SPX FLOW APV DA4 User manual

APV DA4
DOUBLE SEAT MIX PROOF VALVE
FORM NO.: H337927 REVISION: UK-1 READ AND UNDERSTAND THIS MANUAL PRIOR TO OPERATING OR SERVICING THIS PRODUCT.
INSTRUCTION MANUAL

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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Double Seat Mix Proof Valve
APV DELTA DA4
Instruction Manual: UK - rev. 1
APV
Content Page
1. General Terms 6
2. Safety 6
2.1 Symbols
2.2 Safety Instructions
3. Intended Use 7
4. Mode of Operation 8
4.1. General terms
4.2. Valve in "closed" position
4.3. Valve in "open" position
5. Control Units / Valve Position Indication 10
5.1. Control unit and adapter
5.2. Valve position indication
6. Cleaning 11
6.1. Flow areas
6.2. Seal surfaces and seat area
6.3. Leakage chamber
6.4. Cleaning recommendation
6.5. Flushing quantity
6.6. Cleaning of upper area
6.7. Cleaning of lower area
7. Installation and Commissioning 13
7.1. Welding Instructions
8. Dimensions / Weights 14
9. Technical Data 15
9.1. General data
9.2. Compressed air quality
9.3. Kvs values
9.4. Air consumption / Switching times
9.5. Valve stroke / Opening cross section
10. Maintenance 18
11. Service Instructions 19
11.1. Removal from the line system
11.2. Removal of product-wetted parts
11.3. Installation of product-wetted seals and assembly of the valve
11.4. Installation of the valve insert
12. Maintenance of Actuator 23
12.1 Removing the actuator screws
12.2 Installing the seals and assembling the actuator
13. Assembly Instructions and Tools for Seals 24
13.1. Lower shaft seal
13.2. PTFE seal
13.3. Seat seal
13.4 Middle Seal
14. Trouble Shooting 26
15. Spare Parts Lists 26
DA4 Inch and DIN designs RN 502.047.01

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Double Seat Mix Proof Valve
APV DELTA DA4
Instruction Manual: UK - rev. 1
APV
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
2.1 Symbols
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.
Important Note!
Critical technical information
2.2 Safety Instructions
Opening of the actuators and upper shafts is strictly
forbidden. Danger to health and life!
Actuators and upper shafts which are no longer used and/or are
defective must be disposed in professional manner.
Defective actuators and upper shafts 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.
- Never touch the valve or pipelines during hot liquid or sterilisation
processes!
- Disconnect electric and pneumatic connections, e.g. before
maintenance.
- Before any maintenance work, depressurize the line and cleaning
system and discharge the lines if possible.
!
!
!
!
!

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Instruction Manual: UK - rev. 1
APV
2. Safety
- Observe Service Instructions to ensure safe maintenance of the
valve.
- Connections which are not used must be sealed by a plug!
- The safe discharge of the cleaning liquids must be ensured.
- 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.
3. Intended Use
The intended use as eld of application of the double seat mix proof
valve is the safe shut-off of pipeline sections and the separation of
incompatible liquids in the food and beverage industries as well as
in pharmaceutical and chemical applications.
Caution! The standard DA4 valve must not be used in explosive
atmospheres.
Caution! 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
1
2
E
C
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Instruction Manual: UK - rev. 1
APV
4. Mode of Operation
4.1. General terms
Due to its construction and mode of operation as well as to the use
of high quality stainless steel and adequate seal materials, the DA4
double seat mix proof valve is suited for applications in the food
and beverage industries as well as in pharmaceutical and chemical
applications.
- The DA4 valve separates two line passages by two balanced and
independently operating valve shafts with an intervening leakage
chamber.
- The valve opens from the top to the bottom in a low-leakage design.
- Leakages are discharged via the drain pipe (E) in depressurized
state.
- The pneumatic actuator opens the valve via the air connection (1).
The spring force resets the valve into the “closed” safe position.
- The standard DA4 double seat mix proof valve is equipped with a
CU43 control unit.
- Cleaning of the seat and shaft seal areas is controlled via the air
connections.
2 = to lift upper shaft
3 = to lift lower shaft
- The spray connection (C) cleans the leakage chamber.
- As an option, the closed and open positions of the DA4 can be
detected via proximity switches.
actuator
CU4
control unit
adapter
valve housing
drain pipe
operating cams
prox. switch holder
DA4 with valve position indication
spray connection
fig. 4.1
valve
closed
valve
open
fig. 4.1.2.

A
B
L
A
B
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Double Seat Mix Proof Valve
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Instruction Manual: UK - rev. 1
APV
4. Mode of Operation
4.2. Valve in "closed" position
The lower and upper valve shaft are in closed position and safely
separate the different liquids A and B. The leakage chamber L,
which is situated between the two valve shafts, provides for a free
and depressurized discharge to the bottom. The valve shafts are
balanced and protected against pressure hammer.
4.3. Valve in "open" position
The upper valve shaft is pressed against the seal of the lower valve
shaft by control of the actuator.
First, the leakage chamber L is closed against the product chamber.
Then the two valve shafts move downwards into the open position.
The connection between the two pipelines A and B is established.
fig. 4.3.
fig. 4.2.

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Double Seat Mix Proof Valve
APV DELTA DA4
Instruction Manual: UK - rev. 1
APV
5. Control Units / Valve Position Indication
5.1. Control unit and adapter
An adapter is required to assemble the control unit on the DA4
valve.
The following different designs are available:
Designation
Ø Air connection 6 mm 1/4" OD
Direct Connect
reference number
CU43 - D4 - Direct Connect
H336955
000 08-45-381/93
CU43 - D4 - Direct Connect 1/4"OD
H336960
000 08-45-431/93
AS-interface
reference number
CU43 - D4 - AS-i Extended
H336957
000 08-45-383/93
CU43 - D4 - AS-i Extended 1/4"OD
H336962
000 08-45-433/93
AS-interface standard
reference number
CU43 - D4 - AS-i Standard
H338152
000 08-45-385/93
CU43 - D4 - AS-i Standard 1/4"OD
H338153
000 08-45-435/93
Adapter CU4 adapter D4
000 08-46-646/93; H337098
CU4 control unit
5.2. Valve position indication
Proximity switches to signal the closed and open position of the
DA4 valve can be installed at the proximity switch holder.
We recommend using one of these standard types:
three-wire proximity switch
operating distance: 5 mm
diameter: 11 mm
operating voltage: 10–30 V DC
pnp pulse-shifting, closing function
"non-ush" installation
Recommendation:
Proximity switch 24V DC, PNP, 11 mm DIA. (5 m cable): H16223
Proximity switch 24V DC, PNP, 11 mm DIA. (cable box): H16432
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.

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Double Seat Mix Proof Valve
APV DELTA DA4
Instruction Manual: UK - rev. 1
APV
6. Cleaning
In the cleaning process of DA4 valves, distinction is made between
three areas: Flow areas, Seal surfaces and seat area, and Leakage
chamber.
6.1. Flow areas
The CIP-fluid cleans the upper and lower passages of the valve
during CIP.
6.2. Seal surfaces and seat area
The seal surfaces of the upper area (upper shaft and seat seal) and
the lower area (lower shaft and seat seal) are flushed and cleaned
when the individual valve shafts are lifted during cleaning. The seat
area and leakage chamber are also cleaned during this process.
6.3. Leakage chamber
CIP spraying cleans the leakage chamber. The cleaning connection
is at item C in fig. 6.3.
CIP spraying does not produce pressure build-up in the leakage
chamber. SPX FLOW recommends performing CIP-spraying in
the closed valve position; however, it can also be done in the open
valve position.
Under standard conditions 15 valves DN 40-100 / 1,5"-4" can be
cleaned via one spray distribution line DN 25.
6.4. Cleaning recommendation
Cleaning steps Seat lifting cycle CIP spraying
pre-flushing – 3 x 10 sec.
caustic flushing 80°C 3 x 5 sec. 3 x 10 sec.
intermediate flushing 2 x 5 sec. 2 x 10 sec.
acid flushing 3 x 5 sec. 3 x 10 sec.
subsequent flushing 2 x 5 sec. 2 x 10 sec.
- The lifting cycles refer to a cleaning pressure of p = 2-5 bar.
- Depending on the pressure ratio, cleaning temperatures, cleaning
steps and degree of soiling, different cycles must be adjusted.
- Flushing quantities per CIP spraying cycle:
DN 40-100/1,5-4" about 1,2 ltr/10s
- Cleaning pressure at CIP cleaning connection: min. 2 bar
max. 5 bar
Caution!
The cleaning liquid applied must be compatible with the respective
seal material.
C
CIP spraying
free drain
CIP liquid
fig. 6.3.
!

pressure in bar
DN 40, 50, 65
Inch 1,5", 2",
2,5", 3"
DN 80, 100
Inch 4"
0,1 1 2 3 4 5
5000
4500
4000
3500
3000
2500
2000
1500
1000
500
0
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Double Seat Mix Proof Valve
APV DELTA DA4
Instruction Manual: UK - rev. 1
APV
6. Cleaning
6.5. Flushing quantity in ml per lifting cycle / 5 sec.
6.6. Cleaning of upper area (g. 6.6.)
The upper valve shaft is lifted via connection (2), as shown in g.
4.1 on page 8.
Through the lifting of the upper valve shaft, the cleaning uid ushes
over the upper seat seal and the upper valve seat into the leakage
chamber and cleans this area. The cleaning uid is drained off to
the bottom in a depressurized state.
Simultaneously, the upper shaft seal and the outer surface of the
upper valve shaft are cleaned. The cleaning uid is guided into the
leakage chamber and drained off to the bottom.
The lifting stroke is limited by a metallic stop.
6.7. Cleaning of lower area (g. 6.7.)
The lower valve shaft is lifted via connection (3), as shown in g. 4.1
on page 8.
By lifting the lower valve shaft, the cleaning uid ushes over the
lower seat seal into the leakage chamber and cleans this area. The
cleaning uid is drained off to the bottom in a depressurized state.
Simultaneously, the lower shaft seal and the outer surfaces of the
lower valve shaft are cleaned. The cleaning uid is drained off to the
bottom in a depressurized state.
The lifting stroke is limited by a metallic stop.
fig. 6.6.
fig. 6.7.

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Double Seat Mix Proof Valve
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Instruction Manual: UK - rev. 1
APV
7. Installation and Commissioning
- The valve must be installed in vertical position to ensure that
fluids can drain off freely from the valve housing and the leakage
chamber.
Caution! Leakages and fluid losses from seat lifting and CIP
spraying must be safely collected and drained!
- The valve housing can be welded directly into the pipeline
(completely removable valve insert).
Note! Observe welding instructions.
- Observe heights of installation and dismantling!
Caution!
Before first startup:
- Actuate the valve by applying compressed air. The opening, closing
and seat lifting processes must run smoothly.
- Check the function of the control unit or valve position indication.
- Check for possible leakages during commissioning. Replace
defective seals.
7.1. Welding Instructions
- Before welding the valve, remove the valve insert from the housing.
Caution! Handle and store the valve insert carefully to avoid
damaging the part.
- It is not necessary to remove the lower shaft seal as it can be
destroyed during removal.
- Welding should only be carried out by certied welders (DIN EN ISO
9606-1) (seam quality DIN EN ISO 5817).
- 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 recommended.
Caution! 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.
- Welding directives for aseptic applications shall be drawn from the
AWS/ANSI Directives and EHEDG Guidelines.
!
!
!
!
!

DA44 DA43 DA42
DA41 1-6DA41 1-8 DA41 1-7
housing conguration
CU4 control unit
L 1
A 1
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Double Seat Mix Proof Valve
APV DELTA DA4
Instruction Manual: UK - rev. 1
APV
L
ØDi
ØDa
F
F
A
XY
HB
8. Dimensions / Weights
Dimensions in mm install. dimen.
min. in mm weights in kg
with CU
DN A A1 B Ø Da Ø Di F H L L1 X* Y*
40 589 672 120 41 38 125 63 772 855 930 200
50 593 676 126 53 50 125 75 794 877 940 218
65 601 684 134 70 66 125 91 826 909 650 242 18,7
80 678 761 146 85 81 142,5 106 930 1013 1030 274
100 688 771 156 104 100 142,5 125 969 1052 1040 303
Inch
1,5" 588 671 119 38,1 34,8 125 63 770 853 930 197 16,5
2" 594 677 125 50,8 47,6 125 75 794 877 940 216 17,6
2,5" 598 681 131 63,5 60,3 125 85,3 814,3 897,3 950 233 18,5
3" 604 687 137 76,1 72,9 125 97,9 838,9 921,9 960 251 18,8
4" 689 772 155 101,6 97,6 142,5 125 969 1052 1050 301 32,5
*Minimum installation and valve insert removal dimensions

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Double Seat Mix Proof Valve
APV DELTA DA4
Instruction Manual: UK - rev. 1
APV
9. Technical Data
9.1. General data
Product-wetted parts 1.4404, 316L
(DIN EN 10088)
Other parts 1.4301,304
(DIN EN 10088)
Seals
standard EPDM/ PTFE compound
options HNBR/ PTFE compound
FPM/ PTFE compound
Max. line pressure 10 bar
Max. operating temperature 135 °C EPDM, HNBR
*FPM
Short-term load 140 °C EPDM, HNBR
*FPM
*no steam
Tightening torque for stop sleeve 10 Nm
Tightening torque for safety nuts at
lower and upper valve shaft 40 Nm
Spray connection PP
Ø Cleaning connection
DN 40–100/1,5-4" 8 x 1 mm
Ø Air connection 6 x 1 mm, 1/4" OD
Max. pneumatic air pressure 8 bar
Min. pneumatic air pressure 5 bar
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.

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Double Seat Mix Proof Valve
APV DELTA DA4
Instruction Manual: UK - rev. 1
APV
9. Technical Data
9.3. Kvs values in m³/hr
DN
40 48 44 24 24
50 91 75 48 46
65 184 150 74 74
80 205 170 131 126
100 335 246 170 156
Inch
1,5" 42 38 24 23
2" 83 71 46 46
2,5" 147 122 67 67
3" 183 160 83 82
4" 329 237 167 156
9.4. Air consumption / Switching times
Air consumption at 5 bar Switching times in seconds
at 5 bar / CU43
Actuator Seat lift actuator
DN Inch NL/stroke
valve open
NL/stroke
upper seat lift
NL/stroke
lower seat lift Open Closed
40 1,5" 1,7 3,4 0,3 1,5 1,8
50 2" 1,8 3,4 0,3 1,5 1,8
65 2,5" 2,0 3,4 0,3 1,7 2,0
3" 2,0 3,4 0,3 1,7 2,0
80 4" 3,7 7,7 0,4 2,6 3,3
100 3,7 7,7 0,4 2,6 3,3

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APV DELTA DA4
Instruction Manual: UK - rev. 1
APV
9. Technical Data
9.5. Valve stroke / Opening cross section
Dimensions in mm
DN A B C stroke H1 stroke H2
upper shaft lower shaft
40 4 5 21,2 34 28
50 11 10 21,2 39 33
65 21 16 21,2 45 39
80 31 21 35,2 50 44
100 50 21 35,2 50 44
Inch
1,5" 4 5 21,2 34 28
2" 11 10 21,2 39 33
2,5" 15 16 21,2 45 39
3" 28 16 21,2 45 39
4" 50 21 35,2 50 44
H2
B
A
C
H1
valve
closed
valve
open

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Instruction Manual: UK - rev. 1
APV
10. Maintenance
Note!
The maintenance intervals are different depending on the
application and must be determined by the operator performing
regular checks.
- Compressed air is not required to remove the valve.
Caution!
Do not clean the valve with products containing abrasive or
polishing substances. Abrasive and polishing agents are especially
harmful to the upper and lower shaft.
Required tools for standard maintenance:
- 1 x wrench SW13, SW24, SW30, SW32
- 2 x wrench SW17
- 1 x Allen key SW3, SW6
- disassembly and assembly tool for lower shaft seal, see page 24
- assembly tool for middle seal, see page 25
- For valve maintenance SPX FLOW offers complete seal kits (see
spare parts lists).
Caution!
The use of seal materials being compatible with the product,
application and CIP liquids must be ensured. In case of doubt,
contact your local SPX FLOW representative.
- For seal replacement instructions, see pages 20 and 21.
- Provide all seals with a thin layer of grease before their installation!
Recommendation:
Assembly grease for EPDM, HNBR and FPM (Viton)
0,75 kg/tin - ref.-No. 000 70-01-019/93; H147382
60 g/tube - ref.-No. 000 70-01-018/93; H147381
- Provide all screws and threaded parts with grease before their
installation.
Recommendation: Klüber paste UH1 84-201
60 g/Tube - ref.-No. 000 70-01-016/93; H147379
Recommendation for actuator:
Pneumatic grease:
25 ml/tube - ref.-No. 000 70-01-008/93; H164725
- For valve assembly instructions, see page 21.
!
!
!

21
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Double Seat Mix Proof Valve
APV DELTA DA4
Instruction Manual: UK - rev. 1
APV
11. Service Instructions
The item numbers refer to the spare parts drawings
DIN and Inch designs: RN 502.047.01
For the Disassembly/Assembly tools, see chapter 13.
11.1. Removal from the line system
Caution!
1. Shut off the line pressure in the product and cleaning lines, and
discharge the pipes if possible.
2. Remove the compressed air lines from the valve actuator (21).
3. Release the 2 screws at the clamp rings and lift the control unit off
the adapter.
4. Design with proximity switch holder:
Release the screws at the proximity switch holder and lift off the
proximity switch holder.
5. Remove the flange screws (30) in the yoke (6).
6. Screw one flange screw (30) into the threaded bore of the yoke (6)
to lift the complete valve insert. Do not remove the screw. It helps to
re-install the valve insert.
7. Carefully lift the valve insert vertically out of the valve housing (1).
clamp ring
1
30
6
fig. 11.1.
!

operating cam
upper shaft
26
7
27
21
6
16
15
13, 14
24
detail x
3
19
13, 14
12
12
detail x
fig. 11.2.
operating cam
lower shaft
4 screws
18
9
11
5
11
10
20
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Instruction Manual: UK - rev. 1
APV
11. Service Instructions
11.2. Removal of product-wetted parts
1. Remove the lower and upper housing seal (12) from the valve seat
(4).
2. Release the lower safety nut (19). Hold the lower shaft (3) with an
SW17 wrench to keep it from turning.
3. After removing the nut (19), lift off the lower shaft (3).
4. Place the point of the tool along the side of the middle seal (10) and
pull it out of the groove. Take the quad ring (18) out of the groove.
5. Remove the operating cam from the guide rod (7).
6. In order to take off the adapter, remove the 4 screws.
7. Remove the stop screw (26).
8. Take the guide rod (7) out through the top of the actuator and
remove the O-ring (9).
9. Remove the operating cam at the upper shaft.
10. Unscrew the safety nut (27). Hold up the lock washer (28) with a
SW30 key to keep it from turning. Remove the lock washer.
11. Lift off the actuator (21) with yoke (6).
12. Press the upper valve shaft (2) with seat ring (5) to the bottom out of
the valve seat (4).
13. Slide the seat ring (5) over the balancer of the upper valve shaft (2).
14. Remove the seat seals (11) from the grooves.
15. Removing the upper shaft seal (13, 14)
Place the point of a tool along the side of the seat seal (13) and pull
it out of the valve seat, then remove the PTFE seal (14).
16. Remove the quad ring (15) and guide ring (16) from the groove of
the valve seat (4).
17. Removing the lower shaft seal from the housing
Place the point of the disassembly tool along the side of the seat
seal (13) and pull it out through the top of the housing. Then remove
the PTFE seal (14) through the top of the housing, using the mandril
of the assembly tool, see page 20.
28