Alfalaval Toftejorg SaniMega User manual

IM-TE91A590-EN1
August 2005
Toftejorg SaniMega
Instruction Manual
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Contents
Contents ....................................................................................................................1
Introduction................................................................................................................3
General Description...................................................................................................4
Functioning ......................................................................................................................... 4
Technical Data...........................................................................................................5
Options ............................................................................................................................... 5
Principal dimensions ........................................................................................................... 6
Dimensions for Options....................................................................................................... 6
Performance Data............................................................................................................... 7
Installation and Normal Operation.............................................................................8
General Installation Instructions.......................................................................................... 8
Normal Operation................................................................................................................9
Maintenance and repair...........................................................................................10
Preventive Maintenance.................................................................................................... 10
Turbine and Gear Assembly ............................................................................................. 11
Cleaner Head Assembly ................................................................................................... 12
Reference List of Parts............................................................................................13
Rotacheck................................................................................................................14
Installation Guide .............................................................................................................. 14
How to Order Spare Parts and Claim Procedure....................................................16
How to Order Spare Parts................................................................................................. 16
Claim Procedure ............................................................................................................... 16
How to contact Alfa Laval Tank Equipment A/S................................................................ 16
Service Card............................................................................................................17
Claim Report Working Conditions ...........................................................................18
Instruction Manual, Toftejorg SaniMega Page 1
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Introduction
This manual has been prepared as a guide for the persons who operate and maintain the 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 worldwide net of distributors will be pleased to help you. Please
quote the type, article and serial numbers with all of your enquiries; this will help us to help you.
The Serial number is 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.
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General Description
The Toftejorg SaniMega is a media driven and media lubricated tank cleaning machine, which is being
used at fixed vertical installations. The SaniMega rotary spray head provides a controlled rotating fan
impact cleaning action. It is an automatic device with an optimised design for distribution of cleaning
fluids in vertical cylindrical tanks. However, it can also be used for a number of other tank shapes and
vessels.
Functioning
The cleaning media is lead through the inlet
connection and into the housing, where it flows
through the Gear and the Turbine, setting the
Turbine into rotation. It then continues downwards
to the Cleaner head and out through the slots.
The rotation of the Turbine is via the Gear
transmitted to the Drive shaft, which makes the
Cleaner head rotate at a steady speed. The
resulting fan impact jet of the cleaning media
cleans the impacted surfaces and provides a
swirling action down the tank wall.
The Toftejorg SaniMega contains no lubricating
substances such as oil or grease. All materials
are selected for contact with foods, and the
machine is self-cleaning, i.e. all internal and
external surfaces are cleaned.
The Toftejorg SaniMega can, as an option, be
fitted with a non-invasive electronic Rotation
Sensor to verify the rotation of the cleaner.
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Technical Data
Weight of machine : 6.0 kgs (13.3 lbs)
Working pressure : 2-4 bar (28-58 psi)
Recommended pressure : 3 bar (44 psi)
Max. working temperature : 95°C (203°F)
Max. sterilisation temperature : 140°C (284°F)
Max. ambient temperature : 140°C (284°F)
Effective cleaning radius : 3 m (10 ft.)
Standard connection : Inlet: 2” ISO clamp. Tank: 3” ISO clamp
Standard downpipe length : 1,200 or 1.500 mm
Min. tank opening : ø72,5 mm
Materials : Stainless steel AISI 316L, PTFE, PEEK, EPDM
Options
•A non-invasive electronic Rotation Sensor to validate speed of the cleaner can be included
•Downpipe length 800 or 1.000 mm
•Inlet connection as welding end 2” ISO (ø51x1.2)
•Tank inlet as DIN Union NW100
•Counter parts to the standard clamp connections including gaskets and clamp rings
Rotation Sensor Inlet connection as welding end Tank inlet as DIN Union
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Technical Data (continued)
Principal dimensions
Dimensions in mm
Dimensions for Options
* For welding end : 65/99mm
** For NW100 DIN Union : 234 mm
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Technical Data (continued)
Performance Data
Flow Rate Rotating speed
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Installation and Normal Operation
General Installation Instructions
The Toftejorg SaniMega is designed for fixed vertical installation in vertical tanks. It is recommended to
install a filter in the supply line in order to avoid particles larger than 2,5 mm like scale etc. from
clogging the inside of the cleaner. Fine solid particles in the cleaning fluid will result in increase of wear
and may cause slower rotation speed or stoppage.
Before installation, all supply lines and valves must be flushed to remove remains of welding
electrodes, grinding dust, scale and other foreign matter.
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 cleaner head.
In EU-countries the complete system must fulfil the EU-machine directive and shall be CE-marked.
Warning:
The machine is not designed for installation in tanks with a potential explosive
atmosphere, where build up of static electricity on the cleaner head can result in risk of
sparks and consequently an explosion may follow.
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Installation and Normal Operation (continued)
Normal Operation
Cleaning Media
Use only media compatible with Stainless Steel AISI 316L, PTFE, PEEK and EPDM. Please note that
PEEK is not resistant to concentrated sulfuric acid. Normal detergents, moderate solutions of acids and
alkalics will be acceptable. Aggressive chemicals, excessive concentrations of chemicals at elevated
temperatures, as well as certain hypochlorids should be avoided. If you are in doubt, contact your local
Alfa Laval Tank Equipment sales office.
Temperature
Max. temperature 140°C at steam sterilisation.
Pressure
Please make sure that the connections are correctly mounted before opening of the washing valve. Put
on pressure gradually in order to avoid hydraulic shocks, which might stress mechanical parts in the
Toftejorg SaniMega cleaner. Max. pressure is 4.0 bar.
After Use Cleaning
After using the Toftejorg SaniMega, flush the machine with clean 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.
Warning:
Do not touch hot surfaces when working with hot cleaning solutions or steaming.
Never try to loosen clamps without securing against pressure on the pipe line.
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Maintenance and repair
Preventive Maintenance
In order to keep your tank cleaning machine servicing you as an efficient tool in your tank cleaning
operations, it is essential that you maintain its high performance by following a simple preventive
maintenance programme, which will help keep your tank cleaning machine in good condition.
Good maintenance is careful and regular attention!
The following recommended preventive maintenance is based on tank cleaning machines working in
average conditions. A tank cleaning machine, which has a rough and dirty job to do, will need more
frequent attention than one working under ideal conditions. We trust that you will adjust your maintenance
programme accordingly.
Caution:
Always use only the proper tools.
Never force, hammer or pry components together or apart.
Always perform all assembly /disassembly steps in the order described in this manual.
Never assemble components without previous cleaning. This is especially important at
all mating surfaces.
Work in a clear, well-lighted work area.
Every 300-500 working hours
Inspect the gear, turbine parts and bearings:
Disassembly
1. Dismount the Clamp ring, inlet connection and Gasket (Pos. 20, 19 and 21).
2. Remove Circlip (Pos. 11) and lift off Gear wheel (Pos. 4). Push out Cylindrical Pin (Pos. 3). Be
careful not to drop Pin into machine.
3. Lift off the Gear assembly from the Drive shaft (Pos. 9). The Turbine shaft (Pos. 8) is now released
and can be removed.
Check/Inspection
1. Check the Worm and Worm wheel on the Horizontal shaft (Pos. 12). Replace shaft if teeth are
worn more than 50%.
2. Check that the Horizontal shaft (Pos. 12) and the Worm wheel (Pos. 2) can be rotated freely
without any uneven resistance. Check Turbine bearings (Pos. 6). Replace Bearings if hole is worn
to more than ø10.3 mm.
3. Replace if Collar on lower Bearing has been worn to 1.0 mm or less.
Reassembly
Reassembly is carried out in the opposite order.
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Maintenance and repair (continued)
Turbine and Gear Assembly
Disassembly:
1. Remove Circlip (pos. 11) and lift off the Gear wheel (Pos. 4) . Push out Cylindrical Pin (Pos. 3)
2. Lift off the Gear assembly from the Drive Shaft (Pos. 9). The Turbine shaft (Pos. 8) will now be
released and can be removed.
3. Remove Circlip (Pos. 11) and pull out the Pinion (Pos. 1) releasing the Worm wheel (pos. 2) and
Washer (Pos. 14).
4. Remove the Circlip (Pos. 11) and pull off the Horizontal shaft (Pos. 12).
Reassembly:
Reassembly is carried out in the opposite order.
Before mounting Gear wheel (Pos. 4) make sure that the Horizontal shaft (Pos. 12) and the Worm
wheel (Pos. 2) can be rotated easily without any uneven resistance.
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Maintenance and repair (continued)
Cleaner Head Assembly
Disassembly:
It is necessary to disconnect the cleaner from any piping etc. and dismount it from the tank. Place the
machine on a level surface.
1. Dismount the Clamp ring, Inlet connection and Gasket (Pos. 20, 19 and 21).
2. Push up the Cleaner head (Pos. 17) and remove the Lock ring (Pos. 18). If necessary hold Drive
shaft (Pos. 9) in position when pushing up Cleaner head.
3. Pull off Cleaner head.
Reassembly:
Reassembly is carried out in the opposite order.
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Reference List of Parts
Toftejorg SaniMega, Reference List of Parts
Pos. Ref. no. No/Unit Description Material
1 TE12A514 1 Pinion Polymer
2 TE12A508 1 Worm wheel Stainless steel
3 TE51C017 1 Cylindrical Pin Stainless steel
4 TE12A506 1 Gear wheel Stainless steel
5 TE12A528 2 Bush Polymer
6 TE20G549 3 Bearing f. Turbine shaft Polymer
7 TE12A505 1 Gear frame Stainless steel
8 TE12A509 1 Turbine shaft Stainless steel
9 TE12A530/33 1 Drive shaft Stainless steel
10 TE12A507 1 Shaft Stainless steel
11 TE51C202 3 Circlip Stainless steel
12 TE12A513 1 Horizontal shaft Polymer
13 TE51C004 1 Pin Stainless steel
14 TE12A515 1 Washer Polymer
15 TE12A566 1 Washer Stainless steel
16 TE12A545/48 1 Housing Stainless steel
17 TE12A573 1 Cleaner head Stainless steel
18 TE12A559 1 Lock ring Stainless steel
19 TE12A526 1 Inlet connection Stainless steel
20 TE51S128 1 Clamp ring Stainless steel
21 TE51S118 1 Gasket Elastomer
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Rotacheck
Installation Guide
The Rotacheck Sensor is a Namur-type magnetic
sensor according to DIN 19234. The sensor must
be supplied from an external relay.
When the Magnet inside the cleaner passes the
sensor, an impulse is sent to the relay.
Technical Data:
Dimensions: 12x12x30 mm
Connection, electrical: 2m, PVC-cable
2x0.34mm2
Supply voltage: 5-24 V DC
Supply voltage, Ex approv.: Max. 8.2 V DC
Current consumption, Magnet
sensed
3
mA
Current consumption, Magnet not
sensed
1
mA
Operating temperature: -250C to 700C
Material of Housing: PBT
Enclosure: IP67
Ex-class: EEx ia II T6
Standard Symbol:
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Installation Guide (continued)
Rotacheck for Toftejorg SaniMega complete TE12A305, Reference List of Parts
Pos. Ref. No. Number Description Material
1 TE12A555 1 Clamp for sensor Stainless steel
2 TE51A148 1 Screw Stainless steel
3 TE51V555 1 Sensor
4 TE12A557 1 Isolator for sensor Polymer
5 TE12A356 1 Magnet complete
Working Instructions
1. Remove the Inlet connection (Pos. 19, page 13)
2. Remove Circlip (Pos. 11) and Gear wheel (Pos. 4, page 13).
3. Fit Magnet (Pos. 5) in Gear wheel
4. Fit Gear wheel with Magnet complete on shaft
5. Fit Inlet connection
6. Fit pos. 1, 2, 3 and 4 on the Housing. Position of the Sensor is important. It must be fitted on the
right side of tap.
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How to Order Spare Parts and Claim Procedure
How to Order Spare Parts
The drawings on page 11, as well as the instruction drawings on page 12 and 13, show that 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 List of Parts, page 13. For the Rotacheck system the individual parts have a
Pos. No. and are all listed in the Reference list of Parts, same page.
Individual parts should always be ordered from the Reference List of Parts, page 13 or page 14. Ref.
no. and Description should be clearly stated.
Please also quote the type of machine and Serial no. This will help us to help you. The Serial No. is
stamped on the Connection flange of the tank cleaning machine.
Spare part kit: Article no. TE12A299
Pos. Ref. No. Number Description Material
3 TE51C017 2 Cylindrical Pin Stainless steel
6 TE20G549 2 Bearing f. Turbine shaft Polymer
11 TE51C202 3 Circlip Stainless steel
12 TE12A513 1 Horizontal shaft Polymer
18 TE12A559 1 Lock ring Stainless steel
Claim Procedure
In case of failure that needs assistance from Alfa Laval Tank Equipment A/S, it is essential for our
evaluation that the problem, as well as the working conditions of the machine, is described as detailed
as possible.
For description of the working conditions, fill in the form “Claim Report - Working Conditions”, which
you will find at the back of this manual.
How to contact Alfa Laval Tank Equipment A/S
For further information please feel free to contact:
Alfa Laval Tank Equipment A/S
Baldershoej 19
P.O. Box 1149
2635 Ishoej
Denmark
Phone no.: [phone]
Fax no.: [phone]
www.alfalaval.com
www.toftejorg.com
Contact details for all countries are continually updated on our websites.
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Service Card
Type of Machine :
Serial No. :
Length : : mm
Date No. of Working
Hours
Maintenance Actions/
Exchanged Parts Remarks Sign.
0 Machine put into operation
V. 94.2
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Claim Report Working Conditions
Page 1/2
Ref. Claim Case :
Machine/Cleaner Type : Serial No.:
Configuration
- Nozzles : x ø mm
- Turbine/Inlet Guide : %
Working Conditions
Inlet pressure at machine/cleaner :
Type of Valve in inlet line :
Can hydraulic shock be disregarded: : Yes No
Inlet line flushed before installation of tank cleaner? : Yes No
Working hours before failure : hours
Cleaning Programme
Cleaning media and conc. Temperature Time Recirculation?
Is sterilising being used? : Yes No
Procedure (media/temp.)? :
Is steam injection being used for heating? : Yes No
Time: __________
Temperature: __________
v. 98.1
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Claim Report Working Conditions (continued)
Page 2/2
Condition of Cleaning Media
Clean
Contaminated with (nature and description)
Chemicals/Solvents ___________________________ High viscous
Soluble Sticky/tenacious
Low viscous Solidifying
Hard particles/size _____________________________ Crystallising
Soft particles/size ______________________________
Has filter been installed in inlet line? Yes
Mesh size: mm
No
Is tank cleaner flushed with clean water after tank cleaning? Yes No
Type of Soilage/Tank Contents to be removed
Name, formula/concentration of material to be removed from tank :
What is material soluble in :
Nature of material:
Volatile/explosive Sticky/tenacious Contains soft particles
Low viscous Solidifying Contains hard particles/fibres
High viscous Crystallising
Is tank cleaner submerged in material? Yes No
Other information/Remarks
Date: Sign.:
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