Burkert 2103 Quick Start Manual

Piston-controlled diaphragm valve Kolbengesteuertes Membranventil Vanne à membrane commandée par piston

Technische Änderungen vorbehalten. Sous réserve de modifications techniques. © Bürkert Werke GmbH & Co. KG, 2013 - 2018 Operating Instructions 1807/05_EU-ML_00810349 / Original DE

regarding the use of the device. Keep these instructions in a location which is easily accessible to every user, and make these instruc- tions available to every new owner of the device. Important safety information. Failure to observe these instructions may result in hazardous situations. ▶ ▶Quickstart must be read and understood. A detailed description of the device can be found in the operating instructions for Type 2103, 2104 and 2105. The operating instructions can be found on the Internet at: www.burkert.com 1.1 Definition of term The term “device” used in these instructions always stands for the diaphragm valve Type 2103, 2104 or 2105. 1 QUICKSTART......................................................................... 3 2 AUTHORIZED USE................................................................ 4 3 BASIC SAFETY INSTRUCTIONS........................................... 5 4 GENERAL INFORMATION..................................................... 6 5 STRUCTURE AND FUNCTION.............................................. 7 6 TECHNICAL DATA.................................................................. 8 7 INSTALLATION..................................................................... 11 8 REMOVAL............................................................................ 17 9 MAINTENANCE WORK........................................................ 17 10 TRANSPORT, REMOVAL..................................................... 18 english Type 2103, 2104, 2105

▶ ▶Failure to observe the warning may result in a fatal or serious injury. WARNING! Warns of a potentially dangerous situation. ▶ ▶Failure to observe the warning may result in serious injuries or death. CAUTION! Warns of a possible danger. ▶ ▶Failure to observe this warning may result in a moderate or minor injury. NOTE! Warns of damage to property. Important tips and recommendations. Refers to information in these operating instructions or in other documentation. ▶ ▶designates an instruction to prevent risks. → →designates a procedure which you must carry out. 2 AUTHORIZED USE Non-authorized use of the device may be a hazard to people, nearby equipment and the environment. ▶ ▶The device is designed for the controlled flow of liquid and gaseous media. ▶ ▶In areas at risk of explosion, only use devices approved for use in those areas. These devices are labeled with a separate Ex type label. When utilized in a potentially explosive atmo- sphere, always pay attention to the details on the separate Ex type label and the Ex additional instructions contained in the scope of delivery. ▶ ▶During use observe the authorized data, the operating condi- tions and conditions of use specified in the contract docu- ments and operating instructions. ▶ ▶Protect device from damaging environmental influences (e.g. radiation, humidity, steam, etc.). If anything is unclear, consult the relevant sales office. ▶ ▶The device may be used only in conjunction with third-party devices and components recommended and authorized by Bürkert. ▶ ▶Correct transportation, correct storage and installation and careful use and maintenance are essential for reliable and faultless operation. ▶ ▶The exhaust air may be contaminated with lubricants in the actuator. ▶ ▶Use the device only as intended. english Type 2103, 2104, 2105

3 BASIC SAFETY INSTRUCTIONS These safety instructions do not make allowance for any •• contingencies and events which may arise during the installation, operation and maintenance of the devices. •• local safety regulations, whereby the operator is responsible for their compliance, by the installation personnel too. Danger – high pressure. ▶ ▶Before loosening the lines and valves, turn off the pressure and vent the lines. Danger of bursting from overpressure. ▶ ▶Observe the specifications on the type label for maximal control and medium pressure. ▶ ▶Observe permitted medium temperature. Risk of injury from electric shock (when electrical component installed). ▶ ▶Before reaching into the device or the equipment, switch off the power supply and secure to prevent reactivation! Observe applicable accident prevention and safety regulations for electrical equipment! Risk of injury when opening the actuator! The actuator contains a tensioned spring. If the actuator is opened, there is a risk of injury from the spring jumping out! ▶ ▶Do not open the actuator. Risk of injury from moving parts in the device! ▶ ▶Do not reach into openings. ▶ ▶Operate 3-position actuator with transparent cap only. Risk of burns and risk of fire if used continuously through hot device surface. ▶ ▶Keep the device away from highly flammable substances and media and do not touch with bare hands. Danger due to loud noises. ▶ ▶Depending on the operating conditions, the device may generate loud noises. More detailed information on the likelihood of loud noises is available from the relevant sales office. ▶ ▶Wear hearing protection when in the vicinity of the device. Leaking medium when the diaphragm is worn. ▶ ▶Regularly check relief bore for leaking medium. ▶ ▶If medium is leaking out of the relief bore, change the diaphragm. ▶ ▶If the media is hazardous, protect the area surrounding the dis- charge point against dangers. english Type 2103, 2104, 2105

To prevent injury, ensure: ▶ ▶That the system cannot be activated unintentionally. ▶ ▶Installation and repair work may be carried out by authorized technicians only and with the appropriate tools. ▶ ▶After an interruption in the power supply or pneumatic supply, ensure that the process is restarted in a defined or controlled manner. ▶ ▶The device may be operated only when in perfect condition and in consideration of the operating instructions. ▶ ▶Observe the safety regulations specific to the plant for applica- tion planning and operation of the device. ▶ ▶The plant operator is responsible for the safe operation and handling of the plant. ▶ ▶The general rules of technology apply to application planning and operation of the device. To prevent damage to property of the device, ensure: ▶ ▶Supply the media connections only with those media which are specified as flow media in the chapter entitled “6 Technical data”. ▶ ▶Do not put any loads on the valve (e.g. by placing objects on it or standing on it). ▶ ▶Do not make any external modifications to the valves. Do not paint the body parts or screws. ▶ ▶Do not transport, install or remove heavy devices without the aid of a second person and using suitable auxiliary equipment. 4 GENERAL INFORMATION 4.1 Contact address Germany Bürkert Fluid Control Systems Sales Center Chr.-Bürkert-Str. 13-17 D-74653 Ingelfingen Tel. : 07940 - 10 91 111 Fax: 07940 - 10 91 448 E-mail: [email protected] International Contact addresses are found on the final pages of the printed operating manual. You can also find information on the Internet under: www.burkert.com 4.2 Warranty The warranty is only valid if the device is used as authorized in accordance with the specified application conditions. 4.3 Information on the internet The operating instructions and data sheets for Type 2103, 2104 and 2105 can be found on the Internet at: www.burkert.com english Type 2103, 2104, 2105

5 STRUCTURE AND FUNCTION 5.1 Structure The piston-controlled diaphragm valve consists of a pneumatically operated piston actuator and a 2/2-way valve body. The actuator is manufactured from polyphenylene sulphide (PPS) and stainless steel. 5.1.1 2/2-way valve type 2103 Transparent cap with position indicator Actuator cover Actuator housing Diaphragm socket Line connection Valve body Second pilot air port for CFI and air discharge connection for CFA and CFB Pilot air port for CFA, CFB, CFI 2 1 Fig. 1: Piston-controlled diaphragm valve, structure and description 5.1.2 2/3-way valve type 2103 Actuator cover Actuator body Diaphragm socket Line connection Valve body Transparent cap Setting of the center position Pilot air port for control function A - center position Pilot air port for control function A - open 1 2 Fig. 2: Structure and description, 2/3-way valve type 2103 5.1.3 T-valve type 2104 Transparent cap with position indicator Actuator cover Actuator housing VA diaphragm socket (VA = stainless steel) T-valve body Line connection Pilot air port for control function (CF) A, B, I Second pilot air port for CFI and air discharge connection for CFA and CFB 1 2 Fig. 3: Structure and description type 2104 english Type 2103, 2104, 2105

5.1.4 Tank bottom valve type 2105 Transparent cap with position indicator Actuator housing Actuator cover Tank bottom valve with welding flange VA diaphragm socket (VA = stainless steel) Pilot air ports 1 and 2 (see detailed view) Second pilot air port for CFI and air discharge connection for CFA and CFB 2 1 Pilot air port 1 for control function (CF) A, B, I Fig. 4: Structure and description type 2105 5.2 Function Spring force (CFA) or pneumatic pilot pressure (CFB and CFI) gen- erates the closing force on the diaphragm pressure piece. The force is transferred via a spindle which is connected to the actuator piston. 5.2.1 Control functions (CF) WARNING! For control function I: Danger if pilot pressure fails. For control function I (CFI) control and resetting occur pneumati- cally. If the pressure fails, no defined position is reached. ▶ ▶To ensure a controlled restart, first pressurize the device with pilot pressure, then switch on the medium. CFA P A Closed by spring force in rest position. CFB P A Opened by spring force in rest position. CFI P A Actuating function via reciprocal pressurization. 6 TECHNICAL DATA WARNING! Risk of injury from high pressure. Excessive pressure can damage the device. ▶ ▶Comply with pressure range values on the type label. 6.1 Conformity Type 2103, 2104 and 2105 conforms with the EU Directives according to the EU Declaration of Conformity. 6.2 Standards The applied standards, which verify conformity with the EU Directives, can be found on the EU-Type Examination Certificate and / or the EU Declaration of Conformity. 6.3 Type label Example: 00175139 2103 A 20M PTFE VS Tamb 0°C - +60°C Tmed xxx°C - +130°C Pilot 4,8-10bar Pmed 10,0bar Da=26,9 s=1,6 W3ZLT CE Fig. 5: Example of type label english Type 2103, 2104, 2105

6.3.1 Wording on the type label Example: 00175139 2103 A 20M PTFE VS Tamb 0°C - +60°C Tmed xxx°C - +130°C Pilot 4,8-10bar Pmed 10,0bar Da=26,9 s=1,6 W3ZLT CE CE identification Permitted pilot pressure Permitted medium pressure Type Control function Orifice (diaphragm size / actuator size Sealing material Body material Identification number of the product Permitted medium temperature Permitted ambient temperature Date of manufacture (encoded) Main dimensions of body connection 6.4 Labeling of the tube valve body (VP) 1.4435 316L(VP) XXXXXXXX XXXXXXXXXX PN16 / CWP150 XXXXXXXX / XXX XXXX / XXXXXX Material Heat Company logo Nominal pressure Connection orifice and pipe dimensions Self-drain angle / Customer-specific text (optional) Production number / serial number Fig. 6: Labeling of the tube valve body (VP) english Type 2103, 2104, 2105

6.5 Labeling of the forged bodies XXXXXXXXXX XX F 1.4435/316L(VS) PN16/CWP150 XXXXXXXX/XXX XXXXXX XXXX Self-drain angle Customer-specific text (optional) Orifice connection and pipe dimension Batch number Material Production number / serial number Nominal pressure Fig. 7: Labeling of the forged bodies 6.6 Operating conditions Ambient temperature for actuator -10...+60 °C / +100 °C1) Medium temperature for body: Body material Temperature Stainless steel -10...+150 °C PVC (see PT graph) -10...+60 °C PVDF (see PT graph) -10...+120 °C PP (see PT graph) -10...+80 °C Tab. 1: Medium temperature for body Medium temperature for diaphragms: Material Temperature [°C]2) Remarks EPDM (AB) -10...+130 Steam sterilization up to +140 °C / 60 min EPDM (AD) -10...+143 Steam sterilization up to +150 °C / 60 min FKM (FF) 0...+130 No steam / dry heat up to +150 °C / 60 min PTFE (EA) -10...+130 Steam sterilization up to +140 °C / 60 min Advanced PTFE (EU) -5...+143 Steam sterilization up to +150 °C / 60 min Gylon (ER) -5...+130 Steam sterilization up to +140 °C / 60 min Tab. 2: Permitted medium temperature for diaphragms 1) Pilot air ports with push-in connector or threaded bushing 2) The indicated medium temperatures apply only to media which do not corrode or swell the diaphragm materials. The behavior of the medium with respect to the diaphragm may be changed by the medium tem- perature. The function properties, in particular the service life of the diaphragm, may deteriorate if the medium temperature increases. Do not use the diaphragms as steam shut-off element. english Type 2103, 2104, 2105

Permitted medium pressure depending on the medium temperature. Plastic body: DN 15 - 65 10 8 6 4 2 20 40 60 80 100 120 140 PVC PVDF PP Medium pressure [bar] Temperature [°C] Fig. 8: Graph of medium pressure / Medium temperature 6.7 General technical data Media Control medium neutral gases, air Flow media liquids; ultrapure, sterile, dirty, aggressive or abrasive media Installation position Type 2103, 2104 any position, preferably with the actuator face up Type 2105 preferably with the actuator to the bottom (Tank bottom valve) Degree of protection IP67 in accordance with IEC 529 / EN 60529 7 INSTALLATION 7.1 Safety instructions DANGER! Risk of injury from high pressure in the equipment or device. ▶ ▶Before working on equipment or device, switch off the pressure and vent the lines. WARNING! Risk of injury from improper installation. ▶ ▶Installation may be carried out by authorised technicians only and with the appropriate tools. Risk of injury from unintentional activation of the system and an uncontrolled restart. ▶ ▶Secure system from unintentional activation. ▶ ▶Following assembly, ensure a controlled restart. For control function I: Danger if pilot pressure fails. For control function I control and resetting occur pneumati- cally. If the pressure fails, no defined position is reached. ▶ ▶To ensure a controlled restart, first pressurize the device with pilot pressure, then switch on the medium. english Type 2103, 2104, 2105

▶ ▶During transport or during assembly, a heavy device may fall and cause injury. ▶ ▶Do not transport, install or remove heavy devices without the aid of a second person and using suitable auxiliary equipment. ▶ ▶Use appropriate tools. NOTICE! Note the following when installing the device in the plant ▶ ▶The device and the leakage detection bore must be acces- sible to allow inspection and maintenance work. 7.2 Installation position Installation for self-drainage of the body It is the responsibility of the installer and operator to ensure self-drainage. Installation for leakage detection One of the bores in the diaphragm socket for monitoring leakage must be at the lowest point. 7.2.1 Installation position type 2103 •• The piston-controlled diaphragm valve can be installed in any installation position, preferably with the actuator face up. To ensure self-drainage: → →Install valve body inclined by an angle α = 10° – 55° to the horizontal. Forged body, cast body and tube valve body: Mark on the valve body must point upwards (12 o’clock position, see “Fig. 9”). → →Observe an inclination angle of 1° – 5° to the line axis. Inclination to the line axis α = 1° – 5° Mark for self-drainage upwards Fig. 9: Installation position for self-drainage of the valve body α english Type 2103, 2104, 2105

For the installation of the T-valves into circular pipelines, we rec- ommend the following installation positions: When media is supplied: When media is removed: Fig. 10: Installation position type 2104 7.2.3 Installation position tank bottom valve type 2105 Preferably with the actuator to the bottom. 7.3 Before installation NOTE! Damage to the diaphragm or the actuator. ▶ ▶Devices with welded or bonded body: Before welding or bond- ing the body, the actuator and diaphragm must be removed •• Before connecting the valve, ensure the pipelines are flush. •• The flow direction is optional. 7.3.1 Preparatory work → →Clean pipelines (sealing material, swarf, etc.). → →Support and align pipelines. 7.4 Remove the actuator from the valve body NOTICE! Damage to the diaphragm or the seat contour. ▶ ▶When removing the actuator, ensure that the valve is open. → →Control function A pressurize the pilot air port 1 with compressed air (5,5 bar): valve opens. → →Remove actuator with diaphragm by loosening the body screws. Actuator Valve body Air discharge connection CFA, CFB Pilot air port CFI Pilot air port CFA, CFB, CFI 2 1 Body screws (4x) Diaphragm Fig. 11: Installation english Type 2103, 2104, 2105

conveying all free pneumatic connections into a neutral atmosphere with the aid of a pneumatic hose. WARNING! Risk of injury from improper installation. Non-observance of the tightening torque is dangerous as the device may be damaged. ▶ ▶Observe the tightening torques (see “Tab. 3”, page 15). 7.5.1 Installation of the valve body type 2103 and 2104 Welded or glued bodies → →Weld or glue valve body in pipeline system. Other bodies → →Connect body to pipeline. 7.5.2 Welding tank bottom body Observe sequence: 1. Weld the tank bottom body onto the base of the tank before installing the tank. Welding onto a tank which has already been installed is possible but more difficult. Weld the tank bottom body in the middle of the tank base so that the tank can be optimally drained. 2. Weld valve body into the pipeline. Installation requirements: Pipelines: Ensure that the pipelines are aligned. Preparation: Support and align pipelines. To ensure that the pipeline is self-draining, observe an inclination angle of 1° – 5°. DANGER! Risk of injury from high pressure! ▶ ▶Before working on the system, switch off the pressure and vent or drain lines. For information on tanks and instructions on welding observe the standard ASME VIII Division I. Before you start welding, check the batch number indi- cated on the supplied manufacturer’s certificate 3.1 . Observe the applicable laws and regulations of the respective country with regard to the qualification of welders and the execution of welding work. 1. Welding tank bottom body onto the tank: ATTENTION! Before welding, note the following: ▶ ▶Use only welding material which is suitable for the tank bot- tom body. ▶ ▶The tank bottom valve must not collide with any other instal- lation part. The actuator must be easy to install and remove. english Type 2103, 2104, 2105

→ →Weld in tank bottom body. Ensure installation is de-energized and low-vibration. After welding in the valve body: Install the diaphragm and the actuator. 7.6 Installation of the actuator (welded or glued body) NOTICE! Damage to the diaphragm or the seat contour. ▶ ▶When installing the actuator, ensure that the valve is open. Installation for actuator with control function A: → →Control function A pressurize the pilot air port 1 with compressed air (5,5 bar): valve opens. → →Place actuator on the body → →Lightly cross-tighten the body screws until the diaphragm lies between the body and actuator. Do not tighten the screws yet. → →Actuate the diaphragm valve twice to position the diaphragm correctly. → →Tighten body screws without pressurization in diagonal pairs in three stages (approx. 1/3, approx. 2/3, 3/3 of the tightening torque), according to Table ( see “Tab. 3”). The diaphragm should be positioned and pressed evenly all around the actuator and body. Installation for actuator with control functions B and I: → →Place actuator on the body → →Gently tighten the body screws in diagonal pairs without pres- surization until the diaphragm lies between the body and actuator. Do not fully tighten the screws yet. → →Pressurize pilot air port 1 of the actuator with compressed air (5,5 bar). → →Actuate the diaphragm valve twice to position the diaphragm correctly. → →Tighten body screws with pressurization in diagonal pairs in three stages (approx. 1/3, approx. 2/3, 3/3 of the tightening torque), according to Table ( see “Tab. 3”). The diaphragm should be positioned and pressed evenly all around the actuator and body. 1 Pilot air port CFA, CFB, CFI Fig. 12: Pilot air port Orifice DN (diaphragm size) Tightening torques for diaphragms [Nm] EPDM/ FKM PTFE / advanced PTFE / laminated PTFE 8 2.5 2.5 15 3.5 4 20 4 4.5 25 5 6 32 8 10 40 8 10 50 12 15 Tab. 3: Tightening torques for diaphragms → →A tolerance of +10% of the respective tightening torque applies to all values. english Type 2103, 2104, 2105

the actuator can be rotated steplessly by 360 °. → →Rotate actuator using a hook wrench. See “Fig. 13”. Rotate actuator only as far as required (max. 360 °). Recommended hook wrenches as per DIN 1810. Actuator size: ø 50 = A 52 - 55, ø 70 - 130 = A 68 - 75 Fig. 13: Align actuator 7.8 Pneumatic connection DANGER! Danger – high pressure in the equipment. ▶ ▶Before loosening the lines and valves, turn off the pressure and vent the lines. WARNING! Risk of injury from unsuitable connection hoses. ▶ ▶Use only hoses which are authorised for the indicated pres- sure and temperature range. ▶ ▶Observe the data sheet specifications from the hose manufacturers. For control function I: Danger if pilot pressure fails. For control function I control and resetting occur pneumatically. If the pressure fails, no defined position is reached. ▶ ▶To ensure a controlled restart, first pressurize the device with pilot pressure, then switch on the medium. 7.8.1 Connection of the control medium Control functions A and B → →Connect the control medium to the pilot air port 1 of the actuator (see “Fig. 13: Align actuator”). Control function A, 3-position actuator → →Connect the control medium to the pilot air port 1 and 2 of the actuator (see “Fig. 2” in chapter 5) Pressure on connection 1 opens the valve, Pressure on both connections sets the mid- position. Control function I → →Connect the control medium to the pilot air port 1 and 2 of the actuator (see “Fig. 14: Pneumatic connection”) Pressure on connection 1 opens the valve. Pressure on connection 2 closes the valve. english Type 2103, 2104, 2105