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Rotacheck+

This advanced innovative system features unique built-in teach-in and monitoring functions to verify the proper rotation of the rotary jet head.

As the rotary jet head performs the first CIP (cleaning-in-place) cycle, the sensor registers time and pressure data from the cleaning process and stores them as reference data. The reference data represent a unique pattern for a specific cleaning process in terms of the water jet intensity on the tank wall (hits) and the time between the hits from the water jet.

During subsequent CIP cycles, the processor in the sensor board then compares actual values to the digitally stored reference values and alerts the operator if any deviation from the reference values occurs.

The status of rotary jet head operation is shown via digital PLC output as well as a visual light indication. System feedback includes three different outputs:

• Rotation OK: When the operation of the rotary jet head meets the values recorded during the initial CIP cycle, verifying the proper rotation of the jet head.

• Alarm: When the rotation of the rotary jet head falls above or below the acceptable reference values recorded during the initial CIP cycle.

• Idle: When the rotary jet head is not in use and cleaning is not being performed.

Construction

The Alfa Laval Rotacheck control and validation system for tank cleaning machines consists of a sensor unit with top cover, o-rings and electrical cable and/or connector. The sensor unit has a sensing device located inside the processing tank and is connected to a sensor board, which processes and communicates the signal to the PLC.

Operating principle

The Alfa Laval Rotacheck system is available in two versions with digital sensor output via PNP interface to and from a PLC.

Rotacheck Basic

This standard system is suitable for validating the rotation of the rotary jet head. Ideal for retrofitting of Rotacheck systems that are already installed, Rotacheck Basic registers the moment when the sensor head is hit by the cleaning jet.

• Hit: The moment in time when the water jet hits the sensor head.

• Alarm: In case of unit failure or constant hit (cleaning device error).

• Idle: When the rotary jet head is not in use and cleaning is not being performed.

Introduction

The Alfa Laval Rotacheck Sensor is a cleaning validation

instrument that provides verification of the Alfa Laval Rotary

Jet Head tank-cleaning devices. It is highly accurate at

detecting the sweep and impact of the cleaning media

released by the rotary jet head, thereby providing tank

cleaning quality assurance. This device is suitable also when

there is higher pressure during Cleaning-in-Place (CIP) in the

tank.

Application

The Rotacheck Sensor is designed for use in a tank-cleaning

system that uses rotary jet heads and where the tank is

pressurized during CIP and where validation of hygienic

operation is required across the dairy, food, beverage,

brewery and pharmaceutical industries.

Benefits

• Validation of 360° repeatable cleaning pattern

• Verification of tank cleaning coverage

• Highly accurate detection of the jet sweep and impact

• Improved product quality

Standard design

The Alfa Laval Rotacheck Sensor consists of a stainless steel

IP67-rated casing, sensor, diaphragm, welding adaptor, and

cable for relay connection. As standard ATEX-certified version

is for use in potentially explosive areas. The sensor complies

with Category 1/2 requirements for installation in zones 0/1

and 20/21. The relay complies with Category 2 requirements

for installation in zone 1/21.

Working principle

The sensor of the Alfa Laval Rotacheck Sensor detects the

sweep and impact of fluid jets released as the rotary jet head

performs its cleaning cycle. The system is appropriate

wherever rotary jet heads are employed in cleaning tanks and

where the tank is pressurized during CIP. The signal generated

by the system can be audible, visual or integrated into the

customer’s process control specification.

Based on the geared operation of the cleaning device and

signals recording the impact force from the jets, the sensor

verifies hygienic operation of the rotary jet heads, taking into

account any backpressure in the tanks.

The hygienic Rotacheck sensor is precisely installed to detect

the sweep and impact of fluid jets released as the rotary jet

head performs its cleaning cycle. From the geared operation

of the cleaning device, and by reciving the impact force from

the jets, the sensor provides vertification of hygienic operation.

Any back pressure in the tanks is accounted for.

Benefits

• Durable and cost-effective

• Precision operation

• Long service life

• Easy to operate

Standard design

The Indication unit – inductive consists of steel and

plastic components, seals, contact pins, and cable connection

with socket, screw and cable gland. Easy to mount, this indication

unit does not require any mechanical adjustments and must be

installed between the air-operated actuator and the valve.

Working principle

The Alfa Laval Indication unit – Inductive sensor is an

inductive proximity switch that has non-contact electronic

switching elements. It is activated by an electromagnet device

known as a roller leaf. The standard output signal is always

a digital signal (on/off) indicating the position of the valve.

Introduction

The Alfa Laval Indication unit – Inductive is an electrical feedback

unit that offers cost-effective operation and standard

functionality for automated indication on the inductive side of Alfa

Laval butterfly valves. Straightforward and easy to use, this

indication unit provides information about valve operating status

24/7 while boosting productivity.

This inductive indication unit is compatible with any

programmable logic controller (PLC) with a PNP/NPN interface.

Application

The electrical indication unit is designed with inductive sensors for

use with Alfa Laval butterfly valves in hygienic applications across

the dairy, food, beverage, biotechnology, pharmaceutical and

many other industries.

Introduction

The Alfa Laval ThinkTop® DeviceNetTM is a modular valve control

unit that offers reliable, cost-effective operation and standard

functionality for automated sensing and control of hygienic

valves. ThinkTop DeviceNet provides real-time information about

valve operating status 24/7 while boosting productivity and

securing traceability.

Application

The ThinkTop DeviceNet is designed to control the fluid handling

process in hygienic applications across the dairy, food, beverage,

biotechnology, pharmaceutical and many other industries.

Benefits

• Reliable and accurate valve sensing and control

• Proven and inherently safe design

• Low total cost of ownership

• Watertight design

• Easy to operate

Standard design

The ThinkTop DeviceNet valve sensing and control unit consists of

a proven no-touch, set-and-forget sensor system with light

emitting diodes (LEDs), solenoid valves, and valve control sensor

board for connection to any programmable logic controller (PLC)

system with a DeviceNet interface. It fits on all Alfa Laval hygienic

valves; no adapter is required.

Installation is straightforward. No special expertise or tools are

required. To initiate manual setup, simply press a push

button startup sequence. Or set up without dismantling the

control unit using the optional infrared (IR) keypad for remote

control.