IM70007-GB12 2002-03
SRC Sanitary Remote-Controlled Valve
Instruction Manual
Name Title
Company Signature
Alfa Laval
6000 Kolding
+45 79 32 22 00
Company Name
Address
Phone No.
hereby declare that
Denomination Type Year
Declaration of Conformity
The designating company
Designation
Was manufactured in conformity with the provisions in the COUNCIL DIRECTIVE of 14 June
1989 on mutual approximation of the laws of the Member States on the safety of machines (89/
392/EEC as amended by directives 91/368/EEC and 93/44/EEC) with special reference to Annex
1 of the directive on essential safety and health requirements in relation to the construction
and manufacture of machines.
Bjarne Søndergaard Vice President, R & D
Alfa Laval
SANITARY REMOTE-CONTROLLED VALVE SRC
1
Safety
Installation
Operation
Maintenance
Technical data
Drawings/Parts list
This manual is divided into main sections. - See
below.
Table of contents
1. Important information .................................. 2
2. Warning signs ............................................. 2
3. Safety precautions ....................................... 3
1. Unpacking/Delivery ...................................... 4
2. Recommended auxiliary equipment
(DN125-150)................................................ 5
3. General installation ...................................... 6
4. Welding ....................................................... 7
5. Fitting of oil damper (optional extra) ............ 8
6. Fitting of indication equipment
(optional extra) ............................................ 9
7. Adjustment of indication equipment
(optional extra)........................................... 11
1. Operation ................................................... 12
2. Fault finding ............................................... 13
3. Recommended cleaning ............................ 14
1. General maintenance ................................ 15
2. Dismantling of valve .................................. 17
3. Assembly of valve ...................................... 18
4. Dismantling of actuator .............................. 19
5. Assembly of actuator ................................. 20
1. Technical data ........................................... 21
1. Parts lists
- SRC...................................... 22+24+26+28
- SRC DN125-150 .................. 30+32+34+36
- Oil damper ........................................ 38+40
- Indication units ....................................... 42
2. Exploded drawings
- SRC.................................................. 23+27
- SRC DN125-150 .............................. 31+35
- Oil damper .............................................. 39
- Indication units ....................................... 43
3. Drawings
- SRC.................................................. 25+29
- SRC DN125-150 .............................. 33+37
- Oil damper .............................................. 41
2
:
:
Safety
Unsafe practices and other important information are
emphasized in this manual.
Warnings are emphasized by means of special signs.
1. Important information
Always read the manual before using the valve!
Indicates that special procedures must be
followed to avoid severe personal injury.
Indicates that special procedures must be
followed to avoid damage to the valve.
Indicates important information to simplify
practices or to make them clearer.
WARNING! :
CAUTION! :
NOTE! :
2. Warning signs
General warning.
Caustic agents.
3
Installation:
:
:
:
:
Operation:
:
:
:
:
Maintenance:
:
:
:
:
3. Safety precautions
-Always read the technical data thoroughly
(see page 21).
-Always release compressed air after use.
Never touch the clip assembly or the actuator
piston rod if the actuator is supplied with
compressed air.
Never touch the valve or the pipelines when
processing hot liquids or when sterilizing.
-Never dismantle the valve with valve and
pipelines under pressure.
-Never dismantle the valve when it is hot.
-Always read the technical data thoroughly
(see page 21).
-Always release compressed air after use.
Never touch the valve or the pipelines when
processing hot liquids or when sterilizing.
Never touch the clip assembly or the actuator
piston rod if the actuator is supplied with
compressed air.
Always handle lye and acid with great care.
-Always read the technical data thoroughly
(see page 21).
-Always release compressed air after use.
-Never service the valve when it is hot.
-Never service the valve with valve and
pipelines under pressure.
Never stick your fingers through the valve ports if
the actuator is supplied with compressed air.
Never touch the clip assembly or the actuator
piston rod if the actuator is supplied with
compressed air.
All warnings in the manual are summarized on this
page.
Pay special attention to the instructions below so that
severe personal injury and/or damage to the valve are
avoided.
Safety
4
4
2
6
1
5
Installation
The instruction manual is part of the delivery.
Study the instructions carefully.
The items refer to the drawings and the parts list on the
pages 22-37.
The valve is supplied as separate parts as standard (for
welding).
The valve is assembled before delivery, if it is supplied
with fittings.
3
Change-over valve:
1. Complete actuator with bonnet (8).
2. Clip assembly (11).
3. Lip seal (14).
4. Two clamps (15).
5. Valve plug (20).
6. Two valve bodies (16, 18).
7. Valve body seal ring (17).
Remove possible packing materials from the valve/
valve parts.
Inspect the valve/valve parts for visible transport
damages.
Remove
packing
materials!
Avoid damaging the valve/valve parts.
Inspection! Caution!
1. Unpacking/Delivery
CAUTION!
Alfa Laval cannot be held responsible for incorrect
unpacking.
Check the delivery for:
1. Complete valve, stop valve or change-over
valve (see 2 and 3).
2. Delivery note.
3. Instruction Manual.
Please note that the design of sizes DN125-150
differs from that of sizes 25-101.6 mm/DN25-100.
The differences can be seen on pages 22-29 and
30-37.
The drawings in this manual show sizes 25-101.6
mm/DN25-100
Stop valve:
1. Complete actuator with bonnet (8).
2. Clip assembly (11).
3. Lip seal (14).
4. Clamp (15).
5. Valve plug (19).
6. Valve body (16).
5
1. Place the valve in the trestle.
2. Make sure that the actuator rests on the
rubber linings on the trestle support plates.
3. Dismantle/reassemble the valve.
Trestle
50
50
Side view
250
250
Top view
R 99.5
R 101.5
End view
10
Installation
The valve sizes DN125-150 are very heavy.
Therefore Alfa Laval recommends manufacturing and
usage of auxiliary equipment. A proposal is given below.
2. Recommended auxiliary equipment (DN125/150)
Please note that the auxiliary equipment cannot be
supplied by Alfa Laval.
The item refers to the drawings and parts list on pages
30-37.
1
12
43
5 6
6
For lifting the valve:
Screw an eye bolt (6 mm) into top pin (23).
Using a small hook crane or similar, lift the valve
by the eye bolt.
Trestle:
- The purpose of the trestle is to support the valve
during dismantling and reassembly.
- The trestle is made of a base plate, two support
plates, two rubber linings and four bolts.
- The rubber linings are attached to the support
plates so that the valve/actuator will rest on
these.
- To prevent the valve from turning during
dismantling and reassembly the trestle must be
made with the correct measurements (see 3, 4
and 5). All measurements are in mm.
6
Avoid stressing the valve.
Pay special attention to:
- Vibrations.
- Thermal expansion of the tubes.
- Excessive welding.
- Overloading of the pipelines.
-Always read the technical data thoroughly
(see page 21).
-Always release compressed air after use.
CAUTION!
Alfa Laval cannot be held responsible for incorrect
installation.
1
3
5
4
2
6
Study the instructions carefully and pay special
attention to the warnings!
The valve has welding ends as standard but can also be
supplied with fittings.
NO = Normally open.
NC = Normally closed.
A/A = Air/air activated.
2. General installation
Never touch the clip assembly or the
actuator piston rod if the actuator is supplied
with compressed air.
Fittings:
Ensure that the connections are tight.
Moving parts!
Risk of
damage!
Air
Remember seal
rings!
Air
NO NC A/A
It is recommended to install the valve so that:
- The actuator is not turned downwards as the
valve will then not be drained.
- The flow is against the closing direction
to avoid water hammer.
Inlet
Avoid water
hammer!
Stop valve
Inlet
Change-over valve
Installation
Air
R1/8" (BSP)
Air Air
Inlet
Air
Air connection:
7
Valve size A (mm) B1 (mm) B2 (mm)
DN25/25 mm 200 537 647
DN40/38 mm 230 550 730
DN50/51 mm 290 550 730
DN65/63.5 mm 350 550 730
DN80/76 mm 390 600 780
DN100/101.6 mm 490 650 830
DN125 580 730 920
DN150 640 730 920
1
2
4
3
Study the instructions carefully.
The valve is supplied as separate parts to facilitate the
welding.
The items refer to the drawings and the parts list on the
pages 22-37.
Check the valve for smooth operation after welding.
3. Welding
Always weld the valve so that the valve body seal
ring can be replaced (change-over valve).
Maintain the minimum clearances (A and B) so that
the lower valve body and plug (change-over valve)
and the actuator with the internal parts can be
removed.
Stop valve:
Assemble the valve in accordance with the
instructions 2-5 on page 18.
Pay special attention to the warnings!
Change-over valve:
Assemble the valve in accordance with the instruc-
tions 2-6 on page 18.
Pay special attention to the warnings!
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!
Change-over valve
(upper valve body)
Stop valve
B1
B2 (incl. top unit)
Fit seal ring (17)
correctly!
Remember
seal rings!
Air
Open/close!
Installation
B1
B2 (incl.
top unit)
A
5
SRC 25 mm stop valve
The 25 mm actuator is only for use on the SRC 25
mm stop valve.
Warning: When changing from NC to NO please
note that the actuator is spring-loaded. For safety,
place a "Spring-loaded" warning label (ordered
from Technical Support at Alfa Laval) on the valve.
Air (NO/AA)
Air (NC/AA)
8
12
56
34
The valve can be fitted with an oil damper if water
hammer occurs when the valve closes in the flow
direction.
The items refer to the drawings and the parts list on
pages 38-41.
Study the instructions carefully and pay special
attention to the warnings!
NC = normally closed.
A/A = air/air activated.
4. Fitting of oil damper, 25-101.6 mm/DN25-100, optional extra
Fill further oil through the plug hole if large air
bubbles occur under the plexiglas cover.
NOTE!
There should be a small air bubble which equalizes
changes in the pressure because of temperature
changes.
Removal/dismantling:
Remove the damper by following the instructions in
reverse order.
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!
Never touch the valve or the pipelines when
processing hot liquids or when sterilizing.
Burning danger!
1. Supply compressed air to the actuator.
Pay special attention to the warnings!
2. Fit the damper so that damper piston rod (72)
enters actuator piston rod (6).
Oil type SAE 40
Ensure that
no other
equipment
is fitted on the
actuator top!
1. Fit protective hood (84).
2. The valve is now ready for operation.
1. Connect the two piston rods by means of clip
(71).
2. Release compressed air to the actuator.
Pay special attention to the warnings!
Air (NC, A/A)
Installation
Air (NC, A/A)
9
1
3
2
The valve can be fitted with the top units LKT-N and
LKT-S. It can also be fitted with an indication unit.
Study the instructions carefully and pay special
attention to the warnings!
The items refer to the drawings and the parts list on
pages 42-43.
5. Fitting indication equipment, 25-101.6 mm/DN25-100, optional extra
5
4
58
Change-over valve
Indication unit
1. Fit ring (56) on the plug stem.
2. Assemble the valve in accordance with the
instructions 3-6 on page 18.
Pay special attention to the warnings!
Stop valve
Dismantle the valve in accordance with the
instructions 1-4 on page 17.
Pay special attention to the warnings!
-Never dismantle the valve when it is hot.
-Never dismantle the valve with valve and
pipelines under pressure.
Burning
danger!
Installation
CAUTION!
The indication and control equipment must be
electrically installed by authorized personnel.
-Top unit ThinkTop®:
(see the separate instruction manuals).
- Indication unit:
(see the instructions on the pages 9-11).
Micro switch unit:
1. Assemble and fit the switch unit
2. Turn ring (56) so that the edges of holder (51)
guide its movements.
3. Ensure that spring (57) enters the recess in
the ring.
4. Fix the switch unit by means of screws (58).
Atmospheric
pressure required!
ThinkTop®
10
6
78
The indication unit has one or two micro switches or an
inductive proximity switch.
Study the instructions carefully.
The items refer to the drawings and the parts list on the
pages 42-43.
5. Fitting indication equipment, 25-101.6 mm/DN25-100, optional extra
Inductive proximity switch unit:
1. Assemble and fit the switch unit
2. Turn ring (56) so that the edges of holder (51)
guide its movements.
3. Fix the switch unit by means of screws (58).
910
Fit the cable through the cable gland and assemble
cable socket (59).
Micro switch unit:
Connect the cable to switch unit (53) as shown in
the wiring diagram.
Inductive proximity switch unit:
Connect the cable to switch unit (53) as shown in
the wiring diagram.
Tighten screw (59) firmly.
NOTE!
The cable gland should be sealed with silicone
rubber under extreme conditions.
58
Cable
Wiring diagram
Wiring diagram
Male connector
(pin side)
Turn the
cable outlet
downwards!
59
Ø = Connected in cable connector
A = One micro switch
B = Two micro switches
C = Male connector (pin side)
Installation
11
1
2
Adjust the micro switch and inductive proximity switch
units after installation.
Study the instructions carefully.
The items refer to the drawings and the parts list on the
pages 42-43.
6. Adjustment of indication equipment, 25-101.6 mm/DN25-100,
optional extra
Micro switch unit:
(Adjustment of contact point between spring (57)
and switch unit (53)).
1. Loosen switch unit (53) slightly (screw (58)).
2. Rotate adjustment screw (60) until a signal is
obtained.
3. Tighten the switch unit.
4. Check that the signal is correct.
5. Readjust if necessary.
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!
Open/close!
58
Installation
Air (NO/AA)
Air (NC/AA)
12
1
3
2
5
4
Study the instructions carefully and pay special
attention to the warnings!
Ensure that the valve operates smoothly.
The items refer to the drawings and the parts list on the
pages 22-37.
-Always read the technical data thoroughly
(see page 21).
-Always release compressed air after use.
CAUTION!
Alfa Laval cannot be held responsible for incorrect
operation.
Never touch the valve or the pipelines when
processing hot liquids or when sterilizing.
Never touch the clip assembly or the
actuator piston rod if the actuator is supplied
with compressed air.
Moving
parts!
Air (NO)
Burning
danger!
1. Operation
Lubrication of valve:
1. Ensure smooth movement between lip seal
(14) and plug stem (19, 20).
2. Lubricate with silicone oil/grease if necessary.
Lubricate if
necessary!
(see page 15)
Lubrication of actuator
1. Ensure smooth movement of the actuator
(the actuator is lubricated before delivery).
2. Lubricate with oil/grease if necessary.
Operation
Change-over valve:
1. Supply compressed air to the actuator.
2. Loosen and remove lower clamp (15).
3. Remove lower valve body (18).
4. Pull out seal ring (17).
5. Release compressed air.
Pay special attention to the warnings!
Air (NC/AA)
Air (NC, A/A)
Lubricate if
necessary!
(see page 15)
Change-over
valve
Stop valve
13
The valve plug jerks The sealings seize Lubricate:
- O-rings (2)
- O-ring (5) and the inside of
cylinder (3)
- Lip seal (14)
Product leakage Worn/product affected lip - Replace the seals
at stem and/or clamp seal (14) and/or seal ring (17) - Replace with seals of a
different rubber grade
Product leakage - Worn/product affected - Replace the seal ring
(closed valve) plug seal ring - Replace with a seal of a
different rubber grade
- Loose plug parts - Tighten the loose parts
(vibrations)
- Product deposits on - Frequent cleaning
the seat and/or plug
Product leakage - Worn actuator O-rings - Replace the O-rings
(too high pressure or too - Too small actuator or - Replace with a larger actuator
small actuator) actuator spring (for valve sizes 38 - 63.5 mm
(1½ - 2½))
- Fit a stronger spring
- Use auxiliary air on the spring
side (NOT-element)
Water hammer The flow direction is the - The flow direction should be
same as the closing direction against the closing direction
- Fit a damper on the valve
(optional extra)
- Use auxiliary air on the spring
side (NOT-element)
The valve does not - Faulty clip assembly (11) - Replace the clip assembly
open/close - The pressure on the plug - Reduce the pressure
plug is too high - Fit stronger spring/larger
actuator
Study the instructions carefully.
The items refer to the drawings and the parts list the on
pages 22-37.
Problem Cause/result Repair
Pay attention to possible faults.
2. Fault finding
NOTE!
Study the maintenance instructions carefully
before replacing worn parts. - See page 15!
Operation
14
1 kg + 100 l = Cleaning agent.
NaOH water
2.2 l + 100 l = Cleaning agent.
33% NaOH water
0.7 l + 100 l = Cleaning agent.
53% HNO3water
Caustic danger!
1
5
2
6
Always use Always use
rubber gloves! protective goggles!
The valve is designed for cleaning in place (CIP).
CIP = Cleaning In Place.
Study the instructions carefully and pay special
attention to the warnings!
NaOH = Caustic Soda.
HNO3 = Nitric acid.
3. Recommended cleaning
Always handle lye and acid with great care.
Never touch the valve or the pipelines when
sterilizing.
34
Examples of cleaning agents:
Use clean water, free from clorides.
1. 1% by weight NaOH at 70o C.
2. 0.5% by weight HNO3 at 70o C.
NOTE!
The cleaning agents must be stored/disposed of in
accordance with current rules/directives.
1. Avoid excessive concentration of the cleaning
agent
Þ Dose gradually!
2. Adjust the cleaning flow to the process
Þ Milk sterilization/viscous liquids
Þ Increase the cleaning flow!
3. Always rinse well with clean water after the
cleaning.
Change-over valve
Clean the plug and the seats correctly.
Pay special attention to the warnings!
Lift and
lower
momentarily (flip)!
Stop valve
Open!
Burning
danger!
Operation
15
1
34
2
Ordering spare parts
- Contact the Sales Department.
- Order from the Spare Parts List.
Recommended spare parts: Service kits (see Spare Parts List).
-Always read the technical data thoroughly
(see page 21).
-Always release the compressed air after
use.
CAUTION!
All scrap must be stored/disposed of in accordance
with current rules/directives.
Never stick your fingers through the valve
ports if the actuator is supplied with
compressed air.
1. General maintenance
Burning
danger!
Atmospheric
pressure
required!
Cutting
danger!
Air Air
Moving
parts!
Never touch the clip assembly or the
actuator piston rod if the actuator is supplied
with compressed air.
Maintain the valve regularly.
Study the instructions carefully and pay special
attention to the warnings!
Always keep spare rubber seals and lip seals in stock.
-Never service the valve when it is hot.
-Never service the valve with valve and
pipelines under pressure.
Maintenance
16
Maintain the valve regularly.
Study the instructions carefully.
Always keep spare rubber seals and lip seals stock.
Check the valve for smooth operation after service.
1. General maintenance
Valve Valve Actuator
rubber seals lip seal rubber seals
Preventive Replace after Replace when Replace after
maintenance 12 months replacing the 5 years
rubber seals
Maintenance after Replace at the Replace when Replace when
leakage (leakage end of the day replacing the possible
normally starts slowly) rubber seals
Planned - Regular inspection Replace when - Regular inspection
maintenance for leakage and replacing the for leakage and
smooth operation rubber seals smooth operation
- Keep a record of - Keep a record of
the valve the actuator
- Use the statistics for - Use the statistics for
planning of planning of
inspections inspections
Replace after Replace after
leakage leakage
Lubrication Before fitting Before fitting Before fitting
(USDA H1 Silicone oil or Silicone oil or Oil or grease
approved oil/grease) silicone grease silicone grease
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 (NO/AA)
Open/
close!
Maintenance
Air (NC/AA)
17
1
3
5
4
2
6
Handle scrap correctly.
NC = Normally closed.
NO = Normally open.
A/A = Air/air activated.
2. Dismantling of valve
Air (NC, A/A)
Stop valve Change-over valve Stop valve Change-over valve
1. Remove screw (19h, 20h).
2. Dismantle the complete valve plug.
Change-over valve:
1. Supply compressed air to the actuator (Only NC).
2. Loosen and remove lower clamp (15).
3. Remove lower valve body (18).
4. Pull out seal ring (17).
5. Release compressed air.
Pay special attention to the warnings!
Air (NO, A/A) Air (NO, A/A)
Stop valve Change-over valve
1. Supply compressed air to the actuator (only
NO).
2. Remove clip assembly (11).
(For sizes DN125-150: Unscrew valve plug
(19, 20)).
3. Remove valve plug (19, 20).
4. Release compressed air.
Pay special attention to the warnings!
Change-over valve:
1. Remove upper clamp (15).
2. Remove upper valve body (16).
Study the instructions carefully.
The items refer to the drawings and the parts list on the
pages 22-37.
Maintenance
Remove lip seal (14).
(For sizes DN125-150: Remove lip seal (14) and
guide ring (27)).
Stop valve:
1. Supply compressed air to the actuator (Only NC).
2. Loosen and remove clamp (15).
3. Lift out the actuator.
4. Release compressed air.
Pay special attention to the warnings!
Air (NC, A/A)
18
1
3
5
4
2
6
Study the instructions carefully.
The items refer to the drawings and the parts list on the
pages 22-37.
Lubricate the rubber seals and the lip seal before fitting
them.
Lip seal (14) can be replaced by a special stem seal
(sizes 25-101.6 mm/DN40-100).
3. Assembly of valve
1. Assemble the complete valve plug.
2. Fix screw (19h, 20h) by using loctite or
something similar.
Change-over valve:
1. Assemble upper valve body (16) and the
actuator.
2. Fit and tighten upper clamp (15).
Fix!
Change-over valve
Stop valve Stop valve Change-over valve
Air (NC, A/A)
Air (NC, A/A)
Stop valve:
1. Supply compressed air to the actuator (Only NC).
2. Fit the actuator.
3. Fit and tighten clamp (15).
4. Release compressed air.
Pay special attention to the warnings!
Change-over valve:
1. Fit seal ring (17) correctly in lower valve body (18).
2. Supply compressed air to the actuator (Only NC).
3. Assemble lower and upper valve bodies
(16, 18).
4. Fit and tighten lower clamp (15).
5. Release compressed air.
Pay special attention to the warnings!
Turn the diagonal
surface of seal
ring (17) upwards!
Fit lip seal (14).
(For sizes DN125-150: Fit guide ring (27) and lip
seal (14)).
Air (NO, A/A)
1. Fit the plastic ring of clip assembly (11) on the
actuator piston rod.
2. Supply compressed air to the actuator (Only NO).
3. Fit valve plug (19, 20).
4. Fit and assemble clip assembly (11). (For sizes
DN125-150: Screw together valve plug (20) and
piston (6). Fix thread by using Loctite or something
similar)).
5. Release compressed air.
Pay special attention to the warnings!
Change-over
valve
Stop
valve
Maintenance
Air (NO, A/A)
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