Burkert Positioner TopControl Basic 8696 User manual

Quickstart
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Type 8696
Positioner TopControl Basic
Electropneumatic Position Controller
Elektropneumatischer Stellungsregler
Positionneur électropneumatiques

We reserve the right to make technical changes without notice.
Technische Änderungen vorbehalten.
Sous réserve de modifications techniques.
© 2007 - 2013 Bürkert Werke GmbH
Quickstart 1304/03_EU-ML_00805654 / Original DE

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1. QUICKSTART .....................................................................................................4
1.1. Definition of term “Device” .............................................................4
1.2. Symbols .............................................................................................. 4
2. AUTHORIZED USE .........................................................................................5
2.1. Restrictions ........................................................................................ 5
3. BASIC SAFETY INSTRUCTIONS .............................................................5
4. GENERAL INFORMATION ...........................................................................7
4.1. Contact address ...............................................................................7
4.2. Warranty ............................................................................................. 7
4.3. Information on the internet .............................................................7
5. SYSTEM DESCRIPTION ...............................................................................7
5.1. Structure and function .................................................................... 7
5.2. Model for control of third-party devices ...................................... 8
6. TECHNICAL DATA ...........................................................................................9
6.1. Conformity .........................................................................................9
6.2. Standards ........................................................................................... 9
6.3. Operating conditions .......................................................................9
6.4. Mechanical data .............................................................................10
6.5. Type label ........................................................................................10
6.6. Pneumatic data ...............................................................................10
6.7. Electrical data..................................................................................11
6.8. Factory settings of the positioner ...............................................11
7. INSTALLATION ...............................................................................................12
7.1. Safety instructions .........................................................................12
7.2. Installation of the positioner on process valves of
series 2103 and 23xx ....................................................................12
8. FLUID INSTALLATION ................................................................................13
8.1. Safety instructions .........................................................................13
8.2. Installing the process valve ..........................................................14
8.3. Pneumatic connection of the positioner ...................................14
9. ELECTRICAL INSTALLATION ..................................................................15
9.1. Safety instructions .........................................................................15
9.2. Electrical installation with circular plug-in connector ............... 16
10. START-UP ......................................................................................................16
10.1. Safety instructions .......................................................................16
10.2. Automatic adjustment X.TUNE ........................................... 16
10.3. Control and display elements....................................................18
11. SAFETY POSITIONS ................................................................................ 21
12. ACCESSORIES ...........................................................................................21
13. PACKAGING, TRANSPORT, STORAGE ..........................................22
Table of Contents
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Quickstart
1. QUICKSTART
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 Quickstart carefully and thoroughly. Study in particular the
chapters entitled “Basic safety instructions” and “Authorized use”.
• Quickstart must be read and understood.
Quickstart explains, for example, how to install and start-up the
device.
A detailed description of the device can be found in the operating
instructions for positioner Type 8696.
The operating instructions can be found on the enclosed CD
and on the Internet at:
www.burkert.com
1.1. Definition of term “Device”
The term “device” used in these instructions always stands for the
positioner Type 8696.
1.2. Symbols
The following symbols are used in these instructions.
DANGER!
Warns of an immediate danger!
• Failure to observe the warning may result in a fatal or serious
injury.
WARNING!
Warns of a potentially dangerous situation!
• Failure to observe the warning may result in serious injuries or
death.
CAUTION!
Warns of a possible danger!
• Failure to observe this warning may result in a medium or minor
injury.
NOTE!
Warns of damage to property!
indicates important additional information, tips and
recommendations.
refers to information in these operating instructions or in
other documentation.
→designates a procedure that must be carried out.
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Authorized use
2. AUTHORIZED USE
Non-authorized use of the positioner Type 8696 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 oper-
ating 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 installa-
tion, 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 reliable and fault-
less operation.
• Use the positioner Type 8696 only as intended.
2.1. Restrictions
If exporting the system/device, observe any existing restrictions.
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 – 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!
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Basic safety instructions
General hazardous situations.
To prevent injury, ensure:
• 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 of the device, ensure:
• Do not feed any aggressive or flammable media into the pressure
supply connection.
• Do not feed any liquids into the pressure supply connection.
• 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.
NOTE!
Electrostatic sensitive components / modules!
The device contains electronic components which react sensitively
to electrostatic discharge (ESD). Contact with electrostatically
charged persons or objects is hazardous to these components. In
the worst case scenario, they will be destroyed immediately or will
fail after start-up.
• Observe the requirements in accordance with EN 61340-5-1
and 5-2 to minimise 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 positioner Type 8696 was developed with due consider-
ation 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!
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General information
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 8696 is used as intended
in accordance with the specified application conditions.
4.3. Information on the internet
The operating instructions and data sheets for Type 8696 can be found
on the Internet at:
www.burkert.com
5. SYSTEM DESCRIPTION
5.1. Structure and function
Positioner
Actuator
Valve body
Process valve
Fig. 1: Structure 1
Positioner Type 8696 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 from the Bürkert range can be combined with
the positioner. Angle seat valves, straight seat valves or diaphragm
valves of the Type 2300, 2301 or 2103 with an actuator size of 50
mm are suitable.
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System description
Pilot air port
(label: 1)
Exhaust air port
(label: 3)
Electrical connection
(circular plug-in connector)
DIP Switches
Key 2
Key 1
LED 1
LED 2
Communications
interface
Transparent cap removed:
Pressure limiting valve
(for protection against
too high internal pressure
in case of error)
Fig. 2: Structure 2
The position of the actuator is regulated according to the position
set-point value. The nominal position value is specified by an external
standard signal.
5.2. Model for control of third-party
devices
A special model enables the positioner Type 8696 to be attached to
third-party devices.
This model has a different pneumatic connection module so that the
pilot air ports can be connected to the outside of the actuator.
Electrical connection
(circular plug-in connector)
Exhaust air port
(label: 3)
Pilot air port
(label: 1)
Fastening screws (2 x)
Pilot air outlet 22
Pilot air outlet 21
Fig. 3: Model for third-party devices
NOTE!
Damage or malfunction due to ingress of dirt and moisture!
• To comply with protection class IP65 / IP67, connect the pilot
air outlet (only for CFA or CFB) which is not required to the free
pilot air port of the third-party device or seal with a plug.
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Technical data
“In rest position” means that the pilot valves of the positioner
Type 8696 are isolated or not actuated.
If the ambient air is humid, a hose can be connected between
pilot air outlet 22 of the positioner and the unconnected pilot
air port of the third-party device for control function A or
control function B. As a result, the spring chamber of the
third-party device is supplied with dry air from the vent duct
of the positioner.
Control function
(CF)
Pneumatic connection
Type 8696 with third-party device
A
Process valve
closed in rest
position
(by spring force)
Pilot air outlet 21
22
1)
B
Process valve
open in rest
position
(by spring force)
Pilot air outlet 21
22
1)
Tab. 1: Pneumatic connection to third-party device
1) Connection optionally, see note.
6. TECHNICAL DATA
6.1. Conformity
In accordance with the EC Declaration of conformity, the positioner
Type 8696 is compliant with the EC Directives.
6.2. Standards
The applied standards, which verify conformity with the EC Direc-
tives, can be found on the EC-Type Examination Certificate and / or
the EC Declaration of Conformity.
6.3. Operating conditions
WARNING!
Solar radiation and temperature fluctuations may cause mal-
functions 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 minimum value.
Ambient temperature: 0 ... +55 °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 “8.3. Pneumatic con-
nection of the positioner”).
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Technical data
6.4. Mechanical data
Dimensions See data sheet
Body material exterior: PPS, PC, VA
interior: PA6; ABS
Sealing material EPDM / FKM
Stroke range
of valve spindle Series 2103
and 23xx 3 - 32 mm
Third-party devices
(modified guide
element required) 3 - 40 mm
6.5. Type label
8696 24 V DC
single act Pilot 0,6
Pmax 7bar
Tamb 0°C - +55°C
Ser.-Nr. 001000
00185118
D-74653 Ingelfingen
W14UN
CE
Identification number
Supply voltage / Control
Max. pressure
Type
Control function
- Pilot valve
Bar-code
Serial number -
CE mark
Max. ambient
temperature
Fig. 4: Type label (example)
6.6. Pneumatic data
Control medium: neutral gases, air
Quality classes in accordance with DIN ISO
8573-1
Dust content Class 5: max. particle size 40 µm,
max. particle density 10 mg/m³
Water content Class 3: max. pressure dew point
- 20 °C or min. 10 °C below the
lowest operating temperature
Oil content Class 5: max. 25 mg/m³
Temperature range
control medium: 0 – +50 °C
Pressure range
control medium: 3 – 7 bar
Air output of pilot valve: 7 lN / min (for aeration and deaeration)
(QNn - value according to definition for
pressure drop from 7 to 6 bar absolute)
Connections:
23xx / 2103 (Element): Plug-in hose connector ∅ 6mm / 1/4“
Socket connection G 1/8
Model third-party device: Socket connection G 1/8
with M5 connection for connecting to
the third-party device
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Technical data
6.7. Electrical data
Connections Circular plug-in connector
(M12 x 1, 8-pole)
Pilot valve
Supply voltage 24 V DC ± 10%
- max. residual ripple 10 %
Power input ≤ 3.5 W
Input resistance
for set-point value signal 180 Ω at 0/4 – 20 mA /
12 bit resolution
Protection class 3 in accordance with VDE 0580
Analogue position feedback
max. load for current output
0/4 – 20 mA 560 Ω
Binary input not galvanically isolated
0 – 5 V = log “0”,
12 – 30 V = log “1”
inverted input in reverse order
Communications
interface Direct connection to PC via USB
adapter with integrated interface
driver, communication with com-
munications software based on
FDT/DTM technology, see “Tab. 11:
Accessories”.
6.8. Factory settings of the positioner
Functions can be activated via DIP switches:
Function Parameter Value
CUTOFF Sealing function below
Sealing function above
2 %
98 %
CHARACT Select characteristic FREE2)
DIR.CMD Effective direction set-point
value
rise
Tab. 2: Factory settings - functions
Additional functions are described in the operating instruc-
tions Type 8696 and in the communication software.
These instructions can be found on the Internet at
www.burkert.com
and are also available on CD which can be ordered by
quoting identification number 804625.
2) without change to the settings via the communications software
a linear characteristic is stored in FREE.
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Installation
7. INSTALLATION
Only for positioner without pre-assembled process valve.
7.1. Safety instructions
DANGER!
Risk of injury from 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!
WARNING!
Risk of injury from improper installation!
• Installation may be carried out by authorized technicians only
and with the appropriate tools!
Risk of injury from unintentional activation of the system and
an uncontrolled restart!
• Secure system from unintentional activation.
• Following assembly, ensure a controlled restart.
7.2. Installation of the positioner on
process valves of series 2103 and
23xx
Procedure:
When the positioner is being installed, the collets of the pilot
air ports must not be fitted to the actuator.
→Align the puck holder and the positioner until
1. the puck holder can be inserted into the guide rail of the
positioner (see “Fig. 5”) and
2. the supports of the positioner can be inserted into the pilot
air ports of the actuator (see also “Fig. 6”).
NOTE!
Damaged printed circuit board or malfunction!
• Ensure that the puck holder is situated flat on the guide rail.
Guide rail
Puck holder
Supports
Fig. 5: Aligning the puck holder
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Fluid installation
→Push the positioner, without turning it, onto the actuator until no
gap is visible on the form seal.
NOTE!
Too high torque when screwing in the fastening screw does
not ensure protection class IP65 / IP67!
• The fastening screws may be tightened to a maximum torque of
0.5 Nm only.
→Attach the positioner to the actuator using the two side fastening
screws. In doing so, tighten the screws only hand-tight (max.
torque: 0.5 Nm).
Supports
Pilot air ports
(actuator) Fastening
screws
max. 0.5 Nm
Fig. 6: Installation of positioner, 2103 and 23xx series
8. FLUID INSTALLATION
8.1. Safety instructions
DANGER!
Risk of injury from 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!
WARNING!
Risk of injury from improper installation!
• Installation may be carried out by authorized technicians only
and with the appropriate tools!
Risk of injury from unintentional activation of the system and
an uncontrolled restart!
• Secure system from unintentional activation.
• Following installation, ensure a controlled restart.
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Fluid installation
8.2. Installing the process valve
Thread type and dimensions can be found in the corresponding data
sheet.
→Connect the valve according to the operating instructions for the
valve.
8.3. Pneumatic connection of the
positioner
DANGER!
Risk of injury from high pressure!
• Before dismounting pneumatic lines and valves, turn off the
pressure and vent the lines.
Procedure:
→Connect the control medium to the pilot air port (1)
(3 – 7 bar; instrument air, free of oil, water and dust).
→Attach the exhaust airline or a silencer to the exhaust air port (3)
(see “Fig. 7: Pneumatic connection”).
Keep the adjacent supply pressure always at least 0.5 – 1
bar above the pressure which is required to move the actuator
to its end position. This ensures that the control behavior is
not extremely negatively affected in the upper stroke range on
account of too little pressure difference.
During operation keep the fluctuations of the pressure supply
as low as possible (max. ±10 %). If fluctuations are greater,
the control parameters measured with the X.TUNE function
are not optimum.
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Electrical installation
Important information for the problem-free functioning of
the device:
• The installation must not cause back pressure to build up.
• Select a hose for the connection with an adequate
cross-section.
• The exhaust air line must be designed in such a way that
no water or other liquid can get into the device through
the exhaust air port.
Pilot air port
(label: 1)
Exhaust air port
(label: 3)
Fig. 7: Pneumatic connection
Caution: (Exhaust air concept):
In compliance with protection class IP67, an exhaust air line
must be installed in the dry area.
9. ELECTRICAL INSTALLATION
9.1. Safety instructions
DANGER!
Risk of electric shock!
• Before reaching into the system, switch off the power supply
and secure to prevent reactivation!
• Observe applicable accident prevention and safety regulations
for electrical equipment!
WARNING!
Risk of injury from improper installation!
• Installation may be carried out by authorized technicians only
and with the appropriate tools!
Risk of injury from unintentional activation of the system and
an uncontrolled restart!
• Secure system from unintentional activation.
• Following installation, ensure a controlled restart.
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Start-up
9.2. Electrical installation with circular
plug-in connector
→Connect the positioner according to the table.
6
1
7
54
3
2
8
Fig. 8: Circular plug M12 x 1, 8-pole
Pin Wire color3) Configuration
1white Set-point value + (0/4 ... 20 mA)
2brown Set-point value GND
3green Supply voltage GND
4yellow Supply voltage + 24 V DC
5grey Binary input +
6pink Binary input GND
7blue Analogue position feedback GND
8red Analogue position feedback +
Tab. 3: Connection with circular plug-in connector
When the supply voltage is applied, the positioner is operating.
→Actuate the automatic adjustment of the positioner, as described
in the chapter entitled “10.2. Automatic adjustment X.TUNE”.
3) The indicated colors refer to the connecting cable available as an
accessory (919061).
10. START-UP
10.1. Safety instructions
WARNING!
Risk of injury from improper operation!
Improper operation may result in injuries as well as damage to the
device and the area around it.
• Before start-up, ensure that the operating personnel are familiar
with and completely understand the contents of the operating
instructions.
• Observe the safety instructions and intended use.
• Only adequately trained personnel may operate the equipment/
the device.
10.2. Automatic adjustment X.TUNE
To adjust the positioner to local conditions, the X.TUNE
function must be run following installation.
WARNING!
While the X.TUNE function is running, the valve automatically
moves from its current position!
• Never run X.TUNE while a process is running!
• Take appropriate measures to prevent the equipment from being
accidentally actuated!
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Start-up
NOTE!
Avoid maladjustment of the controller due to an incorrect
pilot pressure or applied operating medium pressure!
• Run X.TUNE whenever the pilot pressure (= pneumatic auxil-
iary energy) is available during subsequent operation.
• Run the X.TUNE function preferably without operating medium
pressure to exclude interference caused by flow forces.
To run X.TUNE, the positioner must be in the AUTOMATIC
operating status (DIP switch 4 = OFF).
→Screw off the transparent cap of the positioner to operate the
keys and DIP switches.
→Start the X.TUNE by pressing key 14) for 5 s.
While the X.TUNE is running, LED 1 flashes quickly (green).
DIP Switches
Key 2
Key 1
LED 1
LED 2
Fig. 9: Starting X.TUNE
4) The X.TUNE can also be started via communications software.
X.TUNE Key 1 5 s X.TUNE
STARTED
TUNE #0
INIT
X.TUNE
READY
Fig. 10: Automatic adjustment X.TUNE
When the automatic adjustment is complete, LED 1 flashes slowly
(green)5).
The changes are automatically transferred to the memory (EEPROM)
provided the X.TUNE function is successful.
NOTE!
Damage or malfunction due to penetration of dirt and
humidity!
• To observe protection class IP65 / IP67, screw the transparent
cap in all the way.
→Close the device (assembly tool: 6740786)).
5) if a fault occurs, LED 1 is lit red.
6) The assembly tool (674078) is available from your Bürkert sales
office.
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Start-up
10.3. Control and display elements
A detailed description of the operation and functions of the
positioner and the communication software can be found in
the respective operating instructions.
→Screw off the transparent cap of the positioner to operate the
keys and DIP switches.
DIP switches
Key 2
Key 1
LED 1
LED 2
Communications
interface
Fig. 11: Description of the control elements
NOTE!
Damage or malfunction due to penetration of dirt and
humidity!
• To observe protection class IP65 / IP67, screw the transparent
cap in all the way.
→Close the device (assembly tool: 6740787)).
7) The assembly tool (674078) is available from your Bürkert sales
office.
10.3.1. Operating status
AUTOMATIC (AUTO)
Normal controller mode is implemented and monitored in AUTO-
MATIC operating state.
LED1 flashes green.
MANUAL (MANU)
In MANUAL operating state the valve can be opened and closed
manually via the keys.
LED1 flashes red / green alternately.
ON DIP
12 3 4
The DIP switch 4 can be used to switch between
the two operating states AUTOMATIC and
MANUAL.
DIP switches Function
4 ON Operating status MANUAL (MANU)
OFF Operating status AUTOMATIC (AUTO)
Tab. 4: DIP switches
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Start-up
10.3.2. Functions of the keys
The configuration of the 2 keys on the board varies depending on the
operating status (AUTOMATIC / MANUAL).
Key 2
Key 1
Fig. 12: Keys
MANUAL operating status (DIP switch 4 set to ON):
Key Function8)
1 Aerate (manually open / close the actuator)9)
2 Deaerate (manually open / close the actuator)9)
Tab. 5: Configuration of the keys for MANUAL operating status
AUTOMATIC operating status (DIP switch 4 set to OFF):
Key Function
1 Press for 5 s to start the X.TUNE function
2 -
Tab. 6: Configuration of the keys for AUTOMATIC operating status
8) No function if the binary input was activated with the “Manual/
Auto change-over” via the communications software.
9) depending on the operating principle of the actuator.
10.3.3. Function of the DIP switches
DIP
switches Function
ON DIP
12 3 4
1 ON Reversal of the effective direction of the set-point
value (set-point value 20 – 4 mA corresponds to
position 0 – 100 %), descending (DIR.CMD)
OFF Normal effective direction of the set-point value
(set-point value 4 – 20 mA corresponds to position
0 – 100 %), ascending
2 ON Sealing function active. The valve completely closes
below 2 %10) and opens above 98 % of the set-point
value (CUTOFF)
OFF No sealing function
3 ON Correction characteristic for adjustment of the oper-
ating characteristic (linearization of the process char-
acteristic CHARACT) 10)
OFF Linear characteristic
4 ON Operating status MANUAL (MANU)
OFF Operating status AUTOMATIC (AUTO)
Tab. 7: DIP switches
10) Can be changed via communications software.
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Start-up
10.3.4. Display of the LEDs
LED 1
LED 2
Fig. 13: Display of the LEDs
LED 1
(green / red)
Display of
AUTO, MANU, X.TUNE and FAULT
LED 2
(green / yellow)
Display of state of actuator
(open, closed, opens or closes)
LED 1 (green / red)
LED States Display
green red
on off Acceleration phase when Power ON
flashes slowly off Operating status AUTO (AUTOMATIC)
flashing flashing MANUAL operating status
alternating
flashes quickly off X.TUNE function
off on ERROR (see operating instructions)
flashing flashing AUTO operating status for sensor break
detection
slow
Tab. 8: Display LED 1
LED 2 (green / yellow)
LED States Display
green yellow
on off Actuator closed
off on Actuator open
flashes
slowly off Remaining control deviation (actual value > set-point value)
off flashes
slowly
Remaining control deviation
(actual value < set-point value)
flashes
quickly off Closing in MANUAL operating status
off flashes
quickly Opening in MANUAL operating status
Tab. 9: Display LED 2
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