GEA VARIVENT 24/7 PMO Operating Instructions Manual
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GEA VARIVENT 24/7 PMO Operating Instructions Manual

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Hygienic valves
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GEA VARIVENT
24/7 PMO valve 2.0, type M/2.0
Operating instruction (Translation from the original language)
430BAL009261EN_2

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Summary of Contents for GEA VARIVENT 24/7 PMO

  • Page 1 Hygienic valves ® GEA VARIVENT 24/7 PMO valve 2.0, type M/2.0 Operating instruction (Translation from the original language) 430BAL009261EN_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: 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 UK Declaration of Conformity for the Delivery of Machines (Safety) dated 2008...
  • Page 4 Control top T.VIS M-15 adjustment 6.7.2 Adjustment of the initiators in the lantern Fitting the sliding piece Set the slider Fitting the proximity switch Set the proximity switch Test procedure according to PMO for valve type M/ 2.0 6.8.1 Test procedure 6.8.2 Hardware description Start-up...
  • Page 5 12.2.1 General notes 12.2.2 Valve Actuator Disposal Spare parts list - mixproof valve M/2.0 with cleaning of lower balancer Spare parts list - mixproof valve M/2.0 without cleaning of lower balancer Spare parts list - Lifting actuator M/2.0 Dimension sheet - mixproof valve type M/ 2.0 Appendix 17.1 Lists...
  • Page 6 430BAL009261EN_2 17.04.2023...

  • 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 430BAL009261EN_2 17.04.2023...

  • Page 9: 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 430BAL009261EN_2 17.04.2023...

  • Page 10: 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 11: Uk Declaration Of Conformity For The Delivery Of Machines (Safety) Dated 2008

    Annex VII, Part A, and undertake to forward this documentation by means of data medium upon justified request by the national authorities. GEA Importer into UK: GEA Mechanical Equipment UK Ltd Westfalia House Old Wolverton Road, Old Wolverton, Milton Keynes...

  • Page 12: 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 13: Improper Operating Conditions

    Safety Operator’s Duty of Care In areas with an explosive atmosphere, only valves suitable for use in such areas may be used. Refer to and observe the additional operating instructions “ATEX version valves”. For details regarding the marking of valves for potentially hazardous areas also refer to the additional operating instructions “ATEX version valves”.

  • Page 14: 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 15: Environmental Protection

    Safety Supplementary Regulations • Never touch the pipes and the valve when these components are hot! Avoid opening the valve unless the process plants have been emptied and depressurised. • Observe the accident prevention regulations and all local regulations. 2.4.2 Environmental Protection Harm to the environment can be avoided by safety-conscious and proactive behaviour of the staff.
  • Page 16 Safety Qualification of personnel • be instructed with regard to possible dangers, • know and observe the safety instructions given in the documentation. Only allow qualified electricians to carry out work on the electrical equipment or have a qualified electrician supervise the work. Only allow specially trained personnel to carry out work on an explosion- protected system.

  • Page 17: 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 18: 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. 430BAL009261EN_2 17.04.2023...

  • Page 19: 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 20 Safety Danger zones Fig.4: Danger zones • In the event of malfunctions, shut down the valve (disconnect from the power and air supply) and secure it against being used. 430BAL009261EN_2 17.04.2023...
  • Page 21 Safety • Never reach into the lantern (9) when the valve is switching. Fingers can be crushed or cut off. • On a spring-closing valve, there is a risk of injury upon releasing the clamp connections (43) as the released spring pretension will suddenly lift the actuator (A).

  • Page 22: Description

    Description Design Description Design Fig.5 The Varivent type M/2.0 is fitted with a radial valve disk and double-disk seal. 430BAL009261EN_2 17.04.2023...
  • Page 23 Description Design Design Designation Actuator T.VIS control top Seal ring Rod guide ring Seal disk O-ring V-ring RA Lantern Valve disk Double-disk Lift actuator Valve housing Sterile lock MMU 430BAL009261EN_2 17.04.2023...

  • Page 24: Functional Description

    Description Functional description Functional description 3.2.1 Leakage-Proof Shut-Off The upper and the lower valve housing of the mixproof valve type M/2.0 are each equipped with a valve seat. The chamber between the valve discs is connected to the periphery via a leakage outlet that is integrated into the lower valve disc. If a fault occurs in the seal, leaking fluid can drain securely t the outside.

  • Page 25: 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 26: 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 27: 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.8 The type plate provides the following key data:...

  • Page 28: 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 - Control top type T.VIS M-15, A-15 -20 to +50 °C (-4 ... +122 °F) Product temperature and operating depending on the sealing material temperature Technical data: Compressed air supply Designation...

  • Page 29: Pipe Ends - General Table Of Measurements

    Pipe ends - General table of measurements Due to the various operating conditions (e.g. duration of operation, switching frequency, type and temperature of product and cleaning agents as well as operating environment), GEA Tuchenhagen recommends the performing of resistance tests by the user. Resistance: •...

  • Page 30: Tool

    Technical data Tool Dimensions for tubes in inch OD Outside diameter acc. Inch OD Outside diameter Wall thickness Inside diameter to BS 4825 0.5" 12.7 1.65 0.75" 19.05 1.65 15.75 1" 25.4 1.65 22.1 1.5" 38.1 1.65 34.8 2" 50.8 1.65 47.5 2.5"...

  • Page 31: Lubricants

    Technical data Lubricants List of tools Tool Material no. Assembly tool pickset 5 pieces 221-007248 Eye bolt T.VIS M14 221-104.98 Box spanner SW 36 408-208 Vice support 470-001 Hose cutter 407-065 Snap ring pliers straight J3 408-483 V-ring insertion tool 229-109.88 Lubricants Lubricants...

  • Page 32: 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 33: Valve With Welded Ends

    Assembly and installation Valve with welded ends Caution! Liquids in pipes Danger of injury due to liquid spraying out ► Therefore, before releasing any pipe connections or hinged clamps: drain the pipe and, if necessary, clean or rinse it. ► Separate the pipe section in which the valve is to be fitted from the rest of the piping system to prevent product entering again.

  • Page 34: Pneumatic Connections

    Assembly and installation Pneumatic connections Fit the housing into place and attach it. Prior to welding, the housing must always be kept closed. Flush the housing with forming gas from the inside to push the oxygen out of the system. Weld the housing into the pipe system;...

  • Page 35: 6.6.2.1 Hose Connection Plan - Mixproof Valves M/2.0 With Control Top T.vis

    Assembly and installation Pneumatic connections Use the hose cutter to cut the pneumatic hoses at a right angle. Establish the hose connections in accordance with the hose connection diagram, see . Push the air hose into the air connector on the control top. Re-open the compressed air supply.

  • Page 36: Electrical Connection With T.vis Control Top

    Assembly and installation Electrical connection with T.VIS control top P = Compressed air supply Y1 = Air connection with external main stroke connection with plug (23) Y2 = Discharge, lift valve disk Y3 = Discharge, lift double-seat disk 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.
  • Page 37 Assembly and installation Electrical connection with T.VIS control top Fig.11 Warning! Risk when actuating the valve, if there is fluid in the valve. Fluids can leak or become mixed in the pipes. ► Ensure that there is no fluid in the valve. Carry out the following steps: Connect the control air line to the control top T.VIS A-15 (connection P).

  • Page 38: 6.7.1.2 Control Top T.vis M-15 Adjustment

    Assembly and installation Electrical connection with T.VIS control top Fig.12 ® Done Hint! Refer to the chapter ‘Troubleshooting’ in the operating instructions for T.VIS A-15, if the LED does not shine green permanently after two minutes. 6.7.1.2 Control top T.VIS M-15 adjustment Non-actuated position (idle position) Requirement: •...
  • Page 39 Assembly and installation Electrical connection with T.VIS control top Fig.13 Release the lock screw (2). Fig.14 Fig.15 Presetting sensor 1 Carry out the following steps: Set the sensor (S1) by turning the adjusting screw (1) clockwise to the switchpoint until the LED (D1) shines green. 430BAL009261EN_2 17.04.2023...
  • Page 40 Assembly and installation Electrical connection with T.VIS control top Set the sensor (S1) by turning the adjusting screw (1) clockwise over the switchpoint until the LED (D1) goes off. Switch setting sensor 1 Carry out the following steps: Set the sensor (S1) by turning the adjusting screw (1) anticlockwise to the switchpoint until the LED (D1) shines green.

  • Page 41: Adjustment Of The Initiators In The Lantern

    Assembly and installation Electrical connection with T.VIS control top Also position sensor (S2) with the adjusting screw (1) by one anticlockwise turn. Tighten the lock screw (2). De-activate the solenoid valve Y1. ® The valve disk moves to the non-actuated position. ®...

  • Page 42: 6.7.2.2 Set The Slider

    Assembly and installation Electrical connection with T.VIS control top Tighten the nut (2) against the slot (4.1). Fig.19 ® Done 6.7.2.2 Set the slider Carry out the following steps: Screw the adjusting mandrel (6) into the sliding piece (1) until it reaches the upper edge of the double-disk (7).

  • Page 43: 6.7.2.3 Fitting The Proximity Switch

    Assembly and installation Electrical connection with T.VIS control top Fig.21 Remove the adjusting mandrel (6) ® Done 6.7.2.3 Fitting the proximity switch Carry out the following steps: Screw in the proximity switch M12 (8) together with the lock nut (11) into the sliding piece through to the double-disk (7).
  • Page 44 Assembly and installation Electrical connection with T.VIS control top Fig.23 Tighten the counter nut (11). Attach the connector (10), that is already connected electrically to the control top (B), on the proximity switch (8) using the union nut M12 (10.1). The LED on the proximity switch (8) must now shine in operating mode.

  • Page 45: Test Procedure According To Pmo For Valve Type M

    Assembly and installation Test procedure according to PMO for valve type M/ 2.0 Test procedure according to PMO for valve type M/ 2.0 Purpose With test procedure 1, a controller checks if the sensor systems which detect and confirm the closed position of the upper and lower seats of the PMO - valve (in accordance with PMO Item 15p (B)- point 1.

  • Page 46: Hardware Description

    Assembly and installation Test procedure according to PMO for valve type M/ 2.0 Test procedure 2 With test procedure 2, the controller checks the interlock of the superordinate control system (PLC), via the manually forced opening of a seat, while a CIP circuit is active in the opposite housing.
  • Page 47 Assembly and installation The closed position of the lower seat is detected by a position measuring system. The correct setting of this system, to detect the closed position of the lower seat, can be found at Section 6.7, Page 36. The sensitivity of the position measuring system is 0.1 mm.

  • Page 48: 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 49: 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 50: 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 51: Cleaning The Leakage Outlet Of The Mixproof Valve Type M/ 2.0

    Cleaning Passivation 9.1.3 Cleaning the leakage outlet of the mixproof valve type M/ 2.0 The leakage outlet is cleaned by lifting the upper or lower valve disk when the respective pipe is cleaned. During this process, cleaning fluid flows past the seals via a metal throttle gap in the leakage outlet and cleans the seal surfaces of the lifted valve disc and the leakage outlet.
  • Page 52 Cleaning Valve blocks are usually excepted from this. Passivation is typically performed using nitric acid (HNO ) at approx. 80 °C (176 °F) at a concentration of 3 % and a contact time of 6 to 8 hours. 430BAL009261EN_2 17.04.2023...

  • Page 53: 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 54: 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 55: Electrical Connections

    Maintenance Maintenance intervals Check the operating pressure at the pressure reducing and filter station. Regularly clean the air filter in the filter station. Check that the air hoses sit firmly in the air connections. Check the lines for kinks and leaks. Check the solenoid valves for proper function.

  • Page 56: Prior To Removal

    Maintenance Prior to removal 10.4 Prior to removal Requirement: • Make sure that during maintenance and servicing work no process is in operation in the area concerned. Carry out the following steps: Drain all pipe system elements that lead to the valve and, if necessary, clean or rinse them.
  • Page 57 Maintenance Disassembly Fig.25 Requirement: 430BAL009261EN_2 17.04.2023...
  • Page 58 Maintenance Disassembly • No solenoid valve must be actuated electrically. • The pneumatic and electrical connections on the plant side can remain on the control top. Warning! Spring tension in the valve Danger of injury when detaching the clamp connection (43) as the released spring pretension will suddenly lift the actuator.
  • Page 59 Maintenance Disassembly Fig.26 Release the Philips screws (25) and take off the cap (7). Control the drive via the manual actuator (Y1). Remove the clamp connection (43) between the housing (406) and the lantern (9). Vent the drive via the manual actuator (Y1), 0 bar. Attach the cap (7) and tighten the Philips screws (7) ®...

  • Page 60: Removing The Control Top

    Maintenance Disassembly 10.5.2 Removing the control top Fig.27 Requirement: • No solenoid valve must be actuated electrically. • The pneumatic and electrical connections on the plant side can remain on the control top. Notice The switch bar is sensitive and must be protected from impact stress.

  • Page 61: Disconnecting The Valve From The Housing

    Maintenance Disassembly Hint! If the eyebolt is used for transport, see Section 4.2, Page 25. Unscrew the sliding piece (1.2) with a slot-head screwdriver from the piston rod (A.4.1). ® Done 10.5.3 Disconnecting the valve from the housing Fig.28 430BAL009261EN_2 17.04.2023...
  • Page 62 Maintenance Disassembly Notice Sensitive parts The surfaces of the valves and double-disks (B) are sealing surfaces and may not be damaged. ► When removing the valve from the pipe (B), take care not to hit the balancer against the housing. Carefully disassemble the valve. Carry out the following steps: Carefully remove the valve insert out of the housing (406).

  • Page 63: Removing The Valve Disk

    Maintenance Disassembly 10.5.4 Removing the valve disk Fig.29 Tools required: • Hex socket key • Socket wrench (hex ring wrench) • Open-ended wrench Carry out the following steps: Release the clamp connection (46). Remove the drive (A) from the lift drive (L1). Lift the locking flange (L) from the lift drive.

  • Page 64: Dismantle Double-Disk

    Maintenance Disassembly Lock the carrier (L2) using the hex ring wrench, size 36. Loosen the valve disk with a open-ended wrench on the spanner flats (15.1) and unscrew it from the carrier (L2) ® The V-ring (94) can now be accessed freely. ®...

  • Page 65: Dismantle Lifting Actuator

    Maintenance Disassembly Insert the mandrel into one of the boreholes (16.1) of the double-disk (16). Release the double-disk (16) with the mandrel and pull out of the lantern. ® The V-ring (7), snap seal (74) and O-ring (72) are now accessible. Remove the seal disk (3) with the bearings / guide ring (2), O-ring (5), seal ring (1) from the double-disk (16).
  • Page 66 Maintenance Disassembly Rated widths up to 2'' OD and DN 50: Release and remove the clamp connection (46), see figure 32. Rated widths from 2.5'' OD and DN 65: Release and unscrew the hex screws (110), see figure 32. Remove the lantern (L9 from the lifting actuator (L1). Fig.33 ®...

  • Page 67: Disassembly Sterile Lock

    Maintenance Disassembly 10.5.7 Disassembly sterile lock Fig.34 Tools required: • Open-ended wrench Carry out the following steps: Unscrew and remove the clamp connection (43). Disconnect the sterile lock (113) from the housing. Take the guide MU (112) from the sterile lock. ®...

  • Page 68: Installation

    Maintenance Installation Carry out the following steps: Unscrew and remove the clamp connection (43). Disconnect the balancer plug (92) from the housing. ® The gasket (65) can now be accessed freely. ® Done 10.6 Installation 430BAL009261EN_2 17.04.2023...

  • Page 69: Tightening Torques

    Maintenance Installation 10.6.1 Tightening torques Tighten the corresponding valve components to the torques specified in the table. Tightening [Nm] [lbft] torques Valve disk 16.2 Clamps on the control top Clamp connection cast half rings 16.2 Bolts 10.6.2 Fitting the lifting actuator Tools required: •...
  • Page 70 Maintenance Installation Fig.36 Rated widths up to 2'' DN: Grease the thread of the clamp connection (43) and attach the lantern (9) on the lift (L1) with the clamp connection (43). Rated widths from 2.5'' DN: Attach the lantern (9) with hex screws (110) on the lifting actuator (L1) with a jaw wrench.
  • Page 71 Maintenance Installation Fig.37 Fit the bush (L3) with O-rings (L12, L13.1) and push onto the mandrel (D1). Place the O-ring (13.2) over the mandrel (D1) onto the bush (L5). Push the driver sleeve (L6) onto the mandrel (D1) and bush (L5), then remove the mandrel (D1).

  • Page 72: Installing The Valve

    Maintenance Installation Fig.38 Place the carrier unit (L2, L5, L6, D2) into the lift actuator (L1) and push until below the lantern (9). Use the snap ring pliers to place the circlip (L7) into the groove of the piston (L1.4). ®...
  • Page 73 Maintenance Installation Fig.39 Fig.40 Equip with double-disk (16) with a snap seal (74), O-ring (72) and V-ring (7). Push the seal disk (3) with the bearings / guide ring (2), O-ring (5) and seal ring (1) onto the double-disk (16). Screw in the double-disk (16) with the driver sleeve (L6).
  • Page 74 Maintenance Installation Fig.41 Affix / hold the driver sleeve (L6) with a hook wrench at (Z). Fig.42 Insert the mandrel into one of the boreholes (16.1) and tighten the double-disk (16). Position and affix the wrench to the hex of the carrier (L2). 430BAL009261EN_2 17.04.2023...
  • Page 75 Maintenance Installation Fig.43 Push the valve disk (15) into the double-disk (16) and tighten with the jaw wrench on the wrench surface (15.1). ! Observe torques, see table “Tightening torques" Section 10.6.1, Page 69 430BAL009261EN_2 17.04.2023...
  • Page 76 Maintenance Installation Fig.44 Insert the locking flange (L3) into the lift drive (L1). Push drive (A) with piston rod into the lift drive (L1). Grease the thread of the clamp connections (46) and install. ® Ensure that the clamp connection (43) is firmly installed. ®...

  • Page 77: Mount The Switch Bar And Control Top

    Maintenance Installation 10.6.4 Mount the switch bar and control top Fig.45 Caution! The switch bar is sensitive and must be protected from impact stress. Damage to switch bar. ► Protect the switch bar against impact stress. Hint! Mount the switching bar (1) only after installing the valve disk (15). Tools required: •...

  • Page 78: Assembly Balancer Plug

    Maintenance Installation 10.6.5 Assembly balancer plug Fig.46 Tools required: • Hex socket key Carry out the following steps: Insert the seal ring (65) into the housing. Position the balancer plug (92) into the housing. Grease the thread of the clamp connections (43) and install. ®...

  • Page 79: Installing The Valve In The Housing

    Maintenance Installation • Hex socket key Carry out the following steps: Fit the sterile lock (113) with O-ring (111) and guide MU (112). Insert the seal ring (65) into the housing. Position the sterile lock (113) into the housing. Grease the thread of the clamp connections (43) and install. ®...
  • Page 80 Maintenance Installation Fig.48 Requirement: • No solenoid valve must be actuated electrically. • The pneumatic and electrical connections on the plant side can remain on the control top. 430BAL009261EN_2 17.04.2023...
  • Page 81 Maintenance Installation Notice Sensitive parts The surfaces of the valves and double-disks are sealing surfaces and may not be damaged. ► Carefully lower the valve into the housing. Tools required: • Philips screwdriver • Slotted screwdriver Carry out the following steps: Guide the valve insert (A) carefully into the housing.

  • Page 82: Checking The Function

    Maintenance Maintenance 10.6.8 Checking the function Valve stroke Valve strokes Total stroke Lift stroke Size Double-disk Valve disk Inch OD 1.5" 2" 2.5" 3" 4" 6" 10.6.8.1 Checking the valve stroke Carry out the following steps: Control the lift stroke via the manual actuator (Y1). Check the stroke of the valve (c) in accordance with the table ‘Valve stroke’.

  • Page 83: Replacing Seals

    Maintenance Maintenance Notice The valve disk (15), the double-disk (16), the housing and valve seat are precision parts. Damage to these parts can result in malfunction. ► Handle the valve with care! Notice Sensitive valve parts Damage to the valve parts can result in malfunction. ►...
  • Page 84 Maintenance Maintenance Fig.49: V-ring insertion tool • V-ring insertion tool • Vice support Carry out the following steps: Put a tool from the pickset into the V-ring RA and take it out. Fig.50 Before fitting, wet V-ring RA on the side not in contact with product (rear side). Pay attention that water does not drip into the V-ring groove on the valve disc.

  • Page 85: 10.7.2.2 Replace More Seals

    Maintenance Maintenance Hint! Used seals must not be used again, since the proper function of the seal can then no longer be ensured. 10.7.2.2 Replace more seals Fig.53 10.7.2.3 Lubricating seals and threads 430BAL009261EN_2 17.04.2023...
  • Page 86 Maintenance Maintenance Caution! Damage to seals and threads Stainless steel threads tend to seize and cold weld and must be greased. Damage to seals and threads can result in malfunction. ► Ensure that an adequate film of lubricant is applied. No grease residues must be visible once the valve has been assembled completely.
  • Page 87 Rivolta F.L.G. MD-2 can be ordered from GEA Tuchenhagen. Using other types of grease can result in malfunctions or in premature seal failure.

  • Page 88: 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 precautions. Fault Cause Remedy Check the system Fault in the controller...

  • Page 89: 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 430BAL009261EN_2 17.04.2023...

  • Page 90: Spare Parts List - Mixproof Valve M/2.0 With Cleaning Of Lower Balancer

    Spare parts list - mixproof valve M/2.0 with cleaning of lower balancer Spare parts list - mixproof valve M/2.0 with cleaning of lower balancer Fig.55: Z = ** relevant for variant with cleaning connection up to 2015 for 1.5'' to 4'’ and up to 2023 for DN 150/6'' OD Fig.56 430BAL009261EN_2...
  • Page 91 Spare parts list - mixproof valve M/2.0 with cleaning of lower balancer Item Designation Material 1.5" OD 2" OD 2.5" OD Sealing set MS complete EPDM 221-004538 221-004538 221-004547 221-004539 221-004539 221-004548 HNBR 221-004540 221-004540 221-004549 Seal ring EPDM 924-305 924-305 924-296 924-307...
  • Page 92 Spare parts list - mixproof valve M/2.0 with cleaning of lower balancer Item Designation Material 1.5" OD 2" OD 2.5" OD 404.2 Housing MB/2.0-180 221-725.11 221-725.14 221-725.17 404.3 Housing MB/2.0-270 221-725.12 221-725.15 221-725.18 Housing MC/2.0 221-726.04 221-726.05 221-726.06 Housing ME/2.0 221-723.04 221-723.05 221-723.06...
  • Page 93 Spare parts list - mixproof valve M/2.0 with cleaning of lower balancer Item Designation Material 3" OD 4" OD 6" OD HNBR 221-365.20 221-365.19 Hex head screw 901-043 901-043 901-089 111* O-ring EPDM 930-148 930-923 930-925 Guide MU 221-696.08 221-696.09 221-696.11 Sterile lock MMU 1.4305...
  • Page 94 Spare parts list - mixproof valve M/2.0 with cleaning of lower balancer Sealing sets for mixproof valve M/2.0 with cleaning connection Item Pcs. Designation Material 1.5" OD 2" OD 2.5" OD 3" OD 4" OD 6" OD Seal ring Ø EPDM 924-305 924-305...

  • Page 95: Spare Parts List - Mixproof Valve M/2.0 Without Cleaning Of Lower Balancer

    Spare parts list - mixproof valve M/2.0 without cleaning of lower balancer Spare parts list - mixproof valve M/2.0 without cleaning of lower balancer Fig.57 Fig.58 430BAL009261EN_2 17.04.2023...
  • Page 96 Spare parts list - mixproof valve M/2.0 without cleaning of lower balancer Item Designation Material 1.5" OD 2" OD 2.5" OD Sealing set MS complete EPDM 221-004616 221-004616 221-004547 221-004617 221-004617 221-004548 HNBR 221-004618 221-004618 221-004549 Seal ring EPDM 924-305 924-305 924-296 924-307...
  • Page 97 Spare parts list - mixproof valve M/2.0 without cleaning of lower balancer Item Designation Material 1.5" OD 2" OD 2.5" OD 404.3 Housing MB/2.0-270 221-725.12 221-725.15 221-725.18 Housing MC/2.0 221-726.04 221-726.05 221-726.06 Housing ME/2.0 221-723.04 221-723.05 221-723.06 Actuator 221-119.02 221-119.02 221-119.10 ®...
  • Page 98 Spare parts list - mixproof valve M/2.0 without cleaning of lower balancer Item Designation Material 3" OD 4" OD 6" OD 221-365.11 221-365.12 221-365.17 HNBR 221-365.20 221-365.19 Hex head screw 901-043 901-043 901-089 Proximity switch 1.4404 505-098 505-098 505-098 Sliding piece 1.4301 221-002919 221-002919...
  • Page 99 Spare parts list - mixproof valve M/2.0 without cleaning of lower balancer Sealing sets for mixproof valve M/ 2.0 with cleaning connection Item Pcs. Designation Material 1.5" OD 2" OD 2.5" OD 3" OD 4" OD 6" OD Seal ring Ø...

  • Page 100: Spare Parts List - Lifting Actuator

    Spare parts list - Lifting actuator M/2.0 Spare parts list - Lifting actuator M/2.0 Fig.59 430BAL009261EN_2 17.04.2023...
  • Page 101 Spare parts list - Lifting actuator M/2.0 Item Designation Material 1.5" OD 2" OD 2.5" OD Lifting actuator M/2.0 compl. BLMN35 BLMN48 CLMN56 221-609.46 221-609.47 221-609.45 Lifting actuator LFT-M/2.0 221-605.23 221-605.23 221-605.22 Carrier LFT-M/2.0 221-622.16 221-622.16 221-622.15 Sealing flange LFT-R 200 EN AW-6083 T6 221-613.13 221-613.01...
  • Page 102 Spare parts list - Lifting actuator M/2.0 Item Designation Material 3" OD 4" OD 6" OD Plain bearing IGLIDUR-G 704-043 704-043 704-038 Plain bearing IGLIDUR-G 704-041 704-041 704-042 O-ring 930-026 930-026 930-035 Plain bearing IGLIDUR-G 704-015 704-015 704-015 O-ring 930-850 930-850 930-107 O-ring...

  • Page 103: Dimension Sheet - Mixproof Valve Type M

    Dimension sheet - mixproof valve type M/ 2.0 Dimension sheet - mixproof valve type M/ 2.0 Fig.60 430BAL009261EN_2 17.04.2023...
  • Page 104 Dimension sheet - mixproof valve type M/ 2.0 1"OD 1.5"OD 2"OD 2.5"OD 3"OD 4"OD 6"OD [mm] 71.5 127.5 [mm] Tube ID Ø [mm] 25.4 x 1.65 38.1 x 1.6 50.8 x 1.6 63.5 x 1.6 76.2 x 1.6 101.6 x 2.1 152.4 x 2.7 [mm] [mm]...

  • Page 105: Appendix Lists

    Appendix Lists Appendix 17.1 Lists 17.1.1 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 106 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 107 Appendix 430BAL009261EN_2 17.04.2023...

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