GEA VARIVENT Y Manual de usuario
Hygienic valves
GEA VARIVENT® Valve Type Y
Operating instruction (Translation from the original language)
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COPYRIGHT
These Operating Instructions are the English translation of the original operating
instructions in the sense of the 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
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
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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