assembly instructions · 2018-02-09 · information for your safety information for your safety we...

Assembly Instructions

Gembra Aseptic double seat valves Type: 582x

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Information for your safety


We are pleased that you have decided on a high-quality product from KIESELMANN. When properly operated and maintained, our products offer you many years of reliable use.

Carefully read these instructions and the safety information that they contain before assembly and commissioning. This will allow a reliable, safe functioning of this product or your system. Bear in mind that improper use of process components can lead to severe material damage and personal injury.

The guarantee becomes invalid in the case of damage caused by non-compliance with these instructions, improper commissioning, handling or unauthorized interference!

Identification of safety information Information is found under the item "Safety information" or directly before the respective handling information. The information is marked by a danger symbol and a signal word. Be sure to read and observe the texts next to these symbols before proceeding in the text and continuing work with the valve.

Symbol

Signal word

Meaning

DANGER

Imminent danger that can lead to severe injuries or death.

ATTENTION

Dangerous situation that can lead to slight bodily injuries or material damage.

NOTE

Indicates tips for users and other especially useful information.

Assembly instructions: Gembra aseptic double seat valves type: 582x

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Safety information

Proper use Due to its function, the valve is used in the foodstuffs, beverage, pharmaceutical, and chemical industry. It is mainly used in combination with several valves to empty and fill containers with the possibility of connecting several pipes to a tank. The valve is designed for media properties in accordance with art. 9 of the DGRL 97/23/EG for group 2 (media state gaseous or liquid).

ATTENTION

• To avoid risks and damage, the valve is to be used in accordance with the safety information and technical data listed in the operating instructions.

DANGER

• Danger of crushing or severing of limbs. In the case of pneum. actuation, do not reach into the valve housing or the valve yoke.

• When the valve or valve assemblies are removed from the system, escaping liquids or gases can cause injury. Only remove valves when it is absolutely certain that the system has been relieved free of pressure, liquid and gas.

• Danger from scalding and chemical burns on body parts due to liquids escaping from the drain outlet. Splash-free discharge fixtures should be attached to the drain outlet.

• The drive is removable. Danger of accidents due to pressure springs. Observe the separate assembly instructions. We recommend having drive maintenance done at the factory.

ATTENTION

• In order to avoid air leakage, only use pneumatic connection parts sealed with an O-ring to a flat surface.

• When the sealing clamps are assembled, the max. torque must not be exceeded (see technical data).

• Installation- and production-related external forces on the housing are to be avoided.

General information

NOTE

• All information reflects the state of development. We reserve the right to modifications due to further technical developments.

General safety information

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Changing seals for the double seat valve

Assembly and disassembly - GEMBRA double seat valve P = Control air supply P1 = Control of main stroke P2 = Control of cycling down P3 = Control of cycling up LA1 = Main stroke LA2 = Cycling down LA3 = Main stroke LA4 = Cycling up AE = Actuator L = Leakage connection VE = Valve insert VG = Valve housing PT =Temperature sensor 9 = Sealing clamp 14 = Hexagon socket screws 15 Outlet valve 16 Inlet valve D14 = K-flex sealing rings

Assembly tools

Allen key

Round bar

Open-end wrench set

Soft-faced hammer

GEMBRA ring spanner

Centering ring

Needle


4



Disassembly

NOTE Disassemble control air, steam or condensation pipes and electrical wires.

• Disassemble the actuators on the inlet and outlet valve. (Fig. 1)

Fig. 1

Fig. 2

• Disassemble the inlet and outlet valve (Fig. 2 + 4).

• Remove K-flex sealing ring D14 (Fig.5).

Fig. 3

Fig. 5

D14


5



• Remove the cover from the actuator.

• Connect the control air to the air connection P and lift the top valve head by actuating the slide switch S1 (Fig.6).

Fig. 6

• Unscrew and remove the sealing clamp 9 (Fig.7).

Fig. 7

• Completely remove the valve insert VE from the housing VG (Fig. 8).

• Close the control air at air connection P; the valve moves to the basic position.

• Reassemble the actuator cover to avoid damage to the actuator.

Fig. 8

P

S1

VE

9 VG


6



• Unscrew the bottom piston 2 (Fig. 9).

• Unscrew the air connection LA4.

Fig. 9

• Unscrew the piston head 5 while exerting counter pressure with a round bar (ø8) in borehole B (see Fig. 10).

Fig. 10

• Unscrew the shaft screw 10 (Fig. 11).

Fig. 11

• Unscrew the hexagon socket screws 11 (Fig. 12).

Fig. 12

2

B

LA4

5

10

11


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• Disassemble yoke 8 (Fig. 13).

• Clamp the valve insert at the top piston 7 in a vise with soft jaws.

Fig. 13

• Position a round bar in the borehole B and release the threaded connection between the piston 7 and the piston rod 12 (Fig. 14).

• Open the vise and place the valve insert on the workbench. Unscrew the piston 7 from the piston rod 12

Fig. 14

• Remove O-rings D11 and D12 (Fig. 15 + 16).

• Clean and slightly grease the installation spaces.

• Replace and install O-rings D11 and D12.

Fig. 15

Fig. 16

Fig. 17

B

7

8

12

Round bar 7

D11

D12



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• Pierce the O-ring D7 and the piston guide band D6 with a sharp tool and carefully remove them from the groove (Fig. 18)

• Clean and slightly grease the installation spaces.

• Replace and install the O-ring D7 and the piston guide band D6.

Fig. 18

Fig. 19

• Unscrew the pressure ring 4 from the piston head 5 using the ring spanner (Fig. 20).

• Remove the diaphragm D2, O-ring D3 and the supporting ring 3.

Fig. 20

Fig. 21

D7

D6



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• Unscrew the piston head 1 from the piston 2 and remove the sealing ring D1 (Fig. 22).

Fig. 22

Fig. 23

Fig. 21

D1 1

2


10



Assembly NOTE Clean and slightly grease the installation spaces and running surfaces.

Sealing materials Lubricants

EPDM; Viton; K-Flex Klüber Paraliq GTE NBR; HNBR; silicone Klüber Paraliq GB 363 Thread Teflon grease Interflon

Assembly of the K-flex sealing ring D1 (only with K-flex version)

• Install the O-ring in the K-flex sealing ring. Install the ring shells in the order A, B, C, D as shown in (Fig. 25).

Fig. 25

Assembly of module 1

NOTE The material of the sealing ring D1 varies according to the valve type. In these instructions, assembly and disassembly with the K-flex version is shown.

• Clamp the piston 2 in the vise with an open-end wrench.

• Screw together the piston head 1 and the piston 2 by hand without the sealing ring D1 until a metallic stop and make a color mark (Fig. 27).

• Unscrew the piston head 1 from the piston 2 again.

Fig. 27

Ring shells, four-part

O-ring

k-flex sealing ring

Sealing ring,

2 D1 1

Centering ring


11



Fig. 28

• Push the seal D1 onto the piston 2 and screw the piston head 1 into the piston 2 by hand.

• To center the sealing ring D1, the centering ring is placed on the piston 2 as shown in the drawing (Fig. 29).

• Screw the piston head 1 into the piston up to the mark; this ensures that the seal is optimally compressed. (Fig. 30 / Fig. 31).

Fig. 29

Fig. 30

Fig. 31

Centering ring



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Assembly of module 2

Fig. 32

Fig. 33

• Clamp the piston head 5 in the vise with an open-end wrench.

• Screw together the pressure ring 4 and the piston head 5 by hand without the O-ring D3 and the diaphragm D2 until a metallic stop and make a color mark (Fig. 32).

• Unscrew the pressure ring 4 from the piston head 5 again.

• Slightly grease the thread of the piston head 5 and the pressure ring 4.

• Insert the supporting ring 3 into the piston head 5.

ATTENTION! Observe the installation position of the

supporting ring!

• Install the O-ring D3.

• Place the diaphragm D2 on the piston head 5.

• Screw the pressure ring 4 together with the ring spanner (Fig.

35).

ATTENTION The pressure ring 4 can become deformed if the radial clamping force is too great.

Fig. 34

Fig. 35

3 5



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Assembly of the module 2 with the diaphragm D5 and the piston 7

• Clamp the piston 7 in the vise with soft jaws.

• Push the diaphragm D5 onto the module 2.

• Screw the module 2 into the piston 7 (Fig. 35).

Fig. 35

Assembly of the valve

• Place the yoke 8 on the drive.

ATTENTION! Observe the installation position of the yoke! When the yoke is assembled on the drive, it must be ensured that the through-hole (B1) for the compressed air matches the borehole for the air connection LA4 (Fig. 36).

• Screw in the screws 11 but do not tighten, so that no tension results when the piston 7 is installed (Fig. 37).

• Turn the spindle 6 until the threaded hole for the shaft screw 10 and the groove of the spindle 6 are on top of each other. Screw in the shaft screw 10 (Fig. 38).

Fig. 36

Fig. 37

Fig. 38

D5 7 Module 2

B1

LA4

8

11

10

6


14



• Grease the piston 7 (Fig. 39).

• Screw the piston 7 onto the piston rod 12. While doing this, exert counter pressure with a round bar in the borehole B (Fig. 40).

• Now tighten the screws 11 on the yoke crosswise.

• Assemble the air connection LA4 (Fig. 41). Fig. 39

Fig. 40

• Assemble the air connection LA4 (Fig. 41).

• Screw the module 1 into the spindle 6 (Fig. 42).

NOTE Secure the threaded connection G1 with removable thread locker (e.g. Loctite 243).

Fig. 41

Fig. 42

Fig. 43

8 Grease

7

B

11

LA4

G1

Module 1



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• Remove the cover from the actuator.

• Connect the control air to the air connection P and lift the top valve head by actuating the slide switch S1 (Fig. 6).

• Now carefully attach the diaphragm D5 to the bead of the yoke (Fig. 45).

Fig. 44

Fig. 45

Fig. 46

Fig. 47

• Install the complete valve set in the housing VG (Fig. 46).

• Assemble the sealing clamp 9 and tighten it while observing the torque (Fig. 47).

• Close the control air at air connection P; the valve moves to the basic position.

• Assemble the actuator cover again to avoid damage to the actuator (Fig. 48).

Tightening torque for the sealing clamp 9

Sealing clamp nominal width DN

40 50 65 80

Torque in Nm 15 15 25 20

Fig. 48

P

S1

D5

Bead

15 15 25 20

VG

9

Cover



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assembly instructions · 2018-02-09 · information for your safety information for your safety we...

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