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Maintenance

Source: DICE IOM Manual V12E, Pages: 31–38
Before any disassembly:
  • Turn off electrical power
  • Depressurize the system completely
  • Release both regulating valves
  • Vent fluids to a safe area
  • Flush all fluids from the module
  • Wear protective gloves, glasses, and clothing
  • Refer to the MSDS for all chemicals used

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Ball Valve Disassembly

Exploded view of ball valve showing parts 1-12, 22, 23, 25

Ball valve components

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Preparation

  1. Release inner housing pressure by partially opening the ball valve
  2. Close all ball valves before disassembly
  3. Apply axial force when using sockets to prevent skipping

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Disassembly Procedure

1

Remove connector

Loosen the mushroom nut (25) and remove the connector (26/27/28).
2

Remove sleeve cone

Loosen and remove the sleeve cone (22) with a 27mm socket. Only for evacuation ball valve or center ball valve on DM.
3

Remove carrier

Loosen and remove the ball valve carrier (2) with a 27mm socket.
4

Remove ball

Remove the ball (4) from the valve housing.
5

Remove seats

Remove ball valve seats (6) from the carrier (2) and block (1). Mark the outward-facing side of each seat with a marker to ensure correct reassembly orientation.
6

Remove handle

Loosen the handle set screw (12) with a 3mm Allen key. Remove handle (11).
7

Remove stem

Loosen the stem nut (5) with a 22mm socket. Remove stem nut (5) and stem (3) from block.

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Assembly Procedure

Reverse the disassembly steps, observing these requirements:
  • When reinstalling seats (6), ensure the marked side faces away from the ball
  • If using new seats, operate the ball valve 5 times after torquing the carrier
  • Verify O-ring (31) is positioned in the groove when reinstalling connectors
  • Grease all O-rings with clear food-grade silicone NLGI #1 grease before assembly
  • 27mm socket (carrier, sleeve cone)
  • 22mm socket (stem nut)
  • 3mm Allen key (handle set screw)
  • Torque wrench

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Pressure Relief and Back Pressure Valve Disassembly

Exploded view showing parts 13-21

Regulating valve components

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Disassembly Procedure

1

Remove adjustment hardware

Using a 17mm socket, loosen and remove the adjustment screw (19) along with counter nut (20) and washer (21).
2

Remove mounting bolts

Remove the four mounting bolts (18) with a 5mm Allen key.
3

Remove valve body

Lift off the regulating valve body (13).
4

Remove spring assembly

Remove the spring (17), top seat (15), and bottom seat (14) as a group.
5

Remove diaphragm

Remove the diaphragm (16) from the block (1).
Inspect all parts and replace as needed.

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Assembly Procedure

Reverse disassembly steps, following the bolt tightening pattern:
Star pattern: 1-Right, 2-Left, 3-Top, 4-Bottom

Mounting bolt tightening sequence

Tightening sequence (star pattern): Right → Left → Top → Bottom
Use a filler gauge at four points around the valve body to confirm no gap exists between the regulating valve body (13) and block (1).
  • 17mm socket (adjustment screw)
  • 5mm Allen key (mounting bolts)
  • Torque wrench
  • Filler gauge
After reassembly, perform valve adjustment per the Startup procedures.

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Bleed Valve Maintenance

Bleed valve (32) with O-rings (33)

Bleed valve and O-rings

Disassembly: Completely unscrew and pull the bleed valve (32) from the module. The bleed valve has two replaceable O-rings (33). Assembly: Push and screw the bleed valve completely into the module.
Do not use tools on the bleed valve. Hand-tighten only.

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Pressure Indicator and Isolator

No periodic maintenance is required on the pressure indicator and isolator assembly.
Pressure indicator (24) attached to DICE block

Pressure indicator and isolator assembly

If the pressure indicator or isolator fails:
  1. Depressurize the module completely
  2. Remove the isolator and pressure indicator assembly (24) from the block—hand-loosen only
  3. Contact supplier with RMA form
  4. Ship assembly for repair
Do not disassemble the isolator on site. The isolator filling requires specialized tools and is performed by factory technicians.

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Periodic Maintenance Schedule

  • Visual inspection for leaks at all connection points
  • Verify system operating pressure matches back pressure set point
  • Check for chemical deposits or crystallization
Ball valve operation: Fully open and close each ball valve to prevent seat damage from extended static positions. Record each operation.
Before operating valves, release module pressure by closing the outlet port valve and opening the evacuation valve. Operating valves under pressure can cause chemical spillage from the calibration column.
Regulating valve inspection: Fully inspect back pressure and pressure relief valve diaphragms. Replace diaphragms showing signs of wear.
Clean the DICE module when deposits, scaling, or crystals obstruct flow. Cleaning frequency depends on:
  • Chemical properties
  • Operating conditions
  • Environment
Cleaning fluids must be compatible with both the dosed chemical and all system materials. Consult your chemical supplier.

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Spare Parts

To order spare parts, provide:
  • Module serial number (engraved on block)
  • Part number from the Parts List

DICE DS — Suction Lift

1/2” module for suction lift applications

DICE DM — Flooded Suction

1/2” and 1” modules for flooded suction

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Sources

DICE IOM Manual V12E

Pages 31–38 • July 2022