AS DH -N2 Series Operating Instructions Manual Download

Page: 3 / 44

AS Strömungstechnik GmbH

www.asstroemungstechnik.de

Version date: 09/2020

1 Contents

General information .............................................................................................. 4

1.1 Introduction ............................................................................................................. 4
1.2 Conventions ............................................................................................................ 4
1.3

Symbols and labels ................................................................................................. 5

1.4

1.5

Guarantee and warranty ......................................................................................... 5

2 Safety ..................................................................................................................... 6

2.1

Intended use .......................................................................................................... 6

2.2

Improper use .......................................................................................................... 6

2.3

Responsibility of the user ....................................................................................... 6

2.4

General safety instructions ..................................................................................... 7

3 Setup/function ....................................................................................................... 8

3.1

Auxiliary tools .........................................................................................................11

Technical specifications ..................................................................................... 12

4.1

Fill head DH-R.../GH-R... ...................................................................................... 12

4.2

Fill head DH-_B.../GH-_B.. .................................................................................... 14

4.3

Fill head DH-A.../GH-A.. ........................................................................................ 16

4.4

Fill head DH-…-N2 / GH-…-N2 ............................................................................. 18

4.5

Fill head DH-_U… / GH-_U… ............................................................................... 20

4.6

Fill head DH-_J… / DH-J… / GH-_J… / GH-J… ................................................... 22

4.7

Ambient / operating temperature ........................................................................... 24

4.8

Torques for dip tube closures ................................................................................ 24

5 Assembly/commissioning .................................................................................. 25

5.1

Initial commissioning ............................................................................................. 25

5.2

Tests prior to assembly ......................................................................................... 28

5.3

Mounting the fill head ............................................................................................ 30

6 Operation ............................................................................................................. 34

6.1

Tests before each operation .................................................................................. 34

6.2

Tests during operation ........................................................................................... 35

7 Troubleshooting .................................................................................................. 36

8 Disassembly ........................................................................................................ 38

8.1

Dismantling the fill head ........................................................................................ 38

9 Maintenance/disposal ......................................................................................... 40

9.1

Cleaning the fill head ............................................................................................. 40

9.2

Fill head maintenance ........................................................................................... 40

9.3

Returning fill heads ............................................................................................... 41

9.4

Fill head disposal .................................................................................................. 41

Contents

Summary of Contents for DH -N2 Series

Page 1: ...Operating instructions Translation Fill heads of the series QC2 G Series ...

Page 2: ...s Revision status A 09 2020 creation If you have questions about the products please contact AS Strömungstechnik GmbH manufacturer directly Copyright address of the manufacturer Copyright by AS Strömungstechnik GmbH Elly Beinhorn Str 7 73760 Ostfildern Germany info asstroemungstechnik de www asstroemungstechnik de All rights reserved Printed in Germany Legal notice ...

Page 3: ...2 4 2 Fill head DH _B GH _B 14 4 3 Fill head DH A GH A 16 4 4 Fill head DH N2 GH N2 18 4 5 Fill head DH _U GH _U 20 4 6 Fill head DH _J DH J GH _J GH J 22 4 7 Ambient operating temperature 24 4 8 Torques for dip tube closures 24 5 Assembly commissioning 25 5 1 Initial commissioning 25 5 2 Tests prior to assembly 28 5 3 Mounting the fill head 30 6 Operation 34 6 1 Tests before each operation 34 6 2...

Page 4: ...on in these operating instructions applies in conjunction with additional special documentation The operating instructions are the basis for all training courses that take place with the products Please read the operating instructions carefully before using the products Please read the safety instructions Store the operating instructions in a safe and accessible place during the service life of th...

Page 5: ...e operating instructions are subject to copyright protection and other protective laws Duplication also in ex cerpts requires the prior written consent of AS Strömungstechnik GmbH if duplica tion is not legally permitted General information 1 5 Guarantee and warranty AS Strömungstechnik GmbH assumes no liability for errors or damage that occurred due to improper handling of the products Improper h...

Page 6: ...applica tions refer to the operating instructions for dispense heads of the corresponding series 2 2 Improper use Any use other than the one described in the Section intended use is deemed to be inappropriate use The operator of the products shall be solely responsible for any resulting damage 2 3 Responsibility of the user Operator means any natural or legal per son who operates or controls the d...

Page 7: ...s SOPs Wear appropriate protective clothing when handling chemical substances Ensure that the fill heads are not used after the maximum period of use has expired The duration of use depends on the chemicals used Before using the products check the materials for their chemical resistance 2 4 General safety instructions Always observe the safety data sheets SDS of the chemicals used Only use cleaned...

Page 8: ...valve Plug valve turncock Ball valve DH J DH _J GH J GH _J Fill head with mixing nozzle DH N2 GH N2 Fill head with second vent port for N2 blanketing DH _U GH _U Fill head with overfilling sensor Fill head versions can be combined with each other For example a QC2 Fill head can also have a check valve a limit switch and a overfilling sensor DH RBU The electrically conductive version with limit swi...

Page 9: ...ghtening nut incl red markings 3 Code disk 4 Anti rotation clip red 5 Main body 6 Vent port standard NPT3 8 female thread from 11 2019 on the Figure with screwed in flare adapter 7 Locking pin set screw 8 Top connection vertical or horizontal 9 Check valve depending on model 10 Vent channel 11 Liquid channel 12 Limit switch optional ...

Page 10: ...pressure in the filling line is reduced and the check valve closes The optional limit switch ensures that the fill head is correctly mounted The filling process can only be started after the re lease signal from the limit switch The incorporation of the limit switch requires professional installation to integrate the signals into the system control PLC to properly operate To fill flammable or high...

Page 11: ... 89740 incl bottle QC2 conduc tive RDC 89740 CD without shelf for accesso ries G Se ries RDC 89750 incl bottle G Se ries con ductive RDC 89754 without shelf for accesso ries Universal bung wrench Series Item no Note QC2 RDH 79005 PVDF QC2 conduc tive RDH 79003 CD electrically conductive G Se ries RDH 79010 PVDF G Se ries con ductive RDH 79009 electrically conductive Torque tool The torque tool com...

Page 12: ...e only exemplary representations Depending on the equipment and configuration the actual fill head may vary in appearance Weight Tightening torque Nm QC2 2 6 G Series 2 6 Flow rates l min QC2 max 25 with check valve max 60 without check valve G Series max 100 with check valve max 150 without check valve Opening pressure check valve bar QC2 0 10 G Series 0 05 Period of use Depending on chemical res...

Page 13: ...sk Standard FKM As an alternative EPDM Kalrez Other components Standard PVDF As an alternative PFA on request Connections Characteristic Value Connection vari ants liquid Flare 3 8 1 2 3 4 1 1 1 4 Hose connector 1 2 3 4 1 FNPT MNPT 1 2 3 4 1 G thread 1 2 Others on request e g Tri Clamp Camlock Pillar Grundfos Connection gas QC2 NPT 3 8 female thread since November 2018 G Series NPT 1 2 female thre...

Page 14: ...actual fill head may vary in appearance Weight Tightening torque Nm QC2 2 6 G Series 2 6 Flow rates l min QC2 max 25 with check valve max 60 without check valve G Series max 100 with check valve max 150 without check valve Opening pressure check valve if applicable bar QC2 0 10 G Series 0 05 Period of use Depending on chemical resistance Standard 3 years For electrical data connection diagram and ...

Page 15: ...ip PVC red O ring on code disk Standard FKM As an alternative EPDM Kalrez Other components Standard PVDF As an alternative PFA on request Sensor See data sheet of the sensor Connections Characteristic Value Connection vari ants liquid Flare 3 8 1 2 3 4 1 1 1 4 Hose connector 1 2 3 4 1 FNPT MNPT 1 2 3 4 1 G thread 1 2 Others on request e g Tri Clamp Camlock Pillar Grundfos Connection gas QC2 NPT 3 ...

Page 16: ...the fill head 1 Plug valve turncock 2 Ball valve The fill heads shown here are only exemplary representations Depending on the equipment and configuration the actual fill head may vary in appearance Weight Tightening torque Nm QC2 2 6 G Series 2 6 Flow rates l min QC2 max 60 G Series max 150 Period of use Depending on chemical resistance Standard 3 years Technical specifications ...

Page 17: ...VDF with Kalrez o rings Materials non wetted components Characteristic Value Anti rotation clip PVC red o ring on code disk Standard FKM As an alternative EPDM Kalrez Other components Standard PVDF As an alternative PFA on request Connections Characteristic Value Connection vari ants liquid Flare 3 8 1 2 3 4 1 1 1 4 Hose connector 1 2 3 4 1 FNPT MNPT 1 2 3 4 1 G thread 1 2 Others on request e g Tr...

Page 18: ... The fill heads shown here are only exemplary representations Depending on the equipment and configuration the actual fill head may vary in appearance Weight Tightening torque Nm QC2 2 6 G Series 2 6 Flow rates l min QC2 max 25 with check valve max 60 without check valve G Series max 100 with check valve max 150 without check valve Opening pressure check valve if appli cable bar QC2 0 10 G Series ...

Page 19: ...ndard FKM As an alternative EPDM Kalrez Other components Standard PVDF As an alternative PFA on request Connections Characteristic Value Connection vari ants liquid Flare 3 8 1 2 3 4 1 1 1 4 Hose connector 1 2 3 4 1 FNPT MNPT 1 2 3 4 1 G thread 1 2 Others on request e g Tri Clamp Camlock Pillar Grundfos Connection gas QC2 NPT 3 8 female thread since November 2018 G Series NPT 1 2 female thread sin...

Page 20: ...presentations Depending on the equipment and configuration the actual fill head may vary in appearance Weight Tightening torque Nm QC2 2 6 G Series 2 6 Flow rates l min QC2 max 25 with check valve max 60 without check valve G Series max 100 with check valve max 150 without check valve Opening pressure check valve if appli cable bar QC2 0 10 G Series 0 05 Period of use Depending on chemical resista...

Page 21: ...O ring on code disk Standard FKM As an alternative EPDM Kalrez Other components Standard PVDF As an alternative PFA on request Connections Characteristic Value Connection vari ants liquid Flare 3 8 1 2 3 4 1 1 1 4 Hose connector 1 2 3 4 1 FNPT MNPT 1 2 3 4 1 G thread 1 2 Others on request e g Tri Clamp Camlock Pillar Grundfos Connection gas QC2 NPT 3 8 female thread since November 2018 G Series NP...

Page 22: ...fill heads shown here are only exemplary representations Depending on the equipment and configuration the actual fill head may vary in appearance Weight Tightening torque Nm QC2 2 6 G Series 2 6 Flow rates l min QC2 max 25 with check valve max 60 without check valve G Series max 100 with check valve max 150 without check valve Opening pressure check valve if appli cable bar QC2 0 10 G Series 0 05 ...

Page 23: ...tandard FKM As an alternative EPDM Kalrez Other components Standard PVDF As an alternative PFA on request Connections Characteristic Value Connection vari ants liquid Flare 3 8 1 2 3 4 1 1 1 4 Hose connector 1 2 3 4 1 FNPT MNPT 1 2 3 4 1 G thread 1 2 Others on request e g Tri Clamp Camlock Pillar Grundfos Connection gas QC2 NPT 3 8 female thread since November 2018 G Series NPT 1 2 female thread s...

Page 24: ...ical customer service of AS Strömungstechnik The chemical resistance of plastics and elastomers can deteriorate due to heat at temperatures higher than room tempera ture For fill heads with built in sensors e g limit switch also observe the temperature specifications given in the sensor data sheet These may further restrict the tem perature ranges listed here Technical specifications 4 8 Torques f...

Page 25: ...lead to premature wear of o rings and seals and thus to leaks Dust deposits must be avoided in EX areas in par ticular as there is an increased risk of ignition 2 Connect the fill line to the liquid con nection of the fill head The following must be observed here The fill line must be connected free of stress and load Assembly commissioning The connecting couplings must not be tightened too tight ...

Page 26: ...nitrogen cushion builds up from the bottom in the container In recirculation applications in which a dispense head and a fill head are attached to the container the standard ventilation connections can be used to inert the container with nitrogen before operation Assembly commissioning 5 Mount the fill head on a empty contai ner or for recirculation applications in combination with a dispense head...

Page 27: ...cal resistance which can be used as a guide Link https asstroemungstechnik de de chembank 8 Check whether the fill head shows any damage such as cracks or discoloring 9 Use the first liters of product as flush ing chemistry to condition the fill head and connections 10 In the case of fill heads with overfilling sensors it must be checked whether the medium to be filled is detected by the sensor As...

Page 28: ...losed or incorrectly connected venti lation line will cause the pressure equal ization in the container to fail Excess or negative pressure can occur in the container Chemicals may leak out Make sure that the ventilation line is not blocked and is correctly connect ed Wear the necessary personal pro tective equipment PPE suitable protective clothing protective gloves respirators and safety goggles...

Page 29: ...ine up this can be a sign that it has been tam pered with and could result in leaks Assembly commissioning 8 Check that there is a code disk 5 on the fill head and that the coding matches that of the dip tube 6 and thus the chemical This means that only the correct three pins 7 must be missing and the code disk must not be bent Do not change any coding on the dip tube or the code disk if they do n...

Page 30: ...check whether the sensor in the housing is working properly The ventilation channel must be free of any debris of the medium so that the measuring field of the sensor is not disturbed A ventilation line must be connected to the vent port so that no medium can escape unhindered in the event of overfilling Assembly commissioning 5 3 Mounting the fill head WARNING Hazard from chemicals Chemicals can ...

Page 31: ... Assembly commissioning 3 Slowly open the dip tube closure 2 with the bung wrench 3 in case the contents are under pressure See Section 3 1 If the container is under pressure when opened it is drained via the ven tilation holes in the dip tube You may hear a hissing sound In this case do not open the dip tube closure any fur ther but wait until no more hissing can be heard Check whether a bung wre...

Page 32: ...rom damage 7 Make sure that electrically conductive fill heads are properly grounded with ground wire and terminal 8 Insert the fill head into the dip tube Assembly commissioning 9 Align the code disk using the red or green orientation pins 5 and 6 The orientation pin of the dip tube and the code disk must be on top of each other NOTE The code disk must not be bent or dam aged Never mount the code...

Page 33: ... ensure this e g by using a fill head with limit switch or by using a light barrier 14 Press the anti rotation clip 9 down wards Assembly commissioning The tightening nut can only be moved within the two lugs of the code disk between which the anti rotation clip is located 15 Check again that the head is correctly inserted and tightened WARNING Hazard from chemicals If the head is not completely s...

Page 34: ...e fill heads check that the entire system is ground ed The grounding of the fill head is done via the ground wire with the clamp The ground wire with the termi nal must be free of corrosion Follow the ATEX and OSHA instruc tions and regulations Operation 3 Make sure that the fill head is correctly mounted 4 For fill heads with plug valve ball valve or outlet tap open the manual shut off valve as s...

Page 35: ...that no negative or excess pressure can develop in the container If no pressure range is available mea surable visually check that the flow rate is constant and that the container does not inflate or collapse Check that minimal to no vibrations are transferred to the overall system Carry out a visual inspection of the overall system for leaks or dam ages ...

Page 36: ... line replace particle filter or valves if necessary Ventilation of the container is not sufficient to achieve com plete pressure equalization Reduce the filling flow rate of the operating medium Increase the nominal diameter of the ventilation line Shorten the length of the ventilation line See also Chapter 5 Container contracts when the system is stopped Ventilation line is connected to a suctio...

Page 37: ...d on the fill head dam aged Contact AS Strömungs technik technical custom er service send in the fill head for repair see Section 9 3 Operating medium escapes from fill head outlet liquid chan nel Contaminations deposits in the valve Clean rinse the fill head Valve body or seal damaged Contact AS Strömungs technik technical custom er service send in the fill head for repair see Section 9 3 Pressur...

Page 38: ... sure that there is no positive pressure in the fill line Positive pressure in the fill line would result in the check valve being pushed open and causing liquid to flow out of the fill head and create a spill in the filling area 2 For fill heads with plug valve turn cock ball valve or outlet tap close the manual shut off valve 3 Push the anti rotation clip 1 upwards 4 Slowly unscrew the fill head...

Page 39: ... side 9 Screw the fill head in tight into the docking station 10 Check that the o ring on the dip tube closure is present and undamaged T type W type S type V type 11 Place the dip tube closure on the dip tube opening 12 Close the container by screwing on the dip tube closure 2 hand tight using the bung wrench 3 see Sec tion 3 1 13 Take a torque wrench 4 place it on the bung wrench 3 Tighten the d...

Page 40: ...medium 9 2 Fill head maintenance The following checks must be carried out regularly at least monthly in addition to the checks during assembly Component Testing Fill head Check regularly for discol oration and damage Check valve Regular functionality check O rings on the fill head Regularly check for wear and tear and replace if necessary Electrical con ductivity For CD version check conductivity ...

Page 41: ...ell as the safety of logistic providers 9 4 Fill head disposal WARNING Hazard from chemicals Chemicals can cause irritation and chemical burns Observe residual debris and degas sing of diffused chemicals Observe the safety data sheets SDS of the chemicals used 1 Disassemble the fill head see Section 8 1 2 Clean the disassembled fill head see Section 9 1 3 Dispose of all parts in an environmen tall...

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