Burkert 8697 Pneumatic control Operating Instructions
The Burkert 8697 Pneumatic Control Unit is designed to precisely control single or double-acting process valves. It excels in modular installations, especially with 21xx series valves (Element actuator size 55 and 65). This compact unit provides position feedback via LEDs and allows manual override using the pilot valve. The 8697 is suitable for various industries, including chemical, pharmaceutical, food & beverage, and water treatment.
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Type 8697
Pneumatic Control Unit
Pneumatische Ansteuerung
Unité de commande pneumatique
Operating Instructions
Bedienungsanleitung
Manuel d‘utilisation
We reserve the right to make technical changes without notice.
Technische Änderungen vorbehalten.
Sous réserve de modifications techniques.
© Bürkert Werke GmbH & Co. KG, 2011 - 2021
Operating Instructions 2107/07_EU-ml_00810081 / Original DE
Type 8697
1. OPERATING INSTRUCTIONS ............................... 4
1.1. Symbols ............................................................................ 4
1.2. Definition of term / abbreviation ........................................ 4
2. AUTHORIZED USE .................................................................. 5
2.1. Designs with explosion protection .................................... 5
3. BASIC SAFETY INSTRUCTIONS ............................................ 6
4. GENERAL INFORMATION ...................................................... 7
4.1. Contact address ................................................................ 7
4.2. Warranty ............................................................................ 7
4.3. Information on the internet ................................................ 7
5. DESCRIPTION OF SYSTEM .................................................... 7
5.1. Configuration and function ................................................ 7
6. TECHNICAL DATA ................................................................... 9
6.1. Conformity ........................................................................ 9
6.2. Standards .......................................................................... 9
6.3. Licenses ............................................................................ 9
6.4. Operating conditions ......................................................... 9
6.5. Mechanical data .............................................................. 10
6.6. Type label (example) ........................................................ 10
6.7. UL additional label .......................................................... 10
6.8. Pneumatic data ............................................................... 10
6.9. Electrical data ................................................................. 11
7. INSTALLATION ...................................................................... 12
7.1. Safety instructions .......................................................... 12
7.2. Installation on process valves of series 21xx .................. 12
7.3. Installation on process valves of series 20xx .................. 15
7.4. Rotating the actuator module ......................................... 18
7.6. Manual actuation of the actuator via pilot valve ............. 20
8. FLUID INSTALLATION ........................................................... 21
8.1. Safety instructions .......................................................... 21
8.2. Installing the process valve ............................................. 21
8.3. Pneumatic connection of the Pneumatic Control Unit .... 21
9. ELECTRICAL INSTALLATION................................................ 22
9.1. Safety instructions .......................................................... 22
9.2. Electrical installation with cable gland ............................ 23
9.3. Electrical installation with circular plug-in connector ...... 26
9.4. Display elements: End position LEDs ............................. 27
10. SAFETY POSITIONS .......................................................... 29
11. ACCESSORIES .................................................................... 29
12. DISASSEMBLY .................................................................... 30
12.1. Safety instructions ......................................................... 30
12.2. Disassembly the Pneumatic Control Unit ..................... 30
13. PACKAGING, TRANSPORT, STORAGE .............................. 31
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Type 8697
Operating instructions
1. OPERATING INSTRUCTIONS
The operating instructions describes 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.
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.
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.
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.
▶ Indicates 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 Pneumatic Control Unit Type 8697.
The abbreviation “Ex” used in these instructions always stands for “potentially explosive atmosphere”.
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Type 8697
Authorized use
2. AUTHORIZED USE
Non-authorized use of the Pneumatic Control Unit Type
8697 may be a hazard to people, nearby equipment and the environment.
▶ The device is designed to be mounted on pneumatic actua tors 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 chap-
ter 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 instal lation, it is essential to study and if necessary to test whether the Pneumatic Control Unit 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 Pneumatic Control Unit Type 8697 only as intended.
2.1.
Designs with explosion protection
DANGER!
Explosion hazard.
Improper use in a potentially explosive atmosphere represents an explosion hazard.
▶ Observe the information in the EC Declaration of Conformity as well.
▶ For designs with Ex approval, the information in the EC-Type
Examination Certificate and the additional instructions of Type
8697 must also be observed.
2.1.1.
Ex approval
The Ex approval is only valid if the modules and components autho rized by Bürkert are used as described in the additional instructions for Type 8697.
The Pneumatic Control Unit may be used only in combination with the additional components released by Bürkert, otherwise the Ex approval will be voided!
If any unauthorized changes are made to the device, modules or components, the Ex approval will also be voided.
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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, whereby the operator is responsible for their compliance, by the installation personnel too.
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 reaching into the device, switch off the power supply and secure to prevent reactivation.
▶ Observe applicable accident prevention and safety regulations for electrical equipmen.
Type 8697
Basic safety instructions
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 of the device, ensure:
▶ Do not feed any aggressive or flammable media into the pres sure 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.
▶ The device may be operated only with the transparent hood closed.
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Type 8697
General information
4. GENERAL INFORMATION
4.1.
Contact address
Germany
Sales Center
Christian-Bürkert-Str. 13-17
D-74653 Ingelfingen
Tel. : 07940 - 10 91 111
Fax: 07940 - 10 91 448
E-mail: [email protected]
International
Contact addresses are found on the final pages of the printed operating manual and also on the Internet at: www.burkert.com
4.2.
Warranty
The warranty is only valid if the device is used as authorized in accordance with the specified application conditions.
4.3.
Information on the internet
The operating instructions and data sheets for Type 8697 can be found on the Internet at: www.burkert.com
5. DESCRIPTION OF SYSTEM
5.1.
Configuration and function
The Pneumatic Control Unit Type 8697 can control single or doubleacting process valves. The Pneumatic Control Unit Type 8697 has been optimized for integrated, modular installation on process valves of the 21xx series (Element actuator size ∅ 50). The module configuration permits a variety of expansion steps.
For installation on the 20xx series there is a special model which is described in Chapter
5.1.1.
Pneumatic Control Unit for integrated installation on 21xx series (Element actuator size ∅
50)
Transparent cap
Pressure limiting valve
(for protection against too high internal pressure in case of error)
Pilot air port label: 1
Exhaust air connection label: 3
Cable gland M16 x 1.5 or Circular plug-in connector M12 x 1
Fig. 1: Configuration and function (1) english 7
Type 8697
Description of system
Optical position indicator:
The device status is displayed on the Pneumatic Control Unit
(yellow mark).
Option: Electrical position feedback
Optionally mechanical limit switches (micro switches) or inductive proximity switches can measure the valve position.
View without transparent cap:
Assembly shaft for precision adjustment of the switch cams
(only for model with inductive proximity switches)
Opening for optical position indicator
Screw terminals
Fastening screws (2x)
5.1.2.
Model for control of process valves belonging to the 20xx series
A special model enables the Pneumatic Control Unit Type 8697 to be attached to process valves belonging to the 20xx series.
This model has a different pneumatic connection module so that the pilot air ports can be connected to the outside of the actuator.
Fastening screws
(2x)
Pilot air outlet 2
1
Pilot air outlet 2
2
Fig. 3: Connection module for process valves, 20xx series
Fig. 2: Configuration and function (2)
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Type 8697
Technical data
6. TECHNICAL DATA
6.1.
Conformity
In accordance with the EU Declaration of conformity, the Pneu matic Control Unit Type 8697 is compliant with the EU Directives
(if applicable).
6.2.
Standards
The applied standards, which verify conformity with the EU Direc tives, can be found on the EU-Type Examination Certificate and / or the EU Declaration of Conformity (if applicable).
6.3.
Licenses
The product is approved for use in zone 1, 2, 21 and 22 in accor dance with ATEX directive 2014/34/EU category 2 GD and 3GD.
Observe instructions on operation in a potentially explosive atmosphere (Ex area). Observe the ATEX addi tional instructions.
The product is cULus approved. Instructions for use in the UL area see chapter
.
6.4.
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 minimum value.
Ambient temperature
without pilot valve (feedback head) -20...+60 °C
( -4...+140 °F)
with pilot valve (control head) -10...+55 °C
(+14...+131 °F)
with ATEX approval see ATEX additional instructions
Degree of protection
Evaluated by the manufacturer: IP65 / IP67 according to EN
60529 1)
Evaluated by UL: UL Type 4x Rating indoor only
Operating altitude up to 2000 m above sea level
Relative air humidity max. 90% at 55 °C
(non condensing) english 9
6.5.
Mechanical data
Dimensions see data sheet
Body material external PPS, PC
Sealing material external EPDM, internal FKM
Stroke range of valve spindle Micro switch
Proximity switch
4...36 mm
2...36 mm
6.6.
Type label (example)
8697 -*-I2-E1-* PE51 single act pilot0.6 24V
Pmax 7bar sw.ind.3wire PNP
Tamb 0 - +55°C REV.2
S/N 1001
00248807 W15MA
Bar code
Type; Features of the type code applicable to UL and ATEX
Control function; pilot valve; supply voltage pilot valve
Nominal pressure; limit switch
Max. ambient temperature;
Release version
Serial number; CE mark
Identification number;
Date of manufacture
Fig. 4: Example of type label
6.7.
UL additional label
Type 8697
Technical data
6.8.
Pneumatic data
Control medium neutral gases, air, Quality classes in accordance with DIN ISO 8573-1
Dust content Class 7 max. particle size 40 μm, max. particle density 10 mg/m 3
Water content Class 3 max. pressure dew point -20 °C or min. 10 °C below the lowest operating temperature
Oil content Class X max. 25 mg/m 3
Temperature range 0...+50 °C (32...+122 °F)
Pressure range 3...7 bar (43,5...101,5 psi)
Air output of pilot valve 7 I
Q
N
Nn
/min (for aeration and deaeration,
-value according to definition for pressure drop from 7 to 6 bar absolute)
Connections
21xx (Element) Plug-in hose connector
Socket connection G 1/8
20xx (Classic) Socket connection G 1/8 Connection
M5 for connecting the actuator
Degree of protection
Limit switch: 10...30 V
Type 4X enclosure
Supply voltage limit switch
Fig. 5: Example of UL additional label (example)
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Type 8697
Technical data
6.9.
Electrical data
Connections Cable gland M16 x 1.5, wrench size 19
(clamping area 4...8 mm) with screw terminals for cable cross-sections 0.14...1.5 mm²
Circular plug-in connector M12 x 1, 8-pole
Supply voltage
Pilot valve 24 V DC ± 10 %, residual ripple 10 %
UL: NEC Class 2, 24 V DC, 1 W
Power consumption of pilot valve 1 W
Micro switch For maximum current load see table
Variant for safety extra-low voltage (0...48 V AC/DC)
24 V 48 V resistive load and semi-conductor load inductive load (cos ϕ = 0,3)
2 A AC
2 A DC
2 A AC
2 A DC
2 A AC
2 A DC
1 A DC
1,5 A AC
Variant for low voltage (50...250 V AC/DC) 1)
110/127 V 220/240 V resistive load and semi-conductor load inductive load (cos ϕ = 0,3)
2 A AC
0,4 A DC
0,5 A AC
0,2 A DC
2 A AC
0,2 A DC
0,2 A AC
0,1 A DC
1)
When used in the UL area, voltage and current are limited to 125 V AC
1 A. Also both micro switches must be fed from the same power supply.
Proximity switches
3-wire PNP 10...30 V DC max. 100 mA per
proximity switch
2-wire 24 V DC normally open 10...30 V DC
max. 100 mA, min. 3 mA per proximity switch,
Voltage drop< 5 V Residual current < 0,6 mA
2-wire NAMUR 8,2 V DC, 1,2/2,1 mA
(actuated/not actuated) UL: NEC Class 2
Position feedback (option)
Protection class 3 acc. to DIN EN 61140 (VDE
0140-1):
2 microswitches 0...48 V AC/DC,
2 initiators 10...30 V DC, normally open contact PNP
(3-wire),
2 initiators 10...30 V DC, normally open contact
(2-wire),
2 initiators NAMUR (8.2 V DC) (2-wire)
Protection class 2 acc. to DIN EN 61140 (VDE
0140-1): 2 microswitches 50...250 V AC/DC english 11
7. INSTALLATION
Only for Pneumatic Control Unit without pre-assembled process valve.
7.1.
Safety instructions
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 reaching into the device, 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.
Type 8697
Installation
7.2.
Installation on process valves of series 21xx
Procedure:
1. Install switch spindle
Transparent cap
Pilot air ports
(plug-in hose connectors with collets or threaded bushings)
Actuator
Fig. 6: Installation of the switch spindle (1), 21xx series
→
Unscrew the transparent cap on the actuator and unscrew the position display (yellow cap) on the spindle extension.
→
For version with plug-in hose connector, remove the collets
(white nozzles) from both pilot air ports (if present).
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Type 8697
Installation
Maximum distance
Switch spindle
Switch cam
Spacer sleeve
Groove ring
Guide element max. 1 Nm max. 5 Nm
Actuator cover
O-ring
Spindle extension
Fig. 7: Installation of switch spindle (2), 21xx series
NOTE!
Improper installation may damage the groove ring in the guide element.
The groove ring is already be pre-assembled in the guide element and must be “locked into position” in the undercut.
▶ When installing the switch spindle, do not damage the groove ring.
→
Push the switch spindle through the guide element.
NOTE!
Screw locking paint may contaminate the groove ring.
▶ Do not apply any screw locking paint to the switch spindle.
→
To secure the switch spindle, apply some screw locking paint
(Loctite 290) in the tapped bore of the spindle extension in the actuator.
→
Check that the O-ring is correctly positioned.
→
Screw the guide element to the actuator cover
(maximum torque: 5 Nm).
→
Screw switch spindle onto the spindle extension. To do this, there is a slot on the upper side (maximum torque: 1 Nm).
→
Push spacer sleeve onto the switch spindle up to the guide element.
Position switch cams on the switch spindle:
→
Push lower switch cam up to the spacer sleeve.
→
Push upper switch cam until 3 mm from the start of the switch spindle.
Ensure that the distance between both switch cams is
).
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Type 8697
Installation
2. Install sealing rings
Pilot air ports
Caution:
Collets must not be fitted !
3. Installation of the Pneumatic Control Unit
Form seal
Fig. 8: Installing of the sealing rings, 21xx series
Installation of the form seal
→
Pull the form seal onto the actuator cover
(smaller diameter points upwards).
→
Check that the O-rings are correctly positioned in the pilot air ports.
When the Pneumatic Control Unit is being installed, the collets of the pilot air ports must not be fitted to the actuator.
Supports
Pilot air ports
Fastening screws max. 0,5 Nm
Fig. 9: Installation of the Pneumatic Control Unit, 21xx series
→
Align the Pneumatic Control Unit until the supports of the Pneu matic Control Unit can be inserted into the pilot air ports of the
).
→
Push the Pneumatic Control Unit, 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 degree of protection IP65 / IP67.
▶ The fastening screws may be tightened to a maximum torque of 0.5 Nm only.
→
Attach the Pneumatic Control Unit to the actuator using the two side fastening screws. In doing so, tighten the screws only hand-tight (maximum torque: 0.5 Nm).
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Type 8697
Installation
7.3.
Installation on process valves of series 20xx
Procedure:
1. Install switch spindle
Transparent cap
Position indicator
Actuator
Fig. 10: Installation of the switch spindle (1), series 20xx
→
Unscrew the transparent cap on the actuator.
→
Using a hexagon socket key, unscrew the orange/yellow position indicator from the inside of the actuator.
→
Press the O-ring downwards into the cover of the actuator
→
Manually screw the switch spindle (and the plugged-on guide element) together with the plastic part onto the spindle of the actuator, but do not tighten spindle yet.
Maximum distance
Switch spindle
Switch cam
Spacer sleeve
Groove ring
Guide element
O-ring
Actuator cover
Plastic part of the switch spindle
Spindle (actuator)
Fig. 11: Installation of the switch spindle (2), series 20xx
→
Tighten the guide element with a wrench SW19 into the actuator cover (torque: 8.0 Nm).
→
Tighten the switch spindle on the spindle of the actuator.
To do this, there is a slot on the upper side (torque: 1.0 Nm).
→
Push spacer sleeve onto the switch spindle up to the guide element.
→
Position switch cams on the switch spindle:
→
Push lower switch cam up to the spacer sleeve.
→
Push upper switch cam until 3 mm from the start of the switch spindle.
Ensure that the distance between both switch cams is
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2. Installation of the Pneumatic Control Unit
Fastening screws max. 0.5 Nm
Type 8697
Installation
NOTE!
Too high torque when screwing in the fastening screw does not ensure degree of protection IP65 / IP67.
▶ The fastening screws may be tightened to a maximum torque of 0.5 Nm only.
→
Attach the Pneumatic Control Unit to the actuator using the two side fastening screws. In doing so, tighten the fastening screws hand-tight only (maximum torque: 0.5 Nm).
3. Installation of the pneumatic connection on the actuator
Fig. 12: Installation of the Pneumatic Control Unit, series 20xx
→
Push the Pneumatic Control Unit onto the actuator.
→
Press the Pneumatic Control Unit all the way down as far as the actuator and turn it into the required position.
Ensure that the pneumatic connections of the Pneumatic
Control Unit and those of the actuator are situated pref -
erably vertically one above the other (see “Fig. 12”
).
If they are positioned differently, longer hoses may be required other than those supplied in the accessory kit.
Pilot air outlet 2
2
Pilot air outlet 2
1
Upper pilot air port
Lower pilot air port
Fig. 13: Installation of the pneumatic connection, 20xx series
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Type 8697
Installation
→
Screw the plug-in hose connectors onto the Pneumatic Control
Unit and the actuator.
→
Using the hoses supplied in the accessory kit, make the con nection between the Pneumatic Control Unit and the actuator
with the following “Tab. 1: Pneumatic connection to actuator”
.
NOTE!
Damage or malfunction due to ingress of dirt and moisture.
▶ To comply with degree of protection IP65 / IP67, connect the pilot air outlet which is not required to the free pilot air port of the actuator or seal with a plug.
“In rest position” means that the pilot valves of the Pneu matic Control Unit Type 8697 are isolated or not actuated.
If the ambient air is humid, a hose can be connected between pilot air outlet 2
2
of the Pneumatic Control Unit and the unconnected pilot air port of the actuator for control function A or control function B. As a result, the spring chamber of the actuator is supplied with dry air from the vent duct of the Pneumatic Control Unit.
Control function
A
B
Process valve closed in rest position
(by spring force)
Process valve open in rest position
(by spring force)
Pneumatic connection Type 8697 with actuator
Pilot air outlet
Type 8697
Pilot air port actuator
2
1 lower pilot air port of the actuator
2
2
2
2
1
2 should be connected to the upper pilot air port of the actuator upper pilot air port of the actuator should be connected to the lower pilot air port of the actuator
Tab. 1: Pneumatic connection to actuator english 17
Type 8697
Installation
7.4.
Rotating the actuator module
The actuator module (Pneumatic Control Unit and actuator) can be rotated for straight seat valves and angle seat valves only.
The position of the connections can be aligned steplessly by rotating the actuator module (Pneumatic Control Unit and actuator) through 360°.
Only the entire actuator module can be rotated. The Pneumatic Control Unit cannot be rotated contrary to the actuator.
The process valve must be in the open position for alignment of the actuator module.
Actuator module
Hexagon
Nipple
Series 21xx
Fig. 14: Rotating the actuator module
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Hexagon
Nipple
Series 20xx
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.
Procedure:
→
Clamp valve body in a holding device (only required if the process valve has not yet been installed).
→
Control function A: Open process valve.
→
Using a suitable open-end wrench, counter the wrench flat on the pipe.
→
Place suitable open-end wrench on the hexagon of the actuator.
WARNING!
Risk of injury from discharge of medium and pressure.
If the direction of rotation is wrong, the body interface may become detached.
▶ Rotate the actuator module
in the specified direction only (see
→
Rotate counter-clockwise (as seen from below) to bring the actuator module into the required position.
Type 8697
Installation
Open-end wrench
Fastening screw (2x)
Pneumatic
Control Unit
Pneumatic connection
Fig. 15: Rotating with open-end wrench
Actuator
7.5.
Rotating the Pneumatic Control
Unit for process valves belonging to series 20xx
If the connecting cables or hoses cannot be fitted properly following installation of the process valve, the Pneumatic Control Unit can be rotated contrary to the actuator.
Procedure
→
Loosen the pneumatic connection between the Pneumatic
Control Unit and the actuator.
→
Loosen the fastening screws (hexagon socket wrench size
2.5).
→
Rotate the Pneumatic Control Unit into the required position.
Fig. 16: Rotating the Pneumatic Control Unit, series 20xx
NOTE!
Too high torque when screwing in the fastening screw does not ensure degree of protection IP65 / IP67.
▶ The fastening screw may be tightened to a maximum torque of 0.5 Nm only.
→
Tighten the fastening screws hand-tight only
(maximum torque: 0.5 Nm).
→
Re-attach the pneumatic connections between the Pneumatic
Control Unit and the actuator. If required, use longer hoses.
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7.6.
Manual actuation of the actuator via pilot valve
The actuator can be moved without a power supply from the rest position to its end position and back again, when the control air is connected.
To do this, the pilot valve must be actuated with a screwdriver.
NOTE!
The hand lever may be damaged if it is simultaneously pressed and turned.
▶ Do not press the hand lever when turning it.
Pilot valve non activated
(normal position)
Hand lever to the left
Type 8697
Installation
Move actuator to end position
→
Turn the hand lever to the right using a screwdriver.
Note: Do not press the hand lever when turning it
Move actuator back to the rest position
→
Turn the hand lever to the left using a screwdriver.
Note: Do not press the hand lever when turning it
Pilot valve activated
Hand lever
Hand lever to the right
Fig. 17: Pilot valve for aerate and deaerate the actuator
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Type 8697
Fluid installation
8. FLUID INSTALLATION
The dimensions of the Pneumatic Control Unit and the different complete device models, consisting of Pneumatic Control Unit, actuator and valve, can be found in the relevant data sheets.
8.1.
Safety instructions
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.
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.
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
Pneumatic Control Unit
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.
Procedure:
→
Connect the control medium to the pilot air port (1)
(3...7 bar, oil, water and dust-free instrument air).
→
Attach the exhaust airline or a silencer to the exhaust air port
(3).
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.
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Pilot air port label: 1
Fig. 18: Pneumatic connection
Exhaust air port label: 3
Caution: (Exhaust air concept) :
In compliance with degree of protection IP67, an exhaust air line must be installed in the dry area.
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.
Type 8697
Electrical installation
9. ELECTRICAL INSTALLATION
Two kinds of connections are used for the electrical bonding of the
Pneumatic Control Unit:
• Cable bushing with cable gland M16 x 1.5 and screw-type terminals
• Multi-pole with circular plug-in connector M12 x 1, 8-pole.
9.1.
Safety instructions
DANGER!
Risk of electric shock.
▶ Before reaching into the device, 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.
▶ In the case of devices with UL approval for the electrical instal lation use only cables which are approved for a temperature of at least 70 °C.
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Type 8697
Electrical installation
Risk of injury from unintentional activation of the system and an uncontrolled restart.
▶ Secure system from unintentional activation.
▶ Following installation, ensure a controlled restart.
Minimum temperature rating of the cable to be connected to the field wiring terminals: 75 °C
NOTE!
Damage or malfunction due to penetration of dirt and humidity.
To ensure degree of protection IP65 / IP67:
▶ Tighten the union nut on the cable gland according to the cable size or dummy plugs used. (ca. 1,5 Nm).
▶ Screw the transparent cap in all the way.
→
Tighten union nut on the cable gland (torque approx. 1.5 Nm).
9.2.
Electrical installation with cable gland
DANGER!
Risk of electric shock.
▶ Before reaching into the device, switch off the power supply and secure to prevent reactivation.
▶ Observe applicable accident prevention and safety regulations for electrical equipment.
Procedure:
→
Open the Pneumatic Control Unit: unscrewing the transparent cap in an anticlockwise direction.
→
Push the cables through the cable gland.
→
Connect the wires according to the model (options) of the
Pneumatic Control Unit.
Transparent cap
Joint
Transparent cap
Fig. 19: Position of the seal in the transparent cap
→
Check that the seal is correctly positioned in the transparent cap.
→
Close the Pneumatic Control Unit (assembly tool: 674078 2) ).
2)
The assembly tool (674078) is available from your Bürkert sales office.
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9.2.1.
Connection diagram with micro switches (mechanical limit switches)
Terminal
1
Configuration External circuit
1
NO
2
3
Micro switch top
2
3
NC
Joint connection
4
4
NO
5
Micro switch bottom
5
NC
6
6
Joint connection
Tab. 2: Connection diagram with micro switches
Screw terminals
3
4
5
1
2
6
Fig. 20: Position of the screw terminals
24 english
Type 8697
Electrical installation
9.2.2.
Connection diagram with 3-wire proximity switches (inductive limit switches)
Terminal Configuration External circuit
1
INI + (24 V DC)
Supply
INI GND
Supply
3
Output 1
(24 V)
2
3
INI Top OUT
Output 1
4
2
Output 2
(24 V)
GND
4
5
6
INI Bottom OUT
Output 2
Valve control
0 / 24 V DC
Valve control
GND
5
6
1
+24 V DC
0 / 24 V DC ± 10 %
Residual ripple 10 %
Tab. 3: Connection diagram with 3-wire proximity switches
Screw terminals
3
4
5
1
2
6
Fig. 21: Position of the screw terminals
Type 8697
Electrical installation
9.2.3.
Connection diagram with 2-wire proximity switches (inductive NAMUR limit switches)
Terminal Configuration External circuit
1
2
3
4
INI Top +
INI Top -
INI Bottom +
INI Bottom -
Explosion protected area
1 / 3
Non-hazardous area
+8,2 V DC
2 / 4
NAMUR-
Sensor
R
0 V
3)
5
6
Valve control
+
Valve control
GND
Explosion protected area
Non-hazardous area
Safety barrier
5
6
+
PA
Tab. 4: Connection diagram with 2-wire proximity switches
4)
3)
4)
(Recommended by NAMUR) Observe the max. values of the intrinsically safe circuits in the ATEX additional instructions.
Signal from barrier see PTB 07 ATEX 2048
Screw terminals
3
4
1
2
5
6
Fig. 22: Position of the screw terminals
9.2.4.
Connection diagram with 2-wire proximity switches 24 V (inductive limit switches, normally open)
Terminal Configuration External circuit
1
2
INI Top +
INI Top -
INI Bottom -
Valve control +
1 / 3
2 / 4 load
+
–
3
4
5
INI Bottom +
5
6 Valve control GND 6
Tab. 5: Connection diagram with 2-wire proximity switches 24 V english 25
Screw terminals
Fig. 23: Position of the screw terminals
3
4
1
2
5
6
9.3.
Electrical installation with circular plug-in connector
DANGER!
Risk of electric shock.
▶ Before reaching into the device, switch off the power supply and secure to prevent reactivation.
▶ Observe applicable accident prevention and safety regulations for electrical equipment.
→
Connect the pins.
Type 8697
Electrical installation
Pin assignment with 3-wire proximity switches (inductive limit switches)
2 1
3
8
4 5 6
7
Fig. 24: Circular connector M12x1, 8-pole
Pin Wire
5)
Configuration External circuit
1 white
INI Bottom
OUT
Output
INI Top OUT
Output
1
Output 1
(24 V)
2
3 brown green
INI - (GND)
Supply
2
3
Output 2
(24 V)
GND
4 yellow
INI + (24 V DC)
Supply
4
+24 V DC
5
6 grey pink
Valve control 0
/ 24 V
Valve control
GND
5
6
0 / 24 V DC
± 10 %
Residual ripple
10 %
Tab. 6: Pin assignment with 3-wire proximity switches
5)
The indicated colors refer to the connecting cable available as an accessory (919061)
26 english
Type 8697
Electrical installation
9.4.
Display elements: End position
LEDs
LED Top
LED Bottom
9.4.1.
Display elements LEDs
End position top
Version with 3-wire proximity switches
Version with 2-wire proximity switches
LED Top
Version with 2-wire proximity switches by NAMUR (Ex version) 6) is lit yellow is lit yellow goes out
End position bottom is lit yellow
LED Bottom is lit yellow
Tab. 7: End position LED yellow goes out
The version with micro switches (mechanical limit switches) does not include any LED to indicate position.
Fig. 25: End position LEDs
6)
In the case of the version with 2wire initiators according to NAMUR the LED function is inverse for technical reasons, i.e. the LED glows when the end position is not reached and goes out when the end position is reached.
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9.4.2.
Display elements LEDs REV.2
Version with 3-wire proximity switches
Version with 2-wire proximity switches
Version with
2-wire proximity switches by NAMUR (Ex version) 6)
End position top
LED Top is lit yellow is lit yellow
End position bottom is lit green
LED Bottom is lit green
Tab. 8: End position LEDs release version 2 green off yellow off
The version with microswitches (mechanical limit switches) does not include any LEDs for the position indicator.
Type 8697
Electrical installation
9.5.
Adjustment of the micro switches or the proximity switches (option)
DANGER!
Risk of electric shock.
▶ Before reaching into the device, switch off the power supply and secure to prevent reactivation.
▶ Observe applicable accident prevention and safety regulations for electrical equipment.
Procedure:
→
Open the Pneumatic Control Unit: unscrewing the transparent cap in an anticlockwise direction.
→
Ensure that the distance between both switch cams is maximum.
(see
).
Switch spindle
Switch cam
Maximum distance
Spacer sleeve
7)
In the case of the version with 2wire initiators according to NAMUR the LED function is inverse for technical reasons, i.e. the LED glows when the end position is not reached and goes out when the end position is reached.
28 english
Fig. 26: Distance between the switch cams
→
Pressurize pilot air port 1 with compressed air (5 bar) or, if fitted, actuate the hand lever of the pilot valve in the control unit:
Actuator moves to the 2nd end position.
Type 8697
Safety Positions
The switch cams (and switch points) have now been set.
→
Check the switching point(s) using suitable measuring equipment.
→
If required, the switch points can still be finely adjusted: Using a
screwdriver, push switch cams towards the middle (see “Fig. 27” ).
→
Check that the seal is correctly positioned in the transparent cap.
( “Fig. 19: Position of the seal in the transparent cap”, page 23).
NOTE!
Damage or malfunction due to penetration of dirt and humidity.
To ensure degree of protection IP65 / IP67:
▶ Screw the transparent cap in all the way.
→
Close the Pneumatic Control Unit (assembly tool: 674078 7) ).
Switch cam
10. SAFETY POSITIONS
Safety positions after failure of the electric or pneumatic auxiliary energy:
Operating mode Designation
Safety positions after failure of the auxiliary energy
Electrical Pneumatic up
Single-acting control function A down down down up
Single-acting control function B down
Tab. 9: Safety positions up up
Fig. 27: Adjustment of the micro switch and the proximity switches
8)
The assembly tool (674078) is available from your Bürkert sales office.
11. ACCESSORIES
Designation
Connection cable M12 x 1, 8-pole
Assembly tool
Tab. 10: Accessories english
Order no.
919061
674078
29
12. DISASSEMBLY
12.1.
Safety instructions
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 reaching into the device, 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 disassembly.
▶ Disassembly 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 disassembly, ensure a controlled restart.
Type 8697
Disassembly
12.2.
Disassembly the Pneumatic
Control Unit
Procedure:
1. Pneumatic connection
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.
→
Loosen the pneumatic connection.
→
Series 20xx:
Loosen the pneumatic connection between Pneumatic
Control Unit and actuator.
2. Electrical connection
DANGER!
Risk of electric shock.
▶ Before reaching into the device, switch off the power supply and secure to prevent reactivation.
▶ Observe applicable accident prevention and safety regulations for electrical equipment.
Circular plug-in connector:
→
Loosen the circular connector.
30 english
Type 8697
Packaging, transport, storage
Cable gland:
→
Open the Pneumatic Control Unit: unscrewing the transparent cap in an anticlockwise direction.
→
Unscrew the screw terminals and pull out cables.
3. Mechanical connection
→
Loosen the fastening screws.
→
Remove the Pneumatic Control Unit upwards.
Transparent cap
Pneumatic
Control Unit
Cable gland
Fastening screws
(2x)
Pneumatic connections
Actuator
Pneumatic connection to the actuator
Series 20xx Series 21xx
Fig. 28: Disassembly the Pneumatic Control Unit
13. PACKAGING, TRANSPORT,
STORAGE
NOTE!
Transport damages.
Inadequately protected equipment may be damaged during transport.
▶ During transportation protect the device against wet and dirt in shock-resistant packaging.
▶ Avoid exceeding or dropping below the permitted storage temperature.
▶ Protect the electrical interfaces and the pneumatic connec tions from damage by placing protective caps on them.
-
Incorrect storage may damage the device.
▶ Store the device in a dry and dust-free location!
▶ Storage temperature -20...+65 °C (-4...+149 °F).
Damage to the environment caused by device components contaminated with media.
▶ Dispose of the device and packaging in an environmentally friendly manner.
▶ Observe applicable regulations on disposal and the environment.
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32 english
Type 8697
Packaging, transport, storage
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