Burkert 3360 User manual

Service Manual
Serviceanleitung
Service Manuel
Type 3360, 3361
Electromotive control valve
Elektromotorisches Regelventil
Vanne de régulation électromotorisée

We reserve the right to make technical changes without notice.
Technische Änderungen vorbehalten.
Sous réserve de modifications techniques.
© 2015 Bürkert Werke GmbH
Operating Instructions 1510/00_EUml_00810485 / Original DE

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Content
1 THE SERVICE INSTRUCTIONS ....................................................................................................................................................5
1.1 Symbols ......................................................................................................................................................................................5
1.2 Definition of the term "device" ........................................................................................................................................5
2 BASIC SAFETY INSTRUCTIONS .................................................................................................................................................6
3 GENERAL INFORMATION ................................................................................................................................................................8
3.1 Contact addresses ................................................................................................................................................................8
3.2 Warranty ......................................................................................................................................................................................8
3.3 Information on the Internet ...............................................................................................................................................8
3.4 Auxiliary materials .................................................................................................................................................................8
4 OVERVIEW OF SPARE PARTS ......................................................................................................................................................9
4.1 Replacement part sets for Type 3360 .........................................................................................................................9
4.2 Replacement part sets for Type 3361 .........................................................................................................................9
4.3 Spare parts for Types 3360 and 3361 .....................................................................................................................10
5 CHANGING THE CONTROL CONE SET ...............................................................................................................................11
5.1 Removing the actuator .....................................................................................................................................................11
5.1.1 Opening valve electrically .................................................................................................................11
5.1.2 Opening valve mechanically ............................................................................................................13
5.2 Changing the control cone set ....................................................................................................................................15
5.3 Installing the actuator .......................................................................................................................................................16
5.4 Running X.TUNE ..................................................................................................................................................................17
5.4.1 Adjustment using the buttons in the device .................................................................................17
6 CHANGING THE SEAL SET ........................................................................................................................................................18
6.1 Removing the control cone ...........................................................................................................................................18
6.2 Changing the packing gland .........................................................................................................................................19
6.2.1 Changing the packing gland for the connection size 10/15 (DN4-15) and
vacuum version ...................................................................................................................................21
6.3 Installing the control cone .............................................................................................................................................22
Type 3360, 3361
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Type 3360, 3361
7 CHANGING THE VALVE SET ......................................................................................................................................................23
7.1 Changing the valve set ....................................................................................................................................................23
8 CHANGING THE ENERGY PACK ..............................................................................................................................................25
8.1 Removing the display module or dummy cover ................................................................................................25
8.2 Removing LED and storage module .........................................................................................................................26
8.3 Removing actuator cover ................................................................................................................................................26
8.4 Replacing the SAFEPOS energy-pack ....................................................................................................................26
9 ACCESSORIES, SPARE PARTS ................................................................................................................................................28
9.1 Communications software .............................................................................................................................................28
9.1.1 USB interface ......................................................................................................................................28
9.2 Spare parts .............................................................................................................................................................................29
9.2.1 Spare parts for control valves of Types 3360 and 3361 ..........................................................29
9.2.2 Spare parts for angle seat control valve of Type 3360..............................................................29
9.2.3 Spare parts for straight seat control valve of Type 3361 ..........................................................29
9.3 Installation tools ..................................................................................................................................................................31
9.3.1 Installation tools for control valves of Types 3360 and 3361 ..................................................31
9.3.2 Installation tools for control valves of Type 3361 ........................................................................31
10 PACKAGING, TRANSPORT ..........................................................................................................................................................32
11 STORAGE ..............................................................................................................................................................................................32
12 DISPOSAL ............................................................................................................................................................................................32
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The service instructions
Type 3360, 3361
1 THE SERVICE INSTRUCTIONS
The service instructions describe the procedure for changing spare parts of the process valves of Types 3360 and
3361.
Keep these instructions in a location which is easily accessible to every user and make these instructions available
to every new owner of the device.
The service instructions contain important safety information.
Failure to observe these instructions may result in hazardous situations.
▶The service instructions must be read and understood.
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 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!
• Failure to observe the warning may result in damage to the device or the equipment.
indicates important additional information, tips and recommendations.
refers to information in these operating instructions or in other documentation.
→designates a procedure which you must carry out.
1.2 Definition of the term "device"
In these instructions, the term "device" always refers to the Types 3360 and 3361.
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Basic safety instructions
Type 3360, 3361
2 BASIC SAFETY INSTRUCTIONS
These safety instructions do not make allowance for any
• contingencies and events which may arise during the assembly, operation, and maintenance.
• local safety regulations – the operator is responsible for observing these regulations, also in relation to the instal-
lation personnel.
Risk of injury from high pressure.
▶Before working on the system or device, switch off the pressure and vent or drain lines.
If switched on for a prolonged time, risk of burns or fire due to hot device surface.
▶Keep the device away from highly flammable substances and media and do not touch with bare hands.
Risk of crushing due to mechanically moving parts.
▶Perform installation and maintenance work only in the isolated state.
Devices with SAFEPOS energy-pack: Completely drain SAFEPOS energy-pack. Wait until LED illuminated ring
goes out; the LED status must not be in LED off mode.
▶Keep clear of the openings in the valve body.
Danger due to an uncontrolled process in the event of a power failure.
If devices do not have the optional SAFEPOS energy-pack, the valve remains in an undefined position in the event of
a power failure.
▶If the valve position is relevant as regards safety in the event of a power failure: Use only those devices which have
the SAFEPOS energy-pack (optional energy pack).
▶In the SAFEPOS select a valve position which is safe for the process.
General hazardous situations.
To prevent injuries:
▶Do not make any internal or external changes on the device and do not subject it to mechanical stress.
▶Only feed media specified in the data sheet into the media connections.
▶Secure to prevent unintentional actuation.
▶Only trained technicians may perform installation and maintenance work.
▶The valves must be installed in accordance with the regulations applicable in the country.
▶After an interruption in the power supply, ensure that the process is restarted in a controlled manner. Observe
sequence!
1. Apply supply voltage.
2. Charge the device with medium.
▶Observe the general rules of technology.
▶Install the valves must in accordance with the regulations applicable in the country.
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Basic safety instructions
Type 3360, 3361
NOTE!
Electrostatically sensitive components and modules.
The device contains electronic components which react sensitively to electrostatic discharge (ESD). Contact with
electrostatically charged persons or objects are hazardous to these components. In the worst case scenario, they
will be destroyed immediately or will fail after start-up.
• Observe the requirements in accordance with EN 61340-5-1 to minimize or avoid the possibility of damage
caused by a sudden electrostatic discharge.
• Do not touch electronic components while the supply voltage is switched on.
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General information
Type 3360, 3361
3 GENERAL INFORMATION
3.1 Contact addresses
Germany
Bürkert Fluid Control Systems
Sales Center
Christian-Bürkert-Str. 13-17
D-74653 Ingelfingen
Tel. + 49 (0) 7940 - 10 91 111
Fax + 49 (0) 7940 - 10 91 448
Email: [email protected]
International
Contact addresses can be found on the final pages of the printed operating instructions.
And also on the Internet at:
www.burkert.com
3.2 Warranty
The warranty is only valid if the device is used as intended in accordance with the specified application conditions.
3.3 Information on the Internet
Operating instructions and data sheets for Types 3360 and 3361 can be found on the Internet at:
www.burkert.com
3.4 Auxiliary materials
The following auxiliary materials are recommended in these instructions for carrying out repairs:
Type of auxiliary material Auxiliary material Manufacturer's specifications
Sealer and anti-seize agents Silicone grease OKS 1110-3 OKS Schmierstoffe GmbH
www.oks-germany.com
Lubrication paste Klüber paste UH1 96-402 Klüber Lubrication München
www.klueber.de
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Overview of spare parts
Type 3360, 3361
4 OVERVIEW OF SPARE PARTS
4.1 Replacement part sets for Type 3360
The following replacement part sets are available for Type 3360:
• Control cone set
consisting of: Graphite seal, control cone, dowel pin and lubricant
• Seal set for the packing gland
consisting of: Individual parts of the packing gland, graphite seal and lubricant
• Spindle guide for the packing gland
consisting of: Spindle guide, graphite seal and lubricant
1
2
3
4
5
Item Description
1 Graphite seal
Control cone set2 Control cone
3 Dowel pin
4 Seal set for packing gland
5 Spindle guide for packing gland
4.2 Replacement part sets for Type 3361
The following replacement part sets are available for Type 3361:
• Control cone set
consisting of: Graphite seal, control cone, dowel pin and lubricant
• Valve set
consisting of: Graphite seal, control cone, dowel pin, valve seat and lubricant
• Seal set for the packing gland
consisting of: Individual parts of the packing gland, graphite seal and lubricant
• Spindle guide for the packing gland
consisting of: Spindle guide, graphite seal and lubricant
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Overview of spare parts
Type 3360, 3361
1
2
4
36
5
Item Description
1 Graphite seal Control
cone set Valve set
2 Control cone
3 Dowel pin
4 Valve seat
5 Seal set for packing gland
6 Spindle guide for packing gland
4.3 Spare parts for Types 3360 and 3361
• SAFEPOS energy-pack.
Optionally there is an energy pack for the device. If the supply voltage fails, the energy pack supplies the
actuator with the required energy to move the valve into the required position which can be adjusted via the
menu.
SAFEPOS
energy-pack
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Changing the control cone set
Type 3360, 3361
5 CHANGING THE CONTROL CONE SET
Before the control cone set can be changed, the actuator must be removed from the valve body.
5.1 Removing the actuator
DANGER!
Risk of injury from high pressure.
▶Before working on the system or device, switch off the pressure and vent or drain lines.
WARNING!
Risk of injury if the wrong tools are used.
It is dangerous to use unsuitable tools for installation work as the device may be damaged.
▶To remove the actuator from the valve body, use an open-end wrench, never a pipe wrench.
When removing the actuator from the valve body, ensure that the valve is in the open position. The valve position
must be detected on the mechanical position indicator (as illustrated in "Figure 1").
The control valve can be manually opened in 2 ways: electrically or mechanically.
Body connection
Valve body
Actuator
Actuator base
Valve completely
open
Valve completely
closed
Mechanical position indicator
Figure 1: Mechanical position indicator
5.1.1 Opening valve electrically
Depending on the device version, the valve is manually and electrically opened on the display or by pressing
2 buttons which are located on the LED and storage module under the dummy cover.
Devices with display module
The valve is opened on the display in View 1 (start screen) and in MANUAL operating state.
You can access View 1 by holding down the Back button. To open and close the valve, the
MANU / AUTO layout must be selected for View 1 (preset at the factory). An exact description can be
found in the operating instructions at www.burkert.com.
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Changing the control cone set
Type 3360, 3361
Navigation buttons
Menu button
Symbol for MANUAL
operating state
View 1 of x
CONFIGURATION
View 2
POS 70.7 %
Auto
Open
Closed
Display: View 1 in
MANUAL operating state.
Layout: MANU / AUTO
Back button
Information bar
Figure 2: Electrical manual control on the display
→ Press Menu button: Change to MANUAL operating state.
The HAND symbol can be seen on the information bar. The 2 arrow symbols labeled "open" and "closed"
are shown. The LED illuminated ring on the device flashes.
→ Press upper navigation button until the valve is completely open.
The valve position must be detected on the mechanical position indicator (see "Figure 1").
→Clamp the valve body into a holding fixture.
→Place a suitable open-end wrench on the body connection.
Do not unscrew the body connection with a tool which may damage the body connection.
→Unscrew the actuator off the valve body.
Devices without display module
To actuate the valve, the device must be in MANUAL operating state. The 2 buttons for opening and closing the
valve are located under the dummy cover.
Release
dummy
cover Operating state
MANUAL: DIP 4  ON
DIP switches
Figure 3: Setting MANUAL operating state
→Rotate the dummy cover counter-clockwise by 90° and remove from the actuator housing.
→Set DIP switch 4 to ON.
The device is the MANUAL operating state.
→Press OPEN button until the valve is completely open.
The valve position must be detected on the mechanical position indicator (see "Figure 1").
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Changing the control cone set
Type 3360, 3361
OPEN button
for opening the valve CLOSE button
for closing the valve
Figure 4: Electrical manual control for devices without display module
→Clamp the valve body into a holding fixture.
→Place a suitable open-end wrench on the body connection.
Do not unscrew the body connection with a tool which may damage the body connection.
→Unscrew the actuator off the valve body.
5.1.2 Opening valve mechanically
When the supply voltage is not applied, e.g. during installation or in the event of a power failure, the valve can be
opened with the mechanical manual control.
NOTE!
The mechanical manual control may be used in a de-energized state only, otherwise the device may be
damaged.
NOTE!
Carefully remove display module ensuring that the connection cable and the HMI interface are not damaged.
→Rotate the display module or dummy cover counter-clockwise by 90° and remove from the actuator housing.
On the display module pay attention to the connection cable leading to the HMI interface!
Release
display
Release
dummy
cover
Figure 5: Removing dummy cover or display module from the actuator housing
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Changing the control cone set
Type 3360, 3361
NOTE!
Damage to the manual control by exceeding the tightening torque.
If the tightening torque is exceeded on reaching the valve end position, the mechanical manual control will be
damaged.
▶Do not exceed the maximum tightening torque of 2 Nm.
To adjust the valve, use an Allen key with 4 mm width across flats.
The mechanical position indicator must detect when the valve reaches the end positions (see "Figure 1").
→Applying a gentle pressure, couple the mechanical manual control and simultaneously turn the Allen key
counter-clockwise (see "Figure 6").
Maximum tightening torque 2 Nm!
Mechanical Manual Control
Press and rotate
Turn
Open
valve
Close
valve
Figure 6: Mechanical Manual Control
→After reaching the required valve position, remove the Allen key.
The valve position must be detected on the mechanical position indicator (see "Figure 1").
→Clamp the valve body into a holding fixture.
→Place a suitable open-end wrench on the body connection.
Do not unscrew the body connection with a tool which may damage the body connection.
→Unscrew the actuator off the valve body.
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Changing the control cone set
Type 3360, 3361
5.2 Changing the control cone set
→Knock out dowel pin using a suitable pin punch (see "Table 1").
Spindle diameter
[mm]
Pin punch Connection size
Valve body DN [mm]
10 4 10/15 and 20
14 5 25 to 50
Table 1: Spindle diameter with reference to DN
→Remove control cone.
Spindle
Dowel pin
Control cone
Graphite seal
Figure 7: Changing the control cone set
NOTE!
Important information for the problem-free and safe functioning of the device: The sealing surface and control
contour of the control cone cannot be damaged.
→Attach new control cone to the spindle.
→Align bores of the control cone and spindle.
→Support control cone on the cylindrical part with the help of a prism.
→Put on dowel pin and carefully knock in with a hammer.
→Position the dowel pin in the center of the spindle axis.
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Changing the control cone set
Type 3360, 3361
5.3 Installing the actuator
When installing the actuator, ensure that the valve is in the open position.
→Replace graphite seal.
Graphite seal
Straight seat valve Angle seat valve
Figure 8: Graphite seal
WARNING!
Danger if unsuitable lubricants are used.
Unsuitable lubricant may contaminate the medium. In oxygen applications there is a risk of an explosion.
▶Only use approved lubricants for specific applications, such as oxygen applications or analytical applications.
→Grease the external thread of the body connection (e.g. with Klüber paste UH1 96-402 from Klüber).
→Place a suitable open-end wrench on the body connection.
Do not screw on the body connection with a tool which may damage the body connection.
→Screw actuator onto the valve body.
Observe tightening torque (see "Table 2").
Connection size
valve body DN [mm]
Tightening torques
[Nm]
13/15 45 ±3
20 50 ±3
25 60 ±3
32 65 ±3
40
50 70 ±3
65 100 ±3
Table 2: Tightening torques for valve body / body connection
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Changing the control cone set
Type 3360, 3361
5.4 Running X.TUNE
After installing the actuator, run the X.TUNE function.
When the X.TUNE function is run, the position controller is adjusted to the physical stroke of the actuating
element used.
NOTE!
Do not run X.TUNE without a mandatory requirement.
It is not necessary to rerun the X.TUNE function already run at the factory unless the valve body has been
changed. In this case the position controller must be readjusted to the actuating element.
WARNING!
Danger due to uncontrolled process after running the X.TUNE function.
If the X.TUNE is run under medium pressure, the controller will be incorrectly adjusted. This will result in an
uncontrolled process.
▶Never run the X.TUNE under medium pressure.
▶Secure system against unintentional activation.
5.4.1 Adjustment using the buttons in the device
The 2 buttons for running the X.TUNE are located under the dummy cover.
Release dummy
cover CLOSE button
OPEN button
Figure 9: Adjustment of the position controller using the buttons in the device
→To release the dummy cover, rotate counter-clockwise by 90°.
→Remove actuator housing.
Run X.TUNE function:
Do not run the X.TUNE unless it is absolutely essential.
→Simultaneously hold down the OPEN and CLOSE buttons for 5 s.
The rapidly flashing LEDs indicate that the X.TUNE is running.
When X.TUNE is complete, the LEDs have their previous status
(continuous light for AUTOMATIC operating state, flashing for MANUAL operating state).
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Changing the seal set
Type 3360, 3361
6 CHANGING THE SEAL SET
Before the seal set can be replaced, the actuator must be removed from the valve body and the control cone
must be removed.
DANGER!
Risk of injury from discharge of medium and release of 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 off the pressure. Deaerate lines.
WARNING!
Risk of injury if the wrong tools are used.
It is dangerous to use unsuitable tools for installation work as the device may be damaged.
▶To remove the actuator from the valve body, use an open-end wrench, never a pipe wrench.
▶To replace the packing gland, use a special installation wrench, modified socket wrench or open-end wrench.
▶Observe specified tightening torques.
Observe exact description for removing the actuator in chapter "5.1 Removing the actuator".
6.1 Removing the control cone
WARNING!
Risk of crushing due to mechanically moving parts.
▶Switch off supply voltage.
▶Devices with SAFEPOS energy-pack: Completely drain SAFEPOS energy-pack. Wait until LED illuminated
ring goes out; the LED illuminated display must not be in LED off mode.
▶Keep clear of the openings in the valve body.
→Knock out dowel pin using a suitable pin punch (see "Table 1").
→Remove control cone.
NOTE!
Important information for the problem-free and safe functioning of the device: The sealing surface and control
contour of the control cone must not be damaged.
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Changing the seal set
Type 3360, 3361
6.2 Changing the packing gland
WARNING!
Risk of injury from ejected parts.
When the spindle opening is exposed, the individual parts of the packing gland are pressed out at an undefined
speed when the relief bore is pressurized.
▶Before pressurizing with compressed air, safeguard the ambient area of the discharge opening (e.g. place
spindle on a firm base).
Caution!
Not all individual parts of the packing gland are pressed out by pressurizing with compressed air. Usually
the upper gaskets remain in the packing gland tube. Replace the pressed out individual parts only.
→Place the open-end wrench on the body connection. Unscrew spindle guide with the aid of a modified socket
wrench.
Modified socket wrench is not included in the spare part sets. It can be ordered separately. Order number
of the modified socket wrench can be found in chapter "9 Accessories, spare parts". If you have any ques-
tions, please contact your Bürkert sales office.
Spindle guide
Relief bore
Seal set for packing
gland
Figure 10: Spindle guide for the packing gland
→Place spindle on a firm base.
NOTE!
Individual parts of the packing gland can remain inserted in the threaded part of the packing gland tube. The
individual parts are then ready to hand:
1. Before pressurizing the relief bore: Move the spindle with the aid of the mechanical manual control
(see chapter "5.1.2") into the upper position.
2. After pressurizing the relief bore: Move the spindle with the aid of the mechanical manual control into the
lower position.
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Changing the seal set
Type 3360, 3361
→Pressurize relief bore with approx. 6 bar compressed air.
WARNING!
Danger if unsuitable lubricants are used.
Unsuitable lubricant may contaminate the medium. In oxygen applications there is a risk of an explosion.
▶Only use approved lubricants for specific applications, such as oxygen applications or analytical applications.
→Grease gaskets of the new packing gland package with the supplied lubricant.
→Place the individual parts on the spindle in the prescribed direction and sequence.
→Push packing gland into the packing gland tube.
Upper
gaskets
Pushing direction for packing
gland parts
Lower
gaskets
Upper
pressure ring(s)
Lower pressure ring
Pressure spring
Spindle diameter 14 mm
Spindle diameter 10 mm
Figure 11: Seal set for the packing gland
→Grease spindle guide thread with Klüber paste UH1 96-402.
→Screw in spindle guide.
Observe tightening torque (see "Table 3").
Spindle diameter [mm]Connection size
Valve body DN [mm] Tightening torques [Nm]
10 10/15 15
20 25
14 25 25
32 to 50 60
Table 3: Spindle guide tightening torques
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