Alfalaval GJ Tote Blast Station User manual

First published: XXXX-XX
ESE03473-EN1 2016-12
Original manual
Instruction Manual
Alfa Laval GJ Tote Blast Station

Table of contents
The information herein is correct at the time of issue but may be subject to change without prior notice
1. EC Declaration of Conformity ....................................................................... 4
2. Safety .................................................................................................... 5
2.1. Important information ............................................................................. 5
2.2. Warning signs ..................................................................................... 5
3. Introduction ............................................................................................ 6
3.1. Description ........................................................................................ 6
3.2. Intended use ...................................................................................... 6
3.3. Patents and trademarks ......................................................................... 6
3.4. Marking ............................................................................................ 6
4. Installation .............................................................................................. 7
4.1. Unpacking/delivery ............................................................................... 7
4.2. Tools and materials ............................................................................... 7
4.3. System layout ..................................................................................... 8
4.4. Pump and control panel mounting .............................................................. 9
4.5. pump set-up ...................................................................................... 10
4.6. Pump priming ..................................................................................... 11
4.7. Electrical set-up ................................................................................... 11
5. Operation ............................................................................................... 12
5.1. Operation .......................................................................................... 12
6. Maintenance ........................................................................................... 13
7. Technical data ......................................................................................... 13
7.1. Technical data ..................................................................................... 13
7.2. Pump curves at 60 Hz ........................................................................... 14
8. General information ................................................................................... 15
8.1. Recommendations and general safety precautions ........................................... 15
8.2. Service and Repair ............................................................................... 15
8.3. How to Order Spare Parts ....................................................................... 15
8.4. How to contact Alfa Laval Kolding A/S ......................................................... 15
3

1 EC 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
XXXXXX
Designation
Alfa Laval GJ Tote Blast Station
Type
From serial numbers from T-0100 to T-XXXX
is in conformity with the following directive with amendments:
Machinery Directive 2006/42/EC
- DS/EN ISO 12100:2011
ThePressureDirective97/23/EC
- According to its own volume and the rated pressure range, the product is regarded an Article 3, paragraph 3 Equipment
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
Kolding 2016-12-12
Place Date Signature
4

2 Safety
Unsafe practices and other important information are emphasised in this manual.
Warnings are emphasised by means of special signs.
Always read the manual before using the Alfa Laval GJ Tote Blast Station!
2.1 Important information
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 tank cleaning machine.
NOTE
Indicates important information to simplify or clarify procedures.
2.2 Warning signs
General warning: !
5

3 Introduction
3.1 Description
Perform intermediate bulk container (IBC) cleaning in house, in less than half the time, with the ToteBlast Station. This
complete all-in-one system utilizes patented rotary impingement technology designed to blast residue from the IBC/tote
interior, in a precise, global indexing pattern. This high impact cleaning technology ensures the entire tote interior is thoroughly
cleaned in the most efficient manner, utilizing the least amount of resources, including: time, energy, cleaning chemicals, and
water. The system comes equipped with everything needed to set up an IBC/tote cleaning station. The simplicity in design
and affordability, coupled with the most durable and effective technology, makes this the ideal IBC/ tote cleaning system for
any application, industrial or sanitary.
The ToteBlast Station comes with a vertical multistage centrifugal pump with motor, control panel, a ¾"x50’ hose and all the
necessary fittings and hardware required for permanent installation. The system also comes with a threaded inlet adapter that
can be threaded into any IBC/tote lid with a 2" NPT opening.
3.2 Intended use
It is to be verified by the end-user:
- xxxxxxxxxxxxxxxxxxxxxxx.
- xxxxxxxxxxxxxxxxxxxxxxx.
3.3 Patents and trademarks
This instruction manual is published by Alfa Laval without any warranty. Improvements and changes to this instruction manual
may at any time be made by Alfa Laval without prior notice. Such changes will, however, be incorporated in new editions
of this instruction manual.
© Alfa Laval. All rights reserved.
The Alfa Laval logotype is a trademark or the registered trademark of Alfa Laval Corporate AB. "Gamajet" is a trademark or
registered trademark of Alfa Laval. Other products or company names mentioned herein may be the trademarks of their
respective owners. Any rights not expressly granted herein are reserved.
3.4 Marking
xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx
6

4 Installation
4.1 Unpacking/delivery
The Alfa Laval Tote Blast Station will arrive on a skid with separate boxes for the pump, hose, and control panel.
All of the components in the system include:
- Multistage centrifugal pump
-Controlpanel
- ¾” × 50’ hose
- Two 1-1/4” ANSI flanges
- Two 1-1/4” gaskets
- 1-1/4” × ¾” reducer coupling
- Eight flange bolts
- Eight flange nuts
-¾”90degreeelbow
- 2” Tote insertion fabrication
Open the boxes and remove all of the components with the exception of the pump. The pump will be positioned lying down in
the crate and must be raised in an upright position. To raise upright, use some type of mechanical hoist (fork lift, crane, etc.) and
the J-hooks placed on the motor of the pump to gently raise it upright and remove from the box. In some cases eye bolts may
be needed to move the pump. The mechanical hoist must also be used to position the pump into place for mounting. Remove
the packaging from all of the components and make sure the correct number of each component is included.
If components are missing or excess components were shipped please contact Alfa Laval.
4.2 Tools and materials
Installation of the ToteBlast System requires a basic set of hand tools but Alfa Laval also recommends the following tools
and materials for the mounting of the pump:
- Concrete hammer Drill with ½” bit
- Four vibration-resistant wedge stud anchors (McMaster Carr part # 94475A263) or equivalent
For all electrical work including the mounting, positions, and wiring of all system components, Alfa Laval recommends hiring a
professional electrician and installing everything according to industry standards.
7

4 Installation
4.3 System layout
Plumbing and installation diagram of the ToteBlast System
Tank cleaning
machine
NOTE
Use four (4) vibration-resistant wedge stud anchors or equivalent to mount the vertical multistage pump. For all electrical work
including mounting, positioning and wiring of all system components, Alfa Laval recommends hiring a professional electrician to
install everything according to industry standards.
8

4 Installation
4.4 Pump and control panel mounting
Alfa Laval recommends that when mounting the pump and control panel, to use the supervision and direction of a professional
electrician to ensure proper installation and safety precautions are taken.
For installation of the pump, Alfa Laval recommends the following tools and materials:
- Concrete hammer drill with appropriate drill bits
- McMaster-Carr vibration-resistant wedge concrete stud anchors (Part number 94475A263) or other equivalent anchor bolts
- Some type of mechanical hoist
For mounting of the pump follow the recommended steps below:
Step 1
Place the pump into desired position and mark the mounting holes onto the floor. Be sure to take into account the direction of
the flow of the pump so that the suction hose and discharge hose can be properly routed.
Step 2
Move the pump out of the way to allow proper space for drilling.
Step 3
Drill holes where bolt hole locations have been marked onto floor, making sure to drill to the proper depth required for the
selected mounting anchors (2 in. if using the recommended McMaster-Carr Anchors).
Step 4
Install the anchor bolts into the drilled holes and then lower the pump back into position onto the bolts and install the anchor nuts
and washers making sure to tighten the anchor nuts in a star pattern.
NOTE
Over tightening anchor nuts may crack the base of the pump
For mounting of the control panel, Alfa Laval recommends that it be done by a professional electrician according to industry
standards.
9

4 Installation
4.5 pump set-up
The pump for the Tote Blast Station will have a source hose that is supplied by the customer and a Alfa Laval supplied discharge
hose to deliver the fluid to the Alfa Laval. Both hoses will attach to the pump via a 1-1/4” flange.
NOTE:
Be sure to remove the plastics caps on the flanges of the pump.
The Tote Blast Station comes with one ¾” diameter by 50’ long hose to run from the pump outlet to the Alfa Laval. This hose will
come preassembled from Alfa Laval with a pump flange and reducer bushing on one end. To install to the pump, first remove the
end caps from the pump’s discharge flange which can be determined by the flow arrow located towards the bottom of the pump.
Then, with the flange gasket in-between the two flanges, install the four flange bolts and nuts (NOTE: DO NOT TIGHTEN). All
four flange bolts must be snug first to ensure that the gasket is not cocked or slipping on one side. Once the bolts are snug and
the gasket is in the proper position, tighten the flange bolts using an alternating star pattern. If the gasket is not installed properly
the gasket may tear and the system will leak fluid. If the system leaks, a replacement flange gasket will be needed.
Repeat the same process for the suction flange of the pump after first installing the source hose to the flange provided by
Alfa Laval. Again be sure that the gasket is properly installed to prevent leakage. Snug all flange bolts and tighten in a star
pattern (same process as discharge side of pump).
10

4 Installation
4.6 Pump priming
The pump will also need to be primed before operation. Priming is important to remove all of the air from the system so that
the pump does not get damaged.
To prime the pump, first locate the priming plug on either side of the pump, directly under the motor. The pump must be flooded
in order to operate correctly. To do this, the operator can either let fluid fill the pump from the source and let the pump fill
until overflowing out of the priming hole and then re-install the priming plug. If flooded suction is unavailable, the pump will
have to be completely filled via the priming plug opening.
NOTE
It is important that the priming process is done correctly in order to force all air out of the pump.
4.7 Electrical set-up
Alfa Laval recommends that all electrical work be done by a professional electrician using the proper industry standards. The
electrical diagram for the control panel can be found in the appendix as well as diagrams for the control panel timer. The control
panel is designed for either 3 phase 230 volt or 460 volt power. Again, refer to the Appendix for details on wiring.
The pump can also be wired for 3 phase power. Refer to the pump manual for wiring of the pump in either 3 phase 230
Vor460Vpower.
Also ensure that when the pump is connected to the control panel that the motor rotates in the proper direction. The direction
of the motor rotation is shown on the fan casing of the motor. If the wires are reversed on the pump, it will rotate backwards
and will not work properly. If this occurs have the electrician switch the black and white wires to the opposite pins to reverse
the direction of the pump.
11

5Operation
5.1 Operation
To operate the Tote Blast Station, first ensure that the Alfa Laval GJ tank cleaning machine is inside the tote and secured. Never
start the system without the Alfa Laval GJ tank cleaning machine secured inside the tote. Make sure that the water supply will be
large enough for the full cycle so that the pump does not run dry. Set the timer on the control panel (see appendix for timer
instructions) to the desired cleaning time and press the green button on the control panel to start. If there is an emergency,
the operator can stop the cycle by pressing the red stop button on the control panel. When the timing cycle is complete the
system will automatically shut off.
NOTE
If the tote does not gravity drain through the 2” drain and the tote begins to fill with washing fluid, please contact Alfa Laval
immediately to re-size the Alfa Laval GJ tank cleaning machine to 19gpm or less
12

7 Technical data
It is important to observe the technical data during installation, operation and maintenance.
Inform personnel about the technical data.
7.1 Technical data
TECHNICAL DATA
Pump
Type ..................................Grundfos CRI vertical multistage
Model ................................See table page 14
Mechanical seal .....................Single shaft seal, C/SiC, Viton
Motor ................................Standard NEMA 180TC framed with totally enclosed fan cooled. 2 poles = 3600 rpm at 60
Hz, IP 55, insulation class F. Energy effieciency IE2
Control panel
Type ..................................On/Off/Reset with internal timer
Power rating .........................See table
Mains voltage ........................240/480 dual voltage
On/off ................................Local mains disconnect
Insulation class ......................NEMA
Timers ...............................Internal adjustable.1 min - 1+ hours
PHYSICAL DATA
Materials
Product wetted steel parts ..........AISI 304, AISI 304L
Other non-wetted steel parts .......Cast iron
Finish .................................Semi bright
Product wetted seals ...............EPDM rubber
Operating pressure and temperature
Max. inlet/outlet pressure ...........14 bar (200 psi)
Temperature range, wetted parts .. . -10°C to 95°C (max. temperature)
Ambient temperature range, wetted
parts .................................-10°C to 45°C
Process connection
Inlet and outlet .......................1 1/4 inch flange/DIN11851 (2nd series) unions
Weight
12 gpm system ......................111 kg (245 lbs)
19 gpm system ......................113 kg (250 lbs)
13

7 Technical data
It is important to observe the technical data during installation, operation and maintenance.
Inform personnel about the technical data.
7.2 Pumpcurvesat60Hz
Flow rate Pump model Power rating
12 gpm CRI 3-19 3 HP / 2.2 KW
19 gpm CRI 3-25 5 HP / 3.7 KW
14

8 General information
It is important to observe the technical data during installation, operation and maintenance.
Inform personnel about the technical data.
8.1 Recommendations and general safety precautions
Below are other recommendations and reminders from Alfa Laval about the Tote Blast Station:
- Have a professional electrician service all electrical components
- Be mindful of filtration of the cleaning fluid or water. Large partials or debris in the water can damage the pump and/or the
Alfa Laval GJ tank cleaning machine
- If the tote does not gravity drain through the 2” drain and the tote begins to fill with washing fluid, please contact Alfa
Laval immediately to re-size the Alfa Laval to 19gpm or less
- Using 460 volts to the control panel will cause damage to the control panel. If 460 volts is required please contact Alfa Laval
immediately
- Make sure before use that the pump has been properly primed. If the pump is run dry damage can be caused. See
section F for priming instructions
- The flange gaskets must be properly installed to ensure no leakage
- All safety precautions are taken before starting and while operating the Tote Blast Station
8.2 Service and Repair
Upon every return of a product, no matter if for modifications or repair, it is necessary to contact your local Alfa Laval office to
guarantee a quick execution of your request.
You will receive instructions regarding the return procedure from your local Alfa Laval office. Be sure to follow the instructions
closely.
8.3 How to Order Spare Parts
On the Cross Sectional Drawings as well as on all instruction drawings, the individual parts have a pos. No., which is the same
on all drawings. From the pos. No. the part is easily identified in the Reference Lists of Parts..
Individual parts should always be ordered from the Reference Lists of Parts, page. Ref. No. and description should be clearly
stated.
PleasealsoquotethetypeofmachineandserialNo. This will help us to help you. The type and serial Nos. are stamped on the
Body of the tank cleaning machine.
8.4 How to contact Alfa Laval Kolding A/S
For further information please feel free to contact:
Alfa Laval Kolding A/S
31, Albuen - DK 6000 Kolding - Denmark
Registration number: 30938011
Tel switchboard: [phone] - Fax switchboard: [phone]
www.toftejorg.com, www.alfalaval.dk - [e-mail]
Contact details for all countries are continually updated on our websites
15

How to contact Alfa Laval
Contact details for all countries are
continually updated on our website.
Please visit www.alfalaval.com to access the information directly.
© Alfa Laval Corporate AB
This document and its contents is owned by Alfa Laval Corporate AB and protected by laws governing intellectual property and thereto related rights. It is the responsibility of the user of this
document to comply with all applicable intellectual property laws. Without limiting any rights related to this document, no part of this document may be copied, reproduced or transmitted in any
form or by any means (electronic, mechanical, photocopying, recording, or otherwise), or for any purpose, without the expressed permission of Alfa Laval Corporate AB. Alfa Laval Corporate AB
will enforce its rights related to this document to the fullest extent of the law, including the seeking of criminal prosecution.