GEA Fury 602 User manual

Operating Instructions
GEA Index Cleaner
Fury 602
Edition 01/08/2016
English

2
Operating Instructions · GEA Index Cleaner Fury 602
Edition 01/08/2016
Product Fury 602
Document Operating Instructions
Edition 01/08/2016
English
Manufacturer GEA Tuchenhagen GmbH
Am Industriepark 2-10
D-21514 Büchen
Phone:[phone]
Fax: [phone]
Mail: sales.geatuchenhage[email protected]
Web: http://www.gea.com
These Operating Instructions are the English translation of the original operating instruc-
tions in the sense of the EU Machinery Directive. This document is protected by copy-
right. All rights reserved. The document may not, in whole or in part, be copied,
reproduced, translated or reduced to an electronic medium of machine-readable form
without the express permission of GEA Tuchenhagen GmbH.

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Table of Contents
Notes for the Reader ...................................................................................................................................... 5
Binding Character of These Operating Instructions ......................................................................................... 5
Notes on the Illustrations .................................................................................................................................. 5
Symbols and Highlighting ................................................................................................................................. 6
Abbreviations and Terms ................................................................................................................................. 7
Safety............................................................................................................................................................... 9
Safety Note ....................................................................................................................................................... 9
Operator's Duties .............................................................................................................................................. 9
Qualification of Staff ....................................................................................................................................... 10
Supplementary Regulations ........................................................................................................................... 11
Instructions for the Safe Operation ................................................................................................................. 12
•General Principles ...................................................................................................................................... 12
•Installation .................................................................................................................................................. 12
•Commissioning/Setup Mode ..................................................................................................................... 12
•Setting into Operation ................................................................................................................................ 13
•Operation ................................................................................................................................................... 13
•Shutting Down ........................................................................................................................................... 13
•Maintenance and Repair ............................................................................................................................ 14
•Disassembly ............................................................................................................................................... 14
•Environmental Protection ........................................................................................................................... 15
Signage .......................................................................................................................................................... 15
Residual Risk ................................................................................................................................................. 15
•Hazard Areas ............................................................................................................................................. 15
•Residual Dangers ....................................................................................................................................... 17
Declaration of Incorporation ........................................................................................................................... 18
Transport and Storage................................................................................................................................. 19
Scope of Supply ............................................................................................................................................. 19
Transport ........................................................................................................................................................ 19
Storage ........................................................................................................................................................... 19
Intended Purpose ......................................................................................................................................... 20
Designated Use .............................................................................................................................................. 20
Requirements for the Operation ..................................................................................................................... 20
Improper Operating Conditions ...................................................................................................................... 20
Conversion Work ............................................................................................................................................ 21
Installation and Commissioning ................................................................................................................. 22
Operating Conditions ...................................................................................................................................... 22
Notes on Installation ....................................................................................................................................... 23
Installation Dimensions .................................................................................................................................. 23
Installation ...................................................................................................................................................... 24
Removing ....................................................................................................................................................... 25
Setting into Operation ..................................................................................................................................... 26

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Operating Instructions · GEA Index Cleaner Fury 602
Edition 01/08/2016
Disassembly .................................................................................................................................................. 27
Malfunctions .................................................................................................................................................. 31
Maintenance .................................................................................................................................................. 32
Maintenance Intervals ..................................................................................................................................... 32
Disposal .......................................................................................................................................................... 32
Installation ..................................................................................................................................................... 33
Setting Dimensions ......................................................................................................................................... 33
Assembling the Cleaner .................................................................................................................................. 34
Technical Data............................................................................................................................................... 37
Spare Parts Lists........................................................................................................................................... 38

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Notes for the Reader
Notes on the Illustrations
Notes for the Reader
The present Operating Instructions are part of the user information for the cleaner. The
Operating Instructions contain all the information you need to transport, install, commis-
sion, operate and carry out maintenance for the cleaner.
Binding Character of These Operating Instructions
These Operating Instructions contain the manufacturer's instructions to the operator of
the cleaner and to all persons who work on or use the cleaner regarding the procedures
to follow.
Carefully read these Operating Instructions before starting any work on or using the
cleaner. Your personal safety and the safety of the cleaner can only be ensured if you
act as described in the Operating Instructions.
Store the Operating Instructions in such a way that they are accessible to the operator
and the operating staff during the entire life cycle of the cleaner. When the location is
changed or the cleaner is sold make sure you also provide the Operating Instructions.
Notes on the Illustrations
The illustrations in these Operating Instructions show the cleaner in a simplified form.
The actual design of the cleaner can differ from the illustration. For detailed views and
dimensions of the cleaner please refer to the design documents.

Notes for the Reader
Symbols and Highlighting
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Operating Instructions · GEA Index Cleaner Fury 602
Edition 01/08/2016
Symbols and Highlighting
In these Operating Instructions, important information is highlighted by symbols or
special formatting. The following examples illustrate the most important types of high-
lighting.
DANGER
Warning: Fatal Injuries.
Failure to observe the warning can result in serious damage to health, or even death.
The arrow identifies a precautionary measure you have to take to avoid the hazard.
EXPLOSION HAZARD
Warning: Explosions.
Failure to observe the warning can result in a severe explosion.
The arrow identifies a precautionary measure you have to take to avoid the hazard.
WARNING
Warning: Serious Injuries.
Failure to observe the warning can result in serious damage to health.
The arrow identifies a precautionary measure you have to take to avoid the hazard.
CAUTION
Warning: Injuries.
Failure to observe the warning can result in minor or moderate damage to health.
The arrow identifies a precautionary measure you have to take to avoid the hazard.
IMPORTANT NOTE
Warning: Damage to Property.
Non-observance of the warning note can cause serious damage to the cleaner or in the
vicinity of the cleaner.
The arrow identifies a precautionary measure you have to take to avoid the hazard.

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Notes for the Reader
Abbreviations and Terms
Carry out the following steps: = Start of a set of instructions.
1. First step in a sequence of operations.
2. Second step in a sequence of operations.
Result of the previous operation.
The operation is complete, the goal has been achieved.
NOTE
Further useful information.
Abbreviations and Terms
Abbreviation Explanation
ATEX ATEX is a widely used synonym for the European Union ATEX directives.
The designation ATEX is derived from the abbreviation of the French ATmos-
phère EXplosive.
BS British Standard
bar Unit of measurement of pressure [bar]
All pressure data expressed in [bar/psi] is assumed to be gauge pressure
[barg/psig] unless explicitly specified otherwise.
BSP British Standard Pipe Thread
approx. approximately
°C Unit of measurement of temperature [degree Celsius]
DN DIN nominal width
DIN German standard issued by DIN (Deutsches Institut für Normung e.V.,
German Institute for Standardization)
EN European Standard
°F Unit of measurement of temperature [degree Fahrenheit]
h Unit of measurement of time [hour]
ISO International standard issued by the International Organization for Standardi-
zation
kg Unit of measurement of weight [kilogram]
l Unit of measurement of volume [litre]
min. minimum
max. maximum
mm Unit of measurement of length [millimetre]
m Unit of measurement of length [micrometre]
MMetric
NPT National Pipe Thread

Notes for the Reader
Abbreviations and Terms
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Operating Instructions · GEA Index Cleaner Fury 602
Edition 01/08/2016
Nm Unit of measurement of work [newton metre]
UNIT OF TORQUE 1 Nm = 0.737 lbft
Pound-Force (lb) + Feet (ft)
PA Polyamide
PEEK Polyether ether ketone
C-PEEK Polyether ether ketone containing carbon
PTFE Polytetrafluoroethylene
psi British and American unit of measurement
[Pound force per square inch]
All pressure data expressed in [bar/psi] is assumed to be gauge pressure
[barg/psig] unless explicitly specified otherwise.
a/f Indicates the size of spanners
width across flats
Inch Unit of measurement of length
In the Anglo-American language area
Inch OD Pipe dimension acc. to British standard
(BS), Outside Diameter
Inch IPS US pipe dimension
Iron Pipe Size
Abbreviation Explanation

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Safety
Operator's Duties
Safety
Safety Note
The cleaner is operationally reliable. It was built according to state-of-the-art standards.
Nevertheless, the cleaner can pose dangers, especially if
•the cleaner is not used in accordance with its intended use,
•the cleaner is not used correctly,
•the cleaner is operated under impermissible operating conditions.
Operator's Duties
In your capacity as operator of the facility you bear a particular responsibility for the
proper and safe handling of the cleaner in your facility. Only use the cleaner when it is in
perfect condition to prevent danger to persons and property.
These Operating Instructions contain the information you and your staff need for the
safe and reliable operation during the entire service life of the cleaner. Be sure to read
these Operating Instructions carefully and ensure that the measures described here are
observed.

Safety
Qualification of Staff
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Operating Instructions · GEA Index Cleaner Fury 602
Edition 01/08/2016
The operator's duty of care includes planning the necessary safety measures and moni-
toring that these measures are observed. The following principles apply:
•Only allow qualified staff to work on the cleaner.
•The operator must authorize the staff to carry out the relevant tasks.
•Working areas and the entire environment of the cleaner must be neat and clean.
•The staff must wear suitable work clothing and personal protective equipment. As
the operator of the facility make sure that work clothing and personal protective
equipment are used.
•Instruct the staff with regard to any properties of the product which might pose a
health risk and the preventative measures to be taken.
•Have a qualified first-aider on call during the operation, who can initiate the neces-
sary first-aid measures in case of an emergency.
•Clearly define processes, lines of authority and responsibilities associated with the
cleaner. Everybody must know what to do in case of an emergency. Instruct the staff
in this respect at regular intervals.
•The signs relating to the cleaner must always be complete and legible. Check, clean
and replace the signs as necessary at regular intervals.
NOTE
Carry out regular checks. This way you can ensure that these measures are actually
observed.
Qualification of Staff
This section contains information about the qualifications that staff working on the
cleaner must have.
Operating and maintenance staff must
•have the necessary qualification to carry out their tasks,
•be instructed with regard to possible dangers,
•know and observe the safety instructions given in the documentation.
Only allow qualified electricians to carry out work on the electrical equipment or have a
qualified electrician supervise the work.
Only allow specially trained staff to carry out any work on explosion-protected equip-
ment. When working on explosion-protected equipment observe the standards DIN EN
60079-14 for gases and DIN EN 50281-1-2 for dusts.
The following minimum qualifications are required:
•Vocational training as a skilled worker who can work on the cleaner independently.
•Sufficient instruction to work on the cleaner under the supervision and direction of a
qualified specialist.

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Safety
Supplementary Regulations
Each member of staff must meet the following requirements to be allowed to work on the
cleaner:
•Personal qualification for the relevant task.
•Sufficient professional qualification for the relevant task.
•Instructed with regard to the function of the cleaner.
•Instructed with regard to the operating sequences of the cleaner.
•Familiar with the safety devices and their function.
•Familiar with these Operating Instructions, especially with the safety instructions and
the information which is relevant for the task on hand.
•Familiar with the basic regulations with regard to occupational health and safety and
accident prevention.
For work to be carried out on the cleaner the following user groups are distinguished:
Supplementary Regulations
In addition to the instructions in this documentation the following also has to be
observed:
•pertinent accident prevention regulations,
•generally accepted safety rules,
•national regulations applicable in the country of use,
•work and safety instructions applicable in the facility,
•installation and operating regulations for use in potentially explosive areas.
User groups
Staff Qualifications
Operating staff Adequate instruction and sound knowledge in the following areas:
•Function of the cleaner
•Operating sequences of the cleaner
•What to do in case of an emergency
•Lines of authority and responsibilities with respect to the task
Maintenance staff Adequate instruction as well as sound knowledge of the design and function
of the cleaner.
Sound knowledge in the following areas:
•Mechanical equipment
•Electrical equipment
•Pneumatic system
Authorization with regard to safety engineering standards to carry out the
following tasks:
•Setting devices into operation
•Earthing of devices
•Marking of devices
The relevant certificates of qualification must be submitted before work can
be carried out on ATEX certified machines.

Safety
Instructions for the Safe Operation
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Operating Instructions · GEA Index Cleaner Fury 602
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Instructions for the Safe Operation
Dangerous situations during the operation can be avoided by safety-conscious and
proactive behaviour of the staff.
General Principles
To ensure the safe operation of the cleaner the following principles apply:
•The Operating Instructions must be kept ready to hand and accessible for everyone
at the cleaner's place of use. They must be complete and in clearly legible form.
•Only use the cleaner for its intended use.
•The cleaner must be functional and in good working order. Check the condition of
the cleaner before starting work and at regular intervals.
•Wear tight-fitting work clothing for all work on the cleaner.
•Ensure that nobody can get hurt on the parts of the cleaner.
•Immediately report any faults or noticeable changes on the cleaner to the person
responsible.
•Observe the accident prevention regulations and all local regulations.
Installation
For installation, the following principles apply:
•Only properly qualified staff is allowed to install, assemble and set the cleaner into
operation.
•Ensure that adequate working and traffic areas are available at the place of installa-
tion.
•Observe the maximum load-bearing capacity of the installation surface.
•Observe the transport instructions and markings on the part(s) to be transported.
•Remove any nails protruding from transport crates immediately after opening the
crate.
•Under no circumstances should anyone stand under a suspended load.
•During assembly, the cleaner's safety devices might not be working effectively.
•Reliably secure machine parts which have already been connected against inadvert-
ently being switched on.
Commissioning/Setup Mode
For commissioning, the following principles apply:
•The cleaner must be completely assembled and correctly adjusted. All screw
connections must be securely tightened.
•Reliably secure machine parts which have already been connected against inadvert-
ently being switched on.
•After conversion of the cleaner, residual risks must be reassessed.

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Safety
Instructions for the Safe Operation
Setting into Operation
For setting into operation, the following principles apply:
•Only allow properly qualified staff to set the cleaner into operation.
•Establish all connections correctly.
•When the cleaner is switched on, the danger zones must be free.
•Remove any liquids that have escaped without leaving residues.
Operation
For operation, the following principles apply:
•Monitor the cleaner during the operation.
•Safety devices must not be changed, removed or taken out of service. Check all
safety devices at regular intervals.
•All guards and hoods must be fitted as intended.
•Structural alterations of the cleaner are not permitted. Immediately report any
changes on the cleaner to the person responsible.
•Always keep danger zones clear. Do not leave any objects in the danger zone. Only
allow persons to enter the danger zone when the machine is de-energized.
•Regularly check that all emergency stop devices are working correctly.
•The cleaner contains a threadlocker/sealant (Loctite 243) with NSF P1 approval.
Shutting Down
For shutting down, the following principles apply:
For longer periods of standstill, observe the storage conditions, see “Storage“ (page 19).

Safety
Instructions for the Safe Operation
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Operating Instructions · GEA Index Cleaner Fury 602
Edition 01/08/2016
Maintenance and Repair
For maintenance and repair, the following principles apply:
•Observe the intervals specified in the maintenance schedule.
•Only allow qualified staff to carry out maintenance or repair work on the cleaner.
•Before starting any maintenance or repair work, the cleaner must be switched off
and secured against being switched back on. Work may only be started once any
residual energy has been discharged.
•Block access for unauthorized persons. Put up notice signs which draw attention to
the maintenance or repair work going on.
•Do not climb on the cleaner. Use suitable access aids and working platforms.
•Wear suitable protective clothing.
•Only use suitable and undamaged tools to carry out maintenance work.
•When replacing parts only use approved, fully functional load lifting devices and
lifting accessories which are suitable for the intended purpose.
•Before setting the unit back into operation refit all safety devices as originally
provided in the factory. Then check that all safety devices are working correctly.
•Check pipes are firmly secured, also check for leaks and damage.
•Check that all emergency stop devices are working correctly.
Disassembly
For disassembly, the following principles apply:
•Only allow qualified staff to disassemble the cleaner.
•Before starting disassembly, the cleaner must be switched off and secured against
being switched back on. Work may only be started once any residual energy has
been discharged.
•Disconnect all power and utility lines.
•Markings, e.g. on lines, must not be removed.
•Do not climb on the cleaner. Use suitable access aids and working platforms.
•Mark the lines (if unmarked) prior to disassembly to ensure they are not confused
when re-assembling.
•Protect open line ends with blind plugs against ingress of dirt.
•Pack sensitive parts separately.

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Safety
Residual Risk
Environmental Protection
Harm to the environment can be avoided by safety-conscious and proactive behaviour
of the staff.
For environmental protection the following principles apply:
•Substances harmful to the environment must not be discharged into the ground or
the sewage system.
•Always observe the pertinent regulations relating to waste avoidance, disposal and
utilization.
•Substances harmful to the environment must be collected and stored in suitable
containers. Clearly mark the containers.
•Dispose of lubricants as hazardous waste.
Signage
Dangerous points on the cleaner are indicated by warning signs, prohibition signs and
mandatory signs.
The signs and notes on the cleaner must always be legible. Any illegible signs must be
replaced immediately.
Residual Risk
Hazard Areas
Transport, Installation
Do not set the cleaner down on the lower body. Store the cleaner in horizontal position
and secure it against rolling away to the side.
Signs on the cleaner
Sign Meaning
General hazard warning
Warning Crushing
Explosive atmosphere hazard warning

Safety
Residual Risk
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Operating Instructions · GEA Index Cleaner Fury 602
Edition 01/08/2016
Setting into Operation
Observe the following notes
•When installing the cleaner, secure it against tipping and twisting and secure all
fixing points correctly.
•Only set the cleaner into operation in closed vessels.
Operation
Observe the following notes
•Provide suitable protective measures to ensure that the cleaner cannot be set into
operation outside of the vessel.
•In the event of faults, stop all media supplies immediately.
•Check the installation situation to ensure that the cleaner is not in contact with other
parts and that rotation cannot be obstructed.
•Do not allow the maximum cleaning pressure and the maximum cleaning tempera-
ture to be exceeded.
•Vessels, tanks and road tankers etc. must be grounded by suitable means.
Maintenance
Observe the following notes
•Close all media supply lines and ensure that no hot or aggressive media are applied
to or are in the cleaner.
•Never set the cleaner down on the lower body.
•Do not attempt to turn the nozzles by hand.
•Do not use the lower body as a tool contact point for installation or removal.

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Safety
Residual Risk
Residual Dangers
Dangerous situations can be avoided by safety-conscious and proactive behaviour of
the staff and by wearing personal protective equipment.
Residual dangers on the cleaner and measures
Danger Cause Measure
Danger to life Inadvertent switch-on of
the cleaner
Effectively disconnect all components, effectively
prevent switch-on.
Danger of
injury
Danger presented by
moving or sharp-edged
parts
The operator must exercise caution and prudence.
For all work:
•Wear suitable work clothing.
•Never operate the machine if the cover panels are
not correctly fitted.
•Never open the cover panels during the operation.
•Never reach into openings.
As a precautionary measure, wear personal protective
equipment in the vicinity of the cleaner:
•Protective gloves
•Safety shoes

Safety
Declaration of Incorporation
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Operating Instructions · GEA Index Cleaner Fury 602
Edition 01/08/2016
Declaration of Incorporation
Declaration of Incorporation
in accordance with the EC Machinery Directive 2006/42/EC
We herewith declare that this consignment contains the subsequently identified – but
incomplete – machine and that putting into service is not permitted until it has been estab-
lished that the machinery into which this machine is to be incorporated is in conformity with
the provisions of the EC Machinery Directive.
We declare that the incomplete machine identified here complies with the "Essential Health
and Safety Requirements" defined in Annex I, section 1 and section 2.1. The technical
documentation is compiled in accordance with Annex VII, part B. In response to a
reasoned request the relevant information will be transmitted to the appropriate national
authorities.
This declaration will become invalid if any alterations are made to the machine which have
not been agreed with us.
Büchen, 18/04/2016
Franz Bürmann Matthias Südel
Managing Director Senior Director Product Development
Flow Components
Designation of the machine: Fury 602
Machine type: GEA Index Cleaner
Relevant EC directives: 2006/42/EC
Applicable harmonized standards: DIN EN ISO 12100

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Transport and Storage
Storage
Transport and Storage
Scope of Supply
On receipt of the cleaner check whether
•the details on the type plate correspond to the data in the order and delivery docu-
ments,
•the equipment is complete and all components are in good order.
Transport
For transport, the following principles apply:
•Only use suitable lifting gear and slings for transporting package units/cleaners.
•Observe the pictograms on the package.
•Handle the cleaner with care to avoid damage caused by impact or careless loading
and unloading. The outside synthetic materials are susceptible to breaking.
•Only allow qualified staff to transport the cleaner.
•Movable parts must be properly secured.
•Only use approved, fully functional load lifting devices and lifting accessories which
are suitable for the intended purpose. Observe the maximum load-bearing capaci-
ties.
•Under no circumstances should anyone stand under a suspended load.
•Take care when transporting the cleaner. Do not grip sensitive parts of the unit to lift
or push the unit or to support yourself. Avoid putting the unit down with a jerk.
•Do not set the cleaner down on the lower body. Store the cleaner in horizontal posi-
tion and secure the cleaner against rolling away to the side.
Storage
Store the cleaner in a dry place and ensure it is not subjected to vibration and is
protected from external influence.
Storage temperature +5...+40 °C

Intended Purpose
Improper Operating Conditions
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Operating Instructions · GEA Index Cleaner Fury 602
Edition 01/08/2016
Intended Purpose
Designated Use
The Index Cleaner Fury is intended for the cleaning of tanks and vessels. This cleaner
has been designed for installation vertically up or vertically down.
NOTE
The manufacturer will not accept any liability for damage resulting from any use of the
cleaner which is not in accordance with its designated use. The risk of such misuse lies
entirely with the operator of the facility.
Requirements for the Operation
The prerequisite for the reliable and safe operation of the cleaner is proper transporta-
tion and storage as well as professional installation and assembly. Operating the cleaner
within the limits of its designated use also involves adhering to the operating, inspection
and maintenance instructions.
Improper Operating Conditions
The operational reliability of the cleaner cannot be ensured under improper operating
conditions. Therefore avoid improper operating conditions.
Operating the cleaner is not permitted if
•Persons or objects are in the danger zone.
•Safety devices are not working or were removed.
•Malfunctions have been detected on the cleaner.
•Damage has been detected on the cleaner.
•Maintenance intervals have been exceeded, see “Maintenance Intervals“ (page 32).