Alfa Laval Aseptic Mixproof Series Instruction Manual Download Page 3

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Table of contents

The information herein is correct at the time of issue but may be subject to change without prior notice

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Safety . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .

2.1. Important information .. . . . .. . . . . .. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .

2.2. Warning signs

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2.3. Safety precautions

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Installation

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3.1. Unpacking/delivery

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3.2. General installation . . . .. . . . .. . . . . .. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .

3.3. Welding

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3.4. Recycling information .. . . . .. . . . . .. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .

Operation

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4.1. Operation

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4.2. Trouble shooting

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4.3. Recommended cleaning

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Maintenance

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5.1. General maintenance .. . . . .. . . . . .. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .

5.2. Dismantling shut-off valve .. . . . . .. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . .. . . . . .

5.3. Dismantling change-over valve

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5.4. Plug seal replacement . . . . .. . . . . .. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .

5.5. Assembly of shut-off valve

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5.6. Assembly of change-over valve

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5.7. Dismantling of fully maintainable actuator

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5.8. Mounting of fully maintainable actuator . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . .. . . . . .

5.9. Changing pneumatic movement on fully maintainable actuator (NC/NO)

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Technical data

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6.1. Technical data

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Parts list and service kits

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7.1. Valve overviev

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7.2. Actuators, primary valves (no seat lift)

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7.3. Actuators, primary valves (with seat lift)

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7.4. Actuators, secondary valves . . . .. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . .. . . . . .

7.5. Plugs, primary valves

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7.6. Plugs, secondary valves

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7.7. Clamp, bonnet and body, primary valves . . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . .. . . . . .

7.8. Clamp, bonnet and body, secondary valves

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Summary of Contents for Aseptic Mixproof Series

Page 1: ...2321 0035 100000827 EN2 2019 07 Original manual Instruction Manual Aseptic Mixproof Valve...

Page 2: ......

Page 3: ...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 actuat...

Page 4: ...onformity 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...

Page 5: ...rmation 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 foll...

Page 6: ...event 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...

Page 7: ...ve 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 ha...

Page 8: ...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 t...

Page 9: ...ery 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 conn...

Page 10: ...aphragm 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 Uppe...

Page 11: ...SASSEMBLE 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 o...

Page 12: ...cial attention to the warnings Step 4 Always check if the diaphragm is tight it can be dangerous if it leaks steam CIP The hose must be a 4 mm 1 6 hose for 25 and a 6 mm 1 4 hose for larger types To a...

Page 13: ...ng 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...

Page 14: ...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 3 bar support air 2321 00...

Page 15: ...cling 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 regulati...

Page 16: ...are parts 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 SPR...

Page 17: ...mooth movement between lip seal A and plug stem B 2 Lubricate the lip seal with Kl ber Paraliq GTE 703 if necessary Shut off valve Change over valve A B 2321 0068 A B 2321 0069 Step 5 Lubrication of a...

Page 18: ...y precautions Reduce product pressure Water hammer The flow direction is the same as the closing direction The flow direction should be against the closing direction See section 3 2 General installati...

Page 19: ...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...

Page 20: ...free from chlorides 1 1 by weight NaOH at 70o C 2 0 5 by weight HNO3 at 70o C 1 kg 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 St...

Page 21: ...of the leakage outlet Sterilization before production No seat lift 2321 0080 A B C A From UHT plant Water 135 C B Steam inlet 3 bar C To sterile tank steam 3 bar Sterilization before production subse...

Page 22: ...uction subsequence Seat lift lower 2321 0082 A B C A From UHT plant Water 135 C B Steam inlet 3 bar C To sterile tank steam 3 bar Open valve Production 2321 0083 A B C A From UHT B Steam inlet 1 2 bar...

Page 23: ...in the valve is externally visible by means of the leakage outlet Closed valve UHT sterile CIP 2321 0084 A B C A UHT plant Sterile CIP B Steam inlet 1 2 bar C Sterile tank Tank standby Closed valve St...

Page 24: ...Standard CIP UHT 2321 0086 A C B A CIP of line from UHT plant valve open in order to create turbulence for cleaning leakage chamber B Both leakage chamber valves closed C Sterile tank idle Standard CI...

Page 25: ...rnal leakage in the valve is externally visible by means of the leakage outlet Standard CIP Sterile tank subsequence seat lift 2321 0088 B C A A Line from UHT plant not sterile B CIP forward taken fro...

Page 26: ...d air after use Always read the technical data thoroughly See section 6 1 Technical data Always use Alfa Laval genuine spare parts The warranty of Alfa Laval products is dependent on use of Alfa Laval...

Page 27: ...orking conditions Maintenance after leakage leakage normally starts slowly Replace at the end of the day Replace when possible Planned maintenance Regular inspection for leakage and smooth operation K...

Page 28: ...r is marked with a danger warning do NOT attempt to cut the actuator open DO NOT DISASSEMBLE kg SPRING UNDER LOAD Do not attempt to cut open kg Do NOT attempt to disassemble the actuator due to spring...

Page 29: ...bber seals lip seals and diaphagms in stock Check the valve for smooth operation after servicing Step 1 1 Move the plug in top position 2 Remove the air drain hose 3 Ensure pipe is empty and not press...

Page 30: ...arts Always keep spare rubber seals lip seals and diaphagms in stock Check the valve for smooth operation after servicing Step 3 Remove the bonnet 2321 0094 Step 4 Loosen the plug from the spindle by...

Page 31: ...ng 5 3 Dismantling change over valve A Spindle B Bonnet C Disc D Diaphragm E Clamp F Upper valve body G Seat H Change over plug J Lower valve body D C B E J H G E F A 2205 0018 UP Step 1 When dismount...

Page 32: ...and diaphagms in stock Check the valve for smooth operation after servicing IMPORTANT The mechanical stop is in lower body To adoid overstretching the diaphragm the lower body clamp must not be loosen...

Page 33: ...ays keep spare rubber seals lip seals and diaphagms in stock Check the valve for smooth operation after servicing INCORRECT assembling and disassembling of Aseptic Mixproof Valve change over valve A U...

Page 34: ...upper position before loosing the upper clamp B Remove the air drain hose Ensure pipe is empty and not pressurized C ALWAYS start with dismounting the upper clamp to avoid damaging the diaphragm IMPOR...

Page 35: ...p seals and diaphagms in stock Check the valve for smooth operation after servicing Step 4 Loosen the spindle from the actuator Use 17 mm spanners Ensure actuator stem is in lower position Now the plu...

Page 36: ...lfa Laval genuine spare parts Always keep spare rubber seals lip seals and diaphagms in stock Check the valve for smooth operation after servicing Step 6 Dismount spindle from the plug NOTE The leakag...

Page 37: ...eck the valve for smooth operation after servicing Step 8 Dismount seat from the plug Remember to replace o rings in the seat and the plug 2321 0110 Step 9 Remove bonnet from upper valve body To do th...

Page 38: ...e for smooth operation after servicing Step 10 NOTE It is also possible to use a screw driver between the bonnet and valve There is an opening marked in the bonnet where the screw driver can be fitted...

Page 39: ...face If using a screwdriver it must be placed underneath the plug groove see drawing 1 2 Grease the new seal ring with Paralique GTE 703 which is included in the service kit Only use a very small amou...

Page 40: ...ints from A to B to C and D see drawing 3 The rest of the seal ring can now be pressed into the groove so the whole seal ring is mounted Check that there are NO bulge see drawing 4 If there is a littl...

Page 41: ...n be used for two plug sizes e g plug tool 9614060003 The upper exhaust hole is for the small plug size e g ISO51 small and the lower exhaust hole is for ISO63 large When using a change over plug the...

Page 42: ...lways use Alfa Laval genuine spare parts Always keep spare rubber seals lip seals and diaphagms in stock Check the valve for smooth operation after servicing Drawing 1 Drawing 2 A B 2321 0121 A B 2321...

Page 43: ...seals and diaphagms in stock Check the valve for smooth operation after servicing 5 5 Assembly of shut off valve Step 1 Before mounting all parts must be cleaned A Actuator B Spindle C Bonnet D Disc E...

Page 44: ...nd diaphagms in stock Check the valve for smooth operation after servicing Step 4 Mount spindle 2321 0127 Step 5 Tighten spindle and plug with 51 mm 2 to 76 1 mm 3 with torque 33 Nm 25 mm 1 with torqu...

Page 45: ...bonnet on spindle and fit diaphragm Press only with the fingers to avoid scrates on diaphragm Be sure that diaphragm is correctly fitted on the round edge on the bonnet NOTE Make sure that the diaphr...

Page 46: ...e friction when diaphragm is pressed into the valve body Make sure that the actuator stem is in lower position as this makes it easiest to fit diaphragm into the valve body Mount actuator type NC with...

Page 47: ...for smooth operation after servicing Step 13 Mount the clamp make sure it is located correctly Tighten with a 10mm spanner Torque 10 12 Nm Grease the thread with Molykote Place a hose in the fitting i...

Page 48: ...te on the bonnets round edge before mounting the diaphragm This makes it much easier to mount diaphragm correctly 2321 0128 Step 2 Mount the disc in the bonnet with the plane disc side towards the bon...

Page 49: ...peration after servicing Step 4 We strongly recommend to use grease Paraliq GTE 703 on the edges of the upper valve body to ensure that the diaphragm is mounted correctly The sealing surface must be c...

Page 50: ...stock Check the valve for smooth operation after servicing Step 7 Place the seat on the plug Remember to mount new O rings in the seat and plug 2321 0139 Step 8 Use a little amount of Loctite 243 on...

Page 51: ...keep spare rubber seals lip seals and diaphagms in stock Check the valve for smooth operation after servicing Step 9 Mount upper valve body onto the plug seat 2321 0141 UP Step 10 Assemble spindle and...

Page 52: ...1 Tighten the spindle and plug Use 17 mm spanners It is easiest to use a vice Tighten valve size 51 mm 2 to 76 1 mm 3 with torque 33 Nm Tighten valve size 25 mm 1 with torque 17 Nm 2321 0106 2321 0107...

Page 53: ...in stock Check the valve for smooth operation after servicing Step 13 Tighten the actuator stem and plug Use 17 mm spanners Tighten valve size 51mm 2 to 76 1 mm 3 with torque 33 Nm Tighten valve size...

Page 54: ...ntion to the warnings Always use Alfa Laval genuine spare parts Always keep spare rubber seals lip seals and diaphagms in stock Check the valve for smooth operation after servicing Step 15 Ensure that...

Page 55: ...smooth operation after servicing Step 16 CORRECT assembling and disassembling to avoid destroying stretching diaphragm IMPORTANT The mechanical stop is in lower body To adoid overstretching the diaphr...

Page 56: ...ixproof Valve change over valve A Upper clamp still mounted which is wrong B Lower clamp dismounted C The plug is overstreching the diaphragm as it moves 10 mm further downwards Lower clamp dismounted...

Page 57: ...amp and tighten torque 10 12 Nm IMPORTANT Please remember NOT to dismount the lower clamp unless plug stays in the upper position as diaphragm will be destroyed if plug moves downwards also see Step 1...

Page 58: ...rked with a danger warning do NOT attempt to cut the actuator open DO NOT DISASSEMBLE kg SPRING UNDER LOAD Do not attempt to cut open kg Do NOT attempt to disassemble the actuator due to spring under...

Page 59: ...nd diaphagms in stock Check the valve for smooth operation after servicing 5 8 Mounting of fully maintainable actuator NOTE Depending on type of actuator choose step 1 or step 2 Step 1 1 Reverse order...

Page 60: ...OT attempt to cut the actuator open DO NOT DISASSEMBLE kg 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 attempt to c...

Page 61: ...t pressure Full vacuum Max sterilisation temperature steam short time 150o C 302o F at pressure 380 kPa 3 8 bar 55 psi Temperature range 10o C to 140o C 14 to 284 oF standard EPDM seal Air pressure ac...

Page 62: ...aintenance Inform all personnel about the technical data 7 1 Valve overviev Actuator primary valves no seat lift Plugs primary valves 2321 0036 2321 0039 Actuator primary valves with seat lift Plugs s...

Page 63: ...important to observe the technical data during installation operation and maintenance Inform all personnel about the technical data 7 2 Actuators primary valves no seat lift 2321 0036 5 6 8 7 9 3 1 1...

Page 64: ...Actuator 1 1 Cylinder 2 1 Piston 3 1 O ring 5 1 Adapter 6 2 Bushing 7 2 O ring 8 2 O ring 9 1 Plug air vent 10 1 Lock wire 11 1 O ring 12 1 2 Air fitting 13 1 Yoke 14 1 Spring assembly Service kits D...

Page 65: ...rve the technical data during installation operation and maintenance Inform all personnel about the technical data 7 3 Actuators primary valves with seat lift 2321 0037 2321 0043 5 6 7 8 10 12 9 1 9 3...

Page 66: ...8 1 O ring 9 1 Plug air vent 9 1 1 Plug 10 1 Lock wire 11 1 O ring 12 2 3 Air fitting 13 1 Yoke 14 1 Spring assembly 16 1 Support disc 52 1 Piston 53 1 Thrust plate 54 1 Guide 55 1 Nut 56 3 Spacer 57...

Page 67: ...It is important to observe the technical data during installation operation and maintenance Inform all personnel about the technical data 7 4 Actuators secondary valves 2321 0038 5 6 8 7 9 3 1 10 14...

Page 68: ...Qty Denomination 1 Actuator 1 1 Cylinder 2 1 Piston 3 1 O ring 5 1 Adapter 6 2 Bushing 7 2 O ring 8 2 O ring 9 1 Plug 10 1 Lock wire 11 1 O ring 12 1 2 Air fitting 13 1 Yoke 14 1 Spring assembly Serv...

Page 69: ...rvice kits It is important to observe the technical data during installation operation and maintenance Inform all personnel about the technical data 7 5 Plugs primary valves 2321 0039 2321 0079 31 23...

Page 70: ...hnical data Parts list Pos Qty Denomination 23 1 Plug 23 1 1 Plug 23 2 1 Plug seal 29 1 Diaphragm 30 1 Disc for diaphragm 31 1 Upper spindle Service kits Denomination 51 mm 63 5 mm 76 mm Service kit p...

Page 71: ...tenance Inform all personnel about the technical data 7 6 Plugs secondary valves 2321 0040 Hygienic plugs shut off Hygienic plugs change over 23 1 23 2 2321 0045 23 2321 0046 27 27 2 27 2 27 1 Aseptic...

Page 72: ...Plug 27 2 2 Plug seal 29 1 Diaphragm 30 1 Disc for diaphragm 31 1 Upper spindle Service kits Denomination Hygienic plugs shut off Hygienic plugs change over Aseptic plugs shut off Aseptic plugs change...

Page 73: ...chnical data during installation operation and maintenance Inform all personnel about the technical data 7 7 Clamp bonnet and body primary valves 2321 0075 Vertical mount Horizontal mount 19 22 24 20...

Page 74: ...Denomination 19 2 Clamp 20 2 Bonnet 22 1 Valve body 24 2 Bushing 32 2 Air fitting 117 1 Temperature sensor transmitter accessories 1 Temperature sensor accessories 1 Transmitter accessories 1 Tempera...

Page 75: ...during installation operation and maintenance Inform all personnel about the technical data 7 8 Clamp bonnet and body secondary valves 2321 0072 Hygienic Aseptic 20 2321 0049 19 19 24 21 21 21 25 26...

Page 76: ...nical data during installation operation and maintenance Inform all personnel about the technical data Parts list Pos Qty Denomination 19 2 Clamp 3 Clamp 20 2 Bonnet 21 2 O ring EPDM standard 24 2 Bus...

Page 77: ...77...

Page 78: ...s 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 r...

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