GEA D-tec D Operating Instruction
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GEA D-tec D Operating Instruction

Aseptic valves
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Aseptic Valves
®
GEA D-tec
double-chamber valve type D/DV
Operating instruction (Translation from the original language)
430BAL013307EN_8

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Summary of Contents for GEA D-tec D

  • Page 1 Aseptic Valves ® GEA D-tec double-chamber valve type D/DV Operating instruction (Translation from the original language) 430BAL013307EN_8...
  • Page 2 EU Machinery Directive. This document is protected by copyright. All rights reserved. The document may not, in whole or in part, be copied, reproduced, translated or reduced to an electronic medium of machine-readable form without the express permission of GEA Tuchenhagen GmbH. LEGAL NOTICE Word marks ®...

  • 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 Contact EC Declaration of Conformity for Complete Machines in accordance with the EC Machinery Directive 2006/42/EC, Annex II 1.
  • Page 4 Safety instructions Cleaning Cleaning 9.1.1 Cleaning Process Examples 9.1.2 Cleaning effect Sterilisation Passivation Maintenance 10.1 Safety instructions 10.2 Inspections 10.2.1 Leakage outlet 10.2.2 Pneumatic connections 10.2.3 Electrical connections 10.2.4 Signs on the valve 10.3 Servicing intervals 10.4 Prior to disassembly 10.5 Disassembling the valve 10.5.1...

  • 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

    Second step in a sequence of operations. ® Result of the previous operation. ® The operation is complete, the goal has been achieved. Hint! Further useful information. Manufacturer address GEA Tuchenhagen GmbH Am Industriepark 2-10 21514 Büchen Contact Tel.:+49 4155 49-0 Fax:+49 4155 49-2035 flowcomponents@gea.com www.gea.com 430BAL013307EN_8 04.08.2022...

  • Page 7: Ec Declaration Of Conformity For Complete Machines In Accordance With The Ec Machinery Directive 2006/42/Ec, Annex Ii 1. A

    EC Declaration of Conformity for Complete Machines in accordance with the EC Machinery Directive 2006/42/EC, Annex II 1. A Manufacturer: GEA Tuchenhagen GmbH Am Industriepark 2-10 21514 Buchen, Germany We as the manufacturer hereby declare in sole responsibility that the...

  • Page 8: Safety

    Safety Intended use Safety Intended use Aseptic double-chamber valves are mix-proof stroke valves for highly hygienic and aseptic process systems and permit the safe separation of incompatible media. The media separation is done via the integrated sterile chamber (ISB), which is separated hermetically from the atmosphere with a seal each to both product lines and via two side valves (inlet and outlet).

  • Page 9: Requirements For Operation

    The component is a piece of pressure equipment (without safety function) in the sense of the pressure equipment directive: Directive 2014/68/EG. They are classified according to Annex II, article 4, section 3. In the event of any deviations, GEA Tuchenhagen GmbH will supply a specific Declaration of Conformity. 2.1.3...

  • Page 10: Improper Operating Conditions

    Safety Operator’s Duty of Care 2.1.4 Improper operating conditions The operational reliability of the valve cannot be ensured under improper operating conditions. Therefore avoid improper operating conditions. Operating the valve is not permitted if • Persons or objects are in the danger zone. •...

  • Page 11: Subsequent Changes

    EC Machinery Directive on your own. In general, only original spare parts supplied by GEA Tuchenhagen GmbH should be fitted. This ensures that the component is always operating properly and efficiently.

  • Page 12: Environmental Protection

    Safety Supplementary Regulations 2.4.2 Environmental Protection Harm to the environment can be avoided by safety-conscious and proactive behaviour of the staff. For environmental protection the following principles apply: • Substances harmful to the environment must not be discharged into the ground or the sewage system.
  • Page 13 Safety Qualification of Staff Only allow specially trained staff to carry out any work on explosion-protected equipment. When working on explosion-protected equipment observe the standards DIN EN 60079-14 for gases and DIN EN 50281-1-2 for dusts. The following minimum qualifications are required: •...

  • Page 14: Safety Equipment

    Safety Safety equipment User groups Staff Qualifications Operating staff Adequate instruction and sound knowledge in the following areas: • Function of the valve • Valve operating sequences • What to do in case of an emergency • Lines of authority and responsibilities with respect to the task Maintenance staff Adequate instruction as well as sound knowledge of the design and function of the valve.
  • Page 15 Safety Safety equipment Signs on the valve Sign Meaning General hazard warning Fig.5 Warning Crushing Fig.6 Explosive atmosphere hazard warning Fig.7 430BAL013307EN_8 04.08.2022...

  • Page 16: Residual Dangers

    Spring tension in the Danger to life caused by compression spring in actuator the actuator. Do not open the actuator but return it to GEA Tuchenhagen for proper disposal. Risk of injury Danger presented by The operator must exercise caution and moving or sharp- prudence.

  • Page 17: Danger Zones

    Safety Danger zones Danger zones Fig.8: Danger zone at the valve Please observe the following notes: • 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 (9) or the valve housing (401) when the valve is switching.
  • Page 18 Safety • The housing sockets have very sharp edges. When transporting and assembling the valve be sure to wear suitable protective gloves. 430BAL013307EN_8 04.08.2022...

  • Page 19: Description

    Description Design of the valve Description Design of the valve Fig.9: Design of the valve Designation Actuator T.VIS control top Inlet valve Outlet valve Lift actuator Air connection Stem diaphragm Stem diaphragm O-ring 430BAL013307EN_8 04.08.2022...
  • Page 20 Description Designation Lantern Ring Coupling Stem Bush Valve disk Double disk Electrical connection Clamp connection (safety device) Clamp connection (safety device) Clamp connection (safety device) Leakage housing Valve housing 430BAL013307EN_8 04.08.2022...

  • Page 21: 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 22: Scope Of Supply

    Transport and storage • Only use approved, fully functional load lifting devices and lifting accessories which are suitable for the intended purpose. Observe the maximum load- bearing capacities. • Secure the valve against slipping. Take the weight of the valve into account and the position of the point of gravity.

  • Page 23: Technical Data

    Type plate Technical data Type plate The type plate clearly identifies the valve. Hint! The main, inlet and outlet valves each have their own type plate. GEA Tuchenhagen GmbH Am Industriepark 2-10, 21514 Büchen, Germany Type Serial Mat. Air bar/psi min.

  • Page 24: Resistance Of The Sealing Materials

    Technical data Resistance of the sealing materials Technical data: Compressed air supply Designation Description Air hose Material PE-LD outside Ø 6 mm - metric Inside Ø 4 mm Material PA outside-Ø 6.35 mm - Inch Inside Ø 4.3 mm 5 bar (72.5 psi) standard Product pressure >...
  • Page 25 Technical data Resistance of the sealing materials Seal resistance for EPDM, FKM, HNBR, PTFE Medium Temperature Sealing material (general operation temperature) EPDM HNBR PTFE * -40...+135 °C * -10...+200 °C * -25...+140 °C * Stem diaphragm (-40...275 °F) (+14...+392 °F) (-13...+284 °F) Water up to 80 °C (176 °F)

  • Page 26: Pipe Ends - General Table Of Measurements

    Technical data Pipe ends - General table of measurements Pipe ends - General table of measurements Hint! Not every valve is available in every size. Particulars of available sizes of valves see Section 5.2, Page 23. Dimensions for tubes in DN Metric DN Outer Wall thickness...

  • Page 27: Lubricants

    Technical data Lubricants List of tools Tool Material no. Belt wrench 408-142 Hook wrench 9082051 Oven (not microwave, min. temp. 140°C) 0981.50016 Hex key, a/f 2.5 408-130 Hex key, a/f 4 408-122 Hex socket screw size 3 408-112 Open-ended wrench a/f 10 408-033 Open-ended wrench a/f 13 408-036...

  • Page 28: Weights

    Technical data Weights Weights Weights Size Weight [kg] DN 40 32.5 DN 50 33.0 DN 65 40.2 DN 80 40.8 DN 100 45.6 OD 1.5" 32.4 OD 2" 32.9 OD 2.5" 39.8 OD 3" 40.2 OD 4" 45.6 430BAL013307EN_8 04.08.2022...

  • Page 29: 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 30: Valve With Welded Ends

    Assembly and installation Valve with welded ends Caution! Liquids in pipes Danger of injury due to liquid spraying out ► Therefore, before releasing any pipe connections or hinged clamps: drain the pipe and, if necessary, clean or rinse it. ► Separate the pipe section in which the valve is to be fitted from the rest of the piping system to prevent product entering again.

  • Page 31: Pneumatic Connections

    Assembly and installation Pneumatic connections ® Install the valve with welded ends. Hint! Welding method: We recommend using the automatic orbital welding method. All welding work should only be performed by certified welders or machine operators (orbital welders). Pneumatic connections 6.6.1 Air requirement The air requirement depends on the type of actuator fitted.

  • Page 32: 6.6.2.1 Hose Connection Diagram - Double-Chamber Valve Type D/Dv With Control Top T.vis

    Assembly and installation Pneumatic connections 6.6.2.1 Hose connection diagram - double-chamber valve type D/DV with control top T.VIS Fig.12 Actuator View C Lift actuator Central air supply Lift - valve disk Lift - double seat disk Stroke side valve Actuator E_AA Hint! For an optimal fit at the air connection, it is necessary to cut the pneumatic hoses at a right angle with the hose cutter.

  • Page 33: 6.6.2.2 Hose Connection Diagram - Double-Chamber Valve D/Dv Without Control Top

    Assembly and installation Pneumatic connections 6.6.2.2 Hose connection diagram - double-chamber valve D/DV without control top Fig.13 Actuator Lift actuator Valve - main stroke Lift - valve disk Lift - double seat disk Stroke side valve I = Proximity switch serves to detect the valve end position (main stroke actuated) II = Proximity switch serves to detect the valve rest position (main stroke not actuated) III = Proximity switch serves to detect the double disk rest position (double disk not lifted) Hint!

  • Page 34: Electrical Connections

    Assembly and installation Electrical connections Electrical connections 6.7.1 Electrical connection with T.VIS control top Danger Live parts Electrical shock can result in serious personal injury or death. ► Only allow properly qualified staff to carry out work on the electrical equipment.

  • Page 35: Adjusting The Initiator

    Assembly and installation Electrical connections 6.7.2 Adjusting the initiator Valve closed Fig.15: Initiator bracket main valve Fig.14: Initiator bracket side valve Carry out the following steps: Bring the valve to the lower end position ® Spring-opening valve (NO) Pressurize the actuator with compressed air, max. 8 bar. ®...
  • Page 36 Assembly and installation Valve opened Fig.17: Initiator bracket main valve Fig.16: Initiator bracket side valve Carry out the following steps: Bring the valve to the upper end position ® Spring-opening valve (NO) Pressurize the actuator with compressed air, max. 8 bar. ®...

  • Page 37: Start-Up

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

  • Page 38: 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 staff. For operation, the following principles apply: • Monitor the valve during the operation. • Safety devices must not be changed, removed or taken out of service. Check all safety devices at regular intervals.

  • Page 39: Cleaning

    Cleaning Cleaning Cleaning Cleaning 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 40: Sterilisation

    Cleaning Sterilisation Sterilisation The valve is suitable for SIP sterilisation (sterilisation in place). The permissible sterilisation media and temperatures for the various sealing materials are listed in the resistance table, see . Other sterilisation media (e.g. H ) must be approved by the manufacturer.

  • Page 41: Maintenance

    Maintenance Safety instructions Maintenance 10.1 Safety instructions Maintenance and repair Before starting any maintenance and repair work on the electrical devices of the valve, carry out the following steps in accordance with the "5 safety rules": • Isolate from the power supply •...

  • Page 42: Inspections

    Maintenance Inspections • Do not climb on the valve. Use suitable access aids and working platforms. • Mark the lines (if unmarked) prior to disassembly to ensure they are not confused when re-assembling. • Protect open line ends with blind plugs against ingress of dirt. •...

  • Page 43: Signs On The Valve

    The following information is based on the experience of GEA Flow Components and applies to installations working in a 2- shift operation. Hint! Prior to any work on the open valve, ensure that it has stopped operation, see section Section 10.4, Page 45...
  • Page 44 Maintenance Servicing intervals Servicing intervals Component Measure Valve with Valve with elastomer valve seat seal such as TEFASEP® gold EPDM, FKM, HNBR valve seat seal Maintenance activities to be performed once a month Visual check without Visual check without Valve dismantling dismantling Maintenance activities to be performed after 3 months...

  • Page 45: Prior To Disassembly

    Maintenance Prior to disassembly Servicing intervals Component Measure Valve with Valve with elastomer valve seat seal such as TEFASEP® gold EPDM, FKM, HNBR valve seat seal Check of mechanical Check of mechanical parts and visual parts and visual Feedback inspection of condition – function test inspection of condition –...

  • Page 46: 10.5.1.1 Removing The Control Top

    Maintenance Disassembling the valve 10.5.1.1 Removing the control top Fig.19 Requirement: • No solenoid valve must be actuated electrically or manually. • The pneumatic and electrical connections on the plant side can remain on the control top. Caution! The permanent magnet on the switch bar is fragile. Damage to the permanent magnet.
  • Page 47 Maintenance Disassembling the valve Fig.20: Remove the switch bar Unscrew the switch bar (3) from the piston stem of the actuator. ® Done 430BAL013307EN_8 04.08.2022...

  • Page 48: 10.5.1.2 Disconnecting The Valve From The Housing

    Maintenance Disassembling the valve 10.5.1.2 Disconnecting the valve from the housing Fig.21: Disconnecting the valve from the housing Caution! Risk of injury due to moving valve parts. ► Do not touch the lantern (9). Warning! Spring tension in the valve Danger of injury when opening the clamp connections on the actuator or on the housing as the released spring pretension will suddenly lift the actuator.
  • Page 49 Maintenance Disassembling the valve Unscrew and remove the clamp connection (43). Fig.22 Completely withdraw the valve insert from the housing. ® ! Protect the valve parts against impact stress. ® ! Take note of the weight of the valve parts. Interrupt the compressed air supply to the connection (0).

  • Page 50: Disassembling The Valve Insert Of The Main Valve

    Maintenance Disassembling the valve 10.5.2 Disassembling the valve insert of the main valve Separating the inner parts from the actuator Fig.23 Notice Sensitive valve parts Damage to valve parts. ► Protect the valve parts against impact stress. Hint! Incorrect disassembly when using an incorrect spanner surface. Screw the inner part out of the actuator only using the wrench flat on the valve disc.
  • Page 51 Maintenance Disassembling the valve Remove the retaining ring (11) with the circlip pliers from the two clutch halves (12). Remove the clutch halves (12) from the drive sleeve (L2) and stem (13) over the open lantern (9). Interrupt the compressed air supply to the connection (0). ®...
  • Page 52 Maintenance Disassembling the valve Removing the internal assembly Notice Sensitive valve parts Damage to valve parts. ► Protect the valve parts against impact stress. ► Avoid using too much radial tension! Tools required: • Allen key, assembling device D/DV (or alternatively vice with protective jaws) Carry out the following steps: Clamp mounting tool (M) in vice (W) and insert double disk (16) with aligned surface flat (16.1) into the assembling device:...
  • Page 53 Maintenance Disassembling the valve Fig.26 Remove the double-disk (16) from the assembly device (M) or vice (W), securing the double-disk (16) by hand. Carefully place the double-disk (16) onto the valve disc (15). Clamp the valve disc (15) on the spanner flats (15.1) in the vice with protective jaws.
  • Page 54 Maintenance Disassembling the valve Remove the double-disk (16) from the valve disc (15). Remove the valve disc (15) from the vice. ® Done Disassembling the actuator unit Fig.28 Warning! Spring tension in the valve Danger of injury when loosening the clamp connection (46) on the actuator or on the housing as the released spring pretension will suddenly lift the actuator.
  • Page 55 Maintenance Disassembling the valve Fig.29: 0 = Connection 0 Tools required: • Open-ended wrench, hook wrench Carry out the following steps: Remove the clamp connection (44) and pull the leakage housing (73) from the lantern (9). ® Seals (197, 3) are now accessible. Pressurise the actuator at the connection (0) with compressed air, max.

  • Page 56: Disassembling The Side Valve

    Maintenance Disassembling the valve Loosen the hexagon nut (S) and twist the driver (L5) via the hole (H) with the hook wrench out of the piston stem of the actuator. Pull the threaded bushing (L8) and the adjusting nut (L6) from the piston stem.

  • Page 57: Disassembling The Valve Insert Of The Side Valve

    Maintenance Disassembling the valve Pressurise the actuator (140) at the connection (61) with compressed air, max. 8 bar. Unscrew and remove the clamp connection (43). Completely withdraw the valve insert from the housing. Interrupt the compressed air supply to the connection (61). ®...
  • Page 58 Maintenance Disassembling the valve Pressurise the actuator (140) at the connection (61) with compressed air, max. 8 bar. ® The valve disk (15) is raised. Loosen the valve disk (15) with a open-ended wrench on the spanner flats (15.1) and unscrew it from the piston rod (140.1). Interrupt the compressed air supply to the connection (61).

  • Page 59: Assembling The Valve

    Maintenance Assembling the valve 10.6 Assembling the valve 10.6.1 Assembling the valve insert of the main valve Assembling the actuator unit Fig.32 Tools required: • Jaw wrench, installation mandrel, Allen key, sickle spanner Carry out the following steps: Fit lift actuator with seals (L11, L18, L10, L19, L20) and fasten to lantern (9) with hinged ring (46).
  • Page 60 Maintenance Assembling the valve Fit the bush (L3) with O-rings (L9, L12) and plug it onto the assembly pin (221-105.94). Place the O-ring (L12) in front and push everything into the driver sleeve (L2). Place the driver sleeve (L2) over the sleeve (L4) into the lift actuator (L) and push until below the lantern (9).
  • Page 61 Maintenance Assembling the valve Installing the internal assembly Fig.33 Tools required: • water-soluble pen, assembling device D/DV (or alternately vice with protective jaws), jaw wrench, Allen key Carry out the following steps: Screw the bush (14) and double-disk (16), without O-ring (5) and stem diaphragm (1), together by hand on the stem (13) up to the metal stop and make a coloured mark (M).
  • Page 62 Maintenance Assembling the valve Fig.34 Attach the stem diaphragm (2) onto the valve disc (15). ® ! Install the stem diaphragm (2) in the correct position and seat. Screw the ring (10) clockwise over the spanner flats (10.1) to the marking (metallic stop) on the valve disc (15) using an open-ended wrench.
  • Page 63 Maintenance Assembling the valve Fig.36 Remove the valve disc (15) from the vice. Notice Sensitive valve parts ► Avoid using too much radial tension! Fig.37 430BAL013307EN_8 04.08.2022...
  • Page 64 Maintenance Assembling the valve Clamp the double-disk (16) on the spanner flats (16.1) in the vice with protective jaws (W) or mounting tool (M). Screw the stem (13) clockwise into the double-disk (16) on the spanner flats (13.1) using an open-ended wrench until it reaches the marking (metallic stop).
  • Page 65 Maintenance Assembling the valve Connecting the internal parts of the actuator Tools required: • Seeger circlip pliers Caution! Risk of injury due to moving valve parts. ► Do not touch the lantern (9). Carry out the following steps: Push the retaining ring (11) onto the driver sleeve (L2). Push the internal part (D) over the leakage housing (73) into the actuator (A).
  • Page 66 Maintenance Assembling the valve Fig.39 430BAL013307EN_8 04.08.2022...

  • Page 67: Assembling The Main Valve

    Maintenance Assembling the valve 10.6.2 Assembling the main valve Fig.40 Requirement: • No solenoid valve must be actuated electrically or manually. • The pneumatic and electrical connections on the plant side can remain on the control top. Spring-closing valve NC Warning! Spring tension in the valve A risk of injury exists due to incorrectly installed clamp connections (43)
  • Page 68 Maintenance Assembling the valve Caution! Risk of injury due to moving valve parts. ► Do not touch the lantern (9). Notice Sensitive valve parts Damage to valve parts. ► Protect the valve parts against impact stress. ► Diaphragm position, insert the valve insert into the housing only in the main stroke.
  • Page 69 Maintenance Assembling the valve Fig.41 430BAL013307EN_8 04.08.2022...

  • Page 70: Assembling The Valve Insert Of The Side Valve

    Maintenance Assembling the valve 10.6.3 Assembling the valve insert of the side valve Fig.42 Spring-closing valve NC Caution! Risk of injury due to moving valve parts. ► Do not touch the lantern (9). Tools required: • Strap wrench, open-ended wrench, hook wrench Carry out the following steps: Firmly hold the actuator (140) with a strap wrench and unscrew the lantern (9) from the actuator (140) with a hook wrench (Z).

  • Page 71: Assembling The Side Valves

    Maintenance Assembling the valve 10.6.4 Assembling the side valves Fig.43 Spring-closing valve NC Caution! Risk of injury due to moving valve parts. ► Do not touch the lantern (9). Warning! Spring tension in the valve A risk of injury exists due to incorrectly installed clamp connections (43) when the valve is vented as the spring tension that is released suddenly lifts the actuator.

  • Page 72: Torques For The Clamps And Clamp Connections

    Maintenance Assembling the valve ® ! Observe table "Torques for half rings and clamp connections", see section Section 10.6.5, Page 72 Interrupt the compressed air supply to the connection (61). ® The valve disk (15) is lowered. Check function after assembly. ®...

  • Page 73: Checking The Function

    Maintenance Assembling the valve 10.6.6 Checking the function Checking the valve stroke Notice Sensitive valve parts Damage to the diaphragm. ► Valve strokes must only be carried out in the installed housing Carry out the following steps: Pressurise the valve at the connection (P) with compressed air, max. 8 bar by activating solenoid valve (Y1) at the manual operation element (S).
  • Page 74 Maintenance Assembling the valve Setting the lifting stroke of valve disk for the main valve Requirement: • The valve must be installed into the housing without the control top, if the lift stroke of the valve is being set. • Lift stroke valve disk (recommended setting) 0.9 - 1.4 mm.

  • Page 75: Maintenance

    Maintenance Maintenance Interrupt the compressed air supply to the connection (0). ® The valve insert lowers. ® Actuator (A) raises to the lift actuator (L). Lift actuator (A) and place a spacer between the flanges of the actuators (approx. 25 mm). Pull the threaded bushing (L8) and the adjusting nut (L6) out of the lift actuator (L).

  • Page 76: Cleaning Valve / Replacing Worn Parts

    Maintenance Maintenance 10.7.1 Cleaning valve / replacing worn parts Fig.44 Notice The internal parts, consisting of the valve disk (15), stem (13), double disk (16), the housing seat (15.1 and 16.1), the clamping area (P) of the lantern and housing as well as the V-ring groove and the O-ring groove (A) are precision areas.

  • Page 77: Note On Seal Replacement

    Maintenance Maintenance Carefully clean the individual parts. ® Done 10.7.2 Note on seal replacement Replace defective seals, but always fit new housing O-rings to ensure the tightness of the valve. Always use genuine spare parts. 10.7.3 Replacing the V-ring Fig.45: V-ring insertion tool Requirement: •...

  • Page 78: Changing The Stem Diaphragm

    Maintenance Maintenance Fig.47 Use the insertion tool to press in the V-ring – evenly press in at several opposite points along the circumference. Fig.48 Insert the V-ring evenly. Replace all the other seals identified in the spare parts lists. ® Done Hint! Used seals must not be used again, since the proper function of the...
  • Page 79 Maintenance Maintenance Caution! Risk of injury due to hot and sharp-edged parts! The O-ring cutter cuts the seal with a hot metal tip. This process heats up the seal and possibly also metal parts of the valve. ► When removing the valve seat seal always wear heat-resistant protective gloves.
  • Page 80 Maintenance Maintenance Fig.51 Then use both palms to press the valve seat seal in place in the radial groove. ! When pressing in, pay attention to the “engaging” of the valve seat seal into the radial groove. The generated clicking sound is proof of correct installation. ! After fitting a new TEFASEP gold valve seat seal, it could be that the valve might not be leak-proof yet.

  • Page 81: Lubricating Seals And Threads

    It does not affect the taste or the consistency of the products and is compatible with the seals in contact with product. Rivolta F.L.G. MD-2 can be ordered from GEA Tuchenhagen under material no. 413-071. Using other types of grease can result in malfunctions or in premature seal failure.

  • Page 82: Alarms

    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 83: Decommissioning

    ► Never open the actuator. ► GEA Tuchenhagen accepts unopened actuators and arranges for proper disposal free of charge. Carry out the following steps: Remove the actuator. Pack the actuator safely and send it to GEA Tuchenhagen GmbH. ® Done 430BAL013307EN_8 04.08.2022...

  • Page 84: Parts List - D-Tec Double-Chamber Valve Type D/Dv

    Parts list - D-tec double-chamber valve type D/DV Parts list - D-tec double-chamber valve type D/DV Fig.53: Hard seal Fig.54: Soft seal 430BAL013307EN_8 04.08.2022...
  • Page 85 Parts list - D-tec double-chamber valve type D/DV Fig.55: Housing 430BAL013307EN_8 04.08.2022...
  • Page 86 Parts list - D-tec double-chamber valve type D/DV Item Designation Material DN 40 DN 50 DN 65 DN 80 DN 100 Sealing set complete EPDM 221-748.01 221-748.02 221-748.03 221-748.03 221-748.04 221-748.05 221-748.06 221-748.07 221-748.07 221-748.08 TEFASEP 221-748.09 221-748.10 221-748.11 221-748.11 221-748.12 gold/EPDM Stem diaphragm D/DV (D-tec)
  • Page 87 Parts list - D-tec double-chamber valve type D/DV Item Designation Material DN 40 DN 50 DN 65 DN 80 DN 100 Valve insert D/DV-SV-NC/NO See spare parts list for valve insert D/DV Grease RIVOLTA F.L.G. 100g tube not included with sealing set. 413-136 * The sealing set contains items 3, 5, 7 or 7.1, 8 or 8.1 and A2 ** Diaphragm, item 1 and item 2 are closing parts...
  • Page 88 Parts list - D-tec double-chamber valve type D/DV Item Designation Material 1.5" OD 2" OD 2.5" OD 3" OD 4" OD Housing D/DV-E 3A 1.4404 Housing D/DV-C 1.4404 221-760.15 221-760.17 221-760.19 221-760.21 221-760.23 Housing D/DV-C 3A 1.4404 Actuator 221-118.23 221-118.23 221-118.21 221-118.21 221-118.22...
  • Page 89 Parts list - D-tec double-chamber valve type D/DV Sets of seals for D-tec double-chamber valve type D/DV Item Designation Material DN 40 DN 50 DN 65 DN 80 DN 100 1.5'' OD 2'' OD 2.5'' OD 3'' OD 4'' OD Sealing set complete EPDM 221-748.01...

  • Page 90: Parts List - D-Tec Valve Insert D/Dv-Sv-Nc/No

    Parts list - D-tec valve insert D/DV-SV-NC/NO Parts list - D-tec valve insert D/DV-SV-NC/NO Fig.56: soft seal Fig.57 430BAL013307EN_8 04.08.2022...
  • Page 91 Parts list - D-tec valve insert D/DV-SV-NC/NO Fig.58: hard seal 430BAL013307EN_8 04.08.2022...
  • Page 92 Parts list - D-tec valve insert D/DV-SV-NC/NO Item Designation Material DN 25 DN 25 D/DV-SV D/DV-SV-PT Sealing kit complete 1) EPDM 221-749.01 221-749.01 221-749.02 221-749.02 TEFASEP gold/EPDM 221-749.03 221-749.03 Valve insert D/DV-SV complete 1* 1) Gasket EPDM 924-085 924-085 924-083 924-083 Bearing PTFE/CARBON...
  • Page 93 Parts list - D-tec valve insert D/DV-SV-NC/NO Item Designation Material DN 25 DN 25 D/DV-SV D/DV-SV-PT Grease RIVOLTA F.L.G. MD-2 100g tube not included in the sealing set. 413-136 1) The sealing kit includes the items 1, 6, 7, 29 and 98 * Items marked with an * are wearing parts ** Item 139.1 is not included in the complete proximity switch holder and must be ordered separately *** Do not grease items 7 and 7.1...
  • Page 94 Parts list - D-tec valve insert D/DV-SV-NC/NO Seal kit for D-tec valve insert D/DV-SV-NC/NO Item Designation Material DN 25 Sealing kit complete EPDM 221-749.01 221-749.02 Tefasep Gold/EPDM 221-749.03 Gasket Ø EPDM 924-085 924-083 O-ring Ø 8x1.6 EPDM 930-004 ***7 V-ring Ø...

  • Page 95: Parts List - Lift Actuator

    Parts list - lift actuator _LB-DV Parts list - lift actuator _LB-DV Fig.59 430BAL013307EN_8 04.08.2022...
  • Page 96 Parts list - lift actuator _LB-DV Item Designation Material DN 40 DN 50 DN 65 DN 80 DN 100 Lift actuator LB-DV CLB/DV CLB/DV DLB/ DLB/ DLB/ DV_DN80 DV_DN80 DV_DN100 D=125 D=125 D=160 D=160 D=160 221-608.31 221-608.31 221-608.30 221-608.30 221-608.28 Lift actuator LFT-DV 221-605.30 221-605.30...
  • Page 97 Parts list - lift actuator _LB-DV Item Designation Material 1.5" OD 2" OD 2.5" OD 3" OD 4" OD Plain bearing IGLIDUR-G 704-043 704-043 704-043 704-043 704-043 O-ring 8 x 1.6 930-004 930-004 930-004 930-004 930-004 Vent screw 221-004311 221-004311 221-004311 221-004311 221-004311...

  • Page 98: Dimension Sheet - Double-Chamber Valve Type D/Dv

    Dimension sheet - double-chamber valve type D/DV Dimension sheet - double-chamber valve type D/DV Fig.60 430BAL013307EN_8 04.08.2022...
  • Page 99 Dimension sheet - double-chamber valve type D/DV Fig.61 430BAL013307EN_8 04.08.2022...
  • Page 100 Dimension sheet - double-chamber valve type D/DV Dimension Designation DN 40 DN 50 DN 65 DN 80 DN 100 Main valve Axial spacer housing 112.5 125.5 143.5 158.5 183.5 Connector upper product pipe Connector T-section Tube ID Ø Tube dimension tube ID Ø 41x1.5 53x1.5 70x2...
  • Page 101 Dimension sheet - double-chamber valve type D/DV Dimension Designation 1.5" OD 2" OD 2.5" OD 3" OD 4" OD Main valve Axial spacer housing 135.5 Connector upper product pipe Connector T-section Tube ID Ø Tube dimension tube ID Ø 38.1x1.65 50.8x1.65 63.5x1.65 76.2x1.65...

  • Page 102: Appendix

    Appendix Lists Appendix 17.1 Lists 17.1.1 Abbreviations and terms Abbreviation Explanation British Standard Unit of measurement of pressure [bar] All pressure data expressed in [bar/psi] is assumed to be gauge pressure [bar /psi ] unless explicitly specified otherwise. approx. approximately °C Unit of measurement of temperature [degree Celsius] Cleaning in place...
  • Page 103 Appendix Lists Abbreviation Explanation Unit of measurement of length [millimetre] Unit of measurement of length [micrometre] Metric normally closed Air-to-close/spring-to-open action Unit of measurement of work [newton metre] TORQUE SPECIFICATION: 1 Nm = 0.737 lb-ft Pound-Force (lb)× Feet (ft) normally open Spring-to-close/air-to-open action Polyamide PE-LD...
  • Page 104 Appendix Abbreviation Explanation Tube measurement according to British Standard (BS), Inch OD outside diameter Inch IPS American pipe measurement, iron pipe size 430BAL013307EN_8 04.08.2022...
  • Page 105 Appendix 430BAL013307EN_8 04.08.2022...

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