OI - Valve Q - V1 - 2019-03 - EN

Hygienic valves
GEA VARIVENT® Overflow Valve Q Type D Force
Operating instruction (Translation from the original language)

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COPYRIGHT
These Operating Instructions are the English translation of the original operating
instructions in the sense of the EU Machinery Directive. This document is
protected by copyright. All rights reserved. The document may not, in whole or in
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 designation VARIVENT® is a protected trademark of GEA Tuchenhagen
GmbH.
We kindly request that you answer a few short questions about these Operating
Instructions. Use the following QR code or link to access the questionnaire:
https://www.ntgt.de/ra/s.aspx?s=367112X57707125X58087
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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 for Machines 7
1.5 EC - Declaration of conformity in accordance with the Pressure Equipment Directive 2014/68/EU 8
2 Safety 10
2.1 Intended use 10
2.1.1 Requirements for operation 10
2.1.2 Pressure equipment directive 10
2.1.3 ATEX directive 10
2.1.4 Improper operating conditions 10
2.2 Operator’s Duty of Care 11
2.3 Subsequent changes 11
2.4 General safety instructions and dangers 12
2.4.1 Principles for safe operation 12
2.4.2 Environmental Protection 12
2.4.3 Electrical Equipment 13
2.5 Supplementary Regulations 13
2.6 Qualification of personnel 13
2.7 Safety equipment 14
2.7.1 Signs 14
2.8 Residual dangers 16
2.9 Danger zones 16
3 Description 18
3.1 Design 18
3.2 Functional description 20
3.2.1 Valve Q 20
3.2.2 Possible Response Pressure Settings 21
4 Transport and storage 22
4.1 Storage conditions 22
4.2 Transport 22
4.2.1 Scope of supply 22
5 Technical data 23
5.1 Type plate 23
5.2 Technical data 23
5.3 Resistance of the sealing materials 24
5.4 Pipe ends - General table of measurements 25
5.5 Tool 26
5.6 Lubricants 27
5.7 Weights 27
6 Assembly and installation 29
6.1 Safety instructions 29
6.2 Notes on installation 29
6.3 Valve with Detachable Pipe Connection Elements 29
6.4 Valve with Welded Ends 30
6.5 Pneumatic connections 30
6.5.1 Air Requirement 31
6.5.2 Establishing Hose Connections 31
7 Start-up 32
7.1 Safety notes 32
7.2 Commissioning activities 32
8 Operation and control 33
9 Cleaning 34
9.1 Cleaning 34
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9.1.1 Cleaning Process Examples 34
9.1.2 Cleaning effect 34
9.2 Passivation 35
10 Maintenance 36
10.2 Inspections 37
10.2.1 Product contact seals 37
10.2.2 Pneumatic connections 37
10.3 Maintenance intervals 37
10.4 Prior to disassembly 38
10.5 Disassembling the valve Q 38
10.5.1 Disconnecting the Valve from the Housing 38
10.5.2 Removing the Valve Disk 40
10.6 Maintenance 41
10.6.1 Cleaning the Valve 41
10.6.2 Replacing the V-Ring 42
10.6.3 Lubricating Seals and Threads 43
10.7 Installation 44
10.7.1 Setting the Response Pressure 44
10.7.2 Install valve Q with actuator F-CJ type D-Force 45
10.7.3 Function Check of Actuator M 46
10.7.4 Torques for the Clamp Connections 46
11 Alarms 47
11.1 Malfunctions and remedies 47
12 Decommissioning 48
12.2 Disposal 48
12.2.1 General notes 48
12.2.2 Valve Actuator Disposal 48
13 Spare parts list – overflow valve Q 49
14 Spare Parts List – Actuators F and F-CJ 54
15 Spare Parts List - Actuator M 57
16 Spare Parts List - Actuator CJ 59
17 Dimension sheet – overflow valve Q 61
18 Appendix 64
18.1 Lists 64
18.1.1 Abbreviations and terms 64
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General Information
Information on the Document
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 hazard.
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General Information
Manufacturer address
Warning!
Warning: Serious Injuries
Failure to observe the warning can result in serious damage to health.
the hazard.
Caution!
Warning: Injuries
Failure to observe the warning can result in minor or moderate damage to
health.
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 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
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General Information
EU Declaration of Conformity for Machines
1.4 EU Declaration of Conformity for Machines

in accordance with the EC Machinery Directive 2006/42/EC, Annex II 1. A
Manufacturer: Am Industriepark 2-10
21514 Büchen
We declare under our sole responsibility that the machine

Designation: Valve with actuator
Type: VARIVENT®
conforms with all the relevant provisions of this directive and the
following directives:
Relevant EC directives: 2006/42/EC EC Machinery Directive
Applicable harmonized DIN EN ISO 12100 Safety of Machines -
standards, in particular: General design principles
- Risk assessment and
risk reduction
Other applied standards --
and technical
specifications:
Remarks: 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 Person authorised to compile the

handover of technical documentation: technical file for CE marking
21514 Büchen
Büchen, 16/02/2015
Franz Bürmann i.V. Matthias Südel

Managing Director Senior Director
Product Development
Flow Components
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General Information
EC - Declaration of conformity in accordance with the Pressure Equipment Directive 2014/68/EU
1.5 EC - Declaration of conformity in accordance with the Pressure Equipment

Directive 2014/68/EU

Manufacturer: Am Industriepark 2-10
21514 Büchen
We hereby declare that the product series designated below, based on their
design, type and version brought to market by us, complies with the basic
health and safety requirements of the Pressure Equipment Directive.
This declaration will become invalid if any alterations are made to the pressure
equipment which have not been agreed with us.
VARIVENT®, ECOVENT®,
Product series:
VARINLINE®
Serial numbers: 140000 - 169999
Relevant EC directives: 2014/68/EU Pressure Equipment

Directive
Category I
Conformity assessment
procedure
(Internal production
control)
Applicable harmonized DIN EN 13445-3:2014-12 Experimental methods
standards, in particular: (burst test)
Other applied standards DIN EN 10088-1
Materials standard
and technical DIN EN 10088-2
specifications: Industrial valves - Shell
DIN EN 10088-3
design strength
DIN EN 12516
Remarks: – Valid for substances of fluid group

2.
If substances of fluid group 1 are
used, a new assessment must be
carried out.
– The nominal diameters DN25,
1”OD and smaller are subject to
article 4, paragraph 3 of the
Pressure Equipment Directive
which specifies sound engineering
practice.
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General Information
Person authorised for compilation and Person authorised to compile the

handover of technical documentation: technical file for CE marking
21514 Büchen
Büchen, 08/11/2017
Matthias Südel
Senior Director
Product Development Flow
Components
Michael Wulle
Managing Director
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Safety
Intended use
2 Safety
2.1 Intended use

The Q and Q overflow valves type D-Force are used for overpressure protection
in pipeline sections.
The medium must flow in the opening direction of the valve disk, so that the valve
can open automatically in case of excess pressure.
The valve Q type D-Force can be opened for cleaning. In addition, the preset
response pressure can be changed pneumatically with the valve Q type D-Force.
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 Pressure equipment directive

The stop valves N and U are pressure-keeping equipment (without safety
function) in the sense of the pressure equipment directive: Directive 2014/68/EG.
They are classified according to Annex II, article 4, section 3. 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.
Refer to and observe the additional operating instructions “ATEX version valves”.
For details regarding the marking of valves for potentially hazardous areas also
refer to the additional operating instructions “ATEX version valves”.
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.
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Safety
Operator’s Duty of Care
• 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.
• 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.
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Safety
General safety instructions and dangers
In general, only original spare parts supplied by GEA Tuchenhagen GmbH

should be fitted. This ensures that the component is always operating properly
and efficiently.
2.4 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
2.4.1 Principles for safe operation

Dangerous situations during operation can be avoided by safety-conscious and
proactive behaviour of the staff.
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.
2.4.2 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.
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Safety
Supplementary Regulations
2.4.3 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.
2.5 Supplementary Regulations

In addition to the instructions in this documentation the following also has to be
observed:
• pertinent accident prevention regulations,
• 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.
2.6 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 instructions 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 system. When working on explosion-protected equipment 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.
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Safety
Safety equipment
• Received instruction about operating sequences on the component.

• Familiar with the safety devices and their function.
• Familiar with these Operating Instructions, especially with the safety
instructions 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:
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 relevant certificates of qualification must be submitted before
work can be carried out on ATEX certified machines.
2.7 Safety equipment
2.7.1 Signs
Hazardous locations on the component are marked by warning labels, prohibition
signs and mandatory signs.
The signs and instructions on the component must always be legible. Any
illegible signs must be replaced immediately.
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Safety
Safety equipment
Signs on the valve
Sign Meaning
General hazard warning

Fig.1
Warning Crushing
Fig.2
Explosive atmosphere hazard warning

Fig.3
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Safety
Residual dangers
2.8 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 valve and measures

Danger Cause Measure
Danger to life Inadvertent switch-on Effectively disconnect all components,
of the valve 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.
Spring tension in the Danger to life caused by compression spring in

actuator the actuator. Do not open the actuator but
return it to GEA Tuchenhagen for proper
disposal.
Risk of injury Danger presented by The operator must exercise caution and
moving or sharp- prudence.
edged parts For all work:
• Wear suitable work clothing.
• Never operate the machine if the cover
panels are not correctly fitted.
• Never open the cover panels during the
operation.
• Never reach into openings.
As a precautionary measure, wear personal
protective equipment in the vicinity of the valve:
• Protective gloves
• Safety shoes
Environmental Operating materials For all work:
damage with properties which • Collect lubricants in suitable containers.
are harmful to the
environment • Dispose of lubricants in accordance with the
pertinent regulations.
2.9 Danger zones

Please observe the following notes:
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Safety
Fig.4
• In the event of malfunctions, shut down the valve (disconnect from the power
and air supply) and secure it against being used.
• Never reach into the lantern (9) or the valve housing (401) when the valve is
switching. Fingers can be crushed or cut off.
• On a spring-closing valve there is danger of injury when the clamp connection
(43, 46) is opened, as the released spring pretension will suddenly lift the
actuator. Therefore, release the spring tension before detaching the clamp
connection (43, 46) by supplying the actuator (A) with compressed air.
• Before starting any service, maintenance or repair work, disconnect the valve
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 valve 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.
• The housing sockets have very sharp edges. When transporting and
assembling the valve be sure to wear suitable protective gloves.
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Description
Design
3 Description
3.1 Design
Fig.5
Design
No. Designation
A Actuator
1 Gasket
2 Bearing
3 Sealing washer
4 Bearing disc
9 Lantern
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Description
Design
Design
No. Designation
15 Valve disk
L.1 Air connection to open, valve type F-CJ
L.2 Air connection to close, valve type F-CJ
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Description
Functional description
3.2 Functional description
3.2.1 Valve Q
Closing Direction
Closing direction: from top to bottom
Standard: spring-to-close
Fig.6
Actuator F with Adjustable Spring

– Valve opens when the set opening pressure is exceeded.
Actuator M with Adjustable Spring and Integrated Pneumatic Actuator
– Valve can be lifted pneumatically, e.g. for cleaning
Actuator F-CJ – Type D-Force with Adjustable Spring and Integrated
Pneumatic Actuator
– Valve can be lifted pneumatically, e.g. for cleaning
A greater locking force can be achieved by applying air.
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Description
3.2.2 Possible Response Pressure Settings

The versions are available with different spring packages. For the selection of the
suitable actuator see the following tables:
Response pressure actuators F and M
Nominal width Response pressure (bar)

Metric Inch OD/IPS F11 / F21 / F1 / M1 F2 / M2 F3 / M3 F4 / M4
M11 M21
25 1" OD 1.5 - 4.5 3-9 8 - 16 -- -- --
40 1.5" OD -- 1.5 - 2 1.5 - 5 4 - 15 14 - 16 --
50 2" OD -- -- 1.5 - 4 3 - 11 10 - 16 --
65 2.5" OD -- -- -- 1-4 3 - 10 9 - 15
80 3" OD -- -- -- 1-4 3 - 10 9 - 10
100 4" OD -- -- -- 0.5 - 1.5 0.5 - 4 3-7
Response pressure actuator F-CJ

Metric Inch OD/IPS F1-CJ F2-CJ F3-CJ F4-CJ
25 1" OD 8 - 16 -- -- --
40 1.5" OD 1.5 - 5 4 - 15 14 - 16 --
50 2" OD 1.5 - 4 3 - 11 10 - 16 --
65 2.5" OD -- 1-4 3 - 10 9 - 15
80 3" OD -- 1-4 3 - 10 9 - 10
100 4" OD -- 0.5 - 1.5 0.5 - 4 3-7
Control air pressure required to open the valve

M11 M21 M1 / F1-CJ M2 / F2-CJ M3 / F3-CJ M4 / F4-CJ
Actuator M 3 3 3 4 3 5
Actuator F-CJ 3 3 3 3 4 6.5
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Transport and storage
Storage conditions
4 Transport and storage
4.1 Storage conditions

The valves, valve inserts or spare parts should be stored in a dry place, free of
vibrations and dust, and protected from light. To avoid damage, leave the
components in their original packaging if possible.
If, during transport or storage, the valve is going to be exposed to temperatures ≤
0°C, it must be dried beforehand and suitable measures must be taken to protect
it from damage.
Hint!
We recommend that the valve should be stored at a temperature of ≥ 5

°C for a period of 24 hours prior to any handling (disassembling the
housings / activation of actuators) so that any ice crystals formed by
condensation water can melt.
4.2 Transport
For transport, the following principles apply:
• Only use suitable lifting gear and slings for transporting the package units/
valves.
• Observe the pictograms on the package.
• Handle valves with care to avoid damage caused by impact or careless
loading and unloading. The outside synthetic materials are susceptible to
breaking.
• Only allow qualified staff to transport the valve.
• Movable parts must be properly secured.
• Only use approved, fully functional load lifting devices and lifting accessories
which are suitable for the intended purpose. Observe the maximum load-
bearing capacities.
• Secure the valve against slipping. Take the weight of the valve into account
and the position of the point of gravity.
• Under no circumstances should anyone stand under a suspended load.
• Take care when transporting the valve. Do not grip sensitive parts of the unit
to lift or push the unit or to support yourself. Avoid putting the unit down with a
jerk.
4.2.1 Scope of supply

After taking delivery of the component, check if
• the details on the type plate correspond to the data in the order and delivery
documents,
• the equipment is complete and all components are in good order.
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Technical data
Type plate
5 Technical data
5.1 Type plate

The type plate clearly identifies the valve.
Fig.7
The type plate provides the following key data:
Key data of the valve

Type Overflow valve Q
Serial Serial number
Material 1.4404 (AISI 316L) / EPDM (FDA)
Control air pressure bar/psi min. 5.0 / 72.5; max. 8.0 / 116
Product pressure bar/psi 1.0 / 14.5
5.2 Technical data

Refer to the following tables for the key technical data of the valve:
Technical data: Valve

Designation Description
Size DN 25 to DN 100
1" to 4" OD
2" to 4" IPS
Material of product contact parts Stainless steel 1.4404
Installation position Vertical
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Technical data
Resistance of the sealing materials
Technical data: Ambient temperatures

- Valve 0 to 45 °C (32 ... 113 °F), standard
< 0 °C (32 °F): Use control air with a
low dew point. Protect valve stems
against freezing.
Product temperature and operating
depending on the sealing material
temperature
Technical data: Compressed air supply

Air hose
- metric Material PE-LD
Outside Ø 6 mm
Inside Ø 4 mm
- Inch Material PA
Outside Ø 6.35 mm
Inside Ø 4.3 mm
Product pressure see table in chapter "Adjustable
response pressures" (page 21)
Control air pressure see table in chapter "Adjustable
response pressures" (page 21)
max. 8 bar
Control air acc. to ISO 8573-1
- Solid particle content: Quality class 6
Particle size max. 5 µm
Particle density max. 5 mg/m3
- Water content: Quality class 4
max. dew point +3 °C
If the unit is used at higher altitudes or
at low ambient temperatures, the dew
point must be adapted accordingly.
- Oil content: Quality class 3, preferably oil free
max. 1 mg oil in 1 m3 air
5.3 Resistance of the sealing materials

The resistance of sealing materials depends on the type and temperature of the
medium conveyed. The exposure time can adversely affect the service life of the
seals. The sealing materials comply with the regulations of FDA 21 CFR
177.2600 or FDA 21 CFR 177.1550.
Resistance:
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Technical data
Pipe ends - General table of measurements
• + = good resistance
• o = reduced resistance
• - = no resistance
* Depending on the installation conditions
Seal resistance for EPDM, FKM, HNBR, PTFE
Medium Temperature Sealing material (general operation temperature)

EPDM FKM HNBR
-40...+135 °C * -10...+200 °C * -25...+140 °C *
(-40...275 °F) (+14...+392 °F) (-13...+284 °F)
Alkalis up to 3% up to 80 °C (176 °F) + o +
Alkalis up to 5% up to 40 °C (104 °F) + o o
Alkalis up to 5% up to 80 °C (176° F) + – –
Alkalis more than 5% o – –
Inorganic acids up to 3% up to 80 °C (176 °F) + + +
Inorganic acids up to 5% up to 80 °C (176 °F) o + o
Inorganic acids up to 5% up to 100 °C (212 °F) – + –
Water up to 100 °C (212 °F) + + +
Steam up to 135 °C (275° F) + o o
Steam, approx. 30 min up to 150 °C (320 °F) + o –
Steam, approx. 30 min up to 160 °C (320 °F) – o –
Fuels/hydrocarbons – + +
Product with a fat
+ + +
content of max. 35%
Product with a fat
content of more than – + +
35%
Oils – + +
* Depending on the installation conditions
5.4 Pipe ends - General table of measurements

Hint!
Not every valve is available in every size. Particulars of available sizes
of valves see Chapter 5, Page 23.
Dimensions for Pipes in DN
Metric DN Outer Wall thickness Inner Outer

diameter diameter diameter according to
DIN 11850
15 19 1.5 16 x
20 23 1.5 20 x
25 29 1.5 26 x
40 41 1.5 38 x
50 53 1.5 50 x
65 70 2.0 66 x
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Technical data
Tool
Dimensions for Pipes in DN
Metric DN Outer Wall thickness Inner Outer

DIN 11850
80 85 2.0 81 x
100 104 2.0 100 x
Dimensions for Pipes in Inch OD
Inch OD Outer Wall thickness Inner Outer

BS 4825
0.5" 12.7 1.65 9.4 x
0.75" 19.05 1.65 15.75 x
1" 25.4 1.65 22.1 x
1.5" 38.1 1.65 34.8 x
2" 50.8 1.65 47.5 x
2.5" 63.5 1.65 60.2 x
3" 76.2 1.65 72.9 x
4" 101.6 2.11 97.38 x
Dimensions for Pipes in Inch IPS
Inch IPS Outer Wall thickness Inner Outer

DIN EN ISO 1127
2" 60.3 2 56.3 x
3" 88.9 2.3 84.3 x
4" 114.3 2.3 109.7 x
5.5 Tool
Tool Material no.

Hose cutter 407-065
Belt wrench 408-142
V-ring insertion tool 229-109.88
Vice support 470-001
Scriber 414-001
Open-ended wrench, ends ground, a/f 17-19 229-119.01
Open-ended wrench, a/f 30-32 408-041
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Technical data
Lubricants
5.6 Lubricants
Lubricants
Lubricant designation Material no.
Rivolta F.L.G. MD-2 (1000 g) 413-071
Rivolta F.L.G. MD-2 (100 g) 413-136
5.7 Weights
Valve Without Actuator

Size Weight [kg]
DN 25, 1" approx. 2.0
DN 40, 1.5" approx. 2.6
DN 50, 2" approx. 2.7
DN 65, 2.5" approx. 4.0
DN 80, 3" approx. 5.5
DN 100, 4" approx. 7.0
Actuator type M
Size Weight [kg]
M 11 5.3
M 21 5.4
M1 7.4
M2 7.5
M3 8.9
M4 9.2
Actuator type F
Size Weight [kg]
F 11 1.6
F 21 1.9
F1 2.7
F2 2.8
F3 3.2
F4 3.6
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Technical data
D-Force Actuator Type F-CJ

Size Weight [kg]
F 1-CJ (D-Force) 11.8
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Assembly and installation
Safety instructions
6 Assembly and installation
6.1 Safety instructions

Hazardous situations during installation can be avoided by safety-conscious and
proactive behaviour of the personnel.
For installation, the following principles apply:
• Only qualified personnel are allowed to set-up, install and commission the
component.
• Ensure that adequate working and traffic areas are available at the place of
installation.
• Observe the maximum load-bearing capacity of the installation surface.
• Observe the transport instructions and markings on the part(s) to be
transported.
• Remove any nails protruding from transport crates immediately after opening
the crate.
• Under no circumstances should anyone stand under a suspended load.
• Safety devices of the component may not work effectively during installation.
• Reliably secure sections of the plant which have already been connected
against inadvertently being switched on.
6.2 Notes on installation

The installation position of the valve is upright. Care must be taken to ensure that
the valve housing and the pipe system can drain properly.
To prevent damage, make sure that
• the valve is installed in the pipe system free of tension and
• no foreign materials (e.g. tools, bolts, lubricants) are left in the system.
6.3 Valve with Detachable Pipe Connection Elements

This section describes the procedure to fit the valve.
Caution!
Liquids in pipes
Danger of injury due to liquid spraying out
► Therefore, before releasing any pipe connections or clamp connections:
drain the pipe and, if necessary, clean or rinse it.
► Separate the pipe section in which the valve is to be fitted from the rest
of the piping system to prevent product entering again.
Carry out the following steps:

1. Fit valves with detachable pipe connection elements – using suitable
connection fittings – directly into the pipe system.
® Valve is installed.
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Valve with Welded Ends
6.4 Valve with Welded Ends

This section describes the welding procedure for the valve housing.
Warning!
Spring tension in the valve
Danger of injury when opening the clamp connections on the actuator or on
the housing as the released spring pretension will suddenly lift the actuator.
► Therefore, release the spring tension before detaching the clamp
connections by pressurizing the actuator with compressed air at max. 8 bar.
Notice
Seals are wearing parts
Old seals will cause malfunction of the valve
► When fitting the valve be sure to fit new housing O-rings.

1. Release the spring tension.
2. Remove the valve insert, see and .
3. Weld the housing, without sealing rings, into position, ensuring that the
connection is free of stress.
4. Fit the housing into place and tack it.
5. To avoid welding distortions, always seal the housing before welding.
6. Flush the housing with forming gas from the inside to push the oxygen out of
the system.
7. Weld the housing into the pipe system; use welding filler if necessary. When
technically possible, use the WIG-Orbital welding process with pulse
configuration, according to guidelines EHEDG documentation. 35.
8. Passivate the seam after welding.
9. Assemble the valve and depressurize the actuator.
10. Fit the seals.
® The valve disk is lowered.
® Install the valve with welded ends.
Hint!
Welding method: We recommend using the automatic orbital welding
method. All welding work should only be performed by certified
welders or machine operators (orbital welders).
Housing O-rings: When assembling the valve always replace the
housing O-rings to ensure that the valve is tight.
6.5 Pneumatic connections
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6.5.1 Air Requirement
Actuator Ø Air requirement (dm3n/Stroke) Use

[mm] dm3n at 1.01325 bar
at 0 °C as per DIN 1343
98 0.16
109 0.26
135 0.42
170 0.70 DN 25 - DN 100
1" - 4" OD,
210 1.10 2" - 4" IPS
170 1.60
210 2.00
210 2.20
6.5.2 Establishing Hose Connections

To ensure reliable operation, the compressed air hoses must be cut exactly
square.
Tools required:
• A hose cutter
1. Shut off the compressed air supply.
2. Use the hose cutter to cut the pneumatic hoses square.
3. Push the air hose into the air connector on the control top.
4. Re-open the compressed air supply.
® Establish a hose connection.
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Start-up
Safety notes
7 Start-up
7.1 Safety notes

Initial commissioning
For initial commissioning, the following principles apply:
• Carry out protective measures against dangerous contact voltages in
accordance with the applicable regulations.
Reliably secure sections of the plant which have already been connected
against inadvertently being switched on.
• Completely assemble the component and then adjust it. All screw connections
must be securely tightened.
• Relubricate all lubricating points. Make sure lubricants are used properly.
Commissioning
For commissioning, the following principles apply:
• Allow only qualified personnel to commission the components.
• Make sure all connections are properly established.
• Remove any liquids that have escaped without leaving residues.
• Check the function before starting any work. The safety devices on the
component must be completely installed, in working order and function
properly.
• When switching on the component, the danger zones must be clear.
7.2 Commissioning activities

Carry out the following activities before commissioning:
• Only for actuator types M and F-CJ: Actuate the valve once by applying
compressed air.
• Clean the pipe system prior to the first product run.
• Make sure that there are no foreign objects in the system.
• During commissioning, regularly check all sealing points for leaks. Replace
defective seals.
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Operation and control
Safety instructions
8 Operation and control

Dangerous situations during operation can be avoided by safety-conscious and
proactive behaviour of the personnel.
For operation, the following principles apply:
• Monitor the component during operation.
• Safety devices must not be changed, removed or taken out of service. Check
all safety devices at regular intervals.
• All guards and hoods must be fitted as intended.
• The installation location of the component must always be properly ventilated.
• Structural changes to the component are not permitted. Report any changes
to the component immediately to the person in charge.
• Always keep danger zones clear. Do not leave any objects in the danger
zone. Only allow persons to enter the danger zone when the machine is de-
energized.
• Regularly check that all emergency stop devices are working correctly.
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Cleaning
Cleaning
9 Cleaning
9.1 Cleaning
All parts in contact with product must be cleaned at regular intervals. Always
observe the safety data sheets issued by the cleaning agent manufacturers. Only
use cleaning agents which do not cause damage to the seals and the inner parts
of the valve. When the pipe is cleaned, the cleaning medium also flows through
and cleans the valve housings.
With respect to the cleaning method and parameters like detergents,
temperatures, times, and intervals, the component manufacturer can merely
make recommendations but cannot provide any generally applicable details.
Method and parameters should be determined and defined by the operator in
accordance with the relevant process and product.
The cleaning effect must be checked regularly by the operator!
9.1.1 Cleaning Process Examples

Typical Cleaning Parameters in Dairy Operations
Example of a two-phase cleaning process:
• Sodium hydroxide solution and sodium hydroxide based combination
products in concentrations from 0.5% to 2.5% at 75 °C (167 °F) to 80 °C (176
°F).
• Phosphoric or nitric acid, and combination products based thereon in the
concentrations of 0.3 % to 1.5% at approx. 65 °C (149 °F).
Example of a cleaning operation in one cleaning step:
• Formic acid and formic acid-based combination products at up to 85 °C (185
°F).
Typical Cleaning Parameters in Breweries
• Sodium hydroxide solution and sodium hydroxide based combination
products in concentrations of 1% to 4% at about 85 °C (185 °F).
• Phosphoric or nitric acid, and combination products based thereon in the
concentrations of 0.3 % to 1.5% at 20 °C (68 °F).
9.1.2 Cleaning effect

The cleaning effect depends on the following factors:
• Temperature
• Time
• Mechanics
• Chemicals
• Degree of soiling
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Cleaning
Passivation
These factors can be combined in such a way as to make an optimal cleaning

result probable. Depending on the cleaning method (medium, concentration,
temperature and contact times), the seals are affected to different degrees. This
can impair the function and the service life.
9.2 Passivation
Before commissioning a plant, passivation is commonly carried out for long pipes
and tanks. Valve blocks are usually excepted from this.
Passivation is typically performed using nitric acid (HNO3) at approx. 80 °C (176
°F) at a concentration of 3 % and a contact time of 6 to 8 hours.
The ultimate temperatures, chemicals, concentrations and contact time to be
used must be determined by the plant operator along with its chemical supplier.
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Maintenance
Safety instructions
10 Maintenance

Maintenance and repair
Before carrying out maintenance and repair work on the component's electrical
equipment, perform the following steps in accordance with the "5 safety rules":
• Isolate from the power supply
• Take appropriate measures to prevent switch on
• Test absence of voltage
• Earthing and short-circuiting
• Cover or safeguard any adjacent live parts.
For maintenance and repair, the following principles apply:
• Observe the intervals specified in the maintenance schedule.
• Only qualified personnel may carry out maintenance or repair work on the
component.
• The component must be switched off and secured against being switched
back on before maintenance or repair work. Work may only be started once
any residual energy has been discharged.
• Block access for unauthorized persons. Put up notice signs which draw
attention to the maintenance or repair work going on.
• Do not climb on the component. Use suitable access aids and working
platforms.
• Wear suitable protective clothing.
• Only use suitable and undamaged tools to carry out maintenance work.
• When replacing parts only use approved, fully functional load lifting devices
and lifting accessories which are suitable for the intended purpose.
• Before setting the unit back into operation, refit all safety devices as originally
provided in the factory. Then check that all safety devices are working
correctly.
• Make sure lubricants are used properly.
• Check pipes are firmly secured, also check for leaks and damage.
• Check that all emergency stop devices are working correctly.
Disassembly
For disassembly, the following principles apply:
• Only qualified personnel are allowed to dismantle the component.
• The component must be switched off and secured against being switched
back on before it is dismantled. Work may only be started once any residual
energy has been discharged.
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Maintenance
Inspections
• Disconnect all power and utility lines.

• Markings, e.g. on lines, must not be removed.
• Do not climb on the component. Use suitable access aids and working
platforms.
• Mark the lines (if unmarked) prior to disassembly to ensure they are not
confused when re-assembling.
• Protect open line ends with blind plugs against ingress of dirt.
• Pack sensitive parts separately.
• For longer periods of standstill, observe the storage conditions, see
Section 4.1, Page 22.
10.2 Inspections
Between the maintenance periods, the components must be checked for leakage
and proper function.
10.2.1 Product contact seals

1. Regularly check:
– Stem seal between upper housing and lantern
– V-ring in the valve disks
– O-rings between the valve housings
® Done
10.2.2 Pneumatic connections

1. Check the operating pressure at the pressure reducing and filter station.
2. Regularly clean the air filter in the filter station.
3. Check that the air hoses sit firmly in the air connections.
4. Check the lines for kinks and leaks.
5. Check the solenoid valves for proper function.
® Done
10.3 Maintenance intervals

To ensure the highest operational reliability, all wearing parts should be replaced
at longer intervals.
The actual maintenance intervals can only be determined by the user since they
depend on the operating conditions, for instance:
• daily period of use,
• switching frequency,
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Maintenance
Prior to disassembly
• type and temperature of the product,

• type and temperature of the cleaning solution,
• ambient conditions.
Maintenance Intervals
Maintenance intervals
Applications
(guideline values)
Media at temperatures of
60 °C to 130 °C approx. every 3 months
(140 °F to 266 °F)
Media at temperatures of
< 60 °C approx. every 12 months
(< 140 °F)
10.4 Prior to disassembly

Requirement:
• Make sure that during maintenance and servicing work no process is in
operation in the area concerned.
• Before turning out the pin screw, mark the position of the screw with a pencil
for later assembly.
1. Drain all pipe system elements that lead to the valve and, if necessary, clean
or rinse them.
2. Shut off the control air supply.
3. Disconnect the power supply.
4. Take the valve out of the pipe section, with all housings and housing
connections if possible.
® Done
10.5 Disassembling the valve Q
10.5.1 Disconnecting the Valve from the Housing
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Maintenance
Disassembling the valve Q
Fig.8
Warning!
Spring tension in the valve
Danger of injury when detaching the clamp connections (46, 43) as the
released spring pretension will suddenly lift the actuator.
► Therefore, release the spring tension before detaching the clamp
connections by pressurizing the actuator with compressed air at max. 8 bar.
Notice
The valve disk (15) is a sensitive component.
Damage to this part can result in malfunctions.
► When the valve is pulled out, the stem of the valve disk (15) must not hit
the valve housing!
► Do not set the valve insert down on the valve disk but lay it down.
Actuators M and F-CJ
1. Vent actuator at connection (61) with compressed air, max. 8 bar.
® The valve disc (15) is raised.
2. Remove the clamp connection (43).
3. Vent the actuator.
4. Carefully draw the valve out of the housing.
® The valve is now separated from the housing.
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Maintenance
Disassembling the valve Q
Actuator F
1. Unscrewing the pin screw (S)
2. Remove the clamp connection (43).
3. Carefully draw the valve out of the housing.
® The valve is now separated from the housing.
10.5.2 Removing the Valve Disk
Fig.9
Notice
Sensitive valve parts
Damage to these parts can result in these parts malfunctioning.
► Protect the valve parts against impact stress.
► Do not set the valve insert down on the valve disk but lay it down.
1. Release the clamp connection (46) but do not remove it.
2. Place an open end spanner on the spanner flat (L), another open end
spanner on the spacer nut (10) and detach the valve disk from the actuator.
3. Unscrew the valve disk together with the bearing disk (3), the bearing (2), the
seal ring (1) and the seal disk (4).
! The bearing disk (3) and the seal disk (4) must not hit the rod of the valve disk
when the valve disk is withdrawn.
4. Unscrew the spacer nut (10) from the valve disc using 2 open-ended
wrenches.
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Maintenance
Maintenance
5. Pull off the bearing disk (3) with the bearing (2) and the sealing washer (4)
with the gasket (1) from the valve disk.
6. Remove the clamp connection (46) between the lantern and the actuator.
7. Remove the lantern (9).
® This completes removal of the valve disk.
10.6 Maintenance
10.6.1 Cleaning the Valve
Fig.10
Notice
The rod of the valve disk (15), the housing seat (401), and the V-
ring groove are precision parts.
Damage to these parts can result in malfunction.
► Handle the valve with care!
Notice
Damage to the valve
Damage to the valve can result in a malfunction.
► Observe the safety information sheets issued by the detergent
manufacturers!
► Only use detergents which are non-abrasive and not aggressive towards
stainless steel.
1. Carry out the following steps:
Dismantle valve see, and .
2. Carefully clean the individual parts.
® Done
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Maintenance
Maintenance
10.6.2 Replacing the V-Ring
Hint!
Replace defective seals, but always fit new housing O-rings to ensure
the tightness of the valve. Always use original spare parts.
Fig.11: V-ring insertion tool
Prerequisite:
• Insert V-rings without grease. To facilitate fitting, use water with a drop of
washing-up liquid to remove the surface tension. In order that no rust is
transferred, the washing-up liquid solution must be made up in a ceramic,
plastic, or stainless steel container.
Tools required:
• V-ring insertion tool
Caution!
Danger of injury!
The scriber can slip off when the V-ring is removed
► Grip the valve disk in a vice with protected jaws.
► Unscrew the curved side of the scriber.
1. Put a scriber into the V-ring and take it out.
Fig.12
2. Before fitting, wet the V-ring on the side not in contact with product (rear side).
Pay attention that water does not drip into the V-ring groove on the valve disk.
3. Air out the valve upon connection (22).
4. Put in the V-ring. Make sure the installation position of the V-ring is correct
(see illustration).
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Maintenance
Maintenance
Fig.13
5. Use the insertion tool to press in the V-ring – evenly press in at several
opposite points along the circumference.
Fig.14
6. Insert the V-ring evenly.

7. Replace all the other seals identified in the spare parts lists.
® Done
Hint!
Used seals must not be used again, since the proper function of the
seal can then no longer be ensured.
10.6.3 Lubricating Seals and Threads
Caution!
Damage to seals and threads
Damage to seals and threads can result in malfunction.
► Ensure that an adequate film of lubricant is applied. No grease residues
must be visible once the valve has been assembled completely.
► For product contact seals only use suitable greases and oils.
► Observe the safety data sheets issued by the lubricant manufacturer!
1. Lightly grease the valve disk thread.
2. Grease all seals – including the O-rings at the top and bottom of the actuator
piston rod – very thinly.
! Do not grease the V-ring
® Done
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Maintenance
Installation
Hint!
GEA Tuchenhagen recommends Rivolta F.L.G. MD-2 This lubricant is
food grade, beer foam resistant and has NSF-H1 (USDA H1)
registration. It does not affect the taste or the consistency of the
products and is compatible with the seals in contact with product.
Rivolta F.L.G. MD-2 can be ordered under material no. 413-071 (1000 g
can) or 413-136 (100 g tube) from GEA Tuchenhagen. Using other
types of grease can result in malfunctions or in premature seal failure.
The warranty will also become null and void.
A Manufacturer's Declaration for these products can be obtained from
GEA Tuchenhagen if required.
A thin film of grease is required on the seals to ensure the proper
function of the fittings. It reduces friction and extends the service life
of the seals. This is absolutely harmless from a health and hygienic
point of view.
Running dry must be avoided!
10.7 Installation
Assemble the valve in reverse order of disassembly. Observe the notes and
instructions given in the following sections when doing so.
10.7.1 Setting the Response Pressure

Requirement:
• The valve is used to discharge an overpressure in the lower valve housing or
from the vertical housing connection.
• Install the valve in the pipeline.
• The desired set pressure must be determined with a pressure gauge in the
line.
Fig.15

1. Release the lock nut (K).
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Maintenance
Installation
2. Turn the pin screw (S) to change the spring force acting on the valve disk.
® Turn clockwise:
The spring force is increased and which results in an increase in the
response pressure.
® Turn counter-clockwise:
The spring force is decreased which results in a decrease in the response
pressure.
3. Set the required response pressure.
4. Tighten counter nut (K).
5. Check the required response pressure on the pressure gauge and repeat the
procedure if necessary.
® Done
10.7.2 Install valve Q with actuator F-CJ type D-Force
Fig.16

1. Fit actuator CJ with air connection at the top of the lantern.
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Maintenance
2. Screw rod F-CJ into actuator CJ.

3. Fit actuator F-CJ on actuator CJ.
- L.1 Air connection for full stroke
- Air connection for keeping-shut function
® Done
10.7.3 Function Check of Actuator M

1. Actuate the valve with compressed air.
® Done
10.7.4 Torques for the Clamp Connections

Tighten the clamp connections and semi-rings of the valve to the torques
specified in the table.
Tightening torques required

Torques Nm lbft
Clamp connection M6 9 6.6
cast half rings
Clamp connection M8 22 16.2
cast half rings
Cast clamps M10 45 33
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Alarms
Malfunctions and remedies
11 Alarms
11.1 Malfunctions and remedies

In the event of malfunctions immediately deactivate the valve and secure it
against inadvertent reactivation. Malfunctions may only be remedied by qualified
staff, who must observe the safety instructions.
Malfunction Cause Remedy

Check the system
Fault in the control system
configuration
Check compressed air supply
No compressed air or
and check air hoses for free
Valve with actuator M or F-CJ compressed air too low
passage and air tightness
does not work
Check actuation / external
Fault in the electrical system controller and routing of
electrical lines
Solenoid valve defective Replace the solenoid valve
Dirt/foreign material between Clean valve housing and valve
valve seat and valve disk seat
Valve does not close
V-rings defective Replace the V-rings
Seat defective Replace the seat
O-rings in actuator and control Grease O-rings and sealing
Valve closes too slowly
top are dry (friction losses) rings
Leakage in the area of the Valve disassembly - Housing
Housing O-rings defective
valve housing Replace the O-Ring
Leakage in the lantern Seal ring defective Replace the gasket
Does not respond when the
Valve set incorrectly Setting the Response Pressure
pressure is elevated
Response pressure too high Seals dry Grease the seals
Actuator making loud noise Spring or spring plate broken Replace the spring
Valve with actuator F-CJ does Shut valve briefly by air
Friction too high
not close properly support
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Decommissioning
Safety instructions
12 Decommissioning

For shutting down, the following principles apply:
• Switch off the compressed air.
• Switch off the component with the main switch.
• Padlock the main switch (if fitted) in the off position to prevent it from being
switched back on. The key to the padlock must be deposited with the person
responsible until the machine is restarted.
• For longer periods of standstill, observe the storage conditions, see
Chapter 4, Page 22.
12.2 Disposal
12.2.1 General notes

Dispose of the component in an environmentally safe manner. Observe the
statutory waste disposal regulations applicable at the place of installation.
The component consists of the following materials:
• Metals
• Synthetic materials
• Electronic parts
• Lubricants containing oil and grease
Separate the different materials and dispose of them correctly sorted. Also
observe the instructions regarding disposal in the operating instructions for the
individual components.
12.2.2 Valve Actuator Disposal
Danger
The spring forces in the actuator can be as high as 24 kN.
The pre-stressed spring can cause serious personal injury or death.
► Never open the actuator.
► GEA Tuchenhagen accepts unopened actuators and arranges for proper
disposal free of charge.
1. Remove the actuator.
2. Pack the actuator safely and send it to GEA Tuchenhagen GmbH.
® Done
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Spare parts list – overflow valve Q
13 Spare parts list – overflow valve Q
Fig.17
Fig.18: Housing combinations
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Item Designation Material DN 25 DN 40 DN 50 DN 65 DN 80 DN 100

Sealing set EPDM 221-304.39 221-304.40 221-304.40 221-304.41 221-304.41 221-304.42
complete 1)
FKM 221-519.49 221-519.50 221-519.50 221-519.51 221-519.51 221-519.52
HNBR 221-519.62 221-519.63 221-519.63 221-519.64 221-519.64 221-001019
1* Sealing ring EPDM 924-084 924-084 924-084 924-085 924-085 924-085
FKM 924-082 924-082 924-082 924-083 924-083 924-083
HNBR 924-311 924-311 924-311 924-313 924-313 924-313
2 PTFE/
Bearing 935-001 935-001 935-001 935-002 935-002 935-002
carbon
SUSTA-
Bearing, 3A 935-098 935-098 935-098 935-099 935-099 935-099
PVDF
3 Sealing disk 1.4404 221-141.01 221-141.02 221-141.02 221-141.03 221-141.03 221-141.04
4 Bearing disk 1.4301 221-142.01 221-142.02 221-142.02 221-142.03 221-142.03 221-142.03
5* O-ring EPDM 930-309 930-144 930-144 930-150 930-150 930-156
FKM 930-168 930-171 930-171 930-176 930-176 930-178
HNBR 930-632 930-633 930-633 930-634 930-634 930-863
6* O-ring NBR 930-004 930-004 930-004 930-004 930-004 930-004
**7* V-ring EPDM 932-058 932-046 932-046 932-021 932-021 932-025
FKM 932-049 932-030 932-030 932-033 932-033 932-036
HNBR 932-086 932-087 932-087 932-088 932-088 932-101
9 Motor stool 1.4301 221-121.01 221-121.02 221-121.02 221-121.03 221-121.03 221-121.04
10 Spacer nut 1.4301 221-147.02 221-147.02 221-147.02 221-147.01 221-147.01 221-147.01
15 Valve disk Q 1.4404 221-266.01 221-266.02 221-266.02 221-266.03 221-266.05 221-266.04
Valve disk Q- 1.4404 221-339.05 221-339.01 221-339.01 221-339.02 221-339.03 221-339.04
MET***
33 Seat ring Q 1.4404 221-274.01 221-274.02 221-274.02 221-274.03 221-274.03 221-274.04
35 Cover 1.4404 221-144.01 221-144.02 221-144.02 221-144.03 221-144.03 221-144.04
43 Clamp 1.4401 221-507.02 221-507.04 221-507.04 221-507.09 221-507.09 221-507.11
connection KL
46 Clamp 1.4401 221-507.06 221-507.06 221-507.06 221-507.06 221-507.06 221-507.06
connection KL
401 Housing V1 1.4404 221-101.19 221-101.21 221-101.22 221-101.05 221-101.06 221-101.07
402 Housing V2 1.4404 221-102.41 221-102.43 221-102.44 221-102.05 221-102.06 221-102.07
420 Housing 1.4404 221-572.02 221-572.04 221-572.06 221-572.09 221-572.11 221-572.14
connection Q
A Actuator F/F-CJ See parts list for actuator F/F-CJ
Actuator M See parts list for actuator M
Grease RIVOLTA F.L.G. 100g tube not included with sealing kit. 413-136
** Do not grease Item 7
*** Q-MET > metal sealing (without V-ring)
1) The sealing kit includes the items 1, 5, 6 and 7
The items marked with an * are wearing parts
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Item Designation Material 1" OD 1.5" OD 2" OD 2.5" OD 3" OD 4" OD

Sealing set EPDM 221-304.39 221-304.40 221-304.40 221-304.41 221-304.41 221-304.42
complete 1)
FKM 221-519.49 221-519.50 221-519.50 221-519.51 221-519.51 221-519.52
HNBR 221-519.62 221-519.63 221-519.63 221-519.64 221-519.64 221-001019
1* Sealing ring EPDM 924-084 924-084 924-084 924-085 924-085 924-085
FKM 924-082 924-082 924-082 924-083 924-083 924-083
HNBR 924-311 924-311 924-311 924-313 924-313 924-313
2 Bearing PTFE/
935-001 935-001 935-001 935-002 935-002 935-002
carbon
Bearing, 3A SUSTA-
935-098 935-098 935-098 935-099 935-099 935-099
PVDF
3 Sealing disk 1.4404 221-141.01 221-141.02 221-141.02 221-141.03 221-141.03 221-141.04
4 Bearing disk 1.4301 221-142.01 221-142.02 221-142.02 221-142.03 221-142.03 221-142.03
5* O-ring EPDM 930-309 930-144 930-144 930-150 930-150 930-156
FKM 930-168 930-171 930-171 930-176 930-176 930-178
HNBR 930-632 930-633 930-633 930-634 930-634 930-863
6* O-ring NBR 930-004 930-004 930-004 930-004 930-004 930-004
**7* V-ring EPDM 932-058 932-046 932-046 932-021 932-021 932-025
FKM 932-049 932-030 932-030 932-033 932-033 932-036
HNBR 932-086 932-087 932-087 932-088 932-088 932-101
9 Motor stool 1.4301 221-121.01 221-121.07 221-121.07 221-121.08 221-121.08 221-121.09
10 Spacer nut 1.4301 221-147.02 221-147.02 221-147.02 221-147.01 221-147.01 221-147.01
15 Valve disk Q 1.4404 221-266.01 221-266.02 221-266.02 221-266.03 221-266.05 221-266.04
Valve disk Q- 1.4404 221-339.05 221-339.01 221-339.01 221-339.02 221-339.03 221-339.04
MET***
33 Seat ring Q 1.4404 221-274.01 221-274.02 221-274.02 221-274.03 221-274.03 221-274.04
35 Cover 1.4404 221-144.01 221-144.02 221-144.02 221-144.03 221-144.03 221-144.04
43 Clamp 1.4401 221-507.02 221-507.04 221-507.04 221-507.09 221-507.09 221-507.11
connection KL
46 Clamp 1.4401 221-507.06 221-507.06 221-507.06 221-507.06 221-507.06 221-507.06
connection KL
401 Housing V1 1.4404 221-101.27 221-101.28 221-101.29 221-101.30 221-101.31 221-101.32
402 Housing V2 1.4404 221-102.52 221-102.53 221-102.54 221-102.55 221-102.56 221-102.57
420 Housing 1.4404 221-572.01 221-572.03 221-572.05 221-572.08 221-572.10 221-572.13
connection Q
A Actuator F/F-CJ
Actuator M
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Item Designation Material 2" IPS 3" IPS 4" IPS

Sealing kit complete 1) EPDM 221-304.40 221-304.41 221-304.42
FKM 221-519.50 221-519.51 221-519.52
HNBR 221-519.63 221-519.64 221-001019
1* Sealing ring EPDM 924-084 924-085 924-085
FKM 924-082 924-083 924-083
HNBR 924-311 924-313 924-313
2 Bearing PTFE/carbon 935-001 935-002 935-002
Bearing, 3A SUSTA-PVDF 935-098 935-099 935-099
3 Sealing disk 1.4404 221-141.02 221-141.03 221-141.04
4 Bearing disk 1.4301 221-142.02 221-142.03 221-142.03
5* O-ring EPDM 930-144 930-150 930-156
FKM 930-171 930-176 930-178
HNBR 930-633 930-634 930-863
6* O-ring NBR 930-004 930-004 930-004
**7* V-ring EPDM 932-046 932-021 932-025
FKM 932-030 932-033 932-036
HNBR 932-087 932-088 932-101
9 Motor stool 1.4301 221-121.12 221-121.10 221-121.11
10 Spacer nut 1.4301 221-147.02 221-147.01 221-147.01
15 Valve disk Q 1.4404 221-266.02 221-266.05 221-266.04
Valve disk Q-MET*** 1.4404 221-339.01 221-339.03 221-339.04
33 Seat ring Q 1.4404 221-274.02 221-274.03 221-274.04
35 Cover 1.4404 221-144.02 221-144.03 221-144.04
43 Clamp connection KL 1.4401 221-507.04 221-507.09 221-507.11
46 Clamp connection KL 1.4401 221-507.06 221-507.06 221-507.06
401 Housing V1 1.4404 221-101.37 221-101.35 221-101.36
402 Housing V2 1.4404 221-102.62 221-102.59 221-102.60
420 Housing connection Q 1.4404 221-572.07 221-572.12 221-572.15
A Actuator F/F-CJ
Actuator M
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Sealing kits for overflow valve Q

DN 25 DN 40/50 DN 65/80 DN 100
Item Qty Designation Material
1" 1.5"/2" 2.5"/3" 4"
1 2 Sealing ring Ø 22 22 28 28
EPDM 924-084 924-084 924-085 924-085
FKM 924-082 924-082 924-083 924-083
HNBR 924-311 924-311 924-313 924-313
5 4 O-ring Ø 42 x 3 60 x 3 85 x 4 113 x 4
EPDM 930-309 930-144 930-150 930-156
FKM 930-168 930-171 930-176 930-178
HNBR 930-632 930-633 930-634 930-863
6 1 O-ring Ø 8 x 1.6 8 x 1.6 8 x 1.6 8 x 1.6
NBR 930-004 930-004 930-004 930-004
7* 1 V-ring Ø 17-5 35-5 52-6 81-6
EPDM 932-058 932-046 932-021 932-025
FKM 932-049 932-030 932-033 932-036
HNBR 932-086 932-087 932-088 932-101
EPDM 221-304.39 221-304.40 221-304.41 221-304.42
Sealing kit complete FKM 221-519.49 221-519.50 221-519.51 221-519.52
HNBR 221-519.62 221-519.63 221-519.64 221-001019
Grease RIVOLTA F.L.G. 100g tube not included with sealing kit 413-136
* Do not grease item 7
Storage instructions: storage in accordance with DIN 7716
Relative humidity approx. 65%, temperature 15-25°C and protected from light
When replacing seals, observe the instructions in the Operating Instructions!
429-002
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Spare Parts List – Actuators F and F-CJ
14 Spare Parts List – Actuators F and F-CJ
Fig.20: Actuator F-CJ - only use in combination with actuator

Fig.19: Actuator F CJ (221-136.01)!
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Item Designation Material F 11 F 21 F1 F2 F3 F4

Actuator complete 221-177.10 221-177.11 221-177.01 221-177.02 221-177.03 221-177.09
3 Setscrew A4-70 221-177.05 221-177.05 221-177.05 221-177.05 221-177.05 221-177.05
6 Rod F-CJ 1.4301 -- -- -- -- -- --
9.1 Rod guide ring Turcite 935-017 935-017 935-017 935-017 935-017 935-017
11 Hexagon nut A2 910-036 910-036 910-036 910-036 910-036 910-036
17 Brass/nickel- -- -- -- -- -- --
Screw-in plug connection
plated
46 Clamp connection 1.4401 221-507.06 221-507.06 221-507.06 221-507.06 221-507.06 221-507.06
Designation F 11 F 21 F1 F2 F3 F4
D 85 85 85 85 85 85
H 150 150 250 250 250 250
L 230 230 330 330 330 330

Metric Inch OD/IPS F 11 F 21 F1 F2 F3 F4
25 1" OD 1.5 - 4.5 3-9 8 - 16 -- -- --
40 1.5" OD -- 1.5 - 2 1.5 - 5 4 - 15 14 - 16 --
50 2" OD -- -- 1.5 - 4 3 - 11 10 - 16 --
65 2.5" OD -- -- -- 1-4 3 - 10 9 - 15
80 3 OD -- -- -- 1-4 3 - 10 9 - 10
100 4" OD -- -- -- 0.5 - 1.5 0.5 - 4 3-7
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Item Designation Material F 1-CJ F 2-CJ F 3-CJ F 4-CJ

Actuator complete 221-177.13 221-177.12 221-177.14 221-177.15
3 Setscrew A4-70 221-177.05 221-177.05 221-177.05 221-177.05
6 Rod F-CJ 1.4301 221-001591 221-001591 221-001591 221-001591
9.1 Rod guide ring Turcite -- -- -- --
9.2 O-ring NBR 930-026 930-026 930-026 930-026
9.3 O-ring NBR 930-041 930-041 930-041 930-041
11 Hexagon nut A2 910-036 910-036 910-036 910-036
17 Screw-in plug connection Brass/nickel- 933-176 933-176 933-176 933-176
metric G1/8"-6/4 plated
Screw-in plug connection Brass/nickel- 933-173 933-173 933-173 933-173
inch G1/8"-6.35 plated
46 Clamp connection 1.4401 221-507.06 221-507.06 221-507.06 221-507.06
Designation F 1-CJ F 2-CJ F 3-CJ F 4-CJ

D 85 85 85 85
H 290 290 290 290
L 370 370 370 370

Metric Inch OD/IPS F 1-CJ F 2-CJ F 3-CJ F 4-CJ
25 1" OD 8 - 16 -- -- --
40 1.5" OD 1.5 - 5 4 - 15 14 - 16 --
50 2" OD 1.5 - 4 3 - 11 10 - 16 --
65 2.5" OD -- 1-4 3 - 10 9 - 15
80 3 OD -- 1-4 3 - 10 9 - 10
100 4" OD -- 0.5 - 1.5 0.5 - 4 3-7
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Spare Parts List - Actuator M
15 Spare Parts List - Actuator M
Fig.21: X = actuator identification Fig.22: X = actuator identification
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Spare Parts List - Actuator M
Item Designation Material M 11 M 21 M1 M2 M3 M4

Actuator complete 221-260.05 221-260.06 221-260.01 221-260.02 221-260.14 221-260.13
3 Setscrew A4-70 221-177.05 221-177.05 221-177.05 221-177.05 221-177.05 221-177.05
9 O-ring NBR 930-029 930-029 930-029 930-029 930-029 930-029
10 Plain bearing IGLIDUR-G 704-041 704-041 704-041 704-041 704-041 704-041
11 Hexagon nut A2 910-036 910-036 910-036 910-036 910-036 910-036
13 Bush 1.4301 221-260.15 221-260.15 221-260.15 221-260.15 221-260.15 221-260.15
15 O-ring NBR 930-251 930-251 930-251 930-251 930-251 930-251
17 Screw-in plug connection Brass/nickel- 933-176 933-176 933-176 933-176 933-176 933-176
metric G1/8"-6/4 plated
Screw-in plug connection Brass/nickel- 933-173 933-173 933-173 933-173 933-173 933-173
inch G1/8"-6.35 plated
46 Clamp connection 1.4401 221-507.06 221-507.06 221-507.06 221-507.06 221-507.06 221-507.06
Designation M 11 M 21 M1 M2 M3 M4
D 110 110 110 110 110 110
D1 -- -- 170 170
h -- -- 95 95
H 195 195 295 295 295 295
L 275 275 375 375 375 375
Required control air pressure (bar) 3 3 3 4 3 5

Metric Inch OD/IPS M 11 M 21 M1 M2 M3 M4
25 1" OD 1.5 - 4.5 3-9 8 - 16 -- -- --
40 1.5" OD -- 1.5 - 2 1.5 - 5 4 - 15 14 - 16 --
50 2" OD -- -- 1.5 - 4 3 - 11 10 - 16 --
65 2.5" OD -- -- -- 1-4 3 - 10 9 - 15
80 3 OD -- -- -- 1-4 3 - 10 9 - 10
100 4" OD -- -- -- 0.5 - 1.5 0.5 - 4 3-7
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Spare Parts List - Actuator CJ
16 Spare Parts List - Actuator CJ
Fig.23
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Spare Parts List - Actuator CJ
Item Designation Material Material no.

Actuator CJ complete 221-136.01
5 Screw-in plug connection metric G1/8"-6/4 Brass/nickel-plated 933-176
Screw-in plug connection inch G1/8"-6.35 Brass/nickel-plated 933-173
10 O-ring NBR 930-026
13 Plug LD-PE 922-036
46 Clamp connection 1.4401 221-507.06
Stopping plugs, Pos.13, are only used to protect the thread. They must be removed before using the actuator.
Designation Dimension
D 135 mm
D1 97 mm
H 85 mm
Weight 4.35 kg
Volume V1 not actuated 0.1616 dm3
Volume V2 actuated (stroke 35) 0.4185 dm3
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Dimension sheet – overflow valve Q
17 Dimension sheet – overflow valve Q
Fig.24
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Dimension DN 25 DN 40 DN 50 DN 65 DN 80 DN 100
Dia. 29 x 1.5 41 x 1.5 53 x 1.5 70 x 2 85 x 2 104 x 2
A 50 62 74 96 111 130
C 90 90 90 125 125 125
Actuator F F11 / 21 F1 / 2 F1 / 2 F3 / 4 F3 / 4 F3 / 4
D 85 85 85 85 85 85
H 394 500 506 517 524.5 534
X 480 585 590 660 670 680
Actuator F-CJ D -- 85/135 85/135 85/135 85/135 85/135
in combination
H -- 625 631 642 649.5 659
with actuator
CJ X -- 710 715 785 795 805
Actuator M M11 / 21 M1 / 2 M1 / 2 M3 / 4 M3 / 4 M3 / 4
D 110 110 110 110/170 110/170 110/170
H 439 545 551 562 569.5 579
X 525 630 635 705 715 725
Stroke 10 15 27 30 30 30
Dimension 1" OD 1.5" OD 2" OD 2.5" OD 3" OD 4" OD

Dia. 25.4 x 1.6 38.1 x 1.6 50.8 x 1.6 63.5 x 1.6 76.2 x 1.6 101.6 x 2
A 46 59 71.5 90 103 127.5
C 90 90 90 125 125 125
Actuator F F11 / 21 F1 / 2 F1 / 2 F3 / 4 F3 / 4 F3 / 4
D 85 85 85 85 85 85
H 392 501.5 508 521 527.5 536
X 480 585 595 665 675 680
Actuator F-CJ D -- 85/135 85/135 85/135 85/135 85/135
in combination
H -- 626.5 633 646 652.5 661
with actuator
CJ X -- 710 720 790 800 805
Actuator M M11 / 21 M1 / 2 M1 / 2 M3 / 4 M3 / 4 M3 / 4
D 110 110 110 110/170 110/170 110/170
H 437 546.5 553 566 572.5 581
X 525 630 640 710 720 725
Stroke 6 15 27.5 31 29 30.5
Dimension 2" IPS 3" IPS 4" IPS

Dia. 60.3 x 2 88.9 x 2.3 114.3 x 2.3
A 81 115 140
C 114.3 152.4 152.4
Actuator F F1 / 2 F3 / 4 F3 / 4
D 85 85 85
H 502.5 522.5 529
X 590 670 675
Actuator F-CJ in D 85/135 85/135 85/135
combination with
H 627.5 647.5 654
actuator CJ
X 715 795 800
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Dimension 2" IPS 3" IPS 4" IPS

Actuator M M1 / 2 M3 / 4 M3 / 4
D 110 110/170 110/170
H 547.5 567.5 574
X 635 715 720
Stroke 27 30 30
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Appendix
Lists
18 Appendix
18.1 Lists
18.1.1 Abbreviations and terms
Abbreviation Explanation
BS British Standard
Unit of measurement of pressure [bar]
All pressure data expressed in [bar/psi] is assumed to be
bar
gauge pressure [barg/psig] unless explicitly specified
otherwise.
approx. approximately
°C Unit of measurement of temperature [degree Celsius]
Cv valve coefficient, non-metric flow coefficient, see Kv
Unit of measurement of volume [cubic decimetre] standard
dm3n
volume (standard litres)
DN DIN nominal width
German standard issued by DIN (Deutsches Institut für
DIN
Normung e.V., German Institute for Standardization)
EN European Standard
Material designation
EPDM Short designation according to DIN/ISO 1629: Ethylene
Propylene Diene Rubber
°F Unit of measurement of temperature [degree Fahrenheit]
Material designation, short designation according to DIN/ISO
FKM
1629: Fluorine rubber
h Unit of measurement of time [hour]
Material designation
HNBR Short designation according to DIN/ISO 1629: Hydrogenated
Acrylonitrile Butadiene Rubber
IP Protection class
International Standard of the International Organization for
ISO
Standardization
kg Unit of measurement of weight [kilogram]
kN Unit of measurement of force [kilonewton]
Kv value Flow coefficient [m³/s], 1 Kv = 0.86 × Cv
l Unit of measurement of volume [litre]
max. maximum
mm Unit of measurement of length [millimetre]
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Appendix
Abbreviation Explanation
µm Unit of measurement of length [micrometre]
M Metric
Unit of measurement of work [newton metre]
Nm TORQUE SPECIFICATION: 1 Nm = 0.737 lb-ft
Pound-Force (lb)× Feet (ft)
PA Polyamide
PE-LD Low-density polyethylene
PPE Polytetrafluoroethylene
Anglo-American unit of measurement for pressure [pound-
force per square inch]
psi All pressure data expressed in [bar/psi] is assumed to be
gauge pressure [barg/psig] unless explicitly specified
otherwise.
PTFE Polytetrafluoroethylene
Self-learning installation
During commissioning and maintenance, the SET-UP
SET-UP
procedure carries out all the necessary settings for the
generation of messages.
SW Indicates the size of spanners [width across flats]
T.VIS Tuchenhagen Valve Information System
V AC Volt alternating current
V DC Volt direct current
W Unit of measurement of power [Watt]
Welding method
TIG
Tungsten inert gas welding
Unit of measurement of length in the Anglo-American
Inch
language area
Tube measurement according to British Standard (BS),
Inch OD
outside diameter
Inch IPS American pipe measurement, iron pipe size
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OI - Valve Q - V1 - 2019-03 - EN

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Hygienic valves

GEA VARIVENT® Overflow Valve Q Type D Force

Operating instruction (Translation from the original language)

1.1 Information on the Document

1.1.1 Binding Character of These Operating Instructions

1.1.2 Notes on the Illustrations

1.1.3 Symbols and Highlighting

Carry out the following steps: = Start of a set of instructions.

1.2 Manufacturer address

1.4 EU Declaration of Conformity for Machines

We declare under our sole responsibility that the machine

Remarks: We also declare that the relevant

Person authorised for compilation and Person authorised to compile the

Franz Bürmann i.V. Matthias Südel

1.5 EC - Declaration of conformity in accordance with the Pressure Equipment

GEA Tuchenhagen GmbH

Relevant EC directives: 2014/68/EU Pressure Equipment

Remarks: – Valid for substances of fluid group

Person authorised for compilation and Person authorised to compile the

2.1 Intended use

2.1.1 Requirements for operation

2.1.2 Pressure equipment directive

2.1.3 ATEX directive

2.1.4 Improper operating conditions

• Malfunctions have been detected on the component.

2.2 Operator’s Duty of Care

2.3 Subsequent changes

In general, only original spare parts supplied by GEA Tuchenhagen GmbH

2.4 General safety instructions and dangers

2.4.1 Principles for safe operation

2.4.2 Environmental Protection

2.4.3 Electrical Equipment

2.5 Supplementary Regulations

2.6 Qualification of personnel

• Received instruction about operating sequences on the component.

2.7 Safety equipment

Signs on the valve

General hazard warning

Explosive atmosphere hazard warning

2.8 Residual dangers

Residual dangers on the valve and measures

Spring tension in the Danger to life caused by compression spring in

2.9 Danger zones

3.2 Functional description

Actuator F with Adjustable Spring

3.2.2 Possible Response Pressure Settings

Nominal width Response pressure (bar)

Response pressure actuator F-CJ

Nominal width Response pressure (bar)

Control air pressure required to open the valve

Nominal width Response pressure (bar)

4 Transport and storage

4.1 Storage conditions

We recommend that the valve should be stored at a temperature of ≥ 5

4.2.1 Scope of supply