Alfa Laval Unique RV-ST 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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Installation .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .

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

2.2. Warning signs

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2.3. Safety precautions . . . .. . . . .. . . . . .. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .

Installation .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .

3.1. Unpacking/delivery

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

3.3. Welding

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3.4. Electrical connection

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3.5. Recycling information .. . . . .. . . . . .. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .

Operation

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4.1. Operation

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4.2. Troubleshooting

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4.3. Recommended cleaning

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Maintenance

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

5.2. Dismantling of valve

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5.3. Plug seal replacement . . . . .. . . . . .. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .

5.4. Assembly of valve . . . . .. . . . .. . . . . .. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .

5.5. Assembly instruction for positioner

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5.6. Actuator bushing replacement

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5.7. Dismantling of optional maintainable actuator

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5.8. Assembly of optional maintainable actuator

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5.9. Reversing optional maintainable actuator operation

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Technical data

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6.1. Technical data positioner . .. . . . . .. . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .

6.2. Technical data - valve/actuator

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Parts list and service kits

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7.1. Unique RV-ST Regulating Valve - Shut-off valve . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . .. . . . . .

7.2. Unique RV-ST Maintainable Actuator . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . . .. . . . .. . . . .. . . . . .

Summary of Contents for Unique RV-ST

Page 1: ...2404 0022 ESE02127 EN3 2014 12 Original manual Instruction Manual Unique RV ST Regulating Valve ...

Page 2: ......

Page 3: ...ubleshooting 14 4 3 Recommended cleaning 15 5 Maintenance 17 5 1 General maintenance 17 5 2 Dismantling of valve 20 5 3 Plug seal replacement 20 5 4 Assembly of valve 21 5 5 Assembly instruction for positioner 21 5 6 Actuator bushing replacement 21 5 7 Dismantling of optional maintainable actuator 22 5 8 Assembly of optional maintainable actuator 22 5 9 Reversing optional maintainable actuator ope...

Page 4: ...5099880 to 29999999999 is in conformity with the following directive with amendments Machinery Directive 2006 42 EC Regulation EC No 1935 2004 Pressure Equipment Directive 97 23 EC category 1 and subjected to assessment procedure Module A 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 Koldi...

Page 5: ... information Always read the manual before using the valve WARNING Indicates that special procedures must be followed to avoid severe personal injury CAUTION Indicates that special procedures must be followed to avoid damage to the valve NOTE Indicates important information to simplify or clarify procedures 2 2 Warning signs General warning Caustic agents 5 ...

Page 6: ...nes when processing hot liquids or when sterilising Never touch the moving parts if compressed air is supplied to the actuator Always rinse well with clean water after cleaning Always handle lye and acid with great care Maintenance Always observe the technical data thoroughly see chapter 6 Technical data Always release compressed air after use Never service the valve when it is hot The valve actua...

Page 7: ...d responsible for incorrect unpacking Check the delivery for 1 Complete valve 2 Delivery note 3 Instruction Manual Step 2 1 Complete actuator 2 Bonnet 20 3 Clamp 19 4 Valve plug 23 5 Valve body 22 6 Positioner 77 1 7 Adapter 82 8 Spindle 79 9 Special X ring 80 10 Allen screw 81 11 Puck sensor pad 85 12 O ring 83 13 Gasket for adapter 84 79 80 77 1 82 81 84 83 85 20 23 19 22 2404 0008 Step 3 Remove...

Page 8: ...echnical data thoroughly Always release compressed air after use CAUTION Alfa Laval cannot be held responsible for incorrect installation Step 2 Never touch the moving parts if the actuator is supplied with compressed air Moving parts 2404 0007 Step 3 Avoid stressing the valve Pay special attention to Vibrations Thermal expansion of the tubes Excessive welding Overloading of the pipelines 2404 000...

Page 9: ...or smooth operation after welding 3 3 Welding Step 1 Assemble the valve in accordance with the steps in chapter 5 4 Assembly of valve Pay special attention to the warnings 2404 0010 Step 2 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 Air Open close Air 2404 0011 9 ...

Page 10: ...cal connection Electrical connection Positioner 8694 Without display Terminal strip NC 1 NC 2 Not connected NC 3 IN 0 4 20 mA 4 PLC output signal IN 0 4 20 mA GND 5 Supply 6 Power supply Supply GND 7 Positioner 8692 With display Terminal strip NC 1 NC 2 NC 3 Not connected NC 4 5 NC 6 NC 7 NC 8 NC 9 NC Not connected SET 0 4 20 mA GND 10 PLC output signal SET 0 4 20 mA 11 Not connected NC 12 Supply ...

Page 11: ...Metal straps should be sent for material recycling Maintenance 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 disposed in accordance with local regulations Scrapping At end of use the equ...

Page 12: ...on Step 1 Always read the technical data thoroughly Always release compressed air after use CAUTION Alfa Laval cannot be held responsible for incorrect operation Step 2 Never touch the valve or the pipelines when processing hot liquids or when sterilising 2404 0012 Danger of burns Step 3 Never touch the moving parts if the actuator is supplied with compressed air Air Moving parts 2404 0013 Air 12 ...

Page 13: ...ubrication of valves 1 Ensure smooth movement between lip seal 25 and plug stem 23 2 Lubricate with Klüber Paraliq GTE 703 if necessary see chapter 5 1 General maintenance Shut off valve 2404 0014 25 23 Step 5 Lubrication of actuator 1 Ensure smooth movement of the actuator the actuator is lubricated before delivery 2 Lubricate O ring s with Molykote Longterm 2 plus if necessary TD461 566_1 13 ...

Page 14: ...oduct 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 The product pressure on the plug is too high Reduce product pressure Water hammer The flow direction is the same as the closing direction The flow direction should be against the closing direction The valve does not open close The pressure on the plug...

Page 15: ...le lye and acid with great care Caustic danger Always use rubber gloves Always use protective goggles Step 2 Never touch the valve or the pipelines when sterilising Danger of burns 2404 0012 Step 3 Clean the plug and the seats correctly Pay special attention to the warnings Lift and lower valve plug momentarily Shut off valve 2404 0015 15 ...

Page 16: ...H 100 l 26 4 gal water Cleaning agent 0 7 l 0 2 gal 53 HNO3 100 l 26 4 gal water Cleaning agent 2 2 l 0 6 gal 33 NaOH 100 l 26 4 gal water Cleaning agent Step 5 1 Avoid excessive concentration of the cleaning agent 2 Adjust the cleaning flow to the process 3 Always rinse well with clean water after cleaning Always rinse Clean water Cleaning agents Step 6 NOTE The cleaning agents must be stored dis...

Page 17: ...data thoroughly See chapter 6 Technical data Always release compressed air after use NOTE All scrap must be stored discharged in accordance with current rules directives Step 2 Never service the valve when it is hot Never service the valve with the valve and pipelines under pressure Atmospheric pressure required 2404 0016 Danger of burns Step 3 Never stick your fingers through the valve ports if t...

Page 18: ...refully and pay special attention to the warnings Always keep spare rubber seals and lip seals in stock Check the valve for smooth operation after service Step 4 Never touch the moving parts if compressed air is supplied to the actuator Air Moving parts 2404 0017 Air 18 ...

Page 19: ...lly starts slowly Replace at the end of the day Replace when possible Planned maintenance Regular inspection for leakage and smooth operation Regular inspection for leakage and smooth operation Keep a record of the valve Keep a record of the actuator Use the statistics for inspection planning Use the statistics for inspection planning Replace after leakage Replace after leakage Lubrication Before ...

Page 20: ...remove valve plug 6 Remove O ring lip seal and bushing in bonnet Use bushing tool and rubber mallet Pay special attention to the warnings Note For plug seal replacement please see chapter 5 3 Plug seal replacement 2404 0018 TD 461 837_1 5 3 Plug seal 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 i...

Page 21: ...dication spindle 79 5 Remove top lid a and the cover b from positioner 77 1 77 2 6 Grease seals lightly before assembly of the other parts with KlüberParaliq GTE 703 7 Centring the sensor pad 85 in the guide rail inside the positioner when mounting the positioner unit 77 1 77 2 down over the adapter 8 Fasten positioner 77 1 77 2 by cross tighten the screws 9 Bring the actuator in top position by u...

Page 22: ...stem 2 with O ring 3 and spring assembly 14 6 Remove O rings and support disc TD 461 033 5 8 Assembly of optional maintainable actuator Reverse order of 5 7 Dismantling of optional maintainable actuator Lubricate O ring 3 7 11 with Molykote Longterm 2 plus before fitting 5 9 Reversing optional maintainable actuator operation 2404 0020 1 Rotate cylinder 2 Remove lock wire and pull away cylinder 3 R...

Page 23: ...act free wear free Stroke range valve spindle 3 to 28 mm Installation As required preferably with actuator in upright position Protection class IP 65 67 according to EN 60529 NEMA4x in preparation Power consumption 3 5 W Electrical connection Cable gland in preparation 1xM16x1 5 cable ø5 10mm terminal screws 1 5 mm2 Protection class 3 according to VDE 0580 Conformity CE acc to EMC 2004 108 EC 1 Th...

Page 24: ...technical data during installation operation and maintenance Inform personnel about the technical data 7 1 Unique RV ST Regulating Valve Shut off valve 80 2404 0023 12 NO 79 82 81 84 83 85 22 19 23 2 23 1 23 24 25 21 20 7 6 8 7 8 6 12 NC 9 NO 77 1 77 2 5 9 NC 24 ...

Page 25: ... Spindle 80 1 Special X ring 81 2 Allen screw 82 1 Adapter 83 1 O ring 84 1 Gasket for adapter 85 1 Puck sensor pad cpl Service kits Denomination DN40 38 mm DN50 51 mm DN65 63 5 mm DN80 76 1 mm DN100 101 6 mm Service kit actuator 9611 92 6500 9611 92 6500 9611 92 6500 9611 92 6500 9611 92 6500 Service kit EPDM 9611 92 6502 9611 92 6503 9611 92 6504 9611 92 6505 9611 92 6506 Service kit HNBR 9611 9...

Page 26: ...e the technical data during installation operation and maintenance Inform personnel about the technical data 7 2 Unique RV ST Maintainable Actuator 80 79 82 81 84 83 85 7 8 6 77 1 77 2 5 12 NO 9 NC 1 10 16 3 14 2 15 11 12 NC 9 NO 7 6 8 18 17 13 2404 0006 26 ...

Page 27: ...ing 13 1 Yoke 14 1 Spring assembly 15 1 Bottom 16 1 Support disc 17 3 Washer 18 3 Nut 77 1 1 Positioner 8694 without display 77 2 1 Positioner 8692 with display 79 1 Spindle 80 1 Special X ring 81 2 Allen screw 82 1 Adapter 83 1 O ring 84 1 Gasket for adapter 85 1 Puck sensor pad cpl Service kits Denomination DN40 38 mm DN50 51 mm DN65 63 5 mm DN80 76 1 mm DN100 101 6 mm Service kit Actuator 9611 ...

Page 28: ...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 Lava...

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