GEA T.VIS A-15 User manual

Control and feedback systems
GEA T.VIS® A-15
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 T.VIS®, VARIVENT®, ECOVENT®, STERICOM®, VESTA® und
LEFF® are protected trademarks of GEA Tuchenhagen GmbH.
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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 9
1.5 Translated copy of the EU Declaration of Conformity 10
2 Safety 11
2.1 Intended use 11
2.1.1 Requirements for operation 11
2.1.2 Improper operating conditions 11
2.2 Operator’s Duty of Care 11
2.3 Subsequent changes 12
2.4 General safety instructions and dangers 13
2.4.1 Principles for safe operation 13
2.4.2 Environmental Protection 13
2.4.3 Electrical Equipment 13
2.5 Supplementary Regulations 14
2.6 Qualification of personnel 14
2.7 Safety equipment 15
2.7.1 Signs 15
2.8 Residual dangers 16
2.8.1 Electrostatically Endangered Components and Modules 16
2.9 Danger zones 16
3 Description 18
3.1 Functional description 18
3.1.1 Operation Principle 18
3.1.2 Control top without solenoid valves 18
3.1.3 Control Top with Solenoid Valves 18
3.1.4 Control Top with Cap Including Buttons 19
3.1.5 Control Top with Cap without Buttons 20
3.1.6 Function of the Buttons 20
3.1.7 Safety Air Exhaust/Installation Position 21
4 Transport and storage 22
4.1 Storage conditions 22
4.2 Transport 22
4.2.1 Scope of supply 22
5 Technical data 23
5.1 Type plate 23
5.2 Technical data 26
5.3 Specifications for 24V DC version 28
5.4 IO-Link specifications 28
5.5 Specifications for AS-interface 32
5.6 DeviceNet specifications 35
5.7 Accessories 38
5.8 Tool 39
5.9 Lubricants 39
5.10 Equipment 39
6 Assembly and installation 41
6.1 Safety instructions 41
6.2 Establishing Hose Connections 41
6.3 Pneumatic connections 41
6.3.1 Control Top with 1 Solenoid Valve or Without Solenoid Valve 42
6.3.2 Control Top with 2 Solenoid Valves – for Lifting the Valve Disk 43
6.3.3 Control Top with 2 Solenoid Valves – for Lifting the Double Disk, for External Air Connection of an Air/Air
Actuator or for Main Stroke of an External Process Valve 44
6.3.4 Control Top with 3 Solenoid Valves 45
6.4 Electrical connections 46
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6.4.1 Overview 46
6.4.2 Electrical 24 V DC Wiring 47
Plug M12 / 5-pin (24.1) 47
Plug M12 / 8-pin (24.1) 48
Cable gland (24) 49
6.4.3 Electrical 24 V DC Wiring 49
Plug M12 / 5-pin (24.1) 49
6.4.4 Electrical Wiring of AS-Interface 50
Plug M12 / 5-pin (24.1) 50
6.4.5 Electrical DeviceNet Wiring 50
Plug M12 / 5-pin (24.1) 51
External Proximity Switch (170) 51
6.5 Visual Display 52
6.5.1 Illuminated dome 52
6.5.2 Colour Changeover 53
6.5.3 Connection diagram for T.VIS circuit board (bottom) 54
6.6 Mounting the control top to different valves 55
6.6.1 Mounting to a VARIVENT Valve 55
6.6.2 Fitting to FLOWVENT Valve 56
6.6.3 Installation on VARIVENT Double-Seat Valves with Lifting Actuator Type R, T_R, M/2.0, M_0(06), MT/
T_R(08) 57
6.6.4 Mounting to a Butterfly Valve T-smart 8000 58
6.6.5 Mounting to a Butterfly Valve T-smart 7 and a Mixproof Butterfly Valve T-smart 9 59
6.6.6 Mounting to ECOVENT Valves N_ECO and W_ECO 60
6.6.7 Mounting to VESTA Valve H_A/M 61
6.6.8 Mounting to VESTA Valve H_A/M 62
6.6.9 Mounting to Valve N_/E or W_/E or STERICOM Valve 63
6.6.10 Mounting to a T-smart Single-Seat and Double-Seal Valve 64
6.6.11 Fitting to an ASEPTOMAG Valve 65
6.6.12 Replacing Control Tops 66
7 Start-up 67
7.1 Safety notes 67
7.2 Commissioning – Control Top without Solenoid Valves 67
7.3 Commissioning – Control Top with Solenoid Valves 68
7.4 Service Function 70
7.5 Adjust the proximity switch in the lantern - for unbalanced double disks of the valves D, R, Y, B, T_R 70
7.6 Adjusting the Proximity Switch in the lantern of PMO Valve Type M/2.0 73
7.7 Test procedure for Tuchenhagen PMO valves type M / 2.0 75
7.7.1 Purpose 75
7.7.2 Process Overview 75
7.7.3 Hardware Description 75
7.7.4 Test Procedure 1 76
7.7.5 Test Procedure 2 76
8 Operation and control 78
8.1 Safety instructions 78
8.2 Settings in Programming Mode 78
8.3 Operating Overview 80
9 Cleaning 83
9.1 Cleaning 83
10 Maintenance 84
10.1 Safety instructions 84
10.2 Inspections 85
10.3 Maintenance intervals 86
10.4 Removing the Control Top from the Valve 86
10.5 Dismantling the Control Top into its Components 87
10.5.1 Variants of the Control Top 87
10.5.2 Removing the Cap 87
10.5.3 Removing the printed circuit board 87
10.5.4 Install the circuit board 88
10.5.5 Removing the sensor module (9) 88
10.5.6 Removing the logic element NOT (seal pack) 89
10.5.7 Fitting the Logic Element NOT (Sealing Package) 89
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10.5.8 Removing the Solenoid Valves and the Control Plate 90
10.5.9 Removing the pneumatic block 91
10.5.10 Fitting the Pneumatic Block 92
10.6 Install pneumatic connections 93
10.7 Maintenance 94
10.7.1 Replacing the Seals on the Base 94
10.7.2 Maintenance of Sound Absorber, Filter, Non-Return Valve and Exhaust Air Throttle 94
11 Alarms 96
11.1 Malfunctions and remedies 96
11.2 Carrying out a Reset – Back to Default Standard 98
12 Decommissioning 99
12.1 Safety instructions 99
12.2 Disposal 99
12.2.1 General notes 99
13 Spare parts list - control top type T.VIS A-15 100
14 Spare parts list - Switch bar T.VIS A-15 108
15 Dimension sheet - Control top type T.VIS A-15 110
16 Dimension sheet - Switch bar LFT-R T.VIS A-15 for lifted valves 111
17 Appendix 114
17.1 Lists 114
17.1.1 Abbreviations and terms 114
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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.:[phone]
Fax:[phone]
[email protected]
www.gea.com
General Information
Manufacturer address
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1.4 EU Declaration of Conformity
General Information
EU Declaration of Conformity
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1.5 Translated copy of the EU Declaration of Conformity
Manufacturer: GEA Tuchenhagen GmbH
Am Industriepark 2-10
21514 Buchen, Germany
We hereby declare that the devices named below
Model: Control top T.VIS A-15
Type: 24 VDC
AS-i
DeviceNet
IO-Link
due to their design and construction as well as in the versions sold by us, meet the basic safety and health requirements of the
following guideline:
Relevant EC directives: 2014/30/EU EMC
2011/65/EU RoHS
Applicable harmonized standards, in particular: EN 61000-6-2: 2005
EN 61000-6-4: 2007 + A1:2011
EN IEC 62026-1:2019
EN 62026-2:2013
IEC 61131-9:2013
Other applied standards and technical specifications: DIN EN 61326-1 :2013-07
DIN EN 61131-2: 2008
CISPR11:2015
Remarks: •The device type IO link complies with the IO link test specifications (version 1.1.2 - 2014)
•The standards mentioned have been taken into consideration according to the respective field of
application
Person authorised for compilation and handover of technical
documentation:
GEA Tuchenhagen GmbH
CE Documentation Officer
Am Industriepark 2-10
21514 Büchen, Germany
Büchen, 17. August 2020
Franz Bürmann
Managing Director i.V. Matthias Südel Head of Engineering
General Information
Translated copy of the EU Declaration of Conformity
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2 Safety
2.1 Intended use
With the automatic control top T.VIS A-15 all Tuchenhagen and ASEPTOMAG
process valves with VARIVENT adaptation can be connected pneumatically and
electrically. Using the device for any other purpose is considered contrary to its
designated use.
The control top T.VIS A-15 is available as
•position indicator without solenoid valve
•with solenoid valve as control top
The control top T.VIS A-15 is completely installed on the dedicated actuator/
adapter of the process valve by means of a clamp connection. Due to the internal
air guiding system, the control air can pass directly from the control top into the
actuator on suitable process valves. For process valves which do not allow the air
to be guided internally, the control top has a connection option for supplying the
air externally via a hose.
The control top T.VIS A-15 may not be used in areas where ATEX approval is
required.
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 is borne solely by the operating
company.
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 Improper operating conditions
The operational safety of the component can not be guaranteed under improper
operating conditions. Therefore avoid improper operating conditions.
The operation of the component is not permitted if:
•Persons or objects are in the danger zone.
•Safety devices are not working or were removed.
•Malfunctions have been detected on the component.
•Damage to the component has been detected.
•Maintenance intervals have been exceeded.
2.2 Operator’s Duty of Care
Safety
Intended use
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The operating company of the component has a special responsibility for the
proper and safe handling of the component within their company. Only use the
component when it is in perfect operating condition in order to prevent danger to
persons and property.
This operating manual contains information that you and your employees need
for safe operation over the life of the component. Be sure to read these Operating
Instructions carefully and ensure that the measures 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 personnel may work on the component.
•The operating company must authorize personnel to carry out the relevant
tasks.
•Order and cleanliness must be maintained at the work stations and in the
entire area surrounding the component.
•Personnel must wear suitable work clothing and personal protective
equipment. As the operating company must ensure that work clothing and
personal protective equipment are used.
•Inform personnel regarding any properties of the product which might pose a
health risk and the preventative measures to be taken.
•Have a qualified first-aid representative on call during the operation. This
person must be able to initiate any necessary first-aid measures in case of an
emergency.
•Clearly define procedures, competences and responsibilities for those
working in the area of the component. Everybody must know what to do in
case of an emergency. Instruct the staff in this respect at regular intervals.
•The signs on the component must always be complete and easy to read.
Check, clean and replace the signs as necessary at regular intervals.
•Observe the Technical Data specified and the limits of use!
Hint!
Carry out regular checks. This way you can ensure that these
measures are actually observed.
2.3 Subsequent changes
No technical modifications should ever be made to this component. Otherwise
you will have to undergo a new conformity process in accordance with the 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.
Safety
Subsequent changes
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2.4 General safety instructions and dangers
The component is safe to operate. It was built according to state-of-the-art
science and technology.
Nevertheless, dangers can arise from the component, if:
•the component is not used as intended
•the component is used improperly
•the component is operated under impermissible 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 valve the following principles apply:
•The Operating Instructions must be kept ready to hand at the valve's place of
use. They must be complete and in clearly legible form.
•Only use the valve for its intended use.
•The valve must be functional and in good working order. Check the condition
of the valve before starting work and at regular intervals.
•Wear tight-fitting work clothing for all work on the valve.
•Ensure that nobody can get hurt on the parts of the valve.
•Immediately report any faults or noticeable changes on the valve to the
person responsible.
•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.
For environmental protection the following principles apply:
•Substances harmful to the environment must not be discharged into the
ground or the sewage system.
•Always observe the pertinent regulations relating to waste avoidance,
disposal and utilization.
•Substances harmful to the environment must be collected and stored in
suitable containers. Clearly mark the containers.
•Dispose of lubricants as hazardous waste.
2.4.3 Electrical Equipment
For all work on electrical equipment, the following principles apply:
Safety
General safety instructions and dangers
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•Access to electrical equipment should only be allowed to qualified
electricians. Always keep unattended switch cabinets locked.
•Modifications of the control system can affect the safe and reliable operation.
Modifications are only 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 instructions in this documentation the following also has to be
observed:
•pertinent accident prevention regulations,
•generally accepted safety rules,
•national regulations applicable in the country of use,
•work and safety instructions applicable in the facility,
•installation and operating regulations for use in potentially explosive areas.
2.6 Qualification of personnel
This section provides information on how the personnel working on the
component must be trained.
Operating and maintenance personnel must
•have the necessary qualification to carry out their tasks,
•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. When working on explosion-protected equipment observe the
standards DIN EN 60079-14 for gases and DIN EN 50281-1-2 for dusts.
The following minimum qualifications are required:
•Training as a specialist for working independently on the component.
•Adequate instruction to work on the component under the supervision and
guidance of a trained specialist
Each employee must meet the following requirements to work on the component:
•Personal suitability for the respective task.
•Sufficient professional qualification for the respective task.
•Received instruction about the functionality of the component.
•Received instruction about operating sequences on the component.
•Familiar with the safety devices and their function.
Safety
Supplementary Regulations
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•Familiar with these Operating Instructions, especially with the safety
instructions and the information which is relevant for the task on hand.
•Familiar with the basic regulations with regard to occupational health and
safety and accident prevention.
When working with the component, a distinction is made between the following
user groups:
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.
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:
•Setting devices into operation
•Earthing of devices
•Marking of devices
The relevant certificates of qualification must be submitted before
work can be carried out on ATEX certified machines.
2.7 Safety equipment
2.7.1 Signs
Dangerous points on the control top are indicated by warning signs, prohibition
signs and mandatory signs.
The signs and notes on the control top must always be legible. Any illegible signs
must be replaced immediately.
Safety
Safety equipment
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Signs on the control top
Sign Meaning
Fig.1
General hazard warning
Fig.2
Warning Crushing
2.8 Residual dangers
Dangerous situations can be avoided by safety-conscious and proactive
behaviour of the personnel and by wearing personal protective equipment.
Residual dangers on the control top and measures
Danger Cause Measure
Danger to life Inadvertent switch-on of the control top Effectively disconnect all components, effectively prevent
switch-on.
Electric power Observe the following safety rules:
1. Isolate from the power supply.
2. Take appropriate measures to prevent switch on.
3. Test absence of voltage.
4. Earthing and short-circuiting.
5. Cover or safeguard any adjacent live parts.
Damage to property Welding can cause damage to the electronics
or result in data loss.
Do not carry out any welding work in the vicinity of the control
top or make sure electronics are properly protected.
Voltage peaks The permitted voltage ranges of the respective connection
types can be found in chapters 5.3 to 5.6 and must not be
exceeded.
2.8.1 Electrostatically Endangered Components and Modules
The control top contains electronic components that are sensitive to electrostatic
discharge (ESD). Contact with electrostatically-charged persons or objects can
endanger these components. In the worst case they are destroyed immediately
or fail after being put into operation.
To minimize or prevent the possibility of damage resulting from sudden
electrostatic discharge,
•observe the requirements of DIN EN 61340-5-1 and 5-2 and
•take care not to touch the electronic components!
2.9 Danger zones
Please observe the following notes:
Safety
Residual dangers
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•In the event of malfunctions, shut down the control top (disconnect from the
power and air supply) and secure it against being used.
•Before starting any service, maintenance or repair work, disconnect the
control top from the power supply and secure it against inadvertently being
switched back on again.
•Only allow a qualified electrician to carry out any work on the electrical power
supply.
•Check the electrical equipment of the control top at regular intervals.
Immediately remedy loose connections and molten 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.
Safety
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3 Description
3.1 Functional description
3.1.1 Operation Principle
The control top T.VIS A-15 works with a microprocessor that contains the
software for operation, visualization and intelligent position detection. The valve
stroke is detected by a contactless position measuring system integrated in the
control top and the information is supplied to the microprocessor.
Electrostatically endangered components/modules!
•The control top contains electronic components that are sensitive to
electrostatic discharge (ESD). Contact with electrostatically-charged persons
or objects can endanger these components. In the worst case they are
destroyed immediately or fail after being put into operation.
•Observe the requirements of DIN EN 61340-5-1 and 5-2 to minimize or
prevent the possibility of damage resulting from sudden electrostatic
discharge.
•Also take care not to touch electronic components when supply voltage is
present.
•Use ESD-compliant packaging when returning electronic components.
(Contact GEA Tuchenhagen if you have any questions.)
3.1.2 Control top without solenoid valves
The T.VIS A-15 control top without solenoid valves acts as a position indicator.
After programming, it indicates the status of the process valve locally by coloured
LEDs under the illuminated dome so that it is visible over a long distance.
The position feedback signals are supplied to the user in one of the following
ways, depending on the communication method selected:
•24V DC switching output
•AS interface data bit
•DeviceNet data bit
•IO-Link data bit
For programming, the process valve must be moved once to its end positions by
an external solenoid valve.
3.1.3 Control Top with Solenoid Valves
The control top with solenoid valves acts as a control top. The signalling takes
place in the same way as with the control top without solenoid valves. with the
difference being that the solenoid valve integrated in the base is operated in
accordance with the control signals. Depending on the design of the process
valve, up to 3 solenoid valves can be installed in the control top.
In addition, a pneumatic NOT logic element can be used to support the
compressed air of the drive spring.
Description
Functional description
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The control signals are given by the user's process control system or by the
microprocessor in the control top during automatic end position programming.
In manual mode, the main actuator can be controlled using the buttons in the cap
in order to move the process valve to its end positions or by operating the
solenoid valves manually. To do this, use a screwdriver to turn the screw (S) from
0 to 1, see figure.
Fig.3
To assemble or disassemble the valve insert, the main actuator can be controlled
in service mode using the buttons in the cap in order to relieve the spring tension,
which depends on the valve type.
3.1.4 Control Top with Cap Including Buttons
Fig.4: Control top with cap including buttons (standard variant in IP66)
According to protection class IP66 (EN 60529) the control top T.VIS A-15 is
suitable for use in this design and if the electrical and pneumatic connections are
installed correctly.
The control top is operated with the cap closed using the plus/minus buttons.
Operation see .
Description
Functional description
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3.1.5 Control Top with Cap without Buttons
Fig.5: Control Top with Cap without Buttons
Fig.6: Circuit board (A)
According to protection class IP67 and/or 69k (EN 60529) the control top T.VIS
A-15 is suitable for use in this design and if the electrical and pneumatic
connections are installed correctly.
To operate the control top, take off the cap and press the plus/minus buttons
directly on the circuit board (A).
Observe the general instructions regarding ESD protection.
Operation see .
3.1.6 Function of the Buttons
Automatic end position programming and manual mode are generally activated
using the buttons in the cap. For safety reasons, the buttons are only enabled
within a specific time window after activation of the operating voltage. During this
time window, functions can be started. The buttons are automatically locked
again after the allowed time has expired.
During automatic end position programming, the control top autonomously
detects the number of solenoid valves fitted in the control top and carries out the
required programming steps fully automatically.
After end position programming the following is also possible:
•Changing the tolerance ranges manually,
•factory setting to set the attenuation of feedback signals to inactive,
•activating the LEFF function on double-seat valves with lifting actuator.
It is also possible to change the colours for visualizing the end positions using the
"colour variant" function, which also results in the outputs for the feedback signals
being switched.
Description
Functional description
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