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Related Manuals for RS COMPACT FREEZE TUNNEL
Summary of Contents for RS COMPACT FREEZE TUNNEL
- Page 1 Operation and Maintenance Manual COMPACT FREEZE TUNNEL® Liquid Nitrogen Cryogenic Freezer For service or support, please call: RS CRYO EQUIPMENT, INC. 629 Grove Street Manteno, IL 60950 Phone: (815) 468‐6115, Fax: (815) 468‐2651 http://www.rscryo.com...
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Page 2: Table Of Contents
OPERATION & MAINTENANCE MANUAL CompactFreezer TABLE OF CONTENTS Page TABLE OF CONTENTS ............................ 1 1. General Overview ..........................3 1.1. Inspection ............................3 1.2. Symbols & Identifiers ........................3 2. Safety Precautions ..........................4 2.1. Safety Considerations Before Operation ..................4 2.2. - Page 3 OPERATION & MAINTENANCE MANUAL CompactFreezer 6.6. Freezer Control Variables ......................25 7. Operating Instructions ......................... 27 7.1. Important Operating and Maintenance Pointers ............... 27 7.2. Daily Start‐Up and Operation ..................... 27 7.3. Production Interruptions ......................29 7.4. Vapor Exhaust Collection and Discharge ..................29 7.5.
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Page 4: General Overview
(exhaust, spare parts, bolts, etc.) have been received. If there is any damage, all claims must be made promptly to the shipping company. The RS Cryo Equipment representative should also be notified of any claims made. -
Page 5: General Guidelines
OPERATION & MAINTENANCE MANUAL CompactFreezer It is emphasized that the room in which the freezer will be installed shall be large enough and have sufficient air changes, preferably with high and low level ventilation, to prevent a build‐up of nitrogen gas in case of accidental spillage or malfunctioning of the equipment. - Page 6 OPERATION & MAINTENANCE MANUAL CompactFreezer Exhaust Blower Interlock Injection of liquid nitrogen can only occur if the exhaust blower motor is in operation. In addition, the Compact Freezer is equipped with an optional exhaust interlock that is tied into the emergency stop loop. i.e., if the exhaust blower is not operating, the freezer will shut down (the belt, liquid nitrogen and circulating fans will stop).
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Page 7: Liquid Nitrogen Hazards
OPERATION & MAINTENANCE MANUAL CompactFreezer 2.4. LIQUID NITROGEN HAZARDS Inform all personnel about the potential hazards related to the use of liquid nitrogen in chilling equipment! COLD BURNS: The freezer operates on liquid nitrogen, which can reach temperatures as low as -320°F (- 196°C). -
Page 8: About The Compact Freezer
OPERATION & MAINTENANCE MANUAL CompactFreezer 3. About the Compact Freezer 3.1. EQUIPMENT SPECIFICATIONS ± ± 7 ¼” 120V SINGLE PHASE 35AMP COMPACT FREEZER FREEZER MODULES LENGTH 83” 122” 161”... -
Page 9: The Compact Freezer Process
The liquid nitrogen from the injection nozzles is rapidly converted to cold gas due to absorption of the heat introduced by the food product. The secret to the efficient operation of the Compact Freeze tunnel is accurate temperature control of the modules and constant uninterrupted injection during the processing period. - Page 10 OPERATION & MAINTENANCE MANUAL CompactFreezer warm outer surfaces of the parts to keep cooling losses to a minimum. All fasteners...
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Page 11: Conveyor(S) / Belt(S)
OPERATION & MAINTENANCE MANUAL CompactFreezer attached to the modules are anchored to the inner steel plates through the use of threaded rivet type fasteners. The fiberglass parts are high strength hand lay‐up molded fiberglass parts, coated with a food grade gel coat. -
Page 12: Control Panel
OPERATION & MAINTENANCE MANUAL CompactFreezer 3.6. CONTROL PANEL The freezer controls are conveniently located on the front panel of the NEMA 12 rated control cabinet. The controls are the following: Main motor disconnect switch handle (120 VAC, 1 phase, 60 Hz) 1. -
Page 13: Injection Headers
OPERATION & MAINTENANCE MANUAL CompactFreezer 3.7. INJECTION HEADERS Each assembly feeds the cryogen through the top of the box down into the center of a freezer module. Each drop can control injection of LN2 into either one or two modules through the use of extension headers. -
Page 14: Installation & Assembly
OPERATION & MAINTENANCE MANUAL CompactFreezer 4. Installation & Assembly 4.1. SITE SELECTION REQUIREMENTS The installation site of the Compact Freezer must meet the following requirements for safe operation: • Located in close proximity to the Liquid Nitrogen (LN ) tank or vessel. •... -
Page 15: Unloading The Compact Freezer
OPERATION & MAINTENANCE MANUAL CompactFreezer Overall freezer dimensions, in‐feed height, exit height, etc. can be found in Section 3.1 ‐ Equipment Specifications. Utilize this data to make height adjustments of freezer and/or processing line equipment. 4.2. UNLOADING THE Compact Freezer Professional riggers are recommended when unloading the freezer. -
Page 16: Connecting Freezer Sections And Sealing
OPERATION & MAINTENANCE MANUAL CompactFreezer 4.4. CONNECTING FREEZER SECTIONS AND SEALING (If not shipped assembled) A) Move the freezer sections into their proper relative positions on the floor (the entry vestibule has the drive motor mounted on its sides). The module crates are designed to be moved by fork lift or pallet trucks and can be rolled or skidded. -
Page 17: Installation Of The Conveyor Belts
OPERATION & MAINTENANCE MANUAL CompactFreezer 4.5. INSTALLATION OF THE CONVEYOR BELT Pull the belt through the return track leaving the final 6 to 8 feet still in the pile. This is enough belt to fold over the drive sprockets and splice the conveyor. The conveyor is free to move until the drive sprockets teeth are engaged. -
Page 18: Exhaust Trough And Blower
OPERATION & MAINTENANCE MANUAL CompactFreezer clearance height. The exhaust troughs should be installed as soon as the machine is leveled so that the sheet metal or PVC contractor can install the exhaust piping and blowers (see Section 6 – Auxiliary Connections). -
Page 19: Electrical Wiring Connections
OPERATION & MAINTENANCE MANUAL CompactFreezer 5.1. ELECTRICAL WIRING CONNECTIONS Typically, a single 2” conduit will be required to connect the cabinet on the freezer. Consult the wiring diagrams inside the control box for proper sizing and location. For trouble‐fee operation of the temperature control system, the shielded cable for the RTD sensors should be run in a separate conduit away from control and power wiring lock out/tag out (... - Page 20 OPERATION & MAINTENANCE MANUAL CompactFreezer For operation, the freezer requires a source of liquid nitrogen from a storage tank. The liquid nitrogen supply piping connects the storage tank with the liquid nitrogen injection system of the freezer. Insulate all liquid nitrogen piping up to the connection at the freezer to ensure an efficient and economical operation.
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Page 21: Exhaust System Installation
OPERATION & MAINTENANCE MANUAL CompactFreezer It is recommended that the LN ‐supply line is purged before final hook‐up to the freezer by opening the main supply valve at the tank slowly. Purge the LN ‐line for approximately 30 seconds, and then close the main supply valve. -
Page 22: Initial Start-Up And Tuning
OPERATION & MAINTENANCE MANUAL CompactFreezer Importance of Vapor Balance A correct vapor balance is related to the amount of gas flowing out of the freezer. If properly adjusted, only a small amount of nitrogen gas will arrive in the production area. This slight spill of gas ensures that no room air is drawn into the Cabinet Freezer freezer. -
Page 23: Pre-Startup Checklist
OPERATION & MAINTENANCE MANUAL CompactFreezer 6.1. PRE‐STARTUP CHECKLIST 1. Verify that all packaging material and tools have been removed from the freezer (inside and outside). 2. Verify that all electrical, LN and exhaust connections have been made according to the guidelines provided in Section 5 ‐... -
Page 24: Operating Temperature
OPERATION & MAINTENANCE MANUAL CompactFreezer 4. Start the exhaust blowers. Check for proper blower motor rotation (three module only). Radial blade blowers have a small suction even when rotating backwards. Motor should rotate so the blower blades move towards exhaust spiral outlet. 5. -
Page 25: Freezer Control Variables
OPERATION & MAINTENANCE MANUAL CompactFreezer best efficiency of the cryogen. The circulating fan must be operating; otherwise the high velocity gas will not repeatedly pass the cryogen over the product to enhance the cooling effect. If the product being frozen is very flat or light, the circulating fans may cause the product to lift off the belt. This can cause product damage. -
Page 26: Operating Instructions
OPERATION & MAINTENANCE MANUAL CompactFreezer 7. Operating Instructions 7.1. IMPORTANT OPERATING AND MAINTENANCE POINTERS The following synopsis is intended to be a handy reference of specific, important, Operation, Cleaning, and Maintenance Factors, requiring most frequent attention. However, familiarity and understanding of the detailed explanations and descriptions in the manual is essential. - Page 27 OPERATION & MAINTENANCE MANUAL CompactFreezer Freezer Start‐Up Procedure: 1. Follow the Pre‐Startup Checklist in Section 6.1 prior to start‐up every day. 2. Open the manual shut‐off valve (main valve) of the LN ‐supply at the storage tank if it is not already open.
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Page 28: Production Interruptions
OPERATION & MAINTENANCE MANUAL CompactFreezer 15. Check the temperature and condition of the food coming out of the freezer. Make one or more of the following adjustments if required: a. belt speed and/or belt loading b. production rate c. set point temperature 7.3. -
Page 29: Shutdown
OPERATION & MAINTENANCE MANUAL CompactFreezer and this will become thicker and colder with time. The center of the product will freeze last, and there will be an appreciable difference in the temperature of the outer shell and the center of the product. If a product is to be frozen to X°... -
Page 30: Emergency Shut Down
OPERATION & MAINTENANCE MANUAL CompactFreezer 7.7. EMERGENCY SHUT DOWN Emergency stop, or e‐stop, buttons are located on the control panel or if panel is mounted on the wall the top of the freezer. If an emergency (such as a product jam or unexpected stoppage) occurs, hit any one of the e‐stops and the freezer will shut down. -
Page 31: Maintenance
10. Any removable parts that were taken off the freezer for clean‐up should be replaced; such as stainless steel panels at the ends of the freezer, exhaust duct cleanout cap, exit and entry curtain, etc. 11. The fiberglass walls of the freezer can be polished periodically. Contact RS Cryo for additional information. 9. Maintenance... -
Page 32: Preventative Maintenance
OPERATION & MAINTENANCE MANUAL CompactFreezer • Always de‐energize the control panel before opening and working on any components inside. Follow Lock Out / Tag Out (LOTO) procedures where applicable. • Isolate the cryogen by closing the shutoff valve at the tank and the shutoff valve at the freezer (HV‐100). -
Page 33: Safety Relief Valves
OPERATION & MAINTENANCE MANUAL CompactFreezer c. Adjust the tensioning devices to center position d. Pull the conveyor belt tight through the freezer and determine which drive links cut to shorten the belt. See Figure 1 in Appendix A. e. After cutting out the links, pull the belt ends together and join together with the splice rod; being sure to thread all mesh properly. -
Page 34: Doors
A precaution to take is that if any gasket screws are replaced they should not be any longer than the screws originally supplied by RS Cryo. If a longer screw is added it may go through the UHMW backing and water will be able to get to the insulation. -
Page 35: Temperature Controller
OPERATION & MAINTENANCE MANUAL CompactFreezer When a freezer is installed, the LN2 lines are blown out to clear out debris. There is a strainer on each LN2 drop line that should be cleaned about one time per year. To clean the orifices, remove the nozzle. Probe the orifice in the nozzle with a fine pin and tap the nozzle lightly to remove the foreign material from inside. - Page 36 OPERATION & MAINTENANCE MANUAL CompactFreezer Remove fan blade by first loosening the two cross bolts on it. Remove hex cap screw and thrust washer and slide fan blade and key off shaft. Remove the clamping collar. Force flat point of a screwdriver or similar tool in one of the slits in the bearing housing to pry slightly apart.
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Page 37: Trouble Shooting
This section helps the maintenance or reliability team troubleshoot the freezer and take the appropriate actions. Additional information on the various components can be found in the appendices. Troubleshooting should only be carried out by qualified personnel. Contact RS Cryo with any questions or concerns. - Page 38 OPERATION & MAINTENANCE MANUAL CompactFreezer fails to operate, check the following in order: • Check if the emergency stops have been activated. Reset if necessary. • Check if the main fuses of the drive motor (belt) are intact. • If the conveyor belt does not run at a smooth, uniform speed, check the belt tension. Excessive slack in the belt tension may cause an irregular belt speed.
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Page 39: Troublshooting Table
OPERATION & MAINTENANCE MANUAL CompactFreezer 10.4. TROUBLSHOOTING TABLE TROUBLE PROBABLE CAUSE REMEDY LN2 vapor flowing over Exhaust blower not operating Check blower and correct cause exhaust troughs or wrong rotation Clogged exhaust pipe or full Check and correct cause blast gate in piping Too much air drawn in from Check curtain. - Page 40 OPERATION & MAINTENANCE MANUAL CompactFreezer TROUBLE PROBABLE CAUSE REMEDY freezer curtains Check relay or solenoid valve. Relay or solenoid valve Correct cause or replace item(s), if necessary Temperature indicator Liquid solenoid valve stuck Check for foreign material on valve overshooting open seat.
- Page 41 OPERATION & MAINTENANCE MANUAL CompactFreezer TROUBLE PROBABLE CAUSE REMEDY Product exits freezer too Freezer not sufficiently cooled Wait a few more minutes before warm at start‐up of down. correcting. production. Steady state not reached. Product residence time too Reduce belt speed. short.
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Page 42: Spare Parts List
The following list of spare parts apply to ULTRA‐FREEZE® Freezers with 30” or 48” wide belts, and 1 or 3 tiers. To obtain spare parts for items not listed below, please contact RS CRYO at (866) 305‐1300. 11.1. MOTOR AND FAN ASSEMBLY PARTS... -
Page 43: Other Parts
OPERATION & MAINTENANCE MANUAL CompactFreezer 11.3. OTHER PARTS Part Number Part Description 30‐570010 LN2 Injection Solenoid Valve 30‐570360 Sensor, Temperature (RTD type) 30‐570004 Motor, Conveyor Drive, 1/3HP 30‐550491 Gasket, Door Curved, Spun Polyester 30‐550490 Gasket, Door Straight, Spun Polyester 30‐550489 Guide Strip, Door Gasket, Stainless Steel... -
Page 44: Appendices
OPERATION & MAINTENANCE MANUAL CompactFreezer 12.Appendices Appendix A Liquid Nitrogen MSDS... -
Page 45: Appendix B - Reference Drawings
OPERATION & MAINTENANCE MANUAL CompactFreezer Appendix B Reference Drawings... -
Page 46: Appendix C - Component Manuals
OPERATION & MAINTENANCE MANUAL CompactFreezer Appendix C Component Manuals...
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