Alfalaval SRC User manual

IM70007-GB12 2002-03
SRC Sanitary Remote-Controlled 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 DIRECTIVE of 4 June
989 on mutual approximation of the laws of the Member States on the safety of machines (89/
392/EEC as amended by directives 9 /368/EEC and 93/44/EEC) with special reference to Annex
of the directive on essential safety and health requirements in relation to the construction
and manufacture of machines.
Bjarne Søndergaard Vice Pre ident, R & D
Alfa Laval
SANITARY REMOTE-CONTROLLED VALVE SRC

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. Recommen e auxiliary equipment
(DN125-150)................................................ 5
3. General installation ...................................... 6
4. Wel ing ....................................................... 7
5. Fitting of oil amper (optional extra) ............ 8
6. Fitting of in ication equipment
(optional extra) ............................................ 9
7. A justment of in ication equipment
(optional extra)........................................... 11
1. Operation ................................................... 12
2. Fault fin ing ............................................... 13
3. Recommen e cleaning ............................ 14
1. General maintenance ................................ 15
2. Dismantling of valve .................................. 17
3. Assembly of valve ...................................... 18
4. Dismantling of actuator .............................. 19
5. Assembly of actuator ................................. 20
1. Technical ata ........................................... 21
1. Parts lists
- SRC...................................... 22+24+26+28
- SRC DN125-150 .................. 30+32+34+36
- Oil amper ........................................ 38+40
- In ication units ....................................... 42
2. Explo e rawings
- SRC.................................................. 23+27
- SRC DN125-150 .............................. 31+35
- Oil amper .............................................. 39
- In ication units ....................................... 43
3. Drawings
- SRC.................................................. 25+29
- SRC DN125-150 .............................. 33+37
- Oil amper .............................................. 41

2
:
:
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 using the valve!
In icates that special proce ures must be
followe to avoi severe personal injury.
In icates that special proce ures must be
followe to avoi amage to the valve.
In icates important information to simplify
practices or to make them clearer.
WARNING! :
CAUTI N! :
N TE! :
2. Warning signs
General warning.
Caustic agents.

3
Installation:
:
:
:
:
peration:
:
:
:
:
Maintenance:
:
:
:
:
3. Safety precautions
-Always rea the technical ata thoroughly
(see page 21).
-Always release compresse air after use.
Never touch the clip assembly or the actuator
piston ro if the actuator is supplie with
compresse air.
Never touch the valve or the pipelines when
processing hot liqui s or when sterilizing.
-Never ismantle the valve with valve an
pipelines un er pressure.
-Never ismantle the valve when it is hot.
-Always rea the technical ata thoroughly
(see page 21).
-Always release compresse air after use.
Never touch the valve or the pipelines when
processing hot liqui s or when sterilizing.
Never touch the clip assembly or the actuator
piston ro if the actuator is supplie with
compresse air.
Always han le lye an aci with great care.
-Always rea the technical ata thoroughly
(see page 21).
-Always release compresse air after use.
-Never service the valve when it is hot.
-Never service the valve with valve an
pipelines un er pressure.
Never stick your fingers through the valve ports if
the actuator is supplie with compresse air.
Never touch the clip assembly or the actuator
piston ro if the actuator is supplie with
compresse air.
All warnings in the manual are summarized on this
page.
Pay special attention to the instructions below so that
severe personal in ury 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 the
pages 22-37.
The valve is supplied as separate parts as standard (for
welding).
The valve is assembled before delivery, if it is supplied
with fittings.
3
Change-over valve:
1. Complete actuator with bonnet (8).
2. Clip assembly (11).
3. Lip seal (14).
4. Two clamps (15).
5. Valve plug (20).
6. Two valve bo ies (16, 18).
7. Valve bo y seal ring (17).
Remove possible packing materials from the valve/
valve parts.
Inspect the valve/valve parts for visible transport
amages.
Remove
packing
materials!
Avoi amaging the valve/valve parts.
Inspection! Caution!
1. Unpacking/Delivery
CAUTION!
Alfa Laval cannot be hel responsible for incorrect
unpacking.
Check the elivery for:
1. Complete valve, stop valve or change-over
valve (see 2 an 3).
2. Delivery note.
3. Instruction Manual.
Please note that the esign of sizes DN125-150
iffers from that of sizes 25-101.6 mm/DN25-100.
The ifferences can be seen on pages 22-29 an
30-37.
The rawings in this manual show sizes 25-101.6
mm/DN25-100
Stop valve:
1. Complete actuator with bonnet (8).
2. Clip assembly (11).
3. Lip seal (14).
4. Clamp (15).
5. Valve plug (19).
6. Valve bo y (16).

5
1. Place the valve in the trestle.
2. Make sure that the actuator rests on the
rubber linings on the trestle support plates.
3. Dismantle/reassemble the valve.
Trestle
50
50
Si e view
250
250
Top view
R 99.5
R 101.5
En view
10
Installation
The valve sizes DN125-150 are very heavy.
Therefore Alfa Laval recommends manufacturing and
usage of auxiliary equipment. A proposal is given below.
2. Reco ended auxiliary equip ent (DN125/150)
Please note that the auxiliary equipment cannot be
supplied by Alfa Laval.
The item refers to the drawings and parts list on pages
30-37.
1
12
43
5 6
6
For lifting the valve:
Screw an eye bolt (6 mm) into top pin (23).
Using a small hook crane or similar, lift the valve
by the eye bolt.
Trestle:
- The purpose of the trestle is to support the valve
uring ismantling an reassembly.
- The trestle is ma e of a base plate, two support
plates, two rubber linings an four bolts.
- The rubber linings are attache to the support
plates so that the valve/actuator will rest on
these.
- To prevent the valve from turning uring
ismantling an reassembly the trestle must be
ma e with the correct measurements (see 3, 4
an 5). All measurements are in mm.

6
Avoi stressing the valve.
Pay special attention to:
- Vibrations.
- Thermal expansion of the tubes.
- Excessive wel ing.
- Overloa ing of the pipelines.
-Always rea the technical ata thoroughly
(see page 21).
-Always release compresse air after use.
CAUTION!
Alfa Laval cannot be hel responsible for incorrect
installation.
1
3
5
4
2
6
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 ro if the actuator is supplie
with compresse air.
Fittings:
Ensure that the connections are tight.
Moving parts!
Risk of
amage!
Air
Remember seal
rings!
Air
NO NC A/A
It is recommen e to install the valve so that:
- The actuator is not turne ownwar s as the
valve will then not be raine .
- The flow is against the closing irection
to avoi water hammer.
Inlet
Avoi water
hammer!
Stop valve
Inlet
Change-over valve
Installation
Air
R1/8" (BSP)
Air Air
Inlet
Air
Air connection:

7
Valve size A (mm) B1 (mm) B2 (mm)
DN25/25 mm 200 537 647
DN40/38 mm 230 550 730
DN50/51 mm 290 550 730
DN65/63.5 mm 350 550 730
DN80/76 mm 390 600 780
DN100/101.6 mm 490 650 830
DN125 580 730 920
DN150 640 730 920
1
2
4
3
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 the
pages 22-37.
Check the valve for smooth operation after welding.
3. Welding
Always wel the valve so that the valve bo y seal
ring can be replace (change-over valve).
Maintain the minimum clearances (A an B) so that
the lower valve bo y an plug (change-over valve)
an the actuator with the internal parts can be
remove .
Stop valve:
Assemble the valve in accor ance with the
instructions 2-5 on page 18.
Pay special attention to the warnings!
Change-over valve:
Assemble the valve in accor ance with the instruc-
tions 2-6 on page 18.
Pay special attention to the warnings!
Pre-use check:
1. Supply compresse air to the actuator.
2. Open an close the valve several times to
ensure that it operates smoothly.
Pay special attention to the warnings!
Change-over valve
(upper valve bo y)
Stop valve
B1 B2 (incl. top unit)
Fit seal ring (17)
correctly!
Remember
seal rings!
Air
Open/close!
Installation
B1 B2 (incl.
top unit)
A
5
SRC 25 mm stop valve
The 25 mm actuator is only for use on the SRC 25
mm stop valve.
Warning: When changing from NC to NO please
note that the actuator is spring-loa e . For safety,
place a "Spring-loa e " warning label (or ere
from Technical Support at Alfa Laval) on the valve.
Air (NO/AA)
Air (NC/AA)

8
12
56
34
The valve can be fitted with an oil damper if water
hammer occurs when the valve closes in the flow
direction.
The items refer to the drawings and the parts list on
pages 38-41.
Study the instructions carefully and pay special
attention to the warnings!
NC = normally closed.
A/A = air/air activated.
4. Fitting of oil da per, 25-101.6 /DN25-100, optional extra
Fill further oil through the plug hole if large air
bubbles occur un er the plexiglas cover.
NOTE!
There shoul be a small air bubble which equalizes
changes in the pressure because of temperature
changes.
Removal/ ismantling:
Remove the amper by following the instructions in
reverse or er.
Pre-use check:
1. Supply compresse air to the actuator.
2. Open an 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 liqui s or when sterilizing.
Burning anger!
1. Supply compresse air to the actuator.
Pay special attention to the warnings!
2. Fit the amper so that amper piston ro (72)
enters actuator piston ro (6).
Oil type SAE 40
Ensure that
no other
equipment
is fitte on the
actuator top!
1. Fit protective hoo (84).
2. The valve is now rea y for operation.
1. Connect the two piston ro s by means of clip
(71).
2. Release compresse air to the actuator.
Pay special attention to the warnings!
Air (NC, A/A)
Installation
Air (NC, A/A)

9
1
3
2
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!
The items refer to the drawings and the parts list on
pages 42-43.
5. Fitting indication equip ent, 25-101.6 /DN25-100, optional extra
5
4
58
Change-over valve
In ication unit
1. Fit ring (56) on the plug stem.
2. Assemble the valve in accor ance with the
instructions 3-6 on page 18.
Pay special attention to the warnings!
Stop valve
Dismantle the valve in accor ance with the
instructions 1-4 on page 17.
Pay special attention to the warnings!
-Never ismantle the valve when it is hot.
-Never ismantle the valve with valve an
pipelines un er pressure.
Burning
anger!
Installation
CAUTION!
The in ication an control equipment must be
electrically installe by authorize personnel.
-Top unit ThinkTop®:
(see the separate instruction manuals).
- In ication unit:
(see the instructions on the pages 9-11).
Micro switch unit:
1. Assemble an fit the switch unit
2. Turn ring (56) so that the e ges of hol er (51)
gui e its movements.
3. Ensure that spring (57) enters the recess in
the ring.
4. Fix the switch unit by means of screws (58).
Atmospheric
pressure require !
ThinkTop®

10
6
78
The indication unit has one or two micro switches or an
inductive proximity switch.
Study the instructions carefully.
The items refer to the drawings and the parts list on the
pages 42-43.
5. Fitting indication equip ent, 25-101.6 /DN25-100, optional extra
In uctive proximity switch unit:
1. Assemble an fit the switch unit
2. Turn ring (56) so that the e ges of hol er (51)
gui e its movements.
3. Fix the switch unit by means of screws (58).
910
Fit the cable through the cable glan an assemble
cable socket (59).
Micro switch unit:
Connect the cable to switch unit (53) as shown in
the wiring iagram.
In uctive proximity switch unit:
Connect the cable to switch unit (53) as shown in
the wiring iagram.
Tighten screw (59) firmly.
NOTE!
The cable glan shoul be seale with silicone
rubber un er extreme con itions.
58
Cable
Wiring iagram
Wiring iagram
Male connector
(pin si e)
Turn the
cable outlet
ownwar s!
59
Ø = Connecte in cable connector
A = One micro switch
B = Two micro switches
C = Male connector (pin si e)
Installation

11
1
2
Ad ust the micro switch and inductive proximity switch
units after installation.
Study the instructions carefully.
The items refer to the drawings and the parts list on the
pages 42-43.
6. Adjust ent of indication equip ent, 25-101.6 /DN25-100,
optional extra
Micro switch unit:
(A justment of contact point between spring (57)
an switch unit (53)).
1. Loosen switch unit (53) slightly (screw (58)).
2. Rotate a justment screw (60) until a signal is
obtaine .
3. Tighten the switch unit.
4. Check that the signal is correct.
5. Rea just if necessary.
Pre-use check:
1. Supply compresse air to the actuator.
2. Open an close the valve several times to
ensure that it operates smoothly.
Pay special attention to the warnings!
Open/close!
58
Installation
Air (NO/AA)
Air (NC/AA)

12
1
3
2
5
4
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 the
pages 22-37.
-Always rea the technical ata thoroughly
(see page 21).
-Always release compresse air after use.
CAUTION!
Alfa Laval cannot be hel responsible for incorrect
operation.
Never touch the valve or the pipelines when
processing hot liqui s or when sterilizing.
Never touch the clip assembly or the
actuator piston ro if the actuator is supplie
with compresse air.
Moving
parts!
Air (NO)
Burning
anger!
1. Operation
Lubrication of valve:
1. Ensure smooth movement between lip seal
(14) an plug stem (19, 20).
2. Lubricate with silicone oil/grease if necessary.
Lubricate if
necessary!
(see page 15)
Lubrication of actuator
1. Ensure smooth movement of the actuator
(the actuator is lubricate before elivery).
2. Lubricate with oil/grease if necessary.
Operation
Change-over valve:
1. Supply compresse air to the actuator.
2. Loosen an remove lower clamp (15).
3. Remove lower valve bo y (18).
4. Pull out seal ring (17).
5. Release compresse air.
Pay special attention to the warnings!
Air (NC/AA)
Air (NC, A/A)
Lubricate if
necessary!
(see page 15)
Change-over
valve
Stop valve

13
The valve plug jerks The sealings seize Lubricate:
- O-rings (2)
- O-ring (5) an the insi e of
cylin er (3)
- Lip seal (14)
Pro uct leakage Worn/pro uct affecte lip - Replace the seals
at stem an /or clamp seal (14) an /or seal ring (17) - Replace with seals of a
ifferent rubber gra e
Pro uct leakage - Worn/pro uct affecte - Replace the seal ring
(close valve) plug seal ring - Replace with a seal of a
ifferent rubber gra e
- Loose plug parts - Tighten the loose parts
(vibrations)
- Pro uct eposits on - Frequent cleaning
the seat an /or plug
Pro uct leakage - Worn actuator O-rings - Replace the O-rings
(too high pressure or too - Too small actuator or - Replace with a larger actuator
small actuator) actuator spring (for valve sizes 38 - 63.5 mm
(1½ - 2½))
- Fit a stronger spring
- Use auxiliary air on the spring
si e (NOT-element)
Water hammer The flow irection is the - The flow irection shoul be
same as the closing irection against the closing irection
- Fit a amper on the valve
(optional extra)
- Use auxiliary air on the spring
si e (NOT-element)
The valve oes not - Faulty clip assembly (11) - Replace the clip assembly
open/close - The pressure on the plug - Re uce the pressure
plug is too high - Fit stronger spring/larger
actuator
Study the instructions carefully.
The items refer to the drawings and the parts list the on
pages 22-37.
Problem Cause/result Repair
Pay attention to possible faults.
2. Fault finding
NOTE!
Stu y the maintenance instructions carefully
before replacing worn parts. - See page 15!
Operation

14
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 anger!
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. Reco ended cleaning
Always han le lye an aci with great care.
Never touch the valve or the pipelines when
sterilizing.
34
Examples of cleaning agents:
Use clean water, free from clori es.
1. 1% by weight NaOH at 70o C.
2. 0.5% by weight HNO3 at 70o C.
NOTE!
The cleaning agents must be store / ispose of in
accor ance with current rules/ irectives.
1. Avoi excessive concentration of the cleaning
agent
Þ Dose gra ually!
2. A just the cleaning flow to the process
Þ Milk sterilization/viscous liqui s
Þ Increase the cleaning flow!
3. Always rinse well with clean water after the
cleaning.
Change-over valve
Clean the plug an the seats correctly.
Pay special attention to the warnings!
Lift an
lower
momentarily (flip)!
Stop valve
Open!
Burning
anger!
Operation

15
1
34
2
rdering spare parts
- Contact the Sales Department.
- Or er from the Spare Parts List.
Recommen e spare parts: Service kits (see Spare Parts List).
-Always rea the technical ata thoroughly
(see page 21).
-Always release the compresse air after
use.
CAUTION!
All scrap must be store / ispose of in accor ance
with current rules/ irectives.
Never stick your fingers through the valve
ports if the actuator is supplie with
compresse air.
1. General aintenance
Burning
anger!
Atmospheric
pressure
require !
Cutting
anger!
Air Air
Moving
parts!
Never touch the clip assembly or the
actuator piston ro if the actuator is supplie
with compresse air.
Maintain the valve regularly.
Study the instructions carefully and pay special
attention to the warnings!
Always keep spare rubber seals and lip seals in stock.
-Never service the valve when it is hot.
-Never service the valve with valve an
pipelines un er pressure.
Maintenance

16
Maintain the valve regularly.
Study the instructions carefully.
Always keep spare rubber seals and lip seals stock.
Check the valve for smooth operation after service.
1. General aintenance
Valve Valve Actuator
rubber seals lip seal rubber seals
Preventive Replace after Replace when Replace after
maintenance 12 months replacing the 5 years
rubber seals
Maintenance after Replace at the Replace when Replace when
leakage (leakage en of the ay replacing the possible
normally starts slowly) rubber seals
Planne - Regular inspection Replace when - Regular inspection
maintenance for leakage an replacing the for leakage an
smooth operation rubber seals smooth operation
- Keep a recor of - Keep a recor of
the valve the actuator
- Use the statistics for - Use the statistics for
planning of planning of
inspections inspections
Replace after Replace after
leakage leakage
Lubrication Before fitting Before fitting Before fitting
(USDA H1 Silicone oil or Silicone oil or Oil or grease
approve oil/grease) silicone grease silicone grease
Pre-use check:
1. Supply compresse air to the actuator.
2. Open an close the valve several times to
ensure that it operates smoothly.
Pay special attention to the warnings!
Air (NO/AA)
Open/
close!
Maintenance
Air (NC/AA)

17
1
3
5
4
2
6
Handle scrap correctly.
NC = Normally closed.
NO = Normally open.
A/A = Air/air activated.
2. Dis antling of valve
Air (NC, A/A)
Stop valve Change-over valve Stop valve Change-over valve
1. Remove screw (19h, 20h).
2. Dismantle the complete valve plug.
Change-over valve:
1. upply compressed air to the actuator (Only NC).
2. Loosen and remove lower clamp (15).
3. Remove lower valve body (18).
4. Pull out seal ring (17).
5. Release compressed air.
Pay special attention to the warnings!
Air (NO, A/A) Air (NO, A/A)
Stop valve Change-over valve
1. Supply compresse air to the actuator (only
NO).
2. Remove clip assembly (11).
(For sizes DN125-150: Unscrew valve plug
(19, 20)).
3. Remove valve plug (19, 20).
4. Release compresse air.
Pay special attention to the warnings!
Change-over valve:
1. Remove upper clamp (15).
2. Remove upper valve bo y (16).
Study the instructions carefully.
The items refer to the drawings and the parts list on the
pages 22-37.
Maintenance
Remove lip seal (14).
(For sizes DN125-150: Remove lip seal (14) an
gui e ring (27)).
Stop valve:
1. upply compressed air to the actuator (Only NC).
2. Loosen and remove clamp (15).
3. Lift out the actuator.
4. Release compressed air.
Pay special attention to the warnings!
Air (NC, A/A)

18
1
3
5
4
2
6
Study the instructions carefully.
The items refer to the drawings and the parts list on the
pages 22-37.
Lubricate the rubber seals and the lip seal before fitting
them.
Lip seal (14) can be replaced by a special stem seal
(sizes 25-101.6 mm/DN40-100).
3. Asse bly of valve
1. Assemble the complete valve plug.
2. Fix screw (19h, 20h) by using loctite or
something similar.
Change-over valve:
1. Assemble upper valve bo y (16) an the
actuator.
2. Fit an tighten upper clamp (15).
Fix!
Change-over valve
Stop valve Stop valve Change-over valve
Air (NC, A/A)
Air (NC, A/A)
Stop valve:
1. Supply compresse air to the actuator (Only NC).
2. Fit the actuator.
3. Fit an tighten clamp (15).
4. Release compresse air.
Pay special attention to the warnings!
Change-over valve:
1. Fit seal ring (17) correctly in lower valve body (18).
2. upply compressed air to the actuator (Only NC).
3. Assemble lower and upper valve bodies
(16, 18).
4. Fit and tighten lower clamp (15).
5. Release compressed air.
Pay special attention to the warnings!
Turn the iagonal
surface of seal
ring (17) upwar s!
Fit lip seal (14).
(For sizes DN125-150: Fit gui e ring (27) an lip
seal (14)).
Air (NO, A/A)
1. Fit the plastic ring of clip assembly (11) on the
actuator piston rod.
2. upply compressed air to the actuator (Only NO).
3. Fit valve plug (19, 20).
4. Fit and assemble clip assembly (11). (For sizes
DN125-150: crew together valve plug (20) and
piston (6). Fix thread by using Loctite or something
similar)).
5. Release compressed air.
Pay special attention to the warnings!
Change-over
valve
top
valve
Maintenance
Air (NO, A/A)