Burkert 2101 User manual

Operating Instructions
Bedienungsanleitung
Manuel d‘utilisation
Type 2101
2/2-way globe valve
2/2-Wege-Geradsitzventil
Vanne à siège droit 2/2 voies

We reserve the right to make technical changes without notice.
Technische Änderungen vorbehalten.
Sous réserve de modifications techniques.
© 2008 - 2015 Bürkert Werke GmbH
Operating Instructions 1501/06_EU-ML_00806076 / Original DE

3
1 OPERATING INSTRUCTIONS ................................................................4
1.1 Symbols .......................................................................................4
1.2 Definition of term / abbreviation .............................................4
2 AUTHORIZED USE ......................................................................................5
2.1 Restrictions .................................................................................5
3 BASIC SAFETY INSTRUCTIONS ..........................................................5
4 GENERAL INFORMATION ........................................................................6
4.1 Contact address ........................................................................6
4.2 Warranty ...................................................................................... 6
4.3 Information on the Internet ......................................................6
5 PRODUCT DESCRIPTION ........................................................................7
5.1 General description ..................................................................7
5.2 Versions ....................................................................................... 7
5.3 Properties ....................................................................................7
5.4 Designated application area ...................................................8
6 STRUCTURE AND FUNCTION...............................................................8
6.1 Structure ......................................................................................8
6.2 Function .......................................................................................9
7 TECHNICAL DATA .....................................................................................11
7.1 Conformity .................................................................................11
7.2 Standards ..................................................................................11
7.3 Type label ..................................................................................11
7.4 Operating conditions ..............................................................12
7.5 General technical data ...........................................................16
8 INSTALLATION ............................................................................................17
8.1 Safety instructions ...................................................................17
8.2 Before installation ....................................................................18
8.3 Installation .................................................................................19
8.4 Pneumatic connection ............................................................21
8.5 Start-up ......................................................................................22
8.6 Removal .....................................................................................23
9 ELECTRICAL CONTROL UNIT ............................................................ 23
10 MAINTENANCE, CLEANING ................................................................24
10.1 Safety instructions ...................................................................24
10.2 Maintenance work ...................................................................24
10.3 Replacing the wearing parts .................................................25
11 MALFUNCTIONS ........................................................................................33
12 REPLACEMENT PARTS ..........................................................................34
12.1 Replacement part sets ...........................................................34
12.2 Installation tools .......................................................................35
13 PACKAGING, TRANSPORT, STORAGE .......................................... 36
Table of contents
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Type 2101

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Operating instructions
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 instructions for risk prevention.
→Designates a procedure which you must carry out.
1.2 Definition of term / abbreviation
The term “device” used in these instructions always stands for the
globe valve Type 2101.
The abbreviation “Ex” used in these instructions always stands for
“explosion-protected”.
1 OPERATING INSTRUCTIONS
The operating instructions describes 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 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.
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Type 2101

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Authorized use
2 AUTHORIZED USE
Non-authorized use of the globe valve Type 2101 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 globe valve Type 2101 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. These are
described 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 fault-
less operation.
▶Use the device only as intended.
2.1 Restrictions
If exporting the system or 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, whereby the operator is responsible for their
compliance, by the installation personnel too.
DANGER!
Danger – high pressure!
▶Before dismounting the lines and valves, turn off the pressure
and vent the lines.
Risk of electric shock!
▶Before reaching into the device, switch off the power supply and
secure to prevent reactivation!
▶Observe applicable accident prevention and safety regulations
for electrical equipment!
WARNING!
Risk of injury when opening the actuator!
The actuator contains a tensioned spring. If the actuator is opened,
there is a risk of injury from the spring jumping out!
▶The actuator must not be opened.
Risk of injury from moving parts in the device!
▶Do not reach into openings.
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Type 2101

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General information
CAUTION!
Risk of burns!
The surface of the device may become hot during long-term
operation.
▶Do not touch the device with bare hands.
General hazardous situations.
To prevent injury, 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 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 address
Germany
Bürkert Fluid Control Systems
Sales Center
Chr.-Bürkert-Str. 13-17
D-74653 Ingelfingen
Tel. : 07940 - 10 91 111
Fax: 07940 - 10 91 448
E-mail: [email protected]
International
Contact addresses are found on the final pages of the printed oper-
ating 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 2101 can be found
on the Internet at: www.burkert.com
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Type 2101

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Product description
5 PRODUCT DESCRIPTION
5.1 General description
The 2/2-way globe valve Type 2101 is suitable for liquid and gaseous
media.
It uses neutral gases or air (control media) to control the flow of water,
alcohol, oil, fuel, hydraulic fluid, saline solution, lye, organic solvent and
steam (flow media).
A special feature of globe valves are screwed-in seats which can be
used to reduce the orifice of the control valve in particular.
According to the general understanding of Bürkert, DN
designates the orifice of the seat, not the orifice of the line
connection.
5.2 Versions
There are 2 versions of the globe valve type 2101:
• Standard version – without separate Ex type label.
The standard version must not be used in the potentially explosive
area.
• Ex version – with separate Ex type label.
The Ex version may be used in the potentially explosive area. In
doing so, observe the specifications on the separate Ex type label
and the additional information enclosed with the device together
with safety instructions for the Ex area.
5.3 Properties
• High tightness by self-adjusting packing glands
(spindle sealing element).
• High seat tightness by swivel plate.
• Actuator can be rotated steplessly through 360 °.
• Maintenance-free under normal conditions.
5.3.1 Options
• Control unit
Different versions of the control 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.
5.3.2 Device versions
The globe valve is available for the following actuator sizes:
ø 50 mm, ø 70 mm, ø 90 mm, ø 130 mm.
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Type 2101

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Structure and function
5.3.3 Restrictions
WARNING!
Risk of injury from water hammer.
A water hammer could crack the lines and device.
Due to the risk of water hammer, valves with a flow direction
above seat must not be used for liquid media.
▶Consider the type of flow direction and the type of medium for
operation of the device.
5.4 Designated application area
Observe the maximum pressure range according to the
type label!
• Neutral gases and liquids up to 16 bar.
• Steam up to 11 bar absolute / 185 °C.
• Aggressive media.
5.4.1 Application areas
e.g. Plant construction
Food processing
Chemical engineering
Sterilizer construction
6 STRUCTURE AND FUNCTION
6.1 Structure
The globe valve consists of a pneumatically actuated piston actuator
and a 2/2-way valve body.
The actuator is manufactured from polyphenylene sulphide (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.
Transparent cap with position indicator
Actuator cover
Actuator body
Globe valve body
Flow direction arrow or
numbers for indicating the
direction of flow
Fig. 1: Globe valve Type 2101, structure and description (1)
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Type 2101

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Structure and function
The description of the control function (CF) can be found in
chapter entitled “6.2.1 Control functions (CF)”.
Air discharge connection for CFA, CFB
Pilot air port for CFI
Pilot air port for CFA, CFB, CFI
Interface actuator/body
with flats
Port connection
Release bore
2
1
Fig. 2: Globe valve Type 2101, Structure and Description (2)
6.2 Function
Depending on the version, the seat of the valve is closed with or
against the medium flow.
Spring force (CFA) or pneumatic pilot pressure (CFB and CFI) gen-
erates the closing force on the swivel plate. The force is transferred
via a spindle which is connected to the actuator piston.
6.2.1 Control functions (CF)
WARNING!
For control function I – Danger if pilot pressure fails!
For control function I control and resetting occur pneumatically. If
the pressure fails, no defined position is reached.
▶To ensure a controlled restart, first pressurise the device with
pilot pressure, then switch on the medium.
Control function A (CFA)
Normally closed by spring action
1(P)
2(A)
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Type 2101

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Structure and function
Control function B (CFB)
Normally open by spring action
1(P)
2(B)
Control function I (CFI)
Actuating function via reciprocal pressurisation.
1(P)
2(A)
6.2.2 Flow direction below seat
Depending on the version, the valve is closed against the medium
flow with spring force (control function A, CFA) or with pilot
pressure (control function B or I, CFB or CFI).
As the medium pressure is under the swivel plate, this pressure
contributes to the opening of the valve.
WARNING!
Medium may be discharged if minimum pilot pressure is too
low or medium pressure too high!
If the minimum pilot pressure is too low for CFB and CFI or the
permitted medium pressure is exceeded, leaks may occur.
▶Observe minimum pilot pressure
▶Do not exceed medium pressure.
▶See chapter entitled “7.4.1 Temperature ranges”.
CFA CFB /
CFI
Fig. 3: Flow direction below seat
(Rest open/closed, closing against medium)
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Type 2101

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Technical data
6.2.3 Flow direction above seat
The valve is closed by spring force (control function A, CFA) with
the medium flow. As the medium pressure is over the swivel plate, it
supports the closing process of the valve and also contributes to the
sealing of the valve seat. The valve is opened by the pilot pressure.
WARNING!
Risk of injury from water hammer.
A water hammer could crack the lines and device.
Due to the risk of water hammer, valves with a flow direction
above seat must not be used for liquid media.
▶Consider the type of flow direction and the type of medium for
operation of the device.
To ensure complete opening, the minimum pilot pressure
must be used!
Fig. 4: Flow direction above seat (rest closed, closing with
medium)
7 TECHNICAL DATA
7.1 Conformity
Type 2101 conforms with the EC Directives according to the EC
Declaration of Conformity.
7.2 Standards
The applied standards, which verify conformity with the EC Direc-
tives, can be found on the EC-Type Examination Certificate and / or
the EC Declaration of Conformity.
According to Pressure Equipment Directive the following operating
conditions must be observed:
Line connection
orifice
Maximum pressure for compressible fluids
of Group 1 (hazardous gases and vapors
according to Art. 3 No. 1.3 Letter a first
dash)
DN65 15 bar
7.3 Type label
Example:
00189700
2101 A 25M PTFE VA
Tmed -10°C - +180°C
Flow 1 2 DIN
Pilot 4,8-10bar
Pmed 16,0bar
DN25 Kv13,0W3ZLT
CE
Fig. 5: Example of type label
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Type 2101

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Technical data
WARNING!
Risk of injury from high pressure!
Important device-specific technical specifications are indicated on
the type label.
▶Observe permitted pressure range on the type label of the device.
00189700
2101 A 25M PTFE VA
Tmed -10°C - +180°C
Flow 1 2 DIN
Pilot 4,8-10bar
Pmed 16,0bar
DN25 Kv13,0W3ZLT
CE
CE identification
Permitted
pilot pressure
Permitted
medium pressure
Type
Control function
(CF)
Orifice of the body /
actuator size
Sealing material 1) Body material 1)
ID number of
the device
Flow direction
Permitted medium
temperature
Date of
manufacture
(encoded)
Main dimensions
port connection Flow capacity in
standard production
conditions
1) For a description of the versions see the following chapter entitled “7.5
General technical data”.
7.4 Operating conditions
7.4.1 Temperature ranges
Actuator
size
Actuator
material
Medium
(for PTFE seal) Environment2)
ø 50 mm
PPS -10 – +185 °C 0 – +60 °C3)
0 – +100 °C4)
ø 70 mm
ø 90 mm
ø 130 mm
Tab. 1: Temperature Ranges
2) If a pilot valve is used, the max. ambient temperature is
+55 °C.
The globe valve is suitable for steam sterilization.
3) Pilot air ports with push-in connector
4) Pilot air ports with threaded bushing
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Technical data
7.4.2 Pressure ranges
Actuator size Maximum pilot pressure5)
ø 50 mm
10 barø 70 mm
ø 90 mm
ø 130 mm 7 bar
Tab. 2: Pressure Ranges
5) For the device version ø 70 / Orifice 50 / MC 13 the maximum
permitted pilot pressure is limited to 7 bar.
Medium and pilot pressure for control function A, flow direction
below the seat (standard)
Orifice
DN
Maximum medium pressure
[bar]
Minimum pilot pressure
[bar]
Actuator size ø [mm] Actuator size ø [mm]
50 70 90 130 50 70 90 130
10/15 25 25
-
-
5.2
4.8
-
-
20 16 20
25 916
32
-
8.5 16
-
5
40 616
50
-
10 16 5
65 5.0 16 (15*)
-5.680 -10 -
100 6
Tab. 3: Medium and pilot pressure for CFA, standard
* According to Pressure Equipment Directive for compressible fluids of
Group 1 (hazardous gases and vapors according to Art. 3 No. 1.3 Letter a
first dash)
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Technical data
Medium and pilot pressure for control function A, flow direction
below the seat reduced pressure spring force (EC04)
Orifice
DN
Maximum medium pressure
[bar]
Minimum pilot pressure
[bar]
Actuator size ø [mm] Actuator size ø [mm]
50 70 90 130 50 70 90 130
10/15 14 16
--3.2
2.5
-- 20 612
25 3 6
32
-
3.5 9
-
2.540 2 6 16 2.5
50
-
3.5 10
-65 -7.5 -3.2
80 5
Tab. 4: Medium and pilot pressure for CFA, reduced pressure
spring force (EC04)
Required minimum pilot pressure depending on medium
pressure
The following graphs illustrate the required minimum pilot pressure
depending on the medium pressure for control functions A, B and I.
Control function A, flow direction above seat
Pilot pressure [bar]
Medium pressure [bar]
ø 50
CFA above seat
012345678910
0
2
4
6
8
10
12
14
16
DN15 DN20 DN25
Fig. 6: Pressure graph, actuator ø 50 mm, control function A, flow
direction above seat
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Type 2101

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Technical data
Pilot pressure [bar]
Medium pressure [bar]
ø 70
CFA above seat
012345678910
0
2
4
6
8
10
12
14
16
DN15 DN20 DN25 DN32 DN40
DN50
Fig. 7: Pressure graph, actuator ø 70 mm, control function A, flow
direction above seat
Pilot pressure [bar]
Medium pressure [bar]
ø 90
CFA above seat
012345678910
0
2
4
6
8
10
12
14
16
DN40
DN50
DN65
Fig. 8: Pressure graph, actuator ø 90 mm, control function A, flow
direction above seat
Control functions B and I, flow direction below seat
Pilot pressure [bar]
Medium pressure [bar]
ø 50 CFB/CFI
below seat
012345678910
0
2
4
6
8
10
12
14
16
DN15 DN20
DN25
Fig. 9: Pressure graph, actuator ø 50 mm, control functions B and I,
flow direction below seat
Pilot pressure [bar]
Medium pressure [bar]
ø 70 CFB/CFI
below seat
012345678910
0
2
4
6
8
10
12
14
16
DN15 DN20
DN25
DN32 DN40
DN50
Fig. 10: Pressure graph, actuator ø 70 mm, control functions B and I,
flow direction below seat
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Type 2101

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Technical data
Pilot pressure [bar]
Medium pressure [bar]
ø 90 CFB/CFI
below seat
012345678910
0
2
4
6
8
10
12
14
16
DN65
DN32 DN40 DN50
Fig. 11: Pressure graph, actuator ø 90 mm, control functions B and I,
flow direction below seat
Pilot pressure [bar]
Medium pressure [bar]
ø 130 CFB/CFI
below seat
012345678910
0
2
4
6
8
10
12
14
16
DN65
DN80
DN40 DN50
DN100
Fig. 12: Pressure graph, actuator ø 130 mm, control functions B and
I, flow direction below seat
7.5 General technical data
Actuator size see type label
Control function see type label, description of control func-
tions see chapter “6.2”
Installation as required, preferably with actuator in
upright position
Protection class IP67 in accordance with IEC 529 / EN
60529
Media
Control medium Neutral gases, air
Flow media Water, alcohol, fuel, hydraulic liquids,
saline solutions, lye, organic solvents
Materials
Body 316L
Actuator PPS and stainless steel
Sealing elements FKM and EPDM
Spindle sealing PTFE V rings with spring compensation
(with silicone grease)
Seat seal PTFE (NBR, EPDM, FKM on request)
Swivel plate
Spindle 1.4401 / 1.4404
Spindle guide
DN10-65 PEEK
DN80-100 1.4401 / 1.4404
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Type 2101

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Installation
Connections
Pilot air port Plug-in connector 6/4 mm or 1/4”
others on request
Medium connection Socket: G ½ – G 4 (NPT, RC on request)
Weld end connection: in accordance with
ISO 4200, DIN 11850 R2
other connections on request
8 INSTALLATION
8.1 Safety instructions
DANGER!
Risk of injury from high pressure!
▶Before loosening the lines and valves, turn off the pressure and
vent the lines.
WARNING!
Risk of injury from improper installation!
▶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 installation, ensure a controlled restart.
For control function I – Danger if pilot pressure fails!
For control function I control and resetting occur pneumatically. If
the pressure fails, no defined position is reached.
▶To ensure a controlled restart, first pressurize the device with
pilot pressure, then switch on the medium.
Risk of injury from moving parts in the device!
▶Do not reach into openings.
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Type 2101

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Installation
8.2 Before installation
• The globe valve can be installed in any installation position, pref-
erably with the actuator face up.
• Before connecting the valve, ensure the lines are flush.
• Observe direction of flow (see type label).
8.2.1 Preparatory work
→Clean pipelines (sealing material, swarf, etc.).
Devices with welded body
NOTE!
For valves with installed control:
When welding the valve body into the pipeline, the control must
not be installed.
▶Remove control from the actuator (see installation chapter in the
operating instructions for the corresponding control).
Remove the actuator from the valve body:
→Clamp the valve body in a holding device.
NOTE!
Damage to the seat seal or the seat contour!
▶When removing the actuator, ensure that the valve is in open
position.
→Control function A pressurize the pilot air port 1 with com-
pressed air (5 bar): valve opens.
→Using a suitable open-end wrench, place the wrench flat on the
tube.
→Unscrew the actuator from the valve body.
Actuator
Nipple
Valve body
Air discharge connection
CFA, CFB
Pilot air port
CFI
Pilot air port
CFA, CFB, CFI
Flats for open-end
wrench
Release bore
2
1
Fig. 13: Installation
Other device versions
→Do not remove actuator unless this is a customer-specific
requirement.
→Procedure see “Devices with welded body”.
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Type 2101

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Installation
8.3 Installation
WARNING!
Risk of injury from improper assembly!
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. 5: Tightening torques
of valve body / nipples”).
Dirt trap for devices with authorization in accordance with DIN
EN 161
In accordance with DIN EN 161 “Automatic shut-off valves for gas
burners and gas appliances” a dirt trap must be connected upstream
of the valve and prevent the insertion of a 1 mm plug gauge.
→If the authorisation also applies to stainless steel bodies, the
same type of dirt trap must be attached in front of the globe
valve.
8.3.1 Installation of the valve body
Welded bodies
→Weld valve body in pipeline system.
Other body versions
→Connect body to pipeline.
8.3.2 Install actuator (welded body)
Graphite seal
Fig. 14: Graphite seal
→Check the graphite seal and if required, replace it.
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 authorised lubricants only.
→Grease nipple thread before re-installing the actuator (e.g. with
Klüber paste UH1 96-402 from Klüber).
NOTE!
Damage to the seat seal or the seat contour!
▶When installing the actuator, ensure that the valve is in open
position.
→Control function A pressurize the pilot air port 1 with com-
pressed air (5 bar): valve opens.
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Type 2101

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Installation
→Screw actuator into the valve body.
Observe tightening torque (see “Tab. 5: Tightening torques of
valve body / nipples”).
1
2
Pilot air port
CFA, CFB, CFI
Air discharge connection
CFA, CFB
Pilot air port
CFI
Fig. 15: Connections
Tightening torques of valve body / nipples
DN Tightening torque [Nm]
13/15 45 ±3
20 50 ±3
25 60 ±3
32 65 ±3
40
50 70 ±3
65 100 ± 3
80 120 ± 5
100 150 ± 5
Tab. 5: Tightening torques of valve body / nipples
8.3.3 Install control
Description see Installation chapter in the operating instruc-
tions for the corresponding control.
8.3.4 Rotating the actuator
The position of the connections can be aligned steplessly by rotating
the actuator through 360°.
NOTE!
Damage to the seat seal or the seat contour!
▶When rotating the actuator, ensure that the valve is in open
position.
Procedure:
→Clamp the valve body in a holding device
(applies only to valves which have not yet been installed).
→Control function A pressurize the pilot air port 1 with com-
pressed air (5 bar): valve opens.
→Counter on the flats of the nipple with a suitable open-end
wrench.
→Actuator with hexagon:
Place suitable open-end wrench on the hexagon of the actuator.
→Actuator without hexagon:
Fit special wrench6) exactly to the underside of the actuator.
6) The special key (identification number 665 702) is available from your
Bürkert sales office.
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Type 2101