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 - 2014 Bürkert Werke GmbH
Quickstart 1412/06_EU-ML_00806079 / Original DE

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Contents
1 QUICKSTART ..................................................................................................4
1.1 Definition of term / abbreviation .............................................4
1.2 Symbols .......................................................................................4
2 AUTHORIZED USE ......................................................................................5
2.1 Restrictions .................................................................................5
3 BASIC SAFETY INSTRUCTIONS ..........................................................6
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 Licenses ...................................................................................... 9
6.4 Operating conditions ................................................................ 9
6.5 Mechanical data.........................................................................9
6.6 Type labels ................................................................................10
6.7 Pneumatic data ........................................................................10
6.8 Electrical data ...........................................................................11
7 INSTALLATION ............................................................................................ 12
7.1 Safety instructions ...................................................................12
7.2 Installation of the control head on process valves
of series 21xx ...........................................................................13
7.3 Installation of the control head on process valves
of series 20xx ...........................................................................14
8 PNEUMATIC INSTALLATION ...............................................................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 ..........................................20
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 .................................................26
10 TEACH FUNCTION ...................................................................................28
10.1 Starting the teach function ....................................................28
11 SAFETY POSITIONS ................................................................................29
12 ACCESSORIES ...........................................................................................30
12.1 Communications software.....................................................30
12.2 USB interface ...........................................................................30
12.3 Download ..................................................................................30
13 PACKAGING, TRANSPORT, STORAGE ..........................................30
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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 an instruction to prevent risks.
→designates a procedure that must be carried out.
1 QUICKSTART
The Quickstart describe the entire life cycle of the device. Keep the
Quickstart in a location which is easily accessible to every user and
make the Quickstart 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 / abbreviation
The term “device” used in these instructions always stands for the
control head Type 8691.
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 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.
▶In the potentially explosion-risk area the control head Type 8691
may be used only according to the specification on the separate
approval sticker. For use observe the additional instructions
enclosed with the device together with safety instructions for
the explosion-risk area.
▶Devices without a separate approval sticker may not be used in a
potentially explosive area.
▶Do not expose the device to direct sunlight.
▶Use according to the authorized data, operating conditions and
conditions of use specified in the contract documents and 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.
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Basic safety instructions
3 BASIC SAFETY INSTRUCTIONS
These safety instructions do not make allowance for any
• contingencies and events which may arise during the installation,
operation and maintenance of the devices.
• local safety regulations – the operator is responsible for observing
these regulations, also with reference to the installation personnel.
Risk of injury from high pressure in the equipment/device.
▶Before working on equipment or device, switch off the pressure
and deaerate/drain lines.
Risk of electric shock.
▶Before working on equipment or device, switch off the power
supply and secure to prevent reactivation.
▶Observe applicable accident prevention and safety regulations
for electrical equipment.
General hazardous situations.
To prevent injury, ensure:
▶Installation and repair work may be carried out by authorized
technicians only and with the appropriate tools.
▶After an interruption in the power supply or pneumatic supply,
ensure that the process is restarted in a defined or controlled
manner.
▶The device may be operated only when in perfect condition and
in consideration of the operating instructions.
▶The general rules of technology apply to application planning and
operation of the device.
To prevent damage to property on the device, ensure:
▶Do not feed any aggressive or flammable media into the pilot air
port.
▶Do not feed any liquids into the pilot air port.
▶When unscrewing and screwing in the body casing or the trans-
parent cap, do not hold the actuator of the process valve but the
connection housing of Type 8691.
▶Do not put any loads on the housing (e.g. by placing objects on
it or standing on it).
▶Do not make any external modifications to the device housing. Do
not paint the housing parts or screws.
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General information
4 GENERAL INFORMATION
4.1 Contact address
Germany
Bürkert Fluid Control System
Sales Center
Chr.-Bürkert-Str. 13-17
D-74653 Ingelfingen
Tel. + 49 (0) 7940 - 10 91 111
Fax + 49 (0) 7940 - 10 91 448
E-mail: [email protected]
International
Contact addresses can be found on the final pages of the printed
operating instructions.
And also on the Internet at: www.burkert.com
4.2 Warranty
The warranty is only valid if the control head Type 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
Connection housing
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 connection housing 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
Connection housing
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 EC Declaration of conformity, the control head
Type 8691 is compliant with the EC Directives.
6.2 Standards
The applied standards on the basis of which compliance with the EC
Directives is confirmed are listed in the EC type examination certificate
and/or the EC Declaration of Conformity.
6.3 Licenses
The product is approved for use in zone 2 and 22 in accordance
with ATEX directive 94/9/EC category 3GD.
Observe instructions on operation in an explosion-risk (Ex)
area. Observe the ATEX additional instructions.
The product is cULus approved. Instructions for use in the UL area
see chapter “6.8 Electrical data”.
6.4 Operating conditions
WARNING!
Solar radiation and temperature fluctuations may cause 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 see type label
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 “8 Pneumatic installation”.
6.5 Mechanical data
Dimensions see data sheet
Housing material exterior: PPS, PC, VA
Sealing material exterior: EPDM
interior: NBR
Stroke range of valve spindle: 2 – 28 mm
2 – 47 mm
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Technical data
6.6 Type labels
6.6.1 Type label standard (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
Max. operating
pressure
Typ Control function -
Pilot valve
Bar-code
Serial number -
CE mark
Max. ambient
temperature
Fig. 4: Type label (example)
6.6.2 UL type label (example)
8691 -E3-...-0 PU02
Single act Pilot 3.0 24V
Pmax 7 bar
Tamb -10 - +55 °C
S/N 1001
00123456
D-74653 Ingelfingen
W15MA
CE
Identification number; Date of
manufacture (encoded)
Max. operating pressure
Type; Features of the type code applicable to
UL and ATEX Control function; pilot valve;
Supply voltage pilot valve
Bar code
Serial number; CE mark
Max. ambient temperature
Fig. 5: UL Type label (example)
6.6.3 UL additional label (example)
Type 4X enclosure
NEC Class 2 only
Supply voltage: 24 V
Supply voltage device
Circuit with limited power
Degree of protection
Fig. 6: UL additional label (example)
6.7 Pneumatic data
Control medium neutral gases, air
Quality classes in accordance with ISO 8573-1
Dust content Class 7 max. particle size 40 µm,
max. particle density 10 mg/m³
Water content Class 3 max. pressure dew point
- 20 °C or min. 10 °C below the
lowest operating temperature
Oil content Class X max. 25 mg/m³
Temperature range
control medium -10 – +50 °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)
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Technical data
Connections Plug-in hose connector ∅ 6 mm / 1/4“
Socket connection G 1/8
6.8 Electrical data
WARNING!
Only circuits with limited power may be used for UL approved
components according to “NEC Class 2”.
6.8.1 Electrical data without bus control
24 V DC
Protection class 3 as per DIN EN 61140 (VDE 0140-1)
Connections 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)
6.8.2 Electrical data with AS-Interface bus
control
Protection class 3 as per DIN EN 61140 (VDE 0140-1)
Connections Circular plug-in connector (M12 x 1,
4-pole)
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
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Installation
6.8.3 Electrical data with DeviceNet bus
control
Protection class 3 as per DIN EN 61140 (VDE 0140-1)
Connections Circular plug-in connector
(M12 x 1, 5-pole)
Supply voltage 11 V – 25 V
Max. power consumption < 80 mA
Output
Pull-in current current ≤ 50 mA
Holding current ≤ 30 mA
7 INSTALLATION
Only for control head without pre-assembled process valve.
7.1 Safety instructions
DANGER!
Risk of injury from high pressure in the equipment/device.
▶Before working on equipment or device, switch off the pressure
and deaerate/drain lines.
Risk of electric shock.
▶Before working on equipment or device, switch off the power
supply and secure to prevent reactivation.
▶Observe applicable accident prevention and safety regulations
for electrical equipment.
WARNING!
Risk of injury from improper installation.
▶Installation may be carried out by authorized technicians only
and with the appropriate tools.
Risk of injury from unintentional activation of the system and
an uncontrolled restart.
▶Secure system from unintentional activation.
▶Following assembly, ensure a controlled restart.
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Installation
7.2 Installation of the control head on
process valves of series 21xx
NOTE!
When mounting on process valves with a welded body, follow
the installation instructions in the operating instructions for the
process valve.
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 and the control head until
1. the puck can be inserted into the guide rail of the
control head (see “Fig. 7”) and
2. the connection pieces of the control head can be inserted
into the pilot air ports of the actuator (see also “Fig. 8”).
NOTE!
Damaged printed circuit board or malfunction.
▶Ensure that the puck is situated flat on the guide rail.
Guide rail
Puck
Fig. 7: Aligning the puck
→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 degree of protection IP65 / IP67.
▶The fastening screws may be tightened to a maximum torque of
1.5 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: 1.5 Nm).
Connection
pieces
Pilot air ports Fastening
screws
max. 1.5 Nm
Actuator
Fig. 8: Installation of control head, 21xx series
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Installation
7.3 Installation of the control head on
process valves of series 20xx
Procedure:
Guide rail
Puck
Fig. 9: Aligning the puck
→Push the control head onto the actuator. The puck must be
aligned in such a way that it is inserted into the guide rail of the
control head (see “Fig. 9”).
NOTE!
Damaged printed circuit board or malfunction.
▶Ensure that the puck 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.
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. 10”).
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 control head 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).
Pilot air outlet 21
Pilot air outlet 22
Upper pilot air port
Lower pilot air port
Example
∅ 80, CFA
Fig. 10: Installing the pneumatic connection, 20xx series
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Installation
→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 degree of protection 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.
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
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Pneumatic installation
8 PNEUMATIC INSTALLATION
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:
→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. 11: 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. 11: Pneumatic connection
Caution: (Exhaust air concept):
In compliance with degree of protection 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 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 installation, ensure a controlled restart.
9.2 Electrical installation 24 V DC
9.2.1 Electrical installation with cable gland
NOTE!
Breakage of the pneumatic connection pieces due to rota-
tional impact.
▶When unscrewing and screwing in the body casing, do not hold
the actuator of the process valve but the connection housing.
→Unscrew the body casing (stainless steel) in a counter-clockwise
direction.
Body casing
Connection housing
Actuator
Fig. 12: Open control head
→Push the cables through the cable gland.
→Connect the wires.
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Electrical installation
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. 13: Connection with cable gland
Seal
body casing
Body casing
Connection housing
Fig. 14: 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: 6740772)).
NOTE!
Damage or malfunction due to penetration of dirt and humidity.
To ensure degree of protection 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”).
2) The assembly tool (674077) is available from your Bürkert sales office.
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Electrical installation
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. 15: Circular plug M12 x 1, 8-pole
Pin Wire color3) 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
3) The indicated colors refer to the connecting cable available as an
accessory (919061).
9.3 Display elements 24 V DC
NOTE!
Breakage of the pneumatic connection pieces due to rota-
tional impact.
▶When unscrewing and screwing in the transparent cap, do not
hold the actuator of the process valve but the connection housing.
LED pilot valve (yellow)
Status LED (yellow)
Top LEDs
Connection housing
Fig. 16: Display elements 24 V DC
LED Color
Top LEDs4) 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
4) Color setting ex works. Can be set via jumper (see “Fig. 13: Connection
with cable gland”).
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Electrical installation
NOTE!
Damage or malfunction due to penetration of dirt and humidity.
▶To observe degree of protection IP65 / IP67, screw the trans-
parent cap in all the way.
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
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. 17: Bus connection without external supply voltage
Pin 4:
24 V +
Pin 1:
Bus +
Pin 3:
Bus –
Pin 2:
GND
Fig. 18: Bus connection with external supply voltage (optional)
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