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Tetra Pak Hoyer Frigus 400, Manual

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Summary of Contents for Hoyer Frigus 400

Page 1: ...he information will be of help to you It is based on concrete data and on the best of our current knowledge Read the contents of the manual carefully including the warnings and recommendations No part...

Page 2: ...00 1 Machine identification data 2 General information 3 Description of the machine and technical data 4 Installation 5 Set up 6 Operating procedures 7 Cleaning and maintenance 8 Troubleshooting 9 Spa...

Page 3: ...HOYER FRIGUS 400 1 1 Tetra Pak Hoyer Contents F40 03 AB 00 1 MACHINE IDENTIFICATION DATA 1 1 Introduction 1 2 1 2 Identification plate 1 2 1 3 Servicecentres 1 3...

Page 4: ...rinformationortoarrangefor Fig 1 1 Identification plate 1 1 Introduction Thank you for having chosen a Tetra Pak Hoyer machine Werecommendthatyoureadthismanualcarefully asitcontainsessentialinformatio...

Page 5: ...rie WI 53158 0902 USA Phone 1 414 947 9100 Fax 1 414 947 9190 SOUTH AMERICA Tetra Pak Hoyer Industria e Com rcio Ltda Rua Napoleao de Barros 1038 Cep04024 003 Sao Paulo SP Brazil Phone 55 11 573 9422...

Page 6: ...Tetra Pak Hoyer Contents F40 03 BB 00 2 GENERAL INFORMATION 2 1 Declarationofconformity 2 2 2 2 Preliminarypoints 2 2 2 3 Generalsafetyrules 2 2 2 4 Specialwarnings 2 3 2 5 Residualrisks 2 3 2 6 Ambie...

Page 7: ...ir work not authorised by Tetra Pak Hoyer carried out during the warranty period will automatically invalidate the warranty 2 2 Preliminary observations 2 3 General safety rules THESE SAFETY RULES HAV...

Page 8: ...oroperationinthefollowing ambientconditions Temperaturae 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 wi...

Page 9: ...AL DATA 3 1 Descriptionofthemachine 3 2 3 1 1 Filterset 3 3 3 1 2 Mixpump 3 3 3 1 3 Freezingcylinder 3 3 3 1 4 Refrigeratingplant 3 3 3 1 5 Electricalsystem 3 4 3 1 6 Controlpanel 3 5 3 2 Technicaldat...

Page 10: ...ck consistency arefrigeratingplantconnectedtotheoutsidewall ofthefreezingcylindertocoolitdown an electrical system for command and control ofallmachinefunctions The compressed air supply the machine d...

Page 11: ...1 2 Mixpump that no extraction pump is needed coming off the machine This is the most important part of the machine an uprightpipewithachromecoatingonitsinsidewalls surrounded by a jacket in which coo...

Page 12: ...e ice cream mix whichcoolsdown theheatisthendisposedof 3 1 4 Refrigerating plant Theelectricalsystemconsistsoftheoperatorpanel and the electrical panel which covers all of the rear of the machine The...

Page 13: ...2 7 Dasher start stop selector SL2 8 Compressor start stop switch SL3 9 Overrun air ON OFF switch SL4 10 Hot gas control potentiometer P2 11 C I P washing switch SL5 12 Emergencystoppushbutton 13 Over...

Page 14: ...compressor 6 kW Auxiliaries 0 85 kW Totalinstalledpower 11 6 kW Compressed air Operatingpressure 6 10 bar Consumption max 10 Nl min Filteringdegree A0 Connector 1 2 female Refrigerating plant Coolantg...

Page 15: ...y Informationofusefordisposalofthemachineandits components The machine must be demolished by specialised personnelwearingappropriatesafetygarmentsand workingincompliancewithsafetyandenvironmental legi...

Page 16: ...1 Unpacking delivery checks and transport 4 2 4 2 Installation 4 3 4 2 1 Cooling water connection 4 4 4 2 2 Ice cream intake and outlet connection 4 4 4 2 3 Compressed air connection 4 5 4 2 4 Electri...

Page 17: ...are with the wooden spacers between the walls of the crate b Remove the box containing spare parts and the other components from the crate c Unnail the wooden blocks that hold the machine in place dur...

Page 18: ...adjustments to the machine we recommend that factory settings not be changed Proceed with the installation procedure as follows a Position the machine in its operating position and check the plate dat...

Page 19: ...emperature to obtain constant cooling constant condensation pressure on the coolant side this makes it possible to use water supplies with widely varying temperatures for cooling the condenser The wat...

Page 20: ...Make sure that ice cream pressure in the cylinders does not exceed 12 bar the absolute maximum permitted value if this should occur move the freezer closer to the ice cream utility and or use hot gas...

Page 21: ...s rear panel to the I position Release the emergency button 1 Check that the power on light and the indicators come on Ifonlythepoweronlight comeson changethe directionofrotationofthephasesbyswitchin...

Page 22: ...Tetra Pak Hoyer HOYER FRIGUS 400 5 1 Contents F40 03 EB 00 5 SET UP 5 1 Controlpanelsettings 5 2 5 2 Ice cream pressure settings 5 3 5 3 Emergencystop 5 4...

Page 23: ...activation the refrigerator compressor is shut off This prevents excessive hardening of the ice cream which could stop the dasher When the dasher is stopped the hot gas device comes on for 30 seconds...

Page 24: ...events pressure from damagingthefreezer WARNING The adjustment described above takes effect after an interval of time which varies according to the operating parameters set Wait for the gauge 6 readin...

Page 25: ...gency stop Releasetheemergencybutton Activate the injection of hot gas by turning potentiometer 2 for about 30 seconds Restart the freezer functions including the pump thedasher therefrigeratorcompres...

Page 26: ...HOYER FRIGUS 400 6 1 Tetra Pak Hoyer Contents F40 03 FB 00 6 OPERATING PROCEDURES 6 1 Preliminarychecks 6 2 6 2 Start of production 6 3 6 3 Productionchangeover 6 4 6 4 Endofproduction 6 5...

Page 27: ...the main switch is on c Checkthatthewaterandcompressedairvalves are open d Check that the emergency stop button 1 has been released e Checkthattheclampfittingsaretightlyfitted f Checkthatthesafetyval...

Page 28: ...iontakeseffectafterafewminutes j Thehardnessoftheicecreamcanbemonitored on the gauge 9 which measures the amount of current absorbed by the dasher motor proportionatetothehardnessoftheicecream k When...

Page 29: ...r by turning the switch 3 anti clockwise d Disconnect the supply to the freezer 4 from thevatcontainingthemixforwhichproduction is to be stopped and connect it up to the containercontainingthenew dark...

Page 30: ...tional washing instructions please refer to thesectiononCIPwashinginthismanual WARNING Do not carry out CIP washing without turning ontheCIPcyclewithswitch 6 thiswouldresult in insufficient flow for w...

Page 31: ...3 6 3 g Start up the pump using the switch 2 6 3 h Let hot water flow through the machine until thewaterflowingoutofitisfairlyclean Keep washingasshortaspossibletopreventdamage to the pump i Stop the...

Page 32: ...at could damage the freezer cylinder a shaft raiser ring is supplied The ring must be positioned on the cylinder as shown in the figurebelow Thenassembletheshaft 3 beingvery careful not to hit and dam...

Page 33: ...2 7 1 1 CIPwashing 7 2 7 1 2 Washingtheoutsideofthemachine 7 4 7 2 Maintenance 7 5 7 2 1 Mechanicalmaintenance 7 5 7 2 2 Maintenanceoftheelectricalsystem 7 10 7 2 3 Maintenanceoftherefrigeratingplant...

Page 34: ...for damage resulting from inadequate sanitation of the machine 7 1 1 CIP washing CIP Cleaning In Place washing permits cleaning oftheinternalpartsofthemachinewhichcomeinto contact with the product wit...

Page 35: ...1 max 70 10 recycle P3 PE4 Spezial a Henkel Ecolab Rinse Water 100 20 5 drainaway Disinfectantwash SU330 Diversey Lever 1 1 2 20 10 recycle P3 Dix forte Henkel Ecolab Rinse Water 100 20 10 drainaway 4...

Page 36: ...thewashprogramme stop the tank pump and disconnect the pipe connecting the pump with the cylinder Wait untilallwaterhasflowedout thenturnswitch 11 anti clockwise to end the CIP washing cycle and reass...

Page 37: ...tatingsealhasahousingmadeofhardmetal which underpressurefromthespring 7 rotates againstthefaceofthebush 6 Check that the surface of the housing has no scratches which could affect its hold Usefineemer...

Page 38: ...t 5 spring 7 and lip seals 8 and replace if necessary Cylinder lid Fig 7 4 Check for wear on the gasket 9 and replace if necessary Ice cream mix pipe connection seals 10 Check for wear and replace if...

Page 39: ...orwithacloth Non return valve Inspection Figure 7 5 Checktheintegrityoftheairinletnon returnvalve 1 into the pump In case it is necessary replace the gasket 2 Pump timing Inspection Figure 7 6 Place t...

Page 40: ...lleys and the belt at the same time Check the alignment of the two notches and stop the pulleys with the proper screws Ifitweredifficulttomaintainthetwonotchesaligned loosen the four bolts 4 on the dr...

Page 41: ...Replacement of crankshaft bearings and gaskets Disassemble the ratio motor 9 the flange 10 on themotorside theoppositeflange 11 andextract the gaskets 12 and the bearings 13 Takeoutthecrankshaft disa...

Page 42: ...ponents 7 2 2 Maintenance of the electrical system If the motor compressor on the refrigerating plant shuts down check the pressure switch and electronicprotection locatedintheterminalboard above the...

Page 43: ...anufacturer s instructions and put it in the container Flush it through followingtheinstructionsforuse untilthe solution s indicator colour change pH etc indicatesthatscalehasbeenremoved Thismaytake a...

Page 44: ...heflowof hot gas stays open it will compromise the per formanceoftherefrigeratingplantconsiderably Check the solenoid valve and replace if necessary The liquid solenoid valve automatically closes the...

Page 45: ...thesterilisingfilter CAUTION Donotopenthefiltercartridgepackageuntilready to replace the filter Handle with care Replace the seal on the air intake check valve according to the instructions provided i...

Page 46: ...HOYER FRIGUS 400 8 1 Tetra Pak Hoyer Contents F40 03 HB 00 8 TROUBLESHOOTING 8 1 Troubleshooting 8 2...

Page 47: ...t overrun See problem The pump stops or does not start The pump stops or does not start Switchfault Mainmotorfault Pump rotor seized Bearingsblocked Inverterthermalcutout Inverterfoult Inverterinemerg...

Page 48: ...ualified refrigerator technician Excessivehotgas Excessive ice cream productionrate Imputmixtoohot Water supply to condenser insufficient Condenser cooling water too hot Ice cream outlet valve too ope...

Page 49: ...place as described in the Compressed air system maintenance section Replace as described in the Mechanical maintenance cleaning section Replace the O ring as in point above and clean system Reset Repl...

Page 50: ...Low pressure cutoff tripped Condenser water too cold Bladesworn Thermostatvalvefault Excessive quantiy of coolant gas Inverterfoult Potentiometerfault Inverterfoult Potentiometerfault Instrumentdecal...

Page 51: ...dasher 13020025 1 1 Gruppo uscita miscela Mix outlet unit Groupe sortie m lange 13020350 1 1 Gruppo trazione Drive Traction 13020366 1 1 Pompa a 2 stadi Pump Pompe 13020362 1 1 Gruppo distributori Dis...

Page 52: ...1 Cassetta Q E Electrical cabinet Armoire lectrique 4 12020098 1 Cassetta Q E Electrical cabinet Armoire lectrique 5 12020318 1 Targhetta Data plate Plaquette frigus 6 12000002 4 Piede Foot Pied 7 336...

Page 53: ...Tetra Pak Hoyer 1 4 3 2 5 8 7 8 7 6 6 6 1 1 13020355 9 3 13210152...

Page 54: ...067141 1 Guarnizione O ring Joint 14 336067145 1 Guarnizione O ring Joint 16 016060219 1 Chiusura clamp 2 Clamp lockup Fermeture clamp 17 018020583 1 Guarnizione 2 O ring Joint 18 016060218 5 Chiusura...

Page 55: ...Tetra Pak Hoyer 8 2 11 1 14 10 12 13 6 5 7 3 9 4 22 16 17 23 25 24 21 20 18 20 18 18 19 18 19 19 18 13020113 1 1 13020349 9 5 13210152...

Page 56: ...icroswitch Micro de s curit 2 017035938 1 Micro Microswitch Micro 3 12020282 1 Vite Screw Vis 4 12020283 1 Supporto micro Micro support Support micro 5 17020090 1 Molla Spring Ressort 6 326024270 1 Sp...

Page 57: ...Tetra Pak Hoyer 5 3 4 2 6 1 13020349 1 1 13020113 9 7 13210152...

Page 58: ...20057 1 Bronzina Bushing Douille 4 12020056 1 Bronzina Bushing Douille 5 141015446 1 Ghiera Ring nut Bague 6 141025250 1 Molla Spring Ressort 7 145500029 1 Molla Spring Ressort 8 145500026 1 Ghiera Ri...

Page 59: ...Tetra Pak Hoyer 9 1 9 9 6 5 4 2 3 7 8 10 1 1 13020348 9 9 13210152...

Page 60: ...Molla Spring Ressort 5 12020123 1 Boccola Bush Bague 6 12020122 1 Corpo superiore Upper body Corps sup rieur 7 336066008 1 Guarnizione OR Seal Joint torique OR 8 336067048 1 Guarnizione OR Seal Joint...

Page 61: ...Tetra Pak Hoyer 1 2 2 3 4 5 6 7 8 9 10 1 1 13020025 9 11 13210152...

Page 62: ...51 1 Rondella Washer Rondelle 12 326013124 1 Chiavetta Key Clavette 13 12020344 1 Albero Shaft Arbre 14 12020345 1 Flangia Flange Bride 15 12020343 1 Distanziale Spacer Entretoise 16 336001720 1 Cusci...

Page 63: ...Tetra Pak Hoyer 1 24 6 22 21 8 11 10 14 15 9 16 20 17 7 12 13 5 4 18 3 2 2 19 23 1 1 13020350 9 13 13210152...

Page 64: ...12020376 1 Flangia Flange Bride 22 12020377 1 Anello bloccaggio Ring Anneau 23 12020365 1 Rondella Washer Rondelle 24 12020245 1 Piattello di chiusura Plate Plateau 25 12020278 1 Piastrina Plate Plaqu...

Page 65: ...a Pak Hoyer 4 5 36 7 30 35 27 6 35 30 7 36 26 46 25 3 10 11 11 9 33 29 45 44 34 12 42 8 33 44 45 34 29 15 31 32 17 6 15 31 32 13 12 16 1 40 19 38 37 18 39 2 20 23 21 22 24 28 43 1 1 13020366 9 15 1321...

Page 66: ...13020105 1 Cilindro Cylinder Cylindre 12 GM50E54001 1 Valvola di non ritorno Check valve Soupape de tenue 13 016060218 1 Chiusura clamp 1 Clamp lockup Fermeture clamp 14 336001443 2 Cuscinetto Bearing...

Page 67: ...Tetra Pak Hoyer 1 2 22 3 7 23 5 4 15 14 14 16 6 12 13 10 21 20 19 19 19 8 9 17 18 11 13020362 1 1 13020362 9 17 13210152...

Page 68: ...oint 5 12020203 1 Testata anteriore cilindro Front cylinder head Culasse avant cylindre 6 12020204 1 Cilindro pompa Pump cylinder Cylindre 7 12020244 1 Pistone Piston Piston 8 17020064 1 Guarnizione O...

Page 69: ...Tetra Pak Hoyer 1 2 4 3 7 9 10 8 6 5 3 1 1 13020105 9 19 13210152...

Page 70: ...2 1 Leva Lever Levier 3 12020206 1 Vite per tendicatena Screw Vis 4 17000743 2 Cuscinetto Bearing Roulement 5 17000742 1 Corteco Corteco seal Corteco 6 17000741 1 Corteco Corteco seal Corteco 7 326019...

Page 71: ...Tetra Pak Hoyer 5 1 7 4 4 3 6 2 1 1 13020363 9 21 13210152...

Page 72: ...ienza High performance filter Filtre 8 333012025 1 Cartuccia olio Oil cartridge Cartouche 9 333012026 1 Cartuccia carboni attivi Cartridge Cartouche 10 17000207 1 Pressostato Pressure switch Pressosta...

Page 73: ...Tetra Pak Hoyer 1 2 3 4 4 3 5 6 10 8 9 12 13 11 11 12a 13a 14 1 1 13020096 9 23 13210152...

Page 74: ...ON 1 12020124 1 Attrezzo estrazione albero Shaft removal tool Equipement extraction arbre 2 12020106 1 Ghiera invito albero Shaft raiser ring nut Bague invitation arbre 13020117 1 1 Attrezzi dotazione...

Page 75: ...Tetra Pak Hoyer 2 1 1 1 13020117 9 25 13210152...

Page 76: ...ED hot gas enabling monitor Blinking display indicates that the threshold for turning on hot gas has been exceeded BAR Pressure gauge Displays cylinder outlet pressure between 0 and 16 bar resolution...

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