SPX DSV, D2, SWcip4, SDM4, SD4 Operating Manual

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

Operating Manual

DSV

Double Seal Butterfly Valve

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Table of Contents: Page:

1. General Terms 2

2. Safety Instructions 2

3. Mode of Operation 3

4. Auxiliary Equipment 4 - 5

4.1 Valve position indication - controlled valve (proximity switches)

4.2 CONTROL UNIT

4.3 Adapter for CONTROL UNIT (nominal diameter DN50 - 65 and 2”- 3”)

4.4 Adapter for CONTROL UNIT (nominal diameter DN80 - 125 and 4”)

5. Installation 6

5.1 Welding Instructions

6. Dimensions / Weights 7 - 8

7. Technical Data 9

8. Materials 9

9. Maintenance 10

10. Service Instructions 11 - 13

10.1 Dismantling from the line system

10.2 Dismantling of the actuating device

10.3 Dismantling of manual actuation

10.4 Dismantling of inner parts

10.5 Replacement of seals

10.6 Installation of seals and bush bearing

10.7 Attachment of actuating device

10.8 Assembly of feedback units

10.9 Assembly of manual actuation

11. Spare Parts Lists 13

(see annex)

DSV - FZ (NC = normally closed) DN 50 - 125 - RN 01.039 DSV - FZ (NC = normally closed) inch 1”-4” - RN 01.039.1

DSV - H (manual function) DN 50 - 125 - RN 01.040 DSV - H (manual function) inch 2”-4” - RN 01.040.1

Turning actuator F/L (spring/air) for feedback unit - RN 01.076

Double Seal Butterfly Valve DSV Operating Manual: rev. 2

DSV-UK2.qxp / 10.2005

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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 of operating safety. You will find it wherever the activities

described are bearing risks of personal injury.

- Disconnect electrical and pneumatic connections

- Depressurize the line and cleaning system and discharge the lines,

if possible, before any maintenance work.

- Do not reach into the open valve!

Risk of bruising at movable parts of the valve.

- Risk of injury by sudden valve operation in dismantled valve state.

- Observe Service Instructions to ensure safe maintenance of

the valve.

- During the actuating process, operating leakages spurt out to the

bottom.

- Close cleaning connection and leakage drain which are not used

by a plug.

- DANGER!

Welded turning actuators are preloaded by spring force.

Turning actuators which are no longer used and / or defective

must be disposed in professional manner.

Defective turning 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.

Opening of the turning actuators is strictly forbidden.

Danger to life!

Double Seal Butterfly Valve DSV Operating Manual: rev. 2

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3. Mode of Operation

Due to the use of high quality stainless steel and adequate seal materials, the double seal butterfly valve DSV is suited for applications in the food and beverage industries as well as in the pharmaceutical and chemical industries.

The function of the double seal butterfly valve is to shut off line sections. It is exclusively suited for applications in the CIP area, whereby the valve is subject to defined cleaning and flushing processes.

Valves of the DSV series are remote controlled by a pneumatic actuator. Reset by spring force into the limit position closed.

Extension of operating time of actuated valves by pneumatic air throttle or adjusting screw in the Control Unit CU3 to optimize the flow behaviour.

The valve opens and closes by turning the valve disc by 90°.

Smooth valve passage without diversion of line flow.

The opening diameter complies with the size of the inner line diameter.

Cleaning of the product-wetted valve surface is performed during cleaning of the pipeline.

Leakage arising in the area of the butterfly valve seal flow out in depressurized state via the leakage drain.

The leakage chamber in the area of the double valve disc can be cleaned via a cleaning connection.

As option, the DSV-valve is available in manual design. The two final positions of the valve are fixed by locking of the handle. The handle must be unlocked for change-over.

leakage-drain R1/4”

leakage chambercleaning connection R1/4”

Double Seal Butterfly Valve

DSV

Operating Manual: rev. 2

adapter

DSV with manual actuation

DSV with pneumatic turning actuator

and valve position indicator

proximity switch

holder

air connection

turning actuator

adapter flange

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4. Auxiliary Equipment

4.1 Valve position indication (for actuated valves only)

Proximity switches to signal the limit position of the valve disc can be installed if required.

We recommend to use our APV standard proximity switches. Type: three-wire proximity switch (ref.-No. 08-60-011/93) Operating distance: 4 mm / diameter: 11 mm / length: 30 mm.

Using a valve position indicator other than APV type, we cannot accept any liability for faulty function.

4.2 Control Unit fig. 4.2 (for actuated valves only)

Units with feedback switch and solenoid valve for the pneumatic control of the valve to be assembled on the turning actuator are also available in field bus technology. The assembly of a Control Unit CU3 on the turning actuator is possible.

The following different designs are at disposal:

CU31 Direct Connect

16 - 31 - 232/93

CU31 Profibus

08 - 45 - 001/93

CU31 Device Net

16 - 31 - 240/93

CU31 AS-interface 2.1

08 - 45 - 020/93

fig. 4.2

Double Seal Butterfly Valve DSV Operating Manual: rev. 2

Direct Connect

ref.-No.:

Profibus

ref.-No.:

Device Net

ref.-No.:

AS-interface

ref.-No.:

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Double Seal Butterfly Valve

DSV

Operating manual: rev. 2

4. Auxiliary Equipment

4.3 Adapter for CONTROL UNIT (fig. 4.3)

An adapter is required to install the Control Unit on the DSV valve.

Adapter for the nominal diameters DN50 - 65 und 2” - 3”:

ref.-No.: 000 - 08 - 48 - 416/93 (CU2 adapter SVS1F, DKR)

CU2 adapter SVS1F, DKR

08-48-416/93

Designation:

ref.-No.:

1 2

- 4

- 5

- 6

8 9

1 3

1 1 2 1

1 1 2

08-48-416/93 00-00-000/00

08-60-779/93 08-60-760/15

08-60-333/93 58-06-387/83 58-06-044/83 08-60-728/93

58-06-426/83 58-06-049/83 08-60-740/93

adapter complete seal kit adapter

operating cam cyl. screw M5x18 ISO1207

adapter kit o-ring 88,62 - 1,78 /NBR o-ring 5,28 - 1,78 /NBR adapter

o-ring 90 - 2 /NBR o-ring 13 - 2 / NBR blind plug G1/8”

ref.-No.:pos. stk. designation

* scope of supply: actuator

fig. 4.3

Spare parts lists

CU2 adapter

4.4 Adapter for CONTROL UNIT (Bild 4.4)

Adapter for the nominal diameters DN80 - 125 and 4”:

ref.-No.: 000 - 08 - 48 - 417/93 (CU2 adapter SVS1F 125-250, DKR 80-100)

CU2 Adapter SVS1F 125-250, DKR 80-100

08-48-417/93

Designation:

ref.-No.:

1 2

- 4

- 5

- 6

8 9 10 11

1 3

1 1 2 1

1 1 1 1 2

08-48-417/93 00-00-000/00

08-60-780/93 08-60-760/15

08-60-333/93 58-06-387/83 58-06-044/83 08-60-728/93

58-06-426/83 58-32-010/83 58-06-039/83 58-06-049/83 08-60-740/93

adapter complett seal kit adapter

operating cam cyl. screw M5x18 ISO1207

adapter kit o-ring 88,62 - 1,78 /NBR o-ring 5,28 - 1,78 /NBR adapter

o-ring 90 - 2 /NBR v-seal 20 x 28 x 4 / NBR o-ring 11 - 3 / NBR o-ring 13 - 2 / NBR blind plug G1/8”

ref.-No.:

pos. stk.

designation

* scope of supply: actuator

fig. 4.4

Spare parts lists

CU2 Adapter

adapter for DN50 - 65 and 2”- 3”

adapter for DN80 - 125 and 4”

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The DSV valve is designed only for the upright installation position with actuator vertically to the top!

DSV valves are mounted between "flanges-DSV".

Attention: Observe welding instructions.

5.1 Welding Instructions

- Observe the bore position (see fig.) during the welding of the mating flanges - DSV.

- Welding may only be carried out by certified welders (EN 287-1). (seam quality EN 25817 "B").

- The welding of the mating flanges must be undertaken in such a way that deformation strain cannot arise.

- TIG orbital welding is best!

- Before welding, all sensitive parts of the valve must be removed! Remove the valve core with seals from between the mating flanges.

- After welding 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 or be carried over to other parts of the installation.

- Any damage resulting from the non-observance of these welding instructions is not subject to our guarantee.

5. Installation

Double Seal Butterfly Valve DSV Operating manual: rev. 2

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Double Seal Butterfly Valve

DSV

Operating manual: rev. 2

6. Dimensions / Weights

50 65

80 100 125

50 66

81 100 125

86 86 89 89

101

95 108 119 133

464 474 556 567 581

337 337 386 386 386

108 130 146 166 205

dimensions in mm

weighs

in kg

85 125 125 125

Ø K

B G

295 295 344 344 344

125

A1B

Ø C

inch

2”

2,5”

3” 4”

84 95

105

115

125

38 38 41 41 53

EØ D

422 432 514 525 539

47,8 60,5 72,1 97,6

86 86 89 89

95 108 119

464 474 487 567

337 337 386 386

108 130 146 166

85 125 125

295 295 344 344

84 95

105

115

38 38 41 41

422 432 465 525

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Double Seal Butterfly Valve DSV Operating manual: rev. 2

86 86 89 89

101

165 165 165 178 285

dimensions in mm

L weights in kg

Ø C

inch

2”

2,5”

3” 4”

84 95

105

115

125

EØ D

148 158 167 178 214

47,8 60,5 72,1 97,6

86 86 89 89

165 165 165 178

108 130 146 166

84 95

105

115

38 38 41 41

148 158 167 178

50 65

80 100 125

108 130 146 166 205

50 66

81 100 125

38 38 41 41 53

6. Dimensions / Weights

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Double Seal Butterfly Valve

DSV

Operating Manual: rev. 2

7. Technical Data

- max. line pressure DN 50-125/1”-4” : 10 bar

- max. operating temperature : 135

C EPDM, HNBR

- short-term steam load : 140

C EPDM, HNBR

- opening angle butterfly valves : 90

- min. control pressure : 6 bar

- max. control pressure : 10 bar

- air connection (for hose) : 6 x 1

- cleaning connection : R1/4”

(use dry and clean pneumatic air, only)

- valve disc 1.4462 / 1.4404

- housing (not product-wetted) 1.4301

- mating flange - DSV

DN 50 - 100 1.4404

- DSV seal

standard: EPDM option: HNBR

- bush bearing Cu

- yoke, actuator 1.4301

- coupling 1.4301 / 1.4308

- piston polyacetal POM

- spindle bearingr polyamid PA 12

- air connection polyamid PA 6.6

DN 50-65 / 2”-3”

pneumatic air consumption

at 6 bar control pressure

turning actuator K 080 (F/L) (spring/air)

per movement 1,8 (NL)

closing times in sec.

hose length 1m 10m

2,5 sec. 4,2 sec.

DN 80-125 / 4”

pneumatic air consumption

at 6 bar control pressure

turning actuator K 125 (F/L) (spring/air)

per movement 5,5 (NL)

closing times in sec.

hose length 1m 10m

5,5 sec. 8 sec.

8. Materials

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- The maintenance intervals depend on the application of the valve and should be determined by the operator carrying out regular visual checks of the valve.

- The double seal butterfly valve possesses only a few wear parts: disc seal and bush bearings.

- The customer is recommended to hold spare seals and bush bearings on stock. For valve maintenance APV supplies complete seal kits including seal grease (pl. see spare parts lists).

- If damaged seals are exchanged, generally replace all seals and bush bearings.

- Slightly grease all seals before their installation. Grease the disc seal according to the illustration - especially the cross holes.

- Assembly of the valve and change of the valve design FZ (normally closed) or FO (normally open) according to Service Instructions.

- Installation of turning actuator according to Service Instructions.

- The inner parts of the turning actuator do not need service.

Attention! Use food-grade grease and special grease being

suited for the respective seal material, only.

Recommendation:

APV-food-grade grease for EPDM and HNBR (0,75 kg /can - ref. No. 000 70-01-019/93) (60 g /tube - ref. No. 000 70-01-018/93)

! Do not use grease containing mineral oil for EPDM seals.

grease

disc seal

9. Maintenance

Double Seal Butterfly Valve DSV Operating Manual: rev. 2

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Double Seal Butterfly Valve

DSV

Operating Manual: rev. 2

10.1 Dismantling from the line system

DANGER !

a. Shut off connecting lines, discharge line pressure and drain

lines if possible.

b. Disconnect electric and pneumatic connections.

c. Release the clamp connection at the proximity switch holder.

Pull out proximity switch.

d. Separate cleaning connecting lines and leakage drain lines.

e. Remove the hex. Screws (14) from the mating flange.

f. Take out double seal butterfly valve from between the flanges.

Attention! Dismantling of the valve from the line system

is only possible in closed valve state.

10.2 Dismantling of turning actuator with valve position indicator The item numbers refer to the spare parts lists.

- Remove the fastening screw (12) at the adapter flange (10).

Detach turning actuator to the top.

- Turning actuator with Control Unit

Disassembly of the turning actuator is carried out as described in paragraph Turning Actuator. The Control Unit need not be removed from the turning actuator.

- For further dismantling of the valve, remove coupling and adapter flange.

10.3 Dismantling of manual actuation

- Screw off the fastening screw at the handle and detach the handle to the top.

10. Service Instructions

bush bearing

45° offset

illustration

cyl. pin

seal

thread seal

coupling

adapter flange

turning actuator

inner

hex. screw

inner hex. screw

and spring ring

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10.4 Dismantling of inner parts

Disc seal, disc DSV and bush bearing

- Remove the inner hex. screw (3) from the valve housing

and disperse the housing halves. Pull disc seal with disc DSV out of the valve housing. Remove the bush bearing from the valve housing.

10.5 Replacement of seals

- Turn the disc DSV (2) in the disc seal (5) into the open position.

- Slightly pressing it, the disc seal (5) is deformed in its longitudinal

axis and can be slid over the short bearing spindle.

- Remove the disc seal from the actuating spindle.

- Clean the valve disc DSV

(2).

- Grease the holes of the new disc seal as described in chapter 9

and introduce the long actuating spindle of the disc DSV.

- Turn the disc DSV in the disc seal into open position.

- By a slight pressing, the disc seal is deformed in its longitudinal axis and can be slid over the short bearing spindle.

10.6 Installation of the inner parts

- Introduce bush bearings (6) into the upper housing half.

- Insert the disc DSV being in open position with disc seal into the upper housing half.

- Adjust the lower housing half and fasten the two housing halves with the screws alternately crosswise.

Attention! W hile tightening the screws, the valve disc (2)

must not be within the disc seal (5). The valve disc must be in open position.

10. Service Instructions

Double Seal Butterfly Valve DSV Operating Manual: rev. 2

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10.7 Attachment of turning actuator

- Place the adapter flange (10) on the upper housing and fasten it with the inner hex. screws (9).

- Place the coupling (11) on the square of the actuating spindle of the disc DSV (2).

- Place the turning actuator (16) on the adapter flange and tighten it with the screws (12).

10.8 Assembly of feedback units (proximity switches)

- Valve position indication OPEN: Installation of the feedback unit in the lower proximity switch holder.

- Valve position indication CLOSED: Installation of the feedback unit in the upper proximity switch holder.

- Insert the proximity switch into the proximity switch holder until stop and fasten it with the clamp union.

10.9 Assembly of manual actuation

- Place the handle on the square of the DSV disc and tighten it with the fastening screws. DSV disc and handle are in line.

10. Service Instructions

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 required parts

- reference number

- designation.

subject to modifications

11. Spare Parts Lists

Double Seal Butterfly Valve

DSV

Operating Manual: rev. 2

DSV-UK2.qxp / 10.2005

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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 DSV 0000002 ID-No.: H315841

rev. 2

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