IDD Processing & Packaging SQUIRE PLUS 2 Operation Manual

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2-head washer / filler

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PROCESS & PACKAGING, INC. Address: 5450 Tech Circle, Moorpark, CA 93021 Tel: (805) 529-9890 Fax: (805) 529-9282

SQUIRE “PLUS 2” 2-HEAD WASHER / FILLER

OPERATIONS MANUAL

(Image shows Fill-by-Weight and Double-Doser options)

CREATED: May 29, 2015 REVISION: 1.3

SQUIRE PLUS 2 OPERATIONS MANUAL

TABLE OF CONTENTS INTRODUCTORY STATEMENTS 1.

PREFACE ..........................................................................................................................

4

2.

DISCLAIMER .....................................................................................................................

4

3.

CONFIDENTIALITY AND COPYRIGHTS ..........................................................................

4

SAFETY 4.

OPERATIONAL SAFETY NOTES .....................................................................................

5

SYSTEM PROCEDURES & OPERATIONS 5.

SERVICES .........................................................................................................................

6

SQUIRE “PLUS 2” SERVICES ............................................................................................................. SQUIRE “PLUS 2” DRAINAGE ............................................................................................................. DOUBLE DOSER UNIT OPTION .......................................................................................................... SUGGESTED COMPONENTS ..............................................................................................................

6 7 9 10

6.

SPECIFICATIONS .............................................................................................................

14

7.

CYCLE TIMES ...................................................................................................................

15

8.

SIMPLIFIED START–UP AND SHUT–DOWN PROCEDURES .........................................

16

9.

KEG WASHING & FILLING PROCEDURES .....................................................................

17

KEG W ASHING .................................................................................................................................. END OF DAY CLEANING ................................................................................................................... KEG FILLING ....................................................................................................................................

17 25 26

CLEANING IN PLACE (CIP) PROCEDURE ......................................................................

35

CIP SEQUENCE – PRODUCT FILLING SIDE ......................................................................................... EXTERIOR CLEANUP ........................................................................................................................

35 36

11.

PLANNED MAINTENANCE ...............................................................................................

37

12.

QUALITY CONTROL .........................................................................................................

38

KEG LINE QUALITY ASSURANCE .......................................................................................................

40

OXINE CLEANING/SANITIZING .......................................................................................

41

OXINE DILUTION AND USE ................................................................................................................ OXINE & PUROGENE SANITIZER SUGGESTED USES ........................................................................... CIO2 ACTIVATION ............................................................................................................................ OXINE MATERIAL SAFETY DATA SHEET .............................................................................................

41 42 45 46

10.

13.

SYSTEM DETAIL INFORMATION 14. 15. 16.

PLANT LAYOUT ............................................................................................................... FLOW DIAGRAM ............................................................................................................... ELECTRICAL ....................................................................................................................



52 53 54

SQUIRE PLUS 2 OPERATIONS MANUAL 17.

18. 19. 20.

MECHANICAL ...................................................................................................................

56

EURO & AMERICAN SANKEY KEG VALVE FLOWS ............................................................................... ARES VALVE – INSTALLATION & MAINTENANCE MANUAL ................................................................... PROCESS VALVE ............................................................................................................................. SOLENOID VALVE ............................................................................................................................. PINCH VALVE .................................................................................................................................. TANK DOSING UNIT .......................................................................................................................... FLOAT VALVE W ITH PROPORTIONER ................................................................................................. ADJUSTABLE SINGLE STAGE INJECTORS ........................................................................................... DETERGENT PUMP – NPE/NPE-F INSTRUCTION MANUAL ................................................................... PRODUCT PUMP – OPERATION MAINTENANCE, & PARTS LIST ............................................................

56 57 60 61 62 63 65 68 69 77

PNEUMATICS .................................................................................................................. DIMENSIONS ................................................................................................................... I/O LISTING .......................................................................................................................

108 109 110

GENERAL INFORMATION 21.

APPENDICES .................................................................................................................... Appx. A Appx. B Appx. C Appx. D Appx. E Appx. F

IDENTIFYING AND ANALYZING PROBLEMS .............................................................. COMPLETE KEG WASHING & FILLING SEQUENCE CONTROL PROCESSES ....... SPARE PARTS ................................................................................................................ PROGRAM LISTING ....................................................................................................... TRAINING ........................................................................................................................ WHICH MASK SHOULD I WEAR? ..................................................................................



112 112 118 122 125 125 125

SQUIRE PLUS 2 OPERATIONS MANUAL

INTRODUCTORY STATEMENTS 1.

PREFACE This system has been designed as a self-contained and reliable automatic keg processing machine. Although kegs are loaded and unloaded manually, all washing, sanitizing, and filling operations are fully automatic for consistent high quality results. The information, instructions, and warnings contained in this document have been prepared to clarify operational and maintenance procedures. If followed carefully, they should provide safe, long, and reliable service from the machine. Proper maintenance and the use of approved spare parts will extend the life of the system and its reliability, while the use of any non-approved spare parts may void any warranties or guarantees; actual or implied.

2.

DISCLAIMER The customer assumes all responsibility for the system, once delivered. The system is tried and tested equipment, and as such, IDD Processing & Packaging will not be held responsible for alterations and modifications carried out by anyone, without the written approval of IDD Processing & Packaging.

3.

CONFIDENTIALITY AND COPYRIGHTS All information contained within this document is confidential and the copyright of IDD Process & Packaging, Inc. No portion of this data shall be released, disclosed, used, or duplicated for use in procurement or manufacturing, without the express written permission from IDD Process & Packaging, Inc.

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SQUIRE PLUS 2 OPERATIONS MANUAL

SAFETY 4.

OPERATIONAL SAFETY NOTES EMERGENCY STOP / MANUAL PROCESS STOPS To STOP the process sequence at any time for each of the process heads, use the Manual Stop Process Buttons, located on the system Control Panel.

VENTILATION The work area should have adequate ventilation approved for use by your Safety and Operational Procedures Committees. Respirators should be used during cleaning and other operations where fumes are present. Refer to APPENDIX F – WHICH MASK SHOULD I WEAR?

WEAR SAFETY GOGGLES Wear Safety Goggles approved for use by your Safety and Operational Procedures Committees when operating or observing this system.

WEAR CHEMICAL RESISTANT GLOVES & APRON Wear Chemical Resistant Gloves and Apron approved for use by your Safety and Operational Procedures Committee.

WEAR BACK SUPPORT EQUIPMENT Wear Back Support Equipment and use proper lifting technique as approved by your Safety and Operational Procedures Committees. Note: Use only the proper lifting equipment for full kegs, as they weigh up to 165 lbs.

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SQUIRE PLUS 2 OPERATIONS MANUAL

SYSTEM PROCEDURES & OPERATIONS 5.

SERVICES SQUIRE “PLUS 2” SERVICES LINE

SUPPLY

PRESSURE

FLOW RATE

CONSUMPTION

CONNECTION

1*

CO2/ N2

30 PSIG

20 SCFM

1.75 SCFM

3/4" N/B Hose

2*

AIR PURGE

22.23 PSIG

20 SCFM

1.25 SCFM

3/4" N/B Hose

3 (Ambient)

W ATER

55 PSIG

15 GPM

1.5 SCFM

3/4" N/B Hose

4 (Ambient)

W ATER

55 PSIG

15 GPM

Top Up

1/2" NPTM

5*

AIR

80 PSIG

2.5 SCFM

0.25 SCFM

1/4" NPTM

6

ELECT.

--

--

208V-240V-1PH-50/60Hz-35A

--

7

CAUSTIC

--

--

Dosing at 2% V/V

1/4" OD Tubing

8

PRODUCT

15 PSIG

20 GPM

7.5 GPM

1-1/2" TC

9

OXINE

--

--

Dosing Nominal 50 ppm

1/4" OD Tubing

10 (Option)

ACID

--

--

Dosing at 0.5% V/V

1/4" OD Tubing

11

CIP RETURN

--

10 GPM

--

3/4" N/B Hose

12

FILL DRAIN

--

--

--

3/4" N/B Hose

6 4 7

3

10 2

9

1

5

8 11

* Customer to provide suggested

12

components. Refer to Page 8, Suggested Components.

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SQUIRE PLUS 2 OPERATIONS MANUAL

SQUIRE “PLUS 2” DRAINAGE

Page 8

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SQUIRE PLUS 2 OPERATIONS MANUAL PREVENTING BACK PRESSURE IN DRAIN LINES The following model is the IDD suggested method of process and packaging plant drainage for designated non-wet area locations to prevent back pressure within the drain lines. This method allows enough air-behind-water to prevent backups with 3/4" drain pipes to enter a 2” PVC drain.

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SQUIRE PLUS 2 OPERATIONS MANUAL

DOUBLE DOSER UNIT OPTION

DOUBLE DOSER UNIT OPTION #: MS 50030 - DOSERS TO DOSE ACID AND CAUSTIC INTO THE DETERGENT TANK FOR ALTERNATING YOUR KEG WASHING REGIME IN ORDER TO RID KEGS OF HEAVY PROTEINS AND CALCIUM BUILD UP. ISOLATING VALVE (CHANGEOVER BY OPENING AND CLOSING FROM CAUSTIC AND ACID)

DETERGENT TANK LOWER BLEED VALVE : - ALLOWS FOR THE AUTOMATIC REFRESHING OF CAUSTIC OR ACID DOSING. - LEAK RATE: 3 GAL. (11.4 LITERS) PER HOUR NOTE: SQUIRE "PLUS 2" SYSTEM SHOWN.

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SQUIRE PLUS 2 OPERATIONS MANUAL

SUGGESTED COMPONENTS Water, oil, and random particles are the natural enemies of perfectly prepared compressed air. They will have an adverse effect on components and cost additional energy. In order to improve process reliability and machine availability, start by first analyzing the compressed air supply in detail from source. IDD suggests the following equipment be included in your Purge Air and Inert Gas Regulator configurations. They are available at www.Grainger.com. 1” NPT AIR REGULATOR

PRESSURE GAUGE

(1 ea. For Air Purge & CO2/N2)

Grainger Item # 4ZM10 • 1” NPT • Adjustment Range 5 to 125 PSI (Set to 30 PSI, 2 Bar for CO2/N2) (Set to 22-23 PSI, 1.55 Bar for Air)

• ¼” NPT (Female) Gauge Port

(1 ea. For Air) Grainger Item # 33HR23

• • •

0 to 100 PSI 2 ½” Dial ¼” (Male) NPT Inlet, Back

AIR SUPPLY (AIR COMPRESSOR) Grainger Item # 4ME99 • Electric • 175 PSI Max. Pressure • 5 HP • 2 Stage • 208-230/460V / 3Phase / 60 Hz / 13.4-13.2 A • 60 Gallon Tank (Vertical) • ¾” NPT (Female) Outlet

PRESSURE GAUGE (1 ea. For Air Purge & CO2/N2)

Grainger Item # 33HP99 • 0 to 60 PSI • 2” Dial • ¼” (Male) NPT Inlet, Back RELIEF (SAFETY VALVE) (1 ea. For Air Purge & CO2/N2)

Grainger Item # 15X911 • 60 PSI Preset Setting • ½” (Male) NPT Inlet ¼” NPT AIR REGULATOR (1 ea. For Control Air) Grainger Item # 4ZM18

• ¼” NPT • Adjustment Range 5 to 150 PSI (Set to 80 PSI, 5.8 Bar) • ¼” NPT (Female) Gauge Port

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SQUIRE PLUS 2 OPERATIONS MANUAL CO2 AND LOW PRESSURE (PURGE) AIR • It is suggested that 1" regulators are fitted within 10 feet of the machine and a 3/4" or 1” I/D line is run between the regulator and machine. • A minimum 3/4" supply line set at 100 PSIG should run to the 1” regulators stated above. AIR CONTROLS 3/8” minimum supply line at 100 PSIG and regulated to 80 PSIG at the machine. NOTE: You MUST use an air dryer on your air supplies to the machine, to prevent pre-lubricated pneumatic equipment from seizing up due to moisture condensation. In all instances a water separator is NOT sufficient to ensure dry oil-free air.

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SQUIRE PLUS 2 OPERATIONS MANUAL

Dryers An Air Dryer will remove moisture from compressed air to a certain degree of dryness and this is referred to as Pressure Dew Point. Different types of dryers can achieve different dew points and, for the most part, the drier the air needs to be, the more expensive it is to dry. Refrigerated Dryers condense the moisture out of the air and drain it away as liquid. They are limited to about 35° F because the water freezes if it gets colder Desiccant Dryers adsorb the moisture in the compressed air and remove it while it’s still suspended as vapor. They are typically applied at about -40° F, but may reach below to -100° F Membrane Dryers use permeability to separate the moisture from the air and can also achieve low dew points The selection is made based on personal preferences, the dryness required, and the affordable cost, which should include such things as operating, electrical, and/or utility bills.

Reproduced in part from the web site of: Gulf Atlantic Equipment, Co., Jacksonville, Florida. 904-636-8555 Fax: 904-636-8554 © 2006

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SQUIRE PLUS 2 OPERATIONS MANUAL

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SQUIRE PLUS 2 OPERATIONS MANUAL

6.

SPECIFICATIONS Output is subject to keg size, keg valve style, and wash sequence used. Use the charts below as an internal reference by inserting your specific optimum and acceptable values. This becomes the bench mark in the future of your production. Changes in operating personnel, valves, wash sequences, and mechanical integrity can be tracked with this bench-marking as well. Date:

Keg Size:

Valve Style:

Kegs/Hour:

Keg Size:

Valve Style:

Kegs/Hour:

Keg Size:

Valve Style:

Kegs/Hour:

Keg Size:

Valve Style:

Kegs/Hour:

Keg Size:

Valve Style:

Kegs/Hour:

Special Notes:

Date: Special Notes:

Date: Special Notes:

Date: Special Notes:

Date: Special Notes:

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SQUIRE PLUS 2 OPERATIONS MANUAL

7.

CYCLE TIMES SQUIRE “PLUS 2” SEQUENCE TIMES Oxine Machine With Allen Bradley PLC

WASH HEAD

REGULAR SEQUENCE

LONG SEQUENCE

Wash Water Pre-soak

3 sec.

3 sec.

Air Purge Pre-soak

Event

Event

Wash 1 Water (pulse on long seq.)

7.5 sec.

15 sec.

Low Flow Wash 1 (pulse on long seq.)

7.5 sec.

15 sec.

Event

Event

Wash 2 Detergent (Pulsed Wash)

15 sec.

30 sec.

Low Flow Wash 2

15 sec.

30 sec.

Event

Event

Wash 3 Water (Pulsed Wash)

7.5 sec.

7.5 sec.

Low Flow Wash 3

10 sec.

10 sec.

Wash 3 fill

3 sec.

3 sec.

Sterilize Hold

10 sec.

10 sec.

Depressurize

5 sec.

5 sec.

10 sec. / Event

10 sec. / Event

2.5 sec.

2.5 sec.

REGULAR SEQUENCE

LONG SEQUENCE

Product

Event

Event

Gas Scavenge

4 sec.

4 sec.

De-pressurize time

2 sec.

2 sec.

REGULAR SEQUENCE

LONG SEQUENCE

5 gallon and 20 liter kegs

Up to 30 per hour

Up to 22 per hour

¼ barrel and 30 liter kegs

Up to 28 per hour

Up to 20 per hour

½ barrel and 50 liter kegs

Up to 25 per hour

Up to 17 per hour

Air Purge

Air Purge

CO2 purge CO2 pressurize

FILL HEAD

FILL HEAD OUTPUT

NOTE: Output is subject to keg, keg valve style, and wash sequence used.

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SQUIRE PLUS 2 OPERATIONS MANUAL

8.

SIMPLIFIED START–UP AND SHUT–DOWN PROCEDURES Refer to Sections #9 and #10 for more detailed steps. START UP 1. Turn on the CONTROL power supply 2. Open fresh water supply to STERILANT DOSING UNIT 3. Fill the DETERGENT TANK with cold or 120° to 150° F fresh water and dose with 2% v/v Caustic or a 50/50 blend of Phosphoric/Nitric cleaning agent at 0.3-0.5% v/v. If using cold water, turn on Heater to bring temperature up to required temperature. (120° to 150° F) 4. Turn on the Machine Control Air, Air Purge, CO2 or Nitrogen and Product supplies 5. Start the DETERGENT PUMP 6. Connect the wash coupler to a Keg (ensure any Cap is removed first) and place inverted Keg onto the wash platform 7. Push washer START button and wait for process to complete 8. Disconnect the W ASH COUPLER and replace it on the CLEANING CUP 9. Remove Keg and replace with another •

After the first Keg has been processed on the wash and fill heads, reject it and do not allow it to enter the full Keg warehouse. This will ensure that all the Machine systems were properly primed prior to commencing production

SHUT DOWN Perform these steps after the last keg has been processed and all work is completed for the day. 1. 2. 3. 4. 5.

Turn off DETERGENT PUMP and STERILANT supply Turn off the machine water, CO2 or Nitrogen, Air purge, and Product supplies Place the FILL CONNECTION HEAD into the CLEANING CAP and tighten clockwise Empty DETERGENT TANK Clean with CIP and outer surfaces washing NOTE: See Section 21, Appx. B – Complete Keg Washing & Filling Sequence Control Processes for full operations instructions.

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SQUIRE PLUS 2 OPERATIONS MANUAL

9.

KEG WASHING & FILLING PROCEDURES This section demonstrates the customer operation, without the PLC processes, so that Operator-only commands are clear. If you need trouble-shooting help to understand what is going on with the valves and PLC control, specifically, then you need to read APPX B – COMPLETE KEG WASHING & FILLING SEQUENCE CONTROL PROCESSES.

WARNING: DO NOT Hose Down Electrical Equipment Areas! This includes the pump motors, control panels, and electrical terminal boxes Daily washing of the detergent tank and pipes removes scum, scale, or any residuals that may have formed on the interior. KEG WASHING The wash cycle lengths may be selected from the Sequence Select switch, located on the side of the Control Panel. For specific Cycle Times, see Section 7. Unless specified otherwise, the washes are performed with High Flow, which sprays the inside of the kegs. You may wash a keg at the same time as you fill a keg, as the two systems are entirely separate. In order to control condensates and deposits, IDD suggests that you switch from Acid (0.5%) to Caustic (2%) every other month, as they may not be used simultaneously. This removes scum, scale, or any residuals that may have formed on the interior of the keg. Important: If this is the first time you are using the Squire system after shipment, perform a CIP to ensure that the filling side is clean and sanitized. See Section 10 - CIP. The entire wash process happens very quickly. Most of the valve switching and indicator light changes will occur too fast to follow until you are used to it. If the system stops working at any time during washing or filling, refer to the Rejected Keg Occurrence, page 34. 1. Check that services are hooked up correctly CO2 and Purge at 22-23 psig, Control Air at 80 psi, and Water at 15 gpm with 40-60 psi

2. Supply power to the system (208-240v, 1 PH, 60 Hz, 35 Amps)

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SQUIRE PLUS 2 OPERATIONS MANUAL 3. Turn on the machine air, air purge, CO2 or Nitrogen, and Product supply 4. Set up the wash tank for either Acid or Caustic detergent concentrations: • Acid: 50/50 blend of Phosphoric/Nitric cleaning agent at 0.3-0.5% v/v • Caustic: 2% v/v Caustic

Dual-Doser Option shown

5. Prepare the Detergent Tank with clean water: a. Fill tank with water (or fill with 120° to 150° F water) b. Turn on tank heater at Motor Control Panel (Top) c. Set the Heater temperature gauge between 135-155° F (light remains lit while heating)

6. Open fresh water supply to Sterilant Dosing Unit 7. Connect bucket/container of Activated Oxine solution to manifold water dosing pipe Refer to the setup information provided in Section 12 – OXINE CLEANING/SANITIZING

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SQUIRE PLUS 2 OPERATIONS MANUAL 8. Set Sequence Select knob on side of Control Panel to 1 (Short wash), or 2 (Long wash), for dirtier kegs The Long Wash rinses and cleans for longer than the Short Wash (See SECTION 7 – CYCLE TIMES)

9. Wait for water to be heated within the required range before continuing

10. Prepare the keg: a. Set keg upright on ground (remove any keg cap, if necessary )

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SQUIRE PLUS 2 OPERATIONS MANUAL b. Lean keg top against padded rack bar c. Pull the wash coupler off the cleaning cup and attach to the keg •

Half-turn counter-clockwise and lift, then push with a half-turn clockwise to secure

d. Push the fill handle fully down, into lock position (Handle fully down opens to keg) •

Pull trigger and depress the handle fully, until it’s in the locked down position, then release

e. Flip keg over and place upside-down onto the wash platform

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SQUIRE PLUS 2 OPERATIONS MANUAL

11. Start the detergent pump from Main Control Panel (top) by switching to ON

12. Press START on the Control Panel Washer button to start the Controller / PLC process:

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SQUIRE PLUS 2 OPERATIONS MANUAL a. The Wash SEQUENCE lamp turns on b. The PLC Wash sequences occur . You may see indicator lights and yellow valve indicators switch several times during this process c. The Wash SEQUENCE lamp turns off at PLC process end

13. Flip the keg over and place on ground

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SQUIRE PLUS 2 OPERATIONS MANUAL

14. Unhook the Wash Coupler from the keg: a. Pull trigger and lift the handle until it’s fully in the up position

b. Twist counter-clockwise and lift to unlock from keg (Partially pressurized Oxine solution will spray from connection, so do this slowly or lay it against the padded strut. Solution remaining on Spear Valve is all right)

c. Place coupler back on the Cleaning Cup

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SQUIRE PLUS 2 OPERATIONS MANUAL 15. Cap the washed and pressurized keg and store or fill, as needed 16. After an hour of washing, check the Ph. Levels in the Detergent Tank. You may need to drain some diluted detergent to maintain proper Ph. levels by doing the following: a. Locate the Drain Pipe valves on the bottom of the Acid/Caustic detergent tank b. Close the Bleed Valve (bottom-most – in closed position it has been designed to dribble) c. Open the Drain Valve (top-most) Notes: During washing cycles, this is may be opened after an hour of washing to maintain Ph., or it can be left open for the entire washing cycle. New detergent and water are mixed and introduced into the tank when the float drops below a certain point. If this is left closed, be sure to test your Ph. often during the washing process to determine if you need to drain some detergent and introduce fresh water and detergent to maintain correct Ph. The Drain Valve seals the pipe entirely, while the Bleed Valve allows a small dribble of liquid to escape. Having both open drains the tank in short order, while with the Bleed Valve closed, it allows small amounts of detergent water to escape, in order to maintain Ph. levels when it’s diluted over long periods of wash time.

17. Do one of the following to continue: • To Wash A New Keg - Return to STEP #10, above • To End This Process - Go to END OF DAY CLEANING • To Fill The Keg - Go to KEG FILLING

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SQUIRE PLUS 2 OPERATIONS MANUAL END OF DAY CLEANING 1. The End-Of-Day process begins 2. Turn off detergent pump and sterilant supply 3. Turn off the machine water, CO2 or Nitrogen, Air purge, and product supplies 4. Empty Detergent Tank by opening both Bleed and Drain valves 5. Flush out with cold water

WARNING: NEVER WET electrical panel interiors, such as the MCC PANEL, CONTROL PANEL, or the HEATER CONTROL, shown below.

6. Clean the outer surfaces of the Squire: a. Wash with warm soapy water b. Scrub with a soft brush to clean surfaces c. Rinse Squire by hose with LOW water pressure 7. Air dry or wipe down with chamois or other soft cloth 8. On the drain pipe valves, close the Drain Valve (top-most)

9. The system is ready for a new day

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SQUIRE PLUS 2 OPERATIONS MANUAL KEG FILLING For first-time users who have the FILL BY W EIGHT option, read the FILL BY WEIGHT OPERATIONS MANUAL before continuing this section. 1. Attach Product 1.5” Bright Tank Hose to the Product Pump

2. Ensure the Control Panel Rack/CIP switch is set to RACK

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SQUIRE PLUS 2 OPERATIONS MANUAL

3. Ensure the Drain valve is open and CIP Return valve is closed

(CIP hose shown attached, below)

4. Place a keg upright on the floor, a pallet, or the weight sensor

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SQUIRE PLUS 2 OPERATIONS MANUAL 5. Place Product filling coupler on keg and depress the handle while pushing down, until it’s in the locked down position (Handle in fully down positions opens to keg)

6. Press Racker Start button • •

Pump is primed and PLC controlled fill begins The next few steps occur quickly

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SQUIRE PLUS 2 OPERATIONS MANUAL 7. The Product Pump turns on and Product valve opens, filling the keg

8. Set Back Pressure Regulator (FOB) to pressure desired, + 20 psi (e.g. If 15 is needed, set to 35) • • •

The regulator only functions during a fill. Once set, it should maintain proper pressure FOB = Foam Off Beer Back Pressure Regulator Pressure should be ±30 psig (Product temperature and CO2 pressure dependent)

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SQUIRE PLUS 2 OPERATIONS MANUAL

9. Racker Drain turns off and FOB turns on after a delay (about five seconds), to vent back pressure CO2

(Arrows Indicate air pressure in and air out)

10. Product fills the keg (Hissing may be heard from the Fill Drain as the product displaces CO2 from the keg)

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SQUIRE PLUS 2 OPERATIONS MANUAL 11. When the Infrared Liquid Sensor detects product in the Drain Pipe, the Product Pump is stopped, Product and FOB valves are closed, and the Racker Drain turns on Note:

For systems with the optional weight sensor, the pre-set keg weight trips the filler to stop the process. The infrared liquid sensor acts as a backup to this.

12. Lift the Coupler handle but do not remove it (Handle up opens product in hose to drain hose, bypassing keg)

13. Continue with KEG SCAVENGE SEQUENCE, below

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SQUIRE PLUS 2 OPERATIONS MANUAL

KEG SCAVENGE SEQUENCE 14. Press the SCAV button on the Main Panel

15. SCAV valve opens and Racker Drain valve turns off. CO2 blows left-over product out of fill hose, coupler, and overflow hose, through the drain pipe

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SQUIRE PLUS 2 OPERATIONS MANUAL 16. SCAV stops after a pre-set time 17. SCAV valve closes and Racker Drain turns on

18. Racker Drain remains open for two more seconds, to depressurize coupler and hoses

(no blowback)

19. Remove Product Coupler with a half-turn counter-clockwise and secure to Product Cup

20. Replace the filled keg with a sterilized empty until all product is used 21. When all filling is done for the day, go to Section 10 – CIP PROCEDURE IMPORTANT: After the First Keg has been processed through both the wash and fill sequences, remove it and do not allow it to enter the full Keg warehouse. This will ensure that all the Machine systems were properly primed, prior to commencing actual production. Return this keg to be washed and filled again.

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REJECTED KEG OCCURRENCE This does not happen often and is typically an issue with the Infrared Liquid Sensor, as described in TROUBLESHOOTING. 1. The PLC stops, “rejecting” the current keg, and ending the entire sequence 2. The sequence lamp will continuously flash to warn the operator of an error 3. Operator resolves issue and presses STOP button to acknowledge and shut off warning 4. Pressing START causes the process to begin from KEG WASHING, step #12

Rejected Keg STOP & START for Washing processes

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10. CLEANING IN PLACE (CIP) PROCEDURE Perform these procedures when all kegs have been washed and filled, typically at the end of the day.

WARNING: DO NOT Hose Down Electrical Equipment Areas! This includes the pump motors, control panels, and electrical terminal boxes CIP SEQUENCE – PRODUCT FILLING SIDE This process cleans only the product side routes. Perform this when first using the Squire Plus 2 and whenever the product filling side requires cleaning. Cleaning the pipes removes scum, scale, or any residuals that may have formed on the interior. If this is the first time using the system, you may skip the WATER FLUSH and continue to Caustic FLUSH.

WATER FLUSH 1. Switch on the Product Pump, if needed 2. Ensure the Drain Valve is open 3. Attach water to the Product Pump with a 1.5” Bright Tank Hose 4. Change the Control Panel RACK /CIP switch to CIP to flush product residuals from the system 5. PLC opens the Product and Filler Drain valves o Pump turns on, flushing water through the fill system and exiting the Drain Valve 6. Stop water flow by switching the Control Panel RACK/CIP switch back to RACK 7. PLC closes Product and Rack Drain (R Drain) valves

CAUSTIC FLUSH 8. Attach the separate CIP tank to the Product pump with the 1.5” Bright Tank Hose • Ensure CIP caustic detergent is set at 2 to 3 % caustic, and is at 160° F 9. Connect the return line to the CIP Return Valve for CIP recovery 10. Flush water to drain: a. Change the Control Panel RACK /CIP switch to CIP to flush water b. PLC opens the Product and Filler Drain valves 11. Run detergent until the water is flushed out, then; a. Open the CIP Return Valve (first pipe and valve) b. Close the Drain Valve (bottom most valve) o o

Now the CIP detergent flows through the Product valve, across the connection head, and then recycles through the CIP Return valve The Operator determines exactly how long they wish to run the detergent, but IDD suggests a minimum running time of 20 min.

12. Stop detergent flow by switching the Control Panel RACK/CIP switch back to RACK 13. PLC closes Product and Rack Drain (R Drain) valves

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OXINE FLUSH 14. Attach Oxine to the Product pump and Prime the system with 50 ppm Oxine in water 15. Flush residual detergent and sanitize the system: a. Close the CIP Return Valve (first pipe and valve) b. Open the Drain Valve (bottom most valve) 16. Change the Control Panel RACK/CIP switch to CIP 17. PLC opens the Product and Filler Drain valves: o o

Pump turns on, moving Oxine through the fill system and exiting the Drain Valve The Operator determines exactly how long they wish to run Oxine, but IDD suggests a minimum running time of 3 min.

18. Stop Oxine flow by switching the Control Panel RACK/CIP switch back to RACK 19. PLC closes Product and Rack Drain (R Drain) valves 20. System is ready for new product fills

EXTERIOR CLEANUP Clean the outer surfaces of the Squire.

WARNING:

DO NOT get electrical panels interiors, such as the MCC Panel, Control Panel, or Heater Control, wet.

1. 2. 3. 4.

Wash surfaces with warm soapy water Scrub with a soft brush or sponge Rinse by hose with LOW water pressure Air dry or use a chamois or other soft cloth

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11. PLANNED MAINTENANCE Performing the following inspections can prevent many issues. Be sure to turn off the water supply before servicing the system and be sure that replacement parts have been installed according to supplied drawing specifications. Refer to APPENDIX A – IDENTIFYING & ANALYZING PROBLEMS, for any problems encountered. DAILY: • • • •

Clean machine after use (See SECTION 10, EXTERIOR CLEANUP for details) Check and monitor service pressures and temperatures prior to and during operation per operations manual Monitor pH levels of detergents (See SECTION 9, STEP 16 for details) Check the keg couplers, spear adaptor, and locking mechanism in the handle for damage. Damage may be transferred to the keg valve seal; Change damaged parts as necessary.

WEEKLY: • • • •

Check head seal connections and “O” rings for wear and damage. Replace as necessary Check for leaks on all service lines and unions. Replace seals and/or tighten as necessary Check for loose hardware. Tighten as necessary Check for loose wire terminations. Tighten as necessary

MONTHLY: • • • • •

Check dosing units for accuracy and operation in line with operations manual recommendations. Adjust if necessary Check Infrared Liquid Sensor for cleanliness and good operation by removing from pipework and verify sensor tip is clean and polished. Clean and/or replace if necessary Clean out all airline filters and drain any condensate Check all push-button switches and indicator lamps for damage. Replace as necessary Check all spare parts inventory levels. Replace as necessary. (See APPENDIX C –SPARE PARTS)

QUARTERLY: • • • • • •

Check pressure gauges for accuracy. Adjust and/or replace if necessary Check the transfer system alignment and keg placement over the connection heads. Lubricate, make adjustments, and replace worn parts as necessary Check all hoses for leaks and/or wear. Replace as necessary Check tri-clover seals for wear and/or damage. Replace as necessary Check all electrical power connections and motor overload settings. Reset if necessary Check pumps for leaks

YEARLY: • • • • •

Check process valve, seats, “O” rings, and seals for wear and damage. Replace as necessary Inspect pump seals for wear or damage. Replace as necessary Inspect all air cylinder seals for wear and/or damage. Replace as necessary Check nylon air lines for leaks and continued flexibility. Replace as necessary Check all solenoid valves for proper operation. Replace if necessary

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12. QUALITY CONTROL Quality Control (QC) is a system of maintaining set standards, by testing output samples against specifications. Continued inspection and corrective actions will maintain the desired level of quality in the Product and reduce manufacturing errors. Ensure that the keg machine functions properly and the five cleaning and test procedures listed below (A through E), are effective. A – DETERGENT TANK TITRATION Perform these steps as noted below, to ensure quality control. The detergent set, detergent tank(s), and QC checks should all be made before starting an operating shift. It should also be checked at least twice during each 8-hour shift. Adjust frequency to meet the QC department comfort level. • The acid titration level (phosphoric) range should be between 0.25% to 0.4% v/v • The alkali titration level (caustic) range should be between 1.5 to 2.5% v/v B – KEG W ATER CARRY-OVER AND TITRATION CHECKS Carry out this check once a day, and then reduced to the QC department comfort level frequency. 1) Complete the entire wash head and sanitizing sequences. Allow it to continue through the sterilizing sequence and then reject (stop) it immediately prior to commencing the racking head sequence. At this point, perform the following: a) Cool the keg by placing a cold water hose around the outer surfaces b) Tap the keg with a QC Sample or Funnel Coupler • Invert the keg in order to remove the contents via the CO2 port of the coupler • Allow the keg to drain or force out contents with air or CO2 • The condensate or rinse residuals in a 50 liter or 1/2 barrel keg normally measures between 40 to 80 ml. A limit of 100 ml. should be set as the maximum allowable limit 2) Titrate test the condensate obtained from the keg to ensure that there is no acid and/or alkali carryover from the wash head • If steam is used for purging, it’s Ph. must be a known factor 3) Repeat the checks: a) Get a new keg and allow it to complete the sequences through the racker head b) Run and complete the wash and sanitizing sequences c) Reject the keg prior to starting the beer filling sequence d) The quantity of condensate present in the keg should be less than 15ml C – MICROBIOLOGICAL CHECKS Perform these steps at least once every two weeks, to ensure quality control. Methods of performing a microbiological integrity check vary slightly. The main objective is to ensure that consistency in sampling is maintained i.e. Having introduced the sterile liquid into the keg, each keg should be rotated a set number of times to ensure all surfaces have been covered equally before it is extracted. A known quantity should always go into the keg and a known quantity should always be extracted, filtered and plated.

1) Into a washed and sanitized keg, introduce a liter of sterile liquid (preferably beer), via a sterilized Keg Valve and Funnel Coupler 2) Remove 250 ml. of the liquid into a sterile flask 3) Split the sample into two 100 ml. samples, via Millipore Type Membranes 4) Plate and incubate the membranes on agar suitable for aerobic and anaerobic organisms 5) Check for growth

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SQUIRE PLUS 2 OPERATIONS MANUAL D – CIP SEQUENCE Perform these steps at least once a week, to ensure quality control. 1) Perform a CIP sequence 2) Check the following to ensure that cleaning operation frequencies are effective and adequate: a) Swab the Process Mains, Bright Beer Tank, and Racker Connection Head b) Visually inspect the Process Mains, Bright Beer Tank, and Racker Connection Head E – BEER STABILITY SAMPLING Samples will be taken from a filled keg of beer set aside from the keg line for testing. Remove these samples from the B.B.T. and keg at a frequency set by the brewery QC department standards. 1) Remove a test keg from the line and allow it to stand for 5 to 10 minutes a) Ensure pressure in the keg is approximately 75% of the counter pressure used during the latter part of the filling sequence b) Sterilize the Keg Neck and Pressure Test Coupler 2) Connect the Pressure Test Coupler to the Keg Neck while maintaining the sterile area 3) Force the contents by leaving the keg in a 70°F (21°C) environment for 72 hours 4) Perform the QC standard taste, odor, and clarity tests 5) Take other taste, odor, and clarity tests at regular intervals, as stated in the Q.C. standards NOTE: Funnel, Sample, and Pressure Test Couplers may be purchased from IDD to suit your specific keg valve type. SUMMARY Use the aforementioned tests to determine that these points about the keg machine function and cleaning procedures are occurring properly. • • • • • • •

On the wash head(s), the wash water and detergent is being cleared from the keg during the final steam purge, or CO2 purge sequence The final keg rinse on the wash head(s) removes residual detergent adequately The CO2 purge removes condensate traces from the keg on the racker head prior to filling Microbial integrity, via Oxine (ClO2) or steam sanitizing of the keg, is achieved The cleanliness and microbial integrity is being maintained by the separate plant CIP regime The separate plant CIP sequence is effective in removing all traces of beer protein and other residuals from the keg plant connection head(s) and piping system(s) Verify the residual pressure in the keg after filling indicates that keg CO2 in solution is being maintained properly o If the pressure in the keg is above that of the filling counter pressure, then it is highly probable that the keg was overfilled and has created hydraulic pressure o When filling against a “backup” probe, this hydraulic pressure condition will be normal

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KEG LINE QUALITY ASSURANCE

QC/Sampling Coupler Used for removing samples from the keg under aseptic conditions American Sankey QC/Sampling Coupler: SA 35336 European Sankey QC/Sampling Coupler: SA 35266

Funnel Coupler Used for inserting samples into the keg under aseptic conditions American Sankey Funnel Coupler: SA 35338 European Sankey Funnel Coupler: SA 35265

Pressure Test Coupler Used for pressure testing the keg after filling American Sankey Pressure Test Coupler: SA 35337 European Sankey Pressure Test Coupler: SA 35267

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13. OXINE CLEANING/SANITIZING OXINE DILUTION AND USE If you must dilute Oxine manually, without a titration kit, the following information will be helpful. These figures are applicable with Oxine that has been activated within 48 hours of dilution with a food grade acid at 2.5 to 3 pH. IDD suggests you start sanitizing by using approximately 100 ppm of activated Oxine. Experience indicates that normal usage is in the 20-100 ppm range. Determine through your own QC procedures whether you need to increase or decrease the amount, based upon microbial test results. 1. 2. 3. 4.

Collect a one gallon container with a screw lid Remove the cap and drill a hole into it, large enough to fit the Dosing Unit Siphon Tube Pour in 20 ounces (0.6 liters) of Oxine Add in enough food grade acid and stir well, lowering the pH within approximately 2.5 to 3.0 pH CAUTION: Perform this task in a well-ventilated area and DO NOT breathe the fumes given off during activation. See the OXINE MATERIAL SAFETY DATA SHEET for more details

5. Wait 5-10 minutes until the Oxine completes activation and produces approximately 20,000 ppm of Activated Oxine 6. Add 3 liters (101 ounces) of water (a 5:1 ratio) and stir well to change it to approximately 4,000 ppm 7. Replace the cap with siphon tube attached and ensure it correctly feeds into the Oxine 8. Use the supplied OXINE DOSER VENTURI KIT chart and select the COLORED VENTURI that will give you a 40:1 reduction ratio 9. This now supplies approximately 100 ppm of Activated Oxine to the washing cycle as you rinse the keg(s) or sanitize water pre- and post-rinse •

The activated Oxine dilution can be verified with the OXINE TEST KIT or OXYSTIX, available from IDD Process & Packaging, Inc.

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OXINE & PUROGENE SANITIZER SUGGESTED USES The following information is offered as suggested uses of Oxine and Purogene and is not intended to be definitive or accurate for all applications. IDD Process & Packaging, Inc. does not accept any liability for the use or application of Oxine or Purogene. Oxine and Purogene – Sanitizers for all reasons For years it has been known that chlorine dioxide gas is a powerful anti-microbial agent. However, this gas is toxic and unstable in an aqueous solution. Modern technology has overcome these problems with Oxine and Purogene. Today, stabilized chlorine dioxide (ClO2) is available in a concentrated stable form with very low toxicity. As a powerful oxidant, stabilized ClO2 is virtually unaffected by organic load and hard water. These technical advances have resulted in the FDA, EPA, and USDA approving stabilized ClO2 as an acceptable sterilant for numerous applications within the brewery, dairy, and food processing plants.

Properties The properties which make stabilized ClO2 most attractive to the brewer, maltster, and other beverage plant operators are as follows (in no particular order): LOW CORROSIVITY - Stabilized ClO2 is not harmful to vessels or piping systems when used at the recommended dosages. Typically, brewers like the effectiveness of hypochlorites but a major drawback is hypochlorites’ role in causing stress corrosion fatigue in stainless steel, particularly at weld joints. Stabilized ClO2, which is 4 to 7 times more effective as a sanitizer than hypochlorite, does not enhance or contribute to “stress corrosion fatigue” in the metal. Stabilized ClO2 is only slightly more corrosive than tap water and much of this is due to the acid used to activate the product. When it is a 10 ppm solution used as a final rinse in vessels or piping systems, ClO2 is perfectly safe to leave un-rinsed in a tank, pipe network, or piece of process equipment (i.e. bottle fillers, keg racking machines, sheet or pressure leaf filters, etc.). LOW ODOR - Unlike typical sanitizers such a hypochlorites, quaternary ammonium, or even peroxy-acetic acid, stabilized ClO2 has an almost undetectable odor, all the while surpassing the bacteriocidal efficacy of these other compounds. Hypochlorites can form chlorophenols (a medicinal flavor compound) when combined with organic material in beer: Quaternary ammonia compounds have well-known negative effects on flavor; the end product of the reduction of peroxy-acetic acid is acetic acid, with its typically "vinegar-like" character. Even a small amount remaining in a tank that comes into contact with beer can have a deleterious effect on the flavor. EASE OF HANDLING - While iodophors, peroxy-acetic acid and hypochlorites are popular sanitizers for tanks, fillers, and other equipment, they have some handling drawbacks. Iodophors are really only effective at low pH, thus they are typically carried as a concentrate in a solution of phosphoric or nitric acid, which makes them hazardous to handle. Iodophors also have a tendency to stain equipment (and people). Pereoxyacetic acid is quite volatile at moderately elevated temperatures (120°F/50°C) and can cause spontaneous explosions. In its concentrated form, it is corrosive . Hypochlorites as chlorine gas have a short-term exposure limit slightly higher than that of stabilized ClO2 (1.0 ppm versus 0.3 ppm, respectively). However, since stabilized ClO2 is 4 to 7 times more effective than hypochlorites at normal use levels, it is far less hazardous. NO ENVIRONMENTAL IMPACT - Stabilized ClO2 does not form the highly carcinogenic trihalomethanes as do hypochlorites in the presence of organic materials. Oxine is environmentally- and user-friendly and has been accepted by the EPA has having no environmental impact upon disposal. It is not corrosive nor is it volatile in its concentrated (2%) form. EFFICACY - Stabilized ClO2 does not act by chlorination but by oxidation and has proven effective against all common brewery, winery, and beverage plant microorganisms. It is an effective bacteriostat at use rates as low as 5 to 20 ppm, against such common pests as Lactobacillus and Pediococcus sp. It is an effective bacteriostat at 50 ppm against wild yeasts and mold strains. MEASURING - As with all gaseous products such as stabilized ClO2, Oxine can be monitored by using a standard gas monitoring system such as those supplied by LAB SAFETY SUPPLIES COMPANY. Their toll-free telephone number is (800) 356-0722. It is necessary to have good ventilation during the activation process of Oxine and to monitor gas levels for your safety records.

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SQUIRE PLUS 2 OPERATIONS MANUAL IDD recommends that the chlorine "low range" (0.05 to 16ppm) tube be used to monitor gas levels. These tubes readily detect and measure all types of inorganic chlorine.

Uses In Brewing The brewing uses for stabilized ClO2 are numerous, as follows: Malthouse: Stabilized ClO2 is an effective wash-down sanitizer for walls, floors, germination areas, and steep tanks. At 100 to 500 ppm it will kill and bleach out mold and mildew common to these high-humidity areas. Stabilized ClO2 has been successfully used in barley steep waters to inhibit microbial growth of all types. Typically at 10 to 50 ppm, depending on the microbial load, one can assure a safe re-cycling of the steep water into subsequent batches. Stabilized ClO2’s strong oxidizing capability actually reduces B.O.D. loads for disposal.

Brewhouse: Safe for all vessels and piping systems, whether copper or stainless steel, stabilized ClO2 can ensure a microbial free environment in coppers/kettles, mash filters or lauter tuns, swirl tanks, settlers, and wort cooling systems when used at 50 to 100 ppm. The related piping systems for wort transfer to fermentation areas can be sanitized at 100 ppm. It is also safe to leave a 50 ppm solution in pipelines to keep them sanitized during periods of nonuse. Fermentation/Storage Areas: A 50 ppm solution is adequate to sanitize tank walls and related piping systems. Since low levels of contact with finished product do not effect final beer flavor, brewers can safely use stabilized ClO2 in a final rinse and be able to obtain some residual bacteriostatic value. It is recommended that boots, gloves, yeast-handling tools, and the like be sanitized at 100 ppm. Stabilized ClO2 at 100 ppm is ideal for foot baths at or near tank entry areas. Filtration: Stabilized ClO2 is particularly useful for stabilizing and sanitizing filter systems. It can be used to shock-sanitize activated carbon and sand/gravel filters in water treatment facilities. Typically, a 50 to 100 ppm solution is run slowly through these type filters. Stabilized ClO2 will not be absorbed significantly by the active carbon. Once the bed is sanitized it is then possible to dose Oxine into the water stream, prior to the filter bed, at a concentration of 1 to 5 ppm in order to prevent future contamination. Plate-and-frame filters can be sanitized with a 10 to 50 ppm solution without the typical water flush/rinse required by acid-sanitizers and the like. A standing solution of up to 10 ppm can be left in a filter during periods of non-use with no harm to the filter frame or the sheets. A solution of the same strength sprayed over the outer exposed edges of the filter sheets will prevent mold growth when standing. It is recommended that this procedure be carried out after any normal beer filter use to inhibit the growth of yeasts and bacteria, since residual beer on the sheets makes for an ideal growth media. Active Carbon Bed (ACB): Infected ACB's can be back-flushed and soaked in a 100 ppm solution of ClO2 for 15 to 60 minutes, after which time a forward flush-out of 15 to 30 minutes with the process water can take place. It is then advisable to inject 1 to 3 ppm of activated ClO2 into the process water stream thereafter, prior to the ACB to prevent future infections. Packaging: •

Stabilized ClO2 provides a safe sanitization and soaking solution for keg washer rackers, bottle fillers, and can fillers. Sanitize at 50 ppm and soak or stand filler bowls in cold water at 10 ppm



To enhance beer flavor, use 20 to 50 ppm of stabilized ClO2 as a final cold rinse for aseptic keg, bottle, and can rinsing, immediately prior to filling



The use of stabilized ClO2 as an aseptic "fog" spray around aseptic bottles and can fillers is highly effective at 10 to 20 ppm as both a sanitizer and microbial preventative



The non-corrosive nature of stabilized ClO2 makes it an ideal growth inhibitor in tunnel pasteurizers. Stabilized ClO2 is most effective in the moderate temperature zones (warm-up and cool-down fresh

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SQUIRE PLUS 2 OPERATIONS MANUAL water zones) of the pasteurizer. A 20 to 30 ppm solution is normally adequate and safe on equipment Tank-Truck Washing: As in the typical use for tank washing and sanitizing, stabilized ClO2 can be used for the sanitization and cleanup of bulk tankers and related pipes and hoses. Wash down tank internals, pumps, and hoses at 100 ppm, externals at 250 to 500 ppm. This will prevent transfer of micro-organisms to or from the connecting systems. Washing Of Yeast Slurry With Stabilized CLO2 (Oxine): Stabilized ClO2 (Oxine) will effectively kill unwanted bacteria in yeast at 20 to 40 ppm, while leaving the culture yeast unharmed. Because of stabilized ClO2's unique action, it does not have the drawbacks of phosphoric acid because it does not form chlorophenols (which contribute to a much feared medicinal character in beers) in the presence of organic materials. Mold And Mildew Cleanup And Control: Clean off walls and floors as well as air handling units and machinery using a 200 to 500 ppm solution of stabilized ClO2. This effectively kills mold and mildew spores while still retaining some bleaching ability to remove the tough, black stains. This is good procedure prior to painting, or prior to the application of a mold and slime growth inhibitor such as Alltech's Mold-Zap. Process Water Treatment: The FDA has approved stabilized ClO2 for process water sanitization at between 100 to 200 ppm available ClO2. Potable water treatment is approved for human consumption at 4 ppm available ClO2 . Glass Washing/Rinsing: Even at the final stage of the brewer's trade, where bars and pubs have a need for an effective and safe drinking-glass sanitizer, stabilized ClO2 can fill the need. Since stabilized ClO2 can be safely consumed at 4 ppm, it makes an ideal glass rinse. Unlike typical quaternary ammonium rinses, it will not have any deleterious effect on beer flavor, nor on beer foam quality. Use at 20 to 50 ppm in final rinse water.

W ASHING METHOD: Normally, an initial washing at 20 to 40 ppm (20 ppm for homogenous yeast, 40 ppm for "clumpy" or highly flocculant strains) is effective against most Lactobacilli and Pediococci species. This "wash" is accomplished by adding stabilized ClO2 directly to yeast slurry on a volume/ppm basis. It does not need to be activated as the pH of the yeast slurry is low enough to convert to ClO2. Stabilized ClO2 is supplied at a concentration of 20,000 ppm or 2% Chlorine Dioxide when activated. Therefore, on a volume basis with one gallon of stabilized ClO2 concentrate, can be made one thousand gallons of solution at 20 ppm. By this method, we can also assume with one gallon of concentrate to make up one thousand gallons of yeast slurry at 20 ppm. It is impractical to measure the concentration of ClO2 in the presence of yeast, so the dilution must be made based on the strength of the concentrate. Yeast slurry should be thin enough to allow for homogeneous mixing, usually 20 to 40% solids. The killing action of stabilized ClO2 is very fast compared to the traditional phosphoric acid wash with only 15 to 30 minutes needed for the full bactericidal effect of stabilized ClO2 to occur, with no resultant stress on yeast cells. DOSING RATE – NORMAL W ASH: For regular washing of homogenous recycled brewer’s yeast, only a 20 to 40 ppm wash for a minimum of 30 minutes to 5 hours prior to pitching is required. Mix 1 to 2 ml of stabilized ClO2 concentrate with each liter of yeast slurry and agitate thoroughly during this process.

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CIO2 ACTIVATION ACTIVATE CONCENTRATE: Since ClO2 in concentrate is in a stabilized form, it must be "activated" before use, but this must be performed in a well ventilated area. Activate Oxine by adding acid to lower the pH to below 5 pH. Activation can be verified by a corresponding color change of the concentrate from clear to yellow/green. Any number of acids will activate the stabilized ClO2 , however, food grade Citric or Phosphoric acid is recommended for this application. Normally it requires up to 200 grams of Citric Acid to activate one gallon of stabilized ClO2 concentrate (up to 50 grams per liter of stabilized ClO2 concentrate). Replacement chemicals for your Oxine Test Kits, with important details, are as follows: o 0.00564N PAO (Phenylarsine Oxide) o

0.2N Hydrochloric Acid. Add 16.6 ml Concentrated HCL (39%) to 800 ml water. Bring to 1,000 ml with water

o

10% Potassium Iodide. 100 g diluted to 1,000 ml with distilled water

The following are available for purchase from IDD: o Test kits o

Replacement materials

o

Oxine in 1-, 5-, 30-, and 55-gallon containers

Storage: • Concentrated ClO2 should be stored in dry areas, away from acids. It may last for up to three years under standard conditions •

Activated ClO2 has a half-life of approximately 48 hours under standard conditions



Activated ClO2 can be added to cold water at 4,000 ppm and will have a half-life of approximately two weeks under standard conditions

Automatic Activation Systems: A series of low cost, hands free, automated activation systems are available to provide a continuous volume of activated ClO2 into a storage reservoir to be available as needed. These systems eliminate the need for manual mixing, measuring, and dispensing.

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OXINE MATERIAL SAFETY DATA SHEET

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SYSTEM DETAIL INFORMATION 14. PLANT LAYOUT SQUIRE PLUS 2 LAYOUT

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15. FLOW DIAGRAM

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16. ELECTRICAL Important Electrical Notes: • • •

Customer to supply local disconnect and ground fault device A surge protection device for the system’s power supply is highly recommended During installation, all electrical connections must to be securely fastened before power is turned on

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J.G.

12/13/04

O.M.

8/24/13

SQUIRE PLUS 2 MCC PANEL 230V-1PH-60HZ SUPPLY ME F 00183 6

A

NONE

1

NOTE: MAIN DISCONNECT & FEEDER CIRCUIT PROTECTION PROVIDED BY OTHERS.

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1

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17. MECHANICAL EURO & AMERICAN SANKEY KEG VALVE FLOWS

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ARES VALVE – INSTALLATION & MAINTENANCE MANUAL Features The 2/2 Assured Automation Angle Valves are pneumatically operated and extremely reliable. They guarantee a high number of working cycles, bubble tight sealing, and are equipped with a selflubricating and self-adjusting plug-stem set that automatically adjusts itself as it wears. They are also supplied with a scrapper to avoid the introduction of foreign bodies in the sliding area. The self-aligning plug, with a seal in PTFE, guarantees tight closure even in the most arduous conditions. The ARES stainless steel (AISI 316) valves are guaranteed high compatibility with most media and is equipped with an actuator made in engineering resin.

Installation: Installation must be carried out by qualified personnel. There are different versions of the Assured Automation Angle Valve and the preferred flow direction. For this reason it is necessary to carefully read all the information contained on the label. In particular: Temperature of media, pressure (both controlling and intercepting pressure) and direction of flow. 1. 2. 3. 4.

Before starting valve installation, de-pressurize the system Clean all pipes to avoid seal damage. Remove welding particles, residue, or dribble Connect the pipes according to the reference points (flow direction) found on the valve body Depending on the valve use, slightly lubricate the male end of the threaded pipe • DO NOT lubricate the threading on the female end of the pipe • When tightening, DO NOT use the valve as a support and DO NOT over-tighten Note:

Angle Valves may be installed in any position, because the adjustable control head can turn 360˚, to facilitate access to the control ports. The connection to such ports (power supply and discharge) depends on the valve model (whether it is N.C or N.C. or D.A.) and must be carried out following the appropriate procedure for each version

Application Guidelines Control Media: Dry, filtered compressed air (or other neutral gasses,) not necessarily lubricated Pressure: 11 PSIG to 150 PSIG (0.8 bar to 10 bar) (see sizing charts) 61 PSIG (4.2 bar) to 116 PSIG (8 bar) (spring return) Temperature: 14˚F to 140˚F (-10˚C to 60˚C) (PA66 control head) 23˚F to 266˚F (5˚C to 130˚C) (PPS optional) Working Media: Air, water, oil, petrol, saline solution, steam, etc. (any substance that is compatible with AISI 316, PTFE, or Bronze RGB) Pressure: 0 to 232 PSIG (0 to 16 bar) (see sizing charts) 0 to 150 PSIG (0 to 10 bar) (for steam) Temperature: 14˚F to 356˚F (-10˚C to 180˚C) Maximum Viscosity: 600 cst (mm2 /s) Media Direction: See FUNCTIONAL DIAGRAMS, next

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Functional Diagrams

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MAINTENANCE: SAFETY Before starting any maintenance procedure, be sure to take the following precautions, in order: 1. Ensure you have protection: • Wear protective eyewear • Wear coveralls, gloves, and a helmet (if needed) • Ensure that there is running water available nearby 2. Ascertain the nature of the media as benign, polluting, corrosive, flammable, or in any other way dangerous to handle • Take proper precautions for dangerous media, as needed • When using flammable media in the valve, position the correct fire extinguisher type near at hand 3. Make sure there is no pressure in the system, both before and after the valve position, and isolate the valve for safety 4. Disassemble the valve and perform needed maintenance (see Parts Replacement, below) PREVENTATIVE MAINTENANCE • Follow the above precautions • Test the valve at least once a month to verify that it opens and closes correctly • Regularly verify the state of all connections for both incoming and outgoing media The maintenance of each valve depends on the conditions of its application. Valves should be cleaned and serviced regularly. During each procedure, it is necessary to check the state of each component to make sure that they are not worn out or damaged. Repairs are essential when one of the following occurs: • Unusual noises If any of these occur, the body of the valve • Dripping must be taken apart, the inside carefully • Reduced flow rate (under normal pressure) cleaned, and any damaged parts replaced. • Increased pressure drop PARTS REPLACEMENT: The essential spare parts for all Assured Automation ARES angle valves. used by IDD Process & Packaging, are supplied in a SPARE PARTS KIT listed below. 1. Unscrew the actuator sleeve from the valve body 2. Take the plug pin out 3. Extract the plug from the stem and clean all accessible parts 4. Change the Kit (plug, plug pin, sleeve gasket) a. Place sleeve gasket into valve body b. Re-attach the plug to the stem c. Caulk and Replace the plug pin 5. Screw the actuator sleeve back into the valve body 6. Check that there is no internal or external leaking 7. Check that the valve is functioning correctly 8. Return the valve to service ARES Kit KGJP1004

Size 1/2”

Head DN50

Part No. VA0167

This kit includes a sleeve gasket, plug, and plug pin. Assured Automation will not be held responsible for any damage or injury to people, things, or animals, due to improper use of the product, and declines any responsibility on repairs performed by third parties.

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PROCESS VALVE

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SOLENOID VALVE

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PINCH VALVE OPERATION PRESSURES Operating pressures for controlled material vary depending on sleeve elastomer and valve size, and can range from a moderate vacuum (up to 26" Hg) to a maximum of 90 psi when controlling with air. Required control pressure is normally 20 to 40 psi greater than the material pressure. Use of excessive actuation pressure (air or liquid) than that which results in complete valve closure will impact sleeve life. Use of actuation pressure above 90 psi is not recommended.

RECOMMENDED CONFIGURATION • Airpinch valves are normally open and require constant pressure for complete closure • Reduction or loss of control pressure allows the valve to open • In the event of sleeve failure, controlled material can enter the actuation system.

BACK PRESSURE SOLENOID

AIR PRESSURE REGULATOR & GAUGE

SHUTTER VALVE

PINCH VALVE

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TANK DOSING UNIT

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Call 805-529-9890 for current pricing.

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FLOAT VALVE WITH PROPORTIONER For the following, refer to the Tank Dosing Unit, Figure #1. PARTS LIST FOR TF0400: Item 1 2 3 4 5 6 7 8 9 10 11

Description Valve Assembly Proportioner with Backflow Preventer ¼” ID X 8’ Long Vinyl Supply Tubing & Foot Valve Assembly Float and Chain Mounting Bracket Ceramic Weight ½” ID X 3’ Long Vinyl Discharge Tubing Model 903 Foot Valve (Model 440-24 Only) Metering Tip Kit (61-9k for 440-23T) (100-15K for 440-23BT) Large Lt. Blue & Tan Metering Tips (For 440-24) Bracket Mounting Screws

Qty. 1 1 1 1 1 1 1 1 1 1 2

SYSTEM INSTALLATION 1. Valve Bracket and Proportioner Assembly: a) Attach mounting bracket to valve assembly with the two (2) screws provided b) Screw siphon breaker and proportioner to valve outlet c) Mount bracket to tank as shown d) Do one of the following: • •

Attach a garden hose to the valve assembly via the Inlet Garden Hose Adapter Remove the Garden Hose Adapter and mount the valve assembly directly to a 1/4" NPT pipe

e) Apply pipe dope and hand-tighten valve assembly f) Cinch down assembly with a wrench until tight but DO NOT OVER TIGHTEN! • Attach the plastic discharge tubing as supplied • Verify the pipe or hose outlet extends below the bottom of the float WARNING: Do not use Teflon® tape to seal internal plastic threads as the extra thickness of the tape may crack the plastic. You must use a non-welding liquid sealant. 2. Float Assembly: a) Set the pull wire in UP position b) Run the chain through the clip on the pull wire until the top of the float is 1-2 inches above the desired maximum water level c) Snap the bead into the clip to hold the chain in place. d) Cut off excess chain, if desired 3. Chemical Supply Assembly: a) Place the chemical container in a convenient location, and no lower than six feet below the valve, as greater lifts reduces injection capacity b) Measure the distance required for the Supply Tubing to reach the bottom of the chemical container c) Cut the Supply Tubing to a convenient length that allows it to extend from the bottom of the chemical container to the proportioner inlet barb without being lower than six feet PROCESS & PACKAGING, INC. www.iddeas.com

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SQUIRE PLUS 2 OPERATIONS MANUAL d) Slip the ceramic weight over the Supply Tubing so it rests on the Foot Valve e) Attach the required Metering Tip end of the tubing (see Chemical Injection Adjustments, below) f) Insert the foot-valve end of the tubing into the chemical container SYSTEM OPERATION 1. Turn on the main water valve • •

At least 15 PSI water pressure must be available to operate the proportioner As the tank fills, a certain amount of chemical concentrate will be drawn up thought the plastic tubing, based on the metering tip used, and mixed with the incoming water

2. When the fluid level in the tank reaches 1-2 inches below the top of the float, the valve should close 3. If the tank level drops more than roughly four inches, the valve will open

CHEMICAL INJECTION ADJUSTMENTS Refer to Tables 1, 2, or 3 below, for dilution ratios of various chemical viscosities.

CAUTION: Use care when handling hazardous chemicals • •

Specific Metering Tips are used to control chemical feed rates For very viscous products, the induction rates can be increased by substituting 1/2" ID inlet tubing. Be sure to leave a short piece of 3/8" ID tubing on the proportioner and foot valve barbs, as bushings Note: Induction rates are based on a water pressure of 40 psi 1 cps (centipoise) is equal to the viscosity of water 75 cps is approximately equal to the viscosity of 10-weight motor oil 200 cps is approximately equal to the viscosity of most dishwashing detergents

Table 1 440-23BT – White Proportioner with 1/4” Hose Barb Metering Tip Color Tan Orange Turquoise Pink Clear Brown Red White Green Blue Yellow Black Purple Gray No Tip

1 cps Oz/Gal 0.33 0.42 0.51 0.78 0.87 0.99 1.37 1.52 1.72 2.13 3.05 4.50 7.75 9.86 19.63

Injection Rates For Viscosities Shown 75 cps 200 cps Ratio Oz/Gal Ratio Oz/Gal Ratio 387-1 0.26 500-1 0.12 1090-1 307-1 0.32 430-1 0.17 735-1 251-1 0.34 382-1 0.19 676-1 165-1 0.56 230-1 0.3 422-1 147-1 0.67 192-1 0.33 391-1 129-1 0.74 174-1 0.37 345-1 93-1 0.91 141-1 0.44 289-1 84-1 1.04 123-1 0.48 264-1 74-1 1.22 105-1 0.52 244-1 60-1 1.27 101-1 0.54 239-1 42-1 1.71 75-1 0.56 229-1 28-1 1.96 65-1 0.57 224-1 17-1 2.4 53-1 0.59 217-1 13-1 2.54 50-1 0.63 204-1 7-1 3.16 40-1 0.67 190-1

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Table 2 440-23T – White Proportioner with 3/8” Hose Barb Metering Tip Color Clear Purple Yellow Green Pink Turquoise Black Gray Red Blue Brown White Orange Light Blue* Tan* No Tip

1 cps Oz/Gal 0.30 0.48 1.28 1.67 2.36 3.76 4.47 5.53 7.00 8.78 10.95 14.19 17.58 21.75 27.98 33.15

Injection Rates For Viscosities Shown 75 cps 200 cps Ratio Oz/Gal Ratio Oz/Gal 430-1 0.22 592-1 0.13 265-1 0.32 406-1 0.24 100-1 0.82 157-1 0.6 77-1 1.29 99-1 1 54-1 1.65 77-1 1.25 34-1 2.55 50-1 1.85 29-1 3.03 42-1 2.12 23-1 3.67 35-1 2.58 18-1 4.79 27-1 2.79 15-1 5.39 24-1 3.06 12-1 6.49 20-1 3.35 9-1 7.08 18-1 3.46 7-1 7.91 16-1 3.71 6-1 8.66 15-1 3.9 5-1 9.15 14-1 4.11 4-1 10.54 12-1 4.52

Ratio 864-1 524-1 212-1 128-1 103-1 69-1 60-1 50-1 46-1 42-1 38-1 37-1 35-1 33-1 31-1 28-1

* These tips are not included in the standard tip pack.

Table 3 440-24 – Blue Proportioner with 3/8” Hose Barb Metering Tip Color Clear Purple Yellow Green Pink Turquoise Black Gray Red Blue Brown White Orange Light Blue* Tan* No Tip

Oz/Gal 0.66 1.01 1.53 2.52 3.53 5.73 6.72 8.95 12.34 14.00 18.68 24.45 30.97 38.26 53.96 66.07

Injection Rates For Viscosities Shown 1 cps 75 cps 200 cps Ratio Oz/Gal Ratio Oz/Gal 195-1 .027 470-1 .14 127-1 .041 315-1 .33 83-1 1.03 124-1 .86 51-1 1.64 78-1 1.44 36-1 2.04 63-1 2.09 22-1 3.24 40-1 2.92 19-1 3.88 33-1 3.34 14-1 4.98 26-1 4.04 10-1 6.22 21-1 4.67 9-1 7.28 18-1 4.99 7-1 9.02 14-1 5.35 5-1 10.35 12-1 5.53 4-1 11.86 11-1 5.88 3-1 13.31 10-1 6.22 2.5-1 15.21 8-1 6.49 2-1 18.61 7-1 7.07

Ratio 903-1 393-1 148-1 89-1 61-1 44-1 38-1 32-1 27-1 26-1 24-1 23-1 22-1 21-1 20-1 18-1

* These tips are not included in the standard tip pack. Back To TOC

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ADJUSTABLE SINGLE STAGE INJECTORS MODEL TF0402S

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DETERGENT PUMP – NPE/NPE-F INSTRUCTION MANUAL

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PRODUCT PUMP – OPERATION MAINTENANCE, & PARTS LIST

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18. PNEUMATICS

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19. DIMENSIONS

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20. I/O LISTING 00000

INPUTS

10000

OUTPUTS

002

WASH START

100

WASH DRAIN

003

WASH STOP

101

PURGE

004

FILL START

102

WATER RINSE

005

FILL STOP

103

DETERGENT RINSE

006

SCAVENGE START

104

DETERGENT RETURN

007

LIQUOR SENSOR

105

CO2 PURGE

008

PRODUCT SENSOR

106

PRODUCT

009

CIP

107

FOB

010

RACK

108

CO2 SCAVENGE

011

N/A

109

FILL DRAIN

012

SPARE

110

LOW FLOW

013

SPARE

111

SEQUENCE LAMP

014

CYCLE (OPT)

200

N/A

015

KEG SIZE SELECT

201

N/A

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GENERAL INFORMATION 21. APPENDICES Appx. A

IDENTIFYING AND ANALYZING PROBLEMS

The following are presented as a checklist for safety or if you’re experiencing issues while using the kegs. For problems which cannot be resolved or determined, please call IDD for help. COMMON QUESTIONS What pressure should my Controlled Air be?

What pressure should my Water be?

What should my Air Purge and CO2 pressure be? How Do I know my Caustic/Acid Ph. is correct? or How do I know my Oxine is mixing correctly?

ANSWERS

STILL AN ISSUE

Air should be at 80 psi. This ensures it correctly opens the Process Valves Water pressure should be maintained between 40-60 psi at 15 gpm • If there are problems arising from irregular water pressure supplied by your city, consider getting a reservoir with a pressure regulator and/or a pump connection to the washer • Remember, if you change the water pressure, you may need to change the Venturi Tip to compensate • Connect with at least a ¾” hose 22-23 psig for Air Purge. 30 psig with a 1” regulator

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Use one or both to test with: • Use metering strips wetted directly from the washing side discharge pipe • Use metering strips directly into the detergent tank to test for correct Ph. • Use a titration test kit

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The Infrared Sensor Probe (sensor see’s liquid and shuts off) comes standard with the system. What Filler Sensor does my System have?

Why isn’t the Tank Washer connected to the Fill Side?

There is an optional Weight Filler (reaches selected weight and shuts off). With a weight filler, the infrared sensor becomes its backup. The Tank Washer only services the wash station and is not designed to be used as CIP, and does not connect to the keg fill side. • A separate CIP system is needed • This prevents contamination issues with fills

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SQUIRE PLUS 2 OPERATIONS MANUAL WASH SIDE

Kegs Are Rejecting

WHAT TO DO

STILL FAILS TO WORK

Wash Cycle Rejects Check for the following, in order: 1. Make sure the Water and Wash Drain solenoid lights are ON and the Water and Wash Drain valve yellow indicators are UP (If they are, see #4, below) 2. If the Valve’s yellow indicator is not UP, and solenoid LED is ON, make sure the Control Air is ON and set at 80 psi 3. If Control Air is good, disconnect its pneumatic hose from the Water or Wash Drain valve not working, and check the air flow: • If air is not flowing into valve – Manually over-ride that solenoid with a small flat-bladed screwdriver, by turning clockwise ¼ of a turn. o If Air begins flowing – The solenoid is bad and needs replacing o If Air still does not flow  Check the air supply again  Check for moisture in the solenoid. If moisture is found, use a desiccant filter and an air dryer to resolve • If air is flowing into valve – the valve is bad, see Valve Malfunction 4. If Air is good and the Valves are working, check the coupler: • The Coupler is not working: o Check the Coupler for damage, wear and tear, worn O-Rings (which become misshapen and spread out to block the drain area) o Make sure the handle is working correctly o Use a repair kit if possible, or replace the coupler • The Coupler is working: o Check the IR Probe (run the machine and watch the probe. When water runs out of the drain, and the probe remains ON, it is bad o Check the IR Probe and it turns off, but there is no water:  Check that the drain valve is open  Make sure the drain has not been rerouted or have anything attached to it that could cause flow constriction  Check the air pressure again (from start of this issue)

The IDD coupler may have been replaced with an off-the-shelf standard coupler, which has not been modified to work with the IDD Systems. IDD couplers have been modified to get proper flow and drain, and must be used as replacements to maintain this. (see Coupler Is Not Working) The Infrared Liquid Sensor may have failed • Check for water coming out of wash drain but LED on IR Probe never switches off. If so, the probe could be worn out • Make sure the probe is not in direct sunlight. They are sensitive to UV light and may fail during a PLC liquid check

Detergent Cycle Rejects Check the following, in order: 1. Is the Detergent Pump on and working correctly? • Check that the Detergent Pump is running and there are no grinding noises • Bubbles in wash tank are an indication that the pump is defective • Perform the air checks as described above 2. Are the Detergent and Detergent Return Valves ON? • Perform all pneumatic air checks as described above 3. Are the Detergent and Detergent Return Solenoids ON? • Perform all air checks as described above PROCESS & PACKAGING, INC. www.iddeas.com



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SQUIRE PLUS 2 OPERATIONS MANUAL • If air and valves are OK, check the Infrared Sensor o IR is Bad – replace (Note: IR may sometimes sense water but not detergent) o IR is Good:  Check the Coupler as described above 4. Purge sequence does not stop, and there is no more liquid (air or CO2) • Make sure Air and CO2 are on at proper pressure • Check for a hiss of air o Hissing and Probe is off – the IR Probe is bad o No Hissing – check the air supply and pressure 5. Liquid is purging for a long time • Check that air pressure is set at 22-23 psi and you are using a 1” hose

Mineral deposits or growths

Prevent this by switching between Acid and Caustic wash cycles. • Using just one may allow growths or accumulation of buildup deposits, while using both maintains a balance of cleaning

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Check the following: • The Proportioner outlet tubing is not attached o Connect the tubing and prime the Proportioner Dosing Unit / Proportioner or Fails To Draw Chemical

Dosing Unit / Proportioner or Stops Drawing Chemical

Dosing Unit / Proportioner Continues To Draw Chemical After Water Valve Closes Air Purge Doesn’t Stop

• There is insufficient water supply pressure o Ensure you meet the 15 gpm at 40-60 psi

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• The Proportioner outlet tubing was cut too short for priming o Pinch the outlet tube to create back pressure, which will cause the unit to prime, after which, the foot valve will keep the inlet tube primed Do the following: a) Proportioner metering tip clogged with dried chemical • Remove proportioner tip and inject hot water b) Inspect the foot valve for dried chemical or dirt clogs • Soak in hot water and clean c) Remove the buildup of calcium carbonate (lime) inside the proportioner • Soak it in a delimiting solution, or vinegar, to restore it to working order

Dosing Unit / Proportioner appears clean, but there is no suction • Remove proportioner and soak in hot water to clear interior passages

The chemical supply is resting higher than the bottom of the discharge tube, creating a natural siphon • Lower the supply container or hang up the outlet tube after use Check the IR Probe. If it’s not sensing the difference between liquid and air and switching off, it has become defective. Replace the Sensor. This may occur right after a detergent rinse, and continue to blow air for a long time.

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Moisture In The Solenoids

Valve Malfunction

High humidity is causing this. Purchase an Air Dryer if system resides in a high humidity location. You may also need to purchase an Air Filter – See SECTION 5 – SERVICES, under the SUGGESTED COMPONENTS for further information

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There are several checks to perform: 1. Air Flow Pressure: • Valve will not operate if pressure exceeds 150 psi • Valve will not operate if the pressure is too low o Make sure air pressure is set at 80 psig

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• Check Air Flow to determine cause. See KEG REJECTS, above

FILLING SIDE Drain Is Not Draining or Bad Flow Coupler Spits Product or Coupler Is Not Working

The Process Stops/Stalls or The Process Freezes or There Is Foaming or Fill Kegs Are Rejecting or Fills Are Incomplete or Why is My Keg Half-filled?

WHAT TO DO

STILL FAILS TO WORK

• If a hose is attached to the drain, it may have failed or clogged o See SECTION 5 – SERVICES, under the SUGGESTED COMPONENTS for drain modification information

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• Use SCAV to clear the hoses and coupler of product to prevent blow back. This clears product and equalizes the Coupler to ambient air pressure • Worn O-Rings or damage may cause this problem Foam / Half Full Kegs Check for the following, in order: 1. Check the Backpressure Regulator – it should be set at 30 psi (see Wash/Fill Notes) with modifications for your location, temperature, and CO2 in solution differences • Check the last cycle on Wash side. The CO2 should have a 1” Regulator, maintained at 30 psi, or it will be under-pressurized o Without the proper regulator, fills can be adversely affected from:  Low CO2 pressure inside the keg is creating foam o The CO2 on the Wash side was set too low. Low keg pressure is allowing CO2 to escape product as it enters o The backpressure regulator is set too low, allowing the CO2 displaced from the keg to escape too quickly. Refer to pressure settings in SECTION 9 – KEG FILLING  Incorrect Pressure Regulator is not able to pass the needed volume of CO2. The pressure will read correctly until used, then it will drop, unable to maintain required volume. This may also lead to icing and create a smaller orifice  Ice ups in regulator during fills. Smaller than recommended hoses / regulator can cause this

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See Notes, below

This may also be caused by a bad infrared probe (check). The IDD coupler has been replaced with an offthe-shelf standard coupler, which has not been modified to work with the IDD Systems. IDD couplers have been modified to get proper flow and drain, and must be used as replacements to maintain this. (see Coupler Is Not Working) The Infrared Liquid Sensor may have failed • Check for water coming out of wash drain but LED on IR Probe never switches off. If so, the probe could be worn out • Make sure the probe is not in direct sunlight. They are sensitive to UV light and may fail during a PLC liquid check

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SQUIRE PLUS 2 OPERATIONS MANUAL 2. Ensure you are pressing SCAV to remove excess product at the end of each fill • Product in the coupler causes near-immediate back pressure and sets off the IR sensor, stopping the fill before it is complete Fills Are Stopping Check for the following, in order: 1. Make sure the Product Pump is running 2. Ensure the Bright Tank maintains 15 psi of Head Pressure 3. Make sure the Product Valve is opening and showing the yellow indicator • If not – see Wash Reject notes 4. Make sure the Manual Drain Valve is open and the Manual CIP Return Valve is closed. If both are closed, no CO2 is vented and the keg and hoses reach equilibrium, unable to complete the fill 5. There may be other issues: • There may be a drain hose attached to the Drain – See SECTION 5 – SERVICES, under the SUGGESTED COMPONENTS for drain modification information • The Coupler may be the problem, Refer to Wash Side, Kegs Are Rejecting Fill Cycle Rejects Check for the following, in order: 1. Make sure the solenoid light is ON and the valve indicator is up (see #4, below) 2. If the Valve’s yellow indicator is not up, make sure the air is on and that incoming air is set at 80 psi 3. If the air is good, disconnect hose from the valve and check for air flow: • If air is not flowing into valve – Manually over-ride the solenoid with a small flat-bladed screwdriver, by turning clockwise ¼ of a turn. o Air begins flowing – The solenoid is bad and needs replacing o Air still does not flow  Check the air supply again  Check for water in the solenoid. If water is found, use a desiccant filter and an air dryer to resolve • If air is flowing into valve – the valve is bad, see Valve Malfunction 4. If Air is good and the Valve is working, check the coupler: • The Coupler is not working: o Check the Coupler for damage, wear and tear, worn O-Rings (which become misshapen and spread out to block the drain area) o Make sure the handle is working correctly o Use a repair kit if possible, or replace the coupler • The Coupler is working: o Check the IR Probe (run the machine and watch the probe. When water runs out of the drain, and the probe remains ON, it is bad o Check the IR Probe and it turns off, but there is no water:  Check that the drain valve is open  Check the air pressure again (from start of this issue)

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SQUIRE PLUS 2 OPERATIONS MANUAL

Product Spills and Does Not Switch Off or Takes A Long Time To Shut Off

Replace the Infrared Sensor Probe. This is a rare failure of the Sensor. If this occurs, product will be seen exiting the Discharge Hose, without stopping. • This failure occurs when the internal sensor changes from clear to opaque and misreads due to age discoloration or wear from caustic • When the probe goes bad, it remains ON all the time because it can’t read a change between air and liquid movement o Liquid present = Light OFF. Air present = Light ON

The Fill Takes Too Long

Back pressure is too high. Review SECTION 9 – KEG FILLING for details

---

Pressure has changed

Check the Air Supply, Control Air supply, and Air Regulator for changes

---

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PAGE 117 OF 125

The back pressure could be set too high.

SQUIRE PLUS 2 OPERATIONS MANUAL Appx. B COMPLETE KEG WASHING & FILLING SEQUENCE CONTROL PROCESSES This section steps through the entire washing, sanitizing, and filling processes, demonstrating the customer and the PLC control steps during a complete run. This also serves as a trouble-shooting guide so that each process section’s operations can be reviewed and identified for issues. You will see and understand what is happening with the valves at each step. (For simplicity, see SECTION #9 – KEG WASHING & FILLING PROCEDURES)

KEG STERILIZE/W ASH SEQUENCE The wash cycle lengths may be selected from the Sequence Select switch, located on the side of the MCC Panel. For specific Cycle Times, see Section 7. Unless specified otherwise, the washes are performed with High Flow, which sprays the inside of the kegs. You may wash a keg at the same time as you fill a keg, as the two systems are entirely separate. In order to control condensates and deposits, IDD suggests that you switch from Acid (0.5%) to Caustic (2%) every other month, as they may not be used simultaneously. This removes scum, scale, or any residuals that may have formed on the interior of the keg. Important: If this is the first time you are using the Squire system after shipment, perform a CIP to ensure that the filling side is clean and sanitized. See Section 10 - CIP. The entire wash process happens very quickly. Most of the valve switching and indicator light changes will occur too fast to follow until you are used to it. If the system stops working at any time during washing or filling, refer to the Rejected Keg Occurrence, later in this Appendix. 1. Check that services are hooked up correctly CO2 and Air Purge each with 1” regulator at 30 psig, Control Air at 80 psi, and Water at 15 gpm with 60 psi

2. Supply power to the system (208-240v, 1 PH, 60 Hz, 35 Amps) 3. Turn on the machine air, air purge, CO2 or Nitrogen, and Product supply 4. Set up the wash tank for either Acid or Caustic detergent concentrations: • Acid: 50/50 blend of Phosphoric/Nitric washing agent at 0.3-0.5% v/v • Caustic: 2% v/v Caustic 5. Prepare the Detergent Tank with clean water: d. Fill tank with water (or fill with 120° to 150° F water) e. Turn on tank heater f. Set the Heater temperature gauge between 135-155° F (light remains lit while heating) 6. Open fresh water supply to Sterilant Dosing Unit 7. Connect bucket/container of Activated Oxine solution to manifold water dosing pipe Refer to the setup information provided in Section 12 – OXINE CLEANING/SANITIZING

8. Set Sequence Select knob on side of Control Panel to 1 (Short wash), or 2 (Long wash), for dirtier kegs The Long Wash rinses and washes for about double the time of Short Wash

9. Wait for water to be heated within the required range before continuing 10. Prepare the keg: a. Set keg upright on ground (remove any keg cap, if necessary ) b. Lean keg top against padded rack bar c. Pull the wash coupler off the cleaning cup and attach to the keg •

Half-turn counter-clockwise and lift, then push with a half-turn clockwise to secure

d. Push the fill handle fully down, into lock position (Handle fully down opens to keg) •

Pull trigger and depress the handle fully, until it’s in the locked down position, then release

e. Flip keg over and place upside-down onto the wash platform 11. Start the detergent pump from Main Control Panel (top) PROCESS & PACKAGING, INC. www.iddeas.com

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SQUIRE PLUS 2 OPERATIONS MANUAL 12. Press START on the Control Panel Washer button to start the PLC process 13. The WASH 1 WATER sequence begins: a. The Wash sequence lamp turns ON b. Washer Drain and Water valves open for pre-rinse with water c. Wash Water valve closes and Air Purge valve opens to blow out pre-rinse until the Infrared Liquid Sensor detects no more liquid flow (a keg with product takes longer to clear) d. Air Purge valve closes and Water valve opens to wash the keg e. The Low Flow valve closes, restricting flow for a small amount of water to dribble over the Spear Tube and rinse it (Valve indicator normally shows ON for high flow) f. Low Flow valve opens allowing High Flow to rinse keg g. Water valve closes and Air Purge valve opens to purge rinse water until the Infrared Liquid Sensor detects no more liquid flow 14. The WASH 2 & 3 DETERGENT sequences begins: a. Wash Drain and Air Purge valves close b. Detergent valve opens and Detergent Return valve opens for Detergent Tank recycling (for the Caustic or Acid)

c. The High Flow and Low Flow rinses occur twice, then end with a final High Flow d. Detergent valve closes and Air Purge valve opens to purge detergent until the Infrared Liquid Sensor detects no more liquid flow 15. The WASH 3 OXINE SANITIZER and PRESSURIZATION sequences begins: a. Water with Oxine and Drain valves open to sanitizes keg NOTE: Oxine is pulled in to mix with water from the connection above and behind the Water Inlet valve. It is always open, so whenever Oxine is hooked up, mixing occurs.

b. Low Flow valve closes, allowing only a small amount of Oxine water to dribble over the Spear Tube and rinse it c. Low Flow valve opens allowing High Flow to rinse keg d. There is a High Flow rinse, a Low Flow rinse, and a final High Flow rinse e. Water Drain valve closes for 4-5 seconds to fill Oxine water over Spear Valve spring f. Water valve closes for sanitization hold time of 15 seconds (the red lamps remains ON) g. Wash Drain and CO2 valves open to purge Oxine water until the Infrared Liquid Sensor detects no more liquid flow h. This continues for another 7 seconds to purge air and fill the keg with CO2 and purge O2 i. Drain valve closes. CO2 continues another 3 seconds to partially pressurize keg to 15 psi j. CO2 valve closes k. Wash Sequence lamp turns off as the process ends 16. Flip keg over and place on ground 17. Unhook the Wash Coupler: d. Pull trigger and lift the handle until it’s fully in the up position e. Twist counter-clockwise and lift to unlock from keg (Partially pressurized Oxine solution will spray from connection, so do this slowly or lay it against the padded strut. Solution remaining on Spear Valve is OK)

f.

Place Coupler back on the Cleaning Cup

18. Cap the washed and pressurized keg and store or fill, as needed 19. Check Ph. Levels after an hour of washing. You may need to drain some detergent to maintain proper Ph. levels by doing the following: a. Locate the Drain Pipe valves on the bottom of the Acid/Caustic detergent tank b. Close the Bleed Valve (bottom-most – in closed position it has been designed to dribble) 20. Open the Drain Valve (top-most) Notes: This step does not need to be performed immediately. During washing cycles, this may be opened after an hour of washing to maintain Ph., or it can be left open for the entire wash cycle. New detergent and water are mixed and introduced into the tank when the float drops below a certain point. If this is left closed, be sure to test your Ph. often during PROCESS & PACKAGING, INC. www.iddeas.com

PAGE 119 OF 125

SQUIRE PLUS 2 OPERATIONS MANUAL the washing process to determine if you need to drain some detergent and introduce fresh water and detergent to maintain correct Ph. The Drain Valve seals the pipe entirely, while the Bleed Valve allows a small dribble of liquid to escape. Having both open drains the tank in short order, while with the Bleed Valve closed, it allows small amounts of detergent water to escape, in order to maintain Ph. levels when it’s diluted over long periods of wash time.

21. Do one of the following to continue: • To WASH A NEW KEG - Return to STEP #10, above • To END THIS PROCESS - Go to STEP #21, below - Go down to the KEG FILLING SEQUENCE • To FILL THE KEG 22. The End-Of-Day process begins 23. Turn off Detergent Pump and Sterilant Supply 24. Turn off the machine water, CO2 or Nitrogen, Air purge, and product supplies 25. Empty Detergent Tank by opening both Bleed and Drain valves 26. Flush out with cold water WARNING: NEVER get electrical panel interiors, such as the MCC Panel, Control Panel, or the Heater Control, wet. 27. Clean the outer surfaces of the Squire: d. Wash with warm soapy water e. Scrub with a soft brush to clean surfaces f. Rinse Squire by hose with LOW water pressure 28. Air dry or wipe down with chamois or other soft cloth 29. On the drain pipe valves, close the Drain Valve (top-most) 30. The system is ready for a new day

REJECTED KEG OCCURRENCE This does not happen often and is typically an issue with the Infrared Liquid Sensor, as described in TROUBLESHOOTING. 1. 2. 3. 4.

The PLC will stop, “rejecting” the current keg, and ending the entire sequence The sequence lamp will continuously flash to warn the operator of an error Operator resolves issue and presses STOP button to acknowledge and shut off warning Pressing START causes the process to begin from step #12 above

KEG FILLING SEQUENCE 1. 2. 3. 4.

Ensure the Control Panel Rack/CIP switch is set to RACK Ensure the Drain valve is open and CIP Return valve is closed Place a keg upright on the floor or pallet Place Product filling coupler on keg (Handle fully down opens to keg) •

Depress the handle and push down until it’s in the locked down position

5. Press Racker Start button •

Pump is primed and PLC controlled fill begins

6. Set Back Pressure Regulator (FOB) to pressure desired, + 20 psi (if 15 is needed, set to 35) • • • •

The regulator only functions during a fill (FOB = Foam Off Beer Back Pressure Regulator) At least 15 psi should be maintained in the keg to prevent beer foaming IDD suggests setting the pressure regulator to 35 psi PROCESS & PACKAGING, INC. www.iddeas.com



PAGE 120 OF 125

SQUIRE PLUS 2 OPERATIONS MANUAL 7. Product Pump turns on and Product valve opens 8. Racker Drain turns off and FOB turns on after a delay (about five seconds), when the Product Sensor detects liquid movement 9. Product fills the keg (Hissing may be heard from the Fill Drain as the product displaces CO2 from the keg) 10. When the infrared liquid sensor detects product in the Drain Pipe, the Product Pump is stopped, Product and FOB valves are closed, and the Racker Drain turns on Note:

For systems with the optional weight sensor, the pre-set keg weight trips the filler to stop the process. The infrared liquid sensor acts as a backup to this.

11. Lift the Coupler handle but do not remove it (Handle up opens product in hose to drain hose, bypassing keg) 12. Continue with the KEG SCAVENGE SEQUENCE, below

KEG SCAVENGE SEQUENCE 13. Press the SCAV button on the Main Panel 14. SCAV valve opens and Racker Drain valve turns off. CO2 blows left-over product out of fill hose, coupler, and overflow hose, through the drain pipe 15. SCAV stops after a pre-set time 16. SCAV valve closes and Racker Drain turns on 17. Racker Drain remains open for two more seconds, to depressurize coupler and hoses (no blowback) 18. Remove Product Coupler with a half-turn and place secure to Product Cup 19. Replace the filled keg with a sterilized empty until all product is used 20. When all filling is done for the day, go to SECTION 10 – CIP PROCEDURE IMPORTANT: After the First Keg has been processed through both the wash and fill sequences, remove it and do not allow it to enter the full Keg warehouse. This will ensure that all the Machine systems were properly primed, prior to commencing actual production. Return this keg to be washed and filled again.

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PAGE 121 OF 125

SQUIRE PLUS 2 OPERATIONS MANUAL Appx. C

SPARE PARTS

IDD RECOMMENDED SPARES LIST ** Most Critical Spare Parts – IDD #SP 26108

Qty

IDD Part#

1

CV1400

1

**

Description

Categories General

Specific

LEVELING MOUNT

CONV

FEET

CV1401

CASTER LOCKING

CONV

WHEEL

1

EL0310

CONTACTOR, 240V

ELEC

MCC PANEL

1

EL0358

OVERLOAD, 6.3-10 AMP

ELEC

MCC PANEL

1

EL0360

OVERLOAD, 10-16 AMP

ELEC

MCC PANEL

1

EL0369

AUX. CONTACT

ELEC

MCC PANEL

1

EL0400

**

2 POSITION SWITCH

ELEC

SWITCH

1

EL0402

**

PUSH BUTTON RED (22MM)

ELEC

SWITCH

1

EL0403

**

ELEC

SWITCH

1

EL0411

**

ELEC

SWITCH

1

EL0437

**

PUSH BUTTON BLACK (22MM) PUSH BUTTON GREEN (22MM) BLOCK, N/C CONTACT

ELEC

SWITCH

2

EL0438

**

BLOCK, N/O CONTACT

ELEC

SWITCH

1

EL0623

**

24VDC FUSE HOLDER,GMA

ELEC

FUSE HOLDER

1

EL0624

**

115-220vFUSE HLDR,GMA

ELEC

FUSE HOLDER

5

EL0626

**

GMA 1 AMP FUSE

ELEC

FUSE

5

EL0627

**

GMA 5 AMP FUSE

ELEC

FUSE

5

EL0663

**

GMA 2.5 AMP FUSE

ELEC

FUSE

1

EL0801

LAMP 220V WHITE

ELEC

LAMP

1

EL0808

LAMP 24VDC RED

ELEC

LAMP

1

EL0809

LAMP 24V GREEN

ELEC

LAMP

1

EL1200

**

ELEC

SENSOR

2

MD 35417

**

D SERIES

COUPLER

2

MD 35417RK1

**

IR PROBE, LIQ SENSOR WASH & FILL COUPLER A.SANKEY SEAL KIT AMER. SANKEY

D SERIES

COUPLER

2

MD 35417RK2

**

HANDLE / PIN AMER SANKEY

D SERIES

COUPLER

2

PF1600

TC CLAMP ½” & ¾”

CLAMP

TC

1

PF1601

TC CLAMP 1.5”

CLAMP

TC

1

PN1059

**

REGULATOR 1/8”

PNEU

FILTER REG

2

PN1601

**

MALE ELBOW 1/8 X 5/32

PNEU

AIR FITTINGS

2

PN1159

**

VALVE 3 WAY 24V (CLIPP)

PNEU

SOLENOID

1

PN1213

SHUTTLE VALVE

PNEU

PINCH VALVE

1

PU0084

PROD BOOST PUMP (C114)

PUMP

TOPLINE

1

PU0084RK

SEAL KIT, BOOST PUMP(C114)

PUMP

TOPLINE

1

PU0222

DET WASH PUMP (NPE)

PUMP

GOULD

1

PU0300

**

WASH PUMP SEAL KIT(NPE)

PUMP

GOULD

10

SL0200

**

3/4 EPDM TC SEAL

SEAL

TC

1

SL0202

**

1-1/2" EPDM TC SEAL

SEAL

TC

1

SL0602

**

3/8”NPT IR PROBE NUT

SEAL

SEALING NUT

**

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PAGE 122 OF 125

SQUIRE PLUS 2 OPERATIONS MANUAL 10 FEET

SS0201

**

BREW HOSE ½” BORE

SPECIAL

HOSE

10 FEET

SS0202

**

TYGON HOSE ½” BORE

SPECIAL

HOSE

1

TF0109

THEROMETER, TANK

TANK

THROMETER

1

TF0309

**

220V-1PH-3KW 2"NPT HEATER

TANK

HEATER

1

TF0400

**

COMPLETE UNIT H/TEMP

TANK

DOSERS

1

TF0402S

**

INJECTOR SQUIRE ST/ST

TANK

DOSERS

1

TF0700

KNOB, TANK LID

TANK

KNOB

1

VA0165

**

PROCESS VALVE ¾” N/C

VALVE

PROCESS

1

VA0166

**

VALVE

PROCESS

1

MI 13044

**

VALVE

PROCESS

1

VA0167

**

PROCESS VALVE ¾” N/O (LF) LOW FLOW SEAT,PREINSTALL SEAL KIT FOR VA0165/66

VALVE

PROCESS

1

VA1704

**

5/8" BLADDER, EPDM

VALVE

PINCH

PNEUMATIC SOLENOIDS SPARES LIST – MD F 26107 ITEM NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14

DESCRIPTION Maniford, 12 Way, Clipp Valve, Sol 3 Way 15mm 24V Clipp Blanking Plate, 15mm Clipp Regulator, 1/8” NPT 60psig Din Terminla, Led 6’ Cord Clipp Shuttle Valve, 1/8” NPT Red Nip, 1/4" x 1/8” NPT Brass Straight, 1/4" x 1/8” NPT Straight, 5/16” 8mm TubeX 1/8” NPT Straight, 5/32” 4mm Tube x10-32 Plug, 4mm Stem OD Elbow, 5/32” 4mm Tube x 1/8” NPT Tee, 5/16” 8mm Tube Regulator, Bracket & Nut

PART NO PN1155 PN1159 PN1158 PN1059 PN1160 PN1213 PF1003B PN1509 PN1506 PN1500 PN2200 PN1601 PN1901 PN1059-1

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PAGE 123 OF 125

SQUIRE PLUS 2 OPERATIONS MANUAL

MODIFIED COUPLER ACCESSORIES MD 35417 - IDD MODIFIED WASH/FILL TYPE ‘D’ COUPLER

MODIFIED IDD AMERICAN SANKEY ‘D’ TYPE WASH / FILL COUPLER FOR SQUIRE WASHER / RACKERS & ACCESSORIES

MD 35417RK1 - SEAL KIT COMPRISING

SS0401 – HOSE CLAMP, 5/8” TO 1” WA0117 - COUPLER HANDLE SL0601 - TEFLON SEAL, COUPLER NUT

MD 35417RK3 - HOSE BARB COMPRISING

WA0115 - BOTTOM SEAL

SS0201 – ½” ID BREWERY HOSE (FILL SIDE) MD 35419 - EXTENDED HOSE BARB

WA0118 - PROBE O-RING WA0102 - COUPLER NUT

SS0202 – ½”ID FOOD GRADE TYGON HOSE (WASH SIDE)

SL0502 - PROBE SEAL

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PAGE 124 OF 125

SQUIRE PLUS 2 OPERATIONS MANUAL Appx. D PROGRAM LISTING Program has been loaded into PLC and fully tested.

Appx. E TRAINING On-site training is available from our technical staff at customer’s request.

Appx. F WHICH MASK SHOULD I WEAR? Respiratory protection must be worn whenever you are working in a hazardous atmosphere. The appropriate respirator will depend on the contaminant(s) to which you are exposed and the protection factor (PF) required. Respirators should be used whenever hazardous fumes are present, as listed under Respirator Types. As stated in Section 4 – Safety: The work area should have adequate ventilation as approved by Safety Personnel.

RESPIRATOR TYPES Single-strap dust masks can be used for providing comfort from dirt, dust, pollen, or other allergens. These are not NIOSH-approved and should never be used to protect from hazardous atmospheres.

Approved filtering face pieces (dust masks) can be used for dust, mists, welding fumes, etc. They do not provide protection from gases or vapors. DO NOT USE FOR ASBESTOS OR LEAD; instead, select from the respirators below.

Half-face respirators can be used for protection against most vapors, acid gases, dust, or welding fumes. Cartridges/filters must match contaminant(s) and be changed periodically.

Full-face respirators are more protective than half-face respirators. They can also be used for protection against most vapors, acid gases, dust, or welding fumes. The face-shield protects face and eyes from irritants and contaminants. Cartridges/filters must match contaminant(s) and be changed periodically. Loose-fitting powered-air-purifying respirators (PAPR) offer breathing comfort from a battery-powered fan which pulls air through filters and circulates air throughout helmet/hood. They can be worn by most workers who have beards. Cartridges/filters must match contaminant(s) and be changed periodically. A Self-Contained Breathing Apparatus (SCBA) is used for entry and escape from atmospheres that are considered immediately dangerous to life and health (IDLH), or are oxygen deficient. They use their own air tank.

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PAGE 125 OF 125

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