GEA D-tec D Operating Instruction Download Page 2 | Manualshive

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COPYRIGHT

These Operating Instructions are the English translation of the original operating
instructions in the sense of the EU Machinery Directive. This document is
protected by copyright. All rights reserved. The document may not, in whole or in
part, be copied, reproduced, translated or reduced to an electronic medium of
machine-readable form without the express permission of GEA Tuchenhagen
GmbH.

LEGAL NOTICE

Word marks

The D-tec

®

and TEFASEP

®

designations are trademarks of GEA Aseptomag AG

registered in Switzerland.
The designation T.VIS

®

is a protected trademark of GEA Tuchenhagen GmbH.

430BAL013307EN_8

2

04.08.2022

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Summary of Contents for D-tec D

Page 1: ...Aseptic Valves GEA D tec double chamber valve type D DV Operating instruction Translation from the original language 430BAL013307EN_8...

Page 2: ...The document may not in whole or in part be copied reproduced translated or reduced to an electronic medium of machine readable form without the express permission of GEA Tuchenhagen GmbH LEGAL NOTICE...

Page 3: ...esidual dangers 16 2 9 Danger zones 17 3 Description 19 3 1 Design of the valve 19 4 Transport and storage 21 4 1 Storage conditions 21 4 2 Transport 21 4 2 1 Scope of supply 22 5 Technical data 23 5...

Page 4: ...ert of the main valve 59 10 6 2 Assembling the main valve 67 10 6 3 Assembling the valve insert of the side valve 70 10 6 4 Assembling the side valves 71 10 6 5 Torques for the Clamps and Clamp Connec...

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: ...n serious 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...

Page 7: ...Machinery Directive Applicable harmonized standards in particular DIN EN ISO 12100 Safety of Machines General design principles Risk assessment and risk reduction Other applied standards and technica...

Page 8: ...r During a media transfer through the main valve both side valves must be closed completely Fig 1 Product transfer Cleaning sterile chamber After a media transfer the sterile chamber must be flushed a...

Page 9: ...l installation and assembly Operating the unit within the limits of its designated use also involves adhering to the operating inspection and maintenance instructions 2 1 2 Pressure equipment directiv...

Page 10: ...tions carefully and ensure that the measures described here are observed The operator s duty of care includes planning the necessary safety measures and monitoring that these measures are observed The...

Page 11: ...impermissible operating conditions 2 4 1 Principles for safe operation Dangerous situations during operation can be avoided by safety conscious and proactive behaviour of the staff To ensure safe ope...

Page 12: ...y 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 instruc...

Page 13: ...ts to be allowed to work on the valve Personal qualification for the relevant task Sufficient professional qualification for the relevant task Instructed with regard to the function of the valve Instr...

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

Page 15: ...Signs on the valve Sign Meaning Fig 5 General hazard warning Fig 6 Warning Crushing Fig 7 Explosive atmosphere hazard warning Safety Safety equipment 430BAL013307EN_8 04 08 2022 15...

Page 16: ...life caused by compression spring in the actuator Do not open the actuator but return it to GEA Tuchenhagen for proper disposal Risk of injury Danger presented by moving or sharp edged parts The oper...

Page 17: ...eased spring pretension will suddenly lift the actuator Therefore release the spring tension before detaching the clamp connections 43 44 46 by supplying the actuator A with compressed air Before star...

Page 18: ...The housing sockets have very sharp edges When transporting and assembling the valve be sure to wear suitable protective gloves Safety 430BAL013307EN_8 18 04 08 2022...

Page 19: ...9 Design of the valve Key No Designation A Actuator B T VIS control top C1 Inlet valve C2 Outlet valve L Lift actuator P Air connection 1 Stem diaphragm 2 Stem diaphragm 5 O ring Description Design of...

Page 20: ...3 Stem 14 Bush 15 Valve disk 16 Double disk 24 Electrical connection 43 Clamp connection safety device 44 Clamp connection safety device 46 Clamp connection safety device 73 Leakage housing 401 Valve...

Page 21: ...that any ice crystals formed by condensation water can melt 4 2 Transport Fig 10 For transport the following principles apply When transporting the valve be sure to unscrew the control top and the swi...

Page 22: ...ircumstances should anyone stand under a suspended load Take care when transporting the valve Do not grip sensitive parts of the unit to lift or push the unit or to support yourself Avoid putting the...

Page 23: ...5 2 Technical data Refer to the following tables for the key technical data of the valve Technical data Valve Designation Description Size DN 40 to DN 100 1 5 to 4 OD Material of product contact part...

Page 24: ...sealing materials depends on the type and temperature of the medium conveyed The exposure time can adversely affect the service life of the seals The sealing materials comply with the regulations of...

Page 25: ...ns Seal resistance TEFASEP gold Medium Temperature Sealing material general operation temperature TEFASEP gold Alkalis up to 3 up to 80 C 176 F Alkalis up to 5 up to 40 C 104 F Alkalis up to 5 up to 8...

Page 26: ...es in Inch OD Inch OD Outer diameter Wall thickness Inner diameter Outer diameter according to BS 4825 0 5 12 7 1 65 9 4 x 0 75 19 05 1 65 15 75 x 1 25 4 1 65 22 1 x 1 5 38 1 1 65 34 8 x 2 50 8 1 65 4...

Page 27: ...embly pin FFT 221 105 94 Assembly device D DV DN50 229 109 97 Assembly device D DV DN80 229 109 98 Assembly device D DV DN100 229 109 99 Assembling device ECO lantern 229 000071 Mounting base face spa...

Page 28: ...5 7 Weights Weights Size Weight kg DN 40 32 5 DN 50 33 0 DN 65 40 2 DN 80 40 8 DN 100 45 6 OD 1 5 32 4 OD 2 32 9 OD 2 5 39 8 OD 3 40 2 OD 4 45 6 Technical data Weights 430BAL013307EN_8 28 04 08 2022...

Page 29: ...n Reliably secure sections of the plant which have already been connected against inadvertently being switched on 6 2 Notes on installation The fitting position of the valve is upright Care must be ta...

Page 30: ...sion before detaching the clamp connections by pressurising the actuator with compressed air at max 8 bar Notice Welding distortions An open housing can warp during welding To avoid welding distortion...

Page 31: ...210 1 89 Main valve E_AA 85 0 13 Side valve Air requirement for lift stroke Air requirement dm3 n Stroke Actuator type Actuator diameter mm Valve disk Double disk CL 135 0 3 0 14 DL 170 0 39 0 19 Air...

Page 32: ...actuator P Central air supply Y2 Lift valve disk Y3 Lift double seat disk 61 Stroke side valve 140 Actuator E_AA Hint For an optimal fit at the air connection it is necessary to cut the pneumatic hos...

Page 33: ...ct the valve end position main stroke actuated II Proximity switch serves to detect the valve rest position main stroke not actuated III Proximity switch serves to detect the double disk rest position...

Page 34: ...serious personal injury or death Observe the installation and operating regulations for use in potentially explosive areas Carry out the following steps 1 Connect in accordance with the connection di...

Page 35: ...nut 3 and unscrew the nuts 4 if required 3 Position the centre axis of the initiator 1 1 over the switching edge 6 4 Set distance a between the initiator 1 1 and the head of the switch bar 5 to 0 5 to...

Page 36: ...3 and unscrew the nuts 4 if required 3 Position the centre axis of the initiator 2 1 over the switching edge 6 4 Set distance a between the initiator 2 1 and the head of the switch bar 5 to 0 5 to 1 5...

Page 37: ...es on the component must be completely installed in working order and function properly Check the function before starting any work When switching on the component the danger zones must be clear Remov...

Page 38: ...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 39: ...Cleaning Process Examples Typical Cleaning Parameters in Dairy Operations Example of a two phase cleaning process Sodium hydroxide solution and sodium hydroxide based combination products in concentra...

Page 40: ...be brought to the closed position for a brief period min 5 seconds immediately after CIP or SIP cleaning During commissioning regularly check all sealing points for leaks Exchange defective seals and...

Page 41: ...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 42: ...ion 10 2 1 Leakage outlet Fig 18 Leakage outlet Carry out the following steps 1 Check the leakage opening regularly to determine if they are free of contamination 2 Check the leakage cavity for soilin...

Page 43: ...stem diaphragms and seals in your spare parts stock In practice the actual maintenance intervals can only be determined by the user since they depend on the operating conditions Examples of relevant...

Page 44: ...back Function check Function check Pneumatic connections Check of mechanical parts and visual inspection of condition leak test Check of mechanical parts and visual inspection of condition leak test E...

Page 45: ...Electrical connections Check of mechanical parts and visual inspection of condition Check of mechanical parts and visual inspection of condition 10 4 Prior to disassembly Requirement Make sure that d...

Page 46: ...Caution The permanent magnet on the switch bar is fragile Damage to the permanent magnet Protect the permanent magnet against impact stress Tools required Hex socket key Carry out the following steps...

Page 47: ...4 Fig 20 Remove the switch bar Unscrew the switch bar 3 from the piston stem of the actuator Done Maintenance Disassembling the valve 430BAL013307EN_8 04 08 2022 47...

Page 48: ...ed spring pretension will suddenly lift the actuator Therefore release the spring tension before detaching the clamp connections by pressurising the actuator with compressed air at max 8 bar Tools req...

Page 49: ...he valve insert from the housing Protect the valve parts against impact stress Take note of the weight of the valve parts 5 Interrupt the compressed air supply to the connection 0 The valve insert low...

Page 50: ...sing an incorrect spanner surface Screw the inner part out of the actuator only using the wrench flat on the valve disc Caution Risk of injury due to moving valve parts Do not touch the lantern 9 Tool...

Page 51: ...disc 15 with an open ended wrench with the wrench flat surface 15 1 Notice Clamping the diaphragm Loosen the internal part only on the surface flats 15 1 of the valve disc 15 and unscrew from the actu...

Page 52: ...ernatively clamp the double disk 16 on the spanner flats 16 1 in the vice with protective jaws W Fig 25 2 Loosen the threaded pin 23 from the bush 14 with the hex socket screw and create a bit of dist...

Page 53: ...the vice with protective jaws Fig 27 9 Loosen the threaded pin 23 from the ring 10 with the hex socket screw and create a bit of distance from the valve disc 15 by unscrewing 10 With an open ended wre...

Page 54: ...valve Danger of injury when loosening the clamp connection 46 on the actuator or on the housing as the released spring pretension will suddenly lift the actuator Therefore release the spring tension...

Page 55: ...now accessible 2 Pressurise the actuator at the connection 0 with compressed air max 8 bar 3 Loosen the clamp connection 46 between actuator A and lift actuator L 4 Interrupt the compressed air suppl...

Page 56: ...s L9 L12 L18 L19 L20 are now accessible Done 10 5 3 Disassembling the side valve Fig 30 Spring closing valve NC Tools required Open ended wrench Warning Spring tension in the valve Danger of injury wh...

Page 57: ...2 Unscrew and remove the clamp connection 43 3 Completely withdraw the valve insert from the housing Done 10 5 4 Disassembling the valve insert of the side valve Fig 31 Spring closing valve NC Carry o...

Page 58: ...anner flats 15 1 and unscrew it from the piston rod 140 1 3 Interrupt the compressed air supply to the connection 61 The valve disk 15 is lowered 4 Firmly hold the actuator 140 with a strap wrench and...

Page 59: ...ndrel Allen key sickle spanner Carry out the following steps 1 Fit lift actuator with seals L11 L18 L10 L19 L20 and fasten to lantern 9 with hinged ring 46 Observe table Torques of half rings and clam...

Page 60: ...7 Screw the driver L5 into the piston stem of the actuator A with a hook wrench and lock the nut S against the piston stem with an open ended wrench 8 Pressurise the actuator A at the connection 0 wi...

Page 61: ...and on the stem 13 up to the metal stop and make a coloured mark M 2 Unscrew the bush 14 and double disk 16 from the stem 13 3 Screw the ring 10 and valve disc 15 together by hand and make a coloured...

Page 62: ...em diaphragm is optimally pressed Alternatively tighten the ring with a torque of 35 Nm 9 Screw threaded pin 23 into ring 10 with hex socket wrench and tighten Fig 35 10 Lightly grease the threads of...

Page 63: ...Fig 36 12 Remove the valve disc 15 from the vice Notice Sensitive valve parts Avoid using too much radial tension Fig 37 Maintenance Assembling the valve 430BAL013307EN_8 04 08 2022 63...

Page 64: ...vely tighten the stem with a torque of 120 Nm 15 Attach the stem diaphragm 1 onto the stem 13 Install the stem diaphragm 1 in the correct position and seat 16 Screw the bush 14 onto the stem 13 and sc...

Page 65: ...nal part onto the valve disc in the actuator only using the spanner flats 3 Screw the valve disc 15 to the driver using an open ended wrench over the spanner flats 15 1 until the metal stop is reached...

Page 66: ...Fig 39 Maintenance Assembling the valve 430BAL013307EN_8 66 04 08 2022...

Page 67: ...he control top Spring closing valve NC Warning Spring tension in the valve A risk of injury exists due to incorrectly installed clamp connections 43 when the valve is vented as the spring tension that...

Page 68: ...nnection P with compressed air max 8 bar The valve insert is raised 4 Check that the stem diaphragm 1 is in the correct position see Fig 5 Guide the valve insert completely into the housing 401 Protec...

Page 69: ...Fig 41 Maintenance Assembling the valve 430BAL013307EN_8 04 08 2022 69...

Page 70: ...o the piston stem 140 1 with an open ended wrench on the spanner flats 15 1 Done Spring opening valve NO Carry out the following steps 1 Firmly hold the actuator 140 with a strap wrench and unscrew th...

Page 71: ...ssembled correctly before venting Notice Sensitive valve parts Damage to valve parts Protect the valve parts against impact stress Tools required Open ended wrench Carry out the following steps 1 Pres...

Page 72: ...clamp connections 43 and install Ensure that the clamp connections 43 are firmly installed Observe table Torques for half rings and clamp connections seeSection 10 6 5 Page 72 3 Check function after a...

Page 73: ...e c in accordance with the table Main valve stroke 3 Check the function of the initiators adjust if necessary 4 Interrupt the compressed air supply The stroke is set Strokes depending on size Valve st...

Page 74: ...et Carry out the following steps 1 Pressurise actuator at connection Y2 with compressed air max 8 bar Valve disk is raised 2 Measuring the lifting stroke of valve disk 3 Interrupt the compressed air s...

Page 75: ...Viewing the valve from above 11 Tighten threaded pin L7 with a hex socket wrench Warning Risk of injury due to moving valve parts Do not touch between the actuator A and lantern L 12 Pressurise actua...

Page 76: ...e precision areas Damage to these parts can result in malfunction Handle the valve with care Notice Damage to the valve Damage to these parts can result in malfunction Observe the safety information s...

Page 77: ...on must be made up in a ceramic plastic or stainless steel container Tools required V ring insertion tool Caution Danger of injury The scriber can slip off when the V ring is removed Grip the valve di...

Page 78: ...Changing the stem diaphragm See Section 10 5 2 Page 50 for details on changing the stem diaphragm See Section 10 6 1 Page 59 for details on assembly of the stem diaphragm 10 7 5 Exchanging the O ring...

Page 79: ...at seal at one point using the O ring cutter Pay attention not to damage the edge of the radial groove Fig 49 3 Take out the cut valve seat seal 4 Warm a new O ring TEFASEP gold valve seat seal in the...

Page 80: ...alve seat seal will adjust itself optimally to the sealing surfaces and will ensure perfect sealing up to the maximum closing pressure or vacuum Fig 52 The valve seat seal is still too rigid and canno...

Page 81: ...hagen recommends Rivolta F L G MD 2 This lubricant is food grade beer foam resistant and has NSF H1 USDA H1 registration It does not affect the taste or the consistency of the products and is compatib...

Page 82: ...system Check actuation external controller and routing of electrical lines Solenoid valve defective Replace the solenoid valve Valve does not close Dirt foreign material between valve seat and valve d...

Page 83: ...at the place of installation The component consists of the following materials Metals Synthetic materials Electronic parts Lubricants containing oil and grease Separate the different materials and di...

Page 84: ...13 Parts list D tec double chamber valve type D DV Fig 53 Hard seal Fig 54 Soft seal Parts list D tec double chamber valve type D DV 430BAL013307EN_8 84 04 08 2022...

Page 85: ...Fig 55 Housing Parts list D tec double chamber valve type D DV 430BAL013307EN_8 04 08 2022 85...

Page 86: ...01 221 755 04 221 755 11 15 1 Valve disc D DV TS O ring 1 4404 221 764 05 221 764 07 221 764 01 221 764 04 221 764 11 16 Valve disc D DV V ring 1 4404 221 759 17 221 759 17 221 759 05 221 759 05 221 7...

Page 87: ...1 758 05 221 758 05 11 1 Retaining ring 1 4122 917 156 917 156 917 156 917 156 917 156 12 Clutch D DV complete 1 4305 221 006865 221 006865 221 006865 221 006865 221 006865 13 Stem D DV 1 4404 221 759...

Page 88: ...930 026 930 026 930 026 L Lift actuator D DV 221 608 31 221 608 31 221 608 30 221 608 30 221 608 28 B Control top See parts list for control top T VIS C Valve insert D DV SV NC NO See spare parts lis...

Page 89: ...932 034 932 035 932 035 932 039 7 1 1 O ring 61 8x6 61 8 6 69 6x6 69 6x6 94 8x6 Tefasep Gold 930 108 930 108 930 102 930 102 930 103 8 1 V ring 35 5 44 6 68 6 68 6 96 6 EPDM 932 046 932 019 932 023 9...

Page 90: ...14 Parts list D tec valve insert D DV SV NC NO Fig 56 soft seal Fig 57 Parts list D tec valve insert D DV SV NC NO 430BAL013307EN_8 90 04 08 2022...

Page 91: ...Fig 58 hard seal Parts list D tec valve insert D DV SV NC NO 430BAL013307EN_8 04 08 2022 91...

Page 92: ...ing NBR 930 026 930 026 35 1 Cover ECO E 221 643 23 221 643 23 35 2 Screw plug ECO E 221 643 24 221 643 24 43 Clamp connection KL 1 4404 221 507 02 221 507 02 61 Angle screw in plug connection Brass n...

Page 93: ...and 7 1 2 Pos 9 1 and 9 2 contained in Pos 9 DN 25 D DV SV PT Item Designation Material PT100 with measuring transducer PT100 without measuring transducer D Temperature sensor D DV complete 221 00685...

Page 94: ...asep Gold 930 106 29 1 O ring 20x3 NBR 930 026 98 1 O ring 34x3 NBR 930 046 Grease RIVOLTA F L G MD 2 100g tube not included in the sealing set 413 136 Part of every seal kit Do not grease items 7 7 1...

Page 95: ...15 Parts list lift actuator _LB DV Fig 59 Parts list lift actuator _LB DV 430BAL013307EN_8 04 08 2022 95...

Page 96: ...connection 6 1 8 Brass nickel plated 933 475 933 475 933 475 933 475 933 475 17 Guide ring TURCITE T51 935 015 935 015 935 015 935 015 935 015 18 O ring NBR 930 093 930 093 930 093 930 093 930 093 19...

Page 97: ...16 Elbow screwed plug in connection 6 1 8 Brass nickel plated 933 475 933 475 933 475 933 475 933 475 17 Guide ring TURCITE T51 935 015 935 015 935 015 935 015 935 015 18 O ring NBR 930 093 930 093 9...

Page 98: ...16 Dimension sheet double chamber valve type D DV Fig 60 Dimension sheet double chamber valve type D DV 430BAL013307EN_8 98 04 08 2022...

Page 99: ...Fig 61 Dimension sheet double chamber valve type D DV 430BAL013307EN_8 04 08 2022 99...

Page 100: ...15 16 15 16 15 16 15 16 15 16 S2 Stroke side valve steam inlet Stroke SV15 5 6 5 6 5 6 5 6 5 6 X2 Extension dimension from steam inlet housing 303 303 307 307 328 X3 Extension dimension from steam ou...

Page 101: ...SV25 15 16 15 16 15 16 15 16 15 16 Stroke SV DE Stroke side valve steam inlet Stroke SV15 5 6 5 6 5 6 5 6 5 6 X2 Extension dimension from steam inlet housing 303 303 307 307 328 X3 Extension dimension...

Page 102: ...e V German Institute for Standardization EN European Standard EPDM Material designation Short designation according to DIN ISO 1629 Ethylene Propylene Diene Rubber F Unit of measurement of temperatur...

Page 103: ...icitly specified otherwise PTFE Polytetrafluoroethylene SET UP Self learning installation During commissioning and maintenance the SET UP procedure carries out all the necessary settings for the gener...

Page 104: ...Abbreviation Explanation Inch OD Tube measurement according to British Standard BS outside diameter Inch IPS American pipe measurement iron pipe size Appendix 430BAL013307EN_8 104 04 08 2022...

Page 105: ...Appendix 430BAL013307EN_8 04 08 2022 105...

Page 106: ......

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