Specification - GEA T.VIS® A-15

operating instructions
Translation from the original language
Control and feedback systems
GEA T.VIS® A-15
GEA T uchenhagen GmbH
Document number: 430BAL010699
Language : EN / Dat e: 2025-04
PUBLIC GEA.com
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 designations T.VIS®, VARIVENT®, ECOVENT®, STERICOM®, VESTA® und
LEFF® are protected trademarks of GEA Tuchenhagen GmbH.
TABLE OF CONTENTS
1 General Information
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
1.2 Manufacturer address
1.3 Contact 8
1.4 EU Declaration of Conformity
1.5 Translated copy of the EU Declaration of Conformity
1.6 UK Declaration
1.7 Translated copy of the UK Declaration of Conformity according to the provisions on electromagnetic
compatibility from 2016
2 Safety 13
2.1 Intended use 13
2.1.1 Requirements for operation
2.1.2 Improper operating conditions
2.2 Operator’s Duty of Care 13
2.3 Subsequent changes
2.4 IP Protection classes 15
2.5 General safety instructions and dangers
2.5.1 Principles for safe operation
2.5.2 Environmental Protection
2.5.3 Electrical Equipment
2.6 Supplementary Regulations
2.7 Qualification of personnel
2.8 Safety equipment 18
2.8.1 Signs 18
2.9 Residual dangers
2.9.1 Electrostatically Endangered Components and Modules
2.9.2 Instructions for the Safe Handling of Electronic Components During Welding Work  20
2.10 Danger zones
3 Description 21
3.1 Functional description
3.1.1 Operation Principle
3.1.2 Control top without solenoid valves
3.1.3 Control Top with Solenoid Valves
3.1.4 Control Top with Cap Including Buttons
3.1.5 Control top with hood without buttons
3.1.6 Function of the Buttons 23
3.1.7 Safety Air Exhaust/Installation Position
4 Transport and storage 25
4.1 Storage conditions
4.2 Transport 25
4.2.1 Scope of supply 25
5 Technical data 26
5.1 Type plate 26
5.2 Technical data
5.3 Specifications for 24V DC version
5.4 IO-Link specifications
5.5 Specifications for AS-interface
5.6 DeviceNet specifications
5.7 Accessories 43
5.8 Tool 44
5.9 Lubricants
5.10 Equipment
6 Assembly and installation
6.1 Safety instructions 46
6.2 Establishing Hose Connections
6.3 Pneumatic connections
6.3.1 Control Top with 1 Solenoid Valve or Without Solenoid Valve
6.3.2 Control Top with 2 Solenoid Valves – for Lifting the Valve Disk 48
6.3.3 Control top with 2 solenoid valves – for lifting the double-disk, for the external air connection of an air/air
actuator or for the main stroke of an external process valve
6.3.4 Control top with 2 solenoid valves- for spreader lift of the double-disk  50
6.3.5 Control top with 3 solenoid valves for lifting the valve disk and double-disk  51
6.3.6 Control top with 3 pilot valves - to lift the double-disk and to spread lift the double-disk  53
6.3.7 Control top with 4 pilot valves for the lift of the valve disk and of the double-disk and for the spread lift of
the double-disk
6.4 Electrical connections
6.4.1 Overview
6.4.2 Electrical 24 V DC Wiring
Plug M12 / 5-pin (24.1)  57
Connector M12 / 8-pin (24.1)  58
Connector M12/12-pin / 9-strand  59
Cable gland (24)  60
6.4.3 Electrical 24 V DC Wiring
Plug M12 / 5-pin (24.1)  60
6.4.4 Electrical Wiring of AS-Interface
Plug M12 / 5-pin (24.1)  61
6.4.5 Electrical DeviceNet Wiring
Plug M12 / 5-pin (24.1)  62
External Proximity Switch (170)  62
6.5 Visual Display
6.5.1 Illuminated dome
6.5.2 Colour Changeover
6.5.3 Connection diagram for T.VIS circuit board (bottom)
6.6 Mounting the control top to different valves
6.6.1 Mounting to a VARIVENT Valve
6.6.2 Fitting to FLOWVENT Valve 68
6.6.3 Installation on VARIVENT mixproof valves with Lifting Actuator Type R, T_R, M/2.0, M_0(06), MT/T_R(08),
MX, MT, MT_DA 70
6.6.4 Mounting to a Butterfly Valve T-smart 8000
6.6.5 Mounting to a Butterfly Valve T-smart 7 and a Mixproof Butterfly Valve T-smart 9  72
6.6.6 Mounting to ECOVENT Valves N_ECO and W_ECO
6.6.7 Mounting to VESTA Valve H_A/M
6.6.8 Mounting to VESTA Valve H_A
6.6.9 Mounting to Valve N_/E or W_/E or STERICOM Valve
6.6.10 Mounting to a T-smart Single-Seat and Double-Seal Valve
6.6.11 Fitting to an ASEPTOMAG Valve 78
6.6.12 Replacing Control Tops
7 Start-up 80
7.1 Safety notes 80
7.2 Commissioning – Control Top without Solenoid Valves
7.3 Commissioning – Control Top with Solenoid Valves
7.4 Service Function
7.5 Adjust the initiator in the lantern - for unbalanced double-disks of the valves D, R, Y, B, T_R and MT  83
7.5.1 Adjust the initiator in the lantern - for double-disk of the tank bottom valves MT-DA (spreader lift)  86
7.6 Adjusting the Proximity Switch in the lantern of PMO Valve Type M/2.0  93
7.7 Test procedure for Tuchenhagen PMO valves type M / 2.0
7.7.1 Purpose
7.7.2 Process Overview
7.7.3 Hardware Description
7.7.4 Test Procedure 1
7.7.5 Test Procedure 2
8 Operation and control
8.1 Safety instructions
8.2 Settings in Programming Mode
8.3 Operating Overview
9 Cleaning
9.1 Cleaning
10 Maintenance 106
10.1 Safety instructions
10.2 Inspections 107
10.3 Maintenance intervals
10.4 Removing the Control Top from the Valve
10.5 Dismantling the Control Top into its Components
10.5.1 Variants of the Control Top
10.5.2 Removing the Cap
10.5.3 Removing the printed circuit board
10.5.4 Install the circuit board
10.5.5 Removing the sensor module (9)
10.5.6 Removing the logic element NOT (seal pack)
10.5.7 Fitting the Logic Element NOT (Sealing Package)
10.5.8 Removing the Solenoid Valves and the Valve Plate
10.5.9 Removing the pneumatic block
10.5.10 Fitting the Pneumatic Block
10.6 Install pneumatic connections
10.7 Maintenance
10.7.1 Replacing the Seals on the Base
10.7.2 Maintenance of Sound Absorber, Filter, Non-Return Valve and Exhaust Air Throttle  116
10.7.3 Mounting cap
11 Alarms 119
11.1 Malfunctions and remedies
11.2 Carrying out a Reset – Back to Default Standard
12 Decommissioning
12.1 Safety instructions
12.2 Disposal
12.2.1 General notes
13 Spare parts list - control top type T.VIS A-15
14 Spare parts list - switch bar T.VIS A-15
15 Dimension sheet - Control top type T.VIS A-15
16 Dimension sheet - switch bar LFT-R T.VIS A-15/M-20 for lifted valves R; T_R; L;
M_O(06); MT/T_R(08); M/2.0; MT; MT-DA; MX
17 Appendix
17.1 Lists
17.1.1 Abbreviations and terms
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.
Notes on the Illustrations
The illustrations in these Operating Instructions show the product in a simplified
form. The actual design of the product can differ from the illustration. For detailed
views and dimensions of the product please refer to the design documents.
1.1.3 Symbols and Highlighting
In these Operating Instructions, important information is highlighted by symbols
or special formatting. The following examples illustrate the most important types
of highlighting.
Danger
Warning: Fatal Injuries
Failure to observe the warning can result in serious damage to health, or
even death.
► The arrow identifies a precautionary measure you have to take to avoid
the hazard.
Warning: Explosions
Failure to observe the warning can result in severe explosions.
► The arrow identifies a precautionary measure you have to take to avoid
the hazard.General Information
Information on the Document
Warning!
Warning: Serious Injuries
Failure to observe the warning can result in serious damage to health.
► The arrow identifies a precautionary measure you have to take to avoid
the hazard.
Caution!
Warning: Injuries
Failure to observe the warning can result in minor or moderate damage to
health.
► The arrow identifies a precautionary measure you have to take to avoid
the hazard.
Notice
Warning: Damage to Property
Failure to observe the warning can result in serious damage to the
component or in the vicinity of the component.
► The arrow identifies a precautionary measure you have to take to avoid
the hazard.
Carry out the following steps: = Start of a set of instructions.
1.First step in a sequence of operations.
2.Second step in a sequence of operations.
®Result of the previous operation.
®The operation is complete, the goal has been achieved.
Hint!
Further useful information.
1.2 Manufacturer address
GEA Tuchenhagen GmbH
Am Industriepark 2-10
21514 Büchen
1.3 Contact
Tel.:[phone]
[e-mail]
www.gea.comGeneral Information
Manufacturer address
1.4 EU Declaration of Conformity
GEA INTERNAL   EU Declaration of Conformity
Manufacturer:
GEA Tuchenhagen GmbH
Am Industriepark 2 -10
21514 B üchen, Germany
We hereby declare that the devices named below
Model:
Control Top T.VIS® A-15
Control top T.VIS® A-15/ Class I Division 2
Type:
24 VDC
AS-i
DeviceNet
IO-Link
due to their 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:
2011/65/EU        EMC
RoHS
Applicable harmonized standards, in
particular:
Other applied standards
and technical specifications:  EN 61000 -6-2: 20 19
EN IEC 62026 -1:2019
DIN EN 61326 -1 :2013 -07
DIN EN 61131 -2: 2008
CISPR11:2015
Remarks:
• The device type IO -Link meets the IO -Link test specification (Version 1.1.2 - 2014)
• Model T.VIS® A-15/ Class I Div. 2 not for  type IO-Link!
• The above mentioned standards have been taken into account in accordance with
the respective scope of application
Person authorised for compilation and handover of technical
documentation:
GEA Tuchenhagen GmbH
CE Documentation Officer
Am Industriepark 2 -10
21514 B üchen, Germany
Büchen, 08 November 2022
________________________________    ________________________________
Franz Bürmann        pp. Stephan Dirks
Managing Director  Director Hygienic Valves I & Control Top
General Information
EU Declaration of Conformity
1.5 Translated copy of the EU Declaration of Conformity
Manufacturer: GEA Tuchenhagen GmbH
Am Industriepark 2-10
21514 Buchen, Germany
We hereby declare that the devices named below
Model: Control top T.VIS® A-15
Control top T.VIS® A-15/Class I Division 2
Type: 24 VDC
AS-i
DeviceNet
IO-Link
due to their 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: 2014/30/EU EMC
2011/65/EU RoHS
Applicable harmonized standards, in
particular:EN 61000-6-2: 2019
DIN IEC 62026-2: 2013
Other applied standards and
technical specifications:DIN EN 61326-1: 2013-07
DIN EN 61131-2: 2008
CISPR11: 2015
Remarks:• The device type IO-Link complies with the IO-Link test specifications (version 1.1.2 - 2014)
• Model T.VIS® A-15/ Class I Div. 2 cannot be used with the type IO-Link!
• The standards stated have been taken into consideration according to the respective application area.
Person authorised for compilation and handover of technical
documentation:GEA Tuchenhagen GmbH
CE Documentation Officer
Am Industriepark 2-10
21514 Büchen, Germany
Büchen, 08. November 2022
Franz Bürmann
Managing Director by order Stephan Dirks
Director Hygienic Valves I & Control TopGeneral Information
Translated copy of the EU Declaration of Conformity
1.6 UK Declaration
GEA CONFIDENTIAL  UK- Declaration of Conformity  by Electromagnetic Compatibility Regulations 2016
Manufacturer:
GEA Tuchenhagen GmbH
Am Industriepark 2 -10
21514 B üchen, Germany
Hereby, we declare that the machine designated in the following
Model: Control top T.VIS® A-15
Control top T.VIS® A-15 / Class I Division 2
Type:
24 VDC
AS-i
DeviceNet
IO-Link
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 UK legislation:
Electromagnetic Compatibility Regulations 2016
Regulations: restriction of hazardous substances (RoHS)
Applicable harmonized standards, in
particular:
Other applied standards
and technical specifications:  EN IEC 61000 -6-2: 20 19
EN IEC 61000 -6-4: 20 19
EN IEC 62026 -1: 2019
EN IEC 62026 -2: 2013
EN IEC 61131 -9:2013
DIN EN 61326 -1:2013
DIN EN 61161 -2: 2008
CISPR11:2015
Remarks:
• The device type IO -Link meets the IO -Link test specification (Version 1.1.2 – 2014)
• Model T.VIS® A-15/ Class I Div. 2 not for type IO-Link!
• The above -mentioned standards have been taken into account in accordance with the
respective scope of application
Person authorised for compilation and handover of technical
documentation:
GEA Tuchenhagen GmbH
Documentation Officer
Am Industriepark 2 -10
21514 B üchen, Germany
Büchen, 08 November 2022
________________________________    ________________________________
Franz Bürmann        pp. Stephan Dirks
Managing Director       Director Hygienic Valves I & Control Top
General Information
UK Declaration
1.7 Translated copy of the UK Declaration of Conformity according to the provisions on
electromagnetic compatibility from 2016
Manufacturer: GEA Tuchenhagen GmbH
Am Industriepark 2-10
21514 Büchen, Germany
We hereby declare that the devices named below
Model: Control top T.VIS® A-15
Control top T.VIS® A-15 / Class I Division 2
Type: 24 VDC
AS-i
DeviceNet
IO-Link
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 UK directives: Regulations on electromagnetic compatibility 2016
Regulations: Restriction of hazardous substances (RoHS)
Applicable harmonized standards, in particular: EN IEC 61000-6-2: 2019
DIN IEC 62026-1:2019
DIN IEC 62026-2:2013
DIN IEC 61131-9:2013
Other applied standards and technical specifications: EN IEC 61326-1: 2013
EN IEC 61161-2: 2008
CISPR11:2015
Remarks:• The IO-Link device type meets the IO-Link test specification (version 1.1.2 – 2014)
• Model T.VIS® A-15/ class I div. 2 not for type IO-Link!
• The standards stated have been taken into consideration according to the respective application area.
Person authorised for compilation and handover of technical
documentation:GEA Tuchenhagen GmbH
CE Documentation Officer
Am Industriepark 2-10
21514 Büchen, Germany
Büchen, 08. November 2022
Franz Bürmann
Managing Director by order Stephan Dirks
Director Hygienic Valves I & Control TopGeneral Information
Translated copy of the UK Declaration of Conformity according to the provisions on electromagnetic compatibility from
2 Safety
2.1 Intended use
With the automatic control top T.VIS A-15 all Tuchenhagen and ASEPTOMAG
process valves with VARIVENT adaptation can be connected pneumatically and
electrically. Using the device for any other purpose is considered contrary to its
designated use.
The control top T.VIS A-15 is available as
•position indicator without solenoid valve
•with solenoid valve as control top
The control top T.VIS A-15 is completely installed on the dedicated actuator/
adapter of the process valve by means of a clamp connection. Due to the internal
air guiding system, the control air can pass directly from the control top into the
actuator on suitable process valves. For process valves which do not allow the air
to be guided internally, the control top has a connection option for supplying the
air externally via a hose.
The control top T.VIS A-15 may not be used in areas where ATEX approval is
required.
Hint!
The manufacturer will not accept any liability for damage resulting
from any use of the valve which is not in accordance with the
designated use of the valve. The risk is borne solely by the operating
company.
2.1.1 Requirements for operation
The prerequisite for reliable and safe operation of the component is proper
transportation and storage as well as professional installation and assembly.
Operating the unit within the limits of its designated use also involves adhering to
the operating, inspection and maintenance instructions.
2.1.2 Improper operating conditions
The operational safety of the component can not be guaranteed under improper
operating conditions. Therefore avoid improper operating conditions.
The operation of the component is not permitted if:
•Persons or objects are in the danger zone.
•Safety devices are not working or were removed.
•Malfunctions have been detected on the component.
•Damage to the component has been detected.
•Maintenance intervals have been exceeded.
Operator’s Duty of CareSafety
Intended use
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.
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.Safety
Subsequent changes
2.4 IP Protection classes
The control top T.VIS A-15 in its standard version fulfils the requirements of
protection class IP66, IP67 and IP69 (DIN EN 60529) and protection class IP6k9k
(ISO 20653).
IP classes provide information about the degree of protection an electrical device
housing provides against the ingress of solids (first digit) or humidity (second
digit). So-called IP codes are assigned to the protected systems. Its digits
represent common possible errors the system is protected from. The code always
starts with the letter IP for “international protection”.
First digit * Meaning
ISO 20653 DIN EN 60529 Protection against contact Protection against solids
6k 6 Complete contact protectionComplete protection against dust
ingression (dustproof)
Second digit * Meaning
ISO 20653 DIN EN 60529 Protection against humidity
5 5 Protected against water jet (nozzle) from any angle
6 6 Protected against powerful water jets
6k  Protected against powerful water jets under increased pressure
7 7 Protected against temporary immersion
9 Protected against high pressure spray downs
9k  Protected against high pressure spray downs
* For additional digits and more detailed descriptions please refer to the pertinent standard.
Digits not to be mentioned can be replaced by the letter x (e. g. IPx6).
Concerning the ingress of humidity, IPx6 includes all lower IP classes. This is,
however, not the case for the higher protection class IPx7!
Hint!
The specified IP classes only apply if the connectors are connected
correctly, if the cable gland is properly sealed and if the control top is
fitted on the valve, see Chapter 6, Page 46
.
2.5 General safety instructions and dangers
The component is safe to operate. It was built according to state-of-the-art
science and technology.
Nevertheless, dangers can arise from the component, if:
•the component is not used as intended
•the component is used improperly
•the component is operated under impermissible conditions
2.5.1 Principles for safe operation
Dangerous situations during operation can be avoided by safety-conscious and
proactive behaviour of the staff.
To ensure safe operation of the valve the following principles apply:Safety
IP Protection classes
•The Operating Instructions must be kept ready to hand at the valve's place of
use. They must be complete and in clearly legible form.
•Only use the valve for its intended use.
•The valve must be functional and in good working order. Check the condition
of the valve before starting work and at regular intervals.
•Wear tight-fitting work clothing for all work on the valve.
•Ensure that nobody can get hurt on the parts of the valve.
•Immediately report any faults or noticeable changes on the valve to the
person responsible.
•Never touch the pipes and the valve when these components are hot! Avoid
opening the valve unless the process plants have been emptied and
depressurised.
•Observe the accident prevention regulations and all local regulations.
2.5.2 Environmental Protection
Harm to the environment can be avoided by safety-conscious and proactive
behaviour of the staff.
For environmental protection the following principles apply:
•Substances harmful to the environment must not be discharged into the
ground or the sewage system.
•Always observe the pertinent regulations relating to waste avoidance,
disposal and utilization.
•Substances harmful to the environment must be collected and stored in
suitable containers. Clearly mark the containers.
•Dispose of lubricants as hazardous waste.
Electrical Equipment
For all work on electrical equipment, the following principles apply:
•Access to electrical equipment should only be allowed to qualified
electricians. Always keep unattended switch cabinets locked.
•Modifications of the control system can affect the safe and reliable operation.
Modifications are only permitted with the express permission of the
manufacturer.
•After completion of all work, check that the protective devices are fully
functional.
2.6 Supplementary Regulations
In addition to the instructions in this documentation the following also has to be
observed:
•pertinent accident prevention regulations,
•generally accepted safety rules,Safety
Supplementary Regulations
•national regulations applicable in the country of use,
•work and safety instructions applicable in the facility,
•installation and operating regulations for use in potentially explosive areas.
2.7 Qualification of personnel
This section provides information on how the personnel working on the
component must be trained.
Operating and maintenance personnel must
•have the necessary qualification to carry out their tasks,
•be instructed with regard to possible dangers,
•know and observe the safety 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.
•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:Safety
Qualification of personnel
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.
2.8 Safety equipment
2.8.1 Signs
Dangerous points on the control top are indicated by warning signs, prohibition
signs and mandatory signs.
The signs and notes on the control top must always be legible. Any illegible signs
must be replaced immediately.Safety
Safety equipment
Signs on the control top
Sign Meaning
Fig.1General hazard warning
Fig.2Warning Crushing
2.9 Residual dangers
Dangerous situations can be avoided by safety-conscious and proactive
behaviour of the personnel and by wearing personal protective equipment.
Residual dangers on the control top and measures
Danger Cause Measure
Danger to life Inadvertent switch-on of the control top Effectively disconnect all components, effectively prevent
switch-on.
Electric power Observe the following safety rules:
1. Isolate from the power supply.
2. Take appropriate measures to prevent switch on.
3. Test absence of voltage.
4. Earthing and short-circuiting.
5. Cover or safeguard any adjacent live parts.
Damage to property Welding can cause damage to the electronics
or result in data loss.Do not carry out any welding work in the vicinity of the control
top or make sure electronics are properly protected.
Voltage peaks The permitted voltage ranges of the respective connection
types can be found in chapters 5.3 to 5.6 and must not be
exceeded.
2.9.1 Electrostatically Endangered Components and Modules
The control top contains electronic components that are sensitive to electrostatic
discharge (ESD). Contact with electrostatically-charged persons or objects can
endanger these components. In the worst case they are destroyed immediately
or fail after being put into operation.
To minimize or prevent the possibility of damage resulting from sudden
electrostatic discharge,
•observe the requirements of DIN EN 61340-5-1 and 5-2 and
•take care not to touch the electronic components!Safety
Residual dangers
2.9.2 Instructions for the Safe Handling of Electronic Components During Welding Work
Notice
Stray welding currents during welding
Can cause damage to electronic components
► Follow the steps below to prevent this.
1.Before starting welding work, carry out the following preparations:
1.a. Ensure the device is switched off and no electrical connections are
active.
1.b. Disconnect the device from the power supply.
®This protects the electronic components from potential damage caused by
stray welding currents.
2.Establish a correct grounding connection:
2.a. Place the ground connection of the welding machine as close as
possible to the welding point.
®This minimises the risk of stray welding currents and helps protect nearby
electronic components from damage.
3.After completing the welding work, proceed as follows:
3.a. Remove the welding machine’s ground connection.
3.b. Reconnect the device to the power supply.
3.c. Perform a function test.
2.10 Danger zones
Please observe the following notes:
•In the event of malfunctions, shut down the control top (disconnect from the
power and air supply) and secure it against being used.
•Before starting any service, maintenance or repair work, disconnect the
control top from the power supply and secure it against inadvertently being
switched back on again.
•Only allow a qualified electrician to carry out any work on the electrical power
supply.
•Check the electrical equipment of the control top at regular intervals.
Immediately remedy loose connections and molten cables.
•If work on live parts cannot be avoided, call in a second person, who can
operate the main switch in case of an emergency.Safety
Danger zones
3 Description
3.1 Functional description
3.1.1 Operation Principle
The control top T.VIS A-15 works with a microprocessor that contains the
software for operation, visualization and intelligent position detection. The valve
stroke is detected by a contactless position measuring system integrated in the
control top and the information is supplied to the microprocessor.
Electrostatically endangered components/modules!
•The control top contains electronic components that are sensitive to
electrostatic discharge (ESD). Contact with electrostatically-charged persons
or objects can endanger these components. In the worst case they are
destroyed immediately or fail after being put into operation.
•Observe the requirements of DIN EN 61340-5-1 and 5-2 to minimize or
prevent the possibility of damage resulting from sudden electrostatic
discharge.
•Also take care not to touch electronic components when supply voltage is
present.
•Use ESD-compliant packaging when returning electronic components.
(Contact GEA Tuchenhagen if you have any questions.)
Control top without solenoid valves
The T.VIS A-15 control top without solenoid valves acts as a position indicator.
After programming, it indicates the status of the process valve locally by coloured
LEDs under the illuminated dome so that it is visible over a long distance.
The position feedback signals are supplied to the user in one of the following
ways, depending on the communication method selected:
•24V DC switching output
•AS interface data bit
•DeviceNet data bit
•IO-Link data bit
For programming, the process valve must be moved once to its end positions by
an external solenoid valve.
3.1.3 Control Top with Solenoid Valves
The control top with solenoid valves acts as a control top. The signalling takes
place in the same way as with the control top without solenoid valves. The
difference is that the solenoid valve integrated in the base is operated in
accordance with the control signals. Depending on the design of the process
valve, up to 4 solenoid valves can be installed in the control top.
As an option, a pneumatic NOT logic element can be used to support the
actuator spring with compressed air. This reduces the max. number of solenoid
valves to 3 pieces.Description
Functional description
The control signals are given by the user's process control system or by the
microprocessor in the control top during automatic end position programming.
In manual mode, the main actuator can be controlled using the buttons in the cap
in order to move the process valve to its end positions or by operating the
solenoid valves manually. To do this, use a screwdriver to turn the screw (S) from
0 to 1, see figure.
Fig.3
Fig.4
To assemble or disassemble the valve insert, the main actuator can be controlled
in service mode using the buttons in the cap in order to relieve the spring tension,
which depends on the valve type.
3.1.4 Control Top with Cap Including Buttons
Fig.5: Control top with cap including buttons (standard variant in IP66)
According to protection class IP66 (EN 60529) the control top T.VIS A-15 is
suitable for use in this design and if the electrical and pneumatic connections are
installed correctly.
The control top is operated with the cap closed using the plus/minus buttons.
Operation see Chapter 8, Page 99
.Description
Functional description
3.1.5 Control top with hood without buttons
Fig.6: Control top with hood without buttons
Fig.7: Circuit board (A)
According to protection class IP66, IP67 and IP69 (DIN EN 60529) as well as
protection class Ip6k9k (ISO 20653), the control top T.VIS A-15 is suitable for use
in this design and if the electrical and pneumatic connections are installed
correctly.
To operate the control top, take off the cap and press the plus/minus buttons
directly on the circuit board (A).
Observe the general instructions regarding ESD protection.
Operation see .
3.1.6 Function of the Buttons
Automatic end position programming and manual mode are generally activated
using the buttons in the cap. For safety reasons, the buttons are only enabled
within a specific time window after activation of the operating voltage. During this
time window, functions can be started. The buttons are automatically locked
again after the allowed time has expired.
During automatic end position programming, the control top autonomously
detects the number of solenoid valves fitted in the control top and carries out the
required programming steps fully automatically.
After end position programming the following is also possible:
•Changing the tolerance ranges manually,
•factory setting to set the attenuation of feedback signals to inactive,
•activating the LEFF function on double-seat valves with lifting actuator.
It is also possible to change the colours for visualizing the end positions using the
"colour variant" function, which also results in the outputs for the feedback signals
being switched.Description
Functional description
3.1.7 Safety Air Exhaust/Installation Position
To provide protection against excess pressure which can build up in the inside of
the control top, a vent plug E2 is fitted in the base. In operating mode, the
exhaust air from the lifting actuators is discharged via this vent plug. In the
unlikely event of a damaged solenoid valve or in case of sealing problems,
pressure relief is ensured.
Fig.8: Control top (standard variant in IP66)
This vent plug is a safety device that must be handled as such. Do not cover the
vent plug. When fitting the control top note that the installation position of the vent
plug E2 must never be pointing vertically upwards.Description
4 Transport and storage
4.1 Storage conditions
You must first dry and preserve the control top to prevent damage if the control
top is exposed to temperatures ≤ 0°C during transport or storage.
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/
control tops.
•Observe the pictograms on the package.
•Control tops must be protected from animal and vegetable fats.
•The synthetic materials of the control tops are susceptible to breaking. Take
care when transporting the control top. Do not grip sensitive parts of the unit
to lift or push the unit or to support yourself.
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.Transport and storage
Storage conditions
5 Technical data
5.1 Type plate
The type plate is used to uniquely identify the control top.
Fig.9
Code/Type T A 1 5 L 8 B A H
Item in the order code 14 15 16 17 18 19
Explanation of the items in the order code
Item in the
order codeDesignation Explanation
14 Feedback location
T A 1 5 Control top T.VIS A-15
15 Control top type
N without solenoid valve
P 1 solenoid valve
R 1 solenoid valve Y1 (retrofittable: Y2, Y3)
M 2 solenoid valves Y1= main stroke;
Y4= spread lift double-disk
G 4 solenoid valves Y1 main stroke;
Y2= Lift valve disk; Y3= lift double-disk;
Y4= spread lift double-disk
F 3 solenoid valves Y1 main stroke;
Y3= Lift double-disk; Y4= spread lift double-
disk
N 2 solenoid valves
Y1=main stroke; Y2= valve disk lifting
J 2 solenoid valves
Y1=main stroke; Y3=lifting of the double-
disk, for the external air connection of an
air/air actuator or an external process valveTechnical data
Type plate
Explanation of the items in the order code
Item in the
order codeDesignation Explanation
L 3 solenoid valves
V 1 solenoid valve, 1 NOT element
X 2 solenoid valves, 1 NOT element
Y 3 solenoid valves, 1 NOT element
16 Feedback
6 3 digital feedbacks S1; S2 incl. an external
initiator S3 (spread lift double-disk)
7 3/4 digital feedbacks S1; S2; S4 incl. two
external initiators S3 (spread lift double-disk)
8 2 digital feedbacks S1 and S2
9 3/4 digital feedbacks S1; S2; S4 incl. one
external initiator S3
17 Type of interface/mode
A AS-interface (A/B slave)
B 24 V DC 3-wire PNP
D DeviceNet
N IO-Link
18 Solenoid valve
A 24 V DC
0 without
19 Screw connection (cable/air) for air hose Ø 6/4 mm
J 5-pin connector M12/5-wire/M20x1.5
24 V DC; IO-Link; AS-interface; DeviceNet
H 8-pin plug M12/8-wire/M20x1.5
24 V DC
G 12-pin connector M12/9-wire/M20x1.5
24VDC (only for interface 24VDC and 4.
feedback)
M M20x1.5 cable gland
24 V DC
for air hose Ø 6,35/4,31 mm
P 5-pin connector M12/5-wire/M20x1.5
24 V DC; IO-Link; AS-interface; DeviceNet
N 8-pin plug M12/8-wire/M20x1.5
24 V DCTechnical data
Type plate
Explanation of the items in the order code
Item in the
order codeDesignation Explanation
T 12-pin connector M12/9-wire/M20x1.5
24VDC (only for interface 24VDC and 4.
feedback)
S 0.5 "NPT cable gland
24 V DC
Options /18 Supply air throttle: regulates the opening
speed of the valves (cannot be used with
control top type V; X or Y)
/19 Exhaust air throttle: regulates the closing
speed of the valves
/22 5-pin M12 junction box for screw connection
J, P (Material No. 508-963)
8-pin M12 junction box for screw connection
H, I (Material No. 508-061)
12-pin M12 junction box for screw
connection G; T
/66 Protection class IP 66 (powerful water jet)
/67 Protection class IP 67 (immersion)
/69k Protection class IP 69 (high-pressure
cleaning)
/81 ASi junction box on cable 1m with M12
junction box for screw connection L or U
/82 ASi junction box on cable 2m with M12
junction box for screw connection L or U
/A For ASEPTOMAG valves
Example: TA15L8BAH/A
/UC Certification UL/CSA
For indoor use and only for the type of
interface connection:
A - AS-interface
B - 24 V DC
D - DeviceNet
I - IO-LinkTechnical data
Type plate
Explanation of the items in the order code
Item in the
order codeDesignation Explanation
/CD* UL 121201 - Non-incendive Electrical
Equipment for Use in Class I, Division 2 ,
Hazardous (Classified) Locations.
CSA C22.2 No. 213-17 - Non-incendive
Electrical Equipment for Use in Class I,
Division 2, Locations.
* Please pay attention to separate operating instructions 430BAL013622..!
5.2 Technical data
Refer to the following tables for the key technical data of the control top:
Technical data: compressed air supply, product pressure and CIP
pressure
Designation Description
Air hose
•MetricMaterial PE-LD Outer-Ø 6 mm +/- 0.1
mm
Inside Ø 4 mm
•InchMaterial PA outer-Ø 6.35 mm +/- 0.1
mm
Inside Ø 4.3 mm
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 1m3 air
Control air pressure6 bar (87 psi), max. 8 bar (116 psi)
configuration with standard drive
Alternative combinations of product
pressure and control air pressure on
requestTechnical data
Technical data
Technical data: compressed air supply, product pressure and CIP
pressure
Designation Description
Product pressure5 bar (72.5 psi) configuration with
standard actuator
max. 10 bar (116 psi) configuration
with correspondingly designed
actuator
> 10 bar (145.0 psi) for static
applications and on request
CIP pressure2-5 bar (29-72.5 psi), a test may be
necessary for higher CIP pressures
Technical data: materials
Designation Description
Housing PA 12/L
Seals NBR / EPDM / FKM
Operating elements TPE
Technical data: electrical specifications
Designation Description
Protection class EN 60529* Standard: IP66 - powerful water jet
Optional: IP67 - immersion
Optional: IP69k - high pressure*
IP6k9k - high pressure (ISO 20653)
EC EMC directives 2014/30/EU
Immunity for industrial environments EN 61000-6-2: 2005
Radio frequency interference EN ISO 61000-6-4:2007 + A1: 2011
EC Low Voltage Directive 73/23/EEC
Electrical wiring configuration–5-pin M12 circular connector or
–8-pin M12 circular connector only
for 24 V version with 2 to 3
solenoid valves
–12-pin M12 round connector only
for version 24V with 4 feedbacks
–Terminal strip
Switch point tolerance adjustable 0.3; 0.7; 1.0; 2.0 mm
Signal attenuation of feedback group none; short; medium; longTechnical data
Technical data
* If cleaning agents are used that significantly reduce the surface tension and/or if
high-pressure cleaners are used, we recommend using devices in optional
protection class IP69 (DIN EN 60529) or Ip6k9k (ISO 20653).
5.3 Specifications for 24V DC version
Technical data: supply
Designation Description
Supply voltage UV 24 V DC (+20%... -12.5%)
Current consumption
–No-load current ≤ 25 mA
–one solenoid valve 35...45 mA
–Max. load of the feedback 50 mA
Total approx. 200 mA
Technical data: inputs
Designation Description
Control voltage max. 28.8 V DC
High = ≥ 13 V DC
Low = ≤ 6 V DC
Control current ≤ 10mA
Technical data: outputs
Designation Description
Output voltage High = UV - ≤ 1 V
Low = ≤ 5 V
Max. current per output 100 mA short circuit proof
Switching frequency
(ohmic + inductive loads ≤ 25 mH)2 Hz
5.4 IO-Link specifications
Technical data: supply
Designation Description
Supply voltage UV 24 VDC (±25%)
Current consumption
- No-load current ≤ 45 mATechnical data
Specifications for 24V DC version
Technical data: supply
Designation Description
- One solenoid valve 35...45 mA
Total approx. 135 mA
Material number:
221-005030 --> from software version 0A (see version label 24V/0A)
221-005023 --> from software version A (see version label AIOL)
Technical data: inputs as seen from the IO-Link
Bit Feedback Signal
DIB X
DI0* (single-seated
valves / disk valves)S1
1 = valve in non-
actuated position
Main stroke0 = valve outside
tolerance for non-
actuated position
(double-seated
valves)S1
1 = valve closed
Valve disk 0 = valve outside
tolerance
DI1*  S2
1 = valve in
actuated position
Main stroke0 = valve outside
tolerance for
actuated position
DI2  S3
(if PV Y1 = 0)
1 = double-disk
closed
Double-disk 0 = double-disk
not closed or no
external sensor
present
S3
(if PV Y1 = 1) Technical data
IO-Link specifications
Technical data: inputs as seen from the IO-Link
Bit Feedback Signal
1= double-disk not
spread
Spread lift
Double-disk0 = double-disk
spread
DI3(double-seated
valves)S4
1 = valve in non-
actuated position
Main stroke0= valve disk and
double-disk not
closed
DI4
…
DI7 not assigned
DIB X +1 Actuation Signal
DI0  PV Y1 on1 = solenoid valve
activated
Solenoid valve Y1
activated0 = solenoid valve
inactive
DI1  PV Y2 on1 = solenoid valve
activated
Solenoid valve Y2
activated0 = solenoid valve
inactive
DI2  PV Y3 on1 = solenoid valve
activated
Solenoid valve Y3
activated0 = solenoid valve
inactive
DI3  Error on 1= error active
Error active 0 = error inactive
DI4  Y7
not assigned
DI5  Y6
not assigned
DI6  Y5
not assigned
DI7  SUP 1= setup active
Setup active 0= setup inactiveTechnical data
IO-Link specifications
Technical data: inputs as seen from the IO-Link
Bit Feedback Signal
DIW X +2
Actual valve
position0 … 1023 (10Bit)
Valve position 0 … 78mm
* Assignment for colour variant green, see Section 6.5.2, Page 64.
Technical data: outputs as seen from the IO-Link
Bit Actuation Signal
DOB X
DO0PV Y1
Activation of solenoid valve
Y11 = solenoid valve activated
0 = solenoid valve not
activated
DO1PV Y2
Activation of solenoid valve
Y21 = solenoid valve activated
0 = solenoid valve not
activated
DO2PV Y3 (if PV Y1 = 0)
Activation of solenoid valve
Y31 = solenoid valve activated
0 = solenoid valve not
activated
PV Y4 (if PV Y1 = 1)
Activation of solenoid valve
Y41 = solenoid valve activated
0 = solenoid valve not
activated
DO3X4
not assigned
DO4X5
not assigned
DO5X6
not assigned
DO6X7
not assigned
DO7HAS
Activation of setup1= activate setupTechnical data
IO-Link specifications
Technical data: electrical specifications
Designation Description
IO-Link versionV1.1
Port class A / COM2
Reverse voltage protection yes
SIO mode not supported
You can download the IODD from the following link:
https://ioddfinder.io-link.com/productvariants/search?vendorName=%22GEA
%20Tuchenhagen%20GmbH%22
Technical data: non-cyclical data exchange
Sub-
indexOffset FunctionAccess
rightsRange Default Signal
Index 0x00 - Identification
0x01 0x00 Master Command M 0x00 - 0xFF 0x00
0x02 0x01 Master Cycle Time R/W 0x00 - 0xFF 0x1E
0x03 0x02 Min Cycle Time M 0x00 - 0xFF 0x1E
0x04 0x03 M-Sequence M 0x00 - 0xFF 0x08
0x05 0x04 Revision ID R/W 0x00 - 0xFF 0x11
0x06 0x05 Process Data In M 0x00 - 0xFF 0x83
0x07 0x06 Process Data Out M 0x00 - 0xFF 0x08
0x08 0x07 Vendor ID 1 M 0x00 - 0xFF 0x05
0x09 0x08 Vendor ID 2 M 0x00 - 0xFF 0x2C
0x0A 0x09 Device ID 1 R/W 0x00 - 0xFF 0x12
0x0B 0x0A Device ID 2 R/W 0x00 - 0xFF 0x34
0x0C 0x0B Device ID 3 R/W 0x00 - 0xFF 0x56
Index 0x01 - Parameter
0x01 0x00 Colour Selection R/W 0x00 - 0x01 0x010= yellow
1= green
0x02 0x01 Tolerance R/W 0x00 - 0x04 0x020= 2.0mm
1= 1.0mm
2= 0.7mm
3= 0.3mm
0x03 0x02 Signal Damping R/W 0x00 - 0x04 0x030= 1.0 sec.
1= 0.5 sec.
2= 0.1 sec.
3= OFF
0x04 0x03 LEFF R/W 0x00 - 0x04 0x020= OFF
1= VT-Lift
2= DT-Lift
3= VT + DT-Lift
0x05Not-Activated
PositionM0x00 - 0x04
0x00 - 0xFF 0 … 1023 (10Bit)
0 … 78mmTechnical data
IO-Link specifications
Technical data: non-cyclical data exchange
Sub-
indexOffset FunctionAccess
rightsRange Default Signal
0x07Activated Position M0x00 - 0x04
0x00 - 0xFF 0 … 1023 (10Bit)
0 … 78mm
0x09Lift Position M0x00 - 0x04
0x00 - 0xFF 0 … 1023 (10Bit)
0 … 78mm
Where access to the entire record of an index takes place, the offset within
the record applies (table above).
On account of the setup of the T.VIS necessary for commissioning and
following seal changeover, we have refrained from implementing data
retention!
5.5 Specifications for AS-interface
Technical data: supply
Designation Description
Supply voltage UV 26.5...31 V DC
Current consumption
- No-load current ≤ 25 mA
- One solenoid valve 35...45 mA
Total approx. 90 mA
Software version A and B (see version labels AASi / BASi)
Technical data: inputs as seen from the AS-interface master
Bit  Feedback Signal
S1
DI0*  1 = valve in non-
actuated position
Main stroke0 = valve outside
tolerance for non-
actuated position
S2
DI1*  1 = valve in actuated
position
Main stroke0 = valve outside
tolerance for
actuated position
S3
DI2  1 = double-disk
closedTechnical data
Specifications for AS-interface
Technical data: inputs as seen from the AS-interface master
Bit  Feedback Signal
Double-disk0 = double-disk not
closed or no external
sensor present
DI3  not assigned
* Assignment for colour variant green, see Section 6.5.2, Page 64.
from software version C (see version label #ASI)
Technical data: inputs as seen from the AS-interface master
Bit  Feedback Signal
DI0*
(single-seated
valves /
disk valves)S1
Main stroke1 = valve in non-
actuated position
0 = valve outside
tolerance for non-
actuated position
(double-seated
valves)S1
Valve disk1 = valve disk
closed
0 = valve outside
tolerance
DI1*  S2
1 = valve in
actuated position
Main stroke0 = valve outside
tolerance for
actuated position
DI2  S3 (if PV Y1 = 0)
1 = double-disk
closed
Double-disk0 = double-disk
not closed or no
external sensor
present
S3 (if PV Y1 = 1)
1= double-disk not
spread
Spread lift**0 = double-disk
spread
Double-disk  Technical data
Specifications for AS-interface
Technical data: inputs as seen from the AS-interface master
Bit  Feedback Signal
DI3(double-seated
valves)S4
1 = valve in non-
actuated position
Main stroke0= valve disk and
double-disk not
closed
Technical data: outputs as seen from the AS-interface master
Bit Actuation Signal
DO0PV Y1
Activation of solenoid valve
Y11 = solenoid valve
activated
0 = solenoid valve not
activated
DO1PV Y2
Activation of solenoid valve
Y21 = solenoid valve
activated
0 = solenoid valve not
activated
DO2PV Y3 (if PV Y1 = 0)1 = solenoid valve
activated
Activation of solenoid valve
Y30 = solenoid valve not
activated
PV Y4 (if PV Y1 = 1)1 = solenoid valve
activated
Activation of solenoid valve
Y40 = solenoid valve not
activated
DO3Reserved for A/B
identification
Technical data: electrical specifications
Designation Description
ASi specification V3.0 (A/B slave)
Configuration
IO code / ID code / ID2 code7.A.7.E.
Reverse voltage protection yes
5.6 DeviceNet specificationsTechnical data
DeviceNet specifications
Technical data: supply
Designation Description
Supply voltage UV
without solenoid valve11...26 V DC
Supply voltage UV
with solenoid valve21...26 V DC
Current consumption
- No-load current ≤ 35 mA
- One solenoid valve 35...45 mA
Total approx. 90 mA
Software version C (see version label CDN)
Technical data: inputs as seen from the DeviceNet master
Bit Feedback Signal
S1
I-0*1 = valve in non-actuated
position
Main stroke0 = valve outside tolerance for
non-actuated position
S2
I-1* 1 = valve in actuated position
Main stroke0 = valve outside tolerance for
actuated position
S3
I-2 1 = double-disk closed
Double-disk0 = double-disk not closed or
no external sensor present
* Assignment for colour variant green, see Section 6.5.2, Page 64.
Technical data: outputs as seen from the DeviceNet master
Bit Actuation Signal
DO0PV Y1
Activation of solenoid valve
Y11 = solenoid valve activated
0 = solenoid valve not
activated
DO1PV Y2
Activation of solenoid valve
Y21 = solenoid valve activated
0 = solenoid valve not
activatedTechnical data
DeviceNet specifications
Technical data: outputs as seen from the DeviceNet master
Bit Actuation Signal
DO2PV Y3
Activation of solenoid valve
Y31 = solenoid valve activated
0 = solenoid valve not
activated
DO3  not assigned
Software version C (see version label CDN)
Technical data: inputs as seen from the DeviceNet master
Bit Feedback Signal
S1
I-0* (single seated
valves)1 = valve in non-actuated
position
Main stroke0 = valve outside tolerance
for non-actuated position
S1
I-0* (double seated
valves)1 = valve disk closed
Valve disk 0 = valve outside tolerance
S2
I-1*1 = valve in actuated
position
Main stroke0 = valve outside tolerance
for actuated position
S3 (if PV Y1 = 0)
I-2 1 = double-disk closed
Double-disk0 = double-disk not closed
or no external sensor
present
S3 (if PV Y1 = 1)
1= double-disk not spread
Spread lift** 0 = double-disk spread
Double-disk
S4
I-3 (double seated
valves)1 = valve in non-actuated
position
Main stroke0= valve disk and double-
disk not closed
* Assignment for colour variant green, see Section 6.5.2, Page 64.Technical data
DeviceNet specifications
Technical data: outputs
Bit Actuation Signal
DO0PV Y1
Activation of solenoid valve
Y11 = solenoid valve
activated
0 = solenoid valve not
activated
DO1PV Y2
Activation of solenoid valve
Y21 = solenoid valve
activated
0 = solenoid valve not
activated
DO2PV Y3 (if PV Y1 = 0)
Activation of solenoid valve
Y31 = solenoid valve
activated
0 = solenoid valve not
activated
PV Y4 (if PV Y1 = 1)
Activation of solenoid valve
Y41 = solenoid valve
activated
0 = solenoid valve not
activated
DO3  not assigned
** spread lift function only in connection with printed circuit board 221-005026
(78)
Technical data: LED indicators for module and network status
Description
Green Operation
Flashing greenCommunication time-out or module
faulty
Flashing red Power-up test
Flashing orange Baud rate detection
Red Communication not possible
DIP switches
Fig.10Technical data
DeviceNet specifications
Switches 1 and 2 = baud rate
DIP 1 DIP 2 Baud rate
OFF OFF 125 kBaud
ON OFF 250 kBaud
OFF ON 500 kBaud
ON ONSelectable via software
Delivery state
Fig.11: DIP switches: switches 3 and 8 = MAC ID (address)
Switches 3 to 8 = MAC ID (address)
DIP 3 DIP 4 DIP 5 DIP 6 DIP 7 DIP 8 MAC ID
OFF OFF OFF OFF OFF OFF 0
OFF OFF OFF OFF OFF ON 1
OFF OFF OFF OFF ON OFF 2
ON ON ON ON ON OFF 62
ON* ON ON ON ON ON 63
* Factory settingTechnical data
DeviceNet specifications
Fig.12
5.7 Accessories
Accessories must be ordered separately.
Accessories Part no.
Cable socket, right-angle – M12; 5-pole: A-coded 508-963
Cable socket, straight – M12; 8-pole: A-coded 508-061
Cable socket, straight – M12; with 1 m cable and ASI insulation
displacement terminal508-027
Cable socket, straight – M12; with 2 m cable and ASI insulation
displacement terminal508-028
Supply air throttle for reducing the opening speed of the main
stroke at the central air supply P603-042
Exhaust air throttle for reducing the closing speed of the main
stroke at the exhaust air connection E1603-042Technical data
Accessories
5.8 Tool
List of tools
Tool Material no.
Hose cutter 407-065
Hex key, size 3 408-121
Pin-type face spanner, pin dia. 4 9065837
Open-ended wrench a/f 23 408-046
Open end spanner a/f 16x18 408-138
Open-ended wrench a/f 15 408-035
Open end spanner a/f 13x17 408-036
Open-ended wrench, a/f 24+27 408-040
5.9 Lubricants
Lubricants Material no.
Rivolta F.L.G. MD-2 413-071
PARALIQ GTE 703 413-064
5.10 Equipment
Technical data - equipment
Equipment Material no.
Proximity switch M12x1 in the lantern
•As per NAMUR, normally closed contact
•7.5...30 V DC
•Ambient temperature: -20...+70 °C
•Protection class IP 67
•Non-metal contact switching505-098
Logic element NOT
•Pressure range: 2.0...8.0 bar
•Ambient temperature: -20...+70 °C512-137
Solenoid valve
•24 V DC (+20% / -12.5%), 0.85 W
•Ambient temperature: -20...+60 °C
•Protection class IP 51
•Pressure range: 2.0...8.0 bar512-169Technical data
Tool
Technical data - equipment
Equipment Material no.
Sound absorber G 1/8"
•Filter material: stainless steel wool
•Ambient temperature: -20...+70 °C
•max. pressure 10 bar933-175
Sound absorber G 1/4"
•Filter material: stainless steel wool
•Ambient temperature: -20...+70 °C
•max. pressure 10 bar933-174
Supply/exhaust air throttle G ¹/8"
•Filter material: sintered stainless steel
•Pressure range: 0.2 ... 10 bar
•Infinitely adjustable flow at Δp 6 bar: 310 dm3 / min  n
•Ambient temperature: -10 ... +70 °C
•Flow rate setting at 0 ... +70 °C603-042Technical data
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 Establishing Hose Connections
To ensure reliable operation, the compressed air hoses must be cut exactly at a
right angle.
Tools required:
•Hose cutter
Carry out the following steps:
1.Shut off the compressed air supply.
2.Use the hose cutter to cut the pneumatic hoses at a right angle.
3.Push the air hose into the air connector on the control top.
4.Re-open the compressed air supply.
®Done.
Hint!
Avoid kinks in the pneumatic hoses!
6.3 Pneumatic connectionsAssembly and installation
Safety instructions
6.3.1 Control Top with 1 Solenoid Valve or Without Solenoid Valve
Fig.13: Control top (standard variant in IP66)
E1 Exhaust air of the main stroke Y1 with sound absorber
optional: exhaust air throttle
Connection E1 must not be closed!
E2 Safety vent against excess pressure and exhaust air of lifting actuators
or from an external main stroke via reflux valve/sound absorber
Connection E2 must not be closed!
P Central air supply with integrated filter
optional: supply air throttle
N Air connection for spring force backup
Only with logic element NOT
Y1 Air connection for external main stroke connection
with plug (23)
23 Plug
Control air pressure can be present at the plugs for the air connections!
Before removing a sealing plug (23), make sure that the respective air connection
is pressure-free!
On most of the GEA Tuchenhagen valve types, solenoid valve Y1 internally
guides the main control air through the switch bar into the main actuator. The
external air connection Y1 is provided in addition.Assembly and installation
Pneumatic connections
6.3.2 Control Top with 2 Solenoid Valves – for Lifting the Valve Disk
Fig.14: Control top (standard variant in IP66)
E1Exhaust air of the main stroke Y1 with sound absorber
optional: exhaust air throttle
Connection E1 must not be closed!
E2Safety vent against excess pressure and exhaust air of lifting actuators
or from an external main stroke via reflux valve/sound absorber
Connection E2 must not be closed!
PCentral air supply with integrated filter
optional: supply air throttle
NAir connection for spring force backup
Only with logic element NOT
Y1Air connection for external main stroke connection
with plug (23)
Y2Air connection for lifting the valve disk
Not permitted for the main stroke of an external process valve!
23Plug
Control air pressure can be present at the plugs for the air connections!
Before removing a sealing plug (23), make sure that the respective air connection
is pressure-free!
On most of the GEA Tuchenhagen valve types, solenoid valve Y1 internally
guides the main control air through the switch bar into the main actuator. The
external air connection Y1 is provided in addition.Assembly and installation
Pneumatic connections
6.3.3 Control top with 2 solenoid valves – for lifting the double-disk, for the external air
connection of an air/air actuator or for the main stroke of an external process valve
Fig.15: Control top (standard variant in IP66)
E1Exhaust air of the main stroke Y1 with sound absorber
optional: exhaust air throttle
Connection E1 must not be closed!
E2Safety vent against excess pressure and exhaust air of lifting actuators
or from an external main stroke via reflux valve/sound absorber
Connection E2 must not be closed!
PCentral air supply with integrated filter
optional: supply air throttle
NAir connection for spring force backup
Only with logic element NOT
Y1Air connection for external main stroke connection
with plug (23)
Y3Air connection for lifting the double-disk, for external air connection of an air/air
actuator or for main stroke of an external process valve or for ASEPTOMAG valves
with seat ventilation
23Plug
Control air pressure can be present at the plugs for the air connections!
Before removing a sealing plug (23), make sure that the respective air connection
is pressure-free!
On most of the GEA Tuchenhagen valve types, solenoid valve Y1 internally
guides the main control air through the switch bar into the main actuator. The
external air connection Y1 is provided in addition.Assembly and installation
Pneumatic connections
6.3.4 Control top with 2 solenoid valves- for spreader lift of the double-disk
Fig.16: Control top (standard variant in IP66)
E1Exhaust air of the main stroke Y1 with sound absorber
optional: exhaust air throttle
Connection E1 must not be closed!
E2Safety vent against excess pressure and exhaust air of lifting actuators
or from an external main stroke via reflux valve/sound absorber
Connection E2 must not be closed!
PCentral air supply with integrated filter
optional: supply air throttle
NFor VARIVENT® mixproof valves:
Air connection for spreader lift of the double-disk, if main stroke is active.
Y1Air connection for external main stroke connection
with plug (23)
23Plug
Control air pressure can be present at the plugs for the air connections!
Before removing a sealing plug (23), make sure that the respective air connection
is pressure-free!
On most of the GEA Tuchenhagen valve types, solenoid valve Y1 internally
guides the main control air through the switch bar into the main actuator. The
external air connection Y1 is provided in addition.Assembly and installation
Pneumatic connections
6.3.5 Control top with 3 solenoid valves for lifting the valve disk and double-disk
Fig.17: Control top (standard variant in IP66)
E1 Exhaust air of the main stroke Y1 with sound absorber
optional: exhaust air throttle
Connection E1 must not be closed!
E2 Safety vent against excess pressure and exhaust air of lifting actuators
or from an external main stroke via reflux valve/sound absorber
Connection E2 must not be closed!
P Central air supply with integrated filter
optional: supply air throttle
N Air connection for spring force backup
Only with logic element NOT
Y1 Air connection for external main stroke connection
with plug (23)
Y2 For VARIVENT® valves with lifting actuator:
Air connection for lifting the valve disk
For STERICOM® double-seal valves:
lifting actuator down (air connection at actuator top)
Not permitted for the main stroke of an external process valve!
On ASEPTOMAG valves with lifting of the upper seat
Y3 For VARIVENT® valves with lifting actuator:
Air connection for lifting the double-disk
For STERICOM® double-seal valves:
lifting actuator up (air connection at actuator bottom)
On ASEPTOMAG valves with lifting of the lower seat
23 Plug
Control air pressure can be present at the plugs for the air connections!
Before removing a sealing plug (23), make sure that the respective air connection
is pressure-free!
On most of the GEA Tuchenhagen valve types, solenoid valve Y1 internally
guides the main control air through the switch bar into the main actuator. The
external air connection Y1 is provided in addition.Assembly and installation
Pneumatic connections
Hint!
To ensure adequate compressed air supply to the process actuators, a
max. of 2 solenoid valves are electrically activated at the same time!
It must be ensured that there can be no simultaneous control of the
actuator or the lifts at the same process valve!Assembly and installation
Pneumatic connections
6.3.6 Control top with 3 pilot valves - to lift the double-disk and to spread lift the double-
disk
Fig.18: Control top (standard variant in IP66)
E1Exhaust air of the main stroke Y1 with sound absorber
optional: exhaust air throttle
Connection E1 must not be closed!
E2Safety vent against excess pressure and exhaust air of lifting actuators
or from an external main stroke via reflux valve/sound absorber
Connection E2 must not be closed!
PCentral air supply with integrated filter
optional: supply air throttle
NFor VARIVENT® mixproof valves:
Air connection for spreader lift of the double-disk, if main stroke is activated.
Y1Air connection for external main stroke connection
with plug (23)
Y3For VARIVENT® valves with lift:
Air connection for lifting the double-disk
For STERICOM® double seal valves:
lifting actuator up (air connection at actuator bottom)
On ASEPTOMAG valves with lifting of the lower seat
23Plug
Control air pressure can be present at the plugs for the air connections!
Before removing a sealing plug (23), make sure that the respective air connection
is pressure-free!
On most of the GEA Tuchenhagen valve types, solenoid valve Y1 internally
guides the main control air through the switch bar into the main actuator. The
external air connection Y1 is provided in addition.Assembly and installation
Pneumatic connections
6.3.7 Control top with 4 pilot valves for the lift of the valve disk and of the double-disk
and for the spread lift of the double-disk
Fig.19: Control top (standard variant in IP66)
E1 Exhaust air of the main stroke Y1 with sound absorber
optional: exhaust air throttle
Connection E1 must not be closed!
E2 Safety vent against excess pressure and exhaust air of lifting actuators
or from an external main stroke via reflux valve/sound absorber
Connection E2 must not be closed!
P Central air supply with integrated filter
optional: supply air throttle
N For VARIVENT mixproof valves:
Air connection for spreader lift of the double-disk, if main stroke is activated.
Y1 Air connection for external main stroke connection
with plug (23)
Y2 For VARIVENT® valves with lifting actuator:
Air connection for lifting the valve disk
For STERICOM® double-seal valves:
lifting actuator down (air connection at actuator top)
Not permitted for the main stroke of an external process valve!
On ASEPTOMAG valves with lifting of the upper seat
Y3 For VARIVENT® valves with lifting actuator:
Air connection for lifting the double-disk
For STERICOM® double-seal valves:
lifting actuator up (air connection at actuator bottom)
On ASEPTOMAG valves with lifting of the lower seat
23 Plug
Control air pressure can be present at the plugs for the air connections!
Before removing a sealing plug (23), make sure that the respective air connection
is pressure-free!Assembly and installation
Pneumatic connections
On most of the GEA Tuchenhagen valve types, solenoid valve Y1 internally
guides the main control air through the switch bar into the main actuator. The
external air connection Y1 is provided in addition.
Hint!
To ensure adequate compressed air supply to the process actuators, a
max. of 2 solenoid valves are electrically activated at the same time!
It must be ensured that there can be no simultaneous control of the
actuator or the lifts at the same process valve!
Exception: When using a spreader lift drive and installed solenoid
valve Y4 in the control top.
6.4 Electrical connections
Danger
To satisfy the UL requirements, use a protective insulation power-limited
power supply according to UL/IEC 60950 or power limited according to
UL/IEC 61010-1 3cd cl. 9.4 or a Class II power supply according to NEC.
►Assembly and installation
Electrical connections
6.4.1 Overview
Fig.20
Fig.21
Danger
Only allow properly qualified staff to carry out work on the electrical
equipment. Prior to establishing electrical connections check the maximum
permissible operating voltage.
►Assembly and installation
Electrical connections
Hint!
The electrical cable must be long enough to allow the control top to be
removed via the switch bar!
The cables must be suitable for use in the temperature range from -20
°C to 75 °C!
6.4.2 Electrical 24 V DC Wiring
6.4.2.1 Plug M12 / 5-pin (24.1)
Fig.22: 5-pin M12 plug-in connector A-coded: device connector and view of pin strip
Corresponding cable socket part no. 508-963.
1 L+ UV L+24 V DC supply voltage
2 S2 Feedback end position valve*
3 L- UV L- reference potential
4 S1 Feedback end position valve*
5 PV1 Actuation of solenoid valve Y1
* Assignment for colour variant green, see "Colour changeover" (Page 38).
Carry out the following steps:
1.Connect cable via air connector M12/5-pin.
®Done.Assembly and installation
Electrical connections
6.4.2.2 Connector M12 / 8-pin (24.1)
Fig.23: 8-pin M12 plug-in connector A-coded: device connector and view of pin strip
Corresponding cable socket part no. 508-061.
1 L+ UV L+24V DC supply voltage
2 S2 Feedback end position valve
3 L- UV L- reference potential
4 S1 Feedback non-actuated position valve
5 PV1 Actuation of solenoid valve Y1
6 PV2 Actuation of solenoid valve Y2
7 PV3 Actuation of solenoid valve Y3
8 S3Feedback non-actuated position double-disk closed (only
with external initiator)
Carry out the following steps:
1.Connect cable via air connector M12/8-pin.
®Done.Assembly and installation
Electrical connections
6.4.2.3 Connector M12/12-pin / 9-strand
Fig.24: 12-pin M12 plug-in connector A-coded: device connector and view of pin strip
1 L+ UV L+24V DC supply voltage
2 S2 Feedback end position valve
3 L- UV L- reference potential
4 S1 Feedback idle position valve disk closed
5 PV1 Actuation of solenoid valve Y1
6 PV2 Actuation of solenoid valve Y2
7 PV3 Actuation of solenoid valve Y3
8 S3Feedback idle position double-disk closed or double-disk
not spread (only with external initiator)
9 S4Feedback idle position valve (valve disk or double-disk
closed)
*Assignment for colour variant green, see "Colour changeover” section 6.5. 2,
page 52.
Carry out the following steps:
1.Connect cable via air connector M12/12-pin.
®Done.Assembly and installation
Electrical connections
6.4.2.4 Cable gland (24)
Fig.25: Terminal assignment of the optional additional board 24VDC (78), material no. 221-005025
Carry out the following steps:
1.Insert the cable (diameter 6-12 mm) through the cable gland (24) and connect
to the additional board (78) in the control top according to the connection
diagram.
Use wires with ferrules, max. 1.5 mm².
2.Secure the cable in the cable gland at a tightening torque of 2.5 Nm.
®Done.
6.4.3 Electrical 24 V DC Wiring
Plug M12 / 5-pin (24.1)
Fig.26: 5-pin M12 plug-in connector A-coded: device connector and view of pin strip
Corresponding cable socket part no.: 508-963Assembly and installation
Electrical connections
1 L+
2 Not connected
3 L-
4 IO-Link
5 Not connected
*For assignment for green colour variant, see Section 6.5, Page 63
Carry out the following steps:
1.Connect cable via air connector M12/5-pin.
®Done.
6.4.4 Electrical Wiring of AS-Interface
Plug M12 / 5-pin (24.1)
Fig.27: 5-pin M12 plug-in connector A-coded: device connector and view of pin strip
Associated cable sockets part 508-027, 508-028 and 508-963.
1 AS-I+
2 Not connected
3 AS-I-
4 Not connected
5 Not connected
Carry out the following steps:
1.Connect cable via air connector M12/5-pin.
®Done.
6.4.5 Electrical DeviceNet WiringAssembly and installation
Electrical connections
6.4.5.1 Plug M12 / 5-pin (24.1)
Fig.28: 5-pin M12 plug-in connector A-coded: device connector and view of pin strip
Corresponding cable sockets part no. 508-963.
1 Not connected
2 V+
3 V-
4 CAN_H
5 CAN_L
Carry out the following steps:
1.Connect cable via air connector M12/5-pin.
®Done.
6.4.5.2 External Proximity Switch (170)
50K1; K2
Fig.29
Caution!
Only use proximity switches specified in the chapter "Technical data", see
Chapter 5, Page 26.
►
Carry out the following steps:Assembly and installation
Electrical connections
1.Insert the cable (Ø 3-7mm) through the cable gland (50) and connect it to the
terminals (K1) and (K2) in the control top according to the connection
diagram.
2.Secure the cable in the cable gland at a tightening torque of 2.5 Nm.
®Done.
6.5 Visual Display
Illuminated dome
Fig.30
1 Cap
2 + button
3 Illuminated dome
4 - button
The following statuses are visualized by the illuminated dome:
•Valve in rest position: green, see also Section 6.5.2, Page
•Valve in end position: yellow, see also Section 6.5.2, Page 64
•Lift valve disc (without LEFF): yellow flashing, see also Section 6.5.2,
Page 64
•Lift/spread double-disk (without LEFF): quick flashing yellow, see also
Section 6.5.2, Page 64
•Valve-disk VT or double-disk DT LEFF: flashing yellow/green (with proximity
switch only)
•Valve disk moving to the non-actuated position: flashing green
•Valve disk moving to the actuated position: flashing yellow
•Programming mode active: red
•Error/malfunction: rapidly flashing red
•Default, standard version:Assembly and installation
Visual Display
Control top not programmed: flashing 3 times - pause - flashing 3 times -
pause
•Default, special version:
Control top not programmed: flashing 2 times - pause - flashing 2 times -
pause
There is a power failure if no signal is displayed for more than 5 seconds!
6.5.2 Colour Changeover
The "colour changeover" function allows you to swap the colour from green to
yellow or yellow to green for the following visualizations: valve in non-actuated
position, travel, lift valve disk (without LEFF), lift double-disk (without LEFF).
Carry out the following steps:
1.Disconnect the control top from the power supply.
2.Press both buttons at the same time and keep them pressed.
3.Switch the power supply back on. After switching on the power supply
voltage, continue to press the buttons for another 3 seconds.
®Done.
Hint!
When the colours are swapped, the feedback signals are also
swapped!Assembly and installation
Visual Display
6.5.3 Connection diagram for T.VIS circuit board (bottom)
Fig.31
24VDC 221-005031 with spread lift 221-005026
Fig.32Assembly and installation
Visual Display
24VDC 221-005031 with IO-Link 221-005023 and spread lift 221-005026
Fig.33
Explanation of the pin assignment
Plug position Connector type Item no. in the
Spare Parts
ListDesignation
J1 PicoBlade 5-pin 24.1Plug-in connector M12/5-
wire/M20
J1 IO-Link PicoBlade 5-pin -- Voltage supply
J2 PicoBlade 5-pin 24.1 Plug-in connector M12 / 3-
wire/M20 (only with circuit board
24VDC)
J3 PicoBlade 3-pin 9 T.VIS sensor module
J4 IO-Link PicoBlade 4-pin -- Diagnostics connection / data
interface
J5 PicoBlade 2-pin 63 Solenoid valve Y1
J6 PicoBlade 2-pin 63 Solenoid valve Y2Assembly and installation
Visual Display
Explanation of the pin assignment
Plug position Connector type Item no. in the
Spare Parts
ListDesignation
J7 PicoBlade 2-pin 63 Solenoid valve Y3
J8 Terminal strip 171Cable connection external
initiator
Explanation of the pin assignment of spread lift printed circuit board mat. no. 221-005026
(fig. 28)
Connector
positionConnector typeItem no. in the
spare parts
listDesignation
J1 Pico-Blade 2-pin -- Solenoid valve signal Y1
J2 Pico-Blade 2-pin -- Solenoid valve signal Y3
J3 Pico-Blade 2-pin -- Solenoid valve Y1
J4 Pico-Blade 2-pin -- Solenoid valve Y3
J5 Pico-Blade 2-pin -- Solenoid valve Y4
J9 Terminals 2-pin -- Signal initiator
J10 Terminals 3-pin -- Initiators
6.6 Mounting the control top to different valves
This chapter describes how the control top is installed and removed on actuators
of different valve types. Observe the following notes when doing so.
Notice
The vent plug E2 is a safety element.
If the element is not installed correctly or if the vent is covered, the safety
function is no longer guaranteed.
► The installation position of the vent plug E2 must never be pointing
vertically upwards.
► The vent plug E2 must never be covered.
6.6.1 Mounting to a VARIVENT Valve
This chapter describes how the control top is installed on VARIVENT single and
double-seat valves (also with lifting actuator). The instructions do not apply to
installation on VARIVENT double-seat valve types R, T_R, M/2.0, M_0(06), MT/
T_R(08) with lifting actuator. This installation is described below in chapter
"Installation on VARIVENT mixproof valves with lifting actuator type R, T_R, M/
2.0, M_0(06), MT/T_R(08)" (CROSS REFERENCE).Assembly and installation
Mounting the control top to different valves
Fig.34
Requirement:
•Pay attention not to kink the air hoses when mounting the control top.
Carry out the following steps:
1.Check that the switch bar (1) is firmly in place. If necessary, tighten using a
jaw wrench AF 13, tightening torque 2 Nm (1.4 lbft).
2.Fit the control top (B) over the switch bar (1) and on the actuator (A.1).
3.Fix the clamps (15) by tightening the screws (39) to a torque of 1 Nm
(0.7 lbft).
4.Align the pneumatic and electrical connections in accordance with the valve
block configuration.
5.Close the air connection Y1 with a sealing plug (23) since the control top
T.VIS A-15 has an inner air duct.
Fig.35
6.Perform commissioning, see Chapter 6, Page 46
and Chapter 7, Page 80.
®Done.
6.6.2 Fitting to FLOWVENT Valve
Requirement:
•Pay attention not to kink the air hoses when mounting the control top.Assembly and installation
Mounting the control top to different valves
Fig.36
Carry out the following steps:
1.Insert the O-ring (F1) into the lower O-ring groove of the installation base (F).
2.Lightly grease the O-ring (F1) and the inner thread of the installation base (F)
and then screw the installation base onto the actuator and tighten using a pin-
face spanner and a tightening torque of 20 Nm. When setting the torque heed
the correction factor of the plug tool. If the plug tool (408-451) is used, the
tightening torque to be set is 15 Nm.
3.Screw switch bar (1) into the actuator and tighten with AF 13, tightening
torque 2 Nm (1.4 lbft).
4.Fit the control top (B) over the switch bar (1) onto the installation base and
push until stop. For optimum assembly the O-ring (31) should be slightly
greased.
5.Turn the control top into the required position and tighten the clamp
connection (15) and screws (15) with a tightening torque of 1 Nm (base/
installation base).
On FLOWVENT valves, internal air guiding is not possible!
6.Therefore, use an air hose (L) to connect the air connection (Y1) on the
control top with the connection Y1 on the valve actuator. In the case of a
FLOWVENT valve and control tops with lift stroke, connect the air
connections Y2 and Y3 to the connections Y2 and Y3 of the valve actuator. In
the case of valves with air assist, connect Y2 to connection Y2 of the valve
actuator (see hose connection plan of the valve).
7.Perform commissioning, see Chapter 6, Page
46 and Chapter 7, Page 80.
8.Fit the hood and tighten the screws to 1 Nm.
®Done.Assembly and installation
Mounting the control top to different valves
6.6.3 Installation on VARIVENT mixproof valves with Lifting Actuator Type R, T_R, M/2.0,
M_0(06), MT/T_R(08), MX, MT, MT_DA
Requirement:
•Pay attention not to kink the air hoses when mounting the control top.
Carry out the following steps:
1.Screw the sliding piece (1.2) into the piston rod A 4.1 of the actuator A.4 using
a 12 mm slotted screwdriver, tightening torque 2 Nm (1.4 lbft).
Fig.37
2.Insert the switch bar (1) through the sliding piece into the piston rod A 4.1 and
tighten with an open end spanner (a/f 13) at 1.1 (22 Nm).
3.Fit the control top (B) over the switch bar (1) and on the actuator.
4.Tighten the half rings (15) and screws (39) to a tightening torque of 1 Nm
(0.7 lbft).
5.Align the pneumatic and electrical connections in accordance with the valve
block configuration.
6.Close the air connection Y1 with a sealing plug (23) since the control top
T.VIS A-15 has an inner air duct.Assembly and installation
Mounting the control top to different valves
Fig.38
7.Perform commissioning, see Chapter 6, Page 46
and Chapter 7, Page 80.
®Done.
6.6.4 Mounting to a Butterfly Valve T-smart 8000
Requirement:
•Pay attention not to kink the air hoses when mounting the control top.
Carry out the following steps:
1.Fit the bearing (201) into the locking screw (198).
Fig.39
2.Fit the O-ring (210).
3.Use a face spanner to screw the locking screw (198) into the actuator (A.1).
4.Screw the switch bar (1) together with switch bar (11) into the actuator,
tightening torque 2 Nm.
5.Fit the control top (B) over the switch bar (1) and on the actuator.
6.Tighten the half rings (15) and screws (39) to a tightening torque of 1 Nm
(0.7 lbft).Assembly and installation
Mounting the control top to different valves
7.Align the pneumatic and electrical connections in accordance with the valve
block configuration.
8.Close the air connection Y1 with a sealing plug (23) since the control top
T.VIS A-15 has an inner air duct.
Fig.40
9.Perform commissioning, see Chapter 6, Page 46
and Chapter 7, Page 80.
®Done.
6.6.5 Mounting to a Butterfly Valve T-smart 7 and a Mixproof Butterfly Valve T-smart 9
Requirement:
•Pay attention not to kink the air hoses when mounting the control top.
Carry out the following steps:
1.Screw the switch bar (240) into the actuator and tighten to a tightening torque
of 22 Nm (16 lbft).
Fig.41
2.Fit the control top (B) over the switch bar (240) and on the actuator.
3.Tighten the half rings (15) and screws (39) to a tightening torque of 1 Nm
(0.7 lbft).
4.Align the pneumatic and electrical connections in accordance with the valve
block configuration.Assembly and installation
Mounting the control top to different valves
5.Close the air connection Y1 with a sealing plug (23) since the control top
T.VIS A-15 has an inner air duct.
Fig.42
6.Perform commissioning, see Chapter 6, Page 46
and Chapter 7, Page 80.
®Done.
6.6.6 Mounting to ECOVENT Valves N_ECO and W_ECO
Requirement:
•Pay attention not to kink the air hoses when mounting the control top.
Carry out the following steps:
1.Complete the T.VIS mounting base (198) with O-rings (29, 101) and a plain
bearing (202).
Fig.43
2.Screw the installation base (198) into the actuator (A.4) and tighten using a
face spanner.Assembly and installation
Mounting the control top to different valves
3.Screw the switch bar (1) with ring (99) into the piston rod (A.4.1) and tighten
by applying an a/f 13 jaw wrench at (1.1); tightening torque 2 Nm (1.4 lbft).
4.Fit the control top (B) over the switch bar (1) and on the actuator. 5. Tighten
the half rings (15) and screws (39) to a tightening torque of 1 Nm (0.7 lbft).
5.Align the pneumatic and electrical connections in accordance with the valve
block configuration.
6.Due to the internal air guiding of the control top T.VIS A-15 (B), the
connection A 4.2 on the actuator and air hose Y1 (23) on the steering top are
closed.
Fig.44
7.Perform commissioning, see Chapter 6, Page 46
and Chapter 7, Page 80.
®Done.
6.6.7 Mounting to VESTA Valve H_A/M
Requirement:
•Pay attention not to kink the air hoses when mounting the control top.
Carry out the following steps:
1.Complete the T.VIS mounting base (198) with O-rings (29, 101) and a plain
bearing (202).Assembly and installation
Mounting the control top to different valves
Fig.45
2.Screw the mounting base (198) into the actuator (A4) and tighten using a face
spanner.
3.Screw switch bar (1) with ring (99) into the piston rod (A4.1) and tighten with
jaw wrench SW 13, tightening torque 2 Nm (1.4 lbft).
4.Fit the control top (B) over the switch bar (1) and on the actuator.
5.Tighten the half rings (15) and screws (39) to a tightening torque of 1 Nm
(0.7 lbft).
6.Align the pneumatic and electrical connections in accordance with the valve
block configuration.
7.As internal air guiding is not possible on VESTA valves, connect the air
connection (Y1) on the control top to connection A4.2 on the actuator with an
air hose (L).
8.Perform commissioning, see Chapter 6, Page 46
and Chapter 7, Page 80.
®Done.
6.6.8 Mounting to VESTA Valve H_A
Requirement:
•Pay attention not to kink the air hoses when mounting the control top.
Carry out the following steps:
1.Place O-rings (139.2) in the adapter (139) at the bottom side of the thread
(139.1).Assembly and installation
Mounting the control top to different valves
Fig.46
2.Screw the adapter into the actuator (A4.1) and tighten using an a/f 17 open
end spanner.
3.Complete the T.VIS mounting base (198) with O-rings (29, 101) and a plain
bearing (202).
4.Screw the mounting base (198) into the actuator (A4) and tighten using a face
spanner.
5.Screw the switch bar (1) into the adapter (139) and tighten using a jaw
wrench AF 13; tightening torque 2 Nm (1.4 lbft).
6.Fit the control top (B) over the switch bar (1) and on the actuator.
7.Tighten the half rings (15) and screws (39) to a tightening torque of 1 Nm
(0.7 lbft).
8.Align the pneumatic and electrical connections in accordance with the valve
block configuration.
9.As internal air guiding is not possible on VESTA valves, connect the air
connection (Y1) on the control top to connection A4.2 on the actuator with an
air hose (L).
10.Perform commissioning, see Chapter 6, Page 46 and
Chapter 7, Page 80.
®Done.
6.6.9 Mounting to Valve N_/E or W_/E or STERICOM Valve
Requirement:
•Pay attention not to kink the air hoses when mounting the control top.
Carry out the following steps:Assembly and installation
Mounting the control top to different valves
1.Complete the T.VIS mounting base (198) with O-rings (29, 101) and a plain
bearing (202).
Fig.47
Fig.48
2.Screw the adapter T.VIS E/SHO (139) into the actuator with jaw wrench on
wrench surface (139.1) and tighten.
3.Screw the mounting base (198) into the actuator (A.3) via the adapter T.VIS
E/SHO (139) and tighten using a face spanner.
4.Screw the T.VIS switch bar (1) into the T.VIS E/SHO adapter (139) and
tighten by applying a jaw wrench at (1.2); tightening torque 2 Nm.
5.Place the control top over the T.VIS switch bar (1) and on the actuator.
6.Tighten the clamp connection (15) with screws (39) to a tightening torque of
1 Nm.
7.Align the pneumatic and electrical connections in accordance with the valve
block configuration.
! Internal air guiding is not possible on these valve types. Therefore connect
the air connection (Y1) on the control top and the connection (A.4.2) on the
actuator to the air hose (L).
8.Perform commissioning, see Chapter 6, Page
46 and Chapter 7, Page 80.
®Done.
6.6.10 Mounting to a T-smart Single-Seat and Double-Seal ValveAssembly and installation
Mounting the control top to different valves
Fig.49
Requirement:
•Pay attention not to kink the air hoses when mounting the control top.
Carry out the following steps:
1.Screw the switch bar (1) into the piston rod A4.1 and tighten by applying an
a/f 13 jaw wrench at (1.1), tightening torque 2 Nm.
2.2. Fit the control top (B) over the switch bar (1) and on the actuator (A.4).
3.3. Tighten the clamp connection (15) and screws (39) to a tightening torque
of 1 Nm.
4.4. Align the pneumatic and electrical connections in accordance with the valve
block configuration.
! Internal air guiding is not possible on these valve types. Therefore connect
the air connection (Y1) on the control top and the connection (A.4.2) on the
actuator to the air hose (L).
5.Perform commissioning, see Chapter 6, Page
46 and Chapter 7, Page 80.
®Done.
6.6.11 Fitting to an ASEPTOMAG Valve
Requirement:
•Pay attention not to kink the air hoses when mounting the control top.
Carry out the following steps:
1.Place the T.VIS adapter plate (M), with O-rings (M1), on the actuator (A.4)
and secure it with four M5 screws (M.2).Assembly and installation
Mounting the control top to different valves
Fig.50
2.Screw the switch bar (4) Mat. 221-589.87, into the piston rod (A4.1) and
tighten with jaw wrench AF 13, tightening torque 3 Nm.
3.Fit the control top (B) over the switch bar (4) and on the actuator.
4.Tighten the clamp connection (15) and screws (39) to a tightening torque
of 1 Nm.
5.Align the pneumatic and electrical connections in accordance with the valve
block configuration. ! On ASEPTOMAG valves, internal air guiding is not
possible. Therefore connect the air connection (Y1) on the control top and the
connection (A.4.2) on the actuator to the air hose (L).
6.Connect the pneumatic hose, or 2-3 hoses for valves with seat lifting, in
accordance with the hose connection diagram for the valve.
7.Perform commissioning, see Chapter 6, Page
46 and Chapter 7, Page 80.
®Done.
6.6.12 Replacing Control Tops
When replacing the control top observe the following warning note:
Caution!
Collision of the switch bar with the pneumatic block
If a valve with the wrong type of switch bar is used, there is a risk of injury
as the switch bar can damage the pneumatic block.
► When replacing a predecessor model with a control top T.VIS A-15 the
switch bar must always be replaced!Assembly and installation
7 Start-up
7.1 Safety notes
Initial commissioning
For initial commissioning, the following principles apply:
•Take protective measures against dangerous contact voltages in accordance
with pertinent regulations.
•The control top 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.
•After conversion of the control top, residual risks must be reassessed.
Hint!
The optional external sensor in the lantern is still in the original
factory setting and must therefore be reset during initial
commissioning, see Section 7.2, Page 80. The manufacturer will not
accept any liability for malfunctions. The risk is borne solely by the
operating company.
Commissioning
For commissioning, the following principles apply:
•Only allow properly qualified staff to set the control top into operation.
•Make sure all connections are properly established.
•The safety devices for the control top must be complete, fully functional and in
perfect condition. Check the function before starting any work.
•When the control top is switched on, the danger zones must be free.
•Remove any liquids that have escaped without leaving residues.
7.2 Commissioning – Control Top without Solenoid Valves
Activating the Control Top
Once the control top has been properly mounted on the valve and the electrical
connections have been established correctly, commissioning can be carried out.
Requirement:
•The process valve must be in the safety position, i.e. an external solenoid
valve must not be actuated.
Carry out the following steps:
1.Check the function of the external solenoid valve.
2.Switch on the power supply.Start-up
Safety notes
3.Press the relevant buttons to switch to programming mode, see Section 8.3,
Page 101
.
4.Wait at least 5 seconds after starting the programming function before
activating the external solenoid valve and keeping it activated until the
process valve has reliably reached its actuated end position.
5.Deactivate the solenoid valve. During this period, the illuminated dome is lit
red.
®After completion of end position programming, the colours in the
illuminated dome change cyclically. Here you can select switching point
tolerances and attenuations which deviate from the factory setting, see
Section 8.3, Page 101.
®If no selection is made within 30 seconds, the setting last selected is
automatically adopted. The process valve moves to the non-actuated
position, which is visualized by a steady light in the selected colour.
®The control top is activated.
Hint!
When the colours are swapped, the feedback signals are also
swapped!
Checking the Control Top
Carry out the following steps:
1.Activate and deactivate the external solenoid valve in order to check the
proper function of the T.VIS feedback signals.
®This completes commissioning.
7.3 Commissioning – Control Top with Solenoid Valves
Activating the Control Top
Once the control top has been properly mounted on the valve and the electrical
connections have been established correctly, commissioning can be carried out.
Since the T.VIS A-15 detects its solenoid valve fitting and therefore requires
corresponding process valve conditions, the so-called special default must
selected prior to SETUP in the event of a different.
Notice
Solenoid valve Y3 for the main stroke of an external process
valve is connected.
The main stroke of the external process valve is briefly activated during the
SETUP.
► Only carry out the SETUP when the pipe is empty.
Carry out the following steps:
1.Switch on the control air supply.
2.Check the valve function by activating the solenoid valves:Start-up
Commissioning – Control Top with Solenoid Valves
®Switch on the solenoid valves in sequence Y1, Y2 and Y3 (if fitted) by
means of the manual operating element: Turn the screw (S) from 0 to 1
using a screwdriver.
®Switch off again all pilot valves in sequence Y1, Y2 and Y3 (if fitted): Turn
the screw (S) to 0 using a screwdriver.
Fig.51
Fig.52
®Further information about Y1/Y2/Y3: seeSection 6.3, Page 46.
3.Switch on the power supply.
4.Press the relevant buttons to switch to programming mode, see
Section 8.3,
Page 101.
®While the programming routine runs automatically, the solenoid valves in
the control top are activated and deactivated, which causes the process
valve to automatically move to the positions in succession. During this
period, the illuminated dome is continuously lit red. After completion of end
position programming, the colours in the illuminated dome change
cyclically.
®In deviation from the factory setting you can select switching point
tolerances, attenuations and the LEFF function (only if the valve is LEFF
compatible, i.e. mixproof valve with lifting actuator), see Section 8.3,
Page 101.
®If 24/7 PMO valves (types M_O (06), M/2.0, MT/T_T (08) are used in
conjunction with the control top T.VIS A-15, the factory settings in the
control top may not be changed.
®If no selection is made within 30 seconds, the setting last selected is
automatically adopted and visualized in accordance with the colours
selected.
®The control top is activated.
Checking the Control Top
Once the control top has been properly mounted on the valve and the electrical
connections have been established correctly, commissioning can be carried out.
Carry out the following steps:
1.Activate the solenoid valves in succession via the PLC in order to check the
proper function of the T.VIS feedback signals.Start-up
Commissioning – Control Top with Solenoid Valves
®This completes commissioning.
Hint!
The solenoid valve can also be activated and deactivated in manual
mode using the operating buttons, see .
7.4 Service Function
If maintenance must be conducted on a process valve that is fitted with a control
top T.VIS A-15, the valve core must be pulled out of the housing. For this
purpose, the valve disk pretension of the process valve must be relieved by
actuating the main actuator. This is possible with the service function, see
“Operating overview” .
Another option with the hood removed is the manual override on the solenoid
valve, see “Control top with solenoid valves” .
7.5 Adjust the initiator in the lantern - for unbalanced double-disks of the valves D, R,
Y, B, T_R and MT
Fitting the initiator holder
Carry out the following steps:
1.Preassemble sliding piece (1), countersunk screw (3) and nut NI (2).
Fig.53
2.Insert the preassembled part in the slot (4.1) in the lantern (4) with the
mounting hole (1.1) facing in the direction of the housing (5).
Fig.54Start-up
Service Function
3.Turn the nut NI (2) in the slot (4.1) in the lantern through 90° and tighten with
the countersunk screw (3).
Fig.55
®Done.
Adjusting the proximity switch holder
Carry out the following steps:
1.Screw the adjusting screw (6) into the proximity switch holder down to the
cleaning connection (7).
Fig.56
Fig.57
2.By slightly slackening the countersunk screw, position the proximity switch
holder in the slot in the lantern so that the point of the adjusting screw (6)
rests on the shoulder of the cleaning connection in the direction of the
actuator (A).
3.Fix the proximity switch holder in position with the countersunk screw.
®Done.
Fitting the proximity switch
Carry out the following steps:
1.Remove the adjusting screw.
2.Screw proximity switch M12 (8) into the proximity switch holder until the
cleaning connection is reached.Start-up
Adjust the initiator in the lantern - for unbalanced double-disks of the valves D, R, Y, B, T_R and MT
Fig.58
®Done.
Adjusting the proximity switch
Carry out the following steps:
1.Unscrew the proximity switch by one full turn (360°) to set the gap (a) in the
range from 0.5 to 1.0 mm.
Fig.59
2.Tighten the lock nut (11).
3.Secure the connector (10), which has already been electrically connected to
the control top, to the proximity switch using the cap nut M12 (10.1).
®The LED on the proximity switch must now be lit in operating mode.
®Done.
Checking the function
Carry out the following steps:
1.Check the feedback function by actuating solenoid valve Y3.
®The LED must go out.
®Done
®The proximity switch has now been adjusted and checked.Start-up
Adjust the initiator in the lantern - for unbalanced double-disks of the valves D, R, Y, B, T_R and MT
7.5.1 Adjust the initiator in the lantern - for double-disk of the tank bottom valves MT-DA
(spreader lift)
Hint!
Only in combination with T.VIS A-15.
Fig.60: 1 = Initiator / 2 = Initiator
The valve type MT DA contains tow initiators located in the lantern. Initiator 1
monitors the rest position of the double-disk resp. records the position of the
double-disk when it leaves this position. Initiator 2 records the double-disk in the
spreading lift position resp. the lifted double-disk during the valve main stroke.
Danger
Risk during assembly of initiators 1 and 2 during valve
actuation.
Unintentional actuation or stopping of the valve can lead to serious injuries!
► If the valve is actuated unintentionally, the valve moves to the end
position.
► If the valve is stopped unintentionally (e.g. due to unintentional control
signal or lack of supply air), the valve moves back to the rest position.
► Do not reach into the lantern during assembly of initiators 1 and 2.
Fitting the proximity switch holder
Requirement:Start-up
Adjust the initiator in the lantern - for unbalanced double-disks of the valves D, R, Y, B, T_R and MT
The valve has to be in the non-actuated rest position for adjustment of initiator 1.
To adjust initiator 2, please actuate the valve via the PLC to the main stroke
position.
Switching to spreader lift mode is done via the actuator signal of the pilot valve of
the main stroke.
Carry out the following work steps for initiators 1 and 2:
1.Position the proximity switch nut (2) against the slot (4.1) in the lantern (4)
from the inside and use one finger to hold it in position.
Fig.61
2.Attach the sliding piece (1) with the countersunk screw (3) with the assembly
borehole (1.1) in the direction shown pointing toward the housing (5).
3.Tighten the proximity switch nut (2) with the countersunk screw (3).Start-up
Adjust the initiator in the lantern - for unbalanced double-disks of the valves D, R, Y, B, T_R and MT
Fig.62
®Done
Adjusting the proximity switch holder
Carry out the following steps:
1.Screw the adjusting mandrel (6) into the proximity switch holder until it
reaches the upper edge of the leakage indicator (7).Start-up
Adjust the initiator in the lantern - for unbalanced double-disks of the valves D, R, Y, B, T_R and MT
Fig.63
2.Position the proximity switch holder by slightly loosening the countersunk
screw in the lantern recess in such a way that the tip of the adjusting mandrel
(6) is resting on the collar of the leakage indicator (7) facing the drive (A), see
Figure 63.
3.Tighten the proximity switch holder with the countersunk screw (3).Start-up
Adjust the initiator in the lantern - for unbalanced double-disks of the valves D, R, Y, B, T_R and MT
Fig.64 Start-up
Adjust the initiator in the lantern - for unbalanced double-disks of the valves D, R, Y, B, T_R and MT
Fig.65
®Done
Fitting the proximity switch
Carry out the following steps:
1.Remove the adjusting mandrel (6).
2.Screw in the proximity switch M12 (8) together with the counter nut (11) into
the proximity switch holder (12) up to the leakage indicator (7).Start-up
Adjust the initiator in the lantern - for unbalanced double-disks of the valves D, R, Y, B, T_R and MT
Fig.66
®Done
Adjusting the proximity switch
Carry out the following steps:
1.Unscrew the proximity switch (8) by one full turn (360°) to set the gap (a) by
0.5 to 1.0 mm.Start-up
Adjust the initiator in the lantern - for unbalanced double-disks of the valves D, R, Y, B, T_R and MT
Fig.67: 1 = Initiator / 2 = Initiator
2.Tighten the counter nut (11).
3.Attach the connector (10), that is already connected electrically to the control
panel, on the proximity switch using the cap nut M12 (10.1). The LED on the
proximity switch must now be lit in operating mode.
®Done
7.6 Adjusting the Proximity Switch in the lantern of PMO Valve Type M/2.0
Fitting the proximity switch holder
Carry out the following steps:
1.Position the nut (2) against the slot (4.1) in the lantern (4) from the inside and
hold it in position with a finger.
Fig.68Start-up
Adjusting the Proximity Switch in the lantern of PMO Valve Type M/2.0
2.Secure the sliding piece (1) with the countersunk screw (3). Pay attention that
the orientation is as shown in the diagram. The mounting hole (1.1) must face
in the direction of the housing (5).
3.Tighten the proximity switch nut (2) with the countersunk screw (3).
Fig.69
®Done.
Adjusting the proximity switch holder
Carry out the following steps:
1.Screw the adjusting screw (6) into the proximity switch holder until it reaches
the upper edge of the balancer (7).
Fig.70
2.By slightly slackening the countersunk screw, position the proximity switch
holder in the slot in the lantern so that the point of the adjusting screw (6)
rests on the shoulder of the upper balancer in the direction of the actuator (A).
3.Fix the proximity switch holder in position with the countersunk screw (3).
Fig.71
®Done.Start-up
Adjusting the Proximity Switch in the lantern of PMO Valve Type M/2.0
Fitting the proximity switch
Carry out the following steps:
1.Remove the adjusting screw (6).
2.2. Screw the proximity switch M12 (8), together with the lock nut (11), into the
holder as far as the balancer (7).
Fig.72
®Done.
Adjusting the proximity switch
Carry out the following steps:
1.Unscrew the proximity switch by one full turn (360°) to set a gap (a) in the
range from 0.5 to 1.0 mm.
Fig.73
2.Tighten the lock nut (11).
3.Secure the connector (10), which has already been electrically connected to
the control top, to the proximity switch using the cap nut M12 (10.1).
®During operation, the LED on the proximity switch must now light up
®Done.
Checking the function
Carry out the following steps:
1.Check the feedback function by actuating solenoid valve Y3.
®The LED must go out.
®Done
®The proximity switch has now been adjusted and checked.
7.7 Test procedure for Tuchenhagen PMO valves type M / 2.0Start-up
Test procedure for Tuchenhagen PMO valves type M / 2.0
7.7.1 Purpose
•The purpose of test procedure 1 is to verify and ensure that the detection
devices which detect and confirm the closed position of the upper and lower
seats of the PMO valve (in accordance with PMO Item 15p (B) – point 1. b.
(2)) are adjusted and are functioning properly.
•The purpose of test procedure 2 is to confirm that the interlock provided for
PMO valve type M/2.0 is working correctly during active switching of a CIP
operation.
7.7.2 Process Overview
Carrying out test procedure 1 allows the Regulatory Inspector to manually
perform seat lifting of the upper and the lower valve disk on the valve in order to
verify that the position detection devices for the upper and lower valve disks
change their feedback signals when the corresponding valve disk leaves the
closed position.
Hardware Description
1.Three solenoid valves are installed in the control top T.VIS A-15:
1.a Solenoid valve Y1 – actuation of main valve
1.b Solenoid valve Y2 – lifting of lower seat
1.c Solenoid valve Y3 – lifting of upper seat
1.d Solenoid valve Y4 - lifting of upper seat if main stroke is activated.
These valves can be activated externally by signals from the PLC.
2.The closed position of the lower seat is detected by a position measuring
system. The correct adjustment of the system to detect the closed position of
the lower seat is described in detail in the M/2.0 valve operating instructions
as well as in Section 7.3, Page 81.
The sensitivity of the position measuring system is 0.1 mm.
3.The closed position of the upper seat is detected by proximity switch S3 that
is installed externally on the lantern. The correct setting of this proximity
switch for detecting the closed position of the upper seat is described in detail
in the operating instructions of the M/2.0 valve and in Section 7.6, Page 93.
The sensitivity of the position measuring system is 0.1 mm.
7.7.4 Test Procedure 1
Step 1
The valve should be in the closed position. This position can be identified by the
green LED on the top of the control top.
Step 2
Carry out the following steps:
1.Activate the lower valve disk by activating solenoid valve Y2 via the PLC.Start-up
Test procedure for Tuchenhagen PMO valves type M / 2.0
®When the seat moves downwards (approx. 6 mm), the green LED on the
top of the control top will turn off and changes to a yellow flashing light
(LEFF deactivate) or a green/yellow flashing light (LEFF activated) to
indicate that the position detection device is detecting that the lower valve
disk has left the closed position.
®If the green LED does not go out, the position detection device is NOT set
correctly and the setting must be repeated, refer to the operating
instructions of the M/2.0 valve and Section 7.3, Page 81.
®Done
Step 3
Carry out the following steps:
1.Activate the upper valve disk by activating solenoid valve Y3 via the PLC.
®When the seat moves upwards (approx. 2 mm), the yellow LED on the
external proximity switch in the lantern will turn off to indicate that
proximity switch S3 is detecting that the upper valve disk has left the
closed position. In addition, a quickly flashing yellow (LEFF deactivated) or
green/yellow flashing light (LEFF activated) is visible on the top of the
control top.
®If the yellow LED of the initiator mounted externally in the lantern does not
turn off, the position detection device is NOT set correctly and the
adjustment procedure must be repeated as described, see
Section 7.6,
Page 93.
®Done
7.7.5 Test Procedure 2
Test procedure 2 is carried out by the Regulatory Inspector to verify that the
system interlock programmed in the PLC is working correctly by manually
actuating the valve disk that shuts off the pipe of the valve which currently is not
part of the cleaning circuit. If interlocking is implemented correctly, the CIP supply
pump or the source generating the cleaning solution pressure must switch off
automatically.
Hint!
Please note that test procedure 2 has to be performed with great care.
There is a danger of cleaning solution mixing with product if the
control system interlocks are not working correctly. Make sure that
there is no product in the valve body, which is not part of the active
CIP circuit, for the duration of the test!
Step 1
Make sure that the valve being tested is part of an active cleaning circuit and
determine which of the two housings is part of this active cleaning program.
Step 2
Carry out the following steps:Start-up
Test procedure for Tuchenhagen PMO valves type M / 2.0
1.If the upper housing is part of the active CIP circuit:
Activate lifting of the lower seat by activating solenoid valve Y2 via the PLC.
2.If the lower housing is part of the active CIP circuit:
Activate lifting of the upper seat by activating solenoid valve Y3 via the PLC.
®Done
Step 3
If the programmed control system interlock is working correctly, the CIP supply
pump will be deactivated. If the CIP supply pump or source for generating
cleaning solution pressure is not deactivated, immediately shut down the system
and perform a programmed lockout test.Start-up
8 Operation and control
8.1 Safety instructions
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.
8.2 Settings in Programming Mode
Hint!
If 24/7 PMO valves (types M_O (06), M/2.0, MT/T_T (08) are used T.VIS
A-15 in conjunction with the control top , the factory settings in the
control top may not be changed.
Setting the Position Tolerance for the Main Stroke
If the tolerance is not set in accordance with the intended purpose, this can result
in malfunctions of the valve. GEA Tuchenhagen will not accept any liability for
damage resulting from improper setting: the risk lies entirely with the operator of
the facility.
Tolerance Size Setting for
Tolerance 1 0.3 mmValves with bellows; not for ASEPTOMAG
valves
Tolerance 2 0.7 mm Seat valves (factory setting)
Tolerance 3 1.0 mmValves with logic element NOT
Control air for spring-side power assistance
and ASEPTOMAG valves
Tolerance 4 2.0 mm Butterfly valves
Signal Attenuation for Position Feedback
Attenuation suppresses the signal changes of the feedback device for the
attenuation period specified.Operation and control
Safety instructions
At the same time, a static change of a feedback signal is delayed by the
attenuation period. This allows user-specific process sequences to be optimally
set.
For the reliable monitoring of the valve seat seal GEA Tuchenhagen
recommends the factory setting without signal attenuation. GEA Tuchenhagen
will not accept any liability for damage resulting from the use of signal
attenuation. The risk lies entirely with the operator of the facility.
Setting the LEFF Function
The LEFF function achieves steady pulsing (opening and closing) of the valve
disks during the typical lifting operation for cleaning the leakage cavity on
mixproof valves. For this purpose, solenoid valves Y2 and Y3 are actuated by the
PLC.
When the LEFF function is used on valve types D or B, a lifting stroke of 1.2 to
1.4 must be set in the lifting actuator; also refer to the operating instructions for
the mixproof valve types D and B.
LEFF activation
Off Factory setting
Valve-disk and double-
diskFor mixproof valves with lifting actuator, solenoid
valves Y2 and Y3 and external proximity switch in
the lantern
Valve diskFor mixproof valves with lifting actuator and solenoid
valve Y2
Double-diskFor mixproof valves with lifting actuator and solenoid
valve Y3 and external proximity switch in the lantern
Semi-Automatic SETUP
In the event that SETUP should be required while a process is running that does
not allow activation of the relevant valve, a semi-automatic SETUP can be
performed.
This makes it possible after the replacement of a control top to automatically
detect and output the defined rest position of a process valve, whereas the end
position is only approached and detected by the next process step.
Only after detection of the rest and end positions are both valve states monitored
and the production process can be continued without any danger. If necessary,
parameters specific to valves may have to be set again in a subsequent standard
SETUP, see operating overview .Operation and control
Settings in Programming Mode
8.3 Operating Overview
Without internal solenoid  valve
the external has to be activated!Tolerance  setting
0,3mm  ‐
‐
‐
‐
or wait 30s0,7mm  (for seat valves)
1,0 mm  (for valves with
assisted spring)
2,0mm (for butterfly valves)Tol. 1
Tol. 2
Tol. 3
Tol. 4
LEFF  activation
Off
LEFF ON (upper + lower disk) ‐
‐
‐
‐yesno
amber flashing permanent  amb. green flashing permanent  green
or wait 30s+
LEFF ON (upper disk)LEFF ON (lower disk)Programming  mode
permanent  red
(SETUP active)
Stroke toward  end  End position Stroke toward  start Start position‐+press for 3…7s
color selection green  = 500ms one‐time green flashing
color selection  yellow = 500ms one‐time amber flashingStörung detektiert
+
+Double seat valve with PVY2 and/or PVY3 and external prox.
green flashing permanent  green amber flashing permanent  amb.
Valve status
Selected
colorgreen
or
amberDefault  standard
3x red flashing/PauseFirst commissioning (not  programmed;
(push  buttons  automatically  locked after SETUP)
Note:
xxx(bold and underlined)  =  standard settings+
+
+
+
‐
‐
‐
‐+
+
+
+Signal  damping
no
short
medium
long (1000ms)
or wait 30s
+
red flashingError
red flashing
Mantling/Dismantling
no visualisation
no visualisationProgramming  mode‐+press for 3…7sPower upDecision: Use according  product code?
yes
‐+press for 3…7sno
Betriebsspannung   Ein Betriebsspannung   Ein
‐+ press for 3…7s
Operation  modeyes no
Default special
2x red flashing/PausePower upRecommissioning (programmed;
push  buttons  are locked 30s after power on)
Decision: New SETUP necessary?
Power up Power upStörung detektiertService
Dis‐/Assembling
Power up+press and hold
Attention!
If power will be switched
off the valve disk will return
to the start position because
of spring force.Activation  of main stroke to
eliminate  spring force.
to error‐mode exit by power OffInitial situation:  T.VIS A‐15 de‐energised!
Mounting  of valve insert
Fig.74Operation and control
Operating Overview
Automatic  setting for LEFF  activation
Offyesno
Amber flashing permanent  amber. green flashing permanent  greenSemiautomatic  programming  active (step 1)
Stroke toward  end  End position Stroke toward  start Start positionGreen/amber  flashing when standard position
detected (activation of  feedback “start”)Störung detektiert
Double seat valve with PVY2 and/or PVY3 and external prox.
Valve statusDefault  standard
3x red flashing/PauseFirst commissioning (not  programmed;
push  buttons automatically locked after  SETUP)
)
Automatic  setting for signal damping
off
Red flashingErrorSemiautomatic
Programming  modePower upDecision: Use according product code?
yes
‐+Press for 3…7sno
Betriebsspannung   Ein
‐+ Press for 3…7s Default special
2x red flashing/PausePower upRecommissioning (programmed;
push  buttons are locked 30s  after power on)
Decission:  New SETUP necessary?
Power upStörung detektiert
to error‐modeFirst  commissioning  or recommissioning under  process conditions!
Initial situation:  T.VIS A‐15 de‐enrgized!
Semiautomatic  programming  active (step 2)
Waiting for activation  of solenoid Y1 by PLC
(activation of  feedback “end”)
1,0 mm  Automatic   tolerance  settingSemiautomatic  programming  active (step 3)
Waiting for activation  of solenoid Y2/Y3
(automatic  setting for R or D‐valve lift tolerance)yesnoDouble seat valve with PVY2 and/or PVY3
End of semiautomatic  programming  Press for 3…7s
+red/green flashing
Press for 3…7s
Operation
mode‐
Semiaut. SETUP select.Power off
Programming  mode
Permanent  red
(SETUP active)
Immediately  Power off
3x red flashing/PauseDefault  StandardPower up
Go on with first
commissioning
quick red/green  flashing
Semiaut. SETUP start
back to operation  mode Fig.75Operation and control
Operating Overview
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Fig.76Operation and control
Operating Overview
GEA INTERNAL
Fig.77Operation and control
9 Cleaning
9.1 Cleaning
Observe the safety data sheets supplied by the detergent manufacturers.
Only use detergents which are not aggressive towards synthetic materials and
the sealing materials used and which are non-abrasive.
Hint!
After all cleaning work, make sure that the control top still complies
with all safety instructions in this operating manual and thus that
intended use is still given.Cleaning
Cleaning
10 Maintenance
10.1 Safety instructions
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.Maintenance
Safety instructions
•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 .
10.2 Inspections
Checking parts are firmly secured
Fig.78
Carry out the following steps:
1.Check that the electrical connectors are properly secured.
2.Check that the air hose connections are firmly secured.
3.Check that the clamp (15) is firmly in place.
4.Check that the plug (23) is firmly in place.
5.Check the sound absorber, filter, non-return valve and the exhaust air throttle
for soiling.
6.Check the housing for mechanical damage.
7.Check the union nut for the cable glands for a tight fit.
8.Check solenoid valves and optional NOT element for pressure-tight fit.
9.Check hood and base for firm screws. Tighten all three screws to 2 Nm if
necessary.
®DoneMaintenance
Inspections
10.3 Maintenance intervals
To ensure the highest operational reliability of the magnetic separator, 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.
Maintenance intervals
ApplicationsMaintenance intervals
(guideline values)
Media at temperatures of
60 °C to 130 °C
(140 °F to 266 °F)approx. every 3 months
Media at temperatures of
< 60 °C
(< 140 °F)approx. every 12 months
10.4 Removing the Control Top from the Valve
Fig.79
Requirement:
•Make sure that the solenoid valve is not actuated.
Carry out the following steps:
1.Undo the screw connection (39).
Remove the clamp (15).
Pull the control top vertically off the valve.
®The green LED goes out after 5 seconds and the yellow LED flashes.
®DoneMaintenance
Maintenance intervals
10.5 Dismantling the Control Top into its Components
10.5.1 Variants of the Control Top
The control top can be fitted with:
•3 solenoid valves (63) and without or with 1 logic element NOT (64) or
•2 solenoid valves (63) and 1 control plate (65) and without or with 1 logic
element NOT (64) or
•1 solenoid valve (63) and 2 control plates (65) and without or with 1 logic
element NOT (64) or
•1 solenoid valve (63) or
•without solenoid valve with 1 control plate (65).
Removing the Cap
Fig.80
Notice
Electrical voltage
Danger to life
► Switch off the voltage supply and the control air before removing the
control top.
Carry out the following steps:
1.Undo the 3 screws (25) of the cap (7) and remove the cap (7) from the base
(5).
®Done
10.5.3 Removing the printed circuit board
Carry out the following steps:
1.Unscrew and remove the screws (77).Maintenance
Dismantling the Control Top into its Components
Fig.81
Hint!
IO-Link version can be seen on the label.
2.Remove all wires from the printed circuit board (43).
®Done
Hint!
In order to avoid or minimize the possibility of damage from
electrostatic discharge:
–Observe the requirements of DIN EN 61340-5-1 and 5-2.
–Be careful not to touch the electronic components!
10.5.4 Install the circuit board
To install the circuit board, observe the wiring diagram for the T.VIS circuit board
(underside), see Section 6.5.3, Page 65
!
10.5.5 Removing the sensor module (9)
Carry out the following steps:
1.Loosen the screws (57).Maintenance
Dismantling the Control Top into its Components
Fig.82
2.Lift the sensor module (9) off the base plate.
®Done
10.5.6 Removing the logic element NOT (seal pack)
Requirement:
•Logic element NOT is only provided in connection with the pneumatic block
T.VIS/NOT!
Carry out the following steps:
1.Loosen the screws (67) and remove logic element NOT (64) with flat gasket
and adapter plate (64.1).
Fig.83
®Done.
10.5.7 Fitting the Logic Element NOT (Sealing Package)
Requirement:
•Logic element NOT is only provided in connection with the pneumatic block
T.VIS/NOT!
Carry out the following steps:
1.Fit the logic element NOT (64) in the reverse order.Maintenance
Dismantling the Control Top into its Components
! Place the logic element NOT, with adapter plate and seal, on the pneumatic
block (8) as shown in the illustration.
! When inserting and tightening the screws, be careful to use existing threads.
Fig.84
®Done
Hint!
Faulty assembly may cause malfunctions, as the spring force backup
is then not given.
10.5.8 Removing the Solenoid Valves and the Valve Plate
Fig.85
Requirement:
•Pay attention to the correct assignment of cables between the solenoid valves
and the circuit board (9) – solenoid valve Y1 must be connected to terminal
Y1; solenoid valve Y2 to terminal Y2 and solenoid valve Y3 to terminal Y3.
•Use only solenoid valves as listed in the chapter "Technical data", see
Chapter 5, Page 26.Maintenance
Dismantling the Control Top into its Components
Warning!
Long switch-on time and high ambient temperature.
Risk of burns from the solenoid valve
► Allow to cool before dismantling.
Carry out the following steps:
1.Disconnect the electrical connection from the solenoid valve to the Pico Blade
on the circuit board (43).
2.Loosen the screws (66) and remove the solenoid valve (63) from the
pneumatic block (8).
3.Loosen the screws (66) and remove the control plates (65) from the
pneumatic block (8).
®Done
Fig.86
Hint!
When using the pneumatic block (8.2) with 1 valve plate (65), the
groove (65.12) must be fitted on the left side.
The two screws (66) are located in the left mounting holes.
When using the pneumatic block (8) with 1 or 2 control plates (65), the
groove (65.22) must be mounted upward.
The screws (66) are located in the lower mounting holes.
Hint!
For ASEPTOMAG valves, use special types of the pneumatic block!
Tighten the screws (66) at a tightening torque of 0.8 Nm.
10.5.9 Removing the pneumatic blockMaintenance
Dismantling the Control Top into its Components
Requirement:
•If only the O-rings (42) and (55) must be changed then the solenoid valves
(63)/control plate (65) and element NOT (64) can remain on the pneumatic
block (8).
Carry out the following steps:
1.Undo the screws (57.1, 57.2).
Fig.87
2.Pull off the pneumatic block (8).
3.Change the 6 O-rings (42) of the base (5).
4.Replace the O-ring (55).
®Done
10.5.10 Fitting the Pneumatic Block
Requirement:
•When fitting the pneumatic block, make sure that it is compatible!
•Insert the journal (8.1) on the pneumatic block into the groove of the base (5)!
•Use the following pneumatic block types on ASEPTOMAG valves:
–Pneumatic block T.VIS-15/NOT 3PV/ASG material no. 221-646.93
–Pneumatic block T.VIS-15/ 3PV/ASG material no. 221-646.92
Carry out the following steps:
1.Tighten the screw (57.1): Tightening torque: 1.5 Nm (1.0 lbft).Maintenance
Dismantling the Control Top into its Components
Fig.88
Fig.89
Pneumatic block (8.2) for max. 1 solenoid valve / pneumatic block (8) for
max. 3 solenoid valves
2.Tighten the screw (57.2): Tightening torque: 1.5 Nm (1.0 lbft).
3.For other parts to be installed (sensor, circuit board, solenoid valves, control
plate, element NOT) see previous pages.
®Done
10.6 Install pneumatic connections
Fig.90Maintenance
Install pneumatic connections
No. Designation Tightening torques
6 Screw-in plug connection 2.0 Nm
21 Sound absorber 2.0 Nm
22 Locking screw 0.5 Nm
23 Plug
26 Sound absorber 2.0 Nm
42 O-ring
Carry out the following steps:
1.Establish the pneumatic connections in accordance with the codes on the
control top.
®Done
10.7 Maintenance
Replacing the Seals on the Base
On VARIVENT actuators with a vent hole in the actuator cover the control top
must be fitted without O-ring (54)!
Fig.91
Carry out the following steps:
1.Remove the O-rings (31, 54) and replace.
®Done
10.7.2 Maintenance of Sound Absorber, Filter, Non-Return Valve and Exhaust Air ThrottleMaintenance
Maintenance
Fig.92
Requirement:
•Use only the throttle (21.1) and sound absorber (26) specified in the spare
parts list, see Chapter 13, Page 123 .
Carry out the following steps:
1.Check the sound absorber (21, 26), non-return valve (26.1), filter (5.1) and
exhaust air throttle (21.1) for free control air leakage and replace if necessary.
!
The reflux valve (26.1) cannot be replaced.
2.Do not grease the spare parts before fitting them.
®Done
10.7.3 Mounting cap
Hint!
To ensure the IP protection class, the hood must be correctly mounted
on the base!Maintenance
Maintenance
Fig.93
Carry out the following steps:
1.Use three screws (25) to fasten the hood (7) on the base (5) to tightening
torque 2 Nm.
®DoneMaintenance
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 precautions.
Malfunction, signalling, cause, remedy
Malfunction Signalling Cause Remedy
Programming is not
possible after
connecting the supply
voltage.No LED is lit•No voltage at
connector 1 (PINs
1 and 3)
•Polarity of PINs 1
and 3 mixed up
•Service function
active•Check the
electrical
connections for
correct wiring
•Connect PIN 1 and
PIN 3 correctly
•Disconnect the
plug
SETUP cannot be
activatedGreen or yellow Time window no
longer activeDisconnect from the
power supply again
and carry out the
operation within 30 s
Manual operation
cannot be activatedGreen or yellow Time window no
longer activeDisconnect from the
power supply again
and carry out the
operation within 30 s
After connecting the
supply voltage, green/
yellow is indicated
immediatelyGreen or yellow Device already
programmed at least 1
xProgramme again to
adapt to process
conditions: actuate
keys + and -
simultaneously for 3...
7 s, see restarting
Section 8.3, Page 101
Valve opens very
slowlyTime exceeded in PLC Fault in the
compressed air supply
or filter clogged up•Clean or replace
the filter
•Open the supply air
throttle further
Programming cannot
be completedRapidly flashing red
lightActuated positions
cannot be reached Alarms
Malfunctions and remedies
Malfunction, signalling, cause, remedy
Malfunction Signalling Cause Remedy
due to missing control
air pressure orCheck the control air
pressure: pay attention
to the minimum
pressure of the
solenoid valve on type
plate
due to incorrectly fitted
switch barCheck and tighten the
fitted adapter, see
Section 6.6, Page 67
Throttle settings are
incorrectOpen the supply air
throttle further
The control top
configuration is not
suitable for the valve,
i.e. the number of
solenoid valves does
not correspond to the
number of actuatorsOpen the exhaust air
throttle further
Air hoses for the lifting
actuators mixed upUse a suitable control
top
External proximity
switch connected but
set incorrectlySelect special default,
correct connection, set
proximity switch
correctly
The minimum stroke
when lifting the valve
disk has not been
reached.Correct the lifting
stroke
No feedback signal is
pending at the PLC
although one of the
end positions has
been reachedRed LED flashing T.VIS A-15 in factory
setting and not yet
programmedProgramming
according to
Operating overview,
see Section 8.3,
Page 101Alarms
Malfunctions and remedies
Malfunction, signalling, cause, remedy
Malfunction Signalling Cause Remedy
Red LED permanently
litT.VIS A-15 currently in
programming modeWait until
programming mode
ends
Red LED flashing
rapidlyT.VIS A-15 has a
malfunction:
Programmed position
overrun (possibly from
shape change of the
bellows) only at 0.3
mm tolerance setting)
or
LEFF function
malfunctioningCheck the bellows and
possibly reprogram,
see operating
overview Section 8.3,
Page 101
Acknowledge the fault
on the valve by
pressing the button or
on the PLC by
activating the 3
solenoid valves.
Afterwards check the
LEFF requirements:
air pressure, external
proximity switch
In addition to the LEFF
function, pulsing is
programmed in the
PLC

11.2 Carrying out a Reset – Back to Default Standard
Carry out the following steps:
1.Start the SETUP procedure.
2.Switch off the operating voltage while running the SETUP.
®LED goes out, loss of data in the memory module.
3.Commissioning the control top, see "Commissioning - control top without
solenoid valves" ( Section 7.2, Page 80) or "Commissioning - control top with
solenoid valves" (

Section 7.3, Page 81).
®Done.Alarms
Carrying out a Reset – Back to Default Standard
12 Decommissioning
12.1 Safety instructions
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 25.
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.Decommissioning
Safety instructions
13 Spare parts list - control top type T.VIS A-15
Fig.94 Spare parts list - control top type T.VIS A-15
Control top T.VIS® A-15 with cable connection and air connection with metric connections
without NOT logic element with NOT logic
element
Order code  TA18R...M
1* For switch bar T.VIS A-15 refer to the separate spare parts list 221ELI010728EN.
6 Screw-in plug connection D 6.0 MS CV 933-176 933-176 933-176 933-176
Hood with button T.VIS P/A-15 221-646.87 221-646.87 221-646.87 221-646.87
8 Pneumatic block 3PV without NOT PA12/L -- 221-646.89 -- --
Pneumatic block 3PV with NOT for
VARIVENT valves with spread liftPA12/L -- -- 221-646.90 221-646.90
Pneumatic block with NOT for
ASEPTOMAG valves and VARIVENT
valves with spread liftPA12/L -- -- 221-646.93 221-646.93
Pneumatic block without NOT for
ASEPTOMAG valvesPA12/L 221-646.92 221-646.92 -- --
Pneumatic block 1PV, not for
ASEPTOMAG valvesPA12/L221-646.94 -- -- --
9 Sensor module T.VIS A/P-15 PA6/GF30 221-589.74 221-589.74 221-589.74 221-589.74
15 Clamp connection KU -- 221-507.08 221-507.08 221-507.08 221-507.08
21 Sound absorber G1/8" MS CV 933-175 933-175 933-175 933-175
22 Locking screw G1/8" PE-HD 922-369 922-369 922-369 922-369
26 Sound absorber G1/4" MS CV 933-174 933-174 933-174 933-174
41 O-ring NBR -- -- 930-436 --
43 Printed circuit board 24V DC -- 221-005021# 221-005021# 221-005021# 221-005021#
Printed circuit board ASi except MT-valves -- 221-005022# 221-005022# 221-005022# 221-005022#
Printed circuit board 24VDC for IO-Link
Printed circuit board DeviceNet -- 221-004097A 221-004097A 221-004097A 221-004097A
Printed circuit board ASi only MT-valves -- 221-005032 221-005032 221-005032 221-005032
Printed circuit board 24VDC for IO-Link
57 Thread-forming screw A2 514-750 514-750 514-750 514-750
63 Solenoid valve 24VDC PBT 512-169* *without
64 Logic element NOT -- -- -- -- 512-137
65 Valve plate PPO 221-589.27 221-589.27* *without
TA18L...221-589.27* *without
TA18G...221-589.27* *without
TA18Y...
66 Thread-forming screw A2 514-761 514-761 514-761 514-761
67 Thread-forming screw A2 -- -- 514-758 514-758
77 Thread-forming screw Galv. steel 514-763 514-763 514-763 514-763
78.1 Printed circuit board T.VIS A-15/Zus/24V -- 221-005.025 221-005.025 221-005.025 221-005.025
78.2 Printed circuit board T.VIS A-15/IO-Link/
- Printed circuit board T.VIS A-15/IO-Link -- 221-005023# 221-005023# 221-005023# 221-005023#
- cable IO-Link 5-pole fitted -- 221-007.031 221-007.031 221-007.031 221-007.031
- cable IO-Link 4-pole fitted -- 221-007.032 221-007.032 221-007.032 221-007.032
- Thread-forming screw Galv. steel 514-763 514-763 514-763 514-763
78.3 Printed circuit board T.VIS spread lift/cpl.
- Printed circuit board T.VIS spread lift -- 221-005026 221-005026 221-005026 221-005026
- Round plug-in connector Y-adapter  508-945 508-945 508-945 508-945
- Wire T.VIS A-15 NI -- 221-007034 221-007034 221-007034 221-007034Spare parts list - control top type T.VIS A-15
Control top T.VIS® A-15 with cable connection and air connection with metric connections
without NOT logic element with NOT logic
element
Order code  TA18R...M
- Proximity switch cpl. -- 221-105.111 221-105.111 221-105.111 221-105.111
- Support sleeve (only for IO-Link) -- 933-949 933-949 933-949 933-949
- Thread-forming screw (only for IO-Link) -- 514-768 514-768 514-768 514-768
- Round plug-in connector M12/3 wire -- 508-039 508-039 508-039 508-039
79 Adapter 4PV PA6 -- -- 221-589.111 --
# Placeholder for version status (Please contact GEA Tuchenhagen if there are any questions.)Spare parts list - control top type T.VIS A-15
Control top T.VIS® A-15 with cable connection and air connection with imperial connections
without NOT logic element with NOT logic
element
Order code  TA18R...Z
1* For switch bar T.VIS A-15 refer to the separate spare parts list 221ELI010728EN.
6 Screw-in plug connection D 6.35 MS CV 933-173 933-173 933-173 933-173
Hood with button T.VIS M/A-15 221-646.87 221-646.87 221-646.87 221-646.87
8 Pneumatic block 3PV without NOT PA12/L -- 221-646.89 -- --
Pneumatic block 3PV with NOT for
VARIVENT valves with spread liftPA12/L -- -- 221-646.90 221-646.90
Pneumatic block SPV with NOT for
ASEPTOMAG valves and VARIVENT
valves with spread liftPA12/L -- -- 221-646.93 221-646.93
Pneumatic block SPV without NOT for
ASEPTOMAG valvesPA12/L 221-646.92 221-646.92 -- --
Pneumatic block 1PV, not for
ASEPTOMAG valvesPA12/L 221-646.94 -- -- --
9 Sensor module T.VIS A/P-15 PA6/GF30 221-589.74 221-589.74 221-589.74 221-589.74
15 Clamp connection KU -- 221-507.08 221-507.08 221-507.08 221-507.08
21 Sound absorber G1/8" MS CV 933-175 933-175 933-175 933-175
22 Locking screw G1/8" PE-HD 922-369 922-369 922-369 922-369
26 Sound absorber G1/4" MS CV 933-174 933-174 933-174 933-174
41 O-ring NBR -- -- 930-436 --
43 Printed circuit board 24V DC -- 221-005021# 221-005021# 221-005021# 221-005021
Printed circuit board ASi except MT-valves -- 221-005022# 221-005022# 221-005022# 221-005022#
Printed circuit board 24VDC for IO-Link
Printed circuit board DeviceNet -- 221-004097A 221-004097A 221-004097A 221-004097A
Printed circuit board ASi only MT-valves -- 221-005032 221-005032 221-005032 221-005032
Printed circuit board 24VDC for IO-Link
57 Thread-forming screw A2 514-750 514-750 514-750 514-750
63 Solenoid valve 24VDC PBT 512-169* *without
64 Logic element NOT -- -- -- -- 512-137
65 Valve plate PPO 221-589.27 221-589.27* *without
TA18L...221-589.27* *without
TA18G...221-589.27* *without
TA18Y...
66 Thread-forming screw A2 514-761 514-761 514-761 514-761
67 Thread-forming screw A2 -- -- 514-758 514-758
77 Thread-forming screw Galv. steel 514-763 514-763 514-763 514-763
78.1 Printed circuit board T.VIS A-15/Zus/24V -- 221-005.025 221-005.025 221-005.025 221-005.025
78.2 Printed circuit board T.VIS A-15/IO-Link/
- Printed circuit board T.VIS A-15/IO-Link -- 221-005023# 221-005023# 221-005023# 221-005023#
- cable IO-Link 5-pole fitted -- 221-007.031 221-007.031 221-007.031 221-007.031
- cable IO-Link 4-pole fitted -- 221-007.032 221-007.032 221-007.032 221-007.032
- Thread-forming screw Galv. steel 514-763 514-763 514-763 514-763
78.3 Printed circuit board T.VIS spread lift/cpl.
- Printed circuit board T.VIS spread lift -- 221-005026 221-005026 221-005026 221-005026Spare parts list - control top type T.VIS A-15
Control top T.VIS® A-15 with cable connection and air connection with imperial connections
without NOT logic element with NOT logic
element
Order code  TA18R...Z
- Round plug-in connector Y-adapter  508-945 508-945 508-945 508-945
- Proximity switch cpl. -- 221-105.111 221-105.111 221-105.111 221-105.111
- Support sleeve (only for IO-Link) -- 933-949 933-949 933-949 933-949
- Thread-forming screw (only for IO-Link) -- 514-768 514-768 514-768 514-768
- Round plug-in connector M12/3 wire -- 508-039 508-039 508-039 508-039
79 Adapter 4PV PA6 -- -- 221-589.111 --
# Placeholder for version status (Please contact GEA Tuchenhagen if there are any questions.)Spare parts list - control top type T.VIS A-15
Control top T.VIS® A-15 with metric cable connection and air connection with imperial connections
without NOT logic element with NOT logic
element
Order code  TA18R...ZM
1* For switch bar T.VIS A-15 refer to the separate spare parts list 221ELI010728EN.
6 Screw-in plug connection D 6.35 MS CV 933-173 933-173 933-173 933-173
Hood with button T.VIS M/A-15 221-646.87 221-646.87 221-646.87 221-646.87
8 Pneumatic block 3PV without NOT PA12/L -- 221-646.89 -- --
Pneumatic block 3PV with NOT for
VARIVENT valves with spread liftPA12/L -- -- 221-646.90 221-646.90
Pneumatic block SPV with NOT for
ASEPTOMAG valves and VARIVENT
valves with spread liftPA12/L -- -- 221-646.93 221-646.93
Pneumatic block SPV without NOT for
ASEPTOMAG valvesPA12/L 221-646.92 221-646.92 -- --
Pneumatic block 1PV, not for
ASEPTOMAG valvesPA12/L 221-646.94 -- -- --
9 Sensor module T.VIS A/P-15 PA6/GF30 221-589.74 221-589.74 221-589.74 221-589.74
15 Clamp connection KU -- 221-507.08 221-507.08 221-507.08 221-507.08
21 Sound absorber G1/8" MS CV 933-175 933-175 933-175 933-175
22 Locking screw G1/8" PE-HD 922-369 922-369 922-369 922-369
26 Sound absorber G1/4" MS CV 933-174 933-174 933-174 933-174
41 O-ring NBR -- -- 930-436 --
43 Printed circuit board 24V DC -- 221-005021# 221-005021# 221-005021# 221-005021#
Printed circuit board ASi except MT-valves -- 221-005022# 221-005022# 221-005022# 221-005022#
Printed circuit board 24VDC for IO-Link
Printed circuit board DeviceNet -- 221-004097A 221-004097A 221-004097A 221-004097A
Printed circuit board ASi only MT-valves -- 221-005032 221-005032 221-005032 221-005032
Printed circuit board 24VDC for IO-Link
57 Thread-forming screw A2 514-750 514-750 514-750 514-750
63 Solenoid valve 24VDC PBT 512-169* *without
64 Logic element NOT -- -- -- -- 512-137
65 Valve plate PPO 221-589.27 221-589.27* *without
TA18L...221-589.27* *without
TA18G...221-589.27* *without
TA18Y...
66 Thread-forming screw A2 514-761 514-761 514-761 514-761
67 Thread-forming screw A2 -- -- 514-758 514-758
77 Thread-forming screw Galv. steel 514-763 514-763 514-763 514-763
78.1 Printed circuit board T.VIS A-15/Zus/24V -- 221-005.025 221-005.025 221-005.025 221-005.025
78.2 Printed circuit board T.VIS A-15/IO-Link/
- Printed circuit board T.VIS A-15/IO-Link -- 221-005023# 221-005023# 221-005023# 221-005023#
- cable IO-Link 5-pole fitted -- 221-007.031 221-007.031 221-007.031 221-007.031
- cable IO-Link 4-pole fitted -- 221-007.032 221-007.032 221-007.032 221-007.032
- Thread-forming screw Galv. steel 514-763 514-763 514-763 514-763
78.3 Printed circuit board T.VIS spread lift/cpl.
- Printed circuit board T.VIS spread lift -- 221-005026 221-005026 221-005026 221-005026
- Round plug-in connector Y-adapter  508-945 508-945 508-945 508-945Spare parts list - control top type T.VIS A-15
Control top T.VIS® A-15 with metric cable connection and air connection with imperial connections
without NOT logic element with NOT logic
element
Order code  TA18R...ZM
- Proximity switch cpl. -- 221-105.111 221-105.111 221-105.111 221-105.111
- Support sleeve (only for IO-Link) -- 933-949 933-949 933-949 933-949
- Thread-forming screw (only for IO-Link) -- 514-768 514-768 514-768 514-768
- Round plug-in connector M12/3 wire -- 508-039 508-039 508-039 508-039
79 Adapter 4PV PA6 -- -- 221-589.111 --
# Placeholder for version status (Please contact GEA Tuchenhagen if there are any questions.)Spare parts list - control top type T.VIS A-15
Item Designation Material Material no.
21.1 Throttle valve G 1/8 Brass/
nickel-
plated603-042 to reduce the closing speed main stroke (air outlet with
sound absorber pos. 21)
21.2 Throttle valve G 1/8 Brass/
nickel-
plated603-042to reduce the opening speed main stroke (connection with
screw-in plug connection pos. 6)
24.1 Connector M12/8-pin/
M20x1.5A2 221-005.102 Cable connection 24VDC with cable socket M12/8-pole/A-
coded
24.2 Connector M12/5-pole/
5-wire/M20x1.5A2 221-005.101 Cable connection 24VDC max.1 solenoid valve without
proximity switch on the lantern with cable socket M12/5-
pin/A-coded; cable connection ASi and Device Net
24.3 Connector M12/12-pin/9
wire/M20x1.5A2 221-005103 Cable connection 24VDC with additional 4. Feedback
170 Proximity switch M12 cpl. -- 221-105.28Used in the lantern / items 170.1, 171 and 174 are included
in the proximity switch cpl. (item 170)
170.1Proximity switch M12x1/
externalA2 505-098 Used in the lantern
171Round connector M12 with
cable--508-031 Only with proximity switch item 170.1
174 Holder proximity switch cpl. A2 221-105.26 Only with proximity switch item 170.1
Accessories (to be ordered separately) Material no. Application
Angular cable socket M12 / 5-pole / A-coded / 24VDC /
DeviceNet508-963 Electrical connection to connector Items 24.2/24.5
Straight cable socket M12 / 8-pole / A-coded / 24VDC 508-061 Electrical connection to connector Item 24.1
Angular cable socket M12 / 4-pole / A-coded / ASi 514-161 Electrical connection to connector Item 24.3
Straight cable socket M12 with 1.0m cable and ASi
insulation displacement connector508-027 Electrical connection to connector Item 24.3
Straight cable socket M12 with 2.0m cable and ASi
insulation displacement connector508-028 Electrical connection to connector Item 24.3
Quick air vent valve D6 (with plug connection for hose
6mm on both sides)603-039Spare parts list - control top type T.VIS A-15
14 Spare parts list - switch bar T.VIS A-15
Fig.95 Spare parts list - switch bar T.VIS A-15
Item Designation Material Material no. Application
1 Switch bar PA6/GK30 221-589.104 Standard for all valves with the exception of butterfly valves T-
smart 7 and valves with lifting actuator R; T_R; L; M_O(06);
MT/T_R(08); M/2.0
1.1 Ring T.VIS®/ECO Noryl/GFN2 221-002396 In addition to item 1, only for ECOVENT-valves and VESTA XL
H_A/M-valves
1.2 Switch bar 1.4301 224-000214In addition to item 1, adapter only for T-smart 8000 butterfly
valves
1.3 Switch bar incl. O-ring 1.4305 221-589.57 In addition to item 1, adapter only for valves type XL H_A
1.4 TME/T.VIS adapter 1.4305 221-573.06 In addition to item 1, only for butterfly valves ECOVENT-S
2 Switch bar BFV-7 1.4301/PA6 224-001696 For butterfly valves T-smart 7 and 9
3 Switch bar LFT-R 1.4301/PA6 see typeFor valves with lifting actuator R; T_R; L; M_O(06); MT/
T_R(08); M/2.0
4 Switch bar A/P-15 ASG 1.4305/PA6 221-589.88 For all GEA ASEPTOMAG valves
5 Switch bar A/P-15 N_V 1.4305/PA6 221-589.90 only for VARIVENT long-stroke valves with ZEF/V and ZFD/V
actuator and butterfly valve with limit stop
6 Switch bar T.VIS M-20/A/
P-15/IS1.4301/PA6 221-589.86 only for VARIPUT in-line spray cleaner
Use on standard actuators see dimension sheet 221MBL010805EN
Item Designation Material no.
3 Switch bar LFT-R cpl. incl. slider 221-618.20 221-618.21 221-618.22 221-618.23 221-618.24
L = Length 286 316 346 405 453
3.1 Sliding piece 221-619.04Spare parts list - switch bar T.VIS A-15
15 Dimension sheet - Control top type T.VIS A-15
Fig.96
For assignment of N, Y1, Y2, Y3, E1, E2 and P refer to the Operating Instructions
“Control Top T.VIS A-15”.
X - supply voltage, electric actuation and feedback
S3 - electrical connection for external proximity switchDimension sheet - Control top type T.VIS A-15
16 Dimension sheet - switch bar LFT-R T.VIS A-15/M-20 for lifted valves R;
T_R; L; M_O(06); MT/T_R(08); M/2.0; MT; MT-DA; MX
Fig.97 Dimension sheet - switch bar LFT-R T.VIS A-15/M-20 for lifted valves R; T_R; L; M_O(06); MT/T_R(08); M/2.0; MT;
MT-DA; MX
Actuator Switch bar T.VIS A-15
Type Material no. Actuator Material no. Length
A D  L
AA 221-118.01 95 99 -- --
in valve DN25; 1"OD; or PMO 2.0316
in valve PMO/06356
SM6Z 221-585.04 246 260.5 221-618.24 453Dimension sheet - switch bar LFT-R T.VIS A-15/M-20 for lifted valves R; T_R; L; M_O(06); MT/T_R(08); M/2.0; MT;
MT-DA; MX
Actuator Switch bar T.VIS A-15
Type Material no. Actuator Material no. Length
A D  L
EK6A 221-586.10 246 210 221-618.24 453Dimension sheet - switch bar LFT-R T.VIS A-15/M-20 for lifted valves R; T_R; L; M_O(06); MT/T_R(08); M/2.0; MT;
MT-DA; MX
17 Appendix
17.1 Lists
17.1.1 Abbreviations and terms
Abbreviation
Explanation
BS British Standard
barUnit of measurement of pressure [bar]
All pressure data expressed in [bar/psi] is assumed to be
gauge pressure [barg/psig] unless explicitly specified
otherwise.
approx. approximately
°C Unit of measurement of temperature [degree Celsius]
dm3nUnit of measurement of volume [cubic decimetre] Standard
volume (standard litre)
DN DIN nominal width
DINGerman standard issued by DIN (Deutsches Institut für
Normung e.V., German Institute for Standardization)
EN European Standard
EPDMMaterial designation
Short designation according to DIN/ISO 1629: Ethylene
Propylene Diene Rubber
°F Unit of measurement of temperature [degree Fahrenheit]
FKMMaterial designation, short designation according to DIN/ISO
1629: Fluorine rubber
h Unit of measurement of time [hour]
HNBRMaterial designation
Short designation according to DIN/ISO 1629: Hydrogenated
Acrylonitrile Butadiene Rubber
IP Protection class
ISOInternational standard issued by the International
Organisation for Standardisation
kg Unit of measurement of weight [kilogram]
kN Unit of measurement of force [kilonewton]
Kv value Flow 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]Appendix
Lists
Abbreviation Explanation
M Metric
NmUnit of measurement of work [newton metre]
Specification of torque 1 Nm = 0.737 lbft
Pound-Force (lb) + Feet (ft)
PA Polyamide
PE-LD Low-density polyethylene
PPE Polytetrafluoroethylene
psiAmerica measurement for pressure [Pound-forse per square
inch]
All pressure data expressed in [bar/psi] is assumed to be
gauge pressure [barg/psig] unless explicitly specified
otherwise.
PTFE Polytetrafluoroethylene
SET-UPSelf-learning installation
During commissioning and maintenance, the SET-UP
procedure carries out all the necessary settings for the
generation of messages.
AF Specifications for 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]
TIGWelding method
Tungsten inert gas welding
InchUnit of measurement of length in the Anglo-American
language area
Inch ODPipe measurement according to British Standards (BS),
Outside Diameter
Inch IPS American pipe measure - Iron Pipe SizeAppendix
Appendix
GEA Tuchenhagen GmbH
Am Industriepark 2-10
21514 Büchen, Germany
Telephone [phone]
Copyright © GEA Tuchenhagen - All rights reserved - Subject to modifications.