Burkert 8694 User manual

Operating Instructions
Bedienungsanleitung
Manuel d‘utilisation
Type 8694
Positioner TopControl Basic
Electropneumatic position controller
Elektropneumatischer Stellungsregler
Positionneur électropneumatique

We reserve the right to make technical changes without notice.
Technische Änderungen vorbehalten.
Sous réserve de modifications techniques.
© 2008 - 2012 Bürkert Werke GmbH
Operating Instructions 1203/03_EU-ML_00805886 / Original DE

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Table of ConTenTs
1. OPERATING INSTRUCTIONS ........................................................................................................................................................7
1.1. Symbols ......................................................................................................................................................................................7
2. AUTHORIZED USE .............................................................................................................................................................................8
2.1. Restrictions ...............................................................................................................................................................................8
3. BASIC SAFETY INSTRUCTIONS .................................................................................................................................................9
4. GENERAL INFORMATION .............................................................................................................................................................10
4.1. Contact address ..................................................................................................................................................................10
4.2. Warranty ...................................................................................................................................................................................10
4.3. Trademarks ............................................................................................................................................................................10
4.4. Information on the internet ............................................................................................................................................10
5. SYSTEM DESCRIPTION ................................................................................................................................................................11
5.1. Intended application area ...............................................................................................................................................11
5.2. Function of the positioner and combination with valve types ....................................................................11
5.3. Features of the valve types ...........................................................................................................................................12
5.4. Structure of the positioner ............................................................................................................................................13
5.4.1. Representation .........................................................................................................................................13
5.4.2. Features .....................................................................................................................................................14
5.4.3. Function diagram of the positioner with single-acting actuator ...................................................15
5.5. Type 8694 positioner (position controller) ............................................................................................................16
5.5.1. Schematic representation of the position control Type 8694.......................................................16
5.5.2. Functions of the position controller software ....................................................................................17
5.6. Interfaces of the positioner ..........................................................................................................................................19
6. TECHNICAL DATA .............................................................................................................................................................................20
6.1. Conformity ..............................................................................................................................................................................20
6.2. Standards ................................................................................................................................................................................20
6.3. Operating conditions ........................................................................................................................................................20
6.4. Mechanical data ...................................................................................................................................................................20
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6.5. Pneumatic data ....................................................................................................................................................................21
6.6. Type label ...............................................................................................................................................................................21
6.7. Electrical data .......................................................................................................................................................................22
6.7.1. Electrical data without bus control 24 V DC ....................................................................................22
6.7.2. Electrical data with AS-Interface bus control ...................................................................................22
6.8. Factory settings of the positioner ..............................................................................................................................23
7. CONTROL AND DISPLAY ELEMENTS ...................................................................................................................................24
7.1. Operating status ...................................................................................................................................................................... 24
7.2. Control and display elements of the positioner .................................................................................................24
7.3. Configuration of the keys ................................................................................................................................................... 26
7.4. Function of the DIP switches ........................................................................................................................................... 28
7.5. Display of the LEDs ............................................................................................................................................................... 30
7.6. Error messages ....................................................................................................................................................................... 31
7.6.1. Error messages in MANUAL and AUTOMATIC operating statuses ..............................................31
7.6.2. Error messages while the X.TUNE function is running ...................................................................31
8. INSTALLATION ...................................................................................................................................................................................32
8.1. Safety instructions .............................................................................................................................................................32
8.2. Installation of the positioner Type 8694
on process valves of series 2103, 2300 and 2301 ...........................................................................................32
8.3. Installing the positioner Type 8694 on
process valves belonging to series 26xx and 27xx ................................................................................................ 35
8.4. Rotating the actuator module ......................................................................................................................................39
8.5. Rotating the positioner for
process valves belonging to series 26xx and 27xx ..........................................................................................41
9. FLUID INSTALLATION ....................................................................................................................................................................42
9.1. Safety instructions .............................................................................................................................................................42
9.2. Installing the process valve ...........................................................................................................................................42
9.3. Pneumatic connection of the positioner ................................................................................................................43
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10. ELECTRICAL INSTALLATION 24 V DC ...................................................................................................................................44
10.1. Safety instructions .............................................................................................................................................................44
10.2. Electrical installation with circular plug-in connector .....................................................................................44
10.2.1. Designation of the contacts Type 8694 .............................................................................................44
10.2.2. Connection of the positioner Type 8694 ...........................................................................................45
10.3. Electrical installation with cable gland ....................................................................................................................46
10.3.1. Designation of the screw-type terminals ...........................................................................................46
10.3.2. Connection of the positioner Type 8694 ...........................................................................................46
11. AS-INTERFACE INSTALLATION ................................................................................................................................................48
11.1. AS-Interface connection .................................................................................................................................................48
11.2. Technical data for AS-Interface PCBs .....................................................................................................................48
11.3. Programming data ..............................................................................................................................................................48
11.4. Communication sequence for the version S-7.A.5 profile ..........................................................................49
11.5. LED status display ..............................................................................................................................................................50
11.6. Electrical installation AS-interface ............................................................................................................................51
11.6.1. Safety instructions ...................................................................................................................................51
11.6.2. Connection with circular plug-in connector M12 x 1, 4-pole, male ............................................51
11.6.3. Connection with multi-pole cable and ribbon cable terminal........................................................52
12. START-UP .............................................................................................................................................................................................53
12.1. Safety instructions .............................................................................................................................................................53
12.2. Specifying the standard settings ................................................................................................................................53
12.2.1. Running the automatic adjustment X.TUNE .............................................................................53
13. OPERATION AND FUNCTION ....................................................................................................................................................55
13.1. Basic functions ........................................................................................................................................................................ 55
13.1.1. DIR.CMD - Effective direction of the positioner set-point value .................................................56
13.1.2. CUTOFF - Sealing function for the positioner .................................................................................57
13.1.3. CHARACT - Select the transfer characteristic between input signal
(position set-point value) and stroke ..........................................................................58
13.2. Auxiliary functions .................................................................................................................................................................. 59
14. SAFETY POSITIONS .......................................................................................................................................................................60
14.1. Safety positions after failure of the electrical or pneumatic auxiliary power .....................................60
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15. MAINTENANCE ..................................................................................................................................................................................61
15.1. Safety instructions .............................................................................................................................................................61
15.2. Service at the air intake filter .......................................................................................................................................62
16. ACCESSORIES ..................................................................................................................................................................................63
16.1. Communications software (PC SOFTWARE based on FDT/DTM technology) .................................63
16.1.1. PACTware 3.6 ..........................................................................................................................................63
16.1.2. USB interface ...........................................................................................................................................63
16.1.3. Download ..................................................................................................................................................63
17. DISASSEMBLY ...................................................................................................................................................................................64
17.1. Safety instructions .............................................................................................................................................................64
17.2. Disassembly the positioner ...........................................................................................................................................64
18. PACKAGING AND TRANSPORT ...............................................................................................................................................66
19. STORAGE ..............................................................................................................................................................................................66
20. DISPOSAL ............................................................................................................................................................................................66
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Operating instructions
1. OPERATING INSTRUCTIONS
The operating instructions describe the entire life cycle of the device. Keep these instructions in a location which is
easily accessible to every user, and make these instructions available to every new owner of the device.
WARNING!
The operating instructions contain important safety information!
Failure to observe these instructions may result in hazardous situations.
• The operating instructions must be read and understood.
1.1. Symbols
DANGER!
Warns of an immediate danger!
• Failure to observe the warning will result in a fatal or serious injury.
WARNING!
Warns of a potentially dangerous situation!
• Failure to observe the warning may result in serious injuries or death.
CAUTION!
Warns of a possible danger!
• Failure to observe this warning may result in a moderate or minor injury.
NOTE!
Warns of damage to property!
• Failure to observe the warning may result in damage to the device or the equipment.
Indicates important additional information, tips and recommendations.
refers to information in these operating instructions or in other documentation.
→Designates a procedure which you must carry out.
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Authorized use
2. AUTHORIZED USE
Non-authorized use of the positioner Type 8694 may be a hazard 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.
• Do not expose the device to direct sunlight.
• Use according to the authorized data, operating conditions and conditions of use specified in the contract
documents and operating instructions. These are described in the chapter entitled “6. Technical data”.
• The device may be used only in conjunction with third-party devices and components recommended and
authorized by Bürkert.
• In view of the large number of options for use, before installation, it is essential to study and if necessary to
test whether the positioner is suitable for the actual use planned.
• Correct transportation, correct storage and installation and careful use and maintenance are essential for reli-
able and faultless operation.
• Use the positioner Type 8694 only as intended.
2.1. Restrictions
If exporting the system/device, observe any existing restrictions.
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Basic safety instructions
3. BASIC SAFETY INSTRUCTIONS
These safety instructions do not make allowance for any
• contingencies and events which may arise during the installation, operation and maintenance of the devices.
• local safety regulations – the operator is responsible for observing these regulations, also with reference to the
installation personnel.
DANGER!
Danger – high pressure!
• Before dismounting pneumatic lines and valves, turn off the pressure and vent the lines.
Risk of electric 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 injury, ensure:
• that the system cannot be activated unintentionally.
• Installation and repair 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.
• The device may be operated only when in perfect condition and in consideration of the operating instructions.
• The general rules of technology apply to application planning and operation of the device.
To prevent damage to property on the device, ensure:
• Do not feed any aggressive or flammable media into the pilot air port.
• Do not feed any liquids into the pilot air port.
• Do not put any loads on the body (e.g. by placing objects on it or standing on it).
• Do not make any external modifications to the device bodies. Do not paint the body parts or screws.
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 100 015 - 1 and 5 - 2 to minimize or avoid the possibility of
damage caused by sudden electrostatic discharge!
• Also ensure that you do not touch electronic components when the power supply is on!
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Basic safety instructions
The positioner Type 8694 was developed with due consideration given to the accepted safety rules and is
state-of-the-art. Nevertheless, dangerous situations may occur.
Failure to observe this operating manual and its operating instructions as well as unauthorized tampering with
the device release us from any liability and also invalidate the warranty covering the devices and accessories!
4. GENERAL INFORMATION
4.1. Contact address
Germany
Bürkert Fluid Control System
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 operating instructions.
And also on the Internet at:
www.burkert.com
4.2. Warranty
The warranty is only valid if the positioner Type 8694 is used as intended in accordance with the specified appli-
cation conditions.
4.3. Trademarks
Brands and trademarks listed below are trademarks of the corresponding companies / associations / organizations
Loctite Henkel Loctite Deutschland GmbH
4.4. Information on the internet
The operating instructions and data sheets for Type 8694 can be found on the Internet at:
www.burkert.com
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System description
5. SYSTEM DESCRIPTION
5.1. Intended application area
The positioner Type 8694 is designed to be mounted on pneumatic actuators of process valves for the control of
media.
5.2. Function of the positioner and combination with
valve types
Positioner Type 8694 is an electropneumatic position controller for pneumatically actuated control valves with
single-acting actuators.
Together with the pneumatic actuator, the positioner forms a 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 2103, 2300, 2301, 26xx or 27xx from the Bürkert
range can be combined with the positioner. Angle-seat valves, diaphragm valves or ball valves fitted with a control
cone are suitable.
“Figure 1” shows an overview of the possible combinations of positioner and different pneumatically actuated valves.
Different actuator 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 8694
with angle seat valve
Type 2702
with diaphragm
valve
Type 2730
with angle seat valve
Type 2300
with straight seat valve
Type 2301
Figure 1: Overview of possible combinations
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System description
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.
Pneumatically actuated piston actuators and rotary actuators can be used as an actuator. Single-acting actuators
are offered in combination with the positioner.
For single-acting actuators, only one chamber is aerated and deaerated in the actuator. The generated pressure works
against a spring. The piston moves until there is an equilibrium of forces between compressive force and spring force.
5.3. Features of the valve types
Angle seat control
valves / straight seat
control valves
Diaphragm valves Ball valves Flap valves
Types • 2300
• 2301
• 2702
• 2712
• 2103
• 2730
• 2731
• 2652
• 2655
• 2658
• 2672
• 2675
Features • incoming flow under
seat
• no closing impact
• 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
• no closing impact
• 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
Note
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, propel-
lants, 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: Features of the valve types
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System description
5.4. Structure of the positioner
The positioner Type 8694 consists of the micro-processor controlled electronics, the position measuring system
and the control system. The device is designed using three-wire technology. The positioner is operated via 2 keys
and a 4-pole DIP switch. The pneumatic control system for single-acting actuators consists of 2 solenoid valves.
5.4.1. Representation
LED
Screw-
type
terminals
Pressure supply connection
(label: 1)
Exhaust air con-
nection (label: 3)
Electrical connection
(cable gland M16 x 1.5
or circular plug-in connector M12 x 1)
Body casing removed: Buttons
DIP Switches
LED
Transparent cap
Pressure limiting valve
(for protection against too
high internal pressure in
case of error)
Air intake filter
(exchangeable)
Body casing
Version 1 Version 2
Communications
interface
Pressure supply
connection (label: 1)
Exhaust air con-
nection (label: 3)
Communications
interface
Air intake
filter
(exchangeable)
Additional exhaust air port (label: 3.1)
only for Type 23xx and 2103
with pilot-operated control system for high air output
(actuator size ø 130)
Figure 2: Structure
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System description
5.4.2. Features
• Models
for single-acting valve actuators.
• Position measuring system
Contactless and therefore wear-free position measuring system.
• Microprocessor-controlled electronics
for signal processing, control and valve control.
• Control module
The device is controlled via 2 buttons and a 4-pole DIP switch. 2x 2-colored LEDs indicate different statuses of
the device.
• Control system
The control system consists of 2 solenoid valves. One valve is used to aerate and another to deaerate the
pneumatic actuator. 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. The direct-action model has an orifice of DN 0.6. In larger pneumatic actuators the solenoid
valves feature diaphragm amplifiers to increase the maximum flow and therefore to improve the dynamics (DN
2.5).
• Position feedback (optional)
The position of the valve can be transmitted to the PLC via an analog 0/4-20 mA output.
• Binary input
If a voltage > 10 V is applied, SAFE POSITION is activated, i.e. the valve is moved to the safety position
(factory setting, can be changed with communications software).
Pneumatic interface
Electrical interface
• Pneumatic interfaces
1/4“ connections with different thread forms
(G, NPT)
hose plug-in connection
• Electrical interfaces
Circular plug-in connector or cable gland
• Body
The body of the positioner is protected from excessively high internal pressure, e.g. due to leaks, by a pressure
limiting valve.
• Communications interface
For configuration and parameterization.
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System description
5.4.3. Function diagram of the positioner with single-acting
actuator
The illustrated function diagram describes the function of the positioner (Type 8694).
Control system
1
2
Position
controller
Control system
1: Aeration valve
2: Bleed valve
Pressure
supply
Exhaust air
Position
measuring
system
Actual
position
external
position
set-point value
Positioner
Pneumatic actuator
(single-acting)
Valve
(actuator)
Figure 3: Function diagram
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System description
5.5. Type 8694 positioner (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 standard signal. In case
of a control deviation (Xd1), a pulse-width modulated voltage signal is sent to the control system as a manipu-
lated 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
Control valveControl system
Solenoid valves
Position measuring system
Position
controller
Position
set-point
value
CMD Xd1 B1
E1 PK
Z1
POS
Position control
circuit
+-
Figure 4: Signal flow plan of position controller
5.5.1. Schematic representation of the position control Type 8694
4 ... 20 mA1)
0 ... 20 mA
CHARACT
SPLTRNG2)
DIR.CMD CUTOFF X.TIME2)
X.CONTROL
DBND
POS
CMD
INP
POS
CMD
DIR.ACT2) X.LIMIT2)
1) Default setting
2) Can only be activated with communications software
Figure 5: Schematic representation of position control
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System description
5.5.2. Functions of the position controller software
Functions I
• Activation via DIP switches
• Parameter setting via communications software
Additional function Effect
Sealing function
CUTOFF
Valve closes tight outside the control range. Specification
of the value (as %), from which the actuator is completely
deaerated (when 0 %) or aerated (when 100 %)
(see chapter “7.4. Function of the DIP switches”).
Correction line to adjust the operating characteristic
CHARACT
Linearization of the operating characteristic can be
implemented (see chapter “7.4. Function of the DIP
switches”).
Effective direction of the controller set-point value
DIR.CMD
Reversal of the effective direction of the set-point value
(see chapter “7.4. Function of the DIP switches”).
Table 2: Functions I
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System description
Functions II
• Activation and parameter setting via communications software
Additional function Effect
Standard signal for set-point value
INPUT Select set-point value standard signal
Effective direction of the actuator
DIR.ACTUATOR
Assignment of the aeration status of the actuator
chamber to the actual position.
Signal split range
SPLITRANGE
Standard signal as % for which the valve runs through
the entire mechanical stroke range.
Mechanical stroke range limit
X.LIMIT Limit the mechanical stroke range
Opening and closing time
X.TIME Limit the control speed
Position controller
X.CONTROL Parameterize the position controller
Safety position
SAFE POSITION Definition of the safety position
Signal level fault detection
SIGNAL ERROR Configuration of signal level fault detection
Binary input
BINARY INPUT Configuration of the binary input
Analog output
OUTPUT Configuration of the analog output (optional)
Reset
RESET Reset to factory settings
Table 3: Functions II
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System description
5.6. Interfaces of the positioner
Input for position
set-point value3)
4 – 20 mA4)
0 – 20 mA
Binary input
24 V DC
Communications
interface
Positioner
Analog
position feedback
(optional)
Inputs Outputs
Power
Operation
3) Or optional bus connection AS interface
4) Default setting
Figure 6: Interfaces
The positioner Type 8694 is a 3-wire device, i.e. the power (24 V DC) is supplied separately from the set-
point value signal.
• Input for position set-point value (4 – 20 mA corresponds to 0 – 100 %
(depending on position of DIP switch 1)).
• Binary input
If a voltage > 10 V is applied, SAFE POSITION is activated, i.e. the valve is moved to the safety position
(factory setting, can be changed with communications software).
• Analog position feedback (optional)
The position of the valve can be transmitted via an analog 4 – 20 mA output to the PLC
(4 – 20 mA corresponds to 0 – 100 %).
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Technical data
6. TECHNICAL DATA
6.1. Conformity
In accordance with the EC Declaration of conformity, the positioner Type 8694 is compliant with the EC Directives.
6.2. Standards
Conformity with the EC Directives is verified by the following standards.
EN 61000-6-3, EN 61000-6-2, EN 61010-1
6.3. Operating conditions
WARNING!
Solar radiation and temperature fluctuations may cause malfunctions or leaks.
• If the device is used outdoors, do not expose it unprotected to the weather conditions.
• Ensure that the permitted ambient temperature does not exceed the maximum value or drop below the mini-
mum value.
Ambient temperature 0 ... +60 °C
Protection class: IP65 / IP67 according to EN 60529
(only if cables, plugs and sockets have been connected correctly
and in compliance with the exhaust air concept in chapter “Pneumatic
connection of the positioner”)
6.4. Mechanical data
Dimensions See data sheet
Body material exterior: PPS, PC, VA,
interior: PA 6; ABS
Sealing material EPDM / (NBR)
Stroke range of valve spindle: 3 ... 45 mm
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