Alfa Laval Toftejorg SaniJet 20 Instruction Manual
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Alfa Laval Toftejorg SaniJet 20 Instruction Manual

Alfa Laval Toftejorg SaniJet 20 Instruction Manual

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Instruction Manual
Alfa Laval Toftejorg™ SaniJet 20 Air Driven
Covering: Standard, Hastelloy
Q-doc: Equipment Doc (3.1 Inspection Certificate - EN 10204)
Q-doc+FAT-SAT: Qualification Documentation incl. FAT and SAT)
Improved surface finish (0.5 µm Ra internal/external media contact parts)
Machines delivered with ATEX/IECEx Certification in accordance with Directive 2014/34/EU
First published: 04-2009
ESE01829-EN13
Original manual
2019-07

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Summary of Contents for Alfa Laval Toftejorg SaniJet 20

  • Page 1 Instruction Manual Alfa Laval Toftejorg™ SaniJet 20 Air Driven Covering: Standard, Hastelloy Q-doc: Equipment Doc (3.1 Inspection Certificate - EN 10204) Q-doc+FAT-SAT: Qualification Documentation incl. FAT and SAT) Improved surface finish (0.5 µm Ra internal/external media contact parts) Machines delivered with ATEX/IECEx Certification in accordance with Directive 2014/34/EU...

  • Page 3: Table Of Contents

    5.3. Safety Precautions ................6. Maintenance ................... 6.1. Preventive Maintenance ................6.2. Reserved rights for design changes of Alfa Laval equipment used in validated processes 6.3. Preventive Maintenance of Air Motor ............6.4. Service and repair of ATEX/IECEx certified machines .........
  • Page 4 The information herein is correct at the time of issue but may be subject to change without prior notice 10.3. Toftejorg SaniJet 20 Air Driven Hastelloy (FFKM as standard) ........ 10.4. Toftejorg SaniJet 20 Air Driven Hastelloy improved surface finish (FFKM as standard) ..10.5. Service kits ..................

  • Page 5: Ec/Eu Declaration Of Conformity

    Phone No. hereby declare that Tank Cleaning Machine Designation Alfa Laval Toftejorg SaniJet 20 Air Driven Type From serial number 2019-0001 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 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

    3 Introduction Toftejorg SaniJet 20 Air driven 3.1 Introduction This manual has been prepared as a guide for installation and for the persons who will be operating and maintaining your tank cleaning machine. The key to long life for your tank cleaning machine is a carefully planned system for preventive maintenance;...

  • Page 8: Patents And Trademarks

    If Equipment from Alfa Laval is used in connection with, for example, a validated plant, and an order for replacements is made, the design of the replacement may have been changed even if the specifications /item no. is the same as the existing installed and validated ones.

  • Page 9: Atex/Iecex Marking

    Drive unit The Alfa Laval Toftejorg SaniJet 20A Air drive unit is certified as category 2 component for installation in zone 1/21 (outside tank) in accordance with Directive 2014/34/EU. The certification is carried out by Alfa Laval as a Own Assessment and archived at Certification body Teknologisk Institut.
  • Page 10 3 Introduction Toftejorg SaniJet 20 Air driven Marking positions: 1. Drive unit 2. Cleaner unit A ( 3 : 1 ) 4107-0150 4107-0151 A: For FAT-SAT machines with index no. -6x, the s/n must be yyy-FAT-SAT-xxx...

  • Page 11: Atex/Iecex Temperature Class And Code

    3 Introduction Toftejorg SaniJet 20 Air driven 3.7 ATEX/IECEx temperature class and code The maximum surface temperature depends mainly on operating conditions which are the temperature of the cleaning fluid and the ambient temperature. Group II EPL Ga The gas temperature class is corrected with a safety margin of 80% due to a requirement for Group ll EPL Ga equipment.

  • Page 12: Quality System

    3.8 Quality system The Alfa Laval Toftejorg SaniJet 20 is produced according to Alfa Laval Kolding’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 USP Class VI...

  • Page 13: Installation

    There is a broad range of application areas within pharmaceutical, food and chemical industries. The Alfa Laval Toftejorg SaniJet 20 is a hygienic cleaning device of the rotary jet head type for permanent installation that provides a 360° indexed cleaning pattern. Provided it is installed in an upright position, the Alfa Laval Toftejorg SaniJet 20 is completely self-cleaning and self-draining, and it has an integrated self-cleaning down pipe (patent pending).

  • Page 14: Functioning

    4.2 Functioning Alfa Laval Toftejorg SaniJet 20 consists of 3 main parts: The Drive unit with flow inlet and the Base housing placed outside the tank, and inside the tank: the Down pipe with the rotating Outer tube and the Cleaner unit.
  • Page 15 4 Installation Toftejorg SaniJet 20 Air driven Machine with external motor drive The machine is driven by a gear motor mounted on top of the Inlet housing. Via a Magnetic clutch the rotation of the gear motor is transmitted from the outside through a closed wall to the Output shaft placed inside the Inlet housing. The Output shaft is in mesh with the Down pipe and rotates the Down pipe in the same way as in the media driven version.
  • Page 16 4 Installation Toftejorg SaniJet 20 Air driven Self-cleaning Apart from the main flow flushing the inside of the Base housing and the Down pipe, and thereafter forming the jets through the Nozzles, fluid is flushed through all internal cavities, through Bevel gear, Ball bearings and gabs between moving parts and is finally also used for cleaning of the outside surfaces of the machine.

  • Page 17: Installation Of Air Motor

    4 Installation Toftejorg SaniJet 20 Air driven 4.3 Installation of Air Motor Important information Recommended inlet air pressure is not to exceed 6 bar (87) psi maximum. It is recommended to use an air filter and moisture trap on inlet air supply to avoid contamination being fed into air motor.
  • Page 18 4 Installation Toftejorg SaniJet 20 Air driven Lubrication The pneumatic oil used for lubrication must have a self–ignition temperature above 260°C and have a viscosity between 22 and 46 cst depending on the temperature of the motor operation (e.g. 40°C the viscosity of the oil shall be between 22 and 30 cst).

  • Page 19: General Safety And Installation Instructions

    During handling and installation handle the machine with care in order not to damage the fine surface finish of the machine. The Alfa Laval Toftejorg SaniJet 20 machine has been tested in a test tank, according to Alfa Laval test procedures at the factory before shipping.

  • Page 20: Specific Conditions For Safe Use In Accordance With Atex/Iecex Certification

    4 Installation Toftejorg SaniJet 20 Air driven 4.5 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 not be operated when steaming.
  • Page 21 4 Installation Toftejorg SaniJet 20 Air driven 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 trough the machine and ambient temperature is 140°C.
  • Page 22 4 Installation Toftejorg SaniJet 20 Air driven 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.

  • Page 23: Operation

    Aggressive chemicals, excessive concentrations of chemicals at elevated temperatures as well as certain solvents and hydrochlorides should be avoided. If you are in doubt, contact your local Alfa Laval sales office. Pressure Avoid hydraulic shocks.

  • Page 24: Normal Operation Of Air Motor

    5 Operation Toftejorg SaniJet 20 Air driven 5.2 Normal Operation of Air Motor Never let the machine run dry without cleaning media except for short time under surveillance. It is recommended always to put on pressure with cleaning media before the air motor starts rotating. This will ensure proper cooling and lubrication of the bearings.

  • Page 25: Safety Precautions

    Toftejorg SaniJet 20 Air driven 5.3 Safety Precautions The machine is intended for use inside a tank only. As peak velocity of main jets reaches 40 m/s, Alfa Laval Toftejorg SaniJet 20 must not be operated in open air or when tank is open.

  • Page 26: Maintenance

    If Equipment from Alfa Laval is used in connection with, for example, a validated plant, and an order for replacements is made, the design of the replacement may have been changed even if the specifications /item no. is the same as the existing installed and validated ones.

  • Page 27: Preventive Maintenance Of Air Motor

    6 Maintenance Toftejorg SaniJet 20 Air driven 6.3 Preventive Maintenance of Air Motor General recommendations - Air motor maintenance shall be performed by skilled operators, trained by MODEC or by our after sales service department. - It is advisable to check and clean air motors every six months when used daily.

  • Page 28: 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 29: Service And Repair Of Machines Ordered With Q-Doc And With Q-Doc + Fat-Sat

    - The spare part is sent to the customer incl. Q-doc (Equipment Documentation) incl. Weld-Log documentation (Inner shaft, Outer pipe) as hardcopy. - This service information will not be recorded in the Alfa Laval Q-doc + FAT-SAT folder. The customer has to perform all Qualification tests and documentation (FAT, SAT, IQ & OQ) himself.

  • Page 30: Every 300 Working Hours

    6 Maintenance Toftejorg SaniJet 20 Air driven 6.6 Every 300 working hours 1. Disassemble machine as described on the following pages. 2. Clean material build-up and deposits from internal parts with water or suitable chemical cleaner, possibly Scotch-brite, S-Ultrafine. 3. Check Bearing bushes (20 + 19) in Base housing by fitting Rotor outer (60) and check sideways movement. Replace if necessary.

  • Page 31: Cleaner Head Unit - Dismantling And Reassembling

    1. Loosen Cleaner head unit (1, 2, 3, 4, 5, 6, 7) with Hook spanner (tool no. TE20B701). Insert carefully into holes in Retaining ring (3). Turn counter-clockwise and draw out Cleaner head unit. Never use Pipe wrench or any other tool than the Alfa Laval Toftejorg SaniJet 20 special Hook spanner, which is developed especially to protect the surface from being damaged.

  • Page 32: Base Unit - Dismantling And Reassembling

    Base housing. Tighten with Retaining screw (17). Alfa Laval Toftejorg SaniJet 20 (4”) is as a standard prepared for monitoring by a Rotacheck Sensor (see Rotacheck System). A Plug (22) is fitted in the Base housing in the opening designed for the Rotacheck sensor.

  • Page 33: Air Motor Drive Unit - Dismantling And Reassemebling

    6 Maintenance Toftejorg SaniJet 20 Air driven 6.9 Air Motor Drive Unit - dismantling and reassemebling Dismantling 1. Push the ring on the push-in fittings and release the compressed air tubes. 2. Remove the 3 pcs Screws (80) and take off the Motor cover (81).

  • Page 34: Rotacheck System

    6 Maintenance Toftejorg SaniJet 20 Air driven Further dismantling 1. Lift off the Motor flange (59). 2. Remove Gasket (18) and lift off Inlet housing (61). 3. Withdraw Rotor Outer (60). 4. Remove Gasket (18) from Base housing (16). Further reassembling Before reassembly make sure that all parts are clean without deposits or build-up of foreign matter.

  • Page 35: Trouble Shooting Guide

    7 Trouble shooting guide Toftejorg SaniJet 20 Air driven Slow rotation or failure of machine to rotate Fault finding Possible Causes No or insufficient liquid flow a). Check if supply valve is fully open. b). Check if inlet pressure to machine is correct.

  • Page 36: Technical Data

    8 Technical data Toftejorg SaniJet 20 Air driven Perfomance Data for Alfa Laval Toftejorg SaniJet 20 Air Driven Weight of machine: 11.7 kg (25.8 lbs) Working pressure: 3-13 bar (45-185 psi) Recommended media pressure: 5-8 bar (75-116 psi) Working temperature (Cleaning unit): -20°C to +90°C (-4°F to +194°F) (cleaning fluid and ambient)
  • Page 37 8 Technical data Toftejorg SaniJet 20 Air driven Principal dimensions in mm Inlet connection: 1” Clamp ISO2852 For permanent installation machine can pass through 3” Tank connection: 3” Clamp ISO2852 clamp of max. length 50 mm: A: 1” Clamp ISO2852 B: 3”...
  • Page 38 8 Technical data Toftejorg SaniJet 20 Air driven Performance data for Alfa Laval Toftejorg SaniJet 20 air Driven Flow rate Throw length Inlet pressure Inlet pressure A: m /h. B: USgpm. C: Nozzles mm. D: psi. E: bar A: m. B: ft. C: Nozzles mm. D: psi. E: bar...
  • Page 39 8 Technical data Toftejorg SaniJet 20 Air driven Perfomance Data for Alfa Laval Toftejorg SaniJet 20 Air Driven Air supply pressure: Max. 6 bar (87 psi) Clean, filtered max. 50 μm Air quality: Dry, dew point max. 5°C /h) ~ 95 Usgpm Air consumption at max.

  • Page 40: Product Programme

    9 Product programme This manual covers the product programme for Alfa Laval Toftejorg SaniJet 20 Air Driven. For information on Alfa Laval Toftejorg SaniJet 20 Media Driven please refer to Instruction Manual ESE01819 9.1 Standard configurations Air Driven: Alfa Laval Toftejorg SaniJet 20 (3” connection)
  • Page 41 9 Product programme This manual covers the product programme for Alfa Laval Toftejorg SaniJet 20 Air Driven. For information on Alfa Laval Toftejorg SaniJet 20 Media Driven please refer to Instruction Manual ESE01819 Air Driven: Alfa Laval Toftejorg SaniJet 20 (4” connection)

  • Page 42: Available Add-Ons

    9 Product programme This manual covers the product programme for Alfa Laval Toftejorg SaniJet 20 Air Driven. For information on Alfa Laval Toftejorg SaniJet 20 Media Driven please refer to Instruction Manual ESE01819 9.2 Available add-ons For: TE24BXXX, TE24EXXX, TE24GXXX, TE24FXXX...

  • Page 43: Available Add-Ons For Spare Parts

    9 Product programme This manual covers the product programme for Alfa Laval Toftejorg SaniJet 20 Air Driven. For information on Alfa Laval Toftejorg SaniJet 20 Media Driven please refer to Instruction Manual ESE01819 9.3 Available add-ons for spare parts Item no.

  • Page 44: Parts Drawings And Lists, Service Kits And Tools

    10 Parts drawings and lists, service kits and tools Toftejorg SaniJet 20 Air driven 10.1 Toftejorg SaniJet 20, Air Driven (EPDM as standard)
  • Page 45 Cleaner head TE20B295 Service kit in EPDM for Toftejorg SaniJet 20 air driven Bearing bush version ..........

  • Page 46: Toftejorg Sanijet 20 Air Driven Improved Surface Finish (Epdm As Standard)

    10 Parts drawings and lists, service kits and tools Toftejorg SaniJet 20 Air driven 10.2 Toftejorg SaniJet 20 Air Driven improved surface finish (EPDM as standard)
  • Page 47 Service kits Cleaner head  Service kit in EPDM for Toftejorg SaniJet 20 air driven TE20B295 Bearing bush version ..........

  • Page 48: Toftejorg Sanijet 20 Air Driven Hastelloy (Ffkm As Standard)

    10 Parts drawings and lists, service kits and tools Toftejorg SaniJet 20 Air driven 10.3 Toftejorg SaniJet 20 Air Driven Hastelloy (FFKM as standard)
  • Page 49 Service kits  Cleaner head Service kit in PERLAST for Toftejorg SaniJet 20 air TE20C295 Bearing bush driven version .........

  • Page 50: Toftejorg Sanijet 20 Air Driven Hastelloy Improved Surface Finish (Ffkm As Standard)

    10 Parts drawings and lists, service kits and tools Toftejorg SaniJet 20 Air driven 10.4 Toftejorg SaniJet 20 Air Driven Hastelloy improved surface finish (FFKM as standard)
  • Page 51 Service kits  Cleaner head Service kit in PERLAST for Toftejorg SaniJet 20 air TE20C295 Bearing bush driven version .........

  • Page 52: Service Kits

    TE20B294, TE20B294, TE20B295 or TE20B295 or TE20B295 or TE20C295 TE20C295 TE20C295 Service Kit in Viton for Alfa Laval Toftejorg SaniJet 20 air driven version Article no. TE20B294 Parts list Pos. Denomination Seal ring H Bearing ring, top Plain seal S...

  • Page 53: Tools

    10 Parts drawings and lists, service kits and tools Toftejorg SaniJet 20 Air driven Service Kit in Perlast for Alfa Laval Toftejorg SaniJet 20 air driven version Article no. TE20C295 Parts list Pos. Denomination Seal ring H Bearing ring, top...

  • Page 54: General Information

    Toftejorg SaniJet 20 Air driven 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.
  • Page 56 © 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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