Burkert 2006 User manual

Operating Instructions
Bedienungsanleitung
Manuel d‘utilisation
Type 2006
3/2-Way Globe Valve
3/2-Wege-Geradsitzventil
Vanne à siège droit 3/2 voies

We reserve the right to make technical changes without notice.
Technische Änderungen vorbehalten.
Sous réserve de modifications techniques.
© Bürkert Werke GmbH & Co. KG, 2016 - 2017
Operating Instructions 1804/00_EU-EN_00810459 / Original DE

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1 OPERATING INSTRUCTIONS ................................................................4
1.1 Symbols ....................................................................................... 4
1.2 Definition of the term "Device" ............................................... 4
2 AUTHORIZED USE ......................................................................................5
3 BASIC SAFETY INSTRUCTIONS ..........................................................5
4 GENERAL INFORMATION ........................................................................6
4.1 Contact addresses ...................................................................6
4.2 Warranty ...................................................................................... 6
4.3 Information on the Internet ...................................................... 6
5 PRODUCT DESCRIPTION ........................................................................7
5.1 General description ..................................................................7
5.2 Properties ....................................................................................7
6 STRUCTURE AND FUNCTION...............................................................8
6.1 Structure ...................................................................................... 8
6.2 Function ....................................................................................... 8
7 TECHNICAL DATA .....................................................................................10
7.1 Conformity .................................................................................10
7.2 Standards ..................................................................................10
7.3 Type label ..................................................................................10
7.4 Operating conditions ..............................................................10
7.5 General technical data ...........................................................13
8 ASSEMBLY .................................................................................................... 14
8.1 Safety instructions ...................................................................14
8.2 Before installation ....................................................................14
8.3 Installation .................................................................................15
8.4 Pneumatic connection ............................................................17
9 START-UP ......................................................................................................18
9.1 Control pressure ......................................................................18
9.2 Incoming flow above upper seat
(direction of flow 3 → 2) .........................................................18
9.3 Flow direction below the lower seat
(direction of flow 1 → 2) .........................................................18
10 DISASSEMBLY ............................................................................................ 18
11 MAINTENANCE, TROUBLESHOOTING ......................................... 19
11.1 Safety instructions ...................................................................19
11.2 Maintenance work ...................................................................19
11.3 Malfunctions .............................................................................20
12 SPARE PARTS.............................................................................................21
13 PACKAGING, TRANSPORT, STORAGE .......................................... 22
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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.
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 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 moderately
severe or minor injury.
NOTE!
Warns of damage to property.
▶Failure to observe the warning may result in damage to the
device or the equipment.
Designates additional significant information, tips and
recommendations.
Refers to information in these operating instructions or in
other documentation.
▶designates instructions for risk prevention.
→designates a procedure which you must carry out.
1.2 Definition of the term "Device"
In these instructions, the term "device" always refers to the globe
valve type 2006.
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Authorized Use
2 AUTHORIZED USE
Non-authorized use of the globe valve type 2006 may be a
hazard to people, nearby equipment and the environment.
▶The device is designed for the controlled flow of liquid and
gaseous media.
▶In the potentially explosion-risk area the device may be used only
according to the specification on the separate Ex type label. For
use observe the additional information enclosed with the device
together with safety instructions for the explosion-risk area.
▶Devices without a separate Ex type label may not be used in a
potentially explosive area.
▶The admissible 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 desig-
nated application cases are specified in the chapter entitled “5
Product description”.
▶The device may be used only in conjunction with third-party devices
and components recommended and authorized by Bürkert.
▶Correct transportation, correct storage and installation and careful
use and maintenance are essential for reliable and problem-free
operation.
▶Use the device only as intended.
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 with reference to the installation personnel.
DANGER!
Danger – high pressure.
▶Before loosening the lines and valves, turn off the pressure and
vent the lines.
Risk of electric shock.
▶Before reaching into the device or the equipment, 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 device may become hot during long-term
operation.
▶Do not touch the device with bare hands.
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General information
General hazardous situations.
To prevent injury, ensure that:
▶The system cannot be activated unintentionally.
▶Do not use in areas which are prone to vibrations.
▶Installation and repair work may be carried out by authorized
technicians only and with the appropriate tools.
▶After an interruption in the power supply or pneumatic supply,
ensure that the process is restarted in a defined or controlled
manner.
▶The device 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 device.
To prevent damage to property of the device, 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.
4 GENERAL INFORMATION
4.1 Contact addresses
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
E-mail: [email protected]
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 device is used as authorized in accor-
dance with the specified application conditions.
4.3 Information on the Internet
The operating instructions and data sheets for Type 2006 can be found
on the Internet at: www.burkert.com
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Product description
5 PRODUCT DESCRIPTION
5.1 General description
The externally controlled globe valve type 2006 is suitable for liquid
and gaseous media.
It uses neutral gases or air (control media) to control the flow-rate
of water, alcohol, oil, fuel, hydraulic fluid, saline solution, lye, organic
solvent and steam (flow media).
5.2 Properties
• High tightness by self-adjusting packing glands (spindle sealing
element).
• High seat tightness.
• High flow values by the streamlined valve body made of stainless
steel.
• Actuator can be rotated steplessly through 360°.
5.2.1 Options
• Activation unit
Different versions of the activation units are available depending
on the requirement.
• Stroke limitation
Limit of the maximum open position / flow rate by means of
adjusting screw.
• Feedback indicator
The device features mechanical limit switches or inductive prox-
imity switches.
5.2.2 Device versions
The globe valve is available for the actuator sizes ø 50 mm to ø 125 mm.
5.2.3 Restrictions
WARNING!
Risk of injury from water hammer.
A water hammer could crack the lines and device.
▶Use valves with flow inlet above seat for gaseous media and
steam only.
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Structure and Function
6 STRUCTURE AND FUNCTION
6.1 Structure
The globe valve consists of a pneumatically actuated piston actuator
and a 3-way valve body. The actuator is manufactured from PA or
PPS. The tried and tested, self-adjusting packing gland ensures high
tightness. The flow-enhancing valve body made of stainless steel
enables high flow values.
Line connector
Angle-seat body with
numbers for indicating
the direction of flow
Control air connection
Transparent cap with
position indicator
Actuator cover
Actuator body
Fig. 1: Structure and description
6.2 Function
Depending on the version, the lower seat of the valve is closed with
or against the medium flow.
Spring force (CFA) or pneumatic control pressure (CFB and CFI) gen-
erates the closing force on the closing body. The force is transferred
via a spindle which is connected to the actuator piston.
WARNING!
For control function I – Danger if control 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 device with
control pressure, then switch on the medium.
6.2.2 Control function and flow modes of
operation
Different operating principles can be obtained with the same
control function by swapping the pressure and working
connections.
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Structure and Function
Control function A (CFA)
In rest position line connector 1 closed by spring force.
3
1
2
Flow
modes of
operation
Connection
123
C P A R
D R A P
E P1 A P2
F A P B
A, B: Working connections
P, P1, P2: Pressure connections
R: Pressure relief
Tab. 1: Control function A (CFA)
Flow modes of operation
C
In rest position pressure connection 1
closed, working connection 2 relieved.
D
In rest position pressure connection 3
connected to working connection 2,
relief 1 closed.
E
Mixing valve
In rest position pressure connection 3
connected to working connection 2,
pressure connection 1 closed.
F
Distribution valve
In rest position pressure connection 2
connected to working connection 3,
working connection 1 closed.
Tab. 2: Flow modes of operation
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Technical Data
7 TECHNICAL DATA
7.1 Conformity
The globe valve type 2006 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
Made in Germany
2006 A 50,0 PTFE VA
G1 1/2
Pilot 6–10bar
Pmed 1–2 : 9bar
Pmed 2–3/1: 16bar
00002135 W34ME
Type
Control function
Orifice Seal material
Body material
Port connection
Pilot pressure
Max. medium
pressure
Order number
Fig. 2: Example of the type label
7.4 Operating conditions
7.4.1 Temperature ranges
Actuator
size
[mm]
Actuator
material
Temperature ranges
Medium
(for PTFE seal)
Environment 1)
50, 63 PA –10... see “Fig. 3” –10... see “Fig. 3”
80...125 PA –10...+180 °C –10...+60 °C
50...80 PPS –10...+180 °C +5...+140 °C
125 PPS –10...+180 °C +5...+90 °C
2)
Tab. 3: Temperature ranges
1) If a pilot valve is used, the max. ambient temperature
is + 55 °C
Medium
temperature [°C]
Ambient
temperature
[°C]
100 120 140 160 180 200
70
60
50
40
30
20
∅ 63
∅ 50
Fig. 3: Temperature range of the maximum medium and ambient
temperature for PA actuators
2) briefly up to max. 140 °C
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Technical Data
7.4.2 Pressure ranges
Maximum control pressure:
Actuator
material
Actuator size
[mm]
Max. control pressure
[bar]
PA 50...80 10
125 7
PPS 50...80 10
125 7
Tab. 4: Maximum control pressure
Maximum operating pressure, control function A:
Orifice [mm] Actuator size
[mm]
Max. medium pressure up to
180 °C [bar] direction of flow
1 → 2 2 → 3, 2 → 1
15, 20 50 11 16
63 16 16
25 63 10 16
32, 40 80 916
125 14 16
50 125 10 16
Tab. 5: Max. operating pressure
For control function F the maximum permitted operating
pressure is 16 bar.
7.4.3 Minimum control pressures
Minimum control pressure pmin, control function A:
Orifice [mm] Actuator size
[mm]
Min. control pressure
pmin [bar]
15, 20 50 4,4
15, 20 63 4,7
25 63 4,9
32, 40 80 6,0
32, 40 125 3,4
50 125 4,3
Tab. 6: Minimum control pressure
Minimum control pressure pmin when
direction of flow 3 → 2:
The required minimum control pressure pmin
depends on the medium pressure. 3
1
2
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Technical Data
Control
pressure [bar]
Medium
pressure
[bar]
CFA, ø 50 mm
DN 15 DN 25
DN 20
Fig. 4: Pressure graph, actuator ø 50 mm, control function A
Control
pressure [bar]
Medium
pressure
[bar]
CFA, ø 63 mm
DN 32 DN 40 DN 50 DN 25
DN 20
Fig. 5: Pressure graph, actuator ø 63 mm, control function A
Control
pressure [bar]
Medium
pressure
[bar]
CFA, ø 80 mm
DN 32 DN 40 DN 50 DN 25
Fig. 6: Pressure graph, actuator ø 80 mm, control function A
Control
pressure [bar]
Medium
pressure
[bar]
CFA, ø 100 mm
DN 32 DN 40 DN 50
Fig. 7: Pressure graph, actuator ø 100 mm, control function A
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Technical Data
Control
pressure [bar]
Medium
pressure
[bar]
CFA, ø 125 mm
DN 40 DN 50
Fig. 8: Pressure graph, actuator ø 125, control function A
7.5 General technical data
Control functions (CF)
Control function A Closed by spring force in rest position
Control function B Opened by spring force in rest position
Control function I Actuating function via reciprocal
pressurization
Materials
Body Stainless steel 316L
Actuator PA, PPS
Seal PTFE (other materials on request)
Packing gland (with
silicone grease)
PTFE V rings with spring compensation
Media
Control media Neutral gases, air
Flow media Water, alcohols, oils, fuels, hydraulic liquid,
saline solutions, lyes, organic solvents,
steam
Connections G 1/2 to G 2
Other connections on request.
Installation position Any position, preferably with actuator face
up
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Assembly
8 ASSEMBLY
8.1 Safety instructions
DANGER!
Risk of injury from high pressure in the equipment.
▶Before dismounting pneumatic lines or valves, turn off the pres-
sure and vent the lines.
WARNING!
Risk of injury from improper assembly.
▶Installation may be carried out by authorized 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 control 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 device with
control pressure, then switch on the medium.
8.2 Before installation
• Before connecting the valve, ensure the pipelines are flush.
• Any installation position is possible, preferably with actuator face up.
• Observe direction of flow (see type label).
8.2.1 Preparatory work
→Clean pipelines (sealing material, swarf, etc).
For customer-specific requirement only: Remove actuator
Procedure:
→Clamp valve body into a holding device.
NOTE!
Damage to the seat seal or the seat contour.
▶When removing the actuator, ensure that the valve is in the
open position.
→Control function A and I:
Pressurize lower control air connection with compressed air
(4 bar): Valve opens.
→Place a suitable open-end wrench on the wrench flat of the nipple.
→Unscrew the actuator off the valve body.
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Assembly
8.3 Installation
WARNING!
Risk of injury from improper installation.
Assembly with unsuitable tools or non-observance of the tight-
ening torque is dangerous as the device may be damaged.
▶For installation use an open-end wrench, never a pipe wrench.
▶Observe the tightening torque (see “Tab. 7: Tightening
torques”).
Devices with approval in accordance with DIN EN 161
In accordance with DIN EN 161 "Automatic shut-off valves for gas
burners and gas installations" a dirt trap must be connected upstream
of the valve and prevent the insertion of a 1 mm plug gauge.
8.3.1 Installing the body
→Connect body to pipeline.
8.3.2 Installing the actuator
Graphite seal
Fig. 9: Graphite seal
→Check graphite seal and, if required, replace. Remove all
residues when replacing seal.
WARNING!
Danger if incorrect lubricants used.
Unsuitable lubricant may contaminate the medium. In oxygen
applications there is a risk of an explosion.
▶In specific applications, e.g. oxygen or analysis applications, use
appropriately authorized lubricants only.
→Grease nipple thread before re-installing the actuator
(e.g. with Klüber paste UH1 96-402 from Klüber).
NOTE!
Damage to the seal on the swivel plate.
▶When installing the actuator, ensure that the valve is in the open
position.
→Control function A and I: Pressurize lower control air connection
with compressed air (4 bar) so that the closing body is lifted off
the valve seat and is not damaged when screwed in.
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Assembly
→Screw actuator into the valve body.
Tightening torques:
Orifice (DN) Tightening torque (Nm)
15 45 ± 3
20 50 ± 3
25 60 ± 3
32 65 ± 3
40 65 ± 3
50 70 ± 3
Tab. 7: Tightening torques
If the body is stainless steel, grease the nipple thread with
e.g. Klüber paste UH1 96-402.
8.3.3 Rotating the drive
The position of the connections can be aligned steplessly by rotating
the drive through 360 °.
NOTE!
Damage to the seal on the swivel plate.
▶When turning the actuator, ensure that the valve is in the open
position.
→Clamp the valve body into a holding device (applies only to valves
not yet installed).
→For control function A pressurize the lower control air connection
with compressed air (4 bar): Valve opens.
→Using a suitable open-end wrench, counter the wrench flat on
the pipe.
→Place a suitable open-end wrench on the hexagon of the actuator
(see “Fig. 10”).
WARNING!
Risk of injury from discharge of medium and pressure.
If the direction of rotation is wrong, the body interface may
become detached.
▶Turn the actuator in the specified sense of direction only
(see “Fig. 10”).
→By turning the open-end wrench clockwise (viewed from above),
move the actuator into the required position.
Open-end wrench for
securing the nipple
Open-end wrench
for turning the
actuator
Fig. 10: Turning with open-end wrench
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Assembly
8.4 Pneumatic connection
DANGER!
Risk of injury from high pressure in the equipment.
▶Before dismounting pneumatic lines or valves, turn off the pres-
sure 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.
For control function I: Danger if control 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 device with
control pressure, then switch on the medium.
8.4.1 Connection of the control medium
If the position of the control air connections is unfavorable
for installation of the hoses, these can be steplessly aligned
by turning the actuator through 360°.
The procedure is described in chapter “8.3.3 Rotating the drive”.
Control function A:
On the lower connection of the actuator.
Control function B:
On the upper connection of the actuator.
Control function I:
On the upper and lower connections of the actuator.
Pressure on the lower connection opens the valve,
pressure on the upper connection closes the valve.
Control
function
Control air
connection
Top
Bottom
Control air
Connections
Top Bottom
A
B
I
closes opens
lower valve seat
Fig. 11: Control air connection
If used in an aggressive environment, we recommend
conveying all free pneumatic connections into a neutral
atmosphere with the aid of a pneumatic hose.
Control air hose: Control air hoses of size 1/4" can be used.
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Assembly
9 START-UP
Observe the type label specifications and information on
pressure and temperature values in section “7 Technical Data”.
9.1 Control pressure
WARNING!
For control function I: Danger if control pressure fails.
If the pressure fails, no defined position is reached.
▶For a controlled restart, initially pressurize the equipment with
control pressure and then connect the medium.
→Set the control pressure according to the type label specifications,
see section “7.3” and flow direction (section “9.2” and “9.3”).
9.2 Incoming flow above upper seat
(direction of flow 3 → 2)
Control function A (CFA) closes by spring force the lower valve
seat with the medium flow. The medium pressure supports the
closure and seal of the valve seat. The valve is opened by the control
pressure.
WARNING!
Risk of injury due to water hammer.
A closing shock can cause lines and the equipment to burst.
▶Only use valves with the flow direction above the seat for gas-
eous media.
To ensure complete opening of the upper valve seat, the
minimum control pressure must be used.
9.3 Flow direction below the lower
seat (direction of flow 1 → 2)
Control function A (CFA) closes by spring force against the medium flow.
Control function B (CFB) closes with the control pressure against the
medium flow. The medium pressure supports the opening of the valve.
WARNING!
Seat leaks caused by the minimum control pressure being too
low (on CFB and CFI) or the medium pressure being too high.
▶Observe the minimum control pressure and medium pressure
(see „5.5.1. Pressure ranges“).
10 DISASSEMBLY
DANGER!
Risk of injury from discharge of medium and 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.
→Loosen pneumatic connection.
→Remove device.
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Maintenance, Troubleshooting
11 MAINTENANCE,
TROUBLESHOOTING
11.1 Safety instructions
DANGER!
Risk of injury from high pressure in the equipment.
▶Before dismounting pneumatic lines or valves, turn off the pres-
sure and vent the lines.
Risk of injury from electric shock (only in conjunction with
corresponding actuators).
▶Before reaching into the device or the equipment, 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.
▶Maintenance may be carried out by authorized 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 maintenance, ensure a controlled restart.
WARNING!
For control function I: Danger if control 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 device with
control pressure, then switch on the medium.
11.2 Maintenance work
Actuator:
The actuator is maintenance-free provided it is used according to these
operating instructions.
Wearing parts of the angle seat valve / 3/2-way globe valve:
• Seals
• Closing body
→If leaks occur, replace the particular wearing parts with an appro-
priate spare part (see Chapter “12 Spare parts”).
11.2.1 Recommended maintenance
intervals
The valve should be visually inspected once a year. Shorter mainte-
nance intervals are recommended depending on application condi-
tions. The visual inspection includes the pneumatic connections and
the medium connections as well as the deaeration bore in the pipe.
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Maintenance, Troubleshooting
11.2.2 Cleaning
Commercially available cleaning agents can be used to clean the
outside.
NOTE!
Avoid causing damage with cleaning agents.
▶Before cleaning, check that the cleaning agents are compatible
with the body materials and seals.
11.3 Malfunctions
Malfunction Remedial action
Actuator
does not
switch
Control air connection interchanged 3)
CFA: Connect lower control air connection
CFB: Connect upper control air connection
CFI: Lower control air connection: Open
Upper control air connection: Close
Control pressure too low
→See pressure specifications on the type label
Medium pressure too high
→See pressure specifications on the type label
Direction of flow interchanged
→See direction of flow on the type label
Malfunction Remedial action
Valve is not
sealed
Dirt between seal and valve seat
→Installing dirt trap
Seat seal worn
→Installing new seat seals
Direction of flow interchanged
→See direction of flow on the type label
Medium pressure too high
→See pressure specifications on the type label
Control pressure too low
→See pressure specifications on the type label
Valve is
leaking on
the release
bore
Packing gland worn
→Renew packing gland or replace actuator
Tab. 8: Malfunctions
3) see “8.4 Pneumatic connection”
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Type 2006