Alfa Laval Toftejorg MultiJet 50 Instruction Manual Download

Page: 1 / 56

Covering:
Standard Machines
Machines delivered with ATEX/IECEx Certification in accordance with Directive 2014/34/EU
First published: 2010

ESE02851-EN5

2019-07

Original manual

Instruction Manual

Alfa Laval Toftejorg

MultiJet 50

Summary of Contents for Toftejorg MultiJet 50

Page 1: ...dard Machines Machines delivered with ATEX IECEx Certification in accordance with Directive 2014 34 EU First published 2010 ESE02851 EN5 2019 07 Original manual Instruction Manual Alfa Laval ToftejorgTM MultiJet 50 ...

Page 2: ......

Page 3: ...CEx certification 15 5 Operation 18 5 1 Normal operation 18 5 2 Safety precautions 19 6 Maintenance 20 6 1 Service and repair of ATEX IECEx certified machines 20 6 2 Preventive Maintenance 21 6 3 Top Assembly 22 6 4 Bottom Assembly 24 6 5 Hub Subassembly 26 6 6 Stem Subassembly 28 6 7 Gear Subassembly 30 6 8 Replacement of Collar Bushes 32 6 9 Replacement of Ball Races 34 6 10 Replacement of Main ...

Page 4: ...mation herein is correct at the time of issue but may be subject to change without prior notice 11 General information 55 11 1 Service and repair 55 11 2 How to order spare parts 55 11 3 How to contact Alfa Laval Kolding A S 55 4 ...

Page 5: ...ertificate no Baseefa10ATEX0188X and IECEx BAS xx xxxxX II 1G Ex h IIC 85ºC 175ºC Ga Marking II 1D Ex h IIIC T85ºC T140ºC Da The QAN Quality Assurance Notification is carried out by SGS Fimko Oy Särkiniementie 3 Helsinki 00211 Finland Notified Body No 0598 EU Type Examination Certification is carried out by SGS Fimko Oy Särkiniementie 3 Helsinki 00211 Finland Notified Body no 0598 IECEx Certificat...

Page 6: ... the tank cleaning machine 2 1 Important information WARNING Indicates that special procedures must be followed to avoid serious personal injury CAUTION Indicates that special procedures must be followed to avoid damage to the tank cleaning machine NOTE Indicates important information to simplify or clarify procedures 2 2 Warning signs General warning ATEX IECEx warning 6 ...

Page 7: ...on any product without prior notice or any obligation The English version of the instruction manual is the original manual We make reservations in regard to possible mistranslations in language versions of the instruction manual In case of doubt the English version of the instruction manual applies 3 2 Intended use The end user should verify that the tank cleaning machine is in conformity with res...

Page 8: ...tion of type of machine machine name serial number and manufacturing address The marking is placed on the gear house of the tank cleaning machine Serial number explanation Machines supplied with or without standard documentation yyyy xxxxx serial number yyyy year xxxxx 5 digit sequential number 8 ...

Page 9: ... carried out by the Certification Body SGS Baseefa Ltd who has issued the certificate no IECEx BAS xx xxxxX Note Explosion protection type is constructional safety c The marking on the ATEX IECEx certified Alfa Laval Toftejorg MultiJet 50 is as follows for information on marking position see section 3 4 Marking Serial number explanation Machines supplied with or without standard documentation yyyy...

Page 10: ... C T5 80 C 80 C 135 C T4 108 C 108 C 175 C 140 C 140 C Group III EPL Da The dust temperature class depends on the cleaning fluid temperature or the ambient temperature whichever of the two is the highest No dust layer is considered Table for determining temperature class dust atmospheres Temperature code Cleaning fluid temperature Tp C Ambient temperature Tamb C T85 C 85 C 85 C T100 C 100 C 100 C ...

Page 11: ...rbine rotation is through a gearbox transformed into a combined horizontal rotation of the machine body and a vertical rotation of the nozzles Machines with 2 nozzles The combined motion of the machine body and the nozzles ensures a fully indexed tank cleaning coverage After 11 revolutions of the Hub with nozzles 10 3 4 revolutions of the machine body one coarse cleaning pattern is laid out on the...

Page 12: ...ll pattern In general for both 2 and 4 nozzle machines The speed of rotation of the turbine depends on the flow rate through the machine The higher the flow rate the higher the speed of rotation will be In order to control the RPM of the machine for a wide range of flow rates the efficiency of the turbine can be changed 100 and 0 Turbine Inlet guide Apart from the jet flow through the nozzles flui...

Page 13: ...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 IECEx Directive and other relevant Directives and shall be CE marked before it is set into operation Warning Precautions shall be made to prevent starting of the cleaning operation while personnel are inside t...

Page 14: ...quirements or policies a liquid threadlocker such as Loctite No 243 or equivalent could be used Other methods could be acceptable and subject to customer preference For detailed instruction on pre cleaning and application of the product carefully follow the instruction on the used locking system Method for tightening the nozzles 1 Clamp machine firmly in a vice Protect machine with rubber pad unde...

Page 15: ... cleaning fluid and ambient temperature The temperature class and ambient temperature range are shown in paragraph 3 6 ATEX IECEx temperature class and code page 10 Warning Max permitted temperature When working The maximum permitted cleaning fluid temperature and ambient temperature is 95 C When not working The maximum permitted ambient temperature is 140 C Warning Draining using compressed air D...

Page 16: ...ossible under certain conditions It is necessary to know the current factors such as tank size cleaning solvent and product Additives can be used in the cleaning solvent or for example the tank can be filled with nitrogen The basic guidelines are described in the guide IEC TS 60079 32 1 2013 It must be ensured that the equipollently bonding of all conductive metal objects is in accordance with nat...

Page 17: ...d the residue of process fluid powder compound which can generate heat or a hybrid mixture Chemical reactions in Zone 20 Hybrid mixtures End user must ensure that the cleaning fluid used does not create a hybrid mixture according to IEC 60079 10 1 2015 Annex I 1 in connection with powder dust residues in the tank in zone 20 This should ensure that the atmosphere does not change to a classification...

Page 18: ... of the body in order to avoid risk of machine breakdown Draining should always be done inside the tank See paragraph 4 4 Specific conditions for safe use in accordance with ATEX IECEx certification page 15 Steam cleaning If stream cleaning is done through the machine the steam pressure must not cause the machine body rotation to exceed 17 rpm corresponding to approx 3 5 sec per rev of the body in...

Page 19: ...y to open clamps or other connections while system is in operation Make sure that system is depressurised and drained before disassembly The cleaning jets impinging the tank surface are a source of noise Depending on pressure and distance to the tank walls noise level may reach up to 85 dB Warning Tanks may contain poisonous hazardous products or products which represent an environmental or safety...

Page 20: ...re compliance with the ATEX IECEx regulations and keep the machine ATEX IECEx certification valid the service or repair must be performed by an authorized person with knowledge of the ATEX IECEx requirements and regulations All spare parts must be original Alfa Laval spare parts and the repair or service must be done according to the instructions in this manual Warning If a customer wishes to carr...

Page 21: ...ages 2 Clean material build up and deposits from internal parts with chemical cleaner and fine abrasive cloth 3 Check Slide bearings pos 30 on the cross sectional drawing page for wear If hole is worn oval to max diameter more than 12 4 mm Slide bearing should be replaced If end face of Slide bearing is worn more than x mm into Slide bearing it should be replaced Under Turbine shaft x 1 5 mm At Ho...

Page 22: ... a hole in the Stem 5 Pull off Impeller pos 4 Reassembly 1 Reinstall Impeller pos 4 Make sure that Impeller is correctly rotated to be pushed onto Turbine shaft Do not try to hammer Impeller in position as this will damage Slide bearing under Turbine shaft 2 Mount Washer pos 18 Spring washer pos 16 and Screw pos 17 and tighten To secure Impeller against rotation insert carefully Screwdriver tool N...

Page 23: ...6 Maintenance Top Assembly 23 ...

Page 24: ...ing Gear subassembly Reassembly 1 Reinsert Gear subassembly in bottom of machine body Mount Spring washers pos 16 and Screws pos 17 along circumference of Gear frame pos 31 Tighten screws crosswise Note Turbine shaft is inserted carefully through Gear wheel and Stem Note also that to secure meshing between Gear wheel pos 8 and Pinion pos 11 it might be necessary to rotate slightly either the whole...

Page 25: ...6 Maintenance Bottom Assembly TD523346 25 ...

Page 26: ...y should be replaced as well as the Ball retainer with balls pos 27 How to replace Ball races see page 34 If blue liners on Stem are extremely worn they can be replaced This part requires that a precise procedure is followed to accomplish installation It is highly recommended that an authorized Alfa Laval Tank Equipment Service Center perform the replacement when necessary Reassembly 1 Slide on Hu...

Page 27: ...6 Maintenance Hub Assembly TD523347 27 ...

Page 28: ...ace Ball races see page 34 If blue liners on Stem are extremely worn they can be replaced This part requires that a precise procedure is followed to accomplish installation It is highly recommended that an authorized Alfa Laval Tank Equipment Service Center perform the replacement when necessary Reassembly 1 Push Stem pos 3 into Body Turn machine upside down 2 Place Ball retainer with balls pos 27...

Page 29: ...6 Maintenance Stem Subassembly TD523326 29 ...

Page 30: ... pos 18 4 Draw out Pinion pos 11 and 2nd stage Worm wheel pos 13 also freeing Journal pos 15 after removal of Screw pos 17 Spring washer pos 16 and Washer pos 18 5 Remove Bearing covers pos 32 and Slide bearings pos 30 after removal of Screw pos 17 How to replace Collar bushes pos 12 see page 32 Warning Do not damage driver faces on Turbine shaft Use only proper tools providing a firm grip such as...

Page 31: ... Screw pos 17 Check rotation 4 Insert Turbine shaft pos 7 Mount Washer pos 18 Spring washer pos 16 and fix with Screw pos 17 Use faces on Turbine shaft to hold against rotation when tightening screw 5 Hold Turbine shaft pos 7 against 1st stage Worm wheel and tighten Screws pos 17 in Horizontal shaft pos 29 and Pinion pos 11 Check rotation on Turbine shaft 31 ...

Page 32: ...bush with Pusher 3 Turn Gear frame 900 and hold over support Knock out collar bush with Pusher 4 Remove all remains of old Araldite etc Holes must be perfectly clean before mounting new Collar bushes Rinse with chemical cleaner 5 Coat new Collar bushes with CIBA GEIGY two component Standard blue Araldite and push into Gear frame 6 To hold Collar bushes in correct position insert fixtures tool No T...

Page 33: ...6 Maintenance Removal of old Collar bushes TD523310 Support Support TD523312 Support TD523311 Mounting of new Collar bushes TD523309 33 ...

Page 34: ...sired wooden block carefully hammer Ball races home Ball races must not project over end face of Main collar lower To avoid tilting mandrel must push along the whole circumference of Ball race Do not damage surface of Ball race On Gear wheel 1 Place Gear wheel with ball race pos 8 on support Support only under Ball race pos 8 1 With mandrel press off old Ball race 2 Clean surfaces and press on new...

Page 35: ...6 Maintenance Replacement of Ball races Support TD523329 Support TD52333 35 ...

Page 36: ...dy Do not damage special thread in Body Recess must be absolutely clean and free from remains of old Loctite If desired use solution of ethylene glycol 3 Make sure that new Main collar is clean and free from impurities Apply Loctite No 243 on thread 4 Screw in new Main collar Attention should be given to make sure that thread is in correct engagement before screwing in Main collar 5 Tighten Main c...

Page 37: ...0 Check free rotation of Stem Remove Stem see page 28 Remove foreign material material build up on Stem and inside Main collars Clean Ball races and Ball retainer with balls Also clean main bush e Gearbox jammed sluggish Remove foreign material from Gearbox Check rotation of shafts If restriction is recognized disassemble gearbox see page 30 and remove material build up especially on 2 Stage Worm ...

Page 38: ...Working pressure 5 12 bar 72 174 psi Recommended inlet pressure 5 10 bar 72 145 psi Working temperature max 95 C 200 F Ambient temperature 0 140 C 95 C 140 C when not operated Materials Stainless steel AISI 316 316L PTFE Tefzel PVDF Carbon Principal dimensions in mm 2 BSP or 2 NPT 4109 0022 38 ...

Page 39: ...8 Technical data Toftejorg MultiJet 50 with 2 nozzles Flow rate TD523139_1 A B C D E Inlet pressure A m3 h B USgpm C nozzle sizes D psi E bar 39 ...

Page 40: ...1 3 less Effective throw length is defined as impact centre of jet 250 mm water column 50 lbs sq ft Effective throw length varies depending on jet transverse speed over surface substance to be removed cleaning procedure and agent 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 b...

Page 41: ...8 Technical data Toftejorg MultiJet 50 with 2 nozzles Cleaning Time f complete Pattern 4 cycles A B C D E TD523141_1 Inlet pressure A min B RPM of machine body C nozzle sizes D psi E bar 41 ...

Page 42: ...rking pressure 3 12 bar 44 175 psi Recommended inlet pressure 5 6 5 bar 72 94 psi Working temperature max 95 C 200 F Ambient temperature 0 140 C 95 C 140 C when not operated Materials Stainless steel AISI 316 316L PTFE Tefzel PVDF Carbon Principal dimensions in mm 2 BSP or 2 NPT 41090018_1 42 ...

Page 43: ...8 Technical data Toftejorg MultiJet 50 with 4 nozzles Flow rate D E A B C 4109 0006_1 Inlet pressure A m3 h B USgpm C nozzle sizes D psi E bar 43 ...

Page 44: ...prox 1 3 less Effective throw length is defined as impact centre of jet 250 mm water column 50 lbs sq ft Effective throw length varies depending on jet transverse speed over surface substance to be removed cleaning procedure and agent 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 li...

Page 45: ...8 Technical data Toftejorg MultiJet 50 with 4 nozzles Cleaning Time f complete Pattern 8 cycles A B C D E 4109 0008_1 Inlet pressure A min B RPM of machine body C nozzle sizes D psi E bar 45 ...

Page 46: ...ple 2 x ø12 TE22M128 2 NPT 2 x ø13 TE22M130 2 x ø14 TE22M132 0 2 x ø15 TE22M134 Standard configurations Toftejorg MultiJet 50 with 4 nozzles Connection Turbine Inlet Guide Nozzles mm 3 4 thread connection Article No 4x ø8 TE22M040 Nipple 100 4x ø9 TE22M042 2 Rp BSP 4x ø9 TE22M050 0 4x ø10 TE22M052 4x ø8 TE22M010 Nipple 100 4x ø9 TE22M012 2 NPT 4x ø9 TE22M030 0 4x ø10 TE22M032 The machine is equipp...

Page 47: ...Ex Explanation to Add ons ATEX IECEx includes ATEX IECEx certified machine for use in explosive atmospheres Category 1 for installation in zone 0 20 in accordance with directive 2014 34 EU II 1G Ex h IIC 85 C 175 C Ga II 1D Ex h IIIC T85 C T140 C Da ATEX IECEx 47 ...

Page 48: ...10 Parts list and drawing service kits and tools 10 1 MultiJet 50 with 2 nozzles 4109 0024 48 ...

Page 49: ...8 1 1 Main collar upper 28 2 1 Main collar lower 28 3 1 Ball race 28 4 1 Hub collar 29 1 Horizontal shaft 30 2 Slide bearing 31 1 Gear frame 32 2 Bearing cover 33 1 Bottom cover Service kits Denomination Item no Service kits Minor service kit for MultiJet 50 TE55M000 Major service kit for MultiJet 50 TE55M100 Configuration according to delivery note order Parts marked with are included in the Mino...

Page 50: ...10 Parts list and drawing service kits and tools 10 2 MultiJet 50 with 4 nozzles 4109 0025 50 ...

Page 51: ... collar upper 28 2 1 Main collar lower 28 3 1 Ball race 28 4 1 Hub collar 29 1 Horizontal shaft 30 2 Slide bearing 31 1 Gear frame with bushes 32 2 Bearing cover 33 1 Bottom cover Service kits Denomination Item no Service kits Minor service kit for MultiJet 50 TE55M000 Major service kit for MultiJet 50 TE55M100 Configuration according to delivery note order Parts marked with are included in the Mi...

Page 52: ...or Service Kit TE55M010 Minor Service Kit TE55M000 or Major Service Kit TE55M010 Minor Service Kit TE55M000 or Major Service Kit TE55M010 Please refer to the Spare Part Manual for information on item numbers and materials The Spare Part Manual is available from the online Alfa Laval product catalogue Anytime or the Close at hand spare part catalogue 52 ...

Page 53: ...key for screw 1 pcs TE134A Unbraco Screwdriver 1 pcs TE135 Unbraco key for screw 1 pcs TE135A Unbraco screw driver 1 pcs Available on request Tool No Description TE81B031 Pusher for 2 Gear frame TE81B032 Fixture set f Gear frame Sketch of tools for replacement of Collars bush TE81B031 Pusher for Gear frame TE81B032 Fixture set f Gear frame TD523313 TD523314 53 ...

Page 54: ...10 Parts list and drawing service kits and tools Sketch of tools for replacement of Main collars A TE81B131 Tool for Upper collar B TE81B132 Tool for Lower collar TD523315 A B 54 ...

Page 55: ...be ordered from the parts lists page 48 and 50 Item number and denomination should be clearly stated Please refer to the Spare Part Manual for information on item numbers The Spare Part manual is available from the on line Alfa Laval Product catalogue Anytime or the Close at hand spare part catalogue Please also quote the type of machine and serial number This will help us to help you The type and...

Page 56: ...is the responsibility of the user of this document to comply with all applicable intellectual property laws Without limiting any rights related to this document no part of this document may be copied reproduced or transmitted in any form or by any means electronic mechanical photocopying recording or otherwise or for any purpose without the expressed permission of Alfa Laval Corporate AB Alfa Lava...

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