SPX FLOW Waukesha Cherry-Burrell DA4 User manual

DA4
DOUBLE SEAT MIX PROOF VALVE
FORM NO.: H338798 REVISION: US-2 READ AND UNDERSTAND THIS MANUAL PRIOR TO OPERATING OR SERVICING THIS PRODUCT.
INSTRUCTION MANUAL

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WCB_DA4_US-2_032020.indd
DA4 Series
Double Seat Mix Proof Valve
Instruction Manual: US - rev. 2
Waukesha Cherry-Burrell brand DA4 Valve
Content Page
DA4 Inch and DIN designs RN 502.047.01
1. General Terms 4
2. Safety 4
2.1 Symbols
2.2 Safety Instructions
3. Intended Use 5
4. Mode of Operation 6
4.1. General terms
4.2. Valve in "closed" position
4.3. Valve in "open" position
5. Control Units / Valve Position Indication 8
5.1. Control unit and adapter
5.2. Valve position indication
6. Cleaning 9
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 11
7.1. Welding Instructions
8. Dimensions / Weights 12
9. Technical Data 13
9.1. General data
9.2. Compressed air quality
9.3. Cvs values
9.4. Air consumption / Switching times
9.5. Valve stroke / Opening cross section
10. Maintenance 16
11. Service Instructions 17
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 21
12.1 Removing the actuator screws
12.2 Installing the seals and assembling the actuator
13. Assembly Instructions and Tools for Seals 22
13.1. Lower shaft seal
13.2. PTFE seal
13.3. Seat seal
13.4 Middle Seal
14. Trouble Shooting 24
15. Spare Parts Lists 24

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WCB_DA4_US-2_032020.indd
DA4 Series
Double Seat Mix Proof Valve
Instruction Manual: US - rev. 2
Waukesha Cherry-Burrell brand DA4 Valve
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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!
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DA4 Series
Double Seat Mix Proof Valve
Instruction Manual: US - rev. 2
Waukesha Cherry-Burrell brand DA4 Valve
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-o󰀨 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 a󰀨ect safety as well
as the intended functionality of the valves and are not permitted.
SPX FLOW Valves are intended for use in the food and beverage
industries, as well as in pharmaceutical and chemical applications.
SPX FLOW Valves (without safety function) are allocated to
Category 1 and are evaluated as per Conformity Assessment
Module A of the Pressure Equipment Directive 2014/68/EU.
According to Article 13, the following allocation applies for the uids
processed in the valves.
Product media – Fluid group 2 – valves in all dimensions.
CIP-cleaning liquids – Fluid group 1 – valves in the dimensions
≤ 4“ (DN100) can be used at temperatures up to 284°F (140°C),
valves in the dimensions > 4“ (DN100) at temperatures up to 212°F
(100°C).
Authorizations and External Approvals
To view the certications for this and other innovative SPX FLOW
products, visit
https://www.spxow.com/en/waukesha-cherry-burrell/about-us/
certications/
It is within the responsibility of the plant operator to evaluate
and verify the suitability of SPX FLOW products for the intended
purpose and service conditions, as well as to determine and follow
the applicable laws for the intended applications and areas of
application.
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DA4 Series
Double Seat Mix Proof Valve
Instruction Manual: US - rev. 2
Waukesha Cherry-Burrell brand DA4 Valve
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.
3
1
2
E
C
actuator
CU4
control unit
adapter
valve housing
drain pipe
spray connection
fig. 4.1
operating cams
prox. switch holder
DA4 with valve position indication
valve
closed
valve
open
fig. 4.1.2.

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DA4 Series
Double Seat Mix Proof Valve
Instruction Manual: US - rev. 2
Waukesha Cherry-Burrell brand DA4 Valve
A
B
fig. 4.3.
A
B
L
fig. 4.2.
4. Mode of Operation
4.2. Valve in "closed" position
The lower and upper valve shaft are in closed position and safely
separate the di󰀨erent 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.

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DA4 Series
Double Seat Mix Proof Valve
Instruction Manual: US - rev. 2
Waukesha Cherry-Burrell brand DA4 Valve
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 di󰀨erent designs are available:
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: 0.196" (5 mm)
diameter: 0.433" (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.
Designation
Ø Air connection 1/4" OD
CU4 Control Unit
Direct Connect CU43-D4 Direct Connect
H336960
Direct Connect M12 CU43-D4-M12
Direct Connect M12
H341352
AS-interface
extended
CU43-D4 AS-i extended
H336962
AS-interface extended M12 CU43-D4-M12
AS-i extended M12
H338901
AS-interface standard CU43-D4 AS-i standard
H338153
AS-interface standard M12 CU43-D4-M12
AS-i standard M12
H338903
Adapter CU4 adapter D4
H337098
CU4plus Control Unit
AS-interface extended V1 CU43plus-D4-V1
AS-i extended V1
H338824
AS-interface extended V1 M12 CU43plus-D4-V1-M12
AS-i extended V1 M12
H338869
Adapter CU4plus adapter D4 V1
H336441

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DA4 Series
Double Seat Mix Proof Valve
Instruction Manual: US - rev. 2
Waukesha Cherry-Burrell brand DA4 Valve
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 1.5"-4" (DN40-100) can be
cleaned via one spray distribution line 1" (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 = 29 - 72 psi
(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:
1.5"-4" (DN40-100) about 0.32 US gal/10s (1.2 ltr/10s)
- Cleaning pressure at CIP cleaning connection:
min. 29 psi (2 bar)
max. 72 psi (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.
!

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DA4 Series
Double Seat Mix Proof Valve
Instruction Manual: US - rev. 2
Waukesha Cherry-Burrell brand DA4 Valve
6. Cleaning
6.5. Flushing quantity in gallons 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 6.
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 o󰀨 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 o󰀨 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 6.
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 o󰀨 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 o󰀨 to the
bottom in a depressurized state.
The lifting stroke is limited by a metallic stop.
pressure in psi
Inch 1.5", 2",
2.5", 3"
DN 40, 50, 65
Inch 4"
DN 80, 100
1.5 14.5 29 43.5 58 72.5
1.32
1.18
1.06
0.92
0.79
0.66
0.53
0.40
0.26
0.13
0
fig. 6.6.
fig. 6.7.

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DA4 Series
Double Seat Mix Proof Valve
Instruction Manual: US - rev. 2
Waukesha Cherry-Burrell brand DA4 Valve
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 0.12" (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.
!
!
!
!
!

44 43 42
41 (16)41 (18) 41 (17)
housing conguration
CU4 control unit
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DA4 Series
Double Seat Mix Proof Valve
Instruction Manual: US - rev. 2
Waukesha Cherry-Burrell brand DA4 Valve
8. Dimensions / Weights
Dimensions in IN install. dimen. min.
in IN
weights
in lb.
with CU
Size A A1 B Ø Da Ø Di F HL L1 X* X1* Y*
1.5" 23.1 26.4 4.7 1.5 1.4 4.9 2.5 30.3 33.6 32.1 35.2 7.8 36.4
2" 23.4 26.7 4.9 2.0 1.9 4.9 3.0 31.3 34.5 33.2 36.4 8.5 38.8
2.5" 23.5 26.8 5.2 2.5 2.4 4.9 3.4 32.1 35.3 34.2 37.4 9.2 40.8
3" 23.8 27.0 5.4 3.0 2.9 4.9 3.9 33.0 36.3 35.4 38.6 9.9 41.4
4" 27.1 30.4 6.1 4.0 3.8 5.6 4.9 38.1 41.4 40.9 44.1 11.9 69.2
*Minimum installation and valve insert removal dimensions
NOTE: Add the following approximate dimension to “F” for each clamp port connection 0.5" for valve sizes
1.5" - 3.0", 0.62" for valve size 4".

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DA4 Series
Double Seat Mix Proof Valve
Instruction Manual: US - rev. 2
Waukesha Cherry-Burrell brand DA4 Valve
9. Technical Data
9.1. General data
Product-wetted parts AISI 316L (1.4404)
(DIN EN 10088)
Other parts AISI 304 (1.4301)
(DIN EN 10088)
Seals
standard EPDM/ PTFE compound
options HNBR/ PTFE compound
FPM/ PTFE compound
Max. line pressure 145 psi (10 bar)
Max. operating temperature 275°F
(135°C) EPDM, HNBR
*FPM
Short-term load 284°F
(140°C) EPDM, HNBR
*FPM
*no steam
Tightening torque for stop sleeve 7 ft-lb (10 Nm)
Tightening torque for safety nuts at
lower and upper valve shaft 29 ft-lb (40 Nm)
Spray connection PP (polypropylene)
Ø Cleaning connection
DN 40–100/1.5-4" 0.315 x 0.039" (8x1 mm)
Ø Air connection 1/4" OD
Max. pneumatic air pressure 116 psi (8 bar)
Min. pneumatic air pressure 72 psi (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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DA4 Series
Double Seat Mix Proof Valve
Instruction Manual: US - rev. 2
Waukesha Cherry-Burrell brand DA4 Valve
9. Technical Data
9.3. Cvs values in gpm
Size
1.5" 49 44 28 27
2" 96 82 53 53
2.5" 170 141 77 77
3" 212 185 96 95
4" 380 274 193 180
9.4. Air consumption / Switching times
Air consumption at 72 psi (5 bar) Switching times in seconds
at 72 psi (5 bar) / CU43
Actuator Seat lift actuator
Size ft³/stroke
valve open
ft³/stroke
upper seat lift
ft³/stroke
lower seat lift Open Closed
1.5" 0.06 0.12 0.011 1.5 1.8
2" 0.06 0.12 0.011 1.5 1.8
2.5" 0.07 0.12 0.011 1.7 2.0
3" 0.07 0.12 0.011 1.7 2.0
4" 0.13 0.27 0.014 2.6 3.3

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DA4 Series
Double Seat Mix Proof Valve
Instruction Manual: US - rev. 2
Waukesha Cherry-Burrell brand DA4 Valve
9. Technical Data
9.5. Valve stroke / Opening cross section
Dimensions in IN
Size A B C stroke H1 stroke H2
upper shaft lower shaft
1.5" 0.15 0.96 0.83 1.33 1.10
2" 0.43 0.39 0.83 1.53 1.29
2.5" 0.59 0.62 0.83 1.77 1.53
3" 1.10 0.62 0.83 1.77 1.53
4" 1.96 0.82 1.38 1.96 1.73
H2
B
A
C
H1
valve
closed
valve
open

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DA4 Series
Double Seat Mix Proof Valve
Instruction Manual: US - rev. 2
Waukesha Cherry-Burrell brand DA4 Valve
10. Maintenance
Note!
The maintenance intervals are di󰀨erent 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
- 1 x wrench SW36
- 2 x wrench SW17
- 1 x Allen key SW3, SW6
- pick tool for O-ring and rubber seal removal
- disassembly and assembly tool for lower shaft seal, see page 22
- assembly tool for middle seal, see page 23
- 2 long M8 hex screws for safe removal of valve insert
- 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 18 and 19.
- 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 - Part no. H147382
60 g/tube - Part no. H147381
- Provide all screws and threaded parts with grease before their
installation.
Recommendation: Klüber paste UH1 84-201
60 g/Tube - Part no. H147379
Recommendation for actuator:
Pneumatic grease:
25 ml/tube - Part no. H164725
- For valve assembly instructions, see page 19.
!
!
!

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DA4 Series
Double Seat Mix Proof Valve
Instruction Manual: US - rev. 2
Waukesha Cherry-Burrell brand DA4 Valve
11. Service Instructions
The item numbers refer to the spare parts drawings
Inch and DIN 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). For additional safety,
replace two flange screws with longer screws that are partially
threaded into the flange. Once these longer screws are in place, the
other two flange screws can be safely removed.
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).
21
clamp ring
1
30
6
fig. 11.1.
!

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DA4 Series
Double Seat Mix Proof Valve
Instruction Manual: US - rev. 2
Waukesha Cherry-Burrell brand DA4 Valve
11. Service Instructions
11.2. Removal of product-wetted parts
1. Remove the operating cam from the guide rod (7).
2. In order to take off the adapter, remove the 4 screws.
3. Remove the lower and upper housing seal (12) from the valve seat
(4).
4. Release the lower safety nut (19). Hold the lower shaft (3) with an
SW17 wrench to keep it from turning.
5. After removing the nut (19), lift off the lower shaft (3).
6. Place the point of the pick 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.
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.
detail x
11
5
11
10
operating cam
upper shaft
26
7
27
21
6
16
15
13, 14
24
detail x
3
19
13, 14
12
12
fig. 11.2.
operating cam
lower shaft
4 screws
18
9
28

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DA4 Series
Double Seat Mix Proof Valve
Instruction Manual: US - rev. 2
Waukesha Cherry-Burrell brand DA4 Valve
11. Service Instructions
11.3. Installation of product-wetted seals and assembly of the valve
Note! Make sure that all seals and bearing surfaces in
the product area are slightly greased before
their installation.
1. Install the lower shaft seal (13, 14) in the lower housing ange.
2. Place the quad ring (15) and the guide ring (16) in the valve seat
(4).
3. Installing the upper shaft seal (13, 14) in the valve seat (4).
Insert the PTFE ring (14), rst. Then press the seat seal (13), the
wide side to the front, into the groove between the PTFE seal (14)
and the valve seat (4).
4. Install the upper and lower housing seals (12).
5. Press the upper and lower seat seal (11) into the seat ring (5).
Note! The seal shoulder must t properly into the groove.
6. Slide the seat ring (5) (the larger diameter to the bottom) from the
top over the balancer of the upper valve shaft (2).
7. Slide the valve seat (4) over the balancer of the upper valve shaft
(2) in the same way.
8. Insert the upper valve shaft (2) with seat ring (5) and valve seat (4)
through the yoke (6) and actuator (21) until it stops.
9. Align key and fasten the upper valve shaft (2) with the lock washer
(28) and safety nut (27). Hold the lock washer with a SW30 wrench
to keep the safety nut (27) from turning.
Tightenting torque: 29 ft-lb (40 Nm)
Caution! Overtightening of the safety nut could result in
thread damage on the upper shaft.
10. Screw the operating cam on the upper shaft.
11. Insert the middle seal (10) into the lower shaft (3) using the
assembly tool (see page 21).
12. Assembling without the assembly tool:
Press the slightly greased seal into the groove at four locations.
Then push in the four loops of seal with a blunt object. Vent the seal
groove.
13. Insert the quad ring (18) in the lower shaft (3).
14. Install the O-ring (9) at the guide rod (7).
15. Ensure the key is secure on the guide rod. Slide in the guide rod (7)
from the top through the actuator (21) until it stops.
16. Screw in the stop screw (26) until it stops.
Tightening torque Md = 10 Nm
The stop screw must be ush with the top of the piston.
Note! Check the position of the lower seat seal (11).
operating cam
upper shaft
26
7
28
27
21
6
16
15
13, 14
24
detail x
3
19
13, 14
12
12
fig. 11.3.
operating cam
lower shaft
4 screws
18
9
detail x
11
5
11
10
!
!
!

20
WCB_DA4_US-2_032020.indd
DA4 Series
Double Seat Mix Proof Valve
Instruction Manual: US - rev. 2
Waukesha Cherry-Burrell brand DA4 Valve
11. Service Instructions
17. Slide the lower valve shaft (3) on the guide rod (7). Align key and
fasten it with the safety nut (19).
Tightening torque: 29 ft-lb (40 Nm)
18. Fasten the adapter on the actuator with the 4 screws and ensure
that the air ttings on the control unit will align properly with the air
ttings on the DA4 valve.
19. Screw the operating cam on the guide rod (7).
11.4. Installation of the valve insert
1. Carefully place the valve insert in the valve housing (1) until the
screw stops.
2. Remove the jacking screw and carefully press the valve insert into
the housing (1).
3. Screw in the hex. screws (30) and fasten them crosswise.
4. Place the control unit on the adapter. Make sure that the control unit
is centered on the adapter.
5. Place the clamp ring and fasten it with the screws.
6. Assemble the compressed air lines.
Air connection 1: to open valve
Air connection 2: to lift upper shaft
Air connection 3: to lift lower shaft
7. Check the valve position indicators
Closed valve position feedback – sensor 1 controlled
To adjust Hall sensor 1, ensure that the valve is in the closed
position, the solenoid / manual override are not activated. Turn
adjustment screw 3 into the required position. The LED "Valve
Closed" lights up.
Open valve position feedback – sensor 2 controlled
To adjust Hall sensor 2, rst activate the solenoid valve 1, either
manually or electrically. Then turn adjustment screw 1, to adjust
the open valve position and the corresponding feedback. When it
reaches the required position, the LED “Valve Open” lights up.
Observe the switching hysteresis of the Hall effect sensors!
Therefore, adjust the switch point of the sensors with overlap in
order to permit small variations. We recommend additional 2 x 360°
turns of the adjustment screw.
8. Design with proximity switch holder:
Set the proximity switch holder in position and fasten it with
the screws. Check to see if the “Valve Closed” or “Valve Open”
message appears. Re-position the proximity switch if required.
fig. 11.4.
jacking
screw
3
1
2
1
valve
insert
operating cams
prox. switch holder
DA4 with valve position indication
valve
closed
valve
open
fig. 11.4.1.