Alfalaval Unique Sampling Valve User manual

2900-0140
ESE02433-EN2 2013-10
Original manual
Instruction Manual
Unique Sampling Valve - Accessories - Steam Generator

Table of contents
The information herein is correct at the time of issue but may be subject to change without prior notice
1. Safety .................................................................................................... 4
1.1. Important information ............................................................................. 4
1.2. Warning signs ..................................................................................... 4
1.3. Safety precautions ................................................................................ 5
2. Installation .............................................................................................. 6
2.1. Unpacking/delivery ............................................................................... 6
2.2. Recycling information ............................................................................. 6
3. Operation ............................................................................................... 7
3.1. Operation .......................................................................................... 7
3.2. Troubleshooting ................................................................................... 10
3.3. Recommended cleaning ......................................................................... 10
4. Maintenance ........................................................................................... 11
4.1. General maintenance ............................................................................. 11
5. Technical data ......................................................................................... 12
5.1. Technical data ..................................................................................... 12
6. Parts list and service kit .............................................................................. 14
6.1. Steam generator .................................................................................. 14
3

1 Safety
Unsafe practices and other important information are emphasised in this manual.
Warnings are emphasised by means of special signs.
1.1 Important information
Always read the manual before using the Steam Generator!
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 Steam Generator.
NOTE
Indicates important information to simplify or clarify procedures.
1.2 Warning signs
General warning:
Caustic agents:
4

1 Safety
All warnings in the manual are summarised on this page.
Pay special attention to the instructions below so that serious personal injury and/or damage to the Steam Generator
are avoided.
1.3 Safety precautions
Installation:
Always read the technical data thoroughly. (See chapter 5 Technical data)
Always release compressed air after use.
Never touch moving parts if the actuator is supplied with compressed air.
Never touch the Steam Generator or the pipelines when processing hot liquids or when sterilising.
Never dismantle the Steam Generator while it is under pressure.
Never dismantle the Steam Generator when it is hot.
Operation:
Never dismantle the Steam Generator while it is under pressure.
Never dismantle the Steam Generator when it is hot.
Always read the technical data thoroughly. (See chapter 5 Technical data)
Always release compressed air after use.
Never touch the Steam Generator or the pipelines when processing hot liquids or when sterilising.
Never touch the 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 chapter 5 Technical data)
Always release compressed air after use.
Never service the Steam Generator when it is hot.
Never service the Steam Generator with the valve and pipelines under pressure.
Transportation:
Always make sure that all connections are disconnected before attempting to remove the Steam Generator from the
installation.
Always drain liquid from the Steam Generator before transportation.
5

2 Installation
This instruction manual is part of the delivery. Study the instructions carefully and pay special attention to the warnings!
The items refer to the parts list and service kits section.
2.1 Unpacking/delivery
Step 1
CAUTION
Alfa Laval cannot be held responsible for incorrect unpacking.
Check the delivery for:
1. Steam Generator
2. Instruction manual
Note: the gas canister is not included.
The gas canister can be purchased from the local
hardware store (diameter: Ø110 mm)
Step 2
Remove any possible packing materials from the Steam Generator.
Inspect the Steam Generator for visible transport damage.
Avoid damaging the Steam Generator.
2.2 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 or defective electronic parts should be sent to a licensed handler for material recycling.
- Oil and all non-metal wearing parts must be dealt with in accordance with local regulations.
• Scrapping
- At the end of use, the equipment should be recycled according to the relevant, local regulations. As well as 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.
6

3Operation
Study the instructions carefully and pay special attention to the warnings!
Ensure that the Steam Generator operates smoothly.
The items refer to the parts list and service kits section.
3.1 Operation
Step 1
Always read the technical data thoroughly.
See chapter 5 Technical data
CAUTION
Alfa Laval cannot be held responsible for incorrect operation.
Never touch the Steam Generator or the pipelines when
processing hot liquids or when sterilising.
Attention:
Before using the Steam Generator, it is essential that a non-return
valve* (N) and a pressure relief valve* (P) are mounted on the
sampling valve to ensure proper sterilisation.
*= not included in this package
N: Non-return valve
- Sizes 4 and 10: 9614-1955-01
- Size 25: 9614-1955-04
C: Clamp ring
- Sizes 4 and 10: 211290
- Size 25: 211053
S: Clamp seal
- Sizes 4 and 10: 290273
- Size 25: 9611-99-2012
P: Pressure relief valve
- Sizes 4 and 10: 9614-1957-01
- Size 25: 9614-1957-02
P1: Steam outlet
P2: Quick release of steam
C
P
P2
P1
N
S
2900-0141
Step 2
1. Make sure that the sampling valve is in closed position (single
seat) or in steam position (double seat), before steaming
2. Pull the front handle (A) forwards and mount the steam
generator pistol on the non-return valve (B).
Note: do not activate the handle (G) yet.
2900-0142
B
A
G
7

3Operation
Study the instructions carefully and pay special attention to the warnings!
Ensure that the Steam Generator operates smoothly.
The items refer to the parts list and service kits section.
Step 3
1. Unscrew the tank cap (C) and fill the tank with water (maximum
volume is 1L)
2. Mount the tank cap (C) (tighten by hand)
B = Sight glass for water level
C
B
2900-0143
Step 4
1. Open the gas valve (D).
2. Press and hold the safety valve (E) while pressing the ignition
switch (F). Release the safety valve (E) 5 seconds after the
flame is initiated.
3. Wait until the tank pressure reaches 3 bars.
D
2900-0144
F
E
8

3Operation
Study the instructions carefully and pay special attention to the warnings!
Ensure that the Steam Generator operates smoothly.
The items refer to the parts list and service kits section.
Step 5
1. Activate the gun by pulling the inner handle (G). Slide the pawl
(H) forwards to ensure that handle can hold it’s self.
2. Steam the sampling valve for 2 minutes.
NB: make sure that steam is present at the steam outlet (P1)
on the pressure relief valve (P) doing the 2-minutes steaming.
3. Shut the gun off by sliding back the pawl (H).
P
2900-0145
P2
P1
G
H
Step 6
1. Turn off the gas valve (D).
2. Release the enclosed steam by pulling the handle (P2) on the
Pressure relief valve (P).
3. Remove the gun from the non-return valve. The sampling valve
is now sterilised and ready to take a representative sample.
Note:
the tank cap cannot be opened until all the pressure in the tank
has been released.
2900-0146
D
P2
P
9

3Operation
Study the instructions carefully and pay special attention to the warnings!
Ensure that the Steam Generator operates smoothly.
The items refer to the parts list and service kits section.
3.2 Troubleshooting
NOTE!
Study the maintenance instructions carefully before replacing worn parts.
Problem Cause Remedy
Thegasvalveisc
losed Open the gas valve
Gas cannot be ignited The gas container is empty Replace the gas container
Thepistolhandleisopenandnot
mounted on the sampling valve Mount the pistol handle on the sampling
valve
Thegasvalveisnotfullyopen Open the gas valve fully
The steam pressure cannot exceed 1 bar
The gas container is almost empty Replace the gas container
3.3 Recommended cleaning
Step 1
The Steam Generator can be cleaned using warm water.
We recommend that the water container on the steam generator is emptied after use.
10

4 Maintenance
Maintain the Steam Generator regularly.
Study the instructions carefully and pay special attention to the warnings!
Check the Steam Generator for smooth operation after service.
4.1 General maintenance
Maintenance Action
Regular inspection for leakage and smooth operation
Keep a record of the Steam Generator
Planned maintenance
Use the statistics for inspection planning
Recommended spare parts
Service kits (see section 6 Parts list and service kit)
11

5 Technical data
It is important to observe the technical data during installation, operation and maintenance.
Inform personnel about the technical data.
5.1 Technical data
Attention!
Never touch the Steam Generator or the pipelines when processing hot liquids or when
sterilising.
Never service the Steam Generator when it is hot.
Danger of burns!
Technical data
Max. working pressure 350 kPa (3.5 bar)
Max. working temperature 130 °C
Weight 12 kg
Capacity
Tank volume 1.1 L
Total steam time (full tank, 2 bar) 15 mins.
Steam time for sterilisation (2 bar) 2mins.
Start-up time (full tank) 10-12 mins.
Materials
Water container and pipes 1.4404 (316L)
Steam hose Inside: NBR food grade Outside: NBR/PVC
Pistol handle Brass
Other parts PA 6.6 30% GF, aluminium, copper
Spare parts
Spare parts See section 6 Parts list and service kit
12

.
13

6 Parts list and service kit
It is important to observe the technical data during installation, operation and maintenance.
Inform personnel about the technical data.
6.1 Steam generator
6
4
1
2
3
3
2
7
2900-0148_1
5
17
2900-0151_1
14
15
16
19
18 2900-0171
29
10
9
8
2900-0149_1
2900-0152_1
27 26
25
28
20
21 22 23
24
2900-0172
10
31
10
30
13
11
12
2900-0150_1
27.7
27.6
27.5
27.4
27.3
27.2
27.1
2900-0170
14

6 Parts list and service kit
It is important to observe the technical data during installation, operation and maintenance.
Inform personnel about the technical data.
Parts list
Pos. Qty Denomination
11
Base plate
24Rubber bumpers
34
Screw
41
Gas bracket
51 Jet nozzle
61Gas burner
71Nut
81Heat shield assembly
96
Screw
10 10 Distance piece
11 1 Flame failure valve
12 1Thermocouple
13 1Nut
14 1 Adaptor
15 1 Adaptor
16 1Gas regulator
17 2Nut
18 1Cable glands
19 1Spark electrode
20 1Vessel assembly
21 1Gasket
22 1 Sight glass
23 1 Frame for glass
24 6 Screw
25 1Cross fitting
26 1Adaptor
27 1Pressure relief valve assembly
27.1 1 - Pipe
27.2 1 - Valve housing
27.3 1-Plug
27.4 1-Spring
27.5 1 -O-ring
27.6 1 - Pipe end
27.7 1-Nut
28 1Hose connection
29 2 Screw
30 1Heat shield top
31 14 Screw
15

6 Parts list and service kit
It is important to observe the technical data during installation, operation and maintenance.
Inform personnel about the technical data.
31
32
31
33
2900-0173
39
41
40
2900-0176
37
36
34
35
2900-0174
2900-0177
40.5
40.4
40.3
40.2
40.1
31
38
31
2900-0175
42
2900-0178
16

6 Parts list and service kit
It is important to observe the technical data during installation, operation and maintenance.
Inform personnel about the technical data.
Parts list
Pos. Qty Denomination
31 14 Screw
32 1 Plate
33 1Plate
34 1Top plate
35 1Handle
36 1 Ingiter
37 2 Screw
38 1Nut
39 1Manometer
40 1 Hose assembly
40.1 1-Handle
40.2 1- Hose connection
40.3 1-Cover
40.4 1-Steamhose
40.5 1 -Cover
41 1 Safety cap
42 1 O-ring
43 1 Sticker
17

How to contact Alfa Laval
Contact details for all countries are
continually updated on our website.
Please visit www.alfalaval.com to access the information directly.
© Alfa Laval Corporate AB
This document and its contents is owned by Alfa Laval Corporate AB and protected by laws governing intellectual property and thereto related rights. It is the responsibility of the user of this
document to comply with all applicable intellectual property laws. Without limiting any rights related to this document, no part of this document may be copied, reproduced or transmitted in any
form or by any means (electronic, mechanical, photocopying, recording, or otherwise), or for any purpose, without the expressed permission of Alfa Laval Corporate AB. Alfa Laval Corporate AB
will enforce its rights related to this document to the fullest extent of the law, including the seeking of criminal prosecution.