Control & Automation

Digital Retrofit Solutions for Pneumatic Control Valves

Burkert 4 minutes ago

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Modernising pneumatic control valves doesn’t have to mean replacing existing equipment. Bürkert’s SideCONTROL range offers a practical way to bring digital capabilities to existing installations, adding connectivity, monitoring and control while keeping the valves already in place.

Pneumatic control valves are essential to industrial process control, managing flow, pressure, temperature and liquid levels across many manufacturing applications. They are proven and reliable, but connecting them to modern digital automation systems can be challenging.

For manufacturers looking to improve process visibility and control without replacing an entire system, retrofitting existing pneumatic equipment can be a cost-effective option.

Bürkert’s SideCONTROL range of electropneumatic positioners and process controllers is designed to meet this need. Compatible with virtually all common pneumatic control valve actuators, these devices let operators add digital communication and enhanced control functionality to existing installations—without replacing the valves.

Digital valve retrofitting without replacing existing systems

Moving conventional pneumatic control systems to digital automation can involve significant investment in hardware, engineering, system development and commissioning.

Bürkert SideCONTROL offers another way forward, allowing existing pneumatic control valves to connect with modern industrial automation networks.

With IO-Link technology, compatible SideCONTROL devices communicate bidirectionally with an IO-Link master. Standard cabling supports fast data exchange and straightforward plug-and-play connectivity, with no extra network switches required.

The range also supports several other industrial communication protocols, including PROFIBUS, AS-Interface (AS-i) and Bürkert’s CAN-based system bus, büS.

Depending on the device configuration, users can also choose from Ethernet-based options such as EtherNet/IP, PROFINET, Modbus TCP and EtherCAT.

These communication capabilities allow existing pneumatic control valves to connect to industrial automation systems, making operational data, diagnostics, process monitoring and alarm functions more accessible.

Adding digital connectivity to existing equipment can give manufacturers a clearer view of their processes without the disruption of replacing complete valve assemblies.

SideCONTROL digital positioners for existing pneumatic actuators
The Bürkert SideCONTROL range includes three main devices, each designed to meet different positioning and process control needs.

The Type 8791 digital electropneumatic positioner works with both linear and rotary pneumatic actuators. It includes diagnostic functions for valve monitoring and supports IO-Link, AS-Interface and Bürkert’s büS system bus.

For applications that need more configuration and communication options, the Type 8792 digital electropneumatic positioner comes with a graphical display and keypad. Operators can configure and commission the device directly, while Ethernet and fieldbus options support integration with wider industrial control networks.

The Type 8793 digital electropneumatic process controller builds on these capabilities with an integrated proportional-integral-derivative (PID) controller. This lets users manage local process control loops directly at the valve, adding control capability without a complete system redesign.

All three devices are designed to offer flexible installation.

Universal mounting options let SideCONTROL positioners and controllers fit almost all standard pneumatic control valve actuators, including NAMUR-compliant part-turn and linear models.

Adaptor kits are available for non-standard actuators too, including Samson Type 3277 models, with valve strokes from 7.5 mm to 30 mm.

This broad compatibility allows manufacturers to add digital valve control while keeping their existing pneumatic equipment.

Simplifying pneumatic valve commissioning with automatic tuning

When upgrading pneumatic control valves to digital operation, proper commissioning is crucial. Incorrect positioning parameters can slow response times, destabilise control and affect overall process performance.

To make installation and optimisation easier, Bürkert SideCONTROL devices include automated commissioning functions.

X.TUNE automatically learns and adjusts positioning parameters to suit the connected actuator and process conditions.

Fine-tuning these settings can improve valve response, positioning accuracy and operational stability.

The system works with both single-acting and double-acting pneumatic actuators, so it can be configured for different setups.

For applications with a Type 8793 process controller, the additional P.TUNE function automatically identifies and optimises PID control parameters.

This means less manual adjustment and a simpler way to commission local process control loops.

Together, these automated tuning functions make it easier to retrofit digital controls to pneumatic valves, bringing advanced control capabilities to existing process installations with less complexity.

Supporting digitalisation in industrial process control

As manufacturers adopt more connected automation technologies, upgrading existing pneumatic control equipment can improve operational efficiency without the cost and disruption of replacing everything.

Bürkert SideCONTROL offers a practical way to move towards digitalisation. It combines proven pneumatic valve technology with modern communication protocols, built-in diagnostics and automated control functions.

For process plants looking to modernise their automation, retaining existing valves while adding digital monitoring and enhanced control provides a flexible alternative to a complete system overhaul.

The result is a more connected pneumatic control system, with better process visibility, simpler commissioning and easier integration with modern industrial automation networks.

For further information, visit www.burkert.co.uk.

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Burkert Fluid Control Systems

01285648720
sales.uk@burkert.com
http://www.burkert.com/
Fluid Control Centre 1 Bridge End Gloucestershire Cirencester GL7 1QY GB

About us

Bürkert is present in thirtyfive countries around the world. We also work with a large network of distributors and partners, which means we are as close as possible to our customers. This global presence ensures full service and support to all of our customers in every country around the world. Research is the lifeblood of our company.

At Bürkert, we are never satisfied with the status quo and are continually seeking new technologies and solutions for our customers. Every year, our people develop new and highly advanced products and solutions, ranging from integrated process measurement and control units to the most sophisticated systems used in pharmaceutical research. To be a market leader, we are also an R&D leader.

Therefore, our investment in research & development is one of the highest in our industry. In our research centres in Germany and France, 150 people are committed to working for a common future for our company and our customers. We are committed to offering our expertise wherever it is needed, anywhere in the world. This global presence ensures that our advances in fluid control technology are also global.

What we do in a nutshell

Manufacture of process equipment. One of the few manufacturers to provide solutions for the complete control loop.

Where we supply to

UK Ireland, Europe

Industries we supply to

Food and Beverage, Pharmaceutical Cosmetics Toiletries, Water and Wastewater

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