GEA Aseptomag AV Translation From The Original Operating Manual
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GEA Aseptomag AV Translation From The Original Operating Manual

Aseptic valves
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Aseptic Valves
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GEA Aseptomag
stop valve type AV
Operating instruction (Translation from the original language)
430BAL011547EN_2

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Summary of Contents for GEA Aseptomag AV

  • Page 1 Aseptic Valves ® GEA Aseptomag stop valve type AV Operating instruction (Translation from the original language) 430BAL011547EN_2...
  • Page 2 ® Aseptomag and TEFASEP are registered trademarks of GEA Aseptomag AG and may not be used without the permission of GEA Aseptomag AG. ® T.VIS is a protected trademark of GEA Tuchenhagen GmbH. We kindly request that you answer a few short questions about these Operating Instructions.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS General Information Information on the Document 1.1.1 Binding Character of These Operating Instructions 1.1.2 Notes on the Illustrations 1.1.3 Symbols and Highlighting Manufacturer address Customer service EC Declaration of Incorporation Safety Intended use 2.1.1 Requirements for operation 2.1.2 Pressure equipment directive 2.1.3...
  • Page 4 10.2 Inspections 10.2.1 Bellows 10.2.2 Pneumatic connections 10.2.3 Electrical connections 10.3 Maintenance intervals 10.4 List of tools 10.5 Prior to disassembly 10.6 Disassembling and Assembling the Valve 10.6.1 Disassembling the valve 10.6.2 Assembling the valve 10.6.3 Torques for clamp 10.7 Disassembling and Assembling the Internal Assembly 10.7.1 Disassembling the internal assembly...

  • Page 5: General Information

    General Information Information on the Document General Information Information on the Document The present Operating Instructions are part of the user information for the product. The Operating Instructions contain all the information you need to transport, install, commission, operate and carry out maintenance for the product. 1.1.1 Binding Character of These Operating Instructions These Operating Instructions contain the manufacturer's instructions to the...

  • Page 6: Manufacturer Address

    Result of the previous operation. ® The operation is complete, the goal has been achieved. Hint! Further useful information. Manufacturer address GEA Aseptomag AG Industrie Neuhof 28 CH-3422 Kirchberg Customer service Phone: +41 (0)34 426 29 29 Fax: +41 (0)34 426 29 28 service.aseptomag@gea.com...

  • Page 7: Ec Declaration Of Incorporation

    Teamleader Product Development Flow Components – Aseptic Valves GEA Aseptomag AG GEA Aseptomag AG Tel. +41 34 426 29 29 · Fax +41 34 426 29 28 · gea.com Industrie Neuhof 28, CH-3422 Kirchberg Seite 1 von 1 430BAL011547EN_2 08.07.2019...

  • Page 8: Safety

    The valve is a piece of pressure equipment (without safety function) as defined in the Pressure Equipment Directive: Directive 2014/68/EG. It is classified according to Annex II, article 4, section 3. In the event of any deviations, GEA Aseptomag AG will supply a specific Declaration of Conformity.

  • Page 9: Operator's Duty Of Care

    Safety Operator’s Duty of Care • Persons or objects are in the danger zone. • Safety devices are not working or were removed. • Malfunctions have been detected on the component. • Damage to the component has been detected. • Maintenance intervals have been exceeded.

  • Page 10: General Safety Instructions And Dangers

    EC Machinery Directive on your own. In general, only original spare parts supplied by GEA Aseptomag AG should be fitted. This ensures the reliable and economical operation of the valve.

  • Page 11: Electrical Equipment

    Safety Supplementary Regulations • Dispose of lubricants as hazardous waste. 2.4.3 Electrical Equipment For all work on electrical equipment, the following principles apply: • Access to electrical equipment should only be allowed to qualified electricians. Always keep unattended switch cabinets locked. •...

  • Page 12: Safety Equipment

    Safety Safety equipment • Received instruction about the functionality of the component. • Received instruction about operating sequences on the component. • Familiar with the safety devices and their function. • Familiar with these Operating Instructions, especially with the safety instructions and the information which is relevant for the task on hand.

  • Page 13: Danger Zones

    Safety Danger zones Residual dangers on the valve and measures Danger Cause Measure Danger to life Inadvertent Effectively disconnect all components, effectively prevent switch-on of the switch-on. valve Electric power Observe the following safety rules: Isolate from the power supply. Take appropriate measures to prevent switch on.
  • Page 14 Safety Fig.1: Danger zone at the valve • In the event of malfunctions, shut down the valve (disconnect from the power and air supply) and secure it against being used. • Never reach into the lantern (1) or the valve housing (2) when the valve is switching.

  • Page 15: Description

    Description Design of the valve Description Design of the valve Fig.2: Main components on the valve Designation Housing Internal assembly Actuator Clamp (safety device) 430BAL011547EN_2 08.07.2019...

  • Page 16: Valve Identification

    Description Valve Identification Valve Identification Reference numbers from the following number systems are assigned to each part of components from GEA Aseptomag AG. The reference numbers can be used to clearly identify a component and its composition. Number Designation Description...
  • Page 17 Description Valve Identification Fig.3: Designations on the valve Example Position Details V-50-1002 Valve Drawing number of valve housing housing 1.4435 TC 333937 Material and re-stamping details 0548 10 Valve Serial number of valve housing housing V-50-1004 Clamp Number of clamp drawing V-50-2200 Internal Drawing number of internal assembly...

  • Page 18: Sealing Concepts

    Description Sealing Concepts Sealing Concepts 3.3.1 “Shrink-on Fit" Version • Undivided valve disk • GEA Aseptomag standard • ® For hard sealing materials such as TEFASEP , PTFE or reinforced PTFE Fig.4: "Shrink-on Fit" Version 3.3.2 System "divisible" Valve seat seals ®...
  • Page 19 Description Fig.6: System “divisible” for O-rings 430BAL011547EN_2 08.07.2019...

  • Page 20: Transport And Storage

    Transport and storage Storage conditions Transport and storage Storage conditions The valves, valve inserts or spare parts should be stored in a dry place, free of vibrations and dust, and protected from light. To avoid damage, leave the components in their original packaging if possible. If, during transport or storage, the valve is going to be exposed to temperatures ≤...

  • Page 21: Technical Data

    Technical data Technical data Technical data Technical data ® Operating data (for valve with sealing materials TEFASEP and Silikon) Max. operating temperature 150 °C (302 °F) Max. sterilisation temperature 160 °C (320 °F) for max. 30 min. Max. product pressure 5 ...
  • Page 22 Technical data Compressed air supply Compressed air supply 6 bar, compressed air filtered (at least 0,5 µm), oil-free. Cleaning Cleaning The valve is suitable for CIP cleaning (Cleaning in Place) Recommended cleaning speed At least 2 m/s in the valve Sterilisation Sterilisation The valve is suitable for SIP sterilisation (Sterilisation in Place)

  • Page 23: Assembly And Installation

    Assembly and installation Safety instructions Assembly and installation Safety instructions Hazardous situations during installation can be avoided by safety-conscious and proactive behaviour of the personnel. For installation, the following principles apply: • Only qualified personnel are allowed to set-up, install and commission the component.

  • Page 24: Welding Post-Treatment

    Assembly and installation Welding In a Valve with Pipe Connection Caution! Danger of injury due to spring force being released You can sustain injuries to your fingers when you put your hand into a valve if the valve has not been moved to the open position beforehand. ►...

  • Page 25: Pneumatic Connections

    Assembly and installation Pneumatic connections Pneumatic connections 6.4.1 Air requirement The air requirement depends on the type of actuator fitted. The following tables show guideline values at an air pressure supply of 6 bar per valve size and the corresponding actuator size used as a standard. Air requirement for spring-to-close actuators (NC) Reference Reference air...

  • Page 26: Establishing The Compressed Air Supply

    Assembly and installation Electrical connections 6.4.2 Establishing the Compressed Air Supply A prerequisite for the reliable operation of the valve is that the compressed air hoses are cut exactly square. Tools required: • A hose cutter Carry out the following steps: Depressurize the pneumatic connection at the place where you are working.

  • Page 27: Start-Up

    Start-up Safety instructions Start-up Safety instructions Initial commissioning For initial commissioning, the following principles apply: • Take protective measures against dangerous contact voltages in accordance with pertinent regulations. • The valve must be completely assembled and correctly adjusted. All screw connections must be securely tightened.

  • Page 28: Operation And Control

    Operation and control Safety instructions Operation and control Safety instructions Dangerous situations during operation can be avoided by safety-conscious and proactive behaviour of the personnel. For operation, the following principles apply: • Monitor the component during operation. • Safety devices must not be changed, removed or taken out of service. Check all safety devices at regular intervals.

  • Page 29: Cleaning

    Cleaning Cleaning Cleaning Cleaning The valve is suitable for CIP (Cleaning in Place); recommended cleaning speed in the valve is at least 2 m/s. All parts in contact with product must be cleaned at regular intervals. Always observe the safety data sheets issued by the cleaning agent manufacturers. Only use cleaning agents which do not cause damage to the seals and the inner parts of the valve.
  • Page 30 Cleaning The ultimate temperatures, chemicals, concentrations and contact time to be used must be determined by the plant operator along with its chemical supplier. 430BAL011547EN_2 08.07.2019...

  • Page 31: Maintenance

    Maintenance Safety instructions Maintenance 10.1 Safety instructions Maintenance and repair Before carrying out maintenance and repair work on the component's electrical equipment, perform the following steps in accordance with the "5 safety rules": • Isolate from the power supply • Take appropriate measures to prevent switch on •...
  • Page 32 Maintenance Inspections • Disconnect all power and utility lines. • Markings, e.g. on lines, must not be removed. • Do not climb on the component. Use suitable access aids and working platforms. • Mark the lines (if unmarked) prior to disassembly to ensure they are not confused when re-assembling.
  • Page 33 If information regarding the definition of practical-oriented maintenance intervals is not available or is insufficient, the guideline values listed in the "Maintenance" chapter can be referred. This information is based on empirical values for GEA Flow Components and relates to installations working in two-shift operation.
  • Page 34 Maintenance List of tools List of tools (in alphabetical order) Material Number Tool Figure Intended Purpose GEA Aseptomag AG For divisible internal 0980.50020 Torque wrench assemblies S-12-0086 Fig.10 Pressure control valve Inspection of metal 9999.10090 Ø 6 mm bellows Fig.11...
  • Page 35 Maintenance List of tools List of tools (in alphabetical order) Material Number Tool Figure Intended Purpose GEA Aseptomag AG Valves Hex socket key 0980.50121 DN 10 - DN 80 S-12-0554 Tighten/release clamp Valves Hex socket key 0980.50122 DN 100 - DN 150 Fig.16...
  • Page 36 Maintenance List of tools List of tools (in alphabetical order) Material Number Tool Figure Intended Purpose GEA Aseptomag AG Mounting tool PA255 5050.55468 Clamping piece PA255 Hold cylinder S-12-0405 Fig.21 Mounting tool 5050.51258 Remove/fit seals O-ring S-12-0162 Fig.22 Disassemble hard, O-ring cutter 0980.50022...
  • Page 37 Maintenance Prior to disassembly List of tools (in alphabetical order) Material Number Tool Figure Intended Purpose GEA Aseptomag AG Protective gloves, Remove/fit hard valve heat-resistant seat seals Fig.26 Seeger circlip pliers PA30 - 60 NC/NO 0980.50108 Inside diameter 40-100 Remove/fit PA S-12-0541 angled tip, 90°...
  • Page 38 Maintenance Disassembling and Assembling the Valve Disconnect the power supply. ® Disassembly has been prepared. 10.6 Disassembling and Assembling the Valve 10.6.1 Disassembling the valve Tools required: • Hex socket key Caution! Danger of injury due to spring force being released You can sustain injuries to your fingers when you put your hand into a valve if the valve has not been moved to the open position beforehand.
  • Page 39 Maintenance Disassembling and Assembling the Valve Fig.32: Loosening the clamp screw ! Make sure that the clamp can be moved by hand and without a great deal of force before you carry out the next step. If this is not the case, use a plastic hammer to knock the clamp segments carefully until the pressure escapes and the clamp can then be moved without any problem.
  • Page 40 Maintenance Disassembling and Assembling the Internal Assembly 10.6.2 Assembling the valve Hint! Pay attention to the following point when assembling the valve: • Thoroughly clean all parts and check for damage. Tools required: • Hex socket key Carry out the following steps: Install the valve in the reverse order of disassembly, see Section 10.6.1, Page 38.
  • Page 41 Maintenance Disassembling and Assembling the Internal Assembly Fig.34: Extending piston rod with groove upward Lift the internal assembly slightly to detach it from the T-slot on the drive spindle. Fig.35: Unhooking the internal assembly Remove the housing seal without a tool. ! Do not damage the sealing surfaces on the housing and internal assembly.
  • Page 42 Maintenance Removing and Installing the "Shrunk-on” Valve Seat Seal 10.7.2 Assembling the internal assembly Hint! Pay attention to the following points when assembling the internal assembly: • Thoroughly clean all parts and check for damage. • Replace all dismantled seals. •...
  • Page 43 Maintenance Removing and Installing the "Shrunk-on” Valve Seat Seal Place the heated metal tip of the O-ring cutter at right angles on the valve seat to be removed. Cut through the valve seat seal at one point using the O-ring cutter. ! Pay attention not to damage the edge of the radial groove.
  • Page 44 Maintenance Removing and Installing the "Shrunk-on” Valve Seat Seal Fig.38: Oven Use both thumbs to press the heated valve seat seal into the radial groove at one point. Fig.39: Place the valve seat seal into the groove Then use both thumbs/palms to press the valve seat seal in place in the radial groove.
  • Page 45 Maintenance Removing and Installing the "Divisible System" Valve Seat Seal – Reheat the valve seat seal as described in the previous instruction step. ® When mounting the valve seat seal, the seal does not "click" into place any more? The valve seat seal has been overheated and can no longer be used. –...
  • Page 46 Maintenance Removing and Installing the "Divisible System" Valve Seat Seal Fig.42: Releasing valve axis Remove the seals from the internal assembly: ® Seat seal (no. 1) ® Valve disc seal on version TVT (no. 2) Fig.43: Removing seal(s) ® Divisible valve disk, valve seat seal TEFASEP Divisible valve disk, valve seat seal EPDM (form seal) TVPVF Divisible valve disk, valve seat seal reinforced PTFE (form seal)
  • Page 47 Maintenance Removing and Installing the "Divisible System" Valve Seat Seal 10.9.2 Fitting the Divisible Valve Seat Seal Hint! Pay attention to the following points when assembling the valve seat seal: • Thoroughly clean all parts and check for damage. • Replace all dismantled seals.
  • Page 48 Maintenance Carrying out the "Internal assembly" leak test (bubble test) Thread size of valve Valve size Torque [Nm] disc DN125 M20 x 1.5 DN150 M20 x 1.5 10.10 Carrying out the "Internal assembly" leak test (bubble test) Hint! Observe the inspection interval! The metal bellows must be checked for leaks as part of the annual maintenance using the pressurizing tool .
  • Page 49 Maintenance Carrying out the "Internal assembly" leak test (bubble test) Fig.45: Attach clamping arms Pull the valve cover against the seal by means of the star grip on the pressurizing tool (hand-tight). Fig.46: Secure internal assembly Apply max. 3 bar of compressed air to the pressurizing tool . ! Air pressures >...
  • Page 50 Maintenance Disassembling and Assembling Actuator PA50/PA60 Fig.47: Water bath Remove the internal assembly from the pressurizing tool in reverse order. ® This completes the leak test. 10.11 Disassembling and Assembling Actuator PA50/PA60 10.11.1 Disassembling Actuator PA50/PA60 Caution! Danger of injury due to spring force being released You may be injured if the spring tension is released in an uncontrolled manner, causing actuator parts to be moved or thrown around rapidly.
  • Page 51 Maintenance Disassembling and Assembling Actuator PA50/PA60 Fig.48: Lowering actuator base Remove the circlip from the actuator base using the Seeger circlip pliers. Fig.49: Removing the circlip Slowly remove pressure from the actuator base. 430BAL011547EN_2 08.07.2019...
  • Page 52 Maintenance Disassembling and Assembling Actuator PA50/PA60 Fig.50: Removing pressure from the actuator base Lift off the actuator base from the cylinder. Fig.51: Removing actuator base Perform the following step in accordance with the actuator type: ® NC actuator: Lift out the piston rod with piston disc from the cylinder. ®...
  • Page 53 Maintenance Disassembling and Assembling Actuator PA50/PA60 Fig.52: Lifting out upper actuator components Perform the following step in accordance with the actuator type: ® NC actuator: Carefully draw the compression spring out of the cylinder. ® NO actuator: Lift out the piston rod with piston disc from the cylinder. Fig.53: Lifting out lower actuator components Pull the circlip out of the groove and remove both parts of the lock washer...
  • Page 54 Maintenance Disassembling and Assembling Actuator PA50/PA60 Fig.54: Removing fuse elements Carefully slip off the spacer sleeve and piston disc from the piston rod. ! Pay attention to the alignment of the piston disk (asymmetrical design) already when disassembling. Fig.55: Pulling off actuator components ®...
  • Page 55 Maintenance Disassembling and Assembling Actuator PA80 - PA255 10.11.2 Assembling Actuator PA50/PA60 Hint! Pay attention to the following points when assembling the actuator: • Replace all visible seals. • Thoroughly clean and check the interior cylinder contact surfaces, O-ring grooves, piston rod and piston disc. •...
  • Page 56 Maintenance Disassembling and Assembling Actuator PA80 - PA255 Fig.56: Attaching clamping piece Clamp the actuator at the clamping piece into the vice . Fig.57: Clamping the actuator ® Disassembly has been prepared Removing assembly spring Carry out the following steps: Turn the actuator base counter-clockwise using a flexible head spanner, see illustration.
  • Page 57 Maintenance Disassembling and Assembling Actuator PA80 - PA255 Turn the actuator base clockwise using the flexible head spanner . ! Rotate the actuator base until the assembly spring can be removed. Fig.59: Unscrewing assembly spring ® Assembly spring has been removed. PA80 - PA255: dismantling the actuator Carry out the following steps: Lift off the actuator base from the cylinder.
  • Page 58 Maintenance Disassembling and Assembling Actuator PA80 - PA255 Fig.61: Lifting out spring package ® Actuator has been dismantled into its individual parts. ! Opening the spring assembly is forbidden for safety reasons. ® Actuator PA80 - PA255 has been disassembled. 10.12.2 Assembling Actuator PA80 - PA255 Hint! Pay attention to the following points when assembling the actuator:...
  • Page 59 Maintenance Disassembling and Assembling Actuator PA80 - PA255 • Slotted screwdriver Carry out the following steps: Align the actuator base relative to the cylinder housing so that the hole in the base is visible through the slot in the cylinder. Fig.62: Aligning hole to slot Insert the angled part of the assembly spring into the hole of the actuator...
  • Page 60 Maintenance Disassembling and Assembling Actuator PA80AZ - PA180AZ Fig.65: Fastening the assembly spring ® The assembly spring moves out of the hole when it reaches the slot in the cylinder and actuator base was turned further? – Continue to turn the actuator base counter-clockwise using the flexible head spanner until the hole is again located underneath the position pin of the assembly spring and the pin can be pressed in again with the slotted screwdriver.
  • Page 61 Maintenance Disassembling and Assembling Actuator PA80AZ - PA180AZ Removing assembly spring Carry out the following steps: Disassemble assembly spring, see Page 56. ® Assembly spring has been removed. PA80AZ - PA180AZ: dismantling the actuator Carry out the following steps: Lift off the actuator base from the cylinder. Fig.67: Removing actuator base Use the mounting tool for the spring package to pull the spring package...
  • Page 62 Maintenance Disassembling and Assembling Actuator PA80AZ - PA180AZ Fig.69: Removing circlip Take the buffer segments out of the actuator base. Fig.70: Removing fuse elements Lift the piston disc out of the actuator base. Fig.71: Lifting out the piston disc ® Actuator has been dismantled into its individual parts.
  • Page 63 Prior to any work on the open valve, ensure that it has stopped operation, see Section 10.5, Page 37. The following information and values are based on the experience of GEA Flow Components and apply for installations working in 2-shift operation.
  • Page 64 Maintenance Maintenance Activities to be performed after 3 months (only after initial commissioning or after a process change) Component Activity to be performed Check of mechanical parts and visual inspection of Product contact seals condition Check of mechanical parts and visual inspection of Internal assembly with condition bellows...
  • Page 65 Maintenance Checking the Feedback Unit 10.15 Checking the Feedback Unit After completing maintenance work, check the function of the feedback unit and readjust it if necessary. 10.15.1 Setting the Feedback Unit Carry out the following steps: Set the initiator for detection of the rest position. Actuate the valve with compressed air.
  • Page 66 Alarms Malfunctions and remedies Alarms 11.1 Malfunctions and remedies Notice Warning of damage to property/loss of product Ignoring malfunctions may cause considerable damage to property and loss of product. The safe operation of the valve in the event of a malfunction can no longer be taken for granted and in the worst case can result in a loss of sterility in the process.
  • Page 67 Alarms Malfunction Cause Remedy • Check that the feedback • The feedback unit is not unit has been fitted fitted correctly. correctly. • The proximity switch is not Valve feedback not correct. • Check the position of the in the correct position or is proximity switch and re- defective.
  • Page 68 Decommissioning Safety instructions Decommissioning 12.1 Safety instructions For shutting down, the following principles apply: • Switch off the compressed air. • Switch off the component with the main switch. • Padlock the main switch (if fitted) in the off position to prevent it from being switched back on.
  • Page 69 Appendix Lists Appendix 13.1 Lists 13.1.1 Abbreviations and terms Abbreviation Explanation ° Symbol for the grade of a scale [degrees] All degree data is assumed to be angle degrees unless explicitly specified otherwise. °C Unit of measurement of temperature [degree Celsius] °F Unit of measurement of temperature [degree Fahrenheit] AISI...
  • Page 70 Appendix Abbreviation Explanation Normally Closed; direction of action spring-closing/air-opening Unit of measurement of work [newton metre] Unit of torque 1 Nm = 0.737 lbft Pound-Force (lb) + Feet (ft) Normally Open; direction of action air-closing/spring-opening Outside diameter; short name for outside diameter for inch tubes according to DIN 11866-C Pneumatic actuator PTFE...
  • Page 71 Appendix 430BAL011547EN_2 08.07.2019...

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