Yumpu TE91A750-EN1 User manual
Instruction Manual
Toftejorg SaniMidget Retractor
IM-TE91A750-EN1
August 2004
ï
Return to menu
Instruction Manual, Toftejorg SaniMidget Retractor Page 1
IM-TE91A750-EN1
Contents
Contents.................................................................................................................... 1
Introduction ............................................................................................................... 3
General Description .................................................................................................. 4
Quality system.....................................................................................................................4
Functioning..........................................................................................................................5
Technical Data.......................................................................................................... 8
Performance Data for Toftejorg SaniMidget Retractor........................................................9
Performance Data for Toftejorg SaniMidget Retractor Pneumatic driven...........................9
Installation and Normal Operation .......................................................................... 10
General Installation Instructions........................................................................................10
Safety Precautions............................................................................................................11
Normal Operation..............................................................................................................12
Maintenance and repair .......................................................................................... 14
Preventive Maintenance....................................................................................................14
Check/Inspection...............................................................................................................15
Rear part Media driven......................................................................................................15
Rear Part Pneumatic driven..............................................................................................15
Magnetic Cylinder Sensor....................................................................................... 16
Electrical and Mechanical Data.........................................................................................16
Dimensional drawing.........................................................................................................17
Midget Retractor, Media Driven .............................................................................. 18
Reference List of Parts......................................................................................................18
Cross Sectional Drawing...................................................................................................19
Midget Retractor, Pneumatic Driven....................................................................... 20
Reference List of Parts......................................................................................................20
Cross Sectional Drawing...................................................................................................21
Midget Retractor, Media Drive unit.......................................................................... 22
Reference List of Parts......................................................................................................22
Cross sectional drawing....................................................................................................23
Midget Retractor, Pneumatic Drive unit .................................................................. 24
Reference List of Parts......................................................................................................24
Cross sectional drawing....................................................................................................25
How to Order Spare Parts and Claim Procedure.................................................... 26
How to Order Spare Parts.................................................................................................26
Spare part kit.....................................................................................................................26
Claim Procedure ...............................................................................................................26
How to contact Alfa Laval Tank Equipment A/S ..................................................... 27
Service Card ........................................................................................................... 28
Claim Report Working Conditions........................................................................... 29
Instruction Manual, Toftejorg SaniMidget Retractor Page 3
IM-TE91A750-EN1
Introduction
This manual has been prepared as a guide for installation and for the persons who will be operating
and maintaining your tank cleaning machine.
The key to long life for your tank cleaning machine is a carefully planned system for preventive
maintenance; you must appreciate that a tank cleaning machine which has a rough and dirty job to do
will need more frequent attention than one working under ideal conditions.
Note: Get the best and most economical performance from your tank cleaning machine. Insufficient
preventive maintenance means poor performance, unscheduled stops, shorter lifetime and extra costs.
Good preventive maintenance on the contrary means good performance, no unscheduled stops and
superior total economy.
The information in this manual is simple to follow, but should you require further assistance, our
Customer Service department and worldwide net of distributors will be pleased to help you. Please
quote the type, article and serial numbers with all of your enquiries; this will help us to help you.
The article number and serial number are placed on the front of the tank cleaning machine, SMR
XXXXXX/YYYY-YYY (article number/serial number).
Warning: Before installing the machine and setting it into operation carefully read the General
Installation Instructions (page 10) and the Safety Precautions (page 11) and take all
necessary precautions according to your application and local regulations.
Note: The illustrations and specifications contained in this manual were effective at the date of
printing. However, as continuous improvements are our policy, we reserve the right to alter or modify
any unit specification on any product without prior notice or any obligation.
Page 4 Instruction Manual, Toftejorg SaniMidget Retractor
IM-TE91A750-EN1
General Description
The Toftejorg SaniMidget Retractor is a tank cleaning machine intended for industrial use in closed
tanks for processing storage. There is a broad range of application area within pharmaceutical, food
and chemical industries.
The Toftejorg SaniMidget Retractor is a sanitary cleaning device of the rotating fan jets type for
permanent installation that provides a 270° Up cleaning pattern. During the process, the cleaner head
is not extended into the process but completely sealed off from the product area and is therefore not in
contact with the product. The cleaner head is automatically extended when cleaning starts and is
automatically retracted when cleaning is completed. The machine is designed in such a way that it is
completely self-cleaning. If Installed according to drawing on page 10, the SaniMidget Retractor is
completely self-draining in the shown positions. All products contacts surfaces are AISI 316L stainless
steel or FDA approved polymer materials.
No open thread or screws in the product areas.
The cleaning device is lubricated by the cleaning media. No oil, grease or other lubricants are used.
The Toftejorg SaniMidget Retractor is available in media driven or pneumatic driven versions which
means extended by media or pneumatic.
The Toftejorg SaniMidget Retractor is designed for use in pharmaceutical, biotechnological, food and
dairy processing applications. Process equipment with moving internals, and in processes where
permanently installed cleaner heads may have an undesired influence on the process or product.
It may be used in storage tanks, reactors, mixing tanks, spray dryers and other process equipment with
a volume ranging from 0.1-10m³ (27-2,700 US gallons). For larger volumes, multiple Toftejorg
SaniMidget Retractors may be applied.
Application assistance and optimal position recommendation is available
For use in explosive hazard zones both types can be used, provided they are installed according to the
safety instructions in local regulations.
Quality system
The Toftejorg SaniMidget Retractor is designed in accordance with the 3A Sanitary Standards No. 78-
00 as well as the guidelines of the European Hygienic Design Group (EHEDG) and thus complies with
requirements to design, materials, finish and documentation. It is produced according to Alfa Laval
Tank Equipment´s ISO 9001 international Standard certified quality system. All parts are made from
certified material and all non-metal parts are made from FDA-approved materials, 21 CFR § 177
Instruction Manual, Toftejorg SaniMidget Retractor Page 5
IM-TE91A750-EN1
General Description (continued)
Functioning
The Toftejorg SaniMidget Retractor consists of 2 main parts: The drive unit and the base housing. The
base housing includes the piston with the cleaner head.
Media driven
In the cleaning media operated version the
cleaner head extends from the pressure of the
cleaning media and is retracted by a spring.
The cleaning media is directed through the 1” tri-
clamp inlet connection into the housing. The liquid
pressures the piston, which moves forward to
extended position. At the same time the liquid
passes through drillings in the piston to the
cleaner head and out through the slots.
When cleaning is completed the machine is
automatically retracted by an integrated spring
system.
For total drain of the machine the retraction of the
cleaner head can be delayed by adjusting the
evacuation of air behind the piston. Use a
screwdriver and adjust the needle valve on the
rear part of the machine to correct position.
Pneumatic driven
In the pneumatic operated version, the cleaner
head is extended and retracted by an integrated
pneumatic cylinder. The cleaner head is extended
when air is applied to the pneumatic cylinder,
which must be done before cleaning media supply
has started. It is retracted to its initial position
when cleaning is completed by diverting the air
pressure from the pneumatic cylinder. The
pneumatic cylinder can remain extended during a
draining phase without media supply.
Page 6 Instruction Manual, Toftejorg SaniMidget Retractor
IM-TE91A750-EN1
General Description (continued)
Functioning
In both media and pneumatic driven Toftejorg SaniMidget Retractor versions, the cleaner head starts
rotating with fan jets due to the flow of the cleaning fluid. It projects a swirling pattern of media through
the tank or vessel which generates a vibrating impact and cascading flow coverage of the total internal
surface of the tank or vessel.
When the cleaning media pressure is shut off, the cleaning media is completely drained through the
cleaner head or the 1” tri clamp connection depending on the mounting position of the Toftejorg
SaniMidget Retractor
Spray Pattern
270°
Instruction Manual, Toftejorg SaniMidget Retractor Page 7
IM-TE91A750-EN1
- Blank page -
Page 8 Instruction Manual, Toftejorg SaniMidget Retractor
IM-TE91A750-EN1
Technical Data
Weight of machine : See table below
Working pressure :2-5 bar (29 – 73 psi)
Recommended pressure : 2-4 bar (29 –58 psi)
Max. working temperature :95° C (203° F )
Max. sterilisation temperature : 121° C ( 250° F)
Max. tank temperature :150° C (304° F)
Effective cleaning radius :
Materials, products area :AISI 316L, PEEK, Sealing: EPDM
Materials, non products area : AISI 304, POM, Sealing: NBR
Polymers FDA-approved 21 CFR § 177
Surface finish : Product contacts surfaces: Ra=0.8 µm – except weldings
:Self-lubricant with the cleaning media
Principal Dimensions in mm Connections
➀
➀➀
➀Tank connection
➁
➁➁
➁Inlet connection, cleaning media
1” Clamp ISO 2852
➂
➂➂
➂Air supply – pneumatic driven only
ISO 228-G 1/8
➃Option
Magnetic sensor
➄Adjustable valve – media driven only
Pneumatic version
Dimensions (mm)
Stroke A B C D Weight
100 100 410 510 133 5.0 kg (11.0 lbs)
150 150 510 660 183 5.5 kg (12.1 lbs)
250 250 710 960 283 6.4 kg (14.1 lbs)
Media driven
Dimensions (mm)
Stroke A B C D Weight
100 100 491 591 133 5.6 kg (12.4 lbs)
150 150 621 771 183 6.3 kg (13.9 lbs)
250 250 869 1119 283 7.4 kg (16.3 lbs)
Instruction Manual, Toftejorg SaniMidget Retractor Page 9
IM-TE91A750-EN1
Technical Data(continued)
Performance Data for Toftejorg SaniMidget Retractor
Flow rate Cleaning radius
Note: The inlet pressure has been taken immediately before the machine inlet. In order to achieve the
performance indicated in the curves, the pressure drop in the supply lines between pump and machine
must be taken in consideration.
Performance Data for Toftejorg SaniMidget Retractor Pneumatic driven
Air supply pressure : 2-5 bar (29-75 psi)
Air quality : Clean filtered max. 40 µm
Dry, dew point max. 5°C
Non-lubricated possible
Page 10 Instruction Manual, Toftejorg SaniMidget Retractor
IM-TE91A750-EN1
Installation and Normal Operation
General Installation Instructions
The Toftejorg SaniMidget Retractor is designed for installation according to the orientations shown
below.
The Toftejorg SaniMidget Retractor is self-cleaning and self-draining when positioned in recommended
positions, which is from 2 degrees to 58 degrees below vertical line and from 2 degrees to 20 degrees
below horizontal line.
Instruction Manual, Toftejorg SaniMidget Retractor Page 11
IM-TE91A750-EN1
Installation and Normal Operation (continued)
It is recommended to install a filter with mesh size 250 µm (0.01”) in the supply line in order to avoid
particles, scale etc. from clogging the inside of the cleaner. It is essential to avoid fine solid particles,
such as fine sand, in the cleaning fluid as they will increase wear considerably, and may cause slower
rotation speed or stoppage. This is particular important in case of recirculation.
Before installation, all supply lines and valves must be thoroughly flushed to remove remains of
welding electrodes, grinding dust, scale and other foreign matter.
During handling and installation handle the machine with care in order not to damage the fine surface
of the machine.
The Toftejorg SaniMidget Retractor machine has been tested at the factory before shipping, in
accordance with the Test Specifications.
Note: The machine shall be installed in accordance with national regulations for safety and other
relevant regulations and standards. In EU-countries the complete system must fulfil the EU-Machine
Directive and depending of application, the EU-Pressure Equipment Directive, the EU-ATEX Directive
and other relevant Directives.
Safety Precautions
The Toftejorg SaniMidget Retractor is intended for use inside a tank only, and must not be operated in
open air or when the tank is open.
Warning: Precautions shall be made to prevent starting of the cleaning operation, while personnel
are inside the tank or otherwise can be hit by jets from the cleaner head
Warning: If the machine is used in potential explosive atmospheres, tapes or joint sealing
compounds, which are electrical insulators, must not be used on joints, if this may
violate the grounding of the machine to the tank. Resistance between nozzles and tank
must not exceed 20.000 Ω. The intended installation with standard clamp connections
will ensure this. In addition, connecting pipe work, must be electrically conductive and
earthed to the tank structure.
This is essential to avoid the build-up of static electricity on the nozzles and the
machine. For further information see CENELEC R044-001 Safety of Machinery,
guidance and recommendations for the avoidance of hazards due to static electricity.
Electrical equipment such as magnetic valves and electric actuators must not be installed in Ex-zones
without type approval and marking, corresponding to the EX-class in question. Magnetic cylinder
sensors shall be EX-approved.
Page 12 Instruction Manual, Toftejorg SaniMidget Retractor
IM-TE91A750-EN1
Installation and Normal Operation (continued)
Normal Operation
Cleaning Media
Use only media compatible with Stainless Steel AISI 316L, PEEK and EPDM. Please note that PEEK
is not resistant to concentrated sulfuric acid. Normal detergents, moderate solutions of acids and
alkalics are acceptable. Aggressive chemicals, excessive concentrations of chemicals at elevated
temperatures, as well as certain solvents hydrochlorides should be avoided. If you are in doubt, contact
your local Alfa Laval Tank Equipment sales office.
Temperature
The machine is designed to operate with cleaning media at temperatures up to 95°C (203°F). However,
it stands temperatures up to 150 °C (304 °F) inside the tank, and it is possible to steam the tank
through the machines, 121°C (250°F) at steam sterilisation.
Warning: Tanks with capacities greater than 100 m3that could contain a flammable atmosphere
should not be steam cleaned, as steam issuing from a nozzle could contain charged
droplets.
Tanks smaller than this may be steam cleaned providing that: the steam nozzles and
other metal parts of the system are reliably earthed and grounded to the tank
structure.
Warning: In potentially explosive atmospheres, the temperature must not exceed the maximum
surface temperature according to the temperature class for the combustible gas or
liquid.
Pressure
Please make sure that the connections are correctly mounted before opening of the washing valve. Put
on pressure gradually in order to avoid hydraulic shocks, which might stress mechanical parts in the
Toftejorg SaniMidget Retractor cleaner. Max. pressure is 5.0 bar.
After-Use Cleaning
After use flush the machine with fresh water. Cleaning media should never be allowed to dry or set-up
in the system due to possible "salting out" or "scaling" of the cleaning media If cleaning media contains
volatile chloride solvents, it is recommended not to flush with water after use, as this might create
hydrochloric acid
Warning: Hot chemicals and steam under pressure may be used for cleaning and sterilising.
Protect against scalding and burning. Never tamper with or try to open clamps or other
connections while system is in operation. Make sure that system is de-pressurised and
drained before disassembly.
Instruction Manual, Toftejorg SaniMidget Retractor Page 13
IM-TE91A750-EN1
- Blank page -
Page 14 Instruction Manual, Toftejorg SaniMidget Retractor
IM-TE91A750-EN1
Maintenance and repair
Preventive Maintenance
In order to keep your tank cleaning machine servicing you as an efficient tool in your tank cleaning
operations, it is essential that you maintain its high performance by following a simple preventive
maintenance programme, which will help keep your tank cleaning machine in good condition.
Good maintenance is careful and regular attention!
The following recommended preventive maintenance is based on tank cleaning machines working in
average conditions. However, you will appreciate that a tank cleaning machine, which has a rough and
dirty job to do, will need more frequent attention than one working in ideal conditions. We trust that you
will adjust your maintenance programme to suit.
Caution: Handle machine with care. Take proper action to protect fine surfaces from being
damaged.
Always use only proper tools. Use Alfa Laval Tank Equipment A/S standard tool kit.
Never force or hammer components together or apart. Always perform all
assembly/disassembly steps in the order described in this manual.
Never assemble components without previous cleaning. This is especially important at
all mating surfaces.
Work in a clear well-lighted work area.
Every 100 working hours
Inspect the piston, cleaner head and o-rings:
Disassembly
Disassemble machine as described on the following pages.
1. Clean material build-up and deposits from internal parts with water or suitable chemical cleaner,
possibly Scotch-brite, S-Ultrafine.
2. Dismount the 1”Clamp ring, inlet connection and Gasket.
3. Dismount the 2 1/2”Clamp ring.
4. Lift up the part.
5. Remove the rear part with the piston and cleaner head.
6. Remove the clip and take off the pin from the valve and piston. The cleaner head is free from the
piston.
Instruction Manual, Toftejorg SaniMidget Retractor Page 15
IM-TE91A750-EN1
Maintenance and repair (continued)
Check/Inspection
1. Check the cleaner head for wear and remove possible particles. Look for any damage of the slide
bearings of the cleaner head and on the valve and piston. Replace new parts and cleaner head if
necessary.
2. Check o-ring on valve and piston for wear and replace if necessary.
Reassembly
Reassembly is carried out in the opposite order.
Rear part Media driven
Alfa Laval Tank Equipment A/S do not recommend or support disassembly of the rear part in the field.
Please return the machine to us for disassembly.
Rear Part Pneumatic driven
Alfa Laval Tank Equipment A/S do not recommend or support disassembly of the rear part in the field.
Please return the machine to us for disassembly.
Page 16 Instruction Manual, Toftejorg SaniMidget Retractor
IM-TE91A750-EN1
Magnetic Cylinder Sensor
Electrical and Mechanical Data
Operating voltage Ub: 10 - 30 V DC Wire-break protection : Yes
Ripple Upp : ≤10% of UbReverse polarity protection : Yes
Voltage drop Ud(at lamax.) : ≤1,5 V Enclosure rating to EN 60529 : IP 67
Continuous current la: ≤300 mA Ambient temperature Ta: -25 - + 75°C
Hysteresis H : ≤1.0 mm Housing material : Aluminium, plastic
Power consumption (without
load) : ≤10 mA Connection table
Power-up pulse suppression : PUR-PVC, 3x0.25 mm²
:Yes
Time delay before availability tv: ≤2 ms Short-circuit protection (pulsed) : Yes
Repeatability R
(Ub and Taconstant) : ≤0.1 mm Shock and vibration stress : 30 g. 11 ms
10 to 55 Hz. 1 mm
EMC : to EN 60 947-5-2
•High response sensitivity ≥3 mT
•Frontal sensing face
•No secondary switching ranges
•High repeat accuracy
•Actuating speed ≤5 m/s
•Short-circuit protection (pulsed)
•Solid aluminium housing
•Enclosure rating IP 67
•LED status indicator
Connection diagram
Wire colour Contact Assignment
bn brown 1 + V DC
bk black 4 NO
bu blue 3 - V DC
Instruction Manual, Toftejorg SaniMidget Retractor Page 17
IM-TE91A750-EN1
Magnetic Cylinder Sensor(continued)
Dimensional drawing
Reference List of Parts, Magnetic Cylinder Sensor, with 2 m Cable
Pos. Ref. no. No/
Unit Description Material
1 TE51V556 2 Sensor Aluminium, plasti
c
2TE51V558 2Mounting ring f. sensor Plastic
Reference List of Parts, Magnetic Cylinder Sensor, with 10 m Cable
Pos. Ref. no. No/
Unit Description Material
1 TE51V557 2 Sensor Aluminium, plasti
c
2TE51V558 2Mounting ring f. sensor Plastic
Page 18 Instruction Manual, Toftejorg SaniMidget Retractor
IM-TE91A750-EN1
Midget Retractor, Media Driven
Reference List of Parts
Art. no. TE75M000/077
Pos Ref. no. No/
Unit Description Material Remarks
1 TE75M502 1 Valve Stainless steel Spare part
2TE75M533 1Cleaner head Plastic material Wear part
3 TE52D549 1 Spring pin Stainless steel Spare part
4TE75M529 1Lock-pin Stainless steel Spare part
5See table* 1 Front tube, complete Assy
6TE75M310 1Piston, complete, stroke length = 100 Assy Spare part
TE75M310-15 1 Piston, complete, stroke length = 150 Assy Spare part
TE75M310-25 1Piston, complete, stroke length = 250 Assy Spare part
7 TE51S126 1 Clamp ring Stainless steel Spare part
8TE75M300 1Media drive unit, compl., stroke length = 100 Assy Spare part
TE75M300-15 1 Media drive unit, compl., stroke length = 150 Assy Spare part
TE75M300-25 1Media drive unit, compl., stroke length = 250 Assy Spare part
9TE51T166 2 O-ring EPDM Wear part
TE51T167 2O-ring Viton Wear part
TE51T168 2 O-ring Chemical resistant Wear part
10 TE51T169 1O-ring EPDM Wear part
TE51T170 1 O-ring Viton Wear part
TE51T171 1O-ring Chemical resistant Wear part
11 TE75M508 1 Gasket Plastic material Spare part
*) Pos. 5, Front tube, complete
Tank connection
Welding Clamp 2” Union
Stroke
length DIN
11.850 3”
ISO/US 3” DIN
11.851 DS 722 BS 4825 SMS
1145
100 TE75M315 TE75M316 TE75M318 TE75M319 TE75M320 TE75M321 TE75M322
150 -15 -15 -15 -15 -15 -15 -15
250 -25 -25 -25 -25 -25 -25 -25
Instruction Manual, Toftejorg SaniMidget Retractor Page 19
IM-TE91A750-EN1
Midget Retractor, Media Driven (continued)
Cross Sectional Drawing
Art. no. TE75M000/077
Table of contents
