Alfalaval Toftejorg SaniJet 25 User manual

Covering: Standard Machines
Q-doc - Equipment Documentation (3.1 Inspection Certificate – EN 10204)
Q-doc + FAT-SAT - Qualification Documentation
Machines delivered with ATEX Certification in accordance with Directive 2014/34/EU
USP Class VI materials. TE91A760-EN15
ESE01842-EN15 08-2016
Original manual
Instruction Manual
Alfa Laval Toftejorg™ SaniJet 25
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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 ...................................................................................... 8
3.3. Patents and Trademarks ......................................................................... 8
3.4. Marking ............................................................................................ 9
3.5. ATEX Marking ..................................................................................... 10
4. Installation .............................................................................................. 11
4.1. General description ............................................................................... 11
4.2. Quality system .................................................................................... 11
4.3. Functionality ....................................................................................... 12
4.4. General Safety and Installation Instructions .................................................... 13
4.5. Specific Conditions for Safe Use in accordance with ATEX Certification .................... 15
5. Operation ............................................................................................... 16
5.1. Normal operation ................................................................................. 16
5.2. Safety Precautions ................................................................................ 17
6. Maintenance ........................................................................................... 18
6.1. Preventive Maintenance .......................................................................... 18
6.2. Service and Repair of ATEX Certified Machines ............................................... 18
6.3. Service and repair of machines ordered with Q-doc and with Q-doc + FAT-SAT .......... 19
6.4. Maintenance Intervals and Service Kits ......................................................... 20
7. Trouble Shooting Guide .............................................................................. 23
8. Technical Data ......................................................................................... 24
9. Product program ...................................................................................... 26
9.1. Standard configurations .......................................................................... 26
9.2. Available documentation add-ons .............................................................. 26
9.3. Available add-ons for Spare parts ............................................................... 27
10. Part List Drawing and Lists, Service Kits and Tools ............................................. 28
10.1.Part List Drawing .................................................................................. 28
10.2.For machines with -0x and -7x (after August 2012) ........................................... 29
10.3.For machines with -5x, -6x, -8x and -9x (after August 2012) ................................ 30
10.4.Tool kit and tools for assembly and disassembly .............................................. 31
11. Disassembly ............................................................................................ 32
11.1.Disassembly into main subassemblies ......................................................... 32
11.2.Disassembly of lower parts (Hub) ............................................................... 38
11.3.Disassembly of top parts (Cone and Turbine) .................................................. 41
11.4.Disassembly of Impeller Shaft Assembly ....................................................... 46
11.5.Disassembly of gear ring (bearing for body – Pos. 13.3) ..................................... 47
11.6.Disassembly of planet gear (bushing – Pos. 11.1) ............................................ 48
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Table of contents
The information herein is correct at the time of issue but may be subject to change without prior notice
12. Assembly ............................................................................................... 49
12.1.Assembly of turbine .............................................................................. 49
12.2.Assembly of cone ................................................................................. 52
12.3.Assembly of top parts ............................................................................ 55
12.4.Assembly of lower parts .......................................................................... 60
12.5.Assembly of planet gear ......................................................................... 65
12.6.Assembly of gear ring ............................................................................ 66
12.7.Assembly of body parts .......................................................................... 67
12.8.Checking the assembly of body parts .......................................................... 74
13. General information ................................................................................... 75
13.1.Service and repair ................................................................................ 75
13.2.How to order spare parts ........................................................................ 75
13.3.How to contact Alfa Laval Tank Equipment .................................................... 75
14. Miscellaneous .......................................................................................... 76
14.1.Declaration of Conformity, EN 10204 sub clause 2.2 Test Report ........................... 76
14.2.EHEDG certificate of self-cleanability ........................................................... 77
14.3.Declaration of compliance for food contact materials ......................................... 78
14.4.ATEX - Specific Conditions for Safe Use ....................................................... 79
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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 SaniJet 25
Type
From serial number 2016-0001 to 2030-99999
is in conformity with the following directive with amendments:
Machinery Directive 2006/42/EC
DS/EN ISO 12100:2011
The Pressure Directive 97/23/EC
According to its own volume and the rated pressure range, the product is regarded an Article 3, paragraph 3 Equipment
FDA 21CFR§177
Regulation (EC) 1935/2004
Equipment Explosive Atmospheres (ATEX) Directive 2014/34/EU
(Applicable for machine certified as category 1 and 2 component, see machine engraving)
DS/EN 13463-1:2009, DS/EN 13463-5:2011, DS/EN ISO/IEC 80079-34:2011, Annex A, paragraph A.5.3 Rotating machines
EC Type Examination Certificate no. Baseefa04ATEX0358X
Marking: II 1 GD c T140ºC
SGS Baseefa Ltd., Certification body number 1180, Rockhead Business Park, Staden Lane, Buxton, Derbyshire SK17 9RZ, United Kingdom
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
ATEX Responsible Engineer Denniz Høxbroe
Title Name Signature
Kolding 2016-05-01
Place Date
(This Declaration of Conformity replaces Declaration of Conformity dated 2016-01-01)
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2 Safety
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 :
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3 Introduction
ESE01842
3.1 Introduction
Based on more than 30 years of experience from practical tank
cleaning and production of tank cleaning equipment, the Alfa Laval
Toftejorg SaniJet 25 has been developed to meet the highest de-
mands for efficiency, reliability and hygiene within food, beverage,
pharmaceutical and biotechnology industry.
This manual has been prepared as a guide for the persons who
will be operating and maintaining your tank cleaning machine.
The Alfa Laval Toftejorg SaniJet 25 is the first ever tank cleaning
machine to obtain a certificate of in-place cleanability from EHEDG
(European Hygienic Engineering Design Group). It is designed,
tested and approved according to EHEDG´s requirement for self
cleanability (EHEDG Doc. 2) and tested to be sterilizable (EHEDG
Doc. 5).
In order to maintain the hygienic state of the machine it is of highest importance that the Alfa Laval Toftejorg Sani-
Jet 25 is handled and installed according to the instructions in this manual. Scratched surfaces and/or destroyed
O-rings reduce performance and hygienic design. Therefore, it is recommended to use the correct tools specially
designed for maintenance of the Alfa Laval Toftejorg SaniJet 25 (TE81B149).
Alfa Laval offers maintenance by a trained and certified Alfa Laval Toftejorg SaniJet 25 service engineers.
Warning:
Alfa Laval offers education of you service engineer(s) for your maintenance of the Alfa Laval Toftejorg SaniJet 25
using the special maintenance tools, teaching how to maintain the Alfa Laval Toftejorg SaniJet 25 and its hygienic
state and how to test the Alfa Laval Toftejorg SaniJet 25 after maintenance.
If the Alfa Laval Toftejorg SaniJet 25 stops rotating unintentionally within the warranty period, please return the machine to Alfa
Laval Kolding A/S. Please do not try to fix any mechanical problems before shipping.
You will find the information contained in this manual 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 and serial number with
all your enquiries; this will help us to help you. The type and serial number are placed on the body of the tank cleaning machine.
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 the ATEX certification (page
15) 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.
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3 Introduction
ESE01842
3.2 Intended Use
It is to be verified by the end-user:
- the Alfa Laval Toftejorg SaniJet 25 tank cleaning machine is in conformity with respect to tank -, vessel - or container
size in which it intended to be used.
- the constructions materials (both metallic and non-metallic) are compatible with product, flushing media, cleaning media,
temperatures and pressure under the intended use.
To ensure the self cleanability and drainability the machine must be installed in vertical position
3.3 Patents and Trademarks
This Instruction Manual is published by Alfa Laval Kolding A/S without any warranty. Improvements and changes to this Instruction
Manual may at any time be made by Alfa Laval Kolding A/S 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" and “SaniJet” are trade-
marks or registered trademarks of Alfa Laval Kolding A/S. The Toftejorg™ SaniJet™ 25 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 (200600176 & 200600177 &
200700902). Other products or company names mentioned herein may be the trademarks of their respective owners. Any rights
not expressly granted herein are reserved.
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3 Introduction
ESE01842
3.4 Marking
or
A
4107-0053
A: Marking area
Serial number explanation
Machines supplied with or without normal documentation:
yyyy-xxxxx: serial number
yyyy: year
xxxxx: 5 digit sequential number
Serial number explanation
Machines supplied with or without normal documentation:
yyyy-FAT-SAT-xxx: serial number
yyyy: year
xxx: 3 digit sequential number
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3 Introduction
ESE01842
3.5 ATEX Marking
The Alfa Laval Toftejorg SaniJet 25 is certified as category I components. The certification is carried out by the notified body SGS
Baseefa, who has issued the certificate no. 04ATEX0358X. The marking on the ATEX certified Alfa Laval Toftejorg SaniJet 25
is as follows (see previous page for position of marking):
Serial number explanation
Machines supplied with or without normal documentation:
yyyy-xxxxx: serial number
yyyy: year
xxxxx: 5 digit sequential number
Serial number explanation
Machines supplied with or without normal documentation:
yyyy-FAT-SAT-xxx: serial number
yyyy: year
xxx: 3 digit sequential number
Changes to the machine are not allowed without approval by the person responsible for the ATEX certification at Alfa Laval
Kolding 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 “Maintenance” page 18 regarding special conditions for repair of ATEX certified machines.
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4 Installation
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4.1 General description
The Alfa Laval Toftejorg SaniJet 25 is a media driven and media lubricated tank cleaning machine. No lubricating substances
such as oil, grease etc. are used. All materials complies with FDA 21CFR§177 and for polymers also EU 10/2011, which makes
the SaniJet 25 suited for sanitary and hygienic applications such as Food and Pharmaceutical industries. The machine is self-
cleaning; i.e. all internal and external surfaces are cleanable, drainable and sterilizable.
The Alfa Laval Toftejorg SaniJet 25 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 a vertical position, the Alfa Laval Toftejorg SaniJet 25 is proven completely
self-cleaning by the EHEDG test method and self-draining. Using the Sanitary welding connection between down pipe and
machine provides a self cleanable connection. All product contact surfaces are AISI 316L, duplex SAF 2205 stainless steel or
FDA compliant polymer materials.
No exposed threads or screws are present in the product contact areas.
The Alfa Laval Toftejorg SaniJet 25 is designed for use in pharmaceutical, biotechnology, food and dairy processing applications.
Recommended for use in tanks and vessels between 0.5-30 m3(130-8,000 US gallons) for larger tanks multiple units may be
used.
4.2 Quality system
The SaniJet 25 is designed in accordance with the EHEDG design guidelines for sanitary design of processing equipment and is
the first ever rotating jet head that has been awarded the certificate of compliance from EHEDG, showing that the machine has
passed the EHEDG test (Doc. 2) for cleanability. In addition the machine is proven to be sterilizable based on EHEDG test (Doc.
5). 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 compliant materials and also available as USP Class
VI materials. All materials has full traceability according to EU1935/2004/EC.
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4 Installation
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4.3 Functionality
The cleaning fluid passing through the machine passes through a turbine, which accordingly is set into rotation. The turbine
rotation is transmitted through a set of gears and drive shaft to the machine body and the hub cover with nozzles.
The combined rotation of the machine body and the nozzles ensure a fully indexed tank cleaning coverage as illustrated below
for a spherical tank with the machine placed in the centre. For light soiling only 1 cycle could be sufficient and for heavier soiling
a full pattern (8 cycles) may be needed. One cycle provides a coarse pattern and is build from 55/8 revolutions of the hub
cover with nozzles; corresponding to 53/8 revolutions of the machine body. During the following cycles, this coarse pattern is
repeated 7 times, each coarse pattern displaced slightly. Hence, the pattern gradually becomes denser. Finally, after 8 cycles
(a total of 45 revolutions of the hub cover with nozzles and 43 revolutions of the machine body), a complete cleaning pattern
has been laid out, and the pattern starts over from the original starting point.
First cycleFull pattern
The number of cycles needed to perform a proper cleaning depends on type of soil, distance between tank cleaning machine
and tank wall, cleaning procedure and cleaning agent. For residues that are easily mobilized, i.e. easy to remove, one cycle could
be sufficient. Heavier soiling (high viscous, sticky substances, etc.) requires more cycles (a denser pattern).
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 the wide range of flow rates, the machine has different turbines according
to the nozzle size.
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4 Installation
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Self-cleaning is ensured by flushing the planet gear, the hub, the bevel gear, the nozzle
head, the nozzles and the ball bearings with the CIP liquid. Furthermore, all gaps
between moving parts are flushed with CIP liquid and finally also the outside surfaces
of the machine is cleaned with the main flow of CIP liquid. In the bottom of the body,
the machine is equipped with a hole to ensure self-draining. This self-draining is only
ensured, if the machine is installed in vertical position and the drain hole in not blocked.
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, comes as standard with the machine.
A: Downpipe
B: Welding Adapter
C: Seal PTFE
D: Seal EPDM
TD523518
TD523517
A
B
D
C
E
E: SaniJet 25
4.4 General Safety and Installation Instructions
The Alfa Laval Toftejorg SaniJet 25 tank cleaning machine should be installed in vertical upright position with the connections
pointing upward. Failure to do so means that the Alfa Laval Toftejorg SaniJet 25 is no longer gravity drainable (influences
cleanability and increases risk of corrosion) and the maintenance intervalsmaybeshortened.
It is recommended that the cleaning fluid supply line is equipped with a filter that traps solids with a particle size of 250µm
(0.01”) or smaller. Avoid solid particles, to minimize wear and unscheduled maintenance as particles can be caught in one of
the internal passages of the machine and cause it to stop rotating.
In order to separate 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 gravity 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 SaniJet 25 and/or the entire installation. Ideally, a frequency controlled pump with a ramp function for
start-up is used for supply of cleaning liquid.
Before connecting the machine to the system, all supply lines and valves should be flushed in order to remove foreign
objects.
During handling and installation handle the machine with care in order not to damage surfaces of the machine.
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4 Installation
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The Alfa Laval Toftejorg SaniJet 25 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 (Pos. 1) 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.
Connect the welding adaptor to the supply line. Screw the machine tightly onto the welding adaptor using a 36 mm flat jawed
spanner (tool No. TE81B159) on the flats machined on the inlet cone.
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.
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-Machinery 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.
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.
Warning:
ALWAYS use the welding adaptor included with the machine to connect the machine to the down-pipe. Otherwise the
hygienic state of the installation is compromised. The welding adaptor’s one end is welded onto the downpipe (weld must be
of a hygienic quality following e.g. EHEDG guideline nr. 35 or 3-A recommendations of using AWS/ANSI D18.1)
Subjected to the environment of intended use and any in-house user requirements or policies adhesive such as Loctite No.
243 or equivalent could be used. Other methods could be acceptable and subject to customer preference.
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 IEC/TS 60079-32-1:2013, guidance and recommendations for the avoidance of hazards
due to static electricity.
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4 Installation
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4.5 Specific Conditions for Safe Use in accordance with ATEX Certification
In accordance with the ATEX Certification, Directive 2014/34/EU the following special conditions shall be obeyed.
ATEX warning: The unit may be operated, in a hazardous area, only when filled with the process fluid.
ATEX warning: If a medium other than the process fluid is passed through the equipment the flow must not be high enough
to cause the equipment to operate. If this cannot be avoided the rotor must be removed or secured to
prevent rotation.
ATEX warning: Working temperature max.
The maximum permitted process fluid temperature and ambient temperature when the machine is operating
is 95°C.
Ambient temperature:
When the machine is not operating, the maximum permitted ambient temperature is 140°C.
ATEX warning: The maximum permitted process fluid working pressure is 8 bar.
ATEX warning: The unit must not be operated in a vessel having an enclosed volume of greater than 100 m³.
Tanks larger than 100 m³:
To use Tank Cleaning Machines 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
rules are described in the guide "IEC/TS 60079-32-1:2013“.
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 certification for this product.
ATEX warning: The unit must be effectively earthed at all times when in use.
ATEX warning: 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.
In addition to the above mentioned precautions relating to the ATEX guidelines Directive 2014/34/EU, the Safety Precautions on
page 13 must be observed.
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5Operation
ESE01842
5.1 Normal operation
Cleaning Media
Use only cleaning fluids, which are compatible with Stainless Steel AISI 316L, SAF2205, PEEK, PFA HP, PTFE and EPDM.
Normal detergents, moderate solutions of acids and alkalics are acceptable as well as a number of solvents at ambient
temperature during cleaning. Aggressive chemicals, excessive concentrations of chemicalsatelevatedtemperaturesaswellas
certain solvents and hydrochlorides should be avoided. If you are in doubt, contact your local Alfa Laval sales office.
Note: Please note that PEEK is not resistant to concentrated sulfuric acid.
Product
In cases where the machine is in submerged in, or in other ways exposed to, product the compatibility between stainless steel
AISI 316L, SAF 2205, PEEK, PFA and EPDM and the product must be considered carefully.
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 may increase consumption of wear parts. Too high pressure will also
reduce the cleaning effect.
ATEX warning: Steam cleaning pressure
If steam cleaning is done through the machine, the steam pressure must not cause the machine to rotate.
ATEX warning: Draining
If the machine is drained using compressed air, then the compressed air pressure must not cause the
machine to rotate.
After-use cleaning
After use flush the machine with fresh water. Cleaning media should never be allowed 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.
Temperature
The maximum recommended process fluid temperature is 90°C. The recommended ambient temperature range is 0°C to
140°C. For higher ambient temperatures the machine can be fitted with gasket of compatible material.
In accordance with the ATEX specifications regarding special conditions for safe use, see page 15.
ATEX warning: Atmosphere/surface temperature
In potentially explosive atmospheres, the temperature must not exceed the maximum surface temperature
according to the temperature class for the combustible gas or liquid.
ATEX warning: Steam cleaning
Tanks with capacities greater than 100 m3that could contain a flammable atmosphere should not be steam
cleaned, as steam issuing from a nozzle could contain charged droplets.
Tanks smaller than this may be steam cleaned providing that: the steam nozzles and other metal parts of
the system are reliably earthed and grounded to the tank structure.
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5Operation
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5.2 Safety Precautions
The machine is intended for use inside a tank only. As peak velocity of main jets reaches 40 m/s, Alfa Laval Toftejorg SaniJet 25
must not be operated in open air or when tank is open.
ATEX 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.
ATEX warning: In case potentially explosive liquids are used, precautions should be taken against incidental creation of an
explosive mixture with oxygen in the tank atmosphere.
ATEX 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.
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6 Maintenance
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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 6.4 Maintenance Intervals and
Service Kits on page 20 of this manual or the Spare Parts Manual.
Note: Handle the Alfa Laval Toftejorg SaniJet 25 with care. Take proper action to protect surfaces from being damaged.
Always use proper tools and the Alfa Laval Toftejorg SaniJet 25 standard tool kit (page 31). 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.
6.2 Service and Repair of ATEX Certified Machines
All service and repair of ATEX certified machines can be performed by Alfa Laval Tank Equipment, Kolding, Denmark or by an
Alfa Laval service center approved by Alfa Laval Tank Equipment.
In order to ensure compliance with the ATEX regulations and keep the machine ATEX certification valid the service
or repair must be performed by an authorized person with knowledge of the ATEX 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 the related manual.
ATEX
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 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 ensuring the retention of the
ATEX certification of the machine.
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6 Maintenance
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6.3 Service and repair of machines ordered with Q-doc and with Q-doc + FAT-SAT
In order to ensure full traceability and to obtain full qualification and validation documentation, all service and repair of machines
ordered with Q-doc (Equipment Documentation) and Q-doc + FAT-SAT (Qualification Documentation) should be handled
and ordered in one of the 3 different ways described below:
1. Q-doc + FAT-SAT Service/Repair Order (Item no. TEREP-Qdoc):
(This maintenance order should be selected if the customer wishes to have Alfa Laval Tank Equipment to obtain full file
log of all FAT (Factory Acceptance Test) documents for the Tank Cleaning Machine).
-Maintenance/Repair is carried out at Alfa Laval Tank Equipment and Q-doc + FAT-SAT Maintenance Log.
FAT-SURFACE (if necessary), FAT-WELD (if necessary) and FAT-PERFORMANCE is performed. The FAT documents
are stored in the Q-doc + FAT-SAT Maintenance Log as PDF-files.
-Q-doc (Equipment Documentation) for all steel spare parts are stored in the Q-doc + FAT-SAT Maintenance Log
as PDF-files.
-The machine is returned to the customer incl. the Q-doc + FAT-SAT Log CD and hardcopy of all FAT documents, for
further qualification (SAT: Site Acceptance Test) and validation (PV: Process Validation).
-Word and PDF documents are stored in the Alfa Laval Q-doc + FAT-SAT Maintenance Log folder.
2. Q-doc Spare Part Order (Item no.: TE20JXXX-9X)
(This maintenance order should be selected if the customer wishes to carry out service or repair. The customer or
the repair shop thus carries the full responsibility for the full traceability of the material and FAT documentation
for the Tank Cleaning Machine).
-The spare part is sent to the customer incl. Q-doc (Equipment Documentation) as hardcopy.
3. Q-doc + FAT-SAT Spare Part Order (Item no. TE20JXXX-5X)
(This maintenance order should be selected if the customer wishes to carry out service or repair himself. The customer
or the repair shop thus carries the full responsibility for the full traceability of the material and FAT documentation
for the Tank Cleaning Machine).
-The spare part is sent to the customer incl. Q-doc (Equipment Documentation) incl. Weld-Log documentation (if
necessary) as hardcopy.
-This service information will not be recorded in the Alfa Laval Q-doc + FAT-SAT folder. The customer has to perform all
Qualification tests and documentation himself (FAT, SAT, IQ & OQ).
Contact local Alfa Laval service and support (see. www.alfalaval.com). Important information to give to Alfa Laval:
-Serial No.
-Q-doc maintenance order type:
-Item no.: TEREP-Qdoc
-Item no.: TE20JXXX-9X
or
-Item no.: TE20JXXX-5X (see page 26 for more information)
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6 Maintenance
ESE01842
6.4 Maintenance Intervals and Service Kits
Alfa Laval Service Kits for Tank Cleaning Machine type Alfa Laval Toftejorg SaniJet 25 available in three levels: Inspection
Kit, Minor Service Kit and Major Service Kit.
Service Intervals
200 hours
1 year
200 hours
1 year
200 hours
1 year
200 hours
1 year
200 hours
1 year
>Continues
Inspection Kit
TE20J297 or
TE20J29701
Minor Service Kit
TE20J298 or
TE20J29801
Inspection Kit
TE20J297 or
TE20J2901
Major Service Kit
TE20J299 or
TE20J29901
Inspection Kit
TE20J297 or
TE20J29701
It is recommended to inspect the Alfa Laval Toftejorg SaniJet 25 after every 200 running hours or after 1 year to ensure the
conditions of the machine is acceptable. During the inspection it is recommended that the inspection kit is used in order not to
compromise the hygienic state of the machine.
Major Service kit includes the corresponding Minor Service Kit parts and the Minor Service Kit includes the corresponding
Inspection Kit parts.
TE20J297 and TE20J297-01 Inspection Kit f. Alfa Laval Toftejorg SaniJet 25
P/n
(20J000_004-0x/7x)
P/n
(20J000_004-5x/6x/8x/9x)
Pos. TE20J297 TE20J29701 Qty Denomination
2 TE51T212 TE51T212 1 Gasket
3.3 TE51T135 TE51T135 2 O-ring
6 TE51T138 TE51T194 1 O-ring
7 TE51T139 TE51T139 1 O-ring
9 TE51T141 TE51T196 2 O-ring
10 TE51T140 TE51T195 2 O-ring
16 TE51T136 TE51T192 1 O-ring
17 TE51T137 TE51T193 1 O-ring
19.2 TE52D561 TE52D561 1 Gasket
Inspection Kit is recommended to be replaced every 200 working hours or every year, whichever comes first.
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