Neotecha Sapro Sampling Devices, Neotecha-EN Manuals & Guides

NEOTECHA SAPRO SAMPLING DEVICES

MAINTENANCE AND REPAIR INSTRUCTIONS

Before installation these instructions must be fully read and understood

1 SAPRO SAMPLING DEVICES

Thank you for purchasing Neotecha sampling
equipment. These products incorporate the
latest in design and mated technology and
require little maintenance when applied and
cared for correctly.
Before undertaking any maintenance work on

Wafer body bayonet adaptor

Wafer body bottle adaptor

Neotecha Sapro sampling devices the following
instructions should be read and understood
thoroughly. Any questions about these
instructions should be directed to Neotecha or
any authorized distributor.

2 OPERATION

Details of the installation and operating
procedures will be found in a separate
publication: Maintenance and Installation
Instructions VCIOM-01977 and VCIOM-01978.

Flanged body bayonet adaptor

Flanged body bottle adaptor

3 SAFETY

Prior to any disassembly, ensure that the unit
has been thoroughly cleaned. In every case,
protective equipment such as gloves, eye
protection etc., should be used when operating,
cleaning or maintaining the system. Attention
must be given to any national or company
regulations regarding dangerous media.
Environmental protection regulations may vary
according to the country or industry involved
and must be strictly observed.

Sapro piston syringe

Emerson.com/FinalControl © 2017 Emerson. All Rights Reserved. VCIOM-01984-EN 21/04

NEOTECHA SAPRO SAMPLING DEVICES

MAINTENANCE AND REPAIR INSTRUCTIONS

4 ROUTINE INSPECTION

Sapro sampling valves and syringes are
precision engineered devices and need to
be kept clean and well maintained to ensure
perfect operation. The Sapro units should be
inspected periodically to ensure that seals are
not leaking, as follows:

a. Valve seat

Excessive moisture on the head of the safety
plug may indicate a leaking valve seat.
(Refertoreplacement instruction further on).

b. Spindle seal

Remove the yellow screwed plastic plug at
theleak detection port on the Sapro valve body.
Excessive moisture at this point may indicate
a leaking spindle seal. (Refer to replacement
instructions further on).

c. Syringe nozzle seal

When a sample has been drawn into the
syringe, examine the nozzle seal area and
the O-ring and piston seals on the cylinder.
Any leakage indicates the need to replace
the relevant seals. (Refer to replacement
instruction further on).

5 CLEANING THE SYRINGE

After each use of the Sapro syringe, the unit
should be cleaned by thoroughly rinsing with an
appropriate cleaning fluid as follows:

1. Press the operating lever (8) against
thecylinder cage (9) and lock into position
by moving with the locking lever (6) from
position B and to position C.

2. Immerse the tip of the nozzle into a jar
containing the cleaning fluid.

3. Pull and push the piston rod repeatedly until
the syringe cylinder is clean.

9

8

C

B

Cleaning the syringe

6

2

NEOTECHA SAPRO SAMPLING DEVICES

MAINTENANCE AND REPAIR INSTRUCTIONS

Figure 1

a

b

11

10

9

5

6

2/3

7

4a 4

Figure 2

6 SAPRO SYRINGE: MAINTENANCE

6.1 Syringe disassembly

Disassembly of the syringe unit for cleaning,
sterilization or replacement of components,
isundertaken as follows (see Fig. 1).

1. Unscrew the cage end cap (13) and remove
the cylinder assembly (10, 11, 12, 13 and 14)
from the syringe cage (9).

2. Unscrew the grip (14) and remove the cage
end cap (13).

3. Push the piston assembly (11) out of the
cylinder (12) in the direction of arrow (a), thus
pushing off the cylinder base (10) from the
cylinder. The direction of removal is important
to prevent damage to the piston seals.

4. Clean all disassembled parts and replace
asnecessary.

13

14

12

Figure 3

6.4 Seal replacement

1. Place the nozzle (5) in tool No. 4, asshown
(see Fig. 4).

2. Apply a little silicone oil to the replacement
nozzle seal assembly (2 and 3) and insert it
into the nozzle cavity.

3. Insert tool No. 3 into the nozzle and place
tool No. 2 over tool No. 3, as shown.

4. Tap tool No. 2 with a mallet until the nozzle
seal assembly is correctly located within
thenozzle.

5. Replace the spacer (4) and washer (4a) over
the syringe spindle as shown in Fig. 2.

6. Replace the nozzle assembly over the
syringe spindle and screw into position.

7. Secure the nozzle by tightening set
screws(6).

Nozzle tool
No. 1

Figure 4

Nozzle tool
No. 2

Nozzle tool
No. 3

Nozzle tool
No. 4

CAUTION

Reassemble the syringe by reversing the above
procedure, ensuring that the piston is inserted
into the cylinder in the direction of arrow (b).

6.2 Replacement of syringe nozzle seal

If the nozzle seal is leaking, it should be
replaced by implementing the following
procedure.

6.3 Seal removal (see Fig. 2)

1. With the syringe cap removed, loosen
thetwo set screws (6).

2. Unscrew the nozzle (5) from the syringe
head (7).

3. Ensure that the spacer (4) and washer (4a)
are removed from the nozzle.

4. Place the nozzle on a firm surface. Place
tool No. 1 on top of the nozzle and tap with
a mallet until the nozzle seal assembly
(2 and 3) falls out of the nozzle (see Fig. 3).

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NEOTECHA SAPRO SAMPLING DEVICES

MAINTENANCE AND REPAIR INSTRUCTIONS

7 VALVE SEAT REPLACEMENT

A. Bottle adaptor models

1 Wafer body design (see Fig. 5 and Fig. 6)

You will need: repair kit - SV-Set 1 and tool

kit - SV-W2.

1.1 Take the Sapro valve from the pipe line.

1.2 Loosen the socket head screw (1d) and

remove the safety claw (1c).

1.3 Unscrew and remove bottle adaptor (5a).

1.4 Loosen the set screw (1a).

1.5 Using the 2-pin wrench (provided in tool

kit SV-W2), unscrew the retaining ring (5),
toreveal the valve seat assembly O-ring
(3a), soft seal (3) and valve seat (4).

1.6 Clean the bottle adaptor, valve seat and

retaining ring.

1.7 Replace the O-ring (3a) and seat seal (3)

with new parts from the repair kit SV-Set 1.

2 Flanged body design (see Fig. 7 and Fig. 8)

You will need: repair kit - SV-Set 1 and tool

kit - SV-W2.

2.1 Take the Sapro valve from the pipeline.

2.2 Loosen the three set screws (5a) and

withdraw the bottle adaptor assembly.

2.3 Remove the four socket head screws (1a)

and withdraw the retaining flange (5) to
reveal the valve seat assembly O-ring (3a),
soft seal (3) and valve seat holder (4).

2.4 Clean the bottle adaptor, retaining flange

and valve seat.

2.5 Replace the O-rings (3a, 5d) and seat

seal (3) with new parts from the seal kit
SV-Set1.

2.6 Reassemble by reversing the above

procedure.

Figure 6

2-pin wrench

Figure 5

Figure 8

Figure 7

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NEOTECHA SAPRO SAMPLING DEVICES

MAINTENANCE AND REPAIR INSTRUCTIONS

B. Bayonet adaptor models

3 Wafer body design (See Fig. 9 and Fig. 10)

You will need: repair kit - SV-Set 1 and tool

kit - SV-W1.

3.1 Take the Sapro from the pipeline.

3.2 Loosen the set screws (1a) and unscrew

the bayonet adaptor assembly (5) to reveal
the valve seat assembly O-ring (3a), seat
seal (3) and valve seat (4).

3.3 Clean the bayonet adaptor assembly, valve

body recess and valve seat.

3.4 Replace the O-ring (3a) and seat seal (3)

with new parts from the seal kit SV-Set 1.

3.5 Reassemble by reversing the above

procedure.

4 Flanged body design (see Fig. 11 and Fig. 12)

You will need: repair kit - SV-Set 1 and tool

kit - SV-W1.

4.1 Take the Sapro from the pipeline.

4.2 Remove the four socket head screws

(1a) and withdraw the bayonet adaptor
assembly (5) to reveal the valve seat
assembly O-ring (3a), seat seal (3) and
valveseat (4).

4.3 Clean the bayonet adaptor assembly,

valvebody recess and valve seat.

4.4 Replace the O-ring (3a) and seat seal (3)

with new parts from the seal kit SV-Set 1.

4.5 Reassemble by reversing the above

procedure.

Figure 9 Figure 10

Figure 11

Figure 12

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NEOTECHA SAPRO SAMPLING DEVICES

MAINTENANCE AND REPAIR INSTRUCTIONS

8 SPINDLE SEAL REPLACEMENT

A. Bonnet disassembly

If excessive moisture is found on examination of
the leak detection port (see earlier) this may be
due to wear of the spindle seal. Replacement
of spindle seals should be undertaken by
implementing the following procedure.

1. Identify the model number of the Sapro
valve under consideration. The model
number of a Sapro valve is given on a metal
tag attached to the exterior of the valve
bonnet.

2. Referring to Tables 1 and 3, identify
theappropriate repair kit and tool kit
required for the subject Sapro valve.

3. Remove the Sapro valve from the pipeline.

NOTES

For bottle adaptor units with handlever only
(seeFig.13)
a. Unscrew the handlever (10a).
b. Slide off the protective (10b).
c. Remove adjustment screw (9a) and lock nut (9b).

11c

Figure 13 Figure 14

9a

9b

10b

Lever shown in
closed position

9

8
8a

Lever shown in

open position

10a

9a

11c

9

8

8a

CAUTION

The bonnet (9) is under spring tension. Follow
these instructions carefully.

4. Remove two opposing socket head screws
(8) replacing them with the two threaded
rods from the spring tension device from
tool kit SV-W3.

5. Place the two-hole plates over the threaded
rods followed by the washers and secure
with wing nuts as shown in Fig. 13.1/14.1.

6. Remove the remaining two socket head
screws.

7. Gradually loosen the wing nuts until the
spring tension in the bonnet is completely
relieved and then remove the threaded rods.

8. Remove bonnet (9) and gasket (8a) from
thevalve body.

9. On bayonet adaptor models only: remove
and replace the X-ring seal (9a) (see Fig.14).

10. Remove the spring (11c) from the spindle.

11. Clamp the end of the spindle assembly in a
soft jawed vice and pull the body away from
the spindle assembly.

12. Separate all parts of the spindle assembly
as shown in Fig. 15 and identify replacement
components from the appropriate repair kit.

Spring tension device

assembly

Figure 13.1 Figure 14.1

6

a

NEOTECHA SAPRO SAMPLING DEVICES

MAINTENANCE AND REPAIR INSTRUCTIONS

B. Seal assembly

NOTE

It is recommended that all soft seal components be
replaced at the same time.

• Referring to Tables 1 and 3, identify the repair kit,

spindle seal type and tool kit required for the subject
Sapro valve.

• Secure Sapro valve body upright in a vice. Take care

not to damage PFA sealing faces.

• Apply a little silicone oil to all the commencing

assembly.

• Refer to the assembly instructions below for

therelevant spindle seal type A or B (see Table 1).

1 Spindle seal assembly types A and B

1.1 Introduce valve spindle (2) into the Sapro

body until it rests on the valve seat.

1.2 Position the spindle seal (6) over the

spindle and push down using the spindle
seal drive tool included in tool kit SV-W3.
Gently tap the drive tool with a mallet until
the spindle seal locates at the bottom
ofthe cavity.

1.3 Position the other spindle assembly

components, in order, on the spindle,
asindicated in Fig. 15 A and B, replacing
theparts contained in the appropriate
repair kit.

1.4 Proceed with bonnet assembly as

described in the next section.

Figure 15
Sapro valve spindle seal types

10

11

11a

7a + b

11c

11b

7

7c

7d

6

6a

10b

10a

11

10

7
7
7c

7d

6
6a

2

2

Type A Type B

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NEOTECHA SAPRO SAMPLING DEVICES

MAINTENANCE AND REPAIR INSTRUCTIONS

C. Bonnet re-assembly

1 Bayonet adaptor units only (spindle seal

typeB) (see Fig. 16)

1.1 Position gasket (8a) on valve body.

1.2 Screw spring support (10) onto the spindle
until finger tight, then back off by a quarter
turn.

1.3 Position the coil spring (11) over the spring
support.

1.4 Position the bonnet onto the valve body
over the coil spring and screw the two
threaded rods, from the spring tension
device in tool kit SV-W3, into opposing
holes in the valve body.

1.5 Place the two-hole plate over the threaded
rods, followed by the washers and tighten
the bonnet onto the valve by means of
thewing nuts.

1.6 Screw two socket head screws (8) into
the two remaining bonnet/body holes and
tighten.

1.7 Remove the spring tension device and
replace with two socket head screws (8).

Tighten all four screws to ensure full

compression of the coil spring.

1.8 Screw the position indicator (10b) lightly
onto the cap head screw (10a) through the
top of the bonnet, ensuring that it is finally
flush with the bonnet.

2.3 Screw the tie rod (10) into the spring
support until hand tight; then turn the tie
rod counter clockwise until the hole in the
tie rod is aligned with the next hole in the
spring support.

2.4 Position the locating screw (11c) in the
spring support hole which is aligned with
the non-countersunk side of the tie rod
hole (see Fig. 19).

2.5 Fix the spring support to the spindle by
means of the securing screw (11b) in the
hole opposite the locating screw.

2.6 Rotate the spindle assembly until the
securing screw is aligned with the leak
detection port in the valve body. (This port
has a yellow plastic blanking plug).

2.7 Place the coil spring (11) over the spring
support (11a).

2.8 Position the bonnet over the coil spring
ensuring that the locating screw (11c)
aligns with the key way in the bonnet.

2.9 Applying hand pressure on the bonnet
to compress the coil spring, secure the
bonnet to the valve body using the cap
head screws (8).

2.10 Slide protective sleeve (10b) over bonnet.

2.11 Locate the roller sleeve (10c) onto the
handlever and screw the handlever (10a/b)
into the tie rod (through the bonnet).

2.12 When lateral play is satisfactory, remove
the handlever and roller sleeve (10a/b/c).

2.13 Slide the protective sleeve (10b) into
position over the bonnet.

2.14 Re-fit the roller sleeve to the handlever
and the handlever to the tie rod
(throughthe bonnet).

2.15 Position the locking pin (9e) through the
bonnet. Try to operate the handlever
counter clockwise and check that the
spindle does not move off the valve seat.

2.16 Screw the set screw (9a) with hexagon nut
(9b) into the bonnet.

2 Bottle adaptor units only (spindle seal type A)

(see Fig. 17 and Fig. 18)

2.1 Position the gasket (8a) on the valve body.

2.2 Screw the spring support (11a) onto
thespindle until contact is made with
thelantern ring (7a).

Figure 16

NOTE

Ensure that the handlever has a lateral play of
minimum 7 mm and maximum 20 mm (refertoFig.17).
If lateral play requires adjustment:
a. Remove handlever and bonnet, as previously

described.

b. Loosen the securing screw (11b) to free the spring

support from the spindle.

c. Rotate the spring support a quarter turn counter

clockwise and re-tighten securing screw.

d. Rotate spindle assembly until the securing screw

is again aligned with the leak detection port.

e. Repeat assembly from instruction (2.7).

9a

9b

9e

10

11a

10b

10c

10a

11

Closed

Figure 17

11c

7a

8

9

11b

8a

Figure 18

Figure 19

8

NEOTECHA SAPRO SAMPLING DEVICES

MAINTENANCE AND REPAIR INSTRUCTIONS

Stroke adjustment

The degree of opening of the sampling valve
van be adjusted to the users requirements.

1. Loosen the lock nut (9b) and back off
theset screw (9a).

2. Remove the locking pin.

3. Operate the handlever to open the valve to
the required extent.

4. With the handlever held in this position,
screw down the set screw (9a) as far as
possible and release the handlever.

5. Tighten the hexagon nut (9b) to lock
theposition of the set screw.

6. Replace the locking pin (9e).

TABLE 1 - REPAIR KITS FOR SAPRO VALVE SEATS AND SPINDLE SEALS

Kit contents

Ref. nr. Description Sapro model nr. Spindle seal type

SV-SET1 Repair kit seat seal on all Sapro sampling valves All N/A Soft seal 3

SV-SET9 Repair kit bottle adaptor seal All valves with bottle

adaptor

SV-SET10 Repair kit soft parts TFM stem lip seal SV..........S.. TFM stem seal Sealing sleeve 6

Size range DN 25 (NPS 1) to DN 100 (NPS 4) O-ring set 6a

PTFE/FKM seal ring 7a

SV-SET11 Repair kit soft parts TFM stem lip seal and Belleville set SV..........S.. TFM stem seal Sealing sleeve 6

Size range DN 25 (NPS 1) to DN 100 (NPS 4) O-ring set 6a

SV-SET12 Repair kit spindle seal SV..........A.. Welded bellow seal Guide ring 7a

Size range DN 25 (NPS 1) to DN 100 (NPS 4) O-ring 7b

Part Nr.

O-ring 3a
Set screw 1a
O-ring 5b

Gasket 8a
O-ring 7b

PTFE/FKM seal ring 7a
Gasket 8a
O-ring 7b
Belleville set 7c
Spacer 7d
Compression sleeve 7

O-ring 7c
Gasket 8a

TABLE 2 - REPAIR KITS FOR SAPRO PISTON SYRINGES

Contents

Ref. nr. Description Syringe size

SK-SET1 Maintenance of nozzle seal on Sapro piston syringe All Sealing sleeve 2

SK-SET2 Maintenance of soft seals on Sapro piston syringes 20 ml X-ring 17

SK-SET3 Maintenance of soft seals on Sapro piston syringes 50 ml and 100 ml X-ring 17

SK-SET4 Maintenance of soft seals on Sapro piston syringes 250 ml X-ring 17

SK-SET5 Replacement of piston head on Sapro piston syringes 20 ml Piston head 21a
SK-SET6 Replacement of piston head on Sapro piston syringes 50 ml and 100 ml Piston head 21a
SK-SET7 Replacement of piston head on Sapro piston syringes 250 ml Piston head 21a

Part Nr.

Pressure ring 3

O-ring 18
O-ring 24a

O-ring 18
O-ring 24a

O-ring 18
O-ring 24a

9

NEOTECHA SAPRO SAMPLING DEVICES

MAINTENANCE AND REPAIR INSTRUCTIONS

TABLE 3 - TOOL KITS FOR SAPRO VALVES AND PISTON SYRINGES

Ref. nr. Description Contents

SV-SETW1 Replacement of seat seal on all flanged Sapro valves and on wafer type Sapro’s with

bayonet adaptor

SV-SETW2 Replacement of seat seal on wafer type Sapro valves with bottle adaptor Metric hex key 3 mm

SV-SETW3 Replacement of spindle seals on all Sapro valves Metric hex key 3 mm

SK-SETW1 Replacement of nozzle seal on all Sapro piston syringes Metric hex key 3 mm

Metric hex key 3 mm
Metric hex key 5 mm

2-pin wrench

Metric hex key 4 mm
Metric hex key 5 mm
Spindle seal drive tool
Spring tension device

- 2 hole plate

- 2x threaded rods

- 2 wing nuts

- 2 washers

Metric hex key 4 mm
Nozzle tool nr. 1
Nozzle tool nr. 2
Nozzle tool nr. 3
Nozzle tool nr. 4

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business unit of Emerson Electric Co. The Emerson logo is a trademark and service mark of Emerson Electric Co. All other marks are the property of their prospective
owners.

The contents of this publication are presented for informational purposes only, and while every effort has been made to ensure their accuracy, they are not to be
construed as warranties or guarantees, express or implied, regarding the products or services described herein or their use or applicability. All sales are governed by
our terms and conditions, which are available upon request. We reserve the right to modify or improve the designs or specifications of such products at any time without
notice.

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