WCB Ice Cream MF User manual

MF Freezer Operating manual
WCB Ice Cream 1-29
Operating manual MF Freezer
Index
A Quick Description of the Operator Panel
Pass Codes and Operating Levels
Section 1, The Operator Level
The Main Menu
Starting the pumps
Starting the Dasher
Starting the Compressor
Starting the CIP
The Mimic Screen
Alarms
Section 2, Set Up of Freezer Parameters
CIP Parameters
Pump Parameters
Dasher Parameters
Compressor Parameters
Section 3, Maintenance
Using the Check Screens
Using Test Mode
Operating panel folder

MF Freezer Operating manual
WCB Ice Cream 2-29
A Quick Description of the Operator Panel
For an easy reference please open the operator panel folder in the back of this manual.
K1 Key No 1: Start Pumps.
By pressing this key once the pumps will start if no error conditions exists. At the same time
the green LED L1 will light up. Pressing the key again will stop the pumps.
K2 Key No 2: Start Dasher.
By pressing this key once, the dasher will start if no error conditions exist. At the same time
the green LED L2 will light up. Pressing the key again will stop the dasher.
K3 Key No. 3: Start Compressor.
By pressing this key once, the compressor will start if no error conditions exist. At the same
time the green LED L3 will light up. Pressing the key again will stop the compressor.
K4 Key No. 4: Start CIP.
By pressing this key once, the CIP sequence will start if no other functions are running. At the
same time the green LED L4 will light up. Pressing the key again will stop the CIP Sequence.
K5 Key No 5: Escape.
This button is used to acknowledge alarms as well as exiting the current displayed screen on
the Operator panel.
K6 Key No 6: Left arrow.
This button is used to decrement setpoints on the production screens as well as moving the
cursor in the menu and maintenance screens.
K7 Key No 7: Arrow Up.
This button is used to increment setpoints in the set Up screens as well as activating outputs
and Incrementing control values in the maintenance screens.
K8 Key No 8: Arrow Down.
This button is used to decrement setpoints in the set-up screens as well as deactivating
outputs and Decrementing control values in the maintenance screens.
K9 Key No 9: Right Arrow.
This button is used to increment setpoints on the production screens as well as moving the
cursor In the menu and maintenance screens
K10 Key No 10: Enter.
This button is used to step to the next screen in production, set up, and maintenance screens.

MF Freezer Operating manual
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L4 Alarm LED
This LED will light up in red if an alarm occurs. At the same time the alarm will be displayed on
the screen. When the alarm is acknowledged the led will turn off.
L5 Communication Status
The LED will be steady on in green if communication to the PLC is working properly. If
communication faults this led will flash in green. At the same time the communication error
screen will be displayed on the screen.
L6 Power On
This LED will light up in green when power is applied to the operator terminal
L7 Key Activated
This LED will light up in green if a key is pressed on the operator terminal.
I1 Production Screen Auto Scroll Function Enabled
This symbol will be displayed when the automatic page scroll function is enabled. This
function will automatically display the 4 production related pages on the screen. The pages will
shift for every 10 seconds until the page scroll is disabled. The screens are the Pump Set
point screen, the Dasher Status Screen, The Refrigeration Set point Screen and The Mimic
Screen.
I2 Pass Code Enabled
This symbol will be displayed when a Pass Code is enabled.

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Passwords and Operating Levels
The operation of the freezer is divided into 3 levels protected by pass-codes. A pass code is a
combination of keys that must be pressed at the same time in order to enable access to pass-code
protected functions.
The pass codes will be handed over in a separate envelope. Before running the unit you must
consider who should be entitled to enter the higher levels of operation and distribute the pass codes
accordingly.
First Level –Operator Level
In this level the daily operation of the freezer is allowed, for instance start pumps, dasher and
compressor as well as activating the CIP function. Access to Set up and Maintenance is not allowed.
Second Level –Super User Level
When this level is activated by means of entering the correct pass-code there is access to the Set Up
menu where it is possible to adjust parameters related to the function of the freezer. There is also
access to the Maintenance Menu where it is possible to see the status and function of the In- and
outputs of the PLC.
When leaving the Set Up Manu the user will be prompted to disable the password. If he chooses not
to do so, the pass-code will automatically be disabled after 10 minutes.
Third Level –Master Level
When this level is activated by means of entering the correct pass Code is it possible to manually
operate the Digital and analog outputs of the PLC and thus check if they are working correctly. Please
note that the super user Level must be enabled before the master Level can be selected.
In order to leave the Master Level the Pass Code must be disabled. This is done by keying in the right
key combination once again.

MF Freezer Operating manual
WCB Ice Cream 5-29
Section 1, The Operator Level
The Main Menu
For a quick key reference please open the Operator Panel folder in the back of this manual.
The Main Menu screen gives you access to all the facilities of the freezer. This screen is normally
displayed when an Emergency stop situation is cleared or exiting from production, set-up or
Maintenance mode.
By pressing K6 (Arrow Left or K9 (Arrow Right) it is possible to pre-select production, set-up or
maintenance functions. Pre-selection is indicated by the 3 squares on the screen changing from light
to dark.
By pressing K10 (Enter) when on of the squares are pre-selected you will enter into the specific
screens.

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Starting the pumps
For a quick key reference please open the Operator Panel folder in the end of this manual.
By pressing the pump start key K1 the pumps will start, the pump set point screen will be displayed
and The LED L1 will light up.
By pressing K1 once more the pumps will stop and L1 will turn off.
If any of the following faults are detected the pumps will not start but an error message will displayed
Instead. The faults are the following:
Error 1: Dasher Breaker Tripped
Error 3: Pump Breaker Tripped
Error 5: Pump VFD not ready
Error 6: Error in Mains Supply
For a closer description of the error see the alarm section.
If these alarms occur when the pumps are running the pumps will shut down L1 will turn off and the
relevant alarm message will be displayed.
Screen field description:
1. This field indicates the minimum capacity of the pumps. It can be adjusted in the Set Up Menu
2. This is the pump speed setpoint in litres per hour.
3. The bar graph is showing the pump speed setpoint in litres per hour.
4. This field indicates the maximum capacity of the pumps. It can be adjusted in the Set UP
Menu.
To increase the setpoint press K9 (Arrow Right). To decrease the setpoint press K6 (Arrow Left).
Pressing the K5 (Escape) will display the main menu screen on the display.
Pressing the K10 (Enter) will display the next production screen on the display and at the same enable
the Automatic production page scroll-function.
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Starting the Dasher
For a quick key reference please open the Operator Panel folder in the end of this manual.
By pressing the pump start key K2 the dasher will start, the dasher monitor screen will be displayed
and the LED L2 will light up.
By pressing K2 once more the dasher will stop and L2 will turn off.
If any of the following faults are detected the pumps will not start but an error message will displayed
instead. The faults are the following:
Error 3: Dasher Breaker off
Error 6: Error in Mains Supply
For a closer description of the error see the alarm section.
If these alarms occur when the dasher is running the dasher will shut down L2 will turn off and the
relevant alarm message will be displayed.
If the Dasher load is exceeding the motor load warning threshold an alarm will be displayed and the
back pressure valve will reduce its opening by 10 percent.
If the dasher load is exceeding the motor load shut down limit, the dasher will stop and an alarm will
be displayed.
Screen field description:
1. This field indicates the current consumption of the dasher motor in Amps.
2. This field indicates the current consumption of the dasher in percent of full motor amperage.
3. The bar graph is showing the current consumption of the dasher in percent of full motor
amperage
This screen is a monitor screen only and it is not possible to adjust the motor load.
Pressing the K5 (Escape) will display the main menu screen on the display.
Pressing the K10 (Enter) will display the next production screen on the display and at the same enable
the automatic production page scroll function.
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2
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Starting the Compressor
For a quick key reference please open the Operator Panel folder in the end of this manual.
By pressing the pump start key K3 the Compressor will start, the refrigeration set point screen will be
displayed and the LED L3 will light up.
By pressing K3 once more the compressor will stop and L3 will turn off.
If any of the following faults are detected the compressor will not start but an error message will
displayed instead. The faults are the following:
Error 2: Compressor Breaker Tripped
Error 6: Error in Mains Supply
Error 9: Compressor Overheated
Error 10: High Condenser Pressure
Error 11: Compressor Oil Pressure Low
For a closer description of the error see the alarm section.
If these alarms occur when the compressor is running it will shut down, L3 will turn off and the relevant
alarm message will be displayed.
Screen field description:
1 This is the opening of the backpressure valve in percent.
2 The bar graph is showing the opening of the backpressure valve in percent
To increase the setpoint press K9 (Arrow Right). To decrease the setpoint press K6 (Arrow Left).
Pressing the K5 (Escape) will display the main menu screen on the display.
Pressing the K10 (Enter) will display the next production screen on the display and at the same enable
the automatic production page scroll-function.
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2

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The Mimic Screen
For a quick key reference, please open the Operator Panel folder in the end of this manual.
The Mimic screen will be shown either when the automatic production page scroll function is enabled
Or K10 (Enter) is pressed on the Refrigeration setpoint page.
The screen is showing the actual status of the various parts of the freezer.
These parts are:
1 Main Air valve. When valve activated the symbol will change from light to dark.
2 Mix Pump. When activated the symbol will change from light to dark.
3 Dasher Motor. When activated the symbol will change from light to dark.
4 Dasher Motor Load. Shows the actual load in percent.
5 Product Pump. When activated the symbol will change from light to dark.
6 Pump Speed. Shows the actual pump speed in percent.
7 Hot Gas Valve. When activated the symbol will change from light to dark.
8 Opening of the Back Pressure Valve. Shows the actual opening in percent.
9 Liquid Valve. When activated the symbol will change from light to dark.
10 Compressor. When activated the symbol will change from light to dark.
11 Mix Flow. Shows the calculated mix flow in l/h
Pressing the K5 (Escape) will display the main menu screen on the display.
Pressing the K10 (Enter) will display the next production screen on the display and at the same enable
the automatic production page scroll function.
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Starting the CIP
For a quick key reference please open the Operator Panel folder in the back of this manual.
By pressing the pump start key K4 the CIP will start, the CIP Sequencer Screen will be displayed and
the LED L4 will light up, if neither the pumps, dasher and compressor is running and the Test Mode
function is off. If one or more of these conditions are not met the CIP will not start.
By pressing K4 once more the CIP Sequencer will stop, L4 will turn off and the main menu screen
displayed.
The CIP Sequencer will cyclically perform the following 3 steps:
Step 1: Flushing Cylinder.
Step 2: Running Dasher and Pumps
Step 3: Flipping Pump Covers
The duration of the steps can be adjusted in the Set Up Menu in the Sub Menu “CIP”.
When step 3 is finished the sequencer will do the steps again until CIP maximum time runs out or CIP
is terminated by pressing K4.
The CIP Sequencer can be controlled from an external CIP plant by using the Digital Input “CIP
Acknowledge”, see the electrical diagrams for reference. This input is normally wired to 24VDC and is
therefore “On”. If the 24VDC signal is removed the input goes “Off” and the CIP Sequencer will
pause. It will remain in the pause state until the input goes high again.
The following errors can also pause the CIP Sequencer:
Error 1: Dasher Breaker Tripped.
Error 3: Pump Breaker Tripped.
Error 5: Pump VFD Faulted.
For a closer description of the errors see the alarm section.
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Screen field description:
1. This field is showing the remaining CIP time I minutes.
2. This field is showing the remaining time of the actual CIP step in seconds.
3. This field is showing status messages for the CIP Sequencer. The messages are the
following:
A. No External signal.(The digital signal CIP Acknowledge is off)
B. Flushing. (CIP Sequence Step 1 is running)
C. Run Dasher/Pump. (CIP Sequence Step 2 is running)
D. Flip Covers. (CIP sequence Step 3 is running)
E. CIP Done press F4. (CIP max time is expired, press K4 to end CIP sequence)
F. Functional Error. (One or more of the above mentioned error has paused the
CIP)
G. Restart Press Ent. (The error has been fixed, press K10 (Enter) to continue)

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Alarms
When an Alarm condition happens a corresponding alarm message is immediately displayed on the
operator panel display. If more alarms have appeared at the same time it is possible to see them by
pressing K8 (Arrow Down). If there is more than one alarm pending it is indicated on top of the alarm
display. It is possible to clear the message from the display by pressing K5 (Escape) but this will not
remove the alarm condition. Only by finding the error that caused for the alarm
And repairing it will remove the alarm.
The alarm messages are the following:
Error 1: Breaker Dasher Tripped.
Cause:
The circuit breaker protecting the dasher motor has switched off by an overload, short circuit or by
hand.
Remedy:
Remove overload /short circuit condition and turn on the circuit breaker again.
Error 2: Breaker Compressor Tripped.
Cause:
The circuit breaker protecting the compressor motor has switched off by an overload, short circuit or
by hand.
Remedy:
Remove overload /short circuit condition and turn on the circuit breaker again.
Error 3: Breaker Pump Drive Tripped.
Cause:
The circuit breaker protecting the pump drive VFD has switched off by an overload, short circuit or by
hand.
Remedy:
Remove overload /short circuit condition and turn on the circuit breaker again.
Error 5: Pump Inverter Faulted.
Cause:
The VFD controlling the pump speed has one or more faults..
Remedy:
Connect The Danfoss LCP2 panel supplied with the machine to the VFD and read out the cause of the
error.
Switch off power for at least one minute to the VFD and turn it on again. Check if fault is cleared.
If not refer to the Danfoss VFD manual for further instructions.

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Error 7. Error in Mains supply.
Cause:
The power-monitoring relay has switched off either if a power phase is missing or the phase sequence
is incorrect.
Remedy:
Check if all phases are present. Rewire the main power phase to obtain correct sequence.
Error 9. Compressor Overheated
Cause:
The internal temperature in the compressor is too high.
Remedy:
Wait until compressor has cooled down. Reduce load on compressor.
Error 10. High Condenser Pressure
Cause:
The Condenser Pressure is too high.
Remedy:
Check cooling water supply. Check water temperature.
Error 11. Compressor Oil Pressure Low
Cause:
The Oil Pressure in compressor has dropped below safe limit
Remedy:
Check Oil level, refill Oil.
Error 13. Warning Dasher Load High
Cause:
The Dasher Load has exceeded the warning limit setpoint.
Remedy:
The control system will automatically reduce the refrigeration until load drops below warning limit.
If load does not drop reduce back pressure valve opening setpoint manually.
Error 14. Shutting Down Dasher Load High
Cause:
The Dasher Load has exceeded the shut down limit setpoint.
Remedy:
Reduce refrigeration setpoint

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Section 2, The Set Up of Freezer Parameters
The Main Menu
For a quick key reference please open the Operator Panel folder in the end of this manual.
To get into set-up mode go to the main menu and use K6 (Arrow Left and K9 (Arrow Right) to pre-
select the set-up field. Then press K10 (Enter)
If the super user pass code has not been enabled you will be prompted to do so. When the correct
pass code has been entered you will get into the main set-up screen:
This Set-up Main Page is consisting of 2 parts. By pressing K9 (Arrow Right) as indicated on the
screen you will get into the second part of the screen. By pressing K6 (Arrow Left) as indicated on the
screen you will return to the first part.
You pre-select the various parts of the set-up menu exactly as on the main menu screen by using K6
and K9. When pressing K10 (Enter) you will enter into the set-up screens for the pre-elected part.
When pressing K5 (Escape) you will leave the Set-up main menu. At the same time you will be asked
to decide to disable your pass code. If you do not disable your pass code it will disable itself after 10
minutes.

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CIP Parameters
By pre-selecting the CIP Field on the Main Set-up Menu and pressing K10 (Enter) you will get into the
first of the adjustable CIP Parameters.
CIP sequencer time for step 1 (flushing cylinder)
On this screen you set the step 1 time for the CIP sequencer. By pressing K7 (Arrow) up you increase
the time and by pressing K8 (Arrow Down) you decrease the time. Keeping the keys pressed will
make the adjustments go faster and faster. The setpoint adjustment is immediately being stored.
There Is no need for acknowledging the adjustment.
If you press K5 (Escape) you will return to the Main Set-up Menu. By pressing K10 (Enter) you will go
to the next adjustable CIP Parameter:
CIP sequencer time for step 2 (running dasher and pumps)
On this screen you set the step 2 time for the CIP sequencer. By pressing K7 (Arrow) up you increase
the time and by pressing K8 (Arrow Down) you decrease the time. Keeping the keys pressed will
make the adjustments go faster and faster. The setpoint adjustment is immediately being stored.
There Is no need for acknowledging the adjustment.
If you press K5 (Escape) you will return to CIP Step 1 time. By pressing K10 (Enter) you will go to
The next adjustable CIP Parameter:
Cip sequencer time for step 3 (flipping pump covers)
On this screen you set the step 3 time for the CIP sequencer. By pressing K7 (Arrow) up you increase
the time and by pressing K8 (Arrow Down) you decrease the time. Keeping the keys pressed will
make the adjustments go faster and faster. The Setpoint adjustment is immediately being stored.
There is no need for acknowledging the adjustment.
If you press K5 (Escape) you will return to CIP Step 2 time. By pressing K10 (Enter) you will go to the
next adjustable CIP Parameter:

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CIP sequencer time max time
On this screen you set the max time for the CIP sequencer. By pressing K7 (Arrow) up you increase
the time and by pressing K8 (Arrow Down) you decrease the time. Keeping the keys pressed will
make the adjustments go faster and faster. The setpoint adjustment is immediately being stored.
There is no need for acknowledging the adjustment.
If you press K5 (Escape) you will return to CIP Step 3 time. K10 (Enter) will not work since the CIP
max time is the last parameter in this sub menu.

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Pump Parameters
By pre-selecting the Pump Field on the Main Set-up Menu and pressing K10 (Enter) you will get into
the first of the adjustable Pump Parameters.
Pump Calibration Min Capacity
On this screen you set the pump capacity in litres per hour when the pumps are running at minimum
speed.
As the pump rotors wear down you may have to adjust this value in order to obtain a correct mix flow
read out.
By pressing K7 (Arrow) up you increase the parameter and by pressing K8 (Arrow Down) you
decrease the parameter. Keeping the keys pressed will make the adjustments go faster and faster.
The parameter adjustment is immediately being stored. There is no need for acknowledging the
adjustment.
If you press K5 (Escape) you will return to the Main Set-up Menu. By pressing K10 (Enter) you will go
to the next adjustable Pump Parameter:
Pump Calibration Max Capacity
On this screen you set the pump capacity in litres per hour when the pumps are running at maximum
speed.
As the pump rotors wear down you may have to adjust this value in order to obtain a correct mix flow
read out.
By pressing K7 (Arrow) up you increase the parameter and by pressing K8 (Arrow Down) you
decrease the parameter. Keeping the keys pressed will make the adjustments go faster and faster.
The parameter adjustment is immediately being stored. There is no need for acknowledging the
adjustment.
If you press K5 (Escape) you will return to Pump Calibration Min Capacity. K10 (Enter) will not work
since the Pump Calibration Max Capacity is the last parameter in this sub menu.

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Dasher Parameters
By pre-selecting the Dash Field on the Main Set-up Menu and pressing K10 (Enter) you will get into
the first of the adjustable Dasher Parameters.
Dasher Load Warning Threshold
On this screen you set the load warning threshold. When the dasher is running the control system is
supervising the load of the dasher. When the load is exceeding this threshold an alarm is displayed
and the Back Pressure Valve opening is reduced by 10 percent in order to bring down the dasher
load.
When the load has dropped 5 % below the warning threshold the Back Pressure Valve is returned to
its original opening.
By pressing K7 (Arrow) up you increase the parameter and by pressing K8 (Arrow Down) you
decrease the parameter. Keeping the keys pressed will make the adjustments go faster and faster.
The parameter adjustment is immediately being stored. There is no need for acknowledging the
adjustment.
If you press K5 (Escape) you will return to the Main Set-up Menu. By pressing K10 (Enter) you will go
to the next adjustable Dasher Parameter:
Dasher Max Load
On this screen you set the maximum allowable load of the dasher. When the dasher is running the
control system is supervising the load of the dasher. When the load is equal to or exceeds this
parameter an alarm is displayed and refrigeration and dasher is stopped.
By pressing K7 (Arrow) up you increase the parameter and by pressing K8 (Arrow Down) you
decrease the parameter. Keeping the keys pressed will make the adjustments go faster and faster.
The parameter adjustment is immediately being stored. There is no need for acknowledging the
adjustment.
If you press K5 (Escape) you will return to the previous Dasher parameter. By pressing K10 (Enter)
you will go to the next adjustable Dasher Parameter:

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Dasher Motor Amperage
On this screen you set the nominal amperage of the dasher motor. This value can be seen on the
motor nameplate. The parameter is used by the control system to calculate the dasher load.
By pressing K7 (Arrow) up you increase the parameter and by pressing K8 (Arrow Down) you
decrease the parameter. Keeping the keys pressed will make the adjustments go faster and faster.
The parameter adjustment is immediately being stored. There is no need for acknowledging the
adjustment.
If you press K5 (Escape) you will return to the previous Dasher parameter by pressing K10 (Enter) you
will go to the next adjustable Dasher Parameter:
Dasher Wire Turns
On this screen you tell the control system how many times one of the dasher motors power wired is
turned through the current transducer. Nameplate. The parameter is used by the control system to
calculate the dasher load.
By pressing K7 (Arrow) up you increase the parameter and by pressing K8 (Arrow Down) you
decrease the parameter. Keeping the keys pressed will make the adjustments go faster and faster.
The parameter adjustment is immediately being stored. There is no need for acknowledging the
adjustment.
If you press K5 (Escape) you will return to the previous Dasher parameter. By pressing K10 (Enter)
you will go to the next adjustable Dasher Parameter:

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Dasher Transducer Range
On this screen you tell the control system the range setting of the dashers current transducer.
The standard transducer has 3 ranges, which can be selected on the transducer.
The parameter is used by the control system to calculate the dasher load.
By pressing K7 (Arrow) up you increase the parameter and by pressing K8 (Arrow Down) you
decrease the parameter. Keeping the keys pressed will make the adjustments go faster and faster.
The parameter adjustment is immediately being stored. There is no need for acknowledging the
adjustment.
If you press K5 (Escape) you will return to the previous Dasher parameter K10 (Enter) will not work
since the Dasher Transducer Range is the last parameter in this sub menu.