GEA Jumbo 6, Operating Instructions Manual

Page 1: ...Operating Instructions GEA Orbital Cleaner Jumbo 6 Edition 2016 05 24 English ...

Page 2: ...9 2423 Mail sales geatuchenhagen gea com Web http www gea com These Operating Instructions are the English translation of the original in structions in the sense of the EU Machinery directive This document is protected by copyright All rights reserved The document may not in whole or in part be copied reproduced translated or reduced to an electronic medium of machine readable form without the exp...

Page 3: ...g Down 13 Maintenance and Repair 13 Disassembly 14 Environmental Protection 15 Electrical Equipment 15 Explosion Protection 15 Residual Risk 16 Hazard Areas 16 Residual Dangers 18 Declaration of Incorporation 19 Transport and Storage 20 Scope of Supply 20 Transport 20 Storage 20 Intended Purpose 21 Designated Use 21 Operating Pressure and Nozzle Size 21 Requirements for the Operation 21 Improper O...

Page 4: ...aner Jumbo 6 Edition 2016 05 24 Commissioning 25 Malfunction 26 Maintenance 27 Inspections 27 Maintenance Intervals 27 Prior to Disassembly 27 Disassembly 28 Maintenance 29 Assembly 30 Disposal 32 Technical Data 33 Spare Parts List Jumbo 6 34 ...

Page 5: ...ully read these Operating Instructions before starting any work on or using the cleaner Your personal safety and the safety of the cleaner can only be ensured if you act as described in the Operating Instructions Store the Operating Instructions in such a way that they are accessible to the owner and the operating staff during the entire life cycle of the cleaner When the location is changed or th...

Page 6: ...e to take to avoid the hazard WARNING Warning Serious injuries Failure to observe the warning note can result in serious damage to health The arrow identifies a precautionary measure you have to take to avoid the hazard CAUTION Warning Injuries Failure to observe the warning note can result in minor or moderate damage to health The arrow identifies a precautionary measure you have to take to avoid...

Page 7: ...of measurement of temperature degree Celsius DN DIN nominal width DIN German standard issued by DIN Deutsches Institut für Normung e V German Institute for Standardization EN European Standard GEA GEA AG group of companies GEA stands for Global Engineering Alliance h Unit of measurement of time hour ISO International standard issued by the International Organization for Standardization kg Unit of ...

Page 8: ...ating Instructions GEA Orbital Cleaner Jumbo 6 Edition 2016 05 24 a f Indicates the size of spanners width across flats Inch OD Pipe dimension acc to British standard BS Outside Diameter Inch IPS US pipe dimension Iron Pipe Size Abbreviation Explanation ...

Page 9: ... conditions Operator s Duties In your capacity as operator of the facility you bear a particular responsibility for the proper and safe handling of the cleaner in your facility Only use the cleaner when it is in perfect condition to prevent danger to persons and property These Operating Instructions contain the information you and your staff need for the safe and reliable operation during the enti...

Page 10: ...cesses lines of authority and responsibilities associ ated with the cleaner Everybody must know what to do in case of an emergency Instruct the staff in this respect at regular intervals The signs relating to the cleaner must always be complete and legible Check clean and replace the signs as necessary at regular intervals TIP Carry out regular checks This way you can ensure that these measures ar...

Page 11: ...inguished Supplementary Regulations In addition to the instructions in this documentation the following also has to be observed Pertinent accident prevention regulations Generally accepted safety rules National regulations applicable in the country of use Work and safety instructions applicable in the facility User groups Staff Qualifications Operating staff Adequate instruction and sound knowledg...

Page 12: ...vention regulations and all local regulations Installation For installation the following principles apply Only properly qualified staff is allowed to fit and set the cleaner into operation Observe the transport instructions and markings on the part s to be transported Remove any nails protruding from transport crates immediately after opening the crate Under no circumstances should anyone stand u...

Page 13: ...report any changes on the cleaner to the person responsible Always keep danger zones clear Do not leave any objects in the danger zone Only allow persons to enter the danger zone when the machine is de energized Regularly check that all emergency stop devices are working correctly Shutting Down For shutting down the following principles apply Switch off the cleaner via the main switch Padlock the ...

Page 14: ...approved fully functional load lifting devices and lifting accessories which are suitable for the intended purpose Before setting the unit back into operation refit all safety devices as origi nally provided in the factory Then check that all safety devices are working correctly Check pipes are firmly secured also check for leaks and damage Check that all emergency stop devices are working correct...

Page 15: ... be allowed to qualified electri cians Always keep unattended switch cabinets locked Modifications of the control system can affect the safe and reliable operation Modifications are only permitted with the express permission of the manufacturer After completion of all work check that the protective devices are fully functional Explosion Protection The safety instructions must be adhered to when th...

Page 16: ...detaching the plug in connection Make sure that live wires are not exposed and cannot come in contact with people animals or plant components Cables must be routed in such a way that no chafe marks can be produced They must regularly be checked for damage and chafe marks Interrupt the power circuit and protect it against unauthorized switch on Operation Observe the following notes Ensure by suitab...

Page 17: ...ntenance Observe the following notes Interrupt all media supply lines and ensure that no hot or aggressive media are applied to or are in the cleaner Only allow trained qualified staff to carry out maintenance work on the cleaner ...

Page 18: ...wer Observe the following safety rules 1 Isolate from the power supply 2 Take appropriate measures to prevent switch on 3 Test absence of voltage 4 Earthing and short circuiting 5 Cover or safeguard any adjacent live parts Danger of injury Danger presented by moving or sharp edged parts The operator must exercise caution and prudence For all work Wear suitable work clothing Never operate the machi...

Page 19: ...fied here complies with the Essential Health and Safety Requirements defined in Annex I section 1 and section 2 1 The technical documentation is compiled in accordance with Annex VII part B In response to a reasoned request the relevant information will be transmitted to the appropriate national authorities This declaration will become invalid if any alterations are made to the machine which have ...

Page 20: ...ween moving gear teeth as they mesh There is danger of injury Only use suitable lifting gear and slings for transporting package units cleaners Observe the pictograms on the package Handle the cleaner with care to avoid damage caused by impact or care less loading and unloading The outside synthetic materials are suscep tible to breaking Only allow qualified staff to transport the cleaner Movable ...

Page 21: ...se The risk of such misuse lies entirely with the operator of the facility Operating Pressure and Nozzle Size The recommended operating pressure for the Jumbo tank cleaner is 5 to 10 bar with 4 bar being the minimum and 12 bar being the maximum permis sible pressure The cleaner can be equipped with nozzle sizes 1 4 and 3 8 Nozzle orifice and pump pressure determine the jet length and the flow rate...

Page 22: ...ective If the cleaner is used in areas with a potentially explosive atmosphere you must absolutely comply with directive 94 9 EC with respect to all ignition hazards Observe the supplementary operating instructions GEA Cleaner ATEX Version For details regarding the marking of the cleaner for potentially explosive areas refer to the supplementary operating instructions GEA Cleaner ATEX Version Conv...

Page 23: ...er may only be operated at a maximum pressure of 14 bar Higher pressures can destroy the cleaner TIP The specified pressure is the pressure required at the cleaning head and not at the pump Installation Dimensions Operating flow rate and pressure requirements for Jumbo 6 nozzles Required flow rate m3 h 10 8 13 2 15 0 16 8 18 0 19 2 Required pressure bar 4 0 6 0 8 0 10 0 12 0 14 0 Operating flow ra...

Page 24: ...m mesh in the CIP supply line as close to the cleaning head as possible in order to protect the cleaner from being blocked by particles or against damage Installing CAUTION Moving sharp edged parts Fingers can be caught between the teeth of moving intermeshing gears Carry the cleaner using the eyebolt screwed into the T piece underneath the cylindrical body NOTE Incorrect assembly and wrong tools ...

Page 25: ...ure of the cleaning fluid is too high the cleaner can be damaged Do not exceed the max permitted pressure of 12 bar NOTE The seals in the cleaner are sensitive parts Steam can damage the seals Do not operate the cleaner with steam CAUTION Hot and aggressive liquids are discharged from the cleaner Danger of injury Make sure nobody stands in the area of action of the nozzles The cleaner may only be ...

Page 26: ...r replace the strainer Nozzle and stream straightener blocked Remove nozzle and stream straightener and check for blockage Leave the cleaner to run without nozzles This could flush out any obstructions Motor blocked Detach the cleaner from the CIP line and remove the inlet cap Check whether the motor holes are blocked Remove the motor and check that no obstruction is present that prevents the vert...

Page 27: ... operating conditions for instance type and temperature of the cleaning solution ambient conditions As a guideline value GEA Tuchenhagen GmbH recommends checks at intervals of max 350 operating hours Prior to Disassembly Requirement Make sure that during maintenance and repair work no process is in operation in the area concerned The tank must be depressurized and free from vacuum Carry out the fo...

Page 28: ...wed vice 2 Using a belt wrench on the body 18 unscrew the body from the inlet cap 3 Remove the motor 1 from the body Removing the Body Carry out the following steps 1 Remove the three M5 x 5 socket set screws 28 from the nozzle head T piece 10 2 Insert the tool a 3 4 bar with a central slot 3 4 wide x 7 8 long into the lower vertical shaft 02 and unscrew the shaft The shaft 02 complete with rotor ...

Page 29: ...cing upwards 6 Hold the nozzle body 13 grasp the threaded end of the nozzle body shaft 12 complete with bevel gear 9 and carefully lift it out taking care not to disturb the left hand ball bearing assembly in the nozzle body 13 This completes disassembly Maintenance This cleaner has been designed for ease of maintenance with a small number of mechanical wearing parts which are easy to replace No s...

Page 30: ...evel gear insert rings 35 in the bevel gears can be replaced The two nozzle bodies 13 have replaceable nozzle body insert rings 36 fitted These replacement parts are easy to fit and thus help to considerably reduce maintenance downtime and costs Assembly Assembling the Lower Body Carry out the following steps 1 Place a spare vertical shaft bearing bush 7 on a flat surface Alternatively you can use...

Page 31: ... place 12 stainless steel balls 24 and 12 PTFE balls 33 on this raceway 3 Cut the PTFE O ring 25 as illustrated on the spare parts drawing and insert it into the groove of the nozzle body shaft 12 4 Insert the shaft into the nozzle body 13 taking care not to disturb the position of the balls 5 Apply a light film of water to the raceway of the nozzle body shaft 12 and alternately place 10 stainless...

Page 32: ...r 8 Finally hold the cleaner by the eyebolt 21 and check whether the body 18 and the two nozzle bodies 13 can rotate freely in both directions This completes assembly TIP It is important to fit the two nozzle bodies 13 so that the nozzle orifices on one nozzle body are in the horizontal plane and the nozzle orifices on the other nozzle body are in the vertical plane This ensures the correct spray ...

Page 33: ...ta Key data Value Weight 4 4 kg Inlet 1 BSPT female or 1 NPT female Nozzle size or Materials Stainless steel AISI 316L P PTFE Overall length 260 mm approx 10 Operating temperature max 95 C 140 F Working pressure Min 4 bar Max 12 bar ...

Page 34: ...re Parts List Jumbo 6 Item no Designation Material Quantity Part no 1 Stator D1 4 1 4660 4721 110 Stator D3 8 1 4660 4721 010 2 Guide pipe 316L 1 4404 1 4660 4742 010 4 Impeller 6 tooth PTFE 1 4660 4771 010 6 Bearing disk 316L 1 4404 1 4660 4741 010 7 Bearing flange 316L 1 4404 1 4660 4740 010 8 Bevel gear 45T 1 4660 4770 010 ...

Page 35: ...25 O ring BS1806 020 PTFE 2 4660 4730 020 26 Cylinder head screw M5x10 4 4660 4781 010 27 Cylinder head screw M5x45 8 4660 4730 010 28 Set screw M5x5 ISO 4029 3 4660 4722 010 29 Cap 1 5 BSPT 316L 1 4404 1 4660 8210 110 Cap 1 5 NPT 316L 1 4404 1 4660 8210 210 30 Cylinder head screw M4x45 1 4660 4763 010 Nut M4 1 4660 4773 010 Washer M4 ISO 7090 A4 1 4660 4783 010 31 Hex nut M10 ISO 4033 1 4660 4753...

Page 36: ...n 50 countries Founded in 1881 the company is one of the largest providers of innovative equipment and process technology GEA Group is listed in the STOXX Europe 600 index GEA Mechanical Equipment GEA Tuchenhagen GmbH Am Industriepark 2 10 D 21514 Büchen Tel 49 4155 49 0 Fax 49 4155 49 2423 sales geatuchenhagen gea com http www gea com We live our values ...