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
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Instruction Manual
Alfa Laval Toftejorg™ TJ20G Rotary Jet Head
Covering: Standard Machines, Distillery, Secured
High temperature, Hastelloy
Q-doc - Equipment Doc (3.1 Inspection Certificate - EN 10204)
Machines delivered with ATEX/IECEx Certification in accordance with Directive 2014/34/EU
TE91A600. First published: 2000-06
ESE01794-EN11
Original manual
2019-05

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Summary of Contents for Alfa Laval Toftejorg TJ20G

  • Page 1 Instruction Manual Alfa Laval Toftejorg™ TJ20G Rotary Jet Head Covering: Standard Machines, Distillery, Secured High temperature, Hastelloy Q-doc - Equipment Doc (3.1 Inspection Certificate - EN 10204) Machines delivered with ATEX/IECEx Certification in accordance with Directive 2014/34/EU TE91A600. First published: 2000-06...

  • Page 3: Table Of Contents

    Table of contents The information herein is correct at the time of issue but may be subject to change without prior notice 1. EC/EU Declaration of Conformity ..............2. Safety ....................2.1. Important information ................2.2. Warning signs ..................3. Introduction ....................
  • Page 4 The information herein is correct at the time of issue but may be subject to change without prior notice 11. General information ................... 11.1. Service and repair ................11.2. How to order spare parts ................ 11.3. How to contact Alfa Laval Kolding A/S ............12. Miscellaneous ..................12.1. Declaration of Complaince with 10/2011 – Food contact materials ......

  • Page 5: Ec/Eu Declaration Of Conformity

    Phone No. hereby declare that Tank Cleaning Machine Designation Alfa Laval Toftejorg TJ20G Type From serial number 2018-0001 to 2030-99999 is in conformity with Machinery Directive 2006/42/EC and the following harmonized standard is used: DS/EN ISO 12100:2011 Safety of Machinery - Risk Assessment is in conformity with (Ex / ATEX) Directive 2014/34/EU and the following harmonized standards are used: EN ISO 80079-36:2016, EN ISO 80079-37:2016, DS/EN ISO/IEC 80079-34:2011, Annex A, paragraph A.5.3 Rotating machines...

  • Page 6: Safety

    2 Safety TJ20G 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...

  • Page 7: Introduction

    TJ20G 3.1 Introduction The Alfa Laval Toftejorg TJ20G has been developed to meet the highest demands for efficiency, reliability and hygiene within food and beverage, pharmaceutical and biochemical industry. This manual has been prepared as a guide for installing, operating and maintaining your Alfa Laval Toftejorg tank cleaning machine.

  • Page 8: Patents And Trademarks

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

  • Page 9: Atex/Iecex Marking

    3 Introduction TJ20G 3.5 ATEX/IECEx marking The Alfa Laval Toftejorg TJ20G is certified as category I component. The certification is carried out by the notified body SGS Fimko Oy, who has issued the certificate no. 04ATEX0358X and IECEx BAS 18.0067X. Note Explosion protection type is constructional safety “c”.

  • Page 10: Quality System

    II 1D Ex h IIIC T85°C...T200°C Da 3.7 Quality system The Alfa Laval Toftejorg TJ20G is designed in accordance with the EHEDG design guidelines for sanitary design of processing equipment. It is produced according to Alfa Laval Kolding’s ISO-9001 international Standard certified quality system. All parts...

  • Page 11: Installation

    4.1 General description The Alfa Laval Toftejorg tank cleaning machine is a media driven and media lubricated tank cleaning machine. No lubricating substances such as oil, grease etc. are used. All materials comply with FDA 21CFR§177 and for polymers also EU 10/2011.
  • Page 12 4 Installation TJ20G Apart from the main flow flushing the gear and the Hub, and thereafter forming the jets through the Nozzles, fluid is flushed through all internal areas, through Bevel gear, Ball bearings and gaps between moving parts and finally also used for cleaning of the outside surfaces of the machine.

  • Page 13: General Safety And Installation Instructions

    During handling and installation handle the machine with care in order not to damage the surface finishes of the machine. The Alfa Laval Toftejorg TJ20G machine has been tested at the factory before shipping. You can check that the machine is in operating condition by blowing compressed air into the inlet, while holding the machine by the cone and verify that the rest of the machine rotates evenly.

  • Page 14: Specific Conditions For Safe Use In Accordance With Atex/Iecex Certification

    4 Installation TJ20G 4.4 Specific conditions for safe use in accordance with ATEX/IECEx certification Directive 2014/34/EU NOTE Explosion protection type is constructional safety “c”. Warning: Operated in a hazardous area The unit may be operated in a hazardous area only when completely filled with cleaning fluid / steam. If a medium other than the cleaning fluid / steam is passed through the equipment the flow must not be high enough to cause the equipment to operate.
  • Page 15 4 Installation TJ20G 4.4 Specific conditions for safe use in accordance with ATEX/IECEx certification Warning: Earthed when in use The unit must be effectively earthed at all times when in use. Warning: Max. permitted steaming temperature The maximum permitted steam temperature through the machine and ambient temperature is 140°C. Warning: Steaming tanks larger than 100 m³...
  • Page 16 4 Installation TJ20G 4.4 Specific conditions for safe use in accordance with ATEX/IECEx certification Warning: Process generated electrostatic The user must address the electrostatic hazards generated from the process of the equipment in accordance with guidance document IEC/TS 60079-32-1:2013. Warning: Electrostatically charged liquid Liquids can become electrostatically charged when they move relative to contacting solids or the spraying of liquids can also create a highly charged mist or spray.

  • Page 17: Operation

    Hastelloy version. Normal detergents, moderate solutions of acids and alkalics are acceptable. Aggressive chemicals excessive concentrations of chemicals at elevated temperatures, as well as certain hypochlorids should be avoided. If in doubt, contact your local Alfa Laval sales office. NOTE Do not try to turn the nozzle head by hand, since this may damage the Gear.

  • Page 18: Safety Precautions

    5.2 Safety precautions The machine is intended for use inside a tank only. As peak velocity of main jets reaches 40 m/s, The Alfa Laval Toftejorg TJ20G must not be operated in open air or when tank is open.

  • Page 19: Maintenance

    Handle the Alfa Laval Toftejorg TJ20G with care. Take proper action to protect surfaces from being damaged. Always use only proper tools and the Alfa Laval Toftejorg TJ20G standard tool kit (page 23). Never use force, hammer or pry components together or apart. Always perform all assembly/disassembly steps in the order described in this manual.

  • Page 20: Service And Repair Of Atex/Iecex Certified Machines

    Changes to the machine are not allowed without approval by the person responsible for the ATEX/IECEx certification at Alfa Laval. If changes are made – or spare parts other than Alfa Laval original spare parts are used - the EC Type Examination certification (the ATEX/IECEx Directive) is no longer valid.

  • Page 21: General Assembly /Disassembly Recommendations

    Apart from the parts specifically mentioned above, all the remaining wear parts should regularly be inspected for wear. Which parts that are wear parts appear from the Spare part manual, available from the on-line Alfa Laval product catalogue Anytime or the Close at hand spare part catalogue.

  • Page 22: Available Add-Ons For Spare Parts

    6 Maintenance TJ20G The items (#) refer to section 10 Parts lists and drawings, service kits and tools and section 6.8 Reassembly. 6.5 Available add-ons for spare parts Part no. Denomination • Declaration of Compliance: TE20XXXX-8X - EN 10204 type 3.1 Inspection Certificate TE20XXXX-8X - FDA Declaration of Compliance...

  • Page 23: Tools

    The items (#) refer to section 10 Parts lists and drawings, service kits and tools and section 6.8 Reassembly. 6.6 Tools Disassembly Tools needed for Maintenance and Repair Besides the standard toolkit for the Alfa Laval Toftejorg TJ20G and the Torque Wrench toolkit additional tools are needed: - Flathead screwdriver (size 5/32´´) - Slip joint pliers - Rubber hammer - Drift punch (size ø5 mm)

  • Page 24: Disassembly

    6 Maintenance TJ20G The items (#) refer to section 10 Parts lists and drawings, service kits and tools and section 6.8 Reassembly. 6.7 Disassembly 1. Remove the 4 Screws (8) using a socket wrench (tool No. TE462A). 2. Lift off Cone (1). 3.
  • Page 25 6 Maintenance TJ20G The items (#) refer to section 10 Parts lists and drawings, service kits and tools and section 6.8 Reassembly. 12. Hold Body against table and unscrew Hub nut w. ball race (18) with Caliper (tool number TE369) – see drawing below. If the Stem nut w.

  • Page 26: Reassembly

    6 Maintenance TJ20G The items (#) refer to section 10 Parts lists and drawings, service kits and tools and section 6.8 Reassembly. 6.8 Reassembly 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.

  • Page 27: Replacement Of Ball Races

    6 Maintenance TJ20G The items (#) refer to section 10 Parts lists and drawings, service kits and tools and section 6.8 Reassembly. 6.9 Replacement of ball races 1. Place Stem or Hub completely (16 or 17) in a support ring (e.g. a piece of pipe with an inner diameter of ø84) and press off Ball race.

  • Page 28: Trouble Shooting Guide

    7 Trouble shooting guide TJ20G The items (#) refer to section 10 Parts lists and drawings, service kits and tools and section 6.8 Reassembly. Fault finding Possible Causes Loose Cap nut a) Check that the torque of the Cap nut (23) is at least 25 Nm. Wear b) Remove Cap nut (23) and check Washer (22) for wear and signs of corrosion - replace if needed.
  • Page 29 7 Trouble shooting guide TJ20G The items (#) refer to section 10 Parts lists and drawings, service kits and tools and section 6.8 Reassembly. TD523483...

  • Page 30: Technical Data

    8 Technical data TJ20G 8.1 Technical data Weight of machine: 5.1 kg (11.2 lb) Working pressure: 3-8 bar (40-115 psi) Recommended inlet pressure: 5-7 bar (70-100 psi) Max. inlet pressure: 12 bar (174 psi) Max. recommended working liquid temperature: 95°C (200°F) Max.

  • Page 31: Product Programme

    9 Product Programme This manual covers the product program for Alfa Laval Toftejorg TJ20G tank cleaning machine 9.1 Standard configurations Alfa Laval Toftejorg TJ20G options Nozzles (mm) Standard Distillery Hastelloy Secured High temp. Burst Connection (1/2" thread Article No. Article No.

  • Page 32: Available Add-Ons

    9 Product Programme This manual covers the product program for Alfa Laval Toftejorg TJ20G tank cleaning machine 9.2 Available add-ons TE20XXXX-7X: ATEX/IECEx TE20XXXX-8X: ATEX/IECEx + Q-doc. TE20XXXX-9X: Q-doc Explanation to Add-ons Equipment Documentation includes: - EN 1935/2004 DoC - EN 10204 type 3.1 inspection Certificate and DoC...

  • Page 33: Available Welding Connections

    9 Product Programme This manual covers the product program for Alfa Laval Toftejorg TJ20G tank cleaning machine 9.3 Available welding connections Welding adapter (see right) with sealing assembly between Down pipe, Welding adapter and machine. Welding connections are ordered separately.

  • Page 34: Parts Lists And Drawings, Service Kits And Tools

    10 Parts lists and drawings, service kits and tools TJ20G - article nos. TE20G000_024 + TE20G050_054 (except TE20G010-TE20G018) 10.1 TJ20G - article nos. TE20G000_024 + TE20G050_054 (except TE20G010-TE20G018) TD523483...
  • Page 35 Please note that some of the polymer parts are in PEEK, which is not resistant to concentrated sulfuric acid. Please refer to the Spare part manual for information on item numbers and materials. The Spare part manual is available from the on-line Alfa Laval product catalogue Anytime or the Close at hand spare part catalogue.

  • Page 36: Tj20G - Article Nos. Te20G010-Te20G014

    10 Parts lists and drawings, service kits and tools TJ20G - article nos. TE20G010-TE20G014 10.2 TJ20G - article nos. TE20G010-TE20G014 TD523483...
  • Page 37 Please note that some of the polymer parts are in PEEK, which is not resistant to concentrated sulfuric acid. Please refer to the Spare part manual for information on item numbers and materials. The Spare part manual is available from the on-line Alfa Laval product catalogue Anytime or the Close at hand spare part catalogue.

  • Page 38: Tj20G - Article Nos. Te20G016_018

    10 Parts lists and drawings, service kits and tools TJ20G - article nos. TE20G016_018 10.3 TJ20G - article nos. TE20G016_018 TD523483...
  • Page 39 Please note that some of the polymer parts are in PEEK, which is not resistant to concentrated sulfuric acid. Please refer to the Spare part manual for information on item numbers and materials. The Spare part manual is available from the on-line Alfa Laval product catalogue Anytime or the Close at hand spare part catalogue.

  • Page 40: Tj20G, Distillery - Article Nos. Te20G030_044

    10 Parts lists and drawings, service kits and tools TJ20G, distillery - article nos. TE20G030_044 10.4 TJ20G, distillery - article nos. TE20G030_044 TD523483...
  • Page 41 Please note that some of the polymer parts are in PEEK, which is not resistant to concentrated sulfuric acid. Please refer to the Spare part manual for information on item numbers and materials. The Spare part manual is available from the on-line Alfa Laval product catalogue Anytime or the Close at hand spare part catalogue.

  • Page 42: Tj20G, Hastelloy - Article Nos. Te20Hxxx

    10 Parts lists and drawings, service kits and tools TJ20G, hastelloy - article nos. TE20HXXX 10.5 TJ20G, hastelloy - article nos. TE20HXXX TD523483...
  • Page 43 Please note that some of the polymer parts are in PEEK, which is not resistant to concentrated sulfuric acid. 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.

  • Page 44: Tools

    10 Parts lists and drawings, service kits and tools TJ20G - Tools 10.6 Tools Standard Tool Kit for Toftejorg TJ20G Article no. TE81B085 Caliper Item no. TE369 Socket wrench w. pin Item no. TE462A Spanner for Toftejorg TJ20G Item no. TE81B040 Spanner Item no.
  • Page 45 TJ20G 11.1 Service and repair Upon every return of a product, no matter if for modifications or repair, it is necessary to contact your local Alfa Laval office to guarantee a quick execution of your request. You will receive instructions regarding the return procedure from your local Alfa Laval office. Be sure to follow the instructions closely.
  • Page 46 12 Miscellaneous TJ20G 12.1 Declaration of Complaince with 10/2011 – Food contact materials...
  • Page 48 © 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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