Burkert 2036 User Manual [en, de, fr]

Type 2036

Robolux multiple-way diaphragm valve Robolux Mehrwege-Membranventil Vanne à membrane multivoies Robolux

Operating Instructions

Bedienungsanleitung Manuel d‘utilisation

We reserve the right to make technical changes without notice. Technische Änderungen vorbehalten. Sous réserve de modifications techniques.

Operating Instructions 1312/01_EU-ML_00809601 / Original DE

Type 2036

Contents

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 ...........................................................................8

4. GENERAL INFORMATION ...........................................................................9

4.1. Contact address ............................................................................... 9

4.2. Warranty ............................................................................................. 9

4.3. Information on the Internet ............................................................. 9

5. PRODUCT DESCRIPTION ...........................................................................9

5.1. General description ......................................................................... 9

5.2. Device versions ................................................................................. 9

5.3. Options .............................................................................................10

5.4. Valve self-draining ..........................................................................10

5.5. Valve symbols and flow diagrams ................................................ 12

5.6. Valve marking ..................................................................................14

5.7. Intended application area .............................................................15

6. STRUCTURE AND FUNCTION...............................................................15

6.1. Structure ..........................................................................................15

6.2. Position indicator ............................................................................16

7. TECHNICAL DATA ........................................................................................17

7.1. Conformity .......................................................................................17

7.2. Standards .........................................................................................17

7.3. Approvals .........................................................................................17

7.4. Type label .........................................................................................17

7.5. Operating conditions .....................................................................17

7.6. Mechanical data .............................................................................17

7.7. Fluidic data ......................................................................................19

8. ASSEMBLY .......................................................................................................21

8.1. Safety instructions .........................................................................21

8.2. Before installation ...........................................................................21

8.3. Installation ........................................................................................22

8.4. Pneumatic connection .................................................................23

9. ELECTRICAL CONTROL UNIT ............................................................... 25

10. DISASSEMBLY ............................................................................................ 25

11. MAINTENANCE, CLEANING ................................................................. 25

11.1. Safety instructions .......................................................................25

11.2. Servicing intervals ........................................................................26

11.3. Servicing work ..............................................................................26

11.4. Cleaning .........................................................................................26

12. REPAIRS ......................................................................................................... 27

12.1. Safety instructions .......................................................................27

12.2. Replacing the diaphragm ...........................................................27

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13. MALFUNCTIONS ........................................................................................ 30

14. SPARE PARTS ............................................................................................. 31

14.1. Order table ....................................................................................31

15. TRANSPORT, STORAGE, PACKAGING .......................................... 32

Type 2036

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Type 2036

Operating instructions

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.

▶ Indicates 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 2036.

In these instructions, the term 'Diaphragm Valve' always refers to the Robolux Multiway Diaphragm Valve Type 2036.

In these instructions, the abbreviation “Ex” always refers to “potentially explosive”.

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Type 2036

Authorized use

2. AUTHORIZED USE

Improper use of the Robolux Multiway Diaphragm Valve Type 2036 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 reaching into the 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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Type 2036

Basic safety instructions

CAUTION!

Risk of burns.

The surface of the device may become hot during long-term operation.

▶ Do not touch the device with bare hands.

Risk of being crushed by moving spindle ends.

▶ Install transparent cap.

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 applica-

tion 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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Type 2036

Basic safety instructions

Further instructions:

▶ The user must ensure that the appliance is used in Zone 1/21 or

2/22 only.

▶ The control unit may restrict use in an explosive atmosphere. Follow

operating instructions for control unit.

▶ 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 max. 130 °C

3.1.3. Marking Ex area

PTB 13 ATEX D103 X II 2G c IIC T4 II 2D c T135°C

Warning: Not valid when Non-Ex devices added.

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

electrostatically 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: 0 °C ≤ Tamb ≤ 60 °C

Do not open actuator. Spring loaded cover.

Fig. 1: Marking Ex area

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Type 2036

General information

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 2036 can be found on the Internet at:

www.burkert.com

5. PRODUCT DESCRIPTION

5.1. General description

The manually or pneumatically operated Robolux Multiway Diaphragm Valves of ultra-pure, sterile, aggressive or abrasive media. They allow for optimal collection, draining or distribution of critical process media.

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 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.

High-quality diaphragms ensure complete separation of the critical medium from the actuator.

have been designed as a system for the control

Observe instructions on operation in an explosion-risk (Ex) area. See chapter "3.1. Use in Ex area".

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Type 2036

Product description

The diaphragm valves can be used for a large variety of control functions. Accordingly, there is a very wide range of configuration variations. Depending on the function the valve can have one, two or three actuators.

Pneumatically operated actuator

Diaphragm

Valve body

5.3. Options

The following options are available for controlling the actuators and feedback of the different switching positions.

• Feedback head Type 8685 with up to four position feedback indicators in the versions 24 V DC, AS-Interface and EExi.

• Control head Type 8686 with up to two pilot valves and position indicators in the versions 24 V DC, AS-Interface and EExi.

5.4. 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.

Fig. 2: Diaphragm valve, structure and description

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Type 2036

Product description

Installation positions for self-drainage:

3C2S / 4C2S

drainage connection

B (D)

Fig. 3: Self-draining - 3C2S / 4C2S

3C2S / 4C2S

drainage connection

C (A)

Installation positions for self-drainage:

4C4S CF

drainage connection

Fig. 4: Self-draining - 4C4S CF

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Type 2036

Product description

Installation positions for self-drainage:

4C4S DFP

drainage connection

A (C)

Fig. 5: Self-draining - 4C4S DFP

4C4S DFP

drainage connection

B (D)

5.5. Valve symbols and flow diagrams

3 connections, 2 seats

3C2S

Seat

U1 U2

Seat

4 connections, 2 seats

4C2S

Seat

U1 U2

Seat

Fig. 6: Valve symbols and flow diagrams - 3C2S / 4C2S

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Type 2036

Product description

Seat

4 connections, 4 seats

4C4S CF

upper side lower side

Seat

4 connections, 4 seats

4C4S DFP

upper side lower side

C C

Seat

Fig. 7: Valve symbols and flow diagrams - 4C4S CF

Fig. 8: Valve symbols and flow diagrams - 4C4S DFP

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Type 2036

Product description

5.6. Valve marking

Type label

Marking and warning notices in Ex area

Actuator orientation marking

Port connection markings

Valve body labeling Bürkert company logo, Orifice and connection dimensions Material, charge, manufacturing order and serial No.

Fig. 9: Valve marking

5.6.1. Marking and warning notices in Ex area

See chapter "Use in Ex area" on page 7.

5.6.2. Type label

Company logo

Identification number

Connection dimensions

Fig. 10: Type label

Date of manufacture

Type - Size - Design

- Diaphragm material

Actuator 1 - Actuator 2 - Pilot pressure

Max. medium pressure medium temperature

5.6.3. Port connection markings

All port connections are provided with letters corresponding to the flow diagrams (see chapter "5.5. Valve symbols and flow diagrams").

5.6.4. Actuator orientation marking

The actuator has a marking close to connection A as an aid to ensure correct assembly.

Fig. 11: Actuator orientation marking

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Type 2036

Structure and function

5.7. 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".

5.7.1. Application areas

e.g. plant construction

luxury food and food processing industry bottling plant chemical engineering pharmaceutics

6. STRUCTURE AND FUNCTION

6.1. Structure

The diaphragm valve consists of a pneumatically operated piston actuator, diaphragm and multi-port valve body.

Transparent cap with position indicator

Actuator cover

Pilot air port 4

Pilot air port 2

Pilot air port 3

Pilot air port 1

Actuator body

Body screws

Guide pin

Diaphragm Valve body

Fig. 12: Piston-controlled diaphragm valve, structure and

description

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Type 2036

1(P)

2(A)

1(P)

2(B)

Structure and function

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

Control function B, NO (CFB)

Opened by spring force in rest position

6.2. Position indicator

The position of both actuator chambers is signaled via position indicators. Two positions are possible:

• Short protrusion of the position indicator → valve closed.

• Long protrusion of the position indicator → valve open

CAUTION!

Risk of being crushed by moving spindle ends.

▶ Install transparent cap.

Long protrusion

Short protrusion

Transparent cap removed

Fig. 13: Position indicator

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Type 2036

Technical Data

7. TECHNICAL DATA

7.1. Conformity

The diaphragm valve of Type 2036 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".

7.4. Type label

See chapter "5.6. 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

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)

Diaphragm EPDM, Advanced PTFE/EPDM, FKM,

silicone

Actuator Body stainless steel precision casting 1.4308

Pressure piece PPS (Polyphenylensulfid) and V2A

2) If a control unit or a pilot valve is used, the max. ambient

temperature is +55 °C.

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Type 2036

Technical Data

Connections

Port connections welded spigots

DIN EN ISO 1127 / ISO 4200) / DIN 11866 Series 2, DIN 11850 Series 2 / DIN 11866 Series A ASME BPE / DIN 11866 Series C Clamp DIN 32676 Series A (DIN pipe) DIN 32676 Series B (ISO pipe) ASME BPE (other connections on request)

Pilot air port G1/8

Surface quality interior Ra 0.6 µm passivated

exterior Ra 1.6 µm machined optional electro-polished (other surface finishes on request)

Installation position any position; preferably connection B

downwards; for self-drainage see chapter "5.4. Valve self-draining"

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., and may vary widely in individual cases.

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

EPDM AD Peroxide-vulca-

Advanced PTFE / EPDM

FKM KL Fluorinated

Silicone SK Platinum-sta-

Tab. 1: Diaphragm materials

Code Description of

material

nized ethylenepropylene rubber

EK Advanced PTFE

laminated EPDM

rubber

bilized silicone rubber

Use FDA USP

Oxidizing chemicals, steam and hot water

Most chemicals and acids

Acids and mineral oils

Aliphatic oils x x

x x

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Type 2036

Technical Data

7.7. Fluidic data

Media flow media ultra-pure, sterile, aggressive,

(see also chapter "7.6.1. Diaphragm")

Media pressure see chapter "7.7.1. Pressure ranges"

Media temperature stainless steel/EPDM +5 to +130 °C

(max. +143 °C for 60 min.) stainless steel/ Advanced PTFE +5 to +90 °C (no steam sterilization) stainless steel/FKM +5 to +130 °C (dry heat up to max. +143 °C) stainless steel/silicone +5 to +130 °C (dry heat up to max. +143 °C)

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

3) Pressure values [bar]: Overpressure with respect to atmospheric

pressure

6 – 10 bar (RV50, RV70)

6 – 7 bar (RV110) from 4.2 bar (with reduced medium pressure) on request

7.7.1. Pressure ranges

Pilot pressure and operation pressure for CFA, NC

Values for stainless steel body

max. operation pressure [bar]

EPDM, FKM,

Size

Actuator version

Pilot pressure

[bar]

Test criterion

Silicone Static 7.5 7.5 Dynamic 6.5 5.5 Static 5.0 3.5

Dynamic 4.0 2.5 Static 8.0 8.0 Dynamic 6.0 6.0 Static 5.5 6.0 Dynamic 3.5 4.0 Static 7.0 7.5 Dynamic 5.0 5.5 Static 5.0 5.0 Dynamic 3.0 3.0

RV50

RV70

RV110

D11 D1x; Dx1

6 – 10

D55 4.2 – 10

D11 D1x; Dx1

6 – 10

D55 4.2 – 10

D11 D1x; Dx1

6 – 7

D55 4.2 – 7

Tab. 2: Pilot pressure and operation pressure

4) See type label.

5) Pressure values [bar]: Overpressure with respect to atmospheric

pressure

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Advanced PTFE/ EPDM

Type 2036

Technical Data

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. 14: Static and dynamic leak-tightness

Pilot pressure and operation pressure for CFB, NO

The following graphs illustrate the required minimum pilot pressure depending on the medium pressure for control function B.

Permitted pilot pressure range: 2 – 7 bar.

The pilot pressure should be selected to be as low as possible to reduce wear on the diaphragm.

RV50/RV110 static

RV70

8 7 6 5 4 3

Medium pressure [bar]

2 1 0

0 1 2 3 4 5 6 7

Range for valves with control unit

static

RV70

dynamic

Pilot pressure [bar]

RV50/RV110 dynamic

Fig. 15: Pilot pressure depending on the medium pressure

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Type 2036

Assembly

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.

8.2.1. Installation position

• The piston-controlled diaphragm valve can be installed in any position, preferably with connection B downwards.

• Installation for self-drainage of the body: see chapter "5.4. 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 that connect the valve body with

the actuator. Remove the actuator and the diaphragm.

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Actuator Guide pin

Body screws

Diaphragm Valve body

Fig. 16: Assembly

8.3. Installation

WARNING!

Risk of injury from improper assembly.

Non-compliance with the tightening torques is dangerous due to possible discharge of medium and possible release of pressure.

▶ Observe the tightening torque (see "Tab. 3: Tightening torque").

Type 2036

Assembly

8.3.1. Installing the body

Welded body

→ Weld valve body in pipeline system.

Other body designs

→ Connect body to pipeline.

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). In the case of RV110 the four spacer sleeves must be inserted in the designated body holes (see "Fig. 20: Disassembly / assembly the diaphragm" on page 28).

→ Tighten the diagonally opposed body screws / nuts until there

is visible, uniform mechanical contact between the valve body, diaphragm and actuator.

→ Switch the diaphragm valve twice.

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Type 2036

Assembly

WARNING!

Risk of injury from discharge of medium and release of pressure.

▶ Tighten the body screws sufficiently (see "Tab. 3").

→ Move the actuator to the lower actuator position (CFA, NC: by

removing pilot pressure; CFB, NO: by applying the pilot pressure).

→ Without applying pilot pressure, tighten the body screws to the

permitted tightening torque (see "Tab. 3").

Size Tightening torque [Nm]

RV50 6 RV70 17 RV110 30

Tab. 3: Tightening torque

8.4. Pneumatic connection

DANGER!

Risk of injury from high pressure in the system.

▶ Before disconnecting lines and valves, turn off the pressure and

vent the 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

To comply with the degree of protection IP65 / IP67 on the pilot air port which is not required (for CFA, NC and CFB, NO), install an exhaust air line in the dry area.

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.

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.

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Type 2036

Assembly

Control function A:

→ Connect the control medium to the pilot air port 1 and/or 3

(see "Fig. 17").

Control function B:

→ Connect the control medium to the pilot air port 2 and/or 4

(see "Fig. 17").

Silencer

→ Connect the silencer into the free air discharge connection

(see "Fig. 17").

Actuator 1

(left)

Pilot air port

2 (P2)

Pilot air port

1 (P1)

Actuator 2 (right)

Pilot air port 4 (P4)

Pilot air port 3 (P3)

Actuator version

D11, D55 CFA/CFA (NC/NC)

D12 CFA/CFB (NC/NO)

D21 CFB/CFA (NO/NC)

D22 CFB/CFB (NO/NO)

Tab. 4: Pneumatic connection for actuator versions

CFA, NC : Valve normally closed by spring action CFB, NO : Valve normally open by spring action

Numbers for

actuator 1

Actuator 1 Actuator 2 CF Connection CF Connection

Pilot air P1

CFA, NC

CFB, NO

indicating

P2: air discharge

Pilot air P1 P2: air discharge

Pilot air P2 P1: air discharge

CFA

CFB

CFA

CFB

Pilot air P3 P4: air discharge

Pilot air P4 P3: air discharge

Pilot air P3 P4: air discharge

Pilot air P4 P3: air discharge

Numbers for indicating actuator 2

Fig. 17: Pneumatic connection

Fig. 18: Cover film

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Type 2036

Electrical control unit

9. ELECTRICAL CONTROL UNIT

The electrical connection of the pilot valve / control unit is described in the operating instructions for the pilot valve / control unit.

Observe instructions on operation in an explosion-risk (Ex) area. See chapter "3.1. Use in Ex area".

10. 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.

11. MAINTENANCE, CLEANING

11.1. 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 reaching into the 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.

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Type 2036

Maintenance, Cleaning

11.2. 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.

11.3. Servicing work

Do not repair the device yourself, but replace it with an equivalent device. Repairs may be performed by the manufacturer only.

11.3.1. Actuator

The actuator of the diaphragm valve is maintenance-free provided it is used according to these operating instructions.

11.3.2. Wearing parts of the diaphragm valve

The diaphragm is subject to wear.

→ If leakage occurs replace the diaphragm (see chapter "12. Repairs").

A bulging diaphragm may reduce the flow rate.

The replacement of the diaphragm is described in chapter "12. Repairs".

11.4. Cleaning

NOTE!

Avoid causing damage with cleaning agents.

▶ Before cleaning, check that the cleaning agents are compatible

with the device materials.

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.

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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Type 2036

Repairs

12. REPAIRS

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 reaching into the 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 repair.

▶ Installation must only be carried out by authorized technicians

and with the appropriate tools. ▶ Observe the tightening torques. ▶ On completion of the work check valve for leaks and function.

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. Replacing the diaphragm

Required spare part

• Diaphragm

12.2.1. Disassembly of the actuator and diaphragm

→ 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 that connect the valve body with

the actuator. Remove the valve body.

→ Move the actuator to the lower actuator position (CFA, NC: by

removing pilot pressure; CFB, NO: by applying the pilot pressure).

→ Unscrew guide pin all the way.

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Type 2036

Repairs

Fig. 19: Repairs

Guide pin

Actuator Guide pin

Body screws

Diaphragm

Valve body

Diaphragm

Pressure

pieces

Spacer sleeve

Fig. 20: Disassembly / assembly the diaphragm

→ Turn the diaphragm and pressure pieces through 30° and take

them out (step 1).

→ Take the diaphragm out of the pressure pieces sideways

(step 2).

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Type 2036

Repairs

12.2.2. Assembly of actuator and diaphragm

WARNING!

Risk of injury from moving parts in the device.

• When applying or removing the pilot pressure on the actuator, keep limbs and objects away from the openings of the actuator.

→ Move the actuator to the lower actuator position (CFA, NC: by

removing pilot pressure; CFB, NO: by applying the pilot pressure).

→ Insert the diaphragm into the guide of the pressure pieces. Make

sure that the four spacing sleeves are installed (see "Fig. 20").

→ Insert the pressure pieces into the actuator. Make sure that

the actuator spindles are fully inserted into the corresponding recesses of the pressure pieces (see "Fig. 21").

→ Turn the diaphragm and pressure pieces through approx. 30°.

Fig. 21: Assembly pressure pieces

approx. 30°

Pressure pieces

Actuator spindle

NOTE!

Damage to the diaphragm.

• Turn diaphragm and pressure pieces only as far as is required until the actuator and diaphragm screw holes are in alignment.

→ Screw guide pin all the way in ("Fig. 19"). → Move the actuator to the upper actuator position (CFA, NC: by

applying pilot pressure; CFB, NO: by removing the pilot pressure).

Guide pin

Identification plate diaphragm

Body seat

Fig. 22: Assembly of the actuator

→ Put the actuator / diaphragm on the body with correct alignment

(so that the markings made previously align, or guide pin, identification plate and body seats have been aligned in parallel). In the case of RV110 the four spacer sleeves must be inserted in the designated body holes.

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