GEA XKR User manual

XKR XWR
Issue 2014-10 / Revision 15
Part no. 430-455
English
Operating Instructions
Flow Diversion Device with Proximity Switch

2014-10 · Flow Diversion Device with Proximity switch

Contents
Important Abbreviations and terms ...................... 2
Safety instructions .................................................. 3
Designated use .................................................... 3
Personnel.............................................................. 3
Modifications, spare parts, accessories .............. 3
General instructions ............................................ 3
Marking of safety instructions in the
operating manual................................................ 3
Further symbols .................................................. 3
Special hazardous spots ...................................... 4
Designated use ........................................................ 5
Transport and Storage ............................................ 5
Checking the consignment ................................ 5
Weights ................................................................ 5
Transport .............................................................. 5
Storage ................................................................ 5
General Description ................................................ 5
Design and Function .............................................. 6
Design .................................................................. 6
Function................................................................ 7
Assembly and Operation ........................................ 9
Installation position ............................................ 9
Valve with detachable housing connections .... 9
Valve with welded connections .......................... 9
Pneumatic connections .................................... 10
Electrical connections........................................ 10
Hosing diagram ................................................ 11
Commissioning .................................................. 12
Malfunction, Cause, Remedy................................ 12
Maintenance .......................................................... 12
Inspections ........................................................ 12
Maintenance intervals ........................................ 1
Prior to disassembly the valve .......................... 13
Disassembly of Flow Diversion Device ............ 13
Maintenance ...................................................... 15
Assembling ........................................................ 17
Dual Stem Device – Test Procedures .................... 19
Technical Data ........................................................ 20
Tools / Lubricant ................................................ 20
Resistance of the sealing material.................... 21
Annex
Spare parts lists FDD.......................................... 22
Dimension sheet FDD ........................................ 24
Spare parts lists / Dimension sheet Actuator .. 24
Spare parts lists Control Module FDD.............. 25
2014-10 · Flow Diversion Device with Proximity switch 1

max. maximum
mm Unit of measure for length
millimetre
μm Unit of measure for length
micrometer
M metric
Nm Unit of measure for work
Newton metre
Unit for torque
1 Nm = 0,737 lbft
Pound-Force (lb) + Feet (ft)
Size Size of spanners
see Chapt. see Chapter
s. ill. see illustration
T.VIS®Tuchenhagen Valve Information System
V DC Volt direct current
V AC Volt alternating current
W Unit of measure for power
Watt
Inch OD Pipe dimension acc. to British standard
(BS), Outside Diameter
Inch IPS US pipe dimension
Iron Pipe Size
Important Abbre-
viations and terms
BS British standard
bar Unit of measure for pressure
app. approximately
°C Unit of measure for temperature
degrees centigrade
dm3nUnit of measure for volume
cubic decimetre
Volume (litre) under standard conditions
DN DIN nominal width
DIN Deutsche Norm (German standard)
DIN Deutsches Institut für Normung e.V.
(German institut for Standardization)
EN European standard
EPDM Material designation
Short designation acc. to DIN/ ISO 1629
Ethylene propylene diene (monomer) rubber
GEA GEA AG group of companies
GEA stands for Global Engineering Alliance
FPM Material designation
Short designation acc. to DIN/ ISO 1629
Fluorine rubber
h Unit of measure for time
hour
HNBR Material designation
Short designation acc. to DIN/ ISO 1629
Hydrated acrylonitrile butadiene rubber
IP Protection class
ISO International standard of the
International Organization for
Standardization
kg Unit of measure for weight
kilogram
kN Unit of measure for force
kilo Newton
l Unit of measure for volume
litre
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2014-10 · Flow Diversion Device with Proximity switch
Safety Instructions
Designated use
The Flow diversion device is designed exclusively for
the purposes described below. Using the Flow diversion
device for purposes other than those mentioned is con-
sidered contrary to its designated use. GEA Tuchen-
hagen cannot be held liable for any damage resulting
from such use; the risk of such misuse lies entirely with
the user.
The prerequisite for the reliable and safe operation of
the Flow diversion device is proper transportation and
storage as well as competent installation and assembly.
Operating the Flow diversion device within the limits of
its designated use also involves observing the operating,
inspection and maintenance instructions.
Personnel
Personnel entrusted with the operation and mainte-
nance of the Flow diversion device must have the suit-
able qualification to carry out their tasks. They must be
informed about possible dangers and must understand
and observe the safety instructions given in the relevant
manual. Only allow qualified personnel to make electri-
cal connections.
Modifications, spare parts,
accessories
Unauthorized modifications, additions or conversions
which affect the safety of the Flow diversion device are
not permitted. Safety devices must not be bypassed,
removed or made inactive.
Only use original spare parts and accessories recom-
mended by the manufacturer.
General instructions
The user is obliged to operate the Flow diversion device
only when it is in good working order.
In addition to the instructions given in the operating
manual, please observe the following:
– relevant accident prevention regulations
– generally accepted safety regulations
– regulations effective in the country of installation
– working and safety instructions effective in the user's
plant.
Marking of safety
instructions in the
operating manual
Special safety instructions are given directly before the
operating instructions. They are marked by the follow-
ing symbols and associated signal words.
It is essential that you read and observe the texts belong-
ing to these symbols before you continue reading the
instructions and handling the Flow diversion device.
Symbol Signal word Meaning
DANGER Imminent danger, which
may cause severe bodily
injury or death.
CAUTION Dangerous situation,
which may cause slight
injury or damage to
material.
Further symbols
Symbol Meaning
• Process / operating steps which
must be performed in the specified
order.
✗Information about the optimum
use of the Flow diversion device.
– General enumeration

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1
2
3
4
4
4
Special hazardous spots
DANGER
In the event of malfunctions set the Flow diversion
device out of operation (disconnect the valve from the
power and the air supply) and secure it against reacti-
vation.
Immediately rectify the fault.
Never put your hand into the lantern (2) or into the
valve housing (4).
When the hinged clamps at the actuator (1) or at the
housing (3) of the non-actuated valve (spring-closing
action) are detached, there is danger of injury, since the
released spring pressure suddenly lifts the actuator (5).
Therefore, prior to detaching the hinged clamps, release
the spring tension by
– the pneumatic emergency switchbar
or
– pressurizing the actuator with compressed air.
CAUTION
Housing sockets have very sharp edges. Therefore wear
suitable protection gloves during transport or installa-
tion of the Flow diversion devices.
For transportation of the valve, it is imperative to
remove the control module and the valve stem and to
use the screwed-in eye bolt (R), part no. 221-104.98 for
lifting the valve.
R

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Designated Use
The Tuchenhagen Flow diversion devices consists of
two Tuchenhagen non-slamming divert valves type
XKR or XWR welded together to form an assembly. The
assembly is used to enable the “Divert Flow”, “Leak
Detect” or “Forward Flow”.
Divert valves type X are pressure retention devices
(without safety function) in accordance with the
pressure equipment guideline 97/23/EC. They are
classified according to Appendix II in Article 3, Section
3. In case of deviations thereof, a separate Declaration of
Conformity will be handed out together with the
equipment.
Transport and
Storage
Checking the consignment
On receipt of the Flow diversion device check whether
– the type and serial number on the type plate corre-
spond to the data in the order and delivery documents
and
– the equipment is complete and all components are in
good order.
The forwarding agent must immediately be notified of
any transport damage detectable from the outside
and/or missing packages (confirmation on the consign-
ment note). The consignee shall take recourse against
the forwarding agent immediately in writing and
inform GEA Tuchenhagen accordingly.
Transport damages which cannot be recognized imme-
diately shall be brought to the forwarder´s notice within
6 days. Later claims on damages shall be born by the
consignee.
Weights
Size Weight (kg)
per valve per device
OD 1" app. 10 app. 20
OD 1 1/2" app. 18 app. 36
OD 2" app. 18 app. 36
OD 2 1/2" app. 25 app. 50
OD 3" app. 25 app. 50
OD 4" app. 26 app. 52
OD 6" app. 82 app. 164
Transport
DANGER
For transport of the package, only use suitable lifting
gear and slings. Observe the instruction symbols on the
package and on the Flow diversion device.
Handle the Flow diversion device with care to avoid
damage caused by shock or careless unloading.
The synthetic materials of the control modules are sen-
sitive to breakages.
Storage
In the case that during transport or storage the Flow
diversion device is exposed to temperatures ≤ 0°C, then
store in a dry place against damage.
We recommend, prior to any handling (dismounting
the housings / activation of actuators) an intermediate
storage of 24 hours at a temperature of ≥ 5 °C so that
any ice crystals formed by condensation water melts.
General Description
The Tuchenhagen Flow diversion devices are available
with either vertical down (Type XKR) or horizontal
(Type XWR) divert flow ports to suit the installation
requirements. Refer to Appendix “Dimension sheets”.
The actuator is a type Z air to activate, spring to close
design. It can be activated directly at the actuator by
suitable air connection or through the control module
with a solenoid (if required). The air connection port at
the actuator is provided with a quick exhaust valve to
speed activation. See chapter “Assembly and Operation,
Pneumatic Connections”.
The control module is supplied as standard with two
sensor to detect non-activated and the activated valve
position. See Chapter “Assembly and Operation, Electri-
cal Connections”. A solenoid valve is available.

Design and Function Design
1 control module
4 actuator
5 quick air exhaust
6 lantern
7 limit stop
8 sealing disk
9 sealing ring
10.1 valve disk X 1
10.2 valve disk X 2
11 valve housing
12 bearing
13 bearing disk
14 seat ring
15 pneumatic
connection
✗For housing configura-
tions see the spare parts
drawings.
1
4
5
6
7
11
12
13
14
15
8
9
10.2
10.1
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Divert Valve
Leak Detect Valve
Inlet
Port
Divert Port
⇒ to Balance Tank
Leak Detection Port
⇒ to Balance Tank
Forward Flow Port

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Inlet Port
Divert Port
⇒ to Balance Tank
Function
„Divert Flow“ position
The „Divert Flow“ position is the start position of the
valve after assembling in which the divert valve routes
the product back to the balance tank during periods of
sub-legal pasteurization temperatures.
The valve position is detected by a sensors installed in
the control module. The interface module with two sen-
sors to determine the valve position is installed in the
control module. The sensors determine the valve posi-
tion and the interface module generate the correspond-
ing feedback signals and send them to the master con-
trol system (see operating instructions of the control
module T.VIS M-1 FDD). Divert Valve
Leak Detect Valve

“Leak Detect Flush Time Delay”
position
The Flow Diversion Device will move into the “Leak
Detect” position once the legal pasteurization tempera-
ture is achieved. The time of the clearance is controlled
by a Flow Diversion Device Controller which is a sepa-
rate device.
In this position the common body between the “Divert
Valve” and the “Leak Detect Valve” is purged and the
milk is routed back to the balance tank out of the leak
detection port of the “Leak Detect Valve”. This return
line to the balance tank has to be separated from the
return line of the “Divert Valve”.
In the “Leak Detect” position the “Divert Valve” is in
the activated position. The “Leak Detect Valve” is in the
closed position which is detected by the sensor in the
control module.
The “Flow Diversion Device” will stay in the “Leak
Detect” position until the Flow Diversion Device Con-
troller sends out the signal to transition to the “Forward
Flow” position.
“Forward Flow” position
The “Forward Flow” position enables the pasteurized
product to flow through the “Leak Detect” Valve to the
heat holder and subsequent sections of the pasteurizer.
In the “Forward Flow” position both valves are in the
activated position.
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Inlet
Port
Inlet
Port
Forward
Flow
Port
Divert Valve
Divert Valve
Leak Detect Valve
Leak Detect Valve
Leak Detection Port
⇒ to Balance Tank

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Actuator function
The valve is closed in the non-actuated position.
Distinguishing feature with control module T.VIS:
– Permanent light (1) green:
Valve in non-actuated position
– Permanent light (1) yellow:
Actuated valve position
Assembly and
Operation
Make sure that
– the Flow diversion device is installed in the pipe sys-
tem free of stress and
– no foreign materials (e. g. tools, bolts, lubricants) are
enclosed in the system.
Installation position
The standard installation position of the Flow Diversion
device is in the vertical position. In the case of the XWR
arrangement, the inner parts must be connected to the
external piping in such a way as to be drainable.
Valve with detachable
housing connections
DANGER
If liquids are present in the pipe system, they can cause
injury to people when the pipework is disconnected.
Therefore, prior to detaching pipe connection fittings or
clamp connections:
– drain and – if necessary – rinse or clean the pipe.
– isolate the pipe segment with the valve to be mounted
from the rest of the pipe system to secure the pipe
against incoming product.
Valves with detachable housing connections can be in-
stalled directly into the pipe system, if suitable connec-
tion fittings are used.
Valve with welded
connections
CAUTION
For welding operations, all internals must be removed
from the valve housing.
1
DANGER
When the hinged clamps at the actuator or at the hous-
ing of the non-actuated divert valve X (spring-closing
action) are detached, there is danger of injury, since the
released spring pressure suddenly lifts the actuator.
Therefore, prior to detaching the valve housing,
lift the valve disk, either
– through the pneumatic emergency switchbar or
– by actuating the valve with compressed air,
max. 8 bar.
• Release the spring tension.
• Dismantle the valve (follow the instructions under
“Disassembly”).
• Purge the housing on the inside with forming gas to
remove oxygen from the system.
• Fit in the housing and tack it.
• Use the TIG welding method with pulsating current.
• Weld the housing into the pipe system, if necessary
using a welding filler.
• After welding, passivate the seam.
• Dismount the housing.
CAUTION
When mounting the valve, make sure that the O-rings in
the housing are replaced to ensure the tightness of the
valve.
• Insert the seals.
• Mount the valve.
• Depressurize the actuator.
The valve disk is lowered.

Electrical Connections
DANGER
Only allow qualified personnel to make electrical
connections. Prior to making electrical connections
check the maximum permissible operating voltage and
amperage for each part being connected.
Connecting the electrical cable
Inserting the cable into the gland
• Pull the cable through the cable gland and connect it
in the control module in accordance with the wiring
diagram (see operating instructions of the control
module T.VIS M-1 FDD).
Pneumatic Connections
Air requirement
The compressed air required for switching operations of
the valve is governed by the type of actuator (identifica-
tion at the actuator cap).
Actuator type Actuator dia. Air requirement
(mm) (dm3n/stroke)
A... 89 0.16
B... 108 0.26
C... 133 0.42
D... 168 0.70
E... 212 1.10
E...6 212 2.00
S...6 261 3.20
R...1) 168 1.60
S...1) 212 2.00
T...1) 212 3.10
T...61) 212 4.00
U...61) 261 5.10
1. Actuators with booster cylinder for increasing the pneumatic actuat-
ing force when lower control air pressures are used
Installing the air hose
✗To ensure optimum fit in the air connector, the
pneumatic hoses must be cut square with a hose cutter.
• Shut off the compressed air supply.
• Push the air hose into the air connector (port P) in the
control module.
• Reopen the compressed air supply.
Air connect – no solenoid in con-
trol module
Refer to chapter “Design and Function, Design” for item
numbers.
• Insert air supply to port P on control module.
Use 1
/4" OD polytube to connect port Y1 (item 15)
from control module to quick exhaust air connect
(Item 5).
Air Connect – with solenoid in
control module
Refer to chapter “Design and Function, Design” for item
numbers.
• Insert air supply to port P on control module.
Use 1
/4" OD polytube to connect port Y1 (item 15)
from control module to quick exhaust air connect
(Item 5).
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11
2014-10 · Flow Diversion Device with Proximity switch
Y1
Y1
Actuator
✗To ensure optimum fit in the air connec-
tor, the pneumatic hoses m ust be cut
square with a hose cutter.
Hosing Diagram
Flow Diversion Device FDD
GEA Tuchenhagen
Datum/date: 2009-06-26
A
View A
FDD-P
with solenoid
FDD-N
without solenoid
Y1
Central
Air
Supply
Central
Air Supply
Outlet
P
P
Central
Air Supply
P
Actuator

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Commissioning
• Clean the valve assembly prior to the first production
run.
Functional test
• Actuate each valve of the Flow Diversion Device once
by applying compressed air.
• Prior to the first product run clean the pipe system.
Leak test
• Visually check that all seals are free from leaks.
• Replace defective seals.
Malfunction, Cause,
Remedy
CAUTION
In the event of malfunctions immediately deactivate the
Flow Diversion Device and secure it against inadvertent
reactivation. Defects may only be rectified by qualified
personnel observing the safety instructions.
The following applies to each valve in the Flow
Diversion Device.
Malfunction Cause Remedy
Valve does Error in the Check the plant
not work control system configuration
No compressed Check the
air air supply
Air pressure Check the air
too low hoses for free
passage and
leaks
Error in the Check actuation
electric system /external controller
and routing
of electric lines
Solenoid valve Replace the
defective solenoid valve
Valve does Dirt/foreign Clean the valve
not close materials between housing and
valve seat and the valve seat
valve disk
Valve closes O-rings dry Grease the O-rings
too slowly in the actuator
and in the control
module
(friction losses)
Leakage at the O-rings in the Dismantle the
valve housing housing valve housing,
defective replace the O-rings
Leakage in the Sealing ring Replace the sealing
lantern defective ring
Maintenance
Inspections
Between the maintenance periods, the each valve of the
Flow diversion devices must be checked for leakage and
proper function.
Product contact seals
• Check at regular intervals:
– stem seal between the upper housing and the lantern
– O-rings between the valve housings
– V-ring in the valve disks
Pneumatic connection
• Check the operating pressure at the pressure reducing
and filter station.
• Clean the air filter in the filter station at regular inter-
vals.
• Check whether the air hose sits firmly in the air con-
nector.
• Check the air hoses for bends and leaks.
• Check function of the solenoid valves.
Electrical connection
• Check whether the cap nut on the cable gland is tight.
• Check the cable connections at the adapter module.
• Check function of the solenoid valves.

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Maintenance intervals
To ensure the highest operational reliability of the
valves, all wearing parts should be replaced at longer
intervals.
The actual maintenance intervals can only be deter-
mined by the plant user, since they depend on the oper-
ating conditions, for instance
– daily period of operation
– switching frequency
– type and temperature of the product
– type and temperature of the cleaning solution
– ambient conditions.
Application Maintenance interval
(recommendations)
Media at temperatures of every 3 months
60 °C to 130 °C
Media at temperatures every 12 months
< 60 °C
Prior to disassembly the
Flow diversion device
DANGER
Before detaching the pipe connection and the semi-
annular clamp connections on the valve housing, always
take the following preparatory measures:
• Make sure that during maintenance and repair work
no process is in operation in the area concerned.
• All pipe system elements attached to the Flow diver-
sion device must be drained and, if necessary, cleaned
or rinsed.
• Shut off the control air supply, unless it is required for
disassembly the Flow diversion device.
• Disconnect the power supply.
• If possible, take the valve out of the pipe system togeth-
er with all housings and housing connections.
Disassembly of Flow
Diversion Device
NOTE
The pneumatic and electrical connections can remain in
the control module.
• Loose the cheese head screw (25) and remove cap (B1).
DANGER
When the hinged clamps are detached of the non-actu-
ated valve, the released spring force suddenly lifts the
actuator. There is danger of injury.
Therefore, prior to detaching the hinged clamps, release
the spring tension by actuating the valve actuator with
compressed air.
Lift the valve disk:
Spring-closing valve
• Pressurize the actuator with compressed air,
max. 8 bar by activating solenoid valve Y1 at S.
Spring-opening valve
• Depressurize the actuator.
25
B1
Y1
S

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Disassembly the control module
• Remove the hinged clamps (1).
Lower the valve disk :
• Depressurize the actuator.
✗The pneumatic and electrical connections can remain
connected to the control module.
• Remove the hinged clamps (5) between the control
module and the actuator.
• Lift the control module (6) upwards.
Disassembly the valve insert
CAUTION
When pulling out the valve do not damage the valve
seat.
Do not set the valve insert down on the valve disk, as
this can damage the valve disk, but lay it down
carefully.
•Pull the valve out of the housing (2, 3, 4).
Loosen the valve disk
• Slacken the hinged clamps (7) between the actuator
and the lantern.
• Grip the valve disk at the key face (8) with an open-
end spanner, turn the actuator 3 turns using a strap
wrench. The valve disk will come loose.
1
2
3
4
8
7
5
6

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Disassembly valve disk
• Unscrew the valve disk (2) from the actuator by hand.
• Unscrew the spacer nut (1) from the valve disk.
• Withdraw the valve disk from the housing.
• Withdraw the actuator.
Maintenance
CAUTION
The stem of the valve disk (3), the housing seat (4), the
valve seat (6) and the V-ring groove (5) are precision
parts which must not be damaged!
• Dismantle the Flow diversion device
see Chapter “Disassembly”.
• Carefully clean the individual components.
CAUTION
Observe the safety information sheets issued by the
detergent manufacturers! Only use detergents which are
non abrasive and non-aggressive towards stainless steel.
1
2
3
4
6
5

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Replacing the seals
✗Replace defective seals.
Always replace the housing O-rings to ensure the
tightness of the valve. Always use original spare parts.
CAUTION
When the V-Ring is removed with a scriber, the scriber
can slip off. There is danger of injury. Therefore grip the
valve disk in a vice fitted with protected jaws. Also
unscrew the curved end of the scriber.
• Insert the scriber into the V-ring and lever it out.
Use the insertion tool to mount the new V-ring.
✗Do not grease the V-ring before inserting it.
We recommend using water with household washing-
up liquid (1 drop/1 l) as an aid to inserting V-rings. In
order to prevent oxidation from infiltration prepare
the liquid solution in a ceramic, plastic or stainless
steel container.
Before inserting the V-ring wet it on the back (side not in
contact with the product). Take care that there is no
water in the V-ring groove in the valve disk.
CAUTION
• Observe the required installation position of the
V-ring (see ill.).
• Insert the V-ring (see ill.).
• Using the V-ring insertion tool press the V-ring into
the groove at several opposite places along the cir-
cumference.
• Insert the V-ring evenly into position.
• Replace all the other seals correspondingly
marked in the spare parts drawing.
✗Used seals must not be refitted, since this
would adversely affect the sealing function.

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Lubrication of seals and threads
CAUTION
For product contact seals do not use conventional
greases and oils. Observe the safety information sheets
issued by the lubricant manufacturers.
• Grease the thread of the valve disk and all screws.
• Do not grease the V-ring.
• Apply a very light film of grease to all seals –
including the O-rings at the top and bottom of the
piston rod for the actuator.
GEA Tuchenhagen recommends Rivolta F.L.G. MD-2
and PARALIQ GTE 703. These lubricants are approved
for foodstuff and is resistant to beer froth and have the
NSF-H1 (USDA H1)-registration. PARALIQ GTE 703 can
be ordered from GEA Tuchenhagen under part no. 413-
064 and Rivolta F.L.G. MD-2 under part no. 413-071.
CAUTION
When mounting the control module, make sure that the
air hoses do not get kinked.
Assembling
Mounting to The control
module T.VIS onto FDD
CAUTION
The permanent magnet on the switch bar (1) is fragile
and must therefore be protected against mechanical
impact stress.
The magnetic fields can delete data carriers and affect
or destroy mechanical components.
• Check that the switch bar (1) is firmly in place. If
needed, tighten using an Allen key at (1.1) or an open
spanner, size 13 at (1.2): tightening torque 2Nm (1.4
lbft).
• Pass the control module (B) over the valve stem (1)
and place it on to the actuator (A.1).
• Fix the clamps (15) by tightening the screws (39) at a
torque of 1 Nm (0.7 lbft).
• Align the pneumatic and electrical connections
according to the valve block configura-tion.
• Carry out commissioning, see operating instructions
of the control module T.VIS M-1 FDD.
B
39
15
A.1
1
1.1
1.2

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1
2
DANGER
There is a danger of injury when the spring-opening valve
is assembled. Therefore, do not put your hand in the valve
housing. Before unscrewing the valve disk, pretension the
actuator using an emergency manual actuator (H) (part no.
221.310.74).
Assemble the valve in the reverse sequence of disassembly.
During assembly, observe the following instructions:
• Lock the spacer nut (2) against the actuator rod (1).
• Tighten the nuts of the clamps at the control module with
a torque of 1 Nm.
• Tighten the nuts of the hinged clamps with following
torques:
M 6 9 Nm
M 8 22 Nm
• Tighten the nuts of the cast-semi-annular clamps with a
torque of 45 Nm (33 lbft).
Checking the valve stroke
• Actuate the valve by applying compressed air.
• Check whether the valve stroke (c) is correct.
Valve size Valve stroke c (mm)
OD 1" 15
OD 11/2" 23
OD 2" 30
OD 21/2" 30
OD 3" 30
OD 4" 30
OD 6" 60
• Check the function of the feedback or sensors and, if nec-
essary, readjust them (see operating instructions Control
Module T.VIS M-1 FDD).
C