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Safety

Instructions for the Safe Operation

14

Installation

For installation, the following principles apply:

•

Only properly qualified staff is allowed to install, assemble and set the valve into
operation.

•

Ensure that adequate working and traffic areas are available at the place of installa-
tion.

•

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

•

Observe the transport instructions and markings on the part(s) to be transported. For
transportation and installation of the valve, it is imperative to remove the control top
and the switch bar from the actuator (2) and to use the screwed-in eye bolt (1), part
no. 221-104.98 for lifting the valve, see “Removing the Control Top and the Switch
Bar“ (Page 52).

•

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

•

Under no circumstances should anyone stand under a suspended load.

•

During assembly, the valve safety devices might not be working effectively.

•

Reliably secure machine parts which have already been connected against inadvert-
ently being switched on.

Commissioning/Setup Mode

For commissioning, the following principles apply:

•

Take protective measures against dangerous contact voltages in accordance with
pertinent regulations.

•

The valve must be completely 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 against inadvert-
ently being switched on.

•

Relubricate all lubricating points.

•

Make sure lubricants are used properly.

•

After conversion of the valve, residual risks must be reassessed.

Operating Instructions · VARIVENT

®

Mixproof Valve M-C/2.0

Edition 2018-10-04

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Содержание VARIVENT 24/7 PMO

Страница 1: ...Original Operating Instructions VARIVENT 24 7 PMO Cheese Curd Valve 2 0 Type M_C 2 0 Edition 2018 10 04 430BAL013215EN_1...

Страница 2: ...uchenhagen gea com Web http www tuchenhagen com These Operating Instructions are the original instructions in the sense of the EU Machinery directive These operating instructions are protected by copy...

Страница 3: ...6 Disassembly 17 Environmental Protection 17 Electrical Equipment 17 Signage 18 Residual Risk 19 Hazard Areas 19 Residual Dangers 21 Declaration of Conformity 22 Transport and Storage 23 Scope of Supp...

Страница 4: ...ting 51 Passivation 51 Malfunctions 52 Maintenance 53 Inspections 53 Product Contact Seals 53 Pneumatic Connections 53 Electrical Connections 53 Maintenance Intervals 54 Prior to dismantling the Valve...

Страница 5: ...eneral Notes 74 Valve Actuator Disposal 75 Technical Data 76 Type Plate 76 Technical Data 76 Resistance of Sealing Materials 78 Pipe Ends 79 Weights 79 Tools 80 Lubricants 80 Spare Parts Lists 81 Dime...

Страница 6: ...ctions before starting any work on or using the valve Your personal safety and the safety of the valve can only be ensured if you act as described in the Operating Instructions Store the Operating ins...

Страница 7: ...CAUTION Warning Injuries Failure to observe the warning note can result in minor or moderate damage to health The arrow identifies a precautionary measure you have to take to avoid the hazard IMPORTA...

Страница 8: ...hes Institut f r Normung e V German Institute for Standardization EN European Standard EPDM Material designation Short designation according to DIN ISO 1629 Ethylene Propylene Diene Rubber F Unit of m...

Страница 9: ...lyethylene psi Anglo American Unit of measurement of pressure Pound force per square inch All pressure ratings bar psi stand for over pressure barg psig if this is not explicitly described differently...

Страница 10: ...ved The following principles apply Only allow qualified staff to work on the valve The operator must authorize the staff to carry out the relevant tasks Working areas and the entire environment of the...

Страница 11: ...es and DIN EN 50281 1 2 for dusts The following minimum qualifications are required Vocational training as a specialist who can work on the valve independently Sufficient instruction to work on the va...

Страница 12: ...nstruction and sound knowledge in the following areas Function of the valve Valve operating sequences What to do in case of an emergency Lines of authority and responsibilities with respect to the tas...

Страница 13: ...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 o...

Страница 14: ...ort crates immediately after opening the crate Under no circumstances should anyone stand under a suspended load During assembly the valve safety devices might not be working effectively Reliably secu...

Страница 15: ...e 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 person responsible Always keep danger zones...

Страница 16: ...ock access for unauthorized persons Put up notice signs which draw attention to the maintenance or repair work going on Do not climb on the valve Use suitable access aids and working platforms Wear su...

Страница 17: ...rotection Harm to the environment can be avoided by safety conscious and proactive behaviour of the staff For environmental protection the following principles apply Substances harmful to the environm...

Страница 18: ...nd mandatory signs The signs and notes on the valve must always be legible Any illegible signs must be replaced immediately Signs on the valve Sign Meaning General hazard warning Warning Crushing Expl...

Страница 19: ...en the clamps 43 are opened as the released spring pretension will suddenly lift the actuator Therefore release the spring tension before detaching the clamps by supplying the actuator A with compress...

Страница 20: ...ve cleaning medium escapes from the leakage outlet This leakage must be collected in a suitable container e g a funnel or a drip pan and removed in a controlled manner Observe the instructions in the...

Страница 21: ...tension in the actuator Danger to life caused by compression spring in the actuator Do not open the actuator but return it to GEA Tuchenhagen for proper disposal Danger of injury Danger presented by m...

Страница 22: ...e invalid if any alterations are made to the machine which have not been agreed with us Authorised representative for compilation Authorised representative of the technical documentation CE documentat...

Страница 23: ...le valves with care to avoid damaged caused by impact or careless onloading and unloading The outside synthetic materials are susceptible to breaking The control tops must be protected from animal and...

Страница 24: ...rage the valve is going to be exposed to temperatures 0 C it must be dried and suitable measures be taken to protect it from damage NOTE We recommend that the valve should be stored at a temperature o...

Страница 25: ...torage as well as professional installation and assembly Operating the valve within the limits of its designated use also involves adhering to the operating inspection and maintenance instructions Pre...

Страница 26: ...will have to undergo a new conformity process in accordance with the EC Machinery Direc tive on your own In general only original spare parts supplied by GEA Tuchenhagen GmbH should be fitted This ens...

Страница 27: ...ction Design No Designation No Designation A actuator 9 lantern B control top T VIS 15 valve disk 1 sealing ring 16 double valve disk 2 rod guide ring L1 lifting actuator 3 sealing disk 17 valve housi...

Страница 28: ...ctive seals can thus easily be detected The penetration of leaking fluids from one pipe into the other is excluded under normal oper ating conditions Actuator Function Actuator with spring closing fun...

Страница 29: ...als e g tools bolts lubricants are left in the system Valve with Detachable Pipe Connection Elements This section describes the procedure to fit the valve CAUTION Liquids in pipes Danger of injury due...

Страница 30: ...any In case of incorrect installation position the valve is not working properly Make sure that the housing has the correct orientation TOP see pict Carry out the following steps 1 Release the spring...

Страница 31: ...ut the following steps 1 Shut off the compressed air supply 2 Use the hose cutter to cut the pneumatic hoses square 3 Push the air hose into the air connector on the control top 4 Re open the compress...

Страница 32: ...Date 2012 03 19 Page 32 221BAL009233 fm Hosing Diagram VARIVENT Mixproof Valve M 2 0 Hosing Diagram Operating Instructions VARIVENT Mixproof Valve M C 2 0 Edition 2018 10 04...

Страница 33: ...ctrical equipment Prior to establishing electrical connections check the maximum permissible oper ating voltage EXPLOSION HAZARD Explosive gases or dusts An explosion can result in serious personal in...

Страница 34: ...ion is a summary of the basic adjustment steps and is not intended as a substitute for the official operating instructions The operating instructions should always be consulted for comprehensive opera...

Страница 35: ...up will proceed automatically This will take approx 60 seconds Do not press any buttons during the 60 second set up procedure irrespective of the colors or flashing of the LED Once the LED is a stead...

Страница 36: ...i clock wise rotation downwards Presetting CAUTION Danger if media are present in the valve when this is actuated They can escape or mix in the pipelines Make sure that no media are inside the valve I...

Страница 37: ...ntil the diode turnes off Setting the switch point Carry out the following steps 1 Setting the switchpoint in upward position 1 clockwise rotation Light emitting diode D1 at the interface top shines g...

Страница 38: ...rew 1 in the direction of the upper switching edge 4 of the switching range 3 until the diode turnes off Setting the switch point Carry out the following steps 1 Setting the switchpoint in downward po...

Страница 39: ...ith the mounting hole 1 1 facing in the direction of the housing 5 3 Turn the nut NI 2 in the slot 4 1 in the lantern through 90 and tighten with the countersunk screw 3 Adjusting the prox imity switc...

Страница 40: ...he prox imity switch Carry out the following steps 1 Unscrew the proximity switch by one full turn 360 to set the gap a in the range from 0 5 to 1 0 mm 2 Tighten the lock nut 11 3 Secure the connector...

Страница 41: ...arry out the following steps 1 Place the proximity switch nut 2 against the slot 4 1 from the inside of the lantern 4 and hold it in position with a finger 2 Fix the sliding piece 1 with the countersu...

Страница 42: ...wing steps 1 Screw the adjusting screw 6 into the proximity switch holder down to the upper edge of the balancer 7 2 By slightly slackening the countersunk screw position the proximity switch holder i...

Страница 43: ...e proximity switch Carry out the following steps 1 Unscrew the proximity switch a full rotation 360 to adjust distance a up 0 5 to 1 0 mm 2 Tighten counternut 11 3 Secure the connector 10 which has al...

Страница 44: ...he slot 4 1 from the inside of the lantern 4 and hold it in position with a finger 2 Fix the sliding piece 1 with the countersunk screw 3 in the orientation shown with the mounting hole 1 1 facing in...

Страница 45: ...o that the point of the adjusting screw 6 rests on the shoulder of the balancer in the direction of the actuator A 3 Fix the proximity switch holder in position with the countersunk screw 3 Fitting th...

Страница 46: ...e proximity switch using the cap nut M12 10 1 The LED on the proximity switch must now be lit in operating mode Checking the function Carry out the following steps Check the feedback function by actua...

Страница 47: ...ng that the position detecting devices used for upper and lower seat closed position detection DO change status Hardware Description 1 The T VIS A 15 or T VIS M 15 Control Top on the top of the valve...

Страница 48: ...sition If the GREEN LED does not turn off the position detecting device is NOT adjusted correctly and the adjustment procedure described under Adjusting the Position Detecting Devices Page 34 of the O...

Страница 49: ...ircuit program and determine which housing upper or lower of the valve is part of that active CIP circuit Step 2 Carry out the following steps 1 If the upper housing is part of the active CIP circuit...

Страница 50: ...ation products based on sodium hydroxide in concen trations from 0 5 to 2 5 at 75 C to 80 C 167 F to 176 F Phosphoric acid or nitric acid and combination products based on these acids in concentration...

Страница 51: ...This kind of cleaning is also recommended for sticking and crystallizing media The PMO double seat valve is also fitted with a balancer cleaning device This is used to clean the product contact surfac...

Страница 52: ...valve the valve is operating against the hydraulically closed pipe open pipe Double valve disk oscillates during lifting or does not open Air pressure too low Increase air pressure Product pressure to...

Страница 53: ...n of the valve Done Pneumatic Connections Carry out the following steps 1 Check the operating pressure at the pressure reducing and filter station 2 Clean the air filter at regular intervals 3 Check t...

Страница 54: ...ure of the cleaning solution ambient conditions Prior to dismantling the Valve Requirement Make sure that during maintenance and repair work no process is in operation in the area concerned Carry out...

Страница 55: ...fore release the spring tension before detaching the clamps by pressurizing the actuator with compressed air at max 8bar Carry out the following steps 1 Remove the pneumatic hose at Y3 2 Connect an ex...

Страница 56: ...2 Remove the semi annular clamps 15 at the control top B 3 Remove the pneumatic connections at the lifting actuator 4 Pull the control top B upwards to remove The feedback signal to the higher level c...

Страница 57: ...e a sensitive components The sealing surfaces on the valve disks B may be damaged Take care when removing the valve insert from the housing that the valve disks do not hit the valve housing Carefully...

Страница 58: ...10 04 Dismantling the Valve Disk Carry out the following steps 1 Remove clamp jointClamp joint 46 2 Pull actuator A out of the lifting actuator L1 3 Remove locking flange L3 4 Hold carrier L2 using a...

Страница 59: ...en removing the double valve disk IMPORTANT NOTE The deflection edges on the double valve disk are sensitive parts The edges on the double valve disk may be damaged The deflection edge 16 2 must be ha...

Страница 60: ...018 10 04 2 Insert pin punch into the bore 16 1 and unscrew double valve disk 16 3 Withdraw sealing disk 3 with rod guide ring 2 O ring 5 sealing ring 1 from the lantern 9 Done Dismantling the Lifting...

Страница 61: ...ews 110 7 Pull off lantern 9 from lifting actuator L1 O rings L18 L19 L20 are now accessible Done Maintenance Cleaning the Valve IMPORTANT NOTE The shaft of the valve disk the housing seat the valve s...

Страница 62: ...he scriber can slip off when the V ring RA is removed Danger of injury and damaging the valve disk Grip the valve disk in a vice with protected jaws Carry out the following steps Put a scriber into th...

Страница 63: ...on tool to fit the V ring RA see illustration Carry out the following steps 1 Before fitting wet the V ring RA on the side not in contact with product rear side with the above mentioned fluid Pay atte...

Страница 64: ...be visible after fitting the complete valve For product contact seals only use suitable greases and oils Observe the safety information sheets issued by the lubricant manufacturer Carry out the follow...

Страница 65: ...064 and Rivolta F L G MD 2 can be ordered under part no 413 071 Using other types of grease can result in malfunctions or in premature seal failure The warranty will also become null and void A Manufa...

Страница 66: ...tions VARIVENT Mixproof Valve M C 2 0 Edition 2018 10 04 Assembling Assembling the Lifting Actuator Carry out the following steps 1 Equip the lifting actuator M 2 0 L1 with O rings L18 L19 L20 and fix...

Страница 67: ...bushing L5 with O rings L12 L13 1 and plug it on to the mandrel Then place O ring L13 2 on the top and push everything into the carrier sleeve L6 Remove mandrel 3 Push carrier L2 complete with O ring...

Страница 68: ...ng the Valve IMPORTANT NOTE The deflection edges 16 2 on the double valve disk are sensitive parts The edges on the double valve disk may be damaged The deflection edges must be handeld with care Carr...

Страница 69: ...Maintenance 69 Assembling 2 Hold carrier sleeve at Z using a hook spanner...

Страница 70: ...ition 2018 10 04 3 Tighten the double valve disk 16 complete with V ring RA 7 snap sealing 74 O ring 72 sealing disk 3 O ring 5 sealing ring 1 rod guide ring 2 by applying a pin punch at 16 1 While sc...

Страница 71: ...x box spanner size 36 and tighten valve disk 15 together with installed V ring 94 with flexible head face spanner at 15 1 5 Insert locking flange L3 into the lifting actuator L1 6 Insert actuator A in...

Страница 72: ...eps 1 Screw the sliding piece 1 2 into the piston rod using a 12 mm slotted screw driver tightening torque 2 Nm 1 4 lbft 2 Insert the switch bar 1 through the sliding piece into the piston rod A 4 1 a...

Страница 73: ...ctuator via Y3 For pressure see type plate The valve disk is raised 4 Introduce valve insert carefully into the housing and fix with clamp joint 43 Done Torques of the Semi annular Clamps and Clamp Jo...

Страница 74: ...of the machine at the end of its life cycle in an environmentally friendly manner Observe the statutory waste disposal regulations applicable at the place of installation The valve is made of the fol...

Страница 75: ...s 24 kN The pre stressed spring can cause serious personal injury or death Never open the actuator GEA Tuchenhagen accepts unopened actuators and arranges for proper disposal free of charge Carry out...

Страница 76: ...l number Material 1 4404 AISI 316L EPDM FDA Control air pressure 6 bar up to 8 bar 87 psi up to 116 psi Product pressure 6 bar 145 psi max Technical data Valve Designation Description Size 4 6 OD Mate...

Страница 77: ...al PE LD Outside dia 6 mm Inside dia 4 mm Inch Material PA Outside dia 6 35 mm Inside dia 4 3 mm Product pressure max 6 bar 145 psi standard Control air pressure 6 bar up to 8 bar 87 psi up to 116 psi...

Страница 78: ...40 275 F FKM 10 200 C 14 392 F HNBR 25 140 C 13 284 F Caustics up to 3 up to 80 C 176 F o Caustics up to 5 up to 40 C 104 F o o Caustics up to 5 up to 80 C 176 F Caustics at more than 5 o Inorganic a...

Страница 79: ...de diameter Wall thickness Inside diameter Outside diameter acc DIN EN ISO 1127 1 5 38 1 1 65 60 3 x 2 50 8 1 65 47 6 x 2 5 63 5 1 65 60 2 x 3 76 2 1 65 72 9 x 4 101 6 2 11 97 38 x 6 152 4 2 77 146 86...

Страница 80: ...d screw driver size 2 406 125 Mandrel 4mm 403 209 Mandrel 6 mm 403 211 Mandrel 221 105 76 221 105 77 Mandrel used for installing the bushing into the drive sleeve 221 105 94 1 5 2 2 5 3 221 105 95 6 T...

Страница 81: ...1 Spare parts list double seat valve M C 2 0 Fig 1 Spare parts list double seat valve M C 2 0 04 10 2018 81...

Страница 82: ...ring RA EPDM 221 367 03 221 367 06 221 367 06 FKM 221 367 08 221 367 11 221 367 11 72 O ring EPDM 930 612 930 612 930 612 FKM 930 664 930 664 930 664 74 Snap seal D_C PVDF 221 000524 221 000524 221 00...

Страница 83: ...22 16 221 622 15 3 Locking flange LFT R 200 EN AW 6083 T6 221 613 13 221 613 01 221 613 01 4 Adapter LFT T 200 EN AW 6083 T6 221 614 01 221 614 01 221 614 01 5 Bushing LFT M 2 0 1 4305 221 616 08 221...

Страница 84: ...221 613 01 221 613 02 4 Adapter LFT T 200 EN AW 6083 T6 221 614 01 221 614 01 221 614 04 5 Bushing LFT M 2 0 1 4305 221 616 08 221 616 08 221 616 09 6 carrier sleeve LFT M 2 0 1 4305 221 617 07 221 6...

Страница 85: ...1 Spare parts list Switch bar T VIS A 15 Fig 1 Spare parts list Switch bar T VIS A 15 04 10 2018 85...

Страница 86: ...1 4305 221 573 06 In addition to item 1 only for butterfly valves ECOVENT S 2 Switch bar BFV 7 1 4301 PA6 224 001696 For butterfly valves T smart 7 and 9 3 Switch bar LFT R 1 4301 PA6 see type For va...

Страница 87: ...1 Spare parts list Switch bar T VIS M 15 Fig 1 Spare parts list Switch bar T VIS M 15 04 10 2018 87...

Страница 88: ...only for butterfly valves type ECOVENT S 2 Switch bar BFV 7 1 4301 PA6 224 001697 For butterfly valves T smart 7 and 9 3 Switch bar LFT R 1 4301 PA6 see type For valves with lifting actuator R T_R L...

Страница 89: ...1 Dimension sheet double seat valve M C 2 0 Fig 1 Dimension sheet double seat valve M C 2 0 04 10 2018 1...

Страница 90: ...Tube ID 101 6 x 2 1 101 6 x 2 1 101 6 x 2 1 1 63 5 x 1 6 76 2 x 1 6 101 6 x 2 1 D1 261 261 261 D2 210 210 210 F 622 622 622 H with T VIS A 15 786 0 786 0 786 0 K 171 171 171 X 1150 1150 1150 Stroke 6...

Страница 91: ...152 4 x 2 77 152 4 x 2 77 152 4 x 2 77 152 4 x 2 77 1 63 5 x 1 6 76 2 x 1 6 101 6 x 2 1 152 4 x 2 77 D1 210 210 210 210 D2 210 210 210 210 F 644 5 644 5 644 5 644 5 H with T VIS A 15 808 5 808 5 808 5...

Страница 92: ...1 303 0 282 0 234 0 Tube ID 101 6 x 2 1 101 6 x 2 1 101 6 x 2 1 1 63 5 x 1 6 76 2 x 1 6 101 6 x 2 1 D1 210 210 210 D2 210 210 210 F 644 5 644 5 644 5 H with T VIS A 15 808 5 808 5 808 5 K 190 190 190...

Страница 93: ...countries Founded in 1881 the company is one of the largest providers of innovative equipment and process technology GEA Group is listed in the STOXX Europe 600 index GEA Mechanical Equipment GEA Tuch...

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