Control and feedback systems
GEA FLOWVENT Control Top
Operating instruction (Translation from the original language)430BAL014912EN_3
Page 1: ...Control and feedback systems GEA FLOWVENT Control Top Operating instruction Translation from the original language 430BAL014912EN_3...
Page 2: ...t is protected by copyright All rights reserved The document may not be copied reproduced translated or converted to an electronic medium of machine readable form in whole or in part without the expre...
Page 3: ...9 3 2 2 Control top without solenoid valves 19 3 2 3 Control Top with Solenoid Valves 20 3 2 4 Control Top with Cap 21 3 2 5 Safety Air Exhaust Installation Position 21 3 2 6 Reset Function Activating...
Page 4: ...10 5 Dismantling the Control Top into its Components 62 10 5 1 Variants of the Control Top 62 10 5 2 Removing the Cap 62 10 5 3 Removing the Solenoid Valve from the Base 1 PV variant 63 10 5 4 Removi...
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: ...onent 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 instructions 1 First step in...
Page 7: ...for use in areas with a potentially explosive atmosphere Hint The manufacturer will not accept any liability for damage resulting from any use of the valve which is not in accordance with the designat...
Page 8: ...ctive equipment are used Inform personnel regarding any properties of the product which might pose a health risk and the preventative measures to be taken Have a qualified first aid representative on...
Page 9: ...scriptions please refer to the pertinent standard Digits not to be mentioned can be replaced by the letter x e g IPx6 Concerning the ingress of humidity IPx6 includes all lower IP classes This is howe...
Page 10: ...of the staff For environmental protection the following principles apply Substances harmful to the environment must not be discharged into the ground or the sewage system Always observe the pertinent...
Page 11: ...standards DIN EN 60079 14 for gases and DIN EN 50281 1 2 for dusts The following minimum qualifications are required Training as a specialist for working independently on the component Adequate instru...
Page 12: ...reas Mechanical equipment Electrical equipment Pneumatic system Authorization with regard to safety engineering standards to carry out the following tasks Setting devices into operation Earthing of de...
Page 13: ...s or result in data loss Do not carry out any welding work in the vicinity of the control top or make sure electronics are properly protected 2 9 1 Electrostatically Endangered Components and Modules...
Page 14: ...the power supply and secure it against inadvertently being switched back on again Only allow a qualified electrician to carry out any work on the electrical power supply Check the electrical equipmen...
Page 15: ...8 Terminal strip unit optional 43 Evaluation electronics The FLOWVENT Control Top is made up of a 24 V DC or AS interface evaluation electronics with a position measuring system for the detection of t...
Page 16: ...le optional for the infinitely adjustable setting of the closing velocity of the main stroke a supply air throttle optional for the infinitely adjustable setting of the opening velocity of the main st...
Page 17: ...pin 3 wires 24 5 3 J1 Signals and power supply Plug connector Pico Blade 5 pin 5 wires 24 1 4 Electronics 5 Measuring track 6 PV Y3 Control of pilot valve 3 Plug connector Pico Blade 2 pin 2 wires 63...
Page 18: ...co Blade 5 pin 2 wires 24 3 4 Electronics 5 Measuring track 6 PV Y3 Control of pilot valve 3 Plug connector Pico Blade 2 pin 2 wires 63 7 PV Y2 Control of pilot valve 2 Plug connector Pico Blade 2 pin...
Page 19: ...r throttle The exhaust air from the optional lifting actuators is discharged via separate air connections with sound absorber If the FLOWVENT Control Top is used only as a position indicator without a...
Page 20: ...AS interface data bit with the difference being that the solenoid valve integrated in the base is operated in accordance with the control signals Depending on the design of the process valve up to 3...
Page 21: ...the general instructions regarding ESD protection 3 2 5 Safety Air Exhaust Installation Position To provide protection against excess pressure which can build up inside the FLOWVENT Control Top a vent...
Page 22: ...set The reset button must be pressed for 3 7 sec for this Reset function is possible live After the button has been pressed for 3 seconds the reset is initiated and the LED goes off The actual reset i...
Page 23: ...arning is completed when actuated and non actuated position have been detected and learnt If voltage is only switched off with one learnt position the position already learnt is discarded If the actua...
Page 24: ...table lifting gear and slings for transporting the package units control tops Observe the pictograms on the package The synthetic materials of the control tops are susceptible to breaking Take care wh...
Page 25: ...2 Type of interface mode 24V 24VDC PNP communication max 200 mA ASi AS interface BUS communication max 150 mA 3 Solenoid valves 0 without solenoid valve 1 1 solenoid valve Y1 NC 2 2 solenoid valves Y1...
Page 26: ...data of the control top Technical data temperatures and compressed air supply Designation Description Ambient temperature 20 to 55 C Control air acc to ISO 8573 1 2010 Solid particle content Quality c...
Page 27: ...Immunity for industrial environments EN 61000 6 2 2005 Radio frequency interference EN ISO 61000 6 4 2007 A1 2011 EC Low Voltage Directive 73 23 EEC Electrical wiring configuration 5 pole M12 round c...
Page 28: ...e designation 221 007106 Technical data supply Designation Description Operating voltage UV 21 31 6 V DC Current consumption No load current 30 mA one solenoid valve NC 35 45 mA one solenoid valve NO...
Page 29: ...olour variant Technical data outputs as seen from the AS interface master Bit Function Signal DO0 PV Y1 Activation of solenoid valve Y1 1 solenoid valve activated 0 solenoid valve not activated DO1 PV...
Page 30: ...status steady light no data exchange Colour red status flashing peripheral device fault Colour red yellow status flashing no data exchange address 0 Colour red green status flashing peripheral device...
Page 31: ...alve actuation Valve position DIP switch Illumination Feedback PV Y1 PV Y2 PV Y3 1 Green Yellow S1 S2 0 0 0 not actuated 0 1 0 1 0 1 0 0 Main stroke stroke in S1 tolerance 0 1 0 1 0 1 0 0 Main stroke...
Page 32: ...t 1 1Hz 0 0 0 1 0 0 Main stroke stroke in S1 tolerance 1 1 0 1 0 0 0 0 Main stroke stroke in S1 tolerance 1 1 0 1 0 0 0 0 Main stroke stroke movement 1 0 1Hz 0 0 0 0 0 not actuated 1 0 1 0 1 Lower lif...
Page 33: ...exhaust air outlet EX Y1 with sound absorber item 21 603 042 5 7 Lubricants Lubricants Material no Rivolta F L G MD 2 413 071 PARALIQ GTE 703 413 064 5 8 Equipment Technical data equipment Equipment...
Page 34: ...inless steel Pressure range 0 2 10 bar Gradually adjustable flow at p 6 bar 310 dm3 min n Ambient temperature 10 70 C Flow rate setting at 0 70 C 603 042 Venting screw MIV M12 x 1 5 with membrane Mate...
Page 35: ...pening the crate Under no circumstances should anyone stand under a suspended load Safety devices of the component may not work effectively during installation Reliably secure sections of the plant wh...
Page 36: ...and after SETUP it indicates the status of the process valve locally by a coloured LED under the illuminated dome so that it is visible over a long distance The position feedback signals are supplied...
Page 37: ...es the closing speed of the main stroke The Ex connection must not be closed Air In Central air supply with integrated filter optional supply air throttle reduces the opening speed of the main stroke...
Page 38: ...absorber optional exhaust air throttle The Ex connection must not be closed Air In Central air supply with integrated filter optional supply air throttle Y1 Air connection for main stroke connection...
Page 39: ...Ex Exhaust air of the spring side actuator the Ex connection must not be closed Y3 Closed with locking screw Ex Closed with locking screw 6 3 4 Control top with 3 solenoid valves Fig 17 Assembly and i...
Page 40: ...the main stroke but also of the lift strokes Y1 Air connection for external main stroke connection Y2 For FLOWVENT valves with lift air connection for lifting the valve disk Y3 For FLOWVENT valves wi...
Page 41: ...rmissible operating voltage Carry out the following steps 1 Release the cheese head screws 25 and take off the cap 7 Hint The electrical cable must be long enough to allow the control top to be remove...
Page 42: ...actuated position 3 L UV L reference potential 4 S1 Feedback of non actuated position 5 PV1 Actuation of solenoid valve Y1 Assignment for colour variant green see Colour changeover Table signal outpu...
Page 43: ...potential 4 S1 Feedback of non actuated position 5 PV1 Actuation of solenoid valve Y1 6 PV2 Actuation of solenoid valve Y2 7 PV3 Actuation of solenoid valve Y3 Assignment for colour variant green see...
Page 44: ...21 Terminal assignment of the terminal strip unit 24VDC 50 Fig 22 Terminal assignment of the terminal strip unit 24VDC 50 Carry out the following steps Assembly and installation Electrical connection...
Page 45: ...in the cable gland at a torque of 2 5 Nm Done 6 4 3 Electrical Wiring of AS Interface 6 4 3 1 Connector M12 2 pin 24 3 Fig 23 Corresponding cable sockets part no 508 027 and 508 936 1 AS I 2 Not conne...
Page 46: ...e power supply back on Done Hint When the colours are swapped the feedback signals are also swapped 6 5 2 Illuminated dome Fig 24 Key Position Description 1 Cap 3 Illuminated dome The following status...
Page 47: ...setup LED red flashing for 1 sec pause for 1 sec Default There is a tolerance of 10 for all flashing cycles There is a power failure if no signal is displayed for more than 5 seconds 6 6 Mounting the...
Page 48: ...nd tighten using a pin face spanner and a torque of 20 Nm When setting the torque heed the correction factor of the plug tool If the plug tool 408 451 is used the torque to be set is 15 Nm 4 Screw swi...
Page 49: ...l tops with lift stroke connect the air connections Y2 and Y3 to the connections Y2 and Y3 of the valve actuator In the case of valves with air assist connect Y2 to connection Y2 of the valve actuator...
Page 50: ...e danger zones must be free 7 2 Commissioning Control Top without Solenoid Valves Commissioning can take place if the control top has been mounted correctly on the valve and if the electrical and pneu...
Page 51: ...the following steps 6 Activate and deactivate the external solenoid valve in order to check the proper function of the T VIS feedback signals This completes commissioning 7 3 Commissioning Control Top...
Page 52: ...lready learnt is discarded If the actuated and non actuated positions have been detected and learnt the saved positions are retained when the device is switched back on again following disconnection o...
Page 53: ...the spring tension If maintenance must be conducted on a process valve that is fitted with a control top FLOWVENT Control Top the valve core must be pulled out of the housing For this purpose the valv...
Page 54: ...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 55: ...e not aggressive towards synthetic materials and the sealing materials used and which are non abrasive Hint After all cleaning work make sure that the control top still complies with all safety instru...
Page 56: ...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 57: ...confused when re assembling Protect open line ends with blind plugs against ingress of dirt Pack sensitive parts separately For longer periods of standstill observe the storage conditions see Section...
Page 58: ...the hexagon socket screws on the control top for a tight fit 4 Check the sound absorber filter non return valve and the exhaust air throttle for soiling 5 Check the housing for mechanical damage 6 Che...
Page 59: ...s Servicing Intervals Guideline Values Media at temperatures 60 C to 130 C 140 F to 266 F approx every 3 months Media at temperatures 60 C 140 F approx every 12 months 10 2 3 Signs on the control top...
Page 60: ...anner socket 408 457 406 467 Socket for wrench long 1 4 SW 12 mm 408 458 Tool bit 6 3 PH 2 cross 89 mm 408 459 Tool bit 6 3 10 IP TORX Plus 50 mm 408 460 Tool bit 6 3 20 IP TORX Plus 50 mm 408 461 Too...
Page 61: ...he control top Carry out the following steps 1 Undo the two hexagon socket screws 2 Pull the control top vertically off the valve or installation base The green light goes off and is replaced with a y...
Page 62: ...Variants of the Control Top The control top can be fitted with 1 NC solenoid valve or 2 solenoid valves 1x NC and 1x NO or 3 NC solenoid valves 10 5 2 Removing the Cap Fig 30 Maintenance Dismantling t...
Page 63: ...ne 10 5 3 Removing the Solenoid Valve from the Base 1 PV variant Fig 31 Requirement Only use solenoid valves specified in chapter Technical data Hint In order to avoid or minimize the possibility of d...
Page 64: ...Done Hint Fit the solenoid valves and valve plate in reverse order Tighten the screws 66 to a max tightening torque of 1 Nm 10 5 4 Removing the Solenoid Valves and the Control Plate 2 PV variant Fig 3...
Page 65: ...2 Undo the screws 66 and separate the solenoid valve 63 from the pneumatic block 8 3 Undo the screws 66 and if present separate the valve plate 65 from the pneumatic block 8 Done Hint Fit the solenoid...
Page 66: ...n time and high ambient temperature Risk of burns from the solenoid valve Allow to cool before dismantling Carry out the following steps 1 Undo the connector of the solenoid valves at the evaluation e...
Page 67: ...teps 1 Loosen all the cables and connectors on the evaluation electronics and remove them 2 Unscrew and remove the screws 57 3 Grip the evaluation electronics 43 by the top edges and take out of the b...
Page 68: ...electronics in reverse order Observe the wiring diagrams see Section 6 4 1 Page 41 10 5 7 Dismantling the Pneumatic Block for 2PV and 3PV variant Requirement If only O rings 42 are to be changed sole...
Page 69: ...36 2 Remove the pneumatic block 8 from the base 5 Done 10 5 8 Fitting the Pneumatic Block for 2PV and 3PV variant Maintenance Dismantling the Control Top into its Components 430BAL014912EN_3 25 01 202...
Page 70: ...version 3PV 1x solenoid valve each 24VDC NC to Y2 and Y3 see Figure 32 3 Insert the pneumatic block 8 in the base 5 and heed the positioning aid on the screw dome 8 1 4 Tighten the pneumatic block 8...
Page 71: ...e pneumatic connections in accordance with the codes on the control top see Section 6 3 Page 35 Done 10 6 Maintenance 10 6 1 Replacing the Seals on the Base Only use sound absorber 21 venting screw 52...
Page 72: ...rol air can exit freely from the sound absorber 21 filter 5 1 and exhaust air throttle 21 1 and replace the parts if necessary 3 Inspect the venting screw with an enclosed diaphragm for signs of free...
Page 73: ...data Do not grease these spare parts before fitting them Fig 40 Carry out the following steps 1 Take out the O rings 31 53 54 and replace them with new ones see Fig 31 2 Check that the control air ca...
Page 74: ...Fig 41 Carry out the following steps 1 Use three screws 25 to fasten the hood 7 on the base 5 to tightening torque 1 Nm Done Maintenance 430BAL014912EN_3 74 25 01 2024...
Page 75: ...s control system or the manual override device on the solenoid valve activated Cancel the actuation After connecting the power supply the valve position is indicated by a yellow flashing light Flashin...
Page 76: ...the storage conditions see Section 4 1 Page 24 12 2 Disposal 12 2 1 General notes Dispose of the component in an environmentally safe manner Observe the statutory waste disposal regulations applicable...
Page 77: ...13 Spare Parts List Control Top FLOWVENT Control Top FLOWVENT CT Fig 42 Spare Parts List Control Top FLOWVENT Control Top FLOWVENT CT 430BAL014912EN_3 25 01 2024 77...
Page 78: ...on electronics 24 VDC 221 007105 Evaluation electronics AS interface 221 007106 51 Cylinder screw with journal A2 70 902 145 52 Venting screw MIV PA 933 181 53 O ring NBR 930 094 54 O ring NBR 930 073...
Page 79: ...0 M I C OPV CT 24V 0 M I T OPV CT ASi 0 M I T OPV Air connection metric imperial 822 110 40 822 110 41 822 110 42 822 110 43 Fig 43 Complete assembly Mounting base pos 4 and gaskets pos 31 and 54 Code...
Page 80: ...p Fig 45 Assignment Y1 Y2 Y3 and Air In refer to the Operating Instructions FLOWVENT Control Top X supply voltage electric actuation and feedback EX waste air of the base Dimension sheet FLOWVENT Cont...
Page 81: ...n EN European Standard EPDM Material designation Brief designation according to DIN ISO 1629 Ethylene propylene diene rubber F Unit of measurement of temperature degree Fahrenheit FVCT FLOWVENT Contro...
Page 82: ...pressure barg psig unless explicitly specified otherwise PTFE Polytetrafluoroethylene SET UP Self learning installation During commissioning and maintenance the SET UP procedure carries out all the ne...
Page 83: ...Appendix 430BAL014912EN_3 25 01 2024 83...
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