Burkert Type 2000 User manual

Operating Instructions
Bedienungsanleitung
Manuel d‘utilisation
Type 2000/2002
2/2-Way Angle Seat Valve, 3/2-Way Globe Valve
2/2-Wege Schrägsitzventil, 3/2-Wege Geradsitzventil
Vanne à siège incliné 2/2 voies, vanne à siège droit 3/2 voies

We reserve the right to make technical changes without notice.
Technische Änderungen vorbehalten.
Sous réserve de modifications techniques.
© 2003 - 2013 Bürkert Werke GmbH
Operating Instructions 1309/13_EU-ML_00893086 / Original DE

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1. OPERATING INSTRUCTIONS ...................................................................4
1.1. Symbols ..............................................................................................4
1.2. Definition of the term "Device" ...................................................... 4
2. AUTHORIZED USE .........................................................................................5
2.1. Restrictions ........................................................................................5
3. BASIC SAFETY INSTRUCTIONS .............................................................5
3.1. Instructions for use in explosion protected area ..............................
(Ex area) ...............................................................................................................6
3.2. Special conditions ...........................................................................7
4. GENERAL INFORMATION ...........................................................................8
4.1. Contact addresses .......................................................................... 8
4.2. Warranty ............................................................................................. 8
4.3. Information on the Internet ............................................................. 8
5. PRODUCT DESCRIPTION ...........................................................................8
5.1. General Description ........................................................................8
5.2. Properties ...........................................................................................8
6. STRUCTURE AND FUNCTION..................................................................9
6.1. Structure ............................................................................................9
6.2. Function ............................................................................................10
7. TECHNICAL DATA ........................................................................................ 12
7.1. Conformity .......................................................................................12
7.2. Standards .........................................................................................12
7.3. Approvals .........................................................................................12
7.4. Type label .........................................................................................12
7.5. Operating Conditions ....................................................................13
7.6. General Technical Data ................................................................17
8. ASSEMBLY .......................................................................................................18
8.1. Safety instructions .........................................................................18
8.2. Before Installation ..........................................................................19
8.3. Installation ........................................................................................19
8.4. Pneumatic Connection .................................................................21
9. START-UP ......................................................................................................... 23
9.1. Control pressure.............................................................................23
9.2. Flow direction above the seat .....................................................23
9.3. Flow direction below the seat .....................................................23
10. DISASSEMBLY ............................................................................................ 24
11. MAINTENANCE, TROUBLESHOOTING .......................................... 24
11.1. Safety instructions .......................................................................24
11.2. Maintenance Work .......................................................................25
11.3. Malfunctions ..................................................................................25
12. SPARE PARTS ............................................................................................. 26
12.1. Replacement part sets ................................................................26
13. REPAIRS ......................................................................................................... 29
14. PACKAGING, TRANSPORT, STORAGE .......................................... 29
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Operating Instructions
1. OPERATING INSTRUCTIONS
The operating instructions describe the entire life cycle of the device.
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 operating instructions contain important safety
information!
Failure to observe these instructions may result in hazardous
situations.
• The operating instructions must be read and understood.
1.1. Symbols
DANGER!
Warns of an immediate danger!
• Failure to observe the warning may result in a fatal or serious
injury.
WARNING!
Warns of a potentially dangerous situation!
• Failure to observe the warning may result in serious injuries or death.
CAUTION!
Warns of a possible danger!
• Failure to observe this warning may result in a moderately
severe or minor injury.
NOTE!
Warns of damage to property!
• Failure to observe the warning may result in damage to the
device or the equipment.
Designates additional significant 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 angle
seat valve type 2000 and/or the globe valve type 2002.
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Authorized Use
2. AUTHORIZED USE
Non-authorized use of the 2/2-way angle seat valve type 2000
and 3/2-way globe valve type 2002 may be a hazard to people,
nearby equipment and the environment.
• The device is designed for the controlled flow of liquid and
gaseous media.
• The admissible data, the operating conditions and conditions of
use specified in the contract documents, operating instructions
and on the type label are to be observed during use. The desig-
nated application cases are specified in the chapter entitled “5.
Product description”.
• 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 problem-free
operation.
• Use the device only as intended.
2.1. Restrictions
If exporting the system/device, observe any existing restrictions.
3. BASIC SAFETY INSTRUCTIONS
These safety instructions do not make allowance for any
• contingencies and events which may arise during the installation,
operation and maintenance of the devices.
• local safety regulations; the operator is responsible for observing
these regulations, also with reference to the installation personnel.
DANGER!
Danger – high pressure!
• Before loosening the lines and valves, turn off the pressure and
vent the lines.
Risk of electric shock!
• Before reaching into the device or the equipment, switch off the
power supply and secure to prevent reactivation!
• Observe applicable accident prevention and safety regulations
for electrical equipment!
Risk of burns!
The surface of the device may become hot during long-term
operation.
• Do not touch the device with bare hands.
For model with explosion protection: Danger of explosion!
• Observe the specifications on the certificate of conformity and
ATEX instructions.
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Basic safety instructions
General hazardous situations.
To prevent injury, ensure that:
• The system cannot be activated unintentionally.
• Do not use in areas which are prone to vibrations.
• Installation and repair work may be carried out by authorized
technicians only and with the appropriate tools.
• After an interruption in the power supply or pneumatic supply,
ensure that the process is restarted in a defined or controlled
manner.
• The device may be operated only when in perfect condition and
in consideration of the operating instructions.
• The general rules of technology apply to application planning
and operation of the device.
To prevent damage to property of the device, ensure:
• Supply the media connections only with those media which are
specified as flow media in the chapter entitled “7. Technical Data”.
• Do not put any loads on the valve (e.g. by placing objects on it
or standing on it).
• Do not make any external modifications to the valves. Do not paint
the body parts or screws.
The angle seat valve type 2000 / globe valve type 2002 was
developed with due consideration given to accepted safety
rules and is state-of-the-art. However, dangers can still arise.
3.1. Instructions for use in
explosion protected area
(Ex area)
3.1.1. Values in the Ex area
The values for use within the Ex area are dependent on
the ambient temperature, i.e. the temperature class (gas),
surface temperature (dust), and medium temperature.
3.1.2. Media in the Ex area
If explosive media are used, this may create an additional
risk of explosion!
3.1.3. Use in hazardous area
The user must ensure that the appliance is used in Zone
1/21 or 2/22 only.
3.1.4. Control unit in the Ex area
The control unit may restrict use in an explosive atmosphere.
Follow operating instructions for control unit.
3.1.5. Cleaning in the Ex area
Test cleaning agent for approval in explosive atmosphere.
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Basic safety instructions
3.1.6. Adhesive label for Ex area
II 2G c IIC T4
II 2D c T135°C WARNING: Not valid when Non-Ex devices added
WARNING: Potential electrostatic charging hazard
-see instructions
Fig. 1: Label Ex area
3.1.7. Temperature ranges in the Ex area
max. T
Environment
Medium
<
–
DN 25 > DN 25
T6 85 °C -10 ... +45 °C -10 ... +55 °C
T5 100 °C -10 ... +60 °C -10 ... +70 °C
T4 135 °C -10 ... +95 °C -10 ... +105 °C
Tab. 1: Temperature ranges Ex area
10 20 30 40 50 60 70 80 90 100 110 120 1300
10
20
30
40
50
60
70
80
90
100
110
120
130
140
Temperature class T6
Temperature class T5
Temperature class T4
Medium temperature [°C]
Ambient temperature [°C]
Valves
<
– DN 25
Valves
> DN 25
Fig. 2: Temperature ranges Ex area
3.2. Special conditions
To ensure potential equalization, ground the valve body to the pipe
system using an electrically conductive connection.
For use in Ex area zone (gas) 1 and 2,
zone (dust) 21 and 22, applies:
DANGER!
Danger of explosion caused by electrostatic charge!
In the event of a sudden discharge from electrostatically charged
devices or individuals there is a risk of an explosion in the Ex area.
• Implement suitable measures to ensure that there are no elec-
trostatically charges in the Ex area.
• Only clean the surface of the device by gently wiping with a
damp or anti-static cloth.
Follow instructions for use in the Ex area! See chapter “3.1”.
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General information
4. GENERAL INFORMATION
4.1. 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
E-mail: [email protected]
International
Contact addresses are found on the final pages of the printed
operating manual.
You can also find information on the Internet under:
www.burkert.com
4.2. Warranty
The warranty is only valid if the device is used as authorized in accor-
dance with the specified application conditions.
4.3. Information on the Internet
The operating instructions and data sheets for Type 2000/2002 can
be found on the Internet at: www.burkert.com
5. PRODUCT DESCRIPTION
5.1. General Description
The externally controlled angle seat valve type 2000 / globe valve type
2002 is suitable for liquid and gaseous media.
It uses neutral gases or air (control media) to control the flow-rate
of water, alcohol, oil, fuel, hydraulic fluid, saline solution, lye, organic
solvent and steam (flow media).
Follow instructions for use in the Ex area! See chapter “3.1”.
5.2. Properties
• High tightness by self-adjusting packing glands (spindle sealing
element).
• High seat tightness by swivel plate.
• High flow values by the streamlined valve body made of stainless
steel.
• Actuator can be rotated steplessly through 360°.
5.2.1. Options
• Activation unit
Different versions of the activation units are available depending
on the requirement.
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Structure and Function
Follow instructions for use in the Ex area! See chapter “3.1”.
• Stroke limitation
Limit of the maximum open position/flow rate by means of
adjusting screw.
• Feedback indicator
The device features mechanical limit switches or inductive prox-
imity switches.
5.2.2. Device versions
The angle seat valve / globe valve is available for the following actuator
sizes:
Type 2000: ø 40 mm to ø 125 mm
Type 2002: ø 50 mm to ø 125 mm
5.2.3. Restrictions
WARNING!
Risk of injury from water hammer.
A water hammer could crack the lines and device.
• Use valves with flow inlet above seat for gaseous media and
steam only.
Follow instructions for use in the Ex area! See chapter “3.1”.
6. STRUCTURE AND FUNCTION
6.1. Structure
The angle seat valve / globe valve consists of a pneumatically actuated
piston actuator and a 2-way valve body / 3-way valve body. The actuator
is manufactured from PA or PPS. The tried and tested, self-adjusting
packing gland ensures high tightness. The flow-enhancing valve body
made of stainless steel or red bronze enables high flow values.
Line connector
Angle-seat body
Control air connection
Transparent cap with
position indicator
Actuator cover
Actuator body
Numbers for indicating
the direction of flow
Globe body
Type 2002 Type 2000
Fig. 3: Structure and description
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Structure and Function
6.2. Function
Depending on the version, the seat of the valve is closed with or against
the medium flow.
Spring force (CFA) or pneumatic control pressure (CFB and CFI)
generates the closing force on the swivel plate. The force is transferred
via a spindle which is connected to the actuator piston.
6.2.1. Control function (CF) for Type 2000
2/2-way angle seat valve
Control function (CF)
CFA
P
A
Closed by spring force in rest
position.
CFB
P
A
Opened by spring force in rest
position.
CFI
P
A
Actuating function via reciprocal
pressurization.
Tab. 2: Type 2000 - Control functions
WARNING!
For control function I – Danger if control pressure fails!
For control function I control and resetting occur pneumatically. If
the pressure fails, no defined position is reached.
• To ensure a controlled restart, first pressurize the device with
control pressure, then switch on the medium.
6.2.2. Control function (CF) and flow
modes of operation for
type 2002, 3/2-way globe valve
In the case of the globe valve Type 2002 different operating
principles can be obtained with the same control function by
swapping the pressure and working connections.
Control function A (CFA)
In rest position line connector 1 closed by spring force.
3
1
2
Flow
modes of
operation
Connection
123
C P A R
D R A P
E P1 A P2
F A P B
A, B: Working connections
P, P1, P2: Pressure connections
R: Pressure relief
Tab. 3: Control function A (CFA)
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Structure and Function
Flow modes of operation
C
In rest position pressure connection 1
closed, working connection 2 relieved.
D
In rest position pressure connection 3
connected to working connection 2,
relief 1 closed.
E
Mixing valve
In rest position pressure connection 3
connected to working connection 2,
pressure connection 1 closed.
F
Distribution valve
In rest position pressure connection 2
connected to working connection 3,
working connection 1 closed.
Tab. 4: Type 2001 - flow modes of operation
6.2.3. Incoming flow below seat
Depending on the version, the valve is closed against the medium
flow by spring force (control function A, CFA) or by control pressure
(control function B, CFB).
As the medium pressure is under the swivel plate, this pressure
contributes to the opening of the valve.
WARNING!
Leaking seat if minimum control pressure is too low or
medium pressure too high!
If the minimum control pressure is too low for CFB and CFI or the
permitted medium pressure is exceeded, the seat may leak.
• Observe minimum control pressure.
• Do not exceed medium pressure.
• See chapter „7.5.2. Pressure ranges“.
CFA/CFI CFB/CFI
Fig. 4: Incoming flow below seat (closing against medium)
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Technical Data
6.2.4. Incoming flow above seat
The valve is closed by spring force (control function A, CFA) with
the medium flow. As the medium pressure is over the swivel plate, it
supports the closing process of the valve and also contributes to the
sealing of the valve seat.
The valve is opened by the control pressure.
WARNING!
Risk of injury from water hammer.
A water hammer could crack the lines and device.
• Use valves with flow inlet above seat for gaseous media and
steam only.
To ensure complete opening, the minimum control pressure
must be used!
Follow instructions for use in the Ex area! See chapter “3.1”.
Fig. 5: Incoming flow above seat (closing with medium)
7. TECHNICAL DATA
7.1. Conformity
The angle seat valve type 2000 / globe valve type 2002 conforms
with the EC Directives according to the EC Declaration of Conformity.
7.2. Standards
The applied standards, which verify conformity with the EC Direc-
tives, can be found on the EC-Type Examination Certificate and / or
the EC Declaration of Conformity.
7.3. Approvals
The product is authorized for use in Zone 1 and 21 according to the
ATEX directive 94/9/EC of category 2 G/D.
Follow instructions for use in the Ex area! See chapter “3.1”.
7.4. Type label
Flow 1 2
2000 A 50,0 NBR RG
Made in Germany
00182076 W1X LU
G 2 P med 16 bar
Pilot 1,6 - 10 bar
R„R“ : variantType
Control pressure
Control function
Identification number
Direction of flow Orifice
Seal material
Body material
Nominal pressure
Connection type
Fig. 6: Example of the type label
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Technical Data
7.5. Operating Conditions
7.5.1. Temperature ranges
Actuator
size
[mm]
Actuator
material
Temperature ranges
Medium
(for PTFE seal)
Environment1)
40 - 63 PA –10 ... see “Fig. 7” –10 ... see “Fig. 7”
80 - 125 PA –10 ... +180 °C –10 ... +60 °C
40 - 80 PPS –10 ... +180 °C +5 ... +140 °C
100 - 125 PPS –10 ... +180 °C +5 ... +90 °C
2)
Tab. 5: Temperature ranges
1) If a pilot valve is used, the max. ambient temperature
is + 55 °C
Medium
temperature [°C]
Ambient
temperature
[°C]
100 120 140 160 180 200
70
60
50
40
30
20
∅ 63
∅ 50
∅ 40
Fig. 7: Temperature range of the maximum medium and ambient
temperature for PA actuators
2) * briefly up to max. 140 °C
7.5.2. Pressure ranges
Maximum control pressure 2/2-way and 3/2-way valve:
Actuator
material
Actuator size
[mm]
Max. control pressure
[bar]
PA 40 - 80 10
125 7
PPS 40 - 80 10
125 7
Tab. 6: Maximum control pressure
Maximum operating pressure 3/2-way valve, control function A:
Orifice
[mm]
Actuator
size
[mm]
Max. medium pressure up to
180 °C [bar] direction of flow
Min.
control
pressure
[bar]
1 → 2 2 → 3, 2 → 1
15 - 20 50 11 16 4.4
63 16 16 4.7
25 63 10 16 4.9
32 - 40 80 916 6.0
125 14 16 3.4
50 125 10 16 4.3
Tab. 7: Max. operating pressure
For control function F the maximum permitted operating
pressure is 16 bar.
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Technical Data
7.5.3. Minimum control pressures
Incoming flow below seat
(medium flow against the closing direction of the valve)
The required minimum control pressure P min for control function A is:
Actuator size
[mm]
40 50 63 80 100 125
Pmin [bar] 4.0 3.9 4.5 5.0 4.4 3.2
The following graphs illustrate the required minimum control pressure
depending on the medium pressure for control functions B and I
(incoming flow below seat).
Control
pressure [bar]
Medium
pressure
[bar]
CFB / CFI, ø 40 mm
DN 15 DN 20
Fig. 8: Pressure graph, actuator ø 40 mm, control function B and I
Control
pressure [bar]
Medium
pressure
[bar]
CFB / CFI, ø 50 mm
DN 15 DN 20 DN 25
Fig. 9: Pressure graph, actuator ø 50 mm, control function B and I
Control
pressure [bar]
Medium
pressure
[bar]
CFB / CFI, ø 63 mm
DN 20 DN 32 DN 40 DN 50 DN 25
Fig. 10: Pressure graph, actuator ø 63 mm, control function B and I
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Technical Data
Control
pressure [bar]
Medium
pressure
[bar]
CFB / CFI, ø 80 mm
DN 32 DN 40 DN 50 DN 65 DN 25
Fig. 11: Pressure graph, actuator ø 80 mm, control function B and I
Control
pressure [bar]
Medium
pressure
[bar]
CFB / CFI, ø 100 mm
DN 32 DN 40 DN 50 DN 65
Fig. 12: Pressure graph, actuator ø 100 mm,
control function B and I
Control
pressure [bar]
Medium
pressure
[bar]
CFB / CFI, ø 125 mm
DN 40 DN 50 DN 65
Fig. 13: Pressure graph, actuator ø 125 mm,
control function B and I
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Technical Data
Incoming flow above seat
(medium flow with the closing direction of the valve)
The following graphs illustrate the required minimum control pressure
depending on the medium pressure for control function A (incoming
flow above seat).
Control
pressure [bar]
Medium
pressure
[bar]
CFA, ø 40 mm
DN 15 DN 20
Fig. 14: Pressure graph, actuator ø 40 mm, control function A
Control
pressure [bar]
Medium
pressure
[bar]
CFA, ø 50 mm
DN 15 DN 25
DN 20
Fig. 15: Pressure graph, actuator ø 50 mm, control function A
Control
pressure [bar]
Medium
pressure
[bar]
CFA, ø 63 mm
DN 32 DN 40 DN 50 DN 25
DN 20
Fig. 16: Pressure graph, actuator ø 63 mm, control function A
Control
pressure [bar]
Medium
pressure
[bar]
CFA, ø 80 mm
DN 32 DN 40 DN 50 DN 65 DN 25
Fig. 17: Pressure graph, actuator ø 80 mm, control function A
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Technical Data
Control
pressure [bar]
Medium
pressure
[bar]
CFA, ø 100 mm
DN 32 DN 40 DN 50 DN 65
Fig. 18: Pressure graph, actuator ø 100 mm, control function A
Control
pressure [bar]
Medium
pressure
[bar]
CFA, ø 125 mm
DN 40 DN 50 DN 65
Fig. 19: Pressure graph, actuator ø 125, control function A
7.6. General Technical Data
Control functions (CF)
Control function A Closed by spring force in rest
position
Control function B Opened by spring force in rest
position
Control function I Actuating function via reciprocal
pressurization
Materials
Valve Type 2000
angle seat valve
Type 2002
3/2-way globe valve
Body Socket body:
Red bronze,
stainless steel 316L
Red bronze
Welded and clamped
body:
Stainless steel 316L
Actuator PA or PPS PA (PPS on request)
Seal PTFE
(NBR, FKM, EPDM on request)
Packing
gland (with
silicone
grease)
Stainless-steel body: PTFE V rings with spring
compensation
Red bronze body: PTFE and FKM V rings with
spring compensation
Tab. 8: Materials
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Assembly
Media
Control medium Neutral gases, air
Flow media Water, alcohols, oils, fuels, hydraulic liquid,
saline solutions, lyes, organic solvents,
steam
Connections
Type 2000
angle seat valve
Type 2002
3/2-way globe valve
Socket:
G 3/8 to G 2 1/2
(NPT on request) G 1/2 to G 2
Welded connections:
in accordance with EN ISO 1127,
DIN 11850 R2
clamped connections:
in accordance with ISO 2852,
ASME BPE,
BS 4825
Tab. 9: Connections
Other connections on request.
Installation position any position, preferably with
actuator face up
8. ASSEMBLY
8.1. Safety instructions
DANGER!
Risk of injury from high pressure in the equipment!
• Before dismounting pneumatic lines or valves, turn off the pres-
sure and vent the lines.
WARNING!
Risk of injury from improper assembly!
• Installation may be carried out by authorized technicians only
and with the appropriate tools!
Risk of injury from unintentional activation of the system and
an uncontrolled restart!
• Secure system from unintentional activation.
• Following assembly, ensure a controlled restart.
WARNING!
For control function I – Danger if control pressure fails!
For control function I control and resetting occur pneumatically. If
the pressure fails, no defined position is reached.
• To ensure a controlled restart, first pressurize the device with
control pressure, then switch on the medium.
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Assembly
8.2. Before Installation
• Any installation position is possible, preferably with actuator face up.
• Before connecting the valve, ensure the pipelines are flush.
• Observe direction of flow (see type label).
8.2.1. Preparatory work
→Clean pipelines (sealing material, swarf, etc).
Devices with welded body:
Removing the actuator from the valve body:
→Clamp valve body into a holding device.
NOTE!
Damage to the seat seal or the seat contour!
• When removing the actuator, ensure that the valve is in the
open position.
→Control function A and I:
Pressurize lower control air connection with compressed air
(5 bar): Valve opens.
→Place a suitable open-end wrench on the wrench flat of the nipple.
→Unscrew the actuator off the valve body.
Devices with socket body:
→Do not remove actuator unless this is a customer-specific
requirement.
8.3. Installation
WARNING!
Risk of injury from improper installation!
Assembly with unsuitable tools or non-observance of the tight-
ening torque is dangerous as the device may be damaged.
• For installation use an open-end wrench, never a pipe wrench.
• Observe the tightening torque (see “Tab. 10: Tightening
torques”).
Devices with approval in accordance with DIN EN 161
In accordance with DIN EN 161 "Automatic shut-off valves for gas
burners and gas installations" a dirt trap must be connected upstream
of the valve and prevent the insertion of a 1 mm plug gauge.
8.3.1. Installing the body
Welded body:
→Weld valve body in pipeline system.
Other body designs:
→Connect body to pipeline.
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Assembly
8.3.2. Installing the actuator (welded body)
Graphite seal
Fig. 20: Graphite seal
→Check graphite seal and, if required, replace. Remove all
residues when replacing seal.
WARNING!
Danger if incorrect lubricants used!
Unsuitable lubricant may contaminate the medium. In oxygen
applications there is a risk of an explosion!
• In specific applications, e.g. oxygen or analysis applications, use
appropriately authorized lubricants only.
→Grease nipple thread before re-installing the actuator
(e.g. with Klüber paste UH1 96-402 from Klüber).
NOTE!
Damage to the seal on the swivel plate!
• When installing the actuator, ensure that the valve is in the open
position.
→Control function A and I:
Pressurize lower control air connection with compressed air
(5 bar) so that the swivel plate is lifted off the valve seat and is
not damaged when screwed in.
→Screw actuator into the valve body.
Tightening torques:
Orifice
(DN)
Tightening torque
(Nm)
15 45 ± 3
20 50 ± 3
25 60 ± 3
32 65 ± 3
40 65 ± 3
50 70 ± 3
65 70 ± 3
Tab. 10: Tightening torques
If the body is stainless steel, grease the nipple thread with
e.g. Klüber paste UH1 96-402.
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