Definox DCX3 Operation and maintenance manual

MAINTENANCE NOTICE
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DCX3 & 4 MANUAL COMPRESSION VALVE
www.definox.com

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UPDATE MANAGEMENT
1 CHANGE MANAGEMENT 3
2 SAFETY 4
2.1 IMPORTANT INFORMATION 4
2.2 GENERAL INFORMATION 4
3 INTRODUCTION 5
3.1 DISASSEMBLING THE VALVE (Extracting the actuator and Plug assembly from the body of the valve) 5
3.2 DISASSEMBLING THE ACTUATOR (Changing the internal seals) 5
4 DISASSEMBLING THE VALVE 6
4.1 DISASSEMBLING THE DCX3 VALVE CLAMP COLLAR 6
4.2 DISASSEMBLING THE DCX4 VALVE CLAMP COLLAR 7
4.3 DCX3 SHUT-OFF UNIT AND MANUAL ACTUATOR 8
4.4 DCX4 SHUT-OFF UNIT AND MANUAL ACTUATOR 9
5 CHANGING THE SEALS AND REFITTING 10
5.1 INTRODUCTION 10
5.2 REFITTING THE DCX3 OR 4 VALVE 10
5.3 REPLACING PFA SEALS 11
6 PARTS 12
6.1 DCX3 MANUAL STANDARD PFA VALVE 12
6.2 DCX4 MANUAL STANDARD PFA VALVE 13
6.3 DCX3 MANUAL VALVE WITH ELASTOMER SEAL 14
6.4 DCX4 MANUAL VALVE WITH ELASTOMER SEAL 15
6.5 DCX3 MANUAL VALVE WITH METAL/METAL SEAL 16
6.6 LIST OF SPACE PARTS FOR MANUAL DCX3/4 DN 25 A 53 17
6.7 LIST OF SPACE PARTS FOR MANUAL DCX3/4 DN 63 A 104 18
6.8 LIST OF REFERENCES OF SEAL KITS FOR DCX3/4 MANUAL VALVES 19
6.9 DETAILS OF SEAL SETS FOR DCX3/4 MANUAL VALVES 20

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1 CHANGE MANAGEMENT
CHANGES
INDEX
DATE
PAGES
INITIALS
Newedition
1
September99
/
R. GABORIT
Layout modificationofthespare parts
2
May2000
13/14
R. GABORIT
Modification of the partnumber 24
3
November 2000
13/14
R. GABORIT
Modif. of the plug ref. for DCX4 DN3’’ 7005609 was 7007609
4
June 2001
14
R. GABORIT
Addcommentre/re-assemblyof theplug
5
October2001
7
R. GABORIT
Addex.: grease
6
February2002
7
R. GABORIT
Modif ref of o’ring Nr24 DN4’’/104
7
October2002
14
R. GABORIT
Modif ref of o’ring Nr08 DN70 & kit seal EPDM DCX3 DN80/100
8
June2007
14/15
R. GABORIT
Updatenotice
9
October2009
/
G. ANDRE

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2 SAFETY
2.1 IMPORTANT INFORMATION
Always read the maintenance notice before manipulating the valve
Failure to observe these instructions can result in serious bodily injury or loss of life.
This can also result in less serious injuries or damage to the equipment.
Electricity can result in serious bodily injury or loss of life.
This can also result in less serious injuries or damage to the equipment.
2.2 GENERAL INFORMATION
The following advice is given to ensure optimum use of the equipment.
The tasks must be performed in the order specified.
DANGER !
CAUTION !
DANGER !
CAUTION !
NOTE
!

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MAINTENANCE NOTICE manual DCX3 & 4 floating seal, elastomer seal or metal-
to-metal seal.
3 INTRODUCTION
The disassembly process for DCX3 or DCX4 changeover valve is divided into two distinct
steps :
3.1 DISASSEMBLING THE VALVE (Extracting the actuator and Plug assembly from the body
of the valve)
This operation enables access to the plug seals (Changing the seals) and the removal
of the manual actuator.
This is a straightforward procedure and can be performed on-site as it does not present
any particular problems.
This is the case in the majority of maintenance operations on this type of valve.
3.2 DISASSEMBLING THE ACTUATOR (Changing the internal seals)
This operation is straightforward procedure and can be performed on-site.
NOTE: After carrying out any maintenance work on DEFINOX products it is essential that
you check the correct function of the equipment concerned: tightness, pressure, etc…
DCX3
manu
el
DCX4
NOTE
!

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4 DISASSEMBLING THE VALVE
4.1 DISASSEMBLING THE DCX3 VALVE CLAMP COLLAR
Lift the plug by unscrewing the handle in order to relieve the pressure on the clamp.
Disassemble the clamp collar,
Remove the manual actuator/shut-off unit assembly from the DCX3 body and retrieve
the seal.
Clamp collar
Body seal
DCX3 body
Manual actuator +
shut-off unit

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4.2 DISASSEMBLING THE DCX4 VALVE CLAMP COLLAR
NOTE: If the upper body is installed between couplings, it may be easier to dismantle
it and remove it together with the plug assembly of the DCX4 valve.
In any cases, the bodies have to be moved apart in order to dismantle the valve.
Lift the plug by unscrewing the handle in order to relieve the pressure on the clamp.
Remove the clamp from the DCX3 body.
Remove the manual actuator/shut-off unit assembly from the DCX3 body and retrieve
the seal.
Upper clamp
collar
Seal
Lower clamp
collar
DCX3 body
Manual actuator + DCX4
body + shut-off unit

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4.3 DCX3 SHUT-OFF UNIT AND MANUAL ACTUATOR
Withdraw the plug as far as possible by turning the handle.
Unscrew the hex. head screw then remove the washer and handle.
Remove the drive screw completely from the lantern using a flat-head screwdriver.
Remove the spring, the spacer (for DN38 and 1½” only) and the screw.
Unscrew the plug and the connecting cap with the aid of their flat sides and remove the
seal holder plate.
Screw
Washer
Spring
Spacer for
DN38 and 1½”
Drive screw
Connecting cap
Seal holder
plate
Plug
Flat sides

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4.4 DCX4 SHUT-OFF UNIT AND MANUAL ACTUATOR
Withdraw the plug as far as possible by turning the handle.
Remove the clamp from the DCX4 body.
Unscrew the hex. head screw then remove the washer and handle.
Remove the drive screw completely from the lantern using a flat-head screwdriver.
Remove the spring and screw.
Unscrew the plug and the connecting cap with the aid of their flat sides and remove the
seal holder plate, the body seal and the DCX4 body.
Screw
Washer
Manual
handle
Lantern
Spring
Drive screw
Clamp collar
Connecting cap
Seal holder
plate
Plug
Flats sides
Body seal
DCX4 body

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5 CHANGING THE SEALS AND REFITTING
5.1 INTRODUCTION
Our valve components are listed and identified in our folder and CD-ROM under “Spare
Parts Catalogue”. Here you will find the information required to order your spare parts.
5.2 REFITTING THE DCX3 OR 4 VALVE
This procedure is performed in the reverse order to dismantling. However, it is necessary
to take into account the following information :
We recommend the use of a middle threadlocker to lock the plug during its reassembly
to the manual actuator.
Before reassembling the parts, ensure that the assembly is lubricated with an
appropriate lubricant (water-resistant and temperature-resistant food grade grease
→Example: NEVASTANE 5P7). Ensure that the grease used is compatible with
the elastomer seals.
Avoid damaging the seals on the edges of the components.

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5.3 REPLACING PFA SEALS
To change PFA seals, follow the guidelines given below:
Remove the defective seal using a cutter taking care not to mark the bearing surface
of the plug (protect the stainless steel surface using the edge of a steel rule or a plastic
off-cut),
Place the new seals in an oven at 140°C (+/- 3%) for 30 minutes.
Do not exceed 200 °C.
If the temperature is too low, there is a risk that the seal will deform or tear during
installation.
Insert the seal quickly from one side of the groove, then progressively push it into its
housing.
NOTE: always insert the seal on the bevelled side.
Bevel towards the
inside of the plug
NOTE !

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6 PARTS
6.1 DCX3 MANUAL STANDARD PFA VALVE
Seal kit family (complete): A1, A2 ou A3
Seal kit family (Without PFA seal): B1, B2 ou B3
(According to material grade)
2
21
22
17
19
1
18
16
15
14
12
11
25
5
26
26
23
20

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6.2 DCX4 MANUAL STANDARD PFA VALVE
22
13
21
23
17
19
1
18
16
15
12
11
25
22
26
26
20
3
6
20
23
Seal kit family (complete): C1, C2 ou C3
Seal kit family (Without PFA seal): D1, D2 ou D3
(According to material grade)

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6.3 DCX3 MANUAL VALVE WITH ELASTOMER SEAL
8
21
22
17
19
1
18
16
15
14
12
11
25
5
26
26
24
7
20
Seal kit family : E1, E2 ou E3
(According to material grade)

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6.4 DCX4 MANUAL VALVE WITH ELASTOMER SEAL
13
21
17
19
1
18
16
15
12
11
25
26
26
10
6
20
20
24
24
22
22
9
7
Seal kit family : F1, F2 ou F3
(According to material grade)

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6.5 DCX3 MANUAL VALVE WITH METAL/METAL SEAL
4
21
22
17
19
1
18
16
15
14
12
11
25
5
26
26
20
Seal kit family : B1, B2 ou B3
(According to material grade)

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6.6 LIST OF SPACE PARTS FOR MANUAL DCX3/4 DN 25 A 53
Ref
Description
Qty
DN
25
DN
1’’
DN
28
DN
34
DN
38
DN
1’’1/2
DN
40
DN
2’’
DN
51
DN
53
01
DCX3 valve body
1
Depending on body configuration
02
DCX3 standard seat valve plug
1
7005634
7005580
7005509
03
DCX4 standard seat valve plug
1
7005640
7005641
7005640
7005679
7005579
7005578
7005579
7005514
7005518
04
metal/metal Plug
1
7300221
7300225
7300217
05
Seal support plate for DCX3 manual
1
7005857
7005620
06
Seal support plate for DCX4 manual
1
7005858
7005854
07
Plate elastomer seal plug
1
7300005
7300077
08
DCX3 plug elastomer seal
1
7300004
7300070
7300071
09
DCX4 elastomer seal double plug
1
7300006
7300157
7300158
10
DCX4 elastomer seal valve intermediate stem
1
7300007
7300008
7300007
7300143
7300144
7300008
7300144
7300147
7300146
11
Cap connecting, DCX3/4
1
7005855
7005622
12
Screw, drive, DCX3/4 manual
1
7005623
13
DCX4 body
1
Depending on body configuration
14
DCX3 spacer
1
7300154
15
Lantern, DCX3/4 manual
1
7005856
7005621
16
Handle DCX3/4 manual
1
7005852
17
Knob, manual handle, DCX3/4
1
7009995
18
TH screw
1
7006783
19
Washer, manual handle
1
7380097
20
Seal support plate O-ring EPDM FDA
1 - 2
7380158
7380159
20
Seal support plate O-ring FKM FDA
1 - 2
7380607
7006130
20
Seal support plate O-ring VMQ FDA
1 - 2
7006171
7006175
21
Spring, manual handle
1
7007811
22
Clamp collar
1 - 2
7441831
7441832
23
Plug seal for DCX3/4 PFA
1 - 2
7005138
7005147
24
Elastomer plug O-ring EPDM FDA
1 - 2
7006174
7380158
24
Elastomer plug O-ring FKM FDA
1 - 2
7006173
7380607
24
Elastomer plug O-ring VMQ FDA
1 - 2
7006172
7006171
25
Seal support plate O-ring EPDM FDA
1
7380137
7380179
25
Seal support plate O-ring FKM FDA
1
7006157
7380620
25
Seal support plate O-ring VMQ FDA
1
7006170
7006035
26
seal support plate ring
2
7009993
7009972

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6.7 LIST OF SPACE PARTS FOR MANUAL DCX3/4 DN 63 A 104
Ref
Description
Qty
DN
2’’1/2
DN
63
DN
70
DN
3’’
DN
76
DN
80
DN
4’’
DN
104
01
DCX3 valve body
1
Depending on body configuration
02
DCX3 standard seat valve plug
1
7005651
7005667
7005601
7005560
7005528
03
DCX4 standard seat valve plug
1
7005657
7005656
7005672
7005609
7005604
7005566
7005533
7005536
04
metal/metal Plug
1
7300213
7300209
7300205
05
Seal support plate for DCX3 manual
1
7005660
7005863
06
Seal support plate for DCX4 manual
1
7005861
7005864
07
Plate elastomer seal plug
1
7300078
7300079
7300080
08
DCX3 plug elastomer seal
1
7300072
7300073
7300074
7300075
7300076
09
DCX4 elastomer seal double plug
1
7300159
7300162
7300163
7300160
7300161
10
DCX4 elastomer seal valve intermediate stem
1
7300149
7300148
7300150
7300152
7300151
7300153
7300156
7300155
11
Cap connecting, DCX3/4
1
7005622
7005866
12
Screw, drive, DCX3/4 manual
1
7005859
7005865
13
DCX4 body
1
Depending on body configuration
14
DCX3 spacer
1
15
Lantern, DCX3/4 manual
1
7005862
7005867
16
Handle DCX3/4 manual
1
7005852
17
Knob, manual handle, DCX3/4
1
7009995
18
TH screw
1
7006783
19
Washer, manual handle
1
7380097
20
Seal support plate O-ring EPDM FDA
1-2
7006164
7006183
20
Seal support plate O-ring FKM FDA
1-2
7006131
7006063
20
Seal support plate O-ring VMQ FDA
1-2
7006180
7006184
21
Spring, manual handle
1
7007811
22
Clamp collar
1-2
7441833
7441837
23
Plug seal for DCX3/4 PFA
1-2
7005156
7140038
7005291
24
Elastomer plug O-ring EPDM FDA
1-2
7006193
7380101
7006162
24
Elastomer plug O-ring FKM FDA
1-2
7380609
7006127
7006136
24
Elastomer plug O-ring VMQ FDA
1-2
7006057
7006093
7006198
25
Seal support plate O-ring EPDM FDA
1
7380179
7006160
25
Seal support plate O-ring FKM FDA
1
7380620
7380617
25
Seal support plate O-ring VMQ FDA
1
7006035
7006589
26
seal support plate ring
2
7009972
7009973

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6.8 LIST OF REFERENCES OF SEAL KITS FOR DCX3/4 MANUAL VALVES
DESCRIPTION
DN
25-40
DN
51-52
DN
63-76
DN
80
DN
100-104
For details of kit
A
see following chapter
1
PFA/EPDM FDA seal kit for DCX3 standard valve
(Complete)
7080500
7080501
7080502
7080503
7080504
2
PFA/FKM FDA seal kit for DCX3 standard valve (Complete)
7080505
7080506
7080507
7080508
7080509
3
PFA/VMQ FDA seal kit for DCX3 standard valve (Complete)
7080510
7080511
7080512
7080513
7080514
For details of kit
B
seefollowing chapter
1
EPDM FDA seal kit for DCX3 standard valve (Without PFA
seal)
7080515
7080516
7080517
7080518
2
FKM FDA seal kit for DCX3 standard valve (Without PFA
seal)
7080519
7080520
7080521
7080522
3
VMQ FDA seal kit for DCX3 standard valve (Without PFA
seal)
7080523
7080524
7080525
7080526
For details of kit
C
seefollowing chapter
1
PFA/EPDM FDA seal kit for DCX4 standard valve
(Complete)
7080542
7080543
7080544
7080545
7080546
2
PFA/FKM FDA seal kit for DCX4 standard valve (Complete)
7080547
7080548
7080549
7080550
7080551
3
PFA/VMQ FDA seal kit for DCX4 standard valve (Complete)
7080552
7080553
7080554
7080555
7080556
For details of kit
D
see following chapter
1
EPDM FDA seal kit for DCX4 standard valve (Without PFA
seal)
7080557
7080558
7080559
7080560
2
FKM FDA seal kit for DCX4 standard valve ( Without PFA
seal )
7080561
7080562
7080563
7080564
3
VMQ FDA seal kit for DCX4 standard valve ( Without PFA
seal )
7080565
7080566
7080567
7080568
For details of kit
E
see following chapter
1
EPDM FDA seal kit for DCX3 elastomer seal valve
7080527
7080528
7080529
7080530
7080531
2
FKM FDA seal kit for DCX3 elastomer seal valve
7080532
7080533
7080534
7080535
7080536
3
VMQ FDA seal kit for DCX3 elastomer seal valve
7080537
7080538
7080539
7080540
7080541
For details of kit
F
see following chapter
1
EPDM FDA seal kit for DCX4 elastomer seal valve
7080569
7080570
7080571
7080572
7080573
2
FKM FDA seal kit for DCX4 elastomer seal valve
7080574
7080575
7080576
7080577
7080578
3
VMQ FDA seal kit for DCX4 elastomer seal valve
7080579
7080580
7080581
7080582
7080583

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6.9 DETAILS OF SEAL SETS FOR DCX3/4 MANUAL VALVES
PFA/EPDM FDA valve seal kits for DCX3 standard valves (Complete):
A1
Diameter
DN25-38 SMS
DN51 SMS
DN63-76 SMS
DN25-40 DIN
DN53 DIN
DN70 DIN
DN80 DIN
DN104 DIN
DN1’’-1’’1-2 US
DN2’’ US
DN3’’ US
DN4’’ US
Kit No.
7080500
7080501
7080502
7080503
7080504
Guide
Description
Qty
Seal reference
20
Seal support plate O-ring EPDM
FDA
1
7380158
7380159
7006164
7006183
23
DCX3/4 plug seal PFA
1
7005138
7005147
7005156
7140038
7005291
25
Seal support plate O-ring EPDM
FDA
1
7380137
7380179
7006160
26
Seal support plate ring.
2
7009993
7009972
7009973
PFA/FKM FDA valve seals for DCX3 standard valves (Complete):
A2
Diameter
DN25-38 SMS
DN51 SMS
DN63-76 SMS
DN25-40 DIN
DN53 DIN
DN70 DIN
DN80 DIN
DN104 DIN
DN1’’-1’’1-2 US
DN2’’ US
DN3’’ US
DN4’’ US
Kit No.
7080505
7080506
7080507
7080508
7080509
Guide
Description
Qty
Seal reference
20
Seal support plate O-ring FKM FDA
1
7380607
7006130
7006131
7006063
23
DCX3/4 plug seal PFA
1
7005138
7005147
7005156
7140038
7005291
25
Seal support plate O-ring FKM FDA
1
7006157
7380620
7380617
26
Seal support plate ring.
2
7009993
7009972
7009973
PFA/VMQ FDA valve seals for DCX3 standard valves (Complete):
A3
Diameter
DN25-38 SMS
DN51 SMS
DN63-76 SMS
DN25-40 DIN
DN53 DIN
DN70 DIN
DN80 DIN
DN104 DIN
DN1’’-1’’1-2 US
DN2’’ US
DN3’’ US
DN4’’ US
Kit No.
7080510
7080511
7080512
7080513
7080514
Guide
Description
Qty
Seal reference
20
Seal support plate O-ring VMQ FDA
1
7006171
7006175
7006180
7006184
23
DCX3/4 plug seal PFA
1
7005138
7005147
7005156
7140038
7005291
25
Seal support plate O-ring VMQ FDA
1
7006170
7006035
7006589
26
Seal support plate ring.
2
7009993
7009972
7009973