GEA Aseptomag GD Manuel utilisateur

Aseptic Valves

GEA Aseptomag® counter pressure valve type GD

Operating instruction (Translation from the original language)

430BAL012727EN_1

These Operating Instructions are the English translation of the original operating

instructions in the sense of the EU Machinery Directive. This document is

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

Aseptomag® and TEFASEP® are registered trademarks of GEA Aseptomag AG

and may not be used without the permission of GEA Aseptomag AG.

T.VIS® is a protected trademark of GEA Tuchenhagen GmbH.

We kindly request that you answer a few short questions about these Operating

Instructions. Use the following QR code or link to access the questionnaire:

https://www.ntgt.de/ra/s.aspx?s=367112X57707125X58087

430BAL012727EN_1

2 03.01.2018

TABLE OF CONTENTS

1 General Information 5

1.1 Information on the Document 5

1.1.1 Binding Character of These Operating Instructions 5

1.1.2 Notes on the Illustrations 5

1.1.3 Symbols and Highlighting 5

1.2 Manufacturer address 6

1.3 Customer service 6

1.4 EC Declaration of Incorporation 7

2 Safety 8

2.1 Intended use 8

2.1.1 Requirements for operation 8

2.1.2 Pressure equipment directive 8

2.1.3 ATEX directive 8

2.1.4 Improper operating conditions 8

2.2 Operator’s Duty of Care 9

2.3 Subsequent changes 10

2.4 General safety instructions and dangers 10

2.4.1 Principles for safe operation 10

2.4.2 Environmental Protection 10

2.4.3 Electrical Equipment 11

2.5 Supplementary Regulations 11

2.6 Qualification of Staff 11

2.7 Safety equipment 12

2.7.1 Signage 12

2.8 Residual 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 18

3.3.3 System “divisible” 18

4 Transport and storage 20

4.1 Storage conditions 20

4.2 Transport 20

4.2.1 Scope of supply 20

5 Technical data 21

5.1 Technical data 21

5.2 Determination of closing pressure 22

6 Assembly and installation 24

6.1 Safety instructions 24

6.2 Notes on installation 24

6.3 Welding In a Valve with Pipe Connection 24

6.3.1 Welding In and Installing a Valve 24

6.3.2 Welding post-treatment 25

6.4 Pneumatic connections 25

6.4.1 Air Requirement 25

6.4.2 Establishing the Compressed Air Supply 26

6.5 Electrical connections 27

7 Start-up 28

7.1 Safety instructions 28

7.2 Notes on commissioning 28

8 Operation and control 29

8.1 Safety instructions 29

9 Cleaning 30

9.1 Cleaning 30

9.2 Sterilisation 30

9.3 Passivation 30

430BAL012727EN_1

03.01.2018 3

10 Maintenance 32

10.1 Safety instructions 32

10.2 Inspections 33

10.2.1 Bellows 33

10.2.2 Pneumatic connections 33

10.2.3 Electrical connections 33

10.3 Maintenance intervals 33

10.4 List of tools 34

10.5 Prior to disassembly 37

10.6 Disassembling and Assembling the Valve 38

10.6.1 Disassembling the Valve 38

10.6.2 Assembling the Valve 39

10.6.3 Torques for clamp 40

10.7 Disassembling and Assembling the Internal Assembly 40

10.7.1 Disassembling the Internal Assembly 40

10.7.2 Assembling the Internal Assembly 41

10.8 Removing and Installing the "Shrunk-on” Valve Seat Seal 42

10.8.1 Removing the Shrunk-on Valve Seat Seal 42

10.8.2 Fitting the Shrunk-on Valve Seat Seal 43

10.9 Removing and Installing 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 the “Internal Assembly” Leak Test (Bubble Test) 47

10.11 Disassembling and Assembling Actuator PA30LL - PA60LL 49

10.11.1 Disassembling Actuator PA30LL - PA60LL 49

10.11.2 Assembling Actuator PA30LL - PA60LL 52

10.12 Disassembling and Assembling Actuator PA80LL - PA180LL 52

10.12.1 Disassembling Actuator PA80LL - PA180LL 52

10.12.2 Assembling Actuator PA80LL - PA180LL 55

10.13 Maintenance 57

10.14 Checking the Feedback Unit 58

10.14.1 Setting the Feedback Unit 58

10.14.2 Valve Stroke 59

11 Alarms 60

11.1 Malfunctions and remedies 60

12 Decommissioning 62

12.1 Safety instructions 62

12.2 Disposal 62

12.2.1 General notes 62

13 Appendix 63

13.1 Lists 63

13.1.1 Abbreviations and terms 63

430BAL012727EN_1

4 03.01.2018

1 General Information

1.1 Information on the Document

The present Operating Instructions are part of the user information for the

product. The Operating Instructions contain all the information you need to

transport, install, commission, operate and carry out maintenance for the product.

1.1.1 Binding Character of These Operating Instructions

These Operating Instructions contain the manufacturer's instructions to the

operator of the product and to all persons who work on or use the product

regarding the procedures to follow.

Carefully read these Operating Instructions before starting any work on or using

the product. Your personal safety and the safety of the product can only be

ensured if you act as described in the Operating Instructions.

Store the Operating Instructions in such a way that they are accessible to the

operator and the operating staff during 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 these Operating Instructions show the product in a simplified

form. The actual design of the product can differ from the illustration. For detailed

views and dimensions of the product please refer to the design documents.

1.1.3 Symbols and Highlighting

In these Operating Instructions, important information is highlighted by symbols

or special formatting. The following examples illustrate the most important types

of highlighting.

Danger

Warning: Fatal Injuries

Failure to observe the warning can result in serious damage to health, or

even death.

► The arrow identifies a precautionary measure you have to take to avoid

the hazard.

Warning: Explosions

Failure to observe the warning can result in severe explosions.

► The arrow identifies a precautionary measure you have to take to avoid

the hazard.

General Information

Information on the Document

430BAL012727EN_1

03.01.2018 5

Warning!

Warning: Serious Injuries

Failure to observe the warning can result in serious damage to health.

► The arrow identifies a precautionary measure you have to take to avoid

the hazard.

Caution!

Warning: Injuries

Failure to observe the warning can result in minor or moderate damage to

health.

► The arrow identifies a precautionary measure you have to take to avoid

the hazard.

Notice!

Warning: Damage to Property

Failure to observe the warning can result in 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 instructions.

1. First step in a sequence of operations.

2. Second step in a sequence of operations.

®Result of the previous operation.

®The operation is complete, the goal has been achieved.

Hint!

Further useful information.

1.2 Manufacturer address

GEA Aseptomag AG

Industrie Neuhof 28

CH-3422 Kirchberg

1.3 Customer service

Phone: +41 (0)34 426 29 29

Fax: +41 (0)34 426 29 28

[email protected]

www.gea.com

General Information

Manufacturer address

430BAL012727EN_1

6 03.01.2018

1.4 EC Declaration of Incorporation

GEA Aseptomag AG

Tel. +41 34 426 29 29 · Fax +41 34 426 29 28 · gea.com

Industrie Neuhof 28, CH-3422 Kirchberg Seite 1 von 1

Kirchberg, 16.12.16

Declaration of

Incorporation

According 2006/42/EC from 09.06.2006, appendix II B

INCORPORATION OF PARTLY COMPLETED MACHINERY

We herewith declare that the subsequently described partly completed machine complies with the below listed

essential requirements of the machine directive 2006/42/EC. The technical documentation is compiled in

accordance with part B of Annex VII. In response to reasonable request the relevant technical documentation

will be provided to the national authorities in printed or electronic 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 machine: Valve

Machine type: Aseptomag®Valve Technology

Serial number: xxxx yy (x = serially numbered, y = year of manufacture)

Respective EC standard: 2006/42/EC

Essential requirements: Appendix I, section 1 and 2.1

Applied harmonized standards: DIN EN ISO 12100:2010

The commissioning of this partly completed machine is prohibited until the final machinery into which it is to be

incorporated has been declared in conformity with the provisions of the Machine Directive 2006/42/EC.

Reimar Gutte i.A. Aron Stauffer

Management Board Teamleader Product Development

GEA Aseptomag AG Flow Components –Aseptic Valves

General Information

EC Declaration of Incorporation

430BAL012727EN_1

03.01.2018 7

2 Safety

2.1 Intended use

Aseptic counter pressure valves are stroke valves and are used to control a

predefined pressure in aseptic process systems. The desired product pressure is

achieved by supplying compressed air into the pneumatic actuator. A welded

stainless steel bellows (or PTFE bellows as an option) is used to hermetically

seal the valve disc. Selected sealing materials in the product chamber ensure

optimum tightness. The valve offers a high degree of process reliability and

product quality in aseptic working processes.

Pressure hammers and excessive control air pressures can destroy the bellows.

The control air pressure should therefore not exceed 8 bar and pressure

hammers in the system should be avoided.

The counterpressure valve (GD) should close against the direction of flow of the

medium if possible. Should this not be possible due to technical reasons related

to the plant or process, the valve must be depressurized. Both measures prevent

pressure hammers when the valve is switched. Furthermore, counterpressure

valves must be put into a defined end position (open or closed) to protect the

bellow during 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 not in accordance with the

designated use of the valve. The risk of such misuse lies entirely with

the operator of the facility.

2.1.1 Requirements for operation

The prerequisite for reliable and safe operation of the component is proper

transportation and storage as well as professional 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 directive

The valve is a piece of pressure equipment (without safety function) as defined in

the Pressure Equipment Directive: Directive 2014/68/EG. It is classified according

to Annex II, article 4, section 3. In the event of any deviations, GEA Aseptomag

AG will supply a specific Declaration of Conformity.

2.1.3 ATEX directive

Aseptomag ® valve technology can also be used in ATEX protected areas.

However, the suitability of the component must be checked under consideration

of the respective conditions. Additional information will be made available upon

request.

2.1.4 Improper operating conditions

Safety

Intended use

430BAL012727EN_1

8 03.01.2018

The operational safety of the component can not be guaranteed under improper

operating conditions. Therefore avoid improper operating conditions.

The operation of the component is not permitted if:

•Persons or objects are in the danger zone.

•Safety devices are not working or were removed.

•Malfunctions have been detected on the component.

•Damage to the component has been detected.

•Maintenance intervals have been exceeded.

2.2 Operator’s Duty of Care

In your capacity as operator of the facility you bear a particular responsibility for

the proper and safe handling of the valve in your facility. Only use the valve when

it is in perfect condition to prevent danger to persons and property.

These Operating Instructions contain the information you and your staff need for

the safe and reliable operation during the entire service life of the valve. 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 the necessary safety measures and

monitoring that these 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 environment of the valve must be neat and

clean.

•The staff must wear suitable work clothing and personal protective equipment.

As the operator of the facility make sure that work clothing and personal

protective equipment are used.

•Instruct the staff with regard to any properties of the product which might pose

a health risk and the preventative measures to be taken.

•Have a qualified first-aider on call during the operation, who can initiate the

necessary first-aid measures in case of an emergency.

•Clearly define processes, lines of authority and responsibilities associated

with the valve. Everybody must know what to do in case of an emergency.

Instruct the staff in this respect at regular intervals.

•The signs relating to the valve must always be complete and legible. Check,

clean and replace the signs as necessary at regular intervals.

•Observe the Technical Data specified and the limits of use!

Hint!

Carry out regular checks. This way you can ensure that these

measures are actually observed.

Safety

Operator’s Duty of Care

430BAL012727EN_1

03.01.2018 9

2.3 Subsequent changes

You should never make any technical modifications to the valve. Otherwise you

will have to undergo a new conformity process in accordance with the EC

Machinery Directive on your own.

In general, only original spare parts supplied by GEA Aseptomag AG should be

fitted. This ensures the reliable and economical operation of the valve.

2.4 General safety instructions and dangers

The valve is operationally reliable. It was built according to state-of-the-art

science and technology.

Nevertheless, the valve can pose dangers, especially if

•the valve is not used in accordance with its intended use,

•the valve is not used correctly,

•the valve is operated under 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 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 complete and in clearly legible form.

•Only use the valve for its intended use.

•The valve must be functional and in good working order. Check the condition

of the valve before starting work and at regular intervals.

•Wear tight-fitting work clothing for all work on the valve.

•Ensure that nobody can get hurt on the parts of the valve.

•Immediately report any faults or noticeable changes on the valve to the

person responsible.

•Never touch the pipes and the valve when these components are hot! Avoid

opening the valve unless the process plants have been emptied and

depressurised.

•Observe the accident prevention regulations and all local regulations.

2.4.2 Environmental Protection

Harm to the environment can be avoided by safety-conscious and proactive

behaviour of the staff.

For environmental protection the following principles apply:

•Substances harmful to the environment must not be discharged into the

ground or the sewage system.

•Always observe the pertinent regulations relating to waste avoidance,

disposal and utilization.

Safety

Subsequent changes

430BAL012727EN_1

10 03.01.2018

Table des matières

Autres manuels GEA Unité de contrôle

GEA

GEA VARIVENT TSVN Manuel utilisateur

GEA

GEA H A/T Series Manuel utilisateur

GEA

GEA VARIVENT C Manuel utilisateur

GEA

GEA VARIVENT T R Series Manuel utilisateur

GEA

GEA ECOspace Manuel utilisateur

GEA

GEA VARIVENT T R Manuel utilisateur

GEA

GEA VARIVENT X R Series Manuel utilisateur

GEA

GEA Aseptomag AMV Manuel utilisateur

GEA

GEA HRAB Manuel utilisateur

GEA

GEA SVU 446 Manuel utilisateur

GEA

GEA VARIVENT D Series Manuel utilisateur

GEA

GEA DHV Manuel utilisateur

GEA

GEA DHV DN65/50 KVS 16 Manuel utilisateur

GEA

GEA AVR Series Manuel utilisateur

GEA

GEA DHV DN65/50 KVS 16 Manuel utilisateur

GEA

GEA VARIVENT T R Series Manuel utilisateur

GEA

GEA VARIVENT FRS Manuel utilisateur

GEA

GEA VARIVENT DN 25 Manuel utilisateur

GEA

GEA VP8002 Manuel utilisateur

GEA

GEA Aseptomag AV Manuel utilisateur

GEA

GEA Aseptomag RVIN Manuel utilisateur

GEA

GEA T-smart 7 Manuel utilisateur

GEA

GEA VARIVENT Y Manuel utilisateur

GEA

GEA DHV Manuel utilisateur

Manuels Unité de contrôle populaires d'autres marques

Festo

Festo Compact Performance CP-FB6-E Manuel de la liste des pièces

Elo TouchSystems

Elo TouchSystems DMS-SA19P-EXTME Manuel utilisateur

JS Automation

JS Automation MPC3034A Manuel utilisateur

JAUDT

JAUDT SW GII 6406 Series Guide rapide

Spektrum

Spektrum Air Module System Manuel utilisateur

BOC Edwards

BOC Edwards Q Series Manuel utilisateur

KHADAS

KHADAS BT Magic Manuel utilisateur

Etherma

Etherma eNEXHO-IL Manuel utilisateur

PMFoundations

PMFoundations Attenuverter Manuel utilisateur

Walther Systemtechnik

Walther Systemtechnik VMS-05 Manuel utilisateur

Altronix

Altronix LINQ8PD Instructions de montage

Eaton

Eaton Powerware Series Manuel utilisateur

WAGO

WAGO 750-407/040-000 Manuel utilisateur

Sony

Sony CCU-590 Manuel utilisateur

Graco

Graco 25D614 Manuel utilisateur

Task Force Tips

Task Force Tips YE-RF-900 Manuel de programmation

Shini

Shini SPV-U Series Manuel utilisateur

Flyron

Flyron FN-BC04 Manuel utilisateur