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8

Operation and control

8.1

Safety instructions

Dangerous situations during operation can be avoided by safety-conscious and
proactive behaviour of the staff.
For operation, the following principles apply:

•

Monitor the valve during the operation.

•

Safety devices must not be changed, removed or taken out of service. Check
all safety devices at regular intervals.

•

All guards and hoods must be fitted as intended.

•

The place of installation of the 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 clear. Do not leave any objects in the danger
zone. Only allow persons to enter the danger zone when the machine is de-
energized.

•

Regularly check that all emergency stop devices are working correctly.

Operation and control

Safety instructions

430BAL008451EN_2

36

24.10.2017

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Содержание VARIVENT Y

Страница 1: ...Hygienic valves GEA VARIVENT Valve Type Y Operating instruction Translation from the original language 430BAL008451EN_2...

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: ...dangerous situation which leads to heavy physical injuries or to the death Caution Stands for a possibly dangerous situation which could lead to light physical injuries or to damages to property Hint...

Страница 4: ...nt 1 Numbered list point 2 Handling instructions Handling instructions require you to do something Several consecutive steps result in a handling sequence that should be run in the specified order The...

Страница 5: ...Residual dangers 15 2 9 Hazard Areas 16 3 Description 18 3 1 Design 18 3 2 Functional description 19 3 2 1 Opening and closing the valve 19 3 2 2 Actuator Function 20 3 2 3 Leakage Proof Shut Off 20 4...

Страница 6: ...he drive 45 10 5 6 Separating the valve and the lamp 46 10 5 7 Disassembly of the valve insert 47 10 6 Maintenance 47 10 6 1 Cleaning the Valve 47 10 6 2 Replacing the V Ring 48 10 6 3 Lubricating Sea...

Страница 7: ...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 8: ...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 9: ...iples Risk assessment and risk reduction Other applied standards and technical specifications Remarks We also declare that the relevant technical documentation for this machine has been prepared in ac...

Страница 10: ...nd 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 valve is a...

Страница 11: ...e valve The operator must authorize the staff to carry out the relevant tasks Working areas and the entire environment of the valve must be neat and clean The staff must wear suitable work clothing an...

Страница 12: ...nd 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...

Страница 13: ...tion of Staff This section contains information about the qualifications that staff working on the valve must have Operating and maintenance staff must have the necessary qualification to carry out th...

Страница 14: ...e operating sequences What to do in case of an emergency Lines of authority and responsibilities with respect to the task Maintenance staff Adequate instruction as well as sound knowledge of the desig...

Страница 15: ...e 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 approp...

Страница 16: ...in the vicinity of the valve Protective gloves Safety shoes Environmental damage Operating materials with properties which are harmful to the environment For all work Collect lubricants in suitable co...

Страница 17: ...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 m...

Страница 18: ...esignation A Actuator 11 Cleaning hood B T VIS control top 15 Valve disk 1 Seal 16 Double disk 2 Bearing 17 Additional disc 3 Sealing disk 22 Air connection 4 Bearing disk 24 Electrical connection 9 L...

Страница 19: ...nnection The piston of the actuation cylinder presses up against the spring The actuated lower valve disc is pulled up in a few millimetres stroke and the cavity between the upper and lower valve disc...

Страница 20: ...al disc is opened again 3 2 2 Actuator Function The actuator is of the spring closing type Z The valve is closed in the non actuated position Identification on the T VIS control top once the installat...

Страница 21: ...nted from entering the other pipe The cleaning of the leakage drain system occurs independently from the opening and closing of the valve A cleaning liquid is supplied to the leakage drain system via...

Страница 22: ...that any ice crystals formed by condensation water can melt 4 2 Transport Fig 9 For transport the following principles apply When transporting the valve be sure to unscrew the control top and the swit...

Страница 23: ...no 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...

Страница 24: ...following tables for the key technical data of the valve Technical data Valve Designation Description Size DN 25 to DN 150 1 to 4 OD 2 to 6 IPS Material of product contact parts Stainless steel 1 440...

Страница 25: ...ss 6 Part size max 5mm Part 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 acc...

Страница 26: ...perature 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 Res...

Страница 27: ...th a fat content of max 35 Product with a fat content of more than 35 Oils Depending on the installation conditions 5 5 Pipe ends General table of measurements Hint Not every valve is available in eve...

Страница 28: ...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 38 x 6 152 4 2 77 146 86 x Di...

Страница 29: ...pen end spanner a f 30 32 408 041 Assembly tool DN 40 50 DN 65 100 DN 125 162 229 109 89 229 109 90 229 109 91 Mounting tool supplemental disc DN 50 40 DN 80 65 DN 100 DN 125 150 6 IPS 229 109 10 229...

Страница 30: ...Size Weight kg OD 2 14 OD 2 5 23 OD 3 24 OD 4 34 OD 6 85 IPS 2 15 IPS 3 24 IPS 4 36 IPS 6 86 Technical data 430BAL008451EN_2 30 24 10 2017...

Страница 31: ...rtently 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 prev...

Страница 32: ...o fit new housing O rings 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 e...

Страница 33: ...Stroke dm3n at 1 01325 bar at 0 C according to DIN 1343 A 99 0 16 B 109 0 26 B 5 109 0 34 C 135 0 42 C 5 135 0 54 D 170 0 70 E 210 1 10 E 5 210 1 40 E 6 210 2 00 S 6 261 3 20 D 6 170 1 30 R 170 1 60 S...

Страница 34: ...imum permissible operating voltage Explosive gases or dusts An explosion can result in serious personal injury or death Observe the installation and operating regulations for use in potentially explos...

Страница 35: ...ing 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 v...

Страница 36: ...ls All guards and hoods must be fitted as intended The place of installation of the valve must be adequately ventilated at all times Structural alterations of the valve are not permitted Immediately r...

Страница 37: ...ing 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...

Страница 38: ...ty 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 th...

Страница 39: ...oing on Do not climb on the valve Use suitable access aids and working platforms Wear suitable protective clothing Only use suitable and undamaged tools to carry out maintenance work When replacing pa...

Страница 40: ...er 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 reduc...

Страница 41: ...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 1...

Страница 42: ...2 Detach the clamp connection 43 4 on the lower valve housing 3 Remove the seal 1 seal washer 3 bearing 2 bearing washer 4 1 from the lower housing 4 Hold the cleaning hood 11 on the key area 11 1 an...

Страница 43: ...disc 17 with a spanner SW 19 6 Remove the arbor D 7 Unscrew the supplemental disc 17 Done 10 5 2 Removing the T VIS M 15 Control Top Fig 13 Prerequisite No solenoid valve must be actuated electrically...

Страница 44: ...2 Depressurise the actuator by deactivating the solenoid valve Y1 at the manual operation element S The valve disc should be lifted 3 Remove the clamp connection 43 1 4 Depressurise the actuator by d...

Страница 45: ...tions When the shaft of the valve disc 15 is pulled out the stem of the valve disc must not hit the valve housing Carry out the following steps 1 Carefully draw the valve out of the housing Done 10 5...

Страница 46: ...emove the drive Done 10 5 6 Separating the valve and the lamp Fig 16 Notice The lamp 9 and the shaft 16 of the double disc are precision areas Damage to these parts can result in a malfunction The bea...

Страница 47: ...the spanner onto the spanner surface of the cleaning hood 11 1 and remove the valve disc 3 Unscrew the cleaning hood 11 from the valve disc 4 Remove spring 18 abutment 12 bearing washer 4 bearings 2 s...

Страница 48: ...afety information sheets issued by the detergent manufacturers Only use detergents which are non abrasive and not aggressive towards stainless steel Use only cleaning mediums which do not damage the m...

Страница 49: ...tected 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 fitting wet the V ring on the side not in contact with...

Страница 50: ...unction 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 oil...

Страница 51: ...d void 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...

Страница 52: ...housings so that the arrow later properly displays the direction of the drive when the valve is completely assembled 10 7 4 Installing the valve into the housing Fig 27 Notice Sharp edged valve disc...

Страница 53: ...off the cleaning with the hose cutter at a right angle 2 Place insertion sleeves up to the edge of the hose 3 Grease the threads and cone of the fitting as well as the sealing disc and the threads of...

Страница 54: ...does not turn Checking Carry out the following steps 1 Loosen the union nut 2 Make sure that there is a visible connection 3 in the space before the 1 Make sure the disc fits Fig 30 It will not hurt i...

Страница 55: ...e stroke Carry out the following steps 1 Actuate the valve with compressed air 2 Check the stroke of the valve in accordance with Page 55 The stroke is set Strokes Depending on Size Valve Stroke Valve...

Страница 56: ...Valve Stroke Valve size Valve stroke mm 2 27 3 27 4 27 Maintenance 430BAL008451EN_2 56 24 10 2017...

Страница 57: ...ault 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...

Страница 58: ...e at the place of installation The valve is made of the following materials Metals Synthetic materials Electronic parts Lubricants containing oil and grease Separate the different materials and dispos...

Страница 59: ...13 Spare parts list dual seat two way valve Y Fig 31 Spare Parts Drawing Fig 32 Housing combinations Spare parts list dual seat two way valve Y 430BAL008451EN_2 24 10 2017 59...

Страница 60: ...017 932 019 932 019 932 023 FKM 932 029 932 032 932 032 932 034 HNBR 932 085 932 084 932 084 932 089 9 Lantern 1 4301 221 121 01 221 121 02 221 121 02 221 121 03 11 Cleaning hood 1 4301 221 146 04 22...

Страница 61: ...108 02 221 108 03 43 Clamp connection KL 1 4401 221 507 02 221 507 04 221 507 04 221 507 09 46 Clamp connection KL 1 4401 221 507 06 221 507 06 221 507 06 221 507 06 74 Cleaning nozzle PVDF 221 334 0...

Страница 62: ...5 FKM 932 034 932 038 932 063 932 044 HNBR 932 089 932 099 9 Lantern 1 4301 221 121 03 221 121 04 221 121 06 221 121 22 11 Cleaning hood 1 4301 221 146 01 221 146 01 221 146 02 221 146 02 12 Support b...

Страница 63: ...221 108 06 43 Clamp connection KL 1 4401 221 507 09 221 507 11 221 507 13 221 507 14 46 Clamp connection KL 1 4401 221 507 06 221 507 06 221 507 11 221 507 11 74 Cleaning nozzle PVDF 221 334 02 221 3...

Страница 64: ...017 932 019 932 019 932 023 FKM 932 029 932 032 932 032 932 034 HNBR 932 085 932 084 932 084 932 089 9 Lantern 1 4301 221 121 01 221 121 07 221 121 07 221 121 08 11 Cleaning hood 1 4301 221 146 04 22...

Страница 65: ...108 02 221 108 03 43 Clamp connection KL 1 4401 221 507 02 221 507 04 221 507 04 221 507 09 46 Clamp connection KL 1 4401 221 507 06 221 507 06 221 507 06 221 507 06 74 Cleaning nozzle PVDF 221 334 0...

Страница 66: ...027 932 045 FKM 932 034 932 038 932 044 HNBR 932 089 932 099 9 Lantern 1 4301 221 121 08 221 121 09 221 121 22 11 Cleaning hood 1 4301 221 146 01 221 146 01 221 146 02 12 Support bracket 1 4301 221 1...

Страница 67: ...amp connection KL 1 4401 221 507 09 221 507 11 221 507 14 46 Clamp connection KL 1 4401 221 507 06 221 507 06 221 507 11 74 Cleaning nozzle PVDF 221 334 02 221 334 02 221 334 03 401 Housing V1 1 4404...

Страница 68: ...2 027 932 045 FKM 932 032 932 034 932 038 932 044 HNBR 932 084 932 089 932 099 9 Lantern 1 4301 221 121 12 221 121 10 221 121 11 221 121 05 11 Cleaning hood 1 4301 221 146 01 221 146 01 221 146 01 221...

Страница 69: ...04 221 108 06 43 Clamp connection KL 1 4401 221 507 04 221 507 03 221 507 11 221 507 14 46 Clamp connection KL 1 4401 221 507 06 221 507 09 221 507 06 221 507 11 74 Cleaning nozzle PVDF 221 334 01 22...

Страница 70: ...x 3 22 x 3 28 x 3 28 x 3 35 x 3 35 x 3 EPDM 930 268 930 268 930 243 930 243 930 356 930 356 FKM 930 164 930 164 930 244 930 244 930 357 930 357 HNBR 930 639 930 639 930 640 930 640 23 1 O ring 30 x 3...

Страница 71: ...221 519 61 221 519 39 221 519 40 221 519 41 221 519 42 221 519 43 HNBR 221 519 78 221 519 79 221 519 80 Grease RIVOLTA F L G 100g tube not included with sealing kit Do not grease item 7 and 8 413 136...

Страница 72: ...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...

Страница 73: ...P 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...

Страница 74: ......

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