Om 3285384 0112

OM
Operation Manual
Tetra Pak® Indirect UHT unit D
WARNING
Read and follow all safety precaution instructions throughout this
document and on safety signs attached to this equipment.
Failure to follow all safety precaution instructions could result in death or
serious injury.
Doc. No. OM-3285384-0112

Copyright © 2019 Tetra Pak International S.A.
All rights reserved. No part of this document may be reproduced or copied in any form or by
any means without written permission from Tetra Pak Processing Equipment AB.
, Tetra Pak, and all other trademarks displayed in this document are the property of the
Tetra Pak International SA. Tetra Pak Processing Equipment AB together with Tetra Pak
International SA form part of ‘the Tetra Pak Group’. The content of this document is in
accordance with the design and construction of the machine or equipment at the time of
publishing. The Tetra Pak Group reserves the right to introduce design modifications without
prior notice.
The English language version of this document contains the original instructions. All other
language versions are translations of the original instructions.
This document was produced and printed by:
Tetra Pak Processing Equipment AB
Ruben Rausings gata
S-221 86 LUND
Sweden
Doc. No. OM-3285384-0112

Issue 2019-01
This document is valid for: Introduction
T5845490097 Safety Precautions
1 General Description
Serial No. / Machine No.
Year of Manufacture Sign. 2 Process Description
3 Control Panel
4 Alarms
OM
Operation Manual
5
6
7
Preparations
Operation
Care and Cleaning
Tetra Pak® Indirect UHT

unit D
Machine or equipment configurations that

this document is valid for are described on
the next page.
Doc. No. OM-3285384-0112

Issue 2019-01

Valid for:
Name Drawing Specification and Additional Information
Development Step
Introduction
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Doc. No. OM-3285384-0112 5 (180)
Introduction
About the Introduction Chapter

This chapter contains basic information about this manual and the related Tetra Pak
equipment.
6 (180) Doc. No. OM-3285384-0112

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Introduction Table of Contents
About the Introduction Chapter . . . . . . . . . . . . . . . . . . . . . 6
Manual Information ............................................... 9

Delivered Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Page Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Page Numbering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Typographical Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Machine Introduction .......................................... 12

Intended Use of the Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Manufacturer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
EU Declaration of Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Declaration of Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Identification ..................................................... 13
CE Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3-A Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
EAC Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
China RoHS2 Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Machine Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Hygiene ............................................................ 15
Food product. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Steam Barrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Environment...................................................... 16
Waste Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Fluids and Chemical Products . . . . . . . . . . . . . . . . . . . . . . . . . 16
Hydrogen Peroxide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Cooling Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Separation of Materials and Components. . . . . . . . . . . . . . . 16
Electrical Components. . . . . . . . . . . . . . . . . . . . . . . . . . 17
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Doc. No. OM-3285384-0112 7 (180)
Table of Contents Introduction
How to Use This OM ............................................ 18

Purpose of the OM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Operator Workflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Assistance and Inquiries...................................... 19
8 (180) Doc. No. OM-3285384-0112

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Introduction Manual Information
Manual Information
Tetra Pak recommends reading all delivered manuals carefully. Make sure that the
delivered manuals are available to personnel who operate or maintain the
equipment.
It is important to keep this manual for the lifetime of the equipment and to pass the
manual on to any subsequent holder or user.
Tetra Pak will not be held responsible for any damage to the equipment caused by
not following the instructions given in this manual.
.
Delivered Manuals
Manuals delivered with this equipment:
• Operation Manual
• Technical Manual
• Electrical Manual (if applicable)
.
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Doc. No. OM-3285384-0112 9 (180)
Manual Information Introduction
Page Layout
Every main page in this manual contains a header and a footer. The page header
contains the chapter name (1) and the section name (2). The page footer contains
the page number (3), and the document number (4). See also the page numbering
section.
1 2
9 General 9.2 Technical Data
Doc. No. MM-2730517-0103 41 (60)
4 3
1 Chapter name
2 Section name
3 Page number
4 Document number
.
10 (180) Doc. No. OM-3285384-0112

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Introduction Manual Information
Page Numbering
A page number has two parts:
• Consecutive page number (1)
• Total number of pages in user manual (2)
31 (356)
1 2
1 Consecutive page
number
2 Total number of pages
.
Typographical Conventions
Controls on the operator panel, emergency stop devices, and program steps are
printed in CAPITAL LETTERS.
Menu names, button names and other text displayed in software are printed in
Courier.
Cross-references are underlined.
Symbols
Symbols used in illustrations
A pointer arrow indicates the position of an object.
A zoom arrow indicates that an object view is

enlarged. The arrow points towards the enlarged
view of the object.
A rotation movement arrow indicates rotational

movement of an object. The arrow points in the
direction of rotation.
A straight movement arrow indicates movement
of an object. The arrow points in the direction of
movement.
.
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Doc. No. OM-3285384-0112 11 (180)
Machine Introduction Introduction
Machine Introduction
Intended Use of the Equipment
This equipment is intended for use according to the specifications in Technical data
(see Technical Manual) and related documents.
All other use is prohibited. Tetra Pak will not be held responsible for injury or
damage if the equipment is used for any other purpose.
Manufacturer
This Tetra Pak equipment has been manufactured by
Ruben Rausings gata
S-221 86 LUND
Sweden
EU Declaration of Conformity
For deliveries within EU, or if requested, a signed EU Declaration of Conformity is
delivered with the Technical Manual.
Declaration of Compliance
For deliveries within EU, or if requested, a signed Declaration of Compliance is
delivered with the Technical Manual.
12 (180) Doc. No. OM-3285384-0112

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Introduction Identification
Identification
CE Compliance
This equipment complies with the basic health and safety regulations of the EEA.
3-A Compliance
(If applicable)
This equipment complies with the 3-A Sanitary Standards for Formers, Fillers, and
Sealers of Containers for Fluid Milk and Fluid Milk Products. The applicable version
number of the standard can be found on the machine plate.
EAC Compliance
(If applicable)
This equipment complies with the regulations of the Eurasian Customs Union.
China RoHS2 Compliance

(If applicable)
This equipment may contain one or more of the following substances: Pb, Hg, Cd,
Cr6+, PBB, and PBDE.
The Environmental Protection Use Period is 25 years.
The Hazardous Substances Disclosure Table can be found in the Installation chapter
of the TeM, under the General-subchapter.
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Doc. No. OM-3285384-0112 13 (180)
Identification Introduction
Machine Plate
The illustration below shows an example of the machine plate. The machine plate
carries data needed when contacting Tetra Pak concerning this specific equipment.
Make sure that the equipment data in the front pages of this manual corresponds to
the machine plate data and the machine specification.
The location of the machine plate is clearly marked at the Installation Layout in the
Technical Manual (TeM).
Note! The China RoHS2 sticker is attached to the machine plate.
1
2
11
3 Machine type:
Drawing spec:
Serial no: 12
4 PS (bar): TS (°C):
Group of fluid:
Year of manufacture: Month:

13 16
5 Assembled in:
14
6 15
9 10
7 8
1 Name and address of 6 Group of fluid 11 CE mark (if applicable)
manufacturer 7 Year of manufacture 12 PED mark(if
2 Machine type 8 Country of final applicable)
3 Drawing specification assembly 13 EAC mark (if
4 Machine serial number 9 Design PS (bar) applicable)
5 Design PS (bar) 10 Month of manufacture 14 3-A SS mark (if
applicable)
15 3-A standard number
(if applicable)
16 China RoHS2 mark (if
applicable)
Note! Design pressure PS and design temperature TS stated on the machine plate
is the maximum design pressure and maximum design temperature in the assembly
and is not applicable to all parts or components of the assembly. PS and TS are
.
most often not at the same location in the assembly.
14 (180) Doc. No. OM-3285384-0112

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Introduction Hygiene
Hygiene
Food product
Avoid microbiological contamination of the food product:
• Never clean the floors or the equipment in the process room (area) when the
equipment is in production.
• Compressed air used for cleaning purposes should only be used outside the
process room (area).
• Disinfect your hands before touching anything that may come into contact with the
product.
• Keep your hands and gloves clean.
• Always wear some type of hair protection (cap or hair net) and clean clothes
(preferably white).
• Do not wear a watch, ring, necklace, earrings, or any other exposed jewellery.
.
Secure food safety and quality when introducing new recipes:

• This equipment is intended for use according to the specifications in Technical
Data, see the Technical Manual (TeM).
• Before introducing a new recipe, secure that the equipment fulfils all new
requirements related to the product.
• A re-commissioning is strongly recommended. At re-commissioning, after
emptying step, secure that no non-processed food is left in any parts of the tank
body.
.
Steam Barrier
Steam barriers of the product valve in filling machine or aseptic tank employs a
steam barrier to separate the product supply line from the filling machine/aseptic
tank. The steam barrier allows the filling machine/aseptic tank and the product line to
be independently sterilized or cleaned. Steam barriers can also be found in end
valve clusters to minimize risk of contamination during filling. In applications with full
flexibility between sterilizers, aseptic tanks and fillers, steam barriers are often used
in mixproof valves.
Steam barriers for pump bearings, flange joints safety valves etc are common in
process equipment where sterility is required.
• Never disengage the steam barrier, and never interrupt the steam supply when
any of the equipment above is brought into pre-sterilizing phase or when the
equipment is already in production phase or aseptic intermediate cleaning phase.
• If any maintenance activities require disengagement of the steam barrier or
interruption of the steam supply to the equipment, make sure that no commercial
product can be contaminated.
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Doc. No. OM-3285384-0112 15 (180)
Environment Introduction
Environment
Waste Management
Separate, recycle, or dispose of all material and components in a safe, and
environmentally responsible way, or according to national legislation or local
regulations. If there is any uncertainty regarding what material a component is made
of, contact the Tetra Pak Group. Use a certified (ISO 14001 or similar) scrapping or
waste handling company.
Fluids and Chemical Products

Drain all liquids into collecting vessels. Do not mix different liquids into the same
vessel. Follow the instructions in the Safety Data Sheets for the disposal of the
different fluids and dispose of according to national legislation or local regulations.
Hydrogen Peroxide
Follow the instructions in the Safety Data Sheets, national legislations, and local
regulations for the disposal. Flush the hydrogen peroxide system with distilled water
to dilute any remaining hydrogen peroxide to a safe level.
For further details see the Hazardous Substances section in the Safety Precautions
chapter.
Cooling Media
Equipment containing any kind of cooling media must be dismantled, but only as far
as can be considered safe without any cooling media leakage. Follow national
legislation or local regulations. Send the cooling media to an authorized company
for proper handling.
For further details see the Hazardous Substances section in the Safety Precautions
chapter.
Separation of Materials and Components

Separate the following materials. Recycle or dispose of the materials as
appropriate. Follow specific recycling instructions, if such are given by the
component supplier.
• stainless steel (panels and doors)
• cast iron (frames)
• brass
• glass (windows, and so on)
• rubber (seals, O-rings, and so on)
• nylon and other plastics
• electrical cables
• hydraulic hoses
• central lubrication hoses
• pneumatic hoses
• electrical components
• batteries
• mercury (UV-lamp)
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Introduction Environment
Electrical Components
Electrical components and batteries may need to be disposed of in special waste
management systems. Follow national legislation or local regulations.
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Doc. No. OM-3285384-0112 17 (180)
How to Use This OM Introduction
How to Use This OM

Purpose of the OM
The Operation Manual provides operators with information on handling and
operating the equipment before, during, and after production.
Operator Workflow
Beginning with a PREPARATION CYCLE, the content is structured to follow the
operator workflow with a PRODUCTION CYCLE and then a CARE CYCLE.
18 (180) Doc. No. OM-3285384-0112

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Introduction Assistance and Inquiries
Assistance and Inquiries

For assistance when operating this equipment, submit your questions using the
QuTI-P tool. The QuTI-P tool shall also be used for all other inquiries, comments, or
suggestions that you may have, as well as giving feedback concerning the user
documentation provided with this equipment.
If access to the Tetra Pak® intranet is available, access the QuTI-P tool by typing
“QuTI-P” in the address field of your browser. If access to QuTI-P is not available,
request access by contacting the Global Service Desk.
If access to the Tetra Pak intranet is not available, contact the nearest Tetra Pak
representative.
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Doc. No. OM-3285384-0112 19 (180)
Assistance and Inquiries Introduction
This page intentionally left blank
20 (180) Doc. No. OM-3285384-0112

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Safety Precautions
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Doc. No. OM-3285384-0112 21 (180)
Safety Precautions
Safety Precaution Instructions
WARNING
Read 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 death or serious
injury.
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Safety Precautions Table of Contents
Safety Precaution Instructions. . . . . . . . . . . . . . . . . . . . . 22
Safety Messages Description ................................ 25

Personnel Requirements...................................... 26
Skilled Person . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Instructed Person . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Safety Signs ...................................................... 27

Locations of Safety Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Unexpected Stop during any Sequence ................... 29

Protective Devices .............................................. 30
Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Emergency Stop Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Safeguard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Indicating Tower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Safe Manual Handling.......................................... 33

Personal Protection ............................................ 34
Noise Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Entanglement Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Hazardous Substances ........................................ 35

Disposal of Chemical Substances . . . . . . . . . . . . . . . . . . . . . . . . . 35
Cleaning and Disinfection Chemicals . . . . . . . . . . . . . . . . . . . . . 35
Emergency Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Personal Protective Equipment . . . . . . . . . . . . . . . . . . . . . . . . 37
Inert gases - N2/CO2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Work in Confined Spaces ..................................... 38

Supply Systems ................................................. 39
Definition of Lockout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Electrical Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
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Doc. No. OM-3285384-0112 23 (180)
Table of Contents Safety Precautions
Residual Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Electrical Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Socket Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Steam Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Water Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Working at Height ............................................... 44
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Safety Precautions Safety Messages Description
Safety Messages Description

A safety message is always accompanied by a safety alert symbol and a signal
word. The safety alert symbol is used to alert about potential personal injury hazards.
To avoid hazards, obey all safety messages that follow this symbol.
The following safety alert symbols and signal words are used in this manual to inform
the user of hazards.
Danger indicates an imminently hazardous

DANGERI
DANGER situation which, if not avoided, will result in death
or serious injury.
Warning indicates a potentially hazardous
WARNING situation which, if not avoided, could result in
death or serious injury.
Caution indicates a potentially hazardous situation
CAUTION which, if not avoided, may result in minor or
moderate injury. It may also be used to alert
against unsafe practices.
CAUTION Caution without the safety alert symbol indicates a
potentially hazardous situation which, if not
avoided, may result in property damage.
.
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Doc. No. OM-3285384-0112 25 (180)
Personnel Requirements Safety Precautions
Personnel Requirements
Note! Personnel includes all persons working on or near this equipment.
Only skilled or instructed persons are allowed to work with this equipment.
Skilled Person
A skilled person must have relevant education and experience to enable him or her
to identify hazards, analyse risks, and avoid hazards which electricity, machinery,
chemicals, other energies, and supply systems on this equipment can create.
Skilled persons must meet local regulations, such as certifications and qualifications
for working with these energies and systems.
Instructed Person
An instructed person must be adequately advised or supervised by a skilled person.
The skilled person enables the instructed person to identify hazards, analyse risks,
and avoid hazards which electricity, machinery, chemicals, other energies, and
supply systems on this equipment can create.
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Safety Precautions Safety Signs
Safety Signs
WARNING
Damaged or missing safety signs increase the risk of death or serious injury.
Replace all missing or damaged safety signs immediately.
Safety signs are attached to the equipment, the table below lists all the signs that are
used. There are variants of the safety signs in the table, but only one is used on the
equipment.
• Make sure that each safety sign is legible and in its correct position after
installation and maintenance.
• Replace all missing or damaged safety signs immediately.
ISO Sign ANSI Sign
WARNING
Hazardous noise.
Risk of impaired hearing.
Wear hearing protection.
Hazardous noise.
Risk of impaired hearing. Wear hearing protection.
WARNING
Risk of eye injury.
Wear eye protection.
Risk of eye injury.

Wear eye protection.
WARNING
To prevent serious injury:
Do not operate this machine unless all doors are
closed and guards are in place and operating.
Read manual before first operating machine. If
manual is missing, contact Tetra Pak.
To prevent serious injury:

Do not operate this machine unless all doors are closed and guards are in
place and operating. Read manual before first operating machine. If
manual is missing, contact Tetra Pak.
Hot surface.
Do not touch.
Follow lockout procedure before maintenance.
(Cont’d)
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Doc. No. OM-3285384-0112 27 (180)
Safety Signs Safety Precautions
(Cont’d)
WARNING
Chemical burn hazard.
Wear personal protective
equipment.
Chemical burn hazard.

Wear personal protective equipment.
WARNING
Hot Outlets.
Hot liquids can cause
burns and scalds.
Stay clear of this area
or use personal
protective equipment.
Hot Outlets.
Hot liquid can cause burns and scalds. Stay clear of this area or use
personal protective equipment.
CAUTION
Fall hazard.
Be careful when using
stairways and ladders.
Fall hazard
Be careful when using stairways and ladders.
Locations of Safety Signs

The location of the safety signs are clearly marked in the Installation Layout in the
Technical Manual (TeM).
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Unexpected Stop during any
Safety Precautions Sequence
Unexpected Stop during any Sequence

At powers failure or any unexpected stop during a sequence, the process equipment
may contain trapped hot pressurized liquid in certain areas.
This could be caused by blockage inside the piping or equipment. In addition, a

blocked faulty or missing pressure indicator makes it difficult to verify that
depressurization is completed.
WARNING
Burn Hazard.
There is a risk of residual pressure in the equipment if it has not been depressurized
fully.
To avoid exposure, make sure that skilled personnel is available before any
remedying action.
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Doc. No. OM-3285384-0112 29 (180)
Protective Devices Safety Precautions
Protective Devices
There are different kinds of protective device designed to ensure safe use of the
equipment. See the sections below.
WARNING
Hazardous zones.
Hazardous zones are safeguarded and provided with protective devices. Do not
inch or run this equipment if any protective device is inoperative.
Change inoperative components of the safety system immediately.
Emergency Stop
DANGERI
DANGER
Hazardous voltage.
Will shock, burn, or cause death.
Hazardous voltage remains ON after activating an EMERGENCY STOP.
Emergency stop devices are used to stop this equipment immediately in an
hazardous situation. Learn the positions of all emergency stop devices and how to
use them.
Instructions for a normal production stop, see chapter Operation in Operation

manual.
Emergency Stop Buttons

Push one of the EMERGENCY STOP buttons to stop this equipment immediately.
The location of each EMERGENCY STOP button is shown by an arrow.
The location of the EMERGENCY STOP button is shown by an arrow.

.
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Safety Precautions Protective Devices
Safeguard
WARNING
Moving machinery
Never defeat or bypass the interlocking devices.
Movable guards, for example, doors and covers leading to hazardous zones, are
fitted with interlocking devices where required. These devices are usually electric
safety switches that are parts of the safety system and must never be defeated,
bypassed, or otherwise made inoperative.
CAUTION
Corners and edges
To prevent injury from corners and edges of open doors and covers, close them
unless they must be open during such work.
Be careful when working under an open door, cover or elsewhere below parts of the
equipment with corners and edges.
CAUTION
Burn hazard
Parts of this equipment may be hot after operation.
After installation and maintenance, and before this equipment is inched or run, check
that all safeguards are in place and that they operate correctly.
CAUTION
Equipment damage
The equipment can be damaged if it is not stopped in the correct way. Never stop
this equipment by opening a movable guard, for example, a door or cover, equipped
with an interlocking device.
The location of each interlocking guard is shown by an arrow.
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Doc. No. OM-3285384-0112 31 (180)
Protective Devices Safety Precautions
Indicating Tower
An indicating tower is a column of warning lights:
• Red light (1) indicates that the machine is emergency stopped
• Yellow light (2) flashes when an abnormal condition occurs, an impending critical
condition calling for action by the operator
• Green light (3) indicates a normal condition, such as production
Note! For a complete list of alarms, see the Operation Manual.

The light stops flashing and remains lit when the alarm is acknowledged. After the
fault is corrected or the operator takes the appropriate action, the warning light turns
off.
1 Red light
2 Yellow light
3 Green light
.
32 (180) Doc. No. OM-3285384-0112

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Safety Precautions Safe Manual Handling
Safe Manual Handling

Use mechanical lifting aids whenever possible. If mechanical lifting aids are not
available, do not attempt to lift loads over 23 kg without the assistance of a
colleague. Avoid lifting below knee height and above shoulder height. If it is
necessary to lift from the floor, follow the instructions below to reduce the risk of back
and disc injuries.
• Use safety shoes and be sure that the surface of the floor is not slippery.
• Get close to the load.
• Take a wide stance and find the best positions for your feet.
• Bend your hips and knees, and use your leg muscles.
• Keep the load close to your body.
• Do not twist your body while moving the load.
• Take small steps when turning.
In order to reduce the risk of injury to discs and back muscles, be careful to not bend
or twist your back when lifting. Keep the load close to your body to reduce the strain
on your back.
To reduce the ergonomic risks to each individual operator, job rotation is

recommended, so that recovery and variety are provided.
®
Doc. No. OM-3285384-0112 33 (180)
Personal Protection Safety Precautions
Personal Protection
This section applies to all personnel at all times when this equipment is in operation.
For special personal protection required when handling hazardous substances, see
the Hazardous Substances section.
.
Noise Hazard
WARNING
Hazardous noise.
Risk of impaired hearing.
Wear hearing protection whenever this equipment is in operation.
.
Entanglement Hazard
WARNING
Risk of entanglement.
Do not wear jewellery or loose clothing when working on or near this equipment.
Long hair may not be loose.
.
34 (180) Doc. No. OM-3285384-0112

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Safety Precautions Hazardous Substances
Hazardous Substances
WARNING
Contact with chemicals can cause death, serious injury, or illness.
Always read and follow the instructions in the safety data sheet supplied by the
manufacturer or local supplier, when handling chemicals.
Make sure that:
• the safety data sheet is available
• preparations have been done to ensure that the stated safety measures in the
safety data sheet can be followed
• the locations of the first aid equipment are learned in order to act immediately in
case of an accident
.
Disposal of Chemical Substances

Always read and follow the disposal instructions in the safety data sheet supplied by
the manufacturer or local supplier.
It is strongly recommended that used chemical containers are:

• disposed of according to the instructions immediately after use
• not used as disposal containers for other chemicals in order to avoid uncontrolled
chemical reactions within the container
.
Cleaning and Disinfection Chemicals

DANGERI
DANGER
Contact with chemicals can cause death, serious injury, or illness.
Always read and follow the instructions of the safety data sheet supplied by the
manufacturer or the local supplier, when handling chemicals. Wear personal
protective equipment.
WARNING
Corrosive chemical.
Wear personal protective equipment.
In both liquid and gas states, these chemicals may cause irritation or damage if they
come into contact with skin, mucous membranes, eyes, or clothes. Consult the
instructions on the label of the tank or container. Call for medical attention
immediately if there is an accident.
.
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Doc. No. OM-3285384-0112 35 (180)
Hazardous Substances Safety Precautions
Emergency Procedures
If there is an accident, rinse the affected area as soon as possible with large
amounts of water.
Eyes
If splashes or vapour from these chemicals come in contact with the eyes
• wash the eyes thoroughly with lukewarm water for 15 minutes (keep eyelids wide
apart)
• call for medical attention immediately
Skin
If these chemicals come into contact with skin or clothes

• rinse immediately with plenty of water
• call for medical attention immediately if skin burns appear
• thoroughly wash the clothes before wearing them again
Inhalation
If irritation or pain is experienced due to having inhaled these chemicals vapour

• leave the affected area and get some fresh air
• call for medical attention if the symptoms get worse
Ingestion
If these chemicals are swallowed

• do not attempt to cause vomiting
• drink large amounts of lukewarm water to dilute these chemicals
• call for medical attention immediately
.
36 (180) Doc. No. OM-3285384-0112

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Safety Precautions Hazardous Substances
Personal Protective Equipment

Following personal protective equipment is recommended to wear during normal
operation and maintenance:
• hearing protection
• protective shoes or boots made of PVC or PE plastic, or rubber
• protective clothes
During handling of chemicals, manual cleaning of equipment and maintenance of

machinery that have used chemicals add following extra protection:
• protective goggles (for instance, TP No. 90303-11), tight fitting
If there is a risk of splashes, a visor is a suitable complement
• protective gloves made of neoprene (for instance, TP No. 90303-12), nitrile, or
butyl rubber
• protective apron (for instance, TP No. 90303-13), or protective suit when handling
larger amounts
• protective shoes or boots made of PVC, PE plastic, or rubber
• proper respiratory equipment, if ventilation is insufficient.
WARNING
Risk of burns.
Whenever there is risk of exposure to chemicals, hot water or product, wear
protective clothing, face shield, gloves and shoes of PVC or PE plastic, or rubber.
.
Inert gases - N2/CO2

Applicable if Nitrogen/CO2 injection is used.
DANGERI
DANGER
Risk of suffocation.
If the concentration of N2 or CO2 increases, the oxygen concentration will decrease,
which may result in suffocation. Sufficient ventilation in the process room are of
extreme importance. Ensure you have a safe system for working in a confined
space. Use appropriate protective equipment
Read the section Work in Confined Spaces - Tank Entry for further details regarding
recommended procedures for entry into the tank.
®
Doc. No. OM-3285384-0112 37 (180)
Work in Confined Spaces Safety Precautions
Work in Confined Spaces

If you cannot avoid entry into a confined space, make sure you have a safe system
for working. Always follow local site lockout procedures and procedures for work in
confined spaces.
The first step towards conducting a safe confined-space entry is to plan the entry.
The following suggestion is not intended to be exhaustive, but includes some of the
essential elements to help prepare a safe system of work.
Permit to Work
• No work inside a tank to be started without a permit to work.
Skilled and Instructed Personnel

• Ensure that the personnel, in addition to being skilled and experienced, are
trained in local site procedure for work in confined spaces.
Before Entering the Tank

• Before entering the local safety switch must be switched to “off” and be locked.
See also Definition of Lockout Procedure.
• All inlets to the tank must be blocked, locked and marked, such as the product-,
CIP-, steam- and condensate inlets.
• Allow the tank to cool down and adjust to atmospheric pressure,
Provision of Ventilation
• Ensure that the process room is ventilated in a sufficient way so it can handle the
complete tank gas volume without reaching a critical low oxygen level.
• An atmosphere is considered safe for entry when concentration of oxygen is
19.5% - 21.5 %.
• Oxygen levels below this range are dangerous and could cause irrational
behaviour, unconsciousness within seconds/minutes and in worse case lead to
death.
• Sufficient ventilation of the tank body is extremely important to be done before
entering and throughout the whole duration of the work at all levels.
• Testing the air may be necessary to check that it is fit to breathe. If any doubts,
such in case of using inert gases, testing should be carried out by a competent
person using a suitable gas detector which is correctly calibrated.
Communication
• During work inside the tank position someone outside to keep watch and to
communicate with the person inside.
Personal Protective Equipment

• Ensure that the personnel are provided with suitable personal protective
equipment for the work to be carried out.
• Lifelines attached to harnesses should run back to a point outside the confined
space.
38 (180) Doc. No. OM-3285384-0112

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Safety Precautions Supply Systems
Supply Systems
Definition of Lockout Procedure
A lockout procedure is a procedure to put each necessary energy isolating device in
its safe position to prevent the energisation of the equipment, such as when a
maintenance procedure should be carried out.
A lockout is the use of a device, for example, a padlock, to make sure that an energy
isolating device cannot be operated.
An energy isolating device is a mechanical device that physically prevents

transmission or release of energy, such as a power supply disconnector.
Electrical Supply
WARNING
Hazardous voltage and moving machinery.
The electrical supply disconnecting device must be turned off and secured with a
padlock before any maintenance.
Note! The key to the padlock must be removed by the technician and retained in
his/her possession until all work is completed.
Certain maintenance procedures may require electrical supply systems to be on.
These exceptions are clearly stated in the Component instructions.
WARNING
Hazardous voltage
Circuits identified by orange-coloured conductors are not disconnected by the main
electrical supply disconnecting device. The location of the electrical supply
disconnecting device of these circuits is described in the procedures that include
work on these types of circuit.
(Cont’d)
®
Doc. No. OM-3285384-0112 39 (180)
Supply Systems Safety Precautions
(Cont’d)
The illustrations show the electrical supply disconnecting device and its location.
Residual Voltage
WARNING
Hazardous voltage.
Do not touch any terminals immediately after the power supply disconnector is
turned off. Ensure that no residual voltage remains on the capacitors before
touching. Wait five minutes. Failure to observe this information will cause death or
serious injury.
After the electrical power supply disconnecting device is turned off, residual voltage
remains in the capacitor circuits.
.
40 (180) Doc. No. OM-3285384-0112

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Electrical Cabinet
WARNING
Hazardous voltage
Will shock, burn, or cause death.
Parts behind doors to the electrical cabinet may be live. The electrical supply
disconnecting device must be turned to position O (OFF) and secured with a padlock
before maintenance inside the electrical cabinet.
Note! The key to the padlock must be removed by the technician and retained in
his/her possession until all work is completed.
Make sure that the electrical cabinet doors are closed after working inside the
electrical cabinet. Doors with lock must be locked.
The location of the electrical cabinet is shown by an arrow.
®
Doc. No. OM-3285384-0112 41 (180)
Supply Systems Safety Precautions
Socket Outlet
WARNING
Hazardous voltage.
Can shock, burn, or cause death. Read the Maintenance Manual before using this
socket outlet.
The socket outlet (1) is connected to a residual current device (2) to protect users
against electrical shock if there is an earth fault in the connected equipment. The
residual current device shall be tested each time before the socket outlet is being
used. See relevant MaSP for test procedure.
The illustration shows the socket outlet, the residual current device, and their
location.
Air Supply
WARNING
Compressed air and moving machinery.
Close the main air valve and lock it, and safely release compressed air from the air
system before any maintenance.
Note! The key to the lock must be removed by the technician and retained in
his/her possession until all work is completed. The lock is not a part of the delivery.
Certain maintenance procedures may require air supply systems to be on. These
exceptions are clearly stated in the Component Instructions.
.
42 (180) Doc. No. OM-3285384-0112

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Steam Supply
WARNING
Hot steam can cause scalds.
Pressurized steam can be discharged unexpectedly. Close the steam supply valve
and lock it, depressurize and vent all steam safely before any maintenance on parts
with steam, such as pipes and valves.
Note! The key to the lock must be removed by the technician and retained in his/her
possession until all work is completed.
Certain maintenance procedures may require steam supply systems to be on. These
exceptions are clearly stated in the Component Instructions.
WARNING
Hot parts can cause severe burns.
Pipes, valves, and other parts containing steam can be extremely hot. Do not touch
hot parts.
.
Water Supply
CAUTION
Water under pressure.
Close the water supply valves before any maintenance.
Certain maintenance procedures may require water supply systems to be on. These
exceptions are stated in the Component instructions.
.
®
Doc. No. OM-3285384-0112 43 (180)
Working at Height Safety Precautions
Working at Height
This equipment is provided with a means of access to all locations where routine
tasks for operation and maintenance need to be carried out.
WARNING
Risk of falling.
For any kind of work at height, always ensure that safe means of access is available
and used. Where additional safe means of access other than provided with the
equipment is required, follow local work at height regulations and guidelines. Use
scaffolds or a mobile work platform and a safety harness. Create a safety perimeter
around the working area and secure tools or other objects from falling.
44 (180) Doc. No. OM-3285384-0112

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®
Doc. No. OM-3285384-0112 45 (180)
About the General Description Chapter

This section describes the main parts of the equipment.
46 (180) Doc. No. OM-3285384-0112

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1 General Description Table of Contents
About the General Description Chapter . . . . . . . . . . . . 46
1.1 Working and Service Area .................................... 49

1.1.1 Operator´s Working Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
1.2 Modules Available .............................................. 50

1.2.1 Feed Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
1.2.2 Deaerator Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
1.2.3 Rice Feed Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
1.2.4 Tetra Alcross® Filtration equipment . . . . . . . . . . . . . . . . . . . . . . . 52
1.2.5 Tetra Pak®Standardization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
1.3 Components...................................................... 54
1.3.1 Tetra Pak® Homogenizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1.3.2 Tetra Pak® Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1.3.3 Tetra Pak® Bactofuge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
1.3.4 Heat Exchangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
1.3.4.1 Tetra Pak Tubular Heat Exchanger. . . . . . . . . . . . . . . . . . . . . . 55
1.3.4.2 Tetra Pak Plate Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . 56
1.3.4.3 Tetra Pak Coiled Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . 56
1.3.4.4 Contherm Scraped-Surface Heat Exchanger . . . . . . . . . . . . 57
1.3.5 Spiral Holding Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

1.3.6 Rice Cooking Holding Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
1.3.7 Steam Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
1.3.8 Infusion Vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
1.3.9 Flash Vessel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
1.3.10 External Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
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Doc. No. OM-3285384-0112 47 (180)
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1 General Description 1.1 Working and Service Area
1.1 Working and Service Area

See the installation layout in the Technical Manual (TeM) for the recommended
working and service area.
1.1.1 Operator´s Working Area

Mainly in front of the available operator panels.
WARNING
Hot part can cause severe burns.
Consider one meter safety distance around the equipment due to hot pipes, valves
and other parts.
®
Doc. No. OM-3285384-0112 49 (180)
1.2 Modules Available 1 General Description
1.2 Modules Available

Some of the described modules and components are optional and may not be
included in all equipment. Some of these are also delivered with separate
documentation.
To see the relative position of the different applicable modules, see the Installation
Layout in the Technical Manual (TeM).
1.2.1 Feed Module

The feed module includes components like control panel (1) containing process
controller (PLC), operators interface (HMI), colour screen recorder, and motor
starters. A balance tank (2) with automatic level control by means of level transmitter
and control valve. Feed pump (3) and booster pump (4) . A hot water unit (5), with
expansion vessel, centrifugal pump, plate heat exchanger, and steam control valve.
A Water regen unit (6) with expansion vessel, centrifugal pump, and flow meter.
2 5 6
4 3
The graphics shows an example of a feed module.
50 (180) Doc. No. OM-3285384-0112

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1 General Description 1.2 Modules Available
1.2.2 Deaerator Module

The deaerator module is used to extract gases and air from the product before it
enters the heat exchangers final heating zone.
The product is tangentially fed into the vacuum vessel which is under a vacuum
corresponding to a water evaporation point below the inlet temperature of the
product. Vapour and gases rise to the top of the chamber.
Gases are discharged through the top while the vapours condense in the spiral
condenser and drop back into the liquid product.
After treatment the product is discharged through the bottom outlet of the chamber
for further processing.
7
Example of a deaeration module
1 Deaerator vessel 5 Pressure transmitters
2 Condensor for level control
3 Extraction pump 6 Vacuum control valve
4 Vacuum pump 7 Closed condenser
loop with centrifugal
pump and plate heat
exchanger
.
®
Doc. No. OM-3285384-0112 51 (180)
1.2 Modules Available 1 General Description
1.2.3 Rice Feed Module

The module includes a dosing unit for grains, a balance tank for the milk base and a
centrifugal pump with an inlet funnel. The grains are dosed into the milk in the funnel
at the inlet to the centrifugal pump and the pump is feeding the mix of grains and
milk to the first SSHE heater.
1.2.4 Tetra Alcross® Filtration equipment

For ultra filtration of product.
Example of a Tetra Alcross Filtration module
52 (180) Doc. No. OM-3285384-0112

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1 General Description 1.2 Modules Available
1.2.5 Tetra Pak®Standardization

Used for standardization of the milk and cream fat contents to a precise level
Example of a Tetra Pak Standardization module

.
®
Doc. No. OM-3285384-0112 53 (180)
1.3 Components 1 General Description
1.3 Components
1.3.1 Tetra Pak® Homogenizer
Used for breaking down the fat globules in the product.
Example of a Tetra Pak Homogenizer

.
1.3.2 Tetra Pak® Separator

Used for separation of cream and skim milk from each other. It is also used to clean
the product from heavy particles.
Example of a Tetra Pak Separator

.
1.3.3 Tetra Pak® Bactofuge

Used for an efficient removal of spores and other unwanted organisms from the
product.
Example of a Tetra Pak Bactofuge

.
54 (180) Doc. No. OM-3285384-0112

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1 General Description 1.3 Components
1.3.4 Heat Exchangers

The heat exchanger is used to heat/cool the product, mainly regenerativetly but also
by using media such as ice water or hot water.
1.3.4.1 Tetra Pak Tubular Heat Exchanger

In Tetra Pak Tubular Heat Exchangers CD, CM and CMP models, the product
flows through one tube (CD) or a bundle of parallel tubes (CM, CMP) and the service
medium flows between and around them.
By allowing product-to-product heat recovery, the CMR, and CMRF models offer
unique opportunities for energy savings. The processed product flows through a
bundle of parallel tubes and the unprocessed product flows between and around
them.
The CC model has three concentric tubes. The product flows in the second (middle)
tube and the service medium flows on both sides of the product.
Tubes are normally corrugated to increase turbulence and heat transfer efficiency,
while a few tubes are smooth, for special applications, for example, high-viscosity
products.
Each complete Tetra Pak Tubular Heat Exchanger tube is designed for single-pass
operation, with all inner tubes connected in parallel and in countercurrent flow to the
service medium. The complete tubes are normally connected n series and grouped
on a common frame.
Example of a tubular heat exchanger

.
®
Doc. No. OM-3285384-0112 55 (180)
1.3.4.2 Tetra Pak Plate Heat Exchanger

The Tetra Pak Plate Heat Exchangers consist of a pack of corrugated metal plates.
The corrugation patterns form channels for the passage of two fluids between which
heat transfer takes place. The two fluids enter and leave the heat exchanger unit
through the connections.
The plate pack is assembled between a fixed frame plate nd a movable pressure
plate, and is compressed by tightening bolts. The plates are fitted with gaskets that
seal the channels.
The number of plates is determined by the flow rate, physical properties of the fluids,
pressure drop and temperature program.
Example of a plate heat Exchanger

.
1.3.4.3 Tetra Pak Coiled Heat Exchanger

The Tetra Pak Coiled Heat Exchanger provides efficient heating and cooling of low
to high viscous and smooth to particulate products.
Example of a coiled Heat Exchanger

.
56 (180) Doc. No. OM-3285384-0112

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1.3.4.4 Contherm Scraped-Surface Heat Exchanger

The Contherm scraped-surface heat exchanger is particularly suited for
continuous heating and cooling of viscous, sticky, heat-sensitive and particulate food
products. It can operate with a wide range of media products.
Example of Contherm scraped-surface heat exchangers

.
1.3.5 Spiral Holding Tube

Used for increased holding time.
Example of a spiral holding tube

.
®
Doc. No. OM-3285384-0112 57 (180)
1.3.6 Rice Cooking Holding Tube

Insulated cabinet with a cooking holding tube for products with rice grains. The
cabinet also contains the legal holding tube.
1.3.7 Steam Injector

Pressurized steam is injected into the product flow to raise its temperature. The
product is kept at predefined temperature in the holding tube for a predefined time
1
4
Example of a steam injector

1 Preheated product 3 Pressurized steam
2 Steam injector 4 Holding tube
.
58 (180) Doc. No. OM-3285384-0112

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1.3.8 Infusion Vessel

In an infusion vessel, product is sprayed into an atmosphere of steam to raise the
temperature. The product is kept at predefined temperature in the holding tube for a
predefined time.
Example of a infusion vessel

1 Product inlet 3 Cooling water
2 Steam inlet 4 Product outlet
.
1.3.9 Flash Vessel

Flash cooling takes place in a condenser equipped vacuum vessel (Flash vessel)
where rapid cooling of the product takes place.
1.3.10 External Communication

The unit supports communication with external equipment by use of serial
communication Ethernet. If only I/0 communication is required digital inputs and a set
of potential free contacts as digital outputs are available.
Note! For detailed information see the communication description “CDN

TXXXXXXXXXX” supplied in the Electrical Manual
®
Doc. No. OM-3285384-0112 59 (180)
60 (180) Doc. No. OM-3285384-0112

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2 Process Description
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Doc. No. OM-3285384-0112 61 (180)
About the Process Description Chapter

This section describes the process cycles and working principle.
62 (180) Doc. No. OM-3285384-0112

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2 Process Description Table of Contents
About the Process Description Chapter . . . . . . . . . . . . 62
2.1 Applications ...................................................... 65

2.2 Process Cycle.................................................... 66
2.3 Working Principle ............................................... 67
2.3.1 With Spiraflo CMR 75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2.3.2 With Spiraflo CMR 125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
2.3.3 With Spiraflo CM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
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Doc. No. OM-3285384-0112 63 (180)
64 (180) Doc. No. OM-3285384-0112

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2 Process Description 2.1 Applications
2.1 Applications
An indirect UHT unit is a module for treatment of milk, flavoured milk, cream, dairy
desserts, yoghurt drinks, liquid baby food and other applications like juice, nectar
and tea. Equipment with functionality for deaeration and non-aseptic and aseptic
homogenization is available. The unit is based on either plate heat exchangers or
tubular heat exchangers.
®
Doc. No. OM-3285384-0112 65 (180)
2.2 Process Cycle 2 Process Description
2.2 Process Cycle

This following text in gives a simple description of this process equipment.
The way of function is described with a flow chart, which is adapted to give a clear
picture and do not include all details.
For detailed information, see customised documents in the Technical Manual (TeM)
such as:
• Flow diagram.
• Technical data documents.
• Functional documents.
The process cycle (2) is divided into the following phases:

• Sterilization
• Production
• Aseptic intermediate cleaning (IC)
• Stop
• Cleaning
1 Process cycle
2 Phase
3 Step
66 (180) Doc. No. OM-3285384-0112

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2 Process Description 2.3 Working Principle
2.3 Working Principle

2.3.1 With Spiraflo CMR 75
Before production can commence it is necessary to sterilize the aseptic area of the
module by circulating pressurised hot water for 30 minutes The aseptic part of the
module is equipped with an internal sterilizsation loop in order to minimise the energy
consumption and start up time. After sterilization, the module is cooled down step by
step to production temperatures. Finally sterile water is circulated through the
product circuit.
Production starts by filling the module with product via the balance tank The product
displaces the water/product mix to drain or reject tank. A specially designed balance
tank minimises the amount of mixed products. When a downstream tank or filling
machine is ready production can start.
The product is regeneratively preheated up to approximately 75 °C in the
Tetra SpirafloTHE before being homogenised in a Tetra Alex homogenizer. For
versions with capacities from 4 000 l/h the direct product-to-product regeneration is
performed up to approximately 75 °C in Tetra Spiraflo CMR tubular heat exchangers.
Final heating takes place by means of an indirect hot water circuit. In order to prolong
the production time, two water circuits is standard when THE are used.
The product is held in a holding tube for the required period of time.
Regenerative cooling to packaging temperature is performed either in a PHE or a

corrugated THE.
In order to prolong the production period between full CIP (Cleaning-In-Place), an
Aseptic Intermediate Cleaning (AIC) can be performed.
When AIC is ordered during production the product is displaced by sterile water
followed by a hot water rinse before cleaning phase starts. During the AIC
sequences, the holding tube is kept at the sterilization temperature, thus the aseptic
parts in the module remain sterile.
The AIC can be performed with either lye or flushing acid detergent. After each
production run the module is CIP cleaned with both lye and acid. If product supply
fails or a stop at a filling machine occurs, sterile water replaces the product and the
module goes into sterile circulation.
(Cont’d)
®
Doc. No. OM-3285384-0112 67 (180)
2.3 Working Principle 2 Process Description
(Cont’d)
7
4
2
4 6
1 3
5 8
9
The figure shows a flow diagram for a Tetra Pak® Indirect UHT unit D with a Spiraflo
tube heat exchanger, the principle is basically the same with a plate heat exchanger.
1 Product 6 Holding tube
2 Reject to tank 7 Return from filling
3 Balance tank 8 Steam
4 Cooling water 9 Product to filling
5 Stabilizing holding
tube
68 (180) Doc. No. OM-3285384-0112

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2.3.2 With Spiraflo CMR 125

module by circulating pressurised hot water for 30 minutes. The aseptic part of the
module is equipped with an internal sterilization loop in order to minimise the energy
consumption and start up time. After sterilization, the module is cooled down step by
product circuit.
Production starts by filling the module with product via the balance tank. The product
displaces the water/product mix to drain or reject tank. A specially designed balance
tank minimises the amount of mixed products. When a downstream tank or filling
machine is ready production can start.
The product is regeneratively preheated up to approximately 75 °C in the Tetra
Spiraflo THE before being homogenised in a Tetra Alex homogenizer. For versions
with capacities from 4 000 l/h the direct product-to-product regeneration is performed
up to approximately 125 °C in Tetra Spiraflo CMR tubular heat exchangers.
Final heating takes place by means of an indirect hot water circuit.


corrugated THE.
In order to prolong the production period between full CIP (Cleaning-In- Place), an
followed by a hot water rinse before cleaning phase starts. During the
AIC sequences, the holding tube is kept at the sterilization temperature, thus the
aseptic parts in the module remain sterile.
.
(Cont’d)
®
Doc. No. OM-3285384-0112 69 (180)
(Cont’d)
1 3
7
8
.
2.3.3 With Spiraflo CM

module by circulating pressurised hot water for 30 minutes. The aseptic part of the
module is equipped with an internal sterilisation loop in order to minimise the energy
consumption and start up time. After sterilisation, the module is cooled down step by
product circuit.
Production starts by filling the module with product via the balance tank. The
product displaces the water/product mix to drain or reject tank. A specially designed
balance tank minimises the amount of mixed products. When a downstream tank or
filling machine is ready production can start.
The product is preheated in the Tetra Spiraflo THE before being homogenised in a
Tetra Alex homogenizer.
Preheating and final heating takes place by means of an indirect hot water circuit. In
order to prolong the production time, two water circuits is standard
when THE are used.
(Cont’d)
70 (180) Doc. No. OM-3285384-0112

®
(Cont’d)
corrugated THE.
In order to prolong the production period between full CIP (Cleaning-In- Place), an
followed by a hot water rinse before cleaning phase starts. During the
AIC sequences, the holding tube is kept at the sterilisation temperature, thus the
aseptic parts in the module remain sterile.
4
2
4
5 6
1 3 7
8
5 Stabilizing holding
tube
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Doc. No. OM-3285384-0112 71 (180)
72 (180) Doc. No. OM-3285384-0112

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3 Control Panel
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Doc. No. OM-3285384-0112 73 (180)
3 Control Panel
Description
This chapter describes the control panel and the operator panel with menus
74 (180) Doc. No. OM-3285384-0112

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3 Control Panel Table of Contents
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
3.1 Denomination .................................................... 77

3.2 Operator's Panel ................................................ 78
3.2.1 Log In/Log Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
3.2.2 Access Code Levels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
3.3 HMI.................................................................. 80
3.3.1 Buttons and Symbols on the Window Pictures . . . . . . . . . . . 80
3.3.2 Component Labeling by Reference Designation . . . . . . . . . 80
3.3.3 Home Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
3.3.3.1 Unit Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
3.3.4 Header Navigation Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
3.3.5 Footer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
3.3.6 Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
3.3.7 Command Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
3.3.8 P&ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
3.3.9 Sterilizer/Pasteurizer Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
3.3.9.1 Production History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
3.3.9.2 CIP History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
3.3.10 Sterilizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
3.3.11 Trend. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
3.3.12 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
3.3.12.1 Control Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
3.3.12.2 Analog Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
3.3.12.2.1 Faceplate Description . . . . . . . . . . . . . . . . . . . . . . . . . . 92
3.3.12.3 Digital Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
3.3.12.3.1 Faceplate Description . . . . . . . . . . . . . . . . . . . . . . . . . . 93
3.3.12.4 Valve Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
3.3.12.4.1 Faceplate Description. . . . . . . . . . . . . . . . . . . . . . . . . . . 94
3.3.12.5 Motor Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
3.3.12.5.1 Faceplate Description. . . . . . . . . . . . . . . . . . . . . . . . . . . 95
3.3.12.6 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
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Doc. No. OM-3285384-0112 75 (180)
Table of Contents 3 Control Panel
3.3.12.7 Phases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
3.3.12.8 How to Start a Phase. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
3.3.12.9 Production Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
3.3.13 This Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
3.3.14 IntelliCIP™ (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
3.3.14.1 IntelliCIP Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
3.3.14.2 RFL Trend Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
3.3.14.3 RFL Graph. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
3.3.14.4 Clean Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
3.3.14.5 Automatic iCIP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
3.3.14.6 Positioning of Differential Pressure Transmitters . . . . . . 105
3.3.14.7 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
3.3.14.8 Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
3.3.15 Turbidity (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

3.3.15.1 Fine-tuning of Volume with Turbidity Meter
H51BQ083 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
76 (180) Doc. No. OM-3285384-0112

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3 Control Panel 3.1 Denomination
3.1 Denomination
5
1 Emergency stop
button
2 Operator's panel
3 Digital recorder
4 Indicating tower
5 Cooler
6 Emergency reset
button
7 Electrical supply
disconnecting device
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Doc. No. OM-3285384-0112 77 (180)
3.2 Operator's Panel 3 Control Panel
3.2 Operator's Panel

This process equipment is controlled by a Programmable Logic Controller (PLC).
This PLC contains several sequences that control the execution of the necessary
programs for running production, cleaning and so on.
The PLC program contains all the controllers to control different process values as
level, pressure, and/or temperature.
A Human Machine Interface (HMI) is used as the link between the process
equipment and the operator. With the HMI, the operator can enter the necessary
commands, enter various process and system parameters, and obtain information
about the system status. It is possible to retrieve information about the current step
of the system and which sequence is active. If abnormal conditions occur, alarm are
shown on this unit.
This equipment can also be connected to a main control system. From there, it is
possible to enter and receive the same information as those entered and retrieved
from the system's HMI.
3.2.1 Log In/Log Out

A safety system allowing each user specific defined possibilities. Also all actions
done are logged together with the name of the logged in user.
It is important that each user does Log In and Log Out correctly.
Key in your user name (1) and password (2), acknowledge with LOGIN button (3).
When logged on, the Log In window can be opened with the button (4) always
available in the header.
The name of the logged on user is shown in the header. To log out, press the LOGIN
button again.
4
The user needs to log out when leaving the operator station. If a user leaves without
logging out, the system logs out automatically after a specified time.
Depending on your user rights different functions are controllable. There is however,
no limitation to view information.
Every user is part of one or more user groups and inherits the group access rights.
78 (180) Doc. No. OM-3285384-0112

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3 Control Panel 3.2 Operator's Panel
3.2.2 Access Code Levels

All modules in the Navigator have been set-up with a security level. Depending on
who is logged in, different modules are available. This is because a user is
configured with a certain access authority. The modules that are available have non-
transparent icons. To access modules with transparent icons, log in with a different
username with greater access, or ask the administrator to change the Username’s
access level.
For more information, go to the PlantMaster NAVIGATOR application select with the
navigation button SETTINGS (1), NAVIGATOR (2) and NAVIGATOR HELP (3).
1
2
3
.
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Doc. No. OM-3285384-0112 79 (180)
3.3 HMI 3 Control Panel
3.3 HMI
The HMI (Human Machine Interface) display is a touch sensitive screen which
allows the operator to manage and interact with the machine control system.
The window displays the buttons and icons used to identify the status of the
machine and to access the different menus of the control system.
3.3.1 Buttons and Symbols on the Window Pictures

Note! The following pages in this section contain a selection of buttons, symbols,
and window pictures that may be seen on the HMI. The various options and
equipment that is supplied with each machine determines what is seen on your HMI.
3.3.2 Component Labeling by Reference Designation

Reference designation is a structured way of naming components and functionality
in different subsystems. The example below is a valve (Q0481) located in
subsystem V01.
V01Q0481
The table contains reference designation codes for some of the most common
components
Component Subsystem Code Serial number

Valve V01 Q 0481
Pump G
Temperature BT
transmitter
Pressure BP
transmitter
Level transmitter BL
Flow transmitter BF
Density meter BD
pH meter BQ
Thermometer PT
Manometer PP
Flow indicator PF
.
80 (180) Doc. No. OM-3285384-0112

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3 Control Panel 3.3 HMI
3.3.3 Home Window
To open select Home Window,
The home window gives an overview with basic information on plant status. The
header navigation buttons (1) gives access to different windows see 3.3.4 Header
Navigation Buttons page 82 When logged on, the Log In window can be opened with
the button (2) always available at the header, see also 3.2.1 Log In/Log Out page 78
All information regarding ongoing operations as well as process information is
available here see 3.3.3.1 Unit Informationpage 82.
At the footer other functions and windows are available see 3.3.3.1 Unit Information
page83
Use the search button (9) for control modules in the P&ID window and (10) for
search in the Operation Manual.
1 2
9
10
4
3 5
3 6
3
7
3 8
3
3
The illustration shows an example of a Home Window
1 Header navigation 6 Destination
buttons 7 Reclaim
2 Log in/out 8 Cream
3 Footer function 9 Search button, Control
buttons Modules
4 Source 10 Search button,
5 Pasteurizing Operation Manual
.
®
Doc. No. OM-3285384-0112 81 (180)
3.3.3.1 Unit Information

The colour of the symbol (1) indicates the status of the module/function see 3.3.6
Iconspage 84.
1 2 3
1 Status
2 Name of unit
3 Not used
4 Symbol of the unit
.
3.3.4 Header Navigation Buttons

Button Menu Path
Brings up the Sterilizer or Pasteurizer
Window see page 86
Pasteurizer
Brings up Recipes Window see page 115 and

161
Brings up the Trend Window see page 82on
page 113
Brings up latest visit Alarm window see 4.1

Alarms Navigation
Brings up Maintenance Window see page 91
Brings up Settings Window
Brings up External Window.
82 (180) Doc. No. OM-3285384-0112

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3.3.5 Footer
At the footer (3) the following buttons are available:
Sym- Description
bol
Opens an overview of the plant with reduced information of the existing
units see page 81.
Previous window.
Returns previous process window.
Opens the Trend Window for analogue values, see page 90.
Opens Windows calculator.
Opens notes.
Access to Production Integrator (reports, traceability, etc.)

.
®
Doc. No. OM-3285384-0112 83 (180)
3.3.6 Icons
Following icons are available for the different phases.
1 2 3 4 5
6 7 8 9 10
1 Sterilizing 6 Shutdown
2 Water circulation 7 Emergency empty
3 Hibernation 8 Maintenance
4 Production 9 Product circulation
5 Intermediate cleaning 10 Integrity test
and CIP
Different colour codes on the symbols indicate different status
Symbol Description
Production selected (blue).
Production selected (blue).
Production running (green).
Production held (white/yellow).
Production queued (white/green).

.
84 (180) Doc. No. OM-3285384-0112

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3.3.7 Command Buttons

Sym-
bol Description
Start command. It makes the phase start from Idle status.
Hold command. It makes the phase go to Hold from Running status.
Finalize command. It makes the phase finalize in a controlled way from

Running status.
Restart command. It makes the phase start again from Hold status.
Abort command. It makes the phase abort either from Hold or Running
status.
3.3.8 P&ID
The P&ID Indirect UHT window shows the unit more detailed. It contains dynamic
information on operation status for all control modules (valves, motors, and so on) in
the unit. From here, you can navigate to the control module pop-up windows for
manual control.
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Doc. No. OM-3285384-0112 85 (180)
3.3.9 Sterilizer/Pasteurizer Window

To open select appropriate navigation button Sterilizer or Pasteurizer
The Sterilizer/Pasteurizer window shows the unit line. It contains dynamic
information on operation status for the unit or units.
At the left available icons (1) representation the different phases and status during
production see 3.3.6 Icons page 84
In the window, a second layer of navigation buttons (2) for the sub areas is available
see 3.3.9.1 Production History and 3.3.9.2 CIP History
1 Function icons
2 Navigation buttons
.
86 (180) Doc. No. OM-3285384-0112

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3.3.9.1 Production History

To open select navigation button Sterilzer/Pasteurizer and Production
history.
The production history displays the most relevant data of the last 20 productions.
1 2 3 4 5 6 7 8 9 10
1 Work ID 6 Logged in operator

2 Start (when production 7 Target amount
started) 8 Actual amount
3 End (when production produced
ended) 9 Engineering units
4 Phase (actual 10 Material
production phase)
5 Status (status of
production)
.
®
Doc. No. OM-3285384-0112 87 (180)
3.3.9.2 CIP History

To open select navigation button Sterilzer/Pasteurizer and CIP history.
The CIP history displays the most relevant data of the last 20 cleanings.
1 2 3 4 5 6 7 8
1 CipID 5 CIP/IC
2 Start cleaning 6 Logged in operator
3 End cleaning 7 Cleaning program
4 CIP/IC selected
8 Result (Not
cleaned/Cleaned
.
88 (180) Doc. No. OM-3285384-0112

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3.3.10 Sterilizer
The sterilizer window shows the unit line. It contains dynamic information on
operation status for the unit or units.
In the sterilizer window, a second layer of navigation buttons for the sub areas is
available (1).
Button Description
Brings up Production History see page 87
Brings up CIP History see page 88
®
Doc. No. OM-3285384-0112 89 (180)
3.3.11 Trend
To open select navigation button Trend.
In the Trend window, selected parameters are visualized with the selected colour.
1 7
4
5 8
6 9
2 3 10
1 A curve represents the 7 Push here to pick up
selected process selection and setup for
2 Process value range. trends.
3 Settings for time span 8 Move slider right and
current view. left.
4 Reset all pens. 9 Measurement slide,
there are two. Move
5 Update trend. them to check values
6 Auto update trend. and zoom in.
10 Settings for scrolling
historical trends.
.
90 (180) Doc. No. OM-3285384-0112

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3.3.12 Maintenance
To open select navigation button Maintenance and All.
The window displays an overview of all control modules of the plant and their status.
All control module faceplates can also be accessed.
3.3.12.1 Control Modules

Common Navigation buttons in the available control modules.
Automatic mode Manual mode
MANUAL VALUE buttons to change each signal

manually.
The value will be transferred to output when the control
module is in manual mode.
3.3.12.2 Analog Control

The analogue control module faceplate enables commands to the control module
(CM). From there you are able to change also the control module parameters.
(Cont’d)
®
Doc. No. OM-3285384-0112 91 (180)
(Cont’d)
To open select navigation button Maintenance and AI for Analoque In and

Parameters and AO for Analoque Out and Parameters.
3.3.12.2.1 Faceplate Description

Select button (5) for parameters.
1
Status
2 EU value auto 4
EU value
Parameters
Out of range fault
Hardware fault Min EU value 0.00
Control Max EU value 100.00
3 Mode
Min raw value
Max raw value
0.00
27648.00
EU value
Alarm suppress
5
Pos. Description
1 Control module name
2 Status
EU Value – current analog value scaled to engineering unit
that is being transferred to the output.
EU Value auto - analog value scaled to engineering unit. This
value will be moved to the Control Module output when it is
Auto Mode.
Out of Range Fault – When the control module is out of range
Hardware fault – fault coming from hardware diagnostic.
3 Control
Auto Mode
Manual Value – the value that will be transfered to the output.
Alarm Suppress – if selected, the control module will not
generate any alarms.
4 Control Module Parameters
Engineering unit range - (0 to 100 ºC for example).
Raw range – these are values read from/to in/out analog
modules.
.
3.3.12.3 Digital Control

This is the digital control module faceplate from which you can give any command to
the CM: manual mode, simulation mode, etc.. From there you will be able to change
also the control module parameters:
To open select navigation button Maintenance and DI for Digital In and
Parameters, or DO for Digital Out and Parameters.
92 (180) Doc. No. OM-3285384-0112

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Select button (6) for parameters and (7) for extended parameters.
1
2
Status
4 5
IO Value Parameters Extended parameters
Value auto
Value Debounce on time s Oper counter
Hardware fault
3 Debounce off time s Oper time h
Control
Value
7
6 Alarm suppress
Pos. Description
2 Status
IO Value – raw IO value
Value auto – auto value after the IO Value have being filtered
and inverted (if that is the case).
Value – value that will be transferred to the control module
output by copying either EU Value Auto if in Auto mode or
Manue Value if in Manual Mode.
Out of Range Fault – When the control module is out of range
Hardware fault – fault coming from hardware diagnostic.
3 Control
Auto Mode
Manual Value – the value that will be transferred to the output.
Alarm Suppress – if selected, the control module will not
Debounce on – Debounce time to activate
Debounce off – Debounce time to deactivate.
5 Control Module Extended Parameters
Oper counter – Number of activations
Oper time – Total time that the signals has been active
.
3.3.12.4 Valve Control

The valve control module faceplate enables commands to the CM, manual mode,
simulation mode, etcetera. From there you are able to change also the control
module parameters:
To open select navigation button Maintenance and Valve

Note! After using this faceplate, make sure that the control module is working
properly. For example the feedbacks, so that you can turn off both simulation and
alarm suppress modes.
®
Doc. No. OM-3285384-0112 93 (180)

Select button (6) for parameters and (7) for extended parameters.
2
Status
Main1 auto
Upper seat/Main2 auto
Lower seat/auto
Main1
Upper seat/Main2
Lower seat
Activated feedback
Deactivated feedback
Upper seat feedback
Lower seat feedback
4
Parameters
Main1 fault
Main1 dyn act alarm del s
Upper seat/Main2 fault
3 Lower seat fault Main1 dyn deact act alarm del s
Hardwarefault Upper seat/Main2 dyn act alarm del s 5
Control xxxxx s
Extended parameters
xxxxx s
Main1
xxxxx Main1 oper counter
xxxxx Main1 fault counter

Upper seat Main2
xxxxx Upper seat/Main2 oper counter
Lower seat xxxxx
xxxxx
Alarm suppress xxxxx xxxxx
Simultation xxxxx
6
7
Pos. Description
2 Status
Activation commands to the different outputs, feedbacks of
possible positions and alarms.
3 Control
Auto Mode
Manual Value – the value that will be transfered to the output.
Alarm Supress – if selected, the control module will not
Alarm delays, delay to activate, delay to deactivate, etc.
5 Control Module Extended parameters
Activation counters and alarm counter.
.
3.3.12.5 Motor Control

The valve control module faceplate enables commands to the CM, manual mode,
simulation mode, etcetera.. From there you are able to change also the control
module parameters
To open select navigation button Maintenance and Motor control.
94 (180) Doc. No. OM-3285384-0112

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Select button (6) for parameters and (7) for extended parameters
2
Status
Run auto
Low speed auto auto
Reverse auto
Run
xxxx
xxxx
xxxx
xxxx
xxxx
xxxx
4
Parameters
xxxx
xxxx Fwd/Bwd del to switch s
3 xxxx High/Low speed del to switch s
xxxx
Forward dyn start alarm del switch s 5
Control xxxxx s Extended parameters
xxxxx s
Run Run oper time
xxxxx
Forward oper counter
Low speed xxxxx
Forward fault counter
xxxxx
Reverse xxxxx
xxxxx
Alarm suppress xxxxx
xxxxx
xxxxx
Simultation
6
7
Pos. Description
1 Control Module name
2 Status
Activation commands to the different outputs, feedbacks of
different signals and alarms.
3 Control
Auto/manual mode - value that is scaled to engineering unit.
This value are moved to the control module output when it is
Auto Mode.
Manual Value – buttons to change the value that will be
transfered to the CM output when the control module is in
Manual mode
Alarm Supress – if selected, the control module will not
4 Control Module main parameters: alarm delays, delay to
activate, delay to deactivate, etc..
5 Control Module Extended Parameters: activation counters
and alarm counter.
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Doc. No. OM-3285384-0112 95 (180)
3.3.12.6 Communication
To open select navigation button Maintenance and Communication.
The communication window displays the current status of the communication
between the BPU, source and destination.
Note! Signals with asterisk* are optional. For detailed information , see the
communication description "CDN TXXXXXXXXXX" supplied in the Electrical
Manual.
1 2 3
1 Signals coming in
2 Unit
3 Signals going out
.
96 (180) Doc. No. OM-3285384-0112

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3.3.12.7 Phases
By selecting the Phases, the following window shows the status and all parameters
that are related to the internal functionality of the line.
1 3
4
1 Phase button
2 Phase control buttons
command
3 Phase interlocked
signal
4 Interlock description
.
3.3.12.8 How to Start a Phase

First of all, make sure that the interlock symbol is not present, which would indicate
that there is one or more conditions prohibiting the phase to start. If that is the case,
see at conditions what is interlocking the phase.
It might be possible to bypass some interlocks depending on the project specifics.

Once interlocks/running faults are cleared, click on the phase button which will make
the phase text to be highlighted. Then the Start command will be available
For the other command buttons, see page 85

.
®
Doc. No. OM-3285384-0112 97 (180)
3.3.12.9 Production Unit

By selecting the Production, the following faceplate shows up where the status
and all parameters that are related to the internal functionality of the line can be
accessed.
Source (1) and Destination (2) are selected at the HMI controlling the source
and destination.
PRODUCTION (3) is enabled to start when source and destination have been
selected and no interlock/running fault is present.
3.3.13 This Station

To open select navigation button Settings, System,and This station.
Note! Before power shutdown of Control Panel it is necessary to shutdown HMI.
1 2
1 Restart of application
and PC
2 Shutdown of
application and PC
.
98 (180) Doc. No. OM-3285384-0112

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3.3.14 IntelliCIP™ (Option)

Note! Only valid for Indirect UHT units.
The IntelliCIP™ 2.0 (iCIP) is a function that indicates the degree of fouling in the
most critical parts of the tubular heat exchanger (THE). The degree of fouling is
referred to as Relative Fouling Level (RFL in short) and is expressed as an index
value.
The index value is calibrated to work with reference to a verified totally clean
machine and is indicated as RFL value = 1.00.
The iCIP function indicates individual RFL values for different parts of the Tubular
Heat Exchanger (THE).
During production and cleaning iCIP is updating RFL values to indicate the degree of
fouling in the machine as it is developing in production or is removed in cleaning.
In short terms the function is as follows:
a) Starting with a clean machine iCIP will indicate a RFL value ~ 1.0, during
production RFL value will increment to an index value > 1.00.
b) During cleaning AIC or CIP the RFL value will reduce and when the machine is
fully cleaned and all fouling in THE is removed the RFL value will have returned
to ~ 1.0.
Note! If the total CIP program is finished and not all RFL indicators have come to
status “Clean” an alarm is trigged, Alarm text “Cleaning finished without iCIP
.
indicating clean machine”.
®
Doc. No. OM-3285384-0112 99 (180)
3.3.14.1 IntelliCIP Window

To open select navigation button Setting, Parameters, and Intellicip.
The individual CIP sensors (1) are indicated as below. To the right, the highest of the
individual RFL values is presented as the “ruling” RFL (2).
Below each RFL indicator there is a trend indicator. The trend indicator shows
whether the RFL value is changing during a cleaning phase or whether it has
stabilized at a final value, see 3.3.14.2 RFL Trend Indicators page 101.
Setting for safety finalizing timer, Lye / Acid (3) is set based on observations of the
RFL values and an evaluation of cleaning result so that there is a confidence that
the equipment is clean after the set time. The indication (3) displays current
remaining safety time counting down.
Note! If the total CIP program is finished and not all RFL indicators have come to
status “Clean” an alarm is trigged, Alarm text “Cleaning finished without iCIP
indicating clean machine”.
1 2 3 4
5
The illustration shows the intelliCIP window and the RFL graph showing value
graphically.
1 CIP sensors.
2 Ruling RFL.
3 Safety timer.
4 Input field and
indication for limit
clean machine.
5 Activate clean limit
.
100 (180) Doc. No. OM-3285384-0112

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3.3.14.2 RFL Trend Indicators

Below each RFL indicator there is a trend indicator (1). The trend indicator shows
whether the RFL value is changing during a cleaning phase or whether it has
stabilized at a final value. A trend indicator can indicate the following status.
1 = RFL value changing, either increasing or decreasing.

2 = RFL value stable and not changing, flat trend, RFL value indicating value >
clean.
3 = RFL value stable and not changing, flat trend, RFL value indicating value <
clean.
1 2 3
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Doc. No. OM-3285384-0112 101 (180)
3.3.14.3 RFL Graph

During a cleaning phase, the individual RFL value shows a typical development
profile, the characteristics for the profile depends on the placement of the transmitter
and by that the type of fouling.
In general there are two typical profiles for white milk fouling:
Type A: Low temperature range 80 °C – 100 °C, protein based fouling, reacts to lye
cleaning, will initially respond with a increased RFL value in lye phase before
decreasing
Type B: High temperature range 120 °C – 145 °C, mineral based fouling, reacts to
acid cleaning.
Transmitter A, placed in low temp range 75 °C – 95 °C with protein fouling, typical
increased RFL value during dosing then decreasing value during circulation.
Transmitter B, placed in temperature range 95 °C – 125 °C, mixture of protein and

mineral fouling, proteins giving increased RFL value also in this section.
Transmitter D, placed in temperature range 125 °C – 137 °C, mainly mineral fouling,
and no strong reaction in lye dosing phase, and slow decrease of RFL value during
circulation.
An RFL value ≈ 1.00 indicates that the section is clean. An RFL value that is flat, i.e.
is no longer changing during the circulation phase indicates that continued
circulation of cleaning solution will have no further effect in that particular section.
By studying the RFL values during cleaning phases, following their development
graphically it is easy to gain an understanding of the cleaning progress. In both
cases above, if RFL≈ 1.00 or RFL = flat continuation of the cleaning phase will be of
no advatage.
The information gained from following up on RFL values can with advantage be
used to optimise the CIP.
Note! The iCIP is a tool for guidance; it is not an absolute verification of cleaning
results, the normal procedure for evaluation of cleaning result must always be
.
carried out. For more information see “20100218_CIP_Validation_exhibit4”
102 (180) Doc. No. OM-3285384-0112

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3.3.14.4 Clean Machine

When the machine is cleaned, the RFL values indicates a value close to 1.00.
For practical reasons, there is a limit for when status clean should be set. The setting
of this limit is based on evaluation of the cleaning results. Default value for RFL value
clean machine is 0.05, which gives that RFL value ≤ 1.05, and will be considered as
a clean machine.
1
1 Limit “Clean machine”
value presented in the
RFL trend.
2 Input field and
indication for limit
“Clean machine”.
.
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Doc. No. OM-3285384-0112 103 (180)
3.3.14.5 Automatic iCIP

The automatic iCIP function is activated by including the function in the CIP recipe,
see instruction for CIP recipe.
Note! The name of the CIP recipe should indicate that iCIP function is included.
By
When iCIP function is in CIP recipe, circulation phases in cleaning are automatically
finalized based on the RFL value.
The iCIP functions as follows:
• If all active RFL indicators are detecting status “Flat” or “Clean” a safety delay
timer is started. When the timer expires, the circulation phase is finalized.
The machine will not spend unnecessary time in circulation phases if;
• RFL value is “Flat” and no further progress in removal of fouling is expected or,
• RFL value is “Clean” no further removal of fouling is needed.
If safety timer does not expire within the ordinary circulation time, the circulation
phase is finalized by the ordinary step timer. Ordinary step timer works as a max
step timer for the circulation.
Safety time should be set based on observations of the RFL values and an
evaluation of cleaning result so that there is a confidence that the equipment is
clean after the set time. There are individual safety times for Lye and Acid circulation
phases.
1 Current remaining
safety time counting
down
2 Setting for safety
finalizing timer, Lye /
Acid
.
104 (180) Doc. No. OM-3285384-0112

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3.3.14.6 Positioning of Differential Pressure Transmitters

The sections in THE that are monitored for fouling are equipped with differential
pressure transmitters. These transmitters are placed in such a way that the most
critical parts in terms of fouling of the machine are monitored.
Depending on the design and configuration of the actual machine the number and
position of sensors may vary.
B C
D
Section of flow diagram with example of placement of sensors, labelled A - D.

.
3.3.14.7 Calibration
When the machine is calibrated the nominal values for relationship between flow,
media properties and pressure drop are tuned and set in the PLC program. Based on
this nominal setting the RFL value is calculated and displayed as RFL value = 1.00
for status clean machine in each supervised section.
The machine is to be calibrated on cleaning solution during commissioning.

Before calibration of iCIP, the following parameters in the machine are set and the
cleaning solution that is analysed must be within reasonable limits:
• Requested concentration for lye cleaning.
• Requested concentration for acid cleaning.
• Concentrations of lye concentrate.
• Concentration of acid concentrate.
• Density of lye concentrate.
• Density of acid concentrate.
• Temperature settings for High and low temperature CIP set and verified.
If any of the listed parameters have drastically changed or if any of the pressure
transmitters have been exchanged or tampered the iCIP should be recalibrated.
One way of checking if the calibration is still valid is to perform a CIP of an already
clean machine, for more information see Verification of calibration.
3.3.14.8 Calibration Procedure

Before calibration all sections of the machine, which have a CIP sensor, must be
connected and included in the current product recipe.
Note! All sections must be inspected and found to be perfectly clean.

(Cont’d)
®
Doc. No. OM-3285384-0112 105 (180)
(Cont’d)
Calibration can only be selected in water circulation (step 95), so the machine must
be sterilized before calibration.
To start a calibration see 6.6 IntelliCip Start Calibrationon page 164.
Example of machine that is equipped with bypass connections for sections with iCIP
sensor
106 (180) Doc. No. OM-3285384-0112

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3.3.15 Turbidity (Option)

Turbidity meter is used to measure the turbidity in the product to determine the mix
phases between product and water. Note that the turbidity differs between different
products.
The transmitter is not for clear products.
8
7
1 2 3 4 5 6
1 Bar graph and numeric 8 Accumulated volume
display for H51BQ083 for reclaim of low
( set point and process product content and
value). high product content in
2 Trend curves. filling and emptying
3 Indication if pure with the settings in
product level has been point 4-6. Before
reached before enter running production the
step 135 (in values from previous
production). production that is run
with this recipe and
4 Set point when the low with pure product
product content should signal achieved will be
enter the low product displayed.
reclaim tank.
5 Set point when the 9 Volume for reclaim of
high product content low product content
should enter the high and high product
product reclaim tank. content in filling and
emptying from
6 Set point when pure machine properties
product is achieved. recipe..
7 Accumulated total fill
volume if pure product
level is achieved.
.
®
Doc. No. OM-3285384-0112 107 (180)
3.3.15.1 Fine-tuning of Volume with Turbidity Meter H51BQ083

a) Determine which set point you want for, low product content, high product
content, and pure product for the product you are planning to run.
b) Prepare three different samples for this, leave the samples for enough time to
make air go out from the samples.
c) Put the H51BQ08 in the samples without the gasket, make sure that you do not
trap any air in the transmitter.
d) Key in the set points in the recipe after the reading on the BQ083.
Note! Put the pure product set point slightly lower than the value you got from
the sample to make sure that you reach the pure product level.
e) Make sure that the Volume_BQ083_Dest (volume from BQ083 to the first Tetra
Pak Aseptic Tank/Aseptic Filling Machine is correct set).
f) Measure the length of the pipe in meters and multiply with volume/meter for that
diameter of pipe.
Diameter 38 mm = 0.990 litre/meter
Diameter 63.5 mm = 2.875 litre/meter
g) Start production and observe the reading from BQ083 in step 125 and 130.
When the H51BQ083 is placed on the outlet from the sterilizer:

• If the reading is reaching the pure product set point in the end of step 125/130 or
when it has enter step 135, the setting for total A volume is too small.
Adjust accordingly in the volume setting window, you get a suggestion on the
correct volume in the BQ083 window if you reach the pure product level.
• If the reading reach the pure product set point long before it enters step 29, the
setting for total A volume is too large.
Adjust accordingly in the volume setting window, you will get a suggestion on the
correct volume in the BQ083 window if you reach the pure product level.
After the production, enter the values for the accumulated reclaim volumes E1–E4
into recipe.
Note! The settings in point two has to be correct otherwise the values for E1–E4
will not be correct. The transmitter is not for clear products.
Automation variant
The measured volumes (AccumVolE1 - E4 and AccumTotalA) are saved in a local
database when in step 170 if pure product level has been achieved before entering
the product step 135.
The location of the saved volumes depends on which MP set is used in the product
recipe . The saved volumes are displayed on the HMI if not in product phase.
The volumes which are displayed depends on which MPset is used in the product
recipe .
.
108 (180) Doc. No. OM-3285384-0112

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4 Alarms
®
Doc. No. OM-3285384-0112 109 (180)
4 Alarms
About the Alarms Chapter

This chapter contains information on alarms, how they are displayed, and how they
are remediated.
110 (180) Doc. No. OM-3285384-0112

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4 Alarms Table of Contents
About the Alarms Chapter . . . . . . . . . . . . . . . . . . . . . . . 110
4.1 Alarms Navigation ............................................. 113

4.1.1 Alarm Priority . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
4.1.2 Alarm Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
4.2 Active Summary................................................ 114

4.3 Production Recipe ............................................. 115
Create New Recipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Change an available recipe . . . . . . . . . . . . . . . . . . . . . . 116
Procedure Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
4.4 Alarm History ................................................... 119

4.5 Event .............................................................. 120
4.6 Pareto ............................................................. 121
4.7 Alarm List ........................................................ 122
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Doc. No. OM-3285384-0112 111 (180)
4 Alarms
112 (180) Doc. No. OM-3285384-0112

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4 Alarms 4.1 Alarms Navigation
4.1 Alarms Navigation

Under alarms, a second layer of navigation buttons for the sub areas are available.
Brings up 4.2 Active Summary on page 114.

Summary
Brings up 4.4 Alarm History on page 119.
Brings up 4.5 Event on page 120.
Brings up4.6 Pareto on page 121.
4.1.1 Alarm Priority

Name Description Severity
Hazardous alarm Is a critical problem or 1
error
Immediate action Is a severe caution 2
Mandatory action Is a warning 3
4.1.2 Alarm Status

UNACK (active alarm, not ACK (active alarm, UNACK_RTN (returned
Name acknowledge) acknowledge) alarm, not acknowledge)
Hazardous alarm Red (Light) Red Medium grey
Immediate action Yellow (Light) Yellow Medium grey
Mandatory action Blue (Light) Blue Medium grey
®
Doc. No. OM-3285384-0112 113 (180)
4.2 Active Summary 4 Alarms
4.2 Active Summary

To open select navigation button Alarms and Summary.
1 2 3 4 5
1 Time when actual

state occurred
2 Actual state of the
alarm
3 Alarm priority
4 Alarm group
5 Alarm comment
.
114 (180) Doc. No. OM-3285384-0112

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4 Alarms 4.3 Production Recipe
4.3 Production Recipe

To open select navigation button Recipes and Production.
Note! Only available for personnel with higher access levels
1
vv
In the Overview Recipe window touch the
Search button (1) to bring up the Recipe list
and select an available recipe (2).
To create a new recipe continue according to
1
step 2.
xx1 Skimmed Milk Skimmed Milk
xx2 Whole Milk Whole Milk
xx3 Skimmed Milk Skimmed Milk

To change a recipe continue according to
xx4 step 3 Change an available recipe.
2
vv
XX Create New Recipe
XX
a) Select Save As button (1).
b) Type in the new recipe name (2).
c) Select OK button (3) to confirm the
Pasteurised milk
Whole milk recipe.
1000
d) Then select Procedure button (4).
8000
20000
Then continue according to step 4
Procedure Window
TP XXXX 1 TP XXXX 1
TP XXXX 2
1 2 3 4
®
Doc. No. OM-3285384-0112 115 (180)
4.3 Production Recipe 4 Alarms
3
vv
XX Change an available recipe
XX
To change the recipe parameters.
Select Procedure button (1).
Pasteurised milk
Skimmed milk
1000
500
2000
TP XXXX 1 TP XXXX 1
TP XXXX 2
1 2 4
vv
Procedure Window
xx
a) Select the Pencil (1) to create a new
recipe version.
b) Select the Spanner (2) to edit the
recipe parameters.
116 (180) Doc. No. OM-3285384-0112

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4 Alarms 4.3 Production Recipe
3 5
vv
a) Select material parameters as desired
and Save (3).
b) Select process parameters as desired
and Save in the bottom of the window.
c) Select Close to return to the procedure
window.
Add information about important parameters

as; Ke - killing efficiency -z-value -T0 value
Holding tube temperature set-point Holding
tube temperature guard settings Flow rate
set-point Flow guard settings Holding tube
selection Thermal expansion Added steam
(if direct steam applications) Sterilization
temperature guard settings
1 6
vv
a) Select Back (1) for returning to Recipe
xxxxx window.
TP Proccess
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Doc. No. OM-3285384-0112 117 (180)
4.3 Production Recipe 4 Alarms
7
XX
vv
a) Select Validate button (1) and then
XX
Approve(2) the recipe.
b) Select Back button (3) to go back to the
recipe list.
1000
8000
20000
TP XXXX 1 TP XXXX 1
TP XXXX 2
1 2 3
118 (180) Doc. No. OM-3285384-0112

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4 Alarms 4.4 Alarm History
4.4 Alarm History

To open select navigation button Alarms and History.
1 2 3 4 5
1 Time when actual

state occurred
2 Actual state of the
alarm
3 Alarm priority
4 Alarm group
5 Alarm comment
.
®
Doc. No. OM-3285384-0112 119 (180)
4.5 Event 4 Alarms
4.5 Event
To open select navigation button Alarms and Event.
All events are logged here.
2 3
1 Selection of time span

for display
2 Time when actual
state occurred
3 New value
.
120 (180) Doc. No. OM-3285384-0112

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4 Alarms 4.6 Pareto
4.6 Pareto
To open select navigation button Alarms and Pareto.
The alarm pareto window displays the most frequently activated alarms.
1 Selection of time span

to display
.
®
Doc. No. OM-3285384-0112 121 (180)
4.7 Alarm List 4 Alarms
4.7 Alarm List

Alarm text Cause Severity (1 to 3) Instruction to operator
Alarm General:01 Buffer Buffer full 3 -
full
Alarm General:02 Buffer Buffer alarm limit 3 -
alarm limit exceeded exceeded
Alarm General:03 Internal Internal log bufferfault 3 -
log buffer fault
Alarm General:04 Error Error response from 3 -
response from Collection Collection tool
tool
Alarm General:05 No No response from data 3 -
response from data collection tool
collection tool
Alarm General:11 RM RH Watchdog time out 2 -
communication fault
Alarm General:12 RM BK Watchdog time out 2 -
communication fault
Alarm General:13 PLC Watchdog time out 2 -
Pump communication fault
Alarm 01 Too long product Too long product 3 -
circulation time circulation time
Alarm 02 Queued recipe is Queued recipe is not valid 2 -
not valid
Alarm 03 CIP Recipe Sel Wrong CIP/IC recipe 3 Abort wrong recipe in CIP
Fault selected in CIP Unit Unit and select the right
one
Alarm 08 Missing CIP Run Missing CIP Run from 2 Check why CIP unit does
from cipstation in external cipstation in external cip not send the signal CIP run
cip
-
Alarm A01:01 Emergency Emergency stop pressed 1 -
stop pressed
Alarm A01:02 Power First scan or UPS power 1 -
interrupted delay off
Alarm A01:03 Electronic Electronic fuse fault 1 -
fuse fault
Alarm A01:04 Recorder Recorder disc is full 3 -
disc is full
Alarm A01:05 Low air Low air pressure 1 -
pressure
Alarm A01:06 Panel cooler Panel cooler temp fault 3 -
temp fault
Alarm A01:20 Cycle time Cycle time override 3 -
override
- - - -
Alarm A01:22 Diagnostic Diagnostic fault on module 3 -
fault on module
Alarm A01:23 Moduled Moduled removed/added 3 -
removed/added
Alarm A01:24 IO device SYS_DPBUS_FLT 3 -
failure
(Cont’d)
122 (180) Doc. No. OM-3285384-0112

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4 Alarms 4.7 Alarm List
(Cont’d)

Alarm A01:25 Adress fault, Adress fault, module fault 3 -
module fault
- - - -
Alarm A01:27 Program Program Fault - -
Fault
Alarm A01:28 I/O - access I/O - access fault, removed 3 -
fault, removed module module
Alarm A98:01 Prod supply Supply - Product fault 1 -
fault
Alarm A98:02 Water Supply - Water fault 1 -
supply fault
Alarm A98:03 Supply Communication fault 3 -
communication fault supply
Alarm A98:04 Destination Communication fault 3 -
1 communication fault destination 1
Alarm A98:05 Destination Communication fault 3 -
2 communication fault destination 2
Alarm A98:06 Cream line Communication fault 3 -
CIP communication fault cream line CIP unit
Alarm A98:07 Source CIP Communication fault 3 -
communication fault source line CIP unit
Alarm A98:08 Source CIP Communication fault 3 -
communication fault source line CIP unit
Alarm A98:09 Extern CIP Communication fault 3 -
communication fault external CIP unit
Alarm A98:11 Prod Destination - Product fault 1 -
destination fault
Alarm A98:12 Prod drain Destination - Drain not 1 -
not selected or fault selected or fault
Alarm A98:13 Prod reject Destination - Reject LP not 1 -
LP not selected or fault selected or fault
Alarm A98:14 Prod reject Destination - Reject HP not 1 -
HP not selected or fault selected or fault
Alarm A98:21 Cream Destination 2 - Product 1 -
destination fault fault
Alarm A98:22 Cream drain Destination 2 - Drain not 1 -
fault selected or fault
Alarm A98:23 Cream reject Destination 2- Reject not 1 -
fault selected or fault
Alarm A98:31 Alsafe 1 Alsafe 1 steam barrier fault - -
steam barrier fault
steam barrier fault
steam barrier fault
Alarm A98:34 Alsafe 1 Alsafe 1 high level fault - -
high level fault
high level fault
high level fault
(Cont’d)
®
Doc. No. OM-3285384-0112 123 (180)
(Cont’d)

Alarm A98:37 Alsafe 1 Alsafe 1 fault - -
fault
fault
fault
Alarm A98:41 FM 1 steam FM 1 steam barrier fault - -
barrier fault
barrier fault
barrier fault
barrier fault
barrier fault
Alarm A98:46 FM1 fault FM1 fault - -
Alarm A98:61 Alsafe 1 Alsafe 1 communication - -
communication fault fault
Alarm A98:71 FM 1 FM 1 communication fault - -
communication fault
communication fault
communication fault
communication fault
communication fault
- - - -
Alarm A99:01 Machine is Production aborted. 2 Run Emergency Empty to
in idle with product left Machine is in idle with flush product to reject or
inside. product left inside. drain dependning on
selection
Alarm A99:02 Product Water added into product 3 Select appropiate action
diluted with water. to prevent empty BT (production/empty to
reject/drain) dependning
on milk/water mix %
Alarm A99:03 Machine is CIP aborted. Machine is in 3 Run Emergency Empty to
in idle with detergent left idle with detergent left flush detergent to drain
inside. inside. with the selection or wait
for next CIP
(Cont’d)
124 (180) Doc. No. OM-3285384-0112

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(Cont’d)

Alarm A99:09 Holding tube High flow through holding 1 -
time short due to high flow tube
- FSH BF050/BF319
Alarm A99:11 Target Target amount achieved 3 Reset Target and
amount achieved acknowledge alarm, select
next action
Alarm A99:12 No tank in No tank is selected in 3 -
que. queue
Alarm A99:21 Cream Target amount achieved 3 Reset Target and
target amount achieved acknowledge alarm, select
next action
Alarm C01:01 Legal Low temperature at 1 Check steampressure
Holding tube low temp - holding tube - TSL BT335
TSL BT335
Alarm C01:02 Legal High temperature at 1 -
Holding tube high temp - holding tube - TSH BT335
TSH BT335
Alarm C01:03 Legal Low pressure in holding 3 -
Holding tube low press - tube - PSL BP335
PSL BP335
Alarm C01:04 Legal Critical low pressure in 1 -
Holding tube low low press holding tube - PSLL BP335
- PSLL BP335
Alarm C01:05 Legal Legal Holding tube low 1 -
Holding tube low temp temp deviation - BT335
deviation - BT335
Alarm C01:09 Hot divert Hotdivert test failed 3 Check temperature probe
test failed BT335 and Q333 feedback
Alarm C02:01 Stab hold Stabilisation holding tube 1 Check connection and GS
tube connection fault connection fault
Alarm E01:01 Low diff Low diff pressure - 1 -
pressure - DPSL002 DPSL002
(Cont’d)
®
Doc. No. OM-3285384-0112 125 (180)
(Cont’d)

Alarm E01:11 Connection Connection fault - Split 2 Check connection
fault - Split heater Q0302 heater Q0302
Alarm E01:12 Connection Connection fault - Split 2 Check connection
fault - Split heater Q0303 heater Q0303
Alarm E01:18 Low Low differential pressure 1 -
differential pressure
Alarm E01:19 Low Differential pressure fault 1 -
differential pressure at at cream cooler
creamcooler
Alarm E01:20 High safety High safety pressure - 3 -
pressure - PSH BP336 PSH BP336
- - - -
Alarm E01:22 Critical Critical safety pressure - 1 -
safety pressure - PSHH PSHH BP336
BP336
Alarm E01:23 High safety High safety pressure - 3 -
Alarm E01:24 Critical Critical safety pressure - 1 -
safety pressure - PSHH PSHH BP005
BP005
-
Alarm E21:01 Expansion Expansion vessel low level 3 -
vessel low level - LSL - LSL BL110
BL110
Alarm E21:02 Low flow - Low flow in watercircuit - 3 -
FSL FC100 FSL FC100
Alarm E22:01 Expansion Expansion vessel low level 3 -
vessel low level - LSL - LSL BL140
BL140
FSL FC130 FSL FC130
FSL FC160 FSL FC160
Alarm E31:01 Final cooler Connection fault - 2 Check connection
connection fault - TC235M TC235M Final Cooler
Alarm E31:02 High temp - High temp - TSH TC238 3 -
TSH TC238
TSH TC248
TSH TC295
Alarm E37:02 Low temp - Low temp - TSL TC295 3 -
TSL TC295
Alarm E37:03 high press - High press - PSH PC340 3 -
PSH PC340
Alarm E51:01 Low steam Low steam pressure - PSL 1 -
pressure - PSL BP124 BP124)
- - - -
Alarm E51:02 Legal Low temperature at 1 Check steampressure
Holding tube low temp - holding tube - TSL BT125
TSL BT125
(Cont’d)
126 (180) Doc. No. OM-3285384-0112

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(Cont’d)

Alarm E52:01 Low steam Low steam pressure - PSL 1 Check steampressure
pressure - PSL BP154 BP154
Alarm E53:02 High CIP High CIP temp - TSH 2 -
temp - TSH TC175 TC175
Alarm H01:01 Outlet high Outlet high pressure for 3 -
pressure for G0670 - PSH G0670 - PSH BP670
BP670
Alarm H01:02 Outlet Outlet critical pressure for 1 -
critical pressure for G0670 G0670 - PSHH BP670
- PSHH BP670
Alarm H01:03 Inlet low Inlet low pressure for 3 -
pressure for G0670 - PSL G0670 - PSL BP650
BP650
Alarm H01:04 Inlet critical Inlet critical pressure for 1 -
pressure for G0670 - PSLL G0670 - PSLL BP650
BP650
Alarm H01:05 Outlet low Outlet low temp for G0670 2 -
temp for G0670 - Ster TSL - Ster TSL BT670
BT670
Alarm H01:06 Steam Steam barrier low temp - 2 Check steampressure
barrier low temp - Ster TSL Ster TSL BT667
BT667
Alarm H01:07 Homog Homogeniser condensate 2 -
condensate barrier low barrier low temp - Ster TSL
temp - Ster TSL G0670: G0670:BT830
BT830
condensate barrier low barrier low temp - Ster TSL
temp - Ster TSL G0670: G0670:BT831
BT831
BT689
Alarm H01:10 Outlet high Outlet high pressure for 3 -
pressure for split homog - split homog - PSH BP691
PSH BP691
Alarm H01:11 Outlet Outlet critical pressure for 1 -
critical pressure for split split homog - PSHH BP691
homog - PSHH BP691
Alarm H01:12 Homogeniser connection 1 Check connection
Homogeniser connection fault
fault
BT687
(Cont’d)
®
Doc. No. OM-3285384-0112 127 (180)
(Cont’d)

barrier low temp - TSL TSL BT687
BT687
BT667
BT689
Alarm H01:17 Homog Homogeniser condensate 3 Check steampressure
condensate barrier low barrier low temp - TSL
temp - TSL G0670:BT830 G0670:BT830
condensate barrier low barrier low temp - TSL
temp - TSL G0670:BT831 G0670:BT831
Alarm H01:19 Homog Homog damper filter fault - 3 Change filter
damper filter fault - To To many sterilizations
many sterilizations
Alarm H01:20 Inlet low Inlet low temp at overflow 2 -
temp at overflow valve valve Q0685 - Ster TSL
Q0685 - Ster TSL BT685 BT685
BT676
BT676
BT677
BT677
BT682
Alarm H01:26 Homog Homog damper air filling 2 Check low level switch for
damper air filling fault - ID fault - ID inlet damper
Alarm H01:27 Homog Homog damper air filling 2 Check low level switch for
damper air filling fault - OD fault - OD outlet damper
Alarm H01:28 Homog ID Homog damper full fault - 3 Check high level switch for
high level fault - LSH ID inlet damper
BL672
Alarm H01:29 Homog OD Homog damper full fault - 3 Check high level switch for
high level fault - LSH OD outlet damper
BL673
Alarm H01:30 Homog Homog damper filter fault - 2 Change filter
damper filter fault - Lifetime for filter elapsed
Lifetime for filter elapsed
Alarm H01:31 Product low Product low pressure for 2 -
pressure for G0670 - PSL G0670 - PSL G0670:
G0670:BP827 BP827
(Cont’d)
128 (180) Doc. No. OM-3285384-0112

®
(Cont’d)

Alarm H01:32 Product high Product high pressure for 3 -
pressure for G0670 - PSH G0670 - PSH G0670:
G0670:BP827 BP827
Alarm H01:33 High oil level High oil level crankcase in 1 Check oil level
crankcase - G0670: G0670 - G0670:BL835LSH
BL835LSH
Alarm H01:34 Low oil level Low oil level crankcase in 1 Check oil level, fill up
crankcase - G0670: G0670 - G0670:BL835LSL
BL835LSL
Alarm H01:35 High critical High critical oil level 1 Check oil level
oil level crankcase - crankcase in G0670 -
G0670:BL835LSH G0670:BL835LSH
Alarm H01:36 Low critical Low critical oil level 1 Check oil level, fill up
oil level crankcase - crankcase in G0670 -
G0670:BL835LSL G0670:BL835LSL
Alarm H01:37 Low cooling Low cooling water flow in 1 Check water supply
water flow - PSL G0670: G0670 - PSL G0670:
BF846 BF846
Alarm H01:38 Low critical Low critical cooling water 1 Check water supply
cooling water flow - PSL flow in G0670 - PSL
G0670:BF846 G0670:BF846
Alarm H01:39 High oil High oil temp crankcase in 1 -
temp crankcase - TSH G0670 - TSH G0670:
G0670:BT845 BT845
Alarm H01:40 High critical High critical oil temp 1 -
oil temp crankcase - TSHH crankcase in G0670 -
G0670:BT845 TSHH G0670:BT845
Alarm H01:41 Low critical Low critical oil pressure in 1 -
oil pressure - PSL G0670: G0670 - PSL G0670:
BP814 BP814
Alarm H01:42 Clogged oil Clogged oil filter in G0670 - 1 Change oil filter
filter - PS G0670:BP837 PS G0670:BP837
Alarm H01:43 Critical Critical clogged oil filter in 1 Change oil filter
clogged oil filter - PS G0670 - PS G0670:BP837
G0670:BP837
Alarm H01:44 High oil High oil temp crankcase in 1 -
temp crankcase - TSH G0670 - TSH G0670:
G0670:BT841 BT841
oil temp crankcase - TSH crankcase in G0670 - TSH
G0670:BT841 G0670:BT841
Alarm H01:46 High oil High oil temp gearbox in 1 -
temp gearbox - TSH G0670 - TSH G0670:
G0670:BT842 BT842
oil temp gearbox - TSH gearbox in G0670 - TSH
G0670:BT842 G0670:BT842
Alarm H01:48 High High machine temp in 1 -
machine temp - TSH G0670 - TSH G0670:
G0670:BT815 BT815
- - - -
Alarm H11:01 Separator Separator fault - VLT 5000 3 Check Separator Operator
fault - VLT 5000 Error Error Manual
(Cont’d)
®
Doc. No. OM-3285384-0112 129 (180)
(Cont’d)

Alarm H11:02 Separator Separator fault - Vibr: Pre- 3 Check Separator Operator
fault - Vibr: Pre-warning warning Manual
Alarm H11:03 Separator Separator fault - Vibr: 3 Check Separator Operator
fault - Vibr: alarm alarm Manual
Alarm H11:05 Separator Separator fault - Fuse 3 Check Separator Operator
fault - Fuse failure failure Manual
Alarm H11:06 Separator Separator fault - RPM: 3 Check Separator Operator
fault - RPM: rotation rotation Manual
Alarm H11:07 Separator Separator fault - Slow 3 Check Separator Operator
fault - Slow acceleration acceleration Manual
Alarm H11:08 Separator Separator fault - RPM: low 3 Check Separator Operator
fault - RPM: low speed speed Manual
fault - RPM: time out to time out to delta Manual
delta
fault - RPM: high speed high speed Manual
Alarm H11:11 Separator Separator fault - Motor 3 Check Separator Operator
fault - Motor overload overload Manual
Alarm H11:12 Separator Separator fault - Line 3 Check Separator Operator
fault - Line contactor contactor Manual
Alarm H11:13 Separator Separator fault - Delta 3 Check Separator Operator
fault - Delta contactor contactor Manual
Alarm H11:14 Separator Separator fault - High 3 Check Separator Operator
fault - High motor current motor current Manual
Alarm H11:15 Separator Separator fault - Discharge 3 Check Separator Operator
fault - Discharge too large too large Manual
Alarm H11:16 Separator Separator fault - Discharge 3 Check Separator Operator
fault - Discharge too small too small Manual
Alarm H11:17 Separator Separator fault - 3 Check Separator Operator
fault - Emergency button Emergency button Manual
Alarm H11:18 Separator Separator fault - Cover 3 Check Separator Operator
fault - Cover lock switch lock switch Manual
Alarm H11:19 Separator Separator fault - Safety 3 Check Separator Operator
fault - Safety motor switch motor switch Manual
Alarm H11:20 Separator Separator fault - Too 3 Check Separator Operator
fault - Too frequent frequent discharging Manual
discharging
Alarm H11:21 Separator Separator fault - Power 3 Check Separator Operator
fault - Power supply failure supply failure Manual
Alarm H11:22 Separator Separator fault - Battery 3 Check Separator Operator
fault - Battery failure failure Manual
Alarm H11:23 Separator Separator fault - No 3 Check Separator Operator
fault - No current signal current signal Manual
Alarm H11:24 Separator Separator fault - No 3 Check Separator Operator
fault - No vibration signal vibration signal Manual
Alarm H11:25 Separator Separator fault - No speed 3 Check Separator Operator
fault - No speed signal signal Manual
Alarm H11:26 Separator Separator fault - Speed 3 Check Separator Operator
fault - Speed guard Alarm guard Alarm Manual
(Cont’d)
130 (180) Doc. No. OM-3285384-0112

®
(Cont’d)

Alarm H11:27 Separator Separator fault - High 3 Check Separator Operator
fault - High Level Drain Level Drain Manual
Alarm H11:30 Separator Separator fault - Stop time 3 Check Separator Operator
fault - Stop time too long too long Manual
Alarm H11:31 Separator Separator fault - Overhead 3 Check Separator Operator
fault - Overhead tank low tank low level Manual
level
Alarm H11:32 Separator Separator fault - Low water 3 Check Separator Operator
fault - Low water pressure pressure Manual
Alarm H11:33 Separator Separator fault - Stop time 3 Check Separator Operator
fault - Stop time too short too short Manual
Alarm H11:43 Separator Separator fault - Product 3 Check Separator Operator
fault - Product inlet valve inlet valve Manual
Alarm H11:35 Separator Separator fault - CIP valve 3 Check Separator Operator
fault - CIP valve outlet outlet Manual
Alarm H11:36 Separator Separator fault - Drain CIP 3 Check Separator Operator
fault - Drain CIP valve valve Manual
Alarm H11:37 Separator Separator fault - Fault 3 Check Separator Operator
fault - Fault drain valve1 drain valve1 Manual
Alarm H11:38 Separator Separator fault - Fault 3 Check Separator Operator
Alarm H11:39 Separator Separator fault - No speed 3 Check Separator Operator
fault - No speed control control Manual
Alarm H11:40 Separator Separator fault - No PT100 3 Check Separator Operator
fault - No PT100 signal signal Manual
Alarm H11:41 Separator Separator fault - Bearing 3 Check Separator Operator
fault - Bearing temp, alarm temp, alarm Manual
Alarm H11:42 Separator Separator fault - Bearing 3 Check Separator Operator
fault - Bearing temp, temp, shutdown Manual
shutdown
Alarm H11:51 Separator Separator bypassed in 2 -
fault - bypassed product circulation
Alarm H11:52 Separator Separator inlet valve 1 -
fault - low speed closed
Alarm H11:53 Communication fault 1 -
Communication fault - separator
Separator
Alarm H12:01 Bactofuge Bactofuge fault - VLT 5000 3 Check Bactofuge Operator
fault - VLT 5000 Error Error Manual
Alarm H12:02 Bactofuge Bactofuge fault - Vibr: Pre- 3 Check Bactofuge Operator
fault - Vibr: Pre-warning warning Manual
Alarm H12:03 Bactofuge Bactofuge fault - Vibr: 3 Check Bactofuge Operator
fault - Vibr: alarm alarm Manual
Alarm H12:05 Bactofuge Bactofuge fault - Fuse 3 Check Bactofuge Operator
fault - Fuse failure failure Manual
Alarm H12:06 Bactofuge Bactofuge fault - RPM: 3 Check Bactofuge Operator
fault - RPM: rotation rotation Manual
Alarm H12:07 Bactofuge Bactofuge fault - Slow 3 Check Bactofuge Operator
fault - Slow acceleration acceleration Manual
(Cont’d)
®
Doc. No. OM-3285384-0112 131 (180)
(Cont’d)

Alarm H12:08 Bactofuge Bactofuge fault - RPM: low 3 Check Bactofuge Operator
fault - RPM: low speed speed Manual
fault - RPM: time out to time out to delta Manual
delta
fault - RPM: high speed high speed Manual
Alarm H12:11 Bactofuge Bactofuge fault - Motor 3 Check Bactofuge Operator
fault - Motor overload overload Manual
Alarm H12:12 Bactofuge Bactofuge fault - Line 3 Check Bactofuge Operator
fault - Line contactor contactor Manual
Alarm H12:13 Bactofuge Bactofuge fault - Delta 3 Check Bactofuge Operator
fault - Delta contactor contactor Manual
Alarm H12:14 Bactofuge Bactofuge fault - High 3 Check Bactofuge Operator
fault - High motor current motor current Manual
Alarm H12:15 Bactofuge Bactofuge fault - Discharge 3 Check Bactofuge Operator
fault - Discharge too large too large Manual
Alarm H12:16 Bactofuge Bactofuge fault - Discharge 3 Check Bactofuge Operator
fault - Discharge too small too small Manual
Alarm H12:17 Bactofuge Bactofuge fault - 3 Check Bactofuge Operator
fault - Emergency button Emergency button Manual
Alarm H12:18 Bactofuge Bactofuge fault - Cover 3 Check Bactofuge Operator
fault - Cover lock switch lock switch Manual
Alarm H12:19 Bactofuge Bactofuge fault - Safety 3 Check Bactofuge Operator
fault - Safety motor switch motor switch Manual
Alarm H12:20 Bactofuge Bactofuge fault - Too 3 Check Bactofuge Operator
fault - Too frequent frequent discharging Manual
discharging
Alarm H12:21 Bactofuge Bactofuge fault - Power 3 Check Bactofuge Operator
fault - Power supply failure supply failure Manual
Alarm H12:22 Bactofuge Bactofuge fault - Battery 3 Check Bactofuge Operator
fault - Battery failure failure Manual
Alarm H12:23 Bactofuge Bactofuge fault - No 3 Check Bactofuge Operator
fault - No current signal current signal Manual
Alarm H12:24 Bactofuge Bactofuge fault - No 3 Check Bactofuge Operator
fault - No vibration signal vibration signal Manual
Alarm H12:25 Bactofuge Bactofuge fault - No speed 3 Check Bactofuge Operator
fault - No speed signal signal Manual
Alarm H12:26 Bactofuge Bactofuge fault - Speed 3 Check Bactofuge Operator
fault - Speed guard Alarm guard Alarm Manual
Alarm H12:27 Bactofuge Bactofuge fault - High 3 Check Bactofuge Operator
fault - High Level Drain Level Drain Manual
Alarm H12:30 Bactofuge Bactofuge fault - Stop time 3 Check Bactofuge Operator
fault - Stop time too long too long Manual
Alarm H12:31 Bactofuge Bactofuge fault - Overhead 3 Check Bactofuge Operator
fault - Overhead tank low tank low level Manual
level
Alarm H12:32 Bactofuge Bactofuge fault - Low 3 Check Bactofuge Operator
fault - Low water pressure water pressure Manual
(Cont’d)
132 (180) Doc. No. OM-3285384-0112

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(Cont’d)

Alarm H12:33 Bactofuge Bactofuge fault - Stop time 3 Check Bactofuge Operator
fault - Stop time too short too short Manual
Alarm H12:34 Bactofuge Bactofuge fault - Product 3 Check Bactofuge Operator
fault - Product inlet valve inlet valve Manual
Alarm H12:35 Bactofuge Bactofuge fault - CIP valve 3 Check Bactofuge Operator
fault - CIP valve outlet outlet Manual
Alarm H12:36 Bactofuge Bactofuge fault - Drain CIP 3 Check Bactofuge Operator
fault - Drain CIP valve valve Manual
Alarm H12:37 Bactofuge Bactofuge fault - Fault 3 Check Bactofuge Operator
Alarm H12:38 Bactofuge Bactofuge fault - Fault 3 Check Bactofuge Operator
Alarm H12:39 Bactofuge Bactofuge fault - No speed 3 Check Bactofuge Operator
fault - No speed control control Manual
Alarm H12:40 Bactofuge Bactofuge fault - No PT100 3 Check Bactofuge Operator
fault - No PT100 signal signal Manual
Alarm H12:41 Bactofuge Bactofuge fault - Bearing 3 Check Bactofuge Operator
fault - Bearing temp, alarm temp, alarm Manual
Alarm H12:42 Bactofuge Bactofuge fault - Bearing 3 Check Bactofuge Operator
fault - Bearing temp, temp, shutdown Manual
shutdown
Alarm H12:51 Bactofuge Bactofuge bypassed in 2 -
fault - bypassed product circulation
Alarm H12:52 Bactofuge Bactofuge inlet valve 1 -
fault - low speed closed
Alarm H12:53 Communication fault 1 -
Communication fault - Bactofuge
Bactofuge
Alarm H21:01 Stand Unit Any alarm on 3 For details look at
fault - for details look at Standardizing Unit Standardizing Unit HMI
Stand Unit HMI
Alarm H21:02 Stand Unit Standardised cream fat i 3 For details look at
fault - Standardised cream out of limit. Standardizing Unit HMI
fat outside limit
Alarm H21:03 Stand Unit Standardised milk fat i out 3 For details look at
fault - Standardised milk of limit. Standardizing Unit HMI
fat outside limit
Alarm H21:04 Stand Unit The Q-controller does not 3 For details look at
fault - Q fat sum manage to decrease the Standardizing Unit HMI
deviating amount of fat,
alarm.
Alarm H21:05 Stand Unit Severe alarm warning 3 For details look at
fault - Severe alarm Standardizing Unit HMI
warning
Alarm H21:06 Stand Unit Severe alarm requires 1 For details look at
fault - Severe alarm action action Standardizing Unit HMI
Alarm H21:07 Stand Unit Communcation fault 1 -
fault - Communication fault Standardizing Unit
Alarm H21:08 Flowtransmitter broken - 1 For details look at Alfast
Flowtransmitter broken - H00H21FQ319;FT41 HMI
H00H21FQ319;FT41
(Cont’d)
®
Doc. No. OM-3285384-0112 133 (180)
(Cont’d)

Alarm H21:09 Stand Unit Stand Unit fault - Not in 1 Standardising Unit has not
fault - Not in Running Running mode enetered Production mode
mode as requested. End
Production and restart
Alarm H51:01 High critical High critical outlet temp 1 -
outlet temp fault - TSHH fault - TSHH BT080
BT080
Alarm H51:02 High outlet High outlet temp fault - 3 -
temp fault - TSH BT080 TSH BT080
Alarm H51:03 Low outlet Low outlet temp fault - TSL 3 -
temp fault - TSL BT080 BT080
Alarm H51:04 Low critical Low critical outlet temp 1 -
outlet temp fault - TSLL fault - TSLL BT080
BT080
Alarm H51:11 Sterilisation Sterilisation temp fault - 2 -
temp fault - TSL BT085 TSL BT085
Alarm H51:12 CIP Caustic CIP Caustic temp fault - 2 -
temp fault - TSL BT085 TSL BT085
Alarm H51:13 CIP Acid CIP Acid temp fault - TSL 2 -
temp fault - TSL BT085 BT085
- - - -
Alarm H51:21 Low Low detergent 3 -
detergent concentration concentration fault -
fault - BQ089 BQ089
Alarm H51:22 High High detergent 3 -
detergent concentration concentration fault -
fault - BQ089 BQ089
Alarm H51:23 Low Low detergent conductivity 3 -
detergent conductivity fault fault - BQ089
- BQ089
Alarm H51:24 High High detergent 3 -
detergent conductivity fault conductivity fault - BQ089
- BQ089
Alarm H51:25 Product brix Product brix high limit- HL 3 -
high limit- HL BD084 BD084
Alarm H51:26 Product brix Product brix low limit- LL 1 -
low limit- LL BD084 BD084
Alarm H51:27 Feed brix Feed brix low limit- LL 1 -
low limit- LL BD084 BD084
Alarm H51:29 High rinse High rinse water 3 -
water conductivity fault - conductivity fault - BQ089
BQ089
Alarm H56:01 Return high Return high pressure - 3 -
Alarm H61:01 Inlet high Inlet high temp to G0700 - 2 -
temp to G0700 - TSH TSH BT700
BT700
Alarm H61:02 Inlet critical Inlet critical temp to G0700 1 -
temp to G0700 - TSHH - TSHH BT700
BT700
(Cont’d)
134 (180) Doc. No. OM-3285384-0112

®
(Cont’d)

Alarm H61:03 Inlet high Inlet high pressure to 3 -
pressure to G0700 - PSH G0700 - PSH PB700
PB700
Alarm H61:04 Inlet critical Inlet critical pressure to 1 -
pressure to G0700 - PSHH G0700 - PSHH PB700
PB700
PB710
PB710
PB730
PB730
Alarm V01:01 CIP high CIP high level - LSH 3 -
level - LSH BL496 BL496
Alarm V01:02 CIP - Dosing CIP - Dosing time too long 3 -
time too long
Alarm V01:03 CIP - CIP - Metering time too 3 -
Metering time too long long
Alarm V01:04 CIP - CIP interrupted causing an 3 -
Emergency emptying emergency empty*/ flush
of the dosing equipment
Alarm V01:05 CIP - CIP - Concentrate supply 1 Check connection and GS
Concentrate supply pipe pipe not connected to BT
not connected to BT
Alarm V21:01 Low level in Low level in deaerator Eco 3 -
deaerator Eco cooler water cooler water circuit - LSL
circuit - LSL BL427 BL427
Alarm V21:02 To many low To many low level in 3 -
level in deaerator Eco deaerator Eco cooler water
cooler water circuit - LSL circuit - LSL BL427
BL427
Alarm V21:03 Low level in Low level in deaerator 3 -
deaerator vaccum cooler vaccum cooler water circuit
water circuit - LSL BL431 - LSL BL431
Alarm V21:04 Deaerator Deaerator high level fault - 3 -
high level fault - LSH LSH LC419
LC419
Alarm V21:05 Deaerator Deaerator critical level fault 1 -
critical level fault - LSH - LSH BL410. No signal
BL410 from BL410
Alarm V21:09 Connection Connection fault - 3 Check connection and GS
fault - Deaerator Deaerator
Alarm V21:10 High temp - High temp - TSH TC425 3 -
TSH TC425
Alarm V21:11 Inlet high Inlet high temp - TSH 1 -
temp - TSH BT450 BT450
(Cont’d)
®
Doc. No. OM-3285384-0112 135 (180)
(Cont’d)

Alarm V21:12 Inlet critical Inlet critical temp - TSHH 1 -
temp - TSHH BT450 BT450
Alarm V21:13 Vacuumpump critical temp 2 -
Vacuumpump critical temp - TSH BT431
- TSH BT431
Alarm W01:01 Source not Source not enable for CIP 1 -
enable for CIP
- - - -
- - - -
Alarm W01:04 Connection Connection fault - 2 -
fault - Supply/Reject Supply/Reject
Alarm W01:11 BT high BT high level - LSH BP015 2 -
level - LSH BP015
Alarm W01:12 BT product T product low level - LSM 1 -
low level - LSM BP015 BP0155
Alarm W01:13 BT low level BT low level - LSL BP015 1 -
- LSL BP015
Alarm W01:14 BT empty - BT empty - LSLL BP015 1 -
LSLL BP015
Alarm W01:15 Inlet high Inlet high temp - TSH 1 -
Alarm W01:16 Inlet critical Inlet critical temp - TSHH 1 -
Alarm W01:19 BT lid open BT lid open or unlocked 3 -
or unlocked
Alarm W01:25 Low product Low product flow - FSL 3 -
flow - FSL FC050 FC050
Alarm W01:26 Low product Low product flow - FSLL 1 -
flow - FSLL FC050 FC050
Alarm W01:27 High High pressure - PSH 3 -
pressure - PSH BP050 BP050
Alarm W01:28 High High pressure - PSHH 1 -
pressure - PSHH BP050 BP050
Alarm V01:01 CIP high CIP high level - LSH 3 -
level - LSH BL496 BL496
Alarm V01:02 CIP - Dosing CIP - Dosing time too long 3 -
time too long
Alarm V01:03 CIP - CIP - Metering time too 3 -
Metering time too long long
Alarm V01:04 CIP - CIP interrupted causing an 3 -
Emergency emptying emergency empty*/ flush
of the dosing equipment
Alarm V01:05 CIP - CIP - Concentrate supply 1 Check connection and GS
Concentrate supply pipe pipe not connected to BT
not connected to BT
Alarm V21:01 Low level in Low level in deaerator Eco 3 -
deaerator Eco cooler water cooler water circuit - LSL
circuit - LSL BL427 BL427
(Cont’d)
136 (180) Doc. No. OM-3285384-0112

®
(Cont’d)

Alarm V21:02 To many low To many low level in 3 -
level in deaerator Eco deaerator Eco cooler water
cooler water circuit - LSL circuit - LSL BL427
BL427
Alarm V21:03 Low level in Low level in deaerator 3 -
deaerator vaccum cooler vaccum cooler water circuit
water circuit - LSL BL431 - LSL BL431
Alarm V21:04 Deaerator Deaerator high level fault - 3 -
high level fault - LSH LSH LC419
LC419
Alarm V21:05 Deaerator Deaerator critical level fault 1 -
critical level fault - LSH - LSH BL410. No signal
BL410 from BL410
Alarm V21:09 Connection Connection fault - 3 Check connection and GS
fault - Deaerator Deaerator
Alarm V21:10 High temp - High temp - TSH TC425 3 -
TSH TC425
Alarm V21:11 Inlet high Inlet high temp - TSH 1 -
Alarm V21:12 Inlet critical Inlet critical temp - TSHH 1 -
Alarm V21:13 Vacuumpump critical temp 2 -
Vacuumpump critical temp - TSH BT431
- TSH BT431
Alarm V21:14 Outlet high Outlet high pressure from 3
pressure from G0450 - G0450 - PSH BP450
PSH BP450
Alarm V21:15 Outlet Outlet critical pressure 1
critical pressure from from G0450 - PSHH
G0450 - PSHH BP450 BP450
PSH BP450
G0450 - PSHH BP450 BP450
G0450 - PSHH BP450 BP450
PSH BP450
G0450 - PSHH BP450 BP450
Alarm W01:01 Source not Source not enable for CIP 1 -
enable for CIP
- - - -
- - - -
Alarm W01:04 Connection Connection fault - 2 -
fault - Supply/Reject Supply/Reject
Alarm W01:11 BT high BT high level - LSH BP015 2 -
level - LSH BP015
(Cont’d)
®
Doc. No. OM-3285384-0112 137 (180)
(Cont’d)

Alarm W01:12 BT product T product low level - LSM 1 -
low level - LSM BP015 BP0155
Alarm W01:13 BT low level BT low level - LSL BP015 1 -
- LSL BP015
Alarm W01:14 BT empty - BT empty - LSLL BP015 1
LSLL BP015
Alarm W01:15 Inlet high Inlet high temp - TSH 1 -
Alarm W01:16 Inlet critical Inlet critical temp - TSHH 1 -
Alarm W01:19 BT lid open BT lid open or unlocked 3 -
or unlocked
Alarm W01:25 Low product Low product flow - FSL 3 -
flow - FSL FC050 FC050
Alarm W01:26 Low product Low product flow - FSLL 1 -
flow - FSLL FC050 FC050
Alarm W01:27 High High pressure - PSH 3 -
pressure - PSH BP050 BP050
Alarm W01:28 High High pressure - PSHH 1 -
pressure - PSHH BP050 BP050
138 (180) Doc. No. OM-3285384-0112

®
5 Preparations
®
Doc. No. OM-3285384-0112 139 (180)
5 Preparations
About the Preparations Chapter

This chapter contains a list of necessary checkpoints prior to start.
140 (180) Doc. No. OM-3285384-0112

®
5 Preparations Table of Contents
About the Preparations Chapter . . . . . . . . . . . . . . . . . . 140
5.1 General Checkpoints.......................................... 143

5.1.1 Critical Control points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
5.2 Optional Checkpoints......................................... 145
®
Doc. No. OM-3285384-0112 141 (180)
5 Preparations
142 (180) Doc. No. OM-3285384-0112

®
5 Preparations 5.1 General Checkpoints
5.1 General Checkpoints

Before Start
Check that required utilities are available:

• Water
• Steam
• Air
• Electricity
WARNING
Hot part can cause severe burns.
Consider one meter safety distance around the equipment due to hot pipes, valves
and other parts.
WARNING
Risk of burns and scalds.
Prior to operation, make sure to locate the drain areas, due to the risk of jets of hot
steam and other solutions.
Wear suitable personnel protection. Read the safety precaution chapter.
WARNING
Risk of exposure to pressurized hot liquid or cleaning solution
The process equipment may contain trapped hot pressurized liquid in certain areas
even during powerless conditions.
CAUTION
Risk for unsterility and contaminated product
Leaking components and misleading temperature/flow rate may cause unsterility and
contaminate the product.
If a leakage is detected, shut down production and make a CIP. Check/renew leaking
parts prior to start up of a production. Processed product should be stored and
carefully checked for contamination prior to distribution to market. It is recommended
to perform a check/calibration according to local QA system
WARNING
Risk of injury caused by crushing / Risk of burning
Never remove covers or lids during operation
WARNING
Risk of scalds
This machine works under pressurised conditions and high temperatures. To avoid
jets of hot liquid, steam or cleaning solution, make sure that any operation sequence
is finalised, the machine is cooled down and without pressure before disassembling
any parts.
Continuous and systematic leakage check of the equipment must be done:
• During manual preparation.
• During the presterilisation phase.
• In conjunction with production start up.
(Cont’d)
®
Doc. No. OM-3285384-0112 143 (180)
5.1 General Checkpoints 5 Preparations
(Cont’d)
• During production - once every hour.

• During AIC/CIP phase.
CAUTION
Risk of microbiological growth
If the equipment has been idle for a long time, microbiological growth may occur
Several of the following checkpoint are start conditions to be fulfilled before starting
any sequences.
• Check that the equipment is cleaned.
The equipment must be cleaned direct after each production and if the system
has been closed down for a longer time.
Note! After commissioning, always start with a Cleaning In place (CIP) with both
caustic and acid before the first sterilization is started.
• Check that the homogenizer dampers are free from any product residues after
cleaning.
• Check that the homogenizer dampers are refilled with air.
• Check that the steam supplier is drained from condensate.
• Check tightness of all connection.
• Check that the steam switch at the control panel door is in position
• Check that all hand/auto switches are in position Auto.
• Check that the emergency stop button is released.
• Check that the emergency stop relay is reset.
• Check that all applicable downstream equipment are ready for production for
example. steam barriers, AFM (aseptic filling machines), A-tanks (aseptic tanks).
.
5.1.1 Critical Control points

These parameters and set point are critical and important to set correct during
preparation:
• F0 - value
• E0 - value
• PU - value
• z -value
• % - added stream
• % - thermal expansion
• Holding tube temperature set-point to controller
• Holding tube temperature guard limit
• Flow rate set-point to flow controller
• Holding tube selection
• Selection of correct recipe
.
144 (180) Doc. No. OM-3285384-0112

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5 Preparations 5.2 Optional Checkpoints
5.2 Optional Checkpoints

• Check that all motor security breakers are in position on
• Check that the right holding tube according to the product/capacity you are going
to run is correctly connected.
• Check that the extra cooler is correctly connected.
• Check that the correct operation mode is selected.
.
®
Doc. No. OM-3285384-0112 145 (180)
5.2 Optional Checkpoints 5 Preparations
146 (180) Doc. No. OM-3285384-0112

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6 Operation
®
Doc. No. OM-3285384-0112 147 (180)
6 Operation
Description
This chapter describes how to operate the equipment.
148 (180) Doc. No. OM-3285384-0112

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6 Operation Table of Contents
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
6.1 Start Operation ................................................. 151

Sterilizer Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Production Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
6.2 Phases ............................................................ 152

Sterilization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Start Hibernation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Stop Hibernation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Finalize Hibernation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Queue up Next Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Automatic Start/Stop of Hibernation. . . . . . . . . . . . . . . . . . . . . 153
Product Strainer (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Cleaning Phase (IC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Cleaning Phase (CIP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Shutdown Phase. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Emergency Emptying to Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Emergency Emptying to Reject . . . . . . . . . . . . . . . . . . . . . . . . . . 156
6.3 Production ....................................................... 157

Start Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Emptying from Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
6.4 Emergency Stop................................................ 159

Start after Emergency Stop . . . . . . . . . . . . . . . . . . . . . . 159
One Control Panel (Stand Alone) . . . . . . . . . . . . . . . . . 159
Several Control Panels (Simultaneous
Reset). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160
Several Control Panels (Individual Reset) . . . . . . . . . 160
6.5 CIP Recipes...................................................... 161

Edit CIP Recipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Create CIP Recipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
®
Doc. No. OM-3285384-0112 149 (180)
Table of Contents 6 Operation
CIP Recipes In Model editor . . . . . . . . . . . . . . . . . . . . . 162

6.5.1 CIP Recipes Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
6.6 IntelliCip Start Calibration ................................... 164

In Phase Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
In ICIP Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
In Phase Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
6.7 Safety Backup file.............................................. 166

Backup procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
150 (180) Doc. No. OM-3285384-0112

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6 Operation 6.1 Start Operation
6.1 Start Operation

• Turn the electrical supply disconnecting device to position on.
• Turn on all service media.
Note! Make sure that the homogenizer, separators and so on, are prepared for
operation according to the specific operating manuals for homogenizers and
separators.
Sterilizer Window vv
1
In the Pasteurizer/Sterilizer window, touch
the P&ID area (1) to bring up the Production
menu.
1 2 Production Menu vv
Select Phases (1) and continue according to
Production Phases Parameters Alarms Notes Trends page 152.
Conditions
Sterilization
Settings
Selecet Production (2) and continue
Water Circ Recipe according to page 157.
Hibernation
IC
CIP
Shutdown
Emergency Empty
Maintenance
®
Doc. No. OM-3285384-0112 151 (180)
6.2 Phases 6 Operation
6.2 Phases
Production Phases Parameters Alarms Notes Trends
1 Sterilization
Sterilization
Conditions vv
Water Circ
Settings
Recipe
1
Hibernation
Select Sterilization (1) followed by
IC
CIP START (2).
Shutdown
Emergency Empty When the sterilizing sequence reaches step
Maintenance
40, 45, check hot water flow. If necessary,
adjust the flow.
When the sterilizing sequence is completed
the operator can select:
• Hibernation
• Production
2

Conditions
Start Hibernation vv
Sterilization
1 Water Circ
Settings
Recipe
2
Hibernation
Select Hibernation (1) followed by
IC
CIP START (2).
Shutdown
Emergency Empty During hibernation the flow rate is reduced,
Maintenance
cooling is reduced to its minimum and the
vacuum for deaerator is switched off.
Homogenizer is by-passed or stopped if
possible.
Note! Hibernation can started manually or
by a preset time which is 10 minutes by
2 default. It can be adjusted by changing
parameters
Stop Hibernation vv
3
When finalizing the hibernation the process
values ramps back to production setup.
It is possible to stop the hibernation in two
different ways:
• Finalize the hibernation.
• Queue up the next phase.
152 (180) Doc. No. OM-3285384-0112

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6 Operation 6.2 Phases
Conditions
Finalize Hibernation vv
Sterilization
1 Water Circ
Settings
Recipe
4
Hibernation
Select Hibernation (1) followed by
IC
CIP FINALIZE (2).
Shutdown
Emergency Empty The hibernation ends up in water circulation.
Maintenance
Queue up Next Phase vv

5
Queue up the next phase followed by
START
When the hibernation has
recovered/finalized the queued phase starts
Possible phases to queue are:
• STERILIZATION
• WATER CIRC
• IC
• CIP
Note! Production is also available to queue

up.

Conditions
Automatic Start/Stop of vv
Sterilization
1 Water Circ
Settings
Settings
Recipe
Selections 2
Hibernation
Hibernation
IC
Automatic hibernation
6
CIP 3 a) Select Hibernation (1).
Shutdown
Emergency Empty
Maintenance
b) Select Settings/Selections (2).
c) Select Automatic hibernation (3).
®
Doc. No. OM-3285384-0112 153 (180)
Product Strainer (option) vv

7
Machine with a product strainer installed:
a) Remove the filter element before any
CIP.
b) Replace the element with a blind cap.
c) Start CIP any sequence according to
step 8.or 9.
d) Clean the element manually.
e) Install the cleaned element when CIP
sequences are finished.

Conditions
Cleaning Phase (IC) vv
Sterilization
Water Circ
Settings
Recipe 2 8
1 Hibernation
IC
Cleaning reicpe 1
Cleaning recipe 2
CIP 3
Shutdown WARNING
Emergency Empty
Maintenance
Chemical Hazard
Cleaning solution contains caustic soda
(NaOH) or nitric acid (HNO3). These
Download Recipe
chemicals may cause severe burning to skin
and eyes. Use protective clothes, goggles,
and gloves during handling. If exposed -
wash with water for at least 15 minutes.
4 Seek medical assistance. Follow the
5 instructions given by the supplier.
a) Select desired cleaning program IC(1).
b) Select Recipe (2).
c) Select an available recipe (3) IC
Caustic LT or IC Lut.
d) Select Download Recipe (4).
e) Select START button (5)
154 (180) Doc. No. OM-3285384-0112

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6 Operation 6.2 Phases
Cleaning Phase (CIP) vv
WARNING
Chemical Hazard
Cleaning solution contains caustic soda
(NaOH) or nitric acid (HNO3). These
chemicals may cause severe burning to skin
and eyes. Use protective clothes, goggles,
and gloves during handling. If exposed -
wash with water for at least 15 minutes.
Seek medical assistance. Follow the
instructions given by the supplier.
a) Select desired cleaning program CIP
(1).
b) Select Recipe (2).
c) Select an available recipe (3) CIP or
CIP .
d) Select Download Recipe (4).
e) Select START button (5)

Conditions
Shutdown Phase vv
Sterilization
Water Circ
Hibernation
Settings
Recipe 9
IC The shutdown is selected when you want to
1 CIP
close down the equipment without running a
Shutdown
Emergency Empty CIP.
Maintenance
The shutdown phase cools down the

machine below a certain temperature
Download Recipe
(default 40°C) set by a parameter then it
goes to idle (step 0)
Select Shutdown(1) followed by START (2).
®
Doc. No. OM-3285384-0112 155 (180)
Emergency Emptying to vv
Drain
10
a) Select Emergency Empty (1).
b) Select Settings/Selections (2).
2
c) Select Empty to drain (3).
3
d) Select START (4).
1 The equipment start or continue the

emptying phase and divert everything to
drain.
When the emptying to drain phase is

completed, it goes back to idle.

Conditions
Emergency Emptying to vv
Sterilization
Settings
Settings
Reject
Water Circ
Hibernation
Recipe
Selections 2
IC
Empty to drain
Empty to reject HP
11
CIP
Shutdown Empty to reject LP 3 a) Select Emergency Empty (1).
Emergency Empty
Maintenance b) Select Settings/Selections (2).
1 c) Select Empty to reject HP or Empty
to reject LP (3).
d) Select START (4).
156 (180) Doc. No. OM-3285384-0112

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6 Operation 6.3 Production
6.3 Production
Production Phases Arial Alarms Notes Trends 1
vv
Production running Product queue Cream running Cream queue Select Product running.
Recipe Target amount Conditions
Settings
Material ID Actual amount
Recipe
Source Destination
Production Phases Arial Alarms Notes Trends Start Production vv

Production running Product queue Cream running Cream queue
Conditions
2
Recipe Target amount
Settings a) Select Production (1).
Recipe
Recipe 1 b) Select Recipe (2) (if requested).
Source Destination Recipe 2
c) Select a recipe for the production and
2 Download (3) (if requested).
Note! Verify that the correct recipe is
selected.
Production
d) Select START (4)
1 Download Recipe
4
3
®
Doc. No. OM-3285384-0112 157 (180)
6.3 Production 6 Operation
Production Phases Arial Alarms Notes Trends Emptying from Production vv

Conditions
3
Recipe Target amount
Settings If configured with reclaim HP tank or reclaim
Selections
Recipe
Flush supply line
LP tank:
Source Destination
Prod supply 2 • Check that the tank is connected and
ready to receive product.
1 3
Note! It is possible to cancel the selected
"Flush supply line" in production then the
Production
Prod Circulation
rinse of the inlet is omitted. The "Flush
Download Recipe
supply line" will automatically be included
next time the production is running
a) Select Prod supply (1).
b) Select Setting /Selections (2).
c) Select Flush supply line (3).
Production Phases Arial Alarms Notes Trends 4

vv
a) Select PRODUCTION(1).
Recipe Target amount Conditions

Settings b) Select FINALIZE (2).
Selections
Recipe
Source Destination When the emptying phase is completed the

Prod supply
pasteurizer/sterilizer proceeds to Water
circulation (step 95).
Possible phases to queue are:
• WATER CIRC
Production
Prod Circulation • IC
1 2 Download Recipe
• CIP
• SHUT DOWN
• HIBERNATION
158 (180) Doc. No. OM-3285384-0112

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6 Operation 6.4 Emergency Stop
6.4 Emergency Stop

1
vv
When there is a risk of danger to people or to
the machine, push the EMERGENCY STOP
as quickly as possible.
WARNING
Risk of exposure to pressurised hot
liquid or cleaning solution
The process equipment may contain trapped
hot pressurized liquid in certain areas even
during powerless conditions.
To avoid exposure make sure that skilled
maintenance personnel are available before
any remedying action.
CAUTION
Risk of damage to equipment
The cause of the emergency must be
remedied before attempting to restart the
machine.
Pressing the EMERGENCY STOP stops all
pumps and all valves are deactivated.
2
vv
Start after Emergency Stop
Make sure to eliminate the cause of the stop.
Depending on the configuration of the
emergency stop and the number of control
panels that are connected to the processing
equipment the procedures for resetting the
emergency stop vary.
Continue according to applicable
configuration:
• one control panel (stand alone)
• several control panels (simultaneous
reset)
• several control panels (individual reset)
3
vv
One Control Panel (Stand Alone)
a) Release the EMERGENCY STOP .
b) Press the EMERGENCY STOP RESET
.
The emergency stop relay is released
and the blue lamp in the emergency
Stand alone panel stop reset button goes off.
c) Continue according to step 6
®
Doc. No. OM-3285384-0112 159 (180)
6.4 Emergency Stop 6 Operation
4
vv
Several Control Panels
(Simultaneous Reset)
a) Release all EMERGENCY STOPS .
b) Press the EMERGENCY STOP on the
master control panel
The emergency stop relay is released in
each and every cabinet and the blue
lamp in the emergency stop reset
Master control panel, Slave Control panel 1 and slave control
buttons goes off.
panel #
c) Continue according to step 6
5
vv
Several Control Panels (Individual
Reset)
a) Release all EMERGENCY STOPS.
b) Press the EMERGENCY STOP. on the
master control panel
c) Press the EMERGENCY STOP. on
each and every control panel starting
Master control panel, Slave Control panel 1 and slave control with slave control panel one.
panel # The blue lamp in the emergency stop
reset buttons goes off.
d) Continue according to step 6
6
vv
The machine must be emptied using the
emergency emptying.
A CIP must be selected if product has

entered the machine.
Note! For more information see Emergency
Stop Network in the Electrical Manual (EM)
160 (180) Doc. No. OM-3285384-0112

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6 Operation 6.5 CIP Recipes
6.5 CIP Recipes

A CIP recipe consists of activity types (1)with
2 predefined parameters (2) see 6.5.1 CIP
vv
Recipes Descriptionon page 162
The CIP program runs Activity Types from
top to bottom.
1
vv
Edit CIP Recipe
Note! Only available for personnel with
1 higher access levels
2 To open select navigation button Recipes
(1) and CIP (2).
3 a) In the recipe window touch the Search

button (3) to bring up and select an
4 available recipe (4).
2
vv
In this window it is possible to change the
recipe parameters
Edit the parameter you want to change
or/and put in new Activity Type.
Note! Do not use “Enter” after you edited
parameters.
1 2 3
a) Select Validate (1) and then
Approve (2) the recipe.
b) SelectBack (3) to go back to the recipe
list.
®
Doc. No. OM-3285384-0112 161 (180)
6.5 CIP Recipes 6 Operation
Create CIP Recipe vv

3
Edit an old recipe and select SaveAs (1)
with new name.
4
vv
CIP Recipes In Model editor
To open select navigation button Settings
(1) and Model editor (2).
New CIP recipes needs to be linked to right

circuits in Model editor, see chapter 4.8 in
Model editor manual located in HMI.
“Settings”/”Model editor”
1
2
6.5.1 CIP Recipes Description

Activity type Description
Pre rinse Rinse based on volume (step 405 to
420), always included
Intermediate rinse Rinse based on volume (step 465 to
470)
Intermediate rinse conductivity Rinse based on conductivity (step
465 to 470)
Caustic Caustic based on time (step 425 to
460)
CausticCirc2 Extra caustic to be run direct after
Caustic if LTHT (step 425 to 460)
Acid Acid based on time (step 425 to 460)
AcidCirc2 Extra acid to be run direct after Acid
if LTHT (step 425 to 460)
Final rinse Rinse based on volume (step 480 to
495), always included
Final rinse conductivity Rinse based on conductivity (step
480 to 495)
(Cont’d)
162 (180) Doc. No. OM-3285384-0112

®
6 Operation 6.5 CIP Recipes
(Cont’d)
Parameters Description
Time (s) / VolFactor Setup time / volume factor
depending on activity type
(volume factor must be greater than
0.0)
DetergentToDrain (l) Setup volume going to drain in
detergent dosing
PreTemp (°C) Preheater temperature set point
Temp (°C) Heating temperature set point
Flip mode Amount of flip cycles
Concentrate (%) Requested detergent concentration
Ctrl conc Additional dosing if low detergent
concentration (Option)
Intellicip IntelliCIP used/not used in detergent
activity (Option)
Backflush Amount of backflush cycles
Par group High or low flow CIP parameter
setup to be used.
®
Doc. No. OM-3285384-0112 163 (180)
6.6 IntelliCip Start Calibration 6 Operation
6.6 IntelliCip Start Calibration

1
vv
In Phase Window
Select STERILIZATION.
CIP CIP CalibrationRecipe
2
vv
When machine is in STERILE WATER
CIRCULATION (STEP 95), select
calibration recipes for both IC and CIP.
3
vv
In ICIP Window
Select CALIBRATION.
When calibration has been selected an
alarm will be trigged, The alarm text E01:25
ICIP FUNCTION IS SELECTED TO RUN
CALIBRATION is displayed in the header of
the HMI.
With calibration selected the program will

only allow for operator to run a IC followed
by CIP CLEANING. Phases not relevant for
calibration will be interlocked.
From WATER CIRCULATION (STEP 95) it is
possible to select SHUT DOWN, which will
deselect and abort calibration mode.
During the cleaning phases the program will

sample the process parameters during the
circulation steps.
164 (180) Doc. No. OM-3285384-0112

®
6 Operation 6.6 IntelliCip Start Calibration
4
vv
In Phase Window
Select ICIP and START, (calibration recipe).
The machine will perform an IC cleaning in

normal way; after IC finished the program
CIP CIP CalibrationRecipe
will return to water circulation (step 95).
5
vv
Select CIP and START, (calibration recipe).
The calibration cleaning that will be

performed is including all phases possible
for the machine in order to have possibility to
CIP CIP CalibrationRecipe tune process parameters for all
combinations.
After cleaning finished the calibration
cleaning the CIP recipe selection will be
reset to empty recipe.
When calibration CIP is finished the

calibration mode is over and the machine is
ready for normal use again.
®
Doc. No. OM-3285384-0112 165 (180)
6.7 Safety Backup file 6 Operation
6.7 Safety Backup file

Once every day a backup of database is
vv
stored locally in HMI PC.
• PLC parameters
• CIP recipes
• Product recipes
• Alarm history
It is recommended to do a safety backup of

this data when any parameter has been
changed
Backup procedure vv
1
a) When machine is in Idle (Step 0), exit
HMI application
b) Connect a clean virus free USB memory
stick to the HMI PC USB port.
2
vv
Open the File Explorer
166 (180) Doc. No. OM-3285384-0112

®
6 Operation 6.7 Safety Backup file
3
vv
a) Go to location C:\Heating\AutoBackups
b) Copy latest “DBbackupYYMMDD.bak”
to USB memory stick
4
vv
Restart HMI application by starting
WindowViewer
®
Doc. No. OM-3285384-0112 167 (180)
6.7 Safety Backup file 6 Operation
168 (180) Doc. No. OM-3285384-0112

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7 Care and Cleaning
®
Doc. No. OM-3285384-0112 169 (180)
7 Care and Cleaning
About the Care and Cleaning Chapter

This chapter contains a list of necessary checkpoints prior to care and clean the
plant. Most points are always to be done, but others are valid only if the
corresponding equipment is included in the plant.
170 (180) Doc. No. OM-3285384-0112

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7 Care and Cleaning 7.1 Care
7.1 Care
7.1.1 Self closing gate
The platform is supplied with a self-closing gate. Make sure that gate is automatically
closed after opening.
If not the hinges must be cleaned and greased or adjusted.
WARNING
Fall hazard
Make sure that the gate is properly closed when using the platform
The location of the hinges is shown by an arrow.
7.1.2 Safety Signs

Make sure that each safety sign is undamaged and in its correct position after
installation and maintenance. Change all missing or damaged safety signs
immediately.
Clean the steel surface with ethanol or any fat dissolving cleaning agent and let it dry
for 10 minutes before applying the sign. After application, the adhesive of the sign
must harden for 24 hours before the steel surface around the sign is reoiled.
For locations of the safety signs, see the Installation Layout in the Technical Manual
(TeM).
For preventive maintenance intervals, see preventive maintenance list in TeM
(Technical Manual)
For part numbers see item list in TeM (Technical Manual)

.
®
Doc. No. OM-3285384-0112 171 (180)
7.1 Care 7 Care and Cleaning
7.1.3 Vessels
Secure functionality of CIP nozzles daily in tanks and vessels e.g
• Balance tank
• Deareator
• Flash vessel
• Infusion vessel
7.1.4 Label for Pressure Controller

The valve H01Q0665 and H01Q0685 is a overflow valve and has a label stating the
correct pressure. Ensure that the label is in place and readable.
Item in label to be changed

PC51A → H01R0665
PC51C → H01R0665
PC951A → H01R0685
PC951B → H01R0686
172 (180) Doc. No. OM-3285384-0112

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7 Care and Cleaning 7.2 Cleaning
7.2 Cleaning
WARNING
Risk of exposure to pressurised hot liquid or cleaning solution
The process equipment may contain trapped hot pressurized liquid in certain areas
even during powerless conditions. To avoid exposure make sure that skilled
maintenance personnel are available before any remedying action.
7.2.1 Verify Cleaning

Secure that every CIP cycle has been completed with correct flow rate, temperature,
time and concentration. If necessary adjust CIP parameters in CIP recipe.
CAUTION
Risk of chemicals residues
To avoid residues of chemicals in the equipment a pH value of 6,5 to 7,5 measured in
the final rinse water after any type of cleaning sequence is recommended.
Check with a pH meter or similar equipment.
7.2.1.1 Lye/Acid Concentration

Check that the lye and acid concentrations during cleaning are appropriate.
7.2.1.2 Recommended Detergents

Concentration during cleaning
Chemical Concentration Dairy & Food products Beverage products
*Lye NaOH 35% 1.5 - 2.0 wt% 1.0 - 1.5 wt%
Acid HNO3 50% 1.0 - 1.5 wt% 0. 5 -1.0 wt%
*If the lye detergent origin from solids, it must be carefully mixed in order to avoid
solid particles that will cause problems for the feed pumps.
**The equipment will be adjusted during commissioning to achieve the required
cleaning detergent concentration.
CAUTION
Use of combined or complex detergents
To avoid damages make sure that the detergent supplier can guarantee that the
materials in the machine are resistant to the chemicals in the detergent.
.
®
Doc. No. OM-3285384-0112 173 (180)
7.2 Cleaning 7 Care and Cleaning
7.2.1.3 Critical Control Points
WARNING
Risk of scalds
This machine works under pressurised conditions and high temperatures. To avoid
jets of hot liquid, steam or cleaning solution, make sure that any operation sequence
is finalised, the machine is cooled down and without pressure before disassembling
any parts. Hot pressurized product can be entrapped between blockages even
though components are dismantled in other places in the machine.
Always work with highest caution.
It is recommended to, at regular intervals, verify the cleaning result visually and by a
swab test at critical control points.
The number of control points for a specific installation vary due to the order
specification and the installation layout.
Note! Depending on product and running time, the intervals for inspection may
vary. More frequent checks are recommended after commissioning when the
equipment is new and when a new product is introduced.
Note! Always replace EPDM gaskets or o-rings in unions, flanges, and so on, after
reopening due to deformation by compression.
Consider the following as a general recommendation for critical control points:
• Holding tube
• Stabilizing holding tube
• Coolers
• Valves in product side (hot areas)
• Pumps in product side (hot areas)
• Valves with steam barriers
• Homogenizer dampers
• Balance tank;
- Gasket at lid
- Overflow pipe
• Condenser in top of deaerator
• Infusion
Verify functionality of the CIP nozzle, level pipe, distribution plate and the steam inlet
of the infusion vessel
Note! No product enters the area during normal production at the steam inlet. Make
inspection of steam inlet during replacement/maintenance of flange gaskets
• Contherm scrape surface heat exchanger
• Condenser in top deaerator
174 (180) Doc. No. OM-3285384-0112

®
7.2.1.4 Check After Every CIP

7.2.1.4.1 Homogenizer Dampers
To ensure an air cushion inside the homogenizer dampers, disassemble and check
that it is free from any product residue after cleaning,
• check that they are free from any product residue after cleaning,
• clean the dampers manually if necessary,
• drain the dampers after cleaning.
Note! If the homogenizer dampers are equipped with Automatic CIP and Refill of
dampers this check will not be necessary after every CIP.
7.2.1.4.2 Deaerator
If the deaerator is equipped with an ECO cooler, disassemble the silencer
(V21C0431) on the deaerator and
• check that it is free from any product residue after cleaning,
• clean the silencer manually if necessary.
7.2.1.4.3 Balance tank

If the product balance tank has no CIP device it is recommended to clean it manually.
®
Doc. No. OM-3285384-0112 175 (180)
7.2.1.5 At Regulary Intervals

Depending on, product and running time the intervals for inspection may vary.
More frequent checks are recommended after commissioning when the equipment
is new and when a new product is introduced.
• Holding tube
• Stabilizing holding tube
• Final heater
• Coolers
• Pre-heaters
• Valves in product side (hot areas)
• Pumps in product side (hot areas)
• Valves with steam barriers
• Homogenizer dampers
• Balance tank;
- Gasket at lid
- Overflow pipe
• Steam injector
Note! Be sure that steam supply shut off valve is closed and locked
• Contherm scrape surface heat exchanger
• Condenser in top deaerator
• Infusion
Verify functionality of the CIP nozzle and the CIP validate CIP in level pipe,
distribution plate and the steam inlet of the infusion vessel
Note! No product enters the area during normal production at the steam inlet. Make
.
inspection of steam inlet during replacement/maintenance of flange gaskets
176 (180) Doc. No. OM-3285384-0112

®
7.2.2 External Cleaning

DANGERI
DANGER
Hazardous voltage
The electrical supply disconnecting device must be turned off
CAUTION
Risk of destroyed equipment
Do not use foam cleaning or water on control panel or electrical components such as
motors, regulating valves, transmitters etcetera.
• Rinse the walls, the floor, then the equipment.
• Rinse until visually free of soils.
• Use foam cleaning if possible and then spray with water.
• To minimise aerosols and condensation use lowest effective pressure.
• Lower pressure reduces risk of cross contamination and machine damage.
• Minimize spraying the floor once the equipment begins to be rinsed.
• Never use high pressure cleaning equipment due to risk of cross contamination
and failure of electronical equipment over time.
• Important factors are; contact time and concentration of detergent, and
mechanical action.
.
®
Doc. No. OM-3285384-0112 177 (180)
178 (180) Doc. No. OM-3285384-0112

®
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Doc. No. OM-3285384-0112

Doc. No. OM-3285384-0112

Tetra Pak® Indirect UHT

Machine or equipment configurations that

Doc. No. OM-3285384-0112

Tetra Pak Processing Equipment AB

About the Introduction Chapter

6 (180) Doc. No. OM-3285384-0112

About the Introduction Chapter . . . . . . . . . . . . . . . . . . . . . 6

Manual Information ............................................... 9

Machine Introduction .......................................... 12

How to Use This OM ............................................ 18

Assistance and Inquiries...................................... 19

8 (180) Doc. No. OM-3285384-0112

9 General 9.2 Technical Data

Doc. No. MM-2730517-0103 41 (60)

10 (180) Doc. No. OM-3285384-0112

A pointer arrow indicates the position of an object.

A zoom arrow indicates that an object view is

A rotation movement arrow indicates rotational

12 (180) Doc. No. OM-3285384-0112

China RoHS2 Compliance

Year of manufacture: Month:

14 (180) Doc. No. OM-3285384-0112

Secure food safety and quality when introducing new recipes:

Fluids and Chemical Products

Separation of Materials and Components

16 (180) Doc. No. OM-3285384-0112

How to Use This OM

18 (180) Doc. No. OM-3285384-0112

Assistance and Inquiries

This page intentionally left blank

20 (180) Doc. No. OM-3285384-0112

Safety Precaution Instructions

22 (180) Doc. No. OM-3285384-0112

Safety Precaution Instructions. . . . . . . . . . . . . . . . . . . . . 22

Safety Messages Description ................................ 25

Safety Signs ...................................................... 27

Unexpected Stop during any Sequence ................... 29

Safe Manual Handling.......................................... 33

Hazardous Substances ........................................ 35

Work in Confined Spaces ..................................... 38

Working at Height ............................................... 44

24 (180) Doc. No. OM-3285384-0112

Safety Messages Description

Danger indicates an imminently hazardous

26 (180) Doc. No. OM-3285384-0112

ISO Sign ANSI Sign

Risk of eye injury.

To prevent serious injury:

Chemical burn hazard.

Locations of Safety Signs

28 (180) Doc. No. OM-3285384-0112

Unexpected Stop during any Sequence

This could be caused by blockage inside the piping or equipment. In addition, a

Instructions for a normal production stop, see chapter Operation in Operation

Emergency Stop Buttons

The location of the EMERGENCY STOP button is shown by an arrow.

30 (180) Doc. No. OM-3285384-0112

Note! For a complete list of alarms, see the Operation Manual.

32 (180) Doc. No. OM-3285384-0112

Safe Manual Handling