Burkert 8681 User manual

Operating Instructions
Type 8681
Control Head

We reserve the right to make technical changes without notice.
Technische Änderungen vorbehalten.
Sous resérve de modification techniques.
© Bürkert Werke GmbH, 2010 - 2014
Operating Instructions 1412/05_EN_00806150 / Original DE

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Control Head Type 8681
Contents
1. OPERATING INSTRUCTIONS ........................................................................................................................................................8
2. AUTHORIZED USE .............................................................................................................................................................................9
2.1. Export restrictions .................................................................................................................................................................9
3. BASIC SAFETY INSTRUCTIONS ..............................................................................................................................................10
4. GENERAL INFORMATION .............................................................................................................................................................12
4.1. Contact address ..................................................................................................................................................................12
4.2. Warranty ...................................................................................................................................................................................12
4.3. Information on the Internet ............................................................................................................................................12
5. SYSTEM DESCRIPTION ................................................................................................................................................................13
5.1. Intended application area ...............................................................................................................................................13
5.2. General description ...........................................................................................................................................................13
5.3. Functions / options / designs .....................................................................................................................................14
5.3.1. Structure of the control head .......................................................................................................................14
5.3.2. Fluid diagrams .....................................................................................................................................................15
5.3.3. Number of solenoid valves............................................................................................................................16
5.3.4. Pneumatic interfaces ........................................................................................................................................16
5.3.5. Manual control......................................................................................................................................................17
5.3.6. Position measuring system ..........................................................................................................................17
5.3.7. Other features ......................................................................................................................................................17
6. TECHNICAL DATA .............................................................................................................................................................................18
6.1. Operating conditions ........................................................................................................................................................18
6.2. Conformity with the following standards ...............................................................................................................18
6.3. Rating plate specifications ...........................................................................................................................................19
6.4. Mechanical data ...................................................................................................................................................................21
6.5. Pneumatic data ....................................................................................................................................................................23
6.6. Position measuring system data ................................................................................................................................24
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6.7. Factory settings in the firmware .................................................................................................................................25
6.7.1. Feedback fields (position measuring system) .................................................................25
6.7.2. Service / maintenance notification (maintenance request) ........................................26
6.7.3. Manual control function (magnetic) ...................................................................................26
6.8. Resetting the device (Device Reset) ........................................................................................................................27
7. ASSEMBLY ...........................................................................................................................................................................................28
7.1. Safety instructions .............................................................................................................................................................28
7.2. Assembly of the control head ......................................................................................................................................28
7.2.1. Hub flange ..............................................................................................................................................................28
7.2.2. Assembly sequence on the example of a double-seated valve ...............................................29
7.2.3. Realignment of the control head................................................................................................................30
7.2.4. Assembly of the pneumatic and electrical connections ...............................................................30
7.2.5. Recommended auxiliary materials ............................................................................................................30
8. OPENING AND CLOSING THE HOUSING ..........................................................................................................................31
8.1. Safety instructions .............................................................................................................................................................31
8.2. Opening and closing the housing ..............................................................................................................................31
8.2.1. Opening the housing ........................................................................................................................................31
8.2.2. Closing the housing ..........................................................................................................................................32
9. PNEUMATIC INSTALLATION .......................................................................................................................................................33
9.1. Safety instructions .............................................................................................................................................................33
9.2. Pneumatic connection of the control head ...........................................................................................................33
9.3. Flow restriction function of the solenoid valves ................................................................................................34
10. 24 V DC - DESIGN............................................................................................................................................................................36
10.1. Electrical connection options ......................................................................................................................................36
10.2. Electrical data .......................................................................................................................................................................36
10.3. Design aid ...............................................................................................................................................................................38
10.4. Safety instructions .............................................................................................................................................................39
10.5. Electrical installation / start-up ...................................................................................................................................39
10.5.1. Cable gland with screw terminals .............................................................................................................39
10.5.2. Multi-pole connection.......................................................................................................................................42
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11. AS INTERFACE - DESIGN ............................................................................................................................................................43
11.1. Definition .................................................................................................................................................................................43
11.2. Electrical connection options for AS interface ..................................................................................................44
11.3. Number of connectable control heads and maximum length of the bus line ...................................44
11.4. Electrical data .......................................................................................................................................................................45
11.5. Design aid ...............................................................................................................................................................................47
11.6. Safety instructions .............................................................................................................................................................48
11.7. Electrical installation of the AS interface ...............................................................................................................49
11.8. Programming data ..............................................................................................................................................................51
12. DEVICENET - DESIGN ...................................................................................................................................................................52
12.1. Definition .................................................................................................................................................................................52
12.2. Electrical connection option ........................................................................................................................................52
12.3. DeviceNet specification ...................................................................................................................................................52
12.3.1. Total line length and maximum line length according to DeviceNet specification .........53
12.3.2. Drop line length ...................................................................................................................................................53
12.4. Electrical data .......................................................................................................................................................................54
12.5. Safety position if the bus fails .....................................................................................................................................54
12.6. Design aid ...............................................................................................................................................................................55
12.7. Safety instructions .............................................................................................................................................................56
12.8. Electrical installation - DeviceNet ..............................................................................................................................56
12.9. Network topology of a DeviceNet system .............................................................................................................58
12.10. Configuring the DeviceNet address / baud rate ................................................................................................58
12.10.1. Settings of the DeviceNet address .....................................................................................................59
12.10.2. Setting the baud rate ..................................................................................................................................60
12.11. Configuration of the process data .............................................................................................................................60
12.11.1. Static input assemblies .............................................................................................................................60
12.11.2. Static output assembly ..............................................................................................................................61
12.12. Configuration of the device ...........................................................................................................................................61
12.12.1. Configuration of the safety position of solenoid valves during a bus error ..................61
12.12.2. Configuration example .............................................................................................................................62
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12.13. Display of the status LEDs in the event of a bus error ..................................................................................63
12.13.1. Status of the device status LED "Modules" ....................................................................................63
12.13.2. State of bus status LED "Network" ......................................................................................................64
13. 120 V AC - DESIGN ........................................................................................................................................................................65
13.1. Electrical connection options ......................................................................................................................................65
13.2. Electrical data .......................................................................................................................................................................65
13.3. Design aid ...............................................................................................................................................................................66
13.4. Safety instructions .............................................................................................................................................................67
13.5. Electrical installation / start-up ...................................................................................................................................68
14. CONNECTION OF AN EXTERNAL INITIATOR ....................................................................................................................71
15. SPECIAL DESIGNS ..........................................................................................................................................................................73
15.1. Control head for double-acting actuators .............................................................................................................73
15.1.1. Anomalies ...............................................................................................................................................................73
15.1.2. Fluid diagram .......................................................................................................................................................73
15.1.3. Activation of a double-acting actuator ....................................................................................................73
15.2. Control head (AS-i) with 2 external initiators ......................................................................................................74
15.2.1. Anomalies ...............................................................................................................................................................74
15.2.2. Electrical installation and programming data .....................................................................................74
16. POSITION MEASURING SYSTEM ............................................................................................................................................75
16.1. Setting the position measuring system (Teach-In) ..........................................................................................76
16.2. Teach button functions ....................................................................................................................................................77
16.2.1. Teach functions and Teach reset ...............................................................................................................77
16.2.2. Autotune functions ............................................................................................................................................78
16.2.3. Autotune sequence ..........................................................................................................................................78
17. LED COLOR ASSIGNMENTS ......................................................................................................................................................81
17.1. Setting the color combinations ...................................................................................................................................82
17.2. Blinking pattern & fault signaling ...............................................................................................................................82
17.3. Signal priorities ....................................................................................................................................................................83
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18. SERVICE MODE / MANUAL CONTROL ...............................................................................................................................84
18.1. Magnetic manual control ................................................................................................................................................84
18.2. Mechanical manual control ...........................................................................................................................................85
19. MAINTENANCE, TROUBLESHOOTING .................................................................................................................................86
19.1. Safety instructions .............................................................................................................................................................86
19.2. Safety positions ...................................................................................................................................................................87
19.3. Maintenance / service ......................................................................................................................................................88
19.4. Cleaning ...................................................................................................................................................................................88
19.5. Malfunctions ..........................................................................................................................................................................88
20. REPLACEMENT OF COMPONENTS AND MODULES ...................................................................................................90
20.1. Safety instructions .............................................................................................................................................................90
20.2. Changing the electronics module ..............................................................................................................................91
20.3. Changing the valves ..........................................................................................................................................................92
20.4. Changing the position measuring system ............................................................................................................93
21. SHUTDOWN ........................................................................................................................................................................................96
21.1. Safety instructions .............................................................................................................................................................96
21.2. Dismantling the control head Type 8681 ...............................................................................................................96
22. PACKAGING AND TRANSPORT ...............................................................................................................................................97
23. STORAGE ..............................................................................................................................................................................................97
24. DISPOSAL ............................................................................................................................................................................................97
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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.
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
Incorrect use of the control head Type 8681 may be dangerous to people, nearby equipment and
the environment.
• The control head has been designed for use as actuation of pneumatically operated process valves and / or
for recording the switching states of these.
• Use according to the authorized data, operating conditions and conditions of use specified in the contract
documents and operating instructions. These are described in Chapter 6. Technical data.
• In view of the large number of application options, check and, if necessary, test prior to installation whether
the control head is suitable for the specific application case:
Should you have any questions, please contact your Bürkert Service Center.
• Use the device only in conjunction with third-party devices and components recommended and authorized by
Bürkert.
• Any unauthorized reconstructions and changes to the control head are prohibited for safety reasons.
• Correct transportation, correct storage and installation as well as careful operation and maintenance are
essential for reliable and problem-free operation.
• For connecting the control head, use line installations that do not cause any mechanical stresses.
• Use the device only as intended.
2.1. Export 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 assembly, operation, and maintenance of the devices.
• local safety regulations – the operator is responsible for observing these regulations, also in relation to the instal-
lation personnel.
DANGER!
Danger – high pressure!
• Before loosening lines and valves, turn off the pressure and vent the lines.
Danger of explosion in explosive atmosphere (only in the event of a fault as zone 2)!
• Opening the hood or the housing in an explosive atmosphere is only allowed in a not energized state!
• Secure the housing with a lead seal to prevent it from being opened without a tool!
• Activating the DIP switches on the PCB, using the service interface and the Teach buttons, is not permitted in
an explosive atmosphere!
• Layers of dust on the housing may not exceed 5 mm! Lint, conductive and non-conductive dust particles are
allowed. The inside of the housing must not be dirty!
• When wiping the control head, use a damp or anti-static cloth in the explosion-risk area to prevent electrostatic
charges!
• Use only cables and cable glands which have been approved for the respective application area and which
have been screwed into place according to the respective installation instructions!
• Close all unnecessary openings with locking screws/sealing plugs approved for explosions area!
WARNING!
Risk of electric shock!
• Before reaching into the system (except for the Teach-In procedure in a non-explosive atmosphere) switch off
the power supply and secure it to prevent restarting!
• Observe applicable accident prevention and safety regulations for electrical equipment!
General hazardous situations.
To prevent injuries:
• Ensure that the system cannot be activated unintentionally.
• Installation and maintenance work, as well as operator control actions may be carried out by authorized and
qualified technicians only and with the appropriate tools.
• Do not make any unauthorized internal or external changes to the device!
• After an interruption in the electrical or pneumatic supply, ensure that the process is restarted in a defined or
controlled manner.
• The device may be installed and 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.
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Basic Safety Instructions
NOTE!
Electrostatic sensitive components/modules!
• The device contains electronic components which react sensitively to electrostatic discharge (ESD). Contact
with electrostatically charged persons or objects may be 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 sudden electrostatic discharge!
• Also ensure that you do not touch electronic components when the supply voltage is on!
NOTE!
Risk of damage to property!
• Do not connect any mechanically rigid connection parts, in particular those with long lever arms, as such con-
nections could generate torques that might damage the control head.
• Do not supply the medium connections of the system with liquids or aggressive or flammable media!
• Do not subject the housing to mechanical loads (e.g. by placing objects on it or standing on it).
• Do not make any external changes to the housings of the device. Do not paint housing parts or screws.
• Only use compatible cleaning agents for cleaning the securely closed control head and always rinse thoroughly
with clean water.
Control head Type 8681 was developed with due consideration given to accepted safety rules and is state-
of-the-art. Nevertheless, dangerous situations may occur.
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Basic Safety Instructions
4. GENERAL INFORMATION
4.1. Contact address
Bürkert Fluid Control Systems
Sales Center
Christian-Bürkert-Straße 13-17
D-74653 Ingelfingen, Germany
Tel.: [phone]
Fax: [phone]
Email: [email protected]
Website: www.burkert.com
4.2. Warranty
The warranty is only valid if the control head is used as intended in accordance with the specified application
conditions.
4.3. Information on the Internet
The operating instructions and data sheets for control head type 8681 can be found on the Internet at:
www.burkert.com
> Documentation > Operating instructions/approvals > Type search
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System Description
5. SYSTEM DESCRIPTION
5.1. Intended application area
The control head Type 8681 has been designed for use as an actuator for pneumatically operated process valves
and / or for recording the switching states of these.
5.2. General description
The control head Type 8681 is used for actuating pneumatically operated process valves.
For process valve actuation, the control head can be equipped with up to three solenoid valves.
For the recording and feedback of the process valve switching positions to a higher-level control, the control head
has been equipped with a contact-free position measuring system which operates with 3 discrete, adjustable
feedback signals (Teach-In function).
The control head and the process valve are interconnected by an adapter. This produces an integrated, compact
and decentralized system of feedback, actuation and valve function. The following advantages over centralized
solutions working with valve clusters are achieved:
• low installation expenditure
• easy start-up
• higher application-specific flexibility
• shorter switching times and less air consumption due to shorter distances between the pilot valve and the
process valve.
Various pneumatic and electrical connection variants are available.
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System Description
5.3. Functions / options / designs
5.3.1. Structure of the control head
Electronics module with
connection terminals,
service interface and
Teach-In buttons (rear)
Solenoid valve 3
Solenoid valve 1
Solenoid valve 2
Cable glands
(rear)
Exhaust air connection (3/R)
Mechanical manual control
(red lever)
Supply pressure
connection(1/P)
Working connections
(2/A1...3)
Flow restriction screw(s) for
P and R (2 per solenoid valve)
Solenoid valve 3 (2/A3)
Solenoid valve 2 (2/A2)
Solenoid valve 1 (2/A1)
Position measuring system
with LEDs in 3 colors
Silencer in the exhaust air
connection (3/R), not shown
Sealing lug
(on lower housing part)
2 locking screws
(shoulder screws M5).
No sealing function,
merely as protection
against pulling off from
the hub flange
Locking groove (3x)
Fig. 1: Structure of control head Type 8681
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System Description
5.3.2. Fluid diagrams
Control head Type 8681 - Fluid diagram (with restriction capability for each solenoid
valve):
Model with 3 solenoid valves Type 6524,
e.g. for double-seated valve
Fig. 2: Fluid diagram (model: 3 solenoid valves)
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System Description
Control head Type 8681 - design for double-acting actuators - fluid diagram
(with restriction option of each solenoid valve):
Model with 2 solenoid valves Type 6524 (solenoid valve 1: NC, solenoid valve 2: NO,
for double-acting actuators (safety position) - see also Chapter “15. Special designs” on page 73.
Process valve
up /
open
down /
close
Fig. 3: Fluid diagram (design for double-acting actuators: 2 solenoid valves, NC* + NO** )
5.3.3. Number of solenoid valves
The control head for process valves has been designed for single-acting and double-acting actuators as well as
for double-seated and multi-position valves.
Type of use Number of solenoid valves
Repeater 0
Control head for single-acting actuators 1 (NC*)
Control head for double-acting actuators
(both drive chambers not energized and deaerated) 2 (2 x NC*)
Control head for double-seated valves with integrated aeration of both
valve seats 3 (3 x NC*)
Control head for double-acting actuators (with safety position) 2 (1 x NC* + 1 x NO**)
1
Details on design for double-acting actuators (1 solenoid valve NC*, 1 solenoid valve NO**) - see Chapter “15.
Special designs” on page 73.
5.3.4. Pneumatic interfaces
• Intake & exhaust air connections: G 1/4
Working connections: G 1/8
• Integrated non-return valves in the solenoid valves' exhaust air duct
* NC = 3/2-way valve; closed in rest position, output A relieved
** NO = 3/2-way valve; opened in rest position, output A pressurized
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System Description
• Actuation of Connection 2/A1 (Solenoid Valve 1; normally the main stroke of the process valve) using the mag-
netic manual control that is externally accessible.
(both solenoid valves are actuated simultaneously for the design for double-acting actuators)
• Special silencers with a high flow-rate capacity to connection 3/R have already been mounted.
• The interior of the housing is protected against excessive overpressure, for example due to leakages, by a
pressure-relief valve with output into the joint exhaust air connection 3/R.
5.3.5. Manual control
The control head provides the following as standard:
• a magnetic manual control that is easily accessible from the outside on the basis of encoded magnetic fields for
Solenoid Valve 1 (Connection 2/A1), as well as
• a mechanical manual control accessible when the hood is open on each equipped solenoid valve
The magnetic manual control has the following advantages:
• the control head does not need to be opened
• simple actuation tool for opening/closing solenoid valve 1 (main stroke) -
helpful for service/maintenance work on the process valve
(both solenoid valves are actuated simultaneously for the design for double-acting actuators)
• LED display for the "activated manual control" status = service mode
(see Chapters “17. LED Color Assignments” and “18. Service Mode / Manual Control”)
For a detailed description of the manual control, see Chapter “18. Service Mode / Manual Control”.
5.3.6. Position measuring system
The switching positions of the process valves are reported to the actuator by feedback signals from the sol-
derless position measuring system. Connection to the control head is done by means of a simple adaptation to
the process valve's piston. Details are described in Chapters “6.6. Position measuring system data” on page
24 and “16. Position Measuring System” on page 75.
5.3.7. Other features
• Central optical position indicator for showing the process valve switching positions:
Positions and status information can be indicated by 3 signal colors.
The assignment of the signal colors and the "blinking pattern", which indicates the type of fault, are described in
Chapter “17. LED Color Assignments”.
• Simple adaptation of the control head (for the position measuring system) to the process valve piston rod
• Simple adjustment of the position measuring system by 3 Teach-In buttons on the electronics module
• The capability of restricting the pilot valve (solenoid valve) for the individual setting of the expansion and
retraction rates of the process valve and the individual setting of the flow-rate of the working connections
• More energy efficient solenoid valve actuation by lowering the holding current during long-term operation
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Technical Data
6. TECHNICAL DATA
6.1. Operating conditions
DANGER!
Danger of explosion in explosive atmosphere (only in the event of a fault as zone 2)!
• Do not expose the device to any mechanical or thermal loads that will exceed the limits described in the oper-
ating instructions.
WARNING!
Risk of injury from overheating of the control head.
Heating above the permitted temperature range can endanger people, the device and the environment.
• Do not expose the device to any mechanical or thermal loads that will exceed the limits described in the oper-
ating instructions.
Ambient temperature: Standard version: -10 ... +55 °C
Explosive atmosphere (Zone 2): +5 ... +55 °C
Degree of protection: Standard version:
IP65 / IP67 according to EN 60529
(only if cables, plugs and sockets have been connected correctly, the hood
has been sealed correctly and the adaptation to the process valve was done
correctly)
IP69K according to IEC 40050-9
(Housing seal with connected exhaust air line instead of silencer and ideally
closed cable glands confirmed through IP69K Standard testing)
Version for use in explosive atmosphere (Zone 2):
IP64 according to EN 60529 and requirements EN 60079-0: 2009
(only if cables, plugs and sockets have been connected correctly, the hood
has been sealed correctly and the adaptation to the process valve was done
correctly)
6.2. Conformity with the following standards
The control head conforms to the EC Directives according to the EC Declaration of Conformity.
The applied standards, which are used to demonstrate compliance with the EC Directives, are listed in the EC
Declaration of Conformity and/or the EC type test certificate. These are available from Bürkert.
The specifications on the respective rating plate apply to the respective control head. The symbols on the rating
plate indicate the applicable directives or approvals:
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Technical Data
Pressure Equipment Directive 94/9/EC
Ignition protection type: Dust ATEX category 3D Ex tD A22 T135°C or
Ex tc IIIC T135°C
Gas ATEX category 3G Ex nA IIC T4 or
Ex nAc IIC T4
FM - Factory Mutual
NI/I/2/ABCD/T5; +5°C < Ta < 55°C IP64
(cables and cable glands are not part of the FM approval of the device and are
therefore not fitted at the factory.)
c UL us - Underwriters Laboratories (Canada and USA)
UL 61010-1 AND CSA C22.2 NO. 61010-1
Restrictions: Application area: 0 to +55°C,
Indoor use,
power supply with class-2 power supply unit
6.3. Rating plate specifications
Line 1
Line 2
Line 3
Line 4
Line 5
Line 6
Line 1
Line 2
Line 3
Line 4
Line 5
Symbols:
Device complies with European standards according to EC Declaration of Conformity
Approval according to the Pressure Equipment Directive
FM approval for explosion-proof equipment
UL approval for USA and Canada
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Technical Data
Lines: Rating plate
1 Device designation
2 Operating voltage or type of communication (24 V DC, AS-i, DVN, 120 V DC) /
type of actuator (MV0 = no MV, MV1 = single-action, MV2 = 2 MV, not double-acting,
MV3 = 3 MV, MVD = 2 MV, double-acting) / pressure range
3 Permitted pressure range
4 Permitted temperature range
5 Serial number
6 ID number / manufacturer's specifications
Lines: Warning sign
1 any specifications, if applicable, according to Pressure Equipment Directive (gas) / ambient
temperature
2 any specifications, if applicable, according to Pressure Equipment Directive (dust) / degree
of protection specification
3WARNING! WARNING! In explosion-risk areas ...
4 ... the surface must only be wiped down with a damp cloth.
5 In hazardous areas, the surface may only be cleaned with a damp cloth.
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