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 & Co. KG, 2008 – 2020
Operating Instructions 2009/10_EU-ML_00805642 / Original DE

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Contents
1OPERATING INSTRUCTIONS ................................................................................................................6
1.1 Symbols........................................................................................................................................6
1.2 Denitionofterms........................................................................................................................ 6
2AUTHORIZED USE .................................................................................................................................7
3BASIC SAFETY INSTRUCTIONS ...........................................................................................................8
4GENERAL INFORMATION....................................................................................................................10
4.1 Contactaddress.........................................................................................................................10
4.2 Warranty .....................................................................................................................................10
4.3 Informationontheinternet ........................................................................................................10
5DEVICE DESCRIPTION ........................................................................................................................11
5.1 Generaldescription....................................................................................................................11
5.2 Versions ......................................................................................................................................11
5.3 Options .......................................................................................................................................11
5.4 Designatedapplicationarea......................................................................................................12
6STRUCTURE AND FUNCTION.............................................................................................................13
6.1 Structure.....................................................................................................................................13
6.2 Function......................................................................................................................................15
7TECHNICAL DATA ................................................................................................................................17
7.1 Conformity..................................................................................................................................17
7.2 Standards ...................................................................................................................................17
7.3 Typelabel ...................................................................................................................................17
7.4 Labelingoftheforgedsteelvalvebody....................................................................................18
7.5 Labelingofthetubevalvebody(VP) ........................................................................................18
7.6 Operatingconditions .................................................................................................................19
7.7 Flowcharacteristic.....................................................................................................................29
7.8 Generaltechnicaldata...............................................................................................................34
Piston-controlleddiaphragmvalveType2103,2104,2105
Type 2103, 2104, 2105
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Type 2103, 2104, 2105
8INSTALLATION......................................................................................................................................35
8.1 Safetyinstructions .....................................................................................................................35
8.2 Installationposition....................................................................................................................35
8.3 Beforeinstallation ......................................................................................................................37
8.4 Removetheactuatorfromthevalvebody................................................................................37
8.5 Installationofthevalvebody ....................................................................................................38
8.6 Installationoftheactuator(weldedorgluedbody)..................................................................40
8.7 Alignactuator .............................................................................................................................41
8.8 Pneumaticconnection...............................................................................................................41
8.9 Removal......................................................................................................................................42
9ELECTRICAL CONTROL UNIT.............................................................................................................43
10 MAINTENANCE ....................................................................................................................................44
10.1 Safetyinstructions .....................................................................................................................44
10.2 Maintenance...............................................................................................................................44
11 REPLACING THE DIAPHRAGM ...........................................................................................................46
12 MALFUNCTIONS ..................................................................................................................................49
13 REPLACEMENT PARTS .......................................................................................................................50
13.1 Ordertable .................................................................................................................................50
14 PACKAGING,TRANSPORT..................................................................................................................52
15 STORAGE .............................................................................................................................................52
16 DISPOSAL ............................................................................................................................................52
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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.
Importantsafetyinformation.
▶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!
Warnsofanimmediatedanger.
▶Failure to observe the warning will result in fatal or serious injuries.
WARNING!
Warnsofapotentiallydangeroussituation.
▶Failure to observe the warning may result in serious or fatal injuries.
CAUTION!
Warnsofapossibledanger.
▶Failure to observe the 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 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
Incorrectuseofthedevicecanbedangeroustopeople,nearbyequipmentandtheenvironment.
▶The diaphragm valves of Types 2103, 2104 and 2105 are designed for the controlled ow of liquid and
gaseous media.
▶In potentially explosive atmospheres, only use devices that are approved for this purpose. These
devices are identied by a separate Ex type label. Before use, note the information on the separate Ex
type label and the Ex additional instructions or the separate Ex operating instructions.
▶During use observe the authorized data, the operating conditions and conditions of use specied in the
contract documents, operating instructions and on the type label.
▶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.
▶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.
Riskofinjuryfromhighpressureanddischargeofmedium.
▶Before working on the device or system, switch o the pressure. Vent or empty 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.
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.
Dangerofburnsandriskofre.
Quickly switching actuators or hot medium may cause the surface of the device to become hot.
▶Only touch the device while wearing protective gloves.
▶Keep the device away from highly ammable substances and media.
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 discharge point against dangers.
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Basic safety instructions
Type 2103, 2104, 2105
Generalhazardoussituations.
Topreventinjury,ensure:
▶That the system cannot be activated unintentionally.
▶Only trained technicians may perform installation and maintenance work.
▶Perform installation work and maintenance work using suitable tools only.
▶Do not transport, install or remove heavy devices without the aid of a second person and using suitable
auxiliary equipment.
▶After an interruption, ensure that the process is restarted in a controlled manner. Observe sequence!
1. Apply supply voltage or pneumatic supply.
2. Charge the device with medium.
▶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 application planning and operation of the device.
▶The plant operator is responsible for the safe operation and handling of the plant.
▶Observe the general rules of technology.
▶The exhaust air may be contaminated with lubricants in the actuator.
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 “7 Technical data”.
▶Do not make any changes on the device and do not subject it to mechanical stress.
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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 Quickstart.
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.
•Optimized deadleg.
•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 diaphragms.
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 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 and / 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).
Information on the resistance of materials to the media is available from your Bürkert sales oce.
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
Diaphragm
Transparent cap with position indicator
Actuator cover
Actuator body
Diaphragm socket
Port 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
Port 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
Diaphragm
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
T-valve body
Port connection
Second pilot air port for CFI
and air discharge connection for CFA and CFB
Pilot air port for CFA, CFB, CFI
1
2
Diaphragm
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
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
Diaphragm
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.
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
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.
ControlfunctionA(CFA)
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 weir 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
Openposition[100%Stroke] Centerposition[0...100%Stroke]
Pilot air port 1: 5...7bar
Pilot air port 2: 0bar
Pilot air port 1: 5...7bar
Pilot air port 2: 5...7bar
Deaeration
Stroke
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.
Actuatorsize
[mm]
Diaphragmsize DimensionH±0.3[mm] Stroketotal[mm]
EPDM/FKM PTFE EPDM/FKM PTFE
ø 50 814.6 14.6 2.4 2.4
15 12.3 - 7.0 -
ø 70 15 14.4 15.4 7.0 5.0
20 13.4 13.9 9.0 8.0
25 13.4 13.9 9.0 8.0
ø 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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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!
Riskofinjuryfromhighpressure.
Excessive pressure can damage the device.
▶Comply with pressure range values 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 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
port connection
Figure 6: Description of the type label (example)
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Technical data
Type 2103, 2104, 2105
7.4 Labeling of the forged steel valve 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 dimensions
Batch number
Material
Production number / Serial number
Nominal pressure
Company logo
Figure 7: Labeling of the forged steel valve 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
dimensions
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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Technical data
Type 2103, 2104, 2105
7.6 Operating conditions
7.6.1 Temperature ranges
Permittedambienttemperatureforactuators
Actuatorsize[mm] Actuatormaterial Ambienttemperature1)
ø 50
PPS -10...+60°C2)
-10...+100°C3)
ø 70
ø 90
ø 130
Table 2: Permitted ambient temperature for actuator
1) If using a pilot valve / control unit, observe its temperature range.
Medium temperature for valve 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
Table 3: Medium temperature for valve body
Permittedmediumtemperaturefordiaphragms
Theindicatedmediumtemperaturesapplyonlytomediawhichdonotcorrodeorswellthedia-
phragm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.
Material Temperature[°C] 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
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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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.
Pilotpressureforvalveswithpneumaticpositioncontroller
Actuatorsize[mm] Pilotpressure
ø 50
5.5...7.0 bar
ø 70
ø 90
ø 130
Table 5: Pilot pressure for valves with pneumatic position controller
Maximumpilotpressureforvalveswithoutpneumaticpositioncontroller
Actuatorsize[mm] Actuatormaterial Max.permittedpilotpressure
ø 50
PPS 10 barø 70
ø 90
ø 130 7 bar
Table 6: Maximum pilot pressure for valves without pneumatic position controller
PilotpressureforcontrolfunctionA
Actuatorsize
[mm]
Diaphragmsize Pilotpressure[bar]
formediumpressure
0bar maximal
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 5.5 4.5
ø 130 5.0 4.6
ø 130 50 5.0 4.8
ø 130 65 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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Technical data
Type 2103, 2104, 2105
Maximumpermittedmediumpressure
Permitted medium pressure depending on the medium temperature with plastic valve body:
DN 15 - 65
10
8
6
4
2
20 40 60 80 100 120 140
PVC
PVDF
PP
Medium pressure [bar]
Temperature [°C]
Figure 9: Graph of medium pressure / Medium temperature with plastic valve body
OperatingpressureforcontrolfunctionA
The values apply to valve bodies made of:
•plastic
•stainless steel: block material, forged, casted and tube valve body.
Actuatorsize
[mm] Diaphragmsize
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 -
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 86 6 4
ø 90 40 5.5 5 4 3
ø 130 10 10 10 9
ø 130 50 87 7 5
ø 130 65 5.5 3.5 21.5
Table 8: Operating pressure for control function A
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 valve bodies made of:
•plastic
•stainless steel: block material, forged, casted and tube valve body.
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