KIESELMANN 582x User manual

Operating instruction
Translation of the original
Type 582x
GB
ENGLISHPDF • ak • 04/02/2022

KIESELMANN GmbH
Paul-Kieselmann-Str. 4-10
D - 75438 Knittlingen
( [phone] • 7 [phone]
www.kieselmann.de • [email protected]
Copyright: © KIESELMANN FLUID PROCESS GROUP

KIESELMANN GmbH Table of contents
582x_GEMBRA_EN 3
Table of contents
1 General informations ....................................................................................................................................................4
1.1 Informations for your safety ...............................................................................................................................................4
1.2 Marking of security instructions.........................................................................................................................................4
1.3 General designated use ......................................................................................................................................................4
1.4 Personnel .............................................................................................................................................................................4
1.5 Modifications, spare parts, accessories ............................................................................................................................5
1.6 General instructions ............................................................................................................................................................5
2 Safety instructions........................................................................................................................................................6
2.1 Intended use ........................................................................................................................................................................6
2.2 General notes.......................................................................................................................................................................6
2.3 General safety instructions.................................................................................................................................................6
3 Delivery, transport and storage .....................................................................................................................................8
3.1 Delivery.................................................................................................................................................................................8
3.2 Transport..............................................................................................................................................................................8
3.3 Storage.................................................................................................................................................................................8
4 Modular system ............................................................................................................................................................9
4.1 Valve design.......................................................................................................................................................................10
5 Function and operation ...............................................................................................................................................11
5.1 Description of function......................................................................................................................................................11
5.2 Control system and position indicator.............................................................................................................................11
5.3 Pneumatic valve activation...............................................................................................................................................12
6 Commissioning, service and maintenance ..................................................................................................................13
6.1 Commissioning..................................................................................................................................................................13
6.1.1 Installation instructions....................................................................................................................................... 13
6.1.2 General welding guidelines ................................................................................................................................. 13
6.1.3 ATEX - Guidelines ................................................................................................................................................ 13
6.2 Service................................................................................................................................................................................13
6.3 Cleaning .............................................................................................................................................................................14
7 Technical data ............................................................................................................................................................15
7.1 Gembra Aseptic-Double seat valve ..................................................................................................................................15
8 Disassembly and assembly .........................................................................................................................................16
8.1 Disassembly.......................................................................................................................................................................16
8.1.1 Disassemble the pilot valves .............................................................................................................................. 18
8.1.2 Assembly valve insert VE .................................................................................................................................... 18
8.1.3 Assembly seals D5, D11, D12 ............................................................................................................................. 19
8.1.4 Assembly seals D6, D7........................................................................................................................................ 22
8.1.5 Disassemble lower piston - dismount seal D1 .................................................................................................. 22
8.1.6 Disassemble upper piston - dismount Membrane D2 and O-Ring D3.............................................................. 23
8.2 Assembly ...........................................................................................................................................................................24
8.2.1 Assembling k-flex Seal (D-1)............................................................................................................................... 25
8.2.2 Mounting k-flex - seal D1..................................................................................................................................... 25
8.2.3 Mounting k-flex seal D2 and D3.......................................................................................................................... 27
8.2.4 Mounting Membrane D5 ..................................................................................................................................... 28
8.2.5 Assembling valve................................................................................................................................................. 28
9 Drawings and dimensions ...........................................................................................................................................31
9.1 Drawings ............................................................................................................................................................................31
9.2 Dimensions ........................................................................................................................................................................32
9.3 Control units ......................................................................................................................................................................33
10 Wearing parts .............................................................................................................................................................34
10.1 Wearing parts list...............................................................................................................................................................34
10.2 Wear parts kit.....................................................................................................................................................................35
11 Classification..............................................................................................................................................................36
11.1 Structure of order number ................................................................................................................................................36
12 Appendix ....................................................................................................................................................................38
12.1 Declaration of incorporation.............................................................................................................................................38

Operating instruction | KIESELMANN GmbH1 | General informations
4 / 38 582x_GEMBRA_EN
1 General informations
1.1 Informations for your safety
We are pleased that you have decided for a high-classKIESELMANN product. With correct applica-
tion and adequate maintenance, our products provide long time and reliable operation.
Before installation and initiation, please carefully read this instruction manual and the security ad-
vices contained in it. This guarantees reliable and safe operation of this product and your plant re-
spectively. Please note that an incorrect application of the process components may lead to great
material damages and personal injury.
In case of damages caused by non observance of this instruction manual, incorrect initiation, hand-
ling or external interference, guarantee and warranty will lapse!
Our products are produced, mounted and tested with high diligence. However, if there is still a
reason for complaint, we will naturally try to give you entire satisfaction within the scope of our war-
ranty. We will be at your disposal also after expiration of the warranty. In addition, you will also find
all necessary instructions and spare part data for maintenance in this instruction manual. If you
don't want to carry out the maintenance by yourself, ourKIESELMANN - service team will naturally
be at your disposal.
1.2 Marking of security instructions
Hints are available in the chapter "safety instructions" or directly before the respective operation in-
struction. The hints are highlighted with a danger symbol and a signal word. Texts beside these
symbols have to be read and adhered to by all means. Please continue with the text and with the
handling at the valve only afterwards.
Symbol Signal word Meaning
DANGER Imminent danger which will result severe personal injury or
death.
WARNING Imminent danger which may result severe personal injury or
death.
CAUTION Dangerous situation which may cause slight personal injury or
material damages.
NOTICE An harmful situation which may result in damages of the product
itself or of adjacent vicinity.
INFORMATION Marks application hints and other information which is particu-
larly useful.
1.3 General designated use
The fitting is designed exclusively for the purposes described below. Using the fitting for purposes
other than those mentioned is considered contrary to its designated use.KIESELMANNcannot be
held liable for any damage resulting from such use. The risk of such misuse lies entirely with the
user. The prerequisite for the reliable and safe operation of the fitting is proper transportation and
storage as well as competent installation and assembly. Operating the fitting within the limits of its
designated use also involves observing the operating, inspection and maintenance instructions.
1.4 Personnel
Personnel entrusted with the operation and maintenance of the tank safety system must have the
suitable qualification to carry out their tasks. They must be informed about possible dangers and
must understand and observe the safety instructions given in the relevant manual. Only allow quali-
fied personnel to make electrical connections.

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582x_GEMBRA_EN 5 / 38
1.5 Modifications, spare parts, accessories
Unauthorized modifications, additions or conversions which affect the safety of the fitting are not
permitted. Safety devices must not be bypassed, removed or made inactive. Only use original spare
parts and accessories recommended by the manufacturer.
1.6 General instructions
The user is obliged to operate the fitting only when it is in good working order. In addition to the in-
structions given in the operating manual, please observe the relevant accident prevention regula-
tions, generally accepted safety regulations, regulations effective in the country of installation,
working and safety instructions effective in the user's plant.

Operating instruction | KIESELMANN GmbH2 | Safety instructions
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2 Safety instructions
2.1 Intended use
Based upon its functions, the double seat valve is suitable for use in the food and beverages, in
pharmaceutical, biotechnological and chemical industries. It is used mainly in combinations with
several other double seat valves for the purpose of emptying and filling containers with the possibil-
ity of connecting several pipes to one tank. The valve is designed for media characteristics accord-
ing to DGRL 2014/68/EG for group 2 (media condition gaseous or liquid).
2.2 General notes
NOTICE - observe the operating instructions
To avoid danger and damage, the fitting must be used in accordance with the safety instructions
and technical data contained in the operating instructions.
NOTICE
All data are in line with the current state of development. Subject to change as a result of tech-
nical progress.
2.3 General safety instructions
WARNING
Risk of injury by moving parts
Do not grab into the valve when the actuator is pressurized. Limbs can be crushing or amputating.
– Remove the control air line before dismantling.
– Ensure that the actuator is unpressurized.
WARNING
Risk of injury by moving parts
When dismount the clamp coupling, the spring preloaded valve insert (air open - spring close) may
incur serious injuries by jumping out of the housing.
– First pneumatically open the valve before disassembling the clamp coupling, so that up-
stroke the piston.
– Remove the valve core.
– Remove the control air line at valve insert.
ðEnsure that the actuator is unpressurized.
WARNING
Risk of injury by outflowing medium
Dismantling the valve or valve assemblies from the plant can cause injuries.
– Medias flowing through the leakage drain outlet are to be drained off without splashing
into a discharge arrangement.
– Carry the disassembling only if when the plant has been rendered pressure-less and free
of liquid and gas.

KIESELMANN GmbH | Operating instruction Safety instructions | 2
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WARNING
Risk of injury by pre-stressed pressure spring.
The actuator is spring-loaded. When disassembling the actuator, components that jump out may
cause injuries.
– For dismantling please observe the separate assembly instructions.
– We recommend having the manufacturer do the maintenance work required for the actu-
ation.
WARNING
ATEX - Guidelines
If the valve or the plant is operated in a potentially explosive atmosphere, the valid ATEX directive of
the EC and the installation instructions in this operating manual must be observed.
CAUTION
Damage to the pneumatic actuator when actuated by compressed air!
If actuated by compressed air at the pneumatic actuator (connection P), the actuator can be dam-
aged.
ØThe valve insert must be completely assembled before the pneumatic actuator is pressurized
with compressed air.
– Only now may the valve insert be actuated with compressed air at the connection (P).
CAUTION
When mounting the clamps, the max. torque must not be exceeded.
(see technical data)
CAUTION
To avoid air leaking, only use pneumatic connection parts that have an O-ring seal facing the even
surface.
CAUTION
Before starting the system, the entire pipeline system must be thoroughly cleaned.
CAUTION
Steps should be taken to ensure that no external forces are exerted on the fitting.

Operating instruction | KIESELMANN GmbH3 | Delivery, transport and storage
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3 Delivery, transport and storage
3.1 Delivery
• Immediately after receipt check the delivery for completeness and transport damages.
• Remove the packaging from the product.
• Retain packaging material, or expose of according to local regulations.
3.2 Transport
CAUTION
Risk of injury and damage to the product
During the transport the generally acknowledged rules of technology, the national accident preven-
tion regulationsand company internal work and safety regulations must be observed.
3.3 Storage
NOTICE
Damage to the product due to improper storage!
Observe storage instructions
avoid a prolonged storage
INFORMATION
Recommendation for longer storage
We recommend regularly checking the product and the prevailing storage conditions during long
storage times.
• To avoid damage to seals and bearings,
– products up to DN 125 / OD 5 inch should be stored horizontally for maximum 6 months.
– products larger than DN 125 / 5 inch, should be stored in the upright position with the actu-
ator on top.
• Don't store any objects on the products.
• Protect the products for wetness, dust and dirt.
• The product should be stored in a dry and well ventilated room at a constant temperature (op-
timal indoor temperature: 25 C ±5; indoor humidity data 70% ±5%).
• Protect seals, bearings and plastic parts for UV light and ozone.

KIESELMANN GmbH | Operating instruction Modular system | 4
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4 Modular system
KI-Top control head feedback unit
Stainless steel hood Transparent hood Feedback unit with finger guard
(E)
Actuator pneumatical
PTFE / k-flex | PTFE / EPDM
Valve housing
S - SS SS - SS
with PT100 with PT100

Operating instruction | KIESELMANN GmbH4 | Modular system
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4.1 Valve design
GEMBRA-Aseptic Double seat valve
with Valve housing
S - SS
without PT100 with PT100
in the valve housing
with PT100
in the outlet valve
with Valve housing
S - SS
without PT100 with PT100
in the valve housing
with PT100
in the outlet valve

KIESELMANN GmbH | Operating instruction Function and operation | 5
582x_GEMBRA_EN 11 / 38
5 Function and operation
5.1 Description of function
Due to the combined diaphragm sealing at a locking and leakage space respectively, safe separa-
tion of media is reliably guaranteed.
Cleaning and sterilisation of the locking and leakage space can be carried out inline via lifting/
clocking of one the valve seats.
Valve closed Valve open lifting upper seat lifting lower seat
• Steril barrier active
• Drain outlet A2
pulsed
• Steril supply A1
active
• Steril barrier inact-
ive
• Steril barrier inact-
ive
• Drain outlet A2
open
• Steril barrier inact-
ive
• Drain outlet A2
open
5.2 Control system and position indicator
Feedback unit -optional-
Optionally, modular valve control head systems can be installed to the actuator for reading and ac-
tuating valve positions. The standard version is a closed system with SPS or ASI-bus switch-on
electronics, and integrated 3/2-way solenoid valves. For tough operating conditions we recommend
employing a high-grade steel cover.
Feedback unit with finger guard -optional-
For the acquisition of the valve positions over inductive initiators (Sensors), a feedback unit is
mounted on the actuation. The enquiry takes place over the position of the piston rod.

Operating instruction | KIESELMANN GmbH5 | Function and operation
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5.3 Pneumatic valve activation

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6 Commissioning, service and maintenance
6.1 Commissioning
6.1.1 Installation instructions
Fitting position
The valve must be installed vertically with the actuator at the upwards. Liquid must be able to flow
freely from the valve housing.
6.1.2 General welding guidelines
Sealing elements integrated in weld components must generally be removed prior to welding. To
prevent damage, welding should be undertaken by certified personnel (EN ISO 9606-1). Use the TIG
(Tungsten Inert Gas) welding process.
CAUTION
Damage and injuries due to high temperature supply
To avoid a distortion of the components, all welding parts must be welded to stress-relieved.
Allow all components to cool before assembling.
NOTICE
Damage due to impurities
Impurities can cause damage to the seals and seals area.
Clean inside areas prior to assembly.
6.1.3 ATEX - Guidelines
For valves or plants/installations that are operated in the ATEX area, sufficient bonding (grounding)
must be ensured (see valid ATEX Guidelines EG).
6.2 Service
RECOMMENDATION
Replacement of seals
To achieve optimal maintenance cycles, the following points must be observed!
– When replacement of seals, all product-contacting seals should be replaced.
– Only original spare parts may be installed.
Maintenance interval
The maintenance intervals depend on the operating conditions "temperature, temperature-intervals,
medium, cleaning medium, pressure and opening frequency". We recommend replacing the seals1-
year cycle. The user, however should establish appropriate maintenance intervals according to the
condition of the seals.
Lubricant recommendation
EPDM; HNBR; NBR; FKM; k-flex - Klüber Paraliq GTE703*
Silicone - Klüber Sintheso pro AA2*
Thread - Interflon Food*
*) It is only permitted to use approved lubricants, if the respective fitting is used for the produc-
tion of food or drink. Please observe the relevant safety data sheets of the manufacturers of lub-
ricants.

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6.3 Cleaning
Cleaning
The upper and lower process housing is cleaned via pipeline cleaning. As part of the cleaning pro-
gram, the leakage chamber and the drain pipe can be cleaned by cycling the valve discs. Cleaning
via the purge valves of the sterile barrier is not recommended.

KIESELMANN GmbH | Operating instruction Technical data | 7
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7 Technical data
7.1 Gembra Aseptic-Double seat valve
Model: GEMBRA Aseptic-Double seat valve
Valve size: DN40 - DN80
Connections: Welding end
Temperature range: Ambient temperature:
Operating temperature:
Sterilization temperature:
+4 to +45°C (air)
+0 to +95°C (medium dependent)
k-flex/PTFE +140°C (SIP 30 min)
Working pressure: DN 40 - DN65 = max.10 bar
DN 80 = max. 8 bar
Pressure resistance: 30 bar
Leak rate: A (DIN EN 12266-1)
Control air: Control air pressure:
5,5 - 8,0 bar
Quality of control air:
ISO 8573-1 : 2001 quality class 3
Materials:
(in product contact)
Stainless steel: 1.4404 / AISI316L
Surfaces: Ra < 0,8µm metallic bright, blank
e-polished
Sealing material: k-flex / PTFE (FDA)
EPDM (FDA)
ND
Inch
40
1½
50
2
65
2½
80
3
Torque
Clamp coupling 15 15 25 25
main lift (mm) 26 26 28 35
narrowest flow area H1 (mm) 12 12 12.5 15
seat lift upper (mm) 2222
seat lift lower (mm) 8888
main lift (mm) 10 10 10 10
narrowest flow area h1 (mm) 4.5 4.5 4.5 4.5

Operating instruction | KIESELMANN GmbH8 | Disassembly and assembly
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8 Disassembly and assembly
8.1 Disassembly
Assembly Tools
Tool kit
for GEMBRA Aseptic Double seat valve
DN40 - DN80
ST4, ST10, ST20,
ST21, ST22, ,
5820000010-000
T1 Combination wrench-Set SW 8 - SW 24 -
ST20
ST21
ST22
Spanner SW 30 - 32
SW 41
SW 46
8618030032-000
8618041000-001
8618046000-001
T2 Allen key - Set 1.5 - 10 -
T3 Screwdriver Set Size 2,5 - 10
PH0,PH1
-
T4 Soft-head hammer - -
T10 Joint -pin wrench Pin Ø6 8027000065-000
T31 Round rod ø5 -
T30 Needle - -
ST10 Mounting wrench 5620000000-000
ST4 Centring ring - valve plate
seal
DN 40 - 50
DN 65
DN 80
DN 100
DN 125
DN 150
5620050025-020
5620065025-020
5620080025-020
5620100025-020
5620125025-020
5620150025-020

KIESELMANN GmbH | Operating instruction Disassembly and assembly | 8
582x_GEMBRA_EN 17 / 38
A
A2
LA1
LA2
LA3
LA4
VE
VG
P
R
9
1415
16
P2
P3 P1
D14
D14 14
L
X
A Control unit A2 leakage drain
D14 seal ring L leakage drain
LA1 Activation main stroke LA2 Activation cycling down
LA3 Activation main stroke LA4 Activation cycling up
VE valve-insert VG Valve housing
P Control air supply P1 Activation main stroke
P2 Activation cycling down P3 Activation cycling up
R sound absorber 9 Clamp coupling
14 screw 15 inlet valve
16 outlet valve
NOTICE
All threaded joint have right-hand thread.
Dismantle pneumatic and electrical connections. Unscrew fittings for CIP,discharge and feed lines.

Operating instruction | KIESELMANN GmbH8 | Disassembly and assembly
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8.1.1 Disassemble the pilot valves
• Dismount the control heads from the pilot
valves (Inlet- and outlet valve).
• Unscrew the screws (11).
• Dismount Inlet- and Outlet valve.
• Remove seals (D14).
14 = Screws
15 = Inlet valve
16 = Outlet valve
D14 = Seal
16 14 D14 15D14 14
8.1.2 Assembly valve insert VE

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8.1.3 Assembly seals D5, D11, D12
• Unscrew the lower piston (2).
2
• Screw off the upper piston plate (5) and hold
it against with the round rod (T31) (Ø8) in
the hole (B).
T31
D5
5
B Ø8
• Dismount the membrane (D2).
D5

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• Unscrew set screw (10).
10
• Unscrew air supply (LA4) and screws (11).
11
LA4
8
• Remove lantern (8).
8