Alfalaval Rotacheck User manual

Covering: Standard Machines
Machines delivered with ATEX Certification in accordance with Directive 2014/34/EU
TE91A664
First published: 2012-09
ESE02219-EN5 2017-06
Original manual
Instruction Manual
Alfa Laval Rotacheck+ & Rotacheck Basic

Table of contents
The information herein is correct at the time of issue but may be subject to change without prior notice
1. EC/EU Declaration of Conformity .................................................................. 4
2. Safety .................................................................................................... 5
2.1. Important information ............................................................................. 5
2.2. Warning signs ..................................................................................... 5
2.3. Safety precautions ................................................................................ 6
3. Introduction ............................................................................................ 7
3.1. Introduction ........................................................................................ 7
3.2. Patents and Trademarks ......................................................................... 8
3.3. ATEX Marking ..................................................................................... 9
4. Installation .............................................................................................. 10
4.1. General Description ............................................................................... 10
4.2. Specific Conditions for Safe Use in Accordance with ATEX Certification ................... 11
4.3. Mounting position of Hygienic Tank Connection ............................................... 12
4.4. Overview of installation instructions ............................................................. 13
4.5. Product dimensions .............................................................................. 14
4.6. Mounting Rotacheck on tank – step 1 .......................................................... 15
4.7. Connect electrical cable - step 2 ................................................................ 16
4.8. Digital version - PNP .............................................................................. 18
4.9. Calibrate - step 3 - Rotacheck Basic ........................................................... 19
4.10.Calibrate - step 3 – Rotacheck+ (with TEACH) ................................................ 20
4.11.Recycling information ............................................................................. 23
5. Troubleshooting ....................................................................................... 24
5.1. No light ............................................................................................. 24
5.2. Red light ........................................................................................... 24
5.3. Red/Yellow flashing light ......................................................................... 24
5.4. Other failure modes ............................................................................... 24
6. Technical Data ......................................................................................... 25
6.1. Technical data ..................................................................................... 25
7. Parts Lists and Drawing .............................................................................. 26
7.1. Parts drawing and list ............................................................................ 26
7.2. Optional parts ..................................................................................... 28
8. Short functional guide ................................................................................ 30
8.1. LED signals ....................................................................................... 30
8.2. Push button (PB) operation ..................................................................... 30
9. General Information ................................................................................... 31
9.1. Service & Repair .................................................................................. 31
9.2. Warranty ........................................................................................... 31
9.3. How to contact Alfa Laval Kolding A/S ......................................................... 31
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1 EC/EU Declaration of Conformity
The Designated Company
Alfa Laval Kolding A/S
Company Name
Albuen 31, DK-6000 Kolding, Denmark
Address
[phone]
Phone No.
hereby declare that
Rotacheck+ & Rotacheck Basic
Designation
Unit for rotation validation of tank cleaning machines
Type
is in conformity with the following directives with amendments:
Low Voltage Directive (LVD) 2006/96/EF Directive 2006/95/EC on low voltage
EMC Directive 2014/30/EU
ROHS Directive 2002/95/EEC
Machinery Directive 2006/42/EC
Equipment Explosive Atmospheres (ATEX) Directive 2014/34/EU Annex III
EN 60079-0:2009, EN 60079-11:2007, EN 60079-15:2010, EN 60079-26:2007 & EN 60079-31:2009
EC Type Examination Certificate no. IBExU12ATEX1125 X
Marking: II 1/3G Ex ia/nA IIB T4/T3 Ga/Gc
Marking: II 1/3D Ex ia/tc IIIB T40ºCDa/Dc
IBExU Institut für Sicherheitstechnik GmbH, Certification Body number 0637. Fuchsmühlenweg 7, 09599 Freiberg, Germany
The person authorised to compile the technical file is the signer of this document.
Global Product Quality Manager
Pumps, Valves, Fittings and Tank Equipment Lars Kruse Andersen
Title Name Signature
Kolding 2017-03-01
Place Date
(This Declaration of Conformity replaces Declaration of Conformity dated 2014-10-17)
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2 Safety
Unsafe practices and other important information are emphasized in this manual. Warnings are emphasized by means of special
signs. Pay special attention to the instructions below in order to avoid serious personal injury or damage to the top unit.
2.1 Important information
Always read the manual before using the Rotacheck+ or the Rotacheck Basic.
WARNING
Indicates that special procedures must be followed to avoid serious personal injury.
CAUTION
Indicates that special procedures must be followed to avoid damage to the Rotacheck + or the Rotacheck Basic.
NOTE
Indicates important information to simplify or clarify procedures.
2.2 Warning signs
General warning:
Dangerous electrical voltage:
Caustic agents:
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2Safety
Unsafe practices and other important information are emphasized in this manual. Warnings are emphasized by means of special
signs. Pay special attention to the instructions below in order to avoid serious personal injury or damage to the top unit.
2.3 Safety precautions
Installation:
!
Always read the technical data thoroughly. (See chapter 6.1 Technical data page 25).
Always use a power supply that complies with IEC/EN60950-1 or IEC/EN61010-1 standard and limited-energy circuit
requirements.
Operation:
Always read the technical data thoroughly. (See chapter 6.1 Technical data page 25). !
Never touch the Rotacheck or the connected equipment when processing hot liquids or when sterilizing.
Always handle lye and acid with great care.
Transportation:
Always remove the protective cap directly before starting assembly to avoid damaging the Rotacheck. The delivered
protective cap has to be stored.
Always place the protective cap on the Rotacheck again immediately after disassembly.
Always make sure that all connections are disconnected before attempting to remove the Rotacheck from the installation.
Always ensure adequate fixing of the Rotacheck during transportation – if specially designed packaging material is
availableitmustbeused.
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3 Introduction
3.1 Introduction
This manual has been prepared as a guide for installing, operating and maintaining your Alfa Laval Rotacheck Basic and Ro-
tacheck+. Should you require further assistance, our Technical Sales Support department and worldwide net of sales offices are
pleased to help you.
Important
information:
Before installing the Alfa Laval Rotacheck Basic and Rotacheck+ and setting it into operation, carefully read
the safety precautions (page 6) and the specific conditions for safe use in accordance with ATEX Certification
Directive Directive 2014/34/EU (page 11) and take all necessary precautions according to your application and
local regulations.
NOTE
The illustrations and specifications contained in this manual were effective at the date of printing. However, as continuous
improvements are our policy, we reserve the right to alter or modify any unit specification on any product without prior notice or
any obligation
The English version of the instruction manual is the original manual. We make reservations in regard to possible mistranslations in
language versions of the instruction manual. In case of doubt, the English version of the instruction manual applies.
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3Introduction
3.2 Patents and Trademarks
This Instruction Manual is published by Alfa Laval Kolding A/S without any warranty. Improvements and changes to this
Instruction Manual may at any time be made by Alfa Laval Kolding A/S without prior notice. Such changes will, however,
be incorporated in new editions of this Instruction Manual.
Alfa Laval, Kolding A/S. All rights reserved.
The Rotacheck product has patents in the EPO member states and in other countries. The Alfa Laval logotype is a trademark
or a registered trademark of Alfa Laval Corporate AB. Other products or company names mentioned herein may be the
trademarks of their respective owners. Any rights not expressly granted herein are reserved.
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3 Introduction
If ordered with ATEX certificate
3.3 ATEX Marking
The Alfa Laval Rotacheck+ and Rotacheck Basic is certified as category I components. The certification is carried out by the
certified body IBExU Institut für Sicherheitstechnik GmbH, who has issued the certificate no. IBExU12ATEX1125 X. The marking
on the ATEX certified Alfa Laval Rotacheck+ and Rotacheck Basic is as follows:
Changes to the Alfa Laval Rotacheck+ and Rotacheck Basic are not allowed without approval by the person responsible for the
ATEX certification at Alfa Laval Kolding A/S. If changes are made – or spare parts other than Alfa Laval original spare parts are
used - the EC Type Examination certification (the ATEX Directive) is no longer valid.
Important
ATEX
information:
See also page 11 regarding specific conditions for safe use in accordance with the ATEX certification, Directive
2014/34/EU.
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4 Installation
4.1 General Description
Concept
Rotacheck is a control and validation unit for tank cleaning machines, in particular Rotary Jet Heads. Communication
is digital PNP to and from a PLC.
Rotacheck consists of a sensor unit with its sensing device located on the inside of a processing tank. The sensor is connected
to a sensor board where the signal is processed and communicated to the PLC.
The Alfa Laval Rotacheck is ideal for validation of the cleaning process inside any hygienic tank cleaned with a rotary Jet head.
It is available in two versions: Rotacheck+ with a built-in validation function and Rotacheck Basic with standard functionality.
The hygienic installation is guaranteed by using the new Alfa Laval full flushable connection, certified by 3A and EHEDG.
Rotacheck is designed for use in Ex areas.
Working principle
Rotacheck+
The Alfa Laval Rotacheck+ is based on an Alfa Laval invention which features unique teach-in and monitoring functions. The
teach-in function is used during a reference CIP run. During this first CIP run the Rotacheck+ stores time and pressure data
from the cleaning process.
In terms of cleaning jet intensity on the tank wall (hits) and the time between the hits from the water jet the reference data
represents a unique pattern for the specific process. Status is shown by digital PLC output as well as a visual light indication.
Afterwards, during production, the feedback from the integrated pressure transducer is continuously compared to the stored
acceptance window, and the Rotacheck+ digitally outputs a validated feedback. This digital feedback clearly indicates the
state that the cleaning proces is in.
The system feedback has 3 different outputs.
Rotation OK output: on when rotation is within acceptance window
Alarm output: on when cleaning is out of teach-in acceptance window
IDLE output: on when cleaning is not performed
Rotacheck Basic
The Rotacheck Basic registers when the sensor head is hit by the cleaning jet. Status is shown by digital PLC output as well
as a visual light indication.
The system feedback has 3 different outputs.
Hit output: on when sensor head is hit by cleaning jet
Alarm output: on in case of unit failure or constant hit (cleaning device error)
IDLE output: on when cleaning is not performed
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