Burkert 8692 User manual

Operating Instructions
Bedienungsanleitung
Manuel d‘ utilisation
Type 8692, 8693
Positioner
Electropneumatic positioner

We reserve the right to make technical changes without notice.
Technische Änderungen vorbehalten.
Sous resérve de modification techniques.
© 2008 Bürkert Werke GmbH & Co. KG
Operating Instructions 0804/00_EU-ML_00806169

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Table of Contents
TABLE OF CONTENTS
GENERAL INFORMATION AND SAFETY INSTRUCTIONS ............................................................................................................................. 7
1 The Operating Instructions ............................................................................................................................................................................ 8
2 Intended Use ......................................................................................................................................................................................................... 9
3 General Safety Instructions .........................................................................................................................................................................10
4 General Information.........................................................................................................................................................................................11
DESCRIPTION OF SYSTEM .............................................................................................................................................................................................13
1 Function of the positioner and combination with valve types ..................................................................................................14
2 Structure of the positioner...........................................................................................................................................................................16
3 Type 8692 Positioner with position controller ...................................................................................................................................19
4 Type 8693 positioner with process controller....................................................................................................................................22
5 Interfaces of the positioner for the multipole model.....................................................................................................................25
6 Interfaces of the positioner for the models with cable gland...................................................................................................26
7 Technical Data.....................................................................................................................................................................................................27
CONTROL AND DISPLAY ELEMENTS, OPERATING MODES.....................................................................................................................31
1 Control and display elements.....................................................................................................................................................................32
2 Operating modes...............................................................................................................................................................................................35
3 Operating Levels................................................................................................................................................................................................38
INSTALLATION .........................................................................................................................................................................................................................39
1 Installing the Valve............................................................................................................................................................................................40
2 Rotating the Actuator Module.....................................................................................................................................................................40
3 Fluid Connection of the Positioner ..........................................................................................................................................................41
4 Electrical Connection - Multipole Plug Model....................................................................................................................................42
5 Electrical Connection - Terminal Model for Cable Gland.............................................................................................................45
6 Initial Start-up......................................................................................................................................................................................................48
START-UP AND OPERATION OF THE POSITION CONTROLLER TYPE 8692...................................................................................51
1 Safety instructions............................................................................................................................................................................................53
2 Starting up and installing the position controller Type 8692.....................................................................................................54
3 Operation of the position controllerS.....................................................................................................................................................60
4 Configuring the auxiliary functions..........................................................................................................................................................63
START-UP AND OPERATION OF THE POSITION CONTROLLER TYPE 8693...................................................................................91
1 Safety instructions............................................................................................................................................................................................93
2 Starting up and setting up the process controller Type 8693...................................................................................................93
3 Operation of the process controller.....................................................................................................................................................108
4 Auxiliary functions for the process controller.................................................................................................................................112
Positioner Type 8692, 8693

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PROFIBUS-DP.......................................................................................................................................................................................................................125
1 General Information......................................................................................................................................................................................126
2 Technical Data..................................................................................................................................................................................................126
3 Safety Settings if the Bus Fails ..............................................................................................................................................................127
4 Interfaces............................................................................................................................................................................................................127
5 Electrical connections..................................................................................................................................................................................128
6 Settings on the positioner.........................................................................................................................................................................131
7 Functional Deviations from the Standard Model...........................................................................................................................134
8 Configuration in the Profibus-DP Master ..........................................................................................................................................135
9 Bus Status Display ........................................................................................................................................................................................136
10 Configuration with Siemens Step7.......................................................................................................................................................137
DEVICENET .............................................................................................................................................................................................................................139
1 General Information......................................................................................................................................................................................140
2 Definition of Terms ........................................................................................................................................................................................140
3 Technical Data..................................................................................................................................................................................................140
4 Safety Settings if the Bus Fails ..............................................................................................................................................................141
5 Interfaces............................................................................................................................................................................................................141
6 Electrical connections..................................................................................................................................................................................142
7 Settings on the Positioner in the Main Menu..................................................................................................................................146
8 Functional Deviations from the Standard Model...........................................................................................................................148
9 Configuration of the Process Data........................................................................................................................................................148
10 Bus Status Display ........................................................................................................................................................................................151
11 Configuration Example 1............................................................................................................................................................................152
12 Configuration Example 2............................................................................................................................................................................155
SERVICING AND TROUBLESHOOTING THE POSITION CONTROLLER TYPE 8692.................................................................157
1 Maintenance......................................................................................................................................................................................................158
2 Error Messages and Malfunctions.........................................................................................................................................................158
SERVICING AND TROUBLESHOOTING THE PROCESS CONTROLLER TYPE 8693.................................................................161
1 Maintenance......................................................................................................................................................................................................162
2 Error Messages and Malfunctions.........................................................................................................................................................162
PACKAGING, STORAGE AND DISPOSAL............................................................................................................................................................165
1 Packaging and Transport ...........................................................................................................................................................................166
2 Storage.................................................................................................................................................................................................................166
3 Disposal...............................................................................................................................................................................................................166

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GENERAL RULES (APPENDIX)...................................................................................................................................................................................167
1 Selection Criteria for Continuous Valves...........................................................................................................................................168
2 Properties of PID Controllers...................................................................................................................................................................170
3 Adjustment rules for PID Controllers ..................................................................................................................................................175
OPERATING STRUCTURE OF THE POSITIONER (APPENDIX)..............................................................................................................179
1 Operating Structure of the Positioner.................................................................................................................................................180
POSITION CONTROLLER TABLE TYPE 8692 (APPENDIX).......................................................................................................................187
1 Table for Your Settings on the Position Controller ......................................................................................................................188
PROCESS CONTROLLER TABLE TYPE 8693 (APPENDIX).......................................................................................................................189
1 Table for Your Settings on the Process Controller ......................................................................................................................190
MASTER CODE (APPENDIX)......................................................................................................................................................................................191
1 Master code.......................................................................................................................................................................................................192

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Table of Contents

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General Information
Safety Instructions
General Information and Safety Instructions
TABLE OF CONTENTS
1 THE OPERATING INSTRUCTIONS........................................................................................................................................................................... 8
1.1 Symbols.................................................................................................................................................................................................................... 8
2 INTENDED USE.................................................................................................................................................................................................................. 9
2.1 Restrictions............................................................................................................................................................................................................. 9
2.2 Foreseeable Misuse........................................................................................................................................................................................... 9
3 GENERAL SAFETY INSTRUCTIONS .....................................................................................................................................................................10
4 GENERAL INFORMATION ...........................................................................................................................................................................................11
4.1 Scope of supply .................................................................................................................................................................................................11
4.2 Warranty terms....................................................................................................................................................................................................11
4.3 Master code..........................................................................................................................................................................................................11
4.5 Information on the Internet..........................................................................................................................................................................11

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General Information
Safety Instructions
1 THE OPERATING INSTRUCTIONS
The operating instructions describe the entire life cycle of the device. Keep these instructions in a location which is easily acces-
sible 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 moderately severe or minor injury.•
CAUTION! (without hazard symbol)
Warns of damage to property!
Failure to observe the warning may result in damage to the device or the equipment.•
designates additional significant information, tips and recommendations which are important for your safety and the
proper function 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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General Information
Safety Instructions
2 INTENDED USE
WARNING!
Incorrect use of the positioner Type 8692 and Type 8693 can be dangerous to people, nearby equipment and the
environment.
The device must not be used outside.•
The device must not be exposed to direct sunlight.•
Technical direct voltage must not be used as the power supply.•
During use observe the permitted data, the operating conditions and conditions of use specified in the contract documents•
and operating instructions, as described in chapter “System Description” - “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 authorized by•
Bürkert.
In view of the wide range of possible application cases, check whether the positioner 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 reliable and•
problem-free operation.
Use the positioner Type 8692 and Type 8693 only as intended.•
2.1 Restrictions
If exporting the system/device, observe any existing restrictions.
2.2 Foreseeable Misuse
The positioner Type 8692 and Type 8693 must not be used in areas where there is a risk of explosion.•
Do not introduce any aggressive or flammable media into the system's media connections.•
Do not introduce any liquids into the media connections.•
Do not put any loads on the housing (e.g. by placing objects on it or standing on it).•
Do not make any external modifications to the device housings. Do not paint the housing parts or screws.•

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General Information
Safety Instructions
3 GENERAL 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.
DANGER!
Danger – high pressure!
There is a serious risk of injury when reaching into the equipment.•
Before loosening the lines and valves, turn off the pressure and vent the lines.•
Risk of electric shock!
There is a serious risk of injury when reaching into the equipment.
Before starting work, always switch off the power supply and safeguard to prevent re-activation!•
Observe applicable accident prevention and safety regulations for electrical equipment!•
WARNING!
Unintentional activation or non-permitted impairment may cause general hazardous situations through to physical
injury.
Take appropriate measures to prevent the equipment from being accidentally actuated!•
Hazardous situations can arise during installation and maintenance work.
This work may be carried out by authorized 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!
CAUTION!
The general rules of technology apply to applications planning and operation of the device!
Failure to observe these rules may result in injuries and/or damage to the device, and possibly its environment as well.
Observe the general rules of technology!•
CAUTION!
Electrostatic sensitive components / modules!
The device contains electronic components which react sensitively to electrostatic discharge (ESD). Contact with electro-•
statically 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 100 015 – 1 to minimize or avoid the possibility of damage caused by•
sudden electrostatic discharge!
Also ensure that you do not touch electronic components when the power supply voltage is present!•
The positioners Type 8692 and Type 8693 were developed with due consideration given to the accepted safety rules
and are state-of-the-art. However, dangers can still arise.
Operate the device only when it is in perfect condition and in accordance with the operating instructions.
Failure to observe these instructions and unauthorized 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
Safety Instructions
4 GENERAL INFORMATION
4.1 Scope of supply
Check immediately upon receipt of delivery that the contents are not damaged and that they correspond to the type and quantity
as indicated on the delivery note or packing list.
Generally this consists of:
Pneumatically actuated valve of Type 2300 or 2103 with attached positioner, the operating instructions for the positioner and
for the valve with pneumatic drive.
For the multipole version of the positioner we will provide you with cable connectors as suitable accessories.
If there are any discrepancies, please contact us immediately.
Germany
Contact address:
Bürkert Fluid Control System
Sales Center
Chr.-Bürkert-Str. 13-17
D-74653 Ingelfingen
Phone: 07940 - 10 111
Fax: 07940 - 10 448
e-mail: [email protected]
International
Contact addresses can be found on the final pages of these operating instructions.
And also on the internet at:
www.burkert.com Bürkert Company Locations
4.2 Warranty terms
This document does not offer any form of warranty. Please refer to our general terms of sales and business. The warranty is only
valid if the positioner Type 8692 and Type 8693 is used as intended in accordance with the specified application conditions.
The warranty extends only to defects in the positioners Type 8692 and Type 8693 and their components.
We accept no liability for any kind of consequential damage which could occur due to failure or malfunction of the
device.
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 control actions on the device. This 4-digit master code can be found in the Appendix of these
operating instructions in the chapter entitled Master code.
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 Type 8693 can be found on the Internet at:
www.burkert.com Documentation manuals / data sheets Type 8692 or Type 8693
There is also complete documentation on CD. The complete operating instructions can be ordered by quoting the following
identification number: 806 169

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General Information
Safety Instructions

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Description of System
Description of System
TABLE OF CONTENTS
1 FUNCTION OF THE POSITIONER AND COMBINATION WITH VALVE TYPES ...............................................................................14
1.1 Models of the positioner ............................................................................................................................................................................14
1.2 Features of the valve types.......................................................................................................................................................................15
2 STRUCTURE OF THE POSITIONER......................................................................................................................................................................16
2.1 Representation.................................................................................................................................................................................................16
2.2 Features...............................................................................................................................................................................................................17
2.3 Function diagram of the positioner with single-acting actuator...........................................................................................18
3 TYPE 8692 POSITIONER WITH POSITION CONTROLLER .......................................................................................................................19
3.1 Schematic representation of the positioner Type 8692 ............................................................................................................20
3.2 Properties of the position controller software................................................................................................................................21
4 TYPE 8693 POSITIONER WITH PROCESS CONTROLLER .......................................................................................................................22
4.1 Schematic representation of the process control........................................................................................................................23
4.2 Properties of the process controller software................................................................................................................................24
5 INTERFACES OF THE POSITIONER FOR THE MULTIPOLE MODEL...................................................................................................25
6 INTERFACES OF THE POSITIONER FOR THE MODELS WITH CABLE GLAND............................................................................26
7 TECHNICAL DATA...........................................................................................................................................................................................................27
7.1 Safety positions after failure of the electrical or pneumatic auxiliary power................................................................27
7.2 Factory settings of the positioner .........................................................................................................................................................28
7.3 Specifications of the Positioner .............................................................................................................................................................29
7.3.1 Operating Conditions......................................................................................................................................................... 29
7.3.2 Conformity with the following standards........................................................................................................................ 29
7.3.3 Mechanical data................................................................................................................................................................... 29
7.3.4 Electrical data....................................................................................................................................................................... 29
7.3.5 Pneumatic Data.................................................................................................................................................................... 30

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Description of System
1 FUNCTION OF THE POSITIONER
AND COMBINATION WITH VALVE TYPES
Positioners Type 8692 and Type 8693 are electropneumatic positioner for pneumatically actuated control valves with single-
acting or double-acting actuators.
Together with the pneumatic actuator the positioner forms an optical and functional unit.
The control valve systems can be used for a wide range of control tasks in fluid technology and, depending on the application
conditions, different process valves belonging to series 2300 or 2103 from the Bürkert range can be combined with the posi-
tioner. Angle-seat valves, diaphragm valves or ball valves fitted with a control cone are suitable.
Fig. 1 shows an overview of the possible combinations of positioner and different pneumatically actuated valves. Different actua-
tor sizes and valve nominal widths, not illustrated here, are available for each type. More precise specifications can be found on
the respective data sheets. The product range is being continuously expanded.
Positioner
Type 8692
Type 8693
with slanted seat valve
Type 2300
with diaphragm valve
Type 2103
Fig. 1: Overview of possible combinations
1.1 Models of the positioner
The positioner is available in 2 versions:
Type 8692- Positioner with positioning control
The position of the actuator (stroke) is regulated according to the position set-point value. The position set-point value is speci-
fied by an external uniform signal (or via field bus).
Type 8693- Positioner with process control
The positioner 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
Pneumatically actuated piston actuators and rotary actuators can be used as a actuator. Both single-acting and double-acting
actuators are offered in combination with the positioner.
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 pressurised. In this case, one chamber is aerated when
the other one is deaerated and vice versa. In this design, no spring is installed in the actuator.
1.2 Features of the 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 hermetically•
separated from the
actuator and environ-
ment
cavity-free and self-•
draining body design
any flow direction with•
low-turbulence flow
steam-sterilizable•
CIP-compliant•
closes smoothly•
actuator and•
diaphragm can be re-
moved when the body
is installed
scrapable•
minimum dead space•
unaffected by contami-•
nation
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 contami-•
nation
little pressure loss•
compared to other
valve types
inexpensive•
low construction•
volume
Typical
media
water, steam and•
gases
alcohols, oils, propel-•
lants, hydraulic fluids
salt solutions, lyes•
(organic)
solvents•
neutral gases and•
liquids
contaminated, abrasive•
and aggressive media
media of higher viscos-•
ity
neutral gases and•
liquids
clean water•
slightly aggressive•
media
neutral gases and•
liquids
slightly aggressive•
media

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Description of System
2 STRUCTURE OF THE POSITIONER
The positioners Type 8692 and Type 8693 consist of the micro-processor controlled electronics, the position measuring system
and the control system.
The appliance is designed using three-wire technology. Operation of the positioner is controlled by four keys and a 128x64 dot
matrix graphic display.
The pneumatic control system for single or double-acting actuators consists of two or four solenoid valves.
2.1 Representation
Control module with display and keys
(View without display cover)
Supply pressure connection
3 – 7 bar
(connection: 1)
Exhaust air connection
(connection: 3)
Electrical connection module
(here with multi-pole plugs)
Fig. 2: Structure

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Description of System
2.2 Features
Models•
for single-acting or double-acting valve actuators.
Position measuring system•
Non-contact and therefore non-wearing position measuring system.
Microprocessor-controlled electronics•
for signal processing, control and valve control.
Control module•
Operation of the device is controlled by four keys. The 128x64 dot matrix graphics display enables you to display the set-
point or actual value and to configure and parameterize via menu functions.
Control system•
The control system consists of 2 solenoid valves for single-acting actuators or four solenoid valves for double-acting actua-
tors. In single-acting actuators, one valve serves for the aeration and another for the deaeration of the pneumatic piston
actuator. Double-acting actuators feature 2 valves for aeration and deaeration. The solenoid valves operate according to the
rocker principle and are controlled with a PWM voltage via the controller. Doing so achieves a higher flexibility with regard to
actuator volume and final control speed. On larger pneumatic actuators the solenoid valves feature diaphragm reinforcers to
increase the maximum flow and therefore improve the dynamics.
Position feedback (optional)•
One inductive proximity switch (initiator).
When the valve reaches an upper or a lower position, this can be relayed e.g. to a PLC via binary outputs. By means of set-
screws, the operator can change the initiators or limit positions.
Pneumatic interfaces•
1/4” connections with different thread forms (G, NPT)
Hose plug-in connection
Electrical interfaces•
Multi-pole plug or cable gland
Body•
The body of the positioner is protected from excessively high internal pressure, e.g. caused by leaks, by a pressure limiting
valve.

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Description of System
2.3 Function diagram of the positioner with single-acting actuator
The black lines describe the function of the position controller (Type 8692). The process controller (Type 8693) includes the
position controller and the functions which are illustrated in grey.
Control
system
1
2
Position
controller
Process
controller Nominal
position
Control system
1: Aeriation valve
2: Bleed valve
Compressed-air
supply
Exhaust air
Position
measuring
system
Actual
position
Process set-
point value
external-
position
set-point
value
Positioner
Pneumatic
actuator
(single-acting)
Valve
(actuator)
Sensor
Process actual value
(flow, pressure, level,
temperature, etc.)
Process actual value
Fig. 3: Function diagram

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Description of System
3 TYPE 8692 POSITIONER WITH POSITION CONTROLLER
The position measuring system records the current position (POS) of the pneumatic actuator. The position controller compares
this actual position value with the set-point value (CMD), which is definable as norm 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 dif-
ference 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 measuring
PositionerPosition set-point
value
CMD Xd1 B1
E1
PK
Z1
POS
Position control circuit
+-
Fig. 4: Signal flow plan of position controller