GEA VARIVENT N Operating Instruction Download Page 1

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Hygienic valves

GEA VARIVENT

Shut-off valve type N and U, U_R, N_V and U_V

Operating instruction (Translation from the original language)
430BAL008302EN_10

Summary of Contents for VARIVENT N

Page 1: ...Hygienic valves GEA VARIVENT Shut off valve type N and U U_R N_V and U_V Operating instruction Translation from the original language 430BAL008302EN_10...

Page 2: ...of machine readable form without the express permission of GEA Tuchenhagen GmbH LEGAL NOTICE Wordmarks The designations VARIVENT and T VIS are protected trademarks of GEA Tuchenhagen GmbH The TEFASEP...

Page 3: ...12 2 7 1 Signage 12 2 8 Residual dangers 13 2 9 Danger zones 14 3 Description 16 3 1 Design 16 3 2 Functional description 18 3 2 1 Valve N 18 3 2 2 Valve U 18 4 Transport and storage 20 4 1 Storage c...

Page 4: ...10 7 2 Replacing the V Ring 51 10 7 3 Exchanging the O ring TEFASEP gold 53 10 7 4 Lubricating Seals and Threads 55 10 8 Installation 56 10 8 1 Reversing the resting position 56 10 8 2 Installing the...

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: ...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 i...

Page 7: ...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 8: ...o the scope of directive 2014 34 EC article 1 paragraph 2 f the exception of the directive applies due to conformity with the machine directive 2006 42 EU The nominal diameters smaller than DN 25 are...

Page 9: ...mpany must authorize personnel to carry out the relevant tasks Order and cleanliness must be maintained at the work stations and in the entire area surrounding the component Personnel must wear suitab...

Page 10: ...be kept ready to 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...

Page 11: ...y installation and operating regulations for use in potentially explosive areas 2 6 Qualification of personnel This section provides information on how the personnel working on the component must be t...

Page 12: ...on and sound knowledge in the following areas Functionality of the component Operating sequences on the pump What to do in case of an emergency Lines of authority and responsibilities with respect to...

Page 13: ...alve and measures Danger Cause Measure Danger to life Inadvertent switch on of the valve Effectively disconnect all components effectively prevent switch on Electric power Observe the following safety...

Page 14: ...operties which are harmful to 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...

Page 15: ...lectrician to carry out any work 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...

Page 16: ...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 15 Valve disk 22 Air connection Description Design 430BAL008302EN_1...

Page 17: ...Design No Designation 24 Electrical connection 402 Valve housing Description Design 430BAL008302EN_10 16 03 2023 17...

Page 18: ...ated position Yellow steady light 1 valve in end position actuated position Fig 7 Distinguishing Feature of Spring To Open Actuator A The valve is open in the non actuated position Identification on t...

Page 19: ...ady light 1 valve in non actuated position Yellow steady light 1 Valve in end position actuated position distinguishing feature Fig 9 Distinguishing Feature of Spring To Open Actuator A The valve is o...

Page 20: ...hat any ice crystals formed by condensation water can melt 4 2 Transport Fig 10 For transport the following principles apply When transporting the valve be sure to unscrew the control top and the swit...

Page 21: ...rcumstances 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 u...

Page 22: ...Serial Serial number Material 1 4404 AISI 316L EPDM Control air pressure bar psi 6 87 Product pressure bar psi 5 72 5 5 2 Technical data Refer to the following tables for the key technical data of th...

Page 23: ...aling material Technical data Compressed air supply product pressure Designation Description Air hose Metric Material PE LD outside 6 mm Inside 4 mm Inch Material PA outside 6 35 mm Inside 4 3 mm Cont...

Page 24: ...tandard drive Alternative combinations of product pressure and control air pressure on request Product pressure 5 bar 72 5 psi configuration with standard drive max 10 bar 116 psi configuration with c...

Page 25: ...t the user carries out resistance tests Resistance good resistance o reduced resistance no resistance Table of sealing resistance permitted operating temperature Medium Maximum operating temperatures...

Page 26: ...ons for Pipes in DN Metric DN Outer diameter Wall thickness Inner diameter Outer diameter according to DIN 11850 15 19 1 5 16 x 20 23 1 5 20 x 25 29 1 5 26 x 40 41 1 5 38 x 50 53 1 5 50 x 65 70 2 0 66...

Page 27: ...cutter 407 065 Belt wrench 408 142 O ring cutter heatable 0980 50022 Oven not microwave min temp 140 C 0981 50016 Protective gloves heat resistant V ring insertion tool 229 109 88 Open ended wrench e...

Page 28: ...pprox 17 5 approx 27 0 approx 21 0 DN 100 approx 25 0 approx 30 5 approx 28 0 DN 125 approx 55 0 DN 150 approx 63 5 1 approx 7 5 1 5 approx 10 0 2 approx 10 5 approx 15 0 2 5 approx 17 0 approx 26 5 3...

Page 29: ...being switched on 6 2 Notes on installation The valve can be installed in any position Care must be taken to ensure that the valve housing and the pipe system can drain properly If the valve is instal...

Page 30: ...clamp connections by pressurizing the actuator with compressed air at max 8 bar Notice Seals are wearing parts Old seals will cause malfunction of the valve When fitting the valve be sure to fit new h...

Page 31: ...Actuator mm Air requirement dm3 n Stroke dm3 n at 1 01325 bar at 0 C as per DIN 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...

Page 32: ...the 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...

Page 33: ...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 34: ...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 35: ...ng 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 8...

Page 36: ...ivation Before commissioning an installation passivation is usually carried out for long pipes and vessels Valve blocks are usually excepted from this Passivation is typically performed using nitric a...

Page 37: ...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 38: ...eck Stem seal between upper housing and lantern V ring and O ring TEFASEP gold valve seat seal in the valve disks O rings between the valve housings Done 10 2 2 Pneumatic connections Carry out the fol...

Page 39: ...enance intervals Applications Maintenance Intervals Guideline Values Elastomers Maintenance Intervals Guideline Values TEFASEP gold hard seal Media at temperatures of 60 C to 130 C 140 F to 266 F appr...

Page 40: ...l connections on the plant side can remain on the control top Spring closing valve Warning Spring tension in the valve Danger of injury when opening the clamp connections at the actuator 46 or at the...

Page 41: ...valve insert is withdrawn Do not set the valve insert down on the valve disk but lay it down Carry out the following steps 1 Release three cheese head screws 25 and take off the cap B1 2 Pressurize t...

Page 42: ...m of the valve disk when the valve insert is withdrawn Do not set the valve insert down on the valve disk but lay it down Carry out the following steps 1 Release three cheese head screws 25 and take o...

Page 43: ...ent magnet against impact stress Carry out the following steps 1 Remove the clamps R between control top and actuator 2 Pull off the control top B upwards 3 Release the T VIS switch bar 1 by applying...

Page 44: ...the following steps 1 Withdraw the valve from the housing The bearing disk 4 and the sealing disk 3 must not hit the stem of the valve disk when the valve insert is withdrawn The valve is separated f...

Page 45: ...and the sealing disk 3 The bearing disk 4 and the sealing disk 3 must not hit the stem of the valve disk when the valve disk is withdrawn 4 Unscrew the spacer nut 10 from the valve disk using 2 open e...

Page 46: ...to the valve housing Before releasing the clamp connection 46 pre tension the actuator with an emergency manual actuator H material no 221 310 74 Notice The permanent magnet on the switch bar is fragi...

Page 47: ...t wrench 8 Remove the emergency manual actuator H Spring opening valve Carry out the following steps 1 Vent the actuator The valve disk is lowered 2 Remove the clamp connection 46 between drive and la...

Page 48: ...p B upwards 7 Release the T VIS switch bar 1 by applying a hex key at 1 1 or an a f 13 open ended wrench at 1 2 and remove it Done Removing the Valve Disk Fig 25 Maintenance Disassembling Valve U 430B...

Page 49: ...nscrewed the valve disk could fall out and become damaged For this reason grip the valve disk while removing the spacer nut 10 4 Remove the valve disk 15 downwards The stem of the valve disk is a seal...

Page 50: ...ve disk After the spacer nut 10 is unscrewed the valve disk could fall out and become damaged For this reason grip the valve disk while removing the spacer nut 10 4 Remove the valve disk 15 downwards...

Page 51: ...ve Damage to these parts can result in malfunction Observe the safety information sheets issued by the detergent manufacturers Only use detergents which are non abrasive and not aggressive towards sta...

Page 52: ...s required V ring insertion tool Caution Danger of injury The scriber can slip off when the V ring is removed Grip the valve disk in a vice with protected jaws Unscrew the curved side of the scriber C...

Page 53: ...be used again since the proper function of the seal can then no longer be ensured 10 7 3 Exchanging the O ring TEFASEP gold Tools required O ring cutter Heat resistant protective gloves Oven no micro...

Page 54: ...lve seat seal at one point using the O ring cutter Pay attention not to damage the edge of the radial groove Fig 32 3 Take out the cut valve seat seal 4 Warm a new O ring TEFASEP gold valve seat seal...

Page 55: ...eat the valve seat seal again as described in the first step When mounting the valve seat seal the seal does not click into place any more The valve seat seal has been overheated and can no longer be...

Page 56: ...ctions or in premature seal failure The warranty will also become null and void A Manufacturer s Declaration for these products can be obtained from GEA Tuchenhagen if required A thin film of grease i...

Page 57: ...spring closing actuator action valve U spring closing You can sustain injuries to your fingers when you put your hand into a valve with spring closing action if the valve has not been opened beforehan...

Page 58: ...and Clamp Connections Tighten the clamp connections and clamps on the valve to the torques specified in the table Tightening torques required Torques Nm lbft Nm lbft Clamps on the control top 1 0 7 Cl...

Page 59: ...e see table The stroke is set Strokes depending on size Valve Stroke Valve size Valve stroke mm N N_V E U_V Metric 25 16 18 40 18 25 50 30 40 29 65 30 42 30 80 30 56 30 40 100 30 60 30 40 125 60 60 15...

Page 60: ...ose Dirt foreign material between valve seat and valve disk Clean valve housing and valve seat Spring defective Replace the actuator Valve closes too slowly O rings in actuator and control top are dry...

Page 61: ...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 dis...

Page 62: ...13 Parts list shut off valve N Fig 43 Fig 44 Parts list shut off valve N 430BAL008302EN_10 62 16 03 2023...

Page 63: ...147 02 221 147 01 15 Valve disk N V ring 1 4404 221 114 01 221 114 02 221 114 02 221 114 03 15 1 Valve disk N TS O ring 1 4404 221 221 11 221 221 09 221 221 09 221 221 15 29 O ring NBR 930 026 930 02...

Page 64: ...932 090 932 100 7 1 O ring TEFASEP gold 930 102 930 103 9 Lantern 1 4301 221 121 03 221 121 04 221 121 06 221 121 22 10 Spacer nut 1 4305 221 147 01 221 147 01 221 147 06 221 147 06 15 Valve disk N V...

Page 65: ...930 144 930 150 FKM 930 168 930 171 930 171 930 176 HNBR 930 632 930 633 930 633 930 634 6 O ring NBR 930 004 930 004 930 004 930 004 7 V ring EPDM 932 046 932 021 932 021 932 024 FKM 932 030 932 033...

Page 66: ...7 HNBR 924 313 924 313 2 Bearing PTFE carbon 935 002 935 002 935 003 Bearing 3A PEEK 935 099 935 099 935 102 3 Seal disk 1 4404 221 141 03 221 141 04 221 141 05 4 Bearing disc 1 4301 221 142 03 221 14...

Page 67: ...924 313 924 313 2 Bearing PTFE carbon 935 001 935 002 935 002 935 003 Bearing 3A PEEK 935 098 935 099 935 099 935 102 3 Seal disk 1 4404 221 141 02 221 141 03 221 141 04 221 141 05 4 Bearing disc 1 43...

Page 68: ...flange T 1 4404 221 409 07 221 409 08 221 409 09 Housing connection flange U 1 4404 221 149 02 221 149 03 221 149 04 221 149 06 A Actuator See parts list dimensions sheet for VARIVENT actuator B Cont...

Page 69: ...409 930 259 HNBR 930 632 930 633 930 634 930 863 6 8 x 1 6 8 x 1 6 8 x 1 6 8 x 1 6 9 x 3 9 x 3 NBR 930 004 930 004 930 004 930 004 930 007 930 007 7 1 V ring 35 5 52 6 76 6 104 6 128 6 148 6 EPDM 932...

Page 70: ...14 Parts list shut off valve N_V Fig 45 Fig 46 Parts list shut off valve N_V 430BAL008302EN_10 70 16 03 2023...

Page 71: ...ate 1 4404 221 144 02 221 144 03 221 144 03 221 144 04 43 Clamp join KL 1 4401 221 507 04 221 507 09 221 507 09 221 507 11 46 Clamp join KL 1 4401 221 507 06 221 507 06 221 507 06 221 507 06 61 Lockin...

Page 72: ...03 01 221 603 01 B Control top T VIS See parts list for control top T VIS Grease RIVOLTA F L G 100g tube not included with sealing set 413 136 1 The sealing set includes the items 1 5 6 7 29 and 30 It...

Page 73: ...e 1 4404 221 144 02 221 144 03 221 144 03 221 144 04 43 Clamp join KL 1 4401 221 507 04 221 507 09 221 507 09 221 507 11 46 Clamp join KL 1 4401 221 507 06 221 507 06 221 507 06 221 507 06 61 Locking...

Page 74: ...01 221 603 01 B Control top T VIS See parts list for control top T VIS Grease RIVOLTA F L G 100g tube not included with sealing set 413 136 1 The sealing set includes the items 1 5 6 7 29 and 30 Item...

Page 75: ...15 Parts list shut off valve U Fig 47 Parts list shut off valve U 430BAL008302EN_10 16 03 2023 75...

Page 76: ...Fig 48 Parts list shut off valve U 430BAL008302EN_10 76 16 03 2023...

Page 77: ...147 02 221 147 01 15 Valve disk U 1 4404 221 115 10 221 115 02 221 115 03 221 115 04 29 O ring NBR 930 026 930 026 930 026 930 026 30 O ring NBR 930 026 930 026 930 026 930 026 33 Seat ring N 1 4404 2...

Page 78: ...alve disk U 1 4404 221 115 05 221 115 06 221 115 09 221 115 08 29 O ring NBR 930 026 930 026 930 035 930 035 30 O ring NBR 930 026 930 026 930 026 930 026 33 Seat ring N 1 4404 221 107 03 221 107 04 2...

Page 79: ...147 02 221 147 01 15 Valve disk U 1 4404 221 115 10 221 115 02 221 115 03 221 115 04 29 O ring NBR 930 026 930 026 930 026 930 026 30 O ring NBR 930 026 930 026 930 026 930 026 33 Seat ring N 1 4404 2...

Page 80: ...115 05 221 115 06 221 115 30 29 O ring NBR 930 026 930 026 930 035 30 O ring NBR 930 026 930 026 930 026 33 Seat ring N 1 4404 221 107 03 221 107 04 221 107 06 35 Blanking plate 1 4404 221 144 03 221...

Page 81: ...47 06 15 Valve disk U 1 4404 221 115 03 221 115 05 221 115 06 221 115 08 29 O ring NBR 930 026 930 026 930 026 930 035 30 O ring NBR 930 026 930 026 930 026 930 026 33 Seat ring N 1 4404 221 107 03 22...

Page 82: ...632 930 633 930 634 930 863 6 8 x 1 6 8 x 1 6 8 x 1 6 8 x 1 6 9 x 3 9 x 3 NBR 930 004 930 004 930 004 930 004 930 007 930 007 7 1 V ring 35 5 52 6 76 6 104 6 128 6 148 6 EPDM 932 046 932 021 932 024...

Page 83: ...16 Parts list shut off valve U_V Fig 49 Fig 50 Parts list shut off valve U_V 430BAL008302EN_10 16 03 2023 83...

Page 84: ...05 221 115 06 29 O ring NBR 930 026 930 026 30 O ring NBR 930 026 930 026 33 Seat ring N 1 4404 221 107 03 221 107 04 35 Blanking plate 1 4404 221 144 03 221 144 04 43 Clamp join KL 1 4401 221 507 09...

Page 85: ...5 221 115 06 29 O ring NBR 930 026 930 026 30 O ring NBR 930 026 930 026 33 Seat ring N 1 4404 221 107 03 221 107 04 35 Blanking plate 1 4404 221 144 03 221 144 04 43 Clamp join KL 1 4401 221 507 09 2...

Page 86: ...17 Parts list shut off valve U_R Fig 51 Parts list shut off valve U_R 430BAL008302EN_10 86 16 03 2023...

Page 87: ...Fig 52 Parts list shut off valve U_R 430BAL008302EN_10 16 03 2023 87...

Page 88: ...147 02 221 147 02 221 147 02 221 147 01 15 Valve disk U_R 1 4404 221 115 50 221 115 51 221 115 52 221 115 53 29 O ring NBR 930 026 930 026 930 026 930 026 30 O ring NBR 930 026 930 026 930 026 930 02...

Page 89: ...06 221 147 06 15 Valve disk U_R 1 4404 221 115 54 221 115 55 221 115 56 221 115 57 29 O ring NBR 930 026 930 026 930 035 930 035 30 O ring NBR 930 026 930 026 930 026 930 026 33 Seat ring 1 4404 221 6...

Page 90: ...147 02 221 147 02 221 147 02 221 147 01 15 Valve disk U_R 1 4404 221 115 50 221 115 51 221 115 52 221 115 53 29 O ring NBR 930 026 930 026 930 026 930 026 30 O ring NBR 930 026 930 026 930 026 930 02...

Page 91: ...k U_R 1 4404 221 115 54 221 115 55 221 115 57 29 O ring NBR 930 026 930 026 930 035 30 O ring NBR 930 026 930 026 930 026 33 Seat ring 1 4404 221 699 01 221 699 02 221 699 05 35 Blanking plate 1 4404...

Page 92: ...7 01 221 147 01 221 147 06 15 Valve disk U_R 1 4404 221 115 52 221 115 54 221 115 55 221 115 57 29 O ring NBR 930 026 930 026 930 026 930 035 30 O ring NBR 930 026 930 026 930 026 930 026 33 Seat ring...

Page 93: ...14 221 365 16 FKM 221 365 21 221 365 10 221 365 11 221 365 12 221 365 15 221 365 17 HNBR 221 365 24 221 365 18 221 365 20 221 365 19 29 1 O ring 20 x 3 20 x 3 20 x 3 20 x 3 25 x 3 25 x 3 NBR 930 026 9...

Page 94: ...18 Dimension sheet shut off valve N Fig 53 Dimension sheet shut off valve N 430BAL008302EN_10 94 16 03 2023...

Page 95: ...mm H2 mm Expansio n X mm Stroke S mm Weight kg OD 1 25 4 x 1 65 46 0 29 56 90 99 292 421 506 12 6 OD 1 5 38 1 x 1 65 59 0 39 62 90 110 337 466 551 18 8 OD 2 50 8 x 1 65 71 5 42 68 90 110 343 472 557...

Page 96: ...19 Dimension sheet shut off valve U Fig 54 Dimension sheet shut off valve U 430BAL008302EN_10 96 16 03 2023...

Page 97: ...mm P mm Stroke S mm Weight kg OD 1 25 4 x 1 65 70 x 2 46 0 48 0 90 99 292 421 200 22 8 OD 1 5 38 1 x 1 65 85 x 2 59 0 54 5 90 110 337 466 200 25 10 OD 2 50 8 x 1 65 85 x 2 71 5 60 8 90 110 343 472 20...

Page 98: ...20 Dimensional sheet shut off valve U_R Fig 55 Dimensional sheet shut off valve U_R 430BAL008302EN_10 98 16 03 2023...

Page 99: ...dimensions mm Stroke S mm Weight kg OD 1 25 4 x 1 65 70 x 2 46 0 48 0 90 99 292 421 479 22 8 OD 1 5 38 1 x 1 65 85 x 2 59 0 54 5 90 110 337 466 537 25 10 OD 2 50 8 x 1 65 85 x 2 71 5 60 8 90 110 343 4...

Page 100: ...stitute for Standardization EN European Standard EPDM Material designation Short designation according to DIN ISO 1629 Ethylene Propylene Diene Rubber F Unit of measurement of temperature degree Fahre...

Page 101: ...citly specified otherwise PTFE Polytetrafluoroethylene SET UP Self learning installation During commissioning and maintenance the SET UP procedure carries out all the necessary settings for the genera...

Page 102: ...Abbreviation Explanation Inch OD Tube measurement according to British Standard BS outside diameter Inch IPS American pipe measurement iron pipe size Appendix 430BAL008302EN_10 102 16 03 2023...

Page 103: ...Appendix 430BAL008302EN_10 16 03 2023 103...

Page 104: ......

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GEA VARIVENT N, Operating Instruction

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