Related Manuals for GEA Aseptomag AMV
Summary of Contents for GEA Aseptomag AMV
- Page 1 Aseptic Valves ® GEA Aseptomag stop valve type AMV Operating instruction (Translation from the original language) 430BAL013317EN_1...
- 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.
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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 Maintenance 10.1 Safety instructions 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...
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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 GEA Aseptomag AG Flow Components – Aseptic Valves 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 430BAL013317EN_1 11.03.2019... -
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 The operational safety of the component can not be guaranteed under improper operating conditions. Therefore avoid improper operating conditions. The operation of the component is not permitted if: • Persons or objects are in the danger zone. •... -
Page 10: Subsequent Changes
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 • Substances harmful to the environment must not be discharged into the ground or the sewage system. • Always observe the pertinent regulations relating to waste avoidance, disposal and utilization. • Substances harmful to the environment must be collected and stored in suitable containers. -
Page 12: Safety Equipment
Safety Safety equipment • Training as a specialist for working independently on the component. • Adequate instruction to work on the component under the supervision and guidance of a trained specialist Each employee must meet the following requirements to work on the component: •... -
Page 13: Signage
Safety Residual dangers 2.7.1 Signage No warning signs are affixed to this valve. Residual dangers Dangerous situations can be avoided by safety-conscious and proactive behaviour of the personnel and by wearing personal protective equipment. Residual dangers on the valve and measures Danger Cause Measure... -
Page 14: Danger Zones
Safety Danger zones Danger zones Please observe the following notes: 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 valve housing (1) 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) 430BAL013317EN_1 11.03.2019... -
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 Example Position Details V-10-1047 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-15-1004 Clamp Number of clamp drawing V-10-2043 Internal Drawing number of internal assembly assembly 1424 10 Serial number of internal assembly...
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Page 18: Valve Settings With Manual Actuation
Description Valve settings with manual actuation Valve settings with manual actuation 3.3.1 Valve with hand wheel • Hand wheel with marker disc (H) Fig.4: Valve closed Fig.5: Valve open 430BAL013317EN_1 11.03.2019... -
Page 19: Sealing Concepts
Description Sealing Concepts Sealing Concepts 3.4.1 "Shrink-on Fit" Version • Undivided valve disc • Metal bellows • For hard sealing materials such as PTFE Fig.6: "Shrink-on Fit" version 3.4.2 System “integrated valve seat seal” • Undivided valve disc • PTFE bellows •... -
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 material EPDM) Max. operating temperature 135 °C (275 °F) Max. sterilisation temperature 150 °C (302 °F) for max. 30 min. Max. product pressure 6 bar (others on request) Control air pressure, actuator 6 bar, max. - 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)
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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 Pneumatic connections Caution! If pipes contain liquids, these can spurt out when the pipes are opened. Danger of injury as a result of hot or aggressive liquids. ► Drain all pipe system elements that lead to the valve location and, if necessary, clean or rinse them. -
Page 25: Establishing The Compressed Air Supply
Assembly and installation Pneumatic connections Air requirement for opening the actuators Nominal width of Actuator Reference stroke Air Requirement valve [mm] DN 6 PA35 NC 0.03 DN 8 PA35 NC 0.03 DN 10 OD ½" PA35 NC 0.03 DN 15 OD ¾"... -
Page 26: Electrical Connections
Assembly and installation Electrical connections Electrical connections Requirement: • The valve has been fitted correctly, see Section 10.6, Page 34. 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 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 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 31 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 32 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 33 Maintenance List of tools List of tools (in alphabetical order) Material Number Tool Figure Intended Purpose GEA Aseptomag AG Hex socket key PA35 PV SW2.5 Remove/fit PA Hex socket key PA35 PV H 0980.50113 Remove/fit PA S-12-0546 Valves Hex socket key 0980.50121...
- Page 34 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.14 Inspection of metal Shut-off valve Ø 6 mm 9999.10091 bellows Fig.15 10.5...
- Page 35 Maintenance Disassembling and Assembling the Valve Caution! Danger of injury due to media escaping after removing the clamp You can sustain injuries to your entire body if you open a valve that is still under pressure from the medium. ► Ensure that the valve is no longer under medium pressure before removing the clamp.
- Page 36 Maintenance Disassembling and Assembling the Internal Assembly ! Do not damage the sealing surface on the valve body. Fig.18: Removing actuator and internal assembly ® Internal assembly and actuator are now separated from the housing. 10.6.2 Assembling the Valve Tools required: •...
- Page 37 Maintenance Disassembling and Assembling the Internal Assembly Caution! Danger of injury due to valve parts moved by compressed air! You can sustain injuries to your fingers when you put your hand into the valve while it is switching. ► Wear protective gloves for all work. ►...
- Page 38 Maintenance Disassembling and Assembling the Internal Assembly Fig.20: Removing the valve lid Remove the housing seal without a tool. ! Do not damage the sealing surfaces on the housing and internal assembly. Fig.21: Removing housing seal ® The internal assembly has been disassembled. 10.7.2 Assembling the Internal Assembly Carry out the following steps:...
- Page 39 Maintenance Removing and Installing the "Shrunk-on” Valve Seat Seal 10.8 Removing and Installing the "Shrunk-on” Valve Seat Seal 10.8.1 Removing the Shrunk-on Valve Seat Seal For information on valve seat seals, see Section 3.4, Page 19 Tools required: • O-ring cutter •...
- Page 40 Maintenance Removing and Installing the "Shrunk-on” Valve Seat Seal Carry out the following steps: Heat the new valve seat seal in the oven. – Temperature: 140 °C (guideline value) – Time: 3 - 5 minutes (guideline value) ! Make sure that the seal can be deformed along the circumference without much effort.
- Page 41 Maintenance Carrying out the "Internal assembly" leak test (bubble test) Fig.25: Mounting the valve seat seal ® The valve seat seal is still too rigid and cannot be mounted? – Reheat the valve seat seal as described in the previous instruction step.
- Page 42 Maintenance Carrying out the "Internal assembly" leak test (bubble test) • Water bath Carry out the following steps: Insert the pressurizing tool into the inner assembly. Fig.26: Inserting the pressurizing tool Tightly screw the pressurizing tool to the inner assembly by hand. ! With the inner assembly, ideally apply the force to the valve seat.
- Page 43 Maintenance Carrying out the "Internal assembly" leak test (bubble test) Fig.28: Water bath Remove the internal assembly from the pressurizing tool in reverse order. ® This completes the leak test. 430BAL013317EN_1 11.03.2019...
- Page 44 Maintenance Disassembling and assembling actuator PA35 PV 10.10 Disassembling and assembling actuator PA35 PV 10.10.1 Disassembling actuator PA35 PV 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 45 Maintenance Disassembling and assembling actuator PA35 PV Fig.30: Removing the lock washer Press the actuator cover downwards, remove retaining ring and take the cover off. ! Pay attention to the alignment of the cover (asymmetrical design) already when disassembling. Fig.31: Removing the retaining ring &...
- Page 46 Maintenance Disassembling and assembling actuator PA35 PV Fig.32: Positioning the actuator Press the piston rod upwards by tightening the assembly tool, pull the retaining ring out of the groove and remove both parts of the retaining ring from the piston rod. Fig.33: Stripping the actuator components off Slowly release the pressure on the actuator spring and remove the drive from...
- Page 47 Maintenance Disassembling and assembling actuator PA35 PV Fig.34: Pulling off the actuator cylinder Carefully pull the actuator components off the piston rod. Fig.35: Pulling off actuator components Carefully lift the lifting piston out of the cylinder. ! Pay attention to the alignment of the piston (asymmetrical design) already when disassembling.
- Page 48 Maintenance Disassembling and assembling actuator PA35 PV Fig.36: Lifting out the lifting piston ® Actuator PA35 PV is disassembled. 10.10.2 Assembling actuator PA35 PV Hint! Pay attention to the following points when assembling the actuator: • Replace all visible seals. •...
- Page 49 Maintenance Disassembling and assembling actuator PA35 PV H 10.11 Disassembling and assembling actuator PA35 PV H 10.11.1 Disassembling actuator PA35 PV H Tools required: • Hex socket key • Assembly tool for PA35 Carry out the following steps: Loosen the countersunk screw from the actuator, remove the screw and washer.
- Page 50 Maintenance Disassembling and assembling actuator PA35 PV H Fig.39: Remove the hand wheel Slowly release the pressure on the actuator spring and remove the drive from the assembly tool. Carefully pull the actuator cylinder off the actuator components. Fig.40: Pulling off the actuator cylinder Carefully pull the actuator components off the piston rod.
- Page 51 Maintenance Disassembling and assembling actuator PA35 PV H Fig.41: Pulling off actuator components ® Actuator PA35 PV H is disassembled. 10.11.2 Assembling actuator PA35 PV H Hint! Pay attention to the following points when assembling the actuator: • Replace all visible seals. •...
- Page 52 Prior to any work on the open valve, ensure that it has stopped operation, see Section 10.5, Page 34. The following information and values are based on the experience of GEA Flow Components and apply for installations working in 2-shift operation.
- Page 53 Maintenance Checking the Feedback Unit Activities to be performed once a year Component Activity to be performed Product contact seals Seal replacement Check of mechanical parts and visual inspection of Internal assembly with condition bellows Leak test of bellows (bubble test) Check of mechanical parts and visual inspection of Actuator condition...
- Page 54 Maintenance Checking the Feedback Unit Hint! If a control top is present, the information provided in the corresponding instruction manual must be observed. 430BAL013317EN_1 11.03.2019...
- Page 55 Maintenance 10.13.2 Valve Stroke Strokes Depending on Size Size DN Size OD Valve stroke [mm] DN 6 DN 8 DN 10 OD ½" DN 15 OD ¾" 430BAL013317EN_1 11.03.2019...
- Page 56 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 fault can no longer be taken for granted and in the worst case can result in a loss of sterility in the process.
- Page 57 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 58 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 59 Appendix Abbreviation Explanation 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 Polytetrafluoroethylene...