Alfalaval Toftejorg TJ20G User manual

Instruction Manual
Alfa Laval Toftejorg
T
M
TJ20G
IM-TE91A600-EN6
ESE01794EN
Date of issue: May 8, 2014
First published: June 2000
With
Standard
Distillery
Secured
High temp
Hastelloy
3.1 Inspection Certificate – EN10204
ATEX Certification in accordance with Directive 94/9/EC
Original manual
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Contents
Toftejorg TJ20G, Product Program ...........................................................................3
Introduction................................................................................................................5
Marking......................................................................................................................6
Serial number explanation..................................................................................................6
ATEX Marking ...........................................................................................................6
Serial number explanation..................................................................................................7
Intended use..............................................................................................................8
Patents and trademarks ............................................................................................8
General Description...................................................................................................9
Quality system ...........................................................................................................9
Functionality...............................................................................................................9
Technical Data.........................................................................................................11
Dimensions.......................................................................................................................11
Performance Data.............................................................................................................12
Installation
Installation Manual – Contents ................................................................................13
General Installation Instructions ..............................................................................14
Special Conditions for Safe Use – ATEX ................................................................16
Operation
Operational Manual - Contents................................................................................19
Operation.................................................................................................................20
Cleaning Media.................................................................................................................20
Product .............................................................................................................................20
Pressure ...........................................................................................................................20
Temperature.....................................................................................................................20
After Use Cleaning............................................................................................................21
Safety Precautions............................................................................................................22
Maintenance
Maintenance Manual – Contents.............................................................................23
Preventive Maintenance Guidelines........................................................................24
Service and Repair of ATEX approved machines...................................................25
Maintenance intervals and Service Kits selection....................................................26
Minor Service Kit for Toftejorg™ TJ20G...........................................................................27
Major Service Kit for Toftejorg™ TJ20G...........................................................................28
Available add-on´s for Spare parts...................................................................................29
General recommendations ...............................................................................................29
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Assembly drawing....................................................................................................30
Reference list of parts..............................................................................................31
Toftejorg™ TJ20G, TE20G000_024 + TE20G050_054 (except TE20G010-TE20G018).31
Toftejorg™ TJ20G, TE20G010_014.................................................................................32
Toftejorg™ TJ20G, TE20G016_018.................................................................................33
Toftejorg™ TJ20G, TE20G030_044.................................................................................34
Toftejorg™ TJ20G, TE20HXXX........................................................................................35
Toolkit and tools for assembly and disassembly.....................................................36
Standard Tool Kit for Toftejorg™ TJ20G ..........................................................................36
Torque Wrench Tool Kit for Toftejorg™ TJ20G................................................................36
Disassembly ............................................................................................................37
Assembly.................................................................................................................39
Replacement of Ball Races ..............................................................................................41
Trouble Shooting Guide...........................................................................................42
Symptom: Loose Nozzle Hub ...........................................................................................42
Symptom: Slow rotation or failure of machine to rotate....................................................42
Symptom: Slow rotation or failure of machine to rotate (continued).................................43
How to Order Spare Parts .......................................................................................44
How to contact Alfa Laval Tank Equipment.............................................................44
Miscellaneous
Misc. - Contents.......................................................................................................45
EU Declaration of Conformity incl. ATEX ................................................................46
Declaration of Conformity, EN 10474, sub clause 2.2 Test Report.........................47
ATEX-Special Conditions for safe use ....................................................................49
Declaration of Complaince with 10/2011 – Food contact materials.........................50
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Toftejorg TJ20G, Product Program
This manual covers the product program for ToftejorgTM TJ20G tank cleaning machine
Toftejorg™ TJ20G options
Connection
Nozzles
(mm)
Standard
Article No.
Distillery
Article no.
Hastelloy
Article no.
Secured
Article no.
High temp.
Article no.
1" BSP
Female 4 x ø3.9 4 x ø4.6
4 x ø5.5
TE20G000-xx
TE20G002-xx
TE20G004-xx
TE20G030-xx
TE20G032-xx
TE20G034-xx
TE20H000(-x0)
TE20H002(-x0)
TE20H004(-x0)
TE20G010-xx
TE20G012-xx
TE20G014-xx
TE20G016-x2
TE20G017-x2
TE20G018-x2
1" NPT
Female 4 x ø3.9 4 x ø4.6
4 x ø5.5
TE20G020-xx
TE20G022-xx
TE20G024-xx
TE20G040-xx
TE20G042-xx
TE20G044-xx
TE20H020(-x0)
TE20H022(-x0)
TE20H024(-x0)
1" BSP
Female
Sanitary*
4 x ø3.9
4 x ø4.6
4 x ø5.5
TE20G050-xx
TE20G052-xx
TE20G054-xx
TE20H050(-x0)
TE20H052(-x0)
TE20H054(-x0)
*see below for choices of sanitary welding connectors
Index no.:
TE20GXXX (no postfix): version w. PVDF impeller
TE20GXXX-X2: version w. PEEK impeller
TE20HXXX (no postfix): Hastelloy version w. PEEK impeller
Available documentation add-on’s
TE20XXXX-7X: ATEX
TE20XXXX-8X: 3.1 cert. + ATEX
TE20XXXX-9X: 3.1 cert
Explanation to Add-on’s:
3.1 certificate: Declaration of Compliance according to EN 10204 type 3.1 inspection Certificate
ATEX includes:
For TE20X000_054 except TE20G016_018:
ATEX approved machine for use in explosive atmospheres. Category 1 for installation in zone 0/20
in accordance to Directive 94/9/EC. Ex II 1 GD c T140°C.
For TE20G016_018:
ATEX approved machine for use in explosive atmospheres. Category 1 for installation in zone 0/20
in accordance to Directive 94/9/EC. Ex II 1 GD c T250°C Tamb 0°C to +200°C.
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Toftejorg TJ20G, Product Program
Page 4 Instruction Manual, Alfa Laval Toftejorg TJ20G
Standard machines and machines delivered with ATEX certification
in accordance with Directive 94/9/EC
IM-TE91A600_EN6
Available welding connection
Welding adapter (see right) with sealing assembly between Down pipe,
Welding adapter and machine.
Welding connections are ordered separately.
For use with sanitary connection cones use cone with seal (seals are
included for machines with sanitary cone).
Standard cone
Pipe Dimension in mm Connection Thread Article no.
1“ ISO thread pipe: ø33.7 x 3.25 1” BSP TE52D030
1“ ANSI Sch.40S: ø33.4 x 3.38 1” NPT TE52D031
1 ½” ISO Dairy pipe: ø38 x 1.2 1” BSP TE52D032
Sanitary connection cone
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Introduction
With a new revolutionary patented design, the Toftejorg™ TJ20G introduces a new generation of tank
cleaning machines.
Based on more than 30 years’ experience from practical tank cleaning and production, the 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 the persons who will be operating and maintaining your
tank cleaning machine. The key to long life for your tank cleaning machine is always a system of
carefully planned maintenance; you will appreciate that a tank cleaning machine that has a rough and
dirty job to do, needs more frequent attention than one working in ideal conditions.
Warning:
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.
If the TJ20G 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.
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Marking
Alfa Laval tank cleaning machines are all marked to allow recognition of machine type, machine name,
Serial number and manufacturing address. The marking are placed on the body of the tank cleaning
machine.
Serial number explanation
Machines supplied with or without normal
documentation:
yyyy-xxxxx: serial number
yyyy: year
xxxxx: 5 digit sequential number
Note: The illustrations and specifications contained in this manual were effective at the date of printing.
However, as continuous improvements are part of our policy, we reserve the right to alter or modify any
unit specification on any product without prior notice or any obligation.
ATEX Marking
The Toftejorg™ TJ20G is certified as category I component. The certification is carried out by the
certified body Baseefa, who has issued the certificate no. 04ATEX0358X. The marking on the ATEX
certified Toftejorg™ TJ20G is as follows:
Note:
TE20G016-72, TE20G017-72 and TE20G018-72
TE20G016-82, TE20G017-82 and TE20G018-82.
These machines has a special ATEX text for the “Ex” line.
Next to the “Ex” symbol this text shall be present:
II 1 GD c T250°C Tamb 0°C to +200°C
Marking
area
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Serial number explanation
Machines supplied with or without normal documentation:
yyyy-xxxxx: serial number
yyyy: year
xxxxx: 5 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 page 25
regarding special conditions for repair of ATEX certified
machines.
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Intended use
It is to be verified by the end-user that
•the TJ20G tank cleaning machine is in conformity with respect to tank -, vessel - or container
size in which it intended to be used.
•the construction 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
Warning: Before installation and operation of the tank cleaning machine carefully read the
General Installation Instructions (page 14), the special conditions for safe use in
accordance with ATEX Certification, Directive 94/9/EC (page 16) and the Safety
Precautions (page 22
) and take all necessary precautions according to your
application and local regulations.
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" is a trademark or registered trademark of Alfa Laval Kolding A/S. The 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
© 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.
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