GEA VARIVENT C Manual
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GEA VARIVENT C Manual

Double seal valve
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Hygienic valves
®
GEA VARIVENT
Double seal valve type C
Operating instruction (Translation from the original language)
430BAL008331EN_4

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Summary of Contents for GEA VARIVENT C

  • Page 1 Hygienic valves ® GEA VARIVENT Double seal valve type C Operating instruction (Translation from the original language) 430BAL008331EN_4...
  • 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 Cleaning Cleaning 9.1.1 Cleaning Process Examples 9.1.2 Cleaning effect 9.1.3 Cleaning the leakage cavity 9.1.4 Rinsing operations 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...

  • 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 430BAL008331EN_4 18.02.2022...

  • 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 430BAL008331EN_4 18.02.2022...

  • 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 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

    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. 430BAL008331EN_4 18.02.2022...

  • Page 16: Danger Zones

    Safety Danger zones 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 connection (43, 46) is opened, as the released spring pretension will suddenly lift the actuator. Therefore, release the spring tension before detaching the clamp connection (43, 46) by supplying the actuator (A) with compressed air. •...

  • Page 18: Description

    Description Design Description Design Fig.5 Design Designation Actuator T.VIS control top Seal ring Bearing Seal disk Bearing disc Lantern Spacer nut Valve disc C Valve housing 430BAL008331EN_4 18.02.2022...

  • Page 19: 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 20: 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 21: 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 22: 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 seal valve C Serial Serial number Material 1.4404(AISI316L)/FKM (FDA) Control air pressure bar/psi min.

  • 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 60°C, standard < 0 °C: Use control air with low dew - Valve point. Protect valve rods against freezing. - Initiator -20 to +80 °C (-4 ...
  • Page 24 Resistance and permitted operating temperature of the sealing materials 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: Pipe Ends - General Table Of Measurements

    Technical data Pipe ends - General table of measurements Sealing materials General temperature resistance* -40...+135 °C EPDM (-40...275 °F) -10...+200 °C (+14...+392 °F) -25...+140 °C HNBR (-13...+284 °F) * The general resistance of the material does not correspond to the maximum operating temperature.

  • Page 26: Tool

    Technical data Tool Dimensions for Pipes in Inch OD Outside Outside Wall Inside Inch OD diameter acc. diameter thickness diameter to BS 4825 4" 101.6 2.11 97.38 6" 152.4 2.77 146.86 Tool List of tools Tool Material no. Hose cutter 407-065 Belt wrench 408-142...
  • Page 27 Technical data Size Weight [kg] DN 125 49.1 DN 150; 6" 55.2 430BAL008331EN_4 18.02.2022...

  • Page 28: 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 29: Valve With Welded Ends

    Assembly and installation Valve with Welded Ends 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 30: 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 31 Assembly and installation Pneumatic connections Establish the hose connections in accordance with the hose connection diagram, see Section 6.5.3, Page 32. Shut off the compressed air supply. Use the hose cutter to cut the pneumatic hoses at a right angle. Push the air hose into the air connector on the control top.

  • Page 32: Hose Fitting Valve C

    Assembly and installation Pneumatic connections 6.5.3 Hose fitting valve C With T.VIS connection With 0 connection Fig.10 Fig.9 430BAL008331EN_4 18.02.2022...
  • Page 33 Assembly and installation Pneumatic connections With T.VIS connection and actuator Z ATEX variant with actuator Z Fig.11 Fig.12 430BAL008331EN_4 18.02.2022...

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

    Assembly and installation Electrical connection with T.VIS control top View without hood Fig.13 Item Designation External initiator Electrical connections Hint! For an optimal fit at the air connection, it is necessary to cut the pneumatic hoses at a right angle with the hose cutter. Electrical connection with T.VIS control top Danger Live parts...
  • Page 35 Assembly and installation Hint! The proximity switches are factory set. During transport and installation it can happen that the settings are changed, so that readjustment may be required (see the Operating Instructions for the control top). 430BAL008331EN_4 18.02.2022...

  • Page 36: 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 37: 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 38: 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 39: Cleaning The Leakage Cavity

    Cleaning Passivation 9.1.3 Cleaning the leakage cavity To clean the leakage cavity, two flush valves are fitted in the seat area of the double-seal valve C. Cleaning liquid is flushed into the leakage cavity through one of the flush valves. The cleaning medium is discharged via the second flush valve.

  • Page 40: 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 41: 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 42: 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 43: 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 Ventilating the Actuator for Disassembly The actuator can be ventilated for disassembly via the pilot valve or with the assembly tool.
  • Page 44 Maintenance Disassembling the Valve Fig.15 ® The valve is ventilated. With assembly tool Caution! The permanent magnet on the switch bar is fragile. Mechanical impact may break the permanent magnet. ► Protect the permanent magnet from mechanical impact. Caution! Influence on electronic and mechanical components. Data carriers may be erased by the permanent magnet.

  • Page 45: Removing The Valve Insert

    Maintenance Disassembling the Valve Fig.16 Pull off the control top (B) upwards. Mount the assembly tool (M), part no. 221-105.99, onto the actuator (A) via the switch bar. Fig.17 ® The valve can be ventilated at M1. 10.5.2 Removing the Valve Insert 430BAL008331EN_4 18.02.2022...
  • Page 46 Maintenance Disassembling the Valve Fig.18 Notice The stem of the valve disc (15) is a sensitive component. Damage to these parts can result in malfunction. ► The bearing disc (4) and the sealing disc (3) must not hit the stem (15) of the valve disc when the valve insert is withdrawn.

  • Page 47: Separating The Valve From The Actuator

    Maintenance Disassembling the Valve Carefully pull out the valve along with actuator (A) from the housing (402). ® Done 10.5.3 Separating the Valve from the Actuator Fig.19 Notice The stem of the valve disc (15) is a sensitive component. Damage to these parts can result in malfunction. ►...

  • Page 48: Removing The Flush Valve C

    Maintenance Maintenance Remove the clamp connection (46) between the lantern and the actuator. Remove the lantern (9). ® Done 10.5.4 Removing the flush valve C Fig.20 Carry out the following steps: Depressurise the valve. Take off the air hose. Unscrew the air hose from the housing at surface (2). Remove cylinder SPV-C (1) from housing SPV-C (2).
  • Page 49 Maintenance Maintenance Fig.21 Notice The stem of the valve disc (15), the housing seat, the valve seat (S) and the V-ring groove (8) are precision parts. Damage to these parts can result in malfunction. ► Handle the valve with care! Notice Damage to the valve Damage to these parts can result in malfunction.

  • Page 50: Replacing Seals

    Maintenance Maintenance 10.6.2 Replacing Seals Hint! Replace defective seals to ensure the tightness of the valve. Always use original spare parts. Replacing the V-Ring Fig.22: 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.

  • Page 51: Lubricating Seals And Threads

    Maintenance Maintenance Fig.24 Use the insertion tool to press in the V-ring – evenly press in at several opposite points along the circumference. Fig.25 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...

  • Page 52: 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 53 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.28 ® 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. Make sure that the nozzle is also tight. ®...
  • Page 55 Maintenance Valve Stroke Valve size Valve stroke [mm] Inch OD 1" 1.5" 2" 30.5 2.5" 3" 4" 30.5 6" Inch IPS 2" 3" 4" 6" 430BAL008331EN_4 18.02.2022...

  • Page 56: 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 57: 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 430BAL008331EN_4 18.02.2022...

  • Page 58: Parts List - Double Seal Valve C

    Parts list - Double seal valve C Parts list - Double seal valve C Fig.30 Fig.29 Fig.32: Housing combinations Fig.31: Flush valve SPV-C/SPV-C-S 430BAL008331EN_4 18.02.2022...
  • Page 59 Parts list - Double seal valve C Item Designation Material DN 25 DN 40 DN 50 DN 65 Sealing set complete 1) EPDM 221-528.44 221-511.74 221-511.74 221-511.75 221-528.45 221-519.53 221-519.53 221-519.54 HNBR 221-528.97 221-519.85 221-519.85 221-519.86 Seal ring EPDM 924-084 924-084 924-084 924-085...
  • Page 60 Parts list - Double seal valve C Item Designation Material DN 25 DN 40 DN 50 DN 65 Actuator VARIVENT® See parts list/dimensions sheet for VARIVENT® actuator Control top T.VIS® See parts list for control top T.VIS® Connection 0/C See parts list for connection 0/C Flush valve SPV-C (<...
  • Page 61 Parts list - Double seal valve C Item Designation Material DN 80 DN 100 DN 125 DN 150 Sealing set complete 1) EPDM 221-511.75 221-511.76 221-511.77 221-511.78 221-519.54 221-519.55 221-519.56 221-519.57 HNBR 221-519.86 221-004179 Seal ring EPDM 924-085 924-085 924-088 924-088 924-083 924-083...
  • Page 62 Parts list - Double seal valve C Item Designation Material DN 80 DN 100 DN 125 DN 150 Actuator VARIVENT® See parts list/dimensions sheet for VARIVENT® actuator Control top T.VIS® See parts list for control top T.VIS® Connection 0/C See parts list for connection 0/C Flush valve SPV-C (<...
  • Page 63 Parts list - Double seal valve C Item Designation Material 1" OD 1.5" OD 2" OD 2.5" OD Sealing set complete 1) EPDM 221-528.44 221-511.74 221-511.74 221-511.75 221-528.45 221-519.53 221-519.53 221-519.54 HNBR 221-528.97 221-519.85 221-519.85 221-519.86 Seal ring EPDM 924-084 924-084 924-084 924-085...
  • Page 64 Parts list - Double seal valve C Item Designation Material 1" OD 1.5" OD 2" OD 2.5" OD Actuator VARIVENT® See parts list/dimensions sheet for VARIVENT® actuator Control top T.VIS® See parts list for control top T.VIS® Connection 0/C See parts list for connection 0/C Flush valve SPV-C (<...
  • Page 65 Parts list - Double seal valve C Item Designation Material 3" OD 4" OD 6" OD Sealing set complete 1) EPDM 221-511.75 221-511.76 221-511.78 221-519.54 221-519.55 221-519.57 HNBR 221-519.86 221-004179 Seal ring EPDM 924-085 924-085 924-088 924-083 924-083 924-087 HNBR 924-313 924-313 Bearing...
  • Page 66 Parts list - Double seal valve C Item Designation Material 3" OD 4" OD 6" OD Flush valve SPV-C (< 80°C) See parts list for flush valve SPV Flush valve SPV-C-S (> 80°C) Grease RIVOLTA F.L.G. 100g tube not included with sealing set. 413-136 ** Do not grease item 7 and 8 1) The sealing set includes items 1, 5, 6, 7, 8, 29, 30, 175, 176 and 177...
  • Page 67 Parts list - Double seal valve C Sealing sets for double seal valve C 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" Seal ring Ø EPDM 924-084 924-084 924-085 924-085 924-088...

  • Page 68: Parts List - 0 Connection (0/C)

    Parts list - 0 connection (0/C) Parts list - 0 connection (0/C) Fig.33: Connection type 0 for all VARIVENT valves except type C Fig.34: Connection type 0/C for VARIVENT double seal valve type C 430BAL008331EN_4 18.02.2022...
  • Page 69 Parts list - 0 connection (0/C) Item Designation Material Connection 0/100 for DN25 - DN125 and 1" to 6" Material no. for metric connection for inch connection Clamp connection KU 221-507.08 221-507.08 Connection 0 cpl. 1.4301 221-140.02 221-140.04 117* Angular screw fitting Brass/nickel-plated 933-475 6-1/8”...

  • Page 70: Parts List - Flush Valve Spv

    Parts list - Flush Valve SPV Parts list - Flush Valve SPV Fig.35: Types C and C-S Fig.36: Type M 430BAL008331EN_4 18.02.2022...
  • Page 71 Parts list - Flush Valve SPV Item Designation Material Type C* Type M* Type C-S* Rinsing valve, complete EPDM 221-464.01 221-464.13 221-464.21 221-464.06 221-464.18 221-464.22 Cylinder SPV PVDF 221-464.03 221-464.03 1.4305 221-464.10 Housing SPV 1.4305 221-464.08 221-464.08 221-464.08 Outlet SPV 1.4301 221-464.05 221-464.09...

  • Page 72: Parts List - Hose Connection Diagram

    Parts list - Hose connection diagram Parts list - Hose connection diagram Fig.37: X = with T.VIS connection / Y = with 0 connection 430BAL008331EN_4 18.02.2022...
  • Page 73 Parts list - Hose connection diagram Fig.38: With T.VIS connection and actuator Z Fig.39: ATEX variant with actuator Z 430BAL008331EN_4 18.02.2022...
  • Page 74 Parts list - Hose connection diagram Fig.40: View without hood X = Electrical connection / Z = External initiator For assignment of N, Y1, and P refer to the control top operating instructions. 430BAL008331EN_4 18.02.2022...

  • Page 75: Dimension Sheet - Varivent ® Mixproof Valve C

    ® Dimension Sheet - VARIVENT mixproof valve C ® Dimension Sheet - VARIVENT mixproof valve C Fig.41 430BAL008331EN_4 18.02.2022...
  • Page 76 ® Dimension Sheet - VARIVENT mixproof valve C Dimension DN 25 DN 40 DN 50 DN 65 DN 80 DN 100 DN 125 DN 150 90.5 354.5 383.5 377.5 413.5 425.5 432.5 590.5 614.5 Installation dimension X Installation dimension Dia. E Stroke Dimension 1"...

  • Page 77: Appendix

    Appendix Lists Appendix 18.1 Lists 18.1.1 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 78 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.
  • Page 79 Appendix 430BAL008331EN_4 18.02.2022...

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