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2035

Burkert 2035, 3236 Operating Instructions Manual

Operating Instructions
Bedienungsanleitung Manuel d‘utilisation
Type 2035 / 3236
Robolux multiple-way diaphragm valve Robolux Mehrwege-Membranventil Vanne à membrane multi-voies Robolux
© Bürker t Werke GmbH & Co. KG, 200- 2017
Operating Instructions 1706/_(8(1_00804 / Original DE
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Contents
Type 2035 / 3236
1. OPERATING INSTRUCTIONS ...................................................................5
1.1. Symbols ..............................................................................................5
1.2. Definition of term / abbreviation ....................................................5
2. AUTHORIZED USE .........................................................................................6
2.1. Restrictions ........................................................................................6
3. BASIC SAFETY INSTRUCTIONS .............................................................6
3.1. Use in Ex area ...................................................................................7
3.2. Special conditions ...........................................................................9
4. GENERAL INFORMATION ...........................................................................9
4.1. Contact address ............................................................................... 9
4.2. Warranty ............................................................................................. 9
4.3. Information on the Internet ............................................................. 9
4.4. Trademarks ......................................................................................10
5. PRODUCT DESCRIPTION ........................................................................ 10
5.1. General description .......................................................................10
5.2. Device versions ...............................................................................10
5.3. Valve self-draining ..........................................................................12
5.4. Valve symbols and flow diagrams ................................................ 13
5.5. Valve marking ..................................................................................15
5.6. Intended application area .............................................................17
6. STRUCTURE AND FUNCTION...............................................................17
6.1. Structure of Type 2035.................................................................17
6.2. Structure of Type 3236.................................................................18
7. TECHNICAL DATA ........................................................................................19
7.1. Conformity .......................................................................................19
7.2. Standards .........................................................................................19
7.3. Approvals .........................................................................................19
7.4. Type label .........................................................................................19
7.5. Operating conditions .....................................................................19
7.6. Mechanical data .............................................................................19
7.7. Fluidic data ......................................................................................21
8. ASSEMBLY .......................................................................................................23
8.1. Safety instructions .........................................................................23
8.2. Before installation ...........................................................................23
8.3. Installation ........................................................................................24
8.4. Pneumatic connection (Type 2035 only) ..................................25
8.5. Installation of the inductive proximity switch ............................26
9. OPERATION AND FUNCTION ................................................................27
9.1. Safety instructions .........................................................................27
9.2. Type 2035 - pneumatic operation ..............................................27
9.3. Type 3236 - manual operation ....................................................28
10. ELECTRICAL PRE-CONTROLLER ...................................................... 28
11. DISASSEMBLY ............................................................................................ 28
12. MAINTENANCE, CLEANING ................................................................. 29
12.1. Safety instructions .......................................................................29
12.2. Servicing intervals ........................................................................29
12.3. Servicing work ..............................................................................29
12.4. Cleaning .........................................................................................30
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Type 2035 / 3236
13. REPAIRS ......................................................................................................... 31
13.1. Safety instructions .......................................................................31
13.2. Replacing the diaphragm ...........................................................31
14. SPARE PARTS ............................................................................................. 40
14.1. Order table ....................................................................................40
15. MALFUNCTIONS ........................................................................................ 41
16. TRANSPORT, STORAGE, PACKAGING .......................................... 41
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Operating instructions
Type 2035 / 3236
1. OPERATING INSTRUCTIONS
The operating instructions describe the entire life cycle of the device. Keep these instructions in a location which is easily accessible to every user and make these instructions available to every new owner of the device.
WARNING!
The operating instructions contain important safety information.
Failure to observe these instructions may result in hazardous situations.
▶ The operating instructions must be read and understood.
1.1. Symbols
DANGER!
Warns of an immediate danger.
▶ Failure to observe the warning will 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.
▶ Failure to observe the warning may result in damage to the device
or the equipment.
Indicates important additional information, 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.
1.2. Definition of term / abbreviation
In these instructions, the term 'device' always refers to the Robolux Multiway Diaphragm Valve Type 2035 / 3236.
In these instructions, the term 'diaphragm valve' always refers to the Robolux Multiway Diaphragm Valve Type 2035 / 3236.
In these instructions, the abbreviation “Ex” always refers to “potentially explosive”.
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Authorized use
Type 2035 / 3236
2. AUTHORIZED USE
Improper use of the Robolux Multiway Diaphragm Valve Type 2035 / 3236 may represent a hazard to persons, neighboring equipment and the environment.
The device is designed for controlling the flow-rate of liquid media.
▶ The approved data, the operating conditions and conditions of use
specified in the contract documents, operating instructions and on the type label are to be observed during use. The designated areas of application are specified in chapter "5. Product description".
▶ Use the device only in conjunction with third-party devices and
components recommended and authorized by Bürkert.
▶ Correct transportation, storage, and installation, as well as care-
ful use and maintenance are essential for reliable and faultless operation.
▶ Use the device only as intended.
2.1. Restrictions
If exporting the system/device, observe any existing restrictions.
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 – the operator is responsible for observing
these regulations, also in relation to the installation personnel.
DANGER!
Risk of injury from high pressure in the equipment/device.
▶ Before working on equipment or device, switch off the pressure
and deaerate/drain lines.
Risk of electric shock.
▶ Before working on equipment or device, switch off the power
supply and secure to prevent reactivation.
▶ Observe applicable accident prevention and safety regulations
for electrical equipment.
WARNING!
Risk of injury when opening the actuator.
The actuator contains tensioned springs. If the actuator is opened, injuries may be caused by the springs jumping out!
▶ The actuator must not be opened.
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Basic safety instructions
Type 2035 / 3236
CAUTION!
Risk of burns.
The surface of the device may become hot during long-term operation.
▶ Do not touch the device with bare hands.
Generally hazardous situations.
To prevent injuries:
▶ 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 electrical or pneumatic supply, ensure
that the process is restarted in a defined or controlled manner.
▶ The device must only be operated when in a perfect condition and
in consideration of the operating instructions.
▶ The general rules of technology must be observed for application
planning and operation of the device.
To prevent material damage:
▶ Supply only media to the media connections that are specified in
chapter "7. Technical Data" as flow media.
▶ Do not place the valve under mechanical stress (e.g. by placing
objects on it or standing on it).
▶ Do not make any external alterations to the valves. Do not apply
paint to body parts or screws.
3.1. Use in Ex area
Abbreviation “Ex”: see chapter "1.2. Definition of term / abbreviation"
3.1.1. Safety instructions
For operation in Ex area Zone (gas) 1 and 2,
Zone (dust) 21 and 22, the following applies:
The valve actuator is suitable for use as a Category 2 device for Zone 1 and 21, non-electrical production equipment.
DANGER!
Danger of explosion caused by electrostatic charge.
Depending on the conductivity of the medium, electrostatic charges may occur on the valve membrane if plastic bodies are used.
To prevent electrostatic charges in the fluid, the following instructions must be observed (as per IEC 60079-32-1):
▶ (1) Media with a conductivity ≤ 100 pS/m may only be used if no
flow speeds > 1 m/s occur or if the possibility of the pipe system running dry is excluded by suitable monitoring.
▶ (2) Media with a conductivity > 100 pS/m and ≤ 1000 pS/m may
only be used if they are liquids without any particles, steam or pure gases/steam, or if the instructions in (1) are observed.
▶ (3) Media with a conductivity > 1000 pS/m are not subject to any
restrictions.
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Basic safety instructions
Type 2035 / 3236
Further instructions:
▶ The user must ensure that the appliance is used in Zone 1/21 or
2/22 only.
▶ The attachment of feedback indicators may restrict use in an
explosive atmosphere. Follow operating instructions for feedback indicator.
▶ Check that any cleaning agents are approved for use in explosive
atmospheres.
3.1.2. Media temperature
DANGER!
▶ If explosive media are used this can cause additional explosion risks. ▶ If media temperatures are used between 130 °C and 150 °C, the
temperature class T3 / 200 °C applies (dust).
Media temperature The media temperature must not be higher
than the target temperature class.
3.1.3. Marking and warning notices in Ex area
Type 2035
PTB 13 ATEX D103 X II 2G c IIC T6 II 2D c T85°C
Warning: Not valid when Non-Ex devices added. Do not open actuator. Spring loaded cover. Clean the surface with appropriate cleaning agent only!
Fig. 1: Type 2035 marking and warning notices in Ex area
Type 3236
PTB 13 ATEX D103 X II 2G c IIC T6 II 2D c T85°C
Caution: Clean the surface with appropriate cleaning agent only!
Fig. 2: Type 3236 marking and warning notices in Ex area
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General information
Type 2035 / 3236
The Ex marking is not valid if Non-Ex devices are added.
3.2. Special conditions
→ To ensure potential equalization, ground the valve body to the
pipe system using an electrically conductive connection.
DANGER!
Danger of explosion caused by electrostatic charge.
In the event of a sudden discharge from electrostatically charged devices or individuals there is a risk of an explosion in the Ex area.
▶ Implement suitable measures to ensure that there are no electro-
statically charges in the Ex area (see also "3.1. Use in Ex area").
▶ Clean the device surface by gently wiping it with a damp or anti-
static cloth only. ▶ Earth the actuator and valve body. ▶ If a plastic body is used, earth the actuator separately.
Ambient temperature range: -10 °C ≤ Tamb ≤ 60 °C
4. GENERAL INFORMATION
4.1. Contact address
Germany
Bürkert Fluid Control Systems Sales Center Christian-Bürkert-Str. 13-17 D-74653 Ingelfingen Tel. + 49 (0) 7940 - 10 91 111 Fax + 49 (0) 7940 - 10 91 448 Email: info@de.buerkert.com
International
Contact addresses can be found on the final pages of the printed operating instructions.
And also on the Internet at: www.burkert.com
4.2. Warranty
The warranty is only valid if the diaphragm valve is used as intended in accordance with the specified application conditions.
4.3. Information on the Internet
The operating instructions and data sheets for Types 2035 / 3236 can be found on the Internet at:
www.burkert.com
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Product description
Type 2035 / 3236
4.4. Trademarks
Brands and trademarks listed below are trademarks of the respective companies / associations / organizations:
PFR 91 Solvey Solexis Inc. PFA DuPont Performance Elastomers Inbus Textron Verbindungstechnik GmbH & Co. oHG
5. PRODUCT DESCRIPTION
5.1. General description
The manually or pneumatically operated Robolux Multiway Dia­phragm Valves
1)
have been designed as a system for the control of ultra-pure, sterile, aggressive or abrasive media. They allow for optimal collection, draining or distribution of critical process media.
Observe instructions on operation in an explosion-risk (Ex) area. See chapter "3.1. Use in Ex area".
1) In the following text the Robolux Multiway Diaphragm Valve is
referred to as 'diaphragm valve' for brevity's sake.
5.2. Device versions
The diaphragm valve is available in two variants with either a pneu­matically or manually operated valve.
The diaphragm valve can be adapted to very different usage condi­tions on account of its modular design.
Depending on the connection size of the diaphragm valves three construction sizes are available (RV5O, RV7O, RV110).
The valve body is made from a stainless steel block. For certain usage conditions valve bodies made of plastic (PVDF or PP) are available.
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Product description
Type 2035 / 3236
High-quality diaphragms ensure complete separation of the critical medium from the actuator.
Depending on the function the valve can have one, two or three actuators.
The diaphragm valves can be used for a large variety of control func­tions. Accordingly, there is a very wide range of configuration varia­tions. For instance, according to function:
• the valves in the actuator can vary,
• the actuators can have one or two control pistons that can be operated independently of each other,
• pneumatic actuators can be equipped with inductive proximity switches for querying the various switching states.
5.2.1. Pneumatically operated diaphragm valve Type 2035
The valve has one or two pneumatic actuators that are controlled via compressed air.
Pneumati­cally operated actuator
Diaphragm
Valve body
Diaphragm
Fig. 3: Pneumatically operated diaphragm valve, structure and
description
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Product description
Type 2035 / 3236
5.2.2. Manually operated diaphragm valve Type 3236
The valve is operated manually.
Manually operated actuator
Diaphragm
Valve body
Fig. 4: Manually operated diaphragm valve, structure and
description
5.3. Valve self-draining
The way in which self-draining takes place varies according to the valve type. It is very important to know the flow paths for each indi­vidual valve before the port / connection (marked with A, B, C or D) for draining is selected.
Contact your Bürkert sales office or our Sales Center, email: info@de.buerkert.com if you have any queries.
The following examples illustrate draining for the valve types 3C2S / 4C2S and 4C4S DFP.
3C2S / 4C2S
drainage connection B (D)
3C2S / 4C2S
drainage connection C (A)
Installation positions for self-drainage:
A
C
B
D
A
C
B
A
C
B
B
C
A
Fig. 5: Self-draining - 3C2S / 4C2S
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Product description
Type 2035 / 3236
A
C
B
B
C
A
4C4S DFP
drainage connection
A (C)
4C4S DFP
drainage connection
B (D)
Installation positions for self-drainage:
D
D
A
C
B
D
Fig. 6: Self-draining - 4C4S DFP
5.4. Valve symbols and flow diagrams
3 connections, 2 seats
3C2S
Seat
U1
Seat
U2
A
C
B
A
C
B
Fig. 7: Valve symbols and flow diagrams - 3C2S
4 connections, 2 seats
4C2S
Seat
U1
Seat
U2
A
C
B
D
A
C
B
D
Fig. 8: Valve symbols and flow diagrams - 4C2S
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Product description
Type 2035 / 3236
3 connections, 3 seats
3C3S
upper side lower side
Seat
U1
Seat
U2
C
A
D
Seat
L1
D
A
C
C
A
D
Fig. 9: Valve symbols and flow diagrams - 3C3S
4 connections, 3 seats
4C3S
upper side lower side
Seat
U1
Seat
U2
A C
B
D
Seat
L1
B
C A
D
A
C
B
D
Fig. 10: Valve symbols and flow diagrams - 4C3S
4 connections, 3 seats
4C3S BD filter valve
upper side lower side
Seat
U1
Seat
U2
B
A
C
D
Seat
L2
D
C
A
B
B
D
C
A
Fig. 11: Valve symbols and flow diagrams - 4C3S BD
4 connections, 4 seats
4C4S
upper side lower side
Seat
U1
Seat
U2
A
C
B
D
Seat
L2
Seat
L1
B
C
A
D
A
C
B
D
Fig. 12: Valve symbols and flow diagrams - 4C4S
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Product description
Type 2035 / 3236
4 connections, 4 seats
4C4S DFP through-flow double valve
upper side lower side
Seat
U1
Seat
U2
A
D
B
C
Seat
L2
Seat
L1
C
B
D
A
A
C
B
D
Fig. 13: Valve symbols and flow diagrams - 4C4S DFP
4 connections, 5 seats
4C5S chromatography valve
upper side lower side
Seat
U1
Seat
U2
B1
A
C
Seat
L2
Seat
L1
C
A
B1
B2
A
C
B2
B1
Fig. 14: Valve symbols and flow diagrams - 4C5S
5.5. Valve marking
Type label
Marking and warning
notices in Ex area
Actuator orientation
marking
Port connection
markings
Valve body labeling
Orifice and connection dimensions
Material, charge, manufacturing
order and serial No.
Fig. 15: Valve marking
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Product description
Type 2035 / 3236
5.5.1. Type label
2035 RV50 4C 4S-DFP EPDM-cus D11 -D11 Weld end 19.05x1.65 Pilot 4.2-10 bar Pmed 10bar
12345678
Made in Germany
W14UN
Identification number
Size
Connection type - connection dimensions
Type
Diaphragm material - actuator 1 - actuator 2
Date of manufacture
Max. medium pressure
Pilot pressure
Design
Fig. 16: Type label Type 2035
Robolux 3236 RV50 4C 4S-DFP EPDM-cus D44 -D44 Weld end 19.05x1.65 Pmed 10bar
12345678
Made in Germany
W14UN
Identification number
Connection type - connection dimensions
Diaphragm material - actuator 1 - actuator 2
Date of manufacture
Max. medium pressure
Type - Size - Design
Fig. 17: Type label Type 3236
5.5.2. Marking and warning notices in Ex area
See chapter "3.1.3. Marking and warning notices in Ex area".
5.5.3. Port connection markings
All port connections are provided with letters corresponding to the flow diagrams (see chapter "5.4. Valve symbols and flow diagrams").
5.5.4. Actuator orientation marking
The actuator has a marking close to connection A as an aid to ensure correct assembly.
Fig. 18: Actuator orientation marking
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Structure and function
Type 2035 / 3236
5.6. Intended application area
The diaphragm valve has been designed for use with soiled and aggressive media which do not corrode the body and the seal materials.
Observe the maximum pressure range according to the type label.
• Ultra-pure, sterile, aggressive or abrasive media.
• Highly viscous media.
Observe instructions on operation in an explosion-risk (Ex) area. See chapter "3.1. Use in Ex area".
5.6.1. Application areas
e.g. plant construction
luxury food and food processing industry bottling plant chemical engineering pharmaceutics
6. STRUCTURE AND FUNCTION
6.1. Structure of Type 2035
The diaphragm valve consists of a pneumatically operated piston actuator, diaphragm and multi-port valve body.
Actuator cover
Actuator body
Body screws / nuts
Diaphragm
Valve body
Silencer
Pilot air port
Cover position proximity switch
Cover screw pressure piece
Fig. 19: Piston-controlled diaphragm valve, structure and
description
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Structure and function
Type 2035 / 3236
6.1.1. Actuator
The actuator has two actuator chambers that can be controlled independently of each other and act on one body seat each (double action). Where only one actuator is in operation only one actuator chamber is equipped with the internal functional parts.
Spring force (CFA, NC) or pneumatic pilot pressure (CFB, NO) generates the closing force of the actuator.
The force is transmitted onto the corresponding pressure piece and the diaphragm in each case via a spindle connected to the actuator piston.
6.1.2. Control functions (CF)
Control function A, NC (CFA)
Closed by spring force in rest position
1(P)
2(A)
Control function B, NO (CFB)
Opened by spring force in rest position
1(P)
2(B)
6.2. Structure of Type 3236
The diaphragm valve consists of a manually operated actuator, diaphragm and multi-port valve body.
Hand wheel
Actuator body
Body screws
Diaphragm
Valve body
Fig. 20: Manually operated diaphragm valve, structure and
description
6.2.1. Actuator
The actuator has two hand wheels that can be controlled indepen­dently of each other and act on one body seat each (double action). Where only one actuator is in operation only one actuator side con­tains functional parts.
The force is transmitted onto the corresponding pressure piece and the diaphragm in each case via a spindle connected to the hand wheel.
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Technical Data
Type 2035 / 3236
7. TECHNICAL DATA
7.1. Conformity
The diaphragm valves of Type 2035 and 3236 comply with EC Direc­tives in accordance with the EC Declaration of Conformity.
7.2. Standards
The applied standards on the basis of which compliance with the EC Directives is confirmed are listed in the EC type examination certificate and/or the EC Declaration of Conformity.
7.3. Approvals
The product is approved for use in zone 1 and 21 in accordance with ATEX directive 94/9/EC category 2 GD.
Observe instructions on operation in an explosion-risk (Ex) area. See chapter "3.1. Use in Ex area".
Valve body stainless steel: EN ISO 10204 3.1
polypropylene: USP VI (material PR)
diaphragm FDA CFR 177.2600 for EPDM, FKM and silicone
FDA CFR 177.1550 for PFA USP VI for EPDM, PFA/EPDM, silicone and PFR 91
7.4. Type label
See chapter "5.5. Valve marking".
7.5. Operating conditions
Observe permitted pressure ranges given on the type label of the device.
Ambient temperature -10 – +60 °C
higher temperatures on request
Operating temperature max. +85 °C
Relative humidity max. 80 % (non-condensing)
7.6. Mechanical data
Dimensions see data sheet
Materials
Body material stainless steel: 1.4435/316L
(other materials on request) PP (ultra-pure polypropylene) PP (polypropylene USP VI) PVDF (sterile polyvinyl-difluoride)
Diaphragm EPDM, silicone, PFA/EPDM, FKM, PFR 91
Actuator epoxy powder coated aluminum
PP body (only type 2035 RV50)
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Technical Data
Type 2035 / 3236
Connections
Port connections welded spigots DIN EN ISO 1127
(ISO 4200), DIN 11850 Series 2, ASME BPE SMS 3008, BS4825 (other welded con­nections, clamps and sterile screw fittings on request)
Pilot air port G1/8
Surface quality interior Ra 0.5 µm passivated
exterior Ra 3.2 µm glass bead blasted optional electro-polished (other surface finishes on request)
Installation position any position; preferably connection B
downwards; for self-drainage see chapter "5.3. Valve self-draining"
Service life
The service life of the device depends heavily on the conditions of use. Especially the service life of the diaphragm depends very heavily on the conditions of use, such as the medium, temperatures, switching frequency, pressure etc.
7.6.1. Diaphragm
The diaphragm seals the valve. It must be selected with care. The choice of material should be made bearing in mind the process medium, the temperature and the mechanical boundary conditions (e.g. operating pressure, switching frequency etc.).
The standard materials are contained in the following table.
For conformity with FDA CFR 21 Para. 177.2600 or Para. 177.1550 and USP VI certification, see "Tab. 1: Diaphragm materials".
Diaphragm material
Description of material
Use FDA USP VI
EPDM peroxide-vulcanized
ethylene-propylene rubber
oxidizing chemicals, steam and hot water
x x
PFA / EPDM
PFA laminated EPDM
most chem­icals and acids
x x
FKM fluorinated rubber acids and
mineral oils
x
silicone platinum-stabilized
silicone rubber
aliphatic oils x x
PFR 91 PFR 91
fluorinated rubber
aliphatic oils x
Tab. 1: Diaphragm materials
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Technical Data
Type 2035 / 3236
7.7. Fluidic data
Media flow media ultra-pure, sterile, aggressive,
(see also chapter "7.6.1. Diaphragm")
Media pressure RV50 max. 8 bar
2)
RV70/RV110 max. 6 bar (depending on actuator, diaphragm and body material) see chapter "7.7.1. Pressure ranges"
Media temperature stainless steel -10 to max. +120 °C
(max. +140 °C, 30 min.) plastic -10 to max. +40 °C (see "Fig. 22") PFA diaphragm 0 to max. +95 °C
Viscosity up to highly viscous
Observe instructions on operation in an explosion-risk (Ex) area. See chapter "3.1. Use in Ex area".
Pilot medium Neutral gases, dry air (min. 10 K below min.
operating temperature), preferably unoiled
Pilot pressure
4)
6 – 10 bar (Type 2035 only)
from 4.2 bar (with reduced medium pressure) on request
2) Pressure values [bar]: Overpressure with respect to atmospheric
pressure
7.7.1. Pressure ranges
Pilot pressure and medium pressure
Actuator desig­nation
Pilot pressure [bar]
EPDM, FKM, Silicone, PFR 91
PFA / EPDM
Static leak­tightness [bar]
Dynamic leak­tightness [bar]
Static leak­tightness [bar]
Dynamic leak­tightness
[bar] RV50 6 – 10 8 6 8 6 RV50
EC04
4.2 – 10 6 4 6 4
RV70 6 – 10 6 4 6 4 RV70
EC04
4.2 – 10 3 2 3 2
RV110 6 – 10 6 4 6 4 RV110
EC04
4.2 – 10 3 2 3 2
Tab. 2: Static and dynamic leak-tightness
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Technical Data
Type 2035 / 3236
Remarks
Static leak-tightness: Valve is closed (diaphragm is in contact with the body seat). One
side of the body seat is under pressure. At the given pressure no leakage takes place via the body seat.
Dynamic leak-tightness: Valve is open and the medium is flowing through it. The downstream
flow is only slightly throttled by components placed downstream. Both sides of the body seat are under pressure. The valve is closed (CFA, NC via spring force; CFB, NO via pilot pressure). At the given pressure the valve closes onto the body seat and the seal is complete.
Static leak-tightness:
Dynamic leak-tightness:
Fig. 21: Static and dynamic leak-tightness
Permitted medium pressure depending on the medium temperature for plastic bodies.
0 20 40 60 80 100 120 140
0.0
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
PVDF
PP
Temperature [°C]
Medium pressure [bar]
3)
Fig. 22: Permitted medium pressure depending on the medium
temperature for plastic bodies.
3) The given medium pressure applies for the static leak-tightness
value. For further information on this point see "Kv value".
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Assembly
Type 2035 / 3236
7.7.2. Kv value
Orifice DN Body connection [mm]
Valve size Actuator Kv value water [m³/h] for
diaphragm material
Designation EPDM,
FKM
PFA
10 3/8" RV50 0.8 0.7 15 1/2" RV50 2.5 2 20 3/4" RV50 3.5 3.3 25 1" RV70 10 9 40 1 1/2" RV110 27 22 50 2" RV110 35 27
Tab. 3: Kv value
All Kv values measured on valves with connections according to ASME BPE.
8. ASSEMBLY
8.1. Safety instructions
DANGER!
Risk of injury from high pressure in the equipment/device.
▶ Before working on equipment or device, switch off the pressure
and deaerate/drain lines.
WARNING!
Risk of injury from improper assembly.
▶ Installation must only be carried out by authorized technicians and
with the appropriate tools.
Risk of injury from unintentional activation of the system and uncontrolled restart.
▶ Secure system from unintentional activation. ▶ Following assembly, ensure a controlled restart.
8.2. Before installation
• Before connecting the valve, ensure the pipelines are flush.
• Pay attention to the flow direction.
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Assembly
Type 2035 / 3236
8.2.1. Installation position
• The piston-controlled diaphragm valve can be installed in any position, preferably with connection B / muffler downwards.
• Installation for self-drainage of the body: see chapter "5.3. Valve self-draining"
8.2.2. Preparatory work
→ Clean pipelines (sealing material, swarf, etc.). → Support and align pipelines.
Devices with welded body
NOTE!
Damage to diaphragm or actuator.
▶ Before welding in the body disassemble the actuator and
diaphragm.
Remove the actuator from the valve body:
→ Move the actuator to the upper actuator position (CFA, NC: by
applying pilot pressure; CFB, NO: by removing the pilot pressure).
→ Mark the position of the actuator in relation to the valve body. → Unscrew the four body screws / nuts that connect the valve body
with the actuator. Remove the actuator and the diaphragm.
Actuator
Body screws and washers
Diaphragm
Valve body
Silencer
Fig. 23: Assembly
8.3. Installation
8.3.1. Installing the body
Welded body
→ Weld valve body in pipeline system.
Other body designs
→ Connect body to pipeline.
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Assembly
Type 2035 / 3236
8.3.2. Installing the actuator (welded body)
→ Move the actuator to the upper actuator position (CFA, NC: by
applying pilot pressure; CFB, NO: by removing the pilot pressure).
→ Put the actuator / diaphragm on the body with correct alignment
(so that the markings made previously align).
→ Tighten the diagonally opposed body screws / nuts until there
is visible, uniform mechanical contact between the valve body, diaphragm and actuator.
→ Tighten the diagonally opposed body screws / nuts twice with a
quarter turn and using the same torque in each case.
8.3.3. Test for leak-tightness / valve
function
WARNING!
Danger of injury through egress of flow medium.
▶ Tighten the body screws sufficiently.
Applying an unnecessary degree of force to tighten the body screws / nuts leads to increased wear and therefore shortens the service life of the diaphragm.
If the valve leaks when the medium pressure rises:
→ Tighten the diagonally opposed body screws / nuts by a one-
eighth turn until the valve no longer leaks.
This procedure ensures that the diaphragm and the pressure piece are optimally aligned to each other and the valve function is ensured.
8.4. Pneumatic connection (Type 2035 only)
DANGER!
Risk of injury from high pressure in the equipment/device.
▶ Before working on equipment or device, switch off the pressure
and deaerate/drain lines.
WARNING!
Risk of injury from unsuitable connection hoses.
Hoses which cannot withstand the pressure and temperature range may result in hazardous situations.
▶ Use only hoses which are authorized for the indicated pressure
and temperature range.
▶ Observe the data sheet specifications from the hose manufacturers.
8.4.1. Connection of the pilot medium
For the assignment of pilot air ports refer to the installation and dimen­sional drawing included with delivery of the valve. Compare also the information given in chapter "6. Structure and function".
The use of pneumatic hose with a minimum size of 6/4 is recommended. For longer hose lengths the hose cross-sections should be adapted accordingly.
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Assembly
Type 2035 / 3236
In aggressive surroundings and in situations where moisture could enter the actuator via the exhaust air port or muffler the exhaust air should be collected and ducted to a non­critical location.
Procedure:
→ Remove the yellow protective stopper. → Connect the pilot medium to the pilot air port with the aid of the
installation and dimensional drawing supplied.
Control function B:
The pilot pressure should be selected to be as low as pos­sible to reduce wear on the diaphragm.
Pilot air ports
Connections for proximity sensors
Fig. 24: Pneumatic connection; installation of a proximity switch
8.5. Installation of the inductive proximity switch
The switch is installed using the M8 x 1 or M12 x 1 thread on the side of the actuator (for RV50 with PP cover on the upper side).
→ Connect with the aid of the installation and dimensional drawing
supplied.
→ Remove the yellow protective stopper. → Move the actuator to the position that is to be queried by the
proximity switch: RV50/70: lower proximity switch: Move the actuator to the lower actuator position (CFA, NC: by removing pilot pressure; CFB, NO: by applying the pilot pressure). upper proximity switch: Move the actuator to the upper actuator position (CFA, NC: by applying pilot pressure; CFB, NO: by removing the pilot pressure). RV110: Move the actuator to the lower actuator position (CFA, NC: by removing pilot pressure; CFB, NO: by applying the pilot pressure).
→ Screw in the proximity switches until they connect with the pressure
pieces.
→ Then unscrew the proximity switches by one half to one turn. → Secure the proximity switches with the aid of securing nuts (the
second nut and the two washers supplied are not needed).
→ Test the functionality of the proximity switches.
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Operation and function
Type 2035 / 3236
NOTE!
Ingress of moisture and dirt.
▶ If no proximity switch is used, block the M8 x 1 or M12 x 1 threaded
connection.
9. OPERATION AND FUNCTION
9.1. Safety instructions
WARNING!
Danger due to improper operation.
Improper operation may result in injuries as well as damage to the device and the area around it.
▶ The operating personnel must know and have understood the
contents of the operating instructions. ▶ Observe the safety instructions and intended use. ▶ Only adequately trained personnel may operate the equipment/
the device.
9.2. Type 2035 - pneumatic operation
The diaphragm valve is controlled by compressed air. The com­pressed air reaches the pistons via the pilot air ports and actuates them. This causes the valves to open or close.
For the assignment of pilot air ports refer to the installation and dimensional drawing included with delivery of the valve.
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Electrical pre-controller
Type 2035 / 3236
9.3. Type 3236 - manual operation
The diaphragm valve is actuated by means of hand wheels. Close valve seat Turn clockwise Open valve seat Turn counter-clockwise
Open valve seat
Close valve seat
Fig. 25: Type 3236
10. ELECTRICAL PRE-CONTROLLER
The electrical connection of the pilot valve is described in the operating instructions for the pilot valve.
Observe instructions on operation in an explosion-risk (Ex) area. See chapter "3.1. Use in Ex area".
11. DISASSEMBLY
DANGER!
Risk of injury from discharge of medium and release of pressure.
It is dangerous to remove a device which is under pressure due to the sudden release of pressure or discharge of medium.
▶ Before removing a device, switch off the pressure and vent the
lines.
If the valve is to be reused after removal, the actuator must be removed before disassembly where welded bodies are involved. For this, refer to the assembly instructions.
Procedure:
→ Loosen pneumatic connection. → Remove device.
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Maintenance, Cleaning
Type 2035 / 3236
12. MAINTENANCE, CLEANING
12.1. Safety instructions
DANGER!
Risk of injury from high pressure in the equipment/device.
▶ Before working on equipment or device, switch off the pressure
and deaerate/drain lines.
Risk of electric shock.
▶ Before working on equipment or device, switch off the power
supply and secure to prevent reactivation.
▶ Observe applicable accident prevention and safety regulations
for electrical equipment.
WARNING!
Risk of injury from improper maintenance.
▶ Installation must only be carried out by authorized technicians and
with the appropriate tools!
Risk of injury from unintentional activation of the system and uncontrolled restart.
▶ Secure system from unintentional activation. ▶ Following maintenance, ensure a controlled restart.
12.2. Servicing intervals
Check the diaphragm valves regularly for proper operation in terms of assembly, installation and operation. Take the following factors into account when planning servicing intervals:
• Operational conditions (amount of usage, improper usage),
• Manufacturer's specifications in the technical documentation (e.g.
mechanical service life,
• major system modifications.
12.3. Servicing work
During servicing, check:
• that hoses are secure
• plastic bodies for signs of alteration
• that permissible temperature ranges are adhered to (see Technical
Specifications)
• proper functionality
12.3.1. Actuator
The actuator of the diaphragm valve is maintenance-free provided it is used according to these operating instructions.
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Maintenance, Cleaning
Type 2035 / 3236
12.3.2. Wearing parts of the diaphragm valve
The diaphragm is subject to wear.
→ If leakage occurs replace the diaphragm. (see chapter "13. Repairs").
A bulging diaphragm may reduce the flow rate.
The replacement of the diaphragm is described in chapter "13. Repairs".
12.4. Cleaning
NOTE!
Avoid causing damage with cleaning agents.
▶ Before cleaning, check that the cleaning agents are compatible
with the device materials.
Epoxy powder coatings will be attacked by unsuitable cleaning agents.
▶ Clean the surface with a cleaning agent suitable for this material,
e.g. with 25% alcohol or acetone.
Observe instructions on operation in an explosion-risk (Ex) area. See chapter "3.1. Use in Ex area".
Actuator Clean the actuator surface using a moist cloth. Only use cleaning
agents that do not attack the actuator surface.
The following actuator versions are available: Actuator material (attribute AM):
AM = AE: Actuator body made of epoxy coated aluminium AM = AP: Actuator cover made of polypropylene (PP) AM = AE and
VAR = NC31: Actuator body made of aluminium
Body / Diaphragm The bodies are suitable for CIP. Clean the valves using cleaning
agents that do not attack the body and diaphragm materials. Avoid cleaning agents with high pH values.
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