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GEA Aseptomag ADV, Operating Instruction

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GEA Aseptomag ADV Operating Instruction Download Page 34

•

daily period of use,

•

switching frequency,

•

type and temperature of the product,

•

type and temperature of the cleaning solution,

•

ambient conditions.

For a detailed maintenance schedule, see Section 10.13, Page 60

Hint!

Prior to any work on the open valve, ensure that it has stopped
operation, see Section 10.5, Page 38.

10.4

List of tools

List of tools (in alphabetical order)

Tools

Figure

Intended Purpose

Material Number
GEA Aseptomag AG

Pressurizing tool
DN 10 - DN 80

Fig.10

Valves
DN 10 - DN 80
Inspection of metal
bellows

0980.50003
S-12-0010

Pressurizing tool
DN 80 - DN 100

Fig.11

Valves
DN 80 - DN 100
Inspection of metal
bellows

0980.50074
S-12-0455

Torque wrench

Fig.12

For divisible internal
assemblies

0980.50020
S-12-0086

Maintenance

List of tools

 

430BAL012841EN_1

34

07.03.2018

Summary of Contents for Aseptomag ADV

Page 1: ...Aseptic Valves GEA Aseptomag leakage valve type ADV Operating instruction Translation from the original language 430BAL012841EN_1...

Page 2: ...achine readable form without the express permission of GEA Tuchenhagen GmbH LEGAL NOTICE Word marks Aseptomag and TEFASEP are registered trademarks of GEA Aseptomag AG and may not be used without the...

Page 3: ...nage 14 2 8 Residual dangers 14 2 9 Danger zones 15 3 Description 17 3 1 Design of the Valve 17 3 2 Valve Identification 18 3 3 Sealing Concepts 20 3 3 1 System separable 20 4 Transport and storage 21...

Page 4: ...ve Seat Seal 46 10 9 1 Removing the Divisible Valve Seat Seal 46 10 9 2 Fitting the Divisible Valve Seat Seal 47 10 9 3 Torques for divisible valve discs 50 10 10 Carrying out the Internal Assembly Le...

Page 5: ...the entire life cycle of the product When the location is changed or the product is sold make sure you also provide the Operating Instructions 1 1 2 Notes on the Illustrations The illustrations in the...

Page 6: ...damage to the component or in the vicinity of the component The arrow identifies a precautionary measure you have to take to avoid the hazard Carry out the following steps Start of a set of instructio...

Page 7: ...ic format PDF Manufacturer GEA Aseptomag AG Industrie Neuhof 28 CH 3422 Kirchberg Authorized person GEA Aseptomag AG Engineering Department Industrie Neuhof 28 CH 3422 Kirchberg Commercial name of the...

Page 8: ...diverted through the side valves For safe operation it is mandatory that the following points are observed in the different process steps Transfer During a media transfer through the main valve both s...

Page 9: ...Hint The manufacturer will not accept any liability for damage resulting from any use of the valve which is not in accordance with the designated use of the valve The risk of such misuse lies entirel...

Page 10: ...operation over the life of the component Be sure to read these Operating Instructions carefully and ensure that the measures described here are observed The operator s duty of care includes planning...

Page 11: ...ent is used improperly the component is operated under impermissible conditions 2 4 1 Principles for safe operation Dangerous situations during operation can be avoided by safety conscious and proacti...

Page 12: ...permitted with the express permission of the manufacturer After completion of all work check that the protective devices are fully functional 2 5 Supplementary Regulations In addition to the instructi...

Page 13: ...the component Personal suitability for the respective task Sufficient professional qualification for the respective task Received instruction about the functionality of the component Received instruct...

Page 14: ...Mechanical equipment Electrical equipment Pneumatic system Authorization with regard to safety engineering standards to carry out the following tasks Setting devices into operation Earthing of device...

Page 15: ...ercise caution and prudence For all work Wear suitable work clothing Never operate the machine if the cover panels are not correctly fitted Never open the cover panels during the operation Never reach...

Page 16: ...3 by supplying the actuator A with compressed air Before starting any service maintenance or repair work disconnect the valve from the power supply and secure it against inadvertently being switched b...

Page 17: ...signation 1 Housing 2 Internal assembly 2a Valve seat A 2b Valve seat B 3 Actuator 4 Clamp safety device 5 Inlet valve side valve 5a Connecting pieces for the inlet valve 6 Outlet valve side valve 6a...

Page 18: ...the actuator 0001 14 Serial number main components The serial number has the same structure as the valve s serial number but it is placed on the relevant main component housing internal assembly actua...

Page 19: ...V 50 1004 Clamp Number of clamp drawing 5 1216 10 Actuator Sticker with valve serial number 6 PA100 50 NC V 50 3000 0977 10 Actuator Designation of actuator Number of actuator drawing Serial number o...

Page 20: ...M form seal seat B Concept hard and soft sealing Divisible valve disc For soft seal materials on seat A and for hard seal materials on seat B Additional elastomer O ring behind the valve seat seal B A...

Page 21: ...used by impact or careless loading and unloading The outside synthetic materials are susceptible to breaking Control tops if fitted must be protected from animal and vegetable fats Only allow qualifie...

Page 22: ...t Surface roughness Ra 0 8 m standard Outer surfaces Metal blank fine turned and or polished Inside areas with the exception of the metal bellows in contact with product can be electropolished passiva...

Page 23: ...s suitable for CIP cleaning Cleaning in Place Recommended cleaning speed in the valve At least 2 m s Sterilisation Sterilisation The valve is suitable for SIP sterilisation Sterilisation in Place Ster...

Page 24: ...of the component may not work effectively during installation Reliably secure sections of the plant which have already been connected against inadvertently being switched on 6 2 Notes on installation...

Page 25: ...housing so that the component housing can be welded into position free from stress and distortion 3 Prepare the welding procedure use the 141 TIG tungsten inert gas welding method with butt weld I jo...

Page 26: ...uator fitted The following tables show guideline values at an air pressure supply of 6 bar per valve size and the corresponding actuator size used as a standard Air requirement for spring to close act...

Page 27: ...n fitted correctly see Section 10 6 Page 38 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 eq...

Page 28: ...ish all connections correctly The safety devices for the valve must be complete fully functional and in perfect condition Check the function before starting any work When the valve is switched on the...

Page 29: ...rvals All guards and hoods must be fitted as intended The installation location of the component must always be properly ventilated Structural changes to the component are not permitted Report any cha...

Page 30: ...suitable for SIP sterilisation Sterilisation in Place For valves equipped with the sealing materials Tefasep and EPDM the following specifications applies Sterilization is possible with Hot water at m...

Page 31: ...ox 80 C 176 F at a concentration of 3 and a contact time of 6 to 8 hours The ultimate temperatures chemicals concentrations and contact time to be used must be determined by the plant operator along w...

Page 32: ...to the maintenance or repair work going on Do not climb on the component Use suitable access aids and working platforms Wear suitable protective clothing Only use suitable and undamaged tools to carr...

Page 33: ...ections Carry out the following steps 1 Check the operating pressure at the pressure reducing and filter station 2 Clean the air filter at regular intervals 3 Check that the air hoses sit firmly in th...

Page 34: ...Section 10 5 Page 38 10 4 List of tools List of tools in alphabetical order Tools Figure Intended Purpose Material Number GEA Aseptomag AG Pressurizing tool DN 10 DN 80 Fig 10 Valves DN 10 DN 80 Insp...

Page 35: ...ing 0980 10009 S 12 0332 Flexible head spanner 95 155mm Pin 6mm Fig 15 PA180 PA210 Remove fit assembly spring 0980 50131 S 12 0568 Oven no microwave min temp 140 C Fig 16 Preheat hard valve seat seals...

Page 36: ...ng piece PA20 210 Fig 20 PA20 210 Hold cylinder 5050 51064 S 12 0005 Assembly tool O ring Fig 21 Remove fit seals 5050 51258 S 12 0162 Slotted screwdriver Size 1 Fig 22 PA80AZ PA180AZ Remove circlip f...

Page 37: ...17 Fig 25 DN 50 65 TV Loosen tighten divisible valve disks 5050 51605 S 12 0097 Spanner adapter SW30 Fig 26 DN 80 125 TV Loosen tighten divisible valve disks 5050 51606 S12 0107 Vice with soft jaws or...

Page 38: ...12 0663 10 5 Prior to disassembly Prerequisite 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 1 Drain al...

Page 39: ...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...

Page 40: ...suitable hex socket key but do not unhook the screw yet Fig 35 Loosening the clamp screw Ensure that you can move the clamp by hand and without much effort before carrying out the next step If this i...

Page 41: ...ket key Open end spanner Carry out the following steps 1 Install the valve in the reverse order of disassembly see Section 10 6 1 Page 38 Tighten side valve and connection piece for the side valve up...

Page 42: ...oved or thrown around rapidly Load and unload the spring in a controlled and slow manner Wear protective gloves for all work Always exercise caution and prudence Prerequisite The side valve actuator i...

Page 43: ...components out of the drive cylinder Remove the housing seal 1 without a tool Do not damage the sealing surfaces on the lower part of the motor and piston 2 2 1 Fig 39 Lift out the actuator component...

Page 44: ...at seal and must be replaced as well Tighten the elbow connector up to the metal stop Actuator PA20 side valve has been fitted 10 8 Disassembling and Assembling the Internal Assembly 10 8 1 Disassembl...

Page 45: ...the sealing surfaces on the housing and internal assembly Fig 42 Removing housing gasket The internal assembly has been disassembled 10 8 2 Assembling the Internal Assembly Carry out the following st...

Page 46: ...10 9 1 Removing the Divisible Valve Seat Seal For information on valve seat seals see Section 3 3 Page 20 Tools required Ratchet with square socket drive Socket wrench bit Vice with smooth jaws or equ...

Page 47: ...ag standard Divisible valve disc EPDM radial seal Seat A TEFASEP seal Seat B TVEP GEA Aseptomag option Divisible valve disc EPDM radial seal Seat A PTFE seal Seal B TVE GEA Aseptomag option Divisible...

Page 48: ...Carry out the following steps 1 The screwed on valve seat seal is fitted in the reverse order of removal see Section 10 9 1 Page 46 Note table Torques for divisible valve discs see Section 10 9 3 Page...

Page 49: ...he heated valve seat seal must fit tightly into the groove After inserting the seal immediately carry out the next work step The valve seat seal is still too rigid and cannot be inserted accurately in...

Page 50: ...fitted 10 9 3 Torques for divisible valve discs Valve size Thread size of valve disc Torque Nm DN25 M10 x 1 25 50 DN40 M10 x 1 25 50 DN50 M12 x 1 25 60 DN65 M12 x 1 25 60 DN80 M12 x 1 25 60 10 10 Carr...

Page 51: ...mbly into the pressurizing tool Fig 50 Hook in the internal assembly 2 Place the clamping arms of the pressurizing tool around the valve cap Fig 51 Attach clamping arms 3 Pull the valve cap against th...

Page 52: ...es will be indicated by air bubbles appearing on the surface Fig 53 Water bath 6 Remove the internal assembly from the pressurizing tool in reverse order This completes the leak test 10 11 Disassembli...

Page 53: ...e actuator in the vice using the clamping piece Fig 55 Clamping the actuator Disassembly has been prepared Removing assembly spring Carry out the following steps 1 Turn the actuator base counter clock...

Page 54: ...mbly spring Assembly spring has been removed PA80 PA255 dismantling the actuator Carry out the following steps 1 Lift off the actuator base from the cylinder Fig 58 Removing actuator base 2 Use the as...

Page 55: ...rooves piston rod and piston disc When changing the seals do not damage the seal groove Use only replacement seals from the seal set indicated in the list of spare parts Grease all seals and the assoc...

Page 56: ...ly spring 3 Turn the actuator base 360 counter clockwise using a flexible head spanner The assembly spring is pulled into the cylinder Fig 62 Screwing in the assembly spring 4 As soon as both open end...

Page 57: ...onnection centrally over the slot in the cylinder Fig 64 Placing the air connection Assembly spring has been fitted Actuator PA80 PA255 has been assembled 10 12 Disassembling and Assembling Actuator P...

Page 58: ...ps 1 Lift off the actuator base from the cylinder Fig 65 Removing actuator base 2 Use the assembly tool for the spring assembly to pull the spring assembly upwards and out of the cylinder Fig 66 Lifti...

Page 59: ...disc out of the actuator base Fig 69 Lifting out the piston disc Actuator has been dismantled into its individual parts Opening the spring assembly is not recommended for safety reasons Actuator PA80A...

Page 60: ...to connect actuator base and cylinder see fitting the assembly spring Page 55 Actuator PA80AZ PA180AZ has been assembled 10 13 Maintenance Well planned maintenance is essential to ensure a long servic...

Page 61: ...Activity to be performed Product contact seals Seal replacement Internal assembly with bellows Check of mechanical parts and visual inspection of condition Leak test of bellows bubble test Actuator Ch...

Page 62: ...tiator for the actuated position For reference regarding the stroke to be expected see the Valve Stroke table Section 10 14 2 Page 62 The feedback unit has been set Hint If a control head is present t...

Page 63: ...fitted correctly or damaged Fit the housing seal correctly or replace it if damaged Medium is leaking from the leakage holes of the internal assembly The metal bellows on the internal assembly is def...

Page 64: ...ing Actuator is filling with water Unfavourable installation position of the vent screw on the actuator Unfavourable effect of the exterior cleaning of the plant If possible position the vent screw so...

Page 65: ...the storage conditions see Chapter 4 Page 21 12 2 Disposal 12 2 1 General notes Dispose of the component in an environmentally safe manner Observe the statutory waste disposal regulations applicable...

Page 66: ...tandard issued by DIN Deutsches Institut f r Normung e V German Institute for Standardisation dm3 Unit of measurement of volume cubic decimetre DN DIN nominal width EN European Standard EPDM Ethylene...

Page 67: ...ter for inch tubes according to DIN 11866 C PA Pneumatic actuator PTFE Polytetrafluoroethylene Material designation short designation according to DIN ISO 1629 AF Width across flats indicates the size...

Page 68: ......

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