Burkert 8686 User Manual [en, de, fr]

Type 8685 / 8686

Feedback Head / Control Head Robolux Rückmeldekopf / Steuerkopf Robolux Tête de recopie de position / Tête de commande Robolux

Operating Instructions

Bedienungsanleitung Manuel d‘utilisation

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

Operating Instructions 1312/02_EU-ml_00809600 / Original DE

Type 8685 / 8686

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

English

14 SHUTDOWN .................................................................................................42

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

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

15 ACCESSORIES ........................................................................................... 44

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

Type 8685 / 8686

English

Type 8685 / 8686

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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Type 8685 / 8686

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.

English

Type 8685 / 8686

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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Type 8685 / 8686

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: info@de.buerkert.com

International

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

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

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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Type 8685 / 8686

System description

5.3 Structure of feedback head Type 8685

View without transparent cap:

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

Fig. 1: Structure of feedback head Type 8685

AS interface status LEDs

Drive status OPEN/ CLOSED LEDs (end position)

Slide switch Color selection of end position

DIP switches Select RV50/70/110

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

5.4 Structure of control head Type 8686

View without transparent cap and body casing:

Dummy plug M16 x 1.5

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

Control valve status LED

Slide switch Color selection of end position

Slide switch Pilot valve (Service switch)

DIP switches Select RV50/70/110

Actuator status OPEN/ CLOSED LEDs (end position)

AS-Interface status LEDs

Pilot air port (label: 1)

Exhaust air port (label: 3)

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

Fig. 2: Structure of control head Type 8686

English

Type 8685 / 8686

Technical data

5.5 Structure of adapter set for actuator Type 2036

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 EC directives in accordance with the EC Declaration of Conformity.

6.2 Standards

The applied standards, which verify conformity with the EC Directives, can be found on the EC Type Examination Certificate and / or the EC 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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Type 8685 / 8686

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:

Supply voltage / control or

AS Interface profile

Type

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

Fig. 4: Example of type label

Control function pilot valve

Max operating pressure

Ambient temperature

Serial number, CE symbol

Bar code

6.6 Pneumatic data

Control medium neutral gases, air Quality classes in accordance with

DIN ISO 8573-1

Dust content Class 5 Max. particle size 40 µm,

max. particle density 10 mg/m³

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

min. 10 °C below the lowest operating temperature

Oil content Class 5 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 l

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

/ min (for aeration and deaeration)

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

Socket connection G1/8

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Type 8685 / 8686

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, max. 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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Type 8685 / 8686

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, max. 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)

English

Type 8685 / 8686

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

RV110 RV70

Fig. 5: Switch spindle identification

RV50

Actuator size identification

Switch Spindle Type 8686

RV110 RV70

RV50

Cap

English

Type 8685 / 8686

Assembly

Designation Order no.

Adapter set for Type 8685 684267 Adapter set for Type 8686 684268

Tab. 2: Adapter sets

Procedure:

Step 1: Assembly of adaptation body on the actuator

→ Unscrew the transparent cap from the actuator. → Place the 52 x 3 O-ring in the profile on the bottom of the adap-

tation body.

→ Place the adaptation body on the actuator, paying close attention

to the coding pin.

→ Screw the adaptation body tightly onto the actuator with two

cylinder screws M6 x 12.

Cylinder screws M6 x 12

Adaptation body

O-ring 52 x 3 Coding pin

Actuator

Fig. 6: Assembly of adaptation body

NOTE!

Using a switch spindle that does not fit will result in irreparable destruction of the feedback head and/or control head and the actuator.

▶ Use only switch spindles that match the actuator size. The cor-

responding actuator size identification (RV50, RV70, RV110) for switch spindles are embossed on the front of the PVC cap (see “Fig. 5”).

→ Select the switch spindle that matches the actuator size (see

“Fig. 5: Switch spindle identification”).

→ Wet the thread of two switch spindles that match the actuator

size with Loctite screw locking M290.

NOTE!

Using the wrong spindle lead-through will result in malfunction.

▶ Use only the spindle lead-through that matches the actuator

size (see “Fig. 7”).

Spindle lead-through for actuator size RV50

Spindle lead-through for actuator sizes RV70 and RV110

Fig. 7: Spindle lead-through

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Type 8685 / 8686

Assembly

NOTE!

No detection or faulty detection of end positions.

▶ Do not change the position of the cap on the switch spindle. ▶ Use the hole ∅ 2.3 for fastening the switch spindle.

→ Push the switch spindles through the matching spindle lead-

throughs. The outside lead-throughs are designed for actuator size RV70/110, while the inside lead-throughs for actuator size RV50 (see “Fig. 7”).

Cap

Hole ∅ 2.3 for

screwing in the

switch spindle

Form seal

Fig. 8: Assembly of switch spindles and form seal

→ Using a suitable tool, screw the two switch spindles onto the

actuator spindles. There is a hole ∅ 2.3 on the spindle side for this purpose (torque 1.0 Nm ± 0.1 Nm).

→ Place the form seal on the adaptation body (smaller diameter

points upwards).

Step 2: Assembly of the feedback head / control head on the

adaptation body

If the electrical connection is made with a cable gland, we recommend connecting the wires at this point, since otherwise the feedback head / control head will have to be removed again for the electrical connection.

For electrical installation see: “9.2 Device version 24 V DC” “Device connection for cable gland Type 8685” “Device connection for cable gland Type 8686”

NOTE!

Faulty detection of end positions.

▶ For actuators with control function B (CFB, NO), the lower end

position must be approached before the feedback head / control head is placed on the adaptation body. To do this, pressurize the appropriate pilot air port of the actuator (“Fig. 9”).

▶ Make certain the feedback head / control head is correctly posi-

tioned relative to the actuator: The dummy plug or pressure-relief valve must be located on the side of the pneumatic connections of the actuator (see “Fig. 9”).

→ Place the feedback head / control head on the actuator. As you

do, note:

- The dummy plug or pressure-relief valve must be located on the side of the pneumatic connections of the actuator.

- The switch spindles must lodge inside the recesses on the bottom of the feedback head / control head. Do not move the caps onto the switch spindles.

English

Type 8686

Type 8685 / 8686

Assembly

Recess

Switch spindle

Type 8685

Dummy plug

Mounting hole of the

feedback head / control

head concentric with

square nut of the adap-

tation body

O-ring 3.5 x 1.5

Fastening screw M4

Pressure-relief valve

Form seal

Connection SFB

Connection SFA

Type 2036

Fig. 9: Assembly of feedback head / control head

→ Push the feedback head / control head onto the adaptation body

until no gap is visible on the form seal. Now align the mounting hole of the feedback head / control head on each side with the square nut of the adaptation body.

Fig. 10: Fastening of feedback head / control head

NOTE!

If the torque is too high when screwing in the fastening screw or if the O-ring is missing, degree of protection IP65 / IP67 is not ensured.

▶ The fastening screw may only be tightened to a maximum torque

of 0.5 Nm ± 0.1 Nm.

▶ Check the position of the O-ring.

connections

Pneumatic actuator

→ Use the two fastening screws M4 and matching O-rings to

fasten the feedback head / control head onto the adaptation body (torque: 0.5 Nm ± 0.1 Nm).

The mechanical connection is already completed for the feedback head after these two assembly steps. “Step 3: Assembly of pneumatic connection - install the actuator” must still be performed for the control head.

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Type 8685 / 8686

Assembly

Control head Type 8686 only:

Step 3: Assembly of pneumatic connection - install the actuator

→ Screw the plug-in hose connectors onto the control head and the

actuator.

→ Cut the enclosed hoses (2 x 280 mm) to length as appropriate

for the device layout.

→ Using the hoses supplied in the accessory kit, make the pneumatic

connection between the control head and actuator according to the control function (CF) with the following “Tab. 3: Overview of pneumatic connections for actuator variants”.

Hoses

Plug-in hose

connectors

Fig. 11: Assembly of pneumatic connections

NOTE!

Damage or malfunction due to ingress of dirt and moisture.

▶ To comply with degree of protection IP65 / IP67, install an

exhaust air line on the unneeded pilot air port (for CFA, NC and CFB, NO) in the dry area.

Pilot air outputs for control head

Actuator 1

(left)

Pilot air port

2 (P2)

Pilot air port

1 (P1)

Fig. 12: Pneumatic connection

Actuator 2 (right)

Pilot air port 4 (P4)

Pilot air port 3 (P3)

English

Type 8685 / 8686

Pneumatic installation

Type 2036 Actuator 1 Actuator 2

CF Connection CF Connection

D11, D55 CFA/CFA

D12 CFA/CFB

D21 CFB/CFA

D22 CFB/CFB

CFA

CFB

P2: Deaeration

P1: Deaeration

CFA

CFB

CFA

CFB

2 P4: Deaeration

2 P3: Deaeration

2 P4: Deaeration

2 P3: Deaeration

Tab. 3: Overview of pneumatic connections for actuator variants

CFA, NC: Valve closed in rest position (by spring force) CFB, NO: Valve open in rest position (by spring force)

For the assignment of control connections see the installation and dimensional drawing included with delivery of the valve or in the Type 2036 operating instructions.

8 PNEUMATIC INSTALLATION

The dimensions of the feedback head / control head and the different complete device models, consisting of control, feedback head / control head, actuator and valve, can be found in the relevant data sheets.

8.1 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 installation.

▶ 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 installation, ensure a controlled restart.

English

Type 8685 / 8686

Pneumatic installation

8.2 Pneumatic installation of feedback head Type 8685

The feedback head does not require a pilot air supply.

A description of the pneumatic installation of the actuator is included in the valve operating instructions.

8.3 Pneumatic installation of control head Type 8686

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.

Procedure:

→ Connect the control medium to the pilot air port (1)

(6 – 7 bar; instrument air, free of oil, water and dust).

→ Mount the exhaust air line or a silencer on the exhaust air port (3)

(see “Fig. 13: Pneumatic connection Type 8686”).

Important information for the problem-free functioning of the device:

▶ The installation must not cause back pressure to build up. ▶ To make the connection, select a hose with sufficient cross

section.

▶ The exhaust air line must be designed in such a way that

no water or other liquid can get into the device through the exhaust air connection (3).

Exhaust air port Label: 3

Pilot air port Label: 1

Fig. 13: Pneumatic connection Type 8686

Caution (exhaust air concept): In compliance with degree of protection IP65 / IP67, an exhaust air line must be installed in the dry area.

Always maintain an applied control pressure of at least

0.5 – 1 bar above the pressure which is required to move the actuator to its end position.

English

Type 8685 / 8686

Electrical installation

9 ELECTRICAL INSTALLATION

9.1 Safety instructions

DANGER!

Risk of electric shock.

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

supply and secure to prevent reactivation.

▶ Observe applicable accident prevention and safety regulations

for electrical equipment.

WARNING!

Risk of injury from improper installation.

▶ 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 installation, ensure a controlled restart.

9.2 Device version 24 V DC

9.2.1 Electrical installation for feedback head Type 8685

Device connection for cable gland Type 8685

→ Use a cable cross-section of 0.25 mm² for the electrical

connection.

Fastening

screws

M4 (2x)

Screw terminals

Fig. 14: Position of screw terminals Type 8685

→ Loosen the fastening screws M4 and pull the feedback head up

(only if the feedback head is already installed).

→ Install the cable gland, if necessary (approx. 1,5 Nm). → Guide the cables through the cable gland.

English

Type 8685 / 8686

Electrical installation

Top1

Bot1

Top2

Bot2

Fig. 15: Designation on PCB Type 8685

Designation on PCB

24 V

GND

Top 1

Bot 1

Top 2

Bot 2

Assignment

Supply voltage + 24 V DC ±10%

Supply voltage - GND

Top end position Top actuator 1

Bottom end position Bot actuator 1

Top end position Top actuator 2

Bottom end position Bot actuator 2

Tab. 4: Connection for cable gland Type 8685

GND24V

24 V / 0 V (max. 0.1 A) GND (7)

Actuator 1

(left)

Pilot air port

2 (P2)

Pilot air port

1 (P1)

Actuator 2 (right)

Pilot air port 4 (P4)

Pilot air port 3 (P3)

Fig. 16: Pneumatic connection

→ Connect the wires (see pin assignment in “Tab. 4”).

NOTE!

Damage or malfunction due to ingress of dirt and moisture.

▶ To ensure degree of protection IP65 / IP67, tighten the union

nut of the cable gland according to the cable size you are using (approx. 1.5 Nm).

→ Tighten the union nut of the cable gland on the body (approx. 1.5

Nm).

1) Actuator assignment see “Fig. 16”.

English

Type 8685 / 8686

Electrical installation

NOTE!

Faulty detection of end positions.

▶ For actuators with control function B (CFB, NO), the lower end

position must be approached before the feedback head is placed on the adaptation body. To do this, pressurize the appropriate pilot air port of the actuator (“Fig. 9”).

▶ Make certain the feedback head is correctly positioned relative

to the actuator: The dummy plug or pressure-relief valve must be located on the side of the pneumatic connections of the actuator (see “Fig. 9”).

→ Place the feedback head on the actuator. As you do, note:

- The dummy plug or pressure-relief valve must be located on the side of the pneumatic connections of the actuator.

- The switch spindles must lodge inside the recesses on the bottom of the feedback head. Do not move the caps onto the switch spindles.

→ Push the feedback head onto the adaptation body until no gap is

visible on the form seal. Now align the mounting hole of the feedback head on each side with the square nut of the adaptation body.

NOTE!

If the torque is too high when screwing in the fastening screw or if the O-ring is missing, degree of protection IP65 / IP67 is not ensured.

▶ The fastening screw may only be tightened to a maximum torque

of 0.5 Nm ± 0.1 Nm.

▶ Check the position of the O-ring.

→ Use the two fastening screws M4 and matching O-rings to

fasten the feedback head onto the adaptation body (torque: 0.5 Nm ± 0.1 Nm).

When the supply voltage is applied, the feedback head is operating.

→ Before the device can be used, the basic settings (see section

“10.3.1 Basic settings”) must still be made on the feedback head.

English

Type 8685 / 8686

Electrical installation

9.2.2 Electrical installation of control head Type 8686

Device connection for circular plug-in connector Type 8686

→ Connect the circular plug-in connector of the control head as

described in “Tab. 5”.

Fig. 17: Assignment of circular plug (M12 x 1, 8-pole)

Use only straight connecting socket.

Actuator 1

(left)

Pilot air port

2 (P2)

Pilot air port

1 (P1)

Fig. 18: Pneumatic connection

Actuator 2 (right)

Pilot air port 4 (P4)

Pilot air port 3 (P3)

When the supply voltage is applied, the control head is operating.

→ Before the device can be used, the basic settings (see section

“10.3.1 Basic settings”) must still be made on the control head.

Wire

color

white

brown

green

yellow

gray

pink

blue Supply voltage – GND

red Supply voltage + 24 V DC ±10%

Assignment

Bottom end position Bot actuator 2

Top end position Top actuator 2

Bottom end position Bot actuator 1

Top end position Top actuator 1

Valve control Y2 Actuator 2 activated

Valve control Y1 Actuator 1 activated

Tab. 5: Connection for circular plug-in connector Type 8686

2) The indicated colors refer to the connecting cable available as an

accessory (919061).

3) Actuator assignment see “Fig. 18”.

External circuit

24 V / 0 V (max. 0.1 A) GND (7)

high active, to activate

connect with 24 V high active, to activate

connect with 24 V

English

Type 8685 / 8686

Electrical installation

Device connection for cable gland Type 8686

→ Use a cable cross-section of 0.25 mm² for the electrical connection.

Fastening

screws

M4 (2x)

Cable holder

Screw terminals

Fig. 19: Position of screw terminals Type 8686

→ Loosen the fastening screws M4 and pull the control head up

(only if the control head is already installed).

→ Install the cable gland, if necessary (approx. 1,5 Nm).

24V

GND

Valve1

Valve2

Top1

Bot1

Top2

Bot2

Fig. 20: Designation on PCB Type 8686

→ Guide the cables through the cable gland. → Connect the wires (see pin assignment in “Tab. 6”).

Designation on PCB

Bot2

Top2

Bot1

Top1

Valve2

Valve1

GND

24V

Assignment

Bottom end position Bot actuator 2

Top end position Top actuator 2

Bottom end position Bot actuator 1

Top end position Top actuator 1

Valve control Y2 Actuator 2 activated

Valve control Y1 Actuator 1 activated

Supply voltage - GND

Supply voltage + 24 V DC ±10%

Tab. 6: Connection for cable gland Type 8686

4) Actuator assignment see “Fig. 18”.

External circuit

24 V / 0 V (max. 0.1 A) GND (7)

high active, to activate connect with 24 V

English

Type 8685 / 8686

Electrical installation

NOTE!

Malfunction due to damaged wires.

▶ To keep the spindle guides free, guide all wires through the

cable holders.

Damage or malfunction due to ingress of dirt and moisture.

▶ To ensure degree of protection IP65 / IP67, tighten the union

nut of the cable gland according to the cable size you are using (approx. 1.5 Nm).

→ Guide all wires through the cable holders. → Tighten the union nut of the cable gland on the body (approx. 1.5

Nm).

NOTE!

Faulty detection of end positions.

▶ For actuators with control function B (CFB, NO), the lower end

position must be approached before the control head is placed on the adaptation body. To do this, pressurize the appropriate pilot air port of the actuator (“Fig. 9”).

▶ Make certain the control head is correctly positioned relative to

the actuator: The dummy plug or pressure-relief valve must be located on the side of the pneumatic connections of the actuator (see “Fig. 9”).

→ Place the control head on the actuator. As you do, note:

- The dummy plug or pressure-relief valve must be located on the side of the pneumatic connections of the actuator.

- The switch spindles must lodge inside the recesses on the bottom of the control head. Do not move the caps onto the switch spindles.

→ Push the control head onto the adaptation body until no gap is

visible on the form seal. Now align the mounting hole of the control head on each side with the square nut of the adaptation body.

NOTE!

If the torque is too high when screwing in the fastening screw or if the O-ring is missing, degree of protection IP65 / IP67 is not ensured.

▶ The fastening screw may only be tightened to a maximum torque

of 0.5 Nm ± 0.1 Nm.

▶ Check the position of the O-ring.

→ Use the two fastening screws M4 and matching O-rings to

fasten the control head onto the adaptation body (torque:

0.5 Nm ± 0.1 Nm).

When the supply voltage is applied, the control head is operating.

→ Before the device can be used, the basic settings (see section

“10.3.1 Basic settings”) must still be made on the control head.

English

Type 8685 / 8686

Electrical installation

9.3 Device version AS-Interface

9.3.1 Electrical installation feedback head and control head

The feedback head and control head are electrically connected by a multi-pole cable (M12 circular plug-in connector) and ribbon cable terminal. The circular plug can simply be connected with the ribbon cable terminal (see “Fig. 21”).

Screws

M12 plug-in connector branch circuit

Wiring diagram of circular plug M12

The view shows the image from the front looking at the pins, the solder connections are behind them.

Pin 4:

Pin 1:

Bus +

Fig. 22: Bus connection

Pin Designation Assignment

Bus + AS-Interface bus line +

NC not used

Bus – AS-Interface bus line –

NC not used

Tab. 7: Pin assignment of circular plug-in connector for

AS-Interface

Pin 3: Bus –

Pin 2: NC

Fig. 21: Feedback head / control head with multi-pole cable and

ribbon cable terminal

English

Type 8685 / 8686

Electrical installation

Handling the ribbon cable terminal

The multi-pole cable features a ribbon cable terminal - with M12 plug-in connector branch circuit - for AS-Interface cable harness. The ribbon cable terminal contacts the AS-Interface cable harness by means of penetration technology which allows installation by “clipping in” the ASInterface cable harness without cutting and without removing insulation.

Procedure:

→ Open the ribbon cable terminal

(loosen screws and remove cover).

→ Insert cable harness to fit closely. → Close ribbon cable terminal again. → Tighten the screws

Loosen the thread-forming screws slightly (approx. 3/4 turn to the left) and position them on the existing threaded hole and screw in.

9.3.2 AS-Interface connection

AS-Interface (Actuator Sensor Interface) is a field bus system which is used primarily for networking binary sensors and actuators (slaves) with a higher-level control (master).

Bus line

Unshielded two-wire line (AS-Interface line as AS-Interface cable harness) along which both information (data) and energy (power supply voltage 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

9.3.3 Technical Data for AS-Interface PCBs

Supply: via AS-Interface (29.5 V – 31.6 V) Control head outputs: Valve Y1 and valve Y2,

each with max. 0.8 W, Power reduction after approx. 100 ms with integrated watchdog function

Certification: Feedback head: Certificate No. 94701

based on version 3.0

Control head: Certificate No. 94801

based on version 3.0

9.3.4 Programming data

Programming data for feedback head Type 8685

I/O configuration 0 hex

ID code

Extended ID code 1 7 hex Extended ID code 2 E hex Profile S-0.A.E

Tab. 8: Programming data for feedback head Type 8685

A hex (see below for bit configuration)

English

Type 8685 / 8686

Electrical installation

Bit configuration

Data bit Inputs

Data bit Outputs

Function Assignment

Top end position Top actuator 1

Bottom end position Bot actuator 1

Top end position Top actuator 2

Bottom end position Bot actuator 2

0 Top not reached 1 Top reached

0 Bot not reached 1 Bot reached

0 Top not reached 1 Top reached

0 Bot not reached 1 Bot reached

Function Assignment

D0 - not used

D1 - not used

D2 - not used

D3 - not used

Tab. 9: Bit configuration of AS-Interface for feedback head Type 8685

Programming data for control head Type 8686:

I/O configuration 7 hex

ID code A hex (see below for bit configuration)

Extended ID code 1 7 hex

Extended ID code 2 E hex

Profile S-7.A.E

Tab. 10: Programming data for control head Type 8686

Actuator 1

(left)

Pilot air port

2 (P2)

Pilot air port

1 (P1)

Actuator 2 (right)

Pilot air port 4 (P4)

Pilot air port 3 (P3)

Parameter bits have no function.

5) Actuator assignment see “Fig. 23”.

Fig. 23: Pneumatic connection

English

Type 8685 / 8686

Electrical installation

Bit configuration

Data bit Inputs

Data bit Outputs

Function Assignment

Top end position Top actuator 1

Bottom end position Bot actuator 1

Top end position Top actuator 2

Bottom end position Bot actuator 2

Function Assignment

D0 Pilot valve Y1

D1 Pilot valve Y2

0 Top not reached 1 Top reached

0 Bot not reached 1 Bot reached

0 Top not reached 1 Top reached

0 Bot not reached 1 Bot reached

0 Pilot valve OFF 1 Pilot valve ON

D2 - not used

D3 - not used

Tab. 11: Bit configuration of AS-Interface for control head Type 8686

Parameter bits have no function.

9.3.5 LED status display for AS-Interface

Status LED 1 (green)

off off POWER OFF

off on

on off OK

flashing on Slave address equals 0

Tab. 12: LED status display for AS-Interface

Actuator 1

Pilot air port

2 (P2)

Pilot air port

1 (P1)

(left)

Status LED 2 (red)

No data traffic (expired Watch Dog at slave address does not equal 0)

Actuator 2 (right)

Pilot air port 4 (P4)

Pilot air port 3 (P3)

6) Actuator assignment see “Fig. 24”.

English

Fig. 24: Pneumatic connection

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