Type 8694 Positioner Type 8694 ABLE OF ONTENTS OPERATING INSTRUCTIONS ................................7 Symbols ......................................7 Definition of term / abbreviation ...........................7 AUTHORIZED USE .....................................8 Restrictions ....................................8 BASIC SAFETY INSTRUCTIONS ..............................9 GENERAL INFORMATION ................................10 Contact address ..................................10 Warranty ....................................10 Trademarks ....................................10 Information on the internet ............................10 SYSTEM DESCRIPTION ................................11 Intended application area ...............................11 Function of the positioner and combination with valve types ..............11...
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Type 8694 Mechanical data ...................................20 Pneumatic data ..................................21 Type labels ....................................21 6.7.1 Type label standard ..........................21 6.7.2 UL type label ............................22 6.7.3 UL additional label ..........................22 Electrical data ..................................22 6.8.1 Electrical data without bus control 24 V DC ................22 6.8.2 Electrical data with AS-Interface bus control ................23 Factory settings of the positioner ..........................24 CONTROL AND DISPLAY ELEMENTS ...........................25...
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Type 8694 10.2 Electrical installation with circular plug-in connector ..................46 10.2.1 Designation of the contacts Type 8694 ..................46 10.2.2 Connection of the positioner Type 8694 ..................47 10.3 Electrical installation with cable gland ........................48 AS-INTERFACE INSTALLATION ..............................51 11.1 AS-Interface connection ..............................51 11.2 Maximum length of the bus line ..........................51 11.3 Technical data for AS-Interface PCBs ........................51 11.4 Programming data ................................52...
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Type 8694 13.2 Auxiliary functions .................................. 68 DIR.ACTUATOR - 13.2.1 Effective direction of the actuator ....................68 SPLITRANGE - 13.2.2 Signal split range ..........................69 X.LIMIT - 13.2.3 Limiting the mechanical stroke range ....................70 X.TIME - 13.2.4 Limiting the control speed ........................71 X.CONTROL - 13.2.5 Parameterization of the positioner ....................72...
Type 8694 Operating instructions OPERATING INSTRUCTIONS The operating instructions describe the entire life cycle of the device. Keep these instructions in a location which is easily accessible to every user, and make these instructions available to every new owner of the device. Important safety information.
Type 8694 Authorized use AUTHORIZED USE Non-authorized use of the positioner Type 8694 may be a hazard to people, nearby equipment and the environment. The device is designed to be mounted on pneumatic actuators of process valves for the control of media. ▶...
Type 8694 Basic safety instructions BASIC SAFETY INSTRUCTIONS These safety instructions do not make allowance for any • contingencies and events which may arise during the installation, operation and maintenance of the devices. • local safety regulations – the operator is responsible for observing these regulations, also with reference to the installation personnel.
D-74653 Ingelfingen Tel. + 49 (0) 7940 - 10 91 111 Fax + 49 (0) 7940 - 10 91 448 E-mail: info@burkert.com International Contact addresses can be found on the final pages of the printed operating instructions. And also on the Internet at: www.burkert.com...
Type 8694 System description SYSTEM DESCRIPTION Intended application area The positioner Type 8694 is designed to be mounted on pneumatic actuators of process valves for the control of media. Function of the positioner and combination with valve types Positioner Type 8694 is an electropneumatic position controller for pneumatically actuated control valves with single-acting actuators.
Type 8694 System description The position of the actuator is regulated according to the position set-point value. The position set-point value is specified by an external standard signal. Pneumatically actuated piston actuators and rotary actuators can be used as an actuator. Single-acting actuators are offered in combination with the positioner.
Type 8694 System description Structure of the positioner The positioner Type 8694 consists of the micro-processor controlled electronics, the position measuring system and the control system. The device is designed using three-wire technology. The positioner is operated via 2 keys and a 4-pole DIP switch.
Type 8694 System description 5.4.2 Features • Models for single-acting valve actuators. • Position measuring system Contactless and therefore wear-free position measuring system. • Microprocessor-controlled electronics for signal processing, control and valve control. • Control module The device is controlled via 2 buttons and a 4-pole DIP switch. 2x 2-colored LEDs indicate different statuses of the device.
Type 8694 System description 5.4.3 Function diagram of the positioner with single-acting actuator The illustrated function diagram describes the function of the positioner (Type 8694). external position set-point value Position controller Actual Positioner Control system position 1: Aeration valve Control system 2: Bleed valve Pressure Position...
Type 8694 System description Type 8694 positioner (position controller) The position measuring system records the current position (POS) of the pneumatic actuator. The position controller compares this actual position value with the set-point value (CMD) which is definable as standard signal. In case of a control deviation (Xd1), a pulse-width modulated voltage signal is sent to the control system as a manipu- lated variable.
Type 8694 System description 5.5.2 Functions of the position controller software Functions I • Activation via DIP switches • Parameter setting via communications software Additional function Effect Valve closes tight outside the control range. Specification Sealing function of the value (as %), from which the actuator is completely deaerated (when 0 %) or aerated (when 100 %) CUTOFF (see chapter “7.4 Function of the DIP switches”).
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Type 8694 System description Functions II • Activation and parameter setting via communications software Additional function Effect Standard signal for set-point value Select set-point value standard signal INPUT Effective direction of the actuator Assignment of the aeration status of the actuator chamber to the actual position.
Type 8694 System description Interfaces of the positioner Input for position Analog set-point value position feedback 4 – 20 mA (optional) Positioner 0 – 20 mA Binary input 24 V DC Communications Operation interface Or optional bus connection AS interface Default setting Figure 6: Interfaces...
Type 8694 Technical data TECHNICAL DATA Conformity In accordance with the EU Declaration of conformity, the positioner Type 8694 is compliant with the EU Directives. Standards The applied standards on the basis of which compliance with the EU Directives is confirmed are listed in the EU type examination certificate and/or the EU Declaration of Conformity.
Type 8694 Technical data Pneumatic data Control medium neutral gases, air Quality classes in accordance with ISO 8573-1 Dust content Quality class 7 max. particle size 40 µm, max. particle density 10 mg/m³ Water content Quality class 3 max. pressure dew point - 20 °C or min.
Type 8694 Technical data 6.7.2 UL type label Example: Type; Features of the type code applicable to UL and ATEX Control function; pilot valve; Supply voltage pilot valve 8694 -E3-...-0 PU02 Single act Pilot 3.0 24V Max. operating pressure Pmax 7 bar Tamb -10 - +55 °C Max.
Type 8694 Technical data Analogue position feedback max. load 560 Ω for current output 0/4 – 20 mA Binary input 0 – 5 V = log “0”, 12 - 30 V = log “1” inverted input in reverse order Communications interface Direct connection to PC via USB adapter with integrated interface driver, communication with communications software, see “Table 34: Accessories”.
Type 8694 Technical data Factory settings of the positioner Functions can be activated via DIP switches: Function Parameter Value CUTOFF Sealing function below Sealing function above 98 % CHARACT Select characteristic FREE DIR.CMD Effective direction set-point value rise Table 4: Factory settings - Functions I Functions can be activated via communications software: Function...
Type 8694 Control and display elements CONTROL AND DISPLAY ELEMENTS The following chapter describes the operating statuses as well as the control and display elements of the positioner. Further information on the operation of the positioner can be found in the chapter entitled “12 Start-up”. Operating status AUTOMATIC (AUTO) Normal controller mode is implemented and monitored in AUTOMATIC operating status.
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Type 8694 Control and display elements The positioner features 2 buttons, 4-pole DIP switches and 2x 2-colored LEDs as a display element. NOTE! Breakage of the pneumatic connection pieces due to rotational impact. ▶ When unscrewing and screwing in the body casing or transparent cap, do not hold the actuator of the pro- cess valve but the connection housing.
Type 8694 Control and display elements Configuration of the keys The configuration of the 2 keys varies depending on the operating status (AUTOMATIC / MANUAL). The description of the operating statuses (AUTOMATIC / MANUAL) can be found in the chapter entitled “7.1 Operating status”.
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Type 8694 Control and display elements MANUAL operating status (DIP switch 4 set to ON): Function Aerate (manually open / close the actuator) Deaerate (manually open / close the actuator) Table 6: Configuration of the keys for MANUAL operating status AUTOMATIC operating status (DIP switch 4 set to OFF): Function Press for 5 seconds to start the X.TUNE function...
Type 8694 Control and display elements Function of the DIP switches 1 2 3 4 NOTE! Breakage of the pneumatic connection pieces due to rotational impact. ▶ When unscrewing and screwing in the body casing or transparent cap, do not hold the actuator of the pro- cess valve but the connection housing.
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Type 8694 Control and display elements Information about the communications software: The switching position of the DIP switch has priority over the settings via the communications software. If the values of the sealing function (CUTOFF) or the correction characteristic (CHARACT) are changed via the communications software, the corresponding function must be active (DIP switches set to ON).
Type 8694 Control and display elements Display of the LEDs Version 1 Version 2 LED 1 LED 2 LED 1 Display of mode statuses (green / AUTO, MANUAL, red) X.TUNE and FAULT LED 2 Display of the actuator status (green / (open, closed, opens yellow) or closes)
Type 8694 Control and display elements Error messages 7.6.1 Error messages in MANUAL and AUTOMATIC operating statuses Display Cause of fault Remedial action LED 1 (red) Checksum error in data memory Not possible, device defective → Data memory defective → The device automatically switches to an older (possibly not current) data record.
Type 8694 Installation INSTALLATION Safety instructions DANGER! Risk of injury from high pressure in the equipment/device. ▶ Before working on equipment or device, switch off the pressure and deaerate/drain lines. Risk of electric shock. ▶ Before working on equipment or device, switch off the power supply and secure to prevent reactivation. ▶...
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Type 8694 Installation → For version with plug-in hose connector, remove the collets (white nozzles) from both pilot air ports (if present). Puck Switch spindle Guide element Groove ring max. 1 Nm max. 5 Nm Actuator cover O-ring Spindle extension Figure 20: Installation of the switch spindle (2), series 2103, 2300 and 2301 NOTE!
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Type 8694 Installation 2. Install sealing rings → Pull the form seal onto the actuator cover (smaller diameter points upwards). → Check that the O-rings are correctly positioned in the pilot air ports. When the positioner is being installed, the collets of the pilot air ports must not be fitted to the actuator. Form seal Pilot air port Caution:...
Type 8694 Installation → Push the positioner, without turning it, onto the actuator until no gap is visible on the form seal. NOTE! Too high torque when screwing in the fastening screw does not ensure degree of protection IP65 / IP67.
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Type 8694 Installation Puck Switch spindle Guide element O-ring Plastic part (Switch spindle) Spindle (actuator) Figure 25: Installing the switch spindle (2), series 26xx and 27xx → Press the O-ring downwards into the cover of the actuator. → Actuator size 125 and bigger with high air flow rate: remove existing spindle extension and replace with the new one.
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Type 8694 Installation 2. Install positioner → Push the positioner onto the actuator. The puck must be aligned in such a way that it is inserted into the guide rail of the positioner. NOTE! Damaged printed circuit board or malfunction. ▶...
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Type 8694 Installation 3. Install pneumatic connection between positioner and actuator Pilot air outlet 2 Pilot air outlet 2 Upper pilot air port Example ∅ 80, CFA Lower pilot air port Figure 28: Installing the positioner → Screw the plug-in hose connectors onto the positioner and the actuator. →...
Type 8694 Installation Control function B (CFB) Process valve open in rest position (by spring force) ∅ 80, ∅ 100 Actuator size ∅ 125 Pilot air outlet Upper pilot air port Lower pilot air port Dry area Table 14: Pneumatic connection to actuator - CFB "In rest position"...
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Type 8694 Installation Actuator module Key contour Hexagon Nipple Nipple with hexagon without hexagon Figure 29: Rotating the actuator module → Using a suitable open-end wrench, counter the wrench flat on the pipe. → Actuator module without hexagon: Fit special key exactly in the key contour on the underside of the actuator.
Type 8694 Installation Rotating the positioner for process valves belonging to series 26xx and 27xx If the connecting cables or hoses cannot be fitted properly following installation of the process valve, the positioner can be rotated contrary to the actuator. Fastening screw (2x) Positioner Pneumatic connection...
Type 8694 Pneumatic installation PNEUMATIC INSTALLATION DANGER! Risk of injury from high pressure in the equipment/device. ▶ Before working on equipment or device, switch off the pressure and deaerate/drain lines. WARNING! Risk of injury from improper installation. ▶ Installation may be carried out by authorized technicians only and with the appropriate tools. Risk of injury from unintentional activation of the system and an uncontrolled restart.
Type 8694 Pneumatic installation Caution:(Exhaust air concept): In compliance with degree of protection IP67, an exhaust air line must be installed in the dry area. Keep the adjacent supply pressure always at least 0.5 – 1 bar above the pressure which is required to move the actuator to its end position.
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Type 8694 Pneumatic installation Move actuator to end position Turn the hand levers to the right using a screwdriver. Note: - do not press the hand levers when turning them - observe the sequence as described below → 1. Actuate hand lever pilot valve deaeration. →...
Type 8694 Electrical installation 24 V DC ELECTRICAL INSTALLATION 24 V DC All electrical inputs and outputs of the device are not galvanically isolated from the supply voltage. Two kinds of connections are used for the electrical bonding of the positioner: •...
Type 8694 Electrical installation 24 V DC 10.2.2 Connection of the positioner Type 8694 → Connect the pins according to the model (options) of the positioner. Input signals of the control center (e.g. PLC) - circular plug M12 x 1, 8-pole Wire color Configuration External circuit / signal level...
Type 8694 Electrical installation 24 V DC 10.3 Electrical installation with cable gland DANGER! Risk of electric shock. ▶ Before working on equipment or device, switch off the power supply and secure to prevent reactivation. ▶ Observe applicable accident prevention and safety regulations for electrical equipment. NOTE! Breakage of the pneumatic connection pieces due to rotational impact.
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Type 8694 Electrical installation 24 V DC Figure 38: Connection of screw-type terminals → Connect the positioner according to the following tables: Input signals from the control centre (e.g. PLC) Terminal Configuration External circuit + (0/4 ... 20 mA) Set-point value + Set-point value GND Binary input + 0 ...
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Type 8694 Electrical installation 24 V DC Body casing Seal body casing Connection housing Figure 39: Position of the seal in the body casing → Check that the seal is correctly positioned in the body casing. NOTE! Breakage of the pneumatic connection pieces due to rotational impact. ▶...
Type 8694 AS-Interface installation AS-INTERFACE INSTALLATION 11.1 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). Bus line Unshielded two-wire line (AS-Interface line as AS-Interface flat cable) along which both information (data) and energy (power supply for the actuators and sensors) are transmitted.
Type 8694 AS-Interface installation 11.4 Programming data Version Profile S-7.3.4 Version Profile S-7.A.5 I/O configuration 7 hex 7 hex ID code 3 hex (analog profile) A hex F hex Extended ID code 1 7 hex (Default value, can be changed by the user) Extended ID code 2 4 hex 5 hex...
Type 8694 AS-Interface installation 11.5 Communication sequence for the version S-7.A.5 profile 1. Following start-up, the AS-Interface master (from master class 4) automatically replaces the ID object with the S-7.A.5 slave. Master transmits 3 bytes: S-7.A.5 slave replies with 6 bytes 1.
Type 8694 AS-Interface installation 11.6 LED status display NOTE! Breakage of the pneumatic connection pieces due to rotational impact. ▶ When unscrewing and screwing in the body casing, do not hold the actuator of the process valve but the connection housing. The LED status display indicates the bus status (LED green and red).
Type 8694 AS-Interface installation → Check that the seal is correctly positioned in the body casing. NOTE! Breakage of the pneumatic connection pieces due to rotational impact. ▶ When unscrewing and screwing in the body casing, do not hold the actuator of the process valve but the connection housing.
Type 8694 AS-Interface installation 11.7.2 Connection with circular plug-in connector M12 x 1, 4-pole, male It is not necessary to open the positioner for the multi-pole model. Bus connection without external / with external supply voltage Designation Configuration Bus + AS-Interface bus line + NC or GND (optional) not used or external supply voltage –...
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Type 8694 AS-Interface installation Calculated bus line length: When designing the system, consider the length of the cable which is fed directly to the positioner for the maximum bus line length (multi-pole cable and cable inside: 1.0 m). Example calculation: When using 62 positioner with multi-pole cable, the AS-Interface flat cable may still be maximum 38 m long.
Type 8694 Start-up START-UP 12.1 Safety instructions DANGER! Risk of injury from high pressure in the equipment/device. ▶ Before working on equipment or device, switch off the pressure and deaerate/drain lines. WARNING! Risk of injury from improper operation. Improper operation may result in injuries as well as damage to the device and the area around it. ▶...
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Type 8694 Start-up NOTE! Breakage of the pneumatic connection pieces due to rotational impact. ▶ When unscrewing and screwing in the body casing or transparent cap, do not hold the actuator of the pro- cess valve but the connection housing. →...
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Type 8694 Start-up Body casing Seal body casing Connection housing Figure 48: Position of the seal in the body casing → Version 1: Check that the seal is correctly positioned in the body casing. NOTE! Breakage of the pneumatic connection pieces due to rotational impact. ▶...
Type 8694 Operation and function OPERATION AND FUNCTION The positioner type 8694 has different basic and additional functions which can be configured and parameterized via the DIP switches or the communications software. 13.1 Basic functions The following basic functions can be activated via the DIP switches (CUTOFF and CHARACT) or changed (DIR.CMD).
Type 8694 Operation and function 13.1.1 DIR.CMD - Effective direction of the positioner set-point value You can use this function to adjust the effective direction between the input signal (INPUT) and the nominal position of the actuator. Factory setting: DIP switch set to OFF (ascending) DIP Switches Position Function Reversal of the effective direction of the set-point value (DIR.CMD)
Type 8694 Operation and function 13.1.2 CUTOFF - Sealing function for the positioner This function causes the valve to be sealed outside the control range. Control mode resumes at a hysteresis of 1%. Factory setting: DIP switch 2 set to OFF (no sealing function) DIP Switches Position Function Sealing function active.
Type 8694 Operation and function 13.1.3 CHARACT - Select the transfer characteristic between input signal (position set-point value) and stroke Characteristic (customer-specific characteristic) This function can be used to activate a transfer characteristic with respect to set-point value (set-point position) and valve stroke for correction of the flow-rate or operating characteristic.
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Type 8694 Operation and function The flow characteristic k = f(s) indicates the flow-rate of a valve, expressed by the value k as a function of the stroke s of the actuator spindle. It is determined by the design of the valve seat and the seat seal. In general two types of flow characteristics are implemented, the linear and the equal percentage.
Type 8694 Operation and function Entering the freely programmable characteristic The characteristic is defined by 21 nodes distributed uniformly over the position set-point values ranging from 0 – 100%. They are spaced at intervals of 5%. A freely selectable stroke (adjustment range 0 – 100%) is assigned to each node.
Type 8694 Operation and function 13.1.5 RESET - Reset to factory settings This function can be used to reset the positioner to the factory settings. 13.1.6 X.TUNE - Automatic adjustment of the positioner to the relevant operating conditions The X.TUNE function must be run for a function check of the positioner to adjust to specific local features. WARNING! While the X.TUNE function is running, the valve automatically moves from its current position.
Type 8694 Operation and function 13.2 Auxiliary functions The following additional functions can be configured and parameterized via the communications software: Function Description DIR.ACTUATOR Assignment of the aeration status of the actuator chamber to the actual position SPLITRANGE Signal split range; input signal as a % for which the valve runs through the entire stroke range.
Type 8694 Operation and function 13.2.2 SPLITRANGE - Signal split range Minimum and maximum values of the input signal as a % for which the valve runs through the entire stroke range. Factory setting: Lower signal range split = 0 %; Upper signal range split = 100 % Lower value split range: Input the minimum value of the input signal as a % Adjustment range: 0 –...
Type 8694 Operation and function 13.2.3 X.LIMIT - Limiting the mechanical stroke range This function limits the (physical) stroke to specified % values (lower and upper). In doing so, the stroke range of the limited stroke is set equal to 100 %. If the limited stroke range is left during operation, negative actual posi- tions or actual positions greater than 100 % are shown.
Type 8694 Operation and function 13.2.4 X.TIME - Limiting the control speed Use this function to specify the opening and closing times for the entire stroke and thereby limit control speeds. When the X.TUNE function is running, the minimum opening and closing time for the entire stroke is auto- matically entered for Open and Close.
Type 8694 Operation and function 13.2.5 X.CONTROL - Parameterization of the positioner Use this function to set the parameters for the positioner (dead band and amplification factors (kp)). Deadband: Insensitivity range of the positioner Entry for the deadband as a % in reference to the scaled stroke range; i.e.
Type 8694 Operation and function 13.2.7 SIGNAL ERROR - Configuration of signal level fault detection The SIGNAL ERROR function is used to detect a fault on the input signal. Fault detection Fault detection can be selected for a 4 – 20 mA signal only: Fault if input signal ≤...
Type 8694 Operation and function 13.2.9 OUTPUT (optional) - Configuration of the analog output The OUTPUT menu item only appears in the selection of auxiliary functions if the positioner has an analog output (optional) or if no parameters have been read in yet. The analog output can be used for feedback of the current position or of the set-point value to the control center.
Type 8694 Safety end positions SAFETY END POSITIONS 14.1 Safety end positions after failure of the electrical or pneumatic auxiliary power Safety end positions after failure of the auxiliary power Actuator system Designation electrical pneumatic pilot-controlled control system: single-acting down down Control direct-acting control...
Type 8694 Maintenance MAINTENANCE 15.1 Safety instructions DANGER! Risk of injury from high pressure in the equipment/device. ▶ Before working on equipment or device, switch off the pressure and deaerate/drain lines. Risk of electric shock. ▶ Before working on equipment or device, switch off the power supply and secure to prevent reactivation. ▶...
Type 8694 Maintenance 15.2 Service at the air intake filter DANGER! Risk of injury from high pressure in the equipment/device. ▶ Before working on equipment or device, switch off the pressure and deaerate/drain lines. To protect the internal solenoid valves and the actuator, the pilot air is filtered. The direction of flow of the air intake filter in installed state is from the inside to the outside through the filter material.
Type 8694 Accessories ACCESSORIES Designation Order no. USB adapter for connection to a PC in conjunction with an extension cable 227093 Communicator Information at www.burkert.com Connection cable M12 x 1, 8-pole 919061 Assembly tool 647077 Table 34: Accessories 16.1 Communications software The PC operating program “Communicator”...
Type 8694 Disassembly DISASSEMBLY 17.1 Safety instructions DANGER! Risk of injury from high pressure in the equipment/device. ▶ Before working on equipment or device, switch off the pressure and deaerate/drain lines. Risk of electric shock. ▶ Before working on equipment or device, switch off the power supply and secure to prevent reactivation. ▶...
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Type 8694 Disassembly 2. Electrical connection DANGER! Risk of electric shock. ▶ Before working on equipment or device, switch off the power supply and secure to prevent reactivation. ▶ Observe applicable accident prevention and safety regulations for electrical equipment. Circular plug-in connector: →...
Type 8694 Packaging and transport PACKAGING AND TRANSPORT NOTE! Transport damages. Inadequately protected equipment may be damaged during transport. ▶ During transportation protect the device against wet and dirt in shock-resistant packaging. ▶ Avoid the effects of heat and cold which could result in temperatures above or below the permitted storage temperature.
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