Alfalaval Toftejorg TZ-89 User manual

Covering:
Standard Machines
TE91A500-EN6
First published: 1989
ESE01837-EN6 2016-02
Original manual
Instruction Manual
Alfa Laval Toftejorg™ TZ-89

Table of contents
The information herein is correct at the time of issue but may be subject to change without prior notice
1. EC Declaration of Conformity ....................................................................... 4
2. Safety .................................................................................................... 5
2.1. Important information ............................................................................. 5
2.2. Warning signs ..................................................................................... 5
3. Introduction ............................................................................................ 6
3.1. Introduction ........................................................................................ 6
3.2. Intended Use ...................................................................................... 7
3.3. Patents and Trademarks ......................................................................... 7
3.4. Quality System .................................................................................... 7
4. Installation .............................................................................................. 8
4.1. Functioning ........................................................................................ 8
4.2. General Safety and Installation Instructions .................................................... 9
5. Operation ............................................................................................... 10
5.1. Normal operation ................................................................................. 10
6. Maintenance and Repair ............................................................................. 11
6.1. Preventive Maintenance .......................................................................... 11
6.2. Main Assembly .................................................................................... 12
6.3. Gear Unit .......................................................................................... 14
6.4. Cleaner Head ...................................................................................... 16
7. Trouble Shooting Guide .............................................................................. 18
8. Technical Data ......................................................................................... 19
9. Product Programme .................................................................................. 23
9.1. Standard Configurations ......................................................................... 23
10. Parts Lists, Service Kits and Tools ................................................................. 24
10.1.Reference list of parts, TZ-89 .................................................................... 24
10.2.Reference list of parts, TZ-89LF ................................................................. 25
10.3.Exploded view drawing, TZ-89 & TZ-89LF ..................................................... 26
10.4.Spare part kits, service kits and Tools .......................................................... 27
11. General information ................................................................................... 29
11.1.Service and Repair ............................................................................... 29
11.2.How to Order Spare Parts ....................................................................... 29
11.3.How to contact Alfa Laval Tank Equipment .................................................... 29
3

1 EC 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 TZ-89
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 12100:2010
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
The person authorised to compile the technical file is the signer of this document
Global Product Quality Manager
Pumps, Valves, Fittings and Tank Equipment Lars Kruse Andersen
Title Name Signature
Kolding 2016-02-01
Place Date
(This Declaration of Conformity replaces Declaration of Conformity dated 2015-11-01)
4

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 warning:
5

3 Introduction
3.1 Introduction
This manual has been prepared as a guide for installing, operating and maintaining your Alfa Laval Toftejorg tank cleaning
machine. Should you require further assistance, our Technical Sales Support department and worldwide net of sales offices will
be pleased to help you. Please quote the type, article and serial numbers with all of your enquiries; this helps us to help you.
The type and serial number are placed on the gear house of the tank cleaning machine.
TD523393
Important
information:
Before installing the machine and setting it into operation, carefully read the General Safety and Installation
Instructions (page9) 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.
© 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.
6

3 Introduction
3.2 Intended Use
The end-user should verify:
- that the tank cleaning machine is in conformity with respect to tank, vessel or container size in which it is used.
- that the construction materials (both metallic and non-metallic) are compatibility with product, flushing media, cleaning
media, temperatures and pressure under the intended use.
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" is a trademark or
registered trademark of Alfa Laval Kolding 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.
3.4 Quality System
The Alfa Laval Toftejorg tank cleaning machines are produced according to Alfa Laval Kolding’s ISO 9001 International
Standard certified quality system.
7

4 Installation
The Alfa Laval Toftejorg TZ-89 is a media driven and media lubricated tank cleaning machine. No lubricating substances such
as oil or grease are used. All materials are selected for contact with food.
4.1 Functioning
The flow of the cleaning fluid passes through a guide and a turbine, which
accordingly is set into rotation. Through a gear set and a driver tube, the turbine
rotation is transmitted to the Cleaner Head.
The 90°Angle gear in the Cleaner Head transmits the rotation from the gear
unit to a horizontal rotation of the Cleaner Head body and a vertical rotation of
theNozzlehead.
The combined motion of the Cleaner head and the Nozzle head ensures a fully
indexed tank cleaning coverage. After 5 1/8 (for 2 nozzle version: 10 1/4)
revolutions of the Nozzle head, corresponding to 4 7/8 (for 2 nozzle version: 9
3/4) revolutions of the cleaner head, a coarse cleaning pattern is laid out on the
tank surface and the first cycle has been made. During the following cycles, this
pattern is repeated 7 (for 2 nozzle version: 3) times, each of which is displaced
and the pattern gradually becomes more dense. After 8 (for 2 nozzle version: 4)
cycles - a total of 41 revolutions of the Nozzle head (39 revolutions of the Cleaner
head), a complete cleaning pattern has been laid out, and the first pattern is
repeated.
A complete cleaning pattern is illustrated below for a square tank with the
machine placed in the centre:
First cycle complete pattern
TD523384
8

4 Installation
4.2 General Safety and Installation Instructions
The Alfa Laval Toftejorg TZ-89 is designed to be installed in a vertical upright position, however, the machine can operate
horizontally or in any desired angle position.
The machine is equipped with a sliding and locking type flange connection, permitting to adjust the protruding of the
cleaning head into the tank from 65 - 766 mm for the standard configuration. For the optional lengths, the max. protuding
varies with the length.
It is recommended to install a filter with mesh size 250 μm (0,01") in the supply line in order to avoid particles, scale, etc. from
clogging inside the machine. It is essential to avoid fine solid particles, such as fine sand, in the cleaning fluid as they will
increase wear considerably. This is particular important in case of recirculation.
It is recommended that the fluid valve fitted is of a type that prevents hydraulic shocks, which may cause severe damage to
the entire installation.
Before installation, all supply lines and valves must be flushed to remove remains of welding electrodes, grinding dust, scale
and other foreign matter.
Note: Do not try to turn Nozzle head by hand, since this will damage the Gear. Nozzle head can be turned by blowing air
from an air pistol through the inlet connection.
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 fulfil the EU-machine Directive
and depending of application, the EU-Pressure Equipment Directive and other relevant Directives and shall be CE-marked
before it is set into operation.
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. In addition, connecting pipe work, must be electrically
conductive and earthed to the tank structure. This is essential to avoid the build-up of static electricity on
the machine.
9

5Operation
5.1 Normal operation
Pressure
In order to protect the machine, your pipe and valve installation, etc. against damage:
Avoid hydraulic shocks! Put on pressure gradually!
Recommended working pressure: 3 - 6 bar (44 - 87 psi). Too high pressure will increase consumption of wear parts.
Cleaning Media
Use only cleaning fluids, which are compatible with Stainless Steel AISI 316/316L, SAF2205, FEP/Silicone, PEEK and PTFE.
Please note that PEEK is not resistant to concentrated sulfuric acid. Normal detergents, moderate solutions of acids and
alkalics are acceptable as well as a number of solvents at ambient temperature during cleaning. Use instead the special version
with PEEK Guide and Turbine wheel. Aggressive chemicals, excessive concentrations of chemicals at elevated temperatures as
well as certain dissolvents and hydrochlorides should be avoided. If you are in doubt, contact your local Alfa Laval sales office.
After Use Cleaning
Cleaning solutions must never be allowed to dry out in the machine, due to possible "salting out" or "scaling" of the cleaning
ingredient. Therefore, the machine should always be flushed with fresh water after it has been used. The machine is self-draining.
10

6 Maintenance and Repair
6.1 Preventive Maintenance
In order to keep your tank cleaning machine servicing you as an efficient tool in your tank cleaning operations, it is essential to
maintain its high performance by following a simple preventive maintenance programme, which will always 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.
However, 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. We trust that you will adjust your maintenance programme to suit.
Recommended Preventive Maintenance
Every 300 working hours
1. Disassemble machine as described on the following pages.
2. Clean material build-up and deposits from internal parts with Scotch-brite, S-Ultrafine, eventually chemical cleaner and
fine abrasive cloth.
3. Special attention must be directed to the wear parts. To check which parts that are wear parts, please see Reference Lists of
Parts, page 24 and 25. Replace worn or damaged parts.
4. When holding components in a vice, use lead or aluminium jaws or jaws made from other soft material. If it is necessary to
knock any components, use a plastic hammer.
5. Never place parts directly on dirty floors or tables. Always place the parts on a piece of cloth, cardboard, etc.
6. Always perform all assembly/disassembly steps in the order described in this manual. Never assemble components without
previous cleaning. Work in a well-lighted work area.
Note: Recommended tightening torque for all screws: 4-5 Nm.
11

6 Maintenance and Repair
6.2 Main Assembly
Important: The Cleaner head must never be unscrewed before the Gear unit has been taken out
Dismantling
1. Remove Screws (pos. 1). Lift off Inlet connection (pos. 2)
2. Lift off Guide (pos. 3) and remove O-ring (pos. 4)
3. Unscrew Gear house (pos. 5). Lift off the complete Gear unit (pos. 7) and remove O-ring (pos. 6)
4. Lift out the Driver tube (pos. 12). Unscrew Cleaner head (pos. 16) with a hook-spanner
5. After unscrewing the Pointed screw (pos. 13.2), unscrew Tank Connection (pos. 14) by turning Flange guide (pos. 13)
and holding (pos.14)
6. Remove (pos. 14), Flange guide (pos. 13) and O-ring (pos. 15)
7. Remove screws (pos. 1), take off Gear house lower part (pos. 8) and O-ring (pos. 4)
For normal inspection and repair only steps 4.-7. are necessary.
Reassembling
1. Place the O-ring (pos. 4) in the O-ring groove on Gear house lower part (pos. 8). Mount Gear house lower part on Centre
tube (pos. 11)
2. Mount Screws (pos. 1) and tighten crosswise.
3. Slide on Flange guide (pos. 13), O-ring (pos. 15), and Tank connection (pos. 14) to Centre Tube (pos. 11). Connect Flange
guide and Flange, and tighten. Tighten the Pointed screw (pos. 13.2).
4. Insert Driver tube (pos. 12) in Centre tube (pos. 11). Connect Driver tube and Cleaner head (pos. 16), screw on Cleaner
head and tighten with hook spanner.
5. Mount Gear unit (pos. 7). Make sure that Tubular rivet meshes into slot in Driver tube.
6. Place O-ring (pos. 6), mount Gear house (pos. 5) and tighten O-ring (pos. 4), Guide (pos. 3) and Inlet Connection (pos. 2).
7. Mount Screws (pos. 1) and tighten crosswise.
12

6 Maintenance and Repair
Main Assembly
TD523390
13

6 Maintenance and Repair
6.3 Gear Unit
Dismantling
1. Screw off Turbine shaft (pos. 7.1) and take off Turbine wheel (pos. 7.2)
2. Unscrew Screw (pos. 7.3) and lift off Transverse (pos. 7.4)
3. Remove Distance bush (pos. 7.5), Gear wheel (pos. 7.6) and Gear wheel (pos. 7.7)
4. Unscrew the Screws (pos. 7.13) and lift off Gear frame (pos. 7.14)
5. Carefully knock out Tubular Rivet (pos. 7.12)
6. Take off the Circlip (pos. 7.16)
7. Push out Drive shaft (pos. 7.11) with Bearing bush (pos. 7.10) and Traction wheel (pos. 7.9)
8. Unscrew Traction wheel (pos. 7.9) Note: Left hand thread and remove Bearing bush (pos. 7.10)
Reassembling
1. Place Bearing bush (pos. 7.10) on Drive shaft (pos. 7.11) and screw on Traction wheel (pos. 7.9) (Left hand thread).
2. Mount the assembled Drive shaft in Bearing plate (pos. 7.15)
3. Mount the Circlip (pos. 7.16) on the Bearing bush (pos. 7.10)
4. Mount Tubular Rivet (pos. 7.12)
5. Mount Gear frame (pos. 7.14) and secure with Screws (pos. 7.13)
6. Mount Distance bush (pos. 7.5) on the one shaft and Stainless Steel Gear wheel (pos. 7.7) on the other (N/A in Alfa Laval
Toftejorg TZ-89L). Mount Gear wheels (pos. 7.6)
7. Mount Transverse (pos. 7.4) and secure with Screw (pos. 7.3), while holding Transverse.
8. Mount Turbine wheel (pos. 7.2) and Turbine shaft (pos. 7.1). Tighten Turbine shaft with a screwdriver.
14

6 Maintenance and Repair
Gear Unit
TD523391
15

6 Maintenance and Repair
6.4 Cleaner Head
Dismantling
1. Knock out Tubular Rivet (pos. 16.12)
2. Unscrew the Nozzle head (pos. 16.11) with Nozzles (pos. 16.10). Insert a screwdriver inside the shaft for Cleaner Head (pos.
16.18) into hole in Rotor (pos. 16.17), turn the Nozzle Head (pos. 16.11) anti-clockwise.
3. Remove Circlip (pos. 16.1)
4. Remove Bearing washer (pos. 16.2). Take out the Balls (pos. 16.3)
5. Lift off Stator (pos. 16.6) including the Bearing washer (pos. 16.4) and the Bush for stator (pos. 16.5)
6. Withdraw the Bearing washer (pos. 16.4) and the Bush for stator (pos. 16.5)
7. Lift off Sleeve (pos. 16.8). Remove the two Bushes (pos. 16.7)
8. Unscrew Screw (pos. 16.13), remove Spring washer (pos. 16.14) and Washer (pos. 16.15). Insert a screwdriver inside the
shaft for Cleaner head (pos. 16.18) into hole in Rotor (pos. 16.17) to avoid rotation of Rotor. Remove Rotor (pos. 16.17). If
worn, replace the two Bushes (pos. 16.16)
Important The two Bushes are press fitted and held by barbs. They will be damaged by withdrawing. Only withdraw Bushes
if they are to be replaced.
Reassembling
1. Mount the new Bushes (pos. 16.16) in shaft for Cleaner head (pos. 16.18)
2. Mount Rotor (pos. 16.17), Washer (pos. 16.15), Spring washer (pos. 16.14) and Screw (pos. 16.13) and tighten. To secure
Rotor against rotation insert a screwdriver through shaft for Cleaner head into a hole in the rotor.
3. Mount the two Bushes (pos. 16.7)
4. Locate Sleeve on shaft for Cleaner head (pos. 16.18)
5. Mount the Bush for stator (pos. 16.5) and Bearing washer (pos. 16.4) in the Stator (pos. 16.6)
6. Mount Stator (pos. 16.6)
7. Place the Balls (pos. 16.3) in the Stator (pos. 16.6)
8. Mount Bearing washer (pos. 16.4) and Circlip (pos. 16.1)
9. Screw on Nozzle head (pos. 16.11) and tighten. To secure Rotor against rotation, insert a screwdriver through shaft for
Cleaner head into a hole in the Rotor.
10. Mount Tubular Rivet (pos. 16.12).
16

6 Maintenance and Repair
Cleaner Head
TD523392
17

7 Trouble Shooting Guide
Slow rotation or failure of machine to rotate
Possible Causes Action
No or insufficient liquid flow a). Check if supply valve is fully open
b). Check if inlet pressure to machine is correct
c). Check nozzles for clogging
d). Check supply line and filter for restriction/clogging.
e). Dismount Connection nipple and Guide (see page 12) and check for clogging
in Guide/Turbine wheel area.
If large particles repeatedly get jammed in the machine, install filter or reduce
mesh size of installed filter in supply line.
Foreign material or material build-up Execute a total dismantling of the machine (page 12 to 16). Remove foreign
material/ material build up. Special attention must be paid to the Cleaner head
assembly and the Gear unit assembly.
Cleaner head and Turbine wheel must rotate freely without any sign of restriction.
Mechanical defects Execute a total dismantling of the machine. Special attention must be paid to
the wear parts - to find out which parts are wear parts, see Reference Lists
of Parts, pages 24 and 25.
Damaged parts must be replaced.
18

8 Technical Data
Weight of machine: 7.0 kg (15,4 lb)
Working pressure: 2-7 bar (30-100 psi)
Materials: AISI 316L, AISI 316, SAF2205 (UNS 31803), PEEK, PTFE, FEP/Silicone
Principal dimensions in mm
Inlet Connections:
Thread: 3/4” BSP
3/4” NPT
Clamp: 1” ISO2852
Do = 50.5
Tank Connections:
Flange: 50ND6, DIN2501
Do=140,PC=110
Db = 4 x ø14
Flange: 3” ANSI B16.5 1991
Do = 190.5, PC = 152.4
Db = 4 x ø19
Clamp: 3”ISO2852Do=91
Minimum diameter of hole in tank for cleaning head to pass through:
TD523385
TD523386
19

8 Technical Data
Flow rate)
TD523387-1
AB C
D
E
Inlet pressure
A: m3/h B: USgpm C: nozzle sizes D: psi E: bar
20