Filler User Manual

Technical Documentation
User Manual
FILLER
COMBI MATRIX
SF300 FM 144/24K
(SRMB0119)
Coca-Cola Bottlers Philippines, Inc.
Original instructions
All figures and photos are for information purposes only.
Publication date: 28/06/2013
SIDEL S.p.A. - Via La Spezia, 241/A - (43126), Parma ITALY

Tel.: +39 0521 9991 - Fax: +39 0521 959009
SF300 Filler
User Manual / Table of Contents
Sidel S.p.A.
Page intentionally left blank
II
Matrix Filler
GENERAL REGULATIONS AND WARNINGS
PART I
SAFETY STANDARDS
PART II
TECHNICAL DATA
PART III
INSTALLATION
PART IV
OPERATION
PART V
OPERATING INSTRUCTIONS
PART VI
SIZE CHANGEOVER
PART VII
MAINTENANCE SCHEDULE
PART VIII
DIAGNOSTICS
PART IX
APPENDICES
PART X
TABLE OF CONTENTS
Sidel S.p.A.
GENERAL REGULATIONS AND WARNINGS............................................................................................................... Part I

1.1
Testing and warranty .............................................................................................................................................. 2
1.2
Warnings and personnel......................................................................................................................................... 3
1.2.1 Foreword .................................................................................................................................................... 3
1.2.2 Reproduction rights and copyright.............................................................................................................. 3
1.2.3 Documents supplied with the machine....................................................................................................... 3
1.3
Reference standards .............................................................................................................................................. 4
1.3.1 EC declaration of conformity with machinery directive............................................................................... 5
1.3.2 Identification and CE marking plate............................................................................................................ 6
1.3.3 EC Declaration of conformity as per Pressure Equipment Directive (PED) ............................................... 7
1.3.4 Plates certifying conformity to Pressure Equipment Directive (PED) ......................................................... 9
1.3.5 Quality certificate (countries not in the EEA).............................................................................................. 10
1.3.6 Identification plates (countries not in the EEA)........................................................................................... 11
1.4
Setup provided by the customer ............................................................................................................................. 13
1.5
Technical assistance request procedure ................................................................................................................ 14
1.6
Instructions for ordering spare parts ....................................................................................................................... 15
1.7
Consulting this manual ........................................................................................................................................... 16
1.7.1 General information.................................................................................................................................... 16
1.7.2 Symbols used in this manual...................................................................................................................... 16
1.7.3 Terminology used in this manual................................................................................................................ 17
1.8
Description of the machine ..................................................................................................................................... 19
1.8.1 Intended use............................................................................................................................................... 19
1.8.2 General description .................................................................................................................................... 19
1.8.3 Operation.................................................................................................................................................... 20
1.9
Main units ............................................................................................................................................................... 21
1.9.1 Central manifold ......................................................................................................................................... 23
1.9.2 Carousel ..................................................................................................................................................... 24
1.9.3 Rotary product manifold ............................................................................................................................. 24
1.9.4 Base ........................................................................................................................................................... 24
1.9.5 Drive units .................................................................................................................................................. 25
1.9.6 Bottle conveyor........................................................................................................................................... 26
1.9.7 Filling valve................................................................................................................................................. 30
1.9.8 Operator interface ...................................................................................................................................... 31
1.9.9 Bottle closing .............................................................................................................................................. 32
1.9.10 SKID ........................................................................................................................................................... 33
1.9.11 Guards........................................................................................................................................................ 38
1.9.12 Bottle cooling (if fitted)................................................................................................................................ 40
1.9.13 Automatic centralised lubrication system ................................................................................................... 40
1.9.14 Rinser (only BLOCKRINSER fillers)........................................................................................................... 41
III
SF300 Filler
1.9.15 Filling valve drainage tank (HOTFILL optional) .......................................................................................... 42

SAFETY STANDARDS ...................................................................................................................................................... Part II
2.1 General safety information......................................................................................................................................... 2
2.2 Notes on using the system......................................................................................................................................... 4
2.3 Definition of safety terms ........................................................................................................................................... 5
2.4 Safety signage ........................................................................................................................................................... 6
2.5 Personnel................................................................................................................................................................... 8
2.6 Personal protective equipment (PPE)........................................................................................................................ 9
2.7 Operator safety .......................................................................................................................................................... 10
2.7.1 Operator guard and protection devices ...................................................................................................... 10
2.7.2 Characteristics and operation of safety devices........................................................................................ 12
2.8 Hazardous areas........................................................................................................................................................ 26
2.8.1 Hazard zones ............................................................................................................................................. 26
2.9 Residual risks and hazards........................................................................................................................................ 27
TECHNICAL DATA......................................................................................................................................................... Part III
3.1 Dimensions ................................................................................................................................................................ 2
3.2 Machine configuration................................................................................................................................................ 3
3.2.1 Technical data ............................................................................................................................................ 3
3.3 Machine and environmental characteristics............................................................................................................... 4
3.3.1 Man - machine interface............................................................................................................................. 4
3.3.2 Ambient installation conditions ................................................................................................................... 5
3.4 Performance levels .................................................................................................................................................... 6
3.4.1 Speed variations......................................................................................................................................... 6
3.5 Power and consumption ............................................................................................................................................ 7
3.5.1 Installed voltage and power........................................................................................................................ 7
3.5.2 Tanks.......................................................................................................................................................... 7
3.5.3 Piping ......................................................................................................................................................... 7
3.5.4 Pressurised tank safety valves (if fitted)..................................................................................................... 7
3.6 Weights ...................................................................................................................................................................... 8
3.7 Noise levels................................................................................................................................................................ 9
Sidel S.p.A.
INSTALLATION ............................................................................................................................................................. Part IV

4.1
Packaging and shipping.......................................................................................................................................... 2
4.1.1 Type of packaging ...................................................................................................................................... 2
4.1.2 Incoterm requirement............................................................................................................................... 2
4.1.3 Moving the packed machinery.................................................................................................................... 2
4.1.4 Receiving the material................................................................................................................................ 3
4.1.5 List of components ..................................................................................................................................... 3
4.1.6 Storage conditions for packed machinery .................................................................................................. 4
4.2
Foundations ............................................................................................................................................................ 5
4.3
Movement and positioning...................................................................................................................................... 6
4.3.1 Delivery to the customer's premises........................................................................................................... 6
4.3.2 Tooling supplied with the machine. ............................................................................................................ 6
4.3.3 Unpacking and hoisting .............................................................................................................................. 6
4.3.4 Removal of scrap material.......................................................................................................................... 7
4.3.5 Moving and positioning the machine .......................................................................................................... 8
4.3.6 Hook positioning table ................................................................................................................................ 10
4.4
Connections and cabling ........................................................................................................................................ 11
4.4.1 Electrical connection (responsibility of the manufacturer) .......................................................................... 11
4.4.2 Compressed air connection (responsibility of the customer)...................................................................... 11
4.4.3 Earthing system.......................................................................................................................................... 11
4.4.4 Connection for liquid waste disposal .......................................................................................................... 11
4.4.5 Connection for disposal of fumes ............................................................................................................... 12
4.4.6 Accidental spillage of substances harmful to the environment................................................................... 12
IV
Matrix Filler
4.5
4.6
4.7
Setting up and first startup...................................................................................................................................... 13

4.5.1 Pre-startup settings .................................................................................................................................... 13
4.5.2 Pre-startup checks ..................................................................................................................................... 14
4.5.3 Cleaning and general inspection ................................................................................................................ 15
4.5.4 General cleaning ........................................................................................................................................ 16
4.5.5 Cleaning products and equipment.............................................................................................................. 16
4.5.6 Safety warning............................................................................................................................................ 16
4.5.7 First startup ................................................................................................................................................ 17
4.5.8 Sanitizing the system ................................................................................................................................. 17
4.5.9 Setting up and first startup ......................................................................................................................... 17
Re-installation ......................................................................................................................................................... 18
Decommissioning and disposal .............................................................................................................................. 19
4.7.1 Disposal of packaging ................................................................................................................................ 19
4.7.2 Dismantling and removing the machine ..................................................................................................... 20
4.7.3 Disposal of the machine ............................................................................................................................. 21
OPERATION .................................................................................................................................................................. Part V

5.1
Permitted use. Improper use. Energy reduction ..................................................................................................... 2
5.1.1 Design use ................................................................................................................................................. 2
5.1.2 Operational criteria to reduce consumption................................................................................................ 2
5.2
Production limits ..................................................................................................................................................... 3
5.2.1 Instructions in the event of a fire ................................................................................................................ 3
5.3
operating description .............................................................................................................................................. 4
5.3.1 Filling processes......................................................................................................................................... 4
5.3.2 Filling .......................................................................................................................................................... 6
5.3.3 Filling steps ................................................................................................................................................ 8
5.4
Washing step (if available)...................................................................................................................................... 15
5.5
Machine cleaning and sanitization.......................................................................................................................... 16
5.5.1 Introduction................................................................................................................................................. 16
5.5.2 General information.................................................................................................................................... 17
5.5.3 Use of chemical products to remove limescale deposits from external surfaces ....................................... 18
5.5.4 Limits to using detergents and sanitisation products.................................................................................. 19
Sidel S.p.A.
OPERATING INSTRUCTIONS ....................................................................................................................................... Part VI

6.1
Control panel, warning lights and pushbuttons....................................................................................................... 2
6.1.1 Foreword .................................................................................................................................................... 2
6.1.2 Layout of components ................................................................................................................................ 2
6.1.3 Operator panel ........................................................................................................................................... 3
6.1.4 Operator interface main structure............................................................................................................... 4
6.1.5 Operator panel operations.......................................................................................................................... 10
6.2
Description of individual interfaces ......................................................................................................................... 19
6.2.1 Main functions ............................................................................................................................................ 19
6.2.2 Reception ................................................................................................................................................... 22
6.2.3 Piping circuit ............................................................................................................................................... 23
6.2.4 Machine components ................................................................................................................................. 26
6.3
Electronic filling valves (Mastercard) ...................................................................................................................... 48
6.4
Recipes................................................................................................................................................................... 94
6.4.1 Layout......................................................................................................................................................... 110
6.4.2 Graphics ..................................................................................................................................................... 114
6.4.3 Maintenance............................................................................................................................................... 115
6.4.4 Parameters................................................................................................................................................. 125
6.4.5 Services...................................................................................................................................................... 141
6.5
Operating mode selection....................................................................................................................................... 147
6.5.1 Automatic operation ................................................................................................................................... 147
6.5.2 Manual operation........................................................................................................................................ 147
6.6
Machine startup and production ............................................................................................................................. 148
6.6.1 Preliminary checks ..................................................................................................................................... 148
6.6.2 Starting ....................................................................................................................................................... 149
6.6.3 Procedures for standard operation............................................................................................................. 153
SF300 Filler
6.7
6.8
6.9
Stop and emergency stop modes ........................................................................................................................... 154

6.7.1 Machine emergency stop ........................................................................................................................... 154
6.7.2 Machine stop during production ................................................................................................................. 154
Rinsing.................................................................................................................................................................... 155
Sanitization ............................................................................................................................................................. 156
SIZE CHANGEOVER ..................................................................................................................................................... Part VII

7.1
General precautions ............................................................................................................................................... 2
7.2
Description of the size change parts....................................................................................................................... 3
7.3
Machine cleaning.................................................................................................................................................... 4
7.4
Removing size changeover parts (where fitted) ..................................................................................................... 5
MAINTENANCE SCHEDULE ....................................................................................................................................... Part VIII
8.1
General information about maintenance................................................................................................................. 2
8.1.1 Maintenance operation times ..................................................................................................................... 4
8.1.2 Greasing machine parts ............................................................................................................................. 5
8.1.3 Preventive maintenance............................................................................................................................. 6
8.1.4 Extraordinary maintenance ........................................................................................................................ 7
8.2
Maintenance schedule............................................................................................................................................ 8
DIAGNOSTICS.............................................................................................................................................................Part IX
9.1
Troubleshooting ...................................................................................................................................................... 2
9.1.1 General machine operation ........................................................................................................................ 3
9.1.2 Bottle conveyor........................................................................................................................................... 3
9.1.3 Filling .......................................................................................................................................................... 4
9.1.4 Capping ...................................................................................................................................................... 7
9.1.5 Product level in static tank (if fitted)............................................................................................................ 8
Sidel S.p.A.
APPENDICES ..............................................................................................................................................................Part IX
10.1 Documentation enclosed ........................................................................................................................................ 2
10.1.1 Layout and connections ............................................................................................................................. 3
10.1.2 Moving the machine ................................................................................................................................... 4
10.1.3 Flow circuit diagram ................................................................................................................................... 5
10.1.4 Equipment .................................................................................................................................................. 6
10.1.5 Description of slave card display unit controls ........................................................................................... 7
10.1.6 Appendices for commercial equipment ...................................................................................................... 8
VI
PART I
GENERAL REGULATIONS AND WARNINGS
Sidel S.p.A.
Part I
Matrix Filler
User Manual / General regulations and warnings
1.1
I-1
Matrix Filler
1.1
Part I
TESTING AND WARRANTY
The filling machine is shipped to the customer ready for installation following factory testing performed by the
manufacturer, in compliance with current legislation.
During the period of warranty the manufacturer is bound to resolve faults and defects as long as the machine
has been operated correctly in compliance with that stated in the use and maintenance manuals.
Any consumables, including those supplied by the dealer together with the machine, are not covered by
the warranty.
Sidel S.p.A.
The conditions of the warranty are specified in the agreements stipulated between the parties when the
contract is drafted.
I-2
1.1
Matrix Filler
Part I
1.2
WARNINGS AND PERSONNEL
1.2.1
Foreword
This manual is an integral part of the machine.

This manual was written in the manufacturers language and then translated into the language of the country
where the machine will be installed and operated.
The photos, figures and diagrams in this manual refer to a standard machine. The configurations shown in
the figures may differ from those on the machine in your possession. The functions remain identical.
These manual and the technical documentation must be readily available to all users of the machine.
This manual has been written for the following persons:
-
The installation manager.

The operators starting and operating the machine.
The maintenance technicians.
This manual provides the following general information:

-
A description of the machine operating units and sub-assemblies.

Operating and use instructions.
Maintenance procedures.
This manual contains:

-
Technical data about the machine, its functions, its components and their operation.
Information about receiving, unpacking and handling the machine. Instructions on connecting up the
various electrical cabinets and the power systems to the external supplies.
The machine is commissioned and started for the first time by qualified technicians from SIDEL.
Commissioning includes the following:
-
1.2.2
Final setting up and adjustment. Levelling. Assembly of all sub-components.

Adjustment and testing of machine functions.
Production with the sizes to be used on the machine.
Reproduction rights and copyright
All rights reserved.

Translation rights, electronic storage rights, reproduction and adaptation rights, partial or complete, using
any means (including microfilm and photocopies) are reserved for all countries.
Documents supplied with the machine

User Manual.
Maintenance manual.
Parts manual (list of components with SIDEL codes and overall drawings).
Wiring diagram.
Sidel S.p.A.
1.2.3
1.1
I-3
Matrix Filler
1.3
Part I
REFERENCE STANDARDS
All SIDEL machines are designed and manufactured in compliance EU standards.
The documents supplied to the customer vary in accordance with the country of destination of the
SIDEL machine:
The following are supplied for countries in the European Economic Area (EEA):
CE declaration of conformity with machinery directive
Identification and CE marking plate
Declaration of conformity as per Pressure Equipment Directive (PED) (pressure systems)
CE marking plate as per Pressure Equipment Directive (PED) (pressure systems)
The following are supplied for other countries:

Quality certificate
Identification plates
Sidel S.p.A.
I-4
1.1
Matrix Filler
Part I
1.3.1
EC declaration of conformity with machinery directive
The declaration is given to the customer when the machine is put into service and after the presence of the
user instructions and safety device operating instructions has been verified.
Example:
See the machine identification data on the cover of this manual.
Sidel S.p.A.
(1)
1.1
I-5
Matrix Filler
1.3.2
Part I
Identification and CE marking plate
The plate is attached to the electrical panel of the machine and shows the CE marking, the name of the
manufacturer SIDEL, machine identification, the year of manufacture and the main features of the electrical
system.
Example:
6
1
8
9
10
4
11
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
12
Machine name
Model
Type
Serial number
Year of manufacture
Nominal power rating
Maximum current absorbed
Number of phases
Power supply voltage
Frequency
Short circuit current
Wiring diagram identification
Sidel S.p.A.
Do not remove or tamper with the identification plate.
I-6
1.1
Matrix Filler
Part I
1.3.3
EC Declaration of conformity as per Pressure Equipment Directive (PED)
The customer is given 2 declarations (one for the tank and one for the assembly of pressurised components)
when the machine is put into service. The declarations are drafted following testing at the SIDEL
manufacturing facility.
Example:
Sidel S.p.A.
(1)
1.1
I-7
Matrix Filler
Part I
Sidel S.p.A.
(1)
I-8
1.1
Matrix Filler
Part I
1.3.4
Plates certifying conformity to Pressure Equipment Directive (PED)
The plates are attached to the pressurised tanks of the machine and show the main features of the system.
Example:
2
3
7
2
3
4
8
Identification of the tank or assembly

Design pressure
Hydrostatic test pressure
Design temperature (Min - Max)
Identification of notified test body (if applicable)
Year of manufacture
Nominal capacity
Identification of safety valve
Sidel S.p.A.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Do not remove or tamper with the identification plates.
1.1
I-9
Matrix Filler
1.3.5
Quality certificate (countries not in the EEA)
The certificate is given to the customer when the machine is delivered.

Example:
Sidel S.p.A.
(1)
I - 10
1.1
Part I
Matrix Filler
Part I
1.3.6
Identification plates (countries not in the EEA)
There are 2 identification plates for countries not in the EEA:

-
Plate 1 is attached to the electrical cabinet of the machine and shows the main features of the electrical
system.
Example:
6
1
8
9
10
4
11
Machine name
Model
Type
Serial number
Year of manufacture
Nominal power rating
Maximum current absorbed
Number of phases
Power supply voltage
Frequency
Short circuit current
Wiring diagram identification
Sidel S.p.A.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
12
1.1
I - 11
Matrix Filler
Part I
Plate 2 is attached to the pressurised tank of the machine and shows the main features of the system.
Example:
2
3
7
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Identification of the tank or assembly

Design pressure
Hydrostatic test pressure
Design temperature (Min - Max)
Identification of notified test body (if applicable)
Year of manufacture
Nominal capacity
Sidel S.p.A.
Do not remove or tamper with the identification plates.
I - 12
1.1
Matrix Filler
Part I
1.4
SETUP PROVIDED BY THE CUSTOMER
The following connections must be provided by the customer:

-
Mains water.
Treated water (if applicable).
Compressed air.
Gas (CO2 Sterile air etc.).
Sanitising agent.
Mains power.
Product.
Water drainage.
Conveyance of emissions in the atmosphere.
The following must also be provided by the customer:

Earth connection.
Consumption materials.
Further information concerning the operations required to make the connections can be found in
section 3.5 CONNECTIONS AND CABLING in this manual.
Sidel S.p.A.
1.1
I - 13
Matrix Filler
1.5
Part I
TECHNICAL ASSISTANCE REQUEST PROCEDURE
Requests for the intervention of the customer technical assistance service must be sent by fax to the
following
address:
Sidel S.p.A. Via La Spezia, 241/A - (43126), Parma ITALY
Servizio Assistenza Tecnica Clienti: fax number +39 0521 999530
Please state:
-
Machine type, Serial Number, Year of installation.

Description of the fault(s).
Exact address of the production facility where the machine is installed.
The name of a contact person.
Sidel S.p.A.
For more information about our Customer Technical Assistance Service, www.sidel.com.
I - 14
1.1
Matrix Filler
Part I
1.6
INSTRUCTIONS FOR ORDERING SPARE PARTS
The customer is responsible for purchasing original spare parts to ensure maintenance operations which
keep the machine safe and efficient.
The list of spare parts required, precise instructions for identifying them and the procedure to order them are
shown in detail in the enclosed spare parts catalogue.
The dismantling and reassembly operations must be performed in compliance with the instructions provided
by the manufacturer.
Requests for spare parts must be sent by fax to the following address:
Sidel S.p.A.
Via La Spezia, 241/A
43126 Parma, Italy
Tel. (+39) 05219991
Fax (+39) 0521959009
The following information should be provided with each request to ensure safe and rapid identification of
spare parts:
-
Machine type and serial number.

Drawing number and the position of the part on the drawing.
Description of the part.
Part code specified on the parts list.
Quantity required.
Please also specify whether the request is an executive order or a request for parts, the requested delivery
date, the delivery address, invoicing address and any specific shipping instructions. The name, telephone
number and fax number of the person who shall be the contact with Sidel for the supply of spare parts must
be provided.
When your order has been received, you will be sent an order confirmation including prices, delivery date
and supply conditions.
The address of the spare parts centre is as follows:
Sidel S.p.A. Via La Spezia, 241/A - (43126), Parma ITALY
Sidel S.p.A.
Servizio Ricambi: fax number +39 0521 999530, telephone number +39 0521 999295
1.1
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Matrix Filler
1.7
CONSULTING THIS MANUAL
1.7.1
General information
Part I
All users must read this manual in its entirety. Users must be fully aware of and understand the instructions
contained in this manual.
This manual is a reference and consultation document containing instructions and procedures.
The manual should be available at all times to all personnel responsible for operating or maintaining the
machine.
The manual is designed to enable quick reference and to ensure that you can rapidly find all the information
you need about operation, control and maintenance.
The following features are designed to help users find the information they need quickly:
-
1.7.2
There is a table of contents at the start of the manual and a table of contents at the start of each part
detailing the topic covered in that part.
The manual is divided into parts and sections for each main topic.
The header of each part indicates the exact position inside the manual.
Symbols are used to identify different types of information.
A glossary which explains the technical terms used in the manual.
Symbols used in this manual
The following symbols are used throughout this manual to indicate special instructions and hazard warnings:
Strictly prohibited.
Warning Please read carefully.
Prohibition sign: No persons with pacemaker
Mandatory sign: Read the manual
Notes and comments on the results of an operation.
Sidel S.p.A.
Indications for protecting the environment.
I - 16
1.1
Matrix Filler
Part I
1.7.3
Terminology used in this manual
In the interests of clarity we provide a glossary explaining some of the technical terms used in this manual.
This glossary has been prepared for all the machines we manufacture.
Not all of the terms refer to the machine in your possession and it is possible therefore that some of the
terms may not appear in your manual.
Clean-In-Place (CIP) - a system for cleaning a line or an item of
equipment in a closed cycle.
CIP/SIP UNIT
A Clean-In-Place (CIP) or a Sanitize-In-Place (SIP) unit.
CLEANING
Removal of food residues, dirt, grease or any unwanted material.
CONTACT SURFACES
All equipment surfaces which come into contact with the product either
intentionally or unintentionally (e.g. through splashing).
COP EXTERNAL CLEANING
Clean-Out of-Place (COP) - a system for the external cleaning a line or an

item of equipment in a closed cycle.
DISINFECTANT
A chemical product used after cleaning to eliminate a part or a type of

microorganism remaining on surfaces.
DISINFECTION
The use of chemical agents or physical methods to reduce the number of

microorganisms to a level which does not endanger the safety or
suitability of foodstuffs.
FILLING NOZZLE
End part of the valve which sprays in the filling fluid.
FILLING VALVE
A fluid control system which feeds the fluid into a container through the
filler nozzle.
FORESEEABLE
CONDITIONS OF USE
The reasonably foreseeable conditions of use, including cleaning, under

which the machine will operate. These conditions set the limits for the
variables such as time, temperature and concentration.
ISOLATOR
An area where the environment is controlled by an overpressure cascade

between the various zones (e.g. between the white zone and the grey
zone).
JOG UNIT
An item of equipment used to operate the machine in the manual mode at

low speed.
MANIFOLD
A manifold collects fluid coming from one or more pipes and distributes it
to one or more units.
MANUAL CLEANING
Removal of residues by hand when the equipment is partially or

completely disassembled.
NON PRODUCT CONTACT

SURFACES
All exposed surfaces except those which may potentially come into
contact with the product.
OP
Operator
P&I
Functional diagram of the line complete with the part codes.
PAA
Peracetic acid.
Sidel S.p.A.
CIP INTERNAL CLEANING
1.1
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Matrix Filler
PAA/SW UNIT
The unit for storing peracetic acid and sterile water.
PAM - MP
Machine parameters.
PAR - RP
Recipe parameters
PAT
Technical parameters
PID
Proportional Integral Derivative.
RESIDUE
Any material remaining in the equipment or in the process area. Residues

may or may not contain microorganisms.
ROTARY COUPLING
A component which enables a fluid to pass from a fixed pipe to a rotating

pipe.
SANITIZER
A substance which reduces the microbial contaminants on inanimate

surfaces to within levels considered safe for public health.
SANITIZING
A process applied to a clean surface to reduce the number of resistant

human pathogenic agents. Mechanical or manual methods can be used
for sanitizing using hot water, steam or an approved disinfectant.
SOLUTION
Water or homogeneous mixtures of cleaning agents or disinfectants and

water used for the flow, cleaning, rinsing and disinfection.
SPLASHED CONTACT
SURFACES
Surfaces not in contact with the product which during normal use
accumulate residues which must be cleaned away at regular intervals to
prevent these residues entering the product or the main container.
STERILISATION
A process aimed at removing or killing all forms of microorganism

including bacterial spores.
SW
Sterile Water.
Sidel S.p.A.
I - 18
Part I
1.1
Matrix Filler
Part I
1.8
DESCRIPTION OF THE MACHINE
1.8.1
Intended use
The machine is designed to fill returnable and disposable PET bottles with collar with still
and/or fizzy (CO2 added) soft beverages.
1.8.2
General description
This manual refers to the rotary filler for bottling and capping containers at high speed.
Each machine is manufactured by Sidel S.p.A., PARMA (ITALY) and is designed using the latest techniques
for bottling and capping at high speed.
The machine is able to achieve high production rates. This together with good resistance to corrosive
environments, low maintenance, high reliability and easy size changeover are all features which make this a
safe, versatile and reliable machine suitable for practically any application.
All machine movements are powered by electric motors controlled by a PLC.
The cables to the electrical equipment are suitably dimensioned and are housed inside special trunking and
cableways which enable easy inspection of the cables. The electrical cabinet houses the low tension circuits
for the control and programming equipment. It also houses the power contactors.
Sidel S.p.A.
The operator-machine interface consists of a local pushbutton panel complete with real time displays of
machine states and the controls for operating the machine in the manual mode.
1.1
I - 19
Matrix Filler
1.8.3
Part I
Operation
The containers are filled and capped inside the machine.

This section identifies the main machine units which are then described in more detail in the sections that
follow.
The figure below shows the machine operating process.
The containers are conveyed inside the machine using a starwheel train.
In the filling unit the containers are filled by following the technical filling criteria (see section 5.4.2 Filling).
The capper / crown capper if fitted with the closing device.
At the end of these operations the containers are conveyed to the next processing stage using conveyor
belts.
References
Description
BOTTLE INFEED (empty bottles)
FILLER (bottle filling)
CAPPER CROWN / CAPPER (bottle capping)
BOTTLE OUTFEED (bottles ready for the next processing stage)
Sidel S.p.A.
I - 20
1.1
Matrix Filler
Part I
1.9
MAIN UNITS
COMBI filler main units
10
3
7
15
12
13
9
4
11
16
Reference
Description
Reference
Description
Central manifold
10
SKID
Carousel
11
Guards
Ring manifold
12
Bottle cooling (if fitted)
Base
13
Lubrication
Drive units
14
Bottle conveyor
15
HotFill Filling valve drainage tank

(where fitted)
Filling valve
16
Blower*
Operator interface
17
Capper / Crown capper

Sidel S.p.A.
(*) not included in the documentation
1.1
I - 21
Matrix Filler
Part I
BLOCKRINSER filler main units
10
15
17
13
11
14
Reference
Description
Reference
Description
Central manifold
10
SKID
Carousel
11
Guards
Ring manifold
12
Base
13
Lubrication
Drive units
14
Rinser
Bottle conveyor
15
HotFill Filling valve drainage tank

(where fitted)
Filling valve
16
Operator interface
17
Hema* pulp (if fitted)
Capper / Crown capper
Sidel S.p.A.
(*) not included in the documentation
I - 22
1.1
Matrix Filler
Part I
1.9.1
Central manifold
UPPER CENTRAL MANIFOLD

The upper central manifold (1) supplies the carousel with the following:
-
Compressed air for the pneumatic valves and the jacks (where installed).
Electrical signals for solenoid valves and probes.
Sanitizing solutions for COP (with COP and reduced laminar flow)
LOWER CENTRAL MANIFOLD

The lower central manifold (2) supplies the carousel with the following:
Product.
CO2/N2 (if applicable)
Sanitizing solution for use during the CIP process.
Decompression.
Sidel S.p.A.
1.1
I - 23
Matrix Filler
1.9.2
Part I
Carousel
This consists of two parts:

1.
2.
1.9.3
A fixed part to support the structure.

A rotary part including the support for the filling valves and the product manifold.
Rotary product manifold
The rotary product manifold on the filling machine has a ring design to connect the product infeed pipes and
the sanitization recycling pipes from the central manifold.
1.9.4
Base
Sidel S.p.A.
This contains the drive transmission components for the filler carousel, belts, bottle conveyor starwheels,
capping units and any other connected machinery.
I - 24
1.1
Matrix Filler
Part I
1.9.5
Drive units
All the rotary mechanical components are powered independently by their own brushless motors (1) which
are electronically synchronised.
One of the motors, the master, provides the reference speed used for synchronisation.
In the event of a power failure, any mistiming caused by the different inertias of the rotating masses as they
come to a stop is prevented by an DC energy generating circuit.
The carousels are driven by the reduction gearbox shaft (2) located under the filler carousel. This shaft
drives the drive shaft and the pinion (3) which engages directly with the rack (4).
Sidel S.p.A.
In the base, the drive is transmitted to the reduction gearbox located inside the base. The gearbox drives a
gear train which rotates all the bottle handling parts and the capping units.
1.1
I - 25
Matrix Filler
COMBI Filler Drive Units
Part I
BLOCKRINSER Filler Drive Units
2
2
References
1.9.6
Description
filler carousel drive motor
bottle conveyor starwheel drive gear motor
rinser drive gear motor
Bottle conveyor
The bottles are conveyed into and out from the filling carousel using transfer starwheels and guides. The
path followed by the bottles through the machine is as follows:
1.
2.
2.
3.
4.
Bottle infeed starwheel/s.

Rinser (where fitted)
Filling carousel.
Capper/Crown capper.
Bottle outfeed belt.
BOTTLE OUTFEED
The bottle outfeed module (1) conveys the bottles onto the outfeed conveyor.
Sidel S.p.A.
I - 26
1.1
Matrix Filler
Part I
A pit (2) positioned after the outfeed module stops the machine in the event that the conveyor belt circuit
downstream from the filler jams or is blocked.
2
The height adjustable belt (3) picks up the bottles arriving from the last starwheel of the machine; the belt
picks up the bottles by their bottoms.
An inclined belt enables connection to the conveyor belt line. A safety system stops the machine in the event
that the conveyor belt circuit downstream from the filler jams or is blocked.
3
Description
Bottle outfeed module
Clogged bottle outfeed pit
Adjustable outfeed belt
Adjuster handwheel
Sidel S.p.A.
References
1.1
I - 27
Matrix Filler
Belt with automatic adjustment (optional)

The height of the belt is adjusted automatically by a motor (5).
In the event of a motor fault, the height can be adjusted using the handwheel (6).
References
Description
Adjustable belt motor
Adjuster handwheel
Sidel S.p.A.
I - 28
1.1
Part I
Matrix Filler
Part I
Guides with automatic adjustment (optional)

The width of the guides (7) is adjusted automatically by a motor (8).
Description
Adjustable guides
Adjustable guide motor
Sidel S.p.A.
References
1.1
I - 29
Matrix Filler
1.9.7
Part I
Filling valve
Depending on the type of filler, different types of valves are used:

Alcohol and still product valve
Fizzy product valve
Hot product valve
2
1
1
1
2
5
2
5
4
References
Description
Filling valve body
Fluid distributor
Bell unit
Bottle support with gripper
Dummy bottle
Pilot valve
CIP unit
Sidel S.p.A.
I - 30
1.1
Matrix Filler
Part I
1.9.8
Operator interface
The operator interface includes a part with traditional controls (buttons, selectors, knobs), and another part
integrated into the operator panel.
Pushbutton control panel

The control panel includes all the electric control and
warning devices.
Sidel S.p.A.
Pneumatic control and adjustment panel

The control panel includes all the devices used to
control and adjust the compressed air and CO2.
1.1
I - 31
Matrix Filler
1.9.9
Part I
Bottle closing
The capping tower consists of a series of capping heads on a carousel and a pick-and-place unit (a cap
distribution starwheel).
The cap is transferred to the pick-and-place unit only when a bottle to be capped is present.
The screwing heads (1) perform two movements: rotation on their own axes at a variable angular speed;
axial travel controlled by a cam. The combination of these two movements during rotation of the capper
enables the capping heads to perform the following sequence of operations. The capping heads pick up the
caps from the distribution system, position them on the bottles, screw them on, tighten them and then
disengage from the bottle (see the manual supplied by the manufacturer of the capper).
For further information refer to the manual supplied by the manufacturer of the bottle closing unit.
Sidel S.p.A.
I - 32
1.1
Part I
Matrix Filler
1.9.10 SKID
PROCESS SKID
This is a process unit acting as an interface between the filler infeed and outfeed fluids and also as a device
to store and manage the product used for filling.
If the SKID unit is not fitted, the components described below are part of a sanitizing machine called
COREBLEND (see the specific manual).
SKID composition:
Product delivery
Sidel S.p.A.
Product infeed
1.1
I - 33
Matrix Filler
Product storage
Gas treatment (compressed air, CO2)
CIP infeed and recycling

(optional)
Sidel S.p.A.
Bottle rinsing circuit infeed

(optional)
I - 34
1.1
Part I
Part I
Matrix Filler
Bottle
bottom
cooling
circuit
management, distribution and recycling
(optional)
Foaming control unit for COP external

washing
(optional)
Pneumatic distribution
Sidel S.p.A.
Atmospheric and pressurised drainage
1.1
I - 35
Matrix Filler
ICS
(optional)
Electrical cabinet
The machine is equipped with a main
electrical cabinet containing the following
safety components:
Main ON/OFF switch on the filler.
Emergency stop pushbutton.
Sidel S.p.A.
Before switching on the electrical cabinet

for the first time, proceed as follows:
Check the customers power supply.
Check the connections inside the
electrical cabinet.
Check that the emergency stop
pushbutton is OFF.
Rotate the main ON/OFF switch to
power up the electrical cabinet.
I - 36
1.1
Part I
Part I
Matrix Filler
PAA SKID (where fitted)

This system is used to prepare the solution of water with added PAA at a concentration of 50 ppm at room
temperature. The system is fitted with a mixing tank with a capacity of 400 litres, a pump to keep the solution
circulating and a counter-pressure valve to regulate the pressure in the circuit.
Sidel S.p.A.
Dosing is performed using an electric membrane pump and a flow meter installed on the recycled water inlet.
The flow meter generates a pulse each time a set quantity of water transits through the pump; for each pulse
the dosing pump performs a dosing operation so that the correct volume of water is dosed to produce the
concentration required.
1.1
I - 37
Matrix Filler
Part I
1.9.11 Guards
The machine has 3 types of perimeter guards:
A.
Tight Area Protection
Tight area guards are designed using gates made from tempered glass fitted near to the front and rear of the
machine.
Options:
-
Cover for the dynamic air over-pressure system.

Gutter around the base of the front table
B.
Wide Area Protection
Wide are guards are designed using fixed panels made from Lexan and gates made from tempered glass
fitted near to the front but far from the rear of the machine.
Sidel S.p.A.
Options:
Glass for fixed panels (laminated glass)
Cover for the dynamic air over-pressure system.
Gutter around the base of the front table
I - 38
1.1
Matrix Filler
Part I
C.
Reduced Filling Area
Reduced filling area guards are designed using gates made from tempered glass fitted near to the machine,
collection trays under the filling carousel and gutters around the base.
Sidel S.p.A.
The base and filling area are fitted with reduced guards and the rinsing area is fitted with a cover.
1.1
I - 39
Matrix Filler
Part I
1.9.12 Bottle cooling (if fitted)

The cooling unit nozzles direct jets of cold water on to the bottom of the bottles as they move on the machine
infeed starwheels (at blower outfeed), thus cooling the bottles before they enter the filling carousel.
1.9.13 Automatic centralised lubrication system

The automatic centralised lubrication system is designed to supply a series of users (i.e. components
requiring greasing) with the appropriate amount of grease at regular intervals during machine operation
without any direct intervention by the operator.
The minimum grease level sensor triggers an alarm displayed on the operator panel.
Sidel S.p.A.
The operator panel has a pushbutton for starting the lubrication cycle in the manual mode. Use this button to
run a test lubrication cycle or to run a greasing cycle when starting the machine after a long stoppage.
I - 40
1.1
Matrix Filler
Part I
1.9.14 Rinser (only BLOCKRINSER fillers)

The rinser unit rinses the empty bottles just before they are filled. The structure of the machine is designed to
ensure high standards of hygiene and to enable cleaning during work and sanitizing cycles. The design also
ensures easy access to all zones for scheduled and extraordinary maintenance.
The fixed structure (1) of the rinser consists of the carousel transmission and raising components, cam
support, collection channel and rack; the bottles are rinsed in carousel (2).
Depending on the configuration, bottle washing/cleaning is performed as follows:
Treatment with water only.

Treatment with air only.
Treatment with water and air.
Treatment with sanitizer, draining and rinsing.
References
Description
Fixed structure.
Mobile carousel.
Sidel S.p.A.
1.1
I - 41
Matrix Filler
Part I
Distribution of processes:
8
References
Description
References
Description
Air ring manifold.
Mixer.
Air ring manifold.
Air + water pipe.
Central rotary distributor.
Bottle tipping gripper unit.
Valves.
Pressure transducers.
Sidel S.p.A.
1.9.15 Filling valve drainage tank (HOTFILL optional)
The filling valve drainage tank collects the product before the filling cycle during the valve preparation stage,
when sufficient product is released to completely fill the valve stem. During this operation, the drainage tank
moved forward under the valve to recover any excess product. When the valve is ready, the product is
blocked and the drainage tank moves back to its home position.
I - 42
1.1
PART II
SAFETY STANDARDS
Sidel S.p.A.
Part II
Matrix Filler
User Manual / Safety standards
1.1
II - 1
Matrix Filler
2.1
Part II
GENERAL SAFETY INFORMATION
Carefully read all the safety instructions and regulations described here. They are designed to
prevent injury to persons, damage to property and pollution of the environment. These should
become part and parcel of your daily routines when operating and maintaining this equipment.
Do not attempt to start the machine until you fully understand how it functions.
If you still have any doubts after carefully reading this manual, do not hesitate to contact the
Customer Assistance Service at Sidel S.p.A.
Ensure that all the personnel operating, cleaning and maintaining the equipment are fully aware of
the safety precautions and procedures described in this manual.
Before starting the machine, the operator must:
-
Read and understand this manual.

Be fully aware of the functions and positions of the STOP and the EMERGENCY stop
buttons.
Inspect the machine and its safety devices for any visible defects. Inform Sidel S.p.A.
immediately if the inspection reveals any clear signs of structural or functional faults.
Before you start the machine, warn any persons in the vicinity and advise them to move away from the area.
DO NOT disable, bypass, remove or modify the safety devices on the machine. The manufacturer declines
all liability for damage or injury caused by tampering with, bypassing or removing safety devices.
During maintenance, adjustment and repair it may be necessary to disable some of these safety devices.
This operation must only be performed by authorised and specialist personnel. The number of persons
involved in the operations and their qualification is indicated on the relevant maintenance sheets.
Safety and warning signage must be kept in perfect condition. Damaged or illegible signage must be
substituted immediately.
Only use original spare parts when changing faulty or worn parts. Original spare parts are covered by the
manufacturers warranty. DO NOT implement risky solutions!
Before starting the machine remove any extraneous objects left in the machine work area.
DO NOT operate the machine in the automatic mode with the fixed or mobile guards removed.
DO NOT under any circumstances attempt to work on moving parts. DO NOT attempt to free moving parts
which are jammed.
Sidel S.p.A.
DO NOT wear clothing, personal jewellery or other items which might become trapped in moving parts.
II - 2
1.1
Part II
Matrix Filler
Keep the floor and platforms around the machine clean, dry and free of obstructions.
All technicians must wear the personal protective equipment (PPE) specified in the regulations for the
country of installation.
Pay the maximum attention to the hazard warning, mandatory or other signage on and around the machine.
Do not walk or stand on the cover above the base (where fitted). Walking or standing on the cover could
cause breakage of the cover resulting in a falling hazard and serious injury to the operator.
Sidel S.p.A.
Maintenance involving the central carousel must be performed using the special platform. Personnel must
use a safety harness (PPE).
1.1
II - 3
Matrix Filler
2.2
Part II
NOTES ON USING THE SYSTEM
The machine must only be used for the purposes for which it was designed. These purposes are specified
contractually with Sidel S.p.A.
DO NOT USE THE MACHINE FOR PURPOSES OTHER THAN THOSE SPECIFIED IN THIS MANUAL.
DO NOT USE THE MACHINE TO PROCESS PRODUCTS OR CONTAINERS WHICH ARE DIFFERENT
FROM THOSE SPECIFIED IN THIS MANUAL.
DO NOT INCREASE THE SPEED OF THE MACHINE OVER THE LIMIT VALUE SPECIFIED IN THIS
MANUAL.
Improper use of the machine can cause hazards for machine operators and can damage the machine.
For any problems which may occur during the life cycle of the machine and which are not covered in the
technical documentation, contact our Customer Assistance Service for a rapid solution to the problem.
The CO2 pressure must not exceed the maximum permitted operating pressure (refer to the
technical specifications) and the pressure must not be set at a higher value.
Hazard warning Acid burns
The sanitizing products (acids and alkaline lyes) are corrosive. Implement the safety precautions and
the handling instructions indicated in the manufacturers Safety Data Sheets.
The type of products filled, the containers used and the machine performance are specified in detail in
section 3 Technical Data
THE FOLLOWING ARE STRICTLY FORBIDDEN:
-
Modifying the machine cycle.

Processing products other than those specified.
Substituting machine components. Modifying the speed of components.
Using non-original spare parts.
Modifying electrical connections in order to bypass safety devices.
Removing or modifying guards.
Using the machine in explosive or corrosive atmospheres.
Using products with alcoholic strength greater than 18%.
Before you make any modification to the machine, you must contact Sidel S.p.A. to obtain the
necessary authorisation.
PERMITTED USE
The machine can be used to process products and containers of shapes and sizes other than those
specified in the manual. In this case the machine requires refitting and reprogramming. These operations
must be performed by Sidel S.p.A. technicians or when authorisation has been received from Sidel S.p.A.
Failure to do this shall result in Sidel S.p.A. declining all responsibility for any injury or damage caused.
Sidel S.p.A.
NON-PERMITTED USE
Non-permitted (or improper) uses are defined as all the uses not described in this section.
II - 4
1.1
Matrix Filler
Part II
2.3
DEFINITION OF SAFETY TERMS
The following safety terms are used in this manual:

Exposed person:
Any person who is partially or totally inside a hazard zone.
Operator:
A person authorised to install, operate, adjust, maintain, clean, repair or transport parts of the machine or
who is authorised to perform any other activity required to operate the machine.
Safety components:
A component specially designed by the manufacturer to perform safety functions; the component may be
marketed separately from the machine. A safety component is therefore any mechanism whose failure to
operate may endanger the safety of exposed persons.
Hazardous areas:
Any areas of the machine where there are potential hazards during standard operating and maintenance
operations.
Operator positions:
These are the workstations occupied by operators supervising the machine during standard operating
cycles.
Supervision:
Sidel S.p.A.
The supervision zones are outside the hazard zone and do not therefore present hazards to the operator.
The machine does not require continuous supervision by an operator. In the event of a fault the machine
siren will sound calling the operators attention to the problem.
1.1
II - 5
Matrix Filler
2.4
Part II
SAFETY SIGNAGE
Warning signs regarding operator safety are positioned in clearly visible positions around the machine.
PROHIBITION SIGNS
Sign indicating no access for unqualified personnel. This is located on the rear guard doors and
on the fixed guards of the base.
VAA317 Unqualified personnel are forbidden from accessing areas where this sign is displayed.
Sign indicating safety devices must not be removed. This is located on the rear guard doors
and on the fixed guards of the base.
VAA327
Operators must not remove safety devices with the machine running and connected to
the power supplies when this sign is displayed.
Prohibition sign: do not clean, lubricate, repair or adjusting moving parts. This is located on the
rear guard doors and on the fixed guards of the base.
VAA328
Operators must not perform maintenance on moving parts but must wait until the
machine has stopped before intervening when this sign is displayed.
HAZARD WARNING SIGNS

Hazard warning: container fragments. This is located on the front mobile guards.
Operators must only approach the machine when all fragments of glass have been
removed from the relevant area when this sign is displayed. Wear protective gloves at all
VAA318
times.
Burn hazard: located on the product infeed and sanitizer return piping, on the heater, on the
foamer nozzles.
VAA314 Operators must only approach the machine when all the hot components have cooled
VAA315 sufficiently when this sign is displayed. Wear protective gloves at all times.
Electric shock hazard: positioned on the cableways, junction boxes, inside the electrical
cabinet, on the machine cabinet, inside the upper guards.
EEQ992
Operators must only approach the machine when it is disconnected from the mains
power supply when this sign is displayed. Wear protective gloves at all times.
Do not walk on the cover: located on fillers fitted with covers and on the roof of the base.
Sidel S.p.A.
Operators must not approach the area in front of the signal when this sign is displayed.
II - 6
1.1
Matrix Filler
Part II
Warning sign in various languages indicating

circuits which remain powered up even when
the main ON-OFF switch is off.
EEQ988/EEQ530/EEQ529
MANDATORY WARNING SIGNS

IMPORTANT: Personnel operating the line must wear suitable personal protective equipment
(PPE) such as safety eyewear, gloves, overalls and safety footwear with non-slip, non-piercing
soles).
Mandatory sign: wear safety eyewear. This is located on the columns of the front mobile guards.
Operators must wear safety glasses before intervening on the machine when this sign is
VAA316 displayed.
Mandatory sign: wear safety gloves. This is located on the columns of the front mobile guards.
Operators must wear safety gloves before intervening on the machine when this sign is
VAA312 displayed.
Mandatory sign: wear safety footwear. This is located on the columns of the front mobile guards.
Sidel S.p.A.
Operators must wear safety footwear before intervening on the machine when this sign is
VAA311 displayed.
1.1
II - 7
Matrix Filler
2.5
Part II
PERSONNEL
Operators are classified as follows:

Generic operator:
Non-specialist person who knows how to operate the machine using the controls on the control panel, knows
how to load and unload production material, knows how to perform simple operations such as starting and
restarting production after a forced interruption.
Maintenance technician (mechanical):
Qualified technician who knows how to operate the machine in standard conditions, to perform a size
changeover and to adjust, maintain and repair mechanical components. Technicians at this level are not
allowed to work on electrical equipment which is powered up.
Maintenance technician (electrical):
Qualified technician who knows how to operate the machine in standard conditions and to adjust, maintain
and repair electrical components. This technician is also authorised to modify the operating cycle of the
machine using the programmer case. This technician is authorised to work inside electrical cabinets and
junctions boxes when the machine is powered up.
Sidel S.p.A. technician:
Qualified technician provided by Sidel S.p.A. or by an agent of Sidel S.p.A. This technician is authorised to
perform complex operations.
External technician:
Qualified technician made available by the manufacturer (Siemens, SewEurodrive, etc.) or by the distributor
of widely consumed commercially available components authorised to modify, repair and change these
components.
Sidel S.p.A.
QUALIFIED PERSONNEL are all personnel who have attended specialist training courses and have
experience with the installation, putting into service and maintenance of the equipment. This personnel
must also be fully conversant with the accident prevention regulations. Qualified personnel must also
be trained in first aid procedures in the event of an accident.
II - 8
1.1
Part II
2.6
Matrix Filler
PERSONAL PROTECTIVE EQUIPMENT (PPE)
The employer must provide personnel with information concerning the following safety issues when
using the machine:
-
Accident hazards.
Operator safety devices.
Accident prevention regulations stipulated in international directives and legislation in the country
where the machine is installed.
Operators must know the layout and function of the controls and the characteristics of the machine before
starting work. Operators must read all of this manual and any related manuals.
Operators must:
Pay the maximum attention to the hazard warning, mandatory or other signage on and around the
machine.
Use safety gloves for maintenance operations and when handling tin strip or glass containers.
Wear safety footwear, ear protectors and any other PPE in the areas where these are required.
Use all the personal protective equipment (PPE) specified in the manuals.
Apply safety precautions and ensure that others do so, too. If you have any doubts, read this
manual again before continuing.
When indicated on machine safety signage or in manuals, personnel must wear the following personal
protective equipment (PPE):
Mandatory sign: Helmet must be worn
Mandatory sign: Safety gloves must be worn.
Mandatory sign: Safety footwear must be worn.
Mandatory sign: Safety eyewear must be worn.
Mandatory sign: Overalls must be worn.
Sidel S.p.A.
Mandatory sign: Safety harness must be worn.
1.1
II - 9
Matrix Filler
2.7
Part II
OPERATOR SAFETY
The machine is fitted with fixed guards and opening guard doors around the operating area of the machine.
These limit access to the machine are are designed to protect the safety of the operator. The machine is also
fitted with electro-mechanical safety devices including emergency stop pushbuttons, microswitches and
warning lights. These devices stop the machine or prevent it from being started, display a fault message on
the control panel and light up the red section (flashing) on the signal light column. To restart, trace and
remove the cause of the stoppage and then press the Reset button.
IMPORTANT: Tampering with or removing safety devices is strictly prohibited. The manufacture
declines all liability for damage or injury caused by tampering with, bypassing or removing
safety devices.
2.7.1
Operator guard and protection devices
Tight Area Protection - Reduced Filling Area:
(Example picture)
Sidel S.p.A.
Legend:
Light beacon
Operator area
Front access area
JOG unit
Operator position
Rear access area
Emergency stop button
II - 10
1.1
Matrix Filler
Part II
Wide Area Protection:
(Example picture)
Legend:
Light beacon
Operator area
Front access area
JOG unit
Operator position
Rear access area
Emergency stop button
Sidel S.p.A.
Emergency handle
1.1
II - 11
Matrix Filler
2.7.2
Characteristics and operation of safety devices
Safety devices fitted on the machine:

Fixed guards
COMBI interface protection panel
Rear doors
Front doors
Mushroom-head emergency stop buttons
JOG pushbutton panel
Emergency handle (if present)
JOG production mode selector
Main ON-OFF switch
Valve position sensors
Air ON-OFF valve
CO2 ON-OFF valve (only CSD)
Tank safety valve (if fitted)
ON-OFF valves for chemical solutions
Signal light column with siren
Eye bolts to secure operator safety harness
Sidel S.p.A.
II - 12
1.1
Part II
Matrix Filler
Part II
A.
Fixed guards
The machine is fitted with fixed guards to protect the machine areas which do not need to be accessed
during operation (guards, grills, etc.).
B.
COMBI interface protection panel
The COMBI interface protection panel is interlocked and separates the machine infeed from the blower
outfeed.
A different panel must be fitted depending on whether the machine is no production or sanitization:
Panel OPEN - machine in PRODUCTION

Only the bottles are allowed to pass by reducing to a minimum the area of contamination with
the blower.
Panel CLOSED - machine in SANITIZATION

The panel is completely closed.
To change the Combi interface panel, under safe conditions access the panel through the
blower doors. If necessary temporarily move / remove the guides / starwheels.
Sidel S.p.A.
IMPORTANT: Do not open the panel during a production cycle or during a sanitizing cycle.
1.1
II - 13
Matrix Filler
C.
Part II
Rear doors
Tight Area Protection and Reduced Filling Area

These guards are fitted with safety microswitches (1) and have a mechanical lock opened with a safety key
(2).
The safety key must be managed and kept by the person authorised to manage the equipment.
Access to the rear of the machine is for authorised, qualified personnel only.
The machine must not be operated in the production mode with the rear guard doors open. In the JOG2
production mode all machine movements will be preceded by an acoustic warning.
In the JOG sanitizing mode you may enter through the rear doors to insert the dummy bottles. The acoustic
warning will sound. The procedure is as follows:
a)
b)
c)
d)
e)
Set the machine to the sanitizing mode.

Select the operating mode using the mode selector on the operator interface.
Check that all the rear doors are closed.
Open one of the doors using the key provided.
Enter the machine taking the JOG2 button panel and the safety key with you.
Sidel S.p.A.
IMPORTANT: Do not open the doors during a production cycle or during a sanitizing cycle.
II - 14
1.1
Matrix Filler
Part II
Wide Area Protection
These guards have electro-mechanical microswitches with electrical safety locks.
7
2
6
4
1
5
3
(Example picture)
1
2
3
4
Production Jog selector

Lock unlock selector
Front JOG control socket
Rear JOG control sockets
5
6
7
8
Safety device reset button

Safety device reset buttons
Production Jog internal selector
Emergency handle
There are two different procedures to open the doors, as follows:

Access procedure without use of jog control
a) Stop the machine.
b) Insert the key in one of the Lock - Unlock selectors (2) and turn it to unlock. If the machine is
stopped the guards are unlocked (green light ON), thus allowing access inside the machine.
Remove the key from the selector and keep it on your person.
c) Open the door using the handle (8) and enter.
Sidel S.p.A.
When you have finished:

d) Make sure nobody is inside the machine, close the guards, insert the key in the Lock - Unlock
selector (2) and turn it to lock. This action locks the guards. Remove the gear and keep it on your
person.
e) Press the safety device reset button (5) and then the machine start button.
1.1
II - 15
Matrix Filler
Part II
Access procedure with use of jog control

a) Stop the machine.
b) Move the Production Jog selector (1) to jog.
c) Remove the jog control panel from the front socket (3) and keep it on your person.
d) Insert the key in one of the Lock - Unlock selectors (2) and turn it to unlock. If the machine is
stopped the guards are unlocked thus allowing access inside the machine. Remove the key from
the selector and keep it on your person.
e) Open the door using the handle (8), enter and then close the door.
f) Insert the plug of the jog control panel in one of the rear sockets (4) and insert the key removed
from the selector (2) in the internal Production Jog selector (7). Turn the key to Jog.
g) Press the safety device reset button (6) and then move the machine forward slowly using the jog
control panel.
The operations inside the cabin must be performed by a single person only. If another person
enters the cabin when an operator is already inside, the machine is stopped under safe
conditions and cannot be started.
When you have finished:
h) Check that nobody is inside and turn the internal Production Jog selector (7), previously turned
to jog, back to production.
i) Remove the key and remove the jog control panel from the socket.
j) Exit the cabin and close the guards.
k) Insert the key on one of the two selectors (2) and turn the key to lock. This action locks the guards.
Remove the key and keep it on your person.
l) Turn the Production Jog selector (1) to production.
m) Insert the jog control panel in the front socket (3). Press the safety device reset button (5) and then
the machine start button.
Sidel S.p.A.
In the event of power failure, use the emergency handle (8) to exit the chamber (see below).
II - 16
1.1
Matrix Filler
Part II
Option with wide area protection interlocked keys

With the interlocked keys option, proceed as follows to open the doors:
a)
b)
c)
d)
e)
Stop the machine.

Turn the key selector to open on the main control panel.
When the machine is stopped, the ON/OFF switch 1 is disabled. This releases a key which must be
inserted in the key holder 2.
Insertion of this key in the key holder 2 releases two other keys used to open the locks 3 and 4 located
on the guard uprights.
When the keys, released from the key holder 2, are inserted in the locks 3 and 4, a key is released
which the operator must keep on their person during maintenance operations inside the rear chamber.
When you have finished, repeat the operations described above in reverse order.
If one of the keys from the locks 3 and 4 is missing then the key, destined for the key holder 1, cannot
be released from the key holder 2, and therefore the machine cannot be started.
Sidel S.p.A.
(Example picture)
1.1
II - 17
Matrix Filler
D.
Part II
Front doors
These guards have electro-mechanical microswitches with electrical safety locks.

To open these doors, proceed as follows:
a)
b)
c)
Stop the machine.

Turn the key selector to open on the main control panel.
When the machine has stopped, open the door required.
To restart, close the doors, return the key selector switch to the Close position and then start the machine.
To enter inside the filler in a safe condition, proceed as follows:
a)
b)
Open the door.

Hold the JOG pushbutton panel with the emergency stop pressed down.
Opening the doors will have the following effect:

a)
b)
c)
d)
The automatic controls will move the filling valves to the home position.
The brake will be actuated.
The bottle block will remain in its current position.
The power supply to the main motor contactor will be powered down by hardware.
In some cases in addition to the keyswitch on the main control panel there is also a keyswitch on the
upright close to the outfeed belt.
Sidel S.p.A.
DO NOT use the machine with the guards disabled.
II - 18
1.1
Part II
E.
Matrix Filler
Mushroom-head emergency stop buttons
The machine is fitted with mushroom-head emergency stop buttons. The buttons are red on a yellow
background. Press one of these buttons to stop the machine immediately by overriding all other operations.
These safety devices must be used:
-
In the event of an imminent hazard or mechanical accident.

When the machine has already been stopped after a brief period of time to ensure the machine
remains stopped.
The buttons must be kept pressed in the event of:

Maintenance.
Operations requiring the presence of the operator inside the hazardous area.
To restart the machine after an emergency stop, press the ALARM RESET button and then the
START button.
DO NOT USE THE EMERGENCY STOP BUTTON FOR NORMAL OPERATING STOPS.
Sidel S.p.A.
1.1
II - 19
Matrix Filler
F.
Part II
JOG pushbutton panel
In addition to the main control panel on the console, on board the machine there is also a MAINTENANCE
PUSHBUTTON PANEL with three connectors for plugging into and selecting the intervention zone.
a)
b)
c)
Front connector, for front access to the base.

Rear connector, for access to the rear of the machine (filler carousel).
Side connector, reserved for the side accesses of the base.
The pushbutton panel has a JOG button.

The intervention zones are selected by using the selector on the main control panel and by plugging the JOG
unit into the connector of the zone required. The button panel is mobile and has a coiled connecting cable
1.5 metres long which extends to 4.5 metres.
Joystick pushbutton panel:
Press the button for machine start.

Release or fully press the button for machine stop.
Two hands pushbutton panel:
50
Sidel S.p.A.
Connector
10,5
Press the buttons at the same time for machine start.

Release at least one button for machine stop.
II - 20
1.1
Matrix Filler
Part II
Emergency handle (if present)
G.
The machine is fitted with an emergency handle located on the rear guard doors.
-
The external handle (silver) can be used to open and close the door.
The internal handle (red) can be used to open the door only. The door cannot be closed from the
inside. When the door is open, the red handle moves but the door cannot be closed.
A
B
Handle open position

Handle closed position
The emergency handle is used to exit the chamber in the event of accidental closure of the rear doors
and during power failures.
H.
JOG-AUTO mode selector
2-way selector:
-
JOG pushbutton panel.

Automatic operation.
This is a key selector switch which can be locked in either of the positions by simply removing the key. In the
interests of safety, the key should be removed from the selector and kept by the person authorised to
manage the equipment.
Sidel S.p.A.
This selector is on the control panel.
1.1
II - 21
Matrix Filler
I.
Part II
Main ON-OFF switch
The main ON-OFF switch is on the machine electrical cabinet. It can be padlocked.
Before you start any maintenance on the machine, switch off and lock out the main ON-OFF switch on the
electrical cabinet.
When you have finished maintenance, return the switch to the I (ON) position.
J.
Valve position sensors
Sidel S.p.A.
These sensors check that the CIP and production automatic valves on the CIP and production piping are in
the correct position. Their purpose is to ensure that the flow of product and sanitizer is taking place
efficiently.
II - 22
1.1
Matrix Filler
Part II
K.
Air ON-OFF valve
The air ON-OFF valve switches the supply of air to the machines pneumatic circuits ON and OFF. The valve
can be padlocked.
Before you start any maintenance, switch off and lock out this valve.
When you have finished maintenance, reopen the air ON-OFF valve.
To restart the machine, close the guards and hold the RESET button pressed down for approx. 15 to 20
seconds. This will pressurise the air system, reset the pressure switch and reset the ON-OFF solenoid valve.
Padlocked valve
L.
CO2 ON-OFF valve (only CSD)
The CO2 ON-OFF valve switches the supply of carbon dioxide to the machine ON and OFF. Before you start
any maintenance, switch off this valve.
Sidel S.p.A.
ON-OFF valve
1.1
II - 23
Matrix Filler
M.
Part II
Tank safety valve (if fitted)
The safety valve on the tank pressure circuit is calibrated to trigger when the circuit pressure reaches the
limit value defined in the system design.
IMPORTANT: Carbon dioxide is heavier than air. If the safety valve triggers it will discharge CO2
through the exhaust pipe towards the ground. This does not constitute a hazard to the operator.
However, the concentration of CO2 above certain limits in the area around the machine can be
harmful to the health of exposed persons. The machine should therefore be installed in wellventilated surroundings where a ventilation system ensures a regular, assisted change of air.
IMPORTANT: During normal operation the safety valves do not operate. We recommend that
you check the efficiency of these valves at regular intervals and check that the valve is not
stuck in its seat. To do this, lift the lever until the valve starts to discharge carbon dioxide.
N.
ON-OFF valves for chemical solutions
Sidel S.p.A.
The machine is fitted with ON/OFF valves for the chemical solutions used to sanitize the filling circuit.
II - 24
1.1
Matrix Filler
Part II
O.
Signal light column with siren
The signal light column lights up to indicated various machine operating conditions.
The siren sounds to indicate that the machine is starting in a particular condition.
During production when the machine is electronically interlocked and stopped with other machines the siren
will sound just before restarting.
Red
Yellow
Green
Siren
Green light
Normal start
Flashing yellow light
Bottle block due to external sources
Flashing red light
Stopped under safe conditions
P.
Eye bolts to secure operator safety harness
The eye bolts fitted on the filler carousel column are designed for securing the safety harness worn by
mechanical operators during maintenance on the carousel.
Golfare
Sidel S.p.A.
Golfare
1.1
II - 25
Matrix Filler
2.8
HAZARDOUS AREAS
2.8.1
Hazard zones
Part II
Hazard zones are any areas of the machine where there are potential hazards during standard operations.
These zones are protected by the guard devices listed in the previous section.
Combi
BlockRinser
Electrical hazard zones

Crushing hazard zones
High-temperature hazard zones
Sidel S.p.A.
Chemical hazard zones
II - 26
1.1
Matrix Filler
Part II
2.9
RESIDUAL RISKS AND HAZARDS
The system has been designed and manufactured to ensure the highest standards of protection for operator
health and safety. While every effort has been taken to reduce risks, the following residual risks remain:
a.
Residual crushing hazard:
When an operator enters a hazard zone to perform adjustment or maintenance and another operator
attempts to start the machine.
To reduce this hazard:
-
b.
Follow the procedure for accessing hazard zones. Keep the access door open throughout the
entire operation.
After an Emergency stop pressed alarm, check that there is no-one inside the hazard zone
before restarting the machine.
Residual falling or slipping hazard:
Hazard for the operator during maintenance or repairs at the top of the machine.
Exercise extreme caution when accessing these components. Use appropriate PPE and safety equipment in
compliance with local health and safety regulations.
This hazard increases when working on surfaces which are very slippery, for example during emptying of the
crown capper when the operator support surface is wet.
c.
Residual burn hazard due to acid:
During sanitization when corrosive products such as acids and alkaline lyes are used.
-
Follow general safety guidelines and the specific instructions of the manufacturer when using
these products.
Avoid contact with the skin and especially the eyes.
Wear protective clothing, safety glasses and safety footwear. During the sanitization cycle do not
stand near emptying or drainage piping or near to the filling area.
In the event of accidental contact with acid, rinse the area of the body affected using running
hot water. In the event of prolonged contact, seek immediate medical assistance at the nearest
accident and emergency department making sure you have with you the toxicology sheet for
the product.
d.
Residual falling load hazard:
When the operator lifts machine components during transport, handling and maintenance.
Sidel S.p.A.
Exercise extreme caution when performing these operations. Use appropriate PPE and safety equipment in
compliance with local health and safety regulations.
1.1
II - 27
Matrix Filler
e.
Part II
Residual burn hazard:
When the operator comes into contact with hot machine components during the sanitization process.
-
f.
Wear protective clothing, safety glasses and safety footwear. During the sanitization cycle do not
stand near emptying or drainage piping or near to the filling area.
Allow the hot surfaces to cool naturally. This should take approximately 10-30 minutes. Do not
cool the surfaces artificially to ensure more rapid intervention as this may cause damage to
machinery and injury to personnel.
Residual suffocation hazard:
During production, nitrogen is fed into the tank to create an inert, non-oxidising atmosphere which protects
the filling product. The flow of nitrogen saturates the space inside the tank and as a result eliminates any
oxygen present.
IMPORTANT: Suffocation hazard. The lack of oxygen inside the tank constitutes a residual risk
of suffocation for operators who work inside the tank during maintenance operations.
-
Maintenance operations which involve dismantling of the upper manifold of the tank either alone
or with other components are to be performed by Sidel specialist personnel only. OTHER
PERSONS ARE NOT AUTHORISED FOR THESE OPERATIONS AND MUST NOT PERFORM
SUCH OPERATIONS.
g.
Residual flying material hazard.
h.
Hazard for persons with pacemakers:
The optional stirrer fitted to the tank is magnetic. The manufacturer warns that there is a residual risk for the
wearers of pacemakers. Wearers of pacemakers must not approach this equipment.
-
Sidel S.p.A.
HAZARD WARNING. NO PACEMAKERS. There is a residual risk to wearers of pacemakers.

Wearers of pacemakers are forbidden to approach the tank stirrer.
Users must read all the machine manuals before proceeding with any operation on the machine.
II - 28
1.1
PART III
TECHNICAL DATA
Sidel S.p.A.
Part III
Matrix Filler
User Manual / Technical Data
1.1
III - 1
Matrix Filler
3.1
Part III
DIMENSIONS
Sidel S.p.A.
The dimensions are shown in the drawing in PART X APPENDICES, section 10.1.1 Layout and
connections.
III - 2
1.1
Matrix Filler
Part III
3.2
MACHINE CONFIGURATION
3.2.1
Technical data
Project
SMMM3084
Serial number - WBS
SRMB0119
Description note
Matrix SF300
Machine family
Matrix
Year of manufacture
2013
Bottle type
PET
Filling temperature
Water: Ambient
COKE: 18 C
SPRITE: 18 C
RTO: 18 C
No. of capper heads
24
Capper manufacturer
AROL
EURO PK
Line power voltage
400V
Line power frequency
50Hz
Specifications
Consumption
Flow rate
Production
speed (bph)
Bottle volume
(lt)
Beverage type
Production
(lt/h)
P01QD023-005
36.000
COKE
36.000
11034160-01
36.000
1.5
SPRITE
54.000
11034200-01
36.000
1.5
RTO
54.000
11034102-01
36,000
1.5
COKE
54,000
11034161-01
24.000
COKE
48.000
11060292-01
44.000
0.33
VIVA
13.200
11060326-01
44.000
0.5
VIVA
22.000
11026397-04
36.000
VIVA
36.000
X-Z00-11-6928
44.000
0.3
COKE
13.200
11060349-01
44.000
0.5
WILKINS
22.000
Sidel S.p.A.
Bottle design
1.1
III - 3
Matrix Filler
3.3
MACHINE AND ENVIRONMENTAL CHARACTERISTICS
3.3.1
Man - machine interface
Part III
Movement and control system interface

This includes:
-
Display unit.
Standard controls.
Filling valve test pushbutton panel.
Removable jog pushbutton panel and two front and rear connection sockets.
Display unit
The display unit is used to run non-critical control operations such as response time, that is to say:
-
Operating mode setup (sanitization, jog), etc.

Control operations not included in the standard controls for each operating mode.
Transmission of parameters to the PLC.
The following are also implemented:

-
Summary diagram.
Diagnostics.
Standard controls
Some standard controls have been included to ensure quick and safe intervention by the operator, for
example:
-
Machine stop.
Machine start.
Bottle block.
Etc.
Filling valve test pushbutton panel

A specific pushbutton panel is used to check the efficiency of each filling valve (see section 6.1.2).
Jog pushbutton panel
Sidel S.p.A.
Two sockets have been included to connect the jog mobile pushbutton panel to facilitate machine setup and
maintenance.
III - 4
1.1
Matrix Filler
Part III
3.3.2
Ambient installation conditions
Airing the room

The machine must be installed in a working environment with suitable fresh air circulation.
Ambient temperature
The machine should be installed in a room within the following temperature limits to ensure good operation
and safety:
-
Storage temperature: 10 C to + 60 C.
Ambient operating temperature: 10 C to 45 C.
Electric power cabinet temperature: < 45 C.
Vibrations
Sidel S.p.A.
The machine is designed and manufactured in compliance with current directives and the permitted level of
vibrations.
1.1
III - 5
Matrix Filler
3.4
PERFORMANCE LEVELS
3.4.1
Speed variations
The machine has three operating modes:

-
Production
Jog control
Sanitization or rinsing
The speeds which can be selected are as follows:

-
Sidel S.p.A.
production mode
Speed = 4000 up to max. b/h value
jog mode
Speed = 4000 6000 b/h
sanitization mode
Speed = 4000 8000 b/h
III - 6
1.1
Part III
Matrix Filler
Part III
3.5
POWER AND CONSUMPTION
3.5.1
Installed voltage and power
See PART X APPENDICES, section 10.1.1 Layout and connections
3.5.2
Tanks
External static tank (if fitted)

Maximum pressure (PS)
7 bar
Volume (V)
1030 litres
Maximum temperature (TS)
+95 C
Minimum temperature
-10 C
Fluid unit fitted
1 (Sanitizing) IN SANITIZATION
2 (beverage, CO2) IN PRODUCTION
Manifold tank:
Maximum pressure (PS)
3 bar
Volume (V)
146 litres
Maximum temperature (TS)
+95 C
Minimum temperature
-10 C
Fluid unit fitted
1 (Sanitizing) IN SANITIZATION
2 (beverage, CO2) IN PRODUCTION
3.5.3
Piping
Refer to the relevant parts lists for the dimensions of the following pipes:
3.5.4
Product feed pipe.

Product manifold.
Product infeed pipe.
CO2 infeed / outfeed pipe.
Sanitizer infeed pipe.
Sanitizer return pipe.
Pressurised tank safety valves (if fitted)
Calibration pressure
7 bar
Type of fluid
Gas
Minimum discharge flow rate
1000 m/h
1.1
Sidel S.p.A.
III - 7
Matrix Filler
3.6
WEIGHTS
Base
See PART X APPENDICES, section 10.1.1 Layout and

connections
Filler carousel
SKID + Electrical cabinet
Rinser carousel*
Sidel S.p.A.
* If fitted
III - 8
1.1
Part III
Matrix Filler
Part III
3.7
NOISE LEVELS
The machine is fitted with special devices for limiting the noise emitted at source.
The noise level of the machine, as well as depending on the movement of moving parts, also depends on the
working environment where the machine is installed and the type of filling containers used on the system.
The noise levels measured in the operator position are as follows:
-
Mean continuous acoustic pressure level A1 LAeq = 72 dB(A).

Maximum mean instantaneous acoustic pressure value C1 Lpc < 80 dB(C).
The measurement conditions were as follows:

Product dimensions:
-
length
width
height
20 m
10 m
8m
Installation environment:
-
floors
covers
walls
Coefficient for
environments:
smooth concrete
tiles
with side glass panels
the
type
of
= 0.15 (environments with lots of installations and smooth

walls)
Meter used:
Bruel & Kjaer mod. 2221 Class 1.
Reference standards:
DIN 45635
Sidel S.p.A.
IMPORTANT: If the machine is installed in a reverberating environment or in the presence of

other sources of noise and the level of daily exposure is greater than 87db(A), there is a
potential hazard and employers must supply PPE (ear muffs, ear plugs) to personnel to protect
their hearing.
1.1
III - 9
Matrix Filler
Sidel S.p.A.
III - 10
1.1
Part III
Matrix Filler
User Manual / Installation
Part IV
INSTALLATION
Sidel S.p.A.
PART IV
1.1
IV - 1
Matrix Filler
4.1
PACKAGING AND SHIPPING
4.1.1
Type of packaging
Part IV
Given their large size, Sidel machines are shipped dismantled.

Given the modes of transport used for shipping, SIDEL has designated three levels of packaging to ensure
optimum protection of the various machine components for the entire duration of shipping.
Level 1: Light protection suitable for road transport. Usually a casing to protect against flying objects.
Level 2: Protection suitable for shipping at sea. This is a sealed cover with an air pocket to protect all
components at risk of corrosion. All components outside of the profile are shipped inside wooden crates.
Level 3: Reinforced protection suitable for combined shipping at sea and by road with multiple handovers.
All components are packed in wooden crates and protected inside the crates by a sealed cover with an air
pocket.
Further details concerning these types of packaging are available from SIDEL on request.
4.1.2
Incoterm requirement
The Incoterm defines the risks associated with shipping. The Incoterm is specified in the machine sales
contract.
Whatever the Incoterm, customers must inform hauliers of any visible issues with the crates when they are
unloaded on their premises. Management of damage in relation to insurance policies is the responsibility of
either the customer or SIDEL depending on the Incoterm.
4.1.3
Moving the packed machinery
IMPORTANT: Unless otherwise stated in the sales contract, customers are responsible for
unloading the machinery.
Sidel S.p.A.
Standard pictograms are attached to the crates and packages. The pictograms give instructions
concerning how to handle the crates and packages.
IV - 2
1.1
Matrix Filler
Part IV
4.1.4
Receiving the material
IMPORTANT: When the material is unloaded the customer must thoroughly check all the crates
and packages and inform the haulier of any doubts concerning degradation of the crates or
packages.
Photographic evidence is useful to document the state in which the materials were received.
Degraded packaging must be kept for inspection by personnel from Sidel or the insurer.
4.1.5
List of components
A packing list is included with the delivery documents. See example (A).
This packing list indicates the main components contained in each crate.
1.1
Sidel S.p.A.
A detailed list of each crate / pallet is included in the installation dossier in the possession of the site
manager.
IV - 3
Matrix Filler
4.1.6
Part IV
Storage conditions for packed machinery
As soon as the crates are unloaded, all machinery must be stored in a closed, clean and dry room protected
against freezing temperatures until the SIDEL site manager arrives.
The floor of the building must be strong enough to withstand the weight of the entire machine inside the crate
and allow movement of equipment used to move the machinery.
IMPORTANT: SIDEL accepts no responsibility in the event of failure to comply with these
storage requirements.
IMPORTANT: Do not cover the machine with waterproof sheets as this prevents water
evaporation.
Sidel S.p.A.
IMPORTANT: Do not expose the machine to sunlight.
IV - 4
1.1
Matrix Filler
Part IV
4.2
FOUNDATIONS
The machine does not require special foundations. You should check that the foundations provided can bear
the load of the machine.
Sidel S.p.A.
IMPORTANT: The machine must be positioned on a floor surface with the load bearing capacity
specified by the machine manufacturer and given in section 3.
1.1
IV - 5
Matrix Filler
4.3
MOVEMENT AND POSITIONING
4.3.1
Delivery to the customer's premises
Part IV
The facility receiving the equipment must have already prepared the following:
-
The installation space.

Equipment for unloading and positioning the equipment (crane, fork-lift trucks, transpallets).
Receipt, unloading and handling of the machine must be supervised by the manager authorised.
The manager is responsible for supervising unloading and checking that the material delivered matches that
on the delivery/shipping note. The manager must check for missing or damaged parts.
IMPORTANT: Check that the slings, fork-lift trucks and handling equipment have an appropriate
load bearing capacity.
IMPORTANT: The lifting equipment supplied with the machine (chains, slings, lifting bars and
arms) must be used for handling this machine. The lifting equipment is provided solely for
handling the machine with which it is supplied and described in this manual.
All other uses including use on similar machines is strictly prohibited and constitutes improper
use. SIDEL declines all responsibility for improper use and failure to comply with this
instruction.
4.3.2
Tooling supplied with the machine.
The machine is delivered together with a series of tools required for movement and assembly. The list of
tools is as follows:
1.
2.
3.
4.
5.
6.
4.3.3
Complete set of Allen keys.

Set of spanners from 7 to 22.
Plate spanner.
Special wrench (to be used for the expansion pulleys).
Grease gun.
Pin punch.
Unpacking and hoisting
The following instructions should be followed carefully to ensure safe movement of the machine:
1.
2.
3.
Sidel S.p.A.
4.
IV - 6
Move the unpacked machine as close as possible to the installation area then unpack the machine
making sure the contents of the crates and packages match that specified on the delivery document.
Remove the cover and then all the dismantled components and accessories.
Free very carefully all the material used to package the machine.
Separate the base of the machine from the machine surface by removing, if present, the wooden side
securing plugs or securing screws inserted under the support surface.
Lift the components using the eye bolts, where fitted, or the points indicating where the eye bolts
should be secured. Attach the cables securely to the eye bolts and the hook of the crane or overhead
crane.
Units not fitted with eye bolts or on which eye bolts cannot be secured must be lifted using straps
positioned so that the weight is balanced.
1.1
Matrix Filler
Part IV
5.
When lifting the machine using a forklift truck with flat forks, make sure the forks are at least as long as
the machine.
IMPORTANT: When lifting the machine take up the slack on the straps slowly and make sure
that components unable to withstand the weight of the unit, such as electrical parts, conduits,
rollers, etc., are not affected by the lifting process.
IMPORTANT: The customer is responsible for disposing of packaging material in compliance
with legislation in the country where the machine is installed.
Check that the slings, fork-lift trucks and handling equipment have an appropriate load bearing
capacity.
The machine is fitted with eye bolts and anchoring points to facilitate movement operations.
The nominal load bearing capacity of a forklift truck is not the same as the actual capacity which varies in
accordance with height at which the operation is performed and the barycentre of the load relative to the
spine of the forks.
a)
b)
4.3.4
Crate: take hold of the crate in the positions indicated using the chain pictogram and keep it in the
position indicated by the pictograms.
Machine: Lifting must be done with care to prevent damage to the machine caused by the forklift truck
clamps, straps or lifting hooks of the crane.
Removal of scrap material
Sidel S.p.A.
If the customer has requested special protective greases for the machine then the customer is responsible
for removing them before assembly.
1.1
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Matrix Filler
4.3.5
Part IV
Moving and positioning the machine
Move and position the machine in the following order:

1st blower
2nd transfer table
3rd filling carousel and crown capper
The machine, consisting of the filler, bases and the Skid (if present), must be moved and positioned as
follows:
The filler block is fitted with holes to which the lifting
equipment must be secured (yellow).
The hooks of the chain must be secured to the special
eye bolts (see photo) so that the filling carousel is
balanced.
The bases are fitted with holes to which the lifting

equipment must be secured (yellow).
Sidel S.p.A.
The hooks of the chain must be secured to the special

eye bolts (see photo) so that the base is balanced.
IV - 8
1.1
Part IV
Matrix Filler
Before positioning, make sure the plates used for

shipping are free from the base of the shipping crate.
Position the machine feet securing plates in compliance

with the system layout drawing.
The plates must be bolted to the floor when the correct
position has been identified.
Position the machine in compliance with the system

layout drawing making sure the feet are resting on the
plates bolted to the floor earlier.
Sidel S.p.A.
Adjust the feet support bar to level the machine with the
floor and the line.
1.1
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Matrix Filler
Part IV
Place a spirit level on the special supports to check the

level.
This should be done on all the machine supports.
After positioning and levelling of the machine, remove

the plates used to move the machine (A) by unscrewing
the bolts (B).
Start the machine and wait for it to stabilise.

IMPORTANT: Do not start the machine if it is
not perfectly level.
When stabilisation is complete, weld the feet of the
machine to the plates bolted to the floor in compliance
with the layout shown alongside (see PART X
APPENDICES, section 10.1.2 Moving the machine).
4.3.6
Hook positioning table
Sidel S.p.A.
IMPORTANT: The machine must be positioned by securing the special lifting equipment to the
attachment points of the frames (fitted with eye bolts) indicated in the table shown in PART X
APPENDICES, section 10.1.2 Moving the machine.
IV - 10
1.1
Matrix Filler
Part IV
4.4
CONNECTIONS AND CABLING
Connections and cabling for the electric, hydraulic and compressed air systems must be able to withstand
the maximum machine absorption values, as indicated in the technical data table (section 3.2.1).
IMPORTANT: Only QUALIFIED personnel are permitted to perform the activities described in
this section.
4.4.1
Electrical connection (responsibility of the manufacturer)
The electrical connection is made in compliance with general regulations for installing, preparing and putting
into service industrial electrical systems.
4.4.2
Compressed air connection (responsibility of the customer)
The machine must be supplied with dry air which is not lubricated. Damp air and air with lubricating fluid
cause the pneumatic parts to stop operating immediately and usually these parts are blocked as well.
4.4.3
Earthing system
The metal structures of the machine are earthed using insulated conductors connected to the earth bar of
the electrical cabinet (supplied by the manufacturer).
The earthing system and the connection of the main earth terminal in the electrical cabinet with the earth bar
of the distribution panel must be implemented in compliance with the general regulations for industrial
electrical systems.
4.4.4
Connection for liquid waste disposal
IMPORTANT: Liquid waste may contain substances which are not very biodegradable or even
harmful for the environment. This waste must be purified before disposal.
In the event of disposal into sewer systems or surface water (rivers, lakes sea), authorisation may be
required in compliance with current legislation concerning environmental protection in the country of use.
Sidel S.p.A.
If drain points are connected to tanks then this waste must be treated as liquid waste by following the
procedures described in section 4.7 Decommissioning and Disposal in this manual and in compliance with
current legislation concerning environmental protection in the country of use.
1.1
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Matrix Filler
4.4.5
Part IV
Connection for disposal of fumes
IMPORTANT: All fumes should be conveyed outside the working area or the fumes should be
purified before being recycled into the working area to protect the health and safety of the
workforce.
If fumes are conveyed outside the working area, authorisation may be required in compliance with current
legislation concerning environmental protection in the country of use.
4.4.6
Accidental spillage of substances harmful to the environment
Substances harmful to the environment cannot be released from the machinery during normal operation
because the machinery is designed to store processing liquids internally. Leaks can be classified as
accidental events.
Hazardous substances include:
-
Oils and greases.

Sanitizing products.
OILS AND GREASES

IMPORTANT: During maintenance check the devises used to close the lubrication circuits are
fitted, tightened correctly and that they do not leak. Check there are no leaks or spillages
around seals.
In the event of spillages the lubricant must be collected and disposed of in compliance with
current legislation in the country of use. Clean any parts affected by the spillage.
SANITIZING PRODUCTS
IMPORTANT: Accidental leaks of sanitizing liquid can occur throughout the circuits used to
convey the filling product and the gas used for filling.
Leaks from the circuits can occur around couplings and in all those areas where seals or
gaskets are fitted.
If the liquid which has leaked risks being conveyed towards systems used for disposal into
sewer systems or surface water, authorisation may be required in compliance with current
legislation concerning environmental protection in the country of use.
Sidel S.p.A.
Alternatively the user must install collection and conveying systems in the areas at risk so any
spillages can be treated as liquid waste, by following the procedures described in section 4.7
Decommissioning and Disposal in this manual and in compliance with current legislation
concerning environmental protection in the country of use.
IV - 12
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Matrix Filler
Part IV
4.5
SETTING UP AND FIRST STARTUP

Carefully read all the manuals before you proceed with the operations described below.
The operations described below must only be performed by a SIDEL technician or under the supervision of
this technician.
4.5.1
Pre-startup settings
The machine must only be started by appropriately qualified personnel working in compliance
with all the safety regulations.
The machine has been designed and constructed to operate with the power sources and ratings
specified.
If the user modifies the machine or changes the power source or rating this could damage the
machine.
List of components and units to be adjusted

Machine in order of operation:
Customisation for the production installed.
Guard covers installed.
All the operating and workstation safety devices.
Visually inspect the machine for faults.
Before startup, check that all components are synchronised as specified.
Sidel S.p.A.
1.1
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Matrix Filler
4.5.2
Part IV
Pre-startup checks
The tests and checks must be performed by suitably qualified and trained personnel working in
accordance with the procedures of the country where the machine is installed.
Electrical and safety checks
Before you start the machine for the first time, proceed as follows:
-
Check that all the guards and guard doors are fitted to the machine.
Check that the main ON-OFF switches are ON. Check that the power supply line to these switches is
ON.
Check that the rating of the power supply line to the machine matches the SIDEL S.p.A. specifications.
Check that all the safety equipment (fuse holders, overload switches) are efficient and ready to
operate.
Power up all the service units to the machine.
Switch on the main ON-OFF switches on the electrical cabinets.
Using a voltmeter, test that power is arriving at the terminals of the safety devices (overload switches,
fuses). Follow the instructions in the electrical part of the manual. Close the safety devices again, one
by one.
Check the efficiency of the emergency stops. Check that when an emergency stop is pressed that this
shuts down the electrical and pneumatic power supplies and stops the machine immediately.
Check the efficiency of the electrical safety devices by checking that the appropriate LED lights up.
Mechanical checks
Connect up the circuits for compressed air, cleaning products, products, steam, water, nitrogen and valve
opening and then proceed as follows:
-
Check the pneumatic connectors and connections. Check for leaks.

Check the liquid connectors and connections. Check for leaks.
Check the steam connectors and connections. Check for leaks.
Check the product circuit connectors and connections. Check for leaks.
Check that all mechanical components are positioned correctly and firmly secured.
Check that there are no extraneous objects or obstructions inside the machine.
Checking the supply lines

Electrical power supply: Check that the rating of the power supply line to the machine matches the SIDEL
S.p.A. specifications.
Compressed air supply: Open the valves of the compressed air system. Check that the pressure is as
specified.
Cleaning and sanitizing products: Open the supply valve for the cleaning products.
Product: Open the product supply valve.
Steam: Open the steam supply valve. Check that the steam temperature and pressure are as specified.
Water: Open the water supply valve. Check that the water pressure is as specified.
During these checks, wear a face mask/visor, safety footwear, overalls, safety gloves and a
helmet.
Sidel S.p.A.
Check that there are no leaks of substances which might harm the environment. Repair any
leaks immediately.
IV - 14
1.1
Matrix Filler
Part IV
4.5.3
Cleaning and general inspection
Do not use high-pressure water jets to wash the machine. Water under high pressure will
damage electrical equipment.
Before you use the machine, check that it has been sanitized and cleaned.
Sanitize the machine and clean the machine completely. This will ensure compliance with
standard hygiene regulations.
If you are using chemical substances, check the Safety Data Sheets provided by the manufacturer to
identify any safety and environmental hazards for the chemical used.
Safety Data Sheets indicate the following:
-
Hazards.
Personal protective equipment and general protections required.
First aid instructions.
Fire prevention measures.
Action in the event of accidental spillage and leaks.
Physical and chemical properties.
Stability and reactivity.
Toxicological information.
Ecological information.
Disposal information.
Shipping and handling information.
The use of Safety Data Sheets translated into the language of the country of use is
recommended.
Main operations
Fill the soap and disinfectant dispensers.
Fill the mask, paper and glove dispensers.
Empty and disinfect the waste baskets in the production area.
Remove all extraneous or unused objects from the production area.
Thoroughly clean the platform.
Fill the manual spray jets.
Sidel S.p.A.
1.1
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Matrix Filler
4.5.4
Part IV
General cleaning
The machine must be cleaned immediately after the end of production. The purpose of cleaning is to prevent
the risk of contamination and to remove all product residues from the machine.
Daily cleaning is not related to production cycles.
General cleaning consists of implementing the standard hygiene procedures and includes the following:
-
Supply a sufficient amount of overalls, masks and gloves in the changing rooms.
Keep the work area clean. Remove any dropped containers.
Soiled paper or rags must be disposed of in accordance with waste disposal regulations in the
country where the machine is installed.
4.5.5
Cleaning products and equipment
Only use appropriate equipment to clean the areas inside the machine. Change damaged cleaning
equipment.
4.5.6
Safety warning
During all cleaning operations wear gloves, a mask and overalls.
Sidel S.p.A.
leaks immediately.
IV - 16
1.1
Matrix Filler
Part IV
4.5.7
First startup
Check that you have sufficient caps, capsules and bottles to complete the production cycle which is
about to be started.
The first startup procedure must be performed before the machine is put into service.
The first startup procedure must also be performed if the machine has been out of service for a long period.
4.5.8
Sanitizing the system
After installation run a sanitizing cycle on the machine to remove any machining waste, swarf, dirt and other
contaminants. (For instructions, see the CIP and COP sanitizing sections).
4.5.9
Setting up and first startup
In order to prevent errors and accidents, the machine is connected up to the customers electrical, water and
compressed air supplies by SIDEL S.p.A specialist technicians.
Only SIDEL S.p.A. personnel are authorised to perform the activities described in this section.
Check that all connecting components (couplings, solenoid valves, pumps and piping) are
tightened as per specifications. We recommend that you perform a complete cycle using water
so as to show up any leaks.
Perform the pre-first start up checks and check for any damage resulting from shipping, handling and
positioning.
When you have completed installation, check the machine timing.
Check that all safety devices are correctly fitted and are fully efficient.
Sidel S.p.A.
leaks immediately.
1.1
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Matrix Filler
4.6
Part IV
RE-INSTALLATION
IMPORTANT: The dismantling, reassembly and re-installation of the machine as described in
this section must only be performed by the following qualified personnel:
-
SIDEL S.p.A. technicians assisted by local personnel.

Skilled technician who has attended specialist training courses and has experience with
the installation, putting into service and maintenance of the equipment. This person must
also be fully conversant with the accident prevention regulations.
Refer to that stated in the first section for details of the procedure used to request the technical assistance of
Sidel S.p.A. personnel.
The machine will require dismantling if it is sold, installed in a new position or stored in the customers
premises. The general dismantling procedure is as follows:
a)
b)
c)
d)
e)
f)
g)
h)
Decide how the machine is to be broken down into its component parts. This decision depends on the
size of the transport vehicle(s) to be used and the number of component parts.
Position moving parts in the most favourable position for shipping.
Number the joins of all the parts to be separated. This will make reassembly quicker and easier.
Disconnect the electrical and compressed air supplies to the machine.
Disconnect all the electrical cables as follows:
- Disconnect the cables in the electrical cabinet.
- Pull these cables out of the cableways up to the unit to which they are connected.
Disassemble the machine into the component parts decided previously.
Any parts which might move or slide during transport must be mechanically clamped, fixed or tied
down.
On gear motors where there is a likelihood of oil leaks during transport, substitute the vented caps with
caps without vent holes.
IMPORTANT: See section 4.7 Decommissioning and Disposal for details of how to manage
waste.
Sidel S.p.A.
For instructions on positioning and connecting up the machine in its new position, see the related section of
this manual.
IV - 18
1.1
Matrix Filler
Part IV
4.7
DECOMMISSIONING AND DISPOSAL
The activities described in this section must only be performed by the following qualified personnel:
-

Skilled technician who has attended specialist training courses and has experience with the
installation, putting into service and maintenance of the equipment. This person must also be fully
conversant with the accident prevention regulations.
4.7.1
Disposal of packaging
Packaging complies with standards or current applicable legislation.

Customers are advised that they are under an obligation to dispose of packing materials in
accordance with local waste disposal regulations. See this section entitled DECOMMISSIONING
AND DISPOSAL.
In order to reduce environmental impact, packing should wherever possible be re-used, recycled or sent for
energy recovery treatment. Disposing of packing waste in other ways should be considered as a last resort
and should be reserved for materials that cannot be recycled or treated.
RE-USE OF PACKING
Some packing items such as wooden pallets and filling can be re-used for their original purpose. This
lengthens the life cycle of these items, reduces the amount of raw materials used for packing and reduces
the amount of packing waste.
SEPARATE WASTE COLLECTION. RECYCLING
Plastic packing
Plastic components can be recycled to produce new resources in the sector of origin or to produce
heat and energy through incineration. This ensures that at the end of their lifecycle, these components
do not become a burden on the environment as a result of disposal at a landfill site.
Polyethylene (PE), polypropylene (PP), polyethylene terephthalate (PET), polyvinyl chloride (PVC) are
some examples of recyclable polymers.
Paper, card and cardboard packing
Packing made from paper, card and cardboard can be reused in the papermaking industry.
The conventional papermaking process requires the felling of trees, large amounts of energy, large
amounts of water (which is returned polluted to the environment), various chemical substances and the
use of machinery and vehicles which are also a source of pollution. Recycling paper reduces all this,
reduces waste requiring disposal and reduces the work of purification plant.
Wooden packing
Wooden packing waste can be reused for: the production of wood composites (widely used in the
furniture industry); the production of cellulose pulp for the papermaking industry; the production of
composts following incineration in heat and electrical energy generation plant.
1.1
IV - 19
Sidel S.p.A.
Separating packing waste enables a vast range of waste materials to be reused ensuring significant
economic and environmental advantages.
Matrix Filler
4.7.2
Part IV
Dismantling and removing the machine
The machine will require dismantling if it is sold, installed in a new position or stored in the customers
premises. The general dismantling procedure is as follows:
-
Decide how the machine is to be broken down into its component parts. This decision depends on the
size of the transport vehicle(s) to be used and the number of component parts.
Position moving parts in the most favourable position for shipping.
Number the joins of all the parts to be separated. This will make reassembly quicker and easier.
Disconnect the electrical and compressed air supplies to the machine.
Disconnect all the electrical cables as follows:
Disconnect the cables in the electrical cabinet.
Pull these cables out of the cableways up to the unit to which they are connected.
Disassemble the machine into the component parts decided previously.
Any parts which might move or slide during transport must be mechanically clamped, fixed or tied
down.
On gear motors where there is a likelihood of oil leaks during transport, substitute the vented caps with
caps without vent holes.
For instructions on positioning and connecting up the machine in its new position, see the related section of
this manual.
The dismantling, reassembly and re-installation of the machine as described in this section
must only be performed by the following qualified personnel:
Skilled technician who has attended specialist training courses and has experience with
the installation, putting into service and maintenance of the equipment. This person must
also be fully conversant with the accident prevention regulations.
Sidel S.p.A.
IV - 20
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Matrix Filler
Part IV
4.7.3
Disposal of the machine
Only skilled, qualified personnel are authorised to dismantle this machine. These persons must comply
with all the applicable health and safety regulations.
At the end of the machine life cycle the plant user must decommission and dispose of the machine in
accordance with current regulations. Decommissioning primarily involves emptying lubricants from the
machine, complete general cleaning of the machine and then breaking the machine down into its component
parts.
Once the machine has been dismantled according to the procedure described above, the plant user must
separate the component materials by type in compliance with the regulations of the country where disposal
is to take place. The machine does not contain hazardous substances or components requiring special
dismantling procedures.
MATERIALS COMPRISING THE MACHINE

The materials comprising the machine are not hazardous and are as follows:
-
Stainless steel 300 and 400 series.

Polyethylene plastic, loaded and not loaded. Adiprene plastic.
Elastomers.
Gearbox oil.
Gear motor oil.
Electric motors.
Electric cables with sheathing.
Electronic control and actuating devices.
Support feet and rubber based materials.
During disposal, implement the local waste disposal and recycling regulations.
Sidel S.p.A.
Store polluting materials such as oils and solvents in metal containers.
1.1
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Matrix Filler
Part IV
CONSUMABLES
Consumables must be disposed of as follows:
Sanitizing products
Do not discharge sanitizing products into the public drainage system.
For information about local disposal regulations, contact your local health authority or factory inspectorate.
If you are using chemical substances, check the Safety Data Sheets provided by the manufacturer to
identify any safety and environmental hazards for the chemical used. Safety Data Sheets indicate the
following:
-
Hazards.
recommended.
Batteries
The PLC battery must be substituted by a maintenance electrician.
Used batteries must be separated from ordinary waste and delivered to an authorised disposal centre.
Reject bottles and caps
Reject bottles and caps must be treated according to their type and classification and in compliance with
local waste disposal regulations.
Product remaining
Some products must not be discharged into the public drainage system.
Sidel S.p.A.
For disposal instructions about filling products, contact your local health authority and read the safety data
sheets for each product.
IV - 22
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Matrix Filler
Part IV
Reduction gear oil
Dispose of old oil, oily residues and objects soaked with oil in compliance with local waste
disposal regulations.
Dispose of dirty, oily or greasy paper and cleaning rags in accordance with local waste disposal
regulations.
In the case of lubricating oils, check the Safety Data Sheets provided by the manufacturer to identify
any safety and environmental hazards for the lubricants used. Safety Data Sheets indicate the
following:
-
Hazards.
recommended.
Waste products from the pneumatic system
Sidel S.p.A.
Condensate discharged by the system may contain oil and must not be disposed of in the environment.
It must be collected and treated in compliance with the environmental protection legislation and
standards of the country where the machine is used.
1.1
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Matrix Filler
Part IV
SEPARATE WASTE COLLECTION. RECYCLING

The machine is designed using materials which can be easily recycled and used as materials for other
production processes.
Separating waste enables a vast range of waste materials to be reused ensuring significant economic and
environmental advantages.
Plastics
Plastic components can be recycled to produce new resources in the sector of origin or to produce heat and
energy through incineration. This ensures that at the end of their lifecycle, these components do not become
a burden on the environment as a result of disposal at a landfill site.
This material should be sorted and separated by type in order to facilitate efficient recycling.
Iron and steel
Scrap iron and steel can be sent to steelworks and foundries for use in the production of other metal
products. Once again, this material should be sorted and separated by type in order to facilitate efficient
recycling.
The machine consists almost entirely of stainless steel (non ferromagnetic).
Painted components are made from ferromagnetic steel.
Gears and gear motor bodies are made from cast iron.
Brass parts are easy to identify by their characteristic yellow colour.
PROCEDURE FOR DISMANTLING THE MACHINE

Before you start to decommission the machine, you should check local regulations regarding the following:
-
Compulsory notification and registration with control authorities.

Environmental protection regulations.
Waste and scrap disposal regulations.
Health and safety in the workplace regulations.
To dismantle the machine, proceed as follows:

1)
2)
3)
4)
5)
Sidel S.p.A.
6)
Disconnect the machine from the electrical, water and compressed air supply networks.
Empty the lubricant tanks. To do this, remove the drain plugs and collect the lubricant in a suitable
container. Do not mix different or incompatible types.
Dismantle the units containing grease (racks, couplings, controls). Clean these units.
Empty washing agents from the system. Collect the washing agents in a suitable container. Do not mix
different or incompatible types.
Proceed with dismantling of the machine. Sort and separate the various components by type as
indicated in the section Separate waste collection. Recycling.
Store and dispose of waste and recyclable material as indicated in this section and in compliance with
local regulations.
IV - 24
1.1
Part IV
Matrix Filler
WASTE MANAGEMENT
General instructions about waste management
Identify and classify waste in accordance with the current regulations in the country where the machine is
used.
Do not dump waste in the environment. Waste must be collected, separated and disposed of in a systematic,
controlled manner. Do not discharge waste liquids into surface or underground water.
Do not mix types of waste.
Deliver waste to accredited local agencies authorised to collect, transport and treat wastes.
Prepare the administrative documentation required by local regulations (production, storage and disposal
registers, transport documents).
Complete any administrative procedures required (keeping registers, preparing documentation).
1)
2)
3)
4)
5)
6)
Waste must be sorted and separated by homogeneous types.

Waste must be collected and stored by homogeneous type because this is the only way of:
Preventing the risk of chemical-physical incompatibility between waste products.
Ensuring correct final treatment and enabling the most efficient, least hazardous recycling
method.
It is important therefore not to mix types of waste.
Appropriate containers should be used for handling and stocking waste.
Waste containers must be resistant to the chemical-physical properties of the substances they contain
and must be appropriate to the hazards posed by those substances. (Example: Acid substances must
be kept in plastic containers or in suitably treated metal containers).
Container labelling.
During storage inside the company, containers must be marked with labels or plates enabling rapid
identification of the waste type and related hazards. The labels can be on the containers themselves or
in the storage areas.
The waste containers must be marked with details of the type of waste they contain and the related
health, safety and environmental hazards.
Handling waste inside the company.
During handling, ensure that the containers are completely closed.
When moving containers, avoid routes with drains and gulleys. This precaution is to prevent waste
from entering the public and rainwater drainage systems in the event of an accidental spillage.
You should provide suitable material and equipment in the handling area for absorbing waste in the
event of an accidental spillage.
Storing liquid waste (oil, acid).
In order to prevent spillage, containers holding liquids should be stored inside container basins.
The minimum capacity of these basins must be as great as the largest container to be held in
the basin.
Liquid containers must have closures designed to prevent leakage. Containers must be fitted
with lifting systems enabling safe and easy handling. Containers must be fitted with overflow
prevention systems. (If the overflow prevention system includes an overflow pipe, ensure that
the overflow is channelled in such a way that it does not constitute a health, safety or
environmental hazard).
Storing solid waste in heaps.
In order to prevent soil pollution, bulk waste stored in heaps must be stored on a resistant base
such as a paved flooring. Do not heap bulk waste on unprotected ground surfaces.
1.1
IV - 25
Sidel S.p.A.
General instructions for collecting and storing waste
Matrix Filler
7)
Bulk waste stored in heaps must be protected from the action of rainwater. Rainwater washout
from the heap can pollute ground water.
Storing incompatible wastes (e.g. acids and bases).
Wastes which are incompatible with each other must be stored so there is no possibility of contact
between them. Contact between incompatible wastes can cause hazardous reactions, fire and toxic
emissions and generate large amounts of heat.
Handling empty drums which previously contained hazardous waste.
Drums which previously contained hazardous waste may be used to contain the same type of waste. In
all other cases these drums must be decontaminated. It is important therefore that drums are marked
with details of the substances they contain or contained (if empty).
Sidel S.p.A.
8)
IV - 26
Part IV
1.1
Matrix Filler
User Manual / Operation
Part V
OPERATION
Sidel S.p.A.
PART V
1.1
V-1
Matrix filler
5.1
PERMITTED USE. IMPROPER USE. ENERGY REDUCTION
5.1.1
Design use
Part V
The filling machine is designed and manufactured to fill and cap bottles at high speed.
Uses other than the one for which the machine is explicitly designed and described in this manual are not
permitted. The manufacturer denies all responsibility in the event of incorrect machine use.
Operational criteria to reduce consumption
5.1.2
WATER
Optimum water consumption is achieved by complying with the following prescriptions:

-
Washing cycles should be brief and frequent.

Do not adjust the settings made after startup.
Routinely check the circuits for leaks.
Use cold water for recycling in the liquid loop of the vacuum pump (if fitted).
Dispose of waste washing water in compliance with legislation in the country of installation.
POWER
Optimum power consumption is ensured by routinely checking power absorption during normal machine
operation using the inverter interface fitted in the electrical cabinet. Increases in the consumption of
absorbed power indicate a fault or wear. In this case:
-
Check components are lubricated correctly.

Check the racks and the structures of the carousel and capper for wear.
Make sure the control gears under the base are clean. Make sure there are no leaks of oil from the
reduction gears.
Check the teeth of the gears under the base for wear.
INERT GASES
Optimum filling gas consumption is achieved by complying with the following prescriptions:
-
Sidel S.p.A.
Avoid frequent machine stops and restarts. Normal machine operation should be as constant as
possible.
Use the machine at the maximum nominal operating capacities.
Use pure gas ( 99.9%).
Do not use filling pressures greater than the ones required to ensure the correct balance of the
product.
Check the condition of the containers before filling. Broken containers result in greater consumption.
V-2
1.1
Matrix Filler
Part V
5.2
PRODUCTION LIMITS
IMPORTANT: The machine must be used in compliance with the limits relating to strokes,
dimensions, supported loads, materials and productivity specified in this manual.
Equipment must comply with that indicated in section 3 of this document and in Volume II Spare Parts
Catalogue. The equipment indicated is specifically designed by the manufacturer for the machine.
The manufacturer denies all responsibility for failure to comply with these safety instructions.
5.2.1
Instructions in the event of a fire
In the event of a fire involving the electrical cabinet, the equipment or parts of the cabling on board the
machine, proceed as follows:
Switch off the electrical power supply upstream from the electrical cabinet.
Fight the fire with a suitable extinguisher (powder, CO and other gases).
IMPORTANT: Do not use water.
IMPORTANT: Plant users must install their pressurised systems in surroundings where there is
no risk of fire. This is because pressurised systems which have been in contact with fire cannot
be used again.
Sidel S.p.A.
1.1
V-3
Matrix filler
5.3
OPERATING DESCRIPTION
5.3.1
Filling processes
Part V
The bottle filling process consists of the four steps:

1.
Infeed of empty bottles
COMBI Filler
The empty bottles coming from the blower are conveyed,
hung by their necks, to the filler infeed starwheel.
BLOCKRINSER Filler
The empty bottles arrive from the rinser on an air conveyor
and are fed to a starwheel which spaces them apart. The
spacing is exactly the same as the centre-to-centre distance
of the rinser grippers and the filling valves of the filler.
The bottles are centred under the pickup grippers by a
starwheel and a guide which holds the bottles by the neck.
A lever arm sliding on a twist turns the bottles over onto the
spraying nozzles.
Sidel S.p.A.
The rinsing cycle starts with spraying followed by dripping.

Next, the twist returns the bottles to their original upright
position. The bottles leave the rinser and are conveyed
hung by their necks to the filler infeed starwheel.
A.
B.
V-4
Spraying
Dripping
1.1
A
B
Part V
2.
Matrix Filler
Filling
The filler infeed starwheel positions the empty bottles on the

forks of the filling valves.
The filling cycle begins.
3.
Capping
The filled bottles are now transferred to the capper and

aligned with the capper heads.
After capping, the bottles, assisted by a guide, are
transferred to the starwheel and from here to the outfeed
belt.
4.
Outfeed of filled, capped bottles.
Sidel S.p.A.
The bottles leave the machine and enter the process cycles
of the machines located downstream.
1.1
V-5
Matrix filler
5.3.2
Part V
Filling
The filling module fills bottles (2) with the product stored in the tank (5). This machine employs the
isobarometric filling method. The machines complete filling cycle is described in the following pages.
The filling carousel (1) fills the bottles (2). A series of pipes (3) feed product to the filling valve (4).
Gas
Decompression
Product
Reference
Description
Filler carousel
Bottle
Feed pipes
Filling valve
Tank
Sidel S.p.A.
V-6
1.1
Matrix Filler
Part V
FILLING VALVE OPERATION
The ring storage tank (1) feeds product to the filling nozzle (3).
The ring tank has the following components:
-
A pressure transducer.
A thermometer.
Level sensors.
The chamber (2) feeds CO2 to the filling nozzle (3).

The chamber (4) is used to decompress the bottle.
The various chambers are fed through pipes from a central manifold which distributes the various service
fluids and power.
The product flows into the bottle under the force of gravity. The filling stop is controlled by the pump located
between the external tank and the filler carousel.
A
D
Description
Reference
Description
Filling step controller

unit
Product feed and gas

return spout
Valve opening/closing unit
Pneumatic unit
Valve body
1.1
Sidel S.p.A.
Reference
V-7
Matrix filler
5.3.3
Part V
Filling steps
The machines complete filling cycle is described in the following pages.

For each main step there is a drawing and a description.
The main filling steps are:
1.
2.
3.
4.
5.
6.
7.
Bottle infeed.
Bottle centring.
Pressurisation with CO2.
Filling.
End of filling.
Decompression.
Bell upstroke.
1.
Bottle infeed
In the first step the bottle (1) is transferred from the infeed by the infeed starwheel directly to the bottle
pickup unit.
Valve position
during the step
shown here.
Sidel S.p.A.
V-8
1.1
Part V
2.
Matrix Filler
Bottle centring
After these steps the centring bell (3) travels downwards so that its seal makes contact with the mouth (2) of
the bottle (1).
Valve position
during the step
shown here.
4
3
2
Sidel S.p.A.
1.1
V-9
Matrix filler
3.
Part V
Pressurisation with CO2
The valve (1) opens and the CO2 flows from the chamber (3) into the bottle (2).
The pressure inside the bottle (2) reaches the same pressure as that inside the chamber (3).
1
3
Valve position
during the step
shown here.
Sidel S.p.A.
V - 10
1.1
Part V
4.
Matrix Filler
Filling
At this point the valve (1) opens and filling of the bottle (2) starts.
Valve position
during the step
shown here.
Sidel S.p.A.
1.1
V - 11
Matrix filler
5.
Part V
End of filling
When the product inside the bottle (1) reaches the required level, filling stops.
Valve position
during the step
shown here.
Sidel S.p.A.
V - 12
1.1
Part V
6.
Matrix Filler
Decompression
The valve (1) opens to decompress the gas contained inside the bottle (2).
Before decompression starts there is a short delay to allow the product to stabilise.
Valve position
during the step
shown here.
Sidel S.p.A.
1.1
V - 13
Matrix filler
7.
Part V
Bell upstroke
At the end of the cycle, the bell travels upwards. The mouth of the bottle (2) detaches from the valve (1).
Valve position
during the step
shown here.
Sidel S.p.A.
V - 14
1.1
Part V
5.4
Matrix Filler
WASHING STEP (IF AVAILABLE)
BOTTLE WAY
The washing system consists of a series of fixed nozzles directed on to the filling valves and the bottle
neck at machine outfeed.
AMBIENT COP (with reduced laminar flow)

The washing system consists of a series of mobile nozzles designed to clean the entire bottle line.
WITH DOOR WASHING

The washing system cleans the bottle line and the inside of the doors using nozzles.
1.0
Sidel S.p.A.
This consists of washing ramps which uses water under pressure to remove any residues of accidental
product leaks. When available, the washing step has three different configurations, as follows:
V - 15
Matrix Filler
5.5
MACHINE CLEANING AND SANITIZATION
5.5.1
Introduction
Part V
This section describes the procedures required to clean and sanitize the machine internally and externally.
INTERNAL washing operations:
-
Pre-washing: Washing with lots of water (not recycled) to remove product residue from inside the
machine. The internal surfaces (conduits, valves, tank) are flooded and rinsed using non-recycled
water for approximately 5-10 minutes.
Washing: A detergent and water solution is used to remove traces of product residues and to clean
the internal surfaces and all machine parts in contact with the product.
Sanitisation: Hot water, steam or a chemical solution is used to sanitize all machine conduits involved
in production. This process sterilises all the internal surfaces in contact with the product. As with the
washing procedure, the machine is set up to use dummy bottles so that the filling valves are also
cleaned and sanitized by the detergent and sanitizing solutions.
Rinsing: Washing with lots of water (not recycled) to remove any deposits of detergent or sanitizer
from inside the conduits. The internal surfaces are flooded and rinsed using non-recycled water for
approximately 5-10 minutes.
Draining: Any water remaining inside the machine and infeed manifold is drained. The filling valves
are opened so that any water remaining in the conduits is able to drain.
EXTERNAL washing operations:

External washing of the machine is vital to remove from the transfer components, base and all external
components any traces of dirt, product residues and any chemical product limescale resulting from the
internal washing processes.
External washing can be performed using water, a foamy detergent and water solution or a low
concentration alkaline solution. In the latter two cases washing must be followed by rinsing with lots of water
to remove any residues of detergent or alkaline solution.
NOTE: Make sure any painted parts as well as electrical and electronic components are suitably protected
during external washing.
Sidel S.p.A.
IMPORTANT: At the end of the process, dispose of the water, sanitizer and acid substances in
compliance with the local waste disposal regulations. Do not discharge this type of waste into
water courses or the public drainage system. This type of waste requires pre-treatment before
final disposal.
V - 16
1.0
Matrix Filler
Part V
5.5.2
General information
IMPORTANT: The chemical products used to clean, disinfect and sanitize may cause corrosion
of some of the materials used to manufacture the filling machines and systems used to prepare
beverages.
Carefully follow all the instructions in this section of the manual to prevent problems related to
corrosion.
-
The use of products manufactured by renowned companies is recommended. Follow the user
instructions carefully for each product.
Some types of acid such as:
- hydrochloric acid (HCl)
- sulphurous acid (H2SO3)
- sulphuric acid (H2SO4)
are particularly aggressive towards the steels normally used to manufacture Sidel machines. These
acids or similar chemical products must not be used.
Before using any corrosive products, check the compatibility with the materials used to manufacture
the machinery.
If necessary seek the advice of Sidel S.p.A. or the supplier of the chemical products.
-
If the commercial name or the information provided by the manufacturer does not enable identification
of the chemical agents contained in the product then corrosion tests must be performed.
The corrosion index of detergents also depends on the quality and concentration of chlorine in the
water used to prepare the solution.
This value must not exceed 25 ppm.

-
All halogens (bromine, iodine, chlorine) can cause punctiform corrosion, intercrystalline corrosion and
stress corrosion cracking.
High local concentrations of these chemicals caused by the formation of drips or evaporation must be
avoided.
Rinsing with lots of water is vital after all external cleaning and sanitization.
The duration of rinsing must be established using the analysis method. There must be no traces of the
products used once rinsing is complete.
High concentrations of the chemical solutions used, caused by evaporation of the water in the solution, not
only cause corrosion of metal parts but can also irreparably damage plastic components and rubber seals.
Do not perform the disinfecting procedure when the machine is stopped and therefore flooded with chemical
agents. Do not leave sanitizing products to act over long periods.
Sidel S.p.A.
If you have any doubts concerning the use of detergents or sanitizing products, contact Sidel S.p.a. or
the supplier.
1.0
V - 17
Matrix Filler
5.5.3
Part V
Use of chemical products to remove limescale deposits from external surfaces
The hardness of water used in industrial processes can have negative effects in many applications. Hard
water, specifically when used at high temperatures, can cause chalky deposits. Furthermore, when mixed
with hard water, many substances combine with the calcium and magnesium salts to form insoluble
compounds.
The hardness of water is expressed in conventional degrees which take into consideration not the individual
salts but their equivalent quantities. Three units of measure are used as follows: French degrees, German
degrees and English degrees.
French degrees express hardness as the number of grams of calcium carbonate per 100 litres of water;
German degrees express hardness as the number of grams of calcium oxide per 100 litres of water; English
degrees express hardness as the number of grains of calcium carbonate per gallon of water (1 degree =
0.064 grams; 1 gallon = 4.453 litres). The values are converted as follows:
-
1 German degree = 0.56 French degrees.

1 English degree = 1.18 French degrees.
hardness in fH
hardness in mmol/l
Indication
0-7
0-0.7
very soft
> 7-15
> 0.7-1.5
soft
> 15-25
> 1.5-2.5
not hard
> 25-32
> 2.5-3.2
moderately hard
> 32-42
> 3.2-4.2
hard
> 42
> 4.2
very hard
Products used to reduce calcium levels in water can be divided into three groups, as follows: very
aggressive, aggressive, slightly aggressive.
The level of aggressiveness is determined by the percentage of nitrogen and phosphorous contained in the
chemical composition.
The presence of these two elements, and specifically nitrogen, makes these type of products extremely
corrosive.
Therefore, make sure the appropriate concentration of product is used. Make sure suitable protection is
provided for electronic and electrical components, filling valve seals and any painted, zinc-plated or bronze
components.
Sidel S.p.A.
The use of only slightly aggressive products, consisting mainly of inorganic acids and tensioactive agents, is
recommended. These types of product are recommended to remove, not only deposits derived from water
hardness, but also inorganic contamination residues caused by food processing. The products do not
represent an excessive corrosion hazard for the machine components.
V - 18
1.0
Matrix Filler
Part V
5.5.4
Limits to using detergents and sanitisation products
For filling machines and beverage preparation systems:

IMPORTANT: When using Oxonia during sanitization procedures, make sure the concentration
of chlorine in the water used does not exceed 25 ppm.
Use
PRODUCT
TEMPERATURE
(MAX)
CONCENTRATION
DURATION
(MAX)
ALKALINE
SOLUTIONS OF
SODIUM HYDROXIDE
(NaOH) > 30% w/w
85 C
1.5 to 4% (w/v)
30 mins.
ACID SOLUTIONS OF
NITRIC ACID (HNO3)
> 30% w/w
60 C
0.5 to 1.5% (w/v)
15 mins.
ACID SOLUTIONS OF
PHOSPHORIC ACID
(H3PO4) > 30% w/w
60 C
0.8 to 2% (w/v)
15 mins.
DISINFECTANT
SOLUTION OF
PEROXYACETIC ACID
Ambient (max. 40 C)
50 to 500 ppm as PAA
30 mins.
DISINFECTION WITH
CHLORINE
SOLUTIONS
(200 ppm max chloride
in water and pH>6<8 in
CIP solution)
Do not exceed 30 C
Max. 40 ppm as free

Chlorine
20 mins.
Chlorine Dioxide ClO2
Ambient temperature
5 ppm
20 mins.
Sodium Hypochlorite
NaClO
Ambient temperature
10 to 40 ppm
1 hour
SANITIZATION WITH
HOT WATER
(TREATED F_<10)
98 C
30 mins.
SANITIZATION WITH
STEAM
NOT PERMITTED
Sidel S.p.A.
CLEANING IN PLACE
WASHING AND DISINFECTION
1.0
V - 19
Matrix Filler
Use
PRODUCT
TEMPERATURE
(MAX)
CONCENTRATION
Part V
DURATION
(MAX)
EXTERNAL CLEANING
WASHING AND DISINFECTION

FOAMING ALKALINE
SOLUTIONS OF
SODIUM HYDROXIDE
Ambient temperature
2 to 4% (w/v)
depending on foam
consistency required
30 mins.
FOAMING ACID
SOLUTIONS OF
DESCALING
PRODUCT
Ambient temperature
2 to 4% (w/v)
depending on foam
30 mins.
FOAMING
DISINFECTANT
SOLUTION OF
PEROXYACETIC ACID
Ambient temperature
2 to 4% (w/v)
depending on foam
30 mins.
DISINFECTION WITH
CHLORINE
SOLUTIONS
(200 ppm max
chloride in water e
pH>6.5<8 in
CIP solution)
Ambient temperature
Max 10 ppm as free

Chlorine
30 mins.
OTHER
SANITIZATION WITH
STEAM
NOT PERMITTED
OZONATED RINSING
WATER
30 C
1.0 ppm
Continuous
BOTTLED OZONATED
WATER*
30 C
0.6 ppm
Continuous
Sidel S.p.A.
* 0.4 ppm max in bottle (FDA 21 CFR 184.1563)

0.5 ppm max (EU DIRECTIVE 2003/40/EC).
V - 20
1.0
Matrix Filler
Part V
IMPORTANT: The following table is enclosed to provide important information concerning the
environmental impact of the various sanitizing products:
SUBSTANCE
INDEX OF ENVIRONMENTAL HARM

UTN
IRCH
CAUSTIC SODA (NaOH)
n. d.
29
SODIUM HYPOCHLORITE (NaOCl)
n. d.
33
PERACETIC ACID
80
NITRIC ACID
110
PHOSPHORIC ACID
50
The IRCH index compares various substances to assess their impact on human health, ecosystems
and the environment in general. It is an index of risk (from 0 to 200) based on a calculation algorithm
which takes into consideration the ecological impact on water, air, soil (waste) and the atmosphere
(ozone, greenhouse effect, etc). The impact in the various areas also takes into consideration the
effects on human health (source: Indiana Pollution Prevention and Safe Materials Institute at Purdue
University - EPA Project - 1996).
The UTN index (from 0 to 100) compares different substances in terms of their toxicity for organisms
living in water- and land-based ecosystems (source: G. Davis et al. - EPA/600/R-94/177 - 1996).
IMPORTANT: If you are using hazardous substances, check the Safety Data Sheets to identify
any safety and environmental hazards for the chemical used.
The safety data sheets identify:
Hazards.
Action in the event of accidental spillage and leaks of hazardous substances.
Chemical and physical properties.
Environmental information.
Sidel S.p.A.
1.0
V - 21
Sidel S.p.A.
Matrix Filler
V - 22
1.0
Part V
PART VI
OPERATING INSTRUCTIONS
Sidel S.p.A.
Part VI
Matrix Filler
1.1
V,- 1
Matrix Filler
User Manual / Operating Instructions
6.1
Part VI
CONTROL PANEL, WARNING LIGHTS AND PUSHBUTTONS
3
4
6.1.1
Foreword
The operator interface includes a part with traditional controls (selectors, knobs), and another part integrated
into the operator panel.
Sidel S.p.A.
6.1.2
VI - 2
Layout of components
Maintained mushroom head emergency stop button.
Two-way key selector to implement size changeover (machines for glass bottles).
Three-way key selector with return to central position: adjusts the position of the tank
or capper rinser (machines for glass bottles).
Monitor: displays machine status, messages and control menus.
1.1
Matrix Filler
Part VI
A filling test pushbutton panel is installed on the rear guards of the filling machine:
Bottle feed button.
Filling stop button.
Filling start button.
Filling test selector (located on the HMI when not on the pushbutton panel).
The mobile pushbutton panels have only one button:

-
6.1.3
jog speed.
Operator panel
TECHNICAL SPECIFICATIONS
The operator panel (OP) consists of the following:
-
Touch panel with WINDOWS CE operating system (24 V DC power supply).

Touchscreen monitor.
Internal peripherals
-
Ethernet card.
External peripherals
MASTER card.
Sidel S.p.A.
Software installed
-
The operator interface uses ZENON software on the OP.
1.1
VI - 3
Matrix Filler
6.1.4
Part VI
Operator interface main structure
The operator interface can be divided into the following areas:

2
Sidel S.p.A.
Description of areas:
VI - 4
Main controls: this area contains the main operator controls. This area is displayed on all
the interface pages.
General information: this area contains general information concerning machine operation
and the interface. This area is displayed on all the interface pages.
Main functions: this area contains the buttons to enable the main interface functions. This
area is displayed on all the interface pages.
Main navigation bar: use this area to navigate the pages making up the interface. This
area is displayed on all the interface pages.
Page area: this contains the functions for the page selected using the main navigation bar.
1.1
Matrix Filler
Part VI
DESCRIPTION OF MAIN CONTROLS (1)
The main control area (1) is always displayed and used to access the following functions:
Machine Start/Stop: when the machine is stopped, press and hold this button for the time
A
required to start rotation. When the machine is running, press the button to stop rotation.
B
JOG mode: press this button to enable/disable jog mode on the machine.
Bottle block: press this button to enable/disable bottle block.
Bottle release: press this button to enable/disable bottle release.
Unlock doors: press this button to enable/disable unlocking of the front doors.
Unlock doors: press this button to enable/disable unlocking of the front transfer doors (if fitted).
G
H
Enable actuators: press this button to enable/disable manual control of actuators (valves,
motors, etc.).
Enable controls: press this button to enable/disable manual control of the operator control
selectors on the pages.
Coupling: press this button to enable/disable coupling of the filler with the blower.
Alarm reset: press this button to reset all the alarms in the log (if cause of alarm removed).
All the buttons have the following colours depending on their status:
Button not enabled: cannot be pressed (grey).
Button not active: control not running (light blue).
Button pressed: control sent to PLC (blue).
Sidel S.p.A.
Button active: control running (light red).
Button pressed: control requested (dark red).
1.1
VI - 5
Matrix Filler
Part VI
DESCRIPTION OF GENERAL INFORMATION (2)

2
The general information area (2) is always displayed and used to access the following functions:
A
Machine speed: current machine speed displayed in bottles/hour.
Counter: the number of bottles which have entered the machine is displayed.
Hours: machine operating hours are displayed.
Active recipe: name of the recipe currently being processed is displayed.
User: current active user is displayed.
Level: the active level is displayed.
Machine: current machine status is displayed.
PLC HMI communication status: communication status between the PLC and operator
panel is displayed. If the icon is orange then communication is active; if it is grey then the
operator panel is not communicating correctly with the PLC.
DESCRIPTION OF MAIN FUNCTIONS (3)
Sidel S.p.A.
The main functions area (3) is always displayed and used to access the following functions:
VI - 6
Login: used to set the user and operating level.
Info: the system information window is displayed.
Alarms: the alarm window is displayed.
Changeover: the interface for the CIP system/Auxiliaries in remote system is displayed.
1.1
Matrix Filler
Part VI
DESCRIPTION OF THE MAIN NAVIGATION BAR (4)

4
A
B
D
E
F
G
Reception: displays the main page.
Piping circuit: displays the tank page.
Machine components: displays the component navigation page.
Electronic filling valve: displays the electronic valve navigation page.
Recipe: displays the recipe navigation page.
Efficiency: page reserved for SIDEL operators.
Layout: displays the machine summary page.
Bar graph: displays the trend page.
Maintenance: displays the maintenance functions page.
Parameters: displays the machine step navigation page.
Services: displays the services and general parameters navigation page.
1.1
Sidel S.p.A.
The main navigation bar (4) is always displayed and used to access the following functions:
VI - 7
Matrix Filler
DESCRIPTION OF THE PAGE AREA (5)

There are two main types of page area:
Sidel S.p.A.
VI - 8
Navigation page: contains only navigation buttons to recall sub-pages.
1.1
Part VI
Matrix Filler
Part VI
-
Command and control page: contains diagrams, controls and navigation buttons.
The command and control page (5) is divided into:

Summary area: depending on the machine specifications and/or options installed, this area
A
displays a summary to enable a quick and complete overview of the assembly.
Control area: this area contains buttons and selectors used to perform various actions
B
involving the machine equipment.
C
Page change area: this area contains navigation buttons used to access further sub-pages:
Type of buttons:
Button to access functional sub-page.
Sidel S.p.A.
Button for more page detail.
1.1
VI - 9
Matrix Filler
6.1.5
Part VI
Operator panel operations
The following pages describe how the operator panel may be used to monitor and control the various
components of the system during operation of the machine. In order to make the text which follows easier to
understand, in this section we describe some of the conventions used in the description of the operator
panel.
Physical size display
Two pieces of information are displayed for each physical size controlled by the program, as follows: the size
set point value, i.e. the value desired for the size itself during machine operation, and the size actual
value, i.e. the value actually assumed by the size in real time. The set point value is orange and the actual
value is blue.
Modulating valve opening display
Display showing the opening (as a percentage) of the regulating valve.
Press the button on the valve to specify the opening percentage required:
0% = closed
100% = open
Motor/Pump speed display ( if controlled by an inverter)
Display showing the speed of the actuator as a percentage.
Press this button on the motor/pump to adjust the speed.
Temperature display
Display showing the temperature of the product / CIP solution present in the circuit in C.
Pressure display
Display showing the pressure of the product / CIP solution present in the circuit in bar.
Level display
Display showing the level of the product / CIP solution present in the circuit in mm.
Speed display
Display showing the speed of the product / CIP solution present in the circuit in mc/h.
pH display
Sidel S.p.A.
Display showing the level of acidity of the CIP solution present in the circuit.
VI - 10
1.1
Matrix Filler
Part VI
DISPLAY OF ANALOGUE CONTROL DEVICES

Display showing analogue control devices.
To set the operating values of these analogue control devices, press the related icon.
When the alarm is disabled, the surround of the icon flashes and is coloured fuchsia.
In the event of a fault, the alarm is enabled and the probe surround changes to red.
If the display box is orange then the operating cycle is waiting for the analogue device to
reach the set point value.
DISPLAY OF SENSORS OR DIGITAL DEVICES

Display showing sensors or digital devices.
List of devices:
-
Fs: flow switch.

Ls: level switch.
B: Photocells / detector sensors.
The icon for a digital device can display up to 2 items of information.

OFF (grey)
ON (green)
If the icon of the sensor or the digital device appears as shown below:
Grey on orange background
Sidel S.p.A.
This indicates that the operating cycle is waiting for the digital device to changed state.
1.1
VI - 11
Matrix Filler
Part VI
DISPLAY OF SINGLE ON-OFF VALVE STATES

Valve logic state:
Valve actuator state:
Valve body:
Subject to automatic control
Controlled actuator
N.O.
Normally Open
Subject to manual control (both

ON and OFF)
Actuator without control
N.C.
Normally Closed
Valve in alarm condition
Alarm OFF.
To change the valve state backwards and forwards between open and closed, press the valve icon shown
on the displays in the Modify component state section.
DISPLAY OF THE STATE OF MIXPROOF VALVES

Valve logic state:
Controlled actuator
Subject to manual control (both ON and OFF)
Sidel S.p.A.
VI - 12
1.1
Matrix Filler
Part VI
DISPLAY OF THE STATE OF REGULATING VALVES

Valve logic state:
Valve body:
Controlled actuator
N.O.
Normally Open
Subject to manual control (both

ON and OFF)
N.C.
Normally Closed
Valve in alarm condition
Alarm OFF.
DISPLAY OF MOTOR AND PUMP STATES

Display showing the motors and pumps and their state during machine operation.
Motor / Pump green:

automatic control OFF
Motor / Pump red:

alarm present
Motor / Pump yellow: Manual

control (ON and OFF).
Motor / Pump pink:

Alarm OFF.
Press the icon to change the state manually (from manual (ON OFF) to automatic and back again) using
the displays shown in the Modify component state section.
1.1
VI - 13
Sidel S.p.A.
Motor / Pump green:

automatic control ON
Matrix Filler
Part VI
DISPLAY OF CONTROL CAM STATES

Display showing control cams and their state during machine operation.
Cam actuator green:

automatic control
Cam actuator yellow:

manual control (ON and OFF).
Press the valve icon to change the state manually (from manual (ON OFF) to automatic and back again)
using the displays shown in the Modify component state section.
MODIFY THE STATE OF COMPONENTS

Types of controls:
Sidel S.p.A.
Device control with feedback
VI - 14
Device control without feedback
Press this button to switch the component to ON in the manual mode.
Press this button to enable operation of the component in automatic mode.
Press this button to switch the component to OFF in the manual mode.
Press this button to disable/enable the component position alarm (where present):
When the alarm is disabled, the surround of the component flashes and is coloured
fuchsia.
In the event of a fault, the alarm is enabled and the component surround changes to
red.
1.1
Matrix Filler
Part VI
A.
Sets device actuation to manual.
B.
Sets device management to automatic.
C.
Sets device disabling to manual.
A.
Switches the device ON.
B.
Switches the device OFF.
A.
Starts the device
B.
Stops the device.
Three-way selector:
Two-way selector:
Sidel S.p.A.
Start/Stop button
Press to execute the command.

Single button
1.1
VI - 15
Matrix Filler
Part VI
Adjustment tools
1.
Analogue device pop-up without totalizer:
A.
Process Value adjustment zone.
B.
Set Point adjustment zone.
C.
Alarm enable/disable button.
A
B
This display shows the current value read from the device and the set-point value.
2.
Analogue device pop-up with totalizer:
A.
Actual Value Control Area
B.
Totalizer Control Area
C.
Totalizer Reset Button
D.
Alarm enable/disable button.
A.
Zone for displaying the reference value.
B.
Button to modify the reference manually.
C.
Zone for setting the reference value.
D.
Button to open the parameter setting popup.
A
B
3.
Fixed analogue device reference pop-up
A
B
Sidel S.p.A.
VI - 16
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Matrix Filler
Part VI
PID control pop up
A
B
C
D
Actual value: Actual process value.
Actual set-point: Actual set-point value.
Feed Forward: Disturbance parameter to be entered in the PID setting.
Output: PID adjustment control output, this is the flow valve opening value, the motor control
reference, etc.
Use this to set the Set-Point manually and activate the adjustment.
Use this to set the output manually.
Display zone for the regulation trend.
Opens the parameter setting page.
Sidel S.p.A.
4.
1.1
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Matrix Filler
5.
Part VI
Parameter setting pop-up:
Min Out: Output minimum value.
Max Out: Output maximum value.
You can set a component manually to any user-defined state. Exercise great care when
performing operations in the manual mode. Manual operations performed incorrectly can
seriously damage production and the sanitizing procedure and can also create hazards for
operators working close to the machine.
To enable manual commands, you must be logged on as Inspector and the device functioning
mode on the synoptic page must be set to Manual.
Sidel S.p.A.
When you press any valve or pump icon on the synoptic page, the manual setting menu
for that device will appear.
VI - 18
1.1
Matrix Filler
Part VI
6.2
DESCRIPTION OF INDIVIDUAL INTERFACES
6.2.1
Main functions
PASSWORD PAGE
Function to access the Password page.
A
B
D
Field to enter user name.
Field to enter password.
Button to confirm the data entered.
Button for operator login.
Simply press button 4 for access to the lowest operator login level. To start using the operator panel,
enter your user name and password. The user level for using the operator panel depends on the user
name and password that you enter.
Alarm reset
Warning buzzer stop
CIP line selection
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
1.1
X
X
X
X
X
X
X
X
X
Sidel S.p.A.
Start \ stop \ CIP

Cycle command
X
X
X
X
Exit application
CIP cycle selection
X
X
X
X
Machine configuration
Language selection
X
X
X
X
Recipe review
Alarm filter buttons
0
1
4
10
Valve position control

bypass
Password level
op
ins
dir
sa
Machine / cycle parameters
User ID
Operator
Inspector
Supervisor
Sidel
Manual adjustments
(valves, pumps, etc.)
Name
Displaying the access security level
VI - 19
Matrix Filler
SYSTEM INFORMATION PAGE

System information page access function.
A
B
C
D
E
Sidel S.p.A.
Use this tool to retrieve system information such as:
VI - 20
Free disk space.
Free memory space.
Project version.
Serial number.
Project name.
1.1
Part VI
Matrix Filler
Part VI
ALARM PAGE
Function to access the Alarms page.

A
L
K
J
Use this page to identify any alarms triggered during functioning.
All
Machine
Operator
Filler
Crown capper
Capper
Rinser
Power supplies
External
Specific alarm class selection
Filter removal from classes
Switch from current alarms triggered page to alarm log page.
The recognition of alarms takes place by pressing the Reset button, this makes the alarm disappear if
the reasons that caused it have been removed, and at the same time it makes the messages from the
alarm page disappear.
1.1
VI - 21
Sidel S.p.A.
The following are displayed for each alarm: date and time alarm triggered, description of the alarm, the
variable symbol linked to the alarm and the group of alarms to which it belongs. Select one of the Tab
windows to display a specific group of alarms.
Matrix Filler
6.2.2
Part VI
Reception
Function to access the Reception page.
A
B
Sidel S.p.A.
This is the home page displaying the main machine data:
A.
Use this button to set maximum machine speed during production.
B.
Use this button to zero-set the counter for the number of bottles which have been fed into the
machine.
Display area showing information concerning the status of the main probes on the machine
such as temperature and pressure.
C.
VI - 22
1.1
Matrix Filler
Part VI
6.2.3
Piping circuit
Function to access the Piping page.
COMMAND AND CONTROL PAGE

Summary diagram area
This page shows all the information required to monitor machine operation: flow rates, opening of modulating
vales, On/Off valves, pumps and analogue values. The panel shows the following components:
Motors.
Pneumatic valves.
Flow meters.
Levels.
Analogue values.
Solenoid valves.
Powered modulating valves
Adjustment tool: Area to access display/entry of data to adjust levels or

modulating valve pressures.
Three-way selector: Area to access the manual open, manual closed and
automatic control for the filling valves. This is only possible when the operating
mode of the devices is set to manual.
Three-way selector: pump control
Display of sanitizing information.
Display of production end information.
Sidel S.p.A.
1.1
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Matrix Filler
Control area
Three-way selector: Valve opening control
Three-way selector: Valve bleed control.
Two-way selector: Tank drainage control
Two-way selector: Ring storage tank drainage.
Two-way selector: Co2 bleed bleeding.
Two-way selector: Conductivity meter control.
Start/Stop button Pump control.
Sidel S.p.A.
Three-way selector: Shaker control.
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Part VI
Matrix Filler
Part VI
Page change area
Displays relevant sub-page (Level, Pasteuriser, CIP).
Navigation button: display of Start-up sub-page.
Use this page to start, stop and interrupt the production, rinsing and sanitization cycles of the filler.
A
A
External consent and filler signals must be ready to start any of the machine phases.
The start sequences button is enabled when one of the functions from 1 to 7 is selected.
2.
3.
4.
5.
6.
7.
GAS FLUSHING PRODUCTION: Starts production with CO2 flushing and bleeding of
valves.
FAST PRODUCTION: Starts rapid production.
TANK FLOODING PRODUCTION: Starts production with bleeding of valves and tank
washing with product.
DRAIN: Starts the machine drain sequence.
RINSE: Starts the rinse sequence.
RINSE WITH DUMMY BOTTLE: Starts machine filling with dummy bottles.
CIP: Starts machine sanitization.
The Stop sequences button interrupts the current sequence.
The Abort sequences button is used to quit any of the machine phases and return to the
STANDBY step.
1.1
Sidel S.p.A.
1.
VI - 25
Matrix Filler
6.2.4
Part VI
Machine components
Function to access the Machine components page.

Navigation page: This page displays buttons for opening the following submenus. The submenus available
depend on the machine specifications or options:
Displays Rinsing subpage.
Displays Bottle cooling subpage.
Displays Foamer subpage.
Displays Capper subpage:
Displays Crown Capper subpage:
Displays Clean room subpage.
Displays Size changeover subpage.
Sidel S.p.A.
Displays External foaming subpage.
VI - 26
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Matrix Filler
Part VI
RINSER SUBPAGE
Select this to open the Rinser subpage.
This page shows all the information required to monitor rinser operation: On/Off valves, pumps and analogue
values. The panel shows the following components:
-
Pumps.
Pneumatic valves.
Analogue values (temperatures and levels).
Solenoid valves.
Pressure switches.
Flow gauges.
Chlorine concentration
pH values.
Three-way selector: first rinsing treatment control.
Two-position selector: rinsing sanitization treatment enabling control.
Sidel S.p.A.
Use this button to start the automatic production, drain, rinse and sanitization sequences of
the rinsers which run a repeat treatment process using chlorine. This operation is run
specifically on machines used for hot filling such as RAD.
This area displays the first and second treatment sequence messages.
1.1
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Matrix Filler
Part VI
BOTTLE COOLING SUBPAGE

Select this to open the Bottle cooling subpage.

This page shows all the information required to monitor operation of the bottle cooling unit: On/Off valves,
pumps and analogue values.
The panel shows the following components:
-
Pumps.
Pneumatic valves.
Analogue values (temperatures and levels).
Control area
Two-way selector: water cooling control.
Three-way selector: bottle cooling control
Page change area
Sidel S.p.A.
Navigation button: Displays bottle cooling temperature safety values.
VI - 28
1.1
Matrix Filler
Part VI
FOAMER SUBPAGE
Select this to open the Foamer subpage.

This page shows all the information useful for monitoring operation of the foamer: PID regulator and
adjustment pressures/temperatures.
Area to access display of the set point value and process value for foamer water
temperature.
Area to access display of the set point value and process value for foamer water pressure.
Control area
Three-way selector: foamer control
Sidel S.p.A.
Two-way selector: foamer water heater control.
1.1
VI - 29
Matrix Filler
CROWN CAPPER SUBPAGE

Select this to open the Crown capper subpage.

This page shows all the information useful for monitoring operation of the crown capper.
Control area
Two-way selector: cap on starwheel safety device control.
Two-way selector: UV lamp control.
Two-way selector: cap emptying control.
Two-way selector: cap belt control.
Two-way selector: steam on caps enabling control.
Two-way selector: cap buffer lifting enabling control.
Two-way selector: cap buffer emptying control.
Three-way selector: cap release control.
Three-way selector: hopper control
Sidel S.p.A.
Three-way selector: bottle neck ring washing control.
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Part VI
Matrix Filler
Part VI
Three-way selector: Buffer mode selection - Emptying Production Delay.
Three-way selector: Operating mode selection - Jog Automatic Stop.
Three-way selector: jog selection.
Size changeover enable button.
Encoder reset button.
Page change area
Sidel S.p.A.
Navigation button: display of cap safety device and crown capper starwheel safety device
subpage.
1.1
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Matrix Filler
Part VI
AROL EQUATORQUE
B
Sidel S.p.A.
VI - 32
Maintenance: Gives access to the crown capper maintenance page.
General Information: Gives access to the crown capper control page.
Measuring devices: Reading Equatorque motor temperature probe 1.
Measuring devices: Reading Equatorque motor temperature probe 2.
Measuring devices: Reading crown capper encoder position.
Size changeover Gives access to the size changeover control page.
1.1
Matrix Filler
Part VI
AROL EQUATORQUE
D
Parameterization area:
Parameters: This area accesses the maintenance parameters of the capper head selected in
zone 8. All the parameters may be modified by the operator and transferred to the head using
the special button:
A
Parameters Download button

Enable/Disable: Head Enabling and Disabling
Torque: Torque
Real KT: Motor Torque Constant (Motor and Current)
Torque Correction: Torque Correction Percentage (if necessary)
Parameters: The parameters of the capper head selected in zone 8 may be read in this area.
The data is read by pressing the special button:
B
Parameters Upload button
Encoder: Reading encoder position with zero-setting button:
C
Encoder zero-setting button
Sidel S.p.A.
1.1
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Matrix Filler
Part VI
Calibration area:
D
Sequencer: Reading calibration progress status.

Sequencer: Reading calibration data.
Calibration Offset: Current correction offset
Current: Motor current
Torque Load: Motor torque applied in calibration
Motor Torque: Measured motor torque
The head calibration is started with the special button.
E
-
Calibration start button.
Head rotation button.

This button rotates the head for a rotation test if the calibration is not being performed.
F
Sequencer: Reading current values (A) of the motor during calibration with the head not loaded
and with the clutch installed during calibration.
Sequencer: Reading calibration progress percentage.

Sequencer: Area for selecting the head to be parameterized.
Sidel S.p.A.
VI - 34
1.1
Matrix Filler
Part VI
AROL EQUATORQUE Feed-Back
Crown capper control:
This page displays the torque values of each capping motor corresponding to the respective head and any
feedback alarms (heads 1 to 10):
No Load (SlowTorque not reached): Minimum torque not reached.
No Closure (EndMainAngle reached before ClosureTorque reached): Closure angle reached before
closure torque.
In Torque (EndMainAngle reached before end of In Torque state): Closure angle reached before
necessary time.
CapTurns (no. of turns specified by Cap Turns not reached): Rotation angle no reached.
Following (Head following error): Following error.
Bad Closure (closure torque reached, but stop speed not reached): Closure torque reached but
stopping speed not detected.
No Position (position not reached): No unscrewing.
1.1
Sidel S.p.A.
Press this button to access the next control page:
VI - 35
Matrix Filler
Part VI
AROL EQUATORQUE Feed-Back
This page displays the torque values of each capping motor corresponding to the respective head and any
feedback alarms (heads 11 to 20):
No Load (SlowTorque not reached): Minimum torque not reached.
No Closure (EndMainAngle reached before ClosureTorque reached): Closure angle reached before
closure torque.
In Torque (EndMainAngle reached before end of In Torque state): Closure angle reached before
necessary time.
CapTurns (no. of turns specified by Cap Turns not reached): Rotation angle no reached.
Following (Head following error): Following error.
Bad Closure (closure torque reached, but stop speed not reached): Closure torque reached but
stopping speed not detected.
No Position (position not reached): No unscrewing.
Sidel S.p.A.
Press this button to return to previous page.
VI - 36
1.1
Matrix Filler
Part VI
AROL EQUATORQUE Size Change
Select motor to be checked:
Central guide
Bottle body pad
Extractor pad (Bottle Outfeed)
The boxes display the current position of the motors.

The motor selected is shown in yellow. Based on the selection, the following operations may be performed:
Home Position
Press this button to move the selected motor to the Home position (initial).
Sidel S.p.A.
1.1
VI - 37
Matrix Filler
Part VI
Positioning:
A predetermined position may be entered for the selected motor. This is

useful for defining recipe positions based on the size.
Press buttons + and - to move the selected motor in the desired

direction. The current position of the selected motor is always displayed.
Brake:
Press this button to release the brake of the selected motor (for manual
movements), which will be displayed in the following manner in zone 1.
Sidel S.p.A.
Press this button to reset the brake of the selected motor.
VI - 38
1.1
Matrix Filler
Part VI
CAPPER SUBPAGE
Select this to open the Capper subpage.

This page shows all the information needed to monitor functioning of the capper:
Control area
Two-way selector: capper safety device control.
Three-way selector: channel 1 cap block control.
Three-way selector: channel 2 cap block control.
Three-way selector: capper 1 hopper control.
Three-way selector: Capper 2 hopper control.
Three-way selector: extractor unit cleaning control
Three-way selector: capper washing control.
Channel fault rest button.
Sidel S.p.A.
Navigation button: displays capper safety device.
1.1
VI - 39
Matrix Filler
Part VI
CLEAN ROOM SUBPAGE

Select this to open the Clean room subpage.

This page shows all the information useful for monitoring operation of the clean room: ventilator motor
control and display of clean room pressure values.
Control area
Three-way selector: ventilator start control
Sidel S.p.A.
Control to switch ON internal lighting divided by ventilation areas.
VI - 40
1.1
Ventilator speed control.

Press this button to display a window to read the current speed of the ventilators and to
adjust the speed manually.
Fan status display page.
Sidel S.p.A.
Part VI
Matrix Filler
1.1
VI - 41
Matrix Filler
Part VI
SIZE CHANGEOVER SUBPAGE

Select this to open the Size changeover subpage.
A page for automatic size changeover management or a page for manual size changeover is available
depending on the type of machine.
Automatic size changeover
This page shows all the information needed to monitor the size changeover: current position and adjustment
position of the rinser, filler, cam, capper and crown capper.
Sidel S.p.A.
A.
B.
C.
D.
VI - 42
Alarms
Actual heights
Messages
Heights from recipe
1.1
Part VI
Matrix Filler
Control area
Three-way selector: Size changeover selection Manual Automatic - Disabled.
Two-way selector: Rinser manual lifting selection.
Two-way selector: Filler manual lifting selection.
Two-way selector: Cam manual lifting selection.
Two-way selector: Capper manual lifting selection.
Two-way selector: Crown capper manual lifting selection.
Button: START automatic size changeover.
Button: confirm the size selected.
Sidel S.p.A.
Button: STOP automatic size changeover.
1.1
VI - 43
Matrix Filler
Part VI
Manual size changeover

This page shows all the information needed to monitor the size changeover: current position and adjustment
position of the rinser, filler, cam, capper and crown capper.
Control area
Two-way selector: Rinser manual lifting selection.
Two-way selector: Filler manual lifting selection.
Two-way selector: Capper manual lifting selection.
Sidel S.p.A.
Two-way selector: Crown capper manual lifting selection.
VI - 44
1.1
Matrix Filler
Part VI
EXTERNAL FOAMING SUBPAGE
Select this to open the External foamer subpage.

This page shows all the information useful for monitoring operation of the external foamer. Valves, pumps
and process recipes.
Control area
Two-way selector to enable manual or satellite launch.
Two-way selector to enable recipe in manual.
Sidel S.p.A.
Area to select and display the foaming recipe to be processed using

manual control.
1.1
VI - 45
Matrix Filler
Part VI
This area is used to configure enabling of the foaming recipe during the various processing phases.
For example, before inserting the dummy bottles and after CIP has been performed.
Single button: START recipe selected.
Single button: STOP recipe selected.
Area displaying the name and number of the recipe being processed.
Area displaying the preset time and recipe currently being processed.
Area displaying the name and number of the phase in progress.
Area displaying the preset time and and actual phase in progress.
Navigation button: Displays internal piping of the foaming control unit.
Sidel S.p.A.
Function to access the Foaming recipes page.
VI - 46
1.1
Matrix Filler
Part VI
This page shows all the information needed to set the foaming recipe: times, pressures, washing areas.
A
B
A.
B.
C.
D.
E.
Select recipe to be edited.

Phase type selection.
Phase time setting.
Control unit outfeed pressure setting.
Selection of branches/sections to be enabled during the individual phases.
Control area
Recipe Save: save the recipe data in the archive (enabled for users with Supervisor
access level).
Recipe Read: update the data displayed with the data of the recipe present in archive
(enabled for users with Supervisor access level).
Sidel S.p.A.
Scroll button.
1.1
VI - 47
Matrix Filler
6.3
Part VI
ELECTRONIC FILLING VALVES (MASTERCARD)

Button to access the Electronic Filling Valves page. The version of the installed FMC
child project is displayed top left.
Navigation page:
Depending on the type of filler and the optional devices configured, various buttons are displayed giving
access to specific subpages:
Button to access the Position TX subpage
Button to access the Filling Instruments Measure Data subpage
Button to access the Force Filling Time subpage (only displayed if a flow meter is
configured as a measuring device)
Sidel S.p.A.
Button to access the Filling Valves Data Pressurize subpage
VI - 48
1.1
Button to access the Statistical Analysis Filling Valves subpage.
Button to access the Filling Master Card Diagnostic #1 subpage
Button to access the Disable Filling Valves subpage
Button to access the Manual Filling Test subpage
Button to access the Filling Valves Maintenance subpage
Button to access the Test Outputs Filling Valves subpage
Button to access the Sequencer Outputs Filling Valve #1 subpage
Button to access the B&R Diagnostic subpage
Sidel S.p.A.
Part VI
Matrix Filler
1.1
VI - 49
Matrix Filler
Part VI
POSITION TX SUBPAGE
Button to access the Position TX subpage
Read-only page:
and the number of the valves

This page displays read-only data showing the control software positions
currently present in these positions. On the basis of the rotation direction of the filler (anti-clockwise in the
figure above) and the infeed of empty bottles, the following control software positions can be identified:
Filling in Production Start, Burst Control, Filling Area Outfeed and Data Collection.
The number of the valve currently at a tangent to the filler inlet starwheel (Valve in tang on inlet starwheel)
is also shown. This information is useful for technicians during start-up/testing to search for correct
synchronisation of the electronic filling system with the real mechanical position of the valves (see PAS Filler Tx Step - Filling Master Card page).
The number of the valve currently in the Manual Filling Start position is also displayed. This valve is ready
to receive the filling command sent from the remote pushbutton control panel (where fitted). The duration of
the various phases of the recipe in operation (flushing, pressurisation, filling, snift, etc.) are displayed in the
coloured circular graph and numerically in steps in the legend top right. Calculation of the steps is dynamic
and varies according to real machine speed.
Sidel S.p.A.
This data can be analysed to assess whether the recipe set is correct and whether all available steps are
used. The message Steps Recipe Error! is displayed instead of Steps Recipe OK! if the number of
usable steps is exceeded.
VI - 50
1.1
Displays the current software version of the Filling Master Card.
Displays the current firmware version installed on the majority of the slave
cards fitted on the filler.
Button to simulate a bottle burst on valve no. 1. The button is displayed in
the event of configuration of the burst test using a pressure sensor on the
valve or the burst test using flow variation (if a flow meter is configured). This
button can also be used to test operation of the washing ramps (if
configured) and the bottle ejector if synchronised correctly. Simulation does
not increase the burst counter on valve no. 1 and no alarms are displayed on
the panel.
Button accessible only with Filling Master Card phases, OPER mode
enabled, no selectors enabled and filler rotating with bottles being filled. For
safety reasons it is disabled in the CIP/RINSE mode.
Washing ramp start-up indicator (only displayed if washing ramps
configured).
Only used on glass bottle filling machines with the ramps managed internally
by the Filling Master Card.
Selector to enable valve bleeding in the middle of the starwheels. The
selector is only displayed on the panel if configured. The selector is disabled
when the bleed time of phase 15 of the recipe is set to zero.
Valve bleed control indicator (only displayed if configured).
Green only when the bleed control selector is enabled and passage of a
valve, which has already completed filling, occurs.
Legend of colours for the various phases of the filling recipe.

The duration of the phases is expressed in steps taking into account any
fractions.
Angle Available: expresses the effective size of the filling angle on the
basis of the steps set on the PAS - Filler Tx Step - Filling Master page.
Sidel S.p.A.
Part VI
Matrix Filler
1.1
VI - 51
Matrix Filler
Part VI
FILLING INSTRUMENTS MEASURE DATA SUBPAGE
Button to access the Filling Instruments Measure Data subpage
Read-only page:
These pages display the filling values received from the electronic cards after the switch from the Data
Collection position. These values show the result of the most recent filling operation performed by the valve
with the bottle present. A legend is shown on the right of the page to facilitate understanding of the coloured
indicators. The meaning of the various columns is described below:
Number of the electronic card (slave card), matches the number of the filling valve on the filler. The
green tick
to the left of the valve number indicates the bottle is present.
Filling completed without alarms, bottle OK

Result of
most recent
filling
operation:
Filling completed with at least one alarm, bottle not OK

Valve in CIP/RINSE mode
Filling completed with pre-closing, bottle not OK
Sidel S.p.A.
Valve in recirculation process (only displayed if recirculation option

configured)
Valve disabled
VI - 52
1.1
Matrix Filler
Part VI
If the background box is blue

then the slave card is processing a recipe transferred manually and
not the recipe currently active on the filler. In the absence of bottle OK (green bullet), the bottle is not
capped. A burst, snift, pressurisation, etc. alarm, depending on the type of filler, will result in the bottle
OK signal not being given. For further details concerning the most recent filling operation, open the
specific subpage
called Filling Valve Data Details.
Most recent bottle pressurisation status, check performed using the pressure sensor installed on
the valve (only operates if pressure sensor configured, otherwise displayed as disabled):
Last filling
operation bottle
pressurisation
indicator:
Bottle pressurised
Bottle not pressurised
Valve disabled or pressure control by pressure sensor or not
configured.
Bottle bursts on individual filling valve counter; the counter is incremental.

The counter increases in the event of bursts detected by the control made on the pressure using
the sensor installed on the valve (if configured) and bursts detected by control of the flow
variation (if configured) using a flow meter.
Good bottle
Last filling
operation burst
bottle indicator:
Burst bottle
Valve disabled or burst control using pressure sensor disabled or
burst control using flow variation and pressure sensor not configured
and not fitted
Product set point volume in [ml] set in the recipe currently active on the filler (present if a flow
meter is fitted as a measuring device).
Delay time in [ms] after the probe trigger; filling is complete when the delay expires.
This
value is set in the recipe currently active on the filler (present if a resistive probe is fitted as a
measuring device)
Probe trigger in [mV] detected by the card during the last filling operation when the product
comes into contact with the resistive probe (present if a resistive probe is fitted as a measuring
device).
Sidel S.p.A.
Effective product volume in [ml] counted by the slave card during the last filling operation
(present if a flow meter is fitted as a measuring device).
1.1
VI - 53
Matrix Filler
Part VI
Effective filling time in [ms] calculated by the slave card during the last filling operation
This time period only concerns product valve opening in all recipe phases i.e. pressurisation,
flushing and filling.
Mean flow rate in [ml/s] calculated by the card during the last second of control of the opening
valve (present if a flow meter is fitted as a measuring device).
Flow rate OK
Low flow rate
alarm indicator:
Flow rate lower than the set point limit requested

Valve disabled
Temperature in [C] of the product detected by the card (operates if temperature sensor
configured otherwise disabled).
Temperature OK
Low temperature
alarm indicator:
Temperature lower than the set point threshold requested

Valve disabled or temperature sensor disabled
Tail Time in [ms] calculated by the slave card during the closing transition of the last filling
operation. Transit time of the Tail Volume (present if a flow meter is fitted as a measuring
device).
Tail Volume in [ml] calculated by the slave card during the closing transition of the last filling
operation. The volume of product transiting during the Tail Time (present if a flow meter is fitted
as a measuring device).
Non-dimensional Tail K constant [-] calculated by the slave card taking into consideration the
closing transition of the last filling operations and the previous ones. This constant is used by the
card to calculate the advanced closing to be used in the next filling operation (present if a flow
meter is fitted as a measuring device).
Filling trigger alarm on individual valve counter; the counter is incremental.
Failure to reach the probe trigger (if resistive probe fitted) or the set point trigger (if flow meter
fitted) increases this counter.
Sidel S.p.A.
Last
filling
operation trigger
indicator:
VI - 54
Trigger OK
Trigger not reached
Valve disabled
1.1
Matrix Filler
Part VI
Counter for transmission alarms between individual slave card and Filling Master Card; the
counter is incremental.
Last
transmission
result indicator:
Last transmission OK
Last transmission error
Valve disabled
Filling valve scroll button (up)
Filling valve scroll button (down)
Reset Data button with confirmation pop-up window. Press this button to zero-set all the
filling data on the page (alarm counters, logic states and filling values) except for the Rcp[ml]
or Rcp[ms] column. This button can be pressed at any time (e.g. during production or CIP
cycles) without causing any problems.
Sidel S.p.A.
The button is only enabled when the Filling Master Card is phased.
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Matrix Filler
Part VI
FILLING VALVE DATA DETAILS SUBPAGE

Click the box
corresponding to the valve required to open a subpage called Filling Valve Data
Details for the last filling operation performed by the valve. This page displays detailed information
received from the slave cards in the Data Collection position. As well as the end of filling data
shown on the previous pages, detailed diagnostics is shown for the errors and logic states of the
individual cards. Refer to the colours in the legend shown on the right of the page to identify the
meaning of each alarm and logic state indicator. Depending on the type of filler and the optional
devices configured, different indicators are shown on the page.
Read-only page:
A brief description is given below of the indicators displayed on the screen page:
Manual Recipe status indicator: grey valve disabled; white OFF; blue manual recipe active on
the slave card transferred with filling command in manual. The manual filling command can be
sent from the panel or the remote pushbutton panel (if fitted).
CIP Mode status indicator: grey valve disabled; white OFF; blue CIP/RINSE mode enabled.
Sidel S.p.A.
Parameter alarm indicator: grey valve disabled; green valve parameterised; red valve not
parameterised. In this case you must run the Download Parameters and Check command
from the Filling Valves Maintenance or FMC PAS page.
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1.1
Pressure Sensor alarm indicator: grey valve disabled; green pressure sensor OK; red
pressure sensor installed on filling valve not functioning correctly. In this case, to prevent
triggering of alarms caused by incorrect sensor measurement, disable the corresponding
burst, snift and vacuum alarms on the Disable Filling Valves page. This indicator is only
present if the pressure sensor option is configured.
Flow Meter or Vortex or Mass Flow or Ultra Sonic Sensor (depends on the type of flow
rate measuring device configured). Alarm indicator: grey valve disabled; green measuring
device OK; red measuring device not functioning correctly. The electronic card generates
this alarm when no pulses are counted for a period of one second when the product valve is
open. Before substituting the device, make sure the valve is opening correctly, check the
product is moving in the pipe and the device is connected to the corresponding slave card.
This indicator is only present if a flow meter is configured as a measuring device.
Probe alarm indicator: grey valve disabled; green probe functioning OK; red probe not
functioning correctly. This indicator is only present if a resistive probe is configured as a
measuring device.
PWM alarm indicator: grey valve disabled; green PWM OK; red PWM of the electronic card
used to actuate the the digital outputs of the latter not functioning correctly.
Pressurization alarm indicator: grey valve disabled or burst check using pressure sensor
disabled or not configured; green bottle pressurisation correct; red bottle not pressurised. In
the latter case the bottle is not OK and therefore is not capped. The pressure detected by
the pressure sensor installed on the valve is not equal to the pressure in the tank; therefore
the isobaric condition is missing. Correct pressurisation of the bottle ensures no foam during
filling. With a cracked or damaged PET bottle, failed pressurisation causes filling to be
stopped. Similarly, filling of glass bottles is stopped if the bottle is not gripped perfectly. This
indicator is present only on fillers with the pressure sensor optional installed on the filling
valve. This indicator is only present if the pressure sensor option is configured.
Vacuum alarm indicator: grey valve disabled or vacuum check using pressure sensor
disabled or not configured; green vacuum in bottle OK; red vacuum in bottle less than the
threshold set in the recipe. In the case of bottles which are cracked, damaged or not gripped
perfectly, a missing vacuum does not cause filling to be stopped; however the bottle is not
OK and is not capped. This indicator is only present if the pressure sensor option is
configured.
Sidel S.p.A.
Part VI
Matrix Filler
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Matrix Filler
Part VI
Burst alarm indicator: grey valve disabled or burst check using pressure sensor disabled or
burst check using flow rate variation and pressure sensor not present; green good bottle; red
burst bottle. In the latter case the bottle is not OK and therefore the cap is not released. Burst
bottles often occur during pressurisation when there is a bottle defect (e.g. cracks). If the card
detects, using the sensor installed on the on the valve, a sudden pressure variation or a
difference in pressure between the bottle and the tank greater than the limit values set in the
recipe, filling is stopped and in the event of a glass filler the washing ramps are actuated (if
present and configured). On PET fillers with a flow meter, the burst check is also performed by
checking the flow variation. This indicator is only present if the pressure sensor option or the
flow variation check are configured.
Set Point Trigger alarm indicator: grey valve disabled; green recipe set point trigger in [ml]
reached; red recipe set point trigger in [ml] not reached. In this case the bottle is not OK and
therefore is not capped. In the event of timed filling (mode which can be set if there is a fault
on the flow meter), the set point is when the time set is reached. This indicator is only present
if a flow meter is configured as a measuring device.
Probe Trigger alarm indicator: grey valve disabled; green recipe trigger in [mV] reached; red
recipe trigger in [mV] not reached. In the latter case the bottle is not OK and therefore is not
capped. This indicator is only present if a resistive probe is configured as a measuring device.
Snift alarm indicator: grey valve disabled or snift check using pressure sensor disabled or not
configured; green snift or bottle decompression OK; red snift or bottle decompression
unsuccessful. In the latter case, as a result of failed decompression, the bottle is not OK and
therefore is not capped. The pressure detected by the pressure sensor installed on the valve is
greater than the threshold set in the recipe. This indicator is only present if the pressure sensor
option is configured.
Fill Running status indicator: grey valve disabled; white OFF filling sequence not enabled;
blue sequence enabled filling in progress.
Fill End status indicator: grey valve disabled; white OFF filling not completed or in progress;
green filling completed.
Sidel S.p.A.
Bottle Burst Control with Pressure Sensor status indicator: grey valve disabled or burst
control disabled; blue burst control performed using pressure sensor installed on the filling
valve actuated. This indicator is only present if the burst control using the pressure sensor
option is configured.
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1.1
Bottle Vacuum Control with Pressure Sensor status indicator: grey valve disabled or
vacuum control disabled; blue vacuum control performed using pressure sensor installed on
the filling valve actuated. This indicator is only present if the vacuum control using pressure
sensor option is configured.
Bottle Snift Control with Pressure Sensor status indicator: grey valve disabled or snift
control disabled; blue snift control performed using pressure sensor installed on the filling
valve actuated. This indicator is only present if the snift control using pressure sensor option
is configured.
Displays the tail values calculated by the card during the last filing operation.
This indicator is only present if a flow meter is configured as a measuring
device.
Displays the flow rate values (present only if a flow meter is configured as a
measuring device) and the temperature values (present only if the temperature
sensor is configured).
Displays the current firmware version installed on the slave card selected.
Sidel S.p.A.
Part VI
Matrix Filler
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Matrix Filler
Part VI
FORCE FILLING TIME SUBPAGE

Button to access the Force Filling Time subpage (only displayed if a flow meter is
configured as a measuring device)
Read-only page:
Use this page to force timed filling on a maximum of four valves.

If a flow meter is not functioning correctly, production can be continued by forcing timed filling on the
individual valve. The time used as the filling set point is the mean filling time of all the valves fitted on the
filler.
An adjustment time can be added to or subtracted from this mean time for each individual valve. This page is
only present on fillers with flow meters. In the case of fillers with a resistive probe, the recipe already
contains the Filling Timeout parameter.
Sidel S.p.A.
This is an emergency operating mode to be used only under exceptional circumstances until the faulty
flow meter is substituted. The precision and repeatability of filling are not guaranteed.
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Matrix Filler
Part VI
FILLING VALVES DATA PRESSURIZE SUBPAGE
Button to access the Filling Valves Data Pressurize subpage
Read-only page:
This page displays the filling values received from the electronic cards after the switch from the Data
Collection position. These values show the result of the most recent filling operation performed by the valve
with the bottle present. A legend is shown on the right of the page to facilitate understanding of the coloured
indicators. Most of the indicators on the page have already been described on the Filling Instruments
Measure Data subpage in this manual to which the reader is referred. Only the indicators not already
described are detailed below.
Pressure value [mbar] detected by the sensor installed on the valve during the last filling
operation. A total of six pressure measurements can be taken during filling. The phases in which
pressure is measured during filling must be selected in the recipe (manual or automatic); see the
Pick Pressure parameter. This indicator is only present if the pressure sensor option is
configured.
Sidel S.p.A.
Some of the status indicators shown above may not be displayed on the panel if the corresponding
optionals are not configured of if they are not part of the design for the type of filler selected.
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Matrix Filler
Part VI
FILLING VALVE DATA PRESSURIZE DETAILS SUBPAGE

Click the box
corresponding to the valve required to open a subpage called Filling Valve Data
Pressurize Details for the last filling operation performed by the valve. This page displays detailed
information received from the electronic card in the Data Collection position. As well as the end of
filling data shown on the previous pages, detailed diagnostics is shown for the errors and logic
states of the individual cards. Refer to the colours in the legend shown on the right of the page to
identify the meaning of each alarm and logic state indicator. Depending on the type of filler and the
optional devices configured, different indicators are shown on the page.
Read-only page:
For the description of the indicators present on the pages above, refer to the Filling Instruments Measure
Data, Filling Valve Data Details and Filling Valves Data Pressurize subpages in this manual.
Sidel S.p.A.
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Matrix Filler
Part VI
STATISTICAL ANALYSIS FILLING VALVES SUBPAGE
Button to access the Statistical Analysis Filling Valves subpage.
Sidel S.p.A.
Read-only page:
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Matrix Filler
Part VI
FILLING MASTER CARD DIAGNOSTIC #1 SUBPAGE
Diagnostic page:
Use this page and the ones that follow to check operation of the Filling Master Card by analysing the various
status indicators. The filling system should be considered as a module to run commands (see FMC CMD)
which depend on specific operating conditions and references received as inputs (see FMC DATA IN and
FMC HW INPUT); in turn the system is able to supply status, consent and value signals as outputs and to
create events (see FMC ACK, FMC DATA OUT ,FMC HW OUTPUT, FMC EVENTS).
-
FMC CMD: Requests to the Filling Master Card to run commands.

FMC ACK: Running status of the commands sent or process logic states performed by the Filling
Master Card.
FMC DATA IN: Signal logic states or reference values as inputs to the Filling Master Card.
FMC DATA OUT: Functional signals or values calculated and sent back by the Filling Master Card.
Sidel S.p.A.
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Part VI
Filling master card diagnostic #2 subpage

Diagnostic page:
FMC EVENTS: Events generated by the Filling Master Card as a result of specific operating
conditions. An event is linked to an action, e.g. bottle block or triggering of an alarm signal or display of
a message on the filler alarm page.
Sidel S.p.A.
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Matrix Filler
Part VI

Diagnostic page:
FMC SETTING: Display of Filling Master Card configuration settings currently enabled. On the basis
of the options configured, the various options available on the filler are displayed/disappear with the
relevant status indicators and control parameters (e.g.: purge command, temperature sensor etc.). N.B.
The settings on this page are read-only and cannot be modified.
EXP FMC SETTING: Button to export FMC configuration file to a USB memory stick.
The configuration parameters displayed on this page are set in the FMC_Setting.csv file housed on the
memory card of the Filling Master Card and cannot be modified using the operator panel; this configuration
file is read during each restart. To change these parameters, you must open and modify the file located on
the flash card using Excel. Connect a memory stick to a USB port of the Filling Master Card to export (but
not import) the configuration file. At the end of testing this file must be saved and stored with the machine
documentation. The file exported onto the memory stick is unequivocally form that filler, i.e. it contains the
name of machine serial number e.g. FMC_Setting SRMB0102.csv.
Sidel S.p.A.
optionals are not configured or if they are not part of the design for the type of filler selected.
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Part VI

Diagnostic page:
FMC HW INPUT: Cabled Hardware inputs (fast signals). These inputs are not displayed on the panel
if the Filling Master Card SW module is integrated in the B&R PLC which also manages the filler.
However they are displayed in the case of an external PLC (Siemens, Allen Bradley, B&R etc.)
dedicated to management of the filler and from which fast signals such as Presence or Preclosing can
be received.
FMC HW OUTPUT: Hardware outputs cabled for fast signals. These outputs are not displayed on
the panel if the Filling Master Card SW module is integrated in the B&R PLC which also manages the
filler. However they are displayed in the case of an external PLC (Siemens, Allen Bradley, B&R etc.)
dedicated to management of the filler and to which fast signals such as Burst or Fill OK can be sent.
FMC BUFFER TX: Total counters for the transmissions performed and in error, for each individual
buffer, by the Filling Master Card to the slave cards of the network. The operating status of the RS485
network can be diagnosed from here. Two buttons are also displayed to reset the Tx counters.
FMC CLOCK PHASING: clock time, clock delay, delay time between clock and valve no. 1 sensor.
Sidel S.p.A.
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Part VI
FILLING VALVE DISABLE SUBPAGE
Button to access the Disable Filling Valves subpage
Selection page
Use this page to disable the individual electronic filling valves by making a simple selection. The disabled
valves do not receive the filling during production command when they move away from the opening
position. When the selections are made, the corresponding alarm and status indicators on the diagnostics
(disabled status).
page turn grey
Button with confirmation pop-up window, deselects all the selections made on the page.
Button with confirmation pop-up window, selects all the possible selections on the page.
Sidel S.p.A.
WARNING: no valves can be disabled if CIP/RINSE mode is enabled. In this case the FMC
removes all the disable modes set on the panel.
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Part VI
BURST BOTTLE CONTROL USING PRESSURE SENSOR DISABLE SUBPAGE

Button to access the Burst Bottle Control Using Pressure Sensor Disable subpage
Selection page
Use this page to disable the burst bottle control of the individual electronic filling valves by making a simple
selection. The valves with the control disabled do not perform the burst bottle control during filling in
production. This selection is useful, if the pressure sensor installed on the valve is not operating correctly, to
prevent bottle rejects at outfeed. This page is present only on fillers with both the pressure sensor and burst
bottle control optionals configured. When the selections are made, the corresponding alarm and status
(disabled status).
indicators on the diagnostics page turn grey
Sidel S.p.A.
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Matrix Filler
Part VI
Vacuum Control Using Pressure Sensor Disable Subpage

Button to access the Vacuum Control Using Pressure Sensor Disable subpage
Selection page
Use this page to disable the vacuum control of the individual electronic filling valves by making a simple
selection. The valves with the control disabled do not perform the vacuum control during filling in production.
This selection is useful, if the pressure sensor installed on the valve is not operating correctly, to prevent
bottle rejects at outfeed. This page is present only on fillers with both the pressure sensor and vacuum
control optionals configured. When the selections are made, the corresponding alarm and status indicators
(disabled status).
on the diagnostics page turn grey
Sidel S.p.A.
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Matrix Filler
Part VI
Snift Control Using Pressure Sensor Disable Subpage

Button to access the Snift Control Using Pressure Sensor Disable subpage
Selection page
Use this page to disable the snift control of the individual electronic filling valves by making a simple
selection. The valves with the control disabled do not perform the snift control during filling in production.
This selection is useful, if the pressure sensor installed on the valve is not operating correctly, to prevent
bottle rejects at outfeed. This page is present only on fillers with both the pressure sensor and snift control
optionals configured on the filling valve. When the selections are made, the corresponding alarm and status
(disabled status).
indicators on the diagnostics page turn grey
Sidel S.p.A.
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Matrix Filler
Part VI
TEMPERATURE SENSOR DISABLE SUBPAGE
Button to access the Disable Sensors Temperature subpage
Selection page
Use this page to disable the individual temperature sensors on the electronic filling valves by making a
simple selection. Disabled sensors are ignored by the Filling Mater Card and therefore temperature alarms
are not triggered by these sensors. This page is present only on fillers with the temperature sensor
configured. When the selections are made, the corresponding alarm and status indicators on the diagnostics
(disabled status).
page turn grey
Sidel S.p.A.
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Matrix Filler
Part VI
MANUAL FILLING TEST SUBPAGE
Button to access the Manual Filling Test subpage
Selection page
Use this page to select a valve and send a command to the valve for filling start with a suitably configured
manual recipe.
WARNING: when you have performed a filling operation in this mode, you must reload the production
recipe currently enabled on the filler otherwise the valve continues to perform filling operations using
the recipe sent in manual mode. Refer to the production recipe pages for an explanation of manual
recipe parameters. You must enable the Manual Filling Test mode using the two-position selector
shown below to perform manual filling operations.
Remember that this selector can only be enabled if the filler selectors on the operator panel toolbar are
released.
Only accessible if the Manual Filling Test selector is enabled ON, the filler is
stopped, bullet to the left of the button is selected and manual filling is not in
progress.
1.1
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Sidel S.p.A.
Button with pop-up confirmation window to command manual filling in step by step mode.
To enable the button, select the check mark located to the left before pressing the manual
opening command button on the control panel. Each programmed step in the manual
recipe sequence is performed only after this button is pressed. This operation is useful to
perform filling in sequenced mode to observe better the various phase transitions.
Matrix Filler
Part VI
Manual Filling Test two-position selector enabled ON. When this selector is enabled
ON, the buttons located on the right of the page are released. A bottle block warning
message (info) is displayed on the alarm page to indicate the ON status of the selector. To
restart production in automatic mode at the end of manual filling operations, set the
selector to OFF or remove the filler selectors release function on the operator panel toolbar
If you wish to perform manual filling by sending the start filling command from the remote
pushbutton panel (if fitted), the Manual Filling Test selector on this page must always
be enabled beforehand.
The selector can only be enabled when the filler selector release is enabled, the
Filling Master Card is phased, OPER. or IDLE mode enabled and Manual Test
Enable OK signal from the filler in green ON status (cumulative signal for doors
closed, safety devices enabled, etc.) For safety reasons it cannot be enabled in
CIP/RINSE mode or simultaneously with other selectors of the Filling Master Card.
Field to enter the number of the valve for which manual filling is required. Type in the
number directly or scroll through the valve numbers using the arrows.
By selecting the check marks for the individual burst bottle, vacuum and snift controls, the
corresponding controls can be disabled during manual filling. By enabling the check marks
on the Manual Filling Valve Data Details page, the corresponding status and indicators
(disabled).
and turn grey
Button with confirmation pop-up window to load the recipe values currently present in the
enabled production recipe and transfer them to the values of the manual recipe.
Only accessible if the Manual Filling Test selector is enabled ON and manual
filling is not in progress.
Button with pop-up confirmation window to command manual filling start. The manual
recipe is sent to the valve currently selected on the control panel and filling begins. At the
same time as this operation, recording of the instantaneous values for flow rate, pressure
or probe voltage (depending on the options installed) begins; the values are also displayed
in graph format.
Only accessible if the Manual Filling Test selector is enabled ON, the filler is
stopped and manual filling is not in progress. If an opening command is sent using
the remote pushbutton panel (if fitted), the command is sent to the valve located at
the step set on the FMC PAS page and not to the number of the valve selected on
this page. Manual filling cannot be performed on all the valves in the section between
the outfeed starwheel and the infeed starwheel.
Button with pop-up confirmation window to stop manual filling. The electronic card
immediately stops manual filling by returning to the status of waiting for the initial
command.
Sidel S.p.A.
Only accessible if the Manual Filling Test selector is enabled ON or manual filling
is in progress.
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Part VI
Graph filling instant data subpage
Button with pop-up confirmation window to access the Graph Filling Instant Data
subpage
Read-only page:
The Instant graph displays the data archived by the Filling Master Card during the last filling operation
performed in manual mode.
These values are sampled on the basis of a preset time in the recipe called Scope T. Sample Instant.
This data archiving mode is only enabled during filling operations performed in manual mode.
Contrary to Storage, the type of data to be sampled does not have to be indicated beforehand; therefore the
voltage of the resistive probe (if fitted) or the product flow value (if flow meters are fitted) and the pressure
detected by the sensor (if fitted) are always sampled during each manual filling command.
Press the button above the GetIData.csv file with the data archived by the Filling Master Card to recover the
data from the Filling Master and display it in graph format on the panel. If another filling valve is selected, a
new filling operation must be performed beforehand by pressing the manual opening button to generate a
new file. This file can also be exported to a USB memory stick and analysed on a PC. The type of graph,
filler serial number, the recipe currently enabled on the machine as well as the filler date and time are always
displayed at the top of each graph (see pages below).
If a USB memory stick is inserted in one of the two ports of the Filling Master Card and the last valve to
have performed manual filling is interrogated to obtain the instant data graphs, the GetIData.csv file is
also automatically copied on to the USB stick so it can be analysed on a PC.
Sidel S.p.A.
Each exported graph is copied into a sub-folder of a folder with a name which is identical to the
machine serial number. The sub-folder is named using the valve number, date and time (e.g.:
n94_Y11M03D24h11m13s05)
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Part VI
Machine type with pressure sensor and/or flow meter
The individual graphs can be enlarged to full-screen size by clicking on the corresponding magnifying glass
icon. Note how this page and successive ones can be used to send a new manual opening command, to
modify the valve selection, redraw the graph, display filling details and stop the manual filling operation
currently in progress.
Sidel S.p.A.
By clicking on the upper magnifying glass icon:
Graph displaying the instant flow rate of the filling valve in [ml/s] and [ms].
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Part VI
Matrix Filler
Graph displaying the instant pressure detected by the sensor installed on the valve in [mbar] and [ms].
The individual graphs can be enlarged to full-screen size by clicking on the corresponding magnifying glass
icon. Note how this page and successive ones can be used to send a new manual opening command, to
modify the valve selection, redraw the graph, display filling details and stop the manual filling operation
currently in progress.
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Sidel S.p.A.
Machine type with pressure sensor and/or resistive probe
Matrix Filler
Part VI
Graph displaying the instant voltage of the filling valve probe in [mV] and [ms].
Sidel S.p.A.
Graph displaying the instant pressure detected by the sensor installed on the valve in [mbar] and [ms].
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Part VI
Matrix Filler
Description of buttons on graph pages:

The following buttons can be found on the Graph Filling Instant Data pages and the Graph Filling Storage
Data pages.
Click this button to return to the page displaying both graphs which are also redrawn.
Click this button to zoom in on the graph displayed in full-screen mode.
Click this button to zoom out of the graph displayed in full-screen mode.
Click this button to scroll to the right the graph displayed in full-screen mode.
Click this button to scroll to the left the graph displayed in full-screen mode.
Sidel S.p.A.
Click this button to redraw the graph by highlighting the values actually sampled by the
card during manual filling. The graph displayed is the result of a spline interpolation of the
points sampled.
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Part VI
Graph Filling Storage Data subpage

Button to access the Graph Filling Storage Data subpage
Read-only page:
The Storage graph, contrary to the Instant graph displays the data archived in the internal memory of the
electronic card during the last filling operation. Once an initial delay, called Scope T. Delay Storage has
elapsed, values are sampled on the basis of a preset time in the recipe called Scope T. Sample Storage.
The internal sampling buffer of the slave card has 100 values.
Contrary to Instant, you must first decide which type of value to sample i.e. the voltage of the resistive probe
(if fitted), the product flow rate (if a flow meter is fitted) or the pressure of the sensor (if fitted).
This method of archiving data is always enabled during each filling operation in manual mode (see
manual recipe) and in production (see production recipe).
Press the button shown above to command the Filling Master Card to recover the data from the slave card
and create an archive file called GetSData.csv which is shown in graph format on the panel. This file can
also be exported to a USB memory stick and analysed on a PC. If a new filling valve is selected, press the
button above again to recover the data for this new valve. The type of graph, filler serial number, the recipe
currently enabled on the machine as well as the filler date and time are displayed at the top of each graph
(see pages below).
If a USB memory stick is inserted in one of the two ports of the Filling Master Card and a valve is
interrogated to display the storage data in a graph, the GetSData.csv file is also automatically copied
on to the USB stick so it can be analysed on a PC.
Sidel S.p.A.
Each exported graph is copied into a sub-folder of a folder with a name which is identical to the
machine serial number. The sub-folder is named using the valve number, date and time (e.g.:
n94_Y11M03D24h11m13s05)
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Part VI
Matrix Filler
Machine type with flow meter
This page displays the graph in [ml/s] and [ms] for the flow rate sampled and archived in the internal memory
of the electronic slave card during the last filling operation performed. Note how this page and successive
ones can be used to send a new manual opening command, to modify the valve selection, redraw the graph,
display filling details and stop the manual filling operation currently in progress.
This page displays the graph in [mbar] and [ms] for the pressure sampled and archived in the internal
memory of the electronic card during the last filling operation performed. Note how this page and successive
ones can be used to send a new manual opening command, to modify the valve selection, redraw the graph,
display filling details and stop the manual filling operation currently in progress.
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Sidel S.p.A.
Machine type with pressure sensor
Matrix Filler
Part VI
Machine type with resistive probe
Sidel S.p.A.
This page displays the graph in [mV] and [ms] for the resistive probe data sampled and archived in the
internal memory of the electronic card during the last filling operation performed.
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Part VI
Manual filling valve data details subpage

Button with pop-up confirmation window to display a detailed subpage called Manual
Filling Valve Data Details for the last filling operation performed by the valve selected.
Detailed diagnostics is shown for the errors and logic states of the individual slave card.
Refer to the colours in the legend shown on the right of the page to identify the meaning of
each alarm and logic state indicator. Depending on the type of filler, different indicators are
shown on the page.
Read-only page:
Machine type with flow meter and pressure sensor
These values show the result of the most recent filling operation performed by the valve in manual or in
production.
The data for the valve selected is updated automatically when the page is opened.
Some of the status indicators or fields to insert data shown above may not be displayed on the panel if
the corresponding optionals are not configured or if they are not part of the design for the type of filler
selected.
1.1
VI - 83
Sidel S.p.A.
If another filling valve is selected, press the button again to update the data on the page. For the description
of the indicators present on the pages above, refer to the Filling Instruments Measure Data, Filling
Valve Data Details, Filling Valves Data Pressurize and Filling Valve Data Pressurize Details
subpages in this manual.
Matrix Filler
Part VI
FILLING VALVES MAINTENANCE SUBPAGE

Button to access the Filling Valves Maintenance subpage
Selection page: can only be accessed and used by those with supervisor access
level authority
Read-only page:
Use this page to perform the following maintenance operations on the filling valve electronic-pneumatic
units ( slave cards):
-
slave card addressing with allocation of the new node using the serial number;
verification of the node set on a slave card using the serial number;
verification of the serial number of a slave card using the node;
slave card firmware updating;
firmware writing;
firmware for archive file importation/exportation from/to USB memory stick
backup recipes: importation/exportation from/to USB memory stick of archive file;
sending the abort command to all the slave cards in the network (Abort Valves);
loading of configuration parameters on the slave cards with verification of the firmware installed
(Check Valves).
Sidel S.p.A.
Some of these operations can only be performed when the corresponding two-position selectors are
enabled and when the filler selectors on the operator panel toolbar are released.
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Filling Valves Addressing two-position selector When this selector is enabled ON, the buttons located in
the selector box are released. A bottle block warning message (info) is displayed on the alarm page to
indicate the ON status of the selector. To restart production in automatic mode, set the selector to OFF or
remove the filler selectors release function on the operator panel toolbar.
The selector can only be enabled when the filler selector release is enabled, the filler is empty and
OPER. or IDLE mode are enabled. For safety reasons it cannot be enabled in CIP/RINSE mode or
simultaneously with other selectors of the Master Card.
Button with confirmation pop-up window to display Read Serial Number by Address. Enter the node
number of the electronic-pneumatic unit you wish to interrogate in the Valve Number field and press the
corresponding button; the Filling Master Card sends a command to this card which responds with its own
serial number and the firmware version currently loaded. If the card interrogated is disconnected or not
programmed with this node number, the reply fields Serial Number and Version remain set to zero.
Communication faults may occur in the reply if two cards parameterised with the same node number
are connected to the network (both reply simultaneously thus creating a conflict). In the event of Tx
errors, refer to the transmission alarm counter diagnostics pages and the valve alarm page. Node
numbering is unequivocal.
Button with pop-up confirmation window, Set Address by Serial Number. This function is used if an
entire valve control electronic-pneumatic unit must be substituted. Enter the serial number printed on the
valve control unit in the Serial Number field and the node number you wish to assign in the Valve
Number field and press the corresponding button to command the Filling Master Card card to send a
broadcast to all the slave cards connected to the network. Given that the serial numbers of the control units
are unequivocal, only one node will reply to the command by making the node number sent its own.
Sidel S.p.A.
When you have parameterised the slave card with a new node, perform a check by interrogating the
node you have just configured using the serial number or the node itself to ensure the serial number is
correct.
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Button with pop-up confirmation window, Read Address by Serial Number. Enter the serial number of
the electronic-pneumatic unit you wish to interrogate in the Serial Number field and press the
corresponding button to command the Filling Master Card card to send a broadcast to all the slave cards
connected to the network. Given that the serial number of the control unit is unequivocal, only one node will
reply to the command with its own number. If the slave card interrogated is disconnected or there is no
match for the serial number requested, the Valve Number reply field remains set to zero.
Communication faults may occur in the reply if two slave cards parameterised with the same serial
number are connected to the network (both reply simultaneously thus creating a conflict). In the event
of Tx errors, refer to the transmission alarm counter diagnostics pages and the valve diagnostics alarm
page.
The button to the left is only enabled when a USB memory stick is connected to one of the two USB ports
present on the Filling Master Card. If a memory stick is connected the colour of the indicator top left is
green. Press the button to the left to display the Copy File Firmware MOT pop-up window. Use this
window to decide whether to copy the Filling_Valve.mot file containing the firmware to be updated on
the control units from the USB memory stick to the Filling Master Card or vice versa. If the file is copied
correctly, the indicator top left is green otherwise it is red to indicate a fault. Press the button top right Start
Firmware Compile, with confirmation pop-up window, to compile the firmware; this operation requires
several minutes for completion and must be performed before any updating is performed. If the firmware is
not compiled, the indicator in the top left corner of the button is red. The indicator is green when the
firmware is compiled. The compilation process can be started under any conditions. If there is no MOT file
to compile then the button cannot be accessed. Read the diagnostics messages displayed in the
Messages Diagnostic field.
Sidel S.p.A.
Each time the Filling_Valve.mot file containing the firmware to be updated is copied and
overwritten on the one present on the Filling Master Card, you must recompile the firmware before
proceeding to update the control units. The firmware must also be recompiled if the voltage is cut to
the master card. Compilation should also be performed before each firmware updating operation. If
the firmware is not compiled the message WARNING Filling_Valve.mot Not Compile is
displayed in the field Messages Diagnostic.
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The button opens the pop-up window shown below. The upper and lower buttons are used to copy from and
to the USB memory stick and are only enabled when a memory stick is connected to one of the two USB
ports on the Filling Master Card. The middle button starts the procedure to create the RcpBackup_XXX.csv
file on the flash card of the Filling Master Card; XXX indicates the serial number of the machine e.g.:
RcpBackup_SRMB0102.csv. Creation of this file requires at least 20 minutes during which time all the
buttons are disabled, the middle one is red and the warning Creating File RcpBackup.csv Please Wait
is displayed in the Messages Diagnostic window. The backup process can be started at any time when
the machine is in production or CIP. However once the process has begun it cannot be interrupted. Wait for
the process to finish. If at least one recipe backup file has been created and is present on the flash card,
then the file can be exported to the USB memory stick connected by pressing the lower button in the pop-up
window. Recipe backup files previously saved can also be imported from the USB memory stick by pressing
the button in the upper part of the pop-up window. The import process requires approximately twenty
minutes, just like the backup process. Any faults occurring during transfer or creation of the file are signalled
in the Messages Diagnostic window.
A recipe backup file can only be imported if the serial number contained in the name of the file matches
the name set in the Filler Serial Number parameter (see the FMC_Setting.csv file).
The selector can only be enabled when the firmware is compiled, the filler is empty and OPER. or IDLE
mode is enabled. For safety reasons it cannot be enabled in CIP/RINSE mode or simultaneously with
other selectors of the Filling Master Card. This selector is not linked to the status of the selector release
button located on the filler control toolbar.
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Sidel S.p.A.
Firmware Update two-position selector. When this selector is enabled ON, the Start Firmware Update
button with confirmation window and the From Valve and To Valve data fields contained in the selector
box are released. A bottle block warning message (info) is displayed on the alarm page to indicate the ON
status of the selector. To restart production in automatic mode, set the selector to OFF. The selector can
only be enabled if the firmware present on the Filling Master Card has been compiled. Note the Faults
Counter field showing the faults occurring during the firmware update operation. Also read the diagnostics
messages displayed in the Messages Diagnostic field.
Matrix Filler
Part VI
Check Valves button with confirmation pop-up window. Press this button to send to the control units the
configuration parameters set on the FMC PAS page where a button identical to this one is displayed.
The firmware version currently loaded on the valve control unit is also checked. The button is only enabled
when the machine is empty. A bottle block warning message (info) is displayed on the alarm page to
indicate the running status of the command.
This button must be pressed following the physical substitution of a valve control unit. This button
must also be pressed after modification of one of the configuration parameters on the FMC PAS
page where a button identical to this one is displayed. Furthermore after each restart caused by a
voltage cut, the system performs a filler phasing operation (search for the sensor of valve no. 1) and
then automatically recalls this parameterisation function.
An abort command is sent to all the slave cards present in the network when this button is pressed. Only
press the button when you wish to reset fully all the network nodes by forcing the exit of the nodes from all
enabled modes or commands (OPER., manual test, etc.).
Sidel S.p.A.
The command is always accepted except when the the Filling Valves Addressing or Firmware
Update selectors are enabled or with CIP/RINSE mode enabled.
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Matrix Filler
MANUAL TEST FILLING VALVE OUTPUTS SUBPAGE
Button to access the Test Outputs Filling Valves subpage
Selection page
Manual Test Filling Valve Outputs two position selector enabled ON.
When this selector is enabled ON, the direct commands of the individual outputs located
on the right of the page are enabled. A bottle block warning message (info) is displayed on
the alarm page to indicate the ON status of the selector. To restart production in automatic
mode after the manual test, set the selector to OFF or remove the filler selectors release
function on the operator panel toolbar. This operation also disables OFF all the forced
operations enabled on the filling valve outputs.
The selector can only be enabled when the filler selector release is enabled, the
Filling Master Card is phased, OPER. or IDLE mode enabled and Manual Test
Enable OK signal from the filler in ON status (cumulative signal for doors closed,
safety devices enabled, etc.) For safety reasons it cannot be enabled in CIP/RINSE
mode or together with other selectors of the Filling Master Card.
Sidel S.p.A.
Field to enter the number of the valve for which manual testing is required. Type in the
number directly or scroll through the valve numbers using the arrows.
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Part VI
Button with forcing enabled. The corresponding electrical output of the filling valve
currently selected is forced to OFF status.
Button with forcing disabled. The corresponding electrical output of the filling valve
currently selected is forced to OFF status.
Button with forcing inhibited.
Sidel S.p.A.
selected.
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Part VI
SEQUENCER OUTPUTS FILLING VALVE #1 SUBPAGE
Selection page
Sequencer outputs filling valve #2 subpage

Sidel S.p.A.
Selection page
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Use this page to program the Rinse Sequence, Flushing Sequence, Drain Sequence and Priming
Sequence.
These sequences are fixed (there are no recipes) and involve, for each individual output, programming of
eight timed phases during which the command logic status can be defined (ON or OFF of the individual
outputs).
There is also a sequence start delay parameter expressed in machine steps relative to the command send
position which matches the Filling Start position.
These sequences can be enabled on request (see FMC CMD and
Card Diagnostic subpage) only in OPER. mode when the filler is
incorrect sequence is programmed i.e. the sum of phase times
revolution, the sequence is stopped when the valve moves away
starwheel.
FMC ACK on the first Filling Master

rotating and there are no bottles. If an
exceeds the time needed for a filler
from the tangent position on the inlet
Sidel S.p.A.
The sequences are not performed if the Master Card is in CIP/RINSE or IDLE mode. Their use is
strictly linked to the type of machine (glass, cans, plastic, still water, etc.) in that they enable running of
alternative sequences to filling not linked to product or bottle presence.
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Part VI
FMC DIAGNOSTIC SUBPAGE
Button to access the FMC Diagnostic subpage
Selection page
Sidel S.p.A.
Filling Master Card diagnostics page. The Web Server integrated in the B&R PLC can be used to monitor the
operating status of the PLC by checking for example use of the CPU, allocation of the memory, hardware
status, etc. The page is read-only. If you wish to monitor operating status directly from your own PC, open
Internet Explorer and enter the TCP/IP address of the Filling Master Card, e.g.: http://10.1.20.17/sdm (the
system asks for a plug-in to be installed).
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6.4
Part VI
RECIPES
Function to access the Recipes page.

H
B
P
C
D
E
A.
Press this button to access the active recipe selected.
B.
Press this button to edit any recipe i.e. compile all available parameters.
C.
Press this button to download a recipe.
D.
Press this button to upload a recipe.
E.
Press this button to cancel the recipe selected.
F.
Press this button to copy the recipe required.
Recipe status display: red = ON-LINE green = OFF-LINE
Sidel S.p.A.
G.
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Part VI
Select this menu to access the recipe index page showing all the available OFF-LINE
(inactive) and ON-LINE (active) recipes.
I.
Select this menu to access the general recipes and product pages.
J.
Select this menu to access the recipe page dedicated to tank level control.
K.
Select this menu to access the recipe page dedicated to pressure controls.
L.
Select this menu to access the recipe page dedicated to the rinser, specifically
setting of the times applied to air and water treatment.
M.
Select this menu to access the first part of the production recipe relating to the filling
valves.
N.
Select this menu to access the second part of the production recipe relating to the
filling valves.
O.
Select this menu to access the part of the production recipe concerning the filling Set
Point of the filling valves.
P.
List of recipe names.
Sidel S.p.A.
H.
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Part VI
GENERAL DATA WINDOW
D
This page shows data for the bottle used in the recipe.
GENERAL
A.
B.
C.
Bottle Size: the size in mm of the bottle used in the recipe.

Machine Speed: maximum machine speed for this size.
Outfeed Conveyor Motor 1 KS: ratio constant between machine speed and outfeed belt speed.
CAPPER
Cap type: numeric value representing the type of cap used for this size (see legend).
Sidel S.p.A.
D.
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GENERAL DATA WINDOW FOR HOT MACHINES
A
B
C
D
E
GENERAL
A.
B.
C.
Bottle Size: the size in mm of the bottle used in the recipe.

Machine Speed: maximum machine speed for this size.
Outfeed conveyor motor 1 KS: ratio constant between machine speed and outfeed belt speed.
TEMPERATURE CONTROL
D.
E.
F.
G.
H.
I.
J.
Infeed tank - Set Point 1: Product tank temperature Set Point.

Infeed tank - Low temp. alarm: Product delivery low temperature alarm threshold.
Infeed tank - High temp. alarm: Product delivery high temperature alarm threshold.
Recycling tank - Set Point 1: Recycling tank temperature Set Point.
Recycling tank - Low temp. alarm: Product return low temperature first alarm threshold.
Recycling tank - Very low temp. alarm: Product return low temperature second alarm threshold.
Recycling tank - High temp. alarm: Product return high temperature alarm threshold.
WASHING WITH HOT WATER

Set point: steam temperature Set Point value.
Proportional gain: Gain parameter for PID regulation.
Integral time: Integral parameter for PID regulation.
Derivation time: Derivative parameter for PID regulation.
Feed - Forward: feed forward parameter value for PID adjustment corresponds to opening of the
modulating valve when the machine is operating at speed (maximum speed, full of bottles).
Sidel S.p.A.
K.
L.
M.
N.
O.
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Part VI
General data window for machines with AROL Equatorque crown capper
A
Contains the data relative to the sizes of the AROL Equatorque crown capper.
Positioning of Motors.
Central guide
Bottle body pad
Extractor pad (Bottle Outfeed)
2.
Access to page to enter closing data.
Sidel S.p.A.
1.
-
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2.
Matrix Filler
CLOSING DATA
Contains the data relative to the AROL Equatorque capper:

Press this button to Upload the capper data contained in the PLC or to load the default
operating data.
Closing cycle start angle from which the motor head is activated with rigid axis.
Position always before the Down Main Angle.
Down Main Angle:
Head lowering start angle from which the rotation of the motor head starts.
Close Main Angle:
Angle in which the head starts the actual closing of the bottle; this position must
normally occur before that in which the cap starts to interfere with the neck of the
bottle.
End Main Angle:
End of closing cycle angle, represented by the position in which it lifts from the closed
bottle.
Lock Mode:
Type of closing algorithm used:

0.
Torque:
1.
Torque + No Speed.
2.
Unwarp + No Speed.
50. Position
Closure Torque:
Final closing torque (Nm). Indicates the torque for the final tightening of the bottle.
Gearing Ratio:
Ratio between the carousel speed and the initial rotation speed of the motor head.
Sidel S.p.A.
Start Main Angle:
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Part VI
Slowing torque (Nm), after which the head slows down before the final part of the
closing.
Gearing Holding:
Angle relative to the measurement position of the first threshold for maintaining the
rotation of the heads in Gearing mode with the capper speed.
Closure Speed:
Rotation speed (rpm) for the final tightening; it must be sufficiently low to limit the
inertia effect.
Closing
Acceleration:
Acceleration limit (head revs/s2) during the closing phase.
Stop Factor Speed:
Percentage of the final closing speed to consider the cap closed with LockMode =
"No Speed".
Blind Input Angle:
Angle relative to "Close Main Angle" for measuring the first threshold.
Torque Time:
This is the time for maintaining the cap torque at the end of the closing phase.
Unwrap Angle:
Cap unscrewing angle before low speed closing with LockMode = "Unwrap".
Screwing takes place with a negative value.
Unwrap Speed:
Cap closing speed before low speed closing with LockMode = "Unwrap".
Unwrap
Acceleration:
Acceleration limit (head revs/s2) during any reopening phase with LockMode =
"Unwrap".
Unwrap Blind Main

Angle:
Angle of carousel before which no unscrewing is performed.
Cap Turn
Not Reached:
Rotation angle.
Fault Enable
Not In Torque:
Enabling "Not In Torque alarm (Cycle ended during the Torque phase).
Fault Enable
Bad Closure:
Enabling "Bad Closure" alarm (Torque applied but speed above "Stop Factor
Speed").
Sidel S.p.A.
Slow Torque:
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Matrix Filler
LEVEL DATA WINDOW

A
B
C
D
E
F
G
H
I
J
K
Contains the data required by PID adjustment for the tank level.
F.
G.
H.
I.
J.
K.
Set Point: percentage value of tank level to be adjusted.

Feed Forward: feed - forward parameter value for PID adjustment corresponds to opening of the
Ramp speed: Feed - Forward percentage value added until the maximum or minimum (zero) Feed Forward parameter is reached. Used during transitions (machine filling / emptying). This parameter
sets the opening / closing speed of the modulating valves during transitions.
FF increase ramp delay steps: the delay in machine steps (bottles) before the Feed Forward
increase ramp starts (from zero to the value set). This matches approximately the number of steps
between the opening command and filling start i.e. the number of steps required for vacuum /
pressurisation (by the filling valve recipe).
FF decrease ramp delay steps: the delay in machine steps (bottles) before the Feed Forward
decrease increase ramp starts (from the current value to zero). This matches approximately the
number of steps between the opening command and filling start (by the filling valve recipe).
Maximum level: the percentage level above which the product infeed modulating valve is forced
closed by the safety valve (not the same value as the Set Point).
Minimum level: percentage level below which the machine, if in production, is stopped in alarm status
(absolute value).
Level OK: percentage hysteresis relative to the Set Point which, when reached, is considered the set
point value (not the same value as the Set Point).
Sidel S.p.A.
A.
B.
C.
D.
E.
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Part VI
LEVEL DATA WINDOW FOR HOT MACHINES
G
H
Product tank level

A.
B.
C.
D.
E.
F.
G.
H.
Set point: percentage value of level to be adjusted.

Maximum level: maximum level alarm.
Minimum level: minimum level alarm.
Level OK: correct level off set reached.
Shaker speed: shaper operating speed.
Spray ball infeed time ON: tank infeed with spray balls ON time.
Spray ball infeed time OFF: tank infeed with spray balls OFF time.
Enable spray ball infeed: Product infeed by spray ball enabling.
Recycling tank level

Set point in CIP: percentage value of level to be adjusted during sanitization.
Pump start level in CIP: percentage value to enable pump start during sanitization.
Set point in production: percentage value of level to be adjusted during production.
Pump start level in production: percentage value to enable pump start during production.
Minimum level: minimum level alarm.
Maximum level: maximum level alarm.
Sidel S.p.A.
I.
J.
K.
L.
M.
N.
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Matrix Filler
PRESSURE DATA WINDOW

A
B
C
D
E
F
G
H
I
J
K
L
M
A.
B.
C.
D.
E.
F.
G.
H.
I.
J.
K.
L.
M.

Feed Forward: parameter value for PID adjustment corresponds to opening of the modulating valve
when the machine is in loading transition (bottle feed starts).
Ramp speed: Feed - Forward percentage value added until the maximum or minimum (zero) Feed Forward parameter is reached. Used during transitions (machine filling / emptying). This parameter
sets the opening / closing speed of the modulating valves during transitions.
FF increase ramp delay steps: the delay in machine steps (bottles) before the Feed Forward
increase ramp starts (from zero to the value set). This matches approximately the number of steps
between the opening command and pressurisation start i.e. the number of steps required for vacuum
(by the filling valve recipe).
FF decrease ramp delay steps: the delay in machine steps (bottles) before the Feed Forward
decrease increase ramp starts (from the current value to zero). This matches approximately the
number of steps between the opening command and vacuum end (by the filling valve recipe).
FF change delay time: the time during which the Feed Forward value is maintained before the
decease ramp to Feed Forward value 2. Matches approximately pressurisation time (by the filling valve
recipe).
Feed Forward 2: feed - forward parameter value for PID adjustment corresponds to opening of the
Maximum breather pressure: the pressure at which the breather valves are enabled (not the same
value as the Set Point).
Maximum breather hysteresis: the pressure hysteresis at which the breather valves are disabled (not
the same value as the Set Point).
Minimum pressure in production: pressure value below which the machine, when in production, is
stopped in alarm status (not the same value as the Set Point).
1.1
VI - 103
Sidel S.p.A.
Contains the data required by PID adjustment for the tank pressure.
Matrix Filler
Part VI
HOT PRESSURE DATA WINDOW
A
B
C
D
E
F
Set point: filling value in mm corresponding to the pressure on the bottle.

Set Point 50%: bottle filling value in mm with machine speed at 50% of the nominal value.
Machine stopped recycling percentage: Product recycling percentage when the machine is stopped.
Sidel S.p.A.
A.
B.
C.
D.
E.
F.
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Matrix Filler
FOAMER DATA WINDOW
A
B
C
D
E
F
G
H
Contains the data required by PID adjustment for the foamer temperature and pressure.
H.

Maximum temperature: Maximum temperature parameter for PID adjustment.
Minimum temperature: Minimum temperature parameter for PID adjustment.
Feed Forward: feed forward parameter value for PID adjustment.
This type of control predicts how the system will perform in the future and makes adjustments based on
this estimate.
These corrections are used to correct the mean instantaneous error enabling the PID to correct the
error thus improving the performance of the system.
Pressure: display of filling speed with relative pressure.
Sidel S.p.A.
A.
B.
C.
D.
E.
F.
G.
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Part VI
RECIPE PRODUCTION WINDOW

Machine type with purge option and pressure sensor
A
B
C
D
E
F
I
K
These pages contain the recipe data needed to command the filling valves during production. The recipe is
divided into 14 phases as well as the preliminary flushing (present if configured) and valve spout purge
(present if configured) zero phase. During each phase it is possible to decide which solenoid valves to open,
for how long and where the set point trigger or probe trigger should be set.
selected.
DESCRIPTION OF ELECTRONIC VALVE OUTPUTS ON THE BASIS OF THEIR USE:
A.
B.
C.
Sidel S.p.A.
D.
Fast Filling: solenoid valve used to pressurise the bottle (with the Opening valve closed) or to fill at
higher speed (with Opening valve open) by removing the CO2 inserted during filling from a larger
passage.
Opening: solenoid valve used to open the valve shutter to allow product infeed into the bottle.
Slow Filling: solenoid valve used to pressurise the bottle (with the Opening valve closed) or to fill at
reduced speed (with Opening valve open) by removing the CO2 inserted during filling from a smaller
passage.
Snift/Decompress: solenoid valve used to open the bottle decompression circuit at the end of filing.
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Matrix Filler
Controls which can only be set with the pressure sensor configured:
E.
F.
G.
H.
I.
J.
Control Burst: used to indicate during which phase of the recipe the burst bottle control is to be
performed using the pressure sensor installed on the valve (visible if the Presence Pressure Burst
Control parameter is configured).
Pick Pressure: used to indicate during which phase of the recipe the pressure should be detected
using the pressure sensor installed on the valve. A maximum of 6 pressure value can be detected
during a single filling operation (visible if the Presence Sensor Pressure parameter is configured).
Max Delta Press Tank-Bottle: maximum pressure differential value expressed in [mbar] between the
tank and the bottle; the bottle burst alarm is triggered if this limit is exceeded during filling (visible if the
Presence Pressure Burst Control parameter is configured).
Burst: Max Pressure Variation: maximum pressure variation value expressed in [mbar]; the bottle
burst alarm is triggered if this limit is exceeded during filling (visible if the Presence Pressure Burst
Control parameter is configured).
Burst: Control Time: burst bottle control time expressed in [ms]; indicates the frequency with which
the check on pressure variation indicated in the previous parameter is performed (visible if Presence
Pressure Burst Control parameter is configured).
Snift: Max Pressure: maximum pressure value in [mbar] above which the snift operation performed on
the bottle at the end of filling is considered incorrect and a bottle snift alarm is triggered (visible if the
Presence Pressure Snift Control parameter is configured).
Parameters which can only be set with the flow meter configured:
K.
L.
Burst: Max Flow Variation: maximum flow rate variation value expressed in [mbar]; the bottle burst
alarm is triggered if this limit is exceeded during filling (visible if the Presence Flow Var. Burst Control
parameter is configured).
Trigger Set Point: Phase Wait: recipe phase during which the set point trigger is reached in [ml] (if
flow meter configured) or in [ms] (if no flow meter configured) set on the Set Point recipe subpage.
Decompression/dynamic snift parameters:

Each individual slave card calculates automatically the advance in steps (compared to the outfeed position)
when the final dynamic snift sequence begins. To make this calculation the slave cards receive during each
machine step the real speed of the filler in [bott/min/10] (see parameters relating to filling steps on the FMC
PAS page).
Snift Dynamic: Phase Start: recipe phase in which the dynamic snift operation on the bottle begins
and the snift control becomes operative (only if the Presence Pressure Snift Control is configured).
If the Snift/Decompress outlet is set to ON during the recipe 14 phase, this stays open at the end of the
set dynamic decompression time. The phase 14 time may also be set to zero [ms].
Sidel S.p.A.
M.
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Part VI
RECIPE PRODUCTION WINDOW
B
A
A.
Sidel S.p.A.
B.
Preclosing Time: the filling pre-closing time. This parameter is sent by the Filling Master Card to the
slave card with the valve opening command when a valve must be pre-closed and therefore a bottle
must be under-filled and rejected at outfeed. It is not present in the still product fillers.
Data acquisition parameters for the Storage graph. The values sampled during the last filling
operation are housed on the internal memory of the electronic card. Once an initial delay, called Scope
T. Delay Storage has elapsed, values are sampled on the basis of a preset time in the recipe called
Scope T. Sample Storage. The internal sampling buffer of the card has 100 values. You must first
decide which type of value to sample i.e. the voltage of the resistive probe (if fitted), the product flow
rate (if a flow meter is fitted) or the pressure of the sensor (if fitted). This method of archiving data is
always enabled during each filling operation in manual mode (see manual recipe) and in production
(see production recipe). The internal buffer of the card is filled with the data collected on the basis of
the parameterisation received with the last recipe.
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Part VI
SET-POINT WINDOW
Use this page to set for each individual filling valve the volume set point expressed in [ml] (if flow meter
fitted), the time set point expressed in [ms] (if no measuring device is fitted), or the delay time expressed in
[ms] for valve closing to be counted after intervention of the trigger (if resistive probe fitted).
This is the field for entering the value you wish to add to or subtract from all the fields
on the page.
Button to increase the values of all the fields on the page
Button to decrease the values of all the fields on the page
Sidel S.p.A.
Button to reset all the values on the page
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6.4.1
Layout
Function to access the Layout page.

Displays the overall layout of the machine with the relevant warning icons, such as:
No auxiliaries.
No bottles at infeed.
No bottles at outfeed.
Bottle block.
Gripper released on rinser.

No caps in crown capper starwheel.
Outfeed pit.
Reject outfeed clogged.
Outfeed belt control.
Lubrication alarm.
Greasing alarm.
Sidel S.p.A.
Operator guards.
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Emergency stop buttons.
Double neck.
No bottles at filler outfeed.
Access to the subpage to enter the value (% of CO2) for the safety threshold in the
filling chamber.
Access to the subpage used to display the system designed to count repeat
consecutive errors and total accumulated errors by the photocells used to check bottle
presence at machine infeed and outfeed. A preset value for the errors can also be set
(only on COMBI version machines).
Control area
Button: press to enable the burst bottle test procedure.
2-way selector: conveyor start authorisation.
Displays the window showing the data required for the burst bottle test procedure.
Two-way selector: chamber light ON control.
Displays the window showing burst bottle diagnostics (glass bottle machines).
Sidel S.p.A.
Button to reset the errors accumulated by the photocells used to detect bottle presence
at machine infeed and outfeed (only on COMBI version machines).
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Page change area

Press this to display the Conveyors window.
H
A
F
N
G
O
P
Q
R
S
T
This page displays the status of the signals exchanged between the filler and bottle conveyors.
Signals for conveyors
A.
Machine ready.
B.
Bottle block open.
C.
Conveyors in automatic mode.
D.
Machine empty.
E.
Outfeed conveyor running.
F.
Machine speed.
G.
Conveyor speed.
Sidel S.p.A.
Signals from conveyors

H.
Outfeed conveyor ready.
I.
Bottle block from outfeed belts.
J.
Maximum speed from outfeed conveyors.
K.
Rejects clogged.
L.
Outfeed: FBI fault.
M. Outfeed: FBI too many rejects.
N.
Infeed conveyors ready.
O.
Bottle block from infeed belts.
P.
Speed reduction from infeed conveyors.
Q.
Maximum speed from infeed conveyors.
R.
Restart in automatic.
S.
Speed from labeller.
T.
Line speed reference.
Displays the status of the signals exchanged between the filler and bottle conveyors.
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Displays the Burst Bottle Diagnostics.
E
F
This page displays the status of the filling valves in terms of burst bottles.
System description:
On the Operator Panel a Counter with variable colour background (F) is displayed for each valve, indicating
bottle burst status and the number of burst bottles for the same valve. The colour depends on the code
written inside the Byte related to the valve:
Use the Info key (E) to display a description of the colour code in compliance with the following table:
Code
Colour
Meaning
Grey
no burst detected
Red
burst detected
Orange
Preclosing cycles in progress
Yellow
End of preclosing cycles
Green
End of preclosing and washing cycles
With the Yellow or Green colour the bottles are blocked.

With the Green colour the machine is stopped with the valve positioned at the outfeed of the third washing
ramp (after a complete emptying cycle).
The Operator checks the cleanliness of all the Green valves and then presses the Reset Button (B) that
turns the green counters back to the colour grey.
The machine can re-start only after a command from the Reset Button.
If the Machine Stop selector (A) is disabled, it does not block the bottles and does not stop the machine (the
counters stay in the relative colour)
The Counter Reset Button (D) resets all the counters (numeric display only) by setting them at 0 (zero).
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Sidel S.p.A.
The Burst Reset Button (C) resets all the counters (colour display only) by turning them back to the colour
grey.
Matrix Filler
6.4.2
Graphics
Function to access the Graphics page.
Control area
Sidel S.p.A.
Select the trend to be displayed.
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6.4.3
Maintenance
Function to access the Maintenance page.
Navigation page: Use this page to activate various commands regarding maintenance of the machine so as
to keep it in good working order and efficient over time. This page displays buttons for opening the following
submenus. The submenus available depend on the machine specifications or options:
Displays Machine Drives subpage.
Displays Brushless Machine Drives subpage.
Displays Machine Greasing subpage.
Displays Manifold Lubrication subpage.
Displays Filter Sterilization subpage.
Displays Jack Lubrication subpage.
Displays Profibus Diagnostics subpage.
Control area
Two-way selector: jack air discharge control.
Sidel S.p.A.
Two-way selector: filling valve air discharge control.
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Three-way selector: external washing control.
Two-way selector: burst bottle machine stop control.
Two-way selector: inspector safety device override.
Two-way selector: bottle encoder control.
Two-way selector: filling valve release enabling control.
Three-way selector: filling valve roller washing control.
Button: press to enable the burst bottle test procedure.
Two-way selector: burst bottle machine stop enable.
Two-way selector: Nitrogen doser enable.
Two-way selector: Flushing pad enable.
Two-way selector: Enable supplementary breather process actuated automatically

when the bottles pass through the machine.
Three-way selector: Bottle shower at outfeed control.
Two-way selector: Enable bottle size changeover.
Sidel S.p.A.
Two-way selector: Enable machine washing.
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MACHINE DRIVES SUBPAGE

Select this to open the Machine Drive subpage.
Navigation page: Use this page to access the various subpages for the motors controlled by an inverter
fitted on the machine. This page displays buttons for opening the subpages for the profibus node for the
motor selected. The subpages available depend on the machine specifications or options.
Summary diagram area (only for machine motors on the Combi version)
This page shows all the information needed to monitor functioning of the machine motor selected:
This window displays the states of the frequency converter of the main motor of the filler.
The analogue values of the encoders of the main motor of the Filler (X55-SLAVE) and of the Blower (X56MASTER).
Sidel S.p.A.
The Program State window displays the states of the Syncposs card during synchronisation of the two
machines.
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Summary diagram area (for machine motors in the standard version + all other motors)
This page shows all the information needed to monitor functioning of the motor selected:
E
A.
B.
C.
D.
E.
Number and type of alarm present on the driver.

Driver status.
Select the parameter to be displayed in this section.
Values of selected parameters.
In data values being read from the driver.
Press this to display the "Trend" window. Showing the frequency, current, power and
torques.
Sidel S.p.A.
Press this to display the values read from the driver for the parameters/data selected in
zone #3.
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MACHINE BRUSHLESS MOTOR SUBPAGE

Select this to open the Machine Brushless Motor subpage.

This page shows all the information needed to monitor the operation of the brushless motors on the
machine.
Sidel S.p.A.
This page displays the states and operating modes of the MAX4 controller. It also shows the position, status,
absorbed power and enabling of the motors present on the filler.
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Press this to open the Brushless Motor Maintenance" page.
B
C
D1
D
D2
D3
A.
B.
C.
D.
Sidel S.p.A.
E.
F.
Two-position selector: Enable rinser motor control.

Two-position selector: Enable base motor control.
Two-position selector: Enable filler motor control.
Two-position selector: Position at the distance selected.
D.1 Area to enter the rinser positioning offset.
D.2 Area to enter the base positioning offset.
D.3 Area to enter the filler positioning offset.
Button: Home control (machine in phase).
Two-position selector: Enable brake release control.
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MACHINE GREASING SUBPAGE

Select this to open the Machine Greasing subpage.

This page shows all the information useful for monitoring and performing machine greasing.
Area showing the preset values for greasing times and greasing cycles.
Area showing the actual values for greasing times and greasing cycles.
Press this to display the "Trend" window. Showing the frequency, current, power and
torques.
Press this to display the values read from the driver for the parameters/data selected in
zone #3.
Sidel S.p.A.
A.
B.
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MANIFOLD LUBRICATION SUBPAGE

Select this to open the Manifold Lubrication subpage.

This page shows all the information useful for monitoring and performing manifold lubrication.
A
A.
B.
Area showing the preset values for greasing laps and greasing cycles.
Area showing the actual values for greasing laps and greasing cycles.
Displays window used to set manifold greasing/lubrication data.
Button: manifold greasing manual start control.
Sidel S.p.A.
Button: manifold greasing manual stop control.
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JACK LUBRICATION SUBPAGE

Select this to open the Jack Lubrication subpage.

This page shows all the information useful for monitoring and performing filler jack lubrication.
Area showing the preset values for lubrication times and lubrication cycles.
Area showing the actual values for lubrication pause and operating cycles.
Displays window used to set filler jack lubrication data.
Button: filler jack lubrication manual start control.
Sidel S.p.A.
A.
B.
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PROFIBUS DIAGNOSTIC SUBPAGE

Select this to open the Profibus Diagnostic subpage.

This page displays information concerning the status of each individual node on the filler profibus network.
Sidel S.p.A.
Displays the information page for node faults.
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Parameters
Function to access the Parameters page.
Displays the machine parameter pages.
PAM
Displays the pages used to enter machine technological parameters.
PAT
Displays the pages used to enter machine steps.
PAS
Sidel S.p.A.
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PAM
Main navigation buttons
A. DISPLAYS MACHINE SPEED SUBPAGE

Use this page to set the data for the machine speed:
Speed in sanitization: this is the fixed speed of the machine during sanitization or rinsing
(bottles/hour).
Slowing down percentage: this is the slower speed of the machine (expressed as a percentage of
production speed) when the Bottle Block is active (i.e. when the machine is empty) (%).
External foaming speed: this is the fixed speed of the machine when the external foaming cycle is
enabled (%).
Bleeding speed: this is the fixed speed of the machine during bleeding of the filling valves
(bottles/hour).
PAM list displayed:
B.
DISPLAYS UTILITY SUBPAGE

Displays Valve Washing subpage.
Sidel S.p.A.
PAM list displayed:
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Displays Machine Greasing subpage.
PAM list displayed:
Displays Machine Lubrication subpage.
PAM list displayed:
C.
DISPLAYS FILLER SUBPAGE

Displays CIP Parameters subpage.
Use this page to set the data for CIP:

PRESSURE
Maximum pressure during CIP: maximum pressure permitted inside the tank during sanitization.
Opening: fixed opening value for pressure modulation during the sanitization sequence.
LEVEL
Opening: fixed opening value for level modulation during the sanitization sequence.
TIMES
Times for sanitization of the product pipes, filling valves and pressurisation unit are displayed.
Sidel S.p.A.
PAM list displayed:
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Displays Rinsing Parameters subpage.
Use this page to set the data for rinsing:

LEVEL
Opening: fixed opening value for level modulation during the rinsing sequence.
PRESSURE
Opening: fixed opening value for pressure modulation during the rinsing sequence.
Number of cycles: the rinsing sequence is repeated for the number of cycles set.
Number of cycles with filling valves open: the number of machine cycles with the filling valves open to
rinse the valves.
PAM list displayed:
Displays Draining Parameters subpage.
Use this page to set the data for draining:

PRESSURE
Opening: fixed opening value for pressure modulation during the draining sequence.
Set Point: pressure set point value to be controlled during the draining sequence.
LEVEL
Opening: fixed opening value for level modulation during the draining sequence.
Number of cycles: the draining sequence is repeated for the number of cycles set.
Sidel S.p.A.
PAM list displayed:
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Displays Startup Parameters subpage.
Use this page to set the data for machine Startup during the Startup sequence:
LEVEL
Opening: fixed opening value for level modulation during the startup sequence.
PRESSURE
Opening: fixed opening value for pressure modulation during the startup sequence.
TEMPERATURE (hot machine)
Times for heating the machine and draining the filling valves are displayed. A machine heating bypass
button is fitted.
PAM list displayed:
Displays Production Parameters subpage.
Use this page to set the data for production end:

Tank volume: fixed value showing the capacity of the tank (litres).
Pipe volume: fixed value showing the capacity of the pipes before the tank (litres).
Sidel S.p.A.
PAM list displayed:
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D.
DISPLAYS ELECTRONIC FILLING VALVE / FILLING MASTER CARD SUBPAGE

Displays Electronic Filling Valve / Filling Master Card subpage.
PAM list displayed:
E.
DISPLAYS CAPPER / CROWN CAPPER SUBPAGE

Displays Crown Capper Parameters subpage.
PAM list displayed:
Displays Capper Parameters subpage.
Sidel S.p.A.
PAM list displayed:
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F.
DISPLAYS BOTTLE COOLING PARAMETERS SUBPAGE
PAM list displayed:
G.
DISPLAYS PRODUCT PUMP PARAMETERS SUBPAGE
PAM list displayed:
H.
DISPLAYS BOTTLE SIZE PARAMETERS SUBPAGE
PAM list displayed:
I.
DISPLAYS FOAMER PARAMETERS SUBPAGE

Displays CIP subpage.
Sidel S.p.A.
PAM list displayed:
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Displays Rinsing subpage.
PAM list displayed:
Displays Draining subpage.
Displays Production subpage.
PAM list displayed:
L.
DISPLAYS CLEAN ROOM PARAMETERS SUBPAGE
Sidel S.p.A.
PAM list displayed:
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PAT
A.
DISPLAYS FILTER STERILIZATION SUBPAGE

Displays Air Filter subpage
PAT list displayed:
Displays Nitrogen Filter subpage
Sidel S.p.A.
PAT list displayed:
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B.
DISPLAYS STEAM BARRIER SUBPAGE

Displays Aseptomag Steam Barrier subpage
PAT list displayed:
Displays Product Pump Steam Barrier subpage

PAT list displayed:
Displays Upper Rotary Manifold Steam Barrier subpage
Sidel S.p.A.
PAT list displayed:
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C.
Matrix Filler
DISPLAYS FILLER SUBPAGE
PAT list displayed:
D.
PAT list displayed:
E.
DISPLAYS BOTTLE COOLING SUBPAGE
F.
DISPLAYS PIPE TREATMENT SUBPAGE
Sidel S.p.A.
PAT list displayed:
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G.
DISPLAYS HYDRAULIC SEAL SUBPAGE
PAT list displayed:
DISPLAYS BOTTLE SIZE SUBPAGE
I.
DISPLAYS CLEAN ROOM SUBPAGE
Sidel S.p.A.
H.
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PAS
A
A.
DISPLAYS RINSING SUBPAGE
PAS list displayed:
B.
DISPLAYS FILLER/FILLER WASHING SUBPAGE

Displays Filler subpage
Sidel S.p.A.
PAS list displayed:
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Displays Filler Washing subpage
PAS list displayed:
C.
DISPLAYS FOAMER STEPS SUBPAGE
PAS list displayed:
D.
DISPLAYS TX TRANSMITTER STEPS (Mastercard) SUBPAGE
Sidel S.p.A.
PAS list displayed:
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E.

Displays Crown Capper Parameters subpage.
PAS list displayed:
Displays Capper Parameters subpage.
PAS list displayed:
F.
DISPLAYS MACHINE STEPS SUBPAGE
Sidel S.p.A.
PAS list displayed:
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G.
DISPLAYS DRIVE STEPS SUBPAGE
PAS list displayed:
H.
DISPLAYS PULP DOSER STEPS SUBPAGE
Sidel S.p.A.
PAS list displayed:
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6.4.5
Services
Function to access the Services page.
Displays HMI Management subpage.
Displays Rinser subpage.
Displays Capper subpage.
Displays Crown Capper subpage.
Displays Filler subpage.
Displays Filler TX Steps subpage.
Displays Motor subpage. (Available on machines with brushless motors).
Sidel S.p.A.
These pages are reserved for SIDEL technicians.
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HMI MANAGEMENT SUBPAGE

Function to access the HMI page.
Displays Language change page.
Displays Project information page.
Displays Date and time settings page.
Displays Screen cleaning page
Language change page
Sidel S.p.A.
Use this page to change the language used for the operator interface by selecting the flag for the language
required.
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Project information
A
B
C
D
E
Use this tool to retrieve system information such as:

A.
Free disk space.
B.
Free memory space.
C.
Project version.
D.
Serial number.
E.
Project name.
Date and time setting page
On this page the touch-screen remains disabled for the time shown on the counter (in seconds) to enable
cleaning of the screen.
When the time elapses (1 minute), the Reception page is displayed automatically.
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Sidel S.p.A.
Screen cleaning
Matrix Filler
Part VI
EXPORT DATA PAGE

Use the EXPORT DATA page to save all the machine parameters onto an external
memory using a USB connection.
MACHINE SPEED SUBPAGE

Function to access the Machine speed page.
Use this page to set the data for the machine speed:
Speed in sanitization: this is the fixed speed of the machine during sanitization or rinsing
(bottles/hour).
Slowing down percentage: this is the slower speed of the machine (expressed as a percentage of
production speed) when the Bottle Block is active (i.e. when the machine is empty) (%).
External foaming speed: this is the fixed speed of the machine when the external foaming cycle is
enabled (%).
Bleeding speed: this is the fixed speed of the machine during bleeding of the filling valves
(bottles/hour).
FLUSHING SUBPAGE
Function to access the Flushing page.
Use this page to set the data for machine flushing during the Startup sequence:
Sidel S.p.A.
PRESSURE
Set Point: pressure set point value to be controlled during the gas flushing sequence (bar).
Number of cycles: the gas flushing sequence is repeated for the number of cycles set.
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PRODUCT
Set Point: level set point value to be controlled during the product flushing sequence (bar).
Opening: fixed opening value for level modulation during the product flushing sequence (%).
Number of cycles: the product flushing sequence is repeated for the number of cycles set.
PRODUCTION STARTUP SUBPAGE

Function to access the Startup page.
Use this page to set the data for machine Startup during the Startup sequence:
LEVEL
Opening: fixed opening value for level modulation during the startup sequence.
PRESSURE
Opening: fixed opening value for pressure modulation during the startup sequence.
TEMPERATURE (hot machine)
Times for heating the machine and draining the filling valves are displayed. A machine heating bypass
button is fitted.
PRODUCTION END SUBPAGE

Function to access the Production page.
Use this page to set the data for production end:

Tank volume: fixed value showing the capacity of the tank (litres)
Pipe volume: fixed value showing the capacity of the pipes before the tank (litres)
CIP SUBPAGE
Function to access the CIP page.
Sidel S.p.A.
Use this page to set the data for CIP:

PRESSURE
Maximum pressure during CIP: maximum pressure permitted inside the tank during sanitization.
Opening: fixed opening value for pressure modulation during the sanitization sequence.
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LEVEL
Opening: fixed opening value for level modulation during the sanitization sequence.
TIMES
Times for sanitization of the product pipes, filling valves and pressurisation unit are displayed.
DRAINING SUBPAGE
Function to access the Draining page.
Use this page to set the data for draining:

PRESSURE
Opening: fixed opening value for pressure modulation during the draining sequence.
Set Point: pressure set point value to be controlled during the draining sequence.
LEVEL
Opening: fixed opening value for level modulation during the draining sequence.
Number of cycles: the draining sequence is repeated for the number of cycles set.
RINSING SUBPAGE
Function to access the Rinsing page.
Use this page to set the data for rinsing:
Sidel S.p.A.
LEVEL
Opening: fixed opening value for level modulation during the rinsing sequence.
PRESSURE
Opening: fixed opening value for pressure modulation during the rinsing sequence.
Number of cycles: the rinsing sequence is repeated for the number of cycles set.
Number of cycles with filling valves open: the number of machine cycles with the filling valves open
to rinse the valves.
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6.5
OPERATING MODE SELECTION
6.5.1
Automatic operation
This mode should be maintained during the production phase to allow the machine to fill the product
containers and apply the cap continuously. The machine must be monitored during this phase.
The machine can be operated by a generic machine operator who controls the operating states using the
operator interface.
6.5.2
Manual operation
Before performing any manual operations, make sure there are no physical obstructions preventing the
movement required.
Manual operation requires use of the MAINTENANCE PUSHBUTTON PANEL to run the machine in JOG
mode.
Sidel S.p.A.
The operator must hold the mobile control unit in order to control movements.
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6.6
Part VI
MACHINE STARTUP AND PRODUCTION

WARNING: at the start of each shift and before starting up production, perform a preliminary
check on the efficiency of the safety systems.
To start the machine, proceed as follows:
6.6.1
1.
2.
Make sure the Combi open interface panel is fitted between the machine infeed and blower outfeed
(see section 2.7.2).
Check the equipment is adjusted correctly for the bottles to be filled. Check that the handling parts are
perfectly timed. Check the timing by running one or more bottles all the way through the machine at low
speed using the jog mode.
Make sure the crowns or caps match the product and bottles to be used. Check that a sufficient
quantity of crowns or caps is available.
Sidel S.p.A.
3.
Preliminary checks
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6.6.2
Starting
Power up the machine pneumatic circuit.
Close all the operator guards.
Open the manual supply valve.
Press and hold the reset button until the no pressure warning message is cleared from the monitor.
At this point the entire pneumatic system has reached the pressure value set at infeed.
2.
-
Adjust the air pressures.

Supply the carousel controls at 6 bar.
Sidel S.p.A.
1.
-
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Supply the jacks at 4 bar.

Check these values on the pressure gauges whenever necessary during a filling cycle or when
adjusting the regulators.
Use the special selector to enable the compressed air supply for the jacks.
Press the jack air selector on the Maintenance page:
Disable the component so the jacks are able to pressurise.
Sidel S.p.A.
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3.
On the pressure reducer, set the CO2 tank supply pressure to approx. 1 bar above the filling pressure.
4.
Set the bottle block selector to automatic.
5.
Press the Start/Stop pushbutton.
Sidel S.p.A.
Allow the machine to run in noload conditions until all the filling valves have closed.
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6.
On the Recipe page select the recipe for the type of production and press the button to enable the
recipe:
7.
Set the 2 Enable Actuators and Enable Controls buttons to automatic and make sure all the threeway selectors for valves and motors switch to AUT.
8.
Press one of the following icons on the filler Startup page (see section 6.2.3.):
Fast startup.
Startup with gas flushing (optional).
Sidel S.p.A.
Startup with product flushing (optional).
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9.
Press the button to start the production sequence.
10.
Set the bottle stop selector to the automatic position.
The bottle stop opens, the bottles enter the machine and the filling process starts.
11. If necessary select the machine speed using the special field on the Reception page (section 6.2.2).
6.6.3
Procedures for standard operation
During the cycle check that the parameters remain constant at the set values.
Check the bottle filling level and the closures.
If the machine is stopped by the tripping of an internal safety device, trace and remove the cause. Check for
part damage before restarting the machine.
Restarting a production cycle after a stoppage requires the presence of an operator.
2.
3.
When processing carbonated products, check the extent and formation of foam during the filling step.
When filling beer, regulate the pressures to optimise the efficiency of the foamers.
Monitor the supply and level of crown caps and caps in the hoppers. Fill by hand where necessary.
Check and regulate the machine temperatures, pressures and speeds to obtain the highest production
rates which are compatible with the production quality standards specified.
Sidel S.p.A.
1.
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6.7
STOP AND EMERGENCY STOP MODES
6.7.1
Machine emergency stop
Part VI
This operation must only be performed when there is a genuine EMERGENCY.

When the emergency stop button is pressed on the control panel, the machine stops under safe conditions
with bottles inside.
Rotate the button to release it.
The emergency stop button is red on a yellow background.
6.7.2
Machine stop during production
When the Stop button is pressed, the machine stops with bottles inside.
Or:
1.
Block the bottles at infeed.
2.
Wait until all the bottles are fed out of the machine.
3.
Press the Start / Stop button:
4.
Press STOP on the filler Startup page:
Sidel S.p.A.
The machine ends production by completely emptying the tank.
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6.8
RINSING
The rinsing step can be enabled using the filler Startup page (see section 6.2.3.).
1.
Make sure the Combi closed interface panel is fitted between the machine infeed and blower outfeed
2.
Start the machine
3.
Press the icon to switch the machine to the rinsing mode.
4.
Press:
The power supply to the jacks is disabled and the jacks are depressurised.
All the machine valves are set to rinsing mode (see section 5 for further details).
Rinsing of the internal machine parts begins.
The filling valves open automatically when flooding is complete.

Rinsing is completed by automatic draining assisted by CO2 flow into the filler.
Sidel S.p.A.
Rinsing can be performed before and after production.
1.1
VI - 155
Matrix Filler
6.9
Part VI
SANITIZATION
The sanitization step can be enabled using the filler Startup page (see section 6.2.3.).
1.
Make sure the Combi closed interface panel is fitted between the machine infeed and blower outfeed
2.
Press the icon to switch the machine to the sanitizing mode.
3.
Press:
The jacks are depressurised.
4.
The machine stops and a message is displayed on the monitor requesting the insertion of dummy
bottles. Enable the rear JOG control and insert the dummy bottles manually. Once finished (the
machine checks that all the dummy bottles have been fitted), disable the JOG and start the machine.
5.
Start the sanitizing cycle for the inside of the machine.

The sanitizing cycle runs automatically and consists of sanitizing with a chemical product, a rinse and
final drainage.
6.
To stop and leave the sanitizing mode, press the icon (Stop mode):
The machine displays a message instructing you to remove the dummy bottles.
7.
Enable the rear JOG control and start to remove the dummy bottles in order to end this operating
mode. (The machine will check that the dummy bottles have been removed).
SANITIZATION FOR MACHINES WITH AUTOMATIC DUMMY BOTTLES
Sidel S.p.A.
Machines with a system for automatically inserting and removing the dummy bottles do not require operator
intervention. The machine is not set to JOG mode. On these machines the dummy bottles are inserted and
removed automatically.
VI - 156
1.1
PART VII
SIZE CHANGEOVER
Sidel S.p.A.
Part VII
Matrix Filler
User Manual / Size Changeover
1.0
VII - 1
Matrix Filler
7.1
Part VII
GENERAL PRECAUTIONS
Size changeover operations must be performed without any bottles inside the machine. If the machine has
just come out of service, check that the piping is not hot. When you have completed a size changeover,
check that you have not left any tools or other extraneous objects inside the machine. Before you start a
production cycle, test that the size change is OK by running one or two bottles through the machine at slow
speed.
Cordon off the area around the machine. Place warning signs around the machine indicating
that maintenance work is in progress. Prevent unauthorised persons from entering the area.
A size changeover may require you to move the carousel. You must only use the JOG control to
do this. Do not stay inside the machine. Do not stand close to moving parts. The size
changeover must be performed by one person only using the JOG control. Some operations
may require the assistance of a second person. In this case, only one person is permitted to use
the JOG control. Before using the JOG control this person must check that the second person
is not in the hazard zone.
Size changeover operations are quick and easy.
This section details the areas involved in size changeover.
The size changeover operations described in this section must be performed by QUALIFIED
personnel.
Cordon off the area around the machine during size changeovers. Keep all unauthorised persons away from
the machine. Fix a Work in Progress warning sign to the control panel.
For each bottle type the manufacturer supplies a set of tooling and equipment (size changeover kit) for
mounting on the machine (see Vol. II Spare Parts Catalogue).
The size changeover kits for each bottle type are marked in our works with an unique identifier letter.
Unauthorised modification or substitution of size changeover parts can cause an accident
hazard. The manufacturer declines all liability for damage or injury caused by unauthorised
modifications or substitutions.
AUTOMATIC SIZE CHANGEOVER

The sequence and adjustments for the automatic size changeover are shown on the operator panel. There
are therefore no drawings.
Sidel S.p.A.
In the event of a fault to the lifting motor, see section 7.4 Removing size changeover parts.
VII - 2
1.0
Matrix Filler
Part VII
7.2
DESCRIPTION OF THE SIZE CHANGE PARTS
COMBI Filler Equipment

C
BLOCKRINSER Filler Equipment

C
Reference
Description
Crown capper infeed guide (if fitted)
Crown capper starwheel (if fitted)
Internal outfeed guide (if fitted)
External outfeed guide (if fitted)
Crown capper external guide (if fitted)
Machine outfeed starwheel (if fitted)
Machine infeed guide (where fitted)
Bottle bottom spacers (HOTFILL optional)
Reference
H
Sidel S.p.A.
Description
Bottle bottom spacers (where fitted)
1.0
VII - 3
Matrix Filler
7.3
Part VII
MACHINE CLEANING
Clean the machine thoroughly before you start the size changeover. Clean the area which will receive the
size changeover parts with a jet of compressed air. Remove any deposits present.
Sidel S.p.A.
Clean the machine surface with a damp cloth.
VII - 4
1.0
Part VII
7.4
Matrix Filler
REMOVING SIZE CHANGEOVER PARTS (WHERE FITTED)

Refer to the size changeover diagram in PART X APPENDICES, section 10.1.4 Size
change parts.
1.
Remove the pins A. Rotate the clamps.

Remove and substitute the guide B and
the starwheel C.
A
2.
Remove the pin D. Rotate the clamp.

Remove and substitute the guide E.
D
Unscrew the threaded knob F. Remove
and substitute the starwheel G.
Sidel S.p.A.
3.
1.0
VII - 5
Matrix Filler
4.
Part VII
Remove the pin H. Rotate the clamp.

Remove and substitute the guide I.
I
5.
6.
Loosen the nuts J. Remove and substitute

the guide K.
Adjust the tipping belt L to match the height

of the bottle to be processed.
Automatic size changeover:
Sidel S.p.A.
In the event of lifting motor failure,

use the handwheel M.
VII - 6
1.0
Part VIII
Matrix Filler
User manual / Maintenance Schedule
Sidel S.p.A.
PART VIII MAINTENANCE SCHEDULE
1.0
VIII - 1
Matrix Filler
8.1
Part VIII
GENERAL INFORMATION ABOUT MAINTENANCE
The Maintenance section is the main reference with instructions on how best to maintain your machine.
The section has been written to assist maintenance technicians to optimise maintenance operations.
All technicians working on the machine should be fully conversant with the General Safety Information in
section 1.1 and the Maintenance Levels described in this manual.
This chapter is a maintenance guide providing details of the general maintenance schedule, the lubrication
sheets and the maintenance instructions (with details of maintenance level).
MACHINE OPERATING SYSTEMS
This section indicates the various operations to be performed on the machine, its assemblies and
components. This section also indicates the maintenance operations to be performed on these components.
SIZE CHANGEOVER
The Size Changeover section provides instructions on changing over between bottle sizes and between
product types.
On some pages in this manual there is an icon on the right-hand side. This icon indicates that there is also
relevant maintenance procedure in the Maintenance Procedure Manual.
Icon
Indicates the existence of a procedure for:

Cleaning. Checking of electrical or mechanical components and
checking fluids.
Removing or repairing electrical or mechanical components and
changing fluids.
Lubrication and greasing.
Before you start work on the machine, check once again which part of the machine requires maintenance.
Check that all the personnel involved in these operations have read the safety instructions.
The maintenance intervals in this manual are intended as a guide only. The intervals are based on the
average time needed for the operations to be performed on the machine, including setup:
Every 24 hours or after three shifts.
Weekly
Every five days.
Monthly
Every four weeks.
Yearly:
Every 50 weeks.
Machine cleaning and sterilisation interval:
One cycle of 3 hours every 72 hours of continuous

machine production.
Sidel S.p.A.
Daily
VIII - 2
1.0
Matrix Filler
Part VIII
Therefore, the estimated intervals are:
Interval
Machine operation periods (including setup)

Hours
Machine production cycles (**)
Daily
24
Weekly
125
Monthly
500
Every three months
1500
20
Every six months
3000
40
Every nine months
4500
60
Yearly
6000
80
Every two years
12000
160
Every three years
18000
240
Every four years
24000
320
Variable (*)
(*)
(**)
Maintenance necessitated by component failure, damage or malfunction.

1 cycle = sanitizing + production + cleaning.
In practice machine usage is closely linked to production schedules and the type of beverage processed.
This means that the intervals in the table should be understood as: Whenever an interval (Interval, Hours or
Machine Production Cycles) is reached, maintenance must be performed.
Examples:
-
The machine has already worked for over 6000 hours but the Yearly interval has not yet elapsed. In
this case the maintenance operation indicated must be performed.
The machine has already completed 160 work cycles but the Every Two Years interval has not yet
elapsed. In this case the maintenance operation indicated must be performed.
The machine has already worked for over Two Years but has not yet completed 160 cycles. In this
case the maintenance operation indicated must be performed.
The general maintenance table, the greasing table and the electrical and mechanical maintenance tables
refer to and indicate maintenance procedure numbers.
Operations at level 5 do not have written procedures.
For details of all the other operations not described in the general maintenance table, contact SIDEL S.p.A.
Customer Service.
Follow the safety instructions. Perform the procedures as described. Perform the procedures at the specified
intervals. Use the recommended materials (oils, greases, tools).
Sidel S.p.A.
Failure to follow this advice can lead to injury to persons or damage to machine.
1.0
VIII - 3
Matrix Filler
Part VIII
State of the machine before and after a maintenance operation:

Maintenance procedures start from the assumption that the machine has been installed correctly, that it has
stopped normally (i.e. not because of a fault) and that it is connected to the electrical power supply, to the
water supply and to the low- and high-pressure compressed air supply. Other conditions are specified on the
maintenance procedure sheets.
At the end of the procedure: thoroughly clean the area; make sure that the machine can restart production
normally; check that no tools or size parts have been left inside the machine; check that the machine does
not constitute a hazard for personnel.
Before you restart the machine, perform all the sterilisation and cleaning procedures.
8.1.1
Maintenance operation times
The time needed for a maintenance operation is the theoretical time needed to perform a single maintenance
operation by skilled operators working on individual machine assemblies or components.
This time is provided as a guide only. SIDEL S.p.A. cannot guarantee the accuracy of this value.
Sidel S.p.A.
Each operation time refers to a single machine assembly or component and is to be understood as the total
time necessary for the operation calculated as follows. The operation refers to the machine units z (position
on the synoptic panel or a quantity). The operation requires n number of persons, an intervention time of
itime and an effective time etime to complete the operation. Thus:
VIII - 4
1.0
Matrix Filler
Part VIII
8.1.2
Greasing machine parts
Only certified food contact grease may be used to lubricate machine parts. Parts which come into contact
with the product or containers must only be lubricated with H1 (USDA, NFS) food contact grease. Grease the
grease points with the amount of grease specified and at the frequency specified in the maintenance
schedule.
At the end of the process, dispose of the water, sanitizer and acid substances in compliance with the
local waste disposal regulations. Do not discharge this type of waste into water courses or the public
drainage system. This type of waste requires pre-treatment before final disposal.
regulations.
Hazard warning. The products used in the CIP SYSTEM ARE IRRITANT AND TOXIC. Use the
appropriate PPE.
If you are using chemical substances, check the Safety Data Sheets provided by the manufacturer
to identify any safety and environmental hazards for the chemical used.
-
Hazards.
Sidel S.p.A.
recommended.
1.0
VIII - 5
Matrix Filler
8.1.3
Part VIII
Preventive maintenance
In order to ensure a long, efficient life cycle for SIDEL S.p.A machines, we recommend that you follow the
preventive maintenance procedures specified by SIDEL S.p.A at the intervals indicated and using the parts
and methods indicated. On this type of plant, component wear and seal condition require particular attention.
Good maintenance also requires a system for documenting maintenance operations which matches the
customers needs. Maintenance personnel must be suitably trained and authorised to perform maintenance.
Any liquid removed may contain oil and must not be disposed of in the environment. It must be
collected and treated in compliance with the environmental protection legislation and standards in the
country where the machine is used.
regulations.
Hazard warning. The products used in the CIP SYSTEM ARE IRRITANT AND TOXIC. Use the
appropriate PPE.
If you are using chemical substances, check the Safety Data Sheets provided by the manufacturer
to identify any safety and environmental hazards for the chemical used.
-
Hazards.
Sidel S.p.A.
recommended.
VIII - 6
1.0
Part VIII
8.2
Matrix Filler
MAINTENANCE SCHEDULE
Sidel S.p.A.
Check the maintenance schedule in the Maintenance procedures manual
1.0
VIII - 7
Matrix Filler
Sidel S.p.A.
VIII - 8
1.0
Part VIII
Matrix Filler
User Manual / Diagnostics
Part IX
DIAGNOSTICS
Sidel S.p.A.
PART IX
1.0
IX - 1
Matrix Filler
9.1
Part IX
TROUBLESHOOTING
Troubleshooting is vital to restore the filler to full operation when faults occur. A step-by-step systematic
approach to machine diagnostics significantly increases the chances of identifying the causes of faults.
The list below is a general one designed to facilitate identification of the cause of a fault and then solve the
problem.
Identifying faults
Before any attempt is made to resolve operating faults, as much information as possible should be procured
about the fault. Carefully observe the fault and seek the assistance of the operator to assess machine
performance. Take note of the frequency and type of events. Resolving the effects of the fault does not solve
the problem.
The aim must be to find and eliminate the causes of the fault.
Identify the position of the fault
Faults on the filler machine can usually be traced to one or two of the six machine areas, as follows:
-
Drive units.
Bottle conveyor.
Product distribution.
Container cleaning.
Filling.
Capping.
Follow an investigative procedure

Make corrections and adjustments in a logical sequence i.e. starting from the most likely cause and
proceeding to the most unlikely one. A flurry of blind activity is not only likely to be a waste of time but may
even aggravate the problem.
Proceed step by step
Make only one correction at a time and observe the results before making any other corrections.
After maintenance
Sidel S.p.A.
When you think you have solved the problem, monitor the machine carefully to obtain confirmation that
maintenance has been successful. If production demands dictate a temporary solution, make note of the
problem and then implement a definitive solution during scheduled maintenance.
IX - 2
1.0
Matrix Filler
Part IX
9.1.1
General machine operation
Problem
The machine does not start
when the START button is
pressed or the machine stops
during normal operation.
9.1.2
Cause
Solution
1. Main switch not in the ON

position.
Turn ON the main switch on the

electrical cabinet.
2. Safety device triggered.
Remove the cause, press RESET

and restart the machine.
Bottle conveyor
This section assumes the bottles used are of good quality and match the specifications permitted for the
machine. It also assumes correct bottle infeed and pressure in the system.
The bottle block is not operating

(Standalone only).
The bottles are guided badly in

the rinser infeed area.

the filler infeed area.

the carousel outfeed area.
The bottles are guided badly at

the crown capper outfeed.
Cause
Solution
1. Solenoid valve not working.
Check the controls and cables

connected to the solenoid valves.
2. Air infeed pipes damaged or

loose.
Check and tighten or change the air

infeed hoses.
3. Faulty solenoid valve operation.
Change the
necessary.
4. Bottle block damaged.
Check the bottle block.
1. Rinser infeed starwheel timed

incorrectly relative to the bottle
pickup grippers.
Set the timing of the rinser infeed

starwheel relative to the grippers.
1. Filler infeed starwheel timed

incorrectly relative to the filling
carousel.
Set the timing of the filler carousel.
2. Filling valve bottle support forks

at incorrect height relative to the
infeed starwheel.
Check the height of all the forks

making sure the height is 0.5mm
lower than the starwheel.
1. Filler infeed starwheel timed

incorrectly relative to the outfeed
starwheel.
Set the timing of the filler carousel

relative to the starwheel.
2. Filling valve bottle support forks

at incorrect height.
Check the height of all the forks.
1. Outfeed
starwheel
timed
incorrectly relative to the crown
capper.
Set the timing of the crown capper

with the starwheel.
2. Bottle outfeed guide from the

crown capper sized incorrectly.
Change the guide.
1.0
solenoid
valve
if
Sidel S.p.A.
Problem
IX - 3
Matrix Filler
9.1.3
Part IX
Filling
In general faults related to filling can be divided into four types as follows:
-
No filling.
Insufficient filling.
Excessive filling.
Foaming.
The first step to solving this type of problem is to assess whether the fault is with all the filling valves or only
one of them. The causes and solutions vary in accordance with the size of the problem.
Filling problems are often difficult to solve because of the vast range of components and systems affecting
the filling process.
Operation of the filling valve, the product distribution system, the bottle conveyor system, the product mixing
system and other factors, such as the quality of the bottle to be filled, can affect the filling process.
Another factor to be taken into consideration when solving filling problems is that different faults can have the
same base cause but on different levels.
For example, many filling problems can be caused by a degrading of the filling valve seal.
However, excessive filling can be caused by slight degradation of the seal, insufficient filling by slightly more
degradation and no filling by the complete degradation of the seal.
Sidel S.p.A.
IMPORTANT: If the sanitizing process is run, you should check the condition of all the rubber
seals on the filling valves every 6 months and, if necessary, change them.
IX - 4
1.0
Matrix Filler
Part IX
NO FILLING
Problem
Cause
1. No seal between the bottle and
the centring bell.
No filling
Some filling valves.
No filling
All filling valves.
2. Valve not enabled on the control

panel.
Solution
Check the mouth of the bottle is not
chipped or faulty. Check the filling
seal for faults. Check the position of
the seal.
Make sure there are no foreign
bodies on the centring bell.
Enable the valve by following the
procedure described on the filling
valve ENABLE / DISABLE page.
3. Transmission error between the

master and the electronic filling
valve.
Change the electronic card of the

filling valve in question.
1. Filling valve opening pneumatic

system fault.
Check correct operation of the

control rod membranes.
Check correct operation of the bottle
presence sensor.
2. No product in the tank.
Fill the tank.
3. Transmission error between the

master and the electronic filling
valves.
Change the electronic

transmission card.
Cause
Solution
1. The carousel rotates too quickly

(only Standalone).
Set a lower carousel speed.
2. Product code selected for a

different size.
Select the correct product code.
1. Faulty filling valve.
Dismantle and check the filling

valve.
2. Rubber filling seal damaged.
Change the centring bell and filling

valve seals.
3. Filling set point too low.
Correct the valve filling set point.
control
Problem
All filling valves.
Sidel S.p.A.
INSUFFICIENT FILLING
1.0
IX - 5
Matrix Filler
Part IX
EXCESSIVE FILLING
Problem
Cause
Solution
1. Liquid seal fault.
Change the liquid seal.
2. Rod seals broken.
Change the seals.
3. Flow meter not connected to the

electronic card.
Check the connection between the

flow meter and the electronic card.
4. Flow meter damaged.
Change the flow meter.
Cause
Solution
1. Calibrated decompression hole

blocked.
Clean the nozzle.
2. Rubber bell seal damaged or

worn.
Change the seal.
3. Faulty filling valve.
Remove and check the valve.
4. Decompression
stage
not
performed
due
damaged
electronic card output.
Change the electronic control or

pilot valve.
1. Insufficient pressure in the tank.
Adjust the pressure.
Excessive filling.
FOAMING
Problem
Foaming
2. Product temperature too high.
Foaming
All filling valves.
Adjust the pressure.
3. Too many carousel stops and

starts which agitate the product.
Check flushing and the temperature
of cooling water.
4. Bottles too hot.

5. Dirty bottles.
Sidel S.p.A.
6. Incorrect decompression stage

due to incorrect product recipe.
IX - 6
1.0
Upload the correct product recipe.
Matrix Filler
Part IX
9.1.4
Capping
SCREW CAPS
In general capping problems can divided into two groups:
-
Cap infeed fault.

Poor capping quality.
The caps must be in good condition and within the tolerance limits.
Irregular caps can be considered a possible cause of any faults relating to the cap infeed system during
production and storage.
The caps are not fed out of the

hopper (if fitted).
Cap descent channel empties.
Too many upturned caps in the

channel.
Cap block at pick and place

system infeed.
Caps not screwed up correctly.
Cause
Solution
1. Too many caps in the hopper.
Remove the excess caps.

Adjust the cap level sensor.
2. Too few caps in the hopper.
Adjust the cap level sensor.

Check the efficiency of the system
feeding caps to the hopper.
1. Caps blocked in the automatic

ejector (unit with paddle wheel
and ejection piston) (if fitted).
Remove the caps from the ejector

and check for missing or damaged
seals.
1. Cap selection device not set

correctly.
Check the height of the support

bridge and the position of the cap
support tab.
The cap should be supported by 1-2
mm and should fall freely when
upturned.
1. End section of the channel at

incorrect height relative to the
pick and place unit sliding plate.
Adjust the height of the channel and

specifically make sure it is not too
low relative to the plate.
2. Insufficient air jet flow.
Make sure the air jets are not

blocked.
Adjust the flow, pressure and
direction of the air jets to ensure
correct cap sliding.
1. Non-conforming caps or bottles.
Check the bottle and cap thread for

any faults.
2. Bottles rotate during capping.
See the previous point and make

sure the toothed collars are clean.
3. Speed controller rpm not set

correctly (if the problem only
occurs at high speed).
Increase the rpm of the speed

controller.
4. Insufficient torque wrench setting.
Increase the torque wrench setting.
5. Temperature too low.
Check the internal and external

temperature of the machine.
Sidel S.p.A.
Problem
1.0
IX - 7
Matrix Filler
Bottles rotate on the toothed

anti-rotation collars.
Bent caps.
External cap damage.
Falling caps during transfer

from the pick and place unit to
the bottle.
Cap thread skips bottle thread.
Caps deformed on the bottles

(thread too evident on the
outside).
9.1.5
1. Teeth damaged or worn.
Change the collars.
2. Not enough head compression

and guide set too high.
Check and adjust the compression

and check the guide setting.
1. Non-conforming caps and bottles.
Check the diameters of the bottle

necks and caps are compatible and
within the tolerance limits.
2. Screwer cone not compatible with

caps.
Check and if necessary change the

screw cones.
3. Caps not picked up correctly by

the heads on the pick and place
system plate.
Adjust the timing of the starwheel

relative to the capping piston.
4. Bottle not vertical or too much

play between the starwheel and
bottle body.
Change the starwheel so the bottle

is guided correctly.
1. Incompatible screwer cone or

non-conforming caps.
Check the diameter and profile of

the cap teeth.
1. Cap holding ball compression

spring broken.
Change the spring if damaged.
2. Worn balls.
Change any worn balls.
1. Torque wrench setting too high (if

a general problem with all bottles)
or non-conforming cap.
Adjust the torque wrench setting on

all the heads.
2. Torque wrench setting too high (if

a problem only on one head) or
non-conforming cap.
Adjust the torque wrench setting

and, if necessary, loosen the grub
screw.
1. Torque wrench setting too high.
Reduce the torque wrench setting.

This problem can also arise when
the ambient temperature is too
high).
Product level in static tank (if fitted)

1. Incorrect level parameters.
Set new homogeneous parameters.
2. Faulty probe.
Check, dry and secure the probe

correctly or change it.
3. Too much foam in the tank.
Drain the product from the tank and

repeat the tank filling procedures.
Sidel S.p.A.
Incorrect or unstable tank level.
IX - 8
Part IX
1.0
Matrix Filler
User Manual / Appendices
PART X
APPENDICES
Sidel S.p.A.
PART X
1.0
X-1
Matrix Filler
10.1
DOCUMENTATION ENCLOSED
10.1.1 Layout and connections

10.1.2 Moving the machine
10.1.3 Flow circuit diagram (if present)
10.1.4 Equipment (if present)
10.1.5 Recipes
10.1.6 Description of slave card display unit controls
Sidel S.p.A.
10.1.7 Appendices for commercial equipment
X-2
1.0
PART X
PART X
Matrix Filler
10.1.1 Layout and connections
Sidel S.p.A.
PART III TECHNICAL DATA in section 3.1 Dimensions
1.0
X-3
Sidel S.p.A.
Matrix Filler
X-4
1.0
PART X
PART X
Matrix Filler
10.1.2 Moving the machine
Sidel S.p.A.
PART IV INSTALLATION in section 4.3.6 Hook positioning table
1.0
X-5
Sidel S.p.A.
Matrix Filler
X-6
1.0
PART X
RICAVATO DA:
19
55
02
9
10
57
5111
57
11
DETTAGLIO B
B DETAIL
SCALA 1:10
SCALE 1:10
10
02
11
7404
DETTAGLIO C
C DETAIL
SCALA 1:10
SCALE 1:10
2
2
Gruppi
Groups
Peso Totale
ACCOPPIAMENTI FILETTATI: 100120231

SCREWED COUPLINGS: 100120231
Kg
Total Weight
13600
Peso struttura sollevamento

Weight Lift Structure
300
F
25.08.2011
G.A
Creazione disegno / Drawing creation
316745
01
11.10.2012
G.M
Sostituito pos 10
365871
02
Ind Maj
Ind Min
3
7
ECO
Data/date Nome/name Descrizione modifica/Change Description

ENGINEERING & PACKAGING
SOLUTIONS
DETTAGLIO A
A DETAIL
Rugosit :
(senza indicazione contraria)
Surface condition
(Unless otherwise stated)
SOLLEVAMENTO RIEMPITRICI CZA270 F-M9004
Massa / Mass = g
LIFTING RIEMPITRICI CZA270 F-M9004
Data di Rilascio
Disegnato da / Drawn by
MALPELI
This Drawing is SIDEL property and contains or may contain SIDEL confidential information, including trade secrets. This drawing and all
the information contained therein shall be kept strictly confidential by the recipient and shall not be disclosed to any third party without
SIDEL's express consent. This drawing shall not be used directly or indirectly by the recipient except for the specific purpose for which this
drawing is disclosed by SIDEL. All Intellectual Property Rights, including Copyright, are reserved by SIDEL. No representation or warranty,
express or implied, is made by SIDEL with respect to the truth, accuracy, sufficiency or absence of defect of the information contained in this
drawing or with respect to third party intellectual property rights.
Numero / Number :
/ Release date : 11/10/2012

Data / Date
Scala / Scale
11.10.2012
1:15
Ind Maj Ind min
42879659- 02
a
1
Size
Sheet
A2 1/1
DISPORRE LE CATENE DURANTE IL SOLLEVAMENTO

CON UN ANGOLO MINIMO DI 45
ARRANGE CHAINS IN ORDER TO HAVE MINIMUM ANGLE
EQUAL 45 DURING THE LEFTING
N 10664182
Trattamento / Treatement :
Denominazione / Description :
SCALA 1:10
SCALE 1:10
Specifiche materiale
/ Specification sheet :
Sidel S.p.A.
Via La Spezia 241/A
43100 PARMA - ITALY
Tolleranze generali in accordo

con la specifica :
General tolerances according
to specification :
(unless otherwise stated)
Materiale / Material :
RICAVATO DA / DRAWN FROM: 04284405501

8
BASAMENTO COME IN FIGURA = 2575 KG

ALTEZZA DA TERRA BARICENTRO = 1165 mm
BASE AS SHOWN = 2575 KG
HEIGHT CENTER OF GRAVITY = 1165 mm
4
DETTAGLIO / DETAIL X
SCALA / SCALE 1 : 5
2377,7
DETTAGLIO / DETAIL Y
SCALA / SCALE 1 : 5
2217,7
7
608,4
768,4
2387,7
ATTENZIONE!
DOPO LA REGOLAZIONE IN ALTEZZA
RIPOSIZIONARE LA COPIGLIA DI SICUREZZA
CAUTION!
AFTER HEIGHT REGULATION REPOSITION
THE SAFETY SPLI SPIN
494,3
334,3
COLONNA REGOLABILE IN ALTEZZA

ADJUSTABLE HEIGHT COLUMN
02
a
3
Y
BASAMENTO COMPLETO DI PROTEZIONI = 3375 KG

ALTEZZA DA TERRA BARICENTRO = 1280 mm
BASE WITH PROTECTION = 3375 KG
HEIGHT CENTER OF GRAVITY = 1280 mm
02
a
2487,7
2327,7
134,2
819
979,1
294,2
24.10.2011
B.B
CREAZIONE DISEGNO / NEW DRAWING
324002
01
16.07.2012
A.M
PART. 3; 9
355129
02
ECO
Ind Maj
Ind Min

SOLUTIONS
Sidel S.p.A.
Via La Spezia 241/A
43100 PARMA - ITALY

con la specifica:
to specification :
N 10664182
Rugosit :
Surface condition
SOLLEVAMENTO BASAMENTO COMBI 7 STELLE
Massa / Mass = g
2497,7
LIFTING BASAMENTO COMBI 7 STELLE
Data di Rilascio
MALETTI
Numero / Number :

Data / Date
16.07.2012
1:20
Ind Maj Ind min
42891959- 02
Scala / Scale
Size
Sheet
A1 1/1
A
RICAVATO DA: 04285434802

A
DETTAGLIO/DETAIL A
SCALE 1 : 5
1
B
1945,62
COLONNA REGOLABILE IN ALTEZZA

ADJUSTABLE HEIGHT COLUMN
ATTENZIONE !
DOPO LA REGOLAZIONE IN ALTEZZA
RIPOSIZIONARE LA COPIGLIA DI SICUREZZA
CAUTION !
AFTER HEIGHT REGULATION REPOSITION
THE SAFETY SPLI SPIN.
8
754,67
E
1080,46
F
18.03.2013
B.B
CREAZIONE DISEGNO / DRAWING CREATION
Ind Min
N 10664182
Rugosit :
Surface condition
GRUPPO SOLLEVAMENTO BASAMENTO CAPS 960
Massa / Mass = g
GROUP BASE LIFTING CAPS 960
Data di Rilascio
BSPROGETTI
Numero / Number :

Data / Date
Scala / Scale
18.03.2013
1:20
Ind Maj Ind min
43000833- 01
c
1
Size
Sheet
A2 1/1
H
8
Ind Maj

con la specifica :
to specification :
Sidel S.p.A.
Via La Spezia 241/A
43100 PARMA - ITALY
PESO TOTALE = 3480 KG

BASAMENTO = 880 KG
CASPULATRICE =2600 KG
TOTAL WEIGHT = 3480 KG
BASE = 880 KG
CAPPER STRUCTURE = 2600 KG
ECO

SOLUTIONS
01
385204
PART X
Matrix Filler
Sidel S.p.A.
10.1.3 Flow circuit diagram
1.0
X-7
Sidel S.p.A.
Matrix Filler
X-8
1.0
PART X
PART X
Matrix Filler
10.1.4 Equipment
Sidel S.p.A.
PART VII REMOVING SIZE CHANGEOVER PARTS in section 7.4 Removing size changeover parts
1.0
X-9
Sidel S.p.A.
Matrix Filler
X - 10
1.0
PART X
PART X
Matrix Filler
Sidel S.p.A.
10.1.5 Recipes
1.0
X - 11
Sidel S.p.A.
Matrix Filler
X - 12
1.0
PART X
14/07/2011
COP Suggest Recipes (Diversey) 1.3_EN
DIVERSEY PRODUCTS
STANDARD CIP RECIPES - EXTERNAL CLEANING/FOAMING

Sidel s.r.l. - Via La Spezia 241/A - 43100 Parma - Italy
1 CLEANING FOAM TREATMENT BEFORE COMMISSIONING
STEP
FLUID
TEMPERATURE
RINSING
QUALITY WATER*
Ambient
ALKALINE CLEANING (degreasing)
VE3-Enduro Super
Ambient to 40 C
RINSING
QUALITY WATER*
Ambient
ACID CLEANING (descaling)
VE10-Enduro Cid
Ambient to 40 C
RINSING
QUALITY WATER*
Ambient
CONCENTRATION
DURATION
10 min
2%
6 cycles x 10 mi n***
5 min**
2%
3 cycles x 10 min ***

10 min**
* Recommanded Twh 50< ppm/l as CaC03 (see Tab. 6)

** Check Ph surface are neutral
*** Last area Contact Time
MS
1/7
SIDEL PROCESS
14/07/2011
DIVERSEY PRODUCTS

2 SANITIZATION FOAM BEFORE COMMISSIONING
STEP
FLUID
TEMPERATURE
RINSING#
QUALITY WATER*
Ambient
DISINFECTION
VT70-Diverfoam Active
Ambient
RINSING
QUALITY WATER*
Ambient
CONCENTRATION
DURATION
5 min
2%
3 cycles x 10 min***
20 min**
# Not necessary after previous cleaning

** Check surfaces whit Peracetic Test Strips
MS
2/7
SIDEL PROCESS
14/07/2011
DIVERSEY PRODUCTS

3 CLEANING FOAM AFTER PRODUCTION
STEP
FLUID
TEMPERATURE
RINSING
QUALITY WATER*
Ambient
ALKALINE CLEANING
VE3-Enduro Super
Ambient to 40 C
RINSING
QUALITY WATER*
Ambient
CONCENTRATION
DURATION
5 min
2%
10 min***
2 cycles x 5 min**

** check Ph surface are neutral
MS
3/7
SIDEL PROCESS
14/07/2011
DIVERSEY PRODUCTS

4 SANITIZATION FOAM BEFORE PRODUCTION - DAILY
STEP
FLUID
TEMPERATURE
RINSING#
QUALITY WATER*
Ambient
DISINFECTION
VT70-Diverfoam Active
Ambient
RINSING
QUALITY WATER*
Ambient
CONCENTRATION
DURATION
5 min
2%
10 min***
2 cycles x 10 min**
# Not necessary after previous cleaning

** check surfaces whit Peracetic Test Strips
MS
4/7
SIDEL PROCESS
14/07/2011
DIVERSEY PRODUCTS

5 DESCALING FOAM WEEKLY (DAILY if Filling Water Hardness > 200 ppm CaCO3 ( 20F))
STEP
FLUID
TEMPERATURE
CONCENTRATION
DURATION
ACID CLEANING (descalant)
VE10-Enduro Cid
Ambient to 40 C
2%
10 min***
RINSING
QUALITY WATER*
Ambient
2 cycles x 5 min**

MS
5/7
SIDEL PROCESS
14/07/2011
DIVERSEY PRODUCTS

6 CLEANING - MONTHLY OR AFTER HEAVY MAINTENANCE
STEP
FLUID
TEMPERATURE
RINSING
QUALITY WATER*
Ambient
VE3-Enduro Super
Ambient to 40 C
RINSING
QUALITY WATER*
Ambient
ACID CLEANING (descaling)
VE10-Enduro Cid
Ambient to 40 C
RINSING
QUALITY WATER*
Ambient
CONCENTRATION
DURATION
5 min
2%
2 cycles x 10 mi n***
5 min**
2%
1 cycles x 10 min ***

2 cycles x 5 min**

MS
6/7
SIDEL PROCESS
14/07/2011
DIVERSEY PRODUCTS

7 WATER QUALITY
Parameter
Limit
Microbial Load
<100 CFU/ml
Hardness
< 50 ppm CaCO3 (< 5F)
Chlorides
< 40 ppm (as NaCl)
Chlorine
< 1 ppm (as free Chlorine)
Ph
6.5/7.5
Iron
< 1 ppm
Manganese
< 0.5 ppm
Suspended Solid
None
Smell or taste
None
10
Dissolved solids
E.coli or thermotolerant coliform
bacteria
< 700 mg/l

Must not be detectable in any 100-ml
sample
11
MS
7/7
SIDEL PROCESS
16/04/2012
WP001 - CIP Suggested Recipes - CSD or Soft Drink 1.1_EN.xls
STANDARD CIP RECIPES ( CSD - SOFT DRINK - JUICE )

Sidel s.p.a. - Via La Spezia 241/A - 43100 Parma - Italy
1 CHEMICAL TREATMENT BEFORE COMMISSIONING

ALKALINE AND ACID CHEMICALS MUST BE AVAILABLE
STEP
FLUID
TEMPERATURE
RINSING
QUALITY WATER
ambient
ALKALINE SOLUTION
80C **
RINSING
QUALITY WATER
ambient
ACID CLEANING
NITRIC ACID***
40C **
RINSING
QUALITY WATER
ambient
ALKALINE CLEANING (neutralization)
ALKALINE SOLUTION
80C **
RINSING
QUALITY WATER
ambient
SOLUTIONS
ALKALINE
ACID 1
Pure Chemical
NaOH
HNO3
* start time when <0,1 % of caustic/acid

** temperature on return line to CIP
*** only with fillers manufactured after 2004
MS
1/11
CONCENTRATION
DURATION
5 min
4%
30 min
5 min*
5%
30 min
10 min*
1%
30 min
15 min*
Diversey
VC13-Diverspray
VA5-Pascal
Ecolab
P3-mip CIP
P3-horolith FL
SIDEL PROCESS
16/04/2012

2 DISINFECTION BEFORE COMMISSIONING
(ALTERNATIVE TO RECIPE # 3)
PEROXYACETIC CHEMICAL MUST BE AVAILABLE

STEP
FLUID
TEMPERATURE
RINSING
QUALITY WATER
ambient
DISINFECTION
PAA (peroxyacetic acid)
45 C *
RINSING
QUALITY WATER
ambient
SOLUTIONS
Pure Chemical
* temperature on return line to CIP
CONCENTRATION
DURATION
10 min
1500 ppm ***
10 min
20 min**
Diversey
Hydrogen peroxide
VT6-Divosan Forte
+ peracetic acid
Ecolab
Oxonia Aktiv 30
** rinsing efficiency control. New rinsing if necessary

*** PAA dosed after water has reached 45 C
MS
2/11
SIDEL PROCESS
16/04/2012

3 SANITIZATION BEFORE COMMISSIONING
(ALTERNATIVE TO RECIPE # 2)
STEP
FLUID
TEMPERATURE
CONCENTRATION
RINSING
QUALITY WATER
ambient
10 min
HOT WATER SANITIZATION
QUALITY WATER***
85 C **
40 mi n
COOLING RINSE
QUALITY WATER
ambient
5/10 min
DURATION
** Temperature on return line to CIP. Temperature must not drop below 80C anytime during the sanitize cycle. If so the hot sanitize cycle must restart.
*** Recommanded Twh 50< ppm/l as CaC03 (see Tab. 8)
MS
3/11
SIDEL PROCESS
16/04/2012

4 CLEANING BEFORE PRODUCTION - DAILY - (3 Step Cleaning)

ALKALINE CHEMICAL MUST BE AVAILABLE
STEP
FLUID
TEMPERATURE
RINSING
QUALITY WATER
ambient
ALKALINE CLEANING (Detersion)
ALKALINE SOLUTION
75C *
COOLING/RINSING
QUALITY WATER
ambient
SOLUTIONS
ALKALINE
Pure Chemical
NaOH
MS
4/11
CONCENTRATION
DURATION
5 min
2%
15 min
10 min*
Diversey
VC13-Diverspray
Ecolab
P3-mip CIP
SIDEL PROCESS
16/04/2012

5 CLEANING and SANITIZATION BEFORE PRODUCTION - (3 Step Caustic Sanitization)

STEP
FLUID
TEMPERATURE
RINSING
QUALITY WATER
ambient
ALKALINE SOLUTION
85C **
COOLING/RINSING
QUALITY WATER
ambient
SOLUTIONS
ALKALINE
Pure Chemical
NaOH
CONCENTRATION
DURATION
5 min
2%
30 min
5/10 min*
Diversey
VC13-Diverspray
Ecolab
P3-mip CIP
** Temperature on return line to CIP. Temperature must not drop below 80C
anytime during the sanitize cycle. If so the hot sanitize cycle must restart.
MS
5/11
SIDEL PROCESS
16/04/2012

6 LONG STOPS (WEEK END AND HOLIDAYS) - Flooding

PEROXYACETIC CHEMICAL MUST BE AVAILABLE
STEP
FLUID
TEMPERATURE
CONCENTRATION
DURATION
FLOODING MACHINE
20 C
500 ppm
see note *
* drain and refill every 2/3 days
SOLUTIONS
MS
6/11
Pure Chemical
Diversey
Hydrogen peroxide
VT6-Divosan Forte
+ peracetic acid
Ecolab
Oxonia Aktiv 30
SIDEL PROCESS
16/04/2012

7 CLEANING - MONTHLY OR AFTER HEAVY MAINTENANCE - (5 Step Cleaning)

ALKALINE AND ACID CHEMICALS MUST BE AVAILABLE
STEP
FLUID
TEMPERATURE
RINSING
QUALITY WATER
ambient
ALKALINE SOLUTION
80C **
RINSING
QUALITY WATER
ambient
ACID CLEANING (Descaling)
ACID SOLUTION
50C **
RINSING
QUALITY WATER
ambient
SOLUTIONS
ALKALINE
ACID 1***
ACID 2
ACID 3***
Pure Chemical
NaOH
HNO3
H3PO4
HNO3+H3PO4

*** only fillers manufactured after 2004
MS
7/11
CONCENTRATION
DURATION
5 min
2%
30 min
5 min*
1%
15 min
10 min*
Diversey
VC13-Diverspray
VA5-Pascal
VA3-Alwash
VA4-Superdilac
Ecolab
P3-mip CIP
P3-horolith FL
P3-Horolith PA
P3-Horolith V
SIDEL PROCESS
16/04/2012

8 CLEANING and SANITIZATION - MONTHLY OR AFTER HEAVY MAINTENANCE - (5 Step Cleaning and Hot Sanitization)
STEP
FLUID
TEMPERATURE
RINSING
QUALITY WATER
ambient
ALKALINE SOLUTION
80C **
RINSING
QUALITY WATER
ambient
5 min*
HOT WATER SANITIZATION
QUALITY WATER***
85 C **
20 mi n
COOLING RINSE
QUALITY WATER
ambient
5/10 min
SOLUTIONS
ALKALINE
Pure Chemical
NaOH
CONCENTRATION
DURATION
5 min
2%
Diversey
VC13-Diverspray
30 min
Ecolab
P3-mip CIP
** Temperature on return line to CIP. Temperature must not drop below 80C
anytime during the sanitize cycle. If so the hot sanitize cycle must restart.
*** Recommanded Twh 50< ppm/l as CaC03 (see Tab. 10)
MS
8/11
SIDEL PROCESS
16/04/2012

9 DESCALING - MONTHLY OR HARDNESS WATER >15F - (3 St ep Acid Cleaning )

ACID CHEMICAL MUST BE AVAILABLE
STEP
FLUID
TEMPERATURE
RINSING
QUALITY WATER
ambient
ACID CLEANING (Descaling)
ACID SOLUTION
50C **
RINSING
QUALITY WATER
ambient
SOLUTIONS
ACID 1***
ACID 2
ACID 3***
Pure Chemical
HNO3
H3PO4
HNO3+H3PO4
* start time when <0,1 % of /acid

*** only fillers manufactured after 2004
MS
9/11
CONCENTRATION
DURATION
5 min
1%
15 min
10 min*
Diversey
VA5-Pascal
VA3-Alwash
VA4-Superdilac
Ecolab
P3-horolith FL
P3-Horolith PA
P3-Horolith V
SIDEL PROCESS
16/04/2012

10 WATER QUALITY
MS
Parameter
Limit
Microbial Load
<100 CFU/ml
Hardness
< 50 ppm CaCO3 (< 5F)
Chlorides
< 40 ppm (as NaCl)
Chlorine
< 1 ppm (as free Chlorine)
Ph
6.5/7.5
Iron
< 1 ppm
Manganese
< 0.5 ppm
Suspended Solid
None
Smell or taste
None
10
Dissolved solids
< 700 mg/l
11
E.coli or thermotolerant coliform

bacteria
Must not be detectable in any 100-ml

sample
10/11
SIDEL PROCESS
16/04/2012

11 FEASIBLE RECIPES WITH THE VARIOUS SIDEL CIP SYSTEMS
ML
CSD - SOFT DRINK - JUICE Recipes
ML Standard (PAA+Caustic)
2-3-4-5-6-8
ML 3 Chemicals (PAA+Caustic+Descalant)
1-2-3-4-5-6-7-8-9
ICS
MS
ICS Standard (PAA)
Not Available
ICS 2 Chemicals (PAA+Caustic)
Not Available
ICS 3 Chemicals (PAA+Caustic+Descalant)
Not Available
11/11
SIDEL PROCESS
Matrix Filler
PART X
10.1.6 Description of slave card display unit controls

Slave Display
Description
Command Execution
Slave Card in Tangent at Inlet Starwell
18
Abort
18
Check and Download Parameters
oH
Recipe Download
Burst
13
Wait Phase Start Dynamic Snift/Decompression
Fillling Execution Completed SetPoint Not OK
0.
Filling Execution Completed SetPoint OK
Snift/Decompression
1 + Rotation
Start Filling
C + Rotation
CIP Active
Start Flushing (only in FLAT)
MMM
User Program Mode
h + Rotation
Start Filling in Manual
14
Start Sequencer
Manual Step by Step Active
17
Command Error
Valve Posit > Exit Filling Cam PAS but Fill Not Completed or
Timeout Communication Broadcast Force Centering Cup Up
Start Purge Volume (only in FLAT)
Start Purge Time (only in FLAT)
Read Serial by Node
21
Read Node by Serial
23
N.
Set Node by Serial
22
Slave Card Not Communication with Master
At every start up on display appears Node actual setting in slave card encoded using led segments
Sidel S.p.A.
Led segments:
1.0
X - 13
Matrix Filler
Sidel S.p.A.
10.1.7 Appendices for commercial equipment
X - 14
1.0
PART X
Sidel S.p.A.
SF300 Filler
Montageanleitung / Bettiger
AZM 161
Mounting instructions / Actuators

Instructions de montage / Actionneurs
1/2
Hinweis
Verwenden Sie als Sicherung gegen unbefugtes Lsen Sicherheitsschrauben mit Einwegschlitz (als Zubehr erhltlich). Bei Befestigung, z.B. durch Nieten oder Schweien, ist darauf zu achten,
dass sich die Eintauchtiefe des Bettigers nicht ndert.
Es stehen verschiedene Bettigerformen zur Verfgung: Vorzugsweise
fr verschieb- und abnehmbare Schutzeinrichtungen der Bettiger
AZM 161-B1 und AZM 161-B1E. Fr drehbare Schutzeinrichtungen
der Bettiger AZM 161-B6.
AZM
AZM
AZM
AZM
AZM
AZM
AZM
AZM
AZM
Einstellschraube
Werkseitig ist der Bettiger AZM 161-B6 auf den kleinsten Radius
eingestellt. Bei greren Radien erfolgt die Einstellung durch Drehen
der Einstellschrauben a + b mit einem Innensechskant-Schlssel
SW 2,5 mm.
Set screw
The basis setting of actuator AZM 161-B6 provides a minimum
radius. For larger radii, the angle has to be adjusted correspondingly
by turning the set screws a + b, using an hexagonal key wrench
2.5 mm A/F.
franais
Remarque
Pour viter tout dmontage intempestif, utiliser les vis tte fraise
avec vissage unidirectionnelle (peut tre fourni comme accessoire).
En cas de fixation selon un mode diffrent, par exemple par rivetage
ou soudage, veiller ce que la profondeur de plonge de l'acionneur
ne varie. Different formes dactionneurs sont disponibles. Les
actionneurs AZM 161-B1 et AZM 161-B1E sont recommands pour
les protecteurs coulissants et amovibles. Dans le cas de protecteurs
pivotants, nous vous conseillons lactionneur AZM 161-B6.
161-B1
161-B1-1747
161-B1-2024
161-B1-2053
161-B1-2177
161-B1E
161-B1F
161-B1S
161-B1ES
180
150
150
150
150
180
180
180
180
5
5
5
5
5
5
11
150
150
150
150
150
150
150
150
150
5
5
5
5
5
5
11
AZM 161-B6
AZM 161-B6-2177
AZM 161-B6S
95
95
95
11
17
95
95
95
11
17
The axis of the hinge must be x mm above and in a parallel plane

to the top surface of the safety switch. The basis setting provides
a minimum radius of Rmin.
L'axe de rotation de l'articulation et la face suprieure de linterrupteur de scurit doivent se situer dans deux plans parallles
distants de x mm. Le rglage de base est tabli en fonction du
plus petit rayon, Rmin.
Legende
Legend
Lgende
R min.
x
R min.
x
Radien ber die breite Seite des Bettigers

Radii over the wide edge of the actuator
Rayons d'actionnement sur le grand ct de
l'actionneur
Radien ber die schmale Seite des Bettigers
Radii over the small edge of the actuator
Rayons d'actionnement sur le petit ct de
l'actionneur
Einstellschraube
Set screw
Vis de rglage
Montage
Lors du montage sur des protecteurs pivotants, veiller ce que
l'axe de rotation se trouve dans le plan de la surface de l'interrupteur de scurit dans laquelle l'actionneur plonge (voir table).
Vis de rglage
Le rglage de base AZM 161-B6 est tabli en fonction du plus petit
rayon. Dans le cas de rayons plus grands, modifier le rglage en
tournant la vis de rglage a + b l'aide d'une cl 6 pans de
2,5 mm sur plats.
Rmin [mm] x [mm]
Der Drehpunkt des Scharniers und Oberkante des Sicherheitsschalters mssen zuzglich x mm eine Ebene bilden. Die Grundeinstellung ist auf den kleinsten Radius Rmin eingestellt.
Notice
Please ensure this is fitted the correct way round, and tighten the
actuator with one-way screws (available as accessory), to prevent
deliberate removal. Please ensure with welding or riveting of the
actuator, that the insertion depth of the actuator is not altered.
There are different actuator types available, depending on the application. The actuator AZM 161-B1 and AZM 161-B1E are designed
for sliding and removable safety guards, while AZM 161-B6 is
recommended for hinged safety guards.
Mounting
Please note, that the centre of rotation must be in the same plane
as the upper edge of the safety switch (see table).
x
Rmin [mm] x [mm]
Montage
Bei der Montage an drehbaren Schutzeinrichtungen ist darauf
zu achten, dass der Drehpunkt in der Ebene der Oberflche des
Sicherheitsschalters liegt, in die der Bettigungsbgel eintaucht
(s. Tabelle).
english
R min.
R min.
Bettigungsradien
Actuator radii
Rayons d'actionnement
deutsch
Istruzioni di montaggio / Attuatori
AZM 161
Instrucciones de montaje / Actuadores
2/2
italiano
Avvertenza
Per evitare uno smontaggio non autorizzato o manomissioni
utilizzare viti di sicurezza con intaglio antisvitamento (disponibili
come accessori). Durante il fissaggio, ad esempio mediante rivetti o
saldatura, assicurarsi che la profondit di inserimento dell'attuatore
non venga alterata.
Sono disponibili diversi tipi di attuatori: per protezioni traslabili e
amovibili sono da preferirsi gli attuatori AZM 161-B1 e AZM 161-B1E,
per protezioni a cerniera lattuatore AZM 161-B6.
Raggi d'azionamento
Radios de accionamiento
AZM
AZM
AZM
AZM
AZM
AZM
AZM
AZM
AZM
Vite di regolazione
L'attuatore AZM 161-B6 tarato sul raggio minimo. Per raggi
maggiori modificare la taratura agendo sulle viti di regolazione
a + b con una chiave a brugola da 2,5 mm.
161-B1
161-B1-1747
161-B1-2024
161-B1-2053
161-B1-2177
161-B1E
161-B1F
161-B1S
161-B1ES
180
150
150
150
150
180
180
180
180
5
5
5
5
5
5
11
150
150
150
150
150
150
150
150
150
5
5
5
5
5
5
11
AZM 161-B6
AZM 161-B6-2177
AZM 161-B6S
95
95
95
11
17
95
95
95
11
17
El eje de giro de la bisagra, y la cara superior del interruptor de seguridad deben situarse en dos planos paralelos, separados por x mm.
El reglaje de base viene establecido en funcin del radio mnimo, Rmin.
Legenda
Leyenda
Tornillo de regulacin
La regulacin de base del AZM 161 B6 se establece en funcin del
mnimo radio de giro. En caso de mayores radios de giro, modificar
el reglaje girando los tornillos de regulacin a + b mediante una llave
hexagonal de 2,5 mm entre caras.
R min.
x
R min.
x
Raggio sul lato lungo dell'attuatore

Radios de accionamiento en el lado
mayor del actuador
Raggio sul lato corto dell'attuatore

Radios de accionamiento en el lado
menor del actuador
x000 / v.A. / 07.08 / Teile-Nr. 1148098 / BZ 50161-61V900 / Ausgabe E
Vite di regolazione
Tornillo de regulacin
K. A. Schmersal GmbH
Industrielle Sicherheitsschaltsysteme
Mddinghofe 30, D - 42279 Wuppertal
Postfach 24 02 63, D - 42232 Wuppertal
Telefon
Telefax
E-Mail:
Internet:
Rmin [mm] x [mm]
Il fulcro della cerniera ed il bordo superiore dell'interruttore di

sicurezza devono essere su due piani paralleli distanti fra loro x mm.
Al montaggio la taratura fissata sul raggio minimo Rmin.
Informacin
Se debe asegurar contra desmontajes no autorizados mediante la
utilizacin de los tornillos de seguridad con la cabeza fresada (suministrados como accesorios) que solo permiten el apriete. En caso
de utilizar un modo de fijacin distinto, por ejemplo por remaches o
por soldadura, hay que asegurarse que la profundidad de penetracin sea la misma. Existen distintas versiones de actuador disponibles, dependiendo de cada aplicacin. Los actuadores AZM 161B1 y AZM 161 B1E, han sido previstos para puertas deslizantes o
desmontables, mientras que AZM 161- B6 se recomienda para las
puertas protectoras de seguridad pivotantes.
Montaje
En caso de montajes en protecciones pivotantes, hay que asegurarse
de que el eje de giro se encuentre en el plano de la superficie del interruptor de seguridad en el cual penetra el actuador (ver tabla).
Rmin [mm] x [mm]
Montaggio
Durante il montaggio su dispositivi di sicurezza con cerniere, assicurarsi che lasse di rotazione si trovi sul piano della superficie dellinterruttore di sicurezza nella quale si inserisce lazionatore (vedi tabella).
espaol
R min.
R min.
x
+49 - (0)2 02 - 64 74 - 0
+49 - (0)2 02 - 64 74 - 1 00
info@schmersal.com
http://www.schmersal.com
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MODULO DI MONITORAGGIO VELOCITA DI ROTAZIONE

Filler User Manual

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Technical Documentation

All figures and photos are for information purposes only.

Publication date: 28/06/2013

SIDEL S.p.A. - Via La Spezia, 241/A - (43126), Parma ITALY

Page intentionally left blank

GENERAL REGULATIONS AND WARNINGS

GENERAL REGULATIONS AND WARNINGS............................................................................................................... Part I

1.9.15 Filling valve drainage tank (HOTFILL optional) .......................................................................................... 42

INSTALLATION ............................................................................................................................................................. Part IV

Setting up and first startup...................................................................................................................................... 13

OPERATION .................................................................................................................................................................. Part V

OPERATING INSTRUCTIONS ....................................................................................................................................... Part VI

Stop and emergency stop modes ........................................................................................................................... 154

SIZE CHANGEOVER ..................................................................................................................................................... Part VII

GENERAL REGULATIONS AND WARNINGS

TESTING AND WARRANTY

WARNINGS AND PERSONNEL

This manual is an integral part of the machine.

The installation manager.

This manual provides the following general information:

A description of the machine operating units and sub-assemblies.

This manual contains:

Final setting up and adjustment. Levelling. Assembly of all sub-components.

Reproduction rights and copyright

All rights reserved.

Documents supplied with the machine

The following are supplied for other countries:

EC declaration of conformity with machinery directive

See the machine identification data on the cover of this manual.

Identification and CE marking plate

Do not remove or tamper with the identification plate.

EC Declaration of conformity as per Pressure Equipment Directive (PED)

See the machine identification data on the cover of this manual.

See the machine identification data on the cover of this manual.

Plates certifying conformity to Pressure Equipment Directive (PED)

Identification of the tank or assembly

Do not remove or tamper with the identification plates.

Quality certificate (countries not in the EEA)

The certificate is given to the customer when the machine is delivered.

See the machine identification data on the cover of this manual.

Identification plates (countries not in the EEA)

There are 2 identification plates for countries not in the EEA:

Identification of the tank or assembly

Do not remove or tamper with the identification plates.

SETUP PROVIDED BY THE CUSTOMER

The following connections must be provided by the customer:

The following must also be provided by the customer:

TECHNICAL ASSISTANCE REQUEST PROCEDURE

Machine type, Serial Number, Year of installation.

INSTRUCTIONS FOR ORDERING SPARE PARTS

Machine type and serial number.

CONSULTING THIS MANUAL

Symbols used in this manual

Warning Please read carefully.

Prohibition sign: No persons with pacemaker

Mandatory sign: Read the manual

Notes and comments on the results of an operation.

Indications for protecting the environment.

Terminology used in this manual

A Clean-In-Place (CIP) or a Sanitize-In-Place (SIP) unit.

Removal of food residues, dirt, grease or any unwanted material.

COP EXTERNAL CLEANING

Clean-Out of-Place (COP) - a system for the external cleaning a line or an

A chemical product used after cleaning to eliminate a part or a type of