Type 8690 Pneumatic Control Unit with approval II 2G c T6 Pneumatische Ansteuerung mit Zulassung II 2G c T6 Unité de commande pneumatique avec mode de protection II 2G c T6 Operating Instructions Bedienungsanleitung Manuel d utilisation
We reserve the right to make technical changes without notice. Technische Änderungen vorbehalten. Sous réserve de modifications techniques. 2010-2012 Bürkert Werke GmbH Operating Instructions 1202/00_EU-ml_00806109 / Original DE
Pneumatic Control Unit Type 8690 Ex 1. Operating Instructions...5 1.1. Symbols... 5 1.2. Definition of term device... 5 2. Authorized use...6 2.1. Restrictions... 6 3. Basic safety instructions...7 3.1. Instructions for use in explosion protected area (EX area)... 8 4. General information...11 4.1. Contact address...11 4.2. Warranty...11 4.3. Trademarks...11 4.4. Information on the internet...11 5. Description of system...12 5.1. Configuration and function...12 6. Technical data...13 6.1. Conformity...13 6.2. Standards...13 6.3. Operating conditions...14 6.4. Type label (example)...14 6.5. Mechanical data...14 6.6. Pneumatic data...14 6.7. Electrical data...15 7. Installation...15 7.1. Safety instructions...15 7.2. Installation of the Pneumatic Control Unit Type 8690 on process valves of series 21xx...16 7.3. Installation of the Pneumatic Control Unit Type 8690 on process valves of series 20xx...18 7.4. Rotating the actuator module...21 7.5. Rotating the Pneumatic Control Unit for process valves belonging to series 20xx...23 8. Fluid installation...24 8.1. Safety instructions...24 8.2. Installing the process valve...24 8.3. Pneumatic connection of the Pneumatic Control Unit...24 9. Electrical installation...25 9.1. Safety instructions...25 10. Maintenance...29 10.1. Service at the air intake filter...29 11. Accessories...29 12. Safety Positions...30 13. Disassembly...30 13.1. Safety instructions...30 13.2. Disassembly the Pneumatic Control Unit...31 english 3
14. Packaging, transport, storage...32 4 english
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 accessible 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. Notice! Warns of damage to property! Failure to observe the warning may result in damage to the device or the equipment. 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 important additional information, tips and recommendations. refers to information in these operating instructions or in other documentation. Designates a procedure which you must carry out. 1.2. Definition of term device The term device used in these instructions always stands for the Pneumatic Control Unit Type 8690. english 5
Authorized use 2. Authorized use Non-authorized use of the Pneumatic Control Unit Type 8690 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. It was designed for the use in explosion group IIC, category 2G and temperature class T6 (see information listed on the - certification plate). 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 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 8690 only as intended. Temperature classes and electrical data are specified on the type label, in chapter 6. Technical data and chapter 3.1. Instructions for use in explosion protected area (EX area) of this manual. 2.1. Restrictions If exporting the system/device, observe any existing restrictions. 2.1.1. EX approval The EX approval is only valid if you use the modules and components authorized by Bürkert in such a way as described in this operating manual. If you make any unauthorized changes to the device, the modules or the components, the Ex approval will expire. The type-examination certificate PTB 07 ATEX 2048 has be issued by the Physikalisch Technische Bundesanstalt Bundesallee 100 38116 Braunschweig The institute also audits the manufacture (CE0102). 6 english
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, whereby the operator is responsible for their compliance, by the installation personnel too. Danger! Danger high pressure! Before dismounting pneumatic lines and valves, turn off the pressure and vent the lines. Risk of electric shock! Before reaching into the device or the equipment, switch off the power supply and secure to prevent reactivation! Observe applicable accident prevention and safety regulations for electrical equipment! General hazardous situations. To prevent injury, ensure: that the system cannot be activated unintentionally. Installation and repair work may be carried out by authorized technicians only and with the appropriate tools. After an interruption in the power supply or pneumatic supply, ensure that the process is restarted in a defined or controlled manner. The device may be operated only when in perfect condition and in consideration of the operating instructions. The general rules of technology apply to application planning and operation of the device. To prevent damage to property 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. The Pneumatic Control Unit Type 8690 was developed with due consideration given to the accepted safety rules and is state-of-the-art. Nevertheless, dangerous situations may occur. Failure to observe this operating manual and its operating instructions as well as unauthorized tampering with the device release us from any liability and also invalidate the warranty covering the devices and accessories! english 7
Basic safety instructions 3.1. Instructions for use in explosion protected area (EX area) 3.1.1. Safety instructions For use in EX area zone (gas) 1 and 2 applies: Danger! Risk of explosion! To avoid the risk of explosion, follow not only the safety instructions in the respective operating instructions, but also observe the following information concerning operation in the hazardous area: Observe the specifications relating to temperature class and ambient temperature on the type label. Do not use the devices with gases or dust which have a lower ignition temperature than specified on the type label. Installation, operation and maintenance may be performed by qualified technicians only. Observe the applicable safety regulations (also national safety regulations) as well as the general regulations of technology concerning installation and operation. Do not repair the device yourself, but replace it with an equivalent device. Repairs may be performed by the manufacturer only. Do not expose the device to mechanical and/or thermal stresses which exceed the limits described in the operating instructions. To avoid the risk of explosion, observe the following information when performing installation and maintenance in the hazardous area: Do not open the housing of the device when hazardous atmosphere exist. Using suitable measures, ensure that no electrostatic charges can occur in the EX area. To avoid an electrostatic charge, wipe the housing surface with a damp cloth only. Use only cable and line entries which are authorized for the particular application area and are screwed together according to the appropriate installation instructions. If the cable gland is pre-assembled, install it according to the installation instructions supplied by the manufacturer of the screw connection. Before start-up, check whether the cable gland was installed in the hazardous area as described in the appropriate installation instructions. Seal all cable glands which are not required with ex-approved screw plugs. Do not open the housing of the device for operating inside switches when hazardous atmosphere exist. While bringing into service no hazardous atmosphere shall exist. 8 english
Basic safety instructions 3.1.2. Media in the Ex area If explosive media are used, this may create an additional risk of explosion! 3.1.3. Valves in the Ex area The valve may restrict use in an explosive atmosphere. Follow operating instructions for valve. 3.1.4. Cleaning in the Ex area Test cleaning agent for approval in explosive atmosphere. 3.1.5. Adhesive label for EX area Fig. 1: Device group Device category Label EX area II 2G c T6 Temperature class 3.1.6. Temperature ranges and electrical data in the Ex area Pilot valves A detailed description of the data for the pilot valve can be found on the internet under www.burkert.com Type 6144. Temperature class T6: Max. permissible surface temperature for T6 85 C Max. permissible ambient temperature [ C] Max. permissible output [W] 0 +55 0,4 0 +50 0,5 0 +45 0,6 0 +40 0,7 0 +35 0,8 Tab. 1: Temperature ranges Ex area Version Type 6144 High-impedance version Tab. 2: Resistance R20 [Ω] Ignition protection type Ex ia Minimum terminal voltage [V] 510 11,7 23 Pilot valve data Ex area Explosion group IIC Minimum current [ma] english 9
Basic safety instructions Electrical data The pilot valve with ignition protection type intrinsic safety Ex ia IIC must only be connected to certified, intrinsically safe electric circuits with the following maximum values. Explosion group IIC Category ia Temperature class T6 Max. permissible input voltage (Ui) 35 V Max. permissible input current (Ii) 0,9 A Max. permissible input power (Pi) see Tab. 1 Power supply voltage: For the maximum permissible voltages and the corresponding maximum permissible short-circuit currents for the respective explosion groups, please see standard EN 60079-11. Some value pairs for the explosion group IIC are listed as an example for every ignition protection type. Valve with ignition protection type intrinsic safety Ex ia IIC. Voltage value 15 18 20 22 25 28 30 35 [V] = Ui Current value 0,9 0,44 0,309 0,224 0,158 0,120 0,101 0,073 [A] = Ii Tab. 3: Value pairs Sensor Electrical data Supply and signal circuit: In ignition protection type intrinsically safe Ex ia IIC, for connection only to certified intrinsically safe circuits with the following max. values: Category Permissible ambient temperature Temperature class Ui [Vdc] Ii [ma] Pi [mw] +55 C II 2G T6 20 60 ma 200 Tab. 4: Temperature class and circuit parameters Effective internal capacitance Ci and effective internal inductance Li Ci [nf] Li [µh] 150 150 Tab. 5: Effective capacitance and inductance 10 english
General information 4. General information 4.1. Contact address Germany Bürkert Fluid Control Systems Sales Center Chr.-Bürkert-Str. 13-17 D-74653 Ingelfingen Tel. : 07940-10 91 111 Fax: 07940-10 91 448 E-mail: info@de.burkert.com 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 8690 can be found on the Internet at: www.burkert.com International Contact addresses are found on the final pages of the printed operating manual. You can also find information on the Internet under: 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. english 11
Description of system 5. Description of system 5.1. Configuration and function The Pneumatic Control Unit Type 8690 can control single or doubleacting process valves. The Pneumatic Control Unit Type 8690 has been optimized for integrated, modular installation on process valves of the 21xx series. 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 5.1.2. 5.1.1. Pneumatic Control Unit for integrated installation on 21xx series Cable gland M16 x 1.5 Fig. 2: Configuration and function (1) Transparent cap Pilot air port label: 1 Exhaust air connection label: 3 Pressure limiting valve (for protection against too high internal pressure in case of error) Optical position indicator: The device status is displayed on the pneumatic control unit (yellow mark). Option: Electrical position feedback Optionally inductive limit switches (proximity switches) can measure the valve position. View without transparent cap: Air intake filter (exchangeable) Fig. 3: Configuration and function (2) Screw for adjustment of the lower proximity switch Optical position indicator (yellow mark) Screw for adjustment of the upper proximity switch Screw terminals Pilot valve (3/2-way or 5/2-way solenoid valve with hand lever) Fastening screws (2x) 12 english
Technical data 5.1.2. Model for control of process valves belonging to the 20xx series A special model enables the Pneumatic Control Unit Type 8690 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. Fig. 4: Pilot air outlet 2 1 Pilot air outlet 2 2 Fastening screws (2 x) Connection module for process valves, 20xx series 6. Technical data 6.1. Conformity In accordance with the EC Declaration of conformity, the Pneumatic Control Unit Type 8690 is compliant with the EC Directives. 6.2. Standards Conformity with the EC Directives is verified by the following standards. EN 61000-6-3, EN 61000-6-2, EN 61010-1 6.2.1. Approvals The device is authorized for use in Zone 1 according to the ATEX directive 94/9/EC of category 2 G. Follow instructions for use in the Ex area! See chapter 3.1 english 13
Technical data 6.3. Operating conditions Warning! Solar radiation and temperature fluctuations may cause malfunctions or leaks. If the device is used outdoors, do not expose it unprotected to the weather conditions. Ensure that the permitted ambient temperature does not exceed the maximum value or drop below the minimum value. Ambient temperature: 0 to +55 C Protection class: IP65 / IP67 according to EN 60529 (only if cables have been connected correctly and in compliance with the exhaust air concept in chapter 8.2. Installing the process valve ). 6.4. Type label (example) Supply voltage / Control Type 8690 24 V/DC single act Pilot 0,6 Pmax 7 bar 2 sw.mec. Tamb 0 C - +55 C S/N 001000 CE 00185114 W14UN Fig. 5: D-74653 Ingelfingen Example of type label Control function - pilot valve Nominal pressure - limit switch Max. ambient temperature Serial number - CE mark Bar code Identification number 6.5. Mechanical data Dimensions: see data sheet Body material external PPS, PC Sealing material external EPDM internal NBR Stroke range of valve spindle 7-28 mm 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/m 3 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/m 3 Temperature range 0 to +50 C Pressure range Air output of pilot valve 3 to 7 bar 250 I N /min (for aeration and deaeration, Q Nn -value according to definition for pressure drop from 7 to 6 bar absolute) Connections Plug-in hose connector 6 mm / ¼ Socket connection G 1/8 14 english
Installation 6.7. Electrical data Connections: Cable gland M16 x 1.5, wrench size 22 (clamping area 5 10 mm) with screw terminals for cable cross-sections 0.14 1.5 mm² Supply voltage Pilot valve see 3.1.6. Temperature ranges and electrical data in the Ex area Proximity switches see 3.1.6. Temperature ranges and electrical data in the Ex area Power consumption of pilot valve: Position feedback : see 3.1.6. Temperature ranges and electrical data in the Ex area 1 or 2x Proximity switch NAMUR (8 V DC) Max. permissible surface temperature see 3.1.6. Temperature ranges and electrical data in the Ex area 7. Installation Only for Pneumatic Control Unit without pre-assembled process valve. 7.1. Safety instructions Danger! Risk of injury from high pressure! Before loosening the lines and valves, turn off the pressure and vent the lines. Risk of electric shock! Before reaching into the system, switch off the voltage 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. english 15
Installation 7.2. Installation of the Pneumatic Control Unit Type 8690 on process valves of series 21xx Procedure: 1. Install switch spindle: Fig. 6: Transparent cap Pilot air ports (plug-in hose connectors with collets or threaded bushings) Actuator 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 control air connections (if present). Fig. 7: Switch cam Switch spindle Guide element Groove ring max. 1 Nm max. 5 Nm Actuator cover O-ring Spindle extension Installation of switch spindle (2), 21xx series 10 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. 16 english
Installation 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 central screw 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). Position the switch cam on the switch spindle so that the distance between the switch cam and top of the spindle is 10 mm (see Fig. 7 ) 2. Install sealing rings Pilot air ports Caution: Collets must not be fitted! Fig. 8: Form seal 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 control air connections. When the Pneumatic Control Unit is being installed, the collets of the pilot air ports must not be fitted to the actuator. english 17
Installation 3. Installation of the Pneumatic Control Unit: Supports 7.3. Installation of the Pneumatic Control Unit Type 8690 on process valves of series 20xx Procedure: 1. Install switch spindle Pilot air ports Fastening screws max. 0,5 Nm Transparent cap Position indicator Fig. 9: Installation of the Pneumatic Control Unit, 21xx series Align the Pneumatic Control Unit until the supports of the Pneumatic Control Unit can be inserted into the pilot air ports of the actuator (see also Fig. 9 ). Push the Pneumatic Control Unit, without turning it, onto the Note! actuator until no gap is visible on the form seal. 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 Pneumatic Control Unit to the actuator using the two side fastening screws. In doing so, tighten the screws only handtight (max. torque: 0.5 Nm). 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 (see Fig. 11 ). 18 english
Installation 10 mm Switch cam Switch spindle 2. installation of the masking ring and the Pneumatic Control Unit: Masking ring Fastening screws max. 0.5 Nm Guide element O-ring Plastic part of the switch spindle Spindle (actuator) Fig. 11: Installation of the switch spindle (2), series 20xx 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. Tighten the guide element with a face wrench 1) 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). Position the switch cam on the switch spindle so that the distance between the switch cam and top of the spindle is 10 mm (see Fig. 11 ). 1) journal Ø: 3 mm; journal gap: 23.5 mm Fig. 12: Installation of the masking ring and the Pneumatic Control Unit, series 20xx Pull the masking ring onto the actuator cover (for actuator sizes 50 and 63 only). 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 preferably vertically one above the other (see Fig. 13 ). If they are positioned differently, longer hoses may be required other than those supplied in the accessory kit. english 19
Installation 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 Pneumatic Control Unit to the actuator using the two side fastening screws. In doing so, tighten the fastening screws hand-tight only (max. torque: 0.5 Nm). 3. Installation of the pneumatic connection on the actuator Pilot air outlet 2 1 Pilot air outlet 2 2 Upper pilot air port Lower pilot air port Screw the plug-in hose connectors onto the Pneumatic Control Unit and the actuator. Using the hoses supplied in the accessory kit, make the connection between the Pneumatic Control Unit and the actuator with the following Tab. 6: Pneumatic connection to actuator. Note! Damage or malfunction due to ingress of dirt and moisture! To comply with protection class 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 Pneumatic Control Unit Type 8690 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. Fig. 13: Installation of the pneumatic connection, 20xx series 20 english
Installation Control function Pneumatic connection Type 8690 with actuator A B I Tab. 6: Process valve closed in rest position (by spring force) Process valve open in rest position (by spring force) Process valve closed in rest position Process valve open in rest position Pilot air outlet Type 8690 Pneumatic connection to actuator Pilot air port actuator 2 1 lower pilot air port of the actuator should be connected to the 2 2 upper pilot air port of the actuator upper pilot air port 2 1 of the actuator should be connected to the 2 2 lower pilot air port of the actuator lower pilot air port 2 1 of the actuator upper pilot air port 2 2 of the actuator upper pilot air port 2 1 of the actuator lower pilot air port 2 2 of the actuator 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! DANGER! Risk of injury from high pressure! Before dismounting lines and valves, turn off the pressure and vent the 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. english 21
Installation Warning! Key contour Nipple without hexagon Actuator module Fig. 14: Rotating the actuator module with hexagon Hexagon Nipple Using a suitable open-end wrench, counter the wrench flat on the pipe. Actuator module without hexagon: Fit special key 2) exactly in the key contour on the underside of the actuator. Actuator module with hexagon: Place suitable open-end wrench on the hexagon of the actuator. 2) The special key (665702) is available from your Bürkert sales office. 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 Fig. 15 )! Actuator module without hexagon: Rotate clockwise (as seen from below) to bring the actuator module into the required position. Actuator module with hexagon: Rotate counter-clockwise (as seen from below) to bring the actuator module into the required position. with hexagon Open-end wrench Special key without hexagon Fig. 15: Rotating with special key / open-end wrench 22 english
Installation 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. Fastening screw (2x) Pneumatic Control Unit 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. Note! Too high torque when screwing in the fastening screw does not ensure protection class IP65 / IP67! The fastening screw may be tightened to a maximum torque of 0.5 Nm only. Pneumatic connection Actuator 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. Fig. 16: Rotating the Pneumatic Control Unit, series 20xx english 23
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! Danger high pressure in the equipment! Before loosening the lines and valves, turn off the pressure and vent the lines. Warning! Risk of injury from improper installation! Installation may be carried out by authorised 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. 8.3. Pneumatic connection of the Pneumatic Control Unit Danger! Danger high pressure in the equipment! Before loosening the lines and valves, turn off the pressure and vent the lines. Procedure: Connect the control medium to the pilot air port (1) (3 to 7 bar, oil, water and dust-free instrument air). Attach the exhaust airline or a silencer to the exhaust air connection (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 connection. 24 english
Electrical installation 9. Electrical installation 9.1. Safety instructions DANGER! Fig. 17: Pneumatic connection Pilot air port label: 1 Exhaust air connection label: 3 Caution: (Exhaust air concept): In compliance with protection class 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. 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. english 25
Electrical installation Procedure: Open the Pneumatic Control Unit: unscrewing the transparent cap in an anticlockwise direction. Install the cable gland, if necessary. Installation instructions see 1. Appendix - Anhang Push the cables through the cable gland. Connect the wires. Close the Pneumatic Control Unit. Printed circuit board Screw terminals Fig. 18: Position of the screw terminals Terminal No. Correct polarity is a prerequisite for the functioning of the device! Connect only intrinsically safe circuits to terminals 1 6. 1 2 3 4 5 6 Connection diagram with two-wire proximity switches (inductive NAMUR limit switches) Terminal Configuration External circuit 1 INI Top + 2 INI Top - 3 INI Bottom + 4 INI Bottom - 5 6 Tab. 7: Valve control + Valve control GND Explosion protected area 1 / 3 2 / 4 NAMUR- Sensor Explosion protected area 5 6 PA Non-hazardous area R Safety barrier +8,2 V DC 0 V Non-hazardous area Connection diagram with two-wire proximity switches 3) (recommended by NAMUR) Also observe the type-examination certificate from Turck KEMA 02 ATEX 1090X 4) Maximum value from barrier see PTB 07 ATEX 2048 + 3) 4) 26 english
Electrical installation Maximum connection parameters: Check that the seal is correctly positioned in the transparent cap (see Fig. 19 ). U 0 I 0 P 0 Proximity switches 20 Vdc 60 ma 200 mw Valve control 35 V 0,9 A Tab. 8: Note! Maximum connection parameters see Tab. 1 Damage or malfunction due to ingress of dirt and moisture! To ensure protection class IP65 / IP67, tighten the union nut of the cable gland according to the cable size you are using (installation instructions see 1. Appendix - Anhang ). Tighten the union nut of the cable gland on the body (installation instructions see 1. Appendix - Anhang ). Transparent cap Seal transparent cap Fig. 19: Position of the seal in the transparent cap 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 transparent cap (assembly tool: 674077 5) ). 5) The assembly tool (674077) is available from your Bürkert sales office. english 27
Electrical installation 9.1.1. Adjustment of the proximity switches 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! Screw for adjustment of the lower proximity switch Screw for adjustment of the upper proximity switch Adjustment of the proximity switches upwards downwards turn screw clockwise Fig. 20: Adjustment of the proximity switches turn screw anticlockwise Procedure: Open the Pneumatic Control Unit: unscrewing the transparent cap in an anticlockwise direction. Adjust the the proximity switches via the adjusting screw(s) (see Fig. 20 ). Check the switching point(s) using suitable measuring equipment. Check that the seal is correctly positioned in the transparent cap (see Fig. 21 ). Transparent cap Seal transparent cap Fig. 21: Position of the seal in the transparent cap 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 transparent cap (assembly tool: 674077 6) ). 6) The assembly tool (674077) is available from your Bürkert sales office. 28 english
Maintenance 10. Maintenance The Pneumatic Control Unit is maintenance-free when operated according to the instructions in this manual. 10.1. Service at the air intake filter Danger! Danger high pressure in the equipment! Before loosening the lines and valves, turn off the pressure and vent the lines. To protect the internal solenoid valves and the actuator, the pressure supply air is filtered. The direction of flow of the air intake filter in installed state is from the inside to the outside through the filter material. Quick plug-in connector O-ring Air intake filter Procedure: Unlock the quick plug-in connector by pressing the holding element and pulling out the air intake filter (if necessary, use a suitable tool in between the recesses in the head of the filter). Clean the filter or, if necessary, replace the filter. Check inner O-ring and, if required, clean. Insert the air intake filter all the way into the quick plug-in connector. DANGER! Risk of injury due to improper installation! Ensure that the air intake filter is installed correctly. Check that the air intake filter is secure. 11. Accessories Designation Order no. Special key 665702 Assembly tool 674077 Fig. 22: Service on the air intake filter Tab. 9: Accessories english 29
Safety Positions 12. Safety Positions Safety positions after failure of the electric or pneumatic auxiliary energy: Operating mode up down Designation Single-acting control function A Safety positions after failure of the auxiliary energy Electrical Pneumatic down down 13. Disassembly 13.1. Safety instructions DANGER! Risk of injury from high pressure! Before dismounting 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! up down up down Single-acting control function B Double-acting control function I up down up not defined 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. Tab. 10: Safety positions 30 english
Disassembly 13.2. Disassembly the Pneumatic Control Unit Procedure: 1. Pneumatic connection DANGER! Risk of injury from high pressure! Before dismounting lines and valves, turn off the pressure and vent the 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 system, 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. 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. Series 20xx Transparent cap Pneumatic Control Unit Cable gland Fastening screws (2x) Pneumatic connections Actuator Pneumatic connection to the actuator Fig. 23: Disassembly the Pneumatic Control Unit Series 21xx english 31
Packaging, transport, storage 14. 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. Incorrect storage may damage the device. Store the device in a dry and dust-free location! Storage temperature -20 +65 C. 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. 32 english
Typ 8690 Ex Pneumatische Ansteuerung Typ 8690 Ex 1. Die Bedienungsanleitung...35 1.1. Darstellungsmittel...35 1.2. Begriffsdefinition Gerät...35 2. BestimmungsgemäSSe Verwendung3...36 2.1. Beschränkungen...36 3. Grundlegende Sicherheitshinweise...37 3.1. Hinweise für den Einsatz im explosionsgeschützten (Ex-) Bereich...38 4. Allgemeine Hinweise...41 4.1. Kontaktadresse...41 4.2. Gewährleistung...41 4.3. Warenzeichen...41 4.4. Informationen im Internet...41 5. Systembeschreibung...42 5.1. Aufbau und Funktion...42 6. Technische Daten...43 6.1. Konformität...43 6.2. Normen...43 6.3. Betriebsbedingungen...44 6.4. Typschild (Beispiel)...44 6.5. Mechanische Daten...44 6.6. Pneumatische Daten...44 6.7. Elektrische Daten...45 7. Montage...45 7.1. Sicherheitshinweise...45 7.2. Montage der Pneumatischen Ansteuerung Typ 8690 an Prozessventile der Reihe 21xx...46 7.3. Montage der Pneumatischen Ansteuerung Typ 8690 an Prozessventile der Reihe 20xx...48 7.4. Drehen des Antriebsmoduls...51 7.5. Drehen der Pneumatischen Ansteuerung bei Prozessventilen der Reihe 20xx...53 8. Fluidische Installation...54 8.1. Sicherheitshinweise...54 8.2. Installation des Prozessventils...54 8.3. Pneumatischer Anschluss...54 9. Elektrische Installation...55 9.1. Einstellen der Initiatoren...58 10. Wartung...59 10.1. Service am Zuluftfilter...59 11. Zubehör...59 deutsch 33
Typ 8690 Ex 12. Sicherheitsstellungen...60 13. Demontage...60 13.1. Sicherheitshinweise...60 13.2. Demontage Pneumatische Ansteuerung...61 14. Transport, Lagerung, Verpackung...62 34 deutsch
Typ 8690 Ex Die Bedienungsanleitung 1. Die Bedienungsanleitung Die Bedienungsanleitung beschreibt den gesamten Lebenszyklus des Geräts. Bewahren Sie diese Anleitung so auf, dass sie für jeden Benutzer gut zugänglich ist und jedem neuen Eigentümer des Geräts wieder zur Verfügung steht. Die Bedienungsanleitung enthält wichtige Informationen zur Sicherheit! Das Nichtbeachten dieser Hinweise kann zu gefährlichen Situationen führen. Die Bedienungsanleitung muss gelesen und verstanden werden. 1.1. Darstellungsmittel Gefahr! Warnt vor einer unmittelbaren Gefahr! Bei Nichtbeachtung sind Tod oder schwere Verletzungen die Folge. Warnung! Warnt vor einer möglicherweise gefährlichen Situation! Bei Nichtbeachtung drohen schwere Verletzungen oder Tod. Vorsicht! Warnt vor einer möglichen Gefährdung! Nichtbeachtung kann mittelschwere oder leichte Verletzungen zur Folge haben. hinweis! Warnt vor Sachschäden! Bei Nichtbeachtung kann das Gerät oder die Anlage beschädigt werden. bezeichnet wichtige Zusatzinformationen, Tipps und Empfehlungen. verweist auf Informationen in dieser Bedienungsanleitung oder in anderen Dokumentationen. markiert einen Arbeitsschritt, den Sie ausführen müssen. 1.2. Begriffsdefinition Gerät Der in dieser Anleitung verwendeten Begriff Gerät steht immer für die Pneumatische Ansteuerung Typ 8690. deutsch 35
Typ 8690 Ex Bestimmungsgemäße Verwendung 2. BestimmungsgemäSSe Verwendung Bei nicht bestimmungsgemäßem Einsatz der Pneumatischen Ansteuerung Typ 8690 können Gefahren für Personen, Anlagen in der Umgebung und die Umwelt entstehen. Das Gerät ist für den Anbau an pneumatische Antriebe von Prozessventilen zur Steuerung von Medien konzipiert. Es wurde für den Einsatz in Explosionsgruppe IIC, Kategorie 2G und Temperaturklasse T6 (siehe Angaben auf dem - Zulassungsschild) konzipiert. Das Gerät nicht der direkten Sonneneinstrahlung aussetzen. Für den Einsatz die in den Vertragsdokumenten und der Bedienungsanleitung spezifizierten zulässigen Daten, Betriebs- und Einsatzbedingungen beachten. Diese sind im Kapitel 6. Technische Daten beschrieben. Das Gerät nur in Verbindung mit von Bürkert empfohlenen bzw. zugelassenen Fremdgeräten und -komponenten einsetzen. Angesichts der Vielzahl von Einsatz- und Verwendungsfällen, muss vor dem Einbau geprüft und erforderlichenfalls getestet werden, ob die Pneumatische Ansteuerung für den konkreten Einsatzfall geeignet ist. Voraussetzungen für den sicheren und einwandfreien Betrieb sind sachgemäßer Transport, sachgemäße Lagerung und Installation sowie sorgfältige Bedienung und Instandhaltung. Setzen Sie die Pneumatische Ansteuerung Typ 8690 nur bestimmungsgemäß ein. Temperaturklassen und elektrische Daten sind auf dem Typschild bzw. in den 6. Technische Daten und in 3.1. Hinweise für den Einsatz im explosionsgeschützten (Ex-) Bereich dieser Anleitung spezifiziert. 2.1. Beschränkungen Beachten Sie bei der Ausfuhr des Systems/Geräts gegebenenfalls bestehende Beschränkungen. 2.1.1. Ex-Zulassung Die Ex-Zulassung ist nur gültig, wenn Sie die von Bürkert zugelassenen Module und Komponenten so verwenden, wie es in dieser Bedienungsanleitung beschrieben ist. Nehmen Sie unzulässige Veränderungen am Gerät, den Modulen oder Komponenten vor, erlischt die Ex-Zulassung. Die EG-Baumusterprüfbescheinigung PTB 07 ATEX 2048 wurde durch die PTB (Physikalisch Technische Bundesanstalt, Bundesallee 100, 38116 Braunschweig) ausgestellt, die auch die Fertigung auditiert (CE0102). 36 deutsch
Typ 8690 Ex Grundlegende Sicherheitshinweise 3. Grundlegende Sicherheitshinweise Diese Sicherheitshinweise berücksichtigen keine Zufälligkeiten und Ereignisse, die bei Montage, Betrieb und Wartung der Geräte auftreten können. ortsbezogenen Sicherheitsbestimmungen, für deren Einhaltung, auch in Bezug auf das Montagepersonal, der Betreiber verantwortlich ist. Gefahr! Gefahr durch hohen Druck! Vor dem Lösen von Leitungen und Ventilen den Druck abschalten und Leitungen entlüften. Gefahr durch elektrische Spannung! Vor Eingriffen in das Gerät oder in die Anlage die Spannung abschalten und vor Wiedereinschalten sichern! Die geltenden Unfallverhütungs- und Sicherheitsbestimmungen für elektrische Geräte beachten! Allgemeine Gefahrensituationen. Zum Schutz vor Verletzungen ist zu beachten: Dass die Anlage nicht unbeabsichtigt betätigt werden kann. Installations- und Instandhaltungsarbeiten dürfen nur von autorisiertem Fachpersonal mit geeignetem Werkzeug ausgeführt werden. Nach einer Unterbrechung der elektrischen oder pneumatischen Versorgung ist ein definierter oder kontrollierter Wiederanlauf des Prozesses zu gewährleisten. Das Gerät darf nur in einwandfreiem Zustand und unter Beachtung der Bedienungsanleitung betrieben werden. Für die Einsatzplanung und den Betrieb des Gerätes müssen die allgemeinen Regeln der Technik eingehalten werden. Zum Schutz vor Sachschäden am Gerät ist zu beachten: In den Steuerluftanschluss des Systems keine aggressiven oder brennbaren Medien einspeisen. In den Steuerluftanschluss keine Flüssigkeiten einspeisen. Gehäuse nicht mechanisch belasten (z. B. durch Ablage von Gegenständen oder als Trittstufe). Keine Veränderungen an den Gerätegehäusen vornehmen. Die Pneumatische Ansteuerung Typ 8690 wurde unter Einbeziehung der anerkannten sicherheitstechnischen Regeln entwickelt und entspricht dem Stand der Technik. Trotzdem können Gefahren entstehen. Bei Nichtbeachtung dieser Bedienungsanleitung und ihrer Hinweise sowie bei unzulässigen Eingriffen in das Gerät entfällt jegliche Haftung unsererseits, ebenso erlischt die Gewährleistung auf Geräte und Zubehörteile! deutsch 37
Typ 8690 Ex Grundlegende Sicherheitshinweise 3.1. Hinweise für den Einsatz im explosionsgeschützten (Ex-) Bereich Das Gerät nicht selbst reparieren, sondern durch ein gleichwertiges Gerät ersetzen. Reparaturen darf nur der Hersteller durchführen. Das Gerät keinen mechanischen und/oder thermischen Beanspruchungen aussetzen, welche die in der Bedienungsanleitung beschriebenen Grenzen überschreiten. Zur Vermeidung der Explosionsgefahr muss bei der Montage und Wartung im Ex-Bereich, Folgendes beachtet werden: 3.1.1. Sicherheitshinweise Bei Einsatz im Ex-Bereich Zone (Gas) 1 und 2 gilt: Gefahr! Explosionsgefahr! Zur Vermeidung der Explosionsgefahr muss für den Betrieb im Ex-Bereich, zusätzlich zu den Grundlegenden Sicherheitshinweisen, folgendes beachtet werden: Die Angaben zu Temperaturklasse und Umgebungstemperatur auf dem Typschild beachten. Die Geräte nicht bei Gasen einsetzen, die eine niedrigere Zündtemperatur besitzen als auf dem Typschild angegeben. Installation, Bedienung und Wartung darf nur qualifiziertes Fachpersonal durchführen. Die geltenden Sicherheitsvorschriften (auch nationale Sicherheitsvorschriften) sowie die allgemeinen Regeln der Technik, beim Errichten und Betreiben, einhalten. Das Gehäuse des Gerätes nur öffnen, wenn keine Ex-Atmosphäre vorhanden ist. Durch geeignete Maßnahmen sicherstellen, dass es im Ex Bereich zu keinen elektrostatischen Aufladungen kommen kann. Die Gehäuseoberfläche, zur Vermeidung elektrostatischer Aufladung, nur mit einem feuchten Tuch reinigen. Nur Kabel- und Leitungseinführungen verwenden, die für den jeweiligen Einsatzbereich zugelassen und entsprechend der dazugehörigen Montageanleitung verschraubt sind. Vormontierte Kabelverschraubungen entsprechend der vom Hersteller der Verschraubung mitgelieferten Montageanleitung einbauen. Vor der Inbetriebnahme im Ex-Bereich prüfen, ob die Kabelverschraubung, wie in der dazugehörigen Montageanleitung beschrieben, eingebaut wurde. Alle nicht benötigten Kabelverschraubungen mit Ex-zugelassenen Verschlussschrauben verschließen. Das Öffnen des Gehäuses um innenliegende Schalter zu bedienen ist innerhalb des Ex-Bereiches nicht zulässig. Während der Inbetriebnahme darf keine Ex-Atmosphäre vorhanden sein. 38 deutsch
Typ 8690 Ex Grundlegende Sicherheitshinweise 3.1.2. Medien im Ex-Bereich Werden explosionsfähige Medien verwendet, kann dadurch eine zusätzliche Explosionsgefahr auftreten! 3.1.3. Antriebe / Ventile im Ex-Bereich Die Antriebe / Ventile kann den Einsatz in explosionsfähiger Atmosphäre einschränken. Bedienungsanleitung der Antriebe / Ventile beachten.! 3.1.4. Reinigung im Ex-Bereich Reinigungsmittel auf Zulassung in explosionsfähiger Atmosphäre prüfen. 3.1.5. Klebeschild für Ex-Bereich Bild 1: Gerätegruppe Gerätekategorie II 2G c T6 Klebeschild Ex-Bereich Temperaturklasse 3.1.6. Temperaturbereiche und elektrische Daten im Ex-Bereich Steuerventile Eine detaillierte Beschreibung der Daten für das Steuerventil finden Sie im Internet unter www.buerkert.de Typ 6144. Temperaturklasse T6: Höchstzulässige Oberflächentemperatur bei T6 85 C Max. zul. Umgebungstemperatur [ C] Max. zul. Leistung [W] Zündschutzart 0... +55 0... +50 0,4 0,5 0... +45 0,6 Ex ia 0... +40 0,7 0... +35 0,8 Tab. 1: Temperaturbereiche Ex-Bereich Version Typ 6144 Widerstand R20 [Ω] Hochohmige Version Tab. 2: Explosionsgruppe Mindestklemmenspannung [V] IIC 510 11,7 23 Steuerventildaten Ex-Bereich Mindeststrom [ma] deutsch 39
Typ 8690 Ex Grundlegende Sicherheitshinweise Elektrische Daten Das Steuerventil in Zündschutzart Eigensicherheit Ex ia IIC, darf nur an bescheinigte eingensichere Stromkreise mit folgenden Höchstwerten angeschlossen werden. Explosionsgruppe IIC Kategorie ia Temperaturklasse T6 Max. zulässiger Eingangsspannung (Ui) 35 V Max. zulässiger Eingangsstrom (Ii) 0,9 A Max. zulässige Eingangsleistung (Pi) siehe Tab. 1 Versorgungsspannung: Die maximal zulässigen Spannungen und die dazugehörigen maximal zulässigen Kurzschlussströme für die entsprechende Explosionsgruppe können der Norm EN 60079-11 entnommen werden. Beispielhaft sind für jede Zündschutzart einige Wertpaare für die Explosionsgruppe IIC aufgeführt. Ventil in Zündschutzart Eigensicherheit Ex ia IIC. Spannungswert 15 18 20 22 25 28 30 35 [V] = Ui Stromwert [A] = Ii 0,9 0,44 0,309 0,224 0,158 0,120 0,101 0,073 Tab. 3: Wertepaare Sensor Elektrische Daten Speise- und Signalstromkreis: in Zündschutzart Eigensicherheit Ex ia IIC, nur zum Anschluss an einen bescheinigten eigensicheren Stromkreis, mit folgenden Höchstwerten: Kategorie Maximale Umgebungstemperatur Temperaturklasse Ui [Vdc] Ii [ma] Pi [mw] +55 C II 2G T6 20 60 ma 200 Tab. 4: Temperaturklasse und Stromkreisparameter Wirksame innere Kapazität Ci und wirksame innere Induktivität Li Ci [nf] Li [µh] 150 150 Tab. 5: Wirksame Kapazität und Induktivität 40 deutsch