Alfalaval Unique 7000 Series User manual

ESE00213-ENUS4 2014-12
Original manual
Instruction Manual
Unique 7000 Series Valve - Standard and Reverse Acting

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 ................................................................................ 10
3.3. Welding ............................................................................................ 11
3.4. Recycling information ............................................................................. 12
4. Operation ............................................................................................... 13
4.1. Operation .......................................................................................... 13
4.2. Troubleshooting ................................................................................... 15
4.3. Recommended cleaning ......................................................................... 16
5. Maintenance ........................................................................................... 18
5.1. General maintenance ............................................................................. 18
5.2. Dismantling the valve ............................................................................. 20
5.3. Elastomer seat ring replacement ................................................................ 21
5.4. Assembly of valve ................................................................................. 22
5.5. Actuator bushing replacement .................................................................. 22
5.6. Dismantling of optional maintainable actuator ................................................. 22
5.7. Assembly of optional maintainable actuator ................................................... 22
5.8. Additional equipment ............................................................................. 23
6. Technical data ......................................................................................... 24
6.1. Technical data ..................................................................................... 24
7. Parts list and Service Kits ........................................................................... 25
7.1. Drawing ............................................................................................ 25
7.2. Unique 7000 TR2 - Shut-off-Valve .............................................................. 26
7.3. Unique 7000 TR2 - Change-over-Valve ........................................................ 28
7.4. Unique 7000 Elastomer plug seal - Shut-off-Valve ............................................ 30
7.5.Unique 7000 Elastomer plug seal - Change-over-Valve ...................................... 32
3
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1 EC Declaration of Conformity
Revision of Declaration of Conformity 2009-12-29
The Designated Company
Alfa Laval Kolding A/S
Company Name
Albuen 31, DK-6000 Kolding, Denmark
Address
[phone]
Phone No.
hereby declare that
Valve
Designation
Unique 7000 PN10
Ty p e
From serial number 5099880 to 29999999999
is in conformity with the following directive with amendments:
- Machinery Directive 2006/42/EC
- Regulation (EC) No 1935/2004
The person authorised to compile the technical file is the signer of this document
QHSE Manager, Quality, Health and safety & Environment Annie Dahl
Title Name
Kolding 2013-12-03
Place Date Signature
4
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2 Safety
Unsafe practices and other important information are emphasized in this manual.
Warnings are emphasized by means of special signs.
2.1 Important information
A
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t
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v
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a
a
l
l
v
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e
e
!
!
W
W
A
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R
R
N
N
I
I
N
N
G
G
Indicates that special procedures must be followed to avoid serious personal injury.
C
C
A
A
U
U
T
T
I
I
O
O
N
N
Indicates that special procedures must be followed to avoid damage to the valve.
N
N
O
O
T
T
E
E
Indicates important information to simplify or clarify procedures.
2.2 Warning signs
General warning:
Caustic agents:
5
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2 Safety
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.
2.3 Safety precautions
A
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2
2
0
0
1
1
2
2
(
(
N
N
e
e
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a
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o
o
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i
i
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n
n
)
)
:
:
Alfa Laval recommend only to use 43.5 PSI (3 bar)
support air on the spring side in all the Unique 7000
actuators, to ensure 145 PSI (10 bar) product pressure
without leakage.
Alfa Laval recommend max. 43.5 PSI
(3 bar)
Plastic adapter (Pos. 5) is always used on the new
design.
ø61/5inch
ø157.5 mm
TD 461-990
5
A
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2
2
0
0
0
0
6
6
-
-
2
2
0
0
1
1
1
1
(
(
o
o
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a
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u
u
a
a
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o
o
r
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d
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e
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s
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i
i
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n
n
)
)
:
:
W
W
A
A
R
R
N
N
I
I
N
N
G
G
!
!
Max. 43.5 PSI (3 bar) “support air” on
spring side.
When using “support air” on spring side in all the Unique
7000 actuators, the pressure must N
N
O
O
T
T
exceed 43.5
PSI (3 bar).
ø61/7inch
When using Unique 7000 actuators with OD156 mm
with support air, a
a
l
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use the “steel adapter” (pos. 5).
Tighten the “steel adapter” with torque of 21 lbf-ft (30
Nm) and use Loctite 243.
ø156 mm
The actuator with OD156 mm is mainly used on valves
ISO76/DN80 – ISO101/DN100. The outer actuator
diameter = ø6 1/7 inch (156 mm).
TD 461-990
5
6
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2 Safety
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.
I
I
n
n
s
s
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t
a
a
l
l
l
l
a
a
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i
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o
o
n
n
:
:
A
A
l
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w
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a
a
y
y
s
s
read the technical data thoroughly (See chapter 6 Technical data)
A
A
l
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w
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a
a
y
y
s
s
release compressed air after use
N
N
e
e
v
v
e
e
r
r
touch the moving parts if the actuator is supplied with compressed air
N
N
e
e
v
v
e
e
r
r
touch the valve or the pipelines when processing hot liquids or when sterilizing
N
N
e
e
v
v
e
e
r
r
dismantle the valve with valve and pipelines under pressure
N
N
e
e
v
v
e
e
r
r
dismantle the valve when it is hot
O
O
p
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o
n
n
:
:
N
N
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r
r
dismantle the valve with valve and pipelines under pressure
N
N
e
e
v
v
e
e
r
r
dismantle the valve when it is hot
A
A
l
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a
a
y
y
s
s
read the technical data thoroughly (See chapter 6 Technical data)
A
A
l
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w
w
a
a
y
y
s
s
release compressed air after use
N
N
e
e
v
v
e
e
r
r
touch the valve or the pipelines when processing hot liquids or when sterilizing
N
N
e
e
v
v
e
e
r
r
touch the moving parts if the actuator is supplied with compressed air
A
A
l
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w
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a
a
y
y
s
s
rinse well with clean water after the cleaning
A
A
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a
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handle lye and acid with great care
M
M
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a
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n
c
c
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e
:
:
A
A
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a
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y
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read the technical data thoroughly (See chapter 6 Technical data)
A
A
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a
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y
y
s
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release compressed air after use
N
N
e
e
v
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e
r
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service the valve when it is hot
N
N
e
e
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v
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e
r
r
service the valve with valve and pipelines under pressure
N
N
e
e
v
v
e
e
r
r
stick your fingers through the valve ports if the actuator is supplied with compressed air
N
N
e
e
v
v
e
e
r
r
touch the moving parts if the actuator is supplied with compressed air
7
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3 Installation
The instruction manual is part of the delivery. Study the instructions carefully.
The items refer to parts list and service kits section.
The valve is supplied as separate parts as standard (for welding).
The valve is assembled before delivery, if it is supplied with fittings.
3.1 Unpacking/delivery
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Alfa Laval cannot be held responsible for incorrect unpacking.
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:
:
1. Complete valve, shut off valve (RA) or change-over
valve (RA) (see steps 2a, 2b, 2c and 2d).
2. Delivery note.
3. Instruction manual.
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:
:
1. Complete actuator.
2. Bonnet (20).
3. Clamp (19).
4. Valve plug (23).
5. Valve body (22).
TD 461-304_1
2
2
b
b
C
C
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:
:
1. Complete actuator.
2. Bonnet (20).
3. 2 x clamp (19).
4. Valve plug (27).
5. Lower valve body (22).
6. Valve seat (28).
7. Upper valve body (26).
TD 461-305_1
UP
2
2
c
c
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S
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-
-
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-
-
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:
:
1. Complete actuator.
2. Bonnet (20).
3. 3 x clamp (19).
4. Valve plug (23).
5. 2 x upper valve body (26).
6. Valve seat (28).
7. Lower bonnet (33).
TD 461-306_1
UP
8
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3 Installation
The instruction manual is part of the delivery. Study the instructions carefully.
The items refer to parts list and service kits section.
The valve is supplied as separate parts as standard (for welding).
The valve is assembled before delivery, if it is supplied with fittings.
2
2
d
d
C
C
h
h
a
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n
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-
-
o
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v
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v
v
a
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v
v
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-
-
R
R
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s
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A
A
c
c
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i
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:
:
1. Complete actuator.
2. Bonnet (20).
3. 4 x clamp (19).
4. Upper valve plug (34).
5. Lower valve plug (35).
6. 3 x upper valve body (26).
7. 2 x valve seat (28).
8. Lower bonnet (33).
TD 461-307_1
UP
S
S
t
t
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p
p
3
3
Remove possible packing materials from the valve/valve parts.
Inspect the valve/valve parts for visible transport damages.
Avoid damaging the valve/valve parts.
9
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3 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.
3.2 General installation
S
S
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p
p
1
1
A
A
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y
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read the technical data thoroughly.
See chapter 6 Technical data
A
A
l
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a
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y
y
s
s
release compressed air after use.
C
C
A
A
U
U
T
T
I
I
O
O
N
N
Alfa Laval cannot be held responsible for incorrect installation.
S
S
t
t
e
e
p
p
2
2
N
N
e
e
v
v
e
e
r
r
touch the moving parts if the actuator is supplied with
compressed air.
Air
M
M
o
o
v
v
i
i
n
n
g
g
p
p
a
a
r
r
t
t
s
s
!
!
Air
S
S
t
t
e
e
p
p
3
3
It is recommended to install the valve so that the flow is against
the closing direction to avoid water hammer.
Shock in the actuator must n
n
e
e
v
v
e
e
r
r
occur.
A
A
v
v
o
o
i
i
d
d
w
w
a
a
t
t
e
e
r
r
h
h
a
a
m
m
m
m
e
e
r
r
i
i
n
n
g
g
!
!
Inlet
Inlet
S
S
t
t
e
e
p
p
4
4
Avoid stressing the valve.
P
P
a
a
y
y
s
s
p
p
e
e
c
c
i
i
a
a
l
l
a
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t
t
e
e
n
n
t
t
i
i
o
o
n
n
t
t
o
o
:
:
- Vibrations.
- Thermal expansion of the pipelines.
- Excessive welding.
- Overloading of the pipelines.
R
R
i
i
s
s
k
k
o
o
f
f
d
d
a
a
m
m
a
a
g
g
e
e
!
!
10
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3 Installation
Study the instructions carefully.
The valve is supplied as separate parts to facilitate the welding.
The items refer to the parts list and service kits section.
Check the valve for smooth operation after welding.
3.3 Welding
S
S
t
t
e
e
p
p
1
1
A
A
l
l
w
w
a
a
y
y
s
s
install valves with more than one valve body so that the
seals between the valve bodies can be replaced. Do not weld
more than one valve body into the system.
Valve size A (inch) B (inch)
1” * 24.8
1½” * 27.6
2” * 29.5
2½” * 29.1
3” * 31.5
4” * 31.1
* Depending on body combination and piping solution.
B (incl. top unit)
A*
S
S
t
t
e
e
p
p
2
2
Assemble the valve in accordance with the steps on page 22.
P
P
a
a
y
y
s
s
p
p
e
e
c
c
i
i
a
a
l
l
a
a
t
t
t
t
e
e
n
n
t
t
i
i
o
o
n
n
t
t
o
o
t
t
h
h
e
e
w
w
a
a
r
r
n
n
i
i
n
n
g
g
s
s
!
!
S
S
t
t
e
e
p
p
3
3
P
P
r
r
e
e
-
-
u
u
s
s
e
e
c
c
h
h
e
e
c
c
k
k
:
:
1. Supply compressed air to the actuator.
2. Open and close the valve several times to ensure that it
operates smoothly.
P
P
a
a
y
y
s
s
p
p
e
e
c
c
i
i
a
a
l
l
a
a
t
t
t
t
e
e
n
n
t
t
i
i
o
o
n
n
t
t
o
o
t
t
h
h
e
e
w
w
a
a
r
r
n
n
i
i
n
n
g
g
s
s
!
!
Air
Air
Open/close!
11
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3 Installation
Study the instructions carefully.
The valve is supplied as separate parts to facilitate the welding.
The items refer to the parts list and service kits section.
Check the valve for smooth operation after welding.
3.4 Recycling information
•
•
U
U
n
n
p
p
a
a
c
c
k
k
i
i
n
n
g
g
- 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
•
•
M
M
a
a
i
i
n
n
t
t
e
e
n
n
a
a
n
n
c
c
e
e
- During maintenance oil and wear 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 wear parts must be taken care of in agreement with local regulations
•
•
S
S
c
c
r
r
a
a
p
p
p
p
i
i
n
n
g
g
- At end of use, the equipment shall be recycled according to relevant, local regulations. Beside 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 the local Alfa Laval sales company
12
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4 Operation
Study the instructions carefully and pay special attention to the warnings!
Ensure that the valve operates smoothly.
The items refer to the parts list and service kits section.
4.1 Operation
S
S
t
t
e
e
p
p
1
1
A
A
l
l
w
w
a
a
y
y
s
s
read the technical data thoroughly.
See chapter 6 Technical data
A
A
l
l
w
w
a
a
y
y
s
s
release compressed air after use.
C
C
A
A
U
U
T
T
I
I
O
O
N
N
Alfa Laval cannot be held responsible for incorrect operation.
S
S
t
t
e
e
p
p
2
2
N
N
e
e
v
v
e
e
r
r
touch the valve or the pipelines when processing hot liquids
or when sterilising. B
B
u
u
r
r
n
n
i
i
n
n
g
g
d
d
a
a
n
n
g
g
e
e
r
r
!
!
S
S
t
t
e
e
p
p
3
3
N
N
e
e
v
v
e
e
r
r
touch the moving parts if the actuator is supplied with
compressed air.
Air
M
M
o
o
v
v
i
i
n
n
g
g
p
p
a
a
r
r
t
t
s
s
!
!
Air
13
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4 Operation
Study the instructions carefully and pay special attention to the warnings!
Ensure that the valve operates smoothly.
The items refer to the parts list and service kits section.
S
S
t
t
e
e
p
p
4
4
L
L
u
u
b
b
r
r
i
i
c
c
a
a
t
t
i
i
o
o
n
n
o
o
f
f
v
v
a
a
l
l
v
v
e
e
s
s
:
:
1. Ensure smooth movement between lip seal (25) and
plug stem (23, 27).
2. Lubricate with Klüber Paraliq GTE 703 if necessary
(see section 4.1).
Shut-off valve Change-over valve
S
S
t
t
e
e
p
p
5
5
L
L
u
u
b
b
r
r
i
i
c
c
a
a
t
t
i
i
o
o
n
n
o
o
f
f
a
a
c
c
t
t
u
u
a
a
t
t
o
o
r
r
1. Ensure smooth movement of the actuator (the actuator is
lubricated before delivery).
2. Lubricate with Molykote Longterm 2 plus if necessary.
14
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4 Operation
Pay attention to possible faults. Study the instructions carefully.
The items refer to the parts list and service kits section.
4.2 Troubleshooting
N
N
O
O
T
T
E
E
!
!
Study the maintenance instructions carefully before replacing worn parts. - See section 4.1!
P
P
r
r
o
o
b
b
l
l
e
e
m
m
C
C
a
a
u
u
s
s
e
e
/
/
r
r
e
e
s
s
u
u
l
l
t
t
R
R
e
e
p
p
a
a
i
i
r
r
External product leakage Worn or product affected lip
seal and/or O-ring
- Replace the seals
- Replace with seals of a
different rubber grade
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
- Replace with a high pressure actuator
- Use auxiliary air on the spring side
(do not exceed 3 bar)
- Reduce product pressure
Water hammer The flow direction is the
same as the closing direction
- The flow direction should be
against the closing direction
- Throttle air release of solenoid in
top unit
The valve does not
open/close
Product pressure exceeds
actuator specification
- Replace with a high pressure actuator
- Use auxiliary air on the spring side
- Reduce product pressure
15
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4 Operation
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.
4.3 Recommended cleaning
S
S
t
t
e
e
p
p
1
1
A
A
l
l
w
w
a
a
y
y
s
s
handle lye and acid with great care.
C
C
a
a
u
u
s
s
t
t
i
i
c
c
d
d
a
a
n
n
g
g
e
e
r
r
!
!
A
A
l
l
w
w
a
a
y
y
s
s
use
rubber gloves!
A
A
l
l
w
w
a
a
y
y
s
s
use
protective goggles!
S
S
t
t
e
e
p
p
2
2
N
N
e
e
v
v
e
e
r
r
touch the valve or the pipelines when sterilising.
B
B
u
u
r
r
n
n
i
i
n
n
g
g
d
d
a
a
n
n
g
g
e
e
r
r
!
!
S
S
t
t
e
e
p
p
3
3
Clean the plug and the seats correctly.
P
P
a
a
y
y
s
s
p
p
e
e
c
c
i
i
a
a
l
l
a
a
t
t
t
t
e
e
n
n
t
t
i
i
o
o
n
n
t
t
o
o
t
t
h
h
e
e
w
w
a
a
r
r
n
n
i
i
n
n
g
g
s
s
!
!
L
L
i
i
f
f
t
t
a
a
n
n
d
d
l
l
o
o
w
w
e
e
r
r
v
v
a
a
l
l
v
v
e
e
p
p
l
l
u
u
g
g
m
m
o
o
m
m
e
e
n
n
t
t
a
a
r
r
i
i
l
l
y
y
!
!
Shut-off valve Change-over valve
S
S
t
t
e
e
p
p
4
4
E
E
x
x
a
a
m
m
p
p
l
l
e
e
s
s
o
o
f
f
c
c
l
l
e
e
a
a
n
n
i
i
n
n
g
g
a
a
g
g
e
e
n
n
t
t
s
s
:
:
Use clean water, free from clorides.
1. 1% by weight NaOH at 158oF
2.2 lb
NaOH +26.4 gal water =Cleaning agent.
+=
Cleaning agent.
0.6 gal
33% NaOH
26.4 gal
water
2. 0.5% by weight HNO3at 158oF
+=
Cleaning agent.
0.2 gal
53% HNO3
26.4 gal
water
16
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4 Operation
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.
S
S
t
t
e
e
p
p
5
5
1. Avoid excessive concentration of the cleaning agent.
2. Adjust the cleaning flow to the process.
3. A
A
l
l
w
w
a
a
y
y
s
s
rinse well with clean water after the cleaning.
A
A
l
l
w
w
a
a
y
y
s
s
r
r
i
i
n
n
s
s
e
e
!
!
Clean water Cleaning agents
S
S
t
t
e
e
p
p
6
6
N
N
O
O
T
T
E
E
The cleaning agents must be stored/disposed of in accordance
with current regulations/directives.
17
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5 Maintenance
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.
5.1 General maintenance
S
S
t
t
e
e
p
p
1
1
A
A
l
l
w
w
a
a
y
y
s
s
read the technical data thoroughly.
See chapter 5.
A
A
l
l
w
w
a
a
y
y
s
s
release compressed air after use.
N
N
O
O
T
T
E
E
All scrap must be stored/discharged in accordance
with current rules/directives.
S
S
t
t
e
e
p
p
2
2
N
N
e
e
v
v
e
e
r
r
service the valve when it is hot.
N
N
e
e
v
v
e
e
r
r
service the valve with valve and pipelines under pressure.
A
A
t
t
m
m
o
o
s
s
p
p
h
h
e
e
r
r
i
i
c
c
p
p
r
r
e
e
s
s
s
s
u
u
r
r
e
e
r
r
e
e
q
q
u
u
i
i
r
r
e
e
d
d
!
!
B
B
u
u
r
r
n
n
i
i
n
n
g
g
d
d
a
a
n
n
g
g
e
e
r
r
!
!
S
S
t
t
e
e
p
p
3
3
N
N
e
e
v
v
e
e
r
r
stick your fingers through the valve ports if the actuator is
supplied with compressed air.
Air
C
C
u
u
t
t
t
t
i
i
n
n
g
g
d
d
a
a
n
n
g
g
e
e
r
r
!
!
Air
S
S
t
t
e
e
p
p
4
4
N
N
e
e
v
v
e
e
r
r
touch the moving parts if the actuator is supplied with
compressed air.
Air
M
M
o
o
v
v
i
i
n
n
g
g
p
p
a
a
r
r
t
t
s
s
!
!
Air
18
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5 Maintenance
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.
B
B
e
e
l
l
o
o
w
w
a
a
r
r
e
e
s
s
o
o
m
m
e
e
g
g
u
u
i
i
d
d
e
e
l
l
i
i
n
n
e
e
s
s
f
f
o
o
r
r
m
m
a
a
i
i
n
n
t
t
e
e
n
n
a
a
n
n
c
c
e
e
a
a
n
n
d
d
l
l
u
u
b
b
r
r
i
i
c
c
a
a
t
t
i
i
o
o
n
n
i
i
n
n
t
t
e
e
r
r
v
v
a
a
l
l
s
s
.
.
P
P
l
l
e
e
a
a
s
s
e
e
n
n
o
o
t
t
e
e
t
t
h
h
a
a
t
t
t
t
h
h
e
e
g
g
u
u
i
i
d
d
e
e
l
l
i
i
n
n
e
e
s
s
a
a
r
r
e
e
f
f
o
o
r
r
n
n
o
o
r
r
m
m
a
a
l
l
w
w
o
o
r
r
k
k
i
i
n
n
g
g
c
c
o
o
n
n
d
d
i
i
t
t
i
i
o
o
n
n
s
s
i
i
n
n
o
o
n
n
e
e
s
s
h
h
i
i
f
f
t
t
.
.
P
P
r
r
o
o
d
d
u
u
c
c
t
t
w
w
e
e
t
t
t
t
e
e
d
d
s
s
e
e
a
a
l
l
s
s
A
A
c
c
t
t
u
u
a
a
t
t
o
o
r
r
b
b
u
u
s
s
h
h
i
i
n
n
g
g
s
s
c
c
o
o
m
m
p
p
l
l
e
e
t
t
e
e
Preventive
maintenance
R
R
e
e
p
p
l
l
a
a
c
c
e
e
a
a
f
f
t
t
e
e
r
r
1
1
2
2
m
m
o
o
n
n
t
t
h
h
s
s
d
d
e
e
p
p
e
e
n
n
d
d
i
i
n
n
g
g
o
o
n
n
w
w
o
o
r
r
k
k
i
i
n
n
g
g
c
c
o
o
n
n
d
d
i
i
t
t
i
i
o
o
n
n
s
s
R
R
e
e
p
p
l
l
a
a
c
c
e
e
a
a
f
f
t
t
e
e
r
r
5
5
y
y
e
e
a
a
r
r
s
s
d
d
e
e
p
p
e
e
n
n
d
d
i
i
n
n
g
g
o
o
n
n
w
w
o
o
r
r
k
k
i
i
n
n
g
g
c
c
o
o
n
n
d
d
i
i
t
t
i
i
o
o
n
n
s
s
Maintenance after
leakage (leakage
normally starts slowly)
R
R
e
e
p
p
l
l
a
a
c
c
e
e
a
a
t
t
t
t
h
h
e
e
e
e
n
n
d
d
o
o
f
f
t
t
h
h
e
e
d
d
a
a
y
y
R
R
e
e
p
p
l
l
a
a
c
c
e
e
w
w
h
h
e
e
n
n
p
p
o
o
s
s
s
s
i
i
b
b
l
l
e
e
Planned
maintenance
- Regular inspection
for leakage and
smooth operation
- Keep a record of
the valve
- Use the statistics for
planning of inspections
R
R
e
e
p
p
l
l
a
a
c
c
e
e
a
a
f
f
t
t
e
e
r
r
l
l
e
e
a
a
k
k
a
a
g
g
e
e
- Regular inspection
for leakage and
smooth operation
- Keep a record of
the actuator
- Use the statistics for
planning of inspections
R
R
e
e
p
p
l
l
a
a
c
c
e
e
a
a
f
f
t
t
e
e
r
r
l
l
e
e
a
a
k
k
a
a
g
g
e
e
Lubrication
B
B
e
e
f
f
o
o
r
r
e
e
f
f
i
i
t
t
t
t
i
i
n
n
g
g
Klüber Paraliq GTE 703
or similar USDA H1
approved oil/grease
B
B
e
e
f
f
o
o
r
r
e
e
f
f
i
i
t
t
t
t
i
i
n
n
g
g
Molykote Longterm 2 plus
P
P
r
r
e
e
-
-
u
u
s
s
e
e
c
c
h
h
e
e
c
c
k
k
:
:
Air
Open/close!
Air
1. Supply compressed air to the actuator.
2. Open and close the valve several times to
ensure that it operates smoothly.
P
P
a
a
y
y
s
s
p
p
e
e
c
c
i
i
a
a
l
l
a
a
t
t
t
t
e
e
n
n
t
t
i
i
o
o
n
n
t
t
o
o
t
t
h
h
e
e
w
w
a
a
r
r
n
n
i
i
n
n
g
g
s
s
!
!
R
R
e
e
c
c
o
o
m
m
m
m
e
e
n
n
d
d
e
e
d
d
s
s
p
p
a
a
r
r
e
e
p
p
a
a
r
r
t
t
s
s
Service kits (see page 25)
19
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5 Maintenance
Study the instructions carefully. The items refer to the parts list and service kits section. Handle scrap correctly.
NC = Normally closed.
NO = Normally open.
A/A = Air/air activated.
5.2 Dismantling the valve
S
S
t
t
e
e
p
p
1
1
1
1
a
a
S
S
h
h
u
u
t
t
-
-
o
o
f
f
f
f
v
v
a
a
l
l
v
v
e
e
:
:
1. Supply compressed air to the actuator (only NC).
2. Loosen and remove clamp.
3. Release compressed air (only NC).
4. Lift away the actuator.
5. Unscrew and remove valve plug.
6. Remove O-ring, lip seal and bushing in bonnet.
(Use bushing tool and rubber mallet).
N
N
o
o
t
t
e
e
!
!
Be careful not to damage the bushing.
P
P
a
a
y
y
s
s
p
p
e
e
c
c
i
i
a
a
l
l
a
a
t
t
t
t
e
e
n
n
t
t
i
i
o
o
n
n
t
t
o
o
t
t
h
h
e
e
w
w
a
a
r
r
n
n
i
i
n
n
g
g
s
s
!
!
TD 461-959
N
N
o
o
t
t
e
e
!
!
Be careful not to damage the
bushing.
N
N
o
o
t
t
e
e
!
!
For plug seal replacement please see page 21.
1
1
b
b
C
C
h
h
a
a
n
n
g
g
e
e
-
-
o
o
v
v
e
e
r
r
v
v
a
a
l
l
v
v
e
e
:
:
1. Supply compressed air to the actuator (only NC).
2. Loosen and remove lower clamp.
3. Release compressed air (only NC).
4. Lift away the actuator and upper valve body.
5. Supply compressed air to the actuator (only NO).
6. Unscrew and remove valve plug.
7. Release compressed air (only NO).
8. Remove seat and O-rings.
9. Loosen and remove upper clamp.
10. Remove upper valve body.
11. Remove O-ring, lip seal and bushing in bonnet.
(Use bushing tool and rubber mallet.
See drawing, step 1a).
N
N
o
o
t
t
e
e
!
!
Be careful not to damage the bushing.
P
P
a
a
y
y
s
s
p
p
e
e
c
c
i
i
a
a
l
l
a
a
t
t
t
t
e
e
n
n
t
t
i
i
o
o
n
n
t
t
o
o
t
t
h
h
e
e
w
w
a
a
r
r
n
n
i
i
n
n
g
g
s
s
!
!
N
N
o
o
t
t
e
e
!
!
For plug seal replacement please see page 21.
UP
TD 461-331_1
1
1
c
c
S
S
h
h
u
u
t
t
-
-
o
o
f
f
f
f
v
v
a
a
l
l
v
v
e
e
-
-
R
R
e
e
v
v
e
e
r
r
s
s
e
e
A
A
c
c
t
t
i
i
n
n
g
g
:
:
1. Loosen and remove lower clamp.
2. Remove lower bonnet and O-ring from lower body.
3. Loosen and remove middle clamp.
4. Lift away the actuator and upper valve body.
5. Supply compressed air to the actuator (only NC).
6. Unscrew and remove valve plug.
7. Release compressed air (only NC).
8. Remove seat and O-rings.
9. Loosen and remove upper clamp.
10. Remove upper valve body.
11. Remove O-ring, lip seal and bushing in bonnet.
(Use bushing tool and rubber mallet.
See drawing, step 1a).
N
N
o
o
t
t
e
e
!
!
Be careful not to damage the bushing.
P
P
a
a
y
y
s
s
p
p
e
e
c
c
i
i
a
a
l
l
a
a
t
t
t
t
e
e
n
n
t
t
i
i
o
o
n
n
t
t
o
o
t
t
h
h
e
e
w
w
a
a
r
r
n
n
i
i
n
n
g
g
s
s
!
!
N
N
o
o
t
t
e
e
!
!
For plug seal replacement please see page 21.
UP
UP
TD 462-127_1
20
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5 Maintenance
Study the instructions carefully. The items refer to the parts list and service kits section. Handle scrap correctly.
NC = Normally closed.
NO = Normally open.
A/A = Air/air activated.
1
1
d
d
C
C
h
h
a
a
n
n
g
g
e
e
-
-
o
o
v
v
e
e
r
r
v
v
a
a
l
l
v
v
e
e
-
-
R
R
e
e
v
v
e
e
r
r
s
s
e
e
A
A
c
c
t
t
i
i
n
n
g
g
:
:
1. Loosen and remove lower clamp.
2. Remove lower bonnet and O-ring.
3. Loosen and remove clamp between lower and middle
valve body
4. Lift away the actuator and upper + middle valve body.
5. Supply compressed air to the actuator (only NC).
6. Unscrew and remove lower valve plug.
7. Release compressed air (only NC).
8. Remove lower seat and O-rings.
9. Supply compressed air to the actuator (only NO).
10. Loosen and remove clamp between middle and upper
valve body.
11. Remove middle valve body and upper seat with O-rings.
12. Release compressed air (only NO).
13. Loosen and remove upper clamp.
14. Remove upper valve body.
15. Unscrew and remove upper valve plug.
16. Remove O-ring, lip seal and bushing in bonnet.
(Use bushing tool and rubber mallet. See drawing, step
1a).
N
N
o
o
t
t
e
e
!
!
Be careful not to damage the bushing.
P
P
a
a
y
y
s
s
p
p
e
e
c
c
i
i
a
a
l
l
a
a
t
t
t
t
e
e
n
n
t
t
i
i
o
o
n
n
t
t
o
o
t
t
h
h
e
e
w
w
a
a
r
r
n
n
i
i
n
n
g
g
s
s
!
!
N
N
o
o
t
t
e
e
!
!
For plug seal replacement please see page 21.
UP
UP
UP TD 462-128_1
5.3 Elastomer seat ring replacement
1. Remove old seal ring using a knife, screwdriver or similar.
Be careful not to damage metal parts.
2. Pre-mount plug seal without pressing it into the groove.
3. Squeeze plug seal into the groove using opposite pressure points.
4. Release compressed air behind plug seal.
1
4
3
2TD461309_3
1. Place the plug element on a firm support.
2. Using a utility knife, partially AND CAREFULLY cut through the upper ring
portion of the TR2 plug avoiding contact with stainless steel stem.
3. Force apart both cut ends of the plug for removal from stem.
4. TR2 plugs are installed by applying uniform pressure on all sides.
(Pressure can be applied by using the seat assembly tool.)
5. Using a piece of metal and a rubber mallet, place a precise tab to make
the TR2
plug snap on to the stem. Reverse the tool and tab again to secure
proper fit.
6. Examine seat assembly to be sure the TR2 plug is properly mounted,
holding the seat assembly in one hand - rotate the TR2 plug.
(For proper CIP cleaning the TR2 plug should turn freely on the stem.)
For more explicit instructions, please refer to the maintenance video.
21
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