Alfalaval 5309 User manual

Instruction Manual

5308/5309 Ball Valve / Ball Valve UltraPure

ESE01663-EN3 2011-06

Original manual

Table of contents

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

1. Safety .................................................................................................... 4

1.1. Important information ............................................................................. 4

1.2. Warning signs ..................................................................................... 4

1.3. Safety precautions ................................................................................ 5

2. Maintenance ........................................................................................... 6

2.1. Valve Disassembly ................................................................................ 6

2.2. Valve Inspection ................................................................................... 6

2.3. Valve Assembly ................................................................................... 7

2.4. Attaching the actuator and switch to the valve ................................................ 9

3. Technical data ......................................................................................... 10

3.1. Torque vs Pressure Differential ................................................................... 10

4. Parts list and Service Kits ........................................................................... 12

4.1. Ball Valves, UltraPure for 1/2" to 2" ............................................................. 12

4.2. Ball Valves, UltraPure for 2 1/2" to 4" ........................................................... 14

4.3. Ball Valve, 5308 Series for 1/2” to 2” ........................... ................................ 16

4.4. Ball Valve, 5308 Series for 3” to 4” ........................................................ ...... 18

1Safety

Unsafe practices and other important information are emphasized in this manual.

Warnings are emphasized by means of special signs.

1.1 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.

NOTE

Indicates important information to simplify or clarify procedures.

1.2 Warning signs

General warning:

Caustic agents:

1 Safety

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.

1.3 Safety precautions

Installation

Always read the technical data thoroughly.

Always release compressed air after use.

Operation

Always read the technical data thoroughly.

Never touch the valve or the pipelines when processing hot liquids or when sterilizing.

Always handle lye and acid with great care.

Maintenance

Always read the technical data thoroughly.

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.

2 Maintenance

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.

2.1 Valve Disassembly

To disassemble a ball valve:

1. For a manual valve, remove the top handle nut (20) from the stem (4)

2. Remove the handle (7). For actuated valves remove bracket mounting bolts and remove actuator/bracket and coupler

Note: If you are disassembling a 3 or 4 inch valve, you’ll need to remove the actuator mounting bolts.

3. To remove the second stem nut you must first bend back the side tab of the stop washer (12). This can be done using a

screwdriverorpunc

h. Once the stop washer side tab is flattened you can remove the stem nut (5)

Note: 3 and 4 inch valves will require a socket wrench to reach the nut recessed into the mounting bracket. 36 mm.

4. Remove bevel washers (6) and gland bushing (9)

5. Remove four hex nuts (17) from one side of body bolts (14). For the 4 inch valve remove six hex nuts (17). Remove body

bolts/studs to allow bodyends (2) to fall away

6. Remove the front and rear ball seats (8)

7. Turn the stem (4) clockwise until the ball (3) is in the closed position, allowing the ball to fall free from the valve

8. Press downward on the stem (4) until it presses through the inside of the valve body (1), and remove the stem and bottom

stem seal (11) and the stem packings (10)

9. Remove the joint gasket (5) from valve body ends. (You will need to use a small instrument, such as a dental pick or small

screw driver to pry the o-ring away from the body end. Be careful not to mar the body end in the process

2.2 Valve Inspection

Seat(s)

1. Carefully examine the PTFE valve ball seats for cracking, checking or excessive wear. Leakage past the seat(s) may result

from these types of irregularities.

Surface Finish

2. Inspect the bore of the ball and the valve stem in the valve upper body for signs of galling. Replace both if galling exists.

Galling will continue to occur if only one part is replaced and the other is damaged. Inspect the inside surface of each body

end for marring. Replace the end if damaged. Leakage may occur from this kind of damage

Gaskets/O-ring(s)

3. Inspect for cracks, cuts, abrasions, flat spots or other damage that would cause leakage or ineffective cleaning.

Replace as necessary

2 Maintenance

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.

2.3 Valve Assembly

To assemble a ball valve:

1. Place the lower packing ring (11) on the valve stem (4) and slide

the stem into the stem hole in the upper body of the valve

2. Press the upper packing rings (10) onto the stem (4) until it is

seated against the base of the body

3. Press the packing retainer (9) onto the stem (4) until it is seated

against the upper packing ring (10)

4. Turn the stem (4) until the flat surfaces are parallel to the port

centerline

5. Place a ball seat (8) inside one end of the valve body (1) so that

the tapered side of the seat faces inward and the other side lies

flush against the outer surface of the valve body

6. Seat the ball (3) inside the valve so that the stem base is seated

insidetheboreoftheball

7. Turn the stem 90° so that the valve is in the open position. This

keeps the ball from falling out of the valve

8. Place the other ball seat (8) inside the end of the valve body (1) so

that the tapered side of the seat faces inward and the other side

lies flush against the outer surface of the valve body

3” and 4”

2 Maintenance

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.

9. Assemble the valve body ends (2), with gaskets (13) in place, to each end of the valve body (1). ½” through 2” size use 4

bolts (14) and 4 bolt nuts (17). 3” and 4” size, use 4 studs (14) and 8 stud nuts (17). Refer to Table 1 for proper torques

10. Place spring washers (6) together so that their curved surfaces are facing outward, in opposite directions, and place

them over the stem (4)

11. Place stop washer (12) onto stem (4). Making sure the stop washer lock tab is flat. Instal stem nut (5) onto valve stem (4).

Refertotable2forstemnuttighteningtorque.

Once stem nut is properly tightened, bend tab of lock washer (12) up against the stem nut (5) using a screwdriver or punch.

Instal handle (7) over valve stem (4) and secure with handle nut (20). Be sure the handle locking devise (18) will align

with both locking notches in valve body (1).

If you are using an electric or pneumatic valve, place the actuator/bracket assembly on the upper body of the valve, and

secure it to the valve with two mounting bracket screws.

Bolting Torque Data for Sanitary Ball Valves

Tabl e 1 .

Valve For Body Bolting

Size Size in-lb NM

½” ¼” - 20unc 80 9

¾” ¼” - 20unc 80 9

1” 5/16” - 18unc 110 12

1½” 3/8” - 16unc 170 19

2” 7/16” - 14unc 230 26

3” 5/8” - 11unc 570 64

4” 5/8” - 11unc 600 68

Tabl e 2 .

Valve For Stem Unit

Size Size in-lb NM

½” 3/8” - 24unf 87 9.8

¾” 3/8” - 24unf 87 9.8

1” 3/8” - 24unf 87 9.8

1½” 7/16” - 20unf 122 13.7

2” 9/16” - 18unf 165 18.6

3” M24 191 21.6

4” M24 191 21.6

2 Maintenance

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.

2.4 Attaching the actuator and switch to the valve

Attaching the Switch to the Actuator:

1. Remove the position indicator on the top of the actuator (1)

2. Attach the bracket (10) to the top of the actuator using four bolts

(11)

3. Insert the switch stem through the center hole in the bracket (10)

and align with the slot in the actuator shaft

4. Attach the top of the bracket (10) to the switch using four bolts (9)

Attaching the Actuator to the Valve:

These instructions describe how to attach an assembled actuator to

aBall Valve. For information on servicing your electric or pneumatic

actuator, refer to the service manual that comes with the actuator.

To attach the actuator to the valve:

1. Remove handle nut and handle

2. Sizes ½” through 2”, attach actuator bracket to valve body using

4 bolts provided in kit

3. Place actuator coupler onto the valve stem.

4. Place actuator on the mounting bracket. (on sizes 3” and 4”

valves the bracket is included on all valves as part of the body) Be

sure to line up coupler with actuator. Tighten all bolts

5. Instal 4 actuator mounting bolts through bracket and into the bot

tom of the actuator. Tighten all bolts

3 Technical data

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.

3.1 TorquevsPressureDifferential

Astheamountofpressureinaballvalveincreases,sodoestheamount of torque required to open and close it. Use the charts

below to determine the type of actuator, if any, that is required for your application.

PTFE Seat Material

Reinforced PTFE Seat Material

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