Bürkert 8695 User manual

Operating Instructions
Bedienungsanleitung
Manuel d‘ utilisation
Type 8695
Control Head
Steuerkopf
Tête de commande

We reserve the right to make technical changes without notice.
Technische Änderungen vorbehalten.
Sous réserve de modifications techniques.
© 2008 - 2014 Bürkert Werke GmbH
Operating Instructions 1411/07_EU-ML_00805569 / Original DE

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Control head Type 8695
Table of ConTenTs
1 OPERATING INSTRUCTIONS ........................................................................................................................................................7
1.1 Symbols ......................................................................................................................................................................................7
1.2 Definition of term / abbreviation ...................................................................................................................................7
2 AUTHORIZED USE .............................................................................................................................................................................8
2.1 Restrictions ...............................................................................................................................................................................8
3 BASIC SAFETY INSTRUCTIONS .................................................................................................................................................9
4 GENERAL INFORMATION .............................................................................................................................................................10
4.1 Contact address ..................................................................................................................................................................10
4.2 Warranty ...................................................................................................................................................................................10
4.3 Trademarks ............................................................................................................................................................................10
4.4 Information on the internet ............................................................................................................................................10
5 SYSTEM DESCRIPTION ................................................................................................................................................................11
5.1 Structure and function .....................................................................................................................................................11
5.1.1 Control head for integrated installation on 21xx series (Element) ..........................................11
5.1.2 Model for control of process valves belonging to the 20xx series (Classic) ........................12
6 TECHNICAL DATA .............................................................................................................................................................................13
6.1 Conformity ..............................................................................................................................................................................13
6.2 Standards ................................................................................................................................................................................13
6.3 Licenses ...................................................................................................................................................................................13
6.4 Operating conditions ........................................................................................................................................................13
6.5 Mechanical data ...................................................................................................................................................................13
6.6 Type labels ..............................................................................................................................................................................14
6.6.1 Type label standard ............................................................................................................................14
6.6.2 UL type label ........................................................................................................................................14
6.6.3 UL additional label ..............................................................................................................................15
6.7 Pneumatic data ....................................................................................................................................................................15
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Inhaltsverzeichnis
6.8 Electrical data .......................................................................................................................................................................16
6.8.1 Electrical data without bus control 24 V DC ...............................................................................16
6.8.2 Electrical data with AS-Interface bus control ..............................................................................16
6.8.3 Electrical data with DeviceNet bus control ..................................................................................16
7 INSTALLATION ...................................................................................................................................................................................17
7.1 Safety instructions .............................................................................................................................................................17
7.2 Installation of the control head Type 8695 on process valves of series 21xx (Element) ............17
7.3 Installation of the control head Type 8695 on process valves of series 20xx (Classic) ..............22
7.4 Rotating the actuator module on process valves of series 2100, 2101, 2000 and 2012 .............26
7.5 Rotating the control head for process valves belonging to series 20xx ..............................................28
8 PNEUMATIC INSTALLATION .......................................................................................................................................................29
9 ELECTRICAL INSTALLATION 24 V DC ...................................................................................................................................31
9.1 Safety instructions .............................................................................................................................................................31
9.2 Electrical installation .........................................................................................................................................................32
9.3 Teach function (calibrating the end position) ......................................................................................................33
9.4 Display and control elements 24 V DC ...................................................................................................................35
9.4.1 Status LED yellow ..............................................................................................................................35
9.4.2 Valve LED yellow ................................................................................................................................35
9.4.3 End position LED green and yellow ...............................................................................................36
9.4.4 Jumper function ...................................................................................................................................36
9.4.5 Change assignment of the end position LEDs ............................................................................36
10 AS-INTERFACE INSTALLATION ................................................................................................................................................38
10.1 AS-Interface connection .................................................................................................................................................38
10.2 Technical data for AS-Interface PCBs .....................................................................................................................38
10.3 Programming data ..............................................................................................................................................................38
10.4 Electrical installation AS-Interface ............................................................................................................................39
10.4.1 Safety instructions ..............................................................................................................................39
10.4.2 Connection with circular plug-in connector M12 x 1, 4-pole, male .......................................39
10.4.3 Connection with multi-pole cable and ribbon cable terminal ...................................................40
10.5 Teach function (calibrating the end position) ......................................................................................................41
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10.6 Display and control elements AS-Interface ..........................................................................................................43
10.6.1 Status LED yellow ..............................................................................................................................44
10.6.2 Valve LED yellow ................................................................................................................................44
10.6.3 Bus LED red and green ....................................................................................................................44
10.6.4 End position LEDs..............................................................................................................................45
10.6.5 Jumper function ...................................................................................................................................45
10.6.6 Change assignment of the end position LEDs ............................................................................46
11 DEVICENET INSTALLATION ........................................................................................................................................................47
11.1 Definition .................................................................................................................................................................................47
11.2 Technical data .......................................................................................................................................................................47
11.3 Maximum line lengths ......................................................................................................................................................47
11.3.1 Total line length according to DeviceNet specification .............................................................47
11.3.2 Drop line length...................................................................................................................................48
11.4 Safety setting if the bus fails ........................................................................................................................................48
11.5 Interfaces ................................................................................................................................................................................48
11.6 Electrical connection DeviceNet .................................................................................................................................48
11.6.1 Safety instructions ..............................................................................................................................48
11.6.2 Display and control elements DeviceNet ......................................................................................49
11.6.3 Bus connection (circular connector M12 x 1, 5-pole, male) ....................................................49
11.7 Terminating circuit for DeviceNet systems ...........................................................................................................49
11.8 Network topology of a DeviceNet system .............................................................................................................50
11.9 Configuring the control head .......................................................................................................................................50
11.9.1 DIP switches ........................................................................................................................................50
11.10 Configuration of the process data .............................................................................................................................52
11.11 Configuration of the safety position of pilot valves for bus error .............................................................53
11.12 Teach function (calibrating the end position) ......................................................................................................53
11.12.1 Starting the teach function ...............................................................................................................56
11.13 Display elements DeviceNet .........................................................................................................................................57
11.13.1 Device status LED and bus LED ....................................................................................................58
11.13.2 End position LEDs..............................................................................................................................59
11.13.3 Status LED yellow ..............................................................................................................................59
11.13.4 Valve LED yellow ................................................................................................................................59
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12 SAFETY POSITIONS .......................................................................................................................................................................60
13 MAINTENANCE ..................................................................................................................................................................................60
14 DISASSEMBLY ...................................................................................................................................................................................61
14.1 Safety instructions .............................................................................................................................................................61
14.2 Disassembly the control head .....................................................................................................................................61
15 ACCESSORIES ..................................................................................................................................................................................63
15.1 Communications software .............................................................................................................................................63
15.2 USB interface ........................................................................................................................................................................63
15.3 Download ................................................................................................................................................................................63
16 PACKAGING AND TRANSPORT ...............................................................................................................................................64
17 STORAGE ..............................................................................................................................................................................................64
18 DISPOSAL ............................................................................................................................................................................................64
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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.
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 will 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 moderate or minor injury.
NOTE!
Warns of damage to property.
• Failure to observe the warning may result in damage to the device or the equipment.
Indicates important additional information, tips and recommendations.
refers to information in these operating instructions or in other documentation.
▶Designates an instruction to prevent risks.
→Designates a procedure which you must carry out.
1.2 Definition of term / abbreviation
The term “device” used in these instructions always stands for the control head Type 8695.
In these instructions, the abbreviation “Ex” always refers to “potentially explosive”.
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Authorized use
2 AUTHORIZED USE
Non-authorized use of the control head Type 8695 may be a hazard to people, nearby equipment and
the environment.
The device is designed to be mounted on pneumatic actuators of process valves for the control of media.
▶In the potentially explosion-risk area the control head Type 8695 may be used only according to the specification
on the separate approval sticker. For use observe the additional instructions enclosed with the device together
with safety instructions for the explosion-risk area.
▶Devices without a separate approval sticker may not be used in a potentially explosive area.
▶Do not expose the device to direct sunlight.
▶Use according to the authorized data, operating conditions and conditions of use specified in the contract
documents and operating instructions. These are described in the chapter entitled “6 Technical data”.
▶The device may be used only in conjunction with third-party devices and components recommended and
authorized by Bürkert.
▶In view of the large number of options for use, before installation, it is essential to study and if necessary to
test whether the control head is suitable for the actual use planned.
▶Correct transportation, correct storage and installation and careful use and maintenance are essential for reli-
able and faultless operation.
▶Use the control head Type 8695 only as intended.
2.1 Restrictions
If exporting the system/device, observe any existing restrictions.
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Basic safety instructions
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!
Risk of injury from high pressure in the equipment/device.
▶Before working on equipment or device, switch off the pressure and deaerate/drain lines.
Risk of electric shock.
▶Before working on equipment or device, switch off the power supply and secure to prevent reactivation.
▶Observe applicable accident prevention and safety regulations for electrical equipment..
General hazardous situations.
To prevent injury, ensure:
▶That the system cannot be activated unintentionally.
▶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 on the device, ensure:
▶Do not feed any aggressive or flammable media into the pilot air port.
▶Do not feed any liquids into the pilot air port.
▶When unscrewing and screwing in the body casing or the transparent cap, do not hold the actuator of the pro-
cess valve but the connection housing of Type 8695.
▶Do not put any loads on the body (e.g. by placing objects on it or standing on it).
▶Do not make any external modifications to the device bodies. Do not paint the body parts or screws.
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General information
4 GENERAL INFORMATION
4.1 Contact address
Germany
Bürkert Fluid Control System
Sales Center
Chr.-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 can be found on the final pages of the printed operating instructions.
And also on the Internet at:
www.burkert.com
4.2 Warranty
The warranty is only valid if the control head Type 8695 is used as intended in accordance with the specified appli-
cation conditions.
4.3 Trademarks
Brands and trademarks listed below are trademarks of the corresponding companies / associations / organizations
Loctite Henkel Loctite Deutschland GmbH
4.4 Information on the internet
The operating instructions and data sheets for Type 8695 can be found on the Internet at:
www.burkert.com
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System description
5 SYSTEM DESCRIPTION
5.1 Structure and function
The control head Type 8695 can control single or double-acting process valves.
The control head Type 8695 has been optimized for the integrated modular fitting of series 21xx process valves
(Element) with actuator size ∅ 50. Various expansion stages are possible thanks to the modular design.
For installation on the 20xx series (Classic) there is a special model which is described in chapter “5.1.2”.
The valve position is recorded via a contactless, analog sensor element which automatically detects and saves the
valve end positions by means of the teach function during start-up.
Option: Communication possible via AS-Interface and DeviceNet.
5.1.1 Control head for integrated installation on 21xx series
(Element)
Electrical connection
Circular plug-in connector
M12 x 1 Air exhaust port
(label: 3)
Pressure limiting valve
(for protection against
too high internal pressure
in case of error) Pilot air port
(label: 1)
Teach function
Fastening screws (2 x)
View without transparent cap:
Connection housing
Figure 1: Structure and function
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System description
5.1.2 Model for control of process valves belonging to the 20xx
series (Classic)
A special model enables the control head Type 8695 to be attached to process valves belonging to the 20xx
series.
This model has a different pneumatic connection module so that the pilot air ports can be connected to the
outside of the actuator (see “Figure 2”).
Pilot air outlet 22
Pilot air outlet 21
Figure 2: Model for control of process valves, 20xx series
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Technical data
6 TECHNICAL DATA
6.1 Conformity
In accordance with the EC Declaration of conformity, the control head Type 8695 is compliant with the EC
Directives.
6.2 Standards
The applied standards on the basis of which compliance with the EC Directives is confirmed are listed in the EC
type examination certificate and/or the EC Declaration of Conformity.
6.3 Licenses
The product is approved for use in zone 2 and 22 in accordance with ATEX directive 94/9/EC category 3GD.
Observe instructions on operation in an explosion-risk (Ex) area.
Observe the ATEX additional instructions.
The product is cULus approved. Instructions for use in the UL area see chapter “6.8 Electrical data”.
6.4 Operating conditions
WARNING!
Solar radiation and temperature fluctuations may cause malfunctions or leaks.
▶If the device is used outdoors, do not expose it unprotected to the weather conditions.
▶Ensure that the permitted ambient temperature does not exceed the maximum value or drop below the mini-
mum value.
Ambient temperature see type label
Degree of protection
Evaluated by the manufacturer: Evaluated by UL:
IP65 / IP67 according to EN 60529 1) UL Type 4x Rating1)
1) Only if cables, plugs and sockets have been connected correctly and in compliance with the exhaust air concept see
chapter “8 Pneumatic installation”.
6.5 Mechanical data
Dimensions See data sheet
Body material exterior PPS, PC, VA
interior PA6; ABS
Sealing material exterior EPDM / FKM
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Technical data
Stroke range of valve spindle 21xx series (Element)
and 20xx series (Classic) AS-Interface 2 – 25 mm
24 V DC 2 – 35 mm
DeviceNet 2 – 35 mm
Third-party devices
(modified guide element
required) AS-Interface 2 – 34 mm
24 V DC 2 – 44 mm
DeviceNet 2 – 44 mm
6.6 Type labels
6.6.1 Type label standard
Example:
8695 24 V/DC
single act Pilot 0,6
Pmax 7 bar
Tamb 0°C - +55°C
S/N 001000
00185114
D-74653 Ingelfingen
W14UN
CE
Identification number
Supply voltage / Control
Max. operating pressure
Type Control function - Pilot valve
Bar-code
Serial number - CE mark
Max. ambient temperature
Figure 3: Type label (example)
6.6.2 UL type label
Example:
8695 -E1-...-0 PU02
Single act Pilot 0.6 24V
Pmax 7 bar
Tamb -10 - +55 °C
S/N 1001
00123456
D-74653 Ingelfingen
W15MA
CE
Identification number; Date of
manufacture (encoded)
Max. operating pressure
Type; Features of the type code applicable to UL
and ATEX
Control function; pilot valve;
Supply voltage pilot valve
Bar code
Serial number / CE mark
Max. ambient temperature
Figure 4: UL type label (example)
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Technical data
6.6.3 UL additional label
Example:
Type 4X enclosure
NEC Class 2 only
Supply voltage: 24 V
Supply voltage device
Circuit with limited power
Degree of protection
Figure 5: UL additional label (example)
6.7 Pneumatic data
Control medium neutral gases, air
Quality classes in accordance with ISO 8573-1
Dust content Class 7 max. particle size 40 µm, max. particle density 10 mg/m³
Water content Class 3 max. pressure dew point
- 20 °C or min. 10 °C below the lowest operating temperature
Oil content Class X max. 25 mg/m³
Temperature range -10 – +50 °C
Pressure range 3 – 7 bar
Air output of pilot valve 7 lN / min (for aeration and deaeration)
(QNn - value according to definition for pressure drop from 7 to 6 bar absolute)
Connections 21xx (Element) Plug-in hose connector ∅ 6 mm / 1/4“
Socket connection G 1/8
20xx (Classic) Socket connection G 1/8
with M5 connection for connecting to the actuator
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Technical data
6.8 Electrical data
WARNING!
Only circuits with limited power may be used for UL approved components according to “NEC Class 2”.
6.8.1 Electrical data without bus control 24 V DC
Protection class 3 as per DIN EN 61140 (VDE 0140-1)
Connections Circular plug-in connector (M12 x 1, 8-pole)
Pilot valve
Operating voltage 24 V DC ± 10% - max. residual ripple 10 %
Power input max. 1 W
Output max. 100 mA per output
Display max. 20 mA per illustrated illuminated display (LED)
6.8.2 Electrical data with AS-Interface bus control
Protection class 3 as per DIN EN 61140 (VDE 0140-1)
Connections Circular plug-in connector (M12 x 1, 4-pole)
Profile S-B.A.E. (A/B slave, max. 62 slaves/master)
Operating voltage 29.5 V – 31.6 V DC (according to specification)
Outputs
Max. switching capacity 1 W via AS-Interface
Watchdog function integrated
Max. power consumption 120 mA
Power consumption input during
normal operation
(after current reduction;
valve + 1 end position reached) 90 mA
6.8.3 Electrical data with DeviceNet bus control
Protection class 3 as per DIN EN 61140 (VDE 0140-1)
Connections Circular plug-in connector (M12 x 1, 5-pole)
Operating voltage 11 V – 25 V
Max. power consumption < 80 mA
Output Pull-in current current ≤ 50 mA
Holding current ≤ 30 mA
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Installation
7 INSTALLATION
7.1 Safety instructions
DANGER!
Risk of injury from high pressure in the equipment/device.
▶Before working on equipment or device, switch off the pressure and deaerate/drain lines.
Risk of electric shock.
▶Before working on equipment or device, switch off the power supply and secure to prevent reactivation.
▶Observe applicable accident prevention and safety regulations for electrical equipment.
WARNING!
Risk of injury from improper installation.
▶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.
7.2 Installation of the control head Type 8695 on
process valves of series 21xx (Element)
NOTE!
When mounting on process valves with a welded body, follow the installation instructions in the operating
instructions for the process valve.
Procedure:
1. Install switch spindle
Transparent cap
Actuator
Pilot air ports
(plug-in hose connectors with collets or
threaded bushings)
Figure 6: Installation of switch spindle (1), series 21xx
→Unscrew the transparent cap on the actuator and unscrew the position display (yellow cap) on the spindle
extension (if present).
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Installation
→For version with plug-in hose connector, remove the collets (white nozzles) from both pilot air ports (if present).
Spindle extension
O-ring
Guide element
Actuator cover
Groove ring
Puck
Switch spindle
max. 5 Nm
max. 1 Nm
Figure 7: Installation of the switch spindle (2), series 21xx
NOTE!
Improper installation may damage the groove ring in the guide element.
The groove ring is already be pre-assembled in the guide element and must be “locked into position” in the
undercut.
▶When installing the switch spindle, do not damage the groove ring.
→Push the switch spindle through the guide element.
NOTE!
Screw locking paint may contaminate the groove ring.
▶Do not apply any screw locking paint to the switch spindle.
→To secure the switch spindle, apply some screw locking paint (Loctite 290) in the tapped bore of the spindle
extension in the actuator.
→Check that the O-ring is correctly positioned.
→Screw the guide element to the actuator cover (maximum torque: 5 Nm).
→Screw switch spindle onto the spindle extension. To do this, there is a slot on the upper side
(maximum torque: 1 Nm).
→Push puck onto the switch spindle and lock into position.
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Installation
2. Install sealing rings
→Pull the form seal onto the actuator cover (smaller diameter points upwards).
→Check that the O-rings are correctly positioned in the pilot air ports.
When the control head is being installed, the collets of the pilot air ports must not be fitted to the actuator.
Installation of the form
seal
Form seal
Pilot air ports
Caution:
Collets must not be
fitted !
Figure 8: Installation of the sealing rings
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Installation
3. Install control head
NOTE!
Damaged printed circuit board or malfunction.
▶Ensure that the puck is situated flat on the guide rail.
→Align the puck and the control head until
1. the puck can be inserted into the guide rail of the control head
and
2. the connection pieces of the control head can be inserted into the pilot air ports of the actuator.
Connection
pieces
Pilot air ports
(actuator)
Guide rail
Puck
Guide rail
Puck
Connection
pieces
Figure 9: Aligning the puck and the connection pieces
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