Steridose STERIVALVE 12, STERIVALVE 38, STERIVALVE 25, STERIVALVE 76, STERIVALVE 51 User's Installation And Operation Manual
STERIVALVE®
Installation and operation manual
(Including welding guideline)
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---Table of Contents---
1. Introduction
1.1 Safety information
1.2 Scope and Purpose
1.3 Main Components
1.3.1 Valve housing
1.3.2 Actuators
1.3.3 Diaphragms
2. Assembly
2.1 General
2.1.1 Valve housing to actuator connection
2.1.2 Diaphragm connection
2.2 Assembly Procedure
2.2.1 Pneumatically operated valves
2.2.2 Manually operated valves
2.2.3 Additional procedures for installation of PTFE diaphragms
2.2.4 Position Indicators
2.2.4.1 Stainless Steel Pneumatic Actuators
2.2.4.2 Plastic Pneumatic Actuators
3. Operation
3.1 Pneumatically operated valves
3.2 Manually operated valves
3.3 Position Indicators
3.4 Cleaning
3.4.1 Internal cleaning
3.4.2 External cleaning
4. Maintenance/Service
4.1 Special tools required
4.2 Preventive Maintenance Schedule
4.3 Actuators
4.3.1 Manual Actuator
4.3.2 Pneumatic Actuator
4.4 Diaphragms
4.4.1 Interval of diaphragm inspection
4.4.2 Inspection procedure
5. Troubleshooting
6. Technical specifications
7. Spare parts list
8. Traceability and Conformity information
9. Contact information
APPENDIX A: Welding guide
APPENDIX B: Indicator systems
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1. INTRODUCTION
1.1 Safety information
DANGER! The equipment may be operated and maintained only when this maintenance manual
is thoroughly understood. Negligence to do so can result in personal injury and/or material
damage.
If the Sterivalve® is part of a piping system, please note:
DANGER! The system may be subject to overpressure, steam, hot water, vapors and
chemicals. Incorrect handling of the system may result in electrical shock and burn
injuries.
DANGER! When opening a valve to atmosphere or to a non-pressure vessel, always make sure
the pressure is 0 bar(g) (atmospheric pressure).
DANGER! Operation, maintenance and adjustment of the equipment may be performed by
authorized personnel only.
CAUTION! The valve inner surface is manufactured to a high polish and WILL get damaged if
tools are used improperly or without care.
1.2 Scope and Purpose
This document provides information regarding installation, normal operation, maintenance, and
troubleshooting of the valve, including safety aspects.
1.3 Main Components
The Sterivalve ® is a diaphragm valve especially designed for use in aseptic processes.
The valve consists of four major components:
Housing
Actuator – manual or pneumatic*
Diaphragm
Clamp (Sterivalve
®
51 (2”) and 76 (3”) do not feature a clamp. Instead, the housing and
actuator are bolted together).
*The pneumatic actuator can be fitted with electrical position switches indicating open/closed
position.
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Figure 1: Main Components
Sterivalve 12 (1/2”) to 38 (1.5”) Sterivalve 51(2”) and 76 (3”)
1.3.1 Valve housing
The valve housing is made as standard of stainless steel AISI 316L. Each valve housing is
marked with a respective lot number that links it with a specific material mill certificate.
Several housing configurations are available:
Process valves:
Standard process valves are available as shut-off, flow through, take-off, and divert. Refer to
figure 2. Other custom configurations are available upon request.
Bottom outlet valves:
Standard bottom outlet valves are available as single or double outlet, and double outlet with
steam integrated valve. Refer to figure 2. Outlet (s) can be provided as a straight weld-nose, or
elbow (90° or 45°) with or without TC connection. Other custom configurations are available
upon request.
Sampling valves:
Standard sampling valves are available as single or double outlet, for welding direct into a vessel
wall, or for mounting on a hygienic pad connection, such as Steriflange®. Refer to figure 3.
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Figure 2: Standard Valve Housing Configurations
Figure 3: Standard Sample Valve Housing Configurations
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1.3.2 Actuators
The valve is provided with the following actuator types:
Plastic Pneumatic Actuator 12 (1/2”) to 76 (3”)
The plastic pneumatic actuator is made of PPE (polyphenylene ether) polymer.
The actuators are sealed for life and are not serviceable.
The actuator is provided as spring to close/air to open (normally closed).
Figure 4: Plastic Pneumatic Actuators
Stainless Steel Pneumatic Actuator 12 (1/2”), 25 (1”), and 38 (1 ½”)
The pneumatically operated actuator for Sterivalve® has a stainless steel cover but it is not
autoclavable. The actuator is mounted on the housing with a clamp.
The stainless steel pneumatic actuator is available in two versions:
S-A, where the designation S-A indicates: Spring closed, Air open
A-A, where the designation A-A indicates: Air closed, Air open
Figure 5: Stainless Steel Pneumatic Actuator 12 (1/2"), 25 (1"), & 38 (1-1/2")
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Stainless Steel Pneumatic Actuator 51 (2”) & 76 (3”)
The stainless steel pneumatic actuator for valves 51 (2”) and 76 (3”) is sealed and not serviceable.
The actuator is bolted to the housing.
The pneumatic actuator is provided already pre-assembled with the adapter and adapter plate (see
figure 6).
The pneumatic actuator is spring/air. The cylinder is reversible and can be set-up as either spring
to close/air to open (normally closed), or spring to open/air to close (normally open).
Figure 6: Stainless Steel Pneumatic Actuator 51 (2") & 76 (3")
Manual Actuator 12 (1/2”) to 76 (3”)
The manually operated actuator is manufactured in stainless steel and is autoclavable. The
actuator is mounted in the same manner as with the pneumatic actuators.
An extended handle manual actuator is also available for bottom outlet valves. This option
makes the handle more accessible to the operator. See figure 8.
Figure 7: Manual Actuator 12 (1/2") to 76 (3") Figure 8: Extended Manual Handle
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1.3.3 Diaphragms
The valve has three different diaphragm material options. Consult Steridose for availability of
each material for any particular valve size.
Diaphragm material selection is a function of chemical compatibility with the process fluid (s),
including CIP solutions/steam, operational temperature and number of cycles.
The following materials are offered:
-Platinum cured Silicone, USP <88> Class VI.
-EPDM, USP <88> Class VI.
-Modified PTFE (TFM), USP <88> Class VI.
All diaphragms can be traced by their lot number. The lot number is marked in the packaging.
Additionally, silicone and EPDM diaphragms have markings on the back providing the
manufacturing date. See section 10 for more details.
Figure 9: Diaphragm Materials
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2. Assembly
2.1 General
When installing the valve sufficient clearance to remove/assemble the actuator must be
considered. The amount of space required depends on valve size and actuator configuration.
In order to ensure self draining, the valve must be installed in the correct position. See figures 10
and 11:
Figure 10: Self draining positions for process valves
The housing is self draining in these positions,
but NOT in this position.
Figure 11: Self draining position for bottom outlet valves
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2.1.1 Valve housing to actuator connection
The valve housing and actuator are connected with either a hygienic clamp union or bolts, as
indicated below:
Size 12 (1/2”): TC CLAMP 1"/ 1.5"
Size 25 (1”): TC CLAMP 2.5"
Size 38 (1 ½”): TC CLAMP 2.5"
Size 51 (2”): M8x16mm. ( 4pcs.)
Size 76 (3”): M8x16mm. ( 4pcs.)
2.1.2 Diaphragm connection
The diaphragm connection to the actuator stem is made by means of a pressure plate or threaded
connection depending on valve size and diaphragm material.
For valves 12 (1/2”), 25 (1”), and 38 (1 1/2”), with EPDM and Silicone diaphragms, the
diaphragm is attached by means of a pressure plate installed in the stem, type 1 or 2. As a
standard, the actuators are supplied with a type 1 pressure plate. When using type 1, the
diaphragm is pressed into the plate. The type 2 pressure plate is provided as an option and
recommended when it is expected that the valve would remain in the closed position for prolong
periods of time and would also be subject to steaming. The diaphragm screws into the type 2
pressure plate.
The pressure plates are interchangeable. Refer to Figure 13 for details on how to replace a type 1
for a type 2.
Figure 12: Diaphragm Connection Types
No Pressure Plate Pressure Plate Type 1 Pressure Plate Type 2
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Figure 13: Replacement of pressure plate type 1 for type 2
For valves 12 (1/2”) to 76 (3”), with PTFE diaphragm, no pressure plate is required in the valve
stem. The PTFE diaphragm is provided with a threaded stud that will screw direct to the valve
stem.
In the event of replacing a silicone or EPDM diaphragm for a PTFE diaphragm on an existing
installation, the pressure plate type 1 or 2 must be removed from the stem. The pressure plates
are glued to the stem. Caution should be taken that all residual glue is carefully removed from
the threads in the stem, so that the PTFE diaphragm can screw all the way into the stem. Failure
to do so may result in diaphragm damage. A tap can be run on the stem threads to ensure
removal of all residual glue.
NOTE: When replacing silicone or EPDM diaphragms for PTFE diaphragms on valves that
have been in operation for some years, ensure that the valve is tested for leaking prior to put
back into service. Small scratches, misaligments, etc that may be present in the valve housing
may not affect the sealing capability of silicone or EPDM, but may affect PTFE.
For valves 51 (2”) and 76 (3”), the diaphragm is provided with a threaded insert that screws
directly into the valve stem.
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2.2 Assembly Procedure
2.2.1 Pneumatically operated valves
In order to install the pneumatic actuator to the valve, follow these steps:
1-Attach diaphragm to actuator stem, or screw the valve diaphragm to the actuator stem. Refer
to section 2.1.
2-Actuate the actuator to the open position. If the actuator is set-up as normally closed, actuate
the actuator to the open position. If the actuator is set-up as normally open, continue to step 3.
3-Insert actuator with diaphragm into valve housing.
4-Secure clamp around actuator and valve body. For 51 (2”) and 76 (3”) secure the 4 bolts that
attach the actuator to the valve body. Tighten the bolts.
5-Actuate the actuator to the closed position.
6- For valves with PTFE diaphragms make sure support gasket/o-rings are installed with the
diaphragm. See figure 14. See additional installation procedures for PTFE diaphragms in section
2.2.3.
Figure 14: PTFE diaphragm o-rings (left) and support gasket (right)
2.2.2 Manually operated valves
In order to install the manual actuator to the valve, follow these steps:
1- Turn the actuator hand wheel clockwise (closed).
2- Attach diaphragm to actuator stem or, screw the valve diaphragm to the actuator stem. Refer
to section 2.1.2.
3- Turn the actuator hand wheel counterclockwise (open).
4- Insert actuator with diaphragm into valve body.
O-ring
Support
gasket
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5- Secure clamp around actuator and valve body. For 51 (2”) and 76 (3”) secure the 4 bolts that
attach the actuator to the valve body. Tighten the bolts by using a wrench.
6-Actuate the manual actuator to the closed position by turning the wheel in the opposite
direction.
7- For valves with PTFE diaphragms make sure support gasket/o-rings are installed with the
diaphragm. See figure 14. See additional installation procedures for PTFE diaphragms in section
2.2.3.
2.2.3 Additional Procedure for Installation of PTFE Diaphragms
In order to ensure proper sealing of PTFE diaphragms, it is recommended to heat-treat them
before use. Follow these steps for the heat-treatment procedure:
1- Expose the installed diaphragm to steam at around 121° C for approximately 30 minutes. The
valve should be in the closed position, or closed directly after exposure. Alternatively, the
installed diaphragm can be exposed to hot air at around 100° C for approximately one hour.
2- Re-tighten the clamp (1/2”-1.5” sizes) or bolts (2” and 3” sizes), after the valve has cooled
down to ambient temperature.
3- Repeat this process each time the valve insert (actuator and diaphragm) is disassembled and
reassembled.
2.2.4 Position Indicators
An assortment of models and styles of instrumentation are available to sense the actuator
position. Listed below are some of the most common. Please consult Steridose to determine
the best solution to your particular application.
2.2.4.1 Stainless Steel Pneumatic Actuators
For valves 12 (1/2”), 25 (1”), and 38 (1-1/2”)
To accommodate a wide variety of position indicator solutions various adapters may need to be
used on particular assemblies. Please consult with Steridose representatives to determine overall
dimensions and specifications.
The sensors available are:
Open, micro-switch
Open/Close, micro-switch
Open, inductive proximity switch
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In order to assemble open micro-switches follow these steps:
1. Add/remove any required adapters or sensors from top of actuator.
2. Screw the electrical position indicator in and adjust so that when the actuator is open the
sensor switch is activated.
3. Wire the sensor per manufacturer recommendations.
In order to assemble open/close micro-switches follow these steps:
1. Set the actuator open.
2. Screw in/remove adapters as necessary.
3. Screw in instrumentation bushing.
4. Set stroke limiter.
5. Fix nut against actuator top.
6. Unscrew screw on actuator top lid and remove.
7. Loosen set screw on body.
8. Slip on instrumentation body into correct position.
9. Lock into place with set screw.
10. Reassemble to lid with screw.
In order to assemble open, inductive proximity switches follow these steps:
1. Set the actuator open.
2. Screw the indicator into the tapped hole on top of the actuator, until it stops.
3. Loosen the indicator one turn and fix the indicator against the actuator by screwing the locknut down against the top of the actuator.
4. Compare the measurement A against the chart. Check that measurement A and B are achieved
during operation. The switch can be adjusted by turning it.
5. Secure the switch with the lock-nut.
Chart Sterivalve® 12 (1/2”), 25 (1”), and 38 (1 ½”)
Size / Measures A B
Sterivalve® 12 41 69
Sterivlave® 25 28 56
Sterivlave® 38 29 57
Figure 15: Installation of position indicators for valves 12 (1/2"), 25 (1"), and 38 (1.5")
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For valves 51 (2”) and 76 (3”)
The stainless steel pneumatic actuator for 51(2”) and 76 (3”) valves can be provided with
inductive switches for sensing open and closed position. The same actuator is used with or
without switches. A plastic sensor holder is added to the actuator and the sensors are screwed to
each mounting bracket as shown on figure 16.
The sensors available are:
Open, inductive proximity switch
Open/close, inductive proximity switch
In order to adjust the sensor position, follow these steps:
1. Place the actuator in either the open or closed position.
2. Loosen the vertical adjustment screw on the corresponding mounting bracket and adjust
the position until the switch LED signal light is activated. By carefully moving the
mounting bracket up and down vertically, position the switch in the middle of the sensor
range and then tighten down.
3. Move the actuator to the other position and repeat step 2 for the remaining switch.
Figure 16: Installation of position switches for valves 51 (2") and 76 (3")
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2.2.4.2 Plastic Pneumatic Actuators
For valves 12 (1/2”), 25 (1”), 38 (1-1/2”), 51 (2”), and 76 (3”)
The sensors available are:
Open, micro-switch
Open/Close, micro-switch
Open, inductive proximity switch
Open/close, inductive proximity switch
In order to assemble switches follow these steps:
1. Loosen set screw on instrumentation body.
2. Remove duplication system from instrumentation body.
3. Check that seals are properly seated and undamaged.
4. Unscrew and remove transparent plastic cap on top of actuator.
5. Apply air to position actuator rod to the top position.
6. Unscrew and remove yellow visual indicator.
7. Screw duplication system into actuator rod.
8. Tighten adapter until contact is made with top of the actuator.
9. Fully tighten duplication system rod on actuator rod with screwdriver.
10. Depressurize actuator to return to default position.
11. Insert instrumentation body onto duplication system, making sure not to damage contact
levers on switches.
12. Tighten set screw on instrumentation body
13. Wire according to manufacturer instructions.
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3. OPERATION
3.1 Pneumatically operated Valve
The pneumatically operated actuator type S-A is opened when pressurized and closed otherwise.
The pneumatically operated actuator type A-A is opened when the lower connection is
pressurized and closed when the upper connection is pressurized.
DANGER! Always make sure that the surrounding system is de-pressurized before opening a
valve to atmosphere or non-pressure vessels. Negligence can result in personal injuries or
material damages.
3.2 Manually operated Valve
The handle is turned counterclockwise to open the valve and clockwise to close. The valve is not
suitable as a regulating valve, and should therefore not be set half-way open. Degree of opening
is visually displayed on the side of the handle.
When closing the valve be sure not to over tighten the handle.
The manually actuator with extension handled is opened by turning the handle counter-clockwise
and closed by turning it clockwise.
DANGER! Always make sure that surrounding system is de-pressurized before opening a valve
to atmosphere or non-pressure vessels. Negligence can result in personal injuries or material
damages.
WARNING! The handle will become hot if the valve is cleaned with hot liquid or sterilized with
steam or water. Use glove if the valve must be opened when the valve is hot.
3.3 Position indicators
When installed, the position indicators will indicate if the valve is closed or open by means of
sending an electric signal to a control panel. In some models, a red LED light will also provide a
visual indication that the valve is in the open position.
3.4 Cleaning
3.4.1 Internal cleaning
The valve is designed for Cleaning In Place (CIP) but can also be cleaned manually by
disassembling the parts and manually cleaning housing and diaphragm.
3.4.2 External cleaning
External cleaning is made according the customers standard procedures, designed for the selected
materials of the equipment.
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4. MAINTENANCE / SERVICE
4.1 Special tools required
No special tools are required for operation and ordinary maintenance of the valve.
For maintenance of the pneumatic actuator 12 (1/2”), 25 (1”) and 38 (1 ½”) a special tool and
instruction are needed. It is recommended that the pneumatic actuators 12 (1/2”), 25 (1”) and 38
(1 ½”) are returned to Steridose for repair. Pneumatic actuators 51 (2”) and 76 (3”) are sealed
and not serviceable. All plastic Pneumatic actuators and manual stainless steel actuators are also
sealed and not serviceable.
4.2 Preventive Maintenance Schedule
Table 1 shows the recommended intervals for inspection of the valve components:
Table 1: Intervals of inspection
Preventive maintenance
Section in
manual for
reference
Interval
Leakage inspection
4.2
Daily
Sterivalve diaphragm inspection
4.4
see 4.4.1
Sterivalve pneumatic actuator inspection
4.3.2
12 months
Sterivalve housing inspection
4.2
12 months
Pneumatic tubing
4.3.2
12 months
Electrical cables
4.3.2
12 months
Clamps frequently opened should be greased at the thread with “Molykote 111” regularly.
Negligence may result in damage to threads.
The wetted surfaces of the valve housing should be checked for signs of corrosion and
discoloration.
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4.3 Actuators
4.3.1 Manual Actuator
The manual actuator does not need any maintenance or service. Visual inspection every 12
months is recommended.
4.3.2 Pneumatic Actuator
General
The pneumatic actuator requires inspection every 12 months. The following components shall
be inspected:
1- Inspect pneumatic tubing and replace if damaged. Assure that the pneumatic hose is not in
contact with hot piping etc.
2- Inspect electrical cables and replace if damaged. Assure that the electric cable is not in contact
with hot piping etc.
3- Inspect overall function of the actuator. Any noises that may indicate air leakage would result
in loss of pressure and could result in an inoperative actuator.
Additional service procedures for stainless steel actuators 12 (1/2”), 25 (1”) and 38 (1.5”)
The stainless steel pneumatic actuators 12 through 38 are serviceable and a repair kit is available
for each size. Refer to tables 2-4. The repair kits include all O-rings and gaskets in the actuator
assembly. Special tools are required. See section 4.1.
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STERIVALVE
12
Table 2: Sterivalve 12 (1/2") S-A
STERIVALVE 12 (1/2”) S-A
Part # 104156
Pos:
Qty:
Description:
Material:
Dimension:
Note:
1 1 O-ring
Viton
16.1x1.6
2 1 X-ring
Viton
9.25x1.78
3 1 Compact seal
Nitril
32
4 1 O-ring
Viton
34.65x1.78
5 1
O-ring
Viton
3.1x1.6
6 1 Pressure plate
316 L
STERIVALVE
25
Table 3: Sterivalve 25 (1") S-A
STERIVALVE
38
Table 4: Sterivalve 38 (1-1/2") S-A
STERIVALVE 38 (1 ½”) S-A
Part # 104158
Pos:
Qty:
Description:
Material:
Dimension:
Note:
1 1 O-ring
Viton
17.17x1.78
2 1
X-ring
Viton
9.25x1.78
3 1
Compact seal
Nitril
80
4 1 O-ring
Viton
74.2x5.7
5 1 O-ring
Nitril
4.3x2.4
STERIVALVE 25 (1”) S-A
Part # 104157
Pos:
Qty:
Description:
Material:
Dimension:
Note:
1 1 O-ring
Viton
17.17x1.78
2 1 X-ring
Viton
9.25x1.78
3 1 X-ring
Viton
56.75x3.53
4 1
O-ring
Viton
59.2x5.7
5 1
O-ring
Viton
12x2
6 1
O-ring
Nitril
4.3x2.4
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4.4 Diaphragms
4.4.1 Interval of diaphragm inspection
The service life to the valve diaphragm depends on its working conditions. Important factors
with regard to the service life are temperature and the type of process and CIP fluid (s).
In general, inspection should be made at every 50 hours of sterilization (e.g. exposure to steam or
superheated water) or 1000 hours of operation, whichever occurs first.
The interval may however vary between different installations, depending on the diaphragm
material, chemicals and utilities used, and temperature during SIP.
NOTE:
Once the diaphragm has been replaced, please make sure that the actuator is in open position
before mounting the actuator to the valve.
4.4.2 Inspection procedure
Any leakage from the diaphragm will be indicated by fluid seeping from a telltale hole at the
bottom of the actuator.
DANGER! The inspection must be carried out while the valve is free from harmful chemicals,
cold, and not pressurized. Negligence may result in personal injuries.
When inspecting the diaphragm:
Shut down the system (pumps etc) and purge all pressure.
Secure that the system is clean, drained, ventilated and below 55°C.
Follow the instructions shown below:
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Sterivalve® 12 (1/2”), 25 (1”) and 38 (1 ½”) Sterivalve® 51 (2”) and 76 (3”)
1. Open the valve, manually or pneumatically.
2. Unscrew the four screws and separate the valve
housing from the actuator.
3. Set the actuator to the closed position.
4. Inspect diaphragm. The purpose of the inspection
is to detect visible signs of wear, cracks, significant
deformation or discoloration. Replace the
diaphragm immediately if any fault is detected.
Remove the old diaphragm, by turning it
counterclockwise. It is recommended to exchange
the rubber gasket. Fit the new diaphragm by turning
it clockwise.
5. Set the actuator to the open position.
6. Fit the valve housing and actuator together with
the four screws.
7. Close the valve. The valve is now ready for use.
1. Open the valve, manually or pneumatically.
2. Unscrew the clamp with the wing-nut and separate
the valve housing from the actuator.
3. Set the actuator to the closed position.
4. Inspect diaphragm. The purpose of the inspection
is to detect visible signs of wear, cracks, significant
deformation or discoloration. Replace the diaphragm
immediately if any fault is detected. Remove the
diaphragm and fit the new one in place. Some force
may be needed to push the diaphragm over the
bottom plate on the piston rod (refer to section 2.1.2)
5. Set the actuator to the open position.
6. Fit the valve housing and actuator together with the
clamp. Tighten the clamp manually. Do not use tools.
The diaphragm may be damaged if the clamp is over
tightened.
7. Close the valve. The valve is now ready for use.
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5. TROUBLESHOOTING
Trouble Description
Possible cause
Remedial action
Manual valve does not
open when actuator is
turned counterclockwise
1. Diaphragm is stuck on valve seat.
2. Diaphragm is not mounted properly
on the actuator.
3. Actuator is not functioning
correctly.
4. Incorrect flow direction in
combination with high fluid pressure.
1. Inspect diaphragm and replace if
required.
2. Correct mounting. Some force must
be used to push the diaphragm onto the
actuator stem.
3. Inspect and replace if required.
4. Correct flow direction or lower fluid
pressure.
Manual valve does not
close when actuator is
turned clockwise
1. Incorrect flow direction in
combination with high fluid pressure.
1. Correct flow direction or lower fluid
pressure.
Pneumatic valve does not
open
1. Diaphragm is stuck on valve seat.
2. Diaphragm is not mounted properly
on the actuator.
3. Actuator is not functioning
correctly.
4. Compressed air supply is too low.
5. Pneumatic hose is damaged.
6. Solenoid valve, if supplied, faulted
or in wrong position.
7. Incorrect flow direction in
combination with high fluid pressure.
1. Inspect diaphragm and replace it if
required.
2. Correct mounting. Some force must be
used to push the diaphragm onto the
actuator stem.
3. Inspect and replace if required.
4. Check compressed air supply pressure.
5. Replace pneumatic hose.
6. Check that the solenoid valve is in the
correct position and operating normally.
Replace solenoid valve if required.
7. Correct flow direction or lower fluid
pressure.
Pneumatic valve does not
close
1. Actuator is not functioning
correctly.
2. Solenoid valve electrical cable, if
supplied, is damaged.
3. Pneumatic system does not
ventilate.
4. Incorrect flow direction in
combination
with high fluid pressure.
1. Inspect and replace if required.
2. Replace electrical cable.
3. Check ventilation of pneumatic system
4. Correct flow direction or lower fluid
pressure.
Cleaning in CIP is not
satisfactorily
1. Cleaning chemicals wrong type or
too low concentration.
2. Flow too low.
3. Valve not installed in drainable
position, refer to figure 10.
4. Flow obstructed.
5. Diaphragm is damaged.
1. Use correct chemicals and
concentration.
2. Increase flow.
3. Check valve orientation and change if
required.
4. Check flow path.
5. Replace diaphragm.
Rouging or similar effects
on inner surface
1. No acid used in CIP.
2. Poor WFI or PW quality.
3. Incorrect chemicals used in CIP.
1. Perform passivation regularly.
2. Check quality of WFI and PW.
3. Use compatible chemicals to valve
housing material.
Diaphragm has short
lifespan
1. Incorrect diaphragm material for the
application.
2. Media has too high temperature.
1. Check material compatibility.
2. Lower temperature or use alternate
material.
Telltale hole is leaking
1. Diaphragm is damaged.
1. Replace diaphragm.
Valve is leaking
1. Clamp is not properly mounted.
2. Diaphragm is damaged.
3. Fluid pressure is too high.
1. Mount clamp or replace if broken.
2. Replace diaphragm.
3. Check that pressure does not exceed
design pressure.
Actuator is leaking air
1. Actuator seals are worn out.
1. Replace seals if applicable, or actuator.
Page 24 / 45
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6. TECHNICAL SPECIFICATIONS
Design data for complete valve
Design temperature Sterivalve® 12, 25 & 38 Sterivalve® 51 & 76
(1/2”), (1”) & (1 ½”) (2”) & (3”)
Sterilization In Place (SIP) Max 135° C (at 1 hour) Max 135° C (at 1 hour)
Autoclave Max 135° C (at 1 hour) Max 135° C (at 1 hour)
(manual valves only)
Design pressure
___________________________________________________________________________
Minimum working pressure -1 bar(g) -1 bar(g)
Maximum working pressure +7 bar(g) +5 bar(g)
(At +121°C max pressure 3 bar(g))(At +121°C max pressure 3 bar(g))
Other design data
pH range 3 – 11 3 - 11
Viscosity 0 - 1000 cP 0 - 1000 cP
Material
___________________________________________________________________________
Housing (valve body) For all types and sizes AISI 316L (ASTM 316L, EN 1.4404)
Actuator covers AISI 316 or better AISI 316 or better
Plastic Plastic
Diaphragm
Silicone USP <88> Class VI.
According to FDA specification of
approved material
(FDA 21 CFR § 177.2600)
EPDM USP <88> Class VI
According to FDA specification of
approved material
(FDA 21 CFR § 177.2600)
TFM (Ultra High Density PTFE) USP <88> Class VI.
According to FDA specification of
approved material
(FDA 21 CFR § 177.2600)
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Surface treatment Sterivalve® 12, 25 & 38 Sterivalve® 51 & 76
(1/2”), (1”) & (1 ½”) (2”) & (3”)
__________________________________________________________________________________________
Internally High grade polished High grade polished
Ra 0.5 μm or better Ra 0.5 μm or better
Externally Ra 0.8 μm Ra 0.8 μm
Operating data for pneumatic actuator
__________________________________________________________________________________________
Control air Dry, free from particles Dry, free from particles
(<10 μm) and oil (<10 μm) and oil
Supply pressure, recommended 6.0 bar(g) 6.0 bar(g)
Supply pressure, minimum 4.5 bar(g) 6.0 bar(g)
Supply pressure, maximum 7.0 bar(g) 8.0 bar(g)
Air consumption 12 (1/2”) 0.03 Nl / stroke at 4 bar
Air consumption 25 (1”) 0.12 Nl / stroke at 4 bar
Air consumption 38 (1-1/2”) 0.30 Nl / stroke at 4 bar
Air consumption 51 (2”) 2.1 Nl / stroke at 4 bar
Air consumption 76 (3”) 4.5 Nl / stroke at 4 bar
Air connection M5 thread 1/8” BSPP thread
Hose, quick connection For 4 mm hose fitted For 6 mm hose fitted
into the M5 thread into the 1/8” thread
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7. STERIVALVE PARTS LIST
7.1 Sterivalve 12 (½”)
Diaphragms
Part #
Designation
Description
Picture
103477
NP3006837
EPDM diaphragm - FDA
111164
EPDM diaphragm – USP Class VI
103476
NP3002694
Silicone diaphragm – USP Class VI
110646
PTFE diaphragm – USP Class VI
Actuators
Part #
Designation
Description
Picture
110008
NP3009126
Manual handle, SS
110009
NP2002999
Pneumatic actuator, spring/air – SS
110087
NP2006039
Pneumatic actuator, air/air – SS
110531
Pneumatic actuator, spring/air - plastic
104156
Repair kit actuator spring/air
110014
Clamp – light duty
109999
NP4003016A
Pressure plate type 1
110599
Pressure plate type 2
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Valve Housings
Part #
Designation
Description
Picture
108928
ASTM shut off body w/TC connect – new style
110555
ASTM shut off body w/TC connect – old style
108960
ASTM flow-thru body w/TC connect – new style
110024
ASTM flow-thru body w/TC connect – old style
107205
ASTM TC connectable, double outlet
107322
ASTM bottom outlet, 45° TC, single outlet
107179
ASTM bottom outlet, 45° TC, double outlet
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7.2 Sterivalve 25 (1”)
Diaphragms
Part #
Designation
Description
Picture
103479
NP3001941
EPDM diaphragm – FDA
111165
EPDM diaphragm – USP Class VI
103478
NP3000743
Silicone diaphragm – USP Class VI
105016
PTFE diaphragm – USP Class VI
Actuators
Part #
Designation
Description
Picture
110010
NP2001997
Manual handle, SS
110011
NP2001999
Pneumatic actuator, spring/air – SS
110207
NP2002003
Pneumatic actuator, air/air – SS
110533
Pneumatic actuator, spring/air - plastic
104157
Repair kit actuator spring/air
104557
NP4000813
Pressure plate type 1
103649
NP4007652
Pressure plate type 2
110015
Clamp – light duty
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Valve Housings
Part #
Designation
Description
Picture
108936
ASTM shut off body w/TC connect – new style
108968
ASTM flow-thru body w/TC connect – new
style
107225
ASTM bottom outlet, 45° TC, single outlet
107211
ASTM bottom outlet, 45° TC, double outlet
108411
ASTM bottom outlet w/1/2” satellite valve
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7.3 Sterivalve 38 (1-1/2”)
Diaphragms
Part #
Designation
Description
Picture
103481
NP2006668
EPDM diaphragm – FDA
111166
EPDM diaphragm – USP Class VI
103480
NP2010310
Silicone diaphragm – USP Class VI
105651
PTFE1.5
PTFE diaphragm – USP Class VI
Actuators
Part #
Designation
Description
Picture
110012
NP2006912
Manual handle, SS
110013
NP2006659
Pneumatic actuator, spring/air – SS
110252
Pneumatic actuator, air/air – SS
110535
Pneumatic actuator, spring/air - plastic
110015
Clamp – light duty
104158
Repair kit actuator spring/air
104557
NP4000813
Pressure plate type 1
103649
NP4007652
Pressure plate type 2
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REV. STV20110519
Valve Housings
Part #
Designation
Description
Picture
108893
ASTM shut off body w/TC connect
108976
ASTM flow-thru body w/TC connect – new
style
107251
ASTM bottom outlet, 45° TC, single outlet
107237
ASTM bottom outlet, 45° TC, double outlet
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7.4 Sterivalve 51 (2”)
Diaphragms
Part #
Designation
Description
Picture
127742
NP1010647
Teflon diaphragm, including support gasket
Actuators
Part #
Designation
Description
Picture
110232
NP3010534
Manual handle, SS
110155
Pneumatic actuator, spring/air – SS
110537
Pneumatic actuator, spring/air - plastic
109829
NP1010323
Pneumatic actuator spring/air (cylinder only) - SS
Valve Housings
Part #
Designation
Description
Picture
108897
ASTM shut off body w/TC connect
108984
ASTM flow-thru body w/TC connect
107279
ASTM bottom outlet, 45° TC, single outlet
107263
ASTM bottom outlet, 45° TC, double outlet
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REV. STV20110519
7.5 Sterivalve 76 (3”)
Diaphragms
Part #
Designation
Description
Picture
127743
NP1010675
Teflon diaphragm, including support gasket
Actuators
Part #
Designation
Description
Picture
110243
NP1010659
Manual handle, SS
110214
NP1010743
Pneumatic actuator, spring/air – SS
110539
Pneumatic actuator, spring/air - plastic
109830
NP1010743
Pneumatic actuator spring/air (cylinder only) - SS
Valve Housings
Part #
Designation
Description
Picture
108952
ASTM shut off body w/TC connect
108992
ASTM flow-thru body w/TC connect
107311
ASTM bottom outlet, 45° TC, single outlet
107293
ASTM bottom outlet, 45° TC, double outlet
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REV. STV20110519
8. Traceability & Conformity information
All wetted components in the Sterivalve are traceable and marked with a batch number. All
wetted components are provided with certificates of compliance with regards of the materials of
constructions.
Valve housing
All valve housings are provided with the part number and batch number etched to the outside of
the valve housing.
Figure 17: Part number & batch number etchings
A Certificate of Compliance is included showing the part number, batch number and heat
numbers for all components (this could include the housing, fittings and connections).
Mill certificates are provided for each different heat number shown in the Certificate of
Compliance.
Diaphragms
All diaphragms are traceable. Each diaphragm is provided with a Certificate of Compliance
indicating the material, compliance requirements (e.g.USP<88> Class VI), part number, batch
number, and date of manufacturing.
EPDM and Silicone diaphragms have the batch number molded on the non product contact side.
A code is used to determine the batch number and date of manufacturing
Figure 18: Batch number molded location
Page 35 / 45
REV. STV20110519
Declaration of EC Conformity
We herewith declare, the
Pneumatic actuators used on different Bürkert types
meet the requirements given in the European Directives for
ATEX Directive (94/9/EG)
Pressure Directive (97/23/EG)
For the assessment of the products according to the ATEX the European Standard
EN 13463-1:2002 Non electrical equipment for the use in Hazardous
Locations
was used.
With these results the pneumatic activated process valves may be used as Category 2 units in
Zone 1 or 21.
These units are supposed to be used in Temperature Code T4 applications. The fluid temperature
has to be less than 120 °C.
The grounding of a metal body has to be realized with the complete pipeline.
For the assessment of the products according to the pressure directive the European Standards:
EN 60730-1: 01/02
EN 60730-2-8: 10/95
were used.
According to this directive the CE mark is valid in case the valves control
- gases of group 1 or steam and the orifice size is larger than 25 mm or
- gases of group 2 and the product rated pressure x orifice size is > 1000 and < 3500..
This declaration was issued for the manufacturer by
Sonja Drolshagen
Ingelfingen, 12-10-2009
Page 36 / 45
REV. STV20110519
Declaration of EC Conformity
Herewith we declare, that the supplied products meet all requirements laid down in the following
European Directives:
· Low voltage installations with rated voltage 50 - 1000 V/AC respective 75 - 1000 V/DC
(Directive 73/23 EEC)
· Electromagnetic compatibility (Directive 89/336 EEC)
· Pressure Equipment Directive (97/23/EG)
Specification of products:
Type: 1062
Applied harmonized standards for low voltage installation:
EN 50178: 04/98 Electronic equipment for use in power installations
EN 60730-1: 01/96 Automatic electrical controls for household and similar use;
Part1: General requirements
DIN VDE 0110-1: 04/97 Insulation coordination for equipment within low-voltage
systems;
Part 1: Principles, requirements and tests
EN 60529: 09/00 Degrees of protection provided by enclosures (IP-Code)
DIN VDE 60204-1: 06/93 Safety of machinery - Electrical equipment of machines;
Part 1: General requirements
Additional for solenoid valves:
VDE 0580: 10/94 Electromagnetic devices; General specifications
Applied harmonized standards for electromagnetic compatibility (EMC):
EN 61000-6-4: 08/02 EMC-Generic emission standard; Industrial environment
EN 61000-6-2: 08/02 EMC-Generic immunity standard; Industrial environment
EN 61000-3-2: 12/01 Harmonic Current
EN 61000-3-3: 05/02 Voltage Variation
Applied harmonized standards for pressure equipment directive (PED):
EN 60730-1: 01/02 Automatic electrical controls for household and similar use
Part 1: General requirements
EN 60730-2-8: 10/95 Automatic electrical controls for household and similar use
Part 2: Particular requirements for electrically operated water
valves, including mechanical requirements
The CE mark is valid according to this directive in case the valves
· control gases of group 1 or steam and the orifice size is larger than 25 mm or
· control gases of group 2 and the product rated pressure multiplied with the orifice size
is larger than 1000.
This declaration is given responsible for the producer
Bürkert + Cie. S.a.r.l. Established by
Triembach-au-Val Thouvenin, Bruno
F-67220 Villé Quality Inspector
Triembach-Au-Val, 22-10-2009
Page 37 / 45
REV. STV20110519
9. CONTACT INFORMATION
Steridose is a Swedish company highly specialized
in the design, development and manufacturing of
Mag Drive Mixers. Steridose® and Sterivalve® are
registered trademarks for Steridose Sales AB.
Since its beginning Steridose has progressed to be
a highly respected global supplier, partnering many
multinational companies. We have operational
centers throughout the world to best service our
customers. Through experience in the industry we
have earned an enviable reputation in our market
areas; Sterimixer® and Sterivalver® applications.
Our mission is to enable our customers to achieve a market leading position by being the most competent Mag Drive Mixing solution partner.
Steridose is known for its client’s integrity and proactive approach with involvement stretching beyond our customer’s expectations.
Steridose Head Office
STERIDOSE
HIMMELSBODAVÄGEN 7
SE-147 39 TUMBA
SWEDEN
Phone: +46-8 449 99 00
Fax: +46-8-449 99 90
E-mail: info@steridose.com
Home Page: www.steridose.com
Steridose Regional Office
STERIDOSE
5020 WORLD DAIRY DRIVE
MADISON, WI 53718
USA
Phone: +1-608 229 5225
Fax: +1-608 227 9599
E-mail: info@steridose.com
Home Page: www.steridose.com
Page 38 / 45
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APPENDIX A: Welding Guide
1. Placement of the valve housing
The valve housing is usually placed according to the figure below, but other locations may exist.
Therefore the relevant vessel drawings should be checked in order to determine the desired
location. Position the outlet of the valve housing according to the relevant drawing.
The distance from the valve housing weld seam to any other weld seam shall comply with the
local relevant standards regarding pressure vessels, if applicable. As an example, Figure 1 shows
the required distance according to the 1987 Swedish standards for pressure vessels, TKN 87
(minimum of three times for the thickness of the material of the dished end, 3 x t.)
Figure 1: distance between welds
Welding (TIG)
Cut a hole for the valve housing in the dished
end.
Grind the edge of the hole to prepare a suitable
weld gap.
Position the valve housing in the hole in the
dished end. Make sure that the valve housing
outlet is correctly oriented.
Valve size
Diameter of
weld flange (hole)
Sterivalve® 12
ø 48 mm
Sterivalve® 25
ø 79 mm
Sterivalve® 38
ø 84 mm
Sterivalve® 51
ø115 mm
Sterivalve® 76
ø148 mm
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Tack weld the valve housing with a TIG-welder from the outside. The correct filler depends
on the material in the dished end and valve housing. For a dished end and valve housing of
316L filler Avesta 316L (SKR), 316L-Si/SKR-Si or similar type may be used.
Seal off between the bench and the dished end with the aid of tape etc. Fill the dished end
with an inert protective gas.
Starting from the outside, weld the valve housing to the lower dished end in one operation.
Make sure that the weld is well burned-through and that it is free from pores and cracks. Use
as low heat as possible (low current). High heat can deform the valve housing.
Continue welding until the weld opening is completely filled.
Turn over the dished end and weld from the inside in order to smooth out the weld seam. If it
is considered necessary some filler material may be used.
2. After Welding
On completion of welding, the dished end and the bottom outlet valve house shall be allowed to
cool slowly. No cooling medium other than air is required. The inside and outside of the weld is
ground and polished to the required finish.
Page 40 / 45
REV. STV20110519
APPENDIX B: Indicator systems
1. Position Indicators for Stainless Steel actuator size 12 (1/2”) to 38
(1½”)
1.1 Single induction switch
The electrical position indicator indicates open position of the valve. It is threaded to the top of
the pneumatic actuator.
Technical specifications
Model IFB3002-BPKG/V4A/US
Type Inductive sensor
Connection size Metal thread M12 x 1
Sensing range [mm] 2 [f]
Mounting Flush mountormally open
Operating voltage [V] 10...36 DC
Current rating [mA] 250
Short-circuit protection pulsed
Reverse polarity protection yes
Overload protection yes
Voltage drop [V] < 2.5
Current consumption [mA] <15 (25V)
Real sensing range [mm] 2 ± 10 %
Operating distance [mm] 0...1.6
Switch-point drift [% of Sr] -10...10
Hysteresis [% of Sr] 3...15
Switching frequency [Hz] 1200
Correction factors:
mild steel = 1 / stainless steel approx. 0.7 / brass approx. 0.5 / Al approx. 0.4 /
Cu approx. 0.3
Ambient temperature [°C] -25...80
Protection IP 67, II
EMC EN 60947-5-2
EN 55011: class B
Housing material Stainless Steel 316Ti/1,4571
Function display Yellow
Connection M12 connector
Accessories (included) 2 lock nuts
Page 41 / 45
REV. STV20110519
1.2 Single micro switch
The electrical position indicator indicates open position of the valve. It is threaded to the top of
the pneumatic actuator.
This indicator contains a micro switch with snap action contact mechanism designed for up to
106 switching operations. The silver contacts are gold plated. The housing can be rotated
through 360°.
In addition to the electrical position signal there is also visual indication from a red cam via the
transparent section.
Technical specifications
Ambient temperature [°C] -15...60
Protection IP 65
Operating voltage [V] 250AC/24DC
Current rating [A] 4
Protection Class EX II 2G IIB T6 X
Dimensions – [mm]
Page 42 / 45
REV. STV20110519
1.3 Double micro switch
The electrical position has two micro switches that indicate both open and close position. It is
threaded to the top of the pneumatic actuator.
Both micro switches can be continuously and precisely adjusted, independent of each other, via
thread spindles. The housing can be rotated 360°
Technical specifications
Setting range of limit switch 2 - 20 mm continuous
Ambient temperature [°C] -20...60
Protection IP65
Operating voltage [V] 250AC/24DC
Current rating [A] 4/2,5
Approvals UL 508/ CSA, C22.2
Dimensions – [mm]
Page 43 / 45
REV. STV20110519
2. Position indicators for Plastic Pneumatic actuators (all sizes)
The electrical position feedback is installed on the valve actuator. Valve positions are remotely
reported electrically according to switch type:
- open, closed (version with a limit switch) or
- open and closed (version with two switches or a double limit switch)
LEDs provide optical position indication (except with the inductive 2-wires version). Mechanical
or inductive switches are housed in a compact splash-proof enclosure. The position indicator can
be rotated 360° and is easily fitted to the valve.
Technical specifications
Material Plastic
Protection IP65
Mechanical limit switch (per limit switch)
Ambient temperature [°C] -20 to +60
Operating voltage [V] 110-250 AC/DC
12-48 AC/DC
Current rating [mA] < 8 /< 35
Approval VDE, IEC, UL, CSA
ATEX versions II 2 GD EEx ia II C T6,
T5 or T4-T1
Inductive limit switch with 3-wire technology
Output version PNP
Ambient temperature [°C] -20 to +60
Operating voltage [V] 10-30 DC
Current rating [mA] ≤ 150
Approval VDE, IEC, UL, CSA
ATEX versions II 2 GD EEx ia II C T6,
T5 or T4-T1
Page 44 / 45
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Dimensions – [mm]
Page 45 / 45
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3. Inductive switches for Stainless Steel actuator size 51 (2”) and 76 (3”)
The inductive switches are mounted on a plastic holder mounted on the actuator.
Technical Specifications
Diameter [mm] 11
Length [mm] 32
Operating voltage [V] 10-30 VDC
Connection type [mA] pnp-L
Sensing range [mm] 5
Thread M12
Weight (each) [kg] 0.07
Cable length [m] 5
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