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Translation of the Original Operating Instructions ® VARIVENT Control Valve A Edition 2016-06-07 English...
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EU Machinery Directive. This document is protected by copy- right. 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. ® The designation VARIVENT is a protected trademark of GEA Tuchenhagen GmbH.
Table of Contents Table of Contents Notes for the Reader ............................6 Binding Character of These Operating Instructions ..................6 Notes on the Illustrations ..........................6 Symbols and Highlighting ..........................7 Abbreviations and Terms ..........................8 Safety ................................10 Safety Note ..............................10 Operator's Duties ............................
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Table of Contents Control Valve with Welding Ends ........................27 Pneumatic Connections ..........................29 Electrical Connections............................. 30 Commissioning..............................31 • Checks Prior to Commissioning ........................31 • Testing the Valve Function Without Product ....................31 • Valve Stroke ..............................32 •...
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Table of Contents Spare Parts Lists – Control Valve Housings....................57 Spare Parts List – Control Valve Actuator A....................72...
Notes for the Reader Notes on the Illustrations Notes for the Reader The present Operating Instructions are part of the user information for the valve. The Operating Instructions contain all the information you need to transport, install, commis- sion, operate and carry out maintenance for the valve. Binding Character of These Operating Instructions These Operating Instructions contain the manufacturer's instructions to the operator of the valve and to all persons who work on or use the valve regarding the procedures to...
Notes for the Reader Symbols and Highlighting Symbols and Highlighting In these Operating Instructions, important information is highlighted by symbols or special formatting. The following examples illustrate the most important types of high- lighting. DANGER Warning: Fatal Injuries. Failure to observe the warning can result in serious damage to health, or even death. ...
Notes for the Reader Abbreviations and Terms IMPORTANT NOTE Warning: Damage to Property. Failure to observe the warning can result in serious damage to the valve or in the vicinity of the valve. The arrow identifies a precautionary measure you have to take to avoid the hazard. Carry out the following steps: = Start of a set of instructions.
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Notes for the Reader Abbreviations and Terms Abbreviation Explanation HNBR Material designation Short designation according to DIN/ISO 1629: Hydrogenated Acrylonitrile Butadiene Rubber Protection class International standard issued by the International Organization for Standardi- zation Unit of measurement of weight [kilogram] Unit of measurement of force [kilonewton] value Flow coefficient [m³/s]...
Safety Operator's Duties Safety Safety Note The valve is operationally reliable. It was built according to state-of-the-art standards. Nevertheless, the valve can pose dangers, especially if • the valve is not used in accordance with its intended use, • the valve is not used correctly, •...
Safety Qualification of Staff Qualification of Staff This section contains information about the qualifications that staff working on the valve must have. Operating and maintenance staff must • have the necessary qualification to carry out their tasks, • be instructed with regard to possible dangers, •...
Safety Supplementary Regulations User groups (Cont.) Staff Qualifications Maintenance staff Adequate instruction as well as sound knowledge of the design and function of the valve. Sound knowledge in the following areas: • Mechanical equipment • Electrical equipment • Pneumatic system Authorization with regard to safety engineering standards to carry out the following tasks: •...
Safety Instructions for the Safe Operation Instructions for the Safe Operation Dangerous situations during the operation can be avoided by safety-conscious and proactive behaviour of the staff. General Principles To ensure the safe operation of the valve the following principles apply: •...
Safety Instructions for the Safe Operation Commissioning/Setup Mode For commissioning, the following principles apply: • Take protective measures against dangerous contact voltages in accordance with pertinent regulations. • The valve must be completely assembled and correctly adjusted. All screw connec- tions must be securely tightened.
Safety Instructions for the Safe Operation Shutting Down For shutting down, the following principles apply: • Switch off the compressed air. • Switch off the valve via the main switch. • Padlock the main switch (if fitted) in the off position to prevent it from being switched back on.
Safety Instructions for the Safe Operation Disassembly For disassembly, the following principles apply: • Only allow qualified staff to disassemble the valve. • Before starting disassembly, the valve must be switched off and secured against being switched back on. Work may only be started once any residual energy has been discharged.
Safety Signage Signage Dangerous points on the valve are indicated by warning signs, prohibition signs and mandatory signs. The signs and notes on the valve must always be legible. Any illegible signs must be replaced immediately. Signs on the valve Sign Meaning General hazard warning...
Safety Residual Risk Residual Risk Hazard Areas Please observe the following notes: • In the event of malfunctions, shut down the valve (disconnect from the power and air supply) and secure it against being used. • When the valve is switching, never reach into the valve housing (391), the lantern (9) or into the valve inlet X (on pneumatic actuators).
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 actuators but return them to GEA Tuchenhagen for proper disposal. Danger of injury Danger presented by moving The operator must exercise caution and prudence.
2006/42/EC Applicable harmonized standards: DIN EN ISO 12100 Authorised representative for compilation Authorised representative - CE of the technical documentation documentation GEA Tuchenhagen GmbH At Industriepark 2-10 21514 Büchen Büchen, 16/02/2015 Franz Bürmann i.V. Matthias Südel Managing Director Team Leader Product Development Operating Instructions ·...
Transport and Storage Storage Transport and Storage Scope of Supply On receipt of the valve check whether • the details on the type plate correspond to the data in the order and delivery docu- ments, • the equipment is complete and all components are in good order. Transport For transport, the following principles apply: •...
The control valves are pressure equipment (without safety function) in the sense of the pressure equipment directive 97/23/EC. They are classified according to Annex II, article 3, section 3. In the event of any deviations, GEA Tuchenhagen GmbH will supply a special Declaration of Conformity.
EC Machinery Direc- tive 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.
Design and Function Design Design and Function Design Designation Diaphragm actuator Actuator spindle Lantern Coupling Valve housing Valve insert with control cone The lantern (3) forms the connection between the actuator housing and the upper valve housing (5). It holds the pneumatic positioner. The coupling (4) connects the valve insert (6) with the actuator spindle (2).
Design and Function Function Function Spring-to-close actuator (Z) The valve is closed in the non-actuated position. In the standard version, the control valve is supplied with a spring-to-close actuator – spring closed in the non-actuated position –, i.e.: If the input signal at the positioner increases, the control valve opens. Spring-to-open actuator (A) The valve is open in the non-actuated position.
Installation and Commissioning Notes on Installation GEA Tuchenhagen recommends that the valve should be installed vertically (actuator up, housing bottom). If the control valve is not installed vertically, the stress on the valve stem seals is higher than when installed vertically. Therefore, regularly check the control valve for leakage.
Installation and Commissioning Control Valve with Welding Ends Control Valve with Welding Ends The valve housing must be dismantled for welding. Requirement: WARNING Spring tension in the valve Danger of injury when releasing the hinged clamps (2, 4) as the released spring preten- sion will suddenly lift the actuator.
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Installation and Commissioning Control Valve with Welding Ends Assemble the valve and depressurize the actuator. The valve disk is lowered. Done NOTE Welding method: we recommend using the TIG welding method. When assembling the valve always replace the housing O-rings to ensure that the valve is tight.
Installation and Commissioning Pneumatic Connections Pneumatic Connections Pneumatic connections Item Explanation Exhaust air outlet with sound absorber at the bottom of the housing Supply air Feedback source Signal pressure on single and double-acting actuators Signal pressure on double-acting actuators The control air pressure may be max.
Installation and Commissioning Electrical Connections 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 oper- ating voltage.
Installation and Commissioning Commissioning Commissioning Checks Prior to Commissioning Before starting commissioning observe the following: Mechanical • Check that all visible screws are firmly secured. • Make sure that there are no foreign materials in the system. • Check that all movable parts of the control valve can move freely. •...
Installation and Commissioning Commissioning Valve Stroke Valve Stroke Table Actuator type/size Valve stroke (mm) MFI-20 MFI-30 MFIII-30 MFIII-60 Tests During the Product Run Carry out the following steps: Check by visual inspection whether – all valve functions are correct and –...
Cleaning and Passivation Cleaning Process Examples Cleaning and Passivation Cleaning All parts in contact with product must be cleaned at regular intervals. Always observe the safety data sheets issued by the cleaning agent manufacturers. Only use cleaning agents which do not cause damage to the seals and the inner parts of the valve. When the pipe is cleaned, the cleaning medium also flows through and cleans the valve hous- ings.
Cleaning and Passivation Cleaning Process Examples Cleaning Parameters The cleaning effect depends on the following factors: • Temperature • Time • Mechanics • Chemicals • Degree of soiling. These factors can be combined in various ways to achieve an optimal cleaning result. Please define the cleaning parameters yourself in accordance with your product and process and regularly verify the result.
Malfunctions Malfunctions In the event of malfunctions immediately deactivate the control 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 Fault in the control system Check the system configuration No compressed air Check the compressed air supply Compressed air pressure...
Maintenance Inspections Maintenance Inspections Between the maintenance periods, the control valves must be checked for leakage and proper function. Product Contact Seals Carry out the following steps: Regularly check the seals. Done Pneumatic Connections Carry out the following steps: Check the operating pressure at the pressure reducing and filter station.
Maintenance Prior to Disassembly Maintenance Intervals To ensure the highest operational reliability of the valves, all wearing parts should be replaced at longer intervals. The actual maintenance intervals can only be determined by the user since they depend on the operating conditions, for instance: •...
Maintenance Disassembly Disassembly This section describes disassembly of various components. No solenoid valve must have been activated electrically or manually. Requirement: WARNING Spring tension in the valve Danger of injury when releasing the hinged clamps (2, 4) as the released spring preten- sion will suddenly lift the actuator.
Maintenance Maintenance Maintenance Cleaning the Valve IMPORTANT NOTE Sealing grooves and contact surfaces are precision areas. Damage to the valve can result in a malfunction. Observe the safety information sheets issued by the detergent manufacturers! Only use detergents which are not aggressive towards the materials of the valve, and which are non-abrasive.
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Maintenance Maintenance Replacing the V-Ring CAUTION The scriber can slip off when the V-ring is removed. Danger of injury! Grip the valve disk in a vice with protected jaws. Unscrew the curved side of the scriber. Carry out the following steps: Put a scriber into the V-ring and take it out.
They have the NSF- H1 (USDA H1) registration. 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.
Maintenance Assembly Assembly Carry out the following steps: Assemble control valve and housing in the reverse order of disassembly. Pay attention that the seat rings are positioned correctly: Soft sealing valve disks: inclined seating surface must face the valve disk (A). Metallically sealing valve disks: pointed edge must face the valve disk (B).
Maintenance Checking the Function Dismantling the Actuator Housing Cover Depending on the type and size of the control valve, prestressed actuators can be Requirement: fitted with a certain number of over-long screws. If this is not the case, at least 2 opposite short screws must be replaced by long ones.
GEA Tuchenhagen accepts unopened actuators and arranges for proper disposal free of charge. Carry out the following steps: Remove the actuator, see “Disassembly“ (page 38). Safely pack the actuator and send it to GEA Tuchenhagen GmbH. Done Operating Instructions · Control Valve A...
Technical Data Type Plate Technical Data Type Plate The type plate clearly identifies the valve. Type plate of Control Valve A The type plate provides the following key data: Key data of the valve Type Control Valve A Serial Serial number Material 1.4404 / cone 1.457/EPDM (FDA) Control air pressure bar/psi...
Technical Data Technical Data Technical Data Technical data: Valve Designation Description Size DN 25 to DN 150 1" to 6" OD 2" to 6" IPS Installation position Any position (if valve and pipe system can drain prop- erly) Material of product contact parts Stainless steel 1.4404 (AISI316L) Product pressure DN 25 to 65 = max.
Technical Data Pipe Ends Resistance of Sealing Materials The resistance of sealing materials depends on the type and temperature of the medium conveyed. The exposure time can adversely affect the service life of the seals. The sealing materials comply with the regulations of FDA 21 CFR 177.2600 or FDA 21 CFR 177.1550.
Technical Data Tools Dimensions for Pipes in DN Metric Outside diameter Wall thickness Inside diam- Outside diameter eter acc. to DIN 11850 Dimensions for Pipes in Inch OD Inch OD Outside diameter Wall thickness Inside diam- Outside diameter eter acc. to BS 4825 Part 1"...
Technical Data Weights List of tools (Cont.) Tools Material no. Hexagon screwdriver a/f 6 408-124 (for hexagon socket screws) Hexagon screwdriver a/f 7 (for hexagon socket screws) Screwdriver, crosstip size 2 406-125 Screwdriver, blade width 3.5 406-103 Open end spanner a/f 8x10 408-032 Open end spanner a/f 13x17 408-036...
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Technical Data Weights Size Weight* [kg] DN 125 approx. 55.1 DN 150, 6" approx. 61.1 *Weights for housing combination L. Other weights on request. Operating Instructions · Control Valve A Edition 2016-06-07...
Spare Parts Lists – Control Valves Control Valve A Spare Parts Lists – Control Valves Control Valve A Control valve with EPDM or FPM valve seat seal Control valve with metallic valve seat seal...
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Spare Parts Lists – Control Valves Control Valve A Spare Parts List Control Valve A Designation Actuator Coupling element Sealing ring Bearing Sealing disk Bearing disk O-ring V-ring Lantern Control cone Seat ring Cover Hinged clamp Hex screw Hex nut Housing, 1 socket(s) Housing connection A * Sealing set, complete...
Spare Parts Lists – Control Valves Control Valve A...W Control Valve A...W Spare parts drawing Control Valve A...W...
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Spare Parts Lists – Control Valves Control Valve A...W Spare Parts List Control Valve A...W Designation Actuator Coupling element Sealing ring Bearing Sealing disk Bearing disk O-ring V-ring Lantern Control cone Seat ring Cover Housing, 1 socket(s) Hinged clamp Hex screw Hex nut * Sealing set, complete ** Valve insert complete without seals...
Spare Parts Lists – Control Valves Control Valve A...X Control Valve A...X Spare parts drawing Control Valve A...X...
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Spare Parts Lists – Control Valves Control Valve A...X Spare Parts List Control Valve A...X Designation Actuator Coupling element Sealing ring Bearing Sealing disk Bearing disk O-ring V-ring Lantern Control cone Seat ring Cover Housing, 1 socket(s) Hinged clamp Hex screw Hex nut * Sealing set, complete ** Valve insert complete without seals...
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For housing combinations AA, AB, AC and AE, an additional bearing is possible for nominal widths DN 125 and 6" IPS. This also applies for housing combinations AW and ABK in the nominal widths from DN 40 and from 2" OD. GEA Mechanical Equipment GEA Tuchenhagen GmbH Am Industriepark 2-10, D-21514 Büchen, Germany...
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EPDM 930-165 * The O-ring (Item 158) is not included in the sterile lock HSP cpl. and must be ordered separately. GEA Mechanical Equipment GEA Tuchenhagen GmbH Am Industriepark 2-10, D-21514 Büchen, Germany Telephone +49 4155 49-0, Telefax +49 4155 49-2423...
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Spare Parts List – Control Valve Actuator A Spare Parts List – Control Valve Actuator A Spare Parts List Actuator A Designation Designation Spindle Washer Sealing ring Hex nut Bush Seal Plain bearing Threaded sleeve Operating Instructions · Control Valve A Edition 2016-06-07...
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Spare Parts List – Control Valve Actuator A Spare Parts List Actuator A (Cont.) Designation Designation O-ring O-ring Reversing sleeve Diaphragm cover O-ring Diaphragm disk Diaphragm cover Hex screw Diaphragm disk Diaphragm Lantern Pressure spring Seal Spring cover Locking screw Seal Threaded sleeve Protection cap...
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