Burkert 8685, 8686 Operating Instructions Manual

Operating Instructions

Type 8685 / 8686

Feedback Head / Control Head Robolux

We reserve the right to make technical changes without notice.
Technische Änderungen vorbehalten.
Sous réserve de modifications techniques.

© Bürkert Werke GmbH & Co. KG, 2011 - 2018

Operating Instructions 1810/04_EU-EN_00809600 / Original DE

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Table of contents

1 OPERATING INSTRUCTIONS ................................................................5

1.1 Symbols ....................................................................................... 5

1.2 Definition of term ...................................................................... 5

2 AUTHORIZED USE ......................................................................................6

2.1 Restrictions ................................................................................. 6

3 BASIC SAFETY INSTRUCTIONS ..........................................................6

4 GENERAL INFORMATION ........................................................................8

4.1 Contact address ........................................................................8

4.2 Warranty ...................................................................................... 8

4.3 Information on the Internet ......................................................8

5 SYSTEM DESCRIPTION ............................................................................8

5.1 Intended application area ........................................................ 8

5.2 General description ..................................................................8

5.3 Structure of feedback head Type 8685 ............................... 9

5.4 Structure of control head Type 8686 ...................................9

5.5 Structure of adapter set for actuator Type 2036 .............10

6 TECHNICAL DATA .....................................................................................10

6.1 Conformity .................................................................................10

6.2 Standards ..................................................................................10

6.3 Operating conditions ..............................................................10

6.4 Mechanical data.......................................................................11

6.5 Type label .................................................................................11

6.6 Pneumatic data ........................................................................11

6.7 Electrical data for feedback head Type 8685 ...................12

6.8 Electrical data control head Type 8686 .............................13

7 ASSEMBLY

.................................................................................................... 14

7.1 Safety instructions ...................................................................14

7.2 Assembly of Type 8685 and Type 8686 on the

actuator Type 2036.................................................................14

8 PNEUMATIC INSTALLATION ...............................................................19

8.1 Safety instructions .................................................................... 19

8.2 Pneumatic installation of feedback head Type 8685 ......20

8.3 Pneumatic installation of control head Type 8686 ..........20

9 ELECTRICAL INSTALLATION ............................................................... 21

9.1 Safety instructions ...................................................................21

9.2 Device version 24 V DC ........................................................21

9.3 Device version AS-Interface .................................................27

10 CONTROL AND DISPLAY ...................................................................... 31

10.1 Control and display elements for feedback head

Type 8685 .................................................................................31

10.2 Control and display elements for control head

Type 8686 ......................................................................................... 33

10.3 Control .......................................................................................34

11 SAFETY POSITIONS ................................................................................ 39

12 MAINTENANCE

........................................................................................... 39

12.1 Safety instructions ...................................................................39

12.2 Service at the air intake filter.................................................40

13 MALFUNCTIONS

........................................................................................ 41

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14 SHUTDOWN

.................................................................................................42

14.1 Safety instructions ...................................................................42

14.2 Disassembly..............................................................................42

15 ACCESSORIES

........................................................................................... 44

16 TRANSPORT, STORAGE, PACKAGING .......................................... 44

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Operating instructions

1 OPERATING INSTRUCTIONS

The operating instructions describe the entire life cycle of the device.
Keep these instructions in a location which is easily accessible to
every user and make these instructions available to every new owner
of the device.

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.

1.1 Symbols

DANGER!

Warns of an immediate danger.

▶ Failure to observe the warning will result in a fatal or serious

injury.

WARNING!

Warns of a potentially dangerous situation.

▶ Failure to observe the warning may result in serious injuries or

death.

CAUTION!

Warns of a possible danger.

▶ Failure to observe this warning may result in a moderate or

minor injury.

NOTE!

Warns of damage to property.

▶ Failure to observe the warning may result in damage to the

device or the equipment.

Indicates important additional information, tips and
recommendations.

Refers to information in these operating instructions or in
other documentation.

▶ Indicates an instruction to prevent risks.

→ Designates a procedure which you must carry out.

1.2 Definition of term

The term “device” used in these instructions always stands for the
feedback head Type 8685 and control head Type 8686.

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Authorized use

2 AUTHORIZED USE

Non-intended use of the feedback head Type 8685 and the
control head Type 8686 may be a hazard to people, nearby
equipment and the environment.

The device is designed to be mounted on pneumatic actuators of
process valves for the control of media.

▶ Do not expose the device to direct sunlight.
▶ Use according to the authorized data, service and operating

conditions specified in the contract documents and operating
instructions. These are described in the chapter on “6 Technical
data”.

▶ The device may be used only in conjunction with third-party

devices and components recommended and authorized by
Bürkert.

▶ In view of the large number of options for use, it is essential

prior to installation to study and, if necessary, to test whether
the feedback head or control head is suitable for the specific
application case.

▶ Correct transportation, storage, and installation, as well as care-

ful use and maintenance are essential for reliable and faultless
operation.

▶ Use the device only as intended.

2.1 Restrictions

If exporting the system/device, observe any existing restrictions.

3 BASIC SAFETY INSTRUCTIONS

These safety instructions do not make allowance for any

• contingencies and events which may arise during the assembly,
operation and maintenance of the devices.

• local safety regulations – the operator is responsible for observing
these regulations, also with reference to the installation personnel.

Risk of injury from high pressure in the equipment/device.

▶ Before working on equipment or device, switch off the pressure

and deaerate/drain lines.

Risk of electric shock.

▶ Before working on equipment or device, switch off the power

supply and secure to prevent reactivation.

▶ Observe applicable accident prevention and safety regulations

for electrical equipment.

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Basic safety instructions

General hazardous situations

To prevent injuries:

▶ The feedback head Type 8685 and control head Type 8686 must

not be used in areas where there is a risk of explosion.
▶ Ensure that the system cannot be activated unintentionally.
▶ Installation and maintenance work may be carried out only by

authorized technicians with the appropriate tools.
▶ After an interruption in the power supply or pneumatic supply,

ensure that the process is restarted in a defined or controlled

manner.
▶ The device may be operated only when in perfect condition and

in consideration of the operating instructions.
▶ The general rules of technology must be observed for applica-

tion planning and operation of the device.

To prevent damage to property of the device, ensure:

▶ Do not feed any aggressive or flammable media into the pilot air

port for Type 8686
▶ Do not feed any liquids into the pilot air port for Type 8686.
▶ Do not physically stress the body (e.g. by placing objects on it or

standing on it).
▶ Do not make any external modifications to the device bodies.

NOTE!

Electrostatic sensitive components/modules.

The device contains electronic components, which react sensitively
to electrostatic discharge (ESD). Contact with electrostatically
charged persons or objects is hazardous to these components. In
the worst case scenario, they will be destroyed immediately or will
fail after start-up.

▶ Observe the requirements in accordance with EN 61340-5-1

to minimize/avoid the possibility of damage caused by a sudden
electrostatic discharge.

▶ Also, ensure that you do not touch electronic components when

the power supply voltage is present.

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General information

4 GENERAL INFORMATION

4.1 Contact address

Germany

Bürkert Fluid Control Systems
Sales Center
Christian-Bürkert-Str. 13-17
D-74653 Ingelfingen
Tel. + 49 (0) 7940 - 10 91 111
Fax + 49 (0) 7940 - 10 91 448
E-mail: [e-mail]

International

Contact addresses can be found on the final pages of the printed
operating instructions.

And also on the Internet at: www.burkert.com

4.2 Warranty

The warranty is only valid if the feedback head and control head are used
as intended in accordance with the specified application conditions.

4.3 Information on the Internet

The operating instructions and data sheets for Type 8685 and Type
8686 can be found on the Internet at:

www.burkert.com

5 SYSTEM DESCRIPTION

5.1 Intended application area

The feedback head Type 8685 and the control head Type 8686
are designed to be mounted on pneumatic actuators of valves Type
2036 for the control of media.

5.2 General description

The feedback head Type 8685 and the control head Type 8686 are
designed exclusively for integrated mounting on an actuator of the
diaphragm valve Type 2036 in sizes RV50, RV70, RV110.

The actuator size is adjusted with DIP switches.
The valve position is recorded by a permanent magnet on the

spindle extension. When a stroke movement occurs, the spindle
extension is guided along a reed sensor (lower/upper end position).

In addition to the electrical position feedback, the device status on
the feedback head and control head are represented visually by
colored LEDs. The status of the integrated pilot valve is also indi­cated by LEDs for the control head.

In the variant with AS-Interface communication, bus status LEDs are
also active.

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System description

5.3 Structure of feedback head Type
8685

Electrical connection
Cable gland M12 x 1.5 or circular
plug-in connector M12 x 1

Pressure limiting valve
(for protection against
too high internal pressure
in case of error)

AS interface
status LEDs

Drive status OPEN/
CLOSED LEDs
(end position)

DIP switches
Select RV50/70/110

Slide switch
Color selection of
end position

View without
transparent cap:

Fig. 1: Structure of feedback head Type 8685

5.4 Structure of control head Type 8686

Dummy plug
M16 x 1.5

Electrical connection
Cable gland M12 x 1.5
or circular plug-in connector M12 x 1

Pressure limiting valve
(for protection against too
high internal pressure in
case of error)

Exhaust air port
(label: 3)

Pilot air port
(label: 1)

AS-Interface status
LEDs

Actuator status OPEN/
CLOSED LEDs (end
position)

DIP switches
Select RV50/70/110

Slide switch
Color selection of end
position

Slide switch
Pilot valve
(Service switch)

Control valve status LED

View without transparent
cap and body casing:

Fig. 2: Structure of control head Type 8686

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Technical data

5.5 Structure of adapter set for
actuator Type 2036

2

5

4

1

7

6

3

9

8

Fig. 3: Adapter set for Type 2036

Item Quantity Designation

1 1 Robolux adaptation body
2 6 2 units each Switch spindle RV50, RV70, RV110 cpl.
3 1 O-ring 52 x 3 EPDM 75
4 1 Form seal
5 2 Cylinder head screw M6 x 12 A2 DIN 912
6 2 Cylinder head screw M4 with shaft
7 2 O-ring 3.5 x 1.5 EPDM 70
8 2 Hose 280 mm
9 4 Angular connection G1/8 SL6 Legris

Tab. 1: Parts list for adapter set

6 TECHNICAL DATA

6.1 Conformity

The feedback head Type 8685 and the control head Type 8686 comply
with EU directives in accordance with the EU Declaration of Conformity.

6.2 Standards

The applied standards, which verify conformity with the EU Direc­tives, can be found on the EU Type Examination Certificate and / or
the EU Declaration of Conformity.

6.3 Operating conditions

WARNING!

Solar radiation and temperature fluctuations may cause mal­functions or leaks.

▶ If the device is used outdoors, do not expose it unprotected to

the weather conditions.

▶ Ensure that the permitted ambient temperature does not exceed

the maximum value or drop below the minimum value.

Ambient temperature 0 – +55 °C

Degree of protection IP65 / IP67 according to EN 60529

(only if cables, plugs and sockets have been
connected correctly and in compliance with
the exhaust air concept in chapter “8.3 Pneu­matic installation of control head Type 8686”.

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Technical data

6.4 Mechanical data

Dimensions See data sheet

Body material PPS, PC, VA

Sealing material outside EPDM

inside NBR

Stroke range of valve spindle RV50 actuator size 6 mm

RV70 actuator size 9.5 mm
RV110 actuator size 13.5 mm

6.5 Type label

Example:

8686 AS-i S-7.A.E
2x single pilot 3.0
Pmax 7bar
Tamb 0 ... +55°C
Ser. No. 001000
00XXXXXX

D-74653 Ingelfingen

W14UN

Identification number

Supply voltage, control or

AS-Interface profile

Max operating
pressure

Type

Control function,
pilot valve

Barcode

Serial number,
CE marking

Ambient
temperature

Fig. 4: Example of type label

6.6 Pneumatic data

Control medium neutral gases, air
Quality classes in accordance with

ISO 8573-1

Dust content Class 7 Max. particle size 40 µm,

max. particle density 10 mg/m³

Water content of Class 3 max. pressure dew point - 20 °C or

min. 10 °C below the lowest
operating temperature

Oil content Class X max. 25 mg/m³

Temperature range
Control medium -10 – + 50 °C

Pressure range
Control medium 6 – 7 bar

(for further details see operating
instructions Type 2036 and
chapter “8.3 Pneumatic installation of
control head Type 8686”)

Air output of pilot valve 250 lN / min (for aeration and deaeration)

(QNn value according to definition for
pressure drop from 7 to 6 bar absolute)

Connections Plug-in hose connector Ø 6 mm / 1/4"

Socket connection G1/8

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Technical data

6.7 Electrical data for feedback head
Type 8685

6.7.1 Electrical data without bus control
24 V DC

Connections Cable gland M12 x 1.5, wrench size 15

(clamping area 3 – 6.5 mm)
with screw terminals
(nominal cross section 1.0 mm²,
min. cable cross-section 0.25 mm²)

Supply voltage 24 V DC ± 10%,

max. residual ripple 10%

Output max. 100 mA per output /

short circuit-proof

Display max. 20 mA
(2 end positions = 2 LEDs)

6.7.2 Electrical data with AS-Interface bus
control

Connections Remote 975 mm AS-Interface cable

with circular plug-in connector
(M12 x 1, 4-pole)

Supply voltage 29.5 V – 31.6 V DC

(according to specification)

Max. power consumption 35 mA

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Technical data

6.8 Electrical data
control head Type 8686

6.8.1 Electrical data without bus control
24 V DC

Connections Cable gland M12 x 1.5, wrench size 15

(clamping area 3 – 6.5 mm) with screw terminals
(nominal cross section 1.0 mm²,
min. cable cross-section 0.25 mm²)

Circular plug-in connector (M12 x 1, 8-pole)

Pilot valve
Supply voltage 24 V DC ± 10% ,

max. residual ripple 10%

Power input 2 x 0.8 W

Output max. 100 mA per output / short

circuit-proof

Display max. 20 mA
(2 end positions = 2 LEDs)

Service:

Power consumption 90 mA
(2 end positions + 2 valves /
service switch on)

6.8.2 Electrical data with AS-Interface bus
control

Connections Remote 975 mm AS-Interface cable

with circular plug-in connector
(M12 x 1, 4-pole)

Supply voltage 29.5 V – 31.6 V DC

(according to specification)

Outputs
Max. switching capacity: 2 x 0.8 W via AS-Interface

Watchdog function integrated

Max. power consumption 120 mA
(2 valves when activated +
2 end positions)

Service:

Power consumption 105 mA
(2 end positions
+ 2 valves /
service switch on)

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Assembly

7 ASSEMBLY

7.1 Safety instructions

DANGER!

Risk of injury from high pressure in the equipment/device.

▶ Before working on equipment or device, switch off the pressure

and deaerate/drain lines.

Risk of electric shock.

▶ Before working on equipment or device, switch off the power

supply and secure to prevent reactivation.

▶ Observe applicable accident prevention and safety regulations

for electrical equipment.

WARNING!

Risk of injury from improper assembly.

▶ Installation may only be carried out by authorized technicians

with the appropriate tools.

Risk of injury from unintentional activation of the system and
uncontrolled restart.

▶ Secure system from unintentional activation.
▶ Following assembly, ensure a controlled restart.

7.2 Assembly of Type 8685 and Type
8686 on the actuator Type 2036

An adapter set is required for assembly on the actuator Type 2036.
The adapter set (see “Fig. 3”, page 10) includes an adaptation body,

a form seal, three O-rings, four cylinder screws and three switch spindle
pairs. There are different adapter sets for feedback head and control
head. Because of the different working height for actuator sizes RV50,
RV70 and RV110, an adapter set contains different spindle lengths.

Switch spindle Type 8685

Switch spindle Type 8686

RV110 RV70

RV50

RV110 RV70

RV50

Actuator size
identification

Cap

Fig. 5: Switch spindle identification

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