SPX APV DELTA MF4 Operating Manual

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Read and understand this manual prior to operating or servicing this product.

Operating Manual

DELTA MF4

Membrane Valve with Bellow Unit

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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

Content Page

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

Membrane Valve with Bellow Unit DELTA MF4 Operating Manual rev. 0

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1. General Terms

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.

Membrane Valve with Bellow Unit DELTA MF4 Operating Manual rev. 0

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.

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3. Mode of Operation

DELTA MF4

control unit DELTA CU

valve position

indicator

actuator

yoke

leakage

indicator

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.

housing

- Leakages at the bellow unit are indicated at the leakage drain in

- For the pneumatic control of the valve, a control unit is installed

- The yellow luminous diodes installed in the control unit indicate

MF4 standard design

valve seat sealing

by profile seal (seat seal)

the yoke area.

on top of the actuator.

the position of the valve rod.

MFO4 design

valve seat sealing

by o-ring

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4. Auxiliary Equipment

fig. 4.1

fig. 4.2

PSH

valve position

indication

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:

solenoid valve (SV)

Direct Connect

CU31 Direct Connect

ref.-No.:

Profibus

ref.-No.:

Device Net

ref.-No.:

AS-Interface

ref.-No.:

16 - 31 - 232/93

CU21V

16 - 31 - 237/93

CU31 Device Net

16 - 31 - 240/93

CU31 AS-interface

16 - 31 - 244/93

Membrane Valve with Bellow Unit DELTA MF4 Operating Manual rev. 0

- For the assembly of the control unit on the MF4 valve an adapter is required.

adapter

designation:

ref.-No.:

CU2 - adapter SW4 / SD4 / M4

08-48-415/93

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. Installation

- 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.

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membrane valve with

control unit

6. Dimensions / Weights

membrane valve with

valve positon indicaton (PSH)

125

membrane valve with

MEF valve housing

DN A A1

25 40 50 65 80

100

inch

1”

1,5”

2”

2,5”

3” 4”

Membrane Valve with Bellow Unit DELTA MF4 Operating Manual rev. 0

409 448 499 508 519 531

409 448 499 508 509 531

348 387 438 447 458 470

348 387 438 447 448 470

B Ø Di F H Ø K L

19 28 34 42 49,5 59

17,3 26,5 32,9 39,1 45,0 57,8

26 38 50 66 81

100

22,2 35,1 47,6 60,3 72,9 97,6

50 67 72 85 98

111

50 67 72 85 90

111

32 44 56 74 91

110

28,6 41,1 53,8 68,3 80,1

107,6

86 126 126 189 189 189

459 515 526 593 617 642

459 515 526 593 619 642

398 454 465 532 556 581

398 454 465 532 538 581

weight

in kg

4,2 7,1 7,1

7,9 14,2 15,2

4,2

7,1

15,3

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7. Technical Data

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 )

7.1 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.

closing times in sec.

control pressure 6 bar

hose length 1m and 10m.

DN inch

1”

1,5” 40 50 65 80

100

2”

2,5”

3” 4”

1m 10m

1 1 3 3 3 5 5

2 2 4 4 4 6 6

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7. Technical Data

7.2 DELTA MF4 Kvs - values in m3/ h

DN 25

40 50 65 80

100

inch

1”

1,5”

2”

2,5”

3” 4”

22 42 73

130

342

22 38 70

112

276

7.3 valve stroke / opening section (X)

dimensions in mm

stroke X

Membrane Valve with Bellow Unit DELTA MF4 Operating Manual rev. 0

25 40 50 65 80

100

inch

1”

1,5”

2”

2,5”

3” 4”

6 11 13,5 17,5

22 28

8 11 12

20 25,5

8,5 11 15 19,5

5,5

8,5

9,5 17,5

21,5

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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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control unit

actuator screw

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.

hex. nut

centering washer

guide rod cu adapter

actuator

yoke

guide bush

o-ring (6) o-ring (5) o-ring (4)

shaft with

bellow unit

seat seal housing

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)

valve position indicator

Membrane Valve with Bellow Unit DELTA MF4 Operating Manual rev. 0

actuator screw hex. nut centering washer guide rod

actuator

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.

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control unit

actuator screw

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).

hex. nut

centering washer

guide rod cu adapter

actuator

yoke

guide bush

o-ring (6) o-ring (5) o-ring (4)

shaft with

bellow unit

seat seal housing

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.

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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.

fig. 9.4

proximity switch

holder

positioning screw

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.

Membrane Valve with Bellow Unit DELTA MF4 Operating Manual rev. 0

- Upper valve position indication: valve "normally open" NO

- Lower valve position indication: valve "normally closed" NC

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10. Service Instructions Actuator

10.1 Maintenance of Actuator

fig. 10.3

piston rod

actuator

seal screw

v-seal o-ring

air connection

v-seal

o-ring

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

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11. Service Instructions

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.

seat seal groove

bellow

shaft

seal shoulder

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).

seal profile

seat seal

sketch 1

Membrane Valve with Bellow Unit DELTA MF4 Operating Manual rev. 0

sketch 1a

vent

groove bottom

sketch 2

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12. Trouble Shooting

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.

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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Your local contact:

APV Zechenstraße 49 D-59425 Unna

Phone: +49(0) 23 03/ 108-0 Fax: +49(0) 23 03 / 108-210

For more information about our worldwide locations, approvals, certifications, and local representatives, please visit www.apv.com.

The information contained in this document, including any specifications and other product details, are subject to change without notice. While we have taken care to ensure the information is accurate at the time of going to press, we assume no responsibility for errors or omissions nor for any damages resulting from the use of the information contained herein.

Translation of original manual

BA MF4 0000002 ID-No.: H315258

rev. 0

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