Burkert 8840 User manual

Operating Instructions
Bedienungsanleitung
Manuel d‘utilisation
Type 8840
Modular process valve cluster, DN20 and DN25
Modularer Prozessventilknoten, DN20 und DN25
Nœud de vanne de process modulaire, DN20 et DN25

We reserve the right to make technical changes without notice.
Technische Änderungen vorbehalten.
Sous réserve de modifications techniques.
© Bürkert Werke GmbH & Co. KG, 2018
Operating Instructions 1806/00_EU-ML_00810703 / Original DE

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1 THE OPERATING INSTRUCTIONS....................................... 4
1.1 Denitionofterms ....................................................... 4
1.2 Symbols....................................................................... 4
2 INTENDED USE .................................................................... 5
3 BASIC SAFETY INSTRUCTIONS.......................................... 5
4 GENERAL INFORMATION .................................................... 6
4.1 Contact addresses ...................................................... 6
4.2 Warranty ...................................................................... 6
4.3 InformationontheInternet.......................................... 6
5 PRODUCT DESCRIPTION .................................................... 7
5.1 Structure and description............................................ 7
5.2 Versions ....................................................................... 7
5.3 Function....................................................................... 7
6 TECHNICAL DATA................................................................. 8
6.1 Conformity................................................................... 8
6.2 Standards .................................................................... 8
6.3 Type label .................................................................... 8
6.4 Operating conditions ................................................... 9
6.5 Mechanicaldata .......................................................... 9
6.6 Pneumatic data ........................................................... 9
6.7 Pressure range........................................................... 10
7 INSTALLATION .................................................................... 10
7.1 Preparatory work ....................................................... 11
7.2 Installthevalvebody................................................. 11
7.3 Deviceswithweldendsconnection.......................... 11
7.4 Rotatingtheactuator................................................. 13
7.5 Connectthedevicepneumatically ............................ 13
7.6 Removal .................................................................... 14
8 MAINTENANCE, TROUBLESHOOTING ............................. 15
8.1 Maintenance work ..................................................... 15
8.2 Cleaning .................................................................... 15
8.3 Recommended auxiliary materials ............................ 15
8.4 Malfunction................................................................ 16
9 REPLACEMENT PARTS...................................................... 17
9.1 ReplacementpartsforactuatorCLASSIC ................ 17
9.2 ReplacementpartsforactuatorELEMENT ............... 18
10 TRANSPORT, STORAGE, DISPOSAL................................. 18
Table of contents
Type 8840
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4
The operating instructions
Type 8840
1 THE 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,intendeduse
and operating conditions.
▶Persons,whoworkonthedevice,mustreadandunderstand
theseinstructions.
1.1 Denition of terms
Term in these instructions representative for
Valve cluster,
device
modular process valve cluster Type 8840
Valve body valve body block
Exatmosphere potentiallyexplosiveatmosphere
Exapproval approvalinthepotentiallyexplosive
atmosphere
1.2 Symbols
DANGER
Warns of an immediate danger.
▶Failuretoobservethewarningwillresultinafatalorserious
injury.
WARNING
Warns of a potentially dangerous situation.
▶Failuretoobservethewarningmayresultafatalorserious
injury.
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.
Indicatesimportantadditionalinformation,tipsand
recommendations.
Referstoinformationintheseoperatinginstructionsorin
otherdocumentation.
Highlightsinstructionstoavoidadanger.
Designatesaprocedurewhichyoumustcarryout.
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Intended use
Type 8840
2 INTENDED USE
The modular process valve cluster Type 8840 is designed for
controlling the ow rate of liquid and gaseous media, especially
distributing and collecting or mixing and supplying media.
▶Usethedeviceforitsintendedpurposeonly.Non-intended
useofthedevicemaybedangeroustopeople,nearby
equipmentandtheenvironment.
▶Inareasat risk of explosion,only usedevicesapprovedfor
useinthoseareas.Thesedevicesarelabeledwithaseparate
Extypelabel.Whenutilizedinapotentiallyexplosiveatmo-
sphere,alwayspayattentiontothedetailsontheseparateEx
typelabelandtheExadditionalinstructionscontainedinthe
scopeofdelivery.
▶The prerequisites for safe and ecient operation are correct
transport, storage, assembly, installation, start-up, operation,
and maintenance.
▶Whenusingthedevice,observethepermitteddata,operat-
ingconditionsandapplicationconditions.Thisinformation
canbefoundinthecontractualdocuments,theoperating
instructionsandonthetypelabel.
▶Usethedeviceonlyinconjunctionwiththird-partydevices
andcomponentsrecommendedandauthorizedbyBürkert.
▶Makesurethedeviceisinecientworkingorderbeforeuse.
3 BASIC SAFETY INSTRUCTIONS
These safety instructions do not consider any contingencies or
incidentswhichoccurduringassembly,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 medium leakage.
▶Beforeworkingonthesystemordevice,switchothepressure
and vent or drain lines.
Risk of burns from hot media.
▶Donottouchthedeviceduringoperation.
Risk of injury from moving parts.
▶Donotreachintoopenings.
Risk of injury when opening the actuator due to a tensioned
spring.
Iftheactuatorisopened,thereisariskofinjuryfromthespring
jumping out.
▶TheactuatorType2100mustnotbeopened.
General hazardous situations.
Topreventinjury,ensurethat:
▶Thedevicemaybeoperatedonlywheninperfectcondition
andinconsiderationoftheoperatinginstructions.
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General information
Type 8840
▶Donottransport,installorremoveheavydeviceswithout
theaidofasecondpersonandusingsuitableauxiliary
equipment.
▶Donotmakeanychangesonthedeviceanddonotsubject
ittomechanicalstress.
▶Securethesystemfromunintentionalactuation.
▶Onlytrainedtechniciansmayperforminstallationandmain-
tenance work.
▶Installthedeviceinaccordancewiththeregulationsinforce
inthecountry.
▶Afteraninterruptioninthepowersupply,ensurethatthepro-
cessisrestartedinadenedorcontrolledmanner.
▶Observethegeneralrulesoftechnology.
▶Toattachthevalvecluster,useonlythefactory-provided
fasteningthreads.
▶Feedonlyairorneutralgasesupto60°intothepilotairports.
▶Ensureadequatefreedomofmotionandsucientlylong
pneumatichosesonthepilotairportswhichmoveupand
downasdeterminedbythevalvestroke.
▶Donotremovebodycomponentsfromthevalvecluster.
▶Removethepilotairportsfortransportation.
4 GENERAL INFORMATION
4.1 Contact addresses
Germany
BürkertFluidControlSystems
Sales Center
Christian-Bürkert-Straße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.
AndalsoontheInternetat:www.burkert.com
4.2 Warranty
Thewarrantyisonlyvalidifthedeviceisusedasintendedinaccor-
dancewiththespeciedapplicationconditions.
4.3 Information on the Internet
TheoperatinginstructionsanddatasheetsforBürkert products
canbefoundontheInternetat:www.burkert.com
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Product description
Type 8840
5 PRODUCT DESCRIPTION
5.1 Structure and description
Thevalveclusterissuitableforcontrollingliquidandgaseous
media and can be used to distribute, collect, mix or supply
media.
Thevalvecluster,basedonamodularvalvebody,allowsdierent
congurations. The individual parts are joined hermetically tight
and in a very compact way.
Bodysystem
ActuatorCLASSIC
Actuator
ELEMENT
Fig. 1: Structure of the valve cluster
5.2 Versions
Dependingontherequirementandpreferredtypeofautomation,
dierentactuators(ELEMENT,CLASSIC,INOX)canbeselected.
Thefollowingoricesareavailable:
•DN10(screweddownandsealedwithagraphiteseal),
•DN20 and DN25 (welded).
Theorice10isdescribedinseparateoperating
instructions.
5.3 Function
Function Description of the
application
Representation
Distributor Distributing:
Thevalveclusterdistributes
themediumfromafeedline
to several consumers
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Technical data
Type 8840
Function Description of the
application
Representation
Collector Collecting:
Themediumcanbe
collectedfromseveral
consumers
Mixing:
Dierentmedia,e.g.hot
water and cold water or
variouschemicals,canbe
mixed
Supplying:
Dierentmedia,e.g.
various cleaning agents,
can be supplied alternately
to one consumer
6 TECHNICAL DATA
6.1 Conformity
ThedeviceconformswiththeEUDirectivesaccordingtotheEU
DeclarationofConformity(ifapplicable).
6.2 Standards
Theappliedstandards,whichverifyconformitywiththeEUDirec-
tives,canbefoundontheEU-TypeExaminationCerticateand/
ortheEUDeclarationofConformity(ifapplicable).
6.3 Type label
Type
Controlfunction
Orice
Seal material
Function
S=Collector
Pilot pressure
Port connection
Medium pressure
Order no.
Made in Germany
00283928 W1X LU
8840 A 20,0 PTFE S
Pilot 5,2 - 10 bar
G 3/4 Pmed 16 bar
Fig. 2: Description of the type label
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Technical data
Type 8840
6.4 Operating conditions
Operating conditions
Permitted ambient
temperature
CLASSIC ELEMENT
-10...+60°C
(PA-actuator)
+5...+140°C
(PPS-actuator)
0...+60°C
Permitted medium
temperature
-10...+180°C
Flow media Water,alcohols,oils,fuels,hydraulic
uid,salinesolutions,alkalis,organic
solvents, vapor, air, neutral gases
6.5 Mechanical data
Mechanical data
Controlfunction CFA,CFB(onrequest)
Dimensions Dependingonthenumberofvalve
positions
Weight Dependingonthenumberofvalve
positions and installed actuators
Numberofvalveslots 2to5(othersonrequest)
Bodymaterial Stainlesssteelprecisioncover316L
(CF3M)
Seal material Seatseal:PTFE
Sealbetweenactuatorandbody:
graphite
6.6 Pneumatic data
Pneumatic data
Control media Neutral gases, air
Max. pilot pressure 10 bar
Lineconnection Thread:G3/4toG1,NPT3/4to
NPT1
Weld ends according to ISO 4200
(on request)
ClampaccordingtoDIN32676/
SeriesB(onrequest)
Pilot air port CLASSIC:G1/4
ELEMENT:Push-In6/4
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Installation
Type 8840
6.7 Pressure range
6.7.1 Pressure range for actuator CLASSIC
Orice
[mm]
Actuator
size
[mm]
Minimum pilot
pressure
Maximum operating
pressure up to 180 °C
CFA [bar] CFA [bar] CFB [bar]
20 50 3.9 11 16
25 63 4.2 11 16
6.7.2 Pressure range for actuator ELEMENT
Orice
[mm]
Actuator
size
[mm]
Minimum pilot
pressure
Maximum operating
pressure up to 180 °C
CFA [bar] CFA [bar] CFB [bar]
20 50 5.2 16 16
25 70 5.0 16 16
7 INSTALLATION
DANGER
Risk of injury from high pressure and medium leakage.
▶Beforeworkingonthesystemordevice,switchothepressure
and vent or drain lines.
WARNING
Risk of injury from improper installation.
▶Installationmaybecarriedoutonlybytrainedtechnicians
andwiththeappropriatetools.
▶Secure system against unintentional activation.
▶Afterinstallation,ensurethattheprocessisrestartedina
controlled manner.
Risk of burns from hot media.
▶Donottouchthedeviceduringoperation.
Risk of injury from moving parts.
▶Donotreachintoopenings.
CAUTION
Risk of injury due heavy devices.
Duringtransportorduringassembly,aheavydevicemayfall
and cause injury.
▶Donottransport,installorremoveheavydeviceswithoutthe
aidofasecondpersonandusingsuitableauxiliaryequipment.
▶Use appropriate tools.
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Installation
Type 8840
7.1 Preparatory work
Theinstallationpositionisoptional.Preferablywithactuatorface
up.
→Observeowdirection.
→Observetypeofincomingow.
→Removecontaminantsfrompipelines.
→Ensurethatthepipelinesarealigned.
7.1.1 Install dirt traps
DirttrapfordeviceswithapprovalinaccordancewithDINEN161
InaccordancewithDINEN161(Automaticshut-ovalvesfor
gas burners and gas appliances) a dirt trap must be connected
upstreamofthevalveandpreventtheinsertionofa1mmplug
gauge.
Fordeviceswithstainlesssteelbody:
→Installdirttrapsupstreamofthevalve.
7.2 Install the valve body
Deviceswithweldendsconnection:
→Weldvalvebodyinpipelinesystem.Pleaseobservechapter
“7.3”.
Deviceswiththreadorclampconnection:
→Connect valve body to pipeline.
7.3 Devices with weld ends connection
NOTE
Damage to the actuator during welding of the valve body into
the pipeline.
▶Removetheactuatorbeforeweldingintothepipeline.
7.3.1 Remove the actuator
→Clampthevalvebodyinaholdingdevice.
NOTE
Damage to the seat seal or the seat contour.
▶Whenremovingtheactuator,ensurethatthevalveisopen.
→ForactuatorsCLASSICandcontrolfunctionA:
pressurizelowerpilotairportwithcompressedair(5bar):
valve opens.
→ForactuatorELEMENTandcontrolfunctionA:
pressurizethepilotairport1withcompressedair(5bar):
valve opens.
→Counterontheatsofthenipplewithasuitableopen-end
wrench.
→Unscrewtheactuator.
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Installation
Type 8840
7.3.2 Install the actuator
Nipple
Seal
Fig. 3: Install the actuator
→Checkthesealandifrequired,replaceit.Removeresidues
completely.
WARNING
Danger if incorrect lubricants used.
Unsuitablelubricantmaycontaminatethemedium.Inoxygen
applicationsthereisariskofanexplosion.
▶Inspecicapplications,e.g.oxygenoranalysisapplications,
useappropriatelyauthorisedlubricantsonly.
→Greasenipplethreadbeforere-installingtheactuator(e.g.
withKlüberpasteUH196-402fromKlüber).
NOTE
Damage to the seat seal or the seat contour.
▶Wheninstallingtheactuator,ensurethatthevalveisopen.
→ForactuatorsCLASSICandcontrolfunctionA:
pressurizelowerpilotairportwithcompressedair(5bar):
valve opens.
→ForactuatorELEMENTandcontrolfunctionA:
pressurizethepilotairport1withcompressedair(5bar):
valve opens.
→Counterontheatsofthenipplewithasuitableopen-end
wrench.
→Screwactuatorintothevalvebody.
Observetighteningtorque.
7.3.3 Tightening torque
Orice (DN) Tightening torque [Nm]
20 50 ±3
25 60 ±3
Tab. 1: Tightening torque
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Installation
Type 8840
7.4 Rotating the actuator
Thepositionoftheconnectionscanbealignedsteplessly
byrotatingtheactuatorthrough360°.
NOTE
Damage to the seat seal or the seat contour.
▶Whenrotatingtheactuator,ensurethatthevalveisopen.
→Clampthevalvebodyinaholdingdevice.
→ForactuatorsCLASSICandcontrolfunctionA:
pressurizelowerpilotairportwithcompressedair(5bar):
valve opens.
→ForactuatorELEMENTandcontrolfunctionA:
pressurizethepilotairport1withcompressedair(5bar):
valve opens.
→Counterontheatsofthenipplewithasuitableopen-end
wrench.
DANGER
Risk of injury from discharge of medium and pressure.
Ifthedirectionofrotationiswrong,thebodyinterfacemay
becomedetached.
▶Rotatetheactuatorinthespecieddirectiononly.
→Rotatecounter-clockwise(asseenfrombelow)tobringthe
actuatormoduleintotherequiredposition.
7.5 Connect the device pneumatically
DANGER
Risk of injury from unsuitable connection hoses.
▶Useonlyhoseswhichareauthorisedfortheindicatedpressure
and temperature range.
▶Observethedatasheetspecicationsfromthehose
manufacturers.
upper
lower
ActuatorCLASSIC ActuatorELEMENT
2
1
Fig. 4: Pilot air ports
7.5.1 Connection of the control medium
Thepositionoftheconnectionscanbealignedsteplessly
by rotating the actuator through 360°. The procedure is
describedinthechapter“7.4”.
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14
Installation
Type 8840
Connectionofthecontrolmediumfordeviceswithactuator
CLASSIC:
→ControlfunctionA:
Connectthecontrolmediumtothelowerpilotairport.
→ControlfunctionB:
Connectthecontrolmediumtotheupperpilotport.
Connectionofthecontrolmediumfordeviceswithactuator
ELEMENT:
→ControlfunctionAandB:
Connectthecontrolmediumtothepilotairport1.
Ifusedinanaggressiveenvironment,werecommend
conveyingallfreepneumaticconnectionsintoaneutral
atmospherewiththeaidofapneumatichose.
7.6 Removal
DANGER
Risk of injury from high pressure and medium leakage.
▶Beforeworkingonthesystemordevice,switchothepressure
and vent or drain lines.
→Loosenthepneumaticconnection.
→Removetheactuatorfromvalvebody.
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15
Maintenance, troubleshooting
Type 8840
8 MAINTENANCE,
TROUBLESHOOTING
WARNING
Risk of injury from improper maintenance.
▶Maintenance may only be carried out by trained specialist
personnel using suitable tools.
▶Securesystemfromunintentionalactivation.
▶Following maintenance, ensure a controlled restart.
8.1 Maintenance work
8.1.1 Wearing parts
Partswhicharesubjecttonaturalwear:
Actuator CLASSIC Actuator ELEMENT
•Valveset(swivelplatewith
PTFE-seal,pin,seal)
•Valveset(swivelplatewith
PTFE-seal,pin,seal)
•Sealsetforactuator •Sealsetforthepacking
gland
Theexactprocedureforreplacingthevalvesetandseal
setcanbefoundontheInterneton:
www.burkert.com → Type 2000 www.burkert.com → Type 2100
8.1.2 Visual inspection
Performregularvisualinspectionsaccordingtotheapplication
conditions:
→Checkmediaconnectionsforleaks.
→Checkreleaseboreforleaks.
8.2 Cleaning
Commerciallyavailablecleaningagentscanbeusedtocleanthe
outside.
NOTE
Avoid causing damage with cleaning agents.
▶Beforecleaning,checkthatthecleaningagentsarecompat-
iblewiththebodymaterialsandseals.
8.3 Recommended auxiliary materials
Thefollowingauxiliarymaterialsarerecommendedinthismanual
fortheproperoperation,maintenanceandrepairofthedevice:
Type of aux-
iliary material
Auxiliary material Manufacturer
information
Lubrication
paste
KlüberpasteUH1
96-402
KlüberLubrication
MünchenKG
www.klueber.de
Adhesive Loctite640 MarketingLoctite,
HenkelAG&Co.KGaA
www.loctite.de
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16
Maintenance, troubleshooting
Type 8840
8.4 Malfunction
Malfunction Reason Remedial action
Actuatordoes
notswitch
Pilot air port
interchanged
CFA:Connectthepilot
air port
CLASSIC:lower,
ELEMENT:1
CFB:Connectthepilot
air port
CLASSIC:upper,
ELEMENT:2
Pilot pressure too
low
Observe pressure
specicationsonthe
type label
Medium pressure
toohigh
Flow direction
reversed
Observethedirection
arrowsinchapter“5.3”
Malfunction Reason Remedial action
Valve is not
sealed
Dirt between seal
and valve seat
Installing dirt trap
Seat seal worn Installing new swivel
plate
Flow direction
reversed
Observethedirection
arrowsinchapter“5.3”
Pilot pressure too
low
Observe pressure
specicationsonthe
type label
Medium pressure
toohigh
Valve is leaking
ontherelease
bore
Packing gland
worn
Replace packing gland
or replace actuator
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17
Replacement parts
Type 8840
9 REPLACEMENT PARTS
CAUTION
Risk of injury and/or damage by the use of incorrect parts.
Incorrect accessories and unsuitable replacement parts may
causeinjuriesanddamagethedeviceandthesurrounding
area.
▶Use only original accessories and original replacement parts
fromBürkert.
9.1 Replacement parts for actuator
CLASSIC
Thefollowingreplacementpartsareavailablefortheactuator
CLASSIC:
•Sealsetforactuator
consistsofthesealingoftheactuators
•Valve set
consistsofswivelplate,pinandseal
9.1.1 Seal set for PA-actuator
Actuator
size [mm]
Orice
[mm]
Order number
(VA-body)
50 20 233 588
63 25 233 591
9.1.2 Seal set for PPS-actuator
Actuator
size [mm]
Orice
[mm]
Order number
(VA-body)
50 20 233 582
63 25 233 583
9.1.3 Valve set
Actuator
size [mm]
Orice
[mm]
Order number
(PTFE-seal)
50 20 011 171
50 25 011 202
63 25 160 737
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18
Transport, storage, disposal
Type 8840
9.2 Replacement parts for actuator
ELEMENT
Thefollowingreplacementpartsareavailablefortheactuator
ELEMENT:
•Sealsetforpackinggland
consistsoftheindividualpartsofthepackinggland,sealand
lubricant
•Valve set
consistsofswivelplate,pinandseal
9.2.1 Seal set
Actuator size
[mm]
Orice
[mm]
Spindle
diameter
Order
number
50 20 10 216 433
70 25 10 216 433
9.2.2 Valve set
Actuator size
[mm]
Orice
[mm]
Order number
50 20 011 171
70 25 160 737
10 TRANSPORT, STORAGE,
DISPOSAL
CAUTION
Risk of injury due heavy devices.
Duringtransportorduringassembly,aheavydevicemayfall
and cause injury.
▶Donottransport,installorremoveheavydeviceswithout
theaidofasecondpersonandusingsuitableauxiliary
equipment.
▶Use appropriate tools.
NOTE
Transport damage to inadequately protected devices.
•Duringtransportationprotectthedeviceagainstwetanddirt
inshock-resistantpackaging.
•Maintain permissible storage temperature
Incorrect storage may damage the device.
•Storethedeviceinadryanddust-freelocation.
•Storagetemperature:-20…+65°C.
Damage to the environment caused by device components
contaminated with media.
•Disposeofthedeviceandpackaginginanenvironmentally
friendlymanner.
•Observeapplicableregulationsondisposalandtheenvironment.
english

www.burkert.com