Alfalaval Unique Mixproof CP-3 User manual

2319-0030
ESE02710-ENUS1 2014-05
Original manual
Instruction Manual
Unique Mixproof CP-3

Table of contents
The information herein is correct at the time of issue but may be subject to change without prior notice
1. Introduction ............................................................................................ 5
2. Safety .................................................................................................... 6
2.1. Important information ............................................................................. 6
2.2. Warning signs ..................................................................................... 6
2.3. Safety precautions ................................................................................ 7
3. Installation .............................................................................................. 8
3.1. Unpacking/intermediate storage ................................................................ 8
3.2. Recycling .......................................................................................... 11
3.3. General installation ................................................................................ 11
3.4. Welding ............................................................................................ 13
3.5. Pneumatic functions .............................................................................. 14
3.6. Valve position indication .......................................................................... 15
3.7. Adjustment of indication ......................................................................... 16
3.8. Regulatory Inspection ............................................................................ 18
3.9. Electrical connection chart ....................................................................... 19
4. Operation ............................................................................................... 21
4.1. Operation .......................................................................................... 21
4.2. Recommended cleaning ......................................................................... 22
4.3. Troubleshooting and repair ...................................................................... 27
5. Automation ............................................................................................. 28
5.1. Specifications ..................................................................................... 28
5.2. Installation ......................................................................................... 34
5.3. Setup diagram .................................................................................... 37
5.4. Maintenance ....................................................................................... 42
6. Maintenance ........................................................................................... 44
6.1. General maintenance ............................................................................. 44
6.2. Dismantling of valve .............................................................................. 45
6.3. Lower plug, replacement of radial seal ......................................................... 48
6.4. Upper plug, replacement of axial seal .......................................................... 51
6.5. Assembly of valve ................................................................................. 53
6.6. Dismantling of actuator ........................................................................... 58
6.7. Assembly of actuator ............................................................................. 60
7. Technical data ......................................................................................... 63
7.1. Technical data ..................................................................................... 63
8. Parts list and service kits ............................................................................ 64
8.1. Actuator ............................................................................................ 64
8.2. Plug setup overview .............................................................................. 66
8.3. Plug setup 3 ....................................................................................... 70
8.4. Plug setup 4 ....................................................................................... 74
8.5. Plug setup 5 ....................................................................................... 78
8.6. Plug setup 6 ....................................................................................... 82
8.7. Plug setup 11 ..................................................................................... 86
8.8. Plug setup 12 ..................................................................................... 90
8.9. Plug setup 13 ..................................................................................... 94
8.10.Plug setup 14 ..................................................................................... 98
3

Table of con ten t s
The information herein is correct at the time of issue but may be subject to change without prior notice
8.11.Plug setup 17 ..................................................................................... 102
8.12.Plug setup 18 ..................................................................................... 106
8.13.Plug setup 19 ..................................................................................... 110
8.14.Plug setup 20 ..................................................................................... 114
8.15.Valve body ......................................................................................... 118
8.16.Axial installation tool (upper plug) ............................................................... 120
8.17.Radial installation tool (lower plug) .............................................................. 121
4

1 Introduction
Thank you for purchasing an Alfa Laval product.
This manual has been provided to instruct you in how to operate and service this product correctly and safely. Make sure that
you follow all directions and instructions; failure to do so could result in personal injury or equipment damage.
This manual 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 Laval’s commitment to our customers who operate and
maintain their equipment as this manual dictates. Failure to do so may result in loss of warranty.
Where defects appear on the product during the warranty period, Alfa Laval will take back the product and correct the problem.
Should the equipment be modified or not kept in the manner prescribed within this manual, the warranty will become null and void.
5

2 Safety
Unsafe practices and other important information are emphasised in this manual.
Warnings are emphasised by means of special signs.
2.1 Important information
Important information
Always read the manual before using the valve!
WARNING
Indicates that special procedures must be followed to avoid serious personal injury.
CAUTION
Indicates that special procedures must be followed to avoid damage to the valve.
NOTE
Indicates important information to simplify or clarify procedures.
2.2 Warning signs
General warning: Caustic agents: Cutting danger:
6

2 Safety
Unsafe practices and other important information are emphasised in this manual.
Warnings are emphasised by means of special signs.
2.3 Safety precautions
Installation:
Always
read the technical data thoroughly (see section 7 Technical data)
Always
release compressed air after use
Never
touch the clip assembly or the actuator piston rod if the actuator is supplied with compressed air
(see warning label)
Never
stick your fingers through the valve ports if the actuator is supplied with compressed air
O
Operation:
Always
read the technical data thoroughly (see section 7 Technical data)
Never
touch the clip assembly or the actuator piston rod when the actuator is supplied with compressed
air (see warning label)
N
Never
pressurise air connections (AC1, AC3) simultaneously as both valve plugs can be lifted (can cause mixing)
Never
touch the valve or the pipelines when processing hot liquids or when sterilising.
Never
throttle the leakage outlet
Never
throttle the CIP outlet, if supplied
Always
handle lye and acid with great care
Maintenance:
Always
read the technical data thoroughly (see section 7 Technical data)
Always
fit the seals correctly
Always
release compressed air after use
Always
remove the CIP connections, if supplied, before service.
Never
service the valve when it is hot
Never
pressurise the valve/actuator when the valve is serviced
Never
stick your fingers through the valve ports if the actuator is supplied with compressed air
Never
touch the clip assembly or the actuator piston rod if the actuator is supplied with compressed air
(see warning label)
N
Never
service the valve with valve and pipelines under pressure
Transportation:
Always
ensure that compressed air are released
Always
ensure that all connections is disconnected before attempting to remove the valve from the installation
Always
drain liquid from valves before transportation
Always
used predesigned lifting points if defined
Always
ensure sufficient fixing of the valve during transportation - if specially designed packaging material is available, it
must be used
7

3 Installation
The instruction manual is part of the delivery.
Study the instructions carefully.
Fit the warning label supplied on the valve after installation so that it is clearly visible.
3.1 Unpacking/intermediate storage
Step 1
CAUTION!
Alfa Laval cannot be held responsible for incorrect unpacking.
Check the delivery for:
1. Complete valve
2. Delivery note
3. Warning label
Step 2
Remove upper support
2319-0031
Step 3
Lift out the valve.
NOTE!
Please note weight of valve as printed on box.
2319-0032
8

3 Installation
The instruction manual is part of the delivery.
Study the instructions carefully.
Fit the warning label supplied on the valve after installation so that it is clearly visible.
Step 4
Remove possible packing materials from the valve ports.
2319-0033
S
Step 5
Inspect the valve for visible transport damage.
2319-0034
S
Step 6
Avoid damaging the air connections, the leakage outlet, the valve
ports and the CIP connections.
2319-0035
9

3 Installation
The instruction manual is part of the delivery.
Study the instructions carefully.
Fit the warning label supplied on the valve after installation so that it is clearly visible.
Step 7
Disassemble according to illustrations
(please also see 6.2 Dismantling of valve).
1. Supply compressed air.
2. Remove upper clamp (64).
3. Release compressed air.
4. Lift out actuator with plugs. Compressed
air supply
2319-0036
64
50
64
S
Step 8
While valve body is welded, it is recommended to store the valve
safely in the box together with valve parts.
1. Place actuator and valve parts in the box.
2. Add supports.
3. Close, re-tape and store the box.
ADVICE!
Mark the valve body and box with the same number before
intermediate storage.
2319-0037
10

3 Installation
3.2 Recycling
• Unpacking
- Packing material consists of wood, plastics, cardboard boxes and in some cases metal straps
- Wood and cardboard boxes can be re-used, recycled or used for energy recovery
- Plastics should be recycled or burnt at a licensed waste incineration plant
- Metal straps should be sent for material recycling.
• Maintenance
- During maintenance, oil and wearing parts in the machine are replaced
- All metal parts should be sent for material recycling
- Worn out or defective electronic parts should be sent to a licensed handler for material recycling
- Oil and all non-metal wear parts must be disposed off in accordance with local regulations
• Scrapping
- At the end of use, the equipment must be recycled according to the relevant, local regulations. Besides the equipment itself,
any hazardous residues from the process liquid must be considered and dealt with in a proper manner. When in doubt, or in
the absence of local regulations, please contact your local Alfa Laval sales company
3.3 General installation
Step 1
- Always read the technical data thoroughly (see section 7 Technical data).
- Always release compressed air after use.
- Never touch the clip assembly or the actuator piston rod if the actuator is supplied with compressed air
(see the warning label)
C
CAUTION!
- Fit the supplied warning label on the valve so that it is clearly visible.
- Alfa Laval cannot be held responsible for incorrect installation
NOTE!
- Mount valves vertically, or as close to vertical as possible having the leakage outlet turned downwards.
Step 2
Avoid stresses to the valve as this can result in deformation of
the sealing area and misfunction of the valve (leakage or faulty
indication).
Pay special attention to:
-Vibrations
- Thermal expansion of the tubes (especially at long tube lengths)
- Excessive welding
- Overloading of the pipelines
NOTE!
Please follow Alfa Laval installation guidelines
(literature code ESE00040).
2319-0038
! !
11

3 Installation
Study the instructions carefully and pay special attention to the warnings!
The valve has ends for welding as standard but can also be supplied with fittings.
Step 3
Fittings
Ensure that the connections are tight.
Remember seal
rings!
2319-0039
S
Step 4
1
2
3
B
A
C
D
2319-0099
A=Airout1A
B=Airin
C=Airo
ut 3
D=Airout2
V
Valve Pneumatic Connections
ThinkTop
Fitting ID
Actuator
Fitting ID
Out 1A Air connection 2 (blue)
Out 2 Air connection 3 (yellow)
Out 3 Air connection 1 (red)
Air connection: R 1/8” (BSP).
2319-0040
A
C1
AC2
AC3
AC1 = Air connection 1 (red) upper seat push
AC2 = Air connection 2 (blue) open/close
AC3 = Air connection 3 (yellow) lower seat push
12

3 Installation
Study the instructions carefully and pay special attention to the warnings!
Thevalvehasendsforweldingasstandard.
Weld carefully/aim at stressless welding to avoid deformation on sealing areas.
Check the valve for smooth operation after welding.
3.4 Welding
Step 1
N
Never
stick your fingers in the operating parts of the valve if the
actuator is supplied with compressed air.
2319-0041
!
S
Step 2
Dismantle the valve in accordance with the description of dismantling the valve, see 6.2 Dismantling of valve
Step 3
Before welding the valve into the pipe line please note:
1. Maintain the minimum clearances "A" so that the actuator with
the internal valve parts can be removed - please see later on
in this section!
If there is a risk of foot damage, Alfa Laval recommends leaving
a distance of 4.7” below the valve (look at the specific built-in
conditions).
Size 1½” 2” 2½” 3” 4” 6”
A 7.9” 10.4” 11.8” 11.8” 17.2” 14.76”
B 31.9” 34.3” 40.2” 40.2” 49.2” 55.9”
C2.4” 2.9” 3.4” 3.9” 4.7” 6.9”
Note!
If ThinkTop is mounted, add 7.1” to B measurement.
The measurement C can always be calculated by the formula C = ½ID
upper +½IDlower +1”
2319-0042
Remove label after
installation of valve body
UP
AB
C
S
Step 4
Assemble the valve in accordance with section 6.5 Assembly of valve after welding.
Pay special attention to the warnings and clamp torque (see section 6.5 Assembly of valve).
13

3 Installation
Study the instructions carefully and pay special attention to the warnings!
Thevalvehasendsforwelding as standard.
Weld carefully/aim at stressless welding to avoid deformation on sealing areas.
Check the valve for smooth operation after welding.
Step 5
Pre-use check:
1. Supply compressed air to air connection 1, 2 and 3 one by one.
2. Operate the valve several times to ensure that it runs smoothly.
Pay special attention to the warnings!
AC1 = Air connection 1 (red) upper seat push
AC2 = Air connection 2 (blue) open/close
AC3 = Air connection 3 (yellow) lower seat push
2319-0043
AC1
AC2
AC3
3.5 Pneumatic functions
1
2
3
B
A
C
D
2319-0099
A=Airo
ut 1A
B=Airin
C=Airout3
D=Airout2 2319-0085
A
C1
A
C2
AC3
V
Valve pneumatic connections
ThinkTop
Fitting ID
Actuator
Fitting ID
Out 1A AC 2 (blue)
Out 2 AC 3 (yellow)
Out 3 AC 1 (red)
14

3 Installation
Study the instructions carefully and pay special attention to the warnings!
Thevalvehasendsforweldingasstandard.
Weld carefully/aim at stressless welding to avoid deformation on sealing areas.
Check the valve for smooth operation after welding.
3.6 Valve position indication
ThinkTop Visual Indications LED Indications
LED B “Open valve” (Yellow)
OIR-Receiver
LED D “Setup/Internal fault” (Red)
LED C “Seat-lift 1/2” (Yellow)
LED E “Solenoid valves” (Green)
LED F “Maintenance” (Orange)
LED B
LED D
LED C
LED E
LED F
LED A
LED A “Closed valve” (Yellow)
Note:
If the programmer wishes to detect a physical closed valve position in an “Open Valve” sensor
position, then there is no longer any consistence between the sensor valve detection position
and the visual indications of the ThinkTop.
2319-0085
A
C1
A
C2
AC3
2319-0081
55
2319-0083
55
2319-0082
2/ [70mm]
34"
2319-0084
1/ [50mm]
1516"
External sensor - unbalanced plug External sensor - balanced plug
15

3 Installation
Study the instructions carefully and pay special attention to the warnings!
Thevalvehasendsforwelding as standard.
Weld carefully/aim at stressless welding to avoid deformation on sealing areas.
Check the valve for smooth operation after welding.
3.7 Adjustment of indication
Test 1 - Upper valve seat, position detection
1. Valve at rest (closed) position
”C” LED (seat lift) on ThinkTop is illuminated.
2. Attact a manual air line to actuator air fitting AC1 using a 3-way air
pilot switch.
3. Turn the air pilot switch to ON (open).
”C” LED (seat lift) on ThinkTop is not illuminated.
4. Turn the air pilot switch to OFF (closed).
”C” LED (seat lift) on ThinkTop is illuminated.
5. Test complete. Remove manual air line.
2319-0100
AC1
C
(3)
(4)
(1)
(2)
(5)
T
Test 2 - Lower valve seat, position detection
1. Valve at rest (closed) position
”A” LED (closed valve) on ThinkTop is illuminated.
2. Attact a manual air line to actuator air fitting AC3 using a 3-way air
pilot switch.
3. Turn the air pilot switch to ON (open).
”A” LED (closed valve) on ThinkTop is not illuminated.
4. Turn the air pilot switch to OFF (closed).
”A” LED (closed valve) on ThinkTop is illuminated.
5. Test complete. Remove manual air line.
2319-0101
A
(3)
(4)
(1)
(2)
(5)
AC3
16

3 Installation
Study the instructions carefully and pay special attention to the warnings!
Thevalvehasendsforweldingasstandard.
Weld carefully/aim at stressless welding to avoid deformation on sealing areas.
Check the valve for smooth operation after welding.
Adjustments
Upper valve seat external sensor (24VDC or 110VAC)
(position data existing on ThinkTop)
The following instructions should be made while the valve is hot from
CIP cleaning. (worst case)
1. Valve is in rest position.
2. Loosen sensor lock nut(s).
3. Turn the sensor (83) clockwise to bottom of nylon plug (82), (or in some
cases, until the sensor LED turns off).
4. Turn the sensor (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 actuator fitting AC1 using a 3-way air pilot
switch.
7. Turn the air pilot switch to ON (open). Upper seat lift activated. Sensor
LED turns off.
8. Turn the air pilot switch to OFF (closed). Upper seat lidt deactivated.
Sensor LED turns on.
9. Turn the air pilot switch ON and OFF several times to verify sensor LED
attions as listed in steps 7 and 8 above.
10. Moderately tighten sensor lock nut.
11. Repeat step 9 when the valve is cold and readjust with valve hot if
necessary. 2319-0102
AC1
C
(7)
(8)
(1)
(6)
82 83
(2)+(5)+(10)
(3)
(4)
(9)+(11)
A
Adjustments
Upper valve seat ThinkTop (set position “New” on ThinkTop)
The following instructions can be completed while the valve is at room (ambient) temperature.
1. Enter new “Upper seat lift” position data to ThinkTop memory in step 5 of the programming sequence using the “I” and
“II” keys.
Note! Data entry is done with the valve deactivated (closed).
2. Adjust lateral sensor per instructions for “UPPER VALVE SEAT EXPERNAL SENSOR” in this section.
Refer to “Electrical connections/Instructions” in this manual for ThinkTop programming.
Adjustments
Lower valve seat ThinkTop
The following instructions can be completed while the valve is at room (ambient) temperature.
1. Delete the current “CLOSED VALVE” position data from the ThinkTop memory using the “I” and ”II” keys.
2. Enter new “CLOSED VALVE” position.
3. Repeat “Test - 2, lower valve seat position detection” procedures to confirm adjustment.
Refer to “Electrical connection/instructions” in this manual for ThinkTop programming.
17

3 Installation
Study the instructions carefully and pay special attention to the warnings!
Thevalvehasendsforwelding as standard.
Weld carefully/aim at stressless welding to avoid deformation on sealing areas.
Check the valve for smooth operation after welding.
3.8 Regulatory Inspection
Test 3
Regulatory inspection, confirm control system seat lifting interlock during an operating, active CIP circuit
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 33 for top view of solenoid layout inside ThinkTop®.
a. Solenoid-1, valve full open. (Note: not used for this test procedure)
b. Solenoid-2, lower seat push activation.
c. Solenoid-3, upper seat lift activation.
AC
B
D
Open valve
IR-Receiver
Set-Up/Fault
Seat-Lifts
Solenoids
Maintenance
Closed Valve
A
B
D
C
E
F
2319-0104
A. Solenoid 1
B. Solenoid 2
C. Solenoid 3
D. Manual air pilot buttons
Test procedure listed as follows:
1. Select a valve for interlock testing.
2. Decide if the cleaning solution will flow through the mixproof valve upper or lower body as part of the CIP cleaning circuit
for the test.
3. Start the appropriate CIP circuit. (WARNING: be sure that there is no risk of mixing product with cleaning solution when
conducting this test!!)
4. The CIP supply pump, or source of CIP solution pressure, should now be operating.
5. Remove the cover lid from the Think Top.
Move to step 6 or 7 below:
6. If cleaning solution is flowing through the valve upper body, push and hold the silver manual air pilot button on 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. If cleaning solution is flowing through the valve lower body, push and hold the silver manual air pilot button on solenoid
number 3 (upper seat lift). If the 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.
8. If the control system does NOT de-activate the cleaning solution pressure source as described in either 6 or 7 above, the
control system should be shut down for evaluation, and correction, to the interlock functions written in the PLC logic.
** If solenoids are located in a remote enclosure (not inside Think Top), the above test procedures are to be conducted in
exactly the same method. Selection of the proper solenoids for testing are to be determined using the assistance of plant
operating personnel.
18

3 Installation
Study the instructions carefully and pay special attention to the warnings!
Thevalvehasendsforweldingasstandard.
Weld carefully/aim at stressless welding to avoid deformation on sealing areas.
Check the valve for smooth operation after welding.
3.9 Electrical connection chart
Table 1. ThinkTop, 8-30 VDC (0 solenoid)
ThinkTop
Term no. Function Remarks
9+8-30 VDC Power +
10 -Common Power -
Ground -----------
1Closed valve PLC input - valve closed
2Open valve PLC input - valve open
3Seat lift - 1 PLC input - valve closed
5Status PLC input - optional
24 Seat Lift -1(upper) (signal) External sensor (WHT)
26 Supply + External sensor (BRN)
27 Supply - External sensor (BLU)
Not used - External sensor (BLK)
Table 2. ThinkTop, 8-30 VDC (3 solenoids)
ThinkTop
Term no. Function Remarks
6Solenoid - 1 Output - valve open
7Solenoid - 2 Output - lower seat lift push
8Solenoid - 3 Output - upper seat lift
9 +8-30 VDC Power +
10 -Common Power - *(jump to 11)
11 Solenoid com. Power - * (jump to 10)
Ground -----------
1Closed valve PLC input - valve closed
2Open valve PLC input - valve open
3 Seat lift - 1 PLC input - valve closed
5Status PLC input - optional
24 Seat Lift -1(upper) (signal) External sensor (WHT)
26 Supply + External sensor (BRN)
27 Supply - External sensor (BLU)
Not used - External sensor (BLK)
* = One power supply, positive activation of solenoids.
19

3 Installation
Study the instructions carefully and pay special attention to the warnings!
Thevalvehasendsforwelding as standard.
Weld carefully/aim at stressless welding to avoid deformation on sealing areas.
Check the valve for smooth operation after welding.
Table 3. ThinkTop, 110 VAC (0 solenoid)
ThinkTop
Term no. Function Remarks
9110 VAC Power +
10 - Common Power -
Ground -----------
1Closed valve PLC input - valve closed
2Open valve PLC input - valve open
3 Seat lift - 1 PLC input - valve closed
5Status PLC input - optional
24 Seat Lift -1(upper) (signal) External sensor (red w/BLK rings)
26 Supply + External sensor (red w/WHT rings)
Table 4. ThinkTop, 110 VAC (3 solenoids)
ThinkTop
Term no. Function Remarks
6Solenoid - 1 Output - valve open
7Solenoid - 2 Output - lower seat lift push
8 Solenoid - 3 Output - upper seat lift
9110 VAC Power +
10 - Common Power - *(jump to 11)
11 Solenoid com. Power - * (jump to 10)
Ground -----------
1Closed valve PLC input - valve closed
2Open valve PLC input - valve open
3 Seat lift - 1 PLC input - valve closed
5Status PLC input - optional
24 Seat Lift -1(upper) (signal) External sensor (red w/BLK rings)
26 Supply + External sensor (red w/WHT rings)
27 Supply - External sensor (BLU)
Not used - External sensor (BLK)
* = One power supply, positive activation of solenoids.
20