Alfalaval Unique 7000 Series User manual

Unique 7000 Flo-Diversion Valve
Instruction Manual
2017-02

Thank you for purchasing an Alfa Laval Product!
This manual contains installation, operation, and repair instructions, Flo-Diversion Valves designed and manufactured by Alfa Laval
Inc. It also provides a troubleshooting chart to assist in determining electrical and mechanical malfunctions, if they should occur.
READ THIS MANUAL carefully to learn how to service and recongure these valves. Failure to do so could result in personal injury
or equipment damage.
The information herein is correct at the time of issue but may be subject to change without prior notice.
Table of contents
Introduction and specifications
Valve Assembly Nomenclature ................................................................................................ 6
Actuator Specifications..........................................................................................................................................................7
Air Supply Requirements .......................................................................................................................................................7
Performance and Dimensions................................................................................................................................................8
Pressure/Capacity Limits .......................................................................................................................................................8
Performance Unique 7640 Valves..........................................................................................................................................8
Performance and Dimensions Reverse-Acting .......................................................................................................................9
Pressure/Capacity Limits .......................................................................................................................................................9
Installation
Unpacking Equipment .........................................................................................................................................................10
Installing the Equipment ......................................................................................................................................................10
Installation
Pneumatic Connections with Solenoid in-top.......................................................................................................................11
Pneumatic Connections with External Solenoid ...................................................................................................................11
Electrical connection, internal ..............................................................................................................................................12
Air connections
Valves with solenoid in ThinkTop..........................................................................................................................................12
Operations
Operating Modes ................................................................................................................................................................13
Flush Mode .........................................................................................................................................................................14
Forward Flow Mode ............................................................................................................................................................15
ThinkTop for FDV Addendum
ThinkTop Indication Specifications .......................................................................................................................................16
Valve Assembly Test and Sealing Instructions ......................................................................................................................17
Recommended Cleaning
Recommended Cleaning .....................................................................................................................................................18
Troubleshooting Guidelines
Mechanical trouble ..............................................................................................................................................................20
General Maintenance
General Maintenance ..........................................................................................................................................................21
Disassembly - Standard Flow Diversion Valve ......................................................................................................................23
Disassembly - Reverse-Acting Valve ....................................................................................................................................24
Bushing and seat/seal replacement.....................................................................................................................................25
Actuator bushing replacement.............................................................................................................................................26
Dismantling of optional maintainable actuator......................................................................................................................26
Assembly of maintainable actuator ......................................................................................................................................26
Spare Parts List
Unique 7000 Standard Flow Diversion Valve Exploded View................................................................................................27
Unique 7000 Standard Flow Diversion Valve Part Numbers .................................................................................................28
Reverse-Acting Valve Spares Exploded View.......................................................................................................................29
Reverse-Acting Valve Spare Part Numbers ..........................................................................................................................30
Failed Closed Actuator for Reverse Acting Exploded View...................................................................................................31
Failed Open Actuator for Standard Exploded View ..............................................................................................................31
Unique 7000 Maintainable Actuator - Flow Diversion Valve Part Numbers ...........................................................................32
ThinkTop Exploded View .....................................................................................................................................................33
ThinkTop Part Numbers.......................................................................................................................................................34

5
All warnings in the manual are summarized on this page.
Pay special attention to the instructions below so that severe personal injury and/or damange to the valve are avoided.
Installation
- Always read the technical data thoroughly.
- Always release compressed air after use.
- Never touch the moving parts if the actuator is supplied with compressed air.
- Never touch the valve or the pipeline when processing hot liquids or when sterilizing.
- Never dismantle the valve with valve and pipelines under pressure
- Never dismantle the valve when it is hot
Operation
- Never dismantle the valve with valve and pipelines under pressure.
- Never dismantle the valve when it is hot.
- Always read the technical data thoroughly.
- Always release compressed air after use.
- Never touch the valve or the pipelinees when processing hot liquids or when sterilizing.
- Never touch the moving parts if the actuator is supplied with compressed air.
- Always rinse well with clean water after the cleaning.
- Always handle lye and acid with great care.
Maintenance
- Always read the technical data thoroughly.
- Always release compressed air after use.
- Never service the valve when it is hot.
- Never service the valve with valve and pipelines under pressure.
- Never stick your ngers through the valve ports if the actuator is supplied with compressed air.
- Never touch the moving parts if the actuator is supplied with compressed air.
Introduction and specifications

6
DETAIL A
SCALE 1 : 1
DETAIL B
SCALE 1 : 1
Introduction and Specifications
Valve Assembly Nomenclature
Models: 7640, 7650 (optional reverse-acting tangential)
Sizes: Std. valve 1½", 2", 2½", 3"
RA 2", 2½", 3", 4"
Features: Design based on U7000 Series valve.
Control top available with or without solenoid valves.
Available with either TR2 or elastomer seat rings. RA valve, elastomer seat only.
Fully maintainable.
Use valves with existing control panel or new Alfa Laval PLC control panel.
Control Top
Quick
Exhaust
Yoke
One piece stem
Actuator
Bonnet/Stem Seal
Seat Seal Rings
Leak Detect Valve
Divert Valve
Divert Position
('A' LED)
Divert valve function. Both
valve tops will have ”A”
LED activated

7
Reverse-Acting Valve
pneumatic movement upwards
Standard Valve
pneumatic movement downward
Air Supply Requirements
Minimum Air Pressure: 70 PSI
Air Presure Range: 70-100 PSI
Air Volume Required: Air Consumption (In3 Free air) for one stroke
Valve Size 1" - 1½" 2" - 2½" 3" - 4"
NO and NC 0.96 x air pressure (PSI) 2.17 x air pressure (PSI) 5.51 x air pressure (PSI)
Introduction and Specifications
Actuator Specifications

8
Pressure/Capacity Limits
Performance Unique 7640 Valves
Valve size Max. Product
pressure (PSI)
Required air
supply (PSI)
Maximum Flow
Rates
1½" 87 50 GPM
2" 125 87 85 GPM
2½" 100 87 160 GPM
3" 100 87 200 GPM
Note!
For the diagram the following applies:
Medium: Water (68°F).
Measurement: In accordance with VDI 2173.
Performance and Dimensions
Valve Size 1½" 2" 2½" 3"
A 20.78 22.8 24.32 26.13
B 2.39 2.91 3.4 3.89
C 2.95 2.94 3.73 3.93
D 5.96 5.94 7.52 7.92
Stroke .067 0.87 0.87 1.06
Introduction and Specifications
D
B
C
E
A
B B
B
C
C
B
C D
A
C
C
B

9
Pressure/Capacity Limits
Performance Unique 7640 Valves
Note!
For the diagram the following applies:
Medium: Water (68°F).
Measurement: In accordance with VDI 2173.
Performance and Dimensions Reverse-Acting
Valve Size 2" 2½" 3" 4"
A 22.8 24.32 26.13 31.1
B 2.91 3.4 3.89 4.87
C 2.94 3.73 3.93 4.72
D 5.94 7.52 7.92 10.76
E Stem Up 51.1 56.9 63.5 76.7
E Stem Down 76.1 81.9 93.5 106.7
Stroke 0.87 0.87 1.06 1.06
Introduction and Specifications
Valve size Max. Product
pressure (PSI)
Required air
supply (PSI)
Maximum Flow
Rates
2" 125 87 85 GPM
2½" 100 87 160 GPM
3" 100 87 250 GPM
4" 45 87 485 GPM
D
B
C
E
A
B B
B
C
C
B
C D
A
C
C
B

10
Unpacking Equipment
The Flo-Diversion Valve should be unpacked immediately upon receipt from the factory and carefully inspected for damage that
may have occurred during shipping. The equipment should also be checked against the bill of lading to make sure there are no
shortages. Any damage or shortage should be immediately reported to the carrier.
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 for maintenance and disassembly.
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, and 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
oor, and appropriate xed platform may be required by state and federal regulators.
Installing the Equipment
Secure the valves to an adequate support, and connect the valves to the product piping. The valves are furnished with Tri-Clamp®
ttings for simplied connections. Make sure the piping is self-supporting and that the joints at the valves are properly aligned to
prevent strain on the valves.
Remove ThinkTops from their boxes and install on the valve actuators per installation instruction in ThinkTop manual section. Make
air connections as described on page 12. ThinkTops have been programmed at the factory prior to shipment. Conrm set up
with test procedures desccribed in tihs manual.
Air Supply
Connect a clean dry air supply. All air connections should be made with ¼ OD poly-o tubing or equivalent. Black or galvanized
pipe is not recommended. Before making nal connections blow out all air lines to remove scale, metal llings or other extraneous
particles.
Make sure that the air lines are connected to the proper valves. Quick couplers are not acceptable as air connection joints.
See air connections (next page) for valves with the solenoids in the ThinkTops. For valves with the solenoids at the panel, the air
lines will connect directly to the quick exhaust valve.
Installation
DETAIL A
SCALE 1 : 1
DETAIL B
SCALE 1 : 1
DETAIL B
SCALE 1 : 1
DETAIL C
SCALE 1 : 1
Hanger
support pipe
Support
Support

11
Normally Closed
RA with Solenoid in Top
Normally Open
STD with Solenoid in Top
AIR IN
Supply Air
OUT 1A
Air to Actuator
With Solenoid in Top
Normally Closed
RA with External Solenoid
Air From External Solenoid
Normally Open
STD with External Solenoids
Air From External solenoid
Pneumatic Connections with Solenoid in T-Top
Pneumatic Connections with External Solenoid
Installation
Pneumatic Connections with Solenoid in-top
Normally Closed
RA with Solenoid in Top
Normally Open
STD with Solenoid in Top
AIR IN
Supply Air
OUT 1A
Air to Actuator
With Solenoid in Top
Normally Closed
RA with External Solenoid
Air From External Solenoid
Normally Open
STD with External Solenoids
Air From External solenoid
Pneumatic Connections with Solenoid in T-Top
Pneumatic Connections with External Solenoid
Normally Closed
RA with Solenoid in Top
Normally Open
STD with Solenoid in Top
AIR IN
Supply Air
OUT 1A
Air to Actuator
With Solenoid in Top
Normally Closed
RA with External Solenoid
Air From External Solenoid
Normally Open
STD with External Solenoids
Air From External solenoid
Pneumatic Connections with Solenoid in T-Top
Pneumatic Connections with External Solenoid
Pneumatic Connections with External Solenoid

12
Installation
Electrical connection, internal
Input Solenoid 1 6
7
8
9
10
11
20
21
22
23
1
2
3
5
12
13
24
25
26
27
4
Supply + 24 VDC
Supply - 24 VDC
Earth
Solenoid Common
Legal PLC Output
Power Supply
Solenoid Common
Output Solenoid 1
W
iring to internal solenoid
Output - Valve in Divert Flow
Output - Valve in Forward Flow
PLC Inputs
P1
P2
Note: Terminals 6, 11, 20 and 21 are not used if Think Top was puchased without internal solenoid
for Forward Flow
Air connections
Valves with solenoid in ThinkTop
Cable Gland for
Electrical Connection
Air in
Solenoid valve
Air exhaust
Air out 1A

13
Operating Modes
The Flow Diversion device consists of two (2) valves. Each is a two-position, three-way valve connected by a common body. This
common body is the upper body of the Divert Valve and the middle body of the Leak Detect Valve. The air-to-raise actuators of
the two valves are connected to independent air supplies which cycle the valves to the three operating modes; Divert, Flush and
Forward Flow. A description of the three modes follows:
Divert Mode
Divert is the rst mode of operation assumed by the Flow Diversion Valve in the start-up procedure. Until a legal product
temperature is reached and normal system operation is established, the product is diverted to the Balance Tank. Stem position
can be seen by checking the valve stem in the open yoke portion of the valve.
The Divert Valve should be in the divert position when:
1. The control panel selector switch is in the Divert Position
2. The control panel selector switch is in the "off" position.
3. The power supply is interrupted.
4. The air supply is interrupted.
5. Timing pump off
6. If meter base timing system (MBTS) equals non legal ow condition
7. If temperature is below the STRL cut in set point
1.
2.
A.
DETAIL A
SCALE 1 : 1
DETAIL B
SCALE 1 : 1
Divert Flow
B.
Standard Valve
1. Divert Valve
2. Leak Detect Valve
A. Product Inlet
B. To Balance Tank
C. Stems Raised
DETAIL B
SCALE 1 : 1
DETAIL C
SCALE 1 : 1
Reverse-Acting
1. Divert Valve
2. Leak Detect Valve
A. Product Inlet
B. To Balance Tank
C. Stems Lowered
1.
2.
A.
Divert Flow
B.
Operations
Divert Position
('A' LED)
Divert valve function. Both
valve tops will have ”A”
LED activated
Divert Position
('A' LED)
Divert valve function. Both
valve tops will have ”A”
LED activated

14
Flush Mode
In this mode, correctly pasteurized product ushes and clears the common body between the Divert Valve and the Leak Detect
Valve, prior to initiating product Forward Flow.
The ush time is controlled by a Flow Divert Valve controller. This control system is separate from the Divert and Leak Detect
Valves, but works in conjunction with them. The control system can be from several sources and of several designs but must be
approved by the FDA prior to use.
Product that ows through the valves in the Flush mode is returned to the Balance Tank through the Leak Detect Valve and the
Return Line. This line must be separate from the Divert Product Return Line, but both of these lines return the product to the
Balance Tank.
The valve stems will be in the position as shown in below. Note: ThinkTop LED activated.
NOTE: The Divert and Leak Detect valves are not considered self draining, so the "FLUSH MODE" position must be
held for not less than 1 second, no more than 5 seconds per PMO, before the valves are placed in the full forward flow
position.
1. Divert Valve
2. Leak Detect Valve
A. Product Inlet
B. To Balance Tank
Standard Valve
Operations
DETAIL A
SCALE 1 : 1
DETAIL B
SCALE 1 : 1
1.
2.
A.
B.
Leak Detect Flow
Forward Flow
('B' LED)
Divert Valve
Divert Position
('A' LED)
Leak Detect Valve
Flush valve function. Divert valve
will have “B” LED activated and
Leak Detect will have “A” LED
activated.
Reverse-Acting
DETAIL B
SCALE 1 : 1
DETAIL C
SCALE 1 : 1
1.
A. B.
Leak Detect Flow
2.
Forward Flow
('B' LED)
Divert Valve
Divert Position
('A' LED)
Leak Detect Valve
Flush valve function. Divert valve
will have “B” LED activated and
Leak Detect will have “A” LED
activated.

15
Forward Flow Mode
Forward Flow is the nal operating mode of the Flow Diversion Valve. Product ows through both valves to the cooling sections of
the pasteurization system.
For the Forward Flow mode to be maintained:
1. The legal set temperature must be maintained.
2. The power supply and air supply must be maintained.
3. Timing pump operating
4. If meter base timing system (MBTS) is maintaining legal ow condition
5. If temperature is above STRL cut in set point
Operations
Standard Valve
1. Divert Valve
2. Leak Detect Valve
A. Product Inlet
B. Stems Lowered
C. Forward Flow
Forward Flow
DETAIL A
SCALE 1 : 1
DETAIL B
SCALE 1 : 1
1.
2.
A.
C.
Reverse-Acting
1. Divert Valve
2. Leak Detect Valve
A. Product Inlet
B. Stems Raised
C. Forward Flow
DETAIL B
SCALE 1 : 1
DETAIL C
SCALE 1 : 1
Forward Flow
1.
2.
A.
C.
Forward Flow
('B' LED)
Forward Flow valve
function. Both valves will
have “B” LED activated.
Forward Flow
('B' LED)
Forward Flow valve
function. Both valves will
have “B” LED activated.

16
ThinkTop for FDV Addendum
ThinkTop Sensor Adjustment
Break sealing wire on cover. Loosen four (4) screws and remove domed cover. Locate buttons I and II on the side of the sensor.
Using the I and II buttons, you will set the valve position sensor to control the timing pump and indication lights. With the valve
completely and correctly assembled, you will set and save the proper indication positions for divert and forward ow using the
steps below.
ThinkTop Indication Specifications
ThinkTops use micro chip sensor technology which provides a more accurate position sensing than mechanical switches. The
micro chips in the sensor, utilizing a principle called the Hall Effect, calculate the position of the indicating target to a very high
degree of accuracy. This enables the sensor to detect even the slightest change in stem position.
The ThinkTop provides a sensor band width of 1.5 mm (0.059") accurate to 0.004". In contrast, a micro-switch roller can travel
more than 1.6 mm (0.063") without an indication signal change. See Figure A, next page.
Further, the ThinkTop sensor has no moving parts to contacts to wear or break, so there is very little maintenance required.
The ThinkTop also provides visual indication lights to show valve position.
Note: Prior to attempting to program the ThinkTop sensor ensure that the test spacer in inserted in the magnet asembly
and that all electrical and air connections have been made.
Push: I – and wait until red LED ashes
Push: I
Push: II – hold for 5 sec - until LED lights ash
Push: II (red + yellow LED) Prog 1
Push: II (red + yellow + green LED) Prog 2
Push: II (red + yellow + green + orange LED) Prog 3
Push: II (red + yellow + green + orange + yellow LED) Prog 4
Push: I – to approve program 4 setup
Push: II – to approve valve in divert position
Activate solenoid - forward ow position
Push: II – to approve valve is in forward ow position
Push: I Move to next (no upper seat-lift)
Push: I Move to next (no lower seat-lift)
Push: I Move to next (no selfadjustment)
Push: I Move to next (no maintenance)
Push: II red LED ashes (save & exit by push)
Sealing wire
thumb screw
B: Open valve - Valve in forward ow
position (yellow)
D: Set up
(red)
C: Not used
(yellow)
E: Internal solenoid valve energized
for forward ow - if supplied (green)
F: Maintenance
(Orange)
A: Closed valve - valve in Divert Flow
position (yellow)
Set up button I
Set up button II
Figure 2
Figure 1

17
ThinkTop for FDV Addendum
Figure 1 Figure 2 Figure 3
Test
spacer
CORRECTIVE ACTION: If the flow promoting device (timing pump) fails to respond as indicated in the above described
procedure, an immediate check of the Flow Diversion Valve assembly, ThinkTop adjustment and wiring is required to
locate and correct the cause.
Figure A
Valve Assembly Test and Sealing Instructions
The ThinkTop sensors on these valves are safety devices. They are adjusted so
that the timing pump will not run, at sub-legal pasteurization temperatures, unless
the valves are completely and properly assembled.
To test the sensor adjustment:
A. Make certain the valves are properly assembled, paying particular attention
to the actuator mounting bolts, yoke bonnet and body clamps, and the valve
stem to actuator stem connection.
B. Make sure the temperature sensing element of the Safety Thermal Limit
Recorder Controller is below legal pasteurization temperature.
C. Momentarily turn on the ow promoting device (timing pump) to make sure it
is operating properly, and then turn it off.
D. Break seal wire on ThinkTop cover hold down screws, loosen screws and
remove cover.
E. Test gauge spacer installed at top of magnet. (Figure 1)
Sealing wire
thumb screw
F. Push down on outer ring of indication stem magnet and remover spacer between the stem and magnet. (Figure 2)
G. Apply required air to the actuator for normal operating conditions.
H. Turn the selector switch to the “Product” position and the ow promoting device (timing pump) will not start. (Figure 3)
I. Replace the gauge and reassemble the valve. Ensure valve is properly and completely assembled. (Figure 1)
J. Repeat steps D - I with the divert valve.
K. When positive test results are obtained, attach new seal wire Through the hole of the 2 provided thumb screws on ThinkTop
cover as noted on Figure A.

18
Recommended Cleaning
Recommended Cleaning
The valve is designed for cleaning in place (CIP). CIP = Cleaning In Place. Study the instructions carefully and pay
special attention to the warnings!NaOH = Caustic Soda.
HNO3 = Nitric acid.

19
Recommended Cleaning

20
Troubleshooting Guidelines
The Flo-Diversion valve is relatively maintenance free with the exception periodic inspection. As with any precision equipment,
however, occasional problems can arise. The troubleshooting chart provides a means of determining and correcting most
mechanical and electrical problems.
Note: The troubleshooting chart is divided into two parts, one mechanical and electrical.
Mechanical trouble
Problem Probable Cause Remedy
1. Response time above one second. a. Faulty Quick Exhaust.
b. Defective solenoid valve.
c. Broken diaphragm on quick exhaust
valve.
a. Inspect air lines for leaks or
obstructions and take necessary
corrective action.
b. Test Filter-Regulator and repair or
replace if defective.
c. Test solenoids. Replace if necessary.
d. Replace diaphragm.
e. Check for excessive back pressure.
2. Valves will not assume forward ow
position at any selection switch
setting.
a. Inadequate air supply.
b. Capillary tube of pressure-thermo
switch in controller is broken or
leaking.
c. Electrical difculties.
a. Check air system as described above.
b. Replace switch, refer to controller
manual.
c. Refer to electrical troubleshooting
chart and take corrective action.
3. Valve will not assume divert position. a. Quick exhaust valve is not functioning
properly.
b. Obstruction in divert or leak detector
valve.
a. Inspect quick exhaust valve and
remove obstruction or replace valve.
b. Disassemble valve and remove
obstruction.
4. Timing pump will not start. a. Timing pump switch is not on.
b. One or both valve plug assemblies are
not properly connected to actuator
stem.
a. Turn on switch.
b. Assemble valve stems to actuator
stems correctly.
c. Check for proper adjustment of
ThinkTop.