Steridose STERIVALVE 12 User'S Installation And Operation Manual Download Page 1

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STERIVALVE

Installation and operation manual

(Including welding guideline)

Summary of Contents for STERIVALVE 12

Page 1: ...STERIVALVE Installation and operation manual Including welding guideline ...

Page 2: ...s 2 2 4 1 Stainless Steel Pneumatic Actuators 2 2 4 2 Plastic Pneumatic Actuators 3 Operation 3 1 Pneumatically operated valves 3 2 Manually operated valves 3 3 Position Indicators 3 4 Cleaning 3 4 1 Internal cleaning 3 4 2 External cleaning 4 Maintenance Service 4 1 Special tools required 4 2 Preventive Maintenance Schedule 4 3 Actuators 4 3 1 Manual Actuator 4 3 2 Pneumatic Actuator 4 4 Diaphrag...

Page 3: ...NGER Operation maintenance and adjustment of the equipment may be performed by authorized personnel only CAUTION The valve inner surface is manufactured to a high polish and WILL get damaged if tools are used improperly or without care 1 2 Scope and Purpose This document provides information regarding installation normal operation maintenance and troubleshooting of the valve including safety aspec...

Page 4: ...flow through take off and divert Refer to figure 2 Other custom configurations are available upon request Bottom outlet valves Standard bottom outlet valves are available as single or double outlet and double outlet with steam integrated valve Refer to figure 2 Outlet s can be provided as a straight weld nose or elbow 90 or 45 with or without TC connection Other custom configurations are available...

Page 5: ...Page 5 45 REV STV20110519 Figure 2 Standard Valve Housing Configurations Figure 3 Standard Sample Valve Housing Configurations ...

Page 6: ...pen normally closed Figure 4 Plastic Pneumatic Actuators Stainless Steel Pneumatic Actuator 12 1 2 25 1 and 38 1 The pneumatically operated actuator for Sterivalve has a stainless steel cover but it is not autoclavable The actuator is mounted on the housing with a clamp The stainless steel pneumatic actuator is available in two versions S A where the designation S A indicates Spring closed Air ope...

Page 7: ...n be set up as either spring to close air to open normally closed or spring to open air to close normally open Figure 6 Stainless Steel Pneumatic Actuator 51 2 76 3 Manual Actuator 12 1 2 to 76 3 The manually operated actuator is manufactured in stainless steel and is autoclavable The actuator is mounted in the same manner as with the pneumatic actuators An extended handle manual actuator is also ...

Page 8: ...s fluid s including CIP solutions steam operational temperature and number of cycles The following materials are offered Platinum cured Silicone USP 88 Class VI EPDM USP 88 Class VI Modified PTFE TFM USP 88 Class VI All diaphragms can be traced by their lot number The lot number is marked in the packaging Additionally silicone and EPDM diaphragms have markings on the back providing the manufacturi...

Page 9: ... of space required depends on valve size and actuator configuration In order to ensure self draining the valve must be installed in the correct position See figures 10 and 11 Figure 10 Self draining positions for process valves The housing is self draining in these positions but NOT in this position Figure 11 Self draining position for bottom outlet valves ...

Page 10: ...ith EPDM and Silicone diaphragms the diaphragm is attached by means of a pressure plate installed in the stem type 1 or 2 As a standard the actuators are supplied with a type 1 pressure plate When using type 1 the diaphragm is pressed into the plate The type 2 pressure plate is provided as an option and recommended when it is expected that the valve would remain in the closed position for prolong ...

Page 11: ...residual glue is carefully removed from the threads in the stem so that the PTFE diaphragm can screw all the way into the stem Failure to do so may result in diaphragm damage A tap can be run on the stem threads to ensure removal of all residual glue NOTE When replacing silicone or EPDM diaphragms for PTFE diaphragms on valves that have been in operation for some years ensure that the valve is tes...

Page 12: ...nd 76 3 secure the 4 bolts that attach the actuator to the valve body Tighten the bolts 5 Actuate the actuator to the closed position 6 For valves with PTFE diaphragms make sure support gasket o rings are installed with the diaphragm See figure 14 See additional installation procedures for PTFE diaphragms in section 2 2 3 Figure 14 PTFE diaphragm o rings left and support gasket right 2 2 2 Manuall...

Page 13: ...sition or closed directly after exposure Alternatively the installed diaphragm can be exposed to hot air at around 100 C for approximately one hour 2 Re tighten the clamp 1 2 1 5 sizes or bolts 2 and 3 sizes after the valve has cooled down to ambient temperature 3 Repeat this process each time the valve insert actuator and diaphragm is disassembled and reassembled 2 2 4 Position Indicators An asso...

Page 14: ...y 8 Slip on instrumentation body into correct position 9 Lock into place with set screw 10 Reassemble to lid with screw In order to assemble open inductive proximity switches follow these steps 1 Set the actuator open 2 Screw the indicator into the tapped hole on top of the actuator until it stops 3 Loosen the indicator one turn and fix the indicator against the actuator by screwing the lock nut d...

Page 15: ...roximity switch Open close inductive proximity switch In order to adjust the sensor position follow these steps 1 Place the actuator in either the open or closed position 2 Loosen the vertical adjustment screw on the corresponding mounting bracket and adjust the position until the switch LED signal light is activated By carefully moving the mounting bracket up and down vertically position the swit...

Page 16: ...y seated and undamaged 4 Unscrew and remove transparent plastic cap on top of actuator 5 Apply air to position actuator rod to the top position 6 Unscrew and remove yellow visual indicator 7 Screw duplication system into actuator rod 8 Tighten adapter until contact is made with top of the actuator 9 Fully tighten duplication system rod on actuator rod with screwdriver 10 Depressurize actuator to r...

Page 17: ...ension handled is opened by turning the handle counter clockwise and closed by turning it clockwise DANGER Always make sure that surrounding system is de pressurized before opening a valve to atmosphere or non pressure vessels Negligence can result in personal injuries or material damages WARNING The handle will become hot if the valve is cleaned with hot liquid or sterilized with steam or water U...

Page 18: ...o sealed and not serviceable 4 2 Preventive Maintenance Schedule Table 1 shows the recommended intervals for inspection of the valve components Table 1 Intervals of inspection Preventive maintenance Section in manual for reference Interval Leakage inspection 4 2 Daily Sterivalve diaphragm inspection 4 4 see 4 4 1 Sterivalve pneumatic actuator inspection 4 3 2 12 months Sterivalve housing inspectio...

Page 19: ...ing etc 2 Inspect electrical cables and replace if damaged Assure that the electric cable is not in contact with hot piping etc 3 Inspect overall function of the actuator Any noises that may indicate air leakage would result in loss of pressure and could result in an inoperative actuator Additional service procedures for stainless steel actuators 12 1 2 25 1 and 38 1 5 The stainless steel pneumati...

Page 20: ...25 Table 3 Sterivalve 25 1 S A STERIVALVE 38 Table 4 Sterivalve 38 1 1 2 S A STERIVALVE 38 1 S A Part 104158 Pos Qty Description Material Dimension Note 1 1 O ring Viton 17 17x1 78 2 1 X ring Viton 9 25x1 78 3 1 Compact seal Nitril 80 4 1 O ring Viton 74 2x5 7 5 1 O ring Nitril 4 3x2 4 STERIVALVE 25 1 S A Part 104157 Pos Qty Description Material Dimension Note 1 1 O ring Viton 17 17x1 78 2 1 X rin...

Page 21: ...he diaphragm material chemicals and utilities used and temperature during SIP NOTE Once the diaphragm has been replaced please make sure that the actuator is in open position before mounting the actuator to the valve 4 4 2 Inspection procedure Any leakage from the diaphragm will be indicated by fluid seeping from a telltale hole at the bottom of the actuator DANGER The inspection must be carried o...

Page 22: ...tor together with the four screws 7 Close the valve The valve is now ready for use 1 Open the valve manually or pneumatically 2 Unscrew the clamp with the wing nut and separate the valve housing from the actuator 3 Set the actuator to the closed position 4 Inspect diaphragm The purpose of the inspection is to detect visible signs of wear cracks significant deformation or discoloration Replace the ...

Page 23: ...solenoid valve if required 7 Correct flow direction or lower fluid pressure Pneumatic valve does not close 1 Actuator is not functioning correctly 2 Solenoid valve electrical cable if supplied is damaged 3 Pneumatic system does not ventilate 4 Incorrect flow direction in combination with high fluid pressure 1 Inspect and replace if required 2 Replace electrical cable 3 Check ventilation of pneumat...

Page 24: ...121 C max pressure 3 bar g At 121 C max pressure 3 bar g Other design data pH range 3 11 3 11 Viscosity 0 1000 cP 0 1000 cP Material ___________________________________________________________________________ Housing valve body For all types and sizes AISI 316L ASTM 316L EN 1 4404 Actuator covers AISI 316 or better AISI 316 or better Plastic Plastic Diaphragm Silicone USP 88 Class VI According to ...

Page 25: ...____________________ Control air Dry free from particles Dry free from particles 10 μm and oil 10 μm and oil Supply pressure recommended 6 0 bar g 6 0 bar g Supply pressure minimum 4 5 bar g 6 0 bar g Supply pressure maximum 7 0 bar g 8 0 bar g Air consumption 12 1 2 0 03 Nl stroke at 4 bar Air consumption 25 1 0 12 Nl stroke at 4 bar Air consumption 38 1 1 2 0 30 Nl stroke at 4 bar Air consumptio...

Page 26: ...e diaphragm USP Class VI 110646 PTFE diaphragm USP Class VI Actuators Part Designation Description Picture 110008 NP3009126 Manual handle SS 110009 NP2002999 Pneumatic actuator spring air SS 110087 NP2006039 Pneumatic actuator air air SS 110531 Pneumatic actuator spring air plastic 104156 Repair kit actuator spring air 110014 Clamp light duty 109999 NP4003016A Pressure plate type 1 110599 Pressure...

Page 27: ... w TC connect new style 110555 ASTM shut off body w TC connect old style 108960 ASTM flow thru body w TC connect new style 110024 ASTM flow thru body w TC connect old style 107205 ASTM TC connectable double outlet 107322 ASTM bottom outlet 45 TC single outlet 107179 ASTM bottom outlet 45 TC double outlet ...

Page 28: ... Class VI 105016 PTFE diaphragm USP Class VI Actuators Part Designation Description Picture 110010 NP2001997 Manual handle SS 110011 NP2001999 Pneumatic actuator spring air SS 110207 NP2002003 Pneumatic actuator air air SS 110533 Pneumatic actuator spring air plastic 104157 Repair kit actuator spring air 104557 NP4000813 Pressure plate type 1 103649 NP4007652 Pressure plate type 2 110015 Clamp lig...

Page 29: ... Description Picture 108936 ASTM shut off body w TC connect new style 108968 ASTM flow thru body w TC connect new style 107225 ASTM bottom outlet 45 TC single outlet 107211 ASTM bottom outlet 45 TC double outlet 108411 ASTM bottom outlet w 1 2 satellite valve ...

Page 30: ...USP Class VI 105651 PTFE1 5 PTFE diaphragm USP Class VI Actuators Part Designation Description Picture 110012 NP2006912 Manual handle SS 110013 NP2006659 Pneumatic actuator spring air SS 110252 Pneumatic actuator air air SS 110535 Pneumatic actuator spring air plastic 110015 Clamp light duty 104158 Repair kit actuator spring air 104557 NP4000813 Pressure plate type 1 103649 NP4007652 Pressure plat...

Page 31: ...lve Housings Part Designation Description Picture 108893 ASTM shut off body w TC connect 108976 ASTM flow thru body w TC connect new style 107251 ASTM bottom outlet 45 TC single outlet 107237 ASTM bottom outlet 45 TC double outlet ...

Page 32: ...10232 NP3010534 Manual handle SS 110155 Pneumatic actuator spring air SS 110537 Pneumatic actuator spring air plastic 109829 NP1010323 Pneumatic actuator spring air cylinder only SS Valve Housings Part Designation Description Picture 108897 ASTM shut off body w TC connect 108984 ASTM flow thru body w TC connect 107279 ASTM bottom outlet 45 TC single outlet 107263 ASTM bottom outlet 45 TC double ou...

Page 33: ... NP1010659 Manual handle SS 110214 NP1010743 Pneumatic actuator spring air SS 110539 Pneumatic actuator spring air plastic 109830 NP1010743 Pneumatic actuator spring air cylinder only SS Valve Housings Part Designation Description Picture 108952 ASTM shut off body w TC connect 108992 ASTM flow thru body w TC connect 107311 ASTM bottom outlet 45 TC single outlet 107293 ASTM bottom outlet 45 TC doub...

Page 34: ...e is included showing the part number batch number and heat numbers for all components this could include the housing fittings and connections Mill certificates are provided for each different heat number shown in the Certificate of Compliance Diaphragms All diaphragms are traceable Each diaphragm is provided with a Certificate of Compliance indicating the material compliance requirements e g USP ...

Page 35: ...egory 2 units in Zone 1 or 21 These units are supposed to be used in Temperature Code T4 applications The fluid temperature has to be less than 120 C The grounding of a metal body has to be realized with the complete pipeline For the assessment of the products according to the pressure directive the European Standards EN 60730 1 01 02 EN 60730 2 8 10 95 were used According to this directive the CE...

Page 36: ...id valves VDE 0580 10 94 Electromagnetic devices General specifications Applied harmonized standards for electromagnetic compatibility EMC EN 61000 6 4 08 02 EMC Generic emission standard Industrial environment EN 61000 6 2 08 02 EMC Generic immunity standard Industrial environment EN 61000 3 2 12 01 Harmonic Current EN 61000 3 3 05 02 Voltage Variation Applied harmonized standards for pressure eq...

Page 37: ...an enviable reputation in our market areas Sterimixer and Sterivalver applications Our mission is to enable our customers to achieve a market leading position by being the most competent Mag Drive Mixing solution partner Steridose is known for its client s integrity and proactive approach with involvement stretching beyond our customer s expectations Steridose Head Office STERIDOSE HIMMELSBODAVÄGE...

Page 38: ...dards regarding pressure vessels if applicable As an example Figure 1 shows the required distance according to the 1987 Swedish standards for pressure vessels TKN 87 minimum of three times for the thickness of the material of the dished end 3 x t Figure 1 distance between welds Welding TIG Cut a hole for the valve housing in the dished end Grind the edge of the hole to prepare a suitable weld gap ...

Page 39: ...wer dished end in one operation Make sure that the weld is well burned through and that it is free from pores and cracks Use as low heat as possible low current High heat can deform the valve housing Continue welding until the weld opening is completely filled Turn over the dished end and weld from the inside in order to smooth out the weld seam If it is considered necessary some filler material m...

Page 40: ...en Operating voltage V 10 36 DC Current rating mA 250 Short circuit protection pulsed Reverse polarity protection yes Overload protection yes Voltage drop V 2 5 Current consumption mA 15 25V Real sensing range mm 2 10 Operating distance mm 0 1 6 Switch point drift of Sr 10 10 Hysteresis of Sr 3 15 Switching frequency Hz 1200 Correction factors mild steel 1 stainless steel approx 0 7 brass approx 0...

Page 41: ...on contact mechanism designed for up to 106 switching operations The silver contacts are gold plated The housing can be rotated through 360 In addition to the electrical position signal there is also visual indication from a red cam via the transparent section Technical specifications Ambient temperature C 15 60 Protection IP 65 Operating voltage V 250AC 24DC Current rating A 4 Protection Class EX...

Page 42: ...e pneumatic actuator Both micro switches can be continuously and precisely adjusted independent of each other via thread spindles The housing can be rotated 360 Technical specifications Setting range of limit switch 2 20 mm continuous Ambient temperature C 20 60 Protection IP65 Operating voltage V 250AC 24DC Current rating A 4 2 5 Approvals UL 508 CSA C22 2 Dimensions mm ...

Page 43: ...l or inductive switches are housed in a compact splash proof enclosure The position indicator can be rotated 360 and is easily fitted to the valve Technical specifications Material Plastic Protection IP65 Mechanical limit switch per limit switch Ambient temperature C 20 to 60 Operating voltage V 110 250 AC DC 12 48 AC DC Current rating mA 8 35 Approval VDE IEC UL CSA ATEX versions II 2 GD EEx ia I...

Page 44: ...Page 44 45 REV STV20110519 Dimensions mm ...

Page 45: ...or size 51 2 and 76 3 The inductive switches are mounted on a plastic holder mounted on the actuator Technical Specifications Diameter mm 11 Length mm 32 Operating voltage V 10 30 VDC Connection type mA pnp L Sensing range mm 5 Thread M12 Weight each kg 0 07 Cable length m 5 ...

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