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
3

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)
4

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:
5

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.
6

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.
7

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.
8

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.
9

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
10

4 Installation
4.2 Specific Conditions for Safe Use in Accordance with ATEX Certification
Directive 2014/34/EU
Warning: Surface temperature
The surface temperature must not exceed 140°C.
Warning: Use in explosive atmosphere
The device may be used in an explosive atmosphere, the apparatus of category 1 requires only operate if there
are atmospheric conditions (temperature of -20°C to +60°C, pressure of 0.8 bar to 1.1 bar).
11

4 Installation
4.3 Mounting position of Hygienic Tank Connection
In order to ensure optimum signal quality, the Rotacheck
should be placed with an offset to the downpipe as close as
possible to the offset of the jets nozzles of the tank cleaning
machine in use.
4512-0042
Examples of different offset:
Tank cleaning machine type Offset (E)
Toftejorg TJ20G 75 mm
Toftejorg TZ-74 78 mm
Toftejorg TZ-79 98 mm
Toftejorg MultiJet 65 with 4 nozzles 98 mm
Toftejorg TZ-89 50-90 mm (depending on size of mounting connection)
Toftejorg TZ-750 115 mm
Toftejorg MultiJet 65 with 2 nozzles 115 mm
Deviations from the above given positions may work, but will influence the signal quality.
It is not recommended to go closer to the centerline, as there is a risk of having no signal. If the Rotacheck Sensor is placed
further away from the centerline, the number of times it is directly hit by a jet is reduced.
12

4 Installation
4.4 Overview of installation instructions
Step 1
Mount Rotacheck on tank
4512-0010
Step 2
Connect electrical cable
4512-0011
Step 3
Calibrate.
4512-0012
13

4 Installation
4.5 Product dimensions
4512-0013
22
ø96
178
ø69
Weight: 0.6 kg
14

4 Installation
4.6 Mounting Rotacheck on tank – step 1
Step 1
Remove protective cap from sensor.
Check that o-ring on sensor head is in place.
Step 2
Mount Rotacheck on flange.
Step 3
Tighten clamp ring.
4512-0014
15

4 Installation
4.7 Connect electrical cable - step 2
WARNING
Special considerations for use in hazardous areas
For the installation, maintenance and cleaning of the device, you must absolutely observe the relevant regulations and stipulations
on explosion protection (EN 60079-14 and EN60079-17) as well as the occupational safety provisions.
The device is designed acc. to standards:
EN60079-0:2009, EN60079-11:2007, EN60079-15:2010, EN60079-26:2007 and EN60079-31:2009.
Cable gland version
Step 1
Remove the prism/top cover by turning the prism/top cover
counter-clockwise. Counterhold on the base part. When the mark
on the prism (J) is aligned with the open padlock symbol (K), the
prism/top cover can be lifted off.
4512-0015
J
K
Step 2
Install the cable in the cable gland (M) and tighten nut.
NOTE!
Cable connection:
Cable gland: M16 (ø5-ø8)
Max. wire diameter: 1.0 mm2(AWG 18)
4512-0016
If the cable gland comes loose from the control head during installation, it must be secured with a tightening torque of 4 Nm.
16

4 Installation
Step 3
Connect wires to board according to illustration number 4512-0018 on page 18.
4512-0017
M12 plug version
Step 1
Connect the electrical M12 plug to the connector on Rotacheck.
Tighten the knurled nut.
See wiring diagram on page 18.
17

4 Installation
4.8 Digital version - PNP
Supply voltage
Supply voltage 24 Vdc +÷ 10%
Max. power consumption of the sensor unit
Power consumption max 70 mA
Output signals from the sensor unit to the connected digital interface (PLC)
Outputs (Hit/Rotation OK, Alarm, Idle) Logic PNP
Max. current per output 50 mA
Electrical connection on PCB
Sensor board
Designation No.
Supply 24 VDC 1
Supply 0 VDC 2
Feedback Idle 3
Feedback Hit/Rotation OK 4
Alarm 5
Activate teach (Rotacheck+ only) 6
4512-0018
M12 connector
Designation No.
Supply 24 VDC 1
Supply 0 VDC 3
Feedback Idle 5
Feedback Hit/Rotation OK 2
Alarm 6
Activate teach (Rotacheck+ only) 4
54
ø20
1
2
7
6
543
4512-0019
8
View from mounting side
Alfa Laval part number 9611995257 (not part of delivery)
18

4 Installation
4.9 Calibrate - step 3 - Rotacheck Basic
Step 1
The Rotacheck Basic must be fully installed:
- Mechanically
- Electrically
The unit will flash green on power up and perform an internal
calibration after 5 sec.
The unit is ready to use when the green LED lights steadily.
Optional re-calibration
Pushthebluebutton(N)onthesensorunituntilyouseeayellow
flash.
The Rotacheck Basic will automatically re-calibrate.
4512-0020
N
Step 2
(If unit has been opened)
Put the prism/top cover back on the base part by pushing it down
when the mark on the prism (J) and the open padlock (K) are
aligned. Then turn it clockwise towards the closed padlock (L) to
secure. Counterhold on the base part.
4512-0021
J
K
L
Operating LED and PLC feedback
Rotacheck Basic status LED feedback PLC feedback
Calibration Green, flashing No feedback
Idle Green, steady On
Hit Yellow, 1 sec On, 1 sec
Alarm* Red, steady On
* Unit failure or constant hit (cleaning device error)
19

4 Installation
4.10 Calibrate - step 3 – Rotacheck+ (with TEACH)
Step 1
The Rotacheck Basic must be fully installed:
- Mechanically
- Electrically
Usage before TEACH has been performed:
Rotacheck+ where TEACH has not yet been performed, will show
similar functionality as Rotacheck Basic, except that Idle mode is
indicated by a flashing (mostly on) green LED.
Step 2
Calibration - TEACH
Method 1: Auto-TEACH
- Ensure that cleaning machine is commissioned, and its performance is approved by end-user
- Install Rotacheck+, ensure “green LED is flashing (mostly on)”
- Open top cap of Rotacheck+
- Start cleaning machine
Enable TEACH by pressing the blue button on sensor board for 1 sec and release after 1 yellow LED flash is seen.
Duration of TEACH is preset to 16 minutes.
- A red LED is flashing to indicate TEACH ongoing
- Let the cleaning process run for at least 16 minutes (the Rotacheck+ will teach-in cleaning pattern during this time)
- Every sensor hit during TEACH is indicated by a yellow LED flash
- Rotacheck+ will light up green when teach-in is finished
The TEACH sequence is terminated if no sensor hits are registered within a 4 min. interval.
NOTE
Longer TEACH intervals may be necessary in some cases, to secure proper calibration data. For example in case of
unfavourable placement of Rotacheck, see guidelines for installation, page 12. In these cases manual calibration according to
method 2 is recommended.
Method 2: Manual TEACH
- Ensure that cleaning machine is commissioned, and its performance is approved by end-user
- Install Rotacheck+, ensure “green LED is flashing (mostly on)”
- Start cleaning machine
Enable TEACH by activating input on sensor board, connector number 6, see table page 18.
TEACH will be performed as long as the input is activated, up to maximum 60 minutes.
ForpropercalibrationTEACHmustrunforsufficientlylongtime.This is application dependant and must be determined on-site.
- A red LED is flashing to indicate TEACH ongoing
- Let the cleaning process run for at least 16 minutes (the Rotacheck+ will teach-in cleaning pattern during this time)
- Every sensor hit during TEACH is indicated by a yellow LED flash
- Let the cleaning process run for sufficient time (the Rotacheck+ will teach-in cleaning pattern during this time)
- De-activate TEACH input on sensor board, terminal 6 after the desired time is elapsed.
- Rotacheck+ will light up green when teach-in is finished
20