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.
© 2008 – 2016 Bürkert Werke GmbH
Operating Instructions 1611/09_EU-ML_00805642 / Original DE

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Contents
1OPERATING INSTRUCTIONS ................................................................................................................5
1.1 Symbols........................................................................................................................................5
1.2 ........................................................................................................................ 5
2AUTHORIZED USE .................................................................................................................................6
3BASIC SAFETY INSTRUCTIONS ...........................................................................................................7
4GENERAL INFORMATION......................................................................................................................8
4.1 ...........................................................................................................................8
4.2  .......................................................................................................................................8
4.3  ..........................................................................................................8
5DEVICE DESCRIPTION ..........................................................................................................................9
5.1 ......................................................................................................................9
5.2  ........................................................................................................................................9
5.3  .........................................................................................................................................9
5.4 ......................................................................................................10
6STRUCTURE AND FUNCTION.............................................................................................................11
6.1 .....................................................................................................................................11
6.2 ......................................................................................................................................13
7TECHNICAL DATA ................................................................................................................................15
7.1 ..................................................................................................................................15
7.2  ...................................................................................................................................15
7.3  ...................................................................................................................................15
7.4  ......................................................................................................16
7.5  ........................................................................................16
7.6  .................................................................................................................17
7.7 .....................................................................................................................26
7.8 ...............................................................................................................31

Type 2103, 2104, 2105
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Type 2103, 2104, 2105
8INSTALLATION......................................................................................................................................32
8.1  .....................................................................................................................32
8.2 ....................................................................................................................32
8.3  ......................................................................................................................33
 ................................................................................
8.5  ....................................................................................................
8.6  ................................................................................35
8.7  .............................................................................................................................37
8.8 ...............................................................................................................37
8.9 ......................................................................................................................................38
9ELECTRICAL CONTROL UNIT.............................................................................................................39
10 MAINTENANCE ....................................................................................................................................
10.1  .....................................................................................................................
10.2 ...............................................................................................................................
11 REPLACING THE DIAPHRAGM ...........................................................................................................
12 MALFUNCTIONS ..................................................................................................................................
13 REPLACEMENT PARTS .......................................................................................................................
13.1  .................................................................................................................................
14 ..................................................................................................................
15 STORAGE .............................................................................................................................................
16 ENVIRONMENT ....................................................................................................................................
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Operating instructions
Type 2103, 2104, 2105
1 OPERATING INSTRUCTIONS
The operating instructions describe the entire life cycle of the device. Keep these instructions ready to hand
at the operation site.

▶Carefully read these instructions.
▶Observe in particular the safety instructions, authorized use and operating conditions.
▶Persons, who work on the device, must read and understand these instructions.
1.1 Symbols
DANGER!

▶Failure to observe the warning may result in a fatal or serious injury.
WARNING!

▶Failure to observe the warning may result in serious injuries or death.
CAUTION!

▶Failure to observe this warning may result in a moderate or minor injury.
NOTE!

▶Failure to observe the warning may result in damage to the device or other equipment.
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 Denition of terms
In these instructions the term “device” denotes the following device types: 2103, 2104, 2105.
•Ex area: stands for potentially explosive area.
•Ex approval: stands for approval in the potentially explosive area.
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Authorized use
Type 2103, 2104, 2105
2 AUTHORIZED USE


▶In the potentially explosion-risk area the diaphragm valve may be used only according to the specication
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.
▶When using the device, observe the permitted data, operating conditions and application conditions. This
information can be found in the contractual documents, the operating instructions and on the type label.
▶Correct transportation, correct storage and installation and careful use and maintenance are essential
for reliable and faultless operation.
▶The device may be used only in conjunction with third-party devices and components recommended and
authorised by Bürkert.
▶Use the device only as intended.
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Basic safety instructions
Type 2103, 2104, 2105
3 BASIC SAFETY INSTRUCTIONS
These safety instructions do not consider any contingencies or incidents which occur during installation,
operation and maintenance. The operator is responsible for observing the location-specic safety regulations,
also with reference to the personnel.

▶Before dismounting the lines and valves, turn o the pressure and vent the lines.

▶Before reaching into the device, switch o the power supply and secure to prevent reactivation.
▶Observe applicable accident prevention and safety regulations for electrical equipment..

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.

▶Do not reach into openings.
▶Operate 3-position actuator with transparent cap only.

▶Do not touch the device unless wearing protective gloves.
▶Keep the device away from highly ammable substances and media.

To prevent injury, ensure:
▶The device may be operated only when in perfect condition and in consideration of the operating
instructions.
▶Do not transport, install or remove heavy devices without the aid of a second person and using suitable
auxiliary equipment.
▶Do not make any modications to the device.
▶Secure system against unintentional activation.
▶Installation, operation and maintenance may only be performed by qualied specialists.
▶Install the device according to the regulations applicable in the country.
▶After an interruption in the power supply or pneumatic supply, ensure that the process is restarted in a
dened or controlled manner.
▶Observe the general rules of technology.
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General information
Type 2103, 2104, 2105
4 GENERAL INFORMATION
4.1 Contact address
Germany
Bürkert Fluid Control Systems
Sales Center
Chr.-Bürkert-Str. 13-17
D-74653 Ingelngen
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 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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Device description
Type 2103, 2104, 2105
5 DEVICE 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 ow of dirty, aggressive, abrasive, ultrapure or sterile media, even
highly viscous media can be used (ow media).
5.1.1 Properties
•Any ow direction.
•Self-draining for appropriate installation. The ends of the utilized connections must be cylindrical.
•Free of empty space.
•Low-turbulence ow.
•High ow values by the streamlined valve body.
•Maintenance-free under normal conditions.
•PTFE/EPDM diaphragms can be easily replaced with EPDM membranes.
5.2 Versions
There are 2 versions of the type 2103, 2104 and 2105.
•
The standard version must not be used in the potentially explosive area.
•
The Ex version may be used in the potentially explosive area. In doing so, observe the specications 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 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.
3-position actuator is available for the following actuator sizes ø 50 mm, ø 70 mm, ø 90 mm.
5.2.2 Pilot pressure
Designs with lower pilot pressure (reduced spring force) are available on request. Contact your Bürkert
sales oce or our Sales Center, e-mail: [email protected]
5.3 Options
•Feedback and control units
Depending on the requirements, dierent feedback and control units are available.
•Stroke limitation
Limit of the maximum or minimum open position / ow rate by means of adjusting screw.
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Device description
Type 2103, 2104, 2105
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.
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Structure and function
Type 2103, 2104, 2105
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) and stainless steel.
6.1.1 2/2-way valve Type 2103
Transparent cap with position indicator
Actuator cover
Actuator body
Diaphragm socket
Line connection
Valve body
Second pilot air port for CFI
and air discharge connection for CFA and CFB
Pilot air port for (CF) A, B, I
2
1
Figure 1: Structure and description, 2/2-way valve Type 2103
6.1.2 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
Figure 2: Structure and description, 2/3-way valve Type 2103
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Structure and function
Type 2103, 2104, 2105
6.1.3 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
Figure 3: Structure and description, Type 2104
6.1.4 Tank bottom valve Type 2105
Transparent cap with position
indicator
Actuator body
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 for CFA, CFB, CFI
Figure 4: Structure and description, Type 2105
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Structure and function
Type 2103, 2104, 2105
6.2 Function
6.2.1 Control function (CF) 2/2-way valve
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.

Normally closed by spring action

Normally open by spring action

Actuating function via reciprocal
pressurization
6.2.2 Control function (SF) 2/3-way valve
The 3-position diaphragm valve Type 2103 is available in control function A (CFA) only.

Normally closed by spring action
A spindle, which is connected to the actuator piston, transfers the force onto the pressure piece which presses
the diaphragm against the bar in the body. Pressurization of the pilot air port 2 moves the upper movable group
around the upper piston axially downwards, until the center position, preset via the nut and lock nut, has been
reached. Pressurization of the pilot air port 1 moves the lower movable group around the lower piston axially
upwards until it hits the upper piston and stops. This center position corresponds to a specic adjustable ow
rate of the medium. If the upper air chamber is vented by pilot air port 2, both modules move upwards and the
maximum stroke is reached. If the lower air chamber is vented by pilot air port 1, the spring force acts on the
lower movable group and therefore moves it downwards until the valve is closed (rest position).
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Structure and function
Type 2103, 2104, 2105
6.2.3 Setting of the center position with the 2/3-way valve
 
Pilot air port 1: 5...10bar
Pilot air port 2: 0bar
Pilot air port 1: 5...10bar
Pilot air port 2: 5...10bar
Deaeration
Hub
H
Kv -
0 % Stroke
100 % Stroke Kv +
Nut position
Center position
1
2
3
Figure 5: Setting of the center position
→Unscrew transparent cap (Position 1):
Actuator sizes 50, 70 and 90: Wrench size 28.
→Pressurize pilot air port 1 of the actuator with compressed air (5 bar).
→Loosen lock nut (Position 2):
Actuator size 50: Wrench size 13;
Actuator sizes 70 and 90: Wrench size 17.
→Adjust the center position via the nut (Position 3).
→Retighten lock nut (Position 2):
Actuator size 50 max. 20+5 Nm
Actuator size 70 max. 30+5 Nm
Actuator size 90 max. 45+5 Nm
→Screw transparent cap back on.
To limit the center position to 50 % of the total stroke, set dimension H on the nuts.





 
EPDM PTFE EPDM PTFE
50 8 14.6 14.6 2.4 2.4
15 12.2 13.4 7.2 4.8
70 15 14.6 15.3 6.6 5.2
20 13.3 13.8 9.2 8.2
25 13.2 13.9 9.4 8.0
90 25 16.3 16.8 9.0 8.0
Table 1: Setting of the center position to 50% of the total stroke
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15
Technical data
Type 2103, 2104, 2105
7 TECHNICAL DATA
7.1 Conformity
The device conforms with the EU Directives according to the EU Declaration of Conformity (if applicable).
7.2 Standards
The applied standards, which verify conformity with the EU Directives, can be found on the EU-Type Exami-
nation Certicate and / or the EU Declaration of Conformity (if applicable).
7.3 Type label
WARNING!

Excessive pressure can damage the device.
▶Comply with pressure range values on the type label.

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 control pressure
Permitted medium pressure
Type
Control function
Orice
(Diaphragm size / actuator size)
Seal material Body material
Identication number of the device Permitted
medium tem-
perature
Permitted ambient temperature
Date of manufacture
(encoded)
Main dimensions of
line connection
Figure 6: Description of the type label (example)
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16
Technical data
Type 2103, 2104, 2105
7.4 Labeling of the forged body
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
Figure 7: Labeling of the forged body
7.5 Labeling of the tube valve body (VP)
1.4435
316L(VP)
XXXXXXXX
XXXXXXXXXX
PN16 / CWP150
XXXXXXXX / XXX
XXXX / XXXXXX
Material Heat
Company logo
Nominal pressure
Orice connection and pipe
dimension
Self-drain angle/ customer-
specic text (optional)
Production number /
Serial number
Figure 8: Labeling of the tube valve body (VP)
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17
Technical data
Type 2103, 2104, 2105
7.6 Operating conditions
7.6.1 Temperature ranges

  1)
ø 50 mm
PPS 0...+60°C2)
0...+100°C3)
ø 70 mm
ø 90 mm
ø 130 mm
Table 2: Permitted ambient temperature for actuator
1) If using a pilot valve / control unit, observe its temperature range.

 
Cast body (VG) 1.4435 (AISI 316L)
-10...+150°CForged body (VS) 1.4435 BN2 (AISI 316L)
nach ASME BPE 1997
Tube valve body (VP) 1.4435 BN2 (AISI 316L)
Table 3: Permitted medium temperature for body

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 diaphragm, may deteriorate if the medium
temperature increases.
Do not use the diaphragms as steam shut-o element.
 [°C]
EPDM (AB) -10...+130 Steam sterilization up to +140°C / 60 min
EPDM (AD) -5...+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
Advanced PTFE (ET) -10...+90 -
Gylon (ER) -5...+130 Steam sterilization up to +140°C / 60 min
Table 4: Permitted medium temperature for diaphragms
2) Pilot air ports with push-in connector
3) Pilot air ports with threaded bushing
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18
Technical data
Type 2103, 2104, 2105
7.6.2 Pressure ranges 2/2-way valve
To ensure reliable operation with pneumatic position controller, observe the permitted minimum and
maximum pilot pressure on the type label.

 
ø 50 mm
5.5...7.0 bar
ø 70 mm
ø 90 mm
ø 130 mm
Table 5: Pilot pressure for valves with pneumatic position controller

  
ø 50 mm
PPS 10 barø 70 mm
ø 90 mm
ø 130 mm 7 bar
Table 6: Maximum pilot pressure for valves without pneumatic position controller








 
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 5.5 4.3
ø 90 5.0 4.0
ø 90 32 5.0 4.5
ø 90 40 5.0 4.5
ø 130 5.0 4.6
ø 130 50 5.0 4.8
Table 7: Pilot pressure for control function A
Designs with lower pilot pressure (reduced spring force) are available on request. Contact your
Bürkert sales oce or our Sales Center, e-mail: [email protected]
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19
Technical data
Type 2103, 2104, 2105

The values apply to body made of
•forged steel (VS)
•precision casting (VG)
•tube valve body (VP)






 
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 4.5 5.5 4
ø 90 10 810 7
ø 90 32 8 6 6 4
ø 90 40 5.5 5 4 3
ø 130 10 10 10 9
ø 130 50 10 7 7 5
Table 8: Operating pressure for control function A

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)
•tube valve body (VP)
When using Type 2103, 2104 or 2105 as a control valve, pressure conditions may deviate in some
cases. These conditions appear in the diagrams.

DN8
DN15
0
1
2
3
4
5
6
7
10
012345678910
9
8
Pilot pressure [bar]
Medium pressure [bar]
ø 50 EPDM
Figure 9: Pressure graph, actuator ø 50 mm, control function B, elastomer diaphragm
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20
Technical data
Type 2103, 2104, 2105
DN15
DN20
0
1
2
3
4
5
6
7
10
012345678910
9
8
DN25
Pilot pressure [bar]
Medium pressure [bar]
ø 70 EPDM
Figure 10: 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
Figure 11: Pressure graph for control valve, actuator ø 70 mm, control function B, elastomer diaphragm
DN25
0
1
2
3
4
5
6
7
10
012345678910
9
8
DN40 DN32
Pilot pressure [bar]
Medium pressure [bar]
ø 90 EPDM
Figure 12: 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
Figure 13: Pressure graph for control valve, actuator ø 90 mm, control function B, elastomer diaphragm
english