SPX APV DELTA SDU4 User manual

Read and understand this manual prior to
operating or servicing this product.
Operating Manual
DELTA SDU4
Double Seal Change - Over Valve

1. General Terms 2
2. Safety Instructions 2
3. Mode of Operation 3
4. Auxiliary Equipment 4
5. Cleaning 5
6. Installation 6
6.1 Welding Instructions 6
7. Dimensions / Weights 7
8. Technical Data 8-9
9. Maintenance 10
10. Service Instructions 11-15
11. Installation of Seat Seal 16
12. Trouble Shooting 17
13. Spare Parts Lists
Double Seal Change-Over Valves
SDU 4
DN design RN 01.054.64
Tube design RN 01.054.64-1
Actuator RN 01.054.86
Leakage valve RN 01.054.67
Table of Contents : Page :
1
Double Seal Change-Over Valves
Delta SDU 4
Operating Manual Rev.1
UK

This operating manual has to be read carefully and observed by
the competent operating and maintenance personnel.
We have to 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 system must be
depressurized.
- Do not reach into the open valve.
- Risk of injury by suddenly operating valve. In dismantled state there
is the risk of bruising at movable parts of the valve.
- Observe service instructions to ensure safe maintenance of
the valve.
-Attention!
With valve design NC (normally closed): Before releasing
the housing screws, the valve insert must be relieved by
controlling the actuator.
- The welded actuator is under spring load,do not open it by force.
1. General Terms
2
Double Seal Change-Over Valves
Delta SDU 4
Operating Manual Rev. 1
UK

yoke
3. Mode of Operation
Double seal change-over valves DELTA SDU4 have been
developed for the use in the brewing and beverage industries, in
dairy and food applications as well as for the chemical and
pharmaceutical industries.
The field of application of the DELTA SDU4 comprises the safe
shut-off and change-over of line sections.The upper and middle
housing are separated from one another by two seat seals.
A leakage chamber is arranged between the seals; the leakage
chamber being forcible closed by the two leakage valves or opened
to the atmosphere.
Leakage at the seat seals of the upper valve shaft is discharged
via the leakage valves to the atmosphere and indicated.
- Operation by pneumatic actuator with air connection.
The actuator is generally mounted normally closed (NC).
- The inner parts of the actuator are maitenance-free.
- To avoid pressure hammers,the valve is to be closed against the
flow direction of the fluid.
- As standard design a control unit DELTA CU21N with NOT element
is installed on top of the actuator for the pneumatic control of the
valve.The NOT element fulfills the task to increase the closing
forces of the closed valve.
- The yellow luminous diodes in the control unit indicate the position
of the valve shaft.
- Observe service instructions to ensure safe maintenance of
the valve.
3
actuator
position
indicator
Control Unit
Delta CU21N
clamp
leakage
valves
housing
housing
Double Seal Change-Over Valves
Delta SDU 4
Operating Manual Rev. 1
UK

4. Auxiliary Equipment
- Valve position indication
A proximity switch holder for the valve position indication can be
installed direct on the actuator.
With SDU4 valves being equipped with valve position indication it
must be observed that the max. closing pressure is reduced
compared with the valve design being equipped with the
control unit DELTA CU21N.
(see table item 8)
Proximity switches to signal the limit position of the valve seat can
be installed at the proximity switch holder if requested.
We recommend to use one of our APV standard types:
operating distance: 5 mm / diameter: 11 mm.
If the customer decides for a valve position indication other than
APV type, we cannot take over any guarantee for a faultless
function.
- Control Unit
The Control Unit CU2 can be installed on the SDU4 valve.
The following different designs are possible:
4
Double Seal Change-Over Valves
Delta SDU 4
Operating Manual Rev. 1
1 solenoid valve 1 solenoid valve
with NOT elem ent
standard CU
ref.-No.:CU 21 322 000 804 432 CU 21 N 322 000 804 440
Valve NetProfibus
ref.-No.:CU 21 V 322 000 804 437 CU 21 VN 322 000 804 442
AS – Interface
ref.-No.:CU 21 AS -Interface 322 000 804 578 CU 21 N AS -Interface 322 000 804 579
adapter
designation :
ref.-No.:CU 2 adapter -SW 4 /SD4 /M4 322 000 801 192
- An adapter is required to install the control unit on the SD4 valve.
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5. Cleaning
-Depending on the pressure ratio, cleaning temperatures and degree
of soiling, different times have to be adjusted.
-Flushing quantity per CIP spraying about 1,2ltr/10s
-Cleaning pressure at CIP cleaning connection min. 2 bar.
max. 5 bar.
Recommendation for cleaning times with common operating
conditions and CIP liquids.
Cleaning of the leakage chamber
via the leakage valves.
cleaning step CIP spraying
pre-flushing 3 x 10 sec.
caustic flushing 80 oC 3 x 10 sec.
intermediate flushing 2 x 10 sec.
acid flushing 3 x 10 sec.
subsequent flushing 2 x 10 sec.
CIP in CIP out
Double Seal Change-Over Valves
Delta SDU 4
Operating Manual Rev. 1
For the cleaning of SDU4 valves distinction is made between
two areas.
-The flow chambers
The passages of the valve are cleaned by the cleaning liquid during
the cleaning of the connected pipelines.
- The leakage chamber
The cleaning of the leakage chamber is undertaken via the leakage
valves.The cleaning liquid is supplied via one leakage valve and
discharged to the atmosphere via the second leakage valve.
The restraint passage of the cleaning liquid provides for a perfect
cleaning of the whole leakage chamber.
Under normal conditions,15 valves DN 25/1T - 100/4T can
be cleaned by one spray distribution line DN 25.
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6. Installation
- Installation has to be done in such a way that fluids can drain off
the valve housing and is preferably to be realized in vertical position.
- To provide for the dismantling of the valve insert, the valve housing
ports of the upper and middle housing balls must be connected in a
detachable manner by a flange or clamp connection.
- Attention: Observe welding instructions.
6.1 Welding Instructions
SDU 4
-Before welding of the valve, the valve insert must be dismantled from
the housing. Moreover, the lower housing seal must be removed.
For this purpose, detachable connections (flanges, clamps, etc.) are
to be used in the pipelines to provide for the dismantling of the two
housings and to have access to the lower seal. See to a careful
handling to avoid damage to the parts.
-Welding may only be carried out by certified welders
(EN 287-1).(Seam quality EN 25817 "B").
-The welding of the valve housings must be effected in such a way
that deformation strain cannot be transfered from the outside to the
valve body.
-The preparation of the weld seam up to 3 mm thickness must be
carried out in butt manner as a square butt joint without air.
(Consider shrinkage!)
-TIG orbital welding should be aimed at!
-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 nonobservance of these welding
instructions is not subject to our guarantee.
Double Seal Change-Over Valves
Delta SDU 4
Operating Manual Rev. 1
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7
7. Dimensions / Weights
dimensions in mm
DN A B C D F H L K
stro k e
in
mm
installation
dimensions
in mm
Y X
weight
in Kg
SDU 4
25 397 54,018,026 50 60 529 86 12 100 200
40 403 66,024,038 67 72 567 86 22 100 200
50 440 78,032,050 72 84 634 126 25 100 200
65 448 94,040,066 85 100 682 126 25 100 200
80 501 109,047,581 98 115 772,5189 25 100 200
100 511 128,057,0100 111 134 830 189 25 100 200
Tube
1T 395 50,616,322,650 56,6518,586 12 100 200
1,5T 401 62,922,534,967 68,9557,386 22 100 200
2T 439 75,630,847,672 81,6627 126 25 100 200
2,5T 445 88,337,260,385 94,3664,8126 25 100 200
3T 496 100,943,572,990 106,9747,3189 25 100 200
4T 509 125,655,897,6111 131,6822 189 25 100 200
Double Seal Change-Over Valves
Delta SDU 4
Operating Manual Rev. 1
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8
kvs values forSDU 4
valves in (m 3 /h )
SDU 45,
SDU 46 SDU 45, SDU 46
DN
25
19 14
40
42 33
50
88 58
65
145 100
80
175 160
100
220 245
Tube
1T
15 10
1,5T
39 30
2T
79 54
2,5T
124 87
3T
155 137
4T
215 225
8. Technical Data
Product-wetted parts : 316 L, 1.4404
Other parts : 1.4301
Seals :
Standard : EPDM
Options : FPM,VMQ, HNBR
Actuators : 1.4301
Max. operating temperature : 140°C EPDM
135°C VMQ, FPM, HNBR
Sterilization temperature : 150°C EPDM
(short-term) 140°C VMQ, FPM, HNBR
Air connection (for hose) : 6x1mm
Max. pneumatic air pressure : 8 bar
Min. pneumatic air pressure : 6 bar
(Use dry and clean pneumatic air, only.)
Closing times for double seal change-over valves SDU4
The opening and closing times can be fixed by adjustment of the
throttling screw at the solenoid valve.
Double Seal Change-Over Valves
Delta SDU 4
Operating Manual Rev. 1
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9
8. Technical Data
Operating position: A / NC (normally closed) Operating position: B / valve controlled
DELTA SDU4m ax.productpressure in (bar)
valve norm ally closed withoutNOT elem ent
orwith com pressed air failure
actuator
74 mm actuator 110 mm actuator 165 mm
Valve position A B A B A B
DN Tube
25 1T 6,4
14,5
16,0
40 1,5T 3,6
6,8
9,614,4
50 2T 6,08,311,2
17,6
2,5T 4,711,6
65 3,55,49,3
13,3
3T 8,0
80 6,0
9,4
100 4T 4,4
5,3
Note: The max.product pressure in case of compressed air failure as indicated
in tab. 1 has to be considered for the design of the valves.
-Due to the seal technology, the max.product pressure is limited to 17,6 bar.
DELTA SDU4m ax.productpressure in (bar)
valve norm ally closed and NOTelem ent
actuator
74 mm actuator 110 mm actuator 165 mm
Valve position A B A B A B
DN Tube
25 1T
16,0
14,5
16,8
40 1,5T
12,4
6,8
17,614,4
50 2T 17,68,3
17,6
17,6
2,5T 14,0
16,0
65 10,55,4
17,6
13,3
3T
17,6
80
17,2
9,4
100 4T
12,8
5,3
Table 1
Table 2
Double Seal Change-Over Valves
Delta SDU 4
Operating Manual Rev. 1
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10
-Themaintenance intervals depend on the corresponding
application and are to be determined by the operator himself
carrying out temporary checks.
- Required tools:
- 1 x spanner SW13
- 1 x spanner SW17
- 1 x spanner SW19
- 1 x hexagon socket screw key 6 mm.
- Exchange of seals is done according to service instructions.
-Provide all seals with a thin layer of grease before
their installation.
Recommendation:
APV food-grade-grease for EPDM and HNBR
(0,75 kg/tin - ref.-No. 000 70-01-019/93)
(60 g/tube - ref.-No. 000 70-01-018/93)
! No matter what type of application,use only those greases
being suited for the respective seal material !
9. Maintenance
Double Seal Change-Over Valves
Delta SDU 4
Operating Manual Rev. 1
Assembly tool for upper seat seal
( Do not use the assembly tool but for the
new valve design produced from Nov. 2000).
To simplify the installation of the seat seal, the
following tools are available.
Assem bly toolforupper
Seatseal(15.1 )
DN Tube ref.-No.:
25 1T 000 51-13-200/17
40 1,5T 000 51-13-201/17
50 2T 000 51-13-202/17
2,5T 000 51-13-203/17
65 000 51-13-204/17
3T 000 51-13-205/17
80 000 51-13-206/17
100 4T 000 51-13-207/17
Assem bly toolforlow er
Seatseal(item 3 )
DN Tube ref.-No.:
40 1,5T 000-51-13-111/17
50 2T 000-51-13-112/17
65 000-51-13-113/17
2,5T 000-51-13-120/17
3T 000-51-13-121/17
80 000-51-13-114/17
100 4T 000-51-13-115/17
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10. Service Instructions
Delta SDU 4
The item numbers refer to the corresponding spare parts lists
DN: RN 01.054.64 / Tube: RN 01.054.064-1
I. Dismantling from the line system
a. Shut off line pressure and discharge lines if possible.
b. Remove the control unit (27) from the actuator (23).
(Turn the ring in anticlockwise direction and remove the cover.)
c. Detach the separating connection in the line system (continuing from
the side valve housing port at the upper valve housing).
d. Shut off and discharge the CIP supply line.
e. Remove the CIP supply and drain from the leakage valves.
f. Remove the link joint (5) at the lower housing (1).
g. Dismantle the complete valve (actuator, valve insert and upper valve
housing) from the line system.
II. Dismantling of product-wetted seals (service)
a. Remove the lower housing seal (4).
b. Screw off the operating cam.
c. Unscrew the hexagon nut (26) by holding against the centering
disk (25). Remove the centering disk.
d. Pull the lower valve shaft (6) out of the actuator (23). Remove the
seat seals (3).
( assembly see 10.IV.i.)
e. Control the actuator with air. For this purpose, remove the
connecting hose from the control unit to the T-piece.
Control the actuator with compressed air at the T-piece.
Do not reach for movable parts.
Risk of injury.
f. Remove the housing flange screws (14).
g. Shut off compressed air and compressed air supply. Remove the
connecting hoses to the leakage valves. Lift the valve insert out of
the upper housing (2/2.1).
h. Take the upper valve shaft (7) out of the yoke (12). Remove the
seat seals (15 / 15.1, 16) and (17).
i. Unscrew the yoke (12) from the actuator (23).
Remove the housing seal (8).Take off the seat seal (9),
shaft seal (10) and guide bush (11).
Double Seal Change-Over Valves
Delta SDU 4
Operating Manual Rev. 1
27
26
25
23
24
11
8
14
12
9, 10
15
16
17
2/2.1
7
6
5
4
3
1
modified
from 11/2000
15.1
operating cam
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10. Service Instructions
III.Actuator
Spare parts list RN: 01.054.86
a. Remove the air hoses from the actuator.
b. Take the inner hexagon screws out of the adapter (24) of the
control unit.
c. Screw off the two seal screws (1) by holding against the actuator by
a strap wrench. Remove the O-rings (3) as well as the V-seals (2).
IV. Installation of seals and assembly of actuator
a. Install the slightly greased O-ring (3) and the V-seal (2) in the seal
screw (1).
See to the correct direction of installation of the V-seal.
b. Push the seal screws over the piston rod at both sides of the
actuator and tighten them.
c. Fasten the adapter for the control unit and the yoke at the actuator.
Attention: Observe the position of the adapter.
d. Install the air hoses.
Double Seal Change-Over Valves
Delta SDU 4
Operating Manual Rev. 1
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13
10. Service Instructions
Double Seal Change-Over Valves
Delta SDU 4
Operating Manual Rev. 1
V. Installation of seals and assembly of valve
The item numbers refer to the corresponding spare parts lists
RN: 01.054.65 DN / 01.054.64-1 Tube
a. Slightly grease the housing seal (8) and insert it into the groove
of the yoke flange. Place the guide bush (11) in the yoke (12).
Then insert the shaft seal (10) and press in the slightly greased
seat seal (9).
See to the correct direction of installation.
b. Install the yoke (12) on the actuator (23).
c. Slightly grease the seat seal (3) and insert it into the upper shaft (7).
Insert the two seat seals (15 / 15.1, 16) into the upper shaft (7).
Slightly grease the seat seals before their installation.
During the installation in the seal groove, the seal groove is to be
vented between the seal ring and the groove wall by means of a
thin object. See to a correct fit of the seals.
With modified design of the seat seal 15.1, use the
assembly tool to install the seat seal (see page 16).
d. Insert the seat seal (3) into the lower valve shaft (6).
Use the APV assembly tool (see 11.) to insert the seat seal.
Provide the seat seal with a thin layer of grease before its installation.
When installed manually, vent the seal groove between the seal and
the groove wall by means of a thin object.
e. Control the actuator with compressed air.
f. Push the upper valve shaft (7) through the yoke (12) until it stops.
g. Place the actuator with yoke and upper valve shaft in the
upper valve housing (2 / 2.1). Fix the yoke flange at the valve
housing by means of the hexagon screws (14).
h. Shut off the compressed air and remove the compressed air supply.
i. Push in the lower valve shaft (3) through the upper valve shaft (7)
until it stops.Place the centering disk (25) and tighten the
safety nut (26).
For this purpose, hold against the centering disk.
Tightening torque 40 Nm.
Tighten the operating cam.
j. Slightly grease the lower housing seal (3) and insert it into the
groove of the valve housing (1).
fig. for 10.V.a.
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10. Service Instructions
VI. Assembly of the valve
a. Place the complete valve insert (actuator, yoke,upper valve shaft and
upper valve housing) in the lower valve housing (1) and tighten it with
the link clamp (5).Reconnect the valve housing with the line system.
Reconnect the leakage valves.
b. Place the control unit (27) on the adapter (24) and secure it
by the fastening ring.
c. Connect the compressed air supply.
d.Check the basic adjustment of the valve position indication.
-By turning the positioning screw in the control unit,the shift points
can be adjusted.
VII. Maintenance of the leakage valves
The item numbers refer to the spare parts lists
leakage valves: RN 01.054.67.
a. Pull off pneumatic air hoses at the two leakage valves.
b. Shut off CIP supply line and discharge it.
c. Remove CIP supply and outlet line from the leakage valves.
d. Release inner hex. screw and remove bracket.
e. Turn off cover (3) and pull off piston (2) and spring (6).
f. Dismantle all seals (5, 7, 8).
g. Installation is done in reverse order.
Double Seal Change-Over Valves
Delta SDU 4
Operating Manual Rev. 1
UK
leakege valve

15
Double Seal Change-Over Valves
Delta SDU 4
Operating Manual Rev. 1
10. Service Instructions
VIII. Proximity switch holder (valve design without control unit)
If the valve is equipped with a proximity switch holder, the following
steps have to be observed during the dismantling of the valve:
a. Remove pneumatic air lines.
b. Take the proximity switches off the holder.
c. Dismantle the valve from the line system.
(see service instructions 10.I.a., c.-f.)
d. Release and remove the proximity switch holder.
The O-ring seal can be replaced.
e. Release the operating cam by holding against the centering disk.
Remove the centering disk.
f. Assembly see chapter 10.II.a., d.-i.
(Installation is done in reverse order.)
operating
cam
proximity switch holder
centering
disk
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