OM

Operation Manual
Tetra Therm® Aseptic Flex

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-3284281-0111

Copyright © 2017 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 Dairy & Beverage Systems AB.

, Tetra Pak, and all other trademarks displayed in this document are the property of the
Tetra Pak International SA. Tetra Pak Dairy & Beverage Systems 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 Dairy & Beverage Systems AB
Ruben Rausings gata
S-221 86 Lund
Sweden

Doc. No. OM-3284281-0111

Issue 2017-11
This document is valid for: Introduction
T5844151389 Safety Precautions
1 General Description
Serial No. / Machine No.
Year of Manufacture Sign. 2 Process Description
3 Control Panel
4 Alarm

OM
Operation Manual
5
6
7
8
Preparations
Operation
Care And Cleaning
Option Machine Edition

Tetra Therm® Aseptic

Flex

Machine or equipment configurations that

this document is valid for are described on
the next page.

Doc. No. OM-3284281-0111

Issue 2017-11

Tetra Pak Dairy & Beverage Systems AB

Valid for:
Name Drawing Specification and Additional Information
Development Step
 Introduction

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Doc. No. OM-3284281-0111 5 (242)
 Introduction

About the Introduction Chapter

This chapter contains basic information about this manual and the related Tetra Pak
equipment.

6 (242) Doc. No. OM-3284281-0111

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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-3284281-0111 7 (242)
Table of Contents Introduction

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

Purpose of the OM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Operator Workflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

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

8 (242) Doc. No. OM-3284281-0111

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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-3284281-0111 9 (242)
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 (242) Doc. No. OM-3284281-0111

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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-3284281-0111 11 (242)
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
Tetra Pak Dairy & Beverage Systems AB
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 (242) Doc. No. OM-3284281-0111

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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 Disassembly and
Removal section in the TeM

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Doc. No. OM-3284281-0111 13 (242)
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 (242) Doc. No. OM-3284281-0111

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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 Tetra Alsafe 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-3284281-0111 15 (242)
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)

16 (242) Doc. No. OM-3284281-0111

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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-3284281-0111 17 (242)
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 (242) Doc. No. OM-3284281-0111

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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
manuals delivered 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-3284281-0111 19 (242)
Assistance and Inquiries Introduction

This page intentionally left blank

20 (242) Doc. No. OM-3284281-0111

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 Safety Precautions

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Doc. No. OM-3284281-0111 21 (242)
 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.
Note! This manual does not cover the safety precaution instructions for the
homogenizer. The safety instructions regarding the homogenizer are included in the
delivered homogenizer documentation.

22 (242) Doc. No. OM-3284281-0111

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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 at Production ............................. 29

Protective Devices .............................................. 30
Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Emergency Stop Push-Buttons . . . . . . . . . . . . . . . . . . . . . . . . 30

Self-Closing Gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Safeguards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Indicating Tower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Safe Manual Handling.......................................... 34

Personal Protection ............................................ 35
Personal Protective Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Noise Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Entanglement Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Hazardous Substances ........................................ 36

Disposal of Chemical Substances . . . . . . . . . . . . . . . . . . . . . . . . . 36
Cleaning and Disinfection Chemicals . . . . . . . . . . . . . . . . . . . . . 37
Emergency Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Supply Systems ................................................. 39

Definition of Lockout Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Electrical Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Residual Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

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Doc. No. OM-3284281-0111 23 (242)
Table of Contents Safety Precautions

Electrical Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Socket Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Steam Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Water Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

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

24 (242) Doc. No. OM-3284281-0111

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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-3284281-0111 25 (242)
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.

26 (242) Doc. No. OM-3284281-0111

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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

Hot surface.
Do not touch.
Follow lockout procedure before maintenance.
Art. No ISO 351552-0008 (100x100 mm)
Art. No ISO 351552-0047 (50x50 mm)
Art . No ANSI 359725-0116

WARNING
Chemical burn hazard.
Wear personal protective
equipment.

Chemical burn hazard.

Wear personal protective equipment.
Art. No ISO 351552-0004(100x100 mm)
Art. No ANSI 359725-0104

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.
Art. No ISO 351552-0065 (50x50 mm)
Art. No ISO 351552-0066(100x100 mm)
Art. No ANSI 90459-7582

(Cont’d)

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Doc. No. OM-3284281-0111 27 (242)
Safety Signs Safety Precautions

(Cont’d)

ISO Sign ANSI Sign

WARNING
Pressurized device.
Can cause serious injury.
Follow instructions for
safe work practice.

Pressurized device
Can cause serious injury. Follow instructions for safe work practice in
place and operating. Read manual before first operating machine. If
manual is missing, contact Tetra Pak.
Art.no ISO 50x50 359705-0017
Art.no ISO 100x100 359705-0018
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.
Art. No ISO 351554-0018 (100x100mm)
Art. No ANSI 90600-5233

CAUTION
Fall hazard.
Be careful when using
stairways and ladders.

Fall hazard
Be careful when using stairways and ladders.
Art. No ISO 351552-0032(100x100 mm)
Art. No ANSI 359735-0100

WARNING
Hazardous noise.
Risk of impaired hearing.
Wear hearing protection.

Hazardous noise.
Risk of impaired hearing. Wear hearing protection.
Art. No ISO 351554-0006 (100x100 mm)
Art. No ANSI 90459-1935

Locations of Safety Signs

The location of the safety signs are clearly marked in the Installation Layout in the
Technical Manual (TeM).

28 (242) Doc. No. OM-3284281-0111

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Safety Precautions Unexpected Stop at Production

Unexpected Stop at Production

At powers failure or any abnormal stop during production, the process equipment
may contain trapped pressurized gas or 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 exposure to gas or residual pressure in the equipment if it has not
been depressurised fully.
To avoid exposure, make sure that skilled personnel is available before any
remedying action.

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Doc. No. OM-3284281-0111 29 (242)
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.

WARNING
Hazardous voltage.
Hazardous voltage remains on this equipment after activating an EMERGENCY
STOP or an interlocking device.

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 Push-Buttons

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

30 (242) Doc. No. OM-3284281-0111

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Safety Precautions Protective Devices

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.

The location of the hinges is shown by an arrow.

WARNING
Fall hazard
Make sure that the gate is properly closed when using the platform

Safeguards

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.
(Cont’d)

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Doc. No. OM-3284281-0111 31 (242)
Protective Devices Safety Precautions

(Cont’d)

WARNING
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
Never stop this equipment by operating an interlocking guard.
The location of each interlocking guard is shown by an arrow.

32 (242) Doc. No. OM-3284281-0111

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Safety Precautions Protective Devices

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
.

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Doc. No. OM-3284281-0111 33 (242)
Safe Manual Handling Safety Precautions

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.

34 (242) Doc. No. OM-3284281-0111

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Safety Precautions Personal Protection

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.
.

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 of chemical.
• 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.

WARNING
Risk of falling.
For safe inspection or maintenance of components that can not be reached from
floor level or platform, use lifting device or shoulder harness.
.

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.
.

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Doc. No. OM-3284281-0111 35 (242)
Hazardous Substances Safety Precautions

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
• the showers work
• an eyewash device, movable or wall-mounted, is available and operational
• additional washing facilities are nearby

Note! Learn the locations of washing facilities 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
.

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Safety Precautions Hazardous Substances

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.
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

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 of chemicals
• proper respiratory equipment, if ventilation is insufficient

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-3284281-0111 37 (242)
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
.

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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.

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Supply Systems Safety Precautions

Electrical Supply

WARNING
Hazardous voltage and moving machinery.
The electrical supply disconnecting device must be turned off and secured with a
lock 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.
Certain maintenance procedures may require electrical supply systems to be on.
These exceptions are clearly stated in the Component instructions.

The illustrations show the electrical supply disconnecting device and its location.

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.

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Safety Precautions Supply Systems

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.
.

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 lock
before maintenance inside the electrical cabinet.
Note! The key to the lock 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 each electrical cabinet is shown by an arrow.

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Doc. No. OM-3284281-0111 41 (242)
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.
.

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Safety Precautions Supply Systems

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.
.

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Doc. No. OM-3284281-0111 43 (242)
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 (242) Doc. No. OM-3284281-0111

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 1 General Description

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Doc. No. OM-3284281-0111 45 (242)
 1 General Description

About the General Description Chapter

This section describes the main parts of the equipment.

46 (242) Doc. No. OM-3284281-0111

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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 Main Components .............................................. 50

1.3 Manual Valve Operation Guide .............................. 51
1.4 Optional Equipment ............................................ 52
1.4.1 Deaeration unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

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 1 General Description

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48 (242) Doc. No. OM-3284281-0111

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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.

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Doc. No. OM-3284281-0111 49 (242)
1.2 Main Components 1 General Description

1.2 Main Components

The figure shows an example of a Tetra Therm Aseptic Flex installation, for the
correct installation drawing please see the Technical Manual (TeM)

2
4

3
4

1
4
1 Feed module with
control panel
2 Deaerator (option)
3 Tetra Pak
Homogenizer
4 Tetra Pak® Tubular
Heat Exchanger

50 (242) Doc. No. OM-3284281-0111

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1 General Description 1.3 Manual Valve Operation Guide

1.3 Manual Valve Operation Guide

1

1
2

2
1

1 Open
2 Closed

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Doc. No. OM-3284281-0111 51 (242)
1.4 Optional Equipment 1 General Description

1.4 Optional Equipment

1.4.1 Deaeration unit
A deaerator is used to extract gases and air from the product before it enters the
heat exchangers final heating zone.

1
5

3 4

1 Vacuum vessel
2 Top cover
3 Vacuum pump
4 Product pump
5 Sight glass

52 (242) Doc. No. OM-3284281-0111

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 2 Process Description

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Doc. No. OM-3284281-0111 53 (242)
 2 Process Description

About the Process Description Chapter

This section describes the process cycles and working principle.

54 (242) Doc. No. OM-3284281-0111

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2 Process Description Table of Contents

About the Process Description Chapter . . . . . . . . . . . . 54

2.1 Introduction ...................................................... 57

2.1.1 Process Cycle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

2.2 Working Principle ............................................... 58

2.2.1 With Spiraflo CMR 75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2.2.2 With Spiraflo CMR 125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
2.2.3 With Spiraflo CM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

2.3 Tetra Alrox Deaeration unit ................................... 63

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 2 Process Description

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2 Process Description 2.1 Introduction

2.1 Introduction
This chapter 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.

2.1.1 Process Cycle

The process cycle (2) is divided into the following phases:
• Sterilization
• Production
• Aseptic intermediate cleaning
• Stop
• Cleaning

1 Process cycle
2 Phase
3 Step

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Doc. No. OM-3284281-0111 57 (242)
2.2 Working Principle 2 Process Description

2.2 Working Principle

2.2.1 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)

58 (242) Doc. No. OM-3284281-0111

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2 Process Description 2.2 Working Principle

(Cont’d)

7
4
2

4 6

1 3
5 8

9
The figure shows a flow diagram for Tetra Therm Aseptic Flex with a Spiraflo CMR 75
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

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Doc. No. OM-3284281-0111 59 (242)
2.2 Working Principle 2 Process Description

2.2.2 With Spiraflo CMR 125

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 sterilization 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
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.

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)

60 (242) Doc. No. OM-3284281-0111

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2 Process Description 2.2 Working Principle

(Cont’d)

1 3
7

8
The figure shows a flow diagram for Tetra Therm Aseptic Flex with a Spiraflo CMR 125
tube heat exchanger, the principle is basically the same with a plate heat exchanger.
1 Product 5 Holding tube
2 Reject to tank 6 Return from filling
3 Balance tank 7 Steam
4 Cooling water 8 Product to filling
.

2.2.3 With Spiraflo CM

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 sterilisation loop in order to minimise the energy
consumption and start up time. After sterilisation, 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 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)

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Doc. No. OM-3284281-0111 61 (242)
2.2 Working Principle 2 Process Description

(Cont’d)

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 sterilisation 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.

4
2

4
5 6

1 3 7

8
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

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2 Process Description 2.3 Tetra Alrox Deaeration unit

2.3 Tetra Alrox Deaeration unit

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
3

5
6

4
1 Product inlet
2 Evaporated gases and
vapour
3 Gas outlet
4 Product outlet
5 Condenser
6 Condensed vapour
7 Cooling water
.

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2.3 Tetra Alrox Deaeration unit 2 Process Description

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 3 Control Panel

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Doc. No. OM-3284281-0111 65 (242)
 3 Control Panel

Description
This chapter describes the control panel and the operator panel with menus

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3 Control Panel Table of Contents

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

3.1 Denomination .................................................... 71

3.2 Operator’s Panel ................................................ 72
3.3 Access Code Levels............................................ 73
3.4 TPOP Description ............................................... 74
3.5 TPOP Description #2 ........................................... 75
3.5.1 Time/Volume, Step, and Recipe Indication . . . . . . . . . . . . . . . . 76

3.6 Buttons and Symbols on the Window Pictures.......... 77

3.6.1 Local/Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
3.6.2 Process Values Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
3.6.3 Function Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
3.6.4 Step/Scroll Buttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
3.6.5 Process Value, Data Input and Indication . . . . . . . . . . . . . . . . . 79
3.6.6 Bar Graph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

3.7 TPOP Windows .................................................. 81

3.7.1 Overview Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
3.7.2 Detailed Overview Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
3.7.3 Operating Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
3.7.3.1 Information Text . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
3.7.3.2 Phase Mode Buttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
3.7.3.3 Control Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
3.7.3.4 Dialogue Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
3.7.3.5 Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
3.7.3.6 One Button Action Area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
3.7.4 Start Condition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
3.7.5 Process Value Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
3.7.6 Alarm List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
3.7.7 Event Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

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Table of Contents 3 Control Panel

3.7.8 Trend Diagram Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

3.7.8.1 Select Pen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

3.7.9 Service Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

3.7.10 Product and Capacity Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
3.7.11 PID Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
3.7.12 Recipe Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
3.7.13 AFM Capacity Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
3.7.14 Force Main Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
3.7.15 Force I/O Valves and Motors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
3.7.15.1 Motor Face Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
3.7.15.2 Valve Face Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
3.7.15.3 Analogue Object . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
3.7.15.3.1 Analogue Input Face Plate . . . . . . . . . . . . . . . . . . . . . 101
3.7.15.4 Volume Set Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
3.7.15.4.1 Bar Graph Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
3.7.15.5 Recipe Edit Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
3.7.15.5.1 Edit Recipe or Recipe name . . . . . . . . . . . . . . . . . . . . 105
3.7.15.5.2 Copy Recipe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
3.7.15.6 PID Recipe Edit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
3.7.15.7 PID Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
3.7.15.8 PID Parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
3.7.15.9 Analog Settings for Motors and Valves . . . . . . . . . . . . . . . . 110
3.7.15.10 Pressure Homogeniser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
3.7.15.11 CIP Concentration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
3.7.15.12 Temperature Guard (TSL42) . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
3.7.15.13 Differential Pressure Guard PSL61-64 (Option) . . . . . . . . 114
3.7.15.14 Pressure Guard PSL847 (Option) . . . . . . . . . . . . . . . . . . . . . . 115
3.7.15.15 Pressure Switch PS66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
3.7.15.16 Flow and Holding Time Guards. . . . . . . . . . . . . . . . . . . . . . . . 117
3.7.15.17 Fo Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
3.7.15.18 Level Switch LS08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
3.7.15.19 Step Forward on Temperature Settings . . . . . . . . . . . . . . . . 120

3.7.16 Logger Sterilization Report page 1. . . . . . . . . . . . . . . . . . . . . . . 121

3.7.17 Logger Sterilization Report page 2. . . . . . . . . . . . . . . . . . . . . . . 122

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3 Control Panel Table of Contents

3.7.18 Logger Production Report page 1 . . . . . . . . . . . . . . . . . . . . . . . 123

3.7.19 Logger Production Report page 2 . . . . . . . . . . . . . . . . . . . . . . . 124
3.7.19.1 PAC and CIP Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
3.7.20 IntelliCIPTM 2.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
3.7.20.1 Trend Indicator Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
3.7.20.2 RFL Graph. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
3.7.20.3 Clean Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
3.7.20.4 Positioning of Differential Pressure Transmitters . . . . . . 130
3.7.20.5 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
3.7.20.5.1 Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . 130
3.7.20.5.2 Start Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

3.7.21 Turbidity Meter QT78 (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

3.7.21.1 How to use turbidity meter QT78 to fine tune volume
settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133

3.7.22 Keyboards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

3.7.22.1 Integer Numbers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
3.7.22.2 Alphanumerical Keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

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3 Control Panel 3.1 Denomination

3.1 Denomination
8
1
2
3
4
7

6
5

1 Temperature recorder
(option).
2 Operator panel.
3 Emergency stop
button.
4 Emergency reset
button.
5 Local/Remote
selector.
6 Electrical supply
disconnecting device.
7 Steam switch On/Off.
8 Indicating tower.
.

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3.2 Operator’s Panel 3 Control Panel

3.2 Operator’s Panel

This processing equipment is controlled by a Programmable Logic Controller (PLC).
This PLC contains several sequences, which control the execution of the necessary
programs for running production, cleaning, and so on.

The necessary number of controllers (regulators) are also integrated into the PLC to
control the analogue subprocesses, such as level, pressure and/or temperature
controls.
A Human Machine Interface (HMI) is used as the link between PLC, the processing
equipment, and the operators. Using the HMI the operator can enter the necessary
commands, enter various process and system parameters and obtain information
about system status. It is possible to retrieve information about the current step of
the system and which sequence is active. If abnormal condition occurs, alarms are
shown on this unit.

This processing equipment can also be connected to an overall control system.

From there, it is possible to enter and receive more or less the same information as
entered and retrieved from the HMI of the system.

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3 Control Panel 3.3 Access Code Levels

3.3 Access Code Levels

Access levels to operators panel are divided into two groups:
• Operators have access to level 0 and 1, see table below
• Supervisors have access to level 0, 1 and 2, see table below

Access status Allows to:

0 = No user View and choose among all the pictures
View and see all values
Alarms, trends
Start and stop sequences
Select Product/Capacity
Take away historic alarms
1 = Operator All possibilities as for No user (0)
2 = Supervisor All possibilities as for No user (0) and also:
-Change parameters
-Run controllers in manual mode
-Force I/O
-Change set points for PID:s and Guards
-Set CIP memory

Passwords
Level 1:

Level 2:

Level 3:

Level 4:

Level 5:

Level 6:

Level 7:

Level 8:
Level 9:

OK

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3.4 TPOP Description 3 Control Panel

3.4 TPOP Description

The TPOP main window displays the buttons and icons used identify the status of
the processing equipment and to access the different sections of the processing
equipment control.

Note! If Date and Time area (1) are pushed the CHANGE TIME AND DATE menu
opens. If current user area (3) is pushed the LOGIN WINDOW opens.
The Header bar (A) contains information as follows.

4 5 6 7

1 2 3

1 Date and time. 5 Force indication.

2 Current window name. 6 PID in manual
3 Current user. indication.
4 Intelligent CIP 7 Local/remote
indication. indication.
.

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3 Control Panel 3.5 TPOP Description #2

3.5 TPOP Description #2

The button bar (B) and the ladder bar (C) contains functions and indications as
follows.

18
17

16

15

14

13

12
11

19
B

1 2 3 4 5 6 7 8 9 10
1 Go to OVERVIEW 8 Go to DATA LOGGER 15 Indication for Aseptic
WINDOW. WINDOW. Intermediate Cleaning
2 Go to OPERATORS 9 Go to SETTING (AIC).
WINDOW. WINDOW. 16 Indication for Cleaning
3 Go to PROCESS 10 Go to PREVIOUS In Place (CIP).
VALUES WINDOW. WINDOW. 17 Indication for
4 Go to ALARM WINDOW. 11 Indication for maintenance.
5 Go to TREND WINDOW. sterilization. 18 Indication for alarm.
6 Go to PRODUCT AND 12 Indication for water Push to jump to ALARM
CAPACITY WINDOW. circulation/hibernation. WINDOW.
7 Go to EVENT LOGGER 13 Indication for 19 Time/Volume, Step
WINDOW. production. and recipe indication.
14 Indication for
shutdown/emergency
empty.

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3.5 TPOP Description #2 3 Control Panel

3.5.1 Time/Volume, Step, and Recipe Indication

There are three possible values for position (4):
• time or volume remaining in current step,
• time (min) accumulated in production or water circulation/hibernation,
• time (sec.) accumulated in water circulation/hibernation when waiting to enter
hibernation.

1
2
3
4

1 Current PID recipe.

2 Current product
recipe.
3 Current step.
4 Time or volume.
.

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 3.6 Buttons and Symbols on the
3 Control Panel Window Pictures

3.6 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 sterilizer determines what is seen on your HMI.
The symbols on the ladder bar tell about the operating / functioning modes of the
machine at any given time.
The illustration shows the different modes for the process STERILIZATION.
Different colour codes on the symbols indicate different status.

The push-button position could be flat not selectable (1), up selectable (2) or down
not selectable (3).
The colour represents the process status,
• Gray-Idle (4).
• Green-Run (5).
• Gray/yellow-Held (6).
• Gray/green-Queue (7).

1 2 3

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3.6 Buttons and Symbols on the
Window Pictures 3 Control Panel

3.6.1 Local/Remote Control

Remote control is selected with a key switch on the front of the control panel, if a
separate master control unit is placed in a remote control room
Local control means that the processing equipment is operated from the local panel
control system.

Note! In local, control it is still possible to change pictures and view the application
from the remote control unit, but it is not possible to operate the module.

1 2

1 Local control.
2 Remote control.
.

3.6.2 Process Values Legend

TI Temperature Indicator (view only)
TC/TIC Temperature Controller (associated with a PID controller)
TSL Temperature Set point Level (associated with set point settings)
PT Pressure Transmitter (view only)
PC/PIC Pressure Controller (associated with a PID controller)
PSL Pressure Set point Level (associated with set point settings)
DP Differential Pressure
LT Level Transmitter (view only)
LC/LIC Level Controller (associated with a PID controller)
LSL Level Set point Level (associated with set point settings)
FI Flow Transmitter (view only)
FC/FIC Flow Controller (associated with a PID controller)
FS Flow Switch (associated with set point settings)

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 3.6 Buttons and Symbols on the
3 Control Panel Window Pictures

3.6.3 Function Buttons

The operator can select certain machine functions by pushing one of these buttons.
Different colour codes on the symbols indicate different status.

Symbol Description Symbol Description

Not selected and not Connected, but not
selectable. selected, not
selectable. (Remote
control).
Not selected and Selected, but not
selectable. correctly connected, not
selectable. (Remote
control).
Connected, but not Selected and correctly
selected, selectable. connected, selectable.

Selected, but not Selected and correctly

correctly connected, connected, not
selectable. selectable.
.

3.6.4 Step/Scroll Buttons

Go to first item/alarm in
list (appears when
complete list not
displayed).
Go up one page in list. Go one page down in
list.

Go up one line in list. Go one line down in list.

3.6.5 Process Value, Data Input and Indication

Process value (1) is identified with a code followed by a number. First letter indicates
parameter or device, second letter indicates that functionality and third letter
indicates extra functions for guards. Data input indicates by a push button (2) with
data field showing the current value.

1 2
First letter Second letter Third letter
Temperature (T) Indication (I) High (H)
Flow (F) Guard/switch (S) Low (L)
Pressure (P) Controller (C)
Conductivity (Q)
Valves (V)
Motors (M)
.

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3.6 Buttons and Symbols on the
Window Pictures 3 Control Panel

3.6.6 Bar Graph

The illustration shows an example of bar graph with numeric display used in various
windows.

3 4 5

1
1 Numeric display. 4 Symbol for set point.
2 Bar graph. 5 Symbol for output.
3 Symbol for input.
.

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3 Control Panel 3.7 TPOP Windows

3.7 TPOP Windows

3.7.1 Overview Window
The overview window is a presented as a simplified flowchart where some process
values and indications of importance are visible.

1
3

1 Product available at 4 AFM (Automatic Filling

BTD (Balance Tank). Machine) /Alsafe tank
2 Output from controller indication Ready.
(0-100%). 5 AFM (Automatic Filling
3 Sterilizer that is filled Machine) /Alsafe tank
with product and indication Production.
signal Product
available to
AFM/Alsafe tank.
.

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3.7 TPOP Windows 3 Control Panel

3.7.2 Detailed Overview Window

The detailed overview screen shows a flowchart where more process values and
data input/indication are available.
The symbols for the DHM (1) the CIP header batch tank (2) and the product balance
tank (3) appears also as push buttons and brings up new detailed window.

3.7.3 Operating Window

The operating window is divided into different areas.

2
6

3
7
4
5

1 Information text. 5 Jump to window

2 Phase mode buttons. buttons.
3 Control buttons. 6 Indication area.
4 Dialogue buttons. 7 One button action
area.
.

3.7.3.1 Information Text

Displays more operating status text.

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3 Control Panel 3.7 TPOP Windows

3.7.3.2 Phase Mode Buttons

The operator need in some circumstance to select phase modes when starting AIC
or CIP. A phase mode button is always used together with a dialogue button.

Symbol Description Symbol Description Symbol Description

Lye Lye/Acid PAC,
cleaning. (Standard Production
CIP). Adapted
Cleaning.
.

3.7.3.3 Control Buttons

Control buttons are always used together with a dialogue button

Symbol Description Symbol Description Symbol Description

Sterilisation Water Hibernation
or fill up circulation
BTD in step
0
Production AIC CIP
Intermediate
CIP

Shut down AIC Mainte-

Emergency nance
empty

Product
supply

3.7.3.4 Dialogue Buttons

These buttons are used to perform different operations such as validating or
cancelling any commands.

Symbol Description Symbol Description Symbol Description

Start. Restart. Hold.

Abort. Finalize.

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3.7 TPOP Windows 3 Control Panel

3.7.3.5 Indications
In this area indications are placed. The different functions are selected via recipe or
similar.

Descrip- Descrip- Descrip-

Symbol tion Symbol tion Symbol tion
Deaerator Extra cooler Holding cell
(option). (option). (2 s)
(optional
values
available
are 15 s, 30
s and 60 s).
Aseptic Timing LAD, Low
Homogeniz- pump Acid
er(option). (option). Products
(option).
.

3.7.3.6 One Button Action Area

In this area, push button with one button action are placed.

Symbol Description
Flush product. If selected then include the flush of the inlet
pipe to the sterilizer and the last flush steps. Cancel the
selection if planned to run a new filling to save water. (Option).
CIP supply line. If selected the flow is routed to supply line by
the valve V15. (Not US Version)

V15 to drain. If selected the flow is routed to drain by the valve

V15.

Disable hibernation. If selected it prevents that the hibernation

function starts automatically after a preset time.

V15 to reject. If selected the flow is routed to a reject tank by

the valve V15. (Not US Version).

Fill aseptic dampers. (TA Flex option).

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3 Control Panel 3.7 TPOP Windows

3.7.4 Start Condition

The start condition window. are divided into two parts where the left part (1) holds
push buttons for all process phases and the right part (2) contains the actual start
condition text.
If there is information concerning any process phase this is to be visualised with an i
on the button.

By pressing a push button with an i corresponding information is displayed in the

start condition text area.

1
2

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3.7 TPOP Windows 3 Control Panel

3.7.5 Process Value Window

The process value window consists of one or more windows displaying the process
values and output values.
If a process value is used in a PID controller, a jump to the corresponding PID
window is possible.

For example, press the selectable indication (1) for LT10 to get to 3.7.15.11 CIP
Concentration.

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3 Control Panel 3.7 TPOP Windows

3.7.6 Alarm List

This window shows only an example of an alarm list. The alarms that are displayed
varies depending on the configuration of the module.
Alarm indication:
• Red colour indicates active alarm, not acknowledged.
• Yellow colour indicates active alarm, acknowledged.
• Green colour indicates history, alarm inactive.

1 2 3

1 Toggle display of
alarm time and date.
2 Erase alarm list.
3 Acknowledge alarms.
.

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3.7 TPOP Windows 3 Control Panel

3.7.7 Event Log

This window shows an event log over main event in the module.

1 Event indications.
2 Toggle date/time
indication on/off.
.

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3 Control Panel 3.7 TPOP Windows

3.7.8 Trend Diagram Window

In the trend window, it is possible to view the trending of six simultaneous values.
This is a trend only and the values is not saved.
The colour of the push button corresponds to the colour of the pen in the trend
diagram.

For example, push the red push button to select a variable for the red pen, see
3.7.8.1 Select Pen .
Note! To bring up historic values, touch the window.

1 Trend curve.
2 Display of selected
value.
3 Select value for pen.
.

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3.7 TPOP Windows 3 Control Panel

3.7.8.1 Select Pen

1 Selected pen colour.

2 Variables to trend.
3 Deselect variable.
.

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3 Control Panel 3.7 TPOP Windows

3.7.9 Service Window

To enter register number, select Register or scroll with arrow keys.
To enter new register value, select New Value.

Value: Displays current value in the register.

Note! Ensure that you are inspecting/changing the correct parameter value since
integer and floating point parameters may have the same number.

4
3

1 2

1 Integer parameter, 3 Target volume (setting

always no decimals and display)
2 Floating point 4 Batch accumulated
parameters, with volume (counts up in
decimals step 29 - 43)
5 Status for sub
sequences

Symbol Description Symbol Description

Change of language Save data to memory card

Set CIP memory Log in

(Cont’d)

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3.7 TPOP Windows 3 Control Panel

(Cont’d)

Symbol Description Symbol Description

Log out Go to volume setting

Change password Go to intelliCIP

Restore saved data from Transfer new value to the

memory card selected parameter

Go to Force Main menu Go to PID overview

Reset filter count

3.7.10 Product and Capacity Window

The machine can be configured for either filling machine selection AFM or capacity
selection CAP.
The tank queuing function works as follows: The queue (stack) positions are filled
up from the bottom in the order that the tank select buttons are pushed. It is emptied
from the bottom with the higher positions shifting down.

When production begins, the tank in position 1 is moved to the active tank position,
the tank in position 2 is moved to position 1, and the tank in position 3 is moved to
position 2.
If a tank that holds a place in the queue is deselected, the tanks above are moved
down in consecutive order.

Note! The AFM indication will occur as push button to bring up AFM Capacity
Configuration Window if logged on as supervisor.
(Cont’d)

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3 Control Panel 3.7 TPOP Windows

(Cont’d)

13

12
1 11
6
2 10
3 9
8
7

4
5
1 Indication and 6 Tank selection buttons. 11 Available capacity
selection of running (Option) span for selected HC.
recipe. 7 Queue position 1. 12 Sum of selected AFM
2 Actual PAC cleaning (priority 1) cap including active
sequence (1-6). 8 Active tank position over capacity.
3 Go to PAC CIP setup 9 Queue position 2. 13 AFM selections and
screen. 10 Queue position 3. indication of nominal
4 Go to Product recipe capacity
edit.
5 Product capacity 1 - 4
with set point in l/h.
(Highest flow rate -
Lowest flow rate)

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3.7 TPOP Windows 3 Control Panel

3.7.11 PID Overview

Push any button to go to corresponding PID controller. Yellow indication shows PID
controller in manual mode.

3.7.12 Recipe Overview

The window displays number and name of the available recipes.

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3 Control Panel 3.7 TPOP Windows

3.7.13 AFM Capacity Configuration

1 4
2

5
3 5
6
3
7

8
9

Pos Description
1 Available production capacities in sterilizer with indication of
selected capacity. Flow set point for flow controller
FC06/FC04.
2 Indication of selected capacity. Program selects the capacity
closest over the selected sum of AFM capacity + active extra
capacity.
3 Return flow from FM back to product BTD (option).
4 Capacity configuration 1- 4
5 Selection of active configuration #.
6 Active capacity configuration.
7 Extra capacity overflow that is needed for start of AFM.
8 Active extra overflow that is needed for begin of AFM.
(Program selects the highest selected as active).
9 Sum of selected nominal AFM capacity.
.

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3.7 TPOP Windows 3 Control Panel

3.7.14 Force Main Window

Press FLEX THE to bring up available valves and motors to force. see 3.7.15 Force
I/O Valves and Motors. Press AI FLEX to bring up available analogue inputs to force
see 3.7.15.3 Analogue Object.

1 2
1 Valves and motors.
2 Analogue inputs.
.

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3 Control Panel 3.7 TPOP Windows

3.7.15 Force I/O Valves and Motors

Depending on what object selected, a motor or valve face plate appears, see
3.7.15.1 Motor Face Plate and 3.7.15.2 Valve Face Plate
Press (1) to reset all forces.

Note! Force of an object may cause actions such as start of pumps, opening of
steam valve and so on.

Symbol Description
Grey. Not forced, not activated.
Green. Not Forced, activated.
Dark yellow. Forced, not activated.
Yellow. Forced, activated.
.

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3.7 TPOP Windows 3 Control Panel

3.7.15.1 Motor Face Plate

1
3 4 5

2
6
7

1 Select to force. 4 Put the object in force 7 Fault counter for the
2 Force activate mode object
3 Force deactivate 5 Release/reset 8 Delay time alarm.
6 Indicate operating time Press the white field to
changed delay time.

In the motor face plate screen it's possible to view the status, change parameters
and force the output of motors.
• To force a motor to the current status: Press (4)
• To change the force status of the motor: If a forced activation of the motor is
requested; Press (4) and (1) followed by (2)
• If a forced deactivation of the motor is requested; Press (4) and (1) followed by
(3)
.

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3.7.15.2 Valve Face Plate

1 2 3

4 5 6 7 9
10

1 Main coil for valve 7 Release/reset

2 Middle position valve 8 Activation counter
3 Lower position valve 9 Fault counter
4 Force activate 10 Delay time alarm.
5 Force deactivate Press the white field to
6 Put the object in force change delay time
mode

In the valve face plate it's possible to view the status, change parameters and force
the output of non single mix proof valves.
To force or change the force status of an object continue as for motors 3.7.15.1
Motor Face Plate on page 98

Note! If a valve with more than one air input, select correct air input to force see
next page.
A = Intermediate position
B = Open valve

PC51A = Help pressure to keep valve closed

PC51C = Help pressure to keep valve closed

PC951A = Help pressure to keep valve closed (if applicable).

PC96A = Help pressure to keep valve closed

Note! This is just a general principle illustration, other valve configurations may
occur see the correct flowchart in the Technical Manual (TeM).
(Cont’d)

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(Cont’d)

3.7.15.3 Analogue Object

Selection of analogue inputs to force, brings up the analogue input face plate see
3.7.15.3.1 Analogue Input Face Plate.

Note! Critical inputs for food safety can not be forced.

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3.7.15.3.1 Analogue Input Face Plate

To force or change the force status of an object continue as for motors see 3.7.15.1
Motor Face Plate on page 98

1
2 3

4
5
6

7
1

1 Select to force 5 Minimum range..

2 Force activate Press the white field to
3 Release/reset change value
4 Maximum range. 6 Actual input
Press the white field to 7 Press the white field to
change value change value
.

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3.7.15.4 Volume Set Up

Symbol (pos 1) indicating that reclaim HP mix zone reached the Reclaim HP tank
machine is sending signal to reclaim destination. Bar graphs (pos 2) indicating
progress of volume counters.

1 2

Volume A Volume from BTD up to AFM / Alsafe (additional equipment such as extra cooler and so on
(Green) adds to this volume).
Volume AB Volume between first AFM and first Tetra Alsafe. (Only when steriliser configured for filling both
(Blue/green) to Tetra Alsafe and direct to AFM.)
Volume AB is added to volume A and subtracted from volume B. (Only if Alsafe is selected )
Volume B (Blue) Volume after AFM / Alsafe back to V75.
Volume C Volume for transport to HP (High product content).
(Orange)
Volume D Volume for transport from HP tank to LP (Low product content) tank..
(Yellow)

Symbol Description Symbol Description Symbol Description

Volume in pipe - LP Volume in pipe - V76 - Volume between first
tank. HP and last tank to be
added if more then one
Alsafe tank
LP Mix when filling HP Mix when filling Mix volume when filling

HP Mix when emptying LP Mix when emptying Mix volume when

emptying

Volume up to AFM / Additional vol. A for Volume A

Alsafe (Including extra equipment ifor
equipment) example HC.

(Cont’d)

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(Cont’d)

Symbol Description Symbol Description Symbol Description

Volume in supply line Mix volume in supply Volume from V71 to first
line AFM/Alsafe

Volume from first Volume after Volume between first

AFM/Alsafe back to V71 AFM/Alsafe back to AFM and first Alsafe.
V75

3.7.15.4.1 Bar Graph Indicator

1
2
3
4
5
6
Position (1) REC HP FILL: Volume counter for keeping track of front end mix zone
HP

Position (2) REC HP EMPT. : Volume counter for keeping track of back end mix zone
HP
Position (3) REC LP FILL : Volume counter for keeping track of front end mix zone
LP

Position (4) REC LP EMPT: Volume counter for keeping track of back end mix zone LP
Position (5) MACH TILL: Volumes counter for keeping track of filling up machine with
pure product. Total step volume for step 27 & 28

Position (6) MACH EMPT: Volumes counter for emptying of machine by filling up
machine with water. Total step volume for step 43 & 44 or step 84
.

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3.7.15.5 Recipe Edit Window

The displayed recipe parameters belong to the selected recipe. After selection or
deselection of extra equipment, the recipe must be saved.

Sym- Sym-
bol Description bol Description
Save changed Go to selected line in
parameters/Execute list.
Copy Recipe.
Go to PID RECIPE Selection of holding cell
EDIT (option). This example
is a holding cell of 4
seconds.
Stabilizing holding cell. LAD, Low Acid
Products (option).

CIP Back Flush Select Flex mode.

(option). (If dual mode only)

Select VTIS mode. Select infuser.

(If dual mode only)
.

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3.7.15.5.1 Edit Recipe or Recipe name

a) Select recipe to edit (1).
b) Select ingredient to edit (2) or recipe name to edit (3).
c) Save (4).

4
3
1

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3.7.15.5.2 Copy Recipe

a) Select recipe to be copied (1).
b) Select recipe to be copy to (2.
c) Execute the copying (3).
If recipe to be copied from differs from the recipe to copy to, the push button
turns yellow.

Note! It is not possible to copy to the running recipe.

1 3 2
.

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3.7.15.6 PID Recipe Edit

Note! The displayed recipe parameters belong to the selected recipe
Recipe 1 reserved for pre-sterilisation.

Recipe 2 reserved for main CIP.

Recipe 4-9 reserved for all other steps. (Selected from main Recipe.)

To edit recipe/recipe name see 3.7.15.5.1 Edit Recipe or Recipe name

Symbol Description Symbol Description

Save changed Go to PID RECIPE EDIT
parameters/Execute Copy
Recipe.
Go to selected line in list.

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3.7.15.7 PID Controller

In the PID controller window it is possible to view and change PID controller mode,
PV, SP and CV values.
Press the screen to bring up historic values.

Note! Save output value, speed signal M6 (Only valid for FIC6) The output value
only has to be saved after that the set point value has been changed. When saving
value the PID controller must have stabilised the flow on the set point value.

Symbol Description Symbol Description

Force to fix value

Enable
Set controller to Set controller to
use manual set use manual
point output
Save output
Go to PID value (Speed
PARAMETERS value M6)
.

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3.7.15.8 PID Parameter

1 2

1 PID parameters
2 Set point values

In the PID parameters window is it possible to view and change PID parameters P
(gain), I (integration time), D (derivation time) and SP (set point) values.

Push buttons for display and change of 3 sets of P,I, D parameters. Running set is
indicated by green rectangle (1) at the bottom of the push button
Note! All parameter values are possible to change by pressing the corresponding
.
value on the window.

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3.7.15.9 Analog Settings for Motors and Valves

Note! M6 setting window only used if flow meter is broken.

1 2

Example for motor M2

1 Output values in % for
different capacities
and program steps.
2 Actual output value.
.

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3.7.15.10 Pressure Homogeniser

1 2

3 4 5 6 7 8
1 Product pressure 5 Increment and
stage 1 (bar) decrement stage 1
2 Product pressure 6 Hydraulic pressure
stage 2 (bar) stage 2
3 Hydraulic pressure 7 Actual output value in
stage 1 (bar) & stage2
4 Actual output value in 8 Increment and
% stage 1 decrement stage 2
.

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3.7.15.11 CIP Concentration

3 4 5 6 7 8 9 10

2
1

11
12 16
13 17
18
19

14 15 20

Pos. Description
1 Current level in the CIP header batch tank. (litres)
2 Current set point in the CIP header batch tank. (litres)
3 Low level in CIP header batch tank used in dosing steps (litres)
4 Medium level in CIP header batch tank used to open water valve in product filling steps.
(litres)
5 High level in CIP header batch tank used when filling up tank before product filling steps.
(litres)
6 Flush level in CIP header batch tank used in dosing steps. (litres)
7 Low level in CIP header batch tank used as safety level in product filling steps.
Calculated value. (litres)
8 Current conductivity. (Option)
9 Current set point conductivity. (Option)
10 Conductivity in the rinse water, used for alarm. (Option)
11 Compensating factor acid for standard CIP program
12 Compensating factor lye for standard CIP program.
13 Actual compensating factor. (Over 1 will give higher concentration and under 1 will give
lower concentration).
14 Step number
15 Remaining time in step (sec.)
16 Actual, lye and acid value for the concentrate concentration (weight %).
17 Actual, lye and acid value for the concentrate density (weight %).
18 Actual, lye and acid value for the requested final concentration (weight %) for standard
CIP program
19 Actual, lye or acid value for final concentration (weight %). Setting for the currently active
sequence in PAC cleaning
20 Currently active values

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3.7.15.12 Temperature Guard (TSL42)

3
4
1 5
2

1 Current set point of the

temperature guard
2 Current input signal to
the temperature guard.
3 Current set point value
4 Actual recipe,
indicates the current
value
5 Step 5-12 sterilizing,
indicates the current
value

Note! High temperature product if set point TIC44 > 100 °C. Low temperature
.
product if set point TIC 44 < 100 °C.

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3.7.15.13 Differential Pressure Guard PSL61-64 (Option)

2 3 4 5
1 Differential pressure
guard (bar)
2 Current pressure (bar)
3 Current pressure (bar)
4 Current delta pressure
(bar)
5 Current delta pressure
set point (bar)
.

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3.7.15.14 Pressure Guard PSL847 (Option)

2 3

1 Differential pressure
guard (bar)
2 Current pressure (bar)
3 Current pressure set
point (bar)
.

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3.7.15.15 Pressure Switch PS66

1 2

3 4 5
1 SPH; alarm high
pressure in hot water
circuit
2 SPL; alarm low
pressure in hot water
circuit
3 Current pressure (bar)
4 Current high alarm
pressure set point
(bar)
5 Current low alarm
pressure set point.
(bar)
.

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3.7.15.16 Flow and Holding Time Guards

If temperature compensation on low flow (Option) the value (2) is calculated. For
example if actual flow is lower than normal the temperature compensation will lower
the sterilization temperature and a longer holding cell time alarm set point will be
calculated.

Note! During change of flow/capacity, holding time alarm is supervising Fo value

instead of time.
The calculated flow index (4) is used if AIC flow is higher than the maximum flow for
the actual holding time (Sterilization temperature is also higher to compensate.) and
a shorter holding cell time alarm set point will be calculated.

If no temperature compensation this value will not be over 1.0 as the sterilization
temperature will not be lowered.

1 2

3 4 5 6 7
1 Deviation guard. (%) 5 Current flow. (l/h)
affects both flow alarm 6 Current maximum flow
and short holding time guard set point. (l/h)
alarm 7 Current minimum flow
2 Current holding time guard set point. (l/h)
alarm limit set point
3 Current holding time
(sec)
4 Calculated flow index
.

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3.7.15.17 Fo Calculation
The display of the current holding time (3) and (8) is taking in consideration flow,
heat expansion and holding cells efficiency.
The sterilization point (4) displays the necessary set point to reach the requested Fo
value.

The display of the current holding cell flow (6) is taking in consideration flow and
heat expansion. (litres/sec).

1 2 3 4

5 6 7 8 9 10

1 Current sterilization 6 Current holding cell

set point from recipe flow
2 Selected holding cells 7 Selected holding cells
nominal Fo value volume (litres)
3 Current holding time 8 Current holding time
4 Sterilization set point 9 Current temperature at
5 Selected holding cells the end of the holding
nominal holding time cell
10 Holding cells current
Fo value
.

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3.7.15.18 Level Switch LS08

The low level set points (1) are used in the machine as condition to step forward as
follows:
• The low level set point H2O is a default set point used if no other is active.
• The FILL/EMP is a set point used in step 23-40 (not 29) or 80 -83.
• The PROD is a set point used in step 29, and CIP is set point used in AIC and CIP
steps.

3
1

1 Low level set points

2 Level set point used to
stop the machine.
3 Display of the level in
the BTD (input level
and alarm).
.

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3.7.15.19 Step Forward on Temperature Settings

2 3
1 Temperature step set
point. (ºC)
2 Current step input.
(ºC)
3 Current step set point
(ºC)
.

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3.7.16 Logger Sterilization Report page 1

1
3 2
5 4
7 6
9 8
11 10 18
13 12
15
1 14
1

16 17

1 Production cycle 7 Total time water 13 Saved lowest HC time

report. circulation (h) during step 7 -12 pre-
2 Sterilization cycle start 8 Total time in sterilizing
3 Sterilizing cycle report production (h) 14 Saved lowest HC temp
4 Time taken step 1 - 9 Efficiency factor during step 6 -12 pre-
step 17 (min.) (Production time of sterilizing
5 Time taken entire total running time %) 15 Saved lowest temp
cycle (h) 10 Total amount of TSL71 during step 6
product (m3) sterilization
6 Number of production 16 Scroll between the 4
starts 11 Capacity index
report pages
12 Efficiency factor filling
machines (Production 17 Scroll between the
time of total time with sterilization cycles
product available %) 18 Historical sterilization
cycles
.

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3.7.17 Logger Sterilization Report page 2

1
3 2
5 4
7 6
17
9 8
11 10
13 12

14

15 16

1 See production cycle 7 Average temp. 13 Total circulation time in

report circulation TSL71 acid during CIP
2 Saved lowest during CIP 14 Number of AIC during
temperature steam 8 Average conductivity a sterilization cycle
barrier on pump shaft circulation QT76 15 Scroll between the 4
seals during lye circulation. report pages
3 Saved lowest 9 Average conductivity 16 Scroll between the
temperature pre- circulation QT76 sterilization cycles
sterilizing guards in during acid circulation.
step 6 17 Historical sterilization
10 Average flow during cycles
4 Type of final CIP high temp. CIP
5 Average temp. circulation
circulation TSL42 11 Average flow during
during high low temp. CIP
temperature CIP circulation
6 Average temp. 12 Total circulation time in
circulation TSL42 lye during CIP
during low
temperature CIP
.

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3.7.18 Logger Production Report page 1

1
3 2
5 4
7 6
9 8 14
11 10

12
13
1 Production cycle 6 Total amount of 11 Saved lowest TSL 42
number product (m3) temp. during step 17-
2 Production cycle start 7 Capacity index 62 production.
3 Sterilization cycle 8 Saved lowest HC time 12 Scroll between the 4
report. Number to during step 17-62 report pages.
indicate which production (s) 13 Scroll between the
sterilization is used for 9 Saved lowest HC sterilisation cycles.
this production. temp. during step 17- 14 Historical production
4 Recipe number 62 production cycles
selected during 10 Saved lowest steam
production. barrier pump shafts
5 Total time in temp during step 17-
production (h) 62 production.
.

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3.7.19 Logger Production Report page 2

1
3 2
5 4
6 11
7

9
10
1 Production cycle 5 Saved lowest Fo value 9 Scroll between the 4
number during step 17-62 report pages
2 Saved highest HC production. 10 Scroll between the
time during step 17-62 6 Increase of pressure sterilization cycles
production. compared with clean 11 Historical sterilization
3 Saved highest HC machine. (Optional) cycles
temp during step 17- 7 Saved highest diff
62 production. temp TE09 - TE44
4 Saved highest Fo during step 17-62
value during step 17- production
62 production. 8 Saved highest RFL
value during
production
.

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3.7.19.1 PAC and CIP Setup

The PAC is a CIP program that can be configured by the operator to fit with the
current production situation.

A PAC cleaning can contain up to six consecutive cleaning sequences. By activating

sequence by sequence from top to bottom the different cleaning sequences are
included in the PAC program.
Note! Excessive cleaning of equipment can shorten life time of equipment.

7 1 2 3 4 5 6

1 Select Lye 5 Set Concentration for

2 Select Acid sequence
3 Select type HT CIP 6 Set Circulation Time
sequence for sequence
4 Select type LT CIP 7 Sequence number
sequence 8 Total number and
currently active
sequence number
.

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3.7.20 IntelliCIPTM 2.0

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.

In the HMI all functionality for iCIP is presented in two windows, one with numeric
RFL values and settings, the intelliCIP window and the RFL graph showing value
graphically.
The automatic iCIP function is activated by a push button (1). When the iCIP is
selected active an icon is indicated to the right in the main header in HMI and on the
push buttons for CIP selection in the operator menu a small “i” is indicated.

The individual CIP sensors are indicated as below (3). To the right the highest of the
individual RFL values is presented as the “ruling” RFL (4)
Below each RFL indicator there is a trend indicator (5). The trend indicator shows
whether the RFL value is changing during a cleaning phase or whether it has
stabilized at a final value.

Setting for safety finalizing timer, Lye / Acid (6) 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 (7) displays current
remaining safety time counting down.
.

(Cont’d)

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(Cont’d)

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”.

4
1

2
9 7

6 8

The illustration shows the intelliCIP window and the RFL graph showing value
graphically.
1 Trend indicator. 6 Safety timer.
2 Bring up the RFL value 7 Remaining safety time.
graph. 8 Indication and setting
3 CIP sensors. circulation time normal
4 Ruling RFL. CIP.
5 Trend indicator. 9 Input field and
indication for limit
“Clean Machine”.
.

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3.7.20.1 Trend Indicator Status

Status:
• RFL value changing either increasing or decreasing (pos 1).
• RFL value stable and not changing , flat trend, RFL value indicating value > clean
(pos 2).
• RFL value stable and not changing , flat trend, RFL value indicating value < clean
(pos 3).

1 2 3
.

3.7.20.2 RFL Graph

During a cleaning phase the individual RFL values will show a typical development
profile, the characteristics for the profile depends on the placement of the transmitter
and by that the type of fouling see page .
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 – 145°C, mineral based fouling, reacts to
acid cleaning.

Transmitter A, placed in low temp range 75 - 95 °C with protein fouling, typical

increased RFL value during dosing then decreasing value during circulation.

Transmitter B, placed in temperature range 95 - 125 °C, mixture of protein and

mineral fouling, proteins giving increased RFL value also in this section.
Transmitter D, placed in temperature range 125 - 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 advantage.

The information gained from following up on RFL values can with advantage be
used to optimise the CIP.

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3.7.20.3 Clean Machine

When the machine is cleaned the RFL values (9) (see3.7.20 IntelliCIPTM 2.0) should
indicate 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 must be based on evaluation of the cleaning results. Default
value for RFL value clean machine (1) is 0,02 which gives that RFL value ≤ 1,02 will
be considered as a clean machine.

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.
The illustration shows a typical graph for lye dosing.

1 2
1 Limit “Clean machine”
value (1.02) is
presented also in the
RFL trend
2 Trend RFL values and
“Clean machine” value
represented as trend.
.

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3.7.20.4 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.

.

3.7.20.5 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.

Prior to calibration of iCIP the following parameters in the machine should have
been set and the cleaning solution should have been analysed and be within
reasonable limits:
• Requested concentration for lye cleaning.
• Requested concentration for acid cleaning.
• Concentration 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 above listed parameters have drastically changed or if any of the
pressure transmitters have been exchanged or tampered the iCIP should be
recalibrated
3.7.20.5.1 Calibration Procedure
Prior to 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)

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(Cont’d)

Calibration can only be selected Water circulation (step 17), so the machine must be
sterilized prior to calibration.

Example of machine equipped with by pas connections for sections with iCIP sensor

3.7.20.5.2 Start Calibration

In sterile water (step 17)
Go toICIP WINDOW and select CALIBRATION (1),

When calibration has been started an indication with the text Calibration iCIP
will be displayed (2) in the phase status ladder to the right.
(Cont’d)

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(Cont’d)

3 1

From the operators window, with calibration selected it will be necessary to run a full
AIC followed by full PAC cleaning see Cleaning Sequence in chapter Operation.
Only the required function will be available on the HMI at any stage.

When selecting full AIC cleaning, the machine will perform an AIC cleaning in
normal way; after AIC finished the program will return to Water circulation (step 17).
When selecting PAC cleaning, the PAC cleaning that will be performed is including
all phases possible for the machine in order to have possibility to tune process
parameters for all combinations. After PAC cleaning finished the PAC set up will be
restored to settings as prior calibration.

When PAC cleaning is finished the calibration mode is over and the machine is
ready for normal use again.
Only the required function will be available on the HMI at any stage.

From step 17 it is also possible to select shut down, which will deselect calibration
mode see Shut Down sequence chapter Operation.
During cleaning the program will sample the process parameters during the
circulation steps. The number of sampled values can be seen in the iCIP picture as
shown above (3)

3.7.21 Turbidity Meter QT78 (Option)

Turbidity meter measures the turbidity in the product to determine the mix phases
between product and water. Note that the turbidity will differ between different
products.
(Cont’d)

132 (242) Doc. No. OM-3284281-0111

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3 Control Panel 3.7 TPOP Windows

(Cont’d)

1
2

3
8

4 5 6 7 9
Pos Description
1 Bar graph and numerical display for QT78 (actual setpoint and
process value).
2 Trend curves.
3 Indication if pure product level has been reached before enter
step 29 (in production).
4 Setpoint when the low product content should enter the low
product reclaim tank.
5 Setpoint when the high product content should enter the high
product reclaim tank.
6 Setpoint when pure product is achieved.
7 Accumulated total fill volume if pure product level is achieved.
8 Accumulated volume for reclaim of low product content and
high product content in filling and emptying with the settings in
point 4 - 6. Before running production the values from previous
production run with this recipe and with pure product signal
achieved will be displayed.
9 Volume for reclaim of low product content and high product
content in filling and emptying from running recipe.

3.7.21.1 How to use turbidity meter QT78 to fine tune volume settings
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. (Just prepare
three different samples for this, leave the samples for enough time to make air
go out from the samples. Put the QT78 in the samples without the gasket, make
sure that you do not trap any air in the transmitter and key in the set points in the
recipe after the reading on the QT78.

(Cont’d)

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3.7 TPOP Windows 3 Control Panel

(Cont’d)

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.
b) Make sure that the M volume (volume from OT78 to the first Alsafe/AFM) is
correct set. Just measure the length of the pipe in meters and multiply with
volume/meter for that diameter of pipe.
Ø 38mm = 0.990 liters/meter
Ø 51mm = 1.847 liters/meter
Ø 63.5mm = 2.875 liters/meter
Ø 76mm = 4.072 liters/meter
c) Start production and observe the reading from QT78 in step 27 and 28.
When the QT78 is placed on the outlet from the sterilizer.
If the reading is reaching the pure product set point in the end of step 27/28 or
when it has enter step 29 the setting for total A volume is to little.
d) Adjust accordingly in the volume setting screen, you will get a suggestion on the
correct volume in the QT78 screen 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 to big.
e) Adjust accordingly in the volume setting screen, a suggestion on the correct
volume will be displayed in the QT78 screen if the pure product level is
reached.
f) 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 suitable for clear products.

3.7.22 Keyboards
Different operator commands will bring up different keyboards on the screen.

134 (242) Doc. No. OM-3284281-0111

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3 Control Panel 3.7 TPOP Windows

3.7.22.1 Integer Numbers

The keyboard to the left in the illustration below will be brought up on the screen if
the operator for example wants to choose a recipe number.
The keyboard to the right in the illustration below will be brought up on the screen if
the operator for example wants to change a floating point number.

1 2
1 Integer numbers
2 Floating point numbers
.

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3.7 TPOP Windows 3 Control Panel

3.7.22.2 Alphanumerical Keyboard

The keyboard (1) in the illustration will be brought up on the screen if the user for
example wants to log in.
By pressing the key A-Z or 0-9 the operator brings up different keyboards.

136 (242) Doc. No. OM-3284281-0111

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 4 Alarm

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Doc. No. OM-3284281-0111 137 (242)
 4 Alarm

Description
This chapter describes what to do when alarms occur, and how to read the alarm
list.

138 (242) Doc. No. OM-3284281-0111

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4 Alarm Table of Contents

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

4.1 Alarm Handling ................................................. 141

4.2 Alarm.............................................................. 142
4.3 Fault List ......................................................... 143

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4 Alarm 4.1 Alarm Handling

4.1 Alarm Handling

Press the ALARM WINDOW button to bring up the Alarm list to identify the alarm.
When the fault has been identified and taken care of press the ACKNOWLEDGE
ALARM button.

Note! Alarm feedback fault caused by motors or/and valves has to be

acknowledged before it is possible to restart a phase that has gone to Held due to an
feedback fault
Alarms are divided into two categories as follows:
a) A Faults that will cause an alarm only. The faults are not critical but the alarm will
make the operator aware of an incident.
b) B Faults that will cause action from the PLC, rectify the fault

The category C contains interlock conditions that prevents any sequence to be

started see also “Start condition window” in chapter Control Panel.

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4.2 Alarm 4 Alarm

4.2 Alarm
A complete listing of preset values for timers etc. use to supervise the process, can
be found in the Electrical Manual.

Note! Some of the listed alarms belongs to optional equipment and may not be
applicable.
The following chart gives an outline of the most frequently occurring alarms, their
causes and ways of eliminating them.
General causes of alarms:
• No air supply to valves
• Solenoids valve not working
• Output signal on I/O unit not working
• I/O unit not working
• Always investigate these causes when a fault occurs.

CAUTION
Only authorized personnel are allowed to adjust the parameters and
renew/repair equipment.
Unsterile Product:To ensure the correct procedure in fault-finding, it is of outmost
importance to be able to trace the date and time of production of any unsterile
product.

Always record the date and time when the product was produced.

142 (242) Doc. No. OM-3284281-0111

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4 Alarm 4.3 Fault List

4.3 Fault List

Type A => Alarm only

Type B => Alarm and machine action

Type C => Start interlock

Typ- Alarm Cause Machine Action Instruction to Operator

e
B Alarm 000: Motor is not running Machine stops, if CIP the Check motor, check/reset
Feedback fault M2 function is held. overload device or Frequency
Drive unit
A Alarm 001: Motor is not running - Check motor, check/reset
Feedback fault M3 overload device or Frequency
Drive unit
B Alarm 002: Motor is not running Machine stops, if CIP the Check motor, check/reset
Feedback fault M4 function is held. overload device or Frequency
Drive unit
B Alarm 003: Motor is not running Machine stops, if CIP the Check motor, check/reset
Feedback fault M5 function is held. (Option) overload device or Frequency
Drive unit
B Alarm 004: Motor is not running V51 opens bypass. FC04 take Check motor, check/reset
Feedback fault M6 over flow control, if CIP the overload device or Frequency
function is held. Drive unit
B Alarm 005: Motor is not running - Check motor, check/reset
Feedback fault M15 overload device
A Alarm 006: Motor is not running (Option) Check motor, check/reset
Feedback fault M7 overload device or Frequency
Drive unit
- Alarm 007: - - -
B,C Alarm 008: Motor is not running Close the steam valve. Check motor, check/reset
Feedback fault M9 overload device or Frequency
Drive unit
B,C 009: Feedback fault Motor is not running Close the steam valve. Check motor, check/reset
M10 overload device or Frequency
Drive unit
B,C Alarm 010: Motor is not running (Option) Check motor, check/reset
Feedback fault M11 overload device or Frequency
Drive unit
A Alarm 011: Motor is not running (Option) Check motor, check/reset
Feedback fault M12 overload device or Frequency
Drive unit
A Alarm 012: Motor is not running (Option) Check motor, check/reset
Feedback fault M13 overload device or Frequency
Drive unit
A Alarm 013: Motor is not running (Option) Check motor, check/reset
Feedback fault M14 overload device or Frequency
Drive unit
- Alarm 014: - - -
- 015: - - -
B Alarm 016: Pre Temperature is too If sterilizing, go back to the Check steam supply.
sterilisation fault low at TT71 during heating step. Check/replace PT100
TSL71 sterilization. transmitter. :

(Cont’d)

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4.3 Fault List 4 Alarm

(Cont’d)

Typ- Alarm Cause Machine Action Instruction to Operator

e
B,C Alarm 017: Low Temperature is too If sterilizing, go back to the Check steam supply.
temp fault holding low in the holding heating step. In production an Check/replace PT100
cell TSL42 cell. emptying sequence take place transmitter.
and the product goes to reject.
Interlocks the production and
AIC
B Alarm 018: CIP Temperature is too The step timer is held until Check/replace PT100
temp fault TSL71 low at TT71 during TT71 is at the required transmitter. Check that V75 is
circulation steps of temperature. in position to circulate over the
cleaning. BTD.
B Alarm 019: Low The product balance If in Production, leave Check supply to BTD
level fault product tank level is too low. production. If fault remains for
BTD LSL08 too much time then immediate
stop. If CIP the function is held
- Alarm 020: - - -
C Alarm 021: Valve position not Interlock Production, AIC and Check valve solenoid, air
Feedback fault V83 confirmed CIP lines, operation, and feedback
device.
A Alarm 022: Caustic Time exceeded for - Check valve solenoid and air
fault metering or dosing. lines to V80 or Caustic supply.
A Alarm 023: Acid Time exceeded for - Check valve solenoid and air
fault metering or dosing. lines to V82 or Acid supply.
B Alarm 024: Filling Filling machine has Activates return cooler. Check condition of filling
machine not ready not started machine or selection of filling
or ready but not production within a machine
started certain time
C Alarm 025: Low air Inlet air pressure too Interlocks Sterilisation, CIP Check that air supply pressure
pressure to control low. and emergency emptying is at least 6 bar.
panel.
A Alarm 026: Product The product flow is - Check flow meter.
flow too high or too out of its allowed
low limits.
A Alarm 028: Battery PLC processor - Replace battery
for backup memory backup battery is
in PLC low low.
B Alarm 029: Alsafe Alsafe is not ready If in Production, leave Check condition of Alsafe
not ready or high for production or is production.
level full.
B Alarm 030: Low - If sterilizing, go back to the Check steam supply.
temp steam barrier heating step. Check/replace PT100
TSL46 transmitter.
B Alarm 031: Low Low temperature If sterilizing, go back to the Check steam supply.
temp steam barrier steam barrier valve heating step. Check/replace PT100
TSL47 V78. transmitter.
B Alarm 032: Low Temperature too low If sterilizing, go back to the Check steam supply.
temp steam barrier at the homogenizer. heating step. Check/replace PT100
TS830 transmitter.
- Alarm 033: - - -
- Alarm 034: - - -
- Alarm 035: - - -
Communication
fault Alsafe 1

(Cont’d)

144 (242) Doc. No. OM-3284281-0111

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4 Alarm 4.3 Fault List

(Cont’d)

Typ- Alarm Cause Machine Action Instruction to Operator

e
B,C Alarm 036: Fault in serial All incoming communication Check communication
Communication communications signals are reset. Interlock for network and devices.
fault PLC to PLC with another process sterilisation, production, AIC,
PLC. CIP
B,C Alarm 037: Fault in serial All incoming communication Check communication
Communication communications signals are reset. network and devices.
fault Destination. with PLC in Interlock for sterilisation,
Destination (reclaim production, AIC, CIP.
and or product
tanks).
A Alarm 038: Low The steam valve has - Check steam supply.
steam pressure or been open for too
steam valve too long without the
much open. temperature rising or
low steam pressure
A Alarm 039: Low or Level in vacuum (Option) Check level sensor.
high level in vacuum vessel is too low or
vessel. too high.
A Alarm 040: Low The water pressure - Check incoming water
pressure in hot in the hot water pressure. Check PS66.
water circuit PSL66 circuit is too low.
A Alarm 041: Feed Control panel air- - Check panel air-conditioner.
back fault conditioner is not
compressor AC operation properly.
B,C Alarm 042: TT42 Temperature is out If sterilizing, go back to the Check/replace PT100
Broken of its normal range. heating step. In production an transmitter.
emptying sequence take place
and the product goes to reject.
Interlocks the production and
AIC
B Alarm 043: TT71 Temperature is out If sterilizing, go back to the Check/replace PT100
Broken of its normal range. heating step. transmitter.
B Alarm 044: TT46 Temperature is out If sterilizing, go back to the Check/replace PT100
Broken of its normal range. heating step. transmitter.
B Alarm 045: TT47 Temperature is out If sterilizing, go back to the Check/replace PT100
Broken of its normal range. heating step. transmitter.
B Alarm 046: TT830 Temperature is out If sterilizing, go back to the Check/replace PT100
Broken of its normal range. heating step. transmitter.
(Optional)
B Alarm 047: TT44 Temperature is out If sterilizing, go back to the Check/replace PT100
Broken of its normal range. heating step. transmitter.
- Alarm 048: - - -
- Alarm 049: - - -
- Alarm 050: - - -
- Alarm 051: - - -
A,C Alarm 052: Filter - Interlocks sterilisation, Check TeM manual of
fault crank case production and emergency homogenizer.
PS837 emptying.
(Optional)

(Cont’d)

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4.3 Fault List 4 Alarm

(Cont’d)

Typ- Alarm Cause Machine Action Instruction to Operator

e
A,C Alarm 053: Filter - Interlocks sterilisation, Check TeM manual of
fault gear box production and emergency homogenizer.
PS838 emptying.
(Optional)
A,C Alarm 054: Oil Low oil pressure in Interlocks sterilisation, Check TeM manual of
pressure fault crank crank case production and emergency homogenizer.
case PSL814 homogenizer emptying.
(Optional)
A,C Alarm 055: Oil Low oil pressure in Interlocks sterilisation, Check TeM manual of
pressure fault gear gearbox production and emergency homogenizer.
box PSL840 homogenizer emptying
(Optional)
A,C Alarm 056: Oil High oil temperature Interlocks sterilisation, Check TeM manual of
temperature fault in crank case production and emergency homogenizer.
crank case TS841 homogenizer emptying.
(Optional)
A,C Alarm 057: Oil High oil temperature Interlocks sterilisation, Check TeM manual of
temperature fault in gearbox production and emergency homogenizer.
gear box TS842 homogenizer emptying.
(Optional)
B Alarm 058: Valve position not If sterilising, go back to the Check valve solenoid, air
Feedback fault V71 confirmed heating step, interlock lines, operation, and feedback
production device.
- Alarm 059: - - -
B Alarm 060: Emergency stop Immediate system stop Reset the emergency stop
Emergency stop button pushed at button
panel main control panel
B Alarm 061: Low Temperature too low If sterilizing, go back to the Check steam supply.
temp steam barrier at the homogenizer. heating step. Check/replace PT100
TS831 transmitter.
(Optional)
B Alarm 062: TT831 Temperature is out If sterilizing, go back to the Check/replace PT100
Broken of its normal range. heating step. transmitter.
(Optional)
A,C Alarm 063: High oil - Interlocks sterilisation, Check TeM manual of
temp TSH815 Tetra production and emergency homogenizer.
Alex emptying.
(Optional)
C Alarm 064: Summary of any Interlock start of sterilising Check/replace PT100
Temperature broken PT100 transmitter.
transmitter broken
A Alarm 065: Pressure of the - -
Differential pressure product side is too
sterile cooler fault low compared to the
PSL63 media side of this
(Optional) heat exchanger.

(Cont’d)

146 (242) Doc. No. OM-3284281-0111

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4 Alarm 4.3 Fault List

(Cont’d)

Typ- Alarm Cause Machine Action Instruction to Operator

e
A Alarm 066: Pressure of the - -
Differential pressure product side is too
sterile cooler fault low compared to the
PSL62 media side of this
(Optional) heat exchanger.
A,B, Alarm 067: Pressure of the Alarm If < 0.5 bar for 5 s -
C Differential pressure product side is too during sterilisation. Unsterile if
sterile cooler fault low compared to the < 0.5 bar for 5 s during
PSL61 media side of this production. Sets finalize
heat exchanger. production if in production.
Interlock of Production and
AIC.
A Alarm 068: Not valid - - -
recipe
A Alarm 069: High oil - - Check TeM of homogenizer.
temp Alex, TSH845
(Optional)
A,C Alarm 070: Oil level High oil level Interlocks sterilisation, Check TeM of homogenizer.
Alex LSH835 homogenizer production and emergency
(Optional) emptying.
A,C Alarm 071: Oil level Low oil level Interlocks sterilisation, Check TeM of homogenizer.
Alex LSL835 homogenizer production and emergency
(Optional) emptying.
- Alarm 072: - - -
- Alarm 073: - - -
- Alarm 074: - - -
- Alarm 075: - - -
- Alarm 076: - - -
- Alarm 077: - - -
- Alarm 078: - - -
- Alarm 079: - - -
B Alarm 080: Product Product at unit Leaves production -
not at unit signal from source
not available
B,C Alarm 081: Fault in serial All incoming communication Check communication
Communication communications signals are reset. Interlock for network and devices.
fault with CIP station with CIP station sterilisation, production, AIC,
CIP
B,C Alarm 082: Fault in serial All incoming communication Check communication
Communication communications signals are reset. Interlock for network and devices.
fault with CIP with CIP concentrate sterilisation, production, AIC,
concentrate CIP
A Alarm 083: Comp Comp index has Index > 150. -
Index for lye too been adjusted too
high much
B Alarm 084: Lye Process value is Step timer is held until Abort CIP if there is no
concentration to low below set point concentration is above set possibility to adjust the
point concentration

(Cont’d)

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4.3 Fault List 4 Alarm

(Cont’d)

Typ- Alarm Cause Machine Action Instruction to Operator

e
A Alarm 085: Comp Comp index has Index > 150. -
Index for acid too been adjusted too
high much
B Alarm 086: Acid Process value is Step timer is held until Abort CIP if there is no
concentration to low below set point concentration is above set possibility to adjust the
point concentration
A;B; Alarm 087: Pressure of the Alarm If < 0.5 bar for 5 s -
C Differential pressure product side is too during sterilisation. Unsterile if
fault PSL64 low compared to the < 0.5 bar for 5 s during
media side of this production. Sets finalize
heat exchanger. production if in production.
Interlock of Production and
AIC.
A Alarm 088: 10% - - Change memory card in
storage left in recorder.
recorder
- Alarm 089: - - -
B,C Alarm 090: Product - Step conditions based on -
flow transmitter volumes are replaced with
broken backup timers. Reclaim
handling for product is
disabled. If in Production,
leave production and reset
product at outlet signal.
Interlocks Sterilisation,
Production and AIC.
A Alarm 091: High The water pressure Too much fouling in heat Check setting PC68 and or
pressure in hot in the hot water exchanger, HC and valves. PC67.
water circuit PSH66 circuit is too high.
A Alarm 092: High - Too high flow in HC. -
back pressure
product PSH60
B Alarm 093: HC time - If sterilizing, go back to the -
fault heating step. If in Production,
leave production and reset
product at outlet signal.
Interlocks Production and AIC
B Alarm 094: Production enable Leaves production -
Production not signal from source
enabled not available.
B Alarm 095: Water Water enable signal If step 20 leaves production -
not enabled from source not
available.
A,B, Alarm 096: Pressure of the Alarm If < 0.5 bar for 5 s -
C Differential pressure product side is too during sterilisation. Unsterile if
fault PSL65 low compared to the < 0.5 bar for 5 s during
(Optional) media side of this production. Sets finalize
heat exchanger. production if in production.
Interlock of Production and
AIC.
B Alarm 097: Low Not enough water in If step 25 - 26 leaves -
water level CIP HB CIP HB for step 25 - production
tank 26.

(Cont’d)

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4 Alarm 4.3 Fault List

(Cont’d)

Typ- Alarm Cause Machine Action Instruction to Operator

e
A Alarm 098: Cond - - -
High Fault QT76
rinse
(Optional)
A Alarm 099: To slow Not low level - Check level transmitter LT10
dosing of reached in CIP HB and outlet valves from CIP HB
concentrate Tank at end of tank
dosing step.
A Alarm 100: To fast Low level reached in - Check level transmitter LT10
dosing of CIP HB Tank to and concentrate supply
concentrate early in the dosing
step.
B Alarm 101: Water Step 503 or 507, No action on alarm but the Check water supply to CIP HB
metering fault and max timer. step sequence for CIP HB will tank
be halted in step 503 or 507
until LT10 has reached it’s set
point.
B Alarm 102: Draining Not low level No action on alarm but the Check drain valves on CIP HB
fault CIP HB tank reached in CIP HB step sequence for CIP HB will tank
Tank. be halted in step 502, 508
509, 511 or 515 until tank is
emptied (LT10 <LL or LS51).
B Alarm 103: CIP HB High level in the CIP Closes all supply to CIP HB Check supply valves to CIP
tank over filled header tank tank header tank
B Alarm 104: Low Temperature too low If sterilizing, go back to the Check steam supply.
temp steam barrier at the homogenizer heating step. Check/replace PT100
TS901 Damper. transmitter.
(Optional)
B Alarm 105: Low Temperature too low If sterilizing, go back to the Check steam supply.
temp steam barrier at the homogenizer heating step. Check/replace PT100
TS902 Damper. transmitter.
(Optional)
B Alarm 106: LSL66 The water pressure Valve V66 opens. Check incoming water
Low Level Hot in the hot water pressure. Check LS66. Check
Water Circuit circuit is too low. that V66 opens.
A Alarm 107: PSL847 Inlet pressure to - -
- Tetra Alex Inlet homogenizer to low
Product Press Fault
(Optional)
A Alarm 108: TT2 Temperature is out - Check/replace PT100
Broken of its normal range. transmitter.
A Alarm 109: TT6 Temperature is out - Check/replace PT100
Broken of its normal range. transmitter.
- Alarm 110: - - -
A Alarm 111: TT64 Temperature is out - Check/replace PT100
Broken of its normal range. transmitter.
- Alarm 112: No Tank No Alsafe queued - -
in queue
(Optional)

(Cont’d)

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4.3 Fault List 4 Alarm

(Cont’d)

Typ- Alarm Cause Machine Action Instruction to Operator

e
A Alarm 113: PSL846 Tetra Alex Cooling - Check water supply
- Tetra Alex Cooling Water Pressure to
Water Pressure low
Fault
(Optional)
B,C Alarm 113: LT10 Level is out of its Interlocks AIC, CIP. Check/replace level
Broken normal range. Deactivates chemical valves transmitter.
and pumps
C Alarm 115: Product Product still in Interlocks emergency -
in module machine in step 0 emptying if alarm present and
reclaim destination not
available.
C Alarm 116: TT63 Temperature is out Interlocks sterilisation. Check/replace PT100
Broken of its normal range. transmitter.
(Only US version)
C Alarm 117: TT63.2 Temperature is out Interlocks sterilisation. Only Check/replace PT100
Broken of its normal range. US version. transmitter.
(Only US version)
C Alarm 118: TT73 Temperature is out Interlocks sterilisation. Only Check/replace PT100
Broken of its normal range. US version. transmitter.
(Only US version)
B,C Alarm 119: DPT61 Pressure of the Loss of sterility - If CIP -
Differential Pressure product side is too memory step back to heating
Alarm low compared to the step. If no CIP memory step to
(Only US version) media side of this shut down. Sets finalize
heat exchanger. production if in production.
Interlock of Sterilisation,
Production and AIC.
B,C Alarm 120: DPT62 Pressure of the Loss of sterility - If CIP -
Differential Pressure product side is too memory step back to heating
Alarm low compared to the step. If no CIP memory step to
(Only US version) media side of this shut down. Sets finalize
heat exchanger. production if in production.
Interlock of Sterilisation,
Production and AIC.
B,C Alarm 121: DPT63 Pressure before the Loss of sterility - If CIP -
Differential Pressure steam injector is too memory step back to heating
Alarm low compared to step. If no CIP memory step to
(Only US version) downstream. shut down.Sets finalize
production if in production.
Interlock of Sterilisation,
Production and AIC.
B,C Alarm 122: DPT64 Pressure of the Loss of sterility - If CIP -
Differential Pressure product side is too memory step back to heating
Alarm low compared to the step. If no CIP memory step to
Only US version. media side of this shut down. Sets finalize
heat exchanger. production if in production.
Interlock of Sterilisation,
Production and AIC.

(Cont’d)

150 (242) Doc. No. OM-3284281-0111

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4 Alarm 4.3 Fault List

(Cont’d)

Typ- Alarm Cause Machine Action Instruction to Operator

e
B,C Alarm 123: TSL42A Temperature in the Loss of sterility - If CIP -
Hold Tube ESL hold tube is too low. memory step back to heating
Temp Fault step. If no CIP memory step to
(Only US version) shut down. Sets finalize
production and reset product
at outlet signal if in production
Interlock of Sterilisation,
Production and AIC.
B,C Alarm 124: TSL42B Temperature in the Loss of sterility - If CIP -
Hold Tube Aseptic hold tube is too low. memory step back to heating
Temp Fault step. If no CIP memory step to
shut down. Sets finalize
production and reset product
at outlet signal if in production
Interlock of Sterilisation,
Production and AIC.
B Alarm 125: TSL47A Temperature at the Go back to heating step if in -
Flash Vessel ESL flash vessel is too step 6.
Temp Fault low.
Only US version.
B Alarm 126: TSL47B Temperature at the Go back to heating step if in -
Flash Vessel flash vessel is too step 6.
Aseptic Temp Fault low.
B Alarm 127: TSL73 - Go back to heating step if in -
FDV ESL Temp step 6.
Fault
B Alarm 128: PSLHT Pressure in the hold Loss of sterility - If CIP -
Hold Tube Pressure tube is too low memory step back to heating
Fault step. If no CIP memory step to
shut down.Sets finalize
production if in production.
Interlock of Production and
AIC.
B,C Alarm 129: FSH04 Product flow is too Loss of sterility - If CIP -
Flow Fault low or too high. memory step back to heating
Only US version. step. If no CIP memory step to
shut down. Sets finalize
production and reset product
at outlet signal if in production.
Interlock of Sterilisation,
Production and AIC.
B,C Alarm 130: FDV Valve position is not Loss of sterility - If CIP -
Feedback Fault confirmed. memory step back to heating
Only US version. step. If no CIP memory step to
shut down. Sets finalize
production if in production.
Interlock of Production and
AIC.
B Alarm 131: Alsafe Steam barrier signal If in AIC/CIP Immediate -
diverted AIC/CIP from source tank not system stop
system may not be available
rinsed
Only US version.

(Cont’d)

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4.3 Fault List 4 Alarm

(Cont’d)

Typ- Alarm Cause Machine Action Instruction to Operator

e
B Alarm 132: Alsafe V100 position is If in Sterilising/Shut -
V100 Not in Divert wrong down/Emergency emptying
position Immediate system stop
Only US version.
- Alarm 133: - - -
B Alarm 134: Low Temperature too low If sterilizing, go back to the Check steam supply.
temp steam barrier at the homogenizer heating step. Check/replace PT100
TSL51 Damper. transmitter.
(Optional)
A Alarm 135: Damper Dampers at - Replace filters
filter fault homogenizer has
(Optional) been sterilised to
many times
B Alarm 136: TT901 Temperature is out If sterilizing, go back to the Check/replace PT100
Broken of its normal range. heating step. transmitter.
(Optional)
B Alarm 137: TT901 Temperature is out If sterilizing, go back to the Check/replace PT100
Broken of its normal range. heating step. transmitter.
(Optional)
B Alarm 138: TT51 Temperature is out If sterilizing, go back to the Check/replace PT100
Broken of its normal range. heating step. transmitter.
(Optional)
- Alarm 139: - - -
A Alarm 140: TT845 Temperature is out - Check/replace PT100
Broken of its normal range. transmitter.
(Optional)
A,B, Alarm 141: Pressure of the Alarm If < 0.5 bar for 5 s -
C Differential pressure product side is too during sterilisation. Unsterile if
fault PSL67 low compared to the < 0.5 bar for 5 s during
media side of this production. Sets finalize
heat exchanger. production if in production.
Interlock of Production and
AIC.
B,C Alarm 142: Fault in serial All incoming communication Check communication
Communication communications signals are reset. Interlock for network and devices.
fault Alsafe 2 with Alsafe. 2 sterilisation, production, AIC,
CIP
B,C Alarm 143: Fault in serial All incoming communication Check communication
Communication communications signals are reset. Interlock for network and devices.
fault Alsafe 3 with Alsafe. 3 sterilisation, production, AIC,
CIP
B Alarm 144: Steam Signal from filling If sterilizing, go back to the Check steam supply AFM1.
barrier low AFM1 machine indication heating step. Check signal exchange AFM
steam barrier OK is 1.
missing.
B Alarm 145: Steam Signal from filling If sterilizing, go back to the Check steam supply AFM2.
barrier low AFM2 machine indication heating step. Check signal exchange AFM
steam barrier OK is 2.
missing.

(Cont’d)

152 (242) Doc. No. OM-3284281-0111

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4 Alarm 4.3 Fault List

(Cont’d)

Typ- Alarm Cause Machine Action Instruction to Operator

e
B Alarm 146: Steam Signal from filling If sterilizing, go back to the Check steam supply AFM3.
barrier low AFM3 machine indication heating step. Check signal exchange AFM
steam barrier OK is 3.
missing.
B Alarm 147: Steam Signal from filling If sterilizing, go back to the Check steam supply AFM4.
barrier low AFM4 machine indication heating step. Check signal exchange AFM
steam barrier OK is 4.
missing.
B Alarm 148: Steam Signal from Alsafe If sterilizing, go back to the Check steam supply Alsafe.
barrier low Alsafe 1 indication steam heating step. Check signal exchange
barrier OK is Alsafe.
missing.
B Alarm 149: Steam Signal from Alsafe If sterilizing, go back to the Check steam supply Alsafe.
barrier low Alsafe 2 indication steam heating step. Check signal exchange Alsafe
barrier OK is
missing.
B Alarm 150: Steam Signal from Alsafe If sterilizing, go back to the Check steam supply Alsafe.
barrier low Alsafe 3 indication steam heating step. Check signal exchange Alsafe
barrier OK is
missing.
- Alarm 151: - - -
- Alarm 152: - - -
- Alarm 153: - - -
- Alarm 154: - - -
- Alarm 155: - - -
- Alarm 156: - - -
- Alarm 157: - - -
- Alarm 158: - - -
- Alarm 159: - - -
- Alarm 160: - - -
- Alarm 161: - - -
- Alarm 162: - - -
- Alarm 163: - - -
- Alarm 164: - - -
- Alarm 165: - - -
- Alarm 166: - - -
B,C Alarm 167: PT61A Broken transmitter If in production an emptying Check pressure transmitter.
broken. for differential sequence take place and the
pressure. product goes to reject.
Interlocks production &
Sterilization.
If in sterilization the program
steps back to heating step 5.

(Cont’d)

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4.3 Fault List 4 Alarm

(Cont’d)

Typ- Alarm Cause Machine Action Instruction to Operator

e
B,C Alarm 168: PT62A Broken transmitter If in production an emptying Check pressure transmitter.
broken. for differential sequence take place and the
pressure. product goes to reject.
Interlocks production &
Sterilization.
If in sterilization the program
steps back to heating step 5.
B,C Alarm 169: PT63A Broken transmitter If in production an emptying Check pressure transmitter.
broken. for differential sequence take place and the
pressure. product goes to reject.
Interlocks production &
Sterilization.
If in sterilization the program
steps back to heating step 5.
B,C Alarm 170: PT64A Broken transmitter If in production an emptying Check pressure transmitter.
broken. for differential sequence take place and the
pressure. product goes to reject.
Interlocks production &
Sterilization.
If in sterilization the program
steps back to heating step 5.
B,C Alarm 171: PT65A Broken transmitter If in production an emptying Check pressure transmitter.
broken. for differential sequence take place and the
pressure. product goes to reject.
Interlocks production &
Sterilization.
If in sterilization the program
steps back to heating step 5.
B,C Alarm 172: PT67A Broken transmitter If in production an emptying Check pressure transmitter.
broken. for differential sequence take place and the
pressure. product goes to reject.
Interlocks production &
Sterilization.
If in sterilization the program
steps back to heating step 5.
B Alarm 180: Fuse Electronic fuse Immediate system stop Check fuse in control panel
fault tripped
B Alarm 181: TT951 Temperature is out If sterilising, go back to the Check/replace PT100
Broken of its normal range heating step. transmitter
B Alarm 182: TSL951 Temperature too low If sterilising, go back to the Check steam supply.
(Optional) at the homogenizer heating step. Check/replace PT100
damper transmitter
A Alarm 183: High Insufficient cooling - Check incoming cooling
product outlet temp media temperature media supply
TSH06 or flow rate in
product cooler
- Insufficient hot water - Check hot water temperature
temperature or flow and flow rate
rate in product to
water regenerative
sections (CM)

(Cont’d)

154 (242) Doc. No. OM-3284281-0111

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4 Alarm 4.3 Fault List

(Cont’d)

Typ- Alarm Cause Machine Action Instruction to Operator

e
- Insufficient product - Check product temperature
temperature or flow and flow rate
rate in product to
product regenerative
sections (CMR)
A Alarm 184: Homog Product pressure is - Check product pressure valve
low product out of its normal in homogenizer
pressure PSL827 range
B Alarm 185: LSL11 The water pressure Valve V29 opens. Check incoming water
Low level Deaerator in water circuit to pressure.
water circuit M11 M11 is too low Check LSL11.
Check that V29 opens.
B Alarm 186: LSL22 The water pressure Valve V21 opens. Check incoming water
Low level Deaerator in water circuit to pressure.
water circuit M14 M14 is too low Check LSL22.
Check that V21 opens.
A Alarm 187: TSH11 High water - Check incoming water
High temp at M11 temperature in water pressure
circuit at M11
A Alarm 188: TT11 Temperature is out - Check/replace PT100
broken of its normal range transmitter
A Alarm 189: Air filling Air filling supply is to - Check air filling supply. Check
interrupted - LSL901 low or air filling time air filling time parameter and
not reached in is to less. increase if to low
damper D901
A Alarm 190: Air filling Air filling supply is to - Check air filling supply. Check
interrupted - LSL902 low or air filling time air filling time parameter and
not reached in is to less. increase if to low
damper D902
A Alarm 191: High Level to high in - Manual start air filling of
level in damper damper 901 damper D901 and decrease
D901 interval parameter for damper
D901 air filling.
- - - - -
A Alarm 208: High Level to high in - Manual start air filling of
level in damper damper 902 damper D902 and decrease
D902 interval parameter for damper
D902 air filling.
A Alarm 209: Homog Product pressure is - Check product pressure valve
high product out of its normal in homogenizer
pressure PSH827 range
A Alarm 213: No commercial - Check incoming commercial
Commercial Power power on power
Fault
A Alarm 214: ICIP 2.0 CIP finished without - -
Machine not clean RFL indication clean
machine
B;C Alarm 215: QT78 Broken transmitter Interlocks production. Check turbidity meter
Transmitter broken for turbidity If production an emptying
sequence take place and the
product goes to reject.

(Cont’d)

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4.3 Fault List 4 Alarm

(Cont’d)

Typ- Alarm Cause Machine Action Instruction to Operator

e
B;C Alarm 216: DPT5 Broken transmitter Interlocks sterilisation, Check pressure transmitter
Transmitter broken for differential production, AIC and CIP.
pressure If sterilizing, go back to
heating step.
If production an emptying
sequence take place and the
product goes to reject.
Deactivates homogenizer
pressure vales Y822/Y823.
B,C Alarm 217: DPT6 Broken transmitter Interlocks sterilisation, Check pressure transmitter
Transmitter broken for differential production, AIC and CIP.
pressure If sterilizing, go back to
heating step.
If production an emptying
sequence take place and the
product goes to reject.
Deactivates homogenizer
pressure vales Y822/Y823.
- Alarm 218: DPT8 Broken transmitter Interlocks sterilisation, Check pressure transmitter
Transmitter broken for differential production, AIC and CIP.
pressure If sterilizing, go back to
heating step.
If production an emptying
sequence take place and the
product goes to reject.
Deactivates homogenizer
pressure vales Y822/Y823.
- Alarm 219: DPT9 Broken transmitter Interlocks sterilisation, Check pressure transmitter
Transmitter broken for differential production, AIC and CIP.
pressure If sterilizing, go back to
heating step.
If production an emptying
sequence take place and the
product goes to reject.
Deactivates homogenizer
pressure vales Y822/Y823.
- Alarm 220: DPT10 Broken transmitter Interlocks sterilisation, Check pressure transmitter
Transmitter broken for differential production, AIC and CIP.
pressure If sterilizing, go back to
heating step.
If production an emptying
sequence take place and the
product goes to reject.
Deactivates homogenizer
pressure vales Y822/Y823.

(Cont’d)

156 (242) Doc. No. OM-3284281-0111

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4 Alarm 4.3 Fault List

(Cont’d)

Typ- Alarm Cause Machine Action Instruction to Operator

e
- Alarm 221: DPT11 Broken transmitter Interlocks sterilisation, Check pressure transmitter
Transmitter broken for differential production, AIC and CIP.
pressure If sterilizing, go back to
heating step.
If production an emptying
sequence take place and the
product goes to reject.
Deactivates homogenizer
pressure vales Y822/Y823.
B Alarm 222: PSH13 Too high pressure M4 will run on fixed value until -
High pressure after after M4 pressure is ok.
M4
A 223: Fault in serial - Check communication
Communication communications network and devices.
fault with AFM1 with AFM1
A Alarm 224: Fault in serial - Check communication
Communication communications network and devices.
fault with AFM2 with AFM2
A Alarm 225: Fault in serial - Check communication
Communication communications network and devices.
fault with AFM3 with AFM3
A Alarm 226: Fault in serial - Check communication
Communication communications network and devices.
fault with AFM4 with AFM4
A,B Alarm 227: PSL05 Pressure in the hold Alarm if 0.5 bar below set -
Pressure fault alarm tube is too low point for 5 s. If 1.5 bar below
set point loss of sterility - If
CIP memory step back to
heating step. If no CIP
memory step to shut down.
Sets finalize production if in
production. Interlock of
Production and AIC. Will
activate HC Time Fault alarm.
A Alarm 230: High Blocked or - Check downstream
Pressure PT51/60 restriction in product equipment
line downstream
B Alarm 231: Max Blocked or The machine steps down to Check downstream
Pressure PT51/60 restriction in product step 0 (zero) all pumps and all equipment
line downstream valves will be deactivated.
B,C Alarm 232: PT51/60 Transmitter broken Immediate system stop Check/replace transmitter
broken
B Alarm 233: I/O I/O device failure Immediate stop system Check I/O devices and cables
device failure
C Alarm 234:TSL44 Low Temperature at Sterilization interlock -
Only US version. preheater
- Alarm 235 - - -
- Alarm 236 - - -

(Cont’d)

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4.3 Fault List 4 Alarm

(Cont’d)

Typ- Alarm Cause Machine Action Instruction to Operator

e
B Alarm 237: TT909 Temperature is out If sterilizing, go back to the Check/replace PT100
Broken of its normal range heating step. transmitter
(Optional)
B Alarm 238: Low Temperature too low If sterilizing, go back to the Check steam supply.
temperature steam at the homogenizer heating step. Check/replace PT100
barrier TS909 damper transmitter.
(Optional)

158 (242) Doc. No. OM-3284281-0111

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 5 Preparations

®
Doc. No. OM-3284281-0111 159 (242)
 5 Preparations

Description
This chapter contains a list of necessary checkpoints prior to start.

160 (242) Doc. No. OM-3284281-0111

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5 Preparations Table of Contents

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

5.1 Checkpoints ..................................................... 163

5.2 Optional Checkpoints......................................... 166

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 5 Preparations

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162 (242) Doc. No. OM-3284281-0111

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5 Preparations 5.1 Checkpoints

5.1 Checkpoints
Before Start

Check that required utilities are available:

• Water
• Steam
• Air
• Electricity

Note! Make sure that the homogenizer, separators and so on, are prepared for
operation according to the specific operating manuals for homogenizers and
separators.
Note! If product other than specified in Technical Data is processed the sterilisation
effect might be insufficient. Other products may need other temperature program.

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
(Cont’d)

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5.1 Checkpoints 5 Preparations

(Cont’d)

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.
• 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 directly
after each production and if the system has been closed down for a longer time.
• Check that the homogenizer dampers are free from any product residue after
cleaning.
• Check that the steam supplier is drained from condensate.
• Check tightness of all connection.
• Check that the steam switch is in position on.
• 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 resetted.
• Check that all applicable downstream equipment are ready for production for
example. steam barriers, AFM (aseptic filling machines), A-tanks (aseptic tanks).

To ensure a safe product, it is important that the following checkpoints during the
processing of the product are confirmed:
• That the selected configuration (capacity, temperature...) is valid for the food
product to be processed.
• That the sterilising of the equipment is of sufficient time and temperature.
• That no open tanks etc are exposed to foreign objects/contamination.
• That carry-over of potential allergens between products during product change
and cleaning is considered. A close inspection of the equipment is of utmost
importance if a possible risk occurs - refer to QA system.
• That the correct recipe is selected.
(Cont’d)

164 (242) Doc. No. OM-3284281-0111

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5 Preparations 5.1 Checkpoints

(Cont’d)

• That ingredients are of the correct type and amount according to recipes.
• That the cleaning solutions are of correct type, concentration and amount
according to recipes.
• That no food residue according to defined control points remains after finalized
cleaning.
• That no residue of chemicals is present after cleaning the equipment.
• Food quality may be affected if the food is stored for excessive periods in the tank.
Make sure it is of acceptable quality before resuming production in case of long
interruptions in production or long waiting periods before start of production.

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Doc. No. OM-3284281-0111 165 (242)
5.2 Optional Checkpoints 5 Preparations

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.
.

166 (242) Doc. No. OM-3284281-0111

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 6 Operation

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Doc. No. OM-3284281-0111 167 (242)
 6 Operation

Description
This chapter describes how to operate the equipment.

168 (242) Doc. No. OM-3284281-0111

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6 Operation Table of Contents

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

6.1 Sterilizing Sequence .......................................... 171

Selection/Settings Prior to Start . . . . . . . . . . . . . . . . . . 171
Start Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Start Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Check During Sequence. . . . . . . . . . . . . . . . . . . . . . . . . 173

6.2 Hibernation Sequence ........................................ 174

Start Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Start Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Stop Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

6.3 Production Sequence ......................................... 175

Selection/Settings Prior to Start . . . . . . . . . . . . . . . . . . 175
Start Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Start Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Check During Sequence. . . . . . . . . . . . . . . . . . . . . . . . . 177
Check Functionality of Steam Barriers . . . . . . . . . . . . 178
Stop Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

6.4 Revert to Water Circulation .................................. 179

Revert to Water Circulation . . . . . . . . . . . . . . . . . . . . . . 179

6.5 Shut Down Sequence ......................................... 180

6.6 Emergency Stop................................................ 181
Start after Emergency Stop . . . . . . . . . . . . . . . . . . . . . . 181
One Control Panel (Stand Alone) . . . . . . . . . . . . . . . . . 181
Several Control Panels (Simultaneous
Reset). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .182
Several Control Panels (Individual Reset) . . . . . . . . . 182

6.7 Cleaning Sequence ............................................ 183

Product strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
IntelliCIP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Aseptic Intermediate Cleaning - AIC . . . . . . . . . . . . . . . . . . . . . 184
Start Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

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Doc. No. OM-3284281-0111 169 (242)
Table of Contents 6 Operation

Final Cleaning- CIP Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

Start Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

Halt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Halt Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Resume from Halt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

Emergency Emptying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

Start Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

Cleaning of Supply Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

Start /Stop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

Maintenance Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

Start Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

170 (242) Doc. No. OM-3284281-0111

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6 Operation 6.1 Sterilizing Sequence

6.1 Sterilizing Sequence

WARNING vv
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.

1
vv
Selection/Settings Prior to Start
Note! This chapter describes how to
operate the machine in local mode.
The selection must fit with the equipment
connected. A yellow triangle (1) in the
selection indicates that the selected
equipment do not fit the equipment
connected.
Select desired equipment see the RECIPIE
1 EDIT WINDOW.

Check also chapter Preparations.

2
vv
Select/Check recipe.
(Capacity can be selected/changed at any
time during Sterile Water and Production).

®
Doc. No. OM-3284281-0111 171 (242)
6.1 Sterilizing Sequence 6 Operation

3
vv
Start Conditions
Press START CONDITIONS in the
OPERATION WINDOW.

If the sterilizing icon appear as a push button

with the information symbol (1) the start
conditions are not full filled.
Press the STERILIZING button to check
which start conditions are missing.

4
vv
Start Sequence
a) Press STERILISATION followed by
START in the OPERATION WINDOW.

• When the sterilizing temperature has

been reached, the machine will be
sterilizing for 30 minutes.
• The machine cools down by performing
program steps Cooling 1-3 and
Stabilising.

When the machine is cooled down, sterile

water is indicated on the display.

172 (242) Doc. No. OM-3284281-0111

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6 Operation 6.1 Sterilizing Sequence
5
vv
Check During Sequence
During sterilizing step, visually check
functionality of spray nozzle through the
sight glass in flash vessel.

When the machine is cooled down to

production temperature, sterile water is
indicated on the display.

6
vv
Continue with desired sequence:
• Hibernation
• Production
• AIC
• CIP
• Shut Down

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Doc. No. OM-3284281-0111 173 (242)
6.2 Hibernation Sequence 6 Operation

6.2 Hibernation Sequence

1
vv
Start Conditions
• In step Sterile Water (Step 17)

In hibernation the machine reduces energy

consumption.
To prevent the automatically hibernation
press DISABLE HIBERNATION (1).
Note! If no operator action is taken, the
hibernation will start automatically after 900
1 seconds when in sterile water (step 17) first
time after presterilizing. In the illustration
714 seconds remain.

2
vv
Start Sequence
Press HIBERNATION followed by START
(within 10 seconds).
During hibernation in order to save energy
the capacity will decrease to a minimum,
sterile water cooler temperature is changed
and vacuum of deaerator shuts off.

3
vv
Stop Sequence
Before it is possible to start the
filling/production sequence the hibernation
has to be shut off

Press HIBERNATION followed by FINALIZE

(within 5 seconds).

174 (242) Doc. No. OM-3284281-0111

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6 Operation 6.3 Production Sequence

6.3 Production Sequence

1
vv
Selection/Settings Prior to Start
a) Select capacity/Filling machine in the
PRODUCT AND CAPACITY window.

Note! Can be selected at any time during

Sterile Water and Production. The change
over sequence will take approx. 2 -5 min.
For production to Tetra Alsafe tank press
TANK SYMBOL. (Option).

2
vv
Press the PRODUCT SUPPLY PUMP
followed by START in the OPERATING
WINDOW.

3
vv
a) Fill the product supply line by pressing
V15 to drain or V15 to reject.
b) When the supply line is filled, press V15
to drain or V15 to reject again to close
the valve.

4
vv
Press the PROD SUPPLY PUMP followed
by STOP. in the OPERATION WINDOW.

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Doc. No. OM-3284281-0111 175 (242)
6.3 Production Sequence 6 Operation

5
vv
Start Conditions
Press START CONDITION in the
OPERATING WINDOW.

If the production icon appear as a push

button with an “i” (1) the start conditions are
not fulfilled. Push the button to check which
start conditions are missing.

176 (242) Doc. No. OM-3284281-0111

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6 Operation 6.3 Production Sequence
6
vv
Start Sequence
Press PRODUCTION followed by START in
the OPERATION WINDOW..
• The first filling step is the prepare
production step, which means that cold
water enters the machine to bring down
the filling temperature.
• When the filling temperature (TT6) has
dropped to a preset temperature or a
timer has elapsed, Filling is indicated on
the display.
• The machine will now automatically drain
the water from the balance tank, activate
V13.1 and start the product supply pump.
• A flow counter controls when the product
line contains product only, valve V75
reroutes the flow to the balance tank for
recirculation. (Only if filling directly to
filling machines.)

The machine is ready for production. Signal

is given to the Filling Machines/Alsafe.
Note! If a disturbance occurs during
Production, the machine will automatically
proceed to Emptying and end up in Sterile
water or Parking position.
If a permanent or longer stop at a filling
machine occurs, it is possible to revert to
Sterile water.
Reverting to this phase, sterile water
displaces the product.

7
vv
Check During Sequence
Regular check process values such as:
• flow rate
• temperature
• pressure

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Doc. No. OM-3284281-0111 177 (242)
6.3 Production Sequence 6 Operation

8
vv
Check the pressure drop over the heat
exchanger. If the pressure drop is too big,
production must be stopped and cleaning
has to be done.

It must be taken in consideration to stop

production if the pressure drop has
increased too a high level.
Note! Max pressure after the
homogeniser/booster pump is stated on the
machine sign.
Check the temperature difference between
the heating medium and the product.
Note! Max temperature is stated on the
machine sign.

9
vv
Check Functionality of Steam
Barriers
Verify condensate flow at drain point from
the steam barrier.

CAUTION
Risk of damage
Too much steam might destroy the gasket

10
vv
Stop Sequence
Press one of the following to stop the
production:
• Press PRODUCTION followed by
ABORT. (Only possible in step 20-22) The
machine will immediately revert to sterile
water.
• Press PRODUCTION followed by
FINALIZE (Only possible in step 29,
production.)

Stop AFM before product/water mix reaches

AFM (volume controlled).

Continue with desired sequence.

178 (242) Doc. No. OM-3284281-0111

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6 Operation 6.4 Revert to Water Circulation

6.4 Revert to Water Circulation

1
vv
Revert to Water Circulation
Instead of continuing to circulate the product
during any kind of disturbance, the machine
can be reverted to water circulation.
Press WATER CIRCULATION followed by
START in the OPERATION WINDOW.
The machine will now automatically:
• drain the product from the balance tank to
reject or drain (V75 deactivated),
• deactivate V13,
• deactivation of signal "Product at inlet" to
AFM which will stop filling, before mix-
phase reaches AFM (volume controlled),
• deactivation of signal "Product at inlet" to
Tetra Alsafe tank which will close inlet
valve, before mix-phase reaches inlet
valve (volume controlled).

Note! Max. time for water circulation.

There is a limit for how long time the
machine may run in water circulation before
cleaning is required.

The time in water circulation is dependent of

type of product, quality of product and
temperature of the product in the product
supply pipe.
For example; at a temperature of 15 °C milk
(with a certain quality) can stand about 6
hours before it is destroyed.

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Doc. No. OM-3284281-0111 179 (242)
6.5 Shut Down Sequence 6 Operation

6.5 Shut Down Sequence

1
vv
Can be ordered from all programme steps
except for CIP/AIC.
If ordered from Production, an emptying and
a rinse sequence take place automatically
before the shut down-sequence starts.
The machine will end in Parking position.
Press SHUT DOWN followed by START in
the OPERATION WINDOW.

The balance tank is drained and a cold water

rinse sequence is started. The cooling down
and the machine is ended up in Parking
position.

180 (242) Doc. No. OM-3284281-0111

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6 Operation 6.6 Emergency Stop

6.6 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

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Doc. No. OM-3284281-0111 181 (242)
6.6 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)

182 (242) Doc. No. OM-3284281-0111

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6 Operation 6.7 Cleaning Sequence

6.7 Cleaning Sequence

Cleaning is carried out in the following
vv
sequences:
• Aseptic Intermediate Cleaning-AIC
• Final Cleaning-CIP
• Flush
• Cleaning of Supply Line

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. Follow the instructions that are
given by the supplier.

CAUTION
Risk of insufficient cleaning
The cleaning program is designed for the
products that are specified in the Technical
Data. If any other product is processed, the
cleaning result might be insufficient. Other
products may need new CIP program setup.

Product strainer vv
Note! Optional
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.
d) Clean the element manually.
e) Install the cleaned element when CIP
sequences are finished.

IntelliCIP vv
1
Press INTELLICIP in the INTELLICIP
WINDOW before starting any CIP sequence

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6.7 Cleaning Sequence 6 Operation

Aseptic Intermediate vv
Cleaning - AIC
1
AIC can be ordered to extend the production
period before a full cleaning, CIP, is required.

The AIC takes about 40 minutes. The

machine remains sterile in its aseptic part.

2
vv
Press START CONDITION in the
OPERATING WINDOW.
If the AIC icon appear as a push button with
an “i” (1), the start conditions are not fulfilled.
Push the AIC to check which start conditions
are missing.

3
vv
Start Sequence
a) Go to the operating window and press
desired cleaning program LYE or LYE &
ACID.
b) Press INTERMEDIATE CLEANING
(AIC) followed by START within 10
seconds.

Final Cleaning- CIP Sequence vv

1
Press CIP directly after finished production.
The CIP takes approximately 120 minutes.

184 (242) Doc. No. OM-3284281-0111

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6 Operation 6.7 Cleaning Sequence
2
vv
Press START CONDITION in the
OPERATING WINDOW.

If the CIP icon appear as a push button with

an “i” (1) the start conditions are not fulfilled.
Push the CIP to check which start conditions
are missing.

3
vv
Start Sequence
a) Go to the operating window. and press
desired cleaning program LYE, LYE &
ACID. or PAC CIP.
b) Press CIP followed by START within 10
seconds.

Halt vv
It is possible to temporary halt during
cleaning.

Temporary suspension of the sequence will:

• stop the pumps
• deactivate all valve.
• hold step timer

1
vv
Halt Sequence
Press CIP SEQUENCE followed by PAUSE
within 10 seconds.

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Doc. No. OM-3284281-0111 185 (242)
6.7 Cleaning Sequence 6 Operation

2
vv
Resume from Halt
The halt function can be resumed when the
hold condition is gone.

Press the CIP SEQUENCE followed by

RESTART within 10 seconds.

Emergency Emptying vv
The emergency emptying function is only
selectable from Parking position.
Use the emergency emptying function to:
• flush out the product
• emptying after an emergency stop
to cool down the equipment.

1
vv
Press START CONDITION in the
OPERATING WINDOW.
If the emergency emptying icon appear as a
push button with an “i” (1) the start
conditions are not fulfilled. Push the
EMERGENCY EMPTYING to check which
start conditions are missing.

2
vv
Start Sequence
Press EMERGENCY EMPTYING followed
by START in the OPERATION WINDOW.

186 (242) Doc. No. OM-3284281-0111

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6 Operation 6.7 Cleaning Sequence

Cleaning of Supply Line vv

The cleaning is carried out by an external
CIP-system.

The cleaning solution will be directed

through valve V15, which will pulse to drain
for approx. 10 seconds every 5 minutes.
Valve V15 could be automatically controlled
(if signal is connected).

1
vv
Start /Stop
Press CIP to activate valve V15 during
cleaning of the supply line.

When cleaning of supply line is finished.

Press CIP again to deactivate valve V15.

Maintenance Mode vv
The maintenance function is only selectable
from parking position.
Use the maintenance function to indicate
that maintenance is going on.

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Doc. No. OM-3284281-0111 187 (242)
6.7 Cleaning Sequence 6 Operation

1
vv
Press START CONDITION in the
OPERATING WINDOW.

If the maintenance icon appear as a push

button with an “i” (1) the start conditions are
not fulfilled. Push the button to check which
start conditions are missing.

2
vv
Start Sequence
Press MAINTENANCE followed by START in
the OPERATING WINDOW.

188 (242) Doc. No. OM-3284281-0111

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 7 Care And Cleaning

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Doc. No. OM-3284281-0111 189 (242)
 7 Care And Cleaning

Description
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.

190 (242) Doc. No. OM-3284281-0111

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7 Care And Cleaning Table of Contents

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

7.1 Care ............................................................... 193

7.1.1 Self-Closing Gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
7.1.2 Safety Signs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
7.1.3 Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

7.2 Cleaning ......................................................... 195

7.2.1 Verify Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
7.2.1.1 Lye/Acid Concentration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
7.2.1.2 Recommended Detergents . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
7.2.1.3 Critical control points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
7.2.1.4 After Every CIP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
7.2.1.4.1 Homogenizer Dampers. . . . . . . . . . . . . . . . . . . . . . . . . 198
7.2.1.4.2 Deaerator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
7.2.1.5 At Regularly Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198

7.2.2 External Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199

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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, adjust if necessary.

Check/clean the hinges at regularly intervals.

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Doc. No. OM-3284281-0111 193 (242)
7.1 Care 7 Care And Cleaning

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)

.

7.1.3 Labels
The valve V51 and V951A (option) are safety valves and has labels stating the
correct pressure. Ensure that the label is in place and readable.
For locations of labels, see page 196.

951A

194 (242) Doc. No. OM-3284281-0111

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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

Check daily on the recorder that the cleaning has run the appropriate time with the
appropriate temperatures.

If necessary, adjust cleaning circulation time and detergent concentration.

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
Dairy & Food
Chemical Concentration 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 to avoid solid
particles that cause problems for the feed pumps.

**The equipment is 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.
.

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Doc. No. OM-3284281-0111 195 (242)
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.
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 Tetra Therm Aseptic Flex 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.
Consider the following as a general recommendation for critical control points:
• Holding cell,
• Stabilising holding cell (if available),
• Aseptic or Non-Aseptic dampers,
• Injector,
• Infusion vessel,
• Valve V51 (if steam barrier), or valve V951 see With option 101 (Automatic CIP &
refill of homogenizer dampers),
• Valve V78 (if steam barrier),
• Back pressure valve V330.

With option Automatic CIP & refill of homogenizer dampers ,(valve V51 is replaced).
• Valve V951,
.

(Cont’d)

196 (242) Doc. No. OM-3284281-0111

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7 Care And Cleaning 7.2 Cleaning

(Cont’d)

V51/V951

7 1

5
6

The illustration shows an example of a Tetra Therm Aseptic Flex installation and
location of the critical control points..
1 Dampers. 5 Stabilising holding cell
2 Valve V51 or V951 (Inlet at GS30).
3 Holding cell (Outlet at 6 Stabilising holding cell
TT44). (Outlet at TT04).
4 Holding cell (Outlet at 7 V78 (if steam barrier
TT45). included).
8 Homogenizer with
Automatic CIP & refill
of homogenizer
dampers (option 101)
.

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7.2 Cleaning 7 Care And Cleaning

7.2.1.4 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.

The minimal required cleaning flow is 100% of maximal requested product flow.

Note! If the homogenizer dampers are equipped with Automatic CIP and Refill of
dampers (option 101) 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 (EV11) on
the deaerator and
• check that it is free from any product residue after cleaning,
• clean the silencer manually if necessary.
.

7.2.1.5 At Regularly Intervals

Disassemble the holding cell(s), and valve V51, V78 (if steam barrier is included).
Check that they are free from any product residues after cleaning.

Verify functionality of CIP nozzles on

• Balance tank,
• If the product balance tank has no CIP device, it is recommended to clean it
manually.
• Deaeration vessel (if applicable).

Option 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.

198 (242) Doc. No. OM-3284281-0111

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7 Care And Cleaning 7.2 Cleaning

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.
.

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8 Option Machine Edition

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Doc. No. OM-3284281-0111 201 (242)
 8 Option Machine Edition

Description

202 (242) Doc. No. OM-3284281-0111

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8 Option Machine Edition Table of Contents

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

8.1 General Information ........................................... 207

8.1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
8.1.2 Log In/Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
8.1.3 General windows and definitions . . . . . . . . . . . . . . . . . . . . . . . . 208
8.1.3.1 Main Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
8.1.3.2 Header . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
8.1.3.3 Set Point Selections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
8.1.3.4 Button Selections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
8.1.3.5 Alarm Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
8.1.3.6 An Object Is Forced. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
8.1.3.7 A PID Controller in Manual Mode . . . . . . . . . . . . . . . . . . . . . . 209
8.1.3.8 A Phase Is Allocated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
8.1.3.9 CIP Memory Active . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
8.1.3.10 Indication of Transport Phase . . . . . . . . . . . . . . . . . . . . . . . . . 210
8.1.3.11 Selectable Indication Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
8.1.3.12 Not Selectable Indication Area . . . . . . . . . . . . . . . . . . . . . . . . 210
8.1.3.13 Local / Remote Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
8.1.3.14 Go to Parameter Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
8.1.3.15 Interlock/Running Fault Button. . . . . . . . . . . . . . . . . . . . . . . . 211
8.1.3.16 Store Parameter Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
8.1.3.17 Leave Window Button. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
8.1.3.18 Zoom down to Unit Window . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
8.1.3.19 Process Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

8.1.4 Key Scripts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

8.1.5 Button Bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
8.1.5.1 Window Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
8.1.6 Window Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
8.1.7 Window Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213

8.2 Production Control and Supervision...................... 214

8.2.1 Process Line Overview Window . . . . . . . . . . . . . . . . . . . . . . . . . 214

8.3 Process Unit window.......................................... 215

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Table of Contents 8 Option Machine Edition

8.3.1 Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215

8.3.1.1 Dialogue Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
8.3.1.2 Phase Buttons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
8.3.1.3 How to Start and Stop Sequences in the Unit . . . . . . . . . . 218

8.3.2 Interlock Running Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

8.3.3 Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
8.3.4 Selection Parameter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
8.3.5 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
8.3.6 Activations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
8.3.7 PID Controllers, Guards and Analogue Ramp . . . . . . . . . . 223
8.3.7.1 PID Controller Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
8.3.7.2 PID Parameters Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
8.3.7.3 Guard Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
8.3.7.4 Ramp Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
8.3.7.5 Guard/Ramp Parameters Window . . . . . . . . . . . . . . . . . . . . . 228

8.3.8 Service Menus and Trending . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

8.3.8.1 Service Menu Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
8.3.8.2 Register Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
8.3.8.3 Language Selection Window . . . . . . . . . . . . . . . . . . . . . . . . . . 230
8.3.8.4 Communication Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
8.3.8.5 Recipe Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
8.3.8.6 Control Module Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
8.3.8.6.1 Control Module - Motor . . . . . . . . . . . . . . . . . . . . . . . . 233
8.3.8.6.2 Control Module - Motor Parameters . . . . . . . . . . . . 234
8.3.8.6.3 Control Module - Motor Extended
Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .234
8.3.8.6.4 Control Module - Valve . . . . . . . . . . . . . . . . . . . . . . . . . 235
8.3.8.6.5 Control Module - Valve Parameters . . . . . . . . . . . . . 235
8.3.8.6.6 Control Module - Valve Extended
Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .236
8.3.8.6.7 Control Module - Analogue In . . . . . . . . . . . . . . . . . . 236
8.3.8.6.8 Control Module - Analogue In Parameters . . . . . . 236
8.3.8.6.9 Control Module - Analogue Out . . . . . . . . . . . . . . . . 236
8.3.8.6.10 Control Module - Analogue Out
Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .237

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8.3.8.6.11 Control Module - Digital In . . . . . . . . . . . . . . . . . . . . . 237

8.3.8.6.12 Control Module - Digital In Parameters . . . . . . . . . 237
8.3.8.6.13 Control Module - Digital Out. . . . . . . . . . . . . . . . . . . . 237
8.3.8.6.14 Control Module - Digital Out Parameters. . . . . . . . 237
8.3.8.7 Alarm Windows. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
8.3.8.8 Trend Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
8.3.8.8.1 Selection and Setup of Trends . . . . . . . . . . . . . . . . . 240

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8 Option Machine Edition 8.1 General Information

8.1 General Information

8.1.1 Introduction
Tetra Plant Master Machine Edition is a remote User Interface that allows operator to
control the Branded Processing Unit with same functionality as described earlier plus
logging of alarms and trends.

For detailed information on how to operate the Branded Processing Unit information
please check chapter Operation.

8.1.2 Log In/Out

The system has a safety system allowing each user specific defined possibilities.
Also all actions done are logged together with the name of the logged in user.
Therefore it is important that each user does Log In and Log Out properly.

When logged on the Log In/Out window can be opened with the button always
available in the Button Bar

Users can Log In or Log Out. Type your Name in the upper field and Password in
lower field. Acknowledge by clicking Login the button with the key.
The name of the logged on user is shown in the Header.

To log out, press Logout button.

The User needs to logout when leaving the Operator Station. If a user leaves without
logging out, the system logs out automatically after a specified time.

Depending on the user rights you have, different functions are controllable. There is
however no limitation to view information.
Every user has personal access and user rights.
.

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8.1.3 General windows and definitions

The operator interface is designed with some general functions and features, which
always can be used in the operator interface.
The operator is using the mouse and the screen in combination, in a way that most
people using PCs already are familiar with.

With the mouse you can:

• POINT Move the pointer on the screen until it rests on the object you want to
select.
• DRAG Hold the left mouse button down while moving the mouse. (On Pop-up
windows)
• SELECT and CLICK Point at the object (unit) or function button. Press and
release the left mouse button quickly. All objects and buttons, possible to click on,
display a frame when you point at them.
.

8.1.3.1 Main Body

The main part of the screen will change as the user change between overview,
process cell and support pictures.
.

8.1.3.2 Header
The header is placed in top of the screen and is always shown. The header shows,
Date, Time, Logged on User and Current full-size window name.

1 2 3
1 Time/Date
2 Logged in user
3 Actual shown window
.

8.1.3.3 Set Point Selections

On all Guard, Controller, Increase decrease pictures and other set point pictures this
button is showed.
Note! Set point to change. If the area is white the change of set point is possible. To
change set point it is necessary to be logged in as supervisor.

3
1 2
1 Set point name
2 Set point to change
3 Indication of actual set
point selected
.

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8 Option Machine Edition 8.1 General Information

8.1.3.4 Button Selections

On menu, parameter, controllers and service windows buttons is viewed. When
selected its green when selected or grey when not selected with some buttons is
there a white field connected with the name of the button function. To select a button
function it is necessary to be logged in and the remote local key must be in remote
position. When not in remote mode the buttons will be flat and if not logged in they
will not be selectable. For more information about button see chapter Control Panel.
Here are two examples.

8.1.3.5 Alarm Indication

This symbol is visible when an alarm is active.

Alarm active
.

8.1.3.6 An Object Is Forced

This symbol is used to indicate when an object is forced in the machine.

Object is forced
.

8.1.3.7 A PID Controller in Manual Mode

This symbol is visible when a PID controller has manual mode selected.

PID controller in manual mode

.

8.1.3.8 A Phase Is Allocated

This symbol is visible if a phase is allocated or if the machine is in local mode.

A phase is allocated/Local mode

.

8.1.3.9 CIP Memory Active

This symbol is visible if CIP memory is on (selects from setting menu).

CIP memory active

.

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8.1.3.10 Indication of Transport Phase

For example filling to filling machine or tank.

Indication of transport phase

.

8.1.3.11 Selectable Indication Area

It is possible to select it an area if the area is upraised.

Selectable indication area

.

8.1.3.12 Not Selectable Indication Area

An area not upraised is only for viewing a process value or information. It is not
selectable.

Not selectable indication area

.

8.1.3.13 Local / Remote Control

Local/ remote is selected by means of the key switch in the panel front. (PlantMaster
ME is placed in a remote control room).

Local control means that the plant is operated from the TPOP control system. It is
then possible to change windows on the PlantMaster ME and view everything, but it
is not possible to operate from the PlantMaster ME.

Local control
Remote control means that the plant is operated from the Tetra PlantMaster
Machine Edition.

Remote control
.

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8 Option Machine Edition 8.1 General Information

8.1.3.14 Go to Parameter Button

This button opens a parameter window.

Go to parameter
.

8.1.3.15 Interlock/Running Fault Button

This button opens an Interlock/Running fault window for a specific phase.

Interlock/Running fault button

.

8.1.3.16 Store Parameter Button

This button stores a changed recipe or register value into PLC.

Store parameter
.

8.1.3.17 Leave Window Button

This button closes the selected window.

Leave window
.

8.1.3.18 Zoom down to Unit Window

This button opens the process unit window.

Zoom down to unit window

.

8.1.3.19 Process Value

Includes values set point, output and indication symbols. The symbol is used in
several places.

1 2 3
1 Process value
2 Set point
3 Output
.

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8.1.4 Key Scripts

The following key scripts are used in the application:
• Ctrl + a Show alarm window
• Ctrl + l Show login window
• Ctrl + o Log out
• Ctrl + p Print screen
• F11 Show Trend window
• F12 Show calculator
• F3 Show previous window
.

8.1.5 Button Bar

The alarm list is shown in the button bar window with the two latest occurred alarms
and a scrolling possibility to more alarms. Each alarm shows date, time and alarm
text. The alarm text defines WHICH item is wrong and WHAT the error is.

Button bar
Below the alarm the navigation button are shown with the actual windows that is
possible to reach from here.

1 2 3 4 5

7 8
6
9
1 Go to home 6 Service menu
2 Go back one window 7 Home window
3 Calculator 8 Trend window
4 Print screen 9 Alarm window
5 Log in/out window
.

8.1.5.1 Window Navigation

After logged on, the User Interface is using full-size windows (called pictures), and
pop-up windows. All buttons in the button bar allow change from one full-size
window to another window. To open a Pop-up window move the mouse pointer over
a unit or object on the full size window so a frame appear. Then click with the left
mouse button inside the frame.
.

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8 Option Machine Edition 8.1 General Information

8.1.6 Window Structure

The information about the Branded Processing Unit is organised in a hierarchy of
pictures.

The Overview picture gives an overview with basic information on plant status. All
information regarding ongoing operations and process information is available here.
When operating should be done, a suitable Unit button Menu must be popped up.
The background process cell picture remains.

It is possible to move around the menus on the screen. Point at the Title bar and
drag. Several menus can be opened in a picture at the same time. When you change
to another process picture, the menus close.
Most windows have some information that the operator cannot change.
.

8.1.7 Window Overview

This is a typical window overview.

2 3

4 5 6

1 Line window
2 Unit window
3 Menu
4 Activation
5 Selections
6 Interlock/Running
Fault
.

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8.2 Production Control and
Supervision 8 Option Machine Edition

8.2 Production Control and Supervision

8.2.1 Process Line Overview Window
The process line overview window shows the unit line. It contains dynamic
information on operation status for the unit or units. From here, you can navigate to
menu “pop-up” window and the more detailed process unit window.

5 4 3 2

7
8

9 10 11
Pos. Description
1 Filling machine indication with the status of filling machine and line.
2 Production temperature in unit.
3 Machine unit name.
4 Material name in unit.
5 Go to process unit window.
6 Go to menu.
7 Flow in unit in l/h.
8 Sterile status of supply line.
9 Sterile and CIP status of the machine unit.
10 Main step number of the machine unit.
11 Outlet temperature of the unit.

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8 Option Machine Edition 8.3 Process Unit window

8.3 Process Unit window

The process unit window shows the unit in more detail. It contains dynamic
information on operation status for the unit. From here, you can navigate to “pop-up”
menu windows, “pop-up” activation windows, PID controller windows, guard
windows, and ramp windows.

1 2 3 4 5 6

7 8 9 10 11 12 13

1 Sub step number. 8 Indication of phases in

2 Open guard window machine unit.
for the specific guard. 9 Equipment status of
3 Open PID controller the machine unit.
window for the specific 10 Main step name of the
controller. If the button machine unit.
is yellow, the specific 11 Main step number of
controller is in manual the machine unit.
mode. 12 Time or volume
4 Open ramp window for symbol indication.
the specific object. 13 Time in step.
5 Temperature
indication.
6 Filling machine
indication with the
status of filling
machine and line.
7 Open the
ACTIVATIONS
window.

8.3.1 Menu
The menu pops up when the button bar in the line or unit window is clicked. It is used
to start and stop; select and deselect machine functions.

The menu contains several phase operation buttons and selection buttons. The
buttons also indicate the status of the operation by change of colour or icon.
The menu is separated into three parts. Source part with tanks or supply equipment,
unit line phases part and destination part.
(Cont’d)

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(Cont’d)

6 5 4 3 2 1

8 9 10 11
Pos. Description.
1 Destination part of menu with buttons for selecting filling machines or
destination tanks.
2 Open the parameter window for the specific phase
3 The name and number of the specific unit line.
4 Open interlock running fault window for the specific phase. This
button is blue if any interlock or running fault is active.
5 Control button for indication and selecting phase command for
start/stop of sequence.
6 Source part of menu with buttons for selecting source equipment or
source tanks.
7 Control button. Start to push here and then at start or finalise to start
and stop the pump.
8 Open the parameters window.
9 In this the material name, product number, recipe number or capacity
number is indicated
10 Dialogue buttons.
11 Leave unit menu.

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8 Option Machine Edition 8.3 Process Unit window

8.3.1.1 Dialogue Buttons

Here is a description of the dialogue buttons. You need to be logged in as at least
operator to do any commands, for maintenance sequence you need to be logged in
as maintenance.

Start Re- Hold Abort Final-

start ise

8.3.1.2 Phase Buttons

The phase buttons depends on unit. Some example on phase buttons are illustrated
below.

1 2 3 4 5

6 7 8 9

1 Sterilization
2 Circulation Water
3 Hibernation
4 Production
5 AIC
6 CIP
7 Shut down
8 Emergency empty
9 Maintenance
.

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8.3.1.3 How to Start and Stop Sequences in the Unit

Here is an instruction example on how to start or stop a sequence.

a) Start to log in as at least operator.

b) Check for Interlocks and running faults see also8.3.2 Interlock Running Fault.
c) If the Interlocks and running faults button (1) is blue, then push it and check if
the blue texts are interlock and running faults.
d) If the text "Phase parameter not OK" is blue, select the “Go to parameter”
button (2) for the sequence.
e) Select the right phase mode button that is used for the specific sequence.
f) Push for example one of the “Phase Buttons” (3), then any of the dialogue
buttons are selectable.
g) Finally select the command (4) you want to run.

4
.

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8 Option Machine Edition 8.3 Process Unit window

8.3.2 Interlock Running Fault

You reach this window by pressing the interlock/running fault button (1). If the button
is blue, there is an active interlock or running fault. If the sequence is active only
running fault texts are displayed, otherwise both running fault and interlock texts are
displayed.
For more information about interlock running fault texts, see chapter Control Panel.

2 1

4
1 interlock/running fault
2 Unit name number and
the name of the
sequence.
3 Description of interlock
or running fault. (Blue
text indicates an active
interlock or running
fault.)
4 The interlock or
running fault text that
caused the last state
change for the current
sequence.
.

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8.3.3 Parameters
You reach the parameters window by pressing the “Go to parameter” button (1).
There is one parameter window for each phase, with parameters dedicated to the
specific sequence. In these windows you can set the phase mode button if logged in
as operator and change the parameters if logged in as supervisor.

2 1

1 Go to parameter
button
2 Phase mode buttons.
(In this case for CIP.
They need to be
selected before
selecting the phase
sequence.)
3 Phase parameter. (In
this case for CIP.)
4 Leave this window
.

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8 Option Machine Edition 8.3 Process Unit window

8.3.4 Selection Parameter

Here is the parameter window for the whole machine unit. You reach this window by
pressing the “Go to parameter” button (1) in the lower left corner of the unit menu.
In this window are selection buttons for process equipment etc. They are selectable if
logged in as operator and key in remote mode. Here are also possibilities to change
equipment, cleaning and sterile status if maintenance are running and logged in as
maintenance by using a drop down box.

For more information about the buttons see chapter Control Panel.

3
4
5

6 7 8
Pos Description
1 Go to parameter button
2 Selection buttons for equipment, products and capacities
3 Drop down box for viewing and selection of equipment status
4 Drop down box for viewing and selection of cleaning status
5 Drop down box for viewing and selection of sterile status
6 Viewing of equipment status for the supply line to the machine unit
7 Go to connections window
8 Leave this window
.

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8.3.5 Connections
This is the connections window for the unit if used. The user can reach this window
by clicking the button below, in the selection parameter window. This window shows
swing bend panels for different equipment options.

• Grey colour means that a pipe can be connected.

• Yellow colour means that a pipe is incorrectly connected for the selection.
• Green colour means that a pipe is correctly connected for the selection.

2
Pos Description
1 Swing bend panel with pipes
2 Leave this window
.

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8 Option Machine Edition 8.3 Process Unit window

8.3.6 Activations
Green colour means activated object and yellow colour means fault on the object. It
is possible to click on the objects and force, suppress or adjust parameter for the
selected object if logged in as at least maintenance.

8.3.7 PID Controllers, Guards and Analogue Ramp

These windows are available from the process unit window. The unit must be in local
mode and the operator must be logged in as supervisor to change parameters or
push buttons.
See below about windows for PID controllers, guard, analogue ramp windows and
set point windows.
.

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8.3.7.1 PID Controller Window

1
2
3

4 10

5
6 7 8 9
Pos. Description.
1 PID controller name.
2 If controller status is in running mode, this square is green.
3 If controller status is in running fixed output mode, this square is
green.
4 Bar graph and numeric value for controller input signal.
5 Go to PID parameter window.
6 Bar graph and numeric value for controller set point signal. If set point
is in manual mode it is possible to set the manual value here.
7 Bar graph and numeric value for controller output signal. If output is
in manual mode it is possible to set manual value here.
8 Manual/Auto output button for PID controller. Is green if in manual
mode.
9 Manual/Auto set point button for PID controller. Is green if in manual
mode.
10 Trend plot. Green line represents process values trend. Blue line
represents set points. White line represents output values for the last
5 minutes (plot starts when the window is opened).

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8 Option Machine Edition 8.3 Process Unit window

8.3.7.2 PID Parameters Window

1

2
3
4
5

8 9
1 PID controller name.
2 Running P-value
(gain) at selected
controller.
3 Running I-value
(integration time) at
selected controller.
4 Running D-value
(derivation time) at
selected controller.
5 PID parameters set 1.
6 PID parameters set 2.
7 PID parameters set 3.
8 Set points 1-16. Only
visible if used.
9 Click to leave this
window.
.

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8.3.7.3 Guard Window

1

2
3 5

1 Guard name
2 Bar graph and numeric
value for guard set
point signal
3 Bar graph and numeric
value for guard input
signal
4 Go to guard/ramp
parameter window
5 Trending of process
values (green line) and
set points (blue line)
over the last 5 minutes
(only when window is
open)
.

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8 Option Machine Edition 8.3 Process Unit window

8.3.7.4 Ramp Window

3 4

Pos Description
1 Ramp name
2 Bar graph and numeric value for ramp set point signal
3 Go to set point parameter window
4 Leave this window
.

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8.3.7.5 Guard/Ramp Parameters Window

1 Guard/ramp name
2 Set points 1 to 16
3 Leave this window
.

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8 Option Machine Edition 8.3 Process Unit window

8.3.8 Service Menus and Trending

8.3.8.1 Service Menu Overview

2
3
4
5

1 Go to control module
windows
2 Go to TREND window
3 Go LANGUAGE
SELECTION window
4 Go to REGISTER
MAINTENANCE
window
5 Go to RECIPE window
.

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8.3.8.2 Register Maintenance

2 1

3
4
5
6
7

8
9
1 Increase decrease 6 Send to register if
register number logged in as
2 Integer values of supervisor
register 7 Real values of register
3 Current register 8 CIP Memory button
number 9 Read configure bits
4 Current value in from PLC if logged in
register as supervisor
5 New value to send to
register
.

8.3.8.3 Language Selection Window

Select language by clicking on the corresponding flag (1) for the Tetra Plant Master
ME application.

1 Language selection
.

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8 Option Machine Edition 8.3 Process Unit window

8.3.8.4 Communication Window

Used for configure views of steps, equipment and CIP status on the line window,
green marked means viewed.

1
1
2
3
4
5
1

Pos Description
1 Not used here
2 Equipment or CIP status
3 Step number
4 Queue number (not used here)
5 Only for Tetra Pak personnel
.

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8.3.8.5 Recipe Window

Edit recipe for the Tetra Plant Master ME application. It is necessary be logged in as
supervisor to change parameter here.

Note! New edit recipe selection may not be the same as source or destination
recipe when copying or editing recipe.

1 2
Pos Description
1 Button to copy recipe
2 Button to save edited recipe. Yellow if recipe parameter is changed
.

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8 Option Machine Edition 8.3 Process Unit window

8.3.8.6 Control Module Window

Detailed information is shown about forced and masked objects in the object
overview window. Object Overview pictures are available from the service menu.

8.3.8.6.1 Control Module - Motor

1
2

1 Force on/off or Auto.

2 Masking of alarm.
3 Simulation On/Off.
.

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8.3.8.6.2 Control Module - Motor Parameters

8.3.8.6.3 Control Module - Motor Extended Parameters

1 Running time
.

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8.3.8.6.4 Control Module - Valve

3
4

5
6

7
1
2

1 Masking of alarm.
2 Simulation on/off.
3 Function on/off.
4 Activate.
5 Deactivated.
6 Feedback.
7 Force on/off or Auto.
.

8.3.8.6.5 Control Module - Valve Parameters

1
2

1 Delay to activate.
2 Delay to deactivate.
.

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8.3.8.6.6 Control Module - Valve Extended Parameters

1 Counter of strokes.
.

8.3.8.6.7 Control Module - Analogue In

2
1

1 Suppress of alarm.
2 Force on/off or Auto.
.

8.3.8.6.8 Control Module - Analogue In Parameters

1 Setting of limit
parameters.
.

8.3.8.6.9 Control Module - Analogue Out

2
1

1 Suppress of alarm.
2 Force on/off or Auto.
.

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8 Option Machine Edition 8.3 Process Unit window

8.3.8.6.10 Control Module - Analogue Out Parameters

1 Setting of limit
parameters
.

8.3.8.6.11 Control Module - Digital In

1 Suppress of alarm.
.

8.3.8.6.12 Control Module - Digital In Parameters

1 Counter of strokes.
.

8.3.8.6.13 Control Module - Digital Out

1 Force on/off or Auto.

.

8.3.8.6.14 Control Module - Digital Out Parameters

1 Counter of strokes.
.

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8.3 Process Unit window 8 Option Machine Edition

8.3.8.7 Alarm Windows

The alarm bar is visible in the lower part of the screen, and shows the latest alarm in
all windows.

The alarm list will open by clicking this button on the button bar. It is possible to
scroll the Alarm list and sort the alarm in groups or by clicking the header. The
history alarms looks the same but without acknowledge button.

1 2
1 Group/sort alarms
2 Acknowledge alarm
.

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8 Option Machine Edition 8.3 Process Unit window

8.3.8.8 Trend Window

In the trend window selected parameters are visualised with the selected colour.

1 8

2
9
3
10
4
5
6

7
Pos. Description
1 Process value range.
2 Move slider left.
3 Settings for time span current view.
4 Settings for scrolling historical trends.
5 Reset all pens.
6 Update trend curves.
7 Select which process value to be represented by which colour.
8 Click to open the HISTORICAL TREND SETUP window.
9 Move slider right.
10 Measurement slide, there are two. Move them to check values and
zoom in.
.

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8.3 Process Unit window 8 Option Machine Edition

8.3.8.8.1 Selection and Setup of Trends

Here the trend values are selected and chart start, length and chart display mode
are changed.

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