GEA Jumbo 6 User manual

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

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