Bürkert 8791 User manual

Quickstart
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Type 8791
Positioner SideControl BASIC
Electropneumatic positioner
Elektropneumatischer Positioner
Régulateur de position électropneumatique

We reserve the right to make technical changes without notice.
Technische Änderungen vorbehalten.
Sous réserve de modifications techniques.
© Bürkert Werke GmbH & Co. KG, 20 - 2017
Operating Instructions 1705/0_(8(1_00 / Original DE

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1 QUICKSTART ..................................................................................................5
1.1 Definition of term / abbreviation .............................................5
1.2 Symbols ....................................................................................... 5
2 AUTHORIZED USE ......................................................................................6
2.1 Restrictions ................................................................................. 6
3 BASIC SAFETY INSTRUCTIONS ..........................................................7
4 GENERAL INFORMATION ........................................................................8
4.1 Contact addresses ...................................................................8
5 DESCRIPTION OF SYSTEM ....................................................................8
5.1 Structure ......................................................................................8
5.2 General description .................................................................. 9
6 TECHNICAL DATA ........................................................................................9
6.1 Conformity ................................................................................... 9
6.2 Standards .................................................................................... 9
6.3 Operating conditions ................................................................9
6.4 Mechanical data.......................................................................10
6.5 Electrical data ...........................................................................10
6.6 Electrical data with AS-Interface bus control (optional) 11
6.7 Pneumatic data ........................................................................11
7 OPERATING .................................................................................................. 12
7.1 Operating status ....................................................................... 12
7.2 Control and display elements of the positioner ................12
7.3 Error messages ......................................................................... 16
8 ATTACHMENT AND ASSEMBLY ............................................................17
8.1 Installation of devices for the hazardous area ...................17
8.2 Attachment to a proportional valve with NAMUR linear .....
actuators ....................................................................................17
8.3 Attachment to a proportional valve with rotary actuator . 21
8.4 Remote operation with external position sensor ..............24
9 FLUID CONNECTION ..............................................................................25
9.1 Connection of devices for the hazardous area .................25
9.2 Safety instructions ...................................................................25
9.3 Safety end positions ...............................................................26
10 ELECTRICAL CONNECTION ................................................................28
10.1 Connection of devices for the hazardous area .................28
10.2 Safety instructions ...................................................................28
10.3 Electrical connection with circular plug-in connector ........
M12, 8-pole ..............................................................................28
10.4 Electrical connection with cable gland ...............................30
10.5 Electrical installation AS-Interface........................................32
10.6 LED status display AS-Interface ..........................................33
11 START-UP ...................................................................................................... 34
11.1 Safety instructions ...................................................................34
11.2 Specifying the standard settings .........................................34
Positioner Type 8791
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12 ACCESSORIES ...........................................................................................35
12.1 Communications software.....................................................35
12.2 USB interface ...........................................................................35
12.3 Download ..................................................................................35
13 PACKAGING, TRANSPORT, STORAGE ..........................................36
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Quickstart
1 QUICKSTART
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!
Read Quickstart carefully and thoroughly. Study in particular the
chapters entitled “Basic safety instructions” and “Authorized use”.
▶Quickstart must be read and understood.
Quickstart for positioner Type 8791 explains, for example, how to
install and start-up the device.
A detailed description of the device can be found in the operating
instructions for positioner Type 8791.
The operating instructions can be found on the enclosed CD
and on the Internet at:
www.burkert.com
1.1 Definition of term / abbreviation
The term “device” used in these instructions always stands for the
positioner Type 8791.
In these instructions, the abbreviation “Ex” always refers to “poten-
tially explosive”.
1.2 Symbols
The following symbols are used in these instructions.
DANGER!
Warns of an immediate danger.
▶Failure to observe the warning may result in a fatal or serious injury.
WARNING!
Warns of a potentially dangerous situation.
▶Failure to observe the warning may result in serious injuries or
death.
CAUTION!
Warns of a possible danger.
▶Failure to observe this warning may result in a medium or minor
injury.
NOTE!
Warns of damage to property.
indicates important additional information, tips and
recommendations.
refers to information in these operating instructions or in
other documentation.
▶Designates an instruction to prevent risks.
→designates a procedure that must be carried out.
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Authorized use
2 AUTHORIZED USE
Incorrect use of the positioner Type 8791 can be dangerous
to people, nearby equipment and the environment.
The device is designed for the open-loop control and closed-loop
control of media.
▶The device must not be exposed to direct sunlight.
▶Pulsating direct voltage (rectified alternating voltage without
smoothing) must not be used as power supply.
▶In the potentially explosion-risk area the positioner Type 8791 may
be used only according to the specification on the separate Ex type
label. For use observe the additional information enclosed with the
device together with safety instructions for the explosion-risk area.
▶Devices without a separate Ex type label may not be used in a
potentially explosive area.
▶During use observe the permitted data, the operating conditions
and conditions of use specified in the contract documents and
operating instructions, as described in chapter “6 Technical data”
in this manual and in the operating instruction for the respective
pneumatically actuated valve.
▶The device may be used only in conjunction with third-party devices
and components recommended and authorised by Bürkert.
▶In view of the wide range of possible application cases, check
whether the positioner is suitable for the specific application case.
▶Correct transportation, correct storage and installation and care-
ful use and maintenance are essential for reliable and faultless
operation.
▶Use the positioner Type 8791 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.
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:
▶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 of the device, ensure:
▶Do not supply the supply pressure connection of the system with
aggressive or flammable mediums.
▶Do not supply the supply pressure connection with any liquids.
▶Do not put any loads on the housing (e.g. by placing objects on
it or standing on it).
▶Do not make any external modifications to the device housings.
Do not paint the housing parts or screws.
NOTE!
Electrostatic sensitive components / modules.
The device contains electronic components which react sensitively
to electrostatic discharge (ESD). Contact with electrostatically
charged persons or objects is hazardous to these components. In
the worst case scenario, they will be destroyed immediately or will
fail after start-up.
▶Observe the requirements in accordance with EN 61340-5-1 to
minimise or avoid the possibility of damage caused by sudden
electrostatic discharge.
▶Also ensure that you do not touch electronic components when
the power supply voltage is present.
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General information
4 GENERAL INFORMATION
4.1 Contact addresses
Germany
Bürkert Fluid Control Systems
Sales Center
Christian-Bürkert-Str. 13-17
D-74653 Ingelfingen
Tel. + 49 (0) 7940 - 10 91 111
Fax + 49 (0) 7940 - 10 91 448
E-mail: [email protected]
International
Contact addresses can be found on the final pages of these printed
operating instructions.
And also on the internet at:
www.burkert.com
5 DESCRIPTION OF SYSTEM
5.1 Structure
Mechanical position indicator
Display module with 3 LEDs
Working connection 2
(connection: A2)
Supply pressure
connection 1.4 – 7 bar
(connection: P)
Working connection 1
(connection: A1)
Air exhaust connection/
air exhaust filter
Pressure-relief valve
Fig. 1: Structure, positioner Type 8791
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Technical data
Internal position sensor
Axle for position sensor
Cable gland
Electronic module
Control system
Fig. 2: Structure, positioner Type 8791
5.2 General description
The positioner Type 8791 is a digital, electro-pneumatic position
controller for pneumatically actuated proportional valves. The device
incorporates the main function groups
- Position sensor
- Electro-pneumatic control system
- Microprocessor electronics
The position sensor measures the current positions of the propor-
tional valve. The microprocessor electronics continuously compare
the current position (actual value) with a set-point position value
specified via the standard signal input and supplies the result to the
position controller. If there is a control difference, the electro-pneu-
matic control system corrects the actual position accordingly.
6 TECHNICAL DATA
6.1 Conformity
In accordance with the EC Declaration of conformity, the positioner
Type 8791 is compliant with the EC Directives.
6.2 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.
6.3 Operating conditions
WARNING!
If used outside, the device may be exposed to direct sunlight
and temperature fluctuations which 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 minimum value.
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Technical data
Environmental
temperature 0 to +60 °C
Degree of protection IP65 / IP671) according to EN 60529
(only if cables, plugs and sockets have
been connected correctly)
1) If the positioner is used under IP67 conditions, the ventilation filter (see
“Fig. 1”) must be removed and the exhaust air conducted into the dry
area.
6.4 Mechanical data
Dimensions See data sheet
Material
Housing material Plastic-coated aluminium
Other external parts Stainless steel (V4A), PC, PE, POM, PTFE
Sealing material EPDM, NBR, FKM
Weight approx. 1.0 kg
6.5 Electrical data
Connections 2 cable glands (M20 x 1.5) with screw-
type terminals 0.14 – 1.5 mm2 or circular
plug-in connector (M12, 8 pole plug)
Interfaces Communications interface USB:
Direct connection to PC via USB adapter.
Communication with communications
software.
An external adapter with integrated
interface driver is required.
Supply voltage 24 V DC ± 10 %, max. residual ripple 10%
Power consumption < 3.5 W
Input resistance for
set-point value signal 180 Ω in 0/4 - 20 mA / Resolution 12 bit
Protection class III in accordance with DIN EN 61140
(VDE 0140-1)
Analog position feedback
max. Burden (load)
for current output
0/4 – 20 mA) 560 Ω
Inductive proximity
switches 100 mA current limit
Binary input 0 – 5 V = log “0”, 10 – 30 V = log “1”
inverted input in reverse order
(input current < 6 mA)
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Technical data
6.6 Electrical data with AS-Interface bus
control (optional)
Connections circular plug-in connector
(M12, 4 pole plug)
Supply voltage 29.5 V – 31.6 V DC
(according to specification)
Units without external supply voltage:
Max. power
consumption 150 mA
Units with external supply voltage:
External supply voltage 24 V ± 10 %, the supply voltage unit must
feature a secure disconnection in accor-
dance with IEC 364-4-41 (PELV or SELV)
Max. power
consumption 100 mA
Max. power
consumption
from AS interface 50 mA
6.7 Pneumatic data
Control medium Quality classes in accordance with ISO
8573-1
Dust content Class 7, max. particle size 40 µm, max. par-
ticle density 10 mg/m³
Water content Class 3, max. pressure dew point - 20 °C or
min. 10 degrees below the lowest operating
temperature
Oil content Class X, max. 25 mg/m³
Temperature range
of compressed air 0 – +60 °C
Pressure range 1.4 – 7 bar
Air flow rate 95 lN / min (at 1.4 bar2)) for aeration and
deaeration
150 lN / min (at 6 bar2)) for aeration and
deaeration
(QNn = 100 lN / min (according to definition for
pressure drop from 7 to 6 bar absolute).
Connections Internal thread G1/4“
2) Pressure specifications: Overpressure with respect to atmospheric
pressure
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Operating
7 OPERATING
7.1 Operating status
AUTOMATIC (AUTO)
Normal controller mode is implemented and monitored in AUTO-
MATIC operating status.
→LED 1 (MODE) flashes green.
MANUAL
In MANUAL operating status the valve can be opened and closed
manually via the keys.
→LED 1 (MODE) flashes green.
→LED 3 (FAULT) flashes red.
DIP switch 4 can be used to switch between the two operating sta-
tuses AUTOMATIC and MANUAL (see chapter “7.2.2 Function of the
DIP switches”).
7.2 Control and display elements of the
positioner
LED 1 (MODE)
LED 2 (POSITION)
LED 3 (FAULT)
DIP Switches
Key 2
Key 1
Communications interface
Fig. 3: Description of control elements
The positioner features 2 buttons, 4 DIP switches and 3 LEDs as a
display element.
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Operating
7.2.1 Configuration of the keys
The configuration of the 2 buttons inside the housing varies depending
on the operating status (AUTOMATIC / MANUAL).
The description of the operating status (AUTOMATIC / MANUAL) can
be found in the chapter entitled “7.1 Operating status”.
Key 1
Key 2
Fig. 4: Description of the buttons
MANUAL operating status (DIP switch 4 set to ON):
Key Function
1Aerate3)
(manually open / close the actuator)4)
2Deaerate3)
(manually open / close the actuator)4)
3) No function if the binary input was activated with the “MANUAL /
AUTOMATIC change-over” via the communications software.
4) Depending on the operating principle of the actuator.
Tab. 1: Configuration of the keys for MANUAL operating status
AUTOMATIC operating status (DIP switch 4 set to OFF):
Key Function
1 Press for 5 seconds to start the X.TUNE function
2 -
Tab. 2: Configuration of the keys for AUTOMATIC operating status
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Operating
7.2.2 Function of the DIP switches
ON
12 3 4
DIP-
Switches Position Function
1 ON Reversal of the effective direction of the
set-point value (DIR.CMD)
(set-point value 20 – 4 mA corresponds to
position 0 – 100%)
OFF Normal effective direction of the set-point
value (set-point value 4 – 20 mA corre-
sponds to position 0 – 100%)
2 ON Sealing function active.
The valve completely closes below 2%5)
and opens above 98% of the set-point
value (CUTOFF)
OFF No sealing function
DIP-
Switches Position Function
3 ON Correction characteristic for adjustment of
the operating characteristic (Linearization of
the operating characteristic CHARACT) 6)
OFF Linear characteristic
4 ON MANUAL operating status
OFF AUTO AUTOMATIC operating status
5) Factory setting can be changed via communications software.
6) Characteristic type can be changed via communications software.
Tab. 3: Function of the DIP switches
Information about the communications software:
The switching position of the DIP switch has priority over
the communications software!
If the values of the sealing function (CUTOFF) or the cor-
rection characteristic (CHARACT) are changed via the
communications software, the corresponding function must
be active (DIP switch set to ON).
The effective direction of the set-point value (DIR.CMD) can
be changed via the DIP switches.
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Operating
7.2.3 Display of the LEDs
LED 1, green (MODE)
Display of
AUTO, MANUAL, X.TUNE
LED 2, green / yellow (POSITION)
Display of actuator status
(open, closed, opens or closes)
LED 3, red (FAULT)
Error status
Fig. 5: LED display
LED 1 (green, MODE) and LED 3 (red, FAULT)
LED Status Display
green red
on off Acceleration phase when Power ON
flashing slowly off Operating status AUTO
flashing flashing Operating status MANUAL
alternating
flashing quickly off X.TUNE function
off on FAULT (see chapter
“7.3 Error messages”)
flashing flashing Operating status AUTO for sensor
break detection
slowly
Tab. 4: LED Status, LED 1 and LED 3
LED 2 (green / yellow, POSITION)
LED-Status Display
green yellow
on off Actuator closed
off on Actuator open
flashes slowly off Constant control deviation (actual
value > nominal value)
off flashes slowly Constant control deviation (actual
value > nominal value)
flashes quickly off Closing in operating status
MANUAL
off flashes quickly Opening in operating status
MANUAL
Tab. 5: LED Status, LED 2
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Operating
7.3 Error messages
7.3.1 Error messages in MANUAL and
AUTOMATIC operating status
Display Cause of fault Remedial
action
LED 3
(red,
FAULT)
on
Checksum error in data memory
→ Data memory defective
→ The device automatically switches
to an older (possibly not current)
data record.
not pos-
sible, device
defective.
Contact your
Bürkert sales
office.
Tab. 6: Error messages in MANUAL and AUTOMATIC operating status
7.3.2 Error messages while the X.TUNE
function is running
Display Cause of fault Remedial action
LED 3
(red,
FAULT)
on
No compressed air
connected
Connect compressed air
Compressed air failure
during the X.TUNE
Check compressed air
supply
Actuator or control
system deaeration side
leaking
not possible, device
defective
Control system aeration
side leaking
not possible, device
defective
The angular range of the
position sensor exceeds
180°
Correct the attachment of
the shaft for the position
sensor on the actuator (see
chapter “8.2.1” and “8.3.1”).
Tab. 7: Error messages while the X.TUNE function is running
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Attachment and assembly
8 ATTACHMENT AND ASSEMBLY
8.1 Installation of devices for the
hazardous area
When installing devices in the hazardous area, observe the “Addi-
tional information for use in the hazardous area“ enclosed with the
Ex-devices.
8.2 Attachment to a proportional valve
with NAMUR linear actuators
The valve position is transferred to the position sensor installed in
the positioner via a lever (according to NAMUR).
The attachment kit for the linear actuators can be purchased
from Bürkert as an accessory by quoting the identification
number 787215. The associated parts are listed in the “Tab.
8: Attachment kit for linear actuators”.
Part no. Quantity Name
1 1 NAMUR mounting bracket IEC 534
2 1 Hoop
3 2 Clamping piece
4 1 Driver pin
5 1 Conical roller
6a 1 NAMUR lever for stroke range 3 – 35 mm
6b 1 NAMUR lever for stroke range 35 – 130 mm
7 2 U-bolt
8 4 Hexagon bolt DIN 933 M8 x 20
9 2 Hexagon bolt DIN 933 M8 x 16
10 6 Circlip DIN 127 A8
11 6 Washer DIN 125 B8.4
12 2 Washer DIN 125 B6.4
13 1 Spring VD-115E 0.70 x 11.3 x 32.7 x 3.5
14 1 Spring washer DIN 137 A6
15 1 Locking washer DIN 6799 - 3.2
16 3 Circlip DIN 127 A6
17 3 Hexagon bolt DIN 933 M6 x 25
18 1 Hexagon nut DIN 934 M6
19 1 Square nut DIN 557 M6
21 4 Hexagon nut DIN 934 M8
22 1 Guide washer 6.2 x 9.9 x 15 x 3.5
Tab. 8: Attachment kit for linear actuators
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Attachment and assembly
8.2.1 Installation
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.
Yoke mount procedure:
→Using the bracket ② the clamping pieces ③, hexagon bolts ⑰
and circlips ⑯ attach the hoop to the actuator spindle.
3
17
2
16
Fig. 6: Attaching the hoop
→Select short or long lever according to the stroke of the actuator
(see “Tab. 8: Attachment kit for linear actuators”, part no. 6a/6b).
→Assemble lever (if not pre-assembled) (see “Fig. 7”).
17
16
12
6
19
18
14
12
22
5
4
13
15
Fig. 7: Assembling the lever
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Attachment and assembly
The gap between the driver pin and the axle should be the
same as the drive stroke. This results in the ideal angular
range of the lever of 60° (see “Fig. 8”).
Angular range of the position sensor:
The maximum angular range of the position sensor is 180°.
Rotational range of the lever:
To ensure that the position sensor operates at a good reso-
lution, the rotational range of the lever must be at least 30°.
The rotational movement of the lever must be within the
position sensor angular range of 180°.
The scale printed on the lever is not relevant.
60°
Ideal angular range
of the lever = 60°
(min. 30° / max. 180°)
The swivel movement of the lever must be within the position
sensor slewing range of 180°.
180°
Maximum rotational
range of the lever
Fig. 8: Rotational range of the lever
→Attach lever to the axle of the positioner and screw tight (⑰ and
⑲).
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Attachment and assembly
8.2.2 Attaching mounting bracket
→Attach mounting bracket ① to the back of the positioner with
hexagon bolts ⑨, circlip ⑩ and washers ⑪ (see “Fig. 9”).
The selection of the M8 thread used on the positioner
depends on the size of the actuator.
→To determine the correct position, hold the positioner with
mounting bracket on the actuator.
The conical roller on the lever of the position sensor in the hoop
must be able to run freely on the drive over the entire stroke
range.
At 50% stroke the lever position should be approximately hori-
zontal (see chapter “8.2.3 Aligning lever mechanism”).
①
⑨
⑩⑪
M8 thread
Fig. 9: Attaching mounting bracket
Attaching the positioner with mounting bracket for actuators
with cast frame:
→Attach mounting bracket to the cast frame with one or more
hexagon bolts ⑧, washers ⑪ and circlips ⑩ (see “Fig. 10”).
810 11
8
10
11
Fig. 10: Attach positioner with mounting bracket; for actuators with cast
frame
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