SPX APV DELTA MF4 User manual

Read and understand this manual prior to
operating or servicing this product.
Operating Manual
DELTA MF4
Membrane Valve with Bellow Unit

Content Page
1
Membrane Valve with Bellow Unit
DELTA MF4
Operating Manual rev. 0
DELTA MF4-UK0.qxd / 12.2004
1. General Terms 2
2. Safety Instructions 2
3. Mode of Operation 3
4. Auxiliary Equipment 4
4.1 Valve position indication (proximity switches)
4.2 CONTROL UNIT
4.3 Connections
5. Installation 5
5.1 Welding Instructions
6. Dimensions / Weights 6
7. Technical Data 7 - 8
7.1 Opening and closing times
7.2 kvs values
7.3 valve stroke / opening section
8. Maintenance 9
9. Service Instructions 10 - 12
9.1 Dismantling from the line system
9.2 Disassembly of wear parts (product-wetted parts)
9.3 Installation of seals and Assembly of valve
9.4 Installation of valve insert
10. Service Instructions Actuator 13
10.1 Maintenance of actuator
10.2 Dismantling of seals
10.3 Installation of seals and Assembly of actuator
10.4 Reconstruction of valve design from
NC (normally closed) > NO (normally open) design
11. Service Instructions 14
11.1 Installation of seat seal
12. Trouble Shooting 15
13. Spare Parts Lists
UK

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 technical safety symbol draws your attention to important
directions for operating safety. You will find it wherever the activities
described are bearing risks of personal injury.
-Electric and pneumatic connections must be separated.
-Before any maintenance of the valve, the line and cleaning system
must be depressurized and discharged if possible.
-Do not reach into the open valve.
Risk of injury.
-Observe service instructions to ensure safe maintenance of the
valve. The valve must only be assembled, disassembled and
reassembled by persons who have been trained in APV valves
or by APV service team members. If necessary, contact your
local APV representative.
-If the bellow unit is damaged, leakages drain off the leakage bore
in the yoke area.
-Attention!
With valve design NC (normally closed): control the actuator
with air before releasing the housing screws.
-Attention!Welded actuators are preloaded by spring force.
Opening of the actuators is strictly forbidden.
Danger to life!
Actuators which are no longer used and / or defective
must be disposed in professional manner.
Defective actuators must be returned
to your APV Solutions & Services company
for their professional disposal and free of charge for you.
Please address to your local APV representative.
1. General Terms
2
!
!
!
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DELTA MF4
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3. Mode of Operation
The membrane valves with bellow unit DELTA MF4 have been
developed for use in the brewing and beverage industries,
dairy and food applications as well as in the chemical and
pharmaceutical industries.
The function of the DELTA MF4 valve is to shut off line sections.
The membrane valves with bellow unit offer optimum protection
of the product in hygienic and aseptic applications.
Product safety is provided by the hermetic separation of the product
chamber from the environment (atmosphere) by a metal bellow.
-Operation by pneumatic actuator with air connection,
reset by spring force.
-By different assembly of the actuator, the following designs can
be realized:
NC: actuator normally closed
("fail-down": air-to-raise, spring-to-lower)
NO: actuator normally open
("fail-up": air-to-lower, spring-to-raise)
-The inner parts of the actuator are maitenance-free.
-The cleaning of the inner area of the valve is undertaken during
CIP cleaning of the line system.
-Leakages at the bellow unit are indicated at the leakage drain in
the yoke area.
-For the pneumatic control of the valve, a control unit is installed
on top of the actuator.
-The yellow luminous diodes installed in the control unit indicate
the position of the valve rod.
3
control unit
DELTA CU
DELTA MF4
valve position
indicator
actuator
yoke
leakage
indicator
housing
MF4 standard design
valve seat sealing
by profile seal (seat seal) MFO4 design
valve seat sealing
by o-ring
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DELTA MF4
Operating Manual rev. 0

4.1 Valve position indication (fig. 4.1)
For the valve position indication, a proximity switch holder (PSH)
can be installed direct on the actuator.
To signal the limit position of the valve seat, proximity switches can
be mounted to the holder if required.
We recommend our APV standard types:
operating distance: 5 mm / diameter: 11 mm.
If the user decides to apply valve position indicators other than
APV type, we cannot take over the liability for any malfunctions
resulting therefrom.
4.2 Control Unit (fig. 4.2)
The assembly of a control unit on the MF4 valve is possible.
The following designs are available:
4. Auxiliary Equipment
4
valve position
indication
PSH
fig. 4.2
fig. 4.1
-For the assembly of the control unit on the MF4 valve an adapter
is required.
solenoid valve (SV)
CU31 Direct Connect
16 - 31 - 232/93
CU21V
16 - 31 - 237/93
CU31 Device Net
16 - 31 - 240/93
CU31 AS-interface
16 - 31 - 244/93
Direct Connect
ref.-No.:
Profibus
ref.-No.:
Device Net
ref.-No.:
AS-Interface
ref.-No.:
adapter
CU2 - adapter SW4 / SD4 / M4
08-48-415/93
designation:
ref.-No.:
4.3 Connections:
Beside the housings with weld ends, the following connections
are alternatively available:
-threaded port according to DIN 11851
-threaded port IDF / ISS according to ISO 2853
-threaded port RJT according to BS 4825-5
-threaded port SMS
-threaded port according to DS 722
-flange connection FGN1 DIN
-flange connection FGN1 Inch
-clamp connection according to DIN 32676
-clamp connection according to ISO 2852
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5
-The installation of the valve must be undertaken in such a manner
that fluids can drain off the valve housing and should be provided
preferably in vertical position.
-The valve housing can be welded direct into the pipeline
(completely dismantable valve insert).
-Attention: Observe welding instructions.
5.1 Welding Instructions
-Before welding of the valve, the valve insert must be dismantled
from the housing. Careful handling to avoid damage to the parts
is necessary.
-Welding should only be carried out by certified welders (EN 287-1).
(Seam quality EN 25817 "B").
-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 best!
-After welding of the valve housings or 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.
-Any damage resulting from the non-observance of these welding
instructions is not subject to our guarantee.
5. Installation
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6
6. Dimensions / Weights
DN A A1
409
448
499
508
509
531
348
387
438
447
448
470
17,3
26,5
32,9
39,1
45,0
57,8
22,2
35,1
47,6
60,3
72,9
97,6
50
67
72
85
90
111
28,6
41,1
53,8
68,3
80,1
107,6
86
126
126
189
189
189
459
515
526
593
619
642
398
454
465
532
538
581
BØ Di FHØ K L
50
67
72
85
98
111
32
44
56
74
91
110
459
515
526
593
617
642
398
454
465
532
556
581
4,2
7,1
7,1
7,9
14,2
15,2
4,2
7,1
7,1
15,3
19
28
34
42
49,5
59
L1
25
40
50
65
80
100
26
38
50
66
81
100
86
126
126
189
189
189
348
387
438
447
458
470
weight
in kg
F
K
125
FF
membrane valve with
MEF valve housing
membrane valve with
control unit
membrane valve with
valve positon indicaton (PSH)
1”
1,5”
2”
2,5”
3”
4”
409
448
499
508
519
531
inch
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DELTA MF4
Operating Manual rev. 0

closing times in sec.
control pressure 6 bar
hose length 1m and 10m.
7
Product - wetted parts : 316 L, 1.4404
Other parts : 1.4301
Seals : standard : EPDM
Optional : HNBR, VMQ, FPM
Bellow unit : 1.4404 /1.4571
Actuator : 1.4301
Max. line pressure : 10bar
Max. operating temperature : 135°C EPDM, HNBR
*FPM, *VMQ
short-term steam load : 140°C EPDM, HNBR
*FPM, *VMQ
*(no steam)
Air connection (for hose) : 6x1mm
max. pneumatic air pressure : 8 bar
min. pneumatic air pressure : 6 bar
(Use dry and clean pneumatic air, only )
7. Technical Data
1m 10m
25
40
50
65
80
100
1”
1,5”
2”
2,5”
3”
4”
1
1
3
3
3
5
5
2
2
4
4
4
6
6
DN inch
7.1 The opening and closing times
of the valves equipped with a
control unit DELTA CU
can be fixed by adjusting the
throttle at the soleniod valve.
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Operating Manual rev. 0

8
7. Technical Data
stroke X
1”
1,5”
2”
2,5”
3”
4”
5
8
11
12
20
25,5
3
5,5
8,5
9,5
17,5
21,5
25
40
50
65
80
100
6
11
13,5
17,5
22
28
4
8,5
11
15
19,5
25
inch
DN
dimensions in mm
7.2 DELTA MF4
Kvs - values in m3/ h
DN
25
40
50
65
80
100
1”
1,5”
2”
2,5”
3”
4”
22
42
73
130
342
22
38
70
112
276
inch
7.3 valve stroke / opening section (X)
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DELTA MF4
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9
8. Maintenance
-The maintenance intervals depend on the application and should
be determined by the operator carrying out temporary checks.
-The valve must not be cleaned with products containing abrasive
or polishing substances. Especially the valve shafts must not be
cleaned with such agents under any circumstances. Damage at
the valve shaft can produce leakages.
-Replacement of seals according to Service Instructions.
The customer is recommended to hold spare seals on stock.
For valve maintenance APV supplies complete seal kits including
seal grease (pl. see spare parts lists).
-Tools required:
1 x spanner SW13
1 x spanner SW17
1 x spanner SW19
1 x spanner SW30
1 x strap wrench
-Cleaning rag as well as low solution of a suitable cleaning agent
(observe safety data sheets of cleaning agent manufacturer)
-Slightly grease all seals before their installation !!!!!
Recommendation:
APV food-grade-grease for EPDM, HNBR, FPM and NBR
(0,75 kg/tin - ref.-No. 000 70-01-019/93)
(60 g/tube - ref.-No. 000 70-01-018/93)
or
APV food-grade-grease for VMQ
(0,6 kg/tin - ref.-No. 000 70-01-017/93)
(60 g/tube - ref.-No. 000 70-01-016/93)
!Do not use grease basing on mineral oil for EPDM seals!
!Do not use grease basing on Silicone for VMQ seals!
Recommendation for screw retention
Type: Loctite 243 semi-solid
(5 ml - ref.-No. 00070-01-110/93)
(50 ml - ref.-No. 00070-01-111/93)
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DELTA MF4
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10
9. Service Instructions
9.1 Dismantling from the line system MF4 / MEF4
The item numbers refer to the spare parts darwings
MF4, MEF4: DN design: RN 01.064.6
Inch design: RN 01.064.7
a. Shut off line pressure and discharge lines and tanks if possibe.
b. Valve design NC: control actuator with air.
Do not touch movable parts!
Risk of injury.
c. Remove housing screws (11) and lift complete valve insert
including actuator out of the housing.
d. Valve design NC: cut off compressed air and
remove compressed air supply.
e. CU design:
Remove the control unit.
(Turn safety ring in anticlockwise direction, see symbol on the
control unit.)
= open = closed
-Design with valve position indicator:
Remove the proximity switches. Detach the indicator housing
(proximity switch holder) from the actuator.
9.2 Dismantling of wear parts (product-wetted parts)
a. With CU design and valve position indicator:
First of all, release the actuator screw. Release the hexagon
nut (21), while holding up the centering washer (16). Remove
the centering washer.
b. Pull the shaft with bellow unit (3) and guide rod (9) out of the
actuator (13). Remove the seat seal (2) and o-rings (4, 5).
c. Remove the yoke (8) from the actuator (13).
The actuator is maintainable.
(see 10. Service Instructions, Actuator)
d. Detach the o-ring (6) and the guide bush (7) from the yoke (8).
e. Clean the valve housing, the yoke and the shaft with a low
solution of a cleaning agent. Never use cleaning agents
containing abrasive or polishing substances.
!
actuator screw
hex. nut
centering washer
cu adapter
guide rod
actuator
yoke
housing
guide bush
o-ring (6)
o-ring (4)
o-ring (5)
seat seal
shaft with
bellow unit
control unit
actuator screw
hex. nut
centering washer
guide rod
actuator
valve position indicator
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Operating Manual rev. 0

11
9. Service Instructions
9.3 Installation of seals and assembly of valve
Provide all seals with a thin layer of grease before their
installation.
a. Insert the guide bush (7) and o-ring (6) into the yoke (8).
Fasten the yoke (8) at the actuator (13).
b. Install the seat seal (2) in the lower valve shaft (3).
(see Service Instructions 11.)
c. Insert the o-rings (4, 5) into the shaft grooves.
d. Slide the protective pipe over the thread of the guid rod.
Place the shaft with bellow unit (3) and guide rod (9) through
the yoke (8) and actuator (13).
-The shaft must be led smoothly through the guide bush in
the yoke. If the shaft stiffs, check the right fit of the guide
bush.
e. CU design and valve position indicator:
Place the centering washer (16). Apply a drop of a screw locker
(e.g. type: Loctite - semi-solid) on the thread of the guide rod.
Screw on the hexagon nut (21) and fasten it with a
tightening torque of MD = 40 Nm. Hold up the centering
washer during this process.
-CU: Tighten the plastic actuator screw.
-Valve position
indicator: Screw on the metal actuator screw and
fasten it with a tightening torque of
Md = 40 Nm.
actuator screw
hex. nut
centering washer
cu adapter
guide rod
actuator
yoke
housing
guide bush
o-ring (6)
o-ring (4)
o-ring (5)
seat seal
shaft with
bellow unit
control unit
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Operating Manual rev. 0

12
9. Service Instructions
9.4 Installation of the valve
MF4, MEF4
a. CU design:
Fix the adapter at the actuator.
Place the control unit (20) on the adapter (22) and secure it
with the ring.
Valve position indicator: Fasten the indicator housing (18).
b. To assemble the valve insert in the NC design, proceed
as follows:
Place the valve insert carefully in the valve housing.
The o-ring (4) must not be damaged during the installation in
the housing.
Actuator in NC design: control actuator with min. 6 bar
pneumatic air.
Screw the hex. screws (11) in the housing flange and tighten
them crosswise.
Do not touch movable parts!
Risk of injury.
!NC design: cut off air.
c. Check the basic adjustment of the valve position indicator.
-By turning the positioning screws in the control unit, the shift
points can be adjusted.
d. Design with valve position indicator:
Plug in and fasten the proximity switches.
-Readjust the proximity switches if necessary.
e. Adjustment of proximity switches: (fig. 9.4)
-Move the actuator into one final position.
-Move the corresponding proximity switch into the corresponding
position. For this purpose, release the positioning screw and move
the holder until the corresponding signal is indicated. Then,
continue to slide by 2 to 3 mm to secure the indication.
Tighten the positioning screw.
-Place the actuator in the other final position and position the
second proximity switch.
-Upper valve position indication:
valve "normally open" NO
-Lower valve position indication:
valve "normally closed" NC
!
positioning screw
proximity switch
holder
NC
NO
fig. 9.4
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DELTA MF4
Operating Manual rev. 0

13
10.1 Maintenance of Actuator
a. Remove the air hoses from the actuator.
b. Remove the inner hex. screws from the adapter of the control unit.
-Remove the adapter.
10.2 Dismantling of seals
a. Unscrew the two seal screws with a wrench SW30 by holding
up the actuator with a strap wrench.
b. Remove the o-rings and v-seals.
10.3 Installation of seals and assembly of the actuator
a. Install the greased o-rings and v-seals in the seal screw (fig. 10.3).
See to the right direction of installation of the v-seal.
b. On both sides of the actuator, push the seal screws over the
piston rod and tighten them.
c. Fasten the adapter for the control unit and the yoke on the actuator.
Attention: Observe the position of the adapter.
Attention: Consider the required design NC or NO
for the assembly of the adapter and yoke.
NC =normally closed
NO =normally open
d. Fasten the air hoses.
10.4 Reconstruction of the valve design from NC "normally closed"
to NO "normally open" design
By turning the actuator by 180°, the required design NC or NO
can be adjusted.
NC =normally closed
NO =normally open
air connection
seal screw
v-seal
v-seal
o-ring
o-ring
actuator
piston rod
seal screw
fig. 10.3
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10. Service Instructions Actuator
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14
seal profile
seat seal
11.1 Installation of seat seal
1. Before the assembly, provide the seat seal with a thin layer of grease.
The groove for the seat seal must not be greased.
2. Clamp the valve shaft in a vise. Use protective jaws to avoid damage to the shaft.
3. Press the seal with the assembly tool (or screw driver with round edges) at four
opposite spots 1 - 2, 3 - 4 into the groove (see sketch 1-1a).
4. Proceed step by step to press the seal into the groove. Press the opposite side into the
groove. See to an even fit of the seat seal.
5. Afterwards, press the assembly tool in between the seal shoulder and the groove wall
and drive round completely. The groove is vented and the seal shoulder is locked in
during this procedure (see sketch 2).
13
2
4
sketch 1
shaft
seat seal seal shoulder
groove
bellow
sketch 2
vent
groove bottom
sketch 1a
UK
11. Service Instructions
DELTA MF4-UK0.qxd / 12.2004
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DELTA MF4
Operating Manual rev. 0

Failure Remedy
Valve closed and pressure in upper housing
Valve leaks Replace seat seal (2)
Check line pressure (max. 10bar)
Leakage from the leakage bore Check tightening torque of safety nut.
in the yoke area Replace shaft with bellow unit (3).
Leakages between housing and yoke flange Replace o-rings (4).
Actuator
Air escapes at the actuator rod Replace o-ring (2) at the upper side
of the actuator.
Actuator does not work
(air escapes permanently from the venting plug) Replace the complete actuator.
Valve position indication
No feedback Carry out fine adjustment.
15
12. Trouble Shooting
13. Spare parts Lists
(see annex)
The reference numbers of the spare parts for the different valve
designs and sizes are included in the attached spare parts
drawings with corresponding lists.
Please indicate the following data to place an order for spare parts:
-number of parts required
-reference number
-designation.
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Membrane Valve with Bellow Unit
DELTA MF4
Operating Manual rev. 0