GEA Aseptomag GD Operating Instruction Download Page 35

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List of tools (in alphabetical order)

Tools

Figure

Intended Purpose

Material Number
GEA Aseptomag AG

Pressure control valve
Ø 6 mm

Fig.12

Inspection of metal
bellows

9999.10090

Flexible head spanner
Ø60-90mm,
Pin Ø 5.5mm

Fig.13

PA80-135
Remove/fit assembly
spring

0980.10009
S-12-0332

Flexible head spanner
Ø95-155mm,
Pin Ø 6mm

Fig.14

PA180-PA210
Remove/fit assembly
spring

0980.50131
S-12-0568

Oven
(no microwave,
min. temp. 140 °C)

Fig.15

Preheat hard valve
seat seals

0981.50016
S-12-0084

Hex socket key
SW5

Fig.16

Valves
DN 10 - DN 80
Tighten/release clamp

0980.50121
S-12-0554

Hex socket key
SW6

Valves
DN 100 - DN 150
Tighten/release clamp

0980.50122
S-12-0555

Ratchet, square socket
drive ½"

Fig.17

Release divisible valve
discs

0980.50124
S-12-0557

Maintenance

List of tools

430BAL012727EN_1

03.01.2018

Summary of Contents for Aseptomag GD

Page 1: ...Aseptic Valves GEA Aseptomag counter pressure valve type GD Operating instruction Translation from the original language 430BAL012727EN_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: ...al dangers 13 2 9 Danger zones 13 3 Description 15 3 1 Design of the Valve 15 3 2 Valve Identification 16 3 3 Sealing Concepts 18 3 3 1 System without valve seat gasket 18 3 3 2 Shrink on Fit Version...

Page 4: ...the Divisible System Valve Seat Seal 44 10 9 1 Removing the Divisible Valve Seat Seal 45 10 9 2 Fitting the Divisible Valve Seat Seal 46 10 9 3 Torques for Divisible Valve discs 47 10 10 Carrying out...

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: ...g CIP SIP processes The valve is monitored controlled and operated by the customer s system Hint The manufacturer will not accept any liability for damage resulting from any use of the valve which is...

Page 9: ...measures are observed The following principles apply Only allow qualified staff to work on the valve The operator must authorize the staff to carry out the relevant tasks Working areas and the entire...

Page 10: ...must be kept ready to hand at the valve s place of use They must be complete and in clearly legible form Only use the valve for its intended use The valve must be functional and in good working order...

Page 11: ...tructions applicable in the facility installation and operating regulations for use in potentially explosive areas 2 6 Qualification of Staff This section contains information about the qualifications...

Page 12: ...inguished 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 emer...

Page 13: ...of injury Danger presented by moving or sharp edged parts The operator must exercise caution and prudence For all work Wear suitable work clothing Never operate the machine if the cover panels are no...

Page 14: ...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 ba...

Page 15: ...tion 3 1 Design of the Valve Fig 2 Main components on the valve Key No Designation 1 Housing 2 Internal assembly 3 Actuator 4 Clamp safety device Description Design of the Valve 430BAL012727EN_1 03 01...

Page 16: ...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 17: ...ial number of valve housing 3 V 50 1004 Clamp Number of clamp drawing 4 V 50 2664 1424 10 Internal assembly Drawing number of internal assembly Serial number of internal assembly 5 1216 10 Actuator St...

Page 18: ...nk on Fit Version 3 3 3 System divisible Valve seat seals TVT Divisible valve disc valve seat seal TEFASEP TVE Divisible valve disc valve seat seal EPDM form seal TVPV Divisible valve disc valve seat...

Page 19: ...Concept for Elastomer sealing materials Divisible valve disc For elastomer sealing materials such as EPDM TVE Form gasket with moulded on retention flag Fig 7 Divisible version for elastomer sealing m...

Page 20: ...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 21: ...ther materials in accordance with the valve specification Surface finish Inside areas in contact with product Surface roughness Ra 0 8 m standard Outer surfaces Metal blank fine turned and or polished...

Page 22: ...termination of closing pressure The closing pressure effective at the valve seat during operation can be calculated approximately It is mandatory however that the fine adjustment at the valve must be...

Page 23: ...1 Calculate Supplied air pressure x rear component of the regulation ratio closing pressure Example 6 bar x 0 841 5 05 bar Closing pressure is determined Technical data 430BAL012727EN_1 03 01 2018 23...

Page 24: ...bly the valve safety devices might not be working effectively Reliably secure sections of the plant which have already been connected against inadvertently being switched on 6 2 Notes on installation...

Page 25: ...housing at several points distributed around the circumference under forming gas ensure forming gas supply Adjoining welding ends must not be separated by a gap Otherwise the corrosion resistance of...

Page 26: ...25 OD 1 PA30 LL 0 1 DN 40 OD 1 1 2 PA40 LL 0 3 DN 50 OD 2 PA50 LL 0 5 DN 65 OD 2 1 2 PA80 LL 2 9 DN 80 OD 3 PA80 LL 2 9 DN 100 OD 4 PA100 LL 7 0 6 4 2 Establishing the Compressed Air Supply A prerequ...

Page 27: ...ectly 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 equipment Prior...

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: ...ls All guards and hoods must be fitted as intended The place of installation of the valve must be adequately ventilated at all times Structural alterations of the valve are not permitted Immediately r...

Page 30: ...g data applies for valves equipped with Tefasep and silicone sealing materials Sterilisation is possible using Hot water at max 160 C 320 F for 20 to 30 min Steam at max 160 C 320 F for 20 to 30 min C...

Page 31: ...The ultimate temperatures chemicals concentrations and contact time to be used must be determined by the plant operator along with its chemical supplier Cleaning 430BAL012727EN_1 03 01 2018 31...

Page 32: ...oing on Do not climb on the valve Use suitable access aids and working platforms Wear suitable protective clothing Only use suitable and undamaged tools to carry out maintenance work When replacing pa...

Page 33: ...ure reducing and filter station 2 Clean the air filter at regular intervals 3 Check that the air hoses sit firmly in the air connections 4 Check the lines for kinks and leaks The pneumatic connection...

Page 34: ...ols List of tools in alphabetical order Tools Figure Intended Purpose Material Number GEA Aseptomag AG Pressurizing tool DN 10 DN 80 Fig 9 Valves DN 10 DN 80 Inspection of metal bellows 0980 50003 S 1...

Page 35: ...nner 95 155mm Pin 6mm Fig 14 PA180 PA210 Remove fit assembly spring 0980 50131 S 12 0568 Oven no microwave min temp 140 C Fig 15 Preheat hard valve seat seals 0981 50016 S 12 0084 Hex socket key SW5 F...

Page 36: ...981 50008 S 12 0209 Assembly tool Clamping device PA30 210 Fig 19 PA30 210 Hold cylinder 5050 51064 S 12 0005 Assembly tool O ring Fig 20 Remove fit seals 5050 51258 S 12 0162 O ring cutter heated Fig...

Page 37: ...meter 40 100 mm angled tip 90 Fig 25 PA30 PA60 Remove fit PA 0980 50108 S 12 0541 Shut off valve 6 mm Fig 26 Inspection of metal bellows 9999 10091 Socket wrench bit a f 13 square drive Fig 27 Valves...

Page 38: ...ing 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 befo...

Page 39: ...e clamp can easily be moved afterwards 3 Carefully take off the clamp from the valve 4 Carefully lift the actuator with the internal assembly out of the housing Do not damage the sealing surface on th...

Page 40: ...ing the Internal Assembly 10 7 1 Disassembling 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...

Page 41: ...the sealing surfaces on the housing and internal assembly Fig 33 Removing housing gasket The internal assembly has been disassembled 10 7 2 Assembling the Internal Assembly Carry out the following st...

Page 42: ...o 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 an...

Page 43: ...e 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 The heating time required depends on the t...

Page 44: ...30 Afterwards it will ensure perfect sealing up to the maximum closing pressure or vacuum Fig 37 Mounting the valve seat seal The valve seat seal is still too rigid and cannot be mounted Heat the valv...

Page 45: ...wing steps 1 Clamp the nut of the valve disc into the vice at the spanner flats Fig 38 Clamping internal assembly 2 Use the ratchet with the wrench socket or a hex key to unscrew the spindle from the...

Page 46: ...1 The screwed on valve seat seal is fitted in the reverse order of removal see Section 10 9 1 Page 45 Prepare thermoplastic valve seat seals TEFASEP PTFE in the heater see Section 10 8 2 Page 43 Valve...

Page 47: ...aks as part of the annual maintenance using the pressurizing tool Tools required Pressurizing tool Compressed air supply Shut off valve 6 mm Pressure regulating valve 6 mm Water bath Carry out the fol...

Page 48: ...air to the pressurizing tool Air pressures 3 bar can damage the metal bellows 5 Immerse the internal assembly in a water bath for approx 30 seconds While the internal assembly is immersed check the in...

Page 49: ...ols required Seeger circlip pliers Assembly tool for clamping device Assembly tool for spring assembly Assembly tool for O ring Vice Preparing disassembly Carry out the following steps 1 Bring the act...

Page 50: ...ing device Fig 46 Clamp the clamping piece in the vice Disassembly has been prepared PA30LL PA60LL dismantling the actuator Carry out the following steps 1 Remove the circlip with Seeger circlip plier...

Page 51: ...l the drive components upwards and out of the cylinder Fig 48 Pull the components out of the cylinder 3 Carefully slip off the securing elements sleeve and piston disc from the piston rod Maintenance...

Page 52: ...eals 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 associated contact surfaces with the food grade lubricant...

Page 53: ...e actuator base until the assembly spring begins to move out of the slot in the cylinder Fig 50 Releasing assembly spring 2 Turn the actuator base clockwise using the flexible head spanner Rotate the...

Page 54: ...linder Fig 53 Pull the components out of the cylinder 3 Carefully slip off the securing elements sleeve and piston disc from the piston rod Pay attention to the alignment of the piston disc asymmetric...

Page 55: ...list of spare parts Grease all seals and the associated contact surfaces with the food grade lubricant PARALIQ GTE 703 PA80LL PA180LL assembling the actuator Carry out the following steps 1 Assemble t...

Page 56: ...g 4 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 Car...

Page 57: ...ce intervals Only allow qualified maintenance staff to carry out maintenance work Hint Prior to any work on the open valve ensure that it has stopped operation see Section 10 5 Page 37 The following i...

Page 58: ...check Valve Check of mechanical parts and visual inspection of condition Function check Feedback Check of mechanical parts and visual inspection of condition Function check Pneumatic connections Check...

Page 59: ...14 2 Page 59 The feedback unit has been set Hint If a control head is installed the specifications of the respective operating instructions must be observed 10 14 2 Valve Stroke Strokes Depending on...

Page 60: ...ng seal is not 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 a...

Page 61: ...es downwards When the valve is installed in the vertical position ensure that the vent screw faces away from the cleaning direction if possible The TEFASEP valve seat seal is not tight after commissio...

Page 62: ...the storage conditions see Section 4 1 Page 20 12 2 Disposal 12 2 1 General notes Dispose of the valve in an environmentally friendly manner Observe the statutory waste disposal regulations applicable...

Page 63: ...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 64: ...r short name for outside diameter for inch tubes according to DIN 11866 C PA Pneumatic actuator PTFE Polytetrafluoroethylene Material designation short designation according to DIN ISO 1629 AF Width a...

Page 65: ...Appendix 430BAL012727EN_1 03 01 2018 65...

Page 66: ......

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