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Safety

Residual Risk

Operating Instructions · Control Valve A

Edition 2016-06-07

Declaration of Conformity

in accordance with the EC Machinery Directive 2006/42/EC

We hereby declare that the machine designated as follows, based on its design and
type as well as in the version brought by us to market, complies with the basic safety
and health protection requirements of the EU- machine directive.

This declaration will become invalid if any alterations are made to the machine which
have not been agreed with us.

Authorised representative for compilation

Authorised representative - CE

of the technical documentation

documentation
GEA Tuchenhagen GmbH
At Industriepark 2-10
21514 Büchen

Büchen, 16/02/2015

Franz Bürmann

i.V. Matthias Südel

Managing Director

Team Leader Product Development

Designation of the machine:

Valve with drive

Machine type:

VARIVENT

Relevant EU directives

2006/42/EC

Applicable harmonized standards:

DIN EN ISO 12100

Содержание VARIVENT A

Страница 1: ...Translation of the Original Operating Instructions VARIVENT Control Valve A Edition 2016 06 07 English...

Страница 2: ...ea com Web http www tuchenhagen com These Operating Instructions are the English translation of the original operating instruc tions in the sense of the EU Machinery Directive This document is protect...

Страница 3: ...5 Maintenance and Repair 15 Disassembly 16 Environmental Protection 16 Electrical Equipment 16 Signage 17 Residual Risk 18 Hazard Areas 18 Residual Dangers 19 Declaration of Conformity 20 Transport an...

Страница 4: ...ters 34 Passivation 34 Malfunctions 35 Maintenance 36 Inspections 36 Product Contact Seals 36 Pneumatic Connections 36 Electrical Connections 36 Maintenance Intervals 37 Prior to Disassembly 37 Disass...

Страница 5: ...5 Table of Contents Spare Parts Lists Control Valve Housings 57 Spare Parts List Control Valve Actuator A 72...

Страница 6: ...g the procedures to follow Carefully read these Operating Instructions 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...

Страница 7: ...y measure you have to take to avoid the hazard EXPLOSION HAZARD Warning Explosions Failure to observe the warning can result in a severe explosion The arrow identifies a precautionary measure you have...

Страница 8: ...d Terms Abbreviation Explanation BS British Standard bar Unit of measurement of pressure bar All pressure data expressed in bar psi is assumed to be gauge pressure barg psig unless explicitly specifie...

Страница 9: ...et ft PA Polyamide PE LD Low density polyethylene psi Unit of measurement of pressure psi All pressure data expressed in bar psi is assumed to be gauge pressure barg psig unless explicitly specified o...

Страница 10: ...sary safety measures and moni toring that these measures are observed The following principles apply Only allow qualified staff to work on the valve The operator must authorize the staff to carry out...

Страница 11: ...nstruction to work on the valve under the supervision and direction of a qualified specialist Each member of staff must meet the following requirements to be allowed to work on the valve Personal qual...

Страница 12: ...stallation and operating regulations for use in potentially explosive areas Maintenance staff Adequate instruction as well as sound knowledge of the design and function of the valve Sound knowledge in...

Страница 13: ...f the valve Immediately report any faults or noticeable changes on the valve to the person responsible Observe the accident prevention regulations and all local regulations Installation For installati...

Страница 14: ...et 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...

Страница 15: ...tervals specified in the maintenance schedule Only allow qualified staff to carry out maintenance or repair work on the valve Before starting any maintenance or repair work the valve must be switched...

Страница 16: ...orage page 21 Environmental Protection Harm to the environment can be avoided by safety conscious and proactive behaviour of the staff For environmental protection the following principles apply Subst...

Страница 17: ...by warning signs prohibition signs and 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...

Страница 18: ...ut being damaged Before releasing the grooved cap nut 252 therefore relieve the spring tension by pressurizing the actuator with compressed air The valve is opened The housing sockets have very sharp...

Страница 19: ...tension in the actuator Danger to life caused by compression spring in the actuator Do not open actuators but return them to GEA Tuchenhagen for proper disposal Danger of injury Danger presented by m...

Страница 20: ...requirements of the EU machine directive This declaration will become invalid if any alterations are made to the machine which have not been agreed with us Authorised representative for compilation A...

Страница 21: ...parts must be properly secured Secure the valve against slipping Take the weight of the valve into account and the position of the point of gravity Under no circumstances should anyone stand under a s...

Страница 22: ...to the operating inspection and maintenance instructions Pressure Equipment Directive The control valves are pressure equipment without safety function in the sense of the pressure equipment directiv...

Страница 23: ...are not working or were removed Malfunctions have been detected on the valve Damage has been detected on the valve Maintenance intervals have been exceeded Conversion Work You should never make any te...

Страница 24: ...een the actuator housing and the upper valve housing 5 It holds the pneumatic positioner The coupling 4 connects the valve insert 6 with the actuator spindle 2 The coupling is linked to the stroke sca...

Страница 25: ...ersion the control valve is supplied with a spring to close actuator spring closed in the non actuated position i e If the input signal at the positioner increases the control valve opens Spring to op...

Страница 26: ...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 Fitting the Valve with Detachable Pipe Connec...

Страница 27: ...e grooves is altered Before starting any welding work remove all built in parts from the valve To ensure that a proper weld is formed when the valve is welded into the pipe make sure that the root sid...

Страница 28: ...ctions Control Valve A Edition 2016 06 07 10 Assemble the valve and depressurize the actuator The valve disk is lowered Done NOTE Welding method we recommend using the TIG welding method When assembli...

Страница 29: ...t the following steps 1 Shut off the compressed air supply 2 Use the hose cutter to cut the pneumatic hoses square 3 Establish the pneumatic connections in accordance with the codes on the positioner...

Страница 30: ...rical connections check the maximum permissible oper ating voltage EXPLOSION HAZARD Explosive gases or dusts An explosion can result in serious personal injury or death Observe the installation and op...

Страница 31: ...ing regularly check all sealing points for leaks Replace defective seals Pneumatic Check the compressed air system for proper installation and tightness Check whether the compressed air pressure is co...

Страница 32: ...s immediately deactivate the control valve and secure it against inadvertent reactivation Have any defects rectified immediately If the compressed air supply to the control valve fails the valve assum...

Страница 33: ...operator in accordance with the relevant process The cleaning effect must be checked regularly by the operator Cleaning Process Examples Typical Cleaning Parameters in Dairy Operations Example of a t...

Страница 34: ...achieve an optimal cleaning result Please define the cleaning parameters yourself in accordance with your product and process and regularly verify the result We recommend a flow velocity of at least 2...

Страница 35: ...e and air tightness Fault in the electrical system Check actuation and routing of elec trical lines Valve disk blocked mechanically Clear the blockage Stroke scanning lever has shifted Readjust the st...

Страница 36: ...the following steps Regularly check the seals Done Pneumatic Connections Carry out the following steps 1 Check the operating pressure at the pressure reducing and filter station 2 Clean the air filte...

Страница 37: ...aning solution ambient conditions Prior to Disassembly Requirement Make sure that during maintenance and repair work no process is in operation in the area concerned Carry out the following steps 1 Dr...

Страница 38: ...e actuator with compressed air at max 6 bar or by mechanically adjusting the control cone Carry out the following steps 1 Release the spring tension 2 Move the control cone to the open position either...

Страница 39: ...individual parts Done Replacing Seals Insertion tool Requirement Use the insertion tool to fit the V ring Insert V rings without grease To facilitate fitting use water with a drop of washing up liqui...

Страница 40: ...scriber Carry out the following steps 1 Put a scriber into the V ring and take it out 2 Before fitting wet the V ring on the side not in contact with product rear side Pay attention that water does n...

Страница 41: ...tact with product Do not grease the V ring 3 Grease all screws 4 Grease the balancer Done NOTE GEA Tuchenhagen recommends Rivolta F L G MD 2 and PARALIQ GTE 703 These lubricants are approved for foods...

Страница 42: ...everse order of disassembly Pay attention that the seat rings are positioned correctly Soft sealing valve disks inclined seating surface must face the valve disk A Metallically sealing valve disks poi...

Страница 43: ...the released spring pretension will suddenly lift the housing cover Therefore never slacken all the screws of the housing cover at the same time Carry out the following steps 1 Remove the hex nuts 1 o...

Страница 44: ...em correctly sorted Also observe the instructions regarding disposal in the operating instructions for the individual compo nents Valve Actuator Disposal DANGER The spring forces in the actuator can b...

Страница 45: ...Control Valve A The type plate provides the following key data Key data of the valve Type Control Valve A Serial Serial number Material 1 4404 cone 1 457 EPDM FDA Control air pressure bar psi min 2 5...

Страница 46: ...rol air with a low dew point Protect valve stems against freezing Operating temperature Depending on the sealing material Technical data Compressed air supply Designation Description Air hose Metric M...

Страница 47: ...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 acids up to 3 up...

Страница 48: ...2 11 97 38 x 6 152 4 2 77 146 86 x Dimensions for Pipes in Inch IPS Inch IPS Outside diameter Wall thickness Inside diam eter Outside diameter acc to BS 4825 Part 1 2 60 3 2 56 3 x 3 88 9 2 3 84 3 x...

Страница 49: ...x22 408 038 Open end spanner a f 22x24 408 039 Open end spanner a f 24x27 408 040 Open end spanner a f 36x41 408 042 Open end spanner a f 41x46 Hose cutter 407 065 Pin punches or T bars 5 mm 403 210 C...

Страница 50: ...Technical Data Weights 50 Operating Instructions Control Valve A Edition 2016 06 07 Weights for housing combination L Other weights on request DN 125 approx 55 1 DN 150 6 approx 61 1 Size Weight kg...

Страница 51: ...51 Spare Parts Lists Control Valves Control Valve A Spare Parts Lists Control Valves Control Valve A Control valve with EPDM or FPM valve seat seal Control valve with metallic valve seat seal...

Страница 52: ...al percentage characteristic curve Control cone J linear characteristic curve Spare Parts List Control Valve A No Designation A Actuator C Coupling element 1 Sealing ring 2 Bearing 3 Sealing disk 4 Be...

Страница 53: ...53 Spare Parts Lists Control Valves Control Valve A W Control Valve A W Spare parts drawing Control Valve A W...

Страница 54: ...ol cone F equal percentage characteristic curve Control cone J linear characteristic curve Spare Parts List Control Valve A W No Designation A Actuator C Coupling element 1 Sealing ring 2 Bearing 3 Se...

Страница 55: ...55 Spare Parts Lists Control Valves Control Valve A X Control Valve A X Spare parts drawing Control Valve A X...

Страница 56: ...ol cone F equal percentage characteristic curve Control cone J linear characteristic curve Spare Parts List Control Valve A X No Designation A Actuator C Coupling element 1 Sealing ring 2 Bearing 3 Se...

Страница 57: ...r Table of dimensions Dimension DN 25 DN 40 DN 50 DN 65 DN 80 DN 100 DN 125 DN 150 a 12 12 12 15 15 15 15 15 h 15 52 52 75 75 80 170 170 H 39 76 76 105 105 115 200 200 When ordering also specify the h...

Страница 58: ...404 221 141 01 221 141 02 221 141 02 221 141 03 4 1 Bearing disk D 1 4305 221 142 10 221 142 10 221 142 11 5 O ring EPDM FKM 930 309 930 168 930 144 930 171 930 144 930 171 930 150 930 176 24 3 stage...

Страница 59: ...N 25 DN 65 Designation Hole dia KVS Value Material DN 25 DN 40 DN 50 DN 65 V ring 11 2 5 EPDM FKM 932 058 932 049 16 4 0 EPDM FKM 932 058 932 049 19 7 0 EPDM FKM 932 017 932 029 932 017 932 029 24 11...

Страница 60: ...ation Hole dia KVS Value Material DN 80 DN 100 DN 125 DN 150 V ring 11 2 5 EPDM FKM 16 4 0 EPDM FKM 19 7 0 EPDM FKM 24 11 0 EPDM FKM 32 18 0 EPDM FKM 37 26 0 EPDM FKM 932 019 932 032 48 43 0 EPDM FKM...

Страница 61: ...ator Spare Parts List Seat Ring A Metallic Seal Metric Sizes DN 25 DN 65 Item Hole dia KVS Value Material DN 25 DN 40 DN 50 DN 65 33 5 0 4 1 4404 221 107 84 7 1 0 1 4404 221 107 83 11 2 5 1 4404 221 1...

Страница 62: ...64 48 43 0 1 4404 221 107 65 221 107 67 62 50 0 1 4404 62 68 0 1 4404 221 107 66 221 107 68 62 85 0 1 4404 221 107 66 73 100 1 4404 221 107 69 221 107 71 90 150 1 4404 221 107 70 221 107 72 221 107 74...

Страница 63: ...7 76 Spare Parts List Items 35 36 43 45 401 402 Metric Sizes DN 25 DN 65 Item Designation Material DN 25 DN 40 DN 50 DN 65 35 Cover 1 4404 221 144 01 221 144 02 221 144 02 221 144 03 36 Locking ring 1...

Страница 64: ...221 132 80 221 132 94 24 11 0 1 4404 221 132 79 221 131 91 221 132 95 32 18 0 1 4404 221 107 61 221 132 96 221 132 98 37 26 0 1 4404 221 132 97 221 407 04 48 43 0 1 4404 221 132 56 62 50 0 1 4404 221...

Страница 65: ...221 132 84 221 132 57 24 11 0 1 4404 221 132 85 221 132 89 221 132 58 32 18 0 1 4404 221 132 90 221 132 59 221 132 61 37 26 0 1 4404 221 132 60 221 407 91 48 43 0 1 4404 221 132 92 62 50 0 1 4404 221...

Страница 66: ...ring EPDM FKM 930 309 930 168 930 144 930 171 930 144 930 171 930 150 930 176 930 150 930 176 930 156 930 178 Spare Parts List Seat Ring A Metallic Seal Inch OD Item Hole dia KVS Value Material 1 OD...

Страница 67: ...5 OD 2 OD 2 5 OD 3 OD 4 OD 420 11 2 5 1 4404 221 407 06 16 4 0 1 4404 221 407 07 19 7 0 1 4404 221 407 08 24 11 0 1 4404 221 132 48 32 18 0 1 4404 221 407 11 37 26 0 1 4404 221 407 14 48 43 0 1 4404...

Страница 68: ...07 66 73 100 1 4404 221 107 69 90 150 1 4404 221 107 70 221 107 74 96 260 1 4404 115 260 1 4404 221 107 75 135 380 1 4404 221 107 76 Spare Parts List Seat Ring A for V Ring Seal Inch IPS Item Hole dia...

Страница 69: ...Control Valve Housings for ARCA Diaphragm Actuator Spare Parts List Housing Connection A Metallic Seal Inch IPS Item Hole dia KVS Value Material 2 IPS 3 IPS 4 IPS 6 IPS 420 62 150 1 4404 221 131 55 9...

Страница 70: ...lock HSP Sterile lock HSP Sterile lock HSP DN 65 6 IPS Sterile lock HSP DN 40 50 1 5 2 OD 2 IPS Sterile lock HSP DN 25 1 OD Spare Parts List Item Designation Material DN 25 1 OD DN 40 50 1 5 2 OD 2 I...

Страница 71: ...0 357 930 356 930 357 O ring bottom EPDM FKM 930 268 930 164 930 268 930 164 930 243 930 244 930 243 930 244 930 356 930 357 930 356 930 357 159 Cap nut 1 4571 933 459 933 459 933 459 933 459 933 459...

Страница 72: ...ating Instructions Control Valve A Edition 2016 06 07 Spare Parts List Control Valve Actuator A Spare Parts List Actuator A No Designation No Designation 1 Spindle 22 Washer 3 Sealing ring 23 Hex nut...

Страница 73: ...29 Diaphragm cover 12 Hex screw 30 Diaphragm disk 13 Diaphragm 34 Lantern 14 Pressure spring 38 Seal 15 Spring cover 39 Locking screw 16 Seal 40 Threaded sleeve 17 Protection cap 41 Protection cap 18...

Страница 74: ...ountries 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 Tuche...

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