Manual FPG7575 (Example) - mk4 Issue1 - 0 - 6-Ene-21

OPERATING INSTRUCTIONS
CONSULTING AND USING THIS INSTRUCTION MANUAL
This manual is supplied in a single copy when purchasing the machine. Should the customer require
more copies they must be ordered from Homogenising Systems, stating the machine model and
serial number (this information appears on the machine identification nameplate).
The user of this machine must be a professionally trained operator with a good level of experience
on similar machines. If this is not the case, the User must attend a training course on the machine's
use either on site, at HOMOGENISING SYSTEMS’s factory plant or at the machine retailer's facility,
under the guidance of HOMOGENISING SYSTEMS’s qualified personnel.
This manual must be considered an integral part of the machine and, as such, must always be readily
available for consultation and kept in a dry place, protected from direct sunlight. HOMOGENISING
SYSTEMS authorizes the user to make copies of this document for internal use only.
The term WARNING is used to identify any actions which may compromise the machine's operation
and pose a danger or risk for the operator.
On systems fitted with SCADA Package control, removal of the desktop support folder will affect
telephone support capabilities. Also failure to carryout routine PC complete operating system
backups (windows) in particular the C & F drives which contain the OS and user Programmes
respectively, in addition to your own data backups from the G drive. The maintenance of recent
viable backups is the end users responsibility, Homogenising Systems Ltd cannot accept any liability
for loss of data under any circumstances, furthermore in the event of a computer failure/system
corruption, a system re-configuration even from the original works backup is an expensive exercise
due to the time involved in applying the various OS and application updates which will have
accumulated since the original build. The system is shipped with an AVG internet security installed
and licensed, the end user is responsible for maintaining the computer security by either maintaining
the AVG licensing or installing an equivalent software security package.
HOMOGENISING SYSTEMS reserves the right to change this manual and information within at any
time without prior notice.
FPG7575 HOMOGENISER COMFORT (mk4) issue1_0

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INDEX
FPG7575 HOMOGENISER Comfort ......................................................................................... 5
1. PURPOSE OF EQUIPMENT ........................................................................................... 5
1.1. Function and Application ........................................................................................ 5
2. Specification ............................................................................................................... 7
3. SAFETY ....................................................................................................................... 8
4. WARRANTY ................................................................................................................ 8
Guarantee ...................................................................................................................... 8
Indemnity ....................................................................................................................... 9
Validity ........................................................................................................................... 9
Disclaimer ...................................................................................................................... 9
5. Installation ............................................................................................................... 10
5.1. Machine Weight ................................................................................................... 11
5.2. Mounting.............................................................................................................. 11
5.3. Required Services ................................................................................................. 11
5.3.1. Electrical Supply Connection ............................................................................. 11
5.3.2. Pressure Connections ....................................................................................... 13
6. CONTROLS ................................................................................................................ 14
6.1. EMERGENCY "STOP" BUTTON ............................................................................... 14
6.2. Emergency Stop Reset Button .............................................................................. 14
6.3. Home Screen ........................................................................................................ 15
6.4. Home Button ........................................................................................................ 15
6.5. Alarm List Button .................................................................................................. 15
6.6. Trend Chart Button ............................................................................................... 15
6.7. Run Start Button ................................................................................................... 15
6.8. Stop button .......................................................................................................... 16
6.9. User Login Button ................................................................................................. 16
6.10. Diagnostic Button ................................................................................................. 16
6.11. Shut Down Button ................................................................................................ 16
6.12. Process Pressure Display....................................................................................... 16
6.13. Pressure Display Units Button ............................................................................... 16
6.14. Current User Display ............................................................................................. 16
6.15. USB Manual Button .............................................................................................. 16
6.16. Reports Button ..................................................................................................... 17
6.17. Engineering Button ............................................................................................... 17
6.18. Recipe Button ....................................................................................................... 17
6.19. Pressure Intensifier Animations ............................................................................ 17
6.20. Coolant Valve Open Indicator ............................................................................... 17
6.21. Motor Running Indicator ...................................................................................... 17
6.22. Status Indicator .................................................................................................... 17
6.23. Pressure Control Screen ....................................................................................... 18
6.24. Pressure Function Selection .................................................................................. 18
6.24.1. Flush Mode ....................................................................................................... 18
6.24.2. Clean Mode ...................................................................................................... 18
6.24.3. Auto Mode ....................................................................................................... 19
6.25. OVERLAP TIME INCREASE button .......................................................................... 19
6.26. OVERLAP TIME DECREASE button ......................................................................... 19
6.27. Overlap Increment Indicator ................................................................................. 19
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6.28. Monitored PLC Inputs ........................................................................................... 19
6.28.1. Compressed Air indication ................................................................................ 20
6.28.2. Hydraulic Oil Temperature indication ............................................................... 20
6.28.3. Drive Fluid Level Fault Alarm indication ............................................................ 20
6.28.4. Enclosure Doors Open Alarm indication ............................................................ 20
6.28.5. Motor Overload indication................................................................................ 20
6.28.6. Intensifier End of Stroke Indication ................................................................... 20
6.29. Alarm List Screen .................................................................................................. 21
6.29.1. Unacknowledged Alarms .................................................................................. 21
6.29.2. User Acknowledged Alarms .............................................................................. 21
6.30. Trend Chart Screen ............................................................................................... 22
6.31. Diagnostic Screen ................................................................................................. 23
6.32. Alarm Screen ........................................................................................................ 24
6.33. Reports Screen ..................................................................................................... 24
6.34. Recipe Screen ....................................................................................................... 25
6.35. Engineer Screen .................................................................................................... 26
6.36. Maint Run Button ................................................................................................. 26
6.37. Raise Rams Button ................................................................................................ 26
6.38. Product Hi Temperature Alarm ............................................................................. 26
6.39. Pressure Maintain Low Alarm ............................................................................... 27
6.40. Intensifier Timer Set ............................................................................................. 27
6.41. Data Logging ......................................................................................................... 28
6.41.1. Print/PDF outputs…. ......................................................................................... 31
6.41.2. Pass Number..................................................................................................... 32
6.41.3. Number of Passes ............................................................................................. 32
6.42. Homogenising Process Control Pressure ............................................................... 33
6.43. Manual Hydraulic Drive Pressure Control ............................................................. 33
6.44. Homogenising Valves............................................................................................ 33
6.44.1. FPG560 or FPG4755 1st Stage pressure control VALVE (REVERSE FLOW PISTON
GAP TYPE) ........................................................................................................................ 33
6.44.2. FPG14420 MICRO CHANNEL DEVICE ................................................................. 34
6.45. Pressure Measurement ........................................................................................ 34
6.45.1. Inline HP Transducer ......................................................................................... 34
6.46. Ancillary Devices ................................................................................................... 35
6.46.1. Hydraulic Oil Cooler (fitted as Standard) ........................................................... 35
6.46.2. FPG14415.021 Heat Exchanger (Outlet) ............................................................ 35
6.46.3. FPG7220:050 Heat Exchanger (Outlet) .............................................................. 35
6.46.4. FPG7220:400 Pre-Process Device Heat Exchanger (up to 4000 bar) .................. 36
6.46.5. FPG14388 Intensifier Barrel Heat Exchanger ..................................................... 36
6.46.6. FPG9080 inlet Flow Control Valve ..................................................................... 37
6.46.7. FPG500IIB4%M Purge Valve .............................................................................. 37
7. Daily pre-start up...................................................................................................... 38
7.1. Process Fluid - priming .......................................................................................... 38
8. Normal use Operating procedure ............................................................................. 39
8.1. User Login ............................................................................................................ 39
8.2. Set-up ................................................................................................................... 40
8.2.1. Operating with piston gap type valves .............................................................. 40
8.2.2. Operating with fixed orifice (micro-channel devices) ........................................ 41
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8.3. Pressure Balance Control ...................................................................................... 41
8.4. Running ................................................................................................................ 42
8.5. FLUSHING AND CLEANING .................................................................................... 42
9. SHUT DOWN PROCEDURE ........................................................................................ 43
Short term shutdown periods overnight or a weekend. ............................................ 43
Long Term shut down or Decommissioning .............................................................. 43
10. TROUBLE SHOOTING ............................................................................................ 44
11. ROUTINE SERVICING ............................................................................................. 50
11.1. Preliminary rules to follow before any maintenance ............................................. 50
11.2. General regular system checks ............................................................................. 50
11.2.1. Pressure Measurement..................................................................................... 50
11.3. Fluid Maintenance ................................................................................................ 51
11.3.1. Hydraulic Drive Fluid ......................................................................................... 51
11.3.2. Routine Draining of Compressed Air Regulators and Filters .............................. 51
11.4. Homogenising Valve access – Pressure Control Panel removal ............................. 52
11.5. Filtered Inlet Valve FPG9080 ................................................................................. 52
11.6. Spiral Retaining Ring assembly.............................................................................. 53
12. DETAILED MAINTENANCE ..................................................................................... 54
12.1. High Pressure Pipe Joints ...................................................................................... 54
12.2. Model 14560 Valve Refurbishment ....................................................................... 56
12.3. Model 8060 Valve Refurbishment......................................................................... 58
12.4. Model 9080 Valve Refurbishment......................................................................... 60
12.5. Actuator Maintenance .......................................................................................... 62
12.6. NEEDLE REMOVING PROCEDURE .......................................................................... 64
12.6.1. Needle removal from Actuators ........................................................................ 65
12.6.2. Disaster recovery .............................................................................................. 65
12.7. General Notes for Refurbishing Valves.................................................................. 66
12.7.1. Replacing or refurbishing valve seat.................................................................. 66
12.8. Intensifier Seals – General .................................................................................... 68
12.9. Stripping the Intensifier for Inspection and/or Seal Change. ................................. 68
12.10. WARNING! Release trapped compressed air from Intensifier Blow-Down system
before maintenance ......................................................................................................... 68
12.11. Prime Intensifier ............................................................................................... 68
12.12. Raise Rams Function ......................................................................................... 69
12.13. FPG14385_nnnn INTENSIFIER FULL SEPARATION .............................................. 70
12.14. Model FPG14405.nnn HP End Plug Seal Change ................................................ 72
12.15. FPG14390Q065 INTENSIFIER DRIVE ASSEMBLY ................................................. 74
12.15.1. Replacing Drive End Seals ............................................................................. 76
12.16. FPG170HP QEV Drive End cap - Quick Exhaust Valve Seals ................................ 77
12.17. FPG9100_050 050x9 INTENSIFIER HP ASSEMBLY .............................................. 78
12.18. FPG14400.200 Series Double Check Valve Assembly ......................................... 80
12.19. FPG14400.420 Series Double Check Valve Assembly ......................................... 82
13. Backups with Prosave ........................................................................................... 84
13.1. Add New User....................................................................................................... 85
13.2. Remove User ........................................................................................................ 87
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FPG7575 HOMOGENISER Comfort

Whilst every effort has been made to make these operating and maintenance instructions a
complete and comprehensive guidance for reliable and safe operation: HOMOGENISING
SYSTEMS will not accept liability for any damages occurring in the course of operating the
equipment. Users of the equipment must accept responsibility for becoming aware and
informing all their operators of the potentially hazardous nature of fluids at high pressure,
and the need to apply sound technical knowledge and engineering practices in all aspects of
their involvement with the installation and use of the equipment.
1. PURPOSE OF EQUIPMENT
The Homogenising Systems "Homogeniser" is designed and built by Homogenising Systems
Ltd for processing aqueous fluids under high pressure.
1.1. FUNCTION AND APPLICATION

The FPG7575 series homogeniser, is an integrated system mounted in a stainless steel
support frame with protective covers.
The equipment consists essentially, of a combination of high pressure liquid pumping system
and flow restriction valve which enables the system to force fluid at high pressure through
the restriction.
Pressure generation is through one or two single acting pressure intensifiers. The intensifiers
are electro-hydraulically driven on the forward (power) stroke from a hydraulic power pack
and use compressed air for the retraction (product aspiration) stroke.
Twin intensifier systems, have an operator adjusted stroke overlap function which allows the
system to be operated in most cases with minimal pressure fluctuations between as the
system changes from one intensifier to the other during the pumping cycle.
Flow restriction (processing device) is generated either using pressure balanced valves or
fixed orifice micro-channel devices and these generate effects including high shear forces
which can be used to process products.
Typical applications include, but not limited to, cell rupture, micro-encapsulation,
deagglomeration, and sterilisation.
The system allows control of the processing pressure, which is the method generally used to
regulate the processing effect.
Process pressure, process temperatures and alarms are displayed on the HMI touch screen
along with normal operation controls. Data Logging to customer standalone PC via ethernet
connection or to a USB memory stick at the USB port provided.
The system is highly configurable and a number of options may be included into the system.
These include (but not limited to)
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Product inlet heat exchanger
Intensifier barrel heat exchanger
Pre-processing heat exchanger (between the pressure intensifier system and processing
device)
Outlet fluid heat exchanger
Positive acting inlet flow control valves
Process temperature indicators.
Second stage (back pressure module)
Pre-processing device
Processing device heat exchanger.
Levelling feet / Castors
Purge Valve
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2. SPECIFICATION
Inlet feed line minimum bore (MM)

= (This applies to all inline fittings)
MAXimum Inlet pressure (BAR):
MINimum Inlet Pressure (BAR):
MAXimum Working pressure
Power Consumption (Kw)

Process Fluid OUTLET*
Proccess Fluid INLET*
Maximum Viscity**
Flow Rate (L/H):
Intensifier Ratio
(MPa):
Model
FPG7575:_6300 15:1 3/4"TC 1/2"TC 1 2 420 20 8 8 25 Cst

FPG7575:_5400 10:1 3/4"TC 1/2"TC 1 2 350 45 8 8 25 Cst
FPG7575:_3600 6:1 3/4"TC 1/2"TC 1 2 200 75 8 8 25 Cst
FPG7575:_2900 4:1 3/4"TC 1/2"TC 1 2 140 125 8 8 25 Cst
The system is designed to operate on: WATER, AQUEOUS EMULSIONS. Other fluids may be
used after approval by HSL.
If feed line is of considerable length, an increase in bore size will be required. Contact HSL
technical department for further details.
*TF = Twin Ferrule (Swagelok), TC = Tri-Clamp hygenic connection
**HSL DO NOT RECOMMEND THE USE OF VISCOUS PRODUCTS IN THIS EQUIPMENT. IF WISHING TO USE OTHER THAN RECOMMENDED FLUID,
CONTACT SFP WITH FULL PRODUCT INFORMATION. HSL MAY ALSO REQUEST A SAMPLE FOR TESTING BEFORE CONSENT IS GIVEN.
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3. SAFETY
Only trained operators are to use this apparatus.
The apparatus supplied MUST never be operated with any cover removed from it's fitted
position.
CAUTION should be exercised when undoing any high pressure fitting.
If in any doubt with operation or maintenance do not hesitate to contact Homogenising

Systems Ltd.
4. WARRANTY
The following is taken from the standard Homogenising Systems Ltd Conditions Of Sale:-
GUARANTEE
The following guarantee is given in lieu of and to the exclusion of any other guarantee,
condition or warranty, either express or implied by statute or otherwise.
The Company's liability in respect of goods of their own manufacture (either as originally
supplied or as repaid or replaced as hereinafter mentioned) is limited (a) to repairing such
goods in or in respect of which defects arising solely from faulty materials or workmanship
shall be disclosed or appear under proper use or alternatively at the Company's option, (b)
to refunding to the buyer any sums paid by him in respect of such defective goods, provided
that in either case notice in writing of the defects shall have been given promptly by the
Buyer to the Company and that where practicable and if required by the Company, such
defective goods or part thereof are also promptly returned, carriage paid, to the Company's
works from which they were dispatched or to such other place as the Company shall in
writing direct. The repaired goods, or replacement will be delivered free of charge in Great
Britain, and in the case of goods exported, f.o.b. port of shipment in Great Britain. The
Company liability under this clause, in respect of the goods as originally supplied and/or
repaired goods or replacements, is limited to defects therein arising or appearing within the
period of 12 calendar months from the actual date of delivery of the goods as originally
supplied as aforesaid, of which notice in writing has been given by the buyers to the
Company within the said period. In the case of goods or part thereof, not of the Company
manufacture, proving defective, the buyer shall be entitled only of any guarantee, condition
or warranty which the Company shall have received in respect thereof and only to the extent
that the Company can enforce the same. The aforementioned guarantee shall not apply in
respect of goods of the Company's manufacture that are of an experimental nature, nor shall
any other guarantee, condition or warranty, either express or implied by statute or
otherwise, apply to such goods.
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INDEMNITY
The buyer shall indemnify the Company against all damages, penalties, cost and expenses
arising from any infringement or claim of infringement by any Copyright, Patent or
Registered Design, arising from the use by the Company of the buyer's design or
specification.
VALIDITY
All warranty and guarantee commitments by Homogenising Systems Ltd are valid ONLY
when all contractual obligations on the part of the customer have been fulfilled and
Homogenising Systems Ltd have received full financial settlement within 30 days of invoice.
Any unauthorised: Engineering modification; changes in electrical circuit; or accessing the

PLC program; is liable to invalidate or restrict the warranty and guarantee.
Warranty void if unit is operated without the inlet filter assembly is fitted, unless operation
in this manner has been agreed in writing by HOMOGENISING SYSTEMS.
DISCLAIMER
It is mandatory that any post commissioning claim on the warranty is conditional upon the
equipment having been operated, maintained and periodically inspected in accordance with
the operating instructions, maintenance instructions and inspection instructions, as well as
any other recommendations made in writing by Homogenising Systems Ltd.
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5. INSTALLATION
The single, or twin, Homogenising Systems Series FPG14385 intensifier(s) together with the
hydraulic power pack and associated hydraulic valves are shown in the appropriate
schematic drawing provided.
Note: the removal or addition of optional items onto and off of the system may result in the system as
configured deviating from the schematic drawing supplied.
The equipment is installed in an all stainless steel cabinet.
Control is through dedicated PLC logic controller.
The operating controls and HMI are mounted at an ergonomically convenient height on the
front fascia, for homogenising process temperature display and process fluid pressure
control and display.
An electro-pneumatic regulator controls the air bias pressure applied to the primary
homogenising valve for Piston Gap Type processing or to hydraulic drive relief valve for fixed
orifice micro channel device, which actively adjusts to maintain the set-point for the
homogenising process pressure.
Ensure hydraulic reservoir is filled to the correct level, refer to section Daily Pre-Start Up
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5.1. MACHINE WEIGHT
The standard build single stand-alone machine FPG7575 (mk4) Homogeniser (without
hydraulic oil) 495kg
Non standard builds and multiple machines can vary, refer to individual machine Legend
plate for details.
5.2. MOUNTING
Free standing unit. If system is supplied with levelling feet or castors with levelling pads then
we recommend that once appropriately located, that the system is levelled and locked.
Provision must be made on installation for enough access around the system for an engineer
to carry out servicing; or provision made to move the system to an accessible area for
maintenance.
Side clearance to allow the front and rear access doors to open is essential.
5.3. REQUIRED SERVICES

3-Ph electrical supply (refer to unit legend plate for specification).
8 bar (120psi) pneumatic air supply. Flow rate 10 Nl/min (1/3 scfm)
Cooling water supply: - the hydraulic system is fitted with an oil / water plate heat
exchanger. If the system is being operated for a short duration (less than 20 minutes)
without cooling fluid it is likely that the oil will not heat beyond acceptable levels; in this
instance operation is permissible. However it is recommended that cooling fluid is connected
to the system for operation. The oil system has a thermal cut out which will operate should
the temperature rise too far.
5.3.1. ELECTRICAL SUPPLY CONNECTION
Connection should be made to a fused isolator. The 3 Ph supply must be connected to the
unit’s 3-ph enclosure, to the terminals provided by an approved electrician to current
approved standards. IEE HARMONISED CORE COLOUR CODING APRIL 2006
Brown (L1)
Wiring colours supplied to IEE HARMONISED
Black (L2)
COLOUR as standard unless other wise
agreed at time of order. Grey (L3)
Blue (N)
Note: the system is fitted with a Direct On Line starting motor (unless other wise agreed at
time of order). As such the instantaneous starting current will be high compared with the
12
normal running current. Attention must be paid to the supply fusing/circuit breakers to
ensure they are suitable for the short duration high current load.
13
5.3.2. PRESSURE CONNECTIONS
Compressed Air Inlet port: ¼”BSPF
Process Fluid Inlet port: refer to SPECIFICATION chart on page 7.

Process Fluid Outlet port: refer to SPECIFICATION chart on page 7.
Hydraulic Oil Cooling ports*: 3/8”BSPF

*For connection of external cooling water/system
Temperature Conditioning Fluid ports: 3/8”BSPF (if fitted)
Process Heat exchanger connections: (if fitted) See individual heat exchangers. These may
be individually connected or manifolded to common
inlet and outlets depending on the configuration.
The compressed air supply must be connected with an unrestricted quarter inch nominal
bore feed line, and provide at all times a pressure not less than 6 bar (85 psi).
Compressed air should be dry and filtered.
Cooling fluid should in preference include a corrosion inhibitor, although the cooling circuit is
made in corrosion resistant materials. pH should be between 6.5 and 7.5
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6. CONTROLS
The Homogeniser utilises a colour touch screen LCD user interface (HMI) for Process
Pressure and temperature displays, machine Start and Stop, Pressure Balance adjustment,
simple Data Logging, User Login, machine operational parameters, operational Interlocks
and Fault Indication. Press Home Button at any time.
The HMI panel does not give any access to the data logs for editing or changing. Current User
and time stamps are saved with the recorded parameters. Data logs are not saved to the
PLC. Current recording Data Logs are held on the HMI, until batch number change, at which
point they are exported to user connected standalone PC or a removable USB memory stick.
User systems and procedures must then cover Data Log access requirements using Siemens
WinCC Audit Viewer.
6.1. EMERGENCY "STOP" BUTTON
Dual channel low voltage safety circuit Large Red push button. Deprives power to the control
system outputs including the hydraulic drive motor. Press the push button in until it clicks
and remains pressed in. This method of shut down should only be used as a last resort if the
operator feels the system is out of control, or fears there is a hazard. Twist and Pull to reset
the e-stop button when ready and then carry out Emergency Stop Reset.
It is recommended to leave system with the emergency stop activated at end of day or end
of any particular batch session. This de-energises any control valves that would remain
energised unnecessarily when system is not in use, prolonging service life. Emergency Stop
use also vents compressed air from the pressure intensifiers, in the event of any compressed
air leakage.
NOTE: Power to the Control PLC and HMI remains unless the 3 phase supply is cut at the
isolator / plug connector.
6.2. EMERGENCY STOP RESET BUTTON

Low profile momentary push button located at side of panel next to Emergency Stop. A reset
is required after Emergency Stop activation. The Emergency Stop Button has to be rest prior
to pressing the Reset Button. The alarm fault will not clear if the Emergency Stop Button is
still engaged.
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6.3. HOME SCREEN
*Standard Build shown
Displays normal operating information for Process Pressure, Process Temperatures, Pressure
Balance control buttons, simple Data Logging controls, Current Logged in User, motor
graphic and pressure intensifier animation graphics.
6.4. HOME BUTTON

Virtual HMI momentary push button. Press [ ] to return to the Home Screen after
navigating to other screens.
6.5. ALARM LIST BUTTON

Virtual HMI momentary push button. Press [ ] to display the Alarm List The list shows
only Unacknowledged Alarms since power supply on. User Acknowledged Alarms are cleared
from the list. Full alarm list can be viewed via the Diagnostic Screen. If machine is shut down,
all alarms are cleared.
6.6. TREND CHART BUTTON

Virtual HMI momentary push button. Press [ ] to display the Trend Chart Screen The
trend chart screen shows Live Graph monitoring of Process Pressure and Temperatures.
6.7. RUN START BUTTON

Virtual HMI momentary push button. Press [ ] to initiate hydraulic power pack start-up
and intensifier pressure cycling sequence, once all monitored interlocks are in place. Low oil
temperature will allow hydraulic pump to run but will holt pressure cycling until oil
temperature is within limits. System will operate depending on operator mode selected. See
Pressure_Function_Selection.
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6.8. STOP BUTTON
Virtual HMI momentary push button. Press [ ] in order to stop or halt the process cycling.
The stop button will flash red when pressed during system operation to acknowledge
request while the stop delay timer runs, reducing pressure before system pumping stops.
This timer is factory set to prevent damage to the homogenising valve ceramic needle and
seat from suddenly closing while under high pressure. Default 3 seconds.
6.9. USER LOGIN BUTTON

Virtual HMI momentary push button. Press [ ] in order to access user details screen for
user name, password etc. Users can edit there own password etc while logged in. See User
Login.
There must be a user logged in to activate HMI control buttons for machine operation.
Trying to use HMI control buttons without a user logged in will display the user login dialog
window.
6.10. DIAGNOSTIC BUTTON

Virtual HMI momentary push button. Press [ ] in order to access the Diagnostic Screen.
The diagnostic screen displays all PLC monitored inputs for system control and is a useful
tool for looking at state of inputs i.e. if an input is ON or OFF.
6.11. SHUT DOWN BUTTON

Virtual HMI momentary push button. Press [ ] in order to Shutdown/Reboot the HMI
screen.
6.12. PROCESS PRESSURE DISPLAY

Digital pressure display within the HMI Home Screen for process fluid as measured at the
electronic Inline HP Pressure Transducer.
6.13. PRESSURE DISPLAY UNITS BUTTON

HMI Toggle button allowing user change of pressure display units. Selection Mpa/Bar/Ksi.
Data logging pressure units remain in default Mpa.
6.14. CURRENT USER DISPLAY

Displays the current logged in user. Displays blank when user is automatically logged out
after timed period. See User Login.
6.15. USB MANUAL BUTTON

HMI button to access Web Style user manual installed on the supplied operating instructions
USB Memory Stick for the system . User can navigate the document using
the HMI touch screen and document hyperlinks. Will only work with the supplied memory
stick and has to plugged in at time of use. Attempting to access USB Manual without
memory stick plugged in will display;
, error message.
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6.16. REPORTS BUTTON
Virtual HMI momentary push button. Press [ ] to access Reports_Screen for user
initiated local prints and data logging address’ for PC or USB.
6.17. ENGINEERING BUTTON

Virtual HMI momentary push button. Press [ ] to access Engineer_Screen for
engineer functions and administrator adjustable parameters.
6.18. RECIPE BUTTON

Virtual HMI momentary push button. Press [ ] to access Recipe_Screen for
selection of user defined pressure and temperature parameters, or “recipe” for any
previously saved parameter set.
6.19. PRESSURE INTENSIFIER ANIMATIONS

HMI screen animations to simulate each intensifier ram position during operation.
#1 simulates the Left Hand pressure intensifier when viewed from the machine front.
#2 simulates the Right Hand pressure intensifier when viewed from the machine front.
6.20. COOLANT VALVE OPEN INDICATOR

HMI screen indicator [ ] to give visual indication of the hydraulic oil coolant
admittance valve is open for user coolant supply. Coolant supply is necessary to extend
service life of hydraulic pump and components as operating at elevated temperatures for
prolonged periods, reduces the life span of pumps, valves and hoses. The coolant valve
opens when the hydraulic oil temperature exceeds recommended normal operating
temperature. The valve closes again when hydraulic oil temperature returns below factory
set temperature settings. The valve will open and close automatically to avoid unnecessary
wastage of coolant during normal machine operation and to also avoid over-chilling the
hydraulic oil. Default setpoints are 38° open, 32° close. Normal clean towns water* is
sufficient in most cases. See also Hydraulic_Oil_Temperature.
*Avoid high particulate and high calcium water content. An inhibited coolant system is preferred.
6.21. MOTOR RUNNING INDICATOR
HMI screen indicator [ ] to give visual indication of when the hydraulic powerpack is
running.
6.22. STATUS INDICATOR

HMI screen indicator [ ] to give visual indication of system status,
Standby/Ready/Running. Displays “Standby” if one or more Monitored_PLC_Inputs are not
in place. Displays “Ready” when all Monitored_PLC_Inputs are in place. Displays “Running”
when system is in operation.
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6.23. PRESSURE CONTROL SCREEN
Accessed from the Home_Screen. This screen has Pressure_Function_Selection buttons for
Automatic Pressure Control operation, which illuminate blue when operator selected.
Supervisor/Administrator adjustable fields for both “Clean” mode pressure and “Auto” mode
pressure.
6.24. PRESSURE FUNCTION SELECTION

From the Pressure_Control_Screen the user has access to three function selections under
the automatic pressure control operation. These can be selected at any time, even during
operation.
6.24.1. FLUSH MODE

Press “FLUSH” to select flush mode for system pumping at zero pressure. This is used
primarily for system Process_Fluid_Priming as it is essential to have the intensifiers and
associated pipework free of all trapped air for a smooth and pressure balanced operation
while machine is generating pressure. It is also useful as part of Flushing_and_Cleaning
protocol to pump through without any back pressure.
6.24.2. CLEAN MODE

Press “CLEAN” to select clean mode for system pumping at a low user set pressure. This is
used as part of Flushing_and_Cleaning protocol to help clean system with a small amount of
back pressure once system is primed and air free. Touch the Supervisor/Administrator
adjustable field to input a pressure setpoint. The system will retain this setpoint until
changed.
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6.24.3. AUTO MODE
Press “AUTO” to select the main normal operating mode at user set pressure as per
Normal_Use_Operating_Procedure. In Auto mode, once started, the system will reach and
automatically maintain the pressure setpoint until machine is stopped. Touch the
Supervisor/Administrator adjustable field to input a pressure setpoint. The system will retain
this setpoint until changed by operator.
6.25. OVERLAP TIME INCREASE BUTTON

Virtual HMI button used during system Pressure Balance Control operation. To increase ram
catch-up/overlap time: Press and release [+1] to increase the catch-up/overlap time one
increment. The stroke catch-up/overlap time can be increased up to a maximum of 4 steps.
Each additional step will increase the stroke catch-up/overlap allowing for compensation of
the process product compressibility with increasing pressure and to allow reduction of
pressure fluctuations during intensifier changeover.
This function is particularly useful at the start of operation when the hydraulic oil is cold, due
to the effects of viscosity. The response of the system to overlap control may change as the
oil temperature rises.
When the system is powered down the catch-up/overlap timer resets back to the default
time.
6.26. OVERLAP TIME DECREASE BUTTON

Virtual HMI button used during system Pressure Balance Control operation. To decrease ram
catch-up/overlap time: Press and release [-1] to decrease the catch-up/overlap time one
increment. The catch-up/overlap time can be decreased back down to the default time, if
catch-up/overlap time has been increased previously. Each decreased step will shorten the
stroke catch-up/overlap time.
The response of the system to catch-up/overlap control may change as the oil temperature
rises.
This function is used when the pressure fluctuations increase at changeover of pressure
intensifiers, particularly at higher operating pressures and to a lesser extent, as the hydraulic
oil warms up to its normal operating temperature. This function can only be used if the
catch-up/overlap time has previously been increased.
6.27. OVERLAP INCREMENT INDICATOR

Small number display [0] between Overlap Increase Button and Overlap Decrease Button.
The display indicates which increment state the Pressure Balance Control is operating at.
Zero (0) is the default and can be ramped up to maximum of Four (4).
6.28. MONITORED PLC INPUTS

The PLC control system monitors several inputs for services and interlocks necessary for
system control. The live status list can be seen on the Diagnostic Screen. Inputs show Pink
when loss of input is present. Triggered inputs will display the Alarm List Screen at any time.
20
6.28.1. COMPRESSED AIR INDICATION
PLC monitored system input displayable on the HMI Diagnostic Screen. Shows in Black when
there is sufficient air pressure to operate the system.
6.28.2. HYDRAULIC OIL TEMPERATURE INDICATION

Temperature display on the Home_Screen. The oil temperature display background
illuminates Blue when hydraulic oil is below required operating limit (+20°C). Changes to
White background when hydraulic drive oil is within temperature operating limits.
Illuminates Red when system is halted due to oil temperature over temperature limit/too
hot (+60°C). Connect external cooling system to the internal oil heat exchanger if unit is in
heavy use/hot environment. It is recommended to connect external cooling system when
using Fixed Orifice Devices as the hydraulic control heats the oil rapidly! See also
Coolant_Valve_Open_Indicator.
6.28.3. DRIVE FLUID LEVEL FAULT ALARM INDICATION

HMI Alarm indication when there is insufficient fluid in the hydraulic oil reservoir to carry out
system operation. System is halted due to lack or loss of oil, indicating reason for stoppage.
6.28.4. ENCLOSURE DOORS OPEN ALARM INDICATION

Monitored Alarm indication when the front doors are open. This is a control interlock, which
prevents the system from generating pressure with the front doors open. Alarm indication
when system is halted due to opening doors during operating, indicating reason for
stoppage.
6.28.5. MOTOR OVERLOAD INDICATION

HMI alarm indication in the event of the electrical motor overload/Circuit Breaker operating.
The electrical Circuit Breaker will operate in the event of an electrical overload to the
system. The internal control panel Motor Overload can be manually reset inside the
electrical enclosure. IF the Motor Overload repeatedly trips, consult a Qualified Electrician to
investigate possible causes.
6.28.6. INTENSIFIER END OF STROKE INDICATION

HMI Alarm fault indication IF the pressure intensifier(s) has reached the end of stroke/limit
of travel.
This can happen if the pneumatic air retract pressure is too low to fully retract the intensifier
drive piston fully back to its starting position after each stroke, effectively creeping up further
each time until it trips the sensor. This can also happen if the oil is too cold or a combination
of both insufficient compressed air pressure and cold hydraulic oil.
This can also happen if Intensifier_Timer_Set is incorrectly set for pressure/flow rate in use.
21
6.29. ALARM LIST SCREEN
Displays Unacknowledged Alarms since last system power on until user has acknowledged
each alarm and no active alarms remain. Accessed at anytime by pressing the Alarm List
Button. Triggered control inputs will display Unacknowledged Alarms dialog window at any
time. The dialog window is also displayed when machine is powered on. Press [X] to close
the dialog window.
6.29.1. UNACKNOWLEDGED ALARMS

An unacknowledged alarm is simply an alarm event that has not been seen and
Acknowledged by the user. The Alarm List displays all Unacknowledged Alarms since power
supply on. An active alarm dialog window can be closed at anytime without
acknowledgement by pressing the top corner [X]. If machine is shut down, all alarms are
cleared.
A yellow warning triangle with quantity of active alarms will show while alarms are
present. Touching the Alarm Triangle will open the unacknowledged alarm list by any user.
A white warning triangle remaining on screen with zero active alarms indicates that
alarm notifications are present but have not yet been acknowledged by the user. Once all
alarms are inactive and have also been acknowledged, the warning triangle will clear from
the screen.
6.29.2. USER ACKNOWLEDGED ALARMS

After an alarm event, the alarm can be acknowledged and cleared from the list by
highlighting the alarm within the list and pressing the tick button, after the alarm cause
has first been cleared i.e. Insufficient Compressed Air pressure has been re-established to
above minimum set limit.
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6.30. TREND CHART SCREEN

Trend screen with user tools for monitoring the live line chart plotting for Process Pressure
and Process Temperatures. Includes rewind, Zoom and Ruler Bar. This display is only for live
observation and is not recorded within the system.
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6.31. DIAGNOSTIC SCREEN
Accessed at any time by pressing Diagnostic Button on the HMI. Inputs show Pink when loss
of input is present. Inputs show Black when input is present/within limits.
Alarms Button lists all pending and permanent alarms on the Alarm_Screen.
PLC + HMI Status in the Diagnostic Overview, lists all connected PLC + HMI hardware and its
status. Green tick is good, Red X is not.
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6.32. ALARM SCREEN
Accessible from the Diagnostic_Screen. System permanent notifications ($) as shown in the
example above are not cleared by User Acknowledgement. Unacknowledged Alarms are also
shown in the list if not cleared by user. Monitored PLC Input Alarms can also be cleared by
User Acknowledgement in this diagnostic listing.
6.33. REPORTS SCREEN
Administrator setup parameters required for data logging. Set top network path to
standalone PC within machines ip range and select “Log to Network” button. Active logging
paths should then display paths entered for data logging. IF loss of PC or network during
batch process run, logging path can be changed to USB port by selecting the “Log to USB”
button to enable processing to continue until network logging can be resumed. Important:
25
USB 2 memory stick must be inserted in machine USB port with file folders added to match
logging path for this to function! [……USB\ArchiveData\Logs\snxxxxx] where “xxxxx” is serial
number of machine.
6.34. RECIPE SCREEN
Recipe Name 1-3 Pressure Unit Range, 1=Mpa, 2=Bar, 3=Ksi

Data Record Name ….. User editable file name for data record within
each pressure range recipe
Entry Name Value Description

Clean Pressure (Mpa*) 0-999.9 Meant for low pressure setting (eg 10-50) as
part of Flushing_and_Cleaning procedures.
Could also be used for first pass process
pressure for example.
Run Pressure (Mpa*) 0-999.9 Main Process Pressure setpoint.
Overlap 0-4 Intensifier catch-up/Overlap function for
pressure balance. See Pressure_Balance_Control.
Factory setting dependant on MWP of Homogeniser. E.g.
for 420 Mpa system, 0 = 0-100, 1 = 100-200…
Outlet Temperature Limit 0-99.9°C See Product_Hi_Temperature_Alarm
Times Set 0-1,2,3…. See Intensifier_Timer_Set
Number of passes 0-999 User field to set indicated number of product
passes through Homogeniser. See
Number_of_Passes.
*PRESSURE SETPOINTS WITHIN RECIPE_1 ARE Mpa ONLY
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6.35. ENGINEER SCREEN
The Engineering screen has extra functions and settings not available to the basic
user/operator. Access to these functions are only available to Administrator (full access) and
Engineer (limited access). The screen also has duplicate mode selection buttons and setpoint
fields to allow setup and testing to be carried out without changing screens.
6.36. MAINT RUN BUTTON

The Maint Run button will run just the hydraulic pump without valve operations to enable
fluid leak checks to be carried out after maintenance and also assist in the Raise_Rams
function below.
6.37. RAISE RAMS BUTTON

This is a skilled job and should only be undertaken by competent maintenance personnel
who are familiar with hydraulic systems. The Raise Rams function is provided to enable the
intensifier rams to be raised up while the hp check valve, hp end nut and hp barrel are
removed, to facilitate inspection of the ram surface for wear and/or damage that would
cause the hp pumping system to be unable to generate pressure. See Raise_Rams_Function
in Detailed_Maintenance.
6.38. PRODUCT HI TEMPERATURE ALARM

Product process High Temperature function and setpoint for (T2) thermocouple sensor. An
alarm temperature can be set to either Monitor only or Stop machine operation. Enter
temperature in “Product Hi Temp set-point” field and toggle select ON/OFF on button
above. Select ON (indicated by colour change of button text to Orange) if machine Stop is
required upon reaching temperature setpoint. Select OFF (indicated by default colour of
button text to White) if operator monitoring only is required. Alarm trigger will display on
Alarm_List_Screen.
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6.39. PRESSURE MAINTAIN LOW ALARM
Product process Low Pressure function and setpoint. An alarm can be set to either Monitor
only or Stop machine operation if for any reason, the process pressure drops below the
pressure setpoint for a sustained period. Enter deviation setpoint in “Pressure Alarm Delta”
field and toggle select ON/OFF on button above. Select ON (indicated by colour change of
button text to Orange) if machine Stop is required due to lack of sustained pressure at
Process_Pressure setpoint. Select OFF (indicated by default colour of button text to White) if
operator monitoring only is required. Alarm trigger will display on Alarm_List_Screen.
6.40. INTENSIFIER TIMER SET

Index number for a particular “set” of intensifier stroke timers. Each set of timers are unique
to a given flow rate and pressure. These are normally set dependant on machine build and
matched to the installed intensifier size ratio and pressure when used with Piston Gap type
homogenising valve and should not need changing. However, when using a fixed orifice or
Micro Channel Device, the flow rate can vary depending on size of Micro Channel in use at
any one time. Users can have multiple sizes of Micro Channel that are interchanged
depending on particular product requiring homogenising process.
Each “set” of timers has been factory set based on tests carried out at HS using de-ionised
water for each size of Micro Channel tested. Refer to chart for which intensifier timer set to
use for which size micro channel fitted.
………………….
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6.41. DATA LOGGING

Data logging file paths must be set at the Reports_Screen before any processing of product.
The system continually creates log files which are exported to either a local standalone PC or
USB memory stick every day or at each change of operator entered batch number, whichever
is soonest.
DATA LOGGING CHECK LIST

1 Set static PC Ethernet Port to same IP range as machine(s) 192.168.0.???
(default: PLC 192.168.0.1, HMI 192.168.0.2). Multiple linked machines will have
incremented ip addresses.
2 Create local user account on data PC (name & password) to match HMI (default
“siemens” pw snemeis)
3 Create Shared Folder(s) on data PC to match HMI reports page file paths
(example\\datapc\ArchiveData\Logs\sn?????) where sn????? Is serial number of
machine.
The standalone data logging PC has to have the ethernet connection port in the same IP
Range as the machine(s) it is connected to.
A user account must be set on the PC to match “Network ID” in HMI settings.
29
A shared folder must also be set on the data logging PC to match file path set on the HMI
Reports_Screen. Set both to suit data logging PC. Each file type has its own field for network
path and can either be to the same shared folder or divided into there own shared folders.
The network path given above is an example only. The network path can be made to suit
customers own format. Ensure the shared folders exist first before setting archive path in
the HMI.
NOTE: Changes to folders/network path AFTER log files have began saving to PC could cause
some log files to be stuck in the HMI during change-over. Ensure sufficient time is allowed
for log files to start exporting to the new location before moving or deleting previous
folder(s). If PC is changed, the file path address will have to be changed to suit new PC
connected.
Three files are generated constantly while the system is switched on, and these are;
Alarm Log – CSV file
Audit Log – RDB file
Data Log – CSV file
The file name format is automatic using “Log Type-Date-Time-HMI Panel (serial number)”.
This is not user changeable. All three files are closed and saved with the same date and time
stamp. The user entered “Batch Number” is recorded within the AuditTrail log.
30
The Audit Trail files are RDB (RunTime Database) non-editable and can only be viewed using
the Siemens WinCC Audit Viewer program on PC (not on Homogenising machine). The CSV
files for process Data_log and Alarm_log can also be opened using the WinCC Viewer.
Set batch number to e.g. FINISH when batch is complete and no new batch is about to
commence shortly. This allows the current data logging to complete and export files to
PC/USB. The continuing data logging while machine is idle, is then easy to identify and
disregard. Setting a new batch number prior to processing new product, will complete and
export the idle log files, then immediately commence new data logging with the new batch
number entered.
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6.41.1. PRINT/PDF OUTPUTS….

There are two options available for immediate reports when setting up the machine using
the HMI Printer Properties settings in the HMI Start Centre settings, by Selecting either one
of the following and has to be done before processing product as the HMI Homogenising
program has to be shut down to make changes.
1) Printed Hardcopy reports and alarms can be user initiated to a compatible printer
connected direct to the machine USB port.
Or
2) PDF file output to connected PC.
The two possible reports (AuditTrail or Alarms) are ONLY available at the machine before a
new Batch Number is entered. The reports must be printed Hardcopy or PDF as soon as
product processing has been completed. Once the reports have been exported to the data
logging PC, they are no longer available for local print.
From The HMI Start Centre, available when homogenising program is closed via the
Shut_Down_Button, or at machine power on, select [Settings]. Select the Printer to open
Printer Properties dialog window. In the Printer Language drown down field, select your
required option. Select OK when finished. If local printer to USB port is selected, simply plug
in the compatible printer to the machine USB port. If print to PDF is selected, continue below
to PDF settings.
From the HMI Start Centre, select PDF Setting shortcut to open PDF settings dialog window.
For network, select Storage Location tab, set Primary Location drop down field to
<<Other>>. Enter network path in Enter Path field to Data Logging PC shared folder for PDF
files (example\\DATAPC\ArchiveData\PDF\sn*****) where ***** equals machine serial
number. As a backup in the event of a network failure or data logging PC failure and
Homogeniser Processing has to continue, the reports can still be saved to the Alternative
Location. In this example we have set it to USB Stick,. Ensure the USB stick has folders to
32
match the set path (example\\Storage Card USB\ArchiveData\PDF\sn*****) where *****
equals machine serial number.
Above is an example of the Print/PDF function used to save PDF files direct to the data
logging PC shared folder.
6.41.2. PASS NUMBER

Operator indicator/counter, manually set or incremented before EACH start or restart of
machine for a new batch or reprocessing of same batch of product. Used in conjunction with
Number_of_Passes to visually aid operator in keeping track on number of times product has
been processed.
6.41.3. NUMBER OF PASSES

The number of Passes is set using the Recipe_Screen parameters and is set to suit each
particular user defined recipe profile for product being processed.
33
6.42. HOMOGENISING PROCESS CONTROL PRESSURE
An Electro-Pneumatic air regulator for automatic pressure control. The regulator is
controlled by user input to process pressure setpoint at the Pressure_Control_Screen.
Piston Gap Type systems: The regulator adjusts the bias pressure applied to the
homogenising valve actuator, which in turn controls the backpressure of the process fluid.
Process pressure is indicated on the Process Pressure Display when the system is operating.
Increasing or decreasing the applied pressure will adjust the pressure at which the process
fluid passes through the homogenising valve. Monitoring of the applied actuated pressure to
corresponding process pressure will allow some monitoring of valve wear. The Manual
Hydraulic Drive Pressure Control must be fully closed when using the pneumatic air regulator
controls.
Micro Channel Type Systems: The regulator adjusts the bias pressure applied to the
hydraulic control valve actuator, which bleeds off pressure intensifier hydraulic drive
pressure and so in turn, controls the backpressure of the process fluid. Process pressure is
indicated on the Process Pressure Display when the system is operating.
Increasing or decreasing the applied pressure will adjust the pressure at which the process
fluid passes through the Micro Channel Device. Monitoring of the applied actuated pressure
to corresponding process pressure will allow some monitoring of valve wear.
6.43. MANUAL HYDRAULIC DRIVE PRESSURE CONTROL

Manual pressure controller valve fitted to systems built as Piston Gap
type Homogenisers to give basic operating function when an optional
extra Micro Channel Device is installed by user.
To control the processing pressure in the system with a FPG14420 Micro

Channel Device fitted the hydraulic pressure is limited by an adjustable hydraulic relief valve,
mounted on the left hand side (viewed from the front). Hydraulic Oil Cooling is essential
when using a FPG14420 Micro Channel Device as the oil heats very quickly when spilling oil
constantly through the manual pressure controller.
6.44. HOMOGENISING VALVES
6.44.1. FPG560 OR FPG4755 1ST STAGE PRESSURE CONTROL VALVE

(REVERSE FLOW PISTON GAP TYPE)
Automatic or Manually adjusted through regulation of air pilot pressure. Increasing or

decreasing the applied pressure will adjust the pressure at which the process fluid passes
through the homogenising valve. Monitoring of the applied actuator pressure to
corresponding process pressure will allow some monitoring of valve wear.
34
6.44.2. FPG14420 MICRO CHANNEL DEVICE
The FPG14420 devices incorporate flow control through fixed precision micro-channel(s).
Such devices can pass a certain flow related to flow and viscosity. If not restrictive enough
for the fluid the pressure that can be generated is limited. If too restrictive the flow that can
pass through the device is limited. The normal is to have a device, which has adequate
restriction to allow appropriate pressure to be generated.
To control the processing pressure in the system with a micro channel device fitted the
hydraulic pressure is limited by an manually adjustable Manual Hydraulic Drive Pressure
Controller, mounted on the left hand side (viewed from the front).
Typically one or two micro-channel or fixed orifice devices are mounted in series.
When operating micro channels which significant spillage through the hydraulic regulator
the energy imparted to the oil (heating) will be significant.
Hydraulic Oil Cooling is recommend for the even for short duration operation with micro-
channel (fixed orifice) devices.
6.45. PRESSURE MEASUREMENT
6.45.1. INLINE HP TRANSDUCER

An in-process-line high pressure transducer is fitted for process fluid pressure measurement
during operation. The pressure is displayed on the HMI Home Screen.
35
6.46. ANCILLARY DEVICES
HEAT EXCHANGERS – NOTE: The passing of product from high pressure to low pressure
through the processing device imparts heating to the product being processed. The heating is
dependent on the pressure and the heat capacity of the product. It can be assumed that most
of the energy input manifests itself in heating the product or the oil. For water heating is
approximately 22oC / 100 MPa.
6.46.1. HYDRAULIC OIL COOLER (FITTED AS STANDARD)

Recommended drive oil operating temperature is below 45°C. If the hydraulic oil is
exceeding 45°C, external cooling must be provided to prevent system stoppage by the inbuilt
temperature sensor with loss of the Hydraulic Oil Temperature. Using a Micro Channel
Device will require this oil cooler to be used.
6.46.2. FPG14415.021 HEAT EXCHANGER (OUTLET)

This device is normally used to cool product exiting the system following processing, high
flow 3/8 bore process tubing (although if appropriate for the process, it could be used to
heat the product).
A variety of fluids may be used for the fluid supply dependent on requirements. Those
approved are listed below, for alternatives please contact our technical office.
i) Water, PH 6.5 to 7.5

ii) Glycol in water (as above) 100% to 1%.
The cooling supply pressure should be:-

Minimum, 7.5 psi (0.5 bar, 0.05MPa).
Maximum, 60 psi ( 4 bar, 0.4 MPa).
Maximum fluid supply temperature 120oC (subject to fluid circulation system and fluid choice)
Minimum fluid supply temperature -20oC (subject to fluid circulation system and fluid choice)
NOTE: temperatures which could induce freezing of the product in the intensifiers while not
operating or under pressure MUST BE AVOIDED as they may result in serous damage to the
system.
Suggested Flowrate of 10Ltrs/min. To suit application. HOMOGENISING SYSTEMS
recommend protection from overpressure with a pressure relief valve in the conditioning fluid
circuit to suit the operating parameters.
Connection pipes to cooling fluid supply should not be restricted in bore diameter to less
than 3/8" (10mm).
6.46.3. FPG7220:050 HEAT EXCHANGER (OUTLET)

This device is normally used to cool product exiting the system following processing
(although if appropriate for the process, it could be used to heat the product).
36

system.
Suggested Flowrate of 10Ltrs/min. To suit application. HOMOGENISING SYSTEMS
recommend protection from overpressure with a pressure relief valve in the conditioning fluid
circuit to suit the operating parameters.
than 3/8" (10mm).
6.46.4. FPG7220:400 PRE-PROCESS DEVICE HEAT EXCHANGER (UP TO

4000 BAR)
This device is normally used to heat the product between the pressure intensifiers and the
processing device entering the system following processing (although if appropriate for the
process, it could be used to cool the product).


system.
Flowrate to suit application. HOMOGENISING SYSTEMS recommend protection from
overpressure with a pressure relief valve in the conditioning fluid circuit to suit the operating
parameters.
than 3/8" (10mm).
6.46.5. FPG14388 INTENSIFIER BARREL HEAT EXCHANGER

This device fitted in place of the normal intensifier barrel protection jacket can be used to
heat or cool the intensifier barrels.
37


system.
Flowrate as required. HOMOGENISING SYSTEMS recommend protection from overpressure
with a pressure relief valve in the conditioning fluid circuit to suit the operating parameters.
than 3/8" (10mm).
6.46.6. FPG9080 INLET FLOW CONTROL VALVE

These pneumatic operated pilot operated non return valves (NRVs) if fitted, are in place of
the normal weight/spring loaded NRVs. These being fitted would normally be where the
product was non homogeneous, highly viscous or such that normal NRVs were unable to
function reliably.
6.46.7. FPG500IIB4%M PURGE VALVE

High Pressure manual valve in the pipeline to bypass the adjustable Piston Gap Type
Homogenising Valve and/or Fixed Orifice device during Priming and Setup. Small orifice
valves and devices make it difficult to prime the pressure system and flush all air out. Unless
the system is primed properly, the system will not function correctly or efficiently.
38
7. DAILY PRE-START UP
Before attempting to operate the homogeniser it is essential to check the following:-
Ensure hydraulic oil tank feed isolating valve is OPEN.
The level of hydraulic oil in the sight glass in the tank is adequately
full. The level should be between half and three quarters of the full
volume; do NOT overfill as there must be sufficient ullage to allow
for hydraulic oil being returned due to the displacement of the
intensifier(s). The tank is fitted with a conventional filler assembly, which is accessible by
opening the units rear panel doors. Refer to Hydraulic Drive Fluid for recommended oil.
Homogenised product will be delivered from the Product Discharge on the right hand side of
the homogeniser unit. A suitable connection tube must be attached and led to a suitable
collecting receptacle. It may be desirable to initial run the system to a free discharge while
priming / purging.
Ensure Fluid feed is connected with any pressurising system and operating (if fitted)
Ensure electrical supply is connected and on

Ensure pneumatic supply is connected and on
Ensure heater exchanger fluid supplies rare connected and on, if being used.
7.1. PROCESS FLUID - PRIMING

The pumping system must not be run without any process fluid, as prolonged dry running
can cause seal failure.
If the system does run dry the system may need priming. If fitted, open the bleed/
FPG500IA3=M Purge Valve otherwise ensure homogenising valve(s) are fully relaxed i.e. 0
(zero) actuating pressure. Run the system until air free fluid can be seen exiting from the
outlet tube. Stop pump, close Purge valve.
NOTE
However the process fluid is fed to the system, it is essential that the process fluid
supply is fully primed right up to the intensifier(s) inlet(s). As far as practical/possible, a
positive feed pressure is recommended. Air (gas) in the intensifier(s) will reduce
volumetric efficiency and may lead to accelerated wear.
Note: with a FPG14420 Micro Channel Device fitted it is recommended to have a

FPG500IA3=M Purge Valve, otherwise it may be necessary to purge / bleed the system with
the micro channel device disconnected, and then re-connect after the system is primed.
39
8. NORMAL USE OPERATING PROCEDURE
Having completed the Daily Pre-Start Up sequence, check that the system is connected to
appropriate, electrical, pneumatic, process fluids, heat exchanger fluid supplies and that
they are all turned ON.
If running with FPG14420 Micro Channel Device it is recommended that the Hydraulic Drive
Pressure Control regulator be opened fully (anti-clockwise) before starting homogeniser as
damage to the micro channel could occur if started at FULL Drive Pressure!
Press Home at any time.
System may be stopped at any time by pressing the Stop.
8.1. USER LOGIN

All functions for operating the machine are protected from unauthorised access by means of
a user login name and password. Individual login names and passwords are added and
removed by Manager or Supervisor. Default user at installation is [user1] & pw[1234]
Users are automatically logged out when log out time has lapsed from HMI inactivity.
40
8.2. SET-UP
System may be set up on water or product at the users discretion / choice. We recommend
the system is run on water or pure fluid for initial purging and set up as this will allow good
operation to be assessed eliminating product related effects from this evaluation.
Make a Pressure_Function_Selection and press Run to start machine. IF oil temperature is

below minimum set limit, the hydraulic pump will run without any pressure cycling of the
intensifiers until the oil is at a good operating temperature. The system will start intensifier
operation once oil temperature is stable above min limit for 30 seconds. Continue operation
until a steady air free discharge is seen to issue from the delivery tube. If a Purge Valve is
open, stop the system by pressing the Stop Button and close the purge valve prior to
continuing.
IMPORTANT: Users are automatically logged out when log out time has lapsed from HMI
inactivity. HMI button controls are disabled when user logs out. User Login is required to
activate HMI button controls.
8.2.1. OPERATING WITH PISTON GAP TYPE VALVES

With the system primed (Process_Fluid_Priming), purged of all trapped air and Hydraulic
Drive Pressure Control fully CLOSED, the primary homogenising valve may be loaded by
increasing the air pilot pressure on the Homogenising Process Control Pressure regulator to
the primary valve. This is achieved by setting appropriate operating parameters under
Pressure_Function_Selection.
When operating pressure conditions have been achieved, the Pressure_Balance_Control can
now be optimised.
41
8.2.2. OPERATING WITH FIXED ORIFICE (MICRO-CHANNEL DEVICES)

With the system primed (Process_Fluid_Priming), purged of all trapped air, ensure the
Hydraulic Drive Pressure Control valve is set to minimum (fully anti-clockwise).
Set the Pressure_Function_Selection to Manual and set the PID output factor using +/- to
0%. This is to avoid the electro- pneumatic controller from trying to control air pressure to the
Homogenising Valve if removed or disconnected.
Run the system and increase the Hydraulic Drive Pressure Control valve pressure. This
should be adjusted gradually to allow the system to respond and stabilise. As the Hydraulic
Drive Pressure Control is adjusted the pressure indication on the display should increase and
product should flow from the outlet. As the pressure is increased, the flow should be seen to
increase also. Adjust the Hydraulic Drive Pressure Control valve until the process pressure is
indicating at the desired level.
When operating pressure conditions have been achieved, the Pressure_Balance_Control can
now be optimised.
8.3. PRESSURE BALANCE CONTROL

To achieve system pressure balance control, the intensifier pressure stroke time is
adjustable in 4 steps. Whenever the unit is powered down, the stroke time reverts back to
the factory set default time.
In general, for approximation, the overlap time is increased one step for each 25% of MWP
being worked at.
To increase or decrease intensifier ram stroke time: Press and release Overlap Increase
Button to increase one step, or Overlap Decrease Button to decrease one step. The stroke
time can be increased up to a maximum of 4 steps and back down again to the system
default (0) as displayed on the Overlap Increment Indicator.
If the Process Pressure Display shows a pressure rise on changeover of intensifier strokes,
this indicates that the overlap is excessive –decrease the overlap.
If the Process Pressure Display shows a pressure drop on changeover of intensifier strokes,
this indicates that the overlap is insufficient – increase the overlap.
Note: Well balanced operation is desirable but not essential for processing performance in
the majority of applications. It is however typically most critical when working on microbial
inactivation.
Setting is also required when using the Recipe_Screen option for pre-set parameter function.
42
8.4. RUNNING
Having Setup the system, the product can now be run, starting and halting using the Run
Start Button and Stop Button. Depending on the product and how it compares to the fluid
used for setting up the system, it may prove necessary to make some refinements to settings
during the running of the system. Also as the system stabilises at temperatures it may be
necessary also to make some adjustments to operational settings.
Operating with micro-channel (fixed orifice devices) may see significant difference in
discharge flow rate.
The homogeniser may be halted in between batch changes merely by pressing Stop Button
and restart after refilling by pressing Run Start Button.
IMPORTANT: Users are automatically logged out when log out time has lapsed from HMI
inactivity. HMI button controls are disabled when user logs out. User Login is required to
activate HMI button controls.
8.5. FLUSHING AND CLEANING

At completion of operation the system should be flushed and cleaned. Flushing and cleaning
protocols are for the user to establish due to the variety of possible product fluids in use. See
Flush_Mode and Clean_Mode.
General recommendations are to conduct flushing and cleaning operation at low pressures
(less than 35 MPa).
When working with micro-channels, if the flow through the micro-channels is less than 50%
of the full flow rate of the system then it is as well to first run the system with a purge valve
open and then run some cleaning fluid through the micro-channel after the general system
has been flushed.
Avoid prolonged exposure to acids stronger than pH 4 during cleaning cycles. Acid should be
approved by HOMOGENISING SYSTEMS prior to use.
Avoid prolonged exposure to alkalis stronger than pH 10 during cleaning cycles. Alkalis
should be approved by HOMOGENISING SYSTEMS prior to use.
The system wetted components are corrosion resistant; however, we recommend for
prolonged shut down the system is left wetted with a corrosion inhibiting fluid. Typical is
20% ethanol in water.
For some application 70% ethanol in water can be used for sterilising the system
Please consult with HOMOGENISING SYSTEMS if intending to pass steam through the system
IMPORTANT: after use, inhibit the system with 70% ethyl alcohol following section SHUT
DOWN PROCEDURE.
43
9. SHUT DOWN PROCEDURE
The equipment MUST NOT be allowed to stand idle for an extended period with residual
product remaining in the system. Essential recommendations are in the interests of hygiene
and for the avoidance of possible corrosion of valve seats and critical parts of the intensifier
ram and seals. Plus possible system blockage due to product setting/hardening within the
pipe work, valves and intensifiers. Shutdown procedures must be strictly adhered to as
follows:-
SHORT TERM SHUTDOWN PERIODS OVERNIGHT OR A WEEKEND.

Leave in distilled/deionised/demineralised water or 20% ethanol and water mix.
LONG TERM SHUT DOWN OR DECOMMISSIONING

Prolonged shut down 2 weeks plus.
Inhibit the system and plug inlet and outlet to stop from drying out.
Shut down power to the system
Shut down the compressed air to the system
Shut down the heat exchanger fluids to the system
If shut down will be longer than 6 months consult HOMOGENISING SYSTEMS for advise on
maintaining the PLC programme integrity.
44
10. TROUBLE SHOOTING
WARNING :- The equipment operates from a 380V-415V supply. Caution should be exercised
in investigating electrical faults, and HOMOGENISING SYSTEMS recommend a qualified
electrician investigates such faults. With the protective covers removed, there is risk of
electric shock, if the system is connected to a mains supply. Any attempt to
investigate/operate the system with the covers removed, while electrical supply is
connected should be carried out only by qualified personnel.
GENERAL:- If the system is not operating correctly it is important that a logical approach is
taken to locating the fault. "Its not working" is not specific. If assistance is required our
Technical Department will require information on the nature of the fault in order to
recommend particular actions. I.E. electrical, mechanical; has there been a sudden or
progressive deterioration ? etc.
45
Is Supply NO FPG7575 TROUBLESHOOTING

No display or
ON light
lights showing
illuminated?
YES NOTE: Incorrect Rotation

NO The Phas e Sequence Relay,(if fitted)
Is Electrical Re-establish trips due to los s of 1 or more phases
supply ON? supply or incorrect rotation. If all supply phas es
present, change over two phas es of
incomming s upply. (Pos sible phasing
imbalance due to blown supply fuse)
YES
Check Bulb, OK Are Mains NO Replace

replace if supply fuses
Fuses
necessary OK?
REPLACED
YES
Incorrect Rotation Is unit supply NO

(see Note) OK cable OK?
RECTIFIED
YES
Investigate,
Test for continuity,
replace if necessary
Problem YES
NO solved?
YES Is Panel ON NO NO
Is keyswitch
light
ON?
illuminated? Ensure Key is fitted
and turn to ON
Is emergency NO YES
Problem
stop button Release button
solved?
released?
NO
YES
Investigate,
Are NO YES
Reset Miniature Problem
panel MCBs
Circuit Breakers, solved?
OK?
replace if necessary
NO
YES
IS THERE YES CONTACT

STILL
SFP technical
Start System
A PROBLEM
46
A steady red indicates both
System will not NO
Is the Fault HP rams are at endstop. Problem
start on pressing
Light OFF? Stop, Shutdown and Restart solved? YES
Cycle Start button
system.
YES NO
A steady fault illumination on

Does Fault light YES button press only, indicates a YES
Problem
illuminate when start FALSE START.
solved?
button is pressed? Check set-up parameters and
re-enter.
NO
NO
CHECK STATUS INDICATOR LIGHTS SHOWING
Compressed YES
air,
ON?
Drive Fluid YES

NO OK,
ON?
Test bulb
for continuity. Process YES
Replace if NO Fluid OK,
necessary. ON?
Door
NO Interlock OK,
Investigate,
re-establish supply ON?
NO
Investigate,
re-fill tank if
necessary, with
approved fluid.
Investigate,
re-fill tank if
necessary, with
approved fluid.
Investigate,
Test switch for Close door and ensure
continuity interlock switch is
fully engaged
Are all status

NO lights ON?
YES
STILL
SFP technical
A PROBLEM
NO
Start System
47
Does the YES

Problem
No feed pressure FEED pump Check for leaks
YES solved?
run?
NO
PRIMING.
NO Check that process fluid
is actually reaching the
intensifier(s) and there are
no air locks.
Pysically check fluid level

Is the Process fluid and that fluid is actually Problem YES
reservoir level OK? NO reaching pumps. solved?
I.E. filters are not blocked.
NO
YES
Is the float switch connected/ (if fitted)
in operation?
Connect and/or pysically
check operation.
Replace if necessary.
Is the Process Elivate the feed reservoir to YES

Problem
fluid resevoir provide a possitive feed
YES solved?
on the floor? pressure to the system
NO

STILL
SFP technical
Start System
A PROBLEM
48
If the pump is not
Feed pressure Does the Hydraulic YES
running, Problem
but no main Drive pump
NO check fuse(s) solved?
pressure rise. run?
and/or overload(s).
NO
YES Investigate,
check for cable
continuity
Check PLC output(s) are

Is the YES
cycling ON and OFF for the Problem
Intensifier(s)
cycling? NO intensifier(s) and hydraulic solved?
unloading valve(s).
NO
YES
PRIMING.
Is the Check that process fluid YES
Problem
process pressure is actually reaching the
NO solved?
fully primed? intensifier(s) and there are
no air locks.
NO
YES
(if fitted) Close valve and check

Is the NO fluid is flowing from YES
Problem
bleed valve the bleed valve outlet.
NO solved?
closed? If valve(s) faulty, refurbish
or return to SFP for repair.
NO
YES
Apply a nominal bias

pressure. Check for
Are the Disrupting YES
increase in process Problem
Valve(s) loaded
NO pressure. solved?
with bias pressure?
If valve(s) faulty, refurbish
or return to SFP for repair. NO
YES
(if fitted)
Check filter not blocked.
Is the YES
Check pneumatic air supply Problem
Inlet valve(s)
closing? NO is ON and suffucient and solved?
the air pilot valve is working
NO
YES
Possible seal wear,

Is there fluid
replace with HP seal kit YES
leaking from the Problem
and check flow rate.
intensifier bleed YES solved?
If faulty, refurbish
holes?
or return to SFP for repair.
NO
NO
49
Fluid should be visibly

Is
YES passing through the
there Drive fluid
Sho-Flow sight glass. (if fitted)
returning back to NO Lift tank lid, identify if any
tank?
return pipe has fluid exiting.
Is there Physically check fluid level

sufficient fluid and that fluid is actually Problem YES
in the Drive pump NO reaching pump. solved?
tank? I.E. filters are not blocked.
NO
YES
Check PLC output

indication,
Is the Intensifier Check if valve exhaust YES
Problem
unloading valve is returning fluid to tank.
NO solved?
closed? Manually operate to
check function,
check fuse. NO
YES
Check Drive pump YES

Is the Drive pump Problem
performance.
performance OK? NO solved?
Service if necessary.
NO
YES

STILL
SFP technical Start System
A PROBLEM
50
11. ROUTINE SERVICING
In the operation of the Homogenising Systems HOMOGENISER a certain element of routine
maintenance is required in order to ensure quality and performance for its application. The
best maintenance is preventative maintenance! This is largely common sense providing it is
realised that the pump, in particular, is a precision device, and in many cases has to operate
at very high pressures, which cannot be contained unless seals and valves are perfect! The
enemies are abrasives, cotton fibres etc., and gummy residue of sludge, which need never
affect it if the facts are appreciated and the operator is careful.
The following section is a guide to the user, for any required routine maintenance task. For
step-by-step procedures, refer to section Detailed_Maintenance.
IMPORTANT: after use, inhibit the system with 70% ethyl alcohol following section
SHUT_DOWN_PROCEDURE.
11.1. PRELIMINARY RULES TO FOLLOW BEFORE ANY MAINTENANCE

A. Disconnect from mains electrical supply.
B. Make sure there is no residual pressure in the system.
C. Ensure the compressed air supply is shut off and vented from the system.
NOTE
THERE IS AN INTERNAL PRESSURE REGULATOR INSIDE THE REAR COVER, THIS IS

FACTORY SET, BUT MAY REQUIRE SOME ADJUSTMENT
11.2. GENERAL REGULAR SYSTEM CHECKS
11.2.1. PRESSURE MEASUREMENT

The pressure transducer can be removed complete with Nato plug if required.
51
11.3. FLUID MAINTENANCE
11.3.1. HYDRAULIC DRIVE FLUID

The fluid should be regularly changed, at least Annually. The filter in the tank, on changing
the fluid, should also be cleaned or renewed. If the fluid becomes highly contaminated then
it should be changed. Abrasive foreign bodies in the fluid at high pressure cause
considerable wear on the high pressure components. Recommended oil: Shell Ondina X 420
approximately 40ltrs capacity from empty.
If there are ANY problems conducting maintenance, contact the Technical Dept. at
Homogenising Systems Ltd (01279 813459).
11.3.2. ROUTINE DRAINING OF COMPRESSED AIR REGULATORS AND

FILTERS
Routine checking and draining of the filter bowls is necessary to keep water build up from
becoming excessive and entering the compressed air control system.
52
11.4. HOMOGENISING VALVE ACCESS – PRESSURE CONTROL PANEL REMOVAL
Open the homogeniser front doors, then lift up the front top hood/panel and ensure the
panel stays engage on both side with a click! Access to the homogenising valve(s) is now
possible. To close the top hood, lift up the hood slightly while disengaging the support struts
and then allow the top hood to close.
The hood weight is supported by 2 hydraulic dampers to prevent the hood from slamming
shut during closing. DO NOT TAMPER with the damper!
The top hood is normally secured for transport with 1 small screw at the bottom rear edge on
the right hand side and can be accessed from underneath when the lower double doors are
open.
11.5. FILTERED INLET VALVE FPG9080

(if fitted) On systems with inlet “punch valves”, pneumatically closed 3
valves, they are normally installed with a simple filter mesh. The inlet
filter (FPG9075), which forms part of that valve assembly, can be changed
without dismantling the inlet valve. The filter element should be changed on
a regular basis to avoid blockage and possible seal damage to the pump or
intensifier; frequency is dependant on product being used.
2
Unscrew inlet body retainer (3), lift inlet body (2) up and out, remove
O-ring (5) and take out filter element (4).
Ensuring the lower valve body is clean and free from debris, fit new 5
element and O-ring, fit inlet body into place, screw and
4
hand tighten inlet body retainer.
1
See also Model_9080_Valve_Refurbishment.
FPG90 75 FILTER ED
INLET A SSEMB LY
53
11.6. SPIRAL RETAINING RING ASSEMBLY
Spiral Retaining Ring Assembly issue2_1
Retaining Ring Installation

Shaft
Housing
Manual installation of spiral retaining rings within a housing bore or on a shaft is

accomplished as follows:-
(1) Separate coils and insert end of ring into groove;
Wind ring into groove;
(2) Inspect for proper seating in the groove.
Retaining Ring Removal

Shaft
Housing
Insert screwdriver and twist to remove end of snap ring. Continue to spiral around
circumference of the ring.
54
12. DETAILED MAINTENANCE
THIS IS A DELICATE OPERATION FOR SKILLED TECHNICIANS AND SHOULD ONLY BE CARRIED
OUT BY QUALIFIED PERSONNEL WITH REFERENCE TO THE CORRECT SUB ASSEMBLY
DRAWINGS.
12.1. HIGH PRESSURE PIPE JOINTS

High Pressure Pipe Joints issue2_3
Standard HP Pipe joints are a metal-to-metal seal with no additional sealing material. The
seal is created by a male type cone on the pipe, which is aligned with a female type cone in
the fitting or valve to be connected to and held in place via an external glandnut and internal
threaded collar. The Gland Nut has a Right-Hand thread, which is tightened in the same
direction as a standard nut and bolt. The Collar on the other hand has a Left-Hand thread,
which operates in the opposite direction. Leakage from high pressure joints is readily
evident, and unless joint members are severely deformed, in which case replacement is
required, or as evidenced by no thread visible on the gland nut when screwed up tight, such
leakage is correctable by adjusting the collar distance and re-tightening the gland nut.
Unscrew and remove the pipe end from the fitting. Wind the collar back 1-2 turns only. The
collar is Left-Handed so winds the opposite way to the nut. The collar can also be very tight
to move after being in service and may require pliers on the collar only to help with turning.
Avoid any damage to the pipe cone as this will render the pipe useless and need replacing.
The collar positioning on the pipe is crucial as too little thread showing between the collar
and start of the cone will cause the nut to run out of thread before a pressure tight seal is
made. Too much thread showing between the collar and cone will cause the gland nut not to
engage into the port sufficiently to withstand the pressure or cause the over exposed pipe
thread to buckle during tightening during assembly, which again will render the pipe useless
and need replacing. Therefore the pipe thread visible between the collar and cone needs to
be approximately 3-4mm to be effective for the standard ¼”od HP Pipe Joint.
55
Ensure the pipe end and mating internal cone are intrinsically clean. Reinsert the pipe with
gland nut and adjusted collar into the hp fitting and tighten. DO NOT over-tighten. Excessive
force is not necessary and could cause pipe end damage.
56
12.2. MODEL 14560 VALVE REFURBISHMENT
Model 560II Valve Refurbishment issue2_2
(THESE INSTRUCTIONS ARE FOR GENERAL GUIDANCE, AND VALVE COMPONENTS DO VARY. FOR
SPECIFIC VALVE PARTS REFER TO ASSEMBLY DRAWINGS)
For refurbishment, the following items are required:-
1. Adjustable Wrench To 1¼ A/F

2. Allen Keys Set (Metric & Imperial)
3. Straight Tweezers
4. Pin Punch Set Inc. 3mm Dia.
5. 6.0mm Dia x 100mm long Steel Rod (Aluminium,Brass
Etc.)
6. Grease (* NOT FOR OXYGEN *) Unless specified.
7. Spindle Removal Tool (Supplied By HOMOGENISING SYSTEMS)
8. valve bonnet removing tool (Supplied By HOMOGENISING
SYSTEMS)
Release any residual system pressure; remove the complete valve from the
system.
Place the valve, vertical (actuator to the top), in a vice.
The air operated actuator (FPG3200/FPG4990) can be

unscrewed and removed from the valve. The valve bonnet
retainer can now be re moved using a valve bonnet removing
tool or alternatively a pair of swan neck pliers may be used.
Care must be taken when removing the valve bonnet as the valve
bonnet retains the valve spindle.
Invert the valve body in the vice; remove the valve seat retainer, by turning
anti-clockwise. Remove the valve seat. The seat maybe still held inside the
valve body, if so a gentle knock should free it.
The only parts that should be seen in the valve body are the seals (Items
7,8,9,10,11 and 12 - MP SEALS) / (Items 4,5,6,7,8 and 9 - HP SEALS). These
can be removed by placing the MP S EALS H P S EALS
6mm Dia. steel rod down 8
9 11
through the valve retainer end of 6
9
the valve body. Gentle 'taps' on the end 10

7
of the rod will push out seal arrangement. 8 5
7
4
57
In refurbishing the valve, the only parts that are regularly changed are as follows :-
A. VALV E S P IN DLE
B. SE ALS To change the valve spindle, the special

tool is placed over the spindle. Then whilst
C. V ALVE S EAT
pushing down on the tool, the spindle is
removed by pulling, then remove tool. The
new spindle is inserted in to the blind hole, making sure that the half ball, which supports
the spindle, is correctly orientated. ie the flat of the ball is visible. Refer to
Needle_Removing_Procedure.
(IF THE HALF BALL IS WITHDRAWN WITH THE VALVE SPINDLE, IT CAN BE REINSERTED BY
USING A SMALL AMOUNT OF GREASE ON THE END OF THE NEW
SPINDLE)
All parts of the valve should be cleaned prior to final reassembly.
NOTE:- It is advised to smear all threads with a small amount of Multi- Purpose Engineering
Grease, to inhibit seizure.***NOT FOR USE WITH OXYGEN***
Replace the NEW seals using tweezers, ensuring their CORRECT orientation.
The seal stop is now replaced in the top of the valve body.
Re-fit Actuator or Service and re-fit, with reference to

Actuator_Maintenance.
The complete valve assembly can now be replaced in the system.

58
Model 8060 Valve Refurbishment issue1_0
(THESE INSTRUCTIONS ARE FOR GENERAL GUIDANCE, AND VALVE COMPONENTS DO VARY. FOR
SPECIFIC VALVE PARTS REFER TO ASSEMBLY DRAWINGS)
2
1. Adjustable Wrench To 1¼ A/F

3. 8.5mm Dia x 100mm long Rod (Aluminium, Brass Etc.)
5. Internal Circlip Pliers 40-100mm.
6. Needle Removal Tool “Split for 8mm” (Supplied By
HOMOGENISING SYSTEMS)
1
Release any residual system
pressure; remove the complete valve from the
system.
Place the valve, vertical, actuator (2) to the top, in a vice.
The air operated FPG3200 series valve actuator (2) can then be
unscrewed and removed from the valve body (1), normally by
hand, keeping it aligned until the Valve Needle is clear. Care
must be taken when removing the valve actuator as the valve
stem retains the valve needle and could get
damaged during withdrawal.
Invert the valve body in the vice; remove

the valve seat retainer, by turning anti-
clockwise. Remove the valve seat. The seat
maybe still held inside the valve body, if so
a gentle knock should free it.
S EAL
S TO P The only parts that should be left in the valve body are the
9
seals (Items 6,7,8 and 9) - These can be removed by
pushing the 8.5mm Dia. rod down through the valve
8
retainer end of the valve body. Gentle 'taps' on the end of
the rod will push out seal arrangement.
7
6
59
To change the valve needle, the special “split” NRT tool is

A) VALVE
NE E DLE placed over the spindle, at the reduced diameter end, which
is held in the quick release valve stem. Then whilst pushing
B ) SE AL S
the NRT into the valve stem and at the same time pulling the
C ) V ALV E S E AT valve needle, the needle should be released from the stem
and come free. The new needle is inserted in to the blind
hole, making sure that the half ball, which supports the needle, is correctly orientated. ie the
flat of the ball is visible. Refer to Needle_Removing_Procedure.
(IF THE HALF BALL IS WITHDRAWN WITH THE VALVE NEEDLE, IT CAN BE REINSERTED BY
NEEDLE)
NOTE:- It is advised to smear all threads with a small amount of Multi-

Purpose Engineering Grease, to inhibit seizure.***NOT FOR USE WITH
OXYGEN***
Replace the NEW seals using tweezers, ensuring their CORRECT

orientation.
The seal stop is now replaced in the top section of the valve body,
holding the seals loosely in place.


60
Model 9080 Valve Refurbishment issue1_0
C
(THESE INSTRUCTIONS ARE FOR GENERAL GUIDANCE, AND VALVE COMPONENTS DO VARY. FOR SPECIFIC
VALVE PARTS REFER TO ASSEMBLY DRAWINGS)
7. Adjustable Wrench To 1¼ A/F A
9. 6mm Dia x 100mm long Rod (Aluminium, Brass Etc.)
11. Internal Circlip Pliers 40-100mm.
B
12. Needle Removal Tool (Supplied By HOMOGENISING SYSTEMS)
Release any residual system pressure; remove the

complete valve from the system.
Place the valve, vertical, actuator (B) to the top and

clamp the valve body (A), in a vice. The inlet filter
housing (C) FPG9075, is an optional item and is
substituted with a simple valve seat retainer when the valve is
15
manufactured.
2
The air operated FPG3200 series valve actuator (16) can then be
unscrewed and removed from the valve body (1), normally by hand,
keeping it aligned until the Valve Needle (2) is clear. Care must be taken
13
4 when removing the valve actuator as the valve stem retains the valve
1
needle and could get damaged during withdrawal.
The seal stop (4) is a loose fit and can also be removed with tweezers or
simply turning the valve body upside down, which will also dislodge the
valve ball.
Invert the valve body (1) in the vice; remove the inlet filter 12
housing (12) or valve seat retainer, by unscrewing anti-

clockwise using the spanner. Remove the valve seat (11). The
seat maybe still held inside the valve body, if so a gentle knock
to the valve body should free it. 11
10
9
The only parts that should be left in
the valve body are the seals (Items
7
4,6,7,8,9 and 10) - These can be removed
8 by pushing the 6mm Dia. rod down through the
valve retainer end of the valve body. Gentle 'taps'
6
on the end of the rod will push out seal
4 arrangement.
61
1) valve Needle To change the valve needle, the special NRT

tool is placed over the spindle, which is held
2) Seals in the quick release valve stem. Then whilst
pushing the NRT into the valve stem and at
3) Valve Seat the same time pulling the valve needle, the
needle should be released from the stem and
come free. The new needle is inserted in to
the blind hole, making sure that the half ball, which supports the needle, is correctly
orientated. ie the flat of the ball is visible. Refer to Needle_Removing_Procedure.
(IF THE HALF BALL IS WITHDRAWN WITH THE VALVE NEEDLE, IT CAN BE REINSERTED BY
NEEDLE)
NOTE:- It is advised to smear all threads with a small amount of Multi-

Purpose Engineering Grease, to inhibit seizure.***NOT FOR USE WITH
OXYGEN***
Replace the NEW seals with the aid of tweezers, ensuring their CORRECT
orientation.
The seal stop is now replaced in the top section of the valve body, holding
the seals loosely in place.

Service or replace the valve seat, ensuring the valve ball is inserted into the valve body first
and that the valve seat is correctly orientated so the ball sits into the internal cone. Fit and
tighten the inlet filter housing or seat retainer, ensuring the valve seat is sitting flat and
central, otherwise damage to the seat and retainer can occur.

62
12.5. ACTUATOR MAINTENANCE
Actuator Maintenance issue1_0
(THESE INSTRUCTIONS ARE FOR GENERAL GUIDANCE, AND VALVE COMPONENTS DO VARY. FOR SPECIFIC VALVE PARTS REFER TO
ASSEMBLY DRAWINGS)
For maintenance, the following items are required:-
1. Internal Circlip Pliers 40-100mm (FPG3200N,Q,U).

2. Internal Circlip Pliers 100-200mm (FPG3200W,Y).
3. Intensifier Assembly Tool FPG8125.055 (for FPG3205X ONLY.
Release any residual system pressure; remove the complete valve from the system. Place the
valve, vertical (actuator to the top), in a vice*.
*In some cases it may be able to carry out maintenance in situ as long as it is safe to do so.
For FPG4990 (1) use the adjustable spanner to unscrew

the top cap. The piston should then be exposed. The
1
Valve Bonnet Adapter hex will take a 27mm socket if
the valve actuator has been completely removed from
the valve body. The piston seal can now be accessed
and changed if required. Clean and lightly lubricate the
seal, DO NOT OVER-LUBRICATE! As this can cause the
floating piston o-ring to clog-up and not work. Re- 2
assemble the valve cap, DO NOT OVER-TIGHTEN!
For FPG3200N,Q,U&Y (2): Using the circlip pliers, remove the top cap
retaining circlip. To extract the piston use a screw or bolt of
appropriate size, FPG3200N – M5, FPG3200Q,U,W – M6, FPG3200Y –
63
¼” BSP.
The piston seal can now be accessed and changed if required. Clean and lightly lubricate the
seals, DO NOT OVER-LUBRICATE! As this can cause the floating piston o-ring to clog-up and
not work. Re-assemble the valve cap.
If necessary, the actuator can be disassembled further (3) to access

leaking seals. Remove the internal locking grub screw, circled (if
fitted), which is located in the thread bank. Unscrew the actuator
3 outer body complete with the bottom cap from the valve bonnet
adapter. The bottom cap can now be accessed, by removing the
retaining circlip. The valve bonnet adapter can be further
disassembled (if required), by unscrewing the spring cap to allow the
valve stem assembly to be withdrawn. The seals can now be changed
if required. Clean and lightly lubricate the seals, DO NOT OVER-
LUBRICATE! Re-assemble the actuator.
IMPORTANT: For FPG3205X (4). Ensure that the locking grub screw,
circled (if fitted) has been removed before attempting to unscrew the
cap.
The Intensifier Assembly

Tool is required to 4
unscrew this cap by placing the tool studs into
the two holes on the cap top face and using this
to turn the cap.
The piston seal can now be changed if required.

Clean and lightly lubricate the seal, DO NOT
OVER-LUBRICATE! Re-assemble the actuator.
Refer to Specific Model HP Valve Body

Assembly Drawing and Parts List (schedule) for
individual items and descriptions. (subassembly
numbers can be found on the valve parts
schedule).
64
12.6. NEEDLE REMOVING PROCEDURE
NEEDLE REMOVING PROCEDURE~edition2
A. Remove valve stem from valve

B. Push Needle Removing Tool (FPG2508) onto and down the needle
C. When at base of needle, push NRT home and hold
D. Withdraw needle from valve stem
E. Insert new needle and remove NRT
F. This procedure is also used when carrying out piston replacement.
(IF THE HALF BALL IS WITHDRAWN WITH THE VALVE SPINDLE, IT CAN BE REINSERTED BY
SPINDLE)
NOTE:- It is advised to smear all threads with a small amount of Multi- Purpose Engineering
Grease, to inhibit seizure.***NOT FOR USE WITH OXYGEN***
65
12.6.1. NEEDLE REMOVAL FROM ACTUATORS
Remove the actuator assembly from the valve body to show the stem assembly quick
release. To aid removal, a nominal pressure may be applied to the actuator, to raise the
stem assembly flush with the bonnet adaptor. DO NOT exceed the maximum pressure
rating.
Place the NRT over the spindle / needle, push down and hold. The spindle / needle is then
pulled up and out. Remove the NRT.
If the half ball comes out with the spindle / needle, ensure that the flat side is stuck back
onto the new spindle / needle with suitable lubricant. Carefully insert the new spindle /
needle into the stem assembly, ensuring the half ball is flat side to needle. Push down hard
to ensure spindle needle is locked in place. DO NOT tap or hit the spindle.
12.6.2. DISASTER RECOVERY
If you are unlucky enough to have the spindle / needle snap off at the base, you will need to
equip yourself with the above disaster recovery tools. The angled tweezers are to push down
on the inner collet ring, while the thin nosed pliers are to retrieve the broken section.
If the broken piece is below the collet ring and therefore cannot be retrieved, the whole
stem assembly will have to be replaced.
66
12.7. GENERAL NOTES FOR REFURBISHING VALVES
Refurbishing Decompression Valves edition3_0
A. First establish that the valve is defective, by blowing through with

filtered air or nitrogen, and suitable solvent cleaners as necessary.
B. If it is necessary to refurbish valves, valve seats should be examined
for etch marks on seat. If no obvious defects can be seen, clean
thoroughly and "lightly" re-lap the internal conical ball/needle
seating area, using very fine diamond compound (8-L-00/30) and lubricate with
paraffin (Kerosene)
C. Keep lap square to seat.
D. Valve seats can be refurbished using the same procedure for preparing a new
valve seat.
12.7.1. REPLACING OR REFURBISHING VALVE SEAT
A. "Face the seat" [STEP 1] by lapping with a medium grade compound using a
conical lapping mandrill, until the seat shows an even "Ground glass finish" free
from machining marks, particularly "Chatter" type indications; the critical area
being the bottom 1/3rd of the conical seat.
67
B. "Fit" the seat [STEP 2] by mounting the valve seat on a tapered spindle fitting the
through hole in the seat. Using the medium grade compound lap the seat to its
mating conical faces of the valve body or retainer, to produce a continuous
witness at the small diameter of the cone extending 1-1.5 mm up the conical
surface.
C. "Proving" the seat [STEP 3] by lapping with a ball/needle using very fine polishing
grade compound until a continuous line witness is just evident.
D. Always use new/refurbished parts when reassembling.
E. Thoroughly clean off all lapping compound Etc. Absolute cleanliness is essential.
F. Assemble valve, applying grease to the thread and cone face. Test free action of
valve before tightening.
G. Blow through valves with filtered air and test where possible. In general a valve
that seats at shop air pressure will perform satisfactorily at full pressure.
68
12.8. INTENSIFIER SEALS – GENERAL
Model INTENSIFIER SEALS - GENERAL issue1_0
In the event of a leakage detected at any of the vent ports of either intensifier, a strip down
operation will be necessary in order investigate and replace defective High Pressure seals. A
further possible fault condition, which may necessitate internal investigation, could be oil
leakage from the hydraulic drive piston seals. During normal operation there will always be a
residual film of hydraulic oil left on the bore by the hydraulic seals; this film will be swept
forward by the dead side of the piston on each stroke and will drain into the air retract
exhaust relief bowl, as it accumulates through the piped drain ports. However, although the
hydraulic seals will normally have a very long life and may be allowed to outlast one or more
of the changes of the high pressure seals, long term deterioration, or damage, may result in
an excessive leakage of oil which would be evident by spray witness of oil at the upper vent
port on the dead side of the drive end cylinder.
12.9. STRIPPING THE INTENSIFIER FOR INSPECTION AND/OR SEAL CHANGE.

The intensifier is dismantled using normal engineering tools and techniques; where
applicable two 12 mm dia dowel pins and a suitable lever bar approx 300 mm long may be
used to remove and fit end plugs when peg spanners are not available.
Replacement seals may be fitted with reference to appropriate sub-assembly drawings

provided. Care should be taken to ensure that seals are assembled strictly in accordance
with the diagram.
12.10. WARNING! RELEASE TRAPPED COMPRESSED AIR FROM INTENSIFIER BLOW-

DOWN SYSTEM BEFORE MAINTENANCE
DO NOT ATTEMPT TO DISMANTLE
INTENSIFIERS UNLESS THE
PNEUMATIC AIR SUPPLY HAS BEEN
DISCONNECTED AND LOCKED OFF.
VENT DOWN THE INTENSIFIER BY

PULLING THE RING ATTACHED TO
THE AIR RETRACT EXHAUST BOWL
VENT VALVE UNTIL THE OPERATOR
IS POSITIVE THAT ALL AIR IS VENTED
FROM THE SYSTEM.
12.11. PRIME INTENSIFIER

When refitting or changing seals on the process side of the intensifier (high pressure seals)
while installed in equipment, fill the barrel with inert fluid before fitting hp plug and end cap.
69
12.12. RAISE RAMS FUNCTION

This is a skilled job and should only be undertaken by competent maintenance personnel
who are familiar with hydraulic systems.
This function must be carried out with the front doors open as this automatically vents the
compressed air from the pressure intensifiers, allowing the HP Rams to raise for inspection
without withdrawing back due to the air retraction. IMPORTANT: Closing the doors will
engage the air retraction and allow compressed air back to the intensifiers, causing the rams
to retract back into the interconnecting space.
Press the Maint_Run_Button to start hydraulic pump without pressure cycling. Press&HOLD
the Raise_Rams_Button to raise the rams
70
12.13. FPG14385_NNNN INTENSIFIER FULL SEPARATION
model FPG14385_nnnn INTENSIFIER FULL SEPARATION issue1_0
The FPG14385_nnnn series full separation intensifier build

assembly is divided into several sub-assemblies. *The nnnn
designation denotes the ratio build of the complete assembly.
This is a general overview of the complete assembly. Each sub-

assembly is covered in its own more detailed section.
FPG9100:nnn series High Pressure Barrel assembly is available

in different internal size builds (nnn) dependant on ultimate
maximum working pressure required on user system build.
I.e. 9100:050 = 15:1 ratio with maximum attainable working
pressure of 60Ksi, 410Mpa dependant on the applied hydraulic
drive pressure.
The standard assembly includes a temperature Conditioning

Jacket for the high pressure barrel for connection to customer
fluid temperature unit, i.e. cooler, chiller or heating,
dependant on product to be processed through high pressure.
The rest of the intensifier comes under FPG14390Q065

Hydraulic Drive Barrel assembly and remains the same
component parts regardless of which size High Pressure Barrel
assembly is fitted.
The middle section is a vented interspace called the Separator

Barrel, giving full separation between the hydraulic drive and
high pressure chamber in contact with the product being
processed. An internal connecting rod links the hydraulic drive
to the HP Ram within the HP barrel chamber.
The bottom section is the Hydraulic Drive Barrel containing the

large drive piston, which is pushed along by hydraulic fluid to
the underside during a pressure stroke. Pneumatic air pressure
is used to push the drive piston back to the bottom.
In the bottom end, is the QEV or Quick Exhaust Valve. An

internal shuttle valve is closed during a pressure stroke due to
the influx of hydraulic fluid. At the limit of travel or end of
stroke, the hydraulic drive fluid is stopped, which causes the
large bore internal shuttle valve to open, rapidly releasing the
hydraulic fluid within.
71
72
12.14. MODEL FPG14405.NNN HP END PLUG SEAL CHANGE
Model FPG14405_nnn HP End Plug Seal Change issue1_1
(THESE INSTRUCTIONS ARE FOR GENERAL GUIDANCE, AND VALVE COMPONENTS DO VARY. FOR SPECIFIC VALVE PARTS REFER TO
ASSEMBLY DRAWINGS)
1. 150mm (6”) Adjustable Wrench.

2. FPG14389-5 LUG SPANNER or FPG8124.055 Intensifier Assembly Tool or ½” (1.2cm)
Diameter Steel Rod approximately 6” (15cm) Long.
3. Small Flat Blade Screwdriver (for spiral retaining ring).
4. General Purpose Grease* (*FOOD GRADE if applicable).
Make sure that there is no residual pressure in the system. Loosen and remove all pipes and
fixing screws using the adjustable wrench.
Using the Lug Spanner or intensifier assembly tool handle tip or the steel rod, insert into one
of the hp end cap three external c-spanner holes and using the spanner or rod as a handle,
rotate the end cap counter-clockwise (as looking from above). Once fully unscrewed, the hp
end plug assembly complete with the end cap can be removed from the intensifier hp barrel.
The HP seals are now accessible. Find the small lug at one
end of the spiral retaining ring (A) and using the small flat
blade screwdriver, lever out one end of the ring and carefully
peal out the rest of the ring from the groove it sits in (refer to
Spiral Retaining Ring assembly instruction if required). The
seal support ring (B), o-ring seal (C) and angled wedge ring
(D) can now be removed.
73
Clean off the angled sealing area on the hp plug where the wedge ring
sits and carefully check for operational dents and deep scratches or
erosion lines caused by the hp fluid if the seals have had sustained
leaking. This angled sealing area is vital to containing the working high
pressures and any deep dents, scratches or erosion lines will render the
equipment useless without repairs or replacement. It may be possible
to clean up small scratches but only after consultation with HS technical
department to prevent inadvertently worsening the situation. NOTE:
Persistent use of equipment with leaking seals can cause further
extensive/expensive repairs.
IF reusing the wedge ring, inspection of the inner angled and outer faces is required while
observing the technical notes above. Any damage to the ring, however small should warrant
replacement to avoid more extensive and expensive repairs to the other HP components.
For reassembly of the HP Seals, ensure the hp plug sealing area is

intrinsically clean and free of dirt and debris. Fit the new or cleaned
and inspected wedge ring onto the hp plug, ensuring the ring inner
angled face sits against the hp plug angled sealing face. Fit new o-
ring seal, using a very small smear of grease suitable for the
operational environment to aid smooth reassembly of elastomer
seals. Next fit the seal retainer ring followed by the spiral retaining
ring. Open up the spiral ring slightly to enable one end of the ring to
engage into the retaining groove on the hp plug. While holding this
end in place, follow the ring around while pressing into the groove
until all of the ring is fully engaged. Particular attention must be paid
to ensure ring is properly seated into the groove as the ring could possibly work loose during
operational vibrations if not fully engaged.
With the HP seals in place, the end plug assembly can now be refitted into the intensifier
barrel, ensuring the barrel inner sealing area is clean, free from dirt, debris, dents, scratches
and hp erosion lines.
Prime Intensifier. When refitting or changing seals on the process side of the intensifier (high
pressure seals) while installed in equipment, fill the barrel with inert fluid before fitting hp
plug and end cap.
Screw the hp end cap onto the intensifier barrel until it stops with a positive stop. The end
cap does not need tightening any more than that. The end cap can be unscrewed slightly to
enable the hp plug to be rotated to suit the installation and retightened again.
74
12.15. FPG14390Q065 INTENSIFIER DRIVE ASSEMBLY
model FPG14390Q065 INTENSIFIER DRIVE ASSY FULL SEPARATION issue1_0
To carry out maintenance on the drive barrel assembly, for seal change etc, it is necessary to
first remove the High Pressure Barrel Assembly (refer to detailed section). Also the
separation barrel assembly, see next page.
IMPORTANT: Ensure ALL pneumatic air pressure

is vented from the system and drive barrel (1).
For assembly, the drive barrel must be

completed first and then the separation barrel.
Fit the 2 part piston seals (18) onto the drive

piston (3) followed by the seal retainer (4) and
spiral retaining ring (15) ensuring spiral ring is
fully engaged in the groove. Refer to section
Spiral Retaining Ring Assembly if required.
Slip the spiral retaining ring (14) and ram

retaining ring (6), stepped side up, onto the
connecting rod (13) end. Hold them in place
while fitting the 2 split ring halves onto the
connecting rod end, locating them into the
groove and hold them in place while inserting
the connecting rod complete with rings into the
drive piston (3). Hold in place while inserting the
spiral retaining ring (14) into the drive piston
groove ensuring ring is fully engaged in the
groove. Refer to section Spiral Retaining Ring
Assembly if required.
Apply a small amount of suitable lubricant to the

drive seals (18) and insert the assembled
connecting rod with drive piston into the drive
barrel (1) ensuring insertion is via the barrel end without the pneumatic side ports.
Install seals (16+17) onto the Quick Exhaust Valve (2) ensuring the backup ring (16) concave
face is against the o-ring seal (17).
Apply a small amount of suitable lubricant to the QEV thread and seals. Screw the QEV into
the barrel (1) taking care that the thread does not bind. Tighten the QEV with the LUG
spanner FPG14389-5.
Fit connecting body bearing ring (11) into connecting body hyd/sep (8) internal recess. Fit
wiper seal (20) in internal seal groove of the connecting body using small amount of suitable
lubricant. Fit o-ring (19) into seal recess of drive barrel (1) with small amount of lubricant.
75
Push drive piston and connecting rod assembly
forward enough to facilitate access for spiral
retainer and retaining ring in the crosshead
(10).

retaining ring (6), stepped side up, onto the
connecting rod (13) end. Hold them in place
while fitting the 2 split ring halves (5) onto the
connecting rod end, locating them into the
the connecting rod complete with rings into the
crosshead (10). Hold in place while inserting the
spiral retaining ring (14) into the crosshead
groove ensuring ring is fully engaged in the
groove. Refer to section Spiral Retaining Ring
Assembly if required.
IMPORTANT: HP Ram (R*) has to be installed

before the Separator Barrel (9). *HP Ram (R)
and Connecting body (R) size are specific to the
HP Barrel working pressure ratio build. Refer to
detailed section on HP Barrel Assembly.

retaining ring (6), stepped side up, onto the HP
Ram (R*) end with the groove. Hold them in
place while fitting the 2 split ring halves (5)
onto the ram end, locating them into the
the ram, complete with rings into the crosshead
(10). Hold in place while inserting the spiral
retaining ring (14) into the crosshead groove
ensuring ring is fully engaged in the groove.
Refer to section Spiral Retaining Ring Assembly
if required.
Fit the plastic crosshead bearing (12) onto the

crosshead (10) external groove. Slide the
connecting body (9) with seal recess upwards,
over the crosshead (10) ensuring the bearing
ring (12) is not dislodged from its groove and
screw onto the hyd/sep connecting body (8).
Insert o-ring seal (19) into the connecting body (9) seal recess. Screw in the HP connecting
body (R*) into the separator body (9).
76
12.15.1. REPLACING DRIVE END SEALS
DO NOT ATEMPT TO DISMANTLE
INTENSIFIERS UNLESS THE
PNEUMATIC AIR SUPPLY HAS BEEN
DISCONNECTED AND LOCKED OFF.
VENT DOWN THE INTENSIFIER BY

PULLING THE RING ATTACHED TO
THE AIR RETRACT EXHAUST BOWL
VENT VALVE UNTIL THE OPERATOR
IS POSITIVE THAT ALL AIR IS VENTED
FROM THE SYSTEM.
Removing the partly dismantled intensifier from the

mounting brackets, place horizontally into a vice fitted
with SOFT JAWS, so both end plug and connecting body
are accessible. Unscrew drive end plug. Replace backup
ring then O-ring. To replace drive piston seals, the piston
must be withdrawn from the drive barrel using a length
of M6 studding into the back of the piston. Care must be
taken not to score or scratch the bore of the drive barrel.
NOTE: On intensifiers with pneumatic air retract, the HP ram is secured into the drive piston,
so care must be taken when removing or re-fitting piston, as to not scratch or damage the
HP ram rod, which could lead to leakage or seal damage.
To fit new air retract ram seal; firstly unscrew locking grub screws in the side of the
connecting body. Failure to do so can result in detrimental thread damage. Fit 2 M6 bolts
into the tapped holes in the end of the connecting body and using a suitable lever between
them, unscrew the body and replace the internal ram seal.
Fit new seals and carefully re-insert piston. Refit drive end plug and tighten.
It is NOT necessary to apply leverage to tighten the threads at either end of the high
pressure drive barrel; manual torque applied to the high pressure end cap using a 12 mm dia
bar, not more than 150 mm long, is all that is required to ensure that end butting conditions
have been achieved - excessive torque applied will serve no purpose as the seals are self
energising and would only result in creating unnecessary difficulties on a future occasion
when dismantling.
77
12.16. FPG170HP QEV DRIVE END CAP - QUICK EXHAUST VALVE SEALS
model FPG170HP QEV DRIVE END CAP issue2_0
IMPORTANT: Ensure ALL pressure is vented from the intensifier before attempting to
remove the Hydraulic End Cap.
Ensure the intensifier is fully retracted to avoid excessive oil loss when removing the end cap.
Unscrew the end cap from the intensifier drive barrel using the FPG14389-5 LUG SPANNER
or 3/8” (9.5cm) Diameter Steel Rod approximately 6” (15cm) Long.
SEAL CHANGE ONLY: Unscrew inlet adaptor (6) complete with bonded washer (9). Withdraw
shuttle body (2) assembly; ensuring angled lapped sealing area on opposite end is kept free
of debris, dents or scratches. Remove old seals (7+8) being careful not to scratch the seal
groove. DO NOT remove the poppet valve seat (5) or poppet valve (3) or poppet valve spring
(4) from the shuttle (2) if just carrying out a seal change!
Clean seal groove and replace backup ring (7) then O-ring (8) onto shuttle seal groove recess.
Refit shuttle (2) into end cap (1) ensuring the return spring (10) is on the shuttle narrow end.
Refit inlet adaptor (6) complete with the bonded washer (9), and tighten.
POPPET VALVE REMOVAL (if required): Follow for Seal Change above until the Poppet Valve
Seat (5) is accessible.
Unscrew poppet valve seat (5) using a 3/16” hex key. The poppet Valve (3) should just fall
out along with the spring (4). Inspect both lapped angle sealing areas on poppet valve (3)
and seat (5) for damage, dents, scratches or pressure erosion. Replace or repair as
necessary. Carry out Valve Lapping of sealing areas on new replacements of either part.
78
12.17. FPG9100_050 050X9 INTENSIFIER HP ASSEMBLY
model FPG9100_050 050x9 INTENSIFIER HP ASSEMBLY issue2_0
FPG9100:nnn series High Pressure Barrel assembly is available in

different internal size builds (nnn) dependant on ultimate maximum
working pressure required on user system build.
I.e. 9100:050 = 15:1 ratio with maximum attainable working pressure of
60Ksi, 410Mpa dependant on the applied hydraulic drive pressure.
IMPORTANT: The HP Ram (11) and HP connecting body (10) MUST be

installed during the FPG14390Q065 Hydraulic Drive Barrel assembly
before continuing on this section.
79
Slide the Gland Ring (4) down over the HP Ram (11) until is sits flat within the HP connecting
Body (10) recess.
The “Dynamic” seal set is then fitted onto the HP Ram (11) to sit on top
of the Gland Ring (4) in the following order:
Cuff Mitre Ring (8) with the narrow “cuff” inserting into the gland ring
bore. Plastic A-Ring (6) with flat base against the cuff mitre ring. Plastic
Wedge Ring (5) with the internal angle face against the matching angled
face of the a-ring.
Gland Seal or Variseal or Lipped Seal (17) with flat back against the
wedge ring flat back. The Gland Seal Support Ring (9) fits inside the
gland seal recess.
The HP Barrel (1) can now be screwed into the HP Connecting Body (10) ensuring 3 external
lug grooves on the barrel are uppermost. Tighten the barrel using FPG14389-5 LUG
SPANNER, which locates into the 3 external lug grooves.
Slide the Cooling Jacket (12) over the hp barrel and down onto the hp connecting body (10).
The Protection Jacket (13) then locates into the cooling jacket.
The “Static” seal set is fitted to the HP End Plug. Refer to section
FPG14405.nnn HP End Plug Seal Change for more detailed instruction.
Fit the HP End Plug (2) complete with seals (15+7) and retaining rings
(3+18) into the hp barrel (1).
The End Nut can then be screwed onto the hp barrel using a small
amount of suitable lubricant. The end nut (14) only needs to be hand tight but ensure it is
fully home. The intensifier double check valve can either be fitted to the hp end plug before
or after it is installed into the hp barrel. The end nut can be loosed slightly to allow the plug
to rotate when orientating the double check valve during pipe installation.
Refer to section FPG14400.420 Series Double Check Valve Assembly for maintenance
instructions if required.
80
12.18. FPG14400.200 SERIES DOUBLE CHECK VALVE ASSEMBLY
model FPG14400_200 DOUBLE CHECK VALVE issue1_0
The general standard arrangement of the intensifier double check valve has 3 ports. Inlet
(non-return), mid Intensifier Connection (free flow in and out) and Outlet (non-return).
To disassemble the check valve, ideally first remove the valve from the installation and place
in an engineers vice (can be carried out with Intensifier HP Plug still in place).
Remove the inlet valve

retainer (2). The valve
retainers are very tight, so a
large adjustable spanner is
required.
The inlet valve seat (3), ball (8)

and inlet spring (4) should just
fall out.
Remove the outlet valve retainer (5). The 2 retainers are normally, low pressure port for the
inlet (2) and high pressure port (5) for the outlet retainer, so identification of the retainers is
essential for reassembly.
The outlet valve seat (7), ball (9) should just fall out. The outlet spring (6) may or may not
remain within the outlet retainer (5). If the spring needs to come out for cleaning, simply pull
it out using tweezers.
Careful attention to the springs (4+6), valve balls (8+9) and valve seats (3+7) orientation is
essential to ensure correct flow through the complete reassembled valve.
The valve seats are hard wearing with a machined finish. A “new” seat before assembly into
the valve has to be lapped with fine lapping paste on all the sealing areas, which are, outside
conical surface top and bottom, inside conical cone which has to be finished off with a final
lap using a ball and fine diamond lapping paste. Valve Lapping techniques are available on
document M-VL-001 from HS.
The valve seat conical cone is indicated where the ball seats and provides a
metal-to-metal seal. This area is susceptible to wear and damage from any
particulate matter that may enter the system. Careful attention to this area
is required and any nicks / dents or excessive wear will require re-lapping
or replacement.
Complete Valve Kits (seats, balls and springs)

and smaller Valve Refurbish Kits (balls and
springs only) are available.
81
On assembly the threads require lubricating preferably with a copper loaded grease OR food
compatible grease if in contact with food. Due to the nature of the materials used, un-
lubricated threads can start up bind and may lead to seizure. Ensure all parts are intrinsically
clean before assembly.
Re-assembly starts with the valve body (1) turned on end for ease of internal parts assembly.
It matters not whether the inlet or outlet non-return valve is assembled first but for this
instruction, we shall start with the inlet.
Insert inlet spring (4) into the valve bore inlet port, ensuring
correct orientation (see picture).
Place the valve ball (8) into the bore next, onto the spring.
Place the valve seat (3), conical side to the ball. A tiny amount of
“clean” grease can be applied to the outer surfaces of the seat, to
aid seating if required but is not essential.
Insert the “lubricated” inlet valve retainer (2) into the valve bore
next, being careful not to dislodge the valve seat, and screw tight.
For the Outlet non-return valve, we will place the outlet valve
retainer (5) onto a clean flat surface with the sealing conical face
pointing upwards.
Insert the outlet spring (6) ensuring correct orientation (see

picture) into the outlet valve retainer (5).
Place the valve ball (9) onto the spring (6) in the retainer (5) bore.
Place the valve seat (7), conical side to the ball, onto the retainer
(5) so that it sits flat and captures the ball inside the retainer bore.
A tiny amount of “clean” grease can be applied to the outer
surfaces of the seat, to aid seating but is not essential.
Carefully lower the valve body (1), outlet side, onto and over the
lubricated retainer (5), and screw body down while holding the
retainer steady, being careful not to dislodge the valve seat (7).
Tighten both valve retainers with a large adjustable spanner, tight.

82
12.19. FPG14400.420 SERIES DOUBLE CHECK VALVE ASSEMBLY
model FPG14400_420 DOUBLE CHECK VALVE issue1_0
The general standard arrangement of the intensifier double check valve has 3 ports. Inlet
(non-return), mid Intensifier Connection (free flow in and out) and Outlet (non-return).
To disassemble the check valve, ideally first remove the valve from the installation and place
in an engineers vice (can be carried out with Intensifier HP Plug still in place).
Remove the inlet valve retainer

(2). The valve retainers are very
tight, so a large adjustable
spanner is required.
The valve seat (6), ball (7) and

inlet spring (3) should just fall out.
Remove the outlet valve retainer

(4). The 2 retainers are normally,
low pressure port for the inlet (2)
and high pressure port (4) for the
outlet retainer, so identification of the retainers is essential for reassembly.
The valve seat (6), ball (7) should just fall out. The outlet spring (5) may or may not remain
within the outlet retainer (4). If the spring needs to come out for cleaning, simply pull it out
using tweezers.
Careful attention to the springs (3+5), valve balls (7) and valve seats (6) orientation is
essential to ensure correct flow through the complete reassembled valve.
The valve seats are hard wearing with a machined finish. A “new” seat before assembly into
the valve has to be lapped with fine lapping paste on all the sealing areas, which are, outside
conical surface top and bottom, inside conical cone which has to be finished off with a final
lap using a ball and fine diamond lapping paste. Valve Lapping techniques are available on
document M-VL-001 from HS.
The valve seat conical cone is indicated where the ball seats and provides a
metal-to-metal seal. This area is susceptible to wear and damage from any
particulate matter that may enter the system. Careful attention to this area
is required and any nicks / dents or excessive wear will require re-lapping
or replacement.
Complete Valve Kits (seats, balls and springs) and

smaller Valve Refurbish Kits (balls and springs only)
are available.
83
On assembly the threads require lubricating preferably with a copper loaded grease OR food
compatible grease if in contact with food. Due to the nature of the materials used, un-
lubricated threads can start up bind and may lead to seizure. Ensure all parts are intrinsically
clean before assembly.
Re-assembly starts with the valve body (1) turned on end for ease of internal parts assembly.
It matters not whether the inlet or outlet non-return valve is assembled first but for this
instruction, we shall start with the inlet.
Insert inlet spring (3) into the valve bore inlet port, ensuring
correct orientation (see picture).
Place the valve ball (7) into the bore next, onto the spring.
Place the valve seat (6), conical side to the ball. A tiny amount of
“clean” grease can be applied to the outer surfaces of the seat, to
aid seating if required but is not essential.
Insert the “lubricated” inlet valve retainer (2) into the valve bore
next, being careful not to dislodge the valve seat, and screw tight.
For the Outlet non-return valve, we will place the outlet valve
retainer (4) onto a clean flat surface with the sealing conical face
pointing upwards.
Insert the outlet spring (5) ensuring correct orientation (see picture)
into the outlet valve retainer (4).
Place the valve ball (7) onto the spring (5) in the retainer (4) bore.
Place the valve seat (6), conical side to the ball, onto the retainer (4)
so that it sits flat and captures the ball inside the retainer bore.
A tiny amount of “clean” grease can be applied to the outer surfaces
of the seat, to aid seating but is not essential.
Carefully lower the valve body (1), outlet side, onto and over the
lubricated retainer (4), and screw body down while holding the
retainer steady, being careful not to dislodge the valve seat (6).
Tighten both valve retainers with a large adjustable spanner, tight.

84
13. BACKUPS WITH PROSAVE
Routine backups can be carried out with Siemens Simatic ProSave software on the data
logging PC.
On General Tab, select Device Type, Connection and IP address of HMI/PLC required.
On Backup Tab, select Data type required. Enter suitable file name and save location. Press
start.
Always ensure to save a complete backup WITH licences. Also a backup of Recipes if used
(pressure/product profile settings) and User Administration (User names and Passwords).
85
13.1. ADD NEW USER

These sections on adding and removing users have been deliberately isolated from normal
operations as they are regarded as Manager or Supervisor information only and not for day-
to-day user access.
86
87
13.2. REMOVE USER

These sections on adding and removing users have been deliberately isolated from normal
operations as they are regarded as Manager or Supervisor information only and not for day-
to-day user access.

Manual FPG7575 (Example) - mk4 Issue1 - 0 - 6-Ene-21

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OPERATING INSTRUCTIONS

CONSULTING AND USING THIS INSTRUCTION MANUAL

FPG7575 HOMOGENISER COMFORT (mk4) issue1_0

FPG7575 HOMOGENISER Comfort

1.1. FUNCTION AND APPLICATION

Inlet feed line minimum bore (MM)

MAXimum Working pressure

Power Consumption (Kw)

FPG7575:_6300 15:1 3/4"TC 1/2"TC 1 2 420 20 8 8 25 Cst

*TF = Twin Ferrule (Swagelok), TC = Tri-Clamp hygenic connection

CAUTION should be exercised when undoing any high pressure fitting.

If in any doubt with operation or maintenance do not hesitate to contact Homogenising

Any unauthorised: Engineering modification; changes in electrical circuit; or accessing the

The equipment is installed in an all stainless steel cabinet.

Control is through dedicated PLC logic controller.

5.3. REQUIRED SERVICES

5.3.1. ELECTRICAL SUPPLY CONNECTION

Compressed Air Inlet port: ¼”BSPF

Process Fluid Inlet port: refer to SPECIFICATION chart on page 7.

Hydraulic Oil Cooling ports*: 3/8”BSPF

Temperature Conditioning Fluid ports: 3/8”BSPF (if fitted)

Compressed air should be dry and filtered.

6.1. EMERGENCY "STOP" BUTTON

6.2. EMERGENCY STOP RESET BUTTON

*Standard Build shown

6.4. HOME BUTTON

6.5. ALARM LIST BUTTON

6.6. TREND CHART BUTTON

6.7. RUN START BUTTON

6.9. USER LOGIN BUTTON

6.10. DIAGNOSTIC BUTTON

6.11. SHUT DOWN BUTTON

6.12. PROCESS PRESSURE DISPLAY

6.13. PRESSURE DISPLAY UNITS BUTTON

6.14. CURRENT USER DISPLAY

6.15. USB MANUAL BUTTON

6.17. ENGINEERING BUTTON

6.18. RECIPE BUTTON

6.19. PRESSURE INTENSIFIER ANIMATIONS

6.20. COOLANT VALVE OPEN INDICATOR

6.21. MOTOR RUNNING INDICATOR

6.22. STATUS INDICATOR

6.24. PRESSURE FUNCTION SELECTION

6.24.1. FLUSH MODE

6.24.2. CLEAN MODE

6.25. OVERLAP TIME INCREASE BUTTON

6.26. OVERLAP TIME DECREASE BUTTON

6.27. OVERLAP INCREMENT INDICATOR

6.28. MONITORED PLC INPUTS

6.28.2. HYDRAULIC OIL TEMPERATURE INDICATION

6.28.3. DRIVE FLUID LEVEL FAULT ALARM INDICATION

6.28.4. ENCLOSURE DOORS OPEN ALARM INDICATION

6.28.5. MOTOR OVERLOAD INDICATION

6.28.6. INTENSIFIER END OF STROKE INDICATION

6.29.1. UNACKNOWLEDGED ALARMS

6.29.2. USER ACKNOWLEDGED ALARMS

6.30. TREND CHART SCREEN