Tetra Pak Alfast 200 Series Operation Manual Download | Manualshive

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Summary of Contents for Alfast 200 Series

Page 1: ...OM O p e r a t i o n M a r i u a l Tetra Alfast 200 Type 210 220 A Tetra Pak Doc No OM 1242509 01...

Page 2: ...This document is valid for T5845420261 Series No Machine No OM Operation Manual Doc No OM 1242509 01 Issue 2001 11 Tetra Pak Dairy Beverage Systems AB...

Page 3: ...nnel Operator station Risk area Process description 1 Operation modes 15 Controi panei 17 Operator module 18 Supervision of faults 25 Fault list 27 Preparation 29 Operation 31 Update input fat content...

Page 4: ...Operation remote control 45 Back up operation 46 Hand keys 46 Switches and potentiometers 47 Control module 49 Cleaning 51 Cleaning remote control 53 Sampling of product 55 Settings 57 Standardizatio...

Page 5: ...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 ne...

Page 6: ...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 neares...

Page 7: ...ion Hazard information in this documentation is defined s follows Failure to observe this information results in immediate danger to life A WARNING Failure to observe this information can result in ma...

Page 8: ...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 inform the operator and...

Page 9: ...ear 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 att...

Page 10: ...A Safety precautions This page intentionally left blank Doc No OM 1242509 01 Tetra Alfast 200 Type 210 220...

Page 11: ...personnel Operator basic knowledge of industrial processes Caution Unauthorized personnel Operation by unauthorized personnel may endanger personnel and property Operator station At the operator modu...

Page 12: ...ll remix of cream a Skim milk from separator b Cream from separator c Skim milk d Standardised surplus cream 7 Control valve CV51 milk fat content 8 Shut off valve SV50 if applicable 9 Flow transmitte...

Page 13: ...inet The panel contains operator module with keyboard and display only for version 1 above recorder for fat content only for version 1 above control module components for power supply The operator mod...

Page 14: ...121 8 Selector manual automatic cream fat control S21 9 Potentiometer for control valve positioning cream fat during manual operation R21 10 Indicator for control valve position milk fat 151 11 Select...

Page 15: ...a change in the fat content in the skim milk Only Tetra Alfast 220 g The density of the skim milk is measured by means of the density transmitter I DTll Compensated for the measured fat contents in t...

Page 16: ...y transmitter is no longer used in calculating whole milk fat content control of cream flow is now based on the initial whole milk fat content and information from the flow transmitter Milk standardis...

Page 17: ...tandardised milk n 41 10 Shut off valve for remix cream SV31 11 Non return valve 12 Shut off valve for standardised cream SV50 if applicable 13 Density transmitter for skim milk DT11 only Tetra Alfast...

Page 18: ...tter FY21 to control valve CV21 then flows a through shut off valve SV31 flow transmitter FTSl and a non return valve to the remixing point b through control valve CV51 and if applicable through shut...

Page 19: ...uction During circulation Tetra Alfast will stop accumulating amounts of produced skim milk cream not give any fat content alarm stop the fat content recorder if the cascade control is switched off 18...

Page 20: ...A Process description This page intentionally left blank 8 Doc No OM 1242509 01 Tetra Alfast 200 Type 210 220161...

Page 21: ...nation On the front 1 Recorder channel 1 blue pen milk fat content 0 5 channel 2 red pen cream fat content 0 50 2 Operator panel with display and keys 3 Control module Inside the cabinet Doc No OM 124...

Page 22: ...D indicates that manual fat control is selected total remix is selected skimming is selected 3 Hand key selection deselection of automatic control 4 Arrow up key is used to increase fat content during...

Page 23: ...ashing light indicates unacknowledged alarm steady light indicates that the alarms are acknowledged but remains 3 Numerical keys contains numerical keys 0 9 decimal point key and erase key Erase key i...

Page 24: ...y used to position the cursor on the display 3 ENTER key used to confirm keyed in values scroll between alarms proceed to next parameter 4 Parameter keys are used to change or check a parameter value...

Page 25: ...control module group 2 indicates display level blank is normal information 1 or 2 is sub level information group 3 indicates denomination milk cream group 4 is used to preset volume of milk cream to b...

Page 26: ...0H 1013 44K 4 15 CREAM 3500L 2234L 40 00 38 95 Standardization Alarm queue empty Line 1 sub level 2 only Tetra Alfast 120 220 is used to display information I on the skim milk density measurements E j...

Page 27: ...content set point F group 6 calculated standardised cream fat content F group 7 3 4 5 6 7 MILK OL 32539L 3 00 3 02 DT21 55 030 1435 1 i 965 25K 40 10 Standardizatlon Alarm queue empty Line 2 sub level...

Page 28: ...not active cascade control selected and active production status group 3 1 2 3 4 5 6 7 MILK 35000L 25345L 3 00 3 02 CREAM 3500L 2234L 40 00 38 95 1 A005 0 50 Alarm queue empty Line 4 During inspection...

Page 29: ...the red LED is switched off if the fault has disappeared external alarm if connected is deactivated 1 2 3 4 5 6 7 MILK 35000L 25345L 3 00 3 02 CREAM 3500L 2234L 40 00 45 95 Standardization Cream fat t...

Page 30: ...REAM 3500L 2234L 40 00 45 95 Standardization Cream fat too high 2 2 1 Press Cursor key to move the cursor to line 4 H Gro00042 2 Press Erase key to acknowledge the alarm displayed on line 4 OF000039 3...

Page 31: ...eam volume processed Preselected milk volume processed Cascade control off Cascade control outside preset limits No flow through FT21 Flow should be present No flow through FT41 Flow should be present...

Page 32: ...11 not working No answer density transm 21 Density transmitter DT21 not working Note DT11 Only Tetra Alfast 120 220 Control module alarms PROIVI ERROR D95 Contact Tetra Pak PROM ERROR D96 Contact Tetr...

Page 33: ...d in the buffer tanks for at least one hour d Check the equipment visually to ensure that it is ready to be started e Check that no alarm texts are displayed on the operator module f Check the supply...

Page 34: ...Preparation This page intentionally left blank A Doc No OM 1242509 01 3 0 Tetra Alfast 200 Type 210 220...

Page 35: ...6 7 1 SK WM 0 05 4 00 4 15 CREAM 3500L 2234L 40 00 38 95 Standardi2ation Alarm queue empty 1b This picture is displayed C F O O O O S i 1 2 1 SK WM 0 05 r 4 00 4 15 CREAM 3500L 2234L 40 00 38 95 Stan...

Page 36: ...0 0 0 0 0 0 0 ffiffi 0 0 W 0 0 0 0 0 r j 4 O 0 r j 4 Press the Cursor key or Enter until the auxiliary cursor is no longer displayed Press the left Arrow down key to leave the sub level mm 0 0 so 0 o...

Page 37: ...the Cursor key to position the cursor at line 1 skimmilk or line 2 cream group 4 1 2 MILK OL 25345L 0 00 CREAM OL 2234L 40 00 Standardization Alarm queue empty 0 05 38 95 0 0 0 0 0 0 0 S f f l S S E...

Page 38: ...MILK 35000L 25345L 0 00 0 05 CREAM 3500L 2234L 40 00 38 95 Standardization Alarm queue empty i 0 0 ffiffl E E 0 0 0 0 ffiffl E E 1 0 a s m s a d a Key in 0 zero b Press Enter to confirm and start reg...

Page 39: ...A Operation Press the Cursor key or Enter until the auxiliary cursor is no longer displayed m 1 1 0 0 9 4 5 1 2 0 H a A n B GF000037 Doc No OM 1242509 01 Tetra Alfast 200 Type 210 220 35...

Page 40: ...ream not give any fat content alarms stop the fat content recorder if the cascade control is switched off 18 Valve freeze cascade freeze Performs one of the following functions selected via parameter...

Page 41: ...0 S f f l S S B 0 0 E E 0 0 0 0 1 1 Press the Quick choice key 1 2 MILK 35000L 25345L 0 00 0 05 CREAM 3500L 2234L 40 00 38 95 1 40 00 0 00 Alarm queue empty Key in desired choice number Relevant prese...

Page 42: ...0 o fflffl E E 0 0 0 0 0 0 0 0 0 a 0 0 1 0 II To terminate function 20 Keyboard locking proceed as follows a Press the Quick choice key b Key in 20 c ConJBrm by pressing Enter 38 Doc No OM 1242509 01...

Page 43: ...valves 1 Press applicable Hand key right for cream The yellow LED above the Hand key will be lit The control valve will remain in its current position o o fflffiWS I E 0 SO 0 t Jl 6 21 F O A O B Pres...

Page 44: ...ub level 1 on line 2 Note The LED above the hand must not be lit 1 2 3 32539L 0 00 4 15 40 00 MILK OL CASCADE 1 Standardization Alarm queue empty 0 05 40 10 1 b The following is displayed 0 0 o 0 0 ff...

Page 45: ...cascade control 0 0 S 0 0 0 U B S ffiffl a s E E 0 0 0 4a Press Enter to confirm The cursor is moved to line 1 group 6 s 4b The following is displayed on line 3 group 2 At selection if casca within li...

Page 46: ...E E 0 0 0 M Press the Cursor key or Enter until the auxiliary cursor is no longer displayed 0 0 0 0 0 0 0 0 S E E 0 B E a 3 Press the right Arrow down key to leave the sub level i 42 Doc No OM 1242509...

Page 47: ...isplay sub level 2 on line 1 i 1b The following is displayed 1 2 3 4 5 6 7 2 DT11 60 00C 1446 60 l 1013 44K 9 21 CREAM OL 1423L 40 00 40 15 Standardization Alarm queue empty O 0 X J Q S 0 0 0 0 0 0 0...

Page 48: ...lay sub level 2 on line 3 1b The following is displayed ni r r r 32539L 0 00 14 351 J 965 25K MILK OL 2 DT21 55 03C Standardlzation Alarm queue empty 0 05 40 10 0 0 X o 0 0 El 1 0 0 0 0 0 0 U E E 0 0...

Page 49: ...s made by either relays or computer communication Relay communication The following communication is supported selection of quick choice 1 5 and 17 19 Computer communication The following conmiunicati...

Page 50: ...ontact Tetra Pak 7 0 9 o a 4 5 6 Itl b 1 T 3 7 o H Hand keys Use this back up operation when there e g are major process disturbances a Press the Hand key to deselect the automatic fat content control...

Page 51: ...nit in the control module c Adjust the fat content with potentiometer R51 until the correct value is achieved See the Process data list d Take a fat content sample and re adjust the fat content if nec...

Page 52: ...ter R21 until the correct value is achieved d Take a fat content sample and re adjust the fat content if necessary To end the back up operation e Set switch S21 to position AUT SI to position AUT Note...

Page 53: ...ntrol module Use this back up operation when the communication between operator module and control module is out of order the operator module is out of order All functions available on the operator mo...

Page 54: ...Operation A This page intentionally left blank Doc No OM 1242509 01 5 0 Tetra Alfast 200 Type 210 220...

Page 55: ...ess the Quick choice key 1 2 3 MILK 35000L 25345L 0 00 CREAM 3500L 2234L 20 00 19 Cleaning Alarm queue empty 0 05 38 95 Key in the number 19 The cursor moves to line 3 and the following is displayed L...

Page 56: ...control The Tetra Alfast is now in cleaning mode of operation This following is displayed Start cleaning of surrounding equipment mm 0 0 J s 0 o a s ffl 0 i 3f CSffl Q a After cleaning is completed a...

Page 57: ...tion link or by using external relay signals After an external selection of cleaning the Tetra Alfast is in cleaning mode of operation During external selection of cleaning the following is displayed...

Page 58: ...Cleaning A This page intentionally left blank i Doc No OM 1242509 01 5 4 Tetra Alfast 200 Type 210 220...

Page 59: ...n temperature change of product change of delivery or receiving storage tank etc Whole milk should be of good quality with the fat content within the range that the system is designed for Whole milk t...

Page 60: ...a period of 90 seconds This is to level out fluctuations induced by the control system z u u s In the product tanks If the fat content is close to the setpoint i e within 0 05 units of the milk fat co...

Page 61: ...alculated values All values are momentary These parameters can not be changed by the operator Settings i Standardization method Only Tetra Alfast 220 Standardization of milk fat content can be done in...

Page 62: ...nts These choices include preset setpoints for cream and milk fat contents Each quick choice contains 4 parameters Set point milk fat content F Set point cream fat content F Set point milk fat content...

Page 63: ...5 CREAM 3500L 2234L 40 00 38 95 A006 40 00 Alarm queue empty 1 2 MILK 35000L 25345L 0 00 0 05 CREAM 3500L 2234L 40 00 38 95 Cannot be alerted without key code Alarm queue empty Change of parameter val...

Page 64: ...ry the access code is set at 111 1 2 3 MILK CREAM 1 A252 35000L 25345L 0 00 3500L 2234L 40 00 Alarm queue empty 0 05 38 95 If the code is correct 1 is displayed on line 3 Note Access is lost a preset...

Page 65: ...e The new value of the parameter is now stored and will be used during operation Example to key in 1 234567E 8 proceed as follows 1 Press i for minus 2 Press 1 234567 3 Press to start key in exponents...

Page 66: ...lection C 014 Quick choice 3 cream fat setpoint F relay selection C 017 Quick choice 4 milk fat setpoint F relay selection D 018 Quick choice 4 cream fat setpoint F relay selection D 021 Quick choice...

Page 67: ...tion 0 relay selection 070 Function 17 circulation 0 relay selection 073 Function 18 valve or cascade freeze 1 relay selection 074 Function 18 valve or cascade freeze duration s 120 relay selection 07...

Page 68: ...ice 3 milk fat setpoint F TS 903 Quick choice 4 milk fat setpoint F rs 904 Quick choice 5 milk fat setpoint F rs 905 Quick choice 6 milk fat setpoint F rs 906 Quick choice 7 milk fat setpoint F TS 907...

Page 69: ...k fat setpoint F SNF 926 Quick choice 7 milk fat setpoint F SNF 927 Quick choice 8 milk fat setpoint F SNF 928 Quick choice 9 milk fat setpoint F SNF 929 Quick choice 10 milk fat setpoint F SNF 930 Qu...

Page 70: ...Settings A This page intentionally left blank ii N Doc No OM i 242509 01 6 6 Tetra Alfast 200 Type 210 220...

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