GEA Aseptomag DK Operating Instruction
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GEA Aseptomag DK Operating Instruction

GEA Aseptomag DK Operating Instruction

Aseptic valves, double chamber valve
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Aseptic Valves
®
GEA Aseptomag
double chamber valve type DK / LoTo
Operating instruction (Translation from the original language)
430BAL015409EN_1

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Summary of Contents for GEA Aseptomag DK

  • Page 1 Aseptic Valves ® GEA Aseptomag double chamber valve type DK / LoTo Operating instruction (Translation from the original language) 430BAL015409EN_1...

  • Page 2: Legal Notice

    LEGAL NOTICE Word marks ® ® 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. 430BAL015409EN_1 15.10.2024...

  • 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 Dual-chamber valve 2.1.2 LoTo locking mechanism 2.1.3 Integration of the maintenance fuse LoTo...
  • Page 4 Locking mechanism LoTo - seat A 8.2.1 Unlock seat A 8.2.2 Unlock seat A - restore normal operations Air lock seat B 8.3.1 Lock the seat B air connection 8.3.2 Unlock the seat B air connection Cleaning Cleaning Sterilisation Passivation Maintenance 10.1 Safety instructions...
  • Page 5 11.1 Malfunctions and remedies Decommissioning 12.1 Safety instructions 12.2 Disposal 12.2.1 General notes Appendix 13.1 Lists 13.1.1 Abbreviations and terms 430BAL015409EN_1 15.10.2024...
  • Page 6 430BAL015409EN_1 15.10.2024...

  • Page 7: 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 8: 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 9: 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 430BAL015409EN_1 15.10.2024...

  • Page 10: Safety

    Safety Intended use Safety Intended use 2.1.1 Dual-chamber valve Aseptic double chamber valves of type DK are mix-proof stroke valves for 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 11 Safety Intended use Fig.2: Sterilisation after transfer CIP cleaning with seat venting If seat venting is activated for a CIP cleaning (preferably in cycles) no process must be running in the opposite line. Furthermore, the outlet valve of the sterile chamber to drain the CIP medium must be open.

  • Page 12: Loto Locking Mechanism

    Safety Intended use 2.1.2 LoTo locking mechanism Maintenance lockout according to LoTo LoTo (Lockout-Tagout) is a safety procedure that ensures dangerous machines or systems are properly shut down and isolated from the energy supply before maintenance or repair work is carried out. The Lockout-Tagout procedure typically involves shutting off the energy source and attaching a lock to prevent the unintended reactivation of the equipment.
  • Page 13 Safety Intended use Standard operation Line 1 Maintenance Line 1 production Line 1 CIP /SIP (idle) seat A = n/a seat A = LoTo seat A = LoTo seat B = n/a seat B = n/a seat B = n/a Line 2 Maintenance steam inlet = ball valve (idle)
  • Page 14 Safety Intended use Fig.6: System components and lines Further measures using the Block-Bleed-Block circuit It is recommended, as part of a comprehensive Lockout-Tagout procedure, to further increase safety when dealing with hazardous energies such as steam and CIP cleaning. A Block-Bleed-Block circuit ensures that leakage does not lead to a hazard.
  • Page 15 Safety Intended use Fig.7: Seat B air connection locked Hint! The interrupted compressed air supply prevents accidental opening of the valve at seat B. There is no protection against opening due to high pressure or pressure surges. The following list serves as a guide for creating a Lockout-Tagout procedure using the Block-Bleed-Block circuit: 430BAL015409EN_1 15.10.2024...

  • Page 16: Requirements For Operation

    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 17: Improper Operating Conditions

    Safety Operator’s Duty of Care ® Aseptomag valve technology can also be used in ATEX protected areas. However, the suitability of the component must be checked under consideration of the respective conditions. Additional information will be made available upon request. 2.1.7 Improper operating conditions The operational reliability of the valve cannot be ensured under improper...

  • Page 18: 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 19: Environmental Protection

    Safety Supplementary Regulations • Observe the accident prevention regulations and all local 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 20 Safety Qualification of Staff Only allow qualified electricians to carry out work on the electrical equipment or have a qualified electrician supervise the work. 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.

  • Page 21: 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 22: Residual Dangers

    Safety Residual dangers In normal operating mode, the threaded ring of the LoTo locking mechanism must be tightened onto the lower stop with the specified torque to prevent access to the moving parts. A corresponding label is located on the stop: Fig.8: Note –...
  • Page 23 Safety Residual dangers Residual dangers on the valve and measures Danger Cause Measure Risk of injury Effectively prevent unauthorised persons from • Danger manipulating the valve. The operator must exercise presented by caution and prudence. moving or For all work: sharp-edged parts •...

  • Page 24: Danger Zones

    Safety Danger zones Danger zones Fig.9 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 (1) or the valve housing (2) when the valve is switching.

  • Page 25: Description

    Description Design of the valve Description Design of the valve Fig.10: Main components on the valve Designation Housing Internal assembly Valve seat A Valve seat B Actuator Locking mechanism seat A LoTo Clamp (safety device) Inlet valve (side valve) Outlet valve (side valve) Clamp to side valve (safety installation) Temperature sensor (optional) 430BAL015409EN_1...

  • Page 26: 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 27 Description Valve Identification Fig.11: Designations on the valve Example Position Details V50-1235 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-50-2245 Internal Drawing number of internal assembly...
  • Page 28 Description Valve Identification Example Position Details PA60/25 DK OR NC PT Outlet valve Designation of actuator V25-3121 Number of actuator drawing 0813 10 Serial number of actuator V-15-1004 Number of clamp drawing TR31-K-Z-TT Temperature Type designation sensor 430BAL015409EN_1 15.10.2024...

  • Page 29: Sealing Concepts

    Divisible valve disc, valve seat seal EPDM (form seal) Concept for hard sealing materials • Divisible valve disc • GEA Aseptomag option for seat A • For hard sealing materials like TEFASEP (TVT) • Additional elastomer O-ring behind the valve seat seal Fig.14:...
  • Page 30 Description Fig.15: "Divisible" version - for elastomer sealing materials 430BAL015409EN_1 15.10.2024...

  • Page 31: 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 32: Technical Data

    Technical data Technical data Technical data Technical data Operating data (for valve with sealing materials Tefasep and silicone) Max. operating temperature 150 °C (302 °F) Max. sterilisation temperature 160 °C (320 °F) for max. 30 min. Max. product pressure 6 bar (others on request) Max.
  • Page 33 Technical data Resistance of sealing materials All sealing materials in the product contact area are suitable for applications in the food industry. The durability of the sealing materials depends on the type, temperature and contact time of the conveyed media. The final assessment of the suitability of Product contact seals the material is therefore the sole responsibility of the plant operator, even if the materials meet all common guidelines of...

  • Page 34: Assembly And Installation

    Assembly and installation Safety instructions Assembly and installation Safety instructions Dangerous situations during assembly can be avoided by safety-conscious and proactive behaviour of the staff. For installation, the following principles apply: • Only properly qualified staff is allowed to install, assemble and set the valve into operation.

  • Page 35: 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 36: Pneumatic Connections

    Assembly and installation Pneumatic connections Pneumatic connections 6.4.1 Overview switching positions Fig.16: Air connections valve version EA Function Valve seat Air connection Open “A“ + “B“ "D" Venting “A“ "E" Venting “B“ "C" Control Side valve "4" ® Information on mounting the valve, see Section 3.1, Page 25. 6.4.2 Air requirement The air requirement depends on the type of actuator fitted.

  • Page 37: Establishing The Compressed Air Supply

    Assembly and installation Electrical connections Air requirement DK EA for actuators NC and NO of the side valve Valve associated side valve Nominal width Nominal width Actuator Air requirements [dm direction of direction of action NC action NO DN25 / 1"OD DN15/15 PA50 DN40 / 1½"OD...
  • Page 38 Assembly and installation Explosive gases or dusts An explosion can result in serious personal injury or death. ► Observe the installation and operating regulations for use in potentially explosive areas. Carry out the following steps: Connect in accordance with the control top diagram and the instructions in the corresponding operating instructions for the T.VIS control top or other models.

  • Page 39: 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 40: Notes On Commissioning

    Start-up Notes on commissioning Verification: • Ensure that all energy sources are actually blocked and discharged by performing visual and physical checks. Performing the work: • Once the systems are secured, authorized personnel can begin maintenance or repair work. Releasing the lockout (unlock): •...

  • Page 41: 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 42 Operation and control Locking mechanism LoTo - seat A Fig.17: Loosen the threaded ring Insert the locking bolt fully into the valve axis until it stops. Fig.18: Insert the locking bolt Tighten the threaded ring onto the locking bolt with the specified torque (20 Nm).

  • Page 43: Unlock Seat A - Restore Normal Operations

    Operation and control Locking mechanism LoTo - seat A Fig.19: Tighten the threaded ring Close the shackle and install the padlock. Fig.20: Lock the locking mechanism ® Seat A is locked, and the locking mechanism is secured. 8.2.2 Unlock seat A - restore normal operations Tools required: •...

  • Page 44: Air Lock Seat B

    Operation and control Air lock seat B Loosen threaded ring with a universal joint wrench. Remove locking pin. Tighten the threaded ring on the lantern using the torque hook wrench with the specified torque (20 Nm). Due to the extended lever of the hook wrench adapter, the setting value on the scale of the torque wrench is 15 Nm! Fig.21: Affix threaded ring...
  • Page 45 Operation and control Air lock seat B Fig.22: Shut off the seat B air connections The required locking plugs “Air Lock” are not included in the delivery. These can be purchased separately: Fuse element for air Art. No. 1925.50018 connection Ø 6 mm Fuse element for air Art.

  • Page 46: Lock The Seat B Air Connection

    Operation and control Air lock seat B Hint! The interrupted compressed air supply prevents accidental opening of the valve at seat B. There is no protection against opening due to high pressure or pressure surges. With the instructions explained below, the complete air supply to the valve can be blocked by locking the air supply (P).

  • Page 47: Unlock The Seat B Air Connection

    Operation and control Lock sleeves (2) and (3) against each other. To this end, push the shackle of a LoTo lock through opening (a) and lock. Repeat this process for the other air connection. ® The air supply of the valve is locked. 8.3.2 Unlock the seat B air connection Carry out the following steps:...

  • Page 48: 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 49 Cleaning The ultimate temperatures, chemicals, concentrations and contact time to be used must be determined by the plant operator along with its chemical supplier. 430BAL015409EN_1 15.10.2024...

  • Page 50: 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 51: Inspections

    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 52: Maintenance Intervals

    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 53 Maintenance List of tools List of tools (in alphabetical order) Material Number Tool Figure Intended Purpose GEA Aseptomag AG Valves EA Pressurizing tool EA 0980.10001 DN 40 - DN 100 DN 40 - DN 100 S-12-0313 Inspection of metal bellows Fig.28...
  • Page 54 Maintenance List of tools List of tools (in alphabetical order) Material Number Tool Figure Intended Purpose GEA Aseptomag AG Pressure control valve Inspection of metal 9999.10090 bellows Ø 6 mm Fig.32 PA80-135 Flexible head spanner Remove/fit assembly 0980.10009 Ø60-90mm, spring S-12-0332 Pin Ø...
  • Page 55 Maintenance List of tools List of tools (in alphabetical order) Material Number Tool Figure Intended Purpose GEA Aseptomag AG Oven 0981.50016 Preheat hard valve (no microwave, seat seals S-12-0084 min. temp. 140 °C) Fig.37 Remove / mount cover Hex socket key 0980.50113...
  • Page 56 Maintenance List of tools List of tools (in alphabetical order) Material Number Tool Figure Intended Purpose GEA Aseptomag AG DN 100 TV Mounting tool 5050.51257 Loosen / tighten DN 100 DK TV S-12-0102 divisible valve disks Fig.42 Mounting tool PA100-180 EA 0981.50015...
  • Page 57 Maintenance List of tools List of tools (in alphabetical order) Material Number Tool Figure Intended Purpose GEA Aseptomag AG Mounting tool 5050.51258 Remove/fit seals O-ring S-12-0162 Fig.47 Disassemble hard, O-ring cutter 0980.50022 shrunk valve seat heated S-12-0083 seals Fig.48 PA80AZ - PA180AZ...

  • Page 58: Intended Purpose

    Maintenance List of tools List of tools (in alphabetical order) Material Number Tool Figure Intended Purpose GEA Aseptomag AG DN 50 - 65 EA TV Spanner adapter 5050.51605 Loosen / tighten AF17 S-12-0097 divisible valve disks Fig.52 DN 80 - 100 EA TV Spanner adapter 5050.51606...

  • Page 59: Prior To Disassembly

    Maintenance Prior to disassembly List of tools (in alphabetical order) Material Number Tool Figure Intended Purpose GEA Aseptomag AG Seeger circlip pliers PA50 - 60 NC/NO 0980.50108 Inside diameter 40-100 Remove/fit PA S-12-0541 angled tip, 90° Fig.57 Inspection of metal Shut-off valve Ø...

  • Page 60: Disassembling And Assembling The Valve

    Maintenance Disassembling and Assembling the Valve • Make sure that while work is being performed on the open valve no process is in operation in the area concerned. Carry out the following steps: Drain all pipe system elements that lead to the valve and, if necessary, clean or rinse, and also depressurize them.
  • Page 61 Maintenance Disassembling and Assembling the Valve Fig.63: Apply valves NC Side valve UV: disconnect pipe connection to switch housing. Fig.64: Separate pipe connection ! Ensure that all pipe connections for the divert valve housing have been removed before carrying out the next step. Release the clamp of the side valve with a suitable hex socket key but do not unhook the screw yet.
  • Page 62 Maintenance Disassembling and Assembling the Valve ! Ensure that you can move the clamp by hand and without much effort before carrying out the next step. If this is not the case, carefully hit the clamp segments with a plastic mallet until the pressure is released and the clamp can easily be moved afterwards.

  • Page 63: Installing The Valve

    Maintenance Disassemble and assemble the side valves Fig.68: Removing actuator and internal assembly ® Internal assembly, actuator and side valves are now separated from the housing. 10.6.2 Installing the valve Hint! Pay attention to the following point when assembling the valve: •...

  • Page 64: Disassemble And Assemble Inside Part (Side Valve) - Versions "Lvd" And "Uv

    Maintenance Disassemble and assemble the side valves – Disassemble and assemble inside part (side valve) - version “AV” is included in the disassembly / assembly instructions of drive PA50/PA60 (side valve). – Disassemble and assemble drive PA50/PA60 (side valve), see Section 10.7.4, Page 68.

  • Page 65: Assemble Piston Rod Seal (Side Valve) - Version "Lvd" And "Uv

    Maintenance Disassemble and assemble the side valves Fig.70: Remove components of inside part ® The internal LVD has been disassembled. Side valve UV: Loosen clamp with Allen key and remove. Fig.71: Remove clamp Side valve UV: Remove divert valve housing and valve cover. Remove the housing seal without a tool.

  • Page 66: Disassemble And Assemble Piston Rod Seal (Side Valve) - Version "Lvd" And "Uv

    Maintenance Disassemble and assemble the side valves Tools required: • Torque wrench with open-jawed spanner Carry out the following steps: Install the internal assembly in the reverse order of disassembly, see Section 10.7.2.1, Page 64. ! Grease well the valve axle of the inside part at the thread and 5 mm of the adjoining axle to prevent possible corrosion.

  • Page 67: Assemble Piston Rod Seal (Side Valve) - Version "Lvd" And "Uv

    Maintenance Disassemble and assemble the side valves Fig.74: Remove piston rod seal ® Piston rod seal side valve is dismantled. 10.7.3.2 Assemble piston rod seal (side valve) - version "LVD" and "UV" Tools required: • Food-grade lubricant PARALIQ GTE 703 •...

  • Page 68: Disassemble And Assemble Actuator Pa50/Pa60 (Side Valve)

    Maintenance Disassemble and assemble the side valves Fig.76: Insert piston rod seal Using your thumbs, push the piston rod seal downwards in the opening simultaneously on both sides until it engages in the seal groove. ® Piston rod seal side valve is installed. 10.7.4 Disassemble and assemble actuator PA50/PA60 (side valve) 10.7.4.1 Disassembling Actuator PA50/PA60 (side valve)
  • Page 69 Maintenance Disassemble and assemble the side valves Fig.77: Lowering actuator base Remove the circlip from the actuator base using the Seeger circlip pliers. Fig.78: Removing the circlip Slowly remove pressure from the actuator base. 430BAL015409EN_1 15.10.2024...
  • Page 70 Maintenance Disassemble and assemble the side valves ! For side valve “LVD” and “UV”: The bottom part of the actuator is pressed upwards by the pressure spring when pressure is removed and can be taken out. Fig.79: Removing pressure from the actuator base Side valve "LVD"...
  • Page 71 Maintenance Disassemble and assemble the side valves Fig.81: Lift out the actuator components Pull the bottom circlip out of the groove and remove both parts of the lock washer from the piston rod. Fig.82: Removing bottom securing elements Carefully slip off the actuator components from the piston rod. ! Pay attention to the alignment of the piston disk (asymmetrical design) already when disassembling.
  • Page 72 Maintenance Disassemble and assemble the side valves Fig.84: Remove upper securing elements Side valve "AV": Pull the bottom part of the actuator from the piston rod. Fig.85: Pull off the bottom part of the actuator Actuator NC: Carefully draw the compression spring out of the cylinder. Fig.86: Lift out spring ®...

  • Page 73: Installing Actuator Pa50/Pa60

    Maintenance Disassemble and assemble the side valves 10.7.4.2 Installing Actuator PA50/PA60 Hint! Pay attention to the following points when installing the actuator: • Replace all visible seals. • Thoroughly clean and check the interior cylinder contact surfaces, O-ring grooves, piston rod and piston disc. •...

  • Page 74: Mount Piston Rod Seal (Side Valve) - Version "Av

    Maintenance Disassemble and assemble the side valves Fig.87: Loosen the piston rod seal Insert the slotted screwdriver in the generated gap between piston rod seal and bottom part of actuator and remove the seal from the groove using lever movement. ! Pay attention not to damage the surface of the groove.

  • Page 75: Disassemble And Assemble The Internal Assembly "Ea

    Maintenance Disassemble and assemble the internal assembly “EA” Grease piston rod seal on the external surfaces with food-grade lubricating grease. Position piston rod seal well centred above groove opening of the actuator bottom part and put it on a solid, horizontal ground. Fig.89: Position the piston rod seal Position the flat object with the contact face downwards onto the piston rod...
  • Page 76 Maintenance Disassemble and assemble the internal assembly “EA” 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 77: Assemble Internal Assembly "Ea

    Maintenance Disassemble and assemble the internal assembly “EA” Connection 2 C of the actuator. Lift the circlip out of the groove and pull the lock washer out from the piston rod. Fig.92: Removing fuse elements Position the spanner adapter with socket for wrench at the width across flats of the internal assembly, loosen and carefully screw out from the piston rod of the pneumatic actuator.
  • Page 78 Maintenance Disassemble and assemble the internal assembly “EA” Hint! Pay attention to the following points when assembling the internal assembly: • Thoroughly clean all parts and check for damage. • Replace all dismantled seals. • When changing the seals, do not damage the seal groove. •...

  • Page 79: Torques For Ea Valve Axes

    Maintenance Removing and Installing the "Shrunk-on” Valve Seat Seal Fig.95: Align yoke opening with the leakage socket ® The internal assembly has been assembled. 10.8.3 Torques for EA Valve Axes Thread size of valve Valve size Torque [Nm] axes DN25 M8 x 1 DN40 M12 x 1.25...

  • Page 80: Fitting The "Shrink-On Fit" Valve Seat Seal

    Maintenance Removing and Installing the "Shrunk-on” Valve Seat Seal Caution! Health hazard due to toxic fumes! The O-ring cutter cuts the seal with a hot metal tip. At temperatures of more than 300 °C, toxic fumes can be released. ► Avoid directly inhaling the fumes. Caution! Risk of injury due to hot and sharp-edged parts! The O-ring cutter cuts the seal with a hot metal tip.
  • Page 81 Maintenance Removing and Installing the "Shrunk-on” Valve Seat Seal Tools required: • Oven (no microwave) • Heat-resistant protective gloves Carry out the following steps: Heat new valve seat seal in oven . – Temperature: 140 °C (guideline value) – Time: 3 - 5 minutes (guideline value) ! Ensure that the seal can be deformed along the circumference without much effort.

  • Page 82: Removing And Installing The "Divisible System" Valve Seat Seal (Seat A)

    Maintenance Removing and Installing the "Divisible System" Valve Seat Seal (seat A) Fig.99: 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 83 Maintenance Removing and Installing the "Divisible System" Valve Seat Seal (seat A) Clamp assembly tool assembly tool in in vice. Push the internal assembly at the socket surface of the valve disc into the assembly tool. Position the spanner adapter on the nut of the valve disc. Fig.100: Clamping internal assembly Place the ratchet with the wrench socket on the spanner adapter and loosen the nut of the valve disc.

  • Page 84: Assemble The Valve Seat Seal "System Divisible" - Valve Version "Ea

    Maintenance Carrying out the "Internal assembly" leak test ® The valve seat seal has been removed. 10.10.2 Assemble the valve seat seal “system divisible” - valve version “EA” Tools required: • Torque wrench with wrench socket • Spanner adapter • Assembly tool DK TV •...
  • Page 85 Maintenance Carrying out the "Internal assembly" leak test Hint! Observe the inspection interval! The metal bellows must be checked for leaks as part of the annual maintenance using the pressurizing tool . Notice Risk of damage to the metal bellow from torsion The metal bellow can get damaged, if forces other than those described in these assembly instructions are used on the internal assembly.
  • Page 86 Maintenance Carrying out the "Internal assembly" leak test Fig.104: Align opening with the leakage socket Tighten adapter G1/4“ by hand with internal assembly. Fig.105: Screw adapter Apply max. 3 bar of compressed air to the pressurizing tool . ! Air pressures > 3 bar can damage the metal bellows. Immerse the internal assembly in a water bath for approx.

  • Page 87: Disassembling And Assembling Actuator Pa80Ea - Pa255Ea

    Maintenance Disassembling and Assembling Actuator PA80EA - PA255EA Fig.106: Water bath Remove the internal assembly from the pressurizing tool in reverse order. ® This completes the leak test. 10.12 Disassembling and Assembling Actuator PA80EA - PA255EA 10.12.1 Disassembling the actuator PA80EA - PA255EA Tools required: •...
  • Page 88 Maintenance Disassembling and Assembling Actuator PA80EA - PA255EA Fig.107: Attaching clamping piece Clamp the actuator at the clamping piece into the vice . Fig.108: 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 89 Maintenance Disassembling and Assembling Actuator PA80EA - PA255EA Fig.110: Unscrewing assembly spring ® Assembly spring has been removed. Dismantling the PA80EA - PA255EA actuator Carry out the following steps: Lift off the actuator base from the cylinder. Fig.111: Removing actuator base Pull the spring assembly upwards at the piston rod out of the cylinder.
  • Page 90 Maintenance Disassembling and Assembling Actuator PA80EA - PA255EA Fig.113: Lifting out bottom spring assembly Lift the circlip out of the groove with a slotted screwdriver and remove it. Fig.114: Removing circlip Take the buffer segments out of the actuator base. Fig.115: Removing fuse elements Lift the piston disc out of the actuator base.

  • Page 91: Mounting The Actuator Pa80Ea - Pa255Ea

    Maintenance Disassembling and Assembling Actuator PA80EA - PA255EA ! Opening the spring assembly is prohibited for safety reasons. ® Actuator PA80EA - PA255EA has been removed. 10.12.2 Mounting the actuator PA80EA - PA255EA Hint! Pay attention to the following points when installing the actuator: •...
  • Page 92 Maintenance Disassembling and Assembling Actuator PA80EA - PA255EA Fig.118: Hooking in the assembly spring Turn the actuator base 360° counter-clockwise using a flexible head spanner . ® The assembly spring is pulled into the cylinder. Fig.119: Screwing in the assembly spring As soon as both open ends of the assembly spring are visible in the slot area, the beginning of the assembly spring must be pressed into the hole in the actuator base with a slotted screwdriver.

  • Page 93: Removing/Dismantling Loto Locking Mechanism

    Maintenance Removing/dismantling LoTo locking mechanism Fig.121: Placing the air connection ® Assembly spring has been fitted. ® Actuator PA80EA - PA255EA is mounted. 10.13 Removing/dismantling LoTo locking mechanism 10.13.1 Dismantling LoTo locking mechanism Tools required: • Ratchet, square socket drive ½" •...
  • Page 94 Maintenance Removing/dismantling LoTo locking mechanism Fig.123: Lantern mounting tool Disassemble the cover plate locking mechanism with an internal hex key SW4. Fig.124: Disassemble the cover plate ® The LoTo lockout device is disassembled. 430BAL015409EN_1 15.10.2024...

  • Page 95: Mounting The Loto Locking Mechanism

    Maintenance Removing/dismantling LoTo locking mechanism 10.13.2 Mounting the LoTo locking mechanism Hint! Pay attention to the following points when installing the actuator: • Replace all visible seals. • Thoroughly clean and check the interior cylinder contact surfaces, O-ring grooves, piston rod and piston disc. •...
  • Page 96 Maintenance Removing/dismantling LoTo locking mechanism Fig.126: Check the centering Attaching the mounting tool on the locking mechanism. Fig.127: Attaching the mounting tool Clamp the lantern in the vice. 430BAL015409EN_1 15.10.2024...
  • Page 97 Maintenance Removing/dismantling LoTo locking mechanism Fig.128: Clamping the lantern Positioning the drive cylinder and inserting the centring rod. Fig.129: Inserting the centring rod Tighten the screws with a torque of 15 Nm. Then remove the centring rod. 430BAL015409EN_1 15.10.2024...

  • Page 98: Maintenance

    Prior to any work on the open valve, ensure that it has stopped operation, see Section 10.5, Page 59. The following information and values are based on the experience of GEA Flow Components and apply for installations working in 2-shift operation.
  • Page 99 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 100: Checking The Feedback Unit

    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: Adjust the proximity switch for detecting the non-actuated position. Actuate the valve with compressed air.

  • Page 101: 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 102 Alarms Malfunction Cause Remedy • Check the sealing surfaces The maximum valve stroke is in the actuator for damage. not reached when the valve is Leakage in the actuator. actuated pneumatically. • Replace the seals. • Check that the feedback •...
  • Page 103 Decommissioning Safety instructions Decommissioning 12.1 Safety instructions For shutting down, the following principles apply: • Switch off the compressed air. • Switch off the valve via the main switch. • Padlock the main switch (if fitted) in the off position to prevent it from being switched back on.
  • Page 104 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 105 Appendix Abbreviation Explanation Normally Closed; direction of action spring-closing/air-opening Unit of measurement of work [newton metre] Specification for the 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...

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