Alto PZC Classic Manual

25.10.2004 – 0617551 UK Vers. 1.1
Directions for Use
for Automatic Pump Station
PZC Classic

21.10.2004
ALTO Danmark A/S

21.10.2004
ALTO Danmark A/S
Contents Page
1 Preface 1
2 Connections to low-pressure plant 1
2.1 Directions for mounting 1
2.2 Water connection 1
2.3 Compressed-air connection 2
2.4 Connection of detergents 3
2.5 Layout drawing for pump station PZC 4
3 Directions before operation - Automatic cleaning 8
4. Security devices 10
5. Regular service and control 11
6. Interruption of operation and remedy 12
7. Flow diagram 15
8. Type plate 16
9. Technical data 17
10. Guarantee 18
11. Material and spare parts list 19
Dato:
Godkendt:
E.&.O.E

21.10.2004
ALTO Danmark A/S

21.10.2004
ALTO Danmark A/S
1. Preface
ALTO Danmark A/S congratulates you with your low-pressure foam cleaning system
which full fills the latest technical hygiene requirements.
Prior to installation and start of operation please make sure that your operational staff
reads the directions for use. On operation as laid down in the directions for use you will
achieve optimum cleaning and hygiene in your factory and minimum requirement for
maintenance and repair work.
The combination of a centrifugal pump and an injector offers the possibilities of automatic
and manual:
a) -foam spreading of detergents
b) -rinsing off with water
2. Connections to the Low-pressure Plant
2.1 Mounting of the Plant
The plant should only be mounted in frost-free rooms.
2.2 Water Connection
a) Prior to connection to the plant the supply pipe should be rinsed through
carefully in order to remove coarse impurities and metal shavings.
b) The water connections for pump station PZC (hot or cold water) are at the top of
the plant (A on the layout drawing on page 4).

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ALTO Danmark A/S
c) It is important to ensure abundant water - no less than 150 l/min. per
pumping unit. To meet this requirement the diameter of the supply pipe should
be minimum 1 1/4" (32 mm) at a water pressure of 3,5 bar, and at a water
pressure lower than 3,5 bar the water pipe should be minimum 1 1/2" (38 mm).
d) The plant is equipped with a filter on the supply pipe of the pump.
e) The pressure loss in the supply pipe should be kept as low as possible which
means that:
- unnecessarily long supply pipes should be avoided
- low resistant ball valves should be used
- fittings with high pressure loss should be avoided
f) On pipe mounting care should be taken that no air locks are produced.
g) Max. allowed temperature of inlet water: 70°C
h) Max. allowed pressure of inlet water for pump station PZC: 4 bar
2.3 Compressed-air Connection
a) Prior to connection to the plant the supply pipe should be rinsed through
carefully with air in order to remove coarse impurities and metal shavings.
b) The plant should be connected to a compressed-air pipe or a compressor
offering:
- an inlet pressure to the low-pressure plant of minimum 5 bar
- a minimum capacity of 450 l/min.

21.10.2004
ALTO Danmark A/S
d) The compressed-air pipe should be connected direct to the plant by a union to
facilitate dismounting. All plants are equipped with a closing valve with 1/2" thread
(compressed-air connection for pump station PZC) (O on the layout drawing on
page 4).
2.4 Connection of Detergents
a) place the can with the suitable detergent in the can holder.
b) Control the detergent hose filter for impurities.
c) After pre-rinsing the hose should be placed in the detergent so that the filter is
lowered sufficiently below the surface to avoid suction of air during foam
spreading or disinfection.

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ALTO Danmark A/S
2.5 Layout Drawing
A. Inlet pipe I. Filter/press. gauge/reduction valve, air
B. Ball valve for water J. Solenoid valve for air
C. Strainer K. Dosing valve for detergent
D. Flow switch L. Filter/reduction valve for external air
E. Pump M. Foam outlet
F. External air N. El. box
G. Water outlet O. Air supply
H. Pressure gauge for water

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ALTO Danmark A/S
3. Directions Before Operation
Automatic Cleaning
a) Set a scale value of approx. "4" on the dosing valve for detergents (K on the
layout drawing on page 4). The value of the scale has got nothing to do with % of
detergent sucked up during operation. Final adjustment of the valve should take
place during operation dependent on type of detergent.
b) Start the automatic plant from the control unit by means of the entered program.
c) Set the air pressure at 5 bar on the reducing valve for air (I on the layout drawing
on page 4). Check the air pressure on the pressure gauge for air (I on the layout
drawing on page 4).
NOTE! When setting the reducing valve for air carefully pull up the knob and turn it right
for higher pressure and left for less pressure.
d) The foam quality is correct when the foam is a little moist and small bubbles are
created. Being to wet the foam will slide off quickly. That will cause insufficient
action time and bad utilisation of the detergent.
e) Insufficient foam quality is caused by
- too low concentration of the detergent
- too high temperature of the inlet water
- insufficient air quantity and/or pressure
- detergent not suitable

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ALTO Danmark A/S
4. Security Devices
a) Closing valve for water (B on layout drawing page 4).
On the inlet pipe there is a closing valve in the cabinet by which the water supply
to the pump can be closed.
b) Strainer (C on layout drawing page 4).
On the inlet pipe of the pump a strainer is mounted to prevent impurities from the
water and the pipe work to get into the flow switch, the pump and the injector.
c) Flow switch (D on layout drawing page 4).
For control of the pump a flow switch has been mounted on the inlet pipe. The
flow switch activates the pump as soon as a flow takes place in the flow switch. If
all valves are closed and there is no flow in the flow switch, the flow switch
disconnects the pump after the time interval entered into the control. On the outlet
pipe a non-return valve is mounted to prevent a reflux through the pump and flow
switch into the water inlet.
d) Closing valve for air (O on the layout drawing on page 4)
A manual closing valve for air is mounted on the air inlet for closing the air supply.
e) Solenoid valve for air (J on the layout drawing on page 4)
The air supply for the injector in the automatic part is opened by solenoid valve.
f) Pressure gauge for water (H on layout drawing page 4).
g) Pressure gauge, filter and reduction valve for air (I on layout on page 4).

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ALTO Danmark A/S
5. Regular Control and Service
The plant should at least once a year be checked by a service engineer to prevent errors
and accidents on use of the equipment. Service engineers are persons who due to their
education and experience have sufficient knowledge of low-pressure cleaners or similar
equipment and who are familiar with the state work security regulations, accident
preventing regulations, lines and generally acknowledged technical regulations such as
DIN-norms and VDE-provisions. We refer in this connection to our service department:
ALTO Danmark A/S
Blytækkervej 2
Postboks 805
DK-9100 Aalborg
Tel. + 45 72 18 21 00
Fax + 45 72 18 20 99

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ALTO Danmark A/S
6. Trouble Shooting and Remedy
Measures at trouble shooting
Symptoms
The plant does not start
The plant does not build up
pressure
Unstable pump pressure
Insufficient foam creation
No foam creation
The plant sucks no detergent
Possible causes Remedy
Fuse blown zReplace fuse
Fuse in control box blown zReplace fuse
Motor overload disconnected zSearch error
No water supply zEnsure water supply
Incorrect direction of rotation
of pump zConnect the pump correctly
Flow switch defective zCall for skilled persons
Pressure gauge defective zReplace pressure gauge
Insufficient water supply zzEnsure water supply
Filter in inlet pipe blocked up zClean or replace filter
Detergent unsuited zChoose suited detergent
Insufficient air supply zEnsure air supply
Too high air pressure in
injector zAdjust air supply
Incorrect nozzle mounted zContact SCANIO
No air supply zEnsure air supply
Filter for detergent blocked up zzClean or replace filter
Non-return valve blocked up zzClean injector
Dosing valve for detergents
blocked up zzClean valve

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ALTO Danmark A/S
Fault Cause Remedy
The machine does not
start. Fuse blown.
Power supply fault.
Fuse in the wiring box of
the machine blown.
Motor overload in the
wiring box of machine
disconnected.
Check fuse and replace, if
necessary.
Power supply to be
checked by an expert.
Check fuse and replace, if
necessary.
Before switching on again,
check cause of
disconnection.
The machine does not
build up pressure. The program does not function correctly.
No water supply.
Direction of rotation of
pump not correct.
Check the program. call
for assistance by
FRIGOSCANDIA, if
necessary.
Open inlet valve of
machine.
Change direction of
rotation of pump in
accordance with arrow on
pump.
Unstable or too low pump
pressure. Insufficient water supply.
Strainer on inlet pipe
blocked up.
Provide sufficient water
supply. Min. 1 1/4" piping.
Clean or replace filter.

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ALTO Danmark A/S
Fault Cause Remedy
Unsatisfactory foam
quality. Detergent not suitable.
Too low concentration of
the detergent.
Too high temperature of
the inlet water.
Insufficient air quantity and
pressure.
Change to correct type of
detergent.
Ensure sufficient detergent
supply, 2-4%.
Reduce the temperature of
the water.
Ensure sufficient air
supply, 450 l/min., 5 bar.
Spreading of foam is not
uniform. Insufficient air supply to the plant.
Incorrect air pressure on
the plant.
Too high air pressure in
the injector (read pressure
on pressure gauge).
Incorrect nozzles
mounted.
Ensure sufficient air
supply, 450 l/min., 5 bar.
Set pressure on 5 bar on
the regulating valve.
Set pressure on 5 bar on
the regulating valve.
Contact FRIGOSCANDIA
for instructions.
No spreading of foam. The program does not
function correctly.
The non-return valve in
the injector is blocked up.
The dosing valve for
detergent is blocked up.
Check the program. Call
for FRIGOSCANDIA-
assistance, if necessary.
Clean or replace the valve.
Clean or replace the valve.

21.10.2004
ALTO Danmark A/S
Fault Cause Remedy
No spreading of foam. The filter for detergent is
blocked up.
The suction hose is not
put into the detergent.
The concentration of the
detergent is set too low.
Clean the filter.
Put the hose into the can.
Set dosing valve for
detergent on pos. 4.
No pressure air in the
plant. Inlet valve for pressure air is not open.
The solenoid valve for
pressure air is blocked up
or defective.
Open inlet valve for
pressure air.
Clean or replace the
solenoid valve.

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ALTO Danmark A/S
7. Flow diagram
1. Closing valve, water 12. Non-return valve detergent, foam
2. Filter, water 13. Filter
3. Flow switch 14. Solenoid valve, ejector and injector rinse
4. Pump and motor 15. Non-return valve
5. Pressure gauge, water 16. Solenoid valve, air external air
6. Non-return valve, water 17. Micro filter
7. Solenoid valve, water outlet 18. Filter regulator for external air
8. Solenoid valve, water (foam) 19. Closing valve, air
9. Ejector detergent (foam) 20. Non-return valve, air
10. Injector air (foam) 21. Solenoid valve, air (foam)
11. Dosing valve detergent (foam) 22. Filter/pressure gage/reduction valve, air

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8. Type Plate
1. Producer
2. Serial number
3.Type
4.Date
5. Order number
6. Maximum pressure
7. Voltage
8. Frequency
9. Water volume
10. Consumption of air
11. Maximum temperature

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ALTO Danmark A/S
9. Technical Data
Model PZC-Classic
Permitted operational pressure
Pump pressure
Max. operational pressure
Variable water volume
Max. pressure of inlet water
Max. temperature of inlet water
Motor capacity
Power consumption
Control voltage
Security of electrical wiring
Electrical cable
Weight
Total dimension H x W x D
Max. air inlet pressure
Min. inlet flow for start of plant
25 bar
12 bar + inlet pressure
25 bar
10-100 l/min.
4 bar
70°
50 Hz, 2,2 kW/60 Hz, 3,0 kW
3 x 380 V 5,1 A
3 x 415 V 4,7 A
3 x 440 V 6,0 A
3 x 460 V 5,7 A
3 x 480 V 5,5 A
3 x 550 V 4,6 A
3 x 575 V 4,5 A
3 x 600 V 4,4 A
24 V/50 Hz
20 A or 16 A slow-acting
4 x 1.5 mm²
80 kg
1426 x 600 x 310 mm
10 bar
3 l/min.

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ALTO Danmark A/S
10. Guarantee
Your dealer guarantees for a period of 12 months from the day of delivery all parts which
have demonstrably become unfit for use due to material defects, construction errors,
manufacturing defects or imperfect work. The guarantee will consist of reimbursement,
replacement or repair of the defective or damaged part, at the dealer's option. Possible
mounting costs and freight charges are always to be carried by the buyer. The defective
parts are always the property of the dealer. Claims that may otherwise be raised for any
legal reason will not be acknowledged. No liability will be accepted for damage occurred
indirectly. The purchaser has no right to let any third party mend possible defects on our
account.
All hoses, rubber parts or synthetic materials, natural wear and tear as well as damage
caused by careless and inappropriate treatment, including transport damage are not
covered by the guarantee. Further, the guarantee does not apply if the machine has been
subjected to frost. The obligation of guarantee compensation disappears if non-authorised
persons make changes or repairs. Claims under the guarantee will only be acknowledged
when they are placed immediately after the defect covered by the guarantee has been
observed. The guarantee ceases in case of change of ownership.
The dealer cannot be held responsible for personal injury, damage to equipment, working
deficits, including production loss, loss of profits, loss of stock for the like which may occur
by imperfect and delayed delivery of the sold product, regardless of the reason, including
manufacturing and material defects. Besides, please see our normal conditions of sale
and delivery.
E. & O. E.

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ALTO Danmark A/S
11. Material and Spare Parts List