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GE VARIVENT S Series, Operating Instruction

The GE VARIVENT S Series is an exceptional product that ensures seamless operations and maximum efficiency. With our comprehensive operating instruction manual, which you can download for free from manualshive.com, you'll have all the necessary guidelines to optimize your experience with this outstanding equipment.

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COPYRIGHT

These Operating Instructions are the English translation of the original operating
instructions in the sense of the EU Machinery Directive. This document is
protected by copyright. All rights reserved. The document may not, in whole or in
part, be copied, reproduced, translated or reduced to an electronic medium of
machine-readable form without the express permission of GEA Tuchenhagen
GmbH.

LEGAL NOTICE

Word marks

The designations VARIVENT

®

 and T.VIS

®

 are protected trademarks of GEA

Tuchenhagen GmbH.

 

430BAL011074EN_5

2

08.11.2021

Summary of Contents for VARIVENT S Series

Page 1: ...Hygienic valves GEA VARIVENT control valve type S Operating instruction Translation from the original language 430BAL011074EN_5...

Page 2: ...otected by copyright All rights reserved The document may not in whole or in part be copied reproduced translated or reduced to an electronic medium of machine readable form without the express permis...

Page 3: ...e 15 2 8 Residual dangers 15 2 9 Danger zones 16 3 Description 17 3 1 Design 17 3 2 Functional description 19 3 2 1 Spring to close actuator Z 19 3 2 2 Spring to open actuator A 19 4 Transport and sto...

Page 4: ...Replacing Seals 52 10 6 3 Lubricating Seals and Threads 53 10 7 Installation 54 10 7 1 Control valve 54 10 8 Checking the function 56 10 8 1 Setting the valve stroke 56 NC Valve in closed position 57...

Page 5: ...the entire life cycle of the product When the location is changed or the product is sold make sure you also provide the Operating Instructions 1 1 2 Notes on the Illustrations The illustrations in the...

Page 6: ...n serious damage to the component or in the vicinity of the component The arrow identifies a precautionary measure you have to take to avoid the hazard Carry out the following steps Start of a set of...

Page 7: ...1 4 EC Declaration of Conformity General Information EC Declaration of Conformity 430BAL011074EN_5 08 11 2021 7...

Page 8: ...General Information EC Declaration of Conformity 430BAL011074EN_5 8 08 11 2021...

Page 9: ...Fig 1 General Information 430BAL011074EN_5 08 11 2021 9...

Page 10: ...ipment directive 2014 68 EU Classified according to Annex II in category 1 According to the scope of directive 2014 34 EC article 1 paragraph 2 f the exception of the directive applies due to conformi...

Page 11: ...measures are observed The following principles apply Only qualified personnel may work on the component The operating company must authorize personnel to carry out the relevant tasks Order and cleanli...

Page 12: ...n can be avoided by safety conscious and proactive behaviour of the staff To ensure safe operation of the valve the following principles apply The Operating Instructions must be kept ready to hand at...

Page 13: ...In addition to the instructions in this documentation the following also has to be observed pertinent accident prevention regulations generally accepted safety rules national regulations applicable i...

Page 14: ...upational health and safety and accident prevention When working with the component a distinction is made between the following user groups User groups Staff Qualifications Operating personnel Adequat...

Page 15: ...by wearing personal protective equipment Residual dangers on the valve and measures Danger Cause Measure Danger to life Inadvertent switch on of the valve Effectively disconnect all components effect...

Page 16: ...valve housing 391 the motor stool 9 or into the valve inlet X on pneumatic actuators Fingers can be crushed or cut off When releasing the grooved cap nut 252 of the non actuated valve spring to close...

Page 17: ...3 Description 3 1 Design Fig 5 Description Design 430BAL011074EN_5 08 11 2021 17...

Page 18: ...Design No Designation A Actuator X Air connection 6 Coupling clips 9 Motor stool 10 Adapter 15 Valve disk 401 Valve housing Description Design 430BAL011074EN_5 18 08 11 2021...

Page 19: ...h a spring to close actuator spring closed in the non actuated position i e If the input signal at the positioner increases the control valve opens 3 2 2 Spring to open actuator A The valve is open in...

Page 20: ...the purpose to transport the package units valves Observe the maximum load bearing capacities Observe the pictograms on the package Handle valves with care to avoid damage caused by impact or careles...

Page 21: ...ing key data Key data of the valve Type Modulating Control Valve S Serial Serial number Material 1 4404 AISI316L EPDM FDA Control air pressure bar psi min 4 58 max 6 87 Product pressure bar psi Kvs va...

Page 22: ...e DN 25 to DN 150 1 to 6 OD 2 to 6 IPS Material of product contact parts Stainless steel 1 4404 AISI316L Installation position Any position if valve and pipe system can drain properly Product pressure...

Page 23: ...1 psi depending on the type of positioner Control air acc to ISO 8573 1 Solid particle content Quality class 6 Particle size max 5 m Particle density max 5 mg m3 Water content Quality class 4 max Dew...

Page 24: ...2 This results in the following exemplary permissible seat leakages for 5 barg test medium air KVS m3 h 4 6 3 10 16 25 35 40 60 80 100 160 200 260 360 Permissible leakage water in ml min 20 20 40 60...

Page 25: ...up to 5 up to 80 C 176 F o o Inorganic acids up to 5 up to 100 C 212 F Water up to 80 C 176 F Steam up to 135 C 275 F o o Steam approx 30 min up to 150 C 302 F o Fuels hydrocarbons Product with a fat...

Page 26: ...Wall thickness Inside diameter Outside diameter acc to BS 4825 1 25 4 1 65 22 1 x 1 5 38 1 1 65 34 8 x 2 50 8 1 65 47 5 x 2 5 63 5 1 65 60 2 x 3 76 2 1 65 72 9 x 4 101 6 2 11 97 38 x 6 152 4 2 77 146...

Page 27: ...wdriver blade width 3 5 406 103 Open end spanner a f 6x7 408 030 Open end spanner a f 8x10 408 032 Open end spanner a f 13x17 408 036 Open end spanner a f 24x27 408 040 Open end spanner a f 36x41 408...

Page 28: ...le G1 8 G3 8 933 048 Screw in plug connection G1 8 6 4 933 176 Inch version Reducing nipple G1 8 G3 8 933 048 Screw in plug connection G1 8 6 35 933 173 5 8 Lubricants Lubricants Designation Material...

Page 29: ...N 40 1 5 approx 15 0 DN 50 2 approx 15 5 DN 65 2 5 approx 21 0 DN 80 3 approx 21 0 DN 100 4 approx 24 0 DN 125 approx 63 0 DN 150 6 approx 66 5 Weights for housing combination L Other weights on reque...

Page 30: ...being switched on 6 2 Notes on installation GEA Tuchenhagen recommends that the valve should be installed vertically actuator up housing bottom If the control valve is not installed vertically the st...

Page 31: ...lve To ensure that a proper weld is formed when the valve is welded into the pipe make sure that the root side of the weld is protected against oxidation by forming gas Use welding filler if necessary...

Page 32: ...the pneumatic connections in accordance with the codes on the positioner Observe the operating instructions for the positioner Fig 11 4 Hand tighten the cap nuts Done 6 6 Electrical connections Dange...

Page 33: ...it according to the wiring diagram in the protection cap of the positioner Observe the operating instructions for the positioner Fig 12 2 Tighten the strain relief device on the cable gland 1 Done As...

Page 34: ...ing into Operation For commissioning the following principles apply Only allow properly qualified staff to set the valve into operation Establish all connections correctly The safety devices for the v...

Page 35: ...rvals All guards and hoods must be fitted as intended The installation location of the component must always be properly ventilated Structural changes to the component are not permitted Report any cha...

Page 36: ...aning process Sodium hydroxide solution and sodium hydroxide based combination products in concentrations from 0 5 to 2 5 at 75 C 167 F to 80 C 176 F Phosphoric or nitric acid and combination products...

Page 37: ...assivation is commonly carried out for long pipes and tanks Valve blocks are usually excepted from this Passivation is typically performed using nitric acid HNO3 at approx 80 C 176 F at a concentratio...

Page 38: ...to the maintenance or repair work going on Do not climb on the component Use suitable access aids and working platforms Wear suitable protective clothing Only use suitable and undamaged tools to carr...

Page 39: ...lowing steps 1 Regularly check Regularly check the seals Done 10 2 2 Pneumatic connections Carry out the following steps 1 Check the operating pressure at the pressure reducing and filter station 2 Cl...

Page 40: ...te Make sure that during maintenance and repair work no process is in operation in the area concerned Carry out the following steps 1 Drain all pipe system elements that lead to the valve and if neces...

Page 41: ...Fig 13 Prerequisite No positioner must be actuated electrically or manually Maintenance Disassembling the Valve 430BAL011074EN_5 08 11 2021 41...

Page 42: ...ry out the following steps 1 Pressurize the actuator A via connection X spring to close action The valve opens spring tension has been relieved 2 Remove the clamp connection 43 between the housing 401...

Page 43: ...Disassembly Valve W Fig 14 Prerequisite No positioner must be actuated electrically or manually Maintenance Disassembling the Valve 430BAL011074EN_5 08 11 2021 43...

Page 44: ...valve insert down on the valve disk but lay the valve insert down Protect the valve parts against impact stress The seat ring 33 1 is placed freely in the housing and can hit the valve disk when the...

Page 45: ...Disassembly Valve X Fig 15 Prerequisite No positioner must be actuated electrically or manually Maintenance Disassembling the Valve 430BAL011074EN_5 08 11 2021 45...

Page 46: ...valve pressurize the actuator 2 Remove the clamp connection 43 3 3 Pull the valve out of the housing 401 3 Do not set the valve insert down on the valve disk but lay the valve insert down Protect the...

Page 47: ...Loosen the nut 76 and the adapter 10 and turn them downwards on the valve disk 15 13 Remove the clamp connection 46 take off the actuator A and the motor stool 9 14 Unscrew the nut 76 and adapter 10...

Page 48: ...Fig 16 only valid for DN 25 and 1 OD Prerequisite No positioner must be actuated electrically or manually Maintenance Disassembling the Valve 430BAL011074EN_5 48 08 11 2021...

Page 49: ...ve the clamp connection 43 1 between the housing 401 1 and the motor stool 9 3 Depressurize the actuator A and detach the air supply 4 Unscrew the coupling clips 6 5 Loosen the nut 76 and the adapter...

Page 50: ...the released spring pretension will suddenly lift the back plate Therefore never slacken all the screws of the back plate at the same time Carry out the following steps 1 Remove the hex nuts A 1 of t...

Page 51: ...s slowly and at evenly distributed points along the circumference so that the two housing parts drift apart and the spring pretension is reduced Done 10 6 Maintenance 10 6 1 Cleaning the Valve Mainten...

Page 52: ...ith a drop of washing up liquid to remove the surface tension In order that no rust is transferred the washing up liquid solution must be made up in a ceramic plastic or stainless steel container Repl...

Page 53: ...on position of the V ring is correct see illustration Fig 20 4 Use the insertion tool to press in the V ring evenly press in at several opposite points along the circumference Fig 21 5 Insert the V ri...

Page 54: ...USDA H1 registration They do not affect the taste or the consistency of the products and are compatible with the seals in contact with product PARALIQ GTE 703 can be ordered from GEA Tuchenhagen unde...

Page 55: ...rface must face the valve disk A Metallically sealing valve disks pointed edge must face the valve disk B Fig 22 Fig 23 2 Restore the tension of the actuator spring 3 Check the valve function by actua...

Page 56: ...king the function Setting the valve stroke Fig 24 Prerequisite Valve has been completely fitted into the housing 10 8 1 Setting the valve stroke Maintenance Checking the function 430BAL011074EN_5 56 0...

Page 57: ...lve has been completely fitted into the housing 10 8 1 1 NC Valve in closed position Carry out the following steps 1 Remove the coupling clips 6 Maintenance Checking the function 430BAL011074EN_5 08 1...

Page 58: ...alf turns 6 Remove compressed air and the compressed air connection 7 Tighten the lock nut 76 8 Tighten the coupling clip 6 9 Check the valve stroke If the valve stroke is too high or too low adjust t...

Page 59: ...seal one turn to one and a half turns 7 Actuate the valve with compressed air via X NO for data refer to type plate of the actuator 2 7 bar 39 psi in this case Fig 28 8 Tighten the lock nut 76 9 Tight...

Page 60: ...stem Check actuation external controller and routing of electrical lines Valve disk blocked mechanically Clear the blockage Stroke scanning lever has shifted Readjust the stroke scanning lever Actuato...

Page 61: ...at the place of installation The component consists of the following materials Metals Synthetic materials Electronic parts Lubricants containing oil and grease Separate the different materials and di...

Page 62: ...re parts list VARIVENT control valve type S S_F S_J Fig 29 Metallic seal Fig 30 Soft sealing Fig 31 Housing combinations Spare parts list VARIVENT control valve type S S_F S_J 430BAL011074EN_5 62 08 1...

Page 63: ...75 930 876 HNBR 930 632 930 633 930 633 930 634 Items marked with an are wearing parts Spare parts list item 1 5 metric sizes DN 80 DN 150 Item Designation Material DN 80 DN 100 DN 125 DN 150 1 Seal r...

Page 64: ...2 111 932 111 HNBR 932 085 932 085 932 085 16 0 EPDM 932 046 932 046 FKM 932 030 932 030 FFKM 932 110 932 110 HNBR 932 087 932 087 25 0 EPDM 932 019 932 019 932 019 FKM 932 032 932 032 932 032 FFKM 93...

Page 65: ...2 115 HNBR 932 089 932 089 80 0 EPDM 932 024 932 025 FKM 932 035 932 036 FFKM 932 116 HNBR 932 090 932 101 100 EPDM 932 025 932 025 FKM 932 036 932 036 FFKM HNBR 932 101 932 101 160 EPDM 932 028 932 0...

Page 66: ...1 0 63 1 4301 229 322 01 1 1 4301 229 322 01 1 6 1 4301 229 322 01 2 5 1 4301 229 322 01 4 0 1 4301 229 322 01 6 3 1 4301 229 322 01 229 322 02 10 1 4301 229 322 01 229 322 02 229 322 02 16 1 4301 229...

Page 67: ...01 229 322 22 229 322 22 360 1 4301 229 322 22 Spare parts list valve disk SFM equal percentage metallic seal metric sizes DN 25 DN 65 Item KVS value Material DN 25 DN 40 DN 50 DN 65 15 0 1 1 4404 on...

Page 68: ...4404 2 5 1 4404 4 0 1 4404 6 3 1 4404 10 1 4404 16 1 4404 25 1 4404 35 1 4404 221 762 83 40 1 4404 221 762 88 60 1 4404 221 762 01 221 762 02 80 1 4404 221 762 91 221 762 94 100 1 4404 on request on...

Page 69: ...762 87 221 762 89 60 1 4404 221 762 05 80 1 4404 100 1 4404 160 1 4404 200 1 4404 260 1 4404 360 1 4404 Spare parts list valve disk SJM linear metallic seal metric sizes DN 80 DN 150 Item KVS value Ma...

Page 70: ...4404 0 16 1 4404 0 25 1 4404 0 4 1 4404 0 63 1 4404 1 1 4404 1 6 1 4404 2 5 1 4404 4 0 1 4404 6 3 1 4404 10 1 4404 16 1 4404 25 1 4404 35 1 4404 221 762 82 40 1 4404 221 762 48 60 1 4404 221 762 03 22...

Page 71: ...es DN 25 DN 65 Item KVS value Material DN 25 DN 40 DN 50 DN 65 40 1 4404 221 762 86 221 762 51 60 1 4404 221 762 07 80 1 4404 100 1 4404 160 1 4404 200 1 4404 260 1 4404 360 1 4404 Spare parts list VA...

Page 72: ...107 27 10 1 4404 221 107 25 221 107 27 221 107 27 16 1 4404 221 107 28 221 107 28 25 1 4404 221 107 29 221 107 29 221 107 31 35 1 4404 221 107 30 221 107 32 40 1 4404 221 107 30 221 107 32 60 1 4404...

Page 73: ...etric sizes DN 80 DN 150 Item Designation Material DN 80 DN 100 DN 125 DN 150 35 Blanking plate 1 4404 221 144 03 221 144 04 221 144 06 221 144 05 43 Clamp join KL 1 4401 221 507 09 221 507 11 221 507...

Page 74: ...21 132 105 40 1 4404 221 132 105 60 1 4404 221 132 53 221 131 09 80 1 4404 221 131 80 221 131 83 100 1 4404 221 131 83 221 132 108 160 1 4404 221 131 81 221 132 109 200 1 4404 221 407 77 221 132 107 2...

Page 75: ...106 160 1 4404 221 131 21 221 407 107 200 1 4404 221 132 17 221 407 109 260 1 4404 221 407 108 221 407 87 360 1 4404 221 407 111 Spare parts list housing combinations with EPDM seals metric sizes Desi...

Page 76: ...d with an are wearing parts Spare parts list V ring KVS 0 1 160 inch OD Item Designation KVS value Mate rial 1 OD 1 5 OD 2 OD 2 5 OD 3 OD 4 OD 6 OD 7 V ring 0 1 EPDM FKM FFKM HNBR 932 064 932 073 932...

Page 77: ...2 L 85 M16 229 322 23 0 1 1 4301 229 167 02 0 16 1 4301 229 322 01 0 25 1 4301 229 322 01 0 4 1 4301 229 322 01 0 63 1 4301 229 322 01 1 1 4301 229 322 01 1 6 1 4301 229 322 01 2 5 1 4301 229 322 01 4...

Page 78: ...6 1 4404 on request 2 5 1 4404 on request 4 1 4404 on request 6 3 1 4404 on request on request 10 1 4404 on request on request on request 16 1 4404 on request on request 25 1 4404 on request on reques...

Page 79: ...on request on request 40 1 4404 221 762 86 221 762 51 221 762 51 60 1 4404 221 762 07 221 762 07 221 762 08 80 1 4404 221 762 92 221 762 52 100 1 4404 on request 160 1 4404 221 762 96 200 1 4404 on r...

Page 80: ...32 50 6 3 1 4404 221 407 09 221 132 48 10 1 4404 221 407 09 221 132 48 221 132 113 16 1 4404 221 407 65 221 131 68 25 1 4404 221 131 93 221 132 49 221 407 73 35 1 4404 221 131 98 221 407 20 221 407 23...

Page 81: ...h IPS Item Designation KVS value Material 2 IPS 3 IPS 4 IPS 6 IPS 7 V ring 10 EPDM 932 017 FKM 932 029 FFKM 932 111 HNBR 932 085 16 EPDM 932 046 FKM 932 030 FFKM 932 110 HNBR 932 087 25 EPDM 932 019 F...

Page 82: ...2 25 200 1 4301 229 322 23 260 1 4301 229 322 23 360 1 4301 229 322 23 Spare parts list valve disk SFM equal percentage metallic seal inch IPS Item KVS value Material 2 IPS 3 IPS 4 IPS 6 IPS 15 0 1 1...

Page 83: ...1 4404 on request 16 1 4404 on request 25 1 4404 on request 35 1 4404 on request on request 40 1 4404 221 762 87 221 762 89 60 1 4404 221 762 05 221 762 06 80 1 4404 221 762 93 221 762 95 100 1 4404...

Page 84: ...404 4 1 4404 6 3 1 4404 10 1 4404 221 762 72 16 1 4404 221 762 74 25 1 4404 221 762 76 35 1 4404 221 762 80 221 762 82 40 1 4404 221 762 84 221 762 48 60 1 4404 221 762 03 221 762 04 80 1 4404 221 762...

Page 85: ...92 221 762 52 100 1 4404 on request 160 1 4404 221 762 96 200 1 4404 on request 260 1 4404 221 762 102 360 1 4404 on request Spare parts list seat ring S inch IPS Item KVS value Material 2 IPS 3 IPS 4...

Page 86: ...housing connection S metallic seal inch IPS Item KVS value Material 2 IPS 3 IPS 4 IPS 6 IPS 420 0 1 1 4404 0 16 1 4404 0 25 1 4404 0 4 1 4404 0 63 1 4404 1 1 4404 1 6 1 4404 2 5 1 4404 4 1 4404 6 3 1...

Page 87: ...s list VARIVENT control valve type S divert valve W X Fig 32 Type W SWW Fig 33 Type X SXW Fig 34 Housing combinations Spare parts list VARIVENT control valve type S divert valve W X 430BAL011074EN_5 0...

Page 88: ...02 229 168 11 229 168 07 229 168 08 229 168 08 229 168 09 Items marked with an are wearing parts Spare parts list item 10 metric sizes Item Designation KV value Material DN 25 DN 40 DN 50 DN 65 DN 80...

Page 89: ...e parts list item 33 metric sizes Item Designation KV value Material DN 25 DN 40 DN 50 DN 65 DN 80 DN 100 33 Seat ring 6 3 1 4404 221 107 25 16 1 4404 221 107 28 25 1 4404 221 107 29 35 1 4404 221 107...

Page 90: ...n 1 4301 229 167 02 229 168 16 229 168 17 229 168 14 229 168 14 229 168 15 Items marked with an are wearing parts Spare parts list item 10 inch OD Item Designation KV value Material DN 25 DN 40 DN 50...

Page 91: ...s Spare parts list item 33 inch OD Item Designation KV value Material 1 OD 1 5 OD 2 OD 2 5 OD 3 OD 4 OD 33 Seat ring 6 3 1 4404 221 107 25 16 1 4404 221 107 28 25 1 4404 221 107 29 35 1 4404 221 107 3...

Page 92: ...ts list VARIVENT control valve type S 3 stage seat K Fig 35 X only valid for DN 25 and 1 OD Fig 36 Housing combinations Spare parts list VARIVENT control valve type S 3 stage seat K 430BAL011074EN_5 9...

Page 93: ...176 930 178 HNBR 930 632 930 633 930 633 930 634 930 634 930 863 The items marked with an are wearing parts Spare parts list item 9 metric sizes Item Designation Material DN 25 DN 40 DN 50 DN 65 DN 8...

Page 94: ...229 168 37 14 4 3x KV25 1 4404 229 168 38 23 1 3x KV40 1 4404 229 168 34 34 6 3x KV60 1 4404 229 168 39 Spare parts list items 43 46 75 76 401 and 402 metric sizes Item Designation Material DN 25 DN 4...

Page 95: ...re parts list item 9 inch OD Item Designation Material 1 OD 1 5 OD 2 OD 2 5 OD 3 OD 4 OD 9 Motor stool 1 4301 229 167 02 229 168 16 229 168 17 229 168 14 229 168 14 229 168 15 Spare parts list item 10...

Page 96: ...list items 43 46 75 76 401 and 402 inch OD Item Designation Material 1 OD 1 5 OD 2 OD 2 5 OD 3 OD 4 OD 43 Clamp connection KL 1 4401 221 507 02 221 507 04 221 507 04 221 507 09 221 507 09 221 507 11 4...

Page 97: ...16 Spare parts list sterile lock HSP Fig 37 X sterile lock HSP top Y sterile lock HSP bottom Z only for bottom sterile lock Spare parts list sterile lock HSP 430BAL011074EN_5 08 11 2021 97...

Page 98: ...ing N 1 4301 221 143 01 221 143 02 221 143 02 221 143 02 221 143 02 1 O ring item 158 is not included in the sterile lock HSP cpl and must be ordered separately The items marked with an are wearing pa...

Page 99: ...1 600 04 221 600 05 163 Plug SPS PVDF 221 000870 221 000870 221 000870 221 000870 221 000870 170 Locking ring N 1 4301 221 143 02 221 143 03 221 143 04 221 143 06 221 143 05 1 O ring item 158 is not i...

Page 100: ...Short designation according to DIN ISO 1629 Ethylene Propylene Diene Rubber F Unit of measurement of temperature degree Fahrenheit FKM Material designation short designation according to DIN ISO 1629...

Page 101: ...Self learning installation During commissioning and maintenance the SET UP procedure carries out all the necessary settings for the generation of messages AF Specifications for the size of spanners w...

Page 102: ......

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