Burkert 8631 User manual

Operating Instructions
Bedienungsanleitung
Manuel d‘utilisation
Type 8631
TOP Control on/off

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 1706/_EU-EN_008 / Original DE

8631 - 1
CONTENTS
english
Contents
Operating Instructions
TOP Control on/off Type 8631
GENERAL NOTES
Symbols........................................................................................................................................................................................................................................................ 6
Intended use .......................................................................................................................................................................................................................................... 6
Safety notes............................................................................................................................................................................................................................................ 6
Notes for units with EEx-i approval..................................................................................................................................................................... 7
Notes for use in the Ex-area........................................................................................................................................................................................... 7
Scope of delivery............................................................................................................................................................................................................................ 7
Warranty conditions..................................................................................................................................................................................................................... 7
Transport, storage.......................................................................................................................................................................................................................... 8
Disposal........................................................................................................................................................................................................................................................ 8
TECHNICAL DATA
Construction and function.................................................................................................................................................................................................. 10
Features........................................................................................................................................................................................................................................................ 11
Operating conditions ................................................................................................................................................................................................................. 12
Conformity................................................................................................................................................................................................................................................. 12
Mechanical data............................................................................................................................................................................................................................... 12
Pneumatic data.................................................................................................................................................................................................................................. 12
Electrical data without bus control........................................................................................................................................................................ 13
Electrical data with bus control (AS interface).................................................................................................................................... 13
Electrical data with bus control (DeviceNet).......................................................................................................................................... 13
Electrical data with EEx-i approval...................................................................................................................................................................... 14

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CONTENTS
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COMMISSIONING
Fluidic installation.......................................................................................................................................................................................................................... 16
Installation of the valve.................................................................................................................................................................................................. 16
Turning theTOP Control on/off........................................................................................................................................................................... 16
Fluidic connection of theTOP Control on/off................................................................................................................................16
Opening the housing........................................................................................................................................................................................................ 16
Electrical installation ................................................................................................................................................................................................................. 17
Connection terminals for cable bushings..................................................................................................................................................... 17
24 V - version with inductive proximity switches (make contacts)............................................................................. 18
24 V - version with mechanical limit switches ....................................................................................................................................... 18
230 V - version with mechanical limit switches.................................................................................................................................... 19
Electrical installation of the TOP Control on/off with EEx-i approval ................................................................ 19
Connection terminals for cable connections............................................................................................................................................ 19
Setting the initiators or limit switches (option)..................................................................................................................................... 20
AS INTERFACE
Programming data......................................................................................................................................................................................................................... 22
Status display....................................................................................................................................................................................................................................... 23
Electrical connection................................................................................................................................................................................................................. 24
4-pole M12-circular plug connector..................................................................................................................................................................... 24
Cable bushing with connection terminals.................................................................................................................................................... 24
DEVICENET
Explanation of terms.................................................................................................................................................................................................................. 26
Technical data ..................................................................................................................................................................................................................................... 27
Maximum line lengths.............................................................................................................................................................................................................. 27
Overall line length....................................................................................................................................................................................................................... 27
Drop line length ............................................................................................................................................................................................................................. 27
Safety positions on bus failure ................................................................................................................................................................................... 27
Interfaces..................................................................................................................................................................................................................................................... 28
Electrical connection................................................................................................................................................................................................................. 28
Bus connection (circular plug M12, 5-pole).............................................................................................................................................. 28
Termination for DeviceNet systems.................................................................................................................................................................... 29
Network topology of a DeviceNet system ................................................................................................................................................. 29
Configuring theTOP Control on/off...................................................................................................................................................................... 30
DIP switches.................................................................................................................................................................................................................................... 30

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CONTENTS
english
Configuring of the process data............................................................................................................................................................................... 31
LED status display........................................................................................................................................................................................................................ 32
Statuses of the MNS LED............................................................................................................................................................................................... 33
Example of configuration.................................................................................................................................................................................................... 34
Installation of the EDS file................................................................................................................................................................................................ 34
Setting upt the process map......................................................................................................................................................................................... 34
SAFETY SETTINGS AND MAINTENANCE
Safety positions following failure of electrical and pneumatic auxiliary power................................. 38
Maintenance .......................................................................................................................................................................................................................................... 38
ANNEXE
EC Declaration on conformity 8631 EEx-i................................................................................................................................................ A02
Qualification Test Certificate PTB 00 ATEX 2077 X (complete unit)................................................................. A05
Qualification Test Certificate PTB 01 ATEX 2173 (for integral solenoid valve)................................ A07
Manufacturer's Declaration from Pepperl & Fuchs
(for integrated proximity switch)................................................................................................................................................................................ A10

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CONTENTS
english
Germany / Deutschland / Allemange
Bürkert Fluid Control System
Sales Centre
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 internet at:
Die Kontaktadressen finden Sie im Internet unter:
Les adresses se trouvent sur internet sous :
www.burkert.com Bürkert Company Locations
Contact addresses / Kontaktadressen
Germany / Deutschland / Allemange
Bürkert Fluid Control System
Sales Centre
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 internet at:
Die Kontaktadressen finden Sie im Internet unter:
Les adresses se trouvent sur internet sous :
www.burkert.com Bürkert Company Locations
Contact addresses / Kontaktadressen

8631 - 5
GENERAL NOTES
english
GENERAL
NOTES
Symbols................................................................................................................................................................................................................................................................. 6
Intended use................................................................................................................................................................................................................................................... 6
Safety notes..................................................................................................................................................................................................................................................... 6
Notes for units with EEx-i approval.............................................................................................................................................................................. 7
Notes for use in the Ex-area................................................................................................................................................................................................... 7
Scope of delivery..................................................................................................................................................................................................................................... 7
Warranty conditions............................................................................................................................................................................................................................. 7
Transport, storage................................................................................................................................................................................................................................... 8
Disposal................................................................................................................................................................................................................................................................ 8

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GENERAL NOTES
english
NOTE
ATTENTION!
Symbols
The following symbols are used in these operating instructions:
Marks a work step that you must carry out.
Marks notes on whose non-observance your health or the functioning of the device will
beendangered.
Safety notes
• Keep tostandard engineering rules in planning the use of and operating the device!
• Installation and maintenance work are only allowed by specialist personnel using suitable tools!
• Observe the currentregulations onaccident prevention and safety during operation and maintenance
of the device!
• Switch off the supply voltage in all cases before intervening in the system!
• Note that in systems under pressure, piping and valves may not be loosened!
• Take suitable precautions to prevent inadvertent operation or damage by unauthorized action!
• Make sure that after an interruption to the electrical or pneumatic supply, the process starts up again in
awell-defined, controlled manner!
• On non-observance of these notes and unauthorized interference with the device, we will refuse all
liability and the warranty on device and accessories will become void!
Marks important additionalinformation, tips andrecommendations.
Intended use
In order for the device to function perfectly and have a long service life, you must observe the information
given in these operating instructions and comply with the operating conditions and the permissible data
for theTOP Control on/off, in addition to the information for the respective pneumatically actuated valve,
which is specified in the „Technical Data“ chapter of these instructions and in the valve instructions.
Please note that theTop control on/off may not be used out-of-doors.
In view of the large number of possible applications and categories of use, you should check whether the
Top control on/off is suitable for your specific application, and carry out tests where necessary.

8631 - 7
GENERAL NOTES
english
Warranty conditions
Scope of delivery
Immediately after receipt of a shipment, make sure that the contents are undamaged and match the
scope of delivery stated on the packing slip. In the event of discrepancies, please contact our service
department immediately:
Bürkert Steuer- undRegelungstechnik, Service Department
Chr.-Bürkert-Str.13-17, D-76453 Ingelfingen
Tel.:[phone]/Fax:[phone]
eMail:ser[email protected]
This document contains no warranty promises.We refer in this connection to our General Conditions of
Sale and Business.The condition for the warranty is use of the unit for the intended purpose under the
specifiedapplication conditions.
The guarantee only covers faults in theTOP Control on/off series, and in the integrated
pneumatically-driven valve.No liability will, however, be accepted for subsequent
damage of any kind that may arise as a result of the failure or incorrect functioning of
the device.
ATTENTION!
Notes for use in the Ex-area
Please comply with the following:
• In the case of installation and operation in areas that have a risk of explosion, the respective national
regulations.In Germany, this isVDE 0165.
• When making electrical connections to the inherently safe circuit, the information given in the
correspondingconformity certificates.
• Always follow the information contained in the ATEX approval.
• Take suitable measures to avoid an electrostatic discharge from the plastic
parts of the housing (see EN 100 015 - 1).
• No component should be connected to the inputs and outputs of the circuit
board whose electrical data is outside the limits determined for intrinsically safe
operation quoted in the data sheet of the positioner.
• Work out on the device with the housing open should not be carried in very
dampor aggressive atmospheres.Takeprecautionsto exclude unintentional
mechanical damage to the circuit boards or their components. Limit the period
during which the unit is opened to that which is absolutely necessary.
Notes for units with EEx-i approval
Conformity
In accordance with the EC Declaration of conformity, Type 8631 is compliant with the EC Directives.
Standards
Conformity with the EC Directives is verified by the following standards:
EN 60079-0
Warranty

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GENERAL NOTES
english
Transport, storage
Transport and store the appliance in its original packing only.
ATTENTION!
Disposal
When disponsing of the appliance, observe the national standards for refuse disposal.
ATTENTION!

8631 - 9
TECHNICAL DATA
english
TECHNICAL DATA
Construction and function........................................................................................................................................................................................................... 10
Features................................................................................................................................................................................................................................................................ 11
Operating conditions.......................................................................................................................................................................................................................... 12
Conformity.......................................................................................................................................................................................................................................................... 12
Mechanical data........................................................................................................................................................................................................................................ 12
Pneumatic data.......................................................................................................................................................................................................................................... 12
Electrical data without bus control................................................................................................................................................................................. 13
Electrical data with bus control (AS interface)............................................................................................................................................. 13
Electrical data with bus control (DeviceNet).................................................................................................................................................. 13
Electrical data with EEx-i approval.............................................................................................................................................................................. 14

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TECHNICAL DATA
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Construction and function
The TOP Control on/off serves to drive pneumatically actuated process valves.It may be combined with
various vbalve types from the Bürkert process valve range (see data sheets for types 2000, 2001, 2002,
2012,2030, 2031, 2031K,2652, 2655 and2658).
TOP Control and process valve are connected by an adapter.This results in an integral system consisting
of repeater, actuator and valve function.
Various electrical and pneumatic connection variants are available.
Figure: Construction of the TOP Control on/off with cover removed
Screw for adjusting the lower proximity switch
With AS interface control: Initiator 2 / Data bit D2
Screw for adjusting the upper proximity switch
With AS interface control: Initiator 1 / Data bit D3
Exhaust connection
(marked: 3)
Control connections (connected in
the factory)
Electrical connection module
Pilot valve
(3/2 or 5/2-way solenoid valve)
With AS interface control: Pilot valve / Data bit D0
Pressure supply connection
(marked: 1)
Board with connection terminal + LED
Grub screw

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TECHNICAL DATA
english
Versions
forsingle anddouble-acting solenoidvalves
Control valves
Solenoid valve working on the rocker principle
1 x 3/2-way control valve with single-acting valve actuators
2 x 3/2-way control valve with double-acting valve actuators
TOP Control on/off with EEx-i approval:
Pilot valve - solenoid valve with EEx-i approval (PTB 01 ATEX 2173)
Electrical interfaces
Cablebushings withscrew terminals
Multipolecircular plug connector, 12-pole
With bus control (AS interface), the 4-pole M12 circular plug connectors standardized for this purpose or
cable bushings with screw terminals are used.
TOP Control on/off with EEx-i approval:
Cableconnector withscrew terminals
Pneumatic interfaces
1/4’’connectors in various threads (G, NPT, RC)
Housing
The housing of the TOP Control on/off is protected by a pressure relief valve from excessive internal
pressure, e.g. resulting from leaks.
TOP Control on/off with EEx-i approval:
Housingcoversecured againstunauthorised opening witha self-tapping screw.
Options
Position repeater and display
24V device:
Inductive proximity switches (initiators)
Position repeat via binary outputs (make contacts)
24V, 110V or 230V device:
Mechanical limit switches
Position repeat via binary outputs (make or break contacts)
Adjustment of the switching points on the position repeat switches is done during assembly of theTOP
Control on/off on the valve actuator.
TOP Control on/off with EEx-i approval:
Namursensors with manufacturer´sdeclaration
The sensors can be changed by the operator via adjusting screws.
Intelligent communication circuit
AS interface / DeviceNET
Automatic reduction of the holding current for the control valves.
Features

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TECHNICAL DATA
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Operating conditions
Operatingtemperature -10 ... + 50 °C
Protection type IP 65 to EN 60529
TOP Control on/off with EEx-i approval:
Type of "e" protection II 2 G EEx ia IIC T6
Conformity
CE - symbol conformity wrt.EMC Guideline 89/336/EEC
(only with correctly connected cable or plugs and sockets)
TOP Control on/off with EEx-i approval:
PTBapproval according toDIN EN 50014and 50020
Mechanical data
Dimensions see data sheet
Housingmaterial outer: PPE / PA, PSU; inner:PA 6
Sealingmaterial outer:EPDM;inner: NBR
Pneumatic data
Controlmedium quality classes to DIN ISO 8573-1
Dust content class 5: max. particle size 40 µm, max. particle density
10mg/m3
Water content class 3: max. pressure dew point - 20°C or min. 10
degreesbelow the lowestoperatingtemperature
Oil content class 5: max. 25 mg/m³
Temperaturerangeof
compressedair -10 ... +50°C
Pressurerange 3 ... 7 bar
Variation of supply pressure -
Air flow rate of control valve 100lN / min (for pressurizing and exhausting)
(QNn-valueto definition for pressure drop from 7 to 6 bar abs.)
Internal air consumption as
dimensioned 0.0 lN/min
Connections 1/4’’internal thread G / NPT / RC
ATTENTION!
TheTOP Control on/off is not suitable for outdoor use!
TOP Control on/off with EEx-i approval:
Note the Manufacturer's Declaration for proximity switches.

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TECHNICAL DATA
english
Electrical data without bus control
Connections 2 x M16 cable bushings with screw terminals for
cable cross-sections 0,14 ... 1,5 mm²
Voltage supply 24V DC ± 10 % residual ripple 10%
ATTENTION :Do not use industrial DC!
110 V AC / 230V AC
Powerconsumption < 2 W
Electrical data with bus control (AS interface)
Connections M12 circular plug connectors or
M20 cable bushings with screw terminals for
cable cross-sections 0,14 ... 1,5 mm² (seal for AS interface flat
cable is enclosed)
Voltage supply 29.5 ...31.6 V DC (to specification)
Max.current consumption 120 mA
innormaloperation ≤80 mA
aftercurrent reduction ≤50 mA
Outputs
Max. switching capacity 1 W via AS interface
Watchdog function integral
Inputs
Sensorsupply via AS interface
Sensorsupply voltage 24 V ± 10 %
Currentloading capacity max.60 mA, short-circuit proof
Switching level of 1 signal ≥10V
Input current limited to 6.5 mA
Input current for 0 signal ≤1.5 mA
Electrical data with bus control (DeviceNet)
Connection M12 - Micro Style circular plug 5-pole
Voltage supply 11 ... 24 V
Max.current consumption 125 mA
Outputs
Pick-upcurrent 120 mA
Holdingcurrent 80 mA
Inputs
"0" 0 ... 1.5 V
"1" ≥8V

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TECHNICAL DATA
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Functional data
Resistanceat 20°C (R20) 510ohm
Minimumterminal voltage 11.7V
Minimum current 23 mA
The maximum voltage and current values are determined by the permissible electrical operating
equipment.
Electrical data with EEx-i approval
Connections 2 x M16 cable connector with screw terminals for
cable cross-sections 0,14 ... 1,5 mm²
Sensorpower supply see Manufacturer's Declaration form Fa.Pepperl & Fuchs
(sieheAnhang)
Valvepowersupply see QualificationTest Certificate PTB 01 ATEX 2173
(sieheAnhang)
Safety requirements
he maximum permissible voltages and the associated maximum permissible short-circuit currents for the
corresponding gas group may be taken fromTable A1 in the standard DIN EN 50020, 1994 Edition.
In order that the maximum permissible temperature at the solenoid coil of the valve installed is not
exceeded, the following limits to the applied power for use in the corresponding temperature class must be
observed:
ATTENTION!
1) Ambient temperature for compl.TopControl 8631 (temperature inside the device is higher by max.5°C)
Temperature class Max. permissible ambient
temperature 1) [°C] Max. permissible
power [W]
T6
+50 0,4
+45 0,5
+40 0,7
+35 0,8
T5
+50 0,8
+45 1,0
+40 1,1
The control head must not be exposed directly to sunshine or strong light sources: this
wouldcause additional warming!

8631 - 15
COMMISSIONING
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COMMISSIONING
Fluidic installation.................................................................................................................................................................................................................................. 16
Installation of the valve................................................................................................................................................................................................................. 16
Turning theTOP Control on/off ......................................................................................................................................................................................... 16
Fluidic connection of the TOP Control on/off.................................................................................................................................................. 16
Opening the housing....................................................................................................................................................................................................................... 16
Electrical installation.......................................................................................................................................................................................................................... 17
Connection terminals for cable bushings............................................................................................................................................................. 17
24 V version with inductive proximity switches (make contacts) ......................................................................................... 18
24 V version with mechanical limit switches.................................................................................................................................................. 18
230 V version with mechanical limit switches ................................................................................................................................................ 19
Electrical installation of the TOP Control on/off with EEx-i approval....................................................................... 19
Connection terminals for cable connections.................................................................................................................................................... 19
Setting the initiators or limit switches (option).............................................................................................................................................. 20

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COMMISSIONING
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Fluidic installation
See the relevant data sheet for dimensions ofTOP Control on/off and the variants of the complete
device, consisting ofTOP Control on/off, pneumatic actuator and valve.
Installation of the valve
For dimensions and threads, see data sheet for the process valve.
Turning the TOP Control on/off
If, after installation of the continuous valve, the LEDs of the TOP Control on/off are poorly visible or it is
difficult to attach the cable or hoses, the TOP Control on/off may be rotated relative to the pneumatic
actuator.
Procedure:
Disconnect the fluidic connection betweenTOP Control on/off and pneumatic actuator.
Loosen the grub screws (hex socket SW 3) recessed into the side of the housing.
Rotate the TOP Control on/off without lifting into the desired position.
Retightenthe grubscrews with moderate torque.
Remake the fluidic connection between TOP Control on/off and pneumatic actuator, using longer hoses
if necessary.
Fluidic connection of the TOP Control on/off
Apply the supply pressure to connection 1 (3...7 bar, instrument air, free from oil, water and dust).
Attach an exhaust line or a silencer to connection 3.
Opening the housing
Removeany leadseals orfastenings presentbetween cover and housing.
Turn the transparent cover of theTOP Control on/off slightly anticlockwise and lift it off.
ATTENTION!
3 Exhaust connection
22double-acting pressurized at zero current
single-acting not driven
21pressurized when pilot valve under current
1 Pressure supply connection
No back pressure shall be built up as a result of the installations.This could be
detrimental to the functioning of the device! Use a hose with sufficient cross-section!

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COMMISSIONING
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Electrical installation
For making electrical contact to theTOP Control on/off, various connection concepts are available.
Terminal allocation for cable bushings or plug connectors for bus control is explained in the following.
Connection terminals for cable bushings
Openthehousing.
Connect the wires th the terminals (see connection allocation).
The board with designation of the terminals and LEDs is shown in the following diagram.
Plug connector for initiatior
Limit switch 1
Plug connector for initiatior
Limit switch 2
LED initiator
Limit switch 1
operated
LED initiator
Limit switch 2
operated
LED supply
Initiators
Limit switches
LED
Valve on
NOTE
Limit switches: may be used as make (terminals NO) or
break (terminals NC) contacts.
ControlLEDs: light when respective limit switch is operated
mechanically, i.e.when the valve end position is reached.

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COMMISSIONING
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24 V - version with mechanical limit switches
24 V - version with inductive proximity switches (make contacts)
+24 V DC
9
7
8
5
6
S1
S2 NC1 24V/0V (max. 5 A)
NO1 0V/24V (max. 5 A)
NC2 24V/0V (max. 5 A)
NO2 0V/24V (max. 5 A)
4
3GND
GND
2
1
0/24 V DC ± 10 %
residual ripple 10 %
+24 V DC
9
8
6
4
3
S1
S2 Output 1 (0V/24V)
Output 2 (0V/24V)
GND
GND
2
1
0/24 V DC ± 10 %
residual ripple 10 %
Terminal
no. Allocation External connection
1 Valve actuation GND
2 Valve actuation 0 V / 24 V
3 Initiator supply GND
4 Common reference for initiators GND
5 not connected
6 Binary output initiator 2 (NO)
7 not connected
8 Binary output initiator 1 (NO)
9 Initiator supply + 24 V
Terminal
no. Allocation External connection
1 Valve actuation GND
2 Valve actuation 0 V / 24 V
3 Limit switch supply GND
4Common reference for limit switches
GND
5 Output limit switch 2 (NC)
6 Output limit switch 2 (NO)
7 Output limit switch 1 (NC)
8 Output limit switch 1 (NO)
9 Limit switch supply + 24 V