Burkert 8695 User manual

Quickstart
Type 8695
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
Quickstart 1103/01_EU-ML_00805384 / Original DE

3
1. QUICKSTART .....................................................................................................4
1.1. Symbols ..............................................................................................4
2. AUTHORIZED USE .........................................................................................5
2.1. Restrictions ........................................................................................5
2.2. Predictable Misuse ..........................................................................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
6. TECHNICAL DATA ...........................................................................................8
6.1. Conformity ......................................................................................... 8
6.2. Standards ........................................................................................... 8
6.3. Operating Conditions ...................................................................... 8
6.4. Mechanical Data ...............................................................................9
6.5. Type Label .........................................................................................9
6.6. Pneumatic Data ................................................................................9
6.7. Electrical Data .................................................................................10
7. INSTALLATION ...............................................................................................11
7.1. Safety Instructions .........................................................................11
7.2. Installation of the Control Head
on Process Valves of Series 21xx ..............................................11
7.3. Installation of the Control Head
on Process Valves of Series 20xx ..............................................12
8. FLUID INSTALLATION ................................................................................ 14
8.1. Safety Instructions .........................................................................14
8.2. Installing the Process Valve .........................................................15
8.3. Pneumatic Connection of the Control Head ...........................15
9. ELECTRICAL INSTALLATION ..................................................................16
9.1. Safety Instructions .........................................................................16
9.2. Electrical Installation 24 V DC
with Circular Plug-in Connector .................................................16
9.3. Display Elements 24 V DC ..........................................................17
9.4. Electrical Installation AS Interface ...............................................17
9.5. Programming data ..........................................................................18
9.6. Display Elements AS Interface ....................................................19
10. TEACH FUNCTION .................................................................................... 20
10.1. Starting the Teach Function
(Calibrating the End Position) ...................................................20
11. SAFETY POSITIONS ................................................................................21
12. ACCESSORIES ...........................................................................................21
13. PACKAGING, TRANSPORT, STORAGE .......................................... 22
Table of Contents
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Quickstart
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 8695.
The operating instructions can be found on the enclosed CD
and on the Internet at:
www.burkert.com
1.1. 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.
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Authorized use
2. AUTHORIZED USE
Non-authorized use of the control head Type 8695 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 8695 only as intended.
2.1. Restrictions
If exporting the system/device, observe any existing restrictions.
2.2. Predictable Misuse
• 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.
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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 – 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:
• 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.
The control head Type 8695 was developed with due con-
sideration 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 instruc-
tions 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 8695 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 8695 can be found
on the Internet at:
www.burkert.com
5. SYSTEM DESCRIPTION
5.1. Structure and Function
The control head Type 8695 can control single or double-acting
process valves.
Control head
Actuator
Valve body
Process valve
Fig. 1: Structure 1
Depending on the conditions of use, different process valves from
the Bürkert range can be combined with the control head. Angle-seat
valves, globe valves and diaphragm valves of series 21xx (Element)
and 20xx (Classic) are suitable.
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Technical Data
The control head Type 8695 has been optimized for the integrated
modular fitting of series 21xx process valves (Element) with a 50 mm
actuator. Various expansion stages are possible thanks to the modular
design.
For installation on the 20xx series (Classic) there is a special model.
Electrical connection
Circular plug-in connector
M12 x 1
Air discharge port
(label: 3)
Pressure limiting valve (for pro-
tection against too high internal
pressure in case of error)
Pilot air port
(label: 1)
Teach function
Fastening screws (2 x)
View without transparent cap, series 21xx:
Pilot air outlet 22
Pilot air outlet 21
Model for series 20xx (Classic)
Fig. 2: Structure 2
6. TECHNICAL DATA
6.1. Conformity
In accordance with the Declaration of conformity, the control head
Type 8695 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”).
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Technical Data
6.4. Mechanical Data
Dimensions See data sheet
Body material exterior: PPS, PC, VA
interior: PA6; ABS
Sealing material exterior: EPDM / FKM
Stroke range of valve spindle
21xx series (Element)
and 20xx series (Classic): AS Interface 2 – 25 mm
24 V DC 2 – 35 mm
Third-party devices:
(modified guide element
required) AS Interface 2 – 34 mm
24 V DC 2 – 44 mm
6.5. Type Label
8695 24 V DC
single act Pilot 0,6
Pmax 7bar
Tamb 0°C - +55°C
Ser.-Nr. 001000
00185114
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
Fig. 3: Type label (example)
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: 7 lN / min (for aeration and deaeration)
(QNn - value according to definition for
pressure drop from 7 to 6 bar absolute)
Connections: 21xx
(Element): Plug-in hose connector ∅ 6mm / 1/4“
Socket connection G 1/8
20xx
(Classic): Socket connection G 1/8
with M5 connection for connecting to
the actuator
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Technical Data
6.7. Electrical Data
6.7.1. Electrical data without bus control
24 V DC
Connections: 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)
6.7.2. Electrical data with AS Interface bus
control
Connections: Circular plug-in connector
(M12 x 1, 4-pole)
Profile: S-B.A.E. (A/B slave, max. 62
slaves/master)
Electrical supply voltage: 29.5 V – 31.6 V DC
(according to specification)
Outputs
Max. switching capacity: 1 W via AS-Interface
Watchdog function: integrated
Max. power consumption: 120 mA
Power consumption input during
normal operation:
(after current reduction;
valve + 1 end position reached) 90 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. 4”) and
2. the supports of the control head can be inserted into the
pilot air ports of the actuator (see also “Fig. 5”).
NOTE!
Damaged printed circuit board or malfunction!
• Ensure that the puck holder is situated flat on the guide rail.
Guide rail
Puck holder
Supports
Fig. 4: 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
(max. torque: 0.5 Nm).
Supports
Pilot air ports
(actuator) Fastening
screws
max. 0.5 Nm
Fig. 5: Installation of control head, 21xx series
7.3. Installation of the Control Head on
Process Valves of Series 20xx
Procedure:
Guide rail
Puck holder
Supports
Fig. 6: 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. 6”).
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. 7”).
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
Fastening screws (2x)
Fig. 7: 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 8695 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 (CF) Pneumatic connection Type 8695
with actuator
Pilot air
outlet
Type 8695
Pilot air port actuator
A
Process valve
closed in rest
position
(by spring force)
21
lower pilot air port of the
actuator
22
should be connected to the
upper pilot air port of the
actuator
B
Process valve
open in rest
position
(by spring force)
21
upper pilot air port of the
actuator
22
should be connected to the
lower pilot air port of the
actuator
I
Process valve
closed in rest
position
21
lower pilot air port of the
actuator
22
upper pilot air port of the
actuator
Process valve
open in rest
position
21
upper pilot air port of the
actuator
22
lower pilot air port of the
actuator
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. 8: Pneumatic Connection”).
Caution: (Exhaust air concept):
In compliance with protection class IP67, an exhaust air line
must be installed in the dry area.
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.
Pilot air port
(label: 1)
Exhaust air port
(label: 3)
Fig. 8: Pneumatic Connection
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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 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. 9: Circular plug M12 x 1, 8-pole
Pin Wire color1) 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
1) 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
ye
gn
Bot
Top
Top
Bot
ye
gn
Jumper for assignment of
end position LEDs
End position LED green
End position LED yellow
Valve LED yellow (pilot valve)
Status LED yellow
Fig. 10: Display elements 24 V DC
LED State
End position LED green on End postion bottom2)
End position LED yellow on End postion top2)
LED Valve yellow on Pilot valve is actuated
Status LED yellow flashing Teach function is running
flickers 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.
2) Color setting ex works. Can be set via jumper (see “Fig. 10”).
9.4. Electrical Installation AS Interface
9.4.1. Connection with Circular Plug-in
Connector M12 x 1, 4-pole, male
Pin 4:
NC
Pin 1:
Bus +
Pin 3:
Bus –
Pin 2:
NC
Fig. 11: Connection with circular plug-in connector, AS-Interface
Pin Designation Configuration
1Bus + AS Interface bus line +
2NC not used
3Bus – AS Interface bus line -
4NC not used
Tab. 4: 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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Electrical Installation
9.4.2. Connection with multi-pole cable and
ribbon cable terminal
As an alternative to the bus connection model with 4-pole circular
plug, there is the control head with multi-pole cable (M12 circular plug)
and ribbon cable terminal. The wiring diagram of the circular plug cor-
responds to the bus connection of the M12 4-pole circular plug and
can easily be connected to the ribbon cable terminal (see “Fig. 12”).
Screws
M12 plug-in connector
branch circuit
Fig. 12: Control head 8695 with multi-pole cable and ribbon cable terminal
Handling the ribbon cable terminal
The multi-pole cable features a ribbon cable terminal - with M12 plug-in
connector branch circuit - for AS Interface cable harness. The ribbon
cable terminal contacts the AS Interface cable harness by means of
penetration technology which allows installation by “clipping in” the AS
Interface cable harness without cutting and without removing insulation.
Procedure:
→Open the ribbon cable terminal
(loosen screws and remove cover)
→Insert cable harness conclusively
→Close ribbon cable terminal again
→Tighten screws
Slightly undo thread-forming screws
(approx. 3/4 turn to the left) and position them on the existing
tapped bore and screw in.
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.
9.5. Programming data
I/O configuration B hex
ID code A hex
Extended ID code 1 7 hex
Extended ID code 2 E hex
Profile S-B.A.E
Tab. 5: Programming data
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Electrical Installation
9.6. Display Elements AS Interface
ye
gn
Bot
Top
Top
Bot
gn
ye
Valve LED yellow
(pilot valve)
Bus LED red
Bus LED green
Status LED yellow
End position LED yellow
End position LED green
Jumper for
assignment
of end
position
LEDs
Fig. 13: Display Elements AS Interface
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.
Bus LED
(green)
Bus LED
(red)
off off POWER OFF
off on No data traffic (expired Watch Dog at
slave address does not equal 0)
on off OK
flashing on Slave address equals 0
off flashing Sensor supply overloaded (Periphery
error, manual actuation activated)
Tab. 6: LED Status display bus status
LED State
Status LED yellow flashing Teach function is running
flickers Puck PCB not available
End position LED green on End postion bottom3)
End position LED yellow on End postion top3)
LED Valve yellow on Pilot valve is actuated
Tab. 7: Display elements AS Interface
3) Color setting ex works. Can be set via jumper (see “Fig. 13”).
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Teach function
10. TEACH FUNCTION
The teach function can be used to automatically determine and read
in the end positions of the valve.
For the bus variant AS Interface, the Teach function can also
be started via the bus protocol.
10.1. Starting the Teach Function
(Calibrating the End Position)
Necessary requirements:
Before you can actuate the Teach function, you must
• mount the control head on the actuator,
• connect the supply voltage and
• connect the compressed-air supply.
Procedure:
→Open the control head: turning the transparent cap
anti-clockwise.
→The key in recess for actuating the Teach function keep pressed
for approximately 5 seconds.
→Close the device (assembly tool: 6740784)).
4) The assembly tool (674078) is available from your Bürkert sales office.
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.
Key in recess for
actuating the Teach
function (keep
pressed for approxi-
mately 5 seconds)
Fig. 14: Teach function
Chronological description of the Teach function:
• the bottom position is read in internally
• the pilot valve switches
• the actuator moves automatically to the top position
• the top position is read in internally
• the pilot valve is turned off
• the actuator moves back to the home position.
Important:
When the Teach function is activated the actuator cannot be
actuated via the AS Interface communication.
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