JAUDT DPK GII 6207 Series Quick guide

Translation of the original operating instructions
JAUDT DOUBLE SHUTTLE VALVE
DPK GII 6207…
© BA_DPK_EN_Rev06-2010.docx
Contents
1DESCRIPTION.........................................................................................................2
1.1 VALIDITY OF THIS OPERATING MANUAL ..................................................................4
1.2 IDENTIFICATION POINT..........................................................................................4
1.3 OTHER RELEVANT DOCUMENTS ............................................................................4
1.4 TECHNICAL REQUIREMENTS FOR OPERATION.........................................................4
2SAFETY INSTRUCTIONS.......................................................................................5
2.1 BASIC SAFETY INSTRUCTIONS...............................................................................5
2.2 APPLICATIONS .....................................................................................................6
2.3 NOISE EMISSIONS ................................................................................................6
3TRANSPORT AND STORAGE...............................................................................6
3.1 TRANSPORT ........................................................................................................6
3.2 STORAGE............................................................................................................6
4INSTALLATION, COMMISSIONING, OPERATION...............................................7
4.1 INSTALLATION......................................................................................................7
4.2 COMMISSIONING..................................................................................................8
4.3 OPERATION.........................................................................................................9
5MAINTENANCE.......................................................................................................9
5.1 INSPECTIONS AND SERVICES OF THE JAUDT DOUBLE SHUTTLE VALVE..................10
5.2 DRAG HANDLE ADJUSTMENT...............................................................................11
5.3 REPLACING THE SEALING PLATES........................................................................12
5.4 ADJUSTING AND REPLACING THE GASKETS ..........................................................12
5.5 LUBRICATION.....................................................................................................12
6DRIVES..................................................................................................................12
7SPARE PARTS......................................................................................................13
8TROUBLESHOOTING ..........................................................................................14
9CLEANING ............................................................................................................14
10 DISPOSAL..........................................................................................................14
11 SPECIAL INSTRUCTIONS FOR JAUDT
DPK ATEX DOUBLE SHUTTLE VALVES ........................................................15
12 DECLARATION OF INCORPORATION............................................................17
13 ACCESSORIES..................................................................................................18
JAUDT
Dosiertechnik
Maschinenfabrik
GmbH
Dosing, feeding,
removal, shutting off,
regulating and controlling
Raiffeisenstraße 3-5
D-86167 Augsburg
Tel. [phone]
Fax [phone]
[phone]
[email protected]
www.jaudt.de

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1 Description
JAUDT double shuttle valves (DPK) are used for the infeed and outfeed of dust-like, fine and coarse bulk
goods which are fed to the double shuttle valve in pre-metered volumes.
JAUDT double shuttle valves are suitable for use under filters, separators, cyclones etc, as well as
outfeeding against a slight pressure difference to avoid a continual secondary air flow.
JAUDT double shuttle valves close in a product-tight manner and are robust and low-maintenance.
The dimensions must be designed sufficiently large to avoid product blockages.
Drive mechanisms for JAUDT double shuttle valves:
1. Electromotive actuation
2. Pneumatic actuation
3. Weight actuation
Functionality of electric-motor driven version with cam disc (Figure 1):
The opening and closing movement is controlled via an electric-motor driven cam disc (80). The closing
force is generated through balancing weights (110). The geometry of the cam disc defines and also
guarantees the overlapping of the two sealing discs (30) –that means that both valves are briefly closed
before one of the two sealing discs opens again. This ensures that both sealing discs are never open at the
same time.
The drive system is blockade-proof, as the transmission of power as the sealing disc opens is performed via
a direct-action slip clutch (drag handle). Once the slip clutch has been actuated, a status message can be
set using initiators.
The double shuttle valve can still continue to be operated even after the actuation of the slip clutch, but the
opening angle of the sealing discs diminishes.
The closing movement is also performed in an overload-proof manner thanks to the weight actuation.

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Figure 1: Drawing of electric-motor driven version with cam disc
10
Housing
80
Cam disc
20
Valve handle
110
Weight
30
Sealing disc
140
Roller
40
Thrust piece
270
Limit switch
60
Packing ring
500
Drive unit (gear motor)
70
Gasket ring

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1.1 Validity of this operating manual
This operating manual applies to the JAUDT double shuttle valves with nominal widths of between 200x200
and 600x600 with electric motor-, pneumatic- and weight-actuated drive.
Other sizes available on request.
1.2 Identification point
The identification plate in Figure 3 is fixed to each JAUDT double shuttle valve and identifies the valve. The
model number does not specify the paintwork or accessories.
Figure 2: Identification plate
When making enquiries or placing orders for spare parts, please always quote the order and model
numbers.
1.3 Other relevant documents
The confirmation of order is a part of this operating manual. It contains the following information:
- Model, identical with the model on the identification plate.
- Problem definition; the version of DPK is designed precisely for this problem definition.
-Technical specifications of the DPK and technical specifications of the drive.
Every operating manual is also accompanied by the following documents:
- Dimension sheet, spare parts list and spare parts drawing
- Operating manual with table of lubricants for motors, if supplied with a motor
- The manufacturer’s installation sheet is enclosed for JAUDT double shuttle valves with inductive limit
switches.
- The installation sheet for the 5/2-way valve is enclosed for JAUDT double shuttle valves with
electropneumatic drive.
- Special instructions for JAUDT DPK ATEX double shuttle valves if used as a device under Directive
94/8/EC or if used in potentially explosive atmospheres.
These accompanying documents are part of this operating manual!
1.4 Technical requirements for operation
Fit the drive of the powered JAUDT double shuttle valves with an appropriate safety protective device to
avoid injuries (unless already included in the scope of delivery).
Connect supply voltages:
Refer to the other relevant documents (see chapter 1.2) for the voltage specifications.
Connect compressed air supply:
Electropneumatic drive: 0.7 –0.8 MPa (7 - 8 bar absolute, corresponds to 6 to 7 bar excess pressure),
filtered, free from water and oiled.

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2 Safety instructions
You must make sure that the local health and safety regulations are observed.
JAUDT double shuttle valves (DPK) conform to the very latest state of the art. Nevertheless, personal injury
and material damage can be caused by moving parts or carelessness. We warn you of this through the
corresponding advice. This advice is emphasised by the use of particular symbols.
Danger of death!
This symbol alerts you to a danger that constitutes a risk to personnel from electrical power.
Danger of injury!
This symbol alerts you to a danger that constitutes a risk to personnel.
Danger of material damage!
This symbol alerts you about action that may cause damage to the JAUDT double shuttle
valve.
·
This dot prompts you to carry out a specific action.
The order of these actions must be followed to the letter.
2.1 Basic safety instructions
Installation may only be performed by trained personnel who are familiar with these assembly
instructions. Electrical work may only be carried out by approved trained electricians.
Only use the device for the intended use according to the order and type identification plate!
Note the manufacturer’s specifications for drives and accessories!
For devices to which RL94/9/EC (ATEX) applies, also observe the additional instructions (ATEX
supplement)!
Wear the safety shoes and personal protective equipment specified in your internal plant regulations
when carrying out the relevant work! Observe your operating and work instructions.
For foodstuffs, cosmetics and pharmaceuticals, observe the internal plant regulations for substances,
cleaning and hygiene.
Prior to installation, ensure that the bulk goods system is emptied and protected against inadvertently
being started up.
Use approved lifting tackle and slings with sufficient carrying capacity for installation! In particular,
ensure that drives, accessories, cables and protruding machine parts are protected against damage
during installation.

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2.2 Applications
In their standard version, JAUDT double shuttle valves are suitable for free-flowing substances with a particle
size of between 0.01 mm and 5 mm ; e.g. ash, filter dust, gypsum, lime, sand, cement, de-icing salt.
JAUDT double shuttle valves are not gastight due to the cycle function and due to the metallic sealing in the
valve opening.
Temperatures: -10° C to +80° C in standard version
Extended temperature range from –50°C to 700°C available on request.
Pressure levels: Intake side, max. +250 dPa pressure / max. -500 dPa vacuum
Discharge side, max. -250 dPa vacuum / max. -500 dPa pressure
The usage conditions taken into account in the design are specified in the problem definition!
It is essential that you contact JAUDT if you are planning to use the DPK in any different application
scenario.
We will provide you with expert advice.
2.3 Noise emissions
The noise emission is 85 dB (A).
3 Transport and storage
It must be ensured that the attachments cannot be damaged through exposure to mechanical forces during
transport and storage. Hoses must not be kinked or crushed.
3.1 Transport
Transport the double shuttle valve in an upright position on the outlet flange.
Secure the double shuttle valve properly against vibration and jolting and avoid any damage to the
paintwork by placing suitable elements between the fixing strap and the valve itself.
Secure the double shuttle valve against displacement and protect parts that are particularly exposed, e.g.
drive and accessories.
3.2 Storage
Store the double shuttle valve standing upright on the outlet flange.
Storage temperature 10 °C … 30 °C.
Relative air humidity max. 65%.
Store in a dry and dust-free place.
Protect plastic parts against sunlight.
Do not store in aggressive atmospheres, e.g. atmospheres containing acids or salts.
If storing for longer than 3 months, you must also take the following precautions:
Protect bright parts against corrosion, e.g. with a film of oil.
Seal the double shuttle valve against the ingress of dust.
Operate the double shuttle valve once a year.

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4 Installation, commissioning, operation
4.1 Installation
Installation may only be performed by trained personnel who are familiar with these assembly instructions.
Electrical work may only be carried out by approved trained electricians.
Caution! Danger of death!
Work on the electrics must be carried out by a trained electrician.
The JAUDT double shuttle valves are supplied assembled and ready for use.
4.1.1 Specify installation position
Installation position: vertical.
Do not assemble upside down; please refer to dimension sheet or cover of this operating manual for the
installation position.
4.1.2 Installation instructions
Take particular care with electrically operated double shuttle valves with constantly
moving parts (e.g. cam disc and balancing weights) that they are installed firmly.
This will avoid unnecessary vibrations and the additional noise and strain on the material
that this causes!
Ensure that electrical connection points, type identification plates and inspection points
are easily accessible.
Provide sufficient room for disassembly and servicing!
Clean the flange surfaces.
Align the JAUDT double shuttle valve so that the openings form a passage for the flowing bulk
goods.
Attention! Material damage!
Install the JAUDT double shuttle valve without stresses –otherwise there is a risk of damage
to the material.
Align the mating flanges so that they are plane-parallel.
Use a suitable flange gasket
Tighten the joining elements crossways
Maximum tightening torques:
M8
M10
M12
M16
M20
M24
M30
10 Nm
20 Nm
35 Nm
90 Nm
150 Nm
200 Nm
300 Nm
Earth the device properly if using it in potentially explosive areas and where there is a risk of
electrostatic charging.
Ensure that the device can move freely before commissioning and prevent any obstruction of
operation from dirt or foreign bodies.
After installing the incomplete machine, ensure that all hazards from moving parts have been
removed. The infeed and discharge of the incomplete machine must no longer be accessible.
Moving parts of the drive train and position sensors must not pose a hazard.

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4.2 Commissioning
This work may only be carried out by trained personnel!
Work on the electrics must be carried out by a trained electrician!
Caution! Danger of injury!
Make sure that the system is switched off and secured against inadvertent activation.
Inform the control room.
Attention! Material damage!
Foreign objects and non-specification use should be avoided in the commissioning phase in
particular!
Connect electrical and pneumatic drive and monitoring components properly.
Observe the specifications given on the type indication plate and technical documentation.
Caution: Electrical drives must always be connected with overload protection.
Note the hazards from inadvertent operation following a power failure or a failure of the
compressed air supply!
(Example: valve with solenoid valve function closes so that it is de-energised)
Commissioning may only take place once it has been ensured the specifications of the Machine
Directive 2006/42/EC8/37/EC and other applicable safety instructions have been met!
See also the installation declaration.
Check the JAUDT double shuttle valve for the following in the installed state:
- Leaks (visual inspection of valve “CLOSED” position through inspection cover);
- Whether the fastening elements have been tightened securely;
-Firm seat of cam disc, operating lever with roller and overhauling weight
(for motor drive)
- Firm seat of overhauling weight (for weight-actuated drive)
- Firm seat of cylinder and valves (for pneumatic drive)

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4.3 Operation
Observe the safety instructions. Operation of the JAUDT double shuttle valve is simple with all drive versions.
4.3.1 Motor:
Attention! Moving drive elements such as cam disc or balancing weights!
Always wear the protective equipment prescribed by health and safety regulations when
operating the double shuttle valve.
Caution! Danger of death!
Work on the electrics must be carried out by a trained electrician.
Connect the geared motor as shown in the terminal connection plan. The motor starts as soon as the power is
connected. Observe the operating manual for the drive.
4.3.2 Pneumatic:
Attention! Moving drive elements such as the drive lever on the pneumatic cylinder !
Always wear the protective equipment prescribed by health and safety regulations when
operating the double shuttle valve.
Caution! Danger of death!
Work on the electrics must be carried out by a trained electrician.
Connect the compressed air and the solenoid valve for the cylinder control properly. If using standard solenoid
valves, the functionality of the pneumatic cylinders can be checked via an emergency manual operation on the
solenoid valve. As standard, the timing of the pneumatic cylinders is performed by customers.
4.3.3 Weight-actuated:
The contact pressure is adjusted by increasing the number of overhauling weights or moving the overhauling
weights, depending on the version of valve.
The DPK opens automatically once the set filling weight has been reached. Ensure that the bottom valve
opens slightly more easily than the top valve, so that the outfeeding of the bulk goods is ensured!
5 Maintenance
Maintenance means services, inspections and repairs.
Repairs may only be performed by JAUDT GmbH.
Services and inspections may only be performed by trained specialists.
Work on the electrics must be carried out by trained electricians.
Inspection
Weekly
Service
Every 3 months
For >720 operations/h and/or critical usage conditions
Every 6 months
All other scenarios
Repairs
Every 5 years
We recommend that repairs be carried out by JAUDT every 5
years in the case of continuous operation
Also observe the inspection and service intervals for vendor parts –see “Other relevant documents”
(chapter 1.3 and appendix).

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Cup springs of drag
handle
Lock nut
Limit switch
5.1 Inspections and services of the JAUDT double shuttle valve
The inspection work must also be performed at the same time as the service work.
Check the JAUDT DPK for noise emissions,
Ensure that the motor and cylinder and the unit are running perfectly.
Caution! Danger of injury!
Ensure before starting work that the drive is switched off or disconnected. Make sure that the
system is switched off and secured against inadvertent activation before starting work. Inform
the control room. Only open the inspection apertures when the system and drive are
switched off.
Perform a visual inspection. Replace any damaged components.
Check that the bolts (especially the fixing of the gear motor and the motor bracket) , attachments and
fastening elements are tight.
Remove dirt and rust.
Check the shaft seals and adjust, or replace, the gaskets where necessary.
Check the interior for product encrustations and remove.
Check the valve and interior for wear and replace any worn components.
Check the cup springs on the valve lever every 3 months and repair any worn parts.
In the motor version, and for continuous operation, check the cam disc, roller and the bearing of the
roller every 3 months. Replace any worn parts.
Check that the drag handle is set correctly. The drag handle is set correctly if the valve opens fully and
the limit switches can be operated correctly.
In the event of an overload the drag handle will slip to prevent the mechanism being damaged. The limit
switches may then no longer be reached by the counterweight.
Figure 2: Drag handle area seen from above

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5.2 Drag handle adjustment
Caution! Danger of injury!
Ensure before starting work that the drive is switched off or disconnected. Make sure that the
system is switched off and secured against inadvertent activation before starting work. Inform
the control room. Only open the inspection apertures when the system and drive are
switched off.
Open the inspection hatches and make sure that the double shuttle valve is free of foreign bodies and
encrustation.
Turn the cam disk so that both flaps are completely closed.
Loosen the lock nuts of the cup springs and adjust the drag handles so that the respective rollers are just
about against the cam disk or are max. 3 mm away from the cam disk.
Tighten the first fixing nut of the cup springs and then loosen it again by ¼ of a revolution. Lock this
setting using the lock nut.
Check the setting by turning the cam disk several times. The drag handle is set correctly if the flap opens
and closes fully and the limit switches are properly actuated.
Double shuttle valve with both flaps in "CLOSED" position:
CLOSED" limit switch
Cam disk
Roller

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5.3 Replacing the sealing plates
Upstream containers/pipelines must be emptied and the maintenance slide must be closed.
Ensure that the drive is switched off and secured against inadvertent actuation.
Dismantle the inspection apertures
Detach the valve from the valve lever (see also Figure 1 and spare parts list and spare parts drawing) by
removing the lock nuts from the fastening bolts. Also replace the cup springs when replacing the sealing
plates.
Insert the new valve and assemble on the valve lever with the cup springs. Only tighten the first lock nut
by hand so that the valve still moves freely and can easily adjust itself to the stroke frame. Finally, tighten
the hexagon nut.
Perform a test run and finally replace all protective covers
5.4 Adjusting and replacing the gaskets
Adjust the gaskets of the DPK if air or product escapes. Tighten the two hexagon bolts on the sealing
element of the gaskets evenly by hand.
Ensure that the components move easily and an adequate closing force remains.
Replace the gaskets of the DPK if no further improvement can be achieved by adjusting. Remove the
flange bearing or push it to the back, remove the sealing element and replace the gasket cords.
5.5 Lubrication
If the bearings or shaft seal have been supplied in a version designed for relubrication, note the separate
lubrication specifications.
Standard lubrication interval: 3 months
6 Drives
You have received the JAUDT double shuttle valve with the following types of drives:
1. Electric-motor actuation with weight closing force
2. Pneumatic actuation with pneumatic cylinder
3. Weight actuation

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7 Spare parts
See attached spare parts list and spare parts drawing.
Please send orders for spare parts by e-mail to [email protected] or by fax to ++ 49 (0)821 7960567.
If you have a JAUDT customer number, it is also possible to order spare parts over the internet at
www.jaudt.de.
When ordering spare parts, please provide the following information:
Name and Item from the spare parts list
Order no. and model of JAUDT double shuttle valve as shown in the identification plate
Example:
Suppose you need a new cam disc. We need to know the following:
Cam disc Item 200 or part number from the spare parts list
Order no. as per identification plate, e.g. AB03-0211
Model as per identification plate, e.g. AB03-0211.10

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8 Troubleshooting
Fault
Cause
Remedy
Valve does not open or shut
fully
Encrustations of product on inside
Foreign bodies
Load-limiting device on rocker
arm has tripped
Plate cam or roller is heavily worn
Cleaning
Remove foreign bodies
Reset rocker arm (see piont
5.2)
Check; replace defective parts
Running noises
Loose screws (e.g. on safety
covers)
Plate cam or roller is heavily worn
Shaft bearings defective
Gear motor defective
Check and secure loose screws
Check; replace defective parts
Repair
Check and repair
Valve stationary/not working
Drive or power supply and
controller defective
Check and repair
Shaft seal leaking
Gasket/seal worn
Tighten or replace gasket
Pulse generator not issuing any
signals
Pulse generator defective
Pulse generator incorrectly
adjusted
End positions are not reached
Replace
Check and set
Reset rocker arm (see piont
5.2)
9 Cleaning
You must not use any cleaners containing acids or lyes, or solvents. Use a wire brush for heavier volumes of
dirt and commercially available cleaners where necessary. Make sure that these are not toxic and cannot
contribute to any toxic compounds. Ensure that they do not contain acids or lyes. Rinse with plenty of drinking
water afterwards.
10 Disposal
Waste oil and lubricants are classified as special waste. Please dispose of them in an environmentally friendly
manner.
Observe the safety and instructions in the same way during disassembly.

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11 Special instructions for JAUDT DPK ATEX double shuttle valves
Important
JAUDT equipment which falls under the scope of Directive 94/9/EC or
which is designed for use in potentially explosive atmospheres may only
be commissioned and used if, in addition to the general details relating to
operating and servicing, the following points are satisfied. Failure to
ensure this may result in danger to personnel, equipment and the system
and will render the warranty void.
Equipment which falls under the scope of Directive 94/9/EC may only be commissioned and used if it is covered
by an EC Declaration of Conformity pursuant to Directive 94/9/EC.
The use of JAUDT equipment is only permitted in the conditions defined by the operator and set out in the order
and in the EC Declaration of Conformity (proper usage).
JAUDT which falls under the scope of Directive 94/9/EC must bear the appropriate labelling with details of its
classification:
Check the suitability of the equipment before commissioning it using the details on the model plate.
The commissioning and repair work must be carried out by trained personnel. Airborne sparking caused by
falling metal parts must be prevented. The dangers posed by escaping dust must be taken into account.
Servicing and installation work with the risk of additional ignition sources may only be carried out outside the
danger area of the potentially explosive atmosphere.
The equipment must be reliable earthed when it is installed. If there is no conductive contact to opposite
flanges (for example insulating flange seal) it must also be earthed by an additional earth cable to the connected
pipelines. The leakage resistance must be less than 106Ω.
86167 Augsburg
Maschinenfabrik GmbH
JAUDT Dosiertechnik
Classification
Certificate number of type examination

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Only dust with an ignition temperature of over 200°C and a minimum ignition energy of over > 3 mJ may be
handled by steel structures where there is a the risk of internal strikes by sparking foreign bodies. A gas
atmosphere may only exist in Zone 2. Otherwise a complete stainless steel structure is permitted.
Gases in explosion group II C are generally not permitted.
Only non-conductive coatings with a disruptive discharge voltage of max. kV may be used internally.
No insulating coatings with a thickness of over 2 mm may be applied to the exterior of the equipment.
The maximum surface temperature of the housing is determined by the temperature of the product. This
temperature must be defined outside the equipment on the basis of the glow and ignition temperatures of dusts
and gases. The following rule of thumb applies:
- The maximum surface temperature is 80% of the ignition temperature of the gas (in °C)
- The maximum surface temperature is 2/3 of the ignition temperature of the dust (in °C)
- The surface temperature is at least 75 K below the glow temperature of the dust
Equipment which falls under the scope of Directive 94/9/EC must be inspected and serviced if necessary
regularly and at reasonable intervals. The manufacturer recommends that this be carried out every month –if
the operating conditions remain the same, the intervals may be adjusted.
The exterior surfaces are to be cleaned immediately if they become dirty –dust deposits with a layer thickness
of over 5 mm must be prevented at all costs.
Any modification to the equipment requires the written consent of JAUDT. In particular, speed and velocities
must not be increased. In general the relative speeds between moving metallic parts must not exceed 1 m/s.

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12 DECLARATION OF INCORPORATION
within the meaning of EU Directive 2006/42/EC, Annex II Part 1.B
Manufacturer, address JAUDT Dosiertechnik
Maschinenfabrik GmbH
Raiffeisenstr. 3 - 5
86167 Augsburg
Tel. ++49 (0)821 79605-0
Documentation officer Wolfgang Morell, JAUDT Dosiertechnik GmbH
Product denomination / Device Type douple shuttle valve / 6207…
The above partly completed machinery is governed by the requirements of Directive 2006/42/EC
Annex I, its general principles and its Part 1 and where appropriate Point 2.1. If used in areas at
risk of explosion Directive 94/9/EC (ATEX) also applies.
The fundamental requirements 1.3.3 and 1.3.4 can be ensured. The above requirements can only
be ensured through proper installation.
In addition, the above product conforms in the supplied version to the provisions of Directive
2006/95/EC “Low Voltage Directive” and 2004/108/EC “Electromagnetic Compatibility”.
For the purposes of assessment of conformity the manufacturer produced the special technical
documentation pursuant to Directive 2006/42/EC Annex VII Part B. This documentation will be sent
to the authorities of the individual member states in file form on justified request.
The above partly completed machinery is intended solely for incorporation in another machine.
Commissioning is prohibited until it has been ascertained that the machine / system into which the
partly completed machinery is to be incorporated meets the requirements of all the above
directives.
JAUDT Dosiertechnik GmbH
Raiffeisenstraße 3-5 Robert Roßkopf
D-86167 Augsburg Managing Director
Augsburg, 30.03.2010

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13 Accessories
On the following pages the technical data sheets or the documentation of the accessories are specified.