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2 Safety

Unsafe practices and other important information are emphasized in this manual.
Warnings are emphasized by means of special signs.

2.1

Important information

Important information

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 followed to avoid damage to the valve.

NOTE
Indicates important information to simplify or clarify procedures.

2.2

Warning signs

General warning:

Caustic agents:

Cutting danger:

Содержание Unique TO

Страница 1: ...TD 449 282_1 ESE00156 EN7 2017 03 Original manual Instruction Manual Unique TO Mixproof Tank Outlet Valve ...

Страница 2: ......

Страница 3: ...eneral maintenance 19 5 2 Dismantling of valve 21 5 3 Tank plug replacement of radial seal 24 5 4 Balanced plug replacement of axial seal 25 5 5 Assembly of valve 27 5 6 Dismantling of acutator 30 5 7 Assembly of actuator 32 6 Technical data 34 6 1 Technical data 34 7 Parts list and service kits 36 7 1 Actuator 36 7 2 Plug setup 6 tank flange 38 7 3 Plug setup 12 tank flange 40 7 4 Plug setup 6 st...

Страница 4: ... the following directive with amendments Machinery Directive 2006 42 EC Regulation EC No 1935 2004 The valve is in compliance with the Pressure Equipment Directive 97 23 EC and was subjected to the following assessment procedure Module A Diameters DN125 may not be used for fluids group 1 The person authorised to compile the technical file is the signer of this document Global Product Quality Manag...

Страница 5: ... information 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 followed to avoid damage to the valve NOTE Indicates important information to simplify or clarify procedures 2 2 Warning signs General warning Caustic agents Cutting danger 5 ...

Страница 6: ...handle lye and acid with great care Maintenance Always read the technical data thoroughly see chapter 6 Technical data Always fit the seals correctly Always release compressed air after use Always remove the CIP connections if supplied before service Never service the valve when it is hot Never pressurise the valve actuator when the valve is serviced Never stick your fingers through the valve port...

Страница 7: ...termediate storage Step 1 CAUTION Alfa Laval cannot be held responsible for incorrect unpacking Check the delivery for 1 Complete valve 2 Delivery note 3 Warning label Step 2 Remove upper support TD 449 294_1 Step 3 Lift out the valve NOTE Please note weight of valve as printed on box Step 4 Remove possible packing materials from the valve ports NOTE Remember to fit leakage detection pipe TD 449 2...

Страница 8: ...tep 5 Inspect the valve for visible transport damages Inspection Step 6 Avoid damaging the air connections the leakage outlet the valve ports and the CIP connections if supplied Caution Step 7 Disassemble according to illustrations 1 to 5 please also see 5 2 Dismantling of valve 1 Supply compressed air 2 Remove clamp 3 Release compressed air 4 Lift out actuator with plugs 5 Remove clamp 8 ...

Страница 9: ...n 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 off in agreement with local regulations Scrapping At end of use the equipment must be recycled according to the relevant local regulations Besides the equipment itself an...

Страница 10: ...f the tubes especially at long tube lengths Excessive welding Overloading of the pipelines NOTE Please follow Alfa Laval installation guidelines literature code ESE00040 Risk of damage TD 449 241 Step 3 Fittings Ensure that the connections are tight Remember seal rings Step 4 Air connection R 1 8 BSP AC1 Cleaning of balanced plug AC2 Open valve AC3 Cleaning of tank plug Step 5 CIP connection optio...

Страница 11: ...eration after welding Step 6 It is important to connect CIP inlet to the small inlet nozzle to avoid built up pressure in the cleaning chamber CIP out CIP in Align nozzle edges with recess in sealing element 3 4 Welding Step 1 Never stick your fingers in the operating parts of the valve if the actuator is supplied with compressed air Cutting danger Air Step 2 Dismantle the valve in accordance with...

Страница 12: ...100 125 150 63 5 76 1 63 80 with tank flange A1 579 646 659 753 577 652 667 755 805 890 700 713 706 721 with external cleaning and tank flange A1 616 686 699 813 614 692 707 815 865 N A 740 753 746 761 with stub flange A 588 655 668 762 586 661 676 764 814 899 709 722 715 730 with external cleaning and stub flange A 625 695 708 822 623 701 716 824 874 N A 749 762 755 770 If ThinkTop is mounted add...

Страница 13: ...valve body correctly conical seat downwards before welding NOTE Always weld the valve body into the pipeline so that the seal ring 76 can be replaced Step 5 Assemble the valve in accordance with 5 5 Assembly of valve after welding Pay special attention to the warnings and clamp torque see 5 5 Assembly of valve Step 6 Pre use check 1 Supply compressed air to AC1 AC2 and AC3 one by one 2 Operate the...

Страница 14: ...y see 6 Technical data 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 connections AC1 AC3 simultaneously as both valve plugs can be lifted can cause mixing CAUTION Alfa Laval cannot be held responsible for incorrect operation Step 2 Never touch the valve or t...

Страница 15: ... rubber grade Clean and if necessary replace guide ring 45 Leakage at clamp 64 and 65 Too old product affected o rings 76 and 47 valve body Loose clamp 64 or 65 Replace the o rings Change rubber grade Tighten the clamp max 10 Nm CIP leakage Leakage at spindle clamp 43 Worn o rings 40 67 Damaged o ring 39 Worn product affected lip seal 57 Replace the o rings Replace the o ring Replace the plug seal...

Страница 16: ...ctive goggles Step 2 Never touch the valve or the pipelines when sterilizing Burning danger Step 3 Never throttle the leakage outlet Never throttle the CIP outlet if supplied Risk of mixing due to overpressure A Leakage CIP out B CIP out C CIP in TD 449 247_1 A TD 449 251_1 B C Step 4 Examples of cleaning agents Use clean water free from chlorides 1 1 by weight NaOH at 70o C 158o F 2 0 5 by weight...

Страница 17: ...rease the cleaning flow Step 6 Advisory seat lift cleaning periods Cleaning periods of 1 2 seconds per CIP sequence Product Periods Milk 1 2 Yoghurt 3 5 Beer 2 5 Cold wort 5 10 Step 7 Always rinse well with clean water after the cleaning NOTE The cleaning agents must be stored disposed of in accordance with current rules directives Pay special attention to spillage of hot cleaning fluid water Alwa...

Страница 18: ...ention to the warnings NaOH Caustic Soda HNO3 Nitric acid Internal leakage in the valve is externally visible by means of the leakage outlet Step 10 3 Open valve A Product B Leakage detecting TD 449 292_1 A B Step 11 4 Seat lift cleaning with balanced plug seeStep 6 A Product B CIP C CIP out A B C TD 449 289_1 18 ...

Страница 19: ...ssed air after use Always remove the CIP connections if supplied before service NOTE All scrap must be stored disposed of in accordance with current rules directives Step 2 Never service the valve when it is hot Never service the valve with valve actuator under pressure Never service the valve with fluid in the tank Atmospheric pressure required Burning danger Step 3 Never stick your fingers in op...

Страница 20: ...cle Replace after production cycle Planned maintenance Regular inspection for leakage and smooth operation Keep a record of the valve Use the statistics for planning of inspections Regular inspection for leakage and smooth operation Keep a record of the valve Use the statistics for planning of inspections Replace when required Lubrication When assembling Klüber Paraliq GTE 703 or similar USDA H1 a...

Страница 21: ...ove clamp 64 3 Release compressed air 4 Lift out the actuator together with the internal valve parts from valve body 51 5 Loosen and remove clamp 65 and valve body 51 6 Pull out tube 88 from balanced plug 94 and remove o ring 89 from tube From February 1st 2017 Turn out tube 88 from balanced plug 94 and remove o ring 89 from balanced plug 7 When tank flange Pull out o ring 76 from valve body 51 Wh...

Страница 22: ...osen tank plug 93 while counterholding upper stem 1 3 Remove the tank plug 4 Release compressed air 5 Replace o ring 38 A On B Off If balanced seat lift is available A B TD 449 296_1 2B If no air fitting AC1 is present follow procedure 2B 1 Push sealing element 48 free of intermediate piece 37 2 Loosen tank plug while counterholding upper stem 3 Remove the tank plug 93 4 Replace o ring 38 If no ba...

Страница 23: ...re spindle liner is free of both piston rod and balanced plug If external CIP to leakage chamber Remove o rings 39 Step 4 1 If present unscrew flushing tubes 66 and remove o rings 67 and nozzles 68 69 2 Pull out sealing element 48 from intermediate piece 37 3 Pull out o ring 47 lip seal 49 and o ring 46 from sealing element Step 5 Remove lip seal 57 or spray nozzle 58 if valve is supplied with Spi...

Страница 24: ... similar Be careful not to scratch the plug TD 449 345 Step 2 Pre mount seal ring as shown on drawing A Carefully lubricate sealings with acceptable lubricant before pre mounting B Do not lubricate behind the sealing Rotate along circumference to fix gasket as shown in the picture TD 449 346_1 A B Item numbers for radial tool Seat ø53 3 Seat ø81 3 Seat ø100 3 Seat ø115 3 9613 4260 01 9613 4260 02 ...

Страница 25: ...arts together TD 449 343_2 Tool marked with item number Step 5 1 Supply compressed air 2 Release compressed air 3 Remove tool parts A On B Off TD 449 344_1 A B Step 6 Inspect the seal to ensure it does not twist in the groove and press in the 4 outsticking points with a screwdriver TD 449 347 5 4 Balanced plug replacement of axial seal Step 1 Remove old seal ring 56 using a knife screwdriver or si...

Страница 26: ...sealings with acceptable lubricant before pre mounting Item no for tool for axial sealing upper plug Seat ø53 3 Seat ø81 3 Seat ø101 3 Seat ø115 3 9613 0505 01 9613 0505 02 9613 0505 08 9613 0505 03 Step 3 Place tool part 1 Step 4 1 Place tool part 2 including piston 2 Clamp the two tool parts together Tooling marked with item number Step 5 1 Supply compressed air 2 Release compressed air 3 Rotate...

Страница 27: ...ly pressed into the groove 2 Fit sealing element in intermediate piece 37 3 Place o rings 67 and mount flushing tubes 66 Be sure to align nozzles 68 69 towards recess Lightly lubricate inner grove with Klüber Paralique GT 703 Step 2 1 Place lip seal 57 in upper plug or spray nozzle if the valve has SpiralClean and the o ring 38 in the lower plug 2 Press tank plug 93 rapidly into balanced plug 94 t...

Страница 28: ...ck 44 up over piston rod 29 2 If external CIP to leakage chamber Place o rings 39 3 Place spindle liner 42 on piston rod Fit balanced plug 94 4 Mount clamps 43 on spindle liner 42 5 Fit lock 44 6 Fit o ring 40 Fit flushing tube 41 or plug 15 if no CIP Step 4 Recommended torque values for fitting balanced and tank plug parts Dimension Torque Nm lbf ft 51 mm 2 DN 50 5 3 7 All others 20 14 8 A B TD 4...

Страница 29: ...alve body in tank flange and tighten clamp 65 Maximum torque for clamp bolts 17 Nm 13 lbf ft OR if stub flange Fit o ring 91 in stub flange 92 and mount valve body 51 in stub flange and tighten clamp 65 Maximum torque for clamp bolts 17 Nm 13 lbf ft 2 Supply compressed air and mount the actuator together with the internal valve parts 3 Fit and tighten clamp 64 Maximum torque for clamp nut 10Nm 7 4...

Страница 30: ... washers 35 2 Pull out intermediate piece 37 from the actuator 3 Remove cover disk 25 4 Remove plug 86 with o rings 85 87 from intermediate piece 37 Step 3 1 Remove piston rod 29 bottom 21 and lower piston 30 2 Separate the three parts 3 Remove o rings 20 22 and 23 from bottom o rings 33 and 31 and guide ring 32 from lower piston as well as o ring 28 from piston rod 4 Remove spring assembly 14 Ste...

Страница 31: ...5 Maintenance Study the instructions carefully The items refer to the parts list and service kits section Handle scrap correctly Always use genuine Alfa Laval spare parts Replace seals if necessary 31 ...

Страница 32: ...r 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 27 Step 4 1 Fit spring assembly 14 2 Fit o ring 28 in piston rod fit o rings 33 and 31 and guide ring 32 in lower piston and fit o rings 20 22 and 23 in bottom 3 Fit piston rod 29 lower piston 30 and bottom 21 4 Mount...

Страница 33: ...ce Study the instructions carefully The items refer to the parts list and service kits section Always use genuine Alfa Laval spare parts Replace seals if necessary Lubricate the rubber seals before fitting them 33 ...

Страница 34: ...ure Full vacuum Recommended min pressure for SpiralClean 2 bar 29 psi max 8 bar 116 psi Temperature range 5 C to 125 C 23 F to 257 F NBR only up to 85 C 175 F Air pressure Max 800 kPa 8 bar 116 psi Products acc to PED 97 23 EC Category I Fluids group 1 DN 125 only Fluids group 2 Materials Product wetted steel parts Acid resistant steel AISI 316L Other steel parts Stainless steel AISI 304 Product w...

Страница 35: ... 11 0 8 36 16 3 16 3 11 0 11 0 11 0 11 0 Kv value for Tank Seat lift m3 h 0 90 1 90 1 90 1 40 0 90 1 90 1 90 1 40 3 10 3 10 1 90 1 90 1 90 1 90 CV value for Balanced Tank Seat lift GPM 3 96 8 36 8 36 6 16 3 96 8 36 8 36 6 16 13 7 13 7 8 36 8 36 8 36 8 36 Kv value for SpiralClean Spindle CIP m3 h 0 12 0 12 0 12 0 12 0 12 0 12 0 12 0 12 0 12 0 12 0 12 0 12 0 12 0 12 CV value for SpiralClean Spindle ...

Страница 36: ...Laval products is dependent on the use of Alfa Laval genuine spare parts 7 1 Actuator actuator kit Not used in actuator 1 2 2306 0005 5 3 2 15 16 15 1 3 3 1 6 8 4 2 10 11 1 11 1 12 14 26 28 29 17 32 18 30 19 31 33 13 27 21 20 22 23 24 25 34 35 36 85 86 87 9 7 Not used in actuator 2 3 4 and 6 36 ...

Страница 37: ...embly 15 1 Plug 15 1 1 Plug 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 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 32 1 Guide ring Turcite 33 1 O ring NBR 34 3 Bolt 35 3 Washer 36 3 Nut 85 1 O ring NBR 86 1 Prop 87 1 O ring NBR Serv...

Страница 38: ...rranty of Alfa Laval products is dependent on the use of Alfa Laval genuine spare parts 7 2 Plug setup 6 tank flange 2306 0007 wear parts 37 39 44 43 42 41 43 39 45 15 69 40 46 48 67 67 66 49 68 47 89 66 94 58 88 56 54 57 38 74 93 2306 0006 with SpiralClean in leakage chamber 38 ...

Страница 39: ...ring EPDM 93 1 Tank plug 94 1 Balance plug Service kits Denomination DN OD 51 DN50 Seat ø53 3 DN OD 63 5 DN OD 76 1 DN65 DN80 Seat ø81 3 LongStroke DN OD 63 5 DN OD 76 1 DN65 DN80 Seat ø81 3 DN OD 101 6 DN 100 Seat ø100 3 DN 125 Seat ø115 3 Service kit EPDM 9611926449 9611926453 9611926453 9611926457 9611926461 Service kit NBR 9611926450 9611926454 9611926454 9611926458 9611926462 Service kit FPM ...

Страница 40: ...rts The warranty of Alfa Laval products is dependent on the use of Alfa Laval genuine spare parts 7 3 Plug setup 12 tank flange 94 58 56 54 57 38 74 93 49 47 89 88 45 48 39 37 39 44 43 42 41 43 15 40 2306 0009 2306 0008 wear parts with SpiralClean in leakage chamber 40 ...

Страница 41: ...ion DN OD 51 DN50 Seat ø53 3 DN OD 63 5 DN OD 76 1 DN65 DN80 Seat ø81 3 LongStroke DN OD 63 5 DN OD 76 1 DN65 DN80 Seat ø81 3 DN OD 101 6 DN 100 Seat ø100 3 DN 125 Seat ø115 3 DN 150 Seat ø115 3 Service kit EPDM 9611926433 9611926437 9611926437 9611926441 9611926445 9611926445 Service kit NBR 9611926434 9611926438 9611926438 9611926442 9611926446 9611926446 Service kit FPM 9611926435 9611926439 96...

Страница 42: ...rranty of Alfa Laval products is dependent on the use of Alfa Laval genuine spare parts 7 4 Plug setup 6 stub flange 2306 0007 wear parts 37 39 44 43 42 41 43 39 45 15 69 40 46 48 67 67 66 49 68 47 89 66 94 58 88 56 54 57 38 74 93 2306 0006 with SpiralClean in leakage chamber 42 ...

Страница 43: ...1 O ring EPDM 93 1 Tank plug 94 1 Balance plug Service kits Denomination DN OD 51 DN50 Seat ø53 3 DN OD 63 5 DN OD 76 1 DN65 DN80 Seat ø81 3 LongStroke DN OD 63 5 DN OD 76 1 DN65 DN80 Seat ø81 3 DN OD 101 6 DN 100 Seat ø100 3 DN 125 Seat ø115 3 Service kit EPDM 9611926481 9611926485 9611926485 9611926489 9611926493 Service kit NBR 9611926482 9611926486 9611926486 9611926490 9611926494 Service kit ...

Страница 44: ...rts The warranty of Alfa Laval products is dependent on the use of Alfa Laval genuine spare parts 7 5 Plug setup 12 stub flange 94 58 56 54 57 38 74 93 49 47 89 88 45 48 39 37 39 44 43 42 41 43 15 40 2306 0009 2306 0008 wear parts with SpiralClean in leakage chamber 44 ...

Страница 45: ... 1 Balance plug Service kits Denomination DN OD 51 DN50 Seat ø53 3 DN OD 63 5 DN OD 76 1 DN65 DN80 Seat ø81 3 LongStroke DN OD 63 5 DN OD 76 1 DN65 DN80 Seat ø81 3 DN OD 101 6 DN 100 Seat ø100 3 DN 125 Seat ø115 3 DN 150 Seat ø115 3 Service kit EPDM 9611926449 9611926453 9611926453 9611926457 9611926461 9611926461 Service kit NBR 9611926450 9611926454 9611926454 9611926458 9611926462 9611926462 Se...

Страница 46: ... list and service kits Always use Alfa Laval genuine spare parts The warranty of Alfa Laval products is dependent on the use of Alfa Laval genuine spare parts 7 6 Valve bodies 91 92 51 65 76 90 2306 0011 65 46 ...

Страница 47: ...re parts The warranty of Alfa Laval products is dependent on the use of Alfa Laval genuine spare parts Parts list Pos Qty Denomination 37 1 Intermediate piece 51 1 Valve body upper 65 2 Clamp with screws 76 1 O ring 90 1 Tank flange 91 1 O ring 92 1 Stub flange 47 ...

Страница 48: ...Parts list and service kits Always use Alfa Laval genuine spare parts The warranty of Alfa Laval products is dependent on the use of Alfa Laval genuine spare parts 7 7 Installation kit B 2 1 TD 449 306 48 ...

Страница 49: ... Always use Alfa Laval genuine spare parts The warranty of Alfa Laval products is dependent on the use of Alfa Laval genuine spare parts Parts list Pos Qty Denomination 1 1 Hose PTFE with stainless steel weave 2 1 Welding socket 49 ...

Страница 50: ...Parts list and service kits Always use Alfa Laval genuine spare parts The warranty of Alfa Laval products is dependent on the use of Alfa Laval genuine spare parts 7 8 Installation kit C 1 2 TD 449 307 50 ...

Страница 51: ... and service kits Always use Alfa Laval genuine spare parts The warranty of Alfa Laval products is dependent on the use of Alfa Laval genuine spare parts Parts list Pos Qty Denomination 1 1 Welding liner 2 1 Nut 51 ...

Страница 52: ...and service kits Always use Alfa Laval genuine spare parts The warranty of Alfa Laval products is dependent on the use of Alfa Laval genuine spare parts 7 9 Installation kit G 1 3 2 1 3 2 G1 2 TD 449 308 2 G2 3 2 52 ...

Страница 53: ...e Alfa Laval genuine spare parts The warranty of Alfa Laval products is dependent on the use of Alfa Laval genuine spare parts Parts list Pos Qty Denomination 1 1 Welding male part AISI 316 2 2 3 8 10 mm Female PVDF 3 1 10 mm PVDF hose 1m 53 ...

Страница 54: ...t and service kits Always use Alfa Laval genuine spare parts The warranty of Alfa Laval products is dependent on the use of Alfa Laval genuine spare parts 7 10 Installation kit H and H2 H2 1 3 4 5 2 TD 449 309 54 ...

Страница 55: ...spare parts The warranty of Alfa Laval products is dependent on the use of Alfa Laval genuine spare parts Parts list Pos Qty Denomination 1 1 DIN union DN10 2 1 12 mm CIP pipe long 3 1 12 mm CIP pipe 4 1 Hose PTFE with stainless steel weave 5 1 Welding socket 55 ...

Страница 56: ...t and service kits Always use Alfa Laval genuine spare parts The warranty of Alfa Laval products is dependent on the use of Alfa Laval genuine spare parts 7 11 Axial installation tool 7 5 3 4 6 1 2 TD 449 038_1 56 ...

Страница 57: ...Laval genuine spare parts The warranty of Alfa Laval products is dependent on the use of Alfa Laval genuine spare parts Parts list Pos Qty Denomination 1 1 Lower Part 2 1 Piston 3 1 Upper Part 4 1 O ring NBR 5 1 Clamp 6 1 Wingnut 7 1 Air fitting 57 ...

Страница 58: ...service kits Always use Alfa Laval genuine spare parts The warranty of Alfa Laval products is dependent on the use of Alfa Laval genuine spare parts 7 12 Radial installation tool 3 9 1 6 7 6 2 8 11 4 5 10 TD 449 354 58 ...

Страница 59: ...he warranty of Alfa Laval products is dependent on the use of Alfa Laval genuine spare parts Parts list Pos Qty Denomination 1 1 Piston 2 1 Lower Part 3 1 Upper Part 4 1 Bushing 5 1 Guide 6 2 Guide ring 7 1 O ring NBR 8 1 O ring NBR 9 1 Clamp 10 1 Wingnut 11 1 Air fitting 59 ...

Страница 60: ...ts list and service kits Always use Alfa Laval genuine spare parts The warranty of Alfa Laval products is dependent on the use of Alfa Laval genuine spare parts 7 13 Mounting tool for lip seal TD 449 310 60 ...

Страница 61: ...nd service kits Always use Alfa Laval genuine spare parts The warranty of Alfa Laval products is dependent on the use of Alfa Laval genuine spare parts Parts list Pos Qty Denomination 1 Mounting tool for lip seal 61 ...

Страница 62: ...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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