Burkert 8691 User manual

Quickstart
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Type 8691
Control Head
Steuerkopf
Tête de commande

We reserve the right to make technical changes without notice.
Technische Änderungen vorbehalten.
Sous réserve de modifications techniques.
© 2007 - 2012 Bürkert Werke GmbH
Quickstart 1207/03_EU-ML_00806079 / Original DE

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Contents
1. QUICKSTART .....................................................................................................4
1.1. Definition of term “device” ..............................................................4
1.2. Symbols ..............................................................................................4
2. AUTHORIZED USE .........................................................................................5
2.1. Restrictions ........................................................................................5
3. BASIC SAFETY INSTRUCTIONS .............................................................5
4. GENERAL INFORMATION ...........................................................................7
4.1. Contact address ...............................................................................7
4.2. Warranty ............................................................................................. 7
4.3. Information on the Internet ............................................................. 7
5. SYSTEM DESCRIPTION ...............................................................................7
5.1. Structure and function ....................................................................7
5.2. Control head for integrated installation on the 21xx series .... 8
5.3. Model for control of process valves belonging
to the 20xx series .............................................................................8
6. TECHNICAL DATA ...........................................................................................9
6.1. Conformity ......................................................................................... 9
6.2. Standards ........................................................................................... 9
6.3. Operating conditions .......................................................................9
6.4. Mechanical data ...............................................................................9
6.5. Type label ...........................................................................................9
6.6. Pneumatic data ...............................................................................10
6.7. Electrical data..................................................................................10
7. INSTALLATION ............................................................................................... 12
7.1. Safety instructions .........................................................................12
7.2. Installation of the control head on process valves
of series 21xx ..................................................................................12
7.3. Installation of the control head on process valves
of series 20xx ..................................................................................13
8. FLUID INSTALLATION ................................................................................15
8.1. Safety instructions .........................................................................15
8.2. Installing the process valve ..........................................................16
8.3. Pneumatic connection of the control head ..............................16
9. ELECTRICAL INSTALLATION ..................................................................17
9.1. Safety instructions .........................................................................17
9.2. Electrical installation 24 V DC ....................................................17
9.3. Display elements 24 V DC ...........................................................19
9.4. Programming data AS-Interface .................................................19
9.5. Electrical installation AS-Interface ..............................................20
9.6. Display elements AS-Interface ....................................................22
9.7. Electrical installation DeviceNet ..................................................23
9.8. Display elements DeviceNet ........................................................25
10. TEACH FUNCTION .................................................................................... 27
10.1. Starting the teach function ........................................................27
11. SAFETY POSITIONS ................................................................................28
12. ACCESSORIES ...........................................................................................28
13. PACKAGING, TRANSPORT, STORAGE .......................................... 28
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Quickstart
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 a procedure that must be carried out.
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 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 control head Type 8691.
The operating instructions can be found on the enclosed CD
and on the Internet at:
www.burkert.com
1.1. Definition of term “device”
The term “device” used in these instructions always stands for the
control head Type 8691.
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Authorized use
2. AUTHORIZED USE
Non-authorized use of the control head Type 8691 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.
• 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, before installa-
tion, 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 reliable and fault-
less operation.
• Use the control head Type 8691 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 – high pressure!
• Before dismounting pneumatic lines and valves, turn off the
pressure and vent the lines.
Risk of electric shock!
• Before reaching into the device or the equipment, 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
General hazardous situations.
To prevent injury, ensure:
• 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.
• 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.
The control head Type 8691 was developed with due consider-
ation given to the accepted safety rules and is state-of-the-art.
Nevertheless, dangerous situations may occur.
Failure to observe this operating manual and its operating instructions
as well as unauthorized tampering with the device release us from
any liability and also invalidate the warranty covering the devices
and accessories!
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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 8691 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 8691 can be found
on the Internet at: www.burkert.com
5. SYSTEM DESCRIPTION
5.1. Structure and function
Control head
Actuator
Valve body
Process valve
Fig. 1: Structure
The control head Type 8691 can control single or double-acting
process valves and has been optimized for the integrated modular fitting
of series 21xx process valves (Element) . 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 “5.3”.
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.
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System description
Apart from the electrical position feedback, the status of the device
is optically displayed on the control head itself by a colored high-
power LED.
Option: Communication possible via AS-Interface or DeviceNet.
5.2. Control head for integrated
installation on the 21xx series
Electrical connection
Cable gland
M16 x 1.5 or
Circular plug-in
connector M12 x 1
Exhaust air port
(label: 3)
Pressure limiting valve (for
protection against too high
internal pressure in case
of error)
Pilot air port
(label: 1)
Teach function
Top LEDs
Air intake filter
View without transparent cap
Body
casing
Fig. 2: Structure for process valves belonging to the 21xx series
5.3. Model for control of process valves
belonging to the 20xx series
A special model enables the control head Type 8691 to be attached
to process valves belonging to the 20xx series.
This model features has a different pneumatic connection module so
that the pilot air ports can be connected to the outside of the actuator
(see “Fig. 3”).
Pilot air outlet 21
Fastening screws (2 x)
Pilot air outlet 22
Fig. 3: Structure for process valves belonging to the 20xx series
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Technical data
6. TECHNICAL DATA
6.1. Conformity
In accordance with the Declaration of conformity, the control head
Type 8691 is compliant with the EC Directives.
6.2. Standards
Conformity with the EC Directives is verified by the following
standards.
EN 61000-6-3, EN 61000-6-2, EN 61010-1
6.3. 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: 0 ... +55 °C
Protection class: IP65 / IP67 according to EN 60529
(only if cables, plugs and sockets have
been connected correctly
and in compliance with the exhaust air
concept in chapter “8.3. Pneumatic con-
nection of the control head”).
6.4. Mechanical data
Dimensions See data sheet
Body material exterior: PPS, PC, VA
Sealing material exterior: EPDM
interior: NBR
Stroke range of valve spindle: 2 – 28 mm
2 – 47 mm
6.5. Type label
Example:
8691 AS-i 62SI
single act Pilot 3,0
Pmax 7bar
Tamb 0°C - +55°C
Ser.-Nr. 001000
00179024
D-74653 Ingelfingen
W14UN
CE
Identification number
Supply voltage / Control
Nominal pressure
Typ
Control function
- Pilot valve
Bar-code
Serial number -
CE mark
Max. ambient
temperature
Fig. 4: Type label (example)
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Technical data
6.6. Pneumatic data
Control medium: neutral gases, air
Quality classes in accordance with DIN ISO 8573-1
Dust content Class 5: 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 5: max. 25 mg/m³
Temperature range
control medium: 0 ... +60 °C
Pressure range
control medium: 3 ... 7 bar
Air output of pilot valve: 250 lN / min
(for aeration and deaeration)
(QNn - value according to definition for
pressure drop from 7 to 6 bar absolute)
Connections: Plug-in hose connector ∅ 6 mm / 1/4“
Socket connection G 1/8
6.7. Electrical data
6.7.1. Electrical data without bus control
24 V DC
Connections: Cable gland M16 x 1.5, wrench size 22
(clamping area 5 – 10 mm)
with screw-type terminals for cable cross-
sections 0.14 – 1.5 mm²
Circular plug-in connector
(M12 x 1, 8-pole)
Pilot valve:
Supply 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)
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Technical data
6.7.2. Electrical data with AS-Interface bus
control
Connections: Circular plug-in connector
(M12 x 1, 4-pole)
Supply voltage: 29.5 V – 31.6 V DC
(according to specification)
Outputs
Max. switching capacity: 1 W via AS-Interface
Watchdog function: integrated
Devices without external supply voltage:
Max. power consumption: 120 mA
Power consumption input during
normal operation:
(after current reduction;
valve + 1 end position reached) 90 mA
Devices with external supply voltage:
External supply voltage: 24 V ± 10 %
The power supply unit must include a secure disconnection in
accordance with IEC 364-4-41 (PELV or SELV)
Max. power consumption: 55 mA (after current reduction
≤ 30 mA)
Max. power consumption
from AS-Interface: 55 mA
6.7.3. Electrical data with DeviceNet bus
control
Connections: Circular plug-in connector
(M12 x 1, 5-pole)
Supply 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
Only for control head without pre-assembled process valve.
7.1. Safety instructions
DANGER!
Risk of injury from high pressure!
• Before dismounting pneumatic lines and valves, turn off the
pressure and vent the lines.
Risk of electric shock!
• Before reaching into the device or the equipment, 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 on
process valves of series 21xx
Procedure:
When the control head is being installed, the collets of the
pilot air ports must not be fitted to the actuator.
→Align the puck holder and the control head until
1. the puck holder can be inserted into the guide rail of the
control head (see “Fig. 5”) and
2. the supports of the control head can be inserted into the
pilot air ports of the actuator (see also “Fig. 6”).
NOTE!
Damaged printed circuit board or malfunction!
• Ensure that the puck holder is situated flat on the guide rail.
Guide rail
Puck holder
Fig. 5: Aligning the puck holder
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Installation
→Push the control head, 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 protection class IP65 / IP67!
• The fastening screws may be tightened to a maximum torque of
0.5 Nm only.
→Attach the control head to the actuator using the two side fas-
tening screws. In doing so, tighten the screws only hand-tight
(maximum torque: 0.5 Nm).
Supports
Pilot air ports Fastening
screws
max. 0.5 Nm
Actuator
Fig. 6: Installation of control head, 21xx series
7.3. Installation of the control head on
process valves of series 20xx
Procedure:
Guide rail
Puck holder
Fig. 7: Aligning the puck holder
→Push the control head onto the actuator. The puck holder must
be aligned in such a way that it is inserted into the guide rail of
the control head (see “Fig. 7”).
NOTE!
Damaged printed circuit board or malfunction!
• Ensure that the puck holder is situated flat on the guide rail.
→Press the control head all the way down as far as the actuator
and turn it into the required position.
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Installation
Ensure that the pneumatic connections of the control head
and those of the valve actuator are situated preferably verti-
cally one above the other (see “Fig. 8”).
NOTE!
Too high torque when screwing in the fastening screw does
not ensure protection class IP65 / IP67!
• The fastening screws may be tightened to a maximum torque of
0.5 Nm only.
→Attach the control head to the actuator using the two side fas-
tening screws. In doing so, tighten the fastening screws hand-
tight only (maximum torque: 0.5 Nm).
Pilot air outlet 21
Pilot air outlet 22
Upper pilot air port
Lower pilot air port
Example
∅ 80, CFA
Fig. 8: Installing the pneumatic connection, 20xx series
→Screw the plug-in hose connectors onto the control head and
the actuator.
→Using the hoses supplied in the accessory kit, make the pneu-
matic connection between the control head and actuator with
the “Tab. 1: Pneumatic connection to actuator”.
NOTE!
Damage or malfunction due to ingress of dirt and moisture!
• To comply with protection class IP65 / IP67, connect the pilot
air outlet (only for CFA or CFB) which is not required to the free
pilot air port of the actuator or seal with a plug.
“In rest position” means that the pilot valves of the control
head Type 8691 are isolated or not actuated.
If the ambient air is humid, a hose can be connected
between pilot air outlet 22 of the control head and the
unconnected pilot air port of the actuator for control
function A or control function B. As a result, the spring
chamber of the actuator is supplied with dry air from the
vent duct of the control head.
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Fluid installation
Control function A (CFA)
Process valve closed in rest position (by spring force)
Control head
Pilot air outlet 2221
or
2221
Actuator
Upper pilot air port
Lower pilot air port
Control function B (CFB)
Process valve open in rest position (by spring force)
Control head
Pilot air outlet 2221
or
2221
Actuator
Upper pilot air port
Lower pilot air port
Control function I (CFI)
Process valve in rest position closed open
Control head
Pilot air outlet 22212221
Actuator
Upper pilot air port
Lower pilot air port
Tab. 1: Pneumatic connection to actuator
8. FLUID INSTALLATION
8.1. Safety instructions
DANGER!
Risk of injury from high pressure!
• Before dismounting pneumatic lines and valves, turn off the
pressure and vent the lines.
Risk of electric shock!
• Before reaching into the device or the equipment, 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 installation, ensure a controlled restart.
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Fluid installation
8.2. Installing the process valve
Thread type and dimensions can be found in the corresponding data
sheet.
→Connect the valve according to the operating instructions for the
valve.
8.3. Pneumatic connection of the control
head
DANGER!
Risk of injury from high pressure!
• Before dismounting pneumatic lines and valves, turn off the
pressure and vent the lines.
Procedure:
→Connect the control medium to the pilot air port (1)
(3 – 7 bar; instrument air, free of oil, water and dust).
→Attach the exhaust airline or a silencer to the exhaust air port (3)
(see “Fig. 9: Pneumatic connection”).
Keep the adjacent supply pressure always at least 0.5 –
1 bar above the pressure which is required to move the
actuator to its end position.
Important information for the problem-free functioning of
the device:
• The installation must not cause back pressure to build up.
• Select a hose for the connection with an adequate
cross-section.
• The exhaust air line must be designed in such a way that
no water or other liquid can get into the device through
the exhaust air port.
Exhaust air port
(label: 3)
Pilot air port
(label: 1)
Fig. 9: Pneumatic connection
Caution: (Exhaust air concept):
In compliance with protection class IP67, an exhaust air line
must be installed in the dry area.
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Electrical installation
9. ELECTRICAL INSTALLATION
9.1. Safety instructions
DANGER!
Risk of electric shock!
• Before reaching into the system, 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 installation, ensure a controlled restart.
9.2. Electrical installation 24 V DC
9.2.1. Electrical installation with cable gland
Procedure:
→The screw terminals can be accessed by unscrewing the body
casing (stainless steel).
→Push the cables through the cable gland.
→Connect the wires.
IN 1
IN 2
24 V
Valve
+
-
+
-
Jumper:
Color assignment of the Top LEDs
Screw terminals
end positions
Screw terminals
Supply 24 V DC
Screw terminals
Valve (control)
ye gn
TopBot
Bot Top
IN 1 = Top (top)
IN 2 = Bot (bottom)
y
e
gn
T
o
p
Bot
Bot
To
p
Jumper: assignment p-n-p or n-p-n
outlet (optional)
Fig. 10: Connection with cable gland
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Electrical installation
Seal
Body casing
Body casing
Fig. 11: Position of the seal in the body casing
→Tighten union nut on the cable gland (torque approx. 1.5 Nm).
→Check that the seal is correctly positioned in the body casing.
→Close the device (assembly tool: 6740771)).
NOTE!
Damage or malfunction due to penetration of dirt and humidity!
To ensure protection class IP65 / IP67:
• Tighten the union nut on the cable gland according to the cable
size or dummy plugs used. (ca. 1,5 Nm).
• Screw the body casing in all the way.
The teach function can now be used to automatically determine
and read in the end positions of the valve (description of the teach
function see chapter “10. Teach function”).
1) The assembly tool (674077) is available from your Bürkert sales
office.
9.2.2. Electrical installation 24 V DC with
circular plug-in connector
→Connect the control head according to the table.
The teach function can now be used to automatically determine and
read in the end positions of the valve (description of the teach function
see chapter “10. Teach function”).
6
1
7
54
3
2
8
Fig. 12: Circular plug M12 x 1, 8-pole
Pin Wire color2) Designation Configuration
1white Limit switch top IN 1 (=Top)
2brown Limit switch bottom IN 2 (=Bot)
3green Supply voltage GND
4yellow Supply voltage + 24 V DC
5grey Valve control unit + Valve +
6pink Valve control unit - Valve -
7- not used
8- not used
Tab. 2: Connection with circular plug-in connector
2) The indicated colors refer to the connecting cable available as an
accessory (919061).
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Electrical installation
9.3. Display elements 24 V DC
LED pilot valve (yellow)
Status LED (yellow)
Top LEDs
Fig. 13: Display elements 24 V DC
LED Color
Top LEDs3) is lit green End postion bottom
is lit yellow End postion top
LED
Pilot valve
is lit yellow Pilot valve is actuated
Status LED flashing yellow Teach function is running
flickers yellow Puck PCB not available
Tab. 3: Display elements 24 V DC
NOTE!
Damage or malfunction due to penetration of dirt and humidity!
• To observe protection class IP65 / IP67, screw the transparent
cap in all the way.
3) Color setting ex works. Can be set via jumper (see “Fig. 10:
Connection with cable gland”).
9.4. Programming data AS-Interface
AS-Interface
31 slaves
AS-Interface
62 slaves
I/O configuration B hex (1 input, 2 outputs)
ID code F hex A hex
Extended ID code 1 F hex 7 hex
Extended ID code 2 F hex E hex
Profile S-B.F.F S-B.A.E
Tab. 4: Programming data
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Electrical installation
9.5. Electrical installation AS-Interface
9.5.1. Connection with circular plug-in
connector M12 x 1, 4-pole, male
Connector views
The views show the image from the front looking at the pins, the
solder connections are behind them.
Pin 4:
NC
Pin 1:
Bus +
Pin 3:
Bus –
Pin 2:
NC
Fig. 14: Bus connection without external supply voltage
Pin 4:
24 V +
Pin 1:
Bus +
Pin 3:
Bus –
Pin 2:
GND
Fig. 15: Bus connection with external supply voltage (optional)
Bus connection without external / with external supply voltage
Pin Designation Configuration
1Bus + AS-Interface bus line +
2NC or GND
(optional)
not used or external supply voltage –
(optional)
3Bus – AS-Interface bus line –
4NC or 24 V +
(optional)
not used or external supply voltage +
(optional)
Tab. 5: Pin assignment of circular plug-in connector for AS-Interface
→Connect the control head according to the table.
The teach function can now be used to automatically determine
and read in the end positions of the valve (description of the teach
function see chapter “10. Teach function”).
For the bus variant AS-Interface, the teach function can also
be started via the bus protocol.
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