Packo REM/DX Series User manual

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Installation manual
Milk cooling tanks
General part –160251

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Installation manual: General part
About this manual...............................................................................................................................7
About this manual...............................................................................................................................7
Introduction...................................................................................................................................................................7
Use of the icons.............................................................................................................................................................7
Procedures.....................................................................................................................................................................7
Changes.........................................................................................................................................................................7
Safety instructions...............................................................................................................................8
Stickers..........................................................................................................................................................................8
Maintenance and repairs................................................................................................................................................9
Electricity ......................................................................................................................................................................9
Entering in the tank .....................................................................................................................................................10
Cleaning ......................................................................................................................................................................10
Cleaning unit ...............................................................................................................................................................10
General ........................................................................................................................................................................10
Installation instructions....................................................................................................................11
Overview..........................................................................................................................................................11
Introduction.................................................................................................................................................................11
Warning.......................................................................................................................................................................11
On delivery.......................................................................................................................................................12
Checking the delivery..................................................................................................................................................12
Unpacking ...................................................................................................................................................................12
Moving closed tanks....................................................................................................................................................12
Moving VM/DX..........................................................................................................................................................13
About your milk cooling tank ..........................................................................................................................14
General specifications .................................................................................................................................................14
Measurements...................................................................................................................................................16
Table of measurements and weights of the different DX/DIB-models .......................................................................16
Placing the tank................................................................................................................................................19
Before placing .............................................................................................................................................................19
Directions ....................................................................................................................................................................19
Placing the agitator...........................................................................................................................................20
Introduction.................................................................................................................................................................20
Placing the agitator on closed tanks ............................................................................................................................21
Placing the agitator on open tanks (OM/DX and OM/IB)...........................................................................................22
Placing the agitator on VM/DX...................................................................................................................................23
Levelling the tank.............................................................................................................................................24

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For your information..............................................................................................................................................24
Introduction............................................................................................................................................................24
Procedure...............................................................................................................................................................24
Table for levelling standard LEM tanks......................................................................................................................25
Table for levelling Australian LEM tanks...................................................................................................................26
Table for levelling LS..................................................................................................................................................27
Table for levelling ADX..............................................................................................................................................28
Table for levelling REM tanks ....................................................................................................................................29
Table for levelling RS .................................................................................................................................................30
Table for levelling CRM tanks....................................................................................................................................31
Table for levelling RM/IB...........................................................................................................................................32
Table for levelling OM/DX.........................................................................................................................................33
Table for levelling OM/IB...........................................................................................................................................34
Table for levelling VM/DX.........................................................................................................................................35
Cooling...............................................................................................................................................36
Overview..........................................................................................................................................................36
Introduction.................................................................................................................................................................36
The cooling unit ...............................................................................................................................................37
Illustration ...................................................................................................................................................................37
Parts.............................................................................................................................................................................37
Positioning of the remote cooling unit ........................................................................................................................38
Placing the cooling unit .........................................................................................................................................38
Schematic diagram.................................................................................................................................................38
Piping the remote cooling unit ....................................................................................................................................39
Method...................................................................................................................................................................39
Fitting oil traps.......................................................................................................................................................40
Warnings:...............................................................................................................................................................40
Setting the the pressure switches.................................................................................................................................41
Warning .................................................................................................................................................................41
Low-pressure pressostat.........................................................................................................................................41
High-presssure pressostaat.....................................................................................................................................42
Control of fan motor(s)..........................................................................................................................................42
Fan speed controller ....................................................................................................................................................43
Description.............................................................................................................................................................43
Caution........................................................................................................................................................................43
For your information ...................................................................................................................................................43
Parts of the DX/DIB milk cooling tank............................................................................................................44
Illustration ...................................................................................................................................................................44
Parts.............................................................................................................................................................................44
The DX cooling system...............................................................................................................................................45
Schedule.................................................................................................................................................................45
Parts.......................................................................................................................................................................45
Operation ...............................................................................................................................................................46
Parts of the IB milk cooling tank......................................................................................................................47
Illustration ...................................................................................................................................................................47

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Parts.............................................................................................................................................................................47
The IB cooling system.................................................................................................................................................48
The IB cooling system...........................................................................................................................................48
Diagram .................................................................................................................................................................48
Parts.......................................................................................................................................................................49
Operation of the IB cooling system .......................................................................................................................49
Operation of the cooling unit.................................................................................................................................49
IB: filling the ice water reservoir.................................................................................................................................51
Introduction............................................................................................................................................................51
Warning .................................................................................................................................................................51
Water quality .........................................................................................................................................................51
Inhibitor .................................................................................................................................................................51
Concentration.........................................................................................................................................................51
How to fill it...........................................................................................................................................................52
IB ice thickness sensors.........................................................................................................................................52
TR15......................................................................................................................................................................53
Time switch ...........................................................................................................................................................53
Electrical............................................................................................................................................54
Electrical connection........................................................................................................................................54
Introduction.................................................................................................................................................................54
Regulations..................................................................................................................................................................54
Power required ............................................................................................................................................................54
Connections.................................................................................................................................................................54
Crank-case heating.................................................................................................................................................54
Softstarter ....................................................................................................................................................................54
Voltage control relay...................................................................................................................................................55
Description.............................................................................................................................................................55
Diagram .................................................................................................................................................................55
Differential cut-out......................................................................................................................................................56
Earth............................................................................................................................................................................56
Bonding.......................................................................................................................................................................56
Power...........................................................................................................................................................................56
REM/DX, RS/DX..................................................................................................................................................56
LEM/DX, RS/DX ..................................................................................................................................................57
REM/DIB, RS/DIB, LEM/DIB, LS/DIB...............................................................................................................58
A-TANK................................................................................................................................................................58
RM/IB....................................................................................................................................................................58
OM/DX, OM/IB ....................................................................................................................................................59
EIB, IBR, IBR (COMPACT).................................................................................................................................59
Supply cable ................................................................................................................................................................60
Cleaning.............................................................................................................................................61
Connection to the water mains (with automatic cleaning) ...............................................................................61
Water quality...............................................................................................................................................................61
Water pressure and flow..............................................................................................................................................61
Connect to the water mains .........................................................................................................................................61
About cleaning the milk cooling tank ..............................................................................................................62

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Why clean it?...............................................................................................................................................................62
Automatic cleaning system..........................................................................................................................................62
When to clean..............................................................................................................................................................62
Operation of the automatic cleaning system................................................................................................................62
Options.............................................................................................................................................................63
Automatic dosing ........................................................................................................................................................63
ECO-WASH................................................................................................................................................................63
Manual cooling and cleaning.......................................................................................................................................63
Separation of the rinse waters......................................................................................................................................63
Second dosage cup or third dosage pump....................................................................................................................63
Drain water detection ..................................................................................................................................................63
Hot water boiler...........................................................................................................................................................63
More information ........................................................................................................................................................63
Cleaning agents................................................................................................................................................64
Choise of cleaning agent .............................................................................................................................................64
Using acid or alkaline cleaning products.....................................................................................................................64
Warning.......................................................................................................................................................................64
Recommended products ..............................................................................................................................................64
Dose.............................................................................................................................................................................64
Automatic dosing ........................................................................................................................................................65
The standard automatic cleaning system..........................................................................................................66
Picture..........................................................................................................................................................................66
Parts.............................................................................................................................................................................66
The ECO-WASH automatic cleaning system ..................................................................................................67
Picture..........................................................................................................................................................................67
Parts.............................................................................................................................................................................67
Manual cooling and cleaning (option)..............................................................................................................68
Warning.......................................................................................................................................................................68
Manual cooling............................................................................................................................................................68
Manual cleaning ..........................................................................................................................................................68
Cleaning phases...........................................................................................................................................................69
Commissioning..................................................................................................................................70
Maintenance and trouble shooting...................................................................................................71
Overview..........................................................................................................................................................71
Introduction.................................................................................................................................................................71
Maintenance and checks...................................................................................................................................71
Introduction.................................................................................................................................................................71
Clean the outside .........................................................................................................................................................71
Cleaning the inside ......................................................................................................................................................71
Cleaning the condensor ...............................................................................................................................................71

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Checks.........................................................................................................................................................................72
Solving problems..............................................................................................................................................73
What to do in case of a problem..................................................................................................................................73
After-sales department.................................................................................................................................................73
Safety fuses .................................................................................................................................................................73
Direction of rotation of the motors ........................................................................................................................73
Cooling compressor.....................................................................................................................................................73
Manual cooling and cleaning.......................................................................................................................................74
Specials ..............................................................................................................................................75
The DIB cooling system...................................................................................................................................75
The DIB cooling system ........................................................................................................................................75
Schematic overview...............................................................................................................................................75
Parts.......................................................................................................................................................................75
Operation ...............................................................................................................................................................76
DIB: connection to the ice builder ...................................................................................................................77
Introduction............................................................................................................................................................77
Connection at the milk cooling tank......................................................................................................................77
Connection at the ice builder .................................................................................................................................77
Attention................................................................................................................................................................77
Pre-cooling.......................................................................................................................................................78
Installation...................................................................................................................................................................78

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About this manual
Introduction
The company PACKO INOX N.V. thanks you for choosing one of its products. It hopes it may also count
you as one of its satisfied customers. That is why it does everything possible to inform and be of service to
you as well as possible.
Use of the icons
A number of icons are used in this manual, to draw your attention to, for example, safety information. The
table below provides an overview of the icons used and what they mean:
Icon
Meaning
Description
Remark
A remark provides additional information about a certain topic. The information in a
remark is not invaluable, but can be useful.
Attention!
If you do not follow the directions precisely, then:
The system can be damaged (in this case, damage is not covered by the warranty)
The quality of the milk can be affected.
Warning!
A warning draws your attention to a possible danger or risk of personal injury.
Procedures
The procedures in this manual have been divided into numbered steps. The steps should be carried out in the
order described.
Changes
The company PACKO INOX N.V. reserves the right to make changes to the manual at any time and without
prior notice.

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Safety instructions
Stickers
The stickers below can be fixed on to your tank to assure the safety of the use of the tank. They cannot be
removed according to the CE regulations:
Sticker
Instructions
The machine or part of it is built according
to the CE regulations.
The machine or part of it is certified
according to the EN13732 standard.
You are invited to read the instructions.
Danger : machinery connected to electrical
network
Do not spray water on the motor.

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Sticker
Instructions
Do not spray water on the pump.
Switch off and lock the main switch before
entering the tank.
Insure there is nobody in the tank before
closing the manhole cover.
Maintenance and repairs
Only trained personnel may carry out maintenance or repairs.
Electricity
Before doing the following, turn the main switch to 0 or OFF and lock it:
Before opening the electrical control box of the tank.
Before the servicing of the milk cooling tank.
Before checking the agitator blades, spray balls or the inner vessel.
In case of electrical or mechanical faults, inform the installer immediately.
Before you start working on the cooling unit
Make sure that your hands are dry when you use the buttons.
When you touch electronic equipment make sure you unload yourself of static electricity.
0 1
1
230 / 400V

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Entering in the tank
If someone has to get into the tank for specific work, this should be done under supervision, and only when
the power has been switched off. It must not be possible for the agitator to start. That is why you should
always turn the main switch to 0 or OFF and lock it.
Always use a ladder to enter the milk cooling tank
Cleaning
Never spray water under high pressure at the milk cooling tank.
Keep cleaning agents away from children and animals. Read the packaging or the instructions carefully and
always follow the safety instructions.
Wear protective gloves and safety goggles whilst using the cleaning agents.
Cleaning unit
Never sit, lean or place any foreign objects on the cooling unit.
Do not put anything in front of the condenser. This will reduce air circulation and affect cooling efficiency.
General
Only use the tank for milk. The tank is not suitable for other fluids or solids.
Do not put anything on the tank.
Always wear sturdy, anti-slip footwear when using the steps.
Always hold the handle of the manhole lid when opening or closing the manhole to insure your hands
cannot get caught between the tank and the lid.
Pay attention to the hoses for water supply when mounting the SS plate

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Installation instructions
Overview
Introduction
In this chapter you will find detailed directions for installing your milk cooling tank.
Warning
Only a recognised installer may carry out the installation. The installation is to be carried out in
the order described below.

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On delivery
Checking the delivery
Check whether the delivery is complete, in other words whether it completely meets the order. Check what
has been delivered against what is written on the delivery note. Write any shortcomings on the delivery note
before signing it.
If there is something missing you should immediately inform your supplier.
Unpacking
The tank was packaged with the greatest care for transport. However, when you unpack it, we do advise that
you check for possible damage which the tank may have incurred during transport.
In case of damage, please inform your supplier immediately.
Moving closed tanks
It is important that the guidelines below are observed when lifting a closed tank. If not, the tank may
be damaged. See transport instruction on the packing.
See center of gravity
10 000 - 25 000 l
<10 000 l

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Moving VM/DX
It is important that the guidelines below are observed when moving a tank with a built on cooling unit.
If not, the tank may be damaged.
See center of gravity
WRONG
RIGHT

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About your milk cooling tank
General specifications
The average sound level of the tank (excl. cooling unit) in the working area is less than 70 dBa.
Electrical connections:
-Tank: 200 –240V / 50-60 Hz nominal
No harmonic interferences
-Condensing unit: - Single-phase : 230 V / 50-60 Hz nominal
- Three-phase: 3 x 400 V / 50-60 Hz nominal (3Ph+N)
A protection against low voltage must be installed
Ambient conditions : ambient temperature :
-The tank is operational between -10°C and + 50°C
-The tank can be stored between -20°C and + 70°C
On the tank a fabrication plate is installed on which you find the following information :
1
2
3
17
16
15
4
5
6
7
8
9
10
11
14 13 12

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Item
Function
Item
Function
1
Type of tank: e.g. REM/DX
10
Max. operating current (A)
2
Serial number
11
The absorbed power (KW)
3
Internal code
12
Performance class of the tank (e.g. 2BII)
4
Nominal volume of the tank (L)
13
Nominal kg cooling agent to be charged to the
cooling unit
5
Fabrication date
14
Frequency (Hz)
6
Weight of the tank (kg)
15
Voltage (e.g. 3 x 400 V + N)
7
Test pressure of the heat exchanger (bar)
16
Type of cooling agent (e.g. R404A)
8
Working pressure of the heat exchanger (bar)
17
Manufactured according european standard.
(e.g. EN13732)
9
Protection grade of the control cabinet (e.g.
IP24)

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Measurements
Table of measurements and weights of the different DX/DIB-models
H
l L
Type tank
Volume (in litres)
Milkings
L * (in mm)
l (in mm)
H (in mm)
Weight (in kg)
REM/DX
REM/DIB
1050
T2 –T4
1944
1308
1550 –1585
220
1300
T2 –T4
2250
1308
1550 –1585
295
1700
T2 –T4
2616
1308
1550 –1585
365
2100
T2 –T4
3099
1308
1550 –1585
412
2600
T2 –T4
2458
1660
1852 - 1972
437
3100
T2 –T4
2818
1660
1852 - 1972
500
3800
T2 –T4
3050
1800
1840 –1960
590
4400
T2 –T4
3420
1800
1840 –1960
667
5000
T2 –T4
3760
1800
1840 –1960
730
6150
T2 –T4
3440
2100
2058 - 2178
854
7200
T2 –T4
3900
2100
2058 - 2178
901
8200
T2 –T4
4355
2100
2058 - 2178
1090
9000
T2 –T4
4227
2233
2208 –2328
1155
10000
T2 –T4
4567
2233
2208 - 2328
1229
12000
T2 –T4
5356
2233
2208 - 2328
1450
15000
T2 –T4
6532
2233
2208 - 2328
1800
RS/DX -
RS/DIB
5000
8000
T4
3686
2233
2208 - 2328
1065
LEM/DX +
LEM/DIB
5000
T4 –T6
2965
1876
2260 - 2380
785
6200
T4 –T6
3525
1876
2260 - 2380
905
7000
T4 –T6
3905
1876
2260 - 2380
990
8000
T4 –T6
4375
1876
2260 - 2380
1120
9000
T4 –T6
4148
2033
2440 - 2560
1205

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Type tank
Volume (in litres)
Milkings
L * (in mm)
l (in mm)
H (in mm)
Weight (in kg)
10000
T4 –T6
4535
2033
2440 - 2560
1280
12000
T4 –T6
5335
2033
2440 - 2560
1495
14000
T4 –T6
5570
2133
2550 - 2670
1665
15500
T4 –T6
6115
2133
2550 - 2670
1800
18000
T4 –T6
6870
2133
2550 - 2670
1975
22000
T4 –T6
8165
2133
2550 - 2670
2245
25500
T4 –T6
9743
2133
2550 - 2670
2550
32000
T4 –T6
11648
2133
2550 - 2670
3200
LS/DX
LS/DIB
10250
T6
4205
2133
2550 - 2670
1196
13100
T6
5195
2133
2550 - 2670
1414
14500
T6
4182
2500
2917 - 3037
1421
15500
T6
4358
2500
2917 –3037
1562
17500
T6
4967
2500
2917 –3037
1750
21500
T6
5932
2500
2917 –3037
2078
25500
T6
6752
2500
2917 –3037
2453
30450
T6
8205
2500
2917 - 3037
2925
A/DX
8150
T4 –T6
3705
2033
2440 –2560
980
10350
T4 –T6
3921
2203
2605 –2725
1080
12300
T4 –T6
4534
2203
2605 –2725
1270
* For ECO-WASH: L = L + 190 mm

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Table of measurements and weights of the different models RM/IB
Type tank
Volume (in litres)
Milkings
B*(in mm)
D (in mm)
F (in mm)
Weight
( in kg)
RM/IB
1600
T4
2710
1300
1630 –1750
429
T2
2710
1300
1825 –1945
464
2200
T4
3398
1300
1630 –1750
525
T2
3398
1300
1885 –1945
584
2800
T4
2590
1800
1996 –2116
601
T2
2590
1800
2179 –2299
682
3300
T4
2930
1800
1996 –2116
655
T2
2930
1800
2178 –2299
750
3800
T4
3245
1800
1996 –2116
730
T2
3245
1800
2178 –2299
830
4400
T4
3615
1800
1996 –2116
860
T2
3615
1800
2178 –2299
980
5000
T4
3955
1800
1996 –2116
940
T2
3955
1800
2178 –2299
1076
6000
T4
3955
1800
2269 –2382
1050
T2
4580
1800
2173 –2293
1240
7150
T4 –T6
4580
1800
2269 –2389
1300
9650
T4 –T6
4580
2256
2526 –2646
1700
12400
T6
5621
2256
2526 –2646
1930
15400
T6
6797
2256
2526 –2646
2240
* for ECO-WASH : B* = B + 190 mm

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Placing the tank
Before placing
If the free area above the tank in the dairy is insufficient, then put the agitator blade(s) inside the milk
vessel before placing the tank inside.
Directions
Put the tank in the dairy, bearing in mind the local regulations and the following directions:
The tank must be placed in a frost-free area.
Put the tank (together with the floor plate) on a sturdy and hard underground (concrete or tiles), which
can take a pressure of 12 N/mm² minimum.
Keep at least 0.6 metres around the tank (including e.g. steps, operator console, built on cooling
machine,…) free for cleaning it.
The space between the ceiling and the top ladder step should be min. 2m.
If necessary, you should install a ladder or platform in order to let the installer have access to the milk
entry point without risk.
Preferably, the door should be 20% wider than the maximum width of the milk cooling tank.
There must be a drain on the side of the milk outlet.
Preferably place the tank with the outlet towards a door opening to facilitate milk collection.
There must be sufficient ventilation and lighting in the dairy.

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Placing the agitator
Overview
Introduction
This section covers the installation procedure of the agitator, depending on the type of tank.