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Signs on the valve

Sign

Meaning

Fig.1

General hazard warning

Fig.2

Warning Crushing

Fig.3

Explosive atmosphere hazard warning

2.8

Residual dangers

Dangerous situations can be avoided by safety-conscious and proactive
behaviour of the personnel and by wearing personal protective equipment.

Residual dangers on the 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:

Isolate from the power supply.

Take appropriate measures to prevent switch on.

Test absence of voltage.

Earthing and short-circuiting.

Cover or safeguard any adjacent live parts.

Safety

Residual dangers

430BAL013059EN_7

24.03.2022

Содержание VARIVENT FRS

Страница 1: ...Hygienic valves GEA VARIVENT FRS valve Operating instruction Translation from the original language 430BAL013059EN_7...

Страница 2: ...otected 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 permis...

Страница 3: ...tions 12 2 6 Qualification of personnel 12 2 7 Safety equipment 14 2 7 1 Signage 14 2 8 Residual dangers 15 2 9 Danger zones 16 3 Description 18 3 1 Design 18 3 2 Functional description 20 3 2 1 Insta...

Страница 4: ...43 10 6 Maintenance 43 10 6 1 Cleaning the Valve 43 10 6 2 Replacing Seals 44 10 6 3 Lubricating Seals and Threads 46 10 7 Installation 47 10 7 1 Torques for the Clamps and Clamp Connections 47 10 7...

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 the...

Страница 6: ...n 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...

Страница 7: ...ation 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 430BAL013059EN_7...

Страница 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 prepar...

Страница 9: ...e 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 als...

Страница 10: ...described here are observed The operator s duty of care includes planning the necessary safety measures and monitoring that these measures are observed The following principles apply Only qualified pe...

Страница 11: ...rmissible conditions 2 4 1 Principles for safe operation Dangerous situations during operation can be avoided by safety conscious and proactive behaviour of the staff To ensure safe operation of the v...

Страница 12: ...permitted with the express permission of the manufacturer After completion of all work check that the protective devices are fully functional 2 5 Supplementary Regulations In addition to the instructi...

Страница 13: ...the component Personal suitability for the respective task Sufficient professional qualification for the respective task Received instruction about the functionality of the component Received instruct...

Страница 14: ...s 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 devic...

Страница 15: ...quipment Residual dangers on the valve and measures Danger Cause Measure Danger to life Inadvertent switch on of the valve Effectively disconnect all components effectively prevent switch on Electric...

Страница 16: ...the environment For all work Collect lubricants in suitable containers Dispose of lubricants in accordance with the pertinent regulations 2 9 Danger zones Please observe the following notes Fig 4 In...

Страница 17: ...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 wh...

Страница 18: ...aling ring 3 Lantern 4 Spacer 5 Cylinder cover 6 Valve disk 7 Piston 8 Piston rod 9 Leadership 10 Cap 13 Circlip 14 Clamp connection 17 Cylinder screw hex socket 19 Guide ring 20 V ring 21 O ring pist...

Страница 19: ...Design No Designation 23 O ring piston 24 O ring piston rod seal 25 O ring hood seal 41 Flush valve Description Design 430BAL013059EN_7 24 03 2022 19...

Страница 20: ...on position The valve is usually installed in hanging position overhead 3 2 2 Closing Direction Closing direction in hanging installation position from bottom to top air opening and air closing Fig 6...

Страница 21: ...ge caused 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 sta...

Страница 22: ...DA Control air pressure bar psi min 6 0 87 max 8 0 116 Product pressure bar psi 1 0 14 5 5 2 Technical data Refer to the following tables for the key technical data of the valve Technical data Valve D...

Страница 23: ...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...

Страница 24: ...C 176 F Inorganic acids up to 5 up to 80 C 176 F o Inorganic acids up to 5 up to 100 C 212 F Water up to 100 C 212 F Steam up to 135 C 275 F o Steam approx 30 min up to 150 C 302 F o Fuels hydrocarbo...

Страница 25: ...ist of tools Tools Material no Hose cutter 407 065 V ring insertion tool 229 109 88 Strap wrench 408 142 Open end spanner a f 12 13 408 034 Open end spanner a f 13 17 408 036 Open end spanner a f 24 4...

Страница 26: ...Size process housing CIP housing Weight kg DN80 DN100 31 9 3 OD DN100 31 3 DN100 DN125 32 8 4 OD DN125 32 7 DN125 DN150 49 3 DN350 DN125 65 4 Technical data 430BAL013059EN_7 26 24 03 2022...

Страница 27: ...usually hanging however it can be installed as needed Care must be taken to ensure that the valve housing and the pipe system can drain properly If the valve is installed in the horizontal position p...

Страница 28: ...l cause malfunction of the valve Replace old seals Carry out the following steps 1 Remove valve insert see chapter dismantle valve FRS 2 Dismantle the flush valves 41 3 Weld the housing without sealin...

Страница 29: ...s required A hose cutter Carry out 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 of the dr...

Страница 30: ...eas Carry out the following steps 1 Connect in accordance with the connection diagram and the instructions in the corresponding operating instructions Done Hint The proximity switches are factory set...

Страница 31: ...ly 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...

Страница 32: ...rotection type Protection by housing according to EN 60079 31 from the dust atmosphere and are thus protected The FRS valve may only be commissioned in the context of above device category if the hood...

Страница 33: ...rvals 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 cha...

Страница 34: ...ith the relevant process and product The cleaning effect must be checked regularly by the operator 9 1 1 Cleaning Process Examples Typical Cleaning Parameters in Dairy Operations Example of a two phas...

Страница 35: ...ed to different degrees This can impair the function and the service life 9 2 Passivation Before commissioning a plant passivation is commonly carried out for long pipes and tanks Valve blocks are usu...

Страница 36: ...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 carr...

Страница 37: ...the following steps 1 Regularly check Sealing ring between upper housing and lantern V ring in the valve disks Done 10 2 2 Pneumatic connections Carry out the following steps 1 Check the operating pre...

Страница 38: ...on 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...

Страница 39: ...with sharp edges The valve disk 6 has sharp edges Always wear gloves and suitable safety equipment during installation Notice The valve disk 6 is a sensitive component Damage to these parts can resul...

Страница 40: ...lustration Fig 11 10 5 2 Open drive unit Prerequisite Remove hood 1 using a strap wrench and remove from the lantern 3 Tools required Strap wrench Hint Seal replacement In this state the hood seal 25...

Страница 41: ...tion prior to dismantling the valve Carry out the following steps 1 Undo the cable connection at the board terminal strip 35 to the connector 40 2 Undo the hexagon head screws 18 3 Carefully pull the...

Страница 42: ...red Snap ring pliers Carry out the following steps 7 Undo the cylinder screw 17 and remove guide 9 8 Undo the spring lock washer 13 9 Carefully pull the piston rod 8 out of the valve disk 6 until the...

Страница 43: ...2 Take off the air hose 3 Unscrew the valve from the housing at area 2 4 Remove cylinder SPV C from housing 2 5 Take the spring 5 out of cylinder SPV C 1 6 Pull piston SPV C 4 out of cylinder SPV C 1...

Страница 44: ...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 Carry out the following...

Страница 45: ...is removed Grip the valve disk in a vice with protected jaws Unscrew the curved side of the scriber Carry out the following steps 1 Put a scriber into the V ring and take it out Fig 21 2 Before fitti...

Страница 46: ...ricant 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 iss...

Страница 47: ...d A Manufacturer s Declaration for these products can be obtained from GEA Tuchenhagen if required A thin film of grease is required on the seals to ensure the proper function of the fittings It reduc...

Страница 48: ...ke air connection 35 AS i board or 24 VDC module 36 5 2 way solenoid valve 38 Initiators 39 Outlet and inlet valve of the main stroke the connection must not be closed 40 Connector M12 AS i 4 pole or...

Страница 49: ...inner air routing into the main drive seeSection 10 7 2 Page 48 10 7 3 1 Pneumatic connection Solenoid valve 5 2 way 24VDC Fig 26 X exhaust air Y supply air Shorten all hose connections to minimum le...

Страница 50: ...ns check the maximum permissible operating voltage 10 7 4 1 Electrical 24 V DC Wiring Fig 27 Connector M12 4 pole 1 L UV L 24 V DC supply voltage 2 S1 Feedback unit end position 1 3 L Gnd 4 S2 Feedbac...

Страница 51: ...28 Connector M12 4 pole 1 ASI 2 nc not connected 3 ASI 4 nc not connected Carry out the following steps 1 Connect cable via air connector M12 4 pole Done 10 7 4 3 Setting the feedback Fig 29 Maintenan...

Страница 52: ...quired Hose cutter Carry out 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...

Страница 53: ...roke Valve size process housing CIP housing Valve stroke mm DN80 DN100 124 6 3 OD DN100 124 6 DN100 DN125 124 6 4 OD DN125 124 6 DN125 DN150 151 6 DN350 DN125 124 6 Maintenance 430BAL013059EN_7 24 03...

Страница 54: ...d check air hoses for free passage and air tightness Fault in the electrical system Check actuation external controller and routing of electrical lines Solenoid valve defective Replace the solenoid va...

Страница 55: ...the storage conditions see Chapter 4 Page 21 12 2 Disposal 12 2 1 General notes Dispose of the component in an environmentally safe manner Observe the statutory waste disposal regulations applicable...

Страница 56: ...13 Spare parts list VARIVENT FRS Valve Fig 30 Spare parts list VARIVENT FRS Valve 430BAL013059EN_7 56 24 03 2022...

Страница 57: ...w screw in plug connection G1 8 6 4 Brass nickel plated 933 475 933 475 17 Cylinder screw hex socket 1 4301 902 092 902 092 18 Hexagon nut self locking A2 910 020 910 020 19 Guide ring Turcite T51 935...

Страница 58: ...221 464 26 221 464 26 FKM 221 464 29 221 464 29 Flushing valve FRS 3A EPDM 221 464 34 221 464 34 FKM 221 464 35 221 464 35 42 Locking screw Brass nickel plated 922 344 922 344 Sealing set EPDM NBR 221...

Страница 59: ...ow screw in plug connection G1 8 6 4 Brass nickel plated 933 475 933 475 17 Cylinder screw hex socket 1 4301 902 092 902 092 18 Hexagon nut self locking A2 910 020 910 020 19 Guide ring Turcite T51 93...

Страница 60: ...FRS EPDM 221 464 26 221 464 26 FKM 221 464 29 221 464 29 Flushing valve FRS 3A EPDM 221 464 34 221 464 34 FKM 221 464 35 221 464 35 42 Locking screw Brass nickel plated Sealing set EPDM NBR 221 006982...

Страница 61: ...bow screw in plug connection G1 8 6 4 Brass nickel plated 933 475 933 475 17 Cylinder screw hex socket 1 4301 902 092 902 092 18 Hexagon nut self locking A2 910 020 910 020 19 Guide ring Turcite T51 9...

Страница 62: ...FRS EPDM 221 464 26 221 464 26 FKM 221 464 29 221 464 29 Flushing valve FRS 3A EPDM 221 464 34 221 464 34 FKM 221 464 35 221 464 35 42 Locking screw Brass nickel plated Sealing set EPDM NBR 221 00698...

Страница 63: ...6 Elbow screw in plug connection G1 8 6 4 Brass nickel plated 933 475 933 475 17 Cylinder screw hex socket 1 4301 902 092 902 092 18 Hexagon nut self locking A2 910 020 910 020 19 Guide ring Turcite T...

Страница 64: ...Valve FRS EPDM 221 464 26 221 464 23 FKM 221 464 29 221 464 30 Flushing valve FRS 3A EPDM 221 464 34 221 464 34 FKM 221 464 35 221 464 35 42 Locking screw Brass nickel plated Sealing set EPDM NBR 221...

Страница 65: ...14 Dimension sheet Valve FRS Fig 31 Dimension sheet Valve FRS 430BAL013059EN_7 24 03 2022 65...

Страница 66: ...5 150 150 72 5 DN350 DN125 355 6x3 129x2 259 5 250 250 207 connection is reduced to CIP with length C1 FRS valve Size Process Housing CIP housing Actuator Dimensions Valve D1 H2 Removing Stroke S Wei...

Страница 67: ...tion 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...

Страница 68: ...ethylene SET 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 span...

Страница 69: ...Appendix 430BAL013059EN_7 24 03 2022 69...

Страница 70: ......

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