Burkert 8691 User manual

Operating Instructions
Bedienungsanleitung
Manuel d‘utilisation
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 - 2011 Bürkert Werke GmbH
Operating Instructions 1112/03_EU-ML_00806086 / Original DE

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Control head Type 8691
Table of ConTenTs
1. OPERATING INSTRUCTIONS ........................................................................................................................................................7
1.1. Symbols ......................................................................................................................................................................................7
2. AUTHORIZED USE .............................................................................................................................................................................8
2.1. Restrictions ...............................................................................................................................................................................8
3. BASIC SAFETY INSTRUCTIONS .................................................................................................................................................9
4. GENERAL INFORMATION .............................................................................................................................................................10
4.1. Contact address ..................................................................................................................................................................10
4.2. Warranty ...................................................................................................................................................................................10
4.3. Trademarks ............................................................................................................................................................................10
4.4. Information on the internet ............................................................................................................................................10
5. SYSTEM DESCRIPTION ................................................................................................................................................................11
5.1. Configuration and function ............................................................................................................................................11
5.1.1. Control head for integrated installation on the 21xx series ...........................................................11
5.1.2. Model for control of process valves belonging to the 20xx series ...............................................12
6. TECHNICAL DATA .............................................................................................................................................................................13
6.1. Conformity ..............................................................................................................................................................................13
6.2. Standards ................................................................................................................................................................................13
6.3. Operating conditions ........................................................................................................................................................13
6.4. Mechanical data ...................................................................................................................................................................13
6.5. Type label (example) .........................................................................................................................................................14
6.6. Pneumatic data ....................................................................................................................................................................14
6.7. Electrical data .......................................................................................................................................................................14
6.7.1. Electrical data without bus control 24 V DC ....................................................................................14
6.7.2. Electrical data with AS-Interface bus control ...................................................................................15
6.7.3. Electrical data with DeviceNet bus control .......................................................................................15
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7. INSTALLATION ...................................................................................................................................................................................16
7.1. Safety instructions .............................................................................................................................................................16
7.2. Installing the control head Type 8691 on process valves belonging to series 21xx ......................16
7.3. Installing the control head Type 8691 on process valves belonging to series 20xx ......................20
7.4. Rotating the actuator module ......................................................................................................................................23
7.5. Rotating the control head for process valves belonging to series 20xx ..............................................25
8. FLUID INSTALLATION ....................................................................................................................................................................26
8.1. Safety instructions .............................................................................................................................................................26
8.2. Installing the process valve ...........................................................................................................................................26
8.3. Pneumatic connection of the control head ...........................................................................................................27
9. ELECTRICAL INSTALLATION 24 V DC ...................................................................................................................................28
9.1. Safety instructions .............................................................................................................................................................28
9.2. Electrical installation with cable gland ....................................................................................................................28
9.3. Electrical installation with circular plug-in connector .....................................................................................30
9.4. Teach function (calibrating the end positions) ...................................................................................................30
9.5. Display elements 24 V DC .............................................................................................................................................32
9.5.1. LED status display ..................................................................................................................................32
9.5.2. Device status display - assignment of the Top LEDs .....................................................................33
9.5.3. Change assignment of the Top LEDs (device status) ....................................................................33
10. AS-INTERFACE INSTALLATION ................................................................................................................................................35
10.1. AS-Interface connection .................................................................................................................................................35
10.2. Technical data for AS-Interface PCBs .....................................................................................................................35
10.3. Programming data ..............................................................................................................................................................35
10.4. Electrical installation AS-Interface ............................................................................................................................36
10.4.1. Safety instructions ...................................................................................................................................36
10.4.2. Connection with circular plug-in connector M12x1, 4-pole, male ..............................................36
10.4.3. Connection with multi-pole cable and ribbon cable terminal........................................................37
10.5. Teach function (calibrating the end position) ......................................................................................................38
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10.6. Display elements AS-Interface ....................................................................................................................................40
10.6.1. LED status display ..................................................................................................................................40
10.6.2. Device status - assignment of the LEDs ............................................................................................41
10.6.3. Change assignment of the Top LEDs (device status) ....................................................................41
11. DEVICENET ..........................................................................................................................................................................................43
11.1. Definition .................................................................................................................................................................................43
11.2. Technical data .......................................................................................................................................................................43
11.3. Maximum line lengths ......................................................................................................................................................43
11.3.1. Total line length according to DeviceNet specification ..................................................................43
11.3.2. Drop line length .......................................................................................................................................44
11.4. Safety setting if the bus fails ........................................................................................................................................44
11.5. Interfaces ................................................................................................................................................................................44
11.6. Electrical connection DeviceNet .................................................................................................................................44
11.6.1. Safety instructions ...................................................................................................................................44
11.6.2. Configuration of the PCB DeviceNet .................................................................................................45
11.6.3. Bus connection (circular connector M12 x 1, 5-pole, male) .........................................................45
11.7. Terminating circuit for DeviceNet systems ...........................................................................................................45
11.8. Network topology of a DeviceNet system .............................................................................................................46
11.9. Configuring the control head .......................................................................................................................................46
11.9.1. DIP switches .............................................................................................................................................46
11.10. Configuration of the process data .............................................................................................................................48
11.11. Configuration of the safety position of pilot valves for bus error .............................................................49
11.12. Teach function (calibrating the end position) ......................................................................................................50
11.12.1. Starting the teach function ..................................................................................................................51
11.13. Display elements DeviceNet .........................................................................................................................................52
11.13.1. LED status display ................................................................................................................................52
11.13.2. Function test of the status LEDs .......................................................................................................52
11.13.3. Device status - assignment of the LEDs ..........................................................................................54
11.13.4. Status LED yellow .................................................................................................................................54
12. SAFETY POSITIONS .......................................................................................................................................................................55
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13. MAINTENANCE ..................................................................................................................................................................................56
13.1. Service at the air intake filter .......................................................................................................................................56
14. DISASSEMBLY ...................................................................................................................................................................................57
14.1. Safety instructions .............................................................................................................................................................57
14.2. Disassembly the control head .....................................................................................................................................57
15. ACCESSORIES ..................................................................................................................................................................................59
16. PACKAGING AND TRANSPORT ...............................................................................................................................................59
17. STORAGE ..............................................................................................................................................................................................59
18. DISPOSAL ..........................................................................................................................................................................................59
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Operating instructions
1. OPERATING INSTRUCTIONS
The operating instructions describe the entire life cycle of the device. Keep these instructions in a location which is
easily accessible to every user, and make these instructions available to every new owner of the device.
WARNING!
The operating instructions contain important safety information!
Failure to observe these instructions may result in hazardous situations.
• The operating instructions must be read and understood.
1.1. Symbols
DANGER!
Warns of an immediate danger!
• Failure to observe the warning will result in a fatal or serious injury.
WARNING!
Warns of a potentially dangerous situation!
• Failure to observe the warning may result in serious injuries or death.
CAUTION!
Warns of a possible danger!
• Failure to observe this warning may result in a moderate or minor injury.
NOTE!
Warns of damage to property!
• Failure to observe the warning may result in damage to the device or the equipment.
Indicates important additional information, tips and recommendations.
refers to information in these operating instructions or in other documentation.
→Designates a procedure which you must carry out.
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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 operating 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 installation, 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 reli-
able and faultless 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.
DANGER!
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!
General hazardous situations.
To prevent injury, ensure:
• that the system cannot be activated unintentionally.
• Installation and repair work may be carried out by authorized technicians only and with the appropriate tools.
• After an interruption in the power supply or pneumatic supply, ensure that the process is restarted in a defined
or controlled manner.
• The device may be operated only when in perfect condition and in consideration of the operating instructions.
• The general rules of technology apply to application planning and operation of the device.
To prevent damage to property 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 consideration 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.buerkert.com
4.2. Warranty
The warranty is only valid if the control head Type 8691 is used as intended in accordance with the specified appli-
cation conditions.
4.3. Trademarks
Brands and trademarks listed below are trademarks of the corresponding companies / associations / organizations
Loctite Henkel Loctite Deutschland GmbH
4.4. Information on the internet
The operating instructions and data sheets for Type 8691 can be found on the Internet at:
www.burkert.com
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System description
5. SYSTEM DESCRIPTION
5.1. Configuration and function
The control head Type 8691 can control single or double-acting process valves.
The control head Type 8691 has been optimized for integrated, modular installation on process valves of the 21xx
series. The module configuration permits a variety of expansion steps.
For installation on the 20xx series there is a special model which is described in chapter “5.1.2”.
The valve position is recorded via a contactless, analog sensor element which uses the teach function to automati-
cally detect and save the valve end positions during start-up.
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.
5.1.1. Control head for integrated installation on the 21xx series
24 V DC: Cable gland M16 x 1.5 or circular plug-in connector M12 x 1
Exhaust air connection
label: 3
Pressure limiting valve (for protection against too high internal
pressure in case of error)
Pilot air port
label: 1
Teach function
Description see chapter on the appropriate model
„Teach function (calibrating the end positions)“
Views without transparent cap and body casing
Pilot valve (3/2-way or 5/2-way solenoid valve with hand lever)
Air intake filter (exchangeable)
Fastening screws (2x)
Screw terminals
Device status display (Top LEDs)
Status display pilot valve
Figure 1: Design and function
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System description
5.1.2. 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 “Figure 2”).
Pilot air outlet 21
Fastening screws (2 x)
Pilot air outlet 22
Figure 2: Connection module 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
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 malfunctions or leaks.
• If the device is used outdoors, do not expose it unprotected to the weather conditions.
• Ensure that the permitted ambient temperature does not exceed the maximum value or drop below the mini-
mum 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
connection 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
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Technical data
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
Type Control function - pilot valve
Bar code
Serial number - CE mark
Max. ambient temperature
Figure 3: Example of type label
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 -10 – +50 °C
Pressure range 3 – 7 bar
Air output of pilot valve 250IN/min (for ventilation and exhaust)
(QNn value according to definition for pressure drop from 7 to 6 bar absolute)
Connections Plug-in hose connector Ø 6 mm / 1/4"
Socket connection G1/8
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 % residual ripple 10 %
Power input max. 1W
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
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. Installing the control head Type 8691 on process
valves belonging to series 21xx
Procedure:
1. Install switch spindle
Transparent cap
Actuator
Pilot air ports
(plug-in hose connectors with collets or
threaded bushings)
Figure 4: Installation of the switch spindle (1), 21xx series
→Unscrew the transparent cap on the actuator and unscrew the position display (yellow cap) on the spindle
extension (if present).
→For version with plug-in hose connector, remove the collets (white nozzles) from both pilot air ports (if
present).
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Installation
Spindle extension
Guide element
Actuator cover
Groove ring
Puck holder
Switch spindle
max. 5 Nm
max. 1 Nm
O-ring
Figure 5: Installing of the switch spindle (2), series 21xx
NOTE!
Improper installation may damage the groove ring in the guide element!
The groove ring is already be pre-assembled in the central screw and must be “locked into position” in the
undercut.
• When installing the switch spindle, do not damage the groove ring.
→Push the switch spindle through the guide element.
NOTE!
Screw locking paint may contaminate the groove ring!
• Do not apply any screw locking paint to the switch spindle.
→To secure the switch spindle, apply some screw locking paint (Loctite 290) in the tapped bore of the spindle
extension in the actuator.
→Check that the O-ring is correctly positioned.
→Screw the guide element to the actuator cover (maximum torque: 5 Nm).
→Screw switch spindle onto the spindle extension. To do this, there is a slot on the upper side
(maximum torque: 1 Nm).
→Push puck holder onto the switch spindle and lock into position.
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Installation
2. Install sealing rings
→Pull the form seal onto the actuator cover (smaller diameter points upwards).
→Check that the O-rings are correctly positioned in the pilot air ports.
When the control head is being installed, the collets of the pilot air ports must not be fitted to the actuator.
Form seal
Pilot air ports
Caution:
Collets must not be
fitted !
Installation of the form
seal
Figure 6: Installing of the sealing rings, 21xx series
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Installation
3. Install the control head
NOTE!
Damaged printed circuit board or malfunction!
• Ensure that the puck holder is situated flat on the guide rail.
→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 “Figure 7”) and
2. the supports of the control head can be inserted into the pilot air ports of the actuator
(see “Figure 8”).
Guide rail
Puck holder
Figure 7: Aligning the puck holder
→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 fastening screws. In doing so, tighten the screws
only hand-tight (max. torque: 0.5 Nm).
Supports
Pilot air ports Fastening screws
max. 0,5 Nm
Figure 8: Installation of control head, series 21xx
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Installation
7.3. Installing the control head Type 8691 on process
valves belonging to series 20xx
Procedure:
1. Install switch spindle
Transparent cap
Position indicator
Actuator
Figure 9: Installation of the switch spindle (1), series 20xx
→Unscrew the transparent cap on the actuator.
→Using a hexagon socket key, unscrew the orange/yellow position indicator from the inside of the actuator.
Guide element
O-ring
Plastic part
(of the switch spindle)
Puck holder
Switch spindle
Spindle (actuator)
Figure 10: Installation of the switch spindle (2), series 20xx
→Press the O-ring downwards into the cover of the actuator.
→Manually screw the switch spindle (and the plugged-on guide element) together with the plastic part onto the
spindle of the actuator, but do not tighten spindle yet.
→Tighten the guide element with a face wrench1) into the actuator cover (torque: 8.0 Nm).
→Tighten the switch spindle on the spindle of the actuator. To do this, there is a slot on the upper side (torque:
1.0 Nm).
→Push the puck holder onto the switch spindle until it engages.
1) journal Ø: 3 mm; journal gap: 23.5 mm
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