SPX FLOW APV DELTA DKR2 User manual

APV DELTA DKR2 DN25-100, 1”-4”
DOUBLE SEAT BALL VALVE
SAFETY AGAINST EXPLOSION - FOR SPECIFIC ATEX-APPLICATIONS
FORM NO.: H336346 REVISION: UK-0-ATEX 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
APV double seat ball valves of the series DKR2 ATEX design
in the nominal diameters DN 25 – 100, 1“ – 4“
meet the requirements of:
Machinery Directive 2006/42/EC
(superseding 89/392/EEC and 98/37/EC)
and ProdSG (superseding GPSG - 9.GPSGV)
and
Directive on the Protection against Explosion 2014/34/EU ATEX (superseding 94/9/EC)
for Equipment Category -/2D IIB TX
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 comply with
the basic requirements on safety and health, incl. an analysis of the risks,
an analysis of ignition hazards as well as an instruction manual with safety instructions.
The conformity of the valves is guaranteed.
An ATEX documentation is lodged at the notified body DEKRA EXAM GmbH
in Bochum, Germany (No. 0158).
Authorised person for the documentation:
Frank Baumbach
SPX Flow Technology Germany GmbH
Gottlieb-Daimler-Str. 13, D-59439 Holzwickede, Germany
November 2017
Frank Baumbach
Regional Engineering Manager, F&B Components

1
APV_DKR2 ATEX_UK-0_022018.indd
UK
Double Seat Ball Valve DELTA DKR2
ATEX Design
Instruction Manual: UK-0
APV
Content Page
1 General Terms 2
1.1. Symbols
1.2. ResponsibilityforATEXcertication-Scopeofsupply
2. Safety Instructions 3 - 4
3. Identicationofvalves,Temperatureclasses,Responsibilites  5-6
3.1. IdenticationofvalvesforapplicationinATEXenvironment
3.2. Temperature classes and permissible temperatures
3.3. Responsibilities
4. IntendedUse  6
5. ModeofOperation  7-8
5.1. General terms
5.2. Potential equalization
5.3. Operating leakage reduction
5.4. Operating leakage drain
6. Cleaning  9
6.1. Cleaning recommendation
7. Installation        10
7.1. Welding instructions
7.2. Assembly inserts
8. Dimensions/Weights  11
9. TechnicalData  12–13
9.1 General data
9.2. Compressed air quality
9.3. Max. tightening torque in Nm
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  13
11. Maintenance  14-15
12. ServiceInstructions  16-19
12.1. Dismantling from 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 flanges
12.5.2. Adjustment of operating position without FG flanges
13. ServiceInstructions  20-21
13.1. Leakage reduction for DKR ball valve
13.1.1. Installation of the leakage reduction
13.2. Leakage drain for DKR ball valve
13.2.1 Installation of leakage drain
14. DetectionofSealDamage  22
15. SparePartsLists
Double seat ball valve 1+2S Ex II -/2D IIB TX RN ATEX 01.071
Turning actuator K-80, K-125, K-180 RN 01.073

2
APV_DKR2 ATEX_UK-0_022018.indd
UK
Double Seat Ball Valve DELTA DKR2
ATEX Design
Instruction Manual: UK-0
APV
1. General Terms
This instruction manual applies for the double seat ball valve range
of the DKR2 series in the nominal dimensions DN 25-100, 1"-4" for
use in specific ATEX applications (according to Directive 2014/34/
EU).
The valve must only be assembbled, operated, disassembled,
maintained and serviced by trained personnel. Please contact your
local SPX FLOW representative if required.
This instruction manual must be read and observed by the
responsible 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.
1.1. Symbols
This symbol draws your attention to important directions which have
to be observed with regard to the operation in explosive areas.
This technical safety symbol draws your attention to important
directions for operating safety. You will find it wherever the activities
described are bearing health hazards or risks for persons or
material assets.
1.2. ResponsibilityforATEXcertification-scopeofsupply
SPX FLOW will be held responsible only for the valves supplied
and selected according to the operating conditions indicated by the
customerorenduserandasstatedintheorderconrmation.Ifin
doubt, contact your SPX FLOW partner.
All other assembled equipment and devices must have a separate
certication,providedbythesupplier(s)ofthatequipmentand
devices, of at least the same or higher grade of protection as the
valvesuppliedbySPXFLOW.Thecompleteunitmustbecertied
separatelybythenalassemblingmanufacturerandmusthavea
separate name plate supplied by the unit manufacturer.

3
APV_DKR2 ATEX_UK-0_022018.indd
UK
Double Seat Ball Valve DELTA DKR2
ATEX Design
Instruction Manual: UK-0
APV
2. Safety Instructions
Danger!
Do not touch the open valve ball or the yoke!
Risk of injury due to sudden valve operation.
Risk of injury in dismantled valve state due to sudden valve
operation.
- Regular maintenance including the replacement of all seals and
bearing bushes must be scheduled in order to prevent leakages and
discharge of liquids
- Remove the turning actuator before seal replacement.
- 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.
- Before any maintenance work, the line system must be
depressurized and discharged if possible.
- Separate all electric and pneumatic connections.
- Observe the following Service Instructions to ensure safe
maintenance of the valve.
Danger!
Welded actuators are preloaded by spring force.
Openingoftheactuatorsisstrictlyforbidden.
Dangertolife!
Actuators which are no longer used or defective must be diposed in
professional manner.
Defective actuators must be returned to your SPX FLOW
representative for their professional disposal and free of charge for
you.
Please address to your local SPX FLOW representative.

4
APV_DKR2 ATEX_UK-0_022018.indd
UK
Double Seat Ball Valve DELTA DKR2
ATEX Design
Instruction Manual: UK-0
APV
2. Safety Instructions
Installation, connection, start-up, maintenance and repair work must
onlybecarriedoutbyqualiedpersonnel.
The following aspects must be observed:
- The instructions of this manual together with all relevant instructions
for the components, equipment and installations installed.
- Warningsandinstallationsxedtothecomponents.
- Thespecicregulationsforandrequirementstothesysteminwhich
the valve is installed.
- The currently valid regional, national and international regulations.
- The potential equalization between ball and housing by means of
the spring must generally be ensured.
- Any special requirement and national legislation relative to
theuseofammableliquidsortools,e.g.theriskofignition
in case of spark formation, must be observed.
It must be ensured that the group, the category and the temperature
class of the valve complies with the minimum requirements of the
operating environment!
Inammablegasmixturesordustconcentrationsinconnectionwith
hot, operational and movable parts of the valve can lead to serious
or fatal injury!
Before start of assembly the operator must make sure that an
explosive atmosphere does not exist (detection/measurement of
potential concentration of hazardous substances).
Conductive connection to the pipeline must be provided.
The integration into the internal potential equalization must be
guaranteed!
The APV CU2, CU3 and CU4 Control Units are not suited for use in
ATEX environments!

5
APV_DKR2 ATEX_UK-0_022018.indd
UK
Double Seat Ball Valve DELTA DKR2
ATEX Design
Instruction Manual: UK-0
APV
3. Identicationofvalves,
Temperatureclasses,Responsibilities
3.1. IdenticationofvalvesforuseinATEXenvironment
ATEXidentication:
- Equipment group II
- Equipment category outside 2D
inside no equipment
- Explosionsuntergruppe IIB
Ambient temperature for the operation
0°C≤Tamb≤40°C
- temperature classes TX (according to table 3.2)
3.2. Temperatureclassesandpermissibletemperatures
Media temperature ≤75°C ≤95°C ≤130°C
up to
140 °C =
Tmax.
Saftety addition + 5 °C + 5 °C + 5 °C + 5 °C
Temperature class T6 T5 T4 T3
Under standard operating conditions the highest surface
temperature will be comparably as high as the temperature of the
medium plus a safety addition for local temperature increases. The
valve must be completely free to the environment in order to provide
for sufficient heat release.
All data (temperature classes) refer to an ambient temperature
of 0°C to 40°C. If the ambient temperature is above 40°C, the
temperature difference must be adjusted. In all cases, contact your
responsible SPX FLOW representative!

6
APV_DKR2 ATEX_UK-0_022018.indd
UK
Double Seat Ball Valve DELTA DKR2
ATEX Design
Instruction Manual: UK-0
APV
3. Identicationofvalves,
Temperatureclasses,Responsibilities
3.3 Responsibilites
 Itiswithintheoperator`sresponsibilitytoensurethatthespecied
product temperatures are not exceeded and that regular inspections
and maintenance are carried out to provide for proper function of
the valve.
4. IntendedUse
The intended use as field of application of the butterfly valves
is the shut-off of line sections, especially in beverage and food
installations.
Its use is permissible only within the admissible pressure and
temperature margins and under consideration of chemical and
corrosive influences.
Any use exceeding the margins and specifications set forth,
is considered to be not intended.
Any damage resulting therefrom is not within the responsibility
of the manufacturer. The user will bear the full risk.
Attention!
Improper use of the valve leads to:
- damage
- leakage
- destruction.
Failures in the production process are possible.
Warning!
The valve is suitable for use in hazardous areas
as identified on the valve according to Directive 2014/34/EU.
Earthing of the valves must be guaranteed.
Arbitrary, constructive changes at the valve will influence safety
as well as the intended functionality of the valve and arenot
permissible.
AuthorizationsandExternalEvaluations
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/

7
APV_DKR2 ATEX_UK-0_022018.indd
UK
Double Seat Ball Valve DELTA DKR2
ATEX Design
Instruction Manual: UK-0
APV
5. ModeofOperation
5.1. Generalterms
Due to the use of high-quality stainless steel and seal
materials complying with the specified requirements, the
double seat ball valve DELTA DKR2 can be used in the food
and beverage industries as well as in the chemical and
pharmaceutical industries.
TheeldofapplicationoftheDELTADKR2valvecomprisesthe
separationoftwolinesectionswithdifferentuids(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uid
- The valve opens and closes by turning of the valve ball by 90°.
- Cleaning of the leakage chamber by supply of cleaning liquids via
the cleaning connection (E).
- During the switching process, operating leakages drain off from the
leakage drain (D) tot he bottom. 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ush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.
Proximity switches to signal the limit position of the valve ball can be
mounted in the yoke area.
Proximity switch which are permitted for use in explosive
atmospheres must be used, only.
The use and operation of proximity switches must be evaluated by
the operator of the plant!
B C
A
E
D

8
APV_DKR2 ATEX_UK-0_022018.indd
UK
Double Seat Ball Valve DELTA DKR2
ATEX Design
Instruction Manual: UK-0
APV
5. ModeofOperation
5.2. PotentialEqualization
A possible risk may result from a potential difference between the
components. With non-conducting media or empty pipline sections,
a conducting connection must be created between the valve
components. With double seat ball valves, this is reached by the
installation of a spring.
In explosive atmospheres, we generally recommend to ensure the
potential equalization between ball and housing by installation of the
spring mentioned below.
DN25–100/Inch1"–4"
Designation: Referencenumber:
* pressure spring
potential equalization
000-60-06-010/13
H311619
5.3. 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 retrofit kits to reduce the quantity of operating leakages
are available (see page 20).
5.4. Operatingleakagedrain
To discharge operating leakages via a pipeline, retrofit kits
with weld end are available (see page 18).
spring for
potential equalization

9
APV_DKR2 ATEX_UK-0_022018.indd
UK
Double Seat Ball Valve DELTA DKR2
ATEX Design
Instruction Manual: UK-0
APV
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steps CIPspraying
pre-ushing 2× 10 sec.
causticushing80°C 3× 10 sec.
intermedial flushing 2× 10 sec.
acid flushing 3× 10 sec.
final flushing 2× 10 sec.
(withabreakof10sec.each)
- Theushingtimesrefertoacleaningpressureofp=3-5bar.
- Theushingtimesindicatedfortheindividualcleaningstepsare
referencevalues,only.Inspecicapplicationsthesetimesmust
be adjusted depending on the product, the pressure ratio and the
degree of soiling.
- Theushing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 leakages
are 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.
- Attention:Observeweldinginstructions7.1.

10
APV_DKR2 ATEX_UK-0_022018.indd
UK
Double Seat Ball Valve DELTA DKR2
ATEX Design
Instruction Manual: UK-0
APV
7. Installation
7.1. WeldingInstructions
- Welding may only be carried out by certified welders (DIN EN ISO
9606-1). (seam quality DIN EN ISO 5817).
- Theweldingofthematingangesmustbeeffectedinsuchaway
that deformation strain cannot be transfered to the valve body.
- TIG orbital welding is the most appropriate method.
- Before welding, all heat sensitive parts of the valve must be
removed! Dismantle valve ball housing with seals between the
counter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ofthematinganges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 be
carried over to other parts of the installation.
- Any damage resulting from the non-observance of these welding
instructions is not subject to our guarantee.
7.2. Assemblyinsertsforthedoubleseatballvalvesareavailable:
DN Inch ref.-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
Fig.7.2.assemblyinserts

11
APV_DKR2 ATEX_UK-0_022018.indd
UK
Double Seat Ball Valve DELTA DKR2
ATEX Design
Instruction Manual: UK-0
APV
8. Dimensions/Weights
Dimensions in mm
DN A BØD E F Ø G Weightsinkg
25 384 55 26 60,5 109 85 5,7
40 408 65 38 61,0 109 85 6,5
50 425 75 50 79,0 127 85 7,4
65 448 87 66 100,3 149 85 9,2
80 543 103 81 123,0 171 135 18,0
100 572 117 100 150,0 198 135 21,5
Inch
1" 384 55 22,6 60,5 109 85 5,7
1,5" 408 65 34,9 61,0 109 85 6,5
2" 425 75 47,6 79,0 127 85 7,4
2,5" 448 87 60,3 100,3 149 85 9,2
3" 543 103 72,9 123 171 135 18,0
4" 572 117 97,6 150 198 135 21,5
A
B
E
F
Ø G
Ø D

12
APV_DKR2 ATEX_UK-0_022018.indd
UK
Double Seat Ball Valve DELTA DKR2
ATEX Design
Instruction Manual: UK-0
APV
9. TechnicalData
9.1. Generalterms
- 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 3 bar
admission pressure: 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: tighteningtorque 
 2Nm
- spray connection: G1/8"
- cleaning connection for hose: 8x1
9.2. Compressedairquality
- Compressed air quality: quality class according to ISO 8573-1
- Content of solid particles: quality class 3,
max. number of 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, additional
measures must be considered 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.
turning actuator K080 F/L
threaded union – G1/8"
slewable
tightening torque 2 Nm

13
APV_DKR2 ATEX_UK-0_022018.indd
UK
Double Seat Ball Valve DELTA DKR2
ATEX Design
Instruction Manual: UK-0
APV
9. TechnicalData
DN
Inch
25
1"
40
1,5"
50
2"
65
2,5"
80
3"
100
4"
9.3. max.tighteningtorqueinNm (M) 10 15 22 25 40 65
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
9.5. operatingleakageatabout5barinL
withoperatingleakagereduction
(Qs) 0,4 0,7 0,8 1,2 2,4 2,5
9.6. pneum.airconsumptionin6barNL (V) 1,8 1,8 1,8 2,8 5,5 5,5
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
- spring - potential equalization 1.4310 (DIN EN 10088)
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

14
APV_DKR2 ATEX_UK-0_022018.indd
UK
Double Seat Ball Valve DELTA DKR2
ATEX Design
Instruction Manual: UK-0
APV
11. Maintenance
- The maintenance intervals depend on the corresponding application
and are to be determined by the operator himself carrying out
temporary checks.
- Before start of maintenance and assembly the operator must make
sure that an explosive atmohsphere does not exist (detection/
measurement of potential concentration of hazardous substances).
Alternatively, use spark-resistant tools!
- Customer stock keeping of spare seals is recommended.
For valve service actions we supply complete seal kits (see spare
parts lists).
- If damaged seals are replaced, generally all seals and bearings
should be changed.
- Installation and adjustment of turning actuator according to Service
Instructions.
- Dismantling and installation of seals according to Service
Instructions.
- All seals must be slightly greased before their installation.
- The inner parts of the actuator are maintenance free.
Attention! Use food-grade special grease being suited for the
respective seal material, only.
Recommendation:
APV assembly grease for EPDM, FPM, HNBR and NBR
(0,75 kg /can - 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
(0,6 kg /can - 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 for EPDM seals.
! Do not use Silicone-based grease for VMQ seals.
Less suited grease types can influence the function and
life time.

15
APV_DKR2 ATEX_UK-0_022018.indd
UK
Double Seat Ball Valve DELTA DKR2
ATEX Design
Instruction Manual: UK-0
APV
11. Maintenance
Additionally required maintenance for applications in ATEX
environment
Replacement of spring for potential equalization if damaged.
DKR2Valveactuatedversion
Valvemaintenancefor
actuatorwithspring
Note
Functional test,
visual inspection of actuator
movement (turning angle) and
control of abnormal running
noise of spring
1 x per year
Change interval of actuator
(turning actuator)
In case of damage,
incomplete actuator movement
(turning angle), considerable
running noise of spring as well as
after 250,000 cycles* as
preventive measure, however,
after 10 years at the latest.
*complies with about 8 years in 1-shift-operation and 10-15 cycles per hour.