Burkert 2105 User Manual [en, de, fr]
Type 2103, 2104, 2105
Piston-controlled Diaphragm Valve
Kolbengesteuertes Membranventil
Vanne à membrane commandée par piston
Quickstart
English Deutsch Français
We reserve the right to make technical changes without notice.
Technische Änderungen vorbehalten.
Sous réserve de modifications techniques.
© Bürkert Werke GmbH, 2013 - 2014
Operating Instructions 1403/01_EU-ML_00810349 / Original DE
Type 2103, 2104, 2105
Quickstart
1 QUICKSTART ..................................................................................................3
2 AUTHORIZED USE ......................................................................................4
3 BASIC SAFETY INSTRUCTIONS ..........................................................5
4 GENERAL INFORMATION ........................................................................6
5 DESIGNATED APPLICATION AREA ....................................................6
6 STRUCTURE AND FUNCTION...............................................................7
7 TECHNICAL DATA ........................................................................................8
8 INSTALLATION ............................................................................................ 10
9 REMOVAL ...................................................................................................... 14
10 MAINTENANCE WORK ........................................................................... 15
11 PACKAGING, TRANSPORT, STORAGE ..........................................15
1 QUICKSTART
The Quickstart describes the entire life cycle of the product. Keep these
instructions in a location which is easily accessible to every user, and
make these instructions available to every new owner of the product.
Important Safety Information!
Read Quickstart carefully and thoroughly. Study in particular the
chapters entitled “Authorized use” and “Basic safety instructions”.
▶ Quickstart must be read and understood.
Quickstart explains, for example, how to install and start-up the product.
A detailed description of the product 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 / abbreviation
The term “product” used in these instructions always stands for the
diaphragm valve Type 2103, 2104 or 2105.
The abbreviation “Ex” used in these instructions always stands for
“explosion-protected”.
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Type 2103, 2104, 2105
Authorized use
1.2 Symbols
DANGER!
Warns of an immediate danger.
▶ 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.
2 AUTHORIZED USE
Non-authorized use of the diaphragm valve Type 2103, 2104
or 2105 may be a hazard to people, nearby equipment and the
environment.
▶ The product is designed for the controlled flow of liquid media.
▶ The admissible data, the operating conditions and conditions of
use specified in the contract documents, operating instructions and
on the label are to be observed during use. These are described
in the chapter entitled “7 Technical data”.
▶ The product may be used only in conjunction with third-party
devices and components recommended and authorized by Bürkert.
▶ Correct transportation, correct storage and installation and care-
ful use and maintenance are essential for reliable and faultless
operation.
▶ Use the product only as intended.
2.1 Restrictions
If exporting the system/product, observe any existing restrictions.
▶ Designates an instruction to prevent risks.
→ Designates a procedure which you must carry out.
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Type 2103, 2104, 2105
Basic safety instructions
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 products.
• local safety regulations, whereby the operator is responsible for their
compliance, by the installation personnel too.
DANGER!
Risk of injury from high pressure in the equipment/product!
▶ Before working on equipment or product, switch off the pressure
and vent the lines.
Risk of injury due to electrical shock!
▶ Before reaching into the product, switch off the power supply and
secure to prevent reactivation!
▶ Observe applicable accident prevention and safety regulations
for electrical equipment!
Risk of burns!
The surface of the product may become hot during long-term
operation.
▶ Do not touch the product with bare hands.
Risk of injury from moving parts in the device!
▶ Do not reach into openings.
Risk of injury caused by the spring jumping out when the actuator
is opened!
▶ The actuator must not be opened.
General hazardous situations.
To prevent injury, ensure:
▶ Secure system/equipment from unintentional activation.
▶ Only trained technicians may perform installation and maintenance
work.
▶ After an interruption in the power supply or pneumatic supply,
ensure that the process is restarted in a defined or controlled
manner.
▶ The product may be operated only when in perfect condition and
in consideration of the operating instructions.
▶ The general rules of technology apply to application planning and
operation of the product.
▶ In the potentially explosion-risk area the diaphragm valve may be
used only according to the specification on the separate Ex type
label. For use observe the additional information enclosed with the
product together with safety instructions for the explosion-risk area.
▶ Products without a separate Ex type label may not be used in a
potentially explosive area.
To prevent damage to property of the product, ensure:
▶ Supply the media connections only with those media which
are specified as flow media in the chapter entitled “7 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.
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Type 2103, 2104, 2105
General information
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: info@de.burkert.com
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 product 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
5 DESIGNATED APPLICATION AREA
The diaphragm valve has been designed for use with ultrapure, sterile,
dirty, aggressive or abrasive media. The valves may only control media
which do not corrode the body and the seal materials (see type label).
Observe the maximum pressure range according to the
type label!
• Ultrapure, sterile, dirty, aggressive or abrasive media.
• Highly viscous media.
5.1 Application areas
e.g. plant construction
luxury food and food processing industry
bottling plant
chemical engineering
pharmaceutics
biotechnology
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Type 2103, 2104, 2105
Structure and function
6 STRUCTURE AND FUNCTION
6.1 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) /
stainless steel.
6.1.1 2/2-way valve type 2103
1
Pilot air port for CFA, CFB, CFI
2
Second pilot air port for CFI
and air discharge connection for CFA and CFB
Transparent cap with position indicator
Actuator cover
Actuator body
Diaphragm socket
Line connection
Valve body
Fig. 1: Piston-controlled diaphragm valve, structure and description
6.1.2 T-valve type 2104
1
Pilot air port for CFA,
CFB, CFI
Actuator body
Diaphragm socket
Fig. 2: Structure and description type 2104
Second pilot air port for CFI
2
and air discharge connection for CFA and CFB
Transparent cap with
position indicator
Actuator cover
Mechanical interface
Diaphragm body
Line connection
6.1.3 Tank bottom valve type 2105
Tank bottom valve with
welding flange
Diaphragm socket
Pilot air port for CFA,
CFB, CFI
Second pilot air port for CFI
and air discharge connection for
CFA and CFB
Fig. 3: Structure and description type 2105
1
2
Mechanical
interface
Actuator body
Actuator cover
Transparent cap with
position indicator
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A
A
A
Type 2103, 2104, 2105
Technical data
6.2 Function
Spring force (CFA) or pneumatic pilot pressure (CFB and CFI)
generates the closing force on the diaphragm pressure piece. The
force is transferred via a spindle which is connected to the actuator
piston.
6.2.1 Control functions (CF)
WARNING!
For control function I – Danger if pilot pressure fails!
For control function I (CFI) control and resetting occur pneumatically.
If the pressure fails, no defined position is reached.
▶ To ensure a controlled restart, first pressurize the product with
pilot pressure, then switch on the medium.
CFA
CFB
CFI
Closed by spring force in rest position.
Opened by spring force in rest position.
Actuating function via reciprocal
pressurization.
7 TECHNICAL DATA
WARNING!
Risk of injury from high pressure!
Important product-specific technical specifications are indicated
on the type label.
▶ Observe permitted pressure range on the type label of the product.
7.1 Conformity
Type 2103, 2104 and 2105 conforms with the EC Directives according
to the EC Declaration of Conformity.
7.2 Standards
The applied standards, which verify conformity with the EC Directives, can be found on the EC-Type Examination Certificate and / or
the EC Declaration of Conformity.
7.3 Type label
Example:
2103 A 20M PTFE VS
Tamb 0°C - +60°C
00175139
Fig. 4: Example of type label
Tmed xxx°C - +130°C
Pilot 4,8-10bar
Pmed 10,0bar
Da=26,9 s=1,6
CE
W3ZLT
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Type 2103, 2104, 2105
Technical data
7.3.1 Wording on the type label
Example:
Sealing material
Orifice
(diaphragm size /
Body material
Permitted medium
pressure
actuator size
Control function
Type
00175139
Identification
number of the
2103 A 20M PTFE VS
Tamb 0°C - +60°C
Tmed xxx°C - +130°C
Permitted medium
temperature
Pilot 4,8-10bar
Pmed 10,0bar
Da=26,9 s=1,6
product
Permitted ambient
temperature
Main dimensions of
body connection
Permitted pilot
pressure
CE identification
CE
W3ZLT
Date of manufacture
(encoded)
7.3.2 Labeling of the forged bodies
Batch number
XX F
Material
Production number /
serial number
Surface quality code
1.4435/316L(VS)
PN16/CWP150
XXXXXXXX/XXX
XXXX
XXXXXX
Customer-specific text
(optional)
XXXXXXXXXX
Nominal pressure
Orifice connection and
pipe dimension
Fig. 5: Labeling of the forged bodies
7.4 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)
Protection class IP67 in accordance with IEC 529 / EN 60529
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Type 2103, 2104, 2105
Installation
8 INSTALLATION
8.1 Safety instructions
DANGER!
Risk of injury from high pressure in the equipment/product!
▶ Before working on equipment or product, 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 pneumatically. If
the pressure fails, no defined position is reached.
▶ To ensure a controlled restart, first pressurize the product with
pilot pressure, then switch on the medium.
8.2 Before installation
NOTE!
Damage to the diaphragm or the actuator!
▶ Products with VG/VS welded body: Before welding in the body,
remove the actuator.
• Before connecting the valve, ensure the pipelines are flush.
• The flow direction is optional.
8.2.1 Installation position general
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 actuator base) for monitoring
leakage must be at the lowest point.
8.2.2 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 body inclined by an angle α = 10° – 40° to the horizontal.
→ Observe an inclination angle of 1° – 5° to the line axis.
Forged and cast body: Mark on the body must point upwards
(12 o’clock position, see “Fig. 6”).
→ One of the bores (in the actuator base) for monitoring leakage
must be at the lowest point.
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Type 2103, 2104, 2105
Installation
Mark
α
Angle α: 10° – 40°
Inclination to the line axis 1° – 5°
Fig. 6: Installation position for self-drainage of the body
8.2.3 Installation position T-valve type 2104
For the installation of the T-valves into circular pipelines, we recommend
the following installation positions:
When media is supplied: When media is removed:
Fig. 7: Installation position type 2104
8.2.4 Installation position tank bottom valve
type 2105
Preferably with the actuator to the bottom.
8.2.5 Preparatory work
→ Clean pipelines (sealing material, swarf, etc.).
→ Support and align pipelines.
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 in open
position.
→ Control function A pressurize the pilot air port 1 with compressed
air (5 bar): valve opens.
→ Remove actuator with diaphragm by loosening the body screws.
Pilot air port CFA, CFB, CFI
Air discharge connection CFA, CFB
Pilot air port CFI
Actuator
Diaphragm
Valve body
Body screws (4x)
Fig. 8: Installation
8.3 Installation
If used in an aggressive environment, we recommend conveying all free pneumatic connections into a neutral atmosphere with the aid of a pneumatic hose.
1
2
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Type 2103, 2104, 2105
Installation
WARNING!
Risk of injury from improper installation!
Non-observance of the tightening torque is dangerous as the product
may be damaged.
▶ Observe the tightening torque (see “Tab. 1”, page 13).
8.3.1 Installation of the valve body type 2103
and 2104
Welded bodies
→ Weld valve body in pipeline system.
Other body versions
→ Connect body to pipeline.
8.3.2 Installation of the tank bottom valve Type
2105
For further information on containers and welding instructions,
please refer to the standard ASME VIII Division I.
It is recommended to weld the valve prior to the container
installation. However, it is possible to weld the valves to
ready-assembled containers.
Prior to welding, please check to ensure that:
• The tank bottom valve does not collide with other equipment compo-
nents and assembly/disassembly of the actuator is always possible.
• A minimal distance between two welding joints three times the
thickness of the container wall is adhered to.
It is recommended to weld the valve in the center of the drain
to ensure optimum draining of the container.
The hole diameter in the tank and the housing flange must be the
same size. The housing flange has two welded edges to facilitate
positioning and welding of the valve. The welded edges are approx.
3 mm wide. If the container wall is more than 3 mm thick, it must
be ground down so that the discharge surface is touching the
housing flange surface.
Prior to commencing the welding process, check the charge
number indicated on the supplied manufacturer‘s certificate
3.1.B.
Procedure:
→ Position the flange into the hole so that the flange surface is
tangent to the drain surface.
→ Tack 4 welding points and check the position of the valve.
→ Weld the valve evenly to the inside and outside of the container,
with gas being supplied and using welding material compatible
with the valve‘s stainless steel 316L (DIN 1.4435).
→ Allow the welds to cool down before burnishing and cleaning
them according to the applicable specifications.
These instructions assist in the installation of the tank bottom valves and
allow the prevention of deformation and softening within the containers.
Please observe the applicable laws and regulations of the
respective country with regard to the qualification of welders
and the execution of welding work.
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Type 2103, 2104, 2105
Installation
8.3.3 Installation of the actuator (welded body)
Installation for actuator with control function A:
NOTICE!
Damage to the diaphragm or the seat contour!
▶ When installing the actuator, ensure that the valve is in open
position.
→ Control function A pressurize the pilot air port 1 with compressed
air (5 bar): valve opens.
→ Lightly cross-tighten the body screws until the diaphragm is
between the body and actuator. Do not tighten the screws yet.
→ Actuate the diaphragm valve twice.
→ Without pressurization tighten the body screws to the permitted
tightening torque (see following table “Tab. 1”).
Installation for actuator with control functions B and I:
→ Lightly cross-tighten the body screws without pressurization until
the diaphragm is between the body and actuator.
Do not tighten the screws yet.
→ Pressurize pilot air port 1 of the actuator with compressed air
(5 bar).
→ Actuate the diaphragm valve twice.
→ Tighten the body screws to the permitted tightening torque (see
“Tab. 1”).
Pilot air port
CFA, CFB, CFI
Fig. 9: Pilot air port
1
Orifice DN
(diaphragm size)
[mm]
8 2.5 2.5
15 3.5 4
20 4 4.5
25 5 6
40 8 10
50 12 15
Tab. 1: Tightening torques for diaphragms
Tightening torques for diaphragms [Nm]
EPDM/FKM PTFE / advanced
PTFE / laminated
advanced PTFE
8.4 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!
Hoses which cannot withstand the pressure and temperature range
may result in hazardous situations.
▶ Use only hoses which are authorised for the indicated pressure
and temperature range.
▶ Observe the data sheet specifications from the hose manufacturers.
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