Alfa Laval Gunclean Toftejorg T-82 Instruction Manual
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Alfa Laval Gunclean Toftejorg T-82 Instruction Manual

Alfa Laval Gunclean Toftejorg T-82 Instruction Manual

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Instruction Manual
Gunclean Toftejorg™ T-82
Covering ▪ Standard Machines
▪ Machines delivered with ATEX Certification in accordance with
Directive 94/9/EC
IM-TE91A052-EN4
Date of issue: December 28, 2011

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Summary of Contents for Alfa Laval Gunclean Toftejorg T-82

  • Page 1 Instruction Manual Gunclean Toftejorg™ T-82 Covering ▪ Standard Machines ▪ Machines delivered with ATEX Certification in accordance with Directive 94/9/EC IM-TE91A052-EN4 Date of issue: December 28, 2011...

  • Page 3: Table Of Contents

    Replacement of Main Collars ........................40 Tools ............................42 Trouble Shooting Guide ......................44 Reference List of Parts, Gunclean Toftejorg T-82 Fixed .............. 46 Cross Sectional Drawing, Gunclean Toftejorg T-82 Fixed ............47 Reference List of Parts, Gunclean Toftejorg T-82 Portable ............48 Cross Sectional Drawing, Gunclean Toftejorg T-82 Portable .............

  • Page 5: Introduction

    © 2011 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 Tank Equipment A/S without any warranty. Improvements and changes to this Instruction Manual may at any time be made by Alfa Laval Tank Equipment 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other than Alfa Laval original spare parts are used - the EC Type Examination certification (the ATEX Directive) is no longer valid.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 Gunclean Toftejorg T-82 is a media driven tank cleaning machine. The internal mechanical parts are isolated by seals and lubricated by pre-packed grease. Functioning The flow of the cleaning fluid into the machine passes through a turbine, which is set into rotation. The impeller rotation is through a gearbox transformed into a combined horizontal rotation of the machine body and a vertical rotation of the nozzles.

  • Page 9: Standard Configurations

    (only available for Gunclean Toftejorg T-82F) Explanation to Add-ons ATEX, category 1 for installation in zone 0/20 in accordance with Directive 94/9/EC Instruction Manual, Gunclean Toftejorg T-82 Page 7 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC...

  • Page 10: Technical Data

    Technical data For Gunclean Toftejorg T-82 Fixed Weight of machine 7.0 kgs (15,4 lb) Working pressure 5-12 bar (75-175 psi) Recommended inlet pressure 5-10 bar (75-150 psi) Working temperature max. 78°C (173° F) Ambient temperature 0 – 140°C (78°C - 140°C when not operated)
  • Page 11 Technical data (continued) For Gunclean Toftejorg T-82 Fixed Flow rate Instruction Manual, Gunclean Toftejorg T-82 Page 9 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A052-EN4...
  • Page 12 Option: The Gunclean Toftejorg T-82 Fixed can be supplied with nozzle extensions and E-gearing for longer throw length. Page 10...
  • Page 13 Technical data (continued) For Gunclean Toftejorg T-82 Fixed Cleaning Time, f. Complete Pattern (= 4 cycles) Instruction Manual, Gunclean Toftejorg T-82 Page 11 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A052-EN4...

  • Page 14: For Gunclean Toftejorg T-82 Portable

    Technical data (continued) For Gunclean Toftejorg T-82 Portable Weight of machine 7.0 kgs (15,4 lb) Working pressure 5-12 bar (75-175 psi) Recommended inlet pressure 5-10 bar (75-150 psi) Working temperature max. 78°C (173° F) Ambient temperature 0 – 140°C (78°C - 140°C when not operated)
  • Page 15 Technical data (continued) For Gunclean Toftejorg T-82 Portable Flow rate Instruction Manual, Gunclean Toftejorg T-82 Page 13 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A052-EN4...
  • Page 16 Technical data (continued) For Gunclean Toftejorg T-82 Portable Throw length Note: Throw lengths are measured as max. horizontal throw length at static condition. Vertical throw length upwards is approx. 1/3 less. Effective throw length varies depending on jet transverse speed over surface, substance to be removed, cleaning procedure and agent.
  • Page 17 Technical data (continued) For Gunclean Toftejorg T-82 Portable Cleaning Time, f. Complete Pattern (= 4 cycles) Instruction Manual, Gunclean Toftejorg T-82 Page 15 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A052-EN4...

  • Page 18: Installation And Normal Operation

    Turbine shaft and easily turn Turbine shaft clockwise. If any resistance is recognized, the machine should be disassembled to localize the cause. Page 16 Instruction Manual, Gunclean Toftejorg T-82 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC...
  • Page 19 TE134A) in screw in top of Turbine shaft and easily turn Turbine shaft clockwise. If any resistance is recognised, the machine should be disassembled to localise the cause. Instruction Manual, Gunclean Toftejorg T-82 Page 17 Standard machines and machines delivered with ATEX certification...

  • Page 20: Normal Operation

    Please note that some of the polymer parts are in PEEK, which is not resistant to concentrated sulfuric acid. Normal detergents, moderate solutions of acids and chemicals at elevated temperatures, as well as hypochlorids should be avoided. If you are in doubt, contact your local Alfa Laval Tank Equipment sales office.
  • Page 21 In potentially explosive atmospheres, the temperature must not exceed the maximum Warning: surface temperature according to the temperature class for the combustible gas or liquid. Instruction Manual, Gunclean Toftejorg T-82 Page 19 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC...

  • Page 22: Special Conditions For Safe Use In Accordance With The Atex Certification, Directive 94/9/Ec

    When the machine is not operating, the maximum permitted ambient temperature is 140°C. ATEX The maximum permitted process fluid pressure is 12 bar. Warning: Page 20 Instruction Manual, Gunclean Toftejorg T-82 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A052-EN4...
  • Page 23 In addition to the above mentioned precautions relating to the ATEX guidelines Directive 94/9/EC of March 23 1994, the Safety Precautions on page 16 must be observed. Instruction Manual, Gunclean Toftejorg T-82 Page 21 Standard machines and machines delivered with ATEX certification...

  • Page 24: 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 A/S, Ishoej, Denmark.

  • Page 25: Preventive Maintenance Guidelines And Service Kits

    See page 22 regarding special conditions for repair of ATEX certified machines. Maintenance intervals and Service Kits selection Alfa Laval Service Kits for Tank Cleaning Machine type, T-82 are available in two levels: Minor Service and Major Service. Minor Service kit is recommended to be replaced every 300 working hours or 2 ½ years, whichever comes first.
  • Page 26 These are not included in the price and may be disregarded. • Always replace all parts included in the Service Kit. Page 24 Instruction Manual, Gunclean Toftejorg T-82 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A052-EN4...
  • Page 27 Service Card For your registration of maintenance carried out, fill in service card which you will find at the back of this manual. Instruction Manual, Gunclean Toftejorg T-82 Page 25 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC...

  • Page 28: Top Assembly

    Rotate Nipple to align holes in Nipple and Stem. Mount Screws (pos. 17) with Screwdriver (tool No. TE134A). Tighten with Key (tool No. TE134). Page 26 Instruction Manual, Gunclean Toftejorg T-82 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC...
  • Page 29 Maintenance and repair (continued) Top Assembly Instruction Manual, Gunclean Toftejorg T-82 Page 27 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A052-EN4...

  • Page 30: Bottom Assembly

    (pos. 31). Ensure that the grease is clearly visible the whole way around the edge of the gear frame. Place Bottom cover (pos. 32). Mount Spring washers (pos. 18) and Screws (pos. 17) and tighten crosswise. Page 28 Instruction Manual, Gunclean Toftejorg T-82 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A052-EN4...
  • Page 31 Maintenance and repair (continued) Bottom Assembly Instruction Manual, Gunclean Toftejorg T-82 Page 29 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A052-EN4...

  • Page 32: Hub Subassembly

    Slide on Hub Subassembly, fit Hub cover (pos. 20) into Body and mount Spring washers (pos. 18) and Screws (pos. 17). Screw on Nozzles (pos. 22) and tighten with wrench. Page 30 Instruction Manual, Gunclean Toftejorg T-82 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A052-EN4...
  • Page 33 Maintenance and repair (continued) Hub Assembly Instruction Manual, Gunclean Toftejorg T-82 Page 31 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A052-EN4...

  • Page 34: Stem Subassembly

    If Liners on Stem are extremely worn, they can be replaced. This part requires that a precise procedure is followed to accomplish installation. It is suggested that an authorised Alfa Laval Tank Equipment Service Centre perform the replacement if necessary. However, should the customers insist that they perform the installation, please contact your nearest Service Centre for a copy of the procedure.
  • Page 35 Maintenance and repair (continued) Stem Subassembly Instruction Manual, Gunclean Toftejorg T-82 Page 33 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A052-EN4...

  • Page 36: Gear Subassembly

    Push Ball bearing (pos. 30) for Horizontal shaft (pos. 29) into Gear frame (pos. 31) and fix Bearing cover (pos. 16) with Screws (pos. 17). Tighten crosswise. Page 34 Instruction Manual, Gunclean Toftejorg T-82 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC...
  • Page 37 Horizontal shaft (pos. 29) and Pinion (pos. 10). Remove Turbine shaft (pos. 7) with Ball bearing (pos. 30) before Gear subassembly is inserted in machine body. Instruction Manual, Gunclean Toftejorg T-82 Page 35 Standard machines and machines delivered with ATEX certification...

  • Page 38: Replacement Of Collar Bushes

    Collar bushes are being knocked out. Clean holes and push in new Collar bushes into Gear frame Page 36 Instruction Manual, Gunclean Toftejorg T-82 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A052-EN4...
  • Page 39 Maintenance and repair (continued) Replacement of Collar Bushes Instruction Manual, Gunclean Toftejorg T-82 Page 37 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A052-EN4...

  • Page 40: Replacement Of Ball Races

    Clean surfaces and press in new Ball race. Ball race must be pressed fully home. Press parallel. Do not damage surface of Ball race. Page 38 Instruction Manual, Gunclean Toftejorg T-82 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC...
  • Page 41 Maintenance and repair (continued) Replacement of Ball races Instruction Manual, Gunclean Toftejorg T-82 Page 39 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A052-EN4...

  • Page 42: Replacement Of Main Collars

    Place Body in a vice in upside down position, and repeat procedure described above. Warning: Thread on Main collar lower is left-handed. Page 40 Instruction Manual, Gunclean Toftejorg T-82 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A052-EN4...
  • Page 43 Maintenance and repair (continued) Replacement of Main Collars Instruction Manual, Gunclean Toftejorg T-82 Page 41 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A052-EN4...

  • Page 44: Tools

    Tools Standard Tool kit for Gunclean Toftejorg T-82, Article No. TE81B060 Tool No. Description Number TE134 Unbraco key for Screw 1 pcs. TE134A Unbraco screw driver 2 pcs. TE369 5 mm Caliper 1 pcs. Available on request: TE81B033 Pusher for 1½” Collar bush TE81B034 Fixture set f.
  • Page 45 Tools (continued) Sketch of Tools for Replacement of Main Collars Instruction Manual, Gunclean Toftejorg T-82 Page 43 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A052-EN4...

  • Page 46: Trouble Shooting Guide

    Remove foreign material/material build-up on Stem and inside Main Collars. Clean Ball Races and Ball retainer with balls. Also clean Bush in Stem. Page 44 Instruction Manual, Gunclean Toftejorg T-82 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A052-EN4...
  • Page 47 30 and 32). Hold Body in upside down position and rotate Hub to check that Bevel gears can work together. If damaged: Replace Stem and/or Bevel gear. Instruction Manual, Gunclean Toftejorg T-82 Page 45 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC...

  • Page 48: Reference List Of Parts, Gunclean Toftejorg T-82 Fixed

    Reference List of Parts, Gunclean Toftejorg T-82 Fixed Pos. Ref. No. Unit Description Material Remarks  TE21B510 Flange Stainless steel Spare part  Without flange  TE703 Guide 100% Stainless steel Spare part  TE703-50 Guide 50% Stainless steel Spare part ...

  • Page 49: Cross Sectional Drawing, Gunclean Toftejorg T-82 Fixed

    Cross Sectional Drawing, Gunclean Toftejorg T-82 Fixed Instruction Manual, Gunclean Toftejorg T-82 Page 47 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A052-EN4...

  • Page 50: Reference List Of Parts, Gunclean Toftejorg T-82 Portable

    Reference List of Parts, Gunclean Toftejorg T-82 Portable Pos. Ref. No. Unit Description Material Remarks TE21B500 Nipple 1½” BSP Stainless steel Spare part TE21B501 Nipple 1½” NPT Stainless steel Spare part TE703 Guide 100% Stainless steel Spare part TE703-50 Guide 50%...

  • Page 51: Cross Sectional Drawing, Gunclean Toftejorg T-82 Portable

    Cross Sectional Drawing, Gunclean Toftejorg T-82 Portable Instruction Manual, Gunclean Toftejorg T-82 Page 49 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A052-EN4...

  • Page 52: Service Kits

    1 x TE827G2 Main Collar, Lower 1 x TE827G1 Main Collar, Upper 1 x TE55J000 Service Kit Minor T-82PT/FIX/MUD Page 50 Instruction Manual, Gunclean Toftejorg T-82 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A052-EN4...

  • Page 53: How To Order Spare Parts And Claim Procedure

    Claim Procedure In case of failure that needs assistance from Alfa Laval Tank Equipment A/S, it is essential for our evaluation that the problem, as well as the working conditions of the machine are described as detailed as possible.

  • Page 54: Service Card

    Impeller Guide No. of Working Maintenance Actions/ Remarks Sign. Date Hours Exchanged Parts Machine put into operation V. 94.2 Page 52 Instruction Manual, Gunclean Toftejorg T-82 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A052-EN4...

  • Page 55: Claim Report Working Conditions

    Is sterilising being used? Procedure (media/temp.)?   Is steam injection being used for heating? Time: __________ Temperature: __________ V. 98.1 Instruction Manual, Gunclean Toftejorg T-82 Page 53 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A052-EN4...
  • Page 56 Contains hard particles/fibres   High viscous Crystallizing   Is tank cleaner submerged in material? Other information/Remarks Date: Sign.: Page 54 Instruction Manual, Gunclean Toftejorg T-82 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A052-EN4...

  • Page 57: Declarations Of Conformity

    December 28, 2011 Signature: Signature: Name and title: Henrik Falster Hansen Name and title: Denniz Høxbroe R&D Manager ATEX responsible engineer Instruction Manual, Gunclean Toftejorg T-82 Page 55 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A052-EN4...
  • Page 58 December 28, 2011 Signature: Signature: Name and title: Henrik Falster Hansen Name and title: Denniz Høxbroe R&D Manager ATEX responsible engineer Page 56 Instruction Manual, Gunclean Toftejorg T-82 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A052-EN4...
  • Page 59 © 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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