Alfalaval CPM-2 User manual

IM70775-EN4200-CPM-2 Constant-Pressure Modulating Valve
Instruction Manual

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Name Title
Company Signature
Alfa Laval
6000 Kolding
[phone]
Company Name
Address
Phone No.
hereby declare that
Denomination Type Year
Declaration of Conformity
The designating company
Designation
Constant-Pressure Modulating Valve CPM-2
Bjarne Søndergaard
Manager, Product Centres,
Compact Heat Exchangers & Fluid Handling
Alfa Laval
is in conformity with the following directives:
- Machinery Directive 2006/42/EC

The information contained herein is correct at the time of issue but may be subject to change without prior notice.
5
Table of contents
1. Safety .................................................................................................... 6
1.1 Important information ....................................................................... 6
1.2 Warning signs .................................................................................. 6
1.3 Safety precautions ........................................................................... 6
2. Installation ............................................................................................ 7
2.1 Unpacking/Delivery .......................................................................... 7
2.2 General installation ........................................................................... 8
2.3 Welding ............................................................................................ 9
2.4 Fitting of Booster (optional extra) ................................................... 10
3. Operation ............................................................................................. 12
3.1 Operation ....................................................................................... 12
3.2 Fault finding ................................................................................... 13
3.3 Recommended cleaning ................................................................ 14
4. Maintenance ....................................................................................... 15
4.1 General maintenance ..................................................................... 15
4.2 Dismantling .................................................................................... 16
4.3 Assembly ....................................................................................... 18
5. Technical Data .................................................................................... 20
5.1 Technical Data................................................................................ 20
5.2 Selection / Pressure drop - capacity diagram ............................... 21
6. Parts lists and service kits ................................................................. 22
6.1 CPM-2 ........................................................................................... 22
6.2 Booster .......................................................................................... 24

6
WARNING! Indicates that special procedures must be followed to avoid severe personal injury.
CAUTION! Indicates that special procedures must be followed to avoid damage to the valve.
NOTE! Indicates important information to simplify or clarify practices.
General warning:
Unsafe practices and other important information are emphasized in this manual.
Warnings are emphasized by means of special signs.
All warnings in the manual are summarized on this page.
Pay special attention to the instructions below so that severe personal injury or damage to the valve are avoided.
1.1 Important information
1.2 Warning signs
1.3 Safety precautions
1. Safety
Important information
Always read the manual before using the valve!
Caustic agents:
Installation:
-Always observe the technical data (see chapter 5).
-Always release compressed air after use.
-Never touch the valve top if compressed air is supplied to the valve.
- The valve and the pipelines must never be pressurised when dismantling the valve.
Operation:
Always observe the technical data (see chapter 5).
-Always release compressed air after use.
-Never touch the valve or the pipelines when processing hot liquids or when sterilizing.
-Never touch the valve top if compressed air is supplied to the valve.
Always handle lye and acid with great care.
Maintenance:
-Always observe the technical data (see chapter 5).
-Always disconnect compressed air before service.
- The valve must never be hot when servicing it.
- The valve and the pipelines must never be pressurised when servicing the valve.
Warning signs
Safety precautions
Transportation:
Always
secure that compressed air is released
Always
secure that all connections is disconnected before attemt to remove the valve from the installation
Always
drain liquid out of valves before transportation
Always
used predesigned lifting points if defined
Always
secure sufficient fixing of the valve during transportation - if special designed packaging material is available it
must be used

7
2. Installation
The instruction manual is part of the delivery.
Study the instructions carefully.
CPMI-2: Constant-Pressure Modulating Inlet.
CPMO-2: Constant-Pressure Modulating Outlet.
2.1 Unpacking/Delivery
Step 1
NOTE!
Alfa Laval cannot be held responsible for incorrect unpacking.
Remove packing materials!
Step 2
Check the delivery:
1. Complete valve, CPMI-2 or CPMO-2.
2. Delivery note.
3. Instruction manual.
Step 3
Clean the valve ports for possible packing materials.
Avoid damaging the air connection and the valve ports.
Step 4
Inspect the valve for visible transport damages.
Recycling information.
• Unpacking
- Packing material consists of wood, plastics, cardboard boxes and in some cases metal straps.
- Wood and cardboard boxes can be reused, recycled or used for energy recovery.
- Plastics should be recycled or burnt at a licensed waste incineration plant.
- Metal straps should be sent for material recycling.
• Maintenance
- During maintenance oil and wear parts in the machine are replaced.
- All metal parts should be sent for material recycling.
- Worn out or defective electronic parts should be sent to a licensed handler for material recycling.
- Oil and all non metal wear parts must be taken care of in agreement with local regulations.
• Scrapping
- At end of use, the equipment shall be recycled according to relevant, local regulations. Beside the equipment itself, any
hazardous residues from the process liquid must be considered and dealt with in a proper manner. When in doubt, or in the
absence of local regulations, please contact the local Alfa Laval sales company.

8
Study the instructions carefully and pay special attention to the warnings!
The valve has welding ends as standard but can also be supplied with fittings.
CPMI-2: Constant-Pressure Modulating Inlet.CPMO-2: Constant-Pressure Modulating Outlet.
The required product pressure is preset by means of an air pressure regulating valve (optional extra).
2.2 General installation
Step 1
2. Installation
Step 2
Ensure that the flow direction is correct.
Step 3
Avoid stressing the valve.
Pay special attention to:
- Vibrations.
- Thermal expansion of the tubes.
- Excessive welding.
- Overloading of the pipelines.
Step 4
Fittings:
Ensure that the connections are tight.
Step 5
Air connection:
Step 6
Air pressure regulating valve: (optional extra)
An air pressure regulating valve must be used and should be
installed with min. clearance to the Booster/CPM-2 valve.
CPMI-2
Outlet
Correct!
Remember seal rings!
R1/4 " (BSP)
Pressure regulating valve
Air
As close as possible!
Risk of damage!
-Always observe the technical data (see chapter 5)
-Always release compressed air after use.
-Never touch the valve top if compressed air is supplied to the valve.
NOTE!
Alfa Laval cannot be held responsible for incorrect installation.
Air
Inlet
Outlet
Inlet
CPMO-2

9
2. Installation
Study the instructions carefully.
The valve has welding ends as standard. Weld carefully.
CPMI-2: Constant-Pressure Modulating Inlet.
CPMO-2: Constant-Pressure Modulating Outlet.
Caution!
Only fittings!
Step 6
Pre-use check:
Lift and lower the valve top several times to ensure that the
valve operates smoothly.
Pay special attention to the warning!
Step 2
CPMI-2:
1. Weld the valve body into the pipelines.
2. Maintain the minimum clearance so that the internal valve
parts can be removed.
Step 1
Dismantle the valve in accordance with steps 1-4 in section 4.2.
Pay special attention to the warning!
Step 3
CPMO-2:
1. Weld the valve body into the pipelines (see also step 4).
2. Maintain the minimum clearance so that the valve plug can
be removed.
Step 4
CPMO-2:
Never weld the bottom connection as this will make it
impossible to dismantle the valve.
Caution!
150mm 200mm (Booster)
250mm
Lift and lower by hand!
Step 5
Assemble the valve in accordance with the steps 6-10 in
section 4.3.
Tighten clamp 10-15 Nm
(7.5-11 lbf-ft )
2.3 Welding
200mm 250mm (Booster)

10
2.4 Fitting of Booster (optional extra)
Study the instructions carefully and pay special attention to the warnings!
The items refer to the parts list and service kits section.
The valve can be fitted with a Booster to allow for a product pressure higher than available air pressure.
Step 1
Step 3
1. Fit washer (3).
2. Refit the washer and the top nut on the valve plug.
Step 5
1. Roll diaphragm (7) down half it’s lenght.
2. Fit the diaphragm with piston (6) in Booster housing (1).
Step 2
1. Remove the valve top in accordance with step 3 in section
4.2
Pay special attention to the warnings!
2. Fit Booster housing (1) on the cover.
3. Fit and tighten lock nut (2).
Step 6
1. Fit cover (8) on Booster housing (1).
2. Fit and tighten clamp (9).
3. The valve and the Booster are now ready for operation.
Burning danger!
Step 4
1. Turn diaphragm (7) inside out.
2. Place piston (6) in the diaphragm so that the hole is visible.
Atmospheric
pressure
required!
2. Installation
-Never touch the valve or the pipelines when processing
hot liquids or when sterilizing.
- The valve and the pipelines must never be pressurised
when dismantling the valve.

11
2. Installation
Dimensions:
2.4 Fitting of Booster (optional extra)
ø164
CPMI-2: 232.4 CPMO-2: 272.3
Step 7
Compressed air:
An air pressure compensating regulating valve must be used
and should be installed with min. clearance to the Booster/
CPM-2 valve.
The pressure regulating valve (PR) and the pressure gauge
(PG) are optional extras.
Alfa Laval recommends using the air pressure regulating valve
from Alfa Laval.

12
3. Operation
Never touch the valve or the pipelines when processing hot
liquids or when sterilizing.
-Always observe the technical data (see chapter 5)
-Always release compressed air after use.
NOTE!
Alfa Laval cannot be held responsible for incorrect installation.
The valve is lubricated, adjusted and tested before delivery.
Study the instructions carefully and pay special attention to the warnings!
The items refer to the parts list and service kits section.
Step 5
Lubrication:
1. Ensure smooth movement between diaphragms (10,14)
and support sectors (12).
2. Ensure smooth movement of guide (9).
No vacuum!
Burning danger!
Cutting danger!
Lubricate if necessary!
(See page 11).
3.1 Operation
Never touch the valve top if compressed air is supplied to the
valve.
Step 1
Step 2
Step 3
Step 4
CAUTION!
There must not be vacuum in the valve as air can be drawn into
the product and diaphragms (14) can then be pulled out from
support sectors (12).

13
3. Operation
Problem Cause/result Repair
The valve does not maintain - Faulty diaphragm - Replace the diaphragm
the preset pressure - Guide (9) seizes - Lubricate the guide (see section 3.1)
- Incorrect operating range - Check the pressure drop over the
valve and check the flow rate (see
section 5.2)
- The available air pressure is - Increase the air pressure eg. by using
lower than the product pressure a Booster (see section 2.4).
- The air pressure is not correctly - Readjust the air pressure
adjusted
- Faulty air pressure regulating - Repair the valve or check that it is
valve or incorrect type pressure compensating
Product leakage - Worn diaphragm Replace the diaphragm
- Product affected diaphragm
Air leakage - Worn O-ring - Replace the O-ring
- Worn diaphragm (10) - Replace the diaphragm
- Worn and hard diaphragm (10) - Replace by a diaphragm of a different
grade for higher temperature (see
section 5.1)
Valve plug moving too fast Pressure pulsations because of Use an air throttling valve (optional extra
up and down (unstable) fast changes in process conditions between the air pressure regulating
valve and the CPM-2 valve.
Pay attention to possible break-down.
Study the instructions carefully.
The items refer to the parts list and service kits section.
3.2 Fault finding
NOTE!
Study the maintenance instructions carefully before replacing worn parts - see section 4.1

14
The valve is designed for cleaning in place (CIP).
CIP = Cleaning In Place.
Study the instructions carefully and pay special attention to the warnings!
NaOH = Caustic Soda. HNO
3
= Nitric acid.
3.3 Recommended cleaning
Step 1
Burning danger!
3. Operation
Always handle lye and acid with great care.
Step 2
Step 4
Never touch the valve or the pipelines when sterilizing.
Step 5
Examples of cleaning agents:
Use clean water, free from clorides.
1. 1% by weight NaOH at 700C
(158°F) .
Step 3
Ensure that the valve is fully open to allow for maximum CIP
flow.
2. 0.5% by weight HNO3at 700C
(158°F) .
Step 6
1. Avoid excessive concentration of the cleaning agent
⇒Dose gradually!
2. Adjust the cleaning flow to the process
⇒Milk sterilization/viscous liquids
⇒Increase the cleaning flow!
3. Always rinse well with clean water after the cleaning.
NOTE!
The cleaning agents must be stored/discharged in accordance with current rules/directives.
1 kg (2.2 lb) + 100 l (26.4 gl)
NaOH water
2.2 l
(0.6 gl) + 100 l (26.4 gl)
33%NaOH water
= Cleaning agent.
= Cleaning agent.
0.7 l
(0.2 gl) + 100 l (26.4 gl)
53% HNO3water = Cleaning agent.
Caustic danger!
Always use Always use
rubber gloves! protective goggles!
CPMI-2
No air pressure! Fully open!
CIP in
CIPout
Fully open!
CIP in
CIPout
CPMO-2
Sufficient air
pressure!

15
4. Maintenance
Recommended spare parts: Service kits (see chapter 6)
Order service kits from the service kits list (see chapter 6)
Ordering spare parts: contact the Sales Department
Diaphragms O-ring
Preventive maintenance Replace after 12 months Replace when replacing the
diaphragms
Maintenance after leakage Replace by the end of the day Replace when replacing the
(leakage normally starts slowly) diaphragms
Planned maintenance - Regular inspection for leakage Replace when replacing the
and smooth operation diaphragms
- Keep a record of the valve
- Use the statistics for planning
of inspections
Replace after leakage
Lubrication : (Before assembly)
- Guide: Molycote longtherm 2 Plus.
- Sectors: Molycote 111.
- Threads: Molycote TP42.
Maintain the valve carefully.
Study the instructions carefully and pay special attention to the warnings!
Always keep spare diaphrams and o-rings in stock.
Step 1
4.1 General maintenance
Step 2 Atmospheric
pressure
required!
Burning danger!
-Always observe the technical data (see chapter 5).
-Always disconnect the compressed air before service.
NOTE!
All scrap must be stored/discharged in accordance with current rules/directives.
- The valve must never be hot when servicing it.
- The valve and the pipelines must never be pressurised
when servicing the valve.

16
Study the instructions carefully.
The items refer to the parts list and service kits section.
Handle scrap correctly.
CPMI-2: Constant-Pressure Modulating Inlet. CPMO-2: Constant-Pressure Modulating Outlet.
4.2 Dismantling 4. Maintenance
Step 1
Loosen and remove clamp (6).
Step 2
CPMI-2:
Remove cover (7) together with the internal parts of the valve
from valve body (16).
Step 3
CPMI-2 and CPMO-2 valves:
Remove top nut (1), washer (2) and top (3) from plug 15a or
15b).
Step 4
Remove plug (15a) from the diaphragm unit and guide (9), or
for CPMO-2 remove plug (15b) from valve body (16) and
remove cover (7) and the internal parts of the valve.
CAUTION!
Ensure that cover (7) is turned downwards and plug (15a) is
pulled upwards so that sectors (12) are not separated from
diaphragms (10, 14).
Step 5
Remove lower inner ring (11) and lower diaphragm (14).
Step 6
Remove sectors (12).

17
4. Maintenance
Step 7
Remove outer ring (13), upper inner ring (11) and upper
diaphragm (10).
Step 8
Remove guide (9) from cover (7).
Step 9
Remove O-ring (8) from guide (9).
Step 10
Replace the O-ring and the diaphragms.
4.2 Dismantling

18
Study the instructions carefully.
The items refer to the parts list and service kits section.
Lubricate the guide, the sectors and the threads before assembly.
CPMI-2: Constant-Pressure Modulating Inlet. CPMO-2: Constant-Pressure Modulating Outlet.
Step 1
Fit O-ring (8)
Step 2
Lubricate guide (9) and fit it into cover (7).
NOTE!
Turn cover (7) downwards before continuing.
Step 3
Fit upper diaphragm (10), upper inner ring (11) and outer ring
(13) on guide (9) and cover (7).
NOTE!
The upper diaphragm has a small recess.The outer ring must
be fitted with the recess turned uppermost so that the
indication hole is fixed opposite the indication hole in the cover.
Step 4
Fit sectors (12) between upper inner ring (11) and outer ring
(13).
Step 5
Fit lower inner ring (11) and lower diaphragm (14).
Concentric grooves should point towards the steel segments.
Step 6
CPMI-2:
Fit plug (15a) in the diaphragm unit and guide (9) until the flange
of the plug contacts lower diaphragm (14).
Fit the correct diaphragm!
(Air side)
Fit the correct diaphragm!
4.3 Assembly 4. Maintenance

19
4. Maintenance 4.3 Assembly
Step 7
Fit valve body (16) in cover (7).
Step 8
CPMO-2:
Fit plug (15b) through valve body (16) and in the diaphragm
unit and guide (9) until the flange of the plug contacts lower
diaphragm (14).
Step 9
Fit top (3), washer (2) and top nut (1) on plug (15a or 15b).
Step 10
Fit and torque tighten clamp (6) to 10-15Nm
(7.5-11 lbf-ft) .
Step 11
Pre-use check:
Lift and lower the valve top several times to ensure that the
valve operates smoothly.
Pay special attention to the warning!
10-15Nm
(7.5-11 lbf-ft)

20
It is important to observe the technical data during installation, operation and maintenance.
Inform the personnel about the technical data.
5. Technical Data5.1 Technical Data
Data
Max. product pressure 1000 kPa (10 bar)
(145 psi)
Min. product pressure No vacuum
Temperature range -100C to +950C
(14°F to 203°F)
Temperature range (with upper diaphragm inPTFE/EPDM) -100C to +1400C (14°F to 284°F) (higher on request)
Air pressure 0 to 600 kPa (0 to 6 bar)
(0 to 87 psi)
Flow range Kv (Lv) , fully open (∆p = 1bar) (14.5 psi) Approx. 23m3/h (101 gal/m)
Flow range Kv (Lv) , low capacity (∆p = 1bar) (14.5 psi) Approx. 2m3/h (8.8 gal/m)
(Alternative size) (regulating area)
Approx. 15m3/h
(66 gal/m)
(CIP area)
Materials
Product wetted steel parts AISI 316 L
Other steel parts AISI 304
Upper diaphragm Nitrile (NBR), (standard)
Lower diaphragm PTFE covered EPDM rubber, (standard)
Alternative upper diaphragm EPDM/PTFE, (for temperatures 95-140oC)
(203°F to 284°F)
Alternative upper diaphragm Solid Teflon (PTFE), (for temperatures above 140oC) (284°F)
Alternative lower diaphragm Solid Teflon (PTFE), (for temperatures above 140oC) (284°F)
O-ring Nitrile (NBR), (standard)
Alternative O-ring Viton (FPM), (for temperatures above 95oC)
(203°F)
Finish Semi bright
Noise
One meter away from - and 1.6 meter above the exhaust the noise level of a valve actuator will be approximately 77db(A)
without noise damper and approximately 72 db(A) with damper - Measured at 7 bars air-pressure.

21
5.2 Selection / Pressure drop - capacity diagram
It is important to observe the technical data during installation, operation and maintenance.
Inform the personnel about the technical data.
CPMI-2: Constant-Pressure Modulating Inlet.
CPMO-2: Constant-Pressure Modulating Outlet.
NOTE! For the diagrams the following applies:
Medium: Water (200C)
(68°F) .
Measurement: In accordance with VDI 2173.
Example 2:
CPMI-2:
Pressure drop ∆p = 300 kPa.
(43.5 psi)
Flow Q = 1 m3/h. (4.4 gal/m)
Select: CPMI-2, Kv 2/15 which at working point will be approx.
35% open equal to about 50% of the regulating area.
Example 1:
CPMI-2:
Pressure drop ∆p = 200 kPa.
(29 psi)
Flow Q = 8 m3/h. (35 gal/min)
Select: CPMI-2, Kv 23 which at working point will be 48%
open.
5. Technical Data
∆∆
∆∆
∆P [kPa]
∆∆
∆∆
∆P [kPa]
∆P 500 [kPa]
∆P 400 [kPa]
∆P 300 [kPa]
∆P 200 [kPa]
∆P 100 [kPa]
∆P 50 [kPa]
∆P 500 [kPa]
∆P 400 [kPa]
∆P 300 [kPa]
∆P 200 [kPa]
∆P 100 [kPa]
∆P 50 [kPa]
Q [m3/h]
Q [m3/h]

22
Item Qty. Denomination
1 1 Nut
2 1 Washer
31Top
4 2 Washer
5 2 Screw
6 2 Clamp
7 1 Cover
8∆1 O-ring
9 1 Guide
10 ∆1 Upper diaphragm
11 2 Inner ring
12 12 Support sector
13 1 Outer ring
14 ∆1 Lower diaphragm
15 1 Valve plug
16 1 Valve body
∆: Service kits - product wetted parts
The drawing and the parts list include all items.
6. Parts lists and service kits6.1 CPM-2
Denomination Item number
Product wetted parts
NBR/EPDM-PTFE .......................................9611-92-0218
FPM/ PTFE .................................................9611-92-0515
FPM/EPDM-PTFE .......................................9611-92-0516
FPM/PTFE/EPDM-PTFE .............................9611-92-0517
Service KitsParts list