Om 1225256 0101 PDF

OM
Operation Manual
Tetra Alsafe®
TPOP Operator Interface
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WARNING
Read and follow all safety precaution instructions throughout this
manual and on safety signs attached to this equipment.
Failure to follow all safety precaution instructions could result in death or
serious injury.
Doc. No. OM-1225256-0101

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Copyright © 2009 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.
The English language version of this document contains the original instructions. All other language
versions are translations of the original instructions.
This document was produced by:
Tetra Pak Dairy & Beverage Systems AB
Ruben Rausings gata
SE-221 86 Lund
Sweden
Additional copies can be ordered from Tetra Pak. When ordering additional copies, always provide the
document number.
Doc. No. OM-1225256-0101
Issue 2010-01
This manual is valid for: i Introduction
T5844611018
Series No./ Machine No. Sign.
ii Safety Precautions
1 General Description
OM
Operation Manual
2 Process Description
3 Control Panel
4 Alarms
Tetra Alsafe®
TPOP Operator Interface 5 Preparations
6 Operation
7 Shut Down
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8 Care and Cleaning
Doc. No. OM-1225256-0101
Issue 2010-01

Valid for:
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i Introduction
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i Introduction
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i Introduction Table of Contents
Manual Information . . . . . . . . . . . . . . . . . . . . . . . . i - 5
Delivered Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . i - 5
Page Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i - 6
Page Numbering. . . . . . . . . . . . . . . . . . . . . . . . . . . . i - 7
Typographical Conventions . . . . . . . . . . . . . . . . . . i - 7
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i - 7
Machine Introduction . . . . . . . . . . . . . . . . . . . . . . i - 8
Intended Use of the Equipment . . . . . . . . . . . . . . . i - 8
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i - 8
Support and Feedback . . . . . . . . . . . . . . . . . . . . . . i - 8
Declaration of Conformity . . . . . . . . . . . . . . . . . . . . i - 8
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i - 9
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CE Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . i - 9
Machine Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i - 9
How to Use This OM . . . . . . . . . . . . . . . . . . . . . . i - 10

Purpose of the OM . . . . . . . . . . . . . . . . . . . . . . . . . i - 10
Operator Workflow. . . . . . . . . . . . . . . . . . . . . . . . . i - 10
Doc. No. OM-1225256-0101 i - 3 (10)

i Introduction
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i Introduction Manual Information
Manual Information
Tetra Pak recommends reading all delivered manuals carefully. Make sure
that the delivered manuals are available to personnel who operate or
maintain the equipment.
It is important to keep this manual for the lifetime of the equipment and to
pass the manual on to any subsequent holder or user.
Tetra Pak will not be held responsible for any damage to the equipment
caused by not following the instructions given in this manual.
Delivered Manuals
The documentation for this equipment consists of the following parts:
• Operation Manual
• Technical Manual
• Electrical Manual (if applicable)
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Doc. No. OM-1225256-0101 i - 5 (10)

Manual Information i Introduction
Page Layout
Every main page in this manual contains a header and a footer. The page
header contains the chapter name (1) and the section name (2). The page
footer contains the page number (3), and the document number (4). See also
the Page Numbering section.
1 2
9 General 9.2 Technical Data
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Doc. No. MM-2730517-0103 9 - 41 (60)
4 3
1 Chapter name
2 Section name
3 Page number
4 Document number
i - 6 (10) Doc. No. OM-1225256-0101

i Introduction Manual Information
Page Numbering
A page number has three parts:
• chapter number (1)
• consecutive page number (2) within the chapter
• total number of pages (3) in the chapter.
4 - 11 (18) 1 Chapter number

2 Consecutive page number
1 2 3 3 Total number of pages
Typographical Conventions
Controls on the operator panel, emergency stop devices, and program steps
are printed in CAPITAL LETTERS.
Menu names, button names and other text displayed in software are printed
in Courier.
Cross-references are underlined.
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Symbols
Symbols used in illustrations.
A pointer arrow indicates the position of an object.
A zoom arrow indicates that an object view is

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

movement of an object. The arrow points in the
direction of rotation.
A straight movement arrow indicates movement of an

object.
The arrow points in the direction of movement.
Doc. No. OM-1225256-0101 i - 7 (10)

Machine Introduction i Introduction
Machine Introduction
Intended Use of the Equipment
This equipment is intended for use according to the specifications in
Technical data (see Technical Manual) and related documents.
All other use is prohibited. Tetra Pak will not be held responsible for injury
or damage if the equipment is used for any other purpose.
Manufacturer
This Tetra Pak equipment was produced by:
Ruben Rausings gata
SE-221 86 LUND
Sweden
Support and Feedback

If you encounter problems when operating this equipment or have other
inquiries, comments, or suggestions for improvement, contact Tetra Pak.
Declaration of Conformity
A signed Declaration of Conformity is delivered with this manual.
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i - 8 (10) Doc. No. OM-1225256-0101

i Introduction Identification
Identification
CE Compliance
This equipment complies with the basic health and safety regulations of the
European Economic Area (EEA).
Machine Plate
The illustration below shows an example of the machine plate. The machine
plate carries data needed when contacting Tetra Pak concerning this specific
equipment.
Make sure that the equipment data in the front pages of this manual
corresponds to the machine plate data and the machine specification.
1
Tetra Pak 2
3
4
5
1 Machine type
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2 Drawing specifications
6 3 Machine serial number
4 Designed by
5 Manufacturer
6 Notified body
7 Year of manufacture
8 Group of fluid
9 Design PS (bar)/TS
9 8 7 (°C)
Doc. No. OM-1225256-0101 i - 9 (10)

How to Use This OM i Introduction
How to Use This OM

Purpose of the OM
The Operation Manual provides operators with information on handling and
operating the equipment before, during, and after production.
Operator Workflow
Beginning with a PREPARATION CYCLE the content is structured to
follow the operator workflow with a PRODUCTION CYCLE and then a
CARE CYCLE.
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Doc. No. OM-1225256-0101 ii - 1 (26)

Safety Precaution Instructions
WARNING
Read all safety precaution instructions throughout this manual and on
safety signs attached to this equipment.
Failure to follow all safety precaution instructions could result in death or
serious injury.
Definition of Lockout Procedure

A lockout procedure is a procedure to put each necessary energy isolating
device in its safe position to prevent the energisation of the equipment, such
as when a maintenance procedure should be carried out.
A lockout is the use of a device, for example, a padlock, to make sure that an
energy isolating device cannot be operated.
An energy isolating device is a mechanical device that physically prevents
transmission or release of energy, such as a power supply disconnector.
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ii - 2 (26) Doc. No. OM-1225256-0101

ii Safety Precautions Table of Contents
Safety Messages Description. . . . . . . . . . . . . . . ii - 5
Personnel Requirements . . . . . . . . . . . . . . . . . . ii - 6
Skilled Person . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 6
Instructed Person. . . . . . . . . . . . . . . . . . . . . . . . . . ii - 6
Hygiene. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 7
Food product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 7
Steam Barrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 7
Checkpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 8
Safety Signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 9
Locations of Safety Signs . . . . . . . . . . . . . . . . . . ii - 11
Protective Devices. . . . . . . . . . . . . . . . . . . . . . . ii - 12
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Emergency Stop. . . . . . . . . . . . . . . . . . . . . . . . . . ii - 12
Emergency Stop Push Buttons . . . . . . . . . . . . . . ii - 13
Safeguards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 14
Warning Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 16
Personal Protection. . . . . . . . . . . . . . . . . . . . . . ii - 17
Noise Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 17
Entanglement Hazard . . . . . . . . . . . . . . . . . . . . . ii - 17
Hazardous Materials . . . . . . . . . . . . . . . . . . . . . ii - 18
Inert gases - N2/CO2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 19
Nitrogen gas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 19
Supply Systems. . . . . . . . . . . . . . . . . . . . . . . . . ii - 20
Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 20
Residual Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 21
Electrical Cabinet. . . . . . . . . . . . . . . . . . . . . . . . . . ii - 22
Socket Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 23
Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 24
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Table of Contents ii Safety Precautions
Steam Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 24
Water Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii - 25
External CIP Supply . . . . . . . . . . . . . . . . . . . . . . ii - 25
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ii Safety Precautions Safety Messages Description
Safety Messages Description

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

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

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

which, if not avoided, may result in minor or moderate
CAUTION injury. It may also be used to alert against unsafe
practices.
CAUTION Caution without the safety alert symbol indicates a

potentially hazardous situation which, if not avoided,
may result in property damage.
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Personnel Requirements ii Safety Precautions
Personnel Requirements
Note! Personnel includes all persons performing work on or near the
machine or equipment.
Only skilled or instructed persons are allowed to work with the machine or
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,
mechanics, chemicals, and supply systems 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 to enable him or her to identify hazards, analyse risks, and avoid
hazards which electricity, mechanics, chemicals, and supply systems on the
machine or equipment can create.
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ii Safety Precautions Hygiene
Hygiene
Food product
Avoid microbiological contamination of the food product:
• Never clean the floors or the equipment in the process room (area) when
the equipment is in production.
• Compressed air used for cleaning purposes should only be used outside
the process room (area).
• Disinfect your hands before touching anything that may come into
contact with the product.
• Keep your hands and gloves clean.
• Always wear some type of hair protection (cap or hairnet) and clean
clothes (preferably white).
• Do not wear a watch, ring, necklace, earrings, or any other exposed
jewellery.
Steam Barrier
Steam barriers of the product valve in filling machine or Tetra Alsafe tank
employs a steam barrier to separate the product supply line from the filling
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machine/aseptic tank. The steam barrier allows the filling machine/aseptic

tank and the product line to be independently sterilized or cleaned. Steam
barriers can also be found in end valve clusters to minimize risk of
contamination during filling. In applications with full flexibility between
sterilisers, aseptic tanks and fillers, steam barriers are often used in mix proof
valves.
Steam barriers for pump bearings, flange joints safety valves etc are common
in process equipment where sterility is required.
• Never disengage the steam barrier, and never interrupt the steam supply
when any of the equipment above is brought into pre-sterilizing phase or
when the equipment is already in production phase or aseptic
intermediate cleaning phase.
• If any maintenance activities require disengagement of the steam barrier
or interruption of the steam supply to the equipment, make sure that no
commercial product can be contaminated.
Doc. No. OM-1225256-0101 ii - 7 (26)

Hygiene ii Safety Precautions
Checkpoints
CAUTION
Risk for unsterility and contaminated product
Leaking components may cause unsterility and contaminate the product. If a
leakage is detected, shut down production and make a CIP.
Check/renew leaking parts prior to start up of a production. Processed
product should be stored and carefully checked for contamination prior to
distribution to market.
Continuous and systematic leakage check of the equipment must be done:
• During manual preparation.
• During the pre-sterilisation phase.
• In conjunction with production start up.
• During production - once every hour.
• During AIC/CIP phase.
To ensure a safe product, it is important that the following checkpoints

during the processing of the product are confirmed:
• That the selected configuration (capacity, temperature...) is valid for the
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food product to be processed.
• That the sterilising of the equipment is of sufficient time and
temperature.
• That no open tanks etc are exposed to foreign objects/contamination.
• That carry-over of potential allergens between products during product
change and cleaning is consider. A close inspection of the equipment is
of utmost importance if a possible risk occurs - refer to QA system.
• That the correct recipe is selected.
• That ingredients are of the correct type and amount according to recipes.
• That the cleaning solutions are of correct type, concentration and amount
according to recipes.
• That no food residue according to defined control points remains after
finalized cleaning.
• That no residue of chemicals is present after cleaning the equipment.
ii - 8 (26) Doc. No. OM-1225256-0101

ii Safety Precautions Safety Signs
Safety Signs
WARNING
Hazards without safety signs drastically increase the risk of death or
serious injury.
Replace all missing or damaged safety signs immediately.
Tip! Clean the steel surface with ethanol or any fat dissolving cleaning agent
and let it dry for 10 minutes before applying the sign. After application the
adhesive of the sign must harden for 24 hours before the steel surface
around the sign is reoiled.
There are two types of safety sign
• ISO signs are used in most markets
• ANSI signs are used in the US market only
The table below contains all safety signs that are located on this machine or
equipment.
Note! The position numbers (Pos) within the table refer to the positions in
the illustration(s) in Section Locations of Safety Signs.
Pos ISO sign ANSI sign

1
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WARNING
Hazardous noise level.
Risk of impaired hearing.
Wear hearing protection.
Mandatory action. Always wear hearing protection.

2
WARNING
Chemical burn hazard.
Wear personal protective
equipment.
Chemical burn hazard.

Wear protective equipment.
3
WARNING
Hot surface.
Do not touch.
Follow lockout procedure
before maintenance.
Hot surface.
Do not touch.
Allow to cool before servicing.
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Safety Signs ii Safety Precautions
Pos ISO sign ANSI sign

4
Equipment sensitive to welding

First, disconnect all power and fuses in panel.
Do NOT weld on panel.
Ground close to welding point.
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ii Safety Precautions Safety Signs
Locations of Safety Signs

Note! Always ensure 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 below indicates where the safety signs are located.
Note! The position numbers refer to the table in Section Safety Signs.
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1
3
4
3
1 3 1 3
Machine plate
(Unit identification)
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Protective Devices ii Safety Precautions
Protective Devices
WARNING
Unshielded hazards.
Hazardous zones are safeguarded and provided with protective devices. Do
not inch or run this equipment if any protective device is inoperative.
Change inoperative components of the safety system immediately.
WARNING
Hazardous voltage.
Hazardous voltage remains on this equipment after activating an
EMERGENCY STOP or an interlocking device.
Emergency Stop
Emergency stop devices are used to stop this equipment immediately in an
hazardous situation. Learn the positions of all emergency stop devices and
how to use them.
Instructions for a normal production stop, see chapter Operation in Operation
manual.
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ii Safety Precautions Protective Devices
Emergency Stop Push Buttons

Push one of the EMERGENCY STOP push buttons to stop the machine or
equipment immediately.
The illustration below shows an emergency stop push button. Arrow(s)
indicates where to find them on the machine or equipment.
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1 2
1 Red hat
2 Yellow bottom
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Safeguards
WARNING
Moving machinery.
Never defeat or bypass the interlocking devices.
Movable guards, for example, doors and covers leading to hazardous zones,
are fitted with interlocking devices where required. These devices are usually
electric safety switches that are parts of the safety system and must never be
defeated, bypassed, or otherwise made inoperative.
WARNING
Corners and edges.
To prevent injury from corners and edges of open doors and covers, close
them unless they must be open during such work. Be careful when working
under an open door, cover or elsewhere below parts of the equipment with
corners and edges.
CAUTION
Burn hazard.
Parts of this equipment may be hot after operation.
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After installation and maintenance, and before this equipment is inched or
run, check that all safeguards are in place and that they operate correctly.
(Cont'd)
ii - 14 (26) Doc. No. OM-1225256-0101

ii Safety Precautions Protective Devices
(Cont'd)
CAUTION
Machine or equipment damage.
Never stop the machine or equipment by opening a movable guard, except
in the case of emergency.
The location of each interlocking guard is shown by an arrow.

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Warning Lamp
A warning lamp is a column of warning lights:
• A red light (1) indicates a hazardous condition. This is a situation that
requires immediate action.
• A yellow light (2) indicates an abnormal or impending critical condition.
This is a condition calling for action by the operator.
– flashing light; unacknowledged alarm
– continuous light; acknowledged alarm
• A green light (3) indicates a normal condition.
– continuous light; function in operation
– flashing light; operator action required or function stopped (cleaning)
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.
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2
3
1 Red light
2 Yellow light
3 Green light
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ii Safety Precautions Personal Protection
Personal Protection
This section applies to all personnel at all times when this equipment is in
operation. For special personal protection required when handling hazardous
substances, see the Hazardous Materials section.
Noise Hazard
WARNING
Hazardous noise.
Wear hearing protection whenever this equipment is in operation.
CAUTION
Hazardous noise level.
Hearing protection is recommended whenever this equipment is in
operation.
Entanglement Hazard
WARNING
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Risk of entanglement.
Do not wear jewellery or loose clothing when working on or near this
equipment. Long hair may not be loose.
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Hazardous Materials ii Safety Precautions
Hazardous Materials
WARNING
Contact with chemicals can cause injury and illnesses.
Always follow the manufacturer’s instructions when handling chemical
products.
Always 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 positions of all washing facilities in order to act without
delay in case of an accident.
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ii Safety Precautions Hazardous Materials
Inert gases - N2/CO2
WARNING
Risk of suffocation.
If the concentration of inert gases encreases, the oxygen concentration will
decrease, which may result in suffocation.
Note! Applicable if N2/CO2 injection is used.
Nitrogen gas
When other gas than sterile air is used for pressurising the tank, for instance
nitrogen N2, special routines are applied. Due to the risk of suffocation, the
tank must always be well ventilated before any person enters the tank.
Ventilation can be done by means of compressed air or a mobile fan with a

hose through the open manhole on top of the tank. Let the fan pump air into
the tank for at least 10 - 15 minutes, depending on the size of the tank.
Always be sure that the tank is filled with air.
When work is going on in the tank, always have one person outside the tank
to monitoring the work.
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Supply Systems ii Safety Precautions
Supply Systems
Power Supply
DANGER
Hazardous voltage and moving machinery.
The power supply disconnector must be turned off and secured with a lock
before any maintenance.
Note! The key to the lock must be removed by the technician and retained in
his/her possession until all work is completed.
Certain maintenance procedures may require power supply systems to be on.
These exceptions are clearly stated in the Technical Manual (TeM).
The illustrations show the power supply disconnector and its location.
‘
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ii Safety Precautions Supply Systems
Residual Voltage
DANGER
Hazardous voltage.
Do not touch any terminals immediately after the power supply disconnector
is turned off. Ensure that no residual voltage remains on the capacitors
before touching. Wait five minutes. Failure to observe this information will
cause death or serious injury.
After the power supply disconnector is turned off, residual voltage remains
in the capacitor circuits.
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Electrical Cabinet
DANGER
Hazardous voltage.
Electric shock will cause death or serious injury.
The Power Supply Disconnecting Device must be turned OFF and secured
with a lock before any service is carried out inside the electrical cabinet.
Note! The key to the lock must be removed by the service technician or the
electrician, and retained in his/her possession until all work is completed.
Make sure that the electrical cabinet doors are locked after performing any
work in the electrical cabinet.
An arrow in the illustration below indicates the location of an electrical
cabinet.
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Socket Outlet
WARNING
Hazardous voltage.
Can shock, burn, or cause death. Read the Maintenance Manual before
using this socket outlet.
The socket outlet (1) is connected to a residual current device (2) to protect
users against electrical shock if there is an earth fault in the connected
equipment. The residual current device shall be tested each time before the
socket outlet is being used.
The illustrations show the socket outlet, the residual current device, and their
location.
1
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Air Supply
WARNING
Compressed air and moving machinery.
The Main Air Valve must be turned OFF and secured with a lock
before any service is carried out.
Certain maintenance procedures may require air supply systems to be on.
Steam Supply
WARNING
Hot steam can cause scalds.
Pressurized steam can be discharged unexpectedly.
Close the steam supply valve and lock it, depressurize and vent all steam
safely before any maintenance on parts with steam, such as pipes and
valves.
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Certain maintenance procedures may require steam supply systems to be on.
WARNING
Hot parts can cause severe burns.
Pipes, valves, and other parts containing steam can be extremely hot.
Do not touch hot parts.
ii - 24 (26) Doc. No. OM-1225256-0101

Water Supply
WARNING
Water under pressure.
The Water Supply Valve must be turned OFF and secured with a lock before
any service is carried out.
Note! The key to the lock must be removed by the service technician and
retained in his/her possession until all work is completed.
Certain maintenance procedures require supply systems to be turned on.
External CIP Supply

WARNING
Hot CIP liquids may cause severe burns.
The Supply Valve must be turned OFF and secured with a lock, and all liquid
drained safely before any service is carried out.
Note! The key to the lock must be removed by the service technician and
retained in his/her possession until all work is completed.
Certain maintenance procedures require supply systems to be turned on.
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Doc. No. OM-1225256-0101 ii - 25 (26)

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ii - 26 (26) Doc. No. OM-1225256-0101

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Doc. No. OM-1225256-0101 1 - 1 (18)

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1 - 2 (18) Doc. No. OM-1225256-0101

1 General Description Table of Contents
Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5
Working Principle. . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5
Operator’s Work Station . . . . . . . . . . . . . . . . . . . . 1 - 6
Risk Area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 6
Main Components . . . . . . . . . . . . . . . . . . . . . . . . 1 - 7
Basic Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 8
Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 8
Sterile Air System . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 8
Working Principle, Sterile Air System: . . . . . . . . . 1 - 9
Exchange of Filter Cartridge . . . . . . . . . . . . . . . . 1 - 10
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 10
Valve Cluster. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 10
Weighing Equipment . . . . . . . . . . . . . . . . . . . . . . 1 - 11
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Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 11
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 12
Option 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 12
Option 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 12
Option 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 12
Option 3b, c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 12
Option 3 d . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 13
Option 3 e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 13
Option 3f, g. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 14
Option 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 14
Option 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 14
Option 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 15
Option 7a, b . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 15
Option 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 15
Option 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 15
Option 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 16
Doc. No. OM-1225256-0101 1 - 3 (18)

Table of Contents 1 General Description
Option 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 16
Option 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 16
Option 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 16
Option 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 17
Option 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 17
Option 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 17
Option 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 18
Option 19a, b . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 18
Option 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 18
Option 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 18
Option 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 18
Option 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 18
Option 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 18
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1 - 4 (18) Doc. No. OM-1225256-0101

1 General Description Applications
Applications
Tetra Alsafe acts as an intermediate storage of low-acid products under
aseptic conditions to level out differences in production 'downstream' and
'upstream', (e.g. downstream equipment = filling machines, upstream
equipment = sterilises).
Working Principle
The Tetra Alsafe tank is sterilised by steam at a minimum temperature of
125° C for 30 minutes. It is then cooled by water circulating through the
cooling jacket. During cooling, sterile air is fed into the tank to prevent
creation of vacuum. During production sterile air fills the tank space above
the product level. The pressure is automatically controlled to maintain the
feed pressure required by the filling machine in operation.
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Doc. No. OM-1225256-0101 1 - 5 (18)

Applications 1 General Description
Operator’s Work Station

Normally in front of the control panel.
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Risk Area
2 - 3 meters around the equipment due to:
• hot pipes and equipment
• steam blasts
• jets of hot liquid
1 - 6 (18) Doc. No. OM-1225256-0101

1 General Description Main Components
Main Components
8
TechPub_2614345_0106 - tf507084en.fm
1 7 2 4 9 3
10
1 Valve cluster unit 7 Control panel

2 Sanitary air system 8 Magnetic agitator
3 Weighing equipment - load transmitter 9 Water heater, cooler
4 Weighing equipment - connection box 10 After filling machine, AFM
5 Safety valve
6 Pressure transmitter/sanitary air
system
Doc. No. OM-1225256-0101 1 - 7 (18)

Main Components 1 General Description
Basic Module
Vertical tank with a cylindrical jacket, safety rail and manhole. Three legs
with adjustable ball feet. Load cell in one of the legs.
Valve cluster module with frame- mounted preassembled valves, sterile air
filters, safety device, air pressure equipment for emptying the tank and
control panel. The control system is Siemens or Compact Logix and the
Human Machine Interface, HMI, is TPOP a graphical touch-screen (see also
available options).
Connections for product, cooling water, air and CIP liquids.
Tank
The tank is a vertical pressure vessel with double stainless steel jackets,
designed for pressure range 0 - 350 kPa (0-3.5 bar) with a working pressure
of 0 - 300 kPa (0-3.0 bar).
Equipment included:
• adjustable legs
• man hole with cover
• CIP device for cleaning
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• connections for cooling water
• connections for sanitary air
• common inlet/outlet in the bottom. Separate inlet/outlet as an option.
• connection for steam
Sterile Air System

System for supply and evacuation of sterile air in order to keep tank outlet
pressure constant during processing and to avoid infection of the product,
consisting of:
• stop valves
• presterilizing temperature guards
• sterile air filters
• pressure regulating valves
• pressure transmitter
• pressure controller (implemented in the process control system)
1 - 8 (18) Doc. No. OM-1225256-0101

Working Principle, Sterile Air System:

TechPub_2614345_0106 - tf507084en.fm
Sanitary air supply via valve V141, filter A, sterile filter B and pressure
regulating valve V142.
a) Sanitary air evacuation via pressure regulating valve V143
b) Tank outlet pressure measured by PT130
c) Pressure controller modulates tank outlet pressure by use of valves V142
and V143
Doc. No. OM-1225256-0101 1 - 9 (18)

Main Components 1 General Description
Exchange of Filter Cartridge

The PLC system is counting each presterilising step and will give an alarm
after 50 presterilisation cycles.
Replacement
• Exchange filter cartridge B with a new filter cartridge
• Move the old filter cartridge B to position A
• Discard the old filter cartridge A
Sterile
Pre-filter
NEW!
B
OLD
A
B A
OLD
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Valve Cluster
For a correct and safe installation all valves for steam, product and cleaning
solution are premounted in a compact valve cluster placed beside the tank.
1 - 10 (18) Doc. No. OM-1225256-0101

Weighing Equipment
The amount of product in the tank is measured by a load cell located under a
tank leg.
Control Panel
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Contains all equipment necessary for:

• indication of tank status (e.g. tank pressure, levels)
• supervision of tank parameters such as temperatures and pressures
• control of valves
Tank automation is based on process controller unit. This controller features:
• timers
• temperature and pressure guards
• control loops
• operator interface
Doc. No. OM-1225256-0101 1 - 11 (18)

Options 1 General Description
Options
Option 1
Inner container in AISI 316 for high acid products.
Option 2
Steam Reducing valve set (Pre-erected). To reduce steam pressure to 2.7 bar
and 1.0 bar.
Option 3
Agitator is recommended for products, which can separate in the tank during
storage, such as chocolate milk and juice with fibres. Agitator is also to
recommend when an even product temperature to filling machines is of
concern.
Option 3b, c
This agitator is magnetically driven and frequency controlled. Mounted on a
flange in the tank bottom. For low viscous products (< 50cp) such as
chocolate milk.
Option 3b is for 12 000 and 20 000 litre and 3c is for 30 000 up to 50 000
litre.
(Cont'd) TechPub_2614345_0106 - tf507084en.fm
1 - 12 (18) Doc. No. OM-1225256-0101

1 General Description Options
(Cont'd)
Option 3 d
The Viscojet agitator comes with Huhnseal shaft seal, including steam
barrier mounted centrally on the tank top. For products with higher
viscosity (> 50cp).
Option 3 e
Agitator with aseptic shaft seal (Huhnseal): traditional agitator type, for low
viscous products (<50cp) such as chocolate milk.
TechPub_2614345_0106 - tf507084en.fm
(Cont'd)
Doc. No. OM-1225256-0101 1 - 13 (18)

(Cont'd)
Option 3f, g
IsoMix, for low viscous products (< 50cp) such as milk, chocolate milk clear
juice.
The IsoMix is also used as CIP device. Due to the design of the IsoMix the
sprays from the device are very strong thus cleaning efficient is very high.
Option 3f is for 12 000 and 20 000 litre and 3g is for 30 000 up to 50 000
litre.
Option 4
Inlets from two UHT modules. With this option it is possible to have inlets
TechPub_2614345_0106 - tf507084en.fm
from two UHT modules.
Note! It is not possible to simultaneously feed from the two UHT modules.
Option 5
This option is aimed for sedimentation sensitive products as well as to even
out the product temperature to filling machines and minimize product losses.
Also recommended to achieve circulation and replacement of product stored
in the tank.
(Cont'd)
1 - 14 (18) Doc. No. OM-1225256-0101

(Cont'd)
Option 6
On the Tetra Alsafe, the manway is normally mounted in the bottom of the
tank. With this option, the manway will instead be mounted on the top of the
tank body, safety rail is included.
Option 7a, b
This option allows independent operation of the UHT module, the Tetra
Alsafe and the filling line. Example, CIP can be executed on Tetra Alsafe
while UHT modules are in production. This option is available in two
versions, 7a for single connection (one sterilizer) and 7b for double
connection (two sterilises).
Option 8
Tetra Alcip communication. The control panel will be prepared for
communication with Tetra Alcip for cleaning of the Tetra Alsafe.
Option 9
Atlas Copco air compressor with air cooler and air tank. The air tank is
TechPub_2614345_0106 - tf507084en.fm
designed according to European pressure vessel code (PED) and the inner
container is thermo-plastic treated for clean air applications.
Sanitary Air
(Cont'd)
Doc. No. OM-1225256-0101 1 - 15 (18)

(Cont'd)
Option 10
User Interface of Tetra PlantMaster Machine Edition (Tetra PlantMaster ME)
is application software for remote handling of branded processing units. This
remote operator interface includes same functionality as the local HMI, but
also the extra feature for trending of process values and alarms.
Option 11
Line flex with ISB.
Option 12
Sterile air filter type Pall.
Option 13
Air cooler with compressor for cooling of control panel at a surrounding
temperature of > 28°C, 0,6kW. To protect the PLC in the control panel and to
extend life time on electrical components in the panel. See arrow below.
NOT
INCLUDED
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Control Panel
Tetra Alsafe
(Cont'd)
1 - 16 (18) Doc. No. OM-1225256-0101

(Cont'd)
Option 14
Non standard layout.
Option 15
Stainless steel platform placed on the tank top for personal safety and easier
maintenance.
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Option 16
Aluminium ladder with falling protection for personal safety.
(Cont'd)
Doc. No. OM-1225256-0101 1 - 17 (18)

(Cont'd)
Option 17
Ladder in stainless steel instead of aluminium in option 16.
Option 19a, b
Cooling coil with insulation and cover, in tank body base for quicker cooling.
19a without automation or valves and 19b with automation and valves.
Option 20
Communication with supervisory system via Ethernet.
Option 21
Uninterrupted Power Supply is a battery back-up for the control system. It
prevents the system from closing down during short power drops (seconds).
To preserve battery life it is strongly recommended that option 13 should be
used when UPS is selected.
Option 22
Tetra Alsafe can as standard communicate with 4 filling machines (Type
TBA or A3). This option should be selected if there is a need to
TechPub_2614345_0106 - tf507084en.fm
communicate with more than 4 filling machines.
Option 23
Free standing control panel with a stainless steel frame. To be chosen if the
control panel is separated from the main module. The module is pre-wired
and a connection box is mounted on the main module.
Option 25
Insulation and cooling spiral coil on tank body.
1 - 18 (18) Doc. No. OM-1225256-0101

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Doc. No. OM-1225256-0101 2 - 1 (16)

TechPub_2614345_0106 - tf507085en.fm
2 - 2 (16) Doc. No. OM-1225256-0101

2 Process Description Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 5
Process Cycle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 5
Process Description . . . . . . . . . . . . . . . . . . . . . . 2 - 6
Steam Sterilization . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 6
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 9
Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 13
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 15
New CIP Device . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 15
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Doc. No. OM-1225256-0101 2 - 3 (16)

TechPub_2614345_0106 - tf507085en.fm
2 - 4 (16) Doc. No. OM-1225256-0101

2 Process Description Introduction
Introduction
This chapter describes the working principle of the Tetra Alsafe. The main
process operations Sterilisation, Cooling, Production and Cleaning are
described. The way of function is described by means of a flow diagram,
which are adapted to give a clear picture and may not include all details. For
detailed information see detailed flow diagrams and the Technical Manual
TeM.
Process Cycle
The process cycle is divided into the following process operations:
• Sterilisation
• Cooling
• Production
• Cleaning-in-place, CIP)
Process cycles
Phases
TechPub_2614345_0106 - tf507085en.fm
Sterilisation Cooling Production Cleaning in

place, CIP
Steps
Doc. No. OM-1225256-0101 2 - 5 (16)

Process Description 2 Process Description
Process Description
Steam Sterilization
Tank and pipe system that will be in contact with the product must be
sterilized before use. This is done by use of steam at a temperature of 140° C.
A complete sterilization sequence consists of the following steps:
a) Drain 1.0 bar steam supply pipes.
TechPub_2614345_0106 - tf507085en.fm
From UHT
To UHT
b) Drain 2.7 bar steam supply pipes.
From UHT
To UHT
(Cont'd)
2 - 6 (16) Doc. No. OM-1225256-0101

2 Process Description Process Description
(Cont'd)
c) Steam enters the top and pushes out air/steam mixture through the after filling machine
VCL until a certain temperature is reached.
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To UHT
From UHT
(Cont'd)
Doc. No. OM-1225256-0101 2 - 7 (16)

(Cont'd)
d) The tank is heated with steam until TE101, TE140, TE145, TE150,
TE160 and TE170 reaches 125°C.
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To UHT
From UHT
(Cont'd)
2 - 8 (16) Doc. No. OM-1225256-0101

(Cont'd)
e) Sterilization for 30 minutes above 125°C (if the temperature drops below
125°C sterilization will restart, see step e.)
f) Sterilization finished. Steam barriers are activated to prevent infection of
the sterilized equipment.
Cooling
Before production the Tetra Alsafe equipment have to be cooled to
production temperature.
A complete cooling sequence consists of the following steps:
a) Supply cooling water to the cooling jacket
TechPub_2614345_0106 - tf507085en.fm
(Cont'd)
Doc. No. OM-1225256-0101 2 - 9 (16)

(Cont'd)
b) Supply of sterile air for control of tank pressure.
The sterile air system controls the tank pressure during cooling. V142
and V143 are ramped up to reduce the stress on the filters.
To avoid vacuum, supply of water will be interrupted if the pressure
drops below 0.5 bar.
TechPub_2614345_0106 - tf507085en.fm
(Cont'd)
2 - 10 (16) Doc. No. OM-1225256-0101

(Cont'd)
c) Drain steam from tank and pipes .
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To UHT
From UHT
(Cont'd)
Doc. No. OM-1225256-0101 2 - 11 (16)

(Cont'd)
d) Drain condensate from tank.
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To UHT
From UHT
2 - 12 (16) Doc. No. OM-1225256-0101

Production
To simplify this description presume that the Tetra Alsafe receives product
from a sterilizer and delivers to a filling machine.
A complete production sequence consists of the following steps:
a) Tank ready for filling
b) Filling to low level
c) Filling above low level
d) Filling pipe to filling machine
e) Tank ready for emptying (i.e. production)
During simultaneous production in sterilizer, Tetra Alsafe and filling

machine, product flows directly from sterilizer to filling machine.
Differences in production is levelled out by the Tetra Alsafe.
High level in the tank will initiate a message to sterilizer to stop
production.
(Cont'd)
TechPub_2614345_0106 - tf507085en.fm
Doc. No. OM-1225256-0101 2 - 13 (16)

(Cont'd)
TechPub_2614345_0106 - tf507085en.fm
To UHT
From UHT
(Cont'd)
2 - 14 (16) Doc. No. OM-1225256-0101

(Cont'd)
f) Stop filling from sterilizer.
g) Emptying of tank to filling machine.
h) Empty level in tank detected.
i) Air blow of pipe to filling machine. Empty level (i.e. tank and pipes to
filling machine is empty, indicated by a transmitter in the pipe) will
initiate a message to the filling machine to stop the production.
Cleaning
Cleaning is made by use of an external Cleaning Station.
The equipment is to be cleaned with caustic after production. To avoid
deposits on the stainless steel surfaces it is recommended to clean with an
acid solution once a week.
During cleaning the tank is pressurized with sanitary air to about 1.5 bar to
maintain liquid flow from the tank to the external Cleaning Station.
The Tetra Alsafe process controller unit controls the cleaning sequence and
requests water/cleaning solution from the external Cleaning Station.
A complete cleaning sequence will take approximately 30 minutes and
TechPub_2614345_0106 - tf507085en.fm
consists of the following major steps:

a) Pressurize the tank
b) Drain tank and pipes
c) Rinse with water
d) Drain tank and pipes
e) Circulate detergent
f) Drain tank
g) Rinse with water
h) Depressurize/drain tank and pipes
New CIP Device

Inspect the tank a couple of times/month.
Doc. No. OM-1225256-0101 2 - 15 (16)

TechPub_2614345_0106 - tf507085en.fm
2 - 16 (16) Doc. No. OM-1225256-0101

3 Control Panel
TechPub_2614345_0106 - tf507086en.fm
Doc. No. OM-1225256-0101 3 - 1 (40)

3 Control Panel
TechPub_2614345_0106 - tf507086en.fm
3 - 2 (40) Doc. No. OM-1225256-0101

3 Control Panel Table of Contents
Denominations. . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 5
Operator´s Panel . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 6
Basic Principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 6
Access Code Levels . . . . . . . . . . . . . . . . . . . . . . . . 3 - 7
Layout on the TPOP . . . . . . . . . . . . . . . . . . . . . . 3 - 8

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 8
Buttons on the TPOP . . . . . . . . . . . . . . . . . . . . . . . 3 - 9
Navigation Buttons . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 9
Process Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 10
Function buttons . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 11
Dialogue Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 11
Step Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 11
Local/Remote Control . . . . . . . . . . . . . . . . . . . . . . 3 - 12
Data Input/Indication . . . . . . . . . . . . . . . . . . . . . . . 3 - 12
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Process Values . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 12
Controller Values . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 13
Transmitter Values. . . . . . . . . . . . . . . . . . . . . . . . . 3 - 13
Menu Tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 14
Overview Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 15
Operating Menu . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 16
Start Check Menu . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 18
Process Value Menu . . . . . . . . . . . . . . . . . . . . . . 3 - 19
PID Selections Menu . . . . . . . . . . . . . . . . . . . . . . 3 - 20
PID Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 21
PID Parameters Menu . . . . . . . . . . . . . . . . . . . . . 3 - 22
Alarm List Menu . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 23
Trend Diagram Menu . . . . . . . . . . . . . . . . . . . . . . 3 - 24
Select Pen Menu. . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 25
Service Menu 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 26
Service Menu 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 27
Doc. No. OM-1225256-0101 3 - 3 (40)

Table of Contents 3 Control Panel
Force Select Menu. . . . . . . . . . . . . . . . . . . . . . . . 3 - 28

I/O Signals Menu 1 . . . . . . . . . . . . . . . . . . . . . . . 3 - 29
I/O Signals Menu 2 (Option) . . . . . . . . . . . . . . . . 3 - 30
Force Valve Menu . . . . . . . . . . . . . . . . . . . . . . . . 3 - 31
Force Motor Menu . . . . . . . . . . . . . . . . . . . . . . . . 3 - 32
Force Analogue Menu. . . . . . . . . . . . . . . . . . . . . 3 - 33
Force Analogue Input Menu . . . . . . . . . . . . . . . . 3 - 34
Temperature Guard Menu . . . . . . . . . . . . . . . . . . 3 - 35
Level Guard Menu . . . . . . . . . . . . . . . . . . . . . . . . 3 - 36
Pressure Guard Menu . . . . . . . . . . . . . . . . . . . . . 3 - 37
Recipe Edit Menu . . . . . . . . . . . . . . . . . . . . . . . . 3 - 38
Keyboards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 39
Integer Numbers . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 39
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Floating Point Numbers . . . . . . . . . . . . . . . . . . . 3 - 39
Alphanumerical Keyboard . . . . . . . . . . . . . . . . . 3 - 40
3 - 4 (40) Doc. No. OM-1225256-0101

3 Control Panel Denominations
Denominations
1 2
3
4
5
6
7
8
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1) DANGER INDICATION, red lamp

- flashing or continuous red light.The tank can be pressurized.
2) Fault indication, yellow lamp
- flashing light; unacknowledged alarm
- continuous light; acknowledged alarm
3) PROD/EMPTY, green lamp
- continuous light; function in operation
- flashing light; operator action required or function stopped (cleaning)
4) Operator panel, type TPOP
5) Emergency stop button
6) Emergency stop reset button
7) Local /Remote selector
8) Main switch
Doc. No. OM-1225256-0101 3 - 5 (40)

Denominations 3 Control Panel
Operator´s Panel
Basic Principle
The Tetra Alsafe tank is controlled by a Programmable Logic 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 analogue sub-processes, such as level, pressure and/or
temperature controls.
A Human Machine Interface (HMI) is used as the link between PLC,
Tetra Alsafe tank 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.
The Tetra Alsafe tank can also be connected to an overall control system.
From there, it will be possible to enter and receive more or less the same
information as those entered and retrieved from the Tetra Alsafe tank
system’s HMI.
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3 - 6 (40) Doc. No. OM-1225256-0101

3 Control Panel Denominations
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 level: Allows to:

Level 0 = No user View and choose among all the menus,
View and see all values, alarms, trends,
Start and stop sequences
Level 1 = Operator All possibilities above (0) and also:
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Change recipes to run

Take away historic alarms
Level 2 = Supervisor All possibilities above (0)+ (1) and also:
Change parameters,
Force I/O,
Change recipes,
Service of Contherms
Doc. No. OM-1225256-0101 3 - 7 (40)

Layout on the TPOP 3 Control Panel
Layout on the TPOP

General
The indications and the push-buttons on the picture below are represented on
all of the screen pictures.
5
1 2 3 4 6
7
Header bar
8
9
10
11
12
13
14
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26
15 16
17
Button bar
25 24 23 22 21 20 19 18 Ladder bar
1) Date and time 14) Status indication for Presterilisation

2) Screen name 15) Current recipe
3) Current user 16) Current step
4) Any output forced 17) Remaining time
5) Any controller in manual mode 18) Exit/Return to previous screen
6) Local/Remote indication 19) Go to Service menu, page 3-26
7) Alarm indication. Push to jump to alarm 20) Only valid for TP personnel
screen. 21) Go to Trend diagram menu, page 3-24
8) Emergency stop activated. The tank can 22) Go to Alarm list menu, page 3-23
be pressurized.
23) Go to Process value menu, page 3-19
9) Status indication of Maintenance
24) Go to Operating menu, page 3-16
10) Status indication for CIP
25) Go to Overview menu, page 3-15
11) Status indication for Shutdown
26) Alarm banner
12) Status indication for Source
13) Status indication for Destination
3 - 8 (40) Doc. No. OM-1225256-0101

3 Control Panel Layout on the TPOP
Buttons on the TPOP

Buttons are squares with 3D effect.
Selectable Selected
Navigation Buttons
Navigation buttons always call up a different screen picture. The example
shows a navigation button for calling up Overview menu.
Go to Go to Go to Process
Overview Operating value menu
menu menu
Go to Alarm Go to Trend Only valid for

menu menu TP personnel
Go to Service Exit/Return to
menu previous
screen
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Doc. No. OM-1225256-0101 3 - 9 (40)

Process Buttons
The operator can select certain process sequences by pushing one of the
button below.
Phase mode Phase mode Phase mode

with filter test* without filter lye CIP*
test*
Phase mode Sterilisation Shut down

lye/acid CIP*
Manual Agitator* Sterile water

emptying to flush*
reject
Emptying to Steriliser 1 Steriliser 2*

destination
Cleaning Product
cooler*
Maintenance
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* Option
The symbols on the ladder bar on page 3-8 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.
Push button position

Flat Up Down
Process Idle Grey
status
Run Green
Held Grey/
Yellow
Que Grey/
Green
3 - 10 (40) Doc. No. OM-1225256-0101

Function buttons
The operator can select certain machine functions by pushing one of these
buttons. One example is shown below.
1 1 Change filter
Dialogue Buttons
These buttons are used to perform different operations in dialogue windows,
such as validating or cancelling any commands.
Start Restart Pause
Abort Finalize
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Step Buttons
Go one page backward Go one step up in list
(20 rows)
Go one page forward Go one step down in

(20 rows) list
Go to the beginning of
list
Doc. No. OM-1225256-0101 3 - 11 (40)

Local/Remote Control
Remote control is selected by means of a key switch on the front of the
control panel, if a separate master control unit is placed in a remote control
room.
Local control means that the plant is operated from the local panel control
system.
Note! It is still possible to change pictures and view the application from the
remote control unit, but it is not possible to operate the module.
Local control Remote control
Data Input/Indication
Data is indicated by a navigation button with data field showing the current
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value.
Process Values
Process value indicator: The measured value is indicated.
3 - 12 (40) Doc. No. OM-1225256-0101

Controller Values
Controller parameters LC, PC, TC, FC and temperature limits TSL, PS, PSH,
LS can be viewed or changed by touching the process indicator on the
display:
LC = Level controller
PC = Pressure controller
TC = Temperature controller
FC = Flow controller
TSL = Temperature switch
PS, PSH= Pressure switch
LS = Level switch
Transmitter Values
Transmitter values can be viewed only:
LT = Level Transmitter
TT = Temperature Transmitter
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PT = Pressure Transmitter
Doc. No. OM-1225256-0101 3 - 13 (40)

Menu Tree
Menus available from every screen picture
Overview menu
Operating
menu
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Process values
Service menu
Alarm list
Trend
Logger menu
Only valid for

TP personnel
3 - 14 (40) Doc. No. OM-1225256-0101

Overview Menu
3 4
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1) Process value
2) Simplified flow diagram
3) Empty level (white line=empty) (grey line=filled)
4) Downstream equipment indication (halfgreen=ready for production)
(green=production)
Doc. No. OM-1225256-0101 3 - 15 (40)

Operating Menu
16
1 2 3 4 17
18
19
5 6 7 8
20
9 10 11 12 21
22
13 14 15 23
24
25
26
27
29 28
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1) Phase mode with filter test*
2) Phase mode without filter test*
3) Phase mode Lye CIP*
4) Phase mode Lye/Acid CIP*
5) Sterilisation
6) Shut down
7) Manual emptying to reject
8) Agitator*
9) Sterile water flush*
10) Emptying to destination
11) Select Sterilizer 1
12) Select Sterilizer 2*
13) Cleaning
14) Product Cooler*
15) Maintenance
(Cont'd)
3 - 16 (40) Doc. No. OM-1225256-0101

(Cont'd)
16) Inlet sequence, current step
17) Inlet sequence, remaining time
18) End valve cluster sequence, current step
19) End valve cluster sequence, remaining time
20) Sterile water flush sequence, current step*
21) Sterile water flush sequence; remaining time*
22) ISB CIP, current step*
23) ISB CIP, remaining time*
24) Agitator sequence, current step*
25) Agitator sequence, remaining time*
26) CIP level raise, current step*
27) CIP level raise, remaining time*
28) Go to Start Check Menu, page 3-18
29) Select recipe to run by pressing on the screen
* Option
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Doc. No. OM-1225256-0101 3 - 17 (40)

Start Check Menu

This screen contains information about start conditions. The window will be
divided into two parts where the left part will hold push buttons for all phases
and the right part will contain the actual start condition text.
The push button area contains push buttons for all the phases in the machine.
If there is any information for a phase this is to be visualised with an "i" on
the button.
By pressing a push button with an "i" corresponding information will be
displayed in the right information text area.
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Machine in local mode, Machine in local mode,
no information available, information available, not
not selected selected
Machine in local mode, Machine in local mode,

no information available, information available,
selected selected
Note! If the machine is in remote mode all the push buttons should be flat.
3 - 18 (40) Doc. No. OM-1225256-0101

Process Value Menu
1) Go to Parameter selection screen

2) Process value
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All input process values are indicated.

The process values (2) which are marked with a frame act as push buttons.
By pressing the push button the Parameter selection screen will be brought
up and the corresponding controller parameters can be viewed.
Doc. No. OM-1225256-0101 3 - 19 (40)

PID Selections Menu
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1) Select desired controller to view
(Yellow indication=controller in manual mode)
3 - 20 (40) Doc. No. OM-1225256-0101

PID Menu
2 3 4 5 6
8
9
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10 11 12 13 14
1) Controller text
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 variable - numeric value
8) Set point - numeric value
9) Output-numeric value
10) The controller is running
11) Set the set point into manual mode
12) Set the controller into manual mode
13) Trend curve
14) Go to PID parameter menu
Note! Press on the Trend chart to bring up historic values.
Doc. No. OM-1225256-0101 3 - 21 (40)

PID Parameters Menu

4 5 6 7
1
8
9
2
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1) Controller text
2) Set point
3) The line under each parameter value is grey but for the selected
parameter the line is green.
4) Running set point (SP)
5) P-value (Gain) at selected controller
6) I-value (Integration time) at selected controller
7) D-value (Derivation time) at selected controller
8) PID
controller where the lines under all three parameters are green.
Note! All parameter values are possible to change by pressing the
corresponding value on the screen.
3 - 22 (40) Doc. No. OM-1225256-0101

Alarm List Menu
9
1
8
7
6
2 5
3
1) Alarm indication:
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– Red colour indicates an alarm, not acknowledged

– Yellow colour indicates an active alarm, acknowledged
– Green colour indicates history
2) Erase Alarm list
3) Toggle Date and Time
4) Acknowledge alarm
5) Go one page forward (20 rows)
6) Go one row forward
7) Go one row back
8) Go one page back (20 rows)
9) Go to first alarm
Doc. No. OM-1225256-0101 3 - 23 (40)

Trend Diagram Menu
2
3
1) Trend chart
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2) Analogue value for one of the pens
3) Select which variable to display
Note! 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 pushbutton.This will bring up the Select Pen screen.
Press on the Trend chart (1) to bring up historic values.
3 - 24 (40) Doc. No. OM-1225256-0101

Select Pen Menu
1) Selected pen colour

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2) Select analogue value to trend
Doc. No. OM-1225256-0101 3 - 25 (40)

Service Menu 1
1 2 3 4 5 6 7 8 9 10
11
12
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13 14 15 16
1) Select language
2) Set CIP memory
3) CIP Level Raise*
4) Reset load cells
5) Erase a project on the card
6) Login (enter password)
7) Load a project from the card
8) Logout
9) Save a project on the card
10) Change password
11) Reset filter count
12) Duration of latest power supply failure
13) Go to PID selection menu
14) Go to Force I/O menu
15) Go to Recipe Edit menu
16) Go to Service menu 2
* Option
3 - 26 (40) Doc. No. OM-1225256-0101

Service Menu 2
1 2
4 3
1
5
6
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7 8 9 10
CAUTION
Risk of severe machine damage!
Operation by un authorized personnel may endanger personnel and
equipment. Any change of commands or register parameters can harm or
destroy the equipment. Also valid for all menus connected to the Service
menu.
1) Select integer register to edit/view
2) Select floating point register to edit/view
3) Select step timer to edit/view
4) Current value in selected register

5) Enter new register value
6) Press to transfer the new value to the selected register in the PLC.*
7) Go to Service menu
8) Go to PID selection
9) Go to Force menu
10) Go to Recipe Edit menu
* Visible and yellow if actual and new value differ.
Doc. No. OM-1225256-0101 3 - 27 (40)

Force Select Menu
1) Go to I/O signals to force
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3 - 28 (40) Doc. No. OM-1225256-0101

I/O Signals Menu 1
2 3 4 5 6 7 8 9
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1) Select object to force

2) Inlet sequence
3) End VCL sequence
4) Sterile water flush sequence
5) ISB CIP sequence
6) Agitation sequence
7) CIP level raise sequence
8) Cancel force on all objects
9) Go to I/O Signals Menu 2*, page 3-30
The push buttons occur in 4 different status:
Push button status Meaning

Grey The object is not forced and not activated
Green The object is activated from the PLC-system
Dark yellow The object is forced to 0
Light yellow The object is forced to 1
* Option
Doc. No. OM-1225256-0101 3 - 29 (40)

I/O Signals Menu 2 (Option)
2 3 4 5 6 7 8 9
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2) Go to I/O Signals Menu 1, page 3-29
3) Inlet sequence
4) End VCL sequence
5) Sterile water flush sequence
6) ISB CIP sequence
7) Agitation sequence
8) CIP level raise sequence
The push buttons occur in 4 different status:

3 - 30 (40) Doc. No. OM-1225256-0101

Force Valve Menu
2
3
4
1) Valve name
2) Time the object has been activated (since last reset)
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3) Fault counter for the object (since last reset)

4) Press the white field to change delay time
Main coil for SRC valves. Force deactivate

Status of object (colour)
Middle position SRC Put the object in force

valves. Status of object mode
(colour)
Lower position SRC valve. Release/reset
Status of object (colour)
Force activate

Doc. No. OM-1225256-0101 3 - 31 (40)

Force Motor Menu
2
3
4
1) Motor name
2) Time the object has been activated (since last reset)
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3) Fault counter for the object (since last reset)
4) Press the white field to change delay time
Select to force. Status of Put the object in force

object. (colour) mode
Force activate Release/reset
Force deactivate

3 - 32 (40) Doc. No. OM-1225256-0101

Force Analogue Menu

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Doc. No. OM-1225256-0101 3 - 33 (40)

Force Analogue Input Menu
1 2 3
4
5
6
7
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1) Name of selected object
2) Put the object in force mode
3) Release/Reset
4) Range Max:
Press the white field to get a numeric pad to key in new value
5) Range Min:
Press the white field to get a numeric pad to key in new value
6) Actual Input: Present value
7) New Input:
Press to get a numeric key pad to key in a new force value

3 - 34 (40) Doc. No. OM-1225256-0101

Temperature Guard Menu
2
1
3
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4 5
1) Controller text
2) Set points
parameter the line is green.
4) Bar graph and numeric display of the input signal to the temperature
guard
5) Bar graph and numeric display of the current set point of the temperature
guard
Note! All parameter values are possible to change by pressing the
corresponding value on the screen.
Doc. No. OM-1225256-0101 3 - 35 (40)

Level Guard Menu

1 2
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3
1) Object text
2) Set point
3) Bar graph and numeric display of the actual tank level in%
3 - 36 (40) Doc. No. OM-1225256-0101

Pressure Guard Menu

1
3
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1) Object text
2) Set point
3) Bar graph and numeric display of the actual process value.
Doc. No. OM-1225256-0101 3 - 37 (40)

Recipe Edit Menu
7
8
1 9
10
11
12
2 3 4 5 6
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Each recipe consists of a number of parameters (1 - 14).
1) Recipe parameter
2) Select recipe to edit
Note! The displayed recipe parameters belong to the selected recipe
3) Edit recipe name
4) Copy from recipe number #
5) Execute the copying from one recipe to the other
Note! The push button becomes visible and yellow if the recipes differs.
6) Copy to recipe number #
7) Go to first recipe
8) Go 3 rows back
9) Go 1 row back
10) Go 1 row forward
11) Go 3 rows forward
12) Send changed recipe parameters to the PLC
Note! The push button becomes visible and yellow when a parameter is
changed and not sent to the PLC.
3 - 38 (40) Doc. No. OM-1225256-0101

3 Control Panel Keyboards
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 a recipe number.
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Floating Point Numbers

operator for example wants to change a floating point number.
Doc. No. OM-1225256-0101 3 - 39 (40)

Keyboards 3 Control Panel
Alphanumerical Keyboard
user for example wants to log in.
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3 - 40 (40) Doc. No. OM-1225256-0101

4 Alarms
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Doc. No. OM-1225256-0101 4 - 1 (8)

4 Alarms
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4 - 2 (8) Doc. No. OM-1225256-0101

4 Alarms Table of Contents
Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 5
Alarm Handling. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 5
Alarm List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 6
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Doc. No. OM-1225256-0101 4 - 3 (8)

4 Alarms
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4 - 4 (8) Doc. No. OM-1225256-0101

4 Alarms Indications
Indications
When a fault occurs, the alarm lamp will start to flash.
CAUTION
Always investigate the cause of a fault indication. Otherwise you may
endanger the equipment or the product.
1) Red lamp DANGER INDICATION:
- flashing or continuous red light.
The tank can be pressurized.
2) Yellow lamp FAULT INDICATION:
- flashing light, unacknowledged alarm
- continuous light, acknowledged alarm
3) Green lamp PROD/EMPTY:
- flashing light, operator action required or function stopped (cleaning)
- continuous light, function in operation
When Ack all button in the Alarm ackowledge menu is pressed:

– the alarm lamp will be lit up continuously if the fault remains or
will go off if the fault has been rectified
– alarm text in the alarm menu is updated
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1
2
3
1 Red lamp
2 Yellow lamp
3 Green lamp
Alarm Handling
Alarms are divided into two categories, A and B alarms, as follows:
A = Faults that will cause an alarm only. They are not critical but the
operator should investigate the cause.
B = Faults that will start corrective actions in the control system. These
actions are described in a table as follow.
Doc. No. OM-1225256-0101 4 - 5 (8)

Alarm List 4 Alarms
Alarm List
Type Alarm Cause Machine action Instruction to
operator
A Alarm 0: M1 fault No feedback from M1 Only alarm Check
B Alarm 1: M2 fault No feedback from M2 CIP phases goes to HELD Check
B Alarm 2: M3 fault No feedback from M3 CIP phases goes to HELD Check
A Alarm 3: M1 rotation fault Propeller not rotating Only alarm Check
A Alarm 4: M1 vibration fault Bearing broken Only alarm Check
A Alarm 5: Power break Power failure Only alarm Check
B Alarm 6: Material ID fault Wrong recipe selected Filling not possible Check recipe
B Alarm 7: Emergency stop Emergency stop activated Red light, sterilisation goes to Release the
stop Emergency
stop
B Alarm 8: No commercial Power failure Start not possible Check power
power support
A Alarm 9: Panel cooler fault Panel cooler failure Only alarm Check panel
cooler
B Alarm 10: Air pressure fault Low air pressure to panel Not possible to start Check panel
sterilisation air supply
B Alarm 11: Filter fault Max. sterilisations with Not possible to start Change filter
same filter reached sterilisation
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B Alarm 12: High level fault Level is over HL Stop filling the tank
A Alarm 13: Low level fault Level is under LL Only alarm
B Alarm 14: Empty fault LS102 has detected no In step 105, jump back to 101
product
B Alarm 15: Pressure fault Low pressure in tank In cooling steps, cooling time is Check the
held sterile air
supply
B Alarm 16: Ster temp fault Low temperature in Jump back to 08 Check the
sterilisation steam supply
B Alarm 17: CIP temp fault Low temperature in Program wait for temperature Check the CIP
TE150 in CIP station
B Alarm 18: CIP unit fault CIP station has stopped CIP phase goes to HELD Check the CIP
station
B Alarm 19: Communication Communication error to a The program takes Check the
fault remote panel communication signals to “0” connection to
remote panel
B Alarm 20: TT90 broken Signal out of range Not possible to start Check
sterilisation
sterilisation
B Alarm 22: TT101D broken Signal out of range Not possible to start Check
sterilisation
B Alarm 23: TT201A broken Signal out of range Not possible to start Check
sterilisation
B Alarm 24: TT201D broken Signal out of range Not possible to start Check
sterilisation
sterilisation
4 - 6 (8) Doc. No. OM-1225256-0101

4 Alarms Alarm List

operator
sterilisation
sterilisation
sterilisation
sterilisation
sterilisation
sterilisation
sterilisation
sterilisation
sterilisation
sterilisation
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sterilisation
sterilisation
sterilisation
sterilisation
A Alarm 40: TT90 fault Low steam pressure Only alarm Check
A Alarm 41: TT101fault Low steam pressure Only alarm Check
A Alarm 42: TT101D fault Low steam pressure Only alarm Check
A Alarm 43: TT201A fault Low steam pressure Only alarm Check
A Alarm 44: TT201D fault Low steam pressure Only alarm Check
A Alarm 48:TT140 fault Low steam pressure Only alarm Check
Doc. No. OM-1225256-0101 4 - 7 (8)

Alarm List 4 Alarms

operator
Alarm 58:
B Alarm 60: V101 fault No feedback from V101 Filling not possible Check
A Alarm 61: V101L fault No feedback from V101L Only alarm Check
sterilisation
B Alarm 64: V201 fault No feedback from V201 Filling not possible Check
Alarm 65
Alarm 66
Alarm 67
B Alarm 68: Pressure high High pressure in tank Filling not possible Check the
fault sterile air
supply
A Alarm 69: Battery fault Bad battery in CPU Only alarm Change
battery in CPU
Alarm 70
Alarm 71
Alarm 72
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Alarm 73
Alarm 74
Alarm 75
Alarm 76
Alarm 77
Alarm 78
Alarm 79
Alarm 80
Alarm 81
Alarm 82
Alarm 83
Alarm 84
Alarm 85
Alarm 86
Alarm 87
Alarm 88
Alarm 89
Alarm 90
Alarm 91
4 - 8 (8) Doc. No. OM-1225256-0101

5 Preparations
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Doc. No. OM-1225256-0101 5 - 1 (6)

5 Preparations
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5 - 2 (6) Doc. No. OM-1225256-0101

5 Preparations Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 5
General Checkpoints . . . . . . . . . . . . . . . . . . . . . . . 5 - 5
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Doc. No. OM-1225256-0101 5 - 3 (6)

5 Preparations
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5 - 4 (6) Doc. No. OM-1225256-0101

5 Preparations Introduction
Introduction
This chapter contains a list of necessary checkpoints 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.
General Checkpoints
• Check that the down stream equipment (e.g. filling machines) are ready
for sterilization.
• Check the plant and check that all required swing-bends are correctly
fitted.
• Check that steam is available, check for correct pressure
• Check that water is available, check for correct pressure
• Turn on compressed air, Check for correct pressure.
• Turn the Main switch for the operator panel to position ON.
• Check that all start conditions are confirmed. If the tank pressure is too
high select Sterilisation stop to depressurize the tank.
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Doc. No. OM-1225256-0101 5 - 5 (6)

Introduction 5 Preparations
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5 - 6 (6) Doc. No. OM-1225256-0101

6 Operation
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Doc. No. OM-1225256-0101 6 - 1 (16)

6 Operation
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6 - 2 (16) Doc. No. OM-1225256-0101

6 Operation Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 5
Start Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 6
Selection/settings prior to start. . . . . . . . . . . . . . . . . . .6 - 6
Start conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 6
Agitation (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 6
Sterile Water Flush (Option) . . . . . . . . . . . . . . . . . . . . . . 6 - 7
Emptying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 7
Start command/sequence . . . . . . . . . . . . . . . . . . . . . . .6 - 8
Checks/operation during sequence . . . . . . . . . . . . . . .6 - 8

Sterilization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 8
Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 9
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Agitation (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 9
Stop Process . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 10
To stop the system . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 10
Stop command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 10
Pause Process . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 11
Pause command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 11
Restart after pause . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 11
Cleaning sequence - CIP. . . . . . . . . . . . . . . . . . 6 - 12

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 12
Selection/settings prior to start. . . . . . . . . . . . . . . . . .6 - 13
Start command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 13
Pause . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 14
Restart from Pause. . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 14
Doc. No. OM-1225256-0101 6 - 3 (16)

Table of Contents 6 Operation
Abort from Pause. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 15
Emergency Stop. . . . . . . . . . . . . . . . . . . . . . . . . 6 - 16
Emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 16
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6 - 4 (16) Doc. No. OM-1225256-0101

6 Operation Introduction
Introduction
Content:
• Start tank (Pre-sterilization)
• Stop tank
• Emergency stop
• Agitation (Option)
• Sterile water flush (Option)
• Emptying (Manual emptying)
• Cleaning of tank
The Tetra Alsafe must be heated, sterilized
and cooled before production, PRE-
STERILIZATION
After PRE-STERILIZATION the tank is
ready for filling with product.
The pre-sterilization sequences includes
the following steps:
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• Heating
• Sterilization
• Cooling down
Doc. No. OM-1225256-0101 6 - 5 (16)

Start Process 6 Operation
Start Process
1
CAUTION
Before start! Selection/settings prior to
Do not start when personnel is present in the risk area.
start
– Before start, check the sterile air
filter if it needs to be replaced, see
chapter General description for
details.
2
Start conditions
1) Go to OPERATING MENU.
4 2) Select START CHECK MENU.
3
3) Select the process to start if there is
an “i” on it. Otherwise go back to
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OPERATING MENU.
4) The not fulfilled start condition will
2
1 be displayed in the text area.
2a
Agitation (Option)
Note! The agitator is interlocked from
running when the tank level is below
medium level.
Note! During cleaning the agitator will
run during specific steps regardless of
operator selections and tank level.
6 - 6 (16) Doc. No. OM-1225256-0101

6 Operation Start Process
2b
Sterile Water Flush (Option)
Sterile water flush works only:
In READY FOR FILLING and when the
steriliser is in sterile water condition.
2c
Emptying
EMPTYING is a manual function used to
fill/empty the line between tank and
filling machine.
EMPTYING works only:
– when the tank is not operating.
– in READY FOR FILLING.
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– in READY FOR EMPTYING.
Doc. No. OM-1225256-0101 6 - 7 (16)

Start Process 6 Operation
3
Start command/sequence
1) Select the OPERATING MENU.
2) Press a process button.
2 3) Press the START button.
During all sequences, step No. and actual

3 programme step time are indicated.
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Checks/operation during
sequence
– Watch out for any alarms!
4a
Sterilization
After completed pre-sterilisation
sequence, READY FOR FILLING is
indicated.
6 - 8 (16) Doc. No. OM-1225256-0101

6 Operation Start Process
4b
Production
When product is detected at inlet, filling
of the tank starts.
During filling, FILLING is indicated.
When level above LOW LEVEL is
reached, the outlet pipe will be filled with
product.
READY FOR EMPTYING is indicated.
Note! If the filling to tank stops before

LOW LEVEL is reached and no more
product is available temporarily lower the
LOW LEVEL set point to make the
program advance.
At the Level guard LS110 menu:
– go to “Low level in the tank”, set
a lower value than the actual
value.
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When product supply to the tank stops:

– Indication for FILLING goes out
READY FOR EMPTYING is indicated
as long as there is product in the tank
4c
Agitation (Option)
– The status of the agitator is
indicated.
Note! During cleaning the agitator will
run during specific steps regardless of
operator selections and tank level.
Doc. No. OM-1225256-0101 6 - 9 (16)

Stop Process 6 Operation
Stop Process
1
To stop the system
Note! If FINALIZE is ordered in program
step HEATING or STERILISING, the
tank will be cooled down before the
active function stops.
Note! FINALIZE can not be ordered if
there is product in the tank.
Note! If ABORT is chosen the sequence
is finalized at once.
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2
Stop command
2) Select process to stop.
2 3) Press the ABORT or
4) the FINALIZE button.
6 - 10 (16) Doc. No. OM-1225256-0101

6 Operation Pause Process
Pause Process
1
2 Pause command
2) Select process to pause.
3) Press the PAUSE button.
2
Restart after pause
2) Select process to pause.
3) Press the RESTART button.
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Doc. No. OM-1225256-0101 6 - 11 (16)

Cleaning sequence - CIP 6 Operation
Cleaning sequence - CIP
WARNING
Chemical hazard
Introduction
Cleaning solution contains Caustic soda (NaOH) or Nitric Tetra Alsafe must be cleaned before Pre-
acid (HNO3). sterilization and Production. This is
These chemicals may cause severe burning to skin called CIP (Cleaning In Place).
and eyes. Use protective clothes, goggles, and gloves
during handling. The system must be cleaned direct after
If exposed - wash with water for at least 15 minutes. each production and if the system have
Seek medical assistance. been closed down for a longer time.
Follow the instructions given by the supplier.
The system must be cleaned with lye
every cleaning time and at least once a
week with lye and acid.
Cleaning programmes to choose:
– Cleaning of tank.
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1
The cleaning sequence include the
following steps:
– Pressurise (master/slave).
– Fill up (Tank: master).
– Circulation (Tank: slave/master).
– Flip (Tank: slave/master).
– Drain (Tank: master).
– Depressurization (Tank: slave/
master).
6 - 12 (16) Doc. No. OM-1225256-0101

6 Operation Cleaning sequence - CIP
2
Selection/settings prior to
start
4 1) Go to OPERATING MENU.
3 2) Select START CHECK MENU.
3) Select CIP start condition if there is
an “i” on it. Otherwise go back to
OPERATING MENU.
2
1 4) The not fulfilled start condition will
be displayed in the text area.
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3
Start command
CAUTION
Before start
2 Do not start when personnel is present in
the risk area.
1) Select the Operating menu.
3
2) Select CLEANING.
1 3) Press the START button.
During CLEANING
– step No. and actual step time are
indicated.
Doc. No. OM-1225256-0101 6 - 13 (16)

Cleaning sequence - CIP 6 Operation
4
Pause
To temporarily stop the cleaning
sequence:
2 2) Press the CIP button.
3) Press the PAUSE button.
– the pumps will stop.

– the water and steam supply is
interrupted.
3 the valves are deactivated to keep actual
1 air pressure and cleaning solution in the
tank.
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5
Restart from Pause
CAUTION
Before start!
Do not start when personnel is present in
2 the risk area.
To restart from pause;
2) Press the CIP button
3 3) Press the RESTART button.
1 and the cleaning sequence continue from

where it was paused.
6 - 14 (16) Doc. No. OM-1225256-0101

6 Operation Cleaning sequence - CIP
6
Abort from Pause
CAUTION
Tetra Alsafe is not properly cleaned

2 when it is stopped this way. It must be
cleaned again before Sterilization/
Production is started.

3 2) Press the CIP button.
1 3) Press the ABORT button.
and the cleaning sequence continue from
where it was paused.
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Doc. No. OM-1225256-0101 6 - 15 (16)

Emergency Stop 6 Operation
Emergency Stop
1
WARNING
DANGER INDICATION, red lamp Emergency stop
- flashing or continuous red light.The tank can be Push the EMERGENCY STOP
pressurized.
BUTTON to stop the equipment
immediately.
Note! The EMERGENCY STOP

BUTTON will remain ‘activated’ until
manually pressed:
The programme has stopped as follows:
Presterilising
in steps 01, 02, 03, 04, 05, 06, 07, 08 and
09.
Sterilising
1 2 in steps 10, 11, 12, 13, 14, 15, and 16,
the programme goes to “0”.
Restart from the Operating menu.
1 Red hat
2 Yellow bottom
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Production
in steps 101, 102, 103, 104, and 105,
the programme stops in Production or
Sterile position.
The programme continues from where it
was stopped.
To proceed release the Emergency stop.
Stop
in steps 501 and 502,
the programme goes to “0”.
Restart from the Operating menu.
Cleaning
CIP in steps 601-632
the programme stops in its step.
To proceed release Emergency stop and
restart.
Go to Operating menu, restart CIP and
the programme continues from the step
where it was stopped.
6 - 16 (16) Doc. No. OM-1225256-0101

7 Shut Down
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Doc. No. OM-1225256-0101 7 - 1 (6)

7 Shut Down
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7 - 2 (6) Doc. No. OM-1225256-0101

7 Shut Down Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 5
General Checkpoints . . . . . . . . . . . . . . . . . . . . . . . 7 - 5
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 5
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Doc. No. OM-1225256-0101 7 - 3 (6)

7 Shut Down
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7 - 4 (6) Doc. No. OM-1225256-0101

7 Shut Down Introduction
Introduction
This chapter contains a list of necessary checkpoints prior to shut down the
plant. Most points are always to be done, but others are valid only if the
General Checkpoints
• Close air supply
• Close steam supply
• Close water supply
Control Panel
• Switch off the main switch
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Doc. No. OM-1225256-0101 7 - 5 (6)

Introduction 7 Shut Down
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7 - 6 (6) Doc. No. OM-1225256-0101

8 Care and Cleaning
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Doc. No. OM-1225256-0101 8 - 1 (8)

8 Care and Cleaning
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8 - 2 (8) Doc. No. OM-1225256-0101

8 Care and Cleaning Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 5
General Checkpoints for Care and Cleaning . . . . 8 - 5
Exchange of Filter Cartridge. . . . . . . . . . . . . . . . . . 8 - 5
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 6
Critical Control Points . . . . . . . . . . . . . . . . . . . . . . 8 - 6
External cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 8
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Doc. No. OM-1225256-0101 8 - 3 (8)

8 Care and Cleaning
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8 - 4 (8) Doc. No. OM-1225256-0101

8 Care and Cleaning Introduction
Introduction
This chapter contains a list of necessary checkpoints prior to care and clean
the plant. Most points are always to be done, but others are valid only if the
General Checkpoints for Care and Cleaning

• check for leakage from any equipment
• keep the area around the equipment clean and tidy
Exchange of Filter Cartridge

The PLC system is counting each presterilising step and will give an alarm
after 50 presterilisation cycles. For instructions, see chapter General
Description.
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Doc. No. OM-1225256-0101 8 - 5 (8)

Cleaning 8 Care and Cleaning
Cleaning
Critical Control Points
WARNING
Risk of scalds
This machine works under pressurised conditions and high temperatures. To
avoid jets of hot liquid, steam or cleaning solution, make sure that any
operation sequence is finalised, the machine is cooled down and without
pressure before disassembling any parts.
It is recommended to, at regular intervals, verify the cleaning result visually
and by a swab test at critical control points.
The number of control points for a specific Tetra Alsafe vary due to the order
specification and the installation layout.
Consider the following as a general recommendation for critical control
points:
1) Aseptomag valve
– Inspect metal bellow.
2) Bearings of agitator
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– Check that bearings are clean and have not absorbed magnetic
particles.
3) Filter/strainer
– Needs to be inspected and cleaned regularly.
4) Valve to filling machine
– Need to check that there are no burn-on.
5) V121
– Condensate barrier will reduce burn-on significantly.
6) CR103
– Inspect if risk for foreign matters or particles in product.
(Cont'd)
8 - 6 (8) Doc. No. OM-1225256-0101

8 Care and Cleaning Cleaning
(Cont'd)
1
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Doc. No. OM-1225256-0101 8 - 7 (8)

Cleaning 8 Care and Cleaning
External cleaning
• Rinse the walls, the floor, then the equipment.
• Rinse until visually free of soils.
• Use foam cleaning if possible and then spray with water.
• Use lowest effective pressure to minimize aerosols and condensation.
• Lower pressure reduces risk of cross contamination and machine
damage.
• Minimize spraying the floor once the equipment begins to be rinsed.
• Never use high pressure cleaning equipment due to risk of cross
contamination.
• Important factors are:
– Contact time and concentration of detergent.

– Mechanical action.
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8 - 8 (8) Doc. No. OM-1225256-0101


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OM

Doc. No. OM-1225256-0101

8 Care and Cleaning

Doc. No. OM-1225256-0101

Tetra Pak Dairy & Beverage Systems AB

Doc. No. OM-1225256-0101 i - 1 (10)

i - 2 (10) Doc. No. OM-1225256-0101

How to Use This OM . . . . . . . . . . . . . . . . . . . . . . i - 10

Doc. No. OM-1225256-0101 i - 3 (10)

i - 4 (10) Doc. No. OM-1225256-0101

Doc. No. OM-1225256-0101 i - 5 (10)

9 General 9.2 Technical Data

Doc. No. MM-2730517-0103 9 - 41 (60)

i - 6 (10) Doc. No. OM-1225256-0101

4 - 11 (18) 1 Chapter number

A zoom arrow indicates that an object view is

A rotation movement arrow indicates rotational

A straight movement arrow indicates movement of an

Doc. No. OM-1225256-0101 i - 7 (10)

Support and Feedback

i - 8 (10) Doc. No. OM-1225256-0101

Doc. No. OM-1225256-0101 i - 9 (10)

How to Use This OM

i - 10 (10) Doc. No. OM-1225256-0101

Doc. No. OM-1225256-0101 ii - 1 (26)

Safety Precaution Instructions

Definition of Lockout Procedure

ii - 2 (26) Doc. No. OM-1225256-0101

Safety Messages Description. . . . . . . . . . . . . . . ii - 5

Doc. No. OM-1225256-0101 ii - 3 (26)

ii - 4 (26) Doc. No. OM-1225256-0101

Safety Messages Description

Danger indicates an imminently hazardous situation

Warning indicates a potentially hazardous situation

Caution indicates a potentially hazardous situation

CAUTION Caution without the safety alert symbol indicates a

Doc. No. OM-1225256-0101 ii - 5 (26)

ii - 6 (26) Doc. No. OM-1225256-0101

machine/aseptic tank. The steam barrier allows the filling machine/aseptic

Doc. No. OM-1225256-0101 ii - 7 (26)

To ensure a safe product, it is important that the following checkpoints

ii - 8 (26) Doc. No. OM-1225256-0101

Pos ISO sign ANSI sign

Mandatory action. Always wear hearing protection.

Chemical burn hazard.

Doc. No. OM-1225256-0101 ii - 9 (26)

Pos ISO sign ANSI sign

Equipment sensitive to welding

ii - 10 (26) Doc. No. OM-1225256-0101

Locations of Safety Signs

Doc. No. OM-1225256-0101 ii - 11 (26)

ii - 12 (26) Doc. No. OM-1225256-0101

Emergency Stop Push Buttons

Doc. No. OM-1225256-0101 ii - 13 (26)

ii - 14 (26) Doc. No. OM-1225256-0101

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

Doc. No. OM-1225256-0101 ii - 15 (26)

ii - 16 (26) Doc. No. OM-1225256-0101

Doc. No. OM-1225256-0101 ii - 17 (26)

Always make sure that

ii - 18 (26) Doc. No. OM-1225256-0101

Inert gases - N2/CO2

Ventilation can be done by means of compressed air or a mobile fan with a