Tetra Pak HOYER COMET C User manual

CC901A
Tetra Pak
Hoyer
Tetra Pak Hoyer A/S Tetra Pak Hoyer Inc. Tetra Pak Hoyer S.p.A.
Soeren Nymarks Vej, 13 753 Geneva Parkway Via Monferrato, 52
DK 8270 Hoejbjerg P.O. Box 280 20098 San Giuliano Milanese (Milano)
Denmark Lake Geneva, WI 53147 Italy
Telephone + 45 89 393939 U.S.A. Telephone [phone]
Telefax + 45 86 292200 Telephone [phone] Telefax [phone]
Telex 68770 Alhoy DK Telefax [phone]
Wehopethattheinformationwillbeofhelptoyou.It
isbasedonconcretedataandonthebestofour
currentknowledge.
Readthecontentsofthemanualcarefully,including
thewarningsandrecommendations.Alsoreadthe
conditionsofsale,includingthosegoverningthe
warranty.
Nopartofthismanualmaybereproducedor
transmittedtothirdpartieswithoutthepriorwritten
permission of TETRAPAKHOYER.
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Machine HOYER COMET C
○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○○
Serial Number
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CC901A
Tetra Pak
Hoyer
F
1Machine identification data
2General
3Description of the machine and technical data
4Installation
5Set-up procedures
6Operating procedures
7Cleaning and maintenance
8Troubleshooting
9Spare parts catalogue
NOTE:
Allthe drawingsshowthemachine andstationsforproduction ontwolanes.
Ifthe dimensions of theproductallow,productiononthreelanes is also possible.

HOYER COMET C
CC901AA1-1
Tetra Pak
Hoyer
Contents
1 - MACHINE IDENTIFICATION DATA
1.1 Introduction..............................................................................................................1-2
1.2 Identification plate...................................................................................................1-2
1.3 Service centres.........................................................................................................1-3

CC901AA1-2
Tetra Pak
Hoyer
MODEL
SERIAL N.:
YEAR OF CONSTRUCTION:
ELECTRICAL SUPPLY:
PNEUMATIC SUPPLY:
REFRIGERANT:
HEATING GAS:
THERMAL CAPACITY:
kW
Kg.
Kcal/h
Via Monferrato, 52 - 20098 San Giuliano Milanese
( MI ) Italia - Tel. [phone] - Fax [phone] Made in Italy
Tetra Pak
Hoyer
V
bar Nlt/min.
ph Hz
Type
1.2 Identification plate
For maintenance and service operations not de-
scribedin this manual, or for anyotherproblems
of a technical nature, our Service Department is
at your complete disposal for information or to
Fig. 1.1 - Identification plate
1.1 Introduction
Thank you for buying a machine manufactured
by Tetra Pak Hoyer.
We recommend you read this manual as it is
essential for the installation, checking and
maintenance operations required to keep your
machine in perfect condition.
The manual contains tables, drawings and
diagramswhichwillallowyoutogainfamiliarity
with all parts of the machine.
Please let us know if any explanation has been
leftoutorisnotsufficientlydetailed.Wewilluse
yourcomments to improve thefunctionalnature
of this manual.
arrangeforthenecessarymeasurestobetaken.
WhencontactingourServiceDepartment,please
quote the data given on the identification plate
affixed to the machine and shown in Fig.1.1.

CC901AA 1-3
Tetra Pak
Hoyer
EUROPEand
MIDDLEEAST:
TetraPak HoyerA/S
SoerenNymarks Vej13
DK-8270Hoejbjerg
Denmark
Phone: [phone]
Fax: [phone]
Tlx:687 70 alhoy dk
TetraPak HoyerS.p.A.
Via Monferrato, 52
I- 20098 San GiulianoMilanese
(Milan)
Italy
Phone: + 39 2 98 29 21
Fax: + 39 2 98 80 171
Tetra Pak Hoyer France
c/o Tetra Laval Service SARL
R.C.S. Versailles B403 276 223
P.O. Box 56
F-78340 Les Clayes-Sous-Bois
France
Phone: [phone]
Fax: [phone]
NORTHAMERICA:
Tetra Pak Hoyer Inc.
753 Geneva Parkway
P.O. Box 280
Lake Geneva, WI 53127
USA
Phone: [phone]
Fax: [phone]
SOUTHAMERICA:
Tetra Pak Hoyer Industria e
Comércio Ltda.
Rua Napoleao de Barros, 1038
Cep04024-003 Sao Paulo-SP
Brazil
Phone: [phone]
Fax: [phone]
ASIA/PACIFIC:
Tetra Pak Hoyer Shanghai
Shanghai Overseas Chinese
Mansion
Room 2105-2107
No. 129, Yan'an Xi Lu
200040 Shanghai
P.R. China
Phone: [phone]
Fax: [phone]
Tetra Pak Hoyer Service
3rd Floor, Molace Building
2231 Pasong Tamo Street
Makati, Metro Manila
Philippines
Phone: [phone]
SOUTHKOREA:
Hoyer Ltd.
4fl. Dookyong Bldg.
66-1/9 Hannam-Dong
Yong San-Ku
140-210 Seoul
South Korea
Phone: [phone]
Fax: [phone]
THAILAND:
Tetra Pak Hoyer (Thai) Ltd.
1042Soi Poosin, SukhumvitSoi
66/1
Bangchak, Prakanong
Thailand
Phone: [phone]
Fax: [phone]
C.I.S.:
Tetra Pak Hoyer A/O
4th Rostovsky peureulok
Dom 1, stroenie 1
R-11921 Moscow
C.I.S.
Phone: [phone]
Fax: [phone]
1.3 Service Centres
If you have any requirement or problem that re-
quires our assistance, please contact one of the
following service centres, which are authorised
to perform maintenance and technical service
under warranty to Tetra Pak Hoyer machines.

HOYER COMET C
CC901AB2-1
Tetra Pak
Hoyer
Contents
2 - GENERAL
2.1 Declaration of conformity ........................................................................................ 2-2
2.2 Preliminary points .................................................................................................... 2-2
2.3 General safety rules.................................................................................................. 2-2
2.4 Special warnings ...................................................................................................... 2-3
2.5 Ambient operating limits ......................................................................................... 2-3

CC901AB2-2
Tetra Pak
Hoyer
2.1 Declaration of conformity
This machine has been manufactured in
accordance with international standards and
hygiene and sanitary legislation applicable to
food machinery.
In particular Tetra Pak Hoyer certifies, through
the Declaration of Conformity supplied with the
machine,thattheHOYERCOMET C machine
isdesignedand manufactured in accordance with
the provisions of Directive 89/392/EC
(Machinery Directive) and with the above-
mentioned standards.
•Theillustrationsand drawings of the machine
are intended for general reference only and
are not necessarily accurate in every detail;
•The machine dimensions and specifications
given in this manual are not binding and may
be changed without prior notice;
•The drawings and all other documents
provided as a part of this machine remain the
property of Tetra Pak Hoyer and must not be
passed on to third parties without the written
permission of Tetra Pak Hoyer.
•The manual includes instructions for all
accessories mounted on the standard
machine.
•The machine is covered by warranty as
laid down in the purchase contract. Any
repair work not authorised by Tetra Pak
Hoyer carried out during the warranty
period will automatically invalidate the
warranty.
2.2 Preliminary points
2.3 General safety rules
•THESE SAFETY RULES HAVE BEEN
DRAWN UP IN YOUR INTEREST. Strict
observance will reduce the risk of accident
to yourself or to others.
•DO NOT attempt to move, install or operate
the machine before reading and assimilating
thecontentsofthismanual.Askyoursuperior
in case of doubt;
•make sure that all guards and safety covers
are in place BEFORE starting the machine;
•NEVER leave tools, mechanical parts or
other foreign materials on or inside the
machine;
•in the event of a malfunction, press the
emergency stop button.
•NEVERPUT YOUR HANDSINSIDE THE
MACHINE WHEN IT IS IN OPERATION;
•exercise caution even when the main switch
locatedonthe tunnel is in the"OFF" position,
as the supply conductors will still be live;
•shut off the compressed air supply before
disconnecting any pneumatic component;
•make sure that all guards and safety covers
are correctly in place BEFORE restarting the
production cycle subsequent to maintenance
or repair operations;
•proceed with caution at all times. Remember
that you are responsible for your own safety
and for that of your colleagues;
•make sure that applicable regulations are
observed when moving or lifting the
machine.
Ι

CC901AB 2-3
Tetra Pak
Hoyer
• All personnel operating the machine must be
familiar with the general safety rules and
must observe them strictly. Failure to follow
these rules may result in personal injury or
damage to machine components;
• maintenance work must be performed with
themachineturnedoff.The main switch must
be in the "OFF" position, the tunnel air val-
ve closed and a “work in progress” sign
affixed to the machine;
• the user must make sure that all the
instructions given in the manual are
scrupulously observed;
• users will be solely responsible for risks
caused by tampering with the safety system;
• Thesafetyof otherplantusedtogetherwiththis
machine,unless supplied directly byTetraPak
Hoyer,istheresponsibilityofthecustomer.
• Thepressure, speed, temperatureand voltage
limits and all instructions given are
indispensable for correct operation of the
machine and must always be complied with
by the customer.
• Ambient conditions must be taken into
consideration during installation.
• National legislation governing this type of
machine must be observed.
The machine is suitable for operation in the
following ambient conditions:
• Temperature : from 4°C to 40°C
• Humidity : from 20% to 95%.
FNOTE:
Tetra Pak Hoyer will accept no responsibility for
damage or injury caused by failure to comply
with the above warnings.
2.4 Special warnings
2.5 Ambient operating limits

HOYER COMET C
CC901AC3-1
Tetra Pak
Hoyer
Contents
3 - DESCRIPTION OF THE MACHINE AND TECHNICAL DATA
3.1 Description of the machine ...................................................................................... 3-2
3.2 Operation.................................................................................................................. 3-2
3.3 Technicaldata ............................................................................................................ 3-3
3.4 Programmingandcontrolpanel................................................................................... 3-4

CC901AC3-2
Tetra Pak
Hoyer
Fig.3.1
3
4
1-2
5
6
TheHOYERCOMETCisamachineusedfor
fillingavarietyofice-creamcontainers.
Thestructureofthemachine,themechanical
componentsandthecommercialcomponents
areallfabricatedinstainlesssteelorcorrosion
proofmaterials.Allthepartsdirectlyincontact
withtheproductareincorrosionproofmaterial
orothermaterialsapprovedforuseinthefood
industry.
Inordertopreventaccidentalcontactbetween
partsofthebodyandanymovingpartsinthe
machine,themachineitselfhasbeenfittedwith
protectivepanelsandshields,screw-downcovers
and/orsystemsrequiringspecialtoolsandthe
deliberateactionoftheoperatortoremovethem.
3.1Description of the macine
Themachineconsistsof:
1.Steel structure with adjustable feet.
2.Mechanical transmission system driven by
an electric motor fitted with an inverter.
3.Indexing gear unit for jog feed.
4.Set of lamellas with slots (Part.3 Fig.3.1)
specifically designed to hold the type of
container in production. The lamellas are
supported by two members which guide the
chains driven by the gear wheels.
5.Vacuum generator.
6.Pneumatic system.
7.Control panel with operator interface
program (Part.4 Fig.3.1).
8.Various operating stations.
-A stack of empty containers and a stack of
covers are placed manually in the relative
magazines (Part.1 e Part. 2, Fig.3.1).
-The lamellas, with the appropriate slots
(Part.3 Fig.3.1), move forward with a jog-
ging action. During the standstill period, an
empty container per line is placed in the slot.
-The lamella (Part.3 Fig.3.1) with the empty
containers is jogged forward once (a number
of times) and stops under the dosing stations
(Part.5Fig.3.1).Thedosersfill the containers
with the required quantity of ice-cream,
3.2Operation
chocolate and granules.
-The lamella with the full containers is jogged
forward once (a number of times) and stops
under the lid feed station (Part.6 Fig.3.2).
One lid per row is positioned over the con-
tainers.Atthenextstation,thelidsarepressed
onto the container. (An ink-jet date stamping
station is also available on request.).
-At the end of the conveyor, the sealed con-
tainers are ejected by an electrically powered
combined lifting, extraction and transfer
system.

CC901AC 3-3
Tetra Pak
Hoyer
Fig.3.2
A
B
C
Standardpowersupply:
220-440V /3Ph/50-60Hz
Installedpower
Mainmotor: 0.75kW
Beltmotor: 0.37kW
Totalinstalledpower: 3.5kW
Netweight: 1300Kg
Grossweight: 1900Kg
Compressedair
Inletpressure: 6barminimum
Consumption: 1300Nl/min
Inletpipediameter: 3/4"gas
Dimensions
A(length) = 4050mm
B(width) =1170mm
C(height) =1970mm
No.ofoperators:2
EquivalentA-weightedsoundpressurelevelat1
metre:67.5dBA
MaximuminstantaneousC-weightedsoundpressure
levelattheworkstations:lowerthan130dB/20uPa
3.3 Technical data
FNOTA:
Fig. 3.2 shows a machine for the production of
cones or cups.

CC901AC3-4
Tetra Pak
Hoyer
Fig.3.3
8
y
z
+
A1 A2
1
Enter
pdown
pdup
7
w
w
x
9
*
/
=
5
p
q
r
4
m
n
o
6
s
t
u
2
g
h
i
3
j
k
l
1
d
e
f
0
c
b
a
shift
alarm clr
help print
2
3
3.4 Programming and control panel
Start/Stop main motor
Jog main motor
Select production cycle Auto/Manual
Start/Stop stations and C.I.P. cycle
Data settings
Select format
Save data
Apply data
Position stations (for automatic start-up
of the production cycle), password “1 2
3 4”

CC901AC 3-5
Tetra Pak
Hoyer
Set C.I.P. data
Reset
Start/Stop loading cones-cups
Start/Stop spraying chocolate
Start/Stop doser 1
Start/Stop doser 2
Start/Sop pencil filler
Start/Stop topping
Start/Stop granule
Start/Stop loading sheets
Start/Stop pressing sheets
Start/Stop sealing resistance
Start/Stop date stamp
Shift to the previous paragraph
pdup
Go to the previous page
Shift on the left
Activate value modification
Shift on the right
Enter Confirm data
Shift to the next paragraph
pdown
Go to the next page
alarm
Display alarm messages
clr
Clear
help
Display help
print
Print
A1: Chocolate tank resistances
Optionalsealingresistances
A2: Ice-cream bypass
Pos.1: Emergency push-button
Pos.2: Alphanumerickeyboard
Pos.3: Display

HOYER COMET C
CC901AD4-1
Tetra Pak
Hoyer
Contents
4.1 Unpacking and delivery checks ............................................................................... 4-2
4.2 Transport and installation......................................................................................... 4-2
4.3 Electrical connection................................................................................................ 4-3
4.4 Pneumatic connection .............................................................................................. 4-3
4.5 Checking direction of rotation ................................................................................. 4-4
4.6 Freezer connections.................................................................................................. 4-4
4 - INSTALLATION

CC901AD4-2
Tetra Pak
Hoyer
Fig.4.1
2
2
1
1
2
TheHOYERCOMETCmachineandthevarious
operatingstationsaretransportedinspecialcon-
tainers,generallywoodencrates.Unpackingmust
be done near to the final installation position of
themachine.Thecratescanbeeasilytransported
by a lift truck.
When the crate has been positioned correctly,
unpack as follows:
a. Unnail the lid and remove it. Do the same
thing with the side panels. Pay particular
attentionto the wooden spacer blockslocated
between the sides of the crate.
b. Remove the spare parts box and other com-
ponents from the crate.
c. Unnail the wooden blocks that hold the ma-
chine in place during transport and remove
the cellophane sheet.
d. Check that the contents of the crate corre-
spondto the description giveninthe shipping
documents.
e. Check that all the covers and panels have
been correctly fitted and that there are no
loose parts.
f. Visually inspectall theelectricalcomponents
to make sure that they are not damaged.
g. If any part/component is missing, stop un-
packing and immediately notify Tetra Pak
Hoyer.
h. If the machine has been damaged during
transit, notify the insurance company
immediately. Do not proceed beyond
unpacking until you are authorised to do so
by the insurance company.
4.1 Unpacking and delivery checks
4.2 Transport and installation
The following measures must be adopted during
the installation of the machine:
a. Position the machine at the place of
production. Move the machine using a fork
lift truck of suitable capacity (Part.1 Fig.4.1
fork positions), checking that there is
sufficient space to remove the guards and
allow ease of access to the internal machine
parts.
b. Adjust the feet (Part.2 Fig.4.1) until the ma-
chine is perfectly level both longitudinally
and transversally.

CC901AD 4-3
Tetra Pak
Hoyer
MODEL
SERIAL N.:
YEAR OF CONSTRUCTION:
ELECTRICAL SUPPLY:
PNEUMATIC SUPPLY:
REFRIGERANT:
HEATING GAS:
THERMAL CAPACITY:
kW
Kg.
Kcal/h
Via Monferrato, 52 - 20098 San Giuliano Milanese
( MI ) Italia - Tel. [phone] - Fax [phone] Made in Italy
Tetra Pak
Hoyer
V
bar Nlt./min.
ph Hz
Type
Fig.4.2
4.3 Electrical connection
4.4 Pneumatic connection
Themachine’selectricalsystemhasbeenfactory
checked by Tetra Pak Hoyer engineers.
The machine’s components are electrically pro-
tected against short-circuits.
WARNING:
The connection must be made exclusively by
competent technicians familiar with accident
prevention legislation.
It is recommended that the power is taken from
a master switch fitted with thermal overload
cutoutandultra-rapidfusesofadequateamperage.
WARNING:
The differential cutout switch must be class “A”
and suitable for protecting inverter electronic
power circuits.
• Check the data on the identification plate
(Fig.4.2) to ensure that the machine is com-
patible with the factory voltage.
• Connect the three phases to terminals R S T
and the earth wire to the earth terminals in
the electric panel.
For the minimum sections of the power supply
cable, refer to the voltage and power values
reported on the identification plate (Fig.4.2) and
the standards in force in the country of
installation.
Connectthemachinetothecompressedairsupply.
The minimum working pressure is 6 bar.
If the pressure is less than 4 bar, a factory-set
pressure switch will disable the machine’s
functions.
Refer to CHAPTER 3 - DESCRIPTION OF
THEMACHINEANDTECHNICALCHAR-
ACTERISTICS for air consumption and pipe
sizes.

CC901AD4-4
Tetra Pak
Hoyer
Fig.4.4
Fig.4.3
2
1
2
2
Make sure that the ice-cream pipes from the
bypass valve (Part.1/2 Fig.4.4) to the dosers are
connected as required.
Connectthe ice-creampipesfrom thefreezersto
the ice-cream dosers through the bypass valves
(Part.1/2 Fig.4.4) located above the pneumatic
panel.
fter having made the electrical and pneumatic
connections, check the direction of rotation of
the machine as follows:
• Make sure that there are no foreign bodies
which may prevent the machine from
operating.
• Release the emergency stop button.
• Rotate the main switch.
• Slowly turn on the air supply.
• Press the jog button and check that the
lamellas move from left to right (Part.2
Fig.4.3) when looking at the machine from
4.5 Checking the direction of rotation
4.6 Freezer connection
the operator’s side.
• Press the stop to stop the chain.
WARNING:
Ifthe direction of rotationisincorrect, invert the
two phases at the terminal board.
This operation must be carried out exclusively
by competent technicians familiar with accident
prevention legislation.
Before starting-up the freezers connected to the
machine, place a container under the ice-cream
bypassoutletpipeandanotherunder theproduct
collection chute.

HOYER COMET C
CC901AE5-1
Tetra Pak
Hoyer
Contents
5.1 Control panel adjustments ........................................................................................ 5-2
5.2 Product change......................................................................................................... 5-8
5.3 Mechanical and pneumatic adjustments.................................................................... 5-9
5.3.1 Container feed station adjustment................................................................... 5-9
5.3.1a Cone feed station adjustment .......................................................................... 5-9
5.3.1b Cup feed station adjustment............................................................................ 5-9
5.3.2 Gauging - chocolate spray station adjustment (cones).................................. 5-10
5.3.2a Adjustment of the rate of flow of the chocolate spray pump ........................ 5-10
5.3.3 Ice cream doser - optional decorator station adjustment .............................. 5-11
5.3.3a Optional rotating doser station adjustment ................................................... 5-11
5.3.4 Topping station adjustment ........................................................................... 5-12
5.3.5 Optional pencil filler station adjustment........................................................ 5-12
5.3.6 Granule station adjustment............................................................................ 5-12
5.3.7 Lid feed station adjustment ........................................................................... 5-13
5.3.7a Optional flame product lid feed station adjustment....................................... 5-13
5.3.8 Cone lid closure station adjustment .............................................................. 5-14
5.3.9 Cup lid closure station adjustment ................................................................ 5-14
5.3.10 Cone ejector station adjustment.................................................................... 5-15
5.3.11 Cup ejector station adjustment...................................................................... 5-15
5.3.12 Tube feed and gauge station adjustment ....................................................... 5-16
5.3.13 Volumetric dosing station adjustment ........................................................... 5-16
5.3.14 Ink-jet stamp station adjustment ................................................................... 5-17
5 - ADJUSTMENTS AND FORMAT CHANGE PROCEDURES

CC901AE5-2
Tetra Pak
Hoyer
Fig.5.1
8
y
z
+
A1 A2
Enter
pdown
pdup
7
w
w
x
9
*
/
=
5
p
q
r
4
m
n
o
6
s
t
u
2
g
h
i
3
j
k
l
1
d
e
f
0
c
b
a
shift
alarm clr
help print
5.1 Control panel adjustments
5.1.1 PLCsettings
The various functions of the production line are
controlled by a PLC. Use the keypad (Fig. 5.1)
to programme the PLC as described below.
FNOTE:
The programme is set in the factory. Every time
the control panel is turned on, the main screen
with the text COMET C, the encoder degrees
and machine status will be displayed.
Two led’s come on:the“POWER” led indicating
that the power is on and the “BATTERY” led
which will come on when the battery is low. The
“XO” led willflash ifthere is no communication
between the keypad and the PLC.
: START/STOP MAIN MOTOR
Starts or stops main motor.
: JOG MAIN MOTOR
Jogs or stops the step-by-step chain.
FNOTA:
Only if stations are not turned on using the .
: SELECT PRODUCTION CYCLE
AUTO/MANUAL
When the power is on, the led on the keypad
display will flash if the machine is in manual
mode.
Press this key to display the machine’s current
status on the display.
To put the machine in automatic mode, press
; the led will stay on without flashing and
the display will indicate that the machine is in
automatic mode.
FNOTE:
The keys at the top (F1 through F11) are for
functions to be added to the machine.
: START/STOP STATIONS AND CIP
CYCLE
Turns stations F12 through F22 on and off. This
key is also used for the CIP washing cycle at the
end of production.

CC901AE 5-3
Tetra Pak
Hoyer
To perform CIP washing, stop the stations by
pressingthe key,then enter the required wash
time using the key.
After setting the duration press key to begin
washing.
If duration is already stored in memory, press
.
: DATA SETTINGS
Press this key to display a series of video pages
on all the stations on the machine.
Use the P
g
up
P
g
dn
keys to reach the station
you wish to edit or enable for automatic start.
Press the key to enable data editing. When
you have finished editing data, press
Enter
to
confirm.
Press the key “Savedata” and
Enter
to save
the format in the operator panel and then press
key: “Apply data” to transfer the format to
the PLC.
Press CLR to go back to the first page of the
display, indicating encoder degrees and machine
status.
: SELECT FORMAT
Press this key to call up a video page containing
formats provided by Tetra Pak Hoyer and those
entered by the customer for production.
The following example will appear on the next
page of the video:
CODE: 1
DESCRIPTION: STANDARD CONE
: SAVE DATA
After entering the required format, save it by
pressing and then
Enter
, next press to
transfer the format to the PLC.
: APPLY DATA
Transfers data to the PLC.
: POSITION STATIONS (for setting
maximum speed and the temperature of the
optional sealing heads)
Enter the password and scroll through the pages
using the key until you reach the sealing
head 1...2...3 page, then change the set point of
theresistanceifnecessarybypressing ,then
press
Enter
to store in memory.
: SET C.I.P. DATA
To perform CIP washing, stop the stations by
pressing ,then enter wash time settings ifthey
have not already been entered using the
key.
After setting wash time, press to begin
washing.
: RESET
Resets alarms, broken microswitches, inverter
malfunctions, etc.
When an alarm is displayed, the technician must
check and repair the problem as necessary. Press
RESET on the display to remove the alarm
from the display.