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Summary of Contents for Alfa Laval PlusClean
- Page 1 Alfa Laval PlusClean® - Alfa Laval PlusClean® UltraPure Wall mounted cleaning devices 4129-0060_1 Instruction Manual Lit. Code 200009288-3-EN-GB BRITISH ENGLISH...
- Page 2 © Alfa Laval AB 2024-12 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
UK Declaration of Conformity..................8 2 Safety ..........................9 Safety Signs......................10 Safety Precautions....................12 Warning Signs in Text....................17 Requirements of Personnel..................18 Recycling Information....................19 How to Contact Alfa Laval..................20 3 Introduction .........................21 General Description....................21 3.1.1 Intended Use....................22 3.1.2 Working Principle..................22 3.1.3... - Page 4 Preventive Maintenance..................39 Recommended Service Intervals................41 Dismantling ......................42 6.3.1 Uninstall for Maintenance................42 6.3.2 Disassembly....................42 6.3.2.1 Disassembly of Pneumatic Actuator..........43 6.3.2.2 Disassembly of Alfa Laval PlusClean ® ........45 Assembly.........................50 6.4.1 Assembly of Pneumatic Actuator............... 50 7 Technical Data ......................53 ®...
- Page 5 10 Parts Lists and Exploded Views ..............67 10.1 Media Driven......................67 10.2 Pneumatic Driven....................68 10.3 Accessories and Tools.....................69 11 Appendix ........................71 11.1 Weld Plate Installation..................... 71...
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Page 7: 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 Cleaning Device Designation... -
Page 8: 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 Cleaning Device Designation... -
Page 9: Safety
Instruction Manual without prior notice or any obligation. The English version of the Instruction Manual is the original manual. Alfa Laval cannot be held responsible for incorrect translations. In case of doubt, the English version applies. -
Page 10: Safety Signs
2 Safety 2.1 Safety Signs Mandatory Action Signs General mandatory action sign. Refer to Instruction Manual. Use eye protection - safety glasses. Use protective hand wear - safety gloves. Wear protective equipment - safety helmet. Use ear protection in noisy environments - noise protector. Wear protective equipment - safety shoes. - Page 11 Safety 2 Transportation with forklift truck or other industrial vehicles if heavy. Electricity. Danger of injury (lasermarked on the actuator). Do not attempt to disassemble the actuator due to spring under load danger! (The lock wire opening is blocked). DO NOT DISASSEMBLE Danger of injury (lasermarked on the actuator).
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Page 12: Safety Precautions
All warnings in the Instruction Manual are summarised in this section. Pay special attention to the instructions below so that severe personal injury and/or damage to the supplied Alfa Laval product is avoided. Transportation and Lifting Always ensure that personnel must have experience with lifting operations. - Page 13 Safety 2 Installation Always follow this Instruction Manual thoroughly. Before installing the machine and setting it into operation careful- ly read Safety on page 9, General Installation on page 26 and Operation on page 33. Ensure that the machine is compatible with the product and CIP media.
- Page 14 2 Safety Operation Always follow this Instruction Manual thoroughly. Before installing the machine and setting it into operation careful- ly read Safety on page 9, General Installation on page 26 and Operation on page 33. Ensure that the machine is compatible with the product and CIP media.
- Page 15 77 dB(A) without noise damper and approximately 72 dB(A) with damper – measured at 7 bar air- pressure. Hazards Burn Hazard Various surfaces of the supplied Alfa Laval product and CIP sup- ply line can be hot and cause burns. Wear protective gloves. 200009288-3-EN-GB...
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Page 16: Safety Check
Safety check A visual inspection of any protective device (shield, guard, cover or other) on the supplied Alfa Laval product shall be carried out at least every 12 months. If the protective device is lost or damaged, especially when this leads to deterioration of safety performance, it shall be replaced. -
Page 17: Warning Signs In Text
Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. CAUTION Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate damage to the supplied Alfa Laval product. NOTE Indicates important information to simplify or clarify procedures. 200009288-3-EN-GB... -
Page 18: Requirements Of Personnel
Trainees can perform tasks under the supervision of an experienced employee. People in general The public shall not have access to the supplied Alfa Laval product. In some cases, specially skilled personnel may need to be hired (i.e. electricians, welders). In some cases the personnel has to be certified according to local regulations with experience of similar types of work. -
Page 19: Recycling Information
REFER TO SERVICE BULLETIN DO NOT DISASSEMBLE Maintenance During maintenance, oil (if used) and wear parts in the supplied Alfa Laval product should be replaced. • Oil and all non-metal wear parts must be disposed of in accordance with local regulations •... -
Page 20: 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. 2.6 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 21: Introduction
Alfa Laval Technical Sales Support department or worldwide network of sales offices. Please do not try to fix any mechanical problems on your own. The Alfa Laval ThinkTop range can be mounted on the machine as a sensor and/or for control purposes. See Accessories on page 62. -
Page 22: Intended Use
For larger tanks, multiple wall mounted cleaning devices may be applied. 3.1.2 Working Principle ® The Alfa Laval PlusClean functions by moving a piston with a build in media- spring actuator. The spring is located outside the product contact area. ®... -
Page 23: Design Principle
O-ring that seals the CIP liquid area from the non- liquid area. 3.1.4 Patents and Trademarks This Instruction Manual is published by Alfa Laval Kolding A/S without any warranty. Improvements and changes may at any time be made by Alfa Laval 200009288-3-EN-GB... -
Page 24: Quality System
Alfa Laval Kolding A/S. All rights reserved. The Alfa Laval logotype is a trademark or a registered trademark of Alfa Laval Corporate AB. Other products or company names mentioned herein may be the trademarks of their respective owners. Any rights not expressly granted herein are reserved. -
Page 25: Installation
The machine has been tested at the factory before shipping in accordance with the Test Specifications. If the supplied Alfa Laval product is purchased with an actuator, you can assess the machine’s operating condition. 1. Supply compressed air to the actuator. -
Page 26: General Installation
DO NOT DISASSEMBLE REFER TO SERVICE BULLETIN 4.2.1 Installation Orientation To be operational, the supplied Alfa Laval product should be installed in the recommended orientation, as provided below. If required, the installation shall be made so that self-draining properties (see... -
Page 27: Strainer Recommendations
35° (center 72°), 55° (offset 22°), and 75° (center 27°) inclination to horizontal. When the PlusClean is in the closed state and below the horizontal line, liquid can accumulate in the slots, ranging 0.2 - 0.6 ml ±0.2 ml (0.01 - 0.02 oz ± 0.01 oz). -
Page 28: Welding Recommendation
4 Installation 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 45° inclination to horizontal. ® The fixed weld plate should be used where the Alfa Laval PlusClean installed on the tank bottom or surface with less than 45°... -
Page 29: Installation Of Externally Mounted Tank Cleaning Devices
4129-0062 Adjustable weld plate Fixed weld plate The fixed weld plate allows the PlusClean to rotate around the centre line. The adjustable weld plate allows adjusting the angle of the PlusClean nozzle ±5° from the centre along all 3 axes. -
Page 30: Mounting
Install both O-rings on adapter and then push adapter into the weld plate. 4129-0075 ® Mount the Alfa Laval PlusClean inside the weld plate with adapter and put in the locking rings to hold the device in place. The groove... -
Page 31: Orientation Of Spray
5° 5° 4129-0063 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 32 4 Installation Figure 1: Position of PlusClean nozzle 200009288-3-EN-GB...
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Page 33: Operation
12. Always read Technical Data on page 53. Always use Alfa Laval genuine spare parts. The warranty of Alfa Laval products is dependent on use of Alfa Laval genuine spare parts. WARNING Prevent startup Precaution shall be made to prevent starting the cleaning operation, while personnel are inside the tank or otherwise can be hit by water jets from the cleaner head. -
Page 34: Normal Operation
5 Operation WARNING Never touch the supplied Alfa Laval product and the pipelines when processing hot fluids or when sterilising. 4129-0082 5.1 Normal Operation 5.1.1 Media Driven NOTE Media Only use media compatible with materials shown in chapter Technical Data page 53. -
Page 35: Pneumatic Driven
Function AA: Air/Air (double acting) ® ® • For the Alfa Laval PlusClean it may be used for opening and closing the Alfa Laval PlusClean ® • The Alfa Laval PlusClean is opened by applying control pressure to the bottom control connection and closed by applying control pressure to the top control connection •... -
Page 36: Recommended Cleaning
• Hot chemical may be used for cleaning and sterilization. If steaming is needed, contact you local Alfa Laval office for recommendation. • Protect against scalding and burning 200009288-3-EN-GB... -
Page 37: Troubleshooting
Operation 5 5.3 Troubleshooting NOTE Study the maintenance instructions carefully before replacing worn parts – see Maintenance on page 39. WARNING If the actuator is marked with one of the below warnings, due caution is needed during disassembly. The spring inside is under load – any type of breakage of the actuator can lead to injury! WARNING SPRING UNDER LOAD... - Page 38 This page is intentionally left blank.
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Page 39: Maintenance
Always handle the machine with care. Take proper action to protect fine surfaces from being damaged. Use only proper tools (e.g., the Alfa Laval standard tool kit). Never force or hammer components together or apart. Always perform all assembly/disassembly steps in the order described in this Instruction Manual. - Page 40 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. For further information regarding Alfa Laval Service Kits and service intervals, Recommended Service Intervals on page 41.
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Page 41: Recommended Service Intervals
Maintenance 6 6.2 Recommended Service Intervals It is recommended that the wear parts are checked every 3000 actuations (after 10000 actuations: inspection every 1000 actuations) for machine working under normal conditions. Recommended spare parts and service kits: See Spare Parts on page 65. -
Page 42: Dismantling
6 Maintenance 6.3 Dismantling NOTE Handle scrap correctly – See Recycling Information on page 19. WARNING If the actuator is marked with one of the below warnings, due caution is needed during disassembly. The spring inside is under load – any type of breakage of the actuator can lead to injury! WARNING SPRING UNDER LOAD... -
Page 43: Disassembly Of Pneumatic Actuator
6.3.2.1 Disassembly of Pneumatic Actuator NOTE Never disassemble the pneumatic actuator. Alfa Laval Kolding A/S do not recommend or support disassembly of the pneumatic actuator. The pneumatic actuator is non-serviceable. With malfunction the complete pneumatic actuator must be replaced. Depressurize the Actuator. - Page 44 Actuator from the Alfa Laval ® PlusClean 4129-0021 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...
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Page 45: Disassembly Of Alfa Laval Plusclean
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. 4129-0023 6.3.2.2 Disassembly of Alfa Laval PlusClean ® Use the spring tool and assemble it with the threaded rod, washer and nut provided. - Page 46 6 Maintenance ® Place the Alfa Laval PlusClean with the end plate facing up. Screw spring tool assembly into the piston firmly. Rotate the nut clockwise with help of wrench pushing the end plate down until the retaining ring is aligned with the bigger groove on the end plate.
- Page 47 Maintenance 6 Secure the machine in a vise without causing surface damage to it. WARNING Use soft jaws on the vise. 4129-0052_1 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).
- Page 48 6 Maintenance 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 49 Maintenance 6 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. 4129-0097 Remove the guide ring and both O-rings.
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Page 50: Assembly
Lubricate O-ring (11) with food graded lubricant. 6.4.1 Assembly of 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 51 Maintenance 6 Assemble the Actuator with the stud and spacer. 4129-0048 Mount the Actuator on the Alfa Laval ® PlusClean . Rotate it clockwise until it touches the end plate and all the screw holes are aligned. Fit in the screws.
- Page 52 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 200009288-3-EN-GB...
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Page 53: Technical Data
7 Technical Data NOTE Technical data must be observed during installation, operation and maintenance. All personnel should be informed about the technical data. 7.1 Alfa Laval PlusClean ® Media Driven 7.1.1 Technical Data Temperature / pressure – process contact Temperature range – liquid service -10 °C –... -
Page 54: Dimensions
7 Technical Data 7.1.3 Dimensions 4129-0086 Stroke Weight Adjustable, mm (inch) 10.9 (0.4) 125.4 (4.9) 53.8 (2.1) 130.0 (5.1) 18.0 (0.7) 65.0 (2.6) 2.1 kg (4.6 lbs) Fixed, mm (inch) 10.9 (0.4) 122.0 (4.8) 50.5 (2.0) 130.0 (5.1) 15.0 (0.6) 65.0 (2.6) 2.1 kg (4.6 lbs) 200009288-3-EN-GB... -
Page 55: Performance Data
Technical Data 7 7.1.4 Performance Data NOTE The inlet pressure has been taken immediately before the machine inlet. To achieve the performance indicated in the curves, the pressure drop in the supply lines between pump and machine must be taken into consideration. 7.1.4.1 Flow Rate Flow rate m³/h... -
Page 56: Throw Length
7 Technical Data 7.1.4.2 Throw Length NOTE Throw lengths are measured as horizontal throw length. Effective throw length varies depending on substance to be removed, cleaning procedure and agent. Throw length Max Throw length A1, B1 - Offset Slot A2, B2 - Wide Center Slot A3, B3 - Narrow Center Slot 22 27 32 37 42 47 52 57 62 67 72 77 82 87 92 97 Inlet Pressure... -
Page 57: Alfa Laval Plusclean ® Pneumatic Driven
Technical Data 7 7.2 Alfa Laval PlusClean ® Pneumatic Driven 7.2.1 Technical Data Temperature / pressure – process contact Temperature range – liquid service -10 °C – 95 °C (14 – 284 °F) Temperature max. – steam/gas service 121 °C (250 °F) Temperature max. -
Page 58: Dimensions
7 Technical Data 7.2.3 Dimensions Stroke Weight Adjustable, mm 10.9 238.6 125.4 53.8 227.7 130.0 18.0 65.0 2.7 kg (6 (inch) (0.4) (9.4) (4.9) (2.1) (9.0) (5.1) (0.7) (2.6) lbs) 10.9 235.2 122.0 50.5 224.3 130.0 15.0 65.0 2.7 kg (6 Fixed, mm (inch) (0.4) (9.3) -
Page 59: Performance Data
Technical Data 7 7.2.4 Performance Data NOTE The inlet pressure has been taken immediately before the machine inlet. To achieve the performance indicated in the curves, the pressure drop in the supply lines between pump and machine must be taken into consideration. 7.2.4.1 Flow Rate Flow rate m³/h... -
Page 60: Throw Length
- B1: Impact cleaning - Offset slot - B2: Impact cleaning - Wide center slot B3: Impact cleaning - Narrow center slot ® Performance data for Alfa Laval PlusClean Pneumatic Driven • Air supply pressure:Minimum 4 bar (58 PSI) to open the piston •... -
Page 61: Product Programme
8 Product Programme Please go to https://hygienicfluidhandling-catalogue.alfalaval.com for possible configurations and item numbers. 8.1 Qualification Documentation Documentation specification Standard version Equipment Documentation includes: • EN 1935/2004 DoC • EN 10204 type 3.1 inspection Certificate and DoC • FDA DoC Q-doc •... -
Page 62: Accessories
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. 200009288-3-EN-GB... -
Page 63: Specification Of Pressure Weld Plates According To Asme Viii Div. 1 And Div. 2
The Alfa Laval PlusClean can work with or without a sensor or a control unit. Alfa Laval ThinkTop V20 and V50 series fit onto the actuator of the Alfa Laval Free Rotating Retractor if sensor or control unit is needed. - Page 64 This page is intentionally left blank.
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Page 65: 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. 9.1 Ordering Spare Parts When ordering spare parts, please always state: 1. -
Page 66: Warranty - Definition
9.3 Warranty - Definition WARNING The rules of Intended use are absolute. Use of the supplied Alfa Laval product is allowed only when in compliance with the technical data supplied with the Intended use. Differing utilisation, other than agreed with Alfa Laval Kolding A/S, exclude any liability and warranty. -
Page 67: Parts Lists And Exploded Views
10 Parts Lists and Exploded Views 10.1 Media Driven 4129-0094 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 200009288-3-EN-GB... -
Page 68: 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 200009288-3-EN-GB... -
Page 69: Accessories And Tools
Parts Lists and Exploded Views 10 10.3 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 200009288-3-EN-GB... - Page 70 This page is intentionally left blank.
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Page 71: Appendix
11 Appendix 11.1 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 Instruction 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! NOTE... - Page 72 11 Appendix 1. Cut a hole in the tank sized to the diameter of the weld plate (the gap between the hole and weld plate must be as small as possible). 2. Chamfer the outer edges by 45 degrees, leaving a 1-2 mm (0.039"-0.078") opening with the original diameter toward the inside of the tank.
- Page 73 Appendix 11 9. Once the welding is complete, allow the weld plate to cool completely to room temperature. Do not quench the area with water, in order to avoid material warping. 10. Finish the inside of the tank (and the outside, if desired) by grinding and polishing until flush with the wall.
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