Alfa Laval Toftejorg SaniJet 25 Instruction Manual Download Page 1

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Instruction Manual
Alfa Laval Toftejorg

SaniJet 25

With

•

Standard

•

Q-doc (3.1 Inspection Certificate – EN 10204)

•

Q-doc + FAT-SAT (Qualification Documentation)

•

ATEX Certification in accordance with Directive 94/9/EC

•

USP Class VI materials

IM-TE91A760_EN12

ESE01842EN

Date of issue: January 13, 2015

First published: May 2004

Original manual

Summary of Contents for Toftejorg SaniJet 25

Page 1: ...rd Q doc 3 1 Inspection Certificate EN 10204 Q doc FAT SAT Qualification Documentation ATEX Certification in accordance with Directive 94 9 EC USP Class VI materials IM TE91A760_EN12 ESE01842EN Date o...

Page 2: ......

Page 3: ...llation Instructions 15 Special Conditions for Safe Use ATEX 17 Operation Contents 19 Operation 21 Cleaning Media 21 Product 21 Pressure 21 Temperature 21 After Use Cleaning 21 Safety Precautions 22 M...

Page 4: ...50 Assembly 51 Assembly of turbine 51 Assembly of Cone 54 Assembly of top parts 57 Assembly of lower parts 62 Assembly of planet gear 67 Assembly of gear ring 68 Assembly of body parts 69 Checking the...

Page 5: ...fication Doc ATEX TE20J0XX 9X Qualification Doc Explanation to documentation add on s Explanation to Add on s Qualification Doc includes Declaration of Compliance EN 10204 type 3 1 inspection Certific...

Page 6: ...ct Program Available welding connection Sanitary welding adapter see right with sealing assembly between Down pipe Welding adapter and machine use cone with seal seals comes with machines Pipe Dimensi...

Page 7: ...self cleanability EHEDG Doc 2 see page 84 and tested to be sterilizable EHEDG Doc 5 Warning In order to maintain the hygienic state of the machine it is of highest importance that the SaniJet 25 is h...

Page 8: ...chine or Note The illustrations and specifications contained in this manual were effective at the date of printing However as continuous improvements are part of our policy we reserve the right to alt...

Page 9: ...chines supplied with or without normal documentation yyyy xxxxx serial number yyyy year xxxxx 5 digit sequential number Machines supplied with Qualification Documentation package yyyy FAT SAT xxx seri...

Page 10: ...S without prior notice Such changes will however be incorporated in the next editions of this Instruction Manual Alfa Laval Kolding A S All right reserved The Alfa Laval logotype is a trademark or a r...

Page 11: ...tem The SaniJet 25 is designed in accordance with the EHEDG design guidelines for sanitary design of processing equipment and is the first ever rotating jet head that has been awarded the certificate...

Page 12: ...r to control the RPM of the machine for the wide range of flow rates the machine has different turbines according to the Nozzle size Self cleaning is ensured by flushing the planet gear the Hub the be...

Page 13: ...Data Technical Data Weight of machine 6 3 kg 11 2 lb Working pressure 3 8 bar 40 115 psi Recommended inlet pressure 5 7 bar 70 100 psi Working temperature max 95 C 200 F Ambient temperature 0 140 C 9...

Page 14: ...Note Throw lengths are measured as horizontal throw length at static condition Vertical throw lengths upwards are approx 1 3 less The inlet pressure has been measured immediately at the machine inlet...

Page 15: ...t 25 Standard machines machines delivered with Q Doc and or ATEX certification Dir 94 9 EC IM TE91A760_EN12 Page 13 Instruction Manual Installation Contents Contents 13 General Installation Instructio...

Page 16: ...Page 14 Instruction Manual Alfa Laval Toftejorg SaniJet 25 Standard machines machines delivered with Q Doc and or ATEX certification Dir 94 9 EC IM TE91A760_EN12...

Page 17: ...trolled pump with a ramp function for start up is used for supplying the cleaning liquid Before connecting the machine to the system all supply lines and valves should be flushed in order to remove fo...

Page 18: ...cies adhesive such as Loctite No 243 or equivalent could be used Other methods could be acceptable and subject to customer preference ATEX Warning If the machine is used in potential explosive atmosph...

Page 19: ...The maximum permitted process fluid working pressure is 8 bar ATEX Warning The unit must not be operated in a vessel having an enclosed volume of greater than 100m 3 Tanks larger than 100 m To use Ta...

Page 20: ...Page 18 Instruction Manual Alfa Laval Toftejorg SaniJet 25 Standard machines machines delivered with Q Doc and or ATEX certification Dir 94 9 EC IM TE91A760_EN12...

Page 21: ...chines machines delivered with Q Doc and or ATEX certification Dir 94 9 EC IM TE91A760_EN12 Page 19 Instruction Manual Operation Contents Contents 19 Operation 21 Cleaning Media 21 Product 21 Pressure...

Page 22: ...Page 20 Instruction Manual Alfa Laval Toftejorg SaniJet 25 Standard machines machines delivered with Q Doc and or ATEX certification Dir 94 9 EC IM TE91A760_EN12...

Page 23: ...e Avoid hydraulic shocks Increase pressure gradually Do not exceed 8 bar inlet pressure Recommended inlet pressure 5 7 bar High pressure in combination with high flow rate will increase consumption of...

Page 24: ...aned providing that the steam nozzles and other metal parts of the system are reliably earthed and grounded to the tank structure Safety Precautions The machine is intended for use inside a tank only...

Page 25: ...g 29 Reference list of parts 30 Toolkit and tools for assembly and disassembly 33 TE81B155 Standard toolkit f SaniJet 25 33 Disassembly 34 Disassembly into main subassemblies 34 Disassembly of lower p...

Page 26: ...Page 24 Instruction Manual Alfa Laval Toftejorg SaniJet 25 Standard machines machines delivered with Q Doc and or ATEX certification Dir 94 9 EC IM TE91A760_EN12...

Page 27: ...your local Alfa Laval sales office for discussion Service and Repair of ATEX approved machines In order to ensure compliance with the ATEX regulations for service and repair in accordance with EN 600...

Page 28: ...mity for all spare parts are stored in the Q Doc Maintenance Log as PDF files The machine is returned to the customer incl the Q Doc Log CD and hardcopy of all FAT documents for further qualification...

Page 29: ...7 01 No Unit Description 2 TE51T212 TE51T212 1 Gasket 3 3 TE51T135 TE51T135 2 O ring 6 TE51T138 TE51T194 1 O ring 7 TE51T139 TE51T139 1 O ring 9 TE51T141 TE51T196 2 O ring 10 TE51T140 TE51T195 2 O rin...

Page 30: ...rst disassemble the machine according to the disassembly instruction given later in this manual and check the parts in the Minor Service Kit for excessive wear and replace if needed Available add on s...

Page 31: ...Instruction Manual Alfa Laval Toftejorg SaniJet 25 Standard machines machines delivered with Q Doc and or ATEX certification Dir 94 9 EC IM TE91A760_EN12 Page 29 Assembly drawing Assembly drawing...

Page 32: ...Stainless steel Wear part 9 TE 51T141 2 O ring Elastomer Wear part 10 TE 51T140 2 O ring Elastomer Wear part 11 1 TE 20J521 1 Bushing Polymer Wear part 12 TE 20J515 1 Planet gear Polymer Stainless ste...

Page 33: ...steel Wear part 9 TE 51T196 2 O ring Elastomer Wear part 10 TE 51T195 2 O ring Elastomer Wear part 11 1 TE 20J521 1 Bushing Polymer Wear part 12 TE 20J515 1 Planet gear Polymer Stainless steel Wear p...

Page 34: ...rmation Available add on s for Spare parts Item no Description TE20XXXX 8X TE20XXXX 9X Declaration of Conformity EN 10204 type 3 1 inspection Certificate FDA Declaration of Conformity USP Class VI if...

Page 35: ...0J392 1 Fixture tool f hub and turbine 3 TE20J393 1 Ring key f nuts dismountable 4 TE20J366 1 Fixture tool f nozzle 5 TE20J360 1 Fixture tool f stem 6 TE81B139 1 Drift f bushings 7 TE81B156 1 Torque w...

Page 36: ...o main subassemblies Tools need for disassembly Standard toolkit Ref nr Description TE20J386 Fixture tool f body TE20J593 Ring key f nuts dismountable TE81B157 NV8 socket long TE81B156 Torque wrench 4...

Page 37: ...und the cone until the screws in the ring key are level with the hygienic recesses in the stem nut Pos 4 NOTE Be careful not to damage the surfaces 3 Tighten the 4 screws by hand only symmetrically in...

Page 38: ...ith Q Doc and or ATEX certification Dir 94 9 EC IM TE91A760_EN12 Disassembly into main subassemblies 5 Loosen the stem nut Pos 4 byhand while lifting the cone Pos 1 1 6 Remove the assembled top parts...

Page 39: ...EC IM TE91A760_EN12 Page 37 Disassembly into main subassemblies 8 Remove the 3 screws Pos 13 5 securing the gear ring Pos 13 2 to the body using the torque wrench and NV8 socket long TE81B156 TE81B15...

Page 40: ...s 11 Loosen the bench vise slightly and turn the machine 90 and tighten the bench vise again 12 Lower the ring key TE20J393 around the hub nut Pos 15 and tighten the 4 screws by hand only symmetricall...

Page 41: ...nes machines delivered with Q Doc and or ATEX certification Dir 94 9 EC IM TE91A760_EN12 Page 39 Disassembly into main subassemblies 14 Remove O rings Pos 9 and 10 Same as those used at other end of b...

Page 42: ...assembly of lower parts Hub Disassembly of lower parts Hub Tools required for the disassembly Standard toolkit Ref nr Description TE20J366 Fixture tool f nozzle TE20J392 Fixture tool f hub and turbine...

Page 43: ...cation Dir 94 9 EC IM TE91A760_EN12 Page 41 Disassembly of lower parts Hub 3 Put the hub tool kit TE20J392 on top of the bevel gear Pos 14 and loosen the bevel gear using ring key NV36 TE81B159 4 Remo...

Page 44: ...chines delivered with Q Doc and or ATEX certification Dir 94 9 EC IM TE91A760_EN12 Disassembly of lower parts Hub 5 Carefully lift the hub nut Pos 15 of the Nozzle head Pos 18 while keeping it horizon...

Page 45: ..._EN12 Page 43 Disassembly of top parts Cone and turbine Disassembly of top parts Cone and turbine Tools need for disassembly Standard toolkit Ref nr Description TE20J360 Fixture tool f stem TE81B159 N...

Page 46: ...ines delivered with Q Doc and or ATEX certification Dir 94 9 EC IM TE91A760_EN12 Disassembly of top parts Cone and turbine 3 Loosen cone Pos 1 1 using the 36NV spanner TE81B159 4 Loosen the cone Pos 1...

Page 47: ...ejorg SaniJet 25 Standard machines machines delivered with Q Doc and or ATEX certification Dir 94 9 EC IM TE91A760_EN12 Page 45 Disassembly of top parts Cone and turbine 5 Remove the impeller assembly...

Page 48: ...delivered with Q Doc and or ATEX certification Dir 94 9 EC IM TE91A760_EN12 Disassembly of top parts Cone and turbine 7 Carefully lift the stem nut Pos 4 off the stem Pos 8 while keeping it horizonta...

Page 49: ...c and or ATEX certification Dir 94 9 EC IM TE91A760_EN12 Page 47 Disassembly of top parts Cone and turbine 9 Extract gasket Pos 2 from the inside of the top of the cone Pos 1 1 10 Push out bushing Pos...

Page 50: ...ols need for disassembly Standard toolkit Ref nr Description TE20J392 Fixture tool f hub and turbine TE81B156 Torque wrench 4 24 Nm TE81B158 NV9 socket long 1 Mount the impeller turbine fixture TE20J3...

Page 51: ...ATEX certification Dir 94 9 EC IM TE91A760_EN12 Page 49 Disassembly of gear ring bearing for body Pos 13 3 Disassembly of gear ring bearing for body Pos 13 3 Tools need for disassembly Standard toolk...

Page 52: ...sembly of planet gear bushing Pos 11 1 Disassembly of planet gear bushing Pos 11 1 Tools need for disassembly Standard toolkit Ref nr Description 3 5 mm drift Hammer 2 Withdraw the bushing Pos 11 1 fr...

Page 53: ...ion 3 1 TE20J540 1 Impeller Shaft 3 2 o TE20J544 1 Impeller 4 2mm nozzle o TE20J546 1 Impeller 6 2mm nozzle o TE20J545 1 Impeller 5 2mm nozzle 3 3 TE51T135 2 O ring 3 4 TE20J542 1 Shaft end Tools need...

Page 54: ...elivered with Q Doc and or ATEX certification Dir 94 9 EC IM TE91A760_EN12 1 Place the O rings Pos 3 3 into the grooves of the impeller Pos 3 2 2 Secure the turbine shaft fixture TE20J392 to hold the...

Page 55: ...ed with Q Doc and or ATEX certification Dir 94 9 EC IM TE91A760_EN12 Page 53 4 Place impeller Pos 3 2 with O rings Pos 3 3 onto the impeller shaft 5 Screw the shaft end Pos 3 4 into the turbine shaft...

Page 56: ...Doc and or ATEX certification Dir 94 9 EC IM TE91A760_EN12 Assembly of Cone Assembly of Cone Parts required for the assembly Pos Ref No No Unit Description 1 1 TE20J510 1 Cone 1 2 TE20J514 1 Bushing...

Page 57: ...ines machines delivered with Q Doc and or ATEX certification Dir 94 9 EC IM TE91A760_EN12 Page 55 Assembly of Cone 1 Mount bushing Pos 1 2 in cone Pos 1 1 using the drift punch TE81B139 to put it in p...

Page 58: ...oftejorg SaniJet 25 Standard machines machines delivered with Q Doc and or ATEX certification Dir 94 9 EC IM TE91A760_EN12 Assembly of Cone 3 Mount the gasket Pos 2 into the groove at the bottom of th...

Page 59: ...red for the assembly Pos Ref No No Unit Description 1 Assembled cone 1 Assembled turbine 4 TE20J627 1 Nut for stem 5 TE20G318 2 Ball retainer with balls 6 TE51T138 or TE51T194 1 O ring 7 TE51T139 1 O...

Page 60: ...ed with Q Doc and or ATEX certification Dir 94 9 EC IM TE91A760_EN12 Assembly of top parts 1 Secure the montage tool kit for stem TE20J360 in benchvise 2 Fit the stem Pos 8 onto the fixture tool kit f...

Page 61: ...Place the stem nut Pos 4 onto the stem Pos 8 while keeping the stem horizontal Do not apply any force to it 5 Preparation of O rings Pos 6 and 7 before mounting Dip the O rings in water If water is n...

Page 62: ...food graded FDA compliant grease The grease reduces the risk for galling in threads The grease is enclosed between the O rings and therefore it will not come into contact with the cleaning media Be v...

Page 63: ..._EN12 Page 61 Assembly of top parts 9 Carefully screw the cone Pos 1 1 onto the stem Pos 8 by hand 10 Tighten the cone Pos 1 1 using the ring key spanner TE81B141 or TE81B159 until you feel a stop and...

Page 64: ...TE20J522 1 Bevel gear 15 TE20J638 1 Nut for hub 16 TE51T136 or TE51T192 1 O ring 17 TE51T137 or TE51T193 1 O ring 18 o TE20J320 1 Nozzle head 4 2mm nozzle o TE20J321 1 Nozzle head 5 2mm nozzle o TE20J...

Page 65: ...Q Doc and or ATEX certification Dir 94 9 EC IM TE91A760_EN12 Page 63 Assembly of lower parts 1 Secure the fixture for the nozzles TE20J366 in benchvise 2 Place the nozzle head Pos 18 into the fixture...

Page 66: ...n before mounting the bevel gear Pos 14 on nozzle head Pos 18 It is recommended to grease the nozzle head thread with food graded FDA compliant grease The grease reduces the risk for galling in thread...

Page 67: ...N12 Page 65 Assembly of lower parts 8 Preparation of O rings before mounting Dip the O rings in water If water is not used then be very careful about how the O rings behave when screwing the cone onto...

Page 68: ...bly of lower parts 11 Screw the bevel gear Pos 14 with the hub tool TE20J392 while pressing on the tool Tighten the bevel gear Pos 14 using Ring key TE81B159 until you feel a stop and then tighten it...

Page 69: ...Assembly of planet gear Parts and tools required for the assembly Pos Ref No No Unit Description 11 1 TE20J521 1 Bushing 12 TE20J515 1 Planet gear Tools need for assembly Standard toolkit Ref nr Desc...

Page 70: ...ols required for the assembly Pos Ref No No Unit Description 13 2 TE20J506 1 Gear ring 13 3 TE20J508 1 Bearing for body 13 4 TE20J509 6 Seal ring Tools need for assembly Standard toolkit Ref nr Descri...

Page 71: ...9 EC IM TE91A760_EN12 Page 69 Assembly of body parts Assembly of body parts Parts and tools need for assembly Pos Ref No No Unit Description Assembled top parts Assembled lower parts Assembled gear r...

Page 72: ...scription TE20J386 Fixture tool f body TE20J393 Ring key f nuts dismountable TE81B157 NV8 socket long TE81B158 NV9 socket long TE81B156 Torque wrench 4 24 Nm Brush for applying grease Glass of water G...

Page 73: ...56 TE81B157 to maximum 5 Nm Too much torque breaks the screws 3 Preparation of O rings before mounting Dip the O rings in water If water is not used then be very careful about how the O rings behave w...

Page 74: ...come into contact with the cleaning media Be very careful not to put grease onto the O rings as the O rings swells in contact with grease If the food graded FDA compliant grease is not allowed into t...

Page 75: ..._EN12 Page 73 Assembly of body parts 10 Lower the ring key TE20J393 carefully around the cone Pos 1 1 Tighten the four screws by hand only symmetrically on stem nut 11 Tighten the stem nut Pos 4 until...

Page 76: ...he O ring groove inside the body 16 Preparation before mounting the assembled lower parts on body Pos 13 1 It is recommended to grease the body thread with food graded FDA compliant grease The grease...

Page 77: ...5 Assembly of body parts 18 Lower the ring key TE20J393 carefully around the nozzle head Pos 18 Tighten the four screws by hand only symmetrically on the hub nut Pos 15 19 Tighten the hub nut Pos 15 u...

Page 78: ...hand and rotate the shaft end clockwise using the wrench extension TE81B146 or TE81B156 and NV9 spanner socket TE81B145 or TE81B158 The body Pos 13 1 and nozzle head Pos 18 should rotate easily very...

Page 79: ...atedly get jammed in the machine install filter or reduce mesh size of installed filter in supply line Turbine shaft sluggish in bearings g Remove Turbine shaft with impeller see page 32 and clean bea...

Page 80: ...How to contact Alfa Laval Tank Equipment For further information please feel free to contact Alfa Laval Tank Equipment Alfa Laval Kolding A S 31 Albuen DK 6000 Kolding Denmark Registration number 309...

Page 81: ...ir 94 9 EC IM TE91A760_EN12 Page 79 Instruction Manual Misc Contents Contents 79 EC Declaration of Conformity with ATEX 81 Declaration of Conformity EN 10204 sub clause 2 2 Test Report 82 EHEDG certif...

Page 82: ...Page 80 Instruction Manual Alfa Laval Toftejorg SaniJet 25 Standard machines machines delivered with Q Doc and or ATEX certification Dir 94 9 EC IM TE91A760_EN12...

Page 83: ...lfa Laval Toftejorg SaniJet 25 Standard machines machines delivered with Q Doc and or ATEX certification Dir 94 9 EC IM TE91A760_EN12 Page 81 EC Declaration of Conformity with ATEX EC Declaration of C...

Page 84: ...jorg SaniJet 25 Standard machines machines delivered with Q Doc and or ATEX certification Dir 94 9 EC IM TE91A760_EN12 Declaration of Conformity EN 10204 sub clause 2 2 Test Report Declaration of Conf...

Page 85: ...Manual Alfa Laval Toftejorg SaniJet 25 Standard machines machines delivered with Q Doc and or ATEX certification Dir 94 9 EC IM TE91A760_EN12 Page 83 Declaration of Conformity EN 10204 sub clause 2 2...

Page 86: ...Manual Alfa Laval Toftejorg SaniJet 25 Standard machines machines delivered with Q Doc and or ATEX certification Dir 94 9 EC IM TE91A760_EN12 EHEDG certificate of self cleanability EHEDG certificate o...

Page 87: ...Declaration of compliance for food contact materials Declaration of compliance for food contact materials Instruction Manual Toftejorg SaniJet 25 Page 85 IM TE91A760 EN5...

Page 88: ...Condition for Safe Use 1 The Unit may be operated only when filled with fluid 2 The maximum permitted process fluid temperature is 95 C with an ambient temperature range of 0 C to 140 C 3 The maximum...

Page 89: ...Instruction Manual Alfa Laval ToftejorgSaniJet 25 Page 87 Standard machines machines delivered with Q Doc and or ATEX certification Dir 94 9 EC IM TE91A760_EN12...

Page 90: ...specialized products and engineered solutions Our equipment systems and services are dedicated to helping customers to optimize the performance of their processes Time and time again We help our custo...

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