits, or you’ll irretrievably damage the
probe.
The drawing on the right shows the position of the pins of the connector and the probe connection
diagram.
In order to replace a defective level probe, cut off the switchboard power supply, empty the tank or
pipe where the probe is installed, unscrew the fastening ring of the connector and remove the
connector. Unscrew the instrument and remove it from its seat using a proper wrench. Install the
new probe following the above-mentioned steps in reverse order. Wrap several turns of Teflon
around the threaded part or the instrument in order to prevent leaks. Fix the instrument in position
so that the connector input is oriented downwards. This way, no liquid can be driven by the cable
towards the connector.
Perform some tests to make sure the probe works properly.
For further information see the documentation annexed to the present manual.
109
Maintenance
7.4.9. Electromagnetic flow-meters

The electromagnetic flow-meter (Fig. A) controls the quantity of product introduced into the
containers during production. The instrument provides a series of output pulses which is
proportional to the flow of product passing through it.
Fig. A Fig. B
Possible failures of the instrument are indicated by the closure of the status contact.
In case of failure, before replacing the faulty instrument, make sure the product manual valve is
closed and the pipe where the instrument is installed is not pressurized. Then unscrew the cover to
gain access to the terminal strip and disconnect the electrical cables. Loosen the nuts that fasten
the instrument onto the pipe and remove it.
Install the new instrument performing the above mentioned operations in reverse order.
For further information, see the relevant technical documentation.
110
Maintenance
7.5. Maintenance of washing and filling heads

A regular maintenance of the head components is essential in order to ensure effective operation
of the machine. Poor maintenance and excessive wear of the seals may cause machine failures,
significant downtimes for repairs and consequently a reduced production.
REMARK
To guarantee the machine efficiency, all the seals of the heads must be replaced at least once a year.
The exploded views in the next pages show the position of all the elements composing the
washing and filling heads.
The cross-sectional views show the position of all the seals installed on the treatment heads.
DANGER
Perform all maintenance and cleaning operations only after disconnecting the machine from its energy
sources and closing the fluid shut-off valves (compressed air, steam, etc…).
To remove the head from the machine, disconnect all the pipes connected to the head and
unscrew the screws which fix it to the machine.
Make sure you disassemble the head components in a clean location free of dust. Before
dismounting them, make sure you use the most adequate tools in order not to damage them.
111
Maintenance
7.5.1. Washing head exploded view
1 7
8
2
9
10
6
3
11
4
12
1 Centering ring 7 Joint fastening ring

2 Seal gasket 8 Fastening ring
3 Washing head body 9 Piston coupling head
4 Head support base 10 Piston support base
5 Head support columns 11 Plunger piston
6 Rod* 12 Rod antirotation guide
*Component shown in the following pages
112
Maintenance
7.5.2. Filling head exploded view
13
3
12
14
6
11 8
7
10
1 Centering ring 8 Piston coupling head

2 Seal gasket 9 Piston support base
3 Filling head body 10 Plunger piston
4 Head support columns 11 Rod antirotation guide
5 Rod* 12 Discharge valve*
6 Joint fastening ring 13 Product inlet valve*
7 Fastening ring 14 Filling probe group
*Component shown in the following pages
113
Maintenance
Assembling of the filling head valves
000138191
000048426
000048356 Product inlet valve
000138194
000214599
000138191
000048426
000048356
Residue limitation
valve
000138194
000214599
114
Maintenance
Assembling of the filling probe group
REMARK
One of the two filling probes showed hereafter is mounted on the filling head:
000048356
000048354
000098034
000098034
115
Maintenance
7.5.3. Position of the head gaskets

Washing head
The drawing hereunder indicates the codes to mention when you order the gaskets and their
relevant position on the washing head:
000039270
000048475
000098034
000048475
000225189
000225187
000225189
000098034
000225189
000225188
000123248
116
Maintenance
Filling head
The drawing hereunder indicates the codes to mention when you order the gaskets and their
relevant position on the filling head:
000048475 000039270
000048356 000048356
000214599 000214599
000048426
000048426
000138191
000138191
000138194
000048475
000225187 000138194
000225189
000225189
000225189
000225188
000123248
117
Maintenance
7.5.4. How to separate the rod from the head

In order to extract the rod from the head, perform the operations indicated hereunder: Before
reintroducing the rod in the head, submerge it in hot water for some minutes and then follow the
same procedure in reverse order:
1 2
The small metal hook marked in the picture Extract the metal hook from its seat using a
keeps in place the joint that connects the rod to proper wrench
the cylinder
3 4
Lift the joint fastening ring in order to free the Remove the ring that connects the rod to the
ring connecting the rod to the cylinder cylinder
5 6
Lower the joint fastening ring in order to free the Remove the rod by pulling it upwards from the
rod completely head top
118
Maintenance
7.5.5. How to assemble the rod

The figure below shows the exploded view of a rod complete with plunger, all its components and
their mounting position.
000048475
Unscrew
000048475
000225189
000225187
000225189
000225189
000225188
Unscrew
*This component varies according to the type of spear fitting used
119
Maintenance
How to install the seals

It is recommended to dip the 000225189-type seal in hot water for a few minutes before installing it
on the stem.
Spread the grease (available with the spare parts kit upon request) on the whole surface of the
seals, using your fingers.
For a correct installation, Insert seals in their seats according to the instructions below.
Use the special tool shown in the picture to

1 install the gasket on the lower part of the
rod. Insert the tool in the rod as shown.
Place the gasket on the tool and push it until
it reaches its proper position.
Once the correct position has been reached,
remove the tool from the rod while holding
the gasket so that it doesn't move.
Lower part of the rod
The gasket can be definitely fixed in its

2 proper position by means of the tool shown
in the picture.
Introduce the tool on the lower part of the
rod so as to push the gasket to the correct
position.
Remove the tool from the rod, rotate it by
180 degrees and proceed with gasket
assembling on the upper part of the rod.
Lower part of the rod
Use the special tool shown in the picture to

3 install the first gasket on the upper part of
the rod. Introduce the tool in the rod as
shown. Place the gasket on the tool and
push it until it reaches its proper position.
Once the correct position has been reached,
remove the tool from the rod while holding
the gasket so that it doesn't move.
Upper part of the rod
120
Maintenance

in the picture.
Introduce the tool on the upper part of the
position.
Remove the tool from the rod and assemble
the sliding guide.
After installing the sliding guide, use the

5 special tool shown in the picture to install the
second gasket on the upper part of the rod.
Introduce the tool in the rod as shown. Place
the gasket on the tool and push it until it
reaches its proper position. Once the correct
position has been reached, remove the tool
from the rod while holding the gasket so that
it doesn't move.

in the picture.
Introduce the tool on the upper part of the
position.
Remove the tool and complete the
assembling of the plunger.
121
Maintenance
7.5.6. How to replace the plunger

In order to replace the plunger, perform the following operations:
1. Cut off the main switch and lock it.
2. Cut off the mains air and make sure the pneumatic circuit is not pressurized.
3. Place the wrench (Fig. A) onto the plunger: the notches on the wrench must match the pins
on the plunger as shown in Fig. B.
4. Place the wrench of the ring on the wrench of the plunger and rotate anticlockwise to unlock
the plunger (Fig. C).
5. Unscrew the plunger completely (Fig. D) and then remove it.
6. Install the new plunger following the procedure in reverse order.
Fig. A Fig. B
Fig. C Fig. D
122
Maintenance
7.5.7. How to replace the top seal

In order to replace the top seal, perform the following operations:
1. Place the wrench (Fig. A) on the ring nut.
2. Turn the wrench counterclockwise in order to loosen the ring nut (Fig. B).
3. Remove the ring nut.
4. Remove the seal and replace it with a new one (Fig. C).
5. Place the ring nut back in position and tighten it with the wrench shown in Fig. A.
Fig. A Fig. B
Fig. C
123
Maintenance
124
Dismantling
Chapter 8: Dismantling
8.1. Deactivation of the machine
Once its useful life is over, the machine must be deactivated, making sure that the row materials
which compose it can be recycled.
REMARK
Co.Mac declines all responsibility for any damage to people, domestic animals or things caused as a
result of either improper use of single parts of the machine or use in environments that do not comply with
the characteristics indicated.
DANGER
Deactivation and dismantling operation shall be carried out only by properly trained and equipped
personnel.
In order to deactivate the machine, proceed as follows:

1. Turn it off.
2. Cut off the power supply and disconnect the supply cable of the main switchboard.
3. Close the manual valves of all utilities (liquids and gases).
4. Depressurize all pipes.
5. Disconnect the pipes of all utilities.
6. Separate the different sections of the machine.
After dismantling, all residual risks are eliminated.
WARNING
The machine is made of non-biodegradable materials. Take the machine to an authorized waste disposal
centre. Do not dispose of the machine components in the environment after dismantling.
DANGER
Before disposing of the machine, remove all traces of dangerous substances and pollutants from it. Use
suitable reagents to perform the controls required and make sure the machine has been completely
decontaminated.
WARNING
It is absolutely forbidden to disperse pollutants into the environment, such as oil and greases; their
disposal must follow the regulations in force.
125
Graphic version 3.2
14691MAN_EN
Via G. Garibaldi, 34N - 24040 Bonate Sotto (BG) Italy

Tel. +39 035 499 4211 - Fax +39 035 993 090 - info@comacitalia.it - www.comacitalia.it

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Via G.

Garibaldi, 34N - 24040 Bonate Sotto (BG) Italy

Philter Brewing Pty Ltd

4.5.3. Utilities at customer's charge ..................................................................................................... 33

7.3.1. Pneumatic system ...................................................................................................................... 92

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Chapter 1: General information

1.2. Proprietary information

1.3. Manufacturer identification data

Via Garibaldi, 34N – 24040 Bonate Sotto (BG) Italy

1.4. Machine identification data

1.5. Use of the machine

Space required for machine installation

1.5.2. Improper use

In particular, use of the machine is forbidden:

1.6. Description of the machine

This page has been intentionally left blank

Chapter 2: Safety information

Before using the machine, operators and maintenance technicians must:

2.2. Safety criteria applied

2.2.1. Safety measures

Mobile safety devices

2.2.2. Further protections and safety devices

2.4. Health and safety information

During machine operation:

It is forbidden to disconnect safety devices and emergency stops during production.

During maintenance or repairs:

Disconnect the main switch and lock it.

Always wear personal protective equipment.

Furthermore, it is strictly forbidden to:

2.5. Safety system reset

To reset safety systems after an emergency stop, proceed as follows:

2.5.2. Reset of safety limit switches

2.6. Protection from contact with energized elements

2.7. Visual/acoustic warnings

Image Device Machine status warning

• It emits an intermittent sound whenever an alarm status occurs.

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Chapter 3: Machine characteristics

3.1.2. Overall dimensions

3.1.3. Utilities required

• Air pressure for pneumatic circuit ........................................... 6.0............................................ bar

3.2. Constructional characteristics

4.2. Loading and transport

Wooden crate ready for shipment Fig. A

4.3. Lifting operations

The picture shows, for example, the force lifting systems

In case of machine components whose dimensions prevent 30°

the use of bands or chains converging in a single point, we

Do not overlap or cross two lifting means

4.4. Unloading and inspection

The installation environment must comply with the following characteristics:

4.5.1. Storage conditions

4.5.2. Tips on installation

4.5.3. Utilities at customer's charge

Backpressure gas supply for filling

4.5.4. Connection to the power supply

Direct connection to the main switch:

3-phase + neutral + earth power supply 3-phase + earth power supply

Connection to a dedicated terminal strip:

3-phase + neutral + earth power supply 3-phase + earth power supply

4.5.5. Connection to the earthing system

Machine positioning and levelling.