APV SPX DELTA DKR2 User manual

APV DELTA DKR2
DOUBLE SEAT BALL VALVE WITH CLEANING CONNECTION
FORM NO.: H170755 REVISION: UK-9 READ AND UNDERSTAND THIS MANUAL PRIOR TO OPERATING OR SERVICING THIS PRODUCT.
INSTRUCTION MANUAL
Scan for DKR2 Valve
Maintenance Video

EU Declaration of Conformity
for Valves and Valve Manifolds
SPX Flow Technology Germany GmbH
Gottlieb-Daimler-Str. 13, D-59439 Holzwickede
herewith declares that the
APV double seal and double seat valves of the series
SD4, SDT4, SDU4, SDMS4, SDMSU4, SDTMS4, SWcip4, DSV,
DA4, D4 SL, D4, DA3, DA3SLD, DE3, DEU3, DET3, DKR2, DKRT2, DKRH2
in the nominal diameters DN 25 - 150, ISO 1“ – 6“ and 1 Sh5 - 6 Sh5
APV butterfly valves of the series SV1 and SVS1F, SVL and SVSL
in the nominal diameters DN 25 - 100, DN 125 - 250 and ISO 1“ – 4“
APV ball valves of the series KHI, KHV
in the nominal diameters DN 15 - 100
APV single seat, diaphragm and spring loaded valves of the series
S2, SW4, SWhp4, SW4DPF, SWmini4, SWT4, SWS4, MF4, MS4, MSP4, AP/T1, CPV,
RG4, RG4DPF, RGMS4, RGE4, RGE4DPF, RGEMS4, PR2, PRD2, SI2, UF/R3, VRA/H
in the nominal diameters DN 10 - 150, ISO 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 ProdSG (superseding GPSG - 9.GPSGV).
For official inspections, SPX FLOW 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:
Frank Baumbach
SPX Flow Technology Germany GmbH
Gottlieb-Daimler-Str. 13, D-59439 Holzwickede, Germany
May 2018
Frank Baumbach
Regional Engineering Manager, F&B Components
UK

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APV_DKR2_DE-9_032019.indd
Double Seat Ball Valve
DELTA DKR 2
Instruction Manual: UK - rev. 9
APV UK
Conent Page
DKR2 - FZ - CU DN 25 - 125, Inch 1” - 4” RN 01.071
turning actuator K-80, K-125, K-180 RN 01.073
turning actuator F/L for feedback unit RN 01.076
installation aid DKR complete RN 268.07
1. General Terms 2
2. Safety Instructions 2–3
3. Intended Use 3
4. Mode of Operation 4
4.1. General
5. Auxiliary Equipment 5–6
5.1. Valve position indication
5.2. Control unit
5.3. Turning actuator for control unit
5.4. Operating leakage reduction
5.5. Operating leakage drain
6. Cleaning 7
6.1. Cleaning recommendation
7. Installation 7–8
7.1. Welding instructions
7.2. Assembly inserts
8. Dimensions / Weights 9
9. Technical Data 10–11
9.1. General data
9.2. Compressed air quality
9.3. Tightening torque
9.4. Operating leakage at about 5 bar in l (opening and closing process)
9.5. Operating leakage at about 5 bar in l with operating leakage reducer
9.6. Pneumatic air consumption
10. Materials 11
11. Maintenance 12
12. Service Instructions 13–16
12.1. Dismantling from the line system
12.2. Dismantling of seals and guide bands
12.3. Installation of seals and guide bands
12.4. Assembly of valve
12.5. Adjustment of operating position
12.5.1. Adjustment of operating position with FG anges
12.5.2. Adjustment of operating position without FG anges
13. Service Instructions 17–18
13.1. Leakage reduction for DKR ball valve
13.1.1. Installation of the leakage reducer
13.2. Leakage connection (drain) for DKR ball valve
13.2.1. Installation of leakage drain
14. Detection of Seal Damage 19
15. Spare Parts Lists
(see annex)

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APV_DKR2_DE-9_032019.indd
Double Seat Ball Valve
DELTA DKR 2
Instruction Manual: UK - rev. 9
APV UK
1. General Terms
This instruction 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 instruction
manual.
Descriptions and data given herein are subject to technical
changes.
2. Safety Instructions
The valves must be assembled, disassembled and reassembled
only by persons who have been trained in the valves or by SPX
FLOW service team members. If necessary, contact your local SPX
FLOW representative.
Caution!
The technical safety symbol draws your attention to important
directions for operating safety. You will nd it wherever the activities
described are bearing health hazards and risks for persons and / or
material assets.
-Do not reach into the open valve ball or yoke.
Risk of injury by sudden valve operation!
In dismantled valve state, there is the risk of bruising at movable
valve parts.
- During valve operation, operating leakage spurts out to the bottom.
- If the cleaning connection is not used, it must be sealed by a plug or
operating leakage must be discharged.
- Regular maintenance of the valve including replacement of all seals
must be scheduled in order to prevent leakage and liquid emersion.
- Remove the turning actuator before the replacement of seals.
- Before any maintenance work, the line and cleaning system must
be depressurized and discharged if possible.
- Separate electric and pneumatic connections.
- Observe service instructions to ensure safe maintenance of the
valve.
!
!
!
!
!
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APV_DKR2_DE-9_032019.indd
Double Seat Ball Valve
DELTA DKR 2
Instruction Manual: UK - rev. 9
APV UK
2. Safety Instructions
-Caution!
Welded actuators are preloaded by spring force.
Actuators which are no longer used and/or are defective must be
disposed in professional manner.
Defective actuators must be returned to your SPX FLOW company
for their professional disposal and free of charge for you.
Please address to your local SPX FLOW company.
!
Opening of the turning actuators is strictly forbidden.
Danger to health and life!
The intended use as eld of application of the double seat ball
valve is the shut-off of pipeline sections.
Arbitrary, structural changes at the valves may affect safety as well
as the intended functionality of the valves and are not permitted.
Authorizations and External Approvals
To view the certications for this and other innovative SPX FLOW
products, visit
https://www.spxow.com/en/apv/about-us/certications/
3. Intended Use

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APV_DKR2_DE-9_032019.indd
Double Seat Ball Valve
DELTA DKR 2
Instruction Manual: UK - rev. 9
APV UK
4. Mode of Operation
4.1. Gerneral
Due to the use of high-quality stainless steel and seal materials
complying with the specified requirements, the double seat
ball valve DELTA DKR2 is applicable in the food and beverage
industries as well as in the chemical and pharmaceutical industries.
The field of application of the DELTA DKR2 valve comprises the
separation of two line sections with different fluids (B and C) by two
independent seals with intermediate leakage chamber and free
drain (D) to the atmosphere.
Actuation by the pneumatic turning actuator with air connection at
(A), reset into the limit position "closed" by spring force.
- The free opening cross section has the same dimension as the
nominal diameter of the pipeline.
- Smooth valve passage without diversion of the fluid.
- Cleaning of the leakage chamber by supply of cleaning liquids via
the cleaning connection (E).
- During the operating process, operating leakages drain off from the
leakage drain (D). If a cleaning line is not connected, the cleaning
connection (E) must be sealed by a plug or operating leakages
draining from (E) must be discharged.
- The cleaning nozzle (E) can be used to flush the leakage chamber
with water, or with CIP liquids and clean it with water, for fast
emptying, to vent or to sterilize the leakage chamber with steam.
- DKRX special valves are available, for example for highly viscous
products with extended leakage drain or for horizontal installation.
A
E
BC
D
F

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APV_DKR2_DE-9_032019.indd
Double Seat Ball Valve
DELTA DKR 2
Instruction Manual: UK - rev. 9
APV UK
5. Auxiliary Equipment
5.1. Valve position indication
Switches to signal the limit position of the valve ball can be installed
in the yoke area if requested.
We recommend using APV standard proximity switches.
Type: three-wire proximity switch (ref.-No. 08-60-011/93; H16223)
Operating distance: 5 mm / diameter : 11 mm / length: 30 mm
Feedback complete with support and proximity switch
(ref.-No. 15-33-023/33; H32725) for a limit position.
If the customer decides to use valve position indicators other than
those listed above, SPX FLOW cannot assume any liability for the
functionality of the valve.
5.2. Control unit (CU, fig. 5.2.)
Units with feedback switches and solenoid valves for the pneumatic
control of the valve to be assembled on the actuator are also
available in eldbus technology.
The assembly of the control unit on the prepared variant of the
turning actuator is possible.
For the startup as well as assembly and disassembly of the different
designs, the corresponding operating manuals must be observed.
The following different designs are available:
CU4 Direct Connect
ref.-No.; ID-No.
CU41 - T Direct Connect
08-45-101/93; H320461
CU4 AS-interface 62 Slaves
ref.-No.; ID-No.
CU41 - T - AS-i extended
08-45-111/93; H320468
CU4 AS-interface 31 Slaves
ref.-No.; ID-No.
CU41 - T - AS-i standard
08-45-251/93; H324674
CU3 Profibus
ref.-No.; ID-No.
CU31 Profibus
08-45-001/93; H315495
CU3 DeviceNet
ref.-No.; ID-No.
CU31 DeviceNet
16-31-240/93; H209422
- For the assembly of a control unit on the DKR2 valve, an adapter is
required.
CU4
control unit
CU3
control unit
fig. 5.2.
adapter
DN 25 - 65; 1“ - 2,5“ designation
ref.-No.; ID-No.
CU4-T-adapter
08-48-601/93; H320475
DN 80 - 125; 3“ - 4“ designation
ref.-No.; ID-No.
CU4-Tmax-adapter
08-48-611/93; H321987
DN 25 - 65; 1“ - 2,5“ designation
ref.-No.; ID-No.
CU2 - adapter K080
08-48-416/93; H209431
DN 80 - 125; 3“ - 4“ designation
ref.-No.; ID-No.
CU2 - adapter DKR80-100
08-48-417/93; H209432

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APV_DKR2_DE-9_032019.indd
Double Seat Ball Valve
DELTA DKR 2
Instruction Manual: UK - rev. 9
APV UK
5. Auxiliary Equipment
5.3. Turning actuator for control unit
- For the installation of a control unit on the DKR2 valve a special
turning actuator and an adapter are required. The standard actuator
must be replaced.
turning actuator for control unit
turning actuator K080 F/L
DN25 - 65; 1“ - 2,5“
ref.-No.: 000 – 15 - 37 – 070/17
H123937
turning actuator K125 F/L
DN80 - 100; 3“ - 4“
ref.-No.: 000 – 15 - 37 – 106/17
H128942
turning actuator K180 F/L
DN 125
ref.-No.: 000 – 15 - 37 – 103/17
H134034
5.4. Operating leakage reduction
During the opening and closing process of the valve, a certain
quantity of liquids is lost as operating leakage (see technical data).
Through a reconstruction of the valve, a reduction by about 40 %
can be achieved.
Complete retrot kits to reduce the quantity of operating leakages
are available (see page 17).
5.5. Operating leakage drain
To discharge operating leakage via a pipeline, retrot kits with weld
end are available (see page 18).

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APV_DKR2_DE-9_032019.indd
Double Seat Ball Valve
DELTA DKR 2
Instruction Manual: UK - rev. 9
APV UK
6. Cleaning
6.1. Cleaning recommendation
The valve passage is cleaned by the cleaning liquid during cleaning
of the connected pipelines.
Several switching (“cycling”) of the valve during pipeline cleaning is
benecial for the cleaning of the leakage chamber.
Depending on the degree and contents of soiling, the cleaning
liquids, times and processes for the individual application must be
scheduled.
The compatibility of the individually selected cleaning processes
and liquids with the respectively used cleaning seals must be
veried.
cleaning step CIP spraying
pre-flushing 2 x 10 sec.
caustic flushing 80 °C 3 x 10 sec.
intermediate flushing 2 x 10 sec.
acid flushing 3 x 10 sec.
final flushing 2 x 10 sec.
(with a break of 20 sec. each)
- The flushing times refer to a cleaning pressure of p = 3 - 5 bar.
- The flushing times indicated for the individual cleaning steps are
reference values, only. In specific applications these times must
be adjusted depending on the product, the pressure ratio and the
degree of soiling.
- The flushing quantity per CIP spraying cycle amounts to about 1
litre at a cleaning pressure of 3 - 5 bar.
7. Installation
- The valve must be installed in vertical position. Operating leakage is
freely drainable to the bottom and the leakage chamber drains off.
- For deviating installations (e.g. valve in horizontal position), special
valves are available.
- If several valves are connected parallely in one pipeline, a passage
of the operating leakage to the cleaning connection of adjacent
valves must be avoided. Installation of a shut-off device or a check
valve in front of each cleaning connection is required.
- Cleaning connection with hose 8 x 1.
Caution! Observe welding instructions 7.1.
!

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APV_DKR2_DE-9_032019.indd
Double Seat Ball Valve
DELTA DKR 2
Instruction Manual: UK - rev. 9
APV UK
7. Installation
7.1. Welding Instructions
- Welding should only be carried out by certied welders (DIN EN ISO
9606-1) (seam quality DIN EN ISO 5817).
- Welding of the mating anges must be undertaken in such a way
that deformation strain cannot be transferred.
- TIG orbital welding is recommended.
- Before welding of the valve, all sensitive parts must be removed!
Dismantle the valve ball housing with seals from the mating anges.
- To simplify welding, tting parts can be supplied as assembly inserts
(see table).
- The preparation of the weld seam up to 3 mm thickness must be
carried out as a square butt joint without air. Consider shrinkage!
- After welding the valve housing or mating anges, and after
performing any work on the piping, do not operate the valves until
the corresponding areas of the installation and piping have been
cleaned and welding residue has been removed. If the piping is not
cleaned before operation, welding residue and dirt particles can
settle in the valves and cause damage to the valves and seals.
- If these welding instructions are not followed, any resulting damage
will not be covered by the warranty.
fig. 7.2. assembly insert
7.2. Assembly inserts for double seat ball valves as follows:
DN Inch reference No. ID No.
25 1“ 000 08-48-250/ H207954
40 1,5“ 000 08-48-251/ H207955
50 2“ 000 08-48-252/ H207956
65 2,5“ 000 08-48-253/ H207957
80 000 08-48-254/ H207959
3“ 000 08-48-257/ H207958
100 4“ 000 08-48-255/ H167623
125 000 08-48-256/ H167624

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APV_DKR2_DE-9_032019.indd
Double Seat Ball Valve
DELTA DKR 2
Instruction Manual: UK - rev. 9
APV UK
8. Dimensions / Weights
A
A1
Ø D
B
F
E
Ø D
Ø G
Ø G
Ø 134
dimensions in mm weights in kg
DN A A1 B ØD E F ØG
25 384 534 55 26 60,5 109 85 5,7
40 408 558 65 38 61,0 109 85 6,5
50 425 575 75 50 79,0 127 85 7,4
65 448 599 87 66 100,3 149 85 9,2
80 543 695 103 81 123 171 135 18,0
100 572 724 117 100 150 198 135 21,5
125 663 142 125 190 244 189 40,0
Inch
1“ 384 534 55 22,6 60,5 109 85 5,7
1,5“ 408 558 65 34,9 61,0 109 85 6,5
2“ 425 575 75 47,6 79,0 127 85 7,4
2,5“ 448 599 87 60,3 100,3 149 85 9,2
3“ 543 695 103 72,9 123 171 135 18,0
4“ 572 724 117 97,6 150 198 135 21,5

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APV_DKR2_DE-9_032019.indd
Double Seat Ball Valve
DELTA DKR 2
Instruction Manual: UK - rev. 9
APV UK
9. Technical Data
9.1. General data
- max. line pressure: 10 bar
- max. operating temperature: 135° C EPDM, HNBR *
VMQ, * FPM
- short-term load: 140° C EPDM, HNBR *
VMQ, * FPM * (no steam)
- throughput cleaning at 3bar
- admission pressur: about 5 - 10 l/min.
- turning actuator
min. control pressure: 6 bar
max. control pressure: 10 bar
turning angle: 90°
- air connection (for hose) 6 x 1
threaded angle - G1/8" slewable: torque 2 Nm
- spray connection: G1/8"
- cleaning connection for hose: 8 x 1
9.2. 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 0,5 µm < d < 1,0 µm
500 of 1,0 µm < d < 5,0 µm
Content of water quality class 3,
max. dew point temperature -20°C
For installations at lower temperatures
or at higher altitudes, consider
additional measures to reduce the
pressure dew point accordingly.
Content of oil quality class 1, max. 0,01 mg/m³
The oil applied must be compatible with Polyurethane elastomer
materials.
angle union G1/8" slewable,
tightening torque 2 Nm
turning actuator
K080 F/L

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APV_DKR2_DE-9_032019.indd
Double Seat Ball Valve
DELTA DKR 2
Instruction Manual: UK - rev. 9
APV UK
9. Technical Data
10. Materials
- housing, valve ball, shafts 1.4404 (DIN EN 10088)
- ball seal PTFE
- ange seal standard: EPDM
option: HNBR, FPM, VMQ
- housing seal standard : EPDM
option: HNBR, FPM
- O-rings FPM, NBR
actuator
- yoke, actuator 1.4301 (DIN EN 10088)
- coupling 1.4301 / 1.4308
or 1.4057 / 1.4059
(DIN EN 10088)
- indicator PE-solid
- piston Polyacatal POM
- spindle bearing Polyamide PA 12
- air connection Polyamide PA 6.6
DN Inch 25 1“ 40
1,5“ 50 2“ 65 2,5“ 80 3“ 100 4“ 125
9.3. max. tightening torque in Nm (M) 10 15 22 25 40 65 95
9.4. operating leakage at about 5 bar
in l (opening and closing process) (Qs) 0,7 1,2 1,4 2,0 4,0 4,2 6,0
9.5. operating leakage at about 5 bar
in l with operating leakage reducer (Qs) 0,4 0,7 0,8 1,2 2,4 2,5 3,6
9.6. pneumatic air consumption at
6 bar NL (V) 1,8 1,8 1,8 2,8 5,5 5,5 5,5

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APV_DKR2_DE-9_032019.indd
Double Seat Ball Valve
DELTA DKR 2
Instruction Manual: UK - rev. 9
APV UK
11. Maintenance
- The maintenance intervals depend on the specic application and
should be determined by the user carrying out temporary checks.
- Storage of spare seals by the customer is recommended.
For the valve maintenance, we supply complete set of seals (see
spare parts lists).
- If damaged seals are exchanged, generally all seals should be
replaced.
- Assembly and adjustment of turning actuator according to Service
Instructions.
- Dismantling and installation of seals according to Service
Instructions.
- Slightly grease all seals before their installation
- The inner parts of the turning actuator do not require maintenance.
Caution! Use food-grade special grease which is suited for
the respective seal material, only.
Recommendation:
APV assembly grease for EPDM, FPM, HNBR and NBR
(0,75 kg/ tin - ref.-No. 000 70-01-019/93; H147382)
(60 g/ tube - ref.-No. 000 70-01-018/93; H147381)
or
APV assembly grease for VMQ (Silicone)
(0,6 kg/ tin - ref.-No. 000 70-01-017/93; H147380)
(60 g/ tube - ref.-No. 000 70-01-016/93; H147379)
! Do not use grease containing mineral oil with EPDM seals.
! Do not use Silicone-based grease with VMQ seals.
Less suited grease types can inuence function and life time.
Scan for DKR2 Valve
Maintenance Video

13
APV_DKR2_DE-9_032019.indd
Double Seat Ball Valve
DELTA DKR 2
Instruction Manual: UK - rev. 9
APV UK
12. Service Instructions
The item numbers refer to the spare parts drawing.
DN design: RN 01.071; Inch design: RN 01.074)
12.1. Dismantling from the line system
1. Shut off connecting lines, let off line pressure and discharge if
possible.
2. Disconnect pneumatic and electric connections.
3. Dismantle cleaning line.
4. Screw off valve position indication.
5. Remove flange screws (20).
6. Detach ball valve from the flanges.
12.2. Dismantling of seals and guide bands
1. Detach flange seals (8/8a).
2. Take off turning actuator (15) after removal of screws (16).
3. Release screws (18) and yoke, coupling, indicator and spray
connection
Caution! Do not replace seals before removal of turning
actuator from the valve.
4. Pull out PTFE ball seals (9/9a) with appertaining housing seals
(7/7a).
To pull the ball seals out, half open the ball by hand and grasp
alternately behind the seal.
Caution! Ball and ball seal are sensitive to mechanical
damage, the surfaces must not be touched by tools.
5. Having released the screws (3), slide both shaft bearings (2/22) out
of the housing and replace O-rings (5, 6) and guide bands (4).
Caution! With dismantled shaft bearings and seals, the
housing with ball must not be subject to vibrations.
16
18
20
32
8/8a
7/7a
5, 6, 4
15
9/9a
2, 22
!
!
!

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APV_DKR2_DE-9_032019.indd
Double Seat Ball Valve
DELTA DKR 2
Instruction Manual: UK - rev. 9
APV UK
12. Service Instructions
12.3. Installation of seals and guide bands
1. Slightly grease O-rings (5, 6) and guide bands (4) before their
installation in the shaft bearings (2/22).
2. Push upper and lower shaft bearing (2) with a little grease in the
housing, insert screws (3), but do not fasten them.
3. Slightly grease housing seals (7, 7a) before their installation on the
PTFE ball seals (9, 9a).
4. Turn valve ball into open position by hand and install ball seals with
some grease at both sides.
5. Slightly grease O-rings (12) and insert them in the spray connection
(10).
12.4. Assembly of valve
1. To ensure a safe handling of the valve, clamp the lower bearing
flange into a vice with protective cheeks. Turn the ball into "open
position".
Place yoke (17), spray connection (10), indicator (13) and coupling
(14) on the ball housing. The lower coupling cam must point to the
lower yoke bore (x) and the indicator must point into flow direction.
2. Screw in screws (18), but do not fasten them.
5
7, 7a
9, 9a
12
18
17
14
10
shaft bearing
shaft bearing
shaft bearing
4
6
13
3
X

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APV_DKR2_DE-9_032019.indd
Double Seat Ball Valve
DELTA DKR 2
Instruction Manual: UK - rev. 9
APV UK
12.5. Adjustment of operating position
Caution! For a safe, perfect and fast adjustment of the
operating position, we recommend to use two
separate FG flanges.
12.5.1. Adjustment of operating position with FG flanges
Install the ball seals as described in 12.3.
Assemble the valve as described in 12.4.
Turn the ball into its exact open position.
1. Control actuator (15) with pneumatic air (min. 6 bar) and place it on
the yoke.
2. Screw in screws (16), but do not fasten them.
Caution! Do not reach into the open valve after installation
of the actuator!
Risk of injury by sudden operation of the valve.
3. Screw down FG flanges at the housing. The ball must be in its exact
open position.
4. Release both screws (3) of the shaft bearing (ball centers between
the seals) and retighten them.
5. Slightly turn the actuator in anticlockwise direction to adjust the play
in the connecting parts.
The ball must keep its exact open position!
Caution! Do not reach into the open valve.
Risk of injury by sudden operation of the valve.
6. At first, tighten the screws (18) and then tighten the screws (16).
Operate the turning actuator several times to check the operating
accuracy of the ball in "open position".
7. Shut off the air supply to the turning actuator and dismantle the FG
flanges.
8. Insert the valve in closed position between the flanges into the
pipeline and fasten it with the screws (20).
Tightening torque: M8 Md = 16 Nm
M10 Md = 40 Nm
9. Connect pneumatic air line with the turning actuator
10. Connect the cleaning line.
11. Attach valve position indicators.
12. Service Instructions
FG flange
16
18
3
15
!
!