Instruction Manual

CPM-I-D60 Constant-Pressure Modulating Inlet Valve

DW 433-000

ESE01834-EN4 2015-04
Original manual
 Table of contents

The information herein is correct at the time of issue but may be subject to change without prior notice

1. EC Declaration of Conformity ....................................................................... 4

2. Safety .................................................................................................... 5
2.1. Important information ............................................................................. 5
2.2. Warning signs ..................................................................................... 5
2.3. Safety precautions ................................................................................ 6

3. Installation .............................................................................................. 7
3.1. Unpacking/delivery ............................................................................... 7
3.2. General installation ................................................................................ 8
3.3. Welding ............................................................................................ 10
3.4. Fitting of Booster (optional extra) ................................................................ 11
3.5. Recycling information ............................................................................. 13

4. Operation ............................................................................................... 14
4.1. Operation .......................................................................................... 14
4.2. Fault finding ....................................................................................... 16
4.3. Recommended cleaning ......................................................................... 17

5. Maintenance ........................................................................................... 19
5.1. General maintenance ............................................................................. 19
5.2. Dismantling ........................................................................................ 20
5.3. Assembly .......................................................................................... 23

6. Technical data ......................................................................................... 27

6.1. Technical data ..................................................................................... 27
6.2. Selection / Pressure drop - capacity diagram ................................................. 28

7. Parts lists and service kit ............................................................................ 29

7.1. CPM-I-D60 ........................................................................................ 29
7.2. Booster ............................................................................................ 33

3
1 EC Declaration of Conformity

Revision of Declaration of Conformity 2009-12-29

The Designated Company

Alfa Laval Kolding A/S

Company Name

Albuen 31, DK-6000 Kolding, Denmark

Address

+45 79 32 22 00
Phone No.

hereby declare that

Valve
Designation

CPM-i-d60
Type

is in conformity with the following directive with amendments:

- Machinery Directive 2006/42/EC

- Regulation (EC) No 1935/2004

The person authorised to compile the technical file is the signer of this document

QHSE Manager, Quality, Health and safety & Environment Annie Dahl
Title Name

Kolding 1982-09-01
Place Date Signature

4
 2 Safety
Unsafe practices and other important information are emphasized in this manual.
Warnings are emphasized by means of special signs.

2.1 Important information

Always read the manual before using the valve!

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 procedures.

2.2 Warning signs

General warning:

Caustic agents:

5
2 Safety
Unsafe practices and other important information are emphasized in this manual.
Warnings are emphasized by means of special signs.

2.3 Safety precautions

Installation
Always read the technical data thoroughly (See chapter 6 Technical data)
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 read the technical data thoroughly (See chapter 6 Technical data).
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 thoroughly (See chapter 6 Technical data).
Always release compressed air after use.
Never service the valve when it is hot.
Never service the valve with valve and pipelines under pressure.

Transportation

Always secure that compressed air is released .

Always secure that all connections is disconnected before attempt 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.

6
 3 Installation
The instruction manual is part of the delivery.
Study the instructions carefully.

3.1 Unpacking/delivery

Step 1 Check the delivery:

CAUTION 1. Complete valve.
Alfa Laval cannot be held responsible for incorrect unpacking. 2. Delivery note.
3. Instruction manual.

Step 2
Remove possible packing materials from the valve ports. Remove packing materials!

TD 433-001

Step 3
1. Inspect the valve for visible transport damage. Inspection!

TD 433-001

Step 4
Avoid damaging the air connection and the valve ports. Caution!

TD 433-001

7
3 Installation
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.
The required product pressure is preset by means of an air pressure regulating valve (optional extra).

3.2 General installation

Step 1 CAUTION
Alfa Laval cannot be held responsible for incorrect
Always read the technical data thoroughly. installation.

Always release compressed air after use.

Never touch the valve top if compressed air is supplied to the
valve.

Step 2 Correct
Ensure that the flow direction is correct.

Outlet

TD 433-002

Inlet

Step 3 Risk of damage!

Avoid stressing the valve.
Pay special attention to:
- Vibrations.
- Thermal expansion of the tubes.
- Excessive welding.
- Overloading of the pipelines.

TD 433-003_1

8
 3 Installation
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.
The required product pressure is preset by means of an air pressure regulating valve (optional extra).

Step 4 Remember
Fittings: seal rings!
Ensure that the connections are tight.

TD 433-004

Step 5 R1/4 " (BSP)

Air connection:
Air

TD 433-005

Step 6
Air pressure regulating valve (optional extra):
Pressure regulating valve
It is recommended to install the air pressure regulating valve as
close as possible to the valve.
As close as possible!

Air

TD 433-006

9
3 Installation
Study the instructions carefully.
The valve has welding ends as standard. Weld carefully.

3.3 Welding

Step 1
NOTE!
Never weld both the inlet and outlet connections. If so, it will be impossible to service the lower valve body seal ring (16)

Step 2
Welding the inlet connection
1. Weld the valve body into the pipelines.
2. Maintain the minimum clearance so that the internal valve parts
can be removed.

A
TD 433-007

Caution!
A= 440 mm (without booster) / 540 mm (with booster)

Step 3
Welding the outlet connection
Dismantle the valve in accordance with section 5.2 Dismantling,
Step 1 and Step 2.

TD 433-008_1

Step 4
Welding the outlet connection:
1. Weld the lower body (10) into the pipelines.
2. Maintain the minimum clearance so that the internal valve parts
A

can be removed.

TD 433-009

Caution!
A= 284 mm (without booster) / 384 mm (with booster)

10
 3 Installation
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 increase the permitted product pressure.

Step 5
Welding the outlet connection:
Assemble the valve in accordance with section 5.3 Assembly,
Step 10 and Step 11.

Step 6 Lift and lower by hand!

Pre-use check:
Lift and lower the valve top several times to ensure that the valve
operates smoothly.
Pay special attention to the warning!

TD 433-011

3.4 Fitting of Booster (optional extra)

Step 1 Burning Atmospheric pressure required!

danger!
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.

TD 433-012

11
3 Installation
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 increase the permitted product pressure.

Step 2
1. Remove the valve top in accordance with section 5.2
Dismantling,Step 5.
Pay special attention to the warnings!
2. Fit Booster housing (1) on the cover.
3. Fit and tighten lock nut (2).

Step 3
1. Fit washer (3).
2. Refit the washer and the top nut on the valve plug.

Step 4
1. Turn diaphragm (7) inside out.
2. Place piston (6) in the diaphragm so that the hole is visible.

Step 5
1. Roll diaphragm (7) down half it’s lenght.
2. Fit the diaphragm with piston (6) in Booster housing (1).

12
 3 Installation
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 increase the permitted product pressure.

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.

3.5 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

13
4 Operation
The valve is lubricated, adjusted and tested before delivery.
Study the instructions carefully and pay special attention to the warnings!

4.1 Operation

Step 1 CAUTION
Alfa Laval cannot be held responsible for incorrect
Always read the technical data thoroughly. operation.

Always release compressed air after use.

Step 2 Burning danger!

Never touch the valve or the pipelines when processing hot liquids
or when sterilizing.

TD 433-021

Step 3 Air Cutting danger!

Never touch the valve top if compressed air is supplied to the

valve.

TD 433-013

Step 4
CAUTION!
There must not be vacuum in the valve as air can be drawn into
the product and diaphragms (17) can then be pulled out from
support sectors (20).

18

20

17

TD 433-014

No vacuum!

14
 4 Operation
The valve is lubricated, adjusted and tested before delivery.
Study the instructions carefully and pay special attention to the warnings!

Step 5 Lubricate if necessary!

Lubrication: (See 5.1 General maintenance).
1. Ensure smooth movement between diaphragms (17,18)
and support sectors (20).
2. Ensure smooth movement of guide (5).

18

20
TD 433-015
17

15
4 Operation
Pay attention to possible break-down.
Study the instructions carefully.
The items refer to the parts list and service kits section.

4.2 Fault finding

NOTE!
Study the maintenance instructions carefully before replacing worn parts - see chapter 5.1 General maintenance

Problem Cause/result Repair

The valve does not maintain the preset Faulty diaphragm Replace the diaphragm
pressure
Guide (9) seizes Lubricate the guide (see 4.1 Operation,
Step 5)
Incorrect operating range Check the pressure drop over the valve
and check the flow rate (see chapter
6.2 Selection / Pressure drop - capacity
diagram)
The available air pressure is lower than Increase the air pressure eg. by using
the product pressure a Booster (see chapter 3.4 Fitting of
Booster (optional extra)).
The air pressure is not correctly adjusted Readjust the air pressure
Faulty air pressure regulating valve or Repair the valve or check that it is
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 chapter
6.1 Technical data)
Valve plug moving too fast up and down Pressure pulsations because of fast Use an air throttling valve (optional extra
(unstable) changes in process conditions between the air pressure regulating valve
and the CPM-I-D 60 valve.

16
 4 Operation
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. HNO3 = Nitric acid.

4.3 Recommended cleaning

Step 1 Caustic danger!

Always handle lye and acid with great care.

Always use Always use

rubber gloves! protective goggles!

Step 2

Never touch the valve or the pipelines when sterilizing. Burning danger!

TD 433-021

Step 3 No air pressure!

CPMI-2
Ensure that the valve is fully open to allow for maximum CIP flow.

CIP
out

TD 433-016

CIP in

Step 4
Examples of cleaning agents:
Use clean water, free from clorides.

1. 1% by weight NaOH at 70o C (158o F) 2. 0.5% by weight HNO3 at 70o C (158o F)

1 kg (2.2 lbs) 100 l 0.7 l (0.2 gal) 100 l

+ = Cleaning agent. + = Cleaning agent.
NaOH (26.4 gal) water 53% HNO3 (26.4 gal) water

2.2 l (0.6 gal) 100 l

+ = Cleaning agent.
33% NaOH (26.4 gal) water

17
4 Operation
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. HNO3 = Nitric acid.

Step 5
1. Avoid excessive concentration of the cleaning agent.
- Dose gradually.
2. Adjust the cleaning flow to the process.
- Sterilization of milk/viscous liquids.
- Increase the cleaning flow.
3. Always rinse well with clean water after the cleaning.

Step 6
NOTE
The cleaning agents must be stored/disposed of in accordance with current rules/directives.

18
 5 Maintenance
Maintain the valve carefully.
Study the instructions carefully and pay special attention to the warnings!
Always keep spare diaphrams and o-rings in stock.

5.1 General maintenance

Step 1 NOTE
All scrap must be stored/discharged in accordance
Always read the technical data thoroughly. with current rules/directives.
See chapter 6.1 Technical data

Always disconnect the compressed air before service.

Step 2 Atmospheric
pressure
Never service the valve when it is hot. required!

Burning
Never service the valve with valve and pipelines under pressure. danger!

TD 433-012

Recommended spare parts: Service kits

Order service kits from the service kits list.

Ordering spare parts

Contact the Sales Department.

Diaphragms O-ring

Preventive maintenance Replace after 12 months Replace when replacing the diaphragms
Maintenance after leakage (leakage Replace by the end of the day Replace when replacing the diaphragms
normally starts slowly)
Planned maintenance - Regular inspection for leakage and Replace when replacing diaphragms
smooth operation
- 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.

19
5 Maintenance
Study the instructions carefully.
The items refer to the parts list and service kits section.
Handle scrap correctly.

5.2 Dismantling
Step 1
1. Remove clamps (14,15).
2. Loosen the connection between valve body (12) and inlet tube
(9).

TD 433-017_1

Step 2
1. Remove inlet tube (9) and lower valve body (10).
2. Remove seal rings (8, 16).

TD 433-008_2

Step 3
Remove clamp (22, 23)

Step 4
Remove cover (19) together with the internal parts of the valve.

20
 5 Maintenance
Study the instructions carefully.
The items refer to the parts list and service kits section.
Handle scrap correctly.

Step 5 Counterhold!
Remove top nut (1), washer (2) and top (3).

Step 6
Remove plug (7) from the diaphragm unit and guide (5).

CAUTION!
Ensure that cover (19) is turned downwards and plug (7) is pulled
upwards so that sectors (20) are not separated from diaphragms
(17, 18).

Step 7
Remove lower inner ring (13) and lower diaphragm (17).

Step 8
Remove sectors (20).

21
5 Maintenance
Study the instructions carefully.
The items refer to the parts list and service kits section.
Handle scrap correctly.

Step 9
Remove outer ring (21), upper inner ring (13) and upper diaphragm
(18)

Step 10
Remove guide (5)

Step 11
Remove o-ring (6)

Step 12
Replace the o-ring, the seal rings and the diaphragms.

22
 5 Maintenance
Study the instructions carefully.
Lubricate the guide, the sectors and the threads before assembly.
The items refer to the parts list and service kits section.

5.3 Assembly

Step 1
Fit O-ring (6)

Step 2
Lubricate guide (5), and fit it.
NOTE!
Turn cover (19) downwards before continuing.

Step 3
Fit upper diaphragm (18), upper inner ring (13) and outer ring (21)
on guide (5) and cover (19).
Note!
The outer ring must be turned so that the indication hole is fixed to
the indication hole in the cover.

(air side)

Fit the correct

diaphragm!

23
5 Maintenance
Study the instructions carefully.
Lubricate the guide, the sectors and the threads before assembly.
The items refer to the parts list and service kits section.

Step 4
Fit sectors (20) between upper inner ring (13) and outer ring (21).

Step 5 Fit the correct diaphragm!

Fit lower inner ring (13) and lower diaphragm (17).

Step 6
Fit plug (7) in the diaphragm unit and guide (5) until the flange of
the plug contacts lower diaphragm (17).

24
 5 Maintenance
Study the instructions carefully.
Lubricate the guide, the sectors and the threads before assembly.
The items refer to the parts list and service kits section.

Step 7 Counterhold!
Fit top (3), washer (2) and top nut (1).

Step 8
Fit cover (19) together with the internal parts of the valve.

Step 9
Fit and tighten clamp (22, 23).

Step 10
1. Fit seal rings (8, 16).
2. Fit lower valve body (10) and inlet tube (9)

TD 433-008_1

25
5 Maintenance
Study the instructions carefully.
Lubricate the guide, the sectors and the threads before assembly.
The items refer to the parts list and service kits section.

Step 11
1. Tighten the connection between valve body (12) and inlet tube
(9).
2. Fit and tighten clamps (14,15).

TD 433-017_1

Step 12 Lift and lower by hand!

Pre-use check:
Lift and lower the valve top a few times to ensure that the valve
operates smoothly.
Pay special attention to the warning!

TD 433-011

26
 6 Technical data
It is important to observe the technical data during installation, operation and maintenance.
Inform the personnel about the technical data.

6.1 Technical data

The valves are remote-controlled by means of compressed air. A diaphragm/valve plug system reacts immediately to any
alteration of the product pressure and changes position so that the preset pressure is maintained.

Standard design The CPMI-2 and CPMO-2 consist of a valve body with valve seat, cover, a valve plug with a diaphragm unit
and a clamp.
The cover and the valve body are clamped together.

The valve body and the seat are welded together. The CPM-I-D60 consists of upper and lower valve bodies, an inlet tube, a
cover, a valve plug with diaphragm unit and clamps. The cover and the valve bodies are clamped together.

Valve - data
Max. product pressure 1000 kPa (10 bar) (145 psi)
Min. product pressure 0 kPa (0 bar = Atmospheric)
Temperature range -10 °C to +95 °C (14 °F to 203 °F )
Temperature range
-10 °C to +140 °C (14 °F to 284 °F)
(with upper diaphragm in PTFE/EPDM)
Air pressure 0 to 600 kPa (0 to 6 bar) (0 to 87 psi)
Flow range Kv (Lv), fully open (Δ p = 1bar / 14.5 psi) Approx. 60 m3/h ( 264 gal/m)
Valve - materials
Product wetted steel parts AISI 316L/1.4404
Other steel parts AISI 304
Upper diaphragm Nitrile (NBR), (standard)
Lower diaphragm PTFE covered EPDM rubber, (standard)
Alternative upper diaphragm EPDM/PTFE, (for temperatures 95-140 °C) (203°F to 284 °F)
O-ring Nitrile (NBR), (standard)
Alternative lower diaphragm Solid Teflon (PTFE), (for temperatures above 140 °C) (284 °F)
O-ring Nitrile (NBR), (standard)

Alternative O-ring Flourinated rubber (FPM), (for temperatures above 95 °C) (203 °F)
Finish Semi bright

Weight (kg)

CPMI - 2 CPMO - 2 CPM-I-D60

Size
Kv 23 Kv 7 Kv 2/15 Kv 23 Kv 9 Kv 2/15 76 mm

Weight (kg) 5.5 5.5 5.5 5.5 5.5 5.5 10

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 noise damper - Measured at 7 bars air-pressure.

27
6 Technical data
It is important to observe the technical data during installation, operation and maintenance.
Inform the personnel about the technical data.

6.2 Selection / Pressure drop - capacity diagram

Q (m 3/h)

NOTE!
For the diagrams the following applies:
Medium: Water (20°C) (68°F).
Measurement: In accordance with VDI 2173.

Example of using the diagram:

Pressure drop Δ p = 300 kPa.
Flow = 50 m3/h.
The intersection is on the 50% curve

28
 7 Parts lists and service kit
It is important to observe the technical data during installation, operation and maintenance.
Inform the personnel about the technical data.

7.1 CPM-I-D60

6 19

5 24

13 8

18 9

21

20

17

12

16

14, 15

10

16

14, 15

TD 433-018_01

29
7 Parts lists and service kit
It is important to observe the technical data during installation, operation and maintenance.
Inform the personnel about the technical data.

TD 433-071

30
 7 Parts lists and service kit
It is important to observe the technical data during installation, operation and maintenance.
Inform the personnel about the technical data.

Parts list
Pos. Qty Denomination

2 Screw (Period 8209-9310)

1 1 Nut
2 1 Washer
3 1 Top
5 1 Guide
6  1 O-ring
7 1 Plug
8  1 Seal ring
9 1 Inlet tube
10 1 Valve body, lower
12 1 Valve body
13 2 Inner ring
14+15 2 Clamps and screws (Period
9209-)
14 4 Clamp half (Period -9209)
15 4 Screw (Period -9209)
16  2 Valve body seal ring
17  1 Diaphragm, PTFE covered EPDM
(std.) (product side)
18  1 Diaphragm
19 1 Cover
20 12 Support sector
21 1 Outer ring
22 1 Clamp

Service kits

Denomination

Product wetted parts

 Service kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9611920119

Parts marked with  are included in Service kit.

Recommended spare parts: Service kit.

900-126/0

31
.

32
 7 Parts lists and service kit
It is important to observe the technical data during installation, operation and maintenance.
Inform the personnel about the technical data.

7.2 Booster

33
7 Parts lists and service kit
It is important to observe the technical data during installation, operation and maintenance.
Inform the personnel about the technical data.

34
 7 Parts lists and service kit
It is important to observe the technical data during installation, operation and maintenance.
Inform the personnel about the technical data.

Parts list
Pos. Qty Denomination
1 1 Booster housing
2 1 Lock nut
3 1 Washer
4 1 Spring washer
5 1 Nut
6 1 Booster piston
7 1 Diaphragm
8 1 Booster cover
9 1 Clamps and screws

35
How to contact Alfa Laval
Contact details for all countries are
continually updated on our website.
Please visit www.alfalaval.com to access the information directly.

© Alfa Laval Corporate AB

This document and its contents is owned by Alfa Laval Corporate AB and protected by laws governing intellectual property and thereto related rights. It is the responsibility of the user of this
document to comply with all applicable intellectual property laws. Without limiting any rights related to this document, no part of this document may be copied, reproduced or transmitted in any
form or by any means (electronic, mechanical, photocopying, recording, or otherwise), or for any purpose, without the expressed permission of Alfa Laval Corporate AB. Alfa Laval Corporate AB
will enforce its rights related to this document to the fullest extent of the law, including the seeking of criminal prosecution.