Definox DCX3 User manual

MAINTENANCE MANUAL
NM-288 index 01 Page 1/19 October 2023
SHUT-OFF VALVE DCX3 CLEAN FLUSH
www.definox.com

MAINTENANCE MANUAL
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TABLE OF CONTENTS
1 CHANGE MANAGEMENT 3
2 SAFETY 4
2.1 IMPORTANT INFORMATION 4
2.2 GENERAL INFORMATIONS 4
3 INTRODUCTION 5
3.1 DISASSEMBLING THE VALVE (remove the body, actuator and section) 5
3.2 DISASSEMBLING THE ACTUATOR (changing the inner gaskets) 5
3.2.1 Safety devices 6
4 VALVE DISASSEMBLING 7
4.1 DISASSEMBLING THE SIGNALING BLOCK 7
4.2 DISASSEMBLING THE COLLAR CLAMPS OF THE DCX3 CLEAN FLUSH VALVE 8
4.3 DISMANTLING THE DCX3 CLEAN FLUSH SECTION 9
4.4 DISASSEMBLING THE ACTUATOR 9
4.4.1 Disassembling the accessories 9
4.4.2 Disassembling the internal parts of the actuator 10
5 CHANGING THE SEALS AND REASSEMBLING 11
5.1 INTRODUCTION 11
5.2 ASSEMBLING THE ACTUATOR 11
5.3 REASSEMBLING THE DCX3 CLEAN FLUSH VALVE 12
6 SPARE PARTS 13
6.1 DCX3 CLEAN FLUSH ACTUATOR 13
6.2 DCX3 CLEAN FLUSH VALVE 14
6.3 SPARE PARTS LIST DCX3 AUTOMATIC CLEAN FLUSH DN25 SMS 15
6.4 LIST OF ACTUATORS FOR DCX AUTOMATIC SEAT VALVE 16
6.5 DETAILS OF SEAL KITS FOR DCX3 VALVES 16
6.5.1 Seal kits NBR forDCX3 actuator standard & diaphragm: 17
6.5.2 Process seal kit EPDM DCX3 Clean Flush: 17
6.5.3 Process seal kit FKM DCX3 Clean Flush: 17
6.6 Greases reference 18

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1 CHANGE MANAGEMENT
MODIFICATIONS
INDEX
DATE
PAGES
BY
Newedition
1
October 2023
/
G.BEGAUD

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DANGER!
2 SAFETY
2.1 IMPORTANT INFORMATION
Always read the maintenance manual before manipulating the valve
Failure to observe these instructions can result in serious bodily injury or loss of life.
This can result in less serious injuries or damage to the equipment.
Electricity can result in serious bodily injury or loss of life.
This can result in less serious injuries or damage to the equipment.
Risk of burns.
2.2 GENERAL INFORMATIONS
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 actuator seals and valve seals has been defined in
accordance with their nature and regulations and according to their use (see § 6.6).
NOTE
!
DANGER!
CAUTION!
DANGER!
CAUTION!

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MAINTENANCE INSTRUCTIONS DCX3 shut-off valve CLEAN FLUSH
3 INTRODUCTION
The disassembly of a DCX3 Clean Flush shut-off valve is divided into 2 distinct steps:
3.1 DISASSEMBLING THE VALVE (remove the body, actuator and section)
This operation allows access to the isolating gaskets (Change gaskets, see section 6.6 for
lubrication) and to remove the actuator.
It is simple and can be carried out on site, as it presents no difficulties.
This is the case in most maintenance operations on this type of valve.
3.2 DISASSEMBLING THE ACTUATOR (changing the inner gaskets)
ATTENTION: This operation must be carried out with suitable tools and with the necessary
precautions (SPRING UNDER TENSION)
To change a valve from NC to NO or DE and vice versa, see "Modification of
configuration".
Note: After any maintenance work on DEFINOX products, it is imperative to check the
proper functioning of the equipment concerned: Sealing, pressure, etc.
DANGER!
NOTE
!

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3.2.1 Safety devices
For the maintenance of NC and NO actuators, we offer maintenance kits on request, which
prevent unintentional operation of the valve when the actuator is supplied with air.
DCX3 NC (rod out)
The 7082850-kit containing the following tools is available:
•7814986 Maintenance tools for NC actuator DN25-40
•7814972 Maintenance tools for NC actuator DN51-76
•7814987 Maintenance tools for NC actuator DN80-104
•7814976 Maintenance tools for NO actuator DN25-150
DN
Reference
DN51
7814972
RISKS
When changing the gaskets: Risk
of fingers being pinched between the
actuator rod and the top of the joint
plate
SOLUTIONS
Maintenance tools for NC actuator
Safety device
DANGER!

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4 VALVE DISASSEMBLING
If the valve is fitted with a signalling box, it may be necessary for disassembly to first
separate the signalling assembly from the actuator.
4.1 DISASSEMBLING THE SIGNALING BLOCK
Disassembling without disconnection
CAUTION: Before starting any work on the box, it is important to ensure that the
air supply is closed and that the circuit is purged.
Disassembling with disconnection
CAUTION: 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.
To assembly or disassembly of the control top, refer to maintenance notice:
CAUTION!
CAUTION!
Sorio® box
Maintenance notice
NM-275

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4.2 DISASSEMBLING THE COLLAR CLAMPS OF THE DCX3 CLEAN FLUSH VALVE
•Supply air to the NC actuator, to relieve the lower collar clamp from the compression
force of the spring.
•If a signalling unit is installed on the valve, use the air circuit of the unit to move the
valve in the open position.
•Disassemble the collar clamp [05].
•Cut the air to the pneumatic actuator (the valve returns to the closed position).
•Remove the assembly section (pneumatic actuator) [A] from the DCX3 Clean Flush
body [01] or [02].
•Dismantle the collar clamp [05 bis], remove the flange [14] and the removable plate [13].
•Remove the O-rings [11] and [12] (for replacement if necessary).
14
05 bis
11
13
12
Air supply
05
01
A

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4.3 DISMANTLING THE DCX3 CLEAN FLUSH SECTION
•Unscrew the leakage extension [07].
•Unscrew the diaphragm valve [03] by hand, then remove the intermediate piece [06] and
the gasket plate [08].
•Unscrew the M12 insert valve [04] using the two operating plates located on it and on
the actuator rod.
4.4 DISASSEMBLING THE ACTUATOR
4.4.1 Disassembling the accessories
Remove the air connector [28], the pierced plug [29] and the plastic plugs [30] as well as
the hexagonal screw [32] and washer [31].
07
03
06
08
Operating
elements
Operating
elements
04
29
31
30
32
28
30

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4.4.2 Disassembling the internal parts of the actuator
ATTENTION:This operation is dangerous if the tools are not suitable. We recommend the
use of a hydraulic press or tools as shown in the diagram below (when using the tools,
account for a spring relaxation stroke of 100 mm)
With the actuator placed vertically:
•Push in the lantern [18] to release the ring [20].
•Remove the ring [20] from its groove with a small screwdriver.
•Release the pressure to let the lantern rise.
•Remove the lantern [18] with its gasket [21].
•Remove the shim [16], the rod/piston [19] and the springs [23 and 24] from the actuator
barrel.
DANGER!
100 mm reserve
for the spring
decompression
21
20
19
23
24
18
F
16

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5 CHANGING THE SEALS AND REASSEMBLING
5.1 INTRODUCTION
The components of our valves are listed and marked in these instructions. You can find
there the information you need to order spare parts.
5.2 ASSEMBLING THE ACTUATOR
WARNING: When assembling the actuator for the DCX3 Clean Flush, do not forget to
insert the shim [16].
N.B.: For your safety, make sure that the ring is correctly positioned in its groove. If the
ring is damaged or deformed, it must be replaced.
This is the reverse of disassembling. However, it is necessary to consider the following
remarks:
•A guide pin centred on the actuator rod ensures that the piston is centred in the barrel. It
also prevents the piston from popping if the springs slip askew during compression.
•Before reassembling the parts, provide the assembly with a suitable grease (Food grade
grease, resistant to water and temperature → Example for info: 4025 H1 QUINPLEX
from Lubrication Engineers, see § 6.6). Ensure that the greases used are compatible
with the elastomer seals.
•Do not damage the seals on the edges of the parts.
•Take care not to damage the lantern gasket [21] when assembling the lantern in the
press.
•Make sure the ring [20] is correctly positioned in the groove of the barrel before
releasing the pressure.
•Operate the actuator before continuing with the assembly.
Guide pin number
DN
Actuator
diameter
References
51
Ø 114
7300454
CAUTION!
Guide pin (ATTENTION Beware of protruding pin during re-assembly)
Actuator
diameter
20
21
F
16
NOTE!

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5.3 REASSEMBLING THE DCX3 CLEAN FLUSH VALVE
This is the reverse of disassembling. The following advice should be followed:
•Screw the diaphragm valve onto the M12 valve insert as far as it will go.
•We recommend using a medium threadlocker glue to secure the M12 valve insert
when reassembling it on the actuator, and to retighten the M12 valve insert on the
valves after an initial temperature run.
•Remember to supply air to the actuator before tightening the collar clamps.
•Before the final connections to the network, check the normal working of the valve. If
you encounter any difficulties in carrying out the operations described above, please do
not hesitate to contact us.
•We are also at your disposal for the maintenance of your valves in our workshops or on
site.
Mallet taps on each
side of the collar
clamp before
tightening
Mallet taps on each
side of the collar
clamp before
tightening
Tightening torque
for collar clamps
according to
diameter: see table
Tightening torque
for collar clamps
according to
diameter: see table
Mallet taps on each
side of the collar
clamp before
tightening
Mallet taps on each
side of the collar
clamp before
tightening
Tightening torque
for collar clamps
according to
diameter: see table
Tightening torque
for collar clamps
according to
diameter: see table
DN
Tightening torque for valve insert
Collar clamps tightening torque
DN 51
25 Nm
6 Nm
Tightening torque for valve insert on actuator
depending on diameter: see table
Diaphragm mounting
direction
Thread lock on valve
insert thread

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6 SPARE PARTS
6.1 DCX3 CLEAN FLUSH ACTUATOR
17
24
23
16
25
19
27
Seal kit family: A1
28
27
20
21
26
22
18
26
31
29
30
32

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6.2 DCX3 CLEAN FLUSH VALVE
01
08
17
07
09
10
06
04
03
05
11
05 bis
13
12
14
or
02
Seal kit family: B1 or C1
(Depending on material grade)
DCX3

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6.3 SPARE PARTS LIST DCX3 AUTOMATIC CLEAN FLUSH DN25 SMS
Rp
Description
Nb
DN25 SMS
01
DCX3 Clean Flush L-shaped body
1
7304503
02
DCX3 Clean Flush T-shaped body
1
7304504
03
DCX3 Full Diaphragm Valve
1
7304295
04
M12 insert Full Diaphragm valve
1
7303666
05
Collar clamp
1
7441832
05 bis
Collar clamp
1
7441832
06
Intermediate piece DCX3 Full Diaphragm
1
7303754
07
Leakage collector extension
1
7009107
08
Gasket holder plate DCX3 diaphragm
1
7301534
09
Segment of Gasket holder plate with
diaphragm
1
7009962
10
Gasket holder plate O-ring EPDM
1
7006038
10
Gasket holder plate O-ring FKM
1
7006128
11
Body / plate O-ring EPDM
1
7381009
11
Body / plate O-ring FKM
1
7381010
12
Plate / flange O-ring EPDM
1
7006139
12
Plate / flange O-ring FKM
1
7006124
13
Unperforated removable plate
1
7304507
14
Flange Clamp
1
7304509
15
Transport flange
1
7304510
16
Actuator wedge Clean Flush
1
7304505
17
Actuator DCX3 standard & diaphragm
1
7100301
18
DCX3 standard lantern
1
7301471
19
DCX3/4 piston/rod assembly
1
7005511
20
Stainless steel ring
1
7380157
21
Lantern O-ring NBR
1
7380160
22
Piston O-ring NBR
1
7380161
23
Standard actuator spring (Large)
1
7007797
24
Standard actuator spring (Small)
1
7007796
25
DCX3 actuator barrel
1
7005512
26
Lantern & barrel O-ring seal NBR
2
7380152
27
Segment of lantern, barrel and Gasket
holder plate
2
7009972
28
Adjustable male elbow
1
7010116
29
Pierced plastic plug
1
7002496
30
SKIFFY plug
2
7009954
31
Actuator rod washer
1
7006797
32
Actuator rod TH screw
1
7006814

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6.4 LIST OF ACTUATORS FOR DCX3 AUTOMATIC SHUT-OFF VALVE
Rp
Description
Nb
DN51
17
Actuator DCX3 standard&diaphragm
1
7100301
6.5 DETAILS OF SEAL KITS FOR DCX3 VALVES
DESCRIPTION
DN 25 SMS
See detail kit
A
Next chapter
1
ActuatorsealkitDCX3standard& diaphragm
(DN51Actuator)
7070601
See detail kit
B
Next chapter
1
Processsealkit EPDM DCX3CleanFlush
7072384
2
Processsealkit FKM DCX3CleanFlush
7072401

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6.5.1 Seal kits NBR for DCX3 actuator standard & diaphragm :
A1
Diameter
DN51 SMS
Pouch N°
7070601
Rep
Description
Nb
Seal reference
21
Lantern O-ring NBR
1
7380160
22
Piston O-ring NBR
1
7380161
26
O-ringof lanternandactuatorbarrel
NBR
2
7380152
27
Lanternand actuatorbarrelsegment
2
7009972
6.5.2 Process seal kit EPDM DCX3 Clean Flush :
B1
Diameter
DN25 SMS
Pouch N°
7072384
Rep
Description
Nb.
Seal reference
03
DCX3Full Diaphragm Valve
1
7304295
09
Gasketholderplatesegment
1
7009962
10
Gasket holder plateO-ring EPDM
1
7006038
11
Body/ plateO-ring EPDM
1
7381009
12
Plate /flangeO-ring EPDM
1
7006139
6.5.3 Process seal kit FKM DCX3 Clean Flush :
B2
Diameter
DN25 SMS
Pouch N°
7072401
Rep
Description
Nb.
Seal reference
03
DCX3Full Diaphragm Valve
1
7304295
09
Gasketholderplatesegment
1
7009962
10
Gasket holder plateO-ring FKM
1
7006128
11
Body/ plateO-ring FKM
1
7381010
12
Plate /flangeO-ring FKM
1
7006124

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6.6 Greases reference
Ref
Description
Greaseforactuatorseals
7010662
Greasecartridge400 g
(4025H1QUINPLEX)
Greaseforvalveseals
7030668
Greasecartridge500 g
(KluberParaliqGTE 703, NFS H1,21 CRF§ 178.3570)

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www.definox.com
[e-mail]
FRANCE
DEFINOX SAS
3 Rue des Papetiers - Z.A.C. de Tabari 2
44190 CLISSON - France
Phone: [phone] Fax: [phone]
USA
DEFINOX Inc
16720 W. Victor Road
New Berlin –WISCONSIN 53151 –USA
Phone: [phone] - Fax: [phone]
CHINA
DEFINOX Beijing Stainless Steel Equipment Ltd
No 18 Anningzhuang East Road –HAIDIAN District
BEIJING 100085 –CHINA
Phone: [phone] - Fax: [phone]
The technical characteristics of the products in this document are given as an indication and can be modified according to
technological developments.
The photographs, drawings and diagrams in this document are not contractual.
This document is our property; it cannot be copied, reproduced, modified, or translated without our express authorization.
DEFINOX is a registered trademark.