GEA VARIVENT DN 25 Operating Instruction Download Page 1

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Hygienic valves

GEA VARIVENT

Double-Seat Valve Type R

Operating instruction (Translation from the original language)
430BAL008386EN_3

Summary of Contents for VARIVENT DN 25

Page 1: ...Hygienic valves GEA VARIVENT Double Seat Valve Type R Operating instruction Translation from the original language 430BAL008386EN_3...

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: ...y Regulations 12 2 6 Qualification of personnel 12 2 7 Safety equipment 14 2 7 1 Signage 14 2 8 Residual dangers 15 2 9 Hazard Areas 16 3 Description 18 3 1 Design 18 3 2 Functional description 20 3 2...

Page 4: ...bly of the housing combination 46 10 6 Installation 46 10 6 1 Torques for the clamps and clamp connections 46 10 6 2 Assembling the valve from individual parts 46 10 6 3 Fitting the control top 48 10...

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: ...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 430BAL008386EN_3...

Page 8: ...declaration 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 prepar...

Page 9: ...e operating inspection and maintenance instructions 2 1 2 Pressure equipment directive The valve is a piece of pressure equipment without safety function in the sense of the pressure equipment directi...

Page 10: ...described here are observed The operator s duty of care includes planning the necessary safety measures and monitoring that these measures are observed The following principles apply Only qualified pe...

Page 11: ...rmissible conditions 2 4 1 Principles for safe operation Dangerous situations during operation can be avoided by safety conscious and proactive behaviour of the staff To ensure safe operation of the v...

Page 12: ...permitted with the express permission of the manufacturer After completion of all work check that the protective devices are fully functional 2 5 Supplementary Regulations In addition to the instructi...

Page 13: ...the component Personal suitability for the respective task Sufficient professional qualification for the respective task Received instruction about the functionality of the component Received instruct...

Page 14: ...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 15: ...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 16: ...ve equipment in the vicinity of the valve Protective gloves Safety shoes Environmental damage Operating materials with properties which are harmful to the environment For all work Collect lubricants i...

Page 17: ...rical equipment of the valve at regular intervals Immediately remedy loose connections and molten cables If work on live parts cannot be avoided call in a second person who can operate the main switch...

Page 18: ...1 Design Fig 5 Design No Designation A Actuator B T VIS control top 1 Sealing ring 2 Bearing 3 Sealing disk 4 Bearing disk 9 Lantern 11 Cleaning hood 15 Valve disk Description Design 430BAL008386EN_3...

Page 19: ...Design No Designation 16 Double disk 22 Air connection 24 Electrical connection Description Design 430BAL008386EN_3 07 02 2022 19...

Page 20: ...ng function A cleaning liquid is supplied to the leakage drain system via a separate connection 1 arranged in the lantern The cleaning fluid is sprayed into a cavity between both of the valve discs ov...

Page 21: ...IS control top once the installation SET UP has been completed Green steady light 1 valve in non actuated position Yellow steady light 1 valve in end position actuated position Fig 7 Description 430BA...

Page 22: ...that any ice crystals formed by condensation water can melt 4 2 Transport Fig 8 For transport the following principles apply When transporting the valve be sure to unscrew the control top and the swit...

Page 23: ...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 24: ...data of the valve Technical data Valve Designation Description Size DN 25 to DN 150 1 to 6 OD 2 to 6 IPS Material of product contact parts Stainless steel 1 4404 Check corrosion resistance with respe...

Page 25: ...3 Water content Quality 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 ideally o...

Page 26: ...usage duration switching frequency type and temperature of product and cleaning agents as well as usage environment GEA Tuchenhagen recommends that the user carries out resistance tests Resistance go...

Page 27: ...of the material does not correspond to the maximum operating temperature 5 5 Pipe ends General table of measurements Hint Not every valve is available in every size Particulars of available sizes of...

Page 28: ...er Wall thickness Inside diameter Outside diameter according to DIN EN ISO 1127 2 60 3 2 56 3 x 3 88 9 2 3 84 3 x 4 114 3 2 3 109 7 x 6 168 3 2 77 162 76 x 5 6 Tool List of tools Tool Material no Hose...

Page 29: ...109 06 Manual emergency actuator 221 310 74 Eyebolt 221 104 98 5 7 Lubricants Lubricants Material no Rivolta F L G MD 2 413 071 PARALIQ GTE 703 413 064 5 8 Weights Size Weight kg DN 25 1 11 DN 40 1 5...

Page 30: ...ertently being switched on 6 2 Notes on installation The installation position of the valve is upright Care must be taken to ensure that the valve housing and the pipe system can drain properly To pre...

Page 31: ...o fit new housing O rings Carry out the following steps 1 Release spring tension of the actuator 2 Remove the valve insert see chapter Section 10 5 Page 41 3 Weld the housing without gaskets into posi...

Page 32: ...1343 Use A 98 0 16 DN 25 DN 100 1 4 OD 2 4 IPS B 109 0 26 C 135 0 42 D 170 0 70 E 210 1 10 R 170 1 60 S 210 2 00 T 210 2 20 D 6 170 1 30 DN 125 DN 150 6 OD 6 IPS E 6 210 2 00 S 6 261 3 20 T 6 210 4 0...

Page 33: ...gases or dusts An explosion can result in serious personal injury or death Observe the installation and operating regulations for use in potentially explosive areas Carry out the following steps 1 Con...

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: ...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 37: ...ppropriate systems for cleaning the valve should be regularly used to that an optimal cleanliness is ensured and any damage to the valve is prevented The spray cleaner cleans the leakage cavity while...

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: ...steps 1 Regularly check Stem seal between upper housing and lantern V ring in the valve disks O rings between the valve housings Done 10 2 2 Pneumatic connections Carry out the following steps 1 Check...

Page 40: ...ions for instance daily period of use switching frequency type and temperature of the product type and temperature of the cleaning solution ambient conditions Maintenance Intervals Applications Mainte...

Page 41: ...ng Y1 on the pneumatic block The pneumatic and electrical connections on the plant side can remain on the control top Warning Spring tension in the valve Danger of injury when detaching the clamp conn...

Page 42: ...trol the pilot valve using the manual override Fig 11 S manual override pilot valve 4 Remove the clamp connection 43 1 between housing and lantern 5 Vent the actuator Done 10 5 2 Removing the control...

Page 43: ...gainst impact stress Warning Spring tension in the valve Danger of injury when detaching the clamp connection 43 as the released spring pretension will suddenly lift the actuator Therefore release the...

Page 44: ...e sealing surfaces and must not be damaged When removing the valve from the pipe take care not to hit the balancer against the housing Carefully disassemble the valve Carry out the following steps 1 C...

Page 45: ...and the actuator A and remove the lantern 3 Grip the valve disk 15 at the width across flats C and unscrew the cleaning hood 11 at the width across flats D 4 Remove the bottom clamp connection 46 fro...

Page 46: ...the clamp connections and semi rings of the valve to the torques specified in the table Torques Nm lbft Clamps on the control top 1 0 7 Clamp connection cast half rings M6 9 6 6 Clamp connection cast...

Page 47: ...rod guide strip 2 of the bearing plug into the cleaning hood 11 Screw the cleaning hood 11 on the spanner flat D9 onto the valve disk 15 at the spanner flat C Fig 16 Maintenance Installation 430BAL00...

Page 48: ...Screw the valve disk 15 spanner flat C into the actuator A Hold the actuator with a belt wrench 7 Screw the switch bar into the actuator The valve is assembled from individual parts 10 6 3 Fitting th...

Page 49: ...m the control top B Ensure that the clamp connections 43 are firmly installed Done 10 6 4 Assembly of the housing combination If a housing combination is loose mount it Carry out the following steps 1...

Page 50: ...housings Housing combination is assembled 10 6 5 Assembly balancer plug Fig 20 Before assembly apply a very thin layer of grease to the balancer plug 92 Align the valve insert and let is slide into th...

Page 51: ...Tighten the valve disk 15 and the balancer plug 92 with the correct torque see Section 10 6 1 Page 46 Maintenance Installation 430BAL008386EN_3 07 02 2022 51...

Page 52: ...hen detaching the clamp connection 43 1 as the released spring pretension will suddenly lift the actuator Therefore release the spring tension before detaching the clamp connection by pressurising the...

Page 53: ...control top B When the valve is closed the lower edge of the cleaning hood 11 should be flush with the underside of the abutment 12 Done 10 6 7 Checking the function Checking valve strokes and adjusti...

Page 54: ...c 25 22 40 22 50 30 65 30 80 40 100 40 125 60 150 60 Inch OD 1 5 22 2 30 5 2 5 31 3 39 4 40 5 6 57 Inch IPS 2 30 3 40 4 40 6 60 10 7 Maintenance 10 7 1 Cleaning the valve Notice The stem of the valve...

Page 55: ...tergent manufacturers Only use detergents which are non abrasive and not aggressive towards stainless steel 10 7 2 Replacing Seals 10 7 2 1 Replacing V Ring double disk Hint Replace defective seals bu...

Page 56: ...ake it out Fig 25 2 Before fitting wet the V ring on the side not in contact with product rear side Pay attention that water does not drip into the V ring groove on the valve disc 3 Put in the V ring...

Page 57: ...but always fit new housing O rings to ensure the tightness of the valve Always use genuine spare parts Caution Danger of injury The pickset tool can slip off when the V ring is removed Clamp the valv...

Page 58: ...llustration Fig 30 4 Use the insertion tool to press in the V ring RA evenly press in at several opposite points along the circumference Fig 31 5 Insert V ring RA evenly Check that the V ring RA is ev...

Page 59: ...weld and must be greased Damage to seals and threads can result in malfunction Ensure that an adequate film of lubricant is applied No grease residues must be visible once the valve has been assemble...

Page 60: ...the seals in contact with product Rivolta F L G MD 2 can be ordered from GEA Tuchenhagen Using other types of grease can result in malfunctions or in premature seal failure The warranty will also bec...

Page 61: ...actuation external controller and routing of electrical lines Solenoid valve defective Replace the solenoid valve Valve works against a hydraulically closed pipe Open the pipe Valve does not close Di...

Page 62: ...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 63: ...13 Spare parts list Double seat valve R Fig 33 Fig 34 Spare parts list Double seat valve R 430BAL008386EN_3 07 02 2022 63...

Page 64: ...rn 1 4301 221 121 01 221 121 02 221 121 02 221 121 03 11 Cleaning hood 1 4301 221 146 04 221 146 01 221 146 01 221 146 01 12 Support bracket 1 4301 221 403 04 221 403 01 221 403 01 221 403 02 15 Valve...

Page 65: ...65 07 221 365 07 221 365 08 FKM 221 365 21 221 365 10 221 365 10 221 365 11 HNBR 221 365 24 221 365 18 221 365 18 221 365 20 401 Housing V1 1 4404 221 101 19 221 101 21 221 101 22 221 101 05 402 Housi...

Page 66: ...86 03 221 121 06 221 121 22 11 Cleaning hood 1 4301 221 146 01 221 146 01 221 146 02 221 146 02 12 Support bracket 1 4301 221 403 02 221 403 02 221 403 03 221 403 03 15 Valve disc R 1 4404 221 649 05...

Page 67: ...g RA EPDM 221 365 08 221 365 09 221 365 14 221 365 16 FKM 221 365 11 221 365 12 221 365 15 221 365 17 HNBR 221 365 20 221 365 19 401 Housing V1 1 4404 221 101 06 221 101 07 221 101 18 221 101 66 402 H...

Page 68: ...rn 1 4301 221 121 01 221 121 07 221 121 07 221 121 08 11 Cleaning hood 1 4301 221 146 04 221 146 01 221 146 01 221 146 01 12 Support bracket 1 4301 221 403 04 221 403 01 221 403 01 221 403 02 15 Valve...

Page 69: ...1 365 07 221 365 07 221 365 08 FKM 221 365 21 221 365 10 221 365 10 221 365 11 HNBR 221 365 24 221 365 18 221 365 18 221 365 20 401 Housing V1 1 4404 221 101 27 221 101 28 221 101 29 221 101 30 402 Ho...

Page 70: ...221 186 04 221 186 05 221 121 22 11 Cleaning hood 1 4301 221 146 01 221 146 01 221 146 02 12 Support bracket 1 4301 221 403 02 221 403 02 221 403 03 15 Valve disc R 1 4404 221 649 05 221 649 03 221 6...

Page 71: ...09 221 365 16 FKM 221 365 11 221 365 12 221 365 17 HNBR 221 365 20 221 365 19 401 Housing V1 1 4404 221 101 31 221 101 32 221 101 72 402 Housing V2 1 4404 221 102 56 221 102 57 221 102 58 A Actuator...

Page 72: ...1 12 221 121 08 221 121 04 221 121 05 11 Cleaning hood 1 4301 221 146 01 221 146 01 221 146 01 221 146 02 12 Support bracket 1 4301 221 403 01 221 403 02 221 403 02 221 403 03 15 Valve disc R 1 4404 2...

Page 73: ...g RA EPDM 221 365 07 221 365 08 221 365 09 221 365 16 FKM 221 365 10 221 365 11 221 365 12 221 365 17 HNBR 221 365 18 221 365 20 221 365 19 401 Housing V1 1 4404 221 101 37 221 101 35 221 101 36 221 1...

Page 74: ...930 631 930 631 930 631 24 1 O ring EPDM 930 368 930 235 930 235 930 235 930 268 930 268 FKM 930 616 930 162 930 162 930 162 930 164 930 164 HNBR 930 635 930 638 930 638 930 638 930 639 930 639 29 1 O...

Page 75: ...14 Dimension sheet VARIVENT double seat valve R Fig 35 Dimension sheet VARIVENT double seat valve R 430BAL008386EN_3 07 02 2022 75...

Page 76: ...0 90 93 0 135 327 0 456 0 716 18 11 OD 1 5 38 1 1 65 59 0 90 128 0 135 336 5 465 5 726 22 14 OD 2 50 8 1 65 71 5 90 137 0 135 343 0 472 0 732 30 14 OD 2 5 63 5 1 65 90 0 125 167 5 170 386 0 515 0 920...

Page 77: ...tion 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...

Page 78: ...ene SET UP Self learning installation During commissioning and maintenance the SET UP procedure carries out all the necessary settings for the generation of messages SW Indicates the size of spanners...

Page 79: ...Appendix 430BAL008386EN_3 07 02 2022 79...

Page 80: ......

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GEA VARIVENT DN 25, Operating Instruction

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