GEA FLOWVENT User manual

Control and feedback systems
GEA FLOWVENT Control Top
Operating instruction (Translation from the original language)
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COPYRIGHT
This instruction manual is the English translation of the original instruction manual
in the sense of the EU Machinery Directive. This document is protected by
copyright. All rights reserved. The document may not be copied, reproduced,
translated or converted to an electronic medium of machine-readable form, in
whole or in part, without the express permission of GEA Flow Components India.
LEGAL NOTICE
Word marks
The designation T.VIS®is a protected trademark of GEA.
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TABLE OF CONTENTS
1General 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 Herstelleranschrift 6
1.3 Contact 6
2Safety 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 8
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
3Description 15
3.1 Design 15
3.2 Functional description 19
3.2.1 Operation Principle 19
3.2.2 Control top without solenoid valves 19
3.2.3 Control Top with Solenoid Valves 20
3.2.4 Control Top with Cap 21
3.2.5 Safety Air Exhaust/Installation Position 21
3.2.6 Reset Function / Activating Automatic Programming Mode 22
4Transport and storage 24
4.1 Storage conditions 24
4.2 Transport 24
4.2.1 Scope of supply 24
5Technical data 25
5.1 Type plate 25
5.2 Technical data 26
5.3 Specification for Evaluation Electronics 24V DC Version 27
5.4 Specification for AS-Interface Adapter Module 28
5.5 Switching point tolerances and signal output 31
5.5.1 Switching point tolerances 31
5.5.2 Signal output 31
5.5.3 Signal output inverted 32
5.6 Accessories 33
5.7 Lubricants 33
5.8 Equipment 33
6Assembly and installation 35
6.1 Safety instructions 35
6.2 Establishing hose connections 35
6.3 Pneumatic connections 35
6.3.1 Control top without solenoid valves 36
6.3.2 Control top with 1 solenoid valve 37
6.3.3 Control top with 2 solenoid valves 38
6.3.4 Control top with 3 solenoid valves 39
6.4 Electrical connections 41
6.4.1 Overview 41
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6.4.2 Electrical 24 V DC Wiring 41
Connector M12/5-pin (68.1) 42
Plug M12 / 8-pin (68.2) 43
Cable gland (24) 44
6.4.3 Electrical Wiring of AS-Interface 45
Connector M12 / 2-pin (24.3) 45
6.5 Visual Display 45
6.5.1 Colour Changeover 46
6.5.2 Illuminated dome 46
6.6 Mounting the Control Top to FLOWVENT actuators 47
6.6.1 Fitting to FLOWVENT Valves 48
7Start-up 50
7.1 Safety precautions 50
7.2 Commissioning – Control Top without Solenoid Valves 50
7.3 Commissioning - Control Top with Solenoid Valves 51
7.4 Service Function 53
8Operation and control 54
8.1 Safety instructions 54
9Cleaning 55
9.1 Cleaning 55
10 Maintenance 56
10.1 Safety precautions 56
10.2 Inspections 57
10.2.1 Checking parts are firmly secured 57
10.2.2 Servicing intervals 59
10.2.3 Signs on the control top 59
10.3 Tool 59
10.4 Removing the Control Top from the Valve 61
10.5 Dismantling the Control Top into its Components 62
10.5.1 Variants of the Control Top 62
10.5.2 Removing the Cap 62
10.5.3 Removing the Solenoid Valve from the Base (1-PV variant) 63
10.5.4 Removing the Solenoid Valves and the Control Plate (2-PV variant) 64
10.5.5 Removing the Solenoid Valves (3-PV variant) 65
10.5.6 Removing the Evaluation Electronics 67
10.5.7 Dismantling the Pneumatic Block for 2PV and 3PV variant 68
10.5.8 Fitting the Pneumatic Block for 2PV and 3PV variant 69
10.5.9 Install pneumatic connections 70
10.6 Maintenance 71
10.6.1 Replacing the Seals on the Base 71
10.6.2 Maintenance of Sound Absorber, Filter, Supply and Exhaust Air Throttle 73
10.6.3 Mounting hood 73
11 Alarms 75
11.1 Malfunctions and remedies 75
12 Decommissioning 76
12.1 Safety precautions 76
12.2 Disposal 76
12.2.1 General notes 76
13 Spare Parts List - Control Top FLOWVENT Control Top (FLOWVENT-CT) 77
14 Dimension sheet - FLOWVENT Control Top 80
15 Appendix 81
15.1 Lists 81
15.1.1 Abbreviations and terms 81
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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 Herstelleranschrift
GEA Flow Components India
Division of GEA Westfalia Separator India Pvt. Ltd.
#6 & 6P, Bommasandra industrial area, Hebbagodi
Hosur road, Bengaluru - 560099
India
1.3 Contact
Phone: [phone]
www.gea.com
General Information
Herstelleranschrift
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2 Safety
2.1 Intended use
With the FLOWVENT Control Top, all FLOWVENT valves from GEA Flow
Components India can be connected pneumatically and electrically. Using the
device for any other purpose is considered contrary to its designated use.
The FLOWVENT Control Top is available as
•without solenoid valve as position indicator
•with solenoid valve as control top
The FLOWVENT Control Top is completely installed on the dedicated actuator/
adapter of the process valve by means of a clamp connection. The control air is
routed to the valve by an external hose.
The FLOWVENT Control Top with FLOWVENT VALVES can:
•monitor the non-actuated position of the valve disk,
•monitor the actuated position of the valve disk,
•make the position and status of the valve visible in colour via the illuminated
dome fitted on the control top.
The FLOWVENT Control Top must not be used in areas where approvals are
necessary for use in areas with a potentially explosive atmosphere.
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.
Safety
Intended use
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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.
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.
Only original spare parts from GEA Flow Components should be installed. This
ensures that the component is always operating properly and efficiently.
2.4 IP Protection classes
Safety
Operator’s Duty of Care
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In its standard version, the FLOWVENT Control Top fulfils the requirements of
protection class IP66 and IP67 (DIN EN 60529).
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.
First digit * Meaning
ISO 20653 DIN EN 60529 Protection against contact Protection against solids
6k 6 Complete contact protection Complete protection against dust
ingression (dustproof)
Second digit * Meaning
ISO 20653 DIN EN 60529 Protection against humidity
5 5 Protected against water jet (nozzle) from any angle
6 6 Protected against powerful water jets
6k Protected against powerful water jets under increased pressure
7 7 Protected against temporary immersion
9 Protected against high pressure spray downs
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!
When detergents with high surface tension reduction and/or when using high-
pressure cleaners are used, we recommend the use of devices of protection
class IP69k. If this protection class is necessary, a T.VIS® control top or a
position indicator must be purchased and used.
Hint!
The specified protection classes only apply if the connectors are used
for their intended use, if the cable gland is properly sealed and if the
control top is fitted on the valve, see Chapter 6, Page 35.
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.
Safety
General safety instructions and dangers
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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.
2.5.2 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,
Safety
Supplementary Regulations
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•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.
2.7 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 precautions 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 installation. When working on explosion-protected installation 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.
•Familiarity with this instruction manual, especially with the safety precautions
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:
Safety
Qualification of personnel
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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 corresponding certification must be available for work on
machines subject to an explosion hazard.
2.8 Safety equipment
2.8.1 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
2.9 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.
2.9.1 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,
•be careful not to touch the electronic components,
•also take care not to touch electronic components when supply voltage is
present.
Use ESD-compliant packaging when returning electronic components. (Should
you have any questions, please contact GEA Flow Components India.)
Safety
Residual dangers
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2.10 Danger zones
Please observe the following notes:
•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
Danger zones
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3 Description
3.1 Design
Fig.3
No. Designation No. Designation
7 Cap 63 Solenoid valves
8 Pneumatic block 64 Status light-emitting diode
24 Cable gland 78 Terminal strip unit (optional)
43 Evaluation electronics
The FLOWVENT Control Top is made up of:
•a 24 V DC or AS interface evaluation electronics with a position measuring
system for the detection of the two valve end positions,
•an additional terminal strip unit for the switch-on type 24 V DC (optional),
Description
Design
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•a maximum of three solenoid valves for the actuation of the main stroke and
the lift strokes,
•an exhaust air throttle (optional) for the infinitely adjustable setting of the
closing velocity of the main stroke,
•a supply air throttle (optional) for the infinitely adjustable setting of the
opening velocity of the main stroke (with 3 solenoid valve variant: also
reduces the lift strokes).
Description
Design
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Sensor module structure
Printed circuit board switch-on type 24 VDC
Fig.4: Printed circuit board switch-on type 24 VDC
Item Designation Function Connector type Pos. in spare
parts list
1 DIP switch DIP switch to change the tolerances
2 J2 Signals Plug connector Pico-Blade 5-pin / 3
wires
24.5
3 J1 Signals and power supply Plug connector Pico-Blade 5-pin / 5
wires
24.1
4 Electronics
5 Measuring track
6PV Y3 Control of pilot valve 3 Plug connector Pico-Blade 2-pin / 2
wires
63
7PV Y2 Control of pilot valve 2 Plug connector Pico-Blade 2-pin / 2
wires
63 or 64
8PV Y1 Control of pilot valve 1 Plug connector Pico-Blade 2-pin / 2
wires
63
9 Reset Button to trigger reset
10 LED LED to signal the state
Description
Design
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Printed circuit board switch-on type AS interface
Fig.5: Printed circuit board switch-on type 24 VDC
Item Designation Function Connector type Pos. in spare
parts list
1 DIP switch DIP switch to change the tolerances
2 J2 not assigned
3 J1 Signals and power supply Plug connector Pico-Blade 5-pin / 2
wires
24.3
4 Electronics
5 Measuring track
6 PV Y3 Control of pilot valve 3 Plug connector Pico-Blade 2-pin / 2
wires
63
7 PV Y2 Control of pilot valve 2 Plug connector Pico-Blade 2-pin / 2
wires
63 or 64
8 PV Y1 Control of pilot valve 1 Plug connector Pico-Blade 2-pin / 2
wires
63
9 Reset Button to trigger reset
10 LED LED to signal the state
11 ASi state LED LED to signal the state according to
ASi specification
Description
Design
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3.2 Functional description
3.2.1 Operation Principle
The FLOWVENT Control Top 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.
Pneumatic and electronic modules are located inside the control top. The
pneumatic modules in this case are solenoid valves, the number of which varies
between 0 and 3, depending on the intended purpose. Control air is supplied to
the relevant control air chambers via air connections at the outside of the control
top.
The main control air is supplied to the actuator via a separate air connection on
the control top through a hose. The exhaust air of the main actuator is discharged
via an air connection with sound absorber or optionally via an adjustable exhaust
air throttle. The exhaust air from the optional lifting actuators is discharged via
separate air connections with sound absorber.
If the FLOWVENT Control Top is used only as a position indicator without a pilot
valve, the control air supply must be connected directly to the air connection of
the main actuator.
Due to the illuminated dome integrated in the cap of the control top the light
emitting diode arranged on the evaluation electronics can be seen even if the
hood is closed. The light-emitting diode allows visualization of the main functions
of the valve, see Section 6.5, Page 45
3.2.2 Control top without solenoid valves
The FLOWVENT Control Top, without pilot valves, functions as a position
indicator During and after SETUP it indicates the status of the process valve
locally by a coloured LED 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 PNP switching output
•AS interface data bit
Description
Functional description
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Fig.6
3.2.3 Control Top with Solenoid Valves
The control top with solenoid valves acts as a control top. During and after
SETUP 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 PNP switching output
• AS interface data bit
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.
An NO solenoid valve can be used as compressed air support for the actuator
spring (only 2 solenoid valve variants possible).
The control signals are given by the user's process control system or by
operating the solenoid valves manually. To do this, use a screwdriver to turn the
screw (S) from 0 to 1, see figure.
Description
Functional description
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