VRT Safety Maint Training Service Manual Brasil Foods PDF

Refrigeration Technologies
VRT FREEZER SYSTEM

SAFETY, MAINTENANCE & SERVICE
TRAINING MANUAL
Prepared by:
GEA Refrigeration North America, Inc.
Section: GEA Intec
4319 South Alston Avenue, Suite 105
Durham, NC 27713, USA
Phone: +1 919 433-0131
Fax: +1 919 433-0140
VRT Safety & Maintenance

Training Manual
TABLE OF CONTENTS
SECTION 1 ............................................................................................................SAFETY PROCEDURES
SECTION 2 .............................................................................................................. GENERAL OVERVIEW
SECTION 3 ................................................................................................................................. GLOSSARY
SECTION 4 ...............................................................................................VRT MAINTENANCE PROGRAM
SECTION 5 ..................................................................................................................SERVICE PROGRAM
Page 2 of 45

Section: GEA Intec
Phone: +1 919 433-0131
Fax: +1 919 433-0140
VRT Safety, Maintenance &

Service Training Manual
SECTION 1
INTEC VRT SAFETY PROCEDURES
CONTENTS:
VRT SAFETY - GENERAL ............................................................................................. 4
TERMS OF LIABILITY ..................................................................................................... 4
GENERAL PROCEDURES ............................................................................................. 5
ELECTRICAL SUPPLY ................................................................................................... 7
CLEANING ...................................................................................................................... 7
PRODUCTION PREMISES ............................................................................................. 8
SIGNPLATES / MARKINGS ............................................................................................ 9
EVACUATION ................................................................................................................. 9
VRT FREEZERS / CHILLERS - GENERAL INFORMATION ......................................... 10
VRT OPERATION ......................................................................................................... 11
VRT ENCLOSURE - ENTRY PROCEDURE ................................................................ 12
VRT ENTRY - OPERATORS DURING NORMAL PRODUCTION ................................. 12
VRT ENTRY - MAINTENANCE PERSONNEL .............................................................. 14
VRT ENTRY - GENERAL PRECAUTIONS.................................................................... 16
Page 3 of 45

Section: GEA Intec
Phone: +1 919 433-0131
Fax: +1 919 433-0140

VRT SAFETY - GENERAL

TERMS OF LIABILITY
1
This Safety Manual applies to equipment supplied and installed by GEA Intec
2
The owner of the plant is obliged to ensure compliance with this safety manual
Equipment supplied by Intec shall be installed in premises which design

conforms to national regulations
Equipment supplied by Intec complies at the time of delivery with the provisions in
force in accordance with the Order Agreement
Equipment supplied by another supplier that is connected to equipment supplied

by Intec shall comply with the provisions in force in accordance with the Order
Agreement
Do not connect equipment supplied by another supplier to equipment supplied by

Intec without consulting with Intec as to its compatibility
Page 4 of 45

Section: GEA Intec
Phone: +1 919 433-0131
Fax: +1 919 433-0140

GENERAL PROCEDURES
These procedures also require the following to be in place:
buildings, production equipment, refrigeration plant etc. are designed and built in
accordance with the regulations currently in force
compliance with the regulations that govern protective clothing
Safety Notes
1
The owner is responsible for ensuring that staff operating the VRT and associated
production equipment are suitable for such duties and possess the necessary
skills and equipment
Only undamaged tools suitable for the intended purpose shall be used in any
operations
Do not start up the plant until you have read and understood the Operating and
Safety Instructions and are familiar with and understand the location and function
of the various components
Alarm and indicator lamps are to be observed and obeyed
Areas, system sections or components or their equivalents which are locked may
not be modified without special consent
The plant is never to be operated outside the specifications of the supplier or its
operational settings
Plant safety monitors or protective equipment must never be rendered inoperative

or removed by such means as by-passing or bridging, dismantling, or setting to
operational values outside those permitted
Never place fingers, hands or any other part of the body in equipment which is in
operation or can start automatically
Bear in mind the danger of loose clothing or long unprotected hair catching in
moving parts of the machinery
10
Never remove information, warning or prohibition signs from the plant. A missing or
worn sign shall be replaced immediately
11
Do not start up the plant without drawing this to the attention of the other staff
Page 5 of 45

Section: GEA Intec
Phone: +1 919 433-0131
Fax: +1 919 433-0140

12
Work involving heat or a naked flame, e.g. cutting or welding, always requires a
welding permit or other specific permission
13
There must be no direct connection (passage way) between the machine room
and any other area in which an open flame or hot surfaces are present. This
includes burners, boilers and similar equipment
14
Smoking in the machine room is prohibited
15
The plant shall be continually maintained and monitored in a reliable manner such
that its condition conforms to that laid down in the regulations
16
Only staff who have been approved and trained, and have received authorised
orders may work on the refrigerant/ evaporator system.
17
Work on refrigeration plant is to be done in compliance with the rules and

provisions of the Local or National Code or Standards or refrigeration norms or the
equivalent
18
Note that the noise levels inside the VRT enclosure may cause damage to hearing
if the fans are operating. Employees must wear hearing protection
19
Use only walkways and a type-approved ladder in accordance with the instructions
of the supplier when working on and inside the plant
20
Abnormal activity such as noise, vibration, knocking etc. shall be reported AT

ONCE for expert appraisal
21
Do not start up the plant if any component or part of a system is defective or

incorrect.
22
Before doing any work make sure that the machine is locked out in accordance
with the instructions in this manual
Page 6 of 45

Section: GEA Intec
Phone: +1 919 433-0131
Fax: +1 919 433-0140

ELECTRICAL SUPPLY
1
Only staff who have been approved and trained, and have received orders may
work on the electrical system. Work is to be undertaken in accordance with local
provisions and regulations
2
If this work does not require the supervision of an electrical contractor, liability lies
with the person doing the work, or if the latter does not posses the necessary
expertise, with the person who ordered the work
Check in particular electric heating cables in freezer doors to ensure that they are
in good condition. A damaged cable is a potential cause of fire and may constitute
a lethal danger
Electrical work may be performed only by duly authorised and trained personnel
who are assigned to such work
Before any electrical work commences, the power supply of the unit is to be
switched off by the main circuit breaker and secured / locked in the off position
There is still current in the lighting circuit even when the main VRT circuit breaker
is switched off
CLEANING
1
Cleaning may be done only by staff who have been approved and trained, and
have received orders
2
Cleaning is to be done in accordance with the instructions issued
Cleaning is always to be done only when the plant is shut down and disconnected
from the power supply
If protective guards or other protective equipment has to be removed during

cleaning, it must be re-fitted immediately once cleaning has been done
Page 7 of 45

Section: GEA Intec
Phone: +1 919 433-0131
Fax: +1 919 433-0140

PRODUCTION PREMISES
1
Only staff who have been approved and trained, and have received orders may be
present on the production premises
2
The term production premises embraces both the individual VRT / Conveyor
System and the premises on which it is sited
All machine units shall be easily accessible and have clearly marked emergency
stopping devices
Production premises shall be built in accordance with the regulations relating to

hygiene, fire, the environment, etc.
Production premises and unit shall be kept clean of dirt and oil and refrigerant
spillage
Inflammable material other than that required for production may not be kept on
the production premises or in the unit.
Note that during production there are very cold surfaces on the VRT - which can
be as low as -40F
The operating position, evacuation routes and gangways are to be kept accessible
and free
Observe local rules in respect of protective clothing and equipment
10
Unless the local regulations otherwise provide, at least the following must be
present at a suitable site:
fire extinguisher
hearing protectors
visible/audible signal device for alarms in the event of refrigerant leakage or
other emergency
emergency lighting
first aid kit
Page 8 of 45

Section: GEA Intec
Phone: +1 919 433-0131
Fax: +1 919 433-0140

SIGNPLATES / MARKINGS
1
Note: The following may be overruled by local or national regulations:
2
Emergency stopping devices are to be clearly marked.
Piping to be clearly marked in respect of flow direction and nature of contents, e.g.
NH3 gas, HCFC 22 liquid, etc.
All evacuation routes to be clearly marked with illuminated signs in accordance

with local rules
Projecting parts of equipment are to be marked or provided with protective lining
Machines that contain substances that can burn, explode or are a health hazard
shall be clearly marked with sign plates
Fire-fighting equipment to be clearly marked in respect of type and location
EVACUATION
Note: The following may be overruled by local or national regulations.
1
At suitable sites on the production premises there shall be:
a diagram of evacuation routes

a description of how to alert the emergency services
location of manual alarms and emergency release devices
location of main sectioning valves and sectioning doors
assembly site after evacuation
Evacuation routes from production premises are to be clearly marked
In immediate vicinity of a production unit containing media that can cause a fire,
explosion or health hazard, there is to be an evacuation chart stating the following:
health hazards from escaping media

necessary protective equipment and its location
assembly site after evacuation
measures to be taken in the event of fire or an escape of media
how to act in air containing media if the latter is a health hazard
Page 9 of 45

Section: GEA Intec
Phone: +1 919 433-0131
Fax: +1 919 433-0140

VRT FREEZERS / CHILLERS - GENERAL INFORMATION

Safety starts with YOU!
1
Always follow the operating / safety instructions and precautions
Perform no task for which you are not authorised, qualified or trained
The VRT must be kept clean and may not be used for storage of any objects not
directly required for care of equipment
Emergency stop push buttons are located inside the freezer and outside. Pushing
any one of these buttons switches off all functions of the VRT except for the
lighting
VRT doors intended for personnel must not be blocked, but must be easily
accessible at all times
Drain hatches for water in the VRT must not be blocked, but must be easily
accessible at all times
Under no circumstances may the freezer be exposed to fire or open flame
Operating Manual and Safety Manual must be available
Only duly authorised and trained personnel who are responsible for operation may
enter the VRT
10
Appropriate personnel protective clothing is to be worn on entering the VRT
Page 10 of 45

Section: GEA Intec
Phone: +1 919 433-0131
Fax: +1 919 433-0140

VRT OPERATION
The VRT consists of carriers, conveyors, motors, chains and other moving parts which
are capable of causing various types of injury or damage
1
Never put the unit into operation before you have read and understood the
operation and safety instructions. You must also know and understand the location
and function of the various components
The unit's safety devices and equipment must not be removed, disconnected,
bypassed, dismantled or set outside prescribed operating limits
Loose clothing or long, unprotected hair may get caught in the moving parts of the
machinery. Never put fingers, hands, or other parts of the body in equipment that
is in operation or that can start automatically
Know where all the emergency stop buttons are and how they work
Suitable protective clothing, e.g. safety goggles, gloves, shoes, helmets and
hearing protection is to be worn at all times when working with the VRT
Only duly authorised and trained personnel who are responsible for operation may
enter the freezer
Note Low Temperature Environment:
Low temperatures
Frozen metal surfaces
High air velocity
Moist skin sticks immediately to cold metal surfaces and severe injuries may result.
Do not wear wet clothing which may also stick to cold metal surfaces
Extremely low air temperatures may cause frostbite and possible fatal hypothermia
even on short exposure
10
The nose, cheeks, ears and hands should be especially checked for signs of frost
injury (e.g. white spots) or numbness
Page 11 of 45

Section: GEA Intec
Phone: +1 919 433-0131
Fax: +1 919 433-0140

VRT ENCLOSURE - ENTRY PROCEDURE

The procedures outlined below applies to all people specifically trained as VRT
operators and authorized to enter the VRT enclosure during normal production
VRT ENTRY OPERATORS DURING NORMAL PRODUCTION
As could be required to clear a product jam.
by writing your name and entry / exit times in the log

book provided. After exiting the cause of the
stoppage should also be written into the log book
by informing a trained work mate
CARRY A RADIO
at all times with communication established with an

operator on the outside
STOP & DISABLE
push the E-Stop button on the operator console
turn the main key-switch from the AUTO to the OFF

position and withdraw the key (the key can only be
withdrawn in the off position) - take the key with you
open the external enclosure door

(this action also removes all control and motor power
to internal VRT components - same as pushing EStop)
when inside push the internal E-Stop button located

nearest your area of work
RECORD ENTRY / EXIT
Page 12 of 45

Section: GEA Intec
Phone: +1 919 433-0131
Fax: +1 919 433-0140

ENABLE & RESTART
release the internal E-Stop
open the enclosure door and with door open insert the
key (taken earlier from main Auto / Off / Manual switch)
into the internal door reset switch and toggle once.
remove the key and exit closing the door behind you
release the E-Stop on the operator console
push the Reset push-button and acknowledge any

alarms on the SCADA.
insert the key into the main key-switch and turn to the
AUTO POSITION
Note: All control and motor power will remain physically

isolated until:
First: the internal door reset switch has been activated
and then
Second: the key is inserted into the main key-switch
and the switch is turned to AUTO
Then and only then will power be re-applied to
components provided that also:
- all doors are closed
- all E-Stop buttons have been released
- all VRT alarms have been cleared
a start up lamp and audible alarm will sound

immediately prior to the VRT re-starting and
component movement commencing
Page 13 of 45

Section: GEA Intec
Phone: +1 919 433-0131
Fax: +1 919 433-0140

VRT ENTRY MAINTENANCE PERSONNEL

As could be required to change out an electric motor
RECORD
EXIT
ENTRY
by writing your name and entry / exit times in the log

book provided. After exiting the cause of the stoppage
should also be written into the log book
by informing a trained work mate
CARRY A RADIO
at all times with communication established with an

operator on the outside
STOP & DISABLE
push the E-Stop button on the operator console
turn the main key-switch from the AUTO to the OFF

position and withdraw the key (the key can only be
withdrawn in the off position) - take the key with you
when inside push the internal E-Stop button located

nearest your area of work
the main MCP breaker and lock out
the local motor isolator(s) and lock out
DISCONNECT
all lock outs should only be done with tagged padlocks

unique to each maintenance worker or electrician
RE CONNECT
Once work has been completed:
local motor isolators and switch MCP main breaker

back on and then proceed back into the VRT
Page 14 of 45

Section: GEA Intec
Phone: +1 919 433-0131
Fax: +1 919 433-0140

ENABLE &
RESTART
release the internal E-Stop
open the enclosure door and with door open insert the
key (taken earlier from main Auto / Off / Manual switch)
into the internal door reset switch and toggle once.
remove the key and exit closing the door behind you.
release the E-Stop on the operator console
push the Reset push-button and acknowledge any

alarms on the SCADA.
insert the key into the main key-switch and turn to the
AUTO POSITION
Note: All control and motor power will remain physically

isolated until:
First: the internal door reset switch has been activated
and then
Second: the key is inserted into the main key-switch
and the switch is turned to AUTO
Then and only then will power be re-applied to
components provided that also:
- all doors are closed
- all E-Stop buttons have been released
- all VRT alarms have been cleared
a start up lamp and audible alarm will sound

immediately prior to the VRT re-starting and
component movement commencing
Page 15 of 45

Section: GEA Intec
Phone: +1 919 433-0131
Fax: +1 919 433-0140

VRT ENTRY NEVER
AVOID
GENERAL PRECAUTIONS
ride on the VRT cradles or stand on any VRT

components while in operation
use the rack structure as a ladder - always use

approved ladders and safety harnesses
AFTER THE VRT HAS BEEN STOPPED AND LOCKED

OUT:
standing under the carriers or cradle
lying half way out of the rack structure at the load or

transfer ends
standing inside the sweeparm cross bracing
walking on conveyor surfaces
walking unsupported on any structural members
CLOTHING
suitable for the cold must be worn inside the VRT including suit, gloves, headgear and boots
TIME
spent inside the VRT should be kept to a minimum take regular breaks outside if prolonged work is
required inside
This section introduces the two main controls in the VRT Control Room that are used to
operate the VRT:
the Operator Console, and

the Operator Interface.
Page 16 of 45

Section: GEA Intec
Phone: +1 919 433-0131
Fax: +1 919 433-0140

1 .1
Operator Console
The Operator Console is mounted on the desk in the Control Room, next to the
computer. It has the following controls:
VRT ON-OFF key-switch sets the operating mode of the VRT.

EMERGENCY STOP button stops all the motors inside the VRT.
VFD MODE key-switch is used to set up the SEW Variable Frequency
Drives (referred to as VFDs).
RESET button clears the alarms and messages on the Operator Interface,
and restarts the system after an Emergency Stop.
MANUAL EXT-RET switch is used to operate VRT components in Manual.
Page 17 of 45

Section: GEA Intec
Phone: +1 919 433-0131
Fax: +1 919 433-0140

SECTION 2
GENERAL OVERVIEW
Variable Retention Time Chilling and Freezing
The Intec VRT is a tray blast freezer and

chiller.
The VRT has multiple load levels. Product is

stored on shelves in the levels.
Each level can be assigned a unique retention

time whereby product in that level is
discharged once the retention time has
elapsed, allowing a range of product to be
frozen or chilled at different rates.
Incoming product is sorted into conveyor lines

according to predetermined retention times,
product type or packaging size. From the
infeed conveyors, it is transferred into a load
level. For example if product was sorted
according to its retention time, then product
with a four hour retention time can be loaded
into one level, product with a five hour
retention time into another level and so on.
Page 18 of 45

Section: GEA Intec
Phone: +1 919 433-0131
Fax: +1 919 433-0140

The VRT Cycle

Shelves
Page 19 of 45
The VRT consists of a number of storage, or

load levels. The number of levels is fixed
and is determined by the capacity
requirements of the machine.
Each level contains a set number of shelves
depending on the size of the machine.
Product is accumulated outside the VRT in
shelf lots. A shelf lot is the number of cases
of a particular size that can fit onto a shelf.
Once product enters the VRT, it is arranged
automatically into a pattern to optimize air
flow and shelf area.
Once the product is loaded onto the shelf,
the VRT then transfers the shelf into a load
level where the product and the shelf remain
until the product has meet its predetermined
retention time.

Section: GEA Intec
Phone: +1 919 433-0131
Fax: +1 919 433-0140

The VRT Cycle

Infeed Accumulation Conveyors
Cased product from the production lines is fed automatically into the
VRT via the arrangement of low pressure roller and belt conveyors.
Once product reaches the VRT end of the conveyors, product is

metered into the VRT using the NxA, NxB & NxC brake spacer
conveyors.
As product travel across the NxC brake belt onto the NxB curve, a
speed differential between the conveyors creates a gap between the
cases. This gap is maintained across the NxB to NxA belt.
From time to time, it will be necessary to accumulate product outside

the VRT on the accumulation conveyors.
Accumulation starts on the NxD conveyor. Once cases have

accumulated the full length of the NxD conveyor, a photoeye senses
the section of conveyor is full and shuts off the motor. Product then
begins accumulating on the NxE conveyor and the sequence repeats
itself along the length of the system.
Once the VRT starts loading, product is released off the NxD onto
the brake spacer conveyors. There is a short interval between NxD
starting and NxE starting to ensure down stream cases have time to
clear the system. The start-up sequence repeats itself along the length
Page 20 of 45

Section: GEA Intec
Phone: +1 919 433-0131
Fax: +1 919 433-0140

The VRT Cycle

H Conveyor & F Sweeparm
Page 21 of 45
As product is spaced off the NxA belt, a

predetermined gap is set between cases as
they are loaded onto the H conveyor. This
gap ensure airflow between the cases.
Once 14 cases have loaded onto the H
conveyor, the F sweeparm indexes the cases
off the H conveyor onto the surge table.
The F Arm retracts and another row of 14
cases is loaded onto the H conveyor.
The F Arm extends again sweeping the
second row onto the surge table before
retracting.
A third row is then loaded onto the H
conveyor, at which time the F Arm will
extend and sweep all three rows (42 cases)
onto an empty shelf on the C Cradle.

Section: GEA Intec
Phone: +1 919 433-0131
Fax: +1 919 433-0140

The VRT Cycle

Elevator System
Page 22 of 45
The Elevator system comprises of two

cradles, the C Cradle at the load end and the
D Cradle at the transfer end.
The two cradles are mechanically linked by
the line shafts that run down either side of
the machine. The line shafts are driven by
the E Motors.
These motors are
electronically linked to provide synchronous
operation.
The C Cradle will always be at the same
elevation as the D Cradle and vice versus.
The Cradles are suspended from a top
sprocket assembly and have counterweights
attached to the top chains to offset their
load.
The elevators are raised and lowered by the
bottom chains which wrap around the
underside of the lineshafts.

Section: GEA Intec
Phone: +1 919 433-0131
Fax: +1 919 433-0140

The VRT Cycle

Cradles and Pushers
The Cradles support the shelf as it is

elevated between the conveyors and the load
levels.
On each side of the cradle is a pusher

assembly. The pusher assemblies connect to
the pusher beam which pushes the shelf into
the rack structure.
When a shelf is pushed into a level at one

end of the rack-structure, the last shelf is
pushed out of the same level at the opposite
end of the rack-structure.
The opposite cradle latches the shelf, and

then retracts lightly pulling the shelf clear of
the other shelves and the rack structure.
Both the C and the D Cradle work in exactly

the same manner allowing shelves to be
pushed into any level from either end.
Page 23 of 45

Section: GEA Intec
Phone: +1 919 433-0131
Fax: +1 919 433-0140

The VRT Cycle

G Arm, I Conveyor & Gap Table
After the VRT unloads a shelf of timed-out

product from the load level, the D-Cradle takes it
to the I1-Conveyor level.
The G Sweeparm transfers the product off the
shelf onto the outfeed conveyor and outfeed gap
table.
In order to separate the product, one row of
product remains on the outfeed conveyor while
two rows are placed on the gap table. The gap
table then moves back clear of the I conveyor.
The I conveyor runs discharging the cases from
the VRT onto the O1A discharge conveyor.
Once the first row is clear of the I conveyor, the
Gap table moves forward and one of the two rows
is pushed onto the I conveyor by the G1B
sweeparm. The I conveyor runs discharging
product from the VRT. Once clear, the last row is
transferred off the gap table onto the I conveyor
and is in turn discharged from the VRT.
Page 24 of 45

Section: GEA Intec
Phone: +1 919 433-0131
Fax: +1 919 433-0140

The VRT Cycle

Discharge Conveyors
Product is discharged off the I1 conveyor

onto the O1 discharge conveyors. The
conveyors stream product out to the VRT,
down a decline belt and out into the stack
off / manual palletizing area where the
product is manually stacked onto pallets.
Page 25 of 45

Section: GEA Intec
Phone: +1 919 433-0131
Fax: +1 919 433-0140

The VRT System

SCADA PC
Page 26 of 45
SCADA - Supervisor Control and Data

Acquisition.
The Scada PC is the Human Machine
Interface. It allows operators to input data
into the system as well as view component
status via the many mimic screens.
In conjunction with the Operator Station it
allows an operator to select and manually
control any of the machine components
discussed previously.

Section: GEA Intec
Phone: +1 919 433-0131
Fax: +1 919 433-0140

The VRT System

Operator Station
Page 27 of 45
The operator control station comprises of

the following switches and push buttons.
Emergency Stop Button - pressing this will
immediately stop the machine.
Master Key. This key allows the machine
to be switched between Manual, Automatic
and Off modes.
Reset Button - Used to reset the machine
after the emergency button has been
pressed and to reset the machine after a
fault.
Extend/Retract Selector Switch - Allows
components selected on the SCADA to
extend/retract, raise or lower under manual
control.
Set Up Key Switch - allows components to
be referenced to a known position in case
of certain faults.
Fan On/Off Switch. Allows the operators
to turn the fans on and off.

Section: GEA Intec
Phone: +1 919 433-0131
Fax: +1 919 433-0140

The VRT System

Motor Control Panel
Page 28 of 45
The Motor Control Panel (MCP) houses the

Programmable Logic Controller which
controls the machine operation.
The MCP also houses the Variable
Frequency Drives which control the position
and speed characteristics of the motors.
The MCP distributes incoming power to the
various drives and motor starters and
ancillary components.
The MCP must only be opened by trained
electrical technicians.

Section: GEA Intec
Phone: +1 919 433-0131
Fax: +1 919 433-0140

SECTION 3
GLOSSARY
Accumulating Conveyors.
Designated N1,N2,and N3,N4. N1, N2 are the bottom lines feeding H1 level,
N3,N4 are the upper lines feeding H2 level.
Each category of product is identified as it comes off the production line and
accumulated on its own low line pressure live roller conveyor into shelf-sized lots
ready for loading onto the VRT Infeed Conveyor.
Under normal operation, as the product arrives it will be loaded directly onto the
VRT Infeed Conveyor and the Accumulation Conveyor will only accumulate
product once the Infeed Conveyor is full and is waiting to load product onto an
empty shelf on the C Cradle.
Product is conveyed and accumulated prior to the brake spacer wide side leading.
Brake Spacer and K Transfer Conveyors.

Designated N1B, N1A, K1B, K1A & N2B, N2A, K2B & K2A.
A brake/spacer conveyor meters product off the end of the accumulation conveyor,
counting cases off the spacer belt onto K1B.
Once the required number of cases are counted onto the K1B conveyor, the cases
are transferred onto K1A.
Once cases have transferred onto K1A, a new batch of product will be counted
onto K1B.
H1 and H2 Pushers.
Designated H1P & H2P.
Page 29 of 45

Section: GEA Intec
Phone: +1 919 433-0131
Fax: +1 919 433-0140

Once a slug of product has transferred onto K1A or K2A, the H1 Pusher will
extend and push the row of product off the K1A conveyor onto the H1 Conveyor.
H1 and H2 Infeed Conveyors.
Designated H1 and H2.
The H Conveyors are designed to accommodate product in shelf lots.
Product is pushed off the K1A transfer conveyor onto the H1 infeed belt in rows.
The H1 conveyor then indexes the width of the row plus an additional amount to
allow air to flow between the rows of product.
The H Conveyor is comprised of a galvanized steel frame. Product is conveyed on
the frame on Intralox plastic conveyor belt. The conveyor is driven by a shaft
mounted SEW AC Servo motor.
The motor speed and position is controlled by an SEW Movidrive IPOS controller
in the motor control panel.
Infeed Sweeparms
Designated F1 and F2. F1 sweeps product off H1, F2 sweeps product off H2.
The Infeed Sweeparm sweeps a row of product off the H Conveyor onto an empty
shelf on the C Cradle.
The Infeed Sweeparms consist of a mechanical pusher, driven by a motor gearbox
unit direct coupled to a cross shaft. Using a chain drive, the sweeparm traverses
forward and reverse. The cross shaft is driven by an SEW AC Servo motor direct
coupled to the cross shaft.
Page 30 of 45

Section: GEA Intec
Phone: +1 919 433-0131
Fax: +1 919 433-0140

Cradles
The C Cradle is the cradle at the load end.
The D Cradle is the cradle at the unload end.
The Cradles are the vertically moving platforms that raise or lower the shelves,
either to be loaded, unloaded, or inserted into a level. The Cradles consist of a
main frame supported at each end by End Beams. The End Beams are connected
to the Elevator Chains, which drive the cradle up, or down.
Pushers.
A Pushers are mounted on the C Cradle.
B Pushers are mounted on the D Cradle.
The Pushers are the drive mechanisms located on the cradles that push the shelves
into the rack structure. They consist of two separate electric motors mounted on
the End Beams on each of the cradles. They drive the Pusher Beam forward via a
chain drive assembly.
During normal operation the A Pushers on the C Cradle will extend, pushing a
shelf into the Rack Structure. As a shelf is pushed into the Rack Structure, a shelf
at the opposite end is pushed out of the rack structure onto the opposing D Cradle.
Once the pushers on the C Cradle have fully extended, the B Pushers on the
opposing D Cradle with move forward seeking the shelf. Photoeyes mounted in
the Pusher Beam will sense the shelf as the latches ride up over the pusher plates
mounted on the corners of the shelf. Once the shelf is latched, the Pushers on both
cradles retract.
Once the D Cradle B Pushers have latched the shelf they will retract to the
retracted position, pulling the latched shelf clear of the other shelves and the rack
structure. The C Cradle A Pushers retract to the latch position.
Page 31 of 45

Section: GEA Intec
Phone: +1 919 433-0131
Fax: +1 919 433-0140

Latches
The latches are attached to the Pusher Beams. The latches are a profiled steel
hook used to latch the shelf so that it can be pulled away from the other shelves
and the Rack Structure. When a shelf is pushed through the structure, the
receiving pushers move forward to seek the shelf. The front edge of the latch rides
up over the shelf pusher plates, dropping into position shortly before the shelf seek
movement finishes.
When the Pushers extend, the latch plunger rides up on a guide lifting the latch
clear of the pusher plates so that the shelf is not dragged back out of the rack
structure.
ELEVATORS
Designated Elevator Master and Elevator Slave.
The two motors drive the lineshafts, which raise and lower the cradles.
The two motors are electronically synchronized with one unit running in the
opposite direction to the other unit.
The lineshafts are connected to the cradles via the upper and lower elevator
chains. The upper chains support the cradles and counterweights from the top
shafts. The lower chains drive the cradles up and down.
The line shafts run the full length of the VRT rack structure and connect the C and
D Cradles together ensuring the cradles move in unison.
Page 32 of 45

Section: GEA Intec
Phone: +1 919 433-0131
Fax: +1 919 433-0140

Outfeed Sweeparm
Designated G1.
The Outfeed Sweeparm is the mechanism which sweeps a shelf load of frozen or
chilled product off the full shelf on D Cradle onto the Outfeed Conveyor and
Outfeed Gap Table.
The Outfeed Sweeparm consists of a mechanical pusher, driven by a motor
gearbox unit direct coupled to a cross shaft. Using a chain drive, the sweeparm
traverses forward and reverse. The cross shaft is driven by an SEW AC Servo
motor direct coupled to the cross shaft.
Outfeed Conveyors
Designated I1, O1A & I2 & O2A Conveyor.
Once the G Arm sweeps product onto the I1 Conveyor, the I1A discharges the
complete shelf slot onto the O1A conveyor.
The speed differential between the I1A and O1A conveyor increases the gap
between the rows of product which allows the shelf lot to be singulated into a
single row to be sent to palletizing.
The I Conveyor is comprised of a galvanized steel frame. Product is conveyed on
the frame on Intralox plastic conveyor belt. The conveyor is driven by a shaft
mounted SEW AC Servo motor.
Page 33 of 45

Section: GEA Intec
Phone: +1 919 433-0131
Fax: +1 919 433-0140

Load End
The Load End is the end of the VRT Freezer closest to the control room. It
contains all of the components required to load product into and out of the VRT
Freezer.
Unload End
The Unload End is the end of the VRT Freezer closest to the evaporator coils. The
Unload cradle or D Cradle unloads frozen product from the VRT Freezer and also
transfers shelves out of the load levels into the return level.
Rack Structure
The Rack Structure consists of the main structural columns and beams plus the
rack beams, the parallel flange channels that support the shelves within the rack
structure. It is a multi-level structure into which shelves are injected for horizontal
movement within the VRT. Push a shelf into a level at one end, and another shelf
will be pushed out at the opposite end.
The sides and top of the rack structure is covered in corrugated metal cladding to
ensure that the air flow can only pass over the product. The cladding between the
evaporator coils and the rack structure is known as the plenum.
Shelves
The shelves, or moveable platforms, are used to move product through the VRT.
The shelves consist of galvanized steel frames with a corrugated steel profile top
surface. The shelves slide along the rack beam on UHMW wear strips.
Catenary
The Catenary, which consists of the plastic drag chain and electrical cables, is
attached to the end beams on the cradles at one end and mounted mid height on the
Page 34 of 45

Section: GEA Intec
Phone: +1 919 433-0131
Fax: +1 919 433-0140

adjacent columns at the other. The plastic drag chain protects the electrical cables
from accidental damage. The electrical cables on one side of the tunnel provide
power for the electric motors. The other side provides all power and return signal
wires for the control devices used on the cradles.
Levels
A number, starting from 1 and working up the tunnel to level 32 designates each
level of shelves.
Rows are the number of shelves deep per level, i.e., each level has 15 shelves per
level, or 15 rows.
Certain levels are also known by the level at which an Infeed Conveyor or Outfeed
Conveyor are located at, such as the Infeed level or Outfeed level.
The Infeed and Outfeed Conveyors are pitched at multiples of the level spacing,
and the top of the conveyor rollers are level with the top of the decking when a
shelf sits in the corresponding level.
Return Level
A level is assigned within the control sequence of the program, to be used to
return empty shelves from the unload end to the load end of the tunnel. It is
designated the Return Level and cannot be assigned to receive incoming product.
All empty shelves normally return through the Return Level before they can be
loaded with new product.
Page 35 of 45

Section: GEA Intec
Phone: +1 919 433-0131
Fax: +1 919 433-0140

SECTION 4
VRT Preventative Maintenance Program

Daily (Nominal 8-16 machine hours)
VRT General
Walk around VRT and inspect floor for:
Signs of wear, i.e, metal or pastic shavings;
Oil leaks;
Broken electrical cables;
Spilt product;
Obvious damage or signs of misalignment;
C & D Cradles
Remove old grease from runners and apply new grease.
Oil pusher chains - if required;
Check operation of latch pin and latch plunger - if required;
Check Cradles are level and shelf on cradle is level with shelf in structure;
Reference
A Pushers;
B Pushers;
Elevators.
Every Week (Nominal 100 machine hours)

VRT General
Check that all sensors are secure, in good condition and correctly aligned;
Check that all sensor QD leads are secure and in good condition;
Page 36 of 45

Section: GEA Intec
Phone: +1 919 433-0131
Fax: +1 919 433-0140

C & D Cradles
Remove old grease from runners and apply new grease - if required;
Oil pusher chains - if required;
Lubricate latch pin and latch plunger - if required;
Inspect latch plunger for wear and ensure latch plunger moves freely;
Lubricate latch plunger and latch plunger ramp - if required;
Check transfer plate is secure, straight and clean;
Ensure sensors are clean, secure and aligned correctly;
Elevator
Check gearbox seals for signs of leakage;
Ensure cradles and counterweights are level;
Inspect elevator chains for signs of uneven or excessive wear;
F & G Arms
Remove old grease from runners and apply new grease;
Check bearing and sprocket set screws are tight;
H & I Conveyors
Check bearing set screws are tight;
H & I Transfer Pushers

Check tension of pusher chains, and adjust if necessary;Check pusher
chains for sufficient lubrication, and grease/oil if necessary
N & K Conveyors
Check bearing set screws are tight;
Page 37 of 45

Section: GEA Intec
Phone: +1 919 433-0131
Fax: +1 919 433-0140

Every Month (Nominal 500 machine hours)

Electrical Components
Clean Fan Air filters On VRT and Conveyor MCPs and ensure adequate
ventilation;
C & D Cradles
Inspect tension of pusher chains and adjust as required;
Inspect reaction block pads and pusher wear pads for signs of wear;
Elevator
Chains - inspect for lubrication and oil if required;
Ensure cradle and counterweights are level;
Check lineshaft bearings set screws are tight;
F & G Arms
Inspect drive chains and oil if required;
H & I Conveyors
Check tension / condition of Intralox belts;
Check tension of pusher chains, and adjust if necessary;
Check pusher chains for sufficient lubrication, and grease/oil if necessary
N & K Conveyors
Check tension / condition & tracking of Intralox belts and sprockets;
Every 2 Months (Nominal 1000 machine hours)

VRT General
Check reference position of all components;
Physically check that all motors are rigidly mounted.
Page 38 of 45

Section: GEA Intec
Phone: +1 919 433-0131
Fax: +1 919 433-0140

C & D Cradles
Check gearbox oil levels and top up if necessary;
Check sprockets for wear and position & ensure clamping units are secure;
Grease idle sprocket shafts;
Elevator
Inspect upper bearings for signs of movement, wear or cracking;
Check sprockets for wear and position
Inspect tension of safety wire and adjust as necessary;
Inspect chains for adjustment and adjust as necessary;
F & G Arms
Inspect tension of drive chains and adjust if required;
Grease bearing units as possible (not sealed);
Inspect wheels / runners for signs of wear;
H & I Conveyors
Grease bearing units as possible;
Grease bearing units;
N & K Conveyors
Grease bearing units
Check gearbox oil levels and top up if necessary:

C & D Cradles
Check reaction block plastic bearing surfaces for wear - replace if necessary
Grease runners if necessary
Page 39 of 45

Section: GEA Intec
Phone: +1 919 433-0131
Fax: +1 919 433-0140

F & G Arms
Check bearing surfaces for wear
Replace if necessary
Check UHMW plastic bearing surfaces and rollers for wear
Replace if necessary
Grease runners if necessary
SEW Gearboxes
Check oil quantity and top up to oil level plug if necessary
Roller Bearings
Apply 3 x shots of grease from a grease gun

Test Movidrive Battery backup (Refer to operating instructions).
Test UPS Battery backup (Refer to operating instructions).
Check Electrical Connections MCPs
Clean Electrical MCPs.
VRT General
Physically check that all motors are rigidly mounted;
Check that all sensor QD leads are secure and in good condition.
C & D Cradles
Change Gearbox Oil.
Take oil samples for analysis if appearance dictates.
Page 40 of 45

Section: GEA Intec
Phone: +1 919 433-0131
Fax: +1 919 433-0140

Elevator
Check motor brake gaps and adjust if required (SEW Technician).
Every 24 Months (Nominal 12,000 machine hours)

Test Movidrive Battery backup.(Refer to operating instructions section 9.1.1)
Test UPS Battery backup(Refer to operating instructions section 9.1.2).
Clean Electrical MCPs
VRT General
C & D Cradles
Inspect Electric Motors (SEW Technician).
Elevator
F & G Arms
H & I Conveyors
N & K Conveyors
Page 41 of 45

Section: GEA Intec
Phone: +1 919 433-0131
Fax: +1 919 433-0140

Every 5 Years (Nominal 30,000 machine hours)

VRT General
C & D Cradles
Replace Bronze Bushes on Rear Shafts and Latches
Replace Nylon Reaction Block Pads, UHMW Pusher Wear Pads.
Elevator
Change Gearbox Oil.
F & G Arms
Change Gearbox Oil.
H & I Conveyors
Change Gearbox Oil.
Change Gearbox Oil.
N & K Conveyors
Change Gearbox Oil.
Page 42 of 45

Section: GEA Intec
Phone: +1 919 433-0131
Fax: +1 919 433-0140

Every 10 Years (Nominal 60,000 machine hours)

VRT General
Elevator
Replace Elevator Chains;
Replace Elevator Bearings.
ANNUAL MAINTENANCE BUDGET ESTIMATES:
GEA INTEC recommends an annual budget for Maintenance & Spare Parts for year 1
through year 8 of the VRT System at $5,000.00 per year. This is mainly for low
temperature lubrication and other miscellaneous parts. Year 9 should include a full
mechanical audit of the system and a budget for year 10 somewhere between $50,000
to $80,000. This allowance would include for new elevator chains, sprockets, shafts
and other miscellaneous components that may need to be replaced or upgraded
depending on the production wear and tear of any system ( how hard it works/cycle
time ) and is also tied directly to the PM and Maintenance disciplines of each Company.
The uptime and reliability of each individual VRT System is greatly enhanced by a
proper In-house PM Program and even further enhanced by participating in the GEA
INTEC Service Program. This Program is customized per installation / customer and
driven by the expertise and disciplines of their Maintenance Staffs and Management. It
is minimally one complete audit and re-training exercise per year, but can be as often
as three visits per year.
Page 43 of 45

Section: GEA Intec
Phone: +1 919 433-0131
Fax: +1 919 433-0140

SECTION 5
SERVICE PROGRAM
YEAR 1 PROGRAM:
Four ( 4 ) Service visits are included for a period of 12 months following the
Take-Over Test.
Each Service visit is based on a seven ( 7 ) day window, including travel days.
Service Visits need to be scheduled and confirmed fourteen ( 14 ) in advance.
Costs for the Service Labor is included, but all other associated Travel and
Living expenses are not:
a. Airfares
b. Ground transportation
c. Hotel
d. Fuel
e. Per Diem - $80.00 USD per Day
POST YEAR 1 PROGRAMS:
GEA INTEC SCHEDULE OF SERVICE CHARGES 2012
DAILY RATES: ONSITE SUPPORT

1. Daily Rate, Monday - Friday
2. Daily Rate, Weekends
3. Daily Rate, Holidays
International $1800 USD / day

International $2,100 USD / day
International $2,500 USD / day
TRAVEL AND LIVING EXPENSES

Expenses (Airfare, auto, hotel, fuel, etc.)
Per Diem:
Page 44 of 45
Cost +10%
International $80.00 USD / Day
Section: GEA Intec
Phone: +1 919 433-0131
Fax: +1 919 433-0140

MINIMUM CHARGE OUT TIME

A minimum charge out time of 3 hours shall apply for any phone, online or
dial-up technical support unless a Service Support Contract is in place, then
charges will be real time.
DESCRIPTION OF CHARGES
1. Remote Support is described as any communication between the client
and a service technician while the service tech is not at the clients facility.
As long as the service tech can identify and correct any issues via phone,
VPN or dial-up, remote support rates will apply.
2. Onsite Support is described as any visit to a clients facility by a service
technician. Daily charges start the day of departure and end on the day of
return. A day is considered not more than 10 hours from 12:00am to
11:59pm per calendar day. If more than 10 hours is required an
additional day will be charged. No technician will be allowed to be at a
clients facility more than 16 hours per calendar day.
Please contact Jim Chamblee (Regional Service Manager, East Coast) with any
questions or to enquire about a Service Support Contract.
Mobile: (919) 943-0355

EMAIL: Jim.Chamblee@geagroup.com
Office: (919) 433-0131
FAX: (919) 433-0140
Please also review the attached COMPREHENSIVE SERVICE PLAN program.
Page 45 of 45

Section: GEA Intec
Phone: +1 919 433-0131
Fax: +1 919 433-0140

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Refrigeration Technologies

VRT FREEZER SYSTEM

VRT Safety & Maintenance

GEA Refrigeration North America, Inc.

VRT Safety, Maintenance &

GEA Refrigeration North America, Inc.

VRT Safety, Maintenance &

VRT SAFETY - GENERAL

Equipment supplied by Intec shall be installed in premises which design

Equipment supplied by another supplier that is connected to equipment supplied

Do not connect equipment supplied by another supplier to equipment supplied by

GEA Refrigeration North America, Inc.

VRT Safety, Maintenance &

These procedures also require the following to be in place:

compliance with the regulations that govern protective clothing

Alarm and indicator lamps are to be observed and obeyed

Plant safety monitors or protective equipment must never be rendered inoperative

GEA Refrigeration North America, Inc.

VRT Safety, Maintenance &

Smoking in the machine room is prohibited

Work on refrigeration plant is to be done in compliance with the rules and

Abnormal activity such as noise, vibration, knocking etc. shall be reported AT

Do not start up the plant if any component or part of a system is defective or

GEA Refrigeration North America, Inc.

VRT Safety, Maintenance &

Cleaning is to be done in accordance with the instructions issued

If protective guards or other protective equipment has to be removed during

GEA Refrigeration North America, Inc.

VRT Safety, Maintenance &

Production premises shall be built in accordance with the regulations relating to

Observe local rules in respect of protective clothing and equipment

GEA Refrigeration North America, Inc.

VRT Safety, Maintenance &

Emergency stopping devices are to be clearly marked.

All evacuation routes to be clearly marked with illuminated signs in accordance

Projecting parts of equipment are to be marked or provided with protective lining

Fire-fighting equipment to be clearly marked in respect of type and location

At suitable sites on the production premises there shall be:

a diagram of evacuation routes

Evacuation routes from production premises are to be clearly marked

health hazards from escaping media

GEA Refrigeration North America, Inc.

VRT Safety, Maintenance &

VRT FREEZERS / CHILLERS - GENERAL INFORMATION

Always follow the operating / safety instructions and precautions

Under no circumstances may the freezer be exposed to fire or open flame

Operating Manual and Safety Manual must be available

Appropriate personnel protective clothing is to be worn on entering the VRT

GEA Refrigeration North America, Inc.

VRT Safety, Maintenance &

Note Low Temperature Environment:

Frozen metal surfaces

High air velocity

GEA Refrigeration North America, Inc.

VRT Safety, Maintenance &

VRT ENCLOSURE - ENTRY PROCEDURE

by writing your name and entry / exit times in the log

by informing a trained work mate

at all times with communication established with an

STOP & DISABLE

push the E-Stop button on the operator console

turn the main key-switch from the AUTO to the OFF