GEA VARIVENT 24/7 PMO Original Operating Instructions Download

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Safety

Signage

Dangerous points on the valve are indicated by warning signs, prohibition signs and
mandatory signs.

The signs and notes on the valve must always be legible. Any illegible signs must be
replaced immediately.

Signs on the valve

Sign

Meaning

General hazard warning

Warning Crushing

Explosive atmosphere hazard warning

Operating Instructions · VARIVENT

Mixproof Valve M-C/2.0

Edition 2018-10-04

Summary of Contents for VARIVENT 24/7 PMO

Page 1: ...Original Operating Instructions VARIVENT 24 7 PMO Cheese Curd Valve 2 0 Type M_C 2 0 Edition 2018 10 04 430BAL013215EN_1...

Page 2: ...uchenhagen gea com Web http www tuchenhagen com These Operating Instructions are the original instructions in the sense of the EU Machinery directive These operating instructions are protected by copy...

Page 3: ...6 Disassembly 17 Environmental Protection 17 Electrical Equipment 17 Signage 18 Residual Risk 19 Hazard Areas 19 Residual Dangers 21 Declaration of Conformity 22 Transport and Storage 23 Scope of Supp...

Page 4: ...ting 51 Passivation 51 Malfunctions 52 Maintenance 53 Inspections 53 Product Contact Seals 53 Pneumatic Connections 53 Electrical Connections 53 Maintenance Intervals 54 Prior to dismantling the Valve...

Page 5: ...eneral Notes 74 Valve Actuator Disposal 75 Technical Data 76 Type Plate 76 Technical Data 76 Resistance of Sealing Materials 78 Pipe Ends 79 Weights 79 Tools 80 Lubricants 80 Spare Parts Lists 81 Dime...

Page 6: ...ctions before starting any work on or using the valve Your personal safety and the safety of the valve can only be ensured if you act as described in the Operating Instructions Store the Operating ins...

Page 7: ...CAUTION Warning Injuries Failure to observe the warning note can result in minor or moderate damage to health The arrow identifies a precautionary measure you have to take to avoid the hazard IMPORTA...

Page 8: ...hes Institut f r Normung e V German Institute for Standardization EN European Standard EPDM Material designation Short designation according to DIN ISO 1629 Ethylene Propylene Diene Rubber F Unit of m...

Page 9: ...lyethylene psi Anglo American Unit of measurement of pressure Pound force per square inch All pressure ratings bar psi stand for over pressure barg psig if this is not explicitly described differently...

Page 10: ...ved The following principles apply Only allow qualified staff to work on the valve The operator must authorize the staff to carry out the relevant tasks Working areas and the entire environment of the...

Page 11: ...es and DIN EN 50281 1 2 for dusts The following minimum qualifications are required Vocational training as a specialist who can work on the valve independently Sufficient instruction to work on the va...

Page 12: ...nstruction and sound knowledge in the following areas Function of the valve Valve operating sequences What to do in case of an emergency Lines of authority and responsibilities with respect to the tas...

Page 13: ...hand at the valve s place of use They must be complete and in clearly legible form Only use the valve for its intended use The valve must be functional and in good working order Check the condition o...

Page 14: ...ort crates immediately after opening the crate Under no circumstances should anyone stand under a suspended load During assembly the valve safety devices might not be working effectively Reliably secu...

Page 15: ...e valve must be adequately ventilated at all times Structural alterations of the valve are not permitted Immediately report any changes on the valve to the person responsible Always keep danger zones...

Page 16: ...ock access for unauthorized persons Put up notice signs which draw attention to the maintenance or repair work going on Do not climb on the valve Use suitable access aids and working platforms Wear su...

Page 17: ...rotection Harm to the environment can be avoided by safety conscious and proactive behaviour of the staff For environmental protection the following principles apply Substances harmful to the environm...

Page 18: ...nd mandatory signs The signs and notes on the valve must always be legible Any illegible signs must be replaced immediately Signs on the valve Sign Meaning General hazard warning Warning Crushing Expl...

Page 19: ...en the clamps 43 are opened as the released spring pretension will suddenly lift the actuator Therefore release the spring tension before detaching the clamps by supplying the actuator A with compress...

Page 20: ...ve cleaning medium escapes from the leakage outlet This leakage must be collected in a suitable container e g a funnel or a drip pan and removed in a controlled manner Observe the instructions in the...

Page 21: ...tension in the actuator Danger to life caused by compression spring in the actuator Do not open the actuator but return it to GEA Tuchenhagen for proper disposal Danger of injury Danger presented by m...

Page 22: ...e invalid if any alterations are made to the machine which have not been agreed with us Authorised representative for compilation Authorised representative of the technical documentation CE documentat...

Page 23: ...le valves with care to avoid damaged caused by impact or careless onloading and unloading The outside synthetic materials are susceptible to breaking The control tops must be protected from animal and...

Page 24: ...rage the valve is going to be exposed to temperatures 0 C it must be dried and suitable measures be taken to protect it from damage NOTE We recommend that the valve should be stored at a temperature o...

Page 25: ...torage as well as professional installation and assembly Operating the valve within the limits of its designated use also involves adhering to the operating inspection and maintenance instructions Pre...

Page 26: ...will have to undergo a new conformity process in accordance with the EC Machinery Direc tive on your own In general only original spare parts supplied by GEA Tuchenhagen GmbH should be fitted This ens...

Page 27: ...ction Design No Designation No Designation A actuator 9 lantern B control top T VIS 15 valve disk 1 sealing ring 16 double valve disk 2 rod guide ring L1 lifting actuator 3 sealing disk 17 valve housi...

Page 28: ...ctive seals can thus easily be detected The penetration of leaking fluids from one pipe into the other is excluded under normal oper ating conditions Actuator Function Actuator with spring closing fun...

Page 29: ...als e g tools bolts lubricants are left in the system Valve with Detachable Pipe Connection Elements This section describes the procedure to fit the valve CAUTION Liquids in pipes Danger of injury due...

Page 30: ...any In case of incorrect installation position the valve is not working properly Make sure that the housing has the correct orientation TOP see pict Carry out the following steps 1 Release the spring...

Page 31: ...ut the following steps 1 Shut off the compressed air supply 2 Use the hose cutter to cut the pneumatic hoses square 3 Push the air hose into the air connector on the control top 4 Re open the compress...

Page 32: ...Date 2012 03 19 Page 32 221BAL009233 fm Hosing Diagram VARIVENT Mixproof Valve M 2 0 Hosing Diagram Operating Instructions VARIVENT Mixproof Valve M C 2 0 Edition 2018 10 04...

Page 33: ...ctrical equipment Prior to establishing electrical connections check the maximum permissible oper ating voltage EXPLOSION HAZARD Explosive gases or dusts An explosion can result in serious personal in...

Page 34: ...ion is a summary of the basic adjustment steps and is not intended as a substitute for the official operating instructions The operating instructions should always be consulted for comprehensive opera...

Page 35: ...up will proceed automatically This will take approx 60 seconds Do not press any buttons during the 60 second set up procedure irrespective of the colors or flashing of the LED Once the LED is a stead...

Page 36: ...i clock wise rotation downwards Presetting CAUTION Danger if media are present in the valve when this is actuated They can escape or mix in the pipelines Make sure that no media are inside the valve I...

Page 37: ...ntil the diode turnes off Setting the switch point Carry out the following steps 1 Setting the switchpoint in upward position 1 clockwise rotation Light emitting diode D1 at the interface top shines g...

Page 38: ...rew 1 in the direction of the upper switching edge 4 of the switching range 3 until the diode turnes off Setting the switch point Carry out the following steps 1 Setting the switchpoint in downward po...

Page 39: ...ith the mounting hole 1 1 facing in the direction of the housing 5 3 Turn the nut NI 2 in the slot 4 1 in the lantern through 90 and tighten with the countersunk screw 3 Adjusting the prox imity switc...

Page 40: ...he prox imity switch Carry out the following steps 1 Unscrew the proximity switch by one full turn 360 to set the gap a in the range from 0 5 to 1 0 mm 2 Tighten the lock nut 11 3 Secure the connector...

Page 41: ...arry out the following steps 1 Place the proximity switch nut 2 against the slot 4 1 from the inside of the lantern 4 and hold it in position with a finger 2 Fix the sliding piece 1 with the countersu...

Page 42: ...wing steps 1 Screw the adjusting screw 6 into the proximity switch holder down to the upper edge of the balancer 7 2 By slightly slackening the countersunk screw position the proximity switch holder i...

Page 43: ...e proximity switch Carry out the following steps 1 Unscrew the proximity switch a full rotation 360 to adjust distance a up 0 5 to 1 0 mm 2 Tighten counternut 11 3 Secure the connector 10 which has al...

Page 44: ...he slot 4 1 from the inside of the lantern 4 and hold it in position with a finger 2 Fix the sliding piece 1 with the countersunk screw 3 in the orientation shown with the mounting hole 1 1 facing in...

Page 45: ...o that the point of the adjusting screw 6 rests on the shoulder of the balancer in the direction of the actuator A 3 Fix the proximity switch holder in position with the countersunk screw 3 Fitting th...

Page 46: ...e proximity switch using the cap nut M12 10 1 The LED on the proximity switch must now be lit in operating mode Checking the function Carry out the following steps Check the feedback function by actua...

Page 47: ...ng that the position detecting devices used for upper and lower seat closed position detection DO change status Hardware Description 1 The T VIS A 15 or T VIS M 15 Control Top on the top of the valve...

Page 48: ...sition If the GREEN LED does not turn off the position detecting device is NOT adjusted correctly and the adjustment procedure described under Adjusting the Position Detecting Devices Page 34 of the O...

Page 49: ...ircuit program and determine which housing upper or lower of the valve is part of that active CIP circuit Step 2 Carry out the following steps 1 If the upper housing is part of the active CIP circuit...

Page 50: ...ation products based on sodium hydroxide in concen trations from 0 5 to 2 5 at 75 C to 80 C 167 F to 176 F Phosphoric acid or nitric acid and combination products based on these acids in concentration...

Page 51: ...This kind of cleaning is also recommended for sticking and crystallizing media The PMO double seat valve is also fitted with a balancer cleaning device This is used to clean the product contact surfac...

Page 52: ...valve the valve is operating against the hydraulically closed pipe open pipe Double valve disk oscillates during lifting or does not open Air pressure too low Increase air pressure Product pressure to...

Page 53: ...n of the valve Done Pneumatic Connections Carry out the following steps 1 Check the operating pressure at the pressure reducing and filter station 2 Clean the air filter at regular intervals 3 Check t...

Page 54: ...ure of the cleaning solution ambient conditions Prior to dismantling the Valve Requirement Make sure that during maintenance and repair work no process is in operation in the area concerned Carry out...

Page 55: ...fore release the spring tension before detaching the clamps by pressurizing the actuator with compressed air at max 8bar Carry out the following steps 1 Remove the pneumatic hose at Y3 2 Connect an ex...

Page 56: ...2 Remove the semi annular clamps 15 at the control top B 3 Remove the pneumatic connections at the lifting actuator 4 Pull the control top B upwards to remove The feedback signal to the higher level c...

Page 57: ...e a sensitive components The sealing surfaces on the valve disks B may be damaged Take care when removing the valve insert from the housing that the valve disks do not hit the valve housing Carefully...

Page 58: ...10 04 Dismantling the Valve Disk Carry out the following steps 1 Remove clamp jointClamp joint 46 2 Pull actuator A out of the lifting actuator L1 3 Remove locking flange L3 4 Hold carrier L2 using a...

Page 59: ...en removing the double valve disk IMPORTANT NOTE The deflection edges on the double valve disk are sensitive parts The edges on the double valve disk may be damaged The deflection edge 16 2 must be ha...

Page 60: ...018 10 04 2 Insert pin punch into the bore 16 1 and unscrew double valve disk 16 3 Withdraw sealing disk 3 with rod guide ring 2 O ring 5 sealing ring 1 from the lantern 9 Done Dismantling the Lifting...

Page 61: ...ews 110 7 Pull off lantern 9 from lifting actuator L1 O rings L18 L19 L20 are now accessible Done Maintenance Cleaning the Valve IMPORTANT NOTE The shaft of the valve disk the housing seat the valve s...

Page 62: ...he scriber can slip off when the V ring RA is removed Danger of injury and damaging the valve disk Grip the valve disk in a vice with protected jaws Carry out the following steps Put a scriber into th...

Page 63: ...on tool to fit the V ring RA see illustration Carry out the following steps 1 Before fitting wet the V ring RA on the side not in contact with product rear side with the above mentioned fluid Pay atte...

Page 64: ...be visible after fitting the complete valve For product contact seals only use suitable greases and oils Observe the safety information sheets issued by the lubricant manufacturer Carry out the follow...

Page 65: ...064 and Rivolta F L G MD 2 can be ordered under part no 413 071 Using other types of grease can result in malfunctions or in premature seal failure The warranty will also become null and void A Manufa...

Page 66: ...tions VARIVENT Mixproof Valve M C 2 0 Edition 2018 10 04 Assembling Assembling the Lifting Actuator Carry out the following steps 1 Equip the lifting actuator M 2 0 L1 with O rings L18 L19 L20 and fix...

Page 67: ...bushing L5 with O rings L12 L13 1 and plug it on to the mandrel Then place O ring L13 2 on the top and push everything into the carrier sleeve L6 Remove mandrel 3 Push carrier L2 complete with O ring...

Page 68: ...ng the Valve IMPORTANT NOTE The deflection edges 16 2 on the double valve disk are sensitive parts The edges on the double valve disk may be damaged The deflection edges must be handeld with care Carr...

Page 69: ...Maintenance 69 Assembling 2 Hold carrier sleeve at Z using a hook spanner...

Page 70: ...ition 2018 10 04 3 Tighten the double valve disk 16 complete with V ring RA 7 snap sealing 74 O ring 72 sealing disk 3 O ring 5 sealing ring 1 rod guide ring 2 by applying a pin punch at 16 1 While sc...

Page 71: ...x box spanner size 36 and tighten valve disk 15 together with installed V ring 94 with flexible head face spanner at 15 1 5 Insert locking flange L3 into the lifting actuator L1 6 Insert actuator A in...

Page 72: ...eps 1 Screw the sliding piece 1 2 into the piston rod using a 12 mm slotted screw driver tightening torque 2 Nm 1 4 lbft 2 Insert the switch bar 1 through the sliding piece into the piston rod A 4 1 a...

Page 73: ...ctuator via Y3 For pressure see type plate The valve disk is raised 4 Introduce valve insert carefully into the housing and fix with clamp joint 43 Done Torques of the Semi annular Clamps and Clamp Jo...

Page 74: ...of the machine at the end of its life cycle in an environmentally friendly manner Observe the statutory waste disposal regulations applicable at the place of installation The valve is made of the fol...

Page 75: ...s 24 kN The pre stressed spring can cause serious personal injury or death Never open the actuator GEA Tuchenhagen accepts unopened actuators and arranges for proper disposal free of charge Carry out...

Page 76: ...l number Material 1 4404 AISI 316L EPDM FDA Control air pressure 6 bar up to 8 bar 87 psi up to 116 psi Product pressure 6 bar 145 psi max Technical data Valve Designation Description Size 4 6 OD Mate...

Page 77: ...al PE LD Outside dia 6 mm Inside dia 4 mm Inch Material PA Outside dia 6 35 mm Inside dia 4 3 mm Product pressure max 6 bar 145 psi standard Control air pressure 6 bar up to 8 bar 87 psi up to 116 psi...

Page 78: ...40 275 F FKM 10 200 C 14 392 F HNBR 25 140 C 13 284 F Caustics up to 3 up to 80 C 176 F o Caustics up to 5 up to 40 C 104 F o o Caustics up to 5 up to 80 C 176 F Caustics at more than 5 o Inorganic a...

Page 79: ...de diameter Wall thickness Inside diameter Outside diameter acc DIN EN ISO 1127 1 5 38 1 1 65 60 3 x 2 50 8 1 65 47 6 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 86...

Page 80: ...d screw driver size 2 406 125 Mandrel 4mm 403 209 Mandrel 6 mm 403 211 Mandrel 221 105 76 221 105 77 Mandrel used for installing the bushing into the drive sleeve 221 105 94 1 5 2 2 5 3 221 105 95 6 T...

Page 81: ...1 Spare parts list double seat valve M C 2 0 Fig 1 Spare parts list double seat valve M C 2 0 04 10 2018 81...

Page 82: ...ring RA EPDM 221 367 03 221 367 06 221 367 06 FKM 221 367 08 221 367 11 221 367 11 72 O ring EPDM 930 612 930 612 930 612 FKM 930 664 930 664 930 664 74 Snap seal D_C PVDF 221 000524 221 000524 221 00...

Page 83: ...22 16 221 622 15 3 Locking flange LFT R 200 EN AW 6083 T6 221 613 13 221 613 01 221 613 01 4 Adapter LFT T 200 EN AW 6083 T6 221 614 01 221 614 01 221 614 01 5 Bushing LFT M 2 0 1 4305 221 616 08 221...

Page 84: ...221 613 01 221 613 02 4 Adapter LFT T 200 EN AW 6083 T6 221 614 01 221 614 01 221 614 04 5 Bushing LFT M 2 0 1 4305 221 616 08 221 616 08 221 616 09 6 carrier sleeve LFT M 2 0 1 4305 221 617 07 221 6...

Page 85: ...1 Spare parts list Switch bar T VIS A 15 Fig 1 Spare parts list Switch bar T VIS A 15 04 10 2018 85...

Page 86: ...1 4305 221 573 06 In addition to item 1 only for butterfly valves ECOVENT S 2 Switch bar BFV 7 1 4301 PA6 224 001696 For butterfly valves T smart 7 and 9 3 Switch bar LFT R 1 4301 PA6 see type For va...

Page 87: ...1 Spare parts list Switch bar T VIS M 15 Fig 1 Spare parts list Switch bar T VIS M 15 04 10 2018 87...

Page 88: ...only for butterfly valves type ECOVENT S 2 Switch bar BFV 7 1 4301 PA6 224 001697 For butterfly valves T smart 7 and 9 3 Switch bar LFT R 1 4301 PA6 see type For valves with lifting actuator R T_R L...

Page 89: ...1 Dimension sheet double seat valve M C 2 0 Fig 1 Dimension sheet double seat valve M C 2 0 04 10 2018 1...

Page 90: ...Tube ID 101 6 x 2 1 101 6 x 2 1 101 6 x 2 1 1 63 5 x 1 6 76 2 x 1 6 101 6 x 2 1 D1 261 261 261 D2 210 210 210 F 622 622 622 H with T VIS A 15 786 0 786 0 786 0 K 171 171 171 X 1150 1150 1150 Stroke 6...

Page 91: ...152 4 x 2 77 152 4 x 2 77 152 4 x 2 77 152 4 x 2 77 1 63 5 x 1 6 76 2 x 1 6 101 6 x 2 1 152 4 x 2 77 D1 210 210 210 210 D2 210 210 210 210 F 644 5 644 5 644 5 644 5 H with T VIS A 15 808 5 808 5 808 5...

Page 92: ...1 303 0 282 0 234 0 Tube ID 101 6 x 2 1 101 6 x 2 1 101 6 x 2 1 1 63 5 x 1 6 76 2 x 1 6 101 6 x 2 1 D1 210 210 210 D2 210 210 210 F 644 5 644 5 644 5 H with T VIS A 15 808 5 808 5 808 5 K 190 190 190...

Page 93: ...countries Founded in 1881 the company is one of the largest providers of innovative equipment and process technology GEA Group is listed in the STOXX Europe 600 index GEA Mechanical Equipment GEA Tuch...

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