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Operating Instructions Type 8681

1. Hand lever of the mechanical manual control Red lever left 0 right 1 Fig 37 Mechanical manual control of the solenoid valves When the service measures have been completed reset all manual controls to O for control led oper ation of the system 85 English Control Head Type 8681 burkert FLUID CONTROL SYSTEMS Maintenance troubleshooting 19 MAINTENANCE TROUBLESHOOTING 19 1 Safety instructions AN DANGER Risk of injury from high pressure in the system Before loosening lines and valves turn off the pressure and vent the lines Danger of explosion in explosive atmosphere only in the event of a fault as zone 2 Opening the hood or the housing in an explosive atmosphere is only allowed in a not energized state AN WARNING Risk of injury due to electric shock Before reaching into the system except for the Teach In procedure in a non explosive atmosphere switch off the power supply and secure it to prevent restarting Observe applicable accident prevention and safety regulations for electrical equipment Risk of injury from improper maintenance Maintenance may only be carried out by authorized technicians and with the appropriate tools Risk of injury from unintentional activation of the system and uncontrolled restart Secure system against unintentional activation Following maintenance ensure a controlled restart MAN 1000138
2. S1 S2 S3 S4 Fault Priority Note blinking patterns active active active active S4 Blinking in S4 blinking pattern if S4 has been acti vated by DIP since S3 S4 has priority over S1 and S2 active active S4 Blinking in S4 blinking pattern if S4 has been acti vated by DIP active active active S3 Blinking in S3 blinking pattern since S3 S4 position has priority over S1 and S2 active active S2 Position feedback of S2 has priority 83 English Control Head Type 8681 burkert FLUID CONTROL SYSTEMS Service Mode Manual Control 18 SERVICE MODE MANUAL CONTROL By default the control head provides the following e g for service purposes a magnetic manual control which is easily accessible from the outside for Solenoid Valve 1 2 A1 as well as a mechanical manual control accessible when the hood is open on each equi pped solenoid valve 18 1 Magnetic manual control Markings for magnetic manual control Magnetic Manual Control Fig 36 Manual control on the basis of encoded magnetic fields Activation deactivation is possible using the PC service program Connection to the PC is via the Service interface Details are described in the PC service program manual under the SYSTEM Start up menu option Irrespective of the signal of the higher level control the magnetic manual control sets the output of solenoid valve 1 electrically t
3. 0 80 mm 0 1 mm 0 5 mm when using a target in accordance with the dimensional drawing Material 1 4021 and a piston rod 22 mm Material see Fault refers to the reproducibility of a taught position The diagram in Fig 7 shows the dimensional relationships between the control head and the piston with target 1 Note upper end position of the target H 156 5 mm to prevent putting control head at risk Target 1 4021 in the upper end position Piston rod in the upper end position Target 1 4021 in the lower end position Piston rod 80 ARSE E VILLEN ry IE Hn W F 1 156 5 P 7 C C F lt in the lower end position maximum stroke 80 mm SAIN G 56 5 MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 Fig 7 Sectional view of control head and piston with target in upper and lower end position The fastening materials for target and piston rod as well as the piston rod itself may not be made of material with very good electrical conductivity e g copper aluminum or of ferromagnetic material Stainless steel without ferromagnetic properties is suitable if necessary check after machining 24 latoa Control Head Type 8681 burkert Technical Data FLUID CONTROL SYSTEMS
4. English Control Head Type 8681 burkert FLUID CONTROL SYSTEMS LED Color Assignments 17 1 Setting the color combinations Setting of the possible color combinations with the help of the DIP switches a lt lt lt lt lt O O O OIO O Oo S4IN may be normally open NC or normally closed NO factory setting Normally open contact can be changed via the PC service program connect control head via service interface to the PC note the PC Service Program manual note sub menu General start up 17 2 Blinking pattern amp fault signaling The LEDs flash in different blinking patterns in the event of a fault or in various states Blinking patterns ON OFF Note Flashes three times in the corresponding color for 1 1 1 that position HOME 1008 Teach In confirmation after successful teaching the color for position 1 and 2 is continuously on MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 Flashes three times in the corresponding fault color if target could not be located in the measuring area during teaching or if teach position is too close 40 5 mm to a previously defined teach position or if magnetic manual control is used even though manual control function was disabled by software 82 English Control Head Type 8681 LED Color Assignments
5. NOTE Electrostatic sensitive components modules Before changing the position measuring system switch the electrical power for the control head off so that destruction of the PCB and electronics module is avoided The device contains electronic components which react sensitively to electrostatic discharge ESD Contact with electrostatically charged persons or objects may be hazardous to these components In the worst case scenario they will be destroyed immediately or will fail after start up Observe the requirements in accordance with DIN EN 61340 5 1 to minimize or avoid the possibility of damage caused by sudden electrostatic discharge Also ensure that you do not touch electronic components when the supply voltage is on Deinstallation procedure gt Switch the electrical power to the control head off Loosen the control head from the process valve Open the housing following the instructions in Chapter 8 Opening and Closing the Housing 4 Pull out position measuring system 1 Loosen Torx10 screw 3 Bend break off the snap fit hooks inwards 4x bottom view 2 Fold electronics module to the front MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 Fig 41 Dismantling the position measuring system 94 English Control Head Type 8681 burkert Replacement of Components and Modules FLUID CONTROL SYSTEMS
6. 25 6 7 2 Service maintenance notification maintenance reques t 26 6 7 3 Manual control function magnetic aan anna maa u uu u uuu uu u u u u 26 6 8 Resetting the device Device Reset I U U U ttt tst statt 27 7 ASSENMBIY uu l T Een 28 Zels Safety instructions 44er a a aaa aaa aaa aaa a aaa aa aiaiai 28 7 2 Assembly of the control head 28 TA a PII IIR eec E E E E A E E E 28 7 2 2 Assembly sequence on the example of a double seated valve 29 7 2 8 Realignment of the control head a 30 E 7 2 4 Assembly of the pneumatic and electrical connections 30 7 2 5 Recommended auxiliary materials 30 E 8 OPENING AND CLOSING THE HOUSING u I a asas anna 31 8 1 Safety InStructi ONS iisimmin ae oS N Ev ns 31 8 2 Opening and closing the housing eere ena u u u uuu u uuu uuu 31 E 8 24 Opening the housing uuu u u uuu 31 8 2 2 Glosing th bo sipguQ u u I A I T TA uuu usuka ERE
7. ASI ASI Power 2 TIE iM we Fig 22 LED status displays on the AS i electronics module LED 1 Power LED 2 Fault signalized status green red off off Power OFF on on No data traffic expired Watchdog at slave address does not equal 0 on off OK flashing on Slave address 0 flashing flashing Sensor supply overload manual actuation activated untaught service maintenance request PC service program service mode The central illuminated display flashes in the fault color see Chapter naling if the status LED 2 Fault is active 17 2 Blinking pattern amp fault sig English Control Head Type 8681 burkert AS Interface Design FLUID CONTROL SYSTEMS MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 11 8 Programming data The control heads have been configured as AS interface version with an extended address range A B slaves for 62 slaves or optionally as an AS interface version for 31 slaves A change between the two configurations in the control head is only possibly by exchanging the elec tronic PCB If one control head is replaced with another control head having a different configuration in the AS interface field bus system e g AS interface version 62 slaves A B Slave to replace a device with AS interface version 31 slaves a configuration error will be generated at the
8. burkert FLUID CONTROL SYSTEMS MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 Blinking patterns T L f L ON 250 ms OFF 250 ms Note permanent flashing in the fault color Teaching does notoccur or Teach Reset implemented or bus error or Device Reset implemented permanent flashing in the color for that position Signal from position 3 450 ms 50 ms Internal Fault fault color 50 ms 450 ms Service mode manual control active fault color 17 3 Signal priorities ULL 125 ms 125 ms Signal from the external initiator S4 same as color for position 3 Signal in fault color and additionally color of the corresponding valve position Service maintenance notification maintenance service required If a valve has several overlapping states the following priority list applies 1 2 Internal Fault fault color 450 ms ON 50 ms OFF Control fault color 50 ms ON 450 ms OFF Manual operating mode is active e g by magnetic manual control see Chapter 18 Service Mode Manual Service maintenance request fault color 1 s ON 3 s OFF Other fault e g position measuring system not taught bus error or other see Chapter 17 2 If position feedback signals overlap the following logic applies On principle S4 has the highest priority descending to S1 i e S4 S3 S2 S1
9. or gave l 3x la LE lien 126 mA 33mA 3x20mA 11 6 Safety instructions N DANGER o When using an external initiator its power requirement should be added Danger of explosion in explosive atmosphere only in the event of a fault as zone 2 Opening the hood or the housing in an explosive atmosphere is only allowed in a not energized state N WARNING Risk of injury due to electric shock MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 Before reaching into the system except for the Teach In procedure in a non explosive atmosphere switch off the power supply and secure it to prevent restarting Observe applicable accident prevention and safety regulations for electrical equipment 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 uncontrolled restart Secure system against unintentional activation Following installation ensure a controlled restart 48 sae Ea Control Head Type 8681 burkert AS Interface Design FLUID CONTROL SYSTEMS MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 11 7 Electrical installation of the AS interface Internal cabling work is not required for any of the AS Interface designs with multi pole connection wh
10. 10096 ED 13 mA with a power supply of 120 V AC per illuminated display color switching see Chapter 17 LED Color Assignments S1out S3out Normally open contact L switching short circuit protection via automatically resetting fuse max 50 mA per feedback signal 2 operating voltage 2 V max 1 V in unloaded state 65 English burkert FLUID CONTROL SYSTEMS Control Head Type 8681 120 V AC Design Feedback signal output Input proximity switches external initiator S4 in voltage present at control head U DC 2 and 3 wire Normally open contact L switching Power supply Design S4 out is directly connected to S4in Nominal 120 V AC 50 60 Hz Input current 1 signal Isensor 2 mA Inputs valve actuation Y1 Y3 Signal level active U gt 60VAC Signal level inactive U lt 20VAC Impedance gt 40 kOhm 13 3 Design aid Power consumption of the electronics P 1 2VA or 10mA at 120VA El P 1 7VA Valve ON Power consumption of a valve during activation 200 ms or 14mA at 120VA P 14VA Valve Power consumption of a valve after reduction or 12mA at 120VA P 1 6VA LED Power consumption of an optical position report or 13mA at 120VA Calculation examples gered to the valves Only one valve 1 7 VA will ever be recorded 1 Also if several control head valves were to be opened simultaneously the swit
11. Loosen the pneumatic connections for a detailed description see Chapter 9 Pneumatic Installation Loosen the locking screws shoulder screws M5 96 gt Pull control head upwards and off the adaptation sae Ea Control Head Type 8681 burkert Packaging and Transport FLUID CONTROL SYSTEMS MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 22 PACKAGING AND TRANSPORT NOTE Transport damage Inadequately protected devices may be damaged during transportation During transportation protect the device against moisture and dirt in shock resistant packaging Avoid the effects of heat and cold which could result in temperatures above or below the permitted storage temperature Approved non return and reusable transport containers are used for the transport ex factory and storage of the control head Preferably use this packaging If the control head is stored for further pre assembly of a system for example as part of a process valve module kindly make sure that the control head has been secured sufficiently that the electrical and pneumatic lines cannot be accidentally damaged and or cannot indirectly damage the control head that the control head is not used as support during packaging and transport that the control head is not exposed to any mechanical stress 23 STORAGE NOTE Incorrect storage may damage the device Stor
12. approx 2 5 s long this will reset the device The blinking pattern 250 ms ON 250 ms OFF in the fault color indicates that the device was reset Device Reset resets the following values to the factory settings Teach positions S1 53 Feedback fields from 1 S3 Resettable switching cycle counters V1 V3 Resettable operating duration Service intervals switching cycles V1 V3 Service interval operating duration Service maintenance notification signaling of elapsed maintenance intervals Manual control function External initiator S4 in NO Feedback external initiator S4 as S1 Switching cycle counter Total V1 V3 Operating duration Total AS i address MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 AS i profile DeviceNet Input Assembly Position measuring system averaging system all positions not taught see Chapter 6 7 1 on page 25 see Chapter 6 7 2 on page 26 see Chapter 6 7 2 on page 26 see Chapter 6 7 2 on page 26 see Chapter 6 7 2 on page 26 inactive see Chapter 6 7 2 on page 26 active see Chapter 6 7 3 on page 26 see Chapter 17 1 on page 82 not active see PC service program manual Device Reset does not reset the following values see PC service program see chapter 11 8 on page 51 see Chapter 12 11 1 on page 60 27 English burkert FLUID CONTROL SYSTEMS As
13. q 15 SPECIAL DESIGNS nee ced Peas k k cud otl AV oL cada ou 73 E 15 1 Control head for double acting actuators u u uu uuu uuu 73 ICSRNESTI 73 15 12 Fluid dig8grgmu a u ull Taman N KIN En 73 15 1 3 Activation of a double acting actuator u uu uuu uu uu 73 E 15 2 Control head AS i with 2 external initiators u u u u aa a aa a ana ana naan 74 ILASNEITIIIR 74 E 15 2 2 Electrical installation and programming data 74 s 5 16 POSITION MEASURING SYSTEM u u u a uusammassauasssaaaqqassaiassausaasusssqaasusasiaasassqassissssasssakasqasssisassssasss 75 E 16 1 Setting the position measuring system Teach In I I u u u 76 z 16 2 Teach button functions ss sssssassssmasman iss 77 16 2 1 Teach functions and Teach reset massasta atamaani 77 16 2 2 Autotune functions 78 16 2 3 Autot ne sequence uu u u IILI en Kompan i ons spa aaa 78 lt gt 17 LED COLOR ASSIGNMENTS 22 40 een 81 17 1 Setting the color combinations u u uu uuu uuu 82 17 2 Blinking pattern amp fault signaling u u
14. remove these before use Power consumption standby current 30 mA at 24 V DC 36 sae Ea Control Head Type 8681 24 V DC Design FLUID CONTROL SYSTEMS MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 Solenoid valves Max switching capacity Typ continuous output Power consumption per solenoid valve Operating mode Central display of switching states Outputs binary feedback signals Design Switchable output current Output voltage active Output voltage inactive max 0 9 W per solenoid valve 0 6 W per solenoid valve 50 mA at 12 V DC 25 mA at 24 V DC 22 mA at 28 V DC Long term operation 10096 ED 42 mA with a power supply of 24 V DC per illuminated display color switching see Chapter 17 LED Color Assignments S1 out S4 out Normally open contact PNP output short circuit proof with self clocking short circuit protection max 100 mA per feedback signal 2 operating voltage 2 V max 1 V in unloaded state Input proximity switches external initiator S4 in Power supply Current carrying capacity sensor supply Short circuit protection Design Input current 1 signal Input voltage 1 signal Input current O signal Input voltage O signal Inputs valve actuation Y1 Y3 Signal level active Signal level inactive Impedance Voltage present at the control head 10 max 90 mA DC 2 and 3 cond
15. 13 1 Status of the device status LED Modules LED Device state Explanation Off No supply Device is not supplied with voltage Green Device is working Normal operating state 63 English burkert FLUID CONTROL SYSTEMS Control Head Type 8681 DeviceNet Design MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 64 12 13 2 State of bus status LED Network LED Device state Explanation Troubleshooting Off No voltage not Device is not supplied with voltage Connect other devices if the device online l I is the only network subscriber Device has still not ended Duplicate MAC ID Test test lasts approx 2 s replace device Device cannot end Duplicate MAC check baud rate ID Test check bus connection Green Online connection Normal operating state with estab to master exists lished connection to the master Flashes Online without Normal operating state without green connection to established connection to the master master Flashes Connection One or more I O connections are in New connection establishment by red time out Time Out state master to ensure that the I O data is transmitted cyclically Red Critical fault Another device with the same MAC Check baud rate ID address is in the circuit No bus connection due to communi cation problems Please check address as
16. 2 Stam 160 Preset Speed v5 xx DN1 v2 0 ODV 160 Preset Speed v5 xx DN1 v2 0 Stan 160 Preset Speed v6 xx DN1 V2 0 ODV i 160 Preset Speed v6 xx DNI v1 2 ODV 160 Preset Speed v6 xx DNI v1 2 Stam 1 Active Input Assembly 2 Safety mode 3 Process valve safety posi 4 Teach Function Don t Teach 5 6 7 Teach State 00000000 Teach Reset 0 Device Reset 0 9 ID1Device 99999999 10 ID1Board 99999999 11 ID 2 Device 99999999 12 1D2Board 99999999 13 S N Device 0 SIN Board 0 15 Assembly Date Device 01 01 1972 Abbrechen Obemetmen Hilfe mj 160 Preset Speed v6 xx DN1 v2 0 Stam mj 160 Signal Follower v4 xx DN v2 0 ODV af 160 Signal Follower v4 xx DN1 v1 2 OD jal 160 Signal Follower v4 xx DN1 v1 2 Sta a 160 Signal Follower v4 xx DN1 v2 0 Sta all 160 Signal Follower v5 xx DN1 v1 2 OD 160 Signal Follower v5 xx DN1 v1 2 Sta al 160 Signal Follower v5 xx DN1 v2 0 OD 160 Signal Follower v5 xx DN1 v2 0 Sta 160 Signal Follower v6 xx DN1 v1 2 OD al 160 Signal Follower v6 xx DN1 v1 2 Sta all 160 Signal Follower v6 xx DN1 v2 0 OD sf 160 Signal Follower v6 xx DN1 v2 0 Sta Bul 13291 1HP 115V 1PH 56FR Loc Bul 13291 1HP 115V 1PH 56FR Std MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 M 4 p M Graph Spreadsheet Master Slave Configuration Diagnostics Fig 28 Selecting the input assembly screenshot 6
17. DeviceNet Bus signals Service interface DIP switches for color coding the LEDs Solenoid valve connec tions with status LED for Valves 2 3 Connection for the external initiator Fig 25 DeviceNet electronics module Terminal strip configuration MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 Designation E Designation E Terminal strip SUE TEN Terminal strip susan Power supply V DeviceNet V Power supply for external initiator _ Power supply A I V DeviceNet S4 IN External initiator input CAN_H Bus signal CAN high GND GND external initiator CAN_L Bus signal CAN low 57 English Control Head Type 8681 burkert FLUID CONTROL SYSTEMS DeviceNet Design 12 9 Network topology of a DeviceNet system When installing a DeviceNet system ensure that the terminating circuit of the data lines is correct The circuit pre vents the occurrence of interference caused by signals reflected onto the data lines The trunk line must be terminated at both ends with resistors of 120 O and 1 4 W power loss see Fig 26 Network topology Fig 26 illustrates a line with one trunk line and several drop lines Trunk lines and drop lines consist of identical material Trunk li PA DeviceNet cable V m Me CNL a TT Terminating Terminating resistor DeviceNet cable resistor 1200 max 6 m l
18. MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 Loosen the fastening screw Torx 10 of the electronics module see Chapter 20 2 Changing the electronics module Tilt the electronics forwards to loosen the position measuring system s contact pins from the electronics module Bend the snap fit hooks on the bottom end of the position measuring system inwards In some cases break them off Pull the position measuring system upwards out of the guide Installation procedure Insert the new position measuring system from above so that the contact pins are located on the side of the electronics module Carefully push the housing of the position measuring system downwards until the snap fit hooks snap into place Slide the electronics module carefully onto the contacts pins and fasten the electronics module using the Torx screw Remount the control head on the process valve as described in Chapter 7 Assembly Adjust position measuring system to the process valve by teaching see Chapter 16 1 Setting the position measuring system Teach In Close the housing following the instructions in Chapter 8 Opening and Closing the Housing 95 English Control Head Type 8681 burkert FLUID CONTROL SYSTEMS Sh utd own 21 SHUTDOWN 21 1 Safety instructions AN DANGER Risk of injury from high pressure Before loosening line
19. MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 6 7 Factory settings in the firmware The control head is supplied with the following factory settings of the firmware o The service interface may only be used in non explosive atmosphere 6 7 1 Feedback fields position measuring system A feedback field is the area within which a position e g S1 is reported back Signal Feedback field at top Feedback field at bottom Factory setting Adjustment range Factory setting Adjustment range mm mm mm mm S1 3 00 10 00 0 50 3 00 0 50 10 00 S2 3 00 10 00 0 50 3 00 0 50 10 00 S3 1 00 10 00 0 50 1 00 0 50 10 00 F k Ea Stroke he 1 Ensure that the teach points including their feedback fields are within the mm mm A 80 measuring range Reference of the target Fig 8 Schematic diagram not to scale of the feedback fields using the example of position S1 1 Overlaps of S1 S2 S3 are possible see Chapter 17 3 Signal priorities Changes to the factory settings for the feedback fields are possible using the PC service program for the control head Type 8681 25 English Control Head Type 8681 burkert FLUID CONTROL SYSTEMS Technical Data MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 26 6 7 2 Service mai
20. a IITIN i Il 3G Ex nA IIC T4 Tamb 55 C Line 1 5 II 3D Ex tD A22 T 135 C X IP65 67 Line 2 WARNUNG WARNING In Ex Bereichen 63 z darf die Oberfl che nur mit einem feuchten Tuch gereinigt werden Line 4 e In Hazardous Areas the surface may only be cleaned with a wet towel Line 5 Device complies with European standards according to EC Declaration of Conformity EN Approval according to the Pressure Equipment Directive Q UL approval for USA and Canada LISTED 19 English Control Head Type 8681 burkert FLUID CONTROL SYSTEMS Technical Data Operating voltage or type of communication 24 V DC AS i DVN 120 V DC type of actuator MVO no MV MV1 single action MV2 2 MV not double acting MV3 3 MV MVD 2 MV double acting pressure range MEME s Pewmdpwesweng ooo 4 Pemmedwmpesuerae OC OC x s seann 8 ID number manufactures specimine a C C s s 12 any specifications if applicable according to Pressure Equipment Directive gas ambient temperature WARNING WARNING In explosion risk areas the surface must only be wiped down with a damp cloth 5 In hazardous areas the surface may only be cleaned with a damp cloth 1 2 3 4 5 1 2 3 4 any specifications if applicable according to Pressure Equipment Directive dust degree of protection specification MAN 1000138479 EN Version F Status RL released freigegeben printed 19
21. baud rate Adjustment of the control head to the baud rate of the network Baud rate DIP 7 DIP 8 125 kbaud off off 250 kbaud on off 500 kbaud off on not permitted on on If the settings are changed by actuating the DIP switches this change will not take effect until the device is restarted For a restart briefly disconnect the control head from the power supply and reconnect or Switch the power supply off on or transmit an appropriate reset message 12 11 Configuration of the process data To transmit process data via an I O connection 2 static input and 1 static output assembly can be selected These assemblies contain selected attributes combined into one object so that process data can be transmitted collectively via an I O connection The process data is selected by setting the device parameters Active Input Assembly and Active Output Assembly or if supported by the DeviceNet Master Scanner by setting Produced Connection Path and Consumed Con nection Path when an I O connection is initialized according to the DeviceNet specification 12 11 1 Static input assemblies Name Address of data attribute of the Format of the data attribute assemblies for read access Value 0 OFF Class instance attributes Value 1 ON S1 S4 factory setting 4 1 3 Byte 0 Bit 0 Position S1 Bit 1 Position S2 Bit 2 Position S3 Bit 3 Position S4 1 54 POS with POS Act
22. in grooves and recesses If cleaning agent is not rinsed off properly its concentration may considerably exceed the concentration for use when the water has evaporated The chemical effect will thus be several times stronger Observe the specifications of the manufacturer and the recommendations for use of the cleaning agent manufacturer 19 5 Malfunctions In the event of any malfunctions in spite of a correct installation proceed according to the fault analysis described in the table below MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 Fault description Possible cause of the fault Troubleshooting No feedback signal Position of the position measuring Perform repeat the Teach In procedure system Teach In not appropriate see Chapter 16 1 Setting the Position for the spindle position Measuring System Teach In Setting of the external initiators Set the external initiator according to the incorrect respective operating instructions No or faulty associated feedback Set the connections according to the signals or external initiator pin and plug configurations described in these operating instructions for the respective voltage and communication variant Target is not mounted on the Check the target for correct mounting process valve s spindle or target and condition see Chapter 6 6 Position faulty measuring system data 88 English Contr
23. not occur automatically Offline parameterization of the device When a device has been inserted into the DeviceNet configuration of RSNetWorx the device can be parameterized offline Fig 28 indicates how for example an input assembly which deviates from the factory setting input process data can be transferred via l O connection can be selected However ensure that the length of the process data during a subsequent configuration of the DeviceNet master scanner is adjusted accordingly All parameter changes implemented offline must become operative for the real device at a later date by a download process DeviceNet dnt RSNetWorx for DeviceNet Eile Edit View Network Device Diagnostics Tools Help ER jals M amp X ben amp ale E amp 3 4185 Hardware 1770 KFD R5232 Interface WEZ ENTTTITTITTITOTNFREENENENNS RIE General Parameters 1 0 Data EDS File www Select the parameter that you want to configure and initiate an action using the toolbar F Groups R A All v gt Monitor f e Current Value n EE vendor Bg Burkert Werke GmbH and Co El Generic Device lt Control Head Type 8681 B Rockwell Automation Allen Bradley AC Drive 160 Preset Speed v4 xx DN1 v1 2 ODW 160 Preset Speed v4 xx DN1 v1 2 Stan all 160 Preset Speed v4 xx DNI v2 0 ODW a 160 Preset Speed v4 xx DN1 v2 0 Stam aj 160 Preset Speed v5 xx DN1 v1 2 ODY aj 160 Preset Speed v5 xx DN1 v1
24. of the control head process valve adaptation The fastening materials for target and piston rod as well as the piston rod itself may not be made of material with very good electrical conductivity e g copper aluminum or of ferromagnetic material Stainless steel without ferromagnetic properties is suitable if necessary check after machining To ensure the proper function of the position measuring system the axial deviation of the adapter must be less than 0 1 mm to the spindle when mounted Use B rkert adaptions exclusively Prior to assembling the control head onto the hub flange lightly grease the O rings with a silicone grease The hood must be lead sealed in the explosion risk area to prevent the housing from being opened without a tool For dimensional relationships see also Chapter 6 6 Position measuring system data 7 2 2 Assembly sequence on the example of a double seated valve Procedure Mount the piston rod with the target on the process valve spindle Observe reference dimensions Fasten the hub flange on the process valve During this observe central alignment and sealing conditions Check the secure fit of the sealing rings in the upper and lower grooves 29 English Control Head Type 8681 burkert FLUID CONTROL SYSTEMS Assem bly MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 30 Mount the control head on
25. or e si I 3 X las 1 X lien 147mA 30mA 3x25mA 1x42mA o When using an external initiator its power requirement should be added 38 sae I ja Control Head Type 8681 burkert 24 V DC Design FLUID CONTROL SYSTEMS MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 10 4 Safety instructions N DANGER Danger of explosion in explosive atmosphere only in the event of a fault as zone 2 Opening the hood or the housing in an explosive atmosphere is only allowed in a not energized state N WARNING Risk of injury due to electric shock Before reaching into the system except for the Teach In procedure in a non explosive atmosphere switch off the power supply and secure it to prevent restarting Observe applicable accident prevention and safety regulations for electrical equipment When setting the position measuring system Teach In do not contact any live components 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 uncontrolled restart Secure system against unintentional activation Following installation ensure a controlled restart 10 5 Electrical installation start up 10 5 1 Cable gland with screw terminals Procedure u Open the housing following the inst
26. possible troubleshooting If required replace device English Control Head Type 8681 120 V AC Design burkert FLUID CONTROL SYSTEMS MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 13 120 V AC DESIGN 13 1 Electrical connection options Cable gland Connection left Voltage signals Connection right external initiator Fig 30 Connection concept 120 V AC 13 2 Electrical data Central power supply Connections Cable gland Power consumption standby current Solenoid valves Max switching capacity Typ continuous output Power consumption per solenoid valve Operating mode Central display of the switching states Outputs binary feedback signals Design Switchable output current Output voltage active Output voltage inactive 110 130 V AC 50 60 Hz 1 x M16 x 1 5 cable gland SW22 for power supply and signals only for transportation safety devices sealed with dummy plugs remove these before use for cable diameter 5 10 mm for wire cross sections 0 5 1 5 mm including PE connection terminal tightening torque of the clamping screws max 0 5 Nm 1 x M16 x 1 5 cable gland SW19 connection option for external initiator sealed with dummy plug remove these before use 10 mA at 120 VAC 1 7 VA per solenoid valve 1 4 VA per solenoid valve 12 mA at 120 V AC Long term operation
27. the control head Check the power supply and the com munication settings also refer to detailed descriptions of the respective versions in these operating instructions No or insufficient pneumatic supply of the control head Check the pressure supply and ensure that supply is sufficient Incorrect function of the process valves Confused pneumatic connection lines Check the correct pneumatic connection of the control head to the process valve for fluid diagrams see chapter 5 3 2 Fluid diagrams and the operating instruc tions of the corresponding process valves Valves not correctly connected on electronics module Check the correct electrical connection of the solenoid valves comp Fig 14 24 V DC electronics module In the event of any undefined faults be sure to contact the service department of B rkert see Chapter 4 1 Contact address on page 12 English 89 Control Head Type 8681 burkert FLUID CONTROL SYSTEMS Replacement of Cornponents and Modules 20 REPLACEMENT OF COMPONENTS AND MODULES If components or modules need to be replaced for maintenance or service reasons please observe the following notes and descriptions o Devices that are used in the explosion risk area may only be repaired by the manufacturer 20 1 Safety instructions N DANGER Risk of injury from high pressure Before loosening lines and valves turn off the p
28. the hub flange seamlessly 360 rotatable Secure control head with the two locking screws shoulder screws M5 in the middle groove of the hub flange to prevent it from being pulled off the hub flange tightening torque max 3 2 Nm see Fig 10 Schematic diagram of the control head process valve adaptation and 7 2 3 Realignment of the control head 7 2 3 Realignment of the control head If necessary the control head can be realigned in particular if properly accessible installation of the pneumatic supply lines is not possible due to spatial conditions This might also be required for operational aspects accessibility of the manual control and because of electrical connection possibilities Procedure Loosen the locking screws shoulder screws M5 slightly until the underside of the screw head is flush with the auxiliary surface of the housing o The locking screw has The locking screw is sufficiently been loosened sufficiently tightened when the upper side of when the lower side of the screw head is flush with the the screw head is flush auxiliary surface of the housing with the auxiliary surface Tightening torque max 3 2 Nm of the housing Rotate the control head until the desired alignment has been achieved Secure the control head with locking screws again until the upper side of the screw head is flush with the auxiliary surface of the housing The locking screws have no sealing function The c
29. 01 2015 20 English Control Head Type 8681 burkert Technical Data FLUID CONTROL SYSTEMS 6 4 Mechanical data M16x1 5 2x Securing the hood with lead seal max 92 MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 G1 4 2x G1 8 3x Fig 4 Dimensional drawing for models with 1 to 3 solenoid valves 21 English K T Control Head Type 8681 burkert FLUID CONTROL SYSTEMS Technical Data M16x1 5 2x Securing the hood with lead seal max 02 MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 Sealed Fig 5 Dimensional drawing for models without solenoid valves Weight Approx 0 8 kg Housing material exterior PA PC PPO VA inside ABS PA PMMA Sealing material exterior CR EPDM inside EPDM FKM NBR 22 sae Ea Control Head Type 8681 Technical Data burkert FLUID CONTROL SYSTEMS 6 5 Control medium Dust content Ouality class 7 Water content Quality class 3 Oil content Quality class X Temperature range of compressed air Pressure range Air rate solenoid valve Connections Pneumatic data Air neutral gases Ouality classes in accordance with ISO 8573 1 5 um filter recommended max particle size 40 um max particle density 10 mg m max pressure dew point 20 C or m
30. 120 V AC L switching DIP switch for LEDs Output position 3 0 120 V AC L switching Output position 4 0 120 V AC L switching Input solenoid valve 1 Teen button 0 120 V AC Input solenoid valve 2 0 120 V AC Input solenoid valve 3 0 120 V AC Valve 1 Valve O actuation Valve 2 control LEDs for O Valve 3 valves Fig 32 Circuit diagram 120 VAC sae Ea Control Head Type 8681 burkert Connection of an External Initiator FLUID CONTROL SYSTEMS MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 14 CONNECTION OF AN EXTERNAL INITIATOR DANGER Danger of explosion in explosive atmosphere only in the event of a fault as zone 2 Opening the hood or the housing in an explosive atmosphere is only allowed in a not energized state An external initiator can be connected via the 3 fold screw terminal at bottom right on the respective electronics module in the example AS i Due to the size of the screw terminals the wire cross sections of the external initiator have the following values for the different designs Bo ON Di 0 14 1 5 mm for design 24 V AS i DeviceNet Power Fault BEBE 0 5 1 5mm2 for design 120 V Fig 33 Screw terminal for external initiator Designation of the screw terminals on the different electronics modules Designation according to design Configuration 24 V DC AS i DevNet 120 V AC 2
31. 2 English Control Head Type 8681 burkert DeviceNet Design FLUID CONTROL SYSTEMS MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 Online parameterization of the device Devices can also be parameterized online In doing so you can also select whether only individual parameters single or all parameters all of a group are read from the device upload or are loaded into the device download It is also possible to transfer individual parameters or all parameters of a group cyclically in monitor mode This may be helpful particularly for start up purposes 12 13 Display of the status LEDs in the event of a bus error attern amp fault signaling o Bus errors are also indicated on the central three colored status display see Chapter 17 2 Blinking The device status LED modules and the bus status LED network are located on the electronics module Fig 29 Status LEDs Function tests for both status LEDs after power has been switched on connection of the network cable Status LED Colors of the LED Function test Modules green 250 ms ON green Network green red 250 ms ON green 250 ms ON red Then another function test is run during which the LEDs light up briefly When the test is complete the status LEDs indicate the device states which are described in the following tables 12
32. 2 and 3 conductor NO or NC factory setting NO PNP output Input current 1 signal Isensor gt 6 5 MA limited internally to 10 mA Input voltage 1 signal U gt 10 V Input current 0 signal less 4 mA Input voltage O signal U lt 5 V Inputs from master perspective binary feedback signals The recovery of the 3 valve positions reported back in binary format is described in Chapter 16 on page 75 Outputs from master perspective solenoid valves Max switching capacity max 0 9 W per solenoid valve Typ continuous output 0 6 W per solenoid valve Watchdog function integrated Output reduction via AS interface electronics integrated Pull in current 30 mA or 0 9 W 200 ms at 30 5 V AS i voltage Holding current 20 mA or 0 6 W at 30 5 V AS i voltage Operating mode Long term operation 10096 ED Valve type Type 6524 Central display of the switching states Power consumption from AS interface at 30 5 V AS interface voltage max 33 mA or 1 W per illuminated display Number of representable colors 2 colors for process valve switching states 1 color for signaling a fault For universal color switching see Chapter 17 LED Color Assignments Power supply via AS interface bus without external power supply Max power consumption from AS i 200 mA incl external initiator with 30 mA Power consumption during normal operation from the AS i after current reduction lt 150 mA 3 valves activa
33. 24 solenoid valve 1 NC solenoid valve 2 NO for double acting actuators safety position see also Chapter 15 Special designs on page 73 Process valve up open down close Fig 3 Fluid diagram design for double acting actuators 2 solenoid valves NC NO 5 3 3 Number of solenoid valves The control head for process valves has been designed for single acting and double acting actuators as well as for double seated and multi position valves Type of use Number of solenoid valves Repeater 0 Control head for single acting actuators 1 NC Control head for double acting actuators 2 2xNC9 both drive chambers not energized and deaerated Control head for double seated valves with integrated aeration of both 3 3xNC valve seats Control head for double acting actuators with safety position 2 1 xNC 1 x NO Details on design for double acting actuators 1 solenoid valve NC 1 solenoid valve NO see Chapter 1 Special designs on page 73 MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 5 3 4 Pneumatic interfaces Intake amp exhaust air connections G 1 4 Working connections G 1 8 Integrated non return valves in the solenoid valves exhaust air duct NC 3 2 way valve closed in rest position output A relieved 16 NO 3 2 way valve opened in rest position output A pressurized Englis
34. 479 EN Version F Status RL released freigegeben printed 19 01 2015 86 English Control Head Type 8681 burkert Maintenance troubleshooting FLUID CONTROL SYSTEMS MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 19 2 Safety positions Safety positions after failure of the electrical or pneumatic auxiliary power Safety positions after failure of the auxilia ower Operating mode Process valve ry p design N N electrical pneumatic M single acting Control function A down down up air opening down spring closing single acting Control function B up air closing iie zs down spring opening not defined for double acting both solenoid valves Control function NC but up dde EE not defined a defined for down air closing Solenoid valve1 NC Solenoid valve2 NO By default the control head is equipped with solenoid valves which operate in NC mode the design for double acting actuators is equipped with 1 solenoid valve NC and 1 solenoid valve NO If process valves with several switching positions e g double seated valves are connected the safety positions of the individual actuators can be viewed according to the same logic as for a classical single seated valve Safety positions after failure of the bus communication AS interface If the Watchdog is activated default behavior is the same as a failure of the aux
35. 4V V L Power supply according to design S4 IN S4 IN S4 IN External initiator input GND GND N GND external initiator 24 V DC AS i DevNet or power supply 120 V AC design Electrical requirements of the external initiator for different designs An The electrical reguirements of the external initiator can be found in the respective subchapters Electrical e data under the headword Input proximity switch external initiator S4 in Design 24 V see Page 36 DeviceNet design see Page 54 AS i design see Page 45 120 V design see Page 65 Procedure when connecting the external initiator Open the housing following the instructions in Chapter 8 Opening and Closing the Housing Assemble the connection cables according to the general rules of technology Insert cables through the cable gland connection on right into the interior of the housing Connect the wires to the connection terminals according to the pin assignment Close the housing following the instructions in Chapter 8 Opening and Closing the Housing 71 English E ER Control Head Type 8681 burkert W FLUID CONTROL SYSTEMS Connection of an External Initiator NOTE Ensure IP protection To ensure IP protection the union nuts of the cable glands must be tightened in accordance with the cable sizes or dummy plugs used approx 1 5 Nm f no external initiator is used the right hand connecti
36. Design or Chapter 12 DeviceNet Design or Chapter 13 120 V AC Design or Chapter 15 2 Control head AS i with 2 external initiators 75 English Control Head Type 8681 burkert N FLUID CONTROL SYSTEMS Position Measuring System 16 1 Setting the position measuring system Teach In AN DANGER Danger of explosion in explosive atmosphere only in the event of a fault as zone 2 Opening the hood or the housing in an explosive atmosphere is only allowed in a not energized state Example procedure for 3 valve positions Open the housing following the instructions in Chapter 8 Opening and Closing the Housing Supply electrical power so that the position measuring system and the LED display can function Position the process valve at the lower switching position Depress the lower Teach In button T1 for approx 1 5 seconds The LED corresponding to this position will flash quickly 3 times during the teaching phase When this position has been saved the corresponding LED will remain continuously lit until the position of the piston is changed Afterwards position the process valve at the upper switching position to be recorded Depress the upper Teach In button T2 for approx 1 5 seconds The LED corresponding to this position will flash quickly 3 times during the teaching phase When this position has been saved the corresponding LED will remain continuous
37. Design FLUID CONTROL SYSTEMS MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 11 AS INTERFACE DESIGN 11 1 Definition AS interface connection AS interface Actuator Sensor Interface is a field bus system which is used primarily for networking binary sensors and actuators slaves with a higher level control master Connecting the control heads to higher bus systems is possible using commercially available gateways Contact your distribution partner in this regard Bus line Unshielded two wire line AS interface line as AS interface cable harness along which both information data and energy power supply for the actuators and sensors are transmitted Network topology Freely selectable within wide limits i e star tree and line networks are possible Further details are described in the AS interface specification A B slave model complies with the version 3 0 specification The control heads have been configured as AS interface version with an extended address range A B slaves for 62 slaves or optionally as an AS interface version for 31 slaves For details see Chapter 11 8 Programming data 43 English Control Head Type 8681 burkert FLUID CONTROL SYSTEMS AS Interface Design 11 2 Electrical connection options for AS interface The following connection concepts are available for the electrical connection of the control head Cable gland with mu
38. General description The control head Type 8681 is used for actuating pneumatically operated process valves For process valve actuation the control head can be eguipped with up to three solenoid valves For the recording and feedback of the process valve switching positions to a higher level control the control head has been equipped with a contact free position measuring system which operates with 3 discrete adjustable feedback signals Teach In function The control head and the process valve are interconnected by an adapter This produces an integrated compact and decentralized system of feedback actuation and valve function The following advantages over centralized solutions working with valve clusters are achieved low installation expenditure easy start up higher application specific flexibility shorter switching times and less air consumption due to shorter distances between the pilot valve and the process valve Various pneumatic and electrical connection variants are available 13 English Control Head Type 8681 burkert W FLUID CONTROL SYSTEMS System Description 5 3 Functions options designs 5 3 1 Structure of the control head Position measuring system with LEDs in 3 colors Electronics module with connection terminals service interface and Teach In buttons rear Solenoid valve 2 Solenoid valve 1 I ie lt lt Pi p 1 m If Mechanica
39. ITA aaa PN 13 E 5 3 Functions options designs U LU L L u 14 5 3 1 Structure of the control headi 14 5 32 Fluid diag alfieuu u u qan elan usa ssayasaauaqaasgakaaissaqaqdaqiivasaqskaqcqawasaqslasqasyassast af pup E Emu Ege 15 P 5 3 3 Number of solenoid valves ctrca uuu uu 16 5 5 3 4 Pneumatic Interfaces ULU Lu Qu 16 E 5 3 5 Manual Contr 17 5 3 6 Position measuring system 17 5 3 7 Other features ttt 17 6 TECHNICAL DATA 18 6 1 Operating conditons iiiter adanada ana a a cece 18 6 2 Conformity with the following standards uu u uuu uuu 18 6 3 Rating plate specifications u uuu uuu u aaia aada sa sassa Wa aai 19 6 4 Mechanical dala y au Ei amas tas 21 65 Pneumatic data 23 6 6 Position measuring system data eer terrere uuu u uuu uuu 24 English Control Head Type 8681 burkert FLUID CONTROL SYSTEMS 6 7 Factory settings in the firmware u u u uu ua aa mamman aa au 25 6 7 1 Feedback fields position measuring system
40. MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 burkert FLUID CONTROL SYSTEMS Type 8681 Control Head Operating Instructions MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 We reserve the right to make technical changes without notice Technische Anderungen vorbehalten Sous res rve de modification techniques Burkert Werke GmbH 2010 2014 Operating Instructions 1412 05 EN 00806150 Original DE Control Head Type 8681 ult burkert FLUID CONTROL SYSTEMS Control Head Type 8681 CONTENTS 1 OPERATINGIINSTRUCTIONSI S9 8 2 AUTHORIZED USE pisses c been 9 2 1 Export restriCti OTIS am eaa I Guau utawa u sute aa Gubuk sqa nennen 9 3 BASIC SAFETY INSTRUCTIONS Ey a een 10 4 GENERAL INFORMATION 4 0540 kj tabes usa utua Pun su el ddp lacum pet 12 4 1 Contact address e w M 12 4 2 WAaIra lyu aquaaiuasausisasasaiaaisassssuwsqaqsssmasusiwsqsiasssqsqhisiassamisassssyassssphasassssissssassspasassqhusasaqttaqaaas aQ 12 E 4 32 Information on the Internet nee ee 12 E 5 SYSTEM DESCRIPTION ictor oma kaman av ana n dna v ua ve kmmmud amu u ya vene 13 5 1 Intended application area maansa mana au u u uuu uuu 13 5 2 Gene eralidescriBtiOhhu s u I uuu TT I
41. MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 20 2 Changing the electronics module NOTE Electrostatic sensitive components modules The device contains electronic components which react sensitively to electrostatic discharge ESD Contact with electrostatically charged persons or objects may be hazardous to these components In the worst case scenario they will be destroyed immediately or will fail after start up Observe the requirements in accordance with DIN EN 61340 5 1 to minimize or avoid the possibility of damage caused by sudden electrostatic discharge Also ensure that you do not touch electronic components when the supply voltage is on Removal procedure u Open the housing following the instructions in Chapter 8 Opening and Closing the Housing If necessary mark the electrical connections to ensure correct assignment during reinstallation If necessary note the position of the 4 DIP switches for the set color code and on the DeviceNet electronics module the DIP switches 8 switch block for Baud rate and address On the AS i electronics module note the AS interface address and the jumper positions power supply to AS interface If required read out and note special settings by the PC service program Loosen all electrical connections on the electronics module plug type connections screw type terminal connections Loosen the screw type c
42. Procedure for activating amp deactivating the manual control for valve location 2 A1 Observe safety guidelines for the system prior to using the manual control Activating the magnetic manual control Hold the manual control tool on the identification points the between the cable glands for three seconds see Fig 36 blinking pattern in fault color 50 ms ON 450 ms OFF active manual control blinking pattern in fault color 100 ms ON 100 ms OFF 3x manual control function disabled by the software Once the measure has been completed deactivate the magnetic manual control Hold the manual control tool on the identification points the between the cable glands for another three seconds see Fig 36 After a power failure the magnetic manual control is reset and the control head restarts in standard operating mode i e the signal of the higher level control is accepted 18 2 Mechanical manual control If additional manual controls are required for additional service purposes or in the event of a failure of the elec trical energy it is possible for all voltage and communication designs to switch the connected process valve using the mechanical manual control of the solenoid valves after opening the housing DANGER Danger of explosion in explosive atmosphere only in the event of a fault as zone 2 Opening the hood or the housing in an explosive atmosphere is only allowed in a not energized state
43. S RIED 32 tc E 9 PNEUMATICIINSTADEATION L III aa aa aada tbe otd sedet ala Ru Eee o GRE 33 z 9 4 Safety instructions socados niko dba Ebene ne roe 33 E 9 2 Pneumatic connection of the control head 33 m 9 3 Flow restriction function of the solenoid valves 34 10 24 V DE DESIGN m 36 10 1 Electrical connection options u anna 36 10 2 Electrical p 36 10 3 Design aldi u u u ua issusqsisassssasqssssstssawasayaasakss asas ass als us akuna sssus anna reinen een rennen 38 110 4 Safety Instr ctions mee m M 39 10 5 Electrical installation start up u uuu u u u u 10 5 1 Cable gland with screw terminals 10 5 2 Multi pole connection u u u uu u u u 42 sae Ea Control Head Type 8681 burkert FLUID CONTROL SYSTEMS 14 AS INTERFACE DESIGN siisetccssciecccsccctetecacnscoocssenssescactetenssntctoosieeecoisscietosusatincosieeesancaaazieessattecoadaeesaboast Nasaan aaa daanan iaaiiai 43 TI PR PIS TL ALL 1 0 uuu T uaaanausaaamiauapauaswaasminansasayquassqywssassiysa 43 11 2 Elect
44. Status RL released freigegeben printed 19 01 2015 120 V AC Electronics module terminal strip configuration Service interface Solenoid valve connection with status LED for Valve 1 Terminal strip Protective conductor Protection earth Power supply L N Feedback signals S1 S4 OUT Control solenoid valves Y1 3 Teach In buttons T1 3 Solenoid valve connections with status LED for Valves 2 3 DIP switches for color coding the LEDs Connection for the external initiator Fig 31 120 V AC electronics module Designation N Designation Configuration for external Terminal strip Sant zuratlon Terminal strip initiator PE m sarih protestuo N Power supply conductor L Conductor Power S4 IN External initiator input N om supply 120 V AC N Power supply neutral conductor S1 OUT Output position 1 S2 OUT Output position 2 S3 OUT Output position 3 S4 OUT External initiator output Y1 Solenoid valve 1 input Y2 Solenoid valve 2 input Y3 Solenoid valve 3 input 69 English Control Head Type 8681 burkert FLUID CONTROL SYSTEMS 1 20 V AC Design MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 TO Circuit diagram 120 V AC Protective conductor Service interface Central power supply 120 V AC Output position 1 0 120 V AC L switching 0000 Output position 2 0
45. Type 8681 DeviceNet Design burkert FLUID CONTROL SYSTEMS MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 Inputs Outputs Power consumption from the bus 3 discrete feedback signals from the position measuring system positions S1 S3 1 discrete feedback signal from the external initiator S4 1 analog position signal in mm supply via DeviceNet string 11 25 V DC Switch level high signal 2 5 V Switch level low signal x 1 5 V 3 solenoid valves max output 5 W if all valves are switched 3 x type 6524 with 0 6 W each 12 3 1 Total line length and maximum line length according to DeviceNet specification The bus line is a 4 core cable with additional shielding which must conform to the DeviceNet specification The cable transmits both information data and energy power supply for low power actuators and sensors o The maximum total line length sum of trunk lines and drop lines of a network depends on the baud rate Maximum total line length Baud rate Thick Cable Thin Cable 125 kbaud 500m 250 kbaud 250m 100 m for all baud rates 500 kbaud 100m 1 According to DeviceNet specification If a different cable type is used lower maximum values apply 2 For cable designation and details see DeviceNet specification 12 3 2 Drop line length Length of the drop lines Baud rate n Maximum total leng
46. activate V1 5 Valve closes Wait on position S1 S1 Timeout 15s Intermediate position opens Activate v2 z Wait period 10s e Intermediate position Teach T3 3 Valve closing Deactivate V2 8 Valve closes Wait on position S1 S1 Timeout 15s Autotune mode completed lt sae Ea Control Head Type 8681 LED Color Assignments burkert FLUID CONTROL SYSTEMS 17 LED COLOR ASSIGNMENTS The switching states of the feedback positions are signaled centrally to the outside by super bright LEDs so that quick visual control is possible also for large systems The color assignments for all signals to the process valve states correspond to the subsequently listed tables To respond in the systems to the different process valve designs and signaling philosophies of the customers the assignment of functions to the available colors can be configured individually by means of the 4 DIP switches on site Delivered state DIP 1 4 each set to position 0 When using the control head in an explosive atmosphere the housing may only be opened in a not energized state SSSSSSSSS Electronics module 24 V DC 4 DIP switches Position 1 On up Position 0 Bottom Electronics module ASI Fig 35 MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 DIP switches for setting the color coding in the example of the electronics modules for 24 V DC and AS i 81
47. ands into the interior of the housing Connect the wires to the connection terminals according to the connection configuration described in Fig 31 120 V AC electronics module If required secure the cable with a cable clip DANGER Risk of electric shock if the PE connection is not connected the PE connection must be connected Clamp the protective conductor to the PE connection Check correct grounding u Close the housing following the instructions in Chapter 8 Opening and Closing the Housing NOTE Ensure IP protection To ensure IP protection the union nuts of the cable glands must be tightened in accordance with the cable Sizes or dummy plugs used approx 1 5 Nm f no external initiator is used the right hand connection opening must be tightly sealed using a dummy plug or using a cable gland SW 19 3 6 mm with a dummy plug 5 6 mm MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 NOTE Use of the control head in explosive atmosphere Only use cables and cable glands which are approved for the respective application area and fit the cable glands according to the respective operating instructions Close all unnecessary openings with lock screws plugs approved for explosions area 68 sae Ea Control Head Type 8681 120 V AC Design burkert FLUID CONTROL SYSTEMS MAN 1000138479 EN Version F
48. apters 17 LED Color Assignments and 18 Service Mode Manual Control o For a detailed description of the manual control see Chapter 18 Service Mode Manual Control 5 3 6 Position measuring system The switching positions of the process valves are reported to the actuator by feedback signals from the sol derless position measuring system Connection to the control head is done by means of a simple adaptation to the process valve s piston Details are described in Chapters 6 6 Position measuring system data on page 24 and 16 Position Measuring System on page 75 5 3 7 Other features Central optical position indicator for showing the process valve switching positions Positions and status information can be indicated by 3 signal colors The assignment of the signal colors and the blinking pattern which indicates the type of fault are described in Chapter 17 LED Color Assignments Simple adaptation of the control head for the position measuring system to the process valve piston rod Simple adjustment of the position measuring system by 3 Teach In buttons on the electronics module The capability of restricting the pilot valve solenoid valve for the individual setting of the expansion and retraction rates of the process valve and the individual setting of the flow rate of the working connections More energy efficient solenoid valve actuation by lowering the holding current during long term operat
49. at bear up under common stresses caused by the quick connector Silencer or exhaust air hose When using an exhaust air hose accordingly dimension its length to ensure that a ONn value gt 620 l min is reached Tip Dimension the hose lengths so that the control head can be removed from the process valve if required without any additional disassembly work 9 3 Flow restriction function of the solenoid valves Set the flow restriction screws of the solenoid valves only when needed and after completion of all nec essary installations MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 The flow restriction screws of the solenoid valves see Fig 12 are used for setting the air intake and exhaust for the working connections Factory setting ONn approx 110 l min The flow restriction screws do not serve any sealing function Only tighten the flow restriction screws to the stopper otherwise damage to device may occur Only use appropriate screwdrivers b lt 3 mm 34 English Control Head Type 8681 burkert Pneurnatic Installation FLUID CONTROL SYSTEMS MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 Settings of the flow rate or the control speed with the help of the flow restriction screws Open the housing following the instructions in Chapter 8 Opening and Closing the Housing For proper setting it is adv
50. ch signal will be sent stag MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 Example 1 3 valves are activated simultaneously one position is reported state for 200 ms Preis Pa 1x Pyave on 2x P 1x Pres 7 3VA 1 2VA 1x1 7VA 2x1 4VA 1x 1 6 VA or a ln 1x EN 2x 1x lien 61mA 10mA 1x14mA 2x12mA 1x13mA 66 sae Ea MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 Control Head Type 8681 ult burkert 120 V AC Design FLUID CONTROL SYSTEMS Example 2 3 valves have been activated simultaneously one position is reported persistent state Pra E Pa 3x Pus dx Pien 7 0 VA 1 2 VA 3x1 4VA 1x1 6 VA or La la 3x luae 1x lieb 59mA 10mA 3x12mA 1x13mA o When using an external initiator its power requirement should be added 13 4 Safety instructions DANGER Risk of injury due to electric shock 110 130 V AC Before reaching into the system except for the Teach In procedure in a non explosive atmosphere switch off the power supply and secure it to prevent restarting Observe applicable accident prevention and safety regulations for electrical equipment When setting the position measuring system Teach In do not contact any live components Risk of electric shock if the PE connection is not connected the PE connection m
51. ct on the process valve Internal program Error T2 T3 Autotune mode started ja T3 Autotune 3 starts z Closed position Teach T1 Open valve Activate V1 Wait period 10s S Open position Teach T2 Valve closing Deactivate V1 Valve closes Wait on position S1 S1 Timeout 15s Open clock valve plate Activate V2 Wait period 10s Clock valve plate Teach T3 Valve closing Deactivate V2 Valve closes Wait on position S1 S1 Timeout 15s Autotune mode completed 79 English burkert FLUID CONTROL SYSTEMS Control Head Type 8681 Position Measuring System Autotune 4 80 Autotune 6 Spare function Control Effect on the process valve Internal program Error T2 T3 Autotune mode started T1 T2 Autotune 4 starts Valve closing Activate V2 Wait period 10s Closed position Teach T1 Open valve Deactivate V2 Activate v1 Wait period 10s Open position Teach T2 Valve closing Deactivate V1 Activate V2 D Valve closes Wait on position S1 S1 Timeout 15s amp Neutral position Deactivate V2 S Autotune mode completed 9 c amp Autotune 5 c Control Effect on the process valve Internal program Error 7 2 T2 T3 Autotune mode started T1 T3 Autotune 5 starts 9 Closed position Teach T1 Open valve Activate V1 Wait period 10s 2 Open position Teach T2 a Valve closing De
52. d vent the lines Exhaust air con Supply nection 3 R pressure Silencer connection not shown 1 P Solenoid valve 3 Solenoid valve 2 Solenoid valve 1 2 A3 2 A2 2 A1 Working connections 2 A1 3 Fig 11 Pneumatic connection 33 English Control Head Type 8681 burkert FLUID CONTROL SYSTEMS Pneumatic Installation Procedure If required realign the control head see Chapter 7 2 3 Realignment of the control head A silencer has already been mounted on the Exhaust Air Connection 3 R in the supplied state As needed the silencer can be replaced by an exhaust air hose e g after screwing in an appropriate plug in hose connectors Connect the required working connections 2 A1 to 2 A3 each according to model with the corresponding connections on the process valve Connect the supply line to supply pressure connection 1 P 2 5 8 bar NOTE Hose pipes Only use approved hose pipes with Z6 mm or 1 4 or 28 mm or 5 16 outer diameters tolerance 0 05 0 1 mm Only use a suitable hose cutter when cutting hose pipes This will safeguard against damage and impermissible deformation Accordingly dimension hose length to prevent that the hose ends in the plug in hose connectors generate any diagonally pulling stresses curved outlet without eccentric stress Only use suitable hose qualities in particular for high ambient temperatures th
53. does not run properly or is aborted if e g no compressed air is connected the positions already taught are deleted again the corresponding Autotune function is left and switched to normal operation The Teach positions are set to not taught i e they flash in the fault color In the case of the design for double acting actuators solenoid valves NC NO only Autotune functions 1 and 2 are possible compare Chapter 15 1 on page 73 16 2 3 Autotune sequence Autotune 1 Control Effect on the process valve Internal program Error T2 T3 Autotune mode started T1 Autotune 1 starts Closed position Teach T1 Open valve Activate V1 Wait period 10s Open position Teach T2 Valve closing Deactivate V1 Valve closes Wait on position S1 S1 Timeout 15s Autotune mode completed MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 Example illustration of the Autotune procedure 1 1 Check in what position the process valve must be at the beginning of the Autotune procedure here closed position Close it if necessary 2 Press the teach buttons T2 and T3 at the same time for 2 5 s to select the Autotune mode This mode will be indicated by continuous illumination of all 6 LEDs 3 Press teach button T1 for 0 5 s to start the Autotune 1 mode This will be indicated by illumination of all 6 LEDs in chaser mode The programmed sequence for Auto Teach sequ
54. e taught i Connection for 2 external initiators No Autotune function can be used AS interface connection 15 2 2 Electrical installation and programming data L Compare also Chapter 11 7 Electrical installation of the AS interface on page 49 for the standard designs MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 74 Ext ini Pin External Wire Pin External Wire 5 O tiator 1 initiator2 color initiator1 color 000 1 24V brown 1 DAV brown 2 0 2 Not used 2 Not used View of the two M12 female connectors for 3 GND blue 3 GND blue the two external initiators 4 S5 IN white 4 S4 IN black Compare also Chapter 11 8 Programming data on page 51 for the standard designs Bit configuration table Data bit D3 D2 D1 DO Input Not used Not used External initiator 2 S5 IN External initiator 1 S4 IN Output Not used Solenoid valve 3 Solenoid valve 2 Solenoid valve 1 sae Ea Control Head Type 8681 burkert Position Measuring System FLUID CONTROL SYSTEMS MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 16 POSITION MEASURING SYSTEM Operating principle of the position measuring system The position measurement is based on recording the change in position of the ferromagnetic target inside the system The geometry and the material of
55. e the device in a dry and dust free location Storage temperature 20 65 C Kindly make sure that the devices following storage at low temperatures are heated slowly to room temperature before you carry out any assembly work on the devices or start operation of the devices 24 DISPOSAL Dispose of the device and packaging in an environmentally friendly manner NOTE Damage to the environment caused by device components contaminated with media Observe the relevant disposal and environmental protection regulations o Note Observe the national waste disposal regulations 97 English burkert FLUID CONTROL SYSTEMS 10 e N o 2 v o c a oO a 7 D o www burkert com
56. ence 1 will now run fully automatically 78 sae Ea Control Head Type 8681 Position Measuring System burkert FLUID CONTROL SYSTEMS The position in that the process valve is adjusted will be taught first as position S1 The position of the process valve must therefore be checked first After that valve V1 is activated It initiates opening of the process valve After maximum 10 s the process valve has reached position S2 open position Then position S2 is taught After that valve V1 is deactivated It initiates closing of the process valve Once the process valve is closed after 15 s maximum position S1 is displayed by LED 4 Autotune sequence 1 is complete Positions S1 and S2 are taught In the event that a timeout occurs after 15 seconds wait period the corresponding Autotune function will be exited and switched to normal operation Furthermore the Teach positions are set to not taught i e they flash in the fault color Autotune 2 i Control Effect on the process valve Internal program Error T2 T3 Autotune mode started T2 Autotune 2 starts Open position Teach T2 Valve closing Activate V1 Wait period 10s Closed position Teach T1 Open valve Deactivate V1 Valve opens Wait on position S2 S2 Timeout 15s Autotune mode completed g T m Autotune 3 a 2 Control Effe
57. enoid valves in the event of a bus error If a bus error occurs the configuration data of the solenoid valves can be accessed acyclically via Explicit Messages The Get Attribute Single service stands for a read access of the configuration data The Set Attribute Single service stands for a write access of the configuration data 1 data byte for safety mode 1 data byte for valve safety position attribute address attribute address class 150 instance 1 attributes 7 class 150 instance 1 attributes 6 Bit Mode Value assignment Bit Solenoid valve Value assignment Character 0 Approach BitO Y1 solenoid valve 1 Value 0 OFF value 1 ON i ai s safety position BitO istics in event Retain last val of bus error SA ASE VANS Bit1 Y2 solenoid valve 2 Value 0 OFF value 1 ON position ae not used O always Bit 2 Y3 solenoid valve 3 Value 0 OFF value 1 ON not used O always 61 English ult Control Head Type 8681 burkert FLUID CONTROL SYSTEMS DeviceNet Design 12 12 2 Configuration example The example describes the principle procedure when configuring the device using the RSNetWorx software for DeviceNet Rev 4 21 00 Installation of the EDS File The EDS file is installed with the aid of the EDS Installation Wizard Tool associated with RSNetWorx During the installation procedure the icon can be assigned if this does
58. ention and safety regulations for electrical equipment 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 uncontrolled restart Secure system against unintentional activation Following installation ensure a controlled restart 8 2 Opening and closing the housing 8 2 1 Opening the housing NOTE Improper handling will damage the plastic hood seal Do not use excessive force e g by knocks for opening Make sure that the lubricated seal contour is not soiled when the hood is placed down as this might reduce the IP protection Procedure Remove lead seal if housing is secured Open the plastic hood by turning counterclockwise all the way approx 1 5 cm Due to the tightness of the sealing loosen the plastic hood by carefully tilting it laterally and lift it upwards to remove it 31 English Control Head Type 8681 burkert FLUID CONTROL SYSTEMS Opening and Closing the Housing 8 2 2 Closing the housing 1 If necessary clean the seal contour of the seal and of the hood and lightly lubricate it using a silicone grease Caution Do not use any petroleum based or synthetic lubricants except for silicone grease Procedure Put the plastic hood on the lower part such that the inner lugs are positioned over t
59. eset to 0 when a Device Reset occurs 6 7 3 Manual control function magnetic Factory setting for magnetic manual operation active Deactivation is possible using the PC service program Connection to the PC is via the Service interface see Fig 9 Location of the Service interface on the electronics module Details are described in the PC service program manual under the SYSTEM Start up menu option Compare also chapter 18 1 Magnetic manual control O i _ Service in avi terface on i o the different O 22 electronics av iO EUn modules GND O O e g 24 V D 10UT ee and 120 V so _ ssoUT 2 S40UT D Ni v 2 0 o v2 2 fs vs laLa Fig 9 Location of the Service interface on the electronics module English Control Head Type 8681 Technical Data burkert FLUID CONTROL SYSTEMS 6 8 Resetting the device Device Reset A restricted reset of the device to factory settings can be performed using the PC service program see the PC service program manual or directly on the control head Procedure Simultaneously actuate T1 T2 T3 approx 2 5 s long to access Device Reset mode the corresponding blinking pattern is always alternating 500 ms RED 500 ms GREEN If the device is not reset 10 s after switching to Device Reset mode this mode is automatically left Simultaneously actuate T1 T2 T3 again
60. h Control Head Type 8681 burkert System Description FLUID CONTROL SYSTEMS MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 Actuation of Connection 2 A1 Solenoid Valve 1 normally the main stroke of the process valve using the mag netic manual control that is externally accessible both solenoid valves are actuated simultaneously for the design for double acting actuators Special silencers with a high flow rate capacity to connection S R have already been mounted The interior of the housing is protected against excessive overpressure for example due to leakages by a pressure relief valve with output into the joint exhaust air connection S R 5 3 5 Manual control The control head provides the following as standard a magnetic manual control that is easily accessible from the outside on the basis of encoded magnetic fields for Solenoid Valve 1 Connection 2 A1 as well as a mechanical manual control accessible when the hood is open on each equipped solenoid valve The magnetic manual control has the following advantages the control head does not need to be opened simple actuation tool for opening closing solenoid valve 1 main stroke helpful for service maintenance work on the process valve both solenoid valves are actuated simultaneously for the design for double acting actuators LED display for the activated manual control status service mode see Ch
61. h In buttons on the electronics modules in the example of the electronics modules for 24 V DC and AS i 16 2 Teach button functions 16 2 1 Teach functions and Teach reset Teach Function Activation Optical feedback button duration T1 Teach function S1 1 58 S1 blinks quickly three times then continuously in the encoded color T2 Teach function S2 1 58 S2 blinks quickly three times then continuously in the encoded color T3 Teach function S3 1 58 S3 blinks quickly three times then slowly in the encoded color T1 T2 Teach In reset S1 S2 25s Blinks in the fault color and S3 Difference between the different blinking patterns see Chapter 17 2 Blinking pattern amp fault signaling 77 English Control Head Type 8681 burkert W FLUID CONTROL SYSTEMS Position Measuring System 16 2 2 Autotune functions Teach Mode Activa Opt feed Teach Function Activation Opt feed button tion dura back button duration back tion T1 Autotune 1 green yellow T2 Autotune 2 green d T3 Autotune 3 llow yogqu Autotune 2 5s dk 0 5s i mode Continu T1 T2 Autotune 4 i i T1 73 Autotune 5 chaser mode T2 T3 Autotune 6 The Autotune function can be selected after changing to Autotune mode If an Autotune function has not been started 10 seconds after the change to Autotune mode that mode will be exited If an Autotune function
62. he locking grooves and the external sealing lugs are positioned almost over each other Press the hood completely over the seal of the lower part Turn the hood by approx 1 5 cm clockwise meaning until the sealing lugs are positioned over each other If necessary apply a lead seal to prevent opening without a tool The hood must be lead sealed in the explosion risk area to prevent the housing from being opened without a tool MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 32 English Control Head Type 8681 bi iier jat urkert Pneurnatic Installation FLUID CONTROL SYSTEMS MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 9 PNEUMATIC INSTALLATION 9 1 Safety instructions N DANGER Risk of injury from high pressure in the system Before loosening lines and valves turn off the pressure and vent the lines AN 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 uncontrolled restart Secure system against unintentional activation Following installation ensure a controlled restart 9 2 Pneumatic connection of the control head DANGER Risk of injury from high pressure in the system Before loosening lines and valves turn off the pressure an
63. ich makes installation and start up on site considerably easier and quicker reducing the risk of leaks However you will require the correspondingly assembled cable sets with the following pin assignments Likewise the jumpers on the electronics module must be set correspondingly see figures below NOTE Use of the control head in explosive atmosphere Only use cables and cable glands which are approved for the respective application area and fit the cable glands according to the respective operating instructions Close all unnecessary openings with lock screws plugs approved for explosions area Bus connection for AS interface power supply for solenoid valves via bus external power supply M12 x 1 circular plug 4 pole male according to IEC 61076 2 101 view of the M12 plug from the front onto the pins Pin 2 NC Pin 2 GND Pin 3 ASI Pin 1 ASI Pin 3 ASI Pin 1 ASI Pin 4 NC Pin 4 24 V Bus connection with power supply Bus connection with external for solenoid valves via bus power supply via solenoid valves Fig 19 AS interface bus connection power supply for solenoid valves via bus external power supply Pin Configuration Configuration Wire color supply via bus external power supply 1 AS interface ASI AS interface ASI brown 2 Not used GND white 3 AS interface ASI AS interface ASI blue 4 Not used 24V black Power supply to the solenoid
64. id valves Max switching capacity 1 0 W per solenoid valve Typ continuous output 0 6 W per solenoid valve Output reduction via DeviceNet interface electronics integrated Pull in current 120 mA typ 200 ms 3 valves Holding current 100 mA typ at 24 V DC 3 valves Operating mode Long term operation 10096 ED Valve types 6524 Central display of the switching states Power consumption from DeviceNet at 24 V DC 42 mA with a power supply of 24 V DC per illuminated display color switching see Chapter 17 LED Color Assignments on page 81 12 5 Safety position if the bus fails If the bus fails the solenoid valve is switched to a programmable safety position default solenoid valve not ener gized For configuration data see Chapter 12 12 1 Configuration of the safety position of solenoid valves durin a bus error English Control Head Type 8681 burkert DeviceNet Design FLUID CONTROL SYSTEMS MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 12 6 Design aid Power consumption of the electronics Ps 144W or I 60mA at 24V Power consumption of a valve during activation 200 ms Pauw 10W or NY 42mA at 24V Power consumption of a valve after reduction P bs 0 6W or lass 25mA at 24V Power consumption of an optical position report P ss 10W or I eb 42mA at 24V Calculation example
65. iliary electrical power i e all solenoid valve outputs are set to O DeviceNet See Chapter 12 12 1 Configuration of the safety position of solenoid valves during a bus error NC 3 2 way valve closed in rest position output A unloaded NO 3 2 way valve opened in rest position output A pressurized 87 English Control Head Type 8681 burkert FLUID CONTROL SYSTEMS Maintenance troubleshooting 19 3 Maintenance service When used properly the control head Type 8681 operates maintenance and trouble free For service work contact the B rkert Sales Center Chapter 4 1 on page 12 If the service maintenance notification function is active see Chapter 6 7 Factory settings in the firmware a maintenance prompt is issued indicated by a blinking pattern in the fault color 1 s ON 3 s OFF see Chapter 17 2 Blinking pattern amp fault signaling 19 4 Cleaning NOTE Aggressive cleaning agents may damage the material n the explosion risk area only wipe the control head with a damp or anti static cloth to avoid electro static charges The customary cleaning agents and foam cleaners can be used to clean the outside We recommend checking that the cleaning agents are compatible with the housing materials and seals before using the cleaning agent Clean the control head and rinse it thoroughly with clean water to safeguard against the formation of deposits
66. in 10 C below the lowest operating temperature max 25 mg m 10 50 C 2 5 8 bar 110 l min for ventilation and deaeration aeration 110 l min supplied state 200 l min maximum typical flow rate Oy value according to definition when pressure drops from 7 to 6 bar absolute at 20 C G1 4 G1 8 Intake and exhaust air connection Working connections The intake and exhaust air can be set separately for each solenoid valve using flow restriction screws in order to be able to affect the expansion and retraction rates of the process valve see figure below Flow restriction Flow restriction screw Intake air P MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 screw Exhaust air R Hand lever of the mechanical manual control Red lever left 0 right 1 Fig 6 Flow restriction screws of the solenoid valves When setting the retraction and extension rates of the pneumatic actuator ensure that there is no con stant primary pressure during deaeration Keep in mind that the working conditions in the process valve area on the side of the product flow types pressure variations may result in changes in the set aeration and deaeration times 23 English burkert FLUID CONTROL SYSTEMS Control Head Type 8681 Technical Data 6 6 Position measuring system data Stroke range measuring range Resolution Total error
67. in only otherwise a reliable Switchover from A2 to R cannot be guaranteed only Autotune function 1 and 2 possible 15 1 2 Fluid diagram See Fig 3 Fluid diagram design for double acting actuators 2 solenoid valves NC NO on page 16 15 1 3 Activation of a double acting actuator To open or close the process valve both solenoid valves V1 and V2 must be activated simultaneously Process valve 24V 120V AS interface DeviceNet Solenoid valve V V1 V2 V1 v2 V1 v2 Open Y1 ON Y2 ON DO 1 D1 1 BitO 1 Bit1 1 Close Y1 OFF Y2 OFF D0 0 D1 Bito O Bit1 O For further information on the electrical installation and programming see the relevant chapters for the individual standard designs 24 V design 10 24 V DC Design on page 36 AS i design 11 AS Interface Design on page 43 DVN design 12 DeviceNet Design on page 52 120 V design 13 120 V AC Design on page 65 73 English burkert FLUID CONTROL SYSTEMS Control Head Type 8681 Special designs 15 2 Control head AS i with 2 external initiators 15 2 1 Anomalies This design was configured for the AS interface design This control head differs from control head Type 8681 standard AS i in the following points Connections for 2 external initiators which behave like S1 and S2 LED display No internal positions can b
68. ion 17 English Control Head Type 8681 burkert FLUID CONTROL SYSTEMS Technical Data 6 TECHNICAL DATA 6 1 Operating conditions N DANGER Danger of explosion in explosive atmosphere only in the event of a fault as zone 2 Do not expose the device to any mechanical or thermal loads that will exceed the limits described in the oper ating instructions JN WARNING Risk of injury from overheating of the control head Heating above the permitted temperature range can endanger people the device and the environment Do not expose the device to any mechanical or thermal loads that will exceed the limits described in the oper ating instructions Ambient temperature Standard version 10 55 C Explosive atmosphere Zone 2 5 55 C Degree of protection Standard version IP65 IP67 according to EN 60529 only if cables plugs and sockets have been connected correctly the hood has been sealed correctly and the adaptation to the process valve was done correctly IP69K according to IEC 40050 9 Housing seal with connected exhaust air line instead of silencer and ideally closed cable glands confirmed through IP69K Standard testing Version for use in explosive atmosphere Zone 2 IP64 according to EN 60529 and requirements EN 60079 0 2009 only if cables plugs and sockets have been connected correctly the hood has been sealed correctly and the adaptation to the process valve wa
69. isable to turn the two flow restriction screws initially into the minimum flow rate position The process valve will then initially move slowly so that you have more time to find the optimum setting during a switching operation Minimizing the flow rate Turn clockwise Maximizing the flow rate Turn counterclockwise Observing the safety guidelines activate the valve location to be set either using the system control or the manual controls Turn the flow restriction screw P counterclockwise to set the required flow rate and therefore the opening time for the process valve Tool flat blade screwdriver width lt 3 mm Deactivate valve location Turn the flow restriction screw R counterclockwise to set the required flow rate and therefore the closing time for the process valve Hand lever of the mechanical manual Flow restriction screw control Exhaust air R Red lever left 0 Flow restriction screw right 1 Intake air P Fig 12 Flow restriction screws of the solenoid valves NOTE Makes sure that all manual controls have been deactivated hand lever all the way left as pictured after the setting work has been completed If no further installation work is required close the housing following the instructions in Chapter 8 Opening and Closing the Housing If no system status is available during setting readjust the system under system operation conditions if nece
70. it diagram 24 V DC MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 41 English burkert FLUID CONTROL SYSTEMS Control Head Type 8681 24 V DC Design 10 5 2 Multi pole connection Internal cabling work is not reguired for models with multi pole connection which makes installation and start up on site considerably easier and guicker reducing the risk of leaks However you will reguire the correspondingly packaged or assembled cable sets with the following pin assignment Input and output signals to the higher level control PLC 12 pole circular plug in connector M12 x 1 0 male acc to IEC 61076 2 101 Pin 3 S1 out Pin 4 S2 out lt N gt A Pin 5 S3 out J Pin 6 S4 out N N 42 The center pins q 10 11 and 12 E Pin 7 Y1 are not used 5 E Fig 16 12 pole multi pole connection view onto the plug pins a T 2 D Pin Designation Configuration 1 24V Power supply 24 V 2 GND GND E 3 S1 out Output position S1 4 S2 out Output position S2 5 5 S3 out Output position S3 6 S4 out External initiator output S4 o E 7 Y1 Solenoid valve 1 input 8 Y2 Solenoid valve 2 input LL e 9 Y3 Solenoid valve 3 input t 10 Not used S 11 Not used 12 Not used English Control Head Type 8681 AS Interface
71. l manual control red lever Solenoid valve 3 i ay Flow restriction screw s for Cable glands M T P and R 2 per solenoid valve rear Sl N Locking groove 3x Supply pressure connection 1 P Sealing lug on lower housing part Solenoid valve 1 2 A1 Solenoid valve 2 2 A2 Solenoid valve 3 2 A3 V y J Working connections 2 A1 3 2 locking screws shoulder screws M5 No sealing function Exhaust air connection 3 R merely as protection against pulling off from the hub flange Silencer in the exhaust air connection 3 R not shown MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 Fig 1 Structure of control head Type 8681 14 sae Ea Control Head Type 8681 burkert System Description FLUID CONTROL SYSTEMS MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 5 3 2 Fluid diagrams Control head Type 8681 Fluid diagram with restriction capability for each solenoid valve Model with 3 solenoid valves Type 6524 e g for double seated valve 1 P Fig 2 Fluid diagram model 3 solenoid valves 15 English Control Head Type 8681 burkert e FLUID CONTROL SYSTEMS System Description Control head Type 8681 design for double acting actuators fluid diagram with restriction option of each solenoid valve Model with 2 solenoid valves Type 65
72. lti pole connection on a cable 8 cm length Cable gland with multi pole connection on a cable 80 cm length with multi pole connection M12 plug according with multi pole connection M12 plug according to IEC 61076 2 101 4 pole to 8 cm cable to IEC 61076 2 101 4 pole to 80 cm cable Connection left AS interface Connection left AS interface Connection right external initiator Connection right external initiator Fig 17 AS interface connection concepts 11 3 Number of connectable control heads and maximum length of the bus line The bus cable may be a maximum of 100 m long All AS interface lines of an AS interface string must be considered for the design i e even the drop lines to the individual slaves The level of expansion that is actually possible depends on the total number of all individual operating currents for each control head which are supplied via the bus at the common AS interface bus segment see example calculation MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 Standard AS interface 62 slaves AS interface version with extended addressing range A B slave In AS interface versions with extended addressing range A B slave 1 master can communicate with 62 slaves Option AS interface 31 slaves AS interface version with 31 slave addressing range In this case a maximum of 31 control heads can be connected to a bus line address range rest
73. ly lit until the position of the piston is changed The process valve can now be moved into a third defined position Depress the middle Teach In button T3 for approx 1 5 seconds The LED corresponding to this position will flash quickly 3 times during the teaching phase When this position has been saved the corresponding LED will flash continuously until the position of the piston is changed If required return control head and system to normal state switching position power supply Close the housing following the instructions in Chapter 8 Opening and Closing the Housing If the piston or the target are located outside the measuring area during the teaching phase LED 3 will flash in the defined fault color If the piston or target are outside of the measuring area no positions signals will report back i e no LEDs will be lit The Teach In buttons can be assigned to any of the positions of the piston i e T1 does not have to corre spond to the lower piston position etc MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 76 sae I ja Control Head Type 8681 Position Measuring System burkert FLUID CONTROL SYSTEMS MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 SSSSSSSSS Electronics module 24 V DC Teach In buttons T2 T3 T1 Electronics module ASI Fig 34 Teac
74. master due to the different ID codes In this case intentional replacement the current configuration must be re programmed in the AS interface master Please read the operating instructions of the used AS interface master AS i address factory setting AS i address 0 Programming data table Programming data for 62 slaves AS interface Device for A B slave addressing default device Programming data for 31 slaves AS interface optional I O configuration 7 hex 4 inputs 4 outputs see below Bit configuration table 7 hex 4 inputs 4 outputs see below Bit configuration table ID code A hex F hex Extended ID code 1 7 hex F hex Extended ID code 2 E hex F hex Profile S 7 A E S 7 FF Bit configuration table Data bit D3 D2 D1 DO Input External initiator S4 Position 3 Position 2 Position 1 Output Not used Solenoid valve 3 Solenoid valve 2 Solenoid valve 1 Parameter bit P3 P2 P1 PO Output Not used Not used Not used Not used Compare also the bit configuration for the design 15 2 Control head AS i with 2 external initiators on page 74 51 English Control Head Type 8681 burkert FLUID CONTROL SYSTEMS DeviceNet Design 12 DEVICENET DESIGN 12 1 Definition The DeviceNet is a field bus system which is based on the CAN protocol Controller Area Network It enables actuators and sensors slaves to be
75. minal strip Solenoid valve connection with status LED for Valve 1 Power supply Feedback signals 1 84 OUT Control solenoid valves Y1 3 Service interface DIP switches for color coding the LEDs Solenoid valve connections with status LED for Valves 2 3 Connection for the external initiator MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 40 Fig 14 24 V DC electronics module en Configuration ar pum Configuration 24V Power supply 24 V 24V en 0080 GND GND S4 IN External initiator input S1 OUT Output position 1 GND GND external initiator S2 OUT Output position 2 S3 OUT Output position 3 S4 OUT External initiator output Yi Solenoid valve 1 input Y2 Solenoid valve 2 input Y3 Solenoid valve 3 input English Control Head Type 8681 burkert 24 V DC Design FLUID CONTROL SYSTEMS Circuit diagram 24 V DC Electronics Position measuring system with LEDs O O O Power supply 24 V DC Ground Output position 1 0 24 V PNP 1000 Output position 2 DIP switch 0 24 V PNP for LEDs Output position 3 0 24 V PNP Output position 4 0 24 V PNP Input solenoid valve 1 0 24 V Input solenoid valve 2 0 24 V Input solenoid valve 3 0 24 V Valve actuation control LEDs for valves Service interface Valve 1 Valve 2 Valve 3 Fig 15 Circu
76. ms the outputs are set to O Setting the solenoid valves power supply using jumpers on the AS interface electronics module Via AS interface Externally Connection see Chapter 1 1 7 Electrical installation of the AS interface Power Valve p 24V Power Valve p 24V V V Jumper Jumper Fig 18 Jumper settings for power supply via AS interface or for external power supply The control head Type 8681 was developed according to the Complete Specification V 3 0 and the Profile S 7 A E and S 7 F F of the AS International Association 45 English MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 46 E Control Head Type 8681 burkert FLUID CONTROL SYSTEMS AS Interface Design Connections Multi pole connection version 1 x M16 x 1 5 cable gland SW19 with multi pole connection M12 plug according to IEC 61076 2 101 4 pole on a cable of 8 or 80 cm length for power supply and signals 1 x M16 x 1 5 cable gland SW 19 connection option for external initiator sealed with dummy plug remove these before use Power supply 29 5 31 6 V DC according to specification 21 0 31 6 V DC according to specification Power24 Input proximity switches external initiator S4 in Power supply AS interface voltage present at control head 10 Current carrying capacity sensor power supply max 30 mA Short circuit protection design DC
77. nal activation of the system and uncontrolled restart Secure system against unintentional activation Following installation ensure a controlled restart 12 8 Electrical installation DeviceNet No internal cabling work is required for any of the DeviceNet designs cable with multi pole connection which makes installation and start up on site considerably easier and quicker reducing the risk of leaks However you will require the correspondingly assembled cable sets with the pin assignments described below Multi pole connection DeviceNet The control head features a 5 pole multi pole circular plug M12 x 1 circular plug 5 pole male to a 80 cm long cable The configuration conforms to the DeviceNet specification MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 View of plug from the Pin 4 CAN H Pin 3 V front onto the pins white black Pin 5 CAN L blue Pin 1 Drain Pin 2 V shielding red Fig 24 Bus connection of DeviceNet with power supply Pin 1 2 3 4 5 Signal Shielding V V CAN H CAN L 56 sae Ea Control Head Type 8681 DeviceNet Design burkert FLUID CONTROL SYSTEMS DeviceNet electronics module Teach In buttons T1 3 Solenoid valve connection with status LED for Valve 1 DIP switches for setting the address and baud rate Status LED for device Status LED for network Power supply
78. networked with higher level controllers master The control head in the DeviceNet is a slave device according to the Predefined Master Slave Connection Set stipulated in the DeviceNet specification Polled I O Bit Strobed I O and Change of State COS are supported as I O connection variants With DeviceNet it is necessary to differentiate between cyclical or event driven high priority process messages I O Messages and acyclical low priority management messages Explicit Messages The protocol process conforms to the DeviceNet specification Release April 2010 12 2 Electrical connection option Cable gland with multi pole connection M12 plug according to IEC 61076 2 101 5 pole Connection left Voltage signals Connection right external initiator Fig 23 Connection concept DeviceNet 12 3 DeviceNet specification MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 EDS file 8681 EDS Icons 8681 ICO Baud rate 125 kBit s 250 kBit s 500 kBit s can be adjusted using DIP switches 7 8 factory setting 125 kBit s see Chapter 12 10 2 Setting the baud rate Address 0 63 via DIP switches 1 6 adjustable factory setting 63 see Chapter 12 10 1 Settings of the DeviceNet address Process data 2 static input assemblies Input from control head to DeviceNet master scanner 1 static output assembly 52 English Control Head
79. ntenance notification maintenance request Factory setting for the Service maintenance notification function not active When Service maintenance notification is activated this is indicated by a special blinking pattern see Chap 17 2 Blinking pattern amp fault signaling on page 82 The Service maintenance notification is used to observe predefined maintenance intervals which should occur either after an adjustable number of switching cycles or when a certain time has elapsed The PC service program is used to adjust the service maintenance interval number of days or switching cycles as well as activation deactivation of the Service maintenance notification function Connection to the PC is via the Service interface see Fig 9 Location of the Service interface on the elec tronics module Details on the Service menu option are described in the PC service program manual Feedback indicating that a service maintenance is required Service maintenance notification occurs when a Service maintenance notification is activated after the following counter readings Counter readings service interval Factory setting Adjustment range Switching cycle counter V1 10 000 1 255 x 1000 Switching cycle counter V2 50 000 1 255 x 1000 Switching cycle counter V3 50 000 1 255 x 1000 Operating duration 365 days 1 65 535 days The resettable operating hour and switching cycle counters are r
80. o an ON signal and if control pressure is present switches the 2 A1 output e However if the output of solenoid valve 1 is activated by the control ON signal this switching state cannot be set to an OFF signal with the manual control Caution MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 When the magnetic manual control solenoid valve 1 The peripheral fault bit is set on the AS interface design The mode is switched to Manual control active for the DeviceNet design and can be read out The feedback signals positions 1 3 external initiator function as per normal operation Always observe the safety guidelines and the system states both solenoid valves are actuated simultaneously for the design for double acting actuators see Chapter 15 84 Special designs English Control Head Type 8681 burkert Service Mode Manual Control FLUID CONTROL SYSTEMS MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 The activation of the manual control is signaled by an illuminated LED display in the fault color Blinking patterns 50 ms ON 450 ms OFF The blinking pattern 100 ms ON 100 ms OFF 3x in the fault color signals that the manual control function was disabled by the PC service program the magnetic manual control does not function in this case see Chapter 17 2 Blinking pattern amp fault signaling
81. odule and replace it with the spare part set When inserting the valve module make sure that the form seal fits correctly and fully on the lower side of the respective valve flange Valve module to do this insert the screws Torx T10 into the existing threading by turning them backwards and tighten them to a torque of 1 2 Nm Reattach the electrical connections If other connections apart from the solenoid valve connections have been removed read the corresponding chapters on the electrical installation of the respective voltage bus connection version u Close the housing following the instructions in Chapter 8 Opening and Closing the Housing 20 4 Changing the position measuring system The position measuring system consists of a housing with a PCB mounted above with LEDs and light conductor There are 4 snap fit hooks which secure the position measuring system in the lower housing part by snapping them into place PCB with LEDs and light conductor Housing of the position measuring system MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 Snap fit hooks 4x Fig 40 Position measuring system 93 English Control Head Type 8681 burkert FLUID CONTROL SYSTEMS Replacement of Cornponents and Modules DANGER Risk of injury from high pressure Before loosening lines and valves turn off the pressure and vent the lines
82. ol Head Type 8681 Maintenance troubleshooting burkert FLUID CONTROL SYSTEMS MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 Fault description Possible cause of the fault Troubleshooting Feedback signal is lost in System operation Position in the limit range of the feedback field Repeat the Teach In procedure u see Chapter 16 1 Setting the position measuring system Teach In Check the process valve end positions during operation against the end posi tions in non operative state of the system Check the pressure supply Valve output 2 A1 cannot be switched off with the control Magnetic manual control is still activated Deactivate the manual control compare Chapter 18 1 Magnetic manual contro Valve outputs cannot be switched off by the control Mechanical manual control at the solenoid valve is still activated Deactivate the mechanical manual con trols on the solenoid valves compare Chapter 18 2 Mechanical manual control Faults are signaled by means of LEDs Possible causes may vary depending on the version Please read the corresponding descrip tions of the respective communication variant in these operating instructions see Chapter 17 2 Blinking pattern amp fault signaling on page 82 No or faulty function of the process valves No electrical power supply or com munication for
83. on given to accepted safety rules and is state of the art Nevertheless dangerous situations may occur MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 11 English burkert FLUID CONTROL SYSTEMS Control Head Type 8681 Basic Safety Instructions MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 12 4 2 GENERAL INFORMATION Contact address B rkert Fluid Control Systems Sales Center Christian B rkert Stra e 13 17 D 74653 Ingelfingen Germany Tel 49 7940 10 91 111 Fax 49 7940 10 91 448 Email info de buerkert com Website www burkert com Warranty The warranty is only valid if the control head is used as intended in accordance with the specified application conditions 4 3 Information on the Internet The operating instructions and data sheets for control head type 8681 can be found on the Internet at www burkert com gt Documentation gt Operating instructions approvals gt Type search I jatelikia Control Head Type 8681 bi fa jaa urkert System Description FLUID CONTROL SYSTEMS MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 5 SYSTEM DESCRIPTION 5 1 Intended application area The control head Type 8681 has been designed for use as an actuator for pneumatically operated process valves and or for recording the switching states of these 5 2
84. on on on off off on amp 8 off off off on off off 40 off off off on off on A 9 on off off on off off 41 on off off on off on a 10 off on off on off off 42 off on off on off on E 11 on on off on off off 43 on on off on off on 8 12 off off on on off off 44 off off on on off on 8 13 on off on on off off 45 on off on on off on 14 off on on on off off 46 off on on on off on E 15 on on on on off off 47 on on on on off on 16 off off off off on off 48 off off off off on on E 17 on off off off on off 49 on off off off on on 18 off on off off on off 50 off on off off on on a 19 on on off off on off Sl on on off off on on ja 20 off off on off on off 52 off off on off on on 3 21 on off on off on off 53 on off on off on on 3 22 off on on off on off 54 off on on off on on 23 on on on off on off 55 on on on off on on 24 off off off on on off 56 off off off on on on 25 on off off on on off 57 on off off on on on 26 off on off on on off 58 off on off on on on 27 on on off on on off 59 on on off on on on 28 off off on on on off 60 off off on on on on 29 on off on on on off 61 on off on on on on 30 off on on on on off 62 off on on on on on 31 on on on on on off 63 on on on on on on 59 English burkert FLUID CONTROL SYSTEMS Control Head Type 8681 DeviceNet Design MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 60 12 10 2 Setting the
85. on opening must be tightly sealed using a dummy plug or using a cable gland SW 19 3 6 mm with a dummy plug O 5 6 mm Use of the control head in explosive atmosphere Only use cables and cable glands which are approved for the respective application area and fit the cable glands according to the respective operating instructions Close all unnecessary openings with lock screws plugs approved for explosions area Connecting a 2 wire initiator 24 V DC AS i DevNet 120 V AC V S4 IN GND Connecting a 3 wire initiator 24 V DC AS i MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 72 jafellSie Control Head Type 8681 burkert Special designs FLUID CONTROL SYSTEMS MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 15 SPECIAL DESIGNS 15 1 Control head for double acting actuators This design is configured for double acting actuators Of the two internal solenoid valves one is designed for NC mode of operation and the other for NO mode of operation 15 1 1 Anomalies This design can be configured for all electrical designs o This control head differs from control head Type 8681 standard in the following points Solenoid valve 1 NC Normally Closed Solenoid valve 2 NO Normally Open as a result safety position The flow rate from P to A2 may be restricted to 50 l m
86. ong 1200 14 W 14 W Subscriber 1 node 1 Subscriber n node n Fig 26 Network topology 12 10 Configuring the DeviceNet address baud rate 8 DIP switches are available for configuration DIP switches 1 to6 for the DeviceNet address DIP switches 7 to8 for the baud rate MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 Fig 27 Position of the DIP switches 58 sae Ea Control Head Type 8681 LL urkert DeviceNet Design bt CONTROL SYSTEMS 12 10 1 Settings of the DeviceNet address MAC ID address Medium Access Control Identifier Address MAC ID address DIP1 2 DIP 2 2 DIP 3 22 DIP 4 2 DIP 5 24 DIP 6 25 with DIP x off 0 and DIPx on 1 Table of the settings of the DeviceNet address s DIP1 DIP2 DIP3 DIP4 DIP5 DIP6 A ds DIP1 DIP2 DIP3 DIP4 DIP5 DIP6 0 off off off off off off 32 off off off off off on on off off off off off 33 on off off off off on 2 off on off off off off 34 off on off off off on 3 on on off off off off 35 on on off off off on D 4 off off on off off off 36 off off on off off on 8 5 on off on off off off 37 on off on off off on S 6 off on on off off off 38 off on on off off on 7 on on on off off off 39
87. onnection Torx T10 screw of the electronics module and store the screw in a safe place Carefully press the electronics module forwards so that the contact pins on the position measuring system are exposed Fastening screw Torx 10 Connection for the position measuring system s contact pins 4 DIP switches for color coding Plug in connector for valve V1 Plug in connectors for valves V2 and V3 Jumper for AS interface power supply Electronics module complete lower part cast ready for installation Fig 38 Electronics module here example of AS interface 91 English Control Head Type 8681 burkert FLUID CONTROL SYSTEMS Replacement of Cornponents and Modules Carefully lift the electronics module upwards Installation procedure Carefully insert the entire electronics module into the recess in the lower housing part Plug the electronics module carefully onto the contact pins for the position measuring system Refasten the electronics module with the Torx T10 screw torque 0 4 Nm Reattach the electrical connections Check DIP switch positions 4 switch block for color coding 8 switch block on DeviceNet electronics module for address and Baud rate and set the previously noted switch settings if necessary If necessary set AS interface address and jumper positions If required make set
88. ontrol head is not fixed in place by the locking screws but is merely secured against being pulled off the hub flange 7 2 4 Assembly of the pneumatic and electrical connections Pneumatic installation see Chapter 9 Pneumatic Installation Electrical installation 24 V DC see Chapter 10 24 V DC Design u AS interface see Chapter 11 AS Interface Design DeviceNet see Chapter 12 DeviceNet Design 120 V AC see Chapter 13 120 V AC Design 7 2 5 Recommended auxiliary materials Silicone grease for easy lubrication of the EPDM seals English Control Head Type 8681 burkert Opening and Closing the Housing FLUID CONTROL SYSTEMS MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 8 OPENING AND CLOSING THE HOUSING 8 1 Safety instructions A DANGER Risk of injury from high pressure in the system Before loosening lines and valves turn off the pressure and vent the lines Danger of explosion in explosive atmosphere only in the event of a fault as zone 2 Opening the hood or the housing in an explosive atmosphere is only allowed in a not energized state AN WARNING Risk of injury due to electric shock Before opening the hood and prior to reaching into the system aside from a Teach In procedure in a non explosive atmosphere switch off the power supply and secure to prevent restarting Observe applicable accident prev
89. opology of a DeviceNet system u aa enaa naamaa uu uuu u u 58 N 12 10 Configuring the DeviceNet address baud rate ee rere uu uu u u 58 3 12 10 1 Settings of the DeviceNet address u u 59 8 12 10 2 Setting the baud Tale uu a n isuu Sisswsqsasusasqsqstssqusshasasanaaqusasisasiassqum 60 12 11 Configuration of the process data u u uu uu u 60 123443 Static input assemblies nn 60 12 11 2 Static output assembly u u uu uu 61 12 12 Configuration of the d eViC sssini UU usun 61 12 12 1 Configuration of the safety position of solenoid valves during a bus error 61 124322 Configuration example Ju I toas ee ea 62 English Control Head Type 8681 burkert FLUID CONTROL SYSTEMS 12 13 Display of the status LEDs in the event of a bus error u u 63 123 1 Status of the device status LED Modules u e aamen 63 1213 2 State of bus status LED Network teemana manaamaan 64 13 120 V AC DESIGN u u u 65 13 1 Electrical connection OptlOrs U T LU U u l LL UU 65 13 2 Electrical da uuu A E Mn 65 TBS DESIAN AID t 66 13 4 Safety Ui g odi o pem 67 13 5 Electrical installation 7 start up certes aaa aN 68 14 CONNECTION OF AN EXTERNAL INITIATOR U n 71
90. ply to application planning and operation of the device 10 English Control Head Type 8681 burkert Basic Safety Instructions FLUID CONTROL SYSTEMS NOTE Electrostatic sensitive components modules The device contains electronic components which react sensitively to electrostatic discharge ESD Contact with electrostatically charged persons or objects may be hazardous to these components In the worst case scenario they will be destroyed immediately or will fail after start up Observe the requirements in accordance with EN 61340 5 1 to minimize or avoid the possibility of damage caused by sudden electrostatic discharge Also ensure that you do not touch electronic components when the supply voltage is on NOTE Risk of damage to property Do not connect any mechanically rigid connection parts in particular those with long lever arms as such con nections could generate torques that might damage the control head Do not supply the medium connections of the system with liquids or aggressive or flammable media Do not subject the housing to mechanical loads e g by placing objects on it or standing on it Do not make any external changes to the housings of the device Do not paint housing parts or screws Only use compatible cleaning agents for cleaning the securely closed control head and always rinse thoroughly with clean water Control head Type 8681 was developed with due considerati
91. ressure and vent the lines Danger of explosion in explosive atmosphere only in the event of a fault as zone 2 Opening the hood or the housing in an explosive atmosphere is only allowed in a not energized state N WARNING Risk of injury due to electric shock Before reaching into the system except for the Teach In procedure in a non explosive atmosphere switch off the power supply and secure it to prevent restarting Observe applicable accident prevention and safety regulations for electrical equipment Risk of injury due to improper maintenance work Maintenance work may be carried out by authorized technicians only and with the appropriate tools Risk of injury from unintentional activation of the system and uncontrolled restart Secure system against unintentional activation Following maintenance ensure a controlled restart NOTE IP65 IP67 protection MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 During all work steps make sure that IP65 IP67 protection is once again ensured for the control head when used as intended Opening and closing the control head During all work which requires opening and closing of the control head also observe the notes and comments u in Chapter 8 Opening and Closing the Housing 90 English Control Head Type 8681 burkert Replacement of Components and Modules FLUID CONTROL SYSTEMS
92. rical connection options for AS interface I l u uuu uu uu u u 44 11 3 Number of connectable control heads and maximum length of the bus line 44 HE MI egc c 45 1155 Design GG rec X 47 ju RETMIVHLdeppcMee 48 11 7 Electrical installation of the AS interface 49 11 8 Programming data ara ernennen ER eed 51 o jEalezzsebiice 52 E EMEND me SS 52 12 2 Electrical connection Option uuu Uu aa a aa iiia 52 12 3 DeviceNet specification LL I LIU LLL LLL LLULLU 52 3 12 3 1 Total line length and maximum line length according to DeviceNet specification 53 12 3 2 Drop line VS Ti UI sas LLL u u mua aaa aaa adiada ia i ai 53 z 12 4 Electrical data 54 3 12 5 Safety position if the b s Tails ecc u uuu uuu 54 E 12 6 Design GN RET 55 E 12 7 EBDLPMILE 56 E 12 8 Electrical installation DeviceNet 56 12 9 Network t
93. riction 44 English Control Head Type 8681 burkert AS Interface Design FLUID CONTROL SYSTEMS MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 Table of calculated line length of the control head versions When designing the system consider the length of the round cable leading directly to the control head see fol lowing table and example calculation Model ES K Multi pole cable 8 cm 0 3m Multi pole cable 80 cm 1 0m Example for multi pole connection with 8 cm cable When using 62 control heads the AS interface cable harness may still be 100 m 62 0 3 m 81 4 m long If the calculated line length of 100 m were to be exceeded a commercially available AS interface repeater may be used as needed Observe maximum power supply via certified AS interface power supply units x 8 A For details see AS interface specification Observe the optional design AS Interface with External Power Supply to reduce the load on the AS interface bus segment see Chapters 11 4 and 11 7 Use cables according to the AS interface specification If other cables are used the maximum cable length will change 11 4 Electrical data Comments notes Outputs from master perspective O to 3 solenoid valves Inputs from master perspective 3 binary feedback signals and 1 external initiator Watchdog If bus communication fails for more than 50 to 100
94. rsion F Status RL released freigegeben printed 19 01 2015 o 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 English Control Head Type 8681 burkert Authorized Use FLUID CONTROL SYSTEMS MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 2 AUTHORIZED USE Incorrect use of the control head Type 8681 may be dangerous to people nearby equipment and the environment The control head has been designed for use as actuation of pneumatically operated process valves and or for recording the switching states of these Use according to the authorized data operating conditions and conditions of use specified in the contract documents and operating instructions These are described in Chapter 6 Technical data In view of the large number of application options check and if necessary test prior to installation whether the control head is suitable for the specific application case Should you have any questions please contact your B rkert Service Center Use the device only in conjunction with third party devices and components recommended and authorized by B rkert Any unauthorized reconstructions and changes to the control head are prohibited for safety reasons Correct transportation correct storage and installation as well a
95. ructions in Chapter 8 Opening and Closing the Housing Assemble connection cables for signals and power supply as well as for the external initiator where necessary in observance of the rules of technology Insert cables through the respective cable glands into the interior of the housing Connect the wires to the connection terminals according to the connection configuration described in Fig 14 o If required secure the cable with a cable clip Close the housing following the instructions in Chapter 8 Opening and Closing the Housing NOTE Ensure IP protection To ensure IP protection the union nuts of the cable glands must be tightened in accordance with the cable Sizes or dummy plugs used approx 1 5 Nm If no external initiator is used the right hand connection opening must be tightly sealed using a dummy plug or using a cable gland SW 19 3 6 mm with a dummy plug O 5 6 mm 39 English burkert FLUID CONTROL SYSTEMS Control Head Type 8681 24 V DC Design NOTE Use of the control head in explosive atmosphere Only use cables and cable glands which are approved for the respective application area and fit the cable glands according to the respective operating instructions Close all unnecessary openings with lock screws plugs approved for explosions area 24 V DC Electronics module terminal strip configuration Teach In buttons T1 3 Ter
96. s Example 1 3 valves are activated simultaneously one position is reported state for 200 ms Fu Pa 3x Passi dx Pep 5 44 W 144W 3x1 0W 1x1 0 W or Lad le 3x acon 1x lies 228 mA 60 mA 3x42mA 1x42mA Example 2 3 valves have been activated simultaneously one position is reported persistent state Pd Fu T 3 X ane T 1 X Pito 4 24W 1 4AW 3x0 6W 1x1 0 W or lid ley 3 X Nive 1 X ley 177mA 60 mA 3x25mA 1x42mA o When using an external initiator its power requirement should be added 55 English Control Head Type 8681 burkert FLUID CONTROL SYSTEMS DeviceNet Design 12 7 Safety instructions A DANGER Danger of explosion in explosive atmosphere only in the event of a fault as zone 2 Opening the hood or the housing in an explosive atmosphere is only allowed in a not energized state AN WARNING Risk of injury due to electric shock Before reaching into the system except for the Teach In procedure in a non explosive atmosphere switch off the power supply and secure it to prevent restarting Observe applicable accident prevention and safety regulations for electrical equipment When setting the position measuring system Teach In do not contact any live components Risk of injury from improper installation nstallation may be carried out by authorized technicians only and with the appropriate tools Risk of injury from unintentio
97. s and valves turn off the pressure and vent the lines Danger of explosion in explosive atmosphere only in the event of a fault as zone 2 Opening the hood or the housing in an explosive atmosphere is only allowed in a not energized state AN WARNING Risk of injury due to electric shock Before reaching into the system except for the Teach In procedure switch off the power supply and secure it to prevent reactivation Observe applicable accident prevention and safety regulations for electrical equipment Risk of injury due to improper disassembly Disassembly work may be carried out by authorized technicians only and with the appropriate tools 21 2 Dismantling the control head Type 8681 o Prior to starting with the work check the system status Procedure Cable gland versions Open the housing following the instructions in Chapter 8 Opening and Closing the Housing Uninstall the electrical connections at the terminal strip Close the housing following the instructions in Chapter 8 Opening and Closing the Housing Loosen the pneumatic connections for a detailed description see Chapter 9 Pneumatic Installation MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 Loosen the locking screws shoulder screws M5 Pull control head upwards and off the adaptation Multi pole connection versions Remove the multi pole plugs
98. s careful operation and maintenance are essential for reliable and problem free operation For connecting the control head use line installations that do not cause any mechanical stresses Use the device only as intended 2 1 Export restrictions If exporting the system device observe any existing restrictions English Control Head Type 8681 burkert FLUID CONTROL SYSTEMS Basic Safety Instructions 3 BASIC SAFETY INSTRUCTIONS These safety instructions do not make allowance for any contingencies and events which may arise during the assembly operation and maintenance of the devices local safety regulations the operator is responsible for observing these regulations also in relation to the instal lation personnel DANGER Danger high pressure Before loosening lines and valves turn off the pressure and vent the lines Danger of explosion in explosive atmosphere only in the event of a fault as zone 2 Opening the hood or the housing in an explosive atmosphere is only allowed in a not energized state Secure the housing with a lead seal to prevent it from being opened without a tool Activating the DIP switches on the PCB using the service interface and the Teach buttons is not permitted in an explosive atmosphere Layers of dust on the housing may not exceed 5 mm Lint conductive and non conductive dust particles are allowed The inside of the housing must not be dirt
99. s done correctly 6 2 Conformity with the following standards MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 The control head conforms to the EC Directives according to the EC Declaration of Conformity The applied standards which are used to demonstrate compliance with the EC Directives are listed in the EC Declaration of Conformity and or the EC type test certificate These are available from B rkert The specifications on the respective rating plate apply to the respective control head The symbols on the rating plate indicate the applicable directives or approvals 18 English Control Head Type 8681 Technical Data burkert Pressure Equipment Directive 94 9 EC Ignition protection type Dust ATEX category 3D Ex tD A22 T135 C or Ex tc IIIC T135 C Gas ATEX category 3G Ex nA IIC T4 or Ex nAc IIC T4 FM Factory Mutual NI 2 ABCD T5 5 C lt Ta lt 55 C IP64 cables and cable glands are not part of the FM approval of the device and are lt gt therefore not fitted at the factory c UL us Underwriters Laboratories Canada and USA UL 61010 1 AND CSA C22 2 NO 61010 1 Restrictions Application area 0 to 55 C Indoor use power supply with class 2 power supply unit 6 3 Rating plate specifications i Steuerkopf 8681 Line 1 Fi put 24V DC MV3 Line 2 W P2 5 8 bar Line 3 M 3 Tamb 10 55 C C Line 4 E 4 S N 1210 Line 5 i Bi 00196413 WSXMM
100. sem bly Control Head Type 8681 re ASSEMBLY 7 1 Safety instructions N DANGER Risk of injury from high pressure in the system Before loosening lines and valves turn off the pressure and vent the lines AN WARNING Risk of injury due to electric shock Before reaching into the system except for the Teach In procedure in a non explosive atmosphere switch off the power supply and secure it to prevent restarting Observe applicable accident prevention and safety regulations for electrical equipment Risk of injury from improper assembly Assembly may only be carried out by authorized technicians and with the appropriate tools Risk of injury from unintentional activation of the system and uncontrolled restart Secure system against unintentional activation Following assembly ensure a controlled restart 7 2 Assembly of the control head The control head can be installed in any installation position preferably with the hood face up The control head should be installed such that layers of dust thicker than 5 mm cannot form meaning that such should be ensured through correspondingly regular cleaning When used in explosive atmosphere Zone 2 the devices must be installed in a protected installation location according to IEC EN 60079 0 7 2 1 Hub flange WARNING MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 Risk of injury from improper as
101. sembly Do not improperly stress the control head Do not apply any leverage effect on the head and do not climb on it When sealing the flange from the outside to the inside make sure that the inflow of cleaning agent is consid ered and that the actuator space of the process valve towards the control head is sealed For the installation of the control head Type 8681 to a process valve you will require a process valve specific hub flange as an adapter The hub flange must be adapted to the design of the process valve and produce the mechanical connection E between the process valve and the control head The axial fastening is done by two locking screws shoulder English Control Head Type 8681 bi s japsi urkert Assem bly FLUID CONTROL SYSTEMS MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 screws M5 which engage in the middle groove of the hub flange protection against pulling off The control head can radially slide into any position in 360 arc seamlessly The hub flange and non ferromagnetic piston rod with the target that is used to record the position must comply with the specifications with regard to material and stability see Chapter 6 6 Position measuring system data Control head Target made of 1 4021 Piston rod max O 30 Locking screws 2x Hub flange O rings Process valve Fig 10 Schematic diagram
102. sign aid Design aid for supply of the valves via the AS i bus Power consumption of the electronics P 10W or 33mA at 30 5 V EI EI Power consumption of a valve during activation 200 ms 09W or l 30mA at 30 5 V Pison Valve ON Power consumption of a valve after reduction P 0 6W or l 20mA at 30 5 V Valve Valve MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 Power consumption of an optical position report P 10W or 33mA at 30 5 V LED LED For the design of the maximum line lengths observe Chapter 11 3 Number of connectable control heads and maximum length of the bus line 47 English burkert FLUID CONTROL SYSTEMS Control Head Type 8681 AS Interface Design o Also if several control head valves were to be opened simultaneously via the bus the switch signal will be sent staggered to the valves Only one 0 9 W valve will ever be recorded Calculation examples Example 1 3 valves are activated simultaneously one position is reported state for 200 ms Pisis Pa dx Pa oN 2x Piva 1x Pig 41W 1 0 W 1x0 9 W 2x0 6 W 1x 1 0 W or las la dx lites ON 2x 1x les 136 mA 33mA 1x30mA 2x20mA 1x33 mA Example 2 3 valves have been activated simultaneously one position is reported persistent state Poiss Pa 3x Puas dx Pies 38W 1 0 W 3x0 6 W
103. ssary Observe the safety guidelines during this 35 English Control Head Type 8681 burkert FLUID CONTROL SYSTEMS 24 V DC Design 10 24V DC DESIGN 10 1 Electrical connection options The following connection concepts are available for the electrical connection of the control head Cable gland Cable gland with multi pole connection M12 plug according to IEC 61076 2 101 12 pole Connection left Voltage signals Connection left Voltage signals Connection right external initiator Connection right external initiator Fig 13 Connection concepts 24 V DC 10 2 Electrical data Power supply 12 28 V DC residual ripple 10 Connections Cable gland variant 1 x M16 x 1 5 cable gland SW22 for power supply and signals only for transportation safety device sealed with dummy plugs remove these before use for cable diameter 5 10 mm for wire cross sections 0 14 1 5 mm 1 x M16 x 1 5 cable gland SW19 connection option for external initiator sealed with dummy plug remove these before use MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 Multi pole connection variant 1 x M16 x 1 5 cable gland SW22 with multi pole connection M12 plug according to IEC 61076 2 101 12 pole on a cable of 8 cm length for power supply and signals 1 x M16 x 1 5 cable gland SW19 connection option for external initiator sealed with dummy plug
104. ted 1 position reported back by LED display no external initiator Integrated short circuit protection sae Ea Control Head Type 8681 burkert AS Interface Design FLUID CONTROL SYSTEMS NOTE If all 3 solenoid valves are simultaneously controlled via the AS interface the electronics will activate the valves sequentially with a 200 ms time delay to protect the bus from overloads Please observe the notes on power requirement and maximum expansion stage of the AS interface network contained in Chapter 77 3 Number of connectable control heads and maximum length of the bus line and in the AS i specifications where applicable External power supply for solenoid valves External power supply 19 2 V DC to 31 6 V DC The power supply unit must include a secure disconnect in accordance with IEC 364 4 41 It must conform to the SELV standard The ground potential must not have a ground connection Max power consumption from external power supply for outputs solenoid valves without integrated current limiting lt 110 mA at 24 V DC Max power consumption from AS i for inputs and display lt 150 mA type Integrated short circuit protection Please follow the instructions on power requirement and maximum expansion stage of the AS interface network in Chapter 11 3 Number of connectable control heads and maximum length of the bus line and in the AS interface specifications where applicable 11 5 De
105. th of all drop lines in Maximum length the network 125 kbaud 156 m 250 kbaud 6 m for all baud rates 78 m 500 kbaud 39 m English 53 Control Head Type 8681 burkert FLUID CONTROL SYSTEMS DeviceNet Design MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 54 12 4 Electrical data Connections Multi pole 1xM16 x 1 5 cable gland SW22 with multi pole connection M12 plug according to IEC 61076 2 101 5 pole on a cable of 80 cm length for DeviceNet bus and power supply 1 x M16 x 1 5 cable gland SW19 connection option for external initiator sealed with dummy plug remove these before use Power supply 11 25 V DC according to specification Max power consumption 200 mA at 24 V DC Input proximity switches external initiator S4 in Power supply via DeviceNet power supply 10 Current carrying capacity sensor supply max 30 mA Short circuit protection Design DC 2 and 3 wire Normally open contact PNP output Input current 1 signal laeso gt 6 5 MA limited internally to 10 mA Input voltage 1 signal U gt 10V Input current O signal Sensor lt 4 mA Input voltage O signal U 9 V Inputs from master perspective binary or analog feedback signals The recovery of the 3 valve positions reported back in binary format or the analog position signal is described in Chapter 16 on page 75 Outputs from master perspective soleno
106. the target to be used are synchronized with the sensitivity of the system The measurement precision is determined by the ferromagnetic properties of the target and all other parts in the system Ideally materials are used which do not have any ferromagnetic properties The switching positions of the process valves are reported to the actuator by feedback signals from the sol derless position measuring system Connection to the control head is done by means of a simple adaptation to the process valve s piston Stroke range feedback signals teach in function The recordable stroke range is between O 80 mm 3 discrete feedback signal are evaluated Position 1 discrete S1OUT signal Position 2 discrete S2OUT signal Position 3 discrete S3OUT signal 3 Teach In buttons have been provided for comparison with the actual stroke range see Chapter 16 1 Setting the position measuring system Teach In The switching positions for the position measuring system can be determined with these Teach In buttons or by means of the PC service program connection via the Service interface on the electronics module A discrete external feedback signal standard proximity switch can also be processed S4IN S40UT o If an explosive atmosphere is present the housing may not be opened when voltage is present For a detailed description of the electrical installation see Chapter 10 24 V DC Design or Chapter 11 AS Interface
107. tings again read out by the PC service program using the PC service program Perform Teach In procedure see Chapter 16 1 Setting the position measuring system Teach In o Be sure to work carefully and cautiously so that the electronics are not damaged Close the housing following the instructions in Chapter 8 Opening and Closing the Housing 20 3 Changing the valves According to the design O to 3 valve modules have been installed in the control head The valves have been designed with the flow restriction equipment for intake and exhaust air and must be installed as a valve module o Note Disassemble assemble the valves in upright position oth erwise there is a risk that the non return valve will fall out Valve module from above low restriction screws MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 Torx screws T10 tightening torque 1 Nm Fig 39 Valve module Procedure 92 sae Ea Control Head Type 8681 burkert Replacement of Components and Modules FLUID CONTROL SYSTEMS Open the housing following the instructions in Chapter 8 Opening and Closing the Housing If necessary mark the electrical connections to ensure correct assignment during reinstallation Loosen the electrical connections Loosen the connecting screws Torx T10 for the corresponding valve module Take out the valve m
108. u 96 PACKAGING AND TRANSPORT aneu22enn2ennnunnennazunnunnnunnennanennzunnnnnnunnnunnnunnennnnennennnnnnnunnnennnunnnnnnnunnnnnnnnnennnnennnunnnnnnennnnnnnennnunne 97 STORAGE uu TONER FENN 97 DISPOSAL u unus aa aaa iadaaa adadad iaaa a aaa Aaa aia aa aaia 97 English Control Head Type 8681 burkert FLUID CONTROL SYSTEMS Operating Instructions 1 OPERATING INSTRUCTIONS The operating instructions describe the entire life cycle of the device Keep these instructions in a location which is easily accessible to every user and make these instructions available to every new owner of the device WARNING The operating instructions contain important safety information Failure to observe these instructions may result in hazardous situations The operating instructions must be read and understood Warns of an immediate danger Failure to observe the warning will result in a fatal or serious injury WARNING Warns of a potentially dangerous situation Failure to observe the warning may result in serious injuries or death CAUTION Warns of a possible danger Failure to observe this warning may result in a moderate or minor injury NOTE Warns of damage to property Failure to observe the warning may result in damage to the device or the equipment MAN 1000138479 EN Ve
109. ual position 4 2 3 Byte 0 Bit 0 Position S1 Bit 1 Position S2 Bit 2 Position S3 Bit 3 Position S4 Bit 4 7 not used Byte 1 POS in mm sae lia Control Head Type 8681 burkert DeviceNet Design FLUID CONTROL SYSTEMS MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 The addresses listed in the table above Static input assemblies can be used as path data for the Produced Con nection Path attribute of an I O connection Nevertheless by using this address data the attributes combined in the assemblies can also be accessed acycli cally via Explicit Messages 12 11 2 Static output assembly Name Address of data attribute of the Format of the data attribute assemblies for read access Value 0 OFF Class instance attributes Value 1 ON Solenoid valves 1 3 4 21 3 Byte 0 Bit 0 SV1 Bit 1 MV2 Bit 2 MV3 Bit 3 7 not used The address listed in the table above Static input assembly can be used as path data for the Produced Connection Path attribute of an I O connection Nevertheless by using this address data the attributes combined in the assemblies can also be accessed acycli cally via Explicit Messages 12 12 Configuration of the device 12 12 1 Configuration of the safety position of solenoid valves during a bus error The valve safety position and safety module attributes can be used to configure the sol
110. uctor NO or NC factory setting NO PNP output gt 6 5 mA limited internally to 10 mA Sensor Sensor gt 10V Sensor lt 4mA lt 5V Sensor U gt 10 V max 24 VDC 10 U lt 5V gt 30 kOhm 37 English Control Head Type 8681 burkert FLUID CONTROL SYSTEMS 24 V DC Design 10 3 Design aid Power consumption of the electronics P 07W or 30mA at 24V EI EI Power consumption of a valve during activation 200 ms P 09W or Valve ON 38mA at 24V Valve ON Power consumption of a valve after reduction 0 6W or l 25mA at 24V Valve Valve Power consumption of an optical position report rien 10W or Is 42mA at 24V e q Also if several control head valves were to be opened simultaneously the switch signal will be sent stag gered to the valves Only one 0 9 W valve will ever be recorded 5 s Calculation examples T 2 Example 1 D 3 valves are activated simultaneously one position is reported state for 200 ms Prosa Pa 1x P ave ON 2x Pavo 1x Prep o 2 3 8 W 0 7 W 1x0 9 W 2x0 6W 1x1 0W or z lia I 1x lison 2x lie 1x ligo 2 160mA 30mA 1x38mA 2x25mA 1x42mA amp LL E 2 Example 2 S 3 valves have been activated simultaneously one position is reported persistent state n P oisi Pa ui 3 X Pii T 1 X Pien 35W 0 7 W 3x0 6W 1x1 0 W 8
111. ust be connected Danger of explosion in explosive atmosphere only in the event of a fault as zone 2 Opening the hood or the housing in an explosive atmosphere is only allowed in a not energized state 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 uncontrolled restart Secure system against unintentional activation Following installation ensure a controlled restart 67 English Control Head Type 8681 burkert FLUID CONTROL SYSTEMS 1 20 V AC Design 13 5 Electrical installation start up AN DANGER Risk of injury due to electric shock 110 130 V AC Before reaching into the system except for the Teach In procedure in a non explosive atmosphere switch off the power supply and secure it to prevent restarting Observe applicable accident prevention and safety regulations for electrical equipment When setting the position measuring system Teach In do not contact any live components Procedure u Open the housing following the instructions in Chapter 8 Opening and Closing the Housing Assemble connection cables for signals and power supply as well as for the external initiator where necessary in observance of the rules of technology Insert cables through the respective cable gl
112. uuu u uu uuu uuu 82 17 3 Signal Priorite S siiin aaa UR ma npa denn aE 83 English Control Head Type 8681 FLUID CONTROL SYSTEMS MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 18 19 20 21 22 23 24 SERVICE MODE MANUAL CONTROL u u u u u uuu uuu uuu 84 18 1 Magnetic manual control une 84 18 2 Mechanical manual control u u uuu uuu uuu 85 MAINTENANCE TROUBLESHOOTING u unn sa 86 19 1 Safety instructions LL LU 86 19 2 Safety poSIfi NSux u u l UKA 87 19 3 Maintenance service III III saus tea nan ent nau onpa nsa da aavan naa van nennen 88 19 4 Cleaning ecce cR 88 19 5 MaIf CIRISu III l aqa A 88 REPLACEMENT OF COMPONENTS AND MODULES 90 20 1 Safety Instructions sisia m uman aaa i aasia a aaa aaia 90 20 2 Changing the electronics module uuu u uu uuu uu u 91 20 3 Changing the Valves ssis aa aaa a aan ame SONNAN 92 20 4 Changing the position measuring system u u u uuu uuu 93 SHUTDOWN 96 21 1 Safety instructions aaa ae nn en 96 21 2 Dismantling the control head Type 8681 u u uu uuu uu
113. valves via the bus External power supply to the solenoid valves Power Valve Q 24V Power Valve Q 24V V V Jumper Jumper Fig 20 Jumper setting on AS i electronics module Power supply to the solenoid valves via the bus or externally The cable with multi pole connection version is especially suited for direct and flexible connection to the AS interface cable harness using the ribbon cable terminal M12 branch circuit VA branch circuit that is optionally available English burkert FLUID CONTROL SYSTEMS Control Head Type 8681 AS Interface Design MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 50 The optional ribbon cable terminal contacts the AS interface cable harness by means of penetration technology which allows installation by clipping in the AS interface cable harness without cutting and without removing insulation Screw 2x Branch circuit M12 plug in connector Procedure Insert cable harness Tighten the screws Loosen the thread forming screws slightly and position them on the existing threaded hole and screw in Open the ribbon cable terminal loosen screws and remove cover Close ribbon cable terminal again Fig 21 Optional ribbon cable terminal for AS interface cable harness AS interface electronics module LED status displays LED status displays Power and Fault 24N GND
114. y When wiping the control head use a damp or anti static cloth in the explosion risk area to prevent electrostatic charges Use only cables and cable glands which have been approved for the respective application area and which have been screwed into place according to the respective installation instructions Close all unnecessary openings with locking screws sealing plugs approved for explosions area WARNING Risk of electric shock Before reaching into the system except for the Teach In procedure in a non explosive atmosphere switch off the power supply and secure it to prevent restarting Observe applicable accident prevention and safety regulations for electrical equipment General hazardous situations To prevent injuries Ensure that the system cannot be activated unintentionally MAN 1000138479 EN Version F Status RL released freigegeben printed 19 01 2015 Installation and maintenance work as well as operator control actions may be carried out by authorized and qualified technicians only and with the appropriate tools Do not make any unauthorized internal or external changes to the device After an interruption in the electrical or pneumatic supply ensure that the process is restarted in a defined or controlled manner The device may be installed and operated only when in perfect condition and in consideration of the operating instructions The general rules of technology ap

Operating Instructions Type 8681

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