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Tetra Pak Hoyer Frigus SF 1200 N1, Operation Manual, Page: 2 / 115

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Tetra Pak Hoyer Frigus SF 1200 N1 Operation Manual Download Page 2

Summary of Contents for Hoyer Frigus SF 1200 N1

Page 1: ...A WARNING Read and follow all safety precaution instructions throughout this manual and on safety signs attached to this equipment Failure to follow all safety precaution instructions could result in...

Page 2: ...with the design and construction of the machine or equipment at the time of publishing Tetra Pak reserves the right to introduce design modifications without prior notice The English version of this...

Page 3: ...Introduction ii Safety Precautions 1 Operation Hoyer Frigus SF 1200 N1 Z1381040 01en Machine or equipment configurations that this manual is valid for are described on the next page Doc No 0M Z138104...

Page 4: ...Valid for...

Page 5: ...381040 01 en This table shows all changes made to this manual including installed rebuilding kits added or removed pages Page numbering on added pages begins with UP Date Installed Kit Added Pages Doc...

Page 6: ...Date Installed Kit Added Pages Doc No Removed Pages Signature...

Page 7: ...i Introduction 9 1 S o S a s A Tetra Pak i 1 14...

Page 8: ...i Introduction General informations about Introduction section This chapter contains basic information about this manual and related Tetra Pak equipment s i 2 14 A Tetra Pak...

Page 9: ...9 1 3 5 Symbols 1 9 1 4 Machine Introduction 1 1 0 1 4 1 Intended use of the machine or equipment 1 1 0 1 4 2 Manufacturer 1 1 0 1 4 3 Service 1 1 0 1 5 Identification 1 1 1 1 5 1 CE classification 1...

Page 10: ...i Introduction This page intentionally left blank i o i 4 14 A Tetra Pak...

Page 11: ...hapter Risk of serious personal injury To ensure maximum safety always read the chapter Safety precautions before operating or servicing the machine or equipment This chapter contains basic informatio...

Page 12: ...tions and Terminology i Introduction i 2 Abbreviations and Terminology Abbreviation Terminology Meaning Translation CIP Cleaning In Place MFC Mass Flow Controller SPC Spare parts catalogue s o i 6 14...

Page 13: ...uipment caused by not following the instructions given in this manual i 3 1 Delivered Manuals The documents delivered with this machine or equipment include Operation Manual OM The purpose of this man...

Page 14: ...Manuale dSll operatore 1 Descrizidhe generale 1 3 Pannello comandi 1 3 1 Descrizione funzioni Marjomeiro 2 Maromsiro compmsso 3 Mar jm ro p ssBcr va o a 4 Re9 3lo s p f 6 S 3 i O T e va vo a U K i t...

Page 15: ...RS Cross references are underlined 1 3 5 Symbols The following symbols are used in illustrations A pointer arrow 1 indicates the position of an object A zoom arrow 2 indicates that an object view is e...

Page 16: ...y or damage if the machine or equipment is used for any other purpose 1 4 2 Manufacturer This Tetra Pak machine or equipment has been manufactured by Tetra Pak Food Machinery Shanghai Co Ltd Business...

Page 17: ...te and its location on the machine or equipment The machine plate carries data needed when contacting Tetra Pak concerning this specific machine or equipment 9 1 1 S o Q T p t f o P o l e Type HoyerFr...

Page 18: ...duction i 6 Orientation The illustration below shows the orientation of the equipment This orientation information will be used throughout this manual A Front B Right hand side C Left hand side D Back...

Page 19: ...ent is in production Compressed air used for cleaning purposes is to be used only for cleaning filters Disinfect your hands before touching anything that may come into contact with the product Keep yo...

Page 20: ...erators with information on handling and operating the equipment before during and after production Operator workflow Beginning with Chapter 1 the content is structured to follow the operator workflow...

Page 21: ...ii Safety Precautions E A TetraPak ii 1 20...

Page 22: ...ii Safety Precautions E a o S S ii 2 20 A TetraPak...

Page 23: ...9 11 5 Protective devices 1 1 0 11 5 1 Emergency Stop 1 1 0 11 5 2 Emergency stop push buttons 1 1 0 I ii 6 Personal protection 1 1 1 s ii 6 1 Hearing Protection 1 1 1 0 in 1 ii 6 2 Risk of entanglem...

Page 24: ...ii Safety Precautions E S This page intentionally left blank ii 4 20 A TetraPak...

Page 25: ...working with or near this machine or equipment must carefully read and follow all safety instructions in this manual and warning signs on the machine or equipment itself Failure to do so could result...

Page 26: ...d on the machine or equipment itself to inform the user of hazards A DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury A WARNING indicates...

Page 27: ...ntify hazards analyze risks and avoid hazards which electricity mechanics chemicals and supply systems can create Skilled persons must meet local regulations such as certifications and quali fications...

Page 28: ...safety signs immediately There are two types of safety sign ISO signs are used in most markets ANSI signs are used in the US market only The table below shows all safety signs that are located on thi...

Page 29: ...afety signs on the machine or equipment are undamaged and in their correct position after installation and maintenance The illustration below indicates where the safety signs are located L A i i 1 f I...

Page 30: ...ard does not switch off the power supply to the machine or equipment 11 5 1 Emergency Stop Learn the positions of the EM ERG ENCY STOP devices in order to stop the machine or equipment immediately in...

Page 31: ...ls 11 6 1 Hearing Protection WARNING Hazardous noise level Risk of impaired hearing Wear hearing protection A CAUTION Hazardous noise level Risk of impaired hearing Hearing protection is recommended 1...

Page 32: ...w the manufacturer s instructions when handling chemical products Always make sure that the showers work an eyewash device movable or wall mounted is available and operational additional washing facil...

Page 33: ...ical attention immediately if there is an accident Emergency Procedures If there is an accident involving the products for cleaning and sterilization rinse the affected area as soon as possible with l...

Page 34: ...7 2 Personal Protective Equipment The personal protective equipment for products for cleaning and sterilization IS safety goggles protective gloves made of neoprene apron shoes made of PVC PE plastic...

Page 35: ...ent used for handling and diluting the products is clean before it comes in contact with the products Pumps or other equipment used for handling the products must be used for this puipose only and mus...

Page 36: ...the original container delivered by the supplier Keep the container upright and fitted with its proper cap Make sure that the area used for storage of products for cleaning and sterilization is cool...

Page 37: ...h a lock before any service is carried out inside the electrical cabinet Note The key to the lock must be removed by the service technician or the electrician and retained in his her possession until...

Page 38: ...afety Precautions ii 8 2 Water supply A WARNING Water Under Pressure Certain maintenance procedures may require water supply systems to be on These exceptions are clearly stated in the Maintenance Man...

Page 39: ...3 Air Supply WARNING Compressed air Close the main air valve before any maintenance Certain maintenance procedures may require the air supply systems to be on These exceptions are clearly stated in t...

Page 40: ...ii 8 Supply systems ii Safety Precautions i This page intentionally left blank ii 20 20 A TetraPak...

Page 41: ...1 Operation Q 2 9 CO g s A Tetra Pak 1 1 74...

Page 42: ...1 Operation This page intentionally left blank o 1 2 74 A Tetra Pak...

Page 43: ...3 3 Programming and control panel page 1 13 1 1 4 Main pages 1 18 1 1 4 1 Main menu 1 18 1 1 4 2 Production Menu 1 2 4 1 1 4 3 Recipe Menu 1 2 9 1 1 4 4 Menu Maintenance 1 30 1 1 4 5 Set up Menu 1 33...

Page 44: ...Operation 1 6 2 Automatic stop 1 6 4 1 6 3 Manual Stop 1 6 4 1 7 Care and Cleaning 1 6 5 1 7 2 Manual Washing 1 6 7 1 7 3 Washing the outside of the machine 1 7 1 1 8 Technical Data 1 7 2 E o S s o S...

Page 45: ...mix from ageing vats adds sanitised air and sends the product to the freezing cylinder A mass flow controller which controls the compressed sanitised air capacity that is added to the mix A freezing c...

Page 46: ...or its injection below the pump Finally the clean and pressurised air goes through a sterilizing Teflon 5 membrane filter with microscopic pores specifically intended to stop the passage of bacteria T...

Page 47: ...p By adjusting the capacity of sanitised air the operator therefore controls the desired volume which remains constant throughout the production cycle The pump is driven by an electric motor commanded...

Page 48: ...corporate the mix feed pipe left 3 Mix blended with sanitary air coming from the pump flows into left part of the cylinder 3 on its way to the right it is whisked by the dasher 1 and cooled by contact...

Page 49: ...cream mix which cools down the heat is then disposed of in the condenser where it is transferred to the water coming from the cooling tower or well heating it A pressure switch valve assembled on the...

Page 50: ...en 2 Automatic cycle push button 3 C I P washing push button 4 Pump start stop push button 5 Overrun start push button 6 Dasher start stop push button 7 Compressor start stop push button 8 Reset push...

Page 51: ...the pages is dedicated to the menu while the lower part is dedicated to the sub menu available for the selected menu The menu and sub menu selected are highlighted with the same colour of background...

Page 52: ...ill be described in detail after All the parameters that are modifi able by operator have a 3D edge ex 0 it is enough to push on the cell in order to modify the value All the actual values of the vari...

Page 53: ...een such as buttons input fields and message windows Their operation is basically no different from pressing conventional keys Touch elements are operated by touching them lightly with your finger or...

Page 54: ...splays a numeric screen keyboard for example after touching an input field Keys on the keyboard which are available for operation are highlighted as 3D keys those not available are simply displayed as...

Page 55: ...leted on entering the first character After beginning entering a value it is impossible to exit from the field without either confi rming the entry or cancelling it Characters entered are aligned to t...

Page 56: ...ply displayed as areas After completing the input the keyboard is automatically hidden Below illustrates an example of a normal screen keyboard to enter alphanumeric values The HELP key is only displa...

Page 57: ...aracter after pressing CURSOR RIGHT it skips to the second character In this case the value reverts back to its normal representation and can be edited On exceeding the maximum number of characters th...

Page 58: ...ge when hot gas control is based on ice cream viscosity Fig 2 Main page when hot gas control is based on ice cream temperature In this page are contained the main production parameters of the machine...

Page 59: ...the mix fl ow Viscosity Ice cream viscosity calculated in l percentage referred to nominal dasher motor load current Ice Cream Pressure Ice cream pressure inside the freezing cylinder o s o Ice Cream...

Page 60: ...lights It is suffi cient to remove the alarm cause and push the reset button and the alarm message disappear mm Time Text A kN 1 1 4 1 3 Sub menu Alarms History Si Press Main Menu and Sub menu Alarms...

Page 61: ...croll all the following 16 11 49 Z3lce Z005 H ii ig 23 06 2005 13 11 49 23 06 2005 A l A i Ml m 16 44 48 23 Ce 2005 15 14 48 23 06 2005 13 44 48 E3 06 2005 A b Overrun A is the actual value and S is t...

Page 62: ...s cell appears only if it is active the hot gas e i 16 14 49 14 44 49 13 14 49 23 06 2005 23 06 2005 23 06 2005 A b Ice cream pressure inside the freezing cylinder A is the actual value and S is the s...

Page 63: ...1 Operation s o 16 15 49 23 06 2005 14 45 49 23 06 2005 13 15 49 23 06 2005 a b Suction pressure L and discharge pressure H of the refrigerating system compressors A Tetra Pak 1 23 74...

Page 64: ...ix processed by the machine starting from the beginning of the automatic production cycle and it is reset when a new cycle begins The cell Mix temperature Act is the actual value of the mix inlet temp...

Page 65: ...d to the mix The cell Overrun yellow and the bar graph show the set point value of air percentage that is added to the mix Pressing on the yellow cell it is possible to modify the set point value for...

Page 66: ...you enter in the page that contains the detailed production parameters related to refrigeration Pressure Low and High are the suction and discharge pressure of the compressors Water Temperature In an...

Page 67: ...ice cream temperature in this case the temperature set point is active It is sufficient to pust on the button in order to change its status The cell Viscosity green and the bar graph show the actual v...

Page 68: ...of the ice cream pressure in the freezing cylinder The cell lee Cream Pressure yellow and the bar graph show the set point value of ice cream pressure in the cylinder Pressing on the yellow cell it is...

Page 69: ...rs wanted Return to Recipe page push to save The system ask to confi rm before saving if you are sure press Yes Create a recipe Press on the cell Data Record Name and insert the name of the new t reci...

Page 70: ...is possible Duration working hours to which is suggested to do maintenance to the component Remaning Remaining working hours bifore the component reaches the suggested working hours for maintenance p...

Page 71: ...of the CIP cycle duration The cell Duration yellow and the bar graph show the set point value for CIP cycle duration Pressing on the yellow cell it is possible to modify set point value for the CIP cy...

Page 72: ...this value is higher the warning value the machine gives a warning message to the operator suggesting to do pump regulation Pressing the button Mix pump CLOSE OPEN you open and close the mix pump by p...

Page 73: ...ay Month Press on the cell and set the coiTect month Day Press on the cell and set the correct day Year Press on the cell and set the correct year Hour Press on the cell and set the correct hour Min P...

Page 74: ...or reduce the panel contrast and arrow down you Clean Screen Pressing this button you make the panel insensible to the touch for some seconds allowing the cleaning Touch Calibration Pressing this butt...

Page 75: ...tween actual mix fl ow and set point mix fl ow If this difference exceeds the set value for a time higher than Time window the machine gives a warning message Default value 20 L h Window Alarm This is...

Page 76: ...g a O s o Window Warning This is the warning value for the difference between the actual air fl ow rate ed set point If this difference exceeds the set value for a time higher than Time window the ma...

Page 77: ...to which type of regulation is active reaches the set value If after the time reported in this parameter the set point has not been reached yet the machine starts in any case the flow ramp phase Defau...

Page 78: ...or viscosity too high 100 CIP Page related to CIP cleaning cycle s o ime Motor ON ime Motor OFF TPH1 TPH2 During the CIP cleaning cycle the pumps and dasher motors are periodically activated for a tim...

Page 79: ...US Units 0 NO 1 YES Frigus Type Z Number Cycle Stsp Active TPH f TPH2 US Units 0 for European units L h bar etc for American units Gal h Psi etc Frigus Type Machine Model Z Number Serial Number Cycle...

Page 80: ...achine The modification of these parameters can be done only after Tetrapak Hoyer S p A authorization Not authorized modifi cation will make the machine guarantee not valid Pushing the buttons arrow u...

Page 81: ...ix flow regulation MIX pump FLOW SCALING MAX Regulation Sample KP TPH1 TPH2 Pump conversion Flow rate frequency for the mix pump Default scale MIN MAX l h 200 869 Hz 23 100 Regulation Regulation param...

Page 82: ...d in order to prevent damages to the machine Default value 70 C l e i i MIX Max temperature in the circuit FLOW I _ lUffl I C TPH1 TPH2 Overrun Scaling Page related to the scaling of analogical signal...

Page 83: ...oming from the instruments related to ice cream ICE CREAM SCALING PTIOO mA C Pressure mA bar TPH1 TPH2 PTIOO Ice cream temperature transducer Default scale s o MIN MAX mA 4 20 C 10 10 Pressure Ice cre...

Page 84: ...S I bar TPH1 TPH2 Pump conversion flow rate frequency for the ice cream pump Default scale MIN MAX l h 200 1440 Hz 12 85 S Regulation Regulation parameters Sample Sampling time of the difference betwe...

Page 85: ...e mix pump is stopped to prevent damage to the machine Default value 13 bar A fr W 11502 Dasher Scaling Page related to the scaling of the current absorbed by the dasher motor and to rotation speed 2...

Page 86: ...ported the actual current value Nominal speed Motor nominal motor speed Default value 1450rpm Nominal Current Motor nominal motor current Default value 18 5 A Reduction Gear reduction gear ratio Defau...

Page 87: ...water temperatures l l H H i Pl i ICOOLINGf Kv OFFSET ISCALING I B l M B l i g B PTIOO Outlet K i Y OFFSET s o PTIOO Inlet inlet water thermal probe K gain default value 1 Offeset default value 0 PTI...

Page 88: ...refrigerating system COOLING Pressure Outlet MIN SCALING r Pressure Suction MIN mA I i bar 0 i n TPH1 TPH2 Pressure outlet Compressors discharge pressure Default scale E I MIN MAX mA 4 20 bar 0 50 2...

Page 89: ...gas automatically activated Limit for Compressors OFF When the viscosity exceeds this value for a time higher than Filter for Compressors OFF the compressors switch off automatically Time Hot Gas afte...

Page 90: ...In the greeen cell is shown the ice cream temperature actual value In the yellow cell is shown the ice cream temperature set point value Regulation Regulation parameters Sample Sampling time of the d...

Page 91: ...PH2 A s o In the green cell is shown the viscosity actual value In the yellow cell is shown the ice cream viscosity set point value Regulation Regulation parameters Sample Sampling time of the differe...

Page 92: ...e condensers exceeds this value the machine gives a warning message to the operator Max Difference inlet outlet f the difference between the outlet and inlet temperature to the condeser exceeds this v...

Page 93: ...ossible to enter into the following page that contains the active alarm messages with the time in which the alarm is happened When an alarm happens the reset button is lighted It is enough to eliminat...

Page 94: ...n motor and compressor Decrease the viscosity parameters in the panel 1 Flow overrun irregular Overrun air capacity anomaly Machine in function Only signalling Check the air controller working and the...

Page 95: ...densation water flow is not enough Machine in function Only signalling Check the water flow 35 Inlet water temperature fault The thermal porbe for inlet water to the condenser is out of order Machine...

Page 96: ...imit Stop compressor Check the compressor working 116 Suction safety pressure compressor 2 Suction compressor 2 below the limit Stop compressor Check the compressor working 137 Compressor 2 overload C...

Page 97: ...Turn on hot gas and attend fO N s 0 1 o iT S C N J 3 a 5 1 The refrigerator compressor will not start up Dasher off Thermal cutout tripped Electronic overload tripped Switch fault High pressure cutof...

Page 98: ...Compressed air system maintenance section Replace as described in the Mechanical maintenance Cleaning section Replace the 0 ring as in point above and clean system Reset Replace Correct overrun press...

Page 99: ...as been released e Check that the clamp fittings are tightly fitted f Check that the ice cream outlet 3 pipe is fitted correctly g Check that the safety valve 4 is correctly fitted h Check that the mi...

Page 100: ...king The pump will start up at 2 3 max speed d Wait for the mixture to go out of the freezer exiting pipe e By pressing the button again 1 the pump speed is automatically reduced to the minimum and th...

Page 101: ...1 Operation 1 5 Change of product Cont d When the real viscosity of the ice cream approaches the value set the freezer gradually reaches the productivity set e iQ o ID g s o A Tetra Pak 1 61 74...

Page 102: ...that need be done is close one tap and open another without stopping the freezer If it takes more time to change the mix the machine must be stopped 1 5 1 Automatic stop a By pressing the button 1 the...

Page 103: ...ton 3 d Stop the dasher by pressing the button 4 e Disconnect the supply to the freezer 5 from the vat containing the mix for which production is to be stopped and connect it up to the container conta...

Page 104: ...the pump the dasher after the ice cream pressure is decreased below the stop cycle value set by panel The stop of the various components occurs automatically and in a progressive way 1 6 3 Manual Sto...

Page 105: ...the frigus outlet pipe This involves a capacity of 5000 1 h for a 1 1 2 outlet pipe In these conditions the pressure drop is about 2 bar The CIP washing pump must guarantee these flow rate and pressur...

Page 106: ...11 at a concentration of 1 Use a concentration of 1 2 to 1 6 depending on how dirty the machine is and how hard the water supply is c Rinse with cold water d Descaling wash Use buffered phosphoric ac...

Page 107: ...a Turn off the machine in automatic mode see paragraph 6 2 Automatic stop b Disconnect the mix supply from the tank and supply the freezer pump with warm water no hotter than 60 to 65 C Disassembling...

Page 108: ...ply OFF Air valve OFF Special equipment Protective gloves a Remove the cover 1 by unscrewing the knobs holding it in place b Disconnect the pipes and the cover c Remove the dasher 2 using protection p...

Page 109: ...y the same position as before Be very careful when positioning the blades 1 the sharp part must be facing the cylinder A CAUTION To prevent blows that could damage the freezer cylinder a shaft protect...

Page 110: ...sterilising solution Rinse and then drain the solution i Before beginning production it is recommended that rinse water be pumped through the system for 2 to 3 minutes Drain the water by opening the...

Page 111: ...all soapy emulsified dirt d Descaling wash Use an acidic descaler with low viscosity containing a mixture of wetting and emulsifying agents in a concentration of 2 to 3 The minimum recommended contac...

Page 112: ...crose 12 0 Glycose sirup 5 0 Stabilizer emulsifi er 0 5 Total Solids 38 0 Water 62 0 TOTAL 100 0 Upon receipt of the actual mix recipe a more precise capacity and outlet temperature can be determined...

Page 113: ...ensation water Dwell water Mains water 15 C 2000 l h 59 F 529 gals h Tower water 28 C 6000 l h 82 4 F 1585 gals h Water inlet connector 1 gas female 1 gas female Water outlet connector 1 gas female 1...

Page 114: ...1 8 Technical Data 1 Operation This page intentionally left blank s o 1 74 74 A Tetra Pak...

Page 115: ...A Tetra Pak...

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