Burkert 2103 Series User manual

Quickstart
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Type 2103, 2104, 2105
Piston-controlled diaphragm valve
Kolbengesteuertes Membranventil
Vanne à membrane commandée par piston

We reserve the right to make technical changes without notice.
Technische Änderungen vorbehalten.
Sous réserve de modifications techniques.
© Bürkert Werke GmbH & Co. KG, 2013 - 2018
Operating Instructions 1807/05_EU-ML_00810349 / Original DE

3
Quickstart
1 QUICKSTART
The quickstart contains the most important information and notes
regarding the use of the device. Keep these instructions in a location
which is easily accessible to every user, and make these instruc-
tions available to every new owner of the device.
Important safety information.
Failure to observe these instructions may result in hazardous
situations.
▶Quickstart must be read and understood.
A detailed description of the device can be found in the operating
instructions for Type 2103, 2104 and 2105.
The operating instructions can be found on the Internet
at:
www.burkert.com
1.1 Denition of term
The term “device” used in these instructions always stands for the
diaphragm valve Type 2103, 2104 or 2105.
1 QUICKSTART ........................................................................ 3
2 AUTHORIZED USE ............................................................... 4
3 BASIC SAFETY INSTRUCTIONS.......................................... 5
4 GENERAL INFORMATION .................................................... 6
5 STRUCTURE AND FUNCTION ............................................. 7
6 TECHNICAL DATA................................................................. 8
7 INSTALLATION .................................................................... 11
8 REMOVAL............................................................................ 17
9 MAINTENANCE WORK....................................................... 17
10 TRANSPORT, REMOVAL .................................................... 18
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Type 2103, 2104, 2105

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Authorized use
1.2 Symbols
DANGER!
Warns of an immediate danger.
▶Failure to observe the warning may result in a fatal or serious
injury.
WARNING!
Warns of a potentially dangerous situation.
▶Failure to observe the warning may result in serious injuries
or death.
CAUTION!
Warns of a possible danger.
▶Failure to observe this warning may result in a moderate or
minor injury.
NOTE!
Warns of damage to property.
Important tips and recommendations.
Refers to information in these operating instructions or in
other documentation.
▶designates an instruction to prevent risks.
→designates a procedure which you must carry out.
2 AUTHORIZED USE
Non-authorized use of the device may be a hazard to people,
nearby equipment and the environment.
▶The device is designed for the controlled ow of liquid and
gaseous media.
▶In areas at risk of explosion, only use devices approved for
use in those areas. These devices are labeled with a separate
Ex type label. When utilized in a potentially explosive atmo-
sphere, always pay attention to the details on the separate Ex
type label and the Ex additional instructions contained in the
scope of delivery.
▶During use observe the authorized data, the operating condi-
tions and conditions of use specied in the contract docu-
ments and operating instructions.
▶Protect device from damaging environmental inuences
(e.g. radiation, humidity, steam, etc.). If anything is unclear,
consult the relevant sales oce.
▶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
faultless operation.
▶The exhaust air may be contaminated with lubricants in the
actuator.
▶Use the device only as intended.
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Type 2103, 2104, 2105

5
Basic safety instructions
3 BASIC SAFETY INSTRUCTIONS
These safety instructions do not make allowance for any
•contingencies and events which may arise during the installation,
operation and maintenance of the devices.
•local safety regulations, whereby the operator is responsible for
their compliance, by the installation personnel too.
Danger – high pressure.
▶Before loosening the lines and valves, turn o the pressure
and vent the lines.
Danger of bursting from overpressure.
▶Observe the specications on the type label for maximal
control and medium pressure.
▶Observe permitted medium temperature.
Risk of injury from electric shock (when electrical component
installed).
▶Before reaching into the device or the equipment, switch o
the power supply and secure to prevent reactivation!
Observe applicable accident prevention and safety regulations
for electrical equipment!
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!
▶Do not open the actuator.
Risk of injury from moving parts in the device!
▶Do not reach into openings.
▶Operate 3-position actuator with transparent cap only.
Risk of burns and risk of re if used continuously through hot
device surface.
▶Keep the device away from highly ammable substances and
media and do not touch with bare hands.
Danger due to loud noises.
▶Depending on the operating conditions, the device may generate
loud noises. More detailed information on the likelihood of loud
noises is available from the relevant sales oce.
▶Wear hearing protection when in the vicinity of the device.
Leaking medium when the diaphragm is worn.
▶Regularly check relief bore for leaking medium.
▶If medium is leaking out of the relief bore, change the diaphragm.
▶If the media is hazardous, protect the area surrounding the dis-
charge point against dangers.
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Type 2103, 2104, 2105

6
General information
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 dened or
controlled manner.
▶The device may be operated only when in perfect condition
and in consideration of the operating instructions.
▶Observe the safety regulations specic to the plant for applica-
tion planning and operation of the device.
▶The plant operator is responsible for the safe operation and
handling of the plant.
▶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
specied as ow media in the chapter entitled “6 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 modications to the valves. Do not
paint the body parts or screws.
▶Do not transport, install or remove heavy devices without the aid
of a second person and using suitable auxiliary equipment.
4 GENERAL INFORMATION
4.1 Contact address
Germany
Bürkert Fluid Control Systems
Sales Center
Chr.-Bürkert-Str. 13-17
D-74653 Ingelngen
Tel. : 07940 - 10 91 111
Fax: 07940 - 10 91 448
E-mail: [email protected]
International
Contact addresses are found on the nal pages of the printed
operating manual.
You can also nd information on the Internet under:
www.burkert.com
4.2 Warranty
The warranty is only valid if the device is used as authorized in
accordance with the specied application conditions.
4.3 Information on the internet
The operating instructions and data sheets for Type 2103, 2104 and
2105 can be found on the Internet at: www.burkert.com
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Type 2103, 2104, 2105

7
Structure and function
5 STRUCTURE AND FUNCTION
5.1 Structure
The piston-controlled diaphragm valve consists of a pneumatically
operated piston actuator and a 2/2-way valve body.
The actuator is manufactured from polyphenylene sulphide (PPS)
and stainless steel.
5.1.1 2/2-way valve type 2103
Transparent cap with position
indicator
Actuator cover
Actuator housing
Diaphragm socket
Line connection
Valve body
Second pilot air port for CFI
and air discharge connection for CFA and CFB
Pilot air port for CFA, CFB, CFI
2
1
Fig. 1: Piston-controlled diaphragm valve, structure and description
5.1.2 2/3-way valve type 2103
Actuator cover
Actuator body
Diaphragm socket
Line connection
Valve body
Transparent cap
Setting of the
center position
Pilot air port for
control function A -
center position
Pilot air port for
control function
A - open
1
2
Fig. 2: Structure and description, 2/3-way valve type 2103
5.1.3 T-valve type 2104
Transparent cap
with position
indicator
Actuator cover
Actuator
housing
VA diaphragm socket
(VA = stainless steel) T-valve body
Line connection
Pilot air port
for control function (CF)
A, B, I
Second pilot air port for
CFI and air discharge
connection for CFA and
CFB
1
2
Fig. 3: Structure and description type 2104
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Type 2103, 2104, 2105

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Structure and function
5.1.4 Tank bottom valve type 2105
Transparent cap with
position indicator
Actuator housing
Actuator cover
Tank bottom valve
with welding ange
VA diaphragm socket
(VA = stainless steel)
Pilot air ports 1 and 2
(see detailed view)
Second pilot air port
for CFI and air
discharge connection
for CFA and CFB
2
1
Pilot air port 1
for control function
(CF) A, B, I
Fig. 4: Structure and description type 2105
5.2 Function
Spring force (CFA) or pneumatic pilot pressure (CFB and CFI) gen-
erates the closing force on the diaphragm pressure piece. The force
is transferred via a spindle which is connected to the actuator piston.
5.2.1 Control functions (CF)
WARNING!
For control function I: Danger if pilot pressure fails.
For control function I (CFI) control and resetting occur pneumati-
cally. If the pressure fails, no dened position is reached.
▶To ensure a controlled restart, rst pressurize the device with
pilot pressure, then switch on the medium.
CFA
P
A
Closed by spring force in rest position.
CFB
P
A
Opened by spring force in rest position.
CFI
P
A
Actuating function via reciprocal
pressurization.
6 TECHNICAL DATA
WARNING!
Risk of injury from high pressure.
Excessive pressure can damage the device.
▶Comply with pressure range values on the type label.
6.1 Conformity
Type 2103, 2104 and 2105 conforms with the EU Directives
according to the EU Declaration of Conformity.
6.2 Standards
The applied standards, which verify conformity with the EU
Directives, can be found on the EU-Type Examination Certicate
and / or the EU Declaration of Conformity.
6.3 Type label
Example:
00175139
2103 A 20M PTFE VS
Tamb 0°C - +60°C
Tmed xxx°C - +130°C
Pilot 4,8-10bar
Pmed 10,0bar
Da=26,9 s=1,6W3ZLT
CE
Fig. 5: Example of type label
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Type 2103, 2104, 2105

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Structure and function
6.3.1 Wording on the type label
Example:
00175139
2103 A 20M PTFE VS
Tamb 0°C - +60°C
Tmed xxx°C - +130°C
Pilot 4,8-10bar
Pmed 10,0bar
Da=26,9 s=1,6W3ZLT
CE
CE identication
Permitted pilot
pressure
Permitted medium
pressure
Type
Control function
Orice
(diaphragm size /
actuator size
Sealing material Body material
Identication
number of
the product
Permitted medium
temperature
Permitted ambient
temperature
Date of manufacture
(encoded)
Main dimensions of
body connection
6.4 Labeling of the tube valve body (VP)
1.4435
316L(VP)
XXXXXXXX
XXXXXXXXXX
PN16 / CWP150
XXXXXXXX / XXX
XXXX / XXXXXX
Material HeatCompany logo
Nominal
pressure
Connection orice
and pipe dimensions
Self-drain angle /
Customer-specic text
(optional)
Production number /
serial number
Fig. 6: Labeling of the tube valve body (VP)
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Type 2103, 2104, 2105

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Structure and function
6.5 Labeling of the forged bodies
XXXXXXXXXX
XX F
1.4435/316L(VS)
PN16/CWP150
XXXXXXXX/XXX
XXXXXX
XXXX
Self-drain angle
Customer-specic text
(optional)
Orice connection and pipe dimension
Batch number
Material
Production number /
serial number
Nominal pressure
Fig. 7: Labeling of the forged bodies
6.6 Operating conditions
Ambient temperature for actuator -10...+60°C / +100°C1)
Medium temperature for body:
Body material Temperature
Stainless steel -10...+150 °C
PVC (see PT graph) -10...+60 °C
PVDF (see PT graph) -10...+120 °C
PP (see PT graph) -10...+80 °C
Tab. 1: Medium temperature for body
Medium temperature for diaphragms:
Material Temperature
[°C]2)
Remarks
EPDM (AB) -10...+130 Steam sterilization up to +140°C / 60min
EPDM (AD) -10...+143 Steam sterilization up to +150°C / 60min
FKM (FF) 0...+130 No steam / dry heat up to +150°C /
60min
PTFE (EA) -10...+130 Steam sterilization up to +140°C / 60min
Advanced
PTFE (EU)
-5...+143 Steam sterilization up to +150°C / 60min
Gylon (ER) -5...+130 Steam sterilization up to +140°C / 60min
Tab. 2: Permitted medium temperature for diaphragms
1) Pilot air ports with push-in connector or threaded bushing
2) The indicated medium temperatures apply only to media which do not
corrode or swell the diaphragm materials. The behavior of the medium
with respect to the diaphragm may be changed by the medium tem-
perature. The function properties, in particular the service life of the
diaphragm, may deteriorate if the medium temperature increases. Do
not use the diaphragms as steam shut-o element.
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Type 2103, 2104, 2105

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Installation
6.6.1 Permitted medium pressure
Permitted medium pressure depending on the medium temperature.
Plastic body:
DN 15 - 65
10
8
6
4
2
20 40 60
80
100 120 140
PVC
PVDF
PP
Medium pressure [bar]
Temperature [°C]
Fig. 8: Graph of medium pressure / Medium temperature
6.7 General technical data
Media
Control medium neutral gases, air
Flow media liquids; ultrapure, sterile, dirty,
aggressive or abrasive media
Installation position
Type 2103, 2104 any position, preferably with the
actuator face up
Type 2105 preferably with the actuator to the bottom
(Tank bottom valve)
Degree of protection IP67 in accordance with IEC 529 /
EN 60529
7 INSTALLATION
7.1 Safety instructions
DANGER!
Risk of injury from high pressure in the equipment or device.
▶Before working on equipment or device, switch o the pressure
and vent the lines.
WARNING!
Risk of injury from improper installation.
▶Installation may be carried out by authorised technicians
only and with the appropriate tools.
Risk of injury from unintentional activation of the system and
an uncontrolled restart.
▶Secure system from unintentional activation.
▶Following assembly, ensure a controlled restart.
For control function I: Danger if pilot pressure fails.
For control function I control and resetting occur pneumati-
cally. If the pressure fails, no dened position is reached.
▶To ensure a controlled restart, rst pressurize the device with
pilot pressure, then switch on the medium.
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Type 2103, 2104, 2105

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Installation
CAUTION!
Risk of injury due heavy devices!
▶During transport or during assembly, a heavy device may fall
and cause injury.
▶Do not transport, install or remove heavy devices without the
aid of a second person and using suitable auxiliary equipment.
▶Use appropriate tools.
NOTICE!
Note the following when installing the device in the plant
▶The device and the leakage detection bore must be acces-
sible to allow inspection and maintenance work.
7.2 Installation position
Installation for self-drainage of the body
It is the responsibility of the installer and operator to
ensure self-drainage.
Installation for leakage detection
One of the bores in the diaphragm socket for monitoring
leakage must be at the lowest point.
7.2.1 Installation position type 2103
•The piston-controlled diaphragm valve can be installed in any
installation position, preferably with the actuator face up.
To ensure self-drainage:
→Install valve body inclined by an angle α = 10° – 55° to the
horizontal.
Forged body, cast body and tube valve body: Mark on the
valve body must point upwards (12 o’clock position, see “Fig.
9”).
→Observe an inclination angle of 1° – 5° to the line axis.
Inclination to the line
axis
α = 1° – 5°
Mark for self-drainage
upwards
Fig. 9: Installation position for self-drainage of the valve body
α
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Type 2103, 2104, 2105

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Installation
7.2.2 Installation position T-valve type 2104
For the installation of the T-valves into circular pipelines, we rec-
ommend the following installation positions:
When media is supplied: When media is removed:
Fig. 10: Installation position type 2104
7.2.3 Installation position tank bottom valve
type 2105
Preferably with the actuator to the bottom.
7.3 Before installation
NOTE!
Damage to the diaphragm or the actuator.
▶Devices with welded or bonded body: Before welding or bond-
ing the body, the actuator and diaphragm must be removed
•Before connecting the valve, ensure the pipelines are ush.
•The ow direction is optional.
7.3.1 Preparatory work
→Clean pipelines (sealing material, swarf, etc.).
→Support and align pipelines.
7.4 Remove the actuator from the valve
body
NOTICE!
Damage to the diaphragm or the seat contour.
▶When removing the actuator, ensure that the valve is open.
→Control function A pressurize the pilot air port 1 with compressed
air (5,5 bar): valve opens.
→Remove actuator with diaphragm by loosening the body
screws.
Actuator
Valve body
Air discharge connection CFA, CFB
Pilot air port CFI
Pilot air port CFA, CFB, CFI
2
1
Body screws (4x)
Diaphragm
Fig. 11: Installation
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Type 2103, 2104, 2105

14
Installation
7.5 Installation
If used in an aggressive environment, we recommend
conveying all free pneumatic connections into a neutral
atmosphere with the aid of a pneumatic hose.
WARNING!
Risk of injury from improper installation.
Non-observance of the tightening torque is dangerous as the
device may be damaged.
▶Observe the tightening torques (see “Tab. 3”, page 15).
7.5.1 Installation of the valve body type 2103
and 2104
Welded or glued bodies
→Weld or glue valve body in pipeline system.
Other bodies
→Connect body to pipeline.
7.5.2 Welding tank bottom body
Observe sequence:
1. Weld the tank bottom body onto the base of the tank
before installing the tank.
Welding onto a tank which has already been installed is
possible but more dicult.
Weld the tank bottom body in the middle of the tank
base so that the tank can be optimally drained.
2. Weld valve body into the pipeline.
Installation requirements:
Pipelines: Ensure that the pipelines are aligned.
Preparation: Support and align pipelines. To ensure that the
pipeline is self-draining, observe an inclination angle
of 1° – 5°.
DANGER!
Risk of injury from high pressure!
▶Before working on the system, switch o the pressure and
vent or drain lines.
For information on tanks and instructions on welding
observe the standard ASME VIII Division I.
Before you start welding, check the batch number indi-
cated on the supplied manufacturer’s certicate 3.1 .
Observe the applicable laws and regulations of the
respective country with regard to the qualication of
welders and the execution of welding work.
1. Welding tank bottom body onto the tank:
ATTENTION!
Before welding, note the following:
▶Use only welding material which is suitable for the tank bot-
tom body.
▶The tank bottom valve must not collide with any other instal-
lation part. The actuator must be easy to install and remove.
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Type 2103, 2104, 2105

15
Installation
2. Welding tank bottom body into the pipeline:
→Weld in tank bottom body.
Ensure installation is de-energized and low-vibration.
After welding in the valve body:
Install the diaphragm and the actuator.
7.6 Installation of the actuator (welded or
glued body)
NOTICE!
Damage to the diaphragm or the seat contour.
▶When installing the actuator, ensure that the valve is open.
Installation for actuator with control function A:
→Control function A pressurize the pilot air port 1 with compressed
air (5,5 bar): valve opens.
→Place actuator on the body
→Lightly cross-tighten the body screws until the diaphragm lies
between the body and actuator. Do not tighten the screws yet.
→Actuate the diaphragm valve twice to position the diaphragm
correctly.
→Tighten body screws without pressurization in diagonal pairs in
three stages (approx. 1/3, approx. 2/3, 3/3 of the tightening torque),
according to Table ( see “Tab. 3”). The diaphragm should be
positioned and pressed evenly all around the actuator and body.
Installation for actuator with control functions B and I:
→Place actuator on the body
→Gently tighten the body screws in diagonal pairs without pres-
surization until the diaphragm lies between the body and actuator.
Do not fully tighten the screws yet.
→Pressurize pilot air port 1 of the actuator with compressed air
(5,5bar).
→Actuate the diaphragm valve twice to position the diaphragm
correctly.
→Tighten body screws with pressurization in diagonal pairs in three
stages (approx. 1/3, approx. 2/3, 3/3 of the tightening torque),
according to Table ( see “Tab. 3”). The diaphragm should be
positioned and pressed evenly all around the actuator and body.
1
Pilot air port
CFA, CFB, CFI
Fig. 12: Pilot air port
Orice DN
(diaphragm size)
Tightening torques for diaphragms [Nm]
EPDM/
FKM
PTFE / advanced PTFE /
laminated PTFE
8 2.5 2.5
15 3.5 4
20 4 4.5
25 5 6
32 8 10
40 8 10
50 12 15
Tab. 3: Tightening torques for diaphragms
→A tolerance of +10% of the respective tightening torque
applies to all values.
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Type 2103, 2104, 2105

16
Installation
7.7 Align actuator
If the valve features a stainless steel diaphragm socket,
the actuator can be rotated steplessly by 360 °.
→Rotate actuator using a hook wrench. See “Fig. 13”.
Rotate actuator only as far as required (max. 360 °).
Recommended hook
wrenches as per DIN
1810.
Actuator size:
ø 50 = A 52 - 55,
ø 70 - 130 = A 68 - 75
Fig. 13: Align actuator
7.8 Pneumatic connection
DANGER!
Danger – high pressure in the equipment.
▶Before loosening the lines and valves, turn o the pressure
and vent the lines.
WARNING!
Risk of injury from unsuitable connection hoses.
▶Use only hoses which are authorised for the indicated pres-
sure and temperature range.
▶Observe the data sheet specications from the hose
manufacturers.
For control function I: Danger if pilot pressure fails.
For control function I control and resetting occur pneumatically.
If the pressure fails, no dened position is reached.
▶To ensure a controlled restart, rst pressurize the device with
pilot pressure, then switch on the medium.
7.8.1 Connection of the control medium
Control functions A and B
→Connect the control medium to the pilot air port 1 of the actuator
(see “Fig. 13: Align actuator”).
Control function A, 3-position actuator
→Connect the control medium to the pilot air port 1 and 2 of
the actuator (see “Fig. 2” in chapter 5)
Pressure on connection 1 opens the valve,
Pressure on both connections sets the mid- position.
Control function I
→Connect the control medium to the pilot air port 1 and 2 of
the actuator (see “Fig. 14: Pneumatic connection”)
Pressure on connection 1 opens the valve.
Pressure on connection 2 closes the valve.
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Type 2103, 2104, 2105

17
Removal
1
2
Pilot air port
CFA, CFB, CFI
Air discharge connection CFA, CFB
and second pilot air port CFI
Fig. 14: Pneumatic connection
Silencer
For the versions with a plug-in connection the silencer for
reducing the exhaust air noise is supplied loose.
→Plug the silencer into the free air discharge connection 2
(see “Fig. 14: Pneumatic 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 sizes 6/4 mm or 1/4“ can be used. Optionally
a pilot air port is possible via a G 1/8 thread.
8 REMOVAL
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 o the pressure and vent
the lines.
→Loosen the pneumatic connection.
→Remove the device.
9 MAINTENANCE WORK
9.1 Actuator
The actuator of the diaphragm valve is maintenance-free pro-
vided it is used according to these operating instructions.
9.2 Spare parts of the diaphragm valve
Parts which are subject to natural wear:
•Seals and diaphragm
→If leaks occur, replace the particular wearing part with an
appropriate spare part.
A bulging PTFE diaphragm may reduce the ow.
The replacement of spare parts is described in the operating
instructions at: www.burkert.com.
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Type 2103, 2104, 2105

18
Transport, removal
9.3 Inspection intervals
The following maintenance work is required for the diaphragm valve:
→After the rst steam sterilization or when required retighten
body screws crosswise.
→After maximum 105switching cycles check the diaphragm for
wear and replace if required.
Muddy and abrasive media require correspondingly
shorter inspection intervals.
9.4 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 compat-
ible with the body materials and seals.
10 TRANSPORT, REMOVAL
NOTE!
Incorrect transport and storage may damage the device.
•During transportation protect the device in shock-resistant
packaging.
•Below the permitted storage temperature from -20 to +65 °C.
•Store the device in a dry and dust-free location.
Damage to the environment caused by device components
contaminated with media.
•Dispose of the device and packaging in an environmentally
friendly manner and observe applicable regulations on disposal.
english
Type 2103, 2104, 2105

www.burkert.com