Alfalaval CPM-2 Bedienungsanleitung

IM70775-EN4200-CPM-2 Constant-Pressure Modulating Valve

Instruction Manual

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Name Title

Company Signature

Alfa Laval

6000 Kolding

+45 79 32 22 00

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.

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

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

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.

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

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)

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.

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.

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).

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