Alfa Laval Unique PMO Instruction Manual
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Alfa Laval Unique PMO Instruction Manual

Alfa Laval Unique PMO Instruction Manual

Sanitary mixproof valve
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Instruction Manual
Unique PMO Sanitary Mixproof Valve
ESE03232-ENUS3
Original manual
2019-11

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Summary of Contents for Alfa Laval Unique PMO

  • Page 1 Instruction Manual Unique PMO Sanitary Mixproof Valve ESE03232-ENUS3 2019-11 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. EC Declaration of Conformity ............... 2. Introduction .................... 3. Safety ....................3.1. Follow Safety Directions ................3.2. Do Not Make Machine Modifications ............3.3.
  • Page 4 Table of contents The information herein is correct at the time of issue but may be subject to change without prior notice 12.5. Dismantling of Actuator ................12.6. Reassembly of Actuator ................13. Parts List ....................13.1. Part Numbers Chart ................13.2.

  • Page 5: Ec Declaration Of Conformity

    1 EC Declaration of Conformity Revision of Declaration of Conformity 2009-12-29 The Designated Company Alfa Laval Kolding A/S Company Name Albuen 31, DK-6000 Kolding, Denmark Address +45 79 32 22 00 Phone No. hereby declare that PMO Mixproof Valve Designation...

  • Page 6: Introduction

    Failure to do so may result in loss of warranty. Where defects appear on the product during the warranty period, Alfa Laval Inc. will 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.

  • Page 7: Safety

    Maintain equipment in good working condition. 3.2 Do Not Make Machine Modifications Alfa Laval offers a full range of products to suit all your needs. Therefore, product modification is never necessary. 3.3 Keep Maintenance Safe Replace damaged or worn parts immediately. Never allow old product, debris, or any lubricants to build up on equipment.

  • Page 8: Installation

    4 Installation 4.1 Unpacking The valves should be unpacked immediately upon receipt from the factory and carefully inspected for damage that may be 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 reported to the carrier.

  • Page 9: Specifications

    Polished Ra<32 Note: The Ra-values are only for the internal surfaces. CIP solution flows for seat lift and spiral clean (viscosity and density similar to water) CV Values ® Unique PMO 2” 2½” 3” 4” Upper seat lift 2.95 4.37...

  • Page 10: Pneumatic Connections

    6 Pneumatic Connections Valve Pneumatic Functions: Valve Pneumatic Tubing Interconnect The following charts indicate the pneumatic tubing interconnect between the air solenoids and the valve actuators.
  • Page 11 6 Pneumatic Connections Use the first chart if the solenoids are to be located in the ThinkTops. Use the second chart if the solenoids are to be located in an external remote box. Solenoids Located in ThinkTops: ThinkTop Fitting ID Actuator Fitting ID Air Hose Color Air In...

  • Page 12: Position Indication

    7 Position Indication Valve Position Indication...

  • Page 13: Thinktop ® , 8-30 Vdc #9613-6031-05 (0 Solenoid)

    8 Electrical Connections ® 8.1 ThinkTop , 8-30 VDC #9613-6031-05 (0 Solenoid) Electrical Connection Chart ThinkTop Term. No. Function Remarks +8-30 VDC Power + -Common Power - Ground ----------------------- Closed Valve Input - Valve Closed (Lower Seat) Open Valve Input - Valve Open Input - Valve Closed (Upper Seat) Seat Lift - 1 Input - Optional...

  • Page 14: Thinktop ® , 110 Vac #9634-0686-52 (2 Solenoids)

    8 Electrical Connections ® 8.2 ThinkTop , 8-30 VDC #9613-6031-06 (1 Solenoid) Electrical Connection Chart ThinkTop Term. No. Function Remarks Output - Valve Open Solenoid - 1 +8-30 VDC Power + Power - *(Jump to 11) -Common Solenoid Com. Power - *(Jump to 10) ----------------------- Ground Input - Valve Closed (Lower Seat)

  • Page 15: Thinktop ® , 110 Vac #9634-0686-53 (3 Solenoids)

    8 Electrical Connections ® 8.3 ThinkTop , 8-30 VDC #9613-6013-07 (2 Solenoids) Electrical Connection Chart ThinkTop Term. No. Function Remarks Output - Valve Open Solenoid - 1 Output - Lower Seat Push Solenoid - 2 +8-30 VDC Power + -Common Power - *(Jump to 11) Solenoid Com.

  • Page 16: Thinktop ® , 8-30 Vdc #9613-6013-07 (3 Solenoids)

    8 Electrical Connections ® 8.4 ThinkTop , 8-30 VDC #9613-6013-07 (3 Solenoids) Electrical Connection Chart ThinkTop Term. No. Function Remarks Output - Valve Open Solenoid - 1 Output - Lower Seat Push Solenoid - 2 Solenoid - 3 Output - Upper Seat Lift +8-30 VDC Power + -Common...

  • Page 17: Thinktop ® , 110 Vac #9634-0686-50 (0 Solenoid)

    8 Electrical Connections ® 8.5 ThinkTop , 110 VAC #9634-0686-50 (0 Solenoid) Electrical Connection Chart ThinkTop Term. No. Function Remarks Power + 110 VAC -Common Power - ----------------------- Ground Closed Valve PLC Input - Valve Closed (Lower Seat) Open Valve PLC Input - Valve Open PLC Input - Valve Closed (Upper Seat) Seat Lift - 1...

  • Page 18: Thinktop ® , 110 Vac #9634-0686-51 (1 Solenoid)

    8 Electrical Connections ® 8.6 ThinkTop , 110 VAC #9634-0686-51 (1 Solenoid) Electrical Connection Chart ThinkTop Term. No. Function Remarks Output - Valve Open Solenoid - 1 +110 VAC Power + -Common Power - *(Jump to 11) Solenoid Com. Power - *(Jump to 10) Ground ----------------------- Input - Valve Closed (Lower Seat)
  • Page 19 8 Electrical Connections ® 8.7 ThinkTop , 110 VAC #9634-0686-52 (2 Solenoids) Electrical Connection Chart ThinkTop Term. No. Function Remarks Output - Valve Open Solenoid - 1 Output - Lower Seat Push Solenoid - 2 110 VAC Power + -Common Power - *(Jump to 11) Solenoid Com.
  • Page 20 8 Electrical Connections ® 8.8 ThinkTop , 110 VAC #9634-0686-53 (3 Solenoids) Electrical Connection Chart ThinkTop Term. No. Function Remarks Output - Valve Open Solenoid - 1 Output - Lower Seat Push Solenoid - 2 Solenoid - 3 Output - Upper Seat Lift 110 VAC Power + -Common...

  • Page 21: Automation Thinktop ® Digital 8 - 30 Vdc & 110 Vac Pnp/Npn

    ® Automation ThinkTop Digital 8 - 30 VDC & 110 VAC PNP/NPN ® 9.1 ThinkTop , digital 8-30 or 110 VAC NO/NC Features Tolerance The tolerance band is ±1.5 mm. 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.
  • Page 22 ® Automation ThinkTop Digital 8 - 30 VDC & 110 VAC PNP/NPN Feedback ssignals Output signals from the sensor unit to be connected digital interface (PLC). ® Nominal voltage: ....Must match the selected type of ThinkTop Load current: .
  • Page 23 ® Automation ThinkTop Digital 8 - 30 VDC & 110 VAC PNP/NPN Micro environment demand specifications Temperature Working: -4°F to +185°F IEC 68-2-1/2 Storage: -40°F to +185°F IEC 68-2-1/2 Temperature change: -13°F to +158°F IEC 68-2-14 10-55 Hz, 0.7 mm Vibration IEC 68-2-6 55-500 Hz, 10g...
  • Page 24 ® Automation ThinkTop Digital 8 - 30 VDC & 110 VAC PNP/NPN ® ThinkTop , Digital 8-30 or 110 VAC NO/NC electrical connection A Digital interface command C Feedback signals to digital interface signals B Internal connections to D Jumper connections **) solenoid 1-3 E Incoming signals from external sensors Supply to external sensors...

  • Page 25: Installation

    ® Automation ThinkTop Digital 8 - 30 VDC & 110 VAC PNP/NPN 9.2 Installation Step 1 Always read the technical data thoroughly. ® Always have the ThinkTop electrically connected by authorised personnel. ® Always install the ThinkTop before valve or relay is in a safe position. Step 2 1.
  • Page 26 ® Automation ThinkTop Digital 8 - 30 VDC & 110 VAC PNP/NPN Step 5 Fit the ø6 mm (1/4”) air tubes to ThinkTop. (see drawing “Air connections” page ). Step 6 Fit the air tubes to the actuator (see drawing “Air connections” page ). TD 800-131 Step 7 Untighten the four screws and pull off cover of ThinkTop.

  • Page 27: Air Connection

    ® Automation ThinkTop Digital 8 - 30 VDC & 110 VAC PNP/NPN Step 9 Make sure the cable gland is completely tightened. TD 800-249 Step 10 Set up the ThinkTop (see setup diagram 28). 9.3 Air connection A. Air restriction (throttle function) air inlet/outlet B.

  • Page 28: Setup Diagram

    ® Automation ThinkTop Digital 8 - 30 VDC & 110 VAC PNP/NPN 9.4 Setup diagram ® ThinkTop setup utilising IR keypad General Flashing LED means no value set. Steady LED means value set as shown. Default: Step 2, factory-set tolerance band +/- 5 mm Step 3-8, disabled D LED: Active during set-up:...
  • Page 29 ® Automation ThinkTop Digital 8 - 30 VDC & 110 VAC PNP/NPN Enter setup Step 1 – Save and Exit Next C Exit no change accepted step E Step 2 – Setup valve type Default SRC/ARC Unique Mixproof SMP-SC Unique 7000 (LKLA-T) Unique Mixproof PMO/Curd +/- 5mm...
  • Page 30 ® Automation ThinkTop Digital 8 - 30 VDC & 110 VAC PNP/NPN ® ThinkTop setup utilising local ’I’ and ’II’ keys General Default is: Step 2, tolerance is +/- 5 mm Step 3-8, disabled Timeout: A 60 sec. timeout is started as soon as any button(s) is released. On timeout the setup is exited with no changes saved.
  • Page 31 ® Automation ThinkTop Digital 8 - 30 VDC & 110 VAC PNP/NPN Enter setup Step 1 – Save and Exit NextC Exit no change accepted step E Step 2 – Setup valve type Default SRC/ARC Unique Mixproof SMP-SC Unique 7000 +/- 5mm Series 700 (LKLA-T)
  • Page 32 ® Automation ThinkTop Digital 8 - 30 VDC & 110 VAC PNP/NPN ® ThinkTop Quick setup guide Valve: Unique mixproof valve (with lower seat-lift) - and wait until red LED flashes Push: Push: - hold for 5 sec (clear all stored parameters) Push: Push: (red + yellow LED)

  • Page 33: Fault Finding

    ® Automation ThinkTop Digital 8 - 30 VDC & 110 VAC PNP/NPN 9.5 Fault finding 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.
  • Page 34 ® Automation ThinkTop Digital 8 - 30 VDC & 110 VAC PNP/NPN 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. Corrective action: Make sure that the off state voltage is below 7V.
  • Page 35 ® Automation ThinkTop Digital 8 - 30 VDC & 110 VAC PNP/NPN Green Green steady: Solenoid valves energized. Note! During set-up LED lights have different functions.

  • Page 36: Maintenance

    ® Automation ThinkTop Digital 8 - 30 VDC & 110 VAC PNP/NPN Study the instructions carefully. Handle scrap correctly. Always keep spare X-rings in stock. 9.6 Maintenance ® Dismantling the ThinkTop Step 1 1. Untighten the two Allen screws and remove the ThinkTop from the actuator.
  • Page 37 ® Automation ThinkTop Digital 8 - 30 VDC & 110 VAC PNP/NPN Study the instructions carefully. Handle scrap correctly. Always keep spare X-rings in stock. Step 4 1. To dismantle the adapter (the lower part of the ThinkTop) from base (the middle part), unscrew the three screws. 2.
  • Page 38 ® Automation ThinkTop Digital 8 - 30 VDC & 110 VAC PNP/NPN Study the instructions carefully. Handle scrap correctly. Always keep spare X-rings in stock. Step 2 1. Replace the black X-ring. 2. Assemble base with adapter by turning adapter slightly anticlockwise and tighten the four screws (1.9 Nm).

  • Page 39: Thinktop ® Spare Parts

    ® Automation ThinkTop Digital 8 - 30 VDC & 110 VAC PNP/NPN Study the instructions carefully. Handle scrap correctly. Always keep spare X-rings in stock. ® 9.7 ThinkTop spare parts TD 800-226...
  • Page 40 ® Automation ThinkTop Digital 8 - 30 VDC & 110 VAC PNP/NPN Study the instructions carefully. Handle scrap correctly. Always keep spare X-rings in stock. ® Unique PMO ¼" air Pos. Qty. Denomination Series Mixproof connection Shell complete 9613427901 Screw...

  • Page 41: Cleaning Procedures

    10.1 Recommended Cleaning - General ® In order to be compliant with the Pasteurized Milk Ordinance (PMO), the Unique PMO Plus Series mixproof valves shall be cleaned-in-place (CIP) with the following recommended procedures. Milk, or milk products, shall be removed, or properly isolated, from the mixproof valves during CIP cleaning.

  • Page 42: Valve Pneumatic Operation During Cleaning-In-Place

    10 Cleaning Procedures 10.3 Valve pneumatic operation during Cleaning-In-Place Each valve seat shall be lifted during the length of the cleaning cycle. Seat lift durations shall not exceed 10 seconds. These pneumatic functions include: 1. Upper valve seat lift (takes place during cleaning of upper valve body) 2.

  • Page 43: Flow Of Cleaning Solution Through Valve Vent Tube (Example)

    10 Cleaning Procedures 10.4 Flow of Cleaning Solution Through Valve Vent Tube (example) The table below approximates the flow of cleaning solution through the valve vent tube during lower seat push functions at 40 PSI CIP pressure. (viscosity and density comparable to water) Flow Every 2 Seconds Valve Size Flow Per Second Through Vent Tube...

  • Page 44: Valve Seat Position Indication

    11 Valve Seat Position Indication Test - 1 Upper Valve Seat Position Detection 1. Valve at rest (closed), position "C" LED (Seat Lift) on ThinkTop is illuminated. 2. Attach a manual air line to actuator air fitting AC1 using a 3-way air pilot switch (pos. 89). 3.
  • Page 45 11 Valve Seat Position Indication Test - 2 Lower Valve Seat Position Detection 1. Valve at rest (closed), position "A" LED (Closed Valve) on ThinkTop is illuminated. 2. Attach a manual air line to actuator air fitting AC3 using a 3-way air pilot switch (pos. 89). 3.
  • Page 46 11 Valve Seat Position Indication Adjustments Upper Valve Seat External Sensor (24 VDC or 110 VAC) (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 a rest position. 2.
  • Page 47 11 Valve Seat Position Indication 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 the ThinkTop memory in step 5 of the programming sequence using the ’I’ and ’II’...

  • Page 48: Maintenance

    12 Maintenance Tools Required for Valve Service - 16mm Wrench - Strap Wrench - 17mm Wrench - 2.5mm Allen Wrench - Small Knife - Straight Pick - Small Standard Screw Driver - Air Pilot Switch (Pos.89) Tools Required for Actuator Service - 13mm Wrench - Long Stem Phillips Screw Driver (#2 Point) - Plastic Hammer...
  • Page 49 12 Maintenance 5. Supply compressed air to AC2 (blue ring). 6. Remove upper clamp (64). 7. Lift out the actuator together with the internal valve parts from the body (50). 8. Release compressed air. 9. Remove lower clamp (64). 10. Remove lower sealing element assembly (79). 11.
  • Page 50 12 Maintenance 14. Supply compressed air to AC1 (Red Ring). 15. Loosen lower plug (75) counter clockwise using a strap wrench while counter holding upper actuator stem (1) with a 16mm wrench. 16. Turn counter clockwise by hand and remove lower plug (75). 17.
  • Page 51 12 Maintenance 18. Remove O-ring (38) from lower plug stem (75). 19. Remove plug (15). 20. Slide lock (44) along piston rod (29). 21. Remove two clamps (43). 22. Pull upper plug (55), and upper sealing element (48) out. 23. Remove spindle liner (42).
  • Page 52 12 Maintenance 25. Remove O-ring (47). 26. Remove lip seal (49). 27. Remove guide ring (45). 28. Remove lip seal (57). 29. Remove guide ring (54).

  • Page 53: Replacement Of Seal Ring, Lower Plug

    12 Maintenance 12.2 Replacement of seal ring, lower plug Step 1 Cut and remove old seal ring (74) using a knife, screwdriver or similar. Be careful not to scratch the plug. Step 2 Pre-mount seal ring as shown on drawing. Rotate along circumference to fix gasket as shown in the picture.
  • Page 54 12 Maintenance Step 5 1. Supply compressed air. 2. Release compressed air. 3. Remove tool parts. TD 449-029_1 Step 6 Inspect the seal to ensure it does not twist in the groove, and press in the 4 outsticking points with a screwdriver! TD 449-057_1...

  • Page 55: Replacement Of Seal Ring, Upper Plug

    12 Maintenance 12.3 Replacement of seal ring, upper plug Step 1 Remove old seal ring (56) using a knife, screwdriver or similar. Be careful not to scratch the plug. Step 2 Pre-mount seal ring as shown on drawing. TD 449-031_1 Carefully lubricate sealings with acceptable soap or lubricant, before pre-mounting.

  • Page 56: Re-Assemble Valve (Excluding Actuator)

    12 Maintenance Step 6 1. Inspect the seal. 2. Release air at 3 different positions of the circumference. 12.4 Re-Assemble Valve (excluding actuator) Re-Assemble Valve (Excluding Actuator) Note: * Lubricate seals with Kluber Paraliq GTE 703 or similar USDA H1 Approved lubricant (#022148-213). ** Lubricate threads with Kluber Paste UH1 84-201 or similar.
  • Page 57 12 Maintenance 3. Install guide ring (54). 4. Install *lip seal (57). 5. Hand clean and sanitize guide ring (45). 6. Hand clean and sanitize upper sealing element (48). 7. Install guide ring (45). 8. Install *lip seal (49). 9. Install *o-ring seal (47).
  • Page 58 12 Maintenance 10. Install lock (44) onto piston rod (29). 11. Slide upper sealing element (48) onto upper plug (55). 12. Install spindle liner (42) onto upper plug stem (55). 13. Fit upper plug (55), upper sealing element (48) and spindle liner (42) into intermediate piece (37).
  • Page 59 12 Maintenance 15. Install two clamps (43) Note: Align one clamp with female 17. Install plug (15). thread in spindle liner (42). 18. Install *O-ring (38). 16. Slide lock (44) down over clamps (43) Note: Align holes.
  • Page 60 12 Maintenance 19. Supply compressed air to AC1 (Red Ring). 20. Fit **lower plug stem (75) into ID of upper plug (55) and turn clockwise to tighten by hand. 21. Tighten lower plug (75) clockwise using strap wrench while counter holding upper actuator stem (1) with a 16mm wrench. 22.
  • Page 61 12 Maintenance 23. Hand clean and sanitize guide ring (80). 24. Hand clean and sanitize lower sealing element (79). 25. Install guide ring (80). 26. Install *lip seal (77). 27. Install *O-ring (76). 28. Install lower sealing element (79) onto body (50). 29.

  • Page 62: Dismantling Of Actuator

    12 Maintenance 34. Turn sensor (84) clockwise into nylon plug (85) and tighten by hand. 35. Attach sensor cable (90) to sensor (84) and tighten by hand. 36. Turn magnet (83) clockwise into upper actuator stem (1) and tighten by hand. 37.

  • Page 63: Reassembly Of Actuator

    12 Maintenance Dismantling of Actuator 12.6 Reassembly of Actuator Reassembly of Actuator 1. Fit guide ring (6) and O-ring (5). Note: 2½", 3", and 4" valves only 1. Fit O-rings (7 and 9). Place upper piston (8). 2. Fit stop (4). 3.
  • Page 64 12 Maintenance Reassembly of Actuator...

  • Page 65: Parts List

    13 Parts List...
  • Page 66 13 Parts List 2½", 3" and 4" Sizes only...
  • Page 67 13 Parts List...
  • Page 68 13 Parts List...
  • Page 69 13 Parts List...
  • Page 70 13 Parts List...

  • Page 71: Part Numbers Chart

    13 Parts List 13.1 Part Numbers Chart Parts list Pos. Denomination Upper stem Screw Air fitting Stop for upper piston O-ring, NBR Guide ring, Turcite O-ring, NBR Upper piston O-ring, NBR Spring assembly Distance spacer Washer Spring assembly Plug Cylinder (3A marking) Main piston Guide ring, Turcite O-ring, NBR...

  • Page 72: Valve Body

    13 Parts List 13.2 Valve Body...
  • Page 73 13 Parts List Parts list Pos. Denomination Intermediate piece plus set-up 12 Valve body 11-00 Valve body 12-00 Valve body 21-00 Valve body 22-00 Valve body 11-90 Valve body 12-90 Valve body 21-90 Valve body 22-90 Valve body 11-180 Valve body 11-270...

  • Page 74: Plug Set-Up 12

    13 Parts List 13.3 Plug Set-Up 12...
  • Page 75 13 Parts List Parts list Parts list Pos. Denomination Pos. Denomination Hexnut Lower sealing element Clamp without nut Guide ring, PTFE Lower plug Cover Service kits Denomination 2” 2 1/2” and 3” 4” NBR ..............9611-92-6016 9611-92-6017 9611-92-6018 EPDM...

  • Page 76: Thinktop Complete And Parts

    13 Parts List 13.4 ThinkTop Complete and Parts Parts list Parts list Pos. Denomination Pos. Denomination ThinkTop Complete Air fitting (yellow ring) Magnet, ThinkTop Air tubing (yellow) *Sensor Air Pilot Switch Nylon Plug Cable Shuttle Valve 13.5 Wear Parts Parts list Pos.

  • Page 77: Axial Installation Tool

    13 Parts List 13.6 Axial Installation Tool TD 449-038_1...
  • Page 78 13 Parts List Parts list Pos. Denomination Lower Part Piston Upper part O-ring, NBR Clamp Wing nut Air fitting...

  • Page 79: Radial Installation Tool

    13 Parts List 13.7 Radial Installation Tool...
  • Page 80 13 Parts List Parts list Pos. Denomination Piston Lower Part Upper Part Bushing Guide Guide ring O-ring O-ring Clamp Wing Nut Air fitting...
  • Page 82 © Alfa Laval Corporate AB This document and its contents is owned by Alfa Laval Corporate AB and protected by laws governing intellectual property and thereto related rights. It is the responsibility of the user of this document to comply with all applicable intellectual property laws. Without limiting any rights related to this document, no part of this document may be copied, reproduced or transmitted in any form or by any means (electronic, mechanical, photocopying, recording, or otherwise), or for any purpose, without the expressed permission of Alfa Laval Corporate AB.

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