Alfalaval ARC series User manual

Instruction Manual
IM70815-/8¦ ²¾³¾½¾¦
ARC with reduced stroke Aseptic Remote-Controlled Valve
/
/RIGINAL)NSTRUCTIONS
$!  /VERS TTELSEAFORIGINALEINSTRUKTIONER
)4  4RADUZIONEDELLEISTRUZIONIORIGINALI
&)  !LKUPER ISTENK YTT OHJEIDENK NN S
%3  4RADUCCI NDELASINSTRUCCIONESORIGINALES
04"2 4RADU ODASINSTRU ESORIGINAIS
25    
.,  6ERTALINGVANDEOORSPRONKELIJKEINSTRUCTIES
&2  4RADUCTIONDESINSTRUCTIONSORIGINELLES
%,     
3%  VERS TTNINGAVDEURSPRUNGLIGAANVISNINGARNA
$%  BERSETZUNGDER/RIGINALANWEISUNGEN
0,  4 UMACZENIEORYGINALNEJINSTRUKCJI
#3  0 EKLADP VODN CHINSTRUKC
ࠝ࡝ࠫ࠽࡞ߩ૶↪⺑᣿ᦠߩ⠡⸶
㤦⧮ 㰖㔲㦮 ⻞㡃
ේᆎᠲ૞ᜰධ⊛⠡兣
ේᆎᜰ␜⊛⠡⼎
IM70815EN 2010-03

1 EC Declaration of Conformity
4HE DESIGNATING COMPANY
!LFA ,AVAL
#OMPANY .AME
!LBUEN  $+ +OLDING $ENMARK
!DDRESS

0HONE .O
HEREBY DECLARE THAT

!SEPTIC2EMOTE#ONTROLLED6ALVE!2#WITHREDUCEDSTROKE
$ENOMINATION 4YPE 9EAR
IS IN CONFORMITY WITH THE FOLLOWING DIRECTIVES
 -ACHINERY $IRECTIVE %#
 0RESSURE %QUIPMENT $IRECTIVE %# CATEGORY  AND SUBJECTED TO ASSESSMENT PROCEDURE -ODULE !
-ANAGER 0RODUCT #ENTRES #OMPACT
(EAT %XCHANGERS  &LUID (ANDLING
"JARNE 3NDERGAARD
4ITLE .AME
!LFA ,AVAL +OLDING
#OMPANY 3IGNATURE
$ESIGNATION

1
Safety
Installation
Operation
Maintenance
Technical data
Drawings/Parts list
This manual is divided into main sections. - See
below.
Table of contents
1. Important information .................................. 2
2. Warning signs ............................................. 2
3. Safety precautions ...................................... 3
1. Unpacking/Delivery ..................................... 4
2. General installation ..................................... 5
3. Welding ....................................................... 6
4. Fitting of oil damper (optional extra) ........... 7
5. Fitting of indication equipment
(optional extra) ............................................ 8
1. Operation .................................................... 9
2. Fault finding .............................................. 10
3. Recommended cleaning ........................... 11
1. General maintenance ................................ 12
2. Dismantling of valve ................................. 14
3. Reassembly of valve ................................. 16
4. Dismantling of actuator ............................. 18
5. Reassembly of actuator ............................ 19
1. Technical data ........................................... 20
1. Parts list
- ARC with reduced stroke........ 22+24+26+28
- Oil damper......................................... 30+32
2. Exploded drawing
- ARC with reduced stroke................... 23+27
- Oil damper............................................... 31
3. Drawing
- ARC with reduced stroke................... 25+29
- Oil damper............................................... 33

2
:
:
Safety
Unsafe practices and other important information are
emphasized in this manual. Warnings are emphasized by means of special signs.
1. Important information
Always read the manual before using the valve!
Indicates that special procedures must be fol-
lowed to avoid severe personal injury.
Indicates that special procedures must be fol-
lowed to avoid damage to the valve.
Indicates important information to simplify
practices or to make them clearer.
WARNING! :
CAUTION! :
NOTE! :
2. Warning signs
General warning.
Caustic agents.
Installation:
Always
Always
Never
Never
Never
Never
Operation:
Never
Never
Always
Always
Never
Never
Always
Always
Maintenance:
Always
Always
Never
Never
Never
Never
Transportation:
Always
secure that compressed air is released
Always
secure that all connections is disconnected before attemt to remove the valve from the installation
Always
drain liquid out of valves before transportation
Always
used predesigned lifting points if defined
Always
secure sufficient fixing of the valve during transportation - if special designed packaging material is available it
must be used

3
Installation: :
:
:
:
Operation: :
:
:
:
Maintenance: :
:
:
:
3.Safety precautions
-Always read the technical data thoroughly
(see page 20).
-Always release compressed air after use.
Never touch the clip assembly or the actuator
piston rod if the actuator is supplied with com-
pressed air.
Never touch the valve or the pipelines when
processing hot liquids or when sterilizing.
-Never dismantle the valve when it is hot.
-Never dismantle the valve with valve and
pipelines under pressure.
-Always read the technical data thoroughly
(see page 20).
-Always release compressed air after use.
Never touch the valve or the pipelines when
processing hot liquids or when sterilizing.
Never touch the clip assembly or the actuator
piston rod if the actuator is supplied with com-
pressed air.
Always handle lye and acid with great care.
-Always read the technical data thoroughly
(see page 20).
-Always release compressed air after use.
-Never service the valve when it is hot.
-Never service the valve with valve and pipe-
lines under pressure.
Never stick your fingers through the valve ports
if the actuator is supplied with compressed air.
Never touch the clip assembly or the actuator
piston rod if the actuator is supplied with com-
pressed air.
All warnings in the manual are summarized on this
page. Pay special attention to the instructions below so that severe personal injury and/or damage to the valve
are avoided.
Safety

4
4
2
6
1
5
Installation
The instruction manual is part of the delivery.
Study the instructions carefully.
The items refer to the drawings and the parts list on
pages 22-29.
The valve is supplied as separate parts as standard
(for welding).
The valve is assembled before delivery, if it is
supplied with fittings.
NOTE!
We cannot be held responsible for incorrect
unpacking.
3
Remove possible packing materials from the
valve/valve parts.
Check the delivery:
1. Complete valve, stop valve or change-over
valve (see 2 and 3).
2. Delivery note.
3. Instruction Manual.
1. Unpacking/Delivery
Delivery of stop valve:
1. Complete actuator with bonnet (8).
2. Clip assembly (11).
3. Intermediate ring (13).
4. Diaphragm stem seal (20).
5. Two clamps (15).
6. Valve stem unit (19, 22).
7. Washer (14).
8. Valve body (18).
Delivery of change-over valve:
1. Complete actuator with bonnet (8).
2. Clip assembly (11).
3. Intermediate ring (13).
4. Diaphragm stem seal (20).
5. Three clamps (15).
6. Valve stem unit (19, 22).
7. Two valve bodies (16, 18).
8. Valve body seal ring (17).
Inspect the valve/valve parts for visible transport
damage.

5
-Always read the technical data
thoroughly (see page 20).
-Always release compressed air after
use.
NOTE!
We cannot be held responsible for incorrect
installation.
1
3
5
4
2
6
Installation
Study the instructions carefully and pay special
attention to the warnings!
The valve has welding ends as standard but can also
be supplied with fittings.
NO = Normally open.
NC = Normally closed.
A/A = Air/air activated.
2. General installation
Never touch the clip assembly or the
actuator piston rod if the actuator is
supplied with compressed air.
Avoid stressing the valve.
Pay special attention to:
- Vibrations.
- Thermal expansion of the tubes.
- Excessive welding.
- Overloading of the pipelines.
It is recommended to install the valve so that:
- The actuator is not turned downwards.
- The flow is against the closing direction
to avoid water hammer.
Moving parts!
Fittings:
Ensure that the connections are tight (remember
seal rings).
Air connection: R1/8" (BSP)
Connect air correctly:
- NO: Top connection.
- NC: Side connection.
- A/A: Top and side connection.
Risk of damage!

6
1
2
4
3
Installation
Study the instructions carefully.
The valve is supplied as separate parts to facilitate
the welding.
The items refer to the drawings and the parts list on
pages 22-29.
Check the valve for smooth operation after welding.
3. Welding
Always weld the valve so that the valve body seal
ring can be replaced (change-over valve).
Maintain the minimum clearances (A and B) so
that the lower valve plug (change-over valve)
and the actuator with the internal valve parts
can be removed.
Stop valve:
Reassemble the valve in accordance with instruc-
tions 4-11 on pages 16-17.
Pay special attention to the warnings!
Change-over valve:
Reassemble the valve in accordance with in-
structions 3-11 on pages 16-17.
Pay special attention to the warnings!
Pre-usecheck:
1. Supply compressed air to the actuator.
2. Open and close the valve several times to
ensure that it operates smoothly.
Pay special attention to the warnings!
Valve size A (mm) B1 (mm) B2 (mm)
38 mm 160 550 660
51 mm 160 550 660
Change-over valve
(upper valve body)
Stop valve
B1 B2(incl. top unit)
B1 B2(incl. top unit)
Weld carefully!
A

7
12
56
34
Installation
The valve can be fitted with an oil damper if water
hammer occurs when the valve closes in the flow
direction.
Study the instructions carefully and pay special
attention to the warnings!
NC = normally closed
A/A = air/air activated
4. Fitting of oil damper (optional extra)
Fill further oil through the plug hole if large air
bubbles occur under the plexiglas cover.
NOTE!
There should be a small air bubble which equal-
izes changes in the pressure because of tem-
perature changes.
Removal/dismantling:
Remove the damper by following the instructions
in reverse order.
Pre-use check:
1. Supply compressed air to the actuator.
2. Open and close the valve several times to
ensure that it operates smoothly.
Pay special attention to the warnings!
Never touch the valve or the pipelines
when processing hot liquids or when
sterilizing.
Burning danger!
1. Supply compressed air to the actuator.
Pay special attention to the warnings!
2. Fit the damper so that damper piston rod
(72) enters actuator piston rod (8).
Oil type SAE 40
Ensure that
no other
equipment
is fitted on the
actuator top!
1. Fit protective hood (84).
2. The valve is now ready for operation.
1. Connect the two piston rods by means of
clip (71).
2. Release compressed air to the actuator.
Pay special attention to the warnings!
Air (NC, A/A)
Air (NC, A/A)

8
Pre-use check:
1. Supply compressed air to the actuator.
2. Open and close the valve several times to
ensure that it operates smoothly.
Pay special attention to the warnings!
1
3
2
Installation
The valve can be fitted with the top units LKT-N and
LKT-S. It can also be fitted with an indication unit. Study the instructions carefully and pay special attention to the warnings!
5. Fitting of indication equipment (optional extra)
4
LKT-N Indication unit
LKT-S
Atmospheric
pressure required!
-Never dismantle the valve when it is
hot.
-Never dismantle the valve with valve
and pipelines under pressure.
CAUTION!
The indication and control equipment must be
electrically installed by authorized personnel.
- Top units LKT-N and LKT-S:
(see the separate instruction manuals).
- Indication unit:
(see the instructions on page 8).
1. Fit the ring on the plug stem.
2. Reassemble the valve in accordance with
instructions 10-11 on page 17.
Pay special attention to the warnings!
Dismantle the valve in accordance with instruc-
tions 1-2 on page 14.
Pay special attention to the warnings!
Burning
danger!
5

9
1
3
2
Operation
Study the instructions carefully and pay special
attention to the warnings!
Ensure that the valve operates smoothly.
The items refer to the drawings and the parts list on
pages 22-29.
-Always read the technical data
thoroughly (see page 20).
-Always release compressed air after
use.
NOTE!
We cannot be held responsible for incorrect
operation.
Never touch the valve or the pipelines
when processing hot liquids or when
sterilizing.
Never touch the clip assembly or the
actuator piston rod if the actuator is
supplied with compressed air.
1. Operation
6
Lubricate if
necessary!
(see page 13)
5
4
Lubrication of actuator
1. Ensure smooth movement of the actuator
(the actuator is lubricated before delivery).
2. Lubricate with oil/grease if necessary.
NOTE!
It is recommended not to use the valve under
vacuum as there will be no visual leakage
indication.
Burning danger!
Moving parts!
CAUTION!
It is recommended not to re-use diaphragm
(20b) after dismantling (risk of damage and
leakage).

10
The valve plug jerks The seals seize Lubricate:
- O-rings (2)
- O-ring (6) and the inside of
cylinder (3)
Product leakage Worn/product affected - Replace the seals
at stem and/or clamp diaphragm stem seal and/or - Select a different rubber
seal ring (17) grade
Product leakage - Worn/product affected - Replace the seal ring
(closed valve) plug seal ring - Select a different rubber grade
- Loose plug parts - Tighten the loose parts
(vibrations)
- Product deposits on - Frequent cleaning
the seat and/or plug
Product leakage - Worn actuator O-rings - Replace the O-rings
(too high pressure or too - Too small actuator or - Select a larger actuator
small actuator) actuator spring
- Fit a stronger spring
- Use auxiliary air on the spring
side (NOT-element)
Water hammer The flow direction is - The flow direction should be
the same as the against the closing direction
closing direction - Fit a damper on the valve
(optional extra)
- Use auxiliary air on the spring
side (NOT-element)
The valve does not - Faulty clip assembly - Replace the clip assembly
open/close (11)
- The pressure on the plug - Reduce the pressure
plug is too high - Fit stronger spring/larger
actuator
Operation
Pay attention to possible faults. Study the instructions carefully.
The items refer to the drawings and the parts list on
pages 22-29.
2. Fault finding
Problem Cause/result Repair
NOTE!
Study the maintenance instructions carefully
before replacing worn parts. - See page 12!

11
Examples of cleaning agents:
Use clean water, free from clorides.
1. 1% by weight NaOH at 70oC.
2. 0.5% by weight HNO3 at 70oC.
1 kg + 100 l = Cleaning agent.
NaOH water
2.2 l + 100 l = Cleaning agent.
33% NaOH water
0.7 l + 100 l = Cleaning agent.
53% HNO3water
Caustic danger!
1
5
2
6
Always use Always use
rubber gloves! protective goggles!
The valve is designed for cleaning in place (CIP).
CIP = Cleaning In Place. Study the instructions carefully and pay special
attention to the warnings!
NaOH = Caustic Soda.
HNO3= Nitric acid.
3. Recommended cleaning
Always handle lye and acid with great
care.
Never touch the valve or the pipelines
when sterilizing.
Operation
34
NOTE!
The cleaning agents must be stored/disposed of
in accordance with current rules/directives.
1. Avoid excessive concentration of the clean-
ing agent
⇒⇒
⇒⇒
⇒Dose gradually!
2. Adjust the cleaning flow to the process
⇒⇒
⇒⇒
⇒ Milk sterilization/viscous liquids
⇒⇒
⇒⇒
⇒Increase the cleaning flow!
3. Always rinse well with clean water after
the cleaning.
Burning
danger!
Clean the plug and the seats correctly.
- Stop valve: Open it.
- Change-over valve: Lift and lower momenta-
rily (flip).
Pay special attention to the warnings!

12
1
34
2
Maintenance
Maintain the valve carefully.
Study the instructions carefully and pay special
attention to the warnings!
Always keep spare rubber seals and diaphragms in
stock.
Ordering spare parts
- Contact the Sales Department.
- Order from the Spare Parts List.
Recommended spare parts: Service kits (see Spare Parts List).
-Always read the technical data
thoroughly (see page 20).
-Always release compressed air after
use.
NOTE!
All scrap must be stored/disposed of in accord-
ance with current rules/directives.
Never touch the clip assembly or the
actuator piston rod if the actuator is
supplied with compressed air.
Never stick your fingers through the valve
ports if the actuator is supplied with
compressed air.
1. General maintenance
Burning
danger! Atmospheric
pressure
required!
Cutting
danger!
Moving
parts!
-Never service the valve when it is hot.
-Never service the valve with valve and
pipelines under pressure.

13
Valve Valve Actuator
diaphragm unit rubber seals rubber seals
Preventive Replace after Replace when Replace after
maintenance 12 months replacing the 5 years
(depending on diaphragms
working conditions)
Maintenance after Replace at the Replace when Replace when
leakage (leakage end of the day replacing the possible
normally starts slowly) diaphragms
Planned - Regular inspec- Replace when - Regular inspection
maintenance tion for leakage and replacing the for leakage and
smooth operation diaphragms smooth operation
- Keep a record of - Keep a record of
the valve the actuator
- Use the statistics for - Use the statistics for
planning of planning of
inspections inspections
Replace after Replace after air
leakage leakage
Lubrication Before fitting Before fitting Before fitting
(USDA H1 Silicone oil or Silicone oil or Oil or grease
approved oil/grease) silicone grease silicone grease
Maintenance
Maintain the valve carefully.
Study the instructions carefully. Always keep spare rubber seals and diaphragms in
stock.
Check the valve for smooth operation after service.
1. General maintenance
Pre-use check:
1. Supply compressed air to the actuator.
2. Open and close the valve several times to
ensure that it operates smoothly.
Pay special attention to the warnings!

14
1
3
5
4
2
6
Maintenance
Study the instructions carefully.
The items refer to the drawings and the parts list on
pages 22-29.
Handle scrap correctly.
NC = Normally closed.
NO = Normally open.
A/A = Air/air activated.
2. Dismantling of valve
1. Remove clamp (15).
2. Remove intermediate ring (13).
Remove the complete diaphragm/stem unit
from valve body (16 or 18).
Stop valve:
Remove washer (14) from upper stem (19).
NOactuator:
1. Remove upper clamp (15).
2. Supply compressed air to the actuator.
3. Remove clip assembly (11).
3. Remove the actuator.
5. Release compressed air.
Pay special attention to the warnings!
NCactuator:
1. Remove clip assemply (11).
2. Supply compressed air to the actuator.
3. Remove upper clamp (15).
4. Remove the actuator.
5. Release compressed air.
Pay special attention to the warnings!
Change-over valve:
1. Remove lower clamp (15).
2. Dismantle upper and lower valve bodies
(16, 18).
3. Remove seal ring (17).

15
7
9
11
10
8
Maintenance
2. Dismantling of valve
Study the instructions carefully.
The items refer to the drawings and the parts list on
pages 22-29.
Handle scrap correctly.
NC = Normally closed.
NO = Normally open.
A/A = Air/air activated.
Turn upper stem (19) anticlockwise and remove
it from lower stem (22a), (counterhold with a
spanner).
Change-over valve:
Remove lower stem (22a) from upper valve
body (16).
Change-over valve:
1. Remove screw (22g), O-ring (22f) and was-
her (22e) from lower stem (22as).
2. Remove seal (22d), middle piece (22c) and
seal (22b) from the stem.
Stop valve:
1. Remove screw (22g), O-ring (22f) and
washer (22e) from lower stem (22a).
2. Remove seal (22d) from the stem.
1. Remove diaphragm (20a), diaphragm (20b)
and stem seal (20d) from lower stem (22a).
2. Remove L-seal (20c) from diaphragm (20b).

16
1
34
2
Maintenance
Study the instructions carefully.
The items refer to the drawings and the parts list on
pages 22-29.
Lubricate the rubber seals and the diaphragms be-
fore fitting them.
3. Reassembly of valve
Stop valve:
1. Fit seal (22d) on lower stem (22a).
2. Fit washer (22e), O-ring (22f) and screw
(22g) on the stem (use Loctite 243 or simi-
lar!).
Change-over valve:
1. Fit seal (22b), middle piece (22c) and seal
(22d) on lower stem (22a).
2. Fit washer (22e), O-ring (22f) and screw
(22g) on the stem (use Loctite 243 or simi-
lar!).
1. Apply Loctite 243 or similar on the thread of
lower stem (22a).
2. Fit upper stem (19) on the lower stem, turn
it clockwise and tighten until there is metal-
lic contact between the upper and lower
stems (counterhold with a spanner!).
56
Change-over valve:
Fit lower stem (22a) in upper valve body (16)
so that the stem flange contacts the bottom of
the valve body.
1. Fit L-seal (20c) on diaphragm (20b).
2. Fit stem seal (20d), diaphragm (20b) and
diaphragm (20a) on lower stem (22a).
Stop valve:
Fit washer (14) on upper stem (19).

17
7
910
8
Maintenance
Study the instructions carefully.
The items refer to the drawings and the parts list on
pages 22-29.
Lubricate the rubber seals and the diaphragms be-
fore fitting them.
3. Reassembly of valve
11
1. Fit intermediate ring (13) on valve body (16
or 18).
2. Fit and tighten clamp (15).
Fit the complete diaphragm/stem unit in valve
body (16 or 18).
NOTE!
Ensure that L-seal (20c) is fitted on diaphragm
(20b) before placing the diaphragm unit in the
valve body.
Change-over valve:
1. Fit seal ring (17), (Turn it with the diagonal
surface upwards!) in lower valve body (18).
2. Fit upper valve body (16) and the complete
diaphragm/stem unit together with the lower
valve body.
3. Fit and tighten lower clamp (15).
NOactuator:
1. Fit the plastic ring of clip assembly (11) on
the actuator piston rod.
2. Supply compressed air to the actuator.
3. Fit the actuator on valve body (16 or 18) so
that upper stem (19) enters the actuator
piston rod.
4. Fit and assemble clip assembly (11).
5. Release compressed air.
6. Fit and tighten upper clamp (15).
Pay special attention to the warnings!
NCactuator:
1. Supply compressed air to the actuator.
2. Fit the plastic ring of clip assemply (11) on
the actuator piston rod.
3. Fit the actuator on valve body (16 or 18) so
that upper stem (19) enters the actuator
piston rod.
4. Fit and tighten upper clamp (15).
5. Release compressed air.
6. Fit and assemble clip assembly (11).
Pay special attention to the warnings!
Correct! Wrong!

18
Maintenance
34
Study the instructions carefully.
The items refer to the drawings and the parts list on
pages 22-29.
Handle scrap correctly.
A/A = Air/air activated.
2
12
4. Dismantling of actuator
1.
Turn by hand
or with the
service tool!
1. Turn cylinder (3).
2. Remove lock wire (4).
1. Remove cylinder (3).
2. Remove O-rings (2, 7) from bonnet (8).
Replace the rubber seals.
1. Remove piston (6) and spring assembly
(10).
2. Remove O-ring (5) from the piston.
3. Remove O-ring (2) from cylinder (3).
NOTE!
The A/A actuator has no spring assembly.