Valvula Mixproof

Instruction Manual
Unique Sanitary Mixproof Valve (including US version)
TD 449-006_1
ESE00923-EN8 2015-xx
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. Declaration of Conformity ........................................................................... 4
2. Safety .................................................................................................... 5
2.1. Important information ............................................................................. 5
2.2. Warning signs ..................................................................................... 5
2.3. Safety precautions ................................................................................ 6
3. Installation .............................................................................................. 7
3.1. Unpacking/intermediate storage ................................................................ 7
3.2. General information ............................................................................... 9
3.3. Welding ............................................................................................ 11
3.4. Recycling information ............................................................................. 15
4. Operation ............................................................................................... 16
4.1. Operation .......................................................................................... 16
4.2. Fault finding and repair ........................................................................... 17
4.3. Recommended cleaning ......................................................................... 18
5. Maintenance ........................................................................................... 21
5.1. General maintenance ............................................................................. 21
5.2. Dismantling the valve ............................................................................. 23
5.3. Lower plug, replacement of radial seal ......................................................... 25
5.4. Upper plug, replacement of axial seal .......................................................... 27
5.5. Assembly of valve ................................................................................. 29
5.6. Dismantling of actuator ........................................................................... 32
5.7. Assembly of actuator ............................................................................. 33
6. Technical data ......................................................................................... 34

6.1. Technical data ..................................................................................... 34
7. Parts list and service kits ............................................................................ 36

7.1. Four configurations examples ................................................................... 36
7.2. Wear parts ......................................................................................... 38
7.3. Parts ............................................................................................... 42
7.4. Service kits (plug set-up 1-4) .................................................................... 45
7.5. Service kits (plug set-up 5-8) .................................................................... 47
7.6. Service kits (plug set-up 9-12) ................................................................... 49
7.7. Service kits (plug set-up 13-16) ................................................................. 51
7.8. Service kits - mix with DN125, DN150, Sch. 5 5 and Sch. 5 6 (plug set-up 1-4) ........ 53
7.9. Service kits - mix with DN125, DN150, Sch. 5 5 and Sch. 5 6 (plug set-up 5-8) ........ 55
7.10. Service kits - mix with DN125, DN150, Sch. 5 5 and Sch. 5 6 (plug set-up 9-12) ...... 57
7.11. Service kits - mix with DN125, DN150, Sch. 5 5 and Sch. 5 6 (plug set-up 13-16) ..... 59
7.12. Axial installation tool .............................................................................. 61
7.13. Radial installation tool ............................................................................ 63
3
1 Declaration of Conformity
Revision of Declaration of Conformity 2009-12-29
The Designated Company
Alfa Laval Kolding A/S

Company Name
Albuen 31, DK-6000 Kolding, Denmark

Address
+45 79 32 22 00
Phone No.
hereby declare that

Valve
Designation
Unique std.
Type
From serial number 1181354 - 9999999
is in conformity with the following directive with amendments:
- Machinery Directive 2006/42/EC

- Regulation (EC) No 1935/2004
- The valve is in compliance with the Pressure Equipment Directive 97/23/EC and was subjected to the following assessment
procedure Module A. Diameters DN125 may not be used for fluids group 1.
The person authorised to compile the technical file is the signer of this document
QHSE Manager, Quality, Health and safety & Environment Annie Dahl
Title Name
Kolding 2000-01-01
Place Date Signature
4
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.
NOTE
Indicates important information to simplify or clarify procedures.
2.2 Warning signs
General warning: Caustic agents: Cutting danger:
5
2 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.
2.3 Safety precautions
Installation:
Always read the technical data thoroughly (see chapter 6.1 Technical data)
Always release compressed air after use
Never touch the clip assembly or the actuator piston rod if the actuator is supplied with compressed air
(see warning label)
Never stick your fingers through the valve ports if the actuator is supplied with compressed air
Operation:
Never touch the clip assembly or the actuator piston rod when the actuator is supplied with compressed
air (see warning label)
Never pressurise air connections (AC1, AC3) simultaneously as both valve plugs can be lifted (can cause mixing)
Never touch the valve or the pipelines when processing hot liquids or when sterilizing.
Never throttle the leakage outlet
Never throttle the CIP outlet, if supplied
Always handle lye and acid with great care
Maintenance:
Always fit the seals correctly
Always release compressed air after use
Always remove the CIP connections, if supplied, before service.
Never service the valve when it is hot
Never pressurise the valve/actuator when the valve is serviced
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
(see warning label)
Transportation:
Always ensure that compressed air are released

Always ensure that all connections is disconnected before attempting to remove the valve from the installation
Always drain liquid out of valves before transportation
Always used predesigned lifting points if defined
Always ensure sufficient fixing of the valve during transportation - if specially designed packaging material is available, it
must be used
6
3 Installation
The instruction manual is part of the delivery.
Study the instructions carefully.
Fit the warning label supplied on the valve after installation so that it is normally visible.
3.1 Unpacking/intermediate storage
Step 1
CAUTION
Alfa Laval cannot be held responsible for incorrect unpacking.
Check the delivery for:
1. Complete valve.
2. Delivery note.
3. Warning label.
Step 2
Remove upper support.
Step 3
Lift out the valve.
NOTE!
Please note weight of valve as printed on box.
Step 4
Remove possible packing materials from the valve ports.
TD 449-043_1
7
3 Installation
The instruction manual is part of the delivery.
Fit the warning label supplied on the valve after installation so that it is normally visible.
Step 5
Inspect the valve for visible transport damages.
Inspection!
TD 449-327
Step 6
Avoid damaging the air connections, the leakage outlet, the valve
ports and the CIP connections, if supplied.
Caution!
TD 449-044_1
Step 7 1 3
Disassemble according to illustrations 1 to 6 (please also see
A B
section 5.2 Dismantling the valve).
1. Supply compressed air. C
2. Remove upper clamp.
3. Release compressed air.
4. Lift out actuator with plugs. 4
5. Remove lower clamp.
6. Take away lower sealing element.
5
A = on TD 449-017_1
B = off 6
C = air
Step 8
Mount sealing element on valve.
TD 449-023_1
8
3 Installation
Study the instructions carefully and pay special attention to the warnings!
The valve has ends for welding as standard but can also be supplied with fittings.
Step 9
1. Place actuator part in the box.
2. Add supports.
3. Close box and store.
Advise!
Mark the valve body and box with the same number before
intermediate storage.
24_1
49-0
TD 4
3.2 General information
Step 1
Always read the technical data thoroughly.

See section 6.1 Technical data
Always release compressed air after use.
Never touch the clip assembly or the actuator piston rod if the actuator is supplied with compressed air (see the warning label).
CAUTION
Fit the supplied warning label on the valve so that it is normally visible.
Alfa Laval cannot be held responsible for incorrect installation.
NOTE
Always install the valve vertically.
The leakage outlet must be turned downwards!
Step 2
Avoid stressing the valve as this can result in deformation of
the sealing area and misfunction of the valve (leakage or faulty
indication).
Pay special attention to:

- Vibrations.
- Thermal expansion of the tubes. Risk of damage!
- Excessive welding.
- Overloading of the pipelines.
9
3 Installation
The valve has ends for welding as standard but can also be supplied with fittings.
Step 3
Fittings: Ensure that the connections are tight.
Remember seal rings!
Step 4 AC3
Air connection: R 1/8 (BSP).
AC1: Cleaning of upper seat.
AC2: Open valve.
AC3: Cleaning of lower seat. AC2
AC1
TD 449-047_1
Step 5 CIP in CIP in

CIP connection (optional extra):
1. See description of cleaning in section 4.3 Recommended
cleaning.
2. Connect CIP correctly.
TD 449-048_1
R 3/8 (BSP),
external thread
CIP out
10
3 Installation
The valve has ends for welding as standard.
Weld carefully/aim at stressless welding to avoid deformation on sealing areas.
Check the valve for smooth operation after welding.
Step 6 CIP in CIP out

It is important to connect CIP inlet to the small inlet nozzle to avoid
built-up pressure in the cleaning chamber.
Align nozzle edges with recess in sealing element.
3.3 Welding
Step 1
Never stick your fingers through the valve ports if the actuator is Cutting danger!
supplied with compressed air. Air
TD 449-325
Step 2
Dismantle the valve in accordance with Step 1 in section 5.2 Dismantling the valve.
Step 3
NOTE
Maintain the minimum clearances so that the actuator with the
internal valve parts can be removed - please see later this section!
B
If there is a risk of foot damage, Alfa Laval recommends to leave
a distance of 120 mm (4.7) below the valve (look at the specific
built-in conditions).
A
TD 449-024_1
11
3 Installation
Step 4
WARNING
Make sure to turn the valve body correctly - conical valve seat UP
upwards. Remove label after
installation of valve body
TD 449-329
Step 5
Assemble the valve in accordance with section 5.5 Assembly of valve after welding.
Pay special attention to the warnings!
Step 6 AC3
Pre-use check:
1. Supply compressed air to AC1, AC2 and AC3 one by one.
2. Operate the valve several times to ensure that it runs smoothly.
AC2
AC1
Operate!
TD 449-045_2
12
3 Installation
NOTE!
If ThinkTop is mounted, add 180 mm (7,1) to B measure.
Table 1 and 2
1. Lower sealing element can be removed without taking out
actuator and internal valve parts. B
2. Actuator and internal valve parts can be lifted out of the
valve body.
A
TD 449-024_1
Table 1. (All measures in mm) (1 mm = 0.0394)
ISO DIN
DN/OD DN/OD DN/OD DN/OD DN/OD DN DN DN DN DN DN DN

Size
38 51 63.5 76.1 101.6 40 50 65 80 100 125 150
A
Basic/SeatClean 160 200 250 250 290 160 200 240 220 280 320 305
PMO 195 225 245 279
A
HighClean/UltraClean 200 265 300 300 360 200 265 290 270 350 390 375
PMO 265 300 320 349
*C 60.8 73.8 86.3 98.9 123.6 64 76 92 107 126 151 176
B
Basic 700 760 909 909 1148 700 760 909 909 1148 1350 1370
SeatClean 700 760 880 880 1050 700 760 880 880 1050 1250 1270
PMO 765 885 900 1050
B
PMO 877 1047 1060 1250
* The measure C can always be calculated by the formula C = ID upper + ID lower + 26 mm (1).
Table 2. (All measures in mm) (1 mm = 0.0394)
Sch. 5
Sch. 5 Sch. 5 Sch. 5 Sch. 5 Sch. 5

Size
2 3 4 5 6
A
Basic/SeatClean 190 210 265 315 300
A
HighClean/UltraClean 230 260 340 385 370
*C 83 110.7 136.1 161.8 188.8
B
Basic 760 909 1148 1350 1370
SeatClean 760 880 1050 1250 1270
B
HighClean/UltraClean 870 1020 1250 1420 1420
* The measure C can always be calculated by the formula C = ID upper + ID lower + 26 mm (1).
13
3 Installation
NOTE!
If ThinkTop is mounted, add 180 mm (7,1) to B measure.
Table 3 and 4
1. Lower sealing element can only be dismantled if actuator B

and internal parts are removed.
A
TD 449-024_1
Table 3.
ISO DIN
DN/OD DN/OD DN/OD DN/OD DN/OD DN DN DN DN DN DN DN

Size
38 51 63.5 76.1 101.6 40 50 65 80 100 125 150
A
Basic/Seat Clean 120 140 170 170 200 120 140 170 160 200 250 235
PMO 135 145 165 189
A
PMO 190 220 240 259
Table 4.
Sch. 5
Sch. 5 Sch. 5 Sch. 5 Sch. 5 Sch. 5

Size
2 3 4 5 6
A
Basic/Seat Clean 140 160 190 245 230
A
HighClean/UltraClean 180 210 270 315
14
3 Installation
3.4 Recycling information
Unpacking
- Packing material consists of wood, plastics, cardboard boxes and in some cases metal straps
- Wood and cardboard boxes can be re-used, recycled or used for energy recovery
- Plastics should be recycled or burnt at a licensed waste incineration plant
- Metal straps should be sent for material recycling
Maintenance
- During maintenance, oil and wearing parts in the machine are replaced
- All metal parts should be sent for material recycling
- Worn out or defective electronic parts should be sent to a licensed handler for material recycling
- Oil and all non-metal wear parts must be disposed off in agreement with local regulations
Scrapping
- At end of use, the equipment must be recycled according to the relevant, local regulations. Besides the equipment itself,
any hazardous residues from the process liquid must be considered and dealt with in a proper manner. When in doubt, or
in the absence of local regulations, please contact your local Alfa Laval sales company
15
4 Operation
The valve is adjusted and tested before delivery.
Pay attention to possible faults.
The items refer to the parts list and service kits section.
4.1 Operation
Step 1
Always read the technical data thoroughly.

Never touch the clip assembly or the actuator piston rod if the actuator is supplied with compressed air (see the warning label).
Never pressurise air connections (AC1, AC3) simultaneously as both valve plugs can be lifted (can cause mixing).
CAUTION
Alfa Laval cannot be held responsible for incorrect operation.
Step 2
Burning danger!
Never touch the valve or the pipelines when processing hot liquids
or when sterilising.
TD 449-326
16
4 Operation
The valve is adjusted and tested before delivery.
Pay attention to possible faults.
4.2 Fault finding and repair
NOTE
Study the maintenance instructions carefully before replacing worn parts.
Problem Cause/result Repair
Leakage between sealing element (79) Worn/product affected o-rings/ lip seal - Replace the o-rings/lip seal
and lower plug (75) (76/77/78) - Change rubber grade
- Lubricate correctly
Leakage at the leakage outlet - Particles between valve seats and plug - Remove the particles
seals (56/74) - Check the plug seals
- Worn/product affected plug seal rings - Replace the plug seals
(56/74) - Change rubber grade
- Plug not assembled correctly - Assemble plug, see step 3 section 5.5
Assembly of valve
Leakage at sealing element (48)/upper Worn/product affected o-rings/lip seal - Replace the o-rings/lip seal
plug (55) (sizes 38/39/46/49) - Change rubber grade
- Clean and if necessary replace guide
ring (45)
Leakage at clamp (64) - Too old/product affected o-rings (76 - Replace the o-rings
and 47) (and 52 if clamped valve body) - Change rubber grade
- Loose clamp (64) - Tighten the clamp
CIP leakage Worn o-rings (40/67/71) Replace the o-rings
Leakage at spindle clamp (43) Damaged o-ring (39) W orn/product - Replace the o-ring
affected lip seal (57) or spray nozzle (58) - Replace the plug seals
- Change rubber grade
Lower plug not returning to closed - Wrong rubber grade - Change rubber grade
position - Wrongly fitted gasket - Fit new gasket correctly
- Mounted incorrectly (see section 2.3) - Correct installation
Plug returns with uneven movements - Wrong rubber grade - Change rubber grade
(slip/stick effect) - Wrongly fitted gasket - Fit new gasket correctly
- Mounted incorrectly (see section 2.3) - Correct installation
17
4 Operation
The valve is designed for cleaning in place (CIP). CIP = Cleaning In Place.
NaOH = Caustic Soda. HNO3 = Nitric acid.
Internal leakage in the valve is externally visible by means of the leakage outlet.
4.3 Recommended cleaning
Step 1 Caustic danger!
Never touch the valve or the pipelines when sterilising.
Always use rubber gloves! Always use protective

goggles!
Step 2
Never touch the valve or the pipelines when sterilising.
Burning danger!
TD 449-326
Step 3 CIP in CIP in

TD 449-056_1
Never throttle the leakage outlet.
Never throttle the CIP outlet, if supplied.

(Risk of mixing due to overpressure).
TD449-330
Leakage/CIP out CIP out
Step 4
Examples of cleaning agents:
Use clean water, free from chlorides.
1. 1% by weight NaOH at 70o C (158F) . 2. 0.5% by weight HNO3 at 70o C (158F).
1 kg (2.2 lb) 100 l (26.4 gal) 0.7 l (0.2 gal) 100 l (26.4 gal) Cleaning
+ = Cleaning agent. + =
NaOH water 53% HNO3 water agent.
2.2 l (0.6 gal) 100 l (26.4 gal)

+ = Cleaning agent.
33%NaOH water
18
4 Operation
Step 5
1. Avoid excessive concentration of the cleaning agent
=> Dose gradually!
2. Adjust the cleaning flow to the process.
Milk sterilization/viscous liquids
=> Increase the cleaning flow!
Step 6
Product Periods
Advisory seat lift cleaning periods:
Cleaning periods of 3-6 seconds per CIP sequence. Milk 1-2
Yoghurt 3-5
Beer 2-5
Cold wort 5-10
Step 7 Always rinse!

Always rinse well with clean water after the cleaning.
NOTE
The cleaning agents must be stored/disposed of in accordance
with current regulations/directives.
Clean water Cleaning agents
19
4 Operation
Seat-cleaning cycles:
1. Closed valve
CIP
Product
2. Cleaning through lower line
Product
CIP
3. Open valve
Product
4. Cleaning through upper line
CIP
Product
20
5 Maintenance
Maintain the valve/actuator regularly. Study the instructions carefully and pay special attention to the warnings!
Always keep spare rubber seals and guide rings in stock. The items refer to the parts list and service kits section.
The valve is designed so that internal leakages do not result in the products becoming mixed.
Internal leakage in the valve is externally visible. Check the valve for smooth operation after service.
5.1 General maintenance
Step 1
Always remove the CIP connections, if supplied,

Always read the technical data thoroughly. before service.
NOTE
All scrap must be stored/discharged in accordance
Always fit the seals correctly (risk of mixing).
with current rules/directives.
Step 2
Atmospheric pressure
Never service the valve when it is hot. required!
Never service the valve with valve/actuator under pressure.

Burning danger!
Step 3
Never stick your fingers through the valve ports if the actuator is Cutting danger!
supplied with compressed air. Air
TD 449-325
21
5 Maintenance
Maintain the valve/actuator regularly. Study the instructions carefully and pay special attention to the warnings!
Always keep spare rubber seals and guide rings in stock. The items refer to the parts list and service kits section.
The valve is designed so that internal leakages do not result in the products becoming mixed.
Internal leakage in the valve is externally visible. Check the valve for smooth operation after service.
Step 4
Never touch the clip assembly or the actuator piston rod if the
actuator is supplied with compressed air (see the warning label).
Air
Moving parts
Recommended spare parts: Service kits
Order service kits from the service kits section - see section 7 Parts list and service kits
Ordering spare parts: Contact the Sales Department.
Valve rubber seals Valve plug seals Valve guide rings
Preventive maintenance Replace after 12 months(*) Replace after 12 months(*) Replace when required
Maintenance after leakage Replace after production Replace after production

(leakage normally starts slowly) cycle cycle
Planned maintenance - Regular inspection for - Regular inspection for Replace when required
leakage and smooth leakage and smooth
operation operation
- Keep a record of the valve - Keep a record of the valve
- Use the statistics for - Use the statistics for
planning of inspections planning of inspections
Lubrication When assembling When assembling None

Klber Paraliq GTE 703 or Klber Paraliq GTE 703 or
similar USDA H1 appr oved similar USDA H1 approved
oil/grease (**) (suitable for oil/grease (**) (suitable for
EPDM) EPDM)
NOTE!
Lubricate thread in valve plug parts with Klber Paste UH1 84-201 or similar.
(*) Depending on working conditions! Please contact Alfa Laval.
(**) All products wetted seals.
22
5 Maintenance
Handle scrap correctly.
Replace seals if necessary.
Repairing of actuator:
- The actuator is maintenance-free but repairable.
- If repair is required, replacing all actuator rubber seals is recommended.
- Lubricate seals with Klberplex BE31.
- To avoid possible black remains on pos. 1 and 29, Alfa Laval recommends Klber Paraliq GTE703 (white) for these two
positions.
Pre-use check AC3

1. Supply compressed air to AC1, AC2 and AC3 one by one.
2. Operate the valve several times to ensure that it operates
smoothly.
AC2
AC1
Operate!
TD 449-045_2
5.2 Dismantling the valve
Step 1 A3
Disassemble valve acc. to illustrations ( 1 to 6 ). 1 3
1. Supply compressed air to AC2.
2. Loosen and remove upper clamp (64).
4. Lift out the actuator together with the internal valve parts from A2
valve body (50). A1
5. Loosen and remove lower clamp (64).
6. Take away lower sealing element (79). 4
OPTION:
If clamped valve body: Loosen and remove clamp and pull upper
(51) and lower (53) valve bodies apart. Pull out o-ring (52).
NOTE
Release compressed air.
6
TD 449-073_1
23
5 Maintenance
Step 2
Dismantling of lower sealing element:
1. Pull out o-ring (76) and lip seal (77).
2. Remove o-ring (78).
3. Screw out flushing tubes (70).
4. Remove o-rings (71) and nozzles (72 + 73).
TD 449-067_1
Step 3
If upper seat lift available
3A:
If air fitting AC1 is present, supply compressed air and follow
procedure 3A.
1 4
1. Supply compressed air for AC1. A B
2. Loosen lower plug (75) while counterholding upper stem (1).

3. Remove the plug. 3 2
4. Release compressed air. 2
A. On
B. Off
TD 449-018_1
3B:
If no air fitting AC1 is present, follow procedure 3B.
If no upper seat lift available
1. Push upper sealing element (48) free of intermediate piece (37).
2. Loosen lower plug while counterholding upper stem. 1
3. Remove the plug (75).
Replace o-ring (38).
Note: For replacement of seal ring (74), please see section 5.3 2
2
Lower plug, replacement of radial seal.
TD 449-074_1
Step 4
2
Remove coupling system and upper plug according to illustrations
( 1 to 4 ).
1. Unscrew flushing tube (41) (or plug (15) if no CIP). Remove
o-ring (40).
2. Pull up lock (44) over piston rod (29).
3. Pull away clamps (43) from spindle liner (42).
4. Pull out upper plug (55). Make sure spindle liner is free of both 3
piston rod and upper plug. If external CIP to leakage chamber: TD 449-065_1
Remove o-rings (39).

1
24
5 Maintenance
Step 5
1. If present, unscrew flushing tubes (66) and remove o-rings (67)
and nozzles (68 + 69).
2. Pull out upper sealing element (48) from intermediate piece (37).
3. Pull out o-ring (47), lip seal (49) and o-ring (46) from upper
sealing element.
Step 6
Remove lip seal (57) (or spray nozzle (58) if valve is supplied with
Spiral-Clean). For removal and replacement of seal ring (56),
please see section 5.3 Lower plug, replacement of radial seal.
5.3 Lower plug, replacement of radial seal
Step 1
Cut and remove old seal ring (74) using a knife, screwdriver or
similar. Be careful not to scratch the plug.
25
5 Maintenance
Step 2
Pre-mount seal ring as shown on drawing.
Rotate along circumference to fix gasket as shown in the picture.
Carefully lubricate sealings with acceptable soap or lubricant,
before pre-mounting.
Step 3
Place lower tool part.
TD 449-340
Item no.
Seat 53 Seat 81 Seat 110 Seat 115 Tool for radial sealing, lower plug
9613-4260-01 9613-4260-02 9613-4260-03 9613-4260-04
TD 449-337
Step 4
1. Place upper tool part including piston.
2. Clamp the two tool parts together.
TD 449-338_2
Tool marked with

item number.
26
5 Maintenance
Handle scrap correctly
Step 5 on off
1. Supply compressed air.
3. Remove tool parts.
TD 449-029_1
Step 6
Inspect the seal to ensure it does not twist in the groove, and
press in the 4 outsticking points with a screwdriver!
TD 449-057_1
5.4 Upper plug, replacement of axial seal
Step 1
Remove old seal ring (56) using a knife, screwdriver or similar.
Be careful not to scratch the plug.
Step 2
Pre-mount seal ring as shown on drawing.
B
A
_1
TD 449-031_1
A = Flat side of sealing

B = Balanced plug Carefully lubricate sealings with acceptable soap or lubricant,
C = Do not lubricate behind the sealing before pre-mounting.
27
5 Maintenance
Handle scrap correctly
Step 3
Place tool part 1.
Item no.
Seat 53 Seat 81 Seat 110 Seat 115 Tool for axial sealing, upper plug
9613-0505-01 9613-0505-02 9613-0505-08 9613-0505-03
Step 4 Tooling marked with item number

1. Place tool part 2 including piston.
2. Clamp the two tool parts together.
TD 449-033_1
Step 5
3. Rotate the tool 45 with regards to the plug. A B
5. Release compressed air and remove tool.
TD 449-034_1
A = on B = off
Step 6
1. Inspect the seal.
2. Release air at 3 different positions of the circumference.
28
5 Maintenance
5.5 Assembly of valve

Step 1
1. Fit o-ring (47) (do not twist), lip seal (49) and o-ring (46) in upper
sealing element (48) (Lubricate with Klber Paralique GT 703).
NOTE: The o-ring should be gently pressed into the groove
2. Fit upper sealing element in intermediate piece (37).
3. Place o-rings (67) and mount flushing tubes (66). Be sure to
align nozzles (68 + 69) towards recess.
TD449-144_2
Lubricate with Klber Paralique GT 703
Step 2 2 1
1. Place lip seal (57) in upper plug (or spray nozzle if the valve has
TD 449-076_1
SpiralClean) and the o-ring (38) in the lower plug.
2. Press lower plug (75) rapidly into upper plug (55) through the
lip seal.
Note: Do not damage the lips when lower plug (75) with o-ring
(38) passes the lip seal.
Step 3
Place coupling system and upper plug according to illustrations ( 1 3
to 4 ).
1. Push lock (44) up over piston rod (29).
2. If external CIP to leakage chamber: Place o-rings (39).
3. Place spindle liner (42) on piston rod. Fit upper plug (55).
4. Mount clamps (43) on spindle liner (42). 2
5. Fit lock (44).
4
6. Fit o-ring (40). Fit flushing tube (41) (or plug (15) if no CIP).
1
TD 449-331
29
5 Maintenance
Step 4
Recommended torque values for fitting upper and lower plug parts
Dimension Torque (Nm)/(lbf-ft)
38 mm/DN 40
51 mm/DN 50 5/(3.7)
Sch. 5 2
All others 20/(14.8)
off
1
2 1
A
2
1
TD 449-333
TD 449-332_1
If upper seat lift available If no upper seat lift available
A = air
Step 5
1. Place o-rings (71) and fit nozzles (72 + 73) and flushing tubes
(70), if present.
2. Place o-ring (78) and fit lip seal (77) and o-ring (76) (do not twist
the o-ring) and press it gently into the groove (lubricate with
Klber Paralique GT703)
TD 449-334
TD449-144_2
Lubricate with Klber Paralique GT 703
30
5 Maintenance
Step 6
- Never stick your fingers through the valve ports if the actuator 3 6
is supplied with compressed air.
- Always supply compressed air, before demounting the valve.
A
If clamped valve body: First place o-ring (52) and fit upper (51) and B
lower (53) valve bodies. Fit and tighten clamp (64).

C
Reassemble valve according to illustrations ( 1 - 6 ). 4
1. Fit lower sealing element (79).

2. Fit and tighten lower clamp (64).
3. Supply compressed air and mount the actuator together with
the internal valve parts from valve body (50).
4. Fit and tighten upper clamp (64). Greasing of clamp and clamp
nut recommended!
(Maximum torque for clamp nut: 10Nm/7.4 lbf-ft)
5. Release compressed air. 5
NOTE
Supply compressed air before demounting the valve.
A = on
B = off
C = air 2
1
TD 449-335_1
31
5 Maintenance
5.6 Dismantling of actuator
Step 1
1. Dismantle the valve in accordance with instructions in
section 5.2 Dismantling the valve
2. The actuator is now ready for service.
Please see drawing when dismantling according to steps 2
to 6 on this page.
Note! The actuator is maintenance free but repairable.
Step 2
1. Remove nuts (36) and washers (35).
2. Pull out intermediate piece (37) from the actuator.
3. Remove cover disk (25).
4. Remove retaining ring (24).
Step 3
1. Remove piston rod (29), bottom (21) and lower piston (30).
2. Separate the three parts.
3. Remove o-rings (20, 22 and 23) from bottom, o-rings (33
and 31) and guide ring (32) from lower piston as well as
o-ring (28) from piston rod.
4. Remove spring assembly (14).
Step 4
1. Remove inner stem (27), main piston (17) and distance
spacer (11) if present. Remove guide ring (18) and o-ring
(19).
2. Remove spring assembly (10).
Step 5
Note! Not on actuator 3.
1. Unscrew screws (2) (are glued!).
2. Remove stop (4).
3. Remove upper piston (8). Remove o-rings (7 and 9).
Step 6
Remove o-ring (5) and guide ring (6).
32
5 Maintenance
Lubricate the rubber seals before fitting them.
5.7 Assembly of actuator
Step 1
Please see drawing when reassembling according to steps 2
to 5 on this page.
Note! The actuator is maintenance free but repairable.
Step 2
1. Fit guide ring (6) and o-ring (5).

Note! Not on actuator 3:
2. Fit o-rings (7 and 9). Place upper piston (8).
3. Fit stop (4).
4. Tighten screws (2). (Secure with glue)
Step 3
1. Place spring assembly (10).
2. Fit o-ring (19) and guide ring (18). Mount distance spacer
(11), main piston (17) and inner stem (27).
Step 4
1. Fit spring assembly (14).
2. Fit o-ring (28) in piston rod, fit o-rings (33 and 31) and guide
ring (32) in lower piston and fit o-rings (20, 22 and 23) in
bottom.
3. Fit piston rod (29), lower piston (30) and bottom (21).
4. Mount the three parts.
Step 5
1. Fit retaining ring (24).
2. Fit cover disk (25).
3. Mount intermediate piece (37) on actuator.
4. Fit and tighten nuts (36) and washers (35).
33
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
Unique is remote-controlled by means of compressed air. The valve is a normally closed (NC) valve.
The valve has two independent plug seals, forming a leakage chamber between them under atmospheric pressure during every
working condition. In case of rare accidental leaking of product, this will flow into the leakage chamber and be discharged
through the leakage outlet.
Data
Max. product pressure: 1000 kPa (10 bar) (145 psi)
Min. product pressure: Full vacuum

Recommended min. pressure for SpiralClean: 2 bar (29 psi)
Temperature range: -5C to +125C (23F - 257F) (Depending on rubber quality)
Air pressure: Max. 800 kPa (8 bar) (116 psi)
Products acc. to PED 97/23/EC Category I, Fluids group 1

DN 125 Fluids group 2
Materials
Product wetted steel parts: Acid-resistant steel AISI 316L

Other steel parts: Stainless steel AISI 304
Product wetted parts: EPDM, HNBR, NBR or FPM
Other seals: CIP seals: EPDM
Actuator seals: NBR

Surface finish: Internal/external matt (blasted) Ra < 1.6 (64 )
Internal bright (polished) Ra < 0.8 (32 )
Internal/external bright (internal polished) Ra < 0.8 (32 )
Note! The Ra-values are only for the internal surface.
Weight (kg)
DN/OD DN
Size
38 51 63.5 76.1 101.6 40 50 65 80 100 125 150
Weight (kg) - Basic 13.5 15 24 24 34 13.5 15 24 24 34 44 45
Weight (kg) - SeatClean 13.5 15 24 24 34 13.5 15 24 24 34 47 48
Weight (kg) - High-/UltraClean 14.5 16 27 27 38 14.5 16 27 27 38 51 52
Noise
One metre away from - and 1.6 metre above the exhaust the noise level of a valve actuator will be approimately 77db(A) without
noise damper and approximately 72 db(A) with damper - measured at 7 bars air-pressure.
34
6 Technical data
Below table values for the Unique PMO version please refer to PD sheet PD66352.
Size DN/OD DN Sch. 5
ISO/DIN/Sch.5 38 51 63.5 76.1 101.6 40 50 65 80 100 125 150 2 3 4 5 6
Kv-value
Upper Seat-lift [m3/h] 1.5 1.5 2.5 2.5 3.1 1.5 1.5 2.5 2.5 3.1 3.7 3.7 1.5 2.5 3.1 3.7 3.7
Kv-value
Lower Seat-lift [m3/h] 0.9 0.9 1.9 1.9 2.5 0.9 0.9 1.9 1.9 2.5 3.1 3.1 0.9 1.9 2.5 3.1 3.1
Air consumption
Upper Seat-lift *[n litre] 0.2 0.2 0.4 0.4 0.62 0.2 0.2 0.4 0.4 0.62 0.62 0.62 0.2 0.4 0.62 0.62 0.62
Air consumption
Lower Seat-lift *[n litre] 1.1 1.1 0.13 0.13 0.21 1.1 1.1 0.13 0.13 0.21 0.21 0.21 1.1 0.13 0.21 0.21 0.21
Air consumption
Main Movement *[n litre] 0.86 0.86 1.63 1.63 2.79 0.86 0.86 1.62 1.62 2.79 2.79 2.79 0.86 1.63 2.79 2.79 2.79
Kv-value SpiralClean
Spindle CIP [m3/h] 0.12 0.12 0.12 0.12 0.12 0.12 0.12 0.12 0.12 0.12 0.12 0.12 0.12 0.12 0.12 0.12 0.12
Kv-value SpiralClean
External CIP of leakage
chamber [m3/h] 0.25 0.25 0.29 0.29 0.29 0.25 0.25 0.29 0.29 0.29 0.29 0.29 0.25 0.29 0.29 0.29 0.29
Note:
* [n litre] = volume at atmospheric pressure.
Formula to estimate CIP flow during seat lift (for liquids with comparable viscosity and density to water):
Q = Kv p
Q = CIP - flow (m3/h).
Kv = Kv value from the above table.
p = CIP pressure (bar).
Cv = 1.163 x Kv gpm
1 bar = 14.5 psi
35
7 Parts list and service kits
7.1 Four configurations examples
TD 449-425 TD 449-426
Basic SeatClean
36
TD 449-427 TD 449-428
HighClean UltraClean
37
7.2 Wear parts
120
_3
* = All FPM service kits are supplied with EPDM seal ring (pos. 74)
38
Parts list
Pos. Qty Denomination
38 1 O-ring
39 2 O-ring
40 1 O-ring
46 1 O-ring
47 1 O-ring
49 1 Lip seal
52 1 O-ring
56 1 Seal ring
57 1 Lip seal
67 2 O-ring
71 2 O-ring
74 1 Seal ring
76 1 O-ring
77 1 Lip seal
78 1 O-ring
39
157/186
_3
* = All FPM service kits are supplied with EPDM seal ring (pos. 74)
40
Parts list
38 1 O-ring
39 2 O-ring
40 1 O-ring
46 1 O-ring
47 1 O-ring
49 1 Lip seal
52 1 O-ring
56 1 Seal ring
57 1 Lip seal
67 2 O-ring
71 2 O-ring
74 1 Seal ring
76 1 O-ring
77 1 Lip seal
78 1 O-ring
41
7.3 Parts
*
*
*
*
Clamped valve body
TD 449-007_3
= Wear part
* = Positions not present on actuator 120
42
Parts list
1 1 Upper stem
2 4 Screw
3 3 Air fitting
4 1 Stop for upper piston
5 1 O-ring
6 1 Guide ring, Turcite
7 1 O-ring
8 1 Upper piston
9 1 O-ring
10 1 Spring assembly
11 1 Distance spacer
12 1 Pin
13 1 Washer
14 1 Spring assembly
15 1 Plug
15a 1 Plug
16 1 Cylinder
17 1 Main piston
19 1 O-ring
20 1 O-ring
21 1 Bottom
23 1 O-ring
24 1 Retaining ring
25 1 Cover disk
26 1 O-ring
27 1 Inner stem
28 1 O-ring
29 1 Piston rod
30 1 Lower piston
31 1 O-ring
33 1 O-ring
34 3 Bolt
35 3 Washer
36 3 Nut
41 1 Flushing tube
42 1 Spindle liner
43 2 Clamp
44 1 Lock
45 1 Guide ring
48 1 Upper sealing element
54 1 Guide ring
55 1 Upper plug
58 1 Spray nozzle
60 2 Hexnut
61 2 Wingnut
64 2 Clamp without nut
66 2 Flushing tube
68 1 Drain
69 1 Nozzle
70 2 Flushing tube
72 1 Drain
73 1 Nozzle
75 1 Lower plug
79 1 Lower sealing element
80 1 Guide ring
81 1 Cover
43
44
7.4 Service kits (plug set-up 1-4)
Plug set-up 1 Plug set-up 2 Plug set-up 3 Plug set-up 4
55 55 55 55
48 48 48 48
75 75 75 75
79 79 79 79
TD 449-128_1 TD 449-129_1 TD 449-130_1 TD 449-131_1
1. Find your plug/sealing element set-up.

2. Find the right pos. no. and plug set-up in the table and you have the part no.
An example:
1. Size DN 80, plug set-up 5
2. Pos. no. 55/plug set-up 5 has the part no. 9613-0082-02
45
Service kits
DN/OD 63.5
DN 65 * **
DN/OD 38 DN/OD 51 DN/OD 76.1 DN/OD 101.6 DN/OD 101.6 DN 125
DN 40 DN 50 DN 80 DN 100 DN 100 DN 150
Denomination seat 53.3 seat 53.3 seat 81.3 seat 115.3 seat 100.3 seat 115.3
Plug set-up 1
a Service kit, EPDM . . . . . . . . . . 9611-92-1550 9611-92-1552 9611-92-1554 9611-92-6334 9611-92-6025
a Service kit, NBR . . . . . . . . . . . 9611-92-1556 9611-92-1558 9611-92-1560 9611-92-6335 9611-92-6026
a Service kit, FPM . . . . . . . . . . . . 9611-92-1562 9611-92-1564 9611-92-1566 9611-92-6336 9611-92-6027
a Service kit, HNBR . . . . . . . . . . 9611-92-1568 9611-92-1570 9611-92-1572 9611-92-6337 9611-92-6028
Plug set-up 2
a Service kit, NBR ........... 9611-92-1580 9611-92-1582 9611-92-1584 9611-92-6339 9611-92-6030
a Service kit, FPM . . . . . . . . . . . . 9611-92-1586 9611-92-1588 9611-92-1590 9611-92-6340 9611-92-6031
Plug set-up 3
a Service kit, NBR ........... 9611-92-1605 9611-92-1606 9611-92-1608 9611-92-6343 9611-92-6034
a Service kit, FPM . . . . . . . . . . . . 9611-92-1611 9611-92-1612 9611-92-1614 9611-92-6344 9611-92-6035
Plug set-up 4
a Service kit, EPDM . . . . . . . . . . 9611-92-1622 9611-92-1623 9611-92-1624 9611-92-1626 9611-92-6346 9611-92-6037
a Service kit, NBR ........... 9611-92-1628 9611-92-1629 9611-92-1630 9611-92-1632 9611-92-6347 9611-92-6038
a Service kit, FPM . . . . . . . . . . . . 9611-92-1634 9611-92-1635 9611-92-1636 9611-92-1638 9611-92-6348 9611-92-6039
a Service kit, HNBR . . . . . . . . . . 9611-92-1640 9611-92-1641 9611-92-1642 9611-92-1644 9611-92-6349 9611-92-6040
* = Serial no. below 1030000 - manufactured before 1. October 2003.

** = Serial no. above 1030000 - manufactured after 1. October 2003.
NOTE!
All FPM serice kits are supplied with EPDM seal ring (pos. 74)
If different connection size on upper and lower body, except for sizes DN 125 and DN 150, it is always the smallest body that determines
the service kit.
If clamped valve body an extra O-ring (pos. 52) is required.
46

55
55 48 55
55
48 48
48
75
75 75 75
79 79 79
79
TD 449-132_1 TD 449-133_1 TD 449-134_1 TD 449-135_1

An example:
47
Service kits
DN/OD 63.5
DN 65 * **
DN 40 DN 50 DN 80 DN 100 DN 100 DN 150
Plug set-up 5
a Service kit, NBR . . . . . . . . . . . 9611-92-1653 9611-92-1654 9611-92-1656 9611-92-6351 9611-92-6042
a Service kit, FPM . . . . . . . . . . . . 9611-92-1659 9611-92-1660 9611-92-1662 9611-92-6352 9611-92-6043
Plug set-up 6
a Service kit, NBR ........... 9611-92-1676 9611-92-1677 9611-92-1678 9611-92-1680 9611-92-6355 9611-92-6046
a Service kit, FPM . . . . . . . . . . . . 9611-92-1682 9611-92-1683 9611-92-1684 9611-92-1686 9611-92-6356 9611-92-6047
Plug set-up 7
a Service kit, NBR ........... 9611-92-1701 9611-92-1703 9611-92-1705 9611-92-6359 9611-92-6050
a Service kit, FPM . . . . . . . . . . . . 9611-92-1707 9611-92-1709 9611-92-1711 9611-92-6360 9611-92-6051
Plug set-up 8
a Service kit, NBR ........... 9611-92-1653 9611-92-1654 9611-92-1656 9611-92-6351 9611-92-6042
a Service kit, FPM . . . . . . . . . . . . 9611-92-1659 9611-92-1660 9611-92-1662 9611-92-6352 9611-92-6043

NOTE!
the service kit.
48
55
55
55 55
48
48
48 48
75 75
75 75
79 79 79 79
TD 449-136_1 TD 449-137_1 TD 449-138_1 TD 449-139_1

An example:
49
Service kits
DN/OD 63.5
DN 65 * **
DN 40 DN 50 DN 80 DN 100 DN 100 DN 150
Plug set-up 9
a Service kit, NBR . . . . . . . . . . . 9611-92-1749 9611-92-1751 9611-92-1753 9611-92-6363 9611-92-6058
a Service kit, FPM . . . . . . . . . . . . 9611-92-1755 9611-92-1757 9611-92-1759 9611-92-6364 9611-92-6059
Plug set-up 10
a Service kit, NBR ........... 9611-92-1773 9611-92-1775 9611-92-1777 9611-92-6367 9611-92-6062
a Service kit, FPM . . . . . . . . . . . . 9611-92-1779 9611-92-1781 9611-92-1783 9611-92-6368 9611-92-6063
Plug set-up 11
a Service kit, NBR ........... 9611-92-1773 9611-92-1775 9611-92-1777 9611-92-6367 9611-92-6062
a Service kit, FPM . . . . . . . . . . . . 9611-92-1779 9611-92-1781 9611-92-1783 9611-92-6368 9611-92-6063
Plug set-up 12
a Service kit, NBR ........... 9611-92-1820 9611-92-1821 9611-92-1822 9611-92-1824 9611-92-6371 9611-92-6070
a Service kit, FPM . . . . . . . . . . . . 9611-92-1826 9611-92-1827 9611-92-1828 9611-92-1830 9611-92-6372 9611-92-6071

NOTE!
the service kit.
50
55 55
55
55
48 48 48
48
75 75 75
75
79 79 79 79
TD 449-140_1 TD 449-141_1 TD 449-142_1 TD 449-143_1

An example:
51
Service kits
DN/OD 63.5
DN 65 * **
DN 40 DN 50 DN 80 DN 100 DN 100 DN 150
Plug set-up 13
a Service kit, NBR . . . . . . . . . . . 9611-92-1580 9611-92-1582 9611-92-1584 9611-92-6339 9611-92-6030
a Service kit, FPM . . . . . . . . . . . . 9611-92-1586 9611-92-1588 9611-92-1590 9611-92-6340 9611-92-6031
Plug set-up 14
a Service kit, NBR ........... 9611-92-1628 9611-92-1629 9611-92-1630 9611-92-1632 9611-92-6347 9611-92-6038
a Service kit, FPM . . . . . . . . . . . . 9611-92-1634 9611-92-1635 9611-92-1636 9611-92-1638 9611-92-6348 9611-92-6039
Plug set-up 15
a Service kit, NBR ........... 9611-92-155 9611-92-1558 9611-92-1560 9611-92-6335 9611-92-6026
a Service kit, FPM . . . . . . . . . . . . 9611-92-1562 9611-92-1564 9611-92-1566 9611-92-6336 9611-92-6027
Plug set-up 16
a Service kit, NBR ........... 9611-92-1605 9611-92-1606 9611-92-1608 9611-92-6343 9611-92-6034
a Service kit, FPM . . . . . . . . . . . . 9611-92-1611 9611-92-1612 9611-92-1614 9611-92-6344 9611-92-6035

NOTE!
the service kit.
52
7.8 Service kits - mix with DN125, DN150, Sch. 5 5 and Sch. 5 6 (plug set-up 1-4)
55 55 55 55
48 48 48 48
75 75 75 75
79 79 79 79
TD 449-128_1 TD 449-129_1 TD 449-130_1 TD 449-131_1

An example:
53
Service kits
DN/OD 63.5
DN 65 * **
DN/OD 38 DN/OD 51 DN/OD 76.1 DN/OD 101.6 DN/OD 101.6
DN 40 DN 50 DN 80 DN 100 DN 100
Denomination seat 53.3 seat 53.3 seat 81.3 seat 115.3 seat 100.3
Plug set-up 1
a Service kit, EPDM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9611-92-6105 9611-92-6169 9611-92-6233 9611-92-6374
a Service kit, NBR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9611-92-6106 9611-92-6170 9611-92-6234 9611-92-6375
a Service kit, FPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9611-92-6107 9611-92-6171 9611-92-6235 9611-92-6376
a Service kit, HNBR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9611-92-6108 9611-92-6172 9611-92-6236 9611-92-6377
Plug set-up 2
a Service kit, NBR ............................. 9611-92-6110 9611-92-6174 9611-92-6238 9611-92-6379
a Service kit, FPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9611-92-6111 9611-92-6175 9611-92-6239 9611-92-6380
Plug set-up 3
a Service kit, NBR ............................. 9611-92-6114 9611-92-6178 9611-92-6242 9611-92-6383
a Service kit, FPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9611-92-6115 9611-92-6179 9611-92-6243 9611-92-6384
Plug set-up 4
a Service kit, EPDM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9611-92-6089 9611-92-6117 9611-92-6181 9611-92-6245 9611-92-6386
a Service kit, NBR ............................. 9611-92-6090 9611-92-6118 9611-92-6182 9611-92-6246 9611-92-6387
a Service kit, FPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9611-92-6091 9611-92-6119 9611-92-6183 9611-92-6247 9611-92-6388
a Service kit, HNBR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9611-92-6092 9611-92-6120 9611-92-6184 9611-92-6248 9611-92-6389

NOTE!
54

55
55 48 55
55
48 48
48
75
75 75 75
79 79 79
79
TD 449-132_1 TD 449-133_1 TD 449-134_1 TD 449-135_1

An example:
55
Service kits
DN/OD 63.5
DN 65 * **
DN 40 DN 50 DN 80 DN 100 DN 100
Plug set-up 5
a Service kit, NBR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9611-92-6122 9611-92-6186 9611-92-6250 9611-92-6391
a Service kit, FPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9611-92-6123 9611-92-6187 9611-92-6251 9611-92-6392
Plug set-up 6
a Service kit, NBR ............................. 9611-92-6094 9611-92-6126 9611-92-6190 9611-92-6254 9611-92-6395
a Service kit, FPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9611-92-6095 9611-92-6127 9611-92-6191 9611-92-6255 9611-92-6396
Plug set-up 7
a Service kit, NBR ............................. 9611-92-6130 9611-92-6194 9611-92-6258 9611-92-6399
a Service kit, FPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9611-92-6131 9611-92-6195 9611-92-6259 9611-92-6400
Plug set-up 8
a Service kit, NBR ............................. 9611-92-6122 9611-92-6186 9611-92-6250 9611-92-6391
a Service kit, FPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9611-92-6123 9611-92-6187 9611-92-6251 9611-92-6392

NOTE!
56
55
55
55 55
48
48
48 48
75 75
75 75
79 79 79 79
TD 449-136_1 TD 449-137_1 TD 449-138_1 TD 449-139_1

An example:
57
Service kits
DN/OD 63.5
DN 65 * **
DN 40 DN 50 DN 80 DN 100 DN 100
Plug set-up 9
a Service kit, NBR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9611-92-6138 9611-92-6202 9611-92-6266 9611-92-6403
a Service kit, FPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9611-92-6139 9611-92-6203 9611-92-6267 9611-92-6404
Plug set-up 10
a Service kit, NBR ............................. 9611-92-6142 9611-92-6206 9611-92-6270 9611-92-6407
a Service kit, FPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9611-92-6143 9611-92-6207 9611-92-6271 9611-92-6408
Plug set-up 11
a Service kit, NBR ............................. 9611-92-6142 9611-92-6206 9611-92-6270 9611-92-6407
a Service kit, FPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9611-92-6143 9611-92-6207 9611-92-6271 9611-92-6408
Plug set-up 12
a Service kit, NBR ............................. 9611-92-6098 9611-92-6150 9611-92-6214 9611-92-6278 9611-92-6411
a Service kit, FPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9611-92-6099 9611-92-6151 9611-92-6215 9611-92-6279 9611-92-6412

NOTE!
58
55 55
55
55
48 48 48
48
75 75 75
75
79 79 79 79
TD 449-140_1 TD 449-141_1 TD 449-142_1 TD 449-143_1

An example:
59
Service kits
DN/OD 63.5
DN 65 * **
DN 40 DN 50 DN 80 DN 100 DN 100
Plug set-up 13
a Service kit, NBR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9611-92-6110 9611-92-6174 9611-92-6238 9611-92-6379
a Service kit, FPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9611-92-6111 9611-92-6175 9611-92-6239 9611-92-6380
Plug set-up 14
a Service kit, NBR ............................. 9611-92-6090 9611-92-6118 9611-92-6182 9611-92-6246 9611-92-6387
a Service kit, FPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9611-92-6091 9611-92-6119 9611-92-6183 9611-92-6247 9611-92-6388
Plug set-up 15
a Service kit, NBR ............................. 9611-92-6106 9611-92-6170 9611-92-6234 9611-92-6375
a Service kit, FPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9611-92-6107 9611-92-6171 9611-92-6235 9611-92-6376
Plug set-up 16
a Service kit, NBR ............................. 9611-92-6114 9611-92-6178 9611-92-6242 9611-92-6383
a Service kit, FPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9611-92-6115 9611-92-6179 9611-92-6243 9611-92-6384

NOTE!
60
7.12 Axial installation tool
TD 449-038_1
61
Parts list
1 1 Lower Part
2 1 Piston
3 1 Upper Part
4 1 O-ring, NBR
5 1 Clamp
6 1 Wingnut
7 1 Air fitting
62
7.13 Radial installation tool
10
9
11
TD 449-354
63
Parts list
1 1 Piston
2 1 Lower Part
3 1 Upper Part
4 1 Bushing
5 1 Guide
6 2 Guide ring
7 1 O-ring, NBR
8 1 O-ring, NBR
9 1 Clamp
10 1 Wingnut
11 1 Air fitting
64
65
How to contact Alfa Laval
Contact details for all countries are
continually updated on our website.
Please visit www.alfalaval.com to access the information directly.
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. Alfa Laval Corporate AB
will enforce its rights related to this document to the fullest extent of the law, including the seeking of criminal prosecution.

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Instruction Manual

Unique Sanitary Mixproof Valve (including US version)

1. Declaration of Conformity ........................................................................... 4

6. Technical data ......................................................................................... 34

7. Parts list and service kits ............................................................................ 36

Revision of Declaration of Conformity 2009-12-29

The Designated Company

Alfa Laval Kolding A/S

Albuen 31, DK-6000 Kolding, Denmark

hereby declare that

From serial number 1181354 - 9999999

is in conformity with the following directive with amendments:

- Machinery Directive 2006/42/EC

2.1 Important information

Always read the manual before using the Valve!

2.2 Warning signs

General warning: Caustic agents: Cutting danger:

2.3 Safety precautions

Always ensure that compressed air are released

3.1 Unpacking/intermediate storage

3.2 General information

Always read the technical data thoroughly.

Always release compressed air after use.

Pay special attention to:

Remember seal rings!

Step 5 CIP in CIP in

Step 6 CIP in CIP out

Align nozzle edges with recess in sealing element.

Table 1. (All measures in mm) (1 mm = 0.0394)

DN/OD DN/OD DN/OD DN/OD DN/OD DN DN DN DN DN DN DN

Table 2. (All measures in mm) (1 mm = 0.0394)

Sch. 5 Sch. 5 Sch. 5 Sch. 5 Sch. 5

1. Lower sealing element can only be dismantled if actuator B

DN/OD DN/OD DN/OD DN/OD DN/OD DN DN DN DN DN DN DN

Sch. 5 Sch. 5 Sch. 5 Sch. 5 Sch. 5

3.4 Recycling information

Always read the technical data thoroughly.

Always release compressed air after use.

4.2 Fault finding and repair

Problem Cause/result Repair

CIP leakage Worn o-rings (40/67/71) Replace the o-rings

4.3 Recommended cleaning

Step 1 Caustic danger!

Never touch the valve or the pipelines when sterilising.

Always use rubber gloves! Always use protective

Never touch the valve or the pipelines when sterilising.

Step 3 CIP in CIP in

Never throttle the leakage outlet.

Never throttle the CIP outlet, if supplied.

Leakage/CIP out CIP out

1. 1% by weight NaOH at 70o C (158F) . 2. 0.5% by weight HNO3 at 70o C (158F).

2.2 l (0.6 gal) 100 l (26.4 gal)

Cold wort 5-10

Step 7 Always rinse!

2. Cleaning through lower line

4. Cleaning through upper line

5.1 General maintenance

Always remove the CIP connections, if supplied,

Always release compressed air after use.