OI - GEA Hyg Leakage Butterfly Valve - V7 - EN-230607

Hygienic valves
GEA Hygienic leakage butterfly valve
Operating instruction (Translation from the original language)

430BAL008984EN_7
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 T.VIS® is a protected trademark 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 Flow speed 9
2.1.2 Pressure equipment directive 9
2.1.3 ATEX directive 9
2.1.4 Improper operating conditions 9
2.1.5 Requirements for actuator Operator’s 10
2.2 Duty of Care 10
2.3 Subsequent changes 11
2.4 General safety instructions and 11
2.4.1 dangers Principles for safe actuator 11
2.4.2 Environmental Protection 11
2.4.3 Electrical Equipment 12
2.5 Supplementary Regulations 12
2.6 Qualification of personnel 12
2.7 Safety equipment 13
2.7.1 Signage 13
2.8 Residual dangers 14
2.9 Hazard Areas 15
3 Description 17
3.1 Pneumatic Butterfly Valve with Control Top 17
3.2 Pneumatic Butterfly Valve without Control Top 17
3.3 Butterfly Valve Body without Actuator 18
3.4 Manual Actuator Type H 18
3.5 Functional description 19
3.5.1 Pneumatic Actuator 19
3.5.2 Actuator (A.1) 19
3.5.3 Actuator (A.2) 19
3.5.4 Manual Actuator Type H 20
3.5.5 Valve assembly without actuator 20
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 Sealing Materials 25
5.4 Pipe ends - General table of measurements 26
5.5 Tools 27
5.6 Lubricants 28
5.7 Weights 28
6 Assembly and installation 29
6.1 Safety instructions 29
6.2 Notes on installation 29
6.3 Pneumatic connections 29
6.3.1 Air Requirement 29
6.3.2 Establishing Hose Connections 30
6.3.3 Actuator with T.VIS Control Top 30
6.3.4 Actuator without Control Top 30
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6.4 Electrical connections 30
6.4.1 Electrical connection with T.VIS control top 30
6.4.2 Adjusting the proximity switch – actuator without T.VIS 31
7 Start-up 32
7.2 Notes on commissioning 32
8 Operation and control 33
9 Cleaning 34
9.1 Cleaning 34
9.1.1 Cleaning Process Examples 34
9.1.2 Cleaning effect 34
9.1.3 Cleaning the leakage cavity 35
9.2 Passivation 35
10 Maintenance 37
10.1 Safety notes 37
10.2 Inspections 38
10.2.1 Pneumatic connections 38
10.2.2 Electrical connections 38
10.2.3 Mechanical Connections 38
10.2.4 Signs on the valve 38
10.3 Maintenance intervals 39
10.4 Prior to disassembly 39
10.5 Disassembling the Valve 39
10.5.1 Removing the T.VIS M-15 Control Top 40
10.5.2 Removing the T.VIS A-15 Control Top 41
10.5.3 Removing the Valve 42
10.5.4 Disassembling the Pneumatic Actuator 42
Taking off the Actuator 42
Dismantling the Actuator Parts 43
10.5.5 Disassembling the Manual Actuator 43
10.5.6 Removing the Valve Disk Seal 44
10.6 Maintenance 45
10.6.1 Cleaning the Mixproof Butterfly Valve 45
10.6.2 Lubricating Seals and Threads 46
10.7 Installation 47
10.7.1 Assembling the Valve Disk 47
10.7.2 Torques for the clamps and bolts 48
11 Alarms 49
11.1 Malfunctions and remedies 49
12 Decommissioning 50
12.2 Disposal 50
12.2.1 General notes 50
12.2.2 Valve Actuator Disposal 50
13 Parts list - Manual actuator hygienic leakage butterfly valve 51
14 Parts list - Pneumatic actuator hygienic leakage butterfly valve 53
15 Parts list - Hygienic leakage butterfly valve (valve assembly without actuator) 56
16 Dimension sheet - Hygienic leakage butterfly valve 59
17 Dimension sheet - Hygienic butterfly valve - seals 61
18 Appendix 63
18.1 Lists 63
18.1.1 Abbreviations and terms 63
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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 in accordance with the EC Machinery Directive 2006/42/EC
1.4 EU Declaration of Conformity in accordance with the EC Machinery Directive

2006/42/EC
EU Declaration of conformity within the meaning of the EC machine directive 2006/42/EC
Manufacturer: GEA Tuchenhagen GmbH

21514 Büchen, Germany
Hereby, we declare that the machine designated in the following
Designation: GEA Hygienic Butterfly Valve

GEA Hygienic Leakage Butterfly Valve
Type: Valve with actuator
by virtue of its design and construction and in the versions placed on the market by us, complies with the essential health
and safety requirements of the following directive:
Relevant EC directives: 2006/42/EC EC Machinery Directive
Applicable harmonized standards, in particular: EN ISO 12100: 2010
Remarks: • In the event of a modification to the machine that was not agreed with us, this declaration loses its
validity
• Furthermore, we declare that the specific technical documentation for this machine has been drawn
up in accordance with Annex VII, Part A, and undertake to forward this documentation by means of
data medium upon justified request by the national authorities
Person authorised for compilation and handover of technical GEA Tuchenhagen GmbH
documentation: CE Documentation Officer
21514 Büchen, Germany
Büchen, 29 April 2021
________________________________ ________________________________
Franz Bürmann pp. Matthias Südel
Managing Director Head of Engineering
1/1
GEA INTERNAL
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General Information
Translated copy of the EU - Declaration of conformity in accordance with the Pressure Equipment Directive 2006/42/EU
1.5 Translated copy of the EU - Declaration of conformity in accordance with the

Pressure Equipment Directive 2006/42/EU
GEA Tuchenhagen GmbH

Manufacturer: Am Industriepark 2-10
21514 Büchen
We hereby declare that the machine named below

Designation: GEA Hygienic butterfly valve
GEA Hygienic leakage butterfly valve
Type: Valve with actuator
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 DIN EN ISO 12100
standards, in particular:
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 GEA Tuchenhagen GmbH

handover of technical documentation: CE Documentation Officer
21514 Büchen
Büchen, 29 April 2021
Franz Bürmann i.V. Matthias Südel

Managing Director Head of Engineering
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Safety
Intended use
2 Safety
2.1 Intended use

The Mixproof Butterfly Valve is used for the separation of media in pipe sections.
Using the device for any other purpose is considered contrary to its designated
use.
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 Flow speed

With slow flow speeds, existing solids holding space can potentially settle.
When the butterfly valve is closed quickly, this causes negative pressure on the
disk and in the area of the butterfly valve seal, as a result of a stall. With flow
speeds of ≥ 3.5 m/s, the valve may only be closed with significantly reduced
speed.
2.1.2 Pressure equipment directive

The Mixproof Butterfly Valves are pressure 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.
• Malfunctions have been detected on the component.
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Safety
Operator’s Duty of Care
• Damage to the component has been detected.

• Maintenance intervals have been exceeded.
2.1.5 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.
2.2 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.
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Safety
Subsequent changes
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.
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.
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Safety
Supplementary Regulations
• Substances harmful to the environment must be collected and stored in

suitable containers. Clearly mark the containers.
• Dispose of lubricants as hazardous waste.
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:
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Safety
Safety equipment
• Personal suitability for the respective task.

• Sufficient professional qualification for the respective task.
• Received instruction about the functionality of the component.
• Received instruction about operating sequences on the component.
• Familiar with the safety devices and their function.
• 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 Signage
Dangerous points on the valve are indicated by warning signs, prohibition signs
and mandatory signs.
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Safety
Residual dangers
The signs and notes on the valve must always be legible. Any illegible signs must
be replaced immediately.
Signs on the valve

Sign Meaning
General hazard warning

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

Fig.3
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 of the Effectively disconnect all components, effectively prevent switch-
valve 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 actuator Danger to life caused by compression spring in the actuator. Do
not open the actuator but return it to GEA Tuchenhagen for
proper disposal.
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Safety
Hazard Areas
Residual dangers on the valve and measures
Danger Cause Measure

Risk of injury Danger presented by moving or The operator must exercise caution and prudence.
sharp-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 damage Operating materials with For all work:

properties which are harmful to
• Collect lubricants in suitable containers.
the environment
• Dispose of lubricants in accordance with the pertinent
regulations.
Risk of injury Danger due to liquid escaping

Discharge the liquid in a controlled manner.
from the leakage connections
2.9 Hazard Areas
Please observe the following notes:

• In the event of malfunctions, shut down the valve (disconnect from the power
and air supply) and secure it against being used.
• When the valve is switching, never reach into pipe Y or into bracket X (on
pneumatic actuators). Fingers can be crushed or cut off.
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Safety
• 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.
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Description
Pneumatic Butterfly Valve with Control Top
3 Description
3.1 Pneumatic Butterfly Valve with Control Top
Fig.4
No. Designation
A.1 Pneumatic Actuator
B T.VIS control top
1 Mounting bracket
2 Butterfly valve body
3.2 Pneumatic Butterfly Valve without Control Top
Fig.5
No. Designation
A.2 Pneumatic Actuator
1 Mounting bracket
2 Butterfly valve body
Electrical feedback - proximity switch
Optional
in the mounting bracket
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Description
Butterfly Valve Body without Actuator
3.3 Butterfly Valve Body without Actuator
Fig.6
Butterfly valve design for matrix-piped systems.
3.4 Manual Actuator Type H

Various manual actuator variants are available.
Standard design of manual actuator
Fig.7
No. Manual actuator variants

1 Standard
2 Optional – one electrical feedback signal
3 Optional – two electrical feedback signals
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Description
Functional description
3.5 Functional description
3.5.1 Pneumatic Actuator

The compressed air which enters above the piston causes a downwards
movement of the piston. The flap of the leakage butterfly valve opens or closes,
depending on the definition of the resting position. When the air supply is shut off,
the valve closes automatically as a result of the spring force.
The stroke of the piston is converted into a rotary movement of the shaft. The
travel of the piston is limited, so that the shaft performs a 90° rotation per stroke.
This rotation exactly corresponds to the rotational angle required to open or close
the flap of the leakage butterfly valve.
3.5.2 Actuator (A.1)
Fig.8
The switching state is detected and indicated by the control top (B).
The visual position indication (O) can be recognized by the red marking.
3.5.3 Actuator (A.2)
Fig.9
Feedback of switching states can be provided by proximity switches in the

mounting bracket (1).
The visual position indication (O) can be recognized by the red marking.
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Description
Functional description
3.5.4 Manual Actuator Type H
Fig.10
To open or close the mixproof butterfly valve, unlock the hand lever (1) by gently
pulling it out of the locking device and turn it through 90°. When the lever is
released, it locks into place in the holes provided. The limit positions of the
mixproof butterfly valve can be detected by proximity switches.
3.5.5 Valve assembly without actuator
Fig.11
No. Designation
1 Valve disk
2 Flange
3 Flange
4 Disk seal
5 Plain bearing
6 Radial seal
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Description
No. Designation
7 Leakage connections
8 Hole on the square end
The mixproof butterfly valve is used for separating media. The valve disk (1) as
the shut-off element is supported between two flanges screwed together (2, 3)
and plain bearings (5). The valve positions are OPEN / CLOSED.
In the CLOSED position, two media can be reliably separated from one another.
The leakage cavity is open towards the atmosphere in this case. After switching,
the medium in the valve disk leakage areas can drain by gravity (7).
In the OPEN position (maximum throughflow), the leakage paths towards the
atmosphere are closed. The leakage cavity is sealed by the radial seal (6) on the
short valve disk shaft.
Hint!
The hole (B) in the square end is used to indicate the position of the
valve disk.
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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.
• Control tops must be protected from animal and vegetable fats.
• 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.12
The type plate provides the following key data:
Key data of the leakage butterfly valve

Type Hygienic leakage butterfly valve
Serial Serial number
Material 1.4404/AISI 316L
Control air pressure bar/psi min. 4.8/69.6 max. 8.0/116
Product pressure bar/psi 10/ 145
5.2 Technical data

Refer to the following tables for the key technical data of the mixproof butterfly
valve:
Technical data: Mixproof butterfly valve

Designation Description
DN 15 to DN 100
Size
2" to 4" OD
Stainless steel
Material of product contact parts Check corrosion resistance with
respect to media and detergents.
Technical data: Ambient temperatures

0 to 45 °C (32 ... 113 °F), standard
< 0 °C (32 °F): Use control air with a
- Valve
low dew point. Protect valve stems
against freezing.
- Proximity switch -20 to +80 °C (-4 ... +176 °F)
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Technical data
Technical data
Technical data: Ambient temperatures

- Control top type T.VIS M-15, A-15 -20 to +50 °C (-4 ... +122 °F)
- Control top type T.VIS P-15 0 to +50 °C (-4 ... +122 °F)
Product and operating temperature -40 to +135°C
Technical data: Compressed air supply

Air hose
Material PE-LD outside Ø 6 mm
- metric
Inside Ø 4 mm
Material PA outside-Ø 6.35 mm
- Inch
Inside Ø 4.3 mm
Product pressure max. 10 bar (116 psi)
min. 4.8 bar
Control air pressure
max. 8 bar
Control air pressure for air/air - A/A min. 4.0 bar
actuator max. 8 bar
Control air acc. to ISO 8573
Quality class 6
- Solid particle content: Particle size max. 5 µm
Particle density max. 5 mg/m3
Quality class 4 max. dew point +3 °C
If the unit is used at higher altitudes or
- Water content:
at low ambient temperatures, the dew
point must be adapted accordingly.
Quality class 3, ideally oil-free, max.
- Oil content:
1 mg oil for 1 m3 air
Air requirement per switching operation
Air requirement (dm3 n/

stroke)
Actuator type Actuator diameter [mm]
dm3 n with 1.01325 bar
at 0 °C as per DIN 1343
"DN 50, DN 65 2" OD,
88.9 0.325
2.5" OD"
"DN 80, DN 100 3" OD,
114.3 0.530
4" OD"
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Technical data
Resistance of Sealing Materials
Equipment: Proximity switches – actuator without T.VIS

Operating voltage [V] 10...65 DC 20...25 AC
Switching distance [mm] 5 5
Max. continuous current
>3...<100 >3...<100
[mA]
Ambient temperature [°C] -25...+80 -25...+80
Protection class IP 67 IP 67
5.3 Resistance of 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:
• + = good resistance
• o = reduced resistance
• - = no resistance
Sealing resistance table
Sealing material (general operation temperature)

Medium at permissible EPDM FKM HNBR VMQ
operating -40...+135°C* -10...+200 °C* -25...+140 °C* -50...+200 °C*
temperature (-40...275°F*) (+14...+392°F*) (-13...+284°F*) (-58...+392 °F*)
Caustics up to up to 80 °C +
o + o
3% (176°F)
Caustics up to up to 40 °C
+ o o o
5% (104°F)
Caustics up to up to 80 °C
+ – – o
5% (176°F)
Caustics at more
o – – o
than 5%
Inorganic acids** up to 80 °C
+ + + o
up to 3% (176°F)
o + o o
up to 5% (176°F)
– + – o
up to 5% (212°F)
Water up to 80 °C
+ + + +
(176°F)
Water up to 100 °C
+ + + o
(212°F)
Steam up to 135 °C
+ o o o
(275°F)
Steam, approx. up to 150 °C
+ o – o
30 min (302°F)
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Technical data
Pipe ends - General table of measurements
Sealing resistance table
Sealing material (general operation temperature)

Medium at permissible EPDM FKM HNBR VMQ
operating -40...+135°C* -10...+200 °C* -25...+140 °C* -50...+200 °C*
temperature (-40...275°F*) (+14...+392°F*) (-13...+284°F*) (-58...+392 °F*)
Fuels/
– + + -
hydrocarbons
Product with a fat
content up to + + + o
35%
Product with a fat
content of more – + + o
than 35%
Oils – + + o
Other applications upon request

* Depending on the installation conditions
** Inorganic acids are, e.g. carbonic acid, nitric acid and sulphuric acid
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

Outside
Outside Wall Inside
Metric DN diameter acc.
diameter thickness diameter
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
80 85 2.0 81 x
100 104 2.0 100 x
125 129 2.0 125 x
150 154 2.0 150 x
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Technical data
Tools
Dimensions for Pipes in Inch OD

Outside
Outside Wall Inside
Inch OD diameter acc.
to 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
6" 152.4 2.77 146.86 x
Dimensions for Pipes in Inch IPS

Outside
diameter
Outside Wall Inside
Inch IPS according to
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
6" 168.3 2.77 162.76 x
5.5 Tools
List of tools
Tools Material no.
Hose cutter 407-065
Open-end spanners a/f 8; 9; 10; 12; 13; 14; 15;
16; 17; 24
Pin punch Ø 4 403-209
Belt wrench 408-142
Face pin wrench Ø 4, adjustable 80 408-197
Hex. key a/f 3; 4; 5
Installation mandrel 229-000061
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Technical data
Lubricants
5.6 Lubricants
Lubricants Material no.

Rivolta F.L.G. MD-2 413-071
PARALIQ GTE 703 413-064
5.7 Weights
TYPE GS
Mixproof butterfly valve with drive [kg]

Size Pneumatic actuator Pneumatic actuator with
Manual actuator
without control top T.VIS control top
DN 50, 2" 4.0 7.9 9.1
2 1/2" 5.1 9.0 10.2
DN 65 5.0 8.9 10.1
3" 6.1 10.4 11.8
DN 80 5.9 10.2 11.7
DN 100 8.3 12.4 13.9
4" 8.3 12.4 13.8
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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 mixproof butterfly valve may only be installed in horizontal pipes, with the
actuator in vertically upright position.
To prevent damage, make sure that
• the mixproof butterfly valve is installed in the pipe system free of tension.
• no foreign materials (e.g. tools, bolts, lubricants) are left in the system.
6.3 Pneumatic connections
6.3.1 Air Requirement

The air requirement for the switching operations depends on the actuator type.
Air requirement (dm3n/

stroke) dm3 n at 1.01325
Actuator type Actuator Ø (mm) bar at 0°C in
accordance with
DIN 1343
DN 50, DN 65
88.9 0.325
2" OD, 2.5" OD
DN 80, DN 100
114.3 0.530
3" OD, 4" OD
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Electrical connections
6.3.2 Establishing Hose Connections

To ensure reliable operation, the compressed air hoses must be cut exactly
square.
Tools required:
• A hose cutter
Carry out the following steps:
1. Shut off the compressed air supply.
2. Use the hose cutter to cut the pneumatic hoses square.
® Done.
6.3.3 Actuator with T.VIS Control Top

1. Push the air hose into the air connector on the control top.
2. Re-open the compressed air supply.
® Done.
6.3.4 Actuator without Control Top

1. Remove the plug from the actuator.
2. Screw in connector G 1/8" or an exhaust air throttle for slow closing.
3. Push the air hose into the air connector.
4. Re-open the compressed air supply.
® Done.
6.4 Electrical connections
6.4.1 Electrical connection with T.VIS control top
Danger
Live parts
Electrical shock can result in serious personal injury or death.
► Only allow properly qualified staff to carry out work on the electrical
equipment.
► Prior to establishing electrical connections check the maximum
permissible operating voltage.
Explosive gases or dusts

An explosion can result in serious personal injury or death.
► Observe the installation and operating regulations for use in potentially
explosive areas.
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1. Connect in accordance with the connection diagram and the instructions in

the corresponding operating instructions for control tops T.VIS M-15 or T.VIS
A-15.
® Done.
Hint!
The proximity switches are factory set. During transport and
installation it can happen that the settings are changed, so that
readjustment may be required (see the Operating Instructions for the
control top).
6.4.2 Adjusting the proximity switch – actuator without T.VIS
Danger
Live parts
Electrical shock can result in serious personal injury or death.
► Only allow properly qualified staff to carry out work on the electrical
equipment.
► Prior to establishing electrical connections check the maximum
permissible operating voltage.
Explosive gases or dusts

An explosion can result in serious personal injury or death.
► Observe the installation and operating regulations for use in potentially
explosive areas.

1. Loosen the cap nuts on the proximity switch.
2. Hold the proximity switch and turn the cap nuts until a switching gap of max. 4
mm to the associated contact element is achieved.
3. Tighten the cap nuts.
® Done.
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Start-up
Safety instructions
7 Start-up

Initial commissioning
For initial commissioning, the following principles apply:
• Take protective measures against dangerous contact voltages in accordance
with pertinent regulations.
• The valve must be completely assembled and correctly adjusted. All screw
connections must be securely tightened. All electrical cables must be installed
correctly.
• Reliably secure machine parts which have already been connected against
inadvertently being switched on.
• Relubricate all lubricating points.
• Make sure lubricants are used properly.
• After conversion of the valve, residual risks must be reassessed.
Setting into Operation
For commissioning, the following principles apply:
• Only allow properly qualified staff to set the valve into operation.
• Establish all connections correctly.
• The safety devices for the valve must be complete, fully functional and in
perfect condition. Check the function before starting any work.
• When the valve is switched on, the danger zones must be free.
• Remove any liquids that have escaped without leaving residues.
7.2 Notes on commissioning

Before starting commissioning observe the following:
• Make sure that there are no foreign materials in the system.
• Actuate the valve once by applying compressed air.
• Clean the pipe system prior to the first product run.
• 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
These factors can be combined in such a way as to make an optimal cleaning
result probable.
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Cleaning
Passivation
9.1.3 Cleaning the leakage cavity

On the leakage butterfly valve, two connections for flushing are provided at the
deepest point of the housing to enable cleaning of the leakage cavity.
A special sealing mechanism allows the valve to be operated without any
additional shut-off valves.
• Cleaning liquid is flushed into the leakage cavity through one of the flushing
connections.
• The second flushing connection is used for discharging medium and as a
leakage indicator in the event of sealing damage.
• When the pipe is cleaned, it is recommended to completely open and close
the flap twice per minute (at least 6 times per cleaning operation) so that
medium flows around it, in order to clean the areas underneath the flap.
The leakage cavity can be flushed via the leakage connections when the flap is
closed. The recommended admission pressure for the cleaning medium supply at
the inlet valve to the leakage cavity is 2.5 bar ± 0.5 bar. Pressure build-up
between the seals on the valve disc should always be avoided. Non-pressurised
discharging at the outlet valve is therefore required. Generally also ensure a
positive pressure difference from the product chamber to the leakage cavity. We
recommend also cleaning the leakage cavity as part of all cleaning steps using
the relevant cleaning media.
The duration of the entire washing process depends on the type of soiling and
typically ranges between 10 and 90 seconds.
Flow rates for cleaning the leakage cavity
Size DN 50 2.5" OD DN 65 3" OD DN 100
DN 80
2" OD 4" OD
Kvs values
194 198 178 203 188 163
(l/h)
The table lists the values for the duration and number of rinsing operations.
Number of rinsing
Medium Duration (s)
operations
Beer 1...2 2...3 During every cleaning phase
Yeast 1...2 2...3 1. Prerinse
2. Hot caustic
3. Intermediate rinse
Milk 2...5 3
4. Acid
5. Rinsing
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.
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Cleaning
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.
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Maintenance
Safety notes
10 Maintenance
10.1 Safety notes

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 long-term decommissioning, observe storage conditions, see "Transport
and storage".
10.2 Inspections
Between the maintenance periods, the valves must be checked for leakage and
proper function.
10.2.1 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.
10.2.2 Electrical connections

1. Check that the cap nut on the cable gland is tight.
2. Only for T.VIS control top: check the cable connections on the adapter and
interface module (see operating instructions for control top types T.VIS M-15
or T.VIS A-15).
® Done.
10.2.3 Mechanical Connections

1. Check that all screw connections and locking devices are firmly secured.
® Done.
10.2.4 Signs on the valve

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Maintenance
Maintenance intervals
1. Check the signs on the valve.

2. Replace damaged or missing stickers with new ones.
® Done
10.3 Maintenance intervals

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

Prerequisite:
• Make sure that during maintenance and repair work no process is in operation
in the area concerned.
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
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Maintenance
Disassembling the Valve
10.5.1 Removing the T.VIS M-15 Control Top
Fig.13
Prerequisite:
• The pneumatic and electrical connections on the plant side can remain on the
control top.
Notice
The permanent magnet on the switch bar is fragile.
Damage to the permanent magnet.
► Protect the permanent magnet against impact stress.

1. Undo the screws (39).
2. Remove the clamps (15).
3. Withdraw the control top (B) via the switch bar (1) from the actuator (A.1).
4. Unscrew the switch bar (1).
® Done.
Hint!
Assemble the valve in reverse order. Also refer to the instruction
manual for the T.VIS M-15.
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Maintenance
10.5.2 Removing the T.VIS A-15 Control Top
Fig.14
Prerequisite:
• The pneumatic and electrical connections on the plant side can remain on the
control top.
Notice
The permanent magnet on the switch bar is fragile.
Damage to the permanent magnet.
► Protect the permanent magnet against impact stress.
Notice
The sensor is a sensitive component.
Damage of the sensor and failure of the valve.
► Always handle the sensor with care!

1. Undo the screws (39).
2. Remove the clamps (15).
3. Withdraw the control top (B) via the switch bar (11) from the actuator (A.1).
4. Unscrew the switch bar (11).
® Done.
Hint!
Assemble the valve in reverse order. Also refer to the instruction
manual for T.VIS A-15.
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Maintenance
10.5.3 Removing the Valve
Fig.15

1. Undo the screw connections (3).
2. Remove the valve from the pipe.
® Done.
10.5.4 Disassembling the Pneumatic Actuator
10.5.4.1 Taking off the Actuator
Fig.16

2. Lift off the actuator (A).
® Done.
Hint!
The red position indication marker (2) is aligned with the hole (B) in
the valve disk so that it indicates the position of the disk in the valve.
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Maintenance
10.5.4.2 Dismantling the Actuator Parts
Fig.17

2. Take off the position indicator (2).
3. Remove the mounting bracket (6).
® Done.
10.5.5 Disassembling the Manual Actuator

Removing the proximity switch
Fig.18

1. Use an a/f 4 hex socket screwdriver to unscrew the locking screw (2) until it is
flush with the bushing.
2. Take off the hand lever (1).
® Done.
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Maintenance
Removing the Manual Actuator
Fig.19

1. Use an a/f 4 hex socket screwdriver to unscrew the locking screw (2) until it is
flush with the bushing.
2. Take off the hand lever (1).
® Done.
10.5.6 Removing the Valve Disk Seal

Removing the Flanges
Fig.20
2. Pull the butterfly valve body apart.

3. Remove the radial seal (9).
® The radial seal protects the plain bearing from soiling. The plug protects
the plain bearing from soiling.
4. Take out the valve disk (4) with the disk seal (6).
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Maintenance
Maintenance
® Done.
Removing the Seal

1. Pull off the plain bearings (5).
2. Turn the disk seal (6) until it is positioned at a 90° angle to the valve disk (4).
Fig.21
3. Pull the disk seal over the free end (12) of the valve disk.
4. Unclamp the valve disk.
5. Pull the disk seal over the long end (10).
Fig.22
6. Remove the O-ring (8).

® Done.
® The disk seal is now completely removed.
10.6 Maintenance
10.6.1 Cleaning the Mixproof Butterfly Valve
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Maintenance
Maintenance
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.
► Use only cleaning mediums which do not damage the materials of the
control top (PPE, PA).
1. Carefully clean the individual parts.
2. Check that air can exit freely from the vent screw (3).
Fig.23
® Done.
10.6.2 Lubricating Seals and Threads
Caution!
Damage to seals and threads
Damage to seals and threads can result in a 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 information sheets issued by the lubricant
manufacturer!
1. Apply a light film of lubricant to all threads.
2. Apply a light film of lubricant to all seals.
3. Apply a light film of lubricant to the shaft ends.
® Done.
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Maintenance
Installation
Hint!
GEA Tuchenhagen recommends Rivolta F.L.G. MD-2 and PARALIQ
GTE 703. These lubricants are approved for foodstuff and are resistant
to beer froth. They have the NSF-H1 (USDA H1) registration. They do
not affect the taste or the consistency of the products and are
compatible with the seals in contact with product.
PARALIQ GTE 703 can be ordered from GEA Tuchenhagen under
material no. 413-064, and Rivolta F.L.G. MD-2 can be ordered under
material no. 413-071. 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.
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 Assembling the Valve Disk

Overview Drawing
Fig.24
Observe the following points when assembling:

• Before the valve disk is inserted between the flanges it must be positioned at
a 90° angle to the seal.
• The plain bearings must be refitted. To fit the upper plain bearing on valves
with nominal widths DN 80 and DN 100 or 3" OD and 4" OD put installation
mandrel 229-000061 over the square end to mount the plain bearing.
• When the actuator is mounted, the valve disk must be in the correct position:
for resting position closed: valve disk closed for resting position open: valve
disk at 90° position.
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Maintenance
• Installation outer flange type VV: Arrange additional holes so that bracket can
be dismantled in assembled condition.
10.7.2 Torques for the clamps and bolts

Tighten the clamps and bolts on the valve to the torques specified in the table.
Torques [Nm] [lbft]

Clamps on the control top 1 0.7
Bolts M6 9 6.6
Bolts M8 22 16.2
Bolts M10 45 33
Bolts M12 78 57.5
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Alarms
Malfunctions and remedies
11 Alarms
11.1 Malfunctions and remedies

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

Actuator does not work Air hoses clogged or Clean or replace the air
leaking hoses
Control air pressure too Increase the control air
low pressure
Solenoid valve defective Replace the solenoid
valve
Valve disk is blocked Clear the blockage
No feedback signal Proximity switch adjusted Adjusting the proximity
switch
Proximity switch not Check and correct the
connected correctly wiring
Proximity switch faulty Replace the proximity
switch
Valve disk is blocked Clear the blockage
Leakage at flanges Disk seal defective Replace the disk seal
O-ring defective
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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 valve at the end of its life cycle in an environmentally friendly
manner. Observe the statutory waste disposal regulations applicable at the place
of installation.
The valves 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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Parts list - Manual actuator hygienic leakage butterfly valve
13 Parts list - Manual actuator hygienic leakage butterfly valve
Fig.25: Manual actuator for BFV-L
Fig.26: Installation variants for proximity switches
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Parts list - Manual actuator hygienic leakage butterfly valve
Item Designation Nominal width Nominal width

DN 25 - DN 65 DN 100 / DN 80
2" OD - 2.5" OD 3” OD / 4” OD
X Square 12 mm 14 mm
Manual actuator 224-001055 224-001056
Proximity switch holder 224-001058 224-001058
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Parts list - Pneumatic actuator hygienic leakage butterfly valve
14 Parts list - Pneumatic actuator hygienic leakage butterfly valve
Fig.27
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Fig.28
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Item Designation Material DN 50 DN 65 DN 80 DN 100

2" OD 2.5" OD 3" OD 4" OD
A Actuator BFV-7 / NC/NO/ cpl. -- 224-001822 224-001822 224-001821 224-001821
A (opt.) Actuator BFV-7/NC/NO/cpl./EX -- 224-001831 224-001831 224-001829 224-001829
3 Console BFV-7 1.4301 224-001071 224-001071 224-001071 224-001071
5* Cheese head screw A2-70 902-099 902-099 902-099 902-099
7 Elbow screw-in plug connection, metric Brass/nickel- 933-034 933-034 933-034 933-034
(1/4” - 6/4) plated
Elbow screw-in plug connection Brass/nickel- 933-972 933-972 933-972 933-972
(1/4"-6.35) plated
7.1 Throttle check valve, exhaust air 1/4" Brass/nickel-
603-048 603-048 603-048 603-048
plated
7.2 Screw-in plug connection metric (1/4" - Ms CV 933-480 933-480 933-480 933-480
6/4)
Screw-in plug connection, metric Brass/nickel- 933-477 933-477 933-477 933-477
(1/4"-6.35) plated
8 Hexagon nut A2-70 910-018 910-018 910-018 910-018
9 Initiator M12x1; 10-65V/DC/2wire Synthetic
505-104 (electrical connection with terminal compartment)
material
Initiator M12x1; 10-30V/DC/3wire 1.4301 505-088 (electrical connection with terminal compartment)
505-096 (electrical connection with M12 plug)
11 Position indicator BFV-7 PP 224-001069 224-001069 224-001070 224-001070
12 O-ring NBR 930-041 930-041 930-041 930-041
13 Guide ring Turcite-T51 935-105 935-105 935-105 935-105
14 O-ring NBR 930-903 930-903 930-903 930-903
* Two cylinder screws (pos. 5) are included in each actuator A.
A includes positions A, 3, 8, 11, 12, 13, and 14
Item Material Designation Material no.

Accessories for T.VIS M-15
B Control Top T.VIS M-15 1 1.4301 Switch bar T.VIS 224-001697
Accessories for T.VIS P-15 and A-15
D Control top type T.VIS P-15 240 -- Switch bar for T.VIS P-15 and A-15 224-001696
and A-15
Accessories for control top SES/EX
S Control top SES/EX 220 Switch bar 224-001548
182 Extension 224-001549
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Parts list - Hygienic leakage butterfly valve (valve assembly without actuator)
15 Parts list - Hygienic leakage butterfly valve (valve assembly without

actuator)
Fig.29: Items marked with an * are wearing parts.
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Item Designation Material DN 50 DN 65 DN 80 DN 100

Sealing set cpl. EPDM 224-000696 224-000697 224-000698 224-000699
1 Flap BFV-L 1.4404 224-000583 224-000585 224-000540 224-000568
2** Seal BFV-L EPDM 224-000570 224-000571 224-000535 224-000573
3** Radial seal BFV-L EPDM 224-000536 224-000536 224-000536 224-000536
4 Cheese head screw A2-70 902-136 902-136 902-136 902-137
4x M8 x 75 8x M8 x 75 8x M8 x 75 8x M10 x 80
5 Hexagon nut A2 910-018 910-018 910-018 910-026
4x M8 8x M8 8x M8 8x M10
2x M8 x 30 2x M8 x 30 2x M8 x 30 2x M8 x 30
18** O-ring EPDM 930-546 930-547 930-450 930-549
19 Flange BFV-L 1.4404 224-000587 224-000589 224-000591 224-000592
20 VARIVENT smooth flange 1.4404 752-727 752-728 752-729 752-730
21** Plain bearing IGLIDUR-F 704-046 704-046 704-046 704-046
23 Cap nut M12 x 1.5 1.4571 933-459 933-459 933-459 933-459
24 Cutting ring 6/4 1.4571 933-458 933-458 933-458 933-458
25 Support sleeve 6/4 1.4571 933-380 933-380 933-380 933-380
Grease RIVOLTA F.L.G. MD-2 100g tube not included in the sealing set 413-136
Grease BARRIERTA L 55/3 (only for seals VMQ) 413-137
** The sealing set includes items 2, 3, 18, 21 and 22.
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Item Designation Material 2"OD 2.5"OD 3" OD 4" OD

Sealing set cpl. EPDM 224-000700 224-000701 224-000702 224-000703
1 Flap BFV-L 1.4404 224-000583 224-000584 224-000586 224-000568
2** Seal BFV-L EPDM 224-000570 224-000574 224-000572 224-000573
3** Radial seal BFV-L EPDM 224-000536 224-000536 224-000536 224-000536
4x M8 x 75 8x M8 x 75 8x M8 x 75 8x M10 x 80
5 Hexagon nut A2 910-018 910-018 910-018 910-026
4x M8 8x M8 8x M8 8x M10
2x M8 x 30 2x M8 x 30 2x M8 x 30 2x M8 x 30
18** O-ring EPDM 930-559 930-560 930-319 930-561
19 Flange BFV-L 1.4404 224-000593 224-000588 224-000590 224-000594
20 VARIVENT smooth flange 1.4404 752-741 752-742 752-743 752-744
23 Cap nut M12 x 1.5 1.4571 933-459 933-459 933-459 933-459
24 Cutting ring 6/4 1.4571 933-458 933-458 933-458 933-458
25 Support sleeve 6/4 1.4571 933-380 933-380 933-380 933-380
Grease RIVOLTA F.L.G. MD-2 100g tube not included in the sealing set 413-136
Grease BARRIERTA L 55/3 (only for seals VMQ) 413-137
** The sealing set includes items 2, 3, 18, 21 and 22.
Complete valve bodies can be ordered using the order code.

Select here the actuator type “9 = without actuator”.
e.g. 9881-1002-0900-0000
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Dimension sheet - Hygienic leakage butterfly valve
16 Dimension sheet - Hygienic leakage butterfly valve
Fig.30: Installation of proximity switches optional / observe removal reserve
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Dimension sheet - Hygienic leakage butterfly valve
DN 50 DN 65 DN 80 DN 100
Item Designation Dimension
2" OD 2.5" OD 3" OD 4" OD
A1 Pneumatic actuator with T.VIS control top, B 109 127 141 168
installation dimension X
C2 47.5 47.5 47.5 47.5
D / actuator Ø 90 90 114 114
H / DN 432 441 448 461
H / OD 432 441 448 461
LK 1 DN 77 95 110 137
LK 1 OD 74 88 101 134
Bolts 4 x M8 6 x M8 6 x M8 6 x M8
X 520 520 535 550
A2 Pneumatic actuator without control top, B 109 127 141 168
installation dimension X1
C2 47.5 47.5 47.5 47.5
D / actuator Ø 88.9 88.9 114.3 114.3
H1 268 277 284 297
X1 360 360 380 390
A3 Manual actuator, installation dimension B 109 127 141 168
X2
C2 47.5 47.5 47.5 47.5
Q 160 160 220 220
H2 106 115 122 135
X2 130 139 146 159
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Dimension sheet - Hygienic butterfly valve - seals
17 Dimension sheet - Hygienic butterfly valve - seals
Fig.31
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Dimension sheet - Hygienic butterfly valve - seals
Nominal width Material Material D1 D2 B

DN 50 EPDM 224-000570 56.3 63.2 28.0
DN 65 EPDM 224-000571 74.1 82.7 28.0
DN 80 EPDM 224-000535 88.9 97.5 31.0
DN 100 EPDM 224-000573 109.1 118.7 32.0
2" OD EPDM 224-000570 56.3 63.2 28.0

2.5" OD EPDM 224-000574 68.4 76.7 28.0
3" OD EPDM 224-000572 81.2 89.7 31.0
4" OD EPDM 224-000573 109.1 118.7 32.0
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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]
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 Organisation for
ISO
Standardisation
kg Unit of measurement of weight [kilogram]
kN Unit of measurement of force [kilonewton]
Kv value Flow rate coefficient [m³/s] 1 KV = 0.86 x Cv
l Unit of measurement of volume [litre]
max. maximum
mm Unit of measurement of length [millimetre]
µm Unit of measurement of length [micrometre]
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Appendix
Abbreviation Explanation
M Metric
Unit of measurement of work [newton metre]
Nm SPECIFIED TORQUE: 1 Nm = 0.737 lbft
Pound-Force (lb) + Feet (ft)
PA Polyamide
PE-LD Low-density polyethylene
PPE Polytetrafluoroethylene
Anglo-American measurement of 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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Appendix
430BAL008984EN_7
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OI - GEA Hyg Leakage Butterfly Valve - V7 - EN-230607

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Hygienic valves

GEA Hygienic leakage butterfly valve

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 in accordance with the EC Machinery Directive

EU Declaration of conformity within the meaning of the EC machine directive 2006/42/EC

Manufacturer: GEA Tuchenhagen GmbH

Hereby, we declare that the machine designated in the following

Designation: GEA Hygienic Butterfly Valve

Type: Valve with actuator

Relevant EC directives: 2006/42/EC EC Machinery Directive

Applicable harmonized standards, in particular: EN ISO 12100: 2010

Büchen, 29 April 2021

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

GEA Tuchenhagen GmbH

We hereby declare that the machine named below

Remarks: This declaration will become invalid if

Person authorised for compilation and GEA Tuchenhagen GmbH

Büchen, 29 April 2021

Franz Bürmann i.V. Matthias Südel

2.1 Intended use

2.1.1 Flow speed

2.1.2 Pressure equipment directive

2.1.3 ATEX directive

2.1.4 Improper operating conditions

• Damage to the component has been detected.

2.1.5 Requirements for operation

2.2 Operator’s Duty of Care

2.3 Subsequent changes

2.4 General safety instructions and dangers

2.4.1 Principles for safe operation

2.4.2 Environmental Protection

• Substances harmful to the environment must be collected and stored in

2.4.3 Electrical Equipment

2.5 Supplementary Regulations

2.6 Qualification of personnel

• Personal suitability for the respective task.

2.7 Safety equipment

Signs on the valve

General hazard warning

Explosive atmosphere hazard warning

2.8 Residual dangers

Danger Cause Measure

Residual dangers on the valve and measures

Danger Cause Measure

Environmental damage Operating materials with For all work:

Risk of injury Danger due to liquid escaping

2.9 Hazard Areas

Please observe the following notes:

3.1 Pneumatic Butterfly Valve with Control Top

3.2 Pneumatic Butterfly Valve without Control Top

3.3 Butterfly Valve Body without Actuator

Butterfly valve design for matrix-piped systems.

3.4 Manual Actuator Type H

No. Manual actuator variants

3.5 Functional description

3.5.1 Pneumatic Actuator

3.5.2 Actuator (A.1)