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2 Safety

Unsafe practices and other important information are emphasized in this manual.
Warnings are emphasized by means of special signs.
Always read the manual before using 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:

Содержание Toftejorg MultiJet 65

Страница 1: ...dard machines Machines delivered with ATEX IECEx Certification in accordance with Directive 2014 34 EU First published 1990 ESE02852 EN5 2019 07 Original manual Instruction Manual Alfa Laval ToftejorgTM MultiJet 65 ...

Страница 2: ......

Страница 3: ...ification 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 collars ...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 7: ...ation 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 wi...

Страница 8: ...Jet 65 is certified as category I component The ATEX certification is carried out by the Notified Body SGS Fimko Oy who has issued the certificate no Baseefa10ATEX0188X The IECEx certification is 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...

Страница 9: ...8 C 100 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...

Страница 10: ...The turbine 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 ...

Страница 11: ...cle Full 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 50 100 0 Turbine Inlet guide Apart from the jet flow through the nozzles...

Страница 12: ... 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 IECEx Directive and other relevant Directives and shall be CE marked before it is set into operation Warning Precauti...

Страница 13: ...ith the specified torque However depending on the application and local policies an extra securing may be preferred Subject to the intended use environment and any inhouse user requirements 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...

Страница 14: ...with the torque wrench Step 1 Step 2 Rubber jaw mounted upside down Protect with rubber pad Recommended tightening torque 75 Nm Check that the machine is in operating condition by inserting Hex Screwdriver tool No TE134A in screw in top of Turbine shaft and easily turn Turbine shaft clockwise If any resistance is recognised the machine should be disassembled to localise the cause 14 ...

Страница 15: ... of the 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 9 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...

Страница 16: ...m is possible 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 wi...

Страница 17: ...uid and 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 classifi...

Страница 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 33 rpm corresponding to approx 1 8 sec per rev of the body in ...

Страница 19: ... or try 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 ...

Страница 20: ...o ensure 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 t...

Страница 21: ...needed for each tank cleaning machine model These are not included in the price and may be disregarded Always replace all parts included in the Service Kit Always use only proper tools Use standard tool kit Never force hammer or pry components together or apart Always perform all assembly disassembly steps in the order described in this manual Never assemble components without previous cleaning Th...

Страница 22: ... 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 No TE135A through Impeller pos 4 into a ...

Страница 23: ...6 Maintenance MultiJet 65 Top Assembly 4109 0032 23 ...

Страница 24: ...for holding 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 t...

Страница 25: ...6 Maintenance MultiJet 65 Bottom Assembly TD523346 25 ...

Страница 26: ...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 Alternatively in many cases it is possible to purchase a complete...

Страница 27: ...6 Maintenance MultiJet 65 Hub Assembly 4109 0033 27 ...

Страница 28: ...etainer 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 Alternatively in many cases it is possible to purchase a complete ...

Страница 29: ...6 Maintenance MultiJet 65 Stem Subassembly TD523326 29 ...

Страница 30: ...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 a wrench or a vice Reassembly 1 Push Slide bearings pos 30 into Gear frame pos 31 and fix Bearing covers pos 32 with Screws pos 17 Tighten crosswise 2 Insert 2nd stage Worm wheel pos 13 Pinion pos 11 and Journal pos 15 Mount Washer ...

Страница 31: ...6 Maintenance MultiJet 65 Gear Subassembly TD523327 31 ...

Страница 32: ...ollar 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 too...

Страница 33: ...6 Maintenance MultiJet 65 Removal of old Collar bushes TD523310 Support TD523312 Support TD523311 Mounting of new Collar bushes TD523309 33 ...

Страница 34: ... if desired 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 ...

Страница 35: ...6 Maintenance MultiJet 65 Replacement of Ball races Support TD523329 Support TD52333 35 ...

Страница 36: ...ol see page 53 into Main collar pos 28 1 To loosen Loctite knock hard on tool with hammer Unscrew Main collar 2 Carefully clean thread and recess in Body 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...

Страница 37: ...page 30 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 sluggish rotation of shafts If restriction is recognized disassemble Gear subassembly see page 30 and remove material build up esp...

Страница 38: ...ing 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 Carbon PVDF A4 Tefzel Principal dimensions in mm 2 BSP or 2 NPT 4109 0038 38 ...

Страница 39: ...8 Technical data MultiJet 65 Flow rate A B C 41090035 Inlet pressure A m3 h B Nozzle sizes C bar 39 ...

Страница 40: ... 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 between pump and machine must be taken into consideration Option The Alfa Laval ...

Страница 41: ...8 Technical data MultiJet 65 Cleaning Time f complete Pattern 8 cycles A 4109 0037 B C Inlet pressure A rpm sec B Nozzle sizes C bar 41 ...

Страница 42: ...ing 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 Carbon PVDF A4 Tefzel Principal dimensions in mm 2 BSP or 2 NPT 4109 0039 42 ...

Страница 43: ...t 65 Flow rate 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 5 6 7 8 9 10 11 12 4xø14 4xø13 4xø12 4xø11 75 100 125 150 175 150 200 250 300 350 400 A B C D E T41090011_1 Inlet pressure A m3 h B gpm C Nozzle sizes D psi E bar 43 ...

Страница 44: ...row 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 between pump and machi...

Страница 45: ...ltiJet 65 Cleaning Time f complete Pattern 8 cycles 30 35 40 45 50 55 60 65 70 75 80 5 6 7 8 9 10 11 12 4xø14 4xø13 4xø12 4xø11 75 100 125 150 175 D A B C 41090013_1 Inlet pressure A rpm sec B Nozzle sizes C psi D psi 45 ...

Страница 46: ...ø21 TE23M140 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 Table 2 Machine with 4 nozzles Connection Nozzles mm 1 thread conn Item no 4 x ø12 TE23M012 4 x ø13 TE23M013 4 x ø14 TE23M014 4 x ø15 TE23M015 2 BSP 4 x ø12 TE23M002 4 x ø13 TE23M003 4 x ø14 TE23M004 4 x ø15 TE23M005 2...

Страница 47: ...EX IECEx 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 ...

Страница 48: ...10 Parts List and Drawing service Kits and tools MultiJet 65 10 1 Alfa Laval Toftejorg MultiJet 65 with 2 nozzles 4109 0040 48 ...

Страница 49: ...ain collar lower 28 3 1 Ball race 29 1 Horizontal shaft 30 2 Slide bearing 31 1 Gear frame w bushes 32 2 Bearing cover 33 1 Bottom cover Service kits Denomination Item no Service kits MINOR service kit for MultiJet 65 PTFE TE55M000 MAJOR service kit for MultiJet 65 PTFE TE55M010 Configuration according to delivery note order Parts marked with are included in the Minor Service Kit PTFE TE55M000 Par...

Страница 50: ...10 Parts List and Drawing service Kits and tools MultiJet 65 10 2 Alfa Laval Toftejorg MultiJet 65 with 4 nozzles 4109 0041 50 ...

Страница 51: ...r 28 3 1 Ball race 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 65 PTFE TE55M000 MAJOR service kit for MultiJet 65 PTFE TE55M010 Configuration according to delivery note order Parts marked with are included in the Minor Service Kit PTFE TE55M000 Parts marked with are inclu...

Страница 52: ...EAR Minor service kit TE55M000 TE55M400 E GEAR or Major Service Kit TE55M010 TE55M410 E GEAR Minor service kit TE55M000 TE55M400 E GEAR or Major Service Kit TE55M010 TE55M410 E GEAR 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 ...

Страница 53: ... key for screw 1 pcs TE134A Unbraco Screwdriver 1 pcs TE135 Unbraco key for screw 1 pcs TE135A Unbraco screw driver 1 pcs TE369 Caliper 1 pcs Available on request Tool No Denomination 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 ...

Страница 54: ...10 Parts List and Drawing service Kits and tools MultiJet 65 Sketch of tools for replacement of Main collars 41090042 54 ...

Страница 55: ...d always be ordered from the parts lists page 48 ff 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 online 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...

Страница 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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