GEA VARIVENT A Quick guide

Translation of the Original Operating Instructions
VARIVENT®
Control Valve A
Edition 2016-06-07
English

2
Operating Instructions · Control Valve A
Edition 2016-06-07
Product Control Valve A
Document Translation of the Original Operating Instructions
Edition 2016-06-07
English
Manufacturer GEA Tuchenhagen GmbH
Am Industriepark 2-10
D-21514 Büchen
Phone:[phone]
Fax: [phone]
Mail: sales.geatuchenhage[email protected]
Web: http://www.tuchenhagen.com
These Operating Instructions are the English translation of the original operating instruc-
tions in the sense of the EU Machinery Directive. This document is protected by copy-
right. 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.
Wordmarks The designation VARIVENT®is a protected trademark of GEA Tuchenhagen GmbH.

3
Table of Contents
Table of Contents
Notes for the Reader ...................................................................................................................................... 6
Binding Character of These Operating Instructions ......................................................................................... 6
Notes on the Illustrations.................................................................................................................................. 6
Symbols and Highlighting................................................................................................................................. 7
Abbreviations and Terms ................................................................................................................................. 8
Safety............................................................................................................................................................. 10
Safety Note..................................................................................................................................................... 10
Operator's Duties............................................................................................................................................ 10
Qualification of Staff ....................................................................................................................................... 11
Supplementary Regulations ........................................................................................................................... 12
Instructions for the Safe Operation................................................................................................................. 13
•General Principles ...................................................................................................................................... 13
•Installation .................................................................................................................................................. 13
•Commissioning/Setup Mode ...................................................................................................................... 14
•Setting into Operation................................................................................................................................. 14
•Operation.................................................................................................................................................... 14
•Shutting Down ............................................................................................................................................ 15
•Maintenance and Repair ............................................................................................................................ 15
•Disassembly ............................................................................................................................................... 16
•Environmental Protection ........................................................................................................................... 16
•Electrical Equipment................................................................................................................................... 16
Signage .......................................................................................................................................................... 17
Residual Risk ................................................................................................................................................. 18
•Hazard Areas ............................................................................................................................................. 18
•Residual Dangers....................................................................................................................................... 19
•Declaration of Conformity........................................................................................................................... 20
Transport and Storage................................................................................................................................. 21
Scope of Supply ............................................................................................................................................. 21
Transport ........................................................................................................................................................ 21
Storage........................................................................................................................................................... 21
Intended Purpose ......................................................................................................................................... 22
Designated Use .............................................................................................................................................. 22
Requirements for the Operation ..................................................................................................................... 22
Pressure Equipment Directive........................................................................................................................ 22
ATEX Directive ............................................................................................................................................... 22
Improper Operating Conditions ...................................................................................................................... 23
Conversion Work............................................................................................................................................ 23
Design and Function.................................................................................................................................... 24
Design ............................................................................................................................................................ 24
Function.......................................................................................................................................................... 25
•Spring-to-close actuator (Z)........................................................................................................................ 25
•Spring-to-open actuator (A)........................................................................................................................ 25
Installation and Commissioning ................................................................................................................. 26
Notes on Installation....................................................................................................................................... 26
Fitting the Valve with Detachable Pipe Connection Elements........................................................................ 26

Table of Contents
4
Operating Instructions · Control Valve A
Edition 2016-06-07
Control Valve with Welding Ends ....................................................................................................................27
Pneumatic Connections ..................................................................................................................................29
Electrical Connections.....................................................................................................................................30
Commissioning................................................................................................................................................31
•Checks Prior to Commissioning..................................................................................................................31
•Testing the Valve Function Without Product...............................................................................................31
•Valve Stroke................................................................................................................................................32
•Tests During the Product Run.....................................................................................................................32
•Operation ....................................................................................................................................................32
Cleaning and Passivation.............................................................................................................................33
Cleaning..........................................................................................................................................................33
Cleaning Process Examples ...........................................................................................................................33
•Typical Cleaning Parameters in Dairy Operations ......................................................................................33
•Typical Cleaning Parameters in Breweries .................................................................................................33
•Cleaning Parameters ..................................................................................................................................34
•Passivation..................................................................................................................................................34
Malfunctions..................................................................................................................................................35
Maintenance ..................................................................................................................................................36
Inspections ......................................................................................................................................................36
•Product Contact Seals ................................................................................................................................36
•Pneumatic Connections ..............................................................................................................................36
•Electrical Connections ................................................................................................................................36
Maintenance Intervals.....................................................................................................................................37
Prior to Disassembly .......................................................................................................................................37
Disassembly....................................................................................................................................................38
Maintenance....................................................................................................................................................39
•Cleaning the Valve......................................................................................................................................39
•Replacing Seals ..........................................................................................................................................39
•Lubricating Seals and Threads ...................................................................................................................41
Assembly.........................................................................................................................................................42
Dismantling the Actuator Housing Cover ........................................................................................................43
Checking the Function ....................................................................................................................................43
•Setting the Stroke .......................................................................................................................................43
•Valve Stroke................................................................................................................................................44
Disposal ..........................................................................................................................................................44
•General Notes.............................................................................................................................................44
•Valve Actuator Disposal..............................................................................................................................44
Technical Data...............................................................................................................................................45
Type Plate .......................................................................................................................................................45
Technical Data ................................................................................................................................................46
Resistance of Sealing Materials......................................................................................................................47
Pipe Ends........................................................................................................................................................47
Tools ...............................................................................................................................................................48
Lubricants........................................................................................................................................................49
Weights ...........................................................................................................................................................49
Spare Parts Lists – Control Valves..............................................................................................................51
Control Valve A ...............................................................................................................................................51
Control Valve A...W.........................................................................................................................................53
Control Valve A...X..........................................................................................................................................55

5
Table of Contents
Spare Parts Lists – Control Valve Housings...............................................................................................57
Spare Parts List – Control Valve Actuator A.............................................................................................. 72

Notes for the Reader
Notes on the Illustrations
6
Operating Instructions · Control Valve A
Edition 2016-06-07
Notes for the Reader
The present Operating Instructions are part of the user information for the valve. The
Operating Instructions contain all the information you need to transport, install, commis-
sion, operate and carry out maintenance for the valve.
Binding Character of These Operating Instructions
These Operating Instructions contain the manufacturer's instructions to the operator of
the valve and to all persons who work on or use the valve regarding the procedures to
follow.
Carefully read these Operating Instructions before starting any work on or using the
valve. Your personal safety and the safety of the valve 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 valve. When the location is
changed or the valve is sold make sure you also provide the Operating Instructions.
Notes on the Illustrations
The illustrations in these Operating Instructions show the valve in a simplified form. The
actual design of the valve can differ from the illustration. For detailed views and dimen-
sions of the valve please refer to the design documents.

7
Notes for the Reader
Symbols and Highlighting
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 high-
lighting.
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.
EXPLOSION HAZARD
Warning: Explosions.
Failure to observe the warning can result in a severe explosion.
The arrow identifies a precautionary measure you have to take to avoid the hazard.
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.

Notes for the Reader
Abbreviations and Terms
8
Operating Instructions · Control Valve A
Edition 2016-06-07
IMPORTANT NOTE
Warning: Damage to Property.
Failure to observe the warning can result in serious damage to the valve or in the vicinity
of the valve.
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.
NOTE
Further useful information.
Abbreviations and Terms
Abbreviation Explanation
BS British Standard
bar Unit of measurement of pressure [bar]
All pressure data expressed in [bar/psi] is assumed to be gauge pressure
[barg/psig] unless explicitly specified otherwise.
approx. approximately
°C Unit of measurement of temperature [degree Celsius]
dm3nUnit of measurement of volume [cubic decimetre]
Volume (litre) at standard temperature and pressure
DN DIN nominal width
DIN German standard issued by DIN (Deutsches Institut für Normung e.V,
German Institute for Standardization)
EN European Standard
EPDM Material designation
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:
Fluorine rubber
h Unit of measurement of time [hour]

9
Notes for the Reader
Abbreviations and Terms
HNBR Material designation
Short designation according to DIN/ISO 1629:
Hydrogenated Acrylonitrile Butadiene Rubber
IP Protection class
ISO International standard issued by the International Organization for Standardi-
zation
kg Unit of measurement of weight [kilogram]
kN Unit of measurement of force [kilonewton]
KVvalue Flow coefficient [m³/s]
1 KV= 0.86 x Cv
l Unit of measurement of volume [litre]
max. maximum
mm Unit of measurement of length [millimetre]
μm Unit of measurement of length [micrometre]
MMetric
Nm Unit of measurement of work [newton metre]
UNIT OF TORQUE 1 Nm = 0.737 lbft
Pound-Force (lb) + Feet (ft)
PA Polyamide
PE-LD Low-density polyethylene
psi Unit of measurement of pressure [psi]
All pressure data expressed in [bar/psi] is assumed to be gauge pressure
[barg/psig] unless explicitly specified otherwise.
PTFE Polytetrafluoroethylene
SET-UP Self-learning installation
During commissioning and maintenance, the SET-UP procedure carries out
all the necessary settings for the generation of messages.
a/f Indicates the size of spanners
width across flats
T.VIS Tuchenhagen Valve Information System
V AC Volt alternating current
V DC Volt direct current
W Unit of measurement of power [Watt]
TIG Welding method
Tungsten inert gas welding
Inch Unit of measurement of length in the Anglo-American language area
Inch OD Pipe dimension acc. to British standard
(BS), Outside Diameter
Inch IPS US pipe dimension
Iron Pipe Size
Abbreviation Explanation

Safety
Operator's Duties
10
Operating Instructions · Control Valve A
Edition 2016-06-07
Safety
Safety Note
The valve is operationally reliable. It was built according to state-of-the-art standards.
Nevertheless, the valve can pose dangers, especially if
•the valve is not used in accordance with its intended use,
•the valve is not used correctly,
•the valve is operated under impermissible operating conditions.
Operator's Duties
In your capacity as operator of the facility you bear a particular responsibility for the
proper and safe handling of the valve in your facility. Only use the valve when it is in
perfect condition to prevent danger to persons and property.
These Operating Instructions contain the information you and your staff need for the
safe and reliable operation during the entire service life of the valve. 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 moni-
toring that these measures are observed. The following principles apply:
•Only allow qualified staff to work on the valve.
•The operator must authorize the staff to carry out the relevant tasks.
•Working areas and the entire environment of the valve must be neat and clean.
•The staff must wear suitable work clothing and personal protective equipment. As
the operator of the facility make sure that work clothing and personal protective
equipment are used.
•Instruct the staff with regard to any properties of the product which might pose a
health risk and the preventative measures to be taken.
•Have a qualified first-aider on call during the operation, who can initiate the neces-
sary first-aid measures in case of an emergency.
•Clearly define processes, lines of authority and responsibilities associated with the
valve. Everybody must know what to do in case of an emergency. Instruct the staff
in this respect at regular intervals.
•The signs relating to the valve must always be complete and legible. Check, clean
and replace the signs as necessary at regular intervals.
NOTE
Carry out regular checks. This way you can ensure that these measures are actually
observed.