APV DELTA SW4 User manual

Operating Manual
DELTA SW4
Single Seat and Change-over Valve
Read and understand this manual prior to
operating or servicing this product.
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Declaration of Conformity
for Valves and Valve Manifolds
SPX Flow Technology Rosista GmbH, Zechenstr. 49, D-59425 Unna-Königsborn
herewith declares that the
double seat valves of the series D2, SD4, SDT4, SDM4, SWcip4, DSV,
DA3, DE3, DEU3, DET3, DKR2, DKRT2, DKRH2
in the nominal diameters DN 25 - 150, 1“ – 6“ and 1 Sh5 - 6 Sh5
butterfly valves of the series SV1 and SVS 1 F
in the nominal diameters DN 25 - 100, DN 125 - 250 and 1“ – 4“
ball cocks of the series KH, KHV
in the nominal diameters DN 15 - 100
single seat, diaphragm and spring loaded valves of the series
S2, SW4, SWmini4, SWT4, M3, MF3, M4, MF4, MP4, MS4, AP1, APT1, CPV, RG4, RGM4,
RGE4, RGEM4, PR2, PR3, PR4, SI2, UF3, VRA,VRAH
in the nominal diameters DN 10 - 150, 1/2“ – 4“ and 1 Sh5 - 6 Sh5
and the valve manifolds installed thereof
meet the requirements of the Directives 2006/42/EC (superseding 89/392/EEC
and 98/37/EC) and GPSG - 9.GPSGV.
For official inspections, SPX Flow Technology Rosista GmbH presents
a technical documentation according to Appendix VII of the Machinery Directive,
this documentation consisting of documents of the development and construction,
description of measures taken to meet the conformity and to correspond with
the basic requirements on safety and health, incl. an analysis of the risks,
as well as an operating manual with safety instructions.
The conformity of the valves and valve manifolds is guaranteed.
Authorised person for the documentation:
SPX Flow Technology Rosista GmbH, Frank Baumbach, Zechenstr. 49, D-59425 Unna
November 30, 2010
Manager Research and Development
UK
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DELTA SW4 - UK-3.qxp 23.04.2009
UK
Single Seat and Change-over Valve
DELTA SW4
Operating manual UK - rev. 3
1
1. General Terms 2
2. Safety Instructions 2
3. Mode of Operation 3
4. Auxiliary Equipment 4 - 5
4.1. Valve position indication
4.2. Control Unit
4.3. Stoke limitation SW4 / M4
4.4. Oil dampening cylinder
4.5. SW4 variants
5. Installation 6 - 7
5.1. Connections (threaded connections/clamp flange connections)
5.2. Welding instructions
6. Dimensions / Weights 8 - 9
6.1. Single seat valve
6.2. Change-over valve
7. Technical Data
7.1. General data
7.2. Specification of compressed air quality
7.3. Closing times
7.4. Valve stroke
7.5. Pneumatic air consumption
7.6. Product pressures
7.7. kvs - values in m3/h 10 - 13
8. Maintenance 14
9. Service Instructions - Single seat valve 15 - 16
9.1 Dismantling from the line system
9.2 Disassembly of wear parts (product-wetted parts)
9.3 Installation of seals and assembly of valve
9.4 Installation of valve
10. Service Instructions - Actuator 17
10.1 Maintenance of actuator
10.2 Installation of seals and assembly of actuator
10.3 Actuator with valve position feedback
11. Service Instructions - Change-over valve 18 - 19
11.1 Dismantling from the line system
11.2 Disassembly of wear parts (product-wetted parts)
11.3 Installation of seals and assembly of valve
11.4 Installation of valve
12. Service Instructions 20
Assembly tool for seat seal
13. Reconstruction of Actuator 21
13.1. Reconstruction of actuator / dismantling
13.2. Assembly of actuator
14. Trouble Shooting 22
15. Spare Parts Lists
15.1 Valve housing DN 25-100
15.2 Valve housing Inch 1”-4”
15.3 Actuator
15.4 Valve position indication
Table of Contents Page
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1. General Terms
DELTA SW4 - UK-3.qxp 23.04.2009
UK
Single Seat and Change-over Valve
DELTA SW4
Operating manual UK - rev. 3
2
This operating manual should be read carefully by the competent
operating and maintenance personnel.
We point out that we will not accept any liability for damage or
malfunctions resulting from the non-compliance with this
operating manual.
Descriptions and data given herein are subject to technical
changes.
2. Safety Instructions
- DANGER!
- The technical safety symbol draws your attention to important
directions for operating safety. You will find it wherever the
activities described are bearing risks of personal injury.
- Separate electric and pneumatic connections.
-Depressurize the line system before any maintenance work.
Clean the valve if possible and drain residual liquids.
-Do not reach into the open valve.
Risk of injury by suddenly operating valve. In dismantled state
there is the risk of bruising at movable parts of the valve.
- Observe Service Instructions to ensure safe maintenance
of the valve.
-Attention!
With valve design NC (normally closed): Before releasing the
housing clamp connection, the valve insert must be relieved
by controlling the actuator.
-Attention!
Welded actuators are preloaded by spring force.
Actuators which are no longer used and / or defective
must be disposed in professional manner.
Defective actuators must be returned
to your APV Solutions & Services company
for their professional disposal and free of charge for you.
Please address to your local APV representative.
Opening of the actuators is strictly forbidden.
Danger to life!
!
!
!
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UK
Single Seat and Change-over Valve
DELTA SW4
Operating manual UK - rev. 3
3
Single seat and change-over valves DELTA SW4 have been
developed for use in the brewing and beverage, dairy
and food industries as well as for chemical and pharmaceutical
applications.
The valves are designed for universal applications and stand out
for their increased mechanical reliability and absolute ease of
service.
The field of application of the DELTA SW4 - valve is to shut off
and to change over line sections.
- Operation by pneumatic actuator with air connection,
reset by spring force.
- By different assembly of the actuator, the following designs
are possible:
NC: actuator normally closed / air-to-raise, spring-to-lower
NO: actuator normally open / air-to-lower, spring-to-raise
- The inner parts of the actuator need not be serviced.
- The cleaning of the inner valve is undertaken during CIP cleaning
of the line system.
- The standard SW4 valve is equipped with a control unit
DELTA CU 41 Direct Connect.
- The luminous diodes in the control unit indicate the position
of the valve shaft.
Single seat valve
Change-over valve
clamp
housing seal
housing - upper part
housing
seat seal
clamp
housing seal
shaft
actuator screw
hex. nut
centering washer
CU adapter
housing
shaft
seat seal
clamp
housing seal
yoke
guide bush
shaft seal
actuator
control unit
seat seal
3. Mode of Operation
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UK
Single Seat and Change-over Valve
DELTA SW4
Operating manual UK - rev. 3
4
4.1. Valve position indication (fig. 4.1.)
- Alternatively to the Control Unit, proximity switch holders (PSH)
for the valve position indication can be mounted on the actuator.
Proximity switches to signal the limit position of the valve seat
can be installed at the proximity switch holder if required.
We recommend to use our APV standard type:
Three-wire proximity switch
Operating distance: 5mm / diameter: 11mm
Operating voltage: 10 - 30 V DC
pnp positive switching, closing function
Installation ,,non-flush"
Using a valve position indicator other than APV, we cannot accept
any liability for a faultless function.
4.2 Control Unit (fig. 4.2.)
For the start-up as well as assembly and disassembly of the
different designs please use the respective manual.
The following different designs are available:
- An adapter is required to install the control unit on the SW4 valve.
valve position indication
fig. 4.1.
fig. 4.2.
CU3 Control Unit
CU4 Control Unit
Direct Connect
reference number:
CU41-S-Direct Connect
08 - 45 - 100/93; H320460
Profibus
reference number:
CU31-Profibus
08 - 45 - 001/93; H315495
Device Net
reference number:
CU31 Device Net
16 - 31 - 240/93; H209422
AS-Interface 2.1
reference number:
CU31 AS-interface 2.1
08 - 45 - 020/93; H315507
Benennung:
reference number:
CU3 - adapter SW4 / M4
08-48-480/93; H315806
Benennung:
reference number:
CU4-S-adapter for DN25/1”-100/4”
08-48-600/93; H320474
4. Auxiliary Equipment
DELTA SW4 - UK-3.qxp 23.04.2009
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UK
Single Seat and Change-over Valve
DELTA SW4
Operating manual UK - rev. 3
5
4.3. Stroke limitation SW4 / M4 (fig. 4.3.)
The pneumatic stroke limitation provides for the
continuous adjustment of the total valve stroke of 0 - 100%
The pneumatic stroke limitation is installed on the actuator.
- The valve disc can be in three different positions:
open, throttled and closed.
- The stroke limitation can only be applied with valve design
NC (FS) = normally closed.
To operate the pneumatic stroke limitation a separate control
is required.
The control unit CU43-S-2 Hall sensors - Direct Connect
can be used for this purpose.
4.4. Oil dampening cylinder (fig. 4.4.)
The oil dampening cylinder provides for a slow opening and
closing of the valve (to prevent pressure hammers in the line
system). The oil dampener is installed between the actuator
and the Control Unit.
- Function:
A throttling valve presses the oil from one chamber of the
dampening cylinder into the second chamber of the cylinder
during the switching process. By adjustment of the throttling
screw, the required delay can be variably adjusted.
4.5 SW4 variants
The SW4 range contains the following designs:
- DELTA SW4 - DN125-150
- DELTA SW4 with manual actuation
- DELTA SWT4 - tank outlet valve
- DELTA SW4 - long stroke version
- DELTA SW4 -DPF (with steam chamber)
- DELTA SWR4 (with modulating cone).
Corresponding manuals are available for the different designs.
fig. 4.3.
fig. 4.4.
throttle screw
throttle valve
Control Unit + Adapter
Designation:
reference number:
CU43-S-2 Hall sensors - Direct Connect
000 08-45-106/93; H320466
Designation:
reference number:
CU4-S-adapter complete
000 08-48-600/93; H320474
4. Auxiliary Equipment
DELTA SW4 - UK-3.qxp 23.04.2009
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UK
Single Seat and Change-over Valve
DELTA SW4
Operating manual UK - rev. 3
6
- The installation of the valve must be undertaken in such a manner
that fluids can drain off the valve housing and should be provided
preferably in vertical position.
-Single seat valve : The valve housing can be welded direct
into the pipeline (completely dismantable
valve insert).
-Change-over valve : Through a flange or clamp connection,
the upper housing of change-over valves
is detachable from the pipeline.
(see fig. 5).
-Attention : Observe Welding Instructions.
(see chapter 5.2)
5.1 Connections:
Besides the housings with weld ends, the following connections
are alternatively available:
- male part to DIN 11851
- male part IDF / ISS to ISO 2853
- male part RJT to BS 4825-5
- male part SMS
- male part to DS 722
- flange connection FGN1 DIN
- flange connection FGN1 Zoll
- clamp connection to DIN 32676
- clamp connection to ISO 2852
change-over valve
separate connection
fig. 5.
5. Installation
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UK
Single Seat and Change-over Valve
DELTA SW4
Operating manual UK - rev. 3
7
5. Installation
5.2. Welding Instructions
Shut-off valve:
- Before welding of the valve, the valve insert must be dismantled
from the housing. Careful handling to avoid damage to the parts
is necessary.
Change-over valve:
- Before welding of the valves, the valve insert must be dismantled
from the housing. The lower housing seal must be removed.
Careful handling to avoid damage to the parts is necessary.
- Welding should only be carried out by certified welders (EN 287-1).
(Seam quality EN 25817 "B").
- The welding of the valve housings must be undertaken in such a
way that the valve body is not deformed.
- The preparation of the weld seam up to 3 mm thickness must be
carried out as a square butt joint without air.
(Consider shrinkage!)
- TIG orbital welding is best!
- After welding of the valve housings or of the mating flanges and
after work at the pipelines, the corresponding parts of the
installation or pipelines must be cleaned from welding residues
and soiling. If these cleaning instructions are not observed,
welding residues and dirt particles can settle in the valve and
cause damage.
- Any damage resulting from the non-observance of these welding
instructions is not subject to our guarantee.
DELTA SW4 - UK-3.qxp 23.04.2009
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DELTA SW4 - UK-3.qxp 23.04.2009
UK
Single Seat and Change-over Valve
DELTA SW4
Operating manual UK - rev. 3
8
200
Ø D
FA
L
F
Ø K
Ø 134
SW41
SW42
SWE43
SWE44
A / L1
SWE41/42
H
F F
G
D
H
FF
Ø D
SWE43/44
housing design
valve position
indication
A1 / L1
6.1. Single seat valve
DN A L Ø D F G H Ø K A1 L1 weight in kg
25 410 460 26 50 18 54 86 338 442 5
40 414 481 38 67 24 66 86 342 475 5
50 451 523 50 72 32 78 126 379 529 7
65 459 544 66 85 40 94 126 387 566 7
80 512 610 81 98 47,5 109 189 440 647 13
100 522 633 100 111 57 128 189 450 689 15
Inch
1” 408 458 22,6 50 16,3 50,6 86 336 437 5
1,5” 412 479 34,9 67 22,5 62,9 86 340 470 5
2” 450 522 47,6 72 30,8 75,6 126 378 526 7
2,5” 456 541 60,3 85 37,2 88,3 126 384 557 7
3” 507 605 72,9 98 43,5 100,9 189 435 626 13
4” 520 631 97,6 111 55,8 125,6 189 448 685 15
single seat valve with
CU4 control unit
SWE41
SWE42
6. Dimensions / Weights
dimensions in mm
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UK
Single Seat and Change-over Valve
DELTA SW4
Operating manual UK - rev. 3
9
Ø D
F H A
L
FF
Ø 134
Ø K
change-over valve with
CU4 control unit
200
valve position
indication
A1 / L1
A / A1
SWE45 / 46
H H
F F
G
SW44
SW43
SWE46
SWE45
SW48
SW47
dimensions in mm
housing design
6.2. Change-over valve
DN A L Ø D F G H Ø K A1 L1 weight in kg
25 410 460 26 50 18 54 86 338 442 6
40 414 481 38 67 24 66 86 342 475 6
50 451 523 50 72 32 78 126 379 529 8
65 459 544 66 85 40 94 126 387 566 8
80 512 610 81 98 47,5 109 189 440 647 15
100 522 633 100 111 57 128 189 450 689 17
Inch
1” 408 458 22,6 50 16,3 50,6 86 336 437 6
1,5” 412 479 34,9 67 22,5 62,9 86 340 470 6
2” 450 522 47,6 72 30,8 75,6 126 378 526 8
2,5” 456 541 60,3 85 37,2 88,3 126 384 557 8
3” 507 605 72,9 98 43,5 100,9 189 435 626 15
4” 520 631 97,6 111 55,8 125,6 189 448 685 17
Ø D
6. Dimensions / Weights
DELTA SW4 - UK-3.qxp 23.04.2009
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DELTA SW4 - UK-3.qxp 23.04.2009
UK
Single Seat and Change-over Valve
DELTA SW4
Operating manual UK - rev. 3
10
7. Technical Data
7.1. General data
product-wetted parts: 316 L, 1.4404
other parts: 1.4301
seals: standard: EPDM
option: HNBR, VMQ, HNBR
max. product pressure: 10 bar
max. operating temperature: 135°C EPDM, HNBR
*FPM, *VMQ
short-term load: 140°C EPDM, HNBR
*FPM, *VMQ
*(no steam)
air connection (for hose) : 6 x 1mm
max. pneumatic air pressure: 8 bar
min. pneumatic air pressure: 6 bar
(Use dry and clean pneumatic air, only.)
7.2. Specification of compressed air quality
compressed air quality: quality class acc. to DIN/ISO 8573-1
content of solid particles: quality class 3
max. size of solid particles per m³
10000 of 0,5µm <d<1,0µm
500 of 1,0µm <d<5,0µm
content of water: quality class 4
max. dew point temperature + 3°C
For installations at lower
temperatures or at higher altitudes,
additional measures must be
considered to reduce the pressure
dew point accordingly.
content of oil: quality class 1
max. 0,01mg/m³
(The oil applied must be compatible with Polyurethane
elastomer materials.)
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UK
Single Seat and Change-over Valve
DELTA SW4
Operating manual UK - rev. 3
11
7.4. DELTA SW4
Valve stroke in mm
7.5. DELTA SW4
Pneumatic air consumption at 6 bar control pressure
7.3. Closing times for single seat and change-over valve
DELTA SW4
The opening and closing times of the valves equipped with a control unit
can be determined by adjusting the throttle screw at the solenoid valve.
Closing times in sec.
Pneumatic air 6 bar
hose length in meter
DN Inch 1m 10m
25 1” 1 2
40 1,5” 1 2
50 2” 3 4
65 2,5” 3 4
80 3” 5 6
100 4” 5 6
DN Inch
single-seat valve
SW41, SW42
SWE41, 42, 43, 44
change-over valve
SW43, SW44
SWE45, 46
25 1” 12 9
40 1,5” 25 22
50 2” 28 25
65 2,5” 28 25
80 3” 28 25
100 4” 28 25
actuator per stroke
NL
Ø 74mm 1,0
Ø 110mm 2,1
Ø 165mm 4,5
7. Technical Data
DELTA SW4 - UK-3.qxp 23.04.2009
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DELTA SW4 - UK-3.qxp 23.04.2009
UK
Single Seat and Change-over Valve
DELTA SW4
Operating manual UK - rev. 3
12
7.6. DELTA SW4 calculatory product pressure in (bar)
at 6 bar control air pressure
single seat valve
SW41 FS
single seat valve
SW41 NO with
6 bar air pressure
change-over valve
SW43 NC upper seat
with 6 bar air pressure
change-over valve
SW43 NO
upper seat
change-over valve
SW43 NO with
6 bar air pressure
change-over valve
SW43 NC
lower seat
Ø actuator in mm
DN Inch Ø74 Ø110 Ø165
25 1” 11,7
40 1,5” 5,0 12,5
50 2” 2,8 7,6 19,6
2,5” 2,0 5,4 13,8
65 1,7 5,0 11,7
3” 3,8 9,9
80 3,1 7,9
100 4” 2,1 5,3
Ø actuator in mm
Ø74 Ø110 Ø165
11,2
5,4 11,2
3,4 7,1 16,8
2,4 5,0 11,9
2,0 5,0 10,0
3,6 8,5
2,9 6,8
1,9 5,0
Ø actuator in mm
Ø74 Ø110 Ø165
20,3
6,9 14,4
4,0 8,3 19,5
2,7 5,5 13,1
2,2 5,0 10,9
3,8 9,1
3,0 7,2
2,0 5,0
Ø actuator in mm
Ø74 Ø110 Ø165
21,2
6,0 16,0
3,3 8,8 22,8
2,2 6,0 15,3
1,8 5,0 12,7
4,1 10,6
3,3 8,4
2,1 5,5
7. Technical Data
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UK
Single Seat and Change-over Valve
DELTA SW4
Operating manual UK - rev. 3
13
7.7. DELTA SW4
kvs - values in m³ / h
SW41, 42
SWE41, 42
SWE43, 44
SW41, 42
SWE41, 42
SWE43, 44
SW42
SWE42
SW44
SW43, 44
SW47, 48
SW43, 44
SW47, 48
DN
25 20 21 28 14 13
40 45 53 60 33 31
50 92 85 120 58 51
65 159 159 215 100 89
80 201 209 350 160 137
100 302 325 540 245 212
Inch
1” 16 18 26 10 10
1,5” 38 45 57 30 28
2” 83 77 118 54 49
2,5” 133 133 185 87 76
3” 176 176 300 137 114
4” 292 310 530 225 210
7. Technical Data
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DELTA SW4 - UK-3.qxp 23.04.2009
UK
Single Seat and Change-over Valve
DELTA SW4
Operating manual UK - rev. 3
14
8. Maintenance
- The maintenance intervals depend on the corresponding
application and are to be determined by the operator himself
carrying out temporary checks.
- The valve must not be cleaned with products containing abrasive
or polishing material.
Especially the valve shaft must not, under any circumstances,
be cleaned with such agents.
Damage of the valve shaft can lead to leakages.
- Required tools :
- 1x wrench SW13
- 1x wrench SW17
- 1x wrench SW19
- 1x wrench SW30
- assembly tool for seat seal
(see chapter 12.)
- Exchange of seals is done according to service instructions.
A customer stock keeping of spare seals is recommended.
For the valve service we supply complete seal kits including
seal grease (see spare parts lists).
- Assembly of the valve and change of the valve design NC or NO
according to service instructions.
-Slightly grease all seals before their installation !!!!!
Recommendation:
APV food-grade-grease for EPDM, HNBR, FPM and NBR
(0,75 kg/tin - ref.-No. 000 70-01-019/93)
(60 g/tube - ref.-No. 000 70-01-018/93)
or
APV food-grade-grease for VMQ
(0,6 kg/tin - ref.-No. 000 70-01-017/93)
(60 g/tube - ref.-No. 000 70-01-016/93)
!!! Do not use grease containing mineral oil for EPDM seals.
!!! Do not use Silicone-based grease for VMQ seals.
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UK
Single Seat and Change-over Valve
DELTA SW4
Operating manual UK - rev. 3
15
Single seat valves
DELTA SW41, SW42, SWE41, SWE42, SWE43, SWE44
9.1. Disassembly from the line system
1. Shut off line pressure and drain lines if possible.
2. Valve design NC: Control actuator with air!
Do not touch movable valve parts!
Risk of injury.
3. Detach clamp and lift valve insert off the housing.
4. Shut off compressed air and remove compressed air supply.
5. Take control unit off the actuator.
9.2. Dismantling of wear parts (product-wetted parts)
1. Remove housing seal.
2. Release actuator screw from the guide rod.
Remove the CU adapter.
3. Release the safety nut by holding the centering washer.
Remove the centering washer.
4. Pull the valve shaft out of the actuator.
Remove the seat seal.
5. Unscrew the yoke from the actuator.
6. Detach the seat seal, shaft seal and guide bush.
actuator screw
hex. nut
centering washer
CU adapter
single seat valve
housing
shaft
seat seal
clamp
housing seal
yoke
guide bush
shaft seal
actuator
control unit
seat seal
!
9. Service Instructions - Single Seat Valve
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