SPX APV DELTA SWmini4 Operating Manual

Page 1
Read and understand this manual prior to operating or servicing this product.
Operating Manual
DELTA SWmini4
Single Seat Valve DN10, 15, 20
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Page 3
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SWmini4-UK0.qxd / 08.2004
UK
Table of Contents : Page:
SWmini 4 with weld ends
SWmini 4 with clamp connection
8. Materials 10
9. Maintenance 11
10. Service Instructions 12 - 14
Shut-Off Valve SWmini41 - 42
11. Service Instructions 15 - 17
Change-Over Valve SWmini43 - 44
12. Service Instructions 18
Actuator
13. Assembly Tool 19
14. Trouble Shooting 20
15. Spare Parts Lists SWmini 41 - 44 -FS, VSM, CU DN10,15,20 RN 01.054.815 SWmini 41 - 44 -FS, VSM, CU 1/2”, 3/4”, 1” RN 01.054.816 Actuator RN 01.054.88
Single Seat Valve DN10, 15, 20 DELTA SWmini4 Operating Manual : rev. 0
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1. General Terms

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 / air-to-raise, spring-to-lower): 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.
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3. Mode of Operation

Shut-off valve
actuator
A
optical
valve position
indicator
yoke
valve housing
The Shut-Off and Change-Over Valves DELTA SWmini4 (DN10, 15, 20) 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 valves are designed for universal applications and stand out for their increased mechanical reliability and absolute ease of handling.
The function of the DELTA SWmini4 valve is to shut off and to change over line sections.
- Operation by pneumatic actuator with air connection at (A), reset by spring force.
- By different assembly of the actuator, the following designs are possible:
NC (FS): actuator normally closed (air-to-raise, spring-to-lower) NO (FH): actuator normally open (air-to-lower, spring-to-raise)
(illustrations show NC design)
- The inner parts of the actuator are maitenance-free.
- As standard, the valves are manufactured without support for proximity switches.
Change-over valve
actuator
A
optical
valve position
indicator
yoke
upper
valve housing
- The valve position is indicated optically in the yoke area. Indication in the upper yoke bore: Valve position closed NC (FS).
- The cleaning of the inner area of the valve is carried out during cleaning of the line system.
lower
valve housing
Single Seat Valve DN10, 15, 20
3
DELTA SWmini4
Operating Manual : rev. 0
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4. Auxiliary Equipment

support for
proximity switch

control unit

with adapter
Valve position indication
- A proximity switch holder for the limit position NC or NO of the valve shaft can be installed directly on the actutor.
- We recommend to use our APV standard types: operating distance: 5 mm / diameter: 11 mm.
If the operator decides to use valve position indicators other than APV type, we cannot take over any guarantee for a faultless function.
- Control Unit The assembly of a control unit on the DELTA SWmini4 valve is possible.
The following different designs are available:
1 solenoid valve (EMV)
Direct Connect CU31 Direct Connect
ref.- No.: 16 - 31 - 232/93
Profibus CU21V
ref.- No.: 16 - 31 - 236/93
Device Net CU31 Device Net
ref.- No.: 16 - 31 - 240/93
AS - Interface CU31 AS - Interface
ref.- No.: 16 - 31 - 244/93
valve housing with
clamp connection
Single Seat Valve DN10, 15, 20 DELTA SWmini4 Operating Manual : rev. 0
- For the installation of the control unit on the SWmini 4 valve two adapters are required.
adapter
designation : CU adapter - SWmini4
ref.-No.: 08 - 48 - 355/93
designation : CU 2 adapter - SW4 / SD4 / M4
ref.-No.: 08 - 48 - 415/93
Connections: Clamp connection according to ISO 2852
Valves are available complete with clamp connections. The combination of weld ends and clamp connections is possible.
4
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5. Installation

shut-off valve
change-over valve
yoke
- 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.
- Shut-off valve SWmini41 / 42: The valve housings can be welded direct into the pipeline (completely dismantable valve insert with actuator).
- Change-over valve SWmini 43 / 44: One or two detachable connections e.g. (clamps, etc.) must
!
be assembled to the ports of the upper housing to provide for disassembly (e.g. for seal replacement).
- The position of the medium and upper housing ports to each other can be mounted staggered by 90othrough the screw connections.
upper
valve housing
housing seal
clamp connection
lower
valve housing
- Attention: Observe welding instructions.
Single Seat Valve DN10, 15, 20
5
DELTA SWmini4
Operating Manual : rev. 0
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upper
valve housing
clamp connection
UK

5.1 Welding Instructions

Shut-off valve SWmini41 / 42
- Before welding of the valves, remove the valve insert from the housing (see chapter 10.I.c. - d.). See to a careful handling of the parts to avoid damage.
Change-over valve SW mini 43 / 44
- The lower housing part (1), only, can be welded direct into the pipe system. Before welding of the lower housing, partly dismantle the valve (see chapter 11.I.d. - e. and 11.II. a. - d.). Remove the lower housing seal from the upper housing. Provide the upper housing and the upper pipeline with detachable connections (flange, clamps, etc.). See to a careful handling to avoid damage to the parts.
housing seal
lower
valve housing
- 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 undertaken in such a way that deformation strain cannot be transfered from the outside to the valve body.
- The preparation of the weld must be carried out in butt manner 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 nonobservance of these welding instructions is not subject to our guarantee.
Single Seat Valve DN10, 15, 20 DELTA SWmini4 Operating Manual : rev. 0
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6. Dimensions / Weights

Shut-off valve SWmini 41, 42
with weld ends
53
Change-over valve SWmini 43, 44
with weld ends
53
Proximity switch holder
C
C C
weights in kg
SWmini 41, 42 DN 10 1,55 DN 15 1,6 DN 20 1,75
weights in kg
SWmini 43, 44 DN 10 1,8 DN 15 1,9 DN 20 2,1
SWmini4 with weld ends
dimensions in mm
DN A B C D E G L L1 L / L1 with control unit
SWmini SWmini
41 / 42 43 / 44
10 133 25 45 10 20 60 218 238 295 315 15 135 28 45 16 26 60 223 249 300 326 20 137 30 45 20 30 60 227 257 304 334
Single Seat Valve DN10, 15, 20
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6.1 Dimensions / Weights

Shut-off Valve SWmini 41, 42
with clamp connection
53
C
Change-over valve SWmini 43, 44
with clamp connection
53
Proximity switch holder
C C
weights in kg
SWmini 41, 42 DN 10 1,6 DN 15 1,65 DN 20 1,8
weights in kg
SWmini 43, 44 DN 10 1,9 DN 15 2,0 DN 20 2,3
SWmini4 with clamp connection
dimensions in mm
DN A B C D E F G L L1 L / L1 with control unit
SWmini SWmini
41 / 42 43 / 44
10 133 30 50 10 20 34 60 223 242 299 319 15 135 33 50 16 26 34 60 228 254 305 331 20 137 35 50 20 30 34 60 232 262 309 339
inch
1/2” 133 30 50 10 20 34 60 223 242 299 319 3/4” 135 33 50 16 26 34 60 228 254 305 331
1” 137 35 50 22,6 30 50,5 60 232 262 309 339
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7. Technical Data

line pressure : 5 bar max. operating temperature : 135°C EPDM, HNBR
*FPM, *VMQ
short-term load: 140°C EPDM, HNBR
*FPM, *VMQ *(no steam)
air connection (for hose) : 6x1mm standard
1/4” option
max. pneumatic air pressure : 10 bar min. pneumatic air pressure : 6 bar
(Use dry and clean pneumatic air, only.)
shut-off valve change-over valve
SWmini 41, 42 SWmini 43, 44
stroke closing pressure stroke closing pressure
DN in mm in bar in mm in bar
10 4 8 5 8 15 7 8 7 8 20 7 6,5 7 6,5
kvs values in m3/h
shut-off valve change-over valve
DN
10 2,7 m³/h 2,5 m³/h 15 7,0 m³/h 5,0 m³/h
20 9,0 m³/h 7,5 m3/h
Single Seat Valve DN10, 15, 20
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DELTA SWmini4
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8. Materials

product wetted parts
- housing, upper housing, yoke, valve shaft : 1.4404
other parts
- actuator, actuator screw, centering washer, screws, guide rod, nut : 1.4301
- cover, covering cap, proximity switch holder : PA 12 schwarz
seals
- housing seals : EPDM option : FPM, VMQ, HNBR
- shaft seal : EPDM / PTFE option : VMQ / PTFE
FPM / PTFE HNBR / PTFE
- actuator seal : quadring NBR
o-ring NBR
- guide bush PTFE
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9. Maintenance

- The maintenance intervals depend on the corresponding application and are to be determined by the operator himself carrying out temporary checks.
- Required tools:
- 1x spanner SW 8
- 1x spanner SW 13
- 1x spanner SW 17
- 1x spanner SW 19
- For the valve service we supply complete seal kits (see pare parts lists). With the order of a complete seal kit, the appropriate grease is included in the scope of supply.
- Exchange of seals is done according to service instructions.
- Assembly of the valve and change of valve design NC (FS) or NO (FH), see service instructions.
- Installation of actuator, see service instructions.
- The inner parts of the actuator are maintenance-free.
- Slightly grease all seals before their installation.
Attention! No matter what type of application, use only
those greases being suited for the respective seal material !
Recommendation:
APV food-grade-grease for EPDM, FPM, HNBR and NBR (0,75 kg/ tin - ref.-No. 000 70-01-019/93) (60 g/ tube - ref.-No. 000 70-01-018/93)
oder
APV food-grade-grease for VMQ (Silicone) (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 containing mineral oil for EPDM seals !!! !!! Do not use Silicone-based grease for VMQ seals !!!
Assembly tool for seat seal
To simplify the installation of the seat seal in the valve shaft, the following assembly tools are available.
11
Assembly tool for
SWmini 41 / 42 / 43 / 44
DN ref.-No.:
10 000 - 51 - 13 - 052/17 15 000 - 51 - 13 - 051/17 20 000 - 51 - 13 - 050/17
Single Seat Valve DN10, 15, 20
DELTA SWmini4
Operating Manual : rev. 0
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10. Service Instructions Shut-Off Valve

Shut-off valve DELTA SWmini4
14
The item numbers refer to the corresponding spare parts lists
SWmini 41-44 FS, VSM, CU RN 01.054.815
RN 01.054.816
I. Dismantling from the line system
a. Shut off line pressure and discharge lines if possible. b. Detach electric connections.
- Proximity switches at the proximity switch holder.
- Control Unit, see operating manual.
c. Valve design NC: control actuator with air.
Do not reach for movable parts!
!
Risk of injury.
d. Remove screws (14) M5x12.
Withdraw the insert from the housing .
e. Cut off compressed air and remove compressed air supply.
Single Seat Valve DN10, 15, 20 DELTA SWmini4 Operating Manual : rev. 0
housing
SWmini41
housing
SWmini42
12
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17
16
15
UK
10. Service Instructions Shut-Off Valve

II. Dismantling of wear parts

a. Remove the covering cap (17).
- Valve design with proximity switch holder: Remove proximity switch holder (18) and actuator screw (19).
- Valve design with control unit:
Remove cover, actuator screw and guide rod extension (24). Remove the control unit.
b. Unscrew the safety nut (16) while holding up the centering washer
(15), take off centering washer.
c. Withdraw the valve shaft (4) with guide rod (12) to the bottom. d. Separate the yoke (9) from the actuator (13) by releasing the
hex. screws (10). Remove the washer (11) from the yoke.
e. Remove the o-ring (20). f. Take off the seat seal (3) by means of a pointed object from the
valve shaft.
g. Remove the housing seal (5).
20
13
10
8
9
5
h. Dismantle guide bush (8), seat seal (7) and shaft seal (6)
from the yoke.
Replacement of actuator seals, see chapter 12, Service Instructions Actuator.
!
13
7, 6
3
Single Seat Valve DN10, 15, 20
DELTA SWmini4
Operating Manual : rev. 0
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10. Service Instructions Shut-Off Valve
yoke
8
6
7

III. Installation of wear parts

a. Insert the guide bush (8) into the yoke (9).
Insert the shaft seal (6) and press in the slightly greased seat seal (3).
See to the correct mounting direction.
b. Slightly grease the housing seal (5) and insert it into the groove of
the yoke.
c. Install the seat seal (7) by means of the assembly tool
(see item 13.) in the valve shaft (4).
5
17 16
15 20
13
d. Place the washer (11) in the yoke (9).
Mount the yoke at the actuator (13).
e. Slide the valve shaft (4) through the yoke (9) and the actuator (13),
place the centering washer (15) and tighten it with the safety nut
(16). Hold up the centering washer during this process. f. Insert the o-ring (20) in the actuator cover. g. Fasten the covering cap (17).
- Valve design with proximity switch holder:
Fasten actuator screw (19) and proximity switch holder (18).
- Valve design with control unit:
Fasten control unit (without cover).
Fasten guide rod extension (24) and actuator screw.
Tighten the cover.

IV. Assembly of valve

14
a. Carefully place the valve insert in the housing and slightly screw the
hex. screws (14) M5x12 in the threaded bore (do not tighten).
The housing seal (5) must not be damaged during this process.
b. Connect compressed air supply. c. Valve design NC: control actuator with air.
9
5
4
!
Do not reach for movable valve parts!
Risk of injury by sudden valve actuation. d. Tighten the hex. screws (14). e. Disconnect pneumatic air. f. Connect electric connections.
- Plug proximity switches in their holders and fasten them.
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11. Service Instructions Change-Over Valve

Change-over valve DELTA SWmini4
14
The item numbers refer to the corresponding spare parts lists
SWmini 41-44 FS, VSM, CU RN 01.054.815
I. Disassembly from line system
a. Shut off line pressure and discharge lines if possible. b. Release clamp and flange connection at the upper housing. c. Detach electric connections.
- Proximity switch from holder.
- Control Unit, see operating manual.
d. Valve design NC: control actuator with air.
Do not reach for movable parts!
!
Risk of injury by sudden valve actuation.
e. Remove the hex. screws (14) M5x40.
Withdraw the valve insert with the upper housing from the lower housing.
f. Cut off compressed air and remove compressed air supply.
RN 01.054.816
15
Single Seat Valve DN10, 15, 20
DELTA SWmini4
Operating Manual : rev. 0
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11. Service Instructions Change-Over Valve

II. Dismantling of wear parts

17
12
20
16
15
a. Remove the covering cap (17).
- Valve design with proximity switch holder:
Remove proximity switch holder (18) and actuator screw (19).
- Valve design with control unit:
Remove cover, actuator screw and guide rod extension (24).
Remove the control unit.
b. Unscrew the safety nut (16) while holding up the centering washer
(15), take off centering washer. c. Withdraw the valve shaft (4) with guide rod (12) to the bottom. d. Withdraw upper housing (2) and remove the housing seal (5). e. Separate the yoke (9) from the actuator (13) by releasing
the hex. screws (10).
Remove the washer (11) from the yoke.
f. Remove the o-ring (20). g. Take off the seat seal (3) by means of a pointed object from the
valve shaft (4).
13
h. Remove the housing seal (5) from the yoke (9). i. Dismantle the guide bush (8), seat seal (7) and shaft seal (6)
from the yoke.
9 8
10
2
3
7, 6
5
5
4
Replacement of actuator seals, see chapter 12,
Service Instructions Actuator.
!
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11. Service Instructions Change-Over Valve
yoke
8
6
7
17 16
15
20

III. Installation of wear parts

a. Insert the guide bush (8) into the yoke (9).
Insert the shaft seal (6) and press in the slightly greased seat seal (7).
See to the correct mounting direction.
b. Slightly grease the housing seals (5) and insert them into the
groove of the yoke (9) and of the upper housing (2).
c. Install the seat seal (3) by means of the assembly tool
(see item 13.) in the valve shaft (4).
5
13
9
d. Place the washer (11) in the yoke (9).
Mount the yoke at the actuator (13).
e. Press the yoke with actuator in the upper housing (2).
Attention: Do not damage the housing seal (5).
f. Slide the valve shaft (4) through the housing (2), yoke (9) and
actuator (13), place the centering washer (15) and tighten it with the safety nut (16). Hold up the centering washer during this process.
g. Insert the o-ring (20) in the actuator cover. h. Fasten the covering cap (17).
- Valve design with proximity switch holder:
Fasten actuator screw (19) and proximity switch holder (18).
- Valve design with control unit:
Fasten control unit (without cover). Fasten guide rod extension (24) and actuator screw. Tighten the cover.

IV. Assembly of valve

Observe bore positions of housing and yoke.
17
10
5
2
5 4
14
1
a. Carefully place the valve insert in the housing (1). Check the correct
fit of the seal of the clamp or flange connection at the upper housing during this process. Attention: The housing seal (5) must not be damaged
during this process.
b. Slightly screw the hex. screws (14) M5x40 in the threaded bores
(do not tighten).
c. Connect compressed air supply. d. Valve design NC: control actuator with air.
Do not reach for movable valve parts!
!
Risk of injury by sudden valve actuation.
e. Tighten the hex. screws (14). f. Disconnect pneumatic air. g. Firmly tighten clamp and flange connections.
h. Connect electric connections.
- Plug proximity switches in their holders and fasten them.
Single Seat Valve DN10, 15, 20
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DELTA SWmini4
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actuator cover
quadring
5
piston rod
short
projection
UK

12. Service Instructions Actuator

Actuator
The item numbers refer to the corresponding spare parts lists
Actuator: RN 01.054.88
SWmini 41-44: RN 01.054.815 / RN 01.054.816
I. Disassembly
Attention:
Before starting the disassembly, see to the valve design NC or NO. a. Release hex. screws (5) and remove actuator cover (2) or adapter
SWmini4 (21) from actuator (13).
b. Remove quadrings (6) from the grooves.
II. Assembly
a. Provide quadrings (6) with a thin grease layer and press them
in the seal grooves.
quadring
actuator
long
projection
b. Fasten actuator cover or SWmini4 adapter on the actuator
by means of the hex. screws (5).
Attention: Observe valve design NC or NO.
- short projection of piston rod = design NC
- long projection of piston rod = design NO
III. Change of valve position NC/NO
By turning the actuator by 180othe required design NC or NO
can be determined.
NC (FS) = normally closed (air-to-raise, spring-to-lower)
NO (FH) = normally open (air-to-lower, spring-to-raise)
Crucial for the reconstruction is the assembly of the actuator cover.
Assembly of actuator cover:
- short projection of piston rod = design NC (FS)
- long projection of piston rod = design NO (FH)
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nut
thrust ring
ring
seat seal
housing
shell
13. Assembly Tool for Seat Seal
The assembly tool consists of:
- nut
- thrust ring
- ring with venting nose (to be used for the installation of the seat seal in
position + , see illustration).
- two shells, one with venting nose (to be used for the installation of the seat seal in
position , see illustration).
- housing
- threaded bolt
Installation of seat seal in valve shaft
1. Insert the valve shaft in the housing in such a way that
the seal groove is in the housing.
2. Clamp the shaft in the housing by means of the threaded bolt (observe the corresponding design SW41 or SW43). Clamp the housing in a vice.
1 2
3
UK
1
SW 41
SW 43
identification
SW41
threaded bolt
2
SW 43
identification
SW43
3. Installation +
1 2
Provide the seat seal with a thin layer of APV food-grade grease. Place the seal on the ring with venting nose until it stops. Introduce the ring with the installed seat seal in the housing and
shell
3
press it down to a sensible stop.
4. Installation
3
Provide the seat seal with a thin layer of APV food-grade grease. Place the two shells around the reduced shaft and slide the seat seal over the shaft and over the shells.
5. Slide the thrust ring on the seat seal. Screw on the groove nut and tighten it with a hook spanner until it stops.
6. Release the groove nut. Take thrust ring and ring (shells) off the housing.
7. Take housing out of the vice.
SW 41
8. Unscrew threaded bolts. Take valve shaft from the housing.
Check the even fit of the seat seal.
19
DN
10 15 20
Assembly tool for
SWmini 41 / 42 / 43 / 44
ref.-No.:
000 - 51 -13 -052/17 000 - 51 -13 -051/17 000 - 51 -13 -050/17
Single Seat Valve DN10, 15, 20
DELTA SWmini4
Operating Manual : rev. 0
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14. Trouble Shooting

Trouble Remedy
Leakage between yoke and housing Replace upper housing seal (5)
Leakage between upper and lower housing Replace lower housing seal (5) .
Leakage out of the lower yoke bore Replace guide bush (8), shaft seal (6) and
seat seal (7).
! Check surface of valve shaft,
replace valve shaft if damaged (see instructions for replacement of guide rod).
Actuator
UK
Air escapes permanently at the upper und lower piston rod Replace quadrings (6).
Air escapes permanently from the venting plug Replace complete actuator (13).
guide rod (12)
reception for
guide rod
Instructions
for replacement of guide rod
a. Unscrew the guide rod (12) from the lower
valve shaft (4).
b. Clean the valve shaft
(remove grease and impurities).
c. Apply a drop of a screw locker
(e.g. type: Loctite-semi-solid) in the area of the threaded bore of the lower valve shaft
(see sketch 1).
d. Clamp the valve shaft in a vice.
(Attention: use protective cover.)
e. Screw in guide rod and tighten it.
sketch 1
apply screw locker
in the
threaded bore
valve shaft (4)
Single Seat Valve DN10, 15, 20 DELTA SWmini4 Operating Manual : rev. 0

15. Spare Parts Lists

(see annex)
20
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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.
Copyright © 2008 SPX Corporation
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.
UK
Translation of original manual
BA SWmini4 002 ID-No.: H207909
rev. 0
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