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.
© 2010 - 2011 Bürkert Werke GmbH
Operating Instructions 1103/03_EN_00806150 / Original DE

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Control Head Type 8681
In h a l t
1. OPERATING INSTRUCTIONS.......................................................................................................................................................8
2. AUTHORIZED USE.............................................................................................................................................................................9
2.1. Export Restrictions................................................................................................................................................................9
2.2. Predictable Misuse................................................................................................................................................................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. Special Features..................................................................................................................................................................13
5.4. Functions / Options / Designs....................................................................................................................................14
5.4.1. Structure of the Control Head .....................................................................................................................14
5.4.2. Fluid diagram........................................................................................................................................................15
5.4.3. Number of solenoid valves............................................................................................................................16
5.4.4. Pneumatic Interfaces........................................................................................................................................16
5.4.5. Manual Control.....................................................................................................................................................16
5.4.6. Position Measuring System..........................................................................................................................17
5.4.7. Other Features ....................................................................................................................................................17
6. TECHNICAL DATA.............................................................................................................................................................................18
6.1. Operating Conditions........................................................................................................................................................18
6.2. Conformity with the following Standards ..............................................................................................................18
6.3. Mechanical data...................................................................................................................................................................19
6.4. Pneumatic Data ...................................................................................................................................................................20
6.5. Position Measuring System Data...............................................................................................................................21
6.6. Factory Settings in the Firmware ...............................................................................................................................22
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7. INSTALLATION ...................................................................................................................................................................................23
7.1. Safety instructions .............................................................................................................................................................23
7.2. Assembly of the Control Head.....................................................................................................................................23
7.2.1. Hub flange..............................................................................................................................................................23
7.2.2. Assembly Sequence on the Example of a Double-seated Valve .............................................24
7.2.3. Realignment of the Control Head..............................................................................................................25
7.2.4. Assembly of the Pneumatic and Electrical Connections..............................................................25
7.2.5. Recommended Auxiliary Materials ...........................................................................................................25
8. OPENING AND CLOSING THE HOUSING.........................................................................................................................26
8.1. Safety instructions .............................................................................................................................................................26
8.2. Opening and Closing the Housing ............................................................................................................................26
8.2.1. Opening the Housing .......................................................................................................................................26
8.2.2. Closing the Housing .........................................................................................................................................27
9. PNEUMATIC INSTALLATION ......................................................................................................................................................28
9.1. Safety instructions .............................................................................................................................................................28
9.2. Pneumatic Connection of the Control Head ........................................................................................................28
9.3. Flow Restriction Function of the Solenoid Valves.............................................................................................29
10. 24 V DC - DESIGN...........................................................................................................................................................................31
10.1. Electrical connection options ......................................................................................................................................31
10.2. Electrical Data ......................................................................................................................................................................31
10.3. Design Aid ..............................................................................................................................................................................33
10.4. Safety instructions .............................................................................................................................................................34
10.5. Electrical Installation / Start-up..................................................................................................................................34
10.5.1. Cable Gland with Screw-type Terminals................................................................................................34
10.5.2. Multi-pole Connection......................................................................................................................................37
11. AS INTERFACE - DESIGN...........................................................................................................................................................38
11.1. Definition .................................................................................................................................................................................38
11.2. Electrical Connection Options for AS Interface ................................................................................................39
11.3. Number of Connectable Control Heads and Maximum Length of the Bus Line..............................39
11.4. Electrical Data ......................................................................................................................................................................40
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11.5. Design Aid ..............................................................................................................................................................................42
11.6. Safety instructions .............................................................................................................................................................43
11.7. Electrical installation AS Interface ............................................................................................................................44
11.8. Programming Data.............................................................................................................................................................46
12. DEVICENET - DESIGN ..................................................................................................................................................................47
12.1. Definition .................................................................................................................................................................................47
12.2. Electrical connection option ........................................................................................................................................47
12.3. DeviceNet specification...................................................................................................................................................47
12.3.1. Total line length and maximum line length according to DeviceNet specification.........48
12.3.2. Drop Line Length.................................................................................................................................................48
12.4. Electrical Data ......................................................................................................................................................................49
12.5. Safety Position if the Bus Fails ...................................................................................................................................49
12.6. Design Aid ..............................................................................................................................................................................50
12.7. Safety instructions .............................................................................................................................................................51
12.8. Electrical Installation - DeviceNet..............................................................................................................................51
12.9. Network Topology of a DeviceNet System............................................................................................................53
12.10.Configuring the DeviceNet address / baud rate................................................................................................53
12.10.1. Settings of the DeviceNet address.......................................................................................................54
12.10.2. Setting the baud rate....................................................................................................................................55
12.11.Configuration of Process Data ....................................................................................................................................55
12.11.1. Static Input Assemblies..............................................................................................................................55
12.11.2. Static Output Assembly..............................................................................................................................56
12.12.Configuration of the device...........................................................................................................................................56
12.12.1. Configuration of the Safety Position of Solenoid Valves if Bus Error................................56
12.12.2. Configuration example ...............................................................................................................................57
12.13.Display of the Status LEDs in the event of a bus error..................................................................................58
12.13.1. Status of the device status LED "Modules" .....................................................................................58
12.13.2. State of bus status LED "Network".......................................................................................................59
13. 120 V AC - DESIGN .......................................................................................................................................................................60
13.1. Electrical connection options ......................................................................................................................................60
13.2. Electrical Data ......................................................................................................................................................................60
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13.3. Design Aid ..............................................................................................................................................................................62
13.4. Safety instructions .............................................................................................................................................................63
13.5. Electrical Installation / Start-up..................................................................................................................................63
14. CONNECTION OF AN EXTERNAL INITIATOR...................................................................................................................66
15. POSITION MEASURING SYSTEM..........................................................................................................................................67
15.1. Setting the Position Measuring System (Teach-In)..........................................................................................67
15.2. Teach-In Functions.............................................................................................................................................................68
15.2.1. Teach-In Functions and Teach-In Reset .................................................................................................68
15.2.2. Autotune functions ............................................................................................................................................69
15.2.3. Autotune sequence ..........................................................................................................................................69
16. LED - COLOR ASSIGNMENTS .................................................................................................................................................72
16.1. Setting the Color Combinations .................................................................................................................................73
16.2. Blinking Pattern & Fault Signaling.............................................................................................................................73
16.3. Signal Priorities....................................................................................................................................................................74
17. SERVICE MODE / MANUAL CONTROL ..............................................................................................................................75
17.1. Magnetic Manual Control................................................................................................................................................75
17.2. Mechanical Manual Control...........................................................................................................................................76
18. MAINTENANCE, TROUBLESHOOTING ...............................................................................................................................77
18.1. Safety instructions .............................................................................................................................................................77
18.2. Safety Positions...................................................................................................................................................................78
18.3. Maintenance ..........................................................................................................................................................................79
18.4. Cleaning...................................................................................................................................................................................79
18.5. Malfunctions ..........................................................................................................................................................................79
19. REPLACEMENT OF COMPONENTS AND MODULES.................................................................................................81
19.1. Safety instructions .............................................................................................................................................................81
19.2. Changing the Electronics Module..............................................................................................................................82
19.3. Changing the Valves..........................................................................................................................................................83
19.4. Changing the Position Measuring System............................................................................................................84
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20. SPARE PARTS ....................................................................................................................................................................................87
21. SHUTDOWN........................................................................................................................................................................................88
21.1. Safety instructions .............................................................................................................................................................88
21.2. Dismantling the Control Head Type 8681..............................................................................................................88
22. PACKAGING AND TRANSPORT...............................................................................................................................................89
23. STORAGE..............................................................................................................................................................................................89
24. DISPOSAL............................................................................................................................................................................................89
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Operating Instructions
OPERATING INSTRUCTIONS1.
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 which are important for your safety
and the flawless functioning of the device.
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
AUTHORIZED USE2.
Non-authorized use of the Control Head Type 8681 may be a hazard 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 the chapter 6. Technical Data.
In view of the large number of options for use it might be necessary to test prior to installation whether the•
control head is suitable for the concrete use.
If you have any questions, please contact your Bürkert Service Center.
The device may be used 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 and careful use and maintenance are essential for•
reliable and faultless operation.
For connecting the control head, use line installations that do not cause any mechanical stresses.•
Use the device only as intended.•
Export Restrictions2.1.
If exporting the system/device, observe any existing restrictions.
Predictable Misuse2.2.
Do not supply the medium connectors of the system with aggressive or flammable media.•
Do not supply the medium connectors with any liquids.•
Do not physically stress the housing (e.g. by placing objects on it or standing on it, or using it as attachment point•
for transport work).
Do not make any external modifications to the device housings. Do not paint the housing parts or screws.•
In the explosion-risk area, only wipe the control head with a damp or anti-static cloth to avoid electro-static•
charges!
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Basic Safety Instructions
BASIC SAFETY INSTRUCTIONS3.
These safety instructions do not make allowance for any
contingencies and events which may arise during the installation, operation and maintenance of the devices.•
local safety regulations - the operator is responsible for observing these regulations, also with reference to the•
installation personnel.
DANGER!
Danger – high pressure!
Before loosening pneumatic 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 the isolated state!•
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, quali-•
fied 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 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.•
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 DIN EN 61340-5-1 and 5-2 to minimize or avoid the possibility•
of damage caused by sudden electrostatic discharge!
Also, ensure that you do not touch electronic components when the power supply voltage is present!•
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Basic Safety Instructions
NOTE!
Connection of the Control Head
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.
Operation of the Control Head in Explosive Atmosphere
The housing may not be opened when devices are charged! It should be secured against unintentional opening•
using plastic self-cutting screws or seal (or comparable)!
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 may not be dirty!
Activating the DIP switches on the circuit board, using the service plug and the Teach buttons is• not allowed in
explosive atmosphere!
Cleaning
In the explosion-risk area, only wipe the control head with a damp or anti-static cloth to avoid electro-static•
charges.
Only use compatible cleaning agents for cleaning the securely closed control head and always rinse thoroughly•
with clean water.
For further information refer to the corresponding chapters of these operating instructions!
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.
Failure to observe this operating manual and its operating instructions as well as unauthorized tampering
with the device release us from any liability and also invalidate the warranty covering the devices and
accessories!
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Basic Safety Instructions
GENERAL INFORMATION4.
Contact address4.1.
Bürkert Fluid Control Systems
Sales Center
Christian-Bürkert-Straße 13-17
D-74653 Ingelfingen
Tel. : [phone]
Fax: [phone]
E-mail: [email protected]
Homepage: www.buerkert.com, www.buerkert.de
Warranty4.2.
The warranty is only valid if the control head is used as intended in accordance with the specified application
conditions.
Information on the Internet4.3.
The operating instructions and data sheets for control head type 8681 can be found on the Internet at:
www.buerkert.com
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System Description
SYSTEM DESCRIPTION5.
Intended Application Area5.1.
The Control Head Type 8681 has been designed for use as actuation of pneumatically operated process valves
and / or for recording the switching states of these.
General Description5.2.
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 contactless position measuring system, which works with three 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.
Special Features5.3.
Special features of the Control Head Type 8681 include:
easy-to-clean design with IP65 / IP67 protection•
high cleaning agent compatibility•
use of high-quality materials•
modular structure•
restrictable R- and P-connections for all pilot valves (solenoid valves)•
integrated pressure-relief valve in the inside of the housing for discharging leakage air with connection into the•
common exhaust air connection
collected exhaust air of all valve locations into one common exhaust air connection (by default equipped with a•
silencer)
if equipped with several working connections: one integrated non-return valve per connection in the exhaust air•
duct as protection against faulty switching of the process valves due to return pressure
central, super-bright optical display showing the process valve switching positions and design-specific addi-•
tional information in three signal colors
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System Description
short mechanical and pneumatic installation times.•
For increased safety requirements (e.g. in the explosion-risk area) a seal or a hood safeguard using plastic self-•
cutting screws (3 mm diameter, approx. 10 mm length; e.g. Ejot PT screws K 30 x 10) are required.
conform to the ATEX Directive 94/9/EC (Dust ATEX category 3D and Gas ATEX category 3G - see chapter•
6.2.)
Functions / Options / Designs5.4.
Structure of the Control Head5.4.1.
Electronics module with
connection terminals,
service interface and
Teach-In buttons
(back side)
Solenoid valve 3
Solenoid valve 2
Solenoid valve 1
Cable gland
(back side)
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 LED's in three 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
5.4.2. Fluid diagram
Control Head Type 8681 - Fluid diagram (with restriction capability for each solenoid valve):
Model with three Type 6524 solenoid valves,
e.g. for double-seated valve
Fluid diagram (model: 3 solenoid valves)Fig. 2:
The functions and designs of Control Head Type 8681 are described in the following chapters.
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System Description
Number of solenoid valves5.4.3.
The control head for process valves has been designed for single-acting and double-acting valve actuators as
well as for double-seated and multi-position valves.
Type of use Number of solenoid valves
(3/2-Way Solenoid Valve WWC*)
Repeater 0
Control head for single-acting actuators 1
Control head for double-acting actuators ** 2
Control head for double-seated valves with integrated aeration of both
valve seats 3
* WWC = circuit function C = 3/2-way valve; closed in rest position, output A unloaded
** both drive chambers currentless deaerated
Pneumatic Interfaces5.4.4.
Intake & exhaust air connections: G 1/4•
Working connections: G 1/8
Integrated non-return valves in the solenoid valves' exhaust air duct•
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.
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.
Manual Control5.4.5.
Standardly, the control head provides the following:
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•
a simple activation tool for opening & closing Solenoid Valve 1 (main stroke) -•
helpful for maintenance on the process valve
LED-display for the Activated Manual Control status, meaning service mode•
(see chapter 16. LED - Color Assignments and 17. Service Mode / Manual Control)
For a detailed description of the manual control, see chapter 17. Service Mode / Manual Control.
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System Description
Position Measuring System5.4.6.
The switching positions of the process valves are reported to the higher-level control by feedback signals from
the contactless position measuring system. Connection to the control head is done by means of a simple adap-
tation to the process valve's piston.
The recordable stroke range is between 0 and 80 mm.
Three binary feedback signals are evaluated:
- Position 1 (discrete S1OUT signal)
- Position 2 (discrete S2OUT signal)
- Position 3 (discrete S3OUT signal).
The 24 V DC design is additionally available in the order variant "Analog":
Order variant: - Position 1 (discrete S1OUT signal)
- Position 2 (discrete S2OUT signal)
- Position 3 (analog (4...20 mA) S3OUT signal).
Three Teach-In buttons have been provided for comparison with the actual stroke range (see chapter 15. Position
Measuring System). The switching positions for the position measuring system can be determined with these
buttons or by means of the service interface (on the electronics module).
An discrete, external feedback signal (standard proximity switch) can also be processed (S4IN, S4OUT).
If an explosive atmosphere is present the housing may not be opened when voltage is present.
For a detailed description of the electrical installation, see chapter 10. 24 V DC - Design or
chapter 11. AS Interface - Design.
For the setting of the Teach-In buttons, see chapter 15. Position Measuring System.
Other Features5.4.7.
Central optical position indicator for showing the process valve switching positions:•
Positions and status information can be indicated by means of three signal colors.
The assignment of the signal colors and the blinking pattern, which indicates the type of fault, are described in
chapter 16. 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 three 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 control by lowering the holding current during long-term operation•
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Technical Data
6. TECHNICAL DATA
Operating Conditions6.1.
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: -10 to +55 °C
Protection class: IP65 / IP67 according to EN 60529
(only if cables, plugs and sockets have been connected correctly, the VA hood has
been closed correctly and the adaptation to the process valve was done correctly)
IP69K according to IEC 40050-9
(Housing seal with connected exhaust conduit instead of silencer and ideally closed
cable glands confirmed through IP69K Standard testing)
6.2. Conformity with the following Standards
According to EC Declaration of Conformity (CE mark)
EMC Directive 2004/108/EC (previously: 89/336/EMC)
(only if cables, plugs and sockets have been connected correctly)
A Declaration of Conformity for the specific device can be requested from Bürkert.
ATEX 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
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Technical Data
Mechanical data6.3.
Cover safeguard:
- Seal max Ø2
and / or
- plastic self-cutting
screw 3.0x10
M16x1.5 (2x)
G1/4 (2x)
G1/8 (3x)
Dimensional drawingFig. 3:
Weight: ca. 0.8 kg
Housing material: outside: PA, PP, PPO, VA
inside: ABS, PA, PMMA
Sealing material: outside: CR, EPDM
inside: EPDM, FKM, NBR
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Technical Data
6.4. Pneumatic Data
Control medium: oil-free and dry air, neutral gases
Quality classes in accordance with DIN ISO 8573-1
(5 µm filter recommended)
Dust content Quality class 5: max. particle size 40 µm,
max. particle density 10 mg/m3
Water content Quality class 3: max. pressure dew point -20 °C or min. 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: 2.5 to 8 bar
Air rate solenoid valve: 110 IN/min (for aeration and deaeration, ventilation)
(110 IN/min - supplied state
200 IN/min - maximum typical flow-rate)
(QNn value according to definition for pressure drop from 7 to 6 bar absolute
at +20 °C)
Connections: Intake and exhaust air connection G1/4
Working connections G1/8
The intake and exhaust air can be set separately for each solenoid valve using flow restriction screws, in order to
be able to affect the expansion and retraction rates of the process valve (see figure below).
Mechanical
manual control
Red lever:
left: 0
right: 1
Flow restriction screws
for:
Exhaust R
Intake P
Flow restriction screws of the solenoid valvesFig. 4:
When setting the retraction and expansion rates of the pneumatic actuator consider that constant
"primary pressure" is not present during deaeration!
Keep in mind that the working conditions in the process valve area on the side of the product
(flow types, pressure variations) may result in changes in the set aeration and deaeration times.
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