Burgmer 420 User manual

BWM DBS-E/DBS/F-EP U/F-DK page [1] state: 01.2018
ORIGINAL OPERATION, MAINTENANCE
AND ASSEMBLY INSTRUCTION
SLIDE GATE VALVES
IMPORTANT!
Read these instructions carefully
before initial operation!

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IMPRINT
All rights reserved.
Subject to alterations without prior notice.
Copyright 2011 by BURGMER Apparatebau GmbH 42327 Wuppertal
Details in this documentation are provided to specify products,
not to warrant any specific qualities.

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CONTENTS DIRECTORY
1 Introduction..................................................................................................................................... 4
2 Description ...................................................................................................................................... 6
2.1 Validity of these operating instructions .................................................................................. 6
2.2 Responding documents........................................................................................................... 6
2.3 Marking of gate valves ............................................................................................................ 7
3 Intended use.................................................................................................................................... 7
4 Safety hints...................................................................................................................................... 8
4.1 General safety hints ................................................................................................................ 8
4.2 Safety hints for operator ......................................................................................................... 8
4.3 Special hazards ........................................................................................................................ 9
4.4 Qualified staff .......................................................................................................................... 9
5 Transport and storage ..................................................................................................................... 9
6 Assembly, initial operation, handling, disassembly ........................................................................ 9
6.1 Assembly ............................................................................................................................... 10
6.2 Initial operation phase .......................................................................................................... 12
6.3 Handling ................................................................................................................................ 12
6.4 Disassembly........................................................................................................................... 12
6.4.1 Switching off the system ............................................................................................... 12
6.4.2 Carrying out of disassembly .......................................................................................... 12
6.5 Troubleshooting .................................................................................................................... 13
7 Maintenance ................................................................................................................................. 13
7.1 Safety hints............................................................................................................................ 14
7.2 Inspection list and maintenance works................................................................................. 14
8 Annex............................................................................................................................................. 15
8.1 Necessary nominal pressure level “PN“ of counter flanges.................................................. 15
8.2 Material compatibility of valve ............................................................................................. 15
8.3 Thread locking ....................................................................................................................... 15

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1Introduction
The valves described below are intended for industrial applications. The following
standards were used: EN 558-1, DIN EN 593, EN 1092-1, EN 60529-1 and AD-2000
Regulation.
In case of use outside Germany, the operating company is responsible for ensuring the
compliance with all national regulations.
ATTENTION!
The valves 410 F-EP/ 420 F-EP U/ 460 F-EP FM are not suitable for use in potentially
explosive atmospheres according to - ATEX-regulation 2014/34/EU!
The valves 430 DBS/ 440 DBS-E/ 450 F-DK are outside the scope of directive 2014/34/EU.
At intended use they does not have its own potential ignition source.
For the application range of the Pressure Equipment Directive – DGRL 2014/68/EU, only
valves which bear a CE marking can be used! (observe category!)
ATTENTION!
When removing and / or disguising our nameplate, all guarantee and liability will expire.
If the nameplate is replaced by the costumer, it is his responsibility to ensure the
traceability of the product!
It is not allowed to remove or replace nameplates of valves provided with
CE markings!
The use of these operating instructions requires a proper qualification by the user. Please
refer to chapter 4.4 “Qualified staff”
Operating staff is to be instructed according to operating instructions.
These instructions shall help you to install, operate and maintain the butterfly valves and
provide you with all the necessary information for performing these tasks.
They should be read and kept very carefully. Hints and warnings must be strictly observed!

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ATTENTION!
The following symbols are used to indicate warnings and other important notes in these
operating instructions:
Means that death, severe body injuries or considerable material damage will ensue if the
corresponding precautions are not taken.
Means that death, severe body injuries or considerable material damage may ensue if the
corresponding precautions are not taken.
Means that light body injuries or material damage may ensue if the corresponding
precautions are not taken.
These operating instructions are subject to technical improvements and
alterations at any time.

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2Description
Gate valves can be used for BLOCKING / DOSING and/or DISCHARGING of fluids, gases, pasty
media and bulk materials with different physical features.
The valves can be attached to silos, pipelines, product shafts or conveyors.
However, this requires that the gate valves are designed and manufactured in accordance
with the working conditions and the consumer specification.
Materials, types of actuation and driving power must be suitable for the respective
application.
The applications listed above are grouped below under the term “system”.
2.1 Validity of these operating instructions
These operating instructions are valid for all BURGMER gate valves of types DBS-E/DBS/F-EP
U/F-DK designed for use in the areas described under chapter “1. Introduction“.
Included are the following different types of design:
Gate valves
•with manual actuation
•with hand worm gear
•foreign operated (pneumatic-/ electric driven)
2.2 Responding documents
The offer/work order form drawn up for each butterfly valve as well as all pertinent
documents are an integral part of the internal documentation.
It contains the following information:
•medium / pressure / temperature / state of aggregation
•temperature class
•identification no. of operator or facility (if required)
•nameplate(s) (if required or necessary)
•technical information concerning the butterfly valve and its application
Further responding documents are:
•Assembly, operating and maintenance instructions for all specified attached parts
•Declarations of manufacturer and certificates of conformity

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2.3 Marking of gate valves
All gate valves are marked with information located on a nameplate on the casing.
BURGMER Apparatebau GmbH
Refer to imprint in operating instructions for
address
Type
e.g. DBS-XX
Type of butterfly valve
Serial-No
e.g. 218XXXX-1
Digits 1-7: Burgmer order no., digits 8-9: item no.
Date
e.g. 2018
Date of manufacture
DN
numerical value e.g. 250
Diameter of the valve
PN
numerical value e.g. 10 bar
Necessary nominal pressure levels of counter
flanges. ATTENTION! Don’t apply this pressure
onto the valve!
PS
numerical value e.g. 8 bar
Max. permitted internal working pressure of
valve
∆P
numerical value e.g. 4 bar
Max. permitted difference pressure
TS
numerical value e.g. -20°C
/+80°C
Upper / lower temperature limit
Body
e.g. EN-AC 51100
Body material
Slide
plate
e.g. 1.4571
Slide plate material
Seat
e.g. Polyurethan
Material of inner coating / sealing
3Intended use
The noncompliance with the precautions described in this chapter may endanger the life of
the user and cause damage in the system.
Once incorporated into the system, the gate valves are to be used only for shutting off,
conduction or adjustment.
The gate valves are exclusively intended for the application range described in the
documentation enclosed to order (order/commission number).
It is not permitted to use the gate valves for other purposes than those described in the
specification.
Don’t exceed by any means the permitted pressure and temperature range of the valves!
Don’t exceed by any means the permitted temperature class.
Chapter 4 “Safety hints” is to be strictly observed.

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4Safety hints
4.1 General safety hints
The safety hints applying to the system, into which the butterfly valve is incorporated, apply
also to the gate valve itself.
These operating instructions provide only safety hints to be observed additionally for the
gate valves. Please ensure to read and observe also the enclosed operating and maintenance
instructions of the attached parts.
4.2 Safety hints for operator
Compliance with the safety hints as listed below lies within the sole responsibility of the
operator:
•Please take care to observe all safety regulations valid for the country of operation
and / or the operating company.
•The gate valve is to be used solely for the intended purpose as described in chapter
3 “Intended use”.
•The whole system must be installed and checked periodically by qualified staff.
(Refer to chapter 4.4 “Qualified staff”)
•Appropriate measures are to be taken to avoid human extremities being
entrapped by moving parts of the system!
•Warning signs or barriers must be put up if necessary!
•An accidental starting or stopping of the system is strictly to be avoided!
•Additional pipeline forces or torques acting on the gate valves are not permitted
and must be previously agreed with the manufacturer.
•The correct function of safety appliances provided by the customer (e.g. emergency
stopping, safety valves, etc.) is to be verified and ensured prior to start-up!
•The gate valves are to be started up only when fully incorporated into the system
and only by qualified staff of the operating company.
•The valve may conduct only media previously agreed with its manufacturer!
•Abnormal working conditions like vibrations, cavitation, water hammers, etc. are
not permitted.
•The max. permitted ambient temperature for operating the valves is –20°C to
+40°C. Other temperatures must be previously agreed with the manufacturer!
•In case of operating temperatures below -20°C or above +50°C, the valve is to be
provided with a protection against accidental contact.

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•ATTENTION! Don’t exceed by any means the max. permitted torques indicated in
item 8.1 “Torques”!
•We point out, that there are still risks for the user of gate valves, even if they are
designed and manufactured with the highest possible care. Nevertheless, damage to
persons and parts can only be a result of improper handling.
4.3 Special hazards
•Please ensure to eliminate completely any pressure existing in the system before
removing the gate valve or unscrewing any bolted connections on the attached
parts.
•Please ensure to evacuate completely any medium to prevent any escapes when
removing the gate valve. Proceed with special care in case of hazardous or harmful
substances!
ATTENTION!
Residues may accumulate in any parts of the system and the dead spaces in the
valves.
4.4 Qualified staff
Must be individuals familiarized with transport, assembly, initial operation, operation and
maintenance of valves and provided of the proper qualification for their activities and duties.
This qualification includes, among others:
•Indoctrination and commitment to comply with all national, local and internal
requirements and provisions.
•Indoctrination or training, in accordance to safety standards, in the proper use and
care of the reasonable safety and personal protective equipment.
5Transport and storage
Gate valves are to be handled, transported and stored with absolute care (protected
against shocks, impacts and vibrations)!
All bare parts must be protected against corrosion!
Storage and transport temperature must be within the range of –20°C to +40°C.
ATTENTION! Don’t store the valves in aggressive atmosphere.
The gate valves should be transported in their protective packaging to the place of
incorporation.
6Assembly, initial operation, handling, disassembly
SAFETY HINTS!
Read chapters 3 “Intended use” and 4 “Safety hints” before starting to assemble and/or
disassemble the gate valve.

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6.1 Assembly
BURGMER gate valves are to be installed or attached between or to flanges, according to EN
1092-1 and DIN EN 1759-1, with sealing bars of shapes B1 or B2, which are plane parallel
machined and have to align. Other types of flanges and sealing bars may only be used after
the manufacturer has checked their technical viability.
The seal faces of body and counter flanges must be smooth and clean.
In BA and collar II seals, the sealing insert acts at the same time as flange seal. Please make
sure to use counter flanges with diameters suited to support the seals of the gate valves.
The inner diameter of the counter flanges is intended to cover at least 2/3 of the seal face
and at most the clear width of the valve.
Don’t use additional flange for this type of sealing.
ATTENTION! In case of use as end valve, the seal face located on the outside has to be
supported by a suitable through flange. Moreover, in normal operation, especially in case
of hot, gaseous and/or hazardous media, a blind flange must be installed or the valve
bolted safely in the position (“CLOSED”).
It is forbidden to weld the flanges to the system or other pipeline/conveyor parts after the
gate valve is installed (seal insert can burn!).
INSTALLATION INSTRUCTIONS!
•Check the gate valves for transportation damages. Don’t install the valves if it’s
damaged.
•Make sure to install only gate valves, which technical specifications (permitted
pressure, temperature class, etc.) fulfil the installation requirements.
•The gate valve must be mounted that no big forces may absorb through the casing.
The bulk material must enter the gate valve vertically!
•The gate valves can be installed in a position with regard to the medium flow direction
(marked with a red arrow on the casing).
•The valve may not serve as fixed point; it is supported by the pipeline system.
•Please ensure to insert the gate valves centred between the counter flanges.
•Huge and heavy actuators must be stabilized.
•Clean the flange faces and install flange seals appropriate to the quality of the valve
seal. (IMPORTANT!see also item 6.1.)
•If the valves are provided with grounding screws, shaft and body of the valve must
be integrated mandatorily into the potential equalisation of the whole system. Shaft
and body are provided for this with a specially marked threaded hole. The grounding
cable must have then a cross section of at least 4mm² for nominal widths 50-350
Furthermore, the 90° rotational movement of the shaft is to be taken into account
when dimensioning the length of the shaft grounding cable!
•Thermal expansions in the system are to be compensated through compensators.

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•All flange connections are to be tightened with the torques [Ma in Nm] specified in
the following table. The use of torque wrenches ensures that the necessary tightening
torques are adjusted, but not exceeded. Align flanges in plane parallel first. Tighten
then connecting screws crosswise in 3 steps.
Step 1: 50% of the respective tightening torque
Step 2: 80% of the respective tightening torque
Step 3: 100% of the respective tightening torque
Tightening values for DIN flange connections
Diameter DN 80 100 150 200 250 300 350 400 500
Tightening
torque Ma
[Nm]
50 50 60 65 75 85 85 85 85
Instructions for connecting of pneumatic actuators:
•Make sure to control the system pressure of the control lines when using pneumatic
actuators. The max. control air pressure specified in the order documents must be
strictly observed! Never exceed it!
Instructions for connecting of electric actuators:
•The existing connection voltage must relate to the rate of the actuator manufacturer!
(see nameplate and operation instructions)
•Check sense of rotation right after connecting (phase balance). Observe sense of
rotation arrow in the inspection glass.
•Depending on the design of the electric actuators, safety precautions against overload
(thermal switch or torque switch) are to be integrated as well into the control circuit.
Instructions for connecting of ordered accessories:
•Please refer to the corresponding operation instructions of the ordered accessories for
the connecting of solenoid valves, positioners, signalling units as well as the specified
actuators (pneumatic, electric).

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6.2 Initial operation phase
ATTENTION! Prior to commissioning, it must be ensured that the system contains no
foreign objects!
A test run without product must be always performed first!
Refer to item 6.5 “Troubleshooting” in case of leaks on the gate valve!
The gate valve may only be used after a successful test run has been performed.
6.3 Handling
The gate valve can be provided with either manual operation (hand lever, hand wheel or
hand worm gear) or an actuator (pneumatic or electric) for opening and closing. Normal hand
force is sufficient for manual operation.
The functioning of the gate valve can be monitored by inductive or optic limit switches.
IMPORTANT! It is not permitted to use extensions to increase actuating moment.
6.4 Disassembly
IMPORTANT! Disassembly of the gate valves may be performed only after authorisation by
the responsible company department and only by qualified staff (decision of the operating
company)
6.4.1 Switching off the system
The following points are to be observed mandatorily in addition to the measures indicated
in item 6.1 “Assembly”:
•Relieve pressure in pipeline
•Let the medium cool-off
•Empty plant completely
•Ventilate the pipeline in case of corrosive, aggressive, toxic or inflammable media.
Gate valves with pneumatic or electric actuation must be duly shut down by “qualified
staff” in accordance to the valid occupational safety regulations of country of operation
before disassembly.
6.4.2 Carrying out of disassembly
Remove carefully bolted connections on flanges (IMPORTANT! The system must be
relieved of pressure!).
Remove gate valve in closed position from the system.
Remove carefully any dirt.
Unrepairable valves are to be disposed of according to the valid environment protection
regulations.

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6.5 Troubleshooting
Failure
Reason
Elimination
Slide plate(s) do(es)
not move
Silencer solenoid valve
are blocked
•
Dismount and clean silencer
Slide plate(s) do(es)
not move
System pressure for
pneumatic actuator
insufficient
•Check system pressure
•Ensure minimum pressure (4 bar)
Slide plate(s) do(es)
not move
Service chamber blocked
through medium
•
Switch off system (refer to 6.4.1)
•Open cover
•Remove medium
•Retighten gland packing
•Close cover
•Functional test
Slide plate(s) do(es)
not move
Gland packing worn out
•Manufacturer-revision necessary
Slide plate(s) do(es)
not move
Slide plate(s) worn out
•
Manufacturer-revision necessary
Slide plate(s) do(es)
not move
Material stick to the slide
plates
•Switch off system (refer to 6.4.1)
•Open cover
•Remove medium
•Retighten gland packing
•Close cover
•
Functional test
No signal from limit
switches
Limit switch or flag
damaged
•
Renew limit switches
•Renew flag
ATTENTION! Observe the safety hints listed in chapter 4 when performing works of any
kind on the gate valve!
7Maintenance
The maintenance includes inspection, maintenance and reparation of the gate valve.
RECOMMENDATION! Extensive maintenance and repair must be done by the manufacturer
in order to avoid costs of stand-still.
Relubrication of bearings is not necessary. Bearings are provided with permanent
lubrication by the manufacturer.
ATTENTION! When detecting a defect on a valve or its attachments, the system is to be
shut down immediately and restarted only after elimination of defect!

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7.1 Safety hints
Any kind of work on the gate valves must be done only by “qualified staff” (refer to item
4.4)!
Before starting to work, inform the safety officer.
•Secure the gate valves against accidental start up, cut off pneumatic, electric
connections!
•Do not grasp into the open gate valve!
•Gate valves mounted under vessels have to be secured by an emergency shutoff
before working on them!
•Keep vessels, pipes and feeding parts of plant free of product when doing extensive
maintenance or repair works on the gate valves.
•Avoid after-running of product by closing stop valves or taking other convenient
actions.
7.2 Inspection list and maintenance works
Action weekly
monthly (every
4-5 weeks)
half-yearly
Visual control of electric and
pneumatic connections
Check air-tightness of solenoid
valves and pneumatic connections
Check bolted connections
(actuators, control elements,
flanges) and tighten them if
necessary
Checking for leaks in cover area of
valve:
Gases and dusts: Check for leaks
using leak detection spray!
Liquids: Check visually for leaks!
ATTENTION! When detecting a
leak, shut down plant as soon as
possible and repair valve!
Tightening the gland packing
Additional to the main manual
shut-off valve
Unless
otherwise
noted!

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LUBRICATION
Apply accordingly to double gate valves 440 DBS with bolt-on gear box.
Every 30.000 cycles of every 12 month the lubrication must be replaced or refilled. Therefore
is a lubrication nipple between the two cap screws, which can be found on each side of the
gear box, below the actuator.
RECOMMENDATION! Use a high-performance grease “OKS 470” for use with a
temperature range of -30°C up to +120°C or a similar lubricant! The
amount of lubricant to be used is appr. 20 ml.
8Annex
8.1 Necessary nominal pressure level “PN“ of counter flanges
The “PN“ detailed on the nameplate refers only to the necessary nominal pressure level of
counter flanges.
ATTENTION! Don’t apply this pressure onto the valve!
8.2 Material compatibility of valve
ATTENTION! The valve may conduct only with media agreed previously with its
manufacturer!
The admitted media must be specified in the documentation enclosed to order!
8.3 Thread locking
The screws at the gate valves have been provided with thread locking LOXEAL 24-18.
After maintenance, the released screws must again be provided with thread locking!

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