Burkert 8695 User manual

Quickstart
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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 - 2014 Bürkert Werke GmbH
Quickstart 1412/05_EU-ML_00805384 / Original DE

3
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
6 TECHNICAL DATA ........................................................................................8
6.1 Conformity ................................................................................... 8
6.2 Standards ....................................................................................8
6.3 Licenses ...................................................................................... 8
6.4 Operating conditions ................................................................ 9
6.5 Mechanical data.........................................................................9
6.6 Type labels ..................................................................................9
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 ...........................................................................12
7.3 Installation of the control head on process valves
of series 20xx ...........................................................................13
8 PNEUMATIC INSTALLATION ...............................................................15
9 ELECTRICAL INSTALLATION / DISPLAY ELEMENTS ............16
9.1 Safety instructions ...................................................................16
9.2 Electrical installation 24 V DC .............................................16
9.3 Display elements 24 V DC ....................................................17
9.4 Electrical installation AS-Interface........................................18
9.5 Programming data ...................................................................19
9.6 Display elements AS-Interface .............................................20
9.7 Electrical installation DeviceNet ............................................21
9.8 Display elements DeviceNet .................................................23
10 TEACH FUNCTION ...................................................................................25
10.1 Starting the teach function (calibrating the end
position) .....................................................................................25
11 SAFETY POSITIONS ................................................................................26
12 ACCESSORIES ...........................................................................................27
12.1 Communications software.....................................................27
12.2 USB interface ...........................................................................27
12.3 Download ..................................................................................27
13 PACKAGING, TRANSPORT, STORAGE ..........................................28
Table of Contents
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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 8695.
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 8695.
In these instructions, the abbreviation “Ex” always refers to “poten-
tially explosive”.
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.
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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.
▶In the potentially explosion-risk area the control head Type 8695
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 8695 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 8695.
▶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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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 actuator
size ∅ 50. Various expansion stages are possible thanks to the modular
design.
For installation on the 20xx series (Classic) there is a special model.
Connection housing
Electrical connection
Circular plug-in connector M12 x 1
Exhaust air 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 EC Declaration of conformity, the control
head Type 8695 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”.
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Technical 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 chapter “8 Pneumatic
installation”.
6.5 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
DeviceNet 2 – 35 mm
Third-party devices
(modified guide element
required) AS-Interface 2 – 34 mm
24 V DC 2 – 44 mm
DeviceNet 2 – 44 mm
6.6 Type labels
6.6.1 Type label standard (example)
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
Max. operating
pressure
Type
Control function
- Pilot valve
Bar-code
Serial number -
CE mark
Max. ambient
temperature
Fig. 3: Type label (example)
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Technical data
6.6.2 UL type label (example)
8695 -E1-...-0 PU02
Single act Pilot 0.6 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. 4: 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. 5: 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 -10 – +50 °C
Pressure range 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 ∅ 6 mm / 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
6.8 Electrical data
WARNING!
Only circuits with limited power may be used for UL approved com-
ponents 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 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)
Profile S-B.A.E. (A/B slave, max. 62 slaves/
master)
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
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
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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 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.
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.
When the control head is being installed, the collets of the
pilot air ports must not be fitted to the actuator.
NOTE!
Damaged printed circuit board or malfunction.
▶Ensure that the puck is situated flat on the guide rail.
→Align the puck and the control head until
1. the puck can be inserted into the guide rail of the
control head (see “Fig. 6”) and
2. the connection pieces of the control head can be inserted
into the pilot air ports of the actuator (see also “Fig. 7”).
Guide rail
Puck
Connection
pieces
Fig. 6: Aligning the puck
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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
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
(max. torque: 1.5 Nm).
Connection
pieces
Pilot air
ports
(actuator)
Fastening
screws
max. 1.5 Nm
Fig. 7: Installation of control head, 21xx series
7.3 Installation of the control head on
process valves of series 20xx
Procedure:
Guide rail
Puck
Fig. 8: Aligning the puck
NOTE!
Damaged printed circuit board or malfunction.
▶Ensure that the puck is situated flat on the guide rail.
→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. 8”).
→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. 9”).
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
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
Fastening screws (2x)
Fig. 9: 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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Pneumatic 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 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.
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.
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. 10: 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.
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Electrical installation / display elements
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. 10: Pneumatic connection
Caution: (Exhaust air concept):
In compliance with protection class IP67, an exhaust air line
must be installed in the dry area.
9 ELECTRICAL INSTALLATION /
DISPLAY ELEMENTS
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
→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”).
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Electrical installation / display elements
6
1
7
54
3
2
8
Fig. 11: 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).
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.
→Unscrew the transparent cap in a counter-clockwise direction.
Body casing
Connection housing
Actuator
Transparent cap
Fig. 12: Open control head
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Electrical installation / display elements
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. 13: Display elements 24 V DC
LED State
End position LED green on End position bottom3)
End position LED yellow on End position top3)
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.
3) Color setting ex works. Can be set via jumper (see “Fig. 13”).
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. 14: 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 / display elements
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. 15”).
Screws
M12 plug-in connector
branch circuit
Fig. 15: 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 / display elements
9.6 Display elements AS-Interface
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 hous-
ing (see “Fig. 12: Open control head”).
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. 16: 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 or external
reset
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 position bottom4)
End position LED yellow on End position top4)
LED Valve yellow on Pilot valve is actuated
Tab. 7: Display elements AS-Interface
4) Color setting ex works. Can be set via jumper (see “Fig. 16”).
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