Janschitz FJ-200 CT User manual

Multi function kettle - closed type
FJ - 200 CT
Janschitz G.m.b.H Tel: [phone]
Eisenstrasse 81 Fax: [phone]
A –9330 Althofen www.janschitz-gmbh.at
[e-mail]

FJ200 -CT USER`S MANUAL V3.0
Page 1
TABLE OF CONTENTS
TABLE OF CONTENTS...........................................................................................................1
1. GENERAL SAFETY RECOMMENDATIONS ..................................................................2
2. TECHNICAL SPECIFICATIONS .......................................................................................4
3. UNPACKING .......................................................................................................................5
Accessories .............................................................................................................................5
4. DEVICE SETUP...................................................................................................................5
Main components....................................................................................................................5
Electrical connection...............................................................................................................9
Water connection ....................................................................................................................9
Water filling into secondary coat............................................................................................9
Filling procedure: ..............................................................................................................10
Water quality ..................................................................................................................... 11
5. PROGRAM SETUP............................................................................................................12
Control panel.........................................................................................................................12
Main menu............................................................................................................................14
Settings menu........................................................................................................................14
Detailed menu.......................................................................................................................16
Heating procedure.................................................................................................................18
Cooling procedure.................................................................................................................18
6. CLEANING ........................................................................................................................19
Detergents..........................................................................................................................19
7. MAINTENANCE AND SERVICE.....................................................................................20
Troubleshooting....................................................................................................................20
Electric case contents............................................................................................................21
Advanced settings menu.......................................................................................................22
8. DEVICE ASSEMBY AND SPARE PARTS.......................................................................23
Device spare parts list...........................................................................................................27
Spare parts ordering procedure.............................................................................................27
9. WARRANTY......................................................................................................................28

FJ200 -CT USER`S MANUAL V3.0
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1. GENERAL SAFETY RECOMMENDATIONS
•Before any installation read this manual very carefully.
•When using this device follow instructions in this manual and instructions for safe
work.
oWhen working always wear tight clothes, do not wear a tie.
oProtect long hair with suitable head protection.
oDo not wear jewelery (rings, necklace, etc.).
oWear eye protection –protective glasses.
oBe at full psychofisycal abilities when using this device.
oIlluminate the working area according to regulations.
oAssure the clean and tidy working place, surrounding of the device should
be free.
•Connect the device to a proper electrical socket.
•Only trained personnel is allowed to use this device.
•Before turning on the device always check:
oThat no part of the device is damaged.
oThat moving paths are clear of obstructions.
oThat device is FILLED WITH WATER
•The device has to be switched on by main switch.
•When there is a defect on the device, you must turn it off and put the plug from the
power source.
•Don`t repair the device by yourself, in case of malfunction rather call authorized
service provided by your distributor. Only authorized service with faultless tools
can repair the device.
•Always report every brakedown or defect on device.
•In case of serious malfunctions switch off the main switch and unplug the device
from electrical socket and compressed air socket, then call authorized service.
•You are allowed to use only the procedures that are described in this manual. Use
of any other procedures or adjustments could result in destruction of the device
or injury. Injuries connected with such procedures can not be subject of any
product liability claims.
oDo not reach into danger area –moving parts!
oDo not leave the working area when device is in operation!
oDo not lean the device while in operation!
oDo not remove warning labels or security devices. Blocking or removing
the security devices is forbidden!
•It is forbidden to clean, lubricate or repair the device during operation.
•Disconnect device from electrical socket before cleaning!
•Take care that milk, water or humidity will not come into the device.

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BEFORE FIRST INSTALATION, CONNECT THE HOUSING OF THE
DEVICE TO A PROPER EARTH CONNECTION TO AVOID INJURIES AND
DAMAGE.
CAUTION:
AT NORMAL OPERATION HEATER PARTS COULD WARM UP. RISK OF
BURNING IS POSSIBLE, AVOID CONTACT WITH HOT SURFACES.
CAUTION:
HOT - RISK OF INJURY.
NEVER START THE DEVICE BEFORE FILLING WATER, OTHERWISE HEATING
ELEMENTS WILL BE DESTROYED AND INJURIES MAY ACCUR.
WARNING!
Only trained people who are familiar with rules for safe work are allowed to work with
this device.
We are glad that you decide to buy our device and we promise that it will serve you for a
long time if you will use and clean it according to descriptions stated in this User` s
manual.

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2. TECHNICAL SPECIFICATIONS
PRODUCT
FJ - 200 CT
400 V
Operating voltage
[V/Hz ]
400 / 50
Power supply
3 phase
(3x230V), 18A
Type of heating
[W]
electrical
Heater power
[W]
15.000
Current
[A]
22
Max. capacity
[litres]
200
Minimum capacity
[litres]
40
Volume of heating water
[litres]
15
Dimension of Milk outlet
DN
65
Dimension of cold water inlet (cooling)
[mm]
DN20
Dimension of hot water outlet (cooling)
[mm]
DN20
Dimension of external water inlet (heating)
[mm]
DN20
Dimension of external water outlet (heating)
[mm]
DN20
Maximum temperature
[°C]
100
Dimensions in cm
(w x d x h)
130x120x150
Net weight
[kg]
185
Protection type of electrical box
IP 56
CAUTION!
Minimum voltage applied is 220V, maximum voltage is 250V!
FJ-200 CT multipurpose kettle is designed for thermal processing of milk into dairy products
(pasteurized milk, crème, cheese, yogurt, …). Multipurpose kettle has closed type construction,
so heating water is always under pressure. For cooling, tap water or cooling tank water is used.
Cooling water flows freely through plate heat exchanger when cooling is applied. For heating
one can choose from different modes of heating:
-Electrical heating. Two electrical heaters with 6 kW power are installed and only
heaters are used for heating.
-External heating. The kettle has two connections for external water (External water in
and external water out). When outer heating room has enough capacity and adequate
temperature it can be used for heating when connected to the kettle. In this mode only
external water is used for heating.
-External + Electrical heating. In this mode external water is used to heat up the milk
to preentered temperature. When this temperature is reached, external water heating is
stopped and only electrical heaters are used to heat milk above preentered temperature.
It is easy to use product.

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3. UNPACKING
Unpack the device carefully and check that nothing is left in the cardboard box. Place it on the
plain and stable floor in clean, dry and dust-free place. Before use check that all parts are
assembled according to instructions.
Room temperature where device is placed must never fall under 10°C, also it is not
recommended that room temperature exceeds 30 °C. With low room temperature, the
maximum milk temperature decreases.
Accessories
Packaging of multi purpose kettle contains the following accessories:
•200 liter multi purpose kettle
•Two half covers with handles
•Outlet valve DN65 with outlet elbow
•Option 1 (Stirrer and stirring guide)
•Option 2 (3 part cheese harp, central stirrer and stirring guide)
•User’s Manual
4. DEVICE SETUP
Main components
All important parts of device are named and described below:
1. The kettle
2. Milk outlet valve with knee outlet
3. Two part cover with handles
4. Electric case
5. Controlling cabinet
6. Microprocessor unit
7. Power cord and socket (non European editions come without a socket)
8. Tilting lever (mechanism to lean the kettle when empty)
9. Stable support with wheels
10. Motor cover
11. Rotating motor support
12. Heating unit cover
13. Rotating control box support
14. ON/OFF switch
15. Fixing device for motor support
16. Milk temperature sensor (two temperature probes)
17. Electro heaters
Please note!
Main cord must be connected to safety outlet with grounded terminal!

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Picture 1
Picture 2
1
2
3
4
5
6
7
8
9
10
11
12
14
13
15

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Picture 3
All important parts of heating unit are named and described below:
1. Venting device
2. Expansion vessel
3. Circulating pump
4. Manometer
5. Safety valve for overpressure
6. Manual valve for disconnecting the upper heating element
7. Electronic manometer
8. Plate heat exchanger for cooling water
9. Motor valve for external heating
10. Mixing valve for external heating
11. Solenoid valve for cooling water
16
17
Outlet lower
than kettle
bottom
PU foam
insulation
Thin wall
heating
elements 1 on
bottom and 2
on wall

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Picture 4
Inlet hose
for water
connection
Inlet connection
for external
water heating
Outlet connection
for external water
heating
Inlet
connection
for cooling
water
Outlet
connection
for cooling
water
4
2
1
5
3
6
8
9
10
11
7

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Electrical connection
Before connection of device on electrical network, make sure that data on name label matches
with voltage of power supply. Also connect the kettle housing to the ground –earthing
connection.
NOTE: Version for non European market is supplied without electrical socket! Only trained
personnel may connect proper locally approved multi phase socket to supplied device (see
electrical scheme).
Water connection
Before each start of device, make sure that device is filled with water! You can use water from
tap that fulfils the microbiological and chemical requirements. Water must be poured in slowly,
not more than 3 l/min.
Water filling into secondary coat
Use inlet hose to fill water into the double layer of kettle. The device needs to be properly filled
with secondary water before start. Lack of secondary water or use of inappropriate water can
damage the device. At startup program first checks for the presence of secondary water and
demands the filling if no or inappropriate pressure of secondary water is detected.
Inlet hose for filling the
kettle with water
Venting device to unvent the kettle

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Filling procedure:
•Connect the tap water connection to inlet hose
•Open the venting devices to let the air out
•Choose to fill water at microcontroller and wait 2 minutes.
When electronics is energized it first checks
if heating water is present.
It offers to fill the water by pressing up key
or skip the choice by pressing down key.
Menu with water filling choice will
disappear in 5 seconds after start.
If no pressure is present it will not allow to
proceed.
When you choose to fill water, manually
connect the water supply to the device. You
must wait 2 minutes for the mixing valve to
change position before filling.
Slowly open the manual valve to slowly fill
the water into the device. After correct
pressure is formed 1,5 bar, close the manual
valve and remove the water supply from the
device.
Manually start the pump by electronics by
pressing left key to enter the settings
menu and to go to line “Circulat. Pump:”.
With key change the value from
“AUTO” to “ON” .
•Pump must circulate the water for so long that venting devices put all the air out of
system. Pressure may fall during this procedure, so more water must be added by
opening the valve at inlet hose to maintain the optimal pressure 1,5 bar.
•When kettle is vented, close the valve at inlet hose and remove the water connection
and stop the circulating pump.

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To change mode for circulation pump, press
left key to enter the settings menu.
Go to line “Circulat. Pump:” and then change
the value to “AUTO” by pressing down key.
•With kettle properly vented you will have 1,5 bar pressure inside the kettle. During
operation you will have to check the water pressure regulary and add water if pressure
drops.
Water quality
The quality of the water used for washing, rinsing, heating, cooling is very important. The
water used must be appropriate for drinking. This requirements must be fulfiled to prevent
accumulation of bacteria on equipment surfaces. It is also important to prevent accumulation of
lime scale and to prevent corrosion on surfaces inside the device. Water must be clean both
microbiologically and chemically.
Microbiological requirements for water
All coliform bacteria
Absent in 100ml
Faecal coliform bacteria
Absent in 100ml
Faecal streptococci
Absent in 100ml
Spores of sulfide reducing clostridium
Absent in 100ml
Microflora standard (PCA) at 22°C
Less than 100 CFU in 1ml
Microflora standard (PCA) at 37°C
Less than 100 CFU in 1ml
Pathogenic microorganisms
Absent
Iron oxidizing bacteria
Absent
In the case of chlorination of non-potable water residues that could affect the quality of the
product or corrosion on the installations are not allowed.
Circulating pump
Manometer

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Chemical characteristics of water
-Ammonia, hydrochloric acid, sulfuric acid, hydrogen sulfide and hydrofluoric acid must
be absent from the water.
-The amount of iron can be 0.2 to 0.3 mg / l. The water must not taste of iron.
-Lead must be absent.
-Water should be free of alkaline earth metal salt. This will facilitate the cleaning and
disinfection and improve the transmission of energy and reduce plaque on surfaces.
-The content of chloride ions must be less than 50 ppm.
5. PROGRAM SETUP
Control panel
Control panel of micro controller unit has four buttons (see picture below).
•With pressing on a green button you start a process.
•With pressing on a red button you stop a process.
•With pressing MIX button you start rotating a stirrer or you stop rotating a stirrer if it is
already rotating.
•With four buttons (up, down, left, right) you manipulate process data and settings. With
keys up and down you can change entered values.
START
STOP
UP
RIGHT
LEFT
STIRRER
ON/OFF
DOWN
WARNING!
Hardness of water, water should be soft (4-8 °dH)
Base, acid scale of water, pH value should be neutral pH 7 (+/- 1)
Water must comply with standards DIN 2000 and DIN 1988.
Inappropriate water (inside the device) directly affects the life expectancy of the device
which could be shortened by half. Water should be neutralized (with use of filter,
softening devices, etc.) for longer life of the device.

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When device is energized you can read most important values on the screen.
Control panel of micro controller unit has also indicating led lights.
•ORANGE light above “MIX” button indicates that stirring is activated and mixer or
harp system rotates.
•GREEN BLINKING light on the upper left corner indicates that process is done.
•RED light on the upper left corner indicates that process of heating is currently active.
•BLUE light on the upper left corner indicates that process of heating is currently active.
Before start of the heating process make sure the device is properly filled with water and
that settings are properly adjusted.
TIME
AUTO
START
TIME
MILK
TEMPERATURE
STIRRER
STATUS
Milk
temperature
DEVICE
STATUS
RED –HEATING
BLUE - COOLING
GREEN BLINKING
–PROCESS ENDED
ORANGE –
STIRRER
ROTATING

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Main menu
The control panel of microprocessor unit is clear and easy to use. If no button is pressed it
will show main menu with all necessary data.
On the left side of control panel process
setpoints are displayed when process is
running, otherwise only current clock is
shown.
On the right side of control panel, milk
temperature is displayed in large font.
Below is information about the stirrer and
process state (heating, cooling)
There is also an icon displayed for each
heater and cooling valve when activated.
When the process is running on left side is
information about current phase (1-4),
Setpoint temperature and duration time
(elapsed time –set time)
Settings menu
The settings menu is entered when right key is pressed in main menu configuration.
First page of settings menu is a setpoint
table of temperatures [°C] and times [min].
With pressing up key, value is increased by
1 unit.
With pressing down key, value is decreased
by 1 unit.
With pressing right key, you switch to
another item.
0
20
40
60
80
100
050 100 150 200 250
Phase 1 Phase 2
Phase 3 Phase 4

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Second page of settings menu offers:
-Reduction of heating power from
10-100 % with increments by 10 %
To decrease, press key, to
increase, press key.
-Reduction of cooling power from
10-100 % with increments by 10 %
To decrease, press key, to
increase, press key.
-Option for autostart the process
with entered setpoint table. To
autostart select “Y” with key.
Clock can be set in this page of settings,
values can be changed by pressing up key
for increment and down key for decrease.
Third page of settings menu offers power
settings.
Power source can be set:
-Electric (only electric heaters are
used for heating)
-External + electric (External water
source is used to heat up milk to a
set temperature, above that
temperature external water source is
closed and only electro heaters are
used for heating)
-External (Only external water
source is used to heat up milk)
Switch temperature of milk at which
switch between external power source and
electrical power source is made. (when
External+electric is used)
Circulation pump can be manually
switched on with pressing key.

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Normal setting for circulation pump is
“AUTO”.
Duration time setting is factory made
“Recipe”. That means when milk reaches
setpoint temperature, it then holds at this
temperature for a set amount of time,
before it proceedes to the next phase.
If duration time is set as “Manual” , device
will hold at setpoint temperature for infinite
amount of time. Only with pressing the
key it switches to next phase.
Detailed menu
The detailed menu is entered when up key is pressed in main menu configuration.
In first page of detailed menu on the left
side:
-Milk temperature is shown
-Secondary water temperature is
shown
-Return water temperature is shown
-Pressure state of secondary water is
displayed
-Input sensor states are displayed in
binary form
-Output sensor states are displayed in
binary form
Input sensors in binary form:
Digit 1- level sensor
Digit 2-
Digit 3-
Digit 4-
Digit 5-
Output sensors in binary form:
Digit 1- Heater 1
Digit 2- Heater 2
Digit 3- Circulation pump
Digit 4- Cooling solenoid valve
Digit 5- Mixing valve open (external source)

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Digit 6- Mixing valve close (external
source)
Digit 7-
Digit 8- Motor valve open (external source)
On the right side process control parameters
are calculated.
-On represents temperature of water
when command is activated
-Off represents temperature of water
when command is deactivated
-Cas represents the inclination of
heating curve (for fast or slow
process characterization)
Second page of detailed menu shows
simplified state of main device components.
When component is active the value is 1, if
component is deactivated, value is “0”
Third page of detailed menu shows
calculated parameters.
Heating difference value represents the
maximal heating difference between milk
and secondary water.
Cooling difference value represents the
maximal cooling difference between milk
and secondary water.
Actual difference between milk and
secondary water is calculated.
Analog value of Milk sensor is shown.
Analog value of Water sensor is shown.
Analog value of Return water sensor is
shown.

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Heating procedure
Before heating procedure device must be properly connected.
•Place the device on the firm, plain and stable floor. It is recommended that the source
of cooling water and the drain is not more than 2 m away from the device.
•Connect water supply to inlet hose and start filling procedure explained in chapter 3
•Connect power supply to electric case.
•Pour desired amount of milk into the kettle.
•Turn on the device –Turn the main switch on (located on the side of the electric case).
•Heating can begin when device is properly setup (see chapter 6).
•Press green button to start the heating process. The red light on the upper left part of
control box is lit, indicating the heating is in progress. The display shows the present
temperature and begins to heat till setpoint temperature is reached.
•After set temperature is reached heating transforms to holding, control unit beeps and
the holding time is displayed on screen.
•Device switches to next phase automatically when holding time is passed and stops the
process automatically when fourth phase holding time is passed.
•You can switch the phases if you want, by pressing the start key.
Cooling procedure
Before cooling procedure device must be properly connected. (see chapter 1, 3 and 5).
•Connect cooling water to cooling water inlet connection
•Connect drain hose to cooling water outlet connection.
Slowly open the valve on your water network or cooling tank, that you connected inlet hose to.
Cooling water supply must allways be connected to the device, device will open the flow
automatically, when needed. When setpoint temperature of milk will be lower than current
temperature of milk, the device will automatically start the cooling procedure. The blue light
on the upper left part of control box is lit, indicating the cooling is in progress. Cold water will
slowly come in the device’s plate exchanger and out through outlet hose to the drain or back
to cooling tank (differs from your connection). Cooling speed depends on cooling water
temperature and flow. When desired temperature is reached, cold water flow will be
automatically stopped by solenoid valve.
Cover the kettle with two part lid. If kettle is not covered with lid, the time of heating
will be longer and it will not reach maximal stated temperature!
ATTENTION:
Cooling water coming out of plate heat exchanger hose is hot!
Be careful that hose for outlet cooling water is free (is not pressed)
If you want to move on second process, even if first process is not finished yet, just
press key start.

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6. CLEANING
Before cleaning make sure that the device is switched off and disconnected from main power
supply. Some of device parts could be hot, let them cool down before cleaning.
•The milk kettle and the cover should be cleaned with hot water adding fat soluble
detergents. Afterwards these parts should be rinsed with pure water.
•Other eqipment shall be cleaned only with wet cloth and afterwards dried with dry cloth.
•Do not use abrasive materials to avoid scratches.
•After use always clean the kettle. Do not use aggressive detergent.
•If milk or cream rests get dry do not remove them with sharp objects or sharp duster.
Detergents
The base and acid for cleaning must meet the specifications of the manufacturer and should not
contain foreign content, which would change the effect of the cleaning solution and affect the
equipment. The same applies to disinfectants.
-The base detergent which is usually used is sodium hydroxide (NaOH, caustic soda)
with concentration 30/36%. Dilute it to a final concentration of 0.2 / 2% at 70 ° C.
-Maximum content of chloride ions in the solution of sodium hydroxide is 50 ppm. The
solution should not contain impurities.
-The acid detergent which is normally used is a solution of nitric acid (NOH3) 33/36%
concentration. Dilute it to a final concentration of 0.5 / 2% at 65°C.
-Maximum content of chloride ions in the solution of nitric acid is 50 ppm. The solution
should not contain impurities.
Please note!
Before cleaning you must always disconnect device from electricity.
Use lift handle to lean the empty kettle for easy cleaning.
Ensure that no water comes into contact with electronics and electronic parts.