Definox DCX3 Operation and maintenance manual

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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 51 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
Layoutmodificationofthespareparts 2 May2000 13/14 R. GABORIT
Modification of the part number 24 3 November 2000 13/14 R. GABORIT
Modif.of the plug ref. forDCX4DN3’’ 7005609was 7007609 4 June2001 14 R.GABORIT
Addcommentre/re-assemblyof theplug 5 October 2001 7 R. GABORIT
Addex. : grease 6 February2002 7 R. GABORIT
Modif ref of o’ring Nr24DN4’’/104 7 October 2002 14 R. GABORIT
Modif ref of o’ring Nr08DN70 &kit seal EPDMDCX3 DN80/100 8 June2007 14/15 R. GABORIT
Update notice 9 October 2009 / G. ANDRE
Add clamp collar tightening torque 10 August 2016 10 G.BEGAUD

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2 SAFET
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
DCX
4
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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Tap each side of the
clamp collar with
a mallet before
tightening
Tap each side of the
clamp collar with
a mallet before
tightening
Clamp collar
tightening
torque: 10 Nm
Clamp collar
tightening
torque: 10 Nm
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: 4025 H1 QUINPLEX by Lubrication Engineers). 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 51
Ref Description Qty
DN25
SMS
DN1’’
US
DN25
DIN
DN32
SMS
DN38
SMS
DN1’’1/2
US
DN40
DIN
DN2’’
US
DN51
SMS
DN50
DIN
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
C
lamp
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 F
DA
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
DN2’’1/2
US
DN63
SMS
DN65
DIN
DN3’’
US
DN76
SMS
DN80
DIN DN4’’ US
DN104
SMS
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 suppor
t 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
Sea
l 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
C
lamp
collar
1-2 7441833 7441837
23
Plug seal f
or 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
-
ri
ng
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
50-51
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
seefollowingchapter
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 DN50 DIN DN65 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 DN50 DIN DN65 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 DN50 DIN DN65 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