Aquaduna Dunos rb 50 User manual

Rev. 1 Dunos RB_RN G Description 100728 / Docu / Cleaning tech / Dunos / Dunos RB_RN 1

AquaDuna GmbH & Co KG / Ferdinand-von-Steinbeis-Ring 31 / 75447 Sternenfels / Germany

Telephone: 07045 204980 / www.aquaduna.com

We reserve the right to make technical changes.

Operating instructions

DUNOS RB / RN

Rev. 1 Dunos RB_RN G Description 100728 / Docu / Cleaning tech / Dunos / Dunos RB_RN 2

AquaDuna GmbH & Co KG / Ferdinand-von-Steinbeis-Ring 31 / 75447 Sternenfels / Germany

Telephone: 07045 204980 / www.aquaduna.com

We reserve the right to make technical changes.

These operating instructions are part of the cleaner and must be

available to the user at all times. All safety information is to be

clearly instructed and must be observed. If this unit is passed on,

the operating instructions must be passed on as well.

Rev. 1 Dunos RB_RN G Description 100728 / Docu / Cleaning tech / Dunos / Dunos RB_RN 3

AquaDuna GmbH & Co KG / Ferdinand-von-Steinbeis-Ring 31 / 75447 Sternenfels / Germany

Telephone: 07045 204980 / www.aquaduna.com

We reserve the right to make technical changes.

Content

1 GENERAL INFORMATION.....................................................................................5

1.1 Function.................................................................................................................5

1.2 Design ...................................................................................................................6

1.3 Application.............................................................................................................7

2 TECHNICAL DATA.................................................................................................8

2.1 Dimensions............................................................................................................9

2.1.1 DUNOS RB 50.................................................................................................9

2.1.2 DUNOS RN 90.................................................................................................9

3 SAFETY INFORMATION......................................................................................10

4 DANGERS.............................................................................................................11

5 INSTALLATION AND MAINTENANCE ................................................................12

5.1 Installation ...........................................................................................................12

5.2 Commissioning....................................................................................................12

5.3 Maintenance........................................................................................................13

5.3.1 Required tools................................................................................................13

5.3.2 Disassembly...................................................................................................14

5.3.3 Assembly .......................................................................................................15

5.4 Replacement and wearing parts .........................................................................16

5.4.1 Fluid drive replacement parts ........................................................................16

5.4.2 Spray head replacement parts ......................................................................16

5.4.3 Fluid drive wearing parts................................................................................17

5.4.4 Wearing parts DUNOS RB / RN.....................................................................17

Rev. 1 Dunos RB_RN G Description 100728 / Docu / Cleaning tech / Dunos / Dunos RB_RN 4

AquaDuna GmbH & Co KG / Ferdinand-von-Steinbeis-Ring 31 / 75447 Sternenfels / Germany

Telephone: 07045 204980 / www.aquaduna.com

We reserve the right to make technical changes.

6 INTEGRATION AND CONTROL...........................................................................17

6.1 Integration into a cleaning system .......................................................................17

6.2 Control via manual control elements ...................................................................17

7 TROUBLESHOOTING..........................................................................................18

7.1 Emergency stop...................................................................................................18

8 TRANSPORT ........................................................................................................18

8.1 Delivery scope.....................................................................................................18

8.2 Transport and packaging.....................................................................................19

9 QUALITY ASSURANCE ........................................................................................20

10 DISPOSAL ...........................................................................................................20

I. SYMBOLS............................................................................................................21

II. TERMS USED.....................................................................................................22

III. LIST OF FIGURES.............................................................................................22

Rev. 1 Dunos RB_RN G Description 100728 / Docu / Cleaning tech / Dunos / Dunos RB_RN 5

AquaDuna GmbH & Co KG / Ferdinand-von-Steinbeis-Ring 31 / 75447 Sternenfels / Germany

Telephone: 07045 204980 / www.aquaduna.com

We reserve the right to make technical changes.

1 General Information

1.1 Function

The DUNOS RB / RN spray cleaners are spray units functioning in one

dimension which are driven by the cleaning medium. The cleaners have been

manufactured with as few components as possible. The machines are designed

with minimum clearance volume and are produced in Germany from inspected

materials. The surfaces and their roughness have already been monitored

during production.

The cleaning medium is supplied to the spray cleaner via a pre-filter. The spray

cleaner can be installed within the vessel in all positions. The connection is

made through a flanged nut. A G¾" flanged nut is used for the DUNOS RB50;

for the DUNOS RN90, a G1½" flanged nut. The inrushing medium generates an

output speed of 10 rpm to 16 rpm via a turbine with downstream gearbox. The

connection from the gearbox to the spray head is accomplished through a drive

shaft. Due to the design of the spray cleaner, the emitted cleaning agent stream

can be applied to the entire wall of the vessel with each revolution.

Important: The cleaning medium flows through a bypass, past the gearbox to

the spray head. This prevents braking elements and ensures the maximum flow

for the nozzles.

The spray cleaner can be operated with a wide range of

nozzle diameters. Therefore the unit can be perfectly

adapted to the cleaning task.

Figure 1: DUNOS RB

Rev. 1 Dunos RB_RN G Description 100728 / Docu / Cleaning tech / Dunos / Dunos RB_RN 6

AquaDuna GmbH & Co KG / Ferdinand-von-Steinbeis-Ring 31 / 75447 Sternenfels / Germany

Telephone: 07045 204980 / www.aquaduna.com

We reserve the right to make technical changes.

1.2 Design

The spray cleaner basically consists of three components.

Drive

The fluid drive generates a rotational movement by means of the cleaning

medium flow to drive the spray head.

Drive shaft

The drive shaft couples the drive with the spray head.

Spray head

The universal spray head can be fitted with different drive systems.

Figure 2: Design DUNOS RB / RN

Spray head

Drive shaft

Fluid drive

Spray head

Rev. 1 Dunos RB_RN G Description 100728 / Docu / Cleaning tech / Dunos / Dunos RB_RN 7

AquaDuna GmbH & Co KG / Ferdinand-von-Steinbeis-Ring 31 / 75447 Sternenfels / Germany

Telephone: 07045 204980 / www.aquaduna.com

We reserve the right to make technical changes.

1.3 Application

The spray cleaners of the DUNOS series are water-hydraulically driven

machines. The flowing medium drives the head, which functions in one

dimension. The water streams emitted by the nozzles strike the vessel wall. The

resulting impact and shear forces remove the deposits from the vessel wall.

Depending on the deposit to be removed, adding a portion of chemicals

determined by the respective user to the cleaning agent is recommended.

The unit is made of stainless steel 316 L, PTFE and PEEK. It is resistant to the

chemicals usually used in the pharmaceutical and food industries.

The units must only be used in closed vessels. Due to the high impact forces,

operation outside the vessel may lead to injuries.

These spray cleaners are constructed to be used only inside closed

vessels. They may be used only within the intended ranges. All non-

intended applications are prohibited. The units must only be used by

qualified and instructed persons.

Alterations or modifications are not covered by the manufacturer.

Rev. 1 Dunos RB_RN G Description 100728 / Docu / Cleaning tech / Dunos / Dunos RB_RN 8

AquaDuna GmbH & Co KG / Ferdinand-von-Steinbeis-Ring 31 / 75447 Sternenfels / Germany

Telephone: 07045 204980 / www.aquaduna.com

We reserve the right to make technical changes.

2 Technical Data

DUNOS RB50 DUNOS RN90

Length: 162 mm 192 mm

Built-in diameter: 65 mm 125 mm

Medium connection: G¾" G1½"

Number of nozzles: 4 - 32 4 - 32

Shape of nozzles: 2 - 5 mm 2 - 8 mm

Work pressure: 3 - 12 bar 3 - 15 bar

Cleaning radius: 2.5 - 4.5 m 4 - 9 m

Spray radius: 3.5 - 6 m 4 - 11 m

Weight: 0.8 kg 4.0 kg

Temperature range: 4 - 120 °C

Materials: Stainless steel 316L

PEEK

PTFE

Accessories (optional): Rotation monitoring

Connection parts

Special nozzles

Rev. 1 Dunos RB_RN G Description 100728 / Docu / Cleaning tech / Dunos / Dunos RB_RN 9

AquaDuna GmbH & Co KG / Ferdinand-von-Steinbeis-Ring 31 / 75447 Sternenfels / Germany

Telephone: 07045 204980 / www.aquaduna.com

We reserve the right to make technical changes.

2.1 Dimensions

2.1.1 DUNOS RB50

2.1.2 DUNOS RN90

Figure 4: Dimensions DUNOS RN 90

Figure 3: Dimensions DUNOS RB 50

Rev. 1 Dunos RB_RN G Description 100728 / Docu / Cleaning tech / Dunos / Dunos RB_RN 10

AquaDuna GmbH & Co KG / Ferdinand-von-Steinbeis-Ring 31 / 75447 Sternenfels / Germany

Telephone: 07045 204980 / www.aquaduna.com

We reserve the right to make technical changes.

3 Safety Information

The operator of the spray cleaner is obliged to instruct the operating personnel

as well as the personnel authorised to carry out the maintenance. All persons

working with rotating and spraying machines must be instructed regarding the

dangers these machines may present.

Persons not listed as operating or maintenance personnel are not permitted to

stay within the working range of the machine. The operator must ensure that the

necessary measures are taken.

As a matter of principle, the machines must only be maintained by suitable

qualified personnel. Only original replacement parts are to be used for

maintenance or repair. Use of non-original parts voids the warranty.

Rev. 1 Dunos RB_RN G Description 100728 / Docu / Cleaning tech / Dunos / Dunos RB_RN 11

AquaDuna GmbH & Co KG / Ferdinand-von-Steinbeis-Ring 31 / 75447 Sternenfels / Germany

Telephone: 07045 204980 / www.aquaduna.com

We reserve the right to make technical changes.

4 Dangers

The spray cleaners are subject to high pressures. Therefore we

expressly point out that only original parts are to be used for

maintenance and repair. Damage resulting from use of non-original

parts will not be accepted by the manufacturer.

The spray cleaner must be operated only in the environment it is

intended for. Operation is permitted only in closed vessels / rooms.

Pay attention to rotating parts.

The spray cleaner must not be turned on the machine head with

force. This can destroy the drive.

When working with the spray cleaner, make sure that your hands

cannot get caught between the nozzles and unit body.

Only authorised persons are allowed to stay within the operational

area of the spray cleaner.

Rev. 1 Dunos RB_RN G Description 100728 / Docu / Cleaning tech / Dunos / Dunos RB_RN 12

AquaDuna GmbH & Co KG / Ferdinand-von-Steinbeis-Ring 31 / 75447 Sternenfels / Germany

Telephone: 07045 204980 / www.aquaduna.com

We reserve the right to make technical changes.

5 Installation and Maintenance

5.1 Installation

The spray cleaner is screwed to the threaded connectors of the system with the

thread G¾" or G1½". When screwing onto the machine, make sure the thread is

first coated with a food grade lubricant such as Loctite 8014. Then the machine

DUNOS RB50 is to be firmly screwed to the load-bearing element with a SW 32

spanner, and the machine DUNOS RN90 with a SW 55 spanner.

Before setting the machine into operation, always check all parts for a

tight fit. The operator assumes sole liability for improperly mounted

machines.

5.2 Commissioning

If all pipelines / supply lines are tightly fastened to the spray cleaner and the

shut-off valves are closed, the spray cleaner is ready for initial commissioning.

Check the function of the pre-filter in the supply line to the spray cleaner and

make sure the filter body is inserted.

Before the initial commissioning, rinse out the supply line to the spray cleaner.

Metallic contamination and welding residues can destroy the spray cleaner.

For initial commissioning, make sure all air has been vented from the supply line

to the spray cleaner, especially with longer supply lines. This prevents pressure

shocks which can damage the spray cleaner.

If hand-operated valves are used, in order to avoid pressure impacts

they must not be opened abruptly.

For operation in automatic cleaning systems, the operator must familiarise

himself with the cutoff and/or emergency stop states of the system.

Rev. 1 Dunos RB_RN G Description 100728 / Docu / Cleaning tech / Dunos / Dunos RB_RN 13

AquaDuna GmbH & Co KG / Ferdinand-von-Steinbeis-Ring 31 / 75447 Sternenfels / Germany

Telephone: 07045 204980 / www.aquaduna.com

We reserve the right to make technical changes.

5.3 Maintenance

5.3.1 Required tools

DUNOS RB50

1. Spanner SW 21

2. Spanner SW 22

3. Spanner SW 5

4. Spanner SW 10

5. Tool set DUNOS RB50

Tool 1

Retaining clamps

DUNOS RN90

1. Spanner SW 46

2. Spanner SW 41

3. Spanner SW 10

4. Tool set DUNOS RN90

Tool 1

Tool 2

Retaining clamps

Figure 5: Tool set DUNOS RB50

Figure 6: Tool set DUNOS RD90

Rev. 1 Dunos RB_RN G Description 100728 / Docu / Cleaning tech / Dunos / Dunos RB_RN 14

AquaDuna GmbH & Co KG / Ferdinand-von-Steinbeis-Ring 31 / 75447 Sternenfels / Germany

Telephone: 07045 204980 / www.aquaduna.com

We reserve the right to make technical changes.

5.3.2 Disassembly

The spray cleaner is to be disassembled when the cleaner

1. should be maintained or

2. parts of the cleaner should be replaced. In this case, the repair

instructions apply.

The machine should be disassembled on a clean work surface. The required

tools should be ready at hand. The qualified personnel who carry out the

disassembly must be instructed.

Spanner 1

Spanner 2

Use spanners 1 and 2 to disconnect the fluid drive from the housing of the

spray cleaner. The drive shaft does not need to be removed.

Check the nozzles for free flow. If any residues are visible in the nozzles, use

a soft object to push them out of the nozzle opening. Be certain that the inner

surface of the nozzles is not scratched.

If there are any objects in the spray head, remove them. The drive shaft is

screwed to the lower end of the housing with screw 1. If the shaft interferes

when the head is cleaned, it can be unscrewed with spanner 3.

Check the dismounted fluid drive visually. Check if any contamination is visible

in the supply and/or on the output side of the drive. If contamination is present,

check whether it can be removed from outside. If it is not possible to remove

Figure 7: Disassembly

Rev. 1 Dunos RB_RN G Description 100728 / Docu / Cleaning tech / Dunos / Dunos RB_RN 15

AquaDuna GmbH & Co KG / Ferdinand-von-Steinbeis-Ring 31 / 75447 Sternenfels / Germany

Telephone: 07045 204980 / www.aquaduna.com

We reserve the right to make technical changes.

the contamination from outside, the housing of the fluid drive must be clamped

in the vice with the retaining clamps. Now the supply is unscrewed from the

jacket tube with the SW 46 spanner.

The drive unit can now be taken out of the jacket tube with a small flat pliers.

Now the entire annular gap of the drive is visible. If contamination is visible

here, it can be pushed out with a suitable screwdriver.

The jacket tube can now be blown free with 3 bar compressed air.

If the spray cleaner must be further disassembled for maintenance purposes,

observe the repair instructions. This procedure should only be performed by

very well-instructed personnel.

5.3.3 Assembly

If the fluid drive has been cleaned and the drive unit removed, now it must be

re-inserted. When doing so, take particular care that the gear on the lower end

of the drive unit is inserted into the gearbox under slight rotation.

Attention!! The gear must not press on the teeth of the gearbox.

If the drive unit is seated on the collar, the supply can be screwed on. To do

so, apply lubricant to the thread.

The supply is firmly tightened with spanner 1.

After the fluid drive is assembled, the drive shaft is screwed into the spray

head with the screw and spanner 3. This applies only when the shaft has been

removed. Now the thread of the spray head is provided with lubricant and

screwed into the fluid drive. When doing so, make sure the drive shaft is

inserted smoothly into the drive flange of the gearbox. The spray housing is

screwed to the drive housing with spanners 1 and 2.

Finally, the nozzles are screwed into the nozzle disc with spanner 3 and firmly

tightened. When so doing, lubricant must also be used.

Always make sure that all loosened threads are firmly re-tightened.

Rev. 1 Dunos RB_RN G Description 100728 / Docu / Cleaning tech / Dunos / Dunos RB_RN 16

AquaDuna GmbH & Co KG / Ferdinand-von-Steinbeis-Ring 31 / 75447 Sternenfels / Germany

Telephone: 07045 204980 / www.aquaduna.com

We reserve the right to make technical changes.

5.4 Replacement and wearing parts

5.4.1 Fluid drive replacement parts

 Supply

 Drive unit complete

 Jacket tube

 Gearbox unit

 Base flange

 O-rings (only for external mounting)

5.4.2 Spray head replacement parts

 Dome

 Dome ball bearing

 Locking ring

 Bearing ring

 Dome sealing ring

 Dome ball bearing

 Drive gear

 Spray housing

Figure 8: Exploded view, fluid drive

Figure 9: Exploded view, spray head

Rev. 1 Dunos RB_RN G Description 100728 / Docu / Cleaning tech / Dunos / Dunos RB_RN 17

AquaDuna GmbH & Co KG / Ferdinand-von-Steinbeis-Ring 31 / 75447 Sternenfels / Germany

Telephone: 07045 204980 / www.aquaduna.com

We reserve the right to make technical changes.

5.4.3 Fluid drive wearing parts

1. Drive unit

2. Gearbox unit

5.4.4 Wearing parts DUNOS RB / RN

Wearing parts consist of

Dome ball bearing

Dome sealing ring

Nozzle ball bearing

Nozzle sealing ring

6 Integration and Control

6.1 Integration into a cleaning system

If the spray cleaner is integrated into an automatically working system, make

sure that the function of the spray cleaner can be monitored. This can be done

by means of rotation monitoring or by an optical check. For optical check, the

function monitoring must be documented (system log).

6.2 Control via manual control elements

If the spray cleaner is controlled by manual control elements, make sure that

pressure shocks are avoided. Therefore the operating elements must be

opened and closed slowly. If they are exposed to steam, make sure that the

temperature does not exceed the specified limits. Monitoring of the spray

cleaner must be guaranteed.

Rev. 1 Dunos RB_RN G Description 100728 / Docu / Cleaning tech / Dunos / Dunos RB_RN 18

AquaDuna GmbH & Co KG / Ferdinand-von-Steinbeis-Ring 31 / 75447 Sternenfels / Germany

Telephone: 07045 204980 / www.aquaduna.com

We reserve the right to make technical changes.

7 Troubleshooting

7.1 Emergency stop

In order to force an emergency stop of the spray cleaner, it is imperative

for the system operator to be thoroughly familiar with the system

concept. It is essential to instruct personnel in emergency stop

procedures and to inform them of the elements necessary for an

emergency stop. The instruction of the persons authorised to perform

cleaning must be documented. The plant operator assumes sole

responsibility for all personal injury and property damage resulting from

faulty operation or faulty application.

8 Transport

8.1 Scope of delivery

The complete spray cleaner and operating instructions for the respective model

are included with delivery.

Please refer to the delivery papers for type options.

Figure 10: Delivery scope

Brief

instructions

Rev. 1 Dunos RB_RN G Description 100728 / Docu / Cleaning tech / Dunos / Dunos RB_RN 19

AquaDuna GmbH & Co KG / Ferdinand-von-Steinbeis-Ring 31 / 75447 Sternenfels / Germany

Telephone: 07045 204980 / www.aquaduna.com

We reserve the right to make technical changes.

8.2 Transport and packaging

Our products are carefully produced, assembled and tested. Should there

nonetheless be any reason for complaint, we will naturally ensure your complete

satisfaction within the scope of our warranty. We are also at your service after

the warranty expires.

When receiving a delivery, always check the packing list against the

delivery scope. After determining that delivery is complete, check the

goods for damage.

If there is any damage, it is essential to note it down on the shipping

documents. In case of damage, the forwarder must countersign the

documents.

To return parts, either keep the outer packaging or select a packaging

which will prevent damage to the units.

Rev. 1 Dunos RB_RN G Description 100728 / Docu / Cleaning tech / Dunos / Dunos RB_RN 20

AquaDuna GmbH & Co KG / Ferdinand-von-Steinbeis-Ring 31 / 75447 Sternenfels / Germany

Telephone: 07045 204980 / www.aquaduna.com

We reserve the right to make technical changes.

9 Quality Assurance

For us, quality in design, production, assembly, final inspection and testing is a

matter of course. It is a mandatory precondition for the permanently efficient and

high-quality production of our demanding products. In order to guarantee our high

quality standards, we use a computer-assisted quality assurance system which we

have applied for certification according to ISO 9001:2008. Furthermore, all our

products are subjected to a final function test (100 % control). Thereby we assure

that only 100 % functional products leave our company.

10 Disposal

All the materials used in production of the spray cleaner are harmless to

the environment. The materials used are primarily stainless steel, PTFE

and PEEK. These materials can be disposed of in the ways established

for such disposal.

ATTENTION!! Make sure that there is no longer any contamination by

materials remaining from operation. To do so, use the suitable material

for rinsing the parts to be disposed.

This manual suits for next models

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