Alfa Laval Unique Mixproof CP-3 Instruction Manual
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Alfa Laval Unique Mixproof CP-3 Instruction Manual

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

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Summary of Contents for Alfa Laval Unique Mixproof CP-3

  • Page 1 Instruction Manual Unique Mixproof CP-3 2319-0030 ESE02710-ENUS1 2014-05 Original manual...

  • Page 3: Table Of Contents

    Table of contents The information herein is correct at the time of issue but may be subject to change without prior notice 1. Introduction .................... 2. Safety ....................2.1. Important information ................2.2. Warning signs ..................2.3. Safety precautions ................3.
  • Page 4 Table of contents The information herein is correct at the time of issue but may be subject to change without prior notice 8.11. Plug setup 17 ..................8.12. Plug setup 18 ..................8.13. Plug setup 19 ..................8.14. Plug setup 20 ..................

  • Page 5: Introduction

    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.

  • Page 6: Safety

    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.

  • Page 7: Safety Precautions

    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...

  • Page 8: Installation

    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.
  • Page 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 4 Remove possible packing materials from the valve ports. 2319-0033 S S tep 5 Inspect the valve for visible transport damage.
  • Page 10 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.

  • Page 11: Recycling

    - 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).
  • Page 12 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 S tep 4 2319-0099...

  • Page 13: Welding

    - 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).

  • Page 14: Pneumatic Functions

    3 Installation Study the instructions carefully and pay special attention to the warnings! The valve has ends for welding 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.

  • Page 15: Valve Position Indication

    3 Installation Study the instructions carefully and pay special attention to the warnings! The valve has ends for welding as standard. 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...

  • Page 16: Adjustment Of Indication

    3 Installation Study the instructions carefully and pay special attention to the warnings! The valve has ends for welding 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.
  • Page 17 3 Installation Study the instructions carefully and pay special attention to the warnings! The valve has ends for welding as standard. 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)

  • Page 18: Regulatory Inspection

    3 Installation Study the instructions carefully and pay special attention to the warnings! The valve has ends for welding 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...

  • Page 19: Electrical Connection Chart

    3 Installation Study the instructions carefully and pay special attention to the warnings! The valve has ends for welding as standard. 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.
  • Page 20 3 Installation Study the instructions carefully and pay special attention to the warnings! The valve has ends for welding as standard. Weld carefully/aim at stressless welding to avoid deformation on sealing areas. Check the valve for smooth operation after welding. Table 3.

  • Page 21: Operation

    - N N ever pressurise air connections (AC1, AC3) simultaneously as both valve plugs can be lifted (can cause mixing). CAUTION! Alfa Laval cannot be held responsible for incorrect operation. Step 2 Never touch the valve or the pipelines when processing hot liquids or when sterilising.

  • Page 22: Recommended Cleaning

    4 Operation The valve is designed for cleaning in place (CIP). Study the instructions carefully and pay special attention to the warnings! NaOH = Caustic soda. = Nitric acid. 4.2 Recommended cleaning Step 1 Caustic danger! Always handle lye and acid with great care. Always use Always use rubber gloves!
  • Page 23 The CIP through the SpiralClean nozzle can be controlled by an external valve. Minimum recommended CIP pressure 29 psi. Alfa Laval offers the option of cleaning the OD of the upper and lower valve plug shaft(s) by utilizing the CIP sealing elements.
  • Page 24 4 Operation The valve is designed for cleaning in place (CIP). Study the instructions carefully and pay special attention to the warnings! NaOH = Caustic soda. = Nitric acid. Step 7 Valve pneumatic operation during in-place cleaning Each valve seat shall be lifted during the length of the cleaning cycle. Seat lift durations shall not exceed 10 seconds.
  • Page 25 4 Operation The valve is designed for cleaning in place (CIP). Study the instructions carefully and pay special attention to the warnings! NaOH = Caustic soda. = Nitric acid. Step 9 Guide rings cleaning When the valves are removed for replacement of wetted parts and / or sealing elastomers, it is important to remove, and hand clean, the PTFE guide rings (positions 45, 54, 80 and 98) and their seating groves before placing the valves back into service.
  • Page 26 4 Operation The valve is designed for cleaning in place (CIP). Study the instructions carefully and pay special attention to the warnings! NaOH = Caustic soda. = Nitric acid. Step 11 Seat-cleaning cycles: Pay special attention to the warnings! 1. Closed valve Product 2319-0046 2 2 .

  • Page 27: Troubleshooting And Repair

    4 Operation Study the maintenance instructions carefully before replacing worn parts. - See section 6.1 General maintenance 4.3 Troubleshooting and repair Problem Cause/result Repair Leakage between sealing element (79 or Worn/product affected o-rings/ lip seal - Replace the o-rings/lip seal - Change rubber grade 96/97) and lower plug (75) (76/77/78/95)

  • Page 28: Automation

    19. Supply sensors 10. Terminals 20. External connections 2063-0000 Type: Alfa Laval “No Touch” System. For wire connections: See 3.9 Electrical connection chart“. F F eatures - Tolerance programmes. - Self adjustment programme (SRC/ARC valves only). - Built-in maintenance monitor.
  • Page 29 5 Automation Study the instructions carefully and pay special attention to the warnings! Built-in Maintenance Monitor The unit can be preset to indicate when the time for maintenance of the valve has been reached. A status signal and flashing maintenance LED can be programmed to return after 3, 6, 9 or 12 months or more. Technical specifications Sensor system Sensor accuracy: .
  • Page 30 5 Automation Study the instructions carefully and pay special attention to the warnings! External sensors The external sensors are used for seat-lift supervision when seat-lift can not be internally detected. The sensors get their supply voltage from the terminal row. The output signals from the sensors are connected to two inputs on the terminal row on the internal sensor unit.
  • Page 31 5 Automation Study the instructions carefully and pay special attention to the warnings! Polarity NO or NC function is selected with a jumper in term. 12 and 13. Jumper present = NO. If changing to NC remove the jumper and make a power recycle. A power recycle is always required when changing this function.
  • Page 32 5 Automation Study the instructions carefully and pay special attention to the warnings! Internal connections Terminals for connection of the solenoids mounted internally in the control head. The number of solenoids actually mounted in the control head could be 0 - 3. The signals are taken directly from the terminal row. Technical specifications Up to 3 solenoid valves in each unit.
  • Page 33 5 Automation Study the instructions carefully and pay special attention to the warnings! Air connections A. Air restriction (throttle function) air inlet/outlet B. Air out 1A C. Air exhaust D. Air out 1B (5/2 port solenoid valve only) E. Solenoid 3/2 or 5/2 F.

  • Page 34: Installation

    5 Automation Study the instructions carefully and pay special attention to the warnings! 5.2 Installation Step 1 Always read the technical data thoroughly. ® Always have the ThinkTop electrically connected by authorised personnel. Step 2 1. Fit the air fittings on actuator if not mounted. 2.
  • Page 35 5 Automation Study the instructions carefully and pay special attention to the warnings! Step 5 Fit the ø6 mm (1/4”) air tubes to ThinkTop. (see drawing “Air connections” section 5.1 Specifications). S S tep 6 Fit the air tubes to the actuator (see drawing “Air connections”...
  • Page 36 5 Automation Study the instructions carefully and pay special attention to the warnings! Step 9 Make sure the cable gland is completely tightened. TD 800-249 S S tep 10 Set up the ThinkTop (see section 5.3 Setup diagram).

  • Page 37: Setup Diagram

    5 Automation Study the instructions carefully and pay special attention to the warnings! 5.3 Setup diagram General Flashing LED means no value set. Steady LED means value set as shown. Default: Step 2, factory-set tolerance band +/- 3/16" Step 3-8, disabled D LED: Active during set-up: Flashing in step 1...
  • Page 38 Unique 7000 (LKLA-T) Unique Mixproof PMO/Curd +/- 3/16" Series 700 SMP-SC SF SMP-BC (O O nly used SRC-PV SMP-TO Unique Mixproof CP-3/LP Next C when self SMP-BCA Unique Mixproof HT/VT Reset unit step E adjustment Unique Mixproof 3A feature is...
  • Page 39 5 Automation Study the instructions carefully and pay special attention to the warnings! Below is stated the meaning of the LEDs’ indications for fault finding in connection with the operation of the ThinkTop. 7.1.1 status LED (Red) Red flashing: Unit in set-up mode or internal software fault. If internal software fault, re-programme unit. Red steady: Unit in set-up mode or internal hardware fault.
  • Page 40 5 Automation Study the instructions carefully and pay special attention to the warnings! 7.1.3 Solenoid green LED always on Green E Condition: When using a ThinkTop 110VAC, the Green LED is always on, but the solenoids seems to operate properly. Possible cause: The off state voltage of the solenoid input is not sufficiently low.
  • Page 41 5 Automation Study the instructions carefully and pay special attention to the warnings! Green Green steady: Solenoid valves energized. N N ote! During set-up LED lights have different functions.

  • Page 42: Maintenance

    5 Automation Study the instructions carefully. Handle scrap correctly. Always keep spare X-rings in stock. For spare parts please refer to spare part catalogue. 5.4 Maintenance Step 1 1. Untighten the two Allen screws and remove the ThinkTop from the actuator. 2.
  • Page 43 5 Automation Study the instructions carefully. Handle scrap correctly. Always keep spare X-rings in stock. For spare parts please refer to spare part catalogue. Step 5 To remove the sensor unit untighten screw and pull out the sensor unit. TD 800-256...

  • Page 44: Maintenance

    - If repair is required, replacing all actuator rubber seals is recommended. - Lubricate seals with Klüberplex BE31 - To avoid possible black remains on position number 1 and 29. Alfa Laval recommends Klüber Paraliq GTE 703 (white) for these two positions.

  • Page 45: Dismantling Of Valve

    6 Maintenance The valve is designed so that internal leakages do not result in the products becoming mixed. Internal leakage in the valve is externally visible. Study the instructions carefully. Always keep spare rubber seals and guide rings in stock. Check the valve for smooth operation after service. 6.2 Dismantling of valve Step 1 Disassemble valve acc.
  • Page 46 6 Maintenance The valve is designed so that internal leakages do not result in the products becoming mixed. Internal leakage in the valve is externally visible. Study the instructions carefully. Always keep spare rubber seals and guide rings in stock. Check the valve for smooth operation after service. Step 2 1.
  • Page 47 6 Maintenance The valve is designed so that internal leakages do not result in the products becoming mixed. Internal leakage in the valve is externally visible. Study the instructions carefully. Always keep spare rubber seals and guide rings in stock. Check the valve for smooth operation after service. Step 4 Dismantling of upper sealing element 1.

  • Page 48: Lower Plug, Replacement Of Radial Seal

    6 Maintenance The valve is designed so that internal leakages do not result in the products becoming mixed. Internal leakage in the valve is externally visible. Study the instructions carefully. Always keep spare rubber seals and guide rings in stock. Check the valve for smooth operation after service. 6.3 Lower plug, replacement of radial seal Step 1 Cut and remove old seal ring (74) using a knife, screwdriver or...

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