Tyco 8700 Series User manual

Varioflow double safety process valves - series 8700
Instruction manual DN125 - DN150
Tyco reserves the right to change the contents without notice HOVSB-0017-EN-0511
1 Contents
2 Introduction 2
2.1 Valve use 2
2.2 Application area 2
2.3 Incorrect use 2
3 Safety 2
4 Transport and storage 2
5 Installation instructions 2
5.1 Mounting 2
5.2 Installation into pipework 2
5.3 Operating space 2
5.4 Mounting space 2
6 Operation 3
6.1 Operation with air 3
6.2 Connection of flushing chambers 3
6.3 Indication of valve position 3
6.4 Control unit 3
7 Cleaning and maintenance 3
7.1 Cleaning 3
7.2 Lead-time 3
7.3 Safety measures during maintenance 3
7.4 Grease to be used 4
7.5 Disassembling the valve 4
7.6 Disassembling the actuator 4
7.7 Assembling the actuator 5
7.8 Assembling the valve 5
7.9 Faults 5
Appendix A: Cross-section 6
Appendix B: Parts and spare parts 7
Parts 7
Spare parts 7
Ordering spare parts 7
Appendix C: Technical specification 8
Valve material 8
Gasket material 8
Noise level 8
Air supply pressure 8
Air consumption 8
Version and ordering code 8
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Varioflow double safety process valves - series 8700
Instruction manual DN125 - DN150
Tyco reserves the right to change the contents without notice page 2
2 Introduction
2.1 Valve use
The Hovap Varioflow double safety valve is a valve with a double seat. Mixture of products is
prevented in case of seat leakage. The drain removes any leakage liquid.
2.2 Application area
The valve has been designed for use in the food & beverage and pharmaceutical industries.
2.3 Incorrect use
The valve is not suitable for use in gas systems.
Liquids with hard solid parts cause increased wear of the gaskets.
3 Safety
The valve must be installed or protected in such a way that cleaning- or draining liquids that leave
the drainpipe from the valve or flushing chambers cannot cause harm or damage to anyone who
might be present in the area.
There must be a free space of at least 200 mm above or below the valve. This prevents the
jamming of parts of the body during opening/closing of the valve.
Prevent that, during maintenance, liquids can pressurize the pipework in which the valve has been
installed.
Prevent that fingers or hand get jammed between valve and seats during operation of a
disconnected valve.
During maintenance of the actuator, the indications according to 7.6 and 7.7 must be followed
carefully to avoid injury caused by the expanding pressure springs.
During cleaning and operation at elevated temperatures, the valve can become so hot that
touching the surface causes burning.
4 Transport and storage
The valve has been wrapped in plastic. This prevents dust and dirt to enter the valve interior.
Re-wrap the interior when the valve is unpacked for installation of the body into the pipework.
The quality of O-rings may deteriorate during long-term storage.
5 Installation instructions
5.1 Mounting
To ensure a correct operation of the leakage indication, it is essential that the valve will be installed
vertically with the actuator upwards.
5.2 Installation into pipework
The valve can be installed directly into the pipework. The body can be welded after removing the
valve interior, including all O-rings/gaskets.
The drainpipe and the flushing chambers must not be connected to the pipework. There must be
no pressure build-up to ensure smooth operation.
5.3 Operating space
Above and below the valve, a free space is required of at least 110 mm.
5.4 Mounting space
To enable valve maintenance, a free space above the valve is required of at least 700 mm for the
DN125 valve and 800 mm for the DN150 valve.
Lifting
A lifting tackle must be present above the valve, to allow lifting the valve interior from the body
during maintenance.

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Varioflow double safety process valves - series 8700
Instruction manual DN125 - DN150
6 Operation
6.1 Operation with air
The valve is provided with three air connections with 1/8” BSP female-thread.
P I: Clean drain space via lower valve body.
P II: Open valve.
P III: Clean drain space via upper valve body.
The air supply must be connected to the valve such that it is impossible to pressurize more than
one connection at a time.
During cleaning it must be impossible to pressurize P II and P III simultaneously.
There must be a delay of about 10 s when changing from one connection to another.
Air connections that are not used must be equipped with bleed nipples.
6.2 Connection of flushing chambers.
The flushing chamber has feed and drain connections with 1/8”G (up to 4” - DN100) or 1/4”G
(DN125-150) female thread. To prevent internal contamination or ingress of pollutants, cleaning
liquid or steam (standard of up to 121°C) be applied to the flushing chambers. Liquids enter at the
bottom (B) and exit at the top (A) of the flushing chambers. Steam enters at the top (A) and exits
at the bottom (B). See also 5.2.
6.3 Indication of valve position.
The valve can be provided with a bracket for proximity switches. The following situations are
possible:
6.4 Control unit
The valve can also be provided with a control unit. Most commercially available unites can be
fitted.
21
211
2 111
)
*
)
*
Seat open Seat closed Open/close indication
7 Cleaning and maintenance
7.1 Cleaning
The valve is suitable for C.I.P. cleaning.
The drain space can be cleaned by supplying pressurized air for a few seconds to P III (to clean
the upper body) or P I (to clean the bottom body). See 6.1
The flushing chambers can be cleaned with water or detergents.
Low pressure steam (standard of up to 121°C) can be used for sterilization.
The valve material is resistant to detergents that are commonly used in the food industry, such as
a lye (NaOH) or acid (HNO3) solution of about 2 1/2% at a temperature of about 80°C. After
cleaning, the system must be rinsed with clean water to prevent corrosion.
7.2 Lead-time
Sealing and wearing parts of the valve must be checked once a year. For special applications
(such as highly viscous or crystallizing liquids) the lead-time must be adjusted in consultation with
the manufacturer.
7.3 Safety measures during maintenance
When disassembling the valve, the pipework must be empty. With disassembled valves, it must
be prevented that the pipework can be filled accidentally by, e.g., starting a pump or activating a
valve.
When disassembling or assembling the actuator, the instructions must be followed.
Please take special care when the pressure springs expand!

Tyco reserves the right to change the contents without notice page 4
Varioflow double safety process valves - series 8700
Instruction manual DN125 - DN150
7.4 Grease to be used
See Appendix A
Product side
Quad-rings 17 and O-rings 23, 40 and 41 may only be greased with Molykote 111. Other grease
has an adverse effect on valve operation. O-ring 25 must be installed dry.
Non-product side
These O-rings can be greased with grease that has been approved for use in the food industry.
7.5 Disassembling the valve
See Appendix A
A - Remove, if present, the indicators from the top of the valve.
B - Remove the nipples from the air connections.
C - Loosen clamp 7.
D - Use a tackle to pull actuator 3 with lower valve 31 and upper valve 32 out of valve body 1.
Use eye bolts 37. A hoisting accessory can be supplied by Hovap.
E - Remove positioner 26.
F - Pull lower valve 31 and upper valve 32 out of actuator 3.
G - Use a pin spanner to remove insert 39 from upper valve 32.
H - Loosen clamp 43.
I - Remove protection body 2.
J - Check all O-rings, both bearings 11 and cylindrical bearings 36.
7.6 Disassembling the actuator
See Appendix A
A - Place the actuator on the table of a drill. Put a length of tube on cover 4 over spring cup 10.
If no drill is available, a threaded end with nuts can be used.
B - Press cover 4 about 10 mm downward against the spring pressure.
Caution: springs under pressure!
C - Use a pin to remove circlip 16 from its groove.
D - Allow the springs to expand and disassemble the actuator.
E - Check gaskets, O-rings and cylindrical bearing 15.
M12
16
4
Disassembling with drilling machine
Detail hole for
removing circlip
Disassembling with threaded end

Tyco reserves the right to change the contents without notice page 5
Varioflow double safety process valves - series 8700
Instruction manual DN125 - DN150
7.7 Assembling the actuator
See Appendix A
A - Place the O-rings.
B - Loosely assemble all parts.
C - Put the actuator on the table of a drill or use a threaded end.
D - Mount circlip 16.
F - Allow the springs to expand. Check carefully if circlip 16 fits correctly in the
groove of cover 4.
7.8 Assembling the valve
See Appendix A
A - Use a pin spanner to mount insert 39, together with O-rings 25, 40, 41
and guide ring 44, to upper valve 32.
B - Place O-rings 20 and 23, TV O-ring 18 in upper valve 32.
C - Place TV O-ring 18 in lower valve 31.
D - Place O-ring 22 and spring 27 around valve stem 6.
E - Slide lower valve 31 into upper valve 32 and place tube 46.
F - Place valve set 31/32 in actuator 3.
G - Fasten positioner 26.
H - Place both bearings 11 in valve body 1.
I - Slightly stretch quad-rings 17, which have been greased with Molykote 111, and place them
into valve body 1.
J - Use a tackle to lower actuator 3 with valve set 31/32 into valve body 1. Use eye bolts 37. A
hoisting accessory can be supplied by Hovap.
K - Check the correct installation of quad-rings 17 by blowing into the leakage holes of the
connecting pieces.
L - Fasten clamp 7.
M - Place protection body 2 and fasten clamp 43.
N - Connect the air supply.
O - Check if the valve operates smoothly.
7.9 Failures
See Appendix A
Leakage out of holes at clamp 7 or 43
Check quad-rings 17.
Leakage via drainpipe 30
Check TV ring 18 if leakage occurs in closed position of valve.
Check O-ring 25 if leakage occurs in open position of the valve.
Air leakage via cover 4
Check O-rings 20 and 21.
Air leakage via connections P II or P III (see 6.1)
Check O-rings 20.
Liquid in the actuator
Check O-ring 23 or quad ring 17 at the actuator side, in case of upper valve flushing.
Valve opens/closes slowly
Air supply pressure is below 6 bar.
Air tube is too long, is pinched or the diameter is too small.
Liquid in the actuator.
Valve opens/closes with irregular movement
Quad-rings pos. 17 are dry. Remove these quad-rings and install new ones that have been
greased with Molykote 111.

Tyco reserves the right to change the contents without notice page 6
Varioflow double safety process valves - series 8700
DN125 - DN150 / Appendix A - Cross-section

Varioflow double safety process valves - series 8700
DN125 - DN150 / Appendix B - parts and spare parts
Tyco reserves the right to change the contents without notice page 7
Parts
Pos. Qty. Description Pos. Qty. Description
1 1 Valve body 23 2 O-ring
2 1 Protection body 25 1 O-ring
3 1 Actuator 26 1 Positioner
4 1 Cover 27 1 Spring
6 1 Valve stem 28 1 Pin
7 1 Clamp 29 1 Auxiliary piston
9 1 Spring housing 30 1 Drain pipe
10 1 Spring dish 31 1 Lower valve
11 2 Bearing 32 1 Upper valve
15 1 Cylindrical bearing 36 2 Cylindrical bearing
16 1 Circlip 37 2 Lifting eye bolt
17 4 Quad-ring 39 1 Insert
18 2 TV-O-ring 40 1 O-ring
19 1 O-ring 41 1 O-ring
20 3 O-ring 43 1 Clamp
21 2 O-ring 44 1 Upper valve guide ring
22 1 O-ring 46 1 Tube
Spare parts
Pos. Qty. Description DN125 DN150
11 2 Cylindrical bearing
17 4 Quad-ring 148.6 x 7 160.5 x 7
18 2 TV O-ring 134 x 7 146 x 7
19 1 O-ring 208 x 3 208 x 3
20 3 O-ring 196.22 x 7 196.22 x 7
21 2 O-ring 22 x 3 22 x 3
22 1 O-ring 15 x 1.5 15 x 1.5
23 2 O-ring 43.82 x 5.33 43.82 x 5.33
25 1 O-ring 135.89 x 7 145.42 x 7
36 2 Cylindrical bearing
40 1 O-ring 135.89 x 7 145.42 x 7
41 1 O-ring 72 x 3 72 x 3
Ordering spare parts
When ordering spare parts, please include the
following information:
• The valve number.
• The valve ordering code. See Appendix C.
• The valve size.
• The valve part position number.
• The quality of any quad-rings and O-rings.

Varioflow double safety process valves - series 8700
DN125 - DN150 / Appendix C - technical specification
Tyco reserves the right to change the contents without notice page 8
Valve material
All metal parts that come into contact with the liquid are made of stainless steel according to
W.Nr. 1.4401. The metal parts that do not come into contact with the liquid are made of stainless
steel W.Nr. 1.4301 or of plastics. The bearings in the actuator are made of self-lubricating bronze.
Gasket material
The quad- and O-rings on the product side are made of EPDM. The TV O-rings in the valve have
a FPM core with a PTFE coating. The O-rings in cover 4 are of FPM, other O-rings are of NBR.
Alternatives for the material of quad- and O-rings on the product side are available.
Noise level
The noise caused by the valve has an A-weighted equivalent continuous noise pressure of less
than 70 dB(A).
Air supply pressure
The air supply pressure must be between 5 and 10 bar. Recommended is the use of dry air of
6 bar.
Air consumption
The air consumption in nl per stroke is given in the table below. Air consumption has been
calculated at 6 bar air pressure.
Size Opening Cleaning drain space Cleaning drain space
via upper body via lower body
DN 125 41 10.7 4.1
DN 150 47 9.7 4.1
Version and ordering code
The following versions are available:
8711 8712 8721 8722
Version
Ordering code