Allfi 919115 Handbuch

Operating and maintenance instruction

Shut-off valve 2.0

(4150 bar / 0,000 psi)

Operating and maintenance instruction

ALLFI AG - Riedenmatt 1 – CH- 370 Stans

Tel.: +41 41 18 05 05 - Fax: +41 41 18 05 10

E-Mail: info@allfi.com - http://www.allfi.com

November 2022

General

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Shut-off valve 2.0 (4150 bar / 0,000 psi) 09.01.2023

Scope of application

The present operating and maintenance instruction is valid for:

Shut-off valve 3/8" 2.0 (4150 bar / 0,000 psi)

 919115

 91911

 UH-919115

General

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Shut-off valve 2.0 (4150 bar / 0,000 psi) 09.01.2023

Table of contents

1 General .......................................................................................................................................4

1.1 Information on use of the operation and maintenance instruction ......................................4

1.2 Scope of delivery .................................................................................................................4

1.3 Warranty claim ....................................................................................................................4

1.4 Disclaimer............................................................................................................................4

2 Security .......................................................................................................................................5

2.1 Declaration of symbols ........................................................................................................5

2.2 General arning notes ........................................................................................................5

2.3 Intended use .......................................................................................................................6

2.4 Inadmissible usage ..............................................................................................................7

2.5 Residual risks .......................................................................................................................7

2.6 Safety installations ..............................................................................................................8

2.7 Personal protection equipment ...........................................................................................8

2.8 Qualification of the staff ......................................................................................................8

3 Structure and function ................................................................................................................9

3.1 Structure .............................................................................................................................9

3.2 Funktion ..............................................................................................................................9

3.3 Accessories ..........................................................................................................................9

4 General technical data .............................................................................................................. 10

5 Installation and commissioning ................................................................................................. 11

5.1 Fix cutting head to the machine ......................................................................................... 12

5.2 Function check of the shut-off valve .................................................................................. 14

6 Deinstallation ............................................................................................................................ 14

7 Maintenance, Service and Repair .............................................................................................. 15

7.1 Regular maintenance ......................................................................................................... 15

7.2 Reversing (turning) the valve seat ...................................................................................... 16

7.3 Replace seal kit and valve seat ........................................................................................... 17

8 Faults and Troubleshooting ....................................................................................................... 19

8.1 Leakage of the shut-off valve: ............................................................................................ 19

8.2 Further troubleshooting .................................................................................................... 20

9 Recycling ................................................................................................................................... 20

Appendix A – Technical drawing and parts list (shipped with the product)

General

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Shut-off valve 2.0 (4150 bar / 0,000 psi) 09.01.2023

1 General

1.1 Information on use of the operation and maintenance instruction

This operation and maintenance instruction is a key part of the product. The information in this manual

is mandatory and must be read and understood by all the persons before operating with the Shut-off

valve 3/8 2.0. The manual must be stored in distance as well as always accessible to the persons,

working with the Shut-off valve 3/8 2.0.

Should you have any questions regarding the content of the manual, please contact the manufacturer

directly.

ALLFI AG - Riedenmatt 1 – CH- 370 Stans

Tel.: +41 41 18 05 05 - Fax: +41 41 18 05 10

E-Mail: info@allfi.com - http://www.allfi.com

1.2 Scope of delivery

The individual parts contained in the shipment can be gathered from the set list in the appendix A

(technical drawing and part list). Upon receipt, the shipment has to be checked of integrity. Possible

detected defectives must be reported immediately to the manufacturer.

1.3 Warranty claim

The ALLFI AG grants warranty for the shipped parts as followed:

 Material and manufacturer faults of 12 months from date of delivery or

 Defects within the first 2000 hours of operation

Following spare parts are excluded from the warranty:

 Seal Kit (consist of Valve needle, HP-seal 2.0, spring & Pressure plate 2.0)

 Valve Seat

 O-Ring

 Valve Case

1.4 Disclaimer

ALLFI AG refuses any claims of liability (material damages, physical injury, as well as disruption of op-

eration), that are a result of disregarding this operating and maintenance instruction.

For example, the damage as a consequence of:

 Inadmissible application of the Shut-off valve

 Defective maintenance

 The disregard of operation instructions

 Chemical and electrolytical influences

 Use of parts, spare parts, or accessory from a third-party manufacturer

 Arbitrary modifications

 Not or insufficiently trained staff

The disregard of all these instructions happens on exclusive risk and exclusive responsibility of the cli-

ent. The ALLFI AG is not liable for any production downtimes.

Security

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Shut-off valve 2.0 (4150 bar / 0,000 psi) 09.01.2023

2 Security

2.1 Declaration of symbols

This operating and maintenance instruction manual contains important notes and symbols, which are

to be considered and followed. These include:

DA GER

 Danger emphasizes operating and service procedures that if not avoided,

may lead to death or serious personal injuries.

WAR I G

 Warnings emphasize operating or service procedures, or conditions that

can result in serious personal injury or death.

CAUTIO

 Cautions emphasize operating or service procedures, or conditions that

can result in equipment damage or impairment of system operation. If not

avoided, light or medium body injuries could be the consequence.

NOTE

 otes provide additional information that can expedite or improve operat-

ing or service procedures.

 Danger symbol without key word: Additional notes

2.2 General warning notes

Using of the Shut-off valve, the following warnings are to be considered.

 The specified warnings are not only restricted to the operation with the maximal

permissible operating pressure of 4150 bar / 0,000 psi. They are also valid on

work with reduced operation pressures!

Security

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Shut-off valve 2.0 (4150 bar / 0,000 psi) 09.01.2023

DA GER

 Danger of cutting of extremities on contact with waterjet

 The contact with the high kinetic energy performing waterjet can have the conse-

quence of cutting of extremities or lead to other injuries.

 Therefore:

 Operate the machine only, when nobody stands in the danger zone of the

waterjet.

 Never touch the waterjet, not even with personal protective equipment.

 Always sufficient safety distance during operation of the cutting head.

 Never guide the Shut-off valve by hand during operation.

 Any injuries in connection with the waterjet, alarm the emergency doctor imme-

diately.

CAUTIO

 Danger of breathing difficulties and irritation of the skin and eyes by re-

leased solid particles or dust.

 During machining of certain material, solid particles and dust may float in the air,

which could cause breathing difficulties and irritations to the skin and eyes.

 Therefore:

 Ensure the proper ventilation of the room surrounding the machinery.

 Ensure to wear the personal protective equipment (protection glasses,

breathing mask, gloves, …)

 Additionally, the rules and regulations of the working place are to be followed to

prevent injuries!

2.3 Intended use

The shut-off valve is designed for shutting off buffer bottles with the purpose of making pressure re-

duction and build-up faster. The shut-off valve must be firmly connected in the machine. Only pure wa-

ter may be used as the working fluid. The technical limits must always be observed. The specifications

for connection assignment must be observed.

Security

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Shut-off valve 2.0 (4150 bar / 0,000 psi) 09.01.2023

2.4 Inadmissible usage

Inadmissible usage of the Shut-off valve includes:

 The usage of all other fluids other than water

 The addition of other substances to the water

 Closure of the pressure relief holes

 Excessive stress on the shut-off valve

 Exceeding permitted limits

 Excessive stress on the shut-off valve

 Operating the shut-off valve with demounted or disabled technical protection

Likewise, all other uses of the shut-off valve deviating from the intended use are not permitted. All

questions should be addressed directly to the manufacturer.

ALLFI AG - Riedenmatt 1 – CH- 370 Stans

Tel.: +41 41 18 05 05 - Fax: +41 41 18 05 10

E-Mail: info@allfi.com - http://www.allfi.com

2.5 Residual risks

The manufacturer and/or operator of the machine where the shut-off valve is built in, has taken every

precautionary measure possible to reduce residual risks, as far as possible reasonably practicably.

Operation

phase

Damage Danger Reason (possible) measures

Operation

Physical

injuries

Liquids leaking

under high pres-

sure (e.g. at

pressure relief

holes)

Ignoring the torque Follow the torque

Damaged sealing sur-

faces Regular supervision

Busted/Cracked connec-

tions and high-pressure

components as a result

of defects

Protective wall as a tech-

nical protective measure

Flying fragments

Ignoring the torque Follow the torque

Damaged sealing sur-

faces Regular supervision

Busted/Cracked connec-

tions and high-pressure

components as a result

of defects

Protective wall as a tech-

nical protective measure

High kinetic en-

ergy of water jet

Intrusion of extremities

in working area of water

jet

Wearing safety goggles and

other protective equipment

Carry out regular checks

Hearing

damage

Rapidly dis-

charging of fluid Leakage Wear ear protector

Security

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Shut-off valve 2.0 (4150 bar / 0,000 psi) 09.01.2023

2.6 Safety installations

The manufacturer or the operator of the full machine, which the shut-off valve is built in, has ensured

the following safety arrangements:

 Safety devices to prevent flying fragments or liquids leaking under high pressure

 Emergency stoppage to immediately shut down the operating machine

 Active: Manually triggered by operator

 Passive: Automatically triggered by:

o Failure of high pressure components or gross operating faults

 Danger for the operator will arise if safety protections are not functionally, not

followed or evaded anytime. The operator has to ensure the functionality of the

safety protections anytime.

2.7 Personal protection equipment

The operator must offer his staff following protection equipment while he’s working:

Ear protector against:

 Noise emissions

Wear protection glasses against:

 Fluids and dust particles

 Flying fragments

Hand guards against:

 Sharp edges of components

 Intrusion of micro particles into the skin

Inhalation protection against:

 Dust particles, micro particles and spray mist

2.8 Qualification of the staff

The shut-off valve may only be operated and maintained by certified, trained staff.

Structure and function

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Shut-off valve 2.0 (4150 bar / 0,000 psi) 09.01.2023

3 Structure and function

3.1 Structure

1. Pneumatic Cylinder 2.0

2. Seal Kit 2.0

2.1. Valve needle

2.2. Pressure plate 2.0

2.3. HP-seal 2.0

2.4. Compression Spring

3. Coupling Ring

4. Valve Seat

5. Adapter 3/8" to Valve Case

. O-Ring

7. Reduction m/f

8. Valve case 2.0

3.2 Funktion

The shut-off valve is a high-pressure needle valve and is actuated pneumatically. It is closed by com-

pressed air and a pneumatic piston actuator and opened by spring force. The compressed air supply

is switched on and off by a controlled valve (not included in the scope of delivery). For information on

the maximum permissible operating pressure of the water, see chapter 4.

3.3 Accessories

Article: Ejector mandrel DX Paste P-Paste

Article no: 900070 051055 0510 5

Function: Replace Seal Kit and

Valve Seat

Greasing screw connections

and metallic contact areas for

standard applications

Greasing screw connec-

tions and metallic contact

areas for food safe

General technical data

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Shut-off valve 2.0 (4150 bar / 0,000 psi) 09.01.2023

All accessories for metric cutting heads are included in case set 882101

All accessories for imperial cutting heads are included in case set 882101-I

4 General technical data

Pneumatic pressure: - 7 bar / 87 psi – 102 psi

Minimum working pressure: 0 bar / 0 psi

Maximal working pressure: 4150 bar / 0,000 psi

Connection lines: Appendix A

Nominal size (DN) 1mm

Pressure loss coefficient (l/min & bar) 0.51

Maximal working temperature: 50 °C

Maximum transport and storage temperature: 0 °C

Reaction time: up to 1 switching cycles per seconds

Weight: ca. 1.5 kg

Requested water quality:

Water parameter Unit Value

Electrical Conductivity µS / cm 100 – 450

PH-value - 7.0 - 8.5

Total hardness °dH 2.0 - 10.0

Carbonate hardness

(acid capacity pH 4.3)

°dH 2.0 - 10.0

Degree of alkalinity pH 8.2 mmol / l 0 - 0.25

Chloride mg / l ≤ 50

Iron mg / l ≤ 0.2

Manganese mg / l ≤ 0.05

Copper mg / l ≤ 2.0

Silicate mg / l ≤ 5.0

(Filtrate-) solid content mg / l ≤ 350

Article: Torque wrench Open end fitting Mounting tool for

O-ring

Article no: 0004 8 AF 17 – 000339

AF 22 – 000272

AF 24 – 000280

AF 27 – 000511

040011

Function: Tightens screws with a

specific torque

O-ring assembly and dis-

assembly

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