Burkert 2103 Series User manual

Operating Instructions
Bedienungsanleitung
Manuel d‘utilisation
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, 2008 - 2015
Operating Instructions 1504/06_EU-ML_00805642 / Original DE

3
Piston-controlled diaphragm valve Type 2103, 2104, 2105
1 OPERATING INSTRUCTIONS ................................................................4
1.1 Symbols .......................................................................................4
1.2 Definition of term “product” .....................................................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 Options ........................................................................................ 7
5.4 Designated application area ...................................................8
6 STRUCTURE AND FUNCTION...............................................................8
6.1 Structure ...................................................................................... 8
6.2 Function .....................................................................................10
7 TECHNICAL DATA .....................................................................................11
7.1 Conformity .................................................................................11
7.2 Standards ..................................................................................11
7.3 Type label ..................................................................................11
7.4 Operating conditions ..............................................................12
7.5 Flow values and characteristics ...........................................21
7.6 General technical data ...........................................................27
8 INSTALLATION ............................................................................................ 28
8.1 Safety instructions ...................................................................28
8.2 Installation position general...................................................28
8.3 Installation position 2/2-way valve type 2103 ..................28
8.4 Installation position T-valve type 2104 ...............................29
8.5 Installation position tank bottom valve type 2105 ...........29
8.6 Before installation ....................................................................29
8.7 Installation .................................................................................30
8.8 Pneumatic connection ............................................................33
8.9 Removal .....................................................................................34
9 ELECTRICAL CONTROL UNIT ............................................................ 34
10 MAINTENANCE, CLEANING ................................................................35
10.1 Safety instructions ...................................................................35
10.2 Maintenance work ...................................................................35
11 REPAIRS.........................................................................................................37
11.1 Safety instructions ...................................................................37
11.2 Replacing the diaphragm ......................................................37
12 MALFUNCTIONS ........................................................................................40
13 REPLACEMENT PARTS ..........................................................................40
13.1 Order table ................................................................................41
14 PACKAGING, TRANSPORT, STORAGE ..........................................41
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Type 2103, 2104, 2105

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Operating instructions
1 OPERATING INSTRUCTIONS
The operating instructions describe the entire life cycle of the product.
Keep these instructions in a location which is easily accessible to
every user and make these instructions available to every new owner
of the product.
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
product or the equipment.
Indicates important additional information, tips and
recommendations.
Refers to information in these operating instructions or in
other documentation.
▶Designates an instruction to prevent risks.
→Designates a procedure which you must carry out.
1.2 Definition of term “product”
The term “product” used in these instructions always stands for the
diaphragm valve Type 2103, 2104 or 2105.
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Type 2103, 2104, 2105

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Authorized use
2 AUTHORIZED USE
Non-authorized use of the diaphragm valve Type 2103, 2104
or 2105 may be a hazard to people, nearby equipment and
the environment.
▶The product is designed for the controlled flow of liquid media.
▶In the potentially explosion-risk area the diaphragm valve may be
used only according to the specification on the separate Ex type
label. For use observe the additional information enclosed with the
product 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 label are to be observed during use. The designated
application cases are specified in the chapter entitled “5 Prod-
uct description”.
▶The product may be used only in conjunction with third-party
products and components recommended and authorised by
Bürkert.
▶Correct transportation, correct storage and installation and
careful use and maintenance are essential for reliable and fault-
less operation.
▶Use the product only as intended.
2.1 Restrictions
If exporting the system/product, 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 products.
• 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 product, 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.
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Type 2103, 2104, 2105

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General information
CAUTION!
Risk of injury from moving parts in the device!
▶Do not reach into openings.
Risk of burns!
The surface of the product may become hot during long-term
operation.
▶Do not touch the product 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 product 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 product.
To prevent damage to property on the product, 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 product is used as authorized in
accordance with the specified 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

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Product description
5 PRODUCT DESCRIPTION
5.1 General description
The piston-controlled diaphragm valve Type 2103, 2104 or 2105 is
suitable for liquid media.
Using neutral gases or air (control media), it controls the flow of
dirty, aggressive, abrasive, ultrapure or sterile media, even highly
viscous media can be used (flow media).
5.1.1 Properties
• Any flow direction.
• Self-draining for appropriate installation. The ends of the utilized
connections must be cylindrical.
• Free of empty space.
• Low-turbulence flow.
• High flow values by the streamlined valve body.
• Maintenance-free under normal conditions.
5.2 Versions
There are 2 versions of the type 2103, 2104 and 2105.
• 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.
5.2.1 Product versions
Actuator sizes
The piston-controlled diaphragm valve is available for the following
actuator sizes:
ø 50 mm, ø 70 mm, ø 90 mm, ø 130 mm.
Pilot pressure
Designs with lower pilot pressure (reduced spring force) are
available on request.
Contact your Bürkert sales office or our Sales Center, e-mail:
[email protected]
5.3 Options
• Control 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 product features mechanical limit switches or inductive prox-
imity switches.
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Type 2103, 2104, 2105

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Structure and function
5.4 Designated application area
The diaphragm valve has been designed for use with dirty, aggressive,
abrasive, ultrapure or sterile media. The valves may only control media
which do not corrode the body and the seal materials (see type label).
Observe the maximum pressure range according to the
type label!
• Dirty, aggressive, abrasive, ultrapure or sterile media.
• Highly viscous media.
5.4.1 Application areas
e.g. plant construction
luxury food and food processing industry
bottling plant
chemical engineering
pharmaceutics
biotechnology
6 STRUCTURE AND FUNCTION
6.1 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) /
stainless steel.
6.1.1 2/2-way valve type 2103
Transparent cap with position indicator
Actuator cover
Actuator body
Diaphragm socket
Line connection
Diaphragm 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: Structure and description type 2103
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Type 2103, 2104, 2105

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Structure and function
6.1.2 T-valve type 2104
Transparent cap with position indicator
Actuator cover
Actuator body
VA diaphragm socket (VA = stainless steel)
T-valve body
Line connection
Second pilot air port for CFI
and air discharge connection for CFA and CFB
Pilot air port for CFA, CFB, CFI
1
2
Fig. 2: Structure and description type 2104
6.1.3 Tank bottom valve type 2105
Transparent cap
with position indicator
Actuator body
Actuator cover
Tank bottom valve
with welding flange
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 for CFA, CFB, CFI
Fig. 3: Structure and description type 2105
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Type 2103, 2104, 2105

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Structure and function
6.2 Function
Spring force (CFA) or pneumatic pilot pressure (CFB and CFI)
generates the closing force on the diaphragm pressure piece. The
force is transferred via a spindle which is connected to the actuator
piston.
6.2.1 Control functions (CF)
Control function A (CFA)
Normally closed by spring action
Control function B (CFB)
Normally open by spring action
Control function I (CFI)
Actuating function via reciprocal pressurization.
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 pressurize the product with
pilot pressure, then switch on the medium.
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Type 2103, 2104, 2105

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Technical data
7 TECHNICAL DATA
WARNING!
Risk of injury from high pressure!
Important product-specific technical specifications are indicated
on the type label.
▶Observe permitted pressure range on the type label of the product.
7.1 Conformity
Type 2103, 2104 and 2105 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.
7.3 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. 4: Example of type label
7.3.1 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 identification
Permitted control
pressure
Permitted medium
pressure
Type
Control function
Orifice
(diaphragm size /
actuator size
Sealing material 1) Body material 1)
Identification
number of the
product
Permitted medium
temperature
Permitted ambient
temperature
Date of manufacture
(encoded)
Main dimensions of
body connection
1) For description of versions see “7.4 Operating conditions”
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Type 2103, 2104, 2105

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Technical data
7.3.2 Labeling of the forged bodies
XXXXXXXXXX
XX F
1.4435/316L(VS)
PN16/CWP150
XXXXXXXX/XXX
XXXXXX
XXXX
Surface quality code
Customer-specific text
(optional)
Orifice connection and
pipe dimension
Batch number
Material
Production number /
serial number
Nominal pressure
Fig. 5: Labeling of the forged bodies
7.4 Operating conditions
7.4.1 Temperature ranges
Permitted ambient temperature actuators
Actuator size Actuator material Environment2)
ø 50 mm
PPS 0 – +60 °C3)
0 – +90 °C4)
ø 70 mm
ø 90 mm
ø 130 mm
Tab. 1: Permitted ambient temperature Actuators
2) If using a pilot valve / control unit, observe its tem-
perature range.
Permitted medium temperature for body
Body material Medium
Cast body (VG) 1.4435 (AISI 316L)
-10 – +150 °C
Forged body (VS) 1.4435 BN2 (AISI 316L)
according to ASME BPE 1997
Tab. 2: Permitted medium temperature for body
3) Pilot air ports with push-in connector
4) Pilot air ports with threaded bushing
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Type 2103, 2104, 2105

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Technical data
Permitted medium temperature for diaphragms
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 temperature.
The function properties, in particular the service life of the dia-
phragm, may deteriorate if the medium temperature increases.
Diaphragm Medium Remarks
EPDM -10 – +130 °C Steam sterilisation: up to +150 °C
FKM 0 – +130 °C
• dry up to + 150 °C
• otherwise only briefly up
to +150 °C
PTFE -10 – +130 °C Steam sterilisation: up to +150 °C
Tab. 3: Permitted medium temperature for diaphragms
7.4.2 Pressure ranges
Pilot pressure for valves with pneumatic position controller
To ensure reliable operation with pneumatic position con-
troller, observe the permitted minimum and maximum pilot
pressure!
Actuator size Pilot pressure
ø 50 mm
5.5 – 7.0 bar
ø 70 mm
ø 90 mm
ø 130 mm
Tab. 4: Pilot pressure for valves with pneumatic position controller
Maximum pilot pressure for valves without pneumatic position
controller
Actuator size Actuator material max. permitted pilot
pressure5)
ø 50 mm
PPS 10 barø 70 mm
ø 90 mm
ø 130 mm 7 bar
Tab. 5: Maximum pilot pressure for valves without pneumatic
position controller
5) Observe the maximum pressure range according to the
type label!
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Type 2103, 2104, 2105

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Technical data
Pilot pressure for control function A6)
Actuator
size [mm] Orifice DN [mm]
Pilot pressure [bar]
for medium pressure
0 bar maximum
ø 50
8 EPDM/FKM 2.5 2.3
8 PTFE 3.8 3.5
15 4.5 4.2
ø 70 15 4.8 4.5
ø 70 20 4.8 4.5
ø 70 25 4.8 3.5
ø 90 5.0 4.0
ø 90 40 5,0 4,5
ø 130 5,0 4,6
ø 130 50 5,0 4,8
Tab. 6: Pilot pressure for control function A
Designs with lower pilot pressure (reduced spring force)
are available on request.
Contact your Bürkert sales office or our Sales Center,
e-mail: [email protected]
Operating pressure for control function A6)
The values apply to body made of
• forged steel (VS)
• precision casting (VG)
Actuator
size
[mm]
Orifice
DN
[mm]
Max. sealed medium pressure [bar]
Pressure on one
side
Pressure on both
sides
EPDM/FKM PTFE EPDM/FKM PTFE
ø 50 810 10 10 10
ø 50 15 7.5 5 5 3.5
ø 70 15 10 10 10 10
ø 70 20 10 10 10 7.5
ø 70 25 6.5 65.5 4.5
ø 90 10 810 7
ø 90 40 5,5 5 4 3
ø 130 10 10 10 9
ø 130 50 10 7 7 5
Tab. 7: Operating pressure for control function A
6) The control functions are described in the chapter entitled “6.2.1
Control functions (CF)”.
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Type 2103, 2104, 2105

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Technical data
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 B and I.
The values apply to body made of
• forged steel (VS)
• precision casting (VG)
When using Type 2103, 2104 or 2105 as a control valve,
pressure conditions may deviate in some cases. These con-
ditions appear in the diagrams with a gray background.
Control function B / elastomer diaphragm
DN8
DN15
0
1
2
3
4
5
6
7
10
012345678910
9
8
Pilot pressure [bar]
Medium pressure [bar]
ø 50 EPDM
Fig. 6: Pressure graph, actuator ø 50 mm, control function B,
elastomer diaphragm
DN15
DN20
0
1
2
3
4
5
6
7
10
012345678910
9
8
DN25
Pilot pressure [bar]
Medium pressure [bar]
ø 70 EPDM
Fig. 7: Pressure graph, actuator ø 70 mm, control function B,
elastomer diaphragm
Graph for control valve
DN15
DN20
0
1
2
3
4
5
6
7
10
012345678910
9
8
DN25
Pilot pressure [bar]
Medium pressure [bar]
ø 70 EPDM / control valve
Fig. 8: Pressure graph for control valve, actuator ø 70 mm, control
function B, elastomer diaphragm
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Type 2103, 2104, 2105

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Technical data
DN25
0
1
2
3
4
5
6
7
10
012345678910
9
8
DN40
Pilot pressure [bar]
Medium pressure [bar]
ø 90 EPDM
Fig. 9: Pressure graph, actuator ø 90 mm, control function B,
elastomer diaphragm
Graph for control valve
0
1
2
3
4
5
6
7
10
012345678910
9
8
DN25
Pilot pressure [bar]
Medium pressure [bar]
ø 90 EPDM / control valve
Fig. 10: Pressure graph for control valve, actuator ø 90 mm,
control function B, elastomer diaphragm
0
1
2
3
4
5
6
7
10
012345678910
9
8
DN40 DN50
Pilot pressure [bar]
Medium pressure [bar]
ø 130 EPDM
Fig. 11: Pressure graph, actuator ø 130 mm, control function B,
elastomer diaphragm
Graph for control valve
0
1
2
3
4
5
6
7
10
012345678910
9
8
DN40
DN50
Pilot pressure [bar]
Medium pressure [bar]
ø 130 EPDM / control valve
Fig. 12: Pressure graph for control valve, actuator ø 130 mm,
control function B, elastomer diaphragm
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Type 2103, 2104, 2105

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Technical data
Control function B / PTFE elastomer diaphragm
0
1
2
3
4
5
6
7
10
012345678910
9
8
DN8
DN15
Pilot pressure [bar]
Medium pressure [bar]
ø 50 PTFE
Fig. 13: Pressure graph, actuator ø 50 mm, control function B,
PTFE elastomer diaphragm
0
1
2
3
4
5
6
7
10
012345678910
9
8
DN15
DN25
DN20
Pilot pressure [bar]
Medium pressure [bar]
ø 70 PTFE
Fig. 14: Pressure graph, actuator ø 70 mm, control function B,
PTFE elastomer diaphragm
Graph for control valve
0
1
2
3
4
5
6
7
10
012345678910
9
8
DN15
DN20
DN25
Pilot pressure [bar]
Medium pressure [bar]
ø 70 PTFE / control valve
Fig. 15: Pressure graph for control valve, actuator ø 70 mm,
control function B, PTFE elastomer diaphragm
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Type 2103, 2104, 2105

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Technical data
0
1
2
3
4
5
6
7
10
012345678910
9
8
DN40
DN25
Pilot pressure [bar]
Medium pressure [bar]
ø 90 PTFE
Fig. 16: Pressure graph, actuator ø 90 mm, control function B,
PTFE elastomer diaphragm
Graph for control valve
0
1
2
3
4
5
6
7
10
012345678910
9
8
DN25
Pilot pressure [bar]
Medium pressure [bar]
ø 90 PTFE / control valve
Fig. 17: Pressure graph for control valve, actuator ø 90 mm,
control function B, PTFE elastomer diaphragm
0
1
2
3
4
5
6
7
10
012345678910
9
8
DN40
DN50
Pilot pressure [bar]
Medium pressure [bar]
ø 130 PTFE
Fig. 18: Pressure graph, actuator ø 130 mm, control function B,
PTFE elastomer diaphragm
Graph for control valve
0
1
2
3
4
5
6
7
10
0123456789
10
9
8
DN40
DN50
Pilot pressure [bar]
Medium pressure [bar]
ø 130 PTFE / control valve
Fig. 19: Pressure graph for control valve, actuator ø 130 mm,
control function B, PTFE elastomer diaphragm
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Type 2103, 2104, 2105

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Technical data
Control function I / elastomer diaphragm
0
1
2
3
4
5
6
7
10
012345678910
9
8
DN8 DN15
Pilot pressure [bar]
Medium pressure [bar]
ø 50 EPDM
Fig. 20: Pressure graph, actuator ø 50 mm, control function I, elas-
tomer diaphragm
0
1
2
3
4
5
6
7
10
012345678910
9
8
DN15 DN25
DN20
Pilot pressure [bar]
Medium pressure [bar]
ø 70 EPDM
Fig. 21: Pressure graph, actuator ø 70 mm, control function I, elas-
tomer diaphragm
0
1
2
3
4
5
6
7
10
012345678910
9
8
DN25 DN40
Pilot pressure [bar]
Medium pressure [bar]
ø 90 EPDM
Fig. 22: Pressure graph, actuator ø 90 mm, control function I, elas-
tomer diaphragm
0
1
2
3
4
5
6
7
10
012345678910
9
8
DN40
DN50
Pilot pressure [bar]
Medium pressure [bar]
ø 130 EPDM
Fig. 23: Pressure graph, actuator ø 130 mm, control function I,
elastomer diaphragm
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Type 2103, 2104, 2105

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Technical data
Control function I / PTFE elastomer diaphragm
0
1
2
3
4
5
6
7
10
012345678910
9
8
DN8 DN15
Pilot pressure [bar]
Medium pressure [bar]
ø 50 PTFE
Fig. 24: Pressure graph, actuator ø 50 mm, control function I,
PTFE elastomer diaphragm
0
1
2
3
4
5
6
7
10
012345678910
9
8
DN15 DN25 DN20
Pilot pressure [bar]
Medium pressure [bar]
ø 70 PTFE
Fig. 25: Pressure graph, actuator ø 70 mm, control function I,
PTFE elastomer diaphragm
0
1
2
3
4
5
6
7
10
012345678910
9
8
DN25
DN40
Pilot pressure [bar]
Medium pressure [bar]
ø 90 PTFE
Fig. 26: Pressure graph, actuator ø 90 mm, control function I,
PTFE elastomer diaphragm
0
1
2
3
4
5
6
7
10
012345678910
9
8
DN40
DN50
Pilot pressure [bar]
Medium pressure [bar]
ø 130 PTFE
Fig. 27: Pressure graph, actuator ø 130 mm, control function I,
PTFE elastomer diaphragm
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Type 2103, 2104, 2105