Tetra Pak Alfast 200 Series User manual

OM
OperationMariual
TetraAlfast®200
Type210& 220
A'TetraPak
DocNo.OM-1242509-01

Thisdocumentisvalidfor:
T5845420261
SeriesNo/MachineNo
OM
OperationManual
DocNo.OM-1242509-01
Issue2001-11
TetraPak Dairy & BeverageSystemsAB

A
o
p
Tableofcontent
Introduction1
Equipment1
Document2
Safetyprecautions3
Useofhazardinformation3
General4
Cleaningsolution5
Generaidescription
Applications
Requirementsofpersonnel
Operatorstation
Riskarea
Processdescription1
Operationmodes15
Controipanei17
Operatormodule18
Supervisionoffaults25
Faultlist27
Preparation29
Operation31
Updateinputfatcontent31
Cream/skimmilkpreselectvolume33
Cream/skimmilkresetofvolume34
Selectoperationmode37
Fatcontent,manualcontrol39
Cascadecontrol
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TetraAlfast®200Type210& 220

Tableofcontent A
activate/deactivate40
DisplayDT11values43
DisplayDT21values44
Operation, remotecontrol45
Back-upoperation 46
Handkeys46
Switchesandpotentiometers47
Controlmodule49
Cleaning51
Cleaning,remotecontrol53
Samplingofproduct55
Settings57
Standardizationmethod57
Availableparameters62
DocNo.OM-1242509-01
TetraAlfast®200Type210& 220

A Introduction
A WARNING!
Introduction
Thissectioncontainsbasicinformationaboutthismanualandthe
TetraPakequipmentdescribed.
Toensuremaximumsafety,alwaysreadthesectionSafetyprecautions
beforecarryingoutanyworkontheunit.
Equipment
IntendeduseofthisTetraPakequipment
ThisunitisintendedforuseaccordingtothespecificationsinTechnicaldata
(seeTechnicalManual)andrelateddocuments.
TetraPakwillnotbeheldresponsibleforinjuryordamageiftheequipmentis
usedforanyotherpurpose.
Service
Ifproblemsareencounteredwhenoperatingtheunit,contactthenearestTetra
Pakservicestation.
Manufacturer
ThisTetraPakequipmentwasproducedby:
TetraPakDairy& BeverageSystemsAB
Box64
S-22100LUND
Sweden
Unitidentification
Allunitscarrya machineplatestating:
-unitidentification
-datauniquetotheunit
HavethisinforrnationavailablebeforecontactingTetraPakconcerningthis
particularunit.
DocNo.OM-1242509-01
TetraAlfast®200Type210& 220

Introduction A
Document
OperationManual(OM)
ThepurposeofthisOperationManualistoprovidetheoperatorwith
informationonhowtooperatethemachine.
TetraPakrecommendthatyoustudyitcarefully,and- aboveall- ensureits
availabilitytothosewhowillbeoperatingtheunit.
Furthermore,itisimportantthatyou:
-keepthemanualforthelifeoftheequipment
-passthemanualontoanysubsequentowneroruseroftheequipment.
TetraPakwillnotbeheldresponsibleforanybreakdownoftheequipment
causedbytheowner'sfailuretofollowtheinstructionsgiveninthismanual.
Designmodifications
Theinformationgiveninthisdocumentisinaccordancewiththedesignand
constructionofthemachineatthetimeitwasdeliveredbytheTetraPak
machineproductionfacility.
Furthercopies
AdditionalcopiescanbeorderedfromthenearestTetraPakservicestation.
Whenorderingtechnicalpublications,alwaysquotethedocumentnumber
printedonthefrontcoverofthedocumentconcerned.
Documentproducer
Thisdocumentwasproducedby:
TetraPakDairy& BeverageSystemsAB
Box64
S-22100LUND
Sweden
Numberofpages
Thisdocumentcontainsa totalof68pages.
Copyright© 2001TetraPakDairy& BeverageSystemsAB
Allrightsreserved.Nopartsofthisdocumentorapplicationsoftwareusedin
theproductmaybeedited,reproducedorcopiedinanyformorbyanymeans
withoutthewrittenpermissionofTetraPakDairy& BeverageSystemsAB.
DocNo.OM-1242509-01
TetraAlfast®200Type210& 220

A Safetyprecautions
A DANGER!
Safetyprecautions
Toensuremaximumsafetyfortheoperator,alwaysreadthis
sectioncarefullybeforecarryingoutanyworkontheequipment.
Useofhazardinformation
Hazardinformationinthisdocumentationisdefineds follows:
Failuretoobservethisinformationresultsinimmediatedangertolife.
A WARNING!Failuretoobservethisinformationcanresultinmajorpersonalinjuryor
lossoflife
Caution!Failuretoobservethisinformationcanresultinminorpersonalinjuryor
damagetotheequipment.
DocNo.OM-1242509-01
TetraAlfast®200Type210& 220

ASafetyprecautions
General
Onlytrainedpersonnelareallowedtooperatethemachine.Themachinemay
onlybeusedinaccordancewiththeinstructionsgiveninthemanualsdelivered
withtheequipment.
IftheSafetyprecautionsarenotfollowed,thereisriskofpersonalinjury.
Thisisanautomatedmachine.Itiscontrolledbya processcontrollerandwill
changeitsmodeofoperationwithoutoperatorintervention.Allpersonnelmust
therefore:
•stayoutsidethesafetyarea
regardallelectricalequipmentaslive
regardallpipesashot
•usehearingprotection.
Beforecarryingoutmaintenanceandrepair:
shutoffmainsteamsupply
switchoffpower
•allowthemachinetocooldownandadjusttoatmosphericpressure
•informtheoperatorandotherrelevantpersonnelabouttheworkyouintend
todo
postwarningsignsinprominentplaces.
Pipesandotherpartsofthismachinemaybehot.Contactwithhotequipment
mayresultinsevereburns.Avoidcontactwithhotequipment.
Thismachineoperatesunderpressurizedconditions.Allpersonnelmust
therefore:
watchoutforleakage
depressurizetheequipmentbeforeattemptingmaintenanceandrepairwork
Keepthedoorsofthecontrolpanelclosedtoprotectitfromwaterandsteam.
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TetraAlfast®200Type210& 220

A Safetyprecautions
Cleaningsolution
Handlingofcleaningsolution
Cleaningsolutionsnormallycontaincausticsoda(NaOH)ornitricacid
(HNO3).Thesechemicalsmaycauseburningtoskinandeyes.Followthe
instructionsgivenbythesupplier.
Wheneverthereisa riskofexposuretothesechemicals,alwayswear:
safetyglasses
protectivegloves
•shoesmadeofPVCorPEplastic,orrubber
•apron.
Inthecaseofanaccidentinvolvingcleaningsolution,thebasicruleistorinse
theaffectedareaassoonaspossiblewithasmuchwateraspossible.
Forthisreason,alwaysmakesurethattheshowerswork,thatthereare
additionalwashingfacilities,andthataneyewashdeviceisavailableatornear
eachmachinesite.
Emergencyprecautions
Ifswallowed
Ifyouhappentoswallowcleaningsolution:
drinklargeamountsoflukewarmwater(inordertodilutethecleaning
solution);thenseekmedicalattentionimmediately.
Contactwitheyes
Ifcleaningsolutionissplashedintoyoureyes:
•washtheeyesthoroughlywithlukewarmwaterfor15minutes(keep
eyelidswidelyapart);thenseekmedicalattentionimmediately.
Contactwithskinorclothes
Ifcleaningsolutioncomesintocontactwithskinorclothes:
•rinseimmediatelywithplentyofwater
thoroughlywashtheclothesbeforetheyarewornagain.Ifskinburns
appear,seekmedicaladviceimmediately.
Ifinhaled
Ifyouexperienceirritationorpainduetohavinginhaledvaporizedcleaning
solution:
leavetheaffectedareatogetfreshair.Ifthesymptomsbecomeworse,seek
medicaladvice.
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TetraAlfast®200Type210& 220

ASafetyprecautions
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TetraAlfast®200Type210& 220

A Generaldescription
Generaldescription
Applications
TheTetraPakautomaticdirectstandardisationequipmentTetraAlfasttype210
and220isdesignedtohandlethefollowingapplications:
-skimmingofwholemilkandstandardisationofcream
-standardisationofbothcreamandmilk
Requirementsofpersonnel
Operator:basicknowledgeofindustrialprocesses
Caution!Unauthorizedpersonnel
Operationbyunauthorizedpersonnelmayendangerpersonneland
property
Operatorstation
Attheoperatormodule,whichislocatedin:
a)theoperatorpanel,or
b)ina panelinthecontrolroom
Note!TetraAlfastcanalsobecontrolledbya remotemastercontrolsystem.
Riskarea
2-3metresaroundtheequipmentdueto:
-hotpipesandequipment
-jetsofhotliquid
DocNo.OM-1242509-01
TetraAlfast®200Type210& 220

Generaldescription A
Denominations
1Controlpanel
2Flowtransmitter(FT41),
standardisedmilk
3Pressuregauge,remixpressure
4Flowtransmitter(FT31),cream
remixing
5Controlvalve(CV21),creamfat
content
6Shut-offvalve(SV31),fullremix
ofcream
a)Skimmilkfrom separator
b)Creamfrom separator
c)Skimmilk
d)Standardisedsurpluscream
7Controlvalve(CV51),milkfat
content
8Shut-offvalve(SV50),(if
applicable)
9Flowtransmitter(FT21),
standardisedcream
10Densitytransmitter,cream
(DT21)
11Densitytransmitter,skimmilk
(DT11),onlyTetraAlfast220
1
GF100647.WMF
TypicallayoutofTetraAlfastsystem220
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TetraAlfast®200Type210& 220

A Generaldescription
Densitytransmitter
Providescontinuouson-linemeasurementofliquiddensity.Thecentretubeof
thetransmitter,throughwhichtheproductflows,ismadetovibrateatoneofits
naturalfrequencies, whichismodifiedbytheliquidcontainedherein.This
frequencyisa functionoftheoverallmassperunitlengthofthetubeandhence
ofthedensityofthecontainedliquid.
Flowtransmitter
Providescontinuouson-linemeasurementofliquidflows.Thetransmitter
containsnomovingparts.
Controlpanel
Availableintwodesigns:
a)Withoperatormoduleandfatcontentrecorderplacedinthefrontdoor
b)Withoperatormoduleandfatcontentrecorderremotelylocated,e.g.ina
controlroomcabinet.
Thepanelcontains:
-operatormodulewithkeyboardanddisplay(onlyforversion1 above)
-recorderforfatcontent(onlyforversion1 above)
-controlmodule
-componentsforpowersupply
Theoperatormoduleistheoperator'smeansofcommunicationwiththe
controlmodule.
Theoperatormoduleisusedto:
-enterdataandcommandsintothecontrolmodule
-displaydata,suchasmeasuredvalues,setpoint,messagesetc.
Thecontrolmodulecontains:
-thecomputerthatcontrolsthestandardisationprocess
-connectorsforexternalcomputercommunication
-LEDforalarmindication
-connectorsforinputandoutputsignals
-pushbuttonsforoperatorcommunication
-LEDindicatorsforinputandoutputsignals
Fatcontentrecorderregistersfatcontentinthemilk(bluepen)andthecream
(redpen).A recordingof100%onthepapercorrespondsto:
-milkfatcontent
-creamfatcontentof50%.
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TetraAlfast®200Type210& 220

Generaldescription A
ComponentsintheTetraAlfastpanel
1Operatormodule
2Air-regulatingvalve(PCO)
3Mainswitch(QO)
4Recorderforfatcontent(TR)
5Flowindicator(FI1)
6Selectorforflowindicator(SI)
7Indicatorforcontrolvalveposition,crieamfat(121)
8Selectormanual/automaticcream(fatcontrol(S21)
9Potentiometerforcontrolvalvepositioning,creamfat,duringmanualoperation
(R21)
10Indicatorforcontrolvalveposition,milkfat(151)
11Selectormanual/automaticmilkfatcontrol(S51)
12Potentiometerforcontrolvalvepositioning,milkfat,duringmanualoperation
(R51)
13Selectormanual/automaticcontrolofshut-offvalveintheremixpipe(S31)
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TetraAlfast®200Type210& 220

A Processdescription
Processdescription
Theprocessiscarriedoutintwosteps:
1Skimmingofwholemilk
2Standardisationofcreamfatcontent
3Standardisationofmilkfat(threemethodsavailable):
-standardisationtoa specifiedconstantfatcontent.
(OnlyTetraAlfast220)
-standardisationofratioF/SNF(fat/solidsnonfat)or
-standardisationofratioF/TS(fat/totalsolids)
Skimmingofwholemilic
Theamountoffatintheskimmilkismainlydeterminedbyseparatortype,
pressureintheseparatorskimmilkoutletpipeandthefatcontentinthewhole
milk.
Achangeinpressureintheseparatorskimmilkoutletpipewillresultina
changeinthefatcontentintheskimmilk.
OnlyTetraAlfast220
gThedensityoftheskimmilkismeasuredbymeansofthedensitytransmitter
IDTll.Compensatedforthemeasuredfatcontentsintheskimmilkthesolids
Enonfatcanthenbecalculated.
e\i Creamstandardisation
Theflowfromtheseparatorcreamoutletdeterminesthefatcontentinthe
cream.Theflowrequireddependsonthefatcontentofthewholemilkandthe
desiredcreamfatcontent.A changeinwholemilkfatcontentwillresultina
changeincreamfatcontent.Itisthusnecessarytoadjustthecreamflowto
maintaina constantcreamfatcontent.
ThecreamflowismeasuredbyflowtransmitterFr21andcontrolledbycontrol
valveCV21.
Calculationofflowsetpointisbasedonmass-balance.
(Cont'd)
DocNo.OM-1242509-01
TetraAlfast®200Type210& 2201 1

AProcessdescription
(Cont'd)
Cascadecontrolisusedtocalculatethefatcontentintheincomingwholemilk.
Cascadecontrolworksbycomparing:
-theflowthroughflowtransmitterFT21(thisisinverselyproportionalto
thecreamfatcontent)and
-thedensitymeasuredbythedensitytransmitterDT21(thedensityis
reversedproportionaltothecreamfatcontent)
Ifthedeviationinwholemilkfatcontentexceedsa maximumlimit(see
parameters)thefollowingmeasureswillbetaken:
-analarmisgiven(Cascadecontroloff)
-theinformationfromthedensitytransmitterisnolongerusedin
calculatingwholemilkfatcontent
-controlofcreamflowisnowbasedontheinitialwholemilkfatcontent
andinformationfromtheflowtransmitter.
Milkstandardisation
Thisisachievedbymixingstandardisedcreamwithskimmilkinsuitable
proportions.
ThecreamflowtothemixingpointismeasuredbyflowtransmitterFTSland
controlledbycontrolvalveCV51.
Calculationofremixcreamflowisbasedonmass-balance. 2
llj
Cleaning|
CleaningoftheTetraAlfastunitiscarriedouttogetherwiththesurrounding^
equipment.Followthecleaninginstructionsforupstreamanddownstream^
equipment.
Recommendedcleaningintervals:
-aftereveryproductionshift.
DocNo.OM-1242509-01
TetraAlfast®200Type210& 220121

A Processdescription
Skimmilk2
13
Standardised
9milk
«
Wholemilk
Standardised
cream
Pictureshowingprincipallayoutofa TetraAlfast220process.
Note:Item1 and2 arenotpartoftheTetraAlfast.
GF000304
1Separator
2Constantpressurevalveforskimmilk
3Controlpanel
4Flowtransmitterforcream,FT21
5Densitytransmitterforcream,DT21
6Controlvalveforcream,CV21
7Controlvalveforsurpluscream,CV51
8Flowtransmitterforremixcream,FT31
9Flowtransmitterforstandardised
milk,n"41
10Shut-offvalveforremixcream,SV31
11Non-returnvalve
12Shutoffvalveforstandardisedcream,
SV50(ifapplicable)
13Densitytransmitterforskimmilk,
DT11^onlyTetraAlfast220)
Productflow
Wholemilk,preheatedto50-65°C,flowstotheseparator
Theseparatorproduces:
-skimmilkwitha fatcontentofapprox.0.04-0.06%F
-creamwitha presetfatcontent,normally30-45%F
Skimmilk
-flowsthroughdensitytransmitterDTll(OnlyTetraAlfast220)
-flowsthrougha constant-pressurevalvetotheremixingpoint
-theskimmilk(orremixedmilk)continuesthroughflowtransmitterFr41
tosubsequenttreatment
(Cont'd)
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TetraAlfast®200Type210& 220 13

AProcessdescription
(Cont'd)
Cream
-flowsthroughdensitytransmitterDT21
-flowsthroughflowtransmitterFY21 tocontrolvalveCV21
thenflows
a)throughshut-offvalveSV31,flowtransmitterFTSlanda non-returnvalve
totheremixingpoint
b)throughcontrolvalveCV51and
ifapplicable,throughshut-offvalveSV50
tosubsequenttreatment.
(Cont'd)
DocNo.OM-1242509-01
TetraAlfast®200Type210& 220181

A Processdescription
(Cont'd)
Operationmodes
Operationmodesareselectedbya Quickchoicefunction.Operationmodesare
usedfor:
-presetfatcontentsetpoint
-specialfunctions.
Thesechoicescanalsobemadefromexternalcontrolsystemsbylinkorvia
relay.Fordetailedinformation,seetableconcerningavailableparameters.
Thefollowingchoicesaresupported:
#1-#14Creamfatcontents
Thesechoicesincludepresetsetpointsformilkfatcontents.Thesetpointscan
bechangedbytheoperator.
#17Circulation
Usedwhenthesurroundingequipmente.g.a pasteuriserisnotinproduction.
DuringcirculationTetraAlfastwill:
-stopaccumulatingamountsofproducedskimmilk/cream
-notgiveanyfatcontentalarm
-stopthefatcontentrecorder,ifthecascadecontrolisswitchedoff
#18Valve freeze/cascadefreeze
Performsoneofthefollowingfunctions(selectedviaparameter):
-Maintaininga constantoutputsignaltocontrolvalvefor a periodoftime
-Maintainingthecalculatedvalueofwholemilkfatcontentconstantfora
periodoftime
#19Cleaning
Thischoicecontainssetpointsusedtoobtaingoodcleaningresults.
#20Keyboardlocking
Usedtoavoidunintentionaluseoftheoperatormodule.
Ifanattemptismadetousethekeyboarda messagewillbedisplayedstating
thatthekeyboardislocked.
DocNo.OM-1242509-01
TetraAlfast®200Type210& 220151

AProcessdescription
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8
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TetraAlfast®200Type210& 220161