De Icing Instruction

SECTION 4.
INSTRUCTIONS FOR
FREEZE DRYING PLANT
CONRAD™ 600 XL eco
DE-ICING SYSTEM
Please read the instructions provided in this section of Instruction Handbook thoroughly.
All plant personnel must be familiar with these instructions. Failure to follow these
instructions may result in injury, fatal accident and plant damage.
0610-0zzz
4009 en
032-7024
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Copyright © 2015 GEA Process Engineering A/S. All rights reserved.
0610-0zzz CONRAD™ 600 XL eco
4009 en De-Icing System
TABLE OF CONTENTS PAGE
1 DESCRIPTION OF THE DE-ICING SYSTEM .................................................................1
1.1 General.............................................................................................................................1
1.2 Safety ...............................................................................................................................2

1.2.1 Persons responsible for the safety ...................................................................................2
1.2.2 General safety issues .......................................................................................................2
1.2.3 Environmental protection ..................................................................................................3
1.3 Technical data .................................................................................................................4

1.3.1 Main data ..........................................................................................................................4
1.4 Installation .......................................................................................................................5

1.4.1 Storage .............................................................................................................................5
1.4.2 Placing ..............................................................................................................................5
1.4.3 Erection of pipe system ....................................................................................................6
1.4.4 Handling of components ...................................................................................................6
1.4.5 Tightness test of the de-icing system ...............................................................................7
1.4.6 Vacuum test of the de-icing system .................................................................................7
1.4.7 Documentation..................................................................................................................7
1.5 Operation .........................................................................................................................8

1.5.1 Stop – Step 0 ....................................................................................................................8
1.5.2 Cooling down, start, step 1 and 2 .....................................................................................8
1.5.3 Evacuation – Steps 1, 2, 3, 4 and 5 .................................................................................9
1.5.4 Freeze drying – Step 6 ...................................................................................................10
1.5.5 Vacuum Break – Step 7 ..................................................................................................10
1.5.6 Draining system ..............................................................................................................11
1.5.6.1 De-icing tank and heating system ................................................................................. 11
1.5.6.2 De-icing pump system ................................................................................................... 12
1.5.7 Vacuum break – Step 7 ..................................................................................................14
1.5.8 Automatic safety devices in case of system alarm/stop.................................................14
1.6 Maintenance ..................................................................................................................16

1.6.1 Safety during maintenance .............................................................................................16
1.6.2 Vacuum leak detection ...................................................................................................17
1.7 Regular check points ...................................................................................................18
1.8 Disposal .........................................................................................................................19
1.9 Spare parts ....................................................................................................................19

1.9.1 Ordering of spare parts ...................................................................................................19
1.9.2 Critical spare parts ..........................................................................................................20
1.9.3 Spare parts for operation ................................................................................................20
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1 DESCRIPTION OF THE DE-ICING SYSTEM
1.1 General
See drawing No. 1149461: P/I-Diagram De-icing System
The de-icing system is used to remove the ice which has condensed on the vapor traps
inside the CONRAD™ cabinet. The ice is removed by injecting vacuum steam from the
de-icing tank C4400 into the top of the vapor traps. The condensed steam and de-icing
water is drained off at the bottom of the vapor trap. During the entire de-icing cycle the
vapor trap is held under vacuum. The vapor trap which is being deiced is isolated from
the cabinet with a gate-plate. The pressure during de-icing is about 20-35 mbar.
The water in the de-icing tank C4400 is heated to a temperature of approx. 25°C by
injection of steam through a heating coil mounted in the de-icing tank.
The analogue regulating valve Q4403 uses the measurement of temperature sensor
K4403 to control the temperature inside the de-icing tank by regulating the steam
supply to the built-in coil in the tank and maintain the pressure at the set point.
The pressure in the de-icing piping system is measured by the pressure transmitter
P4408. The pressure transmitters range is between 4-20mA for 0-100mbar.
Using the correlation of temperature/pressure for saturated water vapor, the
temperature of the water in de-icing tank can be calculated and controlled. Especially
for keeping the temperature in the de-icing tank constant by a quick regulation, when
the vapor traps are operating in de-icing mode and energy is required for the process.
Set points for regulation are set on the display as temperatures; alarms are raised
when too low/high values are measured by the sensor K4403 and transmitter P4408.
During de-icing of the vapor traps the valve Q41x4 between the top of the vapor trap
and the de-icing tank C4400 will be open. Due to a lower pressure in the vapor trap,
the water in the de-icing tank C4400 starts to boil and vacuum steam is led from C4400
to the vapor trap, thus melting the condensed ice.
After approx. 5 minutes the drain valve Q41x5 at the bottom of the vapor trap opens
allowing the water inside the vapor trap to be drained off to a drain tank C4200. The
level switches inside the tank regulate when the water is pumped out of the tank by
means of one of the two drain pumps (G4303 or G4313). Level switch K4402
measures the water level inside the de-icing tank. The pump will stop when level switch
K4201 has been LOW for 10 sec.
The system can be set in two modes, either reusing the de-icing water or adding fresh
process water when necessary. From the pumps, the drain-water is led through the
three-way valve Q4340 where it can either be led back to the de-icing tank C4400 to be
reused, or to the overflow tank C4350 or dumped into a foul condensate drain. The
amount of discharged water to the foul condensate drain is monitored at the flow meter
P4350.
A solenoid valve Q4350 for the overflow tank controlled by level switch K4350 has an
on/off function to ensure a minimum level of water always is maintained in the overflow
tank. If the overflow tank is emptied of water, there is a risk that air can be sucked back
through the de-icing system, thus resulting in vacuum problems in the CONRAD™
cabinet.
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1/19 GEA Process Engineering
CONRAD™ 600 XL eco 0610-0zzz
De-Icing System 4009 en
1.2 Safety
1.2.1 Persons responsible for the safety
User:
A user is any natural or legal person that uses the de-icing system or at whose request
the de-icing system is being used.
The user or his safety representative must ensure that:

• All relevant rules and regulations are observed
• Only qualified personnel are working at and with the de-icing system
• The operation manuals are available to the personnel for all relevant tasks
• Unqualified personnel are not allowed to work at and with the de-icing system
Qualified personnel :
Qualified personnel are persons who, based on their education, experience, special
training and knowledge of relevant standards and stipulations, safety regulations and
operating conditions are authorized by the person responsible for the safety on the
plant to perform the necessary actions and who are able to recognize and avoid
possible dangers.
1.2.2 General safety issues
Warning!
It is of the utmost importance that any operator of the de-icing system

has read and understands the guidelines in the manuals including
those from the sub suppliers.
All electrical installation and/or repair work is to be carried out by a

professional electrician.
Warning!
The temperature of the surfaces of the hot water supply valves and
pipes is above 80°C during operation, and it is therefore prohibited to
make any service or maintenance on the hot water supply system
while it’s in operation.
Before personnel enter the CONRAD™ cabinet for maintenance it must be secured
that the heating plates are cooled down to a reasonably low temperature. It is
recommended to cool the heating plates to 40°C before entering the CONRAD™
cabinet.
Signs as shown below should be placed on the hot water equipment.
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Warning!
If it is, however, absolutely necessary to carry out any work on the hot
water equipment during operation, a full covering suit and gloves
should be worn to avoid exposing bare skin to the heat.
NOTE!
The following points should also be noted and adhered to during the installation and
operation of the plant:
• The de-icing unit and the drain unit must be placed on a firm solid base or
foundation and fixed to the support with bolts as indicated on the drawings.
Loads for the tank and pumps are shown on the foundation drawings.
• Remove or secure the handle of the manual drain valve when the CONRAD™ is in
operation.
• Always check that all manual valves are in the correct position before starting
operation.
1.2.3 Environmental protection
Many countries have legislated in the area in the attempt to reduce pollution and
protect the environment. These environmental protection acts that are to be observed
concern all sectors of the industry. It is the obligation of the end user to ensure that
local environmental rules are adhered to, with regard to disposal of consumables and
other waste products from the process.
Especially, please be aware of the liquids lubricants and Waste water:
Lubricants:
Wherever possible, food-approved lubricants (FDA; USDA H1) are used.
At change of oil, the waste oil must be collected in a vessel and sent to an authorized
destructor.
Waste water:
De-icing water being drained from the overflow vessel, C4350 will contain a small
concentration of the product being dried in the CONRAD™.
For operation with sublimation of approx. 1.5 kg/m2/h the contamination will be less
than 0.1% of the production.
The specific contamination will depend on the product and the operation parameters
for the heating, vacuum, refrigeration and transport systems. Changes in vacuum,
sublimation and condenser temperature will influence the contamination.
During start-up and after product change, an analysis of the de-icing water should be
performed, to determine the required treatment of the water before disposal.
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1.3 Technical data
1.3.1 Main data
De-icing system CONRAD™ 600 XL eco

Electricity supply
Drain pumps P motor kW 1.1
G4303 & U motor V 3 x 400
G4313 In A 2.6
Start DOL
Connections:
Steam to De-icing Tank C4400
Steam supply Pipe: DN 50
Steam return Pipe: DN 40
Quantity Kg/h 350
Temperature: °C 165
Sealing water
G4303 & G4313:
Inlet; pipe: DN 15
Quantity: L/h 20
Pressure: Barg 2.0
Temperature °C 30
Overflow tank C4350:

Connection: DN 25
Process water consumed: L/h 100
Drain water discharged: L/h 850
Pressure: Barg 2.0
Temperature °C 20
For distribution of compressed air to the pneumatic actuators, please see the
pneumatic diagram drawing 1149463.
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1.4 Installation
1.4.1 Storage
If the De-icing system is not installed immediately, suitable storage conditions must be
provided.
Up to a year: Dry, frost-free and dust-free rooms protected from sunlight.

Over a year: Please contact the manufacturer.
1.4.2 Placing
Sufficient space around the components for inspection, operation, cleaning and
maintenance is recommended. Please see de-icing arrangement drawing 1200347
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1.4.3 Erection of pipe system
All pipes and fittings must be clean inside. After cutting the cutting edge must be
removed and the pipes must be cleaned of scales inside.
Cuttings should always be made at 90° to the pipe axis to ensure parallel pipes and
proper welds. To facilitate welding the pipe must be sharpened after cutting.
Never use flame cutting for cutting of stainless steel pipes. Preferably a mechanical
cold saw should be used for cutting the pipes.
When welding on flanges it must be ensured that the flange has a 90° angle to the pipe
axis. Otherwise it will be difficult to tighten the flange and a lot of stress will be created
in the pipes.
The pipes should be measured out carefully according to the arrangement drawing and
the actual conditions on the site. Do never force pipes into position as it will create
stress or even breaking of the pipes.
Even if the de-icing system is never under any high pressure welding must be
executed by certified welders to ensure a minimum of leaks in the system.
As the de-icing system is entirely of stainless steel, only TIG/Argon welding may be
used. After welding, the surface must be treated with a suitable acid agent to retain the
stainless surface.
When bolting together flanges remember to grease the bolts with suitable grease i.e.
copper grease or Molycote. Please note that non-asbestos gaskets may not be used
as they are too porous and not vacuum tight.
Note:
Only rubber gaskets without canvas insert should be used.
When using threaded connections a good quality packing yarn and packing grease
should be used. Alternatively Loctite type 572 or similar can be used.
A sufficient number of pipe supports must be used to ensure that load is not applied to
pumps and valves.
1.4.4 Handling of components
When installing components such as pumps and valves it must be checked that
protection covers are removed and that the components are clean inside before
installation.
It must be checked that direction arrows on pumps and valves are according to the flow
diagram.
The circulation pumps and valves must be protected against welding drops and scales
from grinding during erection. The components should be handled with care as
bearings and shaft seals might be damaged by mechanical shock.
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When butterfly valves are installed they must always be slightly opened - about 10 %. If
not, the rubber seat may be squeezed when the flanges are tightened.
1.4.5 Tightness test of the de-icing system
All valves to the CONRAD™ cabinet must be closed and the overflow pipe from the
drain tank must be blinded, before the leak test is made
Air is filled into the system until a pressure of approx. 500 mm Water gage is obtained
(measured with U-tube manometer). All welds and connections in the plant are then
carefully leak tested by means of soap water. If any leaks are found they are marked
for later repair.
After finished test and repairs have been made a retest following the same procedure
as described above are performed. Leak test and repairs are repeated until no leaks
appear any longer.
Stop!
All main components are pressure tested according to PED or ASME

rules. Therefore detection and repairs of leaks at the pressure parts
are only at piping, erection joints and connections!
Warning!
When testing pneumatically local authority safety rules have to be

followed.
Stop!
When doing welding work, or repairs at pressure components or

pressure lines, only certified welders are allowed to.
Authority rules for pressure equipment have to be followed.
The low-pressure steam line is pressure tested with water to a pressure of 1.43 times
the working pressure. If leaks appear, the pressure is taken off and the spotted area
repaired. The procedure is repeated until no more leaks are located.
1.4.6 Vacuum test of the de-icing system
As the de-icing system forms part of the vacuum system it is vacuum tested together
with this system as described under the test of the vacuum system.
1.4.7 Documentation
Leak test, pressure test and vacuum test to be documented with a report showing test
details and signed up by the responsible person for accepted result.
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1.5 Operation
See Working Diagram No. 1205282 (cabinet section)
The de-icing system is operated – started and stopped – together with the vacuum
system on the main faceplate.
1.5.1 Stop – Step 0
All seven vapor traps are out of operation, i.e.:
• Gate plates G10x0 CLOSED

• Vacuum valves Q31x1 CLOSED
• CO 2 -valves Q61x2 CLOSED
• De-icing valves Q41x4 CLOSED
• Drain valves Q41x5 OPEN
(x represents the vapor trap no., i.e. G1020 is the gate plate for vapor trap 2.)
NOTE!
Before start-up, check that the system is filled with water so that the level is normal in
the de-icing tank C4400 and the overflow tank C4350 is filled.
1.5.2 Cooling down, start, step 1 and 2
In this step the preparation for operation of the vapor traps starts one by one.
At start gate plate G1010 OPENS, CO 2 valve Q6112 OPENS the refrigerant supply
branch, cooling media to the coil is now running. Meanwhile valves Q61x3 CLOSES all
refrigerant drainage branches. All de-icing drainage valves Q41x5 stay open.
After time T1 (2 minutes) vacuum valve Q3111 and De-icing valve Q4114 OPEN and
vapor trap no. 1 is put in operation.
At the same time gate plate G1020 OPENS, while CO 2 -valve Q6122 OPENS for
refrigerant flow to the coil.
After time T1 (2 minutes) Vacuum valve Q3121 OPENS and vapor trap no. 2 is put in
operation.
At the same time Gate plate G1030 and CO 2 -valve Q6132 OPENS for refrigerant flow
to the coil.
operation.
At the same time Gate plate G1040 and 3-way CO 2 -valve Q6142 OPENS for
operation.
At the same time Gate plate G1050 and 3-way CO 2 -valve Q6152 OPENS for
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After time T 1 (2 minutes) Vacuum valve Q3151 OPENS and vapor trap no. 5 is put in
operation. At the same time Gate plate G1060 and 3-way CO 2 -valve Q6162 OPENS
for refrigerant flow to the coil.
operation. At the same time Gate plate G1070 and 3-way CO 2 -valve Q6172 OPENS
for refrigerant flow to the coil.
operation.
NOTE!
When the first vapor trap has been cooled down (after time T1), evacuation of the
cabinet is automatically started. Drain valves Q41x5 are already OPEN, so the de-icing
system is evacuated together with the cabinet.
Remark
De-icing of a vapor trap is based on timer function. The setting of the timer is
dependent on the product being dried and must be determined empirically.
The temperature in the de-icing tank must be regulated in such a way that
• de-icing does not influence the vacuum in the cabinet
• all the ice is melted off during de-icing
It is important for the de-icing time that the temperature in the de-icing tank is kept
above the boiling point when the de-icing valves Q41x4 OPENS.
The pressure in the de-icing tank and in the vapor trap will vary between about 20 to 32
mbar during de-icing depending on the temperature of the de-icing water.
1.5.3 Evacuation – Steps 1, 2, 3, 4 and 5
At 40 mbar, de-icing valve Q4114 and drain valves Q41x5 CLOSE.
After the de-icing valves have been closed, the analogue regulating valve Q4403,
which controls the supply of steam to the built-in coil in the de-icing tank starts
operating and the water in the tank is heated to approx. 25°C.
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1.5.4 Freeze drying – Step 6
During the freeze-drying process all seven vapor traps are de-iced one at a time
according to the vapor trap de-icing cycle program. In this way it is secured that at least
six “clean” vapor traps are in operation at any given time.
The time between two consecutive de-icing periods (Timer T 7) and the actual time for
de-icing of the vapor trap coil (Timer T8) should be adjusted during commissioning to
suit the actual product.
1.5.5 Vacuum Break – Step 7
During vacuum break, all the vacuum pumps stop. Bypass valve Q9608 is opened and
de-aeration valves are activated.
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1.5.6 Draining system
1.5.6.1 De-icing tank and heating system
The purpose of the de-icing tank is to have sufficient water to de-ice the vapor trap
coils and to keep the water at a temperature where it will flash up/boil when the
connection to a vapor trap is opened.
The temperature transmitter (K4403) measures the temperature in the de-icing system.
The analogue regulating valve Q4403 operates any position from 0 % to 100 % to
regulate the steam to the built-in coil of the de-icing tank for maintaining the
temperature in the system controlled by transmitter K4403.
The temperature in the de-icing tank is maintained at approx. 25°C.
When one of the de-icing valves Q41x4 is opened, the pressure in the de-icing tank
drops and the water flashes up and streams to the vapor trap. As the water is flashed
up, energy is drawn from the de-icing tank and the temperature will drop slightly until
the heat regulation has compensated for the loss after which the water in the tank will
flash up again. This will continue until the vapor trap has been de-iced completely.
The temperature in the de-icing tank thus has a direct influence on the de-icing time
and it is very important that it is maintained stable.
NOTE!
If the temperature is too high, the pressure in the vapor trap during de-icing will be too
high, and the vacuum in the cabinet could be affected by vacuum steam flowing from
the de-icing tank to the CONRAD™ cabinet through the safety valves on the vapor
traps.
During de-icing, water will be removed from the tank C4400, and the level switch
K4401 may go to LOW. If the system is in mode for reusing the de-icing water, this will
cause three-way valve Q4340 to direct drained de-icing water to C4400. If not in mode
for reuse of the de-icing water, this triggers Q4409 to OPEN and fill fresh process
water on the tank until K4402 goes to HIGH causing Q4409 to CLOSE.
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If the analogue valve Q4403 fails it is possible to maintain the temperature in the de-
icing tank by letting steam through the by-pass valve Q4423 and survey the
temperature on thermometer P4405. An operator must be present at the de-icing tank
to adjust the valve until the fault in the automatic system has been rectified.
1.5.6.2 De-icing pump system
The pump unit drains the melted condensate which gathers in the drain tank C4200
during de-icing of the vapor traps. When level switch K4202 reached goes to HIGH the
pumping is STARTED.
There are two pumps which run in parallel and the program are made in such a way,
that the pumps are operated on alternate days in order to ensure even wear. If pump
system G4313 is in operation and an alarm occurs in the system, pump system G4303
will act as spare and vice versa.
As the drain pumps are connected directly to the vapor trap during de-icing inside the
cabinet, there is a pressure of 20-50 mbar on the suction side of the pump. To avoid
breaking the vacuum in the cabinet, the pump has to create a pressure above
atmospheric pressure before the drain valves Q4305 or Q4315 are opened.
A pressure switch K4305 / K4315 monitors the pressure on the outlet side of each
pump. When the set point (approx. 1.1 Bar) for the pressure switch has been reached,
valve Q4305 or Q4315 OPENS, and the water is pumped from the system.
The water is pumped through the outlet line via the overflow vessel C4350 and
dumped into the foul condensate drain. The amount of discharged water to the foul
condensate drain is measured by the flow meter P4350.
The amount of water passing through the flow indicator P4350 will be equal to the
amount of vapor that has been removed by the vapor traps and thereby named as the
capacity of the CONRAD™.
The capacity must be measured over a period of time, 6, 12 or 24 hours, as the loads
on the 7 vapor traps in the CONRAD™ are not equal.
If reuse of the de-icing water is chosen, level switches K4402 and K4401 in the de-
icing tank C4400 control where the steam is led by the three-way valve Q4340. If
K4402 is HIGH when drain pump G43x3 starts, the water is led to the overflow tank
C4350 and dumped into the foul condensate drain. If level switch K4401 in the de-
icing tank C4400 is LOW when the drain pump G43x3 starts, the drain water is led
back to the de-icing tank C4400.
When K4201 is LOW the active drain pump is STOPPED and the corresponding valves
are closed.
If level switch K4350 indicates low level in the overflow tank C4350, the top-up water
valve Q4350 opens until the low-level alarm is gone. This is to prevent air from being
sucked into the system.
The flow device K43x3 regulates and monitors the flow of sealing water to the drain
pumps. A proximity switch is activated when the flow is sufficient and the pump can
start. If K43x3 is low the corresponding pump cannot start.
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Stop!
The drain pumps G4303 and G4313 must never run without shaft
sealing water as dry running will immediately destroy the shaft seals.
See details below.
Important:
• There must always be a flow of about 20 l/h through the shaft seal of the pump in
operation
• If K43x3 is LOW for 15 sec. the corresponding pump will stop
• The flow must be manually adjusted on needle valve FC4303/FC4313. The actual
flow can be read on the instrument and must be regulated so that the proximity
switch has a stable signal
• The pressure of the water should only be 0.3 to 0.5 Barg.
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1.5.7 Vacuum break – Step 7
All seven vapor traps will take the following positions:

Gate plate GATE10x0 OPEN
Vacuum valve Q31x1 OPEN
CO 2 -valve Q61x2 CLOSED
De-icing valves Q41x4 OPEN
Drain valves Q41x5 OPEN
When the time T 13 + T16 have elapsed, the program automatically moves to Stop –
Step 0 and all vapour traps are out of operation with closed gate plates and open drain
valves as described earlier under the heading Stop – Step 0.
1.5.8 Automatic safety devices in case of system alarm/stop
Automatic devices
• If one of the drain pumps G43 fails the other will start automatically and the
corresponding auto valve Q43x3 will close.
• If the pressure switch P43x5 is low for 10 sec. after the corresponding drain pump
has started, the other drain pump will start instead. The pump that failed to give
pressure will stop and give an alarm.
• If a flow switch K43 registers that the flow of sealing water is LOW for 15 seconds,
it is interlocked to a corresponding drain pump G43xx which it will stop and give an
alarm. The other pump will start.
• If the overflow tank has low level (K4350), valve Q4350 will open and top-up the
level.
Alarms
• LOW LEVEL ALARM (K4401) if water level in de-icing tank is LOW for more than
600 seconds during the freeze drying mode.
• HIGH-LEVEL alarm (K4402) if the level in the de-icing tank is HIGH for more than
300 seconds.
• LOW TEMPERATURE ALARM (K4403) if the temperature in the de-icing tank falls
below the alarm set point.
• HIGH TEMPERATURE ALARM (K4403) if the temperature in the de-icing tank

rises above the alarm set point.
• LOW LEVEL ALARM (K4350) if water level in overflow tank is low for more than
120 sec.
• LOW-PRESSURE alarm if the signal is LOW for 15 sec. (K4305/K4315) when drain
pump G4303/G4313 is running.
• MALFUNCTION ALARM for auto valves: Q4301/Q4311, Q4305/Q4315, when

operating is not correct
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• LOW-FLOW alarm if the signal is LOW (K4303/K4313) for more than 15 seconds
with valve Q4303/Q4313 OPEN
• FAIL TO START or TRIP ALARM in case of pump failure (G4303/G4313)
• LOW TEMPERATURE ALARM (K4408) if the temperature in the system falls below
the alarm set point.
• HIGH TEMPERATURE ALARM (K4408) if the temperature in the system rises

above the alarm set point.
Set points
The de-icing tank works with the following set points:
HIGH TEMPERATURE alarm: 27 °C

SETPOINT: 22 °C
LOW TEMPERATURE alarm: 15 °C
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1.6 Maintenance
1.6.1 Safety during maintenance
The drain pumps G4303 & G4313 can be isolated from the system for maintenance
during operation. The shut-off valves on either side of the pump are closed and the
pneumatic hoses are removed. If the pump is removed for a longer time, the flanges
should be blinded to avoid contamination of the pipeline. Clean the pipeline carefully
before mounting the pump again.
If the hot water regulating valve Q4403 or the steam trap V4412 breaks down during
operation, they can be isolated and bypassed manually.
Warning!
No part of the hot water supply system may be removed while under
pressure or while the temperature is above 40°C.
If the vacuum in the de-icing tank has been lost due to repair or failure, the operating
vacuum level must be re-established before connection to the cabinet.
This can be done in the following way:
• If vacuum lock pump G3801 is in operation switch manually to G3811

• Make sure that valve Q3812 is manually CLOSED so that pump G3811 is isolated
from the cabinet system (also includes closing of Q3819).
• Start pump G3811
• Open manual valve Q3809 and evacuate de-icing system to operating pressure
• Close valve Q3809 and stop pump G3801
Warning!
Never try to evacuate the de-icing tank through the vapour trap, as this
will result in a vacuum peak and will influence the product quality
Warning!
The below mentioned guidelines should always be followed when

carrying out any maintenance work on the de-icing system.
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• Before removing pneumatically operated valves, the compressed air supply lines
must be disconnected. The disconnected air hoses must be blocked with plugs or
by tongs and cleaned carefully before reassembly.
• While the CONRAD™ is under vacuum, it is not possible to remove for

maintenance any of the valves Q41x4 and Q41x5 connected to the vapor traps.
The vapor trap with a faulty valve must be bypassed in the control system until it is
possible to break the vacuum in the cabinet.
• The actuator and position indicators may be replaced during operation.

Please see supplier’s instruction for further details.
• It is not possible to manually drain water from the de-icing tank (C4400) while the
cabinet is under vacuum and it should not be attempted, as it would disturb the
operation of the CONRAD™.
• If the de-icing vessel C4400 has to be moved, a forklift or similar must be used.
Before moving the de-icing vessel, all water must be drained from the tank through
the drain valve.
• Specialists only may perform all maintenance work other than leak detection
• If one of the automatic butterfly valves is used to isolate a pump, the control air to
open the valve must be disconnected before any work is done on the pump.
• Only spare parts mentioned in the spare parts list or other spare parts approved by
GEA Niro may be used when repairing any part of the system.
• Prior to any maintenance or repair work on the pumps, the power must be
disconnected at the source, and it must be ensured that the power cannot be
turned on accidentally by locking the safety breaker with a personally kept pad-lock
or similar.
• For details on repair and maintenance of specific items, please find sub supplier’s
instructions in this Instruction Handbook.
1.6.2 Vacuum leak detection
The de-icing system is an integrated part of the vacuum system, and it is therefore
important that the system is without leaks.
For further details please see the description of the vacuum system.
GEA Niro
1.7 Regular check points
DE-ICING SYSTEM
CONTROL POINT d w m s y ACTION REMARKS
Drain pumps x Check for leaks If defective, replace
G4303 the packing set.
G4313 x Check flow for shaft Adjust to 20 l/h
sealing water
De-icing tank x Check water quality If contaminated,
C4400 replace water.
x Verify indication from Calibrate/replace if
temperature sensor necessary
K4403
x Verify indication on Calibrate/replace if
thermometer P4405 necessary
x Check level sensors Replace if necessary
K4201/K4402
Filter x Clean filter insert Replace insert if
V4421 damaged
Flow indicator x Check calibration Calibrate if
K4350 necessary.
Kytölä flow controllers x Check adjustment of Adjust if necessary
K4303 and flow
K4313 x Check function of Replace if not
flow switch functional
Flanged connections x Check for leaks If leaking replace
packing.
Butterfly valves x Check for leaks Replace worn parts.
x Check function of Verify full 90 deg
actuator operation
x Check function of Replace if faulty.
position indicator
D = daily, w = weekly, m = monthly, s* = special, y = yearly

* see supplier’s instructions; or during routine maintenance
GEA Niro
1.8 Disposal
What? Where?
Transport Pallets To be returned to manufacturer or

materials forwarding agent.
Packaging Cardboard to paper recycling.
Plastic to plastic recycling or residual
waste.
Lubricants Oil, grease To be disposed of according to local
regulations.
Components Motors Electrical Should be returned to the motor
supplier or other specialist for disposal
Actuators Steel Should be returned to the supplier or
Seals other specialist for disposal.
Electrical
Valves Cast iron Housing and seals to be dismantled
Sealing and disposed of separately
Piping and Mild Steel To be sent to scrap yard for recycling
fittings
Instruments Stainless steel Should be returned to supplier or other
Plastic specialist for disposal
Special waste
1.9 Spare parts
1.9.1 Ordering of spare parts
De-icing system
When contacting the service department of GEA Niro, please state full part number
1293528 from the spare parts list. This part number unambiguously identifies the
requested spare part.
Refer to the original GEA Niro main order (032-7024) for the supplied machinery.
For contact about service or other information, state machine type, serial number and
year of manufacture. Such data appear from the nameplate.
Drives
The type designation appears from the nameplate on the drive.
For ordering of separate parts for drive renovation, please see the supplier’s
instructions for repair, which are enclosed in this manual.
Pneumatic valves
Pneumatic components can be ordered from GEA Niro or according to the supplier’s
diagram and parts list, which are enclosed with this manual.
GEA Niro
1.9.2 Critical spare parts
The necessary spares in order to ensure reliable operation have been delivered with
the equipment.
Whenever a spare part is used from the supplied spares the damaged part should be
repaired or replaced.
1.9.3 Spare parts for operation
Drawings and parts lists are enclosed with this manual.
The spare part lists contain information about spare parts for the various components
in the De-icing System.
GEA Niro

De Icing Instruction

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SECTION 4.

FREEZE DRYING PLANT

CONRAD™ 600 XL eco

TABLE OF CONTENTS PAGE

1 DESCRIPTION OF THE DE-ICING SYSTEM .................................................................1

1.2 Safety ...............................................................................................................................2

1.3 Technical data .................................................................................................................4

1.4 Installation .......................................................................................................................5

1.5 Operation .........................................................................................................................8

1.6 Maintenance ..................................................................................................................16

1.7 Regular check points ...................................................................................................18

1.8 Disposal .........................................................................................................................19

1.9 Spare parts ....................................................................................................................19

1 DESCRIPTION OF THE DE-ICING SYSTEM

See drawing No. 1149461: P/I-Diagram De-icing System

1.2.1 Persons responsible for the safety

The user or his safety representative must ensure that:

1.2.2 General safety issues

It is of the utmost importance that any operator of the de-icing system

All electrical installation and/or repair work is to be carried out by a

Signs as shown below should be placed on the hot water equipment.

1.2.3 Environmental protection

Especially, please be aware of the liquids lubricants and Waste water:

Wherever possible, food-approved lubricants (FDA; USDA H1) are used.

1.3 Technical data

1.3.1 Main data

De-icing system CONRAD™ 600 XL eco

Overflow tank C4350:

Up to a year: Dry, frost-free and dust-free rooms protected from sunlight.

1.4.3 Erection of pipe system

Only rubber gaskets without canvas insert should be used.

1.4.4 Handling of components

1.4.5 Tightness test of the de-icing system

All main components are pressure tested according to PED or ASME

When testing pneumatically local authority safety rules have to be

When doing welding work, or repairs at pressure components or

1.4.6 Vacuum test of the de-icing system

See Working Diagram No. 1205282 (cabinet section)

1.5.1 Stop – Step 0

All seven vapor traps are out of operation, i.e.:

• Gate plates G10x0 CLOSED

1.5.2 Cooling down, start, step 1 and 2

1.5.3 Evacuation – Steps 1, 2, 3, 4 and 5

At 40 mbar, de-icing valve Q4114 and drain valves Q41x5 CLOSE.

1.5.4 Freeze drying – Step 6

1.5.5 Vacuum Break – Step 7

1.5.6 Draining system

1.5.6.1 De-icing tank and heating system

The temperature in the de-icing tank is maintained at approx. 25°C.

1.5.6.2 De-icing pump system

1.5.7 Vacuum break – Step 7

All seven vapor traps will take the following positions:

1.5.8 Automatic safety devices in case of system alarm/stop

• HIGH TEMPERATURE ALARM (K4403) if the temperature in the de-icing tank

• MALFUNCTION ALARM for auto valves: Q4301/Q4311, Q4305/Q4315, when

• FAIL TO START or TRIP ALARM in case of pump failure (G4303/G4313)

• HIGH TEMPERATURE ALARM (K4408) if the temperature in the system rises

The de-icing tank works with the following set points:

HIGH TEMPERATURE alarm: 27 °C

1.6.1 Safety during maintenance

This can be done in the following way:

• If vacuum lock pump G3801 is in operation switch manually to G3811

The below mentioned guidelines should always be followed when

• While the CONRAD™ is under vacuum, it is not possible to remove for