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6

Assembly and installation

6.1

Safety instructions

Hazardous situations during installation can be avoided by safety-conscious and
proactive behaviour of the personnel.
For installation, the following principles apply:

•

Only qualified personnel are allowed to set-up, install and commission the
component.

•

Ensure that adequate working and traffic areas are available at the place of
installation.

•

Observe the maximum load-bearing capacity of the installation surface.

•

Observe the transport instructions and markings on the part(s) to be
transported.

•

Remove any nails protruding from transport crates immediately after opening
the crate.

•

Under no circumstances should anyone stand under a suspended load.

•

Safety devices of the component may not work effectively during installation.

•

Reliably secure sections of the plant which have already been connected
against inadvertently being switched on.

6.2

Notes on installation

The mixproof butterfly valve ECOspace should be installed in horizontal pipes,
with the actuator in vertically upright position; in special applications the actuator
can also be installed at a 30° tilt.
To prevent damage, make sure that

•

the mixproof butterfly valve is installed in the pipe system free of tension.

•

no foreign materials (e.g. tools, bolts, lubricants) are left in the system.

•

with all pneumatic actuators that are used in a vertical pipe, the brackets are
facing upwards.

6.3

Pneumatic connections

6.3.1

Air Requirement

The air requirement for the switching operations depends on the actuator type.

Assembly and installation

Safety instructions

430BAL010337EN_7

29.07.2021

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Содержание ECOspace

Страница 1: ...Hygienic valves GEA hygienic leakage butterfly valve type ECOspace Operating instruction Translation from the original language 430BAL010337EN_7 ...

Страница 2: ...nt is protected 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 designation T VIS is a protected trademark of GEA Tuchenhagen GmbH 430BAL010337EN_7 2 29 07 2021 ...

Страница 3: ...s 12 2 6 Qualification of personnel 12 2 7 Safety equipment 13 2 7 1 Signage 13 2 8 Residual dangers 14 2 9 Hazard Areas 15 3 Description 17 3 1 Pneumatic Butterfly Valve with Control Top 17 3 2 Pneumatic Butterfly Valve without Control Top 17 3 3 Butterfly Valve Body without Actuator 18 3 4 Manual Actuator Type H 18 3 5 Functional description 19 3 5 1 Pneumatic Actuator 19 3 5 2 Actuator A 1 19 3...

Страница 4: ...ng the Valve 43 10 5 4 Disassembling the Pneumatic Actuator 43 Taking off the Actuator 43 Dismantling the Actuator Parts 44 10 5 5 Disassembling the Manual Actuator 44 10 5 6 Removing the Valve Disk Seal 45 10 6 Maintenance 46 10 6 1 Cleaning the Mixproof Butterfly Valve 46 10 6 2 Lubricating Seals and Threads 47 10 7 Installation 48 10 7 1 Assembling the Valve Disk 48 10 7 2 Torques for the clamp...

Страница 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 ...

Страница 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...

Страница 7: ...harmonized standards in particular EN ISO 12100 2010 Remarks In the event of a modification 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 with Annex VII Part A and undertake to forward this documentation by means of data medium upon justified request by...

Страница 8: ...lar DIN EN ISO 12100 Remarks This 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 comp...

Страница 9: ...rective Directive 2014 68 EG They are classified according to Annex II article 4 section 3 In the event of any deviations GEA Tuchenhagen GmbH will supply a specific Declaration of Conformity 2 1 3 ATEX directive In areas with an explosive atmosphere only valves suitable for use in such areas may be used Refer to and observe the additional operating instructions ATEX version valves For details reg...

Страница 10: ...ly Only qualified personnel may work on the component The operating company 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 suitable work clothing and personal protective equipment As the operating company must ensure that work clothing and personal protective...

Страница 11: ...t 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 the condition of the valve before starting work and at regular intervals Wear tight fitting work clothing for all work on the valve Ensure that nobody can get hurt on the parts of the valve Immedia...

Страница 12: ...ty 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 trained Operating and maintenance personnel must have the necessary qualification to carry out their tasks be instructed with regard to possible dangers know and observe the safety instructions given ...

Страница 13: ...ion 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 the task Maintenance personnel Appropriate training and a sound knowledge of the structure and functionality of the component Sound knowledge in the following areas Mechanical equipment Electrical eq...

Страница 14: ...e valve 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 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...

Страница 15: ...Environmental damage Operating materials with properties which are harmful to the environment For all work Collect lubricants in suitable containers Dispose of lubricants in accordance with the pertinent regulations Risk of injury Danger due to liquid escaping from the leakage connections Discharge the liquid in a controlled manner 2 9 Hazard Areas Please observe the following notes In the event o...

Страница 16: ...Only allow a qualified electrician 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 parts cannot be avoided call in a second person who can operate the main switch in case of an emergency Safety 430BAL010337EN_7 16 29 07 2021 ...

Страница 17: ...ounting bracket 2 Butterfly valve body 3 2 Pneumatic Butterfly Valve without Control Top Fig 5 No Designation A 2 Pneumatic Actuator 1 Mounting bracket 2 Butterfly valve body Optional Electrical feedback proximity switch in the mounting bracket Description Pneumatic Butterfly Valve with Control Top 430BAL010337EN_7 29 07 2021 17 ...

Страница 18: ...Actuator Type H Various manual actuator variants are available Standard design of manual actuator Fig 7 No Manual actuator variants 1 Standard 2 Optional one electrical feedback signal 3 Optional two electrical feedback signals Description Butterfly Valve Body without Actuator 430BAL010337EN_7 18 29 07 2021 ...

Страница 19: ...t performs a 90 rotation per stroke This rotation exactly corresponds to the rotational angle required to open or close the disk of the mixproof butterfly valve 3 5 2 Actuator A 1 Fig 8 The switching state is detected and indicated by the control top B The visual position indication O can be recognized by the red marking on the coupling 3 5 3 Actuator A 2 Fig 9 Feedback of switching states can be ...

Страница 20: ...s released it locks into place in the holes provided The limit positions of the mixproof butterfly valve can be detected by proximity switches 3 5 5 Butterfly Valve Body without Actuator Fig 11 No Designation 1 Valve disk 2 Flange 3 Flange 4 Disk seal 5 Plain bearing 6 Radial seal 7 Leakage connections 8 Hole on the square end Description Functional description 430BAL010337EN_7 20 29 07 2021 ...

Страница 21: ...ted from one another The leakage cavity is open towards the atmosphere in this case After switching the medium in the valve disk leakage areas can drain by gravity 7 In the OPEN position maximum throughflow the leakage paths towards the atmosphere are closed The leakage cavity is sealed by the radial seal 6 on the short valve disk shaft Hint The hole B in the square end is used to indicate the pos...

Страница 22: ...d 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 staff to transport the valve Movable parts must be properly secured Only use approved fully functional load lifting devices and lifting accessories which are suitable for the intended purpose Observe the maximum...

Страница 23: ...a Refer to the following tables for the key technical data of the mixproof butterfly valve Technical data Mixproof butterfly valve Designation Description Size DN 15 to DN 100 2 to 4 OD Material of product contact parts Stainless steel Check corrosion resistance with respect to media and detergents Technical data Ambient temperatures Designation Description Valve 0 to 45 C 32 113 F standard 0 C 32...

Страница 24: ...for air air A A actuator min 4 0 bar max 8 bar Control air acc to ISO 8573 Solid particle content Quality class 6 Particle size max 5 µm Particle 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 class 3 ideally oil free max 1 mg oil for 1 m3 air Ai...

Страница 25: ...d resistance o reduced resistance no resistance Sealing resistance table Sealing material general operation temperature Medium at permissible operating temperature EPDM 40 135 C 40 275 F FKM 10 200 C 14 392 F HNBR 25 140 C 13 284 F VMQ 50 200 C 58 392 F Caustics up to 3 up to 80 C 176 F o o Caustics up to 5 up to 40 C 104 F o o o Caustics up to 5 up to 80 C 176 F o Caustics at more than 5 o o Inor...

Страница 26: ... Inorganic acids are e g carbonic acid nitric acid and sulphuric acid 5 4 Pipe ends General table of measurements Hint Not every valve is available in every size Particulars of available sizes of valves see Chapter 5 Page 23 Dimensions for Pipes in DN Metric DN Outside diameter Wall thickness Inside diameter Outside diameter acc 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 3...

Страница 27: ...imensions for Pipes in Inch IPS Inch IPS Outside diameter 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 5 Tools List of tools Tools Material no Hose cutter 407 065 Open end spanners a f 8 9 10 12 13 14 15 16 17 24 Pin punch Ø 4 403 209 Belt wrench 408 142 Face pin wrench Ø 4 adjustable 80 4...

Страница 28: ...roof butterfly valve with drive kg Manual actuator Pneumatic actuator without control top Pneumatic actuator with T VIS control top DN 50 2 4 0 7 9 9 1 2 1 2 5 1 9 0 10 2 DN 65 5 0 8 9 10 1 3 6 1 10 4 11 8 DN 80 5 9 10 2 11 7 DN 100 8 3 12 4 13 9 4 8 3 12 4 13 8 Technical data Lubricants 430BAL010337EN_7 28 29 07 2021 ...

Страница 29: ...d Safety devices of the component may not work effectively during installation Reliably secure sections of the plant which have already been connected against inadvertently being switched on 6 2 Notes on installation The mixproof butterfly valve ECOspace should be installed in horizontal pipes with the actuator in vertically upright position in special applications the actuator can also be install...

Страница 30: ...y 2 Use the hose cutter to cut the pneumatic hoses square Done 6 3 3 Actuator with T VIS Control Top Carry out the following steps 1 Push the air hose into the air connector on the control top 2 Re open the compressed air supply Done 6 3 4 Actuator without Control Top Carry out the following steps 1 Remove the plug from the actuator 2 Screw in connector G 1 8 or an exhaust air throttle for slow cl...

Страница 31: ... The proximity switches are factory set During transport and installation it can happen that the settings are changed so that readjustment may be required see the Operating Instructions for the control top 6 4 2 Adjusting the proximity switch actuator without T VIS Danger Live parts Electrical shock can result in serious personal injury or death Only allow properly qualified staff to carry out wor...

Страница 32: ... the proximity switch and turn the cap nuts until a switching gap of max 4 mm to the associated contact element is achieved 3 Tighten the cap nuts Done Assembly and installation 430BAL010337EN_7 32 29 07 2021 ...

Страница 33: ...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...

Страница 34: ...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...

Страница 35: ...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...

Страница 36: ...ssion pressure for the cleaning medium supply at the inlet valve to the leakage cavity is 2 5 bar 0 5 bar Pressure build up between the seals on the valve disk should always be avoided Non pressurized discharging at the outlet valve is therefore required Generally also ensure a positive pressure difference from the product chamber to the leakage cavity We recommend also cleaning the leakage cavity...

Страница 37: ...nd the service life 9 2 Passivation Before commissioning a plant passivation is commonly carried out for long pipes and tanks Valve blocks are usually excepted from this Passivation is typically performed using nitric acid HNO3 at approx 80 C 176 F at a concentration of 3 and a contact time of 6 to 8 hours Cleaning Passivation 430BAL010337EN_7 29 07 2021 37 ...

Страница 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...

Страница 39: ...ck 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 lines for kinks and leaks 5 Check the solenoid valves for proper function Done 10 2 2 Electrical connections Carry out the following steps 1 Check that the cap nut on the cable gland is tight 2 Only for...

Страница 40: ...intenance 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 Prerequisite Make sure that during maintenance and repair work no process is in operation in the area concerned Carry out the following steps 1 Drain all pipe system e...

Страница 41: ... to the permanent magnet Protect the permanent magnet against impact stress Carry out the following steps 1 Undo the screws 39 2 Remove the clamps 15 3 Withdraw the control top B via the switch bar 1 from the actuator A 1 4 Unscrew the switch bar 1 Done Hint Assemble the valve in reverse order Also refer to the instruction manual for the T VIS M 15 Maintenance Disassembling the Valve 430BAL010337E...

Страница 42: ... impact stress Notice The sensor is a sensitive component Damage of the sensor and failure of the valve Always handle the sensor with care Carry out the following steps 1 Undo the screws 39 2 Remove the clamps 15 3 Withdraw the control top B via the switch bar 11 from the actuator A 1 4 Unscrew the switch bar 11 Done Hint Assemble the valve in reverse order Also refer to the instruction manual for...

Страница 43: ...eumatic Actuator 10 5 4 1 Taking off the Actuator Fig 16 Carry out the following steps 1 Undo the screw connections 1 2 Lift off the actuator A Done Hint The red position indication marker 2 is aligned with the hole B in the valve disk so that it indicates the position of the disk in the valve Maintenance Disassembling the Valve 430BAL010337EN_7 29 07 2021 43 ...

Страница 44: ... Remove the mounting bracket 6 Done 10 5 5 Disassembling the Manual Actuator Removing the proximity switch Fig 18 Carry out the following steps 1 Use an a f 4 hex socket screwdriver to unscrew the locking screw 2 until it is flush with the bushing 2 Take off the hand lever 1 Done Maintenance Disassembling the Valve 430BAL010337EN_7 44 29 07 2021 ...

Страница 45: ...5 6 Removing the Valve Disk Seal Removing the Flanges Carry out the following steps 1 Undo the screw connections 3 Fig 20 2 Pull the butterfly valve body apart 3 Remove the radial seal 9 The radial seal protects the plain bearing from soiling The plug protects the plain bearing from soiling 4 Take out the valve disk 4 with the disk seal 6 Maintenance Disassembling the Valve 430BAL010337EN_7 29 07 ...

Страница 46: ...e to the valve disk 4 Fig 21 3 Pull the disk seal over the free end 12 of the valve disk 4 Unclamp the valve disk 5 Pull the disk seal over the long end 10 Fig 22 6 Remove the O ring 8 Done The disk seal is now completely removed 10 6 Maintenance 10 6 1 Cleaning the Mixproof Butterfly Valve Maintenance Maintenance 430BAL010337EN_7 46 29 07 2021 ...

Страница 47: ... Fig 23 Done 10 6 2 Lubricating Seals and Threads Caution Damage to seals and threads Damage to seals and threads can result in a malfunction Ensure that an adequate film of lubricant 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 issued by the lubricant ma...

Страница 48: ...gen if required A thin film of grease is required on the seals to ensure the proper function of the fittings It reduces friction and extends the service life of the seals This is absolutely harmless from a health and hygienic point of view 10 7 Installation Assemble the valve in reverse order of disassembly Observe the notes and instructions given in the following sections when doing so 10 7 1 Ass...

Страница 49: ...tion outer flange type VV Arrange additional holes so that bracket can be dismantled in assembled condition 10 7 2 Torques for the clamps and bolts Tighten the clamps and bolts on the valve to the torques specified in the table Torques Nm lbft Clamps on the control top 1 0 7 Bolts M6 9 6 6 Bolts M8 22 16 2 Bolts M10 45 33 Bolts M12 78 57 5 Maintenance 430BAL010337EN_7 29 07 2021 49 ...

Страница 50: ...ace the air hoses Control air pressure too low Increase the control air pressure Solenoid valve defective Replace the solenoid valve Valve disk is blocked Clear the blockage No feedback signal Proximity switch adjusted Adjusting the proximity switch Proximity switch not connected correctly Check and correct the wiring Proximity switch faulty Replace the proximity switch Valve disk is blocked Clear...

Страница 51: ...ations applicable at the place of installation The valves 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 spri...

Страница 52: ...13 Parts list Hygienic leakage butterfly valve ECOspace Fig 25 Items marked with an are wearing parts Parts list Hygienic leakage butterfly valve ECOspace 430BAL010337EN_7 52 29 07 2021 ...

Страница 53: ...Designation Material 2 OD 2 5 OD 3 OD 4 OD Sealing set cpl EPDM 224 000700 224 000701 224 000702 224 000703 1 Flap BFV L 1 4404 224 000583 224 000584 224 000586 224 000568 2 Seal BFV L EPDM 224 000570 224 000574 224 000572 224 000573 3 Radial seal BFV L EPDM 224 000536 224 000536 224 000536 224 000536 4 Hex head screw A2 70 901 046 901 046 901 046 901 381 8x M8 x 20 16x M8 x 20 16x M8 x 20 16x M10...

Страница 54: ...14 Spare parts list Pneumatic actuator hygienic leakage butterfly valve Fig 26 Spare parts list Pneumatic actuator hygienic leakage butterfly valve 430BAL010337EN_7 54 29 07 2021 ...

Страница 55: ...Fig 27 Spare parts list Pneumatic actuator hygienic leakage butterfly valve 430BAL010337EN_7 29 07 2021 55 ...

Страница 56: ...018 910 018 9 Initiator M12x1 10 65V DC 2wire Synthetic material 505 104 electrical connection with terminal compartment Initiator M12x1 10 30V DC 3wire 1 4301 505 088 electrical connection with terminal compartment 505 096 electrical connection with M12 connector 11 Position indicator BFV 7 PP 224 001069 224 001069 224 001070 224 001070 12 O ring NBR 930 041 930 041 930 041 930 041 13 Guide ring ...

Страница 57: ...l operation hygienic leakage butterfly valve Fig 28 Manual actuator for BFV L Fig 29 Installation variants for proximity switches Dimension sheet Manual operation hygienic leakage butterfly valve 430BAL010337EN_7 29 07 2021 57 ...

Страница 58: ...N 25 DN 65 2 OD 2 5 OD DN 100 DN 80 3 OD 4 OD X Square 12 mm 14 mm Manual actuator 224 001055 224 001056 Proximity switch holder 224 001058 224 001058 Dimension sheet Manual operation hygienic leakage butterfly valve 430BAL010337EN_7 58 29 07 2021 ...

Страница 59: ...n sheet Hygienic leakage butterfly valve ECOspace Fig 30 Installation of proximity switches optional observe removal reserve Dimension sheet Hygienic leakage butterfly valve ECOspace 430BAL010337EN_7 29 07 2021 59 ...

Страница 60: ...s 77 74 4x M8 95 88 6x M8 110 101 6x M8 137 134 6x M8 X 520 520 535 550 A2 Pneumatic actuator without control top installation dimension X1 B 109 127 141 168 C2 47 5 47 5 47 5 47 5 D actuator Ø 88 9 88 9 114 3 114 3 H1 267 5 276 5 283 5 297 X1 360 360 380 390 A3 Manual actuator installation dimension X2 B 109 127 141 168 C2 47 5 47 5 47 5 47 5 F 160 160 220 220 H2 106 5 115 5 122 5 136 X2 130 139 ...

Страница 61: ...17 Dimension sheet Hygienic butterfly valve seals Fig 31 Dimension sheet Hygienic butterfly valve seals 430BAL010337EN_7 29 07 2021 61 ...

Страница 62: ...7 28 0 DN 80 EPDM 224 000535 88 9 97 5 31 0 DN 100 EPDM 224 000573 109 1 118 7 32 0 2 OD EPDM 224 000570 56 3 63 2 28 0 2 5 OD EPDM 224 000574 68 4 76 7 28 0 3 OD EPDM 224 000572 81 2 89 7 31 0 4 OD EPDM 224 000573 109 1 118 7 32 0 Dimension sheet Hygienic butterfly valve seals 430BAL010337EN_7 62 29 07 2021 ...

Страница 63: ...on 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 Internat...

Страница 64: ...T 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 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 Inch Un...

Страница 65: ...Appendix 430BAL010337EN_7 29 07 2021 65 ...

Страница 66: ......

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