GEA VARIVENT 24/7 PMO Operating Instructions Manual Download Page 1

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Hygienic valves

GEA VARIVENT

24/7 PMO valve 2.0, type M/2.0

Operating instruction (Translation from the original language)
430BAL009261EN_2

Summary of Contents for VARIVENT 24/7 PMO

Page 1: ...Hygienic valves GEA VARIVENT 24 7 PMO valve 2 0 type M 2 0 Operating instruction Translation from the original language 430BAL009261EN_2...

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: ...entary Regulations 15 2 6 Qualification of personnel 15 2 7 Safety equipment 17 2 7 1 Signage 17 2 8 Residual dangers 18 2 9 Danger zones 19 3 Description 22 3 1 Design 22 3 2 Functional description 2...

Page 4: ...rical connections 55 10 3 Maintenance intervals 55 10 4 Prior to removal 56 10 5 Disassembly 56 10 5 1 Start disassembly 56 10 5 2 Removing the control top 60 10 5 3 Disconnecting the valve from the h...

Page 5: ...h cleaning of lower balancer 90 14 Spare parts list mixproof valve M 2 0 without cleaning of lower balancer 95 15 Spare parts list Lifting actuator M 2 0 100 16 Dimension sheet mixproof valve type M 2...

Page 6: ...430BAL009261EN_2 6 17 04 2023...

Page 7: ...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 8: ...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 9: ...ation of Conformity in accordance with the EC Machinery Directive 2006 42 EC General Information EU Declaration of Conformity in accordance with the EC Machinery Directive 2006 42 EC 430BAL009261EN_2...

Page 10: ...eclaration will become invalid if any alterations are made to the machine which have not been agreed with us We also declare that the relevant technical documentation for this machine has been prepare...

Page 11: ...to the machine that was not agreed with us this declaration loses its validity Furthermore we declare that the specific technical documentation for this machine has been drawn up in accordance with A...

Page 12: ...the valve which is not in accordance with the designated use of the valve The risk is borne solely by the operating company 2 1 1 Requirements for operation The prerequisite for reliable and safe oper...

Page 13: ...r company Only use the component when it is in perfect operating condition in order to prevent danger to persons and property This operating manual contains information that you and your employees nee...

Page 14: ...ety instructions and dangers The component is safe to operate It was built according to state of the art science and technology Nevertheless dangers can arise from the component if the component is no...

Page 15: ...apply Access to electrical equipment should only be allowed to qualified electricians Always keep unattended switch cabinets locked Modifications of the control system can affect the safe and reliable...

Page 16: ...t under the supervision and guidance of a trained specialist Each employee must meet the following requirements to work on the component Personal suitability for the respective task Sufficient profess...

Page 17: ...s 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 devic...

Page 18: ...e Inadvertent switch on of the valve Effectively disconnect all components effectively prevent switch on Electric power Observe the following safety rules 1 Isolate from the power supply 2 Take approp...

Page 19: ...e cover panels during the operation Never reach into openings As a precautionary measure wear personal protective equipment in the vicinity of the valve Protective gloves Safety shoes Environmental da...

Page 20: ...Fig 4 Danger zones In the event of malfunctions shut down the valve disconnect from the power and air supply and secure it against being used Safety Danger zones 430BAL009261EN_2 20 17 04 2023...

Page 21: ...ork on the electrical power supply Check the electrical equipment of the valve at regular intervals Immediately remedy loose connections and molten cables If work on live parts cannot be avoided call...

Page 22: ...3 Description 3 1 Design Fig 5 The Varivent type M 2 0 is fitted with a radial valve disk and double disk seal Description Design 430BAL009261EN_2 22 17 04 2023...

Page 23: ...or B T VIS control top 1 Seal ring 2 Rod guide ring 3 Seal disk 5 O ring 7 V ring RA 9 Lantern 15 Valve disk 16 Double disk L1 Lift actuator 406 Valve housing 113 Sterile lock MMU Description Design 4...

Page 24: ...vented from entering the other pipe 3 2 2 Cleaning by lifting When cleaning the pipeline the valve disk in contact with the cleaning liquid can be lifted separately This allows the cleaning liquid to...

Page 25: ...that any ice crystals formed by condensation water can melt 4 2 Transport Fig 7 For transport the following principles apply When transporting the valve be sure to unscrew the control top and the swit...

Page 26: ...ircumstances should anyone stand under a suspended load Take care when transporting the valve Do not grip sensitive parts of the unit to lift or push the unit or to support yourself Avoid putting the...

Page 27: ...psi 6 bar to 8 bar 87 psi to 116 psi Product pressure bar psi 10 bar 145 psi max 5 2 Technical data Refer to the following tables for the key technical data of the valve Technical data Valve Designat...

Page 28: ...class 4 max dew point 3 C If the unit is used at higher altitudes or at low ambient temperatures the dew point must be adapted accordingly Oil content Quality class 3 preferably oil free max 1 mg oil...

Page 29: ...0 C 176 F Inorganic acids 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 100 C 176 F Steam up to 135 C 275 F o o Steam approx 30 min up to 150 C 302 F o Fuels hydro...

Page 30: ...ad screwdriver 2 5 mm 406 102 Open end spanner a f 10 11 408 033 Open end spanner a f 16 18 408 183 Open end spanner a f 14 17 406 045 Hook wrench to hold the driver sleeve 30 4 for DN 50 DN100 408 20...

Page 31: ...ose cutter 407 065 Snap ring pliers straight J3 408 483 V ring insertion tool 229 109 88 5 6 Lubricants Lubricants Lubricant designation Material no Rivolta F L G MD 2 1000 g 413 071 Rivolta F L G MD...

Page 32: ...stallation Reliably secure sections of the plant which have already been connected against inadvertently being switched on 6 2 Notes on installation The installation position of the valve is upright C...

Page 33: ...Fig 9 Installation position of the valve housing Warning Spring tension in the valve Danger of injury when opening the clamp connections on the actuator or on the housing as the released spring preten...

Page 34: ...n assembling the valve always replace the housing O rings to ensure that the valve is tight 6 6 Pneumatic connections 6 6 1 Air requirement Size Actuator type Air requirement dm3 n stroke dm3 n at 1 0...

Page 35: ...essed air supply Hose connection has been established 6 6 2 1 Hose connection plan mixproof valves M 2 0 with control top T VIS Fig 10 I Proximity switch serves to detect the double disk rest position...

Page 36: ...maximum permissible operating voltage Explosive gases or dusts An explosion can result in serious personal injury or death Observe the installation and operating regulations for use in potentially exp...

Page 37: ...lly This process lasts approx 90 seconds Do not press any buttons during setup Regardless of whether and in what colours the LED shines or flashes As soon as the LED shines permanently green the setup...

Page 38: ...rds turning it anticlockwise moves the sensor downwards Warning Risk when actuating the valve if there is fluid in the valve Fluids can leak or become mixed in the pipes Ensure that there is no fluid...

Page 39: ...ng sensor 1 Carry out the following steps 1 Set the sensor S1 by turning the adjusting screw 1 clockwise to the switchpoint until the LED D1 shines green Assembly and installation Electrical connectio...

Page 40: ...ion by electrically or manually actuating the solenoid valve Y1 Carry out the following steps 1 Release the lock screw 2 Fig 16 Presetting sensor 2 Carry out the following steps 1 Set the sensor S2 by...

Page 41: ...Adjustment of the initiators in the lantern Hint Only in combination with T VIS A 15 M 15 6 7 2 1 Fitting the sliding piece Carry out the following steps 1 Position the nut 2 against the slot 4 1 in t...

Page 42: ...dge of the double disk 7 Fig 20 2 Position the sliding piece 1 by releasing the countersunk screw 3 in the slot 4 1 in the recess in the lantern so that the tip of the adjusting mandrel 6 lies on the...

Page 43: ...8 together with the lock nut 11 into the sliding piece through to the double disk 7 Fig 22 Done 6 7 2 4 Set the proximity switch Carry out the following steps 1 Unscrew the proximity switch 8 by one...

Page 44: ...dy connected electrically to the control top B on the proximity switch 8 using the union nut M12 10 1 The LED on the proximity switch 8 must now shine in operating mode Done Assembly and installation...

Page 45: ...e control head Step 2 Carry out the following steps 1 Activate the lifting process of the lower seat by controlling the solenoid valve Y2 via the PLC When the seat moves downwards approx 6 mm the gree...

Page 46: ...teps 1 If the upper housing is part of the active CIP circuit Activate the lifting process of the lower seat by controlling the solenoid valve Y2 on the PLC 2 If the lower housing is part of the activ...

Page 47: ...nsitivity of the position measuring system is 0 1 mm The closed position of the upper seat is detected by the externally mounted proximity switch S3 of the lantern The correct setting of this initiato...

Page 48: ...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 49: ...y check that all emergency stop devices are working correctly 8 2 Feedback system signal analysis Hint The purpose of the proximity switch is to monitor the double disk idle position during the idle p...

Page 50: ...ing Parameters in Dairy Operations Example of a two phase cleaning process Sodium hydroxide solution and sodium hydroxide based combination products in concentrations from 0 5 to 2 5 at 75 C 167 F to...

Page 51: ...posed automatically This allows the cleaning fluid to enter the Balancer Cleaning Device and thereby clean the surface of the balancer 9 1 5 Examples for cleaning by lifting Examples Medium Duration s...

Page 52: ...s are usually excepted from this Passivation is typically performed using nitric acid HNO3 at approx 80 C 176 F at a concentration of 3 and a contact time of 6 to 8 hours Cleaning 430BAL009261EN_2 52...

Page 53: ...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 54: ...nst ingress of dirt Pack sensitive parts separately For longer periods of standstill observe the storage conditions see Section 4 1 Page 25 10 2 Inspections Between the maintenance periods the valves...

Page 55: ...electrical cable must be long enough to allow the control top to be removed via the switch bar 10 3 Maintenance intervals To ensure the highest operational reliability all wearing parts should be rep...

Page 56: ...the following steps 1 Drain all pipe system elements that lead to the valve and if necessary clean or rinse them 2 Disconnect the power supply 3 Take the valve out of the pipe section with all housin...

Page 57: ...Fig 25 Requirement Maintenance Disassembly 430BAL009261EN_2 17 04 2023 57...

Page 58: ...of injury when detaching the clamp connection 43 as the released spring pretension will suddenly lift the actuator Therefore release the spring tension before detaching the clamp connection by pressu...

Page 59: ...he drive via the manual actuator Y1 3 Remove the clamp connection 43 between the housing 406 and the lantern 9 4 Vent the drive via the manual actuator Y1 0 bar 5 Attach the cap 7 and tighten the Phil...

Page 60: ...ed screwdriver Carry out the following steps 1 Release the electrical connection plug from the proximity switch in the lantern 2 Undo screws 39 with the inner hex socket key 3 Remove snap rings 15 fro...

Page 61: ...ansport see Section 4 2 Page 25 7 Unscrew the sliding piece 1 2 with a slot head screwdriver from the piston rod A 4 1 Done 10 5 3 Disconnecting the valve from the housing Fig 28 Maintenance Disassemb...

Page 62: ...may not be damaged When removing the valve from the pipe B take care not to hit the balancer against the housing Carefully disassemble the valve Carry out the following steps 1 Carefully remove the va...

Page 63: ...key Socket wrench hex ring wrench Open ended wrench Carry out the following steps 1 Release the clamp connection 46 2 Remove the drive A from the lift drive L1 3 Lift the locking flange L from the li...

Page 64: ...are sensitive components The sealing surfaces of the double disk 16 and the seal disk 3 may become damaged Damage to these parts can result in malfunction Proceed carefully when removing the double d...

Page 65: ...g pliers Open ended wrench Carry out the following steps 1 Remove the leakage indicator 91 from the driver sleeve L6 2 Push the driver sleeve L6 upwards toward the flange of the lifting actuator L1 1...

Page 66: ...ion 46 see figure 32 Rated widths from 2 5 OD and DN 65 Release and unscrew the hex screws 110 see figure 32 7 Remove the lantern L9 from the lifting actuator L1 Fig 33 The O rings L18 L19 L20 are now...

Page 67: ...and remove the clamp connection 43 2 Disconnect the sterile lock 113 from the housing 3 Take the guide MU 112 from the sterile lock Seal ring 65 and O ring 111 are now accessible Done 10 5 8 Disassemb...

Page 68: ...steps 1 Unscrew and remove the clamp connection 43 2 Disconnect the balancer plug 92 from the housing The gasket 65 can now be accessed freely Done 10 6 Installation Maintenance Installation 430BAL00...

Page 69: ...control top 1 0 7 Clamp connection cast half rings Bolts M6 9 6 6 M8 22 16 2 M10 45 33 10 6 2 Fitting the lifting actuator Tools required Installation mandrel D1 D2 Vice Socket wrench Snap ring pliers...

Page 70: ...lift L1 with the clamp connection 43 Rated widths from 2 5 DN Attach the lantern 9 with hex screws 110 on the lifting actuator L1 with a jaw wrench Ensure that the clamp connection 43 is firmly insta...

Page 71: ...eve L6 onto the mandrel D1 and bush L5 then remove the mandrel D1 6 Clamp the mandrel D2 in the vice 7 Push driver sleeve L6 on the threaded side onto the mandrel L2 8 Push the drive sleeve L2 and the...

Page 72: ...rel D2 from the driver sleeve L6 with the socket wrench Done 10 6 3 Installing the valve Tools required Hook wrench Mandrel Socket wrench Open ended wrench Carry out the following steps 1 Push the lea...

Page 73: ...h the seal disk 3 with the bearings guide ring 2 O ring 5 and seal ring 1 onto the double disk 16 4 Screw in the double disk 16 with the driver sleeve L6 When screwing in the double disk 16 press the...

Page 74: ...e L6 with a hook wrench at Z Fig 42 6 Insert the mandrel into one of the boreholes 16 1 and tighten the double disk 16 7 Position and affix the wrench to the hex of the carrier L2 Maintenance Installa...

Page 75: ...alve disk 15 into the double disk 16 and tighten with the jaw wrench on the wrench surface 15 1 Observe torques see table Tightening torques Section 10 6 1 Page 69 Maintenance Installation 430BAL00926...

Page 76: ...piston rod into the lift drive L1 11 Grease the thread of the clamp connections 46 and install Ensure that the clamp connection 43 is firmly installed Observe torques see table Tightening torques Sec...

Page 77: ...Use the slot head screwdriver and a torque of 2 Nm 1 4 lbft to screw the sliding piece 1 2 into the piston rod 2 Push the switch bar 1 into the piston rod A 4 1 and tighten with jaw wrench Tighten th...

Page 78: ...2 Position the balancer plug 92 into the housing 3 Grease the thread of the clamp connections 43 and install Ensure that the clamp connection is firmly installed Observe torques see table Tightening t...

Page 79: ...sing 3 Position the sterile lock 113 into the housing 4 Grease the thread of the clamp connections 43 and install Ensure that the clamp connections 43 are firmly installed Observe torques see table Ti...

Page 80: ...Requirement No solenoid valve must be actuated electrically The pneumatic and electrical connections on the plant side can remain on the control top Maintenance Installation 430BAL009261EN_2 80 17 04...

Page 81: ...roke via the manual actuator Y1 4 Grease the thread of the clamp connections 43 and install Ensure that the clamp connections 43 are firmly installed Observe torques see table Tightening torques Secti...

Page 82: ...ked Hint When strokes are correct it is possible to make adjustments or set the feedback See and the relevant operating instructions of the respective control top 10 6 8 2 Check the lift stroke Carry...

Page 83: ...ee Section 10 5 Page 56 2 Carefully clean the individual parts Done Hint Observe the safety data sheets supplied by the detergent manufacturers Only use detergents which are non abrasive and not aggre...

Page 84: ...attention that water does not drip into the V ring groove on the valve disc 3 Put in V ring RA Make sure the installation position of V ring RA is correct see illustration Fig 51 4 Use the insertion...

Page 85: ...st not be used again since the proper function of the seal can then no longer be ensured 10 7 2 2 Replace more seals Fig 53 10 7 2 3 Lubricating seals and threads Maintenance Maintenance 430BAL009261E...

Page 86: ...letely For product contact seals only use suitable greases and oils Observe the safety data sheets issued by the lubricant manufacturer Carry out the following steps 1 Apply a light film of lubricant...

Page 87: ...d from GEA Tuchenhagen Using other types of grease can result in malfunctions or in premature seal failure The warranty will also become null and void A Manufacturer s Declaration for these products c...

Page 88: ...Replace the solenoid valve Valve works against a hydraulically closed pipe Open the pipe Double disk oscillates during lifting or does not open Air pressure too low Increase air pressure Product pres...

Page 89: ...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 90: ...cleaning of lower balancer Fig 55 Z relevant for variant with cleaning connection up to 2015 for 1 5 to 4 and up to 2023 for DN 150 6 OD Fig 56 Spare parts list mixproof valve M 2 0 with cleaning of...

Page 91: ...7 06 221 507 06 65 Sealing ring RA EPDM 221 367 02 221 367 02 221 367 03 FKM 221 367 12 221 367 12 221 367 08 HNBR 221 367 13 221 367 13 221 367 15 72 O ring EPDM 930 610 930 610 930 610 FKM 930 662 9...

Page 92: ...21 476 01 221 476 02 5 O ring EPDM 930 150 930 156 930 260 FKM 930 176 930 178 930 259 HNBR 930 634 930 863 7 V ring RA I EPDM 221 365 08 221 365 09 221 365 16 FKM 221 365 11 221 365 12 221 365 17 HNB...

Page 93: ...1 403 Housing MA 2 0 1 4404 221 727 01 221 727 02 221 727 03 404 1 Housing MB 2 0 90 221 725 01 221 725 04 221 725 07 404 2 Housing MB 2 0 180 221 725 02 221 725 05 221 725 08 404 3 Housing MB 2 0 270...

Page 94: ...646 930 646 930 646 930 647 74 1 Snap seal DN50 DN50 DN50 DN50 DN100 6 IPS PVDF 221 000522 221 000522 221 000522 221 000522 221 000523 221 000524 94 1 V ring RA I DN50 40 DN50 40 DN80 65 DN80 65 DN100...

Page 95: ...14 Spare parts list mixproof valve M 2 0 without cleaning of lower balancer Fig 57 Fig 58 Spare parts list mixproof valve M 2 0 without cleaning of lower balancer 430BAL009261EN_2 17 04 2023 95...

Page 96: ...06 221 507 06 65 Sealing ring RA EPDM 924 305 924 305 221 367 03 FKM 924 307 924 307 221 367 08 HNBR 924 333 924 333 221 367 15 66 Guide ring 3A MF6 935 117 935 117 935 120 72 O ring EPDM 930 610 930...

Page 97: ...176 930 178 930 259 HNBR 930 634 930 863 7 V ring RA I EPDM 221 365 08 221 365 09 221 365 16 FKM 221 365 11 221 365 12 221 365 17 HNBR 221 365 20 221 365 19 9 Lantern LFT 1 4301 221 651 19 221 651 18...

Page 98: ...3 404 1 Housing MB 2 0 90 221 725 01 221 725 04 221 725 07 404 2 Housing MB 2 0 180 221 725 02 221 725 05 221 725 08 404 3 Housing MB 2 0 270 221 725 03 221 725 06 221 725 09 405 Housing MC 2 0 221 72...

Page 99: ...62 930 662 930 662 930 663 930 664 HNBR 930 646 930 646 930 646 930 646 930 647 74 1 Snap seal DN50 DN50 DN50 DN50 DN100 6 IPS PVDF 221 000522 221 000522 221 000522 221 000522 221 000523 221 000524 94...

Page 100: ...15 Spare parts list Lifting actuator M 2 0 Fig 59 Spare parts list Lifting actuator M 2 0 430BAL009261EN_2 100 17 04 2023...

Page 101: ...057 704 015 18 O ring NBR 930 850 930 850 930 850 19 O ring NBR 930 848 930 848 930 848 20 O ring NBR 930 242 930 242 930 242 Sealing set Lift LR DN40 100 NBR EPDM 221 528 113 221 528 113 221 528 113...

Page 102: ...ng NBR 930 850 930 850 930 107 19 O ring NBR 930 848 930 848 930 849 20 O ring NBR 930 249 930 249 930 249 Sealing set Lift LR DN40 100 NBR EPDM 221 528 113 221 528 113 Sealing set Lift LR DN40 100 NB...

Page 103: ...16 Dimension sheet mixproof valve type M 2 0 Fig 60 Dimension sheet mixproof valve type M 2 0 430BAL009261EN_2 17 04 2023 103...

Page 104: ...5 644 5 H incl T VIS mm 550 563 5 569 75 598 604 5 616 75 808 5 C mm 81 94 5 108 5 124 130 5 142 5 190 LS mm 6 6 6 6 6 6 6 X mm 540 746 5 785 5 857 889 5 950 5 1217 Stroke mm 27 28 35 45 45 45 65 Smal...

Page 105: ...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 106: ...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 107: ...Appendix 430BAL009261EN_2 17 04 2023 107...

Page 108: ......

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