GEA VARIVENT X R Series User manual

Operating Instructions
Hygienic valves
GEA VARIVENT® Shuttle valve type X_R
2023-03
430BAL015128EN

Copyright © GEA Tuchenhagen GmbH 2023. All rights reserved. No liability will be accep-
ted for damage resulting from non-observance of this document. If you have any ques-
tions or require clarication concerning the use of this document, contact the Customer
service .

Table of Contents
1 General
1.1 Information about the document 7
1.1.1 Purpose and structure of the document 7
1.1.2 Design elements 7
1.1.3 Reading obligation and storage 8
1.2 Manufacturer address 8
1.3 Customer service 8
1.4 Declarations of conformity 9
2 Safety
2.1 Intended use 13
2.1.1 Requirements for the operation 13
2.1.2 Pressure equipment directive 13
2.1.3 ATEX directive 13
2.1.4 Improper operating conditions 14
2.2 Modication 14
2.3 Structure of warning notices 14
2.3.1 Preceding warning notices 14
2.3.2 Integrated warning notices 14
2.3.3 Signal words 14
2.4 Personnel qualication 15
2.5 General safety instructions 15
2.5.1 General hazard16
2.5.2 Mechanical hazard16
2.5.3 Electrical hazard16
2.5.4 Thermal hazard16
2.6 Personal protective equipment 17
2.7 Safety devices 17
2.8 Residual hazards 17
2.9 Safety signs 19
2.10 Emergency measures 20
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3 Description
3.1 Set-up and function 21
3.1.1 Design 21
3.1.2 Functional description 23
Spring-to-close actuator function (NC) 23
Spring-To-Open actuator function (NO) 24
Modifying the actuator closing direction 24
3.1.3 Signs 27
3.1.4 Protective devices 28
3.2 Technical data 28
3.2.1 Type plate 28
3.2.2 Technical data 28
3.2.3 Resistance of the sealing materials 30
3.2.4 Pipe ends - General table of measurements 31
3.2.5 Lubricants 32
4 Storage and transport
4.1 Scope of supply 33
4.2 Storage 33
4.3 Transport 34
5 Assembly and installation
5.1 Notes on installation 35
5.2 Control top 35
5.3 Install the valve with detachable pipe connection elements 35
5.4 Install valve with welding ends 35
5.5 Checking the pneumatic connection 37
5.5.1 Air requirement 37
5.5.2 Establishing hose connections 37
5.5.3 Electrical connection with T.VIS control top 39
6 Commissioning
6.1 Preparing commissioning 41
6.2 Restarting 42
7 Operation and control
7.1 Start-up 43
7.2 Monitoring operation 43
7.3 Shutdown 43
8 Cleaning
8.1 General points 45
8.1.1 Cleaning process examples 45
8.1.2 Cleaning results 46
8.2 Passivation 46
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9 Maintenance
9.1 Carrying out inspections 47
9.1.1 Checking seals that come into contact with the product 47
9.1.2 Checking the pneumatic connection 47
9.1.3 Checking the electrical connection 48
9.1.4 Checking the signs on the valve 48
9.2 Servicing intervals 48
9.3 List of tools 48
9.4 Prior to removal 50
9.5 Removing the valve 50
9.5.1 Removing the clamp connection between the housing and lantern
50
9.5.2 Removing the control top 57
9.5.3 Remove connection 0 59
9.5.4 Remove INI holder 60
9.5.5 Disconnecting the valve insert from the housing 60
9.5.6 Dismantling the valve insert into individual parts 62
9.5.7 Dismantling of the housing combination 64
9.6 Installing the valve 64
9.6.1 Tightening torques 64
9.6.2 Assembling the valve insert from individual parts 65
9.6.3 Assembly of the housing combination 68
9.6.4 Placing the valve insert in the housing 69
9.6.5 Mounting the control top 69
9.6.6 Mounting connection 0 71
9.6.7 Mount INI holder 72
9.6.8 Mounting the clamp connection between the housing and lantern
72
9.6.9 Checking the function 80
9.7 Maintenance 81
9.7.1 Cleaning the valve 81
9.7.2 Replacing the V-ring 82
9.7.3 Replacing the V-ring RA on the valve disk 84
9.7.4 Lubricating seals and threads 87
10 Faults
11 Decommissioning, dismantling and disposal
11.1 Decommissioning 91
11.2 Dismantling 91
11.3 Disposal 91
12 Spare parts
12.1 Order information 93
12.2 Spare parts lists 94
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13 Annex
13.1 Dimension sheet 99
13.2 List of abbreviations 101
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1 General
This chapter contains basic instructions for using the valve and explanations of illustra-
tion conventions. It also contains information about the design and structure.
The term valve in these Operating Instructions refers to GEA VARIVENT® Shuttle valve
type X_R.
1.1 Information about the document
1.1.1 Purpose and structure of the document
The objective of these Operating Instructions is to provide information on how to oper-
ate the valve. To achieve this, it is divided into several chapters which are oriented on
the various life phases of the valve. Compliance with the instructions will enhance the
valve's longevity and reliability, and reduce the likelihood of harm to individuals or dam-
age to property. The Operating Instructions also acts as the basis for creating operating
instructions.
1.1.2 Design elements
In this document, the following design elements are used as orientation aids.
General orientation aids
●Figure numbers
●Table numbers
●Chapter numbers
●Page numbers
●Headers and footers
●References
●Lists
Lists
Bullet points are shown in lists and do not prescribe a specic sequence.
●Bullet point
●Bullet point
•Sub-point
•Sub-point
●Bullet point
Numbered lists
In a sequence of actions, the order of the action steps is specied by a numbered list.
Partial results and the result of a sequence of actions are marked by arrows.
1. Action step one
2. Action step two
2.1 First sub-step two
2.2 Second sub-step two
®Partial result
3. Action step three
®Partial result
4. Action step four
ÞResult
1.1 Information about the document - 7 / 104

INFO
Info texts contain additional information about a description or action step.
1.1.3 Reading obligation and storage
Every person who works on or with the valve must have read these Operating Instruc-
tions. They must be available to these persons at all times.
1.2 Manufacturer address
GEA Tuchenhagen GmbH
Am Industriepark 2-10
Germany
21514 Büchen
1.3 Customer service
Phone: [phone]
Fax: [phone]
[email protected]
www.gea.com
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1.4 Declarations of conformity
1.4 Declarations of conformity - 9 / 104

Translated copy of the EU - Declaration of conformity in accordance with the
Pressure Equipment Directive 2006/42/EU
Manufacturer: GEA Tuchenhagen GmbH
Am Industriepark 2-10
21514 Büchen
We hereby declare that the machine named below
Designation: Valve with actuator
Type: VARIVENT®
on the basis of its design and construction, as well
as the version that we have put into circulation,
corresponds with the relevant fundamental health
and safety requirements of the following guide-
line:
Relevant EC directives: 2006/42/EC EC Machinery Directive
Applicable harmonized standards, in particular: EN ISO 12100: 2010
Remarks: ●This declaration will become invalid if any alter-
ations are made to the machine which have
not been agreed with us
●We also declare that the relevant technical
documentation for this machine has been pre-
pared in accordance with Annex VII, Part A,
and agree to submit the documentation on
justied request of national authorities on a
data carrier
Person authorised for compilation and handover
of technical documentation:
GEA Tuchenhagen GmbH
CE Documentation Ofcer
Am Industriepark 2-10
21514 Büchen, Germany
Büchen, 24 January 2020
Franz Bürmann
Managing Director
i.V
. Matthias Südel
Head of Engineering
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