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Type 8694 Positioner Top Control Basic

Positioner Top Control Basic Electropneumatic position controller Operating Instructions We reserve the right to make technical changes without notice. Technische Änderungen vorbehalten. Sous réserve de
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Positioner Top Control Basic Electropneumatic position controller Operating Instructions We reserve the right to make technical changes without notice. Technische Änderungen vorbehalten. Sous réserve de modifications techniques. Bürkert Werke GmbH & Co. KG, Operating Instructions 1802/09_EN-EN_ / Original DE Table of Contents Positioner Type OPERATING INSTRUCTIONS Symbols Definition of term / abbreviation AUTHORIZED USE Restrictions BASIC SAFETY INSTRUCTIONS GENERAL INFORMATION Contact address Warranty Trademarks Information on the internet SYSTEM DESCRIPTION Intended application area Function of the positioner and combination with valve types Features of the valve types Structure of the positioner Representation Features Function diagram of the positioner with single-acting actuator Type 8694 positioner (position controller) Schematic representation of the position control Type Functions of the position controller software Interfaces of the positioner TECHNICAL DATA Conformity Standards Licenses Operating conditions 6.5 Mechanical data Pneumatic data Type labels Type label standard UL type label UL additional label Electrical data Electrical data without bus control 24 V DC Electrical data with AS-Interface bus control Factory settings of the positioner CONTROL AND DISPLAY ELEMENTS Operating status Control and display elements of the positioner Configuration of the keys Function of the DIP switches Display of the LEDs Error messages Error messages in MANUAL and AUTOMATIC operating statuses Error messages while the X.TUNE function is running INSTALLATION Safety instructions Installation of the positioner Type 8694 on process valves of series 2103, 2300 and Installing the positioner Type 8694 on process valves belonging to series 26xx and 27xx Rotating the actuator module Rotating the positioner for process valves belonging to series 26xx and 27xx PNEUMATIC INSTALLATION Manual actuation of the actuator via pilot valves Single-acting actuators (control function A and B) ELECTRICAL INSTALLATION 24 V DC Safety instructions 10.2 Electrical installation with circular plug-in connector Designation of the contacts Type Connection of the positioner Type Electrical installation with cable gland AS-INTERFACE INSTALLATION AS-Interface connection Maximum length of the bus line Technical data for AS-Interface PCBs Programming data Communication sequence for the version S-7.A.5 profile LED status display Electrical installation AS-interface Safety instructions Connection with circular plug-in connector M12 x 1, 4-pole, male Connection with multi-pole cable and ribbon cable terminal START-UP Safety instructions Specifying the standard settings Running the automatic adjustment X.TUNE OPERATION AND FUNCTION Basic functions DIR.CMD - Effective direction of the positioner set-point value CUTOFF - Sealing function for the positioner CHARACT - Select the transfer characteristic between input signal (position set-point value) and stroke INPUT - Enter the input signal RESET - Reset to factory settings X.TUNE - Automatic adjustment of the positioner to the relevant operating conditions 13.2 Auxiliary functions DIR.ACTUATOR - Effective direction of the actuator SPLITRANGE - Signal split range X.LIMIT - Limiting the mechanical stroke range X.TIME - Limiting the control speed X.CONTROL - Parameterization of the positioner SAFE POSITION - Definition of the safe position SIGNAL ERROR - Configuration of signal level fault detection BINARY INPUT - Activation of the binary input OUTPUT (optional) - Configuration of the analog output SAFETY END POSITIONS Safety end positions after failure of the electrical or pneumatic auxiliary power MAINTENANCE Safety instructions Service at the air intake filter ACCESSORIES Communications software USB interface Download DISASSEMBLY Safety instructions Disassembly the positioner PACKAGING AND TRANSPORT STORAGE DISPOSAL 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. Important safety information. Read the operating instruction carefully and thoroughly. Study in particular the chapters entitled Basic safety instructions and Authorized use. The operating instructions must be read and understood. 1.1 Symbols DANGER! Warns of an immediate danger. Failure to observe the warning will result in 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 an instruction to prevent risks. Designates a procedure which you must carry out. 1.2 Definition of term / abbreviation The term device used in these instructions always stands for the positioner Type In these instructions, the abbreviation Ex always refers to potentially explosive. 7 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 reliable and faultless operation. Use the positioner Type 8694 only as intended. 2.1 Restrictions If exporting the system/device, observe any existing restrictions. 8 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! Risk of injury from high pressure in the equipment/device. Before working on equipment or device, switch off the pressure and deaerate/drain lines. Risk of electric shock. Before working on equipment or device, 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: In the potentially explosion-risk area the positioner Type 8694 may be used only according to the specification on the separate approval sticker. For use observe the additional instructions enclosed with the device together with safety instructions for the explosion-risk area. Devices without a separate approval sticker may not be used in a potentially explosive area. 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. When unscrewing and screwing in the body casing or the transparent cap, do not hold the actuator of the process valve but the connection housing of Type 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 bodies. Do not paint the housing parts or screws. 9 Basic safety instructions 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 and 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. 4 GENERAL INFORMATION 4.1 Contact address Germany Bürkert Fluid Control System Sales Center Chr.-Bürkert-Str D Ingelfingen Tel (0) Fax + 49 (0) International Contact addresses can be found on the final pages of the printed operating instructions. And also on the Internet at: Warranty The warranty is only valid if the positioner Type 8694 is used as intended in accordance with the specified application 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: 10 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 diaphragm valve Type 2730 with angle seat valve with straight seat valve with angle seat valve Type 2300 Type 2301 Type 2702 Figure 1: Overview of possible combinations 11 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 Types 2300 Diaphragm valves Ball valves Flap valves Features incoming flow under seat no closing impact straight flow path of the medium self-adjusting stuffing box for high leak-tightness medium is hermetically separated from the actuator and environment cavity-free and selfdraining body design any flow direction with low-turbulence flow steam-sterilizable CIP-compliant no closing impact 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 unaffected by contamination little pressure loss compared to other valve types inexpensive low construction volume actuator and diaphragm can be removed when the body is installed Note can be used as process controller only Typical media water, steam and gases neutral gases and liquids neutral gases and liquids neutral gases and liquids alcohols, oils, propellants, hydraulic fluids salt solutions, lyes (organic) solvents contaminated, abrasive and aggressive media media of higher viscosity clean water slightly aggressive media slightly aggressive media Table 1: Features of the valve types 12 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 Representation Version 1 Version 2 Transparent cap Body casing Pressure limiting valve (for protection against too high internal pressure in case of error) Connection housing Exhaust air connection (label: 3) Body casing removed: Pressure supply connection (label: 1) Buttons LED Exhaust air connection (label: 3) Pressure supply connection (label: 1) Communications interface LED DIP Switches Communications interface Screwtype terminals Air intake filter (exchangeable) Air intake filter (exchangeable) Electrical connection (cable gland M16 x 1.5 or circular plug-in connector M12 x 1) Additional exhaust air port (label: 3.1) only for Type 23xx and 2103 with pilot-operated control system for high air flow rate (actuator size ø 130) Figure 2: Structure 13 System description 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 interfaces 1/4 connections with different thread forms (G, NPT) hose plug-in connection Electrical interfaces Circular plug-in connector or cable gland Pneumatic interface Electrical interface Body The body of the positioner is protected from excessively high internal pressure, e.g. due to leaks, by a pressure limiting valve. 14 Communications interface For configuration and parameterization. System description Function diagram of the positioner with single-acting actuator The illustrated function diagram describes the function of the positioner (Type 8694). external position set-point value Positioner Actual position Position measuring system Position controller Control system 1 2 Control system 1: Aeration valve 2: Bleed valve Pressure supply Exhaust air Pneumatic actuator (single-acting) Valve (actuator) Figure 3: Function diagram 15 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 manipulated variable. If there is a positive control difference in single-acting actuators, the air inlet valve is controlled via output B1. If the control difference is negative, the bleed valve is controlled via output E1. In this way the position of the actuator is changed until control difference is 0. Z1 represents a disturbance variable. Z1 CMD + - Xd1 B1 E1 P K Valve opening Position set-point value Position controller Control system Solenoid valves Control valve POS Position control circuit Position measuring system Figure 4: Signal flow plan of position controller Schematic representation of the position control Type ma 1) ma DIR.ACT 2) X.LIMIT 2) POS POS CMD INP CMD DIR.CMD SPLTRNG 2) CHARACT CUTOFF X.TIME 2) X.CONTROL DBND 1) Default setting 2) Can only be activated with communications software 16 Figure 5: Schematic representation of position control System description Functions of the position controller software Functions I Activation via DIP switches Parameter setting via communications software Additional function Effect Sealing function CUTOFF Correction line to adjust the operating characteristic CHARACT Effective direction of the controller set-point value DIR.CMD 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 ). Linearization of the operating characteristic can be implemented (see chapter 7.4 Function of the DIP switches ). Reversal of the effective direction of the set-point value (see chapter 7.4 Function of the DIP switches ). Table 2: Functions I 17 System description Functions II Activation and parameter setting via communications software Additional function Effect Standard signal for set-point value INPUT Effective direction of the actuator DIR.ACTUATOR Signal split range SPLITRANGE Mechanical stroke range limit X.LIMIT Opening and closing time X.TIME Position controller X.CONTROL Safety position SAFE POSITION Signal level fault detection SIGNAL ERROR Binary input BINARY INPUT Analog output OUTPUT Reset RESET Select set-point value standard signal Assignment of the aeration status of the actuator chamber to the actual position. Standard signal as % for which the valve runs through the entire mechanical stroke range. Limit the mechanical stroke range Limit the control speed Parameterize the position controller Definition of the safety position Configuration of signal level fault detection Configuration of the binary input Configuration of the analog output (optional) Reset to factory settings Table 3: Functions II 18 System description 5.6 Interfaces of the positioner Input for position set-point value 3) 4 20 ma 4) 0 20 ma Positioner Analog position feedback (optional) Binary input Inputs Outputs 24 V DC Communications interface Power Operation Figure 6: 3) Or optional bus connection AS interface 4) Default setting Interfaces The positioner Type 8694 is a 3-wire device, i.e. the power (24 V DC) is supplied separately from the setpoint value signal. Input for position set-point value (4 20 ma corresponds to % (depending on position of DIP switch 1)). Binary input If a voltage 10 V is applied, SAFE POSITION is activa
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