CSI COMPACT CIP Owner's manual

INSTALLATION / OPERATION / MAINTENANCE
COMPACT CIP
CONTROL SYSTEMS

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TABLE OF
CONTENTS
Contents ..............................................................2
The meaning of DANGER, WARNING, and CAUTION in these instructions......3
About This Manual ......................................................4
Application ............................................................4
Technical Data .........................................................4
At A Glance (Equipment Overview)........................................5
Built-in Safety ..........................................................6
Disclaimer of Liability....................................................7
Air Connections ........................................................7
Control Panel ..........................................................7
System Start ...........................................................8
Wash Settings .........................................................10
Tank Settings .........................................................13
System Options .......................................................14
Wash Types and Wash Commands.......................................15
Starting your first Wash Cycle ...........................................16
Trend Screen..........................................................17
History Screen ........................................................17
Alarm Screen .........................................................18
Alarm Statuses Explained ...............................................19
Pump VFD Fault .......................................................19
High Temp Alarm ......................................................19
High Cond Alarm ......................................................19
Low Flow Alarm .......................................................19
Tank High Level Alarm .................................................19
Tank Low Level Alarm ..................................................19
Transmitter Errors - Return Temp, Supply Temp, Conductivity, Flow, Level .....19
Interlocks Explained ...................................................20
Interlock - CIP Supply Pump.............................................20
Interlock – Electric Heater (If Equipped)...................................20
Interlock – Chemical Pumps (If Equipped).................................21
E-Stop Active. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Maintenance Checklist .................................................22
Replacing Components.................................................23
Replacing Poly Tubing..................................................23
Replacing Pressure Regulator Filter Element ..............................24
Replacing the Solenoid Valve ...........................................25
Troubleshooting .......................................................26
Warranty...........................................................27-28

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IMPORTANT
SAFETY
INFORMATION
The Compact CIP Manual includes essential information for installing, operating,
and maintaining equipment properly and in a safe manner. Failure to do so
could result in personal injury and/or equipment damage.
DO NOT attempt to remove and/or modify Compact CIP products or
programming. Doing so can create unsafe conditions for operator(s) and
surrounding persons. Changes to Compact CIP products or programming void
all warranties.
DO NOT place any Compact CIP product in an application where general
product service ratings are exceeded. Doing so puts operator(s) and
surrounding persons at risk of personal injury and may result in equipment
damage.
THE MEANING OF DANGER, WARNING, AND CAUTION IN THESE INSTRUCTIONS
Danger: Indicates an imminently hazardous situation which, if not avoided, has a
high likelihood of resulting in death or serious injury. The word Danger indicates
the most extreme cases of risk that warrant immediate action.
Warning:Indicates a potentially hazardous situation which, if not avoided, could
result in death or serious injury. The word Warning is used for moderately at-risk
cases that warrant immediate action.
Caution: Indicates a potentially hazardous situation which, if not avoided,
may result in minor or moderate injury. “Caution” may also indicate an unsafe
operating or maintenance practice.
If at any point during operation, a Danger, Warning, or Caution indication is
present, the operator should immediately take steps to resolve the problem and
notify a supervisor.
Do not remove warning labels on any Compact CIP product. Immediate
replacement of missing labels is important to the safety of all users.

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INTRODUCTION Thank you for purchasing a Compact CIP Product!
This manual contains operation instructions for the Compact CIP Control System.
ABOUT THIS MANUAL
This manual covers the complete line of Compact CIP systems. All Compact
CIP systems are available with optional equipment that can provide additional
functionality.
Please contact CSI at 800.721.2394 or 417.831.1411 for assistance.
APPLICATION
CSI’s Compact CIP regulates the operation of your Clean-in-Place system.
Compact CIP takes the guesswork out of configuring and selecting the start,
stop, flow, temperature, and chemical concentration required for a successful
clean-in-place cycle. If used properly, your Compact CIP system can be a
source of savings and a vital step in ensuring product quality through rapid and
eective cleaning.
TECHNICAL DATA
• Compressed air pressure: 90–100 psig (requires at least 90, no more than 100)
• Air inlet size: 1/2” FNPT
• Maximum product pressure: 145 psig
• Product Temperature range: 0°F–180°F
• Electrical Requirement: AC 480V, 60Hz +/- 6%
• Amperage requirement based on system configuration: 20Amps without
electric heat, 57 Amps with electric heater option.

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AT A GLANCE
   
  
Touchscreen
Emergency Stop (E-Stop)
Return Temperature &
Conductivity Transmitter
Power Disconnect Switch
Supply Temperature Transmitter
Electric Heater (optional)
Pressure Gauge
Flow Transmitter
Tank
Control Panel
Chemical Reservoirs
Tank Level Transmitter


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AIR LOCKOUT CAPABILITY
The photo on the left shows the air control in the Supply (SUP) position. To
prevent accidental operation, turn the air control to the OFF position and lock it
with a padlock (OSHA lockout/tagout standard for control of hazardous energy).
E-STOP CAPABILITY
Activate E-Stop to turn o all operations.
To release the E-Stop, twist clockwise until it pops up.
BUILT-IN SAFETY
The CSI Compact CIP control package includes built-in safety features including
air lockout and emergency stop capabilities. The control units can also
incorporate system timeouts for added operator safety.
SAFETY


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INSTALLATION The Compact CIP control cabinet arrives mounted to the skid and prewired to
instruments installed on the skid. Typical installation requires a dedicated 480V
3-Phase with Branch Circuit Protection with amperage requirement based on
system configuration: 20 Amps without electric heat, 57 Amps with electric
heater option. Electrical schematics provided with the control panel indicate
the location, voltage and amperage requirement for the panel. The Compact
CIP system is designed to work as a standalone system and does not require
integration with the plant’s infrastructure.
To avoid electrocution, ALL electrical work should be done by a registered
electrician, following industrial safety standards and local codes. All power
must be OFF and safely locked out during installation.
DISCLAIMER OF LIABILITY
CSI does not assume responsibility and expressly disclaims liability for loss,
damage, or expenses that arise in any way from the installation, operation,
use, or maintenance performed in accordance with this manual. CSI assumes
no responsibility for any infringement of patents or other rights of third parties
that may result from use of the module. No license is granted by implication or
otherwise under any patent or patent rights.
CSI reserves the right to make changes to the product, specifications, or this
manual without prior notice
AIR CONNECTIONS
Note: CSI recommends that the control cabinet be supplied with clean
instrument air at the minimum pressure of 90 psig.
AIR INPUT TO CABINET
Air connection 1/2” NPT Female
WARNING


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OPERATION CONTROL PANEL
Use the touchscreen control panel to select wash parameters and cleaning cycle.
Operators should take a moment to familiarize themselves with the items in bold
below.
SYSTEM START
1. Verify all Swing, Hose, and Piping Connections are secure.
2. Verify the Air Relief Valve is in the On position.
3. Verify the E-Stop is not activated.
4. To change wash parameters, press the Config button. On the user login
screen—
a. Input your username and password.
b. Default login to change configuration parameters:
User: engineer
Pass: engineer
c. Adjust wash settings (e.g., Temperature, Flow, Chemical Concentration)
d. Make the desired configuration changes and press the Logo button.
5. To start the system, ensure it is fully connected in a safe manner and press
the Commands button. The system presents the available washes.
a. Select the desired wash type on the left
b. Press the Start button on the right.
c. Press the Abort button to stop and cancel the current wash if needed
during the wash.
d. Press the Hold button to pause the current wash sequence and keep its
current position and time remaining. Press the Restart button to resume
operation.
6. When the system is started, it automatically opens the water fill valve and
maintains tank level according to Tank settings located on the Config
screen.
7. The system continues to run in Automatic mode until the Operator stops
the system by pressing the Abort button, Hold button, E-Stop button, or the
system goes into an Alarm state.
a. If the system goes into Alarm, the issue that caused the alarm must be
resolved before continued operation.
b. Transmitter errors and tank low level limit alarms are indicated on the
screen by a yellow rectangle warning symbol and will auto-acknowl-
edge themselves once the problem has been resolved.
Displays when
there is a
transmitter error
or tank low level
limit alarm
Displays when
a piece of
equipment is
in an alarm state

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OPERATOR
INTERFACE
SCREENS:
MAIN SCREEN
The main screen displays system status.
The main navigation bar is located at the top of every screen for easy navigation.
System status area includes the following possibilities:
• Current Wash Phase – System Idle, Pre-Rinse Running, Caustic Run-
ning, Rinse Running, Acid Running, System Draining, Final Rinse Run-
ning, Sanitizer Running.
• Current Wash Conditions – Waiting Cond. SP, Waiting Temp SP, Waiting
Temp & Cond. SP, Wash Conditions Met.
• Time Remaining – The time remaining, in seconds, of the current wash
phase. If the timer is not counting down while the system is running,
then the system is waiting for a wash condition such as Temperature or
Conductivity to be met. (See Wash Settings on page 11.)
If the system is equipped with an electric heater, its icon turns red when
power is supplied to the heater, and displays “Heater On” text above it.
Equipment indicators change color to green when they are open or running.
When the system is sitting idle and there are no active alarms, operators are
allowed a small amount of manual control of the system as long as built-in
interlock criteria are met. Touch the equipment indicator icon you would like
to open or turn on and it will comply if the interlock permissions are met.
Press again to close or shuto the valve. Refer to our Alarms/Interlocks sec-
tion for more information.
The system auto-maintains its tank level according to the tank settings con-
figured on the Config screen.
• The water supply to the skid must be capable of filling at the same or
greater rate as the CIP supply pump for eective rinsing. For example,
the standard pump is rated for 50gpm at 50 psi, so the supply water to
the skids should be at least 50gpm to maintain level.
    
Green indicates
equipment is
open or running
Red indicates
equipment is
closed or stopped

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The configuration screen displays the overall system settings that can be adjusted
to the desired CIP wash parameters by allowed users.
WASH SETTINGS
Wash settings include Time, Temperature (Temp), Conductivity (Cond), Flow, and
Chemical (Chem) Setpoints (SP) for each wash phase — from Pre-rinse to Sanitizer.
The Compact CIP will not advance to the next step in the wash cycle until the
system is either above or below the setpoint.
Pre-rinse — waits until the system is at or above Flow SP and below Cond SP.

Caustic — waits until the system is at or above Cond SP, Temp SP, and Flow SP.

Rinse — waits until the system is at or above Flow SP and below Cond SP.

Acid — waits until the system is at or above Temp SP, Cond SP, and Flow SP.

Drain — waits until the system is tank is below low limit SP.

Final Rinse — waits until the system is at or above Flow SP and below Cond SP.

Sanitizer — waits until the system is at or above Flow SP and below Cond SP.
For example, in the screenshot shown above, the Pre-rinse phase will not advance
to the Caustic phase until the Flow SP is at or above 20.0 and the Cond SP is
below 2.0. The Temp SP has a value of N/A which indicates that there is neither a
minimum nor maximum requirement for the Pre-rinse Temperature (Temp SP) and
therefore will not delay advancement to the next phase.
OPERATOR
INTERFACE
SCREENS:
CONFIG
SCREEN
      