Alfalaval Toftejorg SaniJet 20 User manual

Instruction Manual
Toftejorg SaniJet 20
IM-TE91A595-EN041
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Contents
Contents ....................................................................................................................1
Introduction................................................................................................................3
General Description...................................................................................................4
Quality System.................................................................................................................... 4
Functioning ......................................................................................................................... 5
Media driven Drive unit ....................................................................................................... 6
Machine with External Motor Drive...................................................................................... 6
Self-cleaning ....................................................................................................................... 8
Cleaning Pattern, The Golden Section................................................................................ 9
Toftejorg SaniJet 20, Product program ...................................................................10
Media Driven: Toftejorg SaniJet 20................................................................................... 10
Air Driven: Toftejorg SaniJet 20A...................................................................................... 10
Electrically Driven: Toftejorg SaniJet 20E ......................................................................... 10
Standard Options .............................................................................................................. 10
Accessories....................................................................................................................... 11
Technical Data.........................................................................................................12
Performance Data for Toftejorg SaniJet 20 Media Driven................................................. 12
Performance Data for Toftejorg SaniJet 20 Motor Driven ................................................. 14
Installation and Normal Operation...........................................................................18
General Installation Instructions........................................................................................ 18
Installation of Air Motor ..................................................................................................... 19
Use of Air Motors in Hazardous Atmospheres .................................................................. 21
Installation of Electric Motor.............................................................................................. 22
Normal Operation.............................................................................................................. 24
Normal Operation of Air Motor .......................................................................................... 25
Safety Precautions............................................................................................................ 26
Safety Precautions for Air Motor ....................................................................................... 27
Maintenance and Repair .........................................................................................28
Preventive Maintenance.................................................................................................... 28
Preventive Maintenance of Air Motor ................................................................................ 30
Preventive Maintenance of Electric Motor......................................................................... 31
Turbine Unit ...................................................................................................................... 32
Cleaner Unit ...................................................................................................................... 34
Base Unit .......................................................................................................................... 36
Air motor Drive unit ........................................................................................................... 40
Rotacheck System ..................................................................................................43
Trouble Shooting Guide ..........................................................................................44
Symptom: Slow rotation or failure of machine to rotate..................................................... 44
Toftejorg SaniJet 20, Turbine Driven ......................................................................46
Reference List of Parts ..................................................................................................... 46
Exploded View Drawing .................................................................................................... 47
Toftejorg SaniJet 20A, Air Driven ............................................................................50
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Reference List of Parts ..................................................................................................... 50
Exploded View Drawing .................................................................................................... 51
Toftejorg SaniJet 20E, Electrically Driven ...............................................................54
Reference List of Parts ..................................................................................................... 54
Exploded View Drawing .................................................................................................... 55
Spare Part Kit and Tools .........................................................................................57
Standard Spare Part Kit in Viton for Toftejorg SaniJet 20 motor driven version................ 57
Standard Spare Part Kit in EPDM for Toftejorg SaniJet 20 motor driven version.............. 57
Standard Spare Part Kit in Viton for Toftejorg SaniJet 20 media driven version ............... 57
Standard Spare Part Kit in EPDM for Toftejorg SaniJet 20 media driven version ............. 58
Standard Spare Part Kit for Toftejorg SaniJet 20, EPDM.................................................. 58
Optional Spare Part Kit for Toftejorg SaniJet 20, Viton ..................................................... 58
Tools ................................................................................................................................. 58
How to Order Spare Parts .......................................................................................59
Claim Procedure......................................................................................................59
How to contact Alfa Laval Tank Equipment ............................................................59
Service Card............................................................................................................60
Claim Report Working Conditions ...........................................................................61
EU Declaration of Conformity..................................................................................63
Toftejorg SaniJet 20A (Air Driven) .................................................................................... 63
Toftejorg SaniJet 20E (Electrically Driven)........................................................................ 64
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Introduction
This manual has been prepared as a guide for installation and for the persons who will be operating
and maintaining your tank cleaning machine. The key to long life for your tank cleaning machine is a
carefully planned system for preventive maintenance; you must appreciate that a tank cleaning
machine which has a rough and dirty job to do will need more frequent attention than one working
under ideal conditions.
Note: Get the best and most economical performance from your tank cleaning machine. Insufficient
preventive maintenance means poor performance, unscheduled stops, shorter lifetime and extra costs.
Good preventive maintenance on the contrary means good performance, no unscheduled stops and
superior total economy.
The information in this manual is simple to follow, but should you require further assistance, our
Customer Service Department and world-wide net of Distributors will be pleased to help you. Please
quote the type, article and serial number with all your enquiries; this will help us to help you. The type,
article and serial number are placed on the tag attached to the Base house of the tank cleaning
machine.
Warning:
Before installing the machine and setting it into operation carefully read the General
Installation Instructions (page 18) and the Safety Precautions (page 26) 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.
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General Description
The Toftejorg SaniJet 20 is a tank cleaning machine intended for industrial use in closed tanks for
processing storage and transportation. There is a broad range of application areas within
pharmaceutical, food and chemical industries.
The Toftejorg SaniJet 20 is a sanitary cleaning device of the rotary jet head type for permanent
installation that provides a 360° indexed cleaning pattern. Provided it is installed in an upright position,
the Toftejorg SaniJet 20 is completely self-cleaning and self-draining, and it has an integrated self-
cleaning down pipe (patent pending). The drive mechanism is located outside the tank or process
equipment, leaving a minimum of parts to be submerged into the product. All product contact surfaces
are either AISI 316L, duplex 2205 stainless steel or FDA approved polymer materials.
No threads or screws have been used in the product contact areas.
The cleaning device is lubricated by the cleaning media. No oil, grease or other lubricants are used.
The Toftejorg SaniJet 20 is available in media driven or motor driven (electrical/air) versions. The motor
driven versions are equipped with a magnetic clutch providing a leakage-proof transmission. The motor
driven versions provide an effective drive for low flow machines in rough environments. The air motor
has variable speed in order to adjust cleaning intensity.
The Toftejorg SaniJet 20 is designed for use in pharmaceutical, biotechnological, food and dairy
processing applications. Tanks and vessels between 0.5-30 m3(130-8,000 US gallons). The design
makes the Toftejorg SaniJet 20 especially well suited when processing high viscous, foaming or
thixotropic products and in chemical processing applications, where product cross contamination is
unacceptable and must be avoided.
For use in explosive hazard zones the media driven and the air motor version can be used, provided it
is installed according to safety instructions in local regulations.
The version with standard electrical motor must not be used in explosive hazard zones.
Quality System
The Toftejorg SaniJet 20 is designed in accordance with the EHEDG design guidelines for sanitary
design of processing equipment and Biotechnological Institute in Kolding, Denmark, has tested the
cleanability. It is produced according to Alfa Laval Tank Equipment’s ISO 9001 International Standard
certified quality system. All parts are made from certified material and all non-metal parts are made
from FDA-approved materials.
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General Description (continued)
Functioning
Toftejorg SaniJet 20 consists of 3 main parts: The Drive unit with flow inlet and the Base housing
placed outside the tank, and inside the tank: the Down pipe with the rotating Outer tube and the
Cleaner unit.
The flow of the cleaning fluid passes from the inlet
through the Base housing, through the Down pipe,
into the Cleaner head and out through the Nozzles.
The Outer tube of the Down pipe is rotably
suspended on a Stationary shaft with a Ball bearing
inside the Outer tube. The Drive mechanism rotates
the Outer tube with the Cleaner unit around the
vertical axis. Via a set of Bevel gears on the
Stationary shaft and the Cleaner head, the Cleaner
head with the Nozzles is simultaneously rotated
around the horizontal axis in a fixed relation thus
moving the nozzles and the jets 360°around in the
tank making a pre-set indexed cleaning pattern.
The Toftejorg SaniJet 20 utilises the patented “Golden Section” cleaning pattern. The distance between
the tracks of the jets ensures an efficient removal of remaining product from the tank surface right from
the beginning of the cleaning sequence, allowing for short cleaning time.
Example – 2 nozzle machine:
0.8 min. 2.3 min. 6 min.
The time needed to perform a proper cleaning depends on type of soilage, distance, cleaning
procedure and agent. For substances that are easily mobilised, i.e. are easy to remove, less than 1
min. could be sufficient while in cases of more heavy soilage (high viscous, sticky substances, etc.) a
more dense pattern/longer time will be needed.
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General Description (continued)
Media driven Drive unit
The machine is driven by the cleaning media, which is supplied under pressure via the inlet connection.
The flow enters the Inlet cap tangentially and rotates the Impeller. The velocity of the liquid determines
the rotation speed of the Impeller. This depends on the actual flow rate and the size of the inlet
opening. The Inlet cap is made with two different size openings.
The Impeller shaft is in mesh with a Planet gear,
of which the Output shaft rotates the Down pipe
with the Cleaner unit. The Planet gear is made
with two different gearing ratios: T1 and T2.
Except for the Planet wheel and the Gear ring, the
parts are identical.
The Planet gear is placed in the middle of the flow
and thus flushed through axially while in
operation, securing that all the Gear parts are
thoroughly lubricated and cleaned. Bearings are
designed to allow flow through the bearings for
lubrication and cleaning.
Machine with External Motor Drive
The machine is driven by a gear motor mounted on top of the Inlet housing. Via a Magnetic clutch the
rotation of the gear motor is transmitted from the outside through a closed wall to the Output shaft
placed inside the Inlet housing. The Output shaft is in mesh with the Down pipe and rotates the Down
pipe in the same way as in the media driven version.
Output shaft
Cup-shaped closed wall
Gear motor
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General Description (continued)
The output shaft of the gear motor is equipped with a Rotor with permanent magnets. The rotor is
placed inside the cavity in the Motor flange, made by the cup protruding into the liquid chamber in the
Inlet housing. The cup is welded to the motor flange as a hermetic sealed closed wall between the
liquid chamber and the outside. The magnetic field from the permanent magnets is transferred through
the wall, to a ring with permanent magnets inside the Output shaft, which is placed around the cup on
the inside the liquid chamber.
Ring w. magnets inside Output
shaft
Cup-shaped closed wall
Rotor w. magnets
Motor flange
The machine with Electrical gear motor (at frequency 50 Hz) is rotating at fixed speed: 14 RPM with
2xø2mm nozzles and 6.5 RPM with 4xø4.2mm nozzles. The machine with 2xø3.8mm nozzles is
available in both a High Speed (14 RPM) and a Low Speed version (6.5 RPM).
The machine with Air motor is equipped with a flow regulator to make the speed adjustable between
approx. 5 and 16 RPM.
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General Description (continued)
Self-cleaning
Apart from the main flow flushing the inside of the Base housing and the Down pipe, and thereafter
forming the jets through the Nozzles, fluid is flushed through all internal cavities, through Bevel gear,
Ball bearings and gabs between moving parts and is finally also used for cleaning of the outside
surfaces of the machine.
From the gab between the Base housing and the rotating Down pipe, a cleaning jet is directed against
the Down pipe, thus loosening and removing product remains on the outside. A liquid film flushing all
around the tube further assists by continuously transporting away loosened product remains. The front
of the Cleaner head is flushed by a liquid flow from the gab between the Cleaner head and the
Retaining ring.
In order to ensure a proper self-cleaning, the machine must be installed in an approx. upright position
and the inlet pressure must be min. 3 bar.
In the bottom of the Cleaner head, in the Retaining ring, the machine is equipped with a hole to ensure
self-draining. This self-draining is only ensured, if the machine is installed in an upright position.
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General Description (continued)
Cleaning Pattern, The Golden Section
The patented Golden Section cleaning pattern (EP-Patent No.: 0495883. US-Patent No.: 5,279.675) is
unique in building up the pattern in an ultimate uniform way. The pattern starts very coarse and refines
itself in a step-less way by laying out the tracks approximately in the middle between the two most
distant tracks already made. This means that the jets always clean the areas containing most
remaining product, and thereby remove as much deposit as possible in the shortest possible way.
In case a complete cleaning pattern is not required, it will be possible to reach the same cleaning level
within half the time and by using half the amount of cleaning fluid compared to a traditional step-wise
cleaning pattern. Furthermore, due to the uniform cleaning pattern, the cleaning can be stopped at any
time, whereas with traditional non-uniform cleaning pattern this would not be advantageous. However,
after the complete cleaning pattern has been established, the difference between the Golden Section
and the traditional stepwise cleaning pattern is negligible.
Golden Section Traditional
Cleaning pattern Cleaning pattern
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Toftejorg SaniJet 20, Product program
Media Driven: Toftejorg SaniJet 20
Length 2xø2mm 2xø3.8mm HS 2xø3.8mm LS 4xø4.2mm
500mm TE20B000 TE20B020 TE20B040 TE20B060
350mm TE20B001 TE20B021 TE20B041 TE20B061
700mm TE20B002 TE20B022 TE20B042 TE20B062
1000mm TE20B004 TE20B024 TE20B044 TE20B064
1200mm TE20B006 TE20B026 TE20B046 TE20B066
1500mm TE20B008 TE20B028 TE20B048 TE20B068
Air Driven: Toftejorg SaniJet 20A
Length 2xø2mm 2xø3.8mm 4xø4.2mm
500mm TE20B100 TE20B120 TE20B160
350mm TE20B101 TE20B121 TE20B161
700mm TE20B102 TE20B122 TE20B162
1000mm TE20B104 TE20B124 TE20B164
1200mm TE20B106 TE20B126 TE20B166
1500mm TE20B108 TE20B128 TE20B168
Electrically Driven: Toftejorg SaniJet 20E
Length 2xø2mm 2xø3.8mm HS 2xø3.8mm LS 4xø4.2mm
500mm TE20B200 TE20B220 TE20B240 TE20B260
350mm TE20B201 TE20B221 TE20B241 TE20B261
700mm TE20B202 TE20B222 TE20B242 TE20B262
1000mm TE20B204 TE20B224 TE20B244 TE20B264
1200mm TE20B206 TE20B226 TE20B246 TE20B266
1500mm TE20B208 TE20B228 TE20B248 TE20B268
HS = High speed; LS = Low speed.
Standard Options
Electric motor variants: Indicated by index-no.
Index.no. Specification
none 1 phase 220-230V, 15W
-01 1 phase 200V, 15W
-02 1 phase 110-115V, 15W
-03 1 phase 100V, 15W
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Toftejorg SaniJet 20, Product program
Standard Options
Machines with Viton seals
Index no. –10 for media and air driven machines.
Index no. for electric motor variants:
Index.no. Specification
-10 1 phase 220-230V, 15W
-11 1 phase 200V, 15W
-12 1 phase 110-115V, 15W
-13 1 phase 100V, 15W
Accessories
Clamp Coupling Parts
Reference no. Description
TE51S101 Clamp welding liner 1”
TE5TS111 Gasket EPDM f. 1” Clamp coupling
TE51S121 Clamp ring 1”
TE51S107 Clamp welding liner 3”
TE51S117 Gasket EPDM f. 3” Clamp coupling
TE51S127 Clamp ring 3”
TE51S140 Clamp adaptor 3”/4”
Accessories for Air Motor
Reference no. Description
TE51U385 Straight adaptor ø8-ø12
TE51U386 Straight adaptor ø12
TE51U305 Air tubing ø8/5.5
TE51U306 Air tubing ø12/ø8
Monitoring
An electronic system with rotation sensor to validate 360° coverage can be included: TE52E067
Rotacheck Sensor ø27 mm
TE52E058 Rotacheck Relay
For further information see page 43.
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Technical Data
Performance Data for Toftejorg SaniJet 20 Media Driven
Weight of machine : 9.5 kg (21 lbs)
Working pressure : 3-13 bar (45-185 psi)
Recommended pressure : 3-8 bar (45-115 psi)
Max. working temperature : 90°C (194°F)
Max. ambient temperature : 140°C (284°F)
Effective throw length : 1.5-4 m (5-13 ft)
Materials : AISI 316L, SAF 2205, PEEK, E-CTFE.
Sealing: EPDM
Polymers FDA-approved 21 CFR §177
Surface finish : Product contact surfaces: Ra=0.8 µm – except weldings
Lubricant : Self-lubricant with the cleaning media
Principal Dimensions in mm
For permanent installation
machine can pass through 3”
clamp of max. length 50 mm:
For portable installation or
installation through long “nozzles” 4”
(100 mm) fittings are recommended.
Adaptor to 4” ISO/ NW100DIN
clamp fitting is available”:
Inlet connection: 1” Clamp ISO2852
Tank connection: 3” Clamp ISO2852
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Technical Data (continued)
Performance Data for Toftejorg SaniJet 20 Media Driven
Flow rate Effective throw length
Note: Effective throw length varies depending on
jet transverse speed over surface, substance to
be removed, cleaning procedure and agent.
The inlet pressure has been taken immediately
before the machine inlet. In order to achieve the
performance indicated in the curves, the pressure
drop in the supply lines between pump and
machine must be taken into consideration.
Cleaning Time, Complete Pattern
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Technical Data (continued)
Performance Data for Toftejorg SaniJet 20 Motor Driven
Weight of machine Electrical driven : 11.8 kg (26 lbs)
Air driven : 11.7 kg (25.8 lbs)
Working pressure : 3-13 bar (45-185 psi)
Recommended pressure : 3-8 bar (45-115 psi)
Max. working temperature : 90°C (194°F)
Max. temperature inside tank : 140°C (284°F)
Max. ambient temp. f. air motor : 121°C (250°F)
Max. ambient temp. f. electr. motor : 50°C (122°F)
Ambient humidity f. electr. motor : Max. 85% (no condensation)
Effective throw length : 1.0-5 m (3-16 ft)
Materials : AISI 316L, SAF 2205, PEEK, E-CTFE.
Sealing: EPDM
Polymers FDA-approved 21 CFR §177
Surface finish : Product contact surfaces: Ra=0.8 µm – except weldings
Lubricant : Machine : Self-lubricant with the cleaning media
Air motor : Non-lubricated possible (see page 20)
Principal Dimensions in mm, Motor driven
For permanent installation
machine can pass through 3”
clamp of max. length 50 mm:
For portable installation or
installation through long “nozzles” 4”
(100 mm) fittings are recommended.
Adaptor to 4” ISO/ NW100DIN
clamp fitting is available”:
Inlet connection: 1” Clamp ISO2852
Tank connection: 3” Clamp ISO2852
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Technical Data (continued)
Performance Data for Toftejorg SaniJet 20 Motor Driven
Flow rate Effective throw length depending on rotation
speed
Time between vertical
jet impingements
Down pipe
RPM 2 Nozzles 4 Nozzles Cleaning time
complete pattern
5 8.7 sec. 4.3 sec. 11.0 min
6 7.2 sec. 3.6 sec. 9.2 min
7 6.2 sec. 3.1 sec. 7.9 min
8 5.4 sec. 2.7 sec. 6.9 min
9 4.8 sec. 2.4 sec. 6.1 min
10 4.3 sec. 2.2 sec. 5.5 min
11 3.9 sec. 2.0 sec. 5.0 min
12 3.6 sec. 1.8 sec. 4.6 min
13 3.3 sec. 1.7 sec. 4.2 min
14 3.1 sec. 1.6 sec. 3.9 min
15 2.9 sec. 1.4 sec. 3.7 min
16 2.7 sec. 1.4 sec. 3.4 min
Note: Effective throw length varies
depending on jet transverse speed over
surface, substance to be removed, cleaning
procedure and agent.
The inlet pressure has been taken
immediately before the machine inlet. In
order to achieve the performance indicated
in the curves, the pressure drop in the supply
lines between pump and machine must be
taken into consideration.
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Technical Data (continued)
Performance Data for Toftejorg SaniJet 20 Motor Driven
Air Driven
Air supply pressure : 7 bar (100 psi)
Air quality : Clean, filtered max. 40 µm
Dry, dew point max. 5°C
Non-lubricated possible
Free air consumption (at 1 bar) : Max. 2 l/sec. (8 m3/h) ∼35 Usgpm
Adjustable speed : 5-16 RPM
Cleaning time : 3-10 min (adjustable)
Electric Driven
Power supply options : 1 phase 220-230V, 15W
1 phase 220V, 15W
1 phase 110-115V, 15W
1 phase 100V, 15W
Cleaning time/rotation speed : 2 x ø2.0 mm: 4.0 min./14 RPM
(at frequency 50 Hz) 2 x ø3.8 mm, HS: 4.0 min./14 RPM
2 x ø3.8 mm, LS: 8.5 min./6.5 RPM
4 x ø4.2 mm: 8.5 min./6.5 RPM
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Installation and Normal Operation
General Installation Instructions
The Toftejorg SaniJet 20 is designed to be installed in a vertical upright position.
It is recommended to install a filter with mesh size 250 µm (0,01") in the supply line in order to avoid
particles, scale etc. from clogging inside the machine. It is essential to avoid fine solid particles, such
as fine sand, in the cleaning fluid as they will increase wear considerably. This is particular important in
case of recirculation.
In order to prevent accidental leakage of cleaning fluid into the tank it is recommended to install a shut-
off valve close to the machine inlet. This will also prevent back-flow of liquid from the tank through the
machine in case the cleaner head is submerged and there is an over-pressure inside the tank. The
installation and operation shall be made in such a way that the draining of the machine is ensured.
It is recommended that the fluid valve fitted is of a type that prevents hydraulic shocks, which may
cause severe damage to the entire installation.
Before installation, all supply lines and valves must be thoroughly flushed to remove remains of welding
electrodes, grinding dust, scale and other foreign matter.
During handling and installation handle the machine with care in order not to damage the fine surface
finish of the machine.
The Toftejorg SaniJet 20 machine has been tested at the factory before shipping. For the media driven
version check that the machine is in operating condition by blowing compressed air into the inlet and
verify that the machine rotates evenly. If resistance is recognised, the machine should be disassembled
in order to localise the cause.
Note: Do not try to turn Nozzle head by hand, since this may damage the Gear. Nozzle head can be
turned by blowing air from an air pistol through the inlet connection of the media driven machine or the
intake port of the air motor.
Note: The machine shall be installed in accordance with national regulations for safety and other
relevant regulations and standards. In EU-countries the complete system must fulfil the EU-Machine
Directive and depending of application, the EU-Pressure Equipment Directive, the EU-ATEX Directive
and other relevant Directives and shall be CE-marked before it is set into operation.
Warning:
Precautions shall be made to prevent starting of the cleaning operation, while personnel
are inside the tank or otherwise can be hit by jets from the nozzles.
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Installation and Normal Operation (continued)
Warning:
If the machine is used in potential explosive atmospheres, tapes or joint sealing
compounds, which are electrical insulators, must not be used on joints, if this may
violate the grounding of the machine to the tank. Resistance between nozzles and
tank must not exceed 20.000 Ω. The intended installation with standard clamp
connections will ensure this. In addition, connecting pipe work, must be electrically
conductive and earthed to the tank structure.
This is essential to avoid the build-up of static electricity on the nozzles and the
machine. For further information see CENELEC R044-001 Safety of Machinery,
guidance and recommendations for the avoidance of hazards due to static electricity.
Electrical equipment such as magnetic valves and electric actuators must not be installed in Ex-zones
without type approval and marking, corresponding to the EX-class in question. The standard Toftejorg
SaniJet electrical motor is not Ex-approved.
Installation of Air Motor
Important Information
Recommended inlet air pressure is not to exceed 7 bar 100 psi maximum. It is recommended to use an
air filter and moisture trap on inlet air supply to avoid contamination being fed into air motor.
General Information
The air motor is designed to be driven by compressed air and under no circumstances be driven with
any other gases. Fluids, particles, solids or any substances mixed with air, particularly combustible
substances likely to cause explosions, must not drive air motor.
Danger:
Do not drive with flammable or explosive gases.
Caution:
Air motor is designed for air only. Do not allow corrosive gases or particulate material
to enter motor. Water vapor, oil-based contaminants, or other liquids must be filtered
out.
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