GEA Aseptomag ADV Bedienungsanleitung

Aseptic Valves

GEA Aseptomag® leakage valve type ADV

Operating instruction (Translation from the original language)

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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

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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 9

2.1.2 Pressure equipment directive 9

2.1.3 ATEX directive 9

2.1.4 Improper operating conditions 10

2.2 Operator’s Duty of Care 10

2.3 Subsequent changes 11

2.4 General safety instructions and dangers 11

2.4.1 Principles for safe operation 11

2.4.2 Environmental Protection 12

2.4.3 Electrical Equipment 12

2.5 Supplementary Regulations 12

2.6 Qualification of personnel 12

2.7 Safety equipment 14

2.7.1 Signage 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

4.1 Storage conditions 21

4.2 Transport 21

4.2.1 Scope of supply 21

5 Technical data 22

5.1 Technical data 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 26

6.4.1 Overview switching positions 26

6.4.2 Air Requirement 26

6.4.3 Establishing the Compressed Air Supply 27

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

10 Maintenance 32

10.1 Safety instructions 32

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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 38

10.6 Disassembling and Assembling the Valve 38

10.6.1 Disassembling the Valve 38

10.6.2 Assembling the Valve 41

10.6.3 Torques for clamp 42

10.7 Disassemble and assemble actuator PA20 (side valve) 42

10.7.1 Disassemble actuator PA20 (side valve) 42

10.7.2 Assemble actuator PA20 (side valve) 43

10.8 Disassembling and Assembling the Internal Assembly 44

10.8.1 Disassembling the Internal Assembly 44

10.8.2 Assembling the Internal Assembly 45

10.9 Removing and Installing the "Divisible System" Valve 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” Leak Test (Bubble Test) 50

10.11 Disassembling and Assembling Actuator PA80 - PA255 52

10.11.1 Disassembling Actuator PA80 - PA255 52

10.11.2 Assembling Actuator PA80 - PA255 55

10.12 Disassembling and Assembling Actuator PA80AZ - PA180AZ 57

10.12.1 Disassembling Actuator PA80AZ - PA180AZ 57

10.12.2 Assembling Actuator PA80AZ - PA180AZ 60

10.13 Maintenance 60

10.14 Checking the Feedback Unit 62

10.14.1 Setting the Feedback Unit 62

10.14.2 Valve Stroke 62

11 Alarms 63

11.1 Malfunctions and remedies 63

12 Decommissioning 65

12.1 Safety instructions 65

12.2 Disposal 65

12.2.1 General notes 65

13 Appendix 66

13.1 Lists 66

13.1.1 Abbreviations and terms 66

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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

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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

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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

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2 Safety

2.1 Intended use

Aseptic leakage valves are mix-proof switch elements for aseptic process

systems and permit the safe separation of incompatible media. The media

separation is done via the integrated sterile chamber (ISB), which is separated

hermetically from the atmosphere with a seal each to both product lines and via

two side valves (inlet and outlet). Any leakage at the sealing elements is 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 side valves must be closed

completely.

Fig.1: Product transfer

Cleaning sterile chamber

After a media transfer the sterile chamber must be flushed at least with one

sterile medium. After the main valve has been closed, both side valves can be

put in the open position and thus permit the flushing of the sterile chamber.

Fig.2: Sterilisation after transfer

Safety

Intended use

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CIP cleaning with seat venting (valve type AZ)

If the seat venting is activated for a CIP cleaning (preferably in cycles) no process

must be running in the opposite line. Furthermore, at least one side valve of the

sterile chamber must be open to drain the CIP medium.

Fig.3: Cleaning valve seat B

Pressure hammers and excessive control air pressure (>8 bar) can damage the

bellow. Therefore, Aseptic Leakage Valves (ADV) should if possible, close

against the flow direction of the medium. Should this not be possible due to

technical reasons related to the plant or process, it is recommended to switch the

valve without pressure. Both measures prevent pressure hammers when the

valve is opened or 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 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

Safety

Intended use

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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

The operational reliability of the valve cannot be ensured under improper

operating conditions. Therefore avoid improper operating conditions.

Operating the valve 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 valve.

•Damage has been detected on the valve.

•Maintenance intervals have been exceeded.

•the position of the side valves is not adjusted to the process steps

2.2 Operator’s Duty of Care

The operating company of the component has a special responsibility for the

proper and safe handling of the component within their company. Only use the

component when it is in perfect operating condition in order to prevent danger to

persons and property.

This operating manual contains information that you and your employees need

for safe 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 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 authorize personnel to carry out the relevant

tasks.

•Order and cleanliness must be maintained at the work stations and in the

entire area surrounding the component.

•Personnel must wear suitable work clothing and personal protective

equipment. As the operating company must ensure that work clothing and

personal protective equipment are used.

•Inform personnel regarding any properties of the product which might pose a

health risk and the preventative measures to be taken.

•Have a qualified first-aid representative on call during the operation. This

person must be able to initiate any necessary first-aid measures in case of an

emergency.

•Clearly define procedures, competences and responsibilities for those

working in the area of the component. Everybody must know what to do in

case of an emergency. Instruct the staff in this respect at regular intervals.

Safety

Operator’s Duty of Care

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