Manual Master MaxxD EN
Manual Master MaxxD EN
Profit from our full array of services: every one of our customers is unique. That’s why FrymaKoruma offers you comprehensive,
individual consulting and support before, during and after your machine purchase. You can also gain valuable, detailed insights into a
variety of topics in the modern rooms of ProTec, our process technology and training centre.
Classic Services
Installation Repair
Enhance the efficiency of your investment from the very first We provide reliable and prompt support if ever your machine
day! Your new FrymaKoruma technology is carefully assembled needs to be repaired.
and installed by our specialists. Faulty parts and / or bugs in the software are replaced or removed
expertly and promptly, so that costly downtime is reduced to a
Commissioning minimum.
You make sure your new machine and your staff are ready to go
fully operational. We connect the mechanical and electrical Retrofit
components for you and test the software features. Our products are continuously developed to bring you into line
with the latest state of the art. We make sure you stay up to date
Inspection – and we listen to you if you have any suggestions of your own or
Our technicians can carry out an as-is analysis of the machine’s if new legislation requires your machine to be extended. We boost
condition on request. You can have this done on your premises your productivity by upgrading existing features or implementing
or, if you prefer, ship the machine to us. We provide you with new ones.
recommendations regarding next steps, for example repair,
maintenance or replacement. Spare parts
Our high quality machines are shipped to you in top condition. We
Maintenance want you to be successful in the marketplace for many years to
Maintenance takes place either on-site on your premises or at come, which is why we supply you with original spare parts as well
our ProTec centre at a time chosen by you. We inspect, test and as all the certificates and attestations you need to manufacture
care for your FrymaKoruma technology and do our best to rule quality products.
out any unexpected disruptions to your production process.
High Value Services (HVS)
HelpLine % Energy and resource
Is there a problem with your application, your engineering or management
your software? Just give us a call and we’ll provide prompt We would be pleased to review your production processes and
expert support! advise you on more effective resource management, energy
saving strategies and sustainable manufacturing.
Feasibility studies
We will gladly carry out feasibility studies on your behalf – after Seminars
all, you want to be certain of achieving the desired result with ProTec, our process technology and training centre, is the venue
our processes and technologies. for numerous events dealing with specific issues in cooperation
with experienced experts from research, science and industry.
Scale-ups Take advantage of this opportunity to broaden your expertise
We reduce your technical and financial risks to a minimum by with an informative mix of theory and practice that casts a
scaling up your manufacturing processes to a larger machine of spotlight on selected applications in the food, pharmaceutical,
identical design. cosmetics and chemical markets.
your processes, for instance, as well as your performance, high-tech instruments. This is essential in order to comply with
formulations and use of raw materials. specific requirements or standards in the framework of certification
procedures.
Development of new
processes/products
FRY_EN_CS_0414
FK-HelpLine:
■ Expertise to protect your productivity
■ Efficient troubleshooting support
■ Emergency operating and process help
VAT no.
Delivery
Address:
Your reference
Phone no.
Machine
Typ of machine Serial No. Year of construction
Safety Regulations
Risk and Hazards, General Safety Recommendations 2
Qualification and Requirements to the Staff
•
TABLE OF CONTENTS • PART 1
Commissioning
Instruction for Assembly and Primary Set-up 5
Wiring Diagram
Operation
Operating and Possibilities. Data Input / Run of Programs / 6
Trouble Shooting, Operating Instructions of the Operating Panel
Maintenance
Service Plan, Supplies and Accessories
Service Operations, Cleaning
7
•
Repairs
Recognising of Troubles, Judging and Trouble Shooting 8
Instruction of Repairs
Recycling 9
Transport 10
Operating Manual
Description of the Machine
TABLE OF CONTENTS
7a 7b
The machine has been developed to produce viscous emulsions, dispersion or suspensions.
Main components
The auxiliary aggregates are integrated in the equipment cabinet. All models have a lid opening
system and a control panel.
Design in accordance with actually GMP- and hygiene directives. Therefore the machine meets
the „CIP“-requirement (Cleaning In Place) i.e. the machine can following a cleaning programme be
cleaned on the spot, if it is furnished correspondingly.
The written consent of FrymaKoruma is necessary for applications that are not mentioned
in this document.
1.1.2 Misuse
Any use other than those agreed upon in the contract or any use of the machine extending beyond
the agreement will be considered as unintended.
Danger!
It is forbidden:
Note: For machines without explosion protection, the electric circuits and equipment are not designed for an operation
with such substances.
to use substances which are harmful or toxic and which can leak out of the
system into the environment.
Note: The system has got no such device, which could prevent the release of
such substances.
Note: Apart from uncontrollable reactions which could under certain circumstances severely injure people, material
damage could happen to the system too such as overloading or breaking bearing components, damage to the scraping
system, the sliding ring seal, the homogenizer and pumps, scratches on the vessels, etc..
Predictable misuse
The machine may never be subjected to the following:
• Permissible operational limit pressure being exceeded, or
• Process settings being made in which an excessive vapour formation occurs.
By exceeding the operational limit pressures on the vessel or double jacket, the safety valve is activated. Excessive
vapour formation can lead to an increase of pressure, the vacuum pump could then become overloaded and sustain
cavitation damages due to condensed vapour.
The product lands in the vacuum system, causing product backlogs in the vacuum line. The vacuum pump can become
damaged because of hammer-blows in the pipes (breaks of bucket wheel, for example). The standard execution level is
not monitored.
• Carrying out chemical reactions that lead to excess temperature or pressure levels of permissible
operational data’s.
• The intermediate and end products of chemical reactions causing damage to used materials
(elastomere, synthetic material or metals).
• The given process limiting values* such as temperature, pressure, level, not being observed.
* The monitoring of the process parameter and limiting values is the responsibility of the operator. The standard
execution is not equipped with redundant components, which provide an automatic emergency disconnection in the
event of technical faults. If the lack of redundant components leads to unacceptable risks, suitable measures are
provided to eliminate risks.
When using wax/grease or other similar substances, their point of ignition should
not be exceeded.
The monitoring of the process limiting temperature is the responsibility of the operator. The standard execution is not
equipped with redundant components, which provide for an automatic emergency disconnection in the event of technical
faults. If by exceeding the limiting temperature, unacceptable risks are taken, suitable measures are provided to
eliminate risks.
Danger areas
Constant or unexpected threats are listed in the danger area plan in chapter 2.5.2.
Product purity
The product ingredients which are processed in the machine must not contain
foreign substances. Possible foreign substances must be removed or restrained
by suitable means (such as filters, checks, for example), before they can enter
the system.
Note: Foreign substances or material particles which enter the machine are grinded to product fineness by the
homogenizer depending on their quality. Metal parts or stones, etc. can damage the processing aggregates, the vessel
or the fittings.
System Operation:
Control panel on machine, switch gear with emergency stop.
Electrical
Information regarding the electric equipment and the standards applied to, are
found in the wiring diagram in the chapter 5.
Water
For personal hygiene and cleanliness during the process, cold and hot water
should be available to the staff on the operation site.
To avoid lime deposition, the hardness of the water should not exceed 6°dH.
(1° dH corresponds 17.8 ppm CaCO3).
Used for pneumatic control/valves and drives. Please observe the requirements
of the suppliers regarding compressed air.
Used for pneumatic logics. A lower dew point and enhanced purity are required
as will be delivered from compressed air.
Specifications for lubricating oils and greases used for the machine are listed in
the “Lubricating schedule” in chapter 7 of the manual.
1.2.3 Interfaces
The branch connections and dimensions of linking’s and interfaces can be found on the machine
dimensional drawing. Quantities, temperatures and operating pressures of medias are to be found
on the data sheet.
1.2.4 Environment
Following table shall be adapted according the customers need. Please mind notes in 2.4.1.
MESURE TO BE
PARTICULAR HAZARDS WHERE ABOUT /WHAT DOCUMENT
TAKEN
- Inflammable materials - -
- Explosible materials - -
- Chem./biolog. effects -
- Dust -
- Explosion-proofness of motors
- Switchgear
The ventilating system of the electrical gear is related to an ambient temperature of maximal
30° Celsius at sea level.
The ambient and compressed air temperature for the rotary drives in the
ex-protected zone must not exceed 68°C.
Lighting
The average flux density in the working area shall be 600 Lux/m2.
1.3 Equipment
1.3.1 Accessory
• Tools
2 Safety Regulations
Aim: Inform the users about the remaining risks and the dangers in case of appropriate use.
TABLE OF CONTENTS
2.1 Layout
The level of danger resulting from a situation or action will be displayed with signal words.
SIGNAL WORD
death. Also used to warn about property could be damaged.
property damages.
RISK
MORE HAZARD LESS
Poisonous/caustic
Danger of suffocation products Wear protection mask Wear safety goggles
*“IMPORTANT“ Operational messages for and other useful information, but not intended to warn of dangerous or critical
situations.
Note: DANGER, WARNING, CAUTION, NOTICE are within the United States of America mandatory signal words.
2.3 General
2.4 Organization/Personnel
• Guidelines on how to handle chemicals used for the process and cleaning.
• First aid measures in case of accidents with chemicals and electric shocks
• Use of personal protective equipment.
Note: These operating manual of FrymaKoruma does not deal with the aspect of dangerous material used in the clients
premise. In most cases, these are not known to FrymaKoruma (professional secret).
• As measure to prevent of danger an analysis of all hazards related to professional risk have to be
executed.
• All personnel must be informed and trained in occupational safety and correct operation of the
machine on a regular basis. In particular, care shall be taken to avoid contact with hot surfaces.
• All personnel have to be informed and instructed accordingly. *(High voltage, steam, hot water,
pressurized air, handling of loads a.s.o.).
According EC- guidelines 2009/104 “Use of working material” it is the responsibility of the operating
company to:
• Inform the employee about all dangers related to them and the working material available in their
environment.
• If trained workers are entrusted to perform simple control activities, they should fully acknowledge
residual risks related to machine operation.
• If dangerous machinery or equipment and agents are being used, an operating manual has to
be established!
• Generally, the operator shall provide suitable platforms and steps. Design of stationary
scaffolding must be in line with harmonized standard EN ISO 14122-1 to 4. If stationary
scaffolding cannot be used, the owner should investigate possibility of safe using ladders or
similar means within a general assessment of risks at workplaces.
User / operator
Is responsible for the correct use and operating of the machine. Conversion of the product recipes,
inputting of process data into control. The operator knows: Start-up and stop procedures, the check
of the process, safety minded behaviour when dealing with deviation and troubles. Servicing of the
machine.
For transportation of the machine and setting up, the directives mentioned in
chapter 10 have to be met.
2.5.2.1 Lab
Make sure the housing is closed before When the lid lifting device or the lid Between lid and vessel rim. Avoid danger
moving the machine. safety device are being defect. zone while closing the vessel.
Warning!
Splashing liquid!
Caution!
Hot parts!
Warning!
Do not allow
to run dry!
On the running homogenizer with the Secure switch with personal lock. Never activate manual valve, if vessel is
housing open. Do not start when the piping is pressurized ! Close valve immediately after
Never insert hand or tools. disconnected. feeding product.
General precautions
When working on open vessel, always bear personal protective means!
When the lid lifting device or the lid safety Use a platform when using the viewing Between lid and vessel rim.
device are being defect. glass or the vacuum control. Avoid danger zone while closing the vessel.
Warning!
Splashing liquid!
Caution!
Hot parts!
Warning!
Do not allow
to run dry!
On the running homogenizer with the Secure switch with personal lock. Never activate manual valve, if vessel is
housing open. Do not start when the piping is pressurized ! Close valve immediately after
Never insert hand or tools. disconnected. feeding product.
General precautions
When working on open vessel, always bear personal protective means!
2.5.3.1 Lab
Make sure the housing is closed before When the lid lifting device or the lid At lid/vessel rim.
moving the machine. safety device are being defect. Avoid danger zone while hoisting/lowering.
Danger!
Serious
injuries!
Warning!
Scalding!
Danger! Danger!
Cutting! Transport!
Seriously injuries by cutting at the Do not fasten ropes a.s.o. to the vessel for
homogenizer. lifting the machine.
Switch mainpower „OFF“ and lock it.
General precautions
When working on open vessel, always bear personal protective means!
When the lid lifting device or the lid safety Use a ladder or platform. At lid/vessel rim. Avoid danger zone while
device are being defect. Do not stand on the slippery housing. hoisting/lowering.
Danger!
Serious
injuries!
Warning!
Scalding!
Hot surfaces and
equipment!
Danger! Danger!
Cutting! Transport!
Seriously injuries by cutting at the Do not fasten ropes a.s.o. to the vessel
homogenizer. Switch mainpower for lifting the machine.
„OFF“ and lock it.
General precautions
When working on open vessel, always bear personal protective means!
TABLE OF CONTENTS
3.1 Introduction
10
A slow-moving scraper agitator (6) with flexible
scrapers rotates inside the vessel (5) with or without
4 a double jacket (for heating or cooling). The scraper
agitator is responsible for turning over and mixing
6 the product. The scraper blades move over the
9 6a inner surface of the vessel wall. In this way, they
prevent the product from adhering to the wall and
improve the heat exchange.
5
8 A fixed flow breaker (6a) increases the mixing
effect.
The product returns to the homogenizer from the
1-3 conical vessel outlet. During this process, the
7 vacuum pump evacuates the vessel and constantly
deaerates the product.
After the vessel has been aerated, the final product
is discharged into the circulation pipe (8) via the
3-way valve.
7a 7b
Caution !
Please note that homogenizers equipped with a single-acting mechanical seal
may not be switched on until the homogenizer has been filled with liquid !
Dry running of the homogenizer will lead to very rapid destruction of the
mechanical seal !
3.2 Structure
The machine is a compact plant; all the components, vacuum or processing vessel, homogenizer,
vacuum pump, instrument cabinet, and the electrical switchgear are are located on the stainless
steel base frame.
The drive motor of the homogenizer and the vacuum system are mounted in the rust-proof
instrument cabinet.
Circulation pipe
Electrical switchgear 3.5.3.5
Product feed
Homogenizer 3.2.1 / 3.5.2
Drive Homogenizer
Pneumatic control 3.5.3.3
Media connections
(Water, steam, air and water
discharge)
Circulation pipe
Housing 3.5.3
Product feed
Homogenizer 3.2.1 / 3.5.2
Drive Homogenizer
3.2.3 Modules
Depending on the properties of the products, the homogenizer can be equipped with rotor / stator
elements (processing tools) specially designed for the particular products. This retrofitting or
modification can be performed by the customer‘s personnel.
Mixing or conveyor elements (1) are below the vessels exhaust passage, in the mixing chamber.
They force the product from the vessel into the centre through the dispersing disc (2) to the suction
blade (3). Latter pushes the mixture through a rotor and the fixed stator (4), shearing it (crushing)
and smashing solid particles.
The utmost rotor (pump blade) which follows into direction of flow the stator works like a pump. Its
pump effect presses the product into the recirculation pipe. Through this the product gets to the
vessel in a circulation process and it will run again the process.
If the desired final quality is achieved, the product is discharged via the multipath valve in the
recirculation pipe.
(4) (3) (2)(1)
7 6
5 4
Fig 3-6 Homogenizer with Disho grinding set Rotierende Welle / Rotating shaf t
arbre tournante
Function: The components fed through the feed studs get straight into the mixing chamber and
enter the homogenising zone formed by the stationary stator (2) and the rotor (1). The product
passes the dispersion/emulsion gap. Here powder particles are cut and shattered and liquids are
decomposed in drops the size of a micron.
(1) (2)
The rotor works like a pump. Its pump effect presses the product into the recirculation pipe.
Through this the product gets to the vessel in a circulation process and it will run again the
process.
If the desired final quality is achieved, the product is discharged via the multi path valve in the
recirculation pipe. The characteristics of the teeth and the width of the dispersion/emulsion gap
have a great influence on the fineness; apart from the standard teeth, a fine teeth option is also
available to produce extreme fineness. The width of the dispersion/emulsion gap can be adjusted
with a distance ring.
Functional chart
MaxxD
1 Viewing glass with lighting 8 Valve 3 Temperature sensor 60 Sealing liquid vessel
19 Double jacket
Vakuumsystem
Vacuum system
Système de vide
CIP Reinigung
CIP Cleaning
Lavage CIP PLC
Control
Heizen/Kühlen
Heating/Cooling
Chauffer/réfroidir
Sperrdruckanlage
Sealing liquid unit
Système de barrage
The individual components reach the homogenizing zone of the homogenizer directly from the
different feed supplies.
The solid matter/liquid particles refine distributed dispersed between the fixed stator and the rotor.
The grinding set supplied with this machine is described under modules 3.2.3.
• Circulation of the heating agent in the double jacket (steam, hot water,
thermo-oil), or
• by injecting steam directly into the batch (through the stud in the circulation
pipe) (optionally).
• Cooling is carried out by cold water, salt water, etc. flowing through the
double jacket.
It prevents:
• the product from adhering or forming crusts during the heating process
• the formation of an insulating layer of product during cooling
Vacuum deaeration
The homogenizer and scraper agitator cause a turbulent flow and continuous
stirring of the product in the vessel. Any air bubbles trapped thus pass into the
vacuum area at the top of the vessel. There, they expand and burst. The air
released is continuously pumped out by the vacuum pump.
Attention !
Please note that when processing products which contain tensides, the maximum
possible useful volume during deaeration must be adjusted to suit the intensity of
foam formation. If the vessel is too full and the product foams too much, the foam
can reach up to the spray heads and be sucked in.
3.3.9 Cleaning
Experience has shown that parts in contact with the product may be exposed to possible
biocontamination or even corrosion due to the long-term adhesion of the product.
This can be counteracted by regularly cleaning the machines and parts in the correct manner.
If cleaning is not carried out correctly, the guarantee expires in the event of a corrosive attack.
Particular importance is placed on fast and simple cleaning. The machine is constructed in
accordance with the GMP guidelines for minimum dead space operating conditions and is CIP-
capable. Any parts that come into contact with the product are easily accessible for control
purposes and can either be quickly removed or are freely accessible for cleaning. Grooves, dead
corners and indentations in which product remnants may collect have been avoided as far as
possible. This means that the machine can also be cleaned with the CIP process. For this purpose,
nozzles can be installed in the vessel as an option.
Furthermore as an option, the machine can be sterilised by steam flowing through. At the
lowermost point of the machine (homogenizer housing) there is a valve to fully discharge any
cleaning fluid or condensation. The cleaning fluid can also be returned to a CIP station via a pipe.
Note: The cleaning fluids can be supplied via the CIP inlet (connection at machine housing) to the vessel (spray heads).
If the CIP supply pressure during filling is too high, fluid can escape from the overpressure valve (on the vessel lid). In
this case, reduce the CIP pressure.
3.3.10 Operation
The machine is operated via a central operating panel. The individual units can be connected as
necessary.
EMERGENCY STOP
There is an emergency switch on the machine (switch cabinet). If the EMERGENCY STOP is
actuated, all the active processes in the machine are interrupted.
Overload protection
The motors and electrically actuated elements are protected by over current triggers and miniature
circuit breakers and are located in the control cabinet.
Lid switch
A limit switch on the lid and vessel flange monitors whether the vessel is closed and prevents the
scraper and homogenizer from starting up when the vessel lid is open.
The safety valves are laid out for the specifications quoted in the order.
In the event that vessel filling is an on-site provision, the efficiency of the safety valves must be
adapted accordingly.
3.5.1.1 Vessel
Conical/cylindrical vessel with lid for vacuum-tight seal.
Lid lock
By means of segmental clamping screws (Lab up to 700 l).
Vessel lid securely bolted, equipped with jack rings (1300 up to 3500 l).
Scraper blades are attached to the arms of the scraper agitator and allow
movement, so that the product can be continuously scraped from the vessel
wall.
Shaft seal
The shaft feed through of the scraper agitator are fitted with two shaft sealing rings which do
not need any sealing liquid. Nevertheless also this sealing considers the GMP requirements.
3.5.2 Homogenizer
Shaft seals
The shaft duct of the homogenizer is sealed by a mechanical seal.
Take measures to prevent the homogenizer from running dry if single-acting mechanical seals are
used.
A sturdy and generously dimensioned liquid ring vacuum pump serves as vacuum pump.
Function
The nominal temperature selected on the temperature regulator is started up automatically. The
tempering block here acts as a switching point for incoming and outgoing heating and cooling
media. The heating or cooling commands for steam, hot water and cooling medium go from the
temperature controller to an electro-pneumatic valve that actuates the corresponding pneumatic
valve on the tempering block.
- Tempering block
The heating and cooling valves are coupled together in the tempering block.
The product valves, CIP cleaning, aeration valve etc. are controlled from the valve block
(pneumatics).
• Motors:
Motors up to 7.5 kW are provided for direct starting, stronger motors for automatic star/delta
starting.All motors are splash-protected. Minimum IP 54 protection in accordance with DIN
40050. Other protection categories are available as an option.
TABLE OF CONTENTS
4.1 Introduction
Even though the machine offers a number of possibilities to influence the process, it contains only
a few control elements. The scraper agitator and the homogenizer, as well as the vacuum unit are
operated from the operating console.
4.2.1 Alarm
The machine does not contain alarm controls in the system as standard.
Note: Optical (signal lamp) or acoustic alarm indicators (sounder) are not included in the system as standard.
Please refer to the instructions for the operating console (chapter 6) for more information
on the alarm indicators.
The homogenizer and the scraper agitator, can only be started if the vessel is closed.
The final position of the vessel is detected by the means of a proximity switch.
The latter will automatically stop the processing aggregates if the lid is not in its final (closed)
position.
The security switch at the homogenizer prevents starting of the dismantled homogenizer.
Pushing the emergency push button cuts OFF the electric power supply to all devices of the
machine.
Note: The emergency stop push button remains in its position until being unlocked (for unlocking turn button). Resume
the process by activating the recipe/program at the control panel.
Appears this signal in the operating manual, steps must be taken to prevent
others to inadvertently starting up the unit.
With exception of the fuses/automatic circuit breakers, no other operating elements are contained.
Further specification about the content of the control cabinet are in the electrical wiring diagram in
chapter 5.
Clamping screws
• Lab
The lid is being opened/closed manually (push-type gas spring).
• 200 up to 700 l
The lid is being opened/closed with an electric lifting
spindle.
The machine is controlled /operated with a two-hand
control at the switchgear.
The operator opening the cover shall verify that there are
Fig. 4-2 Two-hand control
no unauthorized persons in the danger area.
Option
A handle and counterbalanced hinge are used to open and close the lid.
1300 up to 3500 l
Vacuum display
Pressure in the vessel will be displayed at the control panel.
Aeration valve
For aeration a valve opens by activating it at the control panel.
Lab:
The control cabinet fitted to the rear of the machine is designed to be hinged
open. To this end, open the door of the control cabinet and release the nuts on
the opposite side of the cabinet.
Attention: Only for maintenance purposes and only by qualified personnel. Make sure the machine is not moved in the
process; it can otherwise tip over.
F M P E
Fig. 4-10 Water supply
F) Water filter
M) Solenoid valve for the water supply
P) Pressure switch. Pressure signal to the control.
E) Regulating valve (manual). Serves for adjusting the amount of ring liquid flow of
the vacuum pump.
2 1 3
1 Pressure switch
2 Air service unit
3 Pneumatic valve manifold
Sight glass
Circulation pump
Temperature sensor
Flow monitor
Make sure that the sealing liquid system and the mechanical seal are completely
deaerated.
The supply connections of the heating and cooling media lead directly onto the tempering
furnishings.
Comprising:
• Injection socket
• Control valve
• Manometer incl. water siphon
• Dirt trap
• Condenser
• Steam connection
Recirculating pipe
Homogenizer / Feed chamber
Safety switch
Temperature sensor
Connections for hoppers
Studs with manually or pneumatic. activated flaps
*At pneumatic actuators, the knurled adjusting screw enables a variable valve aperture and
consequently product flow. Fix the adjusting screw by tightening the locknut.
Note: If product is sucked from atmosphere, the flow rate among others depends on the pressure (vacuum in the
working vessel.
Normal tap-water can be used as sealing and cooling liquid. When using tap-water, we advise you
to fit a pressure reduction valve to balance pressure fluctuations in the circuit, thus protecting the
seal.
5 Commissioning
Aim: To inform the user of the proper operating methods.
TABLE OF CONTENTS
5 COMMISSIONING������������������������������������������������������������������������������������������������������������������������������� 1
5.1 Safety����������������������������������������������������������������������������������������������������������������������������������� 2
5.1.1 Safety Regulations��������������������������������������������������������������������������������������������������������������� 2
5.1.2 User Requirements��������������������������������������������������������������������������������������������������������������� 2
5.1.3 Technical Documentation����������������������������������������������������������������������������������������������������� 2
5.2 Assembly ����������������������������������������������������������������������������������������������������������������������������� 3
5.2.1 Requirements����������������������������������������������������������������������������������������������������������������������� 3
5.2.2 Transport������������������������������������������������������������������������������������������������������������������������������� 3
5.2.3 Site / Operation room����������������������������������������������������������������������������������������������������������� 3
5.2.4 Handling, Unpacking and Cleaning��������������������������������������������������������������������������������������� 3
5.3 Commissioning��������������������������������������������������������������������������������������������������������������������� 4
5.3.1 Interfaces of delivery and assembly������������������������������������������������������������������������������������� 4
5.3.2 Assembly ����������������������������������������������������������������������������������������������������������������������������� 5
5.3.3 Power supply, operating media��������������������������������������������������������������������������������������������� 7
5.4 Primary Set-up ��������������������������������������������������������������������������������������������������������������������� 9
5.4.1 Measures before Initial Set-up ��������������������������������������������������������������������������������������������� 9
5.4.2 Primary Set-up ������������������������������������������������������������������������������������������������������������������� 12
5.4.3 First cleaning����������������������������������������������������������������������������������������������������������������������� 13
5.4.4 How to determine if cleaning has been successful������������������������������������������������������������� 14
5.4.5 Test procedures ����������������������������������������������������������������������������������������������������������������� 14
5.5 Acceptance������������������������������������������������������������������������������������������������������������������������� 14
5.5.1 Acceptance criteria������������������������������������������������������������������������������������������������������������� 14
5.5.2 Procedure��������������������������������������������������������������������������������������������������������������������������� 14
5.1 Safety
Experienced FrymaKoruma personnel are available to help with installation and initial operation of
the machine if this has been previously arranged. The customer should always take advantage of
this possibility if the requirements stated in chapter 5.1.2 are not fulfilled FrymaKoruma would not
be liable for damage caused by mistakes that were made when setting the machine into operation.
Electrical equipment supplied by the client have to meet the requirements of the standards
EN60204-1 respectively IEC 204-1.
5.2 Assembly
5.2.1 Requirements
Important: The machine requires for the operation:
• Power supply and equipment in accordance with chapter 1.2.2 of the operating manual.
5.2.2 Transport
Storage
Until such time as the assembly is to take place, the machine must be left in its original packaging
and stored protected from the weather. For the recommended storage conditions consult chapter
1.2.4 of the operating manual.
Room Requirements
Floor: The entire floor area must be level. Uneven floors or those with stumbling places and
differences in level pose a high accident risk. Keep work areas free.
Floors made of materials which are easy to clean are recommended. Ceilings, walls and floors
should be kept clean and free of dust. Clean these areas if required and keep them dry whenever
possible.
Lighting
The average flux density in the working area should be 600 Lux/m2.
Danger!
Mind the notes given in chapter 10 about the fixations made for the transport and
the proper use of the lifting devices delivered.
5.3 Commissioning
Customer Preparations*
The customer is responsible for:
• Setting up and grading the machine.
• Assembly of the components which have been removed for dispatch.
• Water supply of cooling- and fresh water, hot water or vapour.
• Connections for the product.
• Piping for compressed air.
• Waste water piping of the vacuum pump or used CIP-water.
• Power supply of the switchgear to the electric net.
• Electrical wiring between switch gear and components of the machine.
• Check of the fixation screws.
5.3.2 Assembly
Order of assembly:
- Putting on place
The machine has to be placed on a level ground. In most cases, no foundation is required, yet the
admissible floor loading imposed by the machine with filled vessel has to be considered.
- Levelling
The machine is to be aligned horizontally and vertically with the levelling screws in the base frame.
Reference horizon for the alignment is the surface of the vessel flange.
- Assembly of the components which have been removed for the dispatch
A list of the parts removed for the transport will be found in the shipment list. These components
have to be assembled according the drawings before start-up again.
• Water supply of cooling- and fresh water, hot water or vapour up to the base.
• Connections for the product.
• Optional piping for compressed air.
• If needed piping e.g. leak connection of the sliding ring seal.
• Sewage piping connection for the vacuum pump or for used CIP-water.
The electrical wiring between switchgear and the machine components are to be made according to the wiring diagram.
Information about the periodic check of the fastening screws are in chapter 7.4.4.2.
Requirements regarding the quality and quantity of operating media are to be found in the chapter 1.2.2 Power supply
and infrastructure.
- Electrical Connections
For the electrical power supply, overcurrent protection according to Chapter 1.2 of the operating
manual must be present. Details are found in the electrical documentation.
The electrical switchgear must be connected by an electrician to current supply.
• the control panel must be installed outside the potentially explosive area or room
• the wiring between the control cabinet and the control panel must be carried out
on site
• earthing cables must be installed
• The sense of rotation of all motors must correspond to the rotary arrow
• Since the machine is prewired, all motors will run correctly if the AC power is carried out with
„rotary field“ runs „clockwise“ (c.w.)
• Homogeniser: when looking from the motor side towards the unit, the rotational direction of the
motor shaft/fan is to the left or anticlockwise
• Scraper agitator: rotates c.c.w. (check through sight glass)
• Vacuum pump: check arrow
• Forced circulating- and CIP -pumps: check arrow
• Sealing liquid pump: check arrow
- Working area/homogeniser
- Sealing liquid
Machines equipped with sealing liquid or forced sealing liquid systems:
The sealing liquid vessel has to be filled up to the marking of the level indicator (sight glass) with
sealing liquid. In the case of a “forced sealing liquid system” subsequently pressurize the sealing
liquid vessel with the force gas. Information about the sealing liquid is to be found in chapter 7.3.1.
The double acting mechanical seal has to be deaerated according to chapter 4.3.4.3
„Components of the sealing liquid system“
Warning !
Inputting a password through a person not authorized to this (user, third person)
would cause damage to the machine. Furthermore, injuries could be the result of
faulty operation by an unauthorized person.
Connection and sense of rotation with rotary field clockwise at the input terminals. Tested successfully
The process aggregates can not be started with vessel open, or stop when opening the vessel?
Safety valve for heating/cooling circuit mounted? Reading of set pressure bar
Start pump and check/adjust flow of ring liquid. For data: Use the operating manual of the pump supplier
Reference
Vacuum and pressure (in mbar) Vacuum and pressure Display
device
Pressure transmitter -900
-250
500
2500
Vessel interior
Water temperature ºC
Loss of the vacuum with user volume (100 mbar abs) testing time min.
Acceptable vacuum loss: 10 mbar within 30 min. Pressure loss mbar
Tightness of shut off valves OK? Yes No
Tightness of the complete pipe layout (heating and coolant feed lines) successful tested
Tightness of the mechanical seal (visual check of mechanical seal and sealing liquid vessel)
Scraper-stirrer
Homogenizer
Vacuum pump
Current consumption with vessel empty at -200 mbar und 0,5 – 1 bar ring liquid pressure A
CIP-pump
Current consumption A
Discharge pump
Heating/cooling time with 13 rpm. Scraper-stirrer and Homogenizer ON, water as a testing medium. min.
Type of device:
Procedure applied:
Procedure applied:
IMPORTANT!
The system user is responsible for the first cleaning procedure (rinsing, chemical cleaning) as well
as for any further surface treatments (e.g. passivation, etc.).
The cleaning procedure described below is merely a recommendation and does not give the user
any guarantee that the customer-specific cleaning quality will be achieved.
This cleaning procedure removes residues in the vessel left over from commissioning. The inlet
and outlet pipes must also be included in this cleaning procedure.
• Recommended equipment:
• Heatable recipient vessel with approx. 50% of the volume of the vessel to be cleaned.
• CIP/pressure pump, conveying capacity 9 m3/h with 4 bars at the pressure joint.
• High-pressure cleaner
If these requirements are not met, the process must be adapted in such a way that heating, for
example, is performed inside the system. If necessary, cleaning must be repeated several times
until the desired level of cleanliness has been achieved.
2. Fill the recipient vessel with 2/3 of the volume with tap water.
• Add cleaning agent (e.g. 1% P3-mipF, supplier: Henkel AG).
• Heat liquid to 63°C.
• Switch on the CIP pump. Let the cleaning liquid circulate over the spray nozzles for approx. 20
minutes. The spray water must be able to drain off freely; no damming up should occur in the
vessel if maximum spray effectiveness is to be achieved.
Raw materials generated at machine operation and service and particularly consumed detergents
are subject to CIP and proper recycling according to relevant valid state and in-house regulations.
The material manufacturer should supply a corresponding safety data sheet. These safety data
sheets together with instructions for safe handling with dangerous materials must be available at
the workplace at any time.
If a charge is changed (other receipt), the machine should be cleaned according to data specified
in the following table.
Caution
Before starting, always fill the vessel with liquid!
Vessel must be filled to the minimum level in order to avoid it running dry.
Note: The scraper or homogenizer must never run dry. In the event of it running dry, the homogenizer might become
blocked or damaged. The scraper might damage the vessel (causing grooves, scratches, etc.).
5.5 Acceptance
5.5.2 Procedure
A report will be made of the acceptance procedure, which will be signed by the purchaser and
FrymaKoruma.
6 Operation
Aim: To guide the user to operate the machine. This covers the safe and economical operation, as
well as the utilization of the various possibilities of the machine.
TABLE OF CONTENTS
6 OPERATION ��������������������������������������������������������������������������������������������������������������������������������������� 1
6.1 Introduction��������������������������������������������������������������������������������������������������������������������������� 2
6.1.1 Safety measures������������������������������������������������������������������������������������������������������������������� 2
6.1.2 Demands on the personnel��������������������������������������������������������������������������������������������������� 2
6.2 Production and organization������������������������������������������������������������������������������������������������� 2
6.2.1 Processing control ��������������������������������������������������������������������������������������������������������������� 2
6.2.2 Option „Automatic processing control“��������������������������������������������������������������������������������� 2
6.2.3 Cleaning Process����������������������������������������������������������������������������������������������������������������� 3
6.2.3.1 Cleaning without CIP / Manual cleaning process����������������������������������������������������������������� 3
6.3 Operation ����������������������������������������������������������������������������������������������������������������������������� 6
6.3.1 Installation/ Settings/ Equipment������������������������������������������������������������������������������������������� 6
6.3.1.1 Settings��������������������������������������������������������������������������������������������������������������������������������� 6
6.3.1.2 Perform maintenance work according to plan of maintenance in chapter 7������������������������� 6
6.3.2 Remarks on the operation����������������������������������������������������������������������������������������������������� 6
6.3.2.1 Product feeding��������������������������������������������������������������������������������������������������������������������� 9
6.3.2.2 Heating and cooling down��������������������������������������������������������������������������������������������������� 11
6.3.2.3 Mixing, homogenizing, emulsifying and grinding ��������������������������������������������������������������� 12
6.3.2.4 Deaeration and cooling down��������������������������������������������������������������������������������������������� 13
6.3.2.5 Discharge of the product����������������������������������������������������������������������������������������������������� 13
6.3.2.6 Direct steam injection (Option)������������������������������������������������������������������������������������������� 13
6.4 Data entry / program run����������������������������������������������������������������������������������������������������� 14
6.5 Switching off / ending��������������������������������������������������������������������������������������������������������� 14
6.5.1 Switching off����������������������������������������������������������������������������������������������������������������������� 14
6.5.2 Long interruption����������������������������������������������������������������������������������������������������������������� 14
6.6 Starting / switching on��������������������������������������������������������������������������������������������������������� 14
6.7 Monitoring, checking����������������������������������������������������������������������������������������������������������� 15
6.8 Trouble shooting����������������������������������������������������������������������������������������������������������������� 15
6.8.1 Possible troubles����������������������������������������������������������������������������������������������������������������� 16
6.1 Introduction
Note: FrymaKoruma would be willing to show users how to operate and maintain its systems. Experienced employees
explain all the steps necessary to process correctly and work safely with the machine.
Note: Data logging, i.e. by continuously storing processing data to create a data logging will only be supported with
automatic process control systems.
a) In many cases, the open cleaning is executed manually in spite of tools and is always
necessary for open surfaces, floors and vessels etc.
b) The closed or CIP cleaning includes the cleaning of vessels, pipelines and components
without having to take them apart and clean them manually.
WARNING!
Tip:
To reduce the noise level, limit the speed of the homogenizer during the CIP process to max. 2500
rpm.
Criteria for a successful cleaning are to be determined for each product and
cleaning process!
Discharge product
Mechanical cleaning
Purpose: Utilize as many products as possible. Keep load of waste water with product small.
• Open lid. Wear suitable protective clothing, gloves and goggles.
• Most of the product residue is to be found on the scraper blades.
• Remove product residues with rubber or synthetic scraper.
• Remove, clean and reinstall scrapers.
Wet cleaning
• Close vessel and apply vacuum. Fill 2/3 of vessel with tap water.
• Add detergent or mixture.
• Aerate vessel.
• Heat up fluid according to the product. When this has improved the cleaning effect, let the
scraper agitator and homogenizer run at maximum speed for about 15 to 20 minutes.
• Release fluid. Raw materials generated at machine operation and service and particularly
consumed detergents are subject to CIP and proper recycling according to relevant valid state
and in-house regulations.
Primary cleaning
Open the valve with the spray nozzles for the
cleaning water.
Close vessel and evacuate vacuum.
Install circulation pipe
Start the CIP cycle!
Fill vessel to the minimum volume
Fine cleaning
Start the CIP cycle!
Fill vessel to the minimum volume.
Start the processing aggregates.
Add detergent (acid, caustic, alkaline, for example).
Scraper and homogenizer at max. speed.
When the vessel is half full, heat up the cleaning
fluid following the instructions.
Switch off the processing aggregates/water supply
after about 30 minutes.
Empty the vessel (or neutralize it!)
Final cleaning
Similar procedure as for the fine cleaning but with
less fluid.
Fill vessel to the minimum volume and add de-
ionized water, a softener, for example, depending on
the requirements.
Start the processing aggregates, scraper and
homogenizer at max. speed.
Heat up to 58°C approx.
Start the CIP cycle!
Switch off the processing aggregates after about
15 minutes, empty vessel.
Dismantle the circulation pipe, lock pipe stub.
6.3 Operation
6.3.1.1 Settings
It may be necessary to mount other processing tools in the homogenizer, depending on the
product. Changing the processing tools is described in chapter 7.4.4.
Note: The machine has a drain or emptying function. Once the vessel has been filled by activating „Water on“ or „CIP on“
and subsequent to the CIP procedure, the vacuum line must be emptied (drained).
Safety instructions
Wear safety goggles when working with the open machine to avoid injury from
splashing.
Caution!
Fill up the vessel up to the minimum volume before starting the processing
aggregates! Avoid dry running!
Danger!
< Max.
> Min.
Observe filling quantity according to type plate, when filling the vessel
4. Never fall below minimal level! 5. Never overfill the vessel! 6. Start processing aggregates
• The sealing surfaces on the lid and vessel flange must be clean before they are closed so that
the machine is tight.
• After cleaning, close the lid and tighten the clamping screws.
IMPORTANT!
Product feeding
• Fill the vessel up to the minimum volume with a liquid phase in order to avoid a dry run.
(with single acting sliding ring seals).
IMPORTANT!
Dry running of the homogenizer will lead to very rapid destruction of the single
acting mechanical seal !
The vessel shall only be filled up to the maximum of its usable volume, otherwise the product
might get into the vacuum system.
• Put starting components in the vessel.
• Add the liquid component first of all.
• Set speed of homogenizer and scraper agitator according to the recipe and start .
• Add dry component according to the recipe.
IMPORTANT!
If melted or block materials are put in the vessel, the solid components have to
be dissolved before the scraper agitator is switched on.
If you do not observe these instructions, the scraper blades, the homogenizer or
the scraper agitator could be damaged.
Warning:
Never open the valves when the vessel is under excess pressure!
The valves must be closed immediately after the product feed.
Warning:
Before working on the system, pressure must be released and it must be emptied.
Note: If the valve of a hopper or a stud is open while the vessel is under pressure, there is a risk of injury by flying
products (such as powders, content of the vessel, steam during cleaning, etc.).
If a valve is not closed properly, during the application of pressure for example, some of the product could be expulsed
during a subsequent pressure operation.
Warning!
Risk of scalding from boiling liquids. Take care to avoid contact with hot surfaces
during machine operation.
It is not permitted to heat up water or products containing water to more than
90°C in vessels not fitted with lid lock (only vacuum operation).
Observe the information given in the manuals of suppliers (file 2, chapter 7).
For systems without a ventilating automatism, the heat cycle and the double jacket must be filled
and deaerated.
Let the scraper agitator and the homogenizer run at low speed during heating up. This results in an
even distribution of temperature and prevents the product from sticking to the vessel walls.
If the vacuum pump is making a loud noise while in operation, this means that it is cavitating
(crackling noise).
Please refer to the diagram in the appendix „Saturation line of steam“ to learn more about the
obtainable vacuum at a given temperature.
Note: The heating can be supported by mechanical energy (adjust high rpm for mixer). Shorter batch times may be
achieved.
• Select the „Homogenizer device“ on the operating panel. This starts the homogenizer.
• Add the dry component. The homogenizer speed must be set in such a way that solid or
powdery materials are directly sucked into the liquid. Set the dosing valve, so that no lumps
or striae appear. Make sure that the fed component are processed directly by the processing
aggregates in the liquid phase. The product runs through the homogenizer which grinds rough
materials and homogenizes or emulsifies the product. Other component can be poured into the
product during this phase.
* In the case of pneumatic valves, please observe the use of the adjusting screw on the valve drives of the homogenizer
(Chapter 4.3.5).
• Set product temperature on the temperature controller (if any) or in the program!
• Apply final vacuum depending on the product temperature! (only possible with automatic process
control / not possible with standard systems). The product is deaerated while being mixed and
homogenized. The vacuum pump runs and continuously sucks the air contained in the product.
By observing the product surface from the sight glass, you can check the progress of the
deaeration. If the product tends to foam, you need to reduce the vacuum.
• Switch off the vacuum pump*
• Open the vacuum aeration valve manually. (Select the „Ventilating“ command on the operating
panel on machines with process control).
If there is no product left in the vessel, the Homogenizer and scraper agitator as well as the
discharge pump, if there is one, must be switched off.
Avoid material damage due to a dry run by switching off all the mechanical aggregates!
Note: The machine must then be cleaned or the next batch must start.
Warning!
• Each aggregate is to be switched off on the control panel with the appropriate “OFF“-Function.
• Additionally, disconnect with the main switch to “OFF“. Always switch the system off when
carrying out repairs, during bank holidays, holidays etc.
Additionally:
• Close the shut-off valve for water as well as cooling water and compressed air
• Set (release) the pressure reducing valve for the compressed air to 0
• Close the compressed air shut-off valve
Checklist
Please use the checklist in chapter 7.
Whether an automatic process control/registration exists or not, we recommend that you check the
following operation parameters regularly and enter them on a check sheet. It is thus possible to
notice trends of incidental changes early and to carry out the necessary corrections in time.
Leakages of the mechanical seal, leakages in the pipelines and fittings, check additionnal devices
periodically such as the sealing liquid vessel and the pumps.
Refill of working stock (sealing liquid, gear oil, etc.).
Temperature and noises/loud noise/vibrations on the bearing of the aggregates and the pumps.
Specific events.
Notes on the alarms at automatized machines find themselves in the appendix of the operating
manual of the control panel.
Warning:
The performance of works through persons not authorized can lead to the loss
of assurance claims. The product liability of the manufacturer is not valid, if as a
result, danger of persons, of the environment or of the product occurs.
REPLACE- REPAIR-
SOURCES OF ERRORS POSSIBLE CAUSES MEASURES FIND IN
CODE (1) CODE (2)
REPLACE- REPAIR-
SOURCES OF ERRORS POSSIBLE CAUSES MEASURES FIND IN
CODE (1) CODE (2)
REPLACE- REPAIR-
SOURCES OF ERRORS POSSIBLE CAUSES MEASURES FIND IN
CODE (1) CODE (2)
REPLACE- REPAIR-
SOURCES OF ERRORS POSSIBLE CAUSES MEASURES FIND IN
CODE (1) CODE (2)
4.3 Pump is noisy strongly Rattling noise of cavitation - Change operational parameter S
REPLACE- REPAIR-
SOURCES OF ERRORS POSSIBLE CAUSES MEASURES FIND IN
CODE (1) CODE (2)
5. Scraper-stirrer / Homogenizer
- Close vessel
5.1 process will not start - Check final switch lifting
«vessel open» 4.2.2 O/F S
„error report“ device and adjust if ne-
cessary
- Close homogenizer
5.2 process will not start - Check safety switch,
«Homogenizer open» 4.2.2 O/F S
„error report“ homogenizer and adjust if
necessary
6. Scraper stirrer
7. Homogenizer
a) Shaft of homogenizer
Aligning required 8.4.1.2 O/F F
bent
Dismantle homogeni-
b) Processing tool dama- zer and check tools for
7.1 Strong vibrations when running 8.4.1.2 O/F F
ged by foreign matter damage
Replace if need
REPLACE- REPAIR-
SOURCES OF ERRORS POSSIBLE CAUSES MEASURES FIND IN
CODE (1) CODE (2)
9. Product quality
7 Maintenance
Aim: To preserve the nominal status and the operational integrity of the machine. Increasing
degree of use by avoiding unforeseen downtime. Efficient planning of the service work and of the
service material.
TABLE OF CONTENTS
7 MAINTENANCE����������������������������������������������������������������������������������������������������������������������������������� 1
7.1 Introduction��������������������������������������������������������������������������������������������������������������������������� 2
7.1.1 Safety regulations����������������������������������������������������������������������������������������������������������������� 2
7.1.2 Requirements on the personnel������������������������������������������������������������������������������������������� 2
7.2 Plan of maintenance������������������������������������������������������������������������������������������������������������� 3
7.3 Supplies and accessories����������������������������������������������������������������������������������������������������� 5
7.3.1 Sealing liquid, lubricant, detergent��������������������������������������������������������������������������������������� 5
7.3.2 Measuring and checking aids����������������������������������������������������������������������������������������������� 5
7.4 Service operations ��������������������������������������������������������������������������������������������������������������� 6
7.4.1 Safety inspection������������������������������������������������������������������������������������������������������������������� 6
7.4.2 Care and cleaning work ������������������������������������������������������������������������������������������������������� 6
7.4.2.1 Cleaning the area where the machine is located ����������������������������������������������������������������� 6
7.4.2.2 Cleaning the vessel��������������������������������������������������������������������������������������������������������������� 7
7.4.2.3 Cleaning the outside of the machine������������������������������������������������������������������������������������� 7
7.4.3 Pressure-limiting unit (valve) on the container‘s lid ������������������������������������������������������������� 7
7.4.3.1 The work of inspection, control and alignment ��������������������������������������������������������������������� 7
7.4.3.2 Parts of the pressure-relief valve ����������������������������������������������������������������������������������������� 8
7.4.3.3 Dismantling for the cleaning������������������������������������������������������������������������������������������������� 9
7.4.3.4 Assembly after the cleaning����������������������������������������������������������������������������������������������� 10
7.4.4 Inspection, check up and adjustment works����������������������������������������������������������������������� 11
7.4.4.1 Tightness of the machine��������������������������������������������������������������������������������������������������� 11
7.4.4.2 Tightness of the operating media��������������������������������������������������������������������������������������� 12
7.4.4.3 Vessel control��������������������������������������������������������������������������������������������������������������������� 12
7.4.5 Checking and replacing submodules ��������������������������������������������������������������������������������� 13
7.4.5.1 Replacing the scraper blades��������������������������������������������������������������������������������������������� 13
7.4.5.2 Rechecking the fixing screws��������������������������������������������������������������������������������������������� 16
7.4.5.3 Tank cleaning head with split pin ��������������������������������������������������������������������������������������� 16
7.4.5.4 Dismantling the homogenizer��������������������������������������������������������������������������������������������� 17
7.4.6 Control/process ����������������������������������������������������������������������������������������������������������������� 19
7.4.7 Mounting instructions for screw connection ����������������������������������������������������������������������� 20
7.1 Introduction
Service and maintenance works of the machine are to be carried out in accordance with the
maintenance plan.
Note: During the initial training, operators are also introduced to maintenance and servicing of the machine.
Column 2, indicates in key words, the work to be carried out. The number designates where to find
information to the topic in the operating manual.
(Service Engineer)
Service specialist
Maintenance / Service MaxxD/DinexH
max. 2 Years
- 3 Months
- 6 Months
- Day/Job
Operator
- Month
- 1 Year
- Week
Cleaning
Vessel 7.4.2.2 x x
Homogenizer x x
Checks
Bearing wear x
Product pump x x
Mechanical seal x
• Lubricants used by FrymaKoruma are listed in the lubricating schedule (see appendix).
• Lubricants employed by suppliers find themselves in the supplier’s documentation.
The flow is to be adjusted such, a maximum outlet temperature of 80°C do not exceed (i.e. water
and similar products). With solvents or alcohol a maximal difference temperature of 60°C will
be allowed. When selecting a forced sealing liquid, make sure the liquid is compatible with the
materials of the mechanical seal.
ATTENTION: The filter at the air service unit is still under pressure!
Don‘t forget: Make sure the air pressure is reset to 6 bar prior to operation.
Electrical connections
Visual inspection to check if the insulation has been damaged:
Warning!
Warning!
Sterilizing the unit with hot steam is only possible for machines that are pressure-proof. For this,
the lid and the vessel must be safely locked using the clamp screws.
”CIP” cleaning
Please refer to chapter 6.2.3.
The control panel can be cleaned separately afterwards with a cleaning cloth. The cleaning agent
used must have a neutral pH-value (6–8), must be free from aroma and above all must not contain
any solvents such as ethanol.
Safety valves or bursting discs are used for containers in the overpressure range. Please take the
information for maintaining these components from the sub-supplier‘s documents.
The pressure-relief valve is used for pure vacuum processing plants and it permits a maximum
overpressure of 0.5 bars, which triggers the pressure-relief valve. This valve ensures that no
overpressure can build up in the container while the plant is operating.
CAUTION !
The working order cannot be ensured any longer whenever there is bad
maintenance!
2. Seal
3. Blind lid
4. Guiding pin
5. Casing
6. Cone
7. O-rings
8. Seal
4) Now the casing (5) is slowly raised from the TC blind lid (3).
Care must be taken while doing so that the cone (6) sits on
the guiding pins (4) and that it is not tilted in the casing (5).
Figure 7-3.
5) The valve casing and all of the inner parts can now be
cleaned.
Figure 7-3. Extension of the internal parts from the valve housing
CAUTION !
It is important that the cone does not fall into the casing. The sealing surface can
be damaged otherwise. The working order is not ensured any longer as a result.
It must be checked that the cone (6) runs smoothly after assembling all of the inner parts and the
TC clamp (1).
The complete pressure-relief valve is now remounted on the container's lid and it is screwed tightly
to the TC clamp (9) and the seal (8).
• Evacuate the vessel to approx. 100 mbar absolute and switch off the vacuum pump.
• If the machine is tight, there should be no noticeable pressure increase after fifteen minutes.
Important: The vessel should only contain cold liquid during this test.
• Leakages can be located using foaming agents.
The amounts of liquid leaked by the MS that is in contact with the product can only be
assessed through the liquid level of the forced sealing liquid vessel. For this purpose, a clear
sticker has been attached to the sight glass. It features a scale which allows a noticeable relative
change of the level to be ascertained.
Replacing seals
General recommendation:
Seals that have been in use for any longer period of time must be replaced when the sealing
connection is opened.
• to have the stipulated and requisite controls carried out on the pressure vessels by a notified
body in accordance with the national pressure vessel regulations (e.g. PED, ASME, etc.)!
• if the temperature regulator is equipped with a separate safety valve, this valve is subject to
testing, too.
Removal
• Bend the locking wire (2) with the special tool (1)
• Bend the spring out off the guide
• Move the sidewards off its bearing
1 2
Installation
CAUTION !
Fit the scraper blade into both bearings and let the spring snap in. Bend back the
locking wire (2) into locking position.
Removal
Installation
CAUTION!
Pay attention to the position of the spring when installing the scraper blade! See
Figure 7-1. When installed, the spring must push the scraper blade firmly against
the bin wall.
Removal
Installation
All fixing screws must be checked and tightened for start-up and on a
monthly basis thereafter.
Otherwise, a tank washing head together with the splint bracket may fall into the
working area resulting in serious damage.
Note:
Bend clip end 30°!
Attention / Achtung !
for single use only / nur für einmal Gebrauch !
Installation instruction / Installationsvorschrift:
Splintende 30°umbiegen !
1) The vessel, hopper, all feed pipes and the homogenizer must be evacuated and cleaned!
Access to the rotor is available via corresponding orifices after dismounting pipelines at
material inlet/outlet. The discharge valve on the homogenizer is open.
2) All power and media lines to the homogenizer (steam, hot water, compressed air, etc.) must
be shut off at the main supply.
Checks:
For wear and damage to the processing tools.
That rotor shaft runs true, without runout or bearing play.
Replace parts depending on wear.
Reassembly:
Replace O-rings and seals that have been removed with new ones.
Please refer to the table in the lubrication plan for lubricants that are to be used.
Activate safety switch!
7.4.6 Control/process
The following means are available to solve hardware or software problems:
• The Operating instructions for the control in the appendix of chapter 6 features information on
how to proceed in the event of alarm signals and lists the system’s error messages.
• Additional descriptions of alarms can be found in the supplier’s documentation, e.g. for
frequency converters or other electronic equipment. These documentations are included with
these operating instructions.
• Please refer to 6.8 “Troubleshooting” for more information on how to clear faults.
• Both the switch cabinet of the unit and chapter 5 include the P+I diagram and the
electrotechnical documentation.
• If you cannot solve the problem with these means, please contact the FrymaKoruma customer
services.
AGIP (Suisse) AG
Verkaufsbüro Zürich
Components which are not in direct contact
AUTOL TOP 2000 Flüelastrasse 54
with products
CH-8047 Zürich
Tel.: 01/491 08 66 / Fax: 01/493 52 29
A C A
C
B
B
D
a) All screw connections with special boundary conditions and under high stress:
- Friction factors mtotal
- Special securing measures (e.g. liquid glues...)
- Different screwing classes and mounting tools
- High / low operating and mounting temperatures
b) Anti-fatigue bolts, flange bolts with ribs...
c) Materials with reduced admissible surface pressure
(e.g. plastics...)
d) Property class for screw and nut different from the one indicated
8 Repairs
Aim: Re-establishing the initial status. Recognising and evaluation of the malfunction.
Troubleshooting sequence.
TABLE OF CONTENTS
8 REPAIRS��������������������������������������������������������������������������������������������������������������������������������������������� 1
8.1 Introduction��������������������������������������������������������������������������������������������������������������������������� 2
8.1.1 Safety regulations����������������������������������������������������������������������������������������������������������������� 2
8.1.2 Requirements on the personnel������������������������������������������������������������������������������������������� 3
8.1.3 Maintenance concept����������������������������������������������������������������������������������������������������������� 3
8.2 General information ������������������������������������������������������������������������������������������������������������� 3
8.2.1 Special tools, measuring and inspection sets����������������������������������������������������������������������� 3
8.2.2 Spares, accessories and repair sets������������������������������������������������������������������������������������� 3
8.3 Troubleshooting and eliminating������������������������������������������������������������������������������������������� 3
8.3.1 Structure according to the functional sequences ����������������������������������������������������������������� 3
8.4 Repairs��������������������������������������������������������������������������������������������������������������������������������� 4
8.4.1 Dismantling and control of wear and tear of the various aggregates����������������������������������� 6
8.4.1.1 Scraper agitator system ������������������������������������������������������������������������������������������������������� 6
8.4.1.2 Homogenizer������������������������������������������������������������������������������������������������������������������������� 7
8.4.1.3 Lifting device (Lab to 700 l)��������������������������������������������������������������������������������������������������� 8
8.4.1.4 Dismantling the vessel or the lid����������������������������������������������������������������������������������������� 11
8.4.2 Discharge and conveying pumps, sealing liquid system����������������������������������������������������� 11
8.4.3 Vacuum pump��������������������������������������������������������������������������������������������������������������������� 11
8.4.4 Fittings, control equipment������������������������������������������������������������������������������������������������� 11
8.4.5 FrymaKoruma customer service����������������������������������������������������������������������������������������� 11
8.5 Wiring diagrams / electric schematics��������������������������������������������������������������������������������� 12
8.1 Introduction
Warning!
Note: This may be done i.e. by jamming a timber between the lid and vessel.
WARNING!
Before executing works at the homogenizer always carry out:
• Discharge product of the vessel and homogenizer.
• If need clean and rinse the equipment.
• After machine modification (e.g., repairs or replacement of parts), check and
ensure that electrical bonding is fully provided.
8.4 Repairs
Gear 8.4.1.1
Scraper agitator
Media piping 5.3.2
Lid 8.4.1.4
Shaft seals
Scraper agitator
8.4.1.1
Vessel 8.4.1.4
Fastening
of fixation
screws 7.4.4.2
Fittings Gear
8.4.4 Scraper agitator 8.4.1.1
Lid 8.4.1.4
Lid lifting
device 8.4.1.3
Shaft seals
Joints / Gaskets
Scraper agitator 8.4.1.1
Scraper blades
7.4.4.1
Electrical
switchgear
4.3.1 / 4.3.2
Homogenizer
8.4.1.2
Mechanical seal
Motor bearings
Fastening
of fixation
Vacuum pump screws 7.4.4.2
5.4.1.4 / 8.4.3
8.4.1 Dismantling and control of wear and tear of the various aggregates
Shaft seal
The shaft bush is equipped with two shaft lip seals. Any serious leaks can be recognised by the
vacuum in the working vessel dropping rapidly with the vacuum pump switched off. In this case,
exchange the shaft lip seals.
Danger!
Due to the risk of injury, it is not advisable for customers to perform repairs on
scraper agitator.
• Lifting device
• Scraper agitator and it’s gear
• Shaft seals in the lid
If performing these works, please ask for support at the FrymaKoruma Customer service.
8.4.1.2 Homogenizer
The main part subject to wear and tear is once again the mechanical seal, the deficiency of which
is shown by the rapid sinking of the vacuum in the vessel.
Please refer to the actual drawing of your machine.
Reassembly
• Use new O-rings and gaskets for all parts being disassembled.
• Use appropriate grease according the lubricating plan.
Danger !
Due to the risk of accidents, it is highly unadvisable to perform work within the
lifting device (Safety component) !
You must not change or repair any parts of the lifting system.
• Do not dismantle this device ! Also mind the information given by the manufacturer.
Danger !
The push type gas spring is loaded when the lid is closed.
• Do not dismantle this device ! Also mind the information given by the manufacturer.
Danger !
Works in the vessel may only be carried out with the safety
pin locked.
A handle and counterbalanced hinge are used to open and close the lid.
Works in the vessel may only be carried out with the safety pin locked.
Danger
Due to the risk of accidents, it is highly unadvisable to remove the vessel or the
lid.
9 Recycling
If you have any questions regarding the disposal of FrymaKoruma components, please contact
FrymaKoruma Customer Service.
10 Transport
Aim: Information on how to correctly transport the machine.
TABLE OF CONTENTS
10 TRANSPORT��������������������������������������������������������������������������������������������������������������������������������������� 1
10.1 Center of gravity of the machine without control cabinet ����������������������������������������������������� 2
10.2 Lifting of the machine����������������������������������������������������������������������������������������������������������� 3
10.3 Transport of the machine ����������������������������������������������������������������������������������������������������� 4
10.3.1 Lifting by means of a crane Lab������������������������������������������������������������������������������������������� 4
10.3.2 Lifting by means of a crane 200 - 1800 l������������������������������������������������������������������������������� 5
10.4 Moving the machine������������������������������������������������������������������������������������������������������������� 6
10.4.1 Moving Lab��������������������������������������������������������������������������������������������������������������������������� 6
Consider the center of gravity when lifting the machine. The procedure is described in Chapter
10.3.2., item 3.
1 2 3 4 5 6
Dimensions Weight Dimensional
Type LxWxH (mm)(approx.) (kg) (approx.) Lifting Bar Eye Bolts Drawing
Danger!
Drawings 2
•
TABLE OF CONTENTS • PART 2
Vacuum System
Operating Instructions 3
Instrumentation
Fittings 6
Pneumatic, Compressed Air
Heating-/Cooling Units
Vessel and Piping 7
Blending Vessel and Mixer
•
Certificates 10
Spare parts
□ Inquiry No.
□ Order No..
Customer Invoice
Address:
VAT no.
Delivery
Address:
Your reference
Phone no.
Machine
Typ of machine Serial No. Year of construction