GEA VARIVENT X R Series Operating Instructions Manual Download Page 69

Page: 69 / 104

9.6.4 Placing the valve insert in the housing

Place the valve insert into the hous-
ing.

! The bearing disk (4) and the seal

disk (3) may not hit the rod of the

valve disk when the valve insert is fit-

ted.

The valve insert is placed into the housing.

9.6.5 Mounting the control top

ATTENTION

The switch bar is sensitive and must be protected from impact stress.

Damage to switch bar.

●

Protect the switch bar against impact stress.

9.6 Installing the valve - 69 / 104

Summary of Contents for VARIVENT X R Series

Page 1: ...Operating Instructions Hygienic valves GEA VARIVENT Shuttle valve type X_R 2023 03 430BAL015128EN...

Page 2: ...2023 All rights reserved No liability will be accep ted for damage resulting from non observance of this document If you have any ques tions or require clarification concerning the use of this documen...

Page 3: ...t directive 13 2 1 3 ATEX directive 13 2 1 4 Improper operating conditions 14 2 2 Modification 14 2 3 Structure of warning notices 14 2 3 1 Preceding warning notices 14 2 3 2 Integrated warning notice...

Page 4: ...3 4 2 Storage 33 4 3 Transport 34 5 Assembly and installation 5 1 Notes on installation 35 5 2 Control top 35 5 3 Install the valve with detachable pipe connection elements 35 5 4 Install valve with w...

Page 5: ...7 Dismantling of the housing combination 64 9 6 Installing the valve 64 9 6 1 Tightening torques 64 9 6 2 Assembling the valve insert from individual parts 65 9 6 3 Assembly of the housing combination...

Page 6: ...13 Annex 13 1 Dimension sheet 99 13 2 List of abbreviations 101 6 104 Table of Contents 0000000881 001 EN GB...

Page 7: ...d of harm to individuals or dam age to property The Operating Instructions also acts as the basis for creating operating instructions 1 1 2 Design elements In this document the following design elemen...

Page 8: ...with the valve must have read these Operating Instruc tions They must be available to these persons at all times 1 2 Manufacturer address GEA Tuchenhagen GmbH Am Industriepark 2 10 Germany 21514 B che...

Page 9: ...1 4 Declarations of conformity 1 4 Declarations of conformity 9 104...

Page 10: ...Applicable harmonized standards in particular EN ISO 12100 2010 Remarks This declaration will become invalid if any alter ations are made to the machine which have not been agreed with us We also dec...

Page 11: ...ation 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 w...

Page 12: ...12 104 1 4 Declarations of conformity 0000000881 001 EN GB...

Page 13: ...ng to the operating maintenance and servicing 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...

Page 14: ...cal operation of the valve 2 3 Structure of warning notices Warning notices warn of hazards which can occur when certain actions are carried out The warning notices described below are used in this do...

Page 15: ...ing groups of people must possess the personnel qualifications or skills listed below and be authorised by the operator to perform actions on the valve Operating staff Trained by the operating company...

Page 16: ...ht fitting clothing Gravity Falling objects Impact Crushing Do not walk under suspen ded loads Eliminate the stumbling haz ards 2 5 3 Electrical hazard Source Consequences Measures Electromagnetic pro...

Page 17: ...manual from the operator or employer 2 7 Safety devices No safety devices are attached to this valve 2 8 Residual hazards Despite all the measures taken the following residual hazards can lead to pers...

Page 18: ...there is a risk of injury upon releasing the clamp connec tion 43 as the released spring pretension will suddenly lift the actuator A There fore release the spring tension before detaching the clamp c...

Page 19: ...equipment in the vi cinity of the valve Protective gloves Safety shoes Environmental dam age Operating materials with properties which are harmful to the environment For all work Collect lubricants in...

Page 20: ...operating regulations must be observed and the following actions implemented Fire Call local specialists Use extinguishing agents as outlined in the operating regulations Exit the hazard zone Warn ind...

Page 21: ...ions on how to install the valve and its functions 3 1 Set up and function 3 1 1 Design 15 B 2 1 4 A 9 3 401 24 22 11 Figure 3 1 Design of the valve Design No Designation A Actuator B T VIS control to...

Page 22: ...disk 4 Bearing disk 9 Lantern 11 Radial groove 15 Valve disk 22 Air connection T VIS 24 Electrical connection 401 Valve housing See spare parts drawings for housing configuration 22 104 3 1 Set up an...

Page 23: ...is closed in the idle posi tion Identification on the spring to close up per valve seat Ring groove 11 on the wrench flat surface of the valve disk rod Identification on the T VIS control top once the...

Page 24: ...ation on the T VIS control top once the installation SET UP has been completed Permanent light 1 green valve in idle position Permanent light 1 yellow valve in end position actuated position 3 1 2 3 M...

Page 25: ...the idle position No Designation 1 Feedback side 2 Installation position spring to close actuator NC idle position closed 3 Installation position spring to open actuator NC idle position open 4 Valve...

Page 26: ...or size for application check the actuator size if necessary 1 Turn the actuator to reverse the idle position 2 Remove the valve see 9 6 Installing the valve The idle position is reversed INFO After m...

Page 27: ...ns 1 Type plate T VIS adhered to T VIS 2 Type plate valve adhered to actuator 3 Warning do not open taut spring adhered to actuator 4 Warning risk of crushing refers to lantern adhered to actuator aft...

Page 28: ...l Serial number Material 1 4404 AISI316L EPDM Control air pressure bar psi 6 87 Product pressure bar psi 5 72 5 3 2 2 Technical data Refer to the following tables for the key technical data of the val...

Page 29: ...terial PA Outside 6 35 mm Inside 4 3 mm Control air acc to ISO 8573 1 Solid particle content Quality class 6 Particle size max 5 m Particle density max 5 mg m3 Water content Quality class 4 max dew po...

Page 30: ...The maximum operating temperature is defined by the sealing type and its mechanical load Due to the versatile conditions of use e g usage duration switching frequency type and temperature of product a...

Page 31: ...ials Sealing materials General temperature resistance EPDM 40 to 135 C 40 F to 275 F FKM 10 to 200 C 14 F to 392 F HNBR 25 to 140 C 13 F to 284 F The general resistance of the material does not corres...

Page 32: ...de diame ter Wall thickness Inside diameter Outside diame ter acc to BS 4825 0 5 12 7 1 65 9 4 X 0 75 19 05 1 65 15 75 X 1 25 4 1 65 22 1 X 1 5 38 1 1 65 34 8 X 2 50 8 1 65 47 5 X 2 5 63 5 1 65 60 2 X...

Page 33: ...he order and delivery docu ments the equipment is complete and all components are in good order 4 2 Storage The valves valve inserts or spare parts should be stored in a dry place free of vibration an...

Page 34: ...tops must be protected from animal and vegetable fats Only allow qualified staff to transport the valve Movable parts must be properly secured Only use approved fully functional load lifting devices...

Page 35: ...rtical installation position Therefore support the actuator and regularly check the valve for leakage 5 2 Control top If the external valves are connected in a control top with several solenoid valves...

Page 36: ...Weld the housing into the pipe system use welding additive if necessary When technically possible use the WIG orbital welding process with pulse configuration according to the EHEDG D 35 guideline 4 P...

Page 37: ...neumatic actuating force when lower control air pressures are used 5 5 2 Establishing hose connections INFO To ensure reliable operation the compressed air hoses must be cut exactly at a right angle T...

Page 38: ...ram with T VIS control top Figure 5 1 Hose Connection Diagram Position Designation A Actuator P Central air supply X Sound absorber Y Locking screw Z Plug 38 104 5 5 Checking the pneumatic connection...

Page 39: ...serious personal injuries or death Observe the installation and operating regulations for use in potentially explosive areas Prerequisites Valve is installed 1 Connect the control top in accordance w...

Page 40: ...40 104 5 5 Checking the pneumatic connection 0000000881 001 EN GB...

Page 41: ...assembled and correctly adjusted All screw connec tions must be securely tightened All electrical cables must be installed correctly Reliably secure machine parts which have already been connected ag...

Page 42: ...all connections are connected properly The safety devices for the valve must be complete fully functional and in perfect condition Check the function before starting any work When the valve is switche...

Page 43: ...ntended The place of installation of the 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 perso...

Page 44: ...44 104 7 3 Shutdown 0000000881 001 EN GB...

Page 45: ...generally applicable details Method and parameters should be determined and defined by the operator in accordance with the relevant process and product The cleaning effect must be checked regularly by...

Page 46: ...to make an optimal cleaning result probable 8 2 Passivation Before a system with long pipes and tanks is commissioned it usually needs to be pas sivated Valve blocks are usually excepted from this Pa...

Page 47: ...t come into contact with the product 1 Regularly check seals that come into contact with the product 1 1 Check the seal ring between upper housing and lantern 1 2 Check the V ring in the valve disks 1...

Page 48: ...ls with new labels The signs on the valve have been checked 9 2 Servicing intervals To ensure the highest operational reliability all wearing parts should be replaced at lon ger intervals The actual s...

Page 49: ...17 Removing the switch bar valve disk DN 25 408 036 Jaw wrench a f 24 27 408 040 Jaw wrench ends ground a f 17 19 Removing the valve disk 229 119 01 Jaw wrench ends ground a f 21 23 Removing the valve...

Page 50: ...125 9 4 Prior to removal Prerequisites Ensure that no active processes are running in the relevant area during mainte nance and servicing work 1 Drain all pipe system elements that lead to the valve...

Page 51: ...n between the housing and lan tern Prerequisites No solenoid valve must be actuated electrically or manually The pneumatic and electrical connections on the plant side can remain on the control top To...

Page 52: ...ilips screws 25 and take off the hood 7 2 Pressurize the actuator with com pressed air max 8 bar by activating the solenoid valve Y1 at the manual operation element S The valve disk is raised 7 43 25...

Page 53: ...op Tools Belt wrench Jaw wrench a f 10 11 Jaw wrench a f 12 13 WARNING Spring tension in the valve NC Danger of injury when opening the clamp connections on the actuator or on the housing as the relea...

Page 54: ...Remove the clamp connection 43 between the housing and lantern 4 Depressurize actuator connection 0 The valve disk is lowered The valve insert is pushed out of the housing 43 The clamp connection bet...

Page 55: ...or manually The pneumatic and electrical connections on the plant side can remain on the control top Tools Philips screwdriver Slotted screwdriver Jaw wrench a f 10 Jaw wrench a f 13 1 Depressurize ac...

Page 56: ...Removal step remove the clamp connection between the housing and lan tern Tools Belt wrench Jaw wrench a f 10 11 Jaw wrench a f 12 13 1 Remove any mounted proximity switches C1 C2 optional version C1...

Page 57: ...and lantern 43 The clamp connection between the housing and lantern has been removed 9 5 2 Removing the control top ATTENTION The switch bar is sensitive and must be protected from impact stress Damag...

Page 58: ...3 and remove the half rings B12 2 Lift off the control top B also refer to the operating instructions for the T VIS control top B B11 B12 1 1 2 3 Loosen the switch bar 1 with a jaw wrench on the wrenc...

Page 59: ...half rings B12 using a hex key a f 3 and remove the half rings B12 2 Release the air connection 117 and reduction nipple 130 using a jaw wrench and unscrew 3 Remove the actuator cover 138 from the ac...

Page 60: ...connec tion 246 with a jaw wrench 3 Remove the mounting for proximity switch INA 243 from the actuator 49 243 B12 B12 49 246 INI holder has been removed 9 5 5 Disconnecting the valve insert from the h...

Page 61: ...ert out of the hous ing The bearing disk 4 and the sealing washer 3 must not hit the stem of the valve disk when the valve insert is withdrawn 3 4 The valve is now separated from the housing 9 5 Remov...

Page 62: ...n the clamp connection 46 be tween the actuator and the lantern The lantern can be turned to al low the jaw wrench to be posi tioned to release the lock nut 10 2 Hold the lock nut 10 tight on the wren...

Page 63: ...flat surface of the valve disk 15 1 from the valve disk 15 and unscrew 6 Pull off the bearing disk 4 with the bearing 2 and the sealing washer 3 with the gasket 1 from the valve disk 15 15 1 10 10 1 1...

Page 64: ...35 3 Remove the seat rings 33 33 35 43 43 Housing combination is dismantled All seals are freely accessible 9 6 Installing the valve 9 6 1 Tightening torques Tighten the following valve connections t...

Page 65: ...g the valve insert from individual parts WARNING Risk of injury when mounting sharp edged parts Do not put your hand into the valve housing ATTENTION Sensitive valve parts Damage to the valve parts ca...

Page 66: ...n the cylinder can become damaged Take care no dirt enters the actuator 1 Push the lantern 9 onto the actuator A 2 Push the bearing disk 4 with bearing 2 and seal disk 3 with seal ring 1 onto the valv...

Page 67: ...15 on the wrench flat surface 15 1 Observe torques see table Tight ening torques 9 6 1 Tightening torques 5 Mount the clamp connection 46 be tween the lantern and the actuator Observe torques see tabl...

Page 68: ...ings 33 with the O ring 5 into the housing and mount the clamp connection 43 Observe torques see table Tight ening torques 9 6 1 Tightening torques 2 Place the blanking plate 35 with the O ring 5 into...

Page 69: ...may not hit the rod of the valve disk when the valve insert is fit ted 3 4 The valve insert is placed into the housing 9 6 5 Mounting the control top ATTENTION The switch bar is sensitive and must be...

Page 70: ...ac tuator A using a jaw wrench Observe torques see 9 6 1 Tight ening torques 2 Place the control top B onto the switch bar 1 from above 3 Mount the half rings B12 on the control top B Ensure that the...

Page 71: ...gs B12 onto the actuator cover Ensure that the half rings are mounted correctly Observe torques see 9 6 1 Tight ening torques 3 Screw the reduction nipple 130 with the air connection 117 into the ac t...

Page 72: ...re mounted correctly 3 Screw the air connection 246 into the actuator using a jaw wrench Observe torques see 9 6 1 Tight ening torques 243 49 49 A 246 INI holder has been mounted 9 6 8 Mounting the cl...

Page 73: ...depending on how the valve is configured see section Spring to close valve NC with control top T VIS see section Spring to close valve NC without control top T VIS see section Spring to open valve NO...

Page 74: ...the actuator with compressed air max 8 bar by activating solenoid valve Y1 at the manual operation element S Valve disk is raised Valve insert lowers into the seat 2 Mount the clamp connection 43 betw...

Page 75: ...4 Attach the hood 7 to the control top using a philips screwdriver Observe torques see 9 6 1 Tighten ing torques 7 43 S Y1 The clamp connection is mounted 9 6 Installing the valve 75 104...

Page 76: ...for wrench long a f 10 Socket for wrench a f 13 1 Pressurize the actuator with compressed air max 8 bar connection 0 Valve disk is raised Valve insert lowers into the seat 2 Mount the clamp connectio...

Page 77: ...4 For optional version with proximity switch holder C mount the proximi ty switches C1 C2 C1 C2 43 C The clamp connection is mounted 9 6 Installing the valve 77 104...

Page 78: ...antern Tools Jaw wrench a f 10 Jaw wrench a f 13 Torque wrench 2 5 25 Nm Socket for wrench long a f 10 Socket for wrench a f 13 1 Mount the clamp connection 43 be tween the housing and lantern Observe...

Page 79: ...2 For optional version with proximity switch holder C mount the proximi ty switches C1 C2 C1 C2 43 C The clamp connection is mounted 9 6 Installing the valve 79 104...

Page 80: ...nstructions for the respective control top into account for adjustment of the feedbacks If the strokes are correct the feedback can be adjusted and checked The valve stroke has been tested The valve s...

Page 81: ...t in 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 Use only cleaning m...

Page 82: ...ts which are non abrasive and not aggressive to wards stainless steel 9 7 2 Replacing the V ring INFO Replace defective seals but always fit new housing O rings to ensure the tightness of the valve Al...

Page 83: ...isk of injury if the pickset tool slips when removing the V ring Clamp the valve disk with the vice mount into the vice INFO Functional and running surfaces of the valves may not be damaged INFO Do no...

Page 84: ...has been exchanged INFO Used seals must not be used again since the proper function of the seal can then no longer be ensured 9 7 3 Replacing the V ring RA on the valve disk INFO Replace defective sea...

Page 85: ...ainer Tools V ring insertion tool Pickset Vice support CAUTION Sharp edged tool Risk of injury if the scriber slips when removing the V ring Grip the valve disk in a vice with protected jaws Unscrew t...

Page 86: ...long the circumference 5 Insert the V ring evenly 6 Replace all the other seals identified in the spare parts lists V ring has been exchanged INFO Used seals must not be used again since the proper fu...

Page 87: ...rease the inside of the seal ring 1 contact surface Seals and threads have been lubricated INFO GEA Tuchenhagen recommends Rivolta F L G MD 2 and PARALIQ GTE 703 These lubricants are approved for food...

Page 88: ...88 104 9 7 Maintenance 0000000881 001 EN GB...

Page 89: ...in the controller Check the system configuration No compressed air or com pressed air too low Check compressed air supply and check air hoses for free pas sage and air tightness Fault in the electric...

Page 90: ...90 104 9 7 Maintenance 0000000881 001 EN GB...

Page 91: ...ndstill observe the storage conditions see 4 2 Storage 11 2 Dismantling Prerequisites Ensure that no active processes are running in the relevant area during disman tling 1 Empty all pipe elements tha...

Page 92: ...Never open the actuator GEA Tuchenhagen accepts unopened actuators and arranges the proper disposal free of charge Prerequisites The valve should be disposed of 1 Remove the actuator 2 Pack the actua...

Page 93: ...are parts from GEA may be used All spare parts are packed in GEA original packaging and marked accordingly The spare parts are not included in the scope of supply of the machine The specifications lis...

Page 94: ...12 2 Spare parts lists Spare parts list shuttle valve X_R 221ELI014419DE_1 01 03 2022 1 Spare parts list shuttle valve X_R Fig 1 Fig 2 94 104 12 2 Spare parts lists 0000000881 001 EN GB...

Page 95: ...15 Valve disk X_R 1 4404 221 700 08 221 700 09 221 700 10 221 700 11 221 700 12 221 700 13 29 O ring NBR 930 026 930 026 930 026 930 026 930 026 930 026 30 O ring NBR 930 026 930 026 930 026 930 026...

Page 96: ...isk X_R 1 4404 221 700 14 221 700 15 221 700 16 221 700 17 221 700 18 221 700 19 29 O ring NBR 930 026 930 026 930 026 930 026 930 026 930 026 30 O ring NBR 930 026 930 026 930 026 930 026 930 026 930...

Page 97: ...932 088 932 090 932 100 29 1 O ring 20 x 3 20 x 3 20 x 3 20 x 3 NBR 930 026 930 026 930 026 930 026 30 1 O ring 20 x 3 20 x 3 20 x 3 20 x 3 NBR 930 026 930 026 930 026 930 026 94 1 V ring RA I DN25 DN...

Page 98: ...98 104 12 2 Spare parts lists 0000000881 001 EN GB...

Page 99: ...13 Annex 13 1 Dimension sheet 21 03 2023 1 Dimension sheet VARIVENT Shuttle valve X_R Dimension sheet VARIVENT Shuttle valve X_R Fig 1 221MBL014435EN_2 13 1 Dimension sheet 99 104...

Page 100: ...470 661 31 14 DN 65 70 0 2 00 96 0 125 135 382 511 748 30 24 DN 80 85 0 2 00 111 0 125 135 390 519 786 30 25 DN 100 104 0 2 00 130 0 125 170 399 528 833 30 34 OD 1 25 4 1 65 46 0 90 99 292 421 537 12...

Page 101: ...ief 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 Fl...

Page 102: ...psig unless explicitly specified otherwise PTFE Polytetrafluoroethylene SET UP Self learning installation During commissioning and maintenance the SET UP procedure carries out all the necessary setti...

Page 103: ...13 2 List of abbreviations 103 104...

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GEA VARIVENT X R Series, Operating Instructions Manual

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