GEA VARIVENT Operating Instruction
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GEA VARIVENT Operating Instruction

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Hygienic valves
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GEA VARIVENT
Valve Type B
Operating instruction (Translation from the original language)
430BAL008326EN_3
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Summary of Contents for GEA VARIVENT

  • Page 1 Hygienic valves ® GEA VARIVENT Valve Type B Operating instruction (Translation from the original language) 430BAL008326EN_3...
  • Page 2 EU Machinery Directive. This document 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 ®...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS General Information Information on the Document 1.1.1 Binding Character of These Operating Instructions 1.1.2 Notes on the Illustrations 1.1.3 Symbols and Highlighting Manufacturer address Contact EU Declaration of Conformity in accordance with the EC Machinery Directive 2006/42/EC Translated copy of the EU - Declaration of conformity in accordance with the Pressure Equipment Directive 2006/42/EU Safety...
  • Page 4 Malfunctions and remedies Decommissioning 12.1 Safety instructions 12.2 Disposal 12.2.1 General notes 12.2.2 Valve Actuator Disposal Spare parts list - mixproof valve B ® Dimension sheet - VARIVENT Double seat valve B Appendix 15.1 Lists 15.1.1 Abbreviations and terms 430BAL008326EN_3 07.02.2022...

  • Page 5: General Information

    General Information Information on the Document General Information Information on the Document The present Operating Instructions are part of the user information for the product. The Operating Instructions contain all the information you need to transport, install, commission, operate and carry out maintenance for the product. 1.1.1 Binding Character of These Operating Instructions These Operating Instructions contain the manufacturer's instructions to the...

  • Page 6: Manufacturer Address

    Second step in a sequence of operations. ® Result of the previous operation. ® The operation is complete, the goal has been achieved. Hint! Further useful information. Manufacturer address GEA Tuchenhagen GmbH Am Industriepark 2-10 21514 Büchen Contact Tel.:+49 4155 49-0 Fax:+49 4155 49-2035 [email protected] www.gea.com 430BAL008326EN_3 07.02.2022...

  • Page 7: Eu Declaration 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 EU Declaration of Conformity in accordance with the EC Machinery Directive 2006/42/EC 430BAL008326EN_3 07.02.2022...

  • Page 8: Translated Copy Of The Eu - Declaration Of Conformity In Accordance With The Pressure Equipment Directive 2006/42/Eu

    Translated copy of the EU - Declaration of conformity in accordance with the Pressure Equipment Directive 2006/42/EU Translated copy of the EU - Declaration of conformity in accordance with the Pressure Equipment Directive 2006/42/EU Manufacturer: GEA Tuchenhagen GmbH Am Industriepark 2-10 21514 Büchen We hereby declare that the machine named below...

  • Page 9: Safety

    Pressure Equipment Directive which specifies sound engineering practice. Nominal diameters ≥ IPS 4“; DN 125 valid for the fluid group II. In the event of any deviations, GEA Tuchenhagen GmbH will supply a specific Declaration of Conformity. 2.1.3...

  • Page 10: Improper Operating Conditions

    Safety Operator’s Duty of Care Refer to and observe the additional operating instructions “ATEX version valves”. For details regarding the marking of valves for potentially hazardous areas also refer to the additional operating instructions “ATEX version valves”. If these valves are used in areas with a potentially explosive atmosphere, you must absolutely comply with directive 2014/34/EC with respect to all ignition hazards.

  • Page 11: Subsequent Changes

    EC Machinery Directive on your own. In general, only original spare parts supplied by GEA Tuchenhagen GmbH should be fitted. This ensures that the component is always operating properly and efficiently.

  • Page 12: Environmental Protection

    Safety Supplementary Regulations • Never touch the pipes and the valve when these components are hot! Avoid opening the valve unless the process plants have been emptied and depressurised. • Observe the accident prevention regulations and all local regulations. 2.4.2 Environmental Protection Harm to the environment can be avoided by safety-conscious and proactive behaviour of the staff.
  • Page 13 Safety Qualification of personnel • be instructed with regard to possible dangers, • know and observe the safety instructions given in the documentation. Only allow qualified electricians to carry out work on the electrical equipment or have a qualified electrician supervise the work. Only allow specially trained personnel to carry out work on an explosion- protected system.

  • Page 14: Safety Equipment

    Safety Safety equipment User groups Staff Qualifications Operating personnel Adequate instruction 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.

  • Page 15: Residual Dangers

    Earthing and short-circuiting. Cover or safeguard any adjacent live parts. Spring 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. 430BAL008326EN_3 07.02.2022...

  • Page 16: Hazard Areas

    Safety Hazard Areas Residual dangers on the valve and measures Danger Cause Measure Danger of injury Danger presented by moving or The operator must exercise caution and prudence. sharp-edged parts For all work: • Wear suitable work clothing. • Never operate the machine if the cover panels are not correctly fitted.
  • Page 17 Safety • Before starting any maintenance, servicing or repair work, disconnect the valve from the power supply and secure it against inadvertently being switched back on again. • Only allow a qualified electrician to carry out any work on the electrical power supply.

  • Page 18: Description

    Description Design Description Design Fig.5 Design Designation Actuator T.VIS control top Air connection Electrical connection Sealing ring Bearing Sealing disk Bearing disk Lantern Cleaning hood 430BAL008326EN_3 07.02.2022...
  • Page 19 Description Design Design Designation Valve disk Double-disk 430BAL008326EN_3 07.02.2022...

  • Page 20: Functional Description

    Description Functional description Functional description 3.2.1 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 installation (SET-UP) has been completed: • Green steady light (1): valve in non-actuated position •...

  • Page 21: Transport And Storage

    Transport and storage Storage conditions Transport and storage Storage conditions The valves, valve inserts or spare parts should be stored in a dry place, free of vibrations and dust, and protected from light. To avoid damage, leave the components in their original packaging if possible. If, during transport or storage, the valve is going to be exposed to temperatures ≤...

  • Page 22: Scope Of Supply

    Transport and storage • Only use approved, fully functional load lifting devices and lifting accessories which are suitable for the intended purpose. Observe the maximum load- bearing capacities. • Secure the valve against slipping. Take the weight of the valve into account and the position of the point of gravity.

  • Page 23: Technical Data

    Technical data Type plate Technical data Type plate The type plate clearly identifies the valve. Fig.8 The type plate provides the following key data: Key data of the valve Type Double seat valve B Serial Serial number Material AISI 304/FKM Control air pressure bar/psi min.

  • Page 24: Cleaning Connection

    Technical data Cleaning connection Technical data: Ambient temperatures Designation Description 0 to 45 °C (32 ... 113 °F), standard < 0 °C (32 °F): use control air with a - Valve low dew point. Protect valve stems against freezing. - Proximity switch -20 to +80 °C (-4 ...

  • Page 25: Resistance And Permitted Operating Temperature Of The Sealing Materials

    The maximum operating temperature is defined by the sealing type and its mechanical load. Due to the versatile conditions of use (e.g. usage duration, switching frequency, type and temperature of product and cleaning agents as well as usage environment), GEA Tuchenhagen recommends that the user carries out resistance tests. Resistance: •...
  • Page 26 Technical data Resistance and permitted operating temperature of the sealing materials Table of sealing resistance / permitted operating temperature Maximum Sealing material Medium operating EPDM HNBR temperatures Alkalis up to 3% up to 80 °C (176°F) + Alkalis up to 5% up to 40 °C (104°F) + Alkalis up to 5% up to 80 °C (176°F) +...

  • Page 27: Pipe Ends - General Table Of Measurements

    Technical data Pipe ends - General table of measurements 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 Outside Outside Wall...

  • Page 28: Tools

    Technical data Tools Dimensions for Pipes in Inch IPS Outside diameter Outside Wall Inside Inch IPS according to diameter thickness diameter DIN EN ISO 1127 2" 60.3 56.3 3" 88.9 84.3 4" 114.3 109.7 6" 168.3 2.77 162.76 Tools List of tools Tools Material no.
  • Page 29 Technical data Size Weight [kg] OD 2.5" OD 3" OD 4" OD 6 " IPS 2" IPS 3" IPS 4" IPS 6" 430BAL008326EN_3 07.02.2022...

  • Page 30: Assembly And Installation

    Assembly and installation Safety instructions Assembly and installation 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.

  • Page 31: Valve With Welded Ends

    Assembly and installation Valve with Welded Ends Carry out the following steps: Fit valves with detachable pipe connection elements – using suitable connection fittings – directly into the pipe system. ® Valve is installed. Valve with Welded Ends This section describes the welding procedure for the valve housing. Warning! Spring tension in the valve Danger of injury when opening the clamp connections on the actuator or on...

  • Page 32: Pneumatic Connections

    Assembly and installation Pneumatic connections Hint! Welding method: We recommend using the automatic orbital welding method. All welding work should only be performed by certified welders or machine operators (orbital welders). Housing O-rings: When assembling the valve always replace the housing O-rings to ensure that the valve is tight.

  • Page 33: Electrical Connection With T.vis Control Top

    Assembly and installation Electrical connection with T.VIS control top Use the hose cutter to cut the pneumatic hoses square. Push the air hose into the air connector on the control top. Re-open the compressed air supply. ® Establish a hose connection. Electrical connection with T.VIS control top Danger Live parts...

  • Page 34: Start-Up

    Start-up Safety instructions Start-up Safety instructions Initial commissioning For initial 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 connections must be securely tightened.

  • Page 35: Operation And Control

    Operation and control Safety instructions Operation and control Safety instructions Dangerous situations during operation can be avoided by safety-conscious and proactive behaviour of the personnel. For operation, the following principles apply: • Monitor the component during operation. • Safety devices must not be changed, removed or taken out of service. Check all safety devices at regular intervals.

  • Page 36: Cleaning

    Cleaning Cleaning Cleaning Cleaning All parts in contact with product must be cleaned at regular intervals. Always observe the safety data sheets issued by the cleaning agent manufacturers. Only use cleaning agents which do not cause damage to the seals and the inner parts of the valve.

  • Page 37: Cleaning The Leakage Cavity

    Cleaning Passivation 9.1.3 Cleaning the Leakage Cavity Cleaning of the leakage cavity is performed using a spray nozzle in the double disk that is connected to a valve seat cleaning pipe. Here, there can only be general recommendations made as to how many and the length of the spray cleaning, which are all dependent on the conditions occurring at each facility, such as type of products, temperatures, cleaning means, cleaning intervals, etc., which could require more frequent or longer spray cleaning.

  • Page 38: Maintenance

    Maintenance Safety instructions Maintenance 10.1 Safety instructions Maintenance and repair Before carrying out maintenance and repair work on the component's electrical equipment, perform the following steps in accordance with the "5 safety rules": • Isolate from the power supply • Take appropriate measures to prevent switch on •...

  • Page 39: Inspections

    Maintenance Inspections • Disconnect all power and utility lines. • Markings, e.g. on lines, must not be removed. • Do not climb on the component. Use suitable access aids and working platforms. • Mark the lines (if unmarked) prior to disassembly to ensure they are not confused when re-assembling.

  • Page 40: Signs On The Valve

    Maintenance Maintenance intervals ® Done Hint! The electrical cable must be long enough to allow the control top to be removed via the switch bar. 10.2.4 Signs on the valve Carry out the following steps: Check the signs on the valve. Replace damaged or missing stickers with new ones.

  • Page 41: Disassembling The Valve

    Maintenance Disassembling the Valve Shut off the control air supply. Disconnect the power supply. Take the valve out of the pipe section, with all housings and housing connections if possible. ® Done 10.5 Disassembling the Valve 10.5.1 Removing the Valve Insert Fig.9 Prerequisite: •...

  • Page 42: Separating The Valve From The Drive

    Maintenance Disassembling the Valve Warning! Spring tension in the valve Danger of injury when detaching the clamp connection (43) as the released spring pretension will suddenly lift the actuator. ► Therefore, release the spring tension before detaching the clamp connections by pressurizing the actuator with compressed air at max. 8 bar. Carry out the following steps: Remove the cleaning connection (30).

  • Page 43: Disassembly Of The Valve Insert

    Maintenance Disassembling the Valve Carry out the following steps: Unscrew the snap ring (46) between the actuator and lantern. Secure drive (A) with a band wrench. Place the spanner onto the spanner surface of the cleaning hood (11) and remove the drive ®...
  • Page 44 Maintenance Disassembling the Valve Fig.12 Unscrew the cleaning hood (11) from the valve disc. Remove spring (18), abutment (12), bearing washer (4), bearings (2), seal (1) with the seal washer (3) and double disc (16) from the valve disc. Fig.13 Remove the snap ring from the housing and take out the components (5, 65, 66, 92).

  • Page 45: Maintenance

    Maintenance Maintenance Fig.14 6. ® The individual components are readily accessible. ® Done 10.6 Maintenance 10.6.1 Cleaning the Valve Fig.15 Notice The shaft of the valve disc (16), the housing seat (402), the valve seat (16.1) and the V-ring groove (16.2) are precision parts. Damage to these parts can result in a malfunction.

  • Page 46: Replacing The V-Ring

    Maintenance Maintenance Notice Damage to the valve Damage to these parts can result in 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 steps: Disassemble the valve, see Section 10.5, Page 41.

  • Page 47: Lubricating Seals And Threads

    Maintenance Maintenance Fig.17 Before fitting, wet the V-ring on the side not in contact with product (rear side). Pay attention that water does not drip into the V-ring groove on the valve disk. Air out the valve upon connection (22). Put in the V-ring.

  • Page 48: Installation

    Rivolta F.L.G. MD-2 can be ordered from GEA Tuchenhagen. Using other types of grease can result in malfunctions or in premature seal failure.

  • Page 49: Spring

    Maintenance Installation 10.7.1 Spring Fig.20 Before the spring is placed into the cleaning hood, both surface ends must be greased. 10.7.2 Cleaning hood Fig.21 When assembling the cleaning hood, the following instructions must be followed: When assembling the cleaning hood (1), carefully insert the rod guide strip (2) of the abutment into the cleaning hood.

  • Page 50: Checking Assembly

    Maintenance Installation Fig.23 Notice Valve disk has sharp edges When the valve is installed in the valve housing, the lower rod seal can become damaged by the valve disk (15). ► For this reason, an assembly mandrel (M) must always be used. Carry out the following steps: Insert assembly mandrel (M) with O-ring side in valve disk (15).
  • Page 51 They have the NSF-H1 (USDA H1) registration. PARALIQ GTE 703 can be ordered under mat. no. 413-064, and Rivolta F.L.G. MD-2 can be ordered under mat. no. 413-071 from GEA Tuchenhagen. Fitting the cleaning hose Slide the union nut (2) and sealing disc (1) over the cleaning hose disc.

  • Page 52: Torques For The Clamps And Clamp Connections

    Maintenance Installation Make sure that there is a visible connection (3) in the space before the 1. Make sure the disc fits. Fig.26 ® It will not hurt if the disc on the end of the cleaning hose turns. Re-assembly Carry out the following steps: After removing the union nut replace it without using aggressive force.
  • Page 53 Maintenance Valve stroke depending on size Valve Stroke Valve size Valve stroke [mm] Metric Inch OD 2.5" 3" 4" Inch IPS 2" 3" 4" 6" 430BAL008326EN_3 07.02.2022...

  • Page 54: Alarms

    Alarms Malfunctions and remedies Alarms 11.1 Malfunctions and remedies In the event of malfunctions immediately deactivate the valve and secure it against inadvertent reactivation. Malfunctions may only be remedied by qualified staff, who must observe the safety instructions. Malfunction Cause Remedy Check the system Fault in the control system...

  • Page 55: Decommissioning

    ► Never open the actuator. ► GEA Tuchenhagen accepts unopened actuators and arranges for proper disposal free of charge. Carry out the following steps: Remove the actuator. Pack the actuator safely and send it to GEA Tuchenhagen GmbH. ® Done 430BAL008326EN_3 07.02.2022...

  • Page 56: Spare Parts List - Mixproof Valve B

    Spare parts list - mixproof valve B Spare parts list - mixproof valve B Fig.27: Spare Parts Drawing Fig.28: Housing combinations 430BAL008326EN_3 07.02.2022...
  • Page 57 Spare parts list - mixproof valve B Item Designation Material DN 65 DN 80 DN 100 DN 125 DN 150 Sealing set complete 1) EPDM 221-511.38 221-511.38 221-511.39 221-511.40 221-511.41 221-519.17 221-519.17 221-519.18 221-519.19 221-519.20 HNBR EPDM 924-085 924-085 924-085 924-088 924-088 Seal ring...
  • Page 58 221-102.06 221-102.07 221-102.29 221-102.09 Actuator VARIVENT® See parts list/dimensions sheet for VARIVENT® actuator Control top T.VIS® See parts list for control top T.VIS® Grease RIVOLTA F.L.G. MD-2 100g tube not included in the sealing set 413-136 ** Do not grease item 7 and 8 * Items marked with an * are wearing parts 1) The sealing set contains items 1, 5, 6, 7, 8, 22, 23, 24, 29, 29.1 and 65...
  • Page 59 Spare parts list - mixproof valve B Item Designation Material 2.5"OD 3"OD 4" OD 2"IPS 3"IPS 4"IPS 6"IPS Sealing set complete 1) EPDM 221-511.38 221-511.38 221-511.39 221-511.37 221-511.38 221-511.39 221-511.41 221-519.17 221-519.17 221-519.18 221-519.16 221-519.17 221-519.18 221-519.20 HNBR 933-455 EPDM 924-085 924-085 924-085...
  • Page 60 221-102.62 221-102.59 221-102.60 221-102.17 Actuator VARIVENT® See parts list/dimensions sheet for VARIVENT® actuator Control top T.VIS® See spare parts list for control top T.VIS® Grease RIVOLTA F.L.G. MD-2 100g tube not included in the sealing set 413-136 ** Do not grease item 7 and 8 * Items marked with an * are wearing parts 1) The sealing set contains items 1, 5, 6, 7, 8, 22, 23, 24, 29, 29.1 and 65...
  • Page 61 Spare parts list - mixproof valve B sealing sets for VARIVENT® mixproof valve B Item Pcs. Designation Material 2" DN 65/80 DN 100 DN 125 DN 150 2.5"/3" 4" 6" Seal ring EPDM 924-084 924-085 924-085 924-088 924-088 924-082 924-083...

  • Page 62: Dimension Sheet - Varivent ® Double Seat Valve B

    ® Dimension sheet - VARIVENT Double seat valve B ® Dimension sheet - VARIVENT Double seat valve B Fig.29 430BAL008326EN_3 07.02.2022...
  • Page 63 ® Dimension sheet - VARIVENT Double seat valve B Nominal Actuato Pipe Housing Size Valve width Expansion Ø Stroke S Weight [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [kg] [mm] DN 65 70.0 × 2.00 96.0 30.0 DN 80 85.0 ×...

  • Page 64: Appendix

    Appendix Lists Appendix 15.1 Lists 15.1.1 Abbreviations and terms Abbreviation Explanation British Standard Unit of measurement of pressure [bar] All pressure data expressed in [bar/psi] is assumed to be gauge pressure [barg/psig] unless explicitly specified otherwise. approx. approximately °C Unit of measurement of temperature [degree Celsius] Unit of measurement of volume [cubic decimetre] Standard volume (standard litre) DIN nominal width...
  • Page 65 Appendix Abbreviation Explanation Metric Unit of measurement of work [newton metre] Specification of torque 1 Nm = 0.737 lbft Pound-Force (lb) + Feet (ft) Polyamide PE-LD Low-density polyethylene Polytetrafluoroethylene America measurement for pressure [Pound-forse per square inch] All pressure data expressed in [bar/psi] is assumed to be gauge pressure [barg/psig] unless explicitly specified otherwise.

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