Alfalaval CSI SPC-2 User manual

IM70736-GB4 1997-08
SPC-2 Sanitary Electro-Pneumatic Modulating Valve
Instruction Manual

Name Title
Company Signature
Alfa Laval
6000 Kolding
[phone]
Company Name
Address
Phone No.
hereby declare that
Denomination Type Year
Declaration of Conformity
The designating company
Designation
Was manufactured in conformity with the provisions in the COUNCIL DIRECTI E of 14 June
1989 on mutual approximation of the laws of the Member States on the safety of machines (89/
392/EEC as amended by directives 91/368/EEC and 93/44/EEC) with special reference to Annex
1 of the directive on essential safety and health requirements in relation to the construction
and manufacture of machines.
Bjarne Søndergaard Vice resident, R & D
Alfa Laval
SANITARY ELECTRO- NEUMATIC
MODULATING VALVE S C-2

1
Safety
This manual is divided up into main sections. - See
below.
1. Important information ................................. 2
2. Warning signs ........................................... 2
3. Safety precautions .................................... 3
1. Unpacking/Delivery .................................... 4
2. Installation ................................................
1. General operation ...................................... 6
2. Fault finding .............................................. 6
3. Adjustment of the valve ............................. 7
4. Adjustment in case of 20 mm stroke
deviation .................................................... 8
. Changing of the actuator function .............. 9
6. Recommended cleaning .......................... 10
1. General maintenance .............................. 11
2. Dismantling ............................................. 12
3. Reassembly ............................................ 13
1. Technical data......................................... 14
2. Selection/Pressure drop - capacity
diagram ................................................... 1
1. Parts list ........................................... 16+18
2. Exploded drawing .................................... 17
3. Drawings ................................................. 19
Table of contents
Installation
Operation
Maintenance
Technical data
Drawings/Parts list

2
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 informations to simplify
practices or to make them clearer.
WARNING! :
CAUTION! :
NOTE! :
:
:
General warning.
Caustic agents.
2. Warning signs
Safety
Unsafe practices and other important information are
emphasized in this manual.
Warnings are emphasized by means of special signs.
1. I portant infor ation
Always read the manual before us ng the valve!

3
3. Safety precautions
Installat on:
:
Operat on:
:
:
:
Ma ntenance:
:
:
-Always read the technical data thoroughly
(See page 14).
-Always release compressed air after use.
-Always read the technical data thoroughly
(See page 14).
-Always release compressed air after use.
-Always disconnect the electrical connection
before dismantling.
-Never touch the valve or the pipelines when
processing hot liquids or when sterilizing.
-Never dismantle the valve with valve and
pipelines under pressure.
Always handle lye and acid with great care.
-Always read the technical data thoroughly
(See page 14).
-Always release compressed air after use.
-Always disconnect the electrical connection
before service.
-Never service the valve when it is hot.
-Never service the valve with valve and pipe-
lines under pressure.
All warnings in the manual are summarized on this
page.
ay special attention to the instructions below so that
severe personal injury and/or damage to the valve
are avoided.
Safety

4
1
3
5
4
2
Caution!
Installation
The instruction manual is a part of the delivery. Study the instructions carefully.
1. Unpacking/Delivery
NOTE!
We cannot be held responsible for incorrect
unpacking.
Check the delivery for:
1. Complete valve.
2. Delivery note.
3. Instruction manual.
Avoid damaging the air connection, the electrical
connection and the valve ports.
Remove possible packing materials from the
valve ports.
Inspection!
Inspect the valve for visible transport damages.
emove
packing
materials!
Air

5
Dimension A (mm)
38mm/DN40 100
1mm/DN 0 10
63. mm/DN6 130
76mm/DN80 14
101.6mm/DN100 180
1
3
5
emember seal rings!
4
2
6
Weld carefully!
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.
2. Installation
Avoid stressing the valve.
Pay special attention to:
- Vibrations.
- Thermal expansion of the tubes.
- Excessive welding.
- Overloading of the pipelines.
Fittings:
Ensure that the connections are tight.
Welding:
1. Remove the internal valve parts in accor-
dance with instruction 1 on page 12.
2. Weld the valve into the pipelines.
3. Assemble the valve in accordance with in-
struction on page 13.
Welding into a manifold:
Maintain the minimum clearance (A) so that the
actuator can be removed.
Electrical connection:
1. Remove the black cover from the actuator.
2. Fit the cable through the cable gland and
connect it to the terminal strip. Ensure
correct polarity (11 = +,12 = -)!
3. Tighten the cable gland and refit the cover.
-Always read the technical data
thoroughly (See page 14).
-Always release compressed air after
use.
CAUTION!
- Always let the valve be electrically connected
by authorized personnel.
- The I/P-converter of the actuator is adjusted
before delivery and must never be opened.
NOTE!
We cannot be held responsible for incorrect
installation.
isk of damage!
A
Cover for
electrical
connection

6
2
-Never touch the valve or the pipelines
when processing hot liquids or when
sterilizing.
-Never dismantle the valve with valve
and pipelines under pressure.
1
-Always read the technical data
thoroughly (See page 14).
-Always release compressed air after
use.
-Always disconnect the electrical con-
nection before dismantling.
CAUTION!
The I/P-converter of the actuator is adjusted be-
fore delivery and must never be opened.
NOTE!
We cannot be held responsible for incorrect
installation.
2. Fault finding
NOTE!
- Study the adjustment instructions carefully be-
fore adjusting the valve. - See page 7-8!
- Study the maintenance instructions carefully
before replacing worn parts. - See page 11!
Operation
The valve is adjusted and tested before delivery.
The adjustment instructions on page 7-8 are only to
be used if further adjustment is required!
Study the instructions carefully and pay special
attention to the warnings!.
ay attention to possible faults.
Problem Cause/result epair
- Leaking lip seal at the piston - Worn lip seal - Replace the lip seal
- Leaking seal at the valve - Incorrect rubber grade - Replace with a seal of a dif-
body ferent rubber grade
Deviation in the flow regulation Worn valve plug Replace the plug and adjust
(See page 7)
Deviation in the flow regulation Mechanical parts have come Tighten and adjust
loose (vibrations) (See page 7)
Actuator does not regulate Actuator errors Return the actuator to the supplier
1. General operation
Atmospheric
pressure re-
quired!

7
1
34
2
Operation
3. Adjust ent of the valve
The valve is adjusted and tested before delivery.
The adjustment instructions on this page are only to
be used if further adjustment is required!
Study the instructions carefully.
Calibrate with care.
1. Loosen and remove clamp fitting (9).
2. Remove the cover from the terminal box.
3. Fit air fittings in entry 9 on the actuator.
4. Supply compressed air (4 bar) to the air fittings.
1. Set the highest signal (20 mA), + on ter-
minal block 11 and - on terminal block 12.
NOTE!
For NC valve the signal must be 4 mA.
2. Make sure that valve plug (2) is pressed
against the valve seat.
1. Adjust valve plug adjuster (7) so that it
contacts the actuator piston rod. (Give 1/4
extra turn to give preforce on the plug).
2. Tighten lock nut (8) using a spanner.
3. Fit and tighten clamp fitting (9) to connect
the actuator piston rod with valve plug (2).
Check the stroke by changing the signal from 20
to 4 mA (NO) (Opposite if NC).
Stroke = 20 mm + 1.
NOTE!
In case of deviation from 20 mm stroke, see
page 8.
5
Move valve plug (2) up and down several times and
check that the valve plug is still in closed position.
If not, readjust.
Terminal box
Supply air
Terminal
blocks
Contact
Stroke = 20 mm±1

8
Contact
1
3
2
Operation
The valve is adjusted and tested before delivery.
The adjustment instructions on this page are only to
be used if further adjustment is required!
Study the instructions carefully.
Adjust with care.
NO = Normally open.
NC = Normally closed.
4. Adjust ent in case of 20 stroke deviation
NOTE!
Maximum stroke is 21 mm.
1. Place a 20 mm block between the actuator piston
rod and the valve plug (2).
2. Adjust valve plug adjuster (7) to a position with a
distance of 0. mm + the 20 mm block between the
actuator piston rod and the valve plug (use a gauge
blade to determine the 0. mm).
3. Adjust with the zero-screw (counterclockwise) until
the actuator piston rod contacts the 20 mm block
and can be moved slightly. Turn the zero-screw 1/2
round (counterclockwise) to give preforce on the
valve plug.
CAUTION!
Do not touch the zero-screw.
1. Pull the spring lever gently down to release
the 20 mm block.
2. Remove the 20 mm block.
zero-screw Entry 9 Entry 36
20.5 mm 20 mm
zero-screw
Spring lever
4
1. Set the highest signal (20 mA), + on the
terminal block 11 and - on the terminal block
12 (4mA for NC valve) (the actuator piston
rod contacts valve plug (2) and gives preforce).
2. Fit and tighten clamp fitting (9) to connect
the actuator piston rod with the valve plug.
3. Check that the stroke is 20 mm.
1. Release compressed air.
2. Remove clamp fitting (9).
3. Remove the terminal box cover.
4. Supply compressed air (4 bar) to entry 9.
. Set the lowest signal (4mA), + on terminal
block 11 and - on terminal block 12 (20mA
for NC valve).
6. Adjust with the zero-screw (clockwise) to
ensure max. open position.

9
2
3
1
Operation
The actuator function can be changed from NO to
NC or vice versa.
NO = Normally open.
NC = Normally closed.
Study the instructions carefully.
5. Changing of the actuator function
NOTE!
Check the actuator type before changing the actuator
function.
1. Separate the actuator from the valve according
to instructions 1-3 on page 12.
2. Unscre and remove the hexagonal nuts and
bolts. The 2 long bolts must be unscre ed and
removed last to slo ly decompress the springs.
3. Lift off diaphragm case (a) and remove
springs (b).
4. Pull out actuator piston rod (c), diaphragm plate
(d), plate (e) and diaphragm (f) from yoke (g).
5. Unthread nut (h) hile counterholding nut (i).
The nut (i) must not be removed on the actuator
piston rod. Should the nut be removed, adjust
the nut so that the dimension 187.5 mm is assured.
Pay special attention to the warnings!
1. Turn over diaphragm plate (d), plate (e)
and diapgragm (f) fit them on actuator
piston rod (c) and thread on nut (h) again.
2. Fit the actuator piston rod with diaphragm
plate, plate and diaphragm in yoke (g).
3. Fit springs (6) and diaphragm case (a).
4. Fit and tighten bolts and hexagonal nuts. Fit
and tighten the 2 long bolts first to slowly
compress the springs.
. Connect the actuator piston rod with the
valve plug according to instructions 4- on
page 13.
Pay special attention to the warnings!
6. Turn the switch over plate.
7. Adjust the valve as described on page 7.
187. mm
Left: NC ight: NO

10
Caustic danger!
1
3
5
Always rinse!
2
4
6
Burning
danger!
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.
3% HNO3water
Always use Always use
rubber gloves! protective goggles!
Operation
The valve is designed for cleaning in place (CI ).
CI = Cleaning In lace.
Study the instructions carefully and pay special
attention to the warnings!
NaOH = Caustic Soda.
HNO3 = Nitric acid.
6. Reco ended cleaning
Always handle lye and acid with great
care.
Never touch the valve or the pipelines
when sterilizing.
Examples of cleaning agents:
Use clean water, free from clorides.
1. 1% by weight NaOH at 700C.
2. 0. % by weight HNO3 at 700C.
1. Avoid excessive concentration of the clean-
ing agent
Þ Dose gradually!
2. Adjust the cleaning flow to the process
Þ Milk sterilization/viscous liquids
Þ Increase the cleaning flow!
NOTE!
The cleaning agents must be stored/disposed of
in accordance with current rules/directives.
Always rinse well with clean water after the
cleaning.
Clean water Cleaning
agents

11
Order ng spare parts
- Contact the Sales Department.
- Order from the Spare Parts List.
ecommended spare parts: Service kits (see Spare Parts List).
Valve lip seal Valve bearing
Preventive maintenance eplace after 12 months Replace when replacing the
lip seal
Maintenance after leakage eplace by the end of the day Replace when replacing the
(leakage normally starts slowly) lip seal
Adjusted maintenance - Regular inspection for leakage Replace when replacing the
and smooth operation lip seal
- Keep a record of the valve
- Use the statistics for planning
of inspections
eplace after leakage
Lubrication Before fitting None
Silicone grease or silicone oil
12
-Never service the valve when it is hot.
-Never service the valve with valve and
pipelines under pressure.
Maintain the valve carefully.
Study the instructions carefully and pay special atten-
tion to the warnings!
Always keep spare lip seals and guide rings in stock.
-Always read the technical data
thoroughly (See page 14).
-Always release compressed air after
use.
-Always disconnect the electrical con-
nection before service.
CAUTION!
The I/P-converter of the actuator is adjusted be-
fore delivery and must never be opened.
NOTE!
All scrap must be stored/disposed of in accord-
ance with current rules/directives.
1. General aintenance
Maintenance
Burning
danger!
Atmospheric
pressure re-
quired!

12
1
3
5
4
2
6
Maintenance
Study the instructions carefully.
The items refer to the drawings and the parts list on
page 16-19.
Handle scrap correctly.
NO = Normally open.
NC = Normally closed.
2. Dis antling
1. Supply compressed air and current of
20mA to open the NC version.
Pay special attention to the warnings!
2. Remove clamp (3).
3. Remove the actuator and the internal valve
parts.
4. Remove seal ring (4c). Loosen and remove clamp fitting (9).
1. Loosen and unscrew lock nut (8) and valve
plug adjuster (7), using a spanner.
2. Remove valve plug (2). Pull off lip seal (4a) and plate (4b).
1. Remove bearing (6).
2. Replace the bearing lip seal (4a) and seal
ring (4c).
1. Loosen striking nut (10) using a plastic-
hammer.
2. Separate actuator (11) from bonnet ( ).

13
1
Maintenance
Study the instructions carefully.
The items refer to the drawings and the parts list on
page 16-19.
Lubricate the lip seal before fitting it.
NO = Normally open.
NC = Normally closed.
3. Reasse bly
1. Supply compressed air and current of
20 mA to open the NC version.
Pay special attention to the warnings!
2. Fit seal ring (4c) in valve body (1).
3. Fit the actuator and the internal valve parts.
4. Fit and tighten clamp (3).
6
5
1. Adjust the valve plug adjuster so that it
contacts the actuator piston rod.
2. Tighten lock nut (8) using a spanner.
3. Fit and tighten clamp fitting (9) to connect
the actuator piston rod with valve plug (2).
4
Screw lock nut (8) and valve plug adjuster (7) onto
valve plug (2).
3
Fit lip seal (4a) and plate (4b) on valve plug (2).
2
Fit bearing (6) in bonnet ( ).
1. Fit bonnet ( ) on actuator (11).
2. Tighten striking nut (10) using a plastic-
hammer.

14
Technical data
It is important to observe the technical data during
installation, operation and maintenance.
Inform the personnel about the technical data.
1. Technical data
Valve-data
Max. product pressure ............................................... 1000kPa (10bar)
Min. product pressure ................................................ Full vacuum
Temperature range ..................................................... -100C to +1400C (EPDM)
Flow range Kv ............................................................ 0. to 110 m3/h/bar
Max. pressure drop .................................................... 00kPa ( bar)
Valve-mater als
Product wetted steel parts ......................................... AISI 316L
Other steel parts ........................................................ AISI 304
Lip seal ...................................................................... EPDM (standard)
Finish ......................................................................... Semi bright
Actuator-a r data
Air consumption at steady state condition.................. With 0.6 bar signal pressure and supply
.................................................................................. pressures up to 6 bar £ 100 In/h
Connection ................................................................. 6/4 mm air tube
Max. air pressure ....................................................... 600kPa (6 bar)
Working pressure ....................................................... 400kPa (4 bar)
Max. size of particles ................................................. 0.01mm
Max. oil content ......................................................... 0.08ppm
Dew point ................................................................... 100C below ambient temp. or lower
Max. water content .................................................... 7. g/kg
Actuator-transducer/convector
Signal range ............................................................... 4-20mA (standard)
Input resistance ......................................................... 200W
Inductivity/capacistance ............................................. Negligible
Actuator-accuracy
Deviation .................................................................... £ 1. %
Hysteresis.................................................................. £ 0. %
Sensitivity .................................................................. < 0.1%
Influence of air supply ................................................. £ 0.1% between 1.4 and 6 bar
Actuator-data
Protection class ......................................................... IP 4
Ambient temperature .................................................. -2 oC to +70oC
Actuator-mater als
Housing...................................................................... Aluminium with plastic coating
Diaphragm .................................................................. NBR with reinforced fabric insert
Springs ...................................................................... Stainless steel uncovered/spring steel epoxy
resin coated
Stem .......................................................................... Stainless steel
Plastic parts............................................................... Polycarbonate/polyamide 6.6
Screws, nuts .............................................................. Stainless steel, polyamide 6.6
Other parts ................................................................. Stainless steel and aluminium

15
Kv Seat Seat Tube Actuator NO NC
area diam. connections (type no.) Piston thrust (N), Piston
(cm2) (mm) (mm) at air pressure (bar) thrust
ISO DIN NO NC 3.0 4.0 .0 6.0 spring (N)
0, E 0.3 6 38 40 3277- 3277- 800 2 000 3 200 4 400 1 00
1,0 E 0.8 10 38 40 3277- 3277- 800 2 000 3 200 4 400 1 00
2 E 1.1 12 38 40 3277- 3277- 800 2 000 3 200 4 400 1 00
4 E 1. 14 38 40 3277- 3277- 800 2 000 3 200 4 400 1 00
8 E 4.2 23 38 40 3277- 3277- 800 2 000 3 200 4 400 1 00
16 E 6.6 29 38 40 3277- 3277- 800 2 000 3 200 4 400 1 00
32 E 18. 48, 1 0 3277- 3277- 800 2 000 3 200 4 400 1 00
64 L 20. 1 63, 6 3277- 3277- 800 2 000 3 200 4 400 1 00
7 L 20. 1 76 80 3277- 3277- 800 2 000 3 200 4 400 1 00
110 L 40.7 72 101,6 100 3277- 3277* 800 2 000 3 200 4 400 2 800
*) Effective diaphragm area = 350 cm2 (all others = 120 cm2).
What product pressure belo the plug ill open the valve?
P= (kPa)
Example:
Kv 32E , 4 bar air pressure (NO), A = 18.5 cm², F = 2000 N
ÞP = = 1080 kPa » 10.8 bar
The valve opens at product pressure above 10 bar.
It is important to observe the technical data during
installation, operation and maintenance.
Inform the personnel about the technical data.
NO = Normally open.
NC = Normally closed.
Technical data
2. Selection / Pressure drop - capacity diagra
NOTE!
Different springs are available for different actuator thrusts.
Always return the actuator to the supplier if changing the springs.
P = Product pressure (bar)
A = Seat area (cm²)
d = Seat diameter (mm)
F = Piston thrust (N)
Pressure Drop Calculation
The Kv designation is the flow rate in m3/h at
a pressure drop of 1 bar when the valve is fully
open (water at 200C or similar liquids).
The Kv value at other pressure drops is
calculated according to the following formular:
Kvq = Q
ÖD p
Where:
Kvq= Flow coefficient (m3/h at D p = 1 bar).
Q = Flow rate (m3/h).
D p = Pressure drop over valve (bar).
F x 10
A
2000 x 10
18.5

16
Drawing/Parts list
Parts list
SPC-2
Item Qty. Denomination
1 1 Valve body
2 1 Valve plug
31Clamp
4 1 Lip seal kit
4aD1 Lip seal
4b 1 Plate
1 Plate for FEP seal
4cD1 Seal ring
1 Seal ring for FEP seal
4d 1 Support ring for FEP seal
4eD1 O-ring for FEP seal
1 Bonnet
6D1 Bearing
7 1 Valve plug adjuster
8 1 Lock nut
9 1 Clamp fitting
10 1 Striking nut
11 1 Actuator
D : Service kits - EPDM, NBR, FPM
(See Spare Parts List)
The drawing and the parts list include all items. The items are identical with the items in the Spare
arts List.
When ordering spare parts, please use the Spare
arts List!

17
Exploded drawing
This page shows an exploded drawing of S C-2.
NO = Normally open.
NC = Normally closed.
The drawing includes all items of the valve.
They are identical with the items in the Spare arts
List
Parts for FEP seal
Drawing/Parts list

18
Drawing/Parts list
Parts list
SPC-2
Item Qty. Denomination
1 1 Valve body
2 1 Valve plug
31Clamp
4 1 Lip seal kit
4aD1 Lip seal
4b 1 Plate
1 Plate for FEP seal
4cD1 Seal ring
1 Seal ring for FEP seal
4d 1 Support ring for FEP seal
4eD1 O-ring for FEP seal
1 Bonnet
6D1 Bearing
7 1 Valve plug adjuster
8 1 Lock nut
9 1 Clamp fitting
10 1 Striking nut
11 1 Actuator
D : Service kits - EPDM, NBR, FPM
(See Spare Parts List)
The drawing and the parts list include all items. The items are identical with the items in the Spare
arts List.
When ordering spare parts, please use the Spare
arts List!