GEA VARIVENT Operating Instruction Download Page 1

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Hygienic valves

GEA VARIVENT

Valve Type B

Operating instruction (Translation from the original language)
430BAL008326EN_3

Summary of Contents for VARIVENT

Page 1: ...Hygienic valves GEA VARIVENT Valve Type B Operating instruction Translation from the original language 430BAL008326EN_3 ...

Page 2: ...rotected 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 permission of GEA Tuchenhagen GmbH LEGAL NOTICE Word marks The designations VARIVENT and T VIS are protected trademarks of GEA Tuchenhagen GmbH 430BAL008326EN_3 2 07 02 2022 ...

Page 3: ...ary 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 1 Actuator Function 20 4 Transport and storage 21 4 1 Storage conditions 21 4 2 Transport 21 4 2 1 Scope of supply 22 5 Technical data 23 5 1 Type plate 23 5 2 Technical data 23 5 3 Cleaning connec...

Page 4: ... Maintenance 45 10 6 1 Cleaning the Valve 45 10 6 2 Replacing the V Ring 46 10 6 3 Lubricating seals and threads 47 10 7 Installation 48 10 7 1 Spring 49 10 7 2 Cleaning hood 49 10 7 3 Place the seating ring between the housings 49 10 7 4 Installing the Valve in the Housing 49 10 7 5 Checking assembly 50 10 7 6 Reconnect the cleaning hose 50 10 7 7 Torques for the Clamps and Clamp Connections 52 1...

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 these Operating Instructions show the product in a simplified form The actual design of the product can differ from the illustration For detailed views and dimensions of the product please refer to the ...

Page 6: ...in 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 instructions 1 First step in a sequence of operations 2 Second step in a sequence of operations Result of the previous operation The operation is complete the goal has been achieved Hint Further usef...

Page 7: ...ration 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 430BAL008326EN_3 07 02 2022 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 prepared in accordance with Annex VII Part A and agree to submit the documentation on justified request of national authorities on a data carrier Person authorised for compilation and handover of technical...

Page 9: ...peration The prerequisite 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 also involves adhering to the operating inspection and maintenance instructions 2 1 2 Pressure equipment directive The component is a piece of pressure equipment without safety fu...

Page 10: ...n perfect operating condition in order to prevent danger to persons and property This operating manual contains information that you and your employees need for safe operation over the life of the component Be sure to read these Operating Instructions carefully and ensure that the measures described here are observed The operator s duty of care includes planning the necessary safety measures and m...

Page 11: ...fety instructions and dangers The component is safe to operate It was built according to state of the art science and technology Nevertheless dangers can arise from the component if the component is not used as intended the component is used improperly the component is operated under impermissible conditions 2 4 1 Principles for safe operation Dangerous situations during operation can be avoided b...

Page 12: ... apply Access to electrical equipment should only be allowed to qualified electricians Always keep unattended switch cabinets locked Modifications of the control system can affect the safe and reliable operation Modifications are only permitted with the express permission of the manufacturer After completion of all work check that the protective devices are fully functional 2 5 Supplementary Regul...

Page 13: ...nt under the supervision and guidance of a trained specialist Each employee must meet the following requirements to work on the component Personal suitability for the respective task Sufficient professional qualification for the respective task Received instruction about the functionality of the component Received instruction about operating sequences on the component Familiar with the safety devi...

Page 14: ...as 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 devices Marking of devices The relevant certificates of qualification must be submitted before work can be carried out on ATEX certified machines 2 7 Safety equipment 2 7 1 Signage Dangerous points on the...

Page 15: ...fe 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 appropriate measures to prevent switch on 3 Test absence of voltage 4 Earthing and short circuiting 5 Cover or safeguard any adjacent live parts Spring tension in the actuator Danger to life caused by comp...

Page 16: ...armful to the environment For all work Collect lubricants in suitable containers Dispose of lubricants in accordance with the pertinent regulations 2 9 Hazard Areas Fig 4 Please observe the following notes In the event of malfunctions shut down the valve disconnect from the power and air supply and secure it against being used Never reach into the lantern 9 when the valve is switching Fingers can ...

Page 17: ...oided call in a second person who can operate the main switch in case of an emergency The housing sockets 402 have very sharp edges When transporting and installing the valve be sure to wear suitable protective gloves When the valve switches when the valve seat is being cleaned or if a seal is defective medium product cleaning medium exits from the leakage outlet 15 Collect this liquid in a suitab...

Page 18: ...g 5 Design No Designation A Actuator B T VIS control top L Air connection S Electrical connection 1 Sealing ring 2 Bearing 3 Sealing disk 4 Bearing disk 9 Lantern 11 Cleaning hood Description Design 430BAL008326EN_3 18 07 02 2022 ...

Page 19: ...Design No Designation 15 Valve disk 16 Double disk Description Design 430BAL008326EN_3 07 02 2022 19 ...

Page 20: ... closed in the non actuated position Identification on the T VIS 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 6 Description Functional description 430BAL008326EN_3 20 07 02 2022 ...

Page 21: ... that any ice crystals formed by condensation water can melt 4 2 Transport Fig 7 For transport the following principles apply When transporting the valve be sure to unscrew the control top and the switch bar from the actuator 2 and use the screwed in eye bolt 1 material no 221 104 98 to lift the valve Only use suitable lifting gear and slings for transporting the package units valves Observe the p...

Page 22: ...circumstances 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 unit down with a jerk 4 2 1 Scope of supply After taking delivery of the component check if the details on the type plate correspond to the data in the order and delivery documents the equipment is c...

Page 23: ...4 8 69 6 max 8 0 116 Product pressure bar psi 10 145 5 2 Technical data Refer to the following tables for the key technical data of the valve Technical data Valve Designation Description Size DN 65 to DN 150 2 5 to 4 OD 2 to 6 IPS Material of product contact parts Stainless steel AISI 304 316L 1 4301 Check corrosion resistance with respect to media and detergents Installation position Vertical Tec...

Page 24: ...r consumption depending on the operating pressure 2 to 3 8 l for DN 25 to DN 125 3 5 to 6 5 l for DN 150 Product pressure 5 bar 72 5 psi standard max 6 bar 87 psi Resistance to pressure surges DN 80 100 OD 4 max 25 bar 362 6 psi Control air pressure 4 8 bar max 8 bar Control air acc to ISO 8573 1 Solid particle content Quality class 6 Particle size max 5 µm Particle density max 5 mg m3 Water conte...

Page 25: ...30 266 5 4 Resistance and permitted operating temperature of the sealing materials The resistance and permitted operating temperature of the sealing materials depend on the type and temperature of the medium conveyed The exposure time can adversely affect the service life of the seals The sealing materials comply with the regulations of FDA 21 CFR 177 2600 or FDA 21 CFR 177 1550 The maximum operat...

Page 26: ...ids up to 5 up to 100 C 212 F Water up to 100 C 176 F Steam up to 135 C 275 F o o Steam approx 30 min up to 150 C 302 F o Fuels hydrocarbons Product with a fat content of max 35 Product with a fat content of more than 35 Oils Sealing materials General temperature resistance EPDM 40 135 C 40 275 F FKM 10 200 C 14 392 F HNBR 25 140 C 13 284 F The general resistance of the material does not correspon...

Page 27: ... 5 26 x 40 41 1 5 38 x 50 53 1 5 50 x 65 70 2 0 66 x 80 85 2 0 81 x 100 104 2 0 100 x 125 129 2 0 125 x 150 154 2 0 150 x Dimensions for Pipes in Inch OD Inch OD Outside diameter Wall thickness Inside diameter Outside diameter 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 3 76 2 1 65 72 9 x 4 101 6 2 11 97...

Page 28: ...rench 408 142 V ring insertion tool 229 109 88 Open end spanner ends ground a f 17 19 229 119 01 Open end spanner ends ground a f 21 23 229 119 05 Open end spanner ends ground a f 22 24 229 119 03 Open end spanner a f 30 32 408 041 Mandrel 6 mm Installation mandrel 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 65 24 DN 80 24 ...

Page 29: ...Size Weight kg OD 2 5 23 OD 3 24 OD 4 32 OD 6 66 IPS 2 13 IPS 3 25 IPS 4 33 IPS 6 67 Technical data 430BAL008326EN_3 07 02 2022 29 ...

Page 30: ...vertently 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 prevent damage make sure that the valve is installed in the pipe system free of tension and no foreign materials e g tools bolts lubricants are left in the system 6 3 Control head If external valves are...

Page 31: ...ng can warp during welding To avoid welding distortions always seal the housing before welding Carry out the following steps 1 Release the spring tension 2 Remove the valve insert see chapter Section 10 5 Page 41 3 Weld the housing without sealing rings into position ensuring that the connection is free of stress 4 Fit the housing into place and tack it 5 To avoid welding distortions always seal t...

Page 32: ...IN 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 00 U 6 261 5 20 1 Actuators with booster cylinder for increasing the pneumatic actuating force when lower control air pressures are used 6 6 2 Establishing Hose Connections To ensure reliable operati...

Page 33: ...e Explosive 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 Connect in accordance with the connection diagram and the instructions in the corresponding operating instructions for control tops T VIS M 15 A 15 or T VIS P 15 Done Hint The proximity switc...

Page 34: ...ting 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 valve must be complete fully functional and in perfect condition Check the function before starting any work When the valve is switched on the danger zones must be free Remove any liquids that have es...

Page 35: ...ervals 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 changes to the component immediately to the person in charge Always keep danger zones clear Do not leave any objects in the danger zone Only allow persons to enter the danger zone when the machine is de...

Page 36: ...ning 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 80 C 176 F Phosphoric or nitric acid and combination products based thereon in the concentrations of 0 3 to 1 5 at approx 65 C 149 F Example of a cleaning operation in one cleaning step Formic acid a...

Page 37: ...appropriate 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 product flow can flow in both lines using a spray nozzle that distributes the CIP fluid throughout the leakage cavity However the seal surfaces of the valve disc seals are not cleaned with them This ...

Page 38: ...n 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 carry out maintenance work When replacing parts only use approved fully functional load lifting devices and lifting accessories which are suitable for the intended purpose Before setting the unit back in...

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 the operating pressure at the pressure reducing and filter station 2 Regularly clean the air filter in the filter station 3 Check that the air hoses sit firmly in the air connections 4 Check the lin...

Page 40: ...tions 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 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 C 140 F approx every 12 months 10 4 Prior to disassembly Prere...

Page 41: ... Removing the Valve Insert Fig 9 Prerequisite No solenoid valve must be actuated electrically or manually The pneumatic and electrical connections on the plant side can remain on the control top Notice The permanent magnet on the switch bar is fragile Damage to the permanent magnet Protect the permanent magnet against impact stress Maintenance Disassembling the Valve 430BAL008326EN_3 07 02 2022 41...

Page 42: ...cs 15 16 are raised 3 Remove the snap ring 43 1 4 Interrupt the compressed air supply to the connection L 5 Pull off the control top B upwards Light emitting diode A green will go out and light emitting diode B will flash yellow The valve insert has been removed 10 5 2 Separating the valve from the drive Fig 10 Notice The piston rod and the shaft of the valve disc are delicate components When unsc...

Page 43: ...disc are delicate components When the valve insert is withdrawn the bearing washer 4 and the sealing washer 3 can damage the shaft 16 of the double disc Carefully remove the valve insert out of the lamp 9 Do not hit the threads of the cleaning hood 11 on the lamp Carry out the following steps 1 Pull the valve insert out of the lamp 9 2 Secure the valve disc on the borehole 15a with a suitable tool...

Page 44: ...pring 18 abutment 12 bearing washer 4 bearings 2 seal 1 with the seal washer 3 and double disc 16 from the valve disc Fig 13 5 Remove the snap ring from the housing and take out the components 5 65 66 92 Maintenance Disassembling the Valve 430BAL008326EN_3 44 07 02 2022 ...

Page 45: ... 1 Cleaning the Valve Fig 15 Notice The shaft of the valve disc 16 the housing seat 402 the valve seat 16 1 and the V ring groove 16 2 are precision parts Damage to these parts can result in a malfunction Handle the valve with care Maintenance Maintenance 430BAL008326EN_3 07 02 2022 45 ...

Page 46: ...n tool Prerequisite Insert V Ring without grease To facilitate fitting use water with a drop of washing up liquid to remove the surface tension In order that no rust is transferred the washing up liquid solution must be made up in a ceramic plastic or stainless steel container Tools required V ring insertion tool Caution Danger of injury The scriber can slip off when the V ring is removed Grip the...

Page 47: ...f the V ring is correct see illustration Fig 18 5 Use the insertion tool to press in the V ring evenly press in at several opposite points along the circumference Fig 19 6 Insert the V ring evenly 7 Replace all the other seals identified in the spare parts lists Done Hint Used seals must not be used again since the proper function of the seal can then no longer be ensured 10 6 3 Lubricating seals ...

Page 48: ...foodstuff and are resistant to beer froth They have the NSF H1 USDA H1 registration They do not affect the taste or the consistency of the products and are compatible with 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 become null and void A Manufactu...

Page 49: ...ve placement has been bolted to the cleaning hood counter the piston rod against it 10 7 3 Place the seating ring between the housings Fig 22 The seating ring should be placed with the arrow pointing to the displayed installation direction Be extremely careful during assembly that the seating ring is properly placed between the housings so that the arrow later properly displays the direction of th...

Page 50: ... the following steps 1 Insert assembly mandrel M with O ring side in valve disk 15 2 Insert valve into housing with assembly mandrel 3 Remove assembly mandrel from valve disk Done 10 7 5 Checking assembly Fig 24 When the valve is closed the lower edge of the cleaning hood 1 should be flush with the underside of the abutment 2 10 7 6 Reconnect the cleaning hose Maintenance Installation 430BAL008326...

Page 51: ...dstuff and are resistant to beer froth They have the NSF H1 USDA H1 registration PARALIQ GTE 703 can be ordered under mat no 413 064 and Rivolta F L G MD 2 can be ordered under mat no 413 071 from GEA Tuchenhagen Fitting the cleaning hose 1 Slide the union nut 2 and sealing disc 1 over the cleaning hose disc Fig 25 Assembling the cleaning hose Carry out the following steps 1 Screw on the union nut...

Page 52: ...es for the Clamps and Clamp Connections Tighten the clamp connection and semi rings on 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 half rings M8 22 16 2 Cast clamps M10 45 33 10 7 8 Checking the function Setting the valve stroke Carry out the following steps 1 Actuate the valve with ...

Page 53: ...ve stroke depending on size Valve Stroke Valve size Valve stroke mm Metric 65 30 80 30 100 30 125 60 150 60 Inch OD 2 5 30 3 29 4 30 Inch IPS 2 30 3 30 4 30 6 60 Maintenance 430BAL008326EN_3 07 02 2022 53 ...

Page 54: ...Fault in the electrical system Check actuation external controller and routing of electrical lines Solenoid valve defective Replace the solenoid valve Valve does not close Dirt foreign material between valve seat and valve disk Clean valve housing and valve seat Valve closes too slowly O rings in actuator and control top are dry friction losses Grease O rings Leakage in the area of the valve housi...

Page 55: ...e 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 dispose of them correctly sorted Also observe the instructions regarding disposal in the operating instructions for the individual components 12 2 2 Valve Actuator Disposal Danger The spring forces in ...

Page 56: ...13 Spare parts list mixproof valve B Fig 27 Spare Parts Drawing Fig 28 Housing combinations Spare parts list mixproof valve B 430BAL008326EN_3 56 07 02 2022 ...

Page 57: ... 04 221 121 06 221 121 22 11 Cleaning hood 1 4301 221 146 01 221 146 01 221 146 01 221 146 02 221 146 02 12 Support bracket 1 4301 221 148 01 221 148 01 221 148 01 221 148 03 221 148 03 15 Valve disc B 1 4404 221 317 05 221 317 05 221 317 03 221 317 02 221 317 28 16 Double disk 1 4404 221 112 03 221 112 04 221 112 05 221 112 08 221 112 07 18 Compression spring 1 4310 931 249 931 249 931 002 931 09...

Page 58: ...21 334 02 221 334 02 221 334 02 221 334 03 221 334 03 92 Balancer fastener 1 4404 221 348 02 221 348 02 221 348 01 221 348 05 221 348 04 401 Housing V1 1 4404 221 101 05 221 101 06 221 101 07 221 101 18 221 101 66 402 Housing V2 1 4404 221 102 05 221 102 06 221 102 07 221 102 29 221 102 09 A Actuator VARIVENT See parts list dimensions sheet for VARIVENT actuator B Control top T VIS See parts list ...

Page 59: ...084 932 089 932 099 9 Lantern 1 4301 221 121 08 221 121 08 221 121 09 221 121 12 221 121 03 221 121 04 221 121 05 11 Cleaning hood 1 4301 221 146 01 221 146 01 221 146 01 221 146 01 221 146 01 221 146 01 221 146 02 12 Support bracket 1 4301 221 148 01 221 148 01 221 148 01 221 148 02 221 148 01 221 148 01 221 148 03 15 Valve disc B 1 4404 221 317 05 221 317 06 221 317 03 221 317 18 221 317 07 221 ...

Page 60: ...6 935 042 935 043 935 045 Guide ring 3A MF 6 935 113 935 113 935 114 935 117 935 113 935 114 935 116 74 Cleaning nozzle PVDF 221 334 02 221 334 02 221 334 02 221 334 01 221 334 02 221 334 02 221 334 03 92 Balancer lock 1 4404 221 348 02 221 348 02 221 348 01 221 348 03 221 348 02 221 348 01 221 348 04 401 Housing V1 1 4404 221 101 30 221 101 31 221 101 32 221 101 37 221 101 35 221 101 36 221 101 1...

Page 61: ...0 246 930 246 930 246 930 266 930 266 FKM 930 247 930 247 930 247 930 265 930 265 HNBR 930 631 930 631 930 631 930 631 930 631 24 1 O ring EPDM 930 235 930 235 930 235 930 268 930 268 FKM 930 162 930 162 930 162 930 164 930 164 HNBR 930 638 930 638 930 638 930 639 930 639 29 1 O ring NBR 930 026 930 026 930 026 930 035 930 035 29 1 1 O ring NBR 930 026 930 026 930 026 930 026 930 026 65 1 Seal rin...

Page 62: ...14 Dimension sheet VARIVENT Double seat valve B Fig 29 Dimension sheet VARIVENT Double seat valve B 430BAL008326EN_3 62 07 02 2022 ...

Page 63: ...5 90 0 125 157 170 386 515 920 31 0 23 OD 3 76 2 1 65 103 0 125 165 5 170 393 522 927 29 0 24 OD 4 101 6 2 11 127 5 125 183 5 210 401 530 935 30 5 32 OD 6 152 4 2 77 177 0 150 276 5 260 578 707 1297 60 0 66 IPS 2 60 3 2 00 81 0 114 3 130 5 110 345 474 734 30 0 13 IPS 3 88 9 2 30 115 0 152 5 163 5 170 392 521 926 30 0 25 IPS 4 114 3 2 30 140 0 152 5 187 210 404 533 938 30 0 33 IPS 6 168 2 2 77 192 ...

Page 64: ...n 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 1629 Fluorine rubber h Unit of measurement of time hour HNBR Material designation Short designation according to DIN ISO 1629 Hydrogenated Acrylonitrile Butadiene Rubber IP Protection class ISO Internati...

Page 65: ...UP Self learning installation During commissioning and maintenance the SET UP procedure carries out all the necessary settings for the generation of messages AF Specifications for the size of spanners width across flats T VIS Tuchenhagen Valve Information System V AC Volt alternating current V DC Volt direct current W Unit of measurement of power Watt TIG Welding method Tungsten inert gas welding ...

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