Home

762 Flo-Diversion Valve Manual

1. ALLEN BRADLEY SLC 500 PLC S PROCESOR Ei O PLEXIGLASS ET UVPROMCHIP WINDOW Weeg is 3 e o 2 n PLUG IN RELAY S es e 24VAC COIL PRIMARY 120 240 VAC tD SECONDARY 24 VAC ole 121212212 4 SS ol 9 TRANSFORMER TERMINALS 115 VAC 29 24 VAC 8 34 39 41 42 40 O 9 1 ini Ew 8 MICROSWITCH WIRING CONNECTIONS PX 14 46 ALLEN BRADLEY SLC 500 WIRING DIA
2. SEAL WIRE THROUGH HOLES IN LATCH amp DOOR LIP Allen Bradley UV PROM Chip EL 11600 0077 1 51 Part No EL 90940 0039 EL 60010 0013 EL 60340 0038 EL 60010 0014 33 192 33 188 w coil 41 6 EL 19870 0102 EL 19870 0103 EL 19870 0104 EL 19870 0101 EL 19870 0100 37 27 41 9 BLACK EL 40200 0002 Qty 20 ft ALLEN BRADLEY SLC 500 PLEXIGLASS WINDOW 39 SI amp 19 0 e SI 39 41 7 40 ALLEN BRADLEY SLC 500 PLC is PROCESSOR 8 elefefelelelslelelslelelelelelelelelele EEE MEMORY SE O BOK SEE UV PROM CHIP OOMMUNCATIONS CONNECTOR BOX E es elelelelelelelelele e elelelelelelele e PLUG IN RELAY
3. 8 24 VAC COIL a o 19 S 91 S J 4 2 amp 9 eS e zs o 24 ao a a o 25 2 2 E 8 alsl z SOLENOIDS al o 120 VAC COILS TRANSFORMER TERMINALS 115 VAC 29 24 VAC 8 14 2 oooga Oleeeeeeeeeeeeeeeeeeeeeeceeeeeeeeeeeeeeelo O O a ZF VALVE AIR LINE CONNECTIONS 0 WIRING CONNECTIONS aN NL MICROSWITCH 52 ALLEN BRADLEY SLC 500 DIAGRAM FOR FLO DIVERSION PANEL 48 2762 2 ALLEN BRADLEY SLC 500 I O DRAWING 120 VOLT AC 2 60 HZ F FOR STLR INSTRUMENT SLC 500 5 INPUT 4 y 5 NEUT O s OCHA 7 AC CT T CLE
4. 18 REDLT 4 GREEN LT DIVERT FORWARD J 10 J 8 No PROD MANUAL 5 NS OP DIVERT ER AIR H FILTER REG xm H mm JE mac y T nes Key Description Part No Qty Key Description S S Enclosure w Window 44 273 1 17 Transformer 120 240 18 H x 14 W x 8 DP Primary 24 VAC Secondary Panel Nameplate Door 38 300 1 18 Plug in Relay Socket Indicating Light Red EL 28460 0028 1 19 Plug in Relay 4PDT 24 VAC Coil Indicating Light Green EL 28460 0029 1 20 Telemecanique Solenoid Din 3 Position Knob Operator w o EL 79730 0068 1 Mounting Track Contact Blocks 21 Telemecanique Head Tail 2 N O Contact Blocks w Latch EL 79170 0035 Module Seat 1 N C Contact Block w o Latch EL 79170 0036 2 22 Telemecanique Solenoid Valve Pushbutton Green w o EL 79610 0095 1 N C 120 VAC Contact Block 23 4 Poly Flo Tubing 1 N O Contact Block w Latch EL 79170 0037 1 24 Terminal End Barrier Plate Pushbutton Nameplate 38 298 2 25 Terminal End Anchor Air Regulator 33 68 8 1 26 Terminal Mounting Rail 1 8 Fitting 42 15 33 1 27 Terminal 24 VAC Blue Bulkhead Fitting 42 15 62 1 28 Terminal 110 220 VAC White Straight Fitting ye NPT x 1 4 PL 42 76 5 3 29 Hose Connector Allen Bradley SLC 500 EL 22590 0019 1 30 Black Hose 10 ft long 1747 L30A 31 Hubbell Cord Grip 16 ALLEN BRADLEY SLC 500 FLO DIVERSION PANEL 48 2762 2 WITH SOLENOIDS
5. SIENA AAAS 58885 888588 S SSSSSSSSSS SS SIS SISSSSSSSSSSSISSSSSSSS S N 9 PLC INPUT TO PULSE DIVERT VALVE 10 PLC INPUT TO PULSE LEAK DETECT VALVE DURING y y 11 PLC INPUT TO RUNT BOOSTER PUMP DURING CIP 26 PLC OUTPUT SIGNAL FORWARD FLOW CUTOMER CONTROL SYSTEM 27 PLC OUTPUT THAT TURNS ON WHEN 10 MINUTE DELAY HAS E M 28 PLC OUTPUT THAT FLASHES WHEN INPUT PAIRS 4 amp 5 OR5 amp 6 MI SIGNAL FLO DIVERSION MICROSWITCH OR STLR FAULT 120 VAC INPUTS LAPSED SMATCH TO 29 PLC OUTPUT INTERLOCK ADDITIONAL FLOW PROMOTING DEVICES AS THE PUMP P 30 PLC OUTPUT THAT TURNS ON WHEN TIMING PUMP IS RUNNING 33 ISOLATED POWER SUPPLY FOR CUSTOMER OUTPUTS LISTED ABOVE 56 OUTPUTS POWERED BY CUSTOMER SUPPLY OR TERMINAL 417 831 1411 csidesigns com CS
6. 53 54 55 56 57 58 59 6l amp 67 68 7 71 72 7 14 75 OPTIONAL WIRING PLUS REQUIRED WIRING LOW VOLTAGE BLUE ERMINAL ERMINAL BLOCK IN FLO DIVERSION PANEL 0600060066606 90066006 ex 10 0 2 amp 8 59 S Bs 000000000000 000000000 11 m 26 gt 27 29 AS 30 m 35 m 10 28 PLC OUTPU SIG PLC INPUT TO PLC INPUT TO PLC OUTPU PLC OUTPU PLC OUTPU TIMING PUMP LC INPUT TO PULSE DIVERT VALVE DURING CIP HAT TURNS ON WI HAT FLASHES WH NAL FLO DIVERSION MICROSWI INTERLOCK AD PLC OUPTU 50 RUN BOOSTER PUMP DURING CIP 120 VAC PULSE LEAK DETECT VALVE DURING CIP INPUTS O SIGNAL FORWARD FLOW TO CUSTOMER CONTROL SYSTEM HEN 10 MIN CIP DELAY HAS ELAPSED EN INPUT PAIRS 4 amp 5 OR 5 amp 6 MISMATCH TO CH OR STLR FAULT DITIONAL FLOW PROMOTING DEVICES SAME HAT TURNS ON WHEN TIMING PUMP IS RUNNING SOLATED POWER SUPPLY FOR CUSTOMER OUTPUTS LISTED ABOVE OUTPUTS POWERED BY CUSTOMER SUPPLY ON TERMINAL 433 1 oak WP NO 10 11 12 13 14 15 14 nimm
7. 9 29 74 115 X Y CONTROL HOUSING CONTROL HOUSING WITH SOLENOID Blocked Hole In 54 98 Selector Block 17 344 U Note Selector Air Passage To O Ring Block Location Actuator Located 34 1114 316 Air Tube CONTROL HOUSING WITHOUT SOLENOID 9613600270 STOP BLOCK SUPPORT T304 54 99 Air Passage Stop Block to actuator 5 505 55 42 81 21 Elbow Air Hole At Underside Of Control Housing Plugged With 17 63 17 14 124 O ring Plug 33 209 Quick 42 81 13 Elb 81 OW 42 81 21 Reducer 14 124 Plug 42 81 22 Nipple 33 169A 33 170A or 42 81 21 Reducer Air Supply MS 105 33 171A Solenoid 58A Vent Air Supply Plug 33 209 Quick Exhaust 17 63 U O Ring Air Passage Location 17 35 U O Ring Vent Plug SC512F SS 2 Req Solenoid to be mounted on top of Selector block as shown MS 105 58A Vent Plug Qty Microswitch 1 2 Y Solenoid ilala la 1 switch X 110 VAC PN 33 169A X 2 switches X 24 PN 33 170A X 24 VDC PN 33 171A X No Solenoid X 30 14 125 S Thumb Screw 17 337B E Gasket 4 Req 17 340B E Gasket 17 139 U 90 O Ring 4 Req SCIO7R SS Screw 44 251 Back Cover 1 36 Base 1 37 Base Cover EL 97515 0058 SCIS0TE 9S m di Cable Assembly Screw 3 Req 17 348 Pressure Relief SC1307H SS Screw LWA1300 SS Lockwasher 17 109 U 25 425 04 O Ring Nylon Retainer EL 97750 0049 Wire Harness Yellow Brown Orange 36 89
8. a Nut 0 Ring Bonnet Gasket Clamp Stem Guard Screw End Cap R H Body Lower Stem O Ring Body Gasket Clamp L H Body Stem O Ring Bushing Lockwasher Screw Yoke Packing Retainer Packing Seal Retainer Actuator O Ring Vent Plug Pin 2 13 171 316L 17 158 U 12 487 11 2 316L 17 325 11 2 U 13MHHM 3 S 23 133 SC1312H SS 23 129 316L 7 1047RM 2 316L 19 1334 2 316L 01 1165 11 7 1071TM 2 316L 40MP U 2 13MHHM 2 S 7 1047LM 2 316L 19 1333 2 316L 17 17 U 40 63 LWA1300 SS SC1308H SS 12 496 5 25 428 04 MAT L 17 98 25 428 05 25 484 S 17 35 U MS 105 58A CP 9 300 21 2 13 171 316L 17 158 U 12 487 2 316L 17 325 2 2 U 13MHHM 4 S 23 133 SC1312H SS 23 129 316L 7 1047RM 2 316L 19 1334 21 2 316L 01 1165 11 7 1071TM 21 2 316L 40 0 21 2 13MHHM 2 2 S 7 1047LM 2 2 316L 19 1333 21 2 316L 17 17 U 40 63 LWA1300 SS SC1308H SS 12 496 S 25 428 04 MAT L 17 98 25 428 05 25 484 S 17 35 U MS 105 58A CP 9 300 36 3 13 171 316L 17 158 U 12 487 3 316L 17 325 3 U 13MHHM 5 S 23 133 SC1312H SS 23 129 316L 7 1047RM 3 316L 19 1334 3 316L 01 1165 11 7 1071TM 3 316L 40MP U 3 13MHHM 3 S 7 1047LM 3 316L 19 1333 3 316L 17 17 U 40 63 LWA1300 SS SC1308H SS 12 496 5 25 428 04 MAT L 17 98 25 428 05 25 484 5 17 35 U MS 105 58A CP 9 300 4 13 174 316L 17 342 U 12 515 316L 17 62 4 2 U H13MHHM 4 S 23 140 SC1312H SS 23 139 316L 7 1047RM 4 316L 19 1409 4 316L
9. H REDLT 4 GREENLT DIVERT FORWARD j 10 PROD MANUAL 5 INS DIVERT H SEAL WIRE THROUGH 5 e ERE LATCH amp Anm 2 6 Key Description Part No Qty Key Description Part No Qty 1 S S Enclosure w Window 44 273 1 11 Allen Bradley SLC 500 EL 22590 0019 1 18 H x 14 W x 8 DP 1747 L30A 2 Panel Nameplate Door 38 300 1 12 Allen Bradley UV PROM Chip EL 11600 0077 1 3 Indicating Light Red EL 28460 0028 1 13 Transformer 120 240 VAC EL 90940 0039 1 4 Indicating Light Green EL 28460 0029 1 Primary 24 VAC Secondary 5 3 Position Knob Operator w o 79730 0068 1 14 Plug in Relay Socket EL 60010 0013 2 Contact Blocks 15 Plug in Relay 4PDT EL 60340 0038 2 6 2N O Contact Blocks EL 79170 0035 1 24 VAC Coil w Latch 16 Terminal End Barrier Plate EL 19870 0102 1 7 1 N C Contact Block EL 79170 0036 2 17 Terminal End Anchor EL 19870 0103 2 w o Latch 18 Terminal Mounting Rail EL 19870 0104 1 8 Pushbutton Green w o EL 79610 0095 1 19 Terminal 24 VAC Blue EL 19870 0101 8 Contact Block 20 Terminal 110 220 VAC EL 19870 0100 29 9 1N O Contact Block w Latch EL 79170 0037 1 White 10 Pushbutton Nameplate 38 298 2 21 Hubbell Cord Grip EL 40200 0002 2 45 ALLEN BRADLEY SLC 500
10. Product position and the timing pump will not start Remove the gauge and reassemble the valve Ensure valve is properly and completely assembled Repeat steps D L with the divert valve AN ALTERNATE TEST METHOD CAN ALSO BE USED TO TEST THE MICROSWITCH ADJUSTMENT Note These are unofficial test methods for troubleshooting purposes only Turn off the air supply to the valves Place the temperature sensing element of the Safety Thermal Limit Recorder Controller in water that is above legal pasteurization temperature Slowly adjust the filter regulator to admit air to the valve actuator When valve stem moves down 1 16 the red light should go out for both valves and the green light comes on when the divert valve is tested If the valves do not meet either of these tests the microswitch must be adjusted Refer to topic Adjustments MICROSWITCH ADJUSTMENT for 762 227 amp 862W 227 The Flo Diversion Valve is precision equipment and has been carefully manufactured and adjusted before leaving the factory As is the case with most precision machinery however the adjustments may have been disturbed during shipping or 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 time delay between op
11. check power main and fuse in STLR controller Blown fuse test primarily solenoid valve coils CTR1 CTR2 and CTR3 for short circuits Push test lamp on terminals 2 and 17 If light on check motor starter coil and overload contacts Terminals 2 16 If no light proceed below If light on check coil and contact Terminals 2 and 4 no light proceed below light on check the thermo controller and timing pump start stop switch and contact block 3 on the Inspect Product Clean switch Terminals 2 and 18 no light adjust or replace the microswitch MS1 in the divert valve If light on adjust or replace the microswitch MS2 in the leak detector Check Steps a1 through a3 above Put test lamp on terminals 2 and 5 If no light test STLR controller high side Check Step a1 above Terminals 2 and 6 no light check controller for contact closure on high side light on check contacts on the manual diversion switch and contact block 2 on Inspect Product Clean switch Disconnect leads to SV1 Test for continuity and if none replace coil Terminals 2 and 11 If no light proceed below If light on check air supply to solenoid SV2 and for mechanical troubles in SV2 Terminals 14 and 2 If no light proceed below If light on check for proper functioning of the timing motor TR2 Adjust or replace the switch Terminals 10 and 2 If no light go to S
12. 17 342 U 7 1071TM 4 316L 40MP U 4 13MHHM 4 S 7 1047LM 4 316L 19 1408 4 316L 17 89 U 40 73 LWA1300 SS SC1308H SS 12 534 5 25 428 04 MAT L 17 98 25 428 04 MAT L 25 428 05 17 35 U MS 105 58A CP 9 300 2 e 0 417 831 1411 csidesigns com CSI 37 ALLEN BRADLEY SLC 500 TRI CLOVER PANEL MODELS 48 2762 1 AND 48 2762 2 The following section of the manual covers the use and application of the Tri Clover programmable controller version of the Flo Diversion Valve Panel The control panel utilizes the Allen Bradley SLC 500 small programmable logic controller PLC with UVPROM memory chip to retain permanent logic storage for the Flo Diversion application program The control panel is available in two versions The first version 48 2762 1 is intended to operate with Flo Diversion valves having solenoids mounted on the valve actuator control top This version control panel supplies 24 VAC to the microswitches by means of an internal transformer This low voltage feature gives added safety protection for maintenance and regulatory personnel when servicing the valve The second version 48 2762 2 includes solenoids mounted inside the control panel The new PLC Panel can also be used with the 262 style Flo Diversion Valve The difference that needs to be observed is the microswitches on the 262 valve are wired to a N C contact instead of the N O contact as with the 762 valves Th
13. PUSHBUTTON DIFF PRESS l 33 e 1 5 Lis IN 15 d 2 34 4 y Ao AA IT IIH PRESSURE SWITCH HLFLOW HI FLOW 36 2 nis 37 NOTE HI FLOW CONTACT USED WITH METER TIMING 38 SYSTEM AND CENTRIFUGAL TIMING PUMP WHEN USING CONVENTIONAL POSITIVE PUMP FOR TIMING JUMPER INPUT 416 TO TERMINAL 43 Y 39 Y 2 DARK LINES INDICATE EXTERNAL WIREEY 4 43 4 47 4 50 5i 52 53 54 55 56 57 56 59 6l amp 63 6 67 70 1 p 73 75 ALLEN BRADLEY SLC 500 LEAK DIVERT VALVE DIVERT VALVE 48 CS SLC 500 OUTPUT amp VAC VDC 1 STOP STAR 01 TIMING PUMP HOMO MOTOR USED AS TIMING 20 PUMP STOP STET HOMO WHEN ouis C Lo o USED AS E TIMING PUMP PS o STOP oL a o O amp CLEANING PUMP 22 M CP OFF sey OL O C BOOSTER PUMP OUT 3 x SOLENOIDS ARE MTD VAC ON THE VALVES
14. Stem Guide EL 79500 0013 Micro Switch b 16 167 S W Retaining Ring 2 54 101 Spacer Block 54 100 Mtg Block SCIOSR SS Purple Screw Solenoid 2 Req EL 19600 0087 Electrical Connector either wire Black Solenoid Yellow Switch COM Brown Switch 44 251 Wall N O Back Cover Orange Switch N O Green Not Used PARTS LIST 762 227M How to order replacement parts All orders for repair parts must contain the following data Note Part numbers are for reference Consult Service Kit Catalogue or Spares CD for proper service kits 1 Complete model number from name plate 2 Serial number from name plate 3 Keynumber and description The following exploded view and accompanying parts list facilitate ordering repair parts from the factory All parts illustrated are indexed to the parts list by key numbers Key Description 11 2 24 2 24 3 1 Body 7 1022TM 1 2 316L 7 1022TM 2 316L 7 1022 21 3161 7 1022TM 3 316L Stem 19 1276 11 2 316L 19 1276 2 316L 19 1276 2 2 316L 19 1276 3 316L Gasket 17 325 11 2 U 17 325 11 2 U 17 325 21 2 1 17 325 3 U Clamp 13MHHVM 3 S 13MHHVM 3 S 13MHHVM 4 S 13MHHM 5 S Upper Body 7 1024TM 1 2 316L 7 1024TM 2 316L 7 1024 21 3161 7 1024TM 3 316L O Ring 17 17 U 17 17 U 17 17 U 17 17 U Bushing 40 64 40 64 40 64 40 64 Yoke 12 496 S 12 496 S 12 496 S 12 496 S Screw SC1308H SS SC1308H SS SC1308H SS SC1308H SS Lockwasher LWA1300 SS LW
15. delay for Product switch 1 sec delay for Timing pump dropout 3 sec delay for leak detect valve and 10 min delay for CIP start VERSION 1 02 Same as 1 01 above except that the leak detect timer is changed from 3 sec to 1 sec The Product switch time changed from 15 sec to 20 sec VERSION 1 03 Same as 1 01 above except that the Booster Pump is delayed from starting for Standard 10 min when in CIP mode and when using the Customer controlled input to the PLC VERSION 1 04 Same as 1 01 above except that all flow promoting devices are shut down when switched to CIP position The Product switch time changed from 15 sec to 30 sec VERSION 1 05 Same as Version 1 03 except that a 16 second time delay has been added after HI FLOW 1 05is the standard installed in all panels shipped unless otherwise noted See version no stamped on UVPROM module CS 417 831 1411 csidesigns com 41 ALLEN BRADLEY SLC 500 FIXED HARDWARE STYLE The SLC 500 Fixed Hardware Style controllers consist of a CPU with 1000 instruction capacity a power supply and a fixed number of I O contained in a single package These processors are designed for industrial environments with ambient temperature from 0 to 60C The Fixed Hardware Style controllers are available in 20 I O 12 Inputs amp 8 Outputs Each device has LED indicators to show the status of each point The internal power supply for a fixed style processor oper
16. forward flow position and twenty seconds later the leak detector valve will go into the forward position 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 pump should shut off After fifteen seconds or when the timing pump stops running the valves should assume the forward flow position with the timing pump remaining off Note For installations using the Slick 500 if the Timing Pump Run Down Time exceeds the pre programmed time of the UV PROM a new chip will be requried with the matching setting before the panel is sealed When the product is below legal pasteurization temperature and the timing pump is on move the selector switch from product position to clean position The timing pump will shut off and the valves will follow the cleaning cycle after a delay of ten minutes CRT5 INSTALLATION With sub legal pasteurazation temperature and the timing pump on move the selector switch from product to inspect position The timing pump will shut off and the valves will assume forward flow fifteen seconds after switch is positioned 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 r
17. solenoid is mounted on valve Leak Detect Valve Solenoid Output to leak detect solenoid Output power is either 120 vac when solenoid is mounted inside panel or 24 vac when solenoid is mounted on valve Forward flow Signal Optional output to signal customer s system when both divert valve and leak detect valve are in forward flow or energized position Ten minute CIP delay timer Optional output to signal customer s system that the ten minute CIP delay timer for valve pulsing is time out Flo Diversion Valve Fault Optional output signal to customer s system indicating a mismatch between input pairs 4 5 and 6 7 Output will flash when mismatch is detected When using magnetic flow meter timing system output will flash when flow alarm is activated during legal temperature periods Timing Pump Interlock Optional output that follows same logic as output 0 Signal may be used to interlock additional flow promoting devices such as booster pumps Timing Pump Running Optional output to customer s control system indicating timing pump is running This output is based on input 8 timing pump contact from relay in motor starter Not used at this time Optional Relay Outputs 6 through 10 are powered by customer supplied voltage to Terminal 33 CS 417 831 1411 csidesigns com 44 ALLEN BRADLEY SLC 500 FLO DIVERSION PANEL 48 2762 1 WITHOUT SOLENOIDS 14 9 1 8
18. total HTST system has been tested and proven to function properly This will prevent access to the internal panel parts unless the seal is broken With the specially marked UVPROM in place and also the door latch sealed the integrity of the legal program and wiring will be maintained TERMINAL COVERS FOLDED BACK TO PREVENT ACCESS TO UVPROM ALLEN BRADLEY SLC 500 PLC PROCESSOR 9 DID 9 9 9 9 CD OUTPUT RUN FAULT MEMORY C3 POWER C FORCED C BATTERY LOW COMMUNICATIONS CONNECTOR BOX DIDID 39 ALLEN BRADLEY SLC 500 If a Regulatory seal has been violated either the door seal or the memory seal the following procedure should be accomplished before attempting to place the control panel in operation Remove power from the control panel Physically check the internal parts of the control panel for damage loose wires additions changes or evidence of tapering Take appropriate action to correct the problems Call Tri Clover for assistance if necessary If
19. valve pulse cycle from four minutes to eight minutes Internal jumper to terminal 3 may be used Not used at this time Not used at this time Differential pressure switch Input to signal the controller that the raw and pasteurized pressure differential is above legal requirements Meter System Hi Flow Input to signal the controller when high flow alarm from the recording flow controller is activated This input is OFF when in alarm When using conventional positive timing pump jumper this input to terminal 3 Not used at this time 43 ALLEN BRADLEY SLC 500 Output amp Function 0 Timing Pump or Homogenizer used as Timing Pump Output enables pump start stop circuit Output is interlocked to valve microswitches during sub legal temperatures to prevent forwarding of unsafe product Output is disabled during CIP operations Homogenizer when not used as timing pump Output enables homogenizer start stop circuit Output is interlocked to valve Microswitches during sub legal temperatures to prevent forwarding of unsafe product Output is enabled during CIP operations Pump Output to enable pump start stop during operations Booster Pump Output to enable booster pump on off circuit Interlocked to inputs 11 amp 15 Divert Valve Solenoid Output to divert solenoid Output power is either 120 vac when solenoid is mounted inside panel or 24 vac when
20. valve stem to the actuator stem remove air to the actuator the microswitch should be positioned in the activated positioned Securethe green switch housing cover with the four mounting screws Reassemble the valve to the valve body and to the process line Turn the power on and test the mircroswitch as described in the topic Microswitch Test Unscrew the nut at the end of the exposed stem for stem removal Slide the stem and o ring off the stem connected to the actuator MICROSWITCH ADJUSTMENT for 762 227MARL TheFlo Diversion Valve is precision equipment and has been carefully manufactured and adjusted before leaving the factory As is the case with most precision machinery however the adjustments may have been disturbed during shipping or 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 time delay between opening of the divert valve to forward flow and the opening of the leak detector valve to forward flow position A Check the valve to ensure it is properly and completely assembled A CAUTION Switch the valve to the forward flow position This will allow removal of one of the valve stems Switch the valve to the forward flow position by turning the sel
21. voce 24 VAC OUT 4 V4 C A DIVERT VALVE OUTS Sv2 LEAK DIVERT VALVE 25 38 VAC es POWER z FORWARD OUT 6 FLOW 10 MIN DELAY DONE m ours rr CUSTOMER S INTERLOCK TO 28 CONTROL TIMING PUMP SYSTEM oue VAC VDC4 TIMING PUMP RUNNNG m OUT 10 30 TRANSFORMER 120 VAC f Y vov 24 VAC di VALVE MICRO SWITCHES MODEL 762 VALVES LEAK DIVERT VALVE e 4 4 DIVERT FLOW T Gi CR2 H4 2 13 FORWARD FLOW 37 VALVE MICRO SWITCHES MODEL 262 VALVES 192 38 417 831 1411 csidesigns com ALLEN BRADLEY SLC 500 EXTERNAL WIRING DIAGRAM FOR FLO DIVERSION PANEL 48 2762 1 REQUIRED WIRING 10 1 n 13 14 15 16 18 19 26 7 2 30 51 32 33 37 38 LOW VOLTAGEE gk BLUE E TERMINALS TERMINAL BLOCK IN FLO DIVERSION PANEL 2 CS SS GS GS G9 SS S SIS SESS SIS CSI CSS S C GY CS SIS CS
22. 384 2 316L 17 325 1 SFY 13MHHVM 3 S 7 1024TM 2 316L 17 17 SFY 40 71 R641 12 496 S 5 1308 55 LWA1300 SS 25 484 5 25 428 04 17 35 U 15 171 316L MS 105 58A CP 40MP SFY 2 13MHHM 2 S SC1320H SS 12 508 316L R3 1 09B 7 SFY 34 21 2 7 1022TM 2 2 316L 19 1384 2 2 3161 17 325 2 2 SFY 1 4 5 7 1024TM 2 2 316L 17 17 5 40 71 641 12 496 5 SC1308H SS LWA1300 SS 25 484 5 25 428 04 17 35 U 15 171 316L MS 105 58A CP 40 MP SFY 2 1 21 2 5 SC1320H SS 12 508 316L R3 1 09B 7 SFY 3 7 1022TM 3 316L 19 1384 3 316L 17 325 3 SFY 1 5 5 7 1024TM 3 316L 17 17 SFY 40 71 R641 12 496 S SC1308H SS LWA1300 SS 25 484 5 25 428 04 17 35 U 15 171 316L MS 105 58A CP 40MP SFY 3 13MHHM 3 S C1320H SS 12 508 316L R3 1 09B 7 SFY 10 15 48 9 19 Ce fI un J 0 17 35 PARTS LIST 762 227MRAL How to order replacement parts All orders for repair parts must contain the following data 1 Complete model number from name plate 2 Serial number from name plate 3 Key number and description The following exploded view and accompanying parts list facilitate ordering repair parts from the factory All parts illustrated are indexed to the parts list by key numbers Description 1 N A N N no m NM a N
23. A1300 SS LWA1300 SS LWA1300 SS Actuator 25 484 S 25 484 S 25 484 S 25 484 S Packing Retainer 25 428 04 25 428 04 25 428 04 25 428 04 O Ring 17 35 U 17 35 U 17 35 U 17 35 U Seal Washer 15 171 316L 15 171 316L 15 171 316L 15 171 316L Vent Plug MS 105 58A CP MS 105 58A CP MS 105 58A CP MS 105 58A CP Gasket 40MP U 11 2 40MP U 2 40 MP U 2 2 40MP U 3 Clamp 13MHHM 11 2 S 13MHHM 2 S 1 21 2 5 13MHHM 3 S mm CS 417 831 1411 csidesigns com 32 33 PARTS LIST 862W 227 How to order replacement parts All orders for repair parts must contain the following data 1 Complete model number from name plate 2 Serial number from name plate 3 Keynumber and description Thefollowing exploded view and accompanying parts list facilitate ordering repair parts from the factory All parts illustrated are indexed to the parts list by key numbers Key Description 1 Body Stem Gasket Clamp O Ring Bushing Yoke A C Screw Lockwasher Actuator Packing Retainer O Ring Seal Washer Vent Plug Gasket Clamp Screw Spacer O Ring Upper Body 7 1022TM 11 2 316L 19 1384 11 2 316L 17 325 1 SFY 13 3 5 7 1024TM 11 2 316L 17 17 SFY 40 71 R641 12 496 S 5 1308 55 LWA1300 SS 25 484 5 25 428 04 17 35 U 15 171 316L MS 105 58A CP 40MP SFY 11 2 1 11 2 5 SC1320H SS 12 508 316L R3 1 09B 7 SFY 2 7 1022TM 2 316L 19 1
24. AN INSPECT E 4 A E ug PRODUCT C 9 40 cii INSPECT 9 o a CX N1 c GLEAN 25 42 MANUAL i TE DIVERSION MANUAL 43 3 DIVERSION DIVERT FLOW LIGHT 4 5 2 2 6 FUSE CHARTDRIVE m LEGAL TEMPERATURE 7 5 STLR 6 EL NO 5 18 5 DIVERSION SWITCH 9 2 i i SAME TAYLOR al 1 ANDERSON NP i PARTLOW 2 T FORWARD FLOW MICROSWITCH wr 24 CR4 TIMING PUMP RUNNING 5 8 8 DIVER 8 VAL 9 LEAKDETECT 52 UNS CUSTOMER S 3 CONTROL 2 VAL N10 SYSTEM 0 BOOSTER PUMP CIP 2 1 2 5 O N12 JUMPER IF 8 MINUTE 30 ROTATION IS DESIRED OPTIONAL O 31 i O N44 D SANITARY PRESSURE INDICATOR DIFF PRESS i 2 1 TEST PUSHBUTTON OK i 3 071 N35 5 7 2 34 4 M 1 i 3 35 PRESSURE SWITCH H FLOW HI FLOW SB 8_ A O Inte NOTE 7 HI FLOW CONTACT USED WITH METER TIMING O N17 SYSTEM AND CENTRIFUGAL TIMING PUMP WHEN USING CONVENTIONAL POSITIVE PUMP FOR TIMING JUMPER INPUT 16 TO TERMINAL 3 39 Y DARK LINES INDICATE EXTERNAL WIRES 2 3 53 4 42 45 45 47 50 51 52 5 54 55 56 57 58 59 61 62 67 65 70 72 H 75 ALLEN B
25. CS 417 831 1411 csidesigns com Instruction Manual Effective 8 1 03 CONTENTS Thank you for purchasing an Alfa Laval Product This manual contains installation operation and repair instructions with parts lists for the Model 762 227 762 227 MRAL and 862W 227 Flo Diversion Valves and control panels designed and manufactured 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 could result in personal injury or equipment damage SAFETY IMPORTANT SAFETY INFORMATION INTRODUCTION GENERAL INSTALLATION UNPACKING AND INSTALLING EQUIPMENT PRESTARTING CLEANING MAINTENANCE INTRODUCTION DISASSEMBLY VALVE COMPONENT INSPECTION CONTROL TOP DISASSEMBLY ACTUATOR BUSHING PACKING REPLACEMENT CONTROL TOP ASSEMBLY VALVE ASSEMBLY TROUBLESHOOTING TROUBLESHOOTING GUIDELINES PARTS LIST ALLEN BRADLEY SLC 500 PLC TRI CLOVER PANEL MODELS 48 2762 1 AND 48 2762 2 SOFTWARE VERSION NUMBERS AS OF 8 4 94 MEMOREY MODULES FIXED HARDWARE STYLE INPUT AND OUTPUT STATUS INDICATORS FLO DIVERSION PANEL 48 2762 1 WITHOUT SOLENOIDS WIRING DIAGRAM FOR FLO DIVERSION PANEL 48 2762 1 EXTERNAL WIRING DIAGRAM FOR FLO DIVERSION PANEL 48 2762 1 WIRING DIAGRAM FOR FLO DIVERSION PANEL 48 2762 2 SAFETY IMPO
26. Divert Valve Remove the lower body from the valve Turn the selector switch to the Inspect position After time 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 gauge as shown in Figure 4 Figure 4 762 227 Gauge Placement 10 INSTALLATION Turn the selector switch to the PRODUCT position and the timing pump will not start Remove the gap gauge and reassemble the valve Ensure the valve is properly and completely assembled ALTERNATE TEST METHOD CAN ALSO BE USED TO TEST THE MICROSWITCH ADJUSTMENT Note These unofficial test methods for troubleshooting purposes only Turn off the air supply to the valves Place the temperature sensing element of the Safety Thermal Limit Recorder Controller in water thatis above legal pasteurization temperature Slowly adjust the filter regulator to admit air to the valve actuator When valve stem moves down 1 6 the red light should go out for both valves and the green light comes on when the divert valve is tested If the valves do not meet either of these tests the microswitch must be adjusted Refer to topic ADJUSTMENTS MICROSWITCH TEST for 762 227MRAL The microswitches in the valve 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 assem
27. G PUMP OOSTER PUMP IVERT VALVE LEAK DIVERT VALVE 10 12 13 14 5 16 17 18 19 30 51 3 35 37 38 39 ALLEN BRADLEY SLC 500 PLC EXTERNAL WIRING DIAGRAM FOR FLO DIVERSION PANEL 48 2762 2 REQUIRED WIRING CONTROL RELAY PROVIDED BY CUSTOMER FOR TIMING PUMP RUNNING CONTACT M TIMING PUMP MOTOR LOW VOLTAGEE LUE T TERMINALS T ERMINAL BLOCK IN FLO DIVERSION PANEL 2 CS GS GS GS SS GS 5925 CS SS GS GS GS SS GS GS SS SIS SIS CSI 29 GS GIGS SIS GS RS G GS GS GIGS SS SS SS GS S GS GS GS GS SS SS GS CS GS S GS GS GS GS SS S 7N 4 3 120 29655 2 LL 60HZ 1 2 B FUSE 3 TEST PUSHBUTTON 5 Ta We spa E DIVERSION SWITCH PRESSURE SWITCH 7 4 w TERMINAL CONNECTIONS TAYLOR AND ANDERSON FREQUENCY PEN CONT
28. GRAM FOR FLO DIVERSION PANEL 48 2762 1 ALLEN BRADLEY SLC 500 I O DRAWING 120 VOLT AC 2 wu c FOR STLR INSTRUMENT SLC 500 8 INPUT 4 Q vac 5 NEUT OH 6 PRODUCT OF INSPECT CLEAN PRODUCT 8 e Q A INO 40 INSPECT 9 o SPEC O ER CLEAN 10 42 ANI UAL DIVERSION 11 e IN3 MANUAL 43 DIVERSION 12 DIVERT FLOW LIGHT 1 i Om 14 HTST CONTROLLER STLR 15 1 2 2 48 H FUSE DIVERT FLOW CHART DRIVE STLR LO Li 3 M LEGAL TEMPERATURE 17 gt STLR 67 6 ING 18 5 DIVERSION SWITCH 19 14 20 TAYLOR ANDERSON PARTLOW 21 FREQUENCY PEN 22 FORWARD FLOW 5 MICROSWITCH 8 IN7 24 TIMING PUMP CR 4 RUNNING 25 e DIVERT VAL 26 Era O IN9 DUSTON R LEAK DETECT VAL 27 CONTROL CO Nio SYSTEM BOOSTER PUMP Tm C IN 11 N 29 7 N12 JUMPER IF 8 MINUTE 30 CIP ROTATION IS DESIRED OPTIONAL Ag IN 13 81 Cw SANITARY PRESSURE INDICATOR 32 TEST
29. RADLEY SLC 500 PLC DIVERT VALVE LEAK DIVERT VALVE 54 38 51 500 OUTPUT 0 STARI STOP __ M TP 01 C 1 o 20 STAR OL STOP M HOMO y OUT 1 5 e o o e gt PS M HOMO STOP SERT M CP OL OUT 2 o 2 OFF ON bob M BP 01 o 9 23 SOLENOIDS ARE MTD IN CONTROL PANEL VAC 120 VAC VDC2 OUT 4 n SV 2 OUT 5 O VAC l emos POWER FORWARD 3 OUT 6 FLOW 10 26 DELAY DONE 3 E i CUSTOMER S FAULT QUIS COH CONTROL INTERLOCKTO 28 SYSTEM OUT 9 TIMING PUMP_ 29 1004 TIMING PUMP OUT 10 ___ 2 90 OUT 11 O TRANSFORMER 120 VAC lt gt 24 VALVE MICRO SWITCHES MODEL 762 VALVES DIVERT VALVE LEAK DIVERT VALVE 14 3 DIVERT FLOW 87 CR2 14 13 FORWARD FLOW d VALVE MICRO SWITCHES MODEL 262 VALVES 6 U P 2 T D MING PUMP T OR HOMO MOTOR SED AS TIMING UMP WHEN USED AS MING PUMP LEANIN
30. ROLLERS HTST CONTROLLER STLR 20 2 21 2 TIMING PUMP OR HOMO USED AS TIMING PUMP HOMO WHEN NOT USED AS TIMING PUMP START STOP ae M TP 04 STOP M HOMO OL SE i Oo C olo o i PS M HOMO men 22 2 23 2 3 OFF ON STOP START M CP 01 Y OL CR Lo 2775 a NANAK M CP BOOSTER PUMP CLEANING PUMP VALVE MICRO SWITCHES MODEL 762 SERIES VALVE 32 35 37 35 36 M OL o NO M O L vg MS BRN ve 62 3PHASE o pe ORG Fe POWER 01 NC NC DIVERT VALVE OR LEAK DETECTOR L_ MICRO SWITCH MICRO SWITCH 24 VAC 24 VAC VALVE MICRO SWITCHES MODEL 262 SERIES VALVE 32 35 37 35 36 BLK NS BED Bx N RED o M DIVERT VALVE LEAK DETECTOR MICRO SWITCH MICRO SWITCH 24 24 VAC 55 417 831 1411 csidesigns com 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 ALLEN BRADLEY SLC 500 PLC OPTIONAL WIRING PLUS REQUIRED WIRING LOW VOLTAGE BLUE TERMINAL TERMINAL BLOCK IN FLO DIVERSION PANEL 1 5558658686658668665866865655865856865656 9 lou fou e S 7
31. RTANT SAFETY INFORMATION 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 service ratings are exceeded The following DANGER WARNING AND CAUTION signs and their meanings are used within these instructions 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 WARNING 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 2 3 N WARNING HAZARDOUS VOLIAGE SPRING UNDER LOAD DISCONNECT POWER DO NOT ATIEMPT TO CUT ACTUATOR OPEN NN J 13 REFER TO SERVICE BULLETIN J I BEFORE SERVICING Part Number 38 294 Part Number 38 228 CS 417 831 1411 csidesigns com INTRODUCTION GENERAL 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 dischar
32. S CSS D GS GS GS SS GS GS SS CSS GS KS GS GS GS SES GS GS GS SS GS GS CSS 71413 120 216 2 15 60 HZ 8 FUSE 3 AP EST PUSHBUTTON CHARTDRVE r io 5 4721 Nofe 4 4 285 5 2 DIVERSION SWITCH PRESSURE SWITCH 4 TERMINAL CONNECTIONS TAYLOR AND ANDERSON FREQUENCY PEN CONTROLLERS HTST CONTROLLER STLR 20 2 21 2 TIMING PUMP OR HOMO USED AS TIMING PUMP HOMO WHEN NOT USED AS TIMING PUMP STOP START MTP 01 STOP START M HOMO OL gt PS M HOMO 2 4 22 23 2 d OFF STOP TN MBP OL CR 4 al o NANAK 0 x Low J BOOSTER PUMP CONTROL RELAY PROVIDED CLEANING PUMP BY CUSTOMER FOR TIMING PUMP RUNNING CONTACT VALVE MICRO SWITCHES MODEL 762 SERIES VALVE CR 4 32 35 137 35 36 38 25 38 01 OX NO SV 1 SV 2 OL YEL MS4 BRN 3 PHASE ce oT pu veL 62 M o DIVERT VALVE LEAK DETECT VALVE OL NC NC 24 24 ee DIVERT VALVE OR LEAK DETECTOR TIMING PUMP MICRO SWITCH OR SWITCH MOTOR 24 VAC 24 VAC VALVE MICRO SWITCHES MODEL 262 SERIES VALVE 32 35 37 35 36 BED NC BK 2 ani o NO NO DIVERT VALVE LEAK DETECTOR MICRO SWITCH MICRO SWITCH 24 VAC 24 VAC 49 ALLEN BRADLEY SLC 500 41 4 4 45 45 48 49 50 51 52
33. 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 federal regulators Divert Flow Leak Detector Flow Forward Flow Figure 3 Reverse Acting Flo Diversion Valve 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 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 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 dete
34. ates from 120 Volts AC There are five LED diagnostic indicators on the front of each processor POWER PCRUN CPUFAULT FORCED I O BATTERY LOW POWER Indicates that the processor is energized and power is being applied PC RUN Indicates the processor is in the Run Mode CPU FAULT Indicates the processor has detected an error in the CPU expansion I O or memory Outputs are turned off and operation is automatically stopped FORCED I O Indicates one or more input or output addresses have been forced to an ON or OFF state BATTERY LOW An optional battery provides backup power for the CMOS RAM Memory This LED alerts you when the battery should be replaced Tri Clover does not supply this option An internal Capacitor backed RAM Memory is provided This will maintain the RAM Memory for approximately 15 days from time of power loss see chart provided in this manual NOTE If battery is not used a jumper is provided to prevent constant illumination of this LED MEMOREY MODULES NOTE Tri Clover provides and installs a UVPROM Memory Module This will provide maximum protection against user program loss or program alteration due to battery backup drain processor malfunction or excessive noise The UVPROM Memory Module plugs into the SLC 500 controller With a memory module you can Save the contents of the processor RAM memory for storage purposes Load the contents of the UVPROM into the processor RAM The UVPROM memory m
35. bled To test the microswitch adjustment A Make certain the valves are properly assembled paying particular attention to the actuator 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 Make sure the temperature sensing element of the Safety Thermal Limit Recorder Controller is below legal pasteurization temperature Momentarily turn on the timing pump to make sure it is operating properly and then turn it off Switch the valve to the forward flow position by selecting the inspect position on the panel Note After time delay valve will switch position Remove the tri clamp that attaches the bonnet clear plastic stem guard assembly Slide the assembly off the stem Unscrew the nut at the end of the exposed stem for stem removal Slide the stem and o ring off the stem connected to the actuator Figure 5 762 227MRAL Gauge Placement 11 INSTALLATION 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 Apply required air to the actuator for normal operating conditions ACTUATOR AIR PRESSURE REQUIREMENTS VALVE SIZE PSIG 2 70 21 2 70 3 70 Turn the selector switch to the
36. blies are not properly connected to actuator stem Microswitch roller is not engaging indicating nut on actuator stem Adjustable cam screw is loose on the timer CT1 Timing cam is loose on shaft Defective timer Timer CT1 will not operate 25 obstructions and take necessary corrective action Test Filter Regulator and repair or replace if defective Test solenoids Replace if necessary Replace diaphragm Check for excessive back pressure Check air system as described above Replace switch refer to controller manual Refer to electrical troubleshooting chart and take corrective action Inspect quick exhaust valve and remove obstruction or replace valve Disassemble valve and remove obstruction Turn on switch Assemble valve stems to actuator stems correctly Adjust microswitch Establish proper setting and tighten screw Tighten setscrew Refer to instructions furnished with the timer and take necessary corrective action Loosen gear rack until timer starts then tighten gear rack screw TROUBLESHOOTING ELECTRICAL TROUBLE PROBLEM 1 Product Position PROBLEM Timing pump does not start cold temperature Timing pump does not run pasteurizing temperature Divert valve does no move to forward flow Leak detector valve does not assume forward flow 26 PROBLEM Put test lamp on terminals two and three lamp lights proceed below If no light
37. ct all electrical and pneumatic power to the control top Hazardous voltage can cause electrical shock The actuator stem moves with extreme force and suddenness Disconnect the Cable Unscrew the knurled ring of the cable counter clockwise After the threads disengage pull the cable off of the connector Remove The Rear Cover Remove the 4 cover screws and o rings located in the screw hole counter 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 Take care not to damage the wire insulation or crimp the terminal Remove the electrical connector nut by turning counter clockwise Push the electrical connector through the hole in the rear cover Remove the rubber electrical connector gasket Remove the rear cover gasket Remove the Front Cover Loosen the four cover screws until they disengage their mounting holes in the base Remove the cover gasket 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 2turns Slide the switches and their black mounting blocks completely from the guide tracks in the base Remove the solenoid NOTE Not every control top contains a solenoid Continue to the next step if no solenoid is present Pull the two solen
38. ct valve making sure that the air lines are connected to the proper valves Quick couplers are not acceptable as air connection joints Pressure Capacity Limits 862W 227M amp 762 227M Series Standard FDV Valve Model Size Maximum Maximum Air Supply Product Pressure Capacity GPM Pressure PSI PSI 762 227M 3 50 762 227M Series Reverse Acting FDV Valve Model Size Maximum Maximum Air Supply Product Pressure Capacity GPM Pressure PSI PSI mw so 0 o 50 lw Maximum differential pressure not to exceed 30psi Product pressure can be increased with the reduction of capacity Please contact Tri Clover if higher limits are required 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 INSTALLATION PRESTARTING PRESTART TESTS Before putting the Flo Diversion Valve into operation it is necessary to check the
39. ctivated by the cams The timer motor drives the camshaft at RPM 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 2096 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 14 INSTALLATION 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
40. divert position and frequency pin Cam Timer 1 CT1 Controls valve cycling during clean operation Returns to start position after CIP cycle is complete Contains drive motor cam shaft three cam actuated switches and three sets of cams both stationary and adjustable Cam 1 is homing cam cam 2 is for divert valve and cam 3 is for leak detector valve Control Relay with Timer 1 CRT1 Delays opening of forward flow part of leak detector valve for a predetermined length of time after divert valve has assumed forward flow position Adjustable setting from 0 to 15 seconds Control Relay with Timer 2 CRT2 Energized when selector switch is placed in Product position It is used to delay valve operation until timing pump is completely stopped Set at 15 seconds Off Delay Control Relay with Timer 3 CRT3 Energized when the timing pump circuit is closed It is used to delay the pump Dropout operation Set at 1 second Manual Diversion Switch Used to manually position valves in divert position when selector switch is in the Product position Terminal Strip TB1 Used to interconnect panel components to external components Also used for troubleshooting electrical circuits Low Temperature Limit Switch Located in the controller not in the Flo Diversion valve control unit Timer CRT5 Places Flo Diversion Valve in divert flow position for ten minutes in the clean position Seal on Control Box Meets requir
41. e below drawings shows the microswitches in their position when no air is on the valve and the pasteurization temperature is below the legal setting Notice that the microswitch wires 18 and 4 are wired to the contacts for the 262 valves and they are wired to the N O contacts for the 762 valves This is the result of mounting the switches in the groove on the 262 valve and on the high part of the nut on the 762 valve Microswitch button is pushed in forcing the common to make with the contact Note The valves do not have air applied to the actuators at this time The control logic is designed accordingly for either valve to reflect this change in the microswitch wiring Microswitch wiring for 762 762RA Valves 18 MS 2 NO NC Divert Valve Leak Detect Microswitch wiring for 262 Valves Activated Switch 3 29 18 7 29 762 GRN a KCN Divert Valve Leak Detect Deactivated Switch 262 38 ALLEN BRADLEY SLC 500 PLC STATE AND FEDERAL REGULATORY SEALS Refer to the picture of the Allen Bradley SLC 500 below NOTE Contact Alfa Laval for information on new Micro Logix 1200 panel A place is provided for the Inspecting Regulatory Agencies to place a seal on the panel The panel door clamping latch has a hole in which to insert a wire seal This is normally done after the
42. e forward flow position until The pasteurization temperature becomes sub legal The selector switch is moved from the product position The manual diversion switch is activated An electrical mechanical malfunction 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 balance tank depending on piping arrangement 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 MSI 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 se
43. ector switch on the panel to the inspect position This will allow removal of one of the valve stems Remove the four screws that secure the green control housing cover and remove the cover Remove the Tri clamp that attaches the bonnet clear plastic stem guard assembly Slide the bonnet stem guard assembly off the stem 13 INSTALLATION Unscrew the nut at the end of the exposed stem for stem removal Slide the stem and o ring off the stem connected to the actuator 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 Position the valve in the divert flow position 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 down until the switch becomes deactivated Tighten the mounting screws 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 Place the gauge in the vacant switch tracks of the control housing Secure the green switch cover with the four mounting screws 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 a
44. emain in this position until the manual diversion switch is released When the switch is released the valves will follow the normal product cycle 4 MICROSWITCH TEST for 762 227 amp 862W 227 The microswitches in the 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 microswitch and adjustment follow the instructions below A Makecertain the valves are properly assembled paying particular attention to the actuator mounting bolts yoke mounting bolts body clamps and the valve stem to actuator stem connection Make sure the temperature sensing element of the Safety Thermal Limit Recorder Controller is below legal pasteurization temperature Momentarily turn on the timing pump to make sure it is operating properly and then turn it off Leak Dectect valve Remove the valve body clamp and the upper valve body port clamp on the valve Liftthe valve off the lower body Turn the selector switch to the Inspect postiion After time delay valve will switch position Unscrew the valve stem off the actuator stem enough to insert the gap hauge between the two stems Tighten the valve stem onto the gauge Turn the selector switch to the PRODUCT position and the timing pump will not start Remove the gap gauge and reassemble the valve Ensure the valve is properly and completely assembled
45. ements of regulatory agencies 28 PARTS LIST PANEL Howto order replacement parts All orders for repair parts must contain the following data 1 Complete model number from name plate 2 Serial number from name plate 3 Keynumber and description The following exploded view and accompanying parts facilitate ordering repair parts from the factory All parts list illustrated are indexed to the parts list by key numbers Description Description 1 Enclosure stainless steel 18 Tubing 1 ft Panel Nameplate 19 Solenoid Valve Air Filter Regulator 19A Solenoid Coil Only Regulator Fitting 1 21 2 Pole Timed Relay 115 or 220 VAC Bulkhead Fitting 22 Relay Bracket Nameplate 23 Pneumatic Timer for Relay Knob Operator with Contact Block 24 3 Timer 115 or 220 VAC 9 Pushbutton green with Contact Block 25 Cam Timer Gear Rack 10 Cord Connector 25A Timer Motor Only 110 or 220 VAC 11 Nut 26 Terminal Strip Assembly complete 12 Connector 26A Barrier Strip Only 13 Hose black each 10 ft long 26B Terminal Only 14 Connector 26C EndClamp Only 15 Brass Nut 27 Timer Socket 16 Elbow Fitting ya NPT x 1 4 PL 28 Timer Solid state plug in 115 or 220 VAC 17 Solenoid Head amp Tail Module Set Itis recommended that one spare part be stocked for each item marked e ado i
46. ening of the divert valve to forward flow and the opening ofthe leak detector valve to forward flow position Follow the microswitch adjustment instructions below for the leak detect valve and then begin again with step A for the divert valve A Checkthe valve to make sure it is properly and completely assembled CAUTION Turn off electrical power to the valve and shut off air supply 12 INSTALLATION Remove the valve body clamp and the upper valve port clamp on the leak detect valve This will allow access to the valve stem when the valve is lifted off the lower body The divert valve requires removal ofthe lower body for access to the valve stem Apply air to the actuator to move the stem off the upper seat Loosen by unscrewing the valve stem enough to insert the gap gauge between the actuator stem and the valve stem Tighten the valve stem onto the gauge Remove air from the actuator Remove the four screws that secure the green control housing cover and remove the cover 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 Tighten microswitch mounting screws Remove the gap gauge by applying air to the actuator and loosening the valve stem Then tighten the
47. enoid mounted into the control top is a single coil spring return model 1 Install all three selector block o rings 2 Place the selector block into the base Pay special attention to its orientation 21 MAINTENANCE 3 Place the solenoid on top of the selector block and fasten with two screws STOP BLOCK INSTALLATION NO SOLENOID ONLY 1 Install all four o rings into the stop block Place S S stop block support on top of stop block and fasten the stop block with two screws 2 3 Fasten the wires to the electrical connector 4 Place the rubber gasket over the electrical connector threads Push the threaded end of the connector through the hole on the rear cover Orientate the connector flange as shown on the inside of the cover and fasten with the connector nut Place all the wire harness and solenoid wires through the access hole on the base Follow the wire connection diagram and push the wire terminals over the electrical connector pins Note Use of needle nose pliers is recommended Take care not to damage the wire insulation REAR COVER INSTALLATION 1 Place the four o rings onto the mounting hole counter bores Place the mounting screws into the holes Coil the wires approximately one half turn so that they will fit into the rear cover cavity The cover can be fastened to the base in any orientation because it is perfectly square Place the t s NPT air fittings in the housing as shown Set the switches See sect
48. ge 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 Recorder Controllers 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 normal position 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 c
49. h 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 16 MAINTENANCE INTRODUCTION The Flo Diversion Valve has been designed to provide many years of trouble free service with a minimum amount of maintenance The only maintenance required other than 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 disassembly procedures DISASSEMBLY WARNING To prevent personal injury relieve pipe line pressure and drain all fluid completely before servicing 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 a
50. h the activating nut with the two retaining rings to the non threaded end of the actuator stem Place all seals on the base Three o rings on the bottom of the base IMPORTANT When installing the largest diameter o ring start it in groove opposite the air relief notch and press it in towards the notch Be careful not to stretch o ring e Rearcovergasket Pressurerelief plug into the hole on the rear of the base above the mounting flange Fasten the base to the actuator IMPORTANT There are two possible configurations when mounting a control top base to an actuator The mounting configuration is dependent upon if a solenoid is contained in the housing or not Orientate the control top so the air passage hole in the actuator lines up with the appropriate air passage in the control housing See control top drawing in back of this manual for proper assembly Fasten the housing to the base with three screws and lock washers on the inside and one bolt and a lock washer on the outside SWITCH INSTALLATION 1 Assemble the switches to the mounting blocks as shown see control top drawing in back of this manual Slide the switch into the base mounting tracks Tighten the switches in a random location Instructions for proper adjustment are described later IMPORTANT Do not over tighten the screws used to mount the switches Place the wire harness onto the switch SOLENOID SELECTOR BLOCK INSTALLATION IMPORTANT The 4 way sol
51. in the actuator end caps to blow out the packings and bushings The nuts on the actuator stem will prevent the bushing form flying off the end of the actuator stem Remove air supply once the bushing and packing are forced out Wipe stem clean Lubricate new packing with Tri clover C137 lubricant Partially insert packing into smallest counter bore using a flat tool to assist the outer lip DO NOT DAMAGE OF ROLL THE PACKING LIP DURING INSTALLATION Place bushing on top of the packing Push on the bushing until outer flange 2 Cy is flush with actuator Slide new packing over the stem with the V side facing the actuator CN 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 s inch 3mm or smaller diameter punch Insert 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 CS 417 831 1411 csidesigns com 20 MAINTENANCE CONTROL TOP ASSEMBLY STP is a registered trademark of STP Corporation Attac
52. 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 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 Mechanical A Turnthe 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 CTI in the control panel should start rotating The divert valve will move to the forward flow position in approximately thirty five seconds and the leak detector valve will move to forward flow approximately twenty seconds after the divert valve has been positioned If the panel also contains a ten minute CIP delay timer the timer will time out after ten minutes then the cam timer will start and operate as described above Cam timer will 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 un
53. ion on switch adjustment FASTEN FRONT COVER 1 Place gasket into cover Mount cover with four screws IMPORTANT The four cover screws must be tightened until the gasket compresses and begins to bulge out the sides The cover gasket must be sufficiently tightened to seal against spraying liquids Failure to tighten could result in control top leakage and electrical failure 2 Attach the Electrical Cable Align the guide of the connector with the cable and push them together Tighten completely by screwing the cable onto the connector 22 MAINTENANCE VALVE ASSEMBLY WARNING To prevent personal injury keep hands and tools out of and away from valve bodies and stems when applying or releasing air to an actuator the actuator stem asembly moves with extreme force and suddenness IMPORTANT Replace all worn or damaged components as required Spray stem and o ring with Tri Clover L 1011 Sanitary Lubricant Make sure all valve bodies are mated properly before securing with clamps Tighten all clamps securely to assure proper alignment When disassembling and assembling valve bench area should be clean to prevent marking and nicking of seats IMPORTANT Replace nylon lock before threading valve stem onto actuator stem see section Actuator Stem Nylon Lock Replacement 762 227 amp 862W 227 VALVE ASSEMBLY Place o ring into counter bore above air port on yoke Place green bearing retainer into bott
54. mp 862W 227 VALVE DISASSEMBLY 1 Besurethe timing pump is turned off Remove the lower body line clamps on the divert valve and the upper body outlet line clamp from the leak detect valve Remove divert valve body clamp and separate the lower body from the upper body Remove leak detect body clamp and separate the upper valve assembly from the lower valve body Move selector switch on the control unit to the inspect position to extend valve stems for removal a RON After the valves have assumed the inspect position unscrew the valve stems from the actuator stems Disconnect electrical power to the control housing and shut off air supply to the valves Separate upper valve body from yoke by removing three bolts Remove split bushing sleeve and o ring from upper bogy 8 Separate yoke from actuator by removing four bolts Remove green bushing retainer and o ring between yoke and actuator 417 831 1411 csidesigns com CS 17 MAINTENANCE 762 227MRAL VALVE DISASSEMBLY 1 Be sure the timing pump is turned off Remove the four tri clamps that connect the valve to the process system To separate the Flo Diversion Valve into two valves remove the tri clamp that connects the valves together Remove Tri clamp and separate the bonnet end cap assembly from the valve body Remove the four screws and washers to separate the bonnet from the end cap Pull the clear plastic stem guard out of the end cap Remove o ring from
55. nk for reprocessing or to continue processing through the HTST unit 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 Leak Detector Solenoid Valve Divert Solenoid Valve SV1 Manual 3 Position Diversion Selector Button Switch CIP CAM Timer CT1 10 Minute Terminal CIP Delay Timer R5 Strip Figure 2 Control Panel INTRODUCTION The product is circulated through the regenerator and 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 SVI 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 th
56. o 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 controls the sequencing of the valves during the CIP Clean in Place operation The Model 48 2120 E voltage Control Panel 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 The Flo Diversion Valve is operated by a HTST controller or a Safety Thermal Limit Recorder Controller to direct product flow either to the raw product tank balance ta
57. odule is used when program security is required because the program in the UVPROM cannot be altered when it is installed in the controller The UVPORM memory is programmed at Tri Clover to download the contents of the UVPORM Memory Module at power up Additionally once downloading takes place the RAM memory will match the UVPROM memory The status table bits are set to tell the processor to detect the presence of a memory module in order to enter RUN mode If UVPROM Memory Module is removed processor will fault when power is reapplied IMPORTANT The UVPROM Memory Compartment and COMMUNICATION PORT located on the face of the PLC can be sealed by the Regulatory Official This will prevent unauthorized entry and protect the integrity of the original memory With the Communication Port sealed a Programming terminal cannot be connected to the processor 42 ALLEN BRADLEY SLC 500 INPUT AND OUTPUT STATUS INDICATORS Red LED indicators are identified with address numbers that correspond to the numbers on the inside of the hinged covers for easy verification The 18 Inputs are 0 17 wired to the bottom of the controller The 12 Outputs are 0 11 and wired to the top of the controller The addresses and their corresponding Inputs and Outputs are as listed below Input Name amp Function When LED ON 0 Switch in PRODUCT position 1 Switch in INSPECT position 2 Switch in CLEAN CIP position 3 Manual divert Pushbot
58. oid wires through the access hole Remove the two mounting screws fastening the solenoid Remove the solenoid and triangular selector block located under the solenoid Remove the control top base from the actuator Remove all the air line 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 19 MAINTENANCE ACTUATOR BUSHING PACKING REPLACEMENT WARNING To prevent personal injury do not attempt to cut actuator open The actuator spring is compressed and under load 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 s nut to the actuator stem threaded end Apply 60 PSIG to the unthreaded air holes
59. om of actuator Place actuator onto yoke with threaded shaft end into the yoke Align yoke air port with unthreaded thru hole in actuator end cap Fasten with four bolts and lock washers Lubricate o ring with Tri Clover L1011 Sanitary Silicone Spray Insert o ring into body place washer on top of o ring place split bushing on top of washer Fasten upper body to yoke with three bolts and lock washers Apply 60 psig air to actuator Push valve stem through bonnet until it meets the actuator stem Partially thread valve stem onto actuator stem by hand until nylon lock resistance is felt Apply an open end wrench over the valve stem flats turn clock wise and tighten until valve stem meets actuator stem shoulder Remove airto actuator Place gasket in body groove and clamp together Cycle valve at least 6 times Operate valves after assembly to be sure they are operating correctly Inspect all air line connections for leaks 23 MAINTENANCE 762 227MRAL VALVE ASSEMBLY Place o ring into counter bore above air port on yoke Place green bearing retainer into bottom of actuator Place actuator onto yoke with short shaft end into the yoke Align yoke air port with unthreaded thru hole in actuator end cap Fasten with four bolts and lock washers Insert the o rings and bushings into the valve bonnets Attach the bonnet to the yoke with four screws and washers Slide the valve stem thru the bonnet and yoke then screw the stem onto
60. ontact block 2 and also check CRT2 timing contact wire number 3 and 9 There is an adjustable time delay before these contacts close Check Step at put test lamp on terminals 2 and 11 Proceed as described under Step a2 Put test lamp on terminals 2 and 8 If no light proceed below If light on check motor on CT1 and cam operated switches Terminals 2 and 12 If no light proceed below If light on test for mechanical problems in the valves Check air supply to solenoid valves Terminals 2 and 9 If no light check timing contact and CRT3 wire number 9 Wait for time delay to elapse If light on check contact block 1 on Inspect Product clean Switch PARTS LIST CONTROL PANEL COMPONENTS 3 position selector switch Places divert and leak detect valve in proper circuit Inspect puts air on valves to permit dismantling Uses solenoid valve 1 and solenoid valve 2 Product permits valve function only in approved and recognized procedures Uses solenoid valve 1 solenoid valve 2 microswitch 1 microswitch 2 timer 2 and timer 3 Clean Permits CIP of the valve with the HTST unit Uses solenoid valve 1 solenoid valve 2 and timer 1 Solenoid Valve 1 SV1 Controls air supply to the divert valve Solenoid Valve 2 SV2 Controls air supply to the leak detect valve Microswitch 1 and 2 MS1 and MS2 Controls red and green indicating lights timing pump in
61. onventional 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 The 862W 227M is a modified version of the standard upright 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 which surrounds the upper portion of the valve stems A fluoroelastomer seat style combines PE with a high temperature bushing both of 18 which are engineered to withstand the high temperatures encountered in aseptic Steam processing applications 4 Steam In a Cross section drawing illustrating the path of steam through the steam collar Figure 1 Flo Diversion Valve INTRODUCTION 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 t
62. quentially 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 CS 417 831 1411 csidesigns com INSTALLATION UNPACKING AND INSTALLING EQUIPMENT UNPACKING EQUIPMENT The Flo Diversion Valve should be unpacked immediately upon receiptfrom 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
63. s a means of determining and correcting most mechanical and electrical problems Note The troubleshooting chart is divided into two parts one mechanical and electrical A list of the control panel components with their reference designations and a brief description of their function is included in the Parts List section following the Troubleshooting section The Low Temperature Limit switch LSI and the indicating lights are part of the applicable HTST Controller or Safety Thermal Limit Recorder Controller used with the Flo Diversion Valve If trouble is encountered with these external components refer to the applicable service manual provided with the equipment MECHANICAL TROUBLE PROBLEM PROBABLE CAUSE REMEDY 1 Inadequate air Inadequate air supply to valves Inspect air lines for leaks or supply to valves Valves will not assume forward flow position at any selection switch setting Valve will not assume divert position Timing pump will not start Divertvalve does not move to forward flow Faulty Filter Regulator Defective solenoid valve Broken diaphragm on quick exhaust valve Response time above one second Inadequate air supply Capillary tube of pressure thermo switch in controller is broken or leaking Electrical difficulties Quick exhaust valve is not functioning properly Obstruction in divert or leak detector valve Timing pump switch is not on One or both valve plug assem
64. tep c2 If light is on check for proper contact closure on TR3 between wire number 10 and 14 Disconnect leads to SV2 Test for continuity and if none replace coil ELECTRICAL TROUBLE CONT PROBLEM 1 Product Position Cont 2 Position 3 Clean Position PROBLEM Green light not on valve moved to forward flow Red light not on STLR controller at low temperature Valve does not assume divert position Divert valve does not assume forward flow Leak detector valve does no assume forward flow Divert valve will not assume forward flow 27 TROUBLESHOOTING PROBLEM Replace bulb with known working one 24VAC If light not on proceed below Put test lamp on terminals 2 and 7 If light on check 220V to 24V light transformer If light not on adjust or replace 51 Check Step 1 Put test lamp on terminal 2 and 4 If light on check the 220V to 24V light transformer If light not on adjust or replace 51 Terminal 2 and 18 If no light adjust or release MS1 If light on adjust or replace MS2 Terminal 2 and 6 If light on STLR recorder temperature contact stuck in high temperature position No light check for mechanical problems in valves Terminals 2 and 3 If light on proceed below no light check power main and fuse in STLR instrument Terminals 2 and 10 If no light check Inspect Product Clean switch c
65. 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 15 MAINTENANCE CLEANING 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 flus
66. the actuator shaft Place the body gasket into the groove of the bonnet Assembly the two valve bodies and tee with two gaskets and two clamps to make up the valve body assembly Each valve that makes up the Flo Diversion Valve consists of one right hand tangential body and one left hand tangential valve body The valve must be assembled to accomodate the process system as well as the capability to drain Insert the stem that is attached to the actuator into the proper end of the valve body assembly Clamp the valve body to the bonnet Apply air to the actuator to allow for stem assembly Slide the o ring and the hollow stem onto the stem attached to the actuator Install the stem nut to hold the stems together and to compress the o ring seal Remove air from the actuator Assembly the end cap to the bonnet with three screws and lock washers Push the grooved end of the clear plastic stem guard into the end cap Install the valve body gasket into the groove of the valve body Slide the end cap bonnet assembly onto the valve stem then clamp to the valve body Operate valves after assembly to be sure they are operating correctly Inspect air line connections for leaks 24 TROUBLESHOOTING 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 provide
67. the end cap and the o ring and bushing from the bonnet Apply air to actuator for stem removal Unscrew the stem nut and remove the stem and o ring Remove air to the actuator Remove the clamp that connects the actuator bonnet yoke and stem assembly to the valve body Unscrew the stem from the actuator shaft Separate bonnet from yoke by removing three bolts Remove bushing and o ring from valve bonnet Separate yoke from actuator by removing four bolts Remove green bushing retainer and o ring between yoke and actuator 10 Remove the two clamps and gaskets to separate the remaining valve body assembly VALVE COMPONENT INSPECTION Valve Body Seats Inspect for nicks and scratches and other signs of excessive wear Leakage past the seats may result from these types of irregularities Valve Stem amp 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 18 MAINTENANCE CONTROL TOP DISASSEMBLY WARNING To prevent personal injury disconne
68. the memory contents of the RAM and UVPROM do not match a fault will be indicated and the controller will not run The controller will not run if a UVPROM module is not installed Test for the proper operation of the panel by following the Prestarting procedures listed elsewhere in this manual Progress through the Inspect Product Clean positions of the selector switch and check for proper valve operation If the control panel functions as designed then the correct legal memory is installed NOTE When calling Tri Clover for assistance be prepared to provide Tri Clover with all the pertinent information the panel model number software version number electrical drawing number and serial number All this information can be found on the two legend plates glued to the outside panel door 40 ALLEN BRADLEY SLC 500 PLC SOFTWARE VERSION NUMBERS as or 8 4 94 It is to be expected that software revisions will have to be accomplished as State and or Federal regulations dictate The Federal FDA Regulatory Agency will be notified of each Tri Clover software revision and version number Atthis time the following Tri Clover software versions exist Additional versions will be included with future reprints of this manual VERSION 1 01 This has the same operating procedure based upon the original Electro mechanical control panel as described in this manual All the switch operations and timing functions are identical 15 sec
69. the seal over the memory compartment is broken open the lid to the compartment and physically examine the UVPROM memory module BE SURE the lamicoid strip is still glued over the module window This lamicoid strip should be labeled with the Tri Clover logo and the software version number stamped on it If the module shows evidence of tampering or the lamicoid strip is missing notify Tri Clover so that anew UVPROM module with the legal program installed can be immediately forwarded to the customer No cable or programming device should be connected to the Communication Port on the processor If a cable exists there is strong evidence of attempted program tampering However program changes cannot be made unless the program PASSWORD is known This PASSWORD is available to only selected Tri Clover engineering personnel Recycle power to the control panel and the contents of the legal UVPROM module will be downloaded to overwrite the contents of the RAM See comments below Make sure the correct Tri Clover memory chip is installed properly in the socket and that the control panel has been checked as described above Place power on the panel The contents of the UVPROM module is downloaded to the RAM memory each time the power is cycled off on This insures that ONLY THE UVPROM MEMORY will run the processor If the RAM memory had been changed tampered with or glitched it will now assume the program as installed on the UVPROM If somehow
70. til the homing cam returns to the start position The homing cam is the cam on the left side of the timer The valves will both return immediately to the divert position Move the selector switch to the inspect position The valves will assume the forward flow position 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 temperature is reached the divert valve will assume the forward flow position The leak detector valve will be delayed in closing the time interval depending on the setting of timer CRTI The green indicator light should come on and the red indicator light go off when the 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 both valves to assume the divert position until temperature is raised to the pasteurization level at which time the valves will again operate in the product cycle Change the selector switch setting from product to clean while pasteurization temperature is being maintained and the timing pump is on The valves should immediately assume the divert position and the timing pump should stop In 35 seconds the divert valve should assume
71. ton Diverts Flo Diversion valves when valves are in forward flow and switch is in PRODUCT position Divert Flow Light Microswitches Input from divert and leak detect valves to indicate both valves are in divert flow DE ENERGIZED Panel mounted red light is also ON whenever this input is ON Divert Flow STLR Input from valve microswitches and STLR to indicate divert flow during sub legal temperatures Used as timing pump interlock Forward Flow Legal Temperature STLR Input from indicating legal temperature has been reached Forward Flow Light Microswitches Input from divert valve microswitch to indicate valve is forward flow energized Panel mounted green light is also ON whenever this input is ON Timing Pump Running Input from timing pump relay to signal the controller that the pump is ON Used as interlock to booster pump Divert Valve CIP Optional input from customer s control to pulse divert valve whenever input is ON and switch is in CLEAN but only after ten minute time delay Leak Detect Valve CIP Optional input from customer s control to pulse leak detect valve whenever input is ON and switch is in CLEAN but only after ten minutes time delay Booster Pump CIP Optional input from customer s control to run booster pump whenever input is ON and switch is in CLEAN Ten minute CIP time delay is not required Eight minute CIP cycle Optional input to increase
72. 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

762 Flo-Diversion Valve Manual

Contents

Download Pdf Manuals

Related Search

Related Contents