Operating Instructions

FAMIX TurboDigi Mixer with

Semi-automatic control
Type TP700

Contents
P. 1 Contents
P. 2 Erection and assembly
P. 3 Preparation
P. 4 Start-up
P. 5 Production
P. 6 End of production
P. 7 CO2 correction
P. 8 Bar graph
P. 9 Curve
P. 10 Product memory
P. 12 Parameter
P. 15 Cleaning and disinfection
P. 18 Special functions
P. 19 Vacuum deaeration
P. 20 Ratio controller
P. 22 CO2 controller
P. 15 CO2 adjustment
P. 24 Alarms
S. 26 Operation and alarm displays

BAFAMIXTDTP700Englisch.docx, 01.08.2013 1
Erection and assembly

The equipment is supplied internally piped and wired on a common base plate.

It must be exactly aligned at the installation point by means of the spindles and
floor plates provided, using a spirit level.

The following must be connected:

1.) Treated water direct to the mains, inlet pressure 3 bar minimum.

2.) Syrup, maximum supply pressure 1.5 bar.

3.) CO2, inlet pressure min. 12 bar, max. 15 bar.

4.) Air for CO2 controller, inlet pressure 6 bar, operating pressure 6 bar, set at
the fitted reducing valve.

5.) Electricity according to information on switch cabinet.

Terminals L1, L2, L3, N and PE are provided in the switch cabinet. Note
correct direction of rotation.

Caution

Before connecting to the installation, newly laid pipes must be thoroughly rinsed
or blown through. The installation has undergone a trial run, cleaning and
rinsing at the factory. However, it is absolutely essential to rinse, clean and
disinfect it again before starting production.

Cleaning and disinfection can be performed with appropriate solutions by

immersion or CIP, possibly hot. We particularly recommend disinfection with hot
water; the equipment can also be treated with steam.

2
Preparation

Switch on mains switch and control voltage.

Check the right position of all valves for production:

Swing bend inlet panel at position production.
CIP valve at panel closed.
Water inlet valve open.
Syrup inlet valve closed until syrup is supplied.
Valve for vacuum pump open.
Flood valve water tank closed.
Valve spray ball water tank closed.
Valve spray ball product tank closed.
Safety valve product tank open until tank has been flooded.
CO2 inlet valve closed until tank has been flooded.
Product outlet valve closed until product is ready, then open.

All switches at the cabinet are in “0” position.

Now the product tank is flooded as follows:

1.) Open safety valve at the product tank.

2.) Switch main selector switch in position "Production". Wait until water tank
has been filled up to maximum level.
3.) Switch water pump, in position "Man".
Water pump starts. Wait until product tank is flooded and water flows
out of the flooding pipe.
4.) Water pump switch in position "0".
5.) Close safety valve at the product tank.
6.) Open CO2 valve, now CO2 flows in the product tank if a value for the CO2
control has been entered in the CO2 controller.
7.) Open drain valve of the product tank or push the water in the tank to the
filler with CO2 gas until the tank is completely empty.

The product tank needs to be deaerated as described every time the

CO2 pressure has been released from the tank to get all air out off
the tank.

3
Start-up

Switch main selector switch to production. The production display appears.

Touch the rectangle for the product name to open the production start display:

To choose a product touch the ▼-key next to the product name line and a list of
the stored products will open.
Touch the desired product in the list so that the name is shown in the product
name line.
Transfer the data to the control by touching the Transfer button.

If soft drinks are produced the syrup part has to be supplied with syrup now.
To do this open the syrup inlet valve and the drain valve of the syrup tank to
drain all water remaining in the pipe and the tank.
Switch main selector switch to “Production” and the switch of the external syrup
pump to “Man”.
Leave the drain valve open until all water arriving through the pipe has been
drained. If proper syrup arrives close the drain valve and open the vent valve to
fill the syrup tank. If the tank is completely full close the vent valve.
Take care that the syrup contains absolutely no air when it is pumped to the
plant.
Open the sample valve at the syrup pump to fill the pump with syrup too.
Switch the external syrup pump switch to “Auto”.

Caution ! Never supply syrup to the machine if there is no pressure in the

product tank. As the syrup will be pushed through to the product tank.

Make sure that CO2 pressure and mixing ratio are adjusted correctly. If yes the
mixer is ready for production.

4
Production

Make sure that all manual valves are in the correct position. There must be no
alarm message on the display. In case of a message set the corresponding
valve correctly and press the “Quit” button to continue.

Check the positions of the switches on the control panel :

Main selector switch in position “Production”
Water pump “Auto”
External syrup pump “Auto”
Syrup pump “Auto”

The water inlet valve opens automatically when there is low level in the water
tank.
The vacuum pump starts automatically.

Push the “Start” button to start the mixer.

When you see syrup in the sight glass on top of the syrup pipe push the “Stop
button”.
Drain the product tank. Now all remaining water is pushed out of the system.

Then switch on again and run the machine for 15 - 30 sec (about 50 l of
product) before you switch off.
Now you can take a sample and read the Brix result.

To push all remaining water out of the pipe between the mixer and the filler the
pipe and the filler should be flooded with product. To do so open the beverage
outlet valve slowly. After the flooding close it again.

If the Brix of the sample is correct the FAMIX is switched on again and runs until
the level control switches off automatically.

If the sample is not correct change the ratio setting accordingly and repeat the
last step until you get proper product.

Check if the filler is pressurized correctly, the minimum pressure on the filler
should be the carbonation pressure at the FAMIX. Then open the beverage
outlet valve slowly and switch on the product pump. The required outlet
pressure can be adjusted in the display at Prod.pump nom..

When the filler vessel is filled and the inlet valve closes bottling can be started.

Check Brix and CO2 regularly and correct if necessary.

While production is running you can follow it on the display.

5
CO2 :
Shows the adjustment for the CO2, the carbonation pressure and the product
temperature. Also the calculated CO2 value is displayed.

Syrup ratio :
Shows the adjusted mixing ratio, the flowrates and the total consumption of
water and syrup.

Prod.pump:
Here the outlet pressure to the filler can be adjusted and the actual pressure is
shown.

In the message text window the alarm messages are shown.

End of production

To end production wait until the syrup is empty in the sight glass of the syrup
inlet. Then close the syrup inlet with the push button at the rear side of the
mixer.

Now touch the End of production key. Then the product pump continues until
the product tank is also empty. When the low level probe is reached the product
pump will stop and the CO2 pressure is raised to the adjusted outlet pressure
level.
Now the gas pushes the product out of the product pipe to empty it completely.
When the filler is empty too close the product outlet valve.

6
CO2 correction

If you find a difference between the CO2 display on the FAMIX and your
laboratory result in the bottle you are able to calibrate CO2 adjustment. When
you touch on the actual value in the production display you will see the above
correction display.

Enter the laboratory result measured in the bottle and touch the Save button.
The control calculates a correction factor and changes the carbonation pressure
accordingly, so that the mixer display will show the same reading as measured
in the bottle.

To store this correction in the product memory, touch the upload symbol in the
recipe and then store it with the disk symbol. Then this product is calibrated for
the next production run and you will get the proper result in the bottle from the
beginning.

Therefore it is important that you enter a recipe for each product and each bottle
size in the product memory.

With the home key you return to the production display.

7
Bar graph

The bar graph shows easily the status and the actual values of the Brix(if
connected) and CO2 measurement.

The status is shown by the colour of the graph:

Not in operation (no product is started)

Grey
Status Manual (product is started but monitoring not activated)
Blue
Status Auto (product is started and monitoring activated)
Green
Alarm (Actual value is out of standard)
Red

If the bar graph is standing in the middle of the range the actual value is close to
the standard.

8
Curve

This graph shows the actual values over time.

The yellow line is the actual value, the black lines are the high and low limits.

With the arrow keys you can move the time position of the graph.

The status is shown by the colour of the graph:

Not in operation (no product is started)

Grey
Status Manual (product is started but monitoring not activated)
Blue
Status Auto (product is started and monitoring activated)
Green
Alarm (Actual value is out of standard)
Red

9
Product memory

In the product memory is stored all data of the products. Only if the products are
stored they can be transferred to the production start display.

To enter a new product or modify an existing one please proceed as follows :

Enter new product

Push the new-key ( ) and then on the head line to enter a name.

Now select one product parameter after the other and enter the value with the
numeric keyboard and push ENTER.

You have to enter :

Ratio : The mixing ratio for this product

Prod.Pump : The set point for the outlet pressure of the product pump.

CO2 : CO2 setpoint and limit for the product

Brix : Brix setpoint and limit for the product

Finally you store the recipe with the disk key ( ).

10
Modify existing product

Select with the▼-key the product you want to change.

The product is shown on the display.

Now modify the parameters.

Finally you store the recipe with the disk key ( ).

Upload a product

If you want to store the product which is running in production in the moment
you can use the upload function.

Select with the▼-key the product you want to change.

The product is shown on the display.

Push the upload-key ( ).

After that you will see the updated parameters for the product.

Finally you store the recipe with the disk key ( ).

With the home key you get back to the standard display.

11
Parameter

For a proper function of the mixer different parameter settings are required.

These settings are usually set by us and should not be modified. If a new input
is required this should be carried out by authorized personal only.
Username and password are required to enter this level.

Start-up delay
This is the time for the flow control alarm delay when the pumps start.
Alarm delay measurement
Time before the mixer stops with Brix (if connected) or CO2 alarm.

12
Ratio controller :

Max./Min. flow water show the max./min. flow rate of the water in l/min
according to the data sheet of the mixer.
Pulse rate shows the number of pulses per litre at 1000 Hz according to the
data sheet of the mixer.
Max./Min. flow syrup show the max./min flow rate of the syrup in l/min according
to the data sheet of the mixer.
Pulse rate shows the number of pulses per litre at 1000 Hz according to the
data sheet of the mixer.
These figures are used to calculate the flow rate from the output frequency of
the flow meter.

Alarm hysteresis:
Allowed deviation from the set point in % before the controller gives an alarm
signal.
Alarm delay:
Time in s before the controller gives an alarm signal.
Gain:
Used to adjust the speed of the control. A higher value makes the controller
quicker and a lower one slower. Can be modified in 0.1 steps only. Should not
be to high to avoid swinging of the control.

13
CO2-Parameter:

Temperature :
Here can be entered the product temperature manually if the temperature
sensor fails. Please be aware that no variations in temperature are read any
more.

Hysteresis Overpressure:
The allowed pressure over the carbonation pressure before the overpressure
valves opens (standard 0.2)

Unit:
You can choose between g/l and vol CO2.

14
Cleaning and disinfection

The FAMIX is suitable for all kinds of cleaning and disinfection processes :

1.) Immersion cleaning and disinfection.

Please observe manufacturer reaction times.
2.) CIP cleaning.
The machine can be part of the whole automatic CIP process.
3.) Hot disinfection with hot water up to 85° C or steam up to 110° C.

For all types of cleaning the cleaning agents are supplied through the syrup
pipe.

For CIP cleaning the CIP pump should be designed for min. 3 bar pressure and
the nominal capacity of the mixer. Only the CIP pump is used for cleaning. All
FAMIX pumps run only from time to time.

Sample, vent, and drain valves must be slightly open to rinse them.

The cleaning circuit is completed by the pipe to the filler, the filler and the return
pipe to the CIP plant.

The contact time for disinfection with hot water of 85° C should be at least 20
minutes.

For disinfection with steam a pressure of 0.5 bar is enough to push through the
whole system.

To start cleaning switch the main selector switch to cleaning position.

15
CIP cleaning
This is a complete cleaning of all parts of the mixer.
The CIP supply needs to be connected to the syrup inlet of the mixer.

Check all valve positions:

CO2 inlet valve closed.
Swing bend inlet panel at position cleaning.
CIP valve at panel open.
Syrup inlet valve open (this is the CIP supply)
Water inlet valve closed.
Valve for vacuum pump closed.
Flood valve water tank open until tank is completely filled, then closed.
Valve spray ball water tank open.
Valve spray ball product tank open.
Safety valve product tank open until tank is completely filled, then closed.
Product outlet valve closed until product tank is completely filled, then open.
All sample and outlet valves are a little bit open.

At switch cabinet :
Water pump, metering pump (external syrup pump if it should run) in position
Auto.
Main selector switch in position cleaning.
Quit all alarms.
Push operation Start.

The pumps will run only until the maximum level in the product tank is reached.
They can also be started manually for a short time, by switching the desired
pump to manual.
The product pump can be started at any time. It can also be used to empty the
mixer between different cleaning agents.

Rinsing
This is a cold or hot water rinse of the syrup and product side, e.g. at product
change over.The water (3 - 6 bar) has to be connected to the syrup inlet.
Check valve positons:
CO2 inlet valve closed.
Swing bend inlet panel at position production.
CIP valve at panel closed.
Syrup inlet valve open (this is the water supply)
Water inlet valve open.
Valve for vacuum pump open.
Flood valve water tank closed.
Valve spray ball water tank closed.
Valve spray ball product tank open.
Safety valve product tank open until tank is completely filled, then closed.
Outlet valve product tank open until product is rinsed out, then closed.
Product outlet valve closed until product tank is completely filled and outlet
valve is closed, then open.
All sample and outlet valves are a little bit open.

16
At switch cabinet :
Water pump in position 0.
Metering pump (external syrup pump if it should run) in position Auto.
Main selector switch in position cleaning.
Push operation Start.

The pumps will run only until the maximum level in the product tank is reached.
They can also be started manually for a short time, by switching the desired
pump to manual.
The product pump can be started at any time. It can also be used to empty the
mixer.

Cleaning parameters

Speed product pump during cleaning.

Sets a fix value for the speed of the product pump during cleaning.
Change this setting if you need more or less pressure arriving at the filler during
cleaning.

To leave the display use the home key.

17
Special functions

The following special functions are available :

Language
Use the flags to select the desired language.

Cleaning touch:
After you have touched this key you are able to clean the Touch Panel for 30
secs. Please use a moist soft tissue only.

Runtime Stop
Stops the program and opens the operating system level of the display.

Control Panel.
Allows adjustments of the display and software backup.

18
Function of the vacuum deaeration :

The treated water is connected to the water inlet of the vacuum tank with a
minimum supply pressure of 3 bar. The vacuum tank is under 98 % vacuum.

The air is sucked out of the tank by the vacuum tank and the tank is filled with
deaerated water. The level in the tank is controlled by probes.

In the standard version the machine has a one step deaeration which achieves
a deaeration efficiency of 85 - 90 %.

To reach a greater efficiency we recommend our two step deaeration.

19
Method of operation of the digital ratio controller

The controller operates as a sequence controller with the water as master flow
Qw and syrup as the slave flow Qx.
As the water starts to flow the water flowmeter send pulses to the Qw input of
the controller. With these pulses the controller forms, together with the set ratio
an output signal of 4 - 20 mA for the frequency converter of the syrup metering
pump.
The syrup flow is also measured with a flowmeter which sends pulses, to the Qx
input of the controller.
By this means it is possible to control and monitor the adjusted ratio
continuously as the incoming pulses of water flow and syrup flow have always
to be in the adjusted set ratio.

The adjusted is calculated by dividing 100 through the ratio.

e.g.:
A ratio of 1:5 (1 part syrup, 5 parts water) means that 100/5 = 20 % of the water
has to be added as syrup. So you have to adjust 20.00 % as the ratio.
(The ratio 1:5.5 is adjusted as 100/5.5 = 18.18 % )
(The ratio 1:4.4 as 100/4.4 = 22.72 %.)

The ratio between water and syrup is adjusted in percent with two decimals.

To enter a value push the value. Type in the figures with the keypad and push
the ENTER key.

When you start a product from the product memory the ratio is automatically
set.

To check the adjusted ratio you can use the flowrate display:
Here one can see the flow rate of water and syrup in l/min and the total
consumption in l.
To check the correct functioning of the controller you can divide the water
flowrate by the set ratio and the result should be the syrup flowrate shown.
E.g. if the water flowrate shows 300 l/min and the ratio is 1 : 5 (= 20 %) the
syrup flowrate should read 60 l/min.

An increasing water flowrate creates a higher syrup flowrate and a decreasing

water flow results in a smaller syrup flow.

To avoid inaccuracies in stop and go operation the position of speed of the

syrup pump is held during a stoppage so that the plant restarts with the same
speed again. This eliminates any hunting effect of the control function on start
up.

To reset the counters you can use the F2 Zero key.

20
If the Brix in the syrup is correct the Brix in the beverage will be very close to
the standard with these adjustments. To adjust the ratio to the exact Brix
standard only the two decimals should be changed. A higher figure for the ratio
causes a higher Brix in the product and a lower figure a lower Brix.

For a ratio of 20.00 % and a Brix in the product of 10.00 each second decimal
will change the Brix x/- 0.005 and each first decimal +/- 0.05.

Generally any ratio can be adjusted up to a maximum ratio of 1:4 in the

standard version. So even if the Brix in the syrup is not correct the product can
be adjusted to the desired standard.

Of course it is possible that the setting has to be changed at a syrup tank

change.

Before you start up the plant please enter the theoretically calculated value or
an empiric value for the product.

You should store your readings in the product memory as described later on.

21
FAMIX CO2 pressure-temperature ratio controller

For the production of soft drinks the product water or the product is carbonated
with CO2 gas. To maintain a constant CO2 content in the product a precise and
quick control system is required.

The FAMIX BMS7 CO2 control system reads the carbonation pressure and the
temperature of the product and compares it with the setpoint for the CO2
content. Using a high accurate control valve the carbonation pressure is
controlled automatically and the CO2 content in the product is maintained
independent of the product temperature.

Layout drawing :
S7
Regler
Controller

Druck
Pressure

4 - 20 mA

CO2 24 V DC

Regelventil
Druck- Überdruckventil
Control valve
behälter Overpressure valve

Pressure
tank

Temperatur

CO2

As variations of the temperature will modify the CO2 content the carbonation
pressure is automatically controlled in relation to the temperature so that the
CO2 content remains constant.

If the carbonation pressure is higher than required because of compression in

the tank or a drop of the temperature an overpressure valve opens to release
the pressure and avoid over carbonation.

So the BMS7 CO2 control system guarantees a constant CO2 carbonation

independent of temperature variations and stops and starts of the plant.

The display shows the actual pressure and temperature and also the set point
for the control.
From these readings a theoretical CO2 content is calculated which can be
calibrated to the result in the bottle using a correction factor.

22
Mixer CO2 adjustment

Enter the required CO2 content in the product.

When the filler has been started, check the CO2 content in the bottle or can and
enter the result in the correction display and store the new setting in the product
memory. So when you start the product next time the carbonation pressure will
be adjusted correctly.

With the butterfly valve "Ø 4 mm" you can reduce the CO2 content without
changing the carbonation pressure. This is interesting for low carbonated
products and for products which tend to foam.

With the butterfly valve "Ø 0 mm" you can stop carbonation completely but still
pressurize the product tank.

To find the exact CO2 content in the bottle please proceed as follows :
Take a bottle from the conveyor.
Turn over the bottle 2-3 times.
Place the bottle and wait until the product has calmed down again i.e. no
bubbles are moving in the bottle.
Connect the pressure tester.
Push the tester through the capsule and release the head pressure.
Shake the bottle or start an automatic tester until the pressure is not increasing
any more.
Read the pressure and measure the temperature in the bottle.
With temperature and pressure you can read the CO2 gas volume from a chart
or a slide rule.
Only as described above you are able to do an exact measurement of the CO2
volume in the bottle.

23
Alarms

On low level of water, syrup or CO2 the plant switches off and the alarm is
shown on the display.

All motors are protected by overload relays. If one relay is actuated the whole
plant stops and the alarm is shown on the display. Open the switch cabinet
reset the motor starter and quit the alarm.

If the ratio controller cannot maintain the adjusted ratio the plant will also switch
off show a corresponding message.

This is possible e.g. if the necessary syrup quantity corresponding to the

adjusted ratio cannot be supplied because of air in the syrup pipe or a water
flow rate higher than 100 %. Also the ratio should not be adjusted higher than
25.00 % (=1:4).

If the controller has switched off the plant first check the syrup supply to the
mixer.
To restart the metering pump switch can be switched off and on again to reset
the controller. This clears the memory of the controller and resets the alarm.
Then the plant can be started again. If the controller switches off again check
the syrup pump and make sure that there is absolutely no air in the syrup pipe.

In case of an alarm find out first what the reason for the alarm was and repair
the fault. Then push Quit to restart the plant. The machine will never restart
automatically.

If the same alarm comes up again immediately please do not start the plant
several times but check what the reason for the lack of water, syrup or CO2 is
and make sure that all ingredients are supplied correctly. Otherwise we cannot
guarantee a correct function of the ratio control.

For a low level alarm of beverage terminals to connect an alarm signal are
provided.

Together with all alarms a red alarm light is switched on.

With a potential free contact the bottle stopper of the filler can be activated or
the whole plant can be switched off.

General remark

If the plant shows electrical or electronic faults only authorized personal should
look after the plant.

If you are in doubt please contact our service department.

24
A history of the alarms can be seen in the alarm archive:

Use the Delete key to delete all messages.

25
Operation and alarm displays

Message

FAMIX TD in production Mixer is running in production mode

FAMIX TD in cleaning Mixer is running in cleaning mode

Swing bend water not at You want to start production but the swing
production bend is not in correct position

Valve vacuum pipe closed The valve in the vacuum pipe is closed for
production. Open the valve

Valve vacuum pipe not closed The valve in the vacuum pipe is not closed
for CIP. Close the valve

Valve spray ball vacuum tank The valve for the spray ball vacuum tank is
closed closed for CIP. Open the valve

Valve spray ball vacuum tank The valve for the spray ball vacuum tank is
not closed not closed for production. Close the valve

Valve spray ball product tank The valve for the spray ball product tank is
closed closed for CIP. Open the valve

Valve spray ball product tank The valve for the spray ball product tank is
not closed not closed for production. Close the valve

Overload vacuum pump Switch on again the overload switch in the

cabinet.
Overload water pump Switch on again the overload switch in the
cabinet.
Overload syrup pump Switch on again the overload switch in the
cabinet.
Overload product pump Switch on again the overload switch in the
cabinet.
Low level water No water in the vacuum tank.

Low level syrup No syrup in the sight glass.

Low level product tank No product in the product tank

Low level air pressure Air supply is switched off.

Low level CO2 pressure CO2 supply is switched off.

Switch control on Switch the control voltage on.

Flow meter water Water flow is too small.

26
Flow meter syrup Syrup flow is too small

Ratio syrup flow low Ratio water/syrup cannot be maintained,

syrup flow is too small at 100 % output.
Ratio syrup flow high Ratio water/syrup cannot be maintained,
syrup flow is too high at 0 % output.

Further trouble shooting :

No Temperature signal in the display

 Check if the cable is wired correctly to all terminals
 Check the 24 V DC supply
 Loop in a mA measuring instrument and check whether you get a 4-20 mA
signal or not.

No pressure signal in the display

Same as temperature signal

CO2-control valve stays closed

 Check pressure and temperature signal and the CO2 setting.
 Loop in a mA measuring instrument and check whether you get a 4-20 mA
output signal or not.
 Check if air supply is open and adjusted to 2.5 bar.

CO2-control valve stays open

 Check signals as described above.
 Check if the seat of the valve is tight.

Overpressure valve stays open

 If the LED at the valve is on i.e. it gets 24 V supply the hysteresis is set too
small or the output of the control is defective.
 If the LED at the valve is off the valve has a mechanical defect.

Overpressure valve stays closed

 If the LED at the valve is on i.e. it gets 24 V supply the coil of the valve is
defective or the valve has a mechanical defect.
If the LED at the valve is off the hysteresis is set too big or the output of the
control is defective.

27