Alfalaval 5308 Bedienungsanleitung

IM70968-GB1 2003-06

5308 / 5309 Ball Valve

Instruction Manual

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

Table of contents

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 ................................................................................ 7

2.3 Valve Assembly ................................................................................. 8

2.4 Attaching the actuator and switch to the valve ................................ 10

3. Technical Data ..................................................................................... 11

3.1 Torque vs Pressure Differential ........................................................ 11

4. Parts List .............................................................................................. 12

4.1 Ball Valves Models 5308 ½” - 2” ..................................................... 12

4.2 Ball Valves Models 5308 3” - 4” ...................................................... 14

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1.1 Important information

1.2 Warning signs

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

Warnings are emphasized by means of special signs.

1. Safety

Always read the manual before using the valve!

WARNING!

Indicates that special procedures must be followed to avoid severe personal injury.

CAUTION!

Indicates that special procedures must be followed to avoid damage to the valve.

NOTE!

Indicates important information to simplify or clarify practices.

General warning.

Caustic agents.

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1. Safety

All warnings in the manual are summarized on this page.

Pay special attention to the instructions below so that severe personal injury or damage to the valve are avoided.

Installation:

- Always observe the technical data (see chapter 5).

- Always release compressed air after use.

Operation:

- Always observe the technical data (see chapter 5).

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

- Always handle lye and acid with great care.

Maintenance:

- Always observe the technical data (see chapter 5)

- Always release compressed air after use.

- The valve must never be hot when servicing it.

- The valve/actuator and the pipelines must never be pressurised when servicing the valve/

actuator.

- Never stick your ﬁngers through the valve ports if the valve is supplied with compressed

air.

1.3 Safety precautions

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2. Maintenance

2.1 Valve disassembly

To disassemble a ball valve:

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

2. 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

screw driver or punch.

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. 36mm.

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

4. 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.

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

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

7 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).

8. 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.)

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2. Maintenance 2.2 Valve Inspection

Seat(s)

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

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)

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

necessary.

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2. Maintenance

2.3 Valve Assembly

3” and 4”

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 inside the bore of the

ball.

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.

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2. Maintenance 2.3 Valve Assembly

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). Refer to table 2 for stem nut tightening torque.

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 allign with

both locking notches in valve body (1).

If you are using an electric or pnuematic 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

Table 1

Valve For Body Bolting

Size Size in-lb NM

½” 1/4” - 20unc 80 9

3/4” 1/4” - 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

Table 2

Valve For Stem Nut

Size Size in-lb NM

½” 3/8” - 24unf 87 9.8

3/4” 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

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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 a Tri-

Clover Ball 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

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 partof 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.

2. Maintenance

2.4 Attaching the actuator and switch to the valve

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