GEA VARIVENT D Series, Operating Instruction

Page 1: ...Hygienic valves GEA VARIVENT Valve Type D Operating instruction Translation from the original language 430BAL008360EN_5...

Page 2: ...otected 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 permis...

Page 3: ...y Regulations 12 2 6 Qualification of personnel 12 2 7 Safety equipment 14 2 7 1 Signage 14 2 8 Residual dangers 15 2 9 Danger zones 16 3 Description 18 3 1 Design 18 3 2 Functional description 19 3 2...

Page 4: ...Valve 45 10 6 2 Replacing the V Ring 46 10 6 3 Lubricating seals and threads 48 10 7 Installation 49 10 7 1 Spring 49 10 7 2 Cleaning hood 49 10 7 3 Place the seating ring between the housings 50 10 7...

Page 5: ...the entire life cycle of the product When the location is changed or the product is sold make sure you also provide the Operating Instructions 1 1 2 Notes on the Illustrations The illustrations in the...

Page 6: ...n serious damage to the component or in the vicinity of the component The arrow identifies a precautionary measure you have to take to avoid the hazard Carry out the following steps Start of a set of...

Page 7: ...ation 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 430BAL008360EN_5...

Page 8: ...declaration will become invalid if any alterations are made to the machine which have not been agreed with us We also declare that the relevant technical documentation for this machine has been prepar...

Page 9: ...sembly Operating the unit within the limits of its designated use also involves adhering to the operating inspection and maintenance instructions 2 1 2 Pressure equipment directive The component is a...

Page 10: ...described here are observed The operator s duty of care includes planning the necessary safety measures and monitoring that these measures are observed The following principles apply Only qualified pe...

Page 11: ...rmissible conditions 2 4 1 Principles for safe operation Dangerous situations during operation can be avoided by safety conscious and proactive behaviour of the staff To ensure safe operation of the v...

Page 12: ...permitted with the express permission of the manufacturer After completion of all work check that the protective devices are fully functional 2 5 Supplementary Regulations In addition to the instructi...

Page 13: ...the component Personal suitability for the respective task Sufficient professional qualification for the respective task Received instruction about the functionality of the component Received instruct...

Page 14: ...s Mechanical equipment Electrical equipment Pneumatic system Authorization with regard to safety engineering standards to carry out the following tasks Setting devices into operation Earthing of devic...

Page 15: ...e Inadvertent switch on of the valve Effectively disconnect all components effectively prevent switch on Electric power Observe the following safety rules 1 Isolate from the power supply 2 Take approp...

Page 16: ...materials with properties which are harmful to the environment For all work Collect lubricants in suitable containers Dispose of lubricants in accordance with the pertinent regulations 2 9 Danger zone...

Page 17: ...ten cables If work on live parts cannot be avoided call in a second person who can operate the main switch in case of an emergency The housing sockets 402 have very sharp edges When transporting and i...

Page 18: ...ignation A Actuator B T VIS control top 1 Sealing ring 2 Bearing 3 Sealing disk 4 Bearing disk 9 Lantern 11 Cleaning hood 15 Valve disk 16 Double disk 22 Air connection 24 Electrical connection Descri...

Page 19: ...the leakage drain system via a separate connection 11 1 arranged in the lantern The cleaning fluid is sprayed into a cavity between both of the valve discs over a ring nozzle 74 and flows out through...

Page 20: ...Fig 7 Description 430BAL008360EN_5 20 07 02 2022...

Page 21: ...that any ice crystals formed by condensation water can melt 4 2 Transport Fig 8 For transport the following principles apply When transporting the valve be sure to unscrew the control top and the swit...

Page 22: ...ircumstances should anyone stand under a suspended load Take care when transporting the valve Do not grip sensitive parts of the unit to lift or push the unit or to support yourself Avoid putting the...

Page 23: ...ical data Refer to the following tables for the key technical data of the valve Technical data Valve Designation Description Size DN 25 to DN 150 1 to 6 OD 2 to 6 IPS Material of product contact parts...

Page 24: ...ntrol air pressure 6 bar max 8 bar Control air acc to ISO 8573 1 Solid particle content Quality class 6 max particle size 5 m max particle density 5 mg m3 Water content Quality class 4 max dew point 3...

Page 25: ...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 The maximum operating temperature i...

Page 26: ...s hydrocarbons Product with a fat content of max 35 Product with a fat content of more than 35 Oils Sealing materials General temperature resistance EPDM 40 135 C 40 275 F FKM 10 200 C 14 392 F HNBR 2...

Page 27: ...tside diameter Wall thickness Inside diameter Outside diameter acc to BS 4825 0 5 12 7 1 65 9 4 x 0 75 19 05 1 65 15 75 x 1 25 4 1 65 22 1 x 1 5 38 1 1 65 34 8 x 2 50 8 1 65 47 5 x 2 5 63 5 1 65 60 2...

Page 28: ...en 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 Installation mandrel up to DN 50 2 OD IPS 229 109 01 Installation m...

Page 29: ...Size Weight kg DN 80 19 DN 100 27 DN 125 58 DN 150 66 OD 1 8 OD 1 5 11 OD 2 11 OD 2 5 18 OD 3 18 OD 4 27 OD 6 67 IPS 2 12 IPS 3 19 IPS 4 28 IPS 6 68 Technical data 430BAL008360EN_5 07 02 2022 29...

Page 30: ...ertently being switched on 6 2 Notes on installation The installation position of the valve is upright Care must be taken to ensure that the valve housing and the pipe system can drain properly To pre...

Page 31: ...g can warp during welding To avoid welding distortions always seal the housing before welding Carry out the following steps 1 Release the spring tension 2 Remove the valve insert see chapter Section 1...

Page 32: ...1343 Use A 98 0 16 DN 25 DN 100 1 4 OD 2 4 IPS B 109 0 26 C 135 0 42 D 170 0 70 E 210 1 10 R 170 1 60 S 210 2 00 T 210 2 20 D 6 170 1 30 DN 125 DN 150 6 OD 6 IPS E 6 210 2 00 S 6 261 3 20 T 6 210 4 0...

Page 33: ...Explosive gases or dusts An explosion can result in serious personal injury or death Observe the installation and operating regulations for use in potentially explosive areas Carry out the following...

Page 34: ...ing into Operation For commissioning the following principles apply Only allow properly qualified staff to set the valve into operation Establish all connections correctly The safety devices for the v...

Page 35: ...rvals All guards and hoods must be fitted as intended The installation location of the component must always be properly ventilated Structural changes to the component are not permitted Report any cha...

Page 36: ...ing Parameters in Dairy Operations Example of a two phase cleaning process Sodium hydroxide solution and sodium hydroxide based combination products in concentrations from 0 5 to 2 5 at 75 C 167 F to...

Page 37: ...ppropriate systems for cleaning the valve should be regularly used to that an optimal cleanliness is ensured and any damage to the valve is prevented The spray cleaner cleans the leakage cavity while...

Page 38: ...to the maintenance or repair work going on Do not climb on the component Use suitable access aids and working platforms Wear suitable protective clothing Only use suitable and undamaged tools to carr...

Page 39: ...steps 1 Regularly check Stem seal between upper housing and lantern V ring in the valve disks O rings between the valve housings Done 10 2 2 Pneumatic connections Carry out the following steps 1 Check...

Page 40: ...ions for instance daily period of use switching frequency type and temperature of the product type and temperature of the cleaning solution ambient conditions Maintenance Intervals Applications Mainte...

Page 41: ...Removing the Control Top Fig 10 Prerequisite No solenoid valve must be actuated electrically or manually The pneumatic and electrical connections on the plant side can remain on the control top Cautio...

Page 42: ...ng steps 1 Remove the cleaning connection 30 2 Air out the valve upon connection 22 3 Air out the valve upon connection 22 The valve discs 15 16 are raised 4 Remove the snap ring 43 1 5 Interrupt the...

Page 43: ...Done 10 5 3 Separating the valve from the drive Fig 12 Notice The piston rod S and the shaft 16 of the double disc are precision parts Damage to these parts can result in a malfunction Secure the lamp...

Page 44: ...ly remove the valve insert out of the lamp 9 Carry out the following steps 1 Pull the valve insert out of the lamp 9 2 Secure the valve disc on the borehole 15 1 with the appropriate mounting device F...

Page 45: ...out the following steps 1 Unscrew the clamp connection 43 on the valve housing 2 Remove the sealing ring 1 sealing washer 3 bearing washer 4 and bearings 2 Done 10 6 Maintenance 10 6 1 Cleaning the Va...

Page 46: ...unction Observe the safety information sheets issued by the detergent manufacturers Only use detergents which are non abrasive and not aggressive towards stainless steel Use only cleaning mediums whic...

Page 47: ...k in a vice with protected jaws Unscrew the curved side of the scriber Carry out the following steps 1 Put a scriber into the V ring and take it out Fig 19 2 Before fitting wet the V ring on the side...

Page 48: ...ls 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 For product contact seals...

Page 49: ...se products can be obtained from GEA Tuchenhagen if required A thin film of grease is required on the seals to ensure the proper function of the fittings It reduces friction and extends the service li...

Page 50: ...perly placed between the housings so that the arrow later properly displays the direction of the drive when the valve is completely assembled 10 7 4 Installing the Valve in the Housing Fig 25 Notice V...

Page 51: ...steps 1 Cut off the cleaning with the hose cutter at a right angle 2 Place insertion sleeves up to the edge of the hose 3 Grease the threads and cone of the fitting as well as the sealing disc and th...

Page 52: ...does not turn Checking Carry out the following steps 1 Loosen the union nut 2 Make sure that there is a visible connection 3 in the space before the 1 Make sure the disc fits Fig 28 It will not hurt i...

Page 53: ...alve stroke Carry out the following steps 1 Actuate the valve with compressed air 2 Check the stroke of the valve in accordance with Page 53 The stroke is set Strokes Depending on Size Valve Stroke Va...

Page 54: ...Valve Stroke Valve size Valve stroke mm 2 30 3 30 4 30 6 60 Maintenance 430BAL008360EN_5 54 07 02 2022...

Page 55: ...ault in the electrical system Check actuation external controller and routing of electrical lines Solenoid valve defective Replace the solenoid valve Valve does not close Dirt foreign material between...

Page 56: ...at the place of installation The component consists of the following materials Metals Synthetic materials Electronic parts Lubricants containing oil and grease Separate the different materials and di...

Page 57: ...13 Spare parts list mixproof valve D Fig 29 Spare Parts Drawing Fig 30 Housing combinations Spare parts list mixproof valve D 430BAL008360EN_5 07 02 2022 57...

Page 58: ...32 032 932 032 932 034 HNBR 932 085 932 084 932 084 932 089 9 Lantern 1 4301 221 121 01 221 121 02 221 121 02 221 121 03 11 Cleaning hood 1 4301 221 146 04 221 146 01 221 146 01 221 146 01 12 Support...

Page 59: ...01 221 334 02 401 Housing V1 1 4404 221 101 19 221 101 21 221 101 22 221 101 05 402 Housing V2 1 4404 221 102 41 221 102 43 221 102 44 221 102 05 A Actuator VARIVENT See spare parts list dimensions s...

Page 60: ...038 932 063 932 044 HNBR 932 089 932 099 9 Lantern 1 4301 221 121 03 221 121 04 221 121 06 221 121 22 11 Cleaning hood 1 4301 221 146 01 221 146 01 221 146 02 221 146 02 12 Support bracket 1 4301 221...

Page 61: ...34 03 221 334 03 401 Housing V1 1 4404 221 101 06 221 101 07 221 101 18 221 101 66 402 Housing V2 1 4404 221 102 06 221 102 07 221 102 29 221 102 09 A Actuator VARIVENT See parts list dimensions sheet...

Page 62: ...2 034 932 038 HNBR 932 085 932 084 932 084 932 089 932 089 932 099 9 Lantern 1 4301 221 121 01 221 121 07 221 121 07 221 121 08 221 121 08 221 121 09 11 Cleaning hood 1 4301 221 146 04 221 146 01 221...

Page 63: ...34 01 221 334 02 221 334 02 221 334 02 401 Housing V1 1 4404 221 101 27 221 101 28 221 101 29 221 101 30 221 101 31 221 101 32 402 Housing V2 1 4404 221 102 52 221 102 53 221 102 54 221 102 55 221 102...

Page 64: ...034 932 038 932 044 HNBR 932 084 932 089 932 099 9 Lantern 1 4301 221 121 12 221 121 10 221 121 11 221 121 05 11 Cleaning hood 1 4301 221 146 01 221 146 01 221 146 01 221 146 02 12 Support bracket 1 4...

Page 65: ...02 221 334 03 401 Housing V1 1 4404 221 101 37 221 101 35 221 101 36 221 101 17 402 Housing V2 1 4404 221 102 62 221 102 59 221 102 60 221 102 17 A Actuator VARIVENT See spare parts list dimensions s...

Page 66: ...KM 930 164 930 164 930 244 930 244 930 357 930 357 HNBR 930 639 930 639 930 640 930 640 23 1 O ring 30 x 3 38 x 3 38 x 3 38 x 3 56 x 3 56 x 3 EPDM 930 525 930 246 930 246 930 246 930 246 930 266 FKM 9...

Page 67: ...14 Spare parts list double seat valve D_V Longstroke Fig 31 Spare parts list double seat valve D_V Longstroke 430BAL008360EN_5 07 02 2022 67...

Page 68: ...221 148 03 15 Valve disk 1 4404 221 111 88 221 111 87 16 Double disk 1 4404 221 238 39 221 238 38 18 Compression spring 1 4310 931 093 931 093 19 Guide ring Turcite T51 935 024 935 024 22 O ring EPDM...

Page 69: ...15 Spare parts list double seat valve D_VC with lifting actuator longstroke Fig 32 Spare parts list double seat valve D_VC with lifting actuator longstroke 430BAL008360EN_5 07 02 2022 69...

Page 70: ...045 FKM 932 063 932 044 9 Lantern 1 4301 221 236 06 221 236 05 15 Valve disk 1 4404 221 111 88 221 111 87 16 Double disk 1 4404 221 238 39 221 238 38 29 O ring NBR 930 035 930 035 43 Clamp connection...

Page 71: ...16 Spare parts list double seat valve D_VL with lifting actuator longstroke Fig 33 Spare parts list double seat valve D_VL with lifting actuator longstroke 430BAL008360EN_5 07 02 2022 71...

Page 72: ...05 15 Valve disk 1 4404 221 111 88 221 111 87 16 Double disk 1 4404 221 238 39 221 238 38 22 O ring EPDM 930 356 930 356 FKM 930 357 930 357 29 O ring NBR 930 035 930 035 30 Cap nut 1 4571 933 482 933...

Page 73: ...17 Dimension sheet VARIVENT double seat valve D Fig 34 Dimension sheet VARIVENT double seat valve D 430BAL008360EN_5 07 02 2022 73...

Page 74: ...65 46 0 90 83 99 292 421 646 18 0 8 OD 1 5 38 1 1 65 59 0 90 94 110 337 466 691 22 0 11 OD 2 50 8 1 65 71 5 90 100 110 343 472 697 30 5 11 OD 2 5 63 5 1 65 90 0 125 128 135 356 485 835 31 0 18 OD 3 76...

Page 75: ...Short designation according to DIN ISO 1629 Ethylene Propylene Diene Rubber F Unit of measurement of temperature degree Fahrenheit FKM Material designation short designation according to DIN ISO 1629...

Page 76: ...P Self learning installation During commissioning and maintenance the SET UP procedure carries out all the necessary settings for the generation of messages AF Specifications for the size of spanners...

Page 77: ...Appendix 430BAL008360EN_5 07 02 2022 77...

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