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Instruction Manual, Gunclean Toftejorg T-82

Standard machines and machines delivered with ATEX certification

in accordance with Directive 94/9/EC

IM-TE91A052-EN4

Declarations of conformity

Manufacturer:

Alfa Laval Tank Equipment A/S

Address:

Baldershoej 19, DK-2635 Ishoej

Phone:

+45 43 55 86 00. Fax: +45 43 55 86 01

E-mail:

[email protected]

herewith declare that the below mentioned product:

Gunclean Toftejorg T-82 Portable

is in conformity with the provisions of:

- The Machinery Directive 2006/42/EC, Annex II, Paragraph 1, Part A

- The Equipment explosive atmospheres (ATEX) Directive 94/9/EC.

- The Pressure Directive 97/23/EC

- FDA 21CFR§177

Harmonised European Standards:

The machine is manufactured in accordance with the relevant clauses of the following standards:

The Machinery Directive:
DS/EN ISO 12100-1, DS/EN ISO 12100-2, EN 1672-2

The pressure directive:

According to its own volume and the rated pressure range the product is regarded an Article 3, par. 3 Equipment.

The ATEX-Directive:

For machines with item nos. TE21F2XX-70 & TE21F2XX-22-70

DS/EN 1127-1, DS/EN 13463-1, DS/EN 13463-5
DS/EN 13980 Annex A, paragraph A.5.3 Rotating machines

ATEX Certification:

EC Type Examination Certificate no. Baseefa10ATEX0188X

Marking:

1 GD c T175°C Tamb 0°C to +140°C

Baseefa (2001) Ltd., Notified Body number 1180. Rockhead Business Park, Staden Lane, Buxton, Derbyshire
SK17 9RZ, United Kingdom

Place:

Ishoej, Denmark

Place:

Ishoej, Denmark

Date:

December 28, 2011

Date:

December 28, 2011

Signature:

Name and title:

Henrik Falster Hansen

Name and title:

Denniz Høxbroe

R&D Manager

ATEX responsible engineer

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Содержание Gunclean Toftejorg T-82

Страница 1: ...Instruction Manual Gunclean Toftejorg T 82 IM TE91A052 EN4 Date of issue December 28 2011 Covering Standard Machines Machines delivered with ATEX Certification in accordance with Directive 94 9 EC ...

Страница 2: ......

Страница 3: ...e 94 9 EC 20 Maintenance and repair 22 Service and Repair of ATEX Approved Machines 22 Preventive Maintenance Guidelines and Service Kits 23 Maintenance intervals and Service Kits selection 23 Top Assembly 26 Bottom Assembly 28 Hub Subassembly 30 Stem Subassembly 32 Gear Subassembly 34 Replacement of Collar Bushes 36 Replacement of Ball Races 38 Replacement of Main Collars 40 Tools 42 Trouble Shoo...

Страница 4: ......

Страница 5: ...net of Distributors will be pleased to help you Please quote the type and serial number with all your enquiries this will help us to help you The type and serial number are placed on the gear house of the tank cleaning machine 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 ri...

Страница 6: ...nts and trademarks This Instruction Manual is published by Alfa Laval Tank Equipment A S without any warranty Improvements and changes to this Instruction Manual may at any time be made by Alfa Laval Tank Equipment A S without prior notice Such changes will however be incorporated in new editions of this Instruction Manual Alfa Laval Tank Equipment A S 2011 All rights reserved The Alfa Laval logot...

Страница 7: ...eefa who has issued the certificate no 10ATEX0188X The marking on the ATEX certified Gunclean Toftejorg TZ 82 is as follows Changes to the machine are not allowed without approval by the person responsible for the ATEX certification at Alfa Laval Tank Equipment A S If changes are made or spare parts other than Alfa Laval original spare parts are used the EC Type Examination certification the ATEX ...

Страница 8: ...tions of Hub with nozzles 103 4 revolutions of the machine body one coarse cleaning pattern is laid out on the tank surface During the following rounds this pattern is repeated 3 times each of which is displaced of the mesh in the pattern After a total of 45 revolutions of the Hub with nozzles 43 revolutions of the machine body a complete cleaning pattern has been laid out and the first pattern is...

Страница 9: ...ine Inlet Guide Nozzles mm 3 4 thread conn Article Ref No Portable with 1 NPT Nipple 50 2xø7 TE21F262 100 2xø8 2xø9 TE21F272 TE21F274 0 2xø10 TE21F280 The hub of the machine is equipped with a clutch in the hub which gives the possibility of rotation by hand the nozzles when the machine is to be lifted out through a tank opening Standard Options Machines with nozzle extensions for longer throw len...

Страница 10: ... IM TE91A052 EN4 Technical data For Gunclean Toftejorg T 82 Fixed Weight of machine 7 0 kgs 15 4 lb Working pressure 5 12 bar 75 175 psi Recommended inlet pressure 5 10 bar 75 150 psi Working temperature max 78 C 173 F Ambient temperature 0 140 C 78 C 140 C when not operated Materials Stainless steel polymer elastomer carbon Principal dimensions in mm ...

Страница 11: ...l Gunclean Toftejorg T 82 Page 9 Standard machines and machines delivered with ATEX certification in accordance with Directive 94 9 EC IM TE91A052 EN4 Technical data continued For Gunclean Toftejorg T 82 Fixed Flow rate ...

Страница 12: ... Vertical throw length upwards is approx 1 3 less 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 between pump and machine must be taken into conside...

Страница 13: ...org T 82 Page 11 Standard machines and machines delivered with ATEX certification in accordance with Directive 94 9 EC IM TE91A052 EN4 Technical data continued For Gunclean Toftejorg T 82 Fixed Cleaning Time f Complete Pattern 4 cycles ...

Страница 14: ...91A052 EN4 Technical data continued For Gunclean Toftejorg T 82 Portable Weight of machine 7 0 kgs 15 4 lb Working pressure 5 12 bar 75 175 psi Recommended inlet pressure 5 10 bar 75 150 psi Working temperature max 78 C 173 F Ambient temperature 0 140 C 78 C 140 C when not operated Materials Stainless steel polymer elastomer carbon Principal dimensions in mm ...

Страница 15: ...Gunclean Toftejorg T 82 Page 13 Standard machines and machines delivered with ATEX certification in accordance with Directive 94 9 EC IM TE91A052 EN4 Technical data continued For Gunclean Toftejorg T 82 Portable Flow rate ...

Страница 16: ...e measured as max horizontal throw length at static condition Vertical throw length upwards is approx 1 3 less 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 sup...

Страница 17: ...rg T 82 Page 15 Standard machines and machines delivered with ATEX certification in accordance with Directive 94 9 EC IM TE91A052 EN4 Technical data continued For Gunclean Toftejorg T 82 Portable Cleaning Time f Complete Pattern 4 cycles ...

Страница 18: ...y on the machine For further information see DS CLC TR 50404 2003 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 Note The machine shall be installed in accordance wi...

Страница 19: ... down wards as illustrated on the figure Clamp on the Hub To protect machine use rubber jaws on the vice 2 Set torque wrench at the specified tightening torque 3 Tighten nozzle with the torque wrench Recommended tightening torque 40m 4 Check that the machine is in operating condition by inserting 3 16 hex Screwdriver tool No TE134A in screw in top of Turbine shaft and easily turn Turbine shaft clo...

Страница 20: ... Use Cleaning After use flush the machine with fresh water Cleaning solutions should never be allowed to dry or set up in the system due to possible salting out or scaling of the cleaning ingredient If cleaning media contains volatile chloride solvents it is recommended not to flush with water after use in case this can create hydrochloric acid Pressure Avoid Hydraulic shocks Put on pressure gradu...

Страница 21: ... ATEX Warning Tanks with capacities greater than 100 m3 that 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 ATEX Warning In potentially explosive atmo...

Страница 22: ...fe Use in accordance with the ATEX Certification Directive 94 9 EC ATEX Warning The unit may be operated in a hazardous area only when filled with the process fluid ATEX Warning The maximum permitted process fluid temperature and ambient temperature when the machine is operating is 78 C When the machine is not operating the maximum permitted ambient temperature is 140 C ATEX Warning The maximum pe...

Страница 23: ...w 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 rules are described in the guide CLC TR 50404 2003 Following a guidance document such as CLC TR 50404 2003 to establish safe use of machinery and process is the users own responsibility and is not covered by the ATEX certif...

Страница 24: ...rk Warning ATEX requirements regarding repair of ATEX approved machines according to EN 60079 19 A tag with the following labelling information must be attached to the machine Repair symbol R Alfa Laval logo and address Repair number Date of repair Machine serial number The tag must be laminated and attached to the machine downpipe outside the tank using a cable tie If a customer wishes to carry o...

Страница 25: ...ertified machines Maintenance intervals and Service Kits selection Alfa Laval Service Kits for Tank Cleaning Machine type T 82 are available in two levels Minor Service and Major Service Minor Service kit is recommended to be replaced every 300 working hours or 2 years whichever comes first TE55J000 Minor Service Kit contains TE21B292 Minor Service Kit for Hub Deflector version contains Pos Qty x ...

Страница 26: ...Minor T 82 All Major Service kits includes the corresponding Minor Service Kits parts Each kit contains a maintenance guide The above recommended preventive maintenance is based on one machine working under average conditions However a system that has a rough and dirty job to do will need more frequent attention than one working under ideal conditions We trust that you will adjust your maintenance...

Страница 27: ...ean material build up and deposits from internal parts with Scotchbrite S Ultrafine eventually chemical cleaner and fine abrasive cloth 4 Replenish Lubricant The quantity of grease required to reach Normal Filling is 0 75 l whereby the gear frame is just covered The quality of lubricant is USDA approved grease NLGI grade 2 The machine is delivered lubricated with grease Shell Alvania WR 2 5 Assemb...

Страница 28: ...aces on Mechanical seal Reassembly 1 Carefully put on the stationary seat of Mechanical seal including O ring into the house When inserting the stationary seats be careful to apply even pressure and use only water or alcohol to reduce O ring friction Note Absolute cleanliness and care is essential when fitting mechanical seals Dirt and damage to sliding faces and O rings jeopardise the function of...

Страница 29: ...ction Manual Gunclean Toftejorg T 82 Page 27 Standard machines and machines delivered with ATEX certification in accordance with Directive 94 9 EC IM TE91A052 EN4 Maintenance and repair continued Top Assembly ...

Страница 30: ...t for holding Gear Subassembly Reassembly 1 Reinsert Gear subassembly in bottom of machine body Turn Gear Frame pos 31 to align holes in Gear frame and 3 16 threads in Body Mount Spring washers pos 18 and Screws pos 17 along circumference of Gear frame pos 31 Tighten screws crosswise Note To secure meshing between Gear wheel pos 9 and Pinion pos 10 it might be necessary to rotate slightly either t...

Страница 31: ...ion Manual Gunclean Toftejorg T 82 Page 29 Standard machines and machines delivered with ATEX certification in accordance with Directive 94 9 EC IM TE91A052 EN4 Maintenance and repair continued Bottom Assembly ...

Страница 32: ...ce Caliper tool No TE369 is used for the unscrewing using the two holes in end face of Hub conical part Note Left hand thread If Ball races in Hub cover pos 21 and in Bevel gear pos 19 1 are extremely worn they should be replaced as well as the Ball retainer with balls pos 27 How to replace Ball races see page 38 5 Remove Lipseal pos 25 and check for wear If the lipseal is worn it has to be replac...

Страница 33: ...ction Manual Gunclean Toftejorg T 82 Page 31 Standard machines and machines delivered with ATEX certification in accordance with Directive 94 9 EC IM TE91A052 EN4 Maintenance and repair continued Hub Assembly ...

Страница 34: ... pos 29 How to replace Ball races see page 38 If Liners on Stem are extremely worn they can be replaced This part requires that a precise procedure is followed to accomplish installation It is suggested that an authorised Alfa Laval Tank Equipment Service Centre perform the replacement if necessary However should the customers insist that they perform the installation please contact your nearest S...

Страница 35: ...ion Manual Gunclean Toftejorg T 82 Page 33 Standard machines and machines delivered with ATEX certification in accordance with Directive 94 9 EC IM TE91A052 EN4 Maintenance and repair continued Stem Subassembly ...

Страница 36: ...18 and Washer pos 14 5 Draw out Pinion pos 10 and 2nd stage Worm wheel pos 12 also freeing Journal pos 13 after removal of Screw pos 17 Spring washer pos 18 and Washer pos 14 6 Remove Bearing cover pos 16 and Ball bearing pos 30 after removal of Screws pos 17 7 Remove Screw pos 17 Spring washer pos 18 Washer pos 14 and Ball bearing pos 30 from Turbine shaft pos 7 Use faces on Turbine shaft to hold...

Страница 37: ...asher pos 18 and fix with screw pos 17 Check rotation 4 Insert 1st stage Worm wheel pos 12 and Horizontal shaft pos 29 Mount Washer pos 14 Spring washer pos 18 and fix with Screw pos 17 Check rotation 5 Reinstall Turbine shaft pos 7 in Gear frame as mentioned under Disassembly point 1 6 Hold Turbine shaft pos 7 against 1st stage Worm wheel and tighten Screws pos 17 in Horizontal shaft pos 29 and P...

Страница 38: ...ce jaws of a vice Do not clamp on machined surfaces With Pusher tool No TE81B033 see page 42 knock out Collar bush 2 Turn Gear frame to upright position and hold over support such as flat steel bar clamped in a vice Knock out Collar bush with Pusher 3 Turn Gear frame 90 and hold over support Knock out Collar bush with Pusher Warning To avoid risk of deforming Gear frame it is utmost important that...

Страница 39: ...nual Gunclean Toftejorg T 82 Page 37 Standard machines and machines delivered with ATEX certification in accordance with Directive 94 9 EC IM TE91A052 EN4 Maintenance and repair continued Replacement of Collar Bushes ...

Страница 40: ...n collar lower pos 34 Press by hand as long as possible By means of a tube mandrel or if desired wooden block carefully hammer Ball race home Ball race must not project over 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 9 and 9 1 on support Support only under ...

Страница 41: ...anual Gunclean Toftejorg T 82 Page 39 Standard machines and machines delivered with ATEX certification in accordance with Directive 94 9 EC IM TE91A052 EN4 Maintenance and repair continued Replacement of Ball races ...

Страница 42: ...r pos 36 Unscrew Main collar 2 Carefully clean thread and recess in Body Do not damage special thread in Body Recess must be absolutely clean 3 Make sure that new Main collar is clean and free from impurities 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 collar fully home and tighten up 6 Check t...

Страница 43: ...nual Gunclean Toftejorg T 82 Page 41 Standard machines and machines delivered with ATEX certification in accordance with Directive 94 9 EC IM TE91A052 EN4 Maintenance and repair continued Replacement of Main Collars ...

Страница 44: ...d Tool kit for Gunclean Toftejorg T 82 Article No TE81B060 Tool No Description Number TE134 Unbraco key for Screw 1 pcs TE134A Unbraco screw driver 2 pcs TE369 5 mm Caliper 1 pcs Available on request TE81B033 Pusher for 1 Collar bush TE81B034 Fixture set f Collar bush Sketch of Tools for replacement of Collar bush TE81B033 Pusher for 1 Collar bush TE81B034 Fixture set f Collar bush ...

Страница 45: ...ual Gunclean Toftejorg T 82 Page 43 Standard machines and machines delivered with ATEX certification in accordance with Directive 94 9 EC IM TE91A052 EN4 Tools continued Sketch of Tools for Replacement of Main Collars ...

Страница 46: ...dly get jammed in the machine install filter or reduce mesh size of installed filter in supply line Foreign Material or Material Build up Insert hex Screwdriver in screw in top of Turbine shaft and easily turn Turbine shaft clockwise If any resistance is recognized disassemble machine to localize the cause a Impeller jammed Remove Guide and Impeller see page 26 and remove foreign material b Turbin...

Страница 47: ...that Ball bearings have only minor axial or radial movement and can be rotated freely without any resistance b Bush in Stem See page 23 24 c Worm wheels See page 23 24 d Collar bushes See page 23 24 e Turbine shaft Check clearance in Bush and in Ball bearing Transverse movement in Bush should not exceed 0 5 mm Also inspect worm for wear f Horizontal shaft Check clearance in Collar bushes Transvers...

Страница 48: ...ess steel Spare part 19 TE722S 1 Bevel gear w ball race Stainless steel Spare part 19 1 TE826 1 Ball race Stainless steel Wear part 20 TE21B340 1 Hub cover w ball race Stainless steel Spare part 21 TE826 1 Ball race Stainless steel Wear part 22 TE50B007 2 Nozzle ø 7 Stainless steel Spare part TE50B008 2 Nozzle ø 8 Stainless steel Spare part TE50B009 2 Nozzle ø 9 Stainless steel Spare part TE50B010...

Страница 49: ...n Manual Gunclean Toftejorg T 82 Page 47 Standard machines and machines delivered with ATEX certification in accordance with Directive 94 9 EC IM TE91A052 EN4 Cross Sectional Drawing Gunclean Toftejorg T 82 Fixed ...

Страница 50: ...l Spare part 17 TE118 38 Screw Stainless steel Spare part 18 TE156 18 Spring washer Stainless steel Spare part 19 TE722S 1 Bevel gear w ball race Stainless steel Spare part 19 1 TE826 1 Ball race Stainless steel Wear part 20 TE21B340 1 Hub cover w ball race Stainless steel Spare part 21 TE826 1 Ball race Stainless steel Wear part 22 TE50B007 2 Nozzle ø 7 Stainless steel Spare part TE50B008 2 Nozzl...

Страница 51: ...Manual Gunclean Toftejorg T 82 Page 49 Standard machines and machines delivered with ATEX certification in accordance with Directive 94 9 EC IM TE91A052 EN4 Cross Sectional Drawing Gunclean Toftejorg T 82 Portable ...

Страница 52: ... 11 3 x TE21A585 Collar Bush 12 2 x TE21A367 Worm Wheel 12 2 x TE21A367 Worm Wheel 15 1 x TE21D563 Packing 15 1 x TE21D563 Packing 25 1 x TE21B549 Lip Seal 25 1 x TE52D062 Lip Seal 30 2 x TE829 Ball Bearing 30 2 x TE829 Ball Bearing 35 1 x TE807 O ring 35 1 x TE807 O ring 37 3 x TE651 Locking Wire TE55J010 Major Service Kit T 82PT FIX MUD Pos Qty x P n Description 7 1 x TE21F510 Turbine Shaft 9 1 ...

Страница 53: ...he type of machine and serial number This will help us to help you The type and serial numbers are stamped on the body of the tank cleaning machine Claim Procedure In case of failure that needs assistance from Alfa Laval Tank Equipment A S it is essential for our evaluation that the problem as well as the working conditions of the machine are described as detailed as possible For description of th...

Страница 54: ...delivered with ATEX certification in accordance with Directive 94 9 EC IM TE91A052 EN4 Service Card Type of Machine Serial No Configuration Nozzle diameter mm Impeller Guide Date No of Working Hours Maintenance Actions Exchanged Parts Remarks Sign 0 Machine put into operation V 94 2 ...

Страница 55: ...zles x ø mm Turbine Inlet Guide Working Conditions Inlet pressure at machine cleaner Type of Valve in inlet line Can hydraulic shock be disregarded Yes No Inlet line flushed before installation of tank cleaner Yes No Working hours before failure hours Cleaning Programme Cleaning media and conc Temperature Time Recirculation Is sterilising being used Yes No Procedure media temp Is steam injection b...

Страница 56: ...rticles size _____________________________ Crystallizing Soft particles size ______________________________ Has filter been installed in inlet line Yes Mesh size mm No Is tank cleaner flushed with clean water after tank cleaning Yes No Type of Soilage Tank Contents to be removed Name formula concentration of material to be removed from tank What is material soluble in Nature of material Volatile e...

Страница 57: ...2100 2 EN 1672 2 The pressure directive According to its own volume and the rated pressure range the product is regarded an Article 3 par 3 Equipment The ATEX Directive For machines with item nos TE21F0XX 70 TE21F2XX X2 70 DS EN 1127 1 DS EN 13463 1 DS EN 13463 5 DS EN 13980 Annex A paragraph A 5 3 Rotating machines ATEX Certification EC Type Examination Certificate no Baseefa10ATEX0188X Marking I...

Страница 58: ...Machinery Directive DS EN ISO 12100 1 DS EN ISO 12100 2 EN 1672 2 The pressure directive According to its own volume and the rated pressure range the product is regarded an Article 3 par 3 Equipment The ATEX Directive For machines with item nos TE21F2XX 70 TE21F2XX 22 70 DS EN 1127 1 DS EN 13463 1 DS EN 13463 5 DS EN 13980 Annex A paragraph A 5 3 Rotating machines ATEX Certification EC Type Examin...

Страница 59: ...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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