Definox VDCI-MC-FC Operation and maintenance manual

MAINTENANCE NOTICE
NM-248 Revision 09 Page 1/33 January 2021
VDCI-MC-FC PFA MIXPROOF VALVE
www.definox.com

MAINTENANCE NOTICE
NM-248 Revision 09 Page 2/33 January 2021
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 DISMANTLING THE SIGNALLING BOX: 5
3.2 SEPARATING THE PNEUMATIC ACTUATOR FROM THE VALVE BODY: 6
3.3 DISASSEMBLY OF VDCI-MC-FC COMPONENTS 8
3.3.1 Dismantling the valves and the seal support plate : 8
3.4 DISASSEMBLY OF THE VDCI-MC PFA TAKE-OFF CYLINDER (ref. 9): (To change the seals if necessary) 10
3.5 DISASSEMBLING THE MAIN PNEUMATIC ACTUATOR 11
3.6 DISASSEMBLING THE LANTERN SUB-ASSEMBLY 12
3.7 DISASSEMBLING THE SHAFT/PISTON SUB-ASSEMBLY 13
3.8 DISASSEMBLING THE LEAKAGE VALVE AND THE WASHING VALVE 14
3.8.1 Disassembling the leakage valve 14
3.8.2 Disassembling the washing valve 15
4 CHANGING THE PLUG SEALS ON THE PLUGS 16
4.1 REMOVING THE SEALS ON THE LOWER PLUG: 16
4.2 DISMANTLING THE PFA SEAL ON THE UPPER PLUG: 17
5 CHANGING SEALS AND REASSEMBLY 18
5.1 INTRODUCTION : 18
5.1.1 REASSEMBLING THE VDCI-MC SHAFT/PISTON ASSEMBLY 18
5.1.2 REASSEMBLING THE VDCI-MC LANTERN ASSEMBLY 19
5.1.3 REASSEMBLING THE VDCI-MC ACTUATOR ASSEMBLY 20
5.1.4 REASSEMBLING THE VALVE ASSEMBLY ON THE VDCI-MC FC PFA BODY 21
6 SPARE PARTS 22
6.1 PARTS FOR THE VDCI-MC PFA BREAKAWAY ACTUATOR SUB-ASSEMBLY (ref. 9) : (seal kits § 6.5.8) 22
6.2 PARTS FOR THE VDCI-MC PFA SP ACTUATOR (ref : 37) : (seal kits § 6.5.9) 23
6.3 PARTS FOR DETECTION LANTERN OPTION : 24
6.4 TABLE OF PARTS FOR VDCI-MC PFA MIXPROOF VALVES 26
6.5 REFERENCES OF SEAL KITS FOR VDCI-MC-FC PFA VALVES 28
6.5.1 PFA seal kits for VDCI-MC-FC PFA valve plugs: 28
6.5.2 EPDM FDA seal kits for VDCI-MC-FC PFA valve plugs: 28
6.5.3 FKM FDA seal kits for VDCI-MC-FC PFA valve plugs: 28
6.5.4 EPDM FDA seal kits for VDCI-MC-FC PFA valve bodies: 29
6.5.5 FKM FDA seal kits for VDCI-MC-FC PFA valve bodies 29
6.5.6 EPDM FDA seal kits for VDCI-MC-FC PFA valve leak and washing valves: 29
6.5.7 FKM FDA seal kits for VDCI-MC-FC PFA valve leakage and washing valves: 29
6.5.8 NBR seal kits for VDCI-MC-FC PFA take-off cylinder (ref. 9) : 30
6.5.9 NBR seal kits for VDCI-MC-FC PFA main actuators : 30
6.6 Reference of greases 31
6.7 References of tool kits for VDCI-MC valves 32

MAINTENANCE NOTICE
NM-248 Revision 09 Page 3/33 January 2021
1 CHANGE MANAGEMENT
For VDCI-MC-PFA DN63-80 actuators.
Use of shaft 7142193 (2) with cam 7142205 (1) for all operators from 05/01 to 05/04.
From 05/05, use of shaft 7142220 (1) with cam 7142222 (1).
CHANGES
INDEX
DATE
PAGE(S)
INITIALS
Modification rep :22
01
February2012
17/18
T.PICOT
Seal 7006124 replace7380826.
02
June2012
17/19
T.PICOT
Modification rep :13 rep:14
03
October2013
6/7/8/9/13/14
T.PICOT
Evolutionupperplugrep :14 andPFAupperplugrep:17
04
March2014
17/18/19
T.PICOT
Add clamp collar tightening torque
05
August 2016
16
G.BEGAUD
Modification of Plug valve wrench A
06
March 2018
10
G.BEGAUD
On DN38-40 modification rep: 10
07
January 2020
18
T.PICOT
Add seal kits for main actuator and take-off cylinder
08
January 2020
9/22
G.BEGAUD
Add of greases recommended for the actuator and the valve
09
January 2021
4/6/18/19/31
G.BEGAUD
Insertion of the old versions of the lower and upper plugs, and
of the disassembly and reassembly of the actuator
/

MAINTENANCE NOTICE
NM-248 Revision 09 Page 4/33 January 2021
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 § 6.6).
DANGER !
CAUTION
DANGER !
CAUTION !
NOTE
!

MAINTENANCE NOTICE
NM-248 Revision 09 Page 5/33 January 2021
VDCI-MC-FC PFA MIXPROOF VALVE
MAINTENANCE NOTICE
3 INTRODUCTION
IMPORTANT: Before carrying out any maintenance work, check with the supervisor that
the installation is stopped and drained (pipes empty and depressurised, pumps stopped,
tanks shut off or empty).
The disassembly of a VDCI-MC-FC PFA mixproof valve breaks down as follows.
First of all, if the valve is equipped with a signaling box, it may be necessary, for
disassembly, to disconnect the signaling assembly from the actuator.
3.1 DISMANTLING THE SIGNALLING BOX:
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.
NOTE: To fit and remove the control top, refer to maintenance notice:
For the previous generations control top, refer to maintenance notice:
•NM-187 for the ACS control top
CAUTION !
CAUTION !
NOTE !
CAUTION
ACS LED
Maintenance notice
NM-259

MAINTENANCE NOTICE
NM-248 Revision 09 Page 6/33 January 2021
3.2 SEPARATING THE PNEUMATIC ACTUATOR FROM THE VALVE BODY:
Remove the body from the valve actuator
•This operation enables access to the isolation seals (Changing the seals, see § 6.6 for
lubrication)andtheremovaloftheaircylinder.
•Thisisa straightforwardprocedure andcanbe performedon-siteas itdoesnotpresentany
particularproblems.
•Thisisthecase inthemajorityofmaintenanceoperationsonthistypeof valve.
Supply air to the main air cylinder to relieve the upper clamp collar of the compression
force from the spring.
IMPORTANT: (Do not place your hands inside the lantern whilst
manipulating the cylinder. Risk of serious injury). See diagram below.
CAUTION
YES
NO





MAINTENANCE NOTICE
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•Supplyairtothemainaircylinder[A]torelievethepressureontheclampcollar[38]fromthe
actuatorspring.
•Disassemblethecamfasteningscrew[10]andthesensingcam[11].
•Disassembletheupperclamp collar[38].
•Cuttheairsupplytothemainaircylinder[37].(The valvereturnstoa closed position).
•Remove theisolation(aircylinder)assembly[A]fromthebodyoftheVDCI.
•Undothescrews[42]and separatethe2half collars [41]tofreethebody[39].
from the welding flange [40].
•RemoveandchangetheO-ringseal[52]if necessary.
A
NEW VERSION
VDCI MC FC
body
assembly
52
40
42
41
10
11
38
37
A
VDCI MC FC
body
assembly
OLD VERSION

MAINTENANCE NOTICE
NM-248 Revision 09 Page 8/33 January 2021
3.3 DISASSEMBLY OF VDCI-MC-FC COMPONENTS
3.3.1 Dismantling the valves and the seal support plate :
OLD VERSION
•Unscrew the index screw [44].
•Unscrew the 2 fixing screws [45].
•Remove the clamp collar [43] of the
lantern.
•Then remove the plugs [46] and [47]
using an open-ended wrench and the
plug holding wrench [83] Actuator side.
NEW VERSION
•Unscrew the index screw [44].
•Unscrew the 2 fixing screws [45].
•Remove the clamp collar [43] of the
lantern.
•Then remove the plugs [46] and [47]
using the tightening wrench [A] and the
plug holding wrench [83] Actuator side.
Diameter
DN 38 to 51
DN 63 to 125
Tightening wrench A
7900016
Plug holding wrench [83]
7142226
Diameter
DN 38 to 125
Plug holding wrench [83]
7142226
44
45
43
A
47
46
83
44
45
43
47
46
83

MAINTENANCE NOTICE
NM-248 Revision 09 Page 9/33 January 2021
•RemoveandreplacethedefectivesealsontheSealSupportPlate[48].
•Scraperseal[51],segment [56],upperform seal[53],bodyseal[54].
54
53
48
56
51

MAINTENANCE NOTICE
NM-248 Revision 09 Page 10/33 January 2021
3.4 DISASSEMBLY OF THE VDCI-MC PFA TAKE-OFF CYLINDER (ref. 9): (To change the seals
if necessary)
See take-off cylinder seal kit VDCI-MC PFA. (See § 6.5.8)
•Remove the screws [1] securing the cover [4].
•Take the takeaway piston [7] out of the cover.
•Remove the seals [2] [6] [8] [5].
2
1
4
7
8
6
5
9

MAINTENANCE NOTICE
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3.5 DISASSEMBLING THE MAIN PNEUMATIC ACTUATOR
For the main actuator seal kits (See § 6.5.9).
•Disassemble the air pipes [3] and [36] from the upper plug supply.
•Position the actuator sub-assembly [37] on the press (see diagram below).
•Ensure that the course of the press is adjusted to dimensions [A] and [B].
•Use a tube [C] to prevent damage to the upper part of the actuator lantern [37].
•Press the springs to release the snap-ring [18].
•Remove the snap-ring [18] from its housing using a screwdriver, then release
the pressure.
•Remove the sub-assembly for the lantern/shaft/piston [34] [27] [26] [30] shaft/main
actuator [12] [23] [21] springs [19] [20] from the actuator body [15].
Diameter
DN 38 to 51
DN 63 to 80
DN 104 to 125
Maximum compression A
(mm)
202
242
307
Minimum expansion B
(mm)
350
360
515
Ø Tube (mm) C
Interior Ø: 78
minimum
Interior Ø: 115
minimum
Interior Ø: 152
minimum
26
C
2
3
36
18
37
34
18
27
30
23
20
12
19
15

MAINTENANCE NOTICE
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3.6 DISASSEMBLING THE LANTERN SUB-ASSEMBLY
•Hold the clamp pin [27] with a drift punch [A] and the drift punch guide [84] held in a
vice.
•Unscrew the breakaway piston nut [26] using a plug valve wrench [82].
•Release the nut [26], the breakaway piston [30] and the clamp pin [27] on the lantern
assembly [34].
Diameter
DN 38 to 80
DN 104 to 125
Plug valve wrench nut [82]
N° 7141988
N° 7141989
Drift punch [A]
Maximum Ø 5 mm
Drift punch guide [84]
N° 7142262
N° 7143285
26
30
34
27
82
A
84

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3.7 DISASSEMBLING THE SHAFT/PISTON SUB-ASSEMBLY
•Release the set screw [22] on the nut [21].
•Unscrew the main piston [23] screw [21] using a plug valve wrench [82] and the holding
wrench [83].
•Release the main piston [23] screw [21] and remove the valve actuator shaft [12].
SHAFT/PISTON DISASSEMBLY TOOLS
Diameter
DN 38 to 80
DN 104 to 125
Plug valve wrench nut [82]
N° 7141988
N° 7141989
Holding wrench [83]
N° 7142226
21
23
12
83
82
22

MAINTENANCE NOTICE
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3.8 DISASSEMBLING THE LEAKAGE VALVE AND THE WASHING VALVE
3.8.1 Disassembling the leakage valve
•Unscrew the leakage valve assembly from the valve body [39].
•Unscrew the seal support [58] using an open-end wrench and remove the seal [59].
•Remove the pneumatic coupling [60] then, using the wrench [A] undo the bottom of
the leakage valve actuator [61].
•Then dismantle the components of the leakage valve assembly.
Diameter
DN 38 to 125
Plug valve wrench [A]
7110296
39
59
58
61
A
60
62
63
64
65
66
67
68
69
70
61
8
71

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NM-248 Revision 09 Page 15/33 January 2021
58
59
39
A
61
62
72
64
65
67
66
68
69
70
61
71
60
3.8.2 Disassembling the washing valve
•Unscrew the washing valve assembly from the valve body [39].
•Remove the bottom of the washing valve actuator [61] with the plug valve wrench
[A].
•Then dismantle the components of the washing valve assembly.
Diameter
DN 38 to 125
Plug valve wrench [A]
7110296

MAINTENANCE NOTICE
NM-248 Revision 09 Page 16/33 January 2021
4 CHANGING THE PLUG SEALS ON THE PLUGS
4.1 REMOVING THE SEALS ON THE LOWER PLUG:
•Take out the lower plug [46] to gain access
to the seals [49] [55] and the ring [57].
IMPORTANT: When re-fitting the PFA
seal [49] be sure to place the bevelled
side correctly on the plug [46].
(See drawing below)
OLD VERSION
49
57
55
46
NEW VERSION
49
57
55
46
CAUTION

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4.2 DISMANTLING THE PFA SEAL ON THE UPPER PLUG:
•IsolatethedamagedPFAseal[50] usinga cuttertakingcarenottomark the bearingsurfaceofthe
plug [47] (protectthestainless-steelsurfaceusingtheedgeofasteelrule oraplasticoff-cut).
•Placethenewseal inanoven165°C(±3%) for30minutes.
IMPORTANT: Do not exceed a maximum of 200°C. If the temperature is too low,
there is a risk that the seal will deform or tear during installation.
•InsertthePFA sealquickly from one sideofthegroove,thenprogressivelypushitinto itshousing.
IMPORTANT: When re-fitting the PFA seal
[17] be sure le côté to place the bevelled
side on the plug [14].
(See drawing below)
CAUTION
50
47
OLD VERSION
NEW VERSION
47
50
CAUTION

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5 CHANGING SEALS AND REASSEMBLY
5.1 INTRODUCTION :
Before reassembling the parts, ensure that the assembly is lubricated with an appropriate
lubricant (water-resistant and temperature-resistant food grade grease).
Example for info : 4025 H1 QUINPLEX from Lubrication Engineers, see § 6.6)
5.1.1 REASSEMBLING THE VDCI-MC SHAFT/PISTON ASSEMBLY
•Remove the torque seals [13] [24] (if a replacement is required, see parts reference at the end of
this notice) and grease the seals with grease (of the type 4025 H1 QUINPLEX by
Lubrication Engineers, see § 6.6)
•Remove the rings [14] and [25] (if a replacement is required, see parts reference at the end of this
notice). Ref.:[25] Assembled only on DN63 to 125.
•After replacing the seals and rings, reassemble the shaft [12] in the main piston [23].
•Tighten the nut [21] using a plug valve wrench nut [82] and the holding wrench [83].
•Then lock the set screw [22].
83
82
22
21
24
25
23
12
13
14

MAINTENANCE NOTICE
NM-248 Revision 09 Page 19/33 January 2021
5.1.2 REASSEMBLING THE VDCI-MC LANTERN ASSEMBLY
•Remove the torque seals [29] [32] [33] [35] (if a replacement is required, see parts reference at
the end of this notice) and grease the seals with grease (of the type 4025 H1 QUINPLEX by
Lubrication Engineers, see § 6.6)
•Remove the rings [31] and [28] (if a replacement is required, see parts reference at the end of this
notice).
•After replacing the seals and rings, position the protector [79] on the thread of the clamp
pin [27].
•Insert the clamp pin [27] in the lantern [34] and the breakaway piston [30].
•Remove the protector [79] to tighten the nut [26] on the thread of the clamp pin [27].
•Use a drift punch [A] and the plug valve wrench [82] to tighten the assembly.
(see table below].
Diameter
DN 38 to 51
DN 63 to 80
DN 104 to 150
Plug protector [79]
N° 7141886
N° 7141887
N° 7141888
Plug valve wrench (nut) [82]
N° 7141988
N° 7141989
Drift punch [A]
Maximum Ø 5 mm
82
A
26
31
30
33
35
34
32
79
28
29
27
31
32

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5.1.3 REASSEMBLING THE VDCI-MC ACTUATOR ASSEMBLY
•Tighten the guides [78] and [80] on the shaft [12] (see table and diagram below).
•Position the spring [19] on the body [15] , reassemble the shaft/piston assembly on
the spring [19] , position in the spring assembly [20] and thread the lantern assembly
on the guide [80] (see diagram below).
•Mount the assembly on the press to position the snap-ring correctly [18] (for press courses
see page 11, idem for disassembly).
•Reassemble the connectors [3] and [36] on the lantern [34]. (check the alignment of the
connectors, see diagram below).
VALVE ACTUATOR ASSEMBLY TOOLS
Diameter
DN 38 to 51
DN 63 to 80
DN 104 to 125
Clamp pin guide [80]
N° 7141889
N° 7141890
N° 7141891
Actuator body guide [78]
N° 7142227
N° 7142228
N° 7141885
3
36
18
34
80
12
20
19
78
15
When reassembling, align the air connection holes