Burkert 3236 User Manual [en, de, fr]
Type 2035 / 3236
Robolux multiple-way diaphragm valve
Robolux Mehrwege-Membranventil
Vanne à membrane multi-voies 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.
© 2005 - 2013 Bürkert Werke GmbH
Operating Instructions 1312/11_EU-ML_00804204 / Original DE
Type 2035 / 3236
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 ...........................................................................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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3
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
Type 2035 / 3236
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Type 2035 / 3236
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.
▶ 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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5
Type 2035 / 3236
Authorized use
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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Type 2035 / 3236
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.
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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7
Type 2035 / 3236
Basic safety instructions
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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Type 2035 / 3236
General information
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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Type 2035 / 3236
Product description
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
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 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.
1)
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 2035 / 3236
Product description
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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Type 2035 / 3236
Product description
5.2.2. Manually operated diaphragm valve
Type 3236
The valve is operated manually.
Manually
operated
actuator
Valve body
Diaphragm
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.
Installation positions for self-drainage:
A
B
3C2S / 4C2S
drainage connection B (D)
A
C
C
B
drainage connection C (A)
A
C
3C2S / 4C2S
A
D
C
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B
Fig. 5: Self-draining - 3C2S / 4C2S
B
Type 2035 / 3236
Product description
Installation positions for self-drainage:
C
D
A
4C4S DFP
drainage connection
A (C)
Fig. 6: Self-draining - 4C4S DFP
B
A
B
A
4C4S DFP
drainage connection
B (D)
D
C
5.4. Valve symbols and flow diagrams
3 connections, 2 seats
D
C
B
A
Seat
U1
Fig. 7: Valve symbols and flow diagrams - 3C2S
A
Seat
U1
B
D
B
C
Seat
U2
4 connections, 2 seats
C
Seat
U2
3C2S
4C2S
A
A
C
B
D
C
B
Fig. 8: Valve symbols and flow diagrams - 4C2S
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Type 2035 / 3236
Product description
3 connections, 3 seats
3C3S
upper side lower side
A
C
Seat
U1
Fig. 9: Valve symbols and flow diagrams - 3C3S
A C
Seat
U1
D
upper side lower side
D
B
A
Seat
Seat
Seat
U2
U2
L1
4 connections, 3 seats
C A
Seat
L1
D
4C3S
D
B
C
C
A
4 connections, 3 seats
4C3S BD filter valve
upper side lower side
A
A
D
D
C
B
B
Seat
U1
Fig. 11: Valve symbols and flow diagrams - 4C3S BD
A
Seat
U1
C
upper side lower side
D
B
D
D
Seat
U2
4 connections, 4 seats
C
C
Seat
U2
Seat
L1
A
C
4C4S
D
B
Seat
L2
Seat
L2
A
B
B
A
A
D
C
D
C
B
Fig. 10: Valve symbols and flow diagrams - 4C3S
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Fig. 12: Valve symbols and flow diagrams - 4C4S
Type 2035 / 3236
Product description
4 connections, 4 seats
4C4S DFP through-flow double valve
upper side lower side
D
A
Seat
U1
Fig. 13: Valve symbols and flow diagrams - 4C4S DFP
Seat
U1
Fig. 14: Valve symbols and flow diagrams - 4C5S
B
upper side lower side
A
B1
C
C
Seat
C
Seat
Seat
U2
4 connections, 5 seats
4C5S chromatography valve
C
Seat
U2
L1
L1
B1
D
B
B2
Seat
L2
A
Seat
L2
A
A
A
D
B
B1
B2
5.5. Valve marking
Marking and warning
notices in Ex area
Type label
C
Orifice and connection dimensions
Material, charge, manufacturing
C
Fig. 15: Valve marking
Actuator orientation
marking
Port connection
markings
Valve body labeling
order and serial No.
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Type 2035 / 3236
Product description
5.5.1. Type label
Size
Type
2035 RV50 4C 4S-DFP
EPDM-cus D11 -D11
Weld end 19.05x1.65
Pilot 4.2-10 bar
Pmed 10bar
Made in Germany
12345678
Identification number
Fig. 16: Type label Type 2035
Robolux
3236 RV50 4C 4S-DFP
EPDM-cus D44 -D44
Weld end 19.05x1.65
Pmed 10bar
Made in Germany
12345678
Fig. 17: Type label Type 3236
W14UN
W14UN
Design
Diaphragm material -
actuator 1 - actuator 2
Connection type -
connection dimensions
Pilot pressure
Max. medium pressure
Date of manufacture
Type - Size - Design
Diaphragm material -
actuator 1 - actuator 2
Connection type -
connection dimensions
Max. medium pressure
Date of manufacture
Identification number
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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Type 2035 / 3236
Structure and function
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
Silencer
Pilot air port
Actuator body
Cover position
proximity switch
Cover screw
pressure piece
Diaphragm
Valve body
Body screws / nuts
Fig. 19: Piston-controlled diaphragm valve, structure and
description
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Type 2035 / 3236
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. Structure of Type 3236
The diaphragm valve consists of a manually operated actuator,
diaphragm and multi-port valve body.
Hand wheel
Actuator body
Diaphragm
Valve body
Body screws
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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Type 2035 / 3236
Technical Data
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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Type 2035 / 3236
Technical Data
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
EPDM peroxide-vulcanized
PFA /
EPDM
FKM fluorinated rubber acids and
silicone platinum-stabilized
PFR 91 PFR 91
Tab. 1: Diaphragm materials
Description of
material
ethylene-propylene
rubber
PFA
laminated EPDM
silicone rubber
fluorinated rubber
Use FDA USP VI
oxidizing
chemicals,
steam and hot
water
most chemicals and acids
mineral oils
aliphatic oils x x
aliphatic oils x
x x
x x
x
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Type 2035 / 3236
Technical Data
7.7. Fluidic data
Media
flow media ultra-pure, sterile, aggressive,
(see also chapter "7.6.1. Diaphragm")
Media pressure RV50 max. 8 bar
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)
7.7.1. Pressure ranges
Pilot pressure and medium pressure
EPDM, FKM,
Actuator
designation
Pilot
pressure
[bar]
Silicone, PFR 91
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
PFA / EPDM
Static
leaktightness
[bar]
Dynamic
leaktightness
[bar]
2) Pressure values [bar]: Overpressure with respect to atmospheric
pressure
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Type 2035 / 3236
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:
Permitted medium pressure depending on the medium temperature
for plastic bodies.
8.0
7.0
3)
6.0
5.0
4.0
3.0
2.0
Medium pressure [bar]
1.0
0.0
0 20 40 60 80 100 120 140
PP
Temperature [°C]
PVDF
Fig. 22: Permitted medium pressure depending on the medium
temperature for plastic bodies.
Fig. 21: Static and dynamic leak-tightness
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3) The given medium pressure applies for the static leak-tightness
value. For further information on this point see "Kv value".
Type 2035 / 3236
Assembly
7.7.2. Kv value
Orifice
DN
Body
connection
[mm]
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
Valve size Actuator Kv value water [m³/h] for
diaphragm material
Designation EPDM,
FKM
All Kv values measured on valves with connections according
to ASME BPE.
PFA
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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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"
Type 2035 / 3236
Assembly
Silencer
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.
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Actuator
Diaphragm
Valve body
Body screws and
washers
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.
Type 2035 / 3236
Assembly
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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Type 2035 / 3236
Assembly
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
Fig. 24: Pneumatic connection; installation of a proximity switch
Connections for
proximity sensors
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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Type 2035 / 3236
Operation and function
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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Type 2035 / 3236
Electrical pre-controller
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
Close valve seat
Open 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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Type 2035 / 3236
Maintenance, Cleaning
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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Type 2035 / 3236
Maintenance, Cleaning
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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