handtmann 75100 User manual

Operating Manual Double Seal Valve DDV
(Type 75100 / 75200)
BA 075100.00 EN

Operating Manual
Double Seal Valve
75100 / 75200
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Overview Page Page
Table of Contents 2
1. General 3 Technical Data 9
Proper Application 3 Valve Housing Forms 9
Incorrect Application Misuse 3 5. Disassembly and Assembly 10
The User's Duty to Exercise Diligence 3 Safety Instructions and Warning Notices 10
2. Safety Information 4 Disassembly and Assembly Instructions 12
Symbols 4 6. Inspection and Maintenance 17
Safety Instructions 5 General Information 17
3. Delivery and Performance, Storage 6 CIP cleaning 18
4. Function and Operation 7 Spare Parts List 18
Valve Description 7 Troubleshooting 19
Valve Operation 8
Safekeeping and Completeness
The operating manual is part of the valve delivery package and must be available to authorised personnel at all times.
It is impermissible to delete chapters from this manual. If the operating manual or pages thereof are missing,
they must be replaced immediately.
Updating Service
This documentation is not subject to the updating service of Albert Handtmann Armaturenfabrik GmbH & Co. KG.
Amendments to this document may be carried out without prior notification.
Copyright
This documentation contains copyrighted information. It should only be used
in connection with the valve application.
Manufacturer
Albert Handtmann Armaturenfabrik GmbH & Co. KG
Arthur-Handtmann-Str. 11; 88400 Biberach, Germany
Tel.: [phone]; Fax: [phone]
E-mail: [email protected]
Operating manual edition
C 05/2011

Operating Manual
Double Seal Valve
75100 / 75200
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1. General
This operating manual must be read and observed by everyone involved with the installation, commissioning,
operation and maintenance of the double seal valve.
This operating manual applies to the following valve versions:
Types Equipment
75100 DDV valve with single-compartment ball housing for installation in a pipeline
75200 DDV valve with double-compartment ball housing for installation in a double pipe
system. Valve equipped with lower and upper balancer
Proper Application
The double seal valve is used in the food and beverage industry and the
pharmaceutical and chemical industry.
The valve is used for the safe separation of two different media and is closed in its normal state.
The valve may be used for the intended purpose only. Please pay attention to
the specified pressure and temperature range, the flow media and the installation situation.
Applicable and generally recognised safety rules as well as the operating manual instructions must be
followed during assembly and disassembly, in operation and during maintenance.
The instructions in the operating manual must be followed without exception.
Foreseeable Misuse
The following are examples of misuse:
Generally recognised safety guidelines are not observed during
installation, operation, assembly and maintenance.
The application of operating conditions and media that deviate from those specified in the operating manual.
Independent modifications or changes to the valve are carried out that restrict safety or functionality.
The double seal valve is operated in a not fully functional state.
The User's Duty to Exercise Diligence
The user must especially ensure that:
The valves are operated according to their intended purpose and are in a fully functional state.
The statutory requirements for operation, assembly and maintenance are observed.
Installation and maintenance of the valves is carried out correctly by trained technical staff.
The personnel responsible for the operation and maintenance is aware of and follows the operating manual.
The safety and warning instructions on the device are not removed and remain legible.

Operating Manual
Double Seal Valve
75100 / 75200
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2. Safety Information
2.1 Symbols
Risk of injuries!
Indicates an immediate hazardous situation!
Non-observance may result in death or serious injury.
Caution – danger zone warning!
Indicates a potentially hazardous situation!
Non-observance may result in minor to moderate injury.
Functional impairment or material damage!
Indicates a possible functional impairment or material damage.
Note
Important additional information, tips and recommendations.
2.2 Safety Instructions
Note
The following safety information must be considered as an addition to the relevant
applicable national accident prevention requirements and laws. Please pay attention
to the respective rules and regulations in other countries.
Basic safety advice
Conditions for problem-free functionality of the armature / components:
Proper transport and storage
Installation and commissioning by trained technical staff
Operation and use according to this operating manual
Proper maintenance

Operating Manual
Double Seal Valve
75100 / 75200
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Danger – endangerment caused by product-specific and process-specific
conditions!
Disassembling the valve from the piping
system without relieving the system
pressure first may result in burns,
scalding or chemical burns.
If the valve in a system is operated with
acidic or alkaline media, your hands and
fingers may suffer chemical burns when
disassembling the valve.
If the valve in a piping system is
operated with hot media, the surface
temperature of the valve can also reach
this value.
Never place your hand inside the valve
housing when the compressed air
supply is connected.
The valve weighs several kilograms.
The valve contains pretensioned
pressure springs. Personal injuries
may occur during installation.
oMake sure that the piping system
pressure has been relieved.
oMake sure that the piping system
has been rinsed
and emptied.
oMake sure that the piping system
has cooled to a value below 50°C.
oMake sure that the compressed air
supply has been disconnected.
oSecure the valve against slipping
and falling during transportation.
oMake sure that the pressure spring
is secured.
Caution – danger zone – Malfunction due to incorrect handling!
The valve must be switched off in the case
of noticeable malfunctions.
Solve faults immediately.
If the valve is not checked or serviced at
regular intervals, it may not work properly.
Check and maintain
valves regularly.
The valve may not work any longer or
malfunction considerably if faulty or non-
specified parts are installed on the valve.
Only use parts approved by the
manufacturer.
The range of application of the valve is
intended for specific operating states
(pressure, temperature and media).
The valve’s function can be disturbed greatly
by different operating conditions.
Make sure of proper utilisation.

Operating Manual
Double Seal Valve
75100 / 75200
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3. Delivery and Performance, Storage
Check the information on the delivery note for correctness and check the delivery for completeness.
Later complaints will not be accepted.
Conduct a visual inspection for transport damage. The forwarding agent must be informed of any visible
damages immediately (comment on the waybill).
Claims due to transport damage not visible right away must be made to the forwarding agent within a week.
Always use suitable lifting gear to unload, transport and store products
Store the delivery in dry rooms and, if possible, in the original packaging to protect it against external
factors. (Temperature 0-40°C, air humidity < 60°).
Outdoor storage is not permitted!

Operating Manual
Double Seal Valve
75100 / 75200
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4. Function and Operation
4.1 Valve Description
Double seal valves separate different media
from each other safely. A leakage radial groove
in the valve disk prevents possible mixing.
The valve types 75100 / 75200 are characterised by:
a closed valve design
solid single-compartment or double-compartment
ball housing
valve disk with doubled seat sealing
safety against leakages
leakage radial groove with leakage valve
leakage chamber rinsing for optional rinsing valve
safe shut-off function and media separation
low-loss switching process
1 Valve actuator
2 Valve rod
3 Housing bushing (upper)
4 Housing
5 Housing bushing (lower)
6 Valve disk with leakage radial groove
7 Leakage and rinsing valve
8 Housing clips
10 Seat sealings
11 Valve piston seals
12 Housing seals
13 O-ring seal
14 Profile seal (leakage, rinsing valve)
Type 75200
10
11
11
12
12
13
14
3
2
4
8
7
6
5
8
1

Operating Manual
Double Seal Valve
75100 / 75200
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4.2 Valve Operation
Switching function – Production
Controlled together via main valve actuator:
- DDV in basic position "CLOSED"
Doubled seat sealing active, leakage valve opened.
- DDV is opened
The double seal valve is controlled and opened with compressed air.
Leakage valve is closed at the same time.
- DDV is closed
The double seal valve is closed.
The leakage valve is opened at the same time.
Switching function – Leakage chamber cleaning (CIP)
Individual control of leakage valve and main drive:
- DDV in basic position "CLOSED"
The leakage valve (and rinsing valve) are controlled and opened with compressed air.
The leakage radial groove is rinsed / cleaned.
The valves are closed again.
Controlled together via main valve actuator:
- DDV in basic position "CLOSED"
The leakage valve (and rinsing valve) are opened.
The leakage radial groove can be rinsed / cleaned via the rinsing valve
(external CIP valve opened)
- DDV is opened
The double seal valve is controlled and opened with compressed air.
The leakage valve (and rinsing valve) are closed at the same time.
A small leak may occur during the opening process.
- DDV is closed
The double seal valve is closed.
The leakage valve (and rinsing valve) are opened at the same time.
A small leak may occur during the opening process.

Operating Manual
Double Seal Valve
75100 / 75200
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4.3 Technical Data
Product range
Materials Stainless steel 1.4404
Seals EPDM, FDA proof
Surface (Ra) ≤0.8 µm
Nominal sizes DN 40, 50, 65, 80, 100
Other parts
Materials Stainless steel 1.4301
Surface Ground, matt
Production / CIP
Flow media Liquids and gases, (non toxic, less aggressive)
Operating pressure (type 75200) 10 bar; for all DN nominal sizes
Operating pressure (type 75100) 8.0, 6.5, 5.0, 3.0, 2.0 bar; for DN 40, 50, 65, 80, 100
Operating temperature 0 - 95°C / 140°C
Control air (for actuator) 6 - 8 bar, 6/4
75100 75200 DN
A
[mm]
B
[mm]
C
[mm]
D
[mm]
E
[mm]
Lift
[mm]
40 90 62 352 38 41 30
50 100 74 365 50 47 36
65 115 90 400 66 55 48
80 130 111 400 81 69 48
100 140 130 410 100 79 48
4.4 Valve Housing Executions
The double seal valve is available with different standard housing designs (2-4 connections).
751..
752..
No. ..01 ..02 No. ..01 ..02 ..03 ..04

Operating Manual
Double Seal Valve
75100 / 75200
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5. Disassembly / Assembly and Maintenance
5.1 Safety Instructions and Warning Notices
Caution – danger zone warning!
Please pay attention to the following prior to installation and commissioning:
• Check the valve for visible external and internal damage.
• Check the valve housing inside for residues.
• Check the current system status (pressure, temperature, medium).
Please pay attention to the following if malfunctions occur and prior to
disassembly:
• The valve must be switched off and secured against re-use in the case of
malfunctions (disconnect the power and air supply).
• Check the current system status (pressure, temperature, medium).
Risk of injuries!
Risk of crushing!
During transportation and assembly / disassembly there is a risk of finger, hand
and foot injuries.
Never place your hand inside the valve housing when the compressed air
supply is connected. When working on the valve, make sure accidental opening
and closing of the valve is prevented.
Personal injuries!
The valve contains pretensioned pressure springs. When opening the valve, the
upper part of the housing can suddenly spring open. The pressure springs must
be mechanically blocked in advance or, if possible, the valve should be controlled
pneumatically.
Risk of burns!
If the valve is integrated in a piping system in which the media can reach a
temperature of more than 50°C, the surface temperature of the valve can also
reach this value.
Risk of scalding, chemical burns!
If the valve is integrated in a piping system that has not been fully emptied or is
still pressurised, there is a risk of scalding and other personal injuries.

Operating Manual
Double Seal Valve
75100 / 75200
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Caution – functional impairment or material damage!
Installation instructions:
• Valves are installed in the piping system upright and free of tension.
• Valves must be dismantled in advance and all seals in the valve housing for
welding in removed.
• The pipe ends to be welded should be sawn off flush and at right-angles
and deburred.
• The housing is then welded into the piping system free of tension.
• Remove welding residue from the piping system.
• The welding work (TIG, welding gas) should only be carried out by qualified
welders (EN 287-1).
• There must be sufficient free space around the installed valve for assembly
and maintenance tasks later on.
Caution – functional impairment or material damage!
Assembly instructions:
• Only disassemble valves after the pressure spring has been mechanically
blocked.
• Do not damage the valve insert, sliding surfaces or sealing surfaces.
Only use suitable tools and tensioning devices.
• Only use suitable and approved spare parts from the manufacturer.
• Bolts, slightly grease threads. Tighten parts evenly.
Caution – functional impairment or material damage!
Seal change:
• Use a suitable tool (dig hook) to remove the seals.
• The sealing ring groove should be cleaned thoroughly before installing the
new seals.
• Slightly grease the seals (only use grease approved for the field of food
processing).
• Insert seals evenly into the sealing ring groove.

Operating Manual
Double Seal Valve
75100 / 75200
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5.2 Disassembly Instructions – Main Valve
1. Loosen the hexagon socket screws M8 on the
upper housing clip (3).
2. Remove the housing clip and pull the
complete valve inset upwards out of the
housing.
3. Loosen the four hexagon socket screws M8
(2) between the actuator and the housing
bushing.
4. Remove the locking ring (1) at the upper end
of the valve rod.
Repeated lifting can loosen a tensioned
locking ring.
5. Pull the valve rod with the housing bushing out
of the actuator.
6. Pull the housing bushing (4) upwards out of
the valve rod.
7. Hold the valve rod with the open-ended
spanner (5) SW17 and unscrew the nut (9)
anti-clockwise (spanner socket 14 mm).
8. Dismantle valve rods, seat sealings (10) can
be changed.
When removing the sealings, ensure that no
damage occurs to the installation spaces.
10
10
1
2
3
4
9
5

Operating Manual
Double Seal Valve
75100 / 75200
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5.3 Assembly Instructions – Main Valve
12. The guide bush (15) can be pressed into the
housing bushing with a press or vice.
Insert a suitable bolt to ensure that the
installation space is correct and to avoid
damage.
9. Dismantle the valve piston seals (11) and housing
seals (12) in the upper and lower housing bushings.
(Possible manually – without tools)
10. Dismantle O-ring (13)
(on valves with rinsing port)
11. Remove guide bush (15) with a dismantling tool or a
suitable bolt.
The guide bush requires no maintenance and only needs
to be replaced if damaged or in case of wear/play.
13. The housing seals (12) and valve piston seals (11)
can be pressed into the sealing groove of the
housing bushing by hand.
Insert the seals in the groove centrally.
14. Assemble the valve rod from the individual parts and
with the seals (10), ensuring the correct position of
the leakage disk (8).
15. Turn the valve rod tight by hand clockwise,
press the seals into the seat equally.
16. Brace the valve rod completely at positions (5)
and (9) – metallic stop, (open-ended spanner SW17,
spanner socket 14 mm)
Valves without a lower balancer have a
screwing key area for a special spanner.
11
12
15
Piston seal Housing seal
Bolt
Do not damage surface
13
9
5
8

Operating Manual
Double Seal Valve
75100 / 75200
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17. Grease the valve rod with assembly grease, than
push the housing bushing (4) on to the valve rod as
far as it will go.
18. Insert the valve rod in the actuator. Screw the
actuator and valve rod together with the 4 hexagon
socket screws M8 (SW13).
Assemble the locking ring (1) on the upper end of
the valve rod (lower groove).
19. Grease the seat sealings and housing seals,
insert the complete valve inset downwards into the
housing.
Install the valve insert in such a way that the gap
between the housing and housing bushing (clamp
connection) is visible.
20. Position housing clip between housing and housing
bushing, insert both hexagon socket screws M8 of
the housing clip and tighten.
4
1

Operating Manual
Double Seal Valve
75100 / 75200
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5.4 Disassembly/Assembly Instructions – Leakage Valve
1. For the disassembly:
remove the screws and leakage valve from the main
valve housing.
Remove adapter plate sidewards.
(Rinsing valve as an option)
3. Release the pressure ring (24) and pull out the
piston (22) with the air connection lid (20).
4. Pull the profile seal (25) forwards out of the housing
body (21).
(The profile seal can also be in the hole in the main
housing.)
5. Remove both O-rings (26, 27) from the piston (22).
Check parts for damage and replace as necessary.
Replace the seal.
6. For the assembly:
insert the O-rings (26, 27) into the piston groove of
the piston (22). Push the pressure spring (24) onto
the piston.
7. Connect all the parts (20-27) and press them
together by hand or with an auxiliary tool (e.g., vice).
Do not damage the seal surfaces.
8. Insert the snap ring in such a way as the snap ring
gap is aligned with respect to the disassembly hole.
9. Insert the profile seal (25) in the housing body.
10. Press the adapter plate into the valve groove.
11. Insert the leakage valve in the main housing and
secure with the screws.
2. Connect the air connection lid (20) and housing
body (21) by hand or with the auxiliary tool (e.g.,
vice).
Do not damage the seal surfaces.
Insert a pointed object (e.g., scriber) carefully into
the hole to press out the snap ring (23).
23
26 24
22
27
26 24 25
20 22 21
27
Spring ring gap
Valve
groove

Operating Manual
Double Seal Valve
75100 / 75200
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5.5 Disassembly/Assembly Instructions – Valve Actuator
1. Only clamp the actuator in the mounting tool.
2. Insert the upper housing lid (1).
3. Lever out the locking ring (2) with screwdriver
(use lateral hole for assembly help).
4. Remove actuator from mounting tool.
5. Pull the complete spring assembly – housing lid (1),
pressure spring (9), piston (10) – out of the actuator
case.
6. Clamp the spring assembly in the mounting tool and
press together.
7. Unscrew the stuck-in hexagon socket screws (3).
8. Release and dismantle spring assembly.
9. Remove the seals (4+5) from the housing lid.
10. Clean the sealing ring grooves and new seals.
Ensure that the sealing ring
does not become twisted.
Ensure that the O-rings lie flush in the groove and
do not create a bead.
11. The seal (6) on the valve rod and the seals (7+8) on
the actuator piston are replaced in the same way.
1
2
9
10
3
3
5
4
8
6
7

Operating Manual
Double Seal Valve
75100 / 75200
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6. Inspection and Maintenance
6.1 General Information
Risk of injuries!
Safety instructions and warning notices – see Chap. 2.2 / 5.1
Caution – functional impairment or material damage!
Inspection and maintenance intervals:
Visual and acoustic inspections must be carried out every 4 weeks.
>> Check electrical and pneumatic supplies, switching function, leaks
To ensure that the valve is ready for operation and functionally reliable, it should
be checked every year within the scope of the general internal maintenance
procedure.
If protection devices were attached for maintenance or supply and exhaust lines to
the valve blocked, the protection devices / line blockings must be disassembled.
Ensure that a function test is always performed on the valve following
maintenance work.
Function check:
The valve must be subjected to a function test prior to installation and after maintenance work. Firstly, the valve
is positioned vertically and secured against toppling. It is then subjected to compressed air (6 bar). Correct
function is recognised by a continuous OPEN-CLOSE movement of the valve rod.
Maintenance intervals
The maintenance intervals are geared to the operating conditions, such as switching frequency, kind of media,
process temperature, temperature change, process pressure, etc. For this reason the maintenance intervals
should be determined by the user.
It is recommended, however, that the seals always be checked every 6 months if they are operated at high
switching frequencies and high media temperatures. A full inspection should be carried out every 12 months.

Operating Manual
Double Seal Valve
75100 / 75200
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6.2 CIP cleaning
The double seal valve and the sealing material in the product-affected area are designed for standard CIP
operation. The interior of the valves must be cleaned regularly.
Note
Observe the safety information sheets of the cleaning agent manufacturer!
The cleaning agents must be stored and disposed of under observation
of the applicable safety directives.
Only employ cleaning agents that do are not aggressive to the seals and
stainless steel.
Use clean, chlorine-free water as a diluting agent.
Rinse the systems thoroughly after CIP cleaning.
The following are to be considered as standard conditions:
CIP media on the basis of commercially available caustic-acid components with given chemical resistance
to EPDM sealing material. Consultation should be carried out with the valve manufacturer
for different kinds of media.
Cleaning additives in the concentration range of 2-3%.
Temperatures for cleaning media in the range of 30-75°C or hot water to 95°C.
Pressure range for housing cleaning 2-8 bar.
Flow velocity 2-4 m/s.
Note
Liquids flowing out via the leakage chamber should be guided over the outflow
equipment without any splashes, particularly in valves with rinsing equipment.
6.3 Spare Parts Set
Nominal sizes
Valve type DN 40 DN 50 DN 65 DN 80 DN 100
75100 075100.00040 L 075100.00050 L 075100.00065 L 075100.00080 L 075100.00100 L
75200 075100.00040 L 075100.00050 L 075100.00065 L 075100.00080 L 075100.00100 L

Operating Manual
Double Seal Valve
75100 / 75200
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6.4 Troubleshooting
All faults must be checked and repaired immediately by qualified personnel.
When carrying out the necessary work, keep strictly to the safety information.
Malfunction Possible causes Measures
Valve
does not open
• Valve seat jammed
• Compressed air insufficient
for opening
• Lifting / opening process is
blocked
• Solenoid valve or electrical
control has been disturbed
• Clean valve seat
• Compressed air at least 6 bar, check
the compressed air hose
• Check the mobility of the valve rod
• Check the solenoid valve
Valve
does not close
• Valve rod stuck
• Solid body in the valve seat
• Seal defective
• The actuator spring is blocked
or broken
• Pressure bleeding defective
• Product pressure too high
• Check valve rod and guide bush
Correct alignment errors
• Clean the valve housing and seat
• Replace the seal
• Repair actuator, only use
spare springs from the manufacturer
• Check the solenoid valve
• Check media pressure and adapt as
necessary
Valve moves slowly
or
unevenly
• Guiding stiff
• Valve rod stuck
• Compressed air too low
• Exhaust hole blocked
• Product pressure too high
• Renew guide bushing and grease
sliding components
• Check valve rod and guide bush
Correct alignment errors
• Compressed air minimum 6 bar
• Clean opening
• Check media pressure
Mechanical
noises
• Insufficient greasing • Grease seal and guide elements
Leak from
leakage hole
• Sealing rings defective
• Housing bushing not
watertight
• Connection clips loose
• Replace valve piston seal
• Replace housing seal
• Check the housing bushing
• Check the position of the locking
clamps
and tighten
No electrical signals • Electrical supply
loose or disconnected
• Defective initiators
• Defective solenoid valve
• Check cable and tighten
• Replace initiators
• Replace solenoid valve