Burkert 8692 User manual

Operating Instructions
Bedienungsanleitung
Manuel d‘utilisation
Type 8692, 8693
Electropneumatic positioner and process controller

We reserve the right to make technical changes without notice.
Technische Änderungen vorbehalten.
Sous réserve de modifications techniques.
© Bürkert Werke GmbH & Co.KG, 20 - 2017
Operating Instructions 1706/_(8(1_0080 / Original DE

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Table of conTenTs
GENERAL INFORMATION AND SAFETY INSTRUCTIONS ....................................................................................................5
1 Operating instructions .........................................................................................................................................................6
2 Authorized use ........................................................................................................................................................................7
3 Basic safety instructions ....................................................................................................................................................8
4 General information ..............................................................................................................................................................9
DESCRIPTION OF SYSTEM ...................................................................................................................................................................11
5 DESCRIPTION AND FEATURES OF TYPE 8692/8693 ....................................................................................13
6 Structure ..................................................................................................................................................................................17
7 Positioner Type 8692 ........................................................................................................................................................19
8 Process controller Type 8693 .......................................................................................................................................23
9 Interfaces of the positioner / process controller ..............................................................................................27
10 Technical data .......................................................................................................................................................................28
11 Accessories ............................................................................................................................................................................32
INSTALLATION ...............................................................................................................................................................................................33
12 Installation ..............................................................................................................................................................................35
13 Electrical Installation 24 V DC ......................................................................................................................................49
14 Disassembly of Type 8692/8693 ................................................................................................................................61
OPERATION .....................................................................................................................................................................................................63
15 Operating levels ...................................................................................................................................................................64
16 Operating and display elements .................................................................................................................................65
17 Operating states ..................................................................................................................................................................73
18 Activating and deactivating auxiliary functions ...................................................................................................74
19 Manually opening and closing the valve ................................................................................................................76
START-UP ..........................................................................................................................................................................................................77
20 Start-up sequence ..............................................................................................................................................................78
21 Safety instructions .............................................................................................................................................................79
22 Basic setting of the device ............................................................................................................................................79
Type 8692, 8693
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Contens

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Type 8692, 8693
23 Activation of the process controller ..........................................................................................................................86
24 Basic setting of the process controller ...................................................................................................................87
AUXILIARY FUNCTIONS .......................................................................................................................................................................107
25 Configuring the auxiliary functions ........................................................................................................................108
OPERATING STRUCTURE / FACTORY SETTINGS ............................................................................................................... 177
26. Operating structure and factory settings ............................................................................................................ 178
PROFIBUS DP ............................................................................................................................................................................................. 193
27 Description of the PROFIBUS DP ...........................................................................................................................194
28 Electrical connections ...................................................................................................................................................196
29 Start-up PROFIBUS DP ................................................................................................................................................ 199
DEVICENET ................................................................................................................................................................................................... 207
30 Description .......................................................................................................................................................................... 208
31 Electrical connections ...................................................................................................................................................212
32 Start-up DeviceNet .......................................................................................................................................................... 216
MAINTENANCE AND TROUBLESHOOTING .............................................................................................................................. 227
33 Maintenance ....................................................................................................................................................................... 228
34 Error messages and malfunctions .........................................................................................................................228
PACKAGING, STORAGE, DISPOSAL ............................................................................................................................................233
35 Packaging and transport .............................................................................................................................................. 234
36 Storage .................................................................................................................................................................................. 234
37 Disposal ................................................................................................................................................................................ 234
ADDITIONAL TECHNICAL INFORMATION .................................................................................................................................235
38 Selection criteria for continuous valves ..............................................................................................................236
39 Properties of PID Controllers .................................................................................................................................... 238
40 Adjustment rules for PID Controllers .................................................................................................................... 243
TABLES FOR CUSTOMER-SPECIFIC SETTINGS .................................................................................................................. 247
41. Table for your settings on the positioner ............................................................................................................ 248
42. Table for your settings on the process controller Type 8693 .................................................................. 249
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Contents

5
conTenTs
1 OPERATING INSTRUCTIONS ........................................................................................................................................................6
1.1 Symbols ......................................................................................................................................................................................6
1.2 Definition of the term “device” ........................................................................................................................................6
2 AUTHORIZED USE .............................................................................................................................................................................7
2.1 Restrictions ...............................................................................................................................................................................7
3 BASIC SAFETY INSTRUCTIONS .................................................................................................................................................8
4 GENERAL INFORMATION ................................................................................................................................................................9
4.1 Scope of supply ......................................................................................................................................................................9
4.2 Contact address .....................................................................................................................................................................9
4.3 Warranty ......................................................................................................................................................................................9
4.4 Master code ..............................................................................................................................................................................9
4.5 Information on the internet ...............................................................................................................................................9
General information and safety instructions
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Type 8692, 8693

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General Information
Safety 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.
1.1 Symbols
DANGER!
Warns of an immediate danger!
▶Failure to observe the warning may result in a fatal or serious injury.
WARNING!
Warns of a potentially dangerous situation!
▶Failure to observe the warning may result in serious injuries or death.
CAUTION!
Warns of a possible danger!
▶Failure to observe this warning may result in a medium or minor injury.
NOTE!
Warns of damage to property!
• 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 that must be carried out.
1.2 Definition of the term “device”
In these instructions, the term “device” always refers to the Type 8692/8693
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Type 8692, 8693

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General Information
Safety Instructions
2 AUTHORIZED USE
Incorrect use of the Type 8692 and 8693 can be dangerous to people, nearby equipment and the
environment.
The device is designed to be mounted on pneumatic actuators of process valves for the control of media.
▶In a potentially explosive area, Type 8692 and 8693 may be used only in accordance with the specification on
the separate Ex rating plate. For the use, observe the ATEX manual with safety instructions for the Ex area.
▶Devices without a separate Ex rating plate may not be used in a potentially explosive area.
▶The device must not be exposed to direct sunlight.
▶Pulsating direct voltage (rectified alternating voltage without smoothing) must not be used as operating
voltage.
▶During use observe the permitted data, the operating conditions and conditions of use specified in the con-
tract documents and operating instructions, as described in chapter “10 Technical data” in this manual and in
the valve manual for the respective pneumatically actuated valve.
▶The device may be used only in conjunction with third-party devices and components recommended and
authorised by Bürkert.
▶In view of the wide range of possible application cases, check whether the device is suitable for the specific
application case and check this out if required.
▶Correct transportation, correct storage and installation and careful use and maintenance are essential for reli-
able and faultless operation.
▶Use the Type 8692 and 8693 only as intended.
2.1 Restrictions
If exporting the system/device, observe any existing restrictions.
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Type 8692, 8693

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General Information
Safety Instructions
3 BASIC SAFETY INSTRUCTIONS
These safety instructions do not make allowance for any
• contingencies and events which may arise during the installation, operation and maintenance of the devices.
• local safety regulations – the operator is responsible for observing these regulations, also with reference to the
installation personnel.
Risk of injury from high pressure in the system/device.
▶Before working on the system or device, switch off the pressure and vent/drain lines.
Risk of injury due to electrical shock.
▶Before reaching into the device or the equipment, switch off the power supply and secure to prevent
reactivation!
▶Observe applicable accident prevention and safety regulations for electrical equipment.
General hazardous situations.
To prevent injuries:
▶The device must only be operated when in a perfect condition and in consideration of the operating
instructions.
▶Secure the system/device from unintentional actuation.
▶Only trained technicians may perform installation and maintenance work.
▶After an interruption in the power supply, ensure that the process is restarted in a controlled manner.
▶Observe the general rules of technology.
To prevent damage to the device:
▶When unscrewing and screwing the housing jacket (with transparent cap) in, do not hold the actuator but the
electrical connection housing of Type 8692/8693.
▶Do not supply the pilot air port with aggressive or flammable media or fluids.
▶Do not make any internal or external changes on the device and do not subject it to mechanical stress.
NOTE!
Electrostatic sensitive components / modules!
The device contains electronic components which react sensitively to electrostatic discharge (ESD). Contact
with electrostatically charged persons or objects is 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 minimise or avoid the possibility of damage
caused by sudden electrostatic discharge!
• Also ensure that you do not touch electronic components when the operating voltage is present!
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Type 8692, 8693

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General Information
Safety Instructions
4 GENERAL INFORMATION
4.1 Scope of supply
In general it consists of:
• Type 8692/8693 and associated operating instructions.
- Brief instructions (Quickstart) in printed form as well as
- Main instructions on CD.
For the circular plug-in connector version (multi-pole version) of Type 8692/8693, we will provide you with
suitable cable connectors as accessories.
If there are any discrepancies, please contact us immediately.
4.2 Contact address
Germany
Bürkert Fluid Control Systems
Sales Center
Chr.-Bürkert-Str. 13-17
D-74653 Ingelfingen
Tel. + 49 (0) 7940 - 10 91 111
Fax + 49 (0) 7940 - 10 91 448
E-mail: [email protected]
International
Contact addresses can be found on the final pages of the printed brief instructions (Quickstart).
And also on the internet at: www.burkert.com
4.3 Warranty
The warranty is only valid if the Type 8692/8693 are used as intended in accordance with the specified application
conditions.
4.4 Master code
Operation of the device can be locked via a freely selectable user code. In addition, there is a non-changeable master
code with which you can perform all operator actions on the device. This 4-digit master code can be found on the
last pages of the printed brief instructions which are enclosed with each device.
If required, cut out the code and keep it separate from these operating instructions.
4.5 Information on the internet
The operating instructions and data sheets for Type 8692 and 8693 can be found on the Internet at:
www.burkert.com
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Type 8692, 8693

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General Information
Safety Instructions
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Type 8692, 8693

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conTenTs
5 DESCRIPTION AND FEATURES OF TYPE 8692/8693 .................................................................................................13
5.1 General description ...........................................................................................................................................................13
5.2 Features ...................................................................................................................................................................................13
5.3 Combinations with valve types and mounting versions ................................................................................14
5.3.1 Overview of mounting possibilities / features of valve types ....................................................15
5.4 Designs ....................................................................................................................................................................................16
5.4.1 Type 8692, positioner .......................................................................................................................16
5.4.2 Type 8693, process controller ........................................................................................................16
6 STRUCTURE ........................................................................................................................................................................................17
6.1 Representation .....................................................................................................................................................................17
6.2 Function diagram ................................................................................................................................................................18
6.2.1 Diagram illustrating single-acting actuator ...................................................................................18
7 POSITIONER TYPE 8692 ..............................................................................................................................................................19
7.1 Schematic representation of the position control ............................................................................................20
7.2 Positioner software ............................................................................................................................................................21
8 PROCESS CONTROLLER TYPE 8693 ....................................................................................................................................23
8.1 Schematic representation of process control .....................................................................................................24
8.2 The process controller software .................................................................................................................................25
9 INTERFACES OF THE POSITIONER / PROCESS CONTROLLER ...........................................................................27
10 TECHNICAL DATA .............................................................................................................................................................................28
10.1 Conformity ..............................................................................................................................................................................28
10.2 Standards ................................................................................................................................................................................28
10.3 Licenses ...................................................................................................................................................................................28
10.4 Operating conditions ........................................................................................................................................................28
10.5 Rating plate ............................................................................................................................................................................29
10.5.1 UL additional label .............................................................................................................................29
10.6 Mechanical data ...................................................................................................................................................................29
Description of System
Type 8692, 8693
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Description of System
Type 8692, 8693
10.7 Pneumatic data ....................................................................................................................................................................29
10.8 Electrical data .......................................................................................................................................................................30
10.9 Safety end positions after failure of the electrical or pneumatic auxiliary power ...........................31
10.10 Factory settings ...................................................................................................................................................................32
11.1 Communications software .............................................................................................................................................32
11.2 USB interface ........................................................................................................................................................................32
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Description of System
Type 8692, 8693
5 DESCRIPTION AND FEATURES OF TYPE
8692/8693
5.1 General description
Positioner Type 8692 / process controller Type 8693 is an electropneumatic position controller for pneumatically
actuated control valves with single-acting or double-acting actuators. The device incorporates the main function groups
- Position sensor
- Electro-pneumatic control system
- Microprocessor electronics
The position sensor measures the current positions of the continuous valve.
The microprocessor electronics continuously compare the current position (actual value) with a position set-point
value specified via the standard signal input and supplies the result to the positioner.
If there is a control difference, the electro-pneumatic control system corrects the actual position accordingly.
5.2 Features
• Models
- Positioner (position controller) Type 8692
- Process controller with integrated position controller, Type 8693
Types 8692 and 8693 are available for both single-acting and double-acting actuators.
• Position sensor
A non-contact and therefore wear parts position sensor.
• Microprocessor-controlled electronics
For signal processing, control and valve control.
• Control module
Operation of the device is controlled by four keys. The 128 x 64 dot matrix graphics display enables you to
display the set-point value or actual value and to configure and parameterize via menu functions.
• Control system
For low air flow rate:
The direct-acting model has an orifice of DN 0.6.
The control system for single-acting actuators consists of 2 solenoid valves and of 4 solenoid valves for double-
acting actuators. In single-acting actuators, one valve serves for the aeration and another for the deaeration of
the pneumatic actuator. Double-acting actuators feature 2 valves for aeration and deaeration.
For high air flow rate:
Orifice DN 2.5 is also available for pneumatic actuators (single-acting only).
The solenoid valves are equipped with diaphragm amplifiers to increase the maximum flow and therefore to
improve the dynamics.
• Position feedback (optional)
Position feedback is implemented either via a proximity switch (initiator), via binary outputs or
via an output (4 ... 20 mA / 0 ... 10 V).
When the valve reaches an upper or lower position, this position can be relayed e.g. to a PLC via binary outputs.
The initiator is used to set the upper and lower end position of the valve. It can be changed with a setting screw.
• Pneumatic interfaces
1/4” connections with different thread forms (G, NPT) of hose plug-in connection.
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Description of System
Type 8692, 8693
• Electrical interfaces
Circular plug-in connector or cable gland.
• Housing
The housing of Type 8692/8693 is protected from excessively high internal pressure, e.g. due to leaks, by a
pressure limiting valve.
5.3 Combinations with valve types and mounting
versions
The positioner Type 8692 / process controller Type 8693 can be mounted on different process valves from the
Bürkert range.
Angle seat valves, straight seat valves, control valves, diaphragm or ball valves are suitable (see chapter“5.3.1
Overview of mounting possibilities / features of valve types”) .
• For single-acting actuators, only one chamber is aerated and deaerated during actuation. The generated pressure
works against a spring. The piston moves until there is an equilibrium of forces between compressive force and
spring force.
• For double-acting actuators the chambers on both sides of the piston are pressurized. In this case, one chamber
is aerated when the other one is deaerated and vice versa.
There are two different procedures for valve installation.
In “Figure 1” shows two combination possibilities that serve as examples of valve installation in general. The two
procedures are explained in chapter „“12 Installation” based on these examples.
Positioner Type 8692
or
Process controller Type
8693
(Pneumatic)
actuator
Valve body
Valve
as an example
of Types 2103,
2300 and 2301
Valve
as an example
of Types 26XX
and 27XX
Figure 1: Mounting versions. Valve types with different installation
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Description of System
Type 8692, 8693
5.3.1 Overview of mounting possibilities / features of valve types
Slanted seat control
valves / screw-down
stop globe control
valves
Diaphragm valves Ball valves Flap valves
Types • 2702
• 2712
• 2300
• 2301
• 2730
• 2103
• 2731
• 2652
• 2655
• 2658
• 2672
• 2675
Features • incoming flow under
seat
• closes smoothly
• straight flow path of
the medium
• self-adjusting
stuffing box for high
leak-tightness
• medium is hermeti-
cally separated from
the actuator and
environment
• cavity-free and self-
draining body design
• any flow direction
with low-turbulence
flow
• steam-sterilizable
• CIP-compliant
• closes smoothly
• actuator and dia-
phragm can be
removed when the
body is installed
• scrapable
• minimum dead
space
• unaffected by
contamination
• little pressure loss
compared to other
valve types
• seat and seal can
be exchanged in the
three-piece ball valve
when installed
Information
Can be used as
process controller only
• unaffected by
contamination
• little pressure loss
compared to other
valve types
• inexpensive
• low construction
volume
Typical
media
• water, steam and
gases
• alcohols, oils, pro-
pellants, hydraulic
fluids
• salt solutions, lyes
(organic)
• solvents
• neutral gases and
liquids
• contaminated,
abrasive and
aggressive media
• media of higher
viscosity
• neutral gases and
liquids
• clean water
• slightly aggressive
media
• neutral gases and
liquids
• slightly aggressive
media
Table 1: Overview of mounting possibilities / features of valve types
Different actuator sizes and valve orifices are available for each valve type. More precise specifications can
be found on the respective data sheets. The product range is being continuously expanded.
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Description of System
Type 8692, 8693
5.4 Designs
5.4.1 Type 8692, positioner
The position of the actuator is regulated according to the position set-point value. The position set-point value is
specified by an external standard signal (or via field bus).
5.4.2 Type 8693, process controller
Type 8693 also features a PID controller which, apart from actual position control, can also be used to implement
process control (e.g. level, pressure, flow rate, temperature) in the sense of a cascade control.
The process controller Type 8693 is operated with a 128 x 64 dot matrix graphics display and a keypad with 4
keys.
The process controller is linked to a control circuit. The position set-point value of the valve is calculated from the
process set-point value and the actual process value via the control parameters (PID controller). The process set-
point value can be set by an external signal.
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Description of System
Type 8692, 8693
6 STRUCTURE
The positioner Type 8692 and process controller Type 8693 consist of the micro-processor controlled electronics,
the position sensor and the control system.
The device is designed using three-wire technology. Operation is controlled by four keys and a 128x64 dot matrix
graphics display.
The pneumatic control system for single-acting and double-acting actuators consists of 2 solenoid valves or
4 solenoid valves.
6.1 Representation
Control module
with display and keys
(View without transparent cap)
Pilot air port
(Label: 1)
Exhaust air port
(Label: 3)
Electrical connection housing
(Connection option with circular
plug-in connector)
Pressure limiting valve
(for protection against too
high internal pressure in
case of error)
Transparent cap
Housing jacket
Additional exhaust air port
(Label: 3.1)
only for Types 23xx and 2103 with
pilot-controlled control system for
a high air flow rate from actuator
size ø 125 / 130
Air intake filter
Figure 2: Structure, Type 8692 / 8693
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Description of System
Type 8692, 8693
6.2 Function diagram
6.2.1 Diagram illustrating single-acting actuator
The black lines in “Figure 3” specify the function of the position controller circuit in Type 8692.
The grey part of the diagram indicates the additional function of the superimposed process control circuit in Type
8693.
Control system
1
2
Positioner
Process
controller Set-point position
Control system
1: Aeriation valve
2: Bleed valve
Compressed-
air supply
Exhaust air
Position
sensor
Actual
position
Process set-point
value
External position
set-point value
Type 8692, 8693
Pneumatic actuator
(single-acting)
Valve
(actuator)
Sensor
Process actual value
(flow, pressure, level, temperature, et cetera.)
Process actual value
Figure 3: Function diagram
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Description of System
Type 8692, 8693
7 POSITIONER TYPE 8692
The position sensor records the current position (POS) of the pneumatic actuator. The positioner compares this
actual position value with the set-point value (CMD) which is specified as a standard signal. In case of a control
deviation (Xd1), a pulse-width modulated voltage signal is sent to the control system as a manipulated variable. If
there is a positive control difference in single-acting actuators, the air inlet valve is controlled via output B1. If the
control difference is negative, the bleed valve is controlled via output E1. In this way the position of the actuator is
changed until control difference is 0. Z1 represents a disturbance variable.
Valve opening
Continuous
valve
Control system
Solenoid valves
Position sensor
PositionerPosition set-
point value
CMD Xd1 B1
E1
PK
Z1
POS
Position control circuit
+-
Figure 4: Position control circuit in Type 8692
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Description of System
Type 8692, 8693
7.1 Schematic representation of the position control
4 ... 20 mA 0 ... 20 mA 0 ... 10 V 0 ... 5 V
DIR.CMD SPLTRNG CHARACT CUTOFF X.TIME
DIR.ACT X.LIMIT
X.CONTROL DBND
POS
CMD
INP
POS CMD TEMP INPUT
Figure 5: Schematic representation of position control
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