GEA VARIVENT FRS Operating Instruction
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GEA VARIVENT FRS Operating Instruction

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Hygienic valves
®
GEA VARIVENT
FRS valve
Operating instruction (Translation from the original language)
430BAL013059EN_7

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Summary of Contents for GEA VARIVENT FRS

  • Page 1 Hygienic valves ® GEA VARIVENT FRS valve Operating instruction (Translation from the original language) 430BAL013059EN_7...
  • 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 Safety instructions Cleaning Cleaning 9.1.1 Cleaning Process Examples 9.1.2 Cleaning effect Passivation Maintenance 10.1 Safety instructions 10.2 Inspections 10.2.1 Product contact seals 10.2.2 Pneumatic connections 10.2.3 Electrical connections 10.2.4 Signs on the valve 10.3 Maintenance intervals 10.4 Prior to disassembly 10.5 Disassembling Valve FRS 10.5.1...

  • 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 flowcomponents@gea.com www.gea.com 430BAL013059EN_7 24.03.2022...

  • 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 430BAL013059EN_7 24.03.2022...

  • 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 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. 2.1.4 Improper operating conditions The operational safety of the component can not be guaranteed under improper operating conditions.

  • 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 2.4.2 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: • Substances harmful to the environment must not be discharged into the ground or the sewage system.
  • Page 13 Safety Qualification of personnel Only allow specially trained personnel to carry out work on an explosion- protected system. When working on explosion-protected equipment observe the standards DIN EN 60079-14 for gases and DIN EN 50281-1-2 for dusts. The following minimum qualifications are required: •...

  • 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

    Safety Residual dangers Signs on the valve Sign Meaning General hazard warning Fig.1 Warning Crushing Fig.2 Explosive atmosphere hazard warning Fig.3 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...

  • Page 16: Danger Zones

    Safety Danger zones Residual dangers on the valve and measures Danger Cause Measure Risk 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 service, maintenance 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 Housing combination Sealing ring Lantern Spacer Cylinder cover Valve disk Piston Piston rod Leadership Circlip Clamp connection Cylinder screw hex socket Guide ring V-ring O-ring piston rod seal O-ring piston 430BAL013059EN_7 24.03.2022...
  • Page 19 Description Design Design Designation O-ring piston O-ring piston rod seal O-ring hood seal Flush valve 430BAL013059EN_7 24.03.2022...

  • Page 20: Functional Description

    Description Functional description Functional description 3.2.1 Installation position Installation 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 430BAL013059EN_7 24.03.2022...

  • 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: Technical Data

    Technical data Type plate Technical data Type plate The type plate clearly identifies the valve. GEA Tuchenhagen GmbH Am Industriepark 2-10, 21514 Büchen, Germany Type Serial Mat. Air bar/psi min. max. PSI bar/psi Fig.7 The type plate provides the following key data and exemplary details.

  • Page 23: Resistance And Permitted Operating Temperature Of The Sealing Materials

    Technical data Resistance and permitted operating temperature of the sealing materials 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.

  • Page 24: Pipe Ends - General Table Of Measurements

    Pipe ends - General table of measurements 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 25: Tools

    Technical data Tools Dimensions for pipes, metric inch OD Metric DN Outer Wall thickness Inner Outer Outer Inch OD diameter diameter diameter according to diameter according to DIN 11850 BS 4825 DN50 DN65 DN80 DN100 DN125 DN150 DN350 355.6 349.6 3"...
  • Page 26 Technical data 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 430BAL013059EN_7 24.03.2022...

  • Page 27: 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 28: 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! Falling of the valve When undoing the clamp connections at the drive or housing there is risk of...

  • Page 29: Air Requirement

    Assembly and installation Electrical connections 6.5.1 Air Requirement FRS valve size: Process Actuator Ø Air requirement housing / CIP housing [mm] /Stroke) at 1.01325 bar at 0 °C as per DIN 1343 DN50/DN65 0.22 DN50/DN80 0.22 DN80/DN100 0.79 3"OD/DN100 0.79 DN100/DN125 0.79 4"OD/DN125...
  • Page 30 Assembly and installation Explosive gases or dusts An explosion can result in serious personal injury or death. ► Observe the installation and operating regulations for use in potentially explosive areas. Carry out the following steps: Connect in accordance with the connection diagram and the instructions in the corresponding operating instructions.

  • Page 31: 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 32 Any use in said category may only be effected, if the FRS valve was ordered with this requirements from GEA Tuchenhagen and if it bears corresponding labelling.

  • Page 33: 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 34: Cleaning

    Cleaning Cleaning Cleaning Cleaning During the cleaning process, the lateral sterile air valves/flush valves must be closed. System-side monitoring and safety installations to ensure valve controls should be planned. All parts in contact with product must be cleaned at regular intervals. Always observe the safety data sheets issued by the cleaning agent manufacturers.

  • Page 35: Passivation

    Cleaning Passivation • Degree of soiling These factors can be combined in such a way as to make an optimal cleaning result probable. Depending on the cleaning method (medium, concentration, temperature and contact times), the seals are affected to different degrees. This can impair the function and the service life.

  • Page 36: 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 37: 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 38: Signs On The Valve

    Maintenance Maintenance intervals 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. ® Done 10.3 Maintenance intervals To ensure the highest operational reliability, all wearing parts should be replaced at longer intervals.

  • Page 39: Disassembling Valve Frs

    Maintenance Disassembling Valve FRS 10.5 Disassembling Valve FRS 10.5.1 Remove clamp connection (14), separate valve insert from housing Fig.10 Prerequisite: • No solenoid valve must be actuated electrically or manually. • The pneumatic and electrical connections on the plant side can remain on the control top.

  • Page 40: Open Drive Unit

    Maintenance Disassembling Valve FRS ® Done Hint! Seal replacement: In this state, the seals in contact with product (2) and (20) can be replaced; see illustration. Fig.11 10.5.2 Open drive unit Prerequisite: • Remove hood (1) using a strap wrench and remove from the lantern (3). Tools required: •...

  • Page 41: Disassembling The Valve Into Individual Parts

    Maintenance Disassembling Valve FRS Fig.13 10.5.3 Disassembling the Valve into Individual Parts Fig.14 Notice Sensitive valve parts Damage to valve parts. ► Protect the valve parts against impact stress. ► Undo the cable screw connection prior to dismantling the valve. Carry out the following steps: Undo the cable connection at the board / terminal strip (35) to the connector (40)
  • Page 42 Maintenance Disassembling Valve FRS Fig.15 Dismantle the elbow screw-in plug connection (16) Undo the hexagon nut (15) of the piston rod thread (8) Carefully pull off the cylinder cover (5) ® The piston rod seal (21) can now be accessed. Fig.16 Tools required: •...

  • Page 43: Removing The Rinsing Valve C

    Maintenance Maintenance Fig.17 10.5.4 Removing the rinsing valve C Fig.18 Carry out the following steps: Depressurize the valve Take off the air hose Unscrew the valve from the housing at area (2) Remove cylinder SPV-C from housing (2) Take the spring (5) out of cylinder SPV-C (1) Pull piston SPV-C (4) out of cylinder SPV-C (1) ®...

  • Page 44: Replacing Seals

    Maintenance Maintenance Fig.19 Notice The shaft of the valve disc (6), the housing seat (1.2), the valve seat (1.1) and the V-ring groove (6.1) are precision parts. Damage to these parts can result in a malfunction. ► Handle the valve with care! Notice Damage to the valve Damage to the valve can result in a malfunction.
  • Page 45 Maintenance Maintenance Replacing the V-Ring Fig.20: V-ring insertion tool Prerequisite: • Insert V-Ring without grease. To facilitate fitting, use water with a drop of 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: Lubricating Seals And Threads

    Maintenance Maintenance Fig.23 Insert the V-ring evenly. Replace all the other seals identified in the spare parts lists. ® Done Hint! Used seals must not be used again, since the proper function of the seal can then no longer be ensured. 10.6.3 Lubricating Seals and Threads Caution!

  • Page 47: Installation

    PARALIQ GTE 703 can be ordered from GEA Tuchenhagen under material no. 413-064, and Rivolta F.L.G. MD-2 can be ordered under material no.

  • Page 48: Connections And Operation

    Maintenance Installation 10.7.2 Connections and Operation Fig.25 Item Designation Main stroke air connection AS-i board or 24 VDC module 5/2-way solenoid valve Initiators Outlet and inlet valve of the main stroke; the connection must not be closed Connector M12 (AS-i: 4-pole or 24 VDC: 8-pole 430BAL013059EN_7 24.03.2022...

  • Page 49: Pneumatic Connection

    Maintenance Installation 10.7.3 Pneumatic connection For valve FRS, the main control air is guided via the air connection (16) internally by the solenoid valve through the 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 length and fix with cable binders if...

  • Page 50: Electrical Connections

    Maintenance Installation 10.7.4 Electrical connections Danger Live parts Electrical shock can result in serious personal injury or death. ► Only allow properly qualified staff to carry out work on the electrical equipment. ► Prior to establishing electrical connections check the maximum permissible operating voltage.

  • Page 51: 10.7.4.2 Electrical Wiring Of As-Interface

    Maintenance Installation 10.7.4.2 Electrical Wiring of AS-Interface Fig.28 Connector M12/4-pole ASI+ not connected ASI- not connected Carry out the following steps: Connect cable via air connector M12/4-pole. ® Done. 10.7.4.3 Setting the feedback Fig.29 430BAL013059EN_7 24.03.2022...

  • Page 52: 10.7.4.4 Establishing Hose Connections

    Maintenance Installation Caution! Only use proximity switch types specified in chapter “Technical data”. ► Install the initiators (38) for the detection of the end position using the retaining plates in such a way that the guide arm (9) can be detected in the end positions.
  • Page 53 Maintenance Valve Stroke Valve size process housing / CIP Valve stroke [mm] housing 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 430BAL013059EN_7 24.03.2022...

  • 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 Valve does not work Check the system...

  • Page 55: Decommissioning

    Decommissioning Safety instructions Decommissioning 12.1 Safety instructions For shutting down, the following principles apply: • Switch off the compressed air. • Switch off the component with the main switch. • Padlock the main switch (if fitted) in the off position to prevent it from being switched back on.

  • Page 56: Spare Parts List - Varivent ® Frs Valve

    ® Spare parts list - VARIVENT FRS Valve ® Spare parts list - VARIVENT FRS Valve Fig.30 430BAL013059EN_7 24.03.2022...
  • Page 57 ® Spare parts list - VARIVENT FRS Valve Item Designation Material DN50/DN65 DN65/DN80 Housing combination 1.4404/1.4301 221-006774 221-006767 Sealing ring RA EPDM 221-367.03 221-367.03 221-367.08 221-367.08 Lantern FRS 1.4301 221-006764 221-006764 Spacer FRS EN AW-6082 T6 221-006759 221-006759 Cylinder cover FRS 1.4301 221-006758 221-006765...
  • Page 58 ® Spare parts list - VARIVENT FRS Valve Item Designation Material DN50/DN65 DN65/DN80 Plug M12 / 4 poles Brass, nickel-plated 508-956 508-956 Optional 8 poles 24VDC Rinsing Valve FRS EPDM 221-464.26 221-464.26 221-464.29 221-464.29 Flushing valve FRS 3A EPDM 221-464.34 221-464.34 221-464.35 221-464.35...
  • Page 59 ® Spare parts list - VARIVENT FRS Valve Item Designation Material DN80/DN100 3"OD/DN100 Housing combination 1.4404/1.4301 221-006736 221-006731 Sealing ring RA EPDM 221-367.04 221-367.04 221-367.09 221-367.09 Lantern FRS 1.4301 221-006727 221-006427 Spacer FRS EN AW-6082 T6 221-006536 221-006536 Cylinder cover FRS 1.4301 221-006537 221-006537...
  • Page 60 ® Spare parts list - VARIVENT FRS Valve Item Designation Material DN80/DN100 3"OD/DN100 Plug M12 / 4 poles Brass, nickel-plated 508-956 508-956 Optional 8 poles 24VDC Rinsing Valve FRS EPDM 221-464.26 221-464.26 221-464.29 221-464.29 Flushing valve FRS 3A EPDM 221-464.34 221-464.34 221-464.35 221-464.35...
  • Page 61 ® Spare parts list - VARIVENT FRS Valve Item Designation Material DN100/DN125 4"OD/DN125 Housing combination 1.4404/1.4301 221-006741 221-006725 Sealing ring RA EPDM 221-367.04 221-367.04 221-367.09 221-367.09 Lantern FRS 1.4301 221-006427 221-006427 Spacer FRS EN AW-6082 T6 221-006536 221-006536 Cylinder cover FRS 1.4301 221-006537 221-006537...
  • Page 62 ® Spare parts list - VARIVENT FRS Valve Item Designation Material DN100/DN125 4"OD/DN125 Plug M12 / 4 poles Brass, nickel-plated 508-956 508-956 Optional 8 poles 24VDC Rinsing Valve FRS EPDM 221-464.26 221-464.26 221-464.29 221-464.29 Flushing valve FRS 3A EPDM 221-464.34 221-464.34 221-464.35 221-464.35...
  • Page 63 ® Spare parts list - VARIVENT FRS Valve Item Designation Material DN125/DN150 DN350/DN125 Housing combination 1.4404/1.4301 221-006569 221-006504 Sealing ring RA EPDM 221-367.05 221-367.04 221-367.10 221-367.09 Lantern FRS 1.4301 221-006578 221-006427 Spacer FRS EN AW-6082 T6 221-006581 221-006536 Cylinder cover FRS 1.4301 221-006583 221-006537...
  • Page 64 ® Spare parts list - VARIVENT FRS Valve Item Designation Material DN125/DN150 DN350/DN125 Plug M12 / 4 poles Brass, nickel-plated 508-956 508-956 Optional 8 poles 24VDC Rinsing Valve FRS EPDM 221-464.26 221-464.23 221-464.29 221-464.30 Flushing valve FRS 3A EPDM 221-464.34 221-464.34 221-464.35 221-464.35...

  • Page 65: Dimension Sheet - Valve Frs

    Dimension sheet - Valve FRS Dimension sheet - Valve FRS Fig.31 430BAL013059EN_7 24.03.2022...
  • Page 66 Dimension sheet - Valve FRS FRS valve Pipe Housing Size Ø PG Ø CIP Ø CIP* Process / Housing CIP housing DN50/DN65 53x1.5 85x2 70x2 87.5 DN 65/DN80 70x2 85x2 95.5 DN80/DN100 85x2 129x2 104x2 50.5 3"OD/DN100 76.2x1.6 129x2 104x2 46.5 DN100/DN125 104x2...

  • Page 67: 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 litres) DIN nominal width...
  • Page 68 Appendix Abbreviation Explanation Metric Unit of measurement of work [newton metre] TORQUE SPECIFICATION: 1 Nm = 0.737 lbft Pound-Force (lb) + Feet (ft) Polyamide PE-LD Low-density polyethylene Polytetrafluoroethylene Powder Anglo-American unit of measurement for pressure [pound- force per square inch] All pressure data expressed in [bar/psi] is assumed to be gauge pressure [barg/psig] unless explicitly specified otherwise.
  • Page 69 Appendix 430BAL013059EN_7 24.03.2022...

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