GEA Aseptomag AMV Bedienungsanleitung

Aseptic Valves

GEA Aseptomag® stop valve type AMV

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 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 personnel 11

2.7 Safety equipment 12

2.7.1 Signage 13

2.8 Residual 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 19

3.4.1 "Shrink-on Fit" Version 19

3.4.2 System “integrated valve seat seal” 19

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

6 Assembly and installation 23

6.1 Safety instructions 23

6.2 Notes on installation 23

6.3 Welding In a Valve with Pipe Connection 23

6.3.1 Welding In and Installing a Valve 23

6.3.2 Welding post-treatment 24

6.4 Pneumatic connections 24

6.4.1 Air Requirement 24

6.4.2 Establishing the Compressed Air Supply 25

6.5 Electrical connections 26

7 Start-up 27

7.1 Safety instructions 27

7.2 Notes on commissioning 27

8 Operation and control 28

8.1 Safety instructions 28

9 Cleaning 29

9.1 Cleaning 29

9.2 Sterilisation 29

9.3 Passivation 29

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10 Maintenance 30

10.1 Safety instructions 30

10.2 Inspections 31

10.2.1 Bellows 31

10.2.2 Pneumatic connections 31

10.2.3 Electrical connections 31

10.3 Maintenance intervals 31

10.4 List of tools 32

10.5 Prior to disassembly 34

10.6 Disassembling and Assembling the Valve 34

10.6.1 Disassembling the Valve 34

10.6.2 Assembling the Valve 36

10.6.3 Torques for clamp 36

10.7 Disassembling and Assembling the Internal Assembly 36

10.7.1 Disassembling the Internal Assembly 36

10.7.2 Assembling the Internal Assembly 38

10.8 Removing and Installing the "Shrunk-on” Valve Seat Seal 39

10.8.1 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 actuator PA35 PV 44

10.10.1 Disassembling actuator PA35 PV 44

10.10.2 Assembling actuator PA35 PV 48

10.11 Disassembling and assembling actuator PA35 PV H 49

10.11.1 Disassembling actuator PA35 PV H 49

10.11.2 Assembling actuator PA35 PV H 51

10.12 Maintenance 52

10.13 Checking the Feedback Unit 53

10.13.1 Setting the Feedback Unit 53

10.13.2 Valve Stroke 55

11 Alarms 56

11.1 Malfunctions and remedies 56

12 Decommissioning 57

12.1 Safety instructions 57

12.2 Disposal 57

12.2.1 General notes 57

13 Appendix 58

13.1 Lists 58

13.1.1 Abbreviations and terms 58

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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 component and to all persons who work on or use the component

regarding the procedures to follow.

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

the component. Your personal safety and the safety of the component 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 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 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 stop valves of type AMV are stroke valves and are used for opening and

closing pipes in aseptic process plants in a controlled manner. Welded metal

bellows (or PTFE bellows as an option) are 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. The compact and virtually pocket-free design

covers a versatile range of applications in pilot systems and very small plant

construction.

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

Therefore, for valves with pneumatic actuator, the control air pressure should not

exceed 8 bar and pressure hammers in the system should be avoided.

The aseptic stop valve AMV 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 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 is borne solely by the operating

company.

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

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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.

•Clamp connections or screw fastenings on the housing are not properly

fastened and secured against accidental loosening.

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.

•The signs on the component must always be complete and easy to read.

Check, clean and replace the signs as necessary at regular intervals.

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

Safety

Operator’s Duty of Care

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Hint!

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

measures are actually observed.

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 component is safe to operate. It was built according to state-of-the-art

science and technology.

Nevertheless, dangers can arise from the component, if:

•the component is not used as intended

•the component is used improperly

•the component is operated under impermissible 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:

Safety

Subsequent changes

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