Burkert 8792 User manual

Operating Instructions
Type 8792, 8793 REV.2
Electropneumatic positioner and process controller

We reserve the right to make technical changes without notice.
Technische Änderungen vorbehalten.
Sous resérve de modification techniques.
© Bürkert Werke GmbH & Co. KG, 2017
Operating Instructions 1804/00_EN-en_00810648 / Original DE

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Contents
1 THE OPERATING INSTRUCTIONS ........................................................................................................9
1.1 Symbols........................................................................................................................................9
1.2 Denitionofterms........................................................................................................................9
2 INTENDED USE ....................................................................................................................................10
3 BASIC SAFETY INSTRUCTIONS .........................................................................................................11
4 GENERAL INFORMATION....................................................................................................................12
4.1 Contactaddresses.....................................................................................................................12
4.2 Warranty .....................................................................................................................................12
4.3 Mastercode ...............................................................................................................................12
4.4 InformationontheInternet........................................................................................................12
5 PRODUCT DESCRIPTION....................................................................................................................13
5.1 Generaldescription....................................................................................................................13
5.2 Properties ...................................................................................................................................13
5.3 Variants.......................................................................................................................................16
6 STRUCTURE AND FUNCTION.............................................................................................................17
6.1 Representation...........................................................................................................................17
6.2 Functiondiagram .......................................................................................................................18
7 POSITIONER TYPE 8792 .....................................................................................................................19
7.1 Schematicrepresentationofthepositioncontrol ....................................................................20
7.2 Thepositionersoftware .............................................................................................................21
8 PROCESS CONTROLLER TYPE 8793.................................................................................................23
8.1 Schematicrepresentationofprocesscontrol ..........................................................................24
8.2 Theprocesscontrollersoftware................................................................................................25
9 INTERFACES ........................................................................................................................................27
10 TECHNICAL DATA ................................................................................................................................28
Generalinformationandsafetyinstructions
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Type 8792, 8793 REV.2
10.1 Conformity..................................................................................................................................28
10.2 Standards ...................................................................................................................................28
10.3 Approvals ...................................................................................................................................28
10.4 Operatingconditions .................................................................................................................28
10.5 Typelabel ...................................................................................................................................29
10.6 Mechanicaldata.........................................................................................................................29
10.7 Electricaldata ............................................................................................................................30
10.8 Pneumaticdata ..........................................................................................................................31
10.9 Safetyendpositionsafterfailureoftheelectricalorpneumaticauxiliarypower...................32
11 ASSEMBLY ...........................................................................................................................................33
11.1 Safetyinstructions .....................................................................................................................33
11.2 AttachmenttoacontinuousvalvewithlinearactuatoraccordingtoNAMUR........................33
11.3 Attachmenttoacontinuousvalvewithrotaryactuator ...........................................................38
11.4 Remoteoperationwithexternalpositionsensor......................................................................40
11.5 Pneumaticconnection...............................................................................................................43
12 ELECTRICAL INSTALLATION...............................................................................................................45
12.1 Electricalinstallationwithcircularplug-inconnector(multipoleversion)...............................45
12.2 Electricalinstallationwithcablegland......................................................................................50
13 OPERATION..........................................................................................................................................54
13.1 Descriptionoftheoperatinganddisplayelements..................................................................54
13.2 Functionofthekeys...................................................................................................................56
13.3 Adjustingthedisplay .................................................................................................................59
13.4 Dateandtime.............................................................................................................................61
13.5 Operatingstates.........................................................................................................................62
13.6 Activatinganddeactivatingauxiliaryfunctions........................................................................63
13.7 Manuallyopeningandclosingthevalve...................................................................................65
14 START-UP .............................................................................................................................................66
14.1 Safetyinstructions .....................................................................................................................66
14.2 Basicsettingofthedevice ........................................................................................................67
14.3 INPUT-Settingtheinputsignal................................................................................................67
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Type 8792, 8793 REV.2
14.4 X.TUNE–Automaticadjustmentofthepositioncontroller ....................................................68
14.5 Activationoftheprocesscontroller ..........................................................................................70
15 BASIC SETTING OF THE PROCESS CONTROLLER..........................................................................71
15.1 P.CONTROL–Settingupandparameterizationoftheprocesscontroller .............................71
15.2 SETUP–Settinguptheprocesscontroller .............................................................................72
15.3 PID.PARAMETER–Parameterizingtheprocesscontroller............................................................. 78
15.4 P.Q’LIN–Linearizationoftheprocesscharacteristic .............................................................82
15.5 P.TUNE–Self-optimizationoftheprocesscontroller .............................................................83
16 AUXILIARY FUNCTIONS ......................................................................................................................87
16.1 Activatinganddeactivatingauxiliaryfunctions........................................................................88
16.2 ManualcongurationofX.TUNE............................................................................................143
17 ACCESS TO THE BÜS SERVICE INTERFACE...................................................................................147
17.1 Settingoptionsforstart-upviaBürkert-Communicator ........................................................147
18 OPERATING STRUCTURE AND FACTORY SETTING .......................................................................149
19 ETHERNET/IP,PROFINETANDMODBUSTCP ................................................................................164
19.1 Technicaldata ..........................................................................................................................164
19.2 IndustrialEthernet....................................................................................................................164
19.3 X7-M12eldbusconnectionD-coded ..................................................................................167
19.4 X1-M12circularplug,8-pole .................................................................................................167
19.5 X4-M8socket,4-pole,optional-Remotesensor(forremotevariantonly) ........................167
19.6 X5-M8circularplug,4-pole-
Processactualvalue(forType8793) ......................................................................................168
19.7 Busstatusdisplay....................................................................................................................169
20 BÜS OPTION ......................................................................................................................................171
20.1 Denition ..................................................................................................................................171
20.2 Interfaces..................................................................................................................................171
20.3 Electricalinstallation-büS......................................................................................................171
20.4 X1-M12circularplug,8-pole .................................................................................................173
20.5 X4-M8socket,4-pole,optional-
Remotesensor(forremotevariantonly).................................................................................174
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Type 8792, 8793 REV.2
20.6 X5-M8circularplug,4-pole-
Processactualvalue(forType8793) ......................................................................................174
20.7 AcceptingandsavingSIMcarddata(option) ............................................................................ 175
21 MAINTENANCE AND TROUBLESHOOTING .....................................................................................178
21.1 Safetyinstruction .....................................................................................................................178
21.2 Maintenance.............................................................................................................................178
21.3 Errormessages ........................................................................................................................178
21.4 Malfunctions.............................................................................................................................182
22 ACCESSORIES...................................................................................................................................183
22.1 Communicationsoftware.........................................................................................................183
22.2 Download .................................................................................................................................183
22.3 USBinterface ...........................................................................................................................183
23 PACKAGING, TRANSPORT................................................................................................................184
24 STORAGE ...........................................................................................................................................184
25 DISPOSAL ..........................................................................................................................................184
26 SUPPLEMENTARY INFORMATION ...................................................................................................185
26.1 Selectioncriteriaforcontinuousvalves..................................................................................185
26.2 PropertiesofPIDcontrollers ...................................................................................................187
26.3 AdjustmentrulesforPIDcontrollers.......................................................................................192
27 TABLE FOR YOUR SETTINGS ON THE POSITIONER ......................................................................196
27.1 Settingsofthefreelyprogrammedcharacteristic ..................................................................196
28 TABLE FOR YOUR SETTINGS ON THE TYPE 8793 PROCESS CONTROLLER ..............................197
28.1 Setparametersoftheprocesscontroller ...............................................................................197
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The operating instructions
Type 8792, 8793 REV.2
1 THE 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.
Importantsafetyinformation.
Read the operating instructions carefully and thoroughly. Study in particular the chapters entitled Basic
safety instructions and Intended use.
▶The operating instructions must be read and understood.
1.1 Symbols
DANGER
Warnsofanimmediatedanger.
▶Failure to observe the warning will result in fatal or serious injuries.
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 other equipment.
Indicatesimportantadditionalinformation,tipsandrecommendations.
Referstoinformationintheseoperatinginstructionsorinotherdocumentation.
▶Indicates instructions for risk prevention.
→Indicates a procedure which you must carry out.
Indicates a result.
1.2 Denition of terms
In these instructions, the term “device” always refers to the Type 8792, 8793 REV.2.
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Intended use
Type 8792, 8793 REV.2
2 INTENDED USE
Use the device for its intended purpose only. Non-intended use of the device may 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 potentially explosive atmospheres, Type 8792 and 8793 may be used only in accordance with the
specication on the separate Ex type label. For the use, observe the ATEX manual with safety instruc-
tions for potentially explosive atmospheres.
▶Devices without a separate Ex type label may not be used in potentially explosive atmospheres.
▶Do not expose the device to direct sunlight.
▶A pulsating direct voltage (rectied alternating voltage without smoothing) must not be used as the
operating voltage.
▶Use according to the authorized data, operating conditions, and conditions of use specied in the
contract documents and operating instructions in chapter “System description” - “10. Technical data” in
these instructions and the valve instructions for the respective pneumatically actuated valve.
▶Use the device only in conjunction with third-party devices and components recommended and autho-
rized by Bürkert.
▶In view of the wide range of possible application cases, check whether the device is suitable for the
specic application case and check this out if required.
▶Correct transportation, storage and installation as well as careful operation and maintenance are essen-
tial for reliable and fault-free operation.
▶Use Types 8792 and 8793 only as intended.
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Basic safety instructions
Type 8792, 8793 REV.2
3 BASIC SAFETY INSTRUCTIONS
These safety instructions do not consider any contingencies or incidents which occur during assembly,
operation and maintenance.
The operator is responsible for observing the location-specic safety regulations, also with reference to the
personnel.
Danger–highpressure!
▶Before loosening lines and valves, turn o the pressure and vent the lines.
Riskofelectricshock.
▶Before reaching into the device or the equipment, switch o the power supply and secure to prevent
reactivation.
▶Observe applicable accident prevention and safety regulations for electrical equipment.
Riskofburns/riskofreduringcontinuousoperationthroughhotdevicesurface.
▶Keep the device away from highly ammable substances and media and do not touch with bare hands.
Generalhazardoussituations.
To prevent injuries:
▶Ensure that the system cannot be activated unintentionally.
▶Installation and maintenance work may only be carried out by authorized specialist personnel and using
the appropriate tools.
▶After an interruption in the electrical or pneumatic supply, ensure that the process is restarted in a
dened or controlled manner.
▶The device may only be operated when in perfect condition and in consideration of the operating
instructions.
▶Do not supply the pressure supply connection of the system with aggressive or ammable media or any
liquids.
▶Do not physically stress the housing (e.g. by placing objects on it or standing on it).
▶Do not make any external modications to the device housings. Do not paint housing parts or screws.
▶The general rules of technology must be observed for application planning and operation of the device.
NOTE
Electrostaticsensitivecomponents/modules.
Thedevicecontainselectroniccomponentsthataresusceptibletoelectrostaticdischarging(ESD).
Componentsthatcomeintocontactwithelectrostaticallychargedpeopleorobjectsareatrisk.Inthe
worstcasescenario,thesecomponentsaredestroyedimmediatelyorfailafterstart-up.
▶Meet the requirements specied by EN 61340-5-1 to minimize or avoid the possibility of damage caused
by sudden electrostatic discharge.
▶Do not touch electronic components when the supply voltage is connected.
Failure to observe these operating instructions and the information contained therein as well as unau
-
thorized tampering with the device release us from any liability and also invalidate the warranty covering
the devices and accessories.
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General information
Type 8792, 8793 REV.2
4 GENERAL INFORMATION
4.1 Contact addresses
Germany
Bürkert Fluid Control System
Sales Center
Chr.-Bürkert-Str. 13-17
D-74653 Ingelngen
Phone + 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 nal pages of the printed brief instructions (Quickstart).
And also on the Internet at: www.burkert.com
4.2 Warranty
The warranty is only valid if the device is used as intended in accordance with the specied condition of use.
4.3 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.
4.4 Information on the Internet
The operating instructions and data sheets for Types 8792 and 8793 can be found on the Internet at:
www.buerkert.de
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Product description
Type 8792, 8793 REV.2
5 PRODUCT DESCRIPTION
5.1 General description
The positioner Type 8792 / process controller Type 8793 is a digital, electro-pneumatic position controller
for pneumatically actuated continuous valves. The device incorporates the main function groups
- Position sensor
- Electro-pneumatic actuating 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 specied via the standard signal input and supplies the result to the positioner.
If there is a control dierence, the electro-pneumatic actuating system corrects the actual position
accordingly.
5.2 Properties
•Variants
- Positioner (position controller) Type 8792
- Process controller with integrated position controller, Type 8793.
•Positionsensor
- internal conductive plastic potentiometer with high resolution or
- external non-contacting non-wearing position sensor (remote).
•Microprocessor-controlled electronics
for signal processing, control and valve control.
•Controlmodule
The device is operated by 4 keys. The 128 x 64 dot matrix graphics display enables you to display the
set-point value or actual value and to congure and parameterize via menu functions.
•Actuatingsystem
The actuating system consists of 2 solenoid valves and 4 diaphragm boosters. In single-acting actuators
the working connection 2 must be sealed with a threaded plug.
•Feedback(optional)
Feedback is either via 2 proximity switches (initiators), 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 operator can change the initiators or limit positions via control lugs.
•Pneumaticinterfaces
Internal thread G1/4"
•Electricalinterfaces
Circular plug-in connector or cable gland
•Housing
Plastic coated aluminum housing with hinged cover and captive screws.
•Attachment
to a linear actuator according to recommendation given by NAMUR (DIN IEC 534-6) or to a rotary actuator
according to VDI/VDE 3845.
•Optional
Remote variant for DIN rail mounting or mounting bracket.
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Product description
Type 8792, 8793 REV.2
5.2.1 Combination with valve types and mounting versions
The positioner Type 8792 / process controller Type 8793 can be mounted on dierent continuous valves.
For example on valves with piston, membrane or rotary actuator. The actuators can be single-acting or
double-acting.
•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 com-
pressive force and spring force. To do this, one of the two air connections must be sealed with a threaded
plug.
•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. In this variant, no spring is installed in
the actuator.
Two basic device variants are available for positioner Type 8792 / process controller Type 8793. They dier
as to the mounting options and the position sensor.
NAMURdevicevariant:
An internal position sensor is used which is designed as a rotary potentiometer.Type 8792/8793 is mounted
directly on the actuator or attached to the side.
Remotedevicevariant:
An external position sensor (linear or rotary) is connected via an interface.Type 8792/8793 is attached to
a wall either with a standard rail or with a mounting bracket (remote variant).
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Product description
Type 8792, 8793 REV.2
5.2.2 Overview of the mounting options
Attachment of
NAMUR on rotary
actuator
Attachment of
NAMUR with a
mounting bracket on
a linear actuator
Remote mounting
with mounting
bracket
Remote mounting
with DIN rail
Table 1: Overview of the mounting options
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Product description
Type 8792, 8793 REV.2
5.3 Variants
5.3.1 Type 8792, positioner
The position of the actuator is controlled according to the position set-point value. The position set-point value
is specied by an external standard signal (or via eldbus).
5.3.2 Type 8793, process controller
Type 8793 also features a PID controller which, apart from actual position control, can also be used to
implement process control (e.g. level, pressure, ow rate, temperature) in the sense of a cascade control.
The process controller Type 8793 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 set-point position of the valve is calculated from
the process set-point value and the process actual value via the control parameters (PID controller). The
process set-point value can be specied by an external signal.
5.3.3 Type 8793, remote variant
Depending on the connection variant type of the position sensor, Type 8793 functions as a
•Process controller or
•Positioner (position controller)
The following connection variants are available:
Function
Type8793
Interface Positionsensor Settinginthemenu(ADD.FUNCTION)
Process
controller
digital (serial) Remote sensor Type 8798 POS.SENSOR → DIGITAL
For menu description see chapter
“16.1.21 POS.SENSOR” on page 118
Positioner
(position
controller)
analog
(4...20 mA) *
any high-resolution position
sensor
POS.SENSOR → ANALOG
For menu description see chapter
“16.1.21 POS.SENSOR” on page 118
Table 2: Connection variants Type 8793 with external position sensor
*IftheexternalpositionsensorisconnectedtotheprocesscontrollerType8793viatheanalog
interface,itcanbeoperatedonlyasapositioner(positioncontroller).
The options for connection of an external position sensor are described in chapter “11.4 Remote
operation with external position sensor” on page 38.
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Structure and function
Type 8792, 8793 REV.2
6 STRUCTURE AND FUNCTION
The positioner Type 8792 and process controller Type 8793 consist of the micro-processor controlled elec-
tronics, the position sensor and the actuating system.
The device is designed using three-wire technology. Operation is controlled by four keys and a 128x64 dot
matrix graphics display.
The pneumatic actuating system for single-acting and double-acting actuators consists of 2 solenoid
valves.
6.1 Representation
Mechanical position indicator
Control module with display and keys
Working connection 2
(connection: A2)
Pressure supply connection 1.4...7 bar
(connection: P)
Working connection 1
(connection: A1)
Air exhaust connection/air exhaust lter
Internal position sensor
Shaft for position sensor
Cable bushing
Electronic module
Actuating system
Pressure-relief valve
Figure 1: Structure, Type 8792/8793
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Structure and function
Type 8792, 8793 REV.2
6.2 Function diagram
6.2.1 Diagram illustrating single-acting actuator
The black lines in “Figure 2” describe the function of the position controller circuit in Type 8792.
The gray part of the diagram indicates the additional function of the superimposed process control circuit in
Type 8793.
* Actuating system
1: Aeration valve
2: Bleed valve
Compressed
air supply
Position
sensor
Process
controller
Positioner
Actuating
system*
1
2
Process
set-point
value
Process
actual
value
Position
set-point
value
Exhaust air
Types8792/8793 Continuousvalve
withsingle-actingactuator
Sensor
Actual position
Set-point position
Figure 2: Structure, positioner Type 8792 / process controller Type 8793
Theremotevarianthasthepositionsensorsituatedoutsidethedevicedirectlyonthecontinuous
valveandisconnectedtothelatterbyacable.
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Positioner Type 8792
Type 8792, 8793 REV.2
7 POSITIONER TYPE 8792
The position sensor records the current position (POS) of the pneumatic actuator. The positioner compares this
position actual value with the set-point value (CMD) which is specied as a standard signal. If there is a control
dierence (Xd1), the actuator is aerated and de-aerated via the actuating system. In this way the position of
the actuator is changed until control dierence is 0. Z1 represents a disturbance variable.
Valve opening
Continuous
valve
Actuating
system
Solenoid
valves
Position sensor
PositionerPosition
set-point
value
CMD Xd1 B1
E1
PK
Z1
POS
Position control circuit
+-
Figure 3: Position control circuit in Type 8792
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Positioner Type 8792
Type 8792, 8793 REV.2
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 4: Schematic representation of position control
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Positioner Type 8792
Type 8792, 8793 REV.2
7.2 The positioner software
Congurableauxiliaryfunctions Eect
Correction line to adjust the operating
characteristic
CHARACT
Selection of the transfer characteristic between input
signal and stroke (correction characteristic).
Sealing function
CUTOFF
Valve closes tight outside the control range. Speci-
cation of the value (as%), from which the actuator is
completely de-aerated (when 0%) or aerated (when
100%).
Eective direction of the controller set-point value
DIR.CMD
Eective direction between input signal and set-point
position.
Eective direction of the actuating drive
DIR.ACT
Adjustment of the eective direction between aeration
state of the actuator and the actual position.
Signal split range
SPLTRNG
Splitting of the standard signal range to two or more
positioners.
Stroke limit
X.LIMIT
Mechanical valve piston movement only within
a dened stroke range.
Limit of the control speed
X.TIME
Input of the opening and closing time for the total
stroke.
Insensitivity range
X.CONTROL
The positioner is initially actuated from a control dif-
ference to be dened.
Code protection
SECURITY
Code protection for settings.
Safety position
SAFEPOS
Denition of the safety position.
Signal level fault detection
SIG.ERROR
Check the input signals for sensor break.
Warning output on the display and approaching the
safety position (if selected).
Binary input
BINARY. IN
Switching between AUTOMATIC / MANU or
approaching the safety position.
Analogue feedback (option)
OUTPUT
Feedback set-point value or actual value.
2 binary outputs (option)
OUTPUT
Output of two selectable binary values.
User calibration
CAL.USER
Change to the factory calibration of the signal input.
Factory settings
SET.FACTORY
Reset to factory settings.
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20
Positioner Type 8792
Type 8792, 8793 REV.2
Congurableauxiliaryfunctions Eect
Serial interface
SER.I/O
Conguration of serial interface.
Setting display
EXTRAS
Adjustment of the display of the process level.
SERVICE For internal use only.
POS.SENSOR Setting interface remote position sensor (available for
Type 8793 Remote only). See chapter “5.3.3 Type 8793,
remote variant” on page 14
Simulation software
SIMULATION
For simulation of the device functions.
DIAGNOSE (option) Monitoring of processes.
Table 3: Positioner software. Congurable auxiliary functions
Hierarchicaloperatingconceptforeasyoperationonthefollowingoperatinglevels
Process level On the process level you switch between the
AUTOMATIC and MANU operating states.
Setting level On the setting level specify certain basic functions
during start-up and congure auxiliary functions if
required.
Table 4: The positioner software. Hierarchical operating concept.
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