Burkert 8835 User manual

Operating Instructions
Bedienungsanleitung
Manuel d‘utilisation
Type 8835
Matrix
Process Valve System
Prozessventilsystem
Système de vannes de process

Matrix type 8835
1
Hose connection supply
5.1
Heating circuit valve channel 3, DN25
Schlauchanschluss Zulauf Heizkreisventil Kanal 3, DN25
Raccord de flexible alimentation Vanne du circuit de chauffage canal 3, DN25
2
Valve block
5.2
Hose connection output channel 3
Ventilblock Schlauchanschluss Ausgang Kanal 3
Bloc de vannes Raccord de flexible sortie canal 3
3.1
Heating circuit valve channel 1, DN25
6.1
Bypass valve, DN25
Heizkreisventil Kanal 1, DN25 Bypassventil, DN25
Vanne du circuit de chauffage canal 1, DN25 Vanne de dérivation, DN25
3.2
Hose connection output channel 1
6.2
Hose connection output bypass
Schlauchanschluss Ausgang Kanal 1 Schlauchanschluss Ausgang Bypass
Raccord de flexible sortie canal 1 Raccord de flexible sortie dérivation
4.1
Heating circuit valve channel 2, DN25
7
Solenoid valve strip with pressure controller
Heizkreisventil Kanal 2, DN25 Magnetventilleiste mit Druckregler
Vanne du circuit de chauffage canal 2, DN25 Barre d'électrovannes avec régulateur de pression
4.2
Hose connection output channel 2
Schlauchanschluss Ausgang Kanal 2
Raccord de flexible sortie canal 2
6.1
5.1
4.1
3.1
2
1
5.2
4.2
3.2
6.2
7
We reserve the right to make technical changes without notice.
Technische Änderungen vorbehalten.
Sous réserve de modifications techniques.
© Bürkert Werke GmbH & Co. KG, 2014 - 2017
Operating Instructions 1804/00_EU-EN_00809504 / Original DE

3
1 OPERATING INSTRUCTIONS ................................................................4
1.1 Symbols .......................................................................................4
1.2 Definition of the term "device" ................................................ 4
2 AUTHORIZED USE ......................................................................................5
3 BASIC SAFETY INSTRUCTIONS ..........................................................5
3.1 Restrictions .................................................................................6
4 GENERAL INFORMATION ........................................................................6
4.1 Contact address ........................................................................6
4.2 Warranty ......................................................................................6
4.3 Information on the Internet ......................................................6
5 SYSTEM DESCRIPTION ............................................................................7
5.1 Intended application area ........................................................7
5.2 General description ..................................................................7
5.3 Functions ..................................................................................... 7
6 TECHNICAL DATA ........................................................................................7
6.1 Conformity ................................................................................... 7
6.2 Standards ....................................................................................7
6.3 Identification ............................................................................... 7
6.4 Operating conditions ................................................................ 8
6.5 General technical data ............................................................. 8
7 ASSEMBLY AND INSTALLATION ......................................................11
7.1 Safety instructions ...................................................................11
7.2 Installing the device ................................................................12
7.3 Fluid and pneumatic connection ..........................................12
7.4 Electrical connection ..............................................................14
8 OPERATION AND FUNCTION ............................................................. 14
8.1 Safety instructions ...................................................................14
8.2 Operating the device ..............................................................14
8.3 Functions ...................................................................................14
9 MAINTENANCE, TROUBLESHOOTING ......................................... 15
9.1 Safety instructions ...................................................................15
9.2 Changing the bypass or heating circuit valve ...................15
9.3 Changing pilot valve bar (VVL) .............................................17
9.4 Changing hose connection ...................................................18
9.5 Changing pressure controller ...............................................19
9.6 Recommended auxiliary materials .......................................19
9.7 Malfunctions .............................................................................19
10 SPARE PARTS.............................................................................................20
10.1 Parts overview triple matrix....................................................20
11 DISASSEMBLY ............................................................................................ 21
11.1 Safety instructions ...................................................................21
11.2 Removing the device ..............................................................21
12 TRANSPORT, STORAGE, PACKAGING .......................................... 21
Contents
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Type 8835

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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.
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 instructions for risk prevention.
→Designates a procedure which you must carry out.
1.2 Definition of the term "device"
In these instructions, the term "device" always refers to the matrix
Type 8835.
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Type 8835

5
Authorized use
2 AUTHORIZED USE
Non-intended use of the matrix Type 8835 may be a hazard to
people, nearby equipment and the environment.
▶The matrix 8835 regulates the flow control of heating and cool-
ing water in commercial vehicles.
▶Do not use the device outdoors.
▶The approved data, the operating conditions and conditions of
use specified in the contract documents, operating instructions
and on the rating plate are to be observed during use. These are
described in Chapter "5 System description".
▶Use the device only in conjunction with third-party devices and
components recommended and authorized by Bürkert.
▶Correct transportation, storage and installation, as well as care-
ful use and maintenance are essential for reliable and faultless
operation.
▶The device must not be used in explosion-risk (Ex) areas.
▶Supply only media to the media connections that are specified
in section "6 Technical data" as flow media.
▶Do not supply the control air connections with liquids.
▶Do not physically stress the housing (e.g. by placing objects on
it or standing on it).
▶Do not cover the vent holes of the valves.
▶Do not make any external alterations to the housing of the
device. Do not paint housing parts or screws.
▶Use the device only for its intended purpose.
3 BASIC SAFETY INSTRUCTIONS
These safety instructions do not make allowance for any
• contingencies and events which may arise during the assembly,
operation, and maintenance of the devices.
• local safety regulations – the operator is responsible for observing
these regulations, also in relation to the installation personnel.
Danger – high pressure!
Scalding caused by discharge of hot medium.
▶Before loosening lines or valves, leave the device to cool down,
turn off the pressure and vent/drain 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.
Risk of burns/risk of fire due to hot device surface and hot
lines.
▶Keep the device away from highly flammable substances and
media and do not touch with bare hands.
General hazardous situations.
To prevent injuries:
▶Ensure that the system cannot be activated unintentionally.
▶The device must only be operated when in a perfect condition
and in consideration of the operating instructions.
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Type 8835

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General information
▶Installation and maintenance work may be carried out only by
authorized technicians with the appropriate tools.
▶After an interruption in the electrical or pneumatic supply, ensure
that the process is restarted in a defined or controlled manner.
▶The general rules of technology must be observed for applica-
tion planning and operation of the device.
NOTE!
Electrostatic sensitive components / modules.
The device contains electronic components which react sensitively
to electrostatic discharge (ESD). Contact with electrostatically
charged persons or objects are hazardous to these components.
In the worst case scenario, they will be destroyed immediately or
will fail after start-up.
▶Observe the requirements in accordance with EN 61340-5-1 to
minimize or avoid the possibility of damage caused by a sudden
electrostatic discharge.
▶Also ensure that you do not touch electronic components when
the power supply voltage is present.
3.1 Restrictions
If exporting the system/device, observe any existing restrictions.
4 GENERAL INFORMATION
4.1 Contact address
Germany
Bürkert Fluid Control Systems
Sales Center
Christian-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 device is used as intended in accordance
with the specified application conditions.
4.3 Information on the Internet
The operating instructions and data sheets for the device can be found
on the Internet at: www.burkert.com
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Type 8835

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System description
5 SYSTEM DESCRIPTION
5.1 Intended application area
The device has been designed to regulate the flow control of heating
and cooling water in commercial vehicles.
5.2 General description
The device is a process valve system based on Type 2000 and
Type 0300 according to the requirement profile of the latest heating
and cooling systems.
The device consists of standard valves. It uses the advantages of control
technology, such as ramp drive during opening and closing, as well as
the speed of the open / closed process technology.
Therefore, simple pulse control of common controllers can be used to
optimize the heating and cooling water flow.
The device operates at opening and closing times of approx. 1 second
almost without water hammers.
5.3 Functions
The device is available as a single, double or triple version with different
control functions.
The double and triple versions can also be fitted with a bypass valve.
6 TECHNICAL DATA
6.1 Conformity
Type 8835 conforms with the EC Directives according to the EC
Declaration of Conformity (if applicable).
6.2 Standards
The applied standards, which verify conformity with the EC Direc-
tives, can be found on the EC-Type Examination Certificate and / or
the EC Declaration of Conformity (if applicable).
6.3 Identification
The device is fitted with a rating plate which uniquely identifies the
device and indicates the most important technical data.
Do not remove the rating plate from the device.
It is essential for identification when installing and servicing
the device.
Serial number Manufacturer code
Type, device designation
Medium pressure
Control pressure
Voltage, type of current,
output
8835 3-fach Matrix
P Medium 0-3 bar
Made in Germany
00210422
W52MM
Pilot 4,5 - 10 bar
24V DC 4W
S/N 1001
Ident number
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Technical data
6.4 Operating conditions
WARNING!
Risk of injury
Malfunction if used outside.
▶Do not use the device outdoors.
▶Avoid heat sources which may cause the allowable temperature
range to be exceeded.
Ambient temperature: –30 ... +80 °C
Medium temperature: –30 ... +100 °C
Medium pressure: –0.35 ... 3.0 bar
Viscosity: max. 40 mm²/s
Flow media: Water, alcohol, oil, steam
Degree of protection: IP65 according to EN 60529
(only if cables, plugs and sockets
have been connected correctly)
6.5 General technical data
6.5.1 Mechanical data
54
50
D
50
86,5
207
187,1
45°
220
Fig. 1: Dimensions single matrix
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Type 8835

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Technical data
93
174
251,55
60 57
7
37
205,2
NC NO NO
55
151
52,8
TU35
TU22
TU22
TU28
93
174
251,55
60 57
7
37
205,2
NC NO NO
55
151
52,8
TU35
TU22
TU22
TU28
Fig. 2: Dimensions double matrix
234
37
93
7
60
60 57
309,5
205,2
NO NC NC NC
55
151
52,8
TU28
TU28
TU28
TU28 TU28
234
37
93
7
60
60 57
309,5
205,2
NO NC NC NC
55
151
52,8
TU28
TU28
TU28
TU28 TU28
Fig. 3: Dimensions triple matrix
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Type 8835

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Technical data
37
37
39
53,85
52,5
48,5
52,14745
TU22 straight
TU22 angle
TU28 angle
TU35 angle
TU28 straight
TU35 straight
Fig. 4: Dimensions for straight and angle connections
(double and triple matrix)
Line connections:
Either TU22, TU28 or TU35, straight or angled.
Weight:
Single matrix: approx. 1.7 kg
Double matrix: approx. 4.8 kg
Triple matrix: approx. 6.1 kg
Materials:
Housing: Aluminum
Seal: PTFE, FKM
Internal valve parts: CuZn, VA
Pneumatic lines: PA 6.6
Hose connection: PA 6 GF 25
6.5.2 Pneumatic data
Control medium: Compressed air, quality classes in accor-
dance with DIN ISO 8573-1
Dust content: Quality class 5
max. particle size 40 μm
max. particle density 10 mg/m3
Water content: Quality class 3, max. 0.88 g/m3
max. pressure dew point -20 °C or at least
10 °C below the lowest operating temperature
Oil content: Quality class 5, max. 25 mg/m3
Temperature range of
compressed air: –10 ... +50 °C
Pressure range: 5.5 ... 10 bar
Operating pressure: 5 ... 5.5 bar (presetting pressure controller)
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Assembly and installation
Kv values with connection TU28 to water
Single matrix: 12 m³/h
Heating circuit valve: 9 m³/h
Bypass valve: 9 m³/h
Measurement at + 20 °C, 1 bar pressure at valve inlet, free output.
6.5.3 Electrical data
Connection: Device socket as per DIN 43650 C
Power supply: 24 V DC (–10 % ... +20 %)
Power consumption: 4 W per circuit
Nominal operating mode: during pulse mode max. 6 pulses per minute
6.5.4 Schematic circuit
1 2 3
Matrix
Consumer
Return travel
Supply
Bypass
The single matrix does not require the bypass valve.
7 ASSEMBLY AND INSTALLATION
7.1 Safety instructions
DANGER!
Danger – high pressure!
Scalding caused by discharge of hot medium.
▶Before loosening lines or valves, leave the device to cool down,
turn off the pressure and vent/drain the lines.
Risk of injury due to 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 assembly.
▶Assembly may only be carried out by authorized technicians and
with the appropriate tools.
Risk of injury from unintentional activation of the system and
uncontrolled restart.
▶Secure system against unintentional activation.
▶Following assembly, ensure a controlled restart.
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Type 8835

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Assembly and installation
7.2 Installing the device
The device can be installed in any position, preferably with
the actuators of the heating circuit valves face up.
Observe flow direction!
We recommend using Multi-Silikonfett OKS 1110 (silicone grease)
for sealing hose connections and O-rings.
Information can be found in Chapter
"9.6 Recommended auxiliary materials".
→Attach the device via the mounting holes
(see "6.5.1 Mechanical data").
7.3 Fluid and pneumatic connection
NOTE!
Damage to the device.
Blocked or soiled pipelines may impair the function of the device
or cause a failure.
▶Before connecting the device, clean the pipelines thoroughly.
7.3.1 Fluid connection
DANGER!
Injury caused by high medium pressure.
Burns caused by hot lines and discharge of hot medium.
▶Before loosening lines or valves, leave the device to cool down,
turn off the pressure and drain the lines.
Twisted line connections can lead to leaks.
▶Make sure that the pipes are in alignment and the line connec-
tors are not twisted during the assembly.
3
2
1
4
5
X
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Assembly and installation
Position Designation
1 Rigid pipeline, e.g. copper
2 Fixing the pipeline to the chassis with a pipe clip
3 Fixing the pipelines one below the other
4 Hose clip
5 Flexible rubber hose
→Connect line connections to the media lines (1). To do this, use
a flexible hose (5) which is attached with suitable hose clips (4).
The distance X between the pipeline and line connection should
be approx. 50 mm.
→Ensure that the pipeline is securely attached to the vehicle
frame (2).
→Ensure that the various installed pipelines in the vehicle are not
subject to forces or vibrations (3).
→Observe flow direction.
7.3.2 Pneumatic connection
NOTE!
Leaking or distorted air mains can lead to malfunctions.
Tight and continuous hose connections are essential for the
flawless functioning of the device.
▶Cut the hose ends of the air lines at right angles, clean and
burr-free to ensure a proper connection.
▶Position the air mains with a sufficient bending radius so that
the air flow is not impaired by kinking.
→Connect the control air to the valve control unit.
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Operation and function
7.4 Electrical connection
DANGER!
Risk of injury due to 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.
NOTE!
Malfunction due to incorrect device connection.
Improper connection can impair the function and damage the
device.
▶Note the connection information specified on the rating plate of
current and the voltage.
▶Do not kink connection lines.
▶Observe the torque when screwing on the device socket.
→Connect the pilot valves via a device socket.
Ground connection: middle plug tab.
Torque for attachment of the device socket: 0.4 Nm.
8 OPERATION AND FUNCTION
8.1 Safety instructions
WARNING!
Danger due to improper operation.
Improper operation may result in injuries as well as damage to the
device and the area around it.
▶The operating personnel must know and have understood the
contents of the operating instructions.
▶Observe the safety instructions and intended use.
▶Only adequately trained personnel may operate the equipment/
the device.
8.2 Operating the device
The matrix is operated using a controller.
Manual operation is not possible.
8.3 Functions
An electrical signal causes the upstream solenoid valve to release the
control air for actuation of a bypass or heating circuit valve. According
to its control function, the bypass or heating circuit valve opens or
closes and releases or blocks the medium.
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Maintenance, troubleshooting
9 MAINTENANCE,
TROUBLESHOOTING
9.1 Safety instructions
DANGER!
Danger – high pressure!
Scalding caused by discharge of hot medium.
▶Before loosening lines or valves, leave the device to cool down,
turn off the pressure and vent/drain 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.
Risk of burns/risk of fire due to hot device surface and hot
lines.
▶Keep the device away from highly flammable substances and
media and do not touch with bare hands.
WARNING!
Risk of injury from improper maintenance.
▶Maintenance may only be carried out by authorized technicians
and with the appropriate tools.
Risk of injury from unintentional activation of the system and
uncontrolled restart.
▶Secure system against unintentional activation.
▶Following maintenance, ensure a controlled restart.
9.2 Changing the bypass or heating
circuit valve
CAUTION!
Damage or malfunction due to incorrect screw joints.
Incorrect screw joints damage the device or impair its functionality.
Please note "9.1 Safety instructions"!
→Remove the pneumatic lines.
→Unscrew bypass or heating circuit valve using an open-end
wrench (DN 25, width across flats 41 mm).
→Remove old seal, clean sealing point, insert new seal.
Fig. 5: Insert seal
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Type 8835

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Maintenance, troubleshooting
CAUTION!
Discharge of medium due to damaged seal.
If the valve is screwed in incorrectly, the seal can be damaged.
▶Observe the thread start when inserting the valve.
Valves with control function A (closed by spring force):
▶In order to avoid damage to the seal, the valve must be pneu-
matically actuated before screwing it in.
→For control function A (SFA) pressurize the lower control air
connection with compressed air (6 bar): Valve opens.
→Screw in the actuator, tighten with an open-end wrench
(tightening torque 60 Nm ± 3 Nm).
→Screw in the angle connection, tighten with an open-end wrench
(tightening torque 6 Nm ± 1 Nm).
→Screw in the silencer, tighten with an open-end wrench
(tightening torque 2 Nm ± 0.2 Nm).
→Connect pneumatic lines.
→Check the device for function and leaks.
Fig. 6: Screw down actuator
Fig. 7: Screw down angle connection
Fig. 8: Screw down silencer
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Maintenance, troubleshooting
9.3 Changing pilot valve bar (VVL)
CAUTION!
Damage or malfunctions due to incorrect screw joints.
Incorrect screw joints damage the device or impair its functionality.
Please note "9.1 Safety instructions" on page 15!
→Remove the pneumatic lines.
→Remove the electrical connections.
→Loosen the fastening screws on the retaining bracket.
→Change pilot valve bar and screw to base block via retaining
bracket (tightening torque 8 Nm ± 1 Nm ).
→Screw device sockets with the associated seals onto the pilot
valves.
→Check the device for function and leaks.
Pilot valve bar with
pneumatic lines and
device sockets
Fastening screws
Retaining bracket
Base block
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Maintenance, troubleshooting
9.4 Changing hose connection
CAUTION!
Damage or malfunctions due to incorrect screw joints.
Incorrect screw joints damage the device or impair its functionality.
"9.1 Safety instructions" on page 15 Please note!
→Loosen cylinder head screws.
→Remove hose connection.
→Remove old O-ring, clean sealing point.
→Grease new O-ring with Multi-Silikonfett OKS 1110
(silicone grease).
→Insert the O-ring into the designated bore.
→Attach new hose connection.
→Screw in cylinder head screws in a criss-cross pattern
(tightening torque 2 Nm ± 0.2 Nm).
→Check the device for function and leaks.
Use only hoses which have a uniform hose thickness and a
central cross-section.
Cylinder head screws (4x)
Hose connection
Collar flange
Fig. 9: Grease new O-ring...
Fig. 10: ... and insert into designated bore.
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Maintenance, troubleshooting
9.5 Changing pressure controller
Please note "9.1 Safety instructions" on page 15!
→Vent pneumatic lines.
→Loosen double nipple using open-end wrench (AF 15).
→Changing pressure controller.
→Screw in double nipple (tightening torque 5 Nm ± 1 Nm).
→Check the device for function and leaks.
Double nipple
Pressure controller
Fig. 11: Changing pressure controller
9.6 Recommended auxiliary materials
To ensure faultless operation, maintenance and repair of the device,
the following auxiliary materials are recommended:
Type of aux-
iliary material
Product
designation
Manufacturer and
Internet address
Sealer and anti-
seize agents
Multi silicone
grease
OKS 1110
OKS Schmierstoffe GmbH
www.oks-germany.com
9.7 Malfunctions
Malfunction Possible cause Remedial action
Bypass or
heating circuit
valve does not
switch
No control air available Check air supply
Leak on hose con-
nection / hose
Change hose
connection / hose
Leak on valve actuator Change bypass valve
or heating circuit valve
No electrical signal
available
Check the power
supply on the
controller
Solenoid valve
defective
Change solenoid valve
or pilot valve bar
Heating circuit valve or
bypass valve defective
Change bypass valve
or heating circuit valve
Discharge
of process
media
Defective heating
circuit or bypass valve
Change bypass valve
or heating circuit valve
Defective
hose connection
Change fitting,
including the seal
Seat leakage
on the bypass
or heating
circuit valve
Change bypass valve
or heating circuit valve
Tab. 1: Malfunctions
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Spare parts
10 SPARE PARTS
CAUTION!
Risk of injury and/or damage due to the use of incorrect parts.
Incorrect accessories and unsuitable spare parts may cause
injuries and damage the device and the surrounding area.
▶Use original accessories and original spare parts from Bürkert
only.
Item Part designation Order no.
1
Heating circuit valve or
bypass valve DN25
NO 255 302
NC 262 941
Seal DN25 641 112
2 Angle connection with flow restrictor 0.5 mm 670 047
3 Silencer Set (10 pcs.) 672 188
4 Device socket with LED 24V AC/DC 423 849
5Solenoid valve strip for double matrix complete 677 410
Solenoid valve strip for triple matrix complete 675 760
6 Pressure controller 692 374
7
Hose connection straight
TU22 665 088
TU28 665 082
TU35 665 080
Hose connection angled
TU22 665 085
TU28 665 083
TU35 665 081
8 O-ring 28 x 2 FKM-70 Set (20 pcs.) 264 208
10.1 Parts overview triple matrix
②
⑥
⑤
④
③
⑦
①
The order numbers of the parts marked with figures can be found in
the table opposite or in the customer-specific spare parts list.
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Type 8835