Alfa Laval RODEM Toftejorg TZ-74 Instruction Manual
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Alfa Laval RODEM Toftejorg TZ-74 Instruction Manual

Alfa Laval RODEM Toftejorg TZ-74 Instruction Manual

Brew kettle
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Instruction Manual
Toftejorg™ TZ-74 Brew Kettle
Covering ▪ Standard Machines
▪ Machines delivered with ATEX Certification in accordance with
Directive 94/9/EC
IM-TE91A160-EN6
ESE01838EN
Date of issue: January 8, 2015
First published: 1974
Original manual

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Summary of Contents for Alfa Laval RODEM Toftejorg TZ-74

  • Page 1 Instruction Manual Toftejorg™ TZ-74 Brew Kettle Covering ▪ Standard Machines ▪ Machines delivered with ATEX Certification in accordance with Directive 94/9/EC IM-TE91A160-EN6 ESE01838EN Date of issue: January 8, 2015 First published: 1974 Original manual...

  • Page 3: Table Of Contents

    Standard Spare Parts Kit ......................42 General Information ........................43 How to Order Spare Parts ........................43 Service and Repair ..........................43 How to contact Alfa Laval Tank Equipment ..................... 43 EC Declaration of Conformity ...................... 44 Instruction Manual, Toftejorg TZ-74 Brew Kettle Page...

  • Page 5: Introduction

    © 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.

  • Page 6: 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 7: Atex Marking

    Changes to the machine are not allowed without approval by the person responsible for the ATEX certification at Alfa Laval Tank Equipment 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other than Alfa Laval original spare parts are used - the EC Type Examination certification (the ATEX Directive) is no longer valid.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 8: General Description

    General Description The Toftejorg TZ-74 Brew Kettle version is a special version of the Toftejorg TZ-74 machine. It is especially designed for rough working conditions in amongst others Brew Kettles where fibres, particles etc. may be recirculated in the cleaning media through the machine. The Toftejorg TZ-74 Brew Kettle is a media driven and media lubricated tank cleaning machine.

  • Page 9: Standard Configurations

    General Description (continued) Standard Configurations Turbine / Nozzles (mm) Article no. Article no. Connection Inlet Guide (½" thread conn.) Standard machines ATEX certified machines 4 x ø6 TE21D108-11 TE21D108-71 Top Cone: 100% 4 x ø7 TE21D110-11 TE21D110-71 4 x ø8 TE21D112-11 TE21D112-71 1½"NPT,...

  • Page 10: Technical Data

    Technical Data Weight of machine 6,1 kgs (13,6 lb) Working pressure 3-12 bar (45-175 psi) Recommended inlet pressure 3-8 bar (45-120 psi) Working temperature max. C (200 F) Ambient temperature 0 – 140°C (95°C – 140°C when not operated) Materials Stainless steel AISI 316L, Tefzel200, Teflon TFM, PEEK, Viton Principal dimensions in mm Page 8...

  • Page 11: Flow Rate

    Technical Data (continued) Flow rate Instruction Manual, Toftejorg TZ-74 Brew Kettle Page 9 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A160-EN6...

  • Page 12: Throw Length

    Technical Data (continued) Throw length Page 10 Instruction Manual, Toftejorg TZ-74 Brew Kettle Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A160-EN6...

  • Page 13: Cleaning Time, Complete Pattern

    Technical Data (continued) Cleaning time, complete pattern Instruction Manual, Toftejorg TZ-74 Brew Kettle Page 11 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A160-EN6...

  • Page 14: Installation And Normal Operation

    Installation and Normal Operation General Safety and Installation Instructions The tank cleaning machine should be installed in a vertical position (upright or upside down). It is recommended to install a filter in the supply line in order to avoid large particles to clog inside the machine.

  • Page 15: Normal Operation

    If you are in doubt, contact your local Alfa Laval Tank Equipment sales office. After Use Cleaning: After use flush the machine with fresh water. Cleaning solutions should never be allowed to dry or set-up in the system due to possible "salting out"...
  • Page 16 Installation and Normal Operation (continued) Normal operation Pressure: Avoid hydraulic shocks. Put on pressure gradually. Do not exceed 12 bar inlet pressure. Recommended inlet pressure appears from Technical Data (page 8-9). High pressure in combination with high flow rate will increase consumption of wear parts. ATEX If stream cleaning is done through the machine, the steam pressure must not cause Warning:...

  • Page 17: Special Conditions For Safe Use In Accordance With The Atex Certification, Directive 94/9/Ec

    Installation and Normal Operation (continued) Special Conditions for Safe Use in accordance with the ATEX Certification, Directive 94/9/EC ATEX Warning: The unit may be operated, in a hazardous area, only when filled with the process fluid. ATEX Warning: The maximum permitted process fluid temperature and ambient temperature when the machine is operating is 95°C.

  • Page 18: Maintenance And Repair

    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 Tank Equipment, Kolding, Denmark.
  • Page 19 - Blank page - Instruction Manual, Toftejorg TZ-74 Brew Kettle Page 17 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A160-EN6...

  • Page 20: Preventive Maintenance

    Maintenance and Repair (continued) Preventive Maintenance In order to keep your tank cleaning machine servicing you as an efficient tool in your tank cleaning operations, it is essential to maintain its high performance by following a simple preventive maintenance programme, which will always keep your tank cleaning machine in good condition. Good maintenance is careful and regular attention! The following recommended preventive maintenance is based on tank cleaning machines working in average conditions.
  • Page 21 Maintenance and Repair (continued) Preventive Maintenance Check Worm wheels (pos. 11 and pos. 33). If extremely worn, they should be replaced. Check Main bush (pos. 5). If worn it should be replaced. Assemble machines as described in the following pages. Check that the machine is in operating condition by inserting Hex Screwdriver (tool No.

  • Page 22: Top Assembly

    Maintenance and Repair (continued) Top Assembly Disassembly Remove Screws (pos. 17). Loosen and unscrew with a socket wrench (tool No. TE462A). Lift off Top Cone (pos. 1). Remove Guide /Guide ring (pos. 2). The Guide has a groove in the outer diameter. The Guide is easily lifted out of the Stem by means of two ordinary Screwdrivers inserted into the groove.
  • Page 23 Maintenance and Repair (continued) Top Assembly Instruction Manual, Toftejorg TZ-74 Brew Kettle Page 21 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A160-EN6...

  • Page 24: Bottom Assembly

    Maintenance and Repair (continued) Bottom Assembly Disassembly Turn machine upside down. Remove Screws (pos. 31) from Bottom cover (pos. 30). Remove Bottom cover (pos. 30) and Gasket (pos. 32). Remove Screws (pos. 15) in Bearing cover (pos. 14). Carefully push out Turbine shaft (pos. 6) from opposite end.
  • Page 25 Maintenance and Repair (continued) Bottom Assembly Instruction Manual, Toftejorg TZ-74 Brew Kettle Page 23 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A160-EN6...

  • Page 26: Hub Assembly

    Maintenance and Repair (continued) Hub Assembly Disassembly Remove Nozzles (pos. 20). Nozzles are untightened with a wrench on the faces of the Nozzles. Remove Screws (pos. 31), Hub cover (pos. 19), and Gasket (pos. 25). Draw out Hub (pos. 21) together with Ball retainer with balls (pos. 24) and Bevel gear (pos. 18). Check Lip seal (pos.
  • Page 27 Maintenance and Repair (continued) Hub Assembly Instruction Manual, Toftejorg TZ-74 Brew Kettle Page 25 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A160-EN6...

  • Page 28: Stem Assembly

    Maintenance and Repair (continued) Stem Assembly Disassembly Place machine in upside-down position. Remove Screws (pos. 15) in Gear wheel (pos. 7). To prevent rotation of Stem (pos. 3) mount two screws in two holes opposite one another in BIG end of Stem. Place Stem in a vice held by the heads of the two screws.
  • Page 29 Maintenance and Repair (continued) Stem Assembly Instruction Manual, Toftejorg TZ-74 Brew Kettle Page 27 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A160-EN6...

  • Page 30: Gear Assembly

    Maintenance and Repair (continued) Gear Assembly Disassembly To make a backstop, remount Turbine shaft (pos. 6) with Slide bearing (pos. 28) and O-ring (pos. 35) into Gear frame (pos. 29). Mount Bearing cover (pos. 14) with Screws (pos. 15). Hold Turbine shaft (pos. 6) against 1 stage Worm wheel (pos.
  • Page 31 Maintenance and Repair (continued) Gear Assembly Insert 2nd stage Worm wheel (pos. 11), Pinion (pos 9) and Journal (pos. 12). Mount Washer (pos. 13), Spring washer (pos. 16) and fix with Screw (pos. 15). Check rotation. Note: It is important that the Screw holding the Pinion is fastened to a torque moment of 5 Nm, to secure it from loosening.

  • Page 32: Replacement Of Collar Bushes

    Maintenance and Repair (continued) Replacement of Collar Bushes Place Gear frame (pos. 29) upside down with a firm support under the flange. Use for instance jaws of a vice. Do not clamp on machined surfaces. With Pusher (tool No. TE81B033, see page 36) knock out Collar bush.
  • Page 33 Maintenance and Repair (continued) Replacement of Collar Bushes Removal of old Collar bushes. Instruction Manual, Toftejorg TZ-74 Brew Kettle Page 31 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A160-EN6...

  • Page 34: Replacement Of Ball Races

    Maintenance and Repair (continued) Replacement of Ball Races In body A. With big end downwards knock several times Body with bearings (pos. 26) hard against firm wooden support until Ball race (pos. 26.3) drops out. B. If it is not possible to knock out Ball race in this way, it is necessary first to screw out Main collar lower (pos.
  • Page 35 Maintenance and Repair (continued) Replacement of Ball races Instruction Manual, Toftejorg TZ-74 Brew Kettle Page 33 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A160-EN6...

  • Page 36: Replacement Of Main Collars

    Maintenance and Repair (continued) Replacement of Main Collars Although normally exposed to very limited wear, it is possible to replace Main collars (pos. 26.1 ) in Body. The procedure to do this is described below. 26.2 Main collar upper: Place Body (pos. 26) in a vice upright position. Do not clamp on machined faces. Insert tool (see page 37) into Main collar upper (pos.
  • Page 37 Maintenance and Repair (continued) Replacement of Main Collars Instruction Manual, Toftejorg TZ-74 Brew Kettle Page 35 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A160-EN6...

  • Page 38: Tools

    Tools Standard Tool kit for Toftejorg TZ-74 Brew Kettle, Article No. TE81B055 Tool No. Description TE134 Hex Key for Screw TE134A Hex Screwdriver for Screw TE462A Socket wrench for Hex Screw TE81B033 Pusher for 1½” Collar bush TE81B034 Fixture set f. Collar bush Sketch of Tools for replacement of Collar bush: TE81B033 Pusher for 1½”...

  • Page 39: Sketch Of Tools For Replacement Of Main Collars

    Tools (continued) Sketch of tools for replacement of Main collars Instruction Manual, Toftejorg TZ-74 Brew Kettle Page 37 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A160-EN6...

  • Page 40: Trouble Shooting Guide

    Trouble Shooting Guide Symptom: Slow rotation or failure of machine to rotate Possible Causes Fault finding No or insufficient liquid flow a). Check if supply valve is fully open b). Check if inlet pressure to machine is correct c). Check supply line filter...
  • Page 41 Trouble Shooting Guide (continued) Possible Causes Fault finding e). Gearbox jammed/sluggish Remove foreign material from Gearbox. Check rotation of shafts. If restriction is recognized, disassemble gearbox (see page 28) and remove material build up, especially on 2. Stage Worm wheel and mating Collar bushes. Hub jammed/sluggish Disassemble Hub Subassembly (see page 24).

  • Page 42: Reference List Of Parts

    Reference List of Parts Toftejorg TZ-74 Brew Kettle, Part List Pos. Ref. No. No/Unit Description Material Remarks  TE21D500 Top Cone 1½" BSP Stainless steel Spare part  TE21D501 Top Cone 1½" NPT Stainless steel Spare part  TE21D511 Top Cone 2” NPT Stainless steel Spare part ...

  • Page 43: Cross Sectional Drawing

    Cross Sectional Drawing Instruction Manual, Toftejorg TZ-74 Brew Kettle Page 41 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A160-EN6...

  • Page 44: Standard Spare Parts Kit

    Standard Spare Parts Kit Service intervals 300 hour 300 hour 300 hour Service Kit: Service Kit: Service Kit: TE21D297 TE21D297 TE21D297 Standard Spare Part Kit for Toftejorg TZ-74 Brew Kettle, Article No. TE21D297 Part No. Description TE21A525 Main bush 1 pcs. TE21A585 Collar bush 3 pcs.

  • Page 45: General Information

    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: Ec Declaration Of Conformity

    EC Declaration of Conformity Page 44 Instruction Manual, Toftejorg TZ-74 Brew Kettle Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A160-EN6...
  • Page 47 © 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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