Alfa Laval Unique Mixproof LP Instruction Manual Download Page 1

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2314-0005

ESE02021-EN2

2016-07

Original manual

Instruction Manual

Unique Sanitary Mixproof LP and LP-F Valve

Summary of Contents for Unique Mixproof LP

Page 1: ...2314 0005 ESE02021 EN2 2016 07 Original manual Instruction Manual Unique Sanitary Mixproof LP and LP F Valve...

Page 2: ......

Page 3: ...ve 25 5 3 Lower plug replacement of radial seal 29 5 4 Upper plug replacement of axial seal 31 5 5 Valve assembly 33 5 6 Dismantling of actuator 4 37 5 7 Assembly of actuator 4 39 5 8 Dismantling of a...

Page 4: ...ollowing directive with amendments Machinery Directive 2006 42 EC Regulation EC No 1935 2004 The valve is in compliance with the Pressure Equipment Directive 2014 68 EU and was subjected to the follow...

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: ...ssed air see the warning label Never pressurise air connections AC1 AC3 simultaneously as both valve plugs can be lifted can cause mixing Never touch the valve or the pipelines when processing hot liq...

Page 7: ...allation so that it is clearly visible 3 1 Unpacking intermediate storage Step 1 CAUTION Alfa Laval cannot be held responsible for incorrect unpacking Check the delivery for 1 Complete valve 2 Deliver...

Page 8: ...alve after installation so that it is clearly visible Step 4 Remove possible packing materials from the valve ports 2314 0008 Step 5 Inspect the valve for visible transport damage Inspection 2314 0009...

Page 9: ...alve after installation so that it is clearly visible Step 7 Disassemble according to illustrations 1 to 6 please also see 5 2 Dismantling of valve 1 Supply compressed air 2 Remove upper clamp 3 Relea...

Page 10: ...rning label supplied on the valve after installation so that it is clearly visible Step 8 Mount sealing element on valve 2314 0011 Step 9 1 Place actuator part in the box 2 Add supports 3 Close box an...

Page 11: ...t is clearly visible CAUTION Alfa Laval cannot be held responsible for incorrect installation NOTE Always install the valve vertically NOTE The leakage outlet must be turned downwards Step 2 Avoid str...

Page 12: ...ngers through the valve ports if the actuator is supplied with compressed air Air Cutting danger 2314 0016 Step 2 Dismantle the valve in accordance with step 1 section 5 2 Dismantling of valve Step 3...

Page 13: ...conical valve seat upwards Remove label after installation of valve body UP Remove label after installation of valve body UP 2314 0018 UP Remove label after installation of valve body Step 5 Assemble...

Page 14: ...elding NOTE If ThinkTop is mounted add 180 mm to B measurement A Lower sealing element can be removed without removing actuator and internal valve parts B Actuator and internal valve parts can be lift...

Page 15: ...a thoroughly Always release compressed air after use Never touch the clip assembly or the actuator piston rod if the actuator is supplied with compressed air see the warning label Never pressurise air...

Page 16: ...p 2 section 5 5 Valve assembly Leakage at sealing element 48 upper plug 55 Worn product affected O rings lip seal 38 39 46 49 Replace the O rings lip seal Change rubber grade Clean and if necessary re...

Page 17: ...a HNO3 Nitric acid Internal leakage in the valve is externally visible by means of the leakage outlet 4 3 Recommended cleaning Step 1 Never touch the valve or the pipelines when sterilising Caustic da...

Page 18: ...IP out Step 4 Examples of cleaning agents Use clean water 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 C...

Page 19: ...ngs NaOH Caustic Soda HNO3 Nitric acid Internal leakage in the valve is externally visible by means of the leakage outlet Step 7 Always rinse well with clean water after cleaning Always rinse Clean wa...

Page 20: ...Nitric acid Internal leakage in the valve is externally visible by means of the leakage outlet Seat cleaning cycles Pay special attention to the warnings 1 Closed valve A Product B CIP 2314 0022 A B...

Page 21: ...after service 5 1 General maintenance Step 1 Always read the technical data thoroughly Always fit the seals correctly risk of mixing Always release compressed air after use Always remove the CIP conn...

Page 22: ...the parts list and service kits section The valve is designed so that internal leakages do not result in the products becoming mixed Internal leakage in the valve is externally visible Check the valv...

Page 23: ...cycle Replace after production cycle Planned maintenance Regular inspection for leakage and smooth operation Keep a record of the valve Use the statistics for inspection planning Regular inspection f...

Page 24: ...rvice kits section The valve is designed so that internal leakages do not result in the products becoming mixed Internal leakage in the valve is externally visible Check the valve for smooth operation...

Page 25: ...f valve NOTE LP F IS SHOWN Step 1 Disassemble valve acc to illustrations 1 to 6 1 Supply compressed air to A2 2 Loosen and remove upper clamp 64 3 Release compressed air 4 Lift out the actuator togeth...

Page 26: ...ement 1 Pull out O ring 76 and lip seal 77 Unique LP F 1 Pull out O ring 76 lip seal 95 and guide ring 98 from sealing element 96 97 2314 0028 98 97 95 96 76 Step 3 1 Supply compressed air for air con...

Page 27: ...ace seals if necessary Step 4 Remove coupling system and upper plug according to illustrations 1 to 4 1 Unscrew plug 15 2 Pull up lock 44 over piston rod 29 3 Pull away clamps 43 from spindle liner 42...

Page 28: ...eals if necessary Step 5 1 Remove upper sealing element 48 from upper plug 55 2 Pull out O ring 47 and lip seal 49 from upper sealing element 55 47 49 48 2314 0031 Step 6 Remove lip seal 57 and guide...

Page 29: ...cement of radial seal Step 1 Cut and remove old seal ring 74 using a knife screwdriver or similar Be careful not to scratch the plug 2314 0033 Step 2 Pre mount seal ring as shown on drawing Rotate alo...

Page 30: ...9613 4260 10 2314 0035 Step 4 Place lower tool part 2314 0036 Step 5 1 Place upper tool part including piston 2 Clamp the two tool parts together 2314 0037 Tool marked with item number Step 6 1 Supply...

Page 31: ...e mount seal ring as shown on drawing A C B 2314 0056 A Flat side of the sealing B Balanced plug C Do not lubricate behind the sealing 2314 0041 Carefully lubricate sealings with suitable soap or lubr...

Page 32: ...Handle scrap correctly Step 6 1 Supply compressed air 2 Release compressed air 3 Rotate the tool 45 in relation to the plug 4 Supply compressed air 5 Release compressed air and remove tool on off 231...

Page 33: ...48 Lubricate with Kl ber Paralique GT 703 NOTE The O ring should be gently pressed into the groove 2 Fit upper sealing element in intermediate piece 37 47 37 49 48 2314 0047 45 Step 2 1 Place lip seal...

Page 34: ...p correctly Replace seals if necessary Step 3 Place coupling system and upper plug according to illustrations 1 Push lock 44 up over piston rod 29 2 Place spindle liner 42 on piston rod Fit upper plug...

Page 35: ...AC1 2 Insert lower plug 75 and tighten 3 Release compressed air Recommended torque for fitting upper and lower plug parts 20 Nm 2 1 2314 0050 3 Step 5 Unique LP 1 Fit lip seal 77 and O ring 76 do not...

Page 36: ...air Always supply compressed air before demounting the valve 1 Fit lower sealing element 79 2 Fit and tighten lower clamp 64 3 Supply compressed air AC2 and mount the actuator together with the intern...

Page 37: ...Handle scrap correctly Replace seals if necessary 5 6 Dismantling of actuator 4 15 27 13 19 18 17 26 1 12 11 10 2 4 8 7 9 16 3 1 15 3 3 2 82 37 83 83 1 34 36 25 35 24 23 22 20 21 31 33 30 32 29 28 14...

Page 38: ...e the pistons 124 132 5 Remove the lock ring 136 and separate the two pistons Remove all O rings and bearings 122 123 125 134 131 133 6 Activate main stroke Air fitting Position 3 7 Remove screw 135 a...

Page 39: ...eals if necessary Lubricate the rubber seals before fitting them 5 7 Assembly of actuator 4 15 27 13 19 18 17 26 1 12 11 10 2 4 8 7 9 16 3 1 15 3 3 2 82 37 83 83 1 34 36 25 35 24 23 22 20 21 31 33 30...

Page 40: ...hree parts Step 5 1 Fit retaining ring 24 2 Fit cover disk 25 3 Mount intermediate piece 37 on actuator 4 Fit and tighten nuts 36 and washers 35 Step 6 1 Place the actuator with the intermediate in a...

Page 41: ...ems refer to the parts list and service kits section Handle scrap correctly Replace seals if necessary 5 8 Dismantling of actuator 6 27 19 13 18 17 26 1 12 10 11 2 4 7 22 8 9 16 37 6 5 34 15 3 3 36 35...

Page 42: ...Remove nuts 36 and washers 35 2 Pull out intermediate piece 37 from the actuator 3 Remove cover disk 25 4 Remove retaining ring 24 Step 3 1 Remove piston rod 29 bottom 21 and lower piston 30 2 Separat...

Page 43: ...o the parts list and service kits section Replace seals if necessary Lubricate the rubber seals before fitting them 5 9 Assembly of actuator 6 27 19 13 18 17 26 1 12 10 11 2 4 7 22 8 9 16 37 6 5 34 15...

Page 44: ...and 9 Place upper piston 8 3 Fit stop 4 4 Tighten screws 2 Secure with glue Step 3 1 Place spring assembly 10 2 Fit O ring 19 and guide ring 18 Mount distance spacer 11 main piston 17 and inner stem...

Page 45: ...is in order to accommodate 45mm particles not supplied with balanced lower plug Data Max product pressure 1000 kPa 10 bar Min product pressure Full vacuum Temperature range 5 C to 125 C depending on r...

Page 46: ...esistant steel AISI 316L Other steel parts Stainless steel AISI 304 Product wetted parts EPDM HNBR NBR or FPM Other seals CIP seals EPDM Actuator seals NBR Surface finish Internal external matt blaste...

Page 47: ...nance Inform personnel about the technical data 7 1 Unique Mixproof LP Valve wear parts 4 and 6 TD 481 021 10 15 11 26 28 29 30 3 31 32 33 3 1 37 38 45 48 60 64 49 47 50 54 56 74 57 76 77 27 81 80 79...

Page 48: ...7 Parts list and service kits It is important to observe the technical data during installation operation and maintenance Inform personnel about the technical data Sensor kit Wear parts 48...

Page 49: ...rve the technical data during installation operation and maintenance Inform personnel about the technical data Parts list Pos Qty Denomination 38 1 O ring 47 1 O ring 49 1 Lip seal 56 1 Seal ring 57 1...

Page 50: ...technical data 7 2 Unique Mixproof LP Valve parts 4 2314 0003_1 60 3 3 135 15 136 134 27 13 19 18 17 26 1 12 11 10 2 4 8 7 43 9 42 15 16 44 3 1 15 3 6 3 2 5 37 34 36 121 120 127 25 35 133 24 132 125 1...

Page 51: ...1 Bottom 22 1 Guide ring Turcite 23 1 O ring NBR 24 1 Retaining ring 25 1 Cover disk 26 1 O ring NBR 27 1 Inner stem 28 1 O ring 29 1 Piston rod 30 1 Lower piston 31 1 O ring NBR Parts list Pos Qty De...

Page 52: ...and maintenance Inform personnel about the technical data 7 3 Unique Mixproof LP Valve parts 6 27 19 13 18 17 26 1 12 10 11 2 4 7 22 8 9 43 42 15 16 37 6 5 34 15 3 1 3 36 35 25 23 64 24 20 3 2 21 64 6...

Page 53: ...12 1 Pin 13 1 Washer 14 1 Spring assembly 15 2 Plug 16 1 Cylinder 17 1 Main piston 18 1 Guide ring Turcite 19 1 O ring NBR 20 1 O ring NBR 21 1 Bottom 22 1 Guide ring Turcite 23 1 O ring NBR 24 1 Reta...

Page 54: ...lation operation and maintenance Inform personnel about the technical data 7 4 Unique Mixproof LP Valve service kits 4 and 6 TYPE 22 00 TYPE 22 90 TYPE 12 00 TYPE 12 90 TYPE 21 00 TYPE 21 90 TYPE 11 0...

Page 55: ...enance Inform personnel about the technical data Parts list Pos Qty Denomination 37 1 Intermediate piece 50 1 Valve body Service kits Denomination 4 6 a Service kit NBR 9611926861 9611926849 a Service...

Page 56: ...28 31 3 29 32 33 3 1 23 24 25 37 38 15 45 48 47 49 9 98 95 76 3 3 128 127 130 129 126 125 131 122 122 123 134 133 121 120 134 136 1 8 6 2 4 12 13 14 16 17 18 19 21 20 22 34 35 36 60 64 54 55 56 74 57...

Page 57: ...the technical data during installation operation and maintenance Inform personnel about the technical data Parts list Pos Qty Denomination 38 1 O ring 47 1 O ring 49 1 Lip seal 56 1 Seal ring 57 1 Lip...

Page 58: ...echnical data 7 6 Unique Mixproof LP F Valve parts 4 2315 0004_1 60 3 3 135 15 136 134 27 13 19 18 17 26 1 12 11 10 2 4 8 7 43 9 42 15 16 44 3 1 15 3 6 3 2 5 37 34 36 121 120 127 25 35 133 24 132 125...

Page 59: ...ide ring Turcite 23 1 O ring NBR 24 1 Retaining ring 25 1 Cover disk 26 1 O ring NBR 27 1 Inner stem 28 1 O ring 29 1 Piston rod 30 1 Lower piston 31 1 O ring NBR Parts list Pos Qty Denomination 32 1...

Page 60: ...nd maintenance Inform personnel about the technical data 7 7 Unique Mixproof LP F Valve parts 6 27 19 13 18 17 26 1 12 10 11 2 4 7 22 8 9 43 42 15 16 37 6 5 34 15 3 1 3 36 35 25 23 64 24 20 3 2 21 64...

Page 61: ...sher 14 1 Spring assembly 15 2 Plug 16 1 Cylinder 17 1 Main piston 18 1 Guide ring Turcite 19 1 O ring NBR 20 1 O ring NBR 21 1 Bottom 22 1 Guide ring Turcite 23 1 O ring NBR 24 1 Retaining ring 25 1...

Page 62: ...ation operation and maintenance Inform personnel about the technical data 7 8 Unique Mixproof LP F Valve service kits 4 and 6 TYPE 22 00 TYPE 22 90 TYPE 12 00 TYPE 12 90 TYPE 21 00 TYPE 21 90 TYPE 11...

Page 63: ...hnical data Parts list Pos Qty Denomination 37 1 Intermediate piece 50 1 Valve body Service kits Denomination 4 a Service kit NBR 9611926865 a Service kit EPDM 9611926866 a Service kit HNBR 9611926867...

Page 64: ...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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