Bürkert TopControl Continuous 8630 position controller Operating instructions
Below you will find brief information for position controller TopControl Continuous 8630. The TopControl Continuous is an electropneumatic position controller for pneumatically actuated continuous valves. It serves as a position controller that can be configured to be a process controller. It has a modular concept and offers a variety of pneumatic and electrical connections as options. The control unit allows you to operate the TopControl using three keys and an 8-character LCD displays setpoint, position and configuration functions.
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TOP
CONTROL CONTINUOUS TYPE 8630
5
5.1
5.2
5.3
5.4
5.4.1
5.4.2
5.4.3
5.3
2
3
3.1
3.2
3.2.1
3.2.2
3.3
3.4
3.5
3.5.1
3.5.2
3.5.3
4
4.1
4.2
4.2.1
4.2.2
4.2.3
4.3
CONTENTS:
1 GENERAL INFORMATION ....................................................................................... 87
1.1
1.2
1.3
1.4
1.5
1.6
Symbols ................................................................................................................................................. 87
Safety information ................................................................................................................................. 87
Important for Handling ......................................................................................................................... 87
Scope of delivery .................................................................................................................................. 87
Warranty conditions .............................................................................................................................. 88
Master code ........................................................................................................................................... 88
SYSTEM CONFIGURATION ..................................................................................... 89
DESCRIPTION OF THE TOP CONTROL CONTINUOUS ......................................... 91
Construction .......................................................................................................................................... 91
Function ................................................................................................................................................. 93
Working as position controller ................................................................................................................. 94
Using as process controller ..................................................................................................................... 95
Top
Control variants ............................................................................................................................... 96
Software characteristics ........................................................................................................................ 97
Technical characteristics ...................................................................................................................... 98
Safety positions according to electrical and pneumatic power supplys ................................................... 98
Factory settings of the TopControl Continuous ........................................................................................ 99
Characteristics of the TopControl Continuous ........................................................................................ 100
INITIAL COMMISSIONING ...................................................................................... 101
Pneumatic connection ........................................................................................................................ 101
Electrical connection .......................................................................................................................... 101
Multipol connection ............................................................................................................................... 101
Cable gland connection ......................................................................................................................... 102
QUICKON connections .......................................................................................................................... 103
Basic configuration ............................................................................................................................. 103
INSTALLATION ....................................................................................................... 107
Installation of the valve ....................................................................................................................... 107
Turning the Top
Control Continuous .................................................................................................. 107
Pneumatic connection of the Top Control Continuous .................................................... 108
Electrical connection .......................................................................................................................... 108
Multipole connection ............................................................................................................................. 109
Cable gland connection ......................................................................................................................... 111
QUICKON connections .......................................................................................................................... 113
Adjusting the inductive proximity switch (option) ........................................................................... 116
Top Control Continuous 85
6
6.1
6.2
6.3
6.3.1
6.3.2
6.4
6.4.1
6.4.2
6.4.3
6.5
6.5.1
6.6
6.6.1
6.6.2
7
OPERATION ............................................................................................................ 117
Control and display elements ............................................................................................................ 117
Operating levels .................................................................................................................................. 117
Commissioning as a position controller ........................................................................................... 118
Basic configuration ................................................................................................................................ 118
Operating mode for basic configuration ................................................................................................. 118
Configuration of the additional functions ......................................................................................... 122
Keys in the configuration menu ............................................................................................................. 122
Configuration menu ............................................................................................................................... 122
Additional functions ............................................................................................................................... 124
Setting a process control function .................................................................................................... 145
Starting the function to obtain linear characteristic curve ..................................................................... 145
Process operation level ...................................................................................................................... 146
AUTOMATIC operating mode ................................................................................................................. 146
MANUAL operating mode ...................................................................................................................... 149
FAILURES AND REPORT ERRORS ..................................................................... 151
7.1
7.2
Report errors on LCD display ............................................................................................................. 151
Miscellaneous failures ........................................................................................................................ 151
APPENDIX A ....................................................................................................................... 153
Selection criteria for continuous valves ........................................................................................................... 153
Characteristics of PID controllers ..................................................................................................................... 155
Rules for adjusting PID controllers .................................................................................................................. 159
APPENDIX B ....................................................................................................................... 161
Operating structure of the Top Control .............................................................................................................. 161
APPENDIX C ....................................................................................................................... 161
Tables for your settings ..................................................................................................................................... 165
FUNCTIONS OF THE TOP CONTROL CONTINUOUS
Function
Actfunc
Input
Addfunct
END
X.tune
Charact
Dir.cmd
Cutoff
Dir.act
SPLtrng
X.limit
X.time
X.control
127
127
128
129
130
130
131
Page
120
120
120
121
121
125
Function
P.control
P.co - dbnd
P.co - para
P.co - setp
P.co - inp
P.co - filt
P.CO SCAL
CODE
Output
BIN-IN cal.user
setfact
P.QLIN
86
135
138
139
139
141
144
145
Page
132
132
133
134
134
134
Operating instructions no. 800607
1 GENERAL INFORMATION
1.1
Symbols
The following symbols are used in these operating instructions: indicates a working step which must be performed
ATTENTION!
Indicates information, which if not observed can result in harmful effects on the health or the serviceability of the unit.
NOTE
Indicates important additional information, tips and recommendations.
1.2
Safety information
Please observe the information in these operating instructions, as well as the operating conditions and permissible data specified in the date sheets of the Top Control and of the relevant pneumatically actuated valve, to ensure satisfactory operation of the unit and a long service life:
• Follow general technical rules when planning the application and operation of the unit!
• Installation and maintenance may only be performed by technical personnel provided with suitable tools!
• Note the accident prevention and safety precautions applicable for electrical units during operation and maintenance of the unit!
• Always switch off the power supply before working on the system!
• Take suitable measures to prevent inadvertent operation or impermissible influences!
• Ensure a defined and controlled re-start of the process following an interruption of the electrical or pneumatic supply!
• We cannot accept any liability if these instructions are ignored or impermissible interventions are made in the unit and the warranty also becomes invalid on units and accessories!
1.3
Important for Handling
This electronic device is sensitive to electrostatic discharge (ESD). Contact with an electrostatic charged person or object endangers the electronic device. The worst case is that it will be destroyed immediately or just fail after putting into operation.
To minimize the possibility of damage by immediate electrostatic discharge, pay attention to the requirements of EN 100 015 -1. Please also pay attention not to assemble the electronic device while supply voltage is put on.
ATTENTION
OBSERVE PRECAUTIONS
FOR HANDLING !
ELECTROSTATIC
SENSITIVE
DEVICES
Top Control Continuous 87
1.4
Scope of delivery
Check the contents of the delivery for damage and agreement with the details specified on the delivery note immediately following receipt. This normally comprises:
• pneumatically actuated valve of types 2652, 2655, 2672, 2700, 2712, 2730, 2731 or 2731K with the Top
Control Continuous
• operating instructions for the valve with pneumatic drive
• operating instructions for the Top Control Continuous
Suitable cable plugs for the multipole connection are available as accessories.
In the event of discrepancies, please contact our service department immediately:
Bürkert Steuer- und Regelungstechnik
Chr.-Bürkert-Str. 13-17
Service-Abteilung
D-76453 Ingelfingen
Tel.: (07940) 10-252
Fax: (07940) 10-428 or your local Bürkert branch.
1.5
Warranty conditions
This document contains no warranty promises. We refer in this connection to our General Conditions of Sale and Business. The condition for the warranty is use of the unit for the intended purpose under the specified application conditions.
ATTENTION!
The guarantee only covers faults in the Top
Control Continuous, and in the integrated pneumatically-driven valve. No liability will, however, be accepted for subsequent damage of any kind that may arise as a result of the failure or incorrect functioning of the device.
1.6
Master code
Operation of the device can be locked via a freely selectable user code. Independent of this, there is an unalterable master code with which you can carry out all operations on the device. This 4-digit master code is printed on the last page of these operating instructions.
If needed you can cut out this code and store it separately from these operating instructions.
88 Operating instructions no. 800607
2 SYSTEM CONFIGURATION
NOTE
The following picture illustrates a complete system, based on
• a control valve with a pneumatic actuator
• a Top Control Continuous
These elements linked together compose a functional unit.
The function ranges of the Bürkert pneumatic control valves are greatly increased when in combination with the Top Control
Continuous. These valves can be fitted with the Top Control Continuous in order to obtain continuous control with variable functions.
The figure 2.1 below shows various combination capabilities of the Top Control Continuous combined with various pneumatic control valves. A vast range of connections and valve diameters is available, although not displayed in the figure below. All technical informations about these products are described in the relevant data sheets. The product range will be continuously increased.
Top Control
Type 8630 with flat seat valve Type 2712
(here with flange connection)
Top Control
Type 8630 with slanted seat valve Type 2700 with diaphragm valve
Type 2730 with ball valve Type 2655
Fig. 2.1: Overview of mounting options for the Top Control Continuous with various valve types
Top Control Continuous with swing valve Type 2672
89
Various control valves from the Bürkert range may be used in connection with the Top Control Continuous depending on the installation conditions. Angle valves, diaphragm valves, including ball valves fitted with a control cone are suitable, as well as piston or rotary driven pneumatic actuators.
Pneumatic piston actuators or rotary actuators may be used as actuators. Single acting and double acting actuators may be used in combination with the Top Control.
Within a single action actuator a single chamber is filled and exhausted. The resulting pressure acts on a spring, which forces the piston to move until the pressure difference between the piston and spring are equal.
Double chamber actuators posses 2 chambers, which supply the pressure to the piston. The filling of one chamber induces the emptying of the other, as there is no spring within this design.
Valves characteristics:
Types
Flat seat control valves
Slanted seat control valve
• 2700
• 2712
Diaphragm valves
• 2730
• 2731
• 2731K
Ball valves
• 265 2 (2 parts)
• 265 5 (3 parts)
Characteristics
• flow over under the seat
• protecte d against water hammer
• straight flow direction
• high tightness through selfpositioning
packing box
• fluid tightly isolated from the actuator and environtment • possibility of inter nal scraping
• no dead volume, self purging design • reduced dead volume
• direction of flow as required with minimal turbulence of
flow
• steam sterilizable
• low retention of deposits
• replaceable seat and seals through 3 parts ball
valve design
• CIP
• water hammer free
• removable diaphragm and actuator throu gh mounted
housing
Typical medium
• water, steam and gas
• alcohol, oil, fuel, hydraulic fluids
• brine, organic fluids, base
• solvent
• neutral fluid and gas
• charged or aggressive fluids
• high pur ity or sterilised fluid
• high viscosity fluids
• neutral fluid and gas
• pure water
• low aggressive fluids
90 Operating instructions no. 800607
3 DESCRIPTION OF THE TOP CONTROL
The type 8630 Top Control Continuous is an electropneumatic position controller for pneumatically actuated continuous valves.
The Top Control Continuous and pneumatic actuator are joined together to build one functional unit.
3.1
Construction
The design of the type 8630 Top Control Continuous (Fig. 3.1) is based on a modular concept.
Wide ranges of pneumatic and electrical connections are available as options.
Screw adjustment for the lower approximate switch
Screw adjustment for the upper approximate switch
Position controller with 2, 3 or 4 solenoid valves
Control unit with display and keypad
Pressure supply connection
(Marked: 1)
Air command connection
(closed on working side)
Exhaust air
(Marked: 3)
Electrical connection module with QUICKON connectors
Fig. 3.1: Design of the TopControl, cover removed
Top Control Continuous 91
92
CONSTRUCTION FEATURES:
•
Design:
for single/double-acting actuators
•
Path measuring system:
high linear resolution with plastic potentiometer. Freely coupled to the piston rod of the actuator
•
Electronic system piloted by a microprocessor:
ensure an efficient configuration, control, and drive of the actuator
•
Control unit:
Operation of the Top Control by mean of 3 keys.
An 8 character LCD ensures the display of setpoint, position, and configuration functions.
•
Positioning system:
Fig. 3.2: Electrical connection
The positioning system is composed and requires 2 solenoid valves for single-acting actuators (air inlet; exhaust air), or 4 solenoid valves for double-acting actuators (2 for air inlet; 2 for exhaust air).
The controller with a PWM-voltage powers the valves according to the rocker principle which allows fast positioning volumes to be reached as required.
A large flexibility concerning the volumes of the chambers and the positioning speed is reached in that way. For use of actuators with larger volumes, the positioning valves are fitted with membrane amplifiers in order to increase the maximal flow and optimise the dynamic of the system.
As an option with single-acting actuators, a fast pressurizing/venting version is available with an additional pressurizing valve and venting valve. This enables the actuator to be completely pressurized and vented more rapidly. This is used with the tight-closing function (see chapter "
CUTOFF
") and on activating a safety position of 0 or 100% (see chapter "
BIN-IN
").
•
Position indicator (option):
2 inductive approximate value switches (capacitive switches) or mechanical limit switches. Signalling the high or low limit positions of the actuator by a digital output or via a
PLC. Positioning screws allow free adjustment of the limit.
•
Electrical connection (Fig. 3.2):
Multipole connector, cable glands with terminals, or
QUICKON box connection.
•
Pneumatic connection (Fig. 3.3):
1/4’’ connection brass or stainless steel with various connection types (G, NPT, RC)
Fig. 3.3: Pneumatic connection
•
Top
Control Continuous body:
Protected against internal over-pressure, (eg. air leakage) by a pressure limit valve.
Protection against non-authorised opening of the cover by a seal or self-cutting screws.
Operating instructions no. 800607
3.2
Function
The figure 3.4 shows the functional diagram of the Top Control Continuous in combination with a single acting piston valve.
Process value
Process setpoint external position setpoint
Process controller
Position feedback
Top Control
Displacement measurement system
Position setpoint
Position controler
Actuator
Actuator
1: Air inlet valve
2: Air exhaust valve
Pressure air inlet
Air exhaust
Pneumatic actuator
(single acting)
Control valve
(Control output)
Sensor
Process value
(Flow, pressure, level, temperature, ...)
Fig. 3.4: Functional diagram of the TopControl Continuous in combination with a single acting piston valve
Top Control Continuous 93
Fig. 3.5: Process control example: TopControl with sensor
3.2.1 Working of the Top Control Continuous as position controller (Fig. 3.6)
The actual position (POS) is measured by the displacement measuring system. This position value is compared to the normalized position setpoint signal (CMD). In cases of difference (Xd1), a voltage pulse-width modulation signal is sent as control signal.
With single-acting actuators, a positive error exists and pulses are sent from output B
1 error exists, and pulses are sent from output E
1 of the actuator and the setpoint is reduced 0. Z1 represents a disturbance variable.
to activate the air supply. When a negative
to activate the exhaust air. With this system, the difference between the position
94
Position setpoint
CMD
Z1
Xd1
B1
E1
P
K
Position controller
POS
Position conctrol solenoid valve
Valve actuator
Valve opening
Path measuring system
Position control
Fig 3.6: Position control diagram
Operating instructions no. 800607
3.2.2 Using the Top Control Continuous as a process controller (Fig. 3.7)
By using the Top Control Continuous as a process controller, the previous position control function is a component of the main control loop.
The process controller within the main control loop posseses a PID function. The process setpoint (SP) is used and compared to the controlled process value (PV). A sensor delivers the actual value. The manipulated variable correction functions as described in chapter 3.2.1 represents a disturbance variable.
Z1
Xd1
B1
E1
Position controller
XPOS
Position control solenoid valve
P
K
Valve actuator
Valve opening
Path measuring system
Position control
SP
Process setpoint
Z2
Xd2
CMD
Process controller solenoid valve
Position control loop
Valve opening
Process
PV
Transmitter
Fig 3.7: Process control diagram
Process value
Top Control Continuous 95
3.3
Top Control Continuous variants
The Top Control Continuous is available in 3 forms, varying in electrical connection and control functions.
• Multipole connection with complete functions (Fig. 3.8)
• Terminal with PG cable glands and terminals with restricted functions (Fig. 3.9)
• QUICKON connection with restricted functions
External setpoint for position or process control
4..20 mA
0..20 mA
0..10 V
0..5 V
Process control value
4..20 mA
Frequency
Pt 100
Binary input
24 V DC
Pt 100
Top Control
Continuous
(Multipole connection)
Operating
2 binary output
Analogue position feedback
Limit switch 1 + 2
Fig. 3.8: Position interface with multipole connections
External setpoint for position or process control
4..20 mA
0..20 mA
0..10 V
0..5 V
Process control value
4..20 mA
Frequency
Pt 100
(as an alternative to binary outputs)
Top Control
Continuous
(PG and QUICKON variants)
2 binary output
(as an alternative to input for process set value)
Analogue position feedback
96
24 V DC
Operating
Advice:
Choose between an analogue position feedback and two binary outputs by setting the jumper.
Fig. 3.9: Interfaces of the TopControl Continuous on the variants with PG screw connectors and QUICKON connectors
NOTE
The Top Control Continuous posses 3-wires instruments. The 24 V DC power supply is isolated from the setpoint signal.
Operating instructions no. 800607
3.4
Software characteristics
Additional function Operation
Positon controller with additional functions
Close tight function Valve tightly closed over the tightness process range
Statement of a value (in %) above which the drive is completely de-aerated
(at 0 %) or ventilated (at 100 %)
Plug travel limitation
Split range
Mechanical movement of the valve piston within a specified stroke range
The signal is split in 2 or more positions
Characteristics curves for process value adjustment
Deadband
The linearization of the characteristic curvecan be processed
The Top Control acts only if a specified control difference is measured
Direction of command of nominal and actual Relationship between the setpoint limit values and the position of the actuator value
Safety position The valve moves to a specified safety position
Automatic adjustment to the connected valve
Connections of the process controller with the following functions
Control type
Available parameters
Input scale
Selection of the setpoint entry mode
PID
Proportional coefficient, reset time, action rate and operating point
Position of the decimal point, lower and upper scale values of the actual value and setpoint
Setpoint entry manual or external
Automatic adjustment to the conditions of the process
Hierarchical concept for easy commissioning with the following levels:
Process mode
Configuration mode
Selection between automatic and manual modes
Selection of the basic functions, and if necessary additional functions within this level
Top Control Continuous 97
3.5
Technical characteristics
3.5.1 Safety positions according to electrical and pneumatic power supplys
Type of actuator Designation
single acting
WW A
Safety settings following failure or auxillary power supply
electrical
down
pneumatic
down single acting
WW B up up double acting
WW I down / up
(depending on connection of control lines)
not assigned
98 Operating instructions no. 800607
3.5.2 Factory settings of the Top Control Continuous
Function
Actfunc
Input
Charact
Dir.cmd
Cutoff
Dir.act
SPLtrng
X.limit
X.time
Factory setting
funcsngl
Inp 4'20A
Cha lin
DIR.crise
CUT
= 1 %
; CUT
= 99%
DIR.Arise
SR =
0 (%)
; SR
= 100 (%)
LIM
= 0%
, LIM
= 100% no limitation
Function
X.control
P.co - dbnd
P.co - setp
P.co - inp
P.CO - FILT
P.co - scal
CODE
Output
BIN-IN
Factory setting
1 %
1 % setp int
Inp 4'20A
0 unit l/s
CODE 0000 out 4'20A
Inp 4'20A
Top Control Continuous 99
3.5.3 Characteristics of the Top Control Continuous
Operating data
Operating temperature
Degree of protection
0...+50°C
IP 65 according to EN 60529
(in correct electrical installation conditions)
Conformity to norms
CE
Mechanical data
Dimensions
Material of the body
According to CE 89/336 refer to data sheet external internal
POM, PSU
PA 6
NBR Material of the seal
Electrical data
Connections
Power supply
Power consumption
Input resistance for actual signal
Input resistance for set-point signal multipole connectors, terminal with two PG 9 screwed glands or
QUICKON connection (see fig. 5.2)
24 V DC ± 10 %
Residual pulsation 10 %
No technical direct voltage!
< 5 W
180
Ω at 4 - 20 mA
17 k
Ω at frequency
180
Ω at 0/4 - 20 mA
19 k
Ω at 0 - 5/10 V
3 according to VDE 0580 Protection class
Analog position feedback:
Max. current for voltage output 0...5/10 V
Max. burden for current output 0/4 mA
Inductive proximity switch:
Current limitation
Binary outputs:
Current limitation
Pneumatic data
10 mA
560
Ω
100 mA
100 mA
Control medium
Compressed air temperature
Oil content
Dust content
Temperature of the pressure air
Pressure range instrument air, class 3 according to DIN ISO 8573-1
-20°C max. 1 mg/m³
5 µm filtered
0..+50°C
3..7 bar 1)
Pressure fluctuations max. ± 10 % during service 2)
Airflow rates Steuerventile 100 l
N
(Q
/min (for air supply and exhaust)
Nn
3)
-Value according to definition of the pressure loss from 7 to 6 bar absolute)
G / NPT / RC 1/4’’ internal thread Union connections
1)
2)
3)
The control pressure has to exceed the pressure from 0.5- 1 bar, in order to ensure the final positioning of the actuator.
Higher pulsation reduces the control accuracy based on the autotune function.
We reserve the right to make technical changes to optimize the function of the Top
Control.
100 Operating instructions no. 800607
4 INITIAL COMMISSIONING
NOTE
This section allows you to perform the quick commissioning of the Top Control Continuous. The not essential additional functions are not described in this section. See chapter 5 and 6 for complete explanations about commissioning and the functions available.
4.1
Pneumatic connection
➔
Install the valve according to the specific requirements.
➔
Connect the air supply (3..7 bar, instrument air, oil, water and duster) to port 1.
➔
Mount the exhaust air pipe or noise reducer on port 3.
M16 M12
4.2
Electrical connection
4.2.1 Multipole connection
➔
Connect the external position setpoint signal to the circular connector M16.
Connection of the circular connector M16:
Pin
B
A
Assignment
Setpoint +
Setpoint GND
(0/4..20 mA) or
0..5 / 10V
Fig. 4.1: TopControl with multipole connectors
B
External connection
+ (0/4..20 mA) or 0..5 / 10V
A
GND
➔
Connect the power supply to the circular connector M12.
Connection of the circular connector M12 :
Pin
1
2
3
4
Assignment
+ 24 V not connected
GND not connected
1
3
External connection
24 V DC ± 10 %
Residual ripple 10 %
Top Control Continuous 101
4.2.2 Cable gland connection
Easy connection of the terminal box:
➔
Remove the 4 self-cutting screws to open the cover of the terminal box.
The connections of the terminals are shown in figure
4.2.
➔
Connect the external position setpoint signal and power supply wires to the terminals (according to the
PG-terminal assignment).
Terminals
Fig. 4.2: TopControl Terminals
Connection of terminals (with cable glands)
Terminal
Assignment
1
2
Setpoint +
Setpoint GND
5
6
Power supply +
Power supply GND
External connection
1
+ (0/4..20 mA or 0..5 / 10V)
2
5
GND
24 V DC ± 10 %
Residual ripple 10 %
6
NOTE
Further installation procedure, see chapter 5.
Once activated, the Top Control Continuous will work and the necessary configuration and self-calibration operations of the
Top Control Continuous will have to be performed (Fig. 4.4).
102
4.2.3
Operating instructions no. 800607
4.2.3 QUICKON connectors
QUICKON Pg9, 3-pole
Fig. 4.3:
QUICKON connectors on
TopControl
QUICKON Pg11, 4-pole
Pin
3
Lay the set-point signal on the QUICKON connector PG11, 4-pole:
Assignment
Set-point GND
4
External connection
+ (0/4..20 mA or 0..5 / 10V)
4 Set-point +
3 GND
1
2
Pin
Lay the supply voltage on the QUICKON connector PG9, 3-pole:
Assignment External connection
Operating voltage +24 V
Operating voltage GND
1
2
24 V DC ± 10 % max. residual ripple 10 %
4.3
Basic configuration
Key assignment:
MANUAL/AUTOMATIC key Choice of menu and sub-menu e. g.
ACT FUNC - FUNCSNGL
ARROW key Choice between level menu functions e.g.
ACTFUNC - INPUT
Fig. 4.4 Key on TopControl
Top Control Continuous 103
MANUAL
Mode
AUTOMATIC
Mode
5 s
Omit during first commissioning
5 s
104
Fig. 4.5: Basic configuration
Operating instructions no. 800607
Configuration within the MAIN menu:
ACTFUNC
Function of the actuator
FUNC SNGL
FUNC DOUB
- single acting
- double acting
INPUT
Selection of the input signal
INP 420A
INP 020A
INP 010V
INP 05V
- Current 4..20 mA
- Current 0..20 mA
- Voltage 0..10 V
- Voltage 0..5 V
ADDFUNCT
X.TUNE
END xx
Omit for quick commissioning
Activation of the self-calibration (Fig. 4.4).
Return to the AUTOMATIC mode.
The message
EEPROM
is displayed until the new parameters are stored.
Top Control Continuous 105
Entry of the setpoint within the AUTOMATIC mode
After the configuration the Top Control acts as a position controller.
➔
Enter the setpoint as a signal input.
➔
Switch between the display possibilities:
Message on display:
• Actual position of the actuator
• Setpoint of the actuator
• Signal entry for the setpoint
(equivalent to setpoint)
• Internal temperature of the Top Control
POS__xxx
CMD__xxx
INP__xxx
TEMP_xx.x
(0..100%)
(0..100%)
(0..100%)
(in °C)
Manual opening and closing of the valve within the MANUAL mode
Open the valveantriebs:
Close the valveantriebs:
Message on display:
NOTE
The previous display within the AUTOMATIC mode remains active.
Advice Select the
POS_xxx
display, to ensure that the actual position of the actuator is displayed.
106 Operating instructions no. 800607
5 INSTALLATION
Please refer to the data sheets for dimensions of the Top Control Continuous and complete instrument variants of the
Top
Control, pneumatic actuators and valves.
5.1
Installation of the valve
NOTE
The actuator must not be connected.
For dimensions and thread types, see data sheet of process valve.
5.2
Turning the Top Control Continuous
If after installation of the continuous valve, the display of the Top Control Continuous is poorly visible or the cables or hoses are difficult to connect, the Top Control Continuous can be turned relative to the pneumatic actuator.
The procedure is as follows:
Loosen the fluidic connection between the Top Control Continuous and the pneumatic actuator.
Loosen the grub screw sunk in the side of the housing (hex socket SW3).
Turn the Top
Control Continuous clockwise, without lifting, into the desired position.
Retighten the grub screw with a moderate torque.
Remake the fluidic connection between theTop Control Continuous and the pneumatic actuator.
If necessary, use longer hoses.
ATTENTION!
If the Top Control Continuous is lifted on turning (displaced axially), the mechanically coupling of the distance measuring system may be damaged. By turning in the wrong direction (anticlockwise), there is a risk of unhooking the distance measuring system. It can only be hooked in again with a special tool!
Top Control Continuous 107
5.3
Pneumatic connection of the Top Control Continuous
➔
Connect the air supply (3..7 bar, instrument air, oil, water and duster) to port 1 (Fig. 5.1).
➔
Mount the exhaust air pipe or noise reducer on port 3 (Fig. 5.1).
Supply pressure connector (inscription: 1)
NOTE
Outlet air connector
(inscription: 3)
Bild 5.1: Fluidic connections of the TopControl
The pressure supply must exceed the pressure required by the pneumatic actuator and must exceed at least 0.5 to 1 bar.
This is to ensure that the control process in the upper ranges of the actuator will not become negative due to a lower pressure difference.
Keep the pressure supply variations within the most restricted limits (max. ±10 %).
Higher variations reduce the reliability of the measured parameters within the AUTOTUNE procedure.
5.4
Electrical connection
Various options are available for electrical connection
• Multipole connection
• Terminals (with cable glands)
• QUICKON connection
ATTENTION!
A screw with a nut is available in the connecting module for connection of the technical earth (TE). In order to comply with the EMC requirements connect this screw to a good earthing point with a short length cable (max. 30 cm).
108 Operating instructions no. 800607
5.4.1 Multipole connection
The figure 5.2 indicates the functions of the multipole connectors and assignment of the pins.
Signal to SPS
Power supply
M16
M8
M12
M8
Process value
Fig 5.2: Circular connector with pin assignment
G
H
J
D
E
F
Output signal to SPS (circular connector M16)
Pin
A
Assignment
Setpoint GND
B
C
Setpoint + (0/4..20 mA or 0..5/10 V)
Analogue position indication +
Analogue position indication GND
Binary output 1
Binary output 2
Binary output GND
Binary input +
Binary input GND
K
L
M not connected not connected not connected
E
F
A
C
B
External connection
D
+ (0/4..20 mA or 0..5 / 10V)
(completely separated galvanically)
GND
+ (0/4..20 mA or 0..5 / 10V)
(completely separated galvanically)
GND
24 V / 0 V
24 V / 0 V
G
GND
H
J
+
GND
0..5V
(log. 0)
10..30 V (log. 1)
Initiators
Top Control Continuous 109
110
Power supply (circular connector M12)
Pin
1
2
3
4
Assignment
+ 24 V not connected
GND not connected
External connection
24 V DC ± 10 %
Residual ripple 10 %
Inductive proximity switch (circular connector M8)
Pin Assignment
1
2
Proximity switch 1 +
Proximity switch 1
(NO)
GND
3
4
Proximity switch 2 + (NO)
Proximity switch 2 GND
External connection
S1
+24 V DC
GND
S2
+24 V DC
GND
3
4
1
2 open / 24 V
GND open / 24 V
GND
Process value (circular connector M8)
Signal *
4..20 mA
- internal power supply
Pin
1
2
3
4
Assignment
+ 24 V transmitter entry
Transmitter output
GND
Strap to GND
Jumper External connection
Transmitter
4..20 mA
- external power supply
Frequency
-internal power supply
Frequency
-external power supply
Pt-100 1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4 not connected
Analogic signal + not connected
Analogic signal -
+24 V supply of sensor
Pulse +
Pulse not connected not connected
Pulse +
Pulse not connected not connected
Process 1
Process 3
Process 2
* Connectable through software (see 6.3.2)
3
4
2
1
2
3
2
3
+24 V
Puls +
Puls -
Puls +
Puls -
Pt 100
Operating instructions no. 800607
5.4.2 Cable gland connection
Easy connection of the terminal box:
Remove the 4 self-cutting screws to open the cover of the terminal box.
The disposal of the terminal is shown on figure 5.3.
Straps
Terminals
Fig. 5.3: TopControl terminals and straps
Connection of terminals (with cable glands)
Terminal
Assignment
1
2
3
4
Setpoint +
Setpoint GND
Analogic position feedback +
Analogic position feedback GND
5
6
Power supply +
Power supply GND
External connection
1
+ 0/4..20 mA
2
3
4
5 or 0..5 / 10V
GND
+ 0/4..20 mA oder 0..5 / 10V
(completely separated galvanically)
GND
24 V DC ± 10 %
Residual ripple 10 %
6
Top Control Continuous 111
Selection between digital output and process value input:
Select using the strap:
2 digital outputs (see terminal assignment when digital output selected) or
process value inputs (see terminal assignment when process value is selected).
The terminals 7 to 10 are connected to the corresponding signals.
Connect the limit switches to the terminals:
Strap
Terminal
7
8
Assignment
Digital output 1
Digital output 1
9
10
Digital output 2
Digital output 2
7
External connection
24 V / 0V
8
9
10
GND
24 V / 0V
GND
112
Connection of the process value to the terminals:
Set the type of entry signal within the configuration menu (see 6.3.2).
Signal
4..20 mA internal power supply
Strap Terminal Assignment
7 +24 V transmitter entry
8
9
10
Transmitter output
GND
GND
Frequency internal power supply
7
8
10
External connection
7
+ 24 V
8
9
10
GND
+24 V
Pulse +
Pulse -
Transmitter
4..20 mA external power supply
Frequency external power supply
Pt-100
10
7
8
9
10
7
8
9
10
7
8
9
10
7
8
9
+24 V power supply
Pulse + not connected
Pulse not connected
Analogic signal + not connected
Analogic signal not connected
Pulse + not connected
Pulse not connected
Process 1
Process 2
Process 3
8
10
8
10
10
8
9
+ (4..20 mA) V
GND
Pulse +
Pulse -
Pt-100
Operating instructions no. 800607
5.4.3 QUICKON connectors
QUICKON PG9, 3-pole
Fig. 5.4: QUICKON connectors on
TopControl
1
2
QUICKON connector PG9, 3-pole:
Pin Assignment
3
Operating voltage +24 V
Operating voltage GND not connected
3
4
1
2
QUICKON connector PG11, 4-pole:
Pin Assignment
Analog position transmitter GND
Analog position transmitter +
Set-point GND
Set-point +
QUICKON Pg11,
4-pole
1
2
2
1
4
3
TE
(Technical
Earth)
External connection
QUICKON Pg11,
4-pole
24 V DC ± 10 %
Residual ripple 10 %
External connection
+ 0/4..20 mA or 0..5 / 10V)
(completely separated galvanically
GND
+ (0/4..20 mA or 0..5 / 10V)
GND
QUICKON connector PG11, 4-pole:
Choice between binary outputs and process actual value input:
Select via jumpers a) 2 binary ouputs (see pin assignment on choice of binary ouputs) b) or
Process actual value input (see pin assignment on choice of process actual value input)
Top Control Continuous 113
114
a) Pin assignment on selection of the binary outputs
Jumper QUICKON pin Assignment
1
2
3
4
Binary output 1+
Binary output 1-
Binary output 2+
Binary output 2-
3
4
External connection
1
2
24 V / 0V
GND
24 V / 0V
GND
b) Pin assignment on selection of the process actual value input
The input type is set via the configuration menu (see 6.3.2).
Input type
4..20 mA supplied internally
Jumper Pin
1
2
3
4
Assignment
+24 V input transmitter output transmitter
GND
GND
+ 24 V
External connection
1
2
Transmitter
3
4
GND
Frequency supplied internally
4..20 mA supplied externally
Frequency supplied externally
Pt-100 1
2
3
4
3
4
1
2
3
4
1
2
1
2
3
4
+24 V supply sensor
Clock input + not connected
Clock input - (GND) not connected
Process actual +
Process actual not connected not connected
Clock input + not connected
Clock input not connected
Process actual 1
Process actual 2
Process actual 3
1
2
4
2
3
4
4
3
2
2
+24 V
Clock input +
Clock input - (GND)
+ (4..20 mA) V
GND
Clock input +
Clock input -
Pt-100
Operating instructions no. 800607
Information on connecting the QUICKON connectors to cable
QUICKON PG9 / 3-pole
Range of wire cross-sections
Strand structure / smallest diameter
Wire insolation material
Outside diameter of conductors
Wire diameter (incl. insolation)
Rated voltage with overvoltage category / degree of contamination
0.34..0.75 mm²
VDE 0295 Class 2 to 5 / 0.2
PVC / PE
4...6 mm
≤
2.5 mm
160 V
III / 3
QUICKON PG11, 4-polig
Range of wire cross-sections
Strand structure / smallest diameter
Aderisolationsmaterial
Outside diameter of conductors
Wire diameter (incl. insolation)
Rated voltage with overvoltage category / degree of contamination
0.34..0.75 mm²
VDE 0295 Class 2 to 5 / 0.2
PVC / PE
4...7.5 mm
≤
2,5 mm
160 V
III / 2
Top Control Continuous 115
5.5
Adjusting the inductive proximity switch (option)
ATTENTION!
It is necessary to open the Top Control housing to install the inductive proximity switch.
Disconnect the power supply before opening open the Top Control.
Opening the Top Control:
➔
Remove the screws and possible seals between the cover and the housing.
➔
Twist the cover to the left and remove it.
Installing the inductive proximity switch:
➔
Mount each inductive proximity switch at the top over the fixing screws. (Fig. 5.4):
Turn right ensures adjustment to the top
Turn left ensures adjustment to the top
Fixing for upper position switch
Fixing for lower position switch
Bild 5.5: Setting of the inductive proximity switch with the setscrews
116 Operating instructions no. 800607
6 OPERATION
6.1
Control and display elements
The Top Control Continuous has 3 keys and a LCD (Fig 6.1).
The functions of the keys are described in the following section.
Arrow up key MANUAL/AUTOMATIC key
LED
(in the MANUAL/
AUTOMATIC key)
Arrow down key
Fig. 6.1: Control and display elements
6.2
Operating levels
2 operating levels are provided for operation of the Top Control Continuous (fig. 6.2):
• Process operation level:
This level is automatically set each time the unit is switched on. It allows changing between the MANUAL and AUTOMATIC operating modes. In the AUTOMATIC mode the position control or process control is automatically processed. In the MANUAL mode the valve can be opened or closed manually.
• Configuration level:
Specify the basic functions on initial commissioning and select further additional functions within the configuration level.
Process mode
MANUAL AUTO-
MATIC
Fig. 6.2: Changing between the operating levels
5 s
Configuration mode
Basic functions
End
Additional menu
Top Control Continuous 117
6.3
Commissioning as a position controller
➔
Follow the pneumatic and electrical connection instructions before commissioning (chapter 5).
6.3.1 Basic configuration
➔
Select the following basic configuration for the initial commissioning :
• Enter the displacement range of the pneumatic actuator.
• Enter the unit of the selected input signal (4..20 mA, 0..20 mA, 0..10 V or 0..5 V).
• Start the self-calibration of the Top Control Continuous to the selected operating conditions(Autotune).
6.3.2 Operating mode for basic configuration
Assignment of the keys:
MANUAL/AUTOMATIC key Changing between main- and submenu e. g.
ACT FUNC - FUNCSNGL
Arrow keys Changing between same level functions e. g.
ACTFUNC - INPUT
118 Operating instructions no. 800607
Main menu for configuration during servicing:
AUTOMATIC
Mode
5 s
MANUAL
Mode
Omit during first commissioning
5 s
Fig. 6.3: Setting within the main menu
Top Control Continuous 119
Description of the overview (Fig. 6.3):
After switching the power on, the Top Control Continuous is in the process operation level in the AUTOMATIC mode. To enter the basic configuration, within the configuration level, press the MANUAL/AUTOMATIC key for a duration of 5 seconds. The submenu
ACTFUNC will then be displayed as the first step of the main menu.
To enter the sub-menu
ACTFUNC quickly press the MANUAL/AUTOMATIC key. One of the functions of the sub-menu will be displayed. To move between the different functions, press the arrow keys, additionally enter any desired settings. Press the MA-
NUAL/AUTOMATIC key to validate the wished settings after selection.
NOTE
The selected function is displayed on 3 or 4 digits right of the 8-characters LCD. These digits will blink on the display.
120
Actfunc
Functions of the actuator
➔
Enter in this sub-menu the configuration of the pneumatical actuator used with the Top Control. See the instrument label for function valve description.
- single acting
- double acting
Input
Selected input signal
➔
In this sub-menu enter the unit used for the setpoint value.
- Current 4..20 mA
- Current 0..20 mA
- Voltage 0..10 V
- Voltage 0..5 V
Addfunct
Configuration of the additional functions (see Fig. 6.4)
➔
Omit this function during the initial operation.
Operating instructions no. 800607
X.tune
Autotuning of the Top Control Continuous
➔
With the
X.TUNE
sub-menu, you start a program that performs an automatic parametring of the Top
Control Continuous.
The following parameters are automatically calculated:
• Matching the sensor signal to the (physical) stroke of the control valve
• Determining the parameters of PWM signals controlling the internal solenoid valves
• Optimum adjustment of the control parameters of the position controller (target function: quickest possible movement to set the position without hunting)
➔
To start the autotune function, call the
X.TUNE
option within the main menu, then leave it by pressing the MANUAL-AUTOMATIC key for 5 seconds.
Start of the automatic adjustment of the Top Control Continuous to the operating conditions
Display
TUNE 5
TUNE 4
:
TUNE 0
¦
X.TUNE 1
¦
X.TUNE 2
¦
X.TUNE 3
¦
X.TUNE 4
:
X.TUNE.END
Description
Countdown from 5 to 0, before starting the autotune
Display the already passed steps of the autotune procedure
(The advancement is figured on a varying barchart (displayed on the right) hand side of the LCD)
Blinking display => End of the autotune function
X.ERR X.X
Display in error occurence
(right display: error number; see chapter 7)
Fig. 6.4: Display during launching and performing the autotune
5 s
Advice:
The basic configuration of the Top Control is pre-set by the factory. On commissioning, however, execution of
”Autotune” is absolutely necessary. The Top Control then determines autonomously the optimum settings for the current operating conditions.
ATTENTION!
Avoid incorrect adaptation of the controller by executing an Autotune in each case at the supply pressure available in later operation (= pneumatic auxiliary energy).
If substantial interfering forces are to be expected from the flow through the valve (e.g. from large pressure fluctuations), Autotune should be executed without medium pressure.
END
Quit the main menu and display the version of the software
➔
In order to quit the main menu, select the submenu
END
with the arrow key, then validate. On the right hand side of the screen, the software version is displayed (
End xx
).Press the MANUAL/AUTOMATIC key for 3-5 seconds, and the message
EEPROM appears on the display during the storage of the changes. The instrument is then in the previous mode (MANUAL-
AUTOMATIC), before the main menu is entered.
Top Control Continuous 121
6.4
Configuration of the additional functions
NOTE
The operating concept of the Top Control Continuous is based on a separate basic and additional functions.
Only the basic functions of the unit are activated on delivery. This enables the basic settings such as specific units to be set during the initial setting up of the unit (Chapter 4). These are sufficient for the normal operations.
For more demanding tasks of position and process control, additional functions can be selected and configurated.
6.4.1 Keys in the configuration menu
Key description
Key description within the Menu
Arrow up key
Arrow down key
within a selected sub-menu
Increase of the numeric value
Decrease of the numeric value
within the Menu
Validation of the selected sub-menu
Validation of the selected value
within the menu
ADDFUNCT
Validation of the selected sub-menu of the additional functions for use within the main menu. The sub-menu is marked with a star (*) within the main-Menu and can there be selected and modified.
Selection of the selected submenu (marked with a star) in order to suppress it from the main menu.
6.4.2 Configuration menu
Process mode
MANUAL AUTO-
MATIC
5 s
Configuration mode
Basic functions
END
Additional menu
Fig. 6.5: Switch between process mode and configuration mode
5 s Within process mode, press the MANUAL/AUTOMATIC key and hold down for 5 sec to activate the configuration mode.
The configuration menu is constituted of the main menu and the additional menu. The main menu will contain the functions as specified during the initial commissioning (Chapter 4). The additional menu contains complementary functions and is available through the ADDFUNCT menu within the main menu. If necessary, you may complete the main menu with functions from the additional sub-menu, which you can then specify.
122 Operating instructions no. 800607
Selection of additional functions within the main menu
➔
Select the sub menu
ADDFUNCT within the main menu.
➔
By pressing the MANUAL/AUTOMATIC key, enter within the additional sub-menu.
➔
Select the required function with the arrow-keys.
➔
By pressing the MANUAL/AUTOMATIC key, validate the additional function within the main menu. The function is marked with a star (*).
➔
All functions are activated within the main menu after validation through
ENDFUNCT
.
➔
Enter the parameters of the additional functions within the main menu.
Withdrawal of additional functions from the main menu
➔
Select the sub menu
ADDFUNCT within the main menu.
➔
By pressing the MANUAL/AUTOMATIC key, enter within the additional sub-menu.
➔
Select a function marked with a star (*) by mean of the arrow-keys.
➔
By pressing the MANUAL/AUTOMATIC key, withdraw the additional function from the main menu (the marking star (*) is removed).
➔
The function is deactivated from the main menu after validation through
ENDFUNCT
.
Entry of numeric values
Enter the numeric values in the previous functions by pressing one or several times the arrow up key (to increase the value) or the arrow down key (to decrease the value). If the value is displayed with 4 digits, only the blinking one can be changed with the arrow key. Pressing the MANUAL/AUTOMATIC key moves to the next position.
Selection of the
ADDFUNCT sub-menu
Extended main menu
Main menu
A C T F U N C
I N P U T
A D D F U N C T
X . T U N E
E N D
A C T F U N C
I N P U T
C H A R A C T
X . C O N T R L
P. C O N T R L
A D D F U N C T
X . T U N E
P . Q ' L I N
E N D
Validation of the selected function
Additional menu
Return to the extended main menu
* C H A R A C T
C U T O F F
D I R E C T N
S P L T R N G
X . L I M I T
* X . C O N T R L
* P. C O N T R L
E N D F U N C T
Validation of the selected additional functions and adding to the main menu
Fig. 6.6: Principle of the selection of an additional function to the main menu
Top Control Continuous 123
6.4.3 Additional functions
Selection of the transmission characteristic curve between the input signal and stroke
(correction characteristic curve)
Close tight function
Relationship between the input signal and the setpoint
Relationship between the indicated position value and the air supply state (Connection 2
1
)
Split range: min. and max. value in % of the set value range of the Top Control Continuous
Stroke limitation to a given min. and max. value
Speed limitation to open or close the valve
Top Control Continuous configuration
Process controller configuration
Protection code for configurations
Operation of binary input
Output configuration
User calibration
Back to factory setting
124 Operating instructions no. 800607
Charact
Selection of the transmission characteristic curve between the input signal and the stroke (correction characteristic curve)
User specific characteristic curve (Characteristic)
Factory setting:
CHA LIN
With this function you select a transmission characteristic curve in relation to the position set value (position setpoint) and to the valve stroke to correct the flow rate respectively the operating characteristic curve.
linear characteristic curve equal percentage characteristic curve,
1 : 25 equal percentage characteristic curve,
1 : 33 equal percentage characteristic curve,
1 : 50 inverse equal percentage,
25 : 1 inverse equal percentage,
33 : 1 inverse equal percentage,
50 : 1 user specific freely programmable characteristic curve based on temporary restart points
The flow characteristic k v
= f
(s)
characterises the flow of a valve and is expressed by the k v
value relative to the stroke s of the valve spindle. It is determined by the shape of the valve body. There are normally two types of flow characteristic curves: linear and equal percentage.
In the case of linear characteristic curves equal changes in stroke ds are assigned to equal k v
value changes dk v
(dk v
= n lin
ds).
In the case of an equal percentage characteristic curve, a change in stroke ds corresponds to an equal percentage change in the k v
value
(dk v
/k v
= n equalperc
ds).
Standard valve stroke [%]
Standard position setpoint [%]
Fig. 6.7: Corrective characteristic curves
The operating curve Q = f
(s)
represents the relationship between the rate of flow Q which flows through a valve fitted in the system and the stroke s. This curve is also affected by the properties of the pipelines, pumps and consumers. It therefore has a form, which deviates from the flow characteristic curve.
Specific requirements are usually laid down for the operating characteristic curve (e.g. linearity) in the case of correcting tasks for closed loop control systems. Therefore it is sometimes necessary for this reason to correct the pattern of the operating curve in a suitable manner. A transmission element, which implements various characteristic curves that can be used to correct the operating curve, is provided in the Top Control Continuous for this purpose.
The equipercentile curves 1:25, 1:33, 1:50, 25:1, 33:1 and 50:1 and a linear characteristic may be set. Furthermore, it is possible to programme any characteristic via reference points or have it calibrated automatically.
Top Control Continuous 125
Input of the freely-programmable characteristic curve
The characteristic curve is defined by means of 21 restart points distributed uniformly over the set positioning range of 0 ... 100%.
These are spaced at 5%. A freely selectable stroke (range 0 ... 100%) can be assigned to each restart (Fig. 6.8). The difference between the values of the stroke of two adjacent restart points shall not exceed 20%.
To input the characteristic curve points (function values), the
CHA FREE
menu item is first set.
After operation of the MANUAL/ AUTOMATIC key the first restart point is input with the display 0 (%). After this the next function value is 0 (%).
A function value from 0 to 100% can be set using the arrow keys. After confirmation using the MANUAL/AUTOMATIC key the next restart point is shown on the display etc. If finally the MANUAL/AUTOMATIC key is pressed to confirm the function value for the last restart point (100%), the program switches back to the
CHARACT
menu item.
Valve stroke
[%]
Input signal
[%]
Entry of the position:
Valve stroke [%]
(input with the arrow keys)
Position setpoint [%]
(restart points) return to
CHARACT
Fig. 6.8: Example of the free programming of a correction curve
NOTE
A table for noting the reference points entered is to be found in the Annex
Operating instructions no. 800607 126
Note: .
Cutoff
Close tight function
Factory setting:
CUT
= 1 %;
CUT
= 99%
The closed tight function ensures that the valve is tightly closed outside the control range. Specification of a value (%) from which the actuator air is completely exhausted or supplied with air. With the fast pressurizing/venting version, two valves are driven in each case in order to completely vent and pressurize more rapidly. The opening or resumption of the control operation takes place with a hysteresis of 1% (refer to Fig. 6.9).
Exhaust aired (0 % inactive)
Range: 0.0 ... 10.0 % for complete exhausting
Plug travel
[%]
Filled with air (100 % inactive)
90.0 ... 100 % for complete air supply
Programmable from 75,0 to 100,0 %
Setpoint [%]
Programmable from 0,0 to 25,0 %
Fig. 6.9: Closed tight function
Dir.cmd
Direction of command of the setpoint of the actuator
Factory setting:
DIR.CRISE
With this additional function, the direction of action according to setpoint of the actuator and the input signal (Fig. 6.10).
Rise direction
(i.e.
4 mA bzw. 0 V
→
0%
20 mA bzw. 5/10 V
→
100%)
Fall direction
(i.e.
4 mA bzw. 0 V
→
100%
20 mA bzw. 5/10 V
→
0%)
Top Control Continuous 127
128
Setpoint
RISE
FALL
Input signal
Fig. 6.10: Sense of action between input signal and setpoint
Dir.act
Relationship or direction of the actuator
Factory setting:
DIR.ARISE
This function determines the direction of action between the air supply state and the actual value indication of the actuator
(Fig. 6.11).
Direct command
(exhausted
→
0%
Inverse command
(exhausted
→
100% supplied
→
100%) supplied
→
0%)
Set position
RISE
Fig.6.11: Relationship between air delivery state
of the actuator and the actual value exhausted
FALL supplied Air supply state
Operating instructions no. 800607
SPLtrng
Splitrange; minimal and maximum values of the input signal (in %) generating the complete displacement of the valve all over the plug range.
Factory setting:
SR
= 0 (%);
SR
= 100 (%)
This additional function enables the set value range of a Top Control Continuous to be restricted by stipulating a minimum and maximum value. This makes it possible to divide the used unit signal range (4..20 mA, 0..20 mA, 0..10 V oder 0..5 V) over several
Top Control Continuous (without or with an overlap). In this way, several valves can be partially used either simultaneously or in
sequence as a final controlling element (Fig. 6.12).
Entry of the minimal value of the input signal in % (0... 75 (%) of the measuring range)
Entry of the maximum value of the input signal in %
(25... 100 (%) of the measuring range)
Plug travel [%]
Fig. 6.12: Splitting a unit signal range into
two set value ranges
Setpoint range
Top Control
Continuous 1
Setpoint range
Top
Control
Continuous 2
Setpoint
[mA]
Top Control Continuous 129
X.limit
Mechanical stroke limitation
Factory setting:
LIM
= 0%,
LIM
= 100%
This additional function enables the (physical) stroke to be limited to a given MIN and MAX percentage value (Fig. 6.13).
There, the stroke range of the limited stroke is set to equal 100%.
If during servicing the selected plug travel is overpassed, then the display of POS value may be greater than 100 % or lower than 0%.
Entry of the lower value of the stroke range in %
0..50% of the total stroke
Entry of the upper value of the stroke range in %
50..100% of the total stroke
The minimum distance between
LIM
and
LIM
is 50%
Limited plug travel [%]
Physical plug travel [%]
Unlimited plug travel
Limited plug travel
130
Fig. 6.13: Stroke limitation
X.time
Setting speed limitation
Factory setting: No limitation
On execution of the function X.TUNE, the minimum opening and closing times for the entire stroke are entered in T.OPN and
T.CLS automatically. In this way, operation at maximum speed is selected.
If the control speed is to be limited, values for T.OPN and T.CLS may be entered that lie between the minimum values determined by X.TUNE and 60 s.
Opening speed
Setpoint [mA]
Entry in s
Closing speed
Operating instructions no. 800607
Valve stroke
[%]
Set-point value
Actual value
T.OPN
Fig. 6.14: Effect of limiting the opening speed for a jump in the set-point value
X.contrl
Parameters setting for the Top
Control Continuous
t
Deadband of the Top
Control Continuous
Enter the deadband in % ( 0 = automatic) Factory setting: 1 %
This function ensures that the Top Control Continuous acts only then a selected control difference is measured (Fig. 6.14).
This function protects the servovalve and pneumatic actuator by controlling the start-up frequency.
The setting is optimized automatically with X.TUNE.
Parameter of the position controller
Proportional factor for the Top Control Continuous (to close the valve)
Proportional factor for the Top
Control Continuous (to open the valve)
End of the parametering of the Top Control Continuous. Return to
X.CONTRL
Top Control Continuous 131
132
Position setpoint
Control difference
Xd1
Actual position
Fig. 6.15: Deadband by position control
P.control
Parameters setting of the process controller
Xd1'
DBND
Xd1 to the controller
Xd1'
Dead band of the controller
Parameters of the PID controller
Mode of setpoint entry
Filtering of the process actual value input
Scale of the controller
Storage of the new parameters
End of the parametering setting of the controller
P.co - dbnd
Deadband of the process controller
Factory setting: 1% (relative to the range of the selected process set-point input
This function ensures that the postioner acts only then a selected control difference is measured (Fig. 6.15). This function protects the servovalve and pneumatic actuator by controlling the start-up frequency.
Entry of the deadband in %
Operating instructions no. 800607
Entry of the dead band in % relative to the range of the selected process set-point input
Input type used for
PV
4..20 mA
Frequency
Pt100
Range
4 .. 20 mA
0 .. 1000Hz
-20 .. +220°C
Spread (as reference for the dead band)
16 mA
1000 Hz
240°C
Example:
1% dead band corresponds to
0,16 mA
10 Hz
2,4°C
Xd2'
Position setpoint
Control difference
Xd2
Actual position
DBND
Xd2 to the controller
Xd2'
Fig. 6.16: Deadband by process control
P.co - para
Controller PID parameters
NOTE
Proportional correction value
0...99.99 (factory setting 1.00)
Reset time
0.5...999.9 (factory setting 999.9)
Rate action time
0.5...999.9 (factory setting 0)
Operating point of process controller
0.0...100 % (factory setting 0 %)
See Appendix
A table for noting the reference points entered is to be found in the Annex
Top Control Continuous 133
P.co - setp
Type of setpoint (internal/external)
Internal setpoint by keys on the TopControl
External setpoint by analogue input
P.co - inp
Analogue input type
Enter the analogue input signal type according to the transmitter signal.
Analogue input 4...20 mA
(Flow; Pressure; Level; Analytical)
Analogue input Frequency (Flow)
Analogue input Pt100
(Temperature)
P.co - filt
Filtering of the process actual values. Valid for all process actual value types.
Range: 0..9
Works setting: 0
FILT xx
Setting in 10 steps: 0..9
134
Setting in 10 steps
5
6
7
8
9
Setting
0
1
2
3
4
Limiting frequency [Hz]
10
5
3
2
1
0,7
0,5
0,3
0,2
0,1
Effect minimum filter effect maximum filter effect
Operating instructions no. 800607
P.CO SCAL
A)
Scale limit for process control by selection of
"4 ..20 mA" (
P.CO inp 4-20A
)
(example see below)
Position of the decimal point for the process setpoint and actual value
(Selectable value: 0..3)
Lower range value for process actual value
(process value); value assigned to 4 mA.
Higher range value for process actual value
(process value); value assigned to 20 mA.
Lower range value for process setpoint
(setpoint); assigned to the highest current/voltage value of the external setpoint signal.
This setting is only activated if
P.CO SETP / SETP EXT
is selected.
Higher range value for process setpoint
(setpoint); assigned to the lowest current/voltage value of the external setpoint signal.
This setting is only activated if
P.CO SETP / SETP EXT
is selected.
Scale limit selection example for the 4..20 mA input (Fig. 6.16):
Actual process value of the transmitter: 4..20 mA match 0..10 l/min
Process setpoint of the SPS: 4..20 mA match 0..8 l/min
Scale limit
[l/min]
Process value
Process setpoint
Example for scale value entries
Variant 1 Variant 2
PV
PV
SP
SP
0
1.0
0
0.8
0
10.0
0
8.0
Variant 3
0
100.0
0
80.0
Input signal
[mA] Fig 6.16: Example of scale limit for controller input
NOTE
Top Control Continuous
On entry of small scaling values, to increase the display accuracy, places after the decimal point are automatically added, so that the maximum possible digit range is obtained between the lower and upper scaling value in each case.
The amplification (KP) of the process controller relates to scale values set.
With
P.CO SETP / SETP INT
(desired value pre-set via the arrow key), no scaling of the desired value
SP
SP
not possible. It can be entered directly in correspondence with the scaled process variable (
PV
and
,
PV
).
135
136
B) Scale limit for process control by selection of frequency input (
P.CO inp Freq
)
NOTE
The valve is closed as this menu is activated. Then, the Teach-In is performed with a defined output conditions.
Unit l/s
Unit l/m
Unit m³/min
Unit m³/h
Unit gal(US)/s
Unit gal(US)/min
Unit gal(US)/h
Unit gal(Imperial)/s
Unit gal(Imperial)/min
Unit gal(Imperial)/h
Operating instructions no. 800607
Entry of the required flow unit
Position of the decimal point for the process setpoint and actual value (Selectable value: 0..3).
Lower range value for process setpoint ; assigned to the lower current/voltage value of the external setpoint signal.
This setting is only activated if
P.CO SETP / SETP EXT
is selected.
Higher range value for process setpoint; assigned to the higher current/voltage value of the external setpoint signal.
This setting is only activated if
P.CO SETP / SETP EXT is selected.
Manual entry of the K-factor of the flow sensor (refer to the data sheet of the flow sensor)
Position of the decimal point of the K-factor (Selectable value: 0..2)
K-factor (range: 0..9999)
Teach-In-Function:
Calculation of the K-Factor, by measuring a known fluid volume .
Starting the measurement.
-
Run the pump or open the valve.
The tank is full, shut the pump or close the valve.
-
Open and close the valve with the arrow keys.
The valve must not be tightly open.
End of the measurement.
Position of the decimal point of the measured volume
(Selectable value: 0..3).
Enter the measured volume (Selectable value: 0..9999).
Unit as previously selected
UNITXXXX
.
Display of the calculated K-Factor
Top Control Continuous 137
138
C) Scale limit for process control with Pt100 (
P.CO inp pt100
)
Position of the decimal point for the process setpoint and actual value (Selectable value: 0..3)
Lower range value for external process setpoint
Assigned to the lower current/voltage value of the external setpoint signal (this setting is only activated if
P.CO SETP / SETP EXT
is selected).
Higher range value for external process setpoint
Assigned to the higher current/voltage value of the external setpoint signal (this setting is only activated if
P.CO SETP / SETP EXT
is selected).
CODE
Code protection for the settings
Factory setting:
Code 0000
Blocking of all actions that would change the operating status of the device.
The contents of the display can be switched over.
Blocking of entry into the configuration level.
Entry of the 4-digit code
When code protection is active, the entry code is demanded every time a blocked operation is attempted:
Alteration of the flashing place/digit
Confirmation of the digit and switching to the next place
Operating instructions no. 800607
BIN-IN
Configuration of the binary input
Binary input not activated
Selection of the function of the binary input
Searching of a security position
Enter the security position
(0..100%) *
Type of binary input normally closed
(0..5 V = 1; 10..30 V = 0) normally open
(0..5 V = 0; 10..30 V = 1)
End of the binary input function
* If the safety position is 0 or 100%, the actuator is completely vented or pressurized, respectively, as soon as the relevant signal is applied to the binary input.
With the fast pressurizing/venting version, two valves are driven in each case in order to completely vent and pressurize more rapidly.
Output
Option
Configuration of the output signals
Setting the analogue output
(see next page)
Setting the binary output
(see next page)
End of the configuration of the output signals
Top Control Continuous 139
out ANL out bin
Unit of analogue position indication
analog output of the actual position of the valve actuator analog output of the set position of the valve actuator with process controller active: analog output of the set value of the process (option) with process controller active: analog output of the actual value of the process (option)
Configuration of the output signal
Current 4..20 mA
Current 0..20 mA
Voltage 0..10 V
Voltage 0..5 V
allowed control range* lower threshold
(output 1) normally closed normally open normally closed normally open normally closed normally open higher threshold
(output 2)
140
OUT DEV
OUT lim
Choice: Alarm output for high control deviation (output 1)
* the selected control deviation
Dev xxx
must not be lower than the deadband.
norm cls norm opn
The output functions as normally closed output.
The output functions as normally open output.
Choice: 2 binary position output signals lower threshold (output 1) higher threshold (output 2) norm cls norm opn
The output functions as normally closed output.
The output functions as normally open output.
Operating instructions no. 800607
cal.user
Calibration of the actual value display, entries for position and process control setpoint, process value, and K-Factor of the valve.
A) POSITION CONTROL ACTIVATED
Description see next page only activated in case of analogue position indication end of the calibration
NOTE
Top Control Continuous
The signal values within parenthesis are only available as a display and cannot be modified. The type of signal as previously selected in the configuration menu is displayed:
CAL Inp:
Display of the selection within the
INPUT menu
CAL OUT:
Display of the selection within the outPUT menu
141
CAl.pos
cal inp cal out
Cal fact
Calibration of the position indication (0 - 100 %)
Entry of the minimal position: set the minimal position of valve with the arrow key, then validate by pressing the MANUAL/AUTOMATIC key
Entry of the maximal position: set the valve to the maximal position with the arrow key, then validate by pressing the MANUAL/
AUTOMATIC key
Calibration of the position setpoint (4..20 mA; 0..20 mA; 0..5 V; 0..10 V)
Entry of the minimal input signal (0 mA; 4 mA; 0 V): set the minimal input signal with the arrow key, then validate by pressing the MANUAL/AUTOMATIC key
Entry of the maximal input signal (20 mA; 5 V; 10 V): set the maximal input signal with the arrow key, then validate by pressing the MANUAL/AUTOMATIC key
Calibration of the analogue signl output (4..20 mA; 0..20 mA; 0..5 V; 0..10 V)
Adjustment of the minimal output signal (0 mA; 4 mA; 0 V):
Change the minimal output signal with the arrow key until the displayed value is correct, then validate by pressing the MANUAL/AUTOMATIC key.
Adjustment of the maximal output signal (20 mA; 5 V; 10 V):
Change the maximal output signal with the arrow key until the displayed value is correct, then validate by pressing the MANUAL/AUTOMATIC key.
Cal out
is only activated in case of analogue position indication!
Return to the factory setting within the Cal.user function:
Press the MANUAL/AUTOMATIC key until the countdown elapsed.
142 Operating instructions no. 800607
B) PROCESS CONTROL ACTIVATED
Description see next page only activated in case of analogue position indication
NOTE
end of the calibration
The signal units within parenthesis are only available as a display and cannot be modified. The type of signal as previously selected in the configuration menu is displayed:
CAL PV:
Display of the selection within the
P.co.inp menu
CAL Sp:
Display of the selection within the
P.co.setp menu
CAL OUT:
Display of the selection within the outPUT menu
Top Control Continuous 143
144
CAl pos cal sp cal pv
Calibration of the position indication
Entry of the minimal position:
Set the minimal position of valve with the arrow key, then validate by pressing the MANUAL/
AUTOMATIC key
Entry of the maximal position:
Set the valve to the maximal position with the arrow key, then validate by pressing the MANUAL/
AUTOMATIC key
Calibration of the position setpoint; the type of setpoint (4..20 mA; 0..20 mA; 0..5 V; 0..10 V) was selected in the
INput menu
Set the minimal setpoint (0 mA; 4 mA; 0 V) with the arrow key, then validate the value by pressing the
MANUAL/AUTOMATIC key
Set the maximal setpoint (20 mA; 5 V; 10 V) with the arrow key, then validate the value by pressing the
MANUAL/AUTOMATIC key
Calibration of the actual process value ; the type of the actual process value (4..20 mA; Pt 100) was selected in the
PCO-inp menu
if 4..20 mA selected:
Set the minimal input then validate by pressing the MANUAL/AUTOMATIC key
Set the maximal input signal then validate by pressing the MANUAL/AUTOMATIC key
if Pt-100 selected:
Correct the displayed value with the arrow key until the display on the TopControl is in accordance with the reference measuring instrument, then validate by pressing the MANUAL/AUTOMATIC key.
cal out
Cal fact
Calibration of the analogue signl output (4..20 mA; 0..20 mA; 0..5 V; 0..10 V)
Adjustment of the minimal output signal (0 mA; 4 mA; 0 V):
Change the minimal output signal with the arrow key until the displayed value is correct, then validate by pressing the MANUAL/AUTOMATIC key .
Adjustment of the maximal output signal (20 mA; 5 V; 10 V):
Change the maximal output signal with the arrow key until the displayed value is correct, then validate by pressing the MANUAL/AUTOMATIC key.
Cal out
is only activated in case of analogue position indication!
Return to the factory setting within the Cal.user function:
Press the MANUAL/AUTOMATIC key until the countdown elapsed.
setfact
Return to the factory setting
This function allows the user to return to the initial factory setting. All EEPROM parameters are reset to default value. Finally a complete hardware reset of the instrument is performed.
3 s
Press the MANUAL/AUTOMATIC key during ca. 3 seconds, until the countdown elapsed.
Operating instructions no. 800607
6.5
Setting a process control function
In order to use the Top
Control Continuous as a process controller, apply the following requirements:
➔
Perform first the self-calibration procedure for the position controller (
X.TUNE
- see 6.3.2).
➔
Select the
P.CONTRL
additional function within the configuration mode in the main menu (see 6.4).
The function
P.CONTRL
will also be activated into the main menu.
➔
Enter the basic configuration of the process controller within the
P.CONTRL
function (see 6.4).
If the process control acts on a flow process control, it is possible to use the automatic linear characteristic curve of the process:
➔
Release the function
P.QLIN
(see 6.5.1).
ATTENTION!
Perform the functions in the following order, in any case!
X.TUNE
P.QLIN
6.5.1 Starting the function to obtain linear characteristic curve
P.QLIN
This function is only useful for a flow process control
➔
Start the function to obtain the automatic linear characteristic curve by selecting the function P.Q’LIN within the main menu and pressing the MANUAL/AUTOMATIC key during 5 seconds.
NOTE
It is only possible to activate the function
P.Q'LIN
within the main menu if the functions
P.CONTRL / P.COINP /
INPFREQ
or
P.CONTRL / P.COINP / INP4'20mA
has been selected.
By activation of the function
P.CONTRL
the function
P.QLIN
is automatically copied within the main menu. Start the function to run the program to obtain the automatic correction curve.
The program increases the valve stroke in 20 steps from 0 to 100 % and measures the associated process variable. The couple of points of the correction characteristic curve are used within the sub-menu
CHARACT/CHAFREE
as a free programmable characteristic curve, and can be checked within this sub-menu.
If the function
CHARACT was not previously, transferred within the main menu by the sub-menu
ADDFUNC this will be automatically performed by the call to the
P.Q'LIN
function, and the function
CHARACT/CHAFREE
will be simultaneously activated.
Display
P.QLIN 5
P.QLIN 4
:
P.QLIN 0
¦ P.QLIN 0
¦ P.QLIN 1
¦ P.QLIN 2
¦ P.QLIN 3
:
P.QLIN.END
Q.ERR X.X
Description
Countdown from 5 to 0 before starting the function
Display the already passed steps of the function performed
(The advancement is figured on a varying bar chart displayed on the right side of the LCD)
(flashing) End of the function
Display in error occurrence
(right display: error number; see chapter 7)
Fig. 6.17 Display during launching and performing the linearisation function
Top Control Continuous 145
6.6
Process operation level
The process operating level is automatically set each time the unit is switched on. From configuration level you can change over to the process operation level by using the MANUAL/AUTOMATIC key and after validation of the instruction
END of the menu.
The process operating level allows viewing of normal control functions (AUTOMATIC mode) and to open and close the valve manually (MANUAL mode).
Change of operating levels:
5 s
To change over between MANUAL and AUTOMATIC operating mode press the
MANUAL/AUTOMATIC key.
From MANUAL or AUTOMATIC mode you can change over to the configuration level by pressing the
MANUAL/AUTOMATIC key for 5 seconds.
Returning to the process operation level, the unit operates in the last selected level before changing.
Operating mode
AUTOMATIC
MANUAL
Yellow LED in
MANUAL/AUTOMATIC key
flashing off
Display
a quotation mark is continuously flashing from left to right.
-
6.6.1 AUTOMATIC operating mode
In AUTOMATIC operating mode the system functions in the process control configuration.
Key functions in AUTOMATIC operating mode:
Display switching
or
or > 3 s
Change of the process setpoint
If the additional function
P.CONTRL / P.CO SETP / SETP INT is configured and
SP selected
146 Operating instructions no. 800607
Display indications in AUTOMATIC operating mode:
•
•
•
A) Process controller not active
The following information from the Top Control Continuous is possible:
Actual position of the valve actuator :
• Set position of the actuator after scaling i.e. split range function or characteristic curves modification:
Input signal for set position:
Internal temperature of the Top Control Continuous:
POS__xxx
(0..100%)
CMD__xxx
(0..100%)
INP__xxx
(0..5/10 V or 0/4 .. 20 mA)
TEMP_xx.x
(in °C)
By pressing the arrow keys you activate the changing over between the 4 display possibilities (Fig. 6.19).
POS__xxx
CMD__xxx
INP__xxx
TEMP_xx.x
AUTOMATIC operating mode
Configuration
Point of Menu
END
or
Chance over of the display
Leave the key
(> 5 s)
No activity of the operator
MANUAL operating mode
Fig. 6.19: Display, operation structure and operating instructions in AUTOMATIC mode with inactive process controller
NOTE
When the menu item
BIN IN / BIN FUNC / FUNC SPOS
is active and the binary input is switched, the message
SAFE xxx
appears in the display.
The value
XXX
indicates the previously selected safety position in %.
Top Control Continuous 147
148
•
•
B) Active process controller
The following points are shown:
Actual process value:
• Process set point:
• Actual position of the actuator:
• Set position of the actuator after scaling i.e. split range function or characteristic curves modification:
Internal temperature of the Top Control Continuous:
PV___
(-999..9999)
SP___
(-999..9999)
POS__xxx
(0..100%)
CMD__xxx
(0..100%)
TEMP_xx.x
(in °C)
By pressing the arrow keys you activate the changing over between the 6 display possibilities (Fig. 6.120).
PV___
SP___
POS__xxx
CMD__xxx
TEMP_xx.x
AUTOMATIC operating mode
Configuration
Point of menu
END
Change over of the display
or
Leave the key
(> 5 s) or
N a c t i v i t y
Leave the key
S e t t i n g o p r o c e s s f
Manual operating mode
Fig. 6.20: Display, operation structure and operating instructions in AUTOMATIC mode with active process controller
NOTE
When the menu item
BIN IN / BIN FUNC / FUNC SPOS
is active and the binary input is switched, the message
SAFE xxx
appears in the display.
The value
XXX
indicates the previously selected safety position in %.
Operating instructions no. 800607
Manual modification of the process set-point:
or > 3 s
If programming the additional functions
P.CONTRL / P.CO SETP / SETP INT is required, it is possible to activate the process set point mode by using one of the arrow keys. Press the key for more than 3 sec. (Fig. 6.18, 6.19). After the first digit of the process set point will blink.
Now select the first digit of the process set point.
or
Validate the value with the MANUAL/AUTOMATIC key.
Use the same procedure for the next digits. After validating of the 4 th digit, the program automatically returns to the menu.
6.6.2 MANUAL operating mode
(yellow LED off)
In the MANUAL operating mode the valve can be opened or closed manually.
Key functions in the MANUAL operating mode:
and
Pressing the ”up arrow” key:
Opens the actuator
Pressing the ”down arrow” key:
Closes the actuator
Continuously pressing the ”up arrow” and ”down arrow” keys simultaneous:
Produces a quick opening action
and
Continuously pressing the ”down arrow” and ”up arrow” keys simultaneous:
Produces a quick closing action
Display indications in MANUAL operating mode:
1. Process controller not active
• The last indication of the AUTOMATIC operation mode is displayed.
Selecting
POS__xxx
provides an option to check the actual value of the actuator.
2. Process controller active
• The last indication of the AUTOMATIC operation mode is displayed.
Selecting
PV__xxx
provides an option to check the actual value of the actuator.
• To display the actual value of the actuator during the MANUAL operation mode, previously selected in the AUTOMATIC mode display
POS__xxx
.
Normal / Quick manual operating of the valve:
By continuously pressing the ”up arrow” key in the MANUAL operating mode, the valve is continuously opened.
To stop the function release the key and the valve will remain in the open position. By pressing the ”down arrow” key the valve will be closed proportionally.
An additional pressing of the second arrow key generates a quick action of the valve (closing or opening) depending on the first selected arrow (Fig. 6.21).
Top Control Continuous 149
AUTOMATIC mode
MANUAL mode
Valve closed normal speed
Leave the key
No activity of the operator
Leave the key
Valve open normal speed
Valve closed high speed
Leave the key
(> 5 s)
Point of menu
Configuration
END
Fig. 6.21: Operation structure and operating instructions in MANUAL mode
Leave the key
Valve open high speed
150 Operating instructions no. 800607
7 FAILURES AND REPORT ERRORS
The Top Control Continuous is maintenance free if used according to the recommendations of this manual.
7.1
Report errors on LCD display
• Faults during initial activation:
Message
INT.ERROR
Possible cause
Internal fault
Remedy
Not possible, unit defective
• Report errors during AUTOTUNE function:
Message
X.ERR 1
X.ERR 2
X.ERR 3
X.ERR 4
Possible cause
Pressure supply not connected
Air pressure failure during
Autotune
Air supply of the actuator/
Top Control not secure
Exhaust air of the positioner not secure
Remedy
Connect the compressed air supply
Control the compressed air supply
Not possible, unit defective
Not possible, unit defective
• Error messages during execution of the P.Q’LIN function:
Causes of error Display
Q.ERR 1
No supply pressure connected
Remedy
Connect supply pressure
No change in process variable Check process, if necessary switch on pump or open the shut-off valve
Q.ERR 2
Current reference point of valve stroke was not reached because
• supply pressure failure occurred • Check supply pressure during
P.QLIN
• no
AUTOTUNE was executed • Execute
AUTOTUNE
7.2
Miscellaneous failures
Problem
POS = 0 (by CMD > 0%) resp.
POS = 100%, (by CMD < 100%)
Possible cause
Close tight function (
CUTOFF
) is involuntary active
Remedy
Disactivate the close tight function
(see 8.7.4)
Top Control Continuous 151
152 Operating instructions no. 800607
APPENDIX A
Selection criteria for continuous valves
For optional control behaviour and the reaching of the desired maximum flowrate the following criteria must be observed:
• The correct selection of the k
V
value, which is in fact defined by the valve size;
• The correct adjustment of the valve size to the pressure conditions, taking into account the pressure differences of the installation.
Sizing guidelines can be given based upon the k
V and fluid.
value. The k
V
value relative to the normal conditions for pressure, temperature
The k v
value is the flowrate in m³/h though a piping port under a pressure difference of
∆ p = 1 bar and T = 20°C.
For continuous valves the k
VS
value is used in addition. It corresponds to the k
V
value of a continuous valve, which is fully open.
In relation with the given data, we distinguish the two following cases for the sizing of the valves: a) The pressures p
1
and p
2
must be known before and after the valve before the desired maximum flowrate Q max
can be calculated:
The needed k
VS
value is calculated according to:
k
VS
=
Q
max
⋅
∆
p
0
∆
p
⋅
ρ
ρ
0
(1)
Where: k
Q
VS
: max
∆ p
0
:
:
ρ
ρ
:
0
:
∆ p: maximal flowrate of fully opened continuous valve [m³/h] maximal volumetric flowrate [m³/h]
= 1 bar; pressure drops of the valve according to the k
V
= 1000 kg/m³; density of water (according to the k
V pressure drop of the valve [bar]
value defined
value definition) density of fluid [kg/m³] b) The pressures p
1
and p
2
at the inlet and outlet of the complete installation for the desired maximum flowrate Qmax can be calculated:
1.Step:
2. Step:
3. Step:
4. Step:
Calculation of the k
Vges
value for the complete installation according to rule (1).
Determination of the flowrate through the installation without a continuous valve (possible by by-passing the pipe where the valve is installed).
Calculation of the k
Va
value of the installation without the continuous valve according to rule (1).
Calculation of the needed k
VS
value of the continuous valve according to rule (2):
k
VS
=
1
k
Vges
2
1
−
1
k
Va
2
(2)
Important rule:
The k
VS
value of the valve should reach at least the value calculated by the formula (1) or (2) depending on the application. It should also not greatly exceed this value.
The often used rule for on/off valves ‘a little bit higher cannot be wrong’ can strongly influence the control behaviour of continuous valves!
Top Control Continuous 153
A practical rule for the determination of the k called ‘valve authority
Ψ
:
VS
value for the upper limits in respect to continuous valves consists of using the so
Ψ =
( )
( )
V
0
0
=
k
Va
2
k
Va
2
+
k
VS
2
(3) with
(
(
∆ p)
V0
∆ p)
0
: pressure drop with a fully open valve
: pressured drop over the complete installation
NOTE
For valve authority
Ψ
< 0,3 the valve is oversized.
In this case, the flow resistance with a fully open valve is much lower than the other components of the installation. This means that only in the lower opening range, the valve position is working according to the characteristics. For that reason the characteristics are strongly deviated. This can be partially compensated and the characteristics linearized within the limits by using an equal percentage characteristic between set position and the plug travel.The valve authority
Ψ
should, even when using a corrected characteristic, be
> 0,1.
The control behaviour (standard choice, maximum adjustment time) is strongly dependent on the working point when using a corrected characteristic.
154 Operating instructions no. 800607
Characteristics of PID controllers
A PID controller has a proportional, an integral and a differential component (P, I and D components).
P component:
Function: Y = Kp · Xd
Kp is the proportional action coefficient. It results from the ratio of the manipulating range
∆
Y to the proportional range
∆
Xd.
Proportional range
∆
Xd
Characteristic Step response
Fig. 8.1: Characteristics and step response of the P component of a PID controller
Characteristics:
Theoretically, a pure P controller operates without delay, i. e. it is fast and therefore dinamically favorable. It has a lasting system deviation, i. e. it does not balance out the effects of disturbances completely and is therefore relatively unfavorable from the static point of view.
I component:
Function:
1
∫
Ti
∫
Xd dt
Ti is the integration or manipulating time. This is the time that elapses before the manipulated variable has passed through the complete manipulating range.
Control range
∆
Xc
Characteristics
Manipulating time Ti
Step response
Fig. 8.2: Characteristics and step response of the I component of a PID controller
Top Control Continuous 155
Characteristics:
A pure I controller eliminates the effects of occuring disturbances completely. Therefore, it has a favorable static response. Owing to its finite manipulating speed, it operates more slowly than the P controller and tends to oscillate. Therefore, it is relatively unfavorable from the dynamic point of view.
D component:
Function: Y = Kd d Xd/dt
Kd is the derivative action coefficient.
The higher Kd is, the stronger the D influence is.
156
Step response Rise response
Fig. 8.3: Characteristics and step response of the D component of a PID controller
Characteristics:
A controller with a D component reacts to changes in the controlled variable and is accordingly capable of dissipating occurring deviations faster.
Supperposition of P-, I- and D components:
Y = Kp Xd +
∫ ∫ ∫ ∫ ∫
Xd dt + d Xd/dt
Ti
Where Kp · Ti = Tn and Kd/Kp = Tv, results with regard to
functioning of the PID controller:
Kp:
Tn:
Tv:
Y = Kp (Xd +
∫ ∫ ∫ ∫ ∫
Xd dt + Tv dXd/dt)
Tn
Proportional action coefficient / gain
Reset time
(the time needed to achieve the same manipulated variable change by the I component as is produced as the result of the P component)
Derivative action time
(the time to achieve a specific manipulated variable on the basis of the D component earlier than when using a pure P controller)
Operating instructions no. 800607
D component
I Component
P Component
Reset time Tn
Step response of the PID controller
Fig. 8.4: Step response and rise response of the PID controller
Realised PID controller
D component with delay:
In the Top Control 8630, the D component is realised with a delay T.
Function: dY
T + Y = Kd dt dXd dt
Superposition of P, I and DT components
I component
D component
P component
Derivative action time
Tv
Rise response of the PID controller
Fig. 8.5: Superposition of P, I and DT components
Top Control Continuous 157
Function of the real PID controller : dY dt Tn
∫ ∫ ∫ ∫ ∫
dXd dt
Step response of the real PID controller:
Fig. 8.6: Step response of the real PID controller
158 Operating instructions no. 800607
Rules for adjusting PID controllers
The litterature on control systems specifies a series of adjustment rules with which a favorable adjustment of controller parameters can be achieved experimentally. To avoid bad adjustments, the conditions under which the respective adjustment rules have been elaborated must always be observed. In addition to the characteristics of the controlled system and of the controller itself, it is important to know whether it is intented to balance out a disturbance change or a command variable change.
Adjustment rules according to Ziegler and Nichols (oscillation method)
When using this method, controller parameters are adjusted on the basis of the control loop's response at the stability limit. In doing so, the controller parameters are adjusted so as to ensure that the control loop begins to oscillate. A conclusion as to a favorable adjustment of the controller parameters is reached from critical characteristic values occurring in this case. It goes without saying that, when using this method, it must be possible to bring the control loop to oscillation.
Method:
• Set the controller as a P controller (i.e. Tn = 999, Tv = 0), initially selecting a low Kp value
• Set the required setpoint.
• Increase Kp until the controlled variable oscillates continuously without attenuation (see following figure).
The proportional action coefficient set at the stability limit is referred as Kcrit. The resulting oscillation period is referred to as Tcrit.
Actual value
T krit
Time
Figure 8.7 : Progression of the control variable at the stability limit
On the basis of Kcrit and Tcrit, the controller parameters can then be calculated in accordance with the following table.
Parameter settings according to Ziegler und Nichols :
Controller Type Parameter settings
P controller Kp = 0,5 Kkrit
PI controller Kp = 0,45 Kkrit
PID controller Kp = 0,6 Kkrit
-
Tn = 0,85 Tkrit
Tn = 0,5 Tkrit
-
-
Tv = 0,12 Tkrit
The Ziegler and Nichols adjustment rules were determined for P systems with a time delay of the first order and a dead time. However, they apply only to controllers with a disturbance response, but not to controllers with a command response.
Adjustment rules according to Chien, Hrones and Reswick (manipulated variable methode)
When using this method, the controller parameters are adjusted on the basis of the control system's transition response. A 100% change in the manipulated variable is output. The time Tu and Tg are derived from the progression of the actual value of the control variable (following figure).
Top Control Continuous 159
Correcting variable Y t
Actual value
Ks *
∆
Y
Controlled variable
160 t
Tu Tg
Figure 8.8: Progression of the controlled variable after a manipulated variable change
∆
Y
Method:
• Set the controller to MANUAL mode
• Output a manipulated variable change and record the controlled variable with a recorder
• Switch off in good time if you encounter critical progressions (e. g. a risk of overheating).
NOTE
Pay attention to the fact that, in thermally inert systems, the actual value of the controlled variable may
increase further switching off.
The following table lists the settings for the controller parameters depending on Tu, Tg and Ks for command and disturbance response and for an aperiodic control operation as well as a control operation with 20% overshoot. They apply to systems with a P response, with a dead time and with a delay of the 1st order.
Parameter settings according to Chien, Hrones and Reswick:
Controller type
Parameter settings
Aperiodic control operation Control operation
(0 % overshoot) with 20 % overshoot
P controller
Command
Kp = 0,3
Tg
Tu*Ks
PI controller
Kp = 0,35
Tg
Tu*Ks
Tn = 1,2 Tg
PID controller
Kp = 0,6
Tg
Tu*Ks
Tn = Tg
Tv = 0,5 · Tu
Disturbance
Kp = 0,3
Kp = 0,6
Tn = 4 · Tu
Tg
Tu*Ks
Tg
Tu*Ks
Command
Kp = 0,7
Tg
Tn = Tg
Tu*Ks
Kp = 0,6
Tg
Tu*Ks
Kp = 0,95
Tg
Tu*Ks
Tn = 2,4 · Tu
Tv = 0,42 · Tu
Kp = 0,95
Tg
Tu*Ks
Tn = 1,35 · Tg
Tv = 0,47 · Tu
Disturbance
Kp = 0,7
Tg
Tu*Ks
Kp = 0,7
Tg
Tu*Ks
Tn = 2,3 · Tu
Kp = 1,2
Tg
Tu*Ks
Tn = 2 · Tu
Tv = 0,42 · Tu
The proportionality factor Ks of the controlled member is given according to Figure 8.8 by:
Ks =
∆
X
∆
Y
Operating instructions no. 800607
APPENDIX B:
OPERATING STRUCTURE OF THE TOP CONTROL CONTINUOUS
Top Control Positioner 161
162
PCO INP = 4'20A
PCO INP = FREQ
Only in the case of external set values
Only in the case of external set values
PCO INP = FREQ
Only in the case of external set values
Betriebsanleitung-Nr. 800607
Top Control Continuous
Position controller active
Process controller active
Process controller active
Analog position feedback
163
164 Operating instructions no. 800607
APPENDIX C
TABLES FOR YOUR SETTINGS
Settings in the freely programmable characteristic
Ref. point
(Set point of position in %)
0
65
70
75
80
85
40
45
50
55
60
20
25
30
35
5
10
15
90
95
100
Date: Date:
Valve stroke [%]
Date:
Parameters set in the process controller
Date:
KP
TN
TV
X0
DBND
Date: Date:
Date:
Date:
Top Control Continuous 165
NOTES
166 Betriebsanleitung-Nr. 800607
Top Control Continuous 167
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Key features
Electropneumatic position controller
Modular concept
Variety of pneumatic and electrical connections
Control unit with 3 keys and 8-character LCD
Self-calibration
Position and process control functions
Safety positions in case of electrical or pneumatic power failure
Single and double-acting actuators
Analog and digital interfaces
PID controller
Frequently asked questions
The TopControl Continuous is an electropneumatic position controller for pneumatically actuated continuous valves.
The TopControl Continuous features a modular concept, a variety of pneumatic and electrical connections, a control unit with 3 keys and an 8-character LCD, self-calibration capabilities, position and process control functions, safety positions in case of electrical or pneumatic power failure, support for single and double-acting actuators, analog and digital interfaces, and a PID controller.
The safety positions of the TopControl Continuous in case of electrical and pneumatic power failure vary depending on the type of actuator. Refer to the table in section 3.5.1 for details.
The TopControl Continuous offers various connection options for electrical and pneumatic connections. You can connect it via multipole connectors, terminals with cable glands, or QUICKON connectors. Refer to sections 4.2 and 5.4 for detailed connection instructions.