Burkert 8798 User manual

Operating Instructions
Bedienungsanleitung
Manuel d‘utilisation
Type 8798
Remote Sensor
Système de mesure de déplacement linéaire et rotatif pour régulateur de position
Rotativer und linearer Wegaufnehmer für Stellungsregler
Rotating and linear position measuring system for position controllers

We reserve the right to make technical changes without notice.
Technische Änderungen vorbehalten.
Sous réserve de modifications techniques.
© Bürkert Werke GmbH, 2009 - 2014
Operating Instructions 1412/07_EU-ML_00806152 / Original DE

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1 OPERATING INSTRUCTIONS ................................................................4
1.1 Symbols .......................................................................................4
1.2 Definition of term / abbreviation .............................................4
2 AUTHORIZED USE ......................................................................................5
2.1 Restrictions .................................................................................5
3 BASIC SAFETY INSTRUCTIONS ..........................................................5
4 GENERAL INFORMATION ........................................................................7
4.1 Contact addresses ...................................................................7
4.2 Warranty ......................................................................................7
4.3 Information on the internet ......................................................7
5 SYSTEM DESCRIPTION ............................................................................7
5.1 General description ..................................................................7
6 TECHNICAL DATA ........................................................................................9
6.1 Conformity ................................................................................... 9
6.2 Standards ....................................................................................9
6.3 Licenses ......................................................................................9
6.4 Operating conditions ................................................................ 9
6.5 Mechanical data.........................................................................9
6.6 Pneumatic data ........................................................................10
6.7 Type label (example) ...............................................................10
6.8 UL additional label (example) ...............................................11
6.9 Electrical data ...........................................................................11
7 CONTROL AND DISPLAY ELEMENTS ............................................12
7.1 Display elements of the linear Remote Sensor ................12
7.2 Display elements of the rotating Remote Sensor ............13
8 INSTALLATION ............................................................................................13
8.1 Safety instructions ...................................................................13
8.2 Installation of the linear Remote Sensor Type 8798 ......14
8.3 Installation of the rotating Remote Sensor Type 8798 ...21
9 FLUID INSTALLATION ............................................................................. 28
9.1 Safety instructions ...................................................................28
9.2 Installing the process valve ...................................................29
9.3 Installation of positioner Type 8791, Type 8792/8793 . . 29
9.4 Pneumatic connection ............................................................29
10 ELECTRICAL INSTALLATION ...............................................................32
10.2 Electrical connection to the positioner Type 8791 or
Type 8792/8793 .....................................................................33
10.3 Electrical connection of the rotating Remote Sensor
to the positioner Type 8791 or Type 8792/8793 ............34
11 START-UP ......................................................................................................34
11.1 Safety instructions ...................................................................34
12 MAINTENANCE ...........................................................................................35
12.1 Safety instructions ...................................................................35
12.2 Maintenance work ...................................................................35
13 TRANSPORT, STORAGE, DISPOSAL .............................................. 36
Contents
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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.
Read the operating instructions carefully and thoroughly. Study
in particular the chapters entitled “Basic safety instructions” and
“Authorized use”.
▶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
Remote Sensor Type 8798.
In these instructions, the abbreviation “Ex” always refers to “poten-
tially explosive”.
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Authorized use
2 AUTHORIZED USE
Non-authorized use of the Remote Sensor may be dangerous
to people, nearby equipment and the environment.
The device is designed to be mounted on pneumatic actuators for
measuring distance on control valves. Operation is possible only
in combination with position controllers.
▶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 oper-
ating 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, it is essential prior to
installation to study and, if necessary, to test whether the Remote
Sensor 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 device only as intended.
2.1 Restrictions
If exporting the system/device, observe any existing restrictions.
3 BASIC SAFETY
INSTRUCTIONS
These safety instructions do not make allowance for any
• contingencies and events which may arise during the installation,
operation and maintenance of the devices.
• local safety regulations – the operator is responsible for observing
these regulations, also with reference to the installation personnel.
DANGER!
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.
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Basic safety instructions
WARNING!
General hazardous situations.
To prevent injury, ensure that:
▶In the potentially explosion-risk area the Remote Sensor Type
8798 may be used only according to the specification on the
separate Ex type label. For use observe the additional instructions
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.
▶Do not supply the medium connectors of the system with aggres-
sive or flammable media.
▶Do not supply the medium connectors with any liquids.
▶When unscrewing and screwing in the body casing or the trans-
parent cap, do not hold the actuator of the process valve but the
connection housing of Type 8798.
▶Do not physically stress 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.
▶The system cannot be activated unintentionally.
▶Installation and repair work may be carried out by authorized
technicians only and with the appropriate tools.
▶The device may be operated only when in perfect condition and
in consideration of the operating instructions.
▶After an interruption in the power supply or pneumatic supply,
ensure that the process is restarted in a defined or controlled
manner.
▶The general rules of technology apply to application planning
and operation of the device.
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
minimize 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 the printed
operating instructions.
And also on the Internet at: www.burkert.com
4.2 Warranty
The warranty is only valid if the Remote Sensor Type 8798 is used
as intended in accordance with the specified application conditions.
4.3 Information on the internet
The operating instructions and data sheets for Type 8798 can be found
on the Internet at: www.burkert.com
5 SYSTEM DESCRIPTION
5.1 General description
The Remote Sensor Type 8798 is a digital non-contact position sensor
for use on pneumatically actuated variable speed drives. This Remote
Sensor is used in combination with the positioners (remote design)
Type 8791 and Type 8792/8793. The Remote Sensor cannot be used
as a stand-alone device. Its main task is to measure the position of a
pneumatically actuated control valve.
5.1.1 Features
Designs
The Remote Sensor is available as a linear and rotating position sensor
to be able to record the position of stroke and swivel actuators.
Position sensor
Robust, non-contact and wear-free position sensor that is connected
to the position controller via a circular line for supply and serial data
transmission.
Display
Display of operating modes via 2 LEDs.
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System description
5.1.2 Combination with valve types and
mounting versions
The Remote Sensor Type 8798 can be mounted on different control
valves. For example on valves with piston or membrane actuator. The
actuators can be single-acting or double-acting.
Linear Remote Sensor
This linear Remote Sensor can be fitted to Bürkert process valves of
the following types: 2103, 2300, 2301, 26xx and 27xx.
Remote Sensor for
Type 26xx and 27xx
Remote Sensor for
Type 2103, 2300 and 2301
Fig. 1: Linear Remote Sensor
Rotating Remote Sensor
This rotating Remote Sensor can be fitted to push actuators
according to NAMUR recommendation (DIN IEC 534 T6) or to
swivel actuators according to VDI/VDE 3845.
Fig. 2: Rotating Remote Sensor
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Technical data
6 TECHNICAL DATA
6.1 Conformity
In accordance with the EC Declaration of conformity, the Remote
Sensor Type 8798 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 “6.9 Electrical data”.
6.4 Operating conditions
WARNING!
Solar radiation and temperature fluctuations may cause mal-
functions 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.
Ambient temperature: -25 °C – +80 °C
Degree of protection:
Evaluated by the manufacturer: Evaluated by UL:
IP65 / IP67 according to EN
605291)
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 “9.4 Pneumatic
connection”.
6.5 Mechanical data
Dimensions: See data sheet
Housing material: Linear Remote Sensor:
exterior: PPS, PC, VA,
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Technical data
Rotating Remote Sensor:
exterior: Chrome-plated steel, stainless
steel, aluminum
Sealing material: Linear Remote Sensor:
exterior: EPDM
inside: NBR
Rotating Remote Sensor:
exterior: Neoprene, PVC
inside: NBR
Area covered by the
measurement sensor: Linear: 0 – 45 mm
Rotating 0° – 360°
6.6 Pneumatic data
Only if installed on process valves with internal air supply
Type 2103, 2300 and 2301
Temperature range
of compressed air: see the process valve operating
instructions
Pressure range: 0 – 7 bar
Connections: Plug-in hose connector Ø 6mm / 1/4"
Socket connection G1/8
6.7 Type label (example)
8798 PU02 digital
P = 0 ... 7 bar
24V IP65/67
Tamb -25 - +80 °C
S/N 1001
00123456
D-74653 Ingelfingen
W15MA
Identification number; Date of
manufacture (encoded)
Operating voltage; Degree of
protection
Type; Features of the type code applicable to UL
and ATEX
Pneumatic Controller
Bar code
Serial number ; CE mark
Max. ambient temperature
Fig. 3: Example of type label; linear Remote Sensor
Wire colors
Operating
voltage
Serial
number
Electrical configuration
Resolution
Fig. 4: Example of type label; rotating Remote Sensor
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Technical data
6.8 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
Fig. 5: UL additional label (example)
6.9 Electrical data
WARNING!
Only circuits with limited power may be used for UL approved
components according to “NEC Class 2”.
Connections: Linear Remote Sensor:
Round cable 10 m
Rotating Remote Sensor:
Round cable 2 m shielded (maximum
extension 10 m)
Supply voltage: (via the positioner Type 8791 or Type
8792/8793)
Linear Remote Sensor:
24 V DC ± 10 %
Rotating Remote Sensor:
10 – 30 V DC
For UL devices: use „NEC Class 2“ power
supply
Power consumption: Linear Remote Sensor: < 0.3 W
Rotating Remote Sensor: < 0.8 W
Protection class: 3 as per DIN EN 61140 (VDE 0140-1)
Communication: via serial interface RS485 (included in the
supply cable)
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Control and display elements
7 CONTROL AND DISPLAY
ELEMENTS
Special operation of this Remote Sensor is not necessary. The necessary
settings are made on the positioner Type 8791 or Type 8792/8793
(see relevant chapter of the positioner operating instructions).
7.1 Display elements of the linear
Remote Sensor
2 LEDs, which are also visible from outside through the transparent
cap, display the sensor mode.
Status
LED
green
Status
LED
red
Display Remedial action
off off No operating
voltage
Check the supply voltage
of positioner
Type 8791,
Type 8792/8793.
Check the cable con-
nection configuration.
flashing on
Sensor is operated
outside the cov-
erage area.
Check adaption to
actuator; the puck on
the switch spindle must
not exceed the sensor
surface.
flashing off Sensor is in operation and sending position value
Tab. 1: LED display elements; linear Remote Sensor
Status LED green
Status LED red
View without transparent cap
Fig. 6: LED display elements; linear Remote Sensor
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Installation
7.2 Display elements of the rotating
Remote Sensor
An LED on the upper side of the sensor housing is used to indicate
the sensor mode.
Status
LED Display Remedial action
off No operating voltage Check supply voltage, connection.
on
(green) Ready for operation -
on
(red)
Starting phase
(during the acceleration
phase – booting)
-
Sensor error
Switch off the operating voltage
and switch it on again. The sensor
is defective if the display con-
tinues to show “Sensor error”.
Tab. 2: LED display elements; rotating Remote Sensor
Status
LED
Fig. 7: LED display elements; rotating Remote Sensor
8 INSTALLATION
8.1 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.
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Installation
8.2 Installation of the linear Remote
Sensor Type 8798
8.2.1 Attachment to process valves with
internal air supply (series 2103,
2300 and 2301)
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)
Fig. 8: Installation of linear Remote Sensor, series 2103, 2300
and 2301
→Unscrew the transparent cap on the actuator and unscrew the
position display (yellow cap) on the spindle extension (if present).
→For version with plug-in hose connector, remove the collets
(white nozzles) from both pilot air ports (if present).
O-ring
Spindle extension
Guide element
Actuator cover
Groove ring
Puck
Switch spindle
max. 5 Nm
max. 1 Nm
Fig. 9: Installation of the switch spindle, series 2103, 2300 and
2301
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.
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Installation
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.
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 Remote Sensor is being installed, the collets of
the pilot air ports must not be fitted to the actuator.
Form seal
Pilot air ports
Caution:
Collets must not be fitted!
Fig. 10: Installation of the sealing rings, series 2103, 2300 and
2301
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Installation
3. Install linear Remote Sensor
→Align the puck and the Remote Sensor in such a way that
1. the puck engages in the guide rail of the Remote
Sensor and
2. the connection pieces of the Remote Sensor engage in the
pilot air ports of the actuator (see “Fig. 12”)
Guide rail
Puck
Fig. 11: Aligning the puck
→Push the Remote Sensor without turning it onto the actuator until
no gap is visible on the form seal.
NOTE!
Too high torque when screwing in the fastening screw does
not ensure degree of protection IP65 / IP67.
▶The fastening screws may be tightened to a maximum torque
of 1.5 Nm only.
→Attach the Remote Sensor to the actuator using the two side
fastening screws. In doing so, tighten the screws only hand-tight
(max. torque: 1.5 Nm).
Connection
pieces
Pilot air
ports
Fastening screws
max. 1.5 Nm
Fig. 12: Installation of linear Remote Sensor, series 2103, 2300
and 2301
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Installation
8.2.2 Attachment to process valves to
series 26xx and 27xx
Procedure:
1. Install switch spindle
Guide piece
Spindle extension
Actuator
Fig. 13: Installing the switch spindle, series 26xx and 27xx - 1
→Unscrew the already fitted guide piece from the actuator
(if present).
→Remove intermediate ring (if present).
→Press the O-ring downwards into the cover of the actuator.
Guide element
O-ring
Spindle extension
Puck
Switch spindle
Spindle (actuator)
Fig. 14: Installing the switch spindle, series 26xx and 27xx - 2
→Actuator size 125 and bigger:
remove existing spindle extension and replace with the new one.
To do this, apply some screw locking paint (Loctite 290) in the
tapped bore of the spindle extension.
→Screw the guide element into the cover of the actuator using a
face wrench2) (torque: 8.0 Nm).
→To secure the switch spindle, apply some screw locking paint
(Loctite 290) to the thread of the switch spindle.
→Screw the switch spindle onto the spindle extension. To do this,
there is a slot on the upper side (maximum torque: 1 Nm).
→Push the puck onto the switch spindle until it engages.
2) journal Ø: 3 mm; journal gap: 23.5 mm
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Installation
2. Install linear Remote Sensor
→Push the Remote Sensor onto the actuator. The puck must be
aligned in such a way that it is inserted into the guide rail of the
Remote Sensor.
Guide rail
Puck
Fig. 15: Aligning the puck
→Press the Remote Sensor all the way down as far as the actuator
and turn it into the required position.
Fastening
screws (2x)
max. 1.5 Nm
Fig. 16: Installing the linear Remote Sensor
NOTE!
Too high torque when screwing in the fastening screw does
not ensure degree of protection IP65 / IP67.
▶The fastening screws may be tightened to a maximum torque of
1.5 Nm only.
→Attach the Remote Sensor to the actuator using the two side fas-
tening screws. In doing so, tighten the fastening screws hand-tight
only (maximum torque: 1.5 Nm).
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Installation
8.2.3 Rotating the actuator module
The actuator module (Remote Sensor and actuator) can
be rotated for straight seat valves and angle seat valves
belonging to series 2300, 2301 and 27xx only.
The position of the connections can be aligned steplessly by rotating
the actuator module (Remote Sensor and actuator) through 360°.
Only the entire actuator module can be rotated. The Remote
Sensor cannot be rotated contrary to the actuator.
The process valve must be in the open position for
alignment of the actuator module.
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.
Procedure:
→Clamp valve body in a holding device (only required if the process
valve has not yet been installed).
→Control function A: Open process valve.
→Using a suitable open-end wrench, counter the wrench flat on
the pipe.
Key contour
Hexagon
Series 27xx
Series 2300 and 2301
Nipple
Actuator
module
Fig. 17: Rotating the actuator module
→Series 2300 and 2301 with key contour:
Fit special key3) exactly in the key contour on the underside of
the actuator.
→Series 2300, 2301 and 27xx with hexagon:
Place suitable open-end wrench on the hexagon of the actuator.
3) The special key (665702) is available from your Bürkert sales office.
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Installation
WARNING!
Risk of injury from discharge of medium and pressure.
If the direction of rotation is wrong, the housing interface may become
detached.
▶Rotate the actuator module in the specified direction only
(series 2300 and 2301 or 27xx, see “Fig. 18”).
→Series 2300, 2301 and 27xx with hexagon:
Rotate counter-clockwise (as seen from below) to bring the
actuator module into the required position.
→Series 2300 and 2301 with key contour:
Rotate clockwise (as seen from below) to bring the actuator
module into the required position.
Special key
Open-end wrench
Series 2300 and 2301
with key contour
Series 2300, 2301
and 27xx with hexagon
Fig. 18: Rotating with special key / open-end wrench
8.2.4 Rotating the linear Remote Sensor
for process valves belonging to
series 26xx and 27xx
If the connecting cable cannot be fitted properly following installation
of the process valve, the Remote Sensor can be rotated contrary to
the actuator.
Fastening
screw (2x)
Actuator
Remote
Sensor
Fig. 19: Rotating the linear Remote Sensor, series 26xx and 27xx
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