GEA VARIVENT FRS Operating Instruction Download Page 63

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Item

Designation

Material

DN125/DN150

DN350/DN125

Housing combination

1.4404/1.4301

221-006569

221-006504

Sealing ring RA

EPDM

221-367.05

221-367.04

FKM

221-367.10

221-367.09

Lantern FRS

1.4301

221-006578

221-006427

Spacer FRS

EN AW-6082 T6

221-006581

221-006536

Cylinder cover FRS

1.4301

221-006583

221-006537

Valve disk FRS

1.4301

221-006571

221-006511

Piston FRS/VT

1.4305

221-006580

221-006343

Piston rod FRS

1.4301

221-006579

221-006344

Guide FRS

EN AW-6082 T6

221-006591

221-006362

Hood FRS

221-006584

221-006444

Retaining plate FRS/NI

1.4301

221-006539

Retaining plate FRS/solenoid valve

1.4301

221-006540

Circlip/bore

1.4122

917-219

917-211

Clamp join KL

221-507.13

221-507.11

Hexagon nut

1.4571

910-155

Elbow screw-in plug connection G1/8"-6/4

Brass, nickel-plated

933-475

Cylinder screw hex socket

1.4301

902-092

Hexagon nut self-locking

910-020

Guide ring

Turcite-T51

935-079

935-076

Guide ring 3A

MF6

935-121

935-119

V-ring AX

EPDM

932-059

932-027

FKM

932-063

932-038

FFKM

932-118

O-ring

NBR

930-016

NBR

930-044

NBR

930-120

930-107

NBR

930-019

930-972

NBR

930-625

930-674

NBR

930-674

930-019

Ring

1.4301

921-002

Cylinder screw slot

1.4301

904-161

1.4301

904-135

904-176

1.4301

904-160

Countersunk screw slot

1.4301

905-017

Ring

921-014

Bush FRS

221-006541

Board FRS

221-006542

Optional: 24VDC

Solenoid valve 5/2 way 24VDC

512-175

Proximity switch 4kt / 3Dr

505-107

Sound absorber

1.4305

933-948

Spare parts list - VARIVENT

FRS Valve

430BAL013059EN_7

24.03.2022

Summary of Contents for VARIVENT FRS

Page 1: ...Hygienic valves GEA VARIVENT FRS valve Operating instruction Translation from the original language 430BAL013059EN_7...

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: ...tions 12 2 6 Qualification of personnel 12 2 7 Safety equipment 14 2 7 1 Signage 14 2 8 Residual dangers 15 2 9 Danger zones 16 3 Description 18 3 1 Design 18 3 2 Functional description 20 3 2 1 Insta...

Page 4: ...43 10 6 Maintenance 43 10 6 1 Cleaning the Valve 43 10 6 2 Replacing Seals 44 10 6 3 Lubricating Seals and Threads 46 10 7 Installation 47 10 7 1 Torques for the Clamps and Clamp Connections 47 10 7...

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 430BAL013059EN_7...

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 for reliable and safe operation of the component is proper transportation and storage as well as professional installation and assembly Operating the unit within the limits of its designated use als...

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: ...quipment Residual dangers on the valve and measures Danger Cause Measure Danger to life Inadvertent switch on of the valve Effectively disconnect all components effectively prevent switch on Electric...

Page 16: ...the environment For all work Collect lubricants in suitable containers Dispose of lubricants in accordance with the pertinent regulations 2 9 Danger zones Please observe the following notes Fig 4 In...

Page 17: ...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 in a second person wh...

Page 18: ...aling ring 3 Lantern 4 Spacer 5 Cylinder cover 6 Valve disk 7 Piston 8 Piston rod 9 Leadership 10 Cap 13 Circlip 14 Clamp connection 17 Cylinder screw hex socket 19 Guide ring 20 V ring 21 O ring pist...

Page 19: ...Design No Designation 23 O ring piston 24 O ring piston rod seal 25 O ring hood seal 41 Flush valve Description Design 430BAL013059EN_7 24 03 2022 19...

Page 20: ...on position The valve is usually installed in hanging position overhead 3 2 2 Closing Direction Closing direction in hanging installation position from bottom to top air opening and air closing Fig 6...

Page 21: ...ge caused by impact or careless loading and unloading The outside synthetic materials are susceptible to breaking Control tops must be protected from animal and vegetable fats Only allow qualified sta...

Page 22: ...DA Control air pressure bar psi min 6 0 87 max 8 0 116 Product pressure bar psi 1 0 14 5 5 2 Technical data Refer to the following tables for the key technical data of the valve Technical data Valve D...

Page 23: ...density max 5 mg m3 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...

Page 24: ...C 176 F Inorganic acids up to 5 up to 80 C 176 F o Inorganic acids up to 5 up to 100 C 212 F Water up to 100 C 212 F Steam up to 135 C 275 F o Steam approx 30 min up to 150 C 302 F o Fuels hydrocarbo...

Page 25: ...ist of tools Tools Material no Hose cutter 407 065 V ring insertion tool 229 109 88 Strap wrench 408 142 Open end spanner a f 12 13 408 034 Open end spanner a f 13 17 408 036 Open end spanner a f 24 4...

Page 26: ...Size process housing CIP housing Weight kg DN80 DN100 31 9 3 OD DN100 31 3 DN100 DN125 32 8 4 OD DN125 32 7 DN125 DN150 49 3 DN350 DN125 65 4 Technical data 430BAL013059EN_7 26 24 03 2022...

Page 27: ...usually hanging however it can be installed as needed Care must be taken to ensure that the valve housing and the pipe system can drain properly If the valve is installed in the horizontal position p...

Page 28: ...l cause malfunction of the valve Replace old seals Carry out the following steps 1 Remove valve insert see chapter dismantle valve FRS 2 Dismantle the flush valves 41 3 Weld the housing without sealin...

Page 29: ...s required A hose cutter Carry out 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 of the dr...

Page 30: ...eas Carry out the following steps 1 Connect in accordance with the connection diagram and the instructions in the corresponding operating instructions Done Hint The proximity switches are factory set...

Page 31: ...ly allow properly qualified staff to set the valve into operation Establish all connections correctly The safety devices for the valve must be complete fully functional and in perfect condition Check...

Page 32: ...rotection type Protection by housing according to EN 60079 31 from the dust atmosphere and are thus protected The FRS valve may only be commissioned in the context of above device category if the hood...

Page 33: ...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 34: ...ith the relevant process and product The cleaning effect must be checked regularly by the operator 9 1 1 Cleaning Process Examples Typical Cleaning Parameters in Dairy Operations Example of a two phas...

Page 35: ...ed to different degrees This can impair the function and the service life 9 2 Passivation Before commissioning a plant passivation is commonly carried out for long pipes and tanks Valve blocks are usu...

Page 36: ...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 37: ...the following steps 1 Regularly check Sealing ring between upper housing and lantern V ring in the valve disks Done 10 2 2 Pneumatic connections Carry out the following steps 1 Check the operating pre...

Page 38: ...on ambient conditions Maintenance Intervals Applications Maintenance intervals guideline values Media at temperatures of 60 C to 130 C 140 F to 266 F approx every 3 months Media at temperatures of 60...

Page 39: ...with sharp edges The valve disk 6 has sharp edges Always wear gloves and suitable safety equipment during installation Notice The valve disk 6 is a sensitive component Damage to these parts can resul...

Page 40: ...lustration Fig 11 10 5 2 Open drive unit Prerequisite Remove hood 1 using a strap wrench and remove from the lantern 3 Tools required Strap wrench Hint Seal replacement In this state the hood seal 25...

Page 41: ...tion prior to dismantling the valve Carry out the following steps 1 Undo the cable connection at the board terminal strip 35 to the connector 40 2 Undo the hexagon head screws 18 3 Carefully pull the...

Page 42: ...red Snap ring pliers Carry out the following steps 7 Undo the cylinder screw 17 and remove guide 9 8 Undo the spring lock washer 13 9 Carefully pull the piston rod 8 out of the valve disk 6 until the...

Page 43: ...2 Take off the air hose 3 Unscrew the valve from the housing at area 2 4 Remove cylinder SPV C from housing 2 5 Take the spring 5 out of cylinder SPV C 1 6 Pull piston SPV C 4 out of cylinder SPV C 1...

Page 44: ...a malfunction Observe the safety information sheets issued by the detergent manufacturers Only use detergents which are non abrasive and not aggressive towards stainless steel Carry out the following...

Page 45: ...is removed Grip the valve disk in a vice with protected jaws Unscrew the curved side of the scriber Carry out the following steps 1 Put a scriber into the V ring and take it out Fig 21 2 Before fitti...

Page 46: ...ricant is applied No grease residues must be visible once the valve has been assembled completely For product contact seals only use suitable greases and oils Observe the safety information sheets iss...

Page 47: ...d A Manufacturer s Declaration for these products can be obtained from GEA Tuchenhagen if required A thin film of grease is required on the seals to ensure the proper function of the fittings It reduc...

Page 48: ...ke air connection 35 AS i board or 24 VDC module 36 5 2 way solenoid valve 38 Initiators 39 Outlet and inlet valve of the main stroke the connection must not be closed 40 Connector M12 AS i 4 pole or...

Page 49: ...inner air routing into the main drive seeSection 10 7 2 Page 48 10 7 3 1 Pneumatic connection Solenoid valve 5 2 way 24VDC Fig 26 X exhaust air Y supply air Shorten all hose connections to minimum le...

Page 50: ...ns check the maximum permissible operating voltage 10 7 4 1 Electrical 24 V DC Wiring Fig 27 Connector M12 4 pole 1 L UV L 24 V DC supply voltage 2 S1 Feedback unit end position 1 3 L Gnd 4 S2 Feedbac...

Page 51: ...28 Connector M12 4 pole 1 ASI 2 nc not connected 3 ASI 4 nc not connected Carry out the following steps 1 Connect cable via air connector M12 4 pole Done 10 7 4 3 Setting the feedback Fig 29 Maintenan...

Page 52: ...quired Hose cutter Carry out 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...

Page 53: ...roke Valve size process housing CIP housing Valve stroke mm DN80 DN100 124 6 3 OD DN100 124 6 DN100 DN125 124 6 4 OD DN125 124 6 DN125 DN150 151 6 DN350 DN125 124 6 Maintenance 430BAL013059EN_7 24 03...

Page 54: ...d check air hoses for free passage and air tightness Fault in the electrical system Check actuation external controller and routing of electrical lines Solenoid valve defective Replace the solenoid va...

Page 55: ...the storage conditions see Chapter 4 Page 21 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 56: ...13 Spare parts list VARIVENT FRS Valve Fig 30 Spare parts list VARIVENT FRS Valve 430BAL013059EN_7 56 24 03 2022...

Page 57: ...w screw in plug connection G1 8 6 4 Brass nickel plated 933 475 933 475 17 Cylinder screw hex socket 1 4301 902 092 902 092 18 Hexagon nut self locking A2 910 020 910 020 19 Guide ring Turcite T51 935...

Page 58: ...221 464 26 221 464 26 FKM 221 464 29 221 464 29 Flushing valve FRS 3A EPDM 221 464 34 221 464 34 FKM 221 464 35 221 464 35 42 Locking screw Brass nickel plated 922 344 922 344 Sealing set EPDM NBR 221...

Page 59: ...ow screw in plug connection G1 8 6 4 Brass nickel plated 933 475 933 475 17 Cylinder screw hex socket 1 4301 902 092 902 092 18 Hexagon nut self locking A2 910 020 910 020 19 Guide ring Turcite T51 93...

Page 60: ...FRS EPDM 221 464 26 221 464 26 FKM 221 464 29 221 464 29 Flushing valve FRS 3A EPDM 221 464 34 221 464 34 FKM 221 464 35 221 464 35 42 Locking screw Brass nickel plated Sealing set EPDM NBR 221 006982...

Page 61: ...bow screw in plug connection G1 8 6 4 Brass nickel plated 933 475 933 475 17 Cylinder screw hex socket 1 4301 902 092 902 092 18 Hexagon nut self locking A2 910 020 910 020 19 Guide ring Turcite T51 9...

Page 62: ...FRS EPDM 221 464 26 221 464 26 FKM 221 464 29 221 464 29 Flushing valve FRS 3A EPDM 221 464 34 221 464 34 FKM 221 464 35 221 464 35 42 Locking screw Brass nickel plated Sealing set EPDM NBR 221 00698...

Page 63: ...6 Elbow screw in plug connection G1 8 6 4 Brass nickel plated 933 475 933 475 17 Cylinder screw hex socket 1 4301 902 092 902 092 18 Hexagon nut self locking A2 910 020 910 020 19 Guide ring Turcite T...

Page 64: ...Valve FRS EPDM 221 464 26 221 464 23 FKM 221 464 29 221 464 30 Flushing valve FRS 3A EPDM 221 464 34 221 464 34 FKM 221 464 35 221 464 35 42 Locking screw Brass nickel plated Sealing set EPDM NBR 221...

Page 65: ...14 Dimension sheet Valve FRS Fig 31 Dimension sheet Valve FRS 430BAL013059EN_7 24 03 2022 65...

Page 66: ...5 150 150 72 5 DN350 DN125 355 6x3 129x2 259 5 250 250 207 connection is reduced to CIP with length C1 FRS valve Size Process Housing CIP housing Actuator Dimensions Valve D1 H2 Removing Stroke S Wei...

Page 67: ...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 68: ...ethylene 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 span...

Page 69: ...Appendix 430BAL013059EN_7 24 03 2022 69...

Page 70: ......

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