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Alfa level CSI RV-ST, Instruction Manual

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ALFA LAVAL UNIQUE RV-ST VALVE INSTRUCTION MANUAL—REV 8/21

Table of contents

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

1. CE Declaration of Incorporation for Machinery ..................................................

4

2. Safety ....................................................................................................

5

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

5

2.2. Warning signs .....................................................................................

7

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

8

3. Installation ..............................................................................................

11

3.1. Unpacking/delivery ...............................................................................

11

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

13

3.3. Welding ............................................................................................

15

3.4. Electrical connection .............................................................................

17

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

18

4. Operation ...............................................................................................

19

4.1. Operation ..........................................................................................

19

4.2. Troubleshooting ...................................................................................

21

4.3. Recommended cleaning .........................................................................

22

5. Maintenance ...........................................................................................

24

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

24

5.2. Dismantling of valve ..............................................................................

27

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

28

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

31

5.5. Assembly instruction for positioner .............................................................

32

5.6. Actuator bushing replacement ..................................................................

33

5.7. Dismantling of fully maintainable actuator (removable yoke with bolts/2006-June 2016) .

38

5.8. Assembly of optional maintainable actuator ...................................................

39

5.9. Mounting of fully maintainable actuator .........................................................

39

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

40

6. Technical data .........................................................................................

41

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

41

6.2. Technical data - valve/actuator ..................................................................

41

7. Parts list and service kits ............................................................................

44

7.1. Unique RV-ST Regulating Valve (sizes 25mm-51mm/DN25-DN50) .........................

44

7.2. Unique RV-ST Regulating Valve (sizes 63.5mm-101.6mm/DN65-DN100) .................

46

7.3. Maintainable actuator (sizes 25mm-51mm/DN25-DN50) ....................................

48

7.4. Maintainable actuator (sizes 63.5mm-101.6mm/DN65-DN100) .............................

50

3

CONTACT CSI FOR MORE INFORMATION  |  CSIDESIGNS.COM  |  [email protected]  |  417.831.1411

Summary of Contents for CSI RV-ST

Page 1: ...ALFA LAVAL UNIQUE RV ST VALVE INSTRUCTION MANUAL REV 8 21 2404 0083 ESE02127 EN8 2021 08 Original manual Instruction Manual Unique RV ST Regulating Valve...

Page 2: ...ALFA LAVAL UNIQUE RV ST VALVE INSTRUCTION MANUAL REV 8 21 CONTACT CSI FOR MORE INFORMATION CSIDESIGNS COM SALES CSIDESIGNS COM 417 831 1411...

Page 3: ...placement 28 5 4 Assembly of valve 31 5 5 Assembly instruction for positioner 32 5 6 Actuator bushing replacement 33 5 7 Dismantling of fully maintainable actuator removable yoke with bolts 2006 June...

Page 4: ...099880 to 29999999999 is in conformity with the following directive with amendments Machinery Directive 2006 42 EC Pressure Equipment Directive 2014 68 EU category 1 and subjected to assessment proced...

Page 5: ...to the relevant section for the task to be carried out or for the information needed This is the complete manual for the supplied product O Op pe er ra at to or rs s The operators shall read and under...

Page 6: ...be opened F Fu ulllly y m ma aiin nt ta aiin na ab blle e a ac ct tu ua at to or r Spring cage and can be opened F Fu ulllly y m ma aiin nt ta aiin na ab blle e a ac ct tu ua at to or r Spring cage an...

Page 7: ...injury an extra yellow label marked on the actuator from June 2016 Do N NO OT T attempt to cut the actuator open due to spring under load The lock wire opening is locked SPRING UNDER LOAD kg Danger o...

Page 8: ...tors If support air is connected always use the 3 bar 43 5 PSI air relief fittings 9611995903 Using the air relief fitting also extends the service life of the actuator piston o ring 2404 0089 26 1 19...

Page 9: ...due to spring under load danger DO NOT DISASSEMBLE kg O OP PE ER RA AT TI IO ON N N Ne ev ve er r dismantle the valve with valve and pipelines under pressure N Ne ev ve er r dismantle the valve when...

Page 10: ...fore transportation A Allw wa ay ys s use predesigned lifting points if defined A Allw wa ay ys s ensure sufficient fixing of the valve during transportation if specially designed packaging material i...

Page 11: ...al S St te ep p 2 2 Actuator version can be ordered either fully maintainable no warning marked on actuator or as non maintainable warning marked on actuator lasermarked warning N No on n m ma aiin nt...

Page 12: ...supplied as separate parts as standard for welding The valve is assembled before delivery if it is supplied with fittings S St te ep p 4 4 Remove possible packing materials from the valve valve parts...

Page 13: ...tion A Allw wa ay ys s release compressed air after use A Allw wa ay ys s read the technical data thoroughly See section DO NOT DISASSEMBLE kg Do N NO OT T attempt to disassemble the actuator due to s...

Page 14: ...also be supplied with fittings S St te ep p 3 3 2404 0096 2404 0097 S St te ep p 4 4 Avoid stressing the valve P Pa ay y s sp pe ec ciia all a at tt te en nt tiio on n t to o Vibrations Thermal expan...

Page 15: ...ls between the valve bodies can be replaced Do not weld more than one valve body into the system Valve size A mm B mm DN25 25 mm 630 DN40 38 mm 700 DN50 51 mm 750 DN65 63 5 mm 740 DN80 76 mm 800 DN100...

Page 16: ...ction Check the valve for smooth operation after welding S St te ep p 3 3 P Pr re e u us se e c ch he ec ck k 1 Supply compressed air to the actuator 2 Open and close the valve several times to ensure...

Page 17: ...r riic ca all c co on nn ne ec ct tiio on n 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...

Page 18: ...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 m...

Page 19: ...he technical data thoroughly See section 6 Technical data A Allw wa ay ys s use Alfa Laval genuine spare parts The warranty of Alfa Laval products is dependent on use of Alfa Laval genuine spare parts...

Page 20: ...St te ep p 4 4 L Lu ub br riic ca at tiio on n o of f v va allv ve es s 1 Ensure smooth movement between lip seal 25 and plug stem 23 2 Lubricate with Alfa Laval Lubricant if necessary see chapter 5...

Page 21: ...spring side do not exceed 3 bar 43 5 PSI Alfa Laval article number 9611995903 See section 2 3 Safety precautions and section 3 2 General installation Step 4 Reduce product pressure Water hammer The f...

Page 22: ...y ys s use rubber gloves A Allw wa ay ys s use protective goggles S St te ep p 2 2 N Ne ev ve er r touch the valve or the pipelines when sterilising 2404 0102 S St te ep p 3 3 Clean the plug and the s...

Page 23: ...F 1 kg 2 2 lbs NaOH 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 S St te ep p 5 5 1 Avoid exc...

Page 24: ...hnical data thoroughly See section 6 Technical data A Allw wa ay ys s use Alfa Laval genuine spare parts The warranty of Alfa Laval products is dependent on use of Alfa Laval genuine spare parts DO NO...

Page 25: ...rubber seals and lip seals in stock Check the valve for smooth operation after service S St te ep p 3 3 N Ne ev ve er r stick your fingers through the valve ports if the actuator is supplied with comp...

Page 26: ...n w wo or rk kiin ng g c co on nd diit tiio on ns s Maintenance after leakage leakage normally starts slowly R Re ep plla ac ce e a at t t th he e e en nd d o of f t th he e d da ay y R Re ep plla ac...

Page 27: ...r due to spring under load danger Do N NO OT T attempt to cut the actuator open due to spring under load danger 1 Supply compressed air to the actuator only NC 2 Loosen and remove clamp 3 Release comp...

Page 28: ...e the plug surface 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 v...

Page 29: ...g 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 little bulge then use the screwdriver to eliminate the bulge Again pres...

Page 30: ...wer exhaust hole as the tool can be used for two plug sizes e g plug tool 9613172902 The upper exhaust hole is for the small plug size e g DN50 ISO51 small and the lower exhaust hole is for DN65 ISO63...

Page 31: ...neath the plug 5 4 Assembly of valve Reverse order of Lubricate O ring 21 and lip seal 25 with Alfa Laval Lubricant Remember to tighten spindle and plug use two 17 mm spanners Change over plug tighten...

Page 32: ...the cover b from positioner 77 1 77 2 6 Grease seals lighty before assembly of the other parts with Alfa Laval Lubricant 7 Centring the sensor pad 85 in the guide rail inside the positioner when moun...

Page 33: ...LOAD kg Do N NO OT T attempt to disassemble the actuator due to spring under load danger Do N NO OT T attempt to cut the actuator open due to spring under load danger S St te ep p 1 1 I In nt tr ro o...

Page 34: ...Gedore Tool EAN4010886621264 2200 0002 S St te ep p 3 3 I In nt tr ro od du uc ct tiio on n A Alliig gn niin ng g s sp piin nd dlle e The actuator spindle can in some cases be forced off centre by the...

Page 35: ...st be carefully fixed in a vice if it is dismounted from the valve Be careful not to press the yoke flange oval when fixing the actuator in the vice Only fix carefully on the yoke leg as shown below 2...

Page 36: ...cate thoroughly both the actuator spindle and o rings 2 Grease with Molykote Longterm 2 plus 3 Fit the b bu us sh hiin ng g on the spindle 2200 0103 DO NOT DISASSEMBLE kg S St te ep p 7 7 Fit the alig...

Page 37: ...p p 8 8 Now pull the aligning spindle to centre the actuator spindle In this position rotate the b bu us sh hiin ng g 180 backwards and then begin to fasten the bushing Make sure that the thread catch...

Page 38: ...BLE kg SPRING UNDER LOAD kg Do N NO OT T attempt to disassemble the actuator due to spring under load danger Do N NO OT T attempt to cut the actuator open due to spring under load danger Before disman...

Page 39: ...Rotate cylinder with service tool 1 Rotate cylinder 2 Remove lock wire and pull away cylinder 3 Remove top and bottom bushings 4 Remove piston with O ring and spring assembly 2404 0121 5 9 Mounting of...

Page 40: ...ASSEMBLE kg SPRING UNDER LOAD kg Do N NO OT T attempt to disassemble the actuator due to spring under load danger Do N NO OT T attempt to cut the actuator open due to spring under load danger Before d...

Page 41: ...detection module Contact 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 NEM...

Page 42: ...upplied product shall be carried out at least every 12 months If the protective device is lost or damaged especially when this leads to deterioration of safety performance it shall be replaced The fix...

Page 43: ...ALFA LAVAL UNIQUE RV ST VALVE INSTRUCTION MANUAL REV 8 21 CONTACT CSI FOR MORE INFORMATION CSIDESIGNS COM SALES CSIDESIGNS COM 417 831 1411...

Page 44: ...the actuator is marked with a danger warning do N NO OT T attempt to cut the actuator open DO NOT DISASSEMBLE kg SPRING UNDER LOAD kg Do N NO OT T attempt to disassemble the actuator due to spring un...

Page 45: ...r rd d D DN N4 40 0 3 38 8 m mm m D DN N5 50 0 5 51 1 m mm m S Se er rv viic ce e k kiit t a ac ct tu ua at to or r 9 96 61 11 19 92 26 65 50 00 0 9 96 61 11 19 92 26 65 50 00 0 9 96 61 11 19 92 26 65...

Page 46: ...If the actuator is marked with a danger warning do N NO OT T attempt to cut the actuator open DO NOT DISASSEMBLE kg SPRING UNDER LOAD kg Do N NO OT T attempt to disassemble the actuator due to spring...

Page 47: ...0 1 10 01 1 6 6 m mm m D DN N1 10 00 0 S Se er rv viic ce e k kiit t a ac ct tu ua at to or r 9 96 61 11 19 92 26 65 50 00 0 9 96 61 11 19 92 26 65 50 00 0 9 96 61 11 19 92 26 65 50 00 0 S Se er rv v...

Page 48: ...T attempt to cut the actuator open DO NOT DISASSEMBLE kg SPRING UNDER LOAD kg Do N NO OT T attempt to disassemble the actuator due to spring under load danger Do N NO OT T attempt to cut the actuator...

Page 49: ...Positioner 8694 77 1 1 Positioner 8694 without display 77 2 1 Positioner 8694 without display US 78 1 Adapter cpl incl Pos 79 to 84 79 1 Spindle 80 1 Special X ring 81 2 Allen screw 82 1 Adapter 83 1...

Page 50: ...OT T attempt to cut the actuator open DO NOT DISASSEMBLE kg SPRING UNDER LOAD kg Do N NO OT T attempt to disassemble the actuator due to spring under load danger Do N NO OT T attempt to cut the actuat...

Page 51: ...16 1 Support disc 18 3 Nut 0616 76 1 Positioner 77 1 1 Positioner 8694 without display 77 2 1 Positioner 8694 without display US 78 1 Adapter cpl incl Pos 79 to 84 79 1 Spindle 80 1 Special X ring 81...

Page 52: ...hts 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...

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