OM

Operation Manual
Tetra Therm® Aseptic Flex 1
TPOP-E

WARNING
Read and follow all safety precautions before working on or near
this equipment.
Read all safety precautions throughout this manual and on safety
signs attached to this equipment. Failure to follow all safety
precautions could result in death or serious injury.

Doc. No. OM-1218635-0101

Copyright © 2004 Tetra Pak Group
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

and all Tetra Pak products are trademarks belonging to the Tetra Pak Group.
The content of this manual is in accordance with the design and construction of the machine or
equipment at the time of publishing. Tetra Pak reserves the right to introduce design modifications
without prior notice.
This document was produced by:
Tetra Pak Dairy & Beverage Systems AB
Ruben Rausings gata
S-221 86 LUND
Sweden
Additional copies can be ordered from Tetra Pak Parts or the nearest Tetra Pak office. When ordering
additional copies, always provide the document number. This can be found in the machine specification
document. It is also printed on the front cover and in the footer on each page of the manual.
Doc. No. OM-1218635-0101
Issue 2005-02
This manual is valid for: 1 Introduction
T5844410033
Series No./ Machine No. Sign.
2 Safety Precautions

3 General Description

OM
Operation Manual
4

5
Process Description

Control Panel

6 Alarm and
Tetra Therm® Aseptic Troubleshooting
Flex 1 7 Preparations
TPOP-E
8 Operation
Tubular heat exchanger 9 Care and Cleaning

Doc. No. OM-1218635-0101

Issue 2005-02

Tetra Pak Dairy & Beverage Systems AB

Valid for:
 1 Introduction

Doc. No. OM-1218635-0101 1 - 1 (6)

 1 Introduction

This page intentionally left blank

1 - 2 (6) Doc. No. OM-1218635-0101

1 Introduction Table of Contents

Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5
Intended Use of This Tetra Pak Equipment . . . . . 1 - 5
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5
Unit Identification. . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5

Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 6
Operation Manual (OM) . . . . . . . . . . . . . . . . . . . . . 1 - 6
Design Modifications . . . . . . . . . . . . . . . . . . . . . . . 1 - 6
Further Copies . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 6

Doc. No. OM-1218635-0101 1 - 3 (6)

 1 Introduction

This page intentionally left blank

1 - 4 (6) Doc. No. OM-1218635-0101

1 Introduction Equipment

Equipment
Intended Use of This Tetra Pak Equipment
This unit 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.

Service
If problems are encountered when operating the unit, contact the nearest
Tetra Pak service station.

Manufacturer
This Tetra Pak equipment was produced by:
Tetra Pak Dairy & Beverage Systems AB
Ruben Rausings gata
S-221 86 LUND
Sweden

Unit Identification
All units carry a machine plate stating:
– unit identification
– data unique to the unit
Have this information available before contacting Tetra Pak concerning this
particular unit.

2 1 Machine type
2 Drawing specifications
3 Machine serial number
3
4 Designed by
4 5 Manufacturer
6 Design TS (°C)
5 7 Notified body
6 8 Year of manufacture
9 Group of fluid
7 10 Design PS (bar)

10 9 8

Doc. No. OM-1218635-0101 1 - 5 (6)

Document 1 Introduction

Document
Operation Manual (OM)
The purpose of this Operation Manual is to provide the operator with
information on how to operate the machine.
Tetra Pak recommend that you study it carefully, and - above all - ensure its
availability to those who will be operating the unit.
Furthermore, it is important that you:
– keep the manual for the life of the equipment
– pass the manual on to any subsequent owner or user of the equipment.
Tetra Pak will not be held responsible for any breakdown of the equipment
caused by the owner’s failure to follow the instructions given in this manual.

Design Modifications
The information given in this document is in accordance with the design and
construction of the machine at the time it was delivered by the Tetra Pak
machine production facility.

Further Copies
Additional copies can be ordered from the nearest Tetra Pak service station.
When ordering technical publications, always quote the document number
printed on the front cover of the document concerned.

1 - 6 (6) Doc. No. OM-1218635-0101

2 Safety Precautions

Doc. No. OM-1218635-0101 2 - 1 (20)

 2 Safety Precautions

This page intentionally left blank

2 - 2 (20) Doc. No. OM-1218635-0101

2 Safety Precautions Table of Contents

Safety Messages Description. . . . . . . . . . . . . . . 2 - 5

Personnel Requirements . . . . . . . . . . . . . . . . . . 2 - 6
Skilled Person . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 6
Instructed Person. . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 6

Safety Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 7
Locations of Safety Signs . . . . . . . . . . . . . . . . . . . 2 - 9

Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 10
Emergency Stop. . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 10
EMERGENCY STOP Push-Buttons . . . . . . . . . . . 2 - 11
Safeguards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 12
Warning Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 13

Personal Protection. . . . . . . . . . . . . . . . . . . . . . 2 - 14
Noise Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 14
Entanglement Hazard . . . . . . . . . . . . . . . . . . . . . 2 - 14

Hazardous Materials . . . . . . . . . . . . . . . . . . . . . 2 - 15

Supply Systems. . . . . . . . . . . . . . . . . . . . . . . . . 2 - 16
Electrical Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 16
Socket Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 17
Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 18
Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 19
Steam Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 19
Water Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 19

Doc. No. OM-1218635-0101 2 - 3 (20)

 2 Safety Precautions

This page intentionally left blank

2 - 4 (20) Doc. No. OM-1218635-0101

2 Safety Precautions Safety Messages Description

Safety Messages Description

A safety message is always accompanied by a safety alert symbol and a
signal word.

This is the safety alert symbol. It 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
Danger indicates an imminently hazardous situation which, if not
avoided, will result in death or serious injury.

WARNING
Warning indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.

CAUTION
Caution indicates a potentially hazardous situation 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.

Doc. No. OM-1218635-0101 2 - 5 (20)

Personnel Requirements 2 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 electricity, mechanical systems, and so on.

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.

2 - 6 (20) Doc. No. OM-1218635-0101

2 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.

There are two types of safety sign

• ISO signs are used worldwide
• ANSI signs are used in the United States only

The table shows all safety signs that are located on this equipment.
Note! The position numbers (Pos.) in the table refer to the positions in
the illustration(s) in the Locations of Safety Signs section.

Pos. ISO sign ANSI sign

1
WARNING
Moving parts
can crush and cut.
Do not operate with guard
removed.
Follow lockout procedure
before maintenance.

Moving parts can crush and cut.

Do not operate with guard removed.
Follow lockout procedure before maintenance.
2
WARNING
Hazardous noise.
Risk of impaired hearing.
Wear hearing protection.

Hazardous noise.
Risk of impaired hearing.
Wear hearing protection.
3
WARNING
Chemical burn hazard.
Wear personal protective
equipment.

Chemical burn hazard.

Wear personal protective equipment.

Doc. No. OM-1218635-0101 2 - 7 (20)

Safety Signs 2 Safety Precautions

Pos. ISO sign ANSI sign

4
WARNING
Hot surface.
Do not touch.
Follow lockout procedure
before maintenance.

Hot surface.
Do not touch.
Follow lockout procedure before maintenance.
5

Equipment sensitive to welding

First, disconnect all power and fuses in panel.
Do NOT weld on panel. Ground close to welding point.

2 - 8 (20) Doc. No. OM-1218635-0101

2 Safety Precautions Safety Signs

Locations of Safety Signs

Note! Make sure that each safety sign is undamaged and in its
correct position after installation and maintenance. Replace all
missing or damaged safety signs immediately.

The illustration shows where the safety signs are located. The position
numbers refer to the table in the Safety Signs section.

2, 3, 4

Doc. No. OM-1218635-0101 2 - 9 (20)

Safety Devices 2 Safety Precautions

Safety Devices
WARNING
Unshielded hazards.
Never inch or run this equipment if any safety device is inoperative.

Change inoperative components of the safety system immediately.

WARNING
Hazardous Voltage.
Activating a safety device, such as pressing an EMERGENCY STOP
push-button or opening a door, does not disconnect the power supply
from this equipment.

Emergency Stop
Emergency stop devices are used to stop this equipment immediately in an
emergency. Learn the positions of all emergency stop devices and how to use
them.
Instructions for a normal production stop are included in the Stop chapter of
the Operation Manual.

2 - 10 (20) Doc. No. OM-1218635-0101

2 Safety Precautions Safety Devices

EMERGENCY STOP Push-Buttons

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

Doc. No. OM-1218635-0101 2 - 11 (20)

Safety Devices 2 Safety Precautions

Safeguards
WARNING
Moving machinery.
Never defeat or bypass the interlocking devices.

All movable guards, such as doors and covers, leading to hazardous areas are
fitted with interlocking devices, usually electric safety switches. These
devices are part of the safety system and must never be defeated, bypassed,
or otherwise made inoperative.

CAUTION
Burn hazard.
Parts of this equipment protected by safeguards may be thermally 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 opening a movable guard.

The location of each movable guard is shown by an arrow.

1 Tetra Alex (400 models

only)
2 Tank cover

2 - 12 (20) Doc. No. OM-1218635-0101

2 Safety Precautions Safety Devices

Warning Lamp
A warning lamp 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
3 2 Yellow light
3 Green light

Doc. No. OM-1218635-0101 2 - 13 (20)

Personal Protection 2 Safety Precautions

Personal Protection
This section applies to all personnel at all times when this equipment is in
operation. For special personal protection required when handling hazardous
materials, see the Hazardous Materials section.

Noise Hazard
WARNING
Hazardous noise.
Risk of impaired hearing.
Wear hearing protection whenever this equipment is in operation.

CAUTION
Hazardous noise.
Risk of impaired hearing.
Hearing protection is recommended 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.

2 - 14 (20) Doc. No. OM-1218635-0101

2 Safety Precautions Hazardous Materials

Hazardous Materials
WARNING
Contact with chemicals can cause death, serious injury, and
illness.
Always follow the chemical manufacturer’s instructions when handling
chemicals.

Make sure that

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

Note! Learn the locations of all washing facilities in order to act

immediately in case of an accident.

Doc. No. OM-1218635-0101 2 - 15 (20)

Supply Systems 2 Safety Precautions

Supply Systems
Electrical Cabinet
DANGER
Hazardous voltage.
Will shock, burn, or cause death.
The power supply disconnector must be switched 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.

2 - 16 (20) Doc. No. OM-1218635-0101

2 Safety Precautions Supply Systems

Socket Outlet

WARNING
Hazardous voltage.
Can shock, burn, or cause death.

The illustrations show the socket outlet (1) and the residual current device.
Their locations in the electrical cabinet (2) are shown by arrows.

1 Socket outlet
2 Electrical cabinet

GF505841

Doc. No. OM-1218635-0101 2 - 17 (20)

 Supply Systems 2 Safety Precautions

Power Supply
DANGER
Hazardous voltage and moving machinery.
The power supply disconnector must be switched 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 power supply systems to be on.

These exceptions are clearly stated in the Maintenance Manual.
The illustration shows the power supply disconnector. The arrow shows its
location on this equipment.
‘

NOTE: The lock is not a part of the delivery

2 - 18 (20) Doc. No. OM-1218635-0101

2 Safety Precautions Supply Systems

Air Supply
WARNING
Compressed air and moving machinery.
Close the main air valve and secure it 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 air supply systems to be on.

These exceptions are clearly stated in the Maintenance Manual.

Steam Supply
WARNING
Hot steam can cause scalds.
Pressurized steam can be discharged unexpectedly.
Close the steam supply valve and secure it with a lock, 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 Maintenance Manual.

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
WARNING
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 clearly stated in the Maintenance Manual.

Doc. No. OM-1218635-0101 2 - 19 (20)

Supply Systems 2 Safety Precautions

This page intentionally left blank

2 - 20 (20) Doc. No. OM-1218635-0101

3 General Description

Doc. No. OM-1218635-0101 3 - 1 (8)

 3 General Description

This page intentionally left blank

3 - 2 (8) Doc. No. OM-1218635-0101

3 General Description Table of Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 5
Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 5
Operator´s Working Area . . . . . . . . . . . . . . . . . . . 3 - 5
Risk Area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 5
Main Components . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 6
Manual Valve Operation Guide . . . . . . . . . . . . . . . 3 - 7

Doc. No. OM-1218635-0101 3 - 3 (8)

 3 General Description

This page intentionally left blank

3 - 4 (8) Doc. No. OM-1218635-0101

3 General Description Introduction

Introduction
This chapter will give a survey of the plant under the following headlines:
• Applications
• Operator´s work station
• Risk area
• Main components
• Manual valve operation guide

Applications
Aseptic processing module for indirect UHT treatment in tubular heat
exchangers of milk, juice, tea, soy milk.

Operator´s Working Area

Mainly in the front of the control panel, see figure below.

Risk Area
One metre around the equipment due to:
– hot pipes and equipment
– jets of hot liquid, steam and cleaning solution

Min 600mm

Min 600mm

Doc. No. OM-1218635-0101 3 - 5 (8)

Introduction 3 General Description

Main Components
Note! All manually operated valves and all gauges are clearly marked
with numbers.

2
3

Main components
1 Feed module with control panel
2 Deaerator (option)
3 Tetra Alex homogeniser, M6
4 Tetra Spiraflo tubular heat exchanger

Manually valves and gauges:

Regulating valve V62 Pressure gauge PI01, before homogeniser
Regulating valve V63 Pressure gauge PI03, after homogeniser
Butterfly valve V15:1 Pressure gauge PI07, product pressure to filling
Butterfly valve V15:2 machine
Regulating valve V26
Change-over valve V76
Pressure gauge PI04, at holding cell

3 - 6 (8) Doc. No. OM-1218635-0101

3 General Description Introduction

Manual Valve Operation Guide

Open
Close

Open Close
The handle rotating counter The handle rotating clockwise,
clockwise, stem in bottom stem in bottom position
position

Close

Open

Doc. No. OM-1218635-0101 3 - 7 (8)

Introduction 3 General Description

This page intentionally left blank

3 - 8 (8) Doc. No. OM-1218635-0101

4 Process Description

Doc. No. OM-1218635-0101 4 - 1 (6)

 4 Process Description

This page intentionally left blank

4 - 2 (6) Doc. No. OM-1218635-0101

4 Process Description Table of Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 5
Process Cycle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 5

Working Principle . . . . . . . . . . . . . . . . . . . . . . . . 4 - 6

Doc. No. OM-1218635-0101 4 - 3 (6)

 4 Process Description

This page intentionally left blank

4 - 4 (6) Doc. No. OM-1218635-0101

4 Process Description Introduction

Introduction
This chapter will give an easy to grasp description of the plant.
The way of function is described by means of a flow chart, which is adapted
to give a clear picture and may not include all details.
The plant may be designed for direct filling to the packaging machines or
filling via an aseptic storage tank. The main difference is that by direct
filling, there is always surplus product returning from the packaging
machines to the product balance tank, whereas by filling via storage tank all
product goes to the tank.

Process Cycle
The process cycle is divided into the following phases:
• Sterilisation loop
• Production
• Aseptic intermediate cleaning
• Stop
• Cleaning

Process cycle

Aseptic
Phases Sterilisation Production Stop Cleaning
intermediate
cleaning

Steps

GF200752

Doc. No. OM-1218635-0101 4 - 5 (6)

Working Principle 4 Process Description

Working Principle
Diverted flow

NaOH
Reject tank
CIP solutions

From filler
Heating loop

Extra holding
3
tube
HNO 3

Product

Cooling water

Product to filling

The Tetra Therm Aseptic Flex is sterilised by circulating hot water for 30
minutes. After sterilisation the plant is cooled down step by step to
production temperatures. Finally sterile water is circulated through the
product circuit.
A production run starts with filling the plant with product via the balance
tank. The product displaces the water/product mix to drain or reject tank.
When a filling machine is ready, production can start.
If product supply fails or a stop at a filling machine occurs, sterile water
replaces the product and the plant goes into circulation.
The product is regeneratively preheated in the Tetra Spiraflo tubular heat
exchanger before being homogenised in a Tetra Alex homogeniser.
Final heating takes place in the tubular heat exchanger. The product is then
held in a holding tube for the required period of time. Regenerative cooling
to packaging temperature. Product regenerative with corrugated tubes.
Final heating is performed by means of an indirect hot water circuit. The
regenerative is performed in Tetra Spiraflo MTR tubular heat exchangers
with product to product regenerative.
In order to prolong the production period between full CIP (Cleaning In
Place), an Aseptic Intermediate Cleaning (AIC) can be performed. The AIC
can be performed with either lye or flushing acid detergent.
After each production run the plant is cleaned with both lye and acid.

4 - 6 (6) Doc. No. OM-1218635-0101

 5 Control Panel

Doc. No. OM-1218635-0101 5 - 1 (34)

 5 Control Panel

This page intentionally left blank

5 - 2 (34) Doc. No. OM-1218635-0101

5 Control Panel Table of Contents

Denomination. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 5

Operator´s Panel . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 6
Basic Principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 6
Access code levels . . . . . . . . . . . . . . . . . . . . . . . . 5 - 7

Menu Tree Overview . . . . . . . . . . . . . . . . . . . . . . 5 - 8

Buttons and Symbols on the Screen Pictures . 5 - 9

Navigation Buttons . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 9
Function Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 9
Process Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 10
Dialogue Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 10

Menu Screen Pictures . . . . . . . . . . . . . . . . . . . . . 5 - 11

Indication/Push-button . . . . . . . . . . . . . . . . . . . . . 5 - 11
Symbols on the Screen Pictures . . . . . . . . . . . . 5 - 12
Data Indication/Navigation . . . . . . . . . . . . . . . . . 5 - 12
General Indications on Set Point Buttons . . . . . 5 - 13
Overview Picture . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 14
Indication/Push-button . . . . . . . . . . . . . . . . . . . . . 5 - 14
Operating Menu . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 15
Indication/Push-button . . . . . . . . . . . . . . . . . . . . . 5 - 15
Start Check Picture . . . . . . . . . . . . . . . . . . . . . . . 5 - 16
Indicator/Push-button . . . . . . . . . . . . . . . . . . . . . . 5 - 16
Process Value Picture . . . . . . . . . . . . . . . . . . . . . 5 - 17
Indication/Push-button . . . . . . . . . . . . . . . . . . . . . 5 - 17
Process Values . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 17
Transmitter Values. . . . . . . . . . . . . . . . . . . . . . . . . 5 - 17
Alarm List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 18
Indication/Push-button . . . . . . . . . . . . . . . . . . . . . 5 - 18
Trend Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 19
Indication/Push-button . . . . . . . . . . . . . . . . . . . . . 5 - 19
Select Pen Picture . . . . . . . . . . . . . . . . . . . . . . . . 5 - 20

Doc. No. OM-1218635-0101 5 - 3 (34)

Table of Contents 5 Control Panel

Indication/Push-button . . . . . . . . . . . . . . . . . . . . . 5 - 20
Product Selection Menu . . . . . . . . . . . . . . . . . . . 5 - 21
Indication/Push-button . . . . . . . . . . . . . . . . . . . . . 5 - 21
Service Menu 1 . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 22
Indication/Push-button . . . . . . . . . . . . . . . . . . . . . 5 - 22
Service Menu 2 . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 23
Indication/Push-button . . . . . . . . . . . . . . . . . . . . . 5 - 23
Force I/O Menu . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 24
Indication/Push-button . . . . . . . . . . . . . . . . . . . . . 5 - 24
Activation Picture . . . . . . . . . . . . . . . . . . . . . . . . 5 - 25
Indication/Push-button . . . . . . . . . . . . . . . . . . . . . 5 - 25
M2 (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 26
Indication/Push-button . . . . . . . . . . . . . . . . . . . . . 5 - 26
M6 (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 27
Indication/Push-button . . . . . . . . . . . . . . . . . . . . . 5 - 27
Temperature Guard (TSL42) . . . . . . . . . . . . . . . . 5 - 28
Indication/Push-button . . . . . . . . . . . . . . . . . . . . . 5 - 28
Temperature Guard (TSL71) . . . . . . . . . . . . . . . . 5 - 29
Indication/Push-button . . . . . . . . . . . . . . . . . . . . . 5 - 29
PID Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 30
Indication/Push-button . . . . . . . . . . . . . . . . . . . . . 5 - 30
PID Parameter Picture. . . . . . . . . . . . . . . . . . . . . 5 - 31
Indication/Push-button . . . . . . . . . . . . . . . . . . . . . 5 - 31

Keyboards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 32
Integer Numbers . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 32
Floating Point Numbers . . . . . . . . . . . . . . . . . . . 5 - 32
Alphanumerical Keyboard . . . . . . . . . . . . . . . . . 5 - 33

5 - 4 (34) Doc. No. OM-1218635-0101

5 Control Panel Denomination

Denomination

8
7
1 6
2

3 P45

4 S10

S5 A2 0

S15

1) Temperature recorder
2) Operator panel, type TPOP-E
3) Emergency stop button (total stop)
4) Steam selector
5) Main switch
6) Warning lamp (green) continuous light; function in operation, flashing
light; operator action required or function stopped (cleaning),
7) Alarm lamp (yellow) flashing light; unacknowledged alarm
continuous light; acknowledged alarm
8) Emergency stop engaged, red light

Doc. No. OM-1218635-0101 5 - 5 (34)

Operator´s Panel 5 Control Panel

Operator´s Panel
Basic Principle
The Tetra Therm Aseptic Flex is controlled by a Programmable Logical
Controller (PLC). This PLC contains several sequences which controls the
execution of the necessary programs for running production, cleaning, etc.
The necessary number of controllers (regulators) are also integrated into the
PLC to control the analog sub-processes, such as level, pressure and/or
temperature controls.
A Human Machine Interface (HMI) is used as the link between PLC, Tetra
Therm Aseptic Flex and the operators. By means of 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. Alarms are shown on this unit if abnormal conditions occurs.

5 - 6 (34) Doc. No. OM-1218635-0101

5 Control Panel Operator´s Panel

(Cont'd)

Access code levels

Passwords
Level 1: Access code for level 1
Level 2:

Level 3:
Access code for level 2
Level 4:

Level 5:

Level 6:

Level 7:

Level 8:
Level 9:

OK

Access levels to operator‘s 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 code status: Allows to:

0 = No user -View and choose among all the menus
-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 & Guards
-Set CIP memory

Doc. No. OM-1218635-0101 5 - 7 (34)

Menu Tree Overview 5 Control Panel

Menu Tree Overview

Overview picture

Operating menu

Process values

Alarm list

Trend diagram Product selection Service menu

5 - 8 (34) Doc. No. OM-1218635-0101

5 Control Panel Buttons and Symbols on the

Buttons and Symbols on the Screen

Pictures
Not selected
Buttons are squares with 3D effect.

Buttons can be:

• Navigation buttons.
• Function buttons.
Selected • Process buttons
• Dialogue buttons

Navigation Buttons
Navigation buttons always call up a different screen picture.Example shows
navigation button for calling up the Process value picture, see page 5-17.

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

1 2 3 4

5 6 7 8

Example shows function 5) Connected but not

button for Cooler: selected, not selectable
1) Not selected and not (Remote control)
selectable 6) Selected but not
2) Not selected and correctly connected,
selectable not selectable (Remote
control)
3) Connected but not
selected, selectable 7) Selected and correctly
connected, selectable
4) Selected but not
correctly connected, 8) Selected and correctly
selectable connected, not
selectable

Doc. No. OM-1218635-0101 5 - 9 (34)

Buttons and Symbols on the 5 Control Panel

Process Buttons
Push button position

Not selectable Selectable Selectable and pressed

Idle
Process phase
Not selected

Que
Process phase
Selected but not yet
active

Held
Process phase
Active but paused

Run
Process phase
Selected and active

Dialogue Buttons
These are used to perform different operations in dialogue windows, such as
validating or cancelling any commands.
Example shows dialogue button to Start and Stop a function.

5 - 10 (34) Doc. No. OM-1218635-0101

5 Control Panel Menu Screen Pictures

Menu Screen Pictures

Note! Following indications and push-button are represented several
of the presented screen pictures.

1 2 3 4 5 6 7

10

11

12

13

14
25 15

24 23 22 21 20 19 18 17 16

Indication/Push-button
1) Date and time
2) Screen name
3) Current user
4) Current recipe
5) Any output forced
6) Any controller in manual mode
7) Local/Remote indication (only Local mode is available)
8) Alarm indication. Press to bring up the ALARM LIST, see page 5-18
9) Status indication for CIP
10) Status indication for AIC (Aseptic Intermediate Cleaning)
11) Status indication for Shutdown
12) Status indication for Empty to drain
13) Status indication for Production
14) Status indication for Pre-sterilisation/Sterile water circulation
(Cont'd)

Doc. No. OM-1218635-0101 5 - 11 (34)

Menu Screen Pictures 5 Control Panel

(Cont'd)
15) Current step
16) Remaining time
17) Exit/Return to previous screen
18) Go to SERVICE MENU, see page 5-22
19) Go to PRODUCT SELECTION MENU, see page 5-21
20) Go to TREND DIAGRAM, see page 5-19
21) Go to ALARM LIST, see page 5-18
22) Go to PROCESS VALUE SCREEN, see page 5-17
23) Go to OPERATING MENU, see page 5-15
24) Go to OVERVIEW PICTURE, see page 5-14
25) Alarm banner

Symbols on the Screen Pictures

The symbols 7-12 on the illustration on the previous page inform about the
operating / functioning modes of the machine at any given time.
The illustration below shows the four different modes for the process
PRE-STERILISATION.

1 2 3 4

1) Production phase Idle, not selected

2) Production phase Running, selected and active
3) Production phase Held, active but paused
4) Production phase Queued, selected but not yet active
Note!

Data Indication/Navigation

Data is indicated by a navigation button with data field showing the current
value.

5 - 12 (34) Doc. No. OM-1218635-0101

5 Control Panel Menu Screen Pictures

General Indications on Set Point Buttons

When the field under the set point value on the set point button is green, this
set point is active. When it’s grey, the set point is not active. See example
below.

Grey - not active

Green - active

Doc. No. OM-1218635-0101 5 - 13 (34)

Menu Screen Pictures 5 Control Panel

Overview Picture

Indication/Push-button
1) Steriliser filled with product
2) AFM/Alsafe indication Ready/Production, see explanation below.

Ready

Production

5 - 14 (34) Doc. No. OM-1218635-0101

5 Control Panel Menu Screen Pictures

Operating Menu
1 2 3 10 11 12

7
5

6
9
8

13
Indication/Push-button
1) Sterile water
2) Production
3) Stop sequence
4) Flush to drain
5) Product supply pump
6) CIP lye + acid
7) Lye cleaning
8) AIC (Aseptic Intermediate Cleaning) lye
9) AIC (Aseptic Intermediate Cleaning) lye + acid
10) Include dearator (optional)
11) Extra cooler I (optional)
12) Holding cell 30s (optional)
13) Bring up the START CHECK PICTURE, see page 5-16

Doc. No. OM-1218635-0101 5 - 15 (34)

Menu Screen Pictures 5 Control Panel

Start Check Picture

3 4 7 8

1
9

5 6

Indicator/Push-button
General Start Conditions
1) All controllers in Auto
2) All EMERGENCY STOP released
3) All toggle switches in Auto
4) Connection and selection match
5) Steam selector ON
6) No alarms: low level balance tank (LL BTD), air pressure or temperature
fault.
Pre-sterilisation Start Conditions
7) CIP memory
8) CIP dosing pipes connected outside the balance tank
CIP/AIC Start Conditions
9) CIP dosing pipes connected in to the balance tank

5 - 16 (34) Doc. No. OM-1218635-0101

5 Control Panel Menu Screen Pictures

Process Value Picture

3 4

2 5

Indication/Push-button
1) Temperature process value
2) Temperature Hot water circuit process values
3) Process values
4) Analogue Out values
5) Recommended Hot water flow
Green symbol indicates ramp of product flow. Adjust hot water flow
slowly with V62 to the recommended flow.
Process Values

Process value indicator: The measured value is indicated.

Transmitter Values
Transmitter values can be viewed only:
LT = Level transmitter
TT = Temperature transmitter
PT = Pressure transmitter

Doc. No. OM-1218635-0101 5 - 17 (34)

Menu Screen Pictures 5 Control Panel

Alarm List

1
5

8
2

3 4

This picture shows a complete alarm list which means that the alarm picture
will vary depending on the configuration of the Tetra Therm Aseptic Flex
module.
Indication/Push-button
1) Alarm indication
– Red colour indicates active alarm, not acknowledged
– Yellow colour indicates active alarm, acknowledged
– Green colour indicates history
2) Toggle Date and Time on/off indication
3) Erase Alarm list
4) Acknowledge alarm
5) Go one page back (20 rows)
6) Go one row back
7) Go one row forward
8) Go one page forward (20 rows)

5 - 18 (34) Doc. No. OM-1218635-0101

5 Control Panel Menu Screen Pictures

Trend Diagram

Indication/Push-button
1) Trend curve
2) Analogue value for one of the pens
3) Select which value to display
The colour of the push-button corresponds to the colour of the pen in the
trend diagram. For example, to select a variable for the red pen -push the red
push-button. This will bring up the SELECT VARIABLES PICTURE, see
page 5-20.

Doc. No. OM-1218635-0101 5 - 19 (34)

Menu Screen Pictures 5 Control Panel

Select Pen Picture

Indication/Push-button
1) Selected pen colour
2) Select analogue value to trend

5 - 20 (34) Doc. No. OM-1218635-0101

5 Control Panel Menu Screen Pictures

Product Selection Menu

2

Indication/Push-button
1) Product selection
2) The steriliser can be configured for either filling machine selection AFM
or capacity selection CAP. Only one of these is visible at a time (in this
picture AFM).
3) Production to Alsafe selection (option)

Doc. No. OM-1218635-0101 5 - 21 (34)

Menu Screen Pictures 5 Control Panel

Service Menu 1
1 2 3 4 5

7 8

9 10 11

Indication/Push-button
1) Select language
2) Set CIP memory
3) Log in (enter password)
4) Log out
5) Change password
6) ERASE program on backup memory card
7) LOAD program from backup memory card
8) SAVE program on backup memory card
9) Go to I/O FORCE MENU, see page 5-24
10) Go to ACTIVATION PICTURE, see page 5-25
11) Go to SERVICE MENU 2, see page 5-23

5 - 22 (34) Doc. No. OM-1218635-0101

5 Control Panel Menu Screen Pictures

Service Menu 2

1
2
3

6
Indication/Push-button
1) Select register to edit/view
2) Current register values displayed
3) Enter new register value
4) Press to transfer the new value to the selected register in PLC
5) Go to SERVICE MENU 1, see page 5-22
6) Go to I/O FORCE MENU, see page 5-24

Doc. No. OM-1218635-0101 5 - 23 (34)

Menu Screen Pictures 5 Control Panel

Force I/O Menu

4 5 6 7
Indication/Push-button
1) Selected I/O card
2) Selected output number
3) Selected object
4) Current status
5) Select force to low status
6) Select force to high status
7) Send the force command to the PLC
Note! As soon as you leave the Force I/O Picture all forces will be
disabled.

5 - 24 (34) Doc. No. OM-1218635-0101

5 Control Panel Menu Screen Pictures

Activation Picture

When a motor or valve is activated the corresponding symbol will light up.
Indication/Push-button
1) Motor symbol
2) Valve symbol
Note! Grey indication - not activated object. Green indication -
activated object.

Doc. No. OM-1218635-0101 5 - 25 (34)

Menu Screen Pictures 5 Control Panel

M2 (Option)
2

The pump M2 is controlling the product flow.

Indication/Push-button
1) Bar graph and numeric display of the current speed for M2
2) Increase
3) Decrease
Note! As for pump M2, available pictures exists for pump M4 (flow in
CIP Option).

5 - 26 (34) Doc. No. OM-1218635-0101

5 Control Panel Menu Screen Pictures

M6 (Option)
2 3

Indication/Push-button
1) Bar graph and numeric value of the current speed for M6
2) Increase
3) Decrease

Doc. No. OM-1218635-0101 5 - 27 (34)

Menu Screen Pictures 5 Control Panel

Temperature Guard (TSL42)

12

1 5 9

6 10

2 7 11

3 8

Set points and parameter values can be changed. Pressing the corresponding
button will bring up the NUMERIC KEY PAD, see page 5-32.
Indication/Push-button
1) Bar graph of the current set point of the temperature guard
2) Bar graph of the current input signal to the temperature guard
3) Numeric value of the current input signal to the temperature guard
4) Numeric value of the current set point of the temperature guard
5) Indication and setting of set point for product 1
6) Indication and setting of set point for product 2
7) Indication and setting of set point for product 3
8) Indication and setting of set point for product 4
9) Indication and setting of set point for product 5
10) Indication and setting of sterilising temperature high temp. products
11) Indication and setting of sterilising temperature low temp. products
12) Indication of current set point value
Note! High temperature product if set point TIC44 > 100 °C. Low
temperature product if set point TIC 44 < 100 °C.

5 - 28 (34) Doc. No. OM-1218635-0101

5 Control Panel Menu Screen Pictures

Temperature Guard (TSL71)

5 6 7

1
2
8
3
9
4
10

Indication/Push-button
1) Bar graph of the current set point of the temperature guard
2) Bar graph of the current input signal to the temperature guard
3) Numeric value of the current input signal to the temperature guard
4) Numeric value of the current set point of the temperature guard
5) Indication and setting of sterilising temperature, high temp. products
6) Indication and setting of sterilising temperature, low temp. products
7) Indication and setting of cooling down step 21, temperature guard
production preparation
8) Indication and setting of high temperature CIP for high temp. products
9) Indication and setting of high temperature CIP for low temp. products
10) Indication and setting of low temperature CIP
Note! High temperature product if set point TIC44 > 100 °C. Low
temperature product if set point TIC 44 < 100 °C.

Doc. No. OM-1218635-0101 5 - 29 (34)

Menu Screen Pictures 5 Control Panel

PID Menu

1
2
3

4
12
5

6 9
7

8
13

10 11

Indication/Push-button
1) Controller name
2) Scale for process value (PV) and set point (SP)
3) Process value - bar graph
4) Set point - bar graph
5) Output - bar graph
6) Scale for output
7) Process value - numeric value
8) Set point - numeric value
9) Output - numeric value
10) The controller is running
11) Set the controller into manual mode
12) Trend curve. Press on the screen to bring up historic values.
13) Go to PID PARAMETER PICTURE, see page 5-31

5 - 30 (34) Doc. No. OM-1218635-0101

5 Control Panel Menu Screen Pictures

PID Parameter Picture

4 5 6

Indication/Push-button
1) Controller name
2) Running set point (SP)
3) Set points 1-16
4) Running P-value (gain) at selected controller
5) Running I-value (integration time) at selected controller
6) Running D-value (derivation time) at selected controller
7) Indication and setting of PID parameters
Note! All parameter values are possible to change by pressing the
corresponding value on the screen.

Doc. No. OM-1218635-0101 5 - 31 (34)

Keyboards 5 Control Panel

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

Integer Numbers
The keyboard in the illustration below will be brought up on the screen if the
operator for example wants to choose an integer number.

Floating Point Numbers

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

5 - 32 (34) Doc. No. OM-1218635-0101

5 Control Panel Keyboards

Alphanumerical Keyboard
The keyboard in the illustration below will be brought up on the screen if the
user for example wants to log in.

1
2

By pressing the key “a-z” (2) the operator brings up the keyboard in the
illustration below.

By pressing the key “0-9” (1) the operator brings up the keyboard in the
illustration below.

Doc. No. OM-1218635-0101 5 - 33 (34)

Keyboards 5 Control Panel

This page intentionally left blank

5 - 34 (34) Doc. No. OM-1218635-0101

 6 Alarm and
Troubleshooting

Doc. No. OM-1218635-0101 6 - 1 (8)

 6 Alarm and Troubleshooting

This page intentionally left blank

6 - 2 (8) Doc. No. OM-1218635-0101

6 Alarm and Troubleshooting Table of Contents

Indications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 5

Alarm Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 5

Fault List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 5

Doc. No. OM-1218635-0101 6 - 3 (8)

 6 Alarm and Troubleshooting

This page intentionally left blank

6 - 4 (8) Doc. No. OM-1218635-0101

6 Alarm and Troubleshooting

Indications
When a fault occurs, the alarm indication lamp on the control panel and the
alarm symbol on the displayed menu will start to flash.
A flashing indication lamp/symbol means an active but not acknowledged
alarm.
Steady light indicates an active alarm that has been acknowledged.

CAUTION
Always investigate the cause of a fault indication. Otherwise you may
endanger the equipment.

Alarm Handling
Press the ALARM MENU button to bring up the ALARM LIST to identify
the alarm.
Explanation of the alarm list, see chapter control panel.

When the fault has been identified and taken care of press the
ACKNOWLEDGE ALARM button.
Fault List
Alarms are divided into two categories as follows:
– 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 Faults that will cause action from the PLC, rectify the fault.

Doc. No. OM-1218635-0101 6 - 5 (8)

 6 Alarm and Troubleshooting

Fault list

Pos Alarm Cause Machine action Instruction to operator

A Aseptic tank No "ready" signal
(option) from Alsafe is
present or if “high
level” signal from
Alsafe is detected.
A Communication Fault in the serial-
fault PLC communication to
another process-
module
A Outlet temp TE6 Wrong adjustment Adjust V26
fault (option) V26
A Caustic Feedback from Check pump
motor M12 or M13 Check wiring
is missing.
A Acid Feedback from Check pump
motor M12 or M13 Check wiring
is missing.
A Water pressure Pressure in water Check incoming water
circuit to low. pressure
Check PS66
Check that V66 is open?
A Air pressure in Inlet air pressure Check incoming air
panel to low. pressure (6 bar)
A Battery fault in Voltage over the Change battery
PLC internal CPU
battery is low
A Filling machine No ready or
production signal
from filling
machine during
production
A Disc < 10% Logo Disc full or missing Insert/change disc
screen in recorder
A Level fault To low or to high
Deaertor vessel level in the
Deaerator vessel
A Air cooler in Fault in air cooler
cabinet
A Steam barrier To low Check steam pressure to
homogeniser temperature homogeniser
(optional)
A V62 adjust The plant enters a Adjust V62
step where V62
has to be adjusted
A V63 open The plant enters a Open V63
step where V63
has to be opened

6 - 6 (8) Doc. No. OM-1218635-0101

6 Alarm and Troubleshooting

Pos Alarm Cause Machine action Instruction to operator

A V63 close The plant enters a Close V63
step where V63
can be closed
B Temperature No signal from Not possible to start plant or if Check sensor and convertor
transmitter broken Temperature running see Temp faults
transmitter
B Sterilizing TT71 indicates a The program steps down to heating. Check sensor and
temperature temperature drop converter
during Plant
sterilisation.
B Production TT42 indicates a If in sterilisation the program steps Check steam supply
temperature temperature drop down to heating. Check sensor and
during sterilisation If in production the plant will stop converter
or Production immediately, the product goes to
reject.
B CIP temperature TSL71 indicates a The CIP timer stops and continues Check steam supply
temperature drop from where it was stopped when the Check sensor and
during circulation alarm is off. converter
steps in Cleaning
Check position of V75
(should be in position
circulate over BTD)
B Level fault in IS65 indicates low If low level during Production the Check incoming water
balance tank level program steps to Emptying. Check pressure (min. 3
If more than 30 sec. the machine will bar)
go to total stop. Check auto switches in
panel (in auto mode)
Check level switch in BTD

B Motor fault Feedback from a If the fault is caused from M2 or M5

motor is missing. (option), the plant stops immediately.
If the fault is caused by M9, the
steam valve V44 closes.

Doc. No. OM-1218635-0101 6 - 7 (8)

 6 Alarm and Troubleshooting

This page intentionally left blank

6 - 8 (8) Doc. No. OM-1218635-0101

 7 Preparations

Doc. No. OM-1218635-0101 7 - 1 (10)

 7 Preparations

This page intentionally left blank

7 - 2 (10) Doc. No. OM-1218635-0101

7 Preparations Table of Contents

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 5

General Checkpoints . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 6

Checkpoints Holding Tube (Option) . . . . . . . . . . . . . . .7 - 7

Checkpoints Deaerator (Option) . . . . . . . . . . . . . . . . . .7 - 8

Doc. No. OM-1218635-0101 7 - 3 (10)

 7 Preparations

This page intentionally left blank

7 - 4 (10) Doc. No. OM-1218635-0101

7 Preparations

Introduction
This chapter contains a list of necessary
check points prior to starting the plant.
Most points are always to be done, but
others are valid only if the corresponding
equipment is included in the plant and is
going to be used for a certain product.
E.g. not all plants include a vacuum
chamber and even if so, it might be used
only for certain products.

CAUTION
If product other than specified in
Technical Data is processed the
sterilisation effect might be
insufficient.
Other products may need other
temperature program.

1
Turn the MAIN SWITCH to position
ON.

2
Turn on the:
• COMPRESSED AIR
• STEAM
• WATER

Doc. No. OM-1218635-0101 7 - 5 (10)

 7 Preparations

3
General Checkpoints
• CHECK that the cover is properly
fitted on the balance tank.
• CHECK that the steam switch is in
position ON.
• CHECK that all emergency stop
buttons are released.

7 - 6 (10) Doc. No. OM-1218635-0101

7 Preparations

4
Checkpoints Holding Tube
(Option)
Make sure that the right holding tube
according to the product you are going to
run is connected.

A = 4 seconds holding tube

B = 4+26 seconds holding tube
(option)

Option
A B

Doc. No. OM-1218635-0101 7 - 7 (10)

 7 Preparations

5
Checkpoints Deaerator
(Option)
Check the pipe connections

A = Deaerator not connected

B = Deaerator connected

A B

7 - 8 (10) Doc. No. OM-1218635-0101

7 Preparations

6
CHECK that the FUNCTION SYMBOL
for cleaning indicates that the Therm
Aseptic Flex is cleaned, if not start with a
cleaning sequence according to chapter
OPERATION.

Doc. No. OM-1218635-0101 7 - 9 (10)

 7 Preparations

This page intentionally left blank

7 - 10 (10) Doc. No. OM-1218635-0101

 8 Operation

Doc. No. OM-1218635-0101 8 - 1 (34)

 8 Operation

This page intentionally left blank

8 - 2 (34) Doc. No. OM-1218635-0101

8 Operation Table of Contents

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 - 5

Start Sterilising Sequence . . . . . . . . . . . . . . . . . . . . . . .8 - 5

Selection/Settings prior to Start . . . . . . . . . . . . . . . . . .8 - 5

Start Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 - 7

Start Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 - 8

Check during Sequence. . . . . . . . . . . . . . . . . . . . . . . . .8 - 9

Start Production Sequence . . . . . . . . . . . . . . . . . . . . . 8 - 11

Selection/Settings prior to Start . . . . . . . . . . . . . . . . . 8 - 11

Checks prior to Start . . . . . . . . . . . . . . . . . . . . . . . . . .8 - 12

Start Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 - 15

Start Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 - 16

Checks during Sequence. . . . . . . . . . . . . . . . . . . . . . .8 - 17

Checks during Sequence. . . . . . . . . . . . . . . . . . . . . . .8 - 18

Stop Production Sequence . . . . . . . . . . . . . . . . . . . . .8 - 19

Revert to Sterile Water . . . . . . . . . . . . . . . . . . . . . . . . .8 - 20

Max Time for Sterile Water. . . . . . . . . . . . . . . . . . . . . .8 - 20

Start Stop Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . .8 - 21

Selection/Settings prior to Start . . . . . . . . . . . . . . . . .8 - 21

Start conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 - 21

Start Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 - 22

Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 - 22

After Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . .8 - 22

Start after Emergency Stop . . . . . . . . . . . . . . . . . . . . .8 - 22

Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 - 23

Doc. No. OM-1218635-0101 8 - 3 (34)

Table of Contents 8 Operation

Aseptic Intermediate Cleaning -AIC . . . . . . . . . . . . . . 8 - 23

Selection/Settings prior to Start . . . . . . . . . . . . . . . . . 8 - 24

Start Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 24

Start Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 25

Checks during Sequence . . . . . . . . . . . . . . . . . . . . . . 8 - 26

Final Cleaning- CIP . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 27

Selection/Settings prior to Start . . . . . . . . . . . . . . . . . 8 - 27

Start Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 29

Start Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 30

Checks during Sequence . . . . . . . . . . . . . . . . . . . . . . 8 - 31

Flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 32

Start Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 32

Start Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 33

Cleaning of Supply Line . . . . . . . . . . . . . . . . . . . . . . . 8 - 34

8 - 4 (34) Doc. No. OM-1218635-0101

8 Operation

Introduction
This chapter describes how to operate the
Therm Aseptic Flex in local mode.

Start Sterilising Sequence

1
Selection/Settings prior to
Start
This selection must fit with the
equipment connected. according to
chapter preparations.
SELECT desired equipment from the
OPERATING MENU:
– If a DEAERATOR is used press a
– If a 30 SECONDS HOLDING
CELL is used press b

a b

Doc. No. OM-1218635-0101 8 - 5 (34)

 8 Operation

2
SELECT Product.
(Capacity can be selected/changed at
anytime during Sterile Water and
Production) (option)

DOSING
3
PIPES a) CHECK that valve V76 is in position
DRAIN
b) CHECK that the caustic/acid dosing
pipes are connected to the CIP
solution drain pipes

V76

8 - 6 (34) Doc. No. OM-1218635-0101

8 Operation

4
Start Conditions
Press START CONDITION in the
OPERATING MENU.

5
All the general and pre-ster. start
conditions are fulfilled when the symbols
background in the START CHECK
MENU are indicated green.
Except from this following conditions
must also be fulfilled:
• The PLC in step 0.
• No low level (LSL65) in balance
tank
• Air pressure in panel OK

The sterilising sequence can now be

started.
General Pre-ster. Note! The start conditions in the start
start conditions start conditions check menu are described in the
chapter CONTROL PANEL.

Doc. No. OM-1218635-0101 8 - 7 (34)

 8 Operation

6
Start Sequence
Press STERILISATION followed by
START in the OPERATION MENU.
– When the sterilising temperature
has been reached, the plant will be
sterilised for 30 minutes.
– The plant cools down by
performing program steps
Cooling 1-3 and Stabilising.
– When the plant is cooled down,
Sterile water is indicated on the
display.

8 - 8 (34) Doc. No. OM-1218635-0101

8 Operation

7
Check during Sequence

7a

a) CHECK pressure at P07 (4 bar) if

HTP (high temperature products) is
to be produced
b) CHECK that the temperature (TE1)
before the homogeniser is 85°C,
adjust with V63.

V63

Doc. No. OM-1218635-0101 8 - 9 (34)

 8 Operation

7b

Option Deaerator
CHECK the water supply for the seals on
the vacuum pump M11 and the pump M5
on the deaerator.
ADJUST the vacuum and the cooling
water by means of valves V30/V33 until
a temperature difference of 4 °C is
achieved.

VAC. ATM.

GF200830

8
Continue with desired sequence:
PRODUCTION: See “Start
Production Sequence” on page 8-11.
AIC: See “Aseptic Intermediate
Cleaning -AIC” on page 8-23.
CIP: See “Final Cleaning- CIP” on
page 8-27.
STOP: See “Start Stop Sequence” on
page 8-21.

8 - 10 (34) Doc. No. OM-1218635-0101

8 Operation

Start Production Sequence

Selection/Settings prior to
Start
1
a) Press desired push button 1 - 4 in the
AFM/CAPACITY MENU to select
the aseptic filling machine or
capacity for production.
Note! Can be selected at any time
during Sterile Water and Production.
The change over sequence will take
approx. 2 -5 min.

Option:
b) Press TANK SYMBOL for
production to Tetra Alsafe tank.

Doc. No. OM-1218635-0101 8 - 11 (34)

 8 Operation

2
Checks prior to Start

2a
Check that the flow at FI66 is enough to
match the chosen capacity, adjust if
necessary with the valve V62.

FI66

V62

8 - 12 (34) Doc. No. OM-1218635-0101

8 Operation

2b
a) CHECK that V15.1 (CIP return) is
closed
b) Open the valve V15.2 towards the
drain

V15.1 V15.2

3
Press PRODUCT SUPPLY PUMP
followed by START in the OPERATION
MENU.

Doc. No. OM-1218635-0101 8 - 13 (34)

 8 Operation

4
a) CLOSE valve V 15.2 when product
is visible at the drain outlet.

V15.2

5
Stop the product supply pump by
pressing PROD SUPPLY followed by
STOP.

8 - 14 (34) Doc. No. OM-1218635-0101

8 Operation

DOSING 6
PIPES a) CHECK that the valve V76 is in
correct position, towards the reject
tank (or drain) to continue pushing
out the product to reclaim tank (or
drain)
b) CHECK that the caustic/acid dosing
pipes are connected to the cip
solution drain pipes

V76

7
Start Conditions
2 1 Ready indication AFM/Alsafe
2 No alarms

Doc. No. OM-1218635-0101 8 - 15 (34)

 8 Operation

8
Start Sequence
Press PRODUCTION followed by
START in the OPERATION MENU.
The first filling step is the prepare
production step, which means that
cold water enters the plant to bring
down the filling temperature.
When the filling temperature (TT71)
has dropped to a preset temperature
or a timer has elapsed, Filling is
indicated on the display.
The plant will now automatically
drain the water from the balance
tank, activate V13. and start the
product supply pump.
A timer controls when the product line
contains product only, valve V75 reroutes
the flow to the balance tank for
recirculation.
The plant is ready for production. Signal
is given to the filling machines.
Note! If a disturbance occurs during
Production, the Therm Aseptic Flex
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. See “Revert to Sterile
Water” on page 8-20.
Reverting to this phase, sterile water
displaces the product.

8 - 16 (34) Doc. No. OM-1218635-0101

8 Operation

9
Checks during Sequence

9a
Regular check on the process values such
as flow, temperature and pressure.
Recommended max time for
production
During operation deposits may build up
on the heat exchanger surfaces and in the
product holding cell.
• 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
– max pressure after the
homogeniser/booster pump is
stated on the machine sign.
• Check the temperature difference
between the heating medium and the
product.
– max temperature is stated on the
machine sign.

Doc. No. OM-1218635-0101 8 - 17 (34)

 8 Operation

9b
Option extra cooler
CHECK that the correct filling
temperature TT6 in maintained, adjust
with valve V26.

V26

9c
Checks during Sequence
Option Deaertor
VAC. ATM.
ADJUST the vacuum and the cooling
water by means of valves V30/V33 until
a temperature difference of 4 °C is
achieved.

GF200830

8 - 18 (34) Doc. No. OM-1218635-0101

8 Operation

Stop Production Sequence

Select one of the following to stop the
production.
• STERILE WATER: See “Revert to
Sterile Water” on page 8-20.
• AIC: See “Aseptic Intermediate
Cleaning -AIC” on page 8-23.
• CIP: See “Final Cleaning- CIP” on
page 8-27.
• STOP: See “Start Stop Sequence” on
page 8-21.
Note! Select CIP directly after
finished production.

Doc. No. OM-1218635-0101 8 - 19 (34)

 8 Operation

Revert to Sterile Water

Instead of continuing to circulate the
product during any kind of disturbance,
the plant can be reverted to Sterile water.
Press STERILISING followed by
START in the OPERATION MENU.
The plant will now automatically:
• drain the product from the balance
tank to reject or drain (V75
deactivated).
• deactivate V13.
• stop AFM before product/water mix
reaches AFM (timer controlled).
Max Time for Sterile Water
There is a limit for how long time the
Therm Aseptic Flex may run in Sterile
Water before cleaning is required.
It depends on the milk temperature in the
supply pipe to the balance tank. At a
temperature of 15 °C the milk can stand
about 6 hours before it is destroyed and
the Therm Aseptic Flex unit has to be
cleaned and resterilised.

8 - 20 (34) Doc. No. OM-1218635-0101

8 Operation

Start Stop Sequence

1
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 Stop-sequence
starts.
The plant will end in Parking position.

Selection/Settings prior to
Start
• Nothing stated

2
Start conditions
• No alarms
• If selected from PRODUCTION.
CHECK that the valve V76 is in
correct position, towards the reject
tank (or drain) to continue pushing
out the product to reclaim tank (or
drain)

V76

Doc. No. OM-1218635-0101 8 - 21 (34)

 8 Operation

3
Start Sequence
Press STOP followed by START in the
OPERATION MENU.
The balance tank is drained and a cold
water rinse sequence is started. The
cooling down and the Therm Aseptic
Flex is ended up in Parking position.

Emergency Stop
Press the emergency stop button on the
control panel to stop the plant
immediately. All pumps will stop and all
valves will be deactivated.

WARNING
Emergency stopped
The machine may contain hot liquid
or
cleaning solution. Handle wit outmost
care to avoid exposure.

After Emergency Stop

After emergency stop has been activated,
the sterile temperature (TT42) will drop
below set point.
Start after Emergency Stop
• Release all emergency stops.
• Reset the homogeniser on the Tetra
Alex control panel.
The Therm Aseptic Flex must be emptied
by means of the FLUSH. See “Flush” on
page 8-32.
Note! CIP must be ordered if product
has entered the plant.

8 - 22 (34) Doc. No. OM-1218635-0101

8 Operation

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

CAUTION
The cleaning program is designed for
the products 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.

Aseptic Intermediate
WARNING Cleaning -AIC
Chemical hazard AIC can be ordered to extend the
Cleaning solution contains Caustic soda (NaOH) or production period before a full cleaning,
Nitric acid (HNO3). CIP, is required.
These chemicals may cause severe burning to skin
and eyes. Use protective clothes, goggles and gloves The AIC takes approximately 40
during handling. minutes. The plant remains sterile in its
If exposed - wash with water for at least 15 minutes. aseptic part.
Seek medical assistance.
Follow the instructions given by the supplier.

Doc. No. OM-1218635-0101 8 - 23 (34)

 8 Operation

1
DOSING Selection/Settings prior to
PIPES Start
a) CONNECT the caustic/acid dosing
pipes to the balance tank
b) CHECK that valve V76 is in position
drain

V76

2
Start Conditions

2a
Press START CONDITION in the
OPERATING MENU.

8 - 24 (34) Doc. No. OM-1218635-0101

8 Operation

2b
• From STERILE WATER: CIP
dosing pipes connected to balance
tank and No alarms

3
Start Sequence
a) Select appropriate AIC followed by
START within 15 seconds.
If AIC is ordered from programme step
Production, an emptying and a rinse
sequence take place automatically before
the intermediate cleaning starts.

When the cleaning is completed, the

indication for AIC goes out and
STERILE WATER is indicated with
green.

Doc. No. OM-1218635-0101 8 - 25 (34)

 8 Operation

4
Checks during Sequence
CHECK that the flow at FI66 is enough
to match the chosen capacity, adjust if
necessary with the valve v62.

FI66

V62

8 - 26 (34) Doc. No. OM-1218635-0101

8 Operation

Final Cleaning- CIP

WARNING
Select CIP directly after finished
Chemical hazard
production.
Cleaning solution contains Caustic soda (NaOH) or
Nitric acid (HNO3). The CIP takes approximately 120
These chemicals may cause severe burning to skin minutes. The plant remains sterile in its
and eyes. Use protective clothes, goggles and gloves aseptic part.
during handling.
If exposed - wash with water for at least 15 minutes.
Seek medical assistance.
Follow the instructions given by the supplier.

1
Selection/Settings prior to
Start

1a
DOSING a) CONNECT the caustic/acid dosing
PIPES pipes to the balance tank
b) CHECK that valve V76 is in position
drain

V76

Doc. No. OM-1218635-0101 8 - 27 (34)

 8 Operation

1b
a) OPEN the valve v62 fully.

V62

8 - 28 (34) Doc. No. OM-1218635-0101

8 Operation

2
Start Conditions

2a
Press START CONDITION in the
OPERATING MENU.

Doc. No. OM-1218635-0101 8 - 29 (34)

 8 Operation

2b
• From Parking position: all general
and CIP start conditions fulfilled.
• From Sterile water: CIP dosing pipes
connected to balance tank

General CIP
start conditions start conditions

3
Start Sequence
a) Select appropriate CIP followed by
START within 15 seconds.
– The CIP function is indicated with
white.
When the cleaning is completed, the
indication for CIP goes off and the plant
stops.

8 - 30 (34) Doc. No. OM-1218635-0101

8 Operation

4
Checks during Sequence
a) During STEP 114
OPEN the valve v63 to avoid boiling
in the BTD.

V63

Doc. No. OM-1218635-0101 8 - 31 (34)

 8 Operation

Flush
The FLUSH FUNCTION is only
selectabled from Parking position.
Use the Flush function to:
– flush out the product.
– emptying after an emergency stop.
to cool down the equipment.

1
Start Conditions

1a
Press START CONDITION in the
OPERATING MENU

1b
In Parking position: all general start
conditions fulfilled.

8 - 32 (34) Doc. No. OM-1218635-0101

8 Operation

2
Start Sequence
Press FLUSH followed by START in the
OPERATION MENU.

Doc. No. OM-1218635-0101 8 - 33 (34)

 8 Operation

Cleaning of Supply Line

The cleaning is controlled by an external
CIP-system.
a) OPEN the valve V15:1 towards cip
return
b) OPEN (Flip) the valve V15:2 for a
short while towards drain during
circulation
Note! The pipes connected to the
Valve V15:2 can easily be removed
for manually cleaning.

V15:1
V15:2

8 - 34 (34) Doc. No. OM-1218635-0101

9 Care and Cleaning

Doc. No. OM-1218635-0101 9 - 1 (6)

 9 Care and Cleaning

This page intentionally left blank

9 - 2 (6) Doc. No. OM-1218635-0101

9 Care and Cleaning Table of Contents

Verify Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 5
Daily Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 5
Cleaning Complete . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 5
Lye/Acid Concentration. . . . . . . . . . . . . . . . . . . . . . 9 - 5
Homogenizer damper . . . . . . . . . . . . . . . . . . . . . . . 9 - 5
Recommended Check . . . . . . . . . . . . . . . . . . . . . . 9 - 5
Holding cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 - 5

Doc. No. OM-1218635-0101 9 - 3 (6)

 9 Care and Cleaning

This page intentionally left blank

9 - 4 (6) Doc. No. OM-1218635-0101

9 Care and Cleaning Verify Cleaning

Verify Cleaning
Daily Check
Cleaning Complete
Check on the recorder that the cleaning has run the appropriate time with the
appropriate temperatures.
Lye/Acid Concentration
Check that the lye and acid concentrations during cleaning are appropriate.
Homogenizer damper
Disassemble the homogenizer damper to ensure an air cushion inside and:
• check that it is free from any product residues after cleaning.
• clean the damper manually if necessary.

Recommended Check
It is recommended to regularly weekly/monthly verify the cleaning result at
critical points such as the holding cell.
Holding cell
Disassemble the holding cell or holding cells (if applicable) and:
• visually check that it is free from any product residues after cleaning
• make a swab test to check that the cleaning result is appropriate
• if necessary, adjust cleaning circulation time and detergent concentration

Doc. No. OM-1218635-0101 9 - 5 (6)

Verify Cleaning 9 Care and Cleaning

This page intentionally left blank

9 - 6 (6) Doc. No. OM-1218635-0101

This page intentionally left blank