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CEA VARIVENT D Operating Instructions Manual

Mixproof valve
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Operating Instructions
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VARIVENT
Mixproof Valve D
Edition 18/08/2016
English

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  • Page 1 Operating Instructions ® VARIVENT Mixproof Valve D Edition 18/08/2016 English...
  • Page 2 Mixproof Valve D Product Operating Instructions Document Edition 18/08/2016 English GEA Tuchenhagen GmbH Manufacturer Am Industriepark 2-10 D-21514 Büchen Phone:+49 4155 49-0 Fax: +49 4155 49-2423 Mail: sales.geatuchenhagen@gea.com Web: http://www.tuchenhagen.com 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.

  • Page 3: Table Of Contents

    Table of Contents Notes for the Reader ............................6 Binding Character of These Operating Instructions ..................6 Notes on the Illustrations ..........................6 Symbols and Highlighting ..........................7 Abbreviations and Terms ..........................8 Safety ................................10 Safety Note ..............................10 Operator's Duties ............................
  • Page 4 Control Module ..............................28 Valve with Detachable Pipe Connection Elements ..................28 Valve with Welding Ends..........................29 Pneumatic Connections ..........................30 • Air Requirement ............................30 • Establishing Hose Connections ........................31 Electrical Connections ............................. 31 Commissioning ..............................32 Cleaning and Passivation..........................33 Cleaning ................................
  • Page 5 Technical Data .............................. 54 Type Plate ..............................54 Technical Data ............................... 54 CIP Connection .............................. 56 Resistance of Sealing Materials ........................57 Pipe Ends ............................... 58 Tools ................................59 Lubricants ............................... 59 Weights ................................59 Spare Parts Lists ............................60 Dimension Sheets............................70...

  • Page 6: Notes For The Reader

    Notes for the Reader Notes on the Illustrations Notes for the Reader The present Operating Instructions are part of the user information for the valve. The Operating Instructions contain all the information you need to transport, install, commis- sion, operate and carry out maintenance for the valve. Binding Character of These Operating Instructions These Operating Instructions contain the manufacturer's instructions to the operator of the valve and to all persons who work on or use the valve regarding the procedures to...

  • Page 7: Symbols And Highlighting

    Notes for the Reader Symbols and Highlighting Symbols and Highlighting In these Operating Instructions, important information is highlighted by symbols or special formatting. The following examples illustrate the most important types of high- lighting. DANGER Warning: Fatal Injuries. Failure to observe the warning can cause serious damage to health, or even death. ...

  • Page 8: Abbreviations And Terms

    Notes for the Reader Abbreviations and Terms IMPORTANT NOTE Warning: Damage to Property. Non-observance of the warning note can cause serious damage to the valve or the vicinity of the valve.  The arrow identifies a precautionary measure you have to take to avoid the hazard. Carry out the following steps: = Start of a set of instructions.
  • Page 9 Notes for the Reader Abbreviations and Terms Abbreviation Explanation HNBR Material designation Short designation according to DIN/ISO 1629: Hydrogenated Acrylonitrile Butadiene Rubber Protection class International standard issued by the International Organization for Standardi- zation Unit of measurement of weight [kilogram] Unit of measurement of force [kilonewton] Kv value Flow coefficient [m³/s]...

  • Page 10: Safety

    Safety Operator's Duties Safety Safety Note The valve is operationally reliable. It was built according to state-of-the-art standards. Nevertheless, the valve can pose dangers, especially if • the valve is not used in accordance with its intended use, • the valve is not used correctly, •...

  • Page 11: Qualification Of Staff

    Safety Qualification of Staff Qualification 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 their tasks, • be instructed with regard to possible dangers, •...

  • Page 12: Supplementary Regulations

    Safety Supplementary Regulations For work to be carried out on the valve the following user groups are distinguished: User groups Staff Qualifications Operating staff Adequate instruction and sound knowledge in the following areas: • Function of the valve • Valve operating sequences •...

  • Page 13: Instructions For The Safe Operation

    Safety Instructions for the Safe Operation Instructions for the Safe Operation Dangerous situations during the operation can be avoided by safety-conscious and proactive behaviour of the staff. General Principles To ensure the safe operation of the valve the following principles apply: •...

  • Page 14: Commissioning/Setup Mode

    Safety Instructions for the Safe Operation 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.

  • Page 15: Shutting Down

    Safety Instructions for the Safe Operation Shutting Down For shutting down, the following principles apply: • Switch off the compressed air. • Switch off the valve via the main switch. • Padlock the main switch (if fitted) in the off position to prevent it from being switched back on.

  • Page 16: Disassembly

    Safety Instructions for the Safe Operation Disassembly For disassembly, the following principles apply: • Only allow qualified staff to disassemble the valve. • Before starting disassembly, the valve must be switched off and secured against being switched back on. Work may only be started once any residual energy has been discharged.

  • Page 17: Signage

    Safety Signage Signage Dangerous points on the valve are indicated 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 hazard warning...

  • Page 18: Residual Risk

    Safety Residual Risk Residual Risk Hazard Areas Please observe the following notes: • In the event of malfunctions, shut down the valve (disconnect from the power and air supply) and secure it against being used. • Never reach into the lantern (9) or the valve housing (402) when the valve is switching.

  • Page 19: Residual Dangers

    Safety Residual Risk Residual Dangers Dangerous situations can be avoided by safety-conscious and proactive behaviour of the staff and by wearing personal protective equipment. Residual dangers on the valve and measures Danger Cause Measure Danger to life Inadvertent switch-on of the Effectively disconnect all components, effec- valve tively prevent switch-on.

  • Page 20: Declaration Of Conformity

    Safety Residual Risk Declaration of Conformity Declaration of Conformity in accordance with the EC Machinery Directive 2006/42/EC We hereby declare that the machine designated below, based on its design and type as well as in the version brought to market by us, complies with the basic safety and health protection requirements of the EC Machinery Directive.

  • Page 21: Transport And Storage

    Transport and Storage Transport Transport and Storage Scope of Supply On receipt of the valve check whether • the details on the type plate correspond to the data in the order and delivery docu- ments, • the equipment is complete and all components are in good order. Transport For transport, the following principles apply: •...

  • Page 22: Storage

    Transport and Storage Storage Storage The valves, valve inserts or spare parts should be stored in a dry place, free of vibra- tions and dust. 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  0°C , it must be dried and suitable measures must be taken to protect it from damage.

  • Page 23: Intended Purpose

    Intended Purpose Pressure Equipment Directive Intended Purpose Designated Use The Mixproof Valve D is used for separating different media at intersection points in pipe systems. The medium should preferably flow in the opening direction of the valve disk to avoid pipe hammers when the valve is opened or closed.

  • Page 24: Atex Directive

    Intended Purpose Conversion Work ATEX Directive In areas with an explosive atmosphere, only valves suitable for use in such areas may be used. Refer to and observe the additional ATEX operating instructions for VARIVENT valves. For details regarding the marking of valves for potentially explosive areas also refer to the additional ATEX operating instructions for VARIVENT valves.

  • Page 25: Design And Function

    Design and Function Design Design and Function Design Designation Actuator T.VIS control module Sealing ring Bearing Sealing disk Bearing disk Lantern CIP bonnet Valve disk Double-disk Air connection Electrical connection...

  • Page 26: Function

    Design and Function Function Function Leakage-Proof Shut-Off On valve D, the upper and the lower valve housing are each fitted with a valve seat. The chamber between the two valve disks is connected to the open environment by an isola- tion outlet pipe (15.1) integrated into the lower valve disk.

  • Page 27: Actuator Function

    Design and Function Function Actuator Function The actuator is of the spring closing type (Z). The valve is closed in the non-actuated position. Identification: – Green steady light (1): valve in non-actuated position – Yellow steady light (1): valve in end position (actuated position)

  • Page 28: Installation And Commissioning

    Installation and Commissioning Valve with Detachable Pipe Connection Elements Installation and Commissioning 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 prevent damage, make sure that •...

  • Page 29: Valve With Welding Ends

    Installation and Commissioning Valve with Welding Ends Valve with Welding Ends This section describes the welding procedure for the valve. WARNING Spring tension in the valve Danger of injury when opening the clamp connections on the actuator or on the housing as the released spring pretension will suddenly lift the actuator.

  • Page 30: Pneumatic Connections

    Installation and Commissioning Pneumatic Connections Pneumatic Connections Air Requirement Actuator type Actuator diameter Air requirement (mm) /stroke) at 1.01325 bar at 0°C as per DIN 1343 A... 0.16 DN 25 - DN 100 1" - 4" OD, 2" - 4" IPS B...

  • Page 31: Establishing Hose Connections

    Installation and Commissioning Electrical Connections Establishing Hose Connections To ensure reliable operation, the compressed air hoses must be cut exactly square.  A hose cutter. Tools required: Carry out the following steps: Shut off the compressed air supply. Use the hose cutter to cut the pneumatic hoses square. Push the air hose into the air connector on the control module.

  • Page 32: Commissioning

    Installation and Commissioning Commissioning Commissioning Before starting commissioning observe the following: • Make sure that there are no foreign materials in the system. • Actuate the valve once by applying compressed air. • Clean the pipe system prior to the first product run. •...

  • Page 33: Cleaning And Passivation

    Cleaning and Passivation Cleaning Cleaning and Passivation 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. When the pipe is cleaned, the cleaning medium also flows through and cleans the valve hous- ings.

  • Page 34: Cleaning Effect

    Cleaning and Passivation Passivation Cleaning Effect The cleaning effect depends on the following factors: • Temperature • Time • Mechanics • Chemicals • Degree of soiling These factors can be combined in such a way as to make an optimal cleaning result probable.

  • Page 35: Malfunctions

    Malfunctions Malfunctions In the event of malfunctions immediately deactivate the valve and secure it against inad- vertent reactivation. Malfunctions may only be remedied by qualified staff, who must observe the safety instructions. Malfunction Cause Remedy Valve does not work Fault in the control system Check the system configura- tion No compressed air or...

  • Page 36: Maintenance

    Maintenance Inspections Maintenance Inspections Between the maintenance periods, the valves must be checked for leakage and proper function. Product Contact Seals Carry out the following steps:  Regularly check: – Stem seal between upper housing and lantern – V-ring in the valve disks –...

  • Page 37: Maintenance Intervals

    Maintenance Prior to Disassembly Maintenance Intervals To ensure the highest operational reliability of the valves, all wearing parts should be replaced at longer intervals. The actual maintenance intervals can only be determined by the user since they depend on the operating conditions, for instance: •...

  • Page 38: Disassembling The Valve

    Maintenance Disassembling the Valve Disassembling the Valve Removing the Control Module  No solenoid valve must be actuated electrically or manually. Requirement  The pneumatic and electrical connections on the plant side can remain on the control module. IMPORTANT NOTE The permanent magnet on the switch bar is fragile.
  • Page 39 Maintenance Disassembling the Valve Pressurize the valve at connection (22).  The valve disks (15/16) are raised. Detach the hinged clamp (43.1). Interrupt the compressed air supply to connection (22). Remove the clamps (49). Pull off the control top (B) upwards. ...

  • Page 40: Disconnecting The Valve From The Housing

    Maintenance Disassembling the Valve Disconnecting the Valve from the Housing IMPORTANT NOTE The stem of the double disk (16) is a sensitive part. Damage to this part can result in malfunctions.  When the valve is pulled out, the stem of the double disk (16) must not hit the valve housing! Carry out the following steps: ...

  • Page 41: Separating The Valve Insert From The Actuator

    Maintenance Disassembling the Valve Separating the Valve Insert from the Actuator IMPORTANT NOTE The piston rod (S) and the stem (16) of the double disk are precision parts. Damage to these parts can result in a malfunction.  Hold the lantern while unscrewing the actuator. Carry out the following steps: Unscrew the clamp connections (46) between the actuator and the lantern.

  • Page 42: Dismantling The Valve Insert

    Maintenance Disassembling the Valve Dismantling the Valve Insert IMPORTANT NOTE The stem (16) of the double disk and the lantern (9) are precision parts. Damage to these parts can result in a malfunction.  The bearing disk (4) and the sealing disk (3) must not hit the stem (16) of the double disk when the valve insert is withdrawn.

  • Page 43: Removing The Internals

    Maintenance Disassembling the Valve Pull off the pressure spring (18), counter bearing (12), bearing disk (4), bearing (2), sealing ring (1) with sealing disk (3) and the double disk (16) from the valve disk.  Done Removing the Internals Carry out the following steps: Remove the clamp connections (43) from the valve housing.

  • Page 44: Maintenance

    Maintenance Maintenance Maintenance Cleaning the Valve IMPORTANT NOTE The stem of the valve disk (16), the housing seat (402), the valve seat (16.1) and the V-ring groove (A) are precision parts. Damage to these parts can result in a malfunction. ...

  • Page 45: Replacing The V-Ring

    Maintenance Maintenance Replacing the V-Ring V-ring insertion tool  Insert the V-ring without grease. To facilitate fitting, use water with a drop of Requirement washing-up liquid to remove the surface tension. In order that no rust is transferred, the washing-up liquid solution must be made up in a ceramic, plastic, or stainless steel container.
  • Page 46 Maintenance Maintenance Use the insertion tool to press in the V-ring – evenly press in at several opposite points along the circumference. Insert the V-ring evenly. Replace all the other seals identified in the spare parts lists.  Done NOTE Used seals must not be used again, since the proper function of the seal can no longer be ensured.

  • Page 47: Lubricating Seals And Threads

    Maintenance Maintenance Lubricating Seals and Threads CAUTION Damage to seals and threads Damage to seals and threads can result in a malfunction.  Ensure that an adequate film of lubricant is applied. No grease residues must be visible after fitting the entire valve. ...

  • Page 48: Assembly

    Maintenance Assembly Assembly Assemble the valve in reverse order of disassembly. Observe the notes and instructions given in the following sections when doing so. Spring Before the spring is inserted into the CIP bonnet both faces must be greased. CIP Bonnet Observe the following instructions when assembling the CIP bonnet: When assembling the CIP bonnet (1) carefully introduce the rod guide ring (2) of the counter bearing into the CIP bonnet.

  • Page 49: Fitting The Valve Into The Housing

    Maintenance Assembly Fitting the Valve into the Housing IMPORTANT NOTE Valve disk has sharp edges When inserting the valve into the valve housing, the lower stem seal can be damaged by the valve disk (15).  Therefore always use an installation mandrel (M) to assemble the valve. Carry out the following steps: Introduce the O-ring end of the installation mandrel (M) into the valve disk (15).

  • Page 50: Connecting A New Cip Hose

    Maintenance Assembly Connecting a New CIP Hose  The CIP hose is made of synthetic material. When the CIP hose is connected by Requirement means of a screw fitting there can be strong constriction of the hose near the cutting ring and the CIP hose can come loose.

  • Page 51: Torques For The Clamps And Clamp Connections

    Maintenance Assembly Check Carry out the following steps: Unscrew the cap nut. Check whether material (3) has bulged in front of the first cutting edge.  It does not matter if the ring on the end of the CIP hose can be turned. Repeated assembly Carry out the following steps: ...
  • Page 52 Maintenance Assembly Strokes Depending on Size Valve Stroke Valve size Valve stroke (mm) metric Inch OD 1" 1.5" 2" 30.5 2.5" 3" 4" 30.5 6" Inch IPS 2" 3" 4" 6" ® Operating Instructions · VARIVENT Mixproof Valve D Edition 18/08/2016...

  • Page 53: Disposal

    Maintenance Disposal Disposal General Notes Dispose 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 following materials: •...

  • Page 54: Technical Data

    Technical Data Technical Data Technical Data Type Plate The type plate clearly identifies the valve. The type plate provides the following key data: Key data of the valve Type Mixproof Valve D Serial Serial number Material 1.4404(AISI316L)/FKM (FDA) Control air pressure bar/psi min.
  • Page 55 Technical Data Technical Data Technical data: Ambient temperatures Designation Description - Valve 0 to 60 °C, standard < 0 °C: use control air with a low dew point. Protect valve stems against freezing. - Proximity switch -20 to +80 °C - Control top type T.VIS M-1, A-8 -20 to +50 °C - Control top type T.VIS P-20...

  • Page 56: Cip Connection

    Technical Data CIP Connection CIP Connection Hose connection 1", DN 25 Ø6/4 mm DN 40...100 Ø8/6 mm 1.5"...4" OD; 2"...4" IPS Ø8/6 mm DN 125, 150; 6" IPS; 6" OD Ø10/8 mm Operating pressure for optimal cleaning • min. 2 bar (29 psi) •...

  • Page 57: Resistance Of Sealing Materials

    Technical Data Resistance of Sealing Materials Resistance of Sealing Materials The resistance of sealing materials depends on the type and temperature 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.

  • Page 58: Pipe Ends

    Technical Data Pipe Ends Pipe Ends Dimensions for Pipes in DN Metric Outside diameter Wall thickness Inside diameter Outside diameter acc. to DIN 11850 Dimensions for Pipes in Inch OD Inch OD Outside diameter Wall thickness Inside diameter Outside diameter acc.

  • Page 59: Tools

    Technical Data Weights Tools Tools Material no. Hose cutter 407-065 Belt wrench 408-142 V-ring insertion tool 229-109.88 Open end spanner, ends ground, a/f 17-19 229-119.01 Open end spanner, ends ground, a/f 21-23 229-119.05 Open end spanner, ends ground, a/f 22-24 229-119.03 Open end spanner, a/f 30-32 408-041...

  • Page 60: Spare Parts Lists

    Spare Parts List Date: 18/08/2016 Page: 60 of 69 Ersatzteillisten.fm Mixproof Valve D Spare Parts Lists Mixproof Valve D Spare Parts Drawing GEA Mechanical Equipment GEA Tuchenhagen GmbH Am Industriepark 2-10, D-21514 Büchen, Germany Telephone +49 4155 49-0, Telefax +49 4155 49-2423 sales.geatuchenhagen@gea.com, http://www.tuchenhagen.com...
  • Page 61 Spare Parts List Date: 18/08/2016 Page: 61 of 69 Ersatzteillisten.fm Mixproof Valve D Housing combinations Spare Parts List – Metric Sizes DN 25 to DN 65 Item Designation Material DN 25 DN 40 DN 50 DN 65 Sealing set, complete EPDM 221-519.58 221-304.07...
  • Page 62 Spare Parts List Date: 18/08/2016 Page: 62 of 69 Ersatzteillisten.fm Mixproof Valve D Spare Parts List – Metric Sizes DN 25 to DN 65 (Cont.) Item Designation Material DN 25 DN 40 DN 50 DN 65 O-ring EPDM 930-368 930-235 930-235 930-235 930-616...
  • Page 63 Spare Parts List Date: 18/08/2016 Page: 63 of 69 Ersatzteillisten.fm Mixproof Valve D Spare Parts List – Metric Sizes DN 80 to DN 150 (Cont.) Item Designation Material DN 80 DN 100 DN 125 DN 150 **7* V-ring EPDM 932-024 932-028 932-060 932-042...
  • Page 64 Spare Parts List Date: 18/08/2016 Page: 64 of 69 Ersatzteillisten.fm Mixproof Valve D Spare Parts List – Inch Sizes 1" OD to 4" OD Item Designation Material 1" OD 1.5" OD 2" OD 2.5" OD 3" OD 4" OD Sealing set, complete EPDM 221-519.58 221-304.07...
  • Page 65 Spare Parts List Date: 18/08/2016 Page: 65 of 69 Ersatzteillisten.fm Mixproof Valve D Spare Parts List – Inch Sizes 1" OD to 4" OD (Cont.) Item Designation Material 1" OD 1.5" OD 2" OD 2.5" OD 3" OD 4" OD Clamp connec- 1.4401 221-507.02...
  • Page 66 Spare Parts List Date: 18/08/2016 Page: 66 of 69 Ersatzteillisten.fm Mixproof Valve D Spare Parts List – Inch Sizes 2" IPS to 6" IPS Item Designation Material 2" IPS 3" IPS 4" IPS 6" IPS Sealing set, complete EPDM 221-304.07 221-304.08 221-304.09 221-304.11...
  • Page 67 Spare Parts List Date: 18/08/2016 Page: 67 of 69 Ersatzteillisten.fm Mixproof Valve D Spare Parts List – Inch Sizes 2" IPS to 6" IPS Item Designation Material 2" IPS 3" IPS 4" IPS 6" IPS Seat ring D 1.4404 221-108.02 221-108.03 221-108.04 221-108.06...
  • Page 68 Spare Parts List Date: 18/08/2016 Page: 68 of 69 Ersatzteillisten.fm Mixproof Valve D ® Sealing Sets for VARIVENT Mixproof Valve Type D Item Qty Designation Material DN 25; 1" DN 40/50; 1.5"/2" DN 65/80; 2.5"/3" DN 100; 4" DN 125 DN 150;...
  • Page 69 Spare Parts List Date: 18/08/2016 Page: 69 of 69 Ersatzteillisten.fm Mixproof Valve D GEA Mechanical Equipment GEA Tuchenhagen GmbH Am Industriepark 2-10, D-21514 Büchen, Germany Telephone +49 4155 49-0, Telefax +49 4155 49-2423 sales.geatuchenhagen@gea.com, http://www.tuchenhagen.com...

  • Page 70: Dimension Sheets

    Dimension Sheet Date: 18/08/2016 Page: 70 of 71 Maßblatt.fm ® VARIVENT Mixproof Valve D Dimension Sheets ® VARIVENT Mixproof Valve D Drawing - Mixproof Valve D Mixproof Valve D Pipe Housing Actuator Dimension Valve  Nominal Expansion X Stroke S Weight diameter [mm]...
  • Page 71 Dimension Sheet Date: 18/08/2016 Page: 71 of 71 Maßblatt.fm ® VARIVENT Mixproof Valve D Mixproof Valve D (Cont.) Pipe Housing Actuator Dimension Valve  Nominal Expansion X Stroke S Weight diameter [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [kg] DN 100 104,0 ×...
  • Page 72 We live our values. Excellence · Passion · Integrity · Responsibility · GEA-versity GEA Group is a global mechanical engineering company with multi-billion euro sales and operations in more than 50 countries. Founded in 1881 the company is one of the largest providers of innovative ®...

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