GEA T.VIS P-15 User manual

Control and feedback systems
GEA T.VIS® P-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.
We kindly request that you answer a few short questions about these instruction
manual. Use the following QR code or link to access the questionnaire:
https://www.ntgt.de/ra/s.aspx?s=367112X57707125X58087
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TABLE OF CONTENTS
1 General Information 5
1.1 Information on the Document 5
1.1.1 Binding Character of These Operating Instructions 5
1.1.2 Notes on the Illustrations 5
1.1.3 Symbols and Highlighting 5
1.2 Manufacturer address 6
1.3 Contact 6
2 Safety 7
2.1 Intended use 7
2.1.1 Requirements for operation 7
2.1.2 Improper operating conditions 7
2.2 Operator’s Duty of Care 7
2.3 Subsequent changes 8
2.4 IP Protection Classes 8
2.5 General safety instructions and dangers 9
2.5.1 Principles for safe operation 9
2.5.2 Environmental Protection 10
2.5.3 Electrical Equipment 10
2.6 Supplementary Regulations 10
2.7 Qualification of personnel 11
2.8 Safety equipment 12
2.8.1 Signs 12
2.9 Residual dangers 13
2.9.1 Electrostatically Endangered Components and Modules 13
2.10 Danger zones 14
3 Description 15
3.1 Functional description 15
3.1.1 Operation Principle 15
3.1.2 Control Top with Cap Including Buttons 16
3.1.3 Control Top with Cap without Buttons 16
3.1.4 Function of the Buttons 17
3.1.5 Safety Air Exhaust/Installation Position 17
4 Transport and storage 18
4.1 Storage conditions 18
4.2 Transport 18
4.2.1 Scope of supply 18
5 Technical data 19
5.1 Type plate 19
5.2 Technical data 20
5.3 Specifications for 24V DC Version 22
5.4 Accessories 23
5.5 Tool 23
5.6 Lubricants 23
5.7 Equipment 24
6 Assembly and installation 25
6.1 Safety instructions 25
6.2 Establishing Hose Connections 25
6.3 Pneumatic connections 25
6.3.1 Control Top with Solenoid Valves 26
6.4 Electrical connections 27
6.4.1 Overview 27
6.4.2 Electrical 24 V DC Wiring 28
Connector M12 / 5-pin, A-coded (24) 28
Connector M12/5-pin, B-coded (50) 29
6.5 Visual Display 29
6.5.1 Illuminated dome 30
6.5.2 Colour Changeover 30
6.5.3 Connection Diagram for T.VIS Circuit Board (Bottom) 31
6.6 Mounting the Control Top to Different Valves 31
6.6.1 Mounting to VARIVENT Shut-Off and Divert Valves 32
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6.6.2 Mounting to a Butterfly Valve T-smart 8000 32
6.6.3 Mounting to a Butterfly Valve T-smart 7 and a Mixproof Butterfly Valve T-smart 9 33
6.6.4 Mounting to ECOVENT Valves N_ECO and W_ECO 34
6.6.5 Mounting to VESTA Valve H_A/M 34
6.6.6 Mounting to VESTA Valve H_A 35
6.6.7 Fitting to an ASEPTOMAG Valve 36
6.6.8 Replacing Control Tops 37
7 Start-up 38
7.1 Safety precautions 38
7.2 Commissioning – Control Top with Solenoid Valves 38
7.3 Service Function 40
8 Operation and control 41
8.1 Safety instructions 41
8.2 Operating Overview 42
9 Cleaning 44
9.1 Cleaning 44
10 Maintenance 45
10.1 Safety precautions 45
10.2 Inspections 46
10.3 Removing the Control Top from the Valve 47
10.4 Dismantling the Control Top into its Components 47
10.4.1 Removing the Cap 47
10.4.2 Remove the circuit board 48
10.4.3 Install the circuit board 48
10.4.4 Removing the sensor module (9) 48
10.4.5 Removing the Solenoid Valves and the Control Plate 49
10.4.6 Removing the pneumatic block 50
10.4.7 Fitting the Pneumatic Block 50
10.4.8 Install valve plates 51
10.5 Maintenance 52
10.5.1 Replacing the Seals on the Base 52
10.5.2 Maintenance of Sound Absorber, Filter, Non-Return Valve and Exhaust Air Throttle 52
11 Alarms 54
11.1 Malfunctions and remedies 54
11.2 Carrying out a Reset – Back to Default Standard 56
12 Decommissioning 57
12.1 Safety instructions 57
12.2 Disposal 57
12.2.1 General notes 57
13 Spare parts list - control top type T.VIS P-15 58
14 Spare parts list - switch bar T.VIS P-15 60
15 Dimension sheet - control top type T.VIS P-15 62
16 Appendix 63
16.1 Lists 63
16.1.1 Abbreviations and terms 63
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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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2 Safety
2.1 Intended use
The programmable positioner T.VIS P-15 (Tuchenhagen Valve Informations
System) kallows GEA Tuchenhagen and ASEPTOMAG single-seat valves to be
set to any position within the given stroke (5-70 mm), provided the pneumatic and
electrical connections are established correctly.
The positioner T.VIS P-15 consists of a base and a hood. It is completely
mounted on the actuator/adapter of the process valve provided for this purpose
using two clamps. The internal hose system directly connects the control air to
the process valve. 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 P-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
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.
Safety
Intended use
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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.
2.4 IP Protection Classes
The control top T.VIS P-15 in its standard version fulfils the requirements of
protection class IP66 (DIN EN 60529). Models in protection classes IP67 or
IP69k (both DIN EN 60529) are also available.
Safety
Subsequent changes
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IP classes provide information about the degree of protection an electrical device
housing provides against the ingress of solids (first digit) or humidity (second
digit). They attempt to reproduce common kinds of failure and assign so-called IP
codes to the protected systems. The letters IP stand for 'International Protection'
and are prefixed to the code numbers.
Position of the digit Explanation
1. digit* Protection against solids
6 Dust tight
2. digit* Protection against humidity
6 Protected against powerful water jets
7Protected against temporary
immersion
9k Protected against high pressure spray
downs
*For additional digits and more detailed descriptions please refer to the
pertinent standard.
Digits not to be mentioned can be replaced by the letter x (e. g. IPx6).
Concerning the ingress of humidity, IPx6 includes all lower IP classes. This is,
however, not the case for the higher protection class IPx7!
If cleaning agents are used that significantly reduce the surface tension and/or if
high-pressure cleaners are used, we recommend using IP69k rated equipment as
an option.
Hint!
The specified IP classes only apply if the connectors are connected
correctly, if the cable gland is properly sealed and if the control top is
fitted on the valve, see Chapter 6, Page 25.
2.5 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
2.5.1 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.
Safety
General safety instructions and dangers
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•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.
2.5.2 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.
2.5.3 Electrical Equipment
For all work on electrical equipment, the following principles apply:
•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.
2.6 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,
Safety
Supplementary Regulations
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