Alfalaval Aseptic Mixproof Series User manual

2321-0035
100000827-EN2 2019-07
Original manual
Instruction Manual
Aseptic Mixproof Valve

Table of contents
The information herein is correct at the time of issue but may be subject to change without prior notice
1. EC Declaration of Conformity ....................................................................... 4
2. Safety .................................................................................................... 5
2.1. Important information ............................................................................. 5
2.2. Warning signs ..................................................................................... 5
2.3. Safety precautions ................................................................................ 6
3. Installation .............................................................................................. 8
3.1. Unpacking/delivery ............................................................................... 8
3.2. General installation ................................................................................ 11
3.3. Welding ............................................................................................ 13
3.4. Recycling information ............................................................................. 15
4. Operation ............................................................................................... 16
4.1. Operation .......................................................................................... 16
4.2. Trouble shooting .................................................................................. 18
4.3. Recommended cleaning ......................................................................... 19
5. Maintenance ........................................................................................... 26
5.1. General maintenance ............................................................................. 26
5.2. Dismantling shut-off valve ........................................................................ 28
5.3. Dismantling change-over valve .................................................................. 31
5.4. Plug seal replacement ............................................................................ 39
5.5. Assembly of shut-off valve ....................................................................... 43
5.6. Assembly of change-over valve ................................................................. 47
5.7. Dismantling of fully maintainable actuator ...................................................... 58
5.8. Mounting of fully maintainable actuator ......................................................... 59
5.9. Changing pneumatic movement on fully maintainable actuator (NC/NO) ................... 60
6. Technical data ......................................................................................... 61
6.1. Technical data ..................................................................................... 61
7. Parts list and service kits ............................................................................ 62
7.1. Valve overviev ..................................................................................... 62
7.2. Actuators, primary valves (no seat lift) .......................................................... 63
7.3. Actuators, primary valves (with seat lift) ........................................................ 65
7.4. Actuators, secondary valves ..................................................................... 67
7.5. Plugs, primary valves ............................................................................. 69
7.6. Plugs, secondary valves ......................................................................... 71
7.7. Clamp, bonnet and body, primary valves ....................................................... 73
7.8. Clamp, bonnet and body, secondary valves ................................................... 75
3

1 EC Declaration of Conformity
The Designated Company
Alfa Laval Kolding A/S
Company Name
Albuen 31, DK-6000 Kolding, Denmark
Address
[phone]
Phone No.
hereby declares that
Valve
Designation
Aseptic Mixproof PN8
Type
from serial number AMV 000001
is in conformity with the following directive with amendments:
- Machinery Directive 2006/42/EC
- Pressure Equipment Directive 2014/68/EU category 1 and subjected to assessment procedure Module A. May only be
used for fluids in Group 2
The person authorised to compile the technical file is the signer of this document
Global Product Quality Manager
Pumps, Valves, Fittings and Tank Equipment Lars Kruse Andersen
Title Name
Kolding October 11th, 2018
Place Date Signature
4

2 Safety
Unsafe practices and other important information are emphasised in this manual.
Warnings are emphasised by means of special signs.
2.1 Important information
Always read the manual before using the valve!
WARNING
Indicates that special procedures must be followed to avoid serious personal injury.
CAUTION
Indicates that special procedures must be followed to avoid damage to the valve.
NOTE
Indicates important information to simplify or clarify procedures.
2.2 Warning signs
General warning !
Caustic agents
5

2 Safety
Unsafe practices and other important information are emphasised in this manual.
Warnings are emphasised by means of special signs.
Pay special attention to the instructions below so that severe personal injury and/or damage to the valve are avoided.
2.3 Safety precautions
Actuators
If support air is utilised:
!
- Shock in the actuator must NEVER occur.
To prevent shock in the actuator and to prevent exceeding 8 bar product pressure, Alfa Laval recommends NOT to exceed 3
bar support air on the spring side in the actuators.
Use the “3 bar air relief fitting” = 9611995903
Using the “3 bar air relief fitting” also extends the service life of the actuator piston O-ring.
If support air is connected then the following must be done:
-Always use the steel adapter (pos. 5) = 9614065301
Tighten torque 30 Nm
-Always use the 3 bar air relief fittings = 9611995903
5
2321-0051
Alfa Laval recommends max. 3 bar support air
Always use the “3 bar air relief fittings” on support air.
Alfa Laval article number = 9611995903
6

2 Safety
Unsafe practices and other important information are emphasised in this manual.
Warnings are emphasised by means of special signs.
Pay special attention to the instructions below so that severe personal injury and/or damagetothevalveareavoided.
Installation
Always read the technical data thoroughly (see section 6.1 Technical data)
Always release compressed air after use
Never touch moving parts if the actuator is supplied with compressed air
Never touch the valve or the pipelines when processing hot liquids or when sterilising
Never dismantle the valve with valve and pipelines under pressure
Never dismantlethevalvewhenitishot
!
Never cut the actuator open, due to spring under load - if marked with this warning
SPRING UNDER LOAD
Do not attempt to cut open
kg
!
Do NOT attempt to disassemble the actuator due to spring under load danger!
DO NOT DISASSEMBLE
kg
!
Operation
Never dismantle the valve with valve and pipelines under pressure
Never dismantlethevalvewhenitishot
Always read the technical data thoroughly (see section 6.1 Technical data)
Always release compressed air after use
Never touch the valve or the pipelines when processing hot liquids or when sterilising
Never touch moving parts if the actuator is supplied with compressed air
Always rinse well with clean water after cleaning
!
Always handle lye and acid with great care
Maintenance
Always read the technical data thoroughly (see section 6.1 Technical data)
Always release compressed air after use
Never service the valve when it is hot
Never service the valve with valve and pipelines under pressure
Never stick your fingers through the valve ports if the actuator is supplied with compressed air
Never touch moving parts if the actuator is supplied with compressed air
Always use Alfa Laval genuine spare parts
!
Never cut the actuator open, due to spring under load danger - if marked with this warning
SPRING UNDER LOAD
Do not attempt to cut open
kg
!
Do NOT attempt to disassemble the actuator due to spring under load danger!
DO NOT DISASSEMBLE
kg
!
Transportation
Always ensure that compressed air is released
Always ensure that all connections are disconnected before attempting to remove the valve from the
installation
Always drain liquid out of valves before transportation
Always use predesigned lifting points if defined
Always ensure sufficient fixing of the valve during transportation - if specially designed packaging material
is available, it must be used
7

3 Installation
This instruction manual is part of the delivery. Study the instructions carefully.
The valve is supplied as separate parts as standard (for welding).
3.1 Unpacking/delivery
Step 1
CAUTION
Alfa Laval cannot be held responsible for incorrect unpacking.
Check the delivery for:
1. Complete valve.
2. Delivery note.
3. Warning label.
Step 2
Remove transportation strips.
Step 3
Lift out the valve.
NOTE!
Please note weight of valve printed on the box.
2321-0052
Step 4
Remove possible packing materials for the valve ports.
2321-0053
Step 5
!
-CAUTION
Alfa Laval cannot be held responsible for incorrect installation.
1. Complete valve, shut-off valve or change-over valve.
2. Delivery note.
8

3 Installation
This instruction manual is part of the delivery. Study the instructions carefully.
The valve is supplied as separate parts as standard (for welding).
Step 6
Inspect the valve for visible transport damages.
2321-0054
Step 7
Avoid damaging the air connections*, the valve ports and the
CIP connections.
2321-0055
*
*
*
9

3 Installation
This instruction manual is part of the delivery. Study the instructions carefully.
The valve is supplied as separate parts as standard (for welding).
Step 8
3a
Shut-off valve:
1. Complete actuator
2. Bonnet (20)
3. Clamp (19)
4. Valve plug (23)
5. Valve body (22)
6. Diaphragm (29)
7. Disc for diaphragm (30)
8. Upper spindle (31)
19
20
2321-0056
2321-0057
31
23
29
30
22
3b
Change-over valve:
1. Complete actuator
2. Bonnet (20)
3. 2 x clamps(19)
4. Valve plug (27)
5. Lower valve body (22)
6. Valve seat (28)
7. Upper valve body (26)
8. Diaphragm (29)
9. Disc for diaphragm (30)
10. Upper spindle (31)
28
31
29
30
26
2321-0058
20
2321-0059
22
19
27
Step 9
Remove possible packing material from the valve/valve parts.
Inspect the valve /valve parts for visible transport damage.
Avoid damaging the valve/valve parts.
10

3 Installation
Study the instructions carefully and pay special attention to the warnings!
3.2 General installation
Step 1
!
-CAUTION
Alfa Laval cannot be held responsible for incorrect installation.
-Always release compressed air after use.
-Always read the technical data thoroughly.
See section 6.1 Technical data.
DO NOT DISASSEMBLE
kg
!
Do NOT attempt to disassemble the actuator due to
spring under load danger!
SPRING UNDER LOAD
Do not attempt to cut open
kg
!
If marked with this warning, do NOT attempt to cut
the actuator open, due to spring under load danger!
Step 2
!
Never touch moving parts if the actuator is supplied with
compressed air.
Moving parts!
2321-0060
Step 3
Avoid stressing the valve.
Pay special attention to:
-Vibrations.
- Thermal expansion of the pipelines.
- Excessive welding.
- Overloading of the pipelines.
Risk of damage!
2321-0061
!
11

3 Installation
Study the instructions carefully and pay special attention to the warnings!
Step 4
!
Always check if the diaphragm is tight - it can be dangerous if
it leaks steam/CIP.
Thehosemustbea4mm(1/6”)hoseforø25anda6mm(1/4”)
hose for larger types.
To avoid all danger, the
hose must reach the
drain!
2321-0062
!
12

3 Installation
Study the instructions carefully.
The valve is supplied as separate parts to facilitate welding.
Check the valve for smooth operation after welding.
3.3 Welding
Step 1
To ensure safe operation and easy maintenance of the valve, be
sure to follow the recommended installation dimensions in the
table below.
Valve size A (mm)* B (mm)* C (mm)*
51 mm / 2” 596 603 644
63.5 mm / 2½” 604 609 652
76 mm / 3” 611 643 659
* Recommended clearance for ThinkTop®included.
2321-0063
CA
B
Step 2
Assemble the valve.
Pay special attention to the warnings!
2321-0064
!
13

3 Installation
Study the instructions carefully.
The valve is supplied as separate parts to facilitate welding.
Check the valve for smooth operation after welding.
Step 3
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!
*Max. 3barsupp
ort air
2321-0065
A
B
C
B
A
D
E
FA. Support air NC*
B. Main stroke
C. Seat lift
D. Steam valve
Main stroke NO
E. Steam valve
Main stroke NC
F. Steam valve
Main stroke NO
Support air NC*
14

3 Installation
3.4 Recycling information
Unpacking
- Packing material consists of wood, plastics, cardboard boxes and in some cases metal straps
- Wood and cardboard boxes can be reused, recycled or used for energy recovery
- Plastics should be recycled or burnt at a licensed waste incineration plant
- Metal straps should be sent for material recycling
Maintenance
- During maintenance, oil and wearing parts in the machine are replaced
- All metal parts should be sent for material recycling
- Worn out or defective electronic parts should be sent to a licensed handler for material recycling
- Oil and all non-metal wearing parts must be disposed of in accordance with local regulations
Scrapping
- At end of use, the equipment must be recycled in accordance with the relevant local regulations. 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. If the actuator is marked
with a danger warning, do not attempt to cut the actuator open.
DO NOT DISASSEMBLE
kg
!
Do NOT attempt to disassemble the actuator due to spring under load danger!
SPRING UNDER LOAD
Do not attempt to cut open
kg
!
If marked with this warning, do NOT attempt to cut the actuator open, due to spring under load danger!
15

4Operation
Study the instructions carefully and pay special attention to the warnings!
Ensure that the valve operates smoothly.
4.1 Operation
Step 1
!
-CAUTION
Alfa Laval cannot be held responsible for incorrect installation.
-Always release compressed air after use.
-Always read the technical data thoroughly.
See section 6.1 Technical data.
-Always useAlfaLavalgenuinespareparts.
The warranty of Alfa Laval products is dependent on use of
Alfa Laval genuine spare parts.
DO NOT DISASSEMBLE
kg
!
Do NOT attempt to disassemble the actuator due to
spring under load danger!
SPRING UNDER LOAD
Do not attempt to cut open
kg
!
If marked with this warning, do NOT attempt to cut
the actuator open, due to spring under load danger!
Step 2
!
Never touch the valve or the pipelines when processing hot
liquids or when sterilising.
Burn hazard!
2321-0066
Step 3
!
Never touch moving parts if the actuator is supplied with
compressed air.
Moving parts!
2321-0067
!
16

4Operation
Study the instructions carefully and pay special attention to the warnings!
Ensure that the valve operates smoothly.
Step 4
If fitted with hyg. plugs:
1. Ensure smooth movement between lip seal (A) and
plug stem (B).
2. Lubricate the lip seal with Klüber Paraliq GTE 703 if necessary.
Shut-off valve Change-over valve
A
B
2321-0068
A
B
2321-0069
Step 5
Lubrication of actuator:
1. Ensure smooth movement of the actuator (the actuator is
lubricated before delivery).
2. Lubricate all seals with Molykote Longterm 2 plus if necessary.
2321-0076
17

4Operation
Pay attention to possible faults. Study the instructions carefully.
4.2 Trouble shooting
Problem Cause/result Repair
External product leakage Worn or damaged lip
seal and/or O-ring
- Replace the seals
- Replace with sealsofa
different rubbergrade
Internal product leakage - Worn or product affected
plug seal - Replace the seal - Replace with a seal of a
different rubber grade
- Product deposits on
the seat and/or plug - Frequent cleaning
- Product pressure exceeds
actuator specification - Use auxiliary air on the spring side (do not exceed 3 bar). Alfa Laval
article number = 9611995903.
- See section 2.3 Safety precautions
- Reduce product pressure
Water hammer The flow direction is the
same as the closing direction
-Theflowdire
ction should be
against the closing direction.
- See section 3.2 General installation
- Throttle air release of solenoid in
top unit
The valve does not
open/close
Product pressure exceeds
actuator specification
- Reduce product pressure
- Use auxiliary air on the spring side.
Always use the pressure relief fittings
(3 bar) on support side.
Alfa Laval article number =
9611995903
If marked with a danger warning, do NOT attempt to cut the actuator open, due to spring under load.
DO NOT DISASSEMBLE
kg
!
Do NOT attempt to disassemble the actuator due to spring under load danger!
SPRING UNDER LOAD
Do not attempt to cut open
kg
!
Do NOT attempt to cut the actuator open due to spring under load danger!
18

4Operation
The valve is designed for cleaning in place (CIP).
Study the instructions carefully and pay special attention to the warnings!
NaOH = Caustic soda. HNO3= Nitric acid.
Internal leakage in the valve is externally visible by means of the leakage outlet.
4.3 Recommended cleaning
Step 1
Always handle lye and acid with great care.
Caustic danger!
Always use
rubber gloves!
Always use
protective goggles!
Step 2
!
Never touch the valve or the pipelines when sterilising.
Burn hazard!
2321-0066
Step 3
Clean the plug and the seats correctly.
Pay special attention to the warnings.
Lift and lower valve plug momentarily!
Shut-off valve Change-over valve
2321-0077
2321-0078
19

4Operation
The valve is designed for cleaning in place (CIP).
Study the instructions carefully and pay special attention to the warnings!
NaOH = Caustic soda. HNO3= Nitric acid.
Internal leakage in the valve is externally visible by means of the leakage outlet.
Step 4
Examples of cleaning agents:
Use clean water, free from chlorides.
1. 1% by weight NaOH at 70oC 2. 0.5% by weight HNO3at 70oC
1kg
NaOH +100 l
water = Cleaning agent. 0.7 l
53% HNO3+100 l
water = Cleaning agent.
2.2 l
33% NaOH +100 l water =Cleaning agent.
Step 5
1. Avoid excessive concentration of the cleaning agent.
2. Adjust the cleaning flow to the process.
3. Always rinse well with clean water after the cleaning.
NOTE
The cleaning agents must be stored/disposed of in accordance
with current regulations/directives.
Always rinse!
Clean water Cleaning agents
20