We have addressed thousands of questions over the years and these frequently asked questions are the most common. Take a look and see if we can answer your questions below. If not, feel free to contact us by phone or email and we will answer your questions ASAP.
- Move the fill straw and hose from the offending location and switch to another location in the fill block. If the problem remains in the same location on the fill block, run a leak test and look for small leaks. If no leaks detected, remove fill block from the machine and disassemble filling block completely and perform a though cleaning looking for debris that may have caused the issue.
- If the problem moved with the straw and the hose, the problem lies with the fill tube, hose or manifold. Most often this is a nucleation problem where a bubble forms reducing flow in that location. This can be caused by dispensing pressures too low for product conditions, over carbonation, product temp too warm for packaging or glycol system set too cold causing instability of carbonation.
- Liquid in the bottle side sensor or sensor line, causing incorrect counter pressure and fill detection issues.
- Uneven filling as mentioned above can cause this issue.
- Low pressure is not correct, resulting in lifting time for the filling heads beyond the 1-second rule.
- Pulse CO2 pressure to the machine is in excess of 25psi, resulting in too much energy when pulsing.
- Liquid in the bottle side sensor tubing or sensor, retarding machine’s response to full bottles and incorrect control pressures.
This is a counter pressure failure, which simply means that the computer did not have the correct pressure in the bottles to begin pouring product.
- CO2 supply does not deliver enough volume soon enough to bring the bottles up to the proper pressure.
- Bottles come up to pressure, but pressure does not bleed down to proper level due to Snift valve failure or blocked with debris.
- A leak in the system that does not allow the bottles to pressurize properly.
- Diagnosis of fault. Under normal operating conditions the blue CO2 bar on the screen must go 1psi higher than the yellow product pressure bar very quickly, then Snift valves opens to bleed off pressure just below liquid pressure to open fill valve.
- If blue bar moves slowly or never gets above yellow bar a CO2 shortage or leak in the system is the problem.
- Run a leak test to determine if the machine has a leak. If leaks are detected correct the problem
- If leaks are not detected the problem is a CO2 delivery shortage, most often caused by a recently filled bulk system or the shut-off valve on the CO2 regulator which houses a back flow preventer. The shut-off valve can be replaced with a straight through fitting which in most cases will resolve this issue.
Most of the time this is attributable to incorrect rotator speed of the crown sorting magnet hubs. Crown sorter should rotate into the hopper to get crowns in about 1.5 seconds and should take 4-5 seconds to place them in the crown slides. Also, the rotator must turn 450 degrees of rotation into the hopper and 450 degrees to put crowns into the slides. If speeds are not correct, adjustments should be made by adjusting the speed controls for each direction of rotation.
Most often this is a result of liquid on the crown slides. Remove crowns from slides and dry them. NEVER attempt to sterilize or get crowns wet before use. This ruins the protective varnish and causes crowns to misfeed.
Assuming the bottle detection sensors have not been moved, this is most often caused by a droplet of liquid getting into the sensor hoses or the red sensor hoses not being completely plugged into the bottom of the panel.
Go to the manual override screen and select the bottle detection screen. In the upper middle part of the screen is a black & red button that when pressed becomes a numeric key pad. Type “3 1 2 4” on the key pad and press “Enter”. The button turns green. Do not touch the green button as this will turn the system back on. Press the “Reset” button and “Main Menu” to continue working with the bottle detection system bypassed.
Automatic bottle fill detection uses the change in product line pressure from before flow starts and just after flow starts to determine the correct filling number needed to detect full bottles with dark pours (meaning no gas breaking out of solution).
- Dispensing pressure is not adequate to keep CO2 in solution for the conditions of the product; increased pressure may help.
- Product is over carbonated; adding pressure to the dispensing tank may help.
- Glycol is too cold and product has been through freeze/thaw cycles. When this happens product cannot be properly packaged and should not be bottled. Turn glycol system to 30F for the next batch.
- There is liquid in the bottle side sensor or sensor line. Clear line and sensor.
- Remove bottle side sensor line labeled “A” from the bottom of the panel and manually override the Pulse valve to blow it clear.
- Unscrew the fitting from the bottom of the panel and flush the sensor using a squire bottle with clean water or alcohol, then roll the corner of a paper towel to a point and make sure the sensor is clean and dry inside.
- There are leaks in the system causing sudden changes in bottle pressure. Run a leak test and correct leaking components.
- Bottle indexing speed is too fast, which will also cause bottles to misfeed due to sliding past filling and capping stations.
- Not enough full bottles on outfeed deck to keep bottles on sloped infeed ramp from sliding on their own. Ensure that filled bottles are not removed from out feed deck until after leg attachment point to frame.
- Out-feed deck has been sprayed with silicone lubricant. Remove all traces of silicone lubrication or flip deck over.
- Air pressure or volume of air is low coming into the machine.
This is a compressed air shortage of either volume or pressure, identifiable by watching the gauge on the air regulator mounted on the machines frame. Nominally set at 95psi in the static condition, the air pressure gauges should not drop below 80psi anytime during operation. If the air pressure does drop below 80psi, most likely the cause is a restriction to air flow, such as quick connect fittings or extra air prep equipment such as driers, filters, regulators, etc. which do not flow enough air.
Pressure in the bottles at the moment the fill valve opens is slightly higher than incoming product.
- There is liquid in the bottle side sensor or sensor line affecting the pressure reading to the computer.
- Over-carbonated or unstable product that the agitation from snapping the pinch bar opens releases gas from the product momentarily over pressuring the bottles.
- Product pressure sensor has been damaged resulting in an elevated pressure reading of the product. Replace or calibrate sensor.