GEA Jumbo 6 User manual

Operating Instructions
GEA Orbital Cleaner
Jumbo 6
Edition 2016-05-24
English

2
Operating Instructions GEA Orbital Cleaner Jumbo 6
Edition 2016-05-24
Product Jumbo 6
Document Operating Instructions
Issue 2016-05-24
English
Manufacturer GEA Tuchenhagen GmbH
Am Industriepark 2-10
D-21514 Büchen
Phone:[phone]
Fax: [phone]
Mail: sales.geatuchenh[email protected]
Web: http://www.gea.com
These Operating Instructions are the English translation of the original in-
structions in the sense of the EU Machinery directive. This document is
protected by copyright. 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.
Wordmarks

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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 ...................................................................................................... 13
•Disassembly ......................................................................................................................... 14
•Environmental Protection ..................................................................................................... 15
•Electrical Equipment ............................................................................................................. 15
•Explosion Protection ............................................................................................................. 15
Residual Risk ............................................................................................................................ 16
•Hazard Areas........................................................................................................................ 16
•Residual Dangers ................................................................................................................. 18
Declaration of Incorporation ................................................................................................. 19
Transport and Storage ........................................................................................................... 20
Scope of Supply ....................................................................................................................... 20
Transport .................................................................................................................................. 20
Storage ..................................................................................................................................... 20
Intended Purpose ................................................................................................................... 21
Designated Use ........................................................................................................................ 21
Operating Pressure and Nozzle Size ....................................................................................... 21
Requirements for the Operation ............................................................................................... 21
Improper Operating Conditions ................................................................................................ 22
ATEX Directive ......................................................................................................................... 22
Conversion Work ...................................................................................................................... 22
Installation and Commissioning ........................................................................................... 23
Operating Conditions ................................................................................................................ 23
Installation Dimensions ............................................................................................................. 23
Notes on Installation ................................................................................................................. 24
Filter/Strainer ............................................................................................................................ 24
Installing ................................................................................................................................... 24
Installation Position ................................................................................................................... 25

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Operating Instructions GEA Orbital Cleaner Jumbo 6
Edition 2016-05-24
Commissioning ......................................................................................................................... 25
Malfunction ............................................................................................................................. 26
Maintenance ............................................................................................................................ 27
Inspections ............................................................................................................................... 27
Maintenance Intervals .............................................................................................................. 27
Prior to Disassembly................................................................................................................. 27
Disassembly ............................................................................................................................. 28
Maintenance ............................................................................................................................. 29
Assembly .................................................................................................................................. 30
Disposal .................................................................................................................................... 32
Technical Data ........................................................................................................................ 33
Spare Parts List – Jumbo 6 ................................................................................................... 34

5 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, commission, operate and carry out maintenance for the
cleaner.
Binding Character of These Operating Instructions
These Operating Instructions contain the manufacturer's instructions to the
owner 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
owner 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 simpli-
fied 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 Orbital Cleaner Jumbo 6
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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 highlighting.
DANGER
Warning: Fatal injuries.
Failure to observe the warning can cause 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 may 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 note 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 note can result in minor or moderate damage
to health.
The arrow identifies a precautionary measure you have to take to avoid
the hazard.
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.
Carry out the following steps: = Start of instructions for a task.
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.

7 Notes for the Reader
Abbreviations and Terms
TIP
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 ATmosphère EXplosive.
BS British Standard
bar Unit of measurement of pressure [bar]
All pressure ratings [bar/psi] are referring to excess pressure
[barg/psig] if no other data is mentioned.
BSP British Standard Pipe Tread
BSPT British Standard Pipe Tapered Tread
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
GEA GEA AG group of companies
GEA stands for Global Engineering Alliance
h Unit of measurement of time [hour]
ISO International standard issued by the International Organization for
Standardization
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]
μm Unit of measurement of length [micrometre]
Mmetric
NPT National Pipe Thread
Nm Unit of measurement of work [newton metre]
UNIT OF TORQUE 1 Nm = 0.737 lbft
Pound-Force (lb) + Feet (ft)
PA Polyamide
PTFE Polytetrafluoroethylene

Notes for the Reader
Abbreviations and Terms
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Operating Instructions GEA Orbital Cleaner Jumbo 6
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a/f Indicates the size of spanners
width across flats
Inch OD Pipe dimension acc. to British standard
(BS), Outside Diameter
Inch IPS US pipe dimension
Iron Pipe Size
Abbreviation Explanation

9 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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The operator's duty of care includes planning the necessary safety
measures and monitoring 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 necessary first-aid measures in case of an emergency.
•Clearly define processes, lines of authority and responsibilities associ-
ated 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.
TIP
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.
The following minimum qualifications are required:
•Vocational training as a skilled worker who can work on the cleaner inde-
pendently.
•Sufficient instruction to work on the cleaner under the supervision and
direction of a qualified specialist.

11 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 in-
structions 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.
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
Authorization with regard to safety engineering standards to
carry out the following tasks:
•Setting devices into operation
•Earthing of devices
•Marking of devices

Safety
Instructions for the Safe Operation
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Instructions for the Safe Operation
Dangerous situations during the operation can be avoided by safety-cons-
cious 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 at the cleaner's
place of use. It 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 fit and set the cleaner into
operation.
•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 inadvertently being switched on.
Commissioning/Setup Mode
For commissioning, the following principles apply:
•Take protective measures against dangerous contact voltages in accor-
dance with pertinent regulations.
•The cleaner must be completely assembled and correctly adjusted. All
screw connections must be securely tightened. All electrical cables must
be installed correctly.
•Reliably secure machine parts which have already been connected
against inadvertently being switched on.
•After conversion of the cleaner, residual risks must be reassessed.

13 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.
•The safety devices for the cleaner must be complete, fully functional and
in perfect condition. Check the function before starting any work.
•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.
Shutting Down
For shutting down, the following principles apply:
•Switch off the cleaner via the main switch.
•Padlock the main switch (if fitted) in the off position to prevent it from
being switched back on. The key to the padlock must be deposited with
the person responsible until the machine is restarted.
•For longer periods of standstill, observe the storage conditions, see
„Storage“ (Page 20).
Maintenance and Repair
Before starting and maintenance and repair work on the electrical devices of
the cleaner, carry out the following steps in accordance with the "5 safety
rules":
•Isolate from the power supply
•Take appropriate measures to prevent switch on
•Test absence of voltage
•Earthing and short-circuiting
•Cover or safeguard any adjacent live parts.

Safety
Instructions for the Safe Operation
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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.
•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 origi-
nally 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.
•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.

15 Safety
Instructions for the Safe Operation
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.
Electrical Equipment
For all work on electrical equipment, the following principles apply:
•Access to electrical equipment should only be allowed to qualified electri-
cians. Always keep unattended switch cabinets locked.
•Modifications of the control system can affect the safe and reliable
operation. Modifications are only permitted with the express permission
of the manufacturer.
•After completion of all work, check that the protective devices are fully
functional.
Explosion Protection
The safety instructions must be adhered to when the cleaner is used in
potentially explosive environments. The operator is responsible for this.
The manufacturer or supplier will not accept liability for any damage caused
if the cleaner is used in a dangerous or explosive environment.
Some of the procedures recommended to minimize the potential of explosion
are:
•Always ensure that cleaner, pipework and tank are earthed at all times.
•Never use tapes and sealing compounds on threads which can insulate
the cleaning head and prevent conduction of static electricity.

Safety
Residual Risk
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Operating Instructions GEA Orbital Cleaner Jumbo 6
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Residual Risk
Hazard Areas
Transport, Installation
Always use safe and certified lifting devices.
Setting into Operation
Observe the following notes
•Never set the cleaner into operation outside of the object to be cleaned.
•Interrupt the power circuit and protect it against unauthorized switch-on.
•Before setting into operation, check the voltage data, the fuse rating and
the supply line.
•Make absolutely sure that nobody is inside the object to be cleaned
during commissioning and that nobody can be hit by the cleaning jet in
any way.
Live parts
Observe the following notes
•The cleaner can be equipped with live sensors.
•Before starting any work on the cleaner the sensors must be de-ener-
gized by disconnecting or detaching the plug-in connection.
•Make sure that live wires are not exposed and cannot come in contact
with people, animals or plant components.
•Cables must be routed in such a way that no chafe marks can be
produced. They must regularly be checked for damage and chafe marks.
•Interrupt the power circuit and protect it against unauthorized switch-on.
Operation
Observe the following notes
•Ensure by suitable protective measures that the cleaner cannot be set
into operation outside of the tank/vessel and that nobody can be inside
the tank/vessel during operation.
•In the event of faults, interrupt all media supplies immediately.
•Check the installation situation to ensure that the machine is not in
contact with other parts and that rotation cannot be obstructed.
•Do not allow the maximum cleaning pressure and the maximum cleaning
temperature to be exceeded.
•Make sure the sealing materials are properly matched to the relevant
cleaning media.
•Vessels, tanks and road tankers etc. must be grounded by suitable
means.

17 Safety
Residual Risk
Maintenance
Observe the following notes
•Interrupt all media supply lines and ensure that no hot or aggressive
media are applied to or are in the cleaner.
•Only allow trained qualified staff to carry out maintenance work on the
cleaner.

Safety
Residual Risk
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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.
Electric power Observe the following safety rules:
1Isolate from the power supply.
2Take appropriate measures to prevent switch on.
3Test absence of voltage.
4Earthing and short-circuiting.
5Cover or safeguard any adjacent live parts.
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 opera-
tion.
•Never reach into openings.
As a precautionary measure, wear personal protec-
tive equipment in the vicinity of the cleaner:
•Protective gloves
•Safety shoes

19 Declaration of Incorporation
Residual Risk
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, 2016-04-18
Franz Bürmann Matthias Südel
Managing Director Senior Director Product Development
Flow Components
Designation of the machine: Jumbo 6
Machine type: GEA Orbital Cleaner
Relevant EC directives: 2006/42/EC
Applicable harmonized standards: DIN EN ISO 12100

Transport and Storage
Storage
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Operating Instructions GEA Orbital Cleaner Jumbo 6
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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 deli-
very documents,
•the equipment is complete and all components are in good order.
Transport
For transport, the following principles apply:
•Carry the cleaner using the eyebolt screwed into the T-piece underneath
the cylindrical body. Do not carry the cleaner holding the cylindrical body
or the nozzles, as your fingers can then be caught between moving gear
teeth as they mesh. There is danger of injury.
•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 care-
less loading and unloading. The outside synthetic materials are suscep-
tible 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 acces-
sories which are suitable for the intended purpose. Observe the
maximum load-bearing capacities.
•Under no circumstances should anyone stand under a suspended load.
Storage
Store the cleaner in a dry place and ensure it is not subjected to vibration
and is protected from external influence.