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Operating Instructions Type 2103, 2104, 2105

1. burkert Type 2103 2104 2105 FLUID CONTROL SYSTEMS Technical data 90 EPDM a S 130 EPDM Sa 10 30 8 8 Z a 9 7 o 8 7 o 8 5 7 5 7 Bs Bc 9 5 5 o 4 a 4 E 3 5 3 3 2 si 3 2 9 1 9 1 o y o 0 1 2 3 4 5 6 7 8 9 10 0 1 2 3 4 5 6 7 8 9 10 Pilot pressure bar Pilot pressure bar Fig 9 Pressure graph actuator 90 mm control function B Fig 11 Pressure graph actuator 130 mm control function B elastomer diaphragm elastomer diaphragm Graph for control valve Graph for control valve 90 EPDM control valve 8 130 EPDM control valve 3 is 7 7 DN50 es it 2 8 2 8 9 7 9 7 H 8 5 P o o a a E E 2 5 2 1 ml So So 0 1 2 3 4 5 6 7 8 9 10 0 1 2 3 4 5 6 7 8 9 10 Pilot pressure bar Pilot pressure bar Fig 10 Pressure graph for control valve actuator e 90 mm Fig 12 Pressure graph for control valve actuator 130 mm control function B elastomer diaphragm control function B elastomer diaphragm nglish Type 2103 2104 2105 Technical data burkert FLUID CONTROL SYSTEMS Control function B PTFE elastomer diaphragm 50 PTFE 2 2 10 zo 2 8 o 7 i 5 6 f a 5 i o a E 2 3 1 2o 1 1 0 1 2 3 4 5 6 7 8 9 10 Pilot pressure bar Fig 13 Pressure gra
2. burkert Technical data Flow values for DN15 Flow characteristics for DN15 SOME Forged body VS Cast body VG 100 pem EPDM PTFE EPDM PTFE 90 Vers Kv value Pd m n m h 9o m h Im n 96 u 60 G VS 0 0 0 0 0 0 0 0 0 3 50 FE ir 10 cal e alo leonl 2 dass E 7 y 20 0 51 11 042 9 025 5 029 7 20 AT 30 ilt 23 0 82 18 0 36 8 i 25 10 er 49 1 9 40 16 36 1 3 28 2 d5 E 0 10 20 30 40 50 60 70 80 90 100 50 2 8 60 2 6 58 DEG 50 2 8 64 Stroke 60 3 5 74 3 3 73 3 4 74 3 4 77 70 44 87 3 7 82 4 87 4 91 Fig 29 Flow characteristics for DN15 80 4 3 91 4 1 91 4 2 91 4 91 90 4 5 96 4 3 96 4 5 98 4 3 98 100 4 7 100 4 5 100 4 6 100 4 4 100 Tab 9 Flow values for DN15 Type 2103 2104 2105 Technical data Flow values for DN20 Srde Forged body VS Cast body VG EPDM PTFE EPDM PTFE Kv value m8 h 9 m3 h 96 m h m3 h 10 0 50 5 0 40 5 0 10 1 0 60 6 20 1 0 11 0 80 9 0 30 3 1 1 10 30 DES 25 1 8 21 DID Dil 225 24 40 3 4 37 2 9 83 4 2 39 3 9 37 50 BE 58 4 9 56 6 1 57 6 3 60 60 6 5 71 6 2 71 7 6 71 7 9 75 70 7 2 79 6 8 78 8 8 82 8 6 82 80 7 7 85 7 5 86 9 8 92 9 5 90 90 8 4 92 8 2 94 10 5 98 10 3 98 100 9 1 100 8 7 100 10 7 100 10 5 100 Tab 10 Flow values for DN20
3. burkert FLUID CONTROL SYSTEMS Flow characteristics for DN20 100 90 VG HET 80 au g rid VS 60 3 50 ad gt 40 E 30 20 F 10 o HF 0 10 20 30 40 50 60 70 80 90 100 Stroke Fig 30 Flow characteristics for DN20 english 23 Type 2103 2104 2105 burkert Technical data Flow values for DN25 Flow characteristics for DN25 Forged body VS Cast body VG 100 p Stroke 90 BW EPDM PTFE EPDM PTFE l pm n Kv value ex 70 VS i a ad VG m n Im n 9o m h m8 h 96 E 60 Se lt 3 50 ond 10 0 43 3 0 33 3 0 71 5 0 35 3 E 2 20 15 11 095 8 15 10 071 5 20 d 30 ST 28 2 1 i7 eU 25 DE 17 10 er em 50 8 4 64 6 4 52 8 6 59 6 2 46 Stroke 60 10 5 80 8 4 69 105 72 8 2 60 70 118 90 100 82 192 84 99 73 Fig 31 Flow characteristics for DN25 80 123 94 111 2 92 113 0 89 11 9 88 90 jer a VS es 141 97 180 96 100 13 1 100 12 2 100 14 6 100 13 6 100 Tab 11 Flow values for DN25 Type 2103 2104 2105 Technical data burkert FLUID CONTROL SYSTEMS Flow values for DN40 Flow characteristics for DN40 Forged body VS Cast body VG EPDM PTFE EPDM PTFE Kv value Stroke m n
4. 70 428 88 417 88 408 86 418 87 Fig 33 Flow characteristics for DN50 80 44 9 93 43 4 92 43 7 93 45 1 94 90 47 4 98 45 6 96 46 97 47 4 99 100 48 4 100 47 3 100 47 2 100 47 9 100 Tab 13 Flow values for DN50 Type 2103 2104 2105 Technical data burkert FLUID CONTROL SYSTEMS 7 6 General technical data Control functions CF Control function A Control function B Control function I Actuator sizes Materials Body type 2103 Body type 2104 2105 Actuator Sealing elements Diaphragm Normally closed by spring action Normally open by spring action Actuating function via reciprocal pressurization 50 mm 70 mm 90 mm 130 mm Precision casting VG forged steel VS VA block material PPS and stainless steel FKM and EPDM EPDM PTFE FKM Connections Pilot air connection Medium connection Media Control medium Flow media Installation position Type 2103 2104 Type 2105 Tank bottom valve Degree of protection Plug in hose connector 6 4 mm or 1 4 others on request Weld end in accordance with EN ISO 1127 ISO 4200 DIN 11850 R2 other connections on request Neutral gases air Liquids ultrapure sterile aggressive or abrasive media any position preferably with the actuator face up preferably with the actuator to the bottom IP67 in accordance with IEC 529 EN 60529 english 27 bur
5. 13 burkert FLUID CONTROL SYSTEMS Type 2103 2104 2105 Technical data Pilot pressure for control function A Pilot pressure bar GORENG Orifice DN mm for medium pressure size mm 0 bar maximum 8 EPDM FKM 2 5 2 3 50 8 PTFE 3 8 3 5 15 4 5 4 2 70 15 4 8 4 5 70 20 4 8 4 5 70 5 5 4 3 90 25 5 0 4 0 90 5 0 4 5 130 i 5 0 4 6 o 130 50 5 0 4 8 Tab 6 Pilot pressure for control function A Designs with lower pilot pressure reduced spring force are available on request Contact your B rkert sales office or our Sales Center e mail info de buerkert com Operating pressure for control function A The values apply to body made of forged steel VS precision casting VG Max sealed medium pressure bar Pressure on one Pressure on both Actuator Orifice size DN FANT rol side sides EPDM FKM PTFE EPDM FKM PTFE 50 8 10 7 5 10 10 50 70 70 15 15 20 130 130 Tab 7 Operating pressure for control function A amp The control functions are described in the chapter entitled 6 2 1 Control functions CF Type 2103 2104 2105 burkert Technical data FLUID CONTROL SYSTEMS Required minimum pilot pressure depending on medium pressure 70 EPD
6. 9 m h oe m h 96 m h 96 30 14 7 48 149 49 153 44 15 4 44 40 20 1 66 20 2 67 21 6 61 21 4 61 50 21 69 223 74 23 6 67 244 70 60 23 76 23 4 78 26 2 75 26 1 75 70 25 4 84 25 5 85 29 1 83 29 83 80 27 6 91 27 4 91 32 2 92 31 6 91 90 29 1 96 29 96 33 8 96 33 7 96 100 30 3 100 30 1 100 35 1 100 34 9 100 Tab 12 Flow values for DN40 100 80 fo 70 I 60 4 Ha 50 VG 40 7 30 a 20 ad 10 0 4 O 10 20 30 40 50 60 70 80 90 100 Stroke Fig 32 Flow characteristics for DN40 Kv value english 25 E Type 2103 2104 2105 burkert Technical data Flow values for DN50 Flow characteristics for DN50 Forged body VS Cast body VG 10 trok zum Stroke EBDM PTFE EPDM PTFE a Kv value 70 em m h mh 9o m h 96 m8 h 96 S 60 3 50 7 4 F vs 10 2 68 6 1 88 4 4 21 9 3 56 7 gt 20 11 9 25 10 4 22 10 4 22 11 5 24 20 7 30 21 6 45 184 39 209 44 20 7 43 10 7 40 30 4 63 28 59 20 2 62 303 63 MENT 50 37 8 78 36 3 79 35 2 75 36 1 75 Stroke 60 411 85 40 85 38 81 394 82
7. a 4 E 3 5 2 9 1 o 0 1 2 5 6 7 8 9 10 3 4 Pilot pressure bar Fig 25 Pressure graph actuator 70 mm control function I PTFE elastomer diaphragm M e on Di a Fig 27 Pressure graph actuator 130 mm control function I PTFE elastomer diaphragm Type 2103 2104 2105 Technical data burkert FLUID CONTROL SYSTEMS 7 5 for valves with 2 2 way valve body Flow values for DN8 Flow values and characteristics YC Forged body VS Cast body VG EPDM PTFE EPDM PTFE Kv value m n m h 9e m h Im n 96 0 0 0 0 0 0 0 0 0 10 0 0 0 0 0 0 0 0 20 0 0 0 21 13 0 0 0 26 17 80 0 04 4 0 42 26 0 0 0 5 33 40 0 2 20 0 64 39 0 14 15 0 73 48 50 OES 25 0 88 54 0 29 31 0 88 58 60 0 52 51 1 09 67 0 45 47 1 08 72 70 0 65 64 11 818 75 0 58 61 1 25 83 80 0 79 77 1 44 88 0 71 75 1 37 91 90 0 91 89 dots 95 0 84 88 1 44 95 100 1 02 100 1 63 100 0 95 100 1 51 100 Tab 8 Flow values for DN8 Flow characteristics for DN8 100 90 80 70 S o 60 3 50 40 30 20 10 0 0 10 20 30 40 50 60 70 80 90 100 Stroke 90 Fig 28 Flow characteristics for DN8 english 21 Type 2103 2104 2105
8. 15 677 664 E02 688 422 E03 677 685 FO1 15 BC 693 162 E02 693 163 E03 693 164 FO1 20 677 665 E02 688 423 E03 677 686 FO1 20 BC 693 165 E02 693 166 EO3 693 167 FO1 25 677 667 EO1 688 424 E03 677 687 FO1 32 677 668 EO1 688 425 E03 677 688 FO1 40 677 669 EO1 688 426 E03 677 689 FO1 50 677 670 EO1 688 427 E03 677 690 FO1 65 677 671 EO1 688 428 E03 677 691 FO1 PTFE Advanced PTFE Laminated EA EU advanced PTFE ET 8 677 674 L04 679 540 LO5 677 694 L02 15 677 675 EO2 679 541 E02 677 695 L02 PTFE PTFE Hole 20 677 676 E02 679 542 E02 677 696 LO2 PTFE PTFE Hole english burkert FLUID CONTROL SYSTEMS Type 2103 2104 2105 Packaging transport storage 25 677677 E02 679543 E02 677697 Lo1 PTFE PTFE Hole 32 677678 E02 679544 E02 PTFE PTFE Hole 40 677 679 E02 679545 E02 677698 Lo1 PTFE PTFE Hole 50 677 680 E02 679546 E02 677699 Lo1 PTFE PTFE Hole 65 677681 E02 679 743 E02 PTFE PTFE Hole Tab 18 Order numbers for diaphragms SAP Code Kennzeichnung auf der Membran 14 PACKAGING TRANSPORT STORAGE NOTE Transport damages Inadequately protected equipment may be damaged during transport During transportation protect the product against wet and dirt i
9. DN50 130 EPDM em 10 mS cu o 8 3 7 a 6 9 5 2 4 E 3 5 2 1 0 2 3 4 5 6 Pilot pressure bar E 8 9 10 Fig 21 Pressure graph actuator 70 mm control function I elas tomer diaphragm Fig 23 Pressure graph actuator 130 mm control function I elastomer diaphragm english 19 burkert FLUID CONTROL SYSTEMS Type 2103 2104 2105 Technical data Control function I PTFE elastomer diaphragm IDN15 50 PTFE 10 5 9 2 8 o 7 3 6 ns 2 4 A d E 2 TD 1 So 0 zu 3 4 5 6 7 8 9 10 Pilot pressure bar 1 90 PTFE N on25 N on40 Medium pressure bar or NWPUOSNDO WO ME 5 6 Pilot pressure bar Z 8 9 10 Fig 24 Pressure graph actuator 50 mm control function I PTFE elastomer diaphragm Fig 26 Pressure graph actuator 90 mm control function I PTFE elastomer diaphragm DN20 ban 40n15 I N 70 PTFE 104 29 o 8 3 7 a 6 9 5 2 4 E 3 5 2 1 0 0 1 2 3 4 5 6 7 8 9 10 Pilot pressure bar 130 PTFE 3 2 10 A S JA L o 2 wn n 9 7 9 5
10. control media which do not corrode the body and the seal materials see type label Observe the maximum pressure range according to the type label Dirty aggressive abrasive ultrapure or sterile media Highly viscous media 5 4 1 Application areas e g plant construction luxury food and food processing industry bottling plant chemical engineering pharmaceutics biotechnology 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 stainless steel 6 1 1 2 2 way valve type 2103 Pilot air port for CFA CFB CFI Second pilot air port for CFI and air discharge connection for CFA and CFB Transparent cap with position indicator Actuator cover Actuator body Diaphragm socket Sp an Line connection Diaphragm body Fig 1 Structure and description type 2103 Type 2103 2104 2105 Structure and function burkert FLUID CONTROL SYSTEMS 6 1 2 T valve type 2104 6 1 3 Tank bottom valve type 2105 2 Second pilot air port for CFI and air discharge connection for CFA and CFB 1 Pilot air port for CFA CFB CFI Transparent cap with position indicator Actuator cover Actuator body 2 va diaphragm socket VA stainless steel T valve body Line connection Fig 2 St
11. controlled restart WARNING For control function I Danger if pilot 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 product with pilot pressure then switch on the medium 11 1 Fastening types Replacing the diaphragm Orifice DN Fastening types for diaphragms diaphragm prep EPDM FKM size 8 Diaphragm buttoned Diaphragm buttoned 15 Diaphragm with bayonet Diaphragm with bayonet 20 catch catch 25 40 Diaphragm with bayonet Diaphragm screwed in catch 50 Tab 15 Fastening types for diaphragms english 37 Tee Type 2103 2104 2105 burkert laa FLUID CONTROL SYSTEMS epal rs DANGER gt Insert the body screws and lightly cross tighten until the dia phragm is between the body and actuator Risk of injury from discharge of medium and pressure Do not tighten the screws yet lt is dangerous to remove a product which is under pressure due Actuate the diaphragm valve twice to the sudden release of pressure or discharge of medium Without pressurization tighten the body screws to the per Before removing a product switch off the pressure and vent the mitted tightening torgue see Tab 16 Tightening torgues for lines diaphragms Replacement for control function A 1 Pilot
12. it through 90 20 4 4 5 For orifice DN25 DN50 observe chapter 11 1 1 25 5 6 Install new diaphragm 40 8 10 Align diaphragm 50 192 15 The marker flap of the diaphragm must be perpendicular to the direction of flow see Fig 40 Tab 16 Tightening torques for diaphragms Place actuator back on the body Lightly cross tighten the body screws without pressurization until 11 1 1 Switch between PTFE and EPDM the diaphragm is between the body and actuator diaphragms Do not tighten screws yet Orifice DNS Pressurize pilot air port 1 of the actuator with compressed air gt Detach PTFE diaphragm and attach new EPDM diaphragm 5 bar see Fig 40 A Here Orifice DN15 and DN20 Fa vave SHIGE Loosen PTFE diaphragm bayonet and attach new EPDM diaphragm Tighten the body screws to the permitted tightening torque see Orifice DN25 up to DN50 Tab 16 Tightening torques for diaphragms Loosen PTFE diaphragm bayonet Place the insert in the pressure piece gt Insert and screw in EPDM diaphragm english 39 je Type 2103 2104 2105 burkert Malfunctions 12 MALFUNCTIONS 13 REPLACEMENT PARTS Malfunction Cause remedial action WARNING ne Pilot air port interchanged Risk of injury when opening the actuator not swi ME CFA Connecting pilot air port 1 The actuator contains a tensioned spring If the actuator is opened CFB Connecting pilot air
13. port 1 there is a risk of injury from the spring jumping out gt The actuator must not be opened CFI Pilot air port 1 Open Pilot air port 2 Close CAUTION Pilot pressure too low See pressure specifications on the type label Risk of injury and or damage by the use of incorrect parts Incorrect accessories and unsuitable replacement parts may cause injuries and damage the product and the surrounding area gt Use only original accessories and original replacement parts Medium pressure too high See pressure specifications on the type label Valve is not Medium pressure too high fram Burkert sealed See pressure specifications on the type label Pilot pressure too low The diaphragm is available as a replacement part for the piston See pressure specifications on the type label controlled diaphragm valve Type 2103 2104 and 2105 Flow rate PTFE diaphragm bulging reduced Replace diaphragm Tab 17 Malfunctions If you have any queries please contact your B rkert sales office o see Fig 39 Pneumatic connection Type 2103 2104 2105 Replacement parts burkert FLUID CONTROL SYSTEMS Diaphragm A Fig 41 Diaphragm replacement part 13 1 Order table Orifice Diaphragm Order numbers for diaphragms size mm EPDM EPDM FKM AB AD FF 8 677 663 E02 688 421 E03 677 684 FO1
14. M 4 g The following graphs illustrate the required minimum pilot pressure T 10 8 8 depending on the medium pressure for control functions B and I a y 8 The values apply to body made of 7 forged steel VS precision casting VG E 4 f 3 3 N 9 1 When using Type 2103 2104 or 2105 as a control valve o 5 6 Z 8 9 10 pressure conditions may deviate in some cases These con E EC NE Pilot pressure bar ditions appear in the diagrams with a gray background Fig 7 Pressure graph actuator 70 mm control function B elastomer diaphragm Control function B elastomer diaphragm Graph for control valve 50 EPDM o 9 70 EPDM control valve 2 amp 8 10 104 7 7 a 5 9 amp o E 2 9 7 a 6 3 6 9 5 IM 3 5 Q 4 a 4 3 53 Ei Ba g 2 z 0 L z 0 1 0 1 2 3 4 5 6 7 8 9 10 0 1 2 3 4 5 6 7 8 9 10 Pilot pressure bar Pilot pressure bar Fig 6 Pressure graph actuator e 50 mm control function B Fig 8 Pressure graph for control valve actuator 70 mm control elastomer diaphragm function B elastomer diaphragm 00009906 M e on H english 15
15. PTFE elastomer diaphragm PTFE elastomer diaphragm Graph for control valve Graph for control valve 90 PTFE control valve 8 130 PTFE control valve 10 A 10 3 E 3 E DN40 o 7 9 7 5 6 5 6 DN50 n 5 B 5 o o B s 7 m 4 E 3 g 3 3 Y 3 1 oO 1 0 1 2 3 4 5 6 7 8 9 10 0 1 2 3 4 5 6 7 8 9 10 Pilot pressure bar Pilot pressure bar Fig 17 Pressure graph for control valve actuator 90 mm Fig 19 Pressure graph for control valve actuator 130 mm control function B PTFE elastomer diaphragm Type 2103 2104 2105 Technical data burkert FLUID CONTROL SYSTEMS Control function I elastomer diaphragm 50 EPDM La o I 1DN8 DN15 Medium pressure bar NU KW ANG o I 0 1 2 3 4 5 6 7 8 9 10 Pilot pressure bar 90 EPDM H o Medium pressure bar KA NU EW O 0 O M DN25 PN DN40 I L I TT 0 RS 2 3 4 5 6 Pilot pressure bar 7 8 9 10 Fig 20 Pressure graph actuator 50 mm control function I elas tomer diaphragm Fig 22 Pressure graph actuator 90 mm control function I elas tomer diaphragm 70 EPDM a 8 S 10 2 9 T 7 8 o E i 6 A 9 5 2 4 E 3 5 2 1 5 0 1 4 5 6 7 8 9 10 Pilot pressure bar DN40
16. RICAL CONTROL UNIT The valve Type 2103 2104 and 2105 can be combined with fol lowing control units Type 8690 Pneumatic control unit actuator size 70 130 Type 8697 Pneumatic control unit actuator size 50 Type 8691 Control head actuator size 70 130 Type 8695 Control head actuator size 50 Type 8692 Positioner actuator size 70 2 130 Type 8693 Process controller actuator size 70 130 Type 8694 Positioner actuator size 70 2 130 Type 8696 Positioner actuator size 50 Type 8645 Automation system FreeLINE Type 6012 Pilot valve Type 6014 P Pilot valve Am The electrical connection of the pilot valve or the control is described in the respective operating instructions for the pilot valve control Type 2103 2104 2105 Maintenance cleaning burkert FLUID CONTROL SYSTEMS 10 MAINTENANCE CLEANING DANGER Danger high pressure in the equipment K Before loosening the lines and valves turn off the pressure and vent the lines Risk of injury due to electrical shock K Before reaching into the system switch off the power supply and secure to prevent reactivation K Observe applicable accident prevention and safety regulations for electrical equipment WARNING Risk of injury from improper maintenance Installation may be carried out by authorized technicians only and with the appropriate tools Risk of injury from un
17. Service life of the diaphragm E pre m a A senn agents are compatible The service life of the diaphragm depends on the following factors Diaphragm material Medium Medium pressure Medium temperature Actuator size Pilot pressure for CFB and CFI Protecting the diaphragm For CFA match the actuator size actuator force to the medium pressure to be actuated If required select the actuator with reduced spring force EC04 For CFB and CFI try and select the pilot pressure not higher than is required to actuate the medium pressure Type 2103 2104 2105 Repairs burkert FLUID CONTROL SYSTEMS 11 REPAIRS DANGER Danger high pressure in the equipment K Before loosening the lines and valves turn off the pressure and vent the lines Risk of injury due to electrical shock K Before reaching into the system switch off the power supply and secure to prevent reactivation K Observe applicable accident prevention and safety regulations for electrical equipment WARNING Risk of injury from improper maintenance Installation may be carried out by authorised technicians only and with the appropriate tools Observe the tightening torgues On completion of the work check valve for leaks and function Risk of injury from unintentional activation of the system and an uncontrolled restart Secure system from unintentional activation Following maintenance ensure a
18. air port CFA CFB CFI Clamp the valve body in a holding product applies only to valves not yet installed NOTICE Damage to the diaphragm or the seat contour K When removing the actuator ensure that the valve is in open position Actuator Pressurize pilot air port 1 of the actuator with compressed air 5 bar valve opens Air discharge connection CFA CFB 2 Pilot air port CFI Diaphragm Loosen the four body screws Valve body Remove the actuator from the body Unbutton or unscrew old diaphragm If attachment is with a bayonet catch remove the diaphragm by rotating it through 90 Body screws For orifice DN25 DN50 observe chapter 11 1 1 4x Install new diaphragm Align diaphragm The marker flap of the diaphragm must be Marker flap of the perpendicular to the direction of flow see Fig 40 diaphragm Place actuator back on the body Fig 40 Repairs Type 2103 2104 2105 Repairs burkert pice o pde karer B and I Orifice DN Tightening torques for diaphragms Nm Clamp the valve body in a holding product diaphragm EPDM FKM PTFE advanced PTFE applies only to valves not yet installed size mm EN ad PTFE Loosen the four body screws dE T Remove the actuator from the body Unbutton or unscrew old diaphragm If attachment is with a 18 a 2 bayonet catch remove the diaphragm by rotating
19. burkert FLUID CONTROL SYSTEMS Type 2103 2104 2105 Piston controlled Diaphragm Valve Kolbengesteuertes Membranventil Vanne membrane command e par piston Operating Instructions Bedienungsanleitung Manuel d utilisation MAN 1000099061 ML Version H Status RL released freigegeben printed 22 09 2015 We reserve the right to make technical changes without notice Technische Anderungen vorbehalten Sous r serve de modifications techniques Burkert Werke GmbH 2008 2015 Operating Instructions 1509 07 EU ML 00805642 Original DE MAN 1000099061 ML Version H Status RL released freigegeben printed 22 09 2015 Type 2103 2104 2105 burkert FLUID CONTROL SYSTEMS OPERATING INSTRUCTIONS nee 4 1 1 Symbols nu GE dene O RD Y aan 4 1 2 Definition of term product sun 4 AUTHORIZED USE antenne 5 2 1 Restriction S aan 5 BASIC SAFETY INSTRUCTIONS rennen 5 GENERAL INFORMATION nenen 6 41 Contact address a 6 A2 NVarranty IG iW TAG RF YD FF chun 6 4 3 Information on the internet 6 PRODUCT DESCRIPTION ennenen 7 5 1 General descriptiori tette 7 5 2 Versio unner BS ele 5 4 Designated application area STRUCTURE AND FUNCTION 8 6 1 Structure 6 2 FUNGON ginea trc les trt ioter ern dre 10 TECHNICAL DATA 7 4 Conformity T Te T sanie mco been tei rote rivus I SYTN CS T3 Type labels ette e tracta 7 4 Operating conditions 7 5 Fl
20. connection the silencer for reducing MAN 00009906 M ersion H a R eleased the exhaust air noise is supplied loose Plug the silencer into the free air discharge connection 2 see Fig 39 Pneumatic connection If used in an aggressive environment we recommend conveying all free pneumatic connections into a neutral atmosphere with the aid of a pneumatic hose Control function I Connect the control medium to the pilot air port 1 and 2 of the actuator see Fig 39 Pneumatic connection Pressure on connection 1 opens the valve Pressure on connection 2 closes the valve Air discharge connection CFA CFB 2 and second pilot air port CFI Pilot air port 1 CFA CFB CFI Fig 39 Pneumatic connection Control air hose Control air hoses of sizes 6 4 mm or 1 4 can be used Optionally a pilot air port is possible via a G 1 8 thread 33 burkert FLUID CONTROL SYSTEMS Type 2103 2104 2105 Electrical control unit Removal 8 8 N DANGER Risk of injury from discharge of medium and pressure It is dangerous to remove a product which is under pressure due to the sudden release of pressure or discharge of medium K Before removing a product switch off the pressure and vent the lines Procedure Loosen the pneumatic connection Remove the product an Replacement of the diaphragm is described in the chapter entitled 11 Repairs 9 ELECT
21. control function A NOTICE Damage to the diaphragm or the seat contour K When installing the actuator ensure that the valve is in open position gt Control function A pressurize the pilot air port 1 with com pressed air 5 bar valve opens gt Lightly cross tighten the body screws until the diaphragm is between the body and actuator Do not tighten the screws yet gt Actuate the diaphragm valve twice Without pressurization tighten the body screws to the permitted n tightening torque see following table Tab 14 Tightening torques for diaphragms Installation for actuator with control functions B and I Lightly cross tighten the body screws without pressurization until the diaphragm is between the body and actuator Do not tighten the screws yet Pressurize pilot air port 1 of the actuator with compressed air 5 bar Actuate the diaphragm valve twice Tighten the body screws to the permitted tightening torque see Tab 14 Tightening torques for diaphragms english 31 Type 2103 2104 2105 Installation burkert FLUID CONTROL SYSTEMS 8 6 4 Align actuator a nn If valves feature a VA diaphragm socket the actuator for the valve body can be rotated steplessly by 360 VA stainless steel PQs Pir anno Rotate actuator using a hook wrench See Fig 38 S I H N Rotate actuator only as far as requi
22. e danger K Failure to observe the warning may result in a fatal or serious injury WARNING Warns of a potentially dangerous situation K Failure to observe the warning may result in serious injuries or death CAUTION Warns of a possible danger K Failure to observe this warning may result in a moderately severe or minor injury NOTE Warns of damage to property K Failure to observe the warning may result in damage to the product or the equipment recommendations o Indicates important additional information tips and an Refers to information in these operating instructions or in other documentation K Designates an instruction to prevent risks Designates a procedure which you must carry out 1 2 Definition of term product The term product used in these instructions always stands for the diaphragm valve Type 2103 2104 or 2105 Type 2103 2104 2105 Authorized use burkert FLUID CONTROL SYSTEMS 2 AUTHORIZED USE Non authorized use of the diaphragm valve Type 2103 2104 or 2105 may be a hazard to people nearby equipment and the environment K The product is designed for the controlled flow of liquid media K In the potentially explosion risk area the diaphragm valve may be used only according to the specification on the separate Ex type label For use observe the additional information enclosed with the product together with safety instructions for the
23. e opens Remove actuator with diaphragm by loosening the body screws english 29 ete Type 2103 2104 2105 burkert Installation 1 8 6 1 Installation of the valve Type 2103 and Pilot air port CFA CFB CFI 2104 Welded bodies Air discharge connection CFA CFB Pilot air port CFI Weld valve body in pipeline system Other body versions Connect body to pipeline Actuator 8 6 2 Installation of the tank bottom valve Diaphragm Type 2105 TEN It is recommended TTE To weld the valve prior to the container installation However it is possible to weld the valves to ready assembled containers Body screws 4x To weld the valve in the center of the drain to ensure optimum draining of the container Fig 36 Installation 8 6 Installation For further information on containers and welding instructions s m please refer to the standard ASME VIII Division I If used in an aggressive environment we recommend con veying all free pneumatic connections into a neutral atmos phere with the aid of a pneumatic hose WARNING Prior to welding please check to ensure that The tank bottom valve does not collide with other equipment compo nents and assembly disassembly of the actuator is always possible Risk of injury from improper installation minimal distance between two welding joints three times the thickness of the container wall is adhered to Non observance of
24. ed bodies 7 4 Operating conditions ad Batch number 7 4 1 Temperature ranges Material Permitted ambient temperature actuators Production number z z E serial number Actuator size Actuator material Environment 50 mm CHI EM WOR Surface quality code 70 mm 0 60 C Customer specific text PPS optional 90 mm 0 100 C Nominal pressure 130 mm m Tab 1 Permitted ambient temperature Actuators Orifice connection and ipe dimension 3 PIP o 2 If using a pilot valve control unit observe its tem Fig 5 Labeling of the forged bodies perature range Permitted medium temperature for body Body material Medium Cast body VG 1 4435 AISI 316L 1 4435 BN2 AISI 316L 10 150 C Forged body VS anian to ASME BPE 1997 Tab 2 Permitted medium temperature for body 3 Pilot air ports with push in connector 4 Pilot air ports with threaded bushing Type 2103 2104 2105 Technical data burkert FLUID CONTROL SYSTEMS Permitted medium temperature for diaphragms which do not corrode or swell the diaphragm materials o The indicated medium temperatures apply only to media 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 dia phragm may deterio
25. ent 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 The actuator must not be opened Risk of injury from moving parts in the device Do not reach into openings Risk of burns and risk of fire if used continuously through hot device surface K Do not touch the product with bare hands english 5 burkert FLUID CONTROL SYSTEMS Type 2103 2104 2105 General information General hazardous situations To prevent injury ensure that K The system cannot be activated unintentionally K Installation and repair work may be carried out by authorized technicians only and with the appropriate tools K After an interruption in the power supply or pneumatic supply ensure that the process is restarted in a defined or controlled manner K The product may be operated only when in perfect condition and in consideration of the operating instructions K The general rules of technology apply to application planning and operation of the product To prevent damage to property on the product 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
26. explosion risk area K Devices without a separate Ex type label may not be used in a potentially explosive area K The admissible data the operating conditions and conditions of use specified in the contract documents operating instructions and on the label are to be observed during use The designated application cases are specified in the chapter entitled 5 Product description K The product may be used only in conjunction with third party products and components recommended and authorised by B rkert K Correct transportation correct storage and installation and careful use and maintenance are essential for reliable and fault less operation K Use the product only as intended 2 1 Restrictions If exporting the system or product 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 products local safety regulations whereby the operator is responsible for their compliance by the installation personnel too N Danger high pressure Before dismounting the lines and valves turn off the pressure and vent the lines Risk of electric shock Before reaching into the product switch off the power supply and secure to prevent reactivation Observe applicable accident prevention and safety regulations for electrical eguipm
27. ged and cast body Mark on the body must point upwards 12 o clock position see Fig 34 gt Observe an inclination angle of 1 5 to the line axis Mark L m Angle a 10 to 409 Inclination to the line axis 19 5 Fig 34 Installation position for self drainage of the body Type 2103 2104 2105 Installation burkert FLUID CONTROL SYSTEMS 8 3 Installation position T valve type 2104 For the installation of the T valves into circular pipelines we recommend the following installation positions When media is supplied When media is removed Fig 35 Installation position type 2104 8 4 Installation position tank bottom valve type 2105 Preferably with the actuator to the bottom 8 5 Before installation Before connecting the valve ensure the pipelines are flush The flow direction is optional 8 5 1 Preparatory work Clean pipelines sealing material swarf etc Support and align pipelines Products with VG VS welded body NOTE Damage to the diaphragm or the actuator K Before welding in the body remove the actuator Remove the actuator from the valve body NOTICE Damage to the diaphragm or the seat contour K When removing the actuator ensure that the valve is in open position Control function A pressurize the pilot air port 1 with com pressed air 5 bar valv
28. intentional activation of the system and an uncontrolled restart Secure system from unintentional activation Following maintenance ensure a controlled restart WARNING For control function I Danger if pilot 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 product with pilot pressure then switch on the medium 10 1 Maintenance work 10 1 1 Actuator The actuator of the diaphragm valve is maintenance free provided it is used according to these operating instructions 10 1 2 Wearing parts of the diaphragm valve Parts which are subject to natural wear Seals Diaphragm If leaks occur replace the particular wearing part with an appro priate spare part see chapter entitled 13 Replacement parts o A bulging PTFE diaphragm may reduce the flow an The replacing of the wearing parts is described in chapter 11 Repairs 35 Type 2103 2104 2105 Maintenance cleaning burkert FLUID CONTROL SYSTEMS 10 1 3 Inspection intervals 10 1 5 Cleaning Check diaphragm for wear after maximum 10 switching cycles Commercially available cleaning agents can be used to clean the outside o Muddy and abrasive media require correspondingly shorter NOTE inspection intervals Avoid causing damage with cleaning agents 10 1 4
29. kert FLUID CONTROL SYSTEMS Type 2103 2104 2105 Installation INSTALLATION 8 N DANGER Danger high pressure in the equipment K Before loosening the lines and valves turn off the pressure and vent the lines WARNING Risk of injury from improper installation Installation may be carried out by authorised 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 For control function I Danger if pilot 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 product with pilot pressure then switch on the medium 8 1 Installation position general Installation for self drainage of the body It is the responsibility of the installer and operator to ensure self drainage Installation for leakage detection One of the bores in the actuator base for monitoring leakage must be at the lowest point 8 2 Installation position 2 2 way valve type 2103 The piston controlled diaphragm valve can be installed in any installation position preferably with the actuator face up To ensure self drainage Install body inclined by an angle a 10 to 40 to the horizontal For
30. ly replaced with EPDM membranes 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 specifications 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 Product versions Actuator sizes The piston controlled diaphragm valve is available for the following actuator sizes 50 mm e 70 mm e 90 mm e 130 mm Pilot pressure Designs with lower pilot pressure reduced spring force are available on request Contact your B rkert sales office or our Sales Center e mail info de buerkert com 5 3 Options Control unit Different versions of the activation units are available depending on the requirement Stroke limitation Limit of the maximum open position flow rate by means of adjusting screw Feedback indicator The product features mechanical limit switches or inductive prox imity switches english 7 burkert FLUID CONTROL SYSTEMS Type 2103 2104 2105 Structure and function 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
31. n shock resistant packaging Avoid exceeding or dropping below the permitted storage temperature Incorrect storage may damage the product Store the product in a dry and dust free location Storage temperature 20 65 C Damage to the environment caused by product components contaminated with media Dispose of the product and packaging in an environmentally friendly manner Observe applicable regulations on disposal and the environment MAN 1000099061 ML Version H Status RL released freigegeben printed 22 09 2015 burkert FLUID CONTROL SYSTEMS www burkert com MAN 1000099061 ML Version H Status RL released freigegeben printed 22 09 2015
32. ow values and characteristics 7 6 General technical data 10 11 12 13 14 INSTALLATION nn 28 8 1 Installation position general 28 8 2 Installation position 2 2 way valve type 2103 28 8 3 Installation position T valve type 2104 29 8 4 Installation position tank bottom valve type 2109 29 8 5 Before installation 8 6 Installation is tentent 8 7 Pneumatic connection 88 R MOVAlS nu nn ELECTRICAL CONTROL UNIT MAINTENANCE CLEANING 10 1 3 Tie Ga TT II II III REPAIRS TTT 37 11 1 Replacing the diaphragm sse 37 MALFUNCTIONS aiikoran 40 REPLACEMENT PARTS wistssssissiovinsscicisocssvssssennsicnisnssonsesscdnnstiaedicuesonssesien 40 13 1 Order tables eiu nie I aa 41 PACKAGING TRANSPORT STORAGE teens 42 english 3 burkert FLUID CONTROL SYSTEMS Type 2103 2104 2105 Operating instructions 1 OPERATING INSTRUCTIONS The operating instructions describe the entire life cycle of the product Keep these instructions in a location which is easily accessible to every user and make these instructions available to every new owner of the product The operating instructions contain important safety information Failure to observe these instructions may result in hazardous situations K The operating instructions must be read and understood 1 1 Symbols DANGER Warns of an immediat
33. ph actuator 50 mm control function B PTFE elastomer diaphragm 70 PTFE 28 8 a dE 7 8 9 5 2 7 a 6 9 5 2 4 E 3 3 L 2 o 1 5 0 1 2 5 6 7 8 9 10 3 4 Pilot pressure bar Fig 14 Pressure graph actuator 70 mm control function B PTFE elastomer diaphragm Graph for control valve 70 PTFE control valve H o DN25 opis i TIDN20 j 3 4 5 6 7 8 9 10 Pilot pressure bar Medium pressure bar or NW RU Duo o 0 1 2 Fig 15 Pressure graph for control valve actuator 70 mm control function B PTFE elastomer diaphragm 17 ES Type 2103 2104 2105 burkert Technical data 90 PTFE 130 PTFE m o 1 DN40 DN50 o i PDN25 N BH DN40 Medium pressure bar KA NU mU 3 10 O Medium pressure bar or NWPLUOONSDO to 0 1 2 3 4 5 6 7 8 9 10 0 1 2 3 4 5 6 7 8 9 10 Pilot pressure bar Pilot pressure bar Fig 16 Pressure graph actuator 90 mm control function B Fig 18 Pressure graph actuator 130 mm control function B
34. rate if the medium temperature increases Do not use the diaphragms as steam shut off element Material Temperature Remarks EPDM AB 10 130 C Steam sterilisation up to 140 C 60 min EPDM AD 5 143 C Steam sterilisation up to 150 C 60 min FKM FF 0 130 C No steam dry heat up to 150 C 60 min PTFE EA 10 130 C Steam sterilisation up to 140 C 60 min Advanced 5 143 C Steam sterilisation up to 150 C 60 min PTFE EU Advanced 10 F909C PTFE ET Gylon ER 5 130 C Steam sterilisation up to 140 C 60 min Tab 3 Permitted medium temperature for diaphragms 7 4 2 Pressure ranges Pilot pressure for valves with pneumatic position controller troller observe the permitted minimum and maximum pilot o To ensure reliable operation with pneumatic position con pressure on the type label Actuator size 50 mm 70 mm 90 mm 130 mm Pilot pressure 5 5 7 0 bar Tab 4 Pilot pressure for valves with pneumatic position controller Maximum pilot pressure for valves without pneumatic position controller Actuator size Actuator material max permitted pilot pressure 50 mm 70 mm 90 mm 130 mm PPS 10 bar 7 bar Tab 5 Maximum pilot pressure for valves without pneumatic position controller english
35. red max 360 diaphragm size EPDM FKM PTFE advanced mm PTFE laminated advanced PTFE Recommended 8 25 25 hook wrenches as 15 3 5 4 per DIN 1810 20 4 4 5 Actuator size 25 5 6 50 A 52 55 70 130 68 75 40 8 10 50 12 15 Fig 38 Align actuator Tab 14 Tightening torques for diaphragms Type 2103 2104 2105 Installation burkert FLUID CONTROL SYSTEMS Pneumatic connection 8 7 A DANGER Danger high pressure in the equipment gt Before loosening the lines and valves turn off the pressure and vent the lines WARNING Risk of injury from unsuitable connection hoses Hoses which cannot withstand the pressure and temperature range may result in hazardous situations gt Use only hoses which are authorised for the indicated pressure and temperature range gt Observe the data sheet specifications from the hose manufacturers For control function Danger if pilot pressure fails For control function I control and resetting occur pneumatically If the pressure fails no defined position is reached K To ensure a controlled restart first pressurize the product with pilot pressure then switch on the medium 8 7 1 Connection of the control medium Control functions A and B Connect the control medium to the pilot air port 1 of the actuator see Fig 39 Pneumatic connection Silencer For the versions with a plug in
36. ructure and description type 2104 Tank bottom valve with welding flange as all VA diaphragm socket VA stainless steel Actuator body Actuator cover Transparent cap with position indicator Pilot air ports 1 and 2 see detailed view amp Second pilot air port for CFI and air discharge connection for CFA and CFB Pilot air port for CFA CFB CFI 1 english ES Type 2103 2104 2105 burkert Structure and function 6 2 Function Control function I CFI Spring force CFA or pneumatic pilot pressure CFB and CFI Actuating furiction via reciproral pressurization generates the closing force on the diaphragm pressure piece The force is transferred via a spindle which is connected to the actuator piston o E xi 6 2 1 Control functions CF Control function A CFA Normally closed by spring action WARNING For control function Danger if pilot pressure fails For control function control and resetting occur pneumatically If the pressure fails no defined position is reached K To ensure a controlled restart first pressurize the product with pilot pressure then switch on the medium lim Control function B CFB Normally open by spring action Type 2103 2104 2105 Technical data burkert FLUID CONTROL SYSTEMS 7 TECHNICAL DATA WARNING Risk of injury from high pres
37. screws 4 GENERAL INFORMATION 4 1 Contact address Germany B rkert Fluid Control Systems Sales Center Chr Biirkert Str 13 17 D 74653 Ingelfingen Tel 49 0 7940 10 91 111 Fax 49 0 7940 10 91 448 E mail info de burkert com International Contact addresses are found on the final pages of the printed oper ating manual You can also find information on the Internet under www burkert com 4 2 Warranty The warranty is only valid if the product is used as authorized in accordance with the specified 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 Type 2103 2104 2105 Product description burkert FLUID CONTROL SYSTEMS 5 PRODUCT 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 flow of dirty aggressive abrasive ultrapure or sterile media even highly viscous media can be used flow media 5 1 1 Properties Any flow direction Self draining for appropriate installation The ends of the utilized connections must be cylindrical Free of empty space Low turbulence flow High flow values by the streamlined valve body Maintenance free under normal conditions PTFE EPDM diaphragms can be easi
38. sure Important product specific technical specifications are indicated on the type label K Observe permitted pressure range on the type label of the product 7 1 Conformity Type 2103 2104 and 2105 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 Type label Example Ku 2103A20MPTFEVS Pilot 4 8 10bar CE burkert Tamb 0 C 460 C Pmed 10 0bar 00175139 Tmed xxx C 130 C Da 26 9 s 1 6 W3ZLT Fig 4 Example of type label 7 3 1 Wording on the type label Example Sealing material Body material Orifice Permitted medium diaphragm size pressure actuator size Permitted control Control function pressure CE identification Type 2103 A 20M PTFE VS D 74653 Ingelfingen y Tamb 0 C 60 C 00175139 Tmed xxx C 130 C Pilot 4 8 10bar CE Pmed 10 0bar Da 26 9 s 1 6 burkert W3ZLT Date of manufacture encoded Permitted medium temperature Identification number of the product Main dimensions of body connection Permitted ambient temperature For description of versions see 7 4 Operating conditions english 11 burkert FLUID CONTROL SYSTEMS Type 2103 2104 2105 Technical data 7 3 2 Labeling of the forg
39. the tightening torque is dangerous as the product may be damaged The hole diameter in the tank and the housing flange must be the E TRT Tab 14 same size The housing flange has two welded edges to facilitate FO RTE Tj positioning and welding of the valve The welded edges are approx Type 2103 2104 2105 Installation burkert FLUID CONTROL SYSTEMS 3 mm wide If the container wall is more than 3 mm thick it must be ground down so that the discharge surface is touching the housing flange surface Prior to commencing the welding process check the charge number indicated on the supplied manufacturer s certificate SALE country with regard to the qualification of welders and the execution of welding work Observe the applicable laws and regulations of the respective Procedure Position the flange into the hole so that the flange surface is tangent to the drain surface Tack 4 welding points and check the position of the valve Weld the valve evenly to the inside and outside of the container with gas being supplied and using welding material compatible with the valve s stainless steel 316L Allow the welds to cool down before burnishing and cleaning them according to the applicable specifications Observance of these instructions will prevent deformation and tension inside the containers 8 6 3 Installation of the actuator welded body Installation for actuator with

Operating Instructions Type 2103, 2104, 2105

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