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Summary of Contents for Alfa Laval PlusClean
- Page 1 Alfa Laval PlusClean® - Alfa Laval PlusClean® UltraPure Wall mounted cleaning nozzle 4129-0060 Instruction Manual Lit. Code 200009288-1-EN-GB Manual No. 100001847 BRITISH ENGLISH...
- Page 2 © Alfa Laval 2023-03 This document and its contents are subject to copyrights and other intellectual property rights owned by Alfa Laval AB (publ) or any of its affiliates (jointly “Alfa Laval”). No part of this document may be copied, re-produced or transmitted in any form or by any means, or for any purpose, without Alfa Laval’s prior express written permission. Information and services provided in this document are made as a benefit and service to the user, and no representations or warranties are made about the accuracy or suitability of this information and these services for any purpose.
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Page 3: Table Of Contents
Troubleshooting.......................28 Recommended Cleaning..................29 Recommended Service Intervals and Service Kits..........30 Dismantling......................31 6.5.1 Dismounting the Pneumatic Actuator............32 6.5.2 ® Disassembly of Alfa Laval PlusClean ............34 6.5.3 Inspection of Parts..................39 6.5.4 ® Reassembly of Alfa Laval PlusClean ............39 6.5.5... - Page 4 9 Parts Lists and Exploded Views ..............49 Media Driven......................49 Pneumatic Driven....................50 Accessories and Tools.....................51 10 Spare Parts .........................53 10.1 Ordering Spare Parts....................53 10.2 Alfa Laval Service....................53 11 Appendix ........................55 11.1 Appendix A - Weld Plate Installation............... 55...
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Page 5: Declarations Of Conformity
1 Declarations of Conformity 1.1 EU Declaration of Conformity The Designated Company Alfa Laval Kolding A/S, Albuen 31, DK-6000 Kolding, Denmark, +45 79 32 22 00 Company name, address and phone number Hereby declare that Wall Mounted Spray Nozzle Designation... -
Page 6: Declaration Of Conformity
1 Declarations of Conformity 1.2 UK Declaration of Conformity The Designated Company Alfa Laval Kolding A/S, Albuen 31, DK-6000 Kolding, Denmark, +45 79 32 22 00 Company name, address and phone number Hereby declare that Wall Mounted Spray Nozzle Designation... -
Page 7: Safety
Not following the instructions can result in serious accidents. This documentation describes the authorized way to use the supplied product. Alfa Laval will take no responsibility for injury or damage if the equipment is used in any other way. This Instruction manual is designed to provide the user with the information to perform tasks safely for all phases in the lifetime of the supplied product. - Page 8 Any tank cleaning machine can develop a static electricity charge while in operation. If the tank being cleaned contains a combustible liquid or vapor having a risk of ignition or explosion, it is imperative to have the Alfa Laval tank cleaning product properly grounded. Operation Always read this manual thoroughly.
- Page 9 ® storage. A clean water rinse through the Alfa Laval PlusClean also wash out any resi- dues of chemical cleaners or recirculated wash water that could adversely affect the O- rings during prolonged contact in storage.
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Page 10: Warning Signs In Text
How to contact Alfa Laval Contact details for all countries are continually updated on our website. Please visit www.alfalaval.com to access the information directly. -
Page 11: Recycling Information
Besides the equipment itself, any hazardous residues from the process liquid must be considered and dealt with in a proper manner. When in doubt, or in the absence of local regulations, please contact your local Alfa Laval sales company. 200009288-1-EN-GB... -
Page 12: Unpacking/Delivery
• It has minimal moving parts and relies on a simple spring mechanism for opening and closing • The spring mechanism is outside the product contact area • In the closed position, the piston and its O-ring seal against the inside of the body of the Alfa Laval ®... -
Page 13: Introduction
PlusClean is smoothly integrated into the tank wall. When activated during Cleaning-in-Place (CIP), PlusClean covers cleaning shadow areas with a high impact fan of cleaning media, giving the market’s first guarantee of 100%... -
Page 14: Functioning
3 Introduction 3.1 Functioning ® The Alfa Laval PlusClean is available in media driven or pneumatic driven versions. Both versions have a spring mechanism located outside the product contact surface area. Media driven: • The piston retracts due to the pressure of the cleaning media and is extended back into closing position by a spring •... - Page 15 The three patterns provide fans with different spread angles and flow rates. When the cleaning media pressure is shut off, the cleaning media is drained through the 3/4" ferrule connection. The mounting position of the Alfa Laval ®...
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Page 16: Marking
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 17: Installation
4 Installation 4.1 General Installation Instructions During handling and installation, handle the machine with care in order not to damage the product contact surface finish of the machine. Before connecting the machine to the system, all supply lines and valves should be flushed to remove foreign particles. -
Page 18: Weld Plate
5° 5° 4129-0063 ® The adjustable weld plate should be used in applications where the Alfa Laval PlusClean is installed on tank walls and tank bottoms with more than 30° inclination to horizontal. ® The fixed weld plate should be used where the Alfa Laval PlusClean is installed on the tank bottom or surface with less than 30°... -
Page 19: Installation
No assembly is required prior to use. Any change to the originally supplied operating conditions will affect the performance of the Alfa Laval tank cleaning product accordingly. 4.3.1 Inlet Connections ®... -
Page 20: Mounting
*) Important: Ensure flexibility in the supply line to accommodate the nozzle adjustment feature. NOTE The adjustable weld plate allows adjusting the angle of the PlusClean nozzle ±5° from the center along all 3 axes. The fixed weld plate allows the PlusClean to rotate around the centerline. Figure 1: Position of PlusClean nozzle... - Page 21 Installation 4 To ensure that the PlusClean nozzle, after service / maintenance, is placed in exactly the same position as when commissioning, we recommend that a clear marking of the position is made already during commissioning. Marking must be done on both the weld plate and the nozzle - as opposed to the inlet orientation (marked with an arrow).
- Page 22 Safety NOTE When Alfa Laval tank cleaning products are operating, there should be covers over any tank openings. These covers should be sealed well enough to withstand the full force of the water striking the cover plate. If the cleaning solution is hot, corrosive, or toxic, a leak would present a serious hazard to any personnel in the immediate vicinity or to any exposed electrical equipment.
- Page 23 Installation 4 WARNING Any tank cleaning machine can develop a static electric charge while in operation. If the tank being cleaned contains a combustible liquid or vapor having a risk of ignition or explosion, it is imperative to have the Alfa Laval tank cleaning product properly grounded.
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Page 24: Mounting Blind Cap
When Alfa Laval PlusClean is not installed, a blind cap can be used to block the opening. For more information on blind cap contact your local Alfa Laval office. • Mount the O-ring that fits the weld plate in the O-ring groove. -
Page 25: Operation
Actuator when using air/steam or when purging the system (otherwise there is a risk of hammering of the piston) Pressure • Please make sure that the CIP process connections are correctly mounted before the Alfa Laval ® PlusClean is put into operation •... -
Page 26: Actuator
Function AA: Air/Air (double acting) ® ® • For the Alfa Laval PlusClean it should only be used for opening the Alfa Laval PlusClean ® • The Alfa Laval PlusClean is opened by applying control pressure to the bottom control connection •... -
Page 27: Maintenance
CIP liquid containing abrasives and/or particulates needs more frequent attention than one exposed to light/no soiling and recirculation with ordinary CIP liquid. Alfa Laval Kolding A/S recommends that you adjust the maintenance program to suit the cleaning task in hand. Contact your local Alfa Laval sales office for discussion. -
Page 28: Troubleshooting
6 Maintenance 6.2 Troubleshooting Problem Possible causes Action Water leaking out of the end • Worn out O-ring • Replace the O-ring with a new one plate Piston not restoring in original • Damaged spring • Replace the spring with a new one state •... -
Page 29: Recommended Cleaning
Maintenance 6 6.3 Recommended Cleaning CAUTION Never touch the supplied product or the pipelines when sterilizing. Always handle CIP and SIP lye and acids with great care. Always use rubber gloves! Always use protective goggles! Always rinse well with clean water after using a cleaning agent. NOTE The cleaning agents must be stored/disposed of in accordance with current regulations/directives. -
Page 30: Recommended Service Intervals And Service Kits
6 Maintenance 6.4 Recommended Service Intervals and Service Kits It is recommended that the wear parts are checked every 500 working hours for machine 4129-0019 working under normal conditions. Every 500 working hours: (#) refers to position numbers, see Parts Lists and Exploded Views on page 49 ff. -
Page 31: Dismantling
A rigorously implemented preventative maintenance program significantly reduces repair costs of the Alfa ® Laval PlusClean The foundation of such a program is regularly scheduled inspections to discover and replace worn or damaged parts before they can cause failure of other, more costly, components. -
Page 32: Dismounting The Pneumatic Actuator
6 Maintenance 6.5.1 Dismounting the Pneumatic Actuator NOTE ® Place a soft towel (or equivalent) under the Alfa Laval PlusClean assembly to prevent it from getting scratched. Depressurize the Actuator. Disconnect the air supply. This will actuate the device to “closed” position. - Page 33 Maintenance 6 In case of tightened stud, use a wrench and rotate the Actuator spindle till the hole on the Alfa Laval Plu- ® sClean piston is in-line with the opening on the body. 4129-0022 Insert a tool like Allen key in the hole (5 mm/0.2") to lock the piston rotation and loosen the Actuator spin- dle to dismount it.
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Page 34: Disassembly Of Alfa Laval Plusclean
6 Maintenance 6.5.2 Disassembly of Alfa Laval PlusClean ® Use the spring tool and assemble it with the threaded rod, washer and nut provided. 4129-0024 ® Place the Alfa Laval PlusClean with the end plate facing up. Screw spring tool assembly into the piston firmly. - Page 35 Maintenance 6 Secure the machine in a vise without causing surface damage to it. WARNING Use soft jaws on the vise. 4129-0052 200009288-1-EN-GB...
- Page 36 6 Maintenance With the help of pliers squeeze the ends of retaining ring until it is disengaged from the groove. Pull the entire assembly of end plate and piston out of the body (if too tight see below). In case it is hard to pull out the assembly, insert a tool like Allen key (5 mm/0.2") in the hole on the piston through the opening on the body and push it downwards to raise the end...
- Page 37 Maintenance 6 Secure the piston with the spring tool mounted on it in a bench vise without causing surface damage to it. 4129-0028 Using a wrench, turn the nut on the spring tool clockwise pulling the piston up from the end plate until the small retaining ring is exposed.
- Page 38 6 Maintenance Carefully unthread the spring tool from the piston to separate the end plate from the piston. Remove the spring from the piston. CAUTION With no retaining ring holding the spring, the spring will push out the end plate with force. 4129-0030 Remove the guide ring and both O-rings.
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Page 39: Inspection Of Parts
6.5.4 Reassembly of Alfa Laval PlusClean ® NOTE All parts must be cleaned thoroughly before reassembling. Any deposits remaining on the parts can cause difficult disassembly the next time the Alfa Laval ® PlusClean needs servicing. Assemble each O-ring using water for lubrication. -
Page 40: Mounting The Pneumatic Actuator
6 Maintenance 6.5.5 Mounting the Pneumatic Actuator NOTE ® Place a soft towel (or equivalent) under the Alfa Laval PlusClean assembly to prevent it from getting scratched. Make sure the hole on the piston is aligned with the opening in the body. - Page 41 11.8 Nm = 8.7 lb ft. 4129-0049 WARNING Never disassemble the Actuator. Alfa Laval Kolding A/S do not recommend or support disassembly of the Actuator. The Actuator is non-serviceable. With malfunction the complete Actuator must be replaced. DO NOT DISASSEMBLE 200009288-1-EN-GB...
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Page 43: Technical Data And Performance Data
7 Technical Data and Performance Data 7.1 Technical Data Technical Data ® Media driven: 2.1 kg (4.6 lbs) Weight of Alfa Laval PlusClean Air driven: 2.7 kg (6 lbs) Working pressure: 1.8 - 7 bar (26.1 - 101.5 PSI) Recommended inlet pressure: 2 - 5 bar (29 - 72.5 PSI) -
Page 44: Dimensions
7 Technical Data and Performance Data 7.2 Dimensions Table 1: Dimensions Media driven, mm (inch) Stroke A Weight Adjustable Fixed Weld Weld Plate Plate 10.9 50.5 2.1 kg (4.6 18 (0.7) 15 (0.6) (0.4) (4.8) (5.2) (5.1) (2.6) lbs) Table 2: Dimensions Pneumatic driven, mm (inch) Stroke A Weight Adjustable Weld... -
Page 45: Performance Data
Technical Data and Performance Data 7 7.3 Performance Data Flow rate Flow rate m³/h Pressure Flow A - Wide Center Slot B - Offset Slot C - Narrow Center Slot 22 27 32 37 42 47 52 57 62 67 72 77 82 87 92 97 Inlet Pressure A: Wide center slot - B: Offset slot - C: Narrow center slot NOTE... - Page 46 ® Performance data for Alfa Laval PlusClean Pneumatic Driven • Air supply pressure:Minimum 4 bar (58 PSI) to open the piston •...
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Page 47: Pressure Rating For Weld Plates
The design is made according to EN 13445-3 and fulfils the requirements of PED 2014/68/EU. Weld plates do not have a component certificate, but material certificate and pressure calculations can be supplied. ® Mount blind cap in the weld plates (not Alfa Laval PlusClean ) when pressure testing the tank. 200009288-1-EN-GB... -
Page 48: Specification Of Pressure Weld Plates According To Asme Viii Div. 1 And Div. 2
The design is made according to ASME VIII div. 1 and div. 2 and fulfils the requirements of the ASME standards. Weld plates do not come with a U2 certificate, but material certificate and pressure calculations can be supplied. ® Mount blind cap in the weld plates (not Alfa Laval PlusClean ) when pressure testing the tank. 200009288-1-EN-GB... -
Page 49: Parts Lists And Exploded Views
9 Parts Lists and Exploded Views 9.1 Media Driven 4129-0069 Pos. Qty. Denomination Pos. Qty. Denomination Weld plate O-ring O-ring O-ring O-ring Guide ring Adapter Piston Locking ring Spring Stud Retaining ring Washer Bushing End plate Body Positioning pin Inlet Retaining ring 200009288-1-EN-GB... -
Page 50: Pneumatic Driven
Guide ring O-ring Piston O-ring Spring Adapter Retaining ring Locking ring Bushing Stud End plate Washer Positioning pin Retaining ring Body 20.1 1 PlusClean Actuator Inlet 20.2 1 Connecting stud O-ring 20.3 1 Actuator spacer O-ring 20.4 4 Screw 200009288-1-EN-GB... -
Page 51: Accessories And Tools
Parts Lists and Exploded Views 9 9.3 Accessories and Tools 4129-0078 4129-0071 Pos. Qty. Denomination Pos. Qty. Denomination Screw Adapter Blind cap Washer Screw Spring mounting tool Washer O-ring Heatsink, Outside O-ring Heatsink, Inside 200009288-1-EN-GB... - Page 52 This page is intentionally left blank.
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Page 53: Spare Parts
Alfa Laval representative for availability. You can find our spare part catalogue at https://hygienicfluidhandling-catalogue.alfalaval.com/ Always use Alfa Laval genuine spare parts. The warranty of Alfa Laval products is dependent on use of Alfa Laval genuine spare parts. 10.1 Ordering Spare Parts When ordering spare parts, please always state: 1. - Page 54 This page is intentionally left blank.
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Page 55: Appendix
11 Appendix 11.1 Appendix A - Weld Plate Installation WARNING Pay special attention to the instructions below so that severe personal injury and/or damage to the weld plate and device is avoided. Always read this manual thoroughly. Install the device only when the tank is depressurized and cooled down. This device may only be installed by qualified technical personnel who has read and understood the instruction manual! Welding recommendations... - Page 56 11 Appendix 3. Align the inside of the weld plate with the inside of the tank surface. When installed the machine has its CIP inlet in not applicable. When mounting the weld plate always have the thread holes in the position such that the machine is drainable when installed. Refer to Mounting on page 20 for machine drain ability information.
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