Alfa Laval Unique SSV Two Step Instruction Manual
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Alfa Laval Unique SSV Two Step Instruction Manual

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Instruction Manual
Unique SSV - Two Step
ESE02027-ENUS6
Original manual
TD 461-703
2019-03
TD 461-702

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Summary of Contents for Alfa Laval Unique SSV Two Step

  • Page 1 Instruction Manual Unique SSV - Two Step TD 461-702 TD 461-703 ESE02027-ENUS6 2019-03 Original manual...

  • Page 3: Table Of Contents

    Table of contents The information herein is correct at the time of issue but may be subject to change without prior notice 1. EC Declaration of Conformity ............... 2. Safety ....................2.1. Important information ................2.2. Warning signs ..................2.3. Safety precautions ................3.

  • Page 4: Ec Declaration Of Conformity

    Address +45 79 32 22 00 Phone No. hereby declare that Valve Designation Unique SSV Two Step PN10 Type From serial number 1000000 to 70000000000 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 procedure Module A. May only be...

  • Page 5: Safety

    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 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.

  • Page 6: Warning Signs

    2 Safety Unsafe practices and other important information are emphasized in this manual. Warnings are emphasized by means of special signs. 2.2 Warning signs General warning Caustic agents Danger of injury (lasermarked on the actuator) Do NOT attempt to disassemble the actuator due to spring under load danger! DO NOT DISASSEMBLE (The lock wire opening is locked)

  • Page 7: Safety Precautions

    - Support air on high pressure actuator versions is NOT allowed To prevent shock in the actuator and to prevent exceeding 145 PSI (10 bar) product pressure, Alfa Laval recommends NOT to exceed 43.5 PSI (3 bar) support air on the spring side in all the Unique SSV actuators.
  • Page 8 Never stick your fingers through the valve ports if the actuator is supplied with compressed air Never touch moving parts if the actuator is supplied with compressed air Always use Alfa Laval genuine spare parts WARNING Never cut the actuator open, due to spring under load danger...

  • Page 9: Installation

    Step 1 Check the delivery for: CAUTION 1. Complete valve, shut-off valve or change-over valve (see steps 2a and 2b). Alfa Laval cannot be held responsible for incorrect unpacking. 2. Delivery note. 3. Instruction manual. Step 2 Shut-off valve: 1. Complete actuator.

  • Page 10: General Installation

    DO NOT DISASSEMBLE - CAUTION Do NOT attempt to disassemble the actuator due to Alfa Laval cannot be held responsible for incorrect installation. spring under load danger. - Always release compressed air after use. - Always read the technical data thoroughly.

  • Page 11: Welding

    3 Installation 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. Step 4 Avoid stressing the valve. Pay special attention to: Risk of damage! - Vibrations.
  • Page 12 3 Installation Study the instructions carefully. The valve is supplied as separate parts to facilitate the welding. The items refer to the parts list and service kits section. Check the valve for smooth operation after welding. Step 1 Always install valves with more than one valve body so that the seals between the valve bodies can be replaced.

  • Page 13: Recycling Information

    When in doubt, or in the absence of local regulations, please contact your local Alfa Laval sales company. If the actuator is marked with a danger warning, do not attempt to cut the actuator open.

  • Page 14: Operation

    NC= Normally closed (pneumatic movemetn upwards) 4.1 Description of valve function The Unique SSV Two step valve has two pistons inside the actuator, which makes it possible to have an intermediate plug position where all body ends are open. The Unique SSV Two step valves are made in a Shut-off valve type and a Change-over valve type.
  • Page 15 4 Operation Study the instructions carefully. The item refer to the parts list and service kits section. NO= Normally open (pneumatic movement downwards) NC= Normally closed (pneumatic movemetn upwards) Step 1b Type Change-over valve (NC and NO) Two step valves as change-over (NC and NO) can be used for drainage of two pipes simultaneously or split of flow in three lines. The valve has a fixed intermediate position and spring return to the end positions.
  • Page 16 4 Operation Study the instructions carefully. The item refer to the parts list and service kits section. NO= Normally open (pneumatic movement downwards) NC= Normally closed (pneumatic movemetn upwards) Spring return to upper position = NO TD461-1017 Intermediate position Closed Open Two step stroke activated The plug opening for different Change-over valves and Actuator size is shown below.

  • Page 17: Operation

    WARNING See section . - Always use Alfa Laval genuine spare parts. SPRING UNDER LOAD The warranty of Alfa Laval products is dependent on use of DO NOT ATTEMPT TO CUT ACTUATOR OPEN REFER TO SERVICE BULLETIN SPRING UNDER LOAD Do not attempt to cut open Alfa Laval genuine spare parts.
  • Page 18 4 Operation Study the instructions carefully and pay special attention to the warnings! Ensure that the valve operates smoothly. The items refer to the parts list and service kits section. Step 4 Shut-off Lubricate Change-over valve Lubrication of valves: valve 1.

  • Page 19: Troubleshooting

    - Use auxiliary air on the spring side. Always use the pressure relief fittings 43.5 PSI (3 bar) on support side. Alfa Laval article number = 9611996094 If marked with a danger warning, do NOT attempt to cut the actuator open, due to spring under load.

  • Page 20: Recommended Cleaning

    4 Operation 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. = Nitric acid. 4.4 Recommended cleaning Step 1 Caustic danger! Always handle lye and acid with great care.
  • Page 21 4 Operation 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. = Nitric acid. Step 5 Always rinse! 1. Avoid excessive concentration of the cleaning agent. 2.

  • Page 22: Maintenance

    WARNING See section . - Always use Alfa Laval genuine spare parts. SPRING UNDER LOAD The warranty of Alfa Laval products is dependent on use of DO NOT ATTEMPT TO CUT ACTUATOR OPEN REFER TO SERVICE BULLETIN SPRING UNDER LOAD Do not attempt to cut open Alfa Laval genuine spare parts.
  • Page 23 5 Maintenance 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. Below are some guidelines for maintenance and lubrication intervals. Please note that the guidelines are for normal working conditions in one shift.

  • Page 24: Dismantling The Valve

    5 Maintenance Study the instructions carefully. The items refer to the parts list and service kits section. Handle scrap correctly. NC = Normally closed. NO = Normally open. A/A = Air/air activated. 5.2 Dismantling the valve If the actuator is marked with a danger warning, do NOT attempt to cut the actuator open. WARNING SPRING UNDER LOAD DO NOT ATTEMPT TO CUT ACTUATOR OPEN...

  • Page 25: Elastomer And Tr2 Seal Ring Replacement

    5 Maintenance Study the instructions carefully. The items refer to the parts list and service kits section. Handle scrap correctly. NC = Normally closed. NO = Normally open. A/A = Air/air activated. 5.3 Elastomer and TR2 seal ring replacement There are two plug seal ring options: A.
  • Page 26 5 Maintenance Study the instructions carefully. The items refer to the parts list and service kits section. Handle scrap correctly. NC = Normally closed. NO = Normally open. A/A = Air/air activated. B Plug seal elastomer 1. Remove old seal ring using a knife, screwdriver or similar. Drawing 1 Be careful not to damage the plug surface.

  • Page 27: Valve Assembly

    - Shut-off plug tighten torque =15 lbf - ft (20 Nm) If there are vibrations in the pipeline Alfa Laval recommend to use loctite nr. 243. The clamps thread must be lubricated before tightening - max. torque for the clamps is 8-9 lbf - ft (10-12 Nm).

  • Page 28: Actuator Types

    5 Maintenance Study the instructions carefully. The items refer to the parts list and service kits section. Handle scrap correctly. NC = Normally closed. NO = Normally open. A/A = Air/air activated. 5.5 Actuator types Different actuator types for the SSV valve In June 2016 the below change was implemented and the “removable yoke with bolts”...

  • Page 29: Actuator Bushing Replacement

    5 Maintenance Study the instructions carefully. The items refer to the parts list and service kits section. Handle scrap correctly. A/A = Air/air activated. Service tool: see spare parts. 5.6 Actuator bushing replacement If the actuator is marked with a danger warning, do NOT attempt to cut the actuator open. See also section 5.5 Actuator types WARNING SPRING UNDER LOAD...
  • Page 30 In these cases, the alignment spindle shown below, together with the socket wrench, is a great help and ensures a reliable mounting of the bushing. The spindle can either be purchased from Alfa Laval together with the socket wrench (9614-1984-01) or it can be manufactured locally using the below dimensions.
  • Page 31 5 Maintenance Study the instructions carefully. The items refer to the parts list and service kits section. Handle scrap correctly. A/A = Air/air activated. Service tool: see spare parts. Step 4 The actuator must 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.
  • Page 32 5 Maintenance Study the instructions carefully. The items refer to the parts list and service kits section. Handle scrap correctly. A/A = Air/air activated. Service tool: see spare parts. Step 6 1. Lubricate thoroughly both the actuator spindle and o-rings. 2.
  • Page 33 5 Maintenance Study the instructions carefully. The items refer to the parts list and service kits section. Handle scrap correctly. A/A = Air/air activated. Service tool: see spare parts. Step 8 Now pull the aligning spindle to centre the actuator spindle. In this position rotate the bushing 180° backwards and then begin to fasten the bushing.

  • Page 34: Dismantling Of (Nc) Maintainable Actuator

    5 Maintenance Study the instructions carefully. The items refer to the parts list and service kits section. 5.7 Dismantling of (NC) maintainable actuator If the actuator is marked with a danger warning, do NOT attempt to cut the actuator open. See also section 5.5 Actuator types WARNING SPRING UNDER LOAD...

  • Page 35: Assembly Of Maintainable Actuator

    5 Maintenance Study the instructions carefully. The items refer to the parts list and service kits section. 56) Only for shut off valves (Not mounted in actuator for change-over valves 59) No wear part 13.1 2206-0006 5.8 Assembly of maintainable actuator Reverse order of 5.7.

  • Page 36: Dismantling Of Change-Over (No) Maintainable Actuator

    5 Maintenance Study the instructions carefully. The items refer to the parts list and service kits section. 5.9 Dismantling of change-over (NO) maintainable actuator If the actuator is marked with a danger warning, do NOT attempt to cut the actuator open. See also section 5.5 Actuator types WARNING SPRING UNDER LOAD...

  • Page 37: Assembly Of Maintainable Actuator

    5 Maintenance Study the instructions carefully. The items refer to the parts list and service kits section. 56) Only for shut off valves (Not mounted in actuator for change-over valves) 59) No wear part 13.1 2206-0007 5.10 Assembly of maintainable actuator Reverse order of 5.7.

  • Page 38: Changing Pneumatic Movement On Fully Maintainable Actuator (Nc/No)

    5 Maintenance Study the instructions carefully. The items refer to the parts list and service kits section. 5.11 Changing pneumatic movement on fully maintainable actuator (NC/NO) If the actuator is marked with a danger warning, do NOT attempt to cut the actuator open. See also section 5.5 Actuator types WARNING SPRING UNDER LOAD...
  • Page 39 5 Maintenance Study the instructions carefully. The items refer to the parts list and service kits section. Step 1 Actuator for the Shut-Off valves can not be reversed as it only is possible to operate in NC position. TD461-743_1 Actuator for the Change-over valves can be reversed from NC to NO and from NO to NC.
  • Page 40 5 Maintenance Study the instructions carefully. The items refer to the parts list and service kits section. Step 3 Drawing of "SSV Two step mounting tool" 1. Use ø32 mm bar and drill two ø4 holes in a diameter (Ø32 bar) ø26 mm.

  • Page 41: Technical Data

    6 Technical data It is important to observe the technical data during installation, operation and maintenance. Inform the personnel about the technical data. 6.1 Technical data The valve is a pneumatic seat valve in a hygienic and modular design for a wide field of duties, e.g. as a shut-off valve with two (2) or three (3) ports or as a change-over valve with three (3) to five (5) ports.

  • Page 42: Parts List And Service Kits

    7 Parts list and Service Kits For parts lists please see section 6.1. The drawings include all items. 7.1 Drawing TD 461-643_3 TD 461-644_3 Shut-off valve Change-over valve 36.1 36.2 2200-0128 37.1 37.2 2200-0129 Shut-off valve (TR2) Shut-off valve (TR2)

  • Page 44: Unique Ssv Tr2 - Two Step - Shut Off Valve

    7 Parts list and Service Kits For parts lists please see section 6.1. The drawings include all items. 7.2 Unique SSV TR2 - Two Step - Shut off valve If the actuator is marked with a danger warning do NOT attempt to cut the actuator open. WARNING SPRING UNDER LOAD DO NOT ATTEMPT TO CUT ACTUATOR OPEN...
  • Page 45 7 Parts list and Service Kits For parts lists please see section 6.1. The drawings include all items. Parts list Pos. Denomination Actuator Cylinder Piston O-ring  Adapter  Bushing  O-ring  O-ring Plug Lock wire  O-ring Air fitting Yoke 13.1 Yoke...

  • Page 46: Unique Ssv Tr2 - Two Step - Change Over Valve

    7 Parts list and Service Kits For parts lists please see section 6.1. The drawings include all items. 7.3 Unique SSV TR2 - Two Step - Change over valve If the actuator is marked with a danger warning do NOT attempt to cut the actuator open. WARNING SPRING UNDER LOAD DO NOT ATTEMPT TO CUT ACTUATOR OPEN...
  • Page 47 7 Parts list and Service Kits For parts lists please see section 6.1. The drawings include all items. Parts list Pos. Denomination Actuator Cylinder Piston  O-ring Adapter Bushing   O-ring  O-ring Plug Lock wire  O-ring Air fitting Yoke 13.1 Yoke (- 0616)

  • Page 48: Unique Ssv Elastomer Plug Seal - Two Step - Shut Off Valve

    7 Parts list and Service Kits For parts lists please see section 6.1. The drawings include all items. 7.4 Unique SSV Elastomer plug seal - Two Step - Shut off valve If the actuator is marked with a danger warning do NOT attempt to cut the actuator open. WARNING SPRING UNDER LOAD DO NOT ATTEMPT TO CUT ACTUATOR OPEN...
  • Page 49 7 Parts list and Service Kits For parts lists please see section 6.1. The drawings include all items. Parts list Pos. Denomination Actuator Cylinder Piston O-ring  Adapter  Bushing  O-ring  O-ring Plug Lock wire  O-ring Air fitting Yoke 13.1 Yoke...

  • Page 50: Unique Ssv Elastomer Plug Seal - Two Step - Change Over Valve

    7 Parts list and Service Kits For parts lists please see section 6.1. The drawings include all items. 7.5 Unique SSV Elastomer plug seal - Two Step - Change over valve If the actuator is marked with a danger warning do NOT attempt to cut the actuator open. WARNING SPRING UNDER LOAD DO NOT ATTEMPT TO CUT ACTUATOR OPEN...
  • Page 51 7 Parts list and Service Kits For parts lists please see section 6.1. The drawings include all items. Parts list Pos. Denomination Actuator Cylinder Piston O-ring  Adapter  Bushing  O-ring  O-ring Plug Lock wire  O-ring Air fitting Yoke 13.1 Yoke...

  • Page 52: Mounting Tool - Unique Ssv - Two Step

    7 Parts list and Service Kits For parts lists please see section 6.1. The drawings include all items. 7.6 Mounting Tool - Unique SSV - Two Step TD 461-916 TD 461-966_1 TD 461-962_1 2200-0154 TD 461-917_1...
  • Page 53 7 Parts list and Service Kits For parts lists please see section 6.1. The drawings include all items. Parts list Pos. Denomination Service tool only for Maintainable actuator Mandrel for bushing Mounting tool for elastomer plug seals Mounting tool Tool for actuator bushing...
  • Page 54 © Alfa Laval Corporate AB This document and its contents is owned by Alfa Laval Corporate AB and protected by laws governing intellectual property and thereto related rights. 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 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.

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