About This Manual

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ABOUTTHIS MANUAL
This manual is designed to help you understand, operate and
maintain your FMC FoodTech´s equipment. The manual is
written for both technical and non-technical readers. It is recom-
mended as a part of basic training for production personnel,
operators, mechanics, and electricians who work closely with
the equipment. This manual shall be used in combination with
the enclosed Component Information from the manufacturers.
The best way to keep the equipment in operation is to care for it
as recommended by the manufacturer. Make sure that regular,
preventative maintenance is established and followed by re-
sponsible personnel. This also helps to ensure a safer working
environment for your employees.
Safety information appears as the first section of this book

because the safety of your personnel is our primary concern at
FMC FoodTech AB. The following chapters provide technical
information about the equipment, the user interface with the
control system and detailed maintenance procedures.
Every effort has been made to ensure that the information

contained in this publication is correct and fully up-to-date.
FMC FoodTech AB reserves the right to make changes at any
time without prior notice.
Trademarks used in this manual are marked with ® and ™.

These trademarks are the exclusive property of FMC FoodTech
AB.
Any comments regarding possible errors and omissions or

suggestions for improvement of this publication would be grate-
fully appreciated.
Published by:
FMC FoodTech AB
Technical Documentation Department
PO Box 913
SE - 251 09 Helsingborg
Sweden
© Copyright FMC FoodTech AB. Printed in Sweden.
~~~
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SAFETY
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SAFETY
WARNINGTEXTS AND SYMBOLS
Warning levels
There are three different warning levels in this manual. These
warnings are placed right next to the text that describes the
particular hazardous operation. It is important to pay attention to
these warnings and act on them in accordance with the text that
describes them.
)
DANGER!
This means that a serious accident will occur if
this provision is not observed. This accident will
result in death, serious injury and/or damage to
property, equipment and/or environment.
)
Warning
This means that a serious accident may occur if
this provision is not observed. This accident will
result in injury and/or damage to property,
equipment and/or environment.
!
Caution
This means that an accident may occur if this
provision is not observed. This accident may
result in injury and/or damage to property,
equipment and/or environment.
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SAFETY
Symbols
A number of symbols occur in the text. These symbols can,
whenever this is advisable, replace the general warning symbol,
a plain exclamation mark or one inside a triangle.
Danger, general warning symbol
Danger, general warning symbol
Health hazard, general
Fire risk
Toxic
Oxidizing agent
Low temperature
Electrical voltage
Risk of slipping
Other warnings
In addition, the remark NB! occurs in a number of instances in
the text. This mark means that no immediate hazard is present
but calls for attention in order to avoid future problems.
NB!
Denotes a risk of breakdown and/or unplanned production
stoppages unless this instruction is followed.
~~~
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SAFETY
SAFETY RULES
A number of national, regional and local regulations govern
handling, hygiene, storage, etc., in the field of industrial foodstuff
production.
• Always observe current rules and legislation.
• Always observe the safety regulations and instructions that
apply to your place of work and are described in the manual.
• Incorrect installation, handling or servicing may cause
personal injury or damage to equipment and the environ-
ment.
• Personnel who work with the equipment must possess an
adequate knowledge of the operations to be performed.
• Hence, it is vital to read, understand and comply with the
instructions contained in this manual.
General safety principles
The enclosure is the guard against moving parts inside.
It is hazardous to linger inside the enclosure while any compo-
nents are moving or when the refrigeration is on.
In general, no person should be allowed to be inside the equip-
ment while:
• any moving parts are in operation.
• moving parts can be started by persons outside the equip-
ment.
Low temperature
Wear suitable and recommended protective clothing when
working at low temperatures or with cold components.
Moving parts
The equipment contains moving parts. Never undertake any kind
of work on parts that are moving.
Take care of your fingers and do not have loose hanging cloth-
ing, jewellery or long hair, which may catch in moving parts and
cause injury or damage the equipment.
Risk of slipping
The floors in and around the equipment can be very slippery due
to water, frost, product residues or other spills.
Area of use
Use equipment solely for those purposes and products for
which it is intended. Incorrect use may result in an unfit product
and/or cause personal injury or damage equipment or the envi-
ronment.
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SAFETY
Alarms
Never disregard an alarm. Always check and remedy the cause
of an alarm before restarting the equipment.
Electricity
Work on the electrical system is the sole province of authorised
personnel. Always follow the local safety regulations. The main
switch can be locked in “off” position with a pad lock to enhance
a “Lock out tag out” routine.
Fire risk
The equipment contains inflammable refrigerants and man-
made materials (e.g., plastics). Consequently, always take
safety measures to avoid fire or explosion in operations involving
heat generation and/or a naked flame.
Refrigerant
Refrigerants are extremely hazardous should they leak. Use
only approved equipment and wear suitable protective gear
when working with refrigerants.
Always observe current regulations!
Hygiene/cleaning
In order to attain optimum results and avoid bacterial growth,
only recommended cleaning intervals, methods and chemicals
are to be used in cleaning and disinfecting the equipment.
Observe local regulations regarding clothing, hair covers, wear-
ing of jewellery, etc.
Maintenance
Maintenance work shall be carried out by authorized and trained
personnel only. Any test run required with removed guards etc.
shall be carried out with great care to avoid injuries.
Always observe the maintenance intervals recommended in the
manual. Use a platform, ladder, etc. to reach all the areas.
Never stand or climb on pipes, components or the like. These
are not attached so as to withstand a load. The component may
loosen and cause injury or damage equipment. Never stand or
walk on the belt. It will not withstand such a major load and can
be damaged.
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SAFETY
Lighting
FMC FoodTech recommends working illuminations of approx.
200 lux around the equipment. Good lighting facilitates checks
and work on the equipment while also lowering the risk of acci-
dents.
FMC FoodTech installes and also recommend shatterproof
fluorescent tubes in all internal light fittings.
Emergency stops
These are located at the equipment and are clearly marked.
Signs and markings

Information signs (for fire-fighting appliances, flow direction in
piping, cutoff valves), warning signs (for, e.g., gas or hot water)
and signs that show a suitable evacuation route, should be fitted
at suitable locations. Follow current regulations on the design of
markings.
Hydraulics / pneumatics
Work on the hydraulic/pneumatic system may be done only by
trained personnel. Always ensure that the system is depressu-
rised before starting work.
Follow the manufacturer's directions with regard to service.
~~~
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SAFETY
HYGIENE AND CLEANING
A number of national, regional and local regulations govern the
handling, hygiene, storage, etc, in the field of industrial foodstuff
production.
• Always observe current rules and legislation.
• Always observe the local regulations and instructions that
apply to your place of work, as well as the instructions in
the manual.
• In order to obtain optimum results and avoid bacterial
growth, only recommended cleaning intervals, methods and
chemicals are to be used in cleaning and disinfecting the
equipment.
• Treat the equipment with care and follow the supplier's
directions for use.
)
Warning
Only authorised personnel may undertake clean-
ing and disinfection operations. Incorrect or badly
implemented cleaning or disinfection may cause
personal injury.
We recommend:
• That cleaning is done only when equipment and production
have been shut down in accordance with the regulations.
If cleaning is programme-controlled, the instructions in the
manual must be followed.
~~~
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SAFETY
ELECTRICAL SYSTEM
Work on the electrical system may only be carried out by au-
thorised personnel and must be undertaken in accordance with
current laws and regulations.
• Always observe both the safety regulations and instructions
applying to the work site and those stated in the manual.
• Always switch off the main power supply before starting
any work on the equipment.
)
Danger!
The internal cabinet lighting, PC power supply
and electrical cabinet ventilation fan are not
connected to the main switch and remain live
even when the main switch is in position ‘0’.
We recommend:
• That the equipment is continuously checked and maintained
by authorised personnel.
• That the "Lock-Out/Tag-Out" procedure is followed when
working on the equipment. This prevents the possibility of
starting the equipment by mistake and display signs indicat-
ing that work on the electrical system is in progress.
~~~
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SAFETY
AMMONIA
Ammonia is a toxic, colourless gas that is highly corrosive and
irritative to eyes, respiratory organs and skin. It readily dis-
solves in water, it is chemically stable and has a strong charac-
teristic smell. Ammonia, which is lighter than air, expands and
forms an aerosol mist on contact with air and air humidity.
Use approved equipment and suitable protective gear when
working with ammonia.
)
Danger!
Ammonia is toxic and harmful to health in larger
concentrations. Discharges can cause peronal
injury and damage the environment.
In the event of an accident/ammonia discharge

1. Evacuate all people within the risk area. Persons exposed to
ammonia fumes should be taken to safety immediately and
made to breath fresh air.
2. Where possible, shut off the supply of ammonia.
3. In the event of an ammonia discharge, water should be
sprayed directly onto the gas and not onto the liquid ammo-
nia. If water is sprayed directly into the liquid ammonia, this
will cause a considerable gas generation that may aggra-
vate the situation.
4. Summon help.
5. Never take unnecessary risks.
6. Observe local regulations.
Fire risk with the use of ammonia

If ammonia is present in open areas with frequent air changes, it
is usually hard to ignite.
)
Danger!
In enclosed rooms the quantity of ammonia in
the air may reach such a concentration that
there is a risk of fire and explosion.
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Data
Name Ammonia
Chemical formula NH3
Synonym R 717
Explosive concentration in air 16-27% by volume
Melting point -77,7 °C
Boiling point +33,4 °C
Ignition temperature +651 °C (DIN 51794)
Critical temperature +133 °C
Critical pressure 11,42 MPa
Concentration Effect on an unprotected person Exposure/injury time

in air
25 ppm The odour is detected by several persons. Eight-hour working day permitted
50 ppm The odour is ver y apparent. Eight-hour working day permitted, MAC
values*
100 ppm The odour is unpleasantly pungent. No harmful effect on healthy persons
400--ppm Immediate irritation of eyes, mucous Exposure time below 1 hour usually causes no
membranes and respirator y organs. harmful injuries
1700--ppm Severe irritation of eyes, mucous membranes Less than 30 minutes' exposure can lead to
and respirator y organs. severe injuries
Cramps and coughing.
2000--ppm Severe irritations of eyes, mucous Less than 30 minutes' exposure can lead to
membranes and respirator y organs. death
Cramps and coughing.
5000--ppm Paralysis of respirator y organs resulting in Death within a few minutes
asphyxiation.
*) MAC-value = Maximum Allowable Concentration, a hygienic limit value
FMC FoodTech recommends that ammonia detectors be in-

stalled in all unsupervised areas where there is a risk of ammo-
nia discharge. Observe local regulations on the handling and
use of ammonia.
~~~
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DESCRIPTION
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DESCRIPTION
DIMENSIONS
GYROCOMPACT® M7 freezer
H H0
740
1700 8850 2) 1050

680
Freezer length Number of evaporator + fan

2 3
2) 8850 9820
3) 7450 8420
Figures in shadowed areas are optional deliver y. Contact FMC

680
FoodTech Sales Suppor t for fur ther information.
682 380
Evaporator size and volume

Evaporator Galvanized steel Stainless steel / Aluminum
type
Number of evaporators + fans Number of evaporators + fans
2 3 2 3
Size Volume Size Volume Size Volume Size Volume
A 7 466 10 699 10 410 16 615
A 10 466 14 699 14 410 21 615
B 14 622 20 933 18 55 0 28 825
C 18 778 26 1167 22 66 0 34 990
D 22 93 4 32 1401 26 81 0 39 1215
Figures in shadowed areas are optional delivery.

Contact FMC FoodTech Sales Suppor t for fur ther information.
® = Registered trade mark.

Subject to change without notice.
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DESCRIPTION
Height for straight through layouts
CCR: NS, EW CR: NS, WE
4800 6200
4800
7450 3)
8850 2)
4800
NS - CCR NS - CR EW - C C R WE - CR
Tiers Lh 80 Lh 100 Lh 120
H0 H H0 H H0 H
Evaporator type Evaporator type Evaporator type
A B C D A B C D A B C D
16 2306 3900 4000 2622 3900 4100 4300 2939 3900 4100 4300 4500
17 2386 4000 4000 2722 4000 4000 4200 4500 3059 4000 4000 4300 4500
18 2466 4000 4000 4300 2822 4100 4100 4300 4500 3179 4000 4000 4300 4500
19 2546 4100 4100 4300 2922 3900 4000 4300 4500 3299 4200 4200 4300 4500
20 2626 3900 4100 4300 3022 4000 4100 4300 4500 3419 4300 4300 4300 4500
21 2706 4000 4100 4300 4500 3122 4100 4100 4200 4500 3539 4400 4400 4400 4500
22 2786 4100 4100 4300 4500 3222 4100 4100 4300 4500 3659 4500 4500 4500 4500
23 2866 4100 4100 4300 4500 3322 4200 4200 4200 4500 3779 4600 4600 4600 4600
24 2946 3900 4100 4300 4500 3422 4300 4300 4300 4500 3899 4800 4800 4800 4800
25 3026 4000 4100 4300 4500 3522 4400 4400 4400 4500 4019 4900 4900 4900 4900
26 3106 4100 4100 4300 4500 3622 4500 4500 4500 4500 4139 5000 5000 5000 5000
27 3186 4000 4000 4300 4500 3722 4600 4600 4600 4600 4259 5100 5100 5100 5100
28 3266 4100 4100 4300 4500 3822 4700 4700 4700 4700 4379 5200 5200 5200 5200
29 3346 4200 4200 4300 4500 3922 4800 4800 4800 4800 4499 5400 5400 5400 5400
30 3426 4200 4200 4300 4500 4022 4900 4900 4900 4900 4619 5500 5500 5500 5500
31 3506 4300 4300 4300 4500 4122 5000 5000 5000 5000 4739 5600 5600 5600 5600
32 3586 4400 4400 4400 4500 4222 5100 5100 5100 5100 4859 5700 5700 5700 5700
33 3666 4500 4500 4500 4500 4322 5200 5200 5200 5200 4979 5800 5800 5800 5800
34 3746 4600 4600 4600 4600 4422 5300 5300 5300 5300 5099 6000 6000 6000 6000
35 3826 4600 4600 4600 4600 4522 5400 5400 5400 5400 5219 6100 6100 6100 6100
36 3906 4700 4700 4700 4700 4622 5500 5500 5500 5500 5339 6200 6200 6200 6200
37 3986 4800 4800 4800 4800 4722 5600 5600 5600 5600 5459 6300 6300 6300 6300
38 4066 4900 4900 4900 4900 4822 5700 5700 5700 5700 5579 6400 6400 6400 6400
39 4146 5000 5000 5000 5000 4922 5800 5800 5800 5800 5699 6600 6600 6600 6600
40 4226 5000 5000 5000 5000 5022 5900 5900 5900 5900 5819 6700 6700 6700 6700
Lh = Link height
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DESCRIPTION
Height for U-layouts
CCR: NN, EE CR: NN, WW
4800 6200
4800
7450 3)
8850 2)
4800
NN - CCR NN - CR EE - CCR WW - C R
H0 H H0 H H0 H
16 2266 3800 4000 2572 3900 4000 4300 2879 3900 4000 4200 4500
17 2346 3900 4000 2672 4000 4000 4300 4500 2999 4000 4000 4300 4500
18 2426 4000 4000 4200 2772 4100 4100 4300 4500 3119 4100 4100 4200 4500
19 2506 4100 4100 4200 2872 4200 4200 4300 4500 3239 4100 4100 4300 4500
20 2586 3900 4000 4200 2972 3900 4000 4300 4500 3359 4200 4200 4300 4500
21 2666 3900 4000 4200 4500 3072 4000 4000 4300 4500 3479 4300 4300 4300 4500
22 2746 4000 4000 4300 4500 3172 4000 4000 4300 4500 3599 4500 4500 4500 4500
23 2826 4100 4100 4300 4500 3272 4100 4100 4200 4500 3719 4600 4600 4600 4600
24 2906 3900 4000 4300 4500 3372 4200 4200 4300 4500 3839 4700 4700 4700 4700
25 2986 4000 4000 4300 4500 3472 4300 4300 4300 4500 3959 4800 4800 4800 4800
26 3066 4000 4000 4300 4500 3572 4400 4400 4400 4500 4079 4900 4900 4900 4900
27 3146 4100 4100 4300 4500 3672 4500 4500 4500 4500 4199 5100 5100 5100 5100
28 3226 4000 4100 4300 4500 3772 4600 4600 4600 4600 4319 5200 5200 5200 5200
29 3306 4100 4100 4300 4500 3872 4700 4700 4700 4700 4439 5300 5300 5300 5300
30 3386 4200 4200 4300 4500 3972 4800 4800 4800 4800 4559 5400 5400 5400 5400
31 3466 4300 4300 4300 4500 4072 4900 4900 4900 4900 4679 5500 5500 5500 5500
32 3546 4400 4400 4400 4500 4172 5000 5000 5000 5000 4799 5700 5700 5700 5700
33 3626 4400 4400 4400 4500 4272 5100 5100 5100 5100 4919 5800 5800 5800 5800
34 3706 4500 4500 4500 4500 4372 5200 5200 5200 5200 5039 5900 5900 5900 5900
35 3786 4600 4600 4600 4600 4472 5300 5300 5300 5300 5159 6000 6000 6000 6000
36 3866 4700 4700 4700 4700 4572 5400 5400 5400 5400 5279 6100 6100 6100 6100
37 3946 4800 4800 4800 4800 4672 5500 5500 5500 5500 5399 6300 6300 6300 6300
38 4026 4800 4800 4800 4800 4772 5600 5600 5600 5600 5519 6400 6400 6400 6400
39 4106 4900 4900 4900 4900 4872 5700 5700 5700 5700 5639 6500 6500 6500 6500
40 4186 5000 5000 5000 5000 4972 5800 5800 5800 5800 5759 6600 6600 6600 6600
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DESCRIPTION
Height for angle layouts
CCR: NE CR: NW
5500
2060 4140
8850 2)
4800
NE - CCR NW - CR
H0 H H0 H H0 H
16 2326 3900 4100 2647 3900 4000 4300 2969 3900 4000 4300 4500
17 2406 4000 4100 2747 4000 4000 4300 4500 3089 4100 4100 4300 4500
18 2486 4100 4100 4300 2847 4100 4100 4300 4500 3209 4100 4100 4200 4500
19 2566 3800 4000 4300 2947 3900 4000 4300 4500 3329 4200 4200 4200 4500
20 2646 3900 4000 4300 3047 4000 4000 4200 4500 3449 4300 4300 4300 4500
21 2726 4000 4000 4200 4500 3147 4100 4100 4300 4500 3569 4400 4400 4400 4500
22 2806 4100 4100 4200 4500 3247 4100 4100 4300 4500 3689 4600 4600 4600 4600
23 2886 3900 4000 4200 4500 3347 4200 4200 4300 4500 3809 4700 4700 4700 4700
24 2966 3900 4000 4200 4500 3447 4300 4300 4300 4500 3929 4800 4800 4800 4800
25 3046 4000 4000 4200 4500 3547 4400 4400 4400 4500 4049 4900 4900 4900 4900
26 3126 4100 4100 4200 4500 3647 4500 4500 4500 4500 4169 5000 5000 5000 5000
27 3206 4000 4000 4200 4500 3747 4600 4600 4600 4600 4289 5200 5200 5200 5200
28 3286 4100 4100 4300 4500 3847 4700 4700 4700 4700 4409 5300 5300 5300 5300
29 3366 4200 4200 4300 4500 3947 4800 4800 4800 4800 4529 5400 5400 5400 5400
30 3446 4300 4300 4300 4500 4047 4900 4900 4900 4900 4649 5500 5500 5500 5500
31 3526 4300 4300 4300 4500 4147 5000 5000 5000 5000 4769 5600 5600 5600 5600
32 3606 4400 4400 4400 4500 4247 5100 5100 5100 5100 4889 5800 5800 5800 5800
33 3686 4500 4500 4500 4500 4347 5200 5200 5200 5200 5009 5900 5900 5900 5900
34 3766 4600 4600 4600 4600 4447 5300 5300 5300 5300 5129 6000 6000 6000 6000
35 3846 4700 4700 4700 4700 4547 5400 5400 5400 5400 5249 6100 6100 6100 6100
36 3926 4700 4700 4700 4700 4647 5500 5500 5500 5500 5369 6200 6200 6200 6200
37 4006 4800 4800 4800 4800 4747 5600 5600 5600 5600 5489 6400 6400 6400 6400
38 4086 4900 4900 4900 4900 4847 5700 5700 5700 5700 5609 6500 6500 6500 6500
39 4166 5000 5000 5000 5000 4947 5800 5800 5800 5800 5729 6600 6600 6600 6600
40 4246 5100 5100 5100 5100 5047 5900 5900 5900 5900 5849 6700 6700 6700 6700
Lh = Link height
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DESCRIPTION
TECHNICAL DATA (SI-SYSTEM)
Model GC M7
Belt
Link height (mm) 80 100 120
Ver tical clearance for product (mm) 65 85 10 5
Number of tiers (min-max) 16-40
Type FRIGoBELT®
Width, total (mm) 760
Width, net (mm) 715
Length per tier (m) 13.1
2
Effective belt area per tier (m ) 7.7
Belt speed (m/min) 3.5 - 30 (standard speed range)
2.0 - 15 (optional speed range)
Electrical data
2 fans 3 fans
Main voltage 3 x 400 V or 3 x 415 V, 50 Hz
Normal power consumption (kW) 38.5 56
1)
Max power requirement (kVA) 60 85.4
Motors more than 1 kW rating 1 x 1.5 + 1 x 4 + 2 -3 x 18
Refrigeration data
Standard design R717 (Ammonia): Pump circulation ratio = 4-6
times evap.
2 fans 3 fans
Base load (kW) 49 67
Base load (kcal/h) 42000 57600
Defrosting system
Defrosting media Hot gas or potable water
2 fans 3 fans
Water consumption (L/min) (at 300 kPa = 3 bar, min 1 bar) 2) 180 270
2) 3)
Minimum water temp. (°C) +15
Noise emissions
According to Machiner y Directive 98/37-EC, 1.7.4(f) Maximum 80 dB(A)
Application data
Normal loading distance on straight belt Rectangular products: 1.7 x product length
Round products: 1.5 x product diameter
1) Valid for dimensioning of power supply fuses/cables.
2) Must be potable water.
3) For cleaning system +60°C is needed.
~~~

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DESCRIPTION
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APPLICATION
DATA
MANUAL 0000 25
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APPLICATION DATA
TECHNICAL ASPECTS
REGARDING FREEZING
GYRoCOMPACT® M6-M10 freezer
Capacity
Experience and careful measurement have
shown that the most efficient evaporation
temperature is normally -40 °C (-40 °F). As shown
in the “Relative product capacity chart” it is
possible to increase capacity by lowering the
evaporation temperature, and conversely, it is
possible to raise the evaporation temperature
and thereby use less energy, reducing capacity.
Evaporation temperature
The infeed temperature also has an effect on

the freezing process, as shown in the diagram
“Relative holding time chart”; the lower the infeed
temperature, the shorter the holding time.
Relative holding time
Product quality demands such as fat content,
water content and product thickness can also
influence evaporation temperature, holding time
and infeed temperature. The graph shows rela-
tive holding time for a specific product ( in this
case raw single meat patties max 9.5 mm thick )
as function of the infeed temperature.
If the patties have an infeed temperature of 0 °C
= +32 °F the relative holding time will be 100%.
When the infeed temperature is raised to +5°C =
41°F the relative holding time is increased to
110%.
Infeed temperature
® = Registered trade mark.


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APPLICATION DATA
Loading the belt

Normal loading distances on a straight belt.
Min. 10 mm
L LxP1
Example with rectangular products
Min. 10 mm
L LxP2
Example with round products
For best results, the belt coverage on a straight belt should not
normally exceed 45%.
P1 = 1,7
P2 = 1,5
~~~
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INFORMATION
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DELIVERY INFORMATION
CONDITIONS FOR GUARANTEE
It is a condition for the (FMC FoodTech) guarantee that the
equipment is carefully operated as instructed and that service
and lubrication are performed at recommended intervals.
Intervals between service and lubrication

The recommended intervals between service and lubrication are
valid for one-shift operation. For two- or three-shift
operation the intervals should be shortened by half. If very hot
water is used during the cleaning down, the lubricating intervals
should be shortened by half.
Shut down for a longer period

If the equipment should be out of operation for a longer period
the following should be done:
1. The equipment should be cleaned down with extra care.
2. All bearings should be lubricated.
3. The doors should be left open for ventilation.
4. The room where the equipment is located should, if
possible, be heated.
5. It is of course advisable to carry out the essential service
and maintenance work during this time.
~~~
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FUNCTION
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FUNCTION
WORKING PRINCIPLE
1
2
1. Evaporator
3 2. Fans
4 3. Outfeed unit
4. Release plate
5. Belt drive units
6. Belt stack
7. Infeed unit
8. Product height limiter
9. Control panel
10. Operating guide
GYRoCOMPACT® M7
10 5 Products are carried into the equipment by the

9 6 belt, which is shaped as a belt stack, as it enters
8 7 the equipment.
The fans circulate air through the evaporator and
belt stack and then back to the evaporator.
When the belt leaves the belt stack the products
are ejected through the outfeed. The outfeed has
a drive unit which provides the necessary force
to the belt. Products are released from the belt by
means of a release plate.
The belt drive drives two chains on which the belt
stack is carried.
All operations are controlled and monitored from
the electric control panel, which is equipped with
a control unit.
All functions are stopped instantly when any of
the emergency stop buttons are pressed; located
at the control panel, infeed and outfeed unit.
An operating guide gives step-by-step instruc-
tions on how to operate the machine.
GYRoCOMPACT M9, M10
®= Registered trade mark of FMC FoodTech.

MANUAL 1000 35
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FUNCTION
14 13 Infeed
11. Tension switch
12. Spring
The infeed section consists of rails and infeed

rollers. Glidestrips are mounted on the rail to
provide a low-friction surface for the belt to ride
on. The infeed is equipped with a tension limit
switch. If the tension is too high, the spring will
activate the switch and stop the equipment.
Product height limiter

13. Height limiter
14. Limit switch (if installed)
At the infeed, a product height limiter with a limit

switch indicates when a product fed onto the
belt is too tall. The belt stops and if the limit
switch is installed an alarm is activated.
The product height limiter can manually be
adjusted vertically according to the product
height.
11
12
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01 - 02 MANUAL
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FUNCTION
FRIGoDRIVE ® drive system
15. Outfeed
16. Belt collapse area
15 17. Belt lifter
18. Drive motors
19. Belt position switch
20. Outer chain
21. Inner chain
16
17 22. Infeed
18
19
20
21 The belt enters the equipment from the infeed
22 and is loaded on two chains. The incoming belt
is loaded between the chains and the bottom of
the stack and forms a spiral.
The belt position switch is positioned closely
after the transfer point on both sides of the belt.
It triggers an alarm when the belt is out of posi-
tion or deformed.
The stack rests on the chains. Each chain has a
drive motor connected to a helical gearbox,
which gives the necessary driving force to the
stack. From the top of the stack the belt is led to
the outfeed via a belt lifter.
Due to wear and temperature changes the belt
length changes over time. To take care of differ-
ences in the belt length one part of the belt is
collapsed (16). The length is adjusted to get a
total collapsed belt length of minimum 1 m for a
warm freezer.
MANUAL 1000 37
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FUNCTION
23 24 Outfeed
23. Chain gearing
24. Release plate
25. Outfeed roller
26. Helical gearbox
27. Drive motor
The outfeed is equipped with a separate drive

unit, synchronized with the main drive. Its force
is sufficient to remove products sticking to the
belt with the aid of the outfeed release plate. The
drive motor with its helical gearbox drives the
outfeed roller by means of a chain gearing. The
outfeed release plate must always be used for
removal of products from the belt.
27 26 25
FRIGoDRIVE lubrication system

28. Button for manually start extra lubrication
29. Oil reservoir
30. Stainless steel cabinet
31. Metering elements
32. Oil filter
33. Pipe
34. Prime outlet
28 29 30
The FRIGoDRIVE lubrication system intermit-
tently lubricates the balls, the ball race and the
31 plastic wear strips. The pump is controlled by
the PLC. The oil pump transfers oil to the lubri-
cation points.
~~~
34
32
33
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FUNCTION
REFRIGERATION PROCESS
The air inside the equipment is cooled by an evaporator consist-
ing of numerous tube circuits, which are finned to enlarge the
surface for air contact. The fin spacing varies with the depth of
the coil, so it is wide at the air inlet and narrow at the outlet. This
ensures frost build-up with minimal air flow restriction.
1 2 3 4 1. Evaporator
2. Surge drum
3. Compressor
4. Condenser/Cascade con-
denser
5. Level control valve
6. Pump
6 5
Figure 1
The refrigerant is either of natural (ammonia, carbon dioxide) or

HFC (hydrofluorocarbon) type. These refrigerants have very low
boiling temperature at atmospheric pressure. The refrigerant is
brought to boil inside the evaporator; the heat required is taken
from the circulated air which also passes over the product to be
frozen or chilled. Since less liquid is evaporated than is fed into
the evaporator, the refrigerant leaving it will be a mixture of liquid
and gas. The excessive liquid is separated in the surge drum so
that only gas is drawn into the compressor. The compressed
gas, which during compression has risen in temperature, is
cooled and re-condensed to liquid in the condenser. The refriger-
ant liquid is then fed back into the surge drum via a level control
valve. From the surge drum the liquid can be fed to the evapora-
tor either by means of a pump or simply through gravity. When
using a gravity feed, the surge drum and its liquid level must be
higher than the evaporator.
The text above describes the principles of an industrial refrig-
eration system which is normally far more complex with several
controls, oil-separating equipment, etc. Many refrigeration sys-
tems also uses two stage compressors to ensure a more effi-
cient refrigeration process.
MANUAL 1000 39
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FUNCTION
Common refrigerants used for freezing purposes
Refrigerant code Trade name Type
Natural, single substance. Most commonly

R717 Ammonia (NH3)
used refrigerant in industrial freezers.
R744 Carbon dioxide (CO2) Natural, single substance
R507 Genetron AZ50, Meforex M57 Mixture of HFC- refrigerants
Forane FX70, Meforex M55,
R404A Mixture of HFC- refrigerants
Recilin 404A, Suva HP62
R134a (CF3 CFH2) HFC- refrigerant, single substance
System with secondary refrigerants
8 9 7
7. Heat exchanger, refrigerant
to secondary refrigerant
8. Cooler (usually a finned air
cooler)
9. Secondary refrigerant pump
Figure 2
The evaporator (Item 1 in figure 1) in a refrigeration system as

described on previous page is a heat exchanger, refrigerant to
air. It could also be a heat exchanger for refrigerant to liquid. If
liquid, cooled in a heat exchanger is used for cooling purpose, it
is called a secondary refrigerant.
A secondary refrigerant is often a waterbased liquid. Examples
are mixtures of glycol/water, ammonia/water or alcohol/water.
Data for the secondary refrigerant (handling instructions, safety
and properties) could be found in separate material specification
sheets or obtained from the supplier.
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FUNCTION
Evaporator
Corrosion
A refrigerant must not cause any corrosion of the materials
used in the system. Ammonia can be used with all-steel or
aluminium, but not with copper and its alloys, as ammonia
rapidly corrodes copper. Used ammonia should be anhydrous
ammonia with a maximum water content of 1%. HFC
(hydrofluorocarbon) can be used with all common metals. HFC-
refrigerants must have extremely low water content.
A number of secondary refrigerants are corrosive, for example
potassium formate, potassium acetate, calcium chloride etc. It is
necessary to do scheduled analyses to ensure the oxygen level
and inhibitors are within the secondary refrigerant suppliers
recommendations. Too high oxygen levels or inactive inhibitors
will result in corrosion and damage the evaporators. Galvaniza-
tion (zinc) will be damaged if exposed to potassium formate/
acetate.
Evaporators with HFC

Most HFC:s solve more water in its liquid phase than in its
vapour phase. This leads to that moist fed to an evaporator may
not be carried back to the refrigeration plant with the vapour. The
free water in the evaporator could penetrate cavities in the
soldered pipe joints. When the water in the cavities is freezing, it
expands and blisters are created. These blisters could later
burst and result in refrigerant leaks.
In systems operating with HFC refrigerants, too high moist
content has even more serious negative effects in addition to
the effects on evaporators described above. Moist in HFC
refrigeration systems that uses polyol ester compressor oil is
reacting with the oil. Reaction products are alcohol and acid
which break down the compressor oil and may result in fatal
compressor failure. To check the risk of getting these problems,
make analyses of the compressor oil.
To avoid leaks and other problems, it is necessary to keep the
moist content in the refrigeration system and compressor oil as
low as possible. Always follow normal practice and maintenance
of refrigeration systems.
MANUAL 1000 41
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FUNCTION
Evaporators with carbon dioxide

Problems with moisture in CO2
One problem with CO2 is the low solubility of water in gas phase
as can be seen in the table below.
Temperature (°C) Water solubility in CO2 (ppm)
in liquid in gas
+10 750 70
-10 400 33
-30 200 12
-40 135 6,5
-50 65 3,5
If more water is solved in the liquid phase than can be solved in

gas phase, this creates free water when the CO2 liquid is
evaporated. If the temperature is below zero the water freezes
to ice immediately. This can happen in evaporators with thermo-
static expansion valves. The free water in the evaporator could
then penetrate cavities in the soldered pipe joints during periods
of standby. When the water in the cavities is freezing, it expands
and blisters are created. These blisters could later burst and
result in refrigerant leaks.
In evaporators with gravity feed or pump circulation, ice can be
created if CO2 liquid is left in an evaporator at standby and the
CO2 liquid is evaporated. To avoid the problem with ice, water
content in CO2 must not exceed the maximum solubility of water
in CO2 gas phase.
An example from the table above shows that the maximum
water content in a container with CO2 (liquid or gas) that is
operating in a temperature at -40°C must not exceed 6,5 ppm.
Note!
CO2 is also known as the refrigerant R744.
4/8 1000 - 04 - 01 -42

07 - 00 MANUAL
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FUNCTION
In order to keep the water content low in the CO2 the following
recommendations must be followed:
• Charge only CO2 with low enough water content
• Evacuation of the refrigeration system must be done care-
fully with all parts of the system warm enough.
• Charge only refrigeration oil with low water content in com-
pressor.
• Install filter dryers in refrigeration system.
• Install sight glass with water content indicator sensible
enough to indicate low water content.
• Maintenance and repair practises must consider the risk of
getting moisture into the refrigeration system.
If polyol ester compressor oil is used, moisture will react with
the oil. Reaction products are alcohol and acid which break
down the compressor oil and may result in fatal compressor
failure. To check the risk of getting these problems, make analy-
ses of the compressor oil.
Evaporator safety valves

Very high pressures can occur in CO2 evaporators at standby
or defrost if stop valves are installed and if CO2 liquid remains in
the evaporator. See saturation pressures at different tempera-
tures in the table below.
CO2 -saturation pressure
Temperature (°C) Saturation pressure (bar)
+30 71,1
+20 56,3
+10 44,0
±0 33,9
-10 25,5
-20 18,7
-30 14,3
-40 9,0
-50 5,8
MANUAL 1000 43
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FUNCTION
In a standard freezer evaporator, the MAWP (Maximum Allow-
able Working Pressure) normally varies between 16 - 28 bar
gauge. Therefore a safety valve must be installed in the con-
necting pipe to each evaporator equipped with stop valves in
liquid and suction line. To avoid blocking the safety valve with
CO2 snow at a release of pressure, no outlet pipe should be
installed after the safety valve.
The safety valve must be sized for the maximum heat load that
can occur at standby or when doing water defrosting. To avoid
high pressures and blowing of the safety valve during water
defrost, the evaporator must be carefully emptied from CO2
liquid before the defrost starts.
Defrosting
The instructions below refer to a refrigeration installation by
FMC FoodTech.
When the evaporator coils are covered with frost, so that air
circulation is restricted, defrosting is necessary.
Defrosting can be performed as:
• hot gas defrosting
• water defrosting
During defrosting the belt drive switch should be in position 0

(zero) and the refrigerant liquid supply shut off.
6/8 1000 - 04 - 01 -44

07 - 00 MANUAL
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FUNCTION
Hot gas defrosting
(not valid for evaporators with CO2)
10
10. Pipe line with hot gas

11. Pressure relief valve
12. Stop valves
Figure 3
12 11
The evaporator can be defrosted with refrigerant hot gas, from a

pipe line running from the compressor discharge to the evapora-
tor. In hot gas defrosting the evaporator has to be shut off using
stop valves. The pressure in the evaporator is controlled by a
pressure relief valve which ensures that the saturation pressure
of the refrigerant is well above freezing point of water. From this
valve the condensed refrigerant liquid and excessive hot gas is
led back to the suction side. When using hot gas defrosting, the
evaporator operates as a condenser.
To be able to defrost with hot gas, there must be at least another
(reasonably large) evaporator in operation in the same refrigera-
tion system. If not, hot gas will not be available.
Water defrosting
Water defrosting takes place with the refrigerant shut off. Water
is sprayed over the evaporator until all frost is melted.
~~~
MANUAL 1000 45
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FUNCTION
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07 - 00 MANUAL
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FUNCTION
ELECTRIC CONTROL
1 1. Ventilation air outlet
2 2. Attention siren
3. Control unit with HMI
3 4. Air conditioner 1)
5. Emergency stop
4 6. Main switch
7. Panel ventilation fan (either in the bottom or
5 in the gable of the cabinet)
6 Electrical cabinet
The front panel is equipped with control unit,
main switch, attention siren and emergency stop
button.
7
Note!
On some equipment the electrical cabinet is
divided into one operating panel and one power
panel. The main switch is then located on the
power panel.
Control unit
The control unit has a graphic display with touch
surface, HMI (Human Machine Interface). All
operations are controlled and monitored from the
control unit.
There are a number of different screens avail-
able for the different equipment processes and
functions.
For further information, see chapter “Operation,
Control unit”.
The pictures show an example of layout.
1) Optional or not on all equipment.
® = Registered trade mark of FMC FoodTech.

MANUAL 1000 47
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O-1320174_gb
FUNCTION
Main switch
The main switch disconnects the power to all functions when
set in position ‘0’ (except for those stated). An alarm is activated
as soon as the main switch is turned on. Reset the alarm in
order to reset the safety relays.
)
Warning
The internal lighting, PC power-supply and
electrical cabinet ventilation fan are not con-
nected to the main switch and remain live even
when the main switch is in position ‘0’.
Electrical connections
For detailed information refer to the appropriate circuit diagram
provided with the equipment.
Inside lighting
The equipment is delivered with a switch for the lighting, prefer-
ably mounted close to one of the equipment doors. Instead of
connecting the switch, it is possible to install a jumper between
the terminals. Then the lighting will always stay on.
Note!
We strongly recommend the lighting always to be turned on, to
dry out residual moisture inside the light fittings. This will prevent
failure with the light fittings and unnecessary maintenance
costs. It is also recommended due to longer start-up time of the
fluorescent tubes during cold conditions to turn on the lighting
before starting production (freezers).
Ventilation in the electrical cabinet

The electrical cabinet is ventilated by a thermostat controlled
fan, provided with a filter. The air leaves the cabinet through
grids with a filter.
Air conditioner
As optional the electrical cabinet could be equipped with an air
conditioner. The air conditioner is supplied from an external
power source and should always be turned on.
Programmable logic controller - PLC

All electrical systems in the equipment, except for the safety
system, are controlled by the PLC. The PLC program is stored
in an EPROM module which is easy to exchange if a PLC
program has to be updated or changed. When the main switch is
set to position I, the PLC rereads the program from the EPROM.
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03 - 02 MANUAL
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FUNCTION
Alarm
If a fault occurs, the alarm signal is activated. The silent alarm
button and the alarm screen button turn yellow. The red alarm
light remains lit until the fault is cleared and the alarm is reset.
For further information, see chapter “Operation, Alarms and trouble
shooting”.
External alarm signal
A volt (potential) free contact is available for connection of an
external alarm.
Emergency stops
When an emergency stop button is pressed the equipment
stops and an alarm is activated. All functions, except the heat-
ing, are switched off.
Door and gate switch

The access doors have safety switches. Inside one (or two) of
the doors there is a protective gate. Here the safety switch is
mounted on the gate instead of on the door. As soon as a door
or gate is opened, the equipment stops and an alarm is acti-
vated.
Service handle
As soon as a service handle is lifted out of its holder, the belt
start warning signal is activated and the service handle symbol
will pop-up instead of the start button symbol. Nothing could
then be selected or started from the control unit. It is only possi-
ble to stop the equipment process or deselect single functions.
Selected functions can be started or stopped from the service
handle.
)
DANGER!
Functions can be started automatically by
programs even when the equipment is being run
from the service handle.
For further information, see chapter “Function, Service handle”.
MANUAL 1000 49
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FUNCTION
Safety system
Mechanism safety system
The equipment is fitted with safety limit switches to protect the
drive mechanism and the belt. If any of the safety switches are
tripped, an alarm is activated.
Temperature safety system

If the temperature safety system registers a temperature fault,
an alarm is activated. The temperature controls or interlocks
several functions.
Air and rail temperature
The rail and air temperature inside the equipment is checked by
the PLC.
Belt drive
The belt starts after a belt start warning. The yellow light on the
indicator bank and the yellow warning light at the infeed and
outfeed start flashing for a short period. The belt speed is con-
trolled by a frequency converter.
Belt drive alarms

The belt drive stops and an alarm is activated if:
• any of the safety limit switches in the equipment are tripped.
• any of the motors in the belt drive stops due to an overload.
• a fault occurs in the frequency converter.
• the air temperature in the equipment rises above freezing
point while the temperature of the rail is still below. This is to
prevent ice build-up on the rail and possible drive system
failure. When the temperature of the rail has risen above
7°C (15 °C for upflow air direction in belt stack), the tem-
perature alarm interlock is disabled and the belt can be
started again.
By-pass of frequency converter 1)

This procedure has to be done by instructed personnel only. In
case of frequency converter fault, it is possible to by-pass and
run the belt with fixed speed (50/60 Hz) in order to empty the
equipment of products.
Production line control

(volt free contacts)
An input signal from the line after the equipment is required
before the belt starts. When the belt stops, an output signal is
sent to the line before the equipment.
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FUNCTION
Belt sag / belt bridge adjustment 1)
If the belt is stopped suddenly, the belt tension could get out of
limit. To start the belt, adjust the belt sag2) or belt bridge3).
Lubrication system for FRIGoDRIVE® system

(not valid for FRIGoDRIVE M system)
The lubrication system pumps a small amount of oil, following
standard settings in the PLC, as long as the drive system is
running. If the pump can not build up pressure or if there is low
level in the container, an alarm is activated.
Evaporator fans
The fans start automatically, in sequence, when production or
drying is started. It is also possible to start single fans sepa-
rately.
Fan alarm indicator
If a fan stops due to an overload, an alarm is activated. Investi-
gate the reason and remedy before resetting the alarm. The
overload protection must be manually reset. When the air tem-
perature rises above 55 °C, the fans stop and an alarm is acti-
vated.
Air balance fan 1)

The air balance fan is started automatically in production mode,
provided that any of the other fans are in operation. If the air
balance fan stops due to an overload, an alarm is activated.
Curve loader 1)
The curve loader is syncronized with the belt drive and starts
automatically when the belt is started. Both the curve loader and
the belt is stopped if a curve loader alarm is activated.
Belt Defrost unit - BDF 1)

The Belt Defrost unit uses high compressed air to remove snow
and debris from the belt. In production mode the BDF is auto-
matically selected. When the production is started, the BDF
runs in intervals. The BDF stops automatically when the produc-
tion is stopped. Time between BDF-actions is set in the “Equip-
ment configuration screen”.

2) Only valid for Descending equipment.
3) Only valid for Twinstack equipment.
MANUAL 1000 51
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FUNCTION
Air Defroster - ADF 1)
The ADF constantly moves back and forth over or under the
evaporator according to a predetermined pattern. The ADF
starts automatically when production is started. The ADF stops
instantly when production is stopped. When production mode is
deselected, the ADF runs to its parking position and then stops.
ADF alarm
If the ADF is started when the equipment temperature is below
freezing point, an alarm is activated. If the ADF stops due to an
overload or because it has passed the turning point (where it
activates a safety limit switch), an alarm is activated.
Cleaning systems 1)
Product Zone Cleaner - PZC
The PZC consists of an semi-automatic defrosting and cleaning
program. If the PZC is started when the rail temperature is
below 7 °C (15 °C for upflow air direction in belt stack), the PZC
stops and an alarm is activated. The heavy duty pump1) starts
automatically during rinsing. If the PZC is stopped due to an
overload of either the belt drier fan, the pump or the heavy duty
pump1), an alarm is activated.
Product Zone and Evaporator cleaner - PZE

The PZE consists of an semi-automatic defrosting and cleaning
program. The heavy duty pump1) starts automatically during
rinsing. If the PZE is stopped due to an overload of either the
belt drier fan, the pump or the heavy duty pump1), an alarm is
activated. At certain points in the program, there are inspection
stops. During an inspection stop, the attention signal is acti-
vated. Press the start button to continue the program.
Cleaning In Place - CIP

The CIP is a complete sanitation program. The heavy duty
pump1) starts automatically during rinsing. If the CIP is stopped
due to an overload of either the belt drier fan, the pump or the
heavy duty pump1), an alarm is activated. At certain points in the
program, there are inspection stops. During an inspection stop,
the attention signal is activated. Press the start button to con-
tinue the program.
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FUNCTION
Chill request 1)
It is possible to choose between two preset evaporation tem-
peratures. An output signal is sent to the refrigeration unit that
the equipment requires the second preset evaporation tempera-
ture.
Cold keeping 1)
Signal to the refrigeration unit that the freezer is in cold keeping
mode and might require refrigerant. A preset temperature is
maintained in the freezer, as closely as possible. This is
achieved by starting and stopping one fan and by requesting
refrigerant if required.
If the temperature rises above the alarm limit, an alarm is acti-
vated and the program is terminated. The cold keeping se-
quence is repeated until another mode is selected or if an alarm
is activated.
)
Warning
It is important that the suction valve is open
when the liquid valve is closed. This is to pre-
vent too high level of refrigerant and too high
pressure in the evaporator.
Cold keeping storage

Stores product in the freezer for a short time, for example over
the night. The evaporator fans run for one belt revolution (ac-
cording to previous settings) in order to freeze/chill the last
inserted products.
Cold keeping with belt running

Keeps the freezer cold without products during shorter periods,
for example over the night.
MANUAL 1000 53
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FUNCTION
Connection to the refrigeration unit
The equipment uses the following signals to communicate with
the refrigeration unit. Parameters might be changed depending
on equipment type and installed system.
Standard signals
Refrigeration request
• Signal to the refrigeration unit that the equipment is starting
production and requires refrigerant. During production stops,
this request remains for default 10 minutes.
Refrigeration running
• Signal from the refrigeration unit that the refrigeration unit is
in operation.
Extended signals 1)
Alarm condition
• Alarm signal from the refrigeration unit, an alarm is acti-
vated.
Not allowed to start fans

• Signal from the refrigeration unit that the fans are not al-
lowed to run. If this signal remains more than 30 minutes,
an alarm is activated.
External defrost
• Defrost request
Signal to the refrigeration unit to start external defrost.
If no response is received within 30 seconds, an alarm is
activated.
• Defrost in progress
Signal from the refrigeration unit that external defrost is
started. The freezer control panel is locked during external
defrost except for emergency stops and internal safety
system.
• Start fans
Request from the refrigeration unit to start the fans. During
external defrost the fans are controlled by the refrigeration
unit.
Fan running
• Signal to the refrigeration unit that one (or more) fan is
running.

~~~
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03 - 02 MANUAL
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FUNCTION
SERVICE HANDLE
Personnel safety system
The equipment is provided with a safety system designed to
ensure maximum safety for operating and maintenance person-
nel, but still allow easy inspection and maintenance work. The
system is also designed for maximum reliability and to comply
with safety norms such as the European Union Machine Direc-
tive 98/37/EC and the US OSHA regulations etc.
Function
The rule of no person inside the equipment while any moving
parts are in operation will have to be overruled by authorised
maintenance personnel.
For their safety and benefit there is a service handle(s) with a
flexible cable easily accessible in a holder on the equipment
wall.
The service handle by-passes the door/gate safety switch and
allows remote emergency stop and restart function. The service
handle can be used during production and when the equipment
is in low operating temperature.
The service handle is provided with a grip button. As long as the
grip button is pressed to its middle position running functions will
continue to run. If the grip button is either released or pressed to
hard, the equipment shuts down.
See further in manual sheet “Operation, Service handle”.
)
Warning
The person who starts any function via the
service handle is responsible for the safety and
must make sure that no one can come to harm.
Control panel override

As long as the service handle is out of its holder, nothing can be
started from the control panel. It is only possible to stop the
equipment process or deselect single functions.
~~~
MANUAL 1000 55
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FUNCTION
2/2 1000 - 04 - 01 -56

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FUNCTION
PRODUCT ZONE CLEANER - PZC

(Optional equipment)
1
Pump station
Picture in general
2
14 1. Air supply
3 2. Electric box
13 3. Water / detergent outlet
4. Filter regulator for air
12 4 5. Dosing valve for detergent (I)
11 6. Water outlet, solenoid valve (manual)
10 1
5 7. Water / foam valve (manual)
9 2
8 3
10 7
6 5
4
8. Detergent container (I)

6 9. Pump
9 10. Solenoid valve, rinse injector
7 11. Flow switch
12. Filter
13. Water valve
14. Water supply
8 The PZC pump station is an automatic low-

pressure pump station for foaming and rinsing.
All necessary valves, strainers, regulators and
gauges are included.
A PLC program controls the valves.
The PZC sequence can be followed in the
control unit. For further information see chapter
Operation, “Control unit”.
The rinse water valve supplies the belt rinser
with approx. 100 litre/min of water. The detergent
valve and the air plant supply valve supplies
approx. 150 litre/min foam for belt foaming. The
foam is a mix of approx. 10 litre of water, 140
litre of air and a small amount of chemicals.
The flush valve cleans the detergent valve and
ejector of remaining chemicals. All valves in the
pump station are normally closed.
For further description and flow chart see sup-
pliers “Directions for use”.
MANUAL 1000 57
- 04 - 01 - 12 - 01 1/2
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FUNCTION
Belt foaming
15 15. Water pipe
16. Spray nozzles
A pipe from the pump station supplies foam to

the nozzles which are located at the top of the
belt stack. The nozzles are wide angle, flat
spray nozzles and apply foam across the belt.
The belt is then rinsed by the belt rinser.
16
Belt rinser
17. Spray nozzles
18. Belt drier fan
17 18 19. Air knife
A pipe with spray nozzles is located inside the

equipment at the infeed end. Flat spray nozzles
create a curtain across the running belt and
rinse the mesh and side links. The water is
supplied by the pump station.
Belt drier fan

The freezer uses a separate centrifugal fan to
dry the belt. The air is led to the air knife which
19 distributes the air across the running belt and to
the side links and dries the belt. The air knife is
located directly after the belt rinser.
~~~
2/2 1000 - 04 - 01 -58

12 - 01 MANUAL
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FUNCTION
AIR BALANCETUNNEL
1
1. Air directing plate
2. Perforated sheet
It is important that no air is sucked into or out of

the freezer through the infeed or outfeed open-
ings. This would cause ice to form on the
evaporator and create climate problems around
the freezer.
To guarantee a good air balance, your freezer is
2 equipped with an air balance tunnel.
Fan driven tunnel (optional)

Air is circulated in the air balance tunnel by the
fan. The fan creates pressure, forcing the air
down through the air directing plate, the belt and
the perforated sheet.
In this way an air curtain is created, preventing
air from escaping through the opening.
The fan speed can be adjusted from the electric
control panel to achieve a perfect air balance.
~~~
MANUAL 1000 59
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FUNCTION
2/2 1000 - 04 - 01 -60

20 - 00 MANUAL
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OPERATION
MANUAL 0000 61
- 05 - 01 - 00 - 00 1/2
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2/2 0000 - 05 - 01 -62

00 - 00 MANUAL
O-1320174_gb
OPERATION
SAFETY PRECAUTION
Always make sure:
that equipment is handled by trained staff.
to understand all warning signs on the equipment.

to identify location of all emergency stops.
to wear suitable protective clothing.
that clothing, hair, etc. does not risk getting caught in the belt or
other moving parts.
Note!
The local conditions where the equipment is installed may vary
and further safety precautions and guards may be required, i.e.
where in- and out-feed conveyors join the equipment.
We recommend the owner of the equipment to carry out a
safety inspection, as suggested in EU Directive 95/63/EC §2,
to establish if further precautions are needed!
OPERATING GUIDE 63- 01 - 01 - 07

0000 - 05 1/2
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OPERATION
to walk carefully in or outside the equipment during maintenance
and inspections. The floor may be slippery.
never to step on the belt.
to switch off the main power supply and lock with a pad lock
before any mechanical or electrical work begins (Lock out Tag out).
)
Warning
The internal lighting, Pc power-supply and electrical
cabinet ventilation fan are not connected to the
main switch and remain live even when the main
switch is in position ‘0’.
)
Warning
Certain components, such as fans will continue to
rotate several minutes after beeing switched off.
Do not enter the freezer before they come to a
stand still.
Open fan guards

To prevent frosting up of the evaporator during long operating hours
some equipment is provided with open fan guards.
This openings exceed the values specified in the European Norm
“EN-294, Safety of Machinery - Safety distance to prevent danger
zones being reached by upper limbs”. To protect the operating
personnel, the fans are switched of automatically when any door or
door gate is opened. The fan wheels however, continue to rotate for
several minutes after the power is switched off.
For further information see your Owner’s Manual - General Information

and Safety.
~~~
2/2 0000 - 05 - 01 - 0164

- 07 OPERATING GUIDE
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OPERATION
MAIN COMPONENTS
2 3 Schematic view
1 1. Conveyor belt
4 2. Evaporator
3. Cooling fans
4. Outfeed unit with release
plate
5. Air balance tunnel 1)
6. Air Defroster-ADF 1)
7. FRIGoDRIVE® chain
(external)
8. FRIGoDRIVE chain
(internal)
9. Infeed unit
5
10. Product height limiter
6 11. Control panel
7
8 In general
11
10 9
Control panel
12. Control unit with touch
surface, HMI
13. Emergency stop
14. Main switch
12
13
14
® = Registered trade mark of FMC FoodTech AB.

OPERATING GUIDE 1000 65

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OPERATION
SAFETY SWITCHES AND SENSORS

General pictures and positions
23
22 17 21
15
20 25 24
19 17
15
21
18
16 15
Safety switches
15. Emergency stops located at
- Control panel
- Infeed unit
- Outfeed unit
16. Belt tension switch
17. Belt position switches
18. Product height limit switch 1)
19. Door switch(es)
20. Belt compressor limit switch
Sensors
21. FRIGoDRIVE rail temperature
22. Air temperature
23. Evaporation temperature
24. Total differential pressure 1)
25. Air temperature for cold keeping 1)
~~~
2/2 1000 - 05 - 01 -66

17 - 01 OPERATING GUIDE
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OPERATION
SERVICE HANDLE
The equipment is provided with a service handle which allows
maintenance people to inspect and maintain the equipment while
it is in operation. The service handle by-passes the door/gate
switch.
Note!
The service handle is to be used by maintenance personnel
only.
)
Warning
The person who starts any function via the
service handle is responsible for the safety and
must make sure that no one can come to harm.
• We strongly recommend that persons who are to be

authorized to use the service handle are properly trained on
the safety system.
A B C A. Grip button with three positions

Grip not pressed: functions stop
Grip pressed to middle position: functions run
Grip pressed to bottom position: functions stop
B. Indication
Green light: functions run
Red light: functions stop
C. Restart button
Using the service handle

1. Start a single function or a program in the control unit.
2. Press the grip button on the service handle to the middle

position (green light) and lift the handle from its holder.
• The chosen functions will continue to operate.

• The attention signal is activated and will remain as long
as the handle is out of its holder.
• The service handle symbol is shown instead of the start
symbol in the control unit.
• Now nothing can be started or selected to start in the
control unit. The equipment can always be stopped in the
control unit or by using one of the emergency stops.
)
DANGER!

- 05 - 01 - 02 - 01 1/2
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OPERATION
• As long as the grip button is in its middle position, the
door/gate switch adjacent to the service handle holder is by-
passed. Access is now possible to the equipment. Be
careful with the cable and make sure that it is not tangled up
in moving parts or otherwise causing hazards.
• If the grip button is either released or pressed too far (red
light), the equipment shuts down.
The fans will however continue to rotate for minutes from
when switched off. Do not open the plenum chamber door
until they have come to a complete stop.
3. If the equipment is stopped, press the grip button back into

the middle position (green light) and then press the restart
button. Now whatever was running before, will restart.
This provides a practical jogging function, for inspection and
maintenance of the equipment.
4. After use, put the service handle back in its holder in the
protective box and press the reset button.
Note!
To be able to start the equipment, make sure to press the
reset button in order to reactivate the control unit and all the
normal safety functions.
• The cable can be coiled up and hanged on the hook under

the protective box.
• We recommend the protective box to be provided with a
padlock, to ensure only authorised use of the system.
~~~
2/2 1000 - 05 - 01 -68

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OPERATION
? BEFORE START
?
Precautions before starting
??
1. Check that no one is inside the equipment.
??
?? ?
???
???
2. Check that the belt stacks correctly, and that all inside
covers are set in correct position.
???
??
??
???
??
???
?? 3. Check that the belt is not stuck at in- or outfeed.
????
??
Check that the outfeed release plate is adjusted according to
product.
????
??
???? 4. Check that the equipment is thoroughly dried. If not run the
drying program.
5. Check that all doors and water discharges are closed.

Press the silent alarm button on the control unit to reset the
safety relays.
~~~
OPERATING GUIDE 1000 - 05 69

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OPERATION
2/2 1000 - 05 - 01 - 04 70
- 01 OPERATING GUIDE
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OPERATION
STARTING
1. Press the mode button.
2. Select production mode.
3. Close the pop-up window.
Note!
The belt must be running when the temperature drops below
freezing point.
If FRIGoPAK® LVS is installed:
Make sure that the FRIGoPAK mode selector switch is in re-
mote position.
Starting, using recipe

1. Go to the recipe screen.
2. Select desired recipe from the list.
3. Download the recipe.
4. Go to previous screen.
5. Press the start button. The belt starts after a belt start
warning and the fans start in sequence.
6. Open valve(s) for refrigerant supply (see separate instruc-

tion).


- 05 - 01 - 05 - 02 1/2
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OPERATION
Starting, manual selections

1. Select/deselect functions and adjust settings if needed.
2. Press the start button. The belt starts after a belt start
warning and the fans start in sequence.
3. Open valve(s) for refrigerant supply (see separate instruc-

tion).
See chapter “Operation, Control unit” for further information.
~~~
2/2 1000 - 05 - 01 -72

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OPERATION
1 2 DURING PRODUCTION
Regularly check:
1. Air temperature
2. Air balance fan speed 1)
3. Holding time or belt speed
4. Rail temperature
5. Evaporation temperature
3 4 5
Alarms
If a fault occurs the alarm signal is set.
)
Warning
It is very important to investigate the reason and
remedy before resetting any alarm.
See chapter “Operation, Alarms and troubleshooting”

for further information.
Noise
Check for abnormal sounds.
Pausing production
1. Press the stop button (all functions will be
stopped). The refrigeration request signal
will remain for 10 minutes.
2. Press the start button to restart the

production.
See chapter “Operation, Control unit” for further

information.
1)
Optional or not on all equipment.
~~~

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OPERATION
2/2 1000 - 05 - 01 -74

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OPERATION
STOPPING
1. Run the equipment until it is emptied from products.
2. Press the stop button (all functions will be stopped). The

refrigeration request signal will remain for 10 minutes.
4. Deselect production mode (all functions will be deselected).

The refrigeration request signal is cancelled.
6. The ADF (if installed) will continue to the parking position

and then stop.
7. Shut refrigerant supply.
~~~
OPERATING GUIDE 100075

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OPERATION
2/2 1000 -05 - 01 -07

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OPERATION
ALARMS ANDTROUBLESHOOTING
Alarms
If a fault occurs the alarm signal is activated. The alarm text is
shown in the system information bar. The alarm indication sym-
bol is also shown on the screen. See alarm list for reason and
remedy.
)
Warning
It is very important to investigate the reason and
remedy before resetting any alarm.
Production related alarms are shown on the production screen

and cleaning related alarms are shown on the cleaning screen.
LVS-related alarms are shown on the LVS overview screen.
Press the symbol to get further information.
Belt safety related alarms are indicated with a belt symbol on

the production screen. Press the symbol to get further informa-
tion from the belt alarm screen .
The silent alarm button turns yellow. Press the button to turn off
the attention signal. The red alarm light remains lit until the fault
is cleared and the alarm is reset.
The alarm screen button turns yellow and flashes with a red
border. Press the button to access the alarm screen, current
alarms are shown.
Press the button to view alarm history. After the fault is cleared,
press the alarm/reset button to reset the alarm.
Alarm reset and indication (non critical alarm)
Alarm reset and indication (critical alarm, if applicable)

- 05 - 01 - 15 - 03 1/8
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OPERATION
Alarm indications and remedy

The alarm lists show all possible alarms, depending on equip-
ment type and installed system.
Symbol Alarm text Reason / remedy

Inner belt motor Call authorised service personnel.
Check that gear motors and all mechanical par ts move freely.
Check that products are not stuck to the belt.
Outer belt motor
Outfeed motor
Auxiliary motor
Take-up motor
Driven ring motor
Curve loader motor
Infeed motor
Infeed conveyor motor
Outfeed conveyor motor
Air balance fan 1 motor Call authorised service personnel. Check reason for overload
and reset motor circuit breaker. Check motor windings and
wiring.
Air balance fan 2 motor
ADF 1 motor Check for snow and ice on the ADF rail.
Check the screw spindel and try to find reason for overload.
Check motor windings and wiring, reset motor circuit breaker.
ADF 2 motor
CIP pump 1 motor Call authorised service personnel. Check reason for overload
wiring.
CIP pump 2 motor
HD pump 1 motor
HD pump 2 motor
Belt drier fan 1 motor
Belt drier fan 2 motor
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OPERATION
Fan 1 motor Call authorised service personnel. Check reason for overload
wiring.
Fan 2 motor
Fan 3 motor
Fan 4 motor
Fan 5 motor
Fan 6 motor
Fan 7 motor
Fan 8 motor
Fan 9 motor
Fan 10 motor
Fan 11 motor
Fan 12 motor
Fan 13 motor
Fan 14 motor
Fan 15 motor
Fan 16 motor
Low speed fan Call authorised service personnel. Check reason for overload
wiring.

- 05 - 01 - 15 - 03 3/8
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OPERATION
Inner chain tensioner Too shor t or too long chain or chain breakage. See chapter
"Corrective maintenance. Check chain passage.
Outer chain tensioner
Outfeed tension Belt tension too high, call auhtorised ser vice personnel.
Auxiliar y chain tensioner Too shor t or too long chain or chain breakage. See chapter
"Corrective maintenance. Check chain passage.
Take-up / Belt compressor limit Long belt: Check return rail/shor ten belt.
Shor t belt: Check outfeed drive. Belt catching somewhere
inside the freezer. Find reason for belt catching and free the
belt. Wrongly adjusted or faulty safety switches. Adjust or
replace safety switch.
Decending / Upper tier limit Check belt and belt drive. Check that the chain could move
freely.
Cur ve loader take-up limit Check length/shor ten cur ve loader belt. See chapter,
Preventive and corrective maintenance.
Infeed tension Shor t belt: Check outfeed drive.

Belt catching somewhere inside freezer. Find reason for belt
catching and free the belt. Wrongly adjusted or faulty safety
switches. Adjust or replace safety switch.
Product height limit Max. product height exceeded. Remove product or pile up of
product. Deformed side links. Straighten side links or if
necessar y replace a piece of belt.
Belt position limit Destacking or ice on rail. Check and correct, remove any ice.
Belt expanding / off stack limit Check if diameter on the stack is to big.
Check for damage on the belt.
Belt sag limit Check belt and belt drive. If there are no mechanical problems,
press the "Belt sag adjustment" button. Otherwise call
authorised ser vice personnel.
Belt bridge limit Belt bridge out of postition. If there are no mechanical
problems, press the "Belt bridge adjustment" button. Otherwise
call authorised ser vice personnel.
Inner ball chain limit Restriction of balls in ball return area. This is a serious
problem, call authorised ser vice personnel. Never reset the
alarm and tr y to restar t.
Outer ball chain limit
ADF 1 safety limit Check function of the limit switches for direction change. See
chapter Preventive and corrective maintenance. Check and
unload safety switches before restar t.
ADF 2 safety limit
ADF 1 home switch (LS)
ADF 1 turn switch (LS)
ADF 2 home switch (LS)
ADF 2 turn switch (LS)
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OPERATION
Door I Door/gate is open. Check where and why. Warning! Make
sure nobody is inside the equipment.
Door II
Door III
Door IV
Fan blocked too long The fans are blocked too long by the refrigeration unit (default
2 minutes). Check external refrigeration system.
Too low temperature cleaning Too low temperature to star t cleaning. Defrost the freezer and
restar t the cleaning.
ADF star t at low temperature The ADF has been star ted at too low temperature. Check that
the ADF is moving an blowing correctly.
Too high temperature equipment External refrigeration not star ted or fans stopped. Check
reason.
Too high temperature cold keeping
Production temperature out of range If the temperature is too high, check the evaporator and the
valves for refrigerant.
If the temperature is too low, check function of the temperature
sensor.
Emergency stop Check reason with the person who has activated the
emergency stop.
Rail temperature Too warm in upper par ts of the freezer, if air temp. is above
freezing point, this could lead to ice build-up. Check for and
remove ice build-up on rails, take-up etc. During operation:
Check freezer temperature. During defrosting: Wait for rail to
reach correct temperature.
External defrost External defrost not possible. Check external refrigeration
system.
Lubrication low level Fill oil according to chapter Preventive maintenance,

Lubrication.
Lubrication low pessure Check oil pump for reason. See chapter Corrective
Maintenance.
External refrigeration Check external refrigeration system.
Refrigeration replay Check external refrigeration system.
Defrost, fan spray water Check water flow.

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OPERATION
Door and floor heating Check the heating cables for visible damage. Call authorised
service personnel.
Curve loader heating See chapter "Preventive and corrective maintenance curve
loader".
Drain hatches in wrong position Check and correct the positions of the hatches.
In/outfeed hatches in wrong position
VFD, main drive See suppliers instruction.
VFD, main drive, Stack 2
VFD, outfeed
VFD, take-up
VFD, infeed conveyor
VFD, outfeed conveyor
VFD, air balance fan I
VFD, air balance fan 2
VFD, low speed fan
VFD, communication fault Check VFD communication cable.
PLC - HMI communication fault Check cable between PLC and PC.
ADF low pressure The working pressure in the ADF is too low. Check reason.
Fan vibration limit Check for ice build-up on fans. Remove the ice and call
authorised ser vice personnel. Check and tighten motor
assembly bolts.
LVS level switch logical failure Call skilled/cer tified refrigeration ser vice personnel!
Note! If the "LVS level switch logical failure" fault is not
solved within 45 minutes, "LVS level switch time out"
LVS level switch time out alarm may be activated. For fur ther information, see
chapter "Corrective maintenance, LVS troubleshooting".
LVS level warning Call skilled/cer tified refrigeration ser vice personnel! For
fur ther information, see chapter "Corrective
maintenance, LVS troubleshooting".
LVS high level
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OPERATION
Troubleshooting
Belt stopped.
Equipment not working.
ê
Identify alarm symbol
Alarm activated? Yes è Press alarm reset. è
and see reason/remedy.
No
ê
Check supply fuses. Call
Power to electric cabinet? No è
electrician.
Yes
ê
Check control fuses.
Is main switch on? Yes è
Call electrician.
No
ê
Turn main switch on.
Press alarm reset.
Star t up equipment.

- 05 - 01 - 15 - 03 7/8
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OPERATION
Products not frozen.
Freezer does not get cold.
ê
Check motors or alter
Are all fans running and if so,
No è rotation according to
in right direction?
arrow on fan wheel.
Yes
ê
Check
Is air flow through evaporator Is freezer equipped
Yes è Yes è function of
restricted by snow build-up? with ADF?
ADF.
No No
ê ê
Close all drain Are any doors or drain
ç Yes Defrost evaporator.
hatches, doors, etc. hatches open?
No
ê
Close all sheetings Is any door or sheeting
ç Yes
hatches, etc. inside the freezer open?
No
ê
See loading
Is recommended loading recommendations in
No è
pattern used? chapter "Application
Data".
Yes
ê
Is the evaporator temperature
correct according to No è Check refrigeration unit.
specification?
Yes
ê
Is liquid refrigerant distributed
to the evaporator(s) as No è Check refrigeration unit.
specified?
Yes
ê
Is oil drained regularly from
No è Drain oil.
evaporator and surge drum?
Yes
ê
Call FMC FoodTech.
~~~
8/8 1000 - 05 - 01 -84

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OPERATION
DEFROSTING
Water or hot gas defrosting.
General
• Every time the equipment is defrosted it should be
thoroughly cleaned.
• Local conditions must be taken into consideration during
defrosting.
!
Caution
Do not start the belt until all steel parts have a
temperature above freezing point.
• If FRIGoPAK LVS is installed: Make sure that the

FRIGoPAK mode selector switch is in remote position.
• The equipment can also be defrosted by spraying hot water
inside the freezer.
Note!
As soon as a door/gate is opened, the equipment stops and an
alarm is activated.
Before defrosting
1. Remove as much product debris and frost as possible while
it is still frozen.
2. Open the equipment door(s) provided with a safety gate

inside. Open all drain covers.
3. Close the refrigerant supply valve (controlled by the refrig-

eration unit).
5. Select cleaning mode.
Note!
You have to deselect and select cleaning mode again to be able
to restart or select a new cleaning program. This to secure that
a cleaning program is not started by mistake.

- 05 - 01 - 18 - 02 1/4
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OPERATION
Manual defrosting
1. Go to the recipe manager screen.
2. Select the desired defrosting recipe from the list.
5. Press the start button. Let the fans run for approximately 5-
15 minutes in order to empty the evaporator from refrigerant.
6. Press the stop button.
7. Open the defrosting valve(s). Leave the valve(s) open for

15-20 minutes until all frost has melted from the evaporator.
8. Let the water drip from the evaporator for about 5 minutes.
10. Deselect and select cleaning mode again.
12. Press the start button in order to start the belt and fans.
The fans will stop automatically according to settings (mini-
mum 20 minutes).
2/4 1000 - 05 - 01 -86

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OPERATION
Automatic defrosting
(only valid for PZE and CIP)
2. Select the desired defrosting recipe from the list.
5. Press the start button. The defrosting will be automatically

performed and no other functions will work until the defrost
is completed.
~~~

- 05 - 01 - 18 - 02 3/4
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OPERATION
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OPERATION
MANUAL CLEANING
General
• FMC FoodTech recommends low pressure foam cleaning
and disinfection which gives an optimum utilization of water
and chemicals.
• Rinse the equipment with hot water (maximum 60°C).
• Use only chemicals recommended by FMC FoodTech, or
equal.
• In order to reduce recontamination, always rinse and foam
from top to bottom.
• Make sure that the equipment is thoroughly rinsed from
detergent and disinfectant.
• Do not spray water directly on electrical components.
• Follow suppliers safety instructions for cleaning solution.
• Always wear proper protective clothing during cleaning.
)
Warning
Always be careful with moving parts in the
freezer during cleaning.
)
Warning
The evaporator fins are extremely sharp! Use
caution when working in and around the freezer.
!
Caution
Do not start the belt until all steel parts have a
temperature above freezing point.
Note!
alarm is activated.

- 05 - 01 - 55 - 04 1/8
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OPERATION
In order to reduce recontamination, always rinse and foam from
top to bottom in the following order:
Mezzanine floor level
• Ceiling and walls
• Between evaporator and wall (only valid for GCM58-106)
• Outfeed rail with belt lifter
• Outfeed tunnel
• Inside spray box
• Mezzanine floor (rinse to ground floor level)
Ground floor level
• Mezzanine ceiling and walls
• Between evaporator and wall (only valid for GCM6-M10)
• Take-up (only valid for GCM58-106)
• Return rails
• Drive system and chain tensioners
• Evaporator plenum chamber
• Floors and drains
• Infeed and outfeed units outside the equipment
Before start
1. Defrost the equipment according to chapter “Operation,
Defrosting / cleaning”.
Note!
!
Caution
To secure the lubrication of balls and rails you
have to select the manual cleaning recipe during
rinsing in order to get intense lubrication during
cleaning.
Note!
The rail temperature must be +7 °C or above before you can
start the belt.
2/8 1000 - 05 - 01 -90

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OPERATION
Rinsing
1. Enter the equipment and rinse from top to bottom with hot
water. Inspect drive components under the stack. Check
that the drive system (ball rails and chains) is free from ice
and frost.
2. Close all doors.
4. Select the manual cleaning recipe.
7. Press the start button in order to start the belt.
8. Rinse the belt at the infeed or outfeed unit to remove loose

product debris, use hot water. The belt stops after one belt
revolution.

- 05 - 01 - 55 - 04 3/8
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OPERATION
Foaming detergent
1. Foam the equipment with detergent, use cold water.
6. Foam the belt with detergent at the infeed or outfeed unit

until the entire belt is foamed, use cold water. The belt stops
after one belt revolution.
7. Let the detergent work for a few minutes.
Rinsing after detergent

1. Rinse the equipment, use hot water. Make sure that all
detergent is rinsed off.
6. Rinse the belt at the infeed or outfeed unit, use hot water.
Make sure all detergent is rinsed off. The belt stops after
one belt revolution.
7. Rinse the equipment floor.
4/8 1000 - 05 - 01 -92

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OPERATION
Foaming disinfectant
1. Foam the equipment with disinfectant, use cold water.
Foam the belt from the top of the belt stack.
6. Select the drying recipe.
This will press the disinfectant down through the belt stack.
10. Stop the drying program after a few minutes by pressing the
stop button.
11. Let the disinfectant work for 15 minutes (or according to

chemical suppliers recommendations).

- 05 - 01 - 55 - 04 5/8
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OPERATION
Rinsing after disinfection
(if applicable)
1. Rinse the equipment, use hot water. Make sure that all
disintectant is rinsed off.
6. Select the manual cleaning recipe.
10. Rinse the belt at the infeed or outfeed, use cold water.
Make sure that all disinfectant is rinsed off. The belt stops
after one belt revolution.
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OPERATION
Drying
1. Open the door(s) provided with a safety gate.
6. Select the drying recipe.
The fans will stop automatically according to settings (min.
20 minutes).
10. Check that the belt is thoroughly dried. If not, start the
drying recipe once more.
~~~

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OPERATION
8/8 1000 - 05 - 01 -96

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OPERATION
CLEANING SYSTEM
(Option)
• FMC FoodTech recommends low pressure foam cleaning
and disinfection which gives an optimum utilization of water
and chemicals.
• Rinse the equipment with hot water (max. 60°C).
• Use only chemicals recommended by FMC FoodTech, or
equal.
• In order to reduce recontamination, always rinse and foam
from top to bottom.
• Make sure that the equipment is thoroughly rinsed from
detergent and disinfectant.
• Do not spray water directly on electrical components.
• Follow suppliers safety instructions for cleaning solution.
• Always wear proper protective clothing during cleaning.
)
Warning
Always be careful with moving parts in the
freezer during cleaning.
)
Warning
The evaporator fins are extremely sharp! Use
caution when working in and around the freezer.
!
Caution
Do not start the belt until all steel parts have
reached a temperature above freezing point.
Note!
alarm is activated.

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OPERATION
Before cleaning
1. Remove as much product debris and frost as possible while
it is still frozen.
2. Only valid for PZR and PZC:

Defrost the equipment manually according to chapter
“Operation, Defrosting”.
3. Only valid for PZC, PZE and CIP:

Check that the amount of detergent and disinfectant is
sufficient.
4. Only valid for Heavy Duty pump:

Close the drain valve and check that the strainers are
clean.
5. Close the doors and open the drains.
Starting cleaning
Note!
5. Select the defrosting recipe.
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OPERATION
8. Press the start button.
During cleaning
• To manually pause the cleaning recipe at any time, press
the stop button. Press the start button to continue the clean-
ing.
• Only valid for PZE and CIP:

The system will pause after some of the sequences allow-
ing inspection, manual cleaning and rinsing of the equip-
ment. The inspection symbol turns green and the attention
signal is set. Turn off the attention signal.
• Every time a door has been opened, close the door and
reset the alarm. This is important in order to reset the safety
relays and to be able to restart the cleaning. Press the start
button to continue.
Manual inspections and cleaning

Valid for PZR, PZC, PZE
• Clean the rest of the the equipment according to chapter
“Operation, Manual cleaning”.
Valid for CIP

After equipment defrost and rinse:
• Check that the equipment, especially the drive system
(ball rails and chains), is free from ice and frost.
• Set the spray gun mode selector switch in position “water”
and rinse the equipment.
Mezzanine floor level
- outfeed rail with belt lifter
- outfeed tunnel
- walls and roof around evaporator
- mezzanine floor (rinse to ground floor level)
Ground floor level
- take-up
- infeed and outfeed unit outside equipment
- return rails
- chain tensioners
- floor and drains

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OPERATION
After detergent:
• Set the spray gun mode selector switch in position “foam”
and foam the equipment.
• Infeed and outfeed unit outside equipment.
• Outfeed tunnel
• Return rail
• Chain tensioners
After equipment rinse:

• Set the spray gun mode selector switch in position “water”.
• Inspect the equipment and rinse if necessary.
• Make a final rinse of floors and drains.
• Rinse the infeed and outfeed units outside the
equipment.
~~~
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- 60 - 03 OPERATING GUIDE
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OPERATION
AIR BALANCETUNNEL
A (air direction in the belt stack - downflow)
A. Air directing plate
B. Perforated sheet
For good air balance:

• products should be distributed over the
entire belt, both in freezer and tunnel.
• the main doors and those inside the freezer
should all be closed.
B • the hatches on the tunnel should be com-
pletely closed.
• the air directing plate should be placed
according to illustration.
• the perforated sheet should be placed with
the largest perforations towards the outfeed
opening.
Cleaning
1. Open the hatches and remove the air direct-
ing plate and the perforated sheets. If there
is a cover, remove it.
2. Clean all parts.
3. Clean the inside of the tunnel.
4. Return all parts to their original position after
cleaning.

Adjustment of the the air balance
If air blows in or out through the infeed or
outfeed opening, adjust the fan speed.
The air balance is adjusted by altering the fan
speed, operated from the electrical control
panel.
Note!
Adjustment of the fan speed should be done with
cold freezer during production.
!
Caution
Switch off the belt before entering the freezer.
~~~

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OPERATION
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OPERATION
CONTROL UNIT
The control unit has a graphic display with touch surface, HMI
(Human Machinery Interface).
There are a number of different screens available for different
equipment processes and functions.
On every screen there is common information according to the
picture below. The screen varies depending on installed system.
System information bar

1 2 3 4 5 6 7 8 1. Last down loaded recipe
2. Name of displayed screen
3. Selected mode status
4. Log in/out
5. Log in name
6. Latest alarm
7. Date and time
Screen select bar
8. Screen buttons
Equipment control bar
9. Stop equipment
10. Start equipment
11. Mode selector
12. Alarm/reset
13. Silent alarm
14. Return to previous screen
9 10 11 12 13 14

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OPERATION
Screen overview
Process overview 1)
Follow the production line, only
valid if process overview is
installed. The picture shows an
example of a layout.
Production
Follow the production, select/
deselect functions and change
parameters.
Production recipe is selected in
the recipe manager.
Activated production alarms are
shown.
Cleaning
Follow the cleaning sequences.
Cleaning recipe is selected in
the recipe manager.
Activated alarms in the cleaning
equipment are shown.
Recipe manager
Create, select and change
recipes for easy and quick
handling of production and
cleaning.
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OPERATION
Real-time data
View actual data such as
temperatures and belt speed.
You can also view a trend for
each data.
System configuration
Get access to following func-
tions: computer time, security
and utilities.
Maintenance
Get access to special func-
tions.
Alarms
View current alarms and alarm
history.

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OPERATION
Status
All symbols have different colours depending on status.
Available (not selected) = grey
Selected but not started = half grey half green
Running = green
Started/paused = green with a sandglass
Stopped = half grey half green with a stop sign
Alarm = yellow
Non-selectable
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OPERATION
Service handle
To allow inspection of moving parts inside the equipment while
in operation, the equipment is provided with service handle(s).
As soon as a service handle is lifted out of its holder, the belt
start warning signal is activated and the service handle symbol
will pop-up instead of the start button symbol.
Now nothing can be selected or started from the control unit. It
is only possible to stop the equipment process or deselect
single functions.
Selected functions can be started or stopped from the service
handle.
)
DANGER!
See chapter “Operation, Service handle” for further information.

- 05 - 01 - 03 - 04 5/22
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OPERATION
Alarm
If a fault occurs the alarm signal is set. The alarm text is shown
in the system information bar.
Production related alarms are shown in the production screen
and cleaning related alarms are shown in the cleaning screen.
LVS-related alarms are shown in the LVS overview screen.
Press the symbol to get further information.
Belt safety related alarms are indicated with a belt symbol in the
production screen. Press the symbol to access the belt alarm
screen to get further information.
The silent alarm button turns yellow. Press the button to turn off
the attention signal. The red alarm light remains lit until the fault is
cleared and the alarm is reset.
The alarm screen button turns yellow and flashes with a red
border. Press the button to access the alarm screen, current
alarms are shown.
Press the button to view alarm history.
After the fault is cleared, press the alarm/reset button to reset
the alarm.
Alarm reset and indication (non critical alarm)
Alarm reset and indication (critical alarm, if applicable)
See chapter “Operation, Alarms and troubleshooting” for further informa-

tion.
Alarm indicator bank

There is an alarm indicator bank. Prefereably mounted at the
infeed end of the equipment where it easily could be observed
from the control panel and the infeed unit.
The status of the indicator bank is also shown in the control unit.
The indicator bank has following indicator lights:

Attention light = Blue flashing light
Alarm light = Red light
Warning light = Yellow flashing light
Signals:
Attention signal = Attention light + siren
Alarm signal = Attention light + alarm light + siren
Belt start warning = Warning light
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OPERATION
Mode selector
You have to select mode to be able to run either production or
cleaning.
Note!
If any mode is running, this has to be deselected before a new
mode can be selected. The mode selector symbol is only ac-
cessible in the screens related to the running mode.
Production mode selector

Production mode, select/deselect.
Production mode options

Cold keeping (storage), select/deselect. 1)
Stores products in the freezer for a short time, for example over
the night. A preset temperature is maintained in the freezer. This
set point could be adjusted in the “Equipment configuration
screen”.
Cold keeping with belt running, select/deselect. 1)
Keeps the freezer cold without products with the belt running at
a preset speed (minimum speed).
Chill request, select/deselect. 1)
It is possible to choose between two preset evaporation tem-
peratures. An output signal is sent to the refrigeration unit that
the equipment requires the second preset evaporation tempera-
ture.
Cleaning mode selector

Cleaning mode, select/deselect.
Cleaning mode options
External defrost, select/deselect. 1)
External defrost is controlled by the customer. The equipment
control panel is locked during external defrost, except for the
emergency stops and the internal safety system.
Note!
to restart or select a new recipe. This is to secure that a clean-
ing recipe is not started by mistake.

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OPERATION
Production screen
1 2 3
4
15
5
6
14
7
13
8
12 11 10 9
The picture shows an example of layout
1. Last downloaded recipe

2. Fans, select/deselect and indication
3. Refrigeration request, select/deselect and indication
4. Air balance fan, select/deselect and indication
5. Air balance fan, speed setpoint
6. Production line control indication 1) 2)
7. Go to LVS overview screen 1)
8. Evaporation temperature indication
9. ADF - Air Defroster, select/deselect and indication 1)
10. Rail temperature indication
11. BDF - Belt Defrost unit, select/deselect and indication 1)
12. Curve loader indication 1)
13. Belt drive, select/deselect and indication
14. Belt speed/holding time setpoint
15. Air temperature indication

2) Selected/deselected in the maintenance screen.
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OPERATION
LVS overview screen 1)
The equipment could have one or more LVS (Low Volume
System) indicator buttons depending on installed system.
The following are shown in the LVS overview screen:

• Refrigeration status
• Evaporation pressure at evaporator
• Air and evaporation temperature
• Valve status
• Level status
• LVS alarms
The picture shows an example of layout.

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OPERATION
Cleaning screen
1 2 3 4 5
8 7 6
The picture shows an example of layout, here complete cleaning

system with CIP (optional).
Indications:
1. Last downloaded recipe
2. Cleaning device status
3. Cleaning sequences
Active sequence is indicated
4. Cleaning steps
5. Total cleaning time
6. Time left to next inspection
7. Air temperature
8. Rail temperature
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OPERATION
Device and function status
Belt run
Belt drier fan
Water pump
HD pump 1)
Disinfectant workout
Fans
External defrost
Sequence indication
Defrosting
Foaming detergent
Rinsing
Foaming desinfection
Drying
Step indication
Equipment
Evaporator
Belt
Drying
Inspection stop
Cleaning completed

- 05 - 01 - 03 - 04 11/22
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OPERATION
Recipe manager screen
From the production screen you have access to production
recipes in the recipe manager.
From the cleaning screen you have access to cleaning recipes
in the recipe manager.
Make desired selections in the recipe screen and save as a
recipe.
Save recipe.
Delete recipe.
Download recipe to PLC.
Create recipe
1. Make desired selections and adjustments in the recipe
manager.
2. Save the recipe.
3. Type a name for the recipe in the pop-up window.
4. Press OK.
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OPERATION
Select and activate recipe
1. Select recipe by name in the list.
2. Download the recipe to the PLC. Functions not included in

the recipe will be stopped/deselected. New functions will be
selected.
4. Start new functions by pressing the start button.
Delete recipe
(only valid for maintenance login)
1. Select recipe by name in the list.
2. Delete recipe.
Note!
It is possible to create, select and change a recipe during ongo-
ing production without any interference. You can then download
the recipe at any time.
Cleaning/defrosting recipes
Available recipes vary depending on installed system.
• Manual cleaning (xstd_manual)
Secures lubrication of the balls and rails during cleaning.
The belt is running to enable manual cleaning of the belt at
the in and outfeed unit.
• Drying (xstd_drying)
The fans and belt are running in order to dry or warm up the
equipment.
• PZR - Product Zone Rinser (xstd_PZR) 1)
• PZC - Product Zone Cleaner (xstd_PZC) 1)
• PZE - Product Zone and Evaporator cleaner (xstd_PZE) 1)
• CIP - Cleaning In Place (xstd_CIP) 1)
• Evaporator defrost/rinse (xstd_evaporator defrost/rinse) 1)
(only valid for GCM58-106)
• Equipment defrost/rinse (xstd_equipment defrost/rinse) 1)
• Equipment foam/rinse (xstd_equipment foam/rinse) 1)
• Disinfection (xstd_disinfection) 1)

- 05 - 01 - 03 - 04 13/22
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OPERATION
Following cleaning parameters can be adjusted:
Drying
• Minimum drying time 20 minutes (20-120 min.)
• Maximum drying time 120 minutes (30-120 min.)
• Drying shut off temperature 55°C (7-55 °C)
• Belt speed max * (5-max m/min)
Rinsing 1)
• Rinse sequence repetitions 3 times (1-5 times)
• Belt speed 15 m/min (5-15 m/min)
• HD pump select/deselect (optional) 1)
Foaming detergent 1)
• Belt speed max * (10-max m/min)
* Max belt speed = standard speed belt drive = 30 m/min

Low speed belt drive = 15 m/min
Defrosting 1)
• Evaporator defrost selected (select/deselect)
• Evaporator defrost time 15 minutes (5-25 min.)
• Equipment defrost time 10 minutes (10-25 min.)
• Equipment defrost/rinse repetitions 3 times (1-5 times)
Foaming disinfectant 1)
• Disinfection selected (select/deselect)
• Disinfection workout time 15 minutes (5-15 min.)
• Rinse after disinfection selected (select/deselect)
• Inspection pauses (select/deselect) 1)
For further information regarding cleaning recipes, see

sequence charts on the following pages.
1)
Optional or not on all equipment.
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OPERATION
Sequence chart GCM6-M10
Programs / Recipes
Sequences Eq Eq
CIP PZE PZ C PZ R defrost/ foam/ Disinf Drying
rinse rinse
Defrost / Rinse Evaporator
Equipment
Air purge Circuits
Inspect
Foaming detergent Equipment
Evaporator
Belt
Air purge Circuits
Inspect
Rinse Evaporator
Equipment
Inspect
Rinse Belt
Air purge Circuits
Foaming disinfectant Equipment
Belt
Evaporator
Workout
Rinse 1)
Air purge Circuits
Dr ying Equipment

- 05 - 01 - 03 - 04 15/22
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OPERATION
Sequence chart GCM58-106
Programs / Recipes
Sequences Evap. Eq Eq
CIP PZE PZC PZR defrost/ defrost/ foam/ Disinf Drying
rinse rinse rinse
Defrost / Rinse Evaporator
Equipment
Inspect
Foaming detergent Equipment
Evaporator
Inspect
Foaming detergent Belt
Rinse Equipment
Evaporator
Inspect
Rinse Belt
Foaming disinfectant Equipment
Evaporator
Belt
Workout
Rinse 1)
Air purge Circuit
Dr ying Equipment
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OPERATION
Real-time data screen
Show trend data graphically

Press one of the buttons to access the trend screen for a single
value. Here you can view trend data graphically.
1. Real-time information
2. History information
3. Zoom time span
4. Scroll time and date
6 page by page
5. Real-time
6. Cursor line
Touch the curser and move
1
it to desired position. Green
2 is real-time trend and blue
is trend history.
7. Value and time at cursor.
3 4 5 7

- 05 - 01 - 03 - 04 17/22
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OPERATION
Maintenance screen
Door heating.
Turn on the heating manually in order to check the function.
Extra lubrication pulse in order to check function.
Production line control, select/deselect.

The belt drive is syncronized with the production line after the
equipment.
By-pass the frequency converter and run the belt with fixed
speed (50/60 Hz) in order to empty the equipment from products
in case of frequency converter fault. 1)
Toggle between holding time (min) and belt speed (m/min).
Belt sag/belt bridge adjustment. 1)

If the belt is stopped suddenly, the belt tension could get out of
limit. To start the belt, adjust the belt sag3) or belt bridge4).
Deactivate touch functions during 30 seconds to make it possi-
ble to clean the screen without interferance.

3) Only valid for Descending equipment.
4) Only valid for Twinstack equipment.
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OPERATION
I/O overview screen
Here you can observe the I/O status on the PLC.
For I/O configuration, see electrical drawings.
VFD overview screen

Here you can observe actual frequency and current for the
frequency converters.
Picture shows an example of layout.

- 05 - 01 - 03 - 04 19/22
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OPERATION
Equipment configuration screen
Here you can adjust different limit values, depending on installed
system. Such as pre alarms, cold keeing temperature or BDF
setting.
Event log screen

The latest events are shown (1000 events).
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OPERATION
System configuration screen
(only valid for maintenance log in)
Touch screen calibration

1. Press the target symbol five times.
2. Press the “OK” button.
Computer time
Set system time.
Set system date.
Security
Create user
It is possible to give users different access levels. This is
connected to the login password.

- 05 - 01 - 03 - 04 21/22
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OPERATION
Backup/restore
Backup/restore production and cleaning recipes or user data-
base to a flash memory card.
Press this button to backup recipe to the memory card.

The data is stored as CSV-format and can be imported to Excel.
Press this button to restore backup recipe from the memory

card to a PC.
Press this button to backup user data to the memory card.
Press this button to restore backup user data from the memory
card to a PC.
Flash memory card

The card is placed inside the electrical cabinet, on the right side
of the back of the control unit. A standard flash memory card,
size 128 MB, is used.
The following data is stored:
• Process values, last 90 days, sample period 1 second.
• Alarm history, last 1000 alarms.
• Event history, last 1000 events.
• System faults, last 1000 faults.
Language
Select language.
~~~
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OPERATION
APPLICATION SPECIFICATION
Approx. set values
Evaporation /
Product specification Product infeed Throughput normal air Freezing time (min)
temp. (°C) (kg/h) temp. (°C) (belt 1 / belt 2)
Your own products - Use waterproof pen
~~~
OPERATING GUIDE 0000 - 125

05 - 01 - 20 - 00 1/2
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OPERATION
2/2 0000 - 05 - 01 - 20
126- 00 OPERATING GUIDE
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OPERATION
MATERIALS IN EQUIPMENT
The table on the next page list the materials in use in
FMC FoodTech equipments.
Always consult with your chemical supplier and check the
manufacturer’s material safety data sheet before decisions
about detergents and disinfectants are made.
)
Warning
Cleaning and disinfection agents must be cho-
sen with respect of the materials in the
equiment.
Please note that agents may be corrosive to
some of the many different materials found in
the equipment. Incorrect use of detergents,
disinfectants or other chemicals could cause
damages to equipment and personal injuries.
MANUAL 0050127
- 05 - 01 - 81 - 00 1/4
2/4
GC400 Classic GC42 GC600 Classic GCM76, GCM92, GC M6-M10
GCM106
Material Specification Used in Used in Used in Used in Used in
Stainless steel SS2333/ AISI 304/ Belt, infeed unit, Conveyor, belt , floor, Conveyor, belt , floor, Conveyor, belt , floor, Conveyor, belt , floor,
1.4301 mezzanine floor, fan, infeed/outfeed infeed/outfeed unit, fan, infeed/outfeed enclosure, infeed/
sheeting, floor, unit, sheeting, enclosure unit, enclosure outfeed unit,
enclosure enclosure evaporator
Aluminum SS4120/ EN AW 5052 Fan cone Fan (NYB) Fan, fan (NYB)
Aluminum SS4125/ EN AW 5754 Hatches Mezzanine floor Mezzanine floor Mezzanine floor
Aluminum SS4007/ EN AW 1050A Fan Sheeting Sheeting, fan Sheeting, fan
Aluminum EN AW 3003 Fan (NYB) Fan (NYB)
Aluminum EN AW 6061 Fan (NYB) Fan (NYB)
Spray galvanized Floor, rail, stand, Gearboxes Floor, gearboxes Floor, evaporator Gearboxes
gearboxes stand, gearboxes
Hot dip galvanized Fan, spray box Fan Fan
0050 - 05 - 01 128
Polyethylene HD-PE Glide strips Glide strips Glide strips Glide strips Glide strips
O-1320174_gb
Polyacetal POM Gaskets, belt, Gaskets, belt, Gaskets, belt, Gaskets, belt, Gaskets, belt,
- 81 - 00
sprocket sprocket sprocket sprocket sprocket
Thermoplastic DuPont, Hytrel Gaskets Gaskets Gaskets Gaskets Gaskets
MS Polymer Caulking Caulking Caulking Caulking Caulking
Paint DIN50016 Motors Motors Motors Motors Motors
Paint PVDF Enclosure Enclosure Enclosure Enclosure Enclosure
Polyester Connection box Connection box Connection box Connection box Connection box
PVC/EPDM Cables Cables Cables Cables Cables
MANUAL
OPERATION
MANUAL
GC400 Classic GC42 GC600 Classic GCM76, GCM92, GC M6-M10
GCM106
Evaporator Specification Used in Used in Used in Used in Used in
Colmac
Aluminum EN AW 1100; 3003
X X X
EN AW 5052; 6061
Goedhart
Aluminum EN AW 5052
X X X X
Stainless steel EN 1.4301
Goedhart DX
Aluminum EN AW 5052
Copper SF-Cu DIN
0050129
1787/17671/1754 X X X X X
O-1320174_gb
Brass CuZn 39Pb3
~~~
Sil-fos 15 CP 102-EN 1044
Dowa Techno DX
Aluminum EN AW 5052
- 05 - 01 - 81 - 00
Copper SF-Cu DIN
1787/17671/1754 X X X
Brass CuZn 39Pb3
Sil-fos 15 CP 102-EN 1044
Raffel
Hot dip galvanized X X X X X
Mebrafe
Hot dip galvanized X X X
3/4
OPERATION
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OPERATION
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- 81 - 00 MANUAL
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MAINTENANCE
MANUAL 0000131
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2/2 0000 - 06 - 01 132

- 00 - 00 MANUAL
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PREVENTIVE AND CORRECTIVE MAINTENANCE

SAFETY PRECAUTION
• Ensure that any local safety regulations are known, under-
stood and followed.
• All procedures described in this manual should be carried
out by authorised personnel.
• The basic rule is that no person shall be inside the equip-
ment while moving parts are in operation. Use the service
handle(s) according to separate instruction.
• Before any work is started, make a risk assessment.
• Always inform other personnel and one “safety support
person” that you are working with the equipment.
• FMC FoodTech´s personnel are not permitted to perform
work alone.
Lock out / Tag out / Verify
Before any maintenance work is started within the equipment,
always follow the “Lock out/Tag out/Verify” procedure:
1. switch off the main power supply and lock it with a pad lock,
keep the key in your pocket.
2. hang a “Do not operate” tag with your name on the switch.
3. verify that the power is off.
)
Warning
The internal light, Pc power-supply and electri-
cal cabinet ventilation fan are not connected to
the main switch and remain live even when the
main switch is in position ‘0’.
External voltage is wired with orange cables.
Risk for release of energy

• Do not cut into pressurized tubes, vessels or live cables.
• Ensure that heavy components in the equipment are se-
curely and stable supported before they are detached.
For further information see complete Owner’s Manual for the specific
equipment.
~~~
MANUAL 0000133
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- 70 - 00 MANUAL
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PREVENTIVE MAINTENANCE
DAILY MAINTENANCE
3
1
Pos. no. Maintenance place Type of maintenance

1 Electrical equipment
Emergency stops Check function
2 Return rails
Belt compressor limit switch Check function
3 Drive system
Belt position switch Check function and adjustment
4 Infeed with infeed rails
Product height limit switch (if installed) Check function
Optional equipment
If any optional equipment is installed, maintenance is to be carried out according to separate instructions. See
chapter ""Preventive and corrective maintenance"".
MANUAL 1000135
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Emergency stops
Function check:
Factory safety regulations may overrule this
check procedure.
There are emergency stops at the infeed and
outfeed unit and on the control panel.
1. Operate the button or pull the cord for each
switch.
2. Check on the control panel that the relevant
symbol lights up and the alarm is activated.
3. Cancel and reset the alarm after each
switch check.
Return rails
A. Belt compressor limit switch
A
Check function of belt compressor limit switch.
1. Push the limiter forward and check that the
alarm is activated.
2. Reset the alarm.
Drive system
B. Belt position switches
Belt position switch check:

1. Stop the belt.
2. Trigger the switches on both sides of the
belt manually and check that the alarm is
activated.
3. Reset the switches and the alarm.
4. The distance between the switch and the
B side link and foot should be 3 mm.
3 mm
3 mm
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Infeed with infeed rails
A. Product height limit switch
Product height limit switch (if installed):

1. Check that the limiter is free to move.
2. Push the limiter out of its position and check
that the alarm is activated
3. Cancel and reset the alarm.
~~~
A
MANUAL 1000137
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WEEKLY MAINTENANCE
When performing weekly maintenance, also carry out daily
maintenance.
P o s. Maintenance place Type of maintenance

no.
1 Outfeed
Release plate Check adjustment according to product
2 Service handle
Flexible cord Check condition
Service handle Check function
Optional equipment
chapter "Preventive and corrective maintenance".
MANUAL 1000139
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Outfeed
Check the condition and setting of the outfeed
release plate and springs:
• Adjust the outfeed release plate (A) angle
according to the product.
Adjust with screws (C).
• Adjust the outfeed release plate setting
with the two adjusting screws (B) and the
spring tension (to the lowest possible setting
depending on the product):
- Sticky products closer to the belt.
- Non sticky products a little away from
the belt.
C B A
Service handle(s)
D. Safety switch
E. Restart button
• Check the condition of the flexible cord.

D E
Function check:
Factory safety regulations may overrule this
check procedure.
• Start the equipment (belt and/or fans).
• Grab the service handle and press the
safety switch to its middle position. Lift the
handle out of its holder. The belt start warn-
ing is activated.
• Release or press the switch too hard. Now
the equipment shall stop.
• Restart the equipment by pressing the
safety switch to its middle position to reset
the safety relay. Press the restart button and
selected function(s) will restart.
• Place the handle in its holder.
If your equipment is provided with two handles
repeat the check with the second handle
~~~
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MONTHLY MAINTENANCE
When performing monthly maintenance, also carry out daily and
weekly maintenance.
7
5
9
2b
6
8 3
2
1
Pos. no. Maintenance place Type of maintenance

1 Infeed with infeed rails
Plastic glidestrips Check condition
Wheels and rollers Check function
2 Belt
Underside of link feet Check condition
Crossrods Check straightness
Welds on link feet Check condition
Side links Check condition
Inside of link feet Check condition
Link play Check distance
Tabs Check position
Mesh Check condition
Belt stack Check for irregularity
Belt collapse area (2b) Check belt length
MANUAL 1000141
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Pos. Maintenance place Type of maintenance
no.
3 Drive system
Chain Check condition
Chain tensioners Check function and position
Aux. drive chain (if installed) Check condition
4 Support ring
Glide strips Check condition
5 Outfeed
Belt lifter side guides Check condition
Drive sprockets Check condition
Chain tensioner Check function
6 Return rails
Roller cassetts (if installed) Check condition and adjustment
7 Evaporator and fans
Defrosting spray nozzles Check function
Fan bearings Check for noise
8 Electrical equipment
Fluorescent tubes Check function Checks on electrical
Door heating Check function equipment should be
carried out by a
Control cabinet ventilation Check and clean filters qualified electrical
Control cabinet air conditioner (if installed) Check and clean filters engineer only.
9 Insulated enclosure
Door rubber seals Check condition
Enclosure Check for damage
Panel seals Check for damage
Door hardware Check and adjust
Optional equipment
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Infeed with infeed rails
A
A. Infeed guards
B. Rollers
C. Wheels
D. Plastic glide strips
Plastic glide strips:

1. Remove the infeed guards.
2. Check the plastic glide strips, on which the
belt rides, for wear, deep scratches and
deformation. Replace when necessary.
D Wheels and rollers:

C 1. Check that all wheels and rollers rotate and
B are fixed sideways to the shaft in the correct
position.
2. Check the rail roller casettes (if installed) for
wear and that they are correctly positioned.
MANUAL 1000143
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B C G FRIGoBELT® conveyor
General
A. Side link
E B. Cross rod
C. Mesh
F D. Link feet
E. Tab
F. Welds
G. Link clearance
D
H. Tension link (only valid for FB W)
A I. Pulling link (only valid for FB M)
1. Remove the guards on the infeed and carry

out checks with the belt running.
2. Put a mark on the belt and run the entire belt
45° through.
3. Check that the side links are straight and
FRIGoBELT belt (FB DC)
E square to the cross rods.
4. Check the mesh for damage.
5. Also check the entire belt stack for irregu-
larities.
6. Check that the underside of the link feet
shows no sign of excessive wear.
7. Check that the cross rods are straight.
8. Check that there is clearance between the
links:
FB DC and FB W: 0,5 mm
FB M: 0,8 mm
9. Check that the welds between the rods and
the links are intact.
10. Make additional checks depending on belt
type, se below.
11. Reposition the infeed guards.

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Additional checks
1. Check that the tabs are in their normal
position, at approx. 45° (75° for FB M) to the
cross rods.
2. Check that the link feets on the inside belt
G edge are not deformed and have no sharp
edges.
F C B H
A
45°
D E
FRIGoBELT Widebelt (FB W)
I B C A
G 75°
D E
0,8 mm
FRIGoBELT M (FB M)
MANUAL 1000145
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Belt length control
A. Belt collapse area
B. Belt compressor
B C. Belt compress limiter
Min.
0,3 m
Check the belt length in the belt collapse area.
A • Minimum 0,3 m belt must be fully expanded
below top of the belt compressor.
Min. 0,3 m
• The collapsed belt length should be 1 meter.
• Minimum 0,3 m belt must be fully expanded
before the stack centre.
• It is not possible to push a collapsed belt
through the curve into the stack.
• 1 m collapsed belt represent 1,5 m
expanded belt.
B
If shortening of the belt is necessary, see chap-
ter “Corrective maintenance, Adjusting the belt
length”.
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A Drive system
A. Drive sprocket
B. Ball-chain tensioners
C. End mark
Ball chain condition check:

1. Carry out a visual check of the ball chains,
from a position after the drive sprocket, with
the equipment running at a low speed.
2. Put a mark on a link and run the entire ball
chain through.
3. Watch the ball chain when it is leaving the
B B drive sprocket. Make sure that the links are
closing smoothly into a straight chain.
4. Listen for odd noises.
Check the position of the ball-chain tensioners,

both tensioners must be within the marks.
• If the tensioner is 10 mm or less from the
C end mark, shorten the ball-chain by taking
out one inner and one outer link.
See chapter “Corrective maintenance, Adjust-

ing the belt length”.
Auxiliary drive system (if installed)

Chain condition:
1. Carry out a visual check of the entire chain,
with the equipment running at a low speed.
2. Check that the links have no excessive
wear marks.
3. Watch the chain when it is leaving the drive
sprocket (D). Make sure that the links form
a straight chain.
4. Watch the positions where the chain is
D entering the drive chain of the FRIGoDRIVE
drive system. Make sure that this runs
smoothly.
5. Listen for odd noises.
MANUAL 1000147
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Support ring
Glide strip condition:
• Check the glide strips for wear. Maximum
wear depth = 5 mm. Replace if necessary.
Max 5 mm
Outfeed
A. Side guides
A B. Belt guards
C. Outfeed drive sprockets
D. Chain tensioner
E. Belt drive sprockets
Belt lifter side guides:

• Check the side guides for damage.
B Adjust if necessary.
Drive and idler sprockets:

C 1. Check the outfeed drive sprockets for wear,
especially the teeth roots.
D 2. Check the belt drive sprockets for wear.
3. Check belt guards for wear. Maximum wear
depth = 5 mm.
C
Chain tensioner function:
1. Check chain condition.
2. Check chain tensioner condition and posi-
tion.
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Return rails
Return rail roller casettes (if installed)
1. Check the rollers for wear and that the
casettes are correctly positioned.
2. Check that the rollers rotate.
Evaporator and fans

A. Spray nozzles
Evaporator:
• Check the tubes and pipes. In case of
damage, contact qualified refrigeration
engineer.
• Check that the water defrosting spray
nozzles are not clogged.
Fan bearings:
A 1. Check the fan bearings for noise.
2. Check for fan vibrations.
MANUAL 1000149
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Electrical equipment
)
Warning
Checks on electrical equipment should be
carried out by a qualified electrical engineer.
• Check function of the internal lighting fluo-

rescent tubes.
• Check function of the door heating function.
Note!
The thermostat switches for all heating functions
are on when the temperature inside equipment
is below freezing point.
Control cabinet
• Check the ventilation air filters in the control
cabinet and clean if necessary.
• Air conditioner (if installed)
Check the air inlet filters and clean if neces-
sary according to manufacturers instruction.
Insulated enclosure
Seal leakage and enclosure damage check:
1. Check the condition of the rubber door seals
and make sure they are not damaged.
2. Check the enclosure for damage.
3. Check panel joint seals. Repair immediately
with MS polymer compound when neces-
sary.
4. Check and if necessary, adjust the door
hardware.
5. Check the pipe and cable penetration seals.
Repair when necessary.
~~~
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YEARLY MAINTENANCE
When performing yearly maintenance also carry out daily,
weekly and monthly maintenance.
5 2
4
1

no.
1 Infeed
Tension switches Check function and check distance to striker plate
Tension spring Check spring length
Product height limiter Check height setting
2 Drive system
Balls Check condition
Drive sprockets Check condition
Bearings Check condition
Rail glide strip Check condition
Auxiliar y drive chain (if installed) Check condition
Auxiliar y drive glide strips (if installed) Check condition
3 Internal rails
Belt lifter Check adjustment and condition
Return rail glide strips Check condition
MANUAL 1000151
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no.
4 Electric equipment
Control panel door Check rubber seal condition
Junction boxes Check tightness
Cables Check condition *
5 FRIGoDRIVE® lubrication system
Oil filter Clean filter
* Checks on electrical equipment should be carried out by a qualified engineer only.
Optional equipment
A
Infeed
Check the tension switches:
A. Infeed guards
B. Spring
C. Tension switch
1. Set all switches except the main switch to

position 0 = (zero).
2. Remove the infeed guards on both sides.
3. Check by pressing the switch that there is
an alarm and indication.
Reset the alarm switch.
4. Clear the alarm.
5. Check that the distance between limit
switch and the striker plate is 0.5 - 1.0 mm.
6. Check the length of the spring, should be
32 mm.
C
B

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Product height limiter
• Check that the distance between the height
limiter and the belt is set correctly, in com-
parison to the link height.
Link height Max. product height H

80 mm 65 mm
100 mm 85 mm
120 mm 105 mm
150 mm 135 mm
H
Drive system
Chain
A. Ball chain elongation
Max 18,6 mm (nominal 18,1 mm)
Ball chain condition check

Wear control:
1. Check ball chain elongation. Measure the
distance between the chain barrels (A). If
the length is more than 18,6 mm, the whole
chain should be replaced.
2. Check the whole ball chain for cracks,
B especially at positions marked (B). If you
find cracks, exchange the whole chain.
A 3. Check the whole ball chain for loose joining
links.
Ball condition and wear check:
• Carry out a visual check on the balls.
Check for marks and wear. If a ball is abnor-
mally worn or has deep marks it should be
replaced.
• Remove 10 balls from each chain and
measure them with a sliding caliper. The
diameter should be > 24.7 mm. If more than
3 out of 10 balls are smaller, measure
another 50 balls. If more than 15 balls are
smaller then 24.7 mm, replace all balls.
• To remove balls, divide the chain at point (C).
See manual sheet “Corrective maintenance,
Changing balls in FD drive systems”.
C
MANUAL 1000153
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D
Drive sprockets
• Check the sprockets (D) for wear.
Bearings
• Check the bearings at the chain
tensioners (E) for wear.
Rail glide strips

Measure the ball rail glide strip.
min 11.5 mm E 1. The minimum height of the glide strip is
min 21.3 mm
21.3 mm.
2. The minimum width is 11.5 mm.
(see illustration)
Support link check

• The slope on the support link should be at
least 0.5 mm, in order not to damage the
glide strip.
Inner chain
0,5 mm
F. Chain barrel
G. Glide strip
H. Lubrication tube
≤ 1.5 mm
F Condition check:
• Carry out a visual check of the rail glide
G strip, section A-A. Check for wear. Using a
feeler gauge, measure the distance between
H the chain barrel and the glide strip at 10-15
points on the inside chain. This distance
must not exceed 1.5 mm.
A-A
Outer chain
I. Lubrication tube
J. Attachment screw
K. Support link
J Condition check:
1. Check the lubrication tubes for wear marks.
Check the clearance between the support
link and the lubrication tubes (≥ 0,1 mm).
K 2. Check with the clearance between the glide
strip surface and the attachment screw
(≥ 0.4 mm).
I
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A Auxiliary drive (if installed)
Chain condition check:
1. Remove the guard.
2. Measure one chain length (A)
( 27 pitches) in tensed position.
If the length is more than 1094 mm, the
chain should be replaced.
3. Remount the guard.
Carry out a visual check of the glide strips.

1. Glidestrip (B) condition check, section B-B.
2. Check for wear:
B Push aux. drive chain close to the drive
B chain. Using a feeler gauge, measure the
distance between the glide strip and the
auxiliary drive chain. This measurement
must not exceed 1,0 mm.
3. Check the clearance between the chain-
locks and the auxiliary chain links. Minimum
distance 1 mm.
≤ 1 mm
≥ 1 mm
B-B ≤ 1 mm
B-B
MANUAL 1000155
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A Internal rails
A. Belt lifter
B. Outfeed rails
C. Return rail
5 - 10 mm
Belt lifter
• Check that the belt lifter is centered to the
belt and that there is 5-10 mm clearance to
the tier below.
B Return rail glide strips

• Check the rail glide strips for wear and that
they are correctly attached.
Electric equipment
)
Warning
Checks on electrical equipment should be
carried out by a qualified electrical engineer.
Leakage checks:
1. Check the rubber seal in control panel door.
2. Check the junction boxes for leakage.
3. Check the cables for damage.

Oil filter (A)
• Check condition of the oil filter on the lubri-
cation pump.
Clean the oil filter when necessary.
~~~
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LUBRICATION 4
2
1
Pos. Lubricating place Lubricant Remarks Daily Monthly Yearly

no.
Type* Qty.
®
1 FRIGoDRIVE lubrication system
Reser voir Oil J Check level and consumption X
Ball rail and glide strips Check lubrication X
2 Main drive / Auxiliary drive (if installed)
Gearboxes Oil F Check level X
Gearboxes Oil F 9,6L Change oil X
Motor bearings Grease K Lubricate X**
3 Outfeed
Gearbox Oil E Check level X
Gearbox Oil E 0,3L Change oil X
Drive chain Oil H Lubricate X
4 Evaporator and fans
Optional equipment
If any optional equipment is installed, lubrication is to be carried out according to separate instructions. See chapter
"Preventive and corrective maintenance".
* According to manual sheet “Preventive maintenance, Recommended lubricants”.
** Electric motors should be regreased only when overhauled. Normally electric motors are delivered without grease
nipples. Overhaule and regrease when bearing change is carried out or when a motor is dismantled for other
reasons.

MANUAL 1000157
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Daily
• Check the level in the oil reservoir (A)
according to manual sheet “Corrective
maintenance, FRIGoDRIVE lubrication
system”.
• Check that the ball rail glide strips and balls
are lubricated.
If necessary refill with oil according to the lubri-
cation chart.
A
B Main drive / Auxiliary drive

Gearboxes
Monthly
1. Drain condensation water through plug (D).
C After drainage, check the oil level in the
reservoir.
2. Check the oil level (C) in the oil reservoir.
Refill as necessary with oil according to the
lubrication chart.
D
Yearly
Changing the oil:
1. Remove cap (B).
2. Drain the oil by removing plug (D).
3. Replace plug (D).
4. Pour new oil up to the oil level (C). Refill with
oil according to the lubrication chart.
5. Replace cap (B).
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E Outfeed
Gearbox
Monthly
• Check the oil level in the gearbox by
loosening the plug (F). The oil level should
reach the plug hole. Refill when necessary
with oil according to the lubrication chart.
Yearly
Changing the oil:
1. Remove the plugs (E), (F) and (G).
G F 2. When the gearbox has been emptied re-
place the plug (G).
3. Pour new oil through the plug hole (E) up to
the plug hole (F). Refill with oil according to
the lubrication chart.
4. Replace the plugs (E) and (F).
Drive chain
Monthly
• Lubricate the outfeed drive chain. Use a
spray can with oil according to the lubrica-
tion chart.
Note!
Use only a thin film of oil, no drops!
~~~
MANUAL 1000159
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RECOMMENDED LUBRICANTS
Oils
Oil A, B
For use in hydraulic systems. Ambient temperatures between
+40 °C and -50 °C.
Examples:
BP Energol SHF - LT 15
Esso Univis J 13
Mobil DTE 11
Shell Tellarctic
Food graded, H1, example:
Klüber Klüberoil 4 UH1 - 15
Molykote L-1368 FG (Viscosity 46)
Oil C
For lubrication of Kopp-variators.
Examples:
BP Energol CS 10
Esso Spin Way 10
Mobil Mobilfluid 62
Shell Vitrea Oil 10
Klüber-Summit HySyn FG15
Molykote L-1605 FG
Oil D, E
For lubrication of standard gearboxes. Ambient temperatures
between +40 °C and -5 °C.
Examples:
BP Energol GR - XP 220
Esso Loadway EP 220
Mobil Mobil gear 630
Shell Omala 220
Molykote L-0122
Molykote L-1122
Klüber Klüberoil 4 UH1 - 220 N
Molykote L-0122 FG
Molykote L-1122 FG
MANUAL 0000161
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Oil F
For lubrication of standard gearboxes. Ambient temperatures
down to -50 °C.
Examples:
BP Bartran HV 15
Esso Hydraulolja SH 15
Mobil SHC 624
Shell Tellus Oil T 15
Klüber Klüberoil 4 UH1 - 15
Oil G, H
For lubrication of roller chains. Ambient temperatures down
to -50 °C.
Examples:
Molykote Supergliss (spray)
Klüber Klüberoil 4 UH1 - 15 (spray)
Oil J
Food graded, H1, oil for lubrication of FRIGoDRIVE® drive
system. Ambient temperatures down to -50 °C.
FMC FoodTech Formula 410
Oil N
For lubrication of PIV variators
PIV Varifluid (No alternatives)
Oil P
For lubrication of warm gears. Ambient temperatures down
to -30 °C.
Examples:
BP Energol GR - XP 150
Esso Loadway EP 150
Mobil Mobil gear 629
Shell Omala 150
Molykote L-1115 FG
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Oil S
Food graded, H1, oil for lubrication of gearboxes in
GYRoSTACK® freezers. Ambient temperatures down to - 40 °C.
Note!
These oils are not to be mixed with other oil qualities.
Food graded, H1, examples:
STATOIL Glycolube 150
FMC FoodTech FLTO
Klüber Klübersynth UH16-150
Oil T
For lubrication of warm gearboxes. Ambient temperatures
between +40°C and -5 °C.
Examples:
Mobil Glygoyle 80
Shell Tivela oil WB
Klüber Syntheso D 220 EP
Molykote L-1122 FG
Oil U
Food graded, H1, oil for lubrication of FRIGoDRIVE drive sys-
tem. Ambient temperatures between 0 °C and +40 °C:
Klüber Klüberoil 4UH1-100 N
Oil V
For lubrication of gearboxes in fryers. Ambient temperatures up
to +80 °C.
Examples:
Mobil Glygoyle 30
Shell Tivela WB
Klüber Klübersynth GH 6-220
Grease
Grease K
For lubrication of roller bearings. Ambient temperatures down
to -50 °C.
Examples:
BP Energrease LT 2
Esso Unirex Lotemp EP
Mobil Mobilgrease 28
Shell Syntix 100
SKF LGLT 2
MANUAL 0000163
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Klüber Klübersynth UH1 14 - 31
Molykote G4500
Grease L
For lubrication of roller bearings. Ambient temperatures down
to -30 °C. More water resistant than Grease K.
Examples:
BP Energrease LS - EP 2
Esso Uni - Way EP 2 N
Mobil Mobilgrease HP
Shell Alvania EP 2
SKF LGEP - 2
Molykote G4500
Grease M
For lubrication of chains in FRIGoDRIVE drive systems.
Example:
Klüber Isoflex Topas NCA 52
Grease R
For use in central lubrication system in GYRoSTACK freezers.
Ambient temperatures down to -40 °C.
Examples:
FMC FoodTech FLTG
Klüber Klübersynth UH1 14-1600
Grease S
For use in fryers. Ambient temperatures up to +250 °C.
Examples:
Molykote TP42
Klüber BARRIERTA L55/2
Molykote HP 300

~~~
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CORRECTIVE MAINTENANCE
ADJUSTINGTHE BELT LENGTH
General
• The splicing should be done at the infeed
unit.
• Use only full length rods for splicing.
• If the belt has to be taken out of the equip-
ment, we recommend consulting
FMC FoodTech.
• There are separate instructions depending
on installed belt type, FRIGoBELT® DC belt,
FRIGoBELT M or FRIGoBELT Widebelt.
Preparation
1. Remove the guards on the infeed.
2. In order to protect the glide strips, put a
plate or a board between the belt and the
glide strips.
3. Pull the spare belt from the belt collapse
area.
4. Thread 2-3 rods through the belt just behind
the infeed rollers to prevent the belt from
slipping after cutting.
FRIGoBELT DC belt
Cutting the belt
1. Cut the rod at the front end of the link.
Cut both sides. Use a cutting wheel with a
small diameter.
2. Pull out the rod from the mesh.
3. Cut the belt to the correct length. Check the
length by observing the belt collapse area
(see “Monthly maintenance”)
4. Remove the rod ends by careful grinding.
Ensure that the link foot is not weakened.

MANUAL 1000165
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Splicing and welding the belt
A. Plate or wood
B. Stainless steel electrode
C. Earth clamp
Fig. I Splicing the belt

1. Pull the two belt ends (see figure I) together
and join the mesh in the correct position
(see figure II). Align the holes in the side
links.
2. Insert the rod through the links and mesh
from either side of the belt. Push the rod
through the hole in the side links on the
opposite side.
Fig. II Note!
Make sure that no link has been bent. Pay
special attention to the link foot.
Before welding make sure:

1. that the frequency converter is discon-
nected. Do this in spite of any recom-
mendations otherwise!
2. that the plate or wood protection between
the belt and the infeed glide strips is cor-
rectly positioned.
3. the earth clamp is placed on the link to be
welded.
A B C
Welding the belt
1. Weld the rod to the link on both sides of the
belt. Use stainless steel electrodes.
2. Check that there is clearance between the
links.
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After welding
1. Make sure that no link is burned through.
2. Brush the welds with a stainless steel
brush.
3. Check that all sparks and drops of metal
under the link foot are thoroughly ground
away. On the upper side of the foot
occasional sparks are allowable.
4. Check that no welding sparks could restrict
the movement of the links.
5. Check that the plastic strips on the infeed
rails are not damaged.
This is important to ensure that the belt runs
smoothly and to avoid unnecessary wear of
the glide strips.
MANUAL 1000167
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FRIGoBELT Widebelt
Cutting the belt
1. Cut the rod at the front end of the link.
Cut both sides. Use a cutting wheel with a
small diameter. Grind carefully in order to
not damage the link.
2. Pull out the rod from the mesh.
3. Cut the belt to the correct length.
Check the length by observing the belt
collapse area.
For further information, see chapter “Pre-
ventive maintenance, Monthly mainte-
nance”.
4. Remove any remaining weld by carefully
grinding the links. Ensure that the link is not
weakened.

Splicing the belt
1. Pull the two belt ends (see figure I) together
and join the mesh in the correct position
(see figure II). Align the holes in the side
links and the tension link.
2. Insert the rod through the links and mesh
Fig. I
from either side of the belt. Push the rod
through the hole in the side links on the
opposite side.
Note!
Make sure that no link has been bent. Pay
special attention to the link foot.
Fig. II
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Before welding make sure:
rectly positioned.
3 that the earth clamp is placed on the link to
A B
be welded.
Welding the belt

1. Fit the heat sink (A) and use a screwdriver
to press it against the plate onto which the
rod is to be welded .
2. The splicing rod is centred so that neither
end points outside the link. Make sure that
the links do not press against each other.
3. Weld across the rod (B).
C 4. Then weld along the rod, starting at the end
(C).
After welding
1. Make sure that no link is burned through.
brush.
3. Check that all sparks and drops of metal
under the link foot are thoroughly ground
away. Occasional sparks on the upper side
of the foot are allowable.
4. Check that no welding sparks restrict the
movement of the links.
rail are not damaged.
This is important and ensures that the belt
runs smoothly and avoids unnecessary
wear of the glide strips.
MANUAL 1000169
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FRIGoBELT M
Cutting the belt
A. Rod
B. Pulling link
C. Side link
D. Mesh
B
Fig. I
A
Note!
Before cutting the belt make sure one inner and
one outer side link and two rods are available for
the splicing.
1. Pull the mesh away form the side link to
avoid damage at cutting, see figure I.
2. Cut the rods at one side of the belt close to
the side link, using a small cutting wheel.
3. Pull the rods out and remove the mesh.
4. Check the length by observing the belt
C collapse area.
D For further information, see chapter “Pre-
ventive maintenance, Monthly mainte-
nance”.
5. Cut the belt to correct length.

D A B
Splicing the belt
1. Pull the belt ends together and join them
using two rods and a piece of mesh.
Make sure the mesh is correctly
assembled, see figure.
2. Put the side links in position, make sure that
the trailing edge is on the inner side of the
trailing link and that the pulling links are
connected properly.
C Before welding make sure:

rectly positioned.
3 that the earth clamp is placed on the link to
be welded.
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0,8 mm Welding the belt
1. Position the side links. The play between the
corresponding side links should be about
0,8 mm.
2. Weld the rods to the side links:
C A. Spot weld the rods to the side link.
B B. Weld the rods starting at the end of the rod
welding towards the side link.
C. Weld the vertical plate at the side link.
A
After welding
B 1. Make sure that no link is burned through.
brush.
3. Check that any welding sparks and drops of
metal under the link foot are thoroughly
ground away. Occasional welding sparks on
the upper side of the foot are allowable.
4. Check that no welding sparks restrict the
movement of the links.
rail are not damaged.
This is important and ensures that the belt
runs smoothly to avoid unnecessary wear
of the glide strips.
MANUAL 1000171
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C REPLACEMENT OF A CHAIN
LENGTH
FRIGoDRIVE® chain
A. Chain tensioner
B. Mount screw clamp here
C. Chain length
D. End mark
A
Check the position of the ball-chain tensioners,
the tensioner must be within the marks.
• If the tensioner is 10 mm or less from the
end mark, shorten the ball-chain by taking
out one inner and one outer link.
Removal or replacement of a chain length

D should be carried out at the drive station. The
following description is valid for the outer chain,
although the process is similar for the inner
chain.
Preparation
1. Position the chain length between the chain
tensioner and the drive unit.
B 2. Slacken the chain by blocking the chain
tensioner in its inner position using a screw
clamp.
Dismantling
1. Dismantle the two chain locks and push the
chain towards the chain tensioner. It should
now be possible to take out the balls under
the chain length to be removed.
2. Twist the chain slightly and lift it away.
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Mounting of new chain length
E. Application tool
F. Locking plate
E G. Washer ø10/6x1
If the new chain length has to be shortened, do

F the following:
1. Cut the chain by carefully grinding off the
riveted end of the chain bolt.
2. Place the chain length on the rail. Refer to
“Preparation” and note that the chain ten-
sioner has to be blocked.
G
3. Re-install the balls and position the chain-
length. Grease the chain lock pins (use
special ISOFLEX TOPAZ NCA 52 grease)
and install the chain-lock. Tighten the
screws to 10 NM. Place a locking plate in
the application tool and use a hammer to
drive the locking plate on.
4. Release the chain tensioner by removing
the screw clamp.
5. Replace the chain guard.
Note!
Use only washer ø10/6x1 and do not reuse old
locking plates.
Auxiliary drive chain

(If installed)
A. Auxiliary chain length
B. Use a M10-screw for chain tension release
A chain length can be replaced or removed if

positioned outside in between the drive station
and the tension station with the chain lock in the
A gap between the drive sprocket and the outer
chain guide.
B
Preparation
1. Remove the auxiliary chain guard.
2. Slacken the chain by blocking the chain
tensioner in its inner position using a M10-
screw.
MANUAL 1000173
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C. Chain teeth
D. Locking plate
E. Locking plate screws
F. Chain lock pin
Dismantling
1. Loosen two chain teeth, one on each side of
the chain locks, according to figure I.
C 2. Remove the locking plate, screws and
I washers according to figure II.
3. Dismantle the upper and lower chain locks
on each end of the length to be replaced.
The chain lock pins can then be removed.
D 4. Pull out the chain length.
The entire auxiliary chain can be removed by
E running the machine very slowly. Carefully
slacken the screw clamp in order not to block
the limit switch.
II Note!
When the entire chain has to be removed, the
chain locks need to be removed at one point
F only.
Mounting of a new chain length

1. Position the tensioner in mid position, in
order not to block the limit switch.
2. Grease the chain lock pins and note the
position of the chain teeth.
3. Mount the chain lengths together except for
the last chain locks (figure IV). The chain
locks must be inserted in the following
manner:
C III
Upper chain - from below.
Lower chain - from above.
4. Mount the washers (Note: use only ø10/6x1
washer) and tighten the screws.
5. Put a new locking plate in the application
tool and use a hammer to drive the locking
plate onto both upper and lower chain.
Note!
Do not reuse old locking plates.
6. Position the chain teeth and tighten the
screws, using new locking nuts.
IV
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7. Mount the chain lengths by running the
machine very slowly and pushing the chain
inside the outer chain guide. Position the
chain in such a way that the last chain locks
can be mounted just after the drive sprocket
on the outer side.
8. Block the chain tensioner in its inner posi-
tion. Mount the last chain locks according to
the above instructions.
If a chain length has to be shortened,
split the chain by carefully grinding off the
riveted end of the chain bolt.
9. Release the chain tensioner and remove the
M10-screw.
10. Remount the chain guards.
Changing balls in FRIGoDRIVE

drive system
C A. Application tool
B. Locking plate
C. Washer ø10/6x1
1. Count out the correct number of balls in a

container.
2. Lubricate the balls thoroughly with ball chain
lubrication oil.
3. Divide the ball chain on the return rail in a
position close to the drive sprocket.
ISOFLEX 4. Remove the balls on the return rail.
TOPAZ-N 5. Put in the same number of new balls.
CA 52
6. Join the divided ball chain ends.
A Note!
B Do not lock the chain joint (D) as you may
need to divide it more than once.
C 7. Run the ball chain until the return rail is filled
with old balls.
8. Repeat until all balls are replaced.
Note!
The balls move with half speed compared to
LocTite the chain. This means that the chain must
243
rotate at least two times before all the balls
are replaced.
9. Lock all divided joining links according to
illustration.
ISOFLE
X Use new locking plates.
TOPAZ-N
CA 52 ~~~
MANUAL 1000175
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C D FRIGODRIVE® LUBRICATION
SYSTEM
B A. Oil reservoir
B. Button for manually start extra lubrication
A C. Filter cap
D. Stainless steel cabinet
E. Distribution pipes
F. Oil filter
G. Metering elements
H. Prime outlet
I. Prime plug
E J. Pipe
Oil filling
G The oil level is visible in the transparent oil
reservoir. Additionally a level gauge actuates a
none fatal PLC alarm when the oil level falls
below minimum level.
Refill the reservoir with oil according to lubrica-
tion chart and reset the alarm by pressing the
start button.
Note!
If the oil reservoir is empty, the oil pump can not
be started.
H
I Piping
• Check that oil comes out at the lubrication
F points both at cold temperatures (not valid
J for proofer) and at ambient temperatures.
• When the equipment is cooled down, the oil
level in the pipes, leading oil to the lubrica-
tion points, are lowered. This may cause
water to enter the pipes and form ice plugs.
Pressure control
If the set pressure is not reached during a
pumping cycle the pump stops and the lubrica-
tion alarm from the PLC is activated.
1. Check the oil level.
2. Look for leaks between pump and metering
elements when restarting the pump.
3. Check for leaking metering elements.
4. Clean the filter and restart the pump.
MANUAL 1000177
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Cleaning and priming

If the oil in the oil reservoir is contaminated with anything from
water to foreign objects the complete lubrication system must
be cleaned and primed.
Note!
Even the smallest amount of water in the oil can lead to dam-
ages in the drive system.
Follow these steps to clean and prime the lubrication system:
1. Dismount the oil reservoir from the pump and pour the oil
out in a waste tank.
2. Clean the oil reservoir and wipe it dry.
3. Wipe off the suction side of the pump.
4. Remount the oil reservoir and refill with new oil according to
chapter “Preventive maintenance, Recommended lubri-
cants”.
Repeat step 5 to step 7 for each metering element.
5. Loosen the pipe from the metering element and place it in
the prime outlet
6. Place the prime plug in the metering element.
7. Manually run the pump 3 times by pushing the button for
manual start of extra lubrication.
8. Replace the prime plug to the prime outlet.
9. Clean up oil spill inside the equipment.
10. Fill up with new oil in the oil reservoir according to chapter
“Preventive maintenance, Recommended lubricants”.
~~~
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PRODUCT ZONE CLEANER - PZC
(Optional equipment)
Preventive maintenance
Pos. Maintenance place Type of maintenance Monthly Yearly

no.
1 Belt rinser
Belt drier fan Check function X
Spray nozzles Check condition and position X
Belt drier fan and motor Check for noise and vibrations X
2 Pump cabinet
Follow suppliers instructions X X
3 Belt foaming
Spray nozzles Check condition and position X
MANUAL 1000179
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Belt rinser
A. Belt drier fan
B. Spray nozzles
A
Monthly
1. Check function of the centrifugal belt drier
fan.
2. Check the spray nozzles and make sure
B they are not clogged. Also check that the
nozzles are correctly positioned. The spray
pattern should be across the belt.
Yearly
• Check the fan wheel and the electric motor
for abnormal noise and vibrations.
Belt foaming
C. Spray nozzles
Monthly
• Check the spray nozzles and make sure
they are not clogged. Also check that the
nozzles are correctly positioned.
~~~
C
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AIR BALANCETUNNEL
Preventive maintenance
Monthly
• Check that the air balance fan motor func-
tions properly.
Run the motor and listen for noise.
• Check the clearance between fan wheel
and fan cone. No contact between wheel
and cone is acceptable in any case. Turn the
wheel by hand, listening for noise.
~~~
MANUAL 1000181
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REPLACEMENT OF FAN MOTOR
C Dismantling
D
A lifting device is included in the delivery.
Note!
Maximum load 180kg.
A. Brace
B. Fan cone
C. Assembly bolts
D. Pivot bolts
E. Lifting device
A
B We advise that this operation is carried out by
two persons.
D
1. Remove the brace.
2. Loosen the fan cone attachment bolts.
!
Caution
The fan assembly could easily tilt over when the
assembly bolts are removed.
In order to avoid this, one man should hold the
fan wheel to prevent the fan assembly from
E tilting out of control.
3. Loosen the fan frame assembly bolts ex-

cept for the pivot bolts.
4. Tilt the frame 90° and secure it with two of
the assembly bolts in position (F). Simulta-
neously remove the fan cone.
5. If necessary, remove the fixing screws for
the electrical cables on the fan frame so the
lifting device could be fitted.
F 6. Mount the lifting device according to figure.
F The attachment bolts are to be fastened
with 76 Nm.
7. Secure the fan motor in the lifting device.
Make sure to have a couple of boards
ready to place the motor on. Minimum board
thickness/width: 25 mm/95 mm.
8. Disconnect the electrical cables, dismount
the fan wheel and loosen the motor bolts.
MANUAL 1000183
- 06 - 01 - 23 - 01 1/4
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9. Remove the screws holding the hatch (C)
and lift up the hatch. Move the plastic pipes
aside to clear the space under the hatch.
B
C
10. Place the motor on the boards using the

A. Mezzanine floor lifting device. The motor could now be pulled
B. Spraybox mezzanine by one man to the hatch by means of a
C. Hatch strap. Relocate the lifting device in order to
bring the motor down through the hatch to
the freezer floor.
!
Caution
Make sure that safety precautions are taken
before handling heavy equipment on the
spraybox and spraybox mezzanine. Never
place the motor on the mezzanine floor (see A in
illustration) near the belt stack as it will create
an unsafe overloading condition in that area.
This could cause personal injury and damage to
the equipment.
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Assembly
1. Hoist up the new motor through the hatch
with the lifting device and place it on the
boards. Pull the motor into a position where
it could be lifted to the fan frame. Relocate
the lifting device and lift the motor into
position at the fan frame.
2. Make sure that the fan frame is secured

with two of the assembly bolts in position
(F).
F F
3. Fasten the motor bolts, mount the fan wheel

and connect the electrical cables.
4. Release the lifting device from the motor.

Loosen the two fan assembly bolts and tilt
the frame 90° while simultaneously mount-
ing the fan cone.
!
Caution
The fan assembly could easily tilt over when the
assembly bolts are removed.
In order to avoid this, one man should hold the
fan wheel to prevent the fan assembly from
tilting out of control.
MANUAL 1000185
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5. Fasten the fan frame assembly bolts (C)
C and the brace (A).
6. Fasten the attachment bolts for the fan cone

(B) .
7. Fasten the fixing screws for the electrical

cables on the fan frame if removed.
8. Fit the hatch and fasten the screws.
A
B
~~~
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- 23 - 01 MANUAL

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Safety information appears as the first section of this book

Every effort has been made to ensure that the information

Trademarks used in this manual are marked with ® and ™.

Any comments regarding possible errors and omissions or

© Copyright FMC FoodTech AB. Printed in Sweden.

MANUAL 0000 -100 - 01 - 01 - 00 1/2

MANUAL 0000 -300 - 01 - 00 - 00 1/2

Danger, general warning symbol

Danger, general warning symbol

Health hazard, general

2/2 0000 - 00 - 01 - 106 - 01 MANUAL

MANUAL 0000 -700 - 01 - 11 - 03 1/4

Signs and markings

MANUAL 0000 -900 - 01 - 11 - 03 3/4

4/4 0000 - 00 - 01 -10

2/2 0000 - 00 - 01 - 1212

MANUAL 13- 01 -13 - 02

2/2 0000 - 00 - 01 -1314

In the event of an accident/ammonia discharge

Fire risk with the use of ammonia

Chemical formula NH3

Explosive concentration in air 16-27% by volume

Melting point -77,7 °C

Boiling point +33,4 °C

Ignition temperature +651 °C (DIN 51794)

Critical temperature +133 °C

Critical pressure 11,42 MPa

Concentration Effect on an unprotected person Exposure/injury time

FMC FoodTech recommends that ammonia detectors be in-

2/2 0000 - 00 - 01 - 2016

2/2 0000 - 01 - 01 -18

1700 8850 2) 1050

Freezer length Number of evaporator + fan

Figures in shadowed areas are optional deliver y. Contact FMC

FoodTech Sales Suppor t for fur ther information.

Evaporator size and volume

Figures in shadowed areas are optional delivery.

® = Registered trade mark.

SALES INFORMATION 1041 19

Tiers Lh 80 Lh 100 Lh 120

Evaporator type Evaporator type Evaporator type

2/6 1041 - 01 - 01 -20

Tiers Lh 80 Lh 100 Lh 120

Evaporator type Evaporator type Evaporator type

SALES INFORMATION 1041 21

Tiers Lh 80 Lh 100 Lh 120

Evaporator type Evaporator type Evaporator type

4/6 1041 - 01 - 01 -22

SALES INFORMATION 1041 23

6/6 1041 - 01 - 01 -24

2/2 0000 - 02 - 01 -26

The infeed temperature also has an effect on

® = Registered trade mark.

SALES INFORMATION 1000 27

Loading the belt

Example with rectangular products

Example with round products

2/2 1000 - 02 - 01 -28

2/2 0000 - 03 - 01 -30

Intervals between service and lubrication

Shut down for a longer period

2/2 0000 - 04 - 01 -34