Alfalaval Toftejorg TJ20G User manual

Covering: Standard Machines, Distillery, Secured
High temperature, Hastelloy
Q-doc - Equipment Doc (3.1 Inspection Certificate - EN 10204)
Machines delivered with ATEX/IECEx Certification in accordance with Directive 2014/34/EU
TE91A600. First published: 2000-06
ESE01794-EN11 2019-05
Original manual
Instruction Manual
Alfa Laval Toftejorg™ TJ20G Rotary Jet Head

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 .................................................................. 5
2. Safety .................................................................................................... 6
2.1. Important information ............................................................................. 6
2.2. Warning signs ..................................................................................... 6
3. Introduction ............................................................................................ 7
3.1. Introduction ........................................................................................ 7
3.2. Intended use ...................................................................................... 7
3.3. Patents and trademarks ......................................................................... 8
3.4. Marking ............................................................................................ 8
3.5. ATEX/IECEx marking ............................................................................. 9
3.6. ATEX/IECEx temperature class and code ...................................................... 9
3.7. Quality system .................................................................................... 10
4. Installation .............................................................................................. 11
4.1. General description ............................................................................... 11
4.2. Functioning ........................................................................................ 11
4.3. General safety and installation instructions ..................................................... 13
4.4. Specific conditions for safe use in accordance with ATEX/IECEx certification .............. 14
5. Operation ............................................................................................... 17
5.1. Normal operation ................................................................................. 17
5.2. Safety precautions ................................................................................ 18
6. Maintenance ........................................................................................... 19
6.1. Preventive maintenance .......................................................................... 19
6.2. Service and repair of ATEX/IECEx certified machines ......................................... 20
6.3. Maintenance intervals and Service Kits ......................................................... 20
6.4. General assembly /disassembly recommendations ........................................... 21
6.5. Available add-ons for spare parts ............................................................... 22
6.6. Tools ............................................................................................... 23
6.7. Disassembly ....................................................................................... 24
6.8. Reassembly ....................................................................................... 26
6.9. Replacement of ball races ....................................................................... 27
7. Trouble shooting guide ............................................................................... 28
8. Technical data ......................................................................................... 30
8.1. Technical data ..................................................................................... 30
9. Product Programme .................................................................................. 31
9.1. Standard configurations .......................................................................... 31
9.2. Available add-ons ................................................................................. 32
9.3. Available welding connections ................................................................... 33
10. Parts lists and drawings, service kits and tools ................................................. 34
10.1.TJ20G - article nos. TE20G000_024 + TE20G050_054 (except TE20G010-TE20G018) 34
10.2.TJ20G - article nos. TE20G010-TE20G014 ................................................... 36
10.3.TJ20G - article nos. TE20G016_018 ........................................................... 38
10.4.TJ20G, distillery - article nos. TE20G030_044 ................................................ 40
10.5.TJ20G, hastelloy - article nos. TE20HXXX ..................................................... 42
10.6.Tools ............................................................................................... 44
3

Table of contents
The information herein is correct at the time of issue but may be subject to change without prior notice
11. General information ................................................................................... 45
11.1.Service and repair ................................................................................ 45
11.2.How to order spare parts ........................................................................ 45
11.3.How to contact Alfa Laval Kolding A/S ......................................................... 45
12. Miscellaneous .......................................................................................... 46
12.1.Declaration of Complaince with 10/2011 – Food contact materials ......................... 46
4

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
Tank Cleaning Machine
Designation
Alfa Laval Toftejorg TJ20G
Type
From serial number 2018-0001 to 2030-99999
is in conformity with Machinery Directive 2006/42/EC and the following harmonized standard is used:
DS/EN ISO 12100:2011 Safety of Machinery - Risk Assessment
is in conformity with (Ex / ATEX) Directive 2014/34/EU and the following harmonized standards are used:
EN ISO 80079-36:2016, EN ISO 80079-37:2016, DS/EN ISO/IEC 80079-34:2011, Annex A, paragraph A.5.3 Rotating machines
EC Type Examination Certificate no. Baseefa04ATEX0358X and IECEx BAS 18.0067X
II 1G Ex h IIC 85ºC...175ºCGa
II 1D Ex h IIIC T85ºC...T140ºCDa
Marking:
II 1G Ex h IIC 85ºC...250ºCGa
II 1D Ex h IIIC T85ºC...T200ºCDa
The QAN (Quality Assurance Notification) is carried out by SGS Fimko Oy, Särkiniementie 3, Helsinki 00211, Finland. Notified Body
No. 0598.
EU Type Examination Certification is carried out by SGS Fimko Oy, Särkiniementie 3, Helsinki 00211, Finland. Notified Body no. 0598.
IECEx Certificate of Conformity is carried out by Baseefa Ltd., Rockhead Business Park, Staden Lane, Buxton, Derbyshire SK17 9RZ,
United Kingdom. IECEx Accepted Certification Body (ExCB).
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 2019-05-01
Place Date (YYYY-MM-DD)
(This Declaration of Conformity replaces Declaration of Conformity dated 2016-01-01)
5

2 Safety
TJ20G
Unsafe practices and other important information are emphasized in this manual.
Warnings are emphasized by means of special signs.
Always read the manual before using the tank cleaning machine!
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:
ATEX/IECEx warning:
6

3 Introduction
TJ20G
3.1 Introduction
The Alfa Laval Toftejorg TJ20G has been developed to meet the highest demands for efficiency, reliability and hygiene within
food and beverage, pharmaceutical and biochemical industry.
This manual has been prepared as a guide for installing, operating and maintaining your Alfa Laval Toftejorg tank cleaning
machine. Should you require further assistance, our Technical Sales Support department and worldwide net of sales offices are
pleased to help you. Please quote the type, article and serial numbers with all of your enquiries; this helps us to help you.
The type and serial number are placed on the body of the tank cleaning machine.
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.
If the Alfa Laval Toftejorg TJ20G stops rotating unintentionally within the warranty period, please return the machine to Alfa
Laval. Please do not try to fix any mechanical problems before shipping.
Warning: Before installing the machine and setting it into operation, carefully read the General safety and installation
instructions (page 13) and the specific conditions for safe use in accordance with ATEX/IECEx Directive
2014/34/EU (page 14) 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.
3.2 Intended use
The end-user should verify:
- that the tank cleaning machine is in conformity with respect to tank, vessel or container size in which it is used.
- that the construction materials (both metallic and non-metallic) are compatibility with product, flushing media, cleaning
media, temperatures and pressure under the intended use.
The tank cleaning machine/rotary jet mixer is intended for use in closed tank, vessel or container. If used in open environment
see 4.3 General safety and installation instructions page 13.
To ensure the self cleanability and drainability the machine must be installed in vertical position.
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3 Introduction
TJ20G
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 Kolding A/S. All rights reserved.
The Alfa Laval logotype is a trademark or a registered trademark of Alfa Laval Corporate AB. "Toftejorg" is a trademark
or registered trademark of Alfa Laval. The Alfa Laval Toftejorg™ TJ20G product has patents in the EPO member states
(EP 0 560 778), in the US (5333630) and in other countries and has a new patent pending (PCT/DK/2007/000062). 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
Alfa Laval tank cleaning machines are all marked to allow for recognition of type of machine, machine name, serial number and
manufacturing address. The marking is placed on the body of the tank cleaning machine.
TJ20G
Serial number explanation
Machines supplied with or without standard documentation:
yyyy-xxxxx: serial number
yyyy: year
xxxxx: 5 digit sequential number
Marking area 4108-0011
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3 Introduction
TJ20G
3.5 ATEX/IECEx marking
The Alfa Laval Toftejorg TJ20G is certified as category I component. The certification is carried out by the notified body SGS
Fimko Oy, who has issued the certificate no. 04ATEX0358X and IECEx BAS 18.0067X.
Note
Explosion protection type is constructional safety “c”.
The marking on the ATEX/IECEx certified Alfa Laval Toftejorg TJ20G is as follows (for information on marking position see section
3.4 Marking):
Rotary Jet Head
TJ20G
s/n.: yyyy-xxxxx
Alfa Laval, DK-6000 Kolding, Albuen 31
II 1G Ex h IIC 85°C…175°C Ga
II 1D Ex h IIIC T85°C…T140°C Da
0598 Baseefa 04ATEX0358X IECEx BAS 18.0067X
Note:
TE20G016-72, TE20G017-72 and TE20G018-72
TE20G016-82, TE20G017-82 and TE20G018-82.
These machines have a special ATEX text for the “Ex” line. Next to the “Ex” symbol this text shall be present:
II 1G Ex h IIC 85°C...250°C Ga
II 1D Ex h IIIC T85°C...T200°C Da
Serial number explanation:
Machines supplied with or without standard documentation:
yyyy-xxxxx: serial number
yyyy: year
xxxxx: 5 digit sequential number
3.6 ATEX/IECEx temperature class and code
The maximum surface temperature depends mainly on operating conditions which are the temperature of the process fluid and
the ambient temperature.
Group II EPL Ga
The gas temperature class is corrected with a safety margin of 80% due to a requirement for Group ll EPL Ga equipment.
The gas temperature class depends on the process fluid temperature or the ambient temperature, whichever of the two is
the highest.
Table for determining temperature class (gas atmospheres)
Temperature Class Process fluid Temperature,
Tp(°C)
Ambient temperature,
Tamb (°C)
85°C (T6) ≤+68°C ≤+68°C
100°C (T5) ≤+80°C ≤+80°C
135°C (T4) ≤+108°C ≤+108°C
175°C ≤+140°C ≤+140°C
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3 Introduction
TJ20G
Group III EPL Da
The dust temperature class depends on the process fluid temperature or the ambient temperature, whichever of the two is
the highest.
No dust layer is considered.
Table for determining temperature class (dust atmospheres)
Temperature code Process fluid temperature,
Tp(°C)
Ambient temperature,
Tamb (°C)
T85°C ≤+85°C ≤+85°C
T100°C ≤+100°C ≤+100°C
T135°C ≤+135°C ≤+135°C
T140°C ≤+140°C ≤+140°C
Example of gas class determination
Process fluid temperature is 67°C and ambient temperature is 75°C.
Gas class = T5
ATEX/IECEx marking on the equipment:
II 1G Ex h IIC 85ºC...175ºCGa
II 1D Ex h IIIC T85ºC...T140ºCDa
Note:
TE20G016-72, TE20G017-72 and TE20G018-72
TE20G016-82, TE20G017-82 and TE20G018-82
These machines have a special ATEX text for the “Ex” line. Next to the “Ex” symbol this text shall be present:
II 1G Ex h IIC 85°C...250°C Ga
II 1D Ex h IIIC T85°C...T200°C Da
3.7 Quality system
The Alfa Laval Toftejorg TJ20G is designed in accordance with the EHEDG design guidelines for sanitary design of processing
equipment. It is produced according to Alfa Laval Kolding’s ISO-9001 international Standard certified quality system. All parts
are made from certified material and all non-metal parts are made from FDA and EU 10/2011 compliant materials.
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4 Installation
TJ20G
4.1 General description
The Alfa Laval Toftejorg tank cleaning machine is a media driven and media lubricated tank cleaning machine. No lubricating
substances such as oil, grease etc. are used. All materials comply with FDA 21CFR§177 and for polymers also EU 10/2011.
The machine is self-cleaning i.e. all internal and external surfaces are cleaned during normal operation.
For use in explosive hazard zones the ATEX/IECEx version can be used, provided it is installed according to safety instructions
in local regulations.
4.2 Functioning
The flow of cleaning fluid into the machine passes through a turbine, which accordingly is set into rotation. Through a gear
set and a driver tube, the turbine rotation is transmitted to the Cleaner Head.
The combined motion of the machine Body and the Nozzles ensures a fully indexed tank cleaning coverage. After 55/8
revolutions of the Hub cover with Nozzles (53/8 revolutions of the machine Body), one coarse cleaning pattern is laid out
on the tank surface and the first cycle has been made. During the following cycles, this pattern is repeated 7 times, each
of which is displaced, and the pattern gradually becomes more dense. Finally, after 8 cycles - a total of 45 revolutions of
the Hub Cover with Nozzles (43 revolutions of the machine Body), a complete cleaning pattern has been laid out, and
the first pattern is repeated.
This is illustrated below for a spherical tank with the machine placed in the centre:
First cycle Second cycle Third cycle Forth cycle
The number of cycles needed to perform a proper cleaning depends on type of soilage, position of the tank cleaning machine,
cleaning procedure, cleaning temperature and cleaning agent.
For substances that are easily mobilised, i.e. are easy to remove, one cycle could be sufficient while in cases of more heavy
soilage (high viscous, sticky substances, etc.) a more dense pattern/more cycles are needed.
The rotation speed of the turbine depends on the flow rate through the machine. The higher the flow rate, the higher the
speed of rotation. In order to control the RPM of the machine for a wide range of flow rates, the machine has different
turbines according to the Nozzle size.
11

4 Installation
TJ20G
Apart from the main flow flushing the gear and the
Hub, and thereafter forming the jets through the
Nozzles, fluid is flushed through all internal areas,
through Bevel gear, Ball bearings and gaps between
moving parts and finally also used for cleaning of
the outside surfaces of the machine. The areas
behind the Screws on the Cone are cleaned through
small spray holes behind the Screws. In the bottom
oftheBody,adrainageholeispresenttoensure
self-draining. This self-draining is only ensured, if the
machine is installed in upright position.
TD523415
For sanitary connection version:
The threaded connection between downpipe and machine is
not a product contact surface as it is enclosed using two seals
and the welding adaptor. A welding adaptor, depending on
downpipe dimensions, is ordered separately (see page 30 ff).
For all versions:
For devices with tapered thread connections to the down pipe,
it is recommended that you secure the connection in a manner
appropriate for the application. Subject to the intended use
environment and any inhouse user requirements or policies, an
adhesive such as Loctite No. 243 or equivalent could be used.
Other methods could be acceptable and subject to customer
preference.
TD523417-1
A
B
C
D
A: Down pipe
B: Welding adapter
C: SealPTFE
D: Seal EPDM
12

4 Installation
TJ20G
4.3 General safety and installation instructions
The tank cleaning machine should be installed in vertical position (upright or upside down). It is recommended to install a filter in
the supply line in order to avoid large particles, scale etc. to clog inside the machine. It is essential to avoid fine solid particles
(e.g. fine sand) in cleaning fluid as they increase wear considerably.
In general, a filter with 3 mm holes is recommended in the supply line. In case of fine solid particles below 500 µm in the
cleaning fluid, choose filter size accordingly.
In order to sperate the CIP system from the process it is recommended to install a shutoff valve close to the machine inlet.
This also prevents 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 self-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 Alfa Laval Toftejorg TJ20G and/or the entire installation. Ideally, a frequency controlled pump with a ramp function for
start-up is used for supplying the cleaning liquid.
Before connecting the machine onto the system, all supply lines and valves should be flushed in order to remove foreign particles.
The machine should be screwed tightly onto its supporting supply line using a 36 mm flat jawed spanner (tool No. TE81B040) on
the flats machined on the inlet Cone.
During handling and installation handle the machine with care in order not to damage the surface finishes of the machine.
The Alfa Laval Toftejorg TJ20G machine has been tested at the factory before shipping. You can check that the machine is
in operating condition by blowing compressed air into the inlet, while holding the machine by the cone and verify that the
rest of the machine rotates evenly. if resistance is recognised, the machine should be disassembled in order to localise the
cause or returned to the nearest Alfa Laval Service Centre.
Upon arrival check that the machine is in operation condition by inserting a flathead Screwdriver in top of turbine shaft and
easily turn Turbine shaft anti-clockwise. If any resistance is recognised, the machine should be disassembled in order to
localise the cause.
For devices with tapered thread connections to the down pipe, it is recommended that you secure the connection in a manner
appropriate for the application. Subject to the intended use environment and any inhouse user requirements or policies, an
adhesive such as Loctite No. 243 or equivalent could be used. Other methods could be acceptable and subject to customer
preference.
NOTE
Do not try to turn the nozzle head by hand, since this may damage the Gear. The Nozzle head can be turned by blowing
compressed air through the inlet connection or using a flathead screwdriver in top of the turbine shaft.
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/IECEx 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/mixing operation, while personnel are inside the
tank or otherwise can be hit by jets from the nozzles.
For information on use in potential explosive atmospheres see paragraph 4.4 Specific conditions for safe use in accordance
with ATEX/IECEx certification page 14.
13

4 Installation
TJ20G
4.4 Specific conditions for safe use in accordance with ATEX/IECEx certification
Directive 2014/34/EU
NOTE
Explosion protection type is constructional safety “c”.
Warning: Operated in a hazardous area
The unit may be operated in a hazardous area only when completely filled with cleaning fluid / steam.
If a medium other than the cleaning fluid / steam is passed through the equipment the flow must not be high
enough to cause the equipment to operate.
Warning: Operating guidance
The unit shall be operated in line with guidance provided by IEC/TS 60079-32-1 for tank cleaning.
Warning: Temperature class and ambient temperature range
The maximum surface temperature depends mainly on operations conditions which is the temperature of the
cleaning fluid and ambient temperature.
The temperature class and ambient temperature range are shown in paragraph 3.6 ATEX/IECEx temperature
class and code, page 9.
Warning: Max. permitted temperature
When working:
The maximum permitted cleaning fluid temperature and ambient temperature is 95°C.
When not working:
The maximum permitted ambient temperature is 140°C.
Warning: Max. permitted temperature, TJ20G high temperature versions
High temperature machines: TE20G016-72 and TE20G016-82, TE20G017-72 and TE20G017-82, TE20G018-72
and TE20G018-82.
When working:
The maximum permitted cleaning fluid temperature and ambient temperature is 95°C.
When not working:
The maximum permitted ambient temperature is 200°C.
Warning: Draining using compressed air
Draining using compressed air must not be done in ex classified zone.
Draining using compressed air is possible in non ex classified zones (see page 17).
Warning: Earthing
All metal and other conductive or dissipative material should be connected to earth with the exception of very
small items.
For further information see IEC/TS 60079-32-1:2013 Explosive atmospheres – Part 32-1: Electrostatic hazards,
guidance. With focus on clause 6.2.3, 7.2.1, 7.3, 7.9.2, 13.
14

4 Installation
TJ20G
4.4 Specific conditions for safe use in accordance with ATEX/IECEx certification
Warning: Earthed when in use
The unit must be effectively earthed at all times when in use.
Warning: Max. permitted steaming temperature
The maximum permitted steam temperature through the machine and ambient temperature is 140°C.
Warning: Steaming tanks larger than 100 m³
Tanks with capacities larger than 100 m³ that could contain a flammable atmosphere should not be steam
cleaned, as steam cleaning tanks produces an electrostatically charged mist. Tanks smaller than 100 m³ may
be steam cleaned.
For further information see IEC/TS 60079-32-1:2013 Explosive atmospheres – Part 32-1: Electrostatic hazards,
guidance. With focus on clause 7.10 and 8.5.
Tank size information
The tank cleaning machine has been certified by accredited notified body and can operate in tanks having an enclosed volume
up to 100 m³ as long as all ATEX warnings in the instruction manual are complied with.
General guidelines for tanks larger than 100 m3:
Tanks larger than 100 m³ must not be steam cleaned – See guide IEC/TS 60079-32-1:2013 clause 7.10.5 and 8.5
To use the unit in tanks larger than 100m³ is possible under certain conditions.
It is necessary to know the current factors such as tank size, cleaning solvent and product.
Additives can be used in the cleaning solvent, or, for example, the tank can be filled with nitrogen. The basic guidelines are
described in the guide IEC/TS 60079-32-1:2013.
It must be ensured that the equipotential bonding of all conductive metal objects is in accordance with national regulations
for use.
The process fluid conductivity must correspond to the products in the group “High conductivity”, cf. IEC/TS 60079-32-1:2013
clause 7.1 and 7.2.
High conductivity >10000pS/m
Medium conductivity between 25 × εr pS/m and 10 000 pS/m
Low conductivity <25×εrpS/m
For liquids with a dielectric constant of around 2, (e.g. hydrocarbons), these classifications reduce to:
High conductivity >10000pS/m
Medium conductivity
Low conductivity
between 50 pS/m and 10 000 pS/m
<50pS/m
Following a guidance document such as IEC/TS 60079-32-1:2013 to establish safe use of machinery and process is the users
own responsibility and is not covered by the ATEX/IECEx certification for this unit except for tanks up to 100 m3.Forfurther
information see IEC/TS 60079-32-1:2013 Explosive atmospheres – Part 32-1: Electrostatic hazards, guidance with focus on
clause 7.1.3, 7.1.4, 7.2.1, 7.2.4.
15

4 Installation
TJ20G
4.4 Specific conditions for safe use in accordance with ATEX/IECEx certification
Warning: Process generated electrostatic
The user must address the electrostatic hazards generated from the process of the equipment in accordance
with guidance document IEC/TS 60079-32-1:2013.
Warning: Electrostatically charged liquid
Liquids can become electrostatically charged when they move relative to contacting solids or the spraying of
liquids can also create a highly charged mist or spray. The liquid must be made electrically conductive by
additives or otherwise.
For further information see IEC/TS 60079-32-1:2013 Explosive atmospheres – Part 32-1: Electrostatic hazards,
guidance. With focus on clause 7.1.3, 7.1.4, 7.2.1, 7.2.4.
Warning: Appropriate cleaning fluid
The cleaning fluid should be appropriate for the application (e.g. so no chemical reaction can take place between
the cleaning fluid and the residue of process fluid/powder/compound which can generate heat or a hybrid mixture).
Chemical reactions in Zone 20 - Hybrid mixtures:
End-user must ensure that the cleaning fluid used does not create a hybrid mixture according to IEC
60079-10-1:2015 Annex I.1 in connection with powder / dust residues in the tank in zone 20.
This should ensure that the atmosphere does not change to a classification that lies outside the machine’s
certified scope. When the machine is used for cleaning tanks containing potentially flammable dust atmospheres,
and a potentially flammable fluid is used as the cleaning fluid then an assessment of the hybrid mixture shall be
undertaken by the user, prior to operation.
For further information see IEC 60079-10-1:2015 Explosive atmospheres – Part 10-1: Classification of areas –
Explosive gas atmospheres. With focus on clause 3.6.6 and Annex I – Hybrid mixtures.
Warning: Fluid pressure
The maximum permitted cleaning fluid pressure is 8 bar.
In addition to the above mentioned precautions relating to Directive 2014/34/EU, the Safety Precautions on page 13 must
be observed.
16

5Operation
TJ20G
5.1 Normal operation
Cleaning Media
Use only media compatible with Stainless Steel AISI 316L, SAF 2205, PVDF or PEEK, PFA HP and EPDM. For more aggressive
chemicals, consider using the Hastelloy version. Normal detergents, moderate solutions of acids and alkalics are acceptable.
Aggressive chemicals excessive concentrations of chemicals at elevated temperatures, as well as certain hypochlorids should
be avoided. If in doubt, contact your local Alfa Laval sales office.
NOTE
Do not try to turn the nozzle head by hand, since this may damage the Gear. The Nozzle head can be turned by blowing
compressed air through the inlet connection.
PEEK is not resistant to concentrated sulphuric acid.
Product
In cases where the machine is submerged in, or in other ways exposed to, product the compatibility between stainless steel
AISI 316L, SAF 2205, PVDF or PEEK, PFA and EPDM and the product must be considered carefully. For more aggressive
products consider using the Hastelloy version
NOTE
EPDM swells significantly exposed to fatty materials.
Pressure
Avoid hydraulic shocks. Increase pressure gradually. Do not exceed 8 bar inlet pressure. Recommended inlet pressure: 5-7
bar. High pressure in combination with high flow rate increase consumption of wear parts. High pressure also reduces
the cleaning effect.
Draining using compressed air
If the machine is drained using compressed air, then the compressed air pressure must not cause the machine body rotation to
exceed 4.5 rpm (corresponding to appx. 13 sec pr. rev of the body) in order to avoid risk of machine breakdown.
Draining should always be done inside the tank.
See paragraph 4.4 Specific conditions for safe use in accordance with ATEX/IECEx certification (page 14).
Steam cleaning
If stream cleaning is done through the machine, the steam pressure must not cause the machine body rotation to exceed 10
rpm (corresponding to appx. 6 sec pr. rev of the body) in order to avoid risk of machine breakdown. See paragraph 4.4 Specific
conditions for safe use in accordance with ATEX/IECEx certification (page 14).
Temperature
Standard versions:
The maximum recommended process liquid temperature is 95oC. The maximum recommended steam temperature is 140oC.
The maximum ambient temperature is 140oC.
No-EPDM version:
The maximum recommended process liquid temperature is 95oC. The maximum recommended steam temperature is 200oC.
The maximum ambient temperature is 200oC.
See paragraph 4.4 Specific conditions for safe use in accordance with ATEX/IECEx certification (page 14).
17

5Operation
TJ20G
After use cleaning
After use flush the machine with fresh water. Cleaning media should never allow to dry or settle in the system due to possible
"salting out" or "scaling" of the cleaning media. If cleaning media contains volatile chloride solvents, it is recommended not to
flush with water after use, as this might create hydrochloric acid.
5.2 Safety precautions
The machine is intended for use inside a tank only. As peak velocity of main jets reaches 40 m/s, The Alfa Laval Toftejorg TJ20G
must not be operated in open air or when tank is open.
Warning: Hot chemicals and steam under pressure may be used for cleaning and sterilising. Protect against scalding
and burning. Never tamper with or try to open clamps or other connections while system is in operation. Make
sure that system is de-pressurised and drained before disassembly.
The cleaning jets impinging the tank surface are a source of noise. Depending on pressure and distance to the tank walls, noise
level may reach up to 85 dB.
Warning: Tanks may contain poisonous/hazardous products or products which represent an environmental or safety
risk. Never open tank and dismount the machine without checking previous tank contents and necessary
precautions.
See also 3.6 ATEX/IECEx temperature class and code, page 9.
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6 Maintenance
TJ20G
6.1 Preventive maintenance
Following the Alfa Laval Tank Equipment Preventive Maintenance Guidelines and using the Alfa Laval Service Kits ensures the
availability of your equipment at all times and enables you to plan your operating budget and your downtime. The risk of
unscheduled breakdowns due to component failure is virtually eliminated and in the long term your operating costs are reduced.
Alfa Laval Tank Cleaning Equipment Service Kits contain all you need. They comprise genuine Alfa Laval spare parts,
manufactured to the original specifications.
The recommended preventive maintenance program is based on tank cleaning machines working in average conditions.
However, a tank cleaning machine, exposed to heavy soiling and recirculation CIP liquid containing abrasives and/or particulates,
needs more frequent attention than one exposed to light/no soiling and recirculation with ordinary CIP liquid. Alfa Laval Kolding
A/S recommends you to adjust the maintenance program to suit the cleaning task in hand. Contact your local Alfa Laval
sales office for discussion.
For further information regarding Alfa Laval Service Kits and service intervals, see paragraph 6.3 Maintenance intervals and
Service Kits on page 20 of this manual or the Spare part manual.
NOTE
Handle the Alfa Laval Toftejorg TJ20G with care. Take proper action to protect surfaces from being damaged.
Always use only proper tools and the Alfa Laval Toftejorg TJ20G standard tool kit (page 23). Never use force, hammer or pry
components together or apart. Always perform all assembly/disassembly steps in the order described in this manual.
Clean all surfaces prior to assembling. Especially take care of the mating surfaces. Work in a clear well-lighted work area.
According to “Regulation (EC) No 1935/2004 - Article 17” effective from 27th of October 2006, producers of food shall ensure
traceability of the materials and articles intended to come into contact with foodstuffs. It is recommended that a traceability
system is setup for replacement of wear parts and spare parts. This makes it possible to identify into which machine a
given wear part or spare part has been inserted.
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6 Maintenance
TJ20G
The items (#) refer to section 10 Parts lists and drawings, service kits and tools and section 6.8 Reassembly.
6.2 Service and repair of ATEX/IECEx certified machines
All service and repair of ATEX/IECEx certified machines can be performed by Alfa Laval Kolding A/S, Denmark
or by an Alfa Laval service center approved by Alfa Laval Kolding A/S.
Changes to the machine are not allowed without approval by the person responsible for the ATEX/IECEx
certification at Alfa Laval. If changes are made – or spare parts other than Alfa Laval original spare parts are used
- the EC Type Examination certification (the ATEX/IECEx Directive) is no longer valid.
In order to ensure compliance with the ATEX/IECEx regulations and keep the machine ATEX/IECEx certification
valid, the service or repair must be performed by an authorized person with knowledge of the ATEX/IECEx
requirements and regulations. All spare parts must be original Alfa Laval spare parts and the repair or service
must be done according to the instructions in this manual.
Warning:
If a customer wishes to carry out service or repair himself, it is the responsibility of the repair shop to ensure that
the ATEX/IECEx requirements are met in any way possible. After performing service or repair, the repair shop
thus carries the full responsibility for traceability of all relevant documents in order to ensure the retention of the
ATEX/IECEx certification of the machine.
6.3 Maintenance intervals and Service Kits
It is recommended that the wear parts are check every 500 working hours for machine working under normal conditions. There
is a Minor and a Major service kit for the Alfa Laval Toftejorg TJ20G (see the following pages).
Service intervals
500 hour 500 hour 500 hour
Minor Service Kit: Minor Service Kit: Minor Service Kit:
TE20G290/91 TE20G290/91 or TE20G290/91 or
or
Major Service Kit Major Service Kit Major Service Kit
TE20G292/93/94 or
TE20H292
TE20G292/93/94 or
TE20H292
TE20G292/93/94 or
TE20H292
Every 500 working hours
1. Disassemble machine as described on the following pages.
2. Clean material build-up and deposits from internal parts with Scotch-brite, S-Ultra-fine, eventually chemical media and
fine abrasive cloth.
3. Check Slide bearing (14) for wear. If end face of Slide bearing is worn more than 1 mm into Slide bearing, it should be replaced.
4. Check bearing for Turbine shaft top (24) in Cone and Body. If holes are worn oval to a max. diameter of more than 10.4
mm, Bearings should be replaced. Thickness of collar is to be min. 3.5 mm for Bearing in Body. If the Bearings are loose in
a horizontal direction, the bearings should be replaced.
5. Check Carrier bearing (15.3). If worn oval to a max. diameter of more than 15.8 mm, it should be replaced.
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