Alfalaval Gunclean Toftejorg T-82 User manual

Instruction Manual
Gunclean Toftejorg™ T-82
IM-TE91A052-EN4
Date of issue: December 28, 2011
Covering ▪Standard Machines
▪Machines delivered with ATEX Certification in accordance with
Directive 94/9/EC

Instruction Manual, Gunclean Toftejorg T-82 Page 1
Standard machines and machines delivered with ATEX certification
in accordance with Directive 94/9/EC
IM-TE91A052-EN4
Contents
Contents ........................................................................................................................................ 1
Introduction.................................................................................................................................... 3
Intended Use ................................................................................................................................. 4
Patents and trademarks ................................................................................................................ 4
ATEX Marking ............................................................................................................................... 5
General Description....................................................................................................................... 6
Functioning ................................................................................................................................................6
Standard configurations .............................................................................................................................7
Standard Options .......................................................................................................................................7
Available add-ons ......................................................................................................................................7
Technical data ............................................................................................................................... 8
For Gunclean Toftejorg T-82 Fixed ............................................................................................................8
For Gunclean Toftejorg T-82 Portable .....................................................................................................12
Installation and Normal Operation............................................................................................... 16
General Safety and Installation Instructions.............................................................................................16
Normal Operation.....................................................................................................................................18
Special Conditions for Safe Use in accordance with the ATEX Certification, Directive 94/9/EC..............20
Maintenance and repair ............................................................................................................... 22
Service and Repair of ATEX Approved Machines....................................................................................22
Preventive Maintenance Guidelines and Service Kits..............................................................................23
Maintenance intervals and Service Kits selection ....................................................................................23
Top Assembly ..........................................................................................................................................26
Bottom Assembly .....................................................................................................................................28
Hub Subassembly....................................................................................................................................30
Stem Subassembly ..................................................................................................................................32
Gear Subassembly ..................................................................................................................................34
Replacement of Collar Bushes.................................................................................................................36
Replacement of Ball Races......................................................................................................................38
Replacement of Main Collars ...................................................................................................................40
Tools............................................................................................................................................ 42
Trouble Shooting Guide .............................................................................................................. 44
Reference List of Parts, Gunclean Toftejorg T-82 Fixed.............................................................. 46
Cross Sectional Drawing, Gunclean Toftejorg T-82 Fixed.......................................................... 47
Reference List of Parts, Gunclean Toftejorg T-82 Portable ........................................................ 48
Cross Sectional Drawing, Gunclean Toftejorg T-82 Portable ..................................................... 49
Service Kits.................................................................................................................................. 50
How to order spare parts and claim procedure ........................................................................... 51
How to contact Alfa Laval Tank Equipment A/S.......................................................................... 51
Service Card................................................................................................................................ 52
Claim Report Working Conditions ............................................................................................... 53
Declarations of conformity........................................................................................................... 55

Instruction Manual, Gunclean Toftejorg T-82 Page 3
Standard machines and machines delivered with ATEX certification
in accordance with Directive 94/9/EC
IM-TE91A052-EN4
Introduction
This manual has been prepared as a guide for the persons who will be operating and maintaining your
tank cleaning machine. The key to long life for your tank cleaning machine will always be a system of
carefully planned maintenance; you will appreciate that a tank cleaning machine which has a rough
and dirty job to do will need more frequent attention than one working in ideal conditions.
It is in your own interest to get the best and most economical performance from your tank cleaning
machine. Neglect of maintenance means poor performance, unscheduled stoppages, shorter life and
expense. Good maintenance means good performance; no unscheduled stoppages and better total
economy.
You will find the information contained in this manual simple to follow, but should you require further
assistance, our Customer Service Department and worldwide net of Distributors will be pleased to help
you. Please quote the type and serial number with all your enquiries; this will help us to help you. The
type and serial number are placed on the gear house of the tank cleaning machine.
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.
© 2011 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.

Page 4 Instruction Manual, Gunclean Toftejorg T-82
Standard machines and machines delivered with ATEX certification
in accordance with Directive 94/9/EC
IM-TE91A052-EN4
Intended Use
It is to be verified by the end-user:
- that the tank cleaning machine is in conformity with respect to tank, vessel or container size in
which it will be 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.
Patents and trademarks
This Instruction Manual is published by Alfa Laval Tank Equipment A/S without any warranty.
Improvements and changes to this Instruction Manual may at any time be made by Alfa Laval Tank
Equipment A/S without prior notice. Such changes will, however, be incorporated in new editions of this
Instruction Manual.
© Alfa Laval Tank Equipment A/S, 2011. All rights reserved.
The Alfa Laval logotype is a trademark or a registered trademark of Alfa Laval Corporate AB. Gunclean
Toftejorg TM is a trademark or registered trademark of Alfa Laval Tank Equipment A/S. Other products
or company names mentioned herein may be the trademarks of their respective owners. Any rights not
expressly granted herein are reserved.

Instruction Manual, Gunclean Toftejorg T-82 Page 5
Standard machines and machines delivered with ATEX certification
in accordance with Directive 94/9/EC
IM-TE91A052-EN4
If ordered with ATEX certificate:
ATEX Marking
The Gunclean Toftejorg T-82 is certified as category I components. The certification is carried out by
the notified body Baseefa, who has issued the certificate no. 10ATEX0188X. The marking on the ATEX
certified Gunclean Toftejorg TZ-82 is as follows:
Changes to the machine are not allowed without approval by the person responsible for the ATEX
certification at Alfa Laval Tank Equipment 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:
Also see page 22
regarding special conditions for repair of ATEX certified
machines.

Page 6 Instruction Manual, Gunclean Toftejorg T-82
Standard machines and machines delivered with ATEX certification
in accordance with Directive 94/9/EC
IM-TE91A052-EN4
General Description
The Gunclean Toftejorg T-82 is a media driven tank cleaning machine. The internal mechanical parts
are isolated by seals and lubricated by pre-packed grease.
Functioning
The flow of the cleaning fluid into the machine passes through a turbine, which is set into rotation. The
impeller rotation is through a gearbox transformed into a combined horizontal rotation of the machine
body and a vertical rotation of the nozzles.
The combined motion of the machine body and the nozzles ensures a fully indexed tank cleaning
coverage. After 11¼ revolutions of Hub with nozzles (103/4revolutions of the machine body), one
coarse cleaning pattern is laid out on the tank surface. During the following rounds, this pattern is
repeated 3 times, each of which is displaced ¼ of the mesh in the pattern. After a total of 45 revolutions
of the Hub with nozzles (43 revolutions of the machine body), a complete cleaning pattern has been
laid out, and the first pattern is repeated.
1st cycle
2nd cycle
3rd cycle
4th cycle
The speed of rotation of the impeller depends on the flow rate through the machine, which in turn
primarily depends on the nozzle diameter chosen. The higher the flow rate is, the higher the speed of
rotation will be. For a given flow rate, the RPM of the machine can be controlled by installing a stator or
no stator in front of the Impeller and by the gear configuration. No stator (0%) and E-gearing will give
the slowest rotation and longest jet throw length for a given flow rate.

Instruction Manual, Gunclean Toftejorg T-82 Page 7
Standard machines and machines delivered with ATEX certification
in accordance with Directive 94/9/EC
IM-TE91A052-EN4
General description (continued)
Standard configurations
Connection Turbine/Inlet Guide Nozzles (mm) (3/4” thread conn.) Article/Ref. No.
Fixed with 127mm
o.d. Flange
50%
2xø7
TE21F002
100%
2xø8
2xø9
TE21F012
TE21F014
0%
2xø10
TE21F020
Connection Turbine/Inlet Guide Nozzles (mm) (3/4” thread conn.) Article/Ref. No.
Fixed
Without flange
50%
2xø7
TE21F032
100% 2xø8
2xø9
TE21F042
TE21F044
0 %
2xø10
TE21F050
Connection Turbine/Inlet Guide Nozzles (mm) (3/4” thread conn.) Article/Ref. No.
Portable with 1½”
BSP Nipple
50%
2xø7
TE21F202
100%
2xø8
2xø9
TE21F212
TE21F214
0 %
2xø10
TE21F230
Connection Turbine/Inlet Guide Nozzles (mm) (3/4” thread conn.) Article/Ref. No.
Portable with 1½”
NPT Nipple
50%
2xø7
TE21F262
100%
2xø8
2xø9
TE21F272
TE21F274
0 %
2xø10
TE21F280
The hub of the machine is equipped with a clutch in the hub, which gives the possibility of rotation by
hand the nozzles, when the machine is to be lifted out through a tank opening.
Standard Options
Machines with nozzle extensions for longer throw length can be supplied as an option. Same article no.
with index no. –22. e.g. TE21F002-22.
Machines with e-gear and nozzle extension: Same article no. with index no. -62, e.g. TE21F002-62.
Only available for Gunclean Toftejorg T-82F).
Available add-ons
ATEX, category 1 for installation in zone 0/20
- TE21FXXX-70 ATEX
- TE21FXXX-22-70 ATEX + nozzle extension
- TE21FXXX-62-70 ATEX + nozzle extension and E-gear (only available for Gunclean Toftejorg T-82F)
Explanation to Add-ons
ATEX, category 1 for installation in zone 0/20 in accordance with Directive 94/9/EC

Page 8 Instruction Manual, Gunclean Toftejorg T-82
Standard machines and machines delivered with ATEX certification
in accordance with Directive 94/9/EC
IM-TE91A052-EN4
Technical data
For Gunclean Toftejorg T-82 Fixed
Weight of machine
:
7.0 kgs (15,4 lb)
Working pressure
:
5-12 bar (75-175 psi)
Recommended inlet pressure
:
5-10 bar (75-150 psi)
Working temperature max. : 78°C (173° F)
Ambient temperature 0 – 140°C (78°C - 140°C when not operated)
Materials : Stainless steel, polymer, elastomer, carbon
Principal dimensions in mm

Instruction Manual, Gunclean Toftejorg T-82 Page 9
Standard machines and machines delivered with ATEX certification
in accordance with Directive 94/9/EC
IM-TE91A052-EN4
Technical data (continued)
For Gunclean Toftejorg T-82 Fixed
Flow rate

Page 10 Instruction Manual, Gunclean Toftejorg T-82
Standard machines and machines delivered with ATEX certification
in accordance with Directive 94/9/EC
IM-TE91A052-EN4
Technical data (continued)
For Gunclean Toftejorg T-82 Fixed
Throw length
Note: Throw lengths are measured as max. horizontal throw length at static condition. Vertical throw
length upwards is approx. 1/3 less. 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.
Option: The Gunclean Toftejorg T-82 Fixed can be supplied with nozzle extensions and E-gearing for
longer throw length.

Instruction Manual, Gunclean Toftejorg T-82 Page 11
Standard machines and machines delivered with ATEX certification
in accordance with Directive 94/9/EC
IM-TE91A052-EN4
Technical data (continued)
For Gunclean Toftejorg T-82 Fixed
Cleaning Time, f. Complete Pattern (= 4 cycles)

Page 12 Instruction Manual, Gunclean Toftejorg T-82
Standard machines and machines delivered with ATEX certification
in accordance with Directive 94/9/EC
IM-TE91A052-EN4
Technical data (continued)
For Gunclean Toftejorg T-82 Portable
Weight of machine
:
7.0 kgs (15,4 lb)
Working pressure
:
5-12 bar (75-175 psi)
Recommended inlet pressure
:
5-10 bar (75-150 psi)
Working temperature max. : 78°C (173°F)
Ambient temperature
0 – 140°C (78°C - 140°C when not operated)
Materials : Stainless steel, polymer, elastomer, carbon
Principal dimensions in mm

Instruction Manual, Gunclean Toftejorg T-82 Page 13
Standard machines and machines delivered with ATEX certification
in accordance with Directive 94/9/EC
IM-TE91A052-EN4
Technical data (continued)
For Gunclean Toftejorg T-82 Portable
Flow rate

Page 14 Instruction Manual, Gunclean Toftejorg T-82
Standard machines and machines delivered with ATEX certification
in accordance with Directive 94/9/EC
IM-TE91A052-EN4
Technical data (continued)
For Gunclean Toftejorg T-82 Portable
Throw length
Note: Throw lengths are measured as max. horizontal throw length at static condition. Vertical throw
length upwards is approx. 1/3 less.
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.

Instruction Manual, Gunclean Toftejorg T-82 Page 15
Standard machines and machines delivered with ATEX certification
in accordance with Directive 94/9/EC
IM-TE91A052-EN4
Technical data (continued)
For Gunclean Toftejorg T-82 Portable
Cleaning Time, f. Complete Pattern (= 4 cycles)

Page 16 Instruction Manual, Gunclean Toftejorg T-82
Standard machines and machines delivered with ATEX certification
in accordance with Directive 94/9/EC
IM-TE91A052-EN4
Installation and Normal Operation
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 to clog inside the
machine. Before connecting the machine into the system, all supply lines and valves should be flushed
to remove foreign matter.
For fixed machines it is recommended to secure bolted connection between machine and down pipe
against loosening to vibrations. Use locking wire, naps or equivalent for the actual application.
ATEX
Warning:
If the machine is used in potential explosive atmospheres, tapes or joint sealing
compounds which are electrical insulators must not be used on threads or joints, unless
an electrical connection is otherwise established to ensure an effective earthing. In
addition, connecting pipe work, must be electrically conductive and earthed to the tank
structure. The resistance between the nozzles and the tank structure should not exceed
20,000 Ohm. This is essential to avoid the build-up of static electricity on the machine.
For further information see DS/CLC/TR 50404:2003 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.
Note:The machine shall be installed in accordance with national regulations for safety and other
relevant regulations and standards.
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.
In EU-countries the complete system must fulfill 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.
It is recommended to mount bumpers on portable tank cleaning machines.
The machine as delivered has been tested at the factory before shipping. For transportation reasons,
the nozzles have been removed prior to shipment. Before installation and use, the nozzles should be
attached and secured appropriately for the application intended.
Check that the machine is in operating condition by inserting 3/16" hex Screwdriver (tool No. TE134A)
in screw in top of Turbine shaft and easily turn Turbine shaft clockwise. If any resistance is recognized,
the machine should be disassembled to localize the cause.

Instruction Manual, Gunclean Toftejorg T-82 Page 17
Standard machines and machines delivered with ATEX certification
in accordance with Directive 94/9/EC
IM-TE91A052-EN4
Installation and Normal Operation (continued)
1. Clamp machine firmly in a vice: Place machine on
top of vice with Hub w. nozzles down wards as
illustrated on the figure. Clamp on the Hub. To
protect machine use rubber jaws on the vice.
2.
Set torque wrench at the specified tightening
torque.
3. Tighten nozzle with the torque wrench.
Recommended tightening torque: 40m
4. Check that the machine is in operating condition by inserting 3/16" hex Screwdriver (tool No.
TE134A) in screw in top of Turbine shaft and easily turn Turbine shaft clockwise. If any resistance
is recognised, the machine should be disassembled to localise the cause.

Page 18 Instruction Manual, Gunclean Toftejorg T-82
Standard machines and machines delivered with ATEX certification
in accordance with Directive 94/9/EC
IM-TE91A052-EN4
Installation and Normal Operation (continued)
Normal Operation
Cleaning Media:Use only media compatible with stainless steel, elastomer, polymer and carbon.
Please note that some of the polymer parts are in PEEK, which is not resistant to concentrated sulfuric
acid. Normal detergents, moderate solutions of acids and chemicals at elevated temperatures, as well
as hypochlorids should be avoided. If you are in doubt, contact your local Alfa Laval Tank Equipment
sales office.
After Use Cleaning:After use flush the machine with fresh water. Cleaning solutions should never be
allowed to dry or set-up in the system due to possible "salting out" or "scaling" of the cleaning
ingredient. If cleaning media contains volatile chloride solvents, it is recommended not to flush with
water after use, in case this can create hydrochloric acid.
Pressure:Avoid Hydraulic shocks. Put on pressure gradually. Do not exceed 12 bar inlet pressure.
Recommended inlet pressure appears from Technical Data (page 8-13). High pressure in combination
with high flow rate will increase consumption of wear parts.
ATEX
Warning:
If stream cleaning is done through the machine, the steam pressure must not cause
the machine to rotate.
ATEX
Warning:
If the machine is drained using compressed air, then the compressed air pressure
must not cause the machine to rotate.