Page 1 II 1D/2G Ex IIIC/IIC T60°C…T70°C/T6…T3 Da/Gb BVS 10 ATEX H 006 X N3 Armaturenwerk Hötensleben GmbH Schulstr. 5-6, D-39393 Hötensleben, Germany Telephone: +49 39405 92-0 Fax: +49 39405 92-111 E-mail: info@awh.eu Internet: http://www.awh.eu ID number: 664BA030000ENX - 2020/01 Rev. 2...
Page 2 NOTE These instructions are an integral part of the device and must be available to operating and maintenance personnel at all times throughout its entire life cycle. The safety instructions contained therein must be observed. If the device is resold, the instructions must always be passed on to the new owner. Translation The operating instructions must be written in an official European Community language acceptable to the manufacturer of the machinery in which the partly completed machinery will be assembled, or to his...
Page 3: Table Of Contents
ATEX Retractor System TANKO-RT/-RTS Contents List of Figures ..........................III List of Tables............................ IV Abbreviations and Units ........................V 1 Introduction ..........................1 1.1 Means of Representation ......................1 1.1.1 Explanation of Signal Words.................... 1 1.1.2 Explanation of the Warnings ................... 2 1.1.3 Pictograms and Symbols ....................
Page 4 ATEX Retractor System TANKO-RT/-RTS 6.3 Switch-On Procedure ........................ 75 6.4 Operation ........................... 76 7 Maintenance ..........................80 7.1 Safety Instructions for Maintenance ..................80 7.2 Removal ............................. 83 7.3 Switch-Off Procedure ........................ 84 7.3.1 Removing the Device ..................... 85 7.4 Maintenance ..........................89 7.4.1 Maintenance Intervals ....................
Page 5: List Of Figures
ATEX Retractor System TANKO-RT/-RTS List of Figures Figure 2.5-1: Type plate position ........................17 Figure 2.5-2: Zone separation ........................18 Figure 3.1-1: General Construction ....................... 28 Figure 3.1-2: Static Spray Head ........................29 Figure 3.2-1: Function Diagram ........................35 Figure 3.3-1: Diagram - Flow Rate for Rotating Spray Head ................ 40 Figure 3.3-2: Diagram - Flow Rate for Static Spray Head ................
Page 6: List Of Tables
ATEX Retractor System TANKO-RT/-RTS List of Tables Table 1.1-1: Overview of Signal Words ......................1 Table 2.5-1: Relationship between zones and device protection levels (EPL) ........... 18 Table 2.5-2: Explanation of EX marking – gas ....................23 Table 2.5-3: Explanation of EX marking - dust ....................26 Table 3.3-1: General Technical Data ......................
Page 7: Abbreviations And Units
ATEX Retractor System TANKO-RT/-RTS Abbreviations and Units Abbreviations ATEX ATmosphère EXplosible; Synonym for the ATEX Directive of the European Union; comprises measures for explosion protection for explosive atmospheres approx. approximately ASSY Assembly Assembly group Armaturenwerk Hötensleben GmbH BetrSichV Betriebssicherheitsverordnung (German industrial safety and health protection ordinance);...
Page 8 ATEX Retractor System TANKO-RT/-RTS Système international d'unités; the most widely used international system of units for physical values Serial number SW [AF] Width across flats [wrench size] TRBS “Technische Regeln für Betriebssicherheit” (German technical rules for operational reliability and safety); these rules specify the details of the “Betriebssicherheitsverordnung”...
Page 9 ATEX Retractor System TANKO-RT/-RTS Units of Measure The following factors given below are intended for orientation and the conversion of the SI units to common units of measure for the American market. Unit of measure for pressure p [bar] All pressure [bar] specifications stand for overpressure [bar o] = positive pressure [bar g], unless expressly described otherwise (e.g.
Page 10 ATEX Retractor System TANKO-RT/-RTS VIII Translation - Operating/installation instructions 2020/01 Contents...
Page 11: Introduction
The instructions must be kept at the place of use of the device so that they are available in legible condition at all times. If the device is resold, the instructions must always be passed on to the new owner. If necessary, download the instructions from the website: http://www.awh.eu/de/downloads. 1.1 Means of Representation 1.1.1 Explanation of Signal Words The warnings are introduced by a signal word that describes the extent of the hazard.
Page 12: Explanation Of The Warnings
ATEX Retractor System TANKO-RT/-RTS 1.1.2 Explanation of the Warnings Section-related Warnings The section-related warnings apply not only to one particular action, but to all actions within a section. In addition, the pictograms and symbols indicate a general or specific danger. DANGER This warning warns of a hazard with a high level of risk! Failure to observe it can result in death or severe physical injury.
Page 13 ATEX Retractor System TANKO-RT/-RTS Further Means of Representation The Information symbol provides useful information, additional tips and recommendations. Texts that follow this mark are bulleted lists. –  Texts that follow this mark describe measures for avoiding the danger. 1. Texts that follow this numbering describe the first step of a task, followed by further numbered steps that have to be performed in the specified order.
Page 14: Pictograms And Symbols
ATEX Retractor System TANKO-RT/-RTS 1.1.3 Pictograms and Symbols The following pictograms and symbols are used as an additional measures in warnings to clarify the sources of dangers and measures. They can appear at all danger levels. Warning of electrical Warning of a potentially Warning of hand Warning of a hot voltage...
Page 15: Warranty And Liability
– Disclaimer AWH reserves the right to make changes to this document at any time and without prior notice. AWH provides no guarantee (neither explicitly nor implied) with regard to all information in this document, including but not limited to the implied warranty of merchantability and suitability for a particular purpose.
Page 16: Safety
For maintenance and repairs, we recommend a training course provided by the manufacturer or by a person authorized by the manufacturer. If you have questions or doubts about handling the cleaning device, please contact AWH. 6/121 Translation - Operating/installation instructions 2020/01...
Page 17: Intended Use
ATEX Retractor System TANKO-RT/-RTS Integrated Safety Systems The integrated safety equipment used by the higher-level plant in which the device is installed is to be checked at regular intervals. WARNING Dangerous situations will result from modifying or disabling safety devices! Only functioning safety equipment can ensure safe operation and prevent non-permissible operating conditions.
Page 18 The provisions of EN 60079-14 regarding the selection and setup of electrical operating materials must be observed. Refer to the order confirmation/parts list from AWH for the materials used in the device. The device is used for cleaning the interiors of containers with and without installed equipment.
Page 19 ATEX Retractor System TANKO-RT/-RTS When using the device, it is necessary to distinguish between the following operating states. Operating state – cleaning process (cleaning > cleaning head extended) In this case, flammable gases, vapors, mists or flammable dust may already be present in the container or are only added by the intended cleaning process in the form of sprayed fluid (aerosol).
Page 20 ATEX Retractor System TANKO-RT/-RTS Operating state – rest position (NO cleaning > cleaning head retracted)  Pressure in the container: -1 to 3.0 bar (-14.5 to 43.5 psi g)  Ambient temperature in the container to be cleaned: -20 °C to +130 °C (O-Ring material EPDM) -15 °C to +140 °C (O-Ring material FKM or FFKM) ...
Page 21 ATEX Retractor System TANKO-RT/-RTS Always observe the following:  Only operate the device when installed in a closed container.  Never direct the cleaning jet or torrent from the device at persons.  Protect the device from freezing (e.g. risk of frost from possible residual water). ...
Page 22: Spare Parts, Replacement Parts And Accessories
Only use the manufacturer's original spare parts. We expressly draw attention to the fact that spare parts and accessories NOT supplied by AWH have NOT been checked or approved by AWH. The installation and/or use of such products could therefore, under certain circumstances, result in changes with negative results to the properties of the device specified by its design and the higher-level plant.
Page 23 ATEX Retractor System TANKO-RT/-RTS A continuous hazard assessment must be carried out for workplaces, including temperature – conditions for the medium and the place of use (falling). The measures are to be defined in operating instructions. Personnel must be instructed accordingly. Supervisors must monitor compliance with the measures specified in the operating instructions.
Page 24 ATEX Retractor System TANKO-RT/-RTS Warnings in the documentation of externally supplied assembly groups must be adhered to and – incorporated into the hazard assessments for the specific workplace. For installation of the device in a plant, the owner must guarantee safe access using steps, –...
Page 25: Personnel Requirements
ATEX Retractor System TANKO-RT/-RTS 2.4 Personnel Requirements The device may only be operated, serviced and repaired by persons with the appropriate qualifications. These persons must be familiar with the instructions and act in accordance with them. The respective authorizations for personnel must be clearly defined. The following qualifications are designated in the instructions for various fields of activity: Expert/Specialist Personnel An expert is a person whose professional training, knowledge, and experience and knowledge of the...
Page 26: Personal Protective Equipment
ATEX Retractor System TANKO-RT/-RTS 2.4.1 Personal Protective Equipment NOTE ON EXPLOSION PROTECTION Persons working in potentially explosive atmospheres must not be dangerously charged. The personal protective equipment must meet the explosion protection requirements. If this is not observed, the explosion protection could be disabled. ...
Page 27: Identification
Section 3.3 Technical Data. 2.5.2 Type Plate Labeling is applied to the device according to the following illustration. A) ID number of the designated body that audits the QA system in AWH B) Manufacturer C) Year of manufacture D) Type, stroke...
Page 28: Identification For Explosion Protection
ATEX Retractor System TANKO-RT/-RTS 2.5.3 Identification for Explosion Protection Devices in explosion-proof design are identified by stating the device group, category, ignition protection type, explosion group, temperature class and EPL on the type plate. A CE and Ex mark confirms compliance of the device with ATEX Directive 2014/34 / EU.
Page 29 ATEX Retractor System TANKO-RT/-RTS The type plate on the device also contains the information required for operation in a potentially explosive atmosphere according to the ATEX directive 2014/34/EU and related standards: Explanation of Identification: Certificate number: BVS 10 ATEX H 006 X II 1/2G Ex IIB/IIC T6/T6…T3 Ga/Gb...
Page 30 ATEX Retractor System TANKO-RT/-RTS The zone separation inside and outside the container is represented by the symbol “/”. The EX markings of the device are in the Table 2.5-2 and Table 2.5-3 explained depending on the possible operating conditions. 20/121 Translation - Operating/installation instructions 2020/01 2 Safety...
Page 31 ATEX Retractor System TANKO-RT/-RTS Flammable gases or vapors within the container Flammable gases or vapors outside the container to be cleaned to be cleaned Operating status II1/...G Ex IIB/… T6/… Ga/… II …/2G EX …/IIC .../T6…T3 …/Gb Temperature Surface temperature of Potentially explosive Surface temperature of the device outside Explosive atmosphere...
Page 32 ATEX Retractor System TANKO-RT/-RTS greater greater The device assumes If potentially explosive --- Temperature monitoring on the pneumatic Gases or vapors of than than max. the temperature mixtures outside atmospheric cylinder necessary! explosion group IIA, IIB 90 °C up 90 °C up of the cleaning medium conditions are possible in the Heating to 95 °C is possible, plus 10 °C...
Page 33: Table 2.5-2: Explanation Of Ex Marking - Gas
ATEX Retractor System TANKO-RT/-RTS greater The device assumes --- Temperature monitoring on the pneumatic Gases or vapors of than max. the temperature If potentially explosive mixtures cylinder necessary! explosion group IIA, IIB 95 °C up of the container. in the container outside Heating to 100 °C is possible, which or IIC The electrical to 100 °C...
Page 34 ATEX Retractor System TANKO-RT/-RTS Flammable dust inside the container to be cleaned Flammable dust outside the container to be cleaned Operating status II 1/… D EX IIIC/… T60°C …T70°C/… Da/… II…/2D EX …/IIIC …/T95°C…T140°C …/Db Temperature Surface temperature of Potentially explosive Surface temperature of the device Explosive atmosphere the device inside the...
Page 35 ATEX Retractor System TANKO-RT/-RTS greater greater The device assumes If potentially explosive --- Temperature monitoring on the Dusts of dust groups IIIA, T105 °C Db than than max. the temperature of mixtures outside pneumatic cylinder necessary! IIIB or IIIC. 85 °C up 85 °C up the cleaning medium or atmospheric conditions are...
Page 36: Table 2.5-3: Explanation Of Ex Marking - Dust
ATEX Retractor System TANKO-RT/-RTS greater The device assumes If potentially explosive --- Temperature monitoring on the Dusts of dust groups IIIA, T100 °C Db than max. the temperature of mixtures in the container pneumatic cylinder necessary! IIIB or IIIC. 95 °C up the container.
Page 37 ATEX Retractor System TANKO-RT/-RTS The maximum surface temperature of the device is determined by the ambient temperature in the system to be cleaned (container) and the temperature of the cleaning medium. Operation generates intrinsic heating of a maximum of 10 K, and the maximum surface temperature is thus obtained by adding the higher value of the cleaning medium temperature or the ambient temperature in the system (container) to be cleaned to 10 K.
Page 38: Design And Function
ATEX Retractor System TANKO-RT/-RTS 3 Design and Function Type TANKO-RT has a rotating spray head. The rotational movement of this ball-bearing spray head is achieved by the flow of the cleaning agent without additional mechanical drive energy. The speed at which the spray head rotates is regulated by the spray pressure of the cleaning fluid.
Page 39: Figure 3.1-2: Static Spray Head
ATEX Retractor System TANKO-RT/-RTS Power cylinder and locking cylinder form the pneumatic part. The compressed air supply to the power cylinder is via two throttle check valves. These are attached to the outside of the power cylinder. The locking cylinder is supplied with compressed air using a plug-in connection, which is located on the end of the locking cylinder.
Page 40: General Function Description
ATEX Retractor System TANKO-RT/-RTS The spray head (all types) is connected to the piston rod by a disposable locking pin. The device is made of stainless steel and has been developed, designed and built exclusively for industrial and commercial use. Several versions of the device are available for different applications and container dimensions.
Page 41 ATEX Retractor System TANKO-RT/-RTS If the compressed air fails for a significant period, this ensures that the retracted power cylinder does not unintentionally lower into the container where it could collide with the internal fittings inside. Before every movement of the power cylinder, the locking cylinder must first unlock it, i.e. compressed air must be applied using a valve.
Page 42 ATEX Retractor System TANKO-RT/-RTS Exceeding the temperature limit of 70 °C in the area of the limit switch can permanently endanger the functional reliability of the limit switch, as the manufacturer specifies a maximum permissible ambient temperature limit of 70 °C for the intended use. This can generally only be done on the limit switch near the hydraulic pipe.
Page 43: Emergency Stop
ATEX Retractor System TANKO-RT/-RTS Remark on the Cleaning Process The result of a cleaning process with the device, like all other cleaning processes, depends on several parameters. According to the “Sinner's Circle”, the four most important parameters for cleaning are: –...
Page 44: Functional Flow Chart
ATEX Retractor System TANKO-RT/-RTS 3.2.2 Functional Flow Chart Components Power cylinder (P), double acting Locking cylinder (L), single acting, with spring return Sensors End position power cylinder, “extended” End position power cylinder (redundant), “retracted” End position locking cylinder extended, “unlocked” End position locking cylinder retracted, “locked”...
Page 45: Figure 3.2-1: Function Diagram
ATEX Retractor System TANKO-RT/-RTS Figure 3.2-1: Function Diagram 3 Design and Function Translation - Operating/installation instructions 2020/01 35/121...
Page 46: Technical Data
ATEX Retractor System TANKO-RT/-RTS 3.3 Technical Data The estimated safe service life of the device is 10 years with single-shift operation and the use of drinking water. The prerequisites for this are that the device must be maintained properly at the intervals specified in Section 7.4 Maintenance, and the wear parts must be replaced regularly.
Page 47: Table 3.3-2: Operating Parameter, Pneumatic Side
ATEX Retractor System TANKO-RT/-RTS Technical Data for Pneumatic Side Designation Retractor system TANKO-RT/RTS Actuator: Pneumatic (compressed air) Drive medium: Dry, oil-free compressed air (if necessary, install corresponding upstream maintenance unit) Operating pressure Range min. 5 bar (72.5 psi g) – max. 6 bar (87 psi g) –...
Page 48 ATEX Retractor System TANKO-RT/-RTS Pneumatic Connection NOTE ON EXPLOSION PROTECTION Restriction on the travel speed of the pneumatic cylinder! The speed for extending and retracting the pneumatic cylinder may not exceed 0.1 m/s. The throttle check valves whose position determines the speed are preset and sealed by the manufacturer of the retractor system.
Page 49: Table 3.3-3: Operating Parameter, Hydraulic Side
ATEX Retractor System TANKO-RT/-RTS Technical Data for Hydraulic Side Designation TANKO-RT/RTS Range Figure 3.3-3: Diagram - Range Operating temperature (permitted): +5 °C (+41 °F) to +95 °C (+203 °F) Cleaning medium – There is no potentially explosive mixture in the container during cleaning.
Page 50: Figure 3.3-1: Diagram - Flow Rate For Rotating Spray Head
ATEX Retractor System TANKO-RT/-RTS Consumption Data – Rotating Spray Head l/min m gpm (US) A – Head type “CD” 270° B – Head type “CC” 270° C – Head type “CB” 270° D – Head type “CA” 270° Figure 3.3-1: Diagram - Flow Rate for Rotating Spray Head Consumption Data –...
Page 51: Figure 3.3-3: Diagram - Range
ATEX Retractor System TANKO-RT/-RTS Consumption Data and Operating Pressure for the Cleaning Process: The specified values for consumption in the charts are average values and may fluctuate by approx. 10% in normal operation. They apply to operation with clear water as the cleaning medium at a temperature of +25 °C / +77 °F.
Page 52: Figure 3.3-4: Example Display Of Pa Weld, Combination Adapter C3 And Biocontrol
ATEX Retractor System TANKO-RT/-RTS Dimensions and Weight stroke Figure 3.3-4: Example Display of PA weld, Combination Adapter C3 and BioControl® Dimension [mm] Stroke 100 Stroke 150 Stroke 250 Stroke 500 1,767 1,187 Table 3.3-4: Overview of Linear Dimensions 42/121 Translation - Operating/installation instructions 2020/01 3 Design and Function...
Page 53: Table 3.3-5: Weights
ATEX Retractor System TANKO-RT/-RTS Process connection [PC] Weights [kg] with stroke length in [mm] Stroke Stroke Stroke Stroke Designation D [mm] Ø 64.0 2" Clamp (DIN 32676) Ø 77.5 2.5" Ø 91.0 3" Ø 50.7 2" Weld-in connector Ø 63.4 2.5"...
Page 54: Cleaning Media
The owner bears the sole responsibility for the type of cleaning media, their use and handling. For this reason, AWH can provide the owner with a few reference points and notes (for a device in a container) but only as a precautionary measure, which must be observed and integrated into the owner's hazard assessments.
Page 55 ATEX Retractor System TANKO-RT/-RTS (3) Ignitable mixtures (e.g. carbon disulfide / air mixtures) require additional measures. (4) Impacting cleaning jets form droplets or mists when they disintegrate that are normally charged and generate electrical charges in the container. Existing turbulence distributes the charged mist throughout the container, thus generating a high space charge density with high field strengths.
Page 56 ATEX Retractor System TANKO-RT/-RTS DANGER Danger due to development of a potentially explosive atmosphere! Splashing or spraying flammable fluids to clean the container can create a potentially explosive atmosphere. There is a risk of death or severe physical injury. Avoid the creation of a hazardous potentially explosive atmosphere and the activation ...
Page 57 ATEX Retractor System TANKO-RT/-RTS WARNING Danger due to corrosive and irritant cleaning medium! When handling the cleaning medium, it is IMPOSSIBLE TO EXCLUDE the risk of inhalation, swallowing, contact with the skin, eyes and mucous membranes. There is a risk of death or severe physical injury. Adhere to the regulations and specifications in the safety data sheets for the cleaning ...
Page 58 ATEX Retractor System TANKO-RT/-RTS The Following Media are Permitted for Use for Container Cleaning: Only clean, sprayable fluids may generally be used. The process of spraying and blasting with fluids always requires individual consideration by the owner. The only permitted cleaning media are solvents with low and medium conductivity (k ≤ 10,000 pS/m, flash point T >...
Page 59: Transport And Storage
ATEX Retractor System TANKO-RT/-RTS 4 Transport and Storage AWH products are checked carefully before they are dispatched, and are packaged in accordance with the respective transport and storage conditions. However, it is NOT possible to rule out the possibility of damage during transportation completely.
Page 60: Packaging
If possible, use the original packaging and the original packaging material. If neither is available anymore, request a packaging company with specialist personnel.  Consult AWH if you have any questions regarding packaging and transport safety. 4.1 Packaging The device is supplied fully assembled. The packaging is adapted to the transport conditions. Required accessories, spare parts, operating or installation instructions and technical documents are packed separately and enclosed with the delivery.
Page 61: Storage
ATEX Retractor System TANKO-RT/-RTS NOTE Improper transport can result in damage to the device. The functional safety and reliability of the device may be impaired.  Observe the symbols and instructions on the packaging.  Always transport the device in dry condition. Protect the device from impact.
Page 62: Installation
ATEX Retractor System TANKO-RT/-RTS 5 Installation 5.1 Safety instructions for installation NOTE ON EXPLOSION PROTECTION Work on the device in a potentially explosive atmosphere is PROHIBITED! If this is not observed, the explosion protection could be disabled.  Only allow instructed personnel to work in potentially explosive atmospheres. The personal protective equipment must meet the explosion protection requirements.
Page 63 ATEX Retractor System TANKO-RT/-RTS WARNING Risk of accidents due to incorrect installation! Incorrect installation, falling components or failure to comply with the indicated safety instructions can result in accidents or material damage. This could result in death, serious injuries and/or burns. Only have experts perform work on the device.
Page 64 ATEX Retractor System TANKO-RT/-RTS CAUTION Risk from protruding sharp edges on the device! Depending on the design, the device may have protruding sharp edges that can be dangerous when handling it. There is a risk of minor cuts. Wear protective gloves when working on the device. ...
Page 65: Installation
ATEX Retractor System TANKO-RT/-RTS 5.2 Installation The safety notes in Section 5.1 Safety instructions for installation must be adhered to before installation of the device in the container. NOTE ON EXPLOSION PROTECTION The o-ring gasket on the spray head does not represent a permanent technical seal to the inside of the container.
Page 66 ATEX Retractor System TANKO-RT/-RTS CAUTION Fault as a result of soiling, foreign matter or damage to the device! Foreign matter, such as scale, burrs, chips, etc. can restrict the flow or enter the pipe system and cause malfunctions or damage to components, including gaskets. That can result in hazards that endanger the functional safety of the device.
Page 67: Interfaces
ATEX Retractor System TANKO-RT/-RTS 5.2.1 Interfaces Figure 5.2-1: Device Interfaces The following interfaces are located on the cleaning device: Process connection [PC], (design based on order) Media connection [MC], cleaning medium supply (design based on order) Compressed air feed on power cylinder for extending the spray head Compressed air feed on power cylinder for retracting the spray head Power cylinder “extended”...
Page 68: Installation Position
If the device is not installed in a vertical position, the retractor systems must be held in place/supported by suitable pipe clamps (see AWH catalog, “Pipes & Assembly Accessories” at http://www.awh.eu); this is recommended for stroke lengths greater than 250 mm.
Page 69: Installing The Device
ATEX Retractor System TANKO-RT/-RTS Compressed air escapes through the locking cylinder while the power cylinder is extended. To save compressed air during a long cleaning cycle, the power cylinder can be depressurized. However, this is only possible at installation positions from 0°- 90° (see adjacent figure), as the cleaning medium present holds the power cylinder in its extended position.
Page 70: Figure 5.2-4: Overview Of Assembly Units
ATEX Retractor System TANKO-RT/-RTS Figure 5.2-4: Overview of Assembly Units Process connection [PC] Media connection [MC] (cleaning agent feed) Connection between hydraulic pipe and pneumatic pipe (power cylinder P) Power cylinder “extension” pneumatic connection Power cylinder “retraction” pneumatic connection Power cylinder “extended” limit switch (1x) Power cylinder “retracted”...
Page 71 5.2.3.1 Installation of the Device with Process Connection: Clamp The sealing points are the crucial part of the clamp connection and have been manufactured and packed by AWH with the utmost care and precision. When handling the clamp connection, the sealing elements can very easily suffer damage.
Page 72: Table 5.2-1: Recommended Filler Materials
For more information, please consult AWH. 1. Take the combination vessel connector out of the packaging and perform a visual inspection for damage.
Page 73: Figure 5.2-5: Combination Vessel Connector Standard Connection
ATEX Retractor System TANKO-RT/-RTS The combination vessel connector has a circumferential marking [M]. This circumferential marking should form an Ø 91 mm intersection with the interior wall of the container and not protrude any deeper into the container. For easier assembly, it is useful to make a second marking at a distance equivalent to the wall thickness [s] from the existing exterior marking onto the combination vessel connector in the direction of the clamp.
Page 74: Figure 5.2-7: Container Seal
ATEX Retractor System TANKO-RT/-RTS In the interior area, an acid cleaning treatment is recommended after the welding. The surface of accessible points can be improved by grinding. The exterior can be treated afterwards by staining, brushing, grinding and polishing. After welding, the combination vessel connector can be ground with the interior wall of the container (see Figure 5.2-6).
Page 75: Figure 5.2-8: Special Connection
® gasket and bracket (or screws for a screwed flange, special design) for media connection are not included in the scope of delivery; please request gasket and bracket from AWH, request block flange, O-ring and 4x screws M10x18 from NEUMO.
Page 76: Connection Of Pneumatic Actuator
ATEX Retractor System TANKO-RT/-RTS 3. Install the retractor system on the block flange with the 4 screws M10 x 18. It is imperative to follow the installation instructions and torques of the block flange manufacturer NEUMO. 4. Cleaning medium supply (standard: Clamp DN25 in accordance with DIN 32676) on the media connection (hydraulic pipe) with suitable gasket and clamp.
Page 77: Figure 5.2-10: Position Of Locking Cylinder Limit Switch
ATEX Retractor System TANKO-RT/-RTS Figure 5.2-10: Position of Locking Cylinder Limit Switch A switch amplifier must be used for the limit switches, which is not supplied (see Power Supply Section 3.3 Technical Data). 3. Mount the cable of the limit switch of the working and locking cylinder on the switch amplifier. WARNING Limit switch temperature exceeded Exceeding the temperature may endanger the functional security of limit switch “F”.
Page 78: Figure 5.2-11: Resistance Thermometer Position
ATEX Retractor System TANKO-RT/-RTS The resistance thermometer must be mounted as follows: Throttle check valve "E" on the rear Resistance Thermometer Limit switch “F” Retaining screw bracket for limit switch Figure 5.2-11: Resistance thermometer position Release the retaining screw of the bracket for the limit switch Mount the hose clamp with the resistance thermometer on the pneumatic pipe Push the hose clamp with the resistance thermometer up to the clamp band of the limit switch Tighten the hose clamp of the resistance thermometer...
Page 79: Start-Up
ATEX Retractor System TANKO-RT/-RTS 6 Start-up Before starting up the device in Germany, the owner of the plant must observe the Industrial Safety and Health Protection Ordinance (BetrSichV). In other countries, the respective national guidelines, statutes and country-specific regulations regarding occupational safety and accident prevention must be complied with. WARNING Hazardous situations as a result of incorrect installation of the device! If the device is not installed properly, unforeseen situations may develop during start-up...
Page 80 ATEX Retractor System TANKO-RT/-RTS NOTE ON EXPLOSION PROTECTION Temperatures over 70 °C on the pneumatic cylinder in the area of the limit switch result in the limit switch malfunctioning. If this is not observed, the explosion protection could be disabled. ...
Page 81 ATEX Retractor System TANKO-RT/-RTS DANGER Danger of ignition in potentially explosive atmosphere due to potential differences! When filling and emptying containers with fluids, when recirculating, stirring, mixing and spraying fluids and also when measuring, sampling and cleaning, the fluids themselves or the interior of the container could be charged in a dangerous manner.
Page 82 Take precautions to allow gases or vapors to escape during operation (e.g. install devices for ventilation). As a result of the variety of practical applications and uses for the cleaning device, AWH CANNOT specify a noise level for the device under load, i.e. installed in the container and operating with cleaning fluid.
Page 83 ATEX Retractor System TANKO-RT/-RTS CAUTION Risk of hearing damage due to an increased noise level! The device emits a noise pressure level of L < 70 dB(A). When the device is operated in a container, the noise level may exceed the maximum permitted exposure value of L = 85 dB(A) and varies depending on the properties of EX,8h...
Page 84: Function Check/Trial Run
ATEX Retractor System TANKO-RT/-RTS 6.2 Function Check/Trial Run All the screw connections on the device are firmly tightened in the factory. Nevertheless, a trial run should be carried out to check that the device functions safely and reliably, and that it is tight once installed.
Page 85: Switch-On Procedure
ATEX Retractor System TANKO-RT/-RTS 6.3 Switch-On Procedure In accordance with the type of device activation and how it is integrated (e.g. manual or automatic) on the cleaning plant, the switch-on procedure must be integrated and the following instructions must be observed when switching on.
Page 86: Operation
ATEX Retractor System TANKO-RT/-RTS NOTE Risk of breakage due to material overload! Pressure surges when switching the cleaning medium on or off, in particular pressure surges that exceed the operating pressure, and gas components in the cleaning medium may result in hammering in the cleaning device. There is a risk of material damage or destruction of plant parts, (e.g.
Page 87 ATEX Retractor System TANKO-RT/-RTS WARNING Risk when used outdoors! If the device is used outdoors, there is a risk of lightning in the case of a storm. There is a risk of death or severe physical injury.  The devices are usually operated in an enclosed factory hall and are thus protected from the risk of lightning.
Page 88 ATEX Retractor System TANKO-RT/-RTS WARNING Danger due to hot surfaces! The device may heat up significantly as a result of the cleaning medium or heat transfer from the container. Contact with the device can cause burns to the skin. There is a risk of burns from the cleaning medium at temperatures of above +60 °C (+140 °F).
Page 89 ATEX Retractor System TANKO-RT/-RTS WARNING Incorrect operation of the device! There is a risk of death or severe physical injury.  Only operate the device in perfect condition.  Only operate the device installed inside a closed container. Drain and depressurize the container to be cleaned. ...
Page 90: Maintenance
(see Section 6.2). If you have questions or doubts about handling the cleaning device, please contact AWH. 7.1 Safety Instructions for Maintenance NOTE ON EXPLOSION PROTECTION Work on the device in a potentially explosive atmosphere is PROHIBITED! If this is not observed, the explosion protection could be disabled.
Page 91 ATEX Retractor System TANKO-RT/-RTS DANGER Risk of fatal injury from electric shock through contact with live parts! Activated electrical components are live with dangerous electrical voltage and may perform uncontrolled movements. There is a risk of death or severe physical injury. Allow only qualified electricians to perform work on the electrical system.
Page 92 ATEX Retractor System TANKO-RT/-RTS WARNING Risk of chemical burns and heat burns when opening the container! The supply line is pressurized. The person could be hit by cleaning jets or come into contact with residual fluid from the supply line and device. There may also be hot vapors in the container.
Page 93: Removal
ATEX Retractor System TANKO-RT/-RTS 7.2 Removal The safety instructions in Section 7.1 Safety Instructions for Maintenance must be observed before removing the device from the container. WARNING Risk of chemical burns and heat burns when opening the container! The supply line is pressurized. The person could be hit by cleaning jets or come into contact with residual fluid from the supply line and device.
Page 94: Switch-Off Procedure
ATEX Retractor System TANKO-RT/-RTS 7.3 Switch-Off Procedure In accordance with the type of device activation and how it is integrated (e.g. manual or automatic) on the cleaning plant, the switch-off procedure has to be integrated and the following instructions have to be observed when switching off.
Page 95: Removing The Device
ATEX Retractor System TANKO-RT/-RTS NOTE Risk of breakage due to material overload! Pressure surges when switching the cleaning medium on or off, in particular pressure surges which exceed the operating pressure, and gas components in the cleaning medium can cause hammering in the cleaning device. There is a risk of material damage, e.g.
Page 96 ATEX Retractor System TANKO-RT/-RTS Spray head, rotating TYPE A, B, C, or D / alternative static spray head type S on TANKO-RTS anti-twist version Hydraulic pipe for holding the spray head Power cylinder, pneumatic actuator with 3 limit switches Central bearing Power cylinder Resistance Thermometer WARNING...
Page 97 7. Seal the process connection using a suitable screw cap. 8. If necessary, close the clamps or combination container connectors on the container. To close off the combination vessel connector, a blind plug can be obtained from AWH. 7 Maintenance...
Page 98 ATEX Retractor System TANKO-RT/-RTS Material Blind plug for combination container connector, article number 1.4435 66R0000004Z30 2.4602 66R0000004Z80 BioControl process connection ® 1. Check the following before pulling the device out of the container: Device in “rest position”, i.e. spray head in hydraulic pipe –...
Page 99: Maintenance
ATEX Retractor System TANKO-RT/-RTS 7.4 Maintenance To ensure the trouble-free operation, high operational safety and long service life of the cleaning device, it is essential to have it cleaned and maintained at regular intervals. NOTE ON EXPLOSION PROTECTION Work on the device in a potentially explosive atmosphere is PROHIBITED! If this is not observed, the explosion protection could be disabled.
Page 100 ATEX Retractor System TANKO-RT/-RTS NOTE Danger due to leaks at the connections! The sealing elements of the process connection [PC] and media connection [MC] are manufactured in accordance with the technical requirements for sealing surfaces. Incorrect operation of the device can cause damage to the sealing elements (e.g.
Page 101: Maintenance Intervals
ATEX Retractor System TANKO-RT/-RTS NOTE Edge pressure in the area of the flats! If workpieces are NOT grasped without play and in a protective manner by the flats during assembly/disassembly, then they are at risk of damage.  For gentle, protective assembly/disassembly work, use an adjustable or pliers wrench with parallel, smooth clamping jaws.
Page 102: Figure 7.4-1: Maintenance Points
ATEX Retractor System TANKO-RT/-RTS The specified times of the maintenance intervals are based on single-shift operation (8 hours per working day, 12 months per year) of the device and operation with Cleaning medium: Water Media pressure: 3 bar (43.5 psi g) Media temperature: +25 °C (+77 °F) Interval:...
Page 103: Table 7.4-1: Inspection And Maintenance Work
ATEX Retractor System TANKO-RT/-RTS The tightening torque values required for the thread connections are listed in Table 7.5-1. The item numbers shown in brackets refer to Figure 7.5-1: Internal Construction. Inspection and Maintenance Work Check compressed air hoses for damage and signs of age. Replace S, F them if necessary.
Page 104: Tools And Tightening Torques
Figure 7.4-2: Tool for TANKO-RT/-RTS Recommended assembly tools: The following assembly tools can be purchased from AWH to facilitate assembly: – Assembly tool for wire locking pin, size A, Art. no. 664MW01010050 – Assembly anvil for central bearing, Art. no. 664MW03020020 –...
Page 105: Replacing The O-Rings, The Central Bearing, The Piston Ring And The Damping Ring
ATEX Retractor System TANKO-RT/-RTS Figure 7.4-4: Assembly Tools, Assembly cone (A) and Assembly Anvil (B) All the screw connections on the device are tightened to the appropriate tightening torque in the factory in order to ensure the necessary clamping force between the components that need to be connected, even when the maximum operating forces are applied.
Page 106: Figure 7.4-5: Replacing Consumables
ATEX Retractor System TANKO-RT/-RTS 1.01 1.04 1.03 1.09 1.25 1.24 2.06 1.21 1.20 2.05 1.19 1.02 1.11 1.22 1.12 1.08 1.10 1.05 3.06 3.04 Figure 7.4-5: Replacing Consumables Item Qty. Designation Article number. Material 1.05 Damping ring 66R01000005P0 Polyurethane 1.10 Piston ring 66R01000024L0 TOMF-0040 PTFE...
Page 107: Figure 7.4-6: Overview Of Assembly Of Central Bearing With Assembly Cone
ATEX Retractor System TANKO-RT/-RTS 3. NOTE The cleaning device can be damaged if not set down in a safe place!  During subsequent work, take particular care to ensure that the disassembled pneumatic section of the cleaning device is stored safely, particularly the centering adapter (1.20). 4.
Page 108: Replacing The Spray Head
ATEX Retractor System TANKO-RT/-RTS 11. Fit the piston rod with the centering adapter and spray head into the hydraulic pipe, with the spray head first. 12. Press the central bearing into the hydraulic pipe as far as it will go (central bearing retaining plate, 1.12).
Page 109: Replacing The Locking Cylinder Assembly Group
ATEX Retractor System TANKO-RT/-RTS 7.4.5 Replacing the Locking Cylinder Assembly Group 1. Release the cable from the limit switches (plug connection with union nut) and pull the pneumatic hose out from the plug connection. 2. Uninstall the locking cylinder assembly group (locking cylinder complete with bolt, 3.06) by unscrewing it from the locking adapter and pulling it completely out of the locking adapter.
Page 110 ATEX Retractor System TANKO-RT/-RTS NOTE Risk of damage to the device during cleaning! The use of an incorrect cleaning agent or sharp objects can damage the device. The functional safety and reliability of the device may be impaired. The cleaning agents must be approved for all materials in the device (e.g. gaskets, ...
Page 111: Spare Parts And Customer Service
For technical questions or spare part requests, you can contact Customer Service as follows: Armaturenwerk Hötensleben GmbH Schulstr. 5-6, D-39393 Hötensleben, Germany Telephone: +49 39405 92-0 Fax: +49 39405 92-111 E-mail: info@awh.eu Internet: http://www.awh.eu 7 Maintenance Translation - Operating/installation instructions 2020/01 101/121...
Page 112: Figure 7.5-1: Internal Construction
ATEX Retractor System TANKO-RT/-RTS Figure 7.5-1: Internal Construction 102/121 Translation - Operating/installation instructions 2020/01 7 Maintenance...
Page 113 ATEX Retractor System TANKO-RT/-RTS Remark: The items marked “X” or “■” are included in the wear parts package and can be ordered. The items marked “■” are required for replacing wear parts [WP]. Tightening Item Qty. Designation torque Article number Material [WP] [Nm]...
Page 114: Table 7.5-1: Replacement Parts List (Standard), Wear Parts, Tightening Torques
ATEX Retractor System TANKO-RT/-RTS 3.04 O-Ring 15 x 1.5 — 1060500001556 EPDM Hexagon socket-head 3.05 540132 screws M5 x 25 3.06 Locking cylinder — 014121 Angled plug connection M5 3.07 420077 to Ø 6 3.08 Limit switch without cable — 393012503 3.09 Fastening set Ø...
Page 115: Table 7.5-4: O-Rings For Centering Adapter And Head
ATEX Retractor System TANKO-RT/-RTS Item 1.19 + 2.05 O-ring Ø 27 x 5 Material Article No. Permitted operating temperature in the TANKO-RT ATEX EPDM 106050253 -20 °C (-4 °F) to +130 °C (+266 °F) FKM (e.g. VITON 1060500002706 -15 °C (+5 °F) to +140 °C (+284 °F) ®...
Page 116: Table 7.5-7: Hydraulic Pipe Depending On Stroke And Process Connection
ATEX Retractor System TANKO-RT/-RTS Item 1.21 SG hydraulic pipe FT Article number PA = Process MA = Media connection clamp DN25, DIN 32676 connection in Stroke accordance with Standard Anti-twist DIN 32676 Weld 2" 66R0115043130 66RS115043130 Weld 2.5" 66R0115043230 66RS115043230 Weld 3"...
Page 117: Faults
ATEX Retractor System TANKO-RT/-RTS 8 Faults 8.1 Safety Instructions for Troubleshooting Before rectifying a fault, the following safety instructions must always be adhered to: NOTE ON EXPLOSION PROTECTION Work on the device in a potentially explosive atmosphere is PROHIBITED! If this is not observed, the explosion protection could be disabled. ...
Page 118 Before rectifying any fault, observe the safety instructions in Chapter 7 Maintenance.  In case of any uncertainty or doubt, contact AWH. WARNING Danger caused by ejection of the cleaning medium! If the cleaning medium returns after a system failure (e.g. pressure drop due to interruption of the pressure supply) there is a risk of accident.
Page 119: Faults And Remedial Action
ATEX Retractor System TANKO-RT/-RTS WARNING Danger caused by ejection of the compressed air! If the compressed air is ejected after a system failure (e.g. pressure drop due to interruption of the pressure supply) there is a risk of accident. There is a risk of death or severe physical injury. Do NOT remove the device if the compressed air supply has failed.
Page 120: Table 8.2-1: Operational Disruptions - Cause And Remedy
Table 8.2-1: Operational Disruptions – Cause and Remedy If the specified measures are NOT successful, please contact AWH. If the device is sent back (e.g. repair/service/return), it is necessary for a hazardous substances declaration to be enclosed with the device in compliance with the German Ordinance on Hazardous Substances (GefStoffV).
Page 121: What To Do In An Emergency
It is for this reason that AWH can offer the owner, solely as a precautionary measure, a few points of reference and notes to be observed and to be integrated into the owner's hazard assessments.
Page 122: Putting The Device Out Of Service
Use protective work clothing, protective gloves and safety goggles when carrying out the work.  In case of any uncertainty or doubt, contact AWH. Removal Only experts are permitted to perform the removal from the container and the disassembly of the device for disposal.
Page 123: Disposal
ATEX Retractor System TANKO-RT/-RTS 9.1 Disposal CAUTION Danger from harmful fluids which are a health hazard! During disposal, there is a risk of injury from contact with harmful fluids. There is a risk of minor or moderate injuries. Use personal protective equipment (e.g. protective gloves, safety shoes, safety ...
Page 124: Index
ATEX Retractor System TANKO-RT/-RTS Index Trial run with the device ....74, 80, 91 Functional Flow Chart ........34 Abbreviations ............V General Function Description ......30 Category ............18 Cleaning ............27 Cleaning Media ..........8, 44 Identification ............. 17 Connection of Pneumatic Actuator ....
Page 125: Change Record
ATEX Retractor System TANKO-RT/-RTS Resistance Thermometer ......37 General Technical Data ........ 36 Hydraulic side ..........39 Product Names and Trademarks ...... 5 Pneumatic Side ..........37 Putting the Device Out of Service ....112 Temperature ............. 27 Ambient temperature ......36, 39 Operating temperature .........
Page 126: Annexes
ATEX Retractor System TANKO-RT/-RTS Annexes Annex 1: Declaration (Translation)......................117 Appendix 2: Corrosion Resistance of Steels (Excerpts from Data Sheets) ........... 119 116/121 Translation - Operating/installation instructions 2020/01 Annexes...
Page 127 Schulstraße 5 – 6 39393 Hötensleben Telephone: +49 39405 92-0 Fax: +49 39405 92-111 E-Mail: info@awh.eu Internet: http://www.awh.eu Declaration for incorporation pursuant to the EC Machinery Directive 2006/42/EC, Annex II B EU declaration of conformity pursuant to the EC directive relating to Equipment and Protective Systems...
Page 128 ATEX Retractor System TANKO-RT/-RTS 3. Supplement (N3) to the EC type test certificate BVS 10 ATEX H 006 X from the designated body DEKRA Testing and Certifikation GmbH, Certification department, code number 0158, Dinnendahlstraße 9, 44809 Bochum, Germany. Quality assurance system according to DIN EN ISO/IEC 80079-34, certified by the designated body TÜV NORD CERT GmbH, identification number 0044, Langemarckstrasse 20, 45141 Essen, Germany.
Page 129 ATEX Retractor System TANKO-RT/-RTS Appendix 2: Corrosion Resistance of Steels (Excerpts from Data Sheets) Material number 1.4301 (AISI 304) as a component that does not come into contact with the medium (e.g. clamp on the clamp connection). Stainless austenitic chrome-nickel steel 1.4301 is the standard for austenitic chrome-nickel steels.
Page 130 ATEX Retractor System TANKO-RT/-RTS Material no. 1.4435 (AISI 316L) 1.4435 has excellent corrosion resistance in natural environmental media (water, rural and urban environments), in industrial sectors with moderate chlorine and salt concentrations, as well as in the food industry and the agricultural food sector. In addition, this grade is also resistant to various acidic media.
Page 131: Notes
ATEX Retractor System TANKO-RT/-RTS Notes Notes Translation - Operating/installation instructions 2020/01 121/121...
Page 132 Armaturenwerk Hötensleben GmbH Schulstr. 5 – 6 D-39393 Hötensleben Telefon: +49 39405 92-0 Telefax: +49 39405 92-111 E-mail: info@awh.eu Internet: http://www.awh.eu OPERATING/INSTALLATION INSTRUCTIONS - ATEX Retractor System TANKO-RT/-RTS ID number: 664BA030000ENX - 2020/01 Rev.

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AWH TANKO RT Operating & Installation Instructions Manual

1 Introduction

2 Safety

3 Design and Function

4 Transport and Storage

5 Installation

6 Start-Up

7 Maintenance

8 Faults

9 Putting the Device out of Service

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