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Alfa Laval ThinkTop Digital 9612578966, Instruction Manual

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Alfa Laval ThinkTop Digital 9612578966 Instruction Manual Download Page 54

51 

Effective 05/04/2012

Unique PMO Plus CP HT Valve Series

 

Series Sanitary Mixproof Valve Instruction Manual

Maintenance

See pages 66 to 74 for part numbers.

Mounting rotating nozzle and O-ring on upper plug:

94

112

113

39

3. Lubricate o-ring.

4. Nozzle and lock ring slides 

over spindle.

5. Mount o-ring on 

upper plug.

Summary of Contents for ThinkTop Digital 9612578966

Page 1: ...ESE 02217 2012 05 Unique PMO Plus CP HT Series Sanitary Mixproof Valve Sizes 2 3 4 6 Instruction Manual Effective 05 04 2012...

Page 2: ......

Page 3: ...hout prior notice Table of Contents Introduction 4 Safety 5 Installation 6 Specifications 8 Pneumatic Connections 10 Position Indication 11 Electrical Connections 12 1 thru 12 4 ThinkTop 13 Cleaning P...

Page 4: ...anual should be considered part of this product and should remain with it at all times for reference If you sell it please be sure to include this manual with it Warranty is provided as part of Alfa L...

Page 5: ...Make Machine Modifications Alfa Laval offers a full range of products to suit all your needs Therefore product modification is never necessary Keep Maintenance Safe Replace damaged or worn parts immed...

Page 6: ...no shortages Any damage or shortage should be reported to the carrier Locating The valves are mounted directly into the product line Care should be taken however to locate the valves in a place where...

Page 7: ...54 OD 2 50 3 00 4 00 6 07 6 07 ID 2 37 2 87 3 84 5 78 5 78 t 0 06 0 06 0 08 0 14 0 14 D 7 32 7 32 7 32 7 32 7 32 E 2 79 3 04 3 63 5 10 5 10 F1 1 50 1 50 2 95 2 95 2 32 F2 Tank plug 0 39 0 39 0 39 0 3...

Page 8: ...eel parts Acid resistant steel AISI 316L Other steel parts Stainless steel AISI 304 304L Product wetted parts NBR HNBR EPDM or FPM Other Seals CIP Seals EPDM Actuator seals NBR Finish int ext Polished...

Page 9: ...n flows for seat lift viscosity and density similar to water CV Values Unique PMO Plus CP HT 2 3 4 6 Upper seat lift 2 6 5 3 12 1 Tank plug push 30 58 3 137 2 The following formula is used to estimate...

Page 10: ...n Manual Pneumatic Connections Out 1A Valve Pneumatic Functions Unique PMO Plus CP HT Valve Series Out 2 Out 3 Valve Pneumatic Connections ThinkTop Fitting ID Actuator Fitting ID Out 1A AC 2 Blue Out...

Page 11: ...ve Series Series Sanitary Mixproof Valve Instruction Manual Position Indication Valve Position Indication Unique PMO Plus CP HT Series External Sensor LED Upper Seat Position Detection Upper Seat Clos...

Page 12: ...9612 5789 66 0 Solenoid Electrical Connection Chart ThinkTop Term No Function Remarks 9 8 30 VDC Power 10 Common Power Ground 1 Closed Valve PLC Input Valve Closed 2 Open Valve PLC Input Valve Open 3...

Page 13: ...t Valve Open 7 Solenoid 2 Output Lower Seat Push 8 Solenoid 3 Output Upper Seat Lift 9 8 30 VDC Power 10 Common Power Jump to 11 11 Solenoid Com Power Jump to 10 Ground 1 Closed Valve PLC Input Valve...

Page 14: ...Top 110 VAC 9612 9906 66 0 Solenoid Electrical Connection Chart ThinkTop Term No Function Remarks 9 110 VAC Power 10 Common Power Ground 1 Closed Valve PLC nput Valve Closed 2 Open Valve PLC Input Val...

Page 15: ...7 Solenoid 2 Output Lower Seat Push 8 Solenoid 3 Output Upper Seat Lift 9 110 VAC Power 10 Common Power Jump to 11 11 Solenoid Com Power Jump to 10 Ground 1 Closed Valve PLC Input Valve Closed 2 Open...

Page 16: ...ThinkTop 13 Effective 05 04 2012 Electrical Connections In structions ThinkTop Digital 8 30 VDC 110 VAC PNP NPN Used with Unique PMO Plus CP HT Series Mixproof Valves Instruction Manual...

Page 17: ...e 8 30 or 100 126 5 VAC Supply voltage nominal 24 or 110 VAC 15 10 pr EN 61131 2 Supply voltage absolute max 30 or 126 5 VAC Supply voltage absolute min 8 or 100 VAC Power consumption Max 1 5 VA 8 30...

Page 18: ...tion possible via 6 mm or Nominal voltage 24 or 110V Nominal power 1 0 W Filter recommended in tropical regions Micro environment demand specifications Temperature Working 4 F to 185 F IEC 68 2 1 2 St...

Page 19: ...seat lift 2 associated with feedback 4 seat lift 2 Note Jumper present NO The selection NO NC is done by the jumper If changing the function a power recycle is necessary Note Remember to isolate wire...

Page 20: ...2 1 Fit the air fittings on actuator if not mounted 2 Fit the activator stem magnet and tighten carefully by hand Step 3 1 Place the ThinkTop on top of the actuator 2 Make sure X ring is mounted Step...

Page 21: ...4 air tubes to ThinkTop see drawing Air connections on page 20 Step 6 Fit the air tubes to the actuator see drawing Air connections on page 20 Step 7 Untighten the four screws and pull off cover of T...

Page 22: ...T Valve Series Series Sanitary Mixproof Valve Instruction Manual 19 Effective 05 04 2012 Step 9 Make sure the cable gland is completely tightened Step 10 Set up the ThinkTop see setup diagram page 21...

Page 23: ...tions 16 4 Installation 4 3 Air connections 1 2 3 TD 800 214 Air restriction throttle function air inlet outlet Air out 1A Air exhaust Air out 1B 5 2 port solenoid valve only 3 2 Solenoid valves only...

Page 24: ...6 See opposite page See opposite page Notes I Scroll across no change Notes Requires Key Function Notes Automatic Progress as Indicated 4 D IND active during set up Flashing in step 1 Steady in all o...

Page 25: ...Move to next step Press I to accept selection Set up Maintenance I Bypass Move to next step II 90 days LED F steady II 180 days LED F steady C flashing II 270 days LED F steady C E flashing II 360 da...

Page 26: ...out The unit has been self adjusted into a maintenance alert condition Valve maintenance is strongly recommended After maintenance Disa bling of maintenance function is required before setting new po...

Page 27: ...tion Manual Note During set up LED lights have different functions Yellow steady Position C Seat lift 1 2 or external sensors Green steady Solenoid valves activated Yellow steady Position B open valve...

Page 28: ...ver of ThinkTop Note Turn banjo connection Step 3 1 Untighten screws 2 Remove solenoid valves up to three and replace them with new ones Step 4 1 To dismantle the adapter the lower part of the ThinkTo...

Page 29: ...Mixproof Valve Instruction Manual 26 Effective 05 04 2012 Step 5 To remove the sensor unit untighten screw and pull out the sensor unit Study the instructions carefully Handle scrap correctly Always k...

Page 30: ...emble base with adapter by turning adapter slightly anticlockwise and tighten the three screws 1 9 Nm Note Turn banjo connection Step 3 1 Replace solenoid valves up to three with new ones 2 Tighten sc...

Page 31: ...ries Sanitary Mixproof Valve Instruction Manual 28 Effective 05 04 2012 Step 5 1 Replace X ring 2 Mount ThinkTop on actuator Study the instructions carefully Handle scrap correctly Always keep spare X...

Page 32: ...2 Unique PMO Plus CP HT Valve Series Series Sanitary Mixproof Valve Instruction Manual Electrical Connections In structions Spare Parts ThinkTop P N 9612578966 P N 9612578969 P N 9612990666 P N 961299...

Page 33: ...30 Effective 05 04 2012 Unique PMO Plus CP HT Valve Series Series Sanitary Mixproof Valve Instruction Manual ThinkTop...

Page 34: ...lves shall be cleaned in place CIP with the following recommended procedures Each mixproof valve shall be properly operated including seat lifting during CIP cleaning to assure exposure to product con...

Page 35: ...cleaning results All data shown is required for each valve during cleaning Use clean water free from chlorides for mixing with chemical cleaning agents CIP Event Exposure Time Temperature Agent Concen...

Page 36: ...on Total Valve Functions Over 3 Minute Rinses and 10 Minute Washes Warm Pre Rinse 3 Minutes Upper Seat Lift 3 Energized 5 sec 2 Lower Seat Push 2 Energized 5 sec 2 Nozzles in Vent 5 sec 2 Hot Alkaline...

Page 37: ...ons at 30 PSI CIP pressure viscosity and density comparable to water Flow Per Second Flow Every 2 Seconds Valve Size Through Vent Tube Through Vent Tube 2 and 3 0 24 gal 0 47 gal 4 0 48 gal 0 97 gal 6...

Page 38: ...rest closed position C LED Seat Lift on ThinkTop is illumated 2 Attach a manual air line to actuator air fitting AC1 using a 3 way air pilot switch pos 102 3 Turn the air pilot switch to ON Open C LED...

Page 39: ...e at rest closed position A LED Closed Valve on ThinkTop is illuminated 2 Attach a manual air line to actuator air fitting AC3 using a 3 way air pilot switch pos 102 3 Turn the air pilot switch to ON...

Page 40: ...s off 4 Turn the sensor pos 83 counter clockwise until the sensor LED turns on or approximately one full turn from bottom of plug 5 Lightly tighten sensor lock nut s 6 Attach a manual air line to actu...

Page 41: ...SEAT EXTERNAL SENSOR in this section Refer to Electrical Connections Instructions in this manual for ThinkTop programming Adjustments Upper Valve Seat ThinkTop Set Position New on ThinkTop Adjustment...

Page 42: ...ircuit Description of components to be used for this test 1 ThinkTop blue control module located on top of the air actuator 2 Compressed air solenoids when furnished inside ThinkTop see page 20 for to...

Page 43: ...solenoid number 2 lower seat push If control system interlock is correct the CIP supply pump or source of CIP solution pressure will be de activated Release manual air pilot button to end this test 7...

Page 44: ...ench 17mm Wrench 2 5mm Allen Wrench Small Knife Straight Pick Small Standard Screw Driver Air Pilot Switch Pos 102 Tools Required for Valve Service Tools Required for Actuator Service 13mm Wrench Long...

Page 45: ...2012 Unique PMO Plus CP HT Valve Series Series Sanitary Mixproof Valve Instruction Manual Maintenance Dis Assemble Valve Excluding Actuator 1 Remove ThinkTop See pages 66 to 74 for part numbers 2 Act...

Page 46: ...12 Unique PMO Plus CP HT Valve Series Series Sanitary Mixproof Valve Instruction Manual Maintenance 3 Remove clamp 4 Remove valve 5 Release air See pages 66 to 74 for part numbers 6 Remove flushing pi...

Page 47: ...ue PMO Plus CP HT Valve Series Series Sanitary Mixproof Valve Instruction Manual Maintenance 7 Remove clamp rings See pages 66 to 74 for part numbers 8 Activate upper seat lift 9 Loosen lower plug by...

Page 48: ...itary Mixproof Valve Instruction Manual Maintenance 10 Turn out lower plug by hand and remove plug assembly 11 Remove spindle liner and lock ring See pages 66 to 74 for part numbers 12 Remove upper st...

Page 49: ...ies Series Sanitary Mixproof Valve Instruction Manual Maintenance 13 Remove lock ring and rotaing nozzle by pulling upwards See pages 66 to 74 for part numbers 14 Remove valve body sealing element 15...

Page 50: ...012 Unique PMO Plus CP HT Valve Series Series Sanitary Mixproof Valve Instruction Manual 16 Remove clamp vent body and sealing element 17 Sanitize guide ring See pages 66 to 74 for part numbers 105 10...

Page 51: ...lubricate behind the sealing Step 3 Place lower tool part Step 4 1 Place upper tool part including piston 2 Clamp the two tool parts together Step 5 1 Supply compressed air 2 Release compressed air 3...

Page 52: ...shown on drawing Step 3 Place tool part 1 Carefully lubricate sealings with acceptable lubricant before pre mounting Do not lubricate behind the sealing Balanced plug Flat side of the sealing TEM NO T...

Page 53: ...eries Sanitary Mixproof Valve Instruction Manual Maintenance 1 Lubricate o rings lip seal 2 Mount all components in sealing element Re Assemble Valve Excluding Actuator Assembly valve body sealing ele...

Page 54: ...es Series Sanitary Mixproof Valve Instruction Manual Maintenance See pages 66 to 74 for part numbers Mounting rotating nozzle and O ring on upper plug 94 112 113 39 3 Lubricate o ring 4 Nozzle and loc...

Page 55: ...ve body sealing element on upper plug 6 Ensure sealing element is orientated so the white guide ring is upwards Mounting two way nozzle spacer and guide rings 7 Lubricate o ring 8 Insert nozzle ensure...

Page 56: ...nique PMO Plus CP HT Valve Series Series Sanitary Mixproof Valve Instruction Manual Maintenance See pages 66 to 74 for part numbers 10 Insert spacer 11 Insert last guide ring 12 Insert tank plug from...

Page 57: ...s Sanitary Mixproof Valve Instruction Manual Maintenance See pages 66 to 74 for part numbers 13A and 13B Mount stem for lower plug 14 Tighten Use a 13mm and 16mm wrench Torque 20Nm 15 Mount o ring Mou...

Page 58: ...nce See pages 66 to 74 for part numbers 17 Mount yoke and the 3 nuts and washers 18 Use a 13mm wrench Tighten nuts to 12Nm 19 Mount o ring on actuator spindle 20 Mount plastic bolt and sensor Assembly...

Page 59: ...truction Manual Maintenance See pages 66 to 74 for part numbers Assembly valve 23 Lubricate o ring 42 43 41 44 40 43 24 Place sealing element with o ring and lip seal upwards 26 Mount vent body 27 Mou...

Page 60: ...28 Activate compressed air on lower seat push yellow air fitting placed on top of actuator 29 Insert valve plug assembly through vent sealing element 30 Tighten lower plug by hand Lower plug 31 Mount...

Page 61: ...nstruction Manual Maintenance 35 Mount flushing pipe tighten with 19mm wrench 36 Deactivate lower seat push 37 Activate compressed air on main stroke blue air fitting placed mid on actuator 38 Mount v...

Page 62: ...ring 24 5 Remove piston rod 29 bottom 21 and lower piston 30 6 Separate the three parts 7 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 rin...

Page 63: ...60 Effective 05 04 2012 Unique PMO Plus CP HT Valve Series Series Sanitary Mixproof Valve Instruction Manual Maintenance Actuator Exploded View...

Page 64: ...ng assembly 10 6 Fit O ring 19 and guide ring 18 Mount distance spacer 11 main piston 17 and inner stem 27 7 Fit spring assembly 14 8 Fit O ring 28 in piston rod fit O rings 33 and 31 and guide ring 3...

Page 65: ...62 Effective 05 04 2012 Unique PMO Plus CP HT Valve Series Series Sanitary Mixproof Valve Instruction Manual Parts List 100 3 2 5 6 16 3 1 3 See pages 66 to 74 for part numbers 100 101 103...

Page 66: ...63 Effective 05 04 2012 Unique PMO Plus CP HT Valve Series Series Sanitary Mixproof Valve Instruction Manual Parts List 9 8 7 4 2 10 11 1 12 26 17 18 19 See pages 66 to 74 for part numbers...

Page 67: ...64 Effective 05 04 2012 Unique PMO Plus CP HT Valve Series Series Sanitary Mixproof Valve Instruction Manual Parts List 13 27 14 28 29 32 30 31 33 21 20 22 See pages 66 to 74 for part numbers...

Page 68: ...65 Effective 05 04 2012 Unique PMO Plus CP HT Valve Series Series Sanitary Mixproof Valve Instruction Manual Parts List See pages 66 to 74 for part numbers 42 43 41 44 40 43 141 142...

Page 69: ...66 Effective 05 04 2012 Unique PMO Plus CP HT Valve Series Series Sanitary Mixproof Valve Instruction Manual Parts List...

Page 70: ...13 4141 01 9613 4141 01 9613 4141 01 9613 4141 01 16 1 Cylinder 3A marking 9613 0051 12 9613 0051 12 9613 0150 28 9613 0150 28 9613 0150 28 17 1 Main piston 9614 0322 01 9614 0322 01 9614 0322 02 9614...

Page 71: ...actuator 9613 0990 02 9613 0990 02 9613 0990 02 9613 0990 02 9613 0990 02 87 1 O ring 9611 99 4599 9611 99 4599 9611 99 4599 9611 99 4599 9611 99 4599 93 1 Tank plug 9614 0079 01 9614 0066 01 9614 008...

Page 72: ...14 0056 01 9614 0059 01 1 Valve body TR clamp end 9614 0050 02 9614 0053 02 9614 0056 02 9614 0059 02 1 Valve body TC clamp end 9614 0050 03 9614 0053 03 9614 0056 03 9614 0059 03 1 Valve body TL weld...

Page 73: ...6 69 9612 9906 69 101 1 Magnet ThinkTop 9612 5623 01 9614 0794 01 83 1 Sensor 24VDC 9611 99 4916 9611 99 4916 83 1 Sensor 110VAC 9613 6036 42 9613 6036 42 82 1 Nylon Plug 24VDC Sensors 9613 0926 03 96...

Page 74: ...9613 0952 09 9613 0952 12 9613 0952 47 1 Seal ring NBR 9613 0952 15 9613 0952 16 9613 0952 48 1 Seal ring HNBR 9613 0952 07 9613 0952 10 9613 0952 45 1 Seal ring FPM 9613 0952 08 9613 0952 11 9613 09...

Page 75: ...72 Effective 05 04 2012 Unique PMO Plus CP HT Valve Series Series Sanitary Mixproof Valve Instruction Manual Parts List Axial Installation Tool...

Page 76: ...alve Instruction Manual Parts List Axial Installation Tool 2 3 4 6 9613 0505 02 9614 0792 01 9613 0505 06 9613 0505 10 Pos Qty Denomination 2 and 3 4 6 1 1 Lower Part 2 1 Piston 3 1 Upper part 4 1 O r...

Page 77: ...74 Effective 05 04 2012 Unique PMO Plus CP HT Valve Series Series Sanitary Mixproof Valve Instruction Manual Parts List Radial Installation Tool 3 9 1 6 7 6 2 8 11 4 5 10 TD 449 354...

Page 78: ...st Radial Installation Tool 2 and 3 4 6 9614 0788 01 9614 0788 02 9614 0788 03 Pos Qty Denomination 2 and 3 4 6 1 1 Piston 2 1 Lower Part 3 1 Upper Part 4 1 Bushing 5 1 Guide 6 2 Guide Ring 9613 0084...

Page 79: ...8th Place Suite 300 Kenosha WI 53144 USA Tel 262 605 2600 Fax 262 605 2667 www alfalaval us The information herein is correct at the time of issue but may be subject to change without prior notice 201...

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