GEA VARIVENT FRS Manuel utilisateur

Hygienic valves

GEA VARIVENT® FRS valve

Operating instruction (Translation from the original language)

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These Operating Instructions are the English translation of the original operating

instructions in the sense of the EU Machinery Directive. This document is

part, be copied, reproduced, translated or reduced to an electronic medium of

machine-readable form without the express permission of GEA Tuchenhagen

GmbH.

LEGAL NOTICE

Word marks

The designations VARIVENT® and T.VIS® are protected trademarks of GEA

Tuchenhagen GmbH.

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TABLE OF CONTENTS

1 General 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 Manufacturer address 6

1.3 Contact 6

1.4 EU Declaration of Conformity in accordance with the EC Machinery Directive 2006/42/EC 7

1.5 Translated copy of the EU - Declaration of conformity in accordance with the Pressure Equipment Directive

2006/42/EU 8

2 Safety 9

2.1 Intended use 9

2.1.1 Requirements for operation 9

2.1.2 Pressure equipment directive 9

2.1.3 ATEX directive 9

2.1.4 Improper operating conditions 10

2.2 Operator’s Duty of Care 10

2.3 Subsequent changes 11

2.4 General safety instructions and dangers 11

2.4.1 Principles for safe operation 11

2.4.2 Environmental Protection 12

2.4.3 Electrical Equipment 12

2.5 Supplementary Regulations 12

2.6 Qualification of personnel 12

2.7 Safety equipment 14

2.7.1 Signage 14

2.8 Residual dangers 15

2.9 Danger zones 16

3 Description 18

3.1 Design 18

3.2 Functional description 20

3.2.1 Installation position 20

3.2.2 Closing Direction 20

4 Transport and storage 21

4.1 Storage conditions 21

4.2 Transport 21

4.2.1 Scope of supply 21

5 Technical data 22

5.1 Type plate 22

5.2 Technical data 22

5.3 Resistance and permitted operating temperature of the sealing materials 23

5.4 Pipe ends - General table of measurements 24

5.5 Tools 25

5.6 Lubricants 25

5.7 Weights 25

6 Assembly and installation 27

6.1 Safety instructions 27

6.2 Notes on installation 27

6.3 Valve with Detachable Pipe Connection Elements 27

6.4 Valve with Welded Ends 28

6.5 Pneumatic connections 28

6.5.1 Air Requirement 29

6.5.2 Establishing Hose Connections 29

6.6 Electrical connections 29

7 Start-up 31

7.1 Safety instructions 31

7.2 Notes on commissioning 31

7.3 Use of the valve in potentially explosive areas 31

8 Operation and control 33

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8.1 Safety instructions 33

9 Cleaning 34

9.1 Cleaning 34

9.1.1 Cleaning Process Examples 34

9.1.2 Cleaning effect 34

9.2 Passivation 35

10 Maintenance 36

10.1 Safety instructions 36

10.2 Inspections 37

10.2.1 Product contact seals 37

10.2.2 Pneumatic connections 37

10.2.3 Electrical connections 37

10.2.4 Signs on the valve 38

10.3 Maintenance intervals 38

10.4 Prior to disassembly 38

10.5 Disassembling Valve FRS 39

10.5.1 Remove clamp connection (14), separate valve insert from housing 39

10.5.2 Open drive unit 40

10.5.3 Disassembling the Valve into Individual Parts 41

10.5.4 Removing the rinsing valve C 43

10.6 Maintenance 43

10.6.1 Cleaning the Valve 43

10.6.2 Replacing Seals 44

10.6.3 Lubricating Seals and Threads 46

10.7 Installation 47

10.7.1 Torques for the Clamps and Clamp Connections 47

10.7.2 Connections and Operation 48

10.7.3 Pneumatic connection 49

Pneumatic connection Solenoid valve 5/2 way 24VDC 49

10.7.4 Electrical connections 50

Electrical 24 V DC Wiring 50

Electrical Wiring of AS-Interface 51

Setting the feedback 51

Establishing Hose Connections 52

10.7.5 Checking the function 52

11 Alarms 54

11.1 Malfunctions and remedies 54

12 Decommissioning 55

12.1 Safety instructions 55

12.2 Disposal 55

12.2.1 General notes 55

13 Spare parts list - VARIVENT® FRS Valve 56

14 Dimension sheet - Valve FRS 65

15 Appendix 67

15.1 Lists 67

15.1.1 Abbreviations and terms 67

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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 Manufacturer address

GEA Tuchenhagen GmbH

Am Industriepark 2-10

21514 Büchen

1.3 Contact

Tel.:+49 4155 49-0

Fax:+49 4155 49-2035

[email protected]

www.gea.com

General Information

Manufacturer address

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1.4 EU Declaration of Conformity in accordance with the EC Machinery Directive

2006/42/EC

General Information

EU Declaration of Conformity in accordance with the EC Machinery Directive 2006/42/EC

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1.5 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®

due to its design and construction as well as in the versions sold by us, meet the basic safety and health requirements of the following

guideline:

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 alterations 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 prepared in accordance with Annex

VII, Part A, and agree to submit the documentation on

justified request of national authorities on a data carrier

Person authorised for compilation and handover of technical

documentation:

GEA Tuchenhagen GmbH

CE Documentation Officer

Am Industriepark 2-10

21514 Buchen, Germany

Büchen, 24 January 2020

Franz Bürmann

Managing Director i.V. Matthias Südel

Head of Engineering

General Information

Translated copy of the EU - Declaration of conformity in accordance with the Pressure Equipment Directive 2006/42/EU

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2 Safety

2.1 Intended use

The VARIVENT® FRS valve is designed for use with powdery media as well as

CIP and drying processes. The powder medium is conveyed through the process

housing with the valve closed. By means of flush bores, preferably sterile

compressed air that flows through a gap in the valve disk to the process housing,

can be applied to the valve seat. Thanks to this pressurisation any collection of

powder at the valve seat can be avoided.

When the valve is open, cleaning medium can be fed via the single-spout CIP

housing. After the CIP cleaning has been carried out, the valve can be dried in

open valve position with hot air or steam (see “Technical data” (page 21).

The FRS valve is used for opening and closing pipeline sections.

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 of such misuse lies entirely with

the operator of the facility.

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 Pressure equipment directive

The component is a piece of pressure equipment (without safety function) in the

sense of the pressure equipment directive 2014/68/EU. Classified according to

Annex II in category 1.

According to the scope of directive 2014/34/EC, article 1, paragraph 2, f, the

exception of the directive applies, due to conformity with the machine directive

2006/42/EU.

The nominal diameters smaller than DN 25 are subject to article 4, paragraph 3

of the Pressure Equipment Directive which specifies sound engineering practice.

Nominal diameters ≥ IPS 4“; DN 125 valid for the fluid group II.

In the event of any deviations, GEA Tuchenhagen GmbH will supply a specific

Declaration of Conformity.

2.1.3 ATEX directive

In areas with an explosive atmosphere, only valves suitable for use in such areas

may be used.

Please observe chapter 7.3 “Use of the valve in potentially explosive

atmospheres”.

Safety

Intended use

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If these valves are used in areas with a potentially explosive atmosphere, you

must absolutely comply with directive 2014/34/EC with respect to all ignition

hazards.

2.1.4 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.

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.

Safety

Operator’s Duty of Care

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