Tetra Alcip 10 User manual

2.212134240101fro.fm
OM
Doc No. OM-1213424-0101
Tetra Alcip® 10
TPOP MINI
Operation Manual

This document is valid for:
Series No/ Machine No
OM
Operation Manual
2.212134240101fro.fm
Issue 2002-01
Tetra Pak Dairy & Beverage Systems AB
Doc No. OM-1213424-0101

Table of contents
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Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Document. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Use of hazard information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Cleaning solution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
General description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Requirements on personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Operator station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Risk area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Denominations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Process description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Denomination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
General rules for indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Control system menu tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
List of alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Manual preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Preparation with metering pump . . . . . . . . . . . . . . . . . . . . . . . . 41
Preparation using the by-pass . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Initial start of cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Cleaning of package machine (optional) . . . . . . . . . . . . . . . . . . 46
Initial start of stations programs . . . . . . . . . . . . . . . . . . . . . . . . . 47
Stepping of cleaning cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Drain of tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Table of contents
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Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Inspection/change of parameter values . . . . . . . . . . . . . . . . . . . 51
Inspection/change of controllers . . . . . . . . . . . . . . . . . . . . . . . . 53

Introduction
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Introduction
This section contains basic information about this manual and the
Tetra Pak equipment described.
To ensure maximum safety, always read the section Safety precautions
before carrying out any work on the unit.
Equipment
Intended use of this Tetra Pak equipment
This unit is intended for use according to the specifications in Technical data
(see Technical Manual) and related documents.
Tetra Pak will not be held responsible for injury or damage if the equipment is
used for any other purpose.
Service
If problems are encountered when operating the unit, contact the nearest Tetra
Pak service station.
Manufacturer
This Tetra Pak equipment was produced by:
Tetra Pak Dairy & Beverage Systems AB
Box 64
S-221 00 LUND
Sweden
Unit identification
All units carry a machine plate stating:
– unit identification
– data unique to the unit
Have this information available before contacting Tetra Pak concerning this
particular unit.
WARNING!
Machine Type
Drawing Spec.
Machine No.
Manufacturer
Year of manufacture
Tetra Pak

Introduction
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Document
Operation Manual (OM)
The purpose of this Operation Manual is to provide the operator with
information on how to operate the machine.
Tetra Pak recommend that you study it carefully, and - above all - ensure its
availability to those who will be operating the unit.
Furthermore, it is important that you:
– keep the manual for the life of the equipment
– pass the manual on to any subsequent owner or user of the equipment.
Tetra Pak will not be held responsible for any breakdown of the equipment
caused by the owner’s failure to follow the instructions given in this manual.
Design modifications
The information given in this document is in accordance with the design and
construction of the machine at the time it was delivered by the Tetra Pak
machine production facility.
Further copies
Additional copies can be ordered from the nearest Tetra Pak service station.
When ordering technical publications, always quote the document number
printed on the front cover of the document concerned.
Document producer
This document was produced by:
Tetra Pak Dairy & Beverage Systems AB
Box 64
S-221 00 LUND
Sweden
Number of pages
This document contains a total of 56 pages.
Copyright 2001 Tetra Pak Dairy & Beverage Systems AB
All rights reserved. No parts of this document or application software used in
the product may be edited, reproduced or copied in any form or by any means
without the written permission of Tetra Pak Dairy & Beverage Systems AB.

Safety precautions
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Safety precautions
To ensure maximum safety for the operator, always read this
section carefully before carrying out any work on the machine or
making any adjustments.
Use of hazard information
Failure to observe this information results in immediate danger to life.
Failure to observe this information can result in major personal injury or
loss of life
Caution! Failure to observe this information can result in minor personal injury or
damage to the equipment.
DANGER!
WARNING!

Safety precautions
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General
Only trained personnel are allowed to operate the machine. The machine may
only be used in accordance with the instructions given in the manuals delivered
with the equipment.
If the safety precautions are not followed, there is risk of personal injury.
This is an automated machine. It is controlled by a process controller and will
change its mode of operation without operator intervention. All personnel must
therefore:
• stay outside the safety area
• regard all electrical equipment as live
• regard all pipes as hot
• use hearing protection.
Before carrying out maintenance and repair:
• shut off main steam supply
• switch off power
• allow the machine to cool down and adjust to atmospheric pressure
• rinse out concentrated chemicals and cleaning solution with water from
pipes and pumps
• inform the operator and other relevant personnel about the work you intend
to do
• post warning signs in prominent places.
Pipes and other parts of this machine may be hot. Contact with hot equipment
may result in severe burns. Avoid contact with hot equipment.
This machine operates under pressurized conditions. All personnel must
therefore:
• watch out for leakage
• depressurize the equipment before attempting maintenance and repair work
• watch out for blasts of air/steam from safety valves.
Keep the doors of the control panel closed to protect it from water and steam.

Safety precautions
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Cleaning solution
Handling of cleaning solution
Cleaning solutions normally contain caustic soda (NaOH) or nitric acid
(HNO3). These chemicals may cause burning to skin and eyes. Follow the
instructions given by the supplier.
Whenever there is a risk of exposure to these chemicals, always wear:
• safety glasses
• protective gloves
• shoes made of PVC or PE plastic, or rubber
• apron.
In the case of an accident involving cleaning solution, the basic rule is to rinse
the affected area as soon as possible with as much water as possible.
For this reason, always make sure that the showers work, that there are
additional washing facilities, and that an eyewash device is available at or near
each machine site.
Emergency precautions
If swallowed
If you happen to swallow cleaning solution:
• drink large amounts of lukewarm water (in order to dilute the cleaning
solution); then seek medical attention immediately.
Contact with eyes
If cleaning solution is splashed into your eyes:
• wash the eyes thoroughlywith lukewarm water for 15 minutes (keep
eyelids widely apart); then seek medical attention immediately.
Contact with skin or clothes
If cleaning solution comes into contact with skin or clothes:
• rinse immediately with plenty of water
• thoroughly wash the clothes before they are worn again. If skin burns
appear, seek medical advice immediately.
If inhaled
If you experience irritation or pain due to having inhaled vaporized cleaning
solution:
• leave the affected area to get fresh air. If the symptoms become worse, seek
medical advice.

Safety precautions
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General description
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General description
Application
All food products demand a very strict standard of hygiene in the manufacturing
process. The raw materials (e.g. milk, juice, beer) are in contact with a number
of surfaces, all of which are potential sources of infection. Sterilization can
reduce but not entirely eliminate the consequences of such an infection. The
cleaning and disinfection equipment is therefore a most important aspect of the
processing in a food plant.
Tetra Alcip 10 is a complete, frame mounted, Cleaning-in-place unit designed
especially to meet the requirements of the food industry.
Control of the CIP is carried out by a process control system, once the program
has been started, the cleaning sequence is fully automatic regarding times,
temperatures, routing of liquids etc.
Requirements on personnel
Operator: basic knowledge of industrial processes.
Caution! Unauthorized personnel
Operation by unauthorized personnel may endanger personnel and
property.
Operator station
In front of the control panel.
Risk area
2 - 3 metres around the equipment due to:
– hot pipes and equipment
– jets of hot liquid

General description
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Denominations
Symbol
Disinfectant metering pump
Lye metering pump
Acid metering pump
GF100604
1
2 3
4
56
7
8910
11
12
13
14 15
1 Acid buffert tank (option)
2 Acid metering pump (option)
3 Lye metering pump (option)
4 Lye buffert tank (option)
5 Level switch
6 Plate heat exchanger
7 Flow switch
8 Steam regulating valve
9Flowmeter
10 Control panel
11 Conductivity transmitter
12 Flow regulating valve
13 Pressure pump
14 Steam trap
15 Balance tank

General description
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Buffer tanks
The buffer tanks are used to:
– prepare cleaning solution
– contain cleaning solution to minimize cleaning solution losses
The tanks are equipped with low level switches indicating when the tanks are
empty.
Control panel
Contains all equipment necessary for:
– indication of process status
– supervision of process performance
– control of automatic functions
Tetra Alcip automation is based on a process controller. This controller features:
– process sequence control
– timers
– control loops
– text display
– numeric and function keyboard
–
Plate heat exchanger (PHE)
PHE is used to heat the cleaning solution with use of steam. The plates are
assembled in packs and clamped in a frame, each adjacent pair of plates forming
a flow channel with the two media flowing in alternate channels. Two or more
sections can be housed in the same frame.

General description
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Process description
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Process description
Presented here is a flow chart simplified to enhance the understanding of the
process. Please see complete flowchart in Technical Manual for details.
Flow during circulation
Cleaning liquid is pumped by pump M1 out to the process lines/CIP circuits.
Returning cleaning liquid flows back to the Tetra Alcip via CIP return pipes
Cleaning liquid flows:
–during lye circulation: through V103, M1, cleaning object, V113, and
the CIP-solution tank,
–during acid circulation: through V102, M1, cleaning object, V112 and
the CIP-solution tank.
Flow to drain
Returning flow is routed to drain via V151.
Flow during disinfection (Option)
Disinfectant is pumped into the CIP circuit via the metering pump M9 and the
disinfection solution is circulated over the balance tank.
MM
2
TE
1
TE
3
Water Water
Lye Acid
Water Lye tank Acid tank Rinse water tank
Balance
tank
CIP
pressure
CIP
return

Process description
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Flow during rinse
Water flows via V100, V101 and pump M1 out to the process lines. Remaining
(in the pipes) cleaning liquid flows back to the Tetra Alcip via CIP return pipes.
The mixture of cleaning liquid/water, and finally pure water, is routed to drain
via V151.
Flow during recovery
Returning cleaning solution is routed to appropriate CIP-solution tank, or rinse
water tank.
Flow during hot water circulation
Water is circulated through the cleaning circuit, by-passing the balance tank.
Cleaning of Active Cleaning Objects (ACO)
The cleaning sequence is controlled by the ACO; the Tetra Alcip merely
executes the commands received.
The ACO can command the Tetra Alcip to:
– stand-by for cleaning of ACO,
– deliver liquid,
– collect liquid,
– heat the liquid being delivered.
The liquids available depends on the Tetra Alcip configuration (lye, acid, rinse
water).
The conductivity instrument sorts the returned liquid to a tank or to drain.
Cleaning sequence step programmes
Tetra Alcip supports 11 types of programmes and a total of 16 cleaning circuits.
Preparation & emptying programs Cleaning programmes
31. Lye preparation 1. Lye
32. Acid preparation 2. Acid
41. Lye emptying 3. Lye and acid
42. Acid emptying 4. Disinfection
52. Rinse water emptying 5. Hot water
6. Flush

Process description
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Programme sequence steps
No Description Note
1Water to object
Water is flushed through the cleaning circuit for a
preset time. Heating is started.
Water from balance
tank if rinse water does
not exist
21 Lye to object
Water in the circuit is purged to drain by lye solution
until lye reaches concerned circuit.
In-line system: water
from circulation tank
22 Empty object
Pump and heating stops during a preset time to allow
the tank to be completely drained.
The step is jumped by
unless “Tank” is config-
ured in “Object type
selection”.
23 Lye to CIP unit
Heating restarts and water in the circuit is purged to
drain by lye solution until the conductivity transmitter
in the return pipe detects the lye solution. This step is
supervised by a min. and a max. time.
In line system: water
from circulation tank,
maximum filling time is
used as step condition.
24 In-line dosing
Lye solution is dosed while water is circulated for a
preset time.
The step is jumped by
if In-line system is not
configured
25 Lye circulation
Hot lye is circulated during a preset time. If tempera-
ture drops below a preset value the time counting will
stop. Time counting restarts when correct tempera-
ture is achieved.
30 Empty balance tank
balance tank is completely emptied.
The step is jumped by
if In-line system is not
configured
31 Water to object
Lye in the circuit is purged to lye tank by water until
water reaches concerned circuit.
In-line system: return
to drain.
32 Empty object
Pump and heating stops during a preset time to allow
the tank to be completely drained.
The step is jumped by
unless “Tank” is config-
ured in “Object type
selection”.
33 Lye recovery
Water purges the lye in the circuit to the CIP solution
tank. Purge continues until the conductivity transmit-
ter in the return pipe detects water. This step is
supervised by a minimum and a maximum time.
41 Acid to object
Water in the circuit is purged to drain by acid solution
until acid reaches concerned circuit.
42 Empty object
Pump and heating stops during a preset time to allow
the tank to be completely drained.
The step is jumped by
unless “Tank” is config-
ured in “Object type
selection”.

Process description
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43 Acid to CIP unit
Heating restarts and water in the circuit is purged by
acid solution until the conductivity transmitter in the
return pipe detects the acid solution. This step is
supervised by a min. and a max. time.
In-line system: water
from balance tank,
maximum filling time is
used as step condition.
44 In-line dosing
Acid solution is dosed while water is circulated for a
preset time.
The step is jumped by
if In-line system is not
configured
45 Acid circulation
Hot acid is circulated during a preset time. If temper-
ature drops below a preset value the time counting
will stop. Time counting restarts when correct tem-
perature is achieved.
50 Empty balance tank
Balance tank is completely drained.
The step is jumped by
if In-line system is not
configured
51 Water to object
Acid in the circuit is purged to acid tank by water until
water reaches concerned circuit.
In-line system: return
to drain.
52 Empty object
Pump and heating stops during a preset time to allow
the tank to be completely empty.
The step is jumped by
unless “Tank” is config-
ured in “Object type
selection”.
53 Acid recovery
Water purges the acid in the circuit to the CIP solu-
tion tank. Purge continues until the conductivity
transmitter in the return pipe detects water. This step
is supervised by a minumun and a maximum time.
61 Hot water circulation
Water is circulated for a preset time. If the tempera-
ture drops below a preset value the time counting will
stop. Time counting restarts when correct tempera-
ture is achieved.
62 Final hot water rinse
Water flows through the circuit to drain for a preset
time.
The step is executed
only if temperature set-
point is > 0 ºC.
71 Water to object
Water is sent to the circuit for a preset time.
72 Empty object
Pump and heating stops during a preset time to allow
the tank to be completetly drained.
The step is jumped by
unless “Tank” is config-
ured in “Object type
selection”.
73 Water to CIP unit
Heating restarts and water in the circuit is flushed to
drain fo a preset time.
74 In-line dosing
Disinfection is dosed while water is circulated for a
preset time.
No Description Note

Process description
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75 Disinfection circulation
Water and disinfection is circulated during a preset
time. If temperature drops below a preset value the
time counting will stop. Time counting restarts when
correct temperature is achieved.
76 Empty balance tank
Balance tank is completely emptied.
77 Final disinfection rinse
Water flows through the circuit to drain for a preset
time.
81 Water to object
Water is flushed through the circuit to drain for a pre-
set time.
Return to rinse water
tank if program no. 6 is
not operating.
91 Empty object
Pump and heating stops during a preset time to allow
the tank to be completetly drained.
Return to rinse water
tank if program no. 6 is
not operating.
(The step is jumped by
unless Tank is config-
ured in Object selec-
tion)
No Description Note

Process description
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Indications during cleaning of ACO
A step sequence is not used in Tetra Alcip during cleaning of ACO.
The function/command in progress is indicated on the operators panel (TPOP as
a three digit value.
The following values are used for the 2:nd and 3:rd digit.
1:st digit = “8”
= “9”
Cleaning of ACO
Cleaning of ACOa
a. with the conductivity transmitter activating the return valve defined by the return
function
2:nd digit request command function
3:rd digit return command function
Function 2:nd digit request 3:rd digit request
None 0 0
Lye 6 6
Acid 5 5
Water 4 4a
a. When return to balance tank during “Hot water circulation”.
Rinse water 3 3
Closed return - 1