Alfalaval 762-227 User manual

Tri-Clover® Flo-Diversion Valve and Panel Models 762-227, 762-227MRAL& 862W-227
Instruction Manual
Effective8/1/03

2
CONTENTS
Thank you for purchasing an Alfa Laval Product!
This manual contains installation, operation, and repair instructions, with parts lists, for the Model 762-
227,762-227MRALand862W-227Flo-DiversionValvesandcontrolpanelsdesignedandmanufactured
by Alfa Laval Inc.. It also provides a trouble shooting chart to assist in determining electrical and
mechanical malfunctions, if they should occur.
READ THIS MANUAL carefully to learn how to service and reconfigure these valves.Failure to do so
couldresultinpersonalinjuryorequipmentdamage.
SAFETY
IMPORTANTSAFETYINFORMATION ............................................................................................ 3
INTRODUCTION
GENERAL........................................................................................................................................ 4
INSTALLATION
UNPACKINGAND INSTALLINGEQUIPMENT ................................................................................. 7
PRESTARTING................................................................................................................................9
CLEANING .................................................................................................................................... 16
MAINTENANCE
INTRODUCTION ............................................................................................................................ 17
DISASSEMBLY ............................................................................................................................. 17
VALVECOMPONENT INSPECTION............................................................................................. 18
CONTROLTOPDISASSEMBLY.................................................................................................... 19
ACTUATOR BUSHING/ PACKING REPLACEMENT ..................................................................... 20
CONTROLTOPASSEMBLY.......................................................................................................... 21
VALVE ASSEMBLY ....................................................................................................................... 23
...................................................................................................................................................... 23
TROUBLESHOOTING
TROUBLESHOOTINGGUIDELINES ............................................................................................. 25
PARTS LIST
CONTROLPANELCOMPONENTS ............................................................................................... 28
PANEL ........................................................................................................................................... 29
74-115-X-YCONTROL HOUSING .................................................................................................. 30
762-227M ....................................................................................................................................... 32
862W-227 ....................................................................................................................................... 34
762-227MRAL ................................................................................................................................36
ALLEN BRADLEY SLC 500 PLC
TRI-CLOVERPANELMODELS48-2762-1AND48-2762-2 ............................................................ 38
SOFTWAREVERSIONNUMBERS(AS OF 8/4/94) ....................................................................... 41
MEMOREYMODULES.................................................................................................................. 42
FIXEDHARDWARE STYLE........................................................................................................... 42
INPUTANDOUTPUT STATUS INDICATORS ................................................................................ 43
FLO-DIVERSIONPANEL#48-2762-1WITHOUTSOLENOIDS ...................................................... 45
WIRINGDIAGRAMFOR FLO-DIVERSION PANEL#48-2762-1..................................................... 47
EXTERNALWIRINGDIAGRAMFOR FLO-DIVERSION PANEL48-2762-1 ................................... 49
WIRINGDIAGRAMFOR FLO-DIVERSION PANEL#48-2762-2..................................................... 53

3
WARNING
HAZARDOUS VOLTAGE
DISCONNECT POWER
BEFORE SERVICING
PartNumber38-294 PartNumber38-228
WARNING
SPRING UNDER LOAD
DO NOT ATTEMPT TO CUT ACTUATOR OPEN
REFER TO SERVICE BULLETIN
IMPORTANT SAFETYINFORMATION
SAFETY
DANGER
WARNING
Indicates an imminently hazardous situation which, if not
avoided, will result in death or serious injury. The word
Danger is used in the most extreme cases.
Indicates a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury. May
also be used to alert against an unsafe operating or
maintenance practice.
CAUTION
Indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
!
Safety is very important!
DO NOT attempt to modify any Alfa Laval product. To do so could create unsafe conditions and
void all warranties. DO NOT place any Alfa Laval product in an application where general product
serviceratingsareexceeded.
ThefollowingDANGER,WARNING, AND CAUTIONsignsandtheir meanings areusedwithin these
instructions.

4
INTRODUCTION
PURPOSE OF THE EQUIPMENT
The Flo-Diversion Valve is used primarily in the dairy industry for controlling the direction of product flow
during the pasteurization process. It is positioned in the product stream at the discharge of the holding
tube and will not forward the product until a safe pasteurization temperature is reached.
The Flo-Diversion Valve is operated in conjunction with HTST Controllers or Safety Thermal Limit
RecorderControllers.
DESCRIPTION
The Flo-Diversion Valves consist of a set of valves. The valves, a divert valve and a leak detector
valve, each contain an actuator, a body, and a valve plug assembly. The valve actuator is air operated
in one direction and spring operated in the other direction. Air, under pressure, is introduced into the
actuator, forcing the piston downward. When air pressure is removed, a spring returns the piston to its
normalposition.
The valve plug assembly is screwed to the actuator stem, and moves up and down in the valve body as
air pressure is applied and released. Inert rubber plugs on the valve stem seat in the valve bodies and
seal the appropriate ports in the valve bodies.
The actuator also mechanically operates a microswitch which is mounted at the top of the actuator in a
housing. The microswitch engages a bump on the actuator indicating nut, and opens or closes an
electrical circuit to the controller as the actuator stem moves up or down.
The purpose of the 762-227 MRAL Reverse Acting Flo-Diversion Valve is to eliminate hydraulic shock in
systems where the differential pressure across the valve is 30 psig or greater. The design of the valve
allows closing against the process flow rather than with the flow as conventional valves do. The valve is
mounted horizontally and is still able to drain due to tangential valve bodies. Two piece stems allow for
assembling and disassembling the valve. The two stems are joined together with a nut and an o-ring
seal. During o-ring failure leakage flows through leak detect holes in the short stem and can be seen
through the clear plastic stem guard.
MODEL 862W-227M, ASEPTIC FLO-DIVERSION VALVE
The862W-227Misamodifiedversionofthestandardupright 762-227M Flo-Diversion Valve.
The modification consists of the addition of a sterile barrier spacer or collar and extended stem on each
valve. The collars mount between the standard valve's yoke and upper bodies.
The collar allows you to pipe steam or other sterile media into the chamber area
whichsurroundstheupperportionofthe
valve stems.
A fluoroelastomer seat style combines
witha high temperaturebushing, bothof
whichareengineeredtowithstandthe
hightemperaturesencounteredinaseptic
processingapplications.
GENERAL
!
""
Steam In Steam Out
1/8 NPT
Cross-section drawing illustrating
the path of steam through the steam
collar. Figure 1: Flo-Diversion Valve

5
The control panel contains a three position selector switch for operating the valve in product flow,
cleaning, or inspection positions. A manual diversion push button allows the operator to divert product
flow into the balance tank at any time during operation of the equipment. Inside the control panel are
solenoid valves, timers and relays required for control of the valves. The solenoid valve are electrically
energized, and control air flow to the divert and leak detect valves. A pneumatic timing relay (CRT2)
delays valve operation until the timing pump is completely stopped when the selector switch is turned to
the “inspect” or “clean” positions from the product position. Pneumatic timing relay (CRT1) delays the
leak detector valve from assuming forward flow until a time delay has elapsed, this time delay is started
at the same time the divert valve moves to forward flow. Cam Timer (CTl) controls the sequencing of
thevalvesduringtheCIP(Clean-in-Place)operation. TheModel48-2120-E-(voltage)ControlPanel
includes a 10 minute timer to delay valve cycling for the 10 minute delay time period. A terminal strip
provides for connecting external electrical wiring, and also is used for trouble shooting the electrical
system. An air filter-regulator mounted on the side of the control panel governs air pressure and filters
the air to the solenoid valves.
A programmable logic controller panel is also available and is described later in this manual.
PRINCIPLES OF OPERATION
TheFlo-Diversion Valve isoperated by aHTST controller ora Safety Thermal Limit Recorder Controller
to direct product flow either to the raw product tank (balance tank) for reprocessing, or to continue
processingthrough the HTSTunit.
PRODUCT POSITION
At the beginning of a cycle the timing pump is started, and the selector switch on the valve control
panel is set in the “product” position. The selector switch is interlocked with the timing pump switch to
prevent accidental forwarding of unsafe product, if the selector switch is inadvertently moved either to
the “clean” or "inspect” position.
INTRODUCTION
LeakDetector
SolenoidValve
(SV2)
Terminal
Strip
10Minute
CIP Delay Timer
(CRT5)
CIP CAM
Timer(CT1)
Manual
Diversion
Button
DivertSolenoid
Valve(SV1)
3Position
Selector
Switch
TimingRelays
(CRT1, CRT2 & CRT3)
Figure 2: Control Panel

6
Theproductiscirculatedthroughtheregeneratorand heater, and into the holding tube and Flo-Diversion
Valve. The valve diverts product back to the balance tank until a safe pasteurization temperature is
reached. When legal temperature is reached, the temperature limit switch closes the circuit to the
solenoid valve (SVl) for the divert valve. The solenoid valve allows air to flow into the divert valve
actuator, placing the valve in the forward flow position. The product then flows through the leak detect
port for the predetermined length of time set on timer (CRT1). When the delay time has elapsed,
solenoid valve (SV2) for the leak detect valve is energized, allowing air to flow to the leak detect valve
actuator, placing it in the forward flow position. The valves will maintain the forward flow position until:
1. Thepasteurizationtemperaturebecomessub-legal
2. Theselector switchis moved from the ‘’product" position
3. Themanualdiversionswitchisactivated
4. Anelectrical, mechanicalmalfunction or air failure occurs
During the time the divert valve is diverting product to the balance tank, the valve plug sealing the
forward flow port in the divert valve body is being tested for leakage.
If leakage past the plug occurs, product is channeled out the leak detect port to atmosphere or to the
balancetank,dependingonpipingarrangement.
The position of the valves is indicated by red and green lights on the controller. The circuit for the lights
is opened and closed by the microswitches (MSl and MS2) on the divert valve and leak detector valve
actuators. When the valve is in the “divert flow” position, the rollers on the microswitches arms engage
the indicating nut on the actuator stems and the circuit to the red light is closed. When the divert and
leak detector valve moves from the divert flow position, the rollers disengage from the indicating nut,
opening the circuit to the red light and divert valve only closes the circuit to the green light.
The timing pump will not operate unless the selector switch is in “product” position and the timing pump
circuit is complete.
CLEAN POSITION
The Flo-Diversion Valve is automatically cleaned in place. When the selector switch is placed in the
“clean” position, the valves are sequentially activated while cleaning solution is circulated through the
system. The recycling cam timer (CT1) activates switches which open and close circuits to the
solenoid valves on a timed basis. The divert, leak detect, and forward flow ports and valve plugs are
thoroughly flushed on each cycle of the timer. The selector switch is interlocked with the timing pump
in this position to prevent forwarding of unsafe product.
INSPECT POSITION
The “inspect” position of the selector switch, sets the valves in forward flow position to permit
dismantling of the valves for inspection and/or repair. The selector switch is interlocked with the timing
pump in this position to prevent forwarding of unsafe product.
INTRODUCTION

7
UNPACKING EQUIPMENT
The Flo-Diversion Valve should be unpacked immediately upon receipt from the factory and carefully
inspectedfor damagethat mayhave occurredduring shipping. The equipment should also be
checked against the bill of lading to make sure there are no shortages. Any damage or shortage
shouldbeimmediatelyreported to thecarrier.
LOCATION OF EQUIPMENT
The valves are mounted directly into the product line, and in close proximity to the press and balance
tank. Care should be taken, however, to locate the valves in a place where they are easily reached
formaintenanceanddisassembly.
The control panel should be located near the valves, and positioned so it can be easily reached for
changing the selector switch position, manual diversion, when necessary, and for service of the
electrical components if malfunctions should occur.
Easy access to the valve and panel is necessary for operator and regulatory agency testing. If
valves are not accessible from the floor an appropriate fixed platform may be required by state and
federalregulators.
UNPACKING AND INSTALLING EQUIPMENT
Figure3: Reverse-Acting Flo-Diversion Valve
INSTALLATION

8
INSTALLATION
INSTALLING THE EQUIPMENT
Secure the valves to an adequate support using appropriate pipe hangers, and connect the valves to
the product piping. The valves are furnished with Tri-Clamp®fittings for simplified connections. Make
sure the piping is self supporting and that the joints at the valves are properly aligned to prevent strain
on the valves.
Mount the control panel on a rigid support using the holes provided in the control box. Avoid mounting
the unit on a support that may be subjected to excessive vibration.
AIR SUPPLY
Connect a clean dry air supply to the filter regulator mounted on the side of the control panel. All air
connections should be made with ¼" OD copper tubing or equivalent. Black or galvanized pipe is not
recommended. Before making final connections blow out all air lines to remove scale, metal filings or
other extraneous particles.
Connect the air lines on the control panel to the divert valve and leak detect valve, making sure that the
air lines are connected to the proper valves. Quick couplers are not acceptable as air connection joints.
ELECTRICAL CONNECTIONS
All the main electrical wiring with the exception of the microswitch wiring is brought into the control
panel through a hole punched in the control unit at the time of installation. The microswitch wiring is
brought into the control unit through holes at the top of the control panel. A terminal board located
inside the control unit provides the necessary connecting points for the wiring. Refer to wiring diagrams
and schematic diagrams on previous pages.
Before connecting power to the control panel, make certain the voltage and frequency agree with the
valves on the data plate.

9
PRESTART TESTS
Before putting the Flo-Diversion Valve into operation it is necessary to check the installation. To make
sure that all parts of the system are functioning properly, the following checklist should be used.
1. Air Supply. Make sure all air line connections are tight and free of leaks. Before turning on the air
supply, loosen the adjusting screw on top of the Filter-Regulator until an compression on the spring
is released. Turn on the air supply and turn the adjusting screw in until the pressure guage registers
the air pressure indicated on the data plate.
2. Electrical Wiring. Check the wiring against the schematic included with the control panel to make
sure wiring is complete and all connections are tight. Cheek the voltage ratings on all
components to be sure that they are compatible.
3 Mechanical.
A. Turn the controller on, but do not turn the timing pump on. Turn the selector switch on the
control panel to the “Clean” position. The cam timer (CTl) in the control panel should start
rotating. Thedivertvalvewillmovetotheforwardflowpositioninapproximatelythirty-five
seconds,andtheleakdetectorvalvewillmovetoforwardflowapproximatelytwentyseconds
afterthe divertvalve has been positioned. If the panel also contains aten minuteCIP delay
timer, the timer will time out after ten minutes, then the cam timer will start and operate as
describedabove. Camtimerwill make one revolution every four minutes. Turn the selector
switch to the “product” position. The timer will continue to rotate for as long as four minutes
until the homing cam returns to the start position. The homing cam is the cam on the left side
ofthe timer. The valves will both return immediately to the divert position. Move the selector
switchto the “inspect” position. The valveswill assume the forward flow position.
B. Place the selector switch in the “product” position, and turn on the timing pump. Cam timer
should be in the “home” position to continue these tests. The red indicating light on the STLR
Controller should be on. Set the temperature control to “pasteurize” setting. When pasteurizing
temperatureisreached,thedivertvalvewillassumetheforwardflowposition. Theleakdetector
valvewill be delayed in closing,the timeinterval depending onthe settingof timer(CRTl). The
greenindicator light shouldcomeonandtheredindicatorlightgooffwhenthe divert valve
assumes the forward flow position. If the lights do not function properly, check for microswitch
adjustment. See topic “Adjustments.” Reducing the temperature to sub-legal should cause
bothvalves to assumethe divertposition until temperature is raisedto thepasteurization level at
which time the valves will again operate in the product cycle.
C. Change the selector switch setting from "product" to "clean" while pasteurization temperature is
beingmaintained, and thetiming pumpis on. The valvesshould immediately assumethe divert
position and the timing pump should stop. In 35 seconds, the divert valve should assume
forwardflowposition and twenty seconds later the leakdetectorvalvewillgointotheforward
position.
D. With the timing pump On, and the product at pasteurization temperature, place the selector
switch in the "product" position. when full forward flow is reached, move the selector switch to
the "inspect" position. The valves should immediately assume the divert position and the timing
pumpshould shutoff. After fifteenseconds, orwhen thetiming pumpstops running,the valves
shouldassumetheforwardflowposition,withthetimingpumpremainingoff.
Note: For installations using the Slick 500, if the Timing Pump Run Down Time exceeds the
pre-programmedtime ofthe UVPROM, anew chip will be requried with the matching
setting before the panel is sealed.
E. Whenthe product is below legal pasteurization temperature andthe timing pumpis on, move
the selector switch from "product" position to "clean" position. The timing pump will shut off and
thevalveswill follow thecleaning cycle aftera delay oftenminutes (CRT5).
PRESTARTING
INSTALLATION

10
Figure4: 762-227GaugePlacement
F. With sub-legal pasteurazation temperature andthe timingpump on, move the selectorswitch
from "product" to "inspect" position. The timing pump will shut off and the valves will assume
forwardflowfifteensecondsafterswitchispositioned.
G. At pasteurization temperatures, press the manual divert button while selector switch is in the
"product" position. The valves will assume the divert position, and will remain in this position
until the manual diversion switch is released. When the switch is released, the valves will follow
the normal "product" cycle.
4. MICROSWITCHTESTfor762-227&862W-227. Themicroswitchesinthevalvesaresafety
devices. They are adjusted so that the timing pump will not run at sub-legal pasteurization
temperatures,unless thevalves are completely and properly assembled. To test the microswitch
andadjustment,followthe instructions below.
A. Makecertainthevalvesareproperlyassembled,paying particular attention totheactuator
mounting bolts, yoke mounting bolts, body clamps, and the valve stem to actuator stem
connection.
B. MakesurethetemperaturesensingelementoftheSafetyThermal Limit Recorder Controller is
belowlegalpasteurizationtemperature.
C. Momentarily turn on the timing pump to make sure it is operating properly, and then turn it off.
D. LeakDectectvalve-Removethevalvebodyclampandtheuppervalvebodyportclampon
the valve. Lift the valve off the lower body. Turn the selector switch to the "Inspect" postiion.
(Aftertime delay, valve will switchposition.) Unscrew the valve stem offthe actuator stem
enoughto insert the gap hauge between the two stems. Tighten the valvestem onto the gauge.
E. Turn the selector switch to the “PRODUCT” position and the timing pump will not start.
F. Removethegapgaugeandreassemblethevalve. Ensurethevalveisproperlyandcompletely
assembled.
G. DivertValve-Removethe lower bodyfromthevalve. Turnthe selector switch tothe"Inspect""
position. (Aftertime delay, valve will switch position.) Unscrew the valve stem off the actuator
stem enough to insert the gap gauge between the two stems. Tighten the valve stem onto the
gaugeas shown in Figure 4.
INSTALLATION

11
H. Turn the selector switch to the “PRODUCT” position and the timing pump will not start.
I. Removethegapgaugeandreassemblethevalve. Ensurethevalveisproperlyandcompletely
assembled.
ALTERNATETESTMETHODCANALSOBEUSEDTOTESTTHEMICROSWITCHADJUSTMENT.
Note: Theseareunofficialtestmethodsfortroubleshootingpurposesonly.
A. Turnofftheairsupplytothevalves.
B. PlacethetemperaturesensingelementoftheSafetyThermalLimitRecorderControllerinwater
thatisabovelegalpasteurizationtemperature.
C. Slowly adjustthe filter regulator to admitair to thevalve actuator.When valve stem movesdown
1/16", the red lightshould go out for bothvalves and the green light comes onwhen the divert
valve is tested. If the valves do not meet either of these tests. the microswitch must be adjusted.
Refertotopic“ADJUSTMENTS”.
4. MICROSWITCHTESTfor762-227MRAL. Themicroswitchesinthevalvearesafetydevices.They
are adjusted so that the timing pump will not run, at sub-legal pasteurization temperatures, unless
thevalves are completelyand properlyassembled. To testthe microswitch adjustment:
A. Makecertainthevalvesareproperlyassembled,paying particular attention totheactuator
mounting bolts, yoke mounting bolts, body clamps, and the valve stem to actuator stem
connection. Ensure that the nylon locking pin is in place on the actuator shaft threads. The pin
should be replaced each time the stems are decoupled.
B. MakesurethetemperaturesensingelementoftheSafetyThermal Limit Recorder Controller is
belowlegalpasteurizationtemperature.
C. Momentarily turn on the timing pump to make sure it is operating properly, and then turn it off.
D. Switch the valve to the forward flow position by selecting the inspect position on the panel (Note:
Aftertimedelay valve willswitch position.)
E. Remove the tri-clamp that attaches the bonnet / clear plastic stem guard assembly. Slide the
assembly off the stem.
F. Unscrew the nut at the end of the exposed stem for stem removal.
G. Slide the stem and o-ring off the stem connected to the actuator.
Figure5: 762-227MRALGaugePlacement
INSTALLATION

12
H. Slide the gauge (stored inside control housing) onto the stem connected to the actuator.
Reassemble the two stems together without the o-ring and tighten the nut to secure the gauge
between the two stems. See Figure 4.
I. Apply requiredair to theactuator fornormal operating conditions.
ACTUATORAIRPRESSUREREQUIREMENTS
VALVE SIZE PSIG
270
21/270
370
J. Turn the selector switch to the “Product” position and the timing pump will not start.
K. Removethegaugeandreassemblethevalve.Ensurevalveisproperlyandcompletely
assembled.
L. Repeatsteps D-Lwiththedivertvalve.
AN ALTERNATE TEST METHOD CAN ALSO BE USED TO TEST THE MICROSWITCH
ADJUSTMENT.
Note: Theseareunofficialtestmethodsfortroubleshootingpurposesonly.
A. Turnofftheairsupplytothevalves.
B. PlacethetemperaturesensingelementoftheSafetyThermalLimitRecorderController
inwaterthatisabovelegalpasteurizationtemperature.
C. Slowly adjustthe filterregulator toadmit air to the valve actuator. Whenvalve stem
movesdown 1/16", thered lightshould goout for bothvalves andthe green light comes
onwhen the divertvalve is tested.If the valves do not meet either of these tests, the
microswitch must be adjusted. Refer to topic “Adjustments”.
5. MICROSWITCHADJUSTMENTfor762-227&862W-227. TheFlo-DiversionValveisprecision
equipment,andhasbeencarefullymanufacturedandadjustedbeforeleavingthefactory.As
isthe case with most precision machinery however, the adjustments may have been
disturbedduringshippingorinstallation.Therearethree adjustments that canbemade.The
microswitch adjustment is most critical because of the switch function in controlling the
timing pump and indicating lights. The other two adjustments are on the timers used to
sequencethevalves during thecleaningcycle, and thetimedelay betweenopeningof the
divertvalvetoforwardflowandtheopeningoftheleakdetectorvalvetoforwardflow
position.
Followthemicroswitch adjustment instructionsbelow for theleakdetect valveandthen begin again
withstep“A”forthedivertvalve.
A. Check the valve to make sure it is properly and completely assembled.
CAUTION
Turn off electrical power to the valve and shut off air
supply.
INSTALLATION

13
B Removethevalvebodyclampandtheuppervalveportclampontheleakdetectvalve.
Thiswill allowaccess tothe valve stem when the valve is lifted off the lower body. The
divertvalverequiresremoval ofthelowerbodyforaccesstothevalvestem.
C Apply air to the actuator to move the stem off the upper seat. Loosen, by unscrewing,
thevalvestem enough to insert thegapgaugebetweentheactuatorstemandthevalve
stem.Tighten thevalvestemontothegauge.Remove airfromtheactuator.
D. Removethefourscrewsthatsecurethegreencontrolhousingcoverandremovethecover.
E. Loosen the microswitch mounting screws just enough to move the switches. Position the
microswitches by starting with the switch above the indicating nut. Move the switch down until
the roller on the switch is just below the flat on the indicating nut and deactivates the switch.
Tightenmicroswitchmountingscrews.
F. Removethegapgauge by applying airtotheactuator and looseningthevalvestem. Then
tighten the valve stem to the actuator stem. remove air to the actuator. the microswitch should
bepositioned in the activated positioned.
G. Securethe green switchhousingcoverwith the fourmountingscrews. Reassemblethe valve to
thevalve bodyand to the process line.
H. Turn the power on and test the mircroswitch as described in the topic "Microswitch Test."
G. Unscrew the nut at the end of the exposed stem for stem removal.
H. Slide the stem and o-ring off the stem connected to the actuator.
5. MICROSWITCHADJUSTMENTfor762-227MARL. TheFlo-DiversionValveisprecisionequipment,
andhas been carefullymanufactured andadjusted beforeleaving the factory.As isthe case with
mostprecisionmachineryhowever,theadjustmentsmayhavebeendisturbedduringshippingor
installation. There are three adjustments that can be made. The microswitch adjustment is most
critical because of the switch function in controlling the timing pump and indicating lights. The other
two adjustments are on the timers used to sequence the valves during the cleaning cycle, and the
timedelaybetweenopeningofthedivertvalvetoforwardflowandtheopeningoftheleakdetector
valvetoforwardflowposition.
A. Checkthe valve toensure it isproperly and completely assembled.
B. Switch the valve to the forward flow position by turning the selector switch on the panel to the
"inspect"position. This will allowremoval of oneof the valve stems.
C. Removethefourscrewsthatsecurethegreencontrolhousingcoverandremovethecover.
D. Remove the Tri-clamp that attaches the bonnet / clear plastic stem guard assembly.
E. Slide the bonnet / stem guard assembly off the stem.
CAUTION
Switch the valve to the forward flow position. This will
allow removal of one of the valve stems.
INSTALLATION

14
F. Unscrew the nut at the end of the exposed stem for stem removal.
G. Slide the stem and o-ring off the stem connected to the actuator.
H. Slide the gauge ( stored inside control housing ) onto the stem connected to the actuator.
Reassemble the two stem together without the o-ring and tighten the nut to secure the gauge
between the two stems.
I. Positionthevalveinthedivertflowposition.
J. Loosen the switch mounting screws just enough to allow adjustment of the switch assembly.
Begin adjustment with the switch roller on the indicating nut flat. Slide the switch assembly
downuntilthe switch becomesdeactivated. Tighten themounting screws.
L. Replace the gauge with the o-ring. Tighten the nut to secure the two stems together. Slide the
bonnet / stem guard assembly onto the stem and secure with the tri-clamp.
M. Place the gauge in the vacant switch tracks of the control housing. Secure the green switch
coverwiththefourmountingscrews.
CIP CAM TIMER (CTL) ADJUSTMENT
The CIP timer is comprised of a drive motor, a camshaft with three sets of cams which are adjustable,
and three switches which are activated by the cams. The timer motor drives the camshaft at 1/4RPM.
The adjustable cam can be set to engage the rollers for any portion of a revolution. The adjustable cam
is set on a percentage of on - off time, that is, if the cam is set for forty-five seconds off time, the
percentage of off time is 20%. The cams are from left to right: the homing cam: the divert valve cam:
and, the leak detect valve cam. The purpose and settings for these cams are as follows:
Figure 6: CIP Timer Adjustments
Homing Cam
This cam and its associated circuitry is used to return the timer to its starting position if the selector
switch moved from the clean position. The homing cam switch is wired to the timer drive motor. This
permits the timer motor to keep driving the cam shaft until the homing cam switch is opened by the
dip in the cam. The normal setting for this cam is one second or less.
INSTALLATION

15
Divert Valve Cam
This cam and its circuitry controls the divert valve opening and closing during the cleaning cycle. The
switch is wired into the circuit for solenoid valve (SV1) When the switch is activated by the cam, the
solenoid is energized allowing air into to the divert valve actuator. The normal setting for this cam is
forty seconds or 16% of off time.
Leak Detect Valve Cam
This cam and its circuitry controls the leak detect valve opening and closing during the cleaning cycle.
The switch is wired into the circuit for solenoid valve (SV2), with operation the same as the divert
valve. The normal setting for this cam is one minute or 25% of off time.
Timer (CRT1)
The (CRT1) timer controls the time delay of the leak detect valve following the divert valve assuming
forward flow. This delay is necessary to prevent possible forwarding of unsafe product. The timer is
adjustable from 0-30 seconds. The time delay is adjusted by turning the wheel to the right to decrease
the time and to the left to increase the time. The time delay can be tested by depressing the button on
the relay and measuring the time required for it to release. The normally closed contacts are delayed
in closing when delay is de-energized. Set at one to five seconds.
Time Delay Relay (CRT2)
This relay is energized when the selector switch is placed in the “product” position. It delays valve
operation until the timing pump is completely stopped. The time delay is adjusted by turning the wheel
to the right to decrease the time and to the left to increase the time. The time delay can be tested by
depressing the button and measuring the time required for it to release. The normally closed contacts
are delayed in closing when relay is de-energized. Set at fifteen seconds or until the pump runs
down.
Time Delay Relay (CRT3)
This relay is energized when the timing pump circuit is completed. The relay is an off delay timer that
maintains the timing pump starter while the STLR Controller is diverting the valves. This allows the
use of pushbuttons from remote starting locations. Set at one second maximum.
Timer (CRT5)
This timer is energized when the selector switch is placed in the clean position. It delays CIP valve
sequencing for ten minutes and keeps the system in diverted flow. When the timer has timed out the
CIP timer cycles as described above. Set at ten minutes.
INSTALLATION

16
The Flo-Diversion Valve is used in the food processing industry and therefore is subject to frequent
cleaning. The clean-in-place (CIP) capability permits cleaning of the process passages and the
components that come in contact with the product, without dismantling the valve. The entire cleaning
process is accomplished automatically once the selector switch has been placed in the “clean’’
position. The cleaning fluid is introduced into the system and follows the same flow pattern as the
process liquid. The cam timer (CT1) in the control unit is programmed to sequentially energize the
solenoid valves supplying air to the valve actuators.
The valves are completely flushed in the divert, leak detect and forward flow positions each time the
timer makes a complete revolution. The cleaning cycle will be repeated until the selector switch is
moved off the clean position.
The cleaning cycle timer (CT1) is based on four minute revolution of the timer cams. The cams are
preset at the factory to produce a forty second flush of the divert valve and piping, a twenty second
flush of the leak detect port, and a three minute flush of the product line. If longer or shorter flush
cycles are desired, refer to topic Timer Adjustment.
CLEANING
MAINTENANCE

17
The Flo-Diversion Valve has been designed to provide many years of trouble-free service with a
minimumamount of maintenance. The only maintenance required otherthan periodic inspection of the
valves and occasional replacement of worn or faulty components, is keeping the air supply to the
valves constant, and clean. This is accomplished by daily opening the drain valve on the air filter, thus
allowing the air system to purge itself of water, oil, and other dirt. Also blow out the receivers on the air
compressor periodically. Refer to the applicable instructions supplied with the compressor.
Inspection of the valve components should be accomplished on a regularly scheduled basis, to assure
maximum efficiency of the Flo-Diversion Valve. Refer to topic Disassembly for the necessary
disassemblyprocedures.
This section describes complete disassembly of the valves, actuators and the control unit. Although
complete disassembly is covered, it is only intended as a guide. The valves, actuators and control unit
should be disassembled to the extent necessary for inspection or needed repair.
762-227 & 862W-227 VALVE DISASSEMBLY
1. Besurethetiming pump isturnedoff. Remove thelower body lineclampson the divertvalveand
theupper bodyoutlet lineclamp from the leak detect valve.
2. Removedivertvalvebodyclampandseparatethelowerbodyfromtheupperbody.
3. Removeleakdetectbodyclampandseparatetheuppervalveassemblyfromthelowervalvebody.
4. Move selector switch on the control unit to the “inspect” position to extend valve stems for removal.
5. Afterthevalveshaveassumedtheinspect positionunscrewthevalvestemsfromtheactuator
stems.
6. Disconnect electrical power to the control housing and shut off air supply to the valves.
7. Separateuppervalvebodyfromyokebyremovingthreebolts.Removesplitbushing,sleeveando-
ringfromupperbody.
8. Separateyokefromactuatorbyremovingfourbolts.Removegreenbushingretainerando-ring
betweenyokeandactuator.
MAINTENANCE
INTRODUCTION
DISASSEMBLY
WARNING
To prevent personal injury, relieve pipe line pressure
and drain all fluid completely before servicing.

18
762-227MRAL VALVE DISASSEMBLY
1. Besure the timing pump is turned off. Remove the four tri-clamps that connect the valve to the
processsystem.ToseparatetheFlo-DiversionValveintotwovalvesremovethetri-clampthat
connectsthevalvestogether.
2. RemoveTri-clampandseparatethebonnet/endcapassemblyfromthevalvebody.Removethe
four screws and washers to separate the bonnet from the end cap. Pull the clear plastic stem
guard out of the end cap.
3. Removeo-ringfromtheendcapandtheo-ringandbushingfromthebonnet.
4. Apply air to actuator for stem removal. Unscrew the stem nut and remove the stem and o-ring.
5. Removeairtotheactuator.
6. Remove the clamp that connects the actuator, bonnet, yoke and stem assembly to the valve
body.
7. Unscrew the stem from the actuator shaft.
8. Separatebonnetfromyokebyremovingthreebolts.Removebushingando-ringfromvalvebonnet.
9. Separateyokefromactuatorbyremovingfourbolts.Removegreenbushingretainerando-ring
betweenyokeandactuator.
10. Removethetwoclampsand gaskets toseparatetheremainingvalve body assembly.
ValveBodySeats
Inspect for nicks and scratches and other signs of excessive wear. Leakage past the seats may
result from these types of irregularities.
Valve Stem & Seats
Inspect rubber or PTFE seats for signs of cracking, tearing, checking, or excessive wear. Note:
Refer to TR-Seat Replacement Section for installation of TR Seats. Inspect stem finish for galling,
nicks, or scratches. Leakage may result from these irregularities.
Split Bushing
Inspect for signs of cracks, nicks, scratches or excessive wear on inside diameter. A worn bushing
will not properly align valve stem.
O-Rings
Inspect for cuts, abrasions, flat spots, or other damage that would cause leakage of ineffective
MAINTENANCE
VALVE COMPONENT INSPECTION

19
cleaning.
1. Disconnect the Cable. Unscrew the knurled ring of the cable counter clockwise. After the threads
disengage,pullthe cableoffof theconnector.
2. RemoveTheRearCover. Removethe4coverscrewsando-ringslocatedinthescrewholecounter
bores. Remove the electrical connector. Remove each of the wires from the male pins of the
connector. Grasp each wire at the base of its terminal connection. Use of needle nose pliers is
recommended.Takecarenot to damage thewireinsulationor crimp theterminal.Removethe
electrical connector nut by turning counter clockwise. Push the electrical connector through the hole
intherearcover. Removetherubberelectricalconnectorgasket. Removetherearcovergasket.
3. RemovetheFront Cover. Loosen the fourcoverscrewsuntiltheydisengagetheirmountingholesin
thebase.Removethecovergasket.
4. Remove the switches. Remove both white wire harness connectors from the switches. Pull the
wires of the harness through the access hole on the base. Loosen the switch mounting screws by
2 turns. Slide the switches and their black mounting blocks completely from the guide tracks in the
base.
5. Removethesolenoid.
NOTE: Not every control top contains a solenoid. Continue to the next step if no solenoid is
present. Pull the two solenoid wires through the access hole. Remove the two
mountingscrewsfasteningthesolenoid. Removethesolenoidandtriangularselector
blocklocated underthe solenoid.
6. Removethe control top base fromthe actuator. Remove all the airline connections from the
base. Remove the three screws from inside the base, and the one bolt outside the base
located below the rear cover. Pull the base straight up and away from the actuator.
NOTE: The green bearing retainer might remain attached to the base. It will come out of its counter
bore in the base when it hits the activating nut. Be aware that a small amount of impact is
required to dislodge it from the base.
CONTROL TOP DISASSEMBLY
To prevent personal injury, disconnect all electrical
and pneumatic power to the control top. Hazardous
voltage can cause electrical shock. The actuator
stem moves with extreme force and suddenness.
WARNING
MAINTENANCE

20
Bushings guide the actuator stem while packings provide sealing around the stem.
The bushing and packing should both be replaced if one or the other fails. Even if
only one end fails both ends of the actuator should be serviced. Disconnect and
remove actuator completely from valve before proceeding with the steps below, see
VALVE DISASSEMBLY and CONTROL TOP DISASSEMBLY.
1. Attach the indicating nut to the actuator stem with the retaining rings on the
Control Top end and screw on a 5/8nut to the actuator stem threaded end.
2. Apply 60 PSIG to the unthreaded air holes in the actuator end caps to blow out
the packings and bushings. The nuts on the actuator stem will prevent the
bushingform flying offthe end of the actuator stem.
3. Removeair supplyoncethebushingandpacking are forced out.
4. Wipestemclean.Lubricate newpackingwith Tri- cloverC137lubricant.
5. Slide new packing over the stem with the “V” side facing the actuator.
Partially insert packing into smallest counter bore using a flat tool to assist
theouterlip.DONOTDAMAGEOFROLLTHEPACKINGLIPDURING
INSTALLATION.
6. Place bushing on top of the packing. Push on the bushing until outer flange
is flush with actuator.
ACTUATOR STEM NYLON LOCK REPLACEMENT
The Nylon Locking Pin located in the middle of the stem thread keeps the valve stem from becoming
loose due to vibrations. After every disassembly, the nylon locking pin must be replaced. Punch out the
old nylon pin with a 1/8inch (3mm) or smaller diameter punch. Insert a new nylon locking pin.
ACTUATOR LUBRICATION
For optimum performance, lubricate once annually. Inject 5cc of STP * into the unthreaded thru hole in
each end of the actuator. Roll actuator on a flat surface repeatedly to obtain uniform coverage of
lubricant. Do not over lubricate. This is not a remedy for actuator failure.
ACTUATOR BUSHING / PACKING REPLACEMENT
To prevent personal injury, do not attempt to cut
actuator open. The actuator spring is compressed
and under load.
WARNING
MAINTENANCE
Figure7
Figure8
Air