Type 8681
Control Head
Operating Instructions
We reserve the right to make technical changes without notice.
Technische Änderungen vorbehalten.
Sous resérve de modification techniques.
© 2010 - 2011 Bürkert Werke GmbH
Operating Instructions 1110/04_EN_00806150 / Original DE
Control Head Type 8681
Control Head Type 8681
In h a l t
1. OPERATING INSTRUCTIONS .......................................................................................................................................................8
2. AUTHORIZED USE .............................................................................................................................................................................9
2.1. Export Restrictions ................................................................................................................................................................9
2.2. Predictable Misuse ................................................................................................................................................................9
3. BASIC SAFETY INSTRUCTIONS .............................................................................................................................................10
4. GENERAL INFORMATION ...........................................................................................................................................................12
4.1. Contact address ..................................................................................................................................................................12
4.2. Warranty ...................................................................................................................................................................................12
4.3. Information on the Internet ............................................................................................................................................12
5. SYSTEM DESCRIPTION ...............................................................................................................................................................13
5.1. Intended Application Area ..............................................................................................................................................13
5.2. General Description ...........................................................................................................................................................13
5.3. Special Features ..................................................................................................................................................................13
5.4. Functions / Options / Designs ....................................................................................................................................14
5.4.1. Structure of the Control Head .....................................................................................................................14
5.4.2. Fluid diagram ........................................................................................................................................................15
5.4.3. Number of solenoid valves............................................................................................................................16
5.4.4. Pneumatic Interfaces........................................................................................................................................16
5.4.5. Manual Control .....................................................................................................................................................16
5.4.6. Position Measuring System ..........................................................................................................................17
5.4.7. Other Features ....................................................................................................................................................17
6. TECHNICAL DATA .............................................................................................................................................................................18
6.1. Operating Conditions ........................................................................................................................................................18
6.2. Conformity with the following Standards ..............................................................................................................18
6.3. Mechanical data ...................................................................................................................................................................19
6.4. Pneumatic Data ...................................................................................................................................................................20
6.5. Position Measuring System Data ...............................................................................................................................21
6.6. Factory Settings in the Firmware ...............................................................................................................................22
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Control Head Type 8681
7. INSTALLATION ...................................................................................................................................................................................23
7.1. Safety instructions .............................................................................................................................................................23
7.2. Assembly of the Control Head .....................................................................................................................................23
7.2.1. Hub flange ..............................................................................................................................................................23
7.2.2. Assembly Sequence on the Example of a Double-seated Valve .............................................24
7.2.3. Realignment of the Control Head ..............................................................................................................25
7.2.4. Assembly of the Pneumatic and Electrical Connections ..............................................................25
7.2.5. Recommended Auxiliary Materials ...........................................................................................................25
8. OPENING AND CLOSING THE HOUSING.........................................................................................................................26
8.1. Safety instructions .............................................................................................................................................................26
8.2. Opening and Closing the Housing ............................................................................................................................26
8.2.1. Opening the Housing .......................................................................................................................................26
8.2.2. Closing the Housing ......................................................................................................................................... 27
9. PNEUMATIC INSTALLATION ......................................................................................................................................................28
9.1. Safety instructions .............................................................................................................................................................28
9.2. Pneumatic Connection of the Control Head ........................................................................................................28
9.3. Flow Restriction Function of the Solenoid Valves .............................................................................................29
10. 24 V DC - DESIGN ...........................................................................................................................................................................31
10.1. Electrical connection options ......................................................................................................................................31
10.2. Electrical Data ......................................................................................................................................................................31
10.3. Design Aid ..............................................................................................................................................................................33
10.4. Safety instructions .............................................................................................................................................................34
10.5. Electrical Installation / Start-up ..................................................................................................................................34
10.5.1. Cable Gland with Screw-type Terminals ................................................................................................34
10.5.2. Multi-pole Connection ......................................................................................................................................37
11. AS INTERFACE - DESIGN ...........................................................................................................................................................38
11.1. Definition .................................................................................................................................................................................38
11.2. Electrical Connection Options for AS Interface ................................................................................................39
11.3. Number of Connectable Control Heads and Maximum Length of the Bus Line .............................. 39
11.4. Electrical Data ......................................................................................................................................................................40
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Control Head Type 8681
11.5. Design Aid ..............................................................................................................................................................................42
11.6. Safety instructions .............................................................................................................................................................43
11.7. Electrical installation AS Interface ............................................................................................................................44
11.8. Programming Data .............................................................................................................................................................46
12. DEVICENET - DESIGN ..................................................................................................................................................................47
12.1. Definition .................................................................................................................................................................................47
12.2. Electrical connection option ........................................................................................................................................47
12.3. DeviceNet specification ...................................................................................................................................................47
12.3.1. Total line length and maximum line length according to DeviceNet specification .........48
12.3.2. Drop Line Length.................................................................................................................................................48
12.4. Electrical Data ......................................................................................................................................................................49
12.5. Safety Position if the Bus Fails ...................................................................................................................................49
12.6. Design Aid ..............................................................................................................................................................................50
12.7. Safety instructions .............................................................................................................................................................51
12.8. Electrical Installation - DeviceNet ..............................................................................................................................51
12.9. Network Topology of a DeviceNet System ............................................................................................................53
12.10. Configuring the DeviceNet address / baud rate ................................................................................................53
12.10.1. Settings of the DeviceNet address .......................................................................................................54
12.10.2. Setting the baud rate....................................................................................................................................55
12.11. Configuration of Process Data ....................................................................................................................................55
12.11.1. Static Input Assemblies ..............................................................................................................................55
12.11.2. Static Output Assembly ..............................................................................................................................56
12.12. Configuration of the device ...........................................................................................................................................56
12.12.1. Configuration of the Safety Position of Solenoid Valves if Bus Error ................................56
12.12.2. Configuration example ...............................................................................................................................57
12.13. Display of the Status LEDs in the event of a bus error ..................................................................................58
12.13.1. Status of the device status LED "Modules" .....................................................................................58
12.13.2. State of bus status LED "Network" .......................................................................................................59
13. 120 V AC - DESIGN .......................................................................................................................................................................60
13.1. Electrical connection options ......................................................................................................................................60
13.2. Electrical Data ......................................................................................................................................................................60
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Control Head Type 8681
13.3. Design Aid ..............................................................................................................................................................................62
13.4. Safety instructions .............................................................................................................................................................63
13.5. Electrical Installation / Start-up ..................................................................................................................................63
14. CONNECTION OF AN EXTERNAL INITIATOR...................................................................................................................66
15. POSITION MEASURING SYSTEM ..........................................................................................................................................67
15.1. Setting the Position Measuring System (Teach-In) ..........................................................................................67
15.2. Teach-In Functions .............................................................................................................................................................68
15.2.1. Teach-In Functions and Teach-In Reset .................................................................................................68
15.2.2. Autotune functions ............................................................................................................................................69
15.2.3. Autotune sequence ..........................................................................................................................................69
16. LED - COLOR ASSIGNMENTS .................................................................................................................................................72
16.1. Setting the Color Combinations .................................................................................................................................73
16.2. Blinking Pattern & Fault Signaling ............................................................................................................................. 73
16.3. Signal Priorities ....................................................................................................................................................................74
17. SERVICE MODE / MANUAL CONTROL ..............................................................................................................................75
17.1. Magnetic Manual Control ................................................................................................................................................75
17.2. Mechanical Manual Control ...........................................................................................................................................76
18. MAINTENANCE, TROUBLESHOOTING ...............................................................................................................................77
18.1. Safety instructions .............................................................................................................................................................77
18.2. Safety Positions ...................................................................................................................................................................78
18.3. Maintenance ..........................................................................................................................................................................79
18.4. Cleaning ...................................................................................................................................................................................79
18.5. Malfunctions ..........................................................................................................................................................................79
19. REPLACEMENT OF COMPONENTS AND MODULES .................................................................................................81
19.1. Safety instructions .............................................................................................................................................................81
19.2. Changing the Electronics Module ..............................................................................................................................82
19.3. Changing the Valves ..........................................................................................................................................................83
19.4. Changing the Position Measuring System ............................................................................................................84
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Control Head Type 8681
20. SPARE PARTS ....................................................................................................................................................................................87
21. SHUTDOWN ........................................................................................................................................................................................88
21.1. Safety instructions .............................................................................................................................................................88
21.2. Dismantling the Control Head Type 8681 ..............................................................................................................88
22. PACKAGING AND TRANSPORT ...............................................................................................................................................89
23. STORAGE ..............................................................................................................................................................................................89
24. DISPOSAL ............................................................................................................................................................................................89
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Operating Instructions
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Control Head Type 8681
OPERATING INSTRUCTIONS1.
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.•
Symbols:
DANGER!
Warns of an immediate danger!
Failure to observe the warning will result in a fatal or serious injury.•
WARNING!
Warns of a potentially dangerous situation!
Failure to observe the warning may result in serious injuries or death. •
CAUTION!
Warns of a possible danger!
Failure to observe this warning may result in a moderate or minor injury. •
NOTE!
Warns of damage to property!
Failure to observe the warning may result in damage to the device or the equipment. •
indicates important additional information, tips and recommendations which are important for your safety
and the flawless functioning of the device.
refers to information in these operating instructions or in other documentation.
designates a procedure which you must carry out.
→
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Authorized use
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Control Head Type 8681
AUTHORIZED USE2.
Non-authorized use of the Control Head Type 8681 may be a hazard 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 the chapter 6. Technical Data.
In view of the large number of options for use it might be necessary to test prior to installation whether the •
control head is suitable for the concrete use.
If you have any questions, please contact your Bürkert Service Center.
The device may be used only in conjunction with third-party devices and components recommended and •
authorized by Bürkert.
Any unauthorized reconstructions and changes to the control head are prohibited for safety reasons.•
Correct transportation, correct storage and installation and careful use and maintenance are essential for •
reliable and faultless operation.
For connecting the control head, use line installations that do not cause any mechanical stresses.•
Use the device only as intended.•
Export Restrictions2.1.
If exporting the system/device, observe any existing restrictions.
Predictable Misuse2.2.
Do not supply the medium connectors of the system with aggressive or flammable media.•
Do not supply the medium connectors with any liquids.•
Do not physically stress the housing (e.g. by placing objects on it or standing on it, or using it as attachment point •
for transport work).
Do not make any external modifications to the device housings. Do not paint the housing parts or screws.•
In the explosion-risk area, only wipe the control head with a damp or anti-static cloth to avoid electro-static •
charges!
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Basic Safety Instructions
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Control Head Type 8681
BASIC SAFETY INSTRUCTIONS3.
These safety instructions do not make allowance for any
contingencies and events which may arise during the installation, operation and maintenance of the devices.•
local safety regulations - the operator is responsible for observing these regulations, also with reference to the •
installation personnel.
DANGER!
Danger – high pressure!
Before loosening pneumatic 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 the isolated state!•
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.•
Installation and maintenance work, as well as operator control actions may be carried out by authorized, quali-•
fied technicians only and with the appropriate tools.
After an interruption in the power supply or pneumatic supply, ensure that the process is restarted in a defined •
or controlled manner.
The device may be installed and operated only when in perfect condition and in consideration of the operating •
instructions.
The general rules of technology apply to application planning and operation of the device. •
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 and 5-2 to minimize or avoid the possibility •
of damage caused by sudden electrostatic discharge!
Also, ensure that you do not touch electronic components when the power supply voltage is present! •
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Basic Safety Instructions
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Control Head Type 8681
NOTE!
Connection of the Control Head
Do not connect any mechanically rigid connection parts, in particular those with long lever arms, as such connections could generate torques that might damage the control head.
Operation of the Control Head in Explosive Atmosphere
The housing may not be opened when devices are charged! It should be secured against unintentional opening •
using plastic self-cutting screws or seal (or comparable)!
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 may not be dirty!
Activating the DIP switches on the circuit board, using the service plug and the Teach buttons is • not allowed in
explosive atmosphere!
Cleaning
In the explosion-risk area, only wipe the control head with a damp or anti-static cloth to avoid electro-static •
charges.
Only use compatible cleaning agents for cleaning the securely closed control head and always rinse thoroughly •
with clean water.
For further information refer to the corresponding chapters of these operating instructions!
Control Head Type 8681 was developed with due consideration given to accepted safety rules and is stateof-the-art. Nevertheless, dangerous situations may occur.
Failure to observe this operating manual and its operating instructions as well as unauthorized tampering
with the device release us from any liability and also invalidate the warranty covering the devices and
accessories!
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Basic Safety Instructions
GENERAL INFORMATION4.
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Control Head Type 8681
Contact address4.1.
Bürkert Fluid Control Systems
Sales Center
Christian-Bürkert-Straße 13-17
D-74653 Ingelfingen
Tel. : +49 7940 10 91 111
Fax: +49 7940 10 91 448
E-mail: info@de.buerkert.com
Homepage: www.buerkert.com, www.buerkert.de
Warranty4.2.
The warranty is only valid if the control head is used as intended in accordance with the specified application
conditions.
Information on the Internet4.3.
The operating instructions and data sheets for control head type 8681 can be found on the Internet at:
www.buerkert.com
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System Description
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Control Head Type 8681
SYSTEM DESCRIPTION5.
Intended Application Area5.1.
The Control Head Type 8681 has been designed for use as actuation of pneumatically operated process valves
and / or for recording the switching states of these.
General Description5.2.
The Control Head Type 8681 is used for actuating pneumatically operated process valves.
For process valve actuation, the control head can be equipped 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 contactless position measuring system, which works with three 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.
Special Features5.3.
Special features of the Control Head Type 8681 include:
easy-to-clean design with IP65 / IP67 protection •
high cleaning agent compatibility•
use of high-quality materials•
modular structure•
restrictable R- and P-connections for all pilot valves (solenoid valves)•
integrated pressure-relief valve in the inside of the housing for discharging leakage air with connection into the •
common exhaust air connection
collected exhaust air of all valve locations into one common exhaust air connection (by default equipped with a •
silencer)
if equipped with several working connections: one integrated non-return valve per connection in the exhaust air •
duct as protection against faulty switching of the process valves due to return pressure
central, super-bright optical display showing the process valve switching positions and design-specific addi-•
tional information in three signal colors
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System Description
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Control Head Type 8681
short mechanical and pneumatic installation times.•
For increased safety requirements (e.g. in the explosion-risk area) a seal or a hood safeguard using plastic self-•
cutting screws (3 mm diameter, approx. 10 mm length; e.g. Ejot PT screws K 30 x 10) are required.
conform to the ATEX Directive 94/9/EC (Dust ATEX category 3D and Gas ATEX category 3G - see chapter •
6.2. )
Functions / Options / Designs5.4.
Structure of the Control Head5.4.1.
Position measuring system
with LED's in three colors
Electronics module with
connection terminals,
service interface and
Teach-In buttons
(back side)
Solenoid valve 1
Solenoid valve 2
Solenoid valve 3
Cable gland
(back side)
Sealing lug
(on lower housing part)
2 locking screws (shoulder
screws M5); no sealing
function, merely as protection
against pulling off from the
hub flange
Mechanical manual
control (red lever)
Exhaust air connection (3/R)
Silencer in the exhaust air
connection (3/R), not shown
Flow restriction screw(s)
for P and R
(2 per solenoid valve)
Locking groove (3x)
Supply pressure
connection(1/P)
Solenoid valve 1 (2/A1)
Solenoid valve 2 (2/A2)
Solenoid valve 3 (2/A3)
Working connections
(2/A1 - 3)
Fig. 1: Structure of Control Head Type 8681
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System Description
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Control Head Type 8681
5.4.2. Fluid diagram
Control Head Type 8681 - Fluid diagram (with restriction capability for each solenoid valve):
Model with three Type 6524 solenoid valves,
e.g. for double-seated valve
Fluid diagram (model: 3 solenoid valves) Fig. 2:
The functions and designs of Control Head Type 8681 are described in the following chapters.
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System Description
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Control Head Type 8681
Number of solenoid valves5.4.3.
The control head for process valves has been designed for single-acting and double-acting valve actuators as
well as for double-seated and multi-position valves.
Type of use
Repeater 0
Control head for single-acting actuators 1
Control head for double-acting actuators ** 2
Control head for double-seated valves with integrated aeration of both
valve seats
* WWC = circuit function C = 3/2-way valve; closed in rest position, output A unloaded
** both drive chambers currentless deaerated
Number of solenoid valves
(3/2-Way Solenoid Valve WWC*)
Pneumatic Interfaces5.4.4.
Intake & exhaust air connections: G 1/4 •
Working connections: G 1/8
Integrated non-return valves in the solenoid valves' exhaust air duct •
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.
Special silencers with a high flow-rate capacity to connection 3/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 3/R.
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Manual Control5.4.5.
Standardly, the control head provides the following:
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•
a simple activation tool for opening & closing Solenoid Valve 1 (main stroke) - •
helpful for maintenance on the process valve
LED-display for the Activated Manual Control status, meaning service mode •
(see chapter 16. LED - Color Assignments and 17. Service Mode / Manual Control )
For a detailed description of the manual control, see chapter 17. Service Mode / Manual Control .
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System Description
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Control Head Type 8681
Position Measuring System5.4.6.
The switching positions of the process valves are reported to the higher-level control by feedback signals from
the contactless position measuring system. Connection to the control head is done by means of a simple adaptation to the process valve's piston.
The recordable stroke range is between 0 and 80 mm.
Three binary feedback signals are evaluated:
- Position 1 (discrete S1OUT signal)
- Position 2 (discrete S2OUT signal)
- Position 3 (discrete S3OUT signal).
The 24 V DC design is additionally available in the order variant "Analog":
Order variant: - Position 1 (discrete S1OUT signal)
- Position 2 (discrete S2OUT signal)
- Position 3 (analog (4...20 mA) S3OUT signal).
Three Teach-In buttons have been provided for comparison with the actual stroke range (see chapter 15. Position
Measuring System). The switching positions for the position measuring system can be determined with these
buttons or by means of the service interface (on the electronics module).
An discrete, external feedback signal (standard proximity switch) can also be processed (S4IN, S4OUT).
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 - Design.
For the setting of the Teach-In buttons, see chapter 15. Position Measuring System.
Other Features 5.4.7.
Central optical position indicator for showing the process valve switching positions: •
Positions and status information can be indicated by means of three signal colors.
The assignment of the signal colors and the blinking pattern, which indicates the type of fault, are described in
chapter 16. 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 three 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 control by lowering the holding current during long-term operation•
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Technical Data
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Control Head Type 8681
6. TECHNICAL DATA
Operating Conditions6.1.
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.
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 (zone2): +5 ... +55 °C
Protection class: Standard version:
IP65 / IP67 according to EN 60529
(only if cables, plugs and sockets have been connected correctly, the VA hood
has been closed 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 to EN 60079-0: 2009
(only if cables, plugs and sockets have been connected correctly, the VA hood
has been closed correctly and the adaptation to the process valve was done
correctly)
6.2. Conformity with the following Standards
According to EC Declaration of Conformity (CE mark)
EMC Directive 2004/108/EC (previously: 89/336/EMC)
(only if cables, plugs and sockets have been connected correctly)
A Declaration of Conformity for the specific device can be requested from Bürkert.
ATEX Directive 94/9/EC
Ignition protection type:
Ex tc IIIC T135°C
Gas ATEX category 3G Ex nA IIC T4 or
Ex nAc IIC T4
Dust ATEX category 3D Ex tD A22 T135°C or
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Technical Data
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Control Head Type 8681
Mechanical data6.3.
M16x1.5 (2x)
Cover safeguard:
- Seal max Ø2
and / or
- plastic self-cutting
screw 3.0x10
Dimensional drawingFig. 3:
Weight: ca. 0.8 kg
Housing material: outside: PA, PP, PPO, VA
inside: ABS, PA, PMMA
G1/4 (2x)
G1/8 (3x)
Sealing material: outside: CR, EPDM
inside: EPDM, FKM, NBR
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Technical Data
6.4. Pneumatic Data
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Control Head Type 8681
Control medium: oil-free and dry air, neutral gases
Quality classes in accordance with DIN ISO 8573-1
(5 µm filter recommended)
Dust content Quality class 5: max. particle size 40 µm,
max. particle density 10 mg/m
3
Water content Quality class 3: max. pressure dew point -20 °C or min. 10 °C below
the lowest operating temperature
Oil content Quality class 5: max. 25 mg/m
3
Temperature range
of compressed air: -10 - +50 °C
Pressure range: 2.5 to 8 bar
Air rate solenoid valve: 110 I
/min (for aeration and deaeration, ventilation)
N
(110 IN/min - supplied state
200 IN/min - maximum typical flow-rate)
(QNn value according to definition for pressure drop from 7 to 6 bar absolute
at +20 °C)
Connections: Intake and exhaust air connection G1/4
Working connections G1/8
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 screws
for:
Exhaust R
Intake P
Flow restriction screws of the solenoid valvesFig. 4:
Mechanical
manual control
Red lever:
left: 0
right: 1
When setting the retraction and expansion rates of the pneumatic actuator consider that constant
"primary pressure" is not present 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.
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Technical Data
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Control Head Type 8681
6.5. Position Measuring System Data
Stroke range (measuring range): 0 ... 80 mm
Resolution: ≤ 0.1 mm
Total fault:
Material 1.4021 and a piston rod (Ø 22 mm, Material - see (*))
(Fault refers to the reproducibility of a taught position)
The illustration in Fig. 5 shows the dimensional relationships between the control head and the piston with a target.
± 0.5 mm - when using a target in accordance with the dimensional drawing,
Note upper end position of
the target (H 156.5 mm) to prevent
putting control head at risk!
Target (1.4021)
and
Piston rod (*)
(both depicted in the upper
and lower end positions,
maximum stroke: 80 mm)
Fig. 5: Cross-section of the control head and piston with target (in upper and lower end position)
(*) The fastening materials for target and piston rod may not be made of material with very good electrical
conductivity (e.g. copper, aluminum) or of ferromagnetic material.
Stainless steels such as e.g. 1.4404 are suitable.
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Technical Data
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Control Head Type 8681
6.6. Factory Settings in the Firmware
The control head is supplied with the following factory settings of the firmware:
The service interface may only be used in non-explosive atmosphere.
Feedback areas (position measuring system):
(A feedback area is the area, within which a position (e.g. S1) is reported back.)
Signal Feedback area, top Feedback area, bottom
Factory setting
[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 + 0.50 + 10.00 ... + 0.50 - 0.50 - 0.50 ... - 10.00
Adjustment range
[mm]
Factory setting
[mm]
Adjustment range
[mm]
Stroke
[mm]
Target
Schematic diagram (not to scale) of the feedback areas, on the example of Position S1 Fig. 6:
Service function (maintenance request):
The service function is deactivated at the time of delivery. It can be activated via the service interface. Feedback
indicating that service is required (service function) is triggered by the following counter states:
Feedbackarea S1 [mm]
The feedback area is automatically reduced in the area
of the end positions:
The firmware ensures that a tolerance of at least 1 mm
towards the center position is present in the end
positions.
Exemplary illustration of the upper end position:
upper end position as taught position
(selected feedback area towards
center position)
actual feedback area ensured by
the firmware
Towards center position
Overlaps between S1, S2 and S3 are possible
(see chapter 16.3. Signal Priorities).
Counter states 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
Manual control function (magnetic) - Factory setting: active
It can be deactivated via the service interface.
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Installation
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Control Head Type 8681
7. INSTALLATION
Safety instructions7.1.
DANGER!
Risk of injury from high pressure in the equipment!
Before loosening pneumatic lines and valves, turn off the pressure and vent the lines.•
WARNING!
Risk of injury due to electrical 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 installation!
Installation may be carried out by authorized technicians only and with the appropriate tools!•
Risk of injury from unintentional activation of the system and an uncontrolled restart!
Secure system from unintentional activation.•
Following assembly, ensure a controlled restart.•
Assembly of the Control Head7.2.
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.
If the control head is used in explosive atmosphere (zone 2) it has to be installed in a protected installation
position according to IEC / EN 60079-0.
Hub flange7.2.1.
WARNING!
Risk of injury from improper installation!
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 drive 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
between the process valve and the control head. The axial fastening is done by two locking screws (shoulder
24
Installation
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Control Head Type 8681
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 6.5. Position Measuring System Data.
Control head
Target made of
1.4021
Piston rod (*)
(max. Ø 30)
Fastening
screws (2x)
O-rings Hub flange
Process valve
Fig. 7: Dimensional diagram of the control head - process valve adaptation
(*) The fastening materials for target and piston rod may not be made of material with very good electrical con-
ductivity (e.g. copper, aluminum) or of ferromagnetic material.
Stainless steels such as e.g. 1.4404 are suitable.
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 exclusively Bürkert adaptations.•
Prior to assembling the control head onto the hub flange, lightly grease the O-rings with a silicone •
grease (e.g. Paraliq GTE 703).
A seal or a hood safeguard using plastic self-cutting screws is required in the explosion-risk area, so •
that unintentional opening of the housing will be prevented!
For dimensional relationships, see also chapter 6.5. Position Measuring System Data.
Assembly Sequence on the Example of a Double-seated 7.2.2.
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!
25
Installation
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Control Head Type 8681
Check the secure fit of the sealing rings (in the upper and lower grooves). →
Mount the control head on 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 pulling off from the hub flange – tightening torque: max. 3.2 Nm (see Fig. 7: Dimensional 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.
The locking screw has
been loosened sufficiently
if the lower side of the
screw head is flush with
the auxiliary surface 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 control head is not fixed in
place by the locking screws; it is merely protected against being pulled off the hub flange.
The locking screw is sufficiently
tightened when the upper side of
the screw head is flush with the
auxiliary surface of the housing.
Tightening torque: max. 3.2 Nm
Assembly of the Pneumatic and Electrical Connections7.2.4.
Pneumatic Installation
See chapter 9. Pneumatic Installation
Electrical Installation
24 V DC: See chapter 10. 24 V DC - Design,
AS Interface: See chapter 11. AS Interface - Design
DeviceNet: See chapter 12. DeviceNet - Design
120 V AC: See chapter 13. 120 V AC - Design
Recommended Auxiliary Materials7.2.5.
Silicone grease Paraliq GTE 703 for easy lubrication of the EPDM seals.
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Opening and Closing the Housing
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Control Head Type 8681
8. OPENING AND CLOSING THE HOUSING
Safety instructions8.1.
DANGER!
Risk of injury from high pressure in the equipment!
Before loosening pneumatic 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 the isolated state! •
WARNING!
Risk of injury due to electrical 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 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 an uncontrolled restart!
Secure system from unintentional activation.•
Following installation, ensure a controlled restart.•
Opening and Closing the Housing8.2.
Opening the Housing8.2.1.
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!
Loosen plastic self-cutting screws or seal, if housing has been 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.
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Opening and Closing the Housing
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Control Head Type 8681
Closing the Housing8.2.2.
If necessary, clean the seal contour of the seal and of the hood, and lightly lubricate it using a recommended silicone grease (e.g. Paraliq GTE 703).
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 the fastening 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).
→
Potentially, apply more sealing and plastic self-cutting screws. →
A seal or a hood safeguard using plastic self-cutting screws is required in the explosion-risk area!
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Pneumatic Installation
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Control Head Type 8681
9. PNEUMATIC INSTALLATION
Safety instructions9.1.
DANGER!
Risk of injury from high pressure in the equipment!
Before loosening pneumatic lines and valves, turn off the pressure and vent the lines.•
WARNING!
Risk of injury from improper installation!
Installation may be carried out by authorized technicians only and with the appropriate tools!•
Risk of injury from unintentional activation of the system and an uncontrolled restart!
Secure system from unintentional activation.•
Following installation, ensure a controlled restart.•
9.2. Pneumatic Connection of the Control Head
DANGER!
Risk of injury from high pressure in the equipment!
Before loosening pneumatic lines and valves, turn off the pressure and vent the lines.•
Exhaust air
connection (3/R)
(Silencer
not shown!)
Pneumatic ConnectionFig. 8:
Solenoid valve 3
(2/A3)
Working connections
Solenoid valve 2
(2/A2)
(2/A1 - 3)
Solenoid valve 1
(2/A1)
Supply pressure
connection
(1/P)
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Pneumatic Installation
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Control Head Type 8681
Procedure:
→ 7.2.3. Realignment of the Control Head)
If necessary, realign the control head (see chapter
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 to 8 bar).
→
NOTE!
Hose pipes!
Only use calibrated hose pipes with • ∅6 mm (or 1/4") or ∅8 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 impermis-•
sible 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) that 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 QNn value > 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.
Flow Restriction Function of the Solenoid Valves9.3.
Set the flow restriction screws of the solenoid valves only when needed and after completion of all necessary installations!
The flow restriction screws of the solenoid valves (see Fig. 9) are used for setting the air intake and exhaust for
the working connections:
Factory setting: QNn 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 screw drivers (width • ≤ 3 mm).
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Pneumatic Installation
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Control Head Type 8681
Settings of the Flow-Rate or the Control Speed with the Help of the Flow Restriction Screws:
→ 8. Opening and Closing the Housing.
Open the housing observing the notes contained in chapter
For proper setting, it is advisable 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 desired flow-rate and thus the opening time for →
the process valve. (Tool: flat-blade screwdriver, width ≤ 3 mm). (Tool: flat-blade screwdriver, width ≤ 3 mm).
Activate valve location. →
Turn the flow restriction screw, "R", counterclockwise to set the desired flow-rate and thus the closing time for →
the process valve.
Hand lever of the
mechanical manual
Flow restriction screw
Exhaust R
Flow restriction screw
Intake P
Fig. 9: Flow restriction screws of the solenoid valves
actuation facility
NOTE!
Makes sure that all manual controls have been deactivated (manual lever all the way left, as pictured) after the •
setting work has been completed!
Close the housing observing the notes contained in chapter
→ 8. Opening and Closing the Housing.
If no system status is available during setting, readjust the system under system operation conditions if
necessary.
Observe the safety guidelines during this!
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24 V DC - Design
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Control Head Type 8681
10. 24 V DC - DESIGN
Electrical connection options 10.1.
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 right: external initiator
Connection Concepts 24 V DCFig. 10:
Connection left: Voltage, signals
Connection right: external initiator
Electrical Data10.2.
Power supply: 12 ... 28 V DC, residual ripple 10 %
Connections:
Cable gland version 1 x M16 x 1.5 cable gland / A/F22
for power supply and signals
clamping area 5 to 10 mm, with dummy plugs
with screw terminals for cable cross-sections of 0.14 to 1.5 mm
1 x M16 x 1.5 cable gland / A/F19
for external initiator
clamping area 3 to 6 mm, with dummy plugs
with screw terminals for cable cross-sections 0.14 to 1.5 mm²
Multi-pole connection version 1 x M16 x 1.5 cable gland / A/F22 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 signal)
2
1 x M16 x 1.5 cable gland / A/F19
for external initiator
clamping area 3 to 6 mm, with dummy plugs
with screw terminals for cable cross-sections 0.14 to 1.5 mm²
Power consumption (standby current): 30 mA at 24 V DC
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24 V DC - Design
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Control Head Type 8681
Solenoid valves:
Power input per solenoid valve: max. 0.8 W (0.9 W during activation)
Power consumption per solenoid valve
: 67 mA at 12 V DC
34 mA at 24 V DC
29 mA at 28 V DC
Operating mode: Long-term operation (100 % ED)
Central display of the switching states: 42 mA with a power supply of 24 V DC per illuminated display;
Color switching see chapter 16. LED - Color Assignments
Outputs/binary feedback signals: S1 out - S4 out
Design: Normally open contact, PNP output
short-circuit-proof,
with self-clocking short-circuit protection
Switchable output current: max. 100 mA per feedback signal
Output voltage - active: ≥ (operating voltage - 2 V)
Output voltage - inactive: max. 1 V in unloaded state
Output/analog S3 out feedback signal (separate order variant "Analog"!):
Signal output: S3 out (binary feedback signal S3out not available)
Type: Current source (4 to 20 mA)
Max. burden: ≤ 500 Ohm
Max. fault: ±1 mm (incl. measurement fault by the position measuring system)
Input / proximity switches (external initiator: S4 in):
Power supply: Voltage present at control head - 10 %
Current carrying capacity, sensor power supply: max. 90 mA
Short-circuit protection
Design: DC 2- and 3-conductor,
NO or NC (factory setting NO), PNP output
Input current 1 signal: I
Input voltage 1 signal: U
Input current 0 signal: I
Input voltage 0 signal: U
> 6.5 mA, limited internally to 10 mA
Sensor
> 10 V
Sensor
< 4 mA
Sensor
< 5 V
Sensor
Valve control inputs (Y1 - Y3):
Signal level - active: U > 10 V, max. 24 V DC + 10 %
Signal level - inactive: U < 5 V
Impedance: > 30 kOhm
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24 V DC - Design
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Control Head Type 8681
Design Aid10.3.
Power consumption of the electronics:
P
El
Power consumption of a valve during activation (200 ms):
P
Valve-On
Power consumption of a valve after reduction:
P
Valve
Power consumption of an optical position report:
P
LED
= 0.7 W or I
= 0.9 W or I
= 0.8 W or I
= 1.0 W or I
El
Valve-On
Valve
LED
= 30 mA at 24 V
= 38 mA at 24 V
= 34 mA at 24 V
= 42 mA at 24 V
Also, if several control head valves were to be opened simultaneously, the switch signal will be sent staggered to the valves. Only one valve will consume 0.9 W at any time.
Calculation Examples:
Example 1:
3 valves are activated simultaneously, one position is reported (state for 200 ms):
P
Total
= P
El
+ 1 x P
Valve-On
+ 2 x P
Valve
+ 1 x P
LED
4,2 W = 0.7 W + 1 x 0.9 W + 2 x 0.8 W + 1 x 1.0 W
or
I
Total
= I
El
+ 1 x I
Valve-On
+ 2 x I
Valve
+ 1 x I
LED
178 mA = 30 mA + 1 x 38 mA + 2 x 34 mA + 1 x 42 mA
Example 2:
3 valves have been activated simultaneously, one position is reported (persistent state):
P
Total
= P
El
+ 3 x P
Valve
+ 1 x P
LED
4.1 W = 0.7 W + 3 x 0.8 W + 1 x 1.0 W
or
I
Total
= I
El
+ 3 x I
Valve
+ 1 x I
LED
174 mA = 30 mA + 3 x 34 mA + 1 x 42 mA
When using an external initiator, its power requirement should be added.
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24 V DC - Design
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Control Head Type 8681
Safety instructions10.4.
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 the isolated state!•
WARNING!
Risk of injury due to electrical 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 touch 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 an uncontrolled restart!
Secure system from unintentional activation.•
Following installation, ensure a controlled restart.•
10.5. Electrical Installation / Start-up
10.5.1. Cable Gland with Screw-type Terminals
Procedure:
→ 8. Opening and Closing the Housing.
Open the housing observing the notes contained in chapter
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.
→
Secure the wires to the connection terminals according to the pin assignments depicted in Fig. → 11.
If necessary, secure the cable with a cable tie!
Close the housing observing the notes contained 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 an external initiator is not used, the cable gland (wrench size 19, Ø 3 - 6 mm) must be tightly sealed with •
the dummy plug (Ø 5 - 6 mm) supplied from the factory!
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24 V DC - Design
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Control Head Type 8681
NOTE!
Use of the Control Head in Explosive Atmosphere
Only use cables and cable glands that are allowed for the respective application area, and mount the cable •
gland 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
Solenoid valve
connection with
status
LED for Valve 1
Service
interface
Terminal strip
Power
supply
Feedback
signals
S1-S4 OUT
Control sole-
noid valves
Y1-3
Fig. 11: 24 V DC electronics module
Designation
Terminal strip
Configuration
24 V Power supply 24V 24 V
Designation
Terminal strip
DIP switches for
color coding the
LEDs
Solenoid valve con-
nection with status
LEDs for
Valves 2 & 3
Connection
for the external
initiator
Configuration
Power supply 24 V for external
initiator
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
(order variant "Analog":
output - analog signal)
S4 OUT External initiator output
Y1 Solenoid valve 1 input
Y2 Solenoid valve 2 input
Y3 Solenoid valve 3 input
36
24 V DC - Design
Circuit diagram 24 V DC:
english
Control Head Type 8681
*) Order variant "Analog": output - analog signal
Circuit diagram 24 V DC Fig. 12:
37
24 V DC - Design
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Control Head Type 8681
Multi-pole Connection10.5.2.
Internal cabling work is not required for models 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 following pin assignments:
Input and output signals to the higher-level control (PLC):
12-pole circular plug-in connector M12 x 0.75 - male (acc. to IEC 61076-2-101)
Pin 3 - S1 out Pin 2 - GND
Pin 4 - S2 out
Pin 1 - 24 V
Pin 5 - S3 out
11
10
12
Pin 6 - S4 out
12-pole multi-pole connection (view onto the plug pins)Fig. 13:
Pin 7 - Y1
Pin 9 - Y3
Pin 8 - Y2
The center pins
(10, 11 and 12)
are not used.
Pin Designation Configuration
1 24 V Power supply 24V
2 GND GND
3 S1 out Output position S1
4 S2 out Output position S2
5 S3 out Output position S3 (order variant "Analog": output - analog signal)
6 S4 out External initiator output S4
7 Y1 Solenoid valve 1 input
8 Y2 Solenoid valve 2 input
9 Y3 Solenoid valve 3 input
10 not used
11 not used
12 not used
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AS Interface - Design
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Control Head Type 8681
11. AS INTERFACE - DESIGN
Definition11.1.
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).
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 conforms to the version 3.0 specification).
Technical Data of the AS Interface of the Control Head:
See chapter 6. Technical 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. For details, see chapter 11.8. Programming
Data.
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AS Interface - Design
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Control Head Type 8681
Electrical Connection Options for AS Interface 11.2.
The following connection concepts are available for the electrical connection of the control head:
Cable gland with multi-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 to IEC 61076-2-101, 4-pole)
on 8 cm cable
left: AS interface
right: external initiator
Connection Concepts for AS InterfaceFig. 14:
with multi-pole connection (M12 plug according to
IEC 61076-2-101, 4-pole) on 80 cm cable
left: AS interface
right: external initiator
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.
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).
Default: 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 (the address range restriction).
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AS Interface - Design
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Control Head Type 8681
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 following table and example calculation).
Model Calculated line length (incl. internal cabling)
Multi-pole (cable 8 cm) 0.3 m
Multi-pole (cable 80 cm) 1.0 m
Example:
for multi-pole connection with 8 cm cable:
The AS interface cable harness may still be 81.4 m (100 m - 62 * 0.3 m) at maximum when using 62 control
heads.
If the calculated line length of 100 m were to be exceeded, a commercially available AS interface repeater may be
used, as needed.
Observe the maximum power supply using certified AS Interface power supplies ≤ 8 A!
For details, refer to the AS Interface Specification.
Observe the optional design "AS Interface with External Power Supply" to reduce the load on the AS interface
bus segment!
Use cables according to the AS Interface Specification.
The maximum cable length may change when using other cables.
Electrical Data11.4.
Comments / Notes:
Outputs (from master perspective): 0 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 up to 100 ms, the
outputs are set to 0
Setting the valve's power supply using jumpers on the AS interface electronics module:
via AS interface Externally
(Connection see chapter 11.7. Electrical installation
AS Interface)
Jumper
Jumper
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.
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AS Interface - Design
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Control Head Type 8681
Connections:
Multi-pole connection version 1 x M16 x 1.5 cable gland / A/F19 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 signal)
1 x M16 x 1.5 cable gland / A/F19
for external initiator
clamping area 3 to 6 mm, with dummy plugs
with screw terminals for cable cross-sections 0.14 to 1.5 mm²
Power supply: 29.5 to 31.6 V DC (according to specification)
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 2- and 3-conductor,
NO or NC (factory setting NO), PNP output
Input current 1 signal: I
Input voltage 1 signal: U
Input current 0 signal: I
Input voltage 0 signal: U
> 6.5 mA, limited internally to 10 mA
Sensor
> 10 V
Sensor
< 4 mA
Sensor
< 5 V
Sensor
Inputs (from master perspective) binary feedback signals:
The retrieval of the 3 valve positions reported back binarily is described in chapter 15. Position Measuring System.
Outputs (from master perspective) / solenoid valves:
Switcing capacity, max. 0.8 W via AS interface or 0.9 W during activation, per solenoid valve
Watchdog function integrated
Output power reduction via AS interface - electronics integrated
pull-in current 30 mA or 0.9 W / 200 ms (at 30.5 V AS Interface voltage)
Holding current 26 mA or 0.8 W (at 30.5 V AS Interface voltage)
Operating mode Long-term operation (100 % ED)
Valve type Type 6524
Central display of the switching states:
power consumption from AS-i
at 30.5V 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 16. LED - Color
Assignments.
Power supply via AS interface bus (without external power supply):
Max. power consumption from AS interface 200 mA (incl. external initiator with 30 mA)
Power consumption input during normal operation
from the AS interface (after current reduction): ≤ 150 mA
3 valves activated, 1 Position reported back by LED
display, no external initiator
Integrated short-circuit protection
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AS Interface - Design
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Control Head Type 8681
NOTE!
If all three 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 AS interface from overloads.
Please observe the notes on power requirement and maximum expansion stage of the AS interface
network contained in chapter 11.3. Number of Connectable Control Heads and Maximum Length of the
Bus Line and in the AS Interface Specifications, where applicable.
External Power Supply:
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 may not have an earth connection.
Max. power consumption from external
power supply for
outputs (solenoid valves) -
without integrated current limiting ≤ 110 mA at 24 V DC
Max. power consumption from AS interface
for inputs and display ≤ 150 mA typ.
Integrated short-circuit protection
Please observe the notes on power requirement and maximum expansion stage of the AS interface
network contained in chapter 11.3. Number of Connectable Control Heads and Maximum Length of the
Bus Line and in the AS Interface Specifications, where applicable.
Design Aid11.5.
Design aid for supply of the valves via the AS Interface Bus
Power consumption of the electronics:
P
El
Power consumption of a valve during activation (200 ms):
P
Valve-On
Power consumption of a valve after reduction:
P
Valve
= 1.0 W or I
= 0.9 W or I
= 0.8 W or I
El
Valve-On
Valve
= 33 mA at 30.5 V
= 30 mA at 30.5 V
= 26 mA at 30.5 V
Power consumption of an optical position report:
P
LED
= 1.0 W or I
LED
= 33 mA at 30.5 V
For the design of the maximum line length observe chapter 11.3. Number of Connectable Control Heads and
Maximum Length of the Bus Line.
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 valve will consume 0.9 W at any time.
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Control Head Type 8681
Calculation Examples:
Example 1:
3 valves are activated simultaneously, one position is reported (state for 200 ms):
P
Slave
= P
El
+ 1 x P
Valve-On
+ 2 x P
Valve
+ 1 x P
LED
4.5 W = 1.0 W + 1 x 0.9 W + 2 x 0.8 W + 1 x 1.0 W
or
I
Slave
= I
El
+ 1 x I
Valve-On
+ 2 x I
Valve
+ 1 x I
LED
148 mA = 33 mA + 1 x 30 mA + 2 x 26 mA + 1 x 33 mA
Example 2:
3 valves have been activated simultaneously, one position is reported (persistent state):
P
Slave
= P
El
+ 3 x P
Valve
+ 1 x P
LED
4.4 W = 1.0 W + 3 x 0.8 W + 1 x 1.0 W
or
I
Slave
= I
El
+ 3 x I
Valve
+ 1 x I
LED
144 mA = 33 mA + 3 x 26 mA + 1 x 33 mA
When using an external initiator, its power requirement should be added.
Safety instructions11.6.
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 the isolated state!•
WARNING!
Risk of injury due to electrical 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 installation!
Installation may be carried out by authorized technicians only and with the appropriate tools!•
Risk of injury from unintentional activation of the system and an uncontrolled restart!
Secure system from unintentional activation.•
Following installation, ensure a controlled restart.•
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Control Head Type 8681
11.7. Electrical installation AS Interface
Internal cabling work is not required for any of the AS Interface designs 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 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 that are allowed for the respective application area, and mount the cable •
gland according to the respective operating instructions!
Close all unnecessary openings with lock screws/plugs approved for explosions area!•
AS interface bus connection (power supply via bus or external power supply)
1 4-pole male M12 round plug (acc. to IEC 61076-2-101)
(view onto the M12 plug, from the front onto the pins)
Pin 2: NC
Pin 3: ASI - Pin 1: ASI +
Pin 4: NC
Bus connection
power supply via bus
AS Interface bus connection (power supply via bus / external power supply)Fig. 15:
Pin Configuration
(supply via bus)
Pin 3: ASI - Pin 1: ASI +
Bus connection
with external power supply
Configuration
(external power supply)
Pin 2: GND
Pin 4: 24 V +
Wire color
1 AS interface, ASI+ AS interface, ASI+ brown
2 not used GND white
3 AS interface, ASI - AS interface, ASI - blue
4 not used 24 V + black
Power supply to the valves via the bus External power supply to the valves
Jumper
Jumper setting on AS interface electronics module: Power supply to the valves via the bus or externallyFig. 16:
Jumper
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AS Interface - Design
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Control Head Type 8681
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.
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.
Procedure:
→
Open the ribbon cable terminal
(loosen screws and remove cover)
Insert cable harness
→
Close ribbon cable terminal again →
Screws
M12 plug-in connector branch circuit
Optional ribbon cable terminal for AS interface cable harnessFig. 17:
AS Interface Electronics Module - LED Status Displays:
LED Status Displays
"Power" and "Fault"
Tighten the screws →
Loosen the thread-forming screws slightly and position
them on the existing tapped bore and screw in.
LED 1 "Power"
(green)
off off Power OFF
on on No data traffic (expired Watch Dog at slave address does not equal 0)
on off OK
flashing on Slave address = 0
flashing flashing Sensor supply overloaded / manual actuation activated / untaught / mainte-
The centre illuminated display flashes in the fault color (see chapter 16.2. Blinking Pattern & Fault Signaling)
when Status LED 2 "Fault" is active.
LED 2 "Fault"
(red)
Signalized status
nance request / smartphone software service mode
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Control Head Type 8681
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 electronic 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 master due to the different ID codes!
In this case (intentional replacement), the current configuration must be reprojected in the AS interface
master. Please read the operating instructions of the used AS interface master!
Programming Data Table:
Programming Data for 62 Slaves
AS interface - Device for A/B slave
addressing (default device)
I/O configuration 7 hex (4 inputs / 4 outputs)
See the 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. F.F
Bit Configuration Table:
Data bit D3 D2 D1 D0
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 P0
Output not used not used not used not used
Programming Data for 31 Slaves
AS Interface (optional)
7 hex (4 inputs / 4 outputs)
See the Bit Configuration Table:
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Control Head Type 8681
12. DEVICENET - DESIGN
Definition12.1.
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 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.
Electrical connection option 12.2.
Connection concept DeviceNetFig. 18:
DeviceNet specification12.3.
EDS file 8681.EDS
Icons 8681.ICO
Cable gland with multi-pole connection
(M12 plug according to IEC 61076-2-101, 5-pole)
Connection left: Voltage, signals
Connection right: external initiator
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 (can be adjusted using DIP switches 1 ... 6);
factory setting: 63
(see chapter 12.10.1. Settings of the DeviceNet address)
Process data 2 static input assemblies
(Input: from the control head to the DeviceNet Master/Scanner)
1 static output assembly:
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Control Head Type 8681
Inputs 3 discrete feedback signal of the position measuring system (positions S1 - S3)
1 discrete feedback signal of the external initiator (S4)
1 analog position signal in mm
supply via DeviceNet string (11 to 25 V DC)
Switch level high signal ≥ 5 V
Switch level low signal ≤ 1.5 V
Outputs 3 solenoid valves
Power consumption
from the bus: max. output 5 W, if all valves are switched (3 x type 6524 with 0.8 W each)
Total line length and maximum line length according to 12.3.1.
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).
The maximum total line length (sum of trunk lines and drop lines) of a network depends on the baud rate.
1
Thin Cable*
2
Baud rate
Maximum total line length*
Thick Cable*
2
125 kbaud 500 m
250 kbaud 250 m
100 m for all baud rates
500 kbaud 100 m
1
According to DeviceNet specification. If a different cable type is used, lower maximum values apply.
*
*2 For cable designation and details refer to DeviceNet specification
Drop Line Length12.3.2.
Length of the drop lines
Baud rate
Maximum length
125 kbaud
250 kbaud 78 m
6 m for all baud rates
500 kbaud 39 m
Maximum total length of all drop lines in the
network
156 m
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Control Head Type 8681
Electrical Data12.4.
Connections:
"Multi-pole" 1 x M16 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 for external initiator
clamping area 3 to6 mm, with dummy plugs
with screw terminals for cable cross-sections 0.14 to 1.5 mm²
Electrical power supply: 11 to 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
power supply: max. 30 mA
Short-circuit protection
Design: DC 2- and 3-conductor,
Normally open contact, PNP output
Input current 1 signal: I
Input voltage 1 signal: U
Input current 0 signal: I
Input voltage 0 signal: U
> 6.5 mA, limited internally to 10 mA
Sensor
> 10 V
Sensor
< 4 mA
Sensor
< 5 V
sensor
Inputs (from master perspective) / binary or analog feedback signals:
The recovery of the 3 valve positions reported back binarily or of the analog position signalis described in
chapter 15. Position Measuring System.
Outputs (from master perspective) / solenoid valves:
max. switching capacity 1.0 W
typ. continuous output 0.8 W
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 (100 % ED)
Valve types 6524
Central display of the switching states:
Power consumption from DeviceNet
at 24 V DC 42 mA with 24 V DC power supply per illuminated display shown;
Color switching see chapter 16. LED - Color Assignments
Safety Position if the Bus Fails12.5.
If the bus fails, the solenoid valve is switched to a programmable safety position (default: solenoid valve is in poweroff-state). For configuration data see chapter "12.12.1. Configuration of the Safety Position of Solenoid Valves if
Bus Error".
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DeviceNet - Design
Design Aid12.6.
english
Control Head Type 8681
Power consumption of the electronics:
P
El
Power consumption of a valve during activation (200 ms):
P
Valve-ON
Power consumption of a valve after reduction:
P
Valve
Power consumption of an optical position report:
P
LED
= 1.44 W or I
= 1.0 W or I
= 0.8 W or I
= 1.0 W or I
El
Valve-ON
Valve
LED
= 60 mA at 24 V
= 42 mA at 24 V
= 34 mA at 24 V
= 42 mA at 24 V
Calculation Examples:
Example 1:
3 valves are activated simultaneously, one position is reported (state for 200 ms):
P
Total
= P
El
+ 3 x P
Valve-ON
+ 1 x P
LED
5.44 W = 1.44 W + 3 x 1.0 W + 1 x 1.0 W
or
I
Total
= I
El
+ 3 x I
Valve-ON
+ 1 x I
LED
228 mA = 60 mA + 3 x 42 mA + 1 x 42 mA
Example 2:
3 valves have been activated simultaneously, one position is reported (persistent state):
P
Total
= P
El
+ 3 x P
Valve
+ 1 x P
LED
4.84 W = 1.44 W + 3 x 0.8 W + 1 x 1.0 W
or
I
Total
= I
El
+ 3 x I
Valve
+ 1 x I
LED
204 mA = 60 mA + 3 x 34 mA + 1 x 42 mA
When using an external initiator, its power requirement should be added.
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Control Head Type 8681
Safety instructions12.7.
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 the isolated state!•
WARNING!
Risk of injury due to electrical 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 an uncontrolled restart!
Secure system from unintentional activation.•
Following installation, ensure a controlled restart.•
Electrical Installation - DeviceNet12.8.
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.
View of plug from the
front onto the pins:
Pin 4: CAN_H
white
Pin 5: CAN_L
blue
Pin 1: Drain
(Shield)
Pin 3: V–
black
Pin 2: V+
red
Bus connection of DeviceNet with external power supplyFig. 19:
Pin 1 2 3 4 5
Signal Shielding V + V – CAN_H CAN_L
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DeviceNet - Design
DeviceNet electronics module:
english
Control Head Type 8681
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
DeviceNet
power supply
Bus
signals
DeviceNet electronics moduleFig. 20:
Teach-In buttons
T1-3
Service
interface
DIP switches for
color coding
the LEDs
Solenoid valve con-
nection with status
LEDs for
Valves 2 & 3
Connection
for the exter-
nal initiator
Terminal strip configuration:
Designation
Terminal strip
V +
V-
Configuration
DeviceNet
power supply
DeviceNet
power supply
Designation
Terminal strip
Configuration
V + Power supply for external initiator
S4 IN External initiator input
CAN_H Bus signal CAN high GND GND external initiator
CAN_L Bus signal CAN low
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Control Head Type 8681
Network Topology of a DeviceNet System12.9.
When installing a DeviceNet system, ensure that the terminating circuit of the data lines is correct. The circuit prevents the occurrence of interference caused by signals reflected onto the data lines.
The trunk line must be terminated at both ends with resistors of 120Ω and 1/4 W power loss (see "Fig. 21:
Network topology").
Fig. 21: illustrates a line with one trunk line and several drop lines. Trunk lines and drop lines consist of identical
material.
Trunk line
V +
V –
CAN_H
CAN_L
DeviceNet cable
Terminating
resistor
120 Ω
¼ W
T01 Tn
Subscriber 1 (node 1) Subscriber n (node n)
Network topologyFig. 21:
Configuring the DeviceNet address / baud rate12.10.
8 DIP switches are available for configuration:
DIP switches 1 to 6 for the DeviceNet address•
DIP switches 7 to 8 for the baud rate•
Drop lines
DeviceNet cable,
max. 6 m long
Terminating
resistor
120 Ω
¼ W
Position of the DIP switchesFig. 22:
54
DeviceNet - Design
Settings of the DeviceNet address12.10.1.
english
Control Head Type 8681
MAC ID address = Medium Access Control Identifier Address
0
MAC ID address = [DIP 1 ⋅ 2
with DIP x = off = 0 and DIP x = on =1
Table of the Settings of the DeviceNet address:
+ DIP 2 ⋅ 21 + DIP 3 ⋅ 22 + DIP 4 ⋅ 2
3
+ DIP 5 ⋅ 24 + DIP 6 ⋅ 25]
MAC
DIP1 DIP2 DIP3 DIP4 DIP5 DIP6
ID
MAC
DIP1 DIP2 DIP3 DIP4 DIP5 DIP6
ID
0 off off off off off off 32 off off off off off on
1 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
4 off off on off off off 36 off off on off off on
5 on off on off off off 37 on off on off off on
6 off on on off off off 38 off on on off off on
7 on on on off off off 39 on on on off off on
8 off off off on off off 40 off off off on off on
9 on off off on off off 41 on off off on off on
10 off on off on off off 42 off on off on off on
11 on on off on off off 43 on on off on off on
12 off off on on off off 44 off off on on off on
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
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
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
19 on on off off on off 51 on on off off on on
20 off off on off on off 52 off off on off on on
21 on off on off on off 53 on off on off on on
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
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Control Head Type 8681
Setting the baud rate12.10.2.
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.•
Configuration of Process Data12.11.
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 Connection Path when an I/O connection is initialized according to the DeviceNet specification.
Static Input Assemblies12.11.1.
Name Address of data attribute of the
assemblies for read access.
Class, instance, attributes
S1 - S4 (factory setting) 4, 1, 3 Byte 0:
S1 - S4 + POS
(with POS:
actual position)
4, 2, 3 Byte 0:
Format of the data attribute
Value 0: OFF
Value 1: ON
Bit 0: Position S1
Bit 1: Position S2
Bit 2: Position S3
Bit 3: Position S4
Bit 0: Position S1
Bit 1: Position S2
Bit 2: Position S3
Bit 3: Position S4
Bits 4-7: not used
Byte 1:
POS in mm
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Control Head Type 8681
The addresses listed in the table above ("Static input assemblies") can be used as a path data for the attribute
Produced Connection Path of an I/O connection.
Nevertheless, by using this address data, the attributes combined in the assemblies can also be accessed acyclically via Explicit Messages.
Static Output Assembly12.11.2.
Name Address of data attribute of the
assemblies for read access.
Class, instance, attributes
Solenoid valves 1-3 4, 21, 3 Byte 0:
The address listed in the table above ("Static input assembly") can be used as a path data for the attribute Produced Connection Path of an I/O connection.
Nevertheless, by using this address data, the attributes combined in the assemblies can also be accessed acyclically via Explicit Messages.
Format of the data attribute
Value 0: OFF,
Value 1: ON
Bit 0: SV1
Bit 1: MV2
Bit 2: MV3
Bits 3-7: not used
Configuration of the device12.12.
Configuration of the Safety Position of Solenoid Valves if 12.12.1.
Bus Error
The valve safety position and safety module attributes can be used to configure the solenoid 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:
(Attribute address:
class 150, instance 1, attribute 7)
Bit Mode Value assignment Bit Solenoid valve Value assignment
0 Drive to
safety position
1 Retain last valve
position
Bit 0
Bits
1-7
Characteristics in event
of bus error
not used 0 (always) Bit 2 Y3 (solenoid valve 3) Value 0: OFF / value 1: ON
1 data byte for valve safety mode:
(Attribute address:
class 150, instance 1, attribute 6)
Bit 0 Y1 (solenoid valve 1) Value 0: OFF / value 1: ON
Bit 1 Y2 (solenoid valve 2) Value 0: OFF / value 1: ON
Bits
3-7
not used 0 (always)
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Control Head Type 8681
Configuration example 12.12.2.
The example describes the principle procedure when configuring the device using the software RSNetWorx 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 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. 23" indicates how, for example, an input assembly which deviates from the factory setting (input process
data can be transferred via I/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.
Selecting the input assembly (screenshot)Fig. 23:
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DeviceNet - Design
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Control Head Type 8681
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.
Display of the Status LEDs in the event of a bus 12.13.
error
Bus errors are also indicated on the central three-colored status display, see chapter 16.2. Blinking
Pattern & Fault Signaling!
The device status LED
("Module") and the bus status
LED ("Network") are located on
the electronics module.
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
"Module" 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.
Status of the device status LED "Modules"12.13.1.
LED Device state Explanation
Off No supply Device is not supplied with voltage•
Green Device is working Normal operating state•
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Control Head Type 8681
State of bus status LED "Network"12.13.2.
LED Device state Explanation Troubleshooting
Off No voltage / not
online
Device is not supplied with voltage•
Device has still not ended Duplicate •
MAC ID Test (test lasts approx. 2 s)
Connect other devices, if the device •
is the only network subscriber,
Replace device•
Green Online, connection
to master exists
Flashes
green
Online, without
connection to
master
Flashes
red
Connection
time-out
Red Critical fault Another device with the same MAC •
Device cannot end Duplicate MAC •
ID Test.
Normal operating state with estab-•
lished connection to the master
Normal operating state without •
established connection to the
master
One or more I/O connections are in •
Time-Out state
ID address is in the circuit
No bus connection due to communi-•
cation problems
Check baud rate•
Check bus connection•
New connection establishment by •
master to ensure that the I/O data
is transmitted cyclically.
Check baud rate•
As a possible remedy of error, •
please check address
If required, replace device•
60
120 V AC - Design
13. 120 V AC - DESIGN
english
Control Head Type 8681
Electrical connection options 13.1.
Cable gland:
Connection left: Voltage, signals
Connection right: external initiator
Connection concept 120 V ACFig. 24:
Electrical Data13.2.
Central power supply: 110 to 130 V AC, 50/60 Hz
Connections: Cable gland 1 x M16 x 1.5 cable gland / SW22
for power supply and signals
clamping area 5 to 10 mm, with dummy plugs
with screwterminals for cable cross-sections of 0.5 to 1.5 mm
incl. PE connection terminal
(tightening torque of the clamping screws max. 0.5 Nm)
1 x M16 x 1.5 cable gland / SW19
for external initiator
clamping area 3 to 6 mm, with dummy plugs
with screw terminals for cable cross-sections of 0.5 to 1.5 mm²
Power consumption (standby current): 10 mA at 120 V AC
Solenoid valves:
Power consumption per solenoid valve: max. 1.4 VA (1.7 VA during activation)
Power consumption per solenoid valve: 12 mA at 120 V AC
Operating mode: Long-term operation (100 % ED)
2,
Central display of the switching states: 13 mA with a power supply of 120 V AC per illuminated
display;
Color switching see chapter 16. LED - Color Assignments
Outputs/binary feedback signals: S1out - S3out
Design: Normally open contact, L switching,
short-circuit protection via automatically resetting fuse
switchable output current: max. 50 mA per feedback signal
Output voltage - active: ≥ (operating voltage - 2 V)
Output voltage - inactive: max. 1 V in unloaded state
61
120 V AC - Design
english
Control Head Type 8681
Feedback signal output: S4 out is directly connected to S4 in
Input / proximity switches (external initiator: S4 in):
Power supply: voltage present at control head U
Nominal
Current carrying capacity, sensor
power supply: max. 0.7 A
Short-circuit protection
Design: DC 2- and 3-conductor,
Normally open contact, L-switching
input current 1-Signal: I
Sensor
< 2 mA
Valve control inputs (Y1 - Y3):
Signal level - active: U > 60 V AC
Signal level - inactive: U < 20 V AC
Impedance: > 40 kOhm
= 120 V AC, 50/60 Hz
62
120 V AC - Design
english
Control Head Type 8681
Design Aid13.3.
Power consumption of the electronics:
P
El
Power consumption of a valve during activation (200 ms):
P
Valve-ON
Power consumption of a valve after reduction:
P
Valve
Power consumption of an optical position report:
P
LED
Also, if several control head valves were to be opened simultaneously, the switch signal will be sent staggered to the valves. Only one valve 1.7 VA will ever be recorded.
= 1.2 VA or I
= 1.7 VA or I
= 1.4 VA or I
= 1.6 VA or I
El
Valve-ON
Valve
LED
= 10 mA at 120 VA
= 14 mA at 120 VA
= 12 mA at 120 VA
= 13 mA at 120 VA
Calculation Examples:
Example 1:
3 valves are activated simultaneously, one position is reported (state for 200 ms):
P
Total
= P
El
+ 1 x P
Valve-ON
+ 2 x P
Valve
+ 1 x P
LED
7.3 VA = 1.2 VA + 1 x 1.7 VA + 2 x 1.4 VA + 1 x 1.6 VA
or
I
Total
= I
El
+ 1 x I
Valve-ON
+ 2 x I
Valve
+ 1 x I
LED
61 mA = 10 mA + 1 x 14 mA + 2 x 12 mA + 1 x 13 mA
Example 2:
3 valves have been activated simultaneously, one position is reported (persistent state):
P
Total
= P
El
+ 3 x P
Valve
+ 1 x P
LED
7.0 VA = 1.2 VA + 3 x 1.4 VA + 1 x 1.6 VA
or
I
Total
= I
El
+ 3 x I
Valve
+ 1 x I
LED
59 mA = 10 mA + 3 x 12 mA + 1 x 13 mA
When using an external initiator, its power requirement should be added.
63
120 V AC - Design
english
Control Head Type 8681
Safety instructions13.4.
DANGER!
Risk of injury due to electrical 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 must 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 the isolated 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 an uncontrolled restart!
Secure system from unintentional activation.•
Following installation, ensure a controlled restart.•
Electrical Installation / Start-up13.5.
DANGER!
Risk of injury due to electrical 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:
→ 8. Opening and Closing the Housing".
Open the housing observing the notes contained in chapter "
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 pin assignment described in → Fig. 25: 120 V
AC electronics module. If necessary, secure the cable with a cable clip!.
64
120 V AC - Design
english
Control Head Type 8681
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. →
Close the housing observing the notes contained 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 an external initiator is not used, the cable gland (wrench size 19, Ø 3 - 6 mm) must be tightly sealed with •
the dummy plug (Ø 5 - 6 mm) supplied from the factory!
NOTE!
Use of the Control Head in Explosive Atmosphere
Only use cables and cable glands that are allowed for the respective application area, and mount the cable •
gland according to the respective operating instructions!
Close all unnecessary openings with lock screws/plugs approved for explosions area!•
120 V AC Electronics Module, Terminal Strip Configuration:
Solenoid valve
connection with
status
LED for Valve 1
Terminal strip
Protective
conductor
(protection earth)
Power supply
(L/N)
Feedback
signals
S1-S4 OUT
Service inter-
face
Teach-In buttons
T1-3
Solenoid valve con-
nection with status
LEDs for Valves 2
& 3
DIP switches for
color coding the
LEDs
120 V AC electronics moduleFig. 25:
Control sole-
noid valves
Y1-3
Connection
for the exter-
nal initiator
65
120 V AC - Design
english
Control Head Type 8681
Designation
Terminal strip
PE
L
Configuration
Protection earth protective conductor
live conductor
Electrical
power supply
N N
neutral conductor
120 V AC
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
Circuit diagram 120 V AC:
Designation
Terminal strip
L
Configuration for external initiator
Electrical power supply -
live conductor
S4 IN External initiator input
Electrical power supply -
neutral conductor
Circuit diagram 120 V AC Fig. 26:
66
Connection of an External Initiator
english
Control Head Type 8681
CONNECTION OF AN EXTERNAL INITIATOR14.
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 the isolated state!•
An external initiator can be connected using the small 3-pin screw terminal - according to the respective design (see e.g. Fig. 25 and the respective chapter "Electrical Installation").
Designation - according to design Configuration
24 V DC, AS-i DevNet 120 V AC
24 V 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)
For the electrical requirements for the external initiator refer to chapter entitled 6. Technical Data.
Procedure:
Open the housing observing the notes contained in chapter
→ 8. Opening and Closing the Housing.
Assemble the connecting cables according to the general 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 pin assignment. →
Close the housing observing the notes contained 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 an external initiator is not used, the cable gland (wrench size 19, Ø 3 - 6 mm) must be tightly sealed with •
the dummy plug (Ø 5 - 6 mm) supplied from the factory!
Use of the Control Head in Explosive Atmosphere
Only use cables and cable glands that are allowed for the respective application area, and mount the cable •
gland according to the respective operating instructions!
Close all unnecessary openings with lock screws/plugs approved for explosions area!•
Connection of a 2-wire or 3-wire initiator:
Connection of a 2-wire initiator: Connection of a 3-wire initiator:
24 V DC, AS-i DevNet 120 V AC 24 V DC, AS-i DevNet 120 V AC
67
Position Measuring System
english
Control Head Type 8681
15. POSITION MEASURING SYSTEM
The switching positions of the process valve are reported to the higher-level control by feedback signals from the
contactless position measuring system. Connection to the control head is done by means of a simple adaptation
to the process valve's piston.
The recordable stroke range is between 0 and 80 mm.
Three binary feedback signals are evaluated:
- Position 1 (a discrete S1OUT signal)
- Position 2 (a discrete S2OUT signal)
- Position 3 (a discrete S3OUT signal).
The 24 V DC design is also in the ordering option "Analog" available:
- Position 1 (a discrete S1OUT signal)
- Position 2 (a discrete S2OUT signal)
- Position 3 (an analog (4...20 mA) S3OUT signal).
Three Teach-In buttons have been provided for comparison with the actual stroke range. The switching positions
for the position measuring system can be determined with these buttons or by means of the service interface
(on the electronics module).
A discrete, external feedback signal (standard proximity switch) can also be processed (S4IN, S4OUT).
S15.1. etting the Position Measuring System (Teach-In)
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 the isolated state!•
Example procedure (for three valve positions):
→ 8. Opening and Closing the Housing.
Open the housing observing the notes contained in chapter
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 three times during the teaching phase.
Once this position has been stored, 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 three times during the teaching phase.
Once this position has been stored, the corresponding LED will remain continuously 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 three times during the teaching phase.
Once this position has been stored, the corresponding LED will flash continuously until the position of the
piston is changed.
68
Position Measuring System
english
Control Head Type 8681
If necessary, return control head and system to normal state (switching position, power supply). →
Close the housing observing the notes contained in chapter → 8. Opening and Closing the Housing.
If the piston or the target are located outside the measuring area during the teaching phase, the LED will
flash 3 times 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 correspond to the lower piston position, etc.
Teach-In buttons
T2
T3
T1
Electronics module, 24 V DC Electronics module, ASI
Teach-In buttons on the electronics modules (on the example of the electronics modules for 24 V DC and AS-i)Fig. 27:
Teach-In Functions15.2.
Teach-In Functions and Teach-In Reset15.2.1.
Teach-In
button
T1 Teach function S1 1.5 s S1 blinks quickly three times, then continuously in the encoded color
T2 Teach function S2 1.5 s S2 blinks quickly three times, then continuously in the encoded color
T3 Teach function S3 1.5 s S3 blinks quickly three times, then continuously in the encoded color
T1 + T2 Teach-In reset S1, S2,
Function Activation
duration
2.5 s Blinks in the fault color
and S3
Optical feedback
Difference between the different "blinking patterns" - see chapter 16.2. Blinking Pattern & Fault Signaling.
69
Position Measuring System
english
Control Head Type 8681
Autotune functions15.2.2.
Teach-In
button
T2 + T3
Mode Activa-
tion
duration
Autotune
mode
2.5s
opt. feed-
back
green +
yellow +
red
continuously
on
Teach-In
button
T1 Autotune 1
T2 Autotune 2
+
T3 Autotune 3
T1 + T2 Autotune 4
T1 + T3 Autotune 5
T2 + T3 Autotune 6
Function Activation
duration
0.5s
opt. feed-
back
green +
yellow +
red
chaser mode
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 is not working properly or is aborted (in case no compressed air is connected, for
example), the already taught positions are deleted again; the corresponding Autotune function is exited
and switched to normal operation.
The teach positions are set to "not taught", i.e. they blink in the fault color.
Autotune sequence 15.2.3.
Autotune 1:
Control Effect on the process valve internal program Error
T2 + T3 Autotune mode starts
T1
Autotune 1 starts
Closed position Teach T1
Valve opens 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
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". Only the programmed sequence
for "Auto-Teach sequence" 1 will run fully automatically:
- 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).
70
Position Measuring System
english
Control Head Type 8681
- 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 have been taught.
In the event that a Timeout occurs, the corresponding Autotune function will be exited and switched to
normal operation.
Furthermore, the Teach-In positions will be set to "not taught", i.e. they will blink in the fault color.
Autotune 2:
Control Effect on the process valve internal program Error
T2 + T3 Autotune mode starts
T2
Autotune 2 starts
Open position Teach T2
Valve closing Activate V1
Wait period 10s
Closed position Teach T1
Valve opens Deactivate V1
Valve opens Wait on position S2 S2 Timeout 15s
Autotune mode completed
Autotune 3:
Control Effect on the process valve internal program Error
T2 + T3 Autotune mode starts
T3
Autotune 3 starts
Closed position Teach T1
Valve opens Activate V1
Wait period 10s
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
71
Position Measuring System
english
Control Head Type 8681
Autotune 4:
Control Effect on the process valve internal program Error
T2 + T3 Autotune mode starts
T1 + T2
Autotune 4 starts
Valve closing Activate V2
Wait period 10s
Closed position Teach T1
Valve opens Deactivate V2
Activate V1
Wait period 10s
Open position Teach T2
Valve closing Deactivate V1
Activate V2
Valve closes Wait on position S1 S1 Timeout 15s
Neutral position Deactivate V2
Autotune mode completed
Autotune 5:
Control Effect on the process valve internal program Error
T2 + T3 Autotune mode starts
T1 + T3
Autotune 5 starts
Closed position Teach T1
Valve opens Activate V1
Wait period 10s
Open position Teach T2
Valve closing Deactivate V1
Valve closes Wait on position S1 S1 Timeout 15s
Intermediate position opens Activate V2
Wait period 10s
Intermediate position Teach T3
Valve closing Deactivate V2
Valve closes Wait on position S1 S1 Timeout 15s
Autotune mode completed
Autotune 6:
Reserved function
72
LED - Color Assignments
english
Control Head Type 8681
16. 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 corresponds to the subsequently listed tables.
To be able 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 four
DIP-switches on site.
(Delivered state DIPs 1 - 4: each set to position 0)
When using the control head in explosive atmosphere, the housing may only be opened in the isolated
state.
4 DIP Switches
Position 1:
On (up)
Position 0:
down
Electronics module, 24 V DC Electronics module, ASI
DIP switches for setting the color coding (on the example of the electronics modules for 24 V DC and AS-i)Fig. 28:
73
LED - Color Assignments
english
Control Head Type 8681
Setting the Color Combinations16.1.
Setting of the possible color combinations with the help of the DIP switches:
S1 S2 S3 S4 Fault DIP1 DIP2 DIP3 DIP4
green yellow green red 0 0 0 0
yellow green yellow red 1 0 0 0
green red green yellow 0 1 0 0
red green red yellow 1 1 0 0
green yellow yellow red 0 0 1 0
yellow green green red 1 0 1 0
green red red yellow 0 1 1 0
red green green yellow 1 1 1 0
green yellow green green red 0 0 0 1
yellow green yellow yellow red 1 0 0 1
green red green green yellow 0 1 0 1
red green red red yellow 1 1 0 1
green yellow yellow yellow red 0 0 1 1
yellow green green green red 1 0 1 1
green red red red yellow 0 1 1 1
red green green green yellow 1 1 1 1
(S4IN may be a normally closed contact (NC) or a normally open contact (NO) - factory setting: NO contact,
it can be changed via the service interface.)
16.2. Blinking Pattern & Fault Signaling
The LEDs blink in different blinking patterns in the event of a fault or in various states.
Blinking patterns ON OFF Note
Blinks three times in the corresponding color for that
100 ms 100 ms
position:
Teach-In confirmation (after successful teaching:
the color for position 1 and 2 is continuously on)
Blinks 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 (±0.5 mm) to a previously
defined teach position, or
- if magnetic manual control is used, even though manual
control function was disabled by software
74
LED - Color Assignments
Blinking patterns ON OFF Note
english
Control Head Type 8681
Permanent blinking in the fault color:
250 ms 250 ms
- Teaching does not occur
- Teach-Reset has been performed or
- Bus error
Permanent blinking 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)
125 ms 125 ms Signal from the external initiator S4
(like "color for position 3")
or
1 s 3 s Signal in fault color (and additionally
color of the corresponding valve position):
Maintenance/service required
16.3. Signal Priorities
If a valve has several overlapping states, the following priority list applies:
Internal Fault (fault color: 450 ms ON, 50 ms OFF) 1.
Manual operating mode is active, e.g. by magnetic manual control - see chapter 2. 17. Service Mode / Manual
Control (fault color: 50 ms ON, 450 ms OFF)
Maintenance/service prompt (fault color: 1 s ON, 3 s OFF)3.
Other fault, e.g. position measuring system not taught, bus error or other (see chapter 4. 16.2. Blinking Pattern
& Fault Signaling)
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).
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
75
Service Mode / Manual Control
english
Control Head Type 8681
17. SERVICE MODE / MANUAL CONTROL
By default, the control head provides the following (e.g. for service purposes):
a magnetic manual control that 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 equipped solenoid valve.•
17.1. Magnetic Manual Control
Markings for
magnetic
manual control
Magnetic
Manual Control
Fig. 29: Manual control on the basis of encoded magnetic fields
Irrespective of the signal of the higher-level control, the magnetic manual control sets the output of Solenoid Valve
1 electrically to an ON signal and, if control pressure is present, thereby switches the 2/A1 output.
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!
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 software - the magnetic manual control does not function in this case!
(see chapter 16.2. Blinking Pattern & Fault Signaling)
Caution!
When the electrical manual control (valve location 1) is activated:
the peripheral fault bit will be set for 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!
76
Service Mode / Manual Control
english
Control Head Type 8681
Procedure for activating & 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 between the cable glands for three seconds
(see Fig. 29)
("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 service measure has been completed, deactivate the magnetic manual control:
→
Hold the manual control tool on the identification points between the cable glands for three seconds
(see Fig. 29).
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 applied.
17.2. Mechanical Manual Control
If additional manual controls are required for additional service purposes or in the event of a failure of the electrical 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 the isolated state!•
Mechanical
manual control
Red lever:
left: 0
right: 1
Mechanical manual control of the solenoid valvesFig. 30:
Once the service measures have been completed, reset all manual controls to "0" for control-operated
operation of the system!
77
Maintenance, Troubleshooting
english
Control Head Type 8681
MAINTENANCE, TROUBLESHOOTING18.
Safety instructions18.1.
DANGER!
Risk of injury from high pressure in the equipment!
Before loosening pneumatic 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 the isolated state!•
WARNING!
Risk of injury due to electrical 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 be carried out by authorized technicians only and with the appropriate tools!•
Risk of injury from unintentional activation of the system and an uncontrolled restart!
Secure system from unintentional activation.•
Following maintenance, ensure a controlled restart.•
78
Maintenance, Troubleshooting
18.2. Safety Positions
english
Control Head Type 8681
Safety positions after failure of the electrical or pneumatic auxiliary power:
Safety positions
Operating mode Process valve design
single-acting
after failure of the auxiliary power
electrical pneumatic
Control function A
up
down
up
down
up
down
By default, the control head is equipped with solenoid valves in circuit function design C
(Circuit function C: 3/2-way valve; closed in rest position, output A unloaded).
If process valves with several switching positions (e.g. double-seated valves) are connected, the safety positions
of the individual drives can be viewed according to the same logic as for a classical one-seated valve.
air opening•
spring closing•
single-acting
Control function B
air closing •
spring opening•
double-acting
Control function I
air opening •
air closing•
down down
up up
not defined not defined
Safety positions after failure of the bus communication:
AS Interface:
If the watchdog is activated (default), behavior corresponds to the event of a failure of the auxiliary electrical
power, i.e. all solenoid valve outputs are set to "0".
DeviceNet:
See chapter "12.12.1. Configuration of the Safety Position of Solenoid Valves if Bus Error".
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Maintenance, Troubleshooting
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Control Head Type 8681
18.3. Maintenance
When used properly, the Control Head Type 8681 operates maintenance and trouble-free.
For service work, we offer spare part sets for certain components or modules (see chapter entitled "20. Spare
Parts").
manufacturer.
If service function is active (see chapter 6.6. Factory Settings in the Firmware) a maintenance prompt is issued signaled by a "blinking pattern" in the fault color (1 s ON, 3 s OFF) - see chapter 16.2. Blinking Pattern & Fault
Signaling.
Repairs to the control head for use in explosive atmosphere, however, are only allowed by the
Cleaning18.4.
NOTE!
Aggressive cleaning agents may damage the material!
In 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
→
in grooves and recesses.
If cleaning agent is not rinsed off carefully, its concentration may considerably exceed the concentration for
use once 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!
Malfunctions18.5.
In the event of any malfunctions in spite of a correct installation, proceed according to the fault analysis described
in the table below:
Fault description Possible cause of the fault Troubleshooting
No feedback signal Position of the position measuring
system (Teach-In) not appropriate
for the spindle position
Setting of the external initiators
incorrect
No or faulty associated feedback
signals or external initiator
Target is not mounted on the
process valve's spindle or target
faulty
Perform or repeat the Teach-In process
(see chapter 15.1. Setting the Position
Measuring System (Teach-In))
Set the external initiator according to the
respective operating instructions.
Set the connections according to the
pin and plug configurations described
in these operating instructions (for the
respective voltage and communication
variant).
Check the target for correct mounting
and condition (see chapter (6.5. Position
Measuring System Data)).
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Maintenance, Troubleshooting
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Control Head Type 8681
Fault description Possible cause of the fault Troubleshooting
Feedback signal is lost in
system operation
Valve output 2/A1 cannot be
switched off with the control
Valve outputs cannot be
switched off by the control
Faults are signaled by means
of LEDs
No or faulty function of the
process valves
Incorrect function of the
process valves
Position in the limit range of the
feedback area
Magnetic manual control is still
activated
Mechanical manual control at the
solenoid valve is still activated
Possible causes may vary
depending on the version
No electrical power supply or communication for the control head
No or insufficient pneumatic supply
of the control head
Confused pneumatic connection
lines
Valves not correctly connected on
electronics module
Repeat the Teach-In process
(see chapter 15.1. Setting the Position
Measuring System (Teach-In))
Check the process valve end positions
during operation against the end positions in non-operative state of the system.
Check the compressed air supply.
Deactivate the manual control -
see chapter "17.1. Magnetic Manual
Control"
Deactivate the manual controls at the
solenoid valves see chapter "17.2. Mechanical Manual
Control"
Please read the corresponding descriptions of the respective communication
variant in these operating instructions.
Check the power supply and the communication settings (also refer to detailed
descriptions of the respective versions in
these operating instructions)
Check the compressed air supply and
ensure that supply is sufficient
Check the correct pneumatic connection
of the control head to the process valve
(for Fluid Diagram, see chapter
"5.4.2. Fluid diagram" and the operating
instructions of the corresponding process
valves)
Check the correct electrical connection
of the solenoid valves see Fig. 11: 24 V DC electronics
module
In the event of any undefined faults, be sure to contact the service department of Bürkert.
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Replacement of Components and Modules
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Control Head Type 8681
REPLACEMENT OF COMPONENTS AND 19.
MODULES
If components or modules need to be replaced for maintenance or service reasons, please observe the following
notes and descriptions.
Devices that are used in the explosion-risk area may be repaired by the manufacturer only.
Safety instructions19.1.
DANGER!
Risk of injury from high pressure!
Before loosening pneumatic 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 the isolated state!•
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!•
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 an uncontrolled restart!
Secure system from unintentional activation.•
Following maintenance, ensure a controlled restart.•
NOTE!
IP65 / IP67 protection
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 that requires opening and closing of the control head, be sure also to observe the notes and •
comments contained in chapter "8. Opening and Closing the Housing"!
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Replacement of Components and Modules
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Control Head Type 8681
19.2. 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 and 5-2 to minimize or avoid the possibility •
of damage caused by sudden electrostatic discharge!
Also, ensure that you do not touch electronic components when the power supply voltage is present! •
Removal procedure:
Open the housing observing the notes contained 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).
Loosen all electrical connections on the electronics module (plug-type connections, screw-type terminal
→
connections).
Loosen the screw-type connection (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.
Connection for the
position measuring
system's contact pins
Jumper
for AS interface power supply
Fastening screw
(Torx 10)
4 DIP switches for
color coding
Plug-type connections
for valves V1-3
Electronics module, complete
(sealed lower part,
ready for installation)
Electronics module (example for AS Interface)Fig. 31:
Carefully lift the electronics module upwards. →
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Replacement of Components and Modules
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Control Head Type 8681
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.
→
Perform Teach-In process (see chapter → 15.1. Setting the Position Measuring System (Teach-In)).
Be sure to work carefully and cautiously, so that the electronics are not damaged.
Close the housing observing the notes contained in chapter "
→ 8. Opening and Closing the Housing".
Changing the Valves19.3.
According to the design, zero to three 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.
Note:
Disassemble/assemble the valves in upright position as there is
otherwise a risk that the non-return valve falls out!
Valve module from above
Flow restriction
screws
Torx screws (T10),
tightening torque:
1 Nm
Valve moduleFig. 32:
Procedure:
→ 8. Opening and Closing the Housing".
Open the housing observing the notes contained in chapter "
If necessary, mark the electrical connections to ensure correct assignment during reinstallation.
→
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Replacement of Components and Modules
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Control Head Type 8681
Loosen the electrical connections. →
Loosen the connecting screws (Torx T10) for the corresponding valve module. →
Take out the valve module 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: For this, insert the screws (Torx T10) in the existing threading by turning them backwards and
→
tighten them with 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).
Close the housing observing the notes contained in chapter "
→ 8. Opening and Closing the Housing".
Changing the Position Measuring System19.4.
The position measuring system consists of a housing, with a PCB mounted above with LEDs and light conductor.
There are four snap-fit hooks with which the position measuring system is secured in the lower housing part by
snapping into place.
PCB with LEDs and light
conductor
Housing of the Position
Measuring System
Snap-fit hooks (4x)
Position Measuring System Fig. 33:
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Replacement of Components and Modules
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Control Head Type 8681
DANGER!
Risk of injury from high pressure!
Before loosening pneumatic lines and valves, turn off the pressure and vent the lines.•
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 and 5-2 to minimize or avoid the possibility •
of damage caused by sudden electrostatic discharge!
Also, ensure that you do not touch electronic components when the power supply voltage is present! •
Deinstallation procedure:
Switch the electrical power to the control head off!
→
Loosen the control head from the process valve. →
Open the housing observing the notes contained in chapter → 8. Opening and Closing the Housing.
4.
Pull out position
measuring system
1.
Loosen Torx10
screw
2.
Fold electronics
module to the
front
3.
Bend/break off the snap-fit hooks
inwards - 4x
(bottom view)
Dismantling the Position Measuring SystemFig. 34:
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Replacement of Components and Modules
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Control Head Type 8681
Loosen the electronics module's fastening screw (Torx 10) (see chapter → 19.2. 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 from above so that the contact pins are located on the side of the elec- →
tronics 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. Installation.
Adjust position measuring system to the process valve by teaching (see chapter
→ 15.1. Setting the Position
Measuring System (Teach-In))
Close the housing observing the notes contained in chapter "
→ 8. Opening and Closing the Housing".
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Spare Parts
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Control Head Type 8681
20. SPARE PARTS
CAUTION!
Risk of injury and/or damage by the use of incorrect parts!
Incorrect accessories and unsuitable spare parts may cause injuries and damage the device and the surrounding area.
Use original accessories and original spare parts from Bürkert only.•
Item No. Spare Parts ID No.
1 O-ring 100 x 1.78 EPDM 797946
2 8681-24V module, casted + programmed 196480
2 8681-AS interface module, casted + programmed 196481
2
2
3 Adapter compl. with Valve 6524 (incl. throttle module) 797935
4 Position measuring sensor with PCB (LDR-85-BUE) 797885
(5) Light conductor (Plexiglas) 797889
(6) Cable with 12-pole plug M12 (IEC 61076-2-101), approx. 8 cm (24 V DC) 217574
(6) Cable with 4-pole plug M12 (IEC 61076-2-101), approx. 8 cm (AS interface) 217573
(6) Cable with 4-pole plug M12 (IEC 61076-2-101), approx. 80 cm (AS interface) 217572
(6) Cable with 5-pin plug M12 (IEC 61076-2-101), approx. 80 cm (DeviceNet) 218187
(10) Cover, coated, with logo 796053
11 Shoulder screw M5 (with pin) 797919
12 Square nut DIN 562 115 197723
8681-DeviceNet module casted + programmed
8681-120V module casted + programmed
196482
196483
2
1
11
4
3
12
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Shutdown
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Control Head Type 8681
SHUTDOWN21.
Safety instructions21.1.
DANGER!
Risk of injury from high pressure!
Before loosening pneumatic 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 the isolated state!•
WARNING!
Risk of 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!•
Dismantling the Control Head Type 868121.2.
Prior to starting with the work, check the system status!
Procedure:
Cable gland versions:
Open the housing observing the notes contained in chapter "
→ 8. Opening and Closing the Housing".
Uninstall the electrical connections at the terminal strip.
→
Close the housing observing the notes contained in chapter " → 8. Opening and Closing the Housing".
Loosen the pneumatic connections (For a detailed description, see chapter "
→ 9. Pneumatic Installation").
Loosen the locking screws (shoulder screws M5).
→
Pull control head upwards and off the adaptation. →
Multi-pole connection versions:
→
Remove the multi-pole plugs.
Loosen the pneumatic connections (For a detailed description, see chapter " → 9. Pneumatic Installation").
Loosen the locking screws (shoulder screws M5).
→
Pull control head upwards and off the adaptation. →
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Packaging and Transport
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Control Head Type 8681
PACKAGING AND TRANSPORT22.
NOTE!
Transport damage!
Inadequately protected equipment may be damaged during transport.
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 pipes cannot be damaged by accident and / or cannot damage the control →
head indirectly!
that the control head is not used as support during packaging and transport!
→
that the control head is not exposed to any mechanical stress! →
STORAGE23.
NOTE!
Incorrect storage may damage the device.
Store 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!
DISPOSAL24.
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.•
Note:
Observe national waste disposal regulations.
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