Definox DCX3 Operation and maintenance manual

MAINTENANCE NOTICE
NM-230 index 18 Page 1/55 September 2020
DCX3 AUTOMATIC REGULATING
CHANGEOVER VALVE
www.definox.com

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TABLE OF CONTENTS
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
3.2.1 Safety devices 6
4 MAINTENANCE OF THE VALVE FOR POSITIONER BURKERT 8630 7
4.1 DISASSEMBLING THE 8630 UNIT 7
4.2 REASSEMBLING THE 8630 UNIT 8
4.3 CONNECTING THE AIR SUPPLY TO THE 8630 UNIT 9
4.4 CONNECTING THE POWER SUPPLY REGULATOR OPERATION 10
4.5 CONNECTING THE POWER SUPPLY POSITIONER OPERATION 11
4.6 CONNECTING POWER (analog card) 12
4.7 SETTING THE VALVE REGULATOR OPERATION 13
4.8 SETTING THE VALVE POSITIONER OPERATOR 14
4.9 SETTING THE VALVE (analog card) 15
5 MAINTENANCE OF THE VALVE FOR POSITIONER BURKERT 8693 16
5.1 DISASSEMBLING THE 8693 UNIT 16
5.1.1 POSITIONER AND ADAPTATION KITS 17
5.2 REASSEMBLING THE 8693 UNIT 18
5.3 CONNECTING THE AIR SUPPLY TO THE 8693 UNIT 18
5.4 CONNECTING THE POWER SUPPLY REGULATOR OPERATION (without 4-20mA generator) 19
5.5 SETTING THE VALVE AUTOMATIC OPERATION 20
5.5.1 AUTOMATIC ADJUSTMENT OF THE POSITIONER TO THE OPERATING CONDITIONS (X.TUNE) 21
5.5.2 SETTING UP THE PROCESS CONTROLLER (auxiliary function P.CONTROL) 22
5.5.3 BASIC SETTING OF THE PROCESS CONTROLLER 23
6 MAINTENANCE OF THE VALVE FOR POSITIONER GEMÜ 1436 26
6.1 DISASSEMBLING THE 1436 UNIT 26
6.2 REASSEMBLING THE 1436 UNIT 27
6.3 CONNECTING THE AIR SUPPLY TO THE 1436 UNIT 28
6.4 CONNECTING THE POWER SUPPLY REGULATOR OPERATION 29
6.5 INITIALIZATION AUTOMATIC 1436 UNIT 30
6.6 SETTING THE VALVE POSITIONER OPERATOR 32
6.7 SETTING THE VALVE REGULATOR OPERATION 32
6.8 SETTING THE VALVE AUTOMATIC OPERATION 33
7 DISASSEMBLING THE VALVE 34
7.1 DISASSEMBLING THE DCX3 REGULATING VALVE CLAMP COLLAR 34
7.2 DISASSEMBLING THE DCX3 REGULATING VALVE SHUT-OFF UNIT 34
8 CHANGING SEALS AND REASSEMBLY 36
8.1 INTRODUCTION 36

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8.2 ASSEMBLING THE ACTUATOR 36
8.3 CHANGING ACTUATOR CONFIGURATION 37
8.4 REASSEMBLING THE VALVE 38
9 PARTS 39
9.1 DCX3 STANDARD VALVE ACTUATOR (elastomer, diaphragm) 39
9.2 DCX3 ASEPTIC SEAT VALVE ACTUATOR 40
9.3 DCX3 STANDARD REGULATING VALVE, ELASTOMER AND SECTION /2 41
9.4 DCX3 DIAPHRAGM REGULATING VALVE, ELASTOMER AND SECTION /2 42
9.5 DCX3 ASEPTIC SEAT REGULATING VALVE 43
9.6 LIST OF PARTS FOR DN 25 to 51 DCX3/4 AUTOMATIC VALVES 44
9.7 LIST OF PARTS FOR DN 63 TO 104 DCX3/4 AUTOMATIC VALVES 45
9.8 LIST OF ACTUATORS FOR DCX3 AUTOMATIC CHANGEOVER VALVES 46
9.9 LIST OF REFERENCES OF SEAL KITS FOR DCX3/4 AUTOMATIC VALVES. 46
9.9.1 DETAILS OF SEAL SETS FOR DCX3 REGULATING VALVES 47
9.10 Reference of greases 54
1 CHANGE MANAGEMENT
CHANGES INDEX DATE PAGE S) INITIALS
New version 1 December 08 / G. ANDRE
Adding electrical connection and adjustment. 2 March 10 8-9-12 G. ANDRE
Add locking kit 3 October 2011 5 G. BEGAUD
Drawing modifications 4 March 2012 17/18 G.BEGAUD
Remove DN125/150 5 December 2012 18-27/36 G.BEGAUD
Add regulation elastomer plug DN65 6 October 2013 27 T.PICOT
Add regulation elastomer plug DN104 – 4’’ 7 November 2013 27 G.BEGAUD
Add positioner GEMÜ 1436 8 February 2015 C. GUILLET
Add positioner BURKERT 8693 9 September 2015 G. BEGAUD
Adding safety devices 10 October 2015 6 G.BEGAUD
Add clamp collar tightening torque 11 August 2016 38 G.BEGAUD
Add of 8693 positioner references and adaptation kits 12 June 2018 17 G.BEGAUD
Modification aseptic actuator and seals kit A2 13 September 2018 40-44-45-48 G.BEGAUD
7082850 was 7815030 14 November 2018 6 F. BRUN
REV.2 wiring 15 May 2019 19 G.BEGAUD
7010801 was 7006130 (Rep 20 and 23) 16 March 2020 44/45/49/50/51/52/
53/54 G.BEGAUD
7010808 was 7380607 (Rep 20 and 24) 17 April 2020 44/48/49/51/52/53 G.BEGAUD
Add of greases recommended for the actuator and the valve 4/5/36/54
Modification of the assembly process of the linking rod 18 September 2020 18 G.BEGAUD

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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.
•A range of greases for cylinder seals and valve seals has been defined for
be in phase with their nature and the regulations according to the uses (See § 9.10).
NOTE
DANGER
!
CAUTION
DANGER
!
CAUTION !

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DCX3 automatic regulating changeover valve MAINTENANCE NOTICE
3 INTRODUCTION
DCX3 regulating changeover valves are disassembled in 2 separate stages :
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, see § 9.10 for
lubrication) and the removal of the 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)
CAUTION: This operation must be performed using a special tool ensuring that the
necessary precautions are taken (STRESSED SPRING)
For changing from an NC valve to an NO valve and vice versa, see ‘’Changing
configuration’’.
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…
DANGER
!
NOTE

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3.2.1 Safety devices
For the maintenance of NC and NO actuators, we offer on request maintenance sets preventing
unintended operation of the plug when the actuator is supplied with air.
DCX3/4 NC rod out)
DCX4 NO rod in)
A tool case reference 7082850 is available which includes the following tools:
•7814986 Maintenance tool for actuator NC DN25-40
•7814972 Maintenance tool for actuator NC DN51-76
•7814987 Maintenance tool for actuator NC DN80-104
•7814976 Maintenance tool for actuator NO DN25-150
DN
Reference
DN25
-
40
7814986
DN51 and DN63
–
76
7814972
DN80
–
104
7814987
DN125
-
150
7814988
DN
Reference
DN25
–
150
7814976
RISKS
When changing seals: Risk of
trapping fingers between the
actuator axis and the top of the seal
plate
SOLUTIONS
Maintenance tools for the NC actuator
RISKS
When fitting and removing the valve:
Risk of trapping fingers between the
valve and the valve body
SOLUTIONS
Maintenance tool for NO actuator
Safety device
Safety device
DANGER
!
DANGER
!

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4 MAINTENANCE OF THE VALVE FOR POSITIONER BURKERT 8630
Before starting the disassembly procedure, if the valve is fitted with a signalling box it may be
necessary to detach the signalling unit from the actuator.
4.1 DISASSEMBLING THE 8630 UNIT
Dismantling without disconnection
IMPORTANT: Before starting any work on the box, it is important to ensure
that the air supply is closed and that the circuit is purged.
Dismantling with disconnection
IMPORTANT: Before starting any work on the box, it is important to ensure
that the mains supply is switched off, that the air supply is closed and that the
circuit is purged.
•Supply air to the actuator so you can lift the stem/detection cam assembly [47-50] and access
the clip retainer [49].
•After disassembling the position indicator clip retainer, unscrew the screw [46] and remove the
cam/clip retainer assembly [47-49].
•Unscrew the locking screw to detach the housing [55] from the base [48] taking care not to
damage the seal [52].
•Unscrew the screws [53] to disassemble the base [48].
•Using the turning flats, remove the stem [50].
CAUTION !
49
46
47
48
50
53
41/56
54
51
52
55
Locking
screw
Position
indicator
Turning
flats

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4.2 REASSEMBLING THE 8630 UNIT
•Refit the stem [50] and lock it in place using the turning flats.
•Attach the base [48] using the screws [53].
•Position the housing [55] on the base [48] taking care not to damage the seal [52].
•Supply air to the actuator so you can lift the stem/detection cam assembly [47-50] and access
the clip retainer [49].
•Fit the clip retainer [49] with the position indicator.
•After fitting the clip retainer with the position indicator, tighten the screw [46] to lock the
detection cam [47] in place.
•Lock the housing [55] in place using the locking screw.
•Fit the connector ([41] or [56] depending on whether the actuator is NC or NO) onto the base
[48].

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4.3 CONNECTING THE AIR SUPPLY TO THE 8630 UNIT
NC assembly
NO assembly
59
58
57
28
56
57

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4.4 CONNECTING THE POWER SUPPLY REGULATOR OPERATION
The signal from a temperature sensor or level, flow, which through with the control box of
the valve that controls it (Regulator mode).
•Remove the 4 screws from the electrical connection box using a flat screwdriver.
•Connect the 24VDC+ wire (red) to 24V [5]
•Connect the 24VDC- wire (black) to GND [6]
•Connect the 4-20mA+ wire (blue) to bin-/Proz1 [8]
•Connect the 4-20mA- wire (white) to bin2+/Proz2 [9]
Screw

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4.5 CONNECTING THE POWER SUPPLY POSITIONER OPERATION
The signal from a temperature sensor or level meter, etc... between the controller which
controls the valve (positioner mode).
•Remove the 4 screws from the electrical connection box using a flat screwdriver.
•Connect the 24VDC+ wire (red) to 24V [5]
•Connect the 24VDC- wire (black) to GND [6]
•Connect the 4-20mA+ wire (blue) to SCOLL + [8]
•Connect the 4-20mA- wire (white) to SCOLL GND [9]
Screw

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4.6 CONNECTING POWER analog card)
•Remove the 4 screws from the electrical connection box using a flat screwdriver.
•Connect the 4-20mA+ wire to ASR+ [3].
•Connect the 4-20mA- wire to ASR GND [4].

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4.7 SETTING THE VALVE REGULATOR OPERATION
•Press once on the button on the right of the box’s display to put it in auto mode (the yellow
light flashes).
•Hold down the button on the right of the display for five seconds to access the main menu.
•Select the ACTFUNC function using the arrows, confirm with the button on the right and select
the FUNCSNGL function. Then confirm.
•Select INPUT and confirm. Then choose 4’20A and confirm.
•Select X.TUNE and hold down the button on the right for five seconds.
•X.TUNE X then searches for and adjusts its position. The yellow light flashes rapidly.
•When TUNE END appears, confirm. Select END (KXX.) and then confirm.
AUTOMATIC
service mode
MANUAL
service mode
skip for the first
commissioning
8630 positioner
display

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4.8 SETTING THE VALVE POSITIONER OPERATOR
•Same as the valve régulator positioner for functions ACTFUNC, INPUT, X.TUNE.
•Then go to ADDFUNCT and uncheck P.CONTRL then placed before the star disappears.
•Exit menu with ENDFUNCT.
Parametrization of the PID controller

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4.9 SETTING THE VALVE analog card)
•For the feedback signal OUTPUT must be in the main menu.
•Select OUTPUT then go OUT ANL, choice (in our case) ANL POS ans select ANL 4’20A.
•Exit menu with OUT END.

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5 MAINTENANCE OF THE VALVE FOR POSITIONER BURKERT 8693
Before starting the disassembly procedure, if the valve is fitted with a signalling box it may be
necessary to detach the signalling unit from the actuator.
5.1 DISASSEMBLING THE 8693 UNIT
Dismantling without disconnection
IMPORTANT: Before starting any work on the box, it is important to ensure
that the air supply is closed and that the circuit is purged.
Dismantling with disconnection
IMPORTANT: Before starting any work on the box, it is important to ensure
that the mains supply is switched off, that the air supply is closed and that the
circuit is purged.
•Unscrew the locking screws to separate the base of the housing taking care not to damage the
seals of the base and the control pin.
•Remove the control pin of the linking rod.
•Unscrew the 2 screws H (ref: 7006729) to disassemble the base.
•Unscrew the linking rod.
CAUTION !
Control pin
Linking rod
Base seal
H screw for fixing base Positioner
8693 (ref: 7006729)
Positioner 8693
Base seal / positioner
Base
Fixing screw of linking rod
positioner 8693
Adaptation
kit

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5.1.1 POSITIONER AND ADAPTATION KITS
Positioner 8693:
Description
Reference
No feedback
7303161
Feedback
7303162
Adaptation kits:
Description
Reference
Adaptation kit DCX3/4 DN25/104 for positioner 8693
7303165
Adaptation kit DPAX DN25/104 for positioner 8693
7303166
Set positioner 8693 and adaptation kit:
Description
Reference
Set positioner 8693 no feedback
+
adaptation kit
DCX3/4 DN25/104
7303153
Set positioner 8693 feedback
+
adaptation kit DCX3/4 DN25/104
7303154
Set positioner 8693 no feedback
+
adaptation kit DPAX DN25/104
7303157
Set positioner 8693 feedback
+
adaptation kit DPAX DN25/104
7303158

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5.2 REASSEMBLING THE 8693 UNIT
•Screw the linking rod by putting a drop of LOCTITE 222 threadlocker on the thread.
•Refit the base using the 2 screws H (ref: 7006729).
•Attach the control pin on the linking rod.
•Lock the housing on the base by using the locking screws taking care not to damage the seals
of the base and the control pin.
•Fit the connector depending on whether the actuator is NC or NO onto the base.
5.3 CONNECTING THE AIR SUPPLY TO THE 8693 UNIT
NC assembly
NO
assembly
C
onnector
Designation
1 Supply air
3 Escapement with silencer
2.1 Air outlet to the control valve
2.2 Stopper
28
59
56
Silencer
2.1
2.2
3
1

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5.4 CONNECTING THE POWER SUPPLY REGULATOR OPERATION without 4-20mA
generator)
The signal from a temperature sensor or level, flow, which through with the control box of the valve
that controls it.
•Remove the 4 screws from the electrical connection box using a flat screwdriver and remove
the connection cover.
•Pushing the son through the screw grommet.
•Connect the + 24VDC wire to + 24VDC [16].
•Connect the 24VDC- wire to GND [15].
•Tighten the nut of the screw grommet (torque approx. 1.5 Nm).
•Reinstall the connection cover with the inserted seal and screw crosswise screws of housing
(torque maximum 0.7 Nm.).
Connection cover
Connection terminals

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5.5 SETTING THE VALVE AUTOMATIC OPERATION