Burkert 2103 Operating Instructions Manual
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Burkert 2103 Operating Instructions Manual

Piston-controlled diaphragm valve
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Type 2103, 2104, 2105
Piston-controlled diaphragm valve
Kolbengesteuertes Membranventil
Vanne à membrane commandée par piston
Operating Instructions
Bedienungsanleitung
Manuel d'utilisation

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Summary of Contents for Burkert 2103

  • Page 1 Type 2103, 2104, 2105 Piston-controlled diaphragm valve Kolbengesteuertes Membranventil Vanne à membrane commandée par piston Operating Instructions Bedienungsanleitung Manuel d‘utilisation...
  • Page 2 We reserve the right to make technical changes without notice. Technische Änderungen vorbehalten. Sous réserve de modifications techniques. © Bürkert Werke GmbH & Co. KG, 2008 – 2020 Operating Instructions 2009/10_EU-ML_00805642 / Original DE...

  • Page 3: Table Of Contents

    Type 2103, 2104, 2105 Piston-controlled diaphragm valve Type 2103, 2104, 2105 ontents OPERATING INSTRUCTIONS ........................6 Symbols ............................6 1.2 Definition of terms ........................6 AUTHORIZED USE ..........................7 BASIC SAFETY INSTRUCTIONS ......................8 GENERAL INFORMATION ........................10 4.1 Contact address .........................10 4.2 Warranty .............................10 4.3 Information on the internet ......................10 DEVICE DESCRIPTION ........................11 5.1 General description ........................11 5.2 Versions ............................11...
  • Page 4 Type 2103, 2104, 2105 INSTALLATION ............................35 8.1 Safety instructions ........................35 8.2 Installation position ........................35 8.3 Before installation ........................37 8.4 Remove the actuator from the valve body................37 8.5 Installation of the valve body ....................38 8.6 Installation of the actuator (welded or glued body) ..............40 8.7 Align actuator ..........................41 8.8 Pneumatic connection .......................41 8.9 Removal ............................42 ELECTRICAL CONTROL UNIT ......................43 MAINTENANCE ............................44 10.1 Safety instructions ........................44 10.2 Maintenance ..........................44...

  • Page 5: Operating Instructions

    Designates a procedure which you must carry out. Definition of terms In these instructions the term “device” denotes the following device types: 2103, 2104, 2105. • Ex area: stands for potentially explosive area. • Ex approval: stands for approval in the potentially explosive area.

  • Page 6: Authorized Use

    Authorized use AUTHORIZED USE Incorrect use of the device can be dangerous to people, nearby equipment and the environment. ▶ The diaphragm valves of Types 2103, 2104 and 2105 are designed for the controlled flow of liquid and gaseous media. ▶ In potentially explosive atmospheres, only use devices that are approved for this purpose. These devices are identified by a separate Ex type label.

  • Page 7: Basic Safety Instructions

    Type 2103, 2104, 2105 Basic safety instructions BASIC SAFETY INSTRUCTIONS These safety instructions do not consider any contingencies or incidents which occur during installation, operation and maintenance. The operator is responsible for observing the location-specific safety regulations, also with reference to the personnel.
  • Page 8 Type 2103, 2104, 2105 Basic safety instructions General hazardous situations. To prevent injury, ensure: ▶ That the system cannot be activated unintentionally. ▶ Only trained technicians may perform installation and maintenance work. ▶ Perform installation work and maintenance work using suitable tools only. ▶ Do not transport, install or remove heavy devices without the aid of a second person and using suitable auxiliary equipment.

  • Page 9: General Information

    The warranty is only valid if the device is used as authorized in accordance with the specified application conditions. 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 english...

  • Page 10: Device Description

    DEVICE DESCRIPTION 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).

  • Page 11: Designated Application Area

    Type 2103, 2104, 2105 Device description Designated application area The diaphragm valve has been designed for use with dirty, aggressive, abrasive, ultrapure or sterile media. The valves may only control media which do not corrode the body and the seal materials (see type label).

  • Page 12: Structure And Function

    Actuator cover Actuator body Diaphragm socket Diaphragm Port connection Valve body Figure 1: Structure and description, 2/2-way valve Type 2103 6.1.2 2/3-way valve Type 2103 Transparent cap Setting of the center position Pilot air port for control function A - center...
  • Page 13 Type 2103, 2104, 2105 Structure and function 6.1.3 T-valve Type 2104 Second pilot air port for CFI and air discharge connection for CFA and CFB Pilot air port for CFA, CFB, CFI Transparent cap with position indicator Actuator cover Actuator body...

  • Page 14: Function

    6.2.2 Control function (SF) 2/3-way valve The 3-position diaphragm valve Type 2103 is available in control function A (CFA) only. Control function A (CFA) Normally closed by spring action A spindle, which is connected to the actuator piston, transfers the force onto the pressure piece which presses the diaphragm against the weir in the body.
  • Page 15 Type 2103, 2104, 2105 Structure and function 6.2.3 Setting of the center position with the 2/3-way valve Open position [100 % Stroke] Center position [0...100 % Stroke] Pilot air port 1: 5...7 bar Pilot air port 1: 5...7 bar Pilot air port 2: 0 bar Pilot air port 2: 5...7bar Deaeration...

  • Page 16: Technical Data

    Body material Orifice Permitted medium pressure (Diaphragm size / actuator size) Permitted control pressure Control function CE identification Type 2103 A 20M PTFE VS Pilot 4,8-10bar Tamb 0°C - +60°C Pmed 10,0bar Tmed xxx°C - +130°C Da=26,9 s=1,6 W3ZLT 00175139...

  • Page 17: Labeling Of The Forged Steel Valve Body

    Type 2103, 2104, 2105 Technical data Labeling of the forged steel valve body Batch number XX F Company logo Production number / Serial number Material XXXXXXXX/XXX Self-drain angle 1.4435/316L(VS) XXXX PN16/CWP150 XXXXXX Nominal pressure Customer-specific text (optional) XXXXXXXXXX Orifice connection and pipe dimensions...

  • Page 18: Operating Conditions

    Type 2103, 2104, 2105 Technical data Operating conditions 7.6.1 Temperature ranges Permitted ambient temperature for actuators Actuator size [mm] Actuator material Ambient temperature ø 50 -10...+60 °C ø 70 ø 90 -10...+100 °C ø 130 Table 2: Permitted ambient temperature for actuator 1) If using a pilot valve / control unit, observe its temperature range.
  • Page 19 ø 90 ø 130 ø 130 ø 130 Table 7: Pilot pressure for control function A Designs with lower pilot pressure (reduced spring force) are available on request. Contact your Bürkert sales office or our Sales Center, e-mail: info@burkert.com english...
  • Page 20 Type 2103, 2104, 2105 Technical data Maximum permitted medium pressure Permitted medium pressure depending on the medium temperature with plastic valve body: DN 15 - 65 PVDF 20 40 60 80 100 120 140 Temperature [°C] Figure 9: Graph of medium pressure / Medium temperature with plastic valve body...
  • Page 21 Type 2103, 2104, 2105 Technical data When using Type 2103, 2104 or 2105 as a control valve, pressure conditions may deviate in some cases. These conditions appear in the diagrams. Control function B / elastomer diaphragm ø 50 EPDM Pilot pressure [bar] Figure 10: Pressure graph, actuator ø 50 mm, control function B, elastomer diaphragm ø...
  • Page 22 Type 2103, 2104, 2105 Technical data ø 90 EPDM Pilot pressure [bar] Figure 13: Pressure graph, actuator ø 90 mm, control function B, elastomer diaphragm Graph for control valve ø 90 EPDM / control valve Pilot pressure [bar] Figure 14: Pressure graph for control valve, actuator ø 90 mm, control function B, elastomer diaphragm ø...
  • Page 23 Type 2103, 2104, 2105 Technical data Control function B / PTFE elastomer diaphragm ø 50 PTFE Pilot pressure [bar] Figure 17: Pressure graph, actuator ø 50 mm, control function B, PTFE elastomer diaphragm ø 70 PTFE Pilot pressure [bar] Figure 18: Pressure graph, actuator ø 70 mm, control function B, PTFE elastomer diaphragm Graph for control valve ø 70 PTFE / control valve...
  • Page 24 Type 2103, 2104, 2105 Technical data Graph for control valve ø 90 PTFE / control valve Pilot pressure [bar] Figure 21: Pressure graph for control valve, actuator ø 90 mm, control function B, PTFE elastomer diaphragm ø 130 PTFE Pilot pressure [bar] Figure 22: Pressure graph, actuator ø 130 mm, control function B, PTFE elastomer diaphragm Graph for control valve ø 130 PTFE / control valve...
  • Page 25 Type 2103, 2104, 2105 Technical data Control function I / elastomer diaphragm ø 50 EPDM Pilot pressure [bar] Figure 24: Pressure graph, actuator ø 50 mm, control function I, elastomer diaphragm ø 70 EPDM Pilot pressure [bar] Figure 25: Pressure graph, actuator ø 70 mm, control function I, elastomer diaphragm ø...
  • Page 26 Type 2103, 2104, 2105 Technical data Control function I / PTFE elastomer diaphragm ø 50 PTFE Pilot pressure [bar] Figure 28: Pressure graph, actuator ø 50 mm, control function I, PTFE elastomer diaphragm ø 70 PTFE Pilot pressure [bar] Figure 29: Pressure graph, actuator ø 70 mm, control function I, PTFE elastomer diaphragm ø...
  • Page 27 Table 10: Operating pressure for control function A Designs with lower pilot pressure (reduced spring force) are available on request. Contact your Bürkert sales office or our Sales Center, e-mail: info@burkert.com Operating pressure for control function A The values apply to valve bodies made of: •...

  • Page 28: Flow Characteristic

    Type 2103, 2104, 2105 Technical data Flow characteristic Example of flow characteristics: Connection size DN 25, according to ASME seal material EPDM Stroke [%] Figure 32: Example of flow characteristics for diaphragm control valve 7.7.1 Flow values for forged bodies...
  • Page 29 Type 2103, 2104, 2105 Technical data Kv values for forged steel valve bodies VS - ISO (EN ISO 1127/ISO 4200 / DIN 11866 series B) Kv value [m3/h] Orifice Diaphragm Seal connection Stroke [%] size material (DN) EPDM 0.05 0.18 0.33 0.48 0.66 0.84 1.01 1.1 PTFE 0.06 0.2 0.33 0.5 0.66 0.82 0.97 1.05 1.1 EPDM 0.05 1.01 2.3 PTFE 0.22 0.86 1.5...
  • Page 30 Type 2103, 2104, 2105 Technical data Kv values for forged steel valve bodies VS - BS 4825 Kv value [m3/h] Orifice Diaphragm Seal connection Stroke [%] size material (DN) EPDM 0.08 0.29 0.45 0.5 1/4“ PTFE 0.18 0.36 0.47 0.5 EPDM 0.18 1.2 1/2“ PTFE 0.35 1.1 Table 15: Kv values for forged steel valve bodies VS - BS 4825 7.7.2...
  • Page 31 Type 2103, 2104, 2105 Technical data 7.7.3 Flow values for tube valve body Kv values for tube valve bodies VP - DIN (DIN 11850 series 2 / DIN 11866 series A) Kv value [m3/h] Orifice Diaphragm Seal connection Stroke [%] size material (DN) EPDM PTFE EPDM PTFE EPDM PTFE EPDM 11.2 12.6 13.8 14.5 14.9 PTFE 12.3 13.2 13.7 EPDM 14.2 16.8 19...
  • Page 32 Type 2103, 2104, 2105 Technical data Kv values for tube valve bodies VP - ASME (ASME BPE / DIN 11866 series C) Kv value [m3/h] Orifice Diaphragm Seal connection Stroke [%] size material (DN) ½" PTFE ¾" PTFE 1" PTFE 10.5 11.6 12.3 12.7 1 ½" PTFE 15.8 20.7 24.9 28.1 31 31.5 32 2" PTFE 14.6 22.5 29.9 35.3 39.9 44.4 45.7 46...

  • Page 33: General Technical Data

    Type 2103, 2104, 2105 Technical data General technical data Materials Valve Bodies Type 2103 Precision casting (VG), forged steel (VS), tube valve body (VP), Plastic (PP, PVC, PVDF) Type 2104, 2105 VA block material Actuator PPS and stainless steel Sealing elements...

  • Page 34: Installation

    Type 2103, 2104, 2105 Installation INSTALLATION Safety instructions DANGER! Danger – high pressure in the equipment. ▶ 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.
  • Page 35 Type 2103, 2104, 2105 Installation 8.2.1 Installation position 2/2-way valve type 2103 Installation position: any installation position, preferably with the actuator face up. Installation for self-drainage of the body It is the responsibility of the installer and operator to ensure self-drainage. Self-draining must be considered during the installation: •...

  • Page 36: Before Installation

    Type 2103, 2104, 2105 Installation 8.2.3 Installation position tank bottom valve type 2105 Installation position: preferably with the actuator to the bottom. Figure 35: Installation position type 2105 Before installation NOTE! Damage to the diaphragm or the actuator. ▶ Before welding or gluing the body, the actuator and the diaphragm must be removed.

  • Page 37: Installation Of The Valve Body

    Type 2103, 2104, 2105 Installation Pilot air port for CFA, CFB, CF Air discharge connection CFA, CFB Pilot air port CFI Actuator Diaphragm Valve body Body screws (4x) Figure 36: Remove the actuator from the valve body Installation of the valve body WARNING! Risk of injury from improper installation.
  • Page 38 Type 2103, 2104, 2105 Installation 8.5.2 Welding of the tank bottom body Observe the sequence: 1. Weld the tank bottom body onto the base of the tank before installing the tank. Welding onto a tank which has already been installed is possible but more difficult. Weld the tank bottom body in the middle of the tank base so that the tank can be optimally drained.

  • Page 39: Installation Of The Actuator (Welded Or Glued Body)

    Type 2103, 2104, 2105 Installation Installation of the actuator (welded or glued body) NOTE! Damage to the diaphragm or the seat contour. ▶ When installing the actuator, ensure that the valve is in open position. Installation for actuator with control function A: → Pressurize pilot air port 1 with compressed air (5.5 bar).

  • Page 40: Align Actuator

    Type 2103, 2104, 2105 Installation Align actuator If valves feature a VA diaphragm socket, the actuator for the valve body can be rotated steplessly by 360 ° (VA = stainless steel). → Rotate actuator using a hook wrench. Rotate actuator only as far as required (max. 360 °).

  • Page 41: Removal

    Type 2103, 2104, 2105 Installation 2/2-way valve: Air discharge connection CFA, CFB and second pilot air port CFI 2/3-way valve: Pilot air port CFA 2/2-way valve: Pilot air port CFA, CFB, CFI 2/3-way-valve: Pilot air port CFA Figure 39: Pneumatic connection Silencer For the versions with a plug-in connection the silencer for reducing the exhaust air noise is supplied loose.

  • Page 42: Electrical Control Unit

    Type 2103, 2104, 2105 Electrical control unit ELECTRICAL CONTROL UNIT The valve Type 2103, 2104 and 2105 can be combined with following control units: • Type 8690 Pneumatic control unit (actuator size Ø 70 - Ø 130) • Type 8697 Pneumatic control unit (actuator size Ø...

  • Page 43: Maintenance

    Type 2103, 2104, 2105 Maintenance MAINTENANCE 10.1 Safety instructions DANGER! Danger – high pressure in the equipment. ▶ Before loosening the lines and valves, turn off the pressure and vent the lines. Risk of injury due to electrical shock. ▶ Before reaching into the system, switch off the power supply and secure to prevent reactivation.
  • Page 44 Type 2103, 2104, 2105 Maintenance A bulging PTFE diaphragm may reduce the flow. The replacing of the wearing parts is described in chapter “11 Replacing the diaphragm”. 10.2.3 Inspection intervals The following maintenance work is required for the diaphragm valve: →...

  • Page 45: Replacing The Diaphragm

    Type 2103, 2104, 2105 Replacing the diaphragm REPLACING THE DIAPHRAGM DANGER! Risk of injury from discharge of medium and pressure. It is dangerous to remove a device which is under pressure due to the sudden release of pressure or dis- charge of medium. ▶ Before removing a device, switch off the pressure and vent the lines.
  • Page 46 Type 2103, 2104, 2105 Replacing the diaphragm → Insert the body screws and lightly cross-tighten until the diaphragm lies between the body and actuator. Do not tighten the screws yet. → Actuate the diaphragm valve twice to position the diaphragm correctly. → Tighten body screws without pressurization in diagonal pairs in three stages (approx. 1/3, approx. 2/3, 3/3 of the tightening torque), according to table (see “Table 22”).
  • Page 47 Type 2103, 2104, 2105 Replacing the diaphragm → Pressurize pilot air port 1 with compressed air (5 bar). → Actuate the diaphragm valve twice to position the diaphragm correctly. → Tighten body screws with pressurization in diagonal pairs in three stages (approx. 1/3, approx. 2/3, 3/3 of the tightening torque), according to table (see “Table 22”).

  • Page 48: Malfunctions

    Type 2103, 2104, 2105 Malfunctions MALFUNCTIONS Malfunction Cause and remedial action Actuator does not switch Pilot air port interchanged CFA: Connecting pilot air port 1 (2/2-way valve) CFA: Pilot air port 1: Open (2/3-way valve) Pilot air port 2: Center position CFB: Connecting pilot air port 1...

  • Page 49: Replacement 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. The diaphragm is available as a replacement part for the piston-controlled diaphragm valve Type 2103, 2104 and 2105. Diaphragm...
  • Page 50 Type 2103, 2104, 2105 Replacement parts Order numbers for diaphragms Diaphragm size PTFE (EA*) Advanced PTFE (EU*) Laminated Gylon (ER*) 677 674 L04/L10** 679 540 L05/L09** 693 175 L06/L08** 677 675 E02/E04- 679 541 E02/E04- 693 176 L06/L08** PTFE** PTFE+Hole** 677 676 E02/E04- 679 542 E02/E04- 693 177...

  • Page 51: Packaging, Transport

    Type 2103, 2104, 2105 Packaging, transport PACKAGING, TRANSPORT CAUTION! Risk of injury due to a heavy device. A heavy device can fall down during transport or during installation and cause injuries. ▶ Transport, install and dismantle a heavy device with the help of another person. ▶ Use appropriate tools.
  • Page 52 www.burkert.com...

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