APV SPX DELTA DKR2 User manual

Read and understand this manual prior to
operating or servicing this product.
Operating Manual
DELTA DKR2
Double - Seat Ball Valve
with Cleaning Connection

1
Double-Seat Ball Valve with Cleaning Connection
DELTA DKR 2
Operating Manual : Rev. 7
1. General Terms 2
2. Safety Instructions 2
3. Mode of Operation 3
4. Auxiliary Equipment 4 - 5
5. Cleaning 5
6. Installation 6
6.1 Welding Instructions 6
7. Dimensions / Weights 7
8. Materials 8
9. Technical Data 8 - 9
10. Maintenance 9
11. Service Instructions 10 - 15
12. Detection of Seal Damage 16
13. Spare Parts Lists
DKR2 - FZ DN25 - 125 RN 01.071
DKR2 - FZ 1” - 4” RN 01.074
Turning actuator K-80, K-125, K-180 RN 01.073
Turning actuator F/L for feedback unit RN 01.076
UK
Table of Contents : Page :

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 line and cleaning system must be depressurized before any
maintenance work.
- Electric and pneumatic connections must be separated.
- Do not reach into the open valve ball!
Risk of injury by sudden valve operation!
- Observe service instructions to ensure safe maintenance
of the valve.
- Dismantle the actuator before the change of seals.
- During valve operation, operating leakages spirt out to the bottom.
- If the cleaning connection is not used, it must be sealed by
a plug or operating leakages must be discharged.
1. General Terms
2
Double-Seat Ball Valve with Cleaning Connection
DELTA DKR 2
Operating Manual : Rev. 7
UK

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 of 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 bleed from the
leakage drain (D) downwards. If a cleaning line is not connected,
the cleaning connection (E) must be sealed by a plug or operating
leakages must be discharged.
- The cleaning connection (E) can be used to vent the leakage
chamber for a faster emptying or to sterilize the leakage chamber
with steam.
3. Mode of Operation
3Double-Seat Ball Valve with Cleaning Connection
DELTA DKR 2
Operating Manual : Rev. 7
UK

4. Auxiliary Equipment
4
-Operating leakage reduction
During the opening and closing process of the valve, a
certain quantity of the fluid is lost as operating leakage
(see technical data).
Through a reconstruction of the valve, a reduction by about 40 %
can be achieved.
Complete retrofit kits to reduce the quantity of operating leakages
are available (see page 14).
-Operating leakage drain
To discharge operating leakages via a pipeline, retrofit kits
with weld end are available (see page 15).
Valve position indication
-Switches to signal the limit position of the valve ball can be installed
in the yoke if requested.
We recommend our APV standard proximity switches.
Type: three-wire proximity switch (ref.-No. 08-60-011/93)
Operating distance: 4 mm / diameter : 11 mm / length: 30 mm
Feedback complete with support and proximity switch
(ref.-No. 15-33-023/93) for a limit position.
If the user decides to apply valve position indicators other than
APV type, we cannot take over the liability for any malfunctions.
-Control Unit
Units with feedback switches and solenoid valves to be assembled
on the actuator, for the pneumatic control of the valve are also
available in fieldbus technology.
The Control Unit CU can be installed on the turning actuator.
Different types are available:
designation : ref.-No.:
CU 31 Direct Connect 16-31-232/93
CU 21 Profibus 16-31-236/93
CU 31 Device Net 16-31-240/93
CU 31 AS - Interface 16-31-244/93
control unit DELTA CU
with adapter
Double-Seat Ball Valve with Cleaning Connection
DELTA DKR 2
Operating Manual : Rev. 7
UK

5
5. Cleaning
Cleaning recommendation for the DKR valve
in the beverage industry
(with a break of 10 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
standard values. 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.
cleaning step CIP - spraying
pre-flushing 2 x 10 sec.
caustic flushing 80° C3 x 10 sec.
intermediate flushing 2 x 10 sec.
acid flushing 3 x 10 sec.
final flushing 2 x 10 sec.
Double-Seat Ball Valve with Cleaning Connection
DELTA DKR 2
Operating Manual : Rev. 7
UK
-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 actuators and corresponding adapters
for control units
ref.-No.:
turning actuator K 080 15-37-070/17
DN 25 - 65 / 1” - 2,5”
CU 2 adapter SV1 / SVS1F / DKR2 08-48-416/93
turning actuator K 125 15-37-106/17
DN 80 - 100 / 3” - 4”
CU 2 adapter SV1 / SVS1F / DKR2 08-48-417/93
turning actuator K 180 15-37-103/17
DN 125
CU 2 adapter SV1 / SVS1F / DKR2 08-48-417/93
turning actuator for
control unit

6. Installation
6
-The valve must be installed in vertical position.
Operating leakages are freely drainable to the bottom and the
leakage chamber drains off.
-With several valves being parallely connected with 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.
-Attention: Observe welding instructions.
6.1 Welding Instructions
-Welding should only be carried out by certified welders (EN 287-1)
(seam quality EN 25817 "B").
-Welding of the mating flanges must be undertaken in such a way
that deformation strain cannot be transfered.
-TIG orbital welding is best!
-Before welding of the valve, all sensitive parts must be removed!
Dismantle the valve ball housing with seals from the mating flanges.
-To simplify welding, fitting parts can be supplied as assembly
inserts.
-The preparation of the weld seam up to 3 mm thickness can be
carried out as a square butt joint without air. (Consider shrinkage!)
-After welding 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 or can be transfered to
other parts of the installation.
-Any damage resulting from the non-observance of these welding
instructions is not subject to our guarantee.
Double-Seat Ball Valve with Cleaning Connection
DELTA DKR 2
Operating Manual : Rev. 7
UK
DN / inch ref.-No.
25 /1” 08-48-250/59
40 / 1,5” 08-48-251/59
50 / 2” 08-48-252/59
65 / 2,5” 08-48-253/59
80 08-48-254/59
3” 08-48-257/59
100 / 4” 08-48-255/59
125 08-48-256/59
assembly insert
DKR complete

7Double-Seat Ball Valve with Cleaning Connection
DELTA DKR 2
Operating Manual : Rev. 7
UK
A A1 B D E F G weight
in kg
DN
25 385 522 55 26,0 60,5 108,5 85 5,7
40 410 546 67 38,0 61,0 109 85 6,5
50 427 563 75 50,0 79,0 127 85 7,4
65 452 587 87 66,0 100,3 148,3 85 9,2
80 543 678 102,5 81,0 123,0 171 130 18,0
100 574 707 117 100,0 150,0 198 130 21,5
125 622 142 125,0 190,0 244 130 40,0
inch
1” 385 522 55 22,2 60,5 108,5 85 5,7
1,5” 410 546 67 34,9 61,0 109 85 6,5
2” 427 563 75 47,6 79,0 127 85 7,4
2,5” 452 587 87 60,3 100,3 148,3 85 9,2
3” 543 678 102,5 72,9 123,0 171 130 18,0
4” 574 707 117 97,6 150,0 198 130 21,5
7. Dimensions / Weights
A
B
F
E
A1
D
GG
dimensions in mm
DKR 2
with turning actuator
DKR 2 with control unit

8
8. Materials
Double-Seat Ball Valve with Cleaning Connection
DELTA DKR 2
Operating Manual : Rev. 7
UK
- housing, valve ball, shafts 1.4404
- ball seal PTFE
- flange seal standard EPDM
option HNBR, FPM, VMQ
- housing seal standard EPDM
option HNBR, FPM
- O-rings FPM, NBR
Actuator
- yoke, actuator 1.4301
- coupling 1.4301 / 1.4308
or 1.4057 / 1.4059
- indicator PE-solid
- piston Polyacatal POM
- spindle bearing Polyamide PA 12
- air connection Polyamide PA 6.6
9. Technical Data
- max. line pressure : 10 bar
- max. operating temperatures : 135oC EPDM,HNBR
*FPM, *VMQ
- short-term load : 140oC EPDM, HNBR
*FPM, *VMQ
*no steam
- throughput cleaning at
3 bar admission pressure : about 5 - 10 l/min.
- turning actuator
max. control pressure : 10 bar
min. control pressure : 6 bar
turning angle : 90o
- air connection (for hose) : 6 x 1
(Use dry and clean air, only.)

9
9. Technical Data
Double-Seat Ball Valve with Cleaning Connection
DELTA DKR 2
Operating Manual : Rev. 7
UK
10. Maintenance
- Dismantling and installation of seals according to service
instructions.
Use complete seal kits according to spare parts list.
- Assembly and adjustment of turning actuator according to service
instructions.
- Lightly grease all seals.
APV recommendation:
assembly grease for EPDM, HNBR, NBR and FPM
(750 g/tin - ref.-No. 000 70-01-019/93)
(60 g/tube - ref.-No. 000 70-01-018/93)
or
assembly grease for VMQ
(600 g/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 with EPDM seals.
!Do not use Silicone-based grease with VMQ seals.
DN 25 40 50 65 80 100 125
inch 1” 1,5” 2” 2,5” 3” 4”
max. tightening torque in Nm ( M ) 10 15 22 25 40 65
operating leakage at about 5 bar in L ( Qs) 0,7 1,2 1,4 2,0 4,0 4,2 6,0
( opening and closing process )
operating leakage at about 5 bar in L ( Qs) 0,4 0,7 0,8 1,2 2,4 2,5 3,6
with operating leakage reducer
pneumatic air consumption at 6 bar NL ( V ) 1,8 1,8 1,8 2,8 5,5 5,5 5,5

10
The item numbers refer to the spare parts drawing
(DN-design: RN 01.071; inch-design: RN 01.074)
11.1 Dismantling from the line system
a. Shut off connecting lines, let off line pressure and discharge if
possible.
b. Disconnect pneumatic and electric connections.
c. Dismantle cleaning line.
d. Screw off valve position indicator.
e. Remove flange screws (20).
f. Detach ball valve from the flanges.
11.2 Dismantling of seals and guide bands
a. Detach flange seals (8).
b. Take off turning actuator (15) after removal of screws (16).
c. Release screws (18) and yoke, coupling, indicator and
spray connection.
Danger! Do not replace seals before removal of turning
actuator from the valve.
d. Pull out PTFE ball seals (9) with appertaining housing seals (7).
To pull the ball seals out, half open the ball by hand and grasp
alternately behind the seal!
Attention! Ball and ball seal are sensitive to mechanical
damage, the surfaces must not be touched
by tools.
e. Having released the screws (3), slide both shaft bearings (2) out
of the housing and replace O-rings (5, 6) and guide bands (4).
Attention! With dismantled shaft bearings and seals, the
housing with ball must not be subject to vibrations.
11. Service Instructions
Double-Seat Ball Valve with Cleaning Connection
DELTA DKR 2
Operating Manual : Rev. 7
UK

11 Double-Seat Ball Valve with Cleaning Connection
DELTA DKR 2
Operating Manual : Rev. 7
UK
11.3 Installation of seals and guide bands
a. Slightly grease O-rings (5, 6) and guide bands (4) before their
installation in the shaft bearings (2).
b. Push upper and lower shaft bearing (2) with a little grease in the
housing, insert screws (3), but do not tighten them.
c. Slightly grease housing seals (7) before their installation on the
PTFE ball seals (9).
d. Turn valve ball into open position by hand and install ball seals
with a little grease at both sides.
e. Slightly grease O-rings (12) and insert them in the spray
connection (10).
11.4 Assembly of valve
a. 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.
b. Screw in screws (18), but do not tighten them.
11. Service Instructions

12
11.5 Adjustment of operating position
Attention! For a safe, perfect and fast adjustment of the
operating position, we recommend to use two
separate FG flanges.
11.5.1 Adjustment of operating position with FG flanges
Install the ball seals as described in 11.3.
Assemble the valve as described in 11.4.
Turn the ball into its exact open position.
a. Control actuator (15) with pneumatic air (min. 6 bar) and place
it on the yoke.
b. Screw in screws (16), but do not tigthen them.
Danger! Do not reach into the open valve after installation
of the actuator.
Risk of injury by sudden operation of the valve.
c. Screw down FG flanges at the housing.The ball must be in
its exact open position during this procedure.
d. Release both screws (3) of the shaft bearing (ball centers between
the seals) and retighten them.
e. Slightly turn the actuator in anticlockwise direction to adjust
the play in the connecting parts.
!!! The ball must keep its exact open position during this procedure!!!
Danger! Do not reach into the open valve.
Risk of injury by sudden operation of the valve.
f. 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".
g. Shut off the air supply to the turning actuator and dismantle the
FG flanges.
h. 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.
i. Connect pneumatic air line with turning actuator.
j. Connect cleaning line.
k. Attach valve position indicators.
11. Service Instructions
Double-Seat Ball Valve with Cleaning Connection
DELTA DKR 2
Operating Manual : Rev. 7
FG - flange
UK

13 Double-Seat Ball Valve with Cleaning Connection
DELTA DKR 2
Operating Manual : Rev. 7
UK
11.5.2 Adjustment of operating position without FG flanges
If FG flanges are not available, the ball can, in exceptional cases,
be adjusted as follows
(Attention! Failure of adjustement is possible.):
Install the ball seals as described in 11.3.
Assemble the valve as described in 11.4.
Turn the ball into its exact open position.
a. Control actuator (15) with pneumatic air (min. 6 bar) and place
it on the yoke.
b. Screw in screws (16), but do not tigthen them.
Danger! Do not reach into the open valve after installation
of the actuator.
Risk of injury by sudden operation of the valve.
! The ball must be in its exact open position !
c. Slightly turn the actuator in anticlockwise direction to adjust
the play in the connecting parts.
!!! The ball must not move during this procedure!!!
(exact open position)
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.
d. Shut off the air supply to the turning actuator and insert the valve in
closed position into the line system. Fasten it with the screws (20).
e. Centering of ball (absolutely necessary)
To center the ball between the seal rings, proceed as follows:
1. Release screws (3) by about ¼ turn.
2. Release one screw (18) by about ¼ turn.
3. Release second screw (18) by about ¼ turn and retighten
it immediately.
Attention! Hold the turning actuator fast during this process.
Bring up holding moment in clockwise direction
(top view of actuator).
4. Tighten screw (18) and, then, screw (3).
f. Tightening torque: Md = 16 Nm M8
Md = 40 Nm M10
g. Connect pneumatic air line with turning actuator.
h. Connect cleaning line.
i. Attach valve position indicator.
11. Service Instructions

14
Leakage reduction for DKR ball valve
If the valve is not dismantled from the pipeline for the installation
of the leakage reduction, it must be guaranteed that the
corresponding pipeline is depressurized!
Leakage reducer compl.
nominal size ref.-No.
DN 25, 1” 000 15-28-143/59
DN 40 - 65, 1,5”- 2,5” 000 15-28-144/59
DN 80,100, 3”, 4” 000 15-28-145/59
DN 125 000 15-28-146/59
parts item 1 000 58-06-078/13
item 2 000 58-06-119/13
DN 25 - 65,1”- 2,5” item 3 2 x 000 08-39-079/93
DN 80, 100, 3”, 4” item 3 3 x 000 08-39-079/93
DN 125 item 3 1 x 000 08-01-160/93
DN 25,1” item 4 000 15-28-143/42
DN 40 - 65, 1,5”- 2,5” item4 000 15-28-144/42
DN 80, 100, 3”, 4” item 4 000 15-28-145/42
DN125 item 4 000 15-28-146/42
Installation of the leakage reducer
- Remove the two hexagon screws (A) and pull out the
shaft bearing (C) by careful turning.
- If the leakage reducer is not equipped with the guides (3) and the
two O-rings (1, 2), these parts can carefully be dismantled from
the shaft bearing (C) and used.
- Lightly grease O-rings (1, 2) before their installation.
!!! Do not use grease containing mineral oil for EPDM seals !!!
- Slide the complete leakage reducer instead of the shaft bearing
over the shaft pivot (B) and tighten it with the hexagon screws (A)
at the housing flange (D).
Double-Seat Ball Valve with Cleaning Connection
DELTA DKR 2
Operating Manual : Rev. 7
11. Service Instructions
UK

15 Double-Seat Ball Valve with Cleaning Connection
DELTA DKR 2
Operating Manual : Rev. 7
UK
Leakage connection (drain) for DKR ball valve
If the valve is not dismantled from the pipeline for the installation of
the leakage drain, it must be guaranteed that the corresponding
pipeline is depressurized!
Leakage connection compl.
nominal sizes ref.-No.
DN 25 - 65,1”- 2,5” 000 16-37-020/59
DN 80 - 125, 3”, 4” 000 16-37-024/59
with 2 spare screws
parts
DN 25 - 65,1”- 2,5” item 1 000 16-37-020/42
DN 80 - 125, 3”, 4” item 1 000 16-37-024/42
DN 80 - 125, 3”, 4” item 2 000 65-01-132/15
DN 25 - 125, 1”, 4” item 3 000 08-39-079/93
DN 25 - 125, 1”, 4” item 4 000 58-06-078/13
DKR ball valve
- Remove the two hexagon screws (A) and push the leakage
connection (E) over the shaft pivot (B) against the shaft bearing (C).
- Lightly grease O-ring (4) in the leakage drain.
!!! Do not use grease containing mineral oil for EPDM seals !!!
- With DN 25 to 65 tighten the shaft bearing (C) together with the
leakage connection at the housing flange (D) by the hexagon
screws (A).
- With DN 80 to 125 use the hexagon screws (2) supplied with the
leakage connection for fastening purposes.
- In its standard version, the leakage connection is provided with
a butt weld end.
11. Service Instructions