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Examples of relevant process parameters are:

•

daily period of use,

•

switching frequency,

•

type and temperature of the product,

•

type and temperature of the cleaning solution,

•

ambient conditions.

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.

10.4

List of tools

List of tools (in alphabetical order)

Tool

Figure

Intended Purpose

Material Number
GEA Aseptomag AG

Pressurizing tool
DN 10 PV

Fig.8

Valves DN 10
Inspection of metal
bellows

0980.50133
S-12-0574

Pressurizing tool
DN 15 PV

Valves DN 15
Inspection of metal
bellows

0980.50068
S-12-0420

Pressure control valve
Ø 6 mm

Fig.9

Inspection of metal
bellows

9999.10090

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

Fig.10

Preheat hard valve
seat seals

0981.50016
S-12-0084

Maintenance

List of tools

430BAL013317EN_1

32

11.03.2019

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Содержание Aseptomag AMV

Страница 1: ...Aseptic Valves GEA Aseptomag stop valve type AMV Operating instruction Translation from the original language 430BAL013317EN_1...

Страница 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...

Страница 3: ...dangers 13 2 9 Danger zones 14 3 Description 15 3 1 Design of the Valve 15 3 2 Valve Identification 16 3 3 Valve settings with manual actuation 18 3 3 1 Valve with hand wheel 18 3 4 Sealing Concepts...

Страница 4: ...1 Removing the Shrunk on Valve Seat Seal 39 10 8 2 Fitting the Shrunk on Valve Seat Seal 39 10 9 Carrying out the Internal assembly leak test bubble test 41 10 10 Disassembling and assembling actuato...

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

Страница 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...

Страница 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...

Страница 8: ...closed 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 not in accord...

Страница 9: ...ning the necessary safety measures and monitoring that these measures are observed The following principles apply Only qualified personnel may work on the component The operating company must authoriz...

Страница 10: ...proactive behaviour of the staff To ensure safe operation of the valve the following principles apply The Operating Instructions must be kept ready to hand at the valve s place of use They must be co...

Страница 11: ...the following also has to be observed pertinent accident prevention regulations generally accepted safety rules national regulations applicable in the country of use work and safety instructions appl...

Страница 12: ...d accident prevention When working with the component a distinction is made between the following user groups User groups Staff Qualifications Operating personnel Adequate instruction and sound knowle...

Страница 13: ...presented by moving or sharp edged parts Danger due to escaping media with properties that are dangerous to health Effectively prevent unauthorised persons from manipulating the valve The operator mus...

Страница 14: ...he clamp 2 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 s...

Страница 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 430BAL013317EN_1 11 03...

Страница 16: ...1 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 actuator by laser mar...

Страница 17: ...sing 3 V 15 1004 Clamp Number of clamp drawing 4 V 10 2043 1424 10 Internal assembly Drawing number of internal assembly Serial number of internal assembly 5 1216 10 Actuator Sticker with valve serial...

Страница 18: ...ve settings with manual actuation 3 3 1 Valve with hand wheel Hand wheel with marker disc H Fig 4 Valve closed Fig 5 Valve open Description Valve settings with manual actuation 430BAL013317EN_1 18 11...

Страница 19: ...For hard sealing materials such as PTFE Fig 6 Shrink on Fit version 3 4 2 System integrated valve seat seal Undivided valve disc PTFE bellows PTFE valve disc adopts sealing function Fig 7 System inte...

Страница 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...

Страница 21: ...hness 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 passivated or ground...

Страница 22: ...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...

Страница 23: ...st inadvertently being switched on 6 2 Notes on installation The valve must be installed so that the housing can drain on its own To prevent damage make sure that the valve is installed in the pipe sy...

Страница 24: ...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...

Страница 25: ...prerequisite for the reliable operation of the valve is that the compressed air hoses are cut exactly square Tools required A hose cutter Carry out the following steps 1 Depressurize the pneumatic co...

Страница 26: ...imum permissible operating voltage Explosive gases or dusts An explosion can result in serious personal injury or death Observe the installation and operating regulations for use in potentially explos...

Страница 27: ...ssioning the following principles apply Only allow properly qualified staff to set the valve into operation Establish all connections correctly The safety devices for the valve must be complete fully...

Страница 28: ...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...

Страница 29: ...t process and product The cleaning effect must be checked regularly by the operating company 9 2 Sterilisation The valve is suitable for SIP sterilisation Sterilisation in Place For valves equipped wi...

Страница 30: ...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...

Страница 31: ...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...

Страница 32: ...values for GEA Flow Components and relates to installations working in two shift operation 10 4 List of tools List of tools in alphabetical order Tool Figure Intended Purpose Material Number GEA Asep...

Страница 33: ...key SW4 PA35 PV H Remove fit PA 0980 50113 S 12 0546 Hex socket key SW5 Valves DN 10 DN 80 Tighten release clamp 0980 50121 S 12 0554 Assembly tool for PA35 Fig 12 PA35 PV assemble disassemble 0980 50...

Страница 34: ...e valve and if necessary clean or rinse and also depressurize them 2 Shut off the control air supply 3 Disconnect the power supply Disassembly has been prepared 10 6 Disassembling and Assembling the V...

Страница 35: ...Fig 16 Opening valve NC 2 Release the clamp with a suitable hex socket key but do not unhook the screw yet Fig 17 Loosening the clamp screw Make sure that the clamp can be moved by hand and without a...

Страница 36: ...6 1 Page 34 Note Torques for clamps table see Section 10 6 3 Page 36 2 Test the function of the valve after assembling Every possible position must be activated and held for 3 5 seconds to assure pro...

Страница 37: ...ellows before working on the valve Always exercise caution and prudence Requirement Internal assembly and actuator have been separated from the housing see Section 10 6 Page 34 Carry out the following...

Страница 38: ...embly in the reverse order of disassembly see Section 10 7 1 Page 36 The internal assembly has been assembled Hint Seals in the product contacting area are generally not lubricated To facilitate assem...

Страница 39: ...his process heats up the seal and possibly also metal parts of the valve When removing the valve seat seal always wear heat resistant protective gloves Carry out the following steps 1 Place the heated...

Страница 40: ...oth thumbs to press the heated valve seat seal into the radial groove at one point Valve seat seals made of hard sealing materials must not be greased Fig 24 Place the valve seat seal into the groove...

Страница 41: ...Internal assembly leak test bubble 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 da...

Страница 42: ...eat Fig 27 Screwing the pressurizing tool 3 Apply max 3 bar of compressed air to the pressurizing tool Air pressures 3 bar can damage the metal bellows 4 Immerse the internal assembly in a water bath...

Страница 43: ...r bath 5 Remove the internal assembly from the pressurizing tool in reverse order This completes the leak test Maintenance Carrying out the Internal assembly leak test bubble test 430BAL013317EN_1 11...

Страница 44: ...around rapidly Load and unload the spring in a controlled and slow manner Wear protective gloves for all work Always exercise caution and prudence Tools required Hex socket key Assembly tool for PA35...

Страница 45: ...take the cover off Pay attention to the alignment of the cover asymmetrical design already when disassembling Fig 31 Removing the retaining ring actuator cover 4 Position actuator in assembly tool ho...

Страница 46: ...oth parts of the retaining ring from the piston rod Fig 33 Stripping the actuator components off 6 Slowly release the pressure on the actuator spring and remove the drive from the assembly tool 7 Care...

Страница 47: ...e piston rod Fig 35 Pulling off actuator components 9 Carefully lift the lifting piston out of the cylinder Pay attention to the alignment of the piston asymmetrical design already when disassembling...

Страница 48: ...IQ GTE 703 Tools required Hex socket key Assembly tool for PA35 Food grade lubricant PARALIQ GTE 703 Carry out the following steps 1 Assemble the actuator in the reverse order of disassembly see Secti...

Страница 49: ...e countersunk screw from the actuator remove the screw and washer Fig 37 Loosening the countersunk screw 2 Position pneumatic actuator in assembly tool holder Fig 38 Positioning the pneumatic actuator...

Страница 50: ...the drive from the assembly tool 5 Carefully pull the actuator cylinder off the actuator components Fig 40 Pulling off the actuator cylinder 6 Carefully pull the actuator components off the piston ro...

Страница 51: ...iston 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 associated contact surfaces...

Страница 52: ...e open valve ensure that it has stopped operation see Section 10 5 Page 34 The following information and values are based on the experience of GEA Flow Components and apply for installations working i...

Страница 53: ...ns Check of mechanical parts and visual inspection of condition Activities to be performed every 5 years Component Activity to be performed Actuator Maintenance including seal replacement 10 13 Checki...

Страница 54: ...Hint If a control top is present the information provided in the corresponding instruction manual must be observed Maintenance Checking the Feedback Unit 430BAL013317EN_1 54 11 03 2019...

Страница 55: ...10 13 2 Valve Stroke Strokes Depending on Size Size DN Size OD Valve stroke mm DN 6 2 DN 8 2 DN 10 OD 2 DN 15 OD 5 Maintenance 430BAL013317EN_1 11 03 2019 55...

Страница 56: ...fitted correctly or damaged Fit the housing seal correctly or replace it if damaged During pressure testing of the internal assembly air escapes from the metal bellows The metal bellows on the intern...

Страница 57: ...the storage conditions see Chapter 4 Page 20 12 2 Disposal 12 2 1 General notes Dispose of the component in an environmentally safe manner Observe the statutory waste disposal regulations applicable...

Страница 58: ...tions d Short name for diameter DIN German standard issued by DIN Deutsches Institut f r Normung e V German Institute for Standardisation dm N Unit of measurement of volume cubic decimetre under stand...

Страница 59: ...ening OD Outside diameter short name for outside diameter for inch tubes according to DIN 11866 C PA Pneumatic actuator PTFE Polytetrafluoroethylene Material designation short designation according to...

Страница 60: ......

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