GEA VARIVENT Y Bedienungsanleitung

Hygienic valves

GEA VARIVENT® Valve Type Y

Operating instruction (Translation from the original language)

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These Operating Instructions are the English translation of the original operating

instructions in the sense of the EU Machinery Directive. This document is

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

The designations VARIVENT® and T.VIS® are protected trademarks of GEA

Tuchenhagen GmbH.

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SYMBOLS USED

Danger

Stands for an immediate danger which leads to heavy physical injuries

or to the death.

Warning!

Stands for a possibly dangerous situation which leads to heavy

physical injuries or to the death.

Caution!

Stands for a possibly dangerous situation which could lead to light

physical injuries or to damages to property.

Hint!

Stands for an important tip whose attention is important for the

designated use and function of the device.

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LAYOUT INFORMATION

Bullet points and numbered list characters

Bullet points are used to separate logical contents within a section:

•Bullet point 1

Types of bullet point 1.

•Bullet point 2

Types of bullet point 2.

Numbered list characters are used to separate enumerations within a

descriptive text:

Descriptive text with consecutive numbering:

–Numbered list point 1

–Numbered list point 2

Handling instructions

Handling instructions require you to do something. Several consecutive steps

result in a handling sequence that should be run in the specified order. The

handling sequence can be divided into separate steps.

Handling sequence

1. Handling sequence step 1

–step 1,

–step 2,

–step 3.

2. Handling sequence step 2

The subsequent handling sequence is the expected result:

®Result of the handling sequence.

Individual handling steps

Individual handling steps are marked thus:

–Individual work steps

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TABLE OF CONTENTS

1 General Information 7

1.1 Information on the Document 7

1.1.1 Binding Character of These Operating Instructions 7

1.1.2 Notes on the Illustrations 7

1.1.3 Symbols and Highlighting 7

1.2 Manufacturer address 8

1.3 Contact 8

1.4 EU Declaration of Conformity for Machines 9

2 Safety 10

2.1 Intended use 10

2.1.1 Requirements for operation 10

2.1.2 Pressure equipment directive 10

2.1.3 ATEX directive 10

2.1.4 Improper operating conditions 10

2.2 Operator’s Duty of Care 11

2.3 Subsequent changes 11

2.4 General safety instructions and dangers 12

2.4.1 Principles for safe operation 12

2.4.2 Environmental Protection 12

2.4.3 Electrical Equipment 13

2.5 Supplementary Regulations 13

2.6 Qualification of Staff 13

2.7 Safety equipment 14

2.7.1 Signage 14

2.8 Residual dangers 15

2.9 Hazard Areas 16

3 Description 18

3.1 Design 18

3.2 Functional description 19

3.2.1 Opening and closing the valve 19

3.2.2 Actuator Function 20

3.2.3 Leakage-Proof Shut-Off 20

4 Transport and storage 22

4.1 Storage conditions 22

4.2 Transport 22

4.2.1 Scope of supply 23

5 Technical data 24

5.1 Type plate 24

5.2 Technical data 24

5.3 Cleaning connection 25

5.4 Resistance of Sealing Materials 26

5.5 Pipe ends - General table of measurements 27

5.6 Tool 29

5.7 Lubricants 29

5.8 Weights 29

6 Assembly and installation 31

6.1 Safety instructions 31

6.2 Notes on installation 31

6.3 Control head 31

6.4 Valve with Detachable Pipe Connection Elements 31

6.5 Valve with Welded Ends 32

6.6 Pneumatic connections 33

6.6.1 Air Requirement 33

6.6.2 Establishing Hose Connections 33

6.7 Electrical connection with T.VIS control top 34

7 Start-up 35

7.1 Safety instructions 35

7.2 Notes on commissioning 35

8 Operation and control 36

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8.1 Safety instructions 36

9 Cleaning 37

9.1 Cleaning 37

9.1.1 Cleaning Process Examples 37

9.1.2 Cleaning effect 37

9.1.3 Cleaning the Leakage Cavity 38

9.2 Passivation 38

10 Maintenance 39

10.1 Safety instructions 39

10.2 Inspections 40

10.2.1 Product contact seals 40

10.2.2 Pneumatic connections 40

10.2.3 Electrical connections 40

10.3 Maintenance intervals 41

10.4 Prior to disassembly 41

10.5 Disassembling the Valve 41

10.5.1 Supplemental disc removal 42

10.5.2 Removing the T.VIS M-15 Control Top 43

10.5.3 Removing the T.VIS A-15 Control Top 44

10.5.4 Disconnecting the Valve from the Housing 44

10.5.5 Separating the valve from the drive 45

10.5.6 Separating the valve and the lamp 46

10.5.7 Disassembly of the valve insert. 47

10.6 Maintenance 47

10.6.1 Cleaning the Valve 47

10.6.2 Replacing the V-Ring 48

10.6.3 Lubricating Seals and Threads 50

10.7 Installation 51

10.7.1 Spring 51

10.7.2 Cleaning hood 51

10.7.3 Place the seating ring between the housings 52

10.7.4 Installing the valve into the housing 52

10.7.5 Checking assembly 52

10.7.6 Reconnect the cleaning hose 53

10.7.7 Torques for the Clamps and Clamp Connections 54

10.7.8 Valve Stroke 55

11 Alarms 57

11.1 Malfunctions and remedies 57

12 Decommissioning 58

12.1 Safety instructions 58

12.2 Disposal 58

12.2.1 General notes 58

12.2.2 Valve Actuator Disposal 58

13 Spare parts list - dual seat two-way valve Y 59

14 Appendix 72

14.1 Lists 72

14.1.1 Abbreviations and terms 72

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1 General Information

1.1 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

operator of the product and to all persons who work on or use the product

regarding the procedures to follow.

Carefully read these Operating Instructions before starting any work on or using

the product. Your personal safety and the safety of the product can only be

ensured if you act as described in the Operating Instructions.

Store the Operating Instructions in such a way that they are accessible to the

operator and the operating staff during 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 these Operating Instructions show the product in a simplified

form. The actual design of the product can differ from the illustration. For detailed

views and dimensions of the product please refer to the design documents.

1.1.3 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 highlighting.

Danger

Warning: Fatal Injuries

Failure to observe the warning can result in serious damage to health, or

even death.

► The arrow identifies a precautionary measure you have to take to avoid

the hazard.

Warning: Explosions

Failure to observe the warning can result in severe explosions.

► The arrow identifies a precautionary measure you have to take to avoid

the hazard.

General Information

Information on the Document

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Warning!

Warning: Serious Injuries

Failure to observe the warning can result in serious damage to health.

► The arrow identifies a precautionary measure you have to take to avoid

the hazard.

Caution!

Warning: Injuries

Failure to observe the warning can result in minor or moderate damage to

health.

► The arrow identifies a precautionary measure you have to take to avoid

the hazard.

Notice!

Warning: Damage to Property

Failure to observe the warning can result in 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 instructions.

1. First step in a sequence of operations.

2. 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.

1.2 Manufacturer address

GEA Tuchenhagen GmbH

Am Industriepark 2-10

21514 Büchen

1.3 Contact

Tel.:+49 4155 49-0

Fax:+49 4155 49-2035

[email protected]

www.gea.com

General Information

Manufacturer address

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1.4 EU Declaration of Conformity for Machines

in accordance with the EC Machinery Directive 2006/42/EC, Annex II 1. A

Manufacturer:

GEA Tuchenhagen GmbH

Am Industriepark 2-10

21514 Büchen

We declare under our sole responsibility that the machine

Designation: Valve with actuator

Type: VARIVENT®

conforms with all the relevant provisions of this directive and the

following directives:

Relevant EC directives: 2006/42/EC EC Machinery Directive

Applicable harmonized

standards, in particular:

DIN EN ISO 12100 Safety of Machines -

General design principles

- Risk assessment and

risk reduction

Other applied standards

and technical

specifications:

Remarks: We also declare that the relevant

technical documentation for this

machine has been prepared in

accordance with Annex VII, Part A, and

agree to submit the documentation on

justified request of national authorities

on a data carrier.

Person authorised for compilation and

handover of technical documentation:

Person authorised to compile the

technical file for CE marking

GEA Tuchenhagen GmbH

Am Industriepark 2-10

21514 Büchen

Büchen, 16/02/2015

Franz Bürmann

Managing Director

i.V. Matthias Südel

Senior Director

Product Development

Flow Components

General Information

EU Declaration of Conformity for Machines

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2 Safety

2.1 Intended use

The double-seat change-over valve Y is used for switching liquid flows in pipeline

systems

The medium should preferably flow in the opening direction of the valve disk to

avoid pipe hammers when the valve is opened or closed.

If the valve is used in the opposite direction (valve closing), a damping cylinder

can be used to avoid pressure drops.

Do not install the valve in spring-opening, as this will open when there is a current

or air failure and leads to product mixing.

In a closed pipe system, hydraulic pressure build-up may occur when the valve

switches and result in seal damage.

Hint!

The manufacturer will not accept any liability for damage resulting

from any use of the valve which is not in accordance with the

designated use of the valve. The risk of such misuse lies entirely with

the operator of the facility.

2.1.1 Requirements for operation

The prerequisite for reliable and safe operation of the component is proper

transportation and storage as well as professional installation and assembly.

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 valve is a piece of pressure equipment (without safety function) as defined in

the Pressure Equipment Directive: Directive 2014/68/EG. They are classified

according to Annex II, article 4, section 3. In the event of any deviations, GEA

Tuchenhagen GmbH will supply a specific Declaration of Conformity.

2.1.3 ATEX directive

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”.

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 reliability of the valve cannot be ensured under improper

operating conditions. Therefore avoid improper operating conditions.

Safety

Intended use

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