Alfa Laval Toftejorg TJ20G Instruction Manual
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Alfa Laval Toftejorg TJ20G Instruction Manual

Alfa Laval Toftejorg TJ20G Instruction Manual

Rotary jet head tank-cleaning device
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Instruction Manual
Alfa Laval Toftejorg
With
 Standard
 Distillery
 Secured
 High temp
 Hastelloy
 3.1 Inspection Certificate – EN10204
 ATEX Certification in accordance with Directive 94/9/EC
TM
TJ20G
www.sks-online.com
www.sks-webshop.com
IM-TE91A600-EN6
ESE01794EN
Date of issue: May 8, 2014
First published: June 2000
Original manual

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Summary of Contents for Alfa Laval Toftejorg TJ20G

  • Page 1 Instruction Manual Alfa Laval Toftejorg TJ20G With  Standard  Distillery  Secured  High temp  Hastelloy  3.1 Inspection Certificate – EN10204  ATEX Certification in accordance with Directive 94/9/EC IM-TE91A600-EN6 ESE01794EN Date of issue: May 8, 2014...
  • Page 2 www.sks-online.com www.sks-webshop.com...

  • Page 3: Table Of Contents

    Contents Toftejorg TJ20G, Product Program ................3 Introduction ........................ 5 Marking ........................6 Serial number explanation ....................6 ATEX Marking ......................6 Serial number explanation ....................7 Intended use ......................8 Patents and trademarks .................... 8 General Description ....................9 Quality system ......................
  • Page 4 Symptom: Slow rotation or failure of machine to rotate ............ 42 Symptom: Slow rotation or failure of machine to rotate (continued) ......... 43 How to Order Spare Parts ..................44 How to contact Alfa Laval Tank Equipment ............. 44 Miscellaneous Misc. - Contents ....................... 45 EU Declaration of Conformity incl.

  • Page 5: Toftejorg Tj20G, Product Program

    Toftejorg TJ20G, Product Program This manual covers the product program for Toftejorg TJ20G tank cleaning machine Toftejorg™ TJ20G options Connection Nozzles Standard Distillery Hastelloy Secured High temp. (mm) Article No. Article no. Article no. Article no. Article no. 1" BSP 4 x ø3.9...
  • Page 6 1” NPT TE52D031 1 ½” ISO Dairy pipe: ø38 x 1.2 1” BSP TE52D032 Sanitary connection cone Page 4 Instruction Manual, Alfa Laval Toftejorg TJ20G Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A600_EN6 www.sks-online.com www.sks-webshop.com...

  • Page 7: Introduction

    Introduction With a new revolutionary patented design, the Toftejorg™ TJ20G introduces a new generation of tank cleaning machines. Based on more than 30 years’ experience from practical tank cleaning and production, the Toftejorg™ TJ20G has been developed to meet the highest demands for efficiency, reliability and hygiene within food and beverage, pharmaceutical and biochemical industry.

  • Page 8: Marking

    Marking Alfa Laval tank cleaning machines are all marked to allow recognition of machine type, machine name, Serial number and manufacturing address. The marking are placed on the body of the tank cleaning machine. Serial number explanation Machines supplied with or without normal...

  • Page 9: Serial Number Explanation

    Changes to the machine are not allowed without approval by the person responsible for the ATEX certification at Alfa Laval Kolding 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 Directive) is no longer valid.

  • Page 10: Intended Use

    This Instruction Manual is published by Alfa Laval Kolding A/S without any warranty. Improvements and changes to this Instruction Manual may at any time be made by Alfa Laval Kolding A/S without prior notice. Such changes will, however, be incorporated in new editions of this Instruction Manual.

  • Page 11: General Description

    The TJ20G is designed in accordance with the EHEDG design guidelines for sanitary design of processing equipment. It is produced according to Alfa Laval Kolding A/S’ ISO 9001 International Standard certified quality system. All parts are made from certified material and all non-metal parts are made from FDA and EU compliant materials.
  • Page 12 Loctite No. 243 or equivalent could be used. Other methods could acceptable subject customer preference. Page 10 Instruction Manual, Alfa Laval Toftejorg TJ20G Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A600_EN6 www.sks-online.com www.sks-webshop.com...

  • Page 13: Technical Data

    Technical Data Weight of machine 5.1 kgs (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 (95°C/200°F - 140°C/284°F when not operated) No-EPDM machines 0 - 200°C (95°C/200°F - 200°C/392°F when not operated) TE20G016-72/TE20G016-82 TE20G017-72/TE20G017-82...

  • Page 14: Performance Data

    Performance Data Flow rate Horizontal throw length at static condition Distillery version (20G030_044) – flow at 5 bar: 4 x Ø3.9 = 10 m 4 x Ø4.6 = 12.4 m 4 x Ø5.5 = 13.9 m Effective throw length is defined as 250 mm water column (50 lbs/sq.ft.) impact force in centre of jet.

  • Page 15: Installation

    Installation Installation Manual – Contents General Installation Instructions ................14 Special Conditions for Safe Use – ATEX ..............16 www.sks-online.com www.sks-webshop.com...

  • Page 16: General Installation Instructions

    If resistance is recognised, the machine should be disassembled in order to localise the cause or returned to the nearest Alfa Laval Service Centre). Upon arrival check that the machine is in operating condition by inserting a flathead Screwdriver in top of Turbine shaft and easily turn Turbine shaft anti-clockwise.
  • Page 17 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 nozzles. If the machine is used in potential explosive atmospheres, tapes or joint sealing ATEX compounds which are electrical insulators must not be used on threads or joints, unless Warning:...

  • Page 18: Special Conditions For Safe Use - Atex

    Special Conditions for Safe Use – ATEX In accordance with the ATEX Certification, Directive 94/9/EC the following special conditions shall be obeyed. ATEX The unit may be operated, in a hazardous area, only when filled with the process fluid. Warning: ATEX For standard machines: Warning:...
  • Page 19 ATEX The unit must not be operated in a vessel having an enclosed volume of greater than Warning: 100m Tanks larger than 100 m³: To use Tank Cleaning Machines in tanks larger than 100m³ is possible under certain conditions. It is necessary to know the current factors such as tank size, cleaning solvent and product.
  • Page 20 Intentionally left blank www.sks-online.com www.sks-webshop.com...

  • Page 21: Operation

    Operation Operational Manual - Contents Operation ......................... 20 Cleaning Media ......................... 20 Product ..........................20 Pressure ........................... 20 Temperature ........................20 After Use Cleaning ......................21 Safety Precautions ......................22 www.sks-online.com www.sks-webshop.com...

  • Page 22: Operation

    Aggressive chemicals, excessive concentrations of chemicals at elevated temperatures, as well as certain hypochlorite’s should be avoided. If you are in doubt, contact your local Alfa Laval sales office. Note: PEEK is not resistant to concentrated sulphuric acid...

  • Page 23: After Use Cleaning

    In accordance with the ATEX specifications regarding special conditions for safe use, see page 16. ATEX Atmosphere/surface temperature: 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.

  • Page 24: Safety Precautions

    Safety Precautions The machine is intended for use inside a tank only. As peak velocity of main jets reaches 40 m/s, TJ20G must not be operated in open air or when tank is open. Hot chemicals and steam under pressure may be used for cleaning and sterilising. Warning: Protect against scalding and burning.

  • Page 25: Maintenance

    Symptom: Slow rotation or failure of machine to rotate ............ 42 Symptom: Slow rotation or failure of machine to rotate (continued) ......... 43 How to Order Spare Parts ..................44 How to contact Alfa Laval Tank Equipment ............. 44 www.sks-online.com www.sks-webshop.com...

  • Page 26: Preventive Maintenance Guidelines

    The risk of unscheduled breakdowns due to component failure is virtually eliminated and in the long term your operating costs are reduced. Alfa Laval Tank Cleaning Equipment Service Kits contain all you need. They comprise genuine Alfa Laval spare parts, manufactured to the original specifications.

  • Page 27: Service And Repair Of Atex Approved Machines

    In order to ensure compliance with the ATEX regulations for service and repair in accordance with EN 60079-19, all service and repair of ATEX approved machines should be performed by Alfa Laval Kolding A/S, Ishoej, Denmark, or Alfa Laval service centre approved by Alfa Laval Kolding A/S.

  • Page 28: Maintenance Intervals And Service Kits Selection

    Maintenance intervals and Service Kits selection It is recommended that the wear parts are check every 500 working hours for machine working under normal conditions. There is a Minor and a Major service kit* for the TJ20G (see the following pages). 500 hour 500 hour 500 hour...

  • Page 29: Minor Service Kit For Toftejorg™ Tj20G

    Wear parts are specified in the Reference List of Parts, page 31. Minor Service Kit for Toftejorg™ TJ20G For all machines with serial number under 0604 xxxx please contact your local Alfa Laval office for correct service kit.

  • Page 30: Major Service Kit For Toftejorg™ Tj20G

    Major Service Kit for Toftejorg™ TJ20G Article no.: TE20G292 – All models except TE20G016_018 & TE20G030_044 (see below). Pos. no. Part No. Description TE20G640 Bearing for Turbine shaft 1 piece TE20G571 Stem nut with ball race 1 piece TE20G318 Ball retainer w. balls 2 pieces TE20G641 Slide bearing...

  • Page 31: Available Add-On´s For Spare Parts

    Article no.: TE20H292 – TE20HXXX version. Pos. no. Part No. Description TE20G640 Bearing for Turbine shaft 1 piece TE20H571 Stem nut with ball race 1 piece TE20H318 Ball retainer w. balls 2 pieces TE20G641 Slide bearing 1 piece 15.1 TE20H542 Cotter pin 2 pieces 15.3...

  • Page 32: Assembly Drawing

    Assembly drawing www.sks-online.com www.sks-webshop.com...

  • Page 33: Reference List Of Parts

    Reference list of parts Toftejorg™ TJ20G, TE20G000_024 + TE20G050_054 (except TE20G010-TE20G018) Pos. Ref. No. No/Unit Description Materials Remarks  TE20G508 Cone 1" BSP Stainless steel Spare part  TE20G517 Cone 1" NPT Stainless steel Spare part  TE20G518 Cone 1" BSP f. sanitary conn. Stainless steel Spare part ...

  • Page 34: Toftejorg™ Tj20G, Te20G010_014

    Toftejorg™ TJ20G, TE20G010_014 Pos. Ref. No. No/Unit Description Materials Remarks  TE20G503 Cone 1" BSP hole f. split Stainless steel Spare part TE20G550 Turbine shaft Stainless steel Spare part TE20G640 Bearing for Turbine shaft Polymer Wear part TE51C201 Circlip Stainless steel Spare part ...

  • Page 35: Toftejorg™ Tj20G, Te20G016_018

    Toftejorg™ TJ20G, TE20G016_018 Pos. Ref. No. No/Unit Description Materials Remarks  TE20G508 Cone 1" BSP Stainless steel Spare part TE20G550 Turbine shaft Stainless steel Spare part TE20G640 Bearing for Turbine shaft Polymer Wear part TE51C201 Circlip Stainless steel Spare part ...

  • Page 36: Toftejorg™ Tj20G, Te20G030_044

    Toftejorg™ TJ20G, TE20G030_044 Pos. Ref. No. No/Unit Description Materials Remarks  TE20G508 Cone 1" BSP Stainless steel Spare part  TE20G517 Cone 1" NPT Stainless steel Spare part TE20G550 Turbine shaft Stainless steel Spare part TE20G640 Bearing for Turbine shaft Polymer Wear part TE51C201...

  • Page 37: Toftejorg™ Tj20G, Te20Hxxx

    Toftejorg™ TJ20G, TE20HXXX Configuration as delivered marked  Pos. Ref. No. No/Unit Description Materials Remarks  TE20H508 Cone 1" BSP Hastelloy C22 Spare part  TE20H517 Cone 1" NPT Hastelloy C22 Spare part  TE20H518 Cone 1" BSP f. sanitary conn. Hastelloy C22 Spare part ...

  • Page 38: Toolkit And Tools For Assembly And Disassembly

    Toolkit and tools for assembly and disassembly Besides the standard toolkit for the TJ20G shown below and the Torque Wrench toolkit (see below) additional tools are needed: • Flathead screwdriver (size 5/32´´) • Slip joint pliers • Rubber hammer • Drift punch (size ø5 mm) •...

  • Page 39: Disassembly

    Disassembly D1.1 Remove the 4 Screws (Pos. 8) using a socket wrench (tool No. TE462A). D1.2 Lift off Cone (Pos. 1). D1.3 Withdraw Turbine shaft (Pos. 2) with Impeller. If necessary, turn Turbine shaft left and right. D1.4 Remove Circlip (Pos. 4) using a flathead Screwdriver and pull off Impeller (Pos. 5). D1.5 Withdraw Carrier assembly (Pos.
  • Page 40 D1.10 Remove the 3 Screws (Pos. 12) with a socket wrench (tool No. TE462A) and draw out Internal gear (Pos. 13). D1.11 Secure the body in Bench vice (NB!!: use cloth between jaws and body to avoid making scratches and imperfections in body surface) so that the hub cover is secured. Insert a 13 mm spanner (tool No.

  • Page 41: Assembly

    Assembly Before reassembly, make sure that all parts are clean without deposits or build-up of foreign matter. Inspect the nozzle vanes for foreign objects (e.g. product pulp, threads, etc.) and if necessary clean with care – damaging nozzles (or fouled nozzles) will decrease the throw length of the machine. Clean using compressed air or tweezers.
  • Page 42 bottom (Pos. 3) in Body: Rotate Carrier Assembly by hand a few rotations to check correct position and function. (Hub cover (pos. 19) is now locked and can only rotate by moving the Carrier assembly). R1.4 Mount Impeller (Pos. 5) on Turbine shaft (Pos. 2) and secure with Circlip (Pos. 4) using flathead Screwdriver.

  • Page 43: Replacement Of Ball Races

    Replacement of Ball Races Place Stem or Hub completely (Pos. 16 or 17, see page 30) in a support ring (e.g. a piece of pipe with an inner diameter of ø84) and press off Ball race. Press parallel. Be careful not to damage teeth and opposite end face of Stem.

  • Page 44: Trouble Shooting Guide

    Trouble Shooting Guide Symptom: Loose Nozzle Hub Possible Causes Fault finding Loose Cap nut a). Check that the torque of the Cap nut (Pos. 23) is at least 25 Nm. b). Remove Cap nut (Pos. 23) and check Washer Wear (Pos.

  • Page 45: Symptom: Slow Rotation Or Failure Of Machine To Rotate (Continued)

    Symptom: Slow rotation or failure of machine to rotate (continued) Possible Causes Fault finding Stem or Hub jammed/sluggish Remove Carrier assembly (see page 37). Turn Hub cover and check unrestricted rotation. Remove Stem and Hub (see page 38). Remove foreign material/ material build-up on Stem, Hub and inside Nut w.

  • Page 46: How To Order Spare Parts

    In connection with ordering of spare parts for machines originally delivered with Q-doc (Qualification Documentation) please note that all service and repair should be performed by Alfa Laval Kolding A/S, Kolding, Denmark, see page 25 “Service and Repair of machines ordered with Q-Doc”.

  • Page 47: Misc. - Contents

    Instruction Manual – Misc. Misc. - Contents EU Declaration of Conformity incl. ATEX ..............46 Declaration of Conformity, EN 10474, sub clause 2.2 Test Report ......47 ATEX-Special Conditions for safe use ..............49 Declaration of Complaince with 10/2011 – Food contact materials......50 www.sks-online.com www.sks-webshop.com...

  • Page 48: Eu Declaration Of Conformity Incl. Atex

    EU Declaration of Conformity incl. ATEX www.sks-online.com www.sks-webshop.com...

  • Page 49: Declaration Of Conformity, En 10474, Sub Clause 2.2 Test Report

    Declaration of Conformity, EN 10474, sub clause 2.2 Test Report www.sks-online.com www.sks-webshop.com...
  • Page 50 www.sks-online.com www.sks-webshop.com...

  • Page 51: Atex-Special Conditions For Safe Use

    ATEX-Special Conditions for safe use ATEX CERTIFICATION EC – Type Examination Certificate Number : Baseefa04ATEX0358X II 1GD c T140°C II 1GD c T250°C Tamb -0°C to +200°C BASEEFA CUSTOMER REFERENCE No. 5322 PROJECT FILE No. 10/0610 Special Condition for Safe Use The Unit may be operated, only when filled with fluid.

  • Page 52: Declaration Of Complaince With 10/2011 - Food Contact Materials

    Declaration of Complaince with 10/2011 – Food contact materials www.sks-online.com www.sks-webshop.com...
  • Page 53 © Alfa Laval Corporate AB This document and its contents is owned by Alfa Laval Corporate AB and protected by laws governing intellectual property and thereto related rights. It 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.

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