GEA VARIVENT Y Operating Instruction
  1. Manuals
  2. Brands
  3. GEA Manuals
  4. Control Unit
  5. VARIVENT Y
  6. Operating instruction
GEA VARIVENT Y Operating Instruction

GEA VARIVENT Y Operating Instruction

Hygienic valves
Hide thumbs
Table of Contents

Advertisement

Quick Links

Hygienic valves
GEA VARIVENT® Valve Type Y
Operating instruction (Translation from the original language)
430BAL008451EN_2

Advertisement

Table of Contents
loading

Related Manuals for GEA VARIVENT Y

Summary of Contents for GEA VARIVENT Y

  • Page 1 Hygienic valves GEA VARIVENT® Valve Type Y Operating instruction (Translation from the original language) 430BAL008451EN_2...
  • 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 SYMBOLS USED Danger Stands for an immediate danger which leads to heavy physical injuries or to the death. Warning! Stands for a possibly 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.
  • Page 4 LAYOUT INFORMATION Bullet points and numbered list characters Bullet points are used to separate logical contents within a section: • Bullet point 1 Types of bullet point 1. • Bullet point 2 Types of bullet point 2. Numbered list characters are used to separate enumerations within a descriptive text: Descriptive text with consecutive numbering: –...

  • Page 5: 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 for Machines Safety Intended use 2.1.1 Requirements for operation 2.1.2 Pressure equipment directive 2.1.3...
  • Page 6 Safety instructions Cleaning Cleaning 9.1.1 Cleaning Process Examples 9.1.2 Cleaning effect 9.1.3 Cleaning the Leakage Cavity 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 10.3 Maintenance intervals 10.4 Prior to disassembly 10.5 Disassembling the Valve 10.5.1...

  • Page 7: 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 8: 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 430BAL008451EN_2 24.10.2017...

  • Page 9: Eu Declaration Of Conformity For Machines

    General Information EU Declaration of Conformity for Machines EU Declaration of Conformity for Machines in accordance with the EC Machinery Directive 2006/42/EC, Annex II 1. A GEA Tuchenhagen GmbH Manufacturer: Am Industriepark 2-10 21514 Büchen We declare under our sole responsibility that the machine...

  • Page 10: Safety

    The valve is a piece of pressure equipment (without safety function) as defined in the Pressure Equipment Directive: Directive 2014/68/EG. They are classified according to Annex II, article 4, section 3. In the event of any deviations, GEA Tuchenhagen GmbH will supply a specific Declaration of Conformity.

  • Page 11: Operator's Duty Of Care

    Safety Operator’s Duty of Care Operating the valve is not permitted if • Persons or objects are in the danger zone. • Safety devices are not working or were removed. • Malfunctions have been detected on the valve. • Damage has been detected on the valve. •...

  • Page 12: General Safety Instructions And Dangers

    EC Machinery Directive on your own. In general, only original spare parts supplied by GEA Tuchenhagen GmbH should be fitted. This ensures the reliable and economical operation of the valve.

  • Page 13: Electrical Equipment

    Safety Supplementary Regulations • Dispose of lubricants as hazardous waste. 2.4.3 Electrical Equipment For all work on electrical equipment, the following principles apply: • Access to electrical equipment should only be allowed to qualified electricians. Always keep unattended switch cabinets locked. •...

  • Page 14: Safety Equipment

    Safety Safety equipment • Sufficient professional qualification for the relevant task. • Instructed with regard to the function of the valve. • Instructed with regard to the operating sequences of the valve. • Familiar with the safety devices and their function. •...

  • 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. 430BAL008451EN_2 24.10.2017...

  • 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 • On a spring-closing valve there is danger of injury when the clamp connections (43.1/43.2) are opened, as the released spring pretension will suddenly lift the actuator. Therefore, release the spring tension before detaching the clamp connections (43.1/43.2) by supplying the actuator (A) with compressed air.

  • Page 18: Description

    Description Design Description Design Fig.5 Design Designation Designation Actuator Cleaning hood T.VIS control top Valve disk Seal Double-disk Bearing Additional disc Sealing disk Air connection Bearing disk Electrical connection Lantern 430BAL008451EN_2 24.10.2017...

  • Page 19: Functional Description

    Description Functional description Functional description 3.2.1 Opening and closing the valve Fig.6 Opening of valve In the closed setting, the upper and lower housings are sealed by a double- seated disc (16). Throttle gaps limit the leakage in case of seal defects, even on both seals.

  • Page 20: Actuator Function

    Description Functional description Closing the valve The closing process happens in the opposite sequence, therefore the upper valve seals are first seated before the lower valve seals leave the middle seal and the lower disc closes. With the downward motion of the valve rod, the additional disc is opened again.
  • Page 21 Description The upper and the lower valve housing are each equipped with a valve seat. The chamber between the two valve disks is connected to the open environment by an isolation outlet (3) integrated into the lower valve stem. In the event of seal damage, the leaking fluid can safely flow into the open.

  • Page 22: 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 23: 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 24: Technical Data

    Technical data Type plate Technical data Type plate The type plate clearly identifies the valve. Fig.10 The type plate provides the following key data: Key data of the valve Type Dual seat two-way valve Y Serial Serial number Material 1.4404 (AISI316L)/EPDM (FDA) Control air pressure bar/psi min.

  • Page 25: Cleaning Connection

    Technical data Cleaning connection Technical data: Ambient temperatures Designation Description - Control top type T.VIS P-15 0 to +50 °C (-4 ... +122 °F) Product temperature and operating Depending on the sealing material temperature Technical data: Compressed air supply Designation Description Air hose Material PE-LD Outer-Ø...

  • Page 26: Resistance Of Sealing Materials

    Technical data Resistance of Sealing Materials The durability of the components of the cleaning connection (sealing disc, support sleeve, PTFE hose) is dependent on the style, pressure and temperature of the required medium. Durability of the cleaning connection Max pressure Temperature Medium [bar]...

  • Page 27: Pipe Ends - General Table Of Measurements

    Technical data Pipe ends - General table of measurements Sealing resistance table Gasket material Medium Temperature (general operating temperature) EPDM HNBR -40...+135°C -10...+200 °C -25...+140 °C (-40...275°F) (+14...+392°F) (-13...+284°F) Inorganic acids up to 80 °C up to 5% (176°F) Inorganic acids up to 100 °C –...
  • Page 28 Technical data Pipe ends - General table of measurements Dimensions for Pipes in DN Outside Outside Wall Inside Metric DN diameter acc. diameter thickness diameter to DIN 11850 Dimensions for Pipes in Inch OD Outside Outside Wall Inside Inch OD diameter acc.

  • Page 29: Tool

    Technical data Tool Tool Tool Material no. Hose cutter 407-065 Manual emergency actuator 221-310.74 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 30 Technical data Size Weight [kg] OD 2" OD 2.5" OD 3" OD 4" OD 6" IPS 2" IPS 3" IPS 4" IPS 6" 430BAL008451EN_2 24.10.2017...

  • Page 31: Assembly And Installation

    Assembly and installation Safety instructions Assembly and installation Safety instructions Dangerous situations during assembly can be avoided by safety-conscious and proactive behaviour of the staff. For installation, the following principles apply: • Only properly qualified staff is allowed to install, assemble and set the valve into operation.

  • Page 32: 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 33: 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 34: Electrical Connection With T.vis Control Top

    Assembly and installation Electrical connection with T.VIS control top 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 top. Re-open the compressed air supply.

  • Page 35: 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 36: 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 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.

  • Page 37: 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 38: Cleaning The Leakage Cavity

    Cleaning Passivation 9.1.3 Cleaning the Leakage Cavity In the case of double seated valves without a lift drive, the leakage chamber is cleaned by means of a spray nozzle in the double disc, which is connected to a valve seat cleaning line. 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...

  • Page 39: Maintenance

    Maintenance Safety instructions Maintenance 10.1 Safety instructions Maintenance and repair Before starting any maintenance and repair work on the electrical devices of the valve, carry out the following steps in accordance with the "5 safety rules": • Isolate from the power supply •...

  • Page 40: Inspections

    Maintenance Inspections • Do not climb on the valve. Use suitable access aids and working platforms. • Mark the lines (if unmarked) prior to disassembly to ensure they are not confused when re-assembling. • Protect open line ends with blind plugs against ingress of dirt. •...

  • Page 41: Maintenance Intervals

    Maintenance Maintenance intervals Hint! The electrical cable must be long enough to allow the control top to be removed via the switch bar. 10.3 Maintenance intervals To ensure the highest operational reliability of the magnetic separator, 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 42: Supplemental Disc Removal

    Maintenance Disassembling the Valve 10.5.1 Supplemental disc removal Fig.11 Hint! For constructed size DN 25 / 1”OD any separate disassembly of the supplemental disc should be noted, see section “disassembly of the supplemental disc - constructed size DN 25 / 1”OD” Page 42. Carry out the following steps: Remove the cleaning connection (11.2).

  • Page 43: Removing The T.vis M-15 Control Top

    Maintenance Disassembling the Valve Fig.12 Remove the seal (1), seal washer (3), bearing (2), bearing washer (4.1) from the lower housing. Secure the valve disc with the arbour (D) Ø 3 mm. Loosen the supplemental disc (17) with a spanner SW 19. Remove the arbor (D).

  • Page 44: Removing The T.vis A-15 Control Top

    Maintenance Disassembling the Valve Caution! The permanent magnet on the switch bar is fragile. Damage to the permanent magnet. ► Protect the permanent magnet against impact stress. Warning! Spring tension in the valve Danger of injury when detaching the clamp connection (43.1, 46) as the released spring pretension will suddenly lift the actuator.

  • Page 45: Separating The Valve From The Drive

    Maintenance Disassembling the Valve Fig.14 Notice! The shaft of the valve disc (15) is a sensitive component. Damage to this part can result in malfunctions. ► When the shaft of the valve disc (15) is pulled out, the stem of the valve disc must not hit the valve housing.

  • Page 46: Separating The Valve And The Lamp

    Maintenance Disassembling the Valve Notice! The piston rod (S) and the shaft (16) of the valve disc are precision areas. Damage to these parts can result in a malfunction. ► Secure the lamp when unscrewing the drive. Carry out the following steps: Remove the clamp connection (46) between drive and lamp.

  • Page 47: Disassembly Of The Valve Insert

    Maintenance Maintenance 10.5.7 Disassembly of the valve insert. Fig.17 Carry out the following steps: Secure the valve disc on the borehole (15.1) with the appropriate tool, for example a pin Ø 5 mm. Place the spanner onto the spanner surface of the cleaning hood (11.1) and remove the valve disc.

  • Page 48: Replacing The V-Ring

    Maintenance Maintenance Fig.19 Notice! The stem of the valve disk (15,16), the housing seat (X), the valve insert (Y) and the V-ring groove (8) are precision parts. Damage to these parts can result in a malfunction. ► Handle the valve with care! Notice! Damage to the valve Damage to these parts can result in a malfunction.
  • Page 49 Maintenance Maintenance • 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 50: 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 51: 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 52: Place The Seating Ring Between The Housings

    Maintenance Installation When assembling the cleaning hood (1), carefully insert the rod guide strip (2) of the abutment into the cleaning hood. After the valve placement has been bolted to the cleaning hood, counter the piston rod against it. 10.7.3 Place the seating ring between the housings Fig.26 The seating ring should be placed with the arrow pointing to the displayed...

  • Page 53: Reconnect The Cleaning Hose

    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 54: Torques For The Clamps And Clamp Connections

    Maintenance Installation Fig.29 Assembling the cleaning hose Carry out the following steps: Screw on the union nut hand tight. When the cleaning hose stops, press it against the inner cone. Turn the union nut about another 1 1/2 turns. Do not turn the cleaning hose with the union nut.

  • Page 55: Valve Stroke

    Maintenance Installation Torques [Nm] [lbft] Clamps on the control top Clamp connection cast half rings Clamp connection 16.2 cast half rings Cast clamps 10.7.8 Valve Stroke Setting the valve stroke Carry out the following steps: Actuate the valve with compressed air. Check the stroke of the valve in accordance with (Page 55).
  • Page 56 Maintenance Valve Stroke Valve size Valve stroke [mm] 2" 3" 4" 430BAL008451EN_2 24.10.2017...

  • Page 57: 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 58: 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 430BAL008451EN_2 24.10.2017...

  • Page 59: Spare Parts List - Dual Seat Two-Way Valve Y

    Spare parts list - dual seat two-way valve Y Spare parts list - dual seat two-way valve Y Fig.31: Spare Parts Drawing Fig.32: Housing combinations 430BAL008451EN_2 24.10.2017...
  • Page 60 Spare parts list - dual seat two-way valve Y Item Designation Material DN 25 DN 40 DN 50 DN 65 Sealing kit complete 1) EPDM 221-519.59 221-304.30 221-304.30 221-304.31 221-519.61 221-519.39 221-519.39 221-519.40 HNBR 221-519.78 221-519.79 221-519.79 221-519.80 Sealing ring EPDM 924-084 924-084...
  • Page 61 Spare parts list - dual seat two-way valve Y Item Designation Material DN 25 DN 40 DN 50 DN 65 O-ring EPDM 930-350 930-312 930-312 930-246 930-269 930-166 930-166 930-247 HNBR 930-628 930-630 930-630 930-631 O-ring 930-026 930-026 930-026 930-026 29.1 O-ring 930-026...
  • Page 62 Spare parts list - dual seat two-way valve Y Item Designation Material DN 80 DN 100 DN 125 DN 150 Sealing kit complete 1) EPDM 221-304.31 221-304.32 221-304.33 221-304.34 221-519.40 221-519.41 221-519.42 221-519.43 HNBR 221-519.80 Sealing ring EPDM 924-085 924-085 924-088 924-088 924-083...
  • Page 63 Spare parts list - dual seat two-way valve Y Item Designation Material DN 80 DN 100 DN 125 DN 150 O-ring EPDM 930-246 930-246 930-364 930-364 930-247 930-247 930-299 930-299 HNBR 930-631 930-631 O-ring 930-026 930-026 930-035 930-035 29.1* O-ring 930-026 930-026 930-026...
  • Page 64 Spare parts list - dual seat two-way valve Y Item Designation Material 1" OD 1.5" OD 2" OD 2.5" OD Sealing kit complete 1) EPDM 221-519.59 221-304.30 221-304.30 221-304.31 221-519.61 221-519.39 221-519.39 221-519.40 HNBR 221-519.78 221-519.79 221-519.79 221-519.80 Sealing ring EPDM 924-084 924-084...
  • Page 65 Spare parts list - dual seat two-way valve Y Item Designation Material 1"OD 1.5"OD 2" OD 2-5" OD O-ring EPDM 930-350 930-312 930-312 930-246 930-269 930-166 930-166 930-247 HNBR 930-628 930-630 930-630 930-631 O-ring 930-026 930-026 930-026 930-026 29.1* O-ring 930-026 930-026 930-026...
  • Page 66 Spare parts list - dual seat two-way valve Y Item Designation Material 3"OD 4"OD 6" OD Sealing kit complete 1) EPDM 221-304.31 221-304.32 221-304.34 221-519.40 221-519.41 221-519.43 HNBR 221-519.80 Sealing ring EPDM 924-085 924-085 924-088 924-083 924-083 924-087 HNBR 924-313 924-313 Bearing PTFE/carbon...
  • Page 67 Spare parts list - dual seat two-way valve Y Item Designation Material 3"OD 4"OD 6" OD O-ring EPDM 930-246 930-246 930-364 930-247 930-247 930-299 HNBR 930-631 930-631 O-ring 930-026 930-026 930-035 29.1* O-ring 930-026 930-026 930-026 Cap nut 1.4571 933-456 933-456 933-482 Cutting ring...
  • Page 68 Spare parts list - dual seat two-way valve Y Item Designation Material 2" IPS 3" IPS 4" IPS 6" IPS Sealing kit complete 1) EPDM 221-304.30 221-304.31 221-304.32 221-304.34 221-519.39 221-519.40 221-519.41 221-519.43 HNBR 221-519.79 221-519.80 Sealing ring EPDM 924-084 924-085 924-085 924-088...
  • Page 69 Spare parts list - dual seat two-way valve Y Item Designation Material 2" IPS 3" IPS 4" IPS 6" IPS O-ring EPDM 930-312 930-246 930-246 930-346 930-166 930-247 930-247 930-299 HNBR 930-630 930-631 930-631 O-ring 930-026 930-026 930-026 930-035 29.1 O-ring 930-026 930-026...
  • Page 70 Spare parts list - dual seat two-way valve Y Sealing kits for dual seat two-way valve Y DN 25 DN 40/50 DN 65/80 DN 100 DN 150 Item Designation Material DN 125 1" 1.5"/2" 2.5"/3" 4" 6" Sealing ring Ø EPDM 924-084 924-084...
  • Page 71 Spare parts list - dual seat two-way valve Y Sealing kits for dual seat two-way valve Y DN 25 DN 40/50 DN 65/80 DN 100 DN 150 Item Designation Material DN 125 1" 1.5"/2" 2.5"/3" 4" 6" 930-026 930-026 930-026 930-026 930-026 930-026...

  • Page 72: Appendix

    Appendix Lists Appendix 14.1 Lists 14.1.1 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 73 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.

Table of Contents