Burkert 8630 Operating Instructions Manual

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Operating Instructions

Bedienungsanleitung

Instructions de Service

Type 8630

TOP Control Continuous

We reserve the right to make technical changes without notice.

Technische Änderungen vorbehalten.

Sous resérve de modification techniques.

Operating Instructions 0507/11_EU-EN_00804575

ONTENTS

Overall Operating Instructions

TOP Control Continuous 8630

GENERAL NOTES

Symbols

..........................................................................................................................................................................................................................................................

Intended use

Safety notes

Protection from damage by electrostatic charging

.........................................................................................................................

Scope of delivery

Warranty conditions

Master code

Transport, storage

Disposal

SYSTEM DESCRIPTION

Valve types

Characteristics of the valve types

......................................................................................................................................................................................

Construction of TOP Control Continuous

.....................................................................................................................................................

Illustrations (cover removed)

...................................................................................................................................................................................................

Design features

Functional diagram as a positioner with single-acting actuator

............................................................................................................

Operation as a positioner

.....................................................................................................................................................................................................

Schematic representation of positioning control

..................................................................................................................................................

Characteristics of the positioner software

..................................................................................................................................................................

* Alternative chapters or functions depending on device configuration

8630 - 1

ONTENTS

*Operation as a process controller (option)

...............................................................................................................................................

Example of process control: TOP Control Continuous with sensor

...................................................................................................

Schematic representation of process control

.........................................................................................................................................................

Characteristics of the process controller software

.............................................................................................................................................

* Operation as a flow rate controller (option)

..........................................................................................................................................

Characteristics of the flow rate controller software

.........................................................................................................................................

Schematic representation of process control with flow rate controller

.......................................................................................

* Interfaces of the TOP Control Continuous in the multipole variant

..................................................................

* Interfaces of the TOP Control Continuous in the variants with

cable bushings

Technical data

Safety settings on failure of auxiliary electrical or pneumatic energy

.........................................................................................

Factory settings on the TOP Control Continuous

.............................................................................................................................................

Data of the TOP Control Continuous

.............................................................................................................................................................................

FIRST COMMISSIONING

Fluidic installation

*Electrical installation - multipole connector

............................................................................................................................................

*Electrical installation - connection terminals for cable bushings

............................................................................

Basic settings of the TOP Control Continuous

.....................................................................................................................................

Settings in the menu items

.......................................................................................................................................................................................................

Entering the position setpoint in the AUTOMATIC mode

..........................................................................................................................

Manual opening and closing of the valve actuator in the MANUAL mode

.............................................................................

INSTALLATION

Installation of the valve

Turning the TOP Control Continuous

..................................................................................................................................................................

Procedure

Fluidic connection of the TOP Control Continuous

.......................................................................................................................

* Alternative chapters or functions depending on device configuration

2 - 8630

ONTENTS

*Electrical connection - multipole connectors

.......................................................................................................................................

Marking of the multipole plugs or sockets and the contacts

...................................................................................................................

Output signals for SPS (circular plug M 16)

.............................................................................................................................................................

Operating voltage (circular plug M 12)

............................................................................................................................................................................

Inductive proximity switches (circular socket M 8)

...........................................................................................................................................

Process value (circular plug M 8)

.......................................................................................................................................................................................

Process value with the option flow rate controller (2 circular plugs M 8)

Option: with temperature sensor input (3 circular plugs M 8)

..............................................................................................................

*Electrical connection - terminals for cable bushing

....................................................................................................................

Connection PCB of the TOP Control Continuous with screw terminals and jumpers

................................................

Terminal configuration with cable bushings

............................................................................................................................................................

Choice of binary outputs or process value input

...............................................................................................................................................

*Setting the inductive proximity switches (option)

...........................................................................................................................

Opening the housing of the TOP Control Continuous

.................................................................................................................................

Positioning the inductive proximity switches

..........................................................................................................................................................

OPERATION AND CONTROLLER FUNCTIONS

Operating and display elements

................................................................................................................................................................................

Operating levels

Commissioning and set-up as a positioner

...............................................................................................................................................

Procedure for specifying the basic settings

............................................................................................................................................................

Main menu for the settings on commissioning

....................................................................................................................................................

Description of the procedure

..................................................................................................................................................................................................

Configuring the supplementary functions

....................................................................................................................................................

Keys in the configuration level

..............................................................................................................................................................................................

Configuration menu

Supplementary functions

Operating the process

Changeover between operating modes

......................................................................................................................................................................

Operating mode AUTOMATIC

.......................................................................................................................................................................................

Meaning of the keys in the AUTOMATIC mode

..................................................................................................................................................

Display of the AUTOMATIC mode

.....................................................................................................................................................................................

Operating mode MANUAL

..................................................................................................................................................................................................

Meaning of the keys in the MANUAL mode

............................................................................................................................................................

Display of the MANUAL mode

..............................................................................................................................................................................................

* Alternative chapters or functions depending on device configuration

8630 - 3

ONTENTS

OPERATING THE PROCESS CONTROLLER

Factory settings on the process controller

...................................................................................................................................................

Setting up a process control system

....................................................................................................................................................................

Self-parametrization of the positioner - X.TUNE

...............................................................................................................................

Supplementary function P.CONTRL

....................................................................................................................................................................

Basic settings of the function P.CONTRL

...................................................................................................................................................................

P.Q’LIN - Starting the routine for linearization of the process curve

.....................................................................

105

Display during call-up and execution of the routine

..........................................................................................................................................

105

P.CO TUNE - Self-optimization of the process controller (process tune)

.....................................................

106

P.CO LEAK - Leakage characteristic for flow rate control

...................................................................................................

110

Operating the process

112

Changeover between the operating modes

................................................................................................................................................................

112

Operating mode AUTOMATIC

.......................................................................................................................................................................................

113

Meaning of the keys

113

Displays

113

Operating structure and procedures

..................................................................................................................................................................................

113

Manually changing the process setpoint

......................................................................................................................................................

114

Operating mode MANUAL

..................................................................................................................................................................................................

114

Meaning of the keys

114

Displays

115

Operating structure and procedures

..................................................................................................................................................................................

115

PROFIBUS DP

General notes

118

Technical data

118

Safety settings on bus failure

.........................................................................................................................................................................................

118

Interfaces

119

Electrical connections

119

Connection with one plugged bus connector

...........................................................................................................................................................

119

Connection with 2 plugged bus connectors

..............................................................................................................................................................

120

Operating voltage (circular plug M12)

.............................................................................................................................................................................

120

Bus connection (circular socket M12)

............................................................................................................................................................................

120

4 - 8630

ONTENTS

Inductive proximity switches (circular socket M8)

.............................................................................................................................................

121

Process value (circular plug M8)

.........................................................................................................................................................................................

121

Termination connection for PROFIBUS systems

................................................................................................................................................

122

Settings on the TOP Control Continuous

.....................................................................................................................................................

123

Explanation of the menu items

..............................................................................................................................................................................................

124

Functional deviations from the standard version

..............................................................................................................................

124

Configuration in the Profibus DP master

......................................................................................................................................................

125

Configuration of the process values

.................................................................................................................................................................................

125

Bus status display

127

Example 1 with COM-Profibus V3.3

....................................................................................................................................................................

128

Example for a positioner

128

Example 2 with COM-Profibus V3.3

....................................................................................................................................................................

131

Example for a process controller

.........................................................................................................................................................................................

131

DEVICE NET

General notes

134

Explanation of terms

134

Technical data

135

Safety settings on bus failure

.........................................................................................................................................................................................

135

Interfaces

136

Electrical connection

136

Operating voltage (4-pole M12 circular plug)

...........................................................................................................................................................

137

Bus connection (4-pole M12 circular plug)

.................................................................................................................................................................

137

Inductive proximity switches (4-pole M8 circular socket)

...........................................................................................................................

137

Process value (circular plug M8)

.........................................................................................................................................................................................

137

Termination connection for DeviceNet systems

...................................................................................................................................................

138

Net topology of a DeviceNet system

...............................................................................................................................................................................

138

Settings on the TOP Control Continuous

.....................................................................................................................................................

139

Explanation of the menu items in the program run-off schematic

......................................................................................................

139

Settings in the main menu

140

Configuring the process data

.........................................................................................................................................................................................

141

Static input assemblies

141

Static output assemblies

143

8630 - 5

ONTENTS

Bus status display

144

Configuration example 1

.......................................................................................................................................................................................................

145

Installation of the EDS file

145

Address allocation

145

Offline parametrization of the device

...............................................................................................................................................................................

146

Online parametrization of the device

...............................................................................................................................................................................

147

Configuration example 2

.......................................................................................................................................................................................................

148

Setting up the process map (mapping)

..........................................................................................................................................................................

149

MAINTENANCE AND ERROR CORRECTION ON THE POSITIONER

Maintenance

152

Error messages and malfunctions

..........................................................................................................................................................................

152

Error messages on the LC display

.....................................................................................................................................................................................

152

Other malfunctions

152

MAINTENANCE AND ERROR CORRETION ON THE

PROCESS CONTROLLER

Maintenance

154

Error messages and malfunctions

..........................................................................................................................................................................

154

Error messages on the LC display

.....................................................................................................................................................................................

154

Other malfunctions

156

Appendix

6 - 8630

ONTENTS

GENERAL RULES

Selection criteria for continuous valves

..........................................................................................................................................................

158

Characteristics of PID controllers

.............................................................................................................................................................................

160

P component

160

I component

161

D component

162

Superimposing the P, I and D components

...............................................................................................................................................................

163

Function of a real PID controller

...........................................................................................................................................................................................

164

Rules for setting PID controllers

................................................................................................................................................................................

165

Setting rules of Ziegler and Nichols (oscillation method)

............................................................................................................................

165

Setting rules of Chien, Hrones and Reswick (controller output step method)

........................................................................

166

OPERATING STRUCTURE

Operating structure of the TOP Control Continuous

.....................................................................................................................

170

TABLE FOR POSITIONER

Table for noting your settings on the positioner

..................................................................................................................................

178

TABLE FOR PROCESS CONTROLLER

Tables for noting your settings on the process controller

.....................................................................................................

180

MASTER CODE

Code number

182

8630 - 7

ONTENTS

8 - 8630

ENERAL

OTES

GENERAL NOTES

Symbols

10 Intended use

10 Safety notes

10 Protection from damage by electrostatic charging

.............................................................................................................................

11 Scope of delivery

11 Warranty conditions

11 Master code

12 Transport, storage

12 Disposal

12

8630 - 9

ENERAL

OTES

Symbols

The following symbols are used in these operating instructions: marks a work step that you must carry out.

ATTENTION!

marks notes on whose non-observance your health or the functioning of the device will be endangered.

NOTE marks important additional information, tips and recommendations.

Intended use

In order for the device to function perfectly and have a long service life, you must observe the information given in these operating instructions and comply with the operating conditions and the permissible data for the TOP Control Continuous, in addition to the information for the respective pneumatically actuated valve, which is specified in the „Technical Data“ chapter of these instructions and in the valve instructions.

Please note that the Top control Continuous may not be used out-of-doors.

In view of the large number of possible applications and categories of use, you should check whether the

Top control Continuous is suitable for your specific application, and carry out tests where necessary.

Safety notes

• Keep to standard engineering rules in planning the use of and operating the device!

• Installation and maintenance work are only allowed by specialist personnel using suitable tools!

• Observe the current regulations on accident prevention and safety during operation and maintenance of the device!

• Switch off the supply voltage in all cases before intervening in the system!

• Note that in systems under pressure, piping and valves may not be loosened!

• Take suitable precautions to prevent inadvertent operation or damage by unauthorized action!

• Make sure that after an interruption to the electrical or pneumatic supply, the process starts up again in a well-defined, controlled manner!

• On non-observance of these notes and unauthorized interference with the device, we will refuse all liability and the warranty on device and accessories will become void!

10 - 8630

ENERAL

OTES

Protection from damage by electrostatic charging

ATTENTION

EXERCISE CAUTION ON HANDLING!

ELECTROSTATICALLY SENSITITVE

COMPONENTS/MODULES

This device contains electronic components that are sensitive to electrostatic discharge (ESD). Contact to electrostatically charged persons or objects will endanger these components. In the worst case, they will be immediately destroyed or will fail after commissioning.

Observe the requirements of EN 100 015 - 1 in order to minimize the possibility of, or avoid, damage from instantaneous electrostatic discharge. Also take care not to touch components that are under supply voltage.

Scope of delivery

Immediately after receipt of a shipment, make sure that the contents are undamaged and match the scope of delivery stated on the packing slip. In general this consists of:

• Pneumatically actuated valve of type 2652, 2655, 2672, 2700, 2712, 2730, 2731 or 2731K with attached

TOP Control Continuous,

• Operating Instructions for the TOP Control Continuous and for the valve with pneumatic actuation.

If there are discrepancies, please contact immediately our customer service:

Bürkert Fluid Control Systems

Chr.-Bürkert-Str. 13-17

Service Department

D-76453 Ingelfingen

Tel.: (07940) 10-111

Fax: (07940) 10-448

E-Mail: [email protected]

NOTE Suitable cable plugs for the multipole connection are available as accessoires.

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 warranty covers only faultless condition of the TOP Control Continuous and the attached valve with pneumatic actuation. No liability will be accepted for consequential damage of any kind that may arise from failure or malfunctioning of the device.

8630 - 11

ENERAL

OTES

Master Code

Operation of this device can be locked by means of a freely selectable user code. Independent of this, there exists an unchangeable master code with which you can execute all operative actions on the device. This 4-digit code is to found on the last page of these operating instructions.

If required, cut out this code and keep it separate from these operating instructions.

Transport, storage

ATTENTION!

Transport and store the appliance in its original packing only.

Disposal

ATTENTION!

When disponsing of the appliance, observe the national standards for refuse disposal.

12 - 8630

YSTEM

ESCRIPTION

SYSTEM DESCRIPTION

Valve types

14

Characteristics of the valve types

..........................................................................................................................................................................

Construction of TOP Control Continuous

....................................................................................................................................................

16

Illustrations (cover removed)

........................................................................................................................................................................................

Design features

Functional diagram as a positioner with single-acting actuator

.......................................................................................

Operation as a positioner

....................................................................................................................................................................................................

19

Schematic representation of positioning control

.................................................................................................................................

Characteristics of the positioner software

...................................................................................................................................................

* Operation as a process controller (option)

..........................................................................................................................................

22

Example of process control: TOP Control Continuous with sensor

............................................................................

Schematic representation of process control

..........................................................................................................................................

Characteristics of the process controller software

............................................................................................................................

* Operation as a flow rate controller (option)

.........................................................................................................................................

25

Characteristics of the flow rate controller software

..........................................................................................................................

Schematic representation of process control with flow rate controller

...................................................................

* Interfaces of the TOP Control Continuous in the multipole variant

.................................................................

27 * Interfaces of the TOP Control Continuous in the variants with cable bushings

...........................

28 Technical data

29

Safety settings on failure of auxiliary electrical or pneumatic energy

......................................................................

Factory settings on the TOP Control Continuous

...............................................................................................................................

Data of the TOP Control Continuous

..................................................................................................................................................................

* Alternative chapters or functions depending on device configuration

8630 - 13

YSTEM

ESCRIPTION

By the combination of the TOP Control with pneumatically actuated process valves, the functionality of the Bürkert process valve series is extended. These valves, in connection with the TOP Control, may also be employed in those control applications requiring continuous behaviour of the actuator.

Valve types

The figure below gives an overview of the possible combinations of TOP Control and various pneumatically actuated valves. For each type, various actuator sizes and valve sizes are available (not shown). More detailled information is to be found on the respective data sheets. The product range is being extended continually.

TOP Control

Continuous

Type 8630 with flat-seat valve

Type 2712

(here with flange connection)

TOP Control

Continuous

Type 8630 with Y-valve Type 2700 with butterfly valve

Type 2672 with ball valve

Type 2655 with diaphragm valve

Type 2730

Various process valves from the Bürkert range can be combined with the TOP Control to suit different applications. Y-, diaphragm or ball valves with control cones are suitable.

14 - 8630

YSTEM

ESCRIPTION

Pneumatically driven piston and rotary actuators may be used to operate them. Both single-acting and doubleacting actuators are offered in combination with TOP Control Continuous.

With single-acting actuators, only one chamber in the actuator is pressurized and vented. The pressure produced works against a spring. The piston moves until an equilibrium is set up between the pressure and the spring force.

With double-acting actuators, the chambers on both sides of the piston are pressurized. When the one chamber is pressurized, the other is vented and vice versa. No spring is installed in this actuator version.

Characteristics of the valve types

Y-valves

Flat seat valves

• 2700

• 2712

Diaphram valves Ball valves Flap valves

Types

Typical media • Water, steam and

gases

• Alcohols, oils, fuels,

hydraulic fluides

• Salt solutions, lyes

(organic)

• Organic solvents

• 2730 (plastic)

• 2731 (metal)

• 2731K (pipe housing)

• 2652 (2-part,VA)

• 2655 (3-part,VA)

• 2658 (plastic)

• Neutral gases and

liquids

• contaminated, ab-

rasive and aggressive

media

• high purity or sterile

media

• high viscosity media

• Neutral gases and

liquids

• pure water

• slightly aggressive

media

• 2672 (metal)

• 2675 (plastic)

Characteristic • Inlet flow under seat

• Non-impact closure

• Medium is hermeti-

cally separated from

actuator and the

ambient

• Straight flow of

medium

• Self-adjusting packed

gland for very tight seal

• Self-draining housing

design without dead

spaces

• Either flow direction

with low turbulence

flow

• May be steam

sterilized

• CIP compatible

• Non-impact closure

• Actuator and dia-

phragm are de-

tachable with the

housing

• Piggable

• Low and dead space

• insensitive to

contamination

• Lower pressure loss

than with other valve

types

• with 3-part ball valve,

seat and seal can be

exchaged while

installed

Note

Only usable as process controller.

• insusceptible to dirt

• less pressure loss

compared to other

valve types

• good value for money

• smaller volume

• Neutral gases and

fluides

• slightly aggressive

media

8630 - 15

YSTEM

ESCRIPTION

Construction of TOP Control Continuous

Illustrations (cover removed)

Screw for adjusting the lower proximity switch

Screw for adjusting the upper proximity switch

Positioning system with 2, 3 or 4 solenoid valves

Operating module with display and keys

Pressure supply port

(marked: 1)

Control ports

(connected in the factory)

Exhaust air ports

(marked 3)

16 - 8630

Fixing screw for fixing the

TOP Control Continuous on the drive

Max. torque 1.2 Nm

Electrical connection module, here with multipole connectors

YSTEM

ESCRIPTION

Design features

• Versions for single and double acting valve actuators

• Position sensor very high resolution conductive plastic potentiometer, coupled without play to the piston rod of the pneumatic actuator

• Microprocessor controlled electronics for signal processing, control and driving the valve

• Operating module

The device is operated via 3 keys. 8-digit, 16-segment LC display for showing the setpoint or actual value and for configuration and parametrization via menu functions.

• Positioning system

With single-acting actuators, the positioning system consists of 2 solenoid valves; with double-acting actuators of four solenoid valves. With single-acting actuators, one valve serves to pressurize the pneumatic piston drive and another to exhaust it. Double-acting actuators contain 2 valves for pressurization and 2 for exhausting.The solenoid valves work on the rocker principle and are driven via the controller with a PWM voltage. This enables great flexibility with regard to actuator volumes and floating speed. For larger pneumatic actuators, the solenoid valve are equipped with diaphragm boosters.

As an option, with single-acting actuators, there are fast pressurizing/exhaust variants with an additional pressurizing valve and an additional exhaust valve. These enable the actuator to be completely pressurized and exhausted more rapidly. This is used with the tight-closure function (see section

" CUTOFF") and on activation of a safety position of 0 or 100% (see section "BIN-IN").

• Position repeater (optional)

2 inductive proximity switches (initiators) or mechanical limit switches.

Attainment of an upper or lower position of the valve can be relayed via binary outputs e.g. to a PLC.

The end settings on the initiators can be adjusted by the owner by means of setscrews.

• Pneumatic interfaces

1/4’’- connectors in various threads

(G, NPT, RC)

• Electrical interfaces

Multipole plug connector or cable bushing

• Housing

The housing of the TOP Control is protected by a pressure relief valve from excessive internal pressure, e.g. resulting from leaks.

The cover may be secured against unauthorized opening with a lead seal or with a self-tapping screw.

8630 - 17

YSTEM

ESCRIPTION

Fuctional diagram as a positioner with single-acting actuator

Actual process value

Process setpoint external position setpoint

Process controller

Actual position

TOP Control Continuous

Position sensor

Setpoint position

Positioner

Positioning system

1: pressurizing valve

2: exhaust valve

Compressed air supply

Exhaust air

Pneumatic actuator

(single-acting)

Valve

(actuator)

Sensor

Actual process value

(flow rate, pressure, level, temperature etc.)

18 - 8630

YSTEM

ESCRIPTION

Operating as a positioner

The actual position (POS) of the pneumatic actuator is measured via the position sensing system. The controller compares this actual value of the position with the setpoint (CMD) , which can be specified as a standard signal. If a control difference (Xd1) exists, a pulse-width modulated voltage signal is sent to the positioning system as the correcting variable. With single-acting actuators, if the difference is positive, the pressurizing valve is driven via output B1; if it is negative, the exhaust valve is driven via output

E1. In this way, the position of the actuator is altered until the control difference is zero. Z1 represents a disturbance.

CMD

Position setpoint

Xd1

Positioner

POS

Positioning system Solenoid

Continious valve

Valve opening

Position control loop

8630 - 19

YSTEM

ESCRIPTION

20 - 8630

YSTEM

ESCRIPTION

Characteristics of the positioner software

Supplementary function

Insensitivity range

Effect

Positioner with supplementary functions

Tight-closing function

Valve closes tight outside control range. A value is given (at %) from which the actuator is completely exhausted (at 0%) or pressurized (at 100 %).

Stroke limitation

Signal range splitting

Correction characteristic to match the operating curve

Mech. valve piston movement only withhin a specified stroke range.

Splitting of the standard signal range over two or more

TOP Control Continuous.

Linearization of the process characteristic can be performed.

The positioner cuts in only above a specified control difference.

Direction of action of the controller setpoint

Safety position

Reversal of the setpoint action direction

Valve moves to a specified safety position.

Hierarchical concept for simple operation with the following levels

Process operation

Configuration

In this level your switch between automatic and manual operation.

In this level you specify on commissioning certain basic functions and configure supplementary functions as needed.

8630 - 21

YSTEM

ESCRIPTION

* Operation as a process controller (option)

On operation of the TOP Control Continuous as a process controller, the abovementioned position control becomes a subordinate auxiliary control loop; the result is a cascade control. The process controller in the main loop of the TOP Control Continuous has a PID function. The setpoint specified is the process setpoint (SP) and it is compared with the process variable to be controlled. The actual position (XPOS) of the pneumatic actuator is measured via the position sensing system. The controller compares this actual value of the position with the setpoint (CMD) , which can be specified as a standard signal. If a control difference (Xd1) exists, a pulse-width modulated voltage signal is sent to the positioning system as the correcting variable. With single-acting actuators, if the difference is positive, the pressurizing valve is driven via output B1. If it is negative, the exhaust valve is driven via output E1.

In this way, the position of the actuator is altered until the control difference is zero. Z2 represents a disturbance.

Xd1

Positioner

XPOS

Positioning system Solenoid valves

Continuous

Valve

Valve opening

Position control loop

Position sensor

Process setpoint

Xd2 CMD Process control loop

Process controller

Valve opening

Process

Process variable

Transmitter

Example of process control:

TOP Control Continuous with sensor

22 - 8630

YSTEM

ESCRIPTION

8630 - 23

YSTEM

ESCRIPTION

Characteristics of the process controller software

Supplementary function Effect

Positioner with supplementary functions

Tight-closing function

Stroke limitation

Signal range splitting

Correction characteristic to match the operating curve

Insensitivity range

Valve closes tight outside control range. A value is given (at %) from which the actuator is completely exhausted (at 0%) or pressurized (at 100%).

Mech. valve piston movement only within a specified stroke range.

Splitting of the standard signal range over two or more

TOP Control Continuous.

Linearization of the process characteristic can be performed.

The positioner cuts in only after a specified control difference.

Direction of action of the controller setpoint

Safety position

Reserval of the setpoint action direction

Analog feedback (option)

Valve moves to a specified safety position

Feedback of the position/process values

Binary outputs

Connectable process controller with the following characteristics (Option)

Controller structure

Parameters that can be set

Scalable input

Method of setpoint setting

PID

Proportional action factor, reset time, rate time and operating point

Decimal point position, upper and lower sacle valures of process value and setpoint

Setting either via standard signal input or via keys

Hierarchical concept for simple operation with the following levels

Process operation

Configuration

In this level your switch between automatic and manual operation.

In this level you specify on commissioning certain basic functions and configure supplementary functions as needed.

24 - 8630

YSTEM

ESCRIPTION

* Operation as a flow rate controller (option)

The flow rate controller is a special type of process controller. The process value (PV) is not measured directly via an analog input but calculated in the device by the dp method. According to the algorithm, the flow rate is dependent on the parameters pressure before valve (p1), pressure after valve (p2), medium temperature (T) and the kv value. For this reason, the TOP Control Continuous FMR has inputs for 2 pressure transmitters and a temperature transmitter which can be optionally connected.

One pressure transmitter measures the pressure before the valve and a second one after the valve. The temperature is either entered manually in the operating menu or is provided as a standard signal by a temperature transmitter. The kv value is determined internally from the current position of the control valve. For this purpose, a kv characteristic curve is provided in the control valve used.

The density of the medium is entered via the operating menu.

Temperature (optional)

Pressure p1

8630

Flow rate controller e.g. valve type 2712 kv value

Pressure p2 p1 p2

In the case of the flow rate controller, the process parameters are either the volumetric flow rate or, for special applications, the transport velocity at the end of a pumping section.

The volumetric flow rate is represented in m 3 /h STP, i.e. referred to 0 °C (medium temperature) and a gas pressure of 1013 mbar (abs).

There are special applications for flow rate controllers in which a pumping section is set up after the valve, in which bulk goods enter via an airlock. These bulk goods are blown through the pumping section by the pumping pressure that builds up behind the valve.

The transport velocity corresponds to the volumetric flow rate of the medium, referred to the piping diameter of the pumping section. However, it is not specified for standard conditions, but reflects the velocity of the gas particles at the existing medium temperature. The diameter is entered in the operating menu.

Characteristics of the flow rate controller software

The flow rate controller offers the same functions as the process controller.

8630 - 25

YSTEM

ESCRIPTION

26 - 8630

YSTEM

ESCRIPTION

* Interfaces of the TOP Control Continuous in the multipole variant

Inputs for position or process setpoint

4..20 mA

0..20 mA

0..10 V

0..5 V

Input for process setpoint

4..20 mA

Frequency

Pt 100

* Flow rate controller

Binary input

24 V DC

TOP Control

Continuous

(multipole - variant)

Operating unit

2 binary outputs

Analog position feedback

*Initiators 1 + 2

* Note:

Inputs for process value with flow rate controller (option): p

, p

, T (optional).

The standard process controller inputs (4 ... 20 mA, frequency, Pt 100) and the initiators cannot be used with this option.

NOTE TOP Control Continuous Type 8630 is a 3-conductor device, i.e. the voltage supply (24 V

DC) is separate from the setpoint signal.

8630 - 27

YSTEM

ESCRIPTION

* Interface of the TOP Control Continuous in the variants with cable bushings

Inputs for position or process setpoint

4..20 mA

0..20 mA

0..10 V

0..5 V

Input for process setpoint*

4..20 mA

Frequency

Pt 100

(alternative to binary outputs)

Binary input

24 V DC

Sup- ply

TOP Control

Continuous

(PG - variant)

Operating unit

2 binary outputs*

(alternative to input for process setpoint)

Analog position feedback

* Note:

The choice between a process setpoint input and two binary outputs is made by positioning the jumper.

NOTE TOP Control Continuous Type 8630 is a 3-conductor device, i.e. the voltage supply (24 V

DC) is separate from the setpoint signal.

28 - 8630

YSTEM

ESCRIPTION

Technical data

Safety settings on failure of auxiliary electrical or pneumatic energy

Actuator type Designation

Single-acting

SFA

Safety position after failure of auxiliary energy

Electrical Pneumatic down down

Single-acting

SFB up up

Double-acting

SFI down / up

(depending on connection of control conductors)

undefined

8630 - 29

YSTEM

ESCRIPTION

Factory settings on the TOP Control Continuous

Function Factory setting Function Factory setting

ACTFUNC

INPUT

CHARACT

FUNCSNGL

INP 4'20 A

CHA LIN

X.CONTRL

X.CO DBND 1 %

X.CO PARA

KX Values calculated by AUTOTUNE

After execution of SETFACT: 1

DIR.CMD

CUTOFF

DIR.ACT

SPLTRNG

X.LIMIT

DIR.CRISE

CUT 0 %, CUT

DIR.ARISE

LIM

100 %

0 (%), SR 100 (%)

0 %, LIM 100 %

X.TIME

T.OPN

T.CLS

Values calculated by AUTOTUNE

After execution of SETFACT: 1 s

P.CONTRL

P.CO DBND 1 %

P.CO PARA

1.00

999.9

0.0

P.CO SETP SETP INT

P.CO INP INP 4´20 A

P.CO FILT

P.CO SCAL

P.CO TUNE

P.CO KV

PV 000.0, PV 100.0

D’ACT

FACT

OUTPUT

OUT ANL:

OUT POS

OUT BIN:

OUT DEV

BIN-IN

B.IN SPOS

OUT 4´20 A

DEV 5.0 NO

SPOS 000 NO

P.CONTRL with flow rate controller

P.CO DBND 1 %

P.CO PARA

KP 1.0

999.9

0.0

P.CO SETP SETP INT

P.CO INP INP P1’P2

P.CO FILT

P.CO SCAL

PV 000.0, PV 100.0

P.TYP

UNIT

TEMP

DENS

DIAM

P.CO TUNE

P.CO KV

FLOW

M3/H

MAN

1.293

0025

D’ACT

FACT

CODE CODE 0000

NOTE The functions and factory settings shown in grey are valid for the optional flow rate control.

30 - 8630

YSTEM

ESCRIPTION

Data of the TOP Control Continuous

OPERATING CONDITIONS

Permissible ambient temperature

Protection type cable or

- 10 ... + 50 °C

IP 65 to EN 60529 (only with correctly connected plug and socket)

ATTENTION!

The TOP Control Continuous is not suitable for outdoor use.

CONFORMITY TO THE FOLLOWING STANDARDS

CE conformity wer. EMC Guideline 89/336/EWG

MECHANICAL DATA

Dimensions

Housing material TOP Control

Dichtmaterial see data sheet outer: Noryl (PPE/PA), PSU, inner: PA 6

NBR

ELECTRICAL DATA

Connections

Voltage supply

Power consumption

Housing internal temperature indication

Input resistance for actual value signal

Choice between multipole connector or

3 bushings M 16 x 1.5

with screw terminals 0.14 ... 1.5 mm²

24 V DC ± 10 % residual ripple 10 %

No industrial DC!

< 5 W

- 55 ... + 125 °C, accuracy ± 2 °C

180 Ω at 4 - 20 mA/resolution 12 bit

17 k Ω at frequency, 0 ... 1000 Hz / 1‰ of mean

> 300 V ss

sinus, square-wave, sawtooth

PT-100 - 20 ... + 220 °C, resolution < 0.1 °C

180 Ω at 0/4 - 20 mA/resolution 12 bit

19 k Ω at 0 - 5/10 V /resolution 12 bit

3 to VDE 0580

Input resistance for setpoint signal

Protection class

Analog position feedback: max. current for voltage output 0 ... 5/10 V max. burden for current output 0/4 ... 20 mA

Inductive proximity switch current limitation

10 mA

560 Ω

100 mA

8630 - 31

YSTEM

ESCRIPTION

Binary outputs current limitation

Binary input

PNEUMATIC DATA

Control medium

Dust content

Water content

Oil content

Temperature range of compressed air

Pressure range

Supply pressure variation

Air flow capacity of control valve

Intrinsic air consumption with zero control output

Connections electrically isolated

100 mA, output is clocked electrically isolated

0 ... 5 V = log "0", 10 ... 30 V = log "1" inverted output reversed accordingly

Qualitiy Classes to DIN ISO 8573-1

Class 5 max. particle size 40 µm, max. particle density 10 mg/m 3

Class 3 max.pressure dew point

- 20 °C or min. 10 deg. below the lowest operating temperature

Class 5 max. 25 mg/m³

-10 ... + 50 °C

3 ... 7 bar max. ± 10 % during operation

100 l

/ min STP (for pressurizing and exhausting)

- value acc. to definition on pressure drop from 7 to 6 bar abs.)

0.0 l

/min STP

G 1/4’’ internal thread G / NPT / RC

32 - 8630

IRST

OMMISSIONING

FIRST

COMMISSIONING

Fluidic installation

34 * Electrical installation - multipole connector

.........................................................................................................................................

35 * Electrical installation - connection terminals for cable bushings

........................................................................

36 Basic settings of the TOP Control Continuous

...................................................................................................................................

37

Settings in the menu items

..............................................................................................................................................................................................

Entering the position setpoint in the AUTOMATIC mode

.........................................................................................................

Manual opening and closing of the valve actuator in the MANUAL mode

.........................................................

* Alternative chapters or functions depending on device configuration

8630 - 33

IRST

OMMISSIONING

NOTE This section enable you to put the TOP Control Continuous rapidly into operation for a functional check. Supplementary functions unnecessary for this purpose are not dealt with here.

Fluidic installation

➔ Install the valve according to operating instructions!

➔ Connect supply pressure to connection "1" (3

.. 7 bar; instrument air, free from oil, water and dust)

➔ Attach the exhaust line or silencer to connection "3"!

NOTE Remove the protective caps from the valve and and the TOP Control

Continuous!

34 - 8630

* Electrical installation - multipole connector

IRST

OMMISSIONING

M16 M12

➔ Apply the setpoint signal to the circular connector M16

Configuration of the circular connector M 16

Pin

Allocation

Setpoint + (0/4 ... 20 mA

or 0 ... 5/10 V)

Setpoint GND

External connection/Signal level

+ (0/4 ... 20 mA or 0 ... 5 / 10 V)

GND

➔ Apply the supply voltage to the circular connector M12

Configuration of the circular connector M 12

Pin

Allocation

+ 24 V not connected

GND not connected

External connection

24 V DC ± 10 % max. residual ripple 10 %

NOTE Further installation notes are to be found in the chapter Installation.

After application of the supply voltage, the TOP Control Continuous is in operation. Carry out the necessary basic settings and initiate self-parametrization of the TOP Control.

8630 - 35

IRST

OMMISSIONING

* Electrical installation - connection terminals for cable bushings

➔ Remove the cover with the cable bushings to gain access to the terminals. This is done by unscrewing the 4 self-tapping screws.

➔

Apply the setpoint signal and the supply voltage to the respective terminals (see

Terminal configuration with cable bushings).

screw terminals

Terminal configuration with cable bushings

Terminal

Allocation

Setpoint +

Setpoint GND

Operating voltage +

Operating voltage GND

External connection

1 + + (0/4 ... 20 mA or 0 ... 5/10 V)

GND

24 V DC ± 10 % max. residual ripple 10 %

NOTE Further installation notes are to be found in the chapter Installation.

After application of the supply voltage, the TOP Control Continuous is in operation. Carry out the necessary basic settings and initiate self-parametrization of the TOP Control.

36 - 8630

Basic settings of the TOP Control Continuous

Configuration of the keys

MANUAL/AUTOMATIC-key

Arrow keys

Switch between main and subitems, e.g. ACT FUNC - FUNCSNGL

Switch between equal-ranking menu items, e.g. ACTFUNC - INPUT

AUTOMATIC

MODE

IRST

OMMISSIONING

MANUAL

MODE

Jump over on first commissioning

8630 - 37

IRST

OMMISSIONING

Settings in the menu items

ACTFUNC Actuator function

FUNC SNGL - single-acting

FUNC DOUB - double-acting

INPUT Standard signal

INP 4’20A - Current 4 ... 20 mA

INP 0’20A - Current 0 ... 20 mA

INP 0’10V - Voltage 0 ... 10 V

INP 0’5V - Voltage 0 ... 5 V

ADDFUNCT

X.TUNE

Jump over

Initiate self-parametrization

END XX Return to AUTOMATIC mode ;

the display EEPROM appears until the settings have been in the

memory.

Entering the position setpoint in the AUTOMATIC mode

After selection of the basic settings and return to the AUTOMATIC mode, the TOP Control Continuous works as a positioner.

Enter the position setpoint via the signal.

Switching between the display options:

Display:

• Actual position of valve actuator

• Setpoint position of valve actuator

• Input signal for setpoint position

(here identical to setpoint position)

• Temperature inside

TOP Control Continuous housing

POS__XXX (0 ... 100 %)

CMD__XXX (0 ... 100 %)

INP__XXX

(0 ... 5/10 V or 0/4 ... 20 mA)

TEMP_XX.X (in °C)

38 - 8630

Manual opening and closing of the valve actuator in the

MANUAL mode

IRST

OMMISSIONING

Open valve actuator:

Close valve actuator:

Display: the display set in the AUTOMATIK mode is retained.

NOTE Select the display POS_XXX , in this case the actual position of the valve actuator can be checked.

8630 - 39

IRST

OMMISSIONING

40 - 8630

NSTALLATION

INSTALLATION

Installation of the valve

42 Turning the TOP Control Continuous

.................................................................................................................................................................

42

Procedure

Fluidic connection of the TOP Control Continuous

.......................................................................................................................

43 * Electrical connection - multipole connectors

.....................................................................................................................................

44

Marking of the multipole plugs or sockets and the contacts

..................................................................................................

Output signals for SPS (circular plug M 16)

................................................................................................................................................

Operating voltage (circular plug M 12)

...............................................................................................................................................................

Inductive proximity switches (circular socket M 8)

..............................................................................................................................

Process value (circular plug M 8)

.............................................................................................................................................................................

Process value with the option flow rate controller (2 circular plugs M 8)

Option: with temperature sensor input (3 circular plugs M 8)

...............................................................................................

* Electrical connection - terminals with cable bushing

.............................................................................................................

47

Connection PCB of the TOP Control Continuous with screw terminals and jumpers

...........................

Terminal configuration with cable bushings

.................................................................................................................................................

Choice of binary outputs or process value input

...................................................................................................................................

* Setting the inductive proximity switches (option)

.........................................................................................................................

50

Opening the housing of the TOP Control Continuous

....................................................................................................................

Positioning the inductive proximity switches

...............................................................................................................................................

* Alternative chapters or functions depending on device configuration

8630 - 41

NSTALLATION

NOTE See data sheet for dimensions of TOP Control and the variants of the complete device, consisting of TOP Control Continuous, pneumatic actuator and valve.

Installation of the valve

NOTE The actuator must not be connected.

For dimensions and threads, see data sheet for the process valve.

Turning the TOP Control Continuous

If, after installation of the continuous valve, the display of the TOP Control Continuous is poorly visible or it is difficult to attach the cable or hoses, the TOP Control Continuous may be rotated relative to the pneumatic actuator.

Procedure

➔ Disconnect the fluidic connection between TOP Control Continuous and pneumatic actuator.

➔ Loosen the fixing screws recessed into the side of the housing (hex socket SW3, see chapter System description - Construction of the TOP Control Continuous).

➔ Rotate the TOP Control Continuous clockwise without lifting into the desired position.

➔ Retighten the fixing screw with 1.2 Nm moderate torque.

➔ Remarke the fluidic connection between TOP Control Continuous and pneumatic actuator, using longer hoses if necessary.

ATTENTION!

If theTOP Control Continuous is lifted during rotation (axially displaced), the mechanical coupling to the position sensor mechanism may be damaged. By turning in the wrong direction (anticlockwise), there is a risk of unhooking the position sensor mechanism.

This can be reconnected only with a special tool!

ATTENTION!

To assure leak tightness of the device (IP65), the screw for connecting TOP Control

Continuous and process valve shall be tightened with a torque not exceeding 1.2 Nm!

42 - 8630

Fluidic connection of the TOP Control Continuous

NSTALLATION

➔ Apply the supply pressure to connection“1" (3..7 bar, instrument air, free from oil, water and dust)

➔ Attach the exhaust line or silencer to connection „3“

NOTE Maintain the applied supply pressure, without fail , at least 0.5 - 1 bar over that required to bring the pneumatic actuator into the end position. This assures that the control behaviour in the upper region of the stroke will not be significantly affected negatively if the pressure difference is too small.

Keep variations in the supply pressure as low as possible during operation (max. ± 10

%). With larger variations, the controller parameters calibrated with the AUTOTUNE function will not be optimal.

Remove the protective caps from the valve and the TOP Control Continuous.

8630 - 43

NSTALLATION

* Electrical connection - multipole connectors

ATTENTION!

For connection to the technical earth (ground) (TE), a threaded stud with nut is provided on the connection module. To assure electromagnetic compatibility (EMC), connect this stud to a suitable earthing (grounding) point using as short a cable as possible (max. 30 cm).

NOTE Use of the 4 - 20 mA setpoint input

If the voltage supply of a TOP Control device fails in a row of such devices connected in series, the input of the failed device will become high-impedance. This will cause the 4 -

20 mA standard signal to fail. If this occurs, please contact Bürkert Service directly.

With Profibus DP or DeviceNet:

The markings of the multipole plugs and sockets, and the contacts are to be found in the respective chapters.

Marking of the multipole plugs or sockets and the contacts

M16

M12

Output signals to

SPC

Operating voltage

Process value

44 - 8630

Initiators (inductive proximity switches)

NSTALLATION

Output signals for SPS (circular plug M16)

Pin

Allocation

Setpoint GND

Setpoint + (0/4..20 mA or 0..5/10 V)

Analog position feedback +

Analog position feedback GND

Binary output 1

Binary output 2

Binary output GND

Binary input +

Binary input GND not connected not connected not connected

External connection/signal level

+ (0/4 ... 20 mA or 0..5/10 V)

completely isolated electrically

GND

+ (0/4 ... 20 mA or 0 ... 5/10 V)

completely isolated electrically

GND

24 V / 0 V

GND

0 ... 5 V (log. 0)

10 ... 30 V (log. 1)

Operating voltage (circular plug M 12)

External connection Pin

Allocation

+ 24 V not connected

GND not connected

24 V DC ± 10 % max. residual ripple 10 %

Inductive proximity switches (circular socket M 8)

Pin

Allocation

Proximity switch 1 + (NO)

Proximity switch 1 GND

Proximity switch 2 + (NO)

Proximity switch 2 GND

Signal level

+24 V DC

GND

+24 V DC

GND

4 open / 24 V

GND open / 24 V

GND

8630 - 45

NSTALLATION

Process value (circular plug M 8)

Input type *

4 ... 20 mA

- internal

supply

4 ... 20 mA

- external

supply

Frequency

- internal

supply

Frequency

- external

supply

Pin Allocation

Jumper** External connection

+ 24 V supply transmitter

Output Transmitter

GND bridge to GND (GND from

3-conductor transmitter) not connected

Process actual + not connected

Process actual -

+ 24 V - supply sensor

Clock input +

Clock input - (GND) not connected not connected

Clock input +

Clock input not connected

4 ... 20 mA

GND

+24 V

Clock +

Clock -

Clock +

Clock -

Pt-100

(see

Note below)

2 not connected process actual 1(current supply) process actual 3 (GND) process actual 2 (compensation)

Pt 100

* May be set via software (section Procedure for specifying the basic settings)

** The jumper is situated on the connection board of the TOP Control Continuous (see next page)

NOTE For line compensation reasons, connect sensor Pt-100 via 3 conductors. PIN 3 and PIN 4 must be bridged at the sensor.

Process value with the option flow rate controller (2 circular plugs M8)

Option: with temperature sensor input (3 circular plugs M8)

Input type No. of plugs

1 internally supplied transmitter*

Option: temperature transmitter

Pin Configuration

3 + 4

+ 24 V - supply to transmitter p1

4 ... 20 mA - output from transmitter p1 n.c.

+ 24 V - supply to transmitter p2

4 ... 20 mA - output from transmitter p2 n.c.

3 + 4

+ 24 V - supply to transmitter

4 ... 20 mA - output from temperature transmitter n.c.

Jumper ext. connection

* With external supply of the sensors, the mass of the standard signal must be

connected to the mass of the supply voltage.

Circular plug

M12

46 - 8630

NSTALLATION

* Electrical connection - terminals for cable bushing

ATTENTION!

For connection to the technical earth (ground) (TE), a threaded stud with nut is provided on the connection module. To assure electromagnetic compatibility

(EMC), connect this stud to a suitable earthing (grounding) point using as short a cable as possible (max. 30 cm).

NOTE Use of the 4 - 20 mA setpoint input

If the voltage supply of a TOP Control Continuous device fails in a row of such devices connected in series, the input of the failed device will become high-impedance. This will cause the 4 - 20 mA standard signal to fail. If this occurs, please contact Bürkert Service directly.

Connection PCB of the TOP Control Continuous with screw terminals and jumpers

➔ Remove the cover with the cable bushings to gain access to the screw terminals. This is done by unscrewing the 4 self-tapping screws.

Terminal configuration with cable bushings

Terminal

Allocation

Setpoint +

Setpoint GND

Analog position feedback +

Analog position feedback GND

Operating voltage +

Operating voltage GND

External connection

1 + + (0/4 ... 20 mA or 0 ... 5/10 V

GND

+ (0/4 ... 20 mA or 0 ... 5/10 V)

completely isolated electrically

GND

24 V DC ± 10 % max. residual ripple 10 %

8630 - 47

NSTALLATION

Choice of binary outputs or process value input

➔

Select using the jumpers:

2 binary outputs (see terminal Allocation when binary outputs selected) or

Process value input (see terminal Allocation when process value input selected).

Terminals 7 to 10 are connected to the corresponding signals.

Jumper Terminal Allocation

Binary output 1

Binary output 2

External connection

24 V / 0 V NC / NO

GND

24 V / 0 V NC / NO

10 GND

Terminal allocation on selection of process value input:

➔ The input type is set via the configuration menu (see Procedure for specifying the basic settings) .

Input type* Jumper Terminal Allocation

4 ... 20 mA internal supply

+ 24 V input transmitter

Output transmitter

Bridge to GND (GND from

3-conductor transmitter)

GND

Frequency internal supply

4 ... 20 mA external supply

Frequency external supply

Pt-100

(see

Note below)

External connection

+ 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 (current supply)

Process actual 2 (compensation)

Process actual 3 (GND)

+24 V

Clock +

Clock - (GND)

+ (4 ... 20 mA)

GND

Clock +

Clock -

Pt100

NOTE For reasons of line compensation, connect the Pt 100 sensor over 3 conductors. Be sure to bridge terminals 9 and 10 at the sensor.

48 - 8630

NSTALLATION

Terminal allocation with binary outputs

Terminal Allocation

Binary input +

Binary input GND

External connection

GND

0 ... 5 V (log. 0)

10 ... 30 V (log. 1)

8630 - 49

NSTALLATION

* Setting the inductive proximity switches (Option)

ATTENTION!

In order to set the inductive proximity switches, the housing of the TOP Control

Continuous must opened. Switch off the operating voltage before making this intervention!

Opening the housing of the TOP Control Continuous

➔

Remove any lead seals or fastenings present between cover and housing.

➔

Turn the cover anticlockwise and lift it off.

Positioning the inductive proximity switches

➔ The inductive proximity switches are positioned vertically with one adjusting screw each:

Turning clockwise causes upward adjustment

Turning anticlockwise causes downward adjustment

ATTENTION!

On adjusting the height of the inductive proximity switches, make sure that adjacent flexes are not pulled (e.g. by getting hooked in the proximity switches). If this is not adhered to, plugged connections may be damaged or loosened).

Screw to adjust the lower proximity switch

Screw to adjust the upper proximity switch

50 - 8630

PERATION AND

ONTROLLER

UNCTIONS

OPERATION

AND

CONTROLLER FUNCTION

Operating and display elements

...............................................................................................................................................................................

52 Operating levels

52 Commissioning and set-up as a positioner

..............................................................................................................................................

53

Procedure for specifying the basic settings

...............................................................................................................................................

Main menu for the settings on commissioning

......................................................................................................................................

Description of the procedure

........................................................................................................................................................................................

Configuring the supplementary functions

...................................................................................................................................................

59

Keys in the configuration level

....................................................................................................................................................................................

Configuration menu

Supplementary functions

..................................................................................................................................................................................................

Operating the process

86

Changeover between operating modes

.........................................................................................................................................................

Operating mode AUTOMATIC

......................................................................................................................................................................................

87

Meaning of the keys in the AUTOMATIC mode

....................................................................................................................................

Display of the AUTOMATIC mode

........................................................................................................................................................................

Operating mode MANUAL

.................................................................................................................................................................................................

88

Meaning of the keys in the MANUAL mode

...............................................................................................................................................

Display of the MANUAL mode

....................................................................................................................................................................................

8630 - 51

PERATION AND CONTROLLER FUNCTIONS

Operating and display elements

The TOP Control Continuous is equipped with a 3-key operating and display element with LC display.

The functions of the keys are described in the following sections.

MANUAL/AUTOMATIC KEY

LED (yellow) in the MANUAL/AUTOMATIC-key

(see chapter Operating the process controller)

Arrow key up Arrow key down

Operating levels

Operation of the TOP Control Continuous is done via two operating levels:

• Process operating level:

After the device is switched on, the process operating level is active. In this level, you can switch between the operating modes AUTOMATIC and MANUAL. In the AUTOMATIC mode, position or process control (only for the process controller option) runs. In the MANUAL mode, the valve can be manually opened and closed.

• Configuration level:

In the configuration level, you can specify on first commissioning the basic functions and configure supplementary functions if needed.

Process operating level

MANUAL AUTO-

MATIC

5 sec

Configuration level

Basic funktions

End

Supplementary functions

52 - 8630

PERATION AND

ONTROLLER

UNCTIONS

Commissioning and set-up as a positioner

➔ Before commissioning, execute the fluidic and electrical installations.

Procedure for specifying the basic settings

➔

On first commissioning of the TOP Control Continuous, carry out the following basic settings:

• Specify the function of the pneumatic actuator used.

• Specify the standard signal input for setpoint setting (4..20 mA, 0..20 mA, 0..10 V or 0..5 V).

• Start the automatic adaptation of the positioner to the current operating conditions (AUTOTUNE).

Configuration of the keys

MANUAL/AUTOMATIC-key

Arrow keys

Switch between main and sub-menu items, e.g.

ACT FUNC - FUNCSNGL

Switch between eual-ranking menu items, e.g.

ACTFUNC - INPUT

Factory setting of the positioner

Function Factory setting

ACTFUNC FUNCSNGL

INPUT INP 4'20A

CHARACT CHA LIN

DIR.CMD DIR.CRISE

CUTOFF CUT = 0 %; CUT = 100 %

DIR.ACT DIR.ARISE

SPLTRNG SR = 0 (%); SR = 100 (%)

X.LIMIT LIM = 0%, LIM = 100%

X.TIME

T.OPN Values determined by AUTOTUNE

T.CLS Values determined by AUTOTUNE

After execution of SETFACT: 1 s

Function

OUTPUT

OUT ANL:

OUT POS

OUT BIN:

OUT DEV

BIN-IN

B.IN SPOS

Factory setting

OUT 4'20 A

DEV 5.0 NO

SPOS 000 NO

X.CONTROL

X.CO DBND 1 %

X.CO PARA

KX Values determined by AUTOTUNE

After execution of SETFACT: 1

CODE CODE 0000

8630 - 53

PERATION AND CONTROLLER FUNCTIONS

Main menu for the settings on commissioning

AUTOMATIC

MODE

5 s

MANUAL

MODE

Jump over on first commissioning

5 s

54 - 8630

PERATION AND

ONTROLLER

UNCTIONS

Description of the procedure

After the voltage supply has been switched on, the positioner is in the process operating level in the

AUTOMATIC mode. To specify the basic settings, switch to the configuration level. Depress the MANU-

AL/AUTOMATIC key for 5 seconds. The display then shows ACTFUNCT, the first item of the main menu.

To make a setting under the menu item ACTFUNC, press the MANUAL/AUTOMATIC key briefly.

Then one of the sub-menu items appears on the display. The arrow keys are used to switch between these sub-items, enabling the desired settings to be made. The desired setting is confirmed after selection by pressing the MANUAL/AUTOMATIC key. The arrow keys are also used to switch between the items of the main menu ( ACTFUNCT, INPUT, ...).

NOTE At the level of the sub-menu items, the selected function is shown by the three or four characters at the right of the 8-digit display. These characters flash on the display.

ACTFUNC - Function of actuator

➔ Enter under this menu item the function of the pneumatic actuator used in combination with the TOP

Control. This function is marked on the rating plate of the actuator.

- single-acting

- double-acting

INPUT - Selected standard signal

➔ Enter under this menu item the standard signal used for the setpoint.

- Current 4 ... 20 mA

- Current 0 ... 20 mA

- Voltage 0 ... 10 V

- Voltage 0 ... 5 V

8630 - 55

PERATION AND CONTROLLER FUNCTIONS

ADDFUNCT

See section Configuring the supplementary functions.

➔

Jump over this menu item on first commissioning.

X.TUNE

- Autotune for positioner

➔ Start the program for automatic parametrization of the TOP Control Continuous via the menu item

X.TUNE.

The following functions are initiated automatically:

• Adaptation of the sensor signal to the (physical) stroke of the valve used

• Determination of parameters of the PWM signals for driving the solenoid valves integrated in the

TOP Control Continuous.

• Setting of the controller parameters of the positioner. Optimization is done according to the criteria: as short a correcting time as possible and simultaneously freedom from overshoot.

➔

Start AUTOTUNE by calling up X.TUNE in the main menu.

➔ Then depress the MANUAL/AUTOMATIC key for 5 seconds.

NOTE To cancel AUTOTUNE, operate both arrow keys at the same time and select X.TUN BRK .

Start the automatic adaptation of the positioner to the current operating conditions

Display

TUNE 5

TUNE 4

TUNE 0

¦ X.T INIT

¦ X.T A1-P

¦ X.T TOPN

¦ X.T TCLS

TUNE-END

X.ERR X

Description

Countdown from 5 to 0 start of AUTOTUNE

Display of the autotune phase in progress at the moment

(continuation is indicated by a rotating bar to the left of the display)

Flashing display

➞ end of AUTOTUNE

Message on occurrence of an error

(Indication right: Error number, see chapter Maintenance and controller fault rectification)

NOTE The basic settings onthe TOP Control Continuous are made in the factory. On commissioning, nevertheless, execution of X.TUNE is absolutely necessary . TOP Control

Continuous then determines automatically the optimum settings for the current operating conditions.

If the supplementary function X.CONTRL is present in the main menu during execution of

X.TUNE, the positioner dead band X.CO DBND is additionally determined automatically as a function of the frictional behaviour of the positioning mechanism (see chapter

Supplementary Functions - X.CONTROL).

56 - 8630

PERATION AND

ONTROLLER

UNCTIONS

ATTENTION!

During execution of the AUTOTUNE function, the valve moves on its own away from its current position. For this reason, never execute AUTOTUNE while the process is running!

MANUAL TUNE - FUNCTIONS

Access to the manual TUNE functions is obtained by selection X.TUNE in the main menu and briefly pressing the MANUAL/AUTOMATIC key, or on abortion of countdown, by releasing the MANUAL/

AUTOMATIC key.

AUTOTUNE MANUAL TUNE release

5 s move to max.

position move to min.

position change min. PWM T.V.

for pressurizing valve display of opening time (s) change min. PWM T.V. for venting valve display of closing time (s)

The following parameters, which are automatically determined during X.TUNE, may be manually present or adjusted afterwards.

TUNE-END - Return to main menu

TUNE-POS Present end position

The AUTOTUNE function determines the end positions of the control armature from the physically stops.

Certain armatures (e.g. rotating vanes) have no physically stops, so that the end positions must be manually present using TUNE-POS. When executed immediately afterwards, AUTOTUNE assumes the manual end settings and continues with the setting of the positioning system and optimization of the positioner.

NOTE If manual presetting of the end positions by means of TUNE-POS is necessary, it must be done before execution of AUTOTUNE.

8630 - 57

PERATION AND CONTROLLER FUNCTIONS

TUNE-PWM - Readjust minimum PWM pulse-duty factor for driving the solenoid integrated in

the TOP Control Continuous

The AUTOTUNE function determines automatically the minimum PWM pulse-duty factor necessary for driving the solenoid integrated in the TOP Control Continuous. If the frictional characteristics of the positioning mechanism are unfavourable, these values may deviate from the optimum. By using TUNE-

PWM, however, they can be readjusted to obtain the lowest possible speed in both directions.

NOTE

The function TUNE-PWM must be executed after AUTOTUNE!

TUNE-AIR Adapt the opening to the closing time of the process valve

With spring-closing process valves, the opening speed may be varied within certain limits by changing the supply pressure. The closing speed, however, is independent of the supply pressure and given by the spring force and the nominal diameter of the venting valve. By using TUNE-AIR, the opening time may be adapted to the closing time. This results in symmetrical motion, which has a favourable effect on the process control.

NOTE The function TUNE-AIR must be executed after AUTOTUNE!

ATTENTION!

Avoid faulty adaptation of the controller by executing X.TUNE in all cases at the supply pressure (pneumatic auxiliary energy) that will exist in later operation.

The function X.TUNE should preferably be executed without operating medium pressure to avoid disturbing influences from flow forces.

END - Quitting the main menu and display of the software version

➔ To quit the main menu, select the item END with the arrow keys. To the right of the display the software version is shown (END XX).If the MANUAL/AUTOMATIC key is pressed, EEPROM appears on the display until the changes have been saved. After that, the device returns to the mode in which it was before switching over to the main menu (MANUAL or AUTOMATIC).

58 - 8630

PERATION AND

ONTROLLER

UNCTIONS

Configuring the supplementary functions

NOTE The operating concept for the TOP Control Continuous is based on a strict separation between the basic and supplementary functions. In the delivered state, only the basic functions are activated. These suffice for normal operation. For more demanding control applications, you can select and specify supplementary functions in the configuration level.

Keys in the configuration level

Press key

Press key in Menu

Scroll up

(select)

Scroll down

(select) in a selected and confirmed menu item

Increment (increase) numeric value

Decrement (decrease) numeric value in Menu confirm selected menu item

Confirm set values in menu ADDFUNCT

Confirm selected menu item of supplementary menu to add it to the main menu. The menu item is marked with an asterisk (*) in the supplementary menu.

The menu item appears int he main menu and can be selected and edited there. Confirm the menu item selected and marked with asterisk in the supplementary menu for deletion from the main menu.

Configuration menu

Switching between the process operating level and the configuration level

Process operating level

MANUAL AUTO-

MATIC

5 sec

Configuration level

Basic functions

END

Supplementary menu

8630 - 59

PERATION AND CONTROLLER FUNCTIONS

5 s To activate the configuration menu, press (in the process operating level), the MANUAL/

AUTOMATIC key for 5 seconds.

The configuration menu consists of a main and a supplementary menu. The main menu contains initially the basic functions which are specified during first commissioning. The supplementary menu comprises supplementary functions which may be reached via the menu item ADDFUNCT of the main menu.

Specification of device functions and parameters is possible only within the main menu. If needed, the main menu may be augmented by additional functions and parameters from the supplementary menu, which can then be specified.

Addition of supplementary functions to the main menu

➔ Select in the main menu the item ADDFUNCT.

➔ By pressing the MANUAL/AUTOMATIC key, enter the supplementary menu.

➔ With the arrow keys, select the desired supplementary function.

➔ By pressing the MANUAL/AUTOMATIC key, confirm addition of the supplementary function to the main menu. The function is automatically marked with an asterisk (*).

➔ All marked functions are added to the main menu after confirmation of ENDFUNCT.

➔ In the main menu, enter the parameters for the supplementary functions.

Deletion of supplementary functions from the main menu

NOTE By removing a function from the main menu, the settings previously made under this function are again invalidated.

➔ Select in the main menu the item ADDFUNCT.

➔ By pressing the MANUAL/AUTOMATIC key, enter the supplementary menu.

➔ With the arrow keys, select a supplementary function marked with (*).

➔ By pressing the MANUAL/AUTOMATIC key, confirm deletion of the supplementary function (the asterisk (*) marking is deleted).

➔ After confirmation of ENDFUNCT, the supplementary function is deactivated and deleted from the main menu.

Setting of numeric values

Numeric values are set in the menu items provided by pressing the keys „arrow up“ (increment value) or

„arrow down“ (decrement value) one or more times. In the case of 4-digit numbers, only the flashing digit can be set with the arrow keys. By pressing the MANUAL/AUTOMATIC key, you can switch to the next digit.

60 - 8630

PERATION AND

ONTROLLER

UNCTIONS

Principle of adding supplementary functions to the main menu

8630 - 61

PERATION AND CONTROLLER FUNCTIONS

Supplementary Functions

ADDFUNCT

CHARACT

CUTOFF

DIR.CMD

DIR.ACT

SPLTRNG

X.LIMIT

X.TIME

X.CONTRL

P.CONTRL

CODE

SAFEPOS

SIG-ERR

BIN-IN

OUTPUT

CAL USER

SETFACT

SER-I/O

ENDFUNCT

Select the transfer characteristic between input signal ans stroke (correction characteristic)

Tight closure function for positioners or process controllers (if activated)

Sense of action between input signal ans setpoint position

Allocation of state of pressurization of actuator chamber (Port 2

) to actual position

Signal range splitting; input signal in % for which the valvetransverses the entire stroke

Limitation of mechanical stroke range

Limitation of correcting speed

Parametrization of positioner

(Parametrization of the PID process controller).

Without function in the version as positioner!

Code protection for settings

Enter safety position

Configure error recognition signal level

Activation of binary input

(Configuration of the outputs, only with supplementary board for analog feedback or binary outputs)

Calibration

Reset to factory settings

Configuration of the serial interface

62 - 8630

PERATION AND

ONTROLLER

UNCTIONS

CHARACT

Selection of the transfer characteristic between input signal (position setpoint) and stroke (correction curve)

Customized characteristic

Factory setting: CHA LIN

With this function, you can select a transfer characteristic with respect to setpoint position (setpoint position CMD) and valve stroke (POS) to correct the flow or operating curve.

Linear characteristic

Equipercentile characteristic 1:25

Equipercentile characteristic: 1:33

Equipercentile characteristic 1:50

Inverse equipercentile characteristic 25:1

Inverse equipercentile characteristic 33:1

Inverse equipercentile characteristic 50:1

User-defined characteristic, freely programmable via fixed points

The flow characteristic k v

= f(s) describes the flow through a valve, expressed by the k v

value, as a function of the stroke s of the actuator spindle. It is determined by the shape of the valve seat and the seat seal. In general, two types of flow characteristic are realized: the linear and the equipercentile.

With linear characteristics, equal changes in stroke ds are allocated to equal changes in k v

value dk v

(dk

= n lin

* ds).

With an equipercentile characteristic, a change in stroke ds corresponds to an equipercentile change in k v

value

(dk

= n gleichpr

* ds).

The operating characteristic Q = f(s) represents the relationship between the volumetric flow Q passing through a valve installed in a system and the stroke s. This characteristic contains the properties of the piping, pumps and consumers. It hence has a different shape from the flow characteristic.

8630 - 63

PERATION AND CONTROLLER FUNCTIONS

Normalized valve stroke [%] (POS)

Normalized position setpoint [%]

(CMD)

For positioning applications of control systems, special requirements are usually made on the shape of the characteristic, e.g. linearity. For this reason it is sometimes necessary to correct its shape in a suitable manner.

For this purpose, a transfer member is provided in the

TOP Control Continuous which realizes different characteristics. These are used to correct the operation characteristic.

The equipercentile characteristics 1:25, 1:33, 25:1,

33:1 and 50:1 and a linear characteristic may be set.

Furthermore, it is possible to freely program a characteristic via fixed points or have it calibrated automatically.

Entering the freely programmable characteristic

The characteristic is defined via 21 fixed points distributed evenly over the 0...100 % range of the position setpoint. They are separated by 5 %. Each fixed point may be allocated to a freely selectable stroke (setting range 0...100 %). The difference between two adjacent values of stroke may not exceed

20 %.

To enter the point on the characteristic (values of the function), first select the menu item CHR FREE.

After pressing the MANUAL/AUTOMATIC key, the first fixed point is displayed (0 %). Next to it is the value of the function (initially 0 %).

With the arrow keys, set a value of the function between 0 and 100 %. After pressing the MANUAL/

AUTOMATIC key, the next fixed point is displayed, etc. Finally, press the MANUAL/AUTOMATIC key to confirm the value of the function belonging to the last fixed point (100 %). The display returns to the menu item CHARACT.

64 - 8630

Example of a programmed characteristic

Valve stroke [%]

(POS)

PERATION AND

ONTROLLER

UNCTIONS

Setpoint signal [%]

(CMD)

Entering the fixed points:

NOTE

Valve stroke [%]

(enter with arrow keys)

Position setpoint [%]

(fixed point)

Return to

CHARACT

The fixed points that were entered should be noted in the table in the Appendix.

8630 - 65

PERATION AND CONTROLLER FUNCTIONS

CUTOFF

Tight closure function for positioners or process controllers

Factory setting: CUT = 0 %; CUT = 100 %

This function causes the valve to close tightly outside the control range. Enter here the limits in percent for the position setpoint (CMD) or, with activated PID controller either for the position setpoint or for the process setpoint SP, from which the actuator is to be completely vented or pressurized. In the case of the fast pressurization/venting version, two valves are driven in each case in order to obtain complete venting more rapidly. Opening or resumption of controlled operation is performed with a hysteresis of 1

If the process valve is in the region of tight closure, there appears in the display a flashing MIN or MAX symbol.

Tight-closing threshold exhaust (0 = inactive); setting range: 0..25 %.

Tight-closing threshold pressurize (100 = inactive); setting range: 75 ... 100 %

Menu appears only with activated PID controller

Limits refer to process setpoint (SP)

Limits refer to position setpoint (CMD)

Valve stroke [%]

(POS)

Setting range: 75 ... 100 %

66 - 8630

Setting range: 0 ... 25 %

Setpoint [%]

(CMD)

PERATION AND

ONTROLLER

UNCTIONS

DIR.CMD

Sense of action or direction of the positioner setpoint

Factory setting: DIR.CRISE

With this supplementary function, you can set the sense of action between the input signal (INP) and the setpoint position (CMD) of the actuator.

Direct sense of action

(e.g. 4 mA or 0 V ➔ 0 %,

20 mA or 5/10 V ➔ 100%)

Inverse sense of action

(e.g. 4 mA or 0 V ➔ 100%,

20 mA or 5/10 V ➔ 0%)

Setpoint position

(CMD)

Inputsignal

(INP)

8630 - 67

PERATION AND CONTROLLER FUNCTIONS

DIR.ACT

Sense of action or direction of the actuator

Factory setting: DIR.ARISE

With this supplementary function, you can set the sense of action between the state of pressurization of the actuator and the actual position (POS).

Direct sense of action

(exhausted ➔ 0 %; pressurized ➔ 100 %)

Inverse Wirkungsrichtung

(entlüftet ➔ 100 %; belüftet ➔ 0 %)

Actual position

(POS)

Exhausted Pressurized State of pressurization

68 - 8630

PERATION AND

ONTROLLER

UNCTIONS

SPLTRNG

Split range

Split range; min. and max. values of the input signal in % for which the valve traverses the entire stroke

Factory setting: SR = 0 (%); SR = 100 (%)

NOTE This function is only effective when operating as a positioner.

This supplementary function limits the Position setpoint range of the TOP Control Continuous by specifying a minimum and maximum values. In this way it is possible to distribute the standard signal range used (4..20 mA, 0..20 mA, 0..10 V or 0..5 V) over several TOP Control Continuous (with or without overlap). Several valves can thus be used as final control elements either alternating or, if the setpoint ranges overlap, simultaneously.

XX

XXX

Entering the minimum value of the input signal in %

(0 ... 75 (%) of the standard signal range)

Entering the maximum value of the input signal in %

(25 ... 100 (%) of the standard signal rage)

Splitting the standard signal range into tow setpoint ranges

Valve stroke

[%]

(POS)

Setpoint range

TOP Control

Continuous 1

Setpoint range

TOP Control

Continuous 2

Setpoint range [mA]

(INP)

8630 - 69

PERATION AND CONTROLLER FUNCTIONS

X.LIMIT

Limitation of the mechanical stroke range

Factory setting: LIM = 0%, LIM = 100%

This supplementary function limits the (physical) stroke to preset % values (minimum and maximum).

The range of the limited stroke is thereby set to 100 %.If the limited stroke range is left during operation, negative or positive POS values greater than 100 % are displayed.

XX

Entering the start value of the stroke range in %,

0 ... 50 % of the overall stroke

XXX

Entering the end value of the stroke rage in %,

50 ... 100 % of the overall stroke

The minimum separation between LIM is 50 %.

and LIM

Limited stroke [%]

(POS)

Physical stroke

[%] (POS) unlimited stroke limited stroke

Setpoint [mA]

(INP)

70 - 8630

PERATION AND

ONTROLLER

UNCTIONS

X.TIME

Limitation of the correcting speed

Factory setting: 1 s

NOTE When executing the function X.TUNE, the minimum opening and closing time for T.OPN

and T.CLS is automatically entered for the full stroke. In this way it is possible to traverse at maximum speed.

If the correcting speed is to be limited, values can be entered for T:OPN and T.CLS that lie between the minimum values determined by X:TUNE and 60 s.

XX

Opening time for full stroke (in seconds)

XX

Closing time for full stroke (in seconds)

Effect of limitation of the opening speed after a step in the setpoint

Valve stroke [%]

(POS, CMD)

Setpoint

Actual value t

T.OPN

NOTE If positioning times < 1 s are determined from the AUTOTUNE, X.TIME is automatically copied to the main menu and the relevant value is set to 1 s.

8630 - 71

PERATION AND CONTROLLER FUNCTIONS

X.CONTRL

Parametrization of the positioner

XXXX

Insensitivity range (dead band) of the positioner

Entry of the dead band in %, referred to the scaled stroke range; i.e. LIM minus LIM (see function X.LIMIT). This function assures that the positioner cuts in only above a certain control difference. The function reduces wear on the solenoid valves in the TOP Control Continuous and the pneumatic actuator.

NOTE If, during execution of X.TUNE (AUTOTUNE of the positioner), the supplementary function

X.CONTRL is in the main menu, the dead band X.CO DBND is automatically determined in dependence on the frictional behaviour of the positioning mechanism. The value resulting is a guide value. It can be readjusted manually.

Xd1'

Position setpoint

(CMD)

Control difference

Xd1

Position actual value

(POS)

Dead band

Xd1

Parameters of the positioner

Gain factor of the positioner (to close the valve)

Gain factor of the positioner (to open the valve)

72 - 8630

End of parametrization of positioner. Jump back to X.CONTRL.

to controller

Xd1'

PERATION AND

ONTROLLER

UNCTIONS

CODE

Code protection for the settings

Factory setting: CODE 0000

Locking of all functions that cloud change the operating status of the device. (The display on the display unit can be switched over).

Locking of the entry into the configuration level.

Locking of all actions (including bus parameterd and binary input) that change the operating status of the device. (The display on the display unit can be switched over.)

Entry of the 4-digit code.

If the code protection is activated, entry of the code will be demanded on every protected operative manipulation:

Change the flasching digit

Confirm the digit and switch to next digit

8630 - 73

PERATION AND CONTROLLER FUNCTIONS

SAFEPOS

Entering the safety position

Factory setting: 0 %

SAFEPOS SPOS XXX

Enter safety position (0 ... 100 %) *

* When the safety position is 0 % or 100 %, the actuator will be fully vented or pressurized as soon as the safety position is

activated int he supplementary function SIG-ERR or BIN-IN.

ATTENTION!

The safety position set is only moved to when a corresponding signal is present at the binary input (for configuration see BIN-IN), or on occurrence of a signal error (for configuration see SIG-ERR).

This function is executed only in the AUTOMATIC mode.

With the fast pressurize / fast vent variant, two valves are driven in each case to obtain faster pressurizing and venting.

74 - 8630

PERATION AND

ONTROLLER

UNCTIONS

SIG-ERR

Configuration of error recognition signal level

Activate signal error recognition

SIG-ERR

ERR INP INP ON

ERR P.INP

INP OFF

P.INP ON

P.INP OFF

Activate move to safety position

Configure error recognition of setpoint signal

SPOS ON

SPOS OFF

SPOS ON

Move to safety position if signal in error

Configure error recognition of process value signal

SPOS OFF

Move to safety position if signal error

ERR END

When signal error recognition is activated, the error is displayed (see chapter: Maintenance and Error

Correction).

NOTE Error recognition

Error recognition can be selected only with 4 ... 20 mA, Pt100 and P1’P2 signals.

4 ... 20 mA

Error in input signal

≤

3.5 mA (± 0.5 % of end value, hysteresis 0.5 % of end value)

Pt100

Error in input signal ≥ 225 °C (± 0.5 % of end value, hysteresis 0.5 % of end value)

P1’P2

Error in input signal ≤ 3.5 mA (± 0.5 % of end value, hysteresis 0.5 % of end value)

If other types of signal are selected or if the process controller is unactivated, the respective branch of menu will be faded out. If because of this configuration neither of the error recognition modes is possible, the message NOT.AVAIL

is displayed in the selection menu.

Safety position SPOS ON

If SPOS ON is set, the following configurations may occur:

Activated menu item SAFEPOS

On error recognition the actuatur moves to the position set under SAFEPOS.

Deactivated menu item SAFEPOS

On error recognition the actuator moves to the end position which it would assume in the zero-voltage state.

8630 - 75

PERATION AND CONTROLLER FUNCTIONS

BIN-IN

Activating the binary input

BIN-IN

Select the function of the binary input

B.IN SPOS

Safety position

B.IN M / A

Operating mode changeover

Type of binary input

NORM OPN

NORM CLS

NORM OPN

NORM CLS

Type of binary input normally closed

(0 ... 5 V = 1; 10 ... 30 V = 0) normally open

(0 ... 5 V = 0; 10 ... 30 V = 1)

Safety position B.IN SPOS

Moving to a safety position.

Activated menu item SAFEPOS

The actuator moves to the position set under SAFEPOS.

Deactivated menu item SAFEPOS

The actuator moves to the end position which it would assume in the zero-voltage state.

Switching over the operating mode B.IN M / A

Switching over the operating mode into MANUAL or AUTOMATIC.

Binary input = 0

Binary input = 1

Operating mode AUTOMATIC

Operating mode MANUAL

If the operating mode switchover has been selected, you can then no longer switch over the operating mode using the MANUAL/AUTOMATIC key.

76 - 8630

PERATION AND

ONTROLLER

UNCTIONS

OUTPUT (Option)

Configuration of the outputs

Configure the analog output

Configure binary output 1

Configure binary output 2

End of configuration of the outputs

OUT ANL - Standard signal for the analog position output

Selection of the desired output Selection of the desired standard signal

Actual position

Setpoint position

Actual value of process

Current 4..20 mA

Current 0..20 mA

Voltage 0..10 V

Voltage 0..5 V

NOTE The signal types shown in gray are only selectable with active process controller.

8630 - 77

PERATION AND CONTROLLER FUNCTIONS

OUT BIN1 - Configuring binary output 1

Permissible actuating signal *

Limit position

NOTE NORM CLS (NC) "Normally Closed" output, in switched state low (

≅

0 V)

NORM OPN (NO) "Normally Open" output, in switched state high ( ≅

24 V)

78 - 8630

PERATION AND

ONTROLLER

UNCTIONS

BIN1 DEV.X

Selection: alarm output for too great an actuation signal from the positioner

* The permissible actuating signal DEV.X XXX shall not be smaller than dead band.

BIN1 LIM.X

Selection: binary position output

LIM.X XXX - limit position

OUT BIN1

POS > LIM

POS < LIM

NORM OPN

0 V

24 V

NORM CLS

24 V

0 V

BIN1 SPOS

Selection: actuator in safety position

BIN1 SIG

Selection: error message setpoint signal

BIN1 SIG.P

Selection: error message process value signal

BIN1 RMOT

Selection: operating mode AUTOMATIC and EXTERNAL Setpoint activated

OUT BIN1

Operating mode

AUTO +

External set-value

Operating mode

MANUAL or internal set-value

NORM OPN

0 V

24 V

NORM CLS

24 V

0 V

8630 - 79

PERATION AND CONTROLLER FUNCTIONS

OUT BIN2 - Configuring binary output 2

Permissible actuating signal *

Limit position

NOTE NORM CLS (NC) "Normally Closed" output, in switched state low ( ≅

0 V)

NORM OPN (NO) "Normally Open" output, in switched state high ( ≅

24 V)

80 - 8630

PERATION AND

ONTROLLER

UNCTIONS

BIN2 DEV.X

Selection: alarm output for too great an actuation signal from the positioner

* The permissible actuating signal DEV.X XXX shall not be smaller than dead band.

BIN2 LIM.X

Selection: binary position output

LIM.X XXX - limit position

OUT BIN2

POS > LIM

POS < LIM

NORM OPN

0 V

24 V

NORM CLS

24 V

0 V

BIN2 SPOS

Selection: actuator in safety position

BIN2 SIG

Selection: error message setpoint signal

BIN2 SIG.P

Selection: error message process value signal

BIN2 RMOT

Selection: operating mode AUTOMATIC and EXTERNAL Setpoint activated

OUT BIN2

Operating mode

AUTO + external set-value

Operating mode

MANUAL or internal set-value

NORM OPN

0 V

24 V

NORM CLS

24 V

0 V

8630 - 81

PERATION AND CONTROLLER FUNCTIONS

CAL.USER

Calibration of the actual value display, the inputs for position setpoint, process setpoint, process actual value and of the K factor for the valve

NOTE

82 - 8630

With the removal of the additional function CALUSER, the factory calibration will be re-established.

NOTE

PERATION AND

ONTROLLER

UNCTIONS

The signal types shown in grey can be selected only with the process controller activated.

The signal surrounded by a dotted line can be selected only with the process controller deactivated.

The signal types in brackets are only shown in this menu; they cannot be changed here. The type of signal shown is that which you have selected in the associated menus:

CAL INP (CAL SP) Display of the selection in the menu INPUT

CAL PV Display of the selection in the menu P.CONTROL / P.CO INP

The signal types over a grey background can be selected only with the option flow rate controller.

CAL.POS

Calibration of the position display (0 - 100 %)

Storage of the minimum position:

Move to minimum position via arrow keys and confirm by pressing the MANUAL / AUTOMATIC key.

Storage of the maximum position:

Move to maximum position via arrow keys and confirm by pressing the MANUAL / AUTOMATIC key.

CAL INP

Calibration of the position setpoint (4 ... 20 mA; 0 ... 20 mA; 0 ... 5 V; 0 ... 10 V)

CAL SP

Calibration of the process setpoint (4 ... 20 mA; 0 ... 20 mA; 0 ... 5 V; 0 ... 10 V)

Menu point does not appear with selection of actual value frequency!

Storage of the minimum input signal (0 mA; 4 mA; 0 V):

Apply the minimum value of the standard signal to the input and confirm ist by pressing the MANUAL/

AUTOMATIC key.

Storage of the maximum input signal (20 mA; 5 V; 10 V):

Apply the maximum value of the standard signal to the input and confirm it by pressing the MANUAL/

AUTOMATIC key.

CAL PV

Calibration of the process setpoint (4 ... 20 mA; Pt-100)

This menu item does not appear on selection of frequency setpoint

Select 4 ... 20 mA:

Apply the minimum value of the process setpoint signal to the input and confirm the value by pressing the MANUAL/AUTOMATIC key.

Apply the maximum value of the process setpoint signal to the input and confirm the value by pressing the MANUAL/AUTOMATIC key.

Select Pt-100:

Alter the value displayed using the arrow keys until thedisplay on the SIDE Control S/HART agrees with that on the reference measuring instrument. Then confirm the value by pressing the MANUAL/

AUTOMATIC key.

8630 - 83

PERATION AND CONTROLLER FUNCTIONS

+ +

CAL P1, CAL P2, CAL TEMP

Calibrating the transmitter inputs at the flow rate controller (4 ... 20 mA)

Apply 4 mA to the input to be calibrated (p1/p2/temperature) and confirm the value by pressing the MANU-

AL/AUTOMATIC key.

Apply 20 mA to the input to be calibrated (p1/p2/temperature) and confirm the value by pressing the

MANUAL/AUTOMATIC key.

At the inputs p1/p2, 4 mA corresponds to a pressure of 0.0 bar (rel).

20 mA corresponds to a pressure of 10.0 bar (rel) or the end value set under CAL PLIM .

At the temperature input, 4 mA correspond to a temperature of 0°C.

20 mA correspond to a temperature of 150°C or the end value set under CAL TLIM .

CAL PLIM, CAL TLIM

Setting up the sensor measurement range

First, enter the lower pressure/temperature value that corresponds to the 4 mA transmitter signal. Then enter the upper pressure/temperature value that corresponds to the 20 mA transmitter signal.

PMIN must be within the range -1.01 ... 15.0 bar (rel), PMAX in the range 0.0 ... 16.0 bar (rel).

TMIN and TMAX must be within the 0 ... 150 °C range.

CAL P1P2

Balancing the pressure transmitters

The pressure transmitters p1 and p2 can be balanced in order to increase the measurement accuracy at small pressure differences. To do this, the feed line behind process valve must be closed, and a constant pressure must be applied to the controller unit.

With a pressure < 10 % of the sensor measurement range, the zero-point can be balanced, with a pressure > 55 % of the sensor measurement range, the upper calibration value.

Change the display between p1 and p2 using the arrow keys.

If you press the MANUAL/AUTOMATIC key, the displayed value will be confirmed and the other value will be matched to ist.

The process will be cancelled with the message P1P2 ERR if the pressure lies between 10 % and 55 % of the des sensor measurement range or if the difference between p1 and p2 > 1.5 %.

CAL FACT

Reset the settings under CAL.USER to the factory settings

Hold down the MANUAL/AUTOMATIC key until the countdown has expired.

84 - 8630

PERATION AND

ONTROLLER

UNCTIONS

SETFACT

Resetting to the factory settings

Using this function, all settings made by the user can be reset to the status existing on delivery.

All EEPROM parameters, with the exception of the calibration values, are reset to the default values.

Following this a hardware reset is executed.

5 s

To initiate the function, hold the MANU-

AL/AUTOMATIC key depressed for ca.

5 s until the countdown has finished.

8630 - 85

PERATION AND CONTROLLER FUNCTIONS

Operating the process

Each time after switching on the voltage supply, the TOP Control Continuous is automatically in the process operating level. To get there from the configuration level, confirm the menu item END by pressing the MANUAL/AUTOMATIC key.

In the process operating level, the normal controlled operation is executed and monitored (in the

AUTOMATIC mode), and the valve opened or closed by hand (MANUAL mode).

Changeover between operating modes

5 sec

Operate the MANUAL/AUTOMATIC key to switch between the MANUAL and AUTOMATIC modes.

Both in the MANUAL and the AUTOMATIC modes, you can change to the configuration level by pressing the MANUAL/AUTOMATIC key for longer than 5 seconds. On switching back to the process operating level, the operating mode is resumed that was set before switching over.

Operating mode

AUTOMATIC

MANUAL yellow LED in the

MANUAL/AUTOMATIC key flashes

Display off -

An apostrophe (') runs continuously from left to right.

86 - 8630

PERATION AND

ONTROLLER

UNCTIONS

Operating mode AUTOMATIC

(yellow LED flashes)

In the AUTOMATIC mode, normal controlled operation is executed and monitored.

Meaning of the keys in the AUTOMATIC mode:

or Switch over the display or

> 3 s

Change the process setpoint: with configured supplementary functions P.CONTRL / P.CO SETP / SETP INT and display set to SP

Display of the AUTOMATIC mode

With regard to the positioner, the following parameters can be displayed:

• Actual position of valve actuator POS__XXX (0 ... 100 %)

• Setpoint position of valve actuator after rescaling through optionally activated split-range function or correction characteristic:

• Input signal for setpoint position:

• Temperature inside housing of TOP Control Continuous

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 can switch between these 4 display options.

AUTOMATIC mode

Configuration

Menu item

END

Switch over display or

(> 5 sec.)

No operating action

Release key

MANUAL mode

NOTE If the device is in the safety position (for the relevant configuration, see menu item BIN-IN or SIG-ERR), SAFE XXX appears in the display.

If the menu item CUTOFF is activated and the process vave is in the tight-closing range, a flashing MIN or MAX symbol appears in the display.

8630 - 87

PERATION AND CONTROLLER FUNCTIONS

Operating mode MANUAL

(yellow LED off)

In the manual mode, the valve can be opened and closed by hand.

Meaning of the keys in the MANUAL mode:

+

Press the key in the MANUAL mode:

Pressurization of the actuator

SFA: valve opens

SFB: valve closes

SFI: port 2.1 pressurized

Press the key in the MANUAL mode:

Venting of the actuator

SFA: valve closes

SFB: valve opens

SFI: port 2.2 pressurized

Hold down the key and simultaneously press the :

Fast pressurization

Hold down the key and simultaneously press the :

Fast venting

NOTE SFA: actuator closing by spring force

SFA: actuator opening by spring force

SFI: actuator with double action

Displays of the MANUAL mode:

The last display set in the AUTOMATIC mode is shown.

By selecting POS_XXX, the actual position of the valve actuator can be checked.

AUTOMATIC mode

88 - 8630

MANUAL mode

Valve closes at normal speed

Release key release

Valve closes fast

No operating action

(> 5 sec.)

Menu item

END

Configuration

Release key

Valve opens at normal speed release

Valve opens fast

PERATING THE PROCESS CONTROLLER

OPERATING THE PROCESS

CONTROLLER

Factory settings on the process controller

................................................................................................................................................

90 Setting up a process control system

..................................................................................................................................................................

90 Self-parametrization for positioner - X.TUNE

.......................................................................................................................................

91 Supplementary function P.CONTRL

.................................................................................................................................................................

91

Basic settings of the function P.CONTRL

.....................................................................................................................................................

P.Q’LIN - Starting the routine for linearization of the process curve

................................................................

105

Display during call-up and execution of the routine

......................................................................................................................

105

P.CO TUNE - Self-optimization of the process controller (process tune)

................................................

106 P.CO LEAK - Leakage characteristic for flow rate control

..............................................................................................

110 Operating the process

112

Changeover between the operating modes

...........................................................................................................................................

112

Operating mode AUTOMATIC

..................................................................................................................................................................................

113

Meaning of the keys

113

Displays

113

Operating structure and procedures

...............................................................................................................................................................

113

Manually changing the process setpoint

.................................................................................................................................................

114 Operating mode MANUAL

.............................................................................................................................................................................................

114

Meaning of the keys

114

Displays

115

Operating structure and procedures

...............................................................................................................................................................

115

8630 - 89

PERATING THE PROCESS CONTROLLER

Factory settings on the process controller

Factory setting Function

P.CONTRL

P.CO DBND

P.CO PARA

P.CO SETP

P.CO INP

P.CO FILT

P.CO SCAL

P.CO TUNE

P.CO KV

1 %

1.00

999.9

0.0

SETP INT

INP 4´20 A

PV 000.0,

PV 100.0

D’ACT

FACT

Function Factory setting

P.CONTRL with flow rate controller

P.CO DBND 1 %

P.CO PARA

KP 1.0

999.9, TN

0.0

P.CO SETP

P.CO INP

P.CO FILT

P.CO SCAL

SETP INT

INP P1’P2

PV 000.0, PV 100.0,

P.TYP

UNIT

TEMP

DENS

DIAM

P.CO TUNE

FLOW

M3/H,

MAN

1.293,

0025

D’ACT

P.CO KV FACT

NOTE The functions and factory settings shown in grey are valid for the optional flow rate control.

Setting up a process control system

In order to be able to operate the TOP Control Continuous as a process controller, you must execute the following steps:

➔ In all cases, carry out the self-parametrization for positioners ( X.TUNE).

➔

Via the configuration menu, add the supplementary function P.CONTRL to the main menu.

With the function P.CONTRL, the function P.Q'LIN is also inserted into the main menu.

➔ Call up the basic settings for the process controller under P.CONTRL.

Linearization of the process characteristic:

If you are dealing with a flow control system, the process characteristic can be linearized automatically:

➔ Initiate the function P.Q’LIN.

Self-optimization of the process controller

➔

Activate the function P.CO TUNE and initiate self-optimization of the PID parameters of the process controller.

Activate valve characteristic curve

➔ Initiate the function P.CO KV to activate the valve characteristic.

Read in leakage characteristic

➔ Initiate automatic determination of the leakage characteristic using the functions

P.CO LEAK ➔ P.CO MEAS .

ATTENTION!

In all cases, keep to the following sequence! X.TUNE

➔ P.Q’LIN ➔ P.CO TUNE

90 - 8630

PERATING THE PROCESS CONTROLLER

Self-parametrization of the positioner - X.TUNE

The description of the self-optimization of controllers is to be found in the chapter Operating and

Controller Functions / Commissioning and Setting Up as a Positioner / Main Menu for the Settings on

Commissioning / X.TUNE.

Supplementary function P.CONTRL

(see also the section „Operating the positioner - configuring the supplementary functions“)

Parametrization of the PID controller

8630 - 91

PERATING THE PROCESS CONTROLLER

Basic settings of the function

P.CONTRL

Parametrization of the process controller

Insensitivity range (dead band) of the PID process controller

Parameters of the PID process controller

Type of setpoint setting

Specification of the signal type for process actual value

Filtering of the process actual value input

Scaling of the process controller

Self-optimization of the process controller

(process tune) kv characteristic curve of process valve

Leakage characteristic for flow rate control

Storage of the new parameters

End of the parametrization

92 - 8630

PERATING THE PROCESS CONTROLLER

P.CO - DBND

Insensitivity range (dead band) of the process controller

Factory setting: 1% (refers to the span of the process actual value scaled by means of SCAL PV and PV )

This function assures that the process controller cuts in only above a certain control difference . The function reduces wear on the solenoid valves in the TOP Control Continuous and the pneumatic actuator.

Entering the dead band in %

Insensitivity range with process control

Process setpoint

(SP)

Control difference

Xd2

Process actual value

(PV)

Xd2'

Dead band

Xd2 to controller

Xd2'

8630 - 93

PERATING THE PROCESS CONTROLLER

P.CO - PARA

Parameters of the PID process controller

Gain factor of the process controller

0 ... 99.99 (factory setting 1.00)

Reset time

0.5 s ... 999.9 s (factory setting 999.9 s)

Rate time

0 s ... 999.9 s (factory setting 0 s)

Operating point

0.0 ... 100 % (factory setting 0 %)

NOTE For self-optimization of the PID parameters, see Step

The parameters entered should be noted in the table in the Appendix Tables for process controller.

For definition of the parameters of a PID controllers, see Appendix General rules.

P.CO - SETP

Type of setpoint setting (internal/external)

Setpoint setting internally via the keys on the TOP

Control Continuous.

Setpoint setting externally via the standard signal input.

94 - 8630

PERATING THE PROCESS CONTROLLER

P.CO - INP

Specification of the signal type for process actual value

Frequency signal (flow rate) 0 ... 1000 Hz

Connection with Pt100 (temperature)

- 20 °C ... + 220 °C

Configuration for flow rate controller - option standard signal current 4 ... 20 mA (flow rate, pressure, level)

P.CO - FILT

Filtering of the process actual value input

Factory setting: 0

Valid for all types of process actual value.

Filter has low-pass behavior (PT1).

Range: 0 ... 9

FILT XX

Setting in 10 steps: 0 ... 9

Setting in 10 steps

Setting

Corresponds to limiting frequency (Hz)

0.5

0.2

0.1

0.07

0.05

0.03

Effect minimum filtering maximum filtering

8630 - 95

PERATING THE PROCESS CONTROLLER

P.CO SCAL

Scaling the process controller on selection of analog input 4 ... 20 mA (P.CO INP 4 - 20 A)

XX.XX

Position of the decimal point for process actual value and setpoint (Setting range: 0..3)

Lower scaling value for process actual value (process value); the value is assigned to 4 mA. (*)

Upper scaling value for process actual value (process value); the value is assigned to 20 mA. (*)

Lower scaling value for process setpoint; the value is assigned to the smallest current or voltage value of the standard signal. (**)

Upper scaling value for process setpoint; the value is assigned to the largest current or voltage value of the standard signal.

(**)

(*) This setting determines the reference span for the dead-band of the process controller and the analog feedback of the process actual value (option).

(**) This setting is only active when P.CO SETP / SETP EXT is selected.

96 - 8630

PERATING THE PROCESS CONTROLLER

Example of scaling for 4 ... 20 mA input:

Process actual value from transmitter :

Process setpoint from SPS:

4 ... 20 mA corresponds 0 ... 10 l/min

4 ... 20 mA corresponds 0 ... 8 l/min

Scaling value

[l/min]

Process actual value

Process setpoint

Example for entering scaling values

Variant 1 Variant 2 Variant 3

1.0

0.8

10.0

8.0

100.0

80.0

Input signal

[mA]

NOTE

On entering small scaling values, decimal places are automatically added to increase the precision of display, such that the maximum possible digit range is given between the lower and upper scaling values in each case. The amplification factor KP of the process controller refers to the scaling values set.

With P.CO SETP / SETP INT (setpoint entry via the arrow keys), scaling of the setpoint via

SP and SP is not possible. The setpoint may be entered directly corresponding to the scaled process variable (PV , PV ).

8630 - 97

PERATING THE PROCESS CONTROLLER

P.CO SCAL

Scaling the process controller on selection of the frequency input

(P.CO INP FREQ)

NOTE On entry into this menu the valve is closed in order to have a well-defined starting conditions for execution of the teach-in function.

Unit l/s

Unit l/min

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

98 - 8630

PERATING THE PROCESS CONTROLLER

Position of the decimal point for process actual value and setpoint

(Setting range: 0 ... 3).

Lower scaling value for process actual value; the value is entered in the unit that subsequently selected for the flow rate. This setting determines the reference span for the dead-band of the process controller and the analog feedback of the process actual value (option).

Upper scaling value for process actual value; the value is entered in the unit that is subsequently selected for the flow rate. This setting determines the reference span for the dead-band of the process controller and the analog feedback of the process actual value (option).

Lower scaling value for process setpoint; the value is assigned to the minimum current or voltage value of the standard signal. This setting is active only when P.CO SETP / SETP EXT has been selected.

Upper scaling value for process setpoint; the value is assigned to the maximum current or voltage value of the standard signal. This setting is active only when P.CO SETP / SETP EXT has been selected.

Setting the desired unit of the flow rate

Manual entry of the K factor for the flow rate sensor

(e.g. from the data sheet for the flow rate sensor)

Position of the decimal point for the K factor (setting range: 0 ... 2)

K factor (setting range: 0 ... 9999)

8630 - 99

PERATING THE PROCESS CONTROLLER

Teach-In funktion:

Calibration of the k factor by measurement of a certain quantity of fluid.

Start of measurement

Open the valve. Close the valve when the tank is filled.

Use the arrow keys for opening and closing the valve. For this the valve must not be fully open.

End of measurement

Position of the decimal point for entry of the volume measured

(setting range: 0..3).

Enter the volume measured (setting range: 0..9999).

Unit as selected before under UNITXXXX.

Display of the calculated K factor.

100 - 8630

PERATING THE PROCESS CONTROLLER

P.CO SCAL

Scaling the process controller on selection of Pt 100 input

(P.CO INP PT100)

Position of the decimal point

(Setting range: 0... 3)

Lower scaling value for process actual value the value is entered in the unit that is subeequently selected for the flow rate. (*)

Upper scaling value for process actual value

the value is entered in the unit that is subsequently selected for the flow rate. (*)

Lower scaling value for external process setpoint the value is assigned to the minimum current or voltage value of the standard signal. (**)

Upper scaling value for process setpoint the value is assigned to the maximum current or voltage value of the standard signal. (**)

Setting the desired unit of temperature

Unit °C

Unit °F

(*) This setting determines the reference span for the dead-band of the process controller and the analog feedback of the process actual value (option).

(**) This setting is only active when P.CO SETP / SETP EXT is selected.

8630 - 101

PERATING THE PROCESS CONTROLLER

P.CO SCAL

Scaling the process controller on selection of the p

(P.CO INP P1’P2)

/p

input

Position of the decimal point

(Setting range: 0 ... 3)

Lower scaling value for process value -

The value is entered in the unit that is subsequently selected for the flow rate. (*)

Upper scaling value for process value -

The value is entered in the unit that is subsequently selected for the flow rate. (*)

Lower scaling value for external process setpoint The value is assigned to the minimum current or voltage value of the standard signal.

(**)

Upper scaling value for process setpoint The value is assigned to the maximum current or voltage value of the standard signal. (**)

Display of the flow rate As a transport velocity in m/s

(e.g. with bulk goods) or as a volumetric flow rate in m³

Temperature of the medium – Activate the temperature transmitter (optional) or enter the temperature value.

Temperature default value from the Master as process data output (for PROFIBUS DP or DeviceNet).

Medium density (kg/m³) under standard conditions

Diameter of piping in the pumping section (mm)

A dialog appears only when transport velocity (Velocity) has been selected as a process parameter.

(*) This setting specifies the reference range for the deadband of the process controller and for the analog display of the process value (option).

(**) This setting is active only when P.CO SETP/SETP EXT has been selected.

102 - 8630

PERATING THE PROCESS CONTROLLER

P.CO TUNE

Activating the self-optimization of the process controller (process tune)

Activate process tune

Select controlled member

NOTE Process tune is started in the operating mode AUTOMATIC.

Controlled member unknown

Flow rate control

Temperature control

Pressure control

Filling level control

P.CO KV

Display or enter kv characteristic curve of the process valve

(option flow rate controller)

Enter user-defined kv curve

Display factoryset kv curve

No. of places after the decimal point for entry of kv curve.

Display/enter kvs value in m 3 /h

Display/enter kv curve in %, referred to the kvs value

8630 - 103

PERATING THE PROCESS CONTROLLER

P.CO LEAK

Reading-in of the leakage characteristic (Flow rate control option)

Deactivate leakage characteristic

Activate leakage characteristic

Release

Start automatic determination of the leakage characteristic

*Show the leakage characteristic display

Reference points are displayed alternately as conveyance pressure in mbar and air flow or conveyance speed in m 3 /h or m/s respectively.

NOTE To interrupt the leakage determination, press both arrow buttons simultaneously and select

LEAK BRK.

104 - 8630

PERATING THE PROCESS CONTROLLER

P.Q’LIN

Starting the routine for linearization of the process curve

This function makes sense only when flow control is to be carried out.

➔ You start the routine for linearization of the process characteristic by calling up the menu item P.Q’LIN in the main menu and pressing the MANUAL/AUTOMATIC key for 5 seconds.

NOTE The function P.Q’LIN can only be started when the menu item P.CONTRL / P.COINP /

INP FREQ or item P.CONTRL / P.COINP / INP420 has been selected.

With the activation of the function P.CONTRL, the functions P.Q’LIN, which are required for process control, are copied into the main menu. Via these functions, the program is started for autonomous determination of the fixed points for a correction characteristic.

The program increases in 20 steps the valve stroke from 0 to 100 % and measures the associated process variables. The pairs of values of the correction characteristic are stored as a freely programmable characteristic under the menu item CHARACT/CHAFREE and may be viewed under this menu item.

If the menu item CHARACT was not transferred under the menu item ADDFUNCT to the main menu, this is done automatically on execution of the function P.Q’LIN. At the same time, the menu item

CHARACT/CHAFREE is activated.

Display during call-up and execution of the routine

Display

P.Q’LIN 5

P.Q’LIN 4

P.Q’LIN 0

¦ P.Q’LIN 0

¦ P.Q’LIN 1

¦ P.Q’LIN 2

¦ P.Q’LIN 3

P.Q’LIN.END

Q.ERR X.X

Description

Countdown from 5 to 0 for starting der Routine

Display of the fixed point that is being approached at the moment

(der Fortgang wird durch einen sich drehenden Balken am linken

Rand des Displays angezeigt)

(flashing) End of routine

Message on occurrence of an error

(shown on the right is the error number - see chapter Maintenance process controller)

8630 - 105

PERATING THE PROCESS CONTROLLER

P.CO TUNE

Self-optimization of the process controller (process tune)

The control system TOP Control Continuous is equipped with a positioner which if required can be supplemented by a superimposed process controller (see chapter: Operation as a Process Controller).

The positioner controls the position of the process valve to the desired setpoint and is automatically parametrized and optimized by the X.TUNE function.

The superimposed process controller, which together with a sensor forms a process control loop, can control any process parameter. It has a PID structure whose components may be combined in various ways (P, PI, PD, PID), and freely parametrized (KP, TN, TV).

In order to obtain good control behaviour, the structure of the controller must be adapted to the characteristics of the process (controlled member). The parameters must be chosen to obtain a short setting time, a small overshoot width and good damping.

Parametrization demands experience in control tecnique, measuring equipment and is time consuming.

For this reason, TOP Control Continuous has a self-optimization function P.TUNE. This function provides an unique, direct determination of the parameters. The results may be read out as needed and modified in any way desired.

METHOD OF OPERATION

During commissioning of the control system, the process is excited by a step in the setpoint in a closed control loop. This step is carried out within the future working range of the process control system and serves to determine characteristic variables of the process. Calculation of the PID controller parameters is carried out on the basis of these characteristic variables by use of a modified Ziegler-Nichols procedure.

SETPOINT MODULATOR

In addition to optimization of the PID parameters, a setpoint modulator (filter) is calculated for the reduction of unwanted non-linear effects. Such effects may arise because of physical limitation of the correcting variables and the floating time of the control valve.

The setpoint modulator further improves the control behaviour. It is activated as long as the P.TUNE

function is activated in the operating menu of the TOP Control Continuous ( P.TUN ACT ). When the function P.TUNE is deactivated in the operating menu ( P.TUN D’ACT ) after completion of selfoptimization, the process is controlled with the optimized PID parameters and the setpoint modulator is deactivated.

ATTENTION!

Be sure to comply with the sequence ... on setting up the process control system!

106 - 8630

PERATING THE PROCESS CONTROLLER

Operation

To carry out self-optimization (process tune) on the process controller, proceed as follows with the steps

... described.

NOTE All operating steps for the execution of process tune are performed on the spot using the operating elements (keypad and display) of the TOP Control Continuous.

Step - Activate process tune

You are in the menu item P.CONTROL in the configuration level of the TOP Control Continuous.

Activate process tune on the process controller P.TUN ACT and select the process type corresponding to your control job.

If the process is unknown, enter P.TYP N.DEF (not defined).

Activate process tune

Select the controlled member

Controlled member unknown

Flow rate control

Temperature control

Pressure control

Filling level control

Change to the process operation level by leaving the configuration level via the menu item END X.XX

and switching the device to the operating mode AUTOMATIC (yellow LED in the MANUAL/AUTOMATIC key flashes).

8630 - 107

PERATING THE PROCESS CONTROLLER

Step - Process tune ready to start

You are in the process operating level in the AUTOMATIC mode (yellow LED in the MANUAL/

AUTOMATIC key flashes).

Make ready process tune by the following operating procedure:

Make ready P.TUNE

(process tune) process tune ready process tune not ready

The next setpoint step entered via the keypad (see Step ) is now used for parameter optimization. The setpoint SP is set equal to the actual sensor value PV and is the starting value for the optimization step.

Adaptation/modification of this starting value is described in Step .

Readiness of process tune is symbolized int he display by three horizontal bars behind the flashing setpoint symbol SP.

Step - Adaptation of the starting value for the optimization step (optional)

If required you can carry out an adaptation of the starting value for the optimization step. Switch the device to the MANUAL mode (LED in the MANUAL/AUTOMATIC key is off). By pressing the arrow keys, open or close the process valve, which causes a corresponding change in the process value PV. As soon as the desired starting value is set, switch the device back to the AUTOMATIC mode.

Step - Initiate process tune

You are in the process operating level in the AUTOMATIC mode (yellow LED in the MANUAL/

AUTOMATIC key flashes).

Process tune is now initiated by entering via the keypad a setpoint step. This step should take place in the future working range of the process control system.

The procedure is as follows: or

> 3 s or

With the display SP (setpoint) set, press one of the arrow keys for longer than 3 seconds to activate the mode for changing the process setpoint. After release of the key, the first digit of the process setpoint flashes.

Set the value of the flashing digit of the process setpoint SP.

Confirm the value set and move to the next digit. After confirmation of the fourth digit, the process setpoint set is stored as the end value of the process setpoint step.

108 - 8630

PERATING THE PROCESS CONTROLLER

NOTE

The setpoint step for parameter optimization must always be entered via the operating keypad. This also applies when, on configuration, the function P.CONTRL / P.CO SETP /

SETP EXT (setpoint setting via analog input) is specified. In this case, the external setpoint setting is reactivated only after completion of process tune.

Self-optimization of the process controller now runs automatically. The display shows a rotating bar and the message P.TUNE. After completion of process tune, the device is in the AUTO mode. The process controller works from this point on with the optimized PID parameters and controls to the current, internal or external setpoint SP.

To execute a new optimization cycle, repeat Steps ... .

NOTE The Process Tune in the conrol menu of the TOP Control Continuous remains active, so that the process control takes place with the Set-value-Modulation (Filer) for the reduction of unwanted, non-linear effects. If the control will be carried out without the Set-value-Modulator, the process tune in the control menu must be deactivated: P.CONTRL / P.CO TUNE / P. TUN

D´ACT

To stop the self-optimization, press both arrow keys at the same time and select

P.TUN BRK.

8630 - 109

PERATING THE PROCESS CONTROLLER

P.CO LEAK Leakage characteristic for flow rate control (Flow rate control option)

The program function P.CO LEAK enables air leakage compensation, which increases the accuracy of the flow rate control.

Background: during transport of pourable solids, there arises at a cellular wheel sliuce an air leakage dependent on the pressure. The air flow through the controller unit is the sum of this leakage and the air flow of the conveying pipe.

QFMR = Q air leak

+ Q conv. pipe

To achieve an air leakage compensation, an air leakage characteristic must be read-in once with the conveying pipe closed.

Reading-in of the leakage characteristic

Boundary conditions

For exact measurement of the leakage, the system should be started up in the normal mode.

However, the following exceptions apply:

•

The conveying pipe must be closed off behind the components causing the leak.

•

The material to be transported is omitted.

ATTENTION!

•

In the case of pneumatic conveying of pourable solids with a rotary valve, the following must be observed:

•

The conveying pipe must be closed off behind the rotary valve.

•

The rotary valve must be empty and run at the nominal rpm..

•

Measures for sealing the system (e. g. blocking air that enters from above into the rotary valve) must be connected.

•

The compressor must be switched on.

Measurement and reading-in of the leakage characteristic

Select program to initiate automatic recording of leakage characteristic using

P.CONTRL

P.CO LEAK P.CO MEAS menu

Press and hold the button for 5 seconds.

The leakage characteristic is now automatically captured and read-in.

Display

TUNE 5

TUNE 4

TUNE 0

LEAK IN

LEAK PO

LEAK OPN

LEAK PAR

LEAK END

L.ERR X

Description

Countdown from 5 to 0 to the start of leakage determination

Display of the momentarily running phase of leakage determination

(progress is indicated by a rotating beam at the left hand edge of the display)

Display flashes. Leakage determination successfully completed

Display on occurrence of an error (display on the right: error number, see chapter Maintenance and Troubleshooting in the controller manual)

NOTE Press both buttons simultaneously to interrupt the determination of the characteristic and select LEAK BRK .

110 - 8630

PERATING THE PROCESS CONTROLLER

Program sequence

•

The control valve is closed.

•

After 10 sec settling time, the admission pressure at the controller unit (FMR) is registered.

NOTE Scaling of the x-axis of the leakage characteristic is based upon this pressure value. The upper limit is this value times a factor of 0.85

Up to 21 reference points are determined.

Example: at an admission pressure of 2.0 bar, the characteristic curve is obtained from 0 to

1.7 bar in 85 mbar steps.

•

The control valve is slowly opened in a ramp time of 60 sec.

•

Parallel to this, the conveyance pressure (pressure at the outlet side of the FMR) is monitored.

For each reference point of the characteristic, the conveyance pressure and the air flow are registered.

•

Reading in is complete when after 60 sec the contol valve is fully open, or the conveyance pressure previously reaches the uper limit of the scaling.

•

Air leakage compensation is now activated. The process value is now obtained from the difference between the measured air flow and the air leak rate calculated from the characteristic:

Q conv. pipe

= Q

FMR

- Q air leak

Deactivate leakage characteristic

Activate leakage characteristic

Release

Start automatic determination of the leakage characteristic

*Show the leakage charateristic display.

* Reference points are displayed alternately as conveyance pressure in mbar and air flow or conveyance speed in m 3 /h or m/s respectively.

Deactivation of the characteristic curve

The leakage characteristic that has been read-in can be deactivated using the function LEAK D'ACT in the

P.CO LEAK menu.

8630 - 111

PERATING THE PROCESS CONTROLLER

Operating the process

Each time after switching on the voltage supply, the TOP Control Continuous is automatically in the process operating level. To change to the process operating level from the configuration level, confirm the menu item END by pressing the MANUAL/AUTOMATIC key.

In the process operating level, normal controlled operation is executed and monitored (in the

AUTOMATIC mode), and the valve opened or closed by hand (MANUAL mode).

Switching between the operating modes

5 sec

Operate the MANUAL/AUTOMATIC key to switch between the MANUAL and

AUTOMATIC modes.

Operating mode

AUTOMATIC

MANUAL

Yellow LED in the

MANUAL/AUTOMATIC key flashes

Display off -

An apostrophe (') runs continuously from left to right.

112 - 8630

PERATING THE PROCESS CONTROLLER

Operating mode AUTOMATIC

In the AUTOMATIC mode, normal controlled operation is executed and monitored.

Meaning of the keys

or Switch over the display or

> 3 sec and

Change the process setpoint

With configured supplementary functions P.CONTRL/P.CO SETP/SETP INT and SP display set.

Make P.TUNE (process tune) ready for start.

With PID self-optimization activated, P.CONTRL/P.CO TUNE/ P.TUN ACT

Displays

With the process controller activated, the following parameters can be displayed:

• Actual value of process variable (process value) PV_____ (- 999 ... 9999)

• Setpoint of process variable (process setpoint) SP_____ (- 999 ... 9999)

• Setpoint position of valve actuator after rescaling through optionally activated split-range function or correction curve

• Temperature inside housing of the TOP Control Continuous

CMD __XXX (0 ...100 %)

TEMP__XX.X (in °C)

By pressing the arrow keys, you can switch between these display options.

Operating structure and procedures

PV_____

SP_____

POS__XXX

CMD __XXX

TEMP__XX.X

AUTOMATIC mode

Switch over display

Configuration

Menu item

END and

P.TUNE

(process tune) ready for start or

Release key

(> 5 s)

No operating action

SP active or

(> 3 s)

Set the process setpoint

Release key

P.TUNE

(process tune)

MANUAL mode

NOTE If the device is in the safety position (for the relevant configuration, see menu item BIN-IN or SIG-ERR), SAFE XXX appears in the display.

If the menu item CUTOFF is activated and the process vave is in the tight-closing range, a flashing MIN or MAX symbol appears in the display.

If the process value ( PV) is above or below the measurement range, a flashing bar appears in the display.

8630 - 113

PERATING THE PROCESS CONTROLLER

Manually changing the process setpoint

> 3 sec or

If the supplementary function P.CONTRL / P.CO SETP / SETP INT (setting of the setpoint via keys) was specified on configuration, then with the display

SP set (setpoint) and on pressing one of the arrow keys for longer than 3 seconds, the mode for changing the process setpoint can be activated. After release of the key, the first digit of the process setpoint flashes.

The first digit of the process setpoint can be set.

After confirmation with the MANUAL/AUTOMATIC key, the set value is stored.

In the same manner, the other digits are set. After confirmation of the last digit, the display returns to the previous mode.

Operating mode MANUAL

(yellow LED off)

In the manual mode, the valve can be opened and closed by hand.

Meaning of the keys in the MANUAL mode:

+

Press the key in the MANUAL mode:

Pressurization of the actuator

SFA: valve opens

SFB: valve closes

SFI: port 2.1 pressurized

Press the key in the MANUAL mode:

Venting of the actuator

SFA: valve closes

SFB: valve opens

SFI: port 2.2 pressurized

Hold down the key and simultaneously press the :

Fast pressurization

Hold down the key and simultaneously press the :

Fast venting

NOTE SFA: actuator closing by spring force

SFA: actuator opening by spring force

SFI: actuator with double action

114 - 8630

PERATING THE PROCESS CONTROLLER

Displays

The last display set in the AUTOMATIC mode is shown.

By selecting PV_XXX, the actual value of the process variable can be checked.

To display the actual position of the valve actuator during MANUAL operation, change to the display

POS_XXX in advance in the AUTOMATIC mode.

Operating structure and procedures

AUTOMATIC mode

MANUAL mode

Valve closed at normal speed

Release key

No operating action

Release key

Valve opens at normal speed

Valve closes fast release (> 5 sec.)

Menu item

END

Configuration

Valve opens fast release

8630 - 115

PERATING THE PROCESS CONTROLLER

116 - 8630

ROFIBUS

PROFIBUS DP

General notes

118 Technical data

118 Safety settings on bus failure

....................................................................................................................................................................................

118 Interfaces

119 Electrical connections

119

Connection with one plugged bus connector

.......................................................................................................................................

119

Connection with 2 plugged bus connectors

...........................................................................................................................................

120

Operating voltage (circular plug M12)

...........................................................................................................................................................

120

Bus connection (circular socket M12)

..........................................................................................................................................................

120

Inductive proximity switches (circular socket M8)

........................................................................................................................

121

Process value (circular plug M8)

.........................................................................................................................................................................

121

Termination connection for Profibus systems

.....................................................................................................................................

122

Settings on the TOP Control Continuous

................................................................................................................................................

123

Explanation of the menu items

................................................................................................................................................................................

124

Functional deviations from the standard version

.........................................................................................................................

124 Configuration in the PROFIBUS DP master

......................................................................................................................................

125

Configuration of the process values

................................................................................................................................................................

125

Bus status display

127 Example 1 with COM-Profibus V3.3

...............................................................................................................................................................

128

Example for a positioner

.................................................................................................................................................................................................

128

Example 2 with COM-Profibus V3.3

...............................................................................................................................................................

131

Example for a process controller

.........................................................................................................................................................................

131

8630 - 117

ROFIBUS

General notes

he following functions are invalid for the TOP Control Continuous with PROFIBUS DP:

• INPUT

• CAL.USER / CAL INP

• CAL.USER / CAL OUT

• CAL.USER / CAL SP

Technical data

The protocol sequence corresponds to DIN 19245 Part 3.

GSD file

Bitmap files

PNO-ID

Baud rate

Sync and freeze mode

Diagnosis telegram

Parameter telegram

BUERC630.GSD

BUEC630.DIB

BUEC630N.BMP (for Siemens COM-PROFIBUS)

BUEC630D.BMP (for Siemens COM-PROFIBUS)

C630 Hex max. 1.5 Mbaud

(automatically set by TOP Control Continuous) not supported no device-specific diagnosis no user parameters

Configuration of the process data is performed in the TOP Control and in the PROFIBUS Master.

A maximum of 10 process values (sum of input and output) can be transferred.

Safety settings on bus failure

The actuator moves to the position corresponding to the setpoint last transmitted (default setting).

For other setting options (see the chapter Settings on the TOP Control Continuous)

118 - 8630

ROFIBUS

Interfaces

Bus

Inputs for process actual value

4 ... 20 mA

Frequency

Pt 100

Bus

Initiators 1-2

24 V DC

Operating unit

Electrical connections

For operating the device it is imperative to connect the 5-pole, inverse-coded M12 circular socket connector and the 4-pole M12 circular plug connector (voltage supply).

Connection with one plugged bus connector

M8 plug,

4-pole

(process value)

M12 plug

4-pole

(operating voltage)

M12 socket

5-pole inverse coded

(Profibus DP)

M8 socket,

4-pole

(initiators)

8630 - 119

ROFIBUS

Connection with 2 plugged bus connectors

M12 plug,

5-pole inverse coded

(Profibus DP)

M12 socket,

5-pole inverse coded

(Profibus DP)

M12 plug,

4-pole

(operating voltage)

Operating voltage (circular plug M12, 4-pole)

External connection Pin

Allocation

+ 24 V not connected

GND not connected

Bus connection (circular socket/plug M12, 5-pole)

Pin Signal

1 VP+5

Meaning

Supply for terminating resistors

2 RxD/TxD-N Received/transmitted data (minus)

3 DGND Data transmission potential (mass to 5 V)

4 RxD/TxD-P Received/transmitted data (plus)

5 Screen Screen/protective earth (ground)

120 - 8630

ROFIBUS

Inductive proximity switches (circular socket M 8)

Signal level Pin

Allocation

Proximity switch 1 + (NO)

Proximity switch 1 GND

Proximity switch 2 + (NO)

Proximity switch 2 GND

Process value (circular plug M 8)

Input type *

4 ... 20 mA

- internally

supplied

4 ... 20 mA

- externally

supplied

Frequency

- internally

supplied

Frequenz

- externally

supplied

Pt-100

(see

Note below)

Pin Assignment

+ 24 V input transmitter output transmitter

GND bridge after GND not assigned process actual + not assigned process actual -

+ 24 V - sensor supply clock input + clock input - (GND) not assigned

Jumper** external circuit

+(4..20 mA)

GND

+24 V clock + clock not assigned clock input + clock input not assigned not assigned process actual 1 (current supply) process actual 3 (GND) process actual 2 (compensation)

4 clock + clock -

Pt 100

* Adjustable via software (see chapter Procedure for determining the basic settings)

** The jumper is located on the connector board of the TOP Control Continuous.

NOTE For line compensation reasons, connect sensor Pt-100 via 3 conductors, PIN 3 and PIN 4 must be bridged at the sensor.

8630 - 121

ROFIBUS

Termination connection for PROFIBUS systems

On installation of a PROFIBUS system, care must be taken to terminate the data lines correctly. The termination generates a well-defined potential state and avoids the occurrence of disturbances by signal reflections on the data lines. For this purpose, the data lines must be terminated at both ends by resistors as shown.

122 - 8630

ROFIBUS

Settings on the TOP Control Continuous

In deviation from the details in the enclosed operating instructions, the following settings must be made in the main menu of the device:

On activation, moves to,

safety position

8630 - 123

ROFIBUS

Explanation of the menu items

BUS ADDR

ADDR xxx

Entry of the device address (default: 3)

Values from 0 to 126 can be set with the arrow keys; confirmation is done with the MANUAL/AUTOMATIC key.

BUS PDI

* PDI. POS

* PDI. ERR

Selection of the process values that are to be transferred from the TOP Control

Continuous to the control (master).

with the MANUAL/AUTOMATIC key, each process value can be either activated (* appears) or deactivated (no * )

For significance of the process values, see table PDI: Process Data Input

BUS PDO

* PDO. INP

* PDO. ERR

Selection of the process values that are to be transferred from the control

(master) to the TOP Control Continuous.

With the MANUAL/AUTOMATIC key, each process value can be either activated (* appears) or deactivated (no * ).

For significance of the process values, see table PDO: Process Data Output

BUS FAIL

SPOS OFF

SPOS ON

Activation for movement to saftey position on bus communication failure

The actuator moves to the position corresponding to the setpoint last transmitted

(default setting).

With SPOS ON set, the following configurations can occur:

Activated menu item SAFEPOS

On error in bus communication, the actuator moves to the position set under

SAFEPOS.

Deactivated menu item SAFEPOS

On error in bus communication, the actuator moves to the end position it would occupy in the zero voltage condition.

Functional deviations from the standard version

The operating mode can be switched between MANUAL and AUTOMATIC in the process operating level either with the keypad on the TOP Control Continuous or over the bus.

MANUAL/AUTOMATIC switchover on the keypad is no longer possible when an operating mode (under

“PDO MODE”) is transmitted to the TOP Control Continuous over the bus.

124 - 8630

ROFIBUS

Configuration in the PROFIBUS DP master

User parameters (hex paramaters) are not required.

Configuration of the process values

First the process data input are entered (from the TOP Control Continuous to the control).

NOTE In the same order as in the selection in the TOP Control Continuous and only process data ( PDI) activated in the configuration menu may be entered.

PDI : Process Data Input

(from the TOP Control Continuous to the control)

Name

PDI:POS

PDI:CMD

PDI:PV

PDI:SP

Description

Actual position (Position)

Actual value of positioner in ‰.

Range of values 0 ... 1000.

Values < 0 or > 1000 are possible when e.g.

AUTOTUNE was not run throug properly.

Setpoint position (Command)

Positioner setpoint in ‰. Range of values 0 ... 1000.

Identifiers

GSD file: PDI:POS

Identifiers (HEX): 41, 40, 00

GSD file: PDI:CMD

Process actual value (Process Value)

Actual value of process controller in physical units

(as set in menu P.CO INP or P.CO SCAL ), max.

range of values -999 ... 9999, depending on internal scaling

Process setpoint (Setpoint)

Setpoint of value of process controller in physical units

(as set in menu P.CO INP or P.CO SCAL ), max. range of values -999 ... 9999, depending on internal scaling

Identifiers (HEX): 41, 40, 01

GSD file: PDI:PV

Identifiers (HEX): 41, 40, 02

GSD file: PDI:SP

Identifiers (HEX): 41, 40, 03

PDI:TEMP

PDI:MODE

PDI:ERR

Device temperature (Temperature)

Temperature in 0.1 °C is measured on the CPU board with a sensor, range of values -550 (-55 °C) ... +1250 (+125 °C)

GSD file: PDI:TEMP

Identifiers (HEX): 41, 40, 04

Operation mode (Operation Mode)

Operation mode:

0: AUTO 10: P.TUNE

1: HAND 12: BUSSAFEPOS

2: XTUNE

3: MENUE

9: P.QLIN

GSD file: PDI:Mode

Identifiers (HEX): 41, 00, 05

Error (Error)

States the number of the process value (output) that was not written. The value is retained until deleted with

PD-O:ERR .

HEX

14 PD-O:CMD

15 PD-O:SP

16 PD-O:MODE

GSD file: PDI:ERR

Identifiers (HEX): 41, 00, 06

8630 - 125

ROFIBUS

PDI : Process Data Input (continued)

(from the TOP Control Continuous to the controller)

Name

PDI:P1

PDI:P2

PDI:MTMP

Description

Forward pressure p1

Pressure in mbar (rel) that is present in front of the process valve.

The value will be determined using a pressure transmitter.

Value range -1013 ... +16000

Back pressure p2

Pressure in mbar (rel) that is present behind the process valve.

The value will be determined using a pressure transmitter.

Value range -1013 ... +16000

Medium temperature

Temperature of the medium in °C. The value will be predefined from the menu, the bus, or using a temperature transmitter.

Value range -20 ... +150

NOTE

Identifiers

GSD file: PDI:P1

Identifiers (HEX): 41, 40, 07

GSD file: PDI:P2

Identifiers (HEX): 41, 40, 08

GSD file: PDI:MTMP

Identifiers (HEX): 41, 40, 09

PDI. PV and PDI. SP can only be selected if the process controller has been activated.

PDI.P1/P2/MTMP can only be selected if the fluid flow controller option is active.

Finally, the process data output (from the controller to the TOP Control Continuous) is entered.

NOTE In the same order as in the selection in the TOP Control Continuous and only process data

( PDI) activated in the configuration menu may be entered.

The updating of the process data output only takes place in the MANUAL and

AUTOMATIC modes.

126 - 8630

ROFIBUS

PDO : Process Data Output

(from the control to TOP Control Continuous)

Name

PDO:INP

Description

Set position (Input)

Set-value positioner in ‰, value range 0 ... 1000.

In the "pure" positioner operation (PCONTRL inanctive), the transmission of the set position INP is required, as process controller ( PCONTRL active), the transmission of

INP is not possible.

If the value is too small or too large, the last valid value will be used and will be displayed in ERR with HEX 14.

PDO:SP Process-set-value (Set-point)

Set-value process controller in physical unit (as set up in the P.CO INP or P.CO SCAL menu), max. value range

-999 ... 9999, depending on the internal scaling.

If the value is too small or too large, the last valid value will be used and will be displayed i n ERR with HEX 15.

PDO:MODE Operation Mode

Value range 0 ( AUTO ) ... 1 ( MANUAL ) ...

12 ( BUSSAFEPOS )

Operation mode:

0: AUTO 12: BUSSAFEPOS

1: HAND

If the value is too small or too large, the last valid value will be used and will be displayed in ERR with HEX 16.

PDO:ERR Reset of error message

If the value > 0, ERR is reset.

Identifiers

GSD file: PDO:INP

Identifiers (HEX): 81, 40, 14

GSD file: PDO:SP

Identifiers (HEX): 81, 40, 15

GSD file: PDO:MODE

Identifiers (HEX): 81, 00, 16

GSD file: PDO:ERR

Identifiers (HEX): 81, 00, 17

GSD file: PDO:MTMP PDO:MTMP Medium temperature

Temperature of the medium in °C. The value will be predefined from the menu, the bus, or using a temperature transmitter.

Value range -20 ... +150

If the value is too small or too large, the last valid value will be used and will be displayed in ERR with HEX 18.

Identifiers (HEX): 81, 40, 18

NOTE PDO. INP is always active with the positioner, not present with process conroller.

PDO. SP can only be selected if the process controller is activated.

PDO. MTMP can only be selected if the fluid flow controller option is active.

Bus status display

The bus standard is indicated on the display.

Display message

BUS OFFL alternates with the display value set

Device status offline

Explanation/problem elimination

Device is no connection to the bus

- bus connection incl. plug configuration correct?

- voltage supple and bus connection of the other

subscribers correct?

Device is engaged in cyclic data exchange 4 dots to the left beneath the display value set online, active connection

8630 - 127

ROFIBUS

Example 1 with COM Profibus V3.3

Example for a positioner

Settings in the configuration menu of the TOP Control Continuous:

ADDR: 3 PDI:

• PDI:POS

• PDI:MODE

PDO:

• PDO:INP

• PDO:MODE

After starting COM Profibus and the setting of master and SPS information, one gets the following screen:

• Select CONTROLLER

• Set an element under the control

• Set the 3rd address in the menu address (without image)

• Confirm with OK

The following screen appears:

• Select CONTROLLER family

• Select Type 8630

• Select Configuration ...

128 - 8630

The following screen appears:

• Select Order no. ...

The following screen appears:

ROFIBUS

Here the process values are entered corresponding to the selection in the configuration menu of the TOP

Control Continuous.

Important: 1. Observe sequence of process values

2. Input before output

• Select process value PDI:POS

• Select process value PDI:MODE

• Select process value PDO:INP

• Select process value PDO:MODE

- Enter inputs and outputs in the process diagram.

8630 - 129

ROFIBUS

Final configuration screen:

130 - 8630

Example 2 with COM Profibus V3.3

Example for a process controller

Settings in the configuration menu of the TOP Control Continuous:

ADDR: 3 PDI:

• PDI:PV

PDO:

• PDO:SP

Procedure as in Example 1.

Final configuration screen:

ROFIBUS

8630 - 131

ROFIBUS

132 - 8630

EVICE

DEVICE-NET

General notes

134 Explanation of terms

134 Technical data

135 Safety settings on bus failure

....................................................................................................................................................................................

135 Interfaces

136 Electrical connection

136

Operating voltage (4-pole M12 circular plug)

.......................................................................................................................................

137

Bus connection (4-pole M12 circular plug)

..............................................................................................................................................

137

Inductive proximity switches (4-pole M8 circular socket)

....................................................................................................

137

Process value (circular plug M8)

.........................................................................................................................................................................

137

Termination connection for DeviceNet systems

...............................................................................................................................

138

Net topology of a DeviceNet system

..............................................................................................................................................................

138

Settings on the TOP Control Continuous

................................................................................................................................................

139

Explanation of the menu items in the program run-off schematic

..............................................................................

139

Setting in the main menu

.................................................................................................................................................................................................

140

Configuring the process data

....................................................................................................................................................................................

141

Static input assemblies

.....................................................................................................................................................................................................

141

Static output assemblies

.................................................................................................................................................................................................

143

Bus status display

144 Configuration example 1

..................................................................................................................................................................................................

145

Installation of the EDS file

.............................................................................................................................................................................................

145

Address allocation

145

Offline parametrization of the device

..............................................................................................................................................................

146

Online parametrization of the device

..............................................................................................................................................................

147

Configuration example 2

..................................................................................................................................................................................................

148

Setting up the process map (mapping)

........................................................................................................................................................

149

8630 - 133

EVICE

General notes

The following sections of the complete operating instructions are not applicable to the DeviceNet variant of the TOP Control Continuous 8630:

• Variants of the TOP Control Continuous

• First commissioning

• Electrical connection

• Defining the basic settings

Function INPUT

Function SPLTRNG

Function BIN-IN

Function OUTPUT

Function CAL.USER / CAL INP

Function CAL.USER / CAL OUT

Function CAL.USER / CAL SP

Explanation of terms

DeviceNet

• DeviceNet is a field bus system based on the CAN protocol (Controller Area Network). It permits the networking of actuators and sensors (slaves) with higher ranking control devices (masters).

• In the DeviceNet the TOP Control Continuous is a slave device according to the Predefined Master/

Slave Connection Set defined in the DeviceNet specification. Polled I/0, Bit Strobed I/O and Change of

State (COS) are supported as I/O connection variants.

• With the DeviceNet a distinction is made between cyclic or event-controlled transferred process messages of high priority (I/O Messages) and acyclic management messages of low priority (Explicit

Messages).

• The protocol sequence corresponds to DeviceNet Specification Release 2.0.

134 - 8630

EVICE

Technical data

EDS file

Icons

Baud rate

Adress

Process data

BUER8630.EDS

BUER8630.ICO

125 kBit/s, 250 kBit/s, 500 kBit/s (adjustable via keys at the device or via network);

Factory setting 125 kBit/s

0 ... 63; (adjustable via keys at the device or via network);

Factory setting 63

7 static Input Assemblies

(Input: from TOP Control Continuous to DeviceNet Master/Scanner)

4 static Output Assemblies

Total line length according to DeviceNet specification

(Total line length = sum of all mein and drop lines)

Baud rate

125 kBaud

250 kBaud

500 kBaud

Thick Cable

500 m

250 m

100 m

Maximum total line length

Thin Cable

100 m for all baud rates

Drop line length (Drop Lines)

Baud rate

Maximum length

6 m for all baud rates 125 kBaud

250 kBaud

500 kBaud

Length of drop lines

Maximum total length of drop lines in network

156 m

78 m

39 m

Safety settings on bus failure

The actuator moves to the position corresponding to the setpoint last transmitted (default setting).

For other setting options (see the chapter Settings on the TOP Control Continuous)

8630 - 135

EVICE

Interfaces

Bus

Inputs for process value

4 .. 20 mA

Frequency

Pt 100

24 V DC

TOP Control

Continuous

DeviceNet

Bus

Initiators 1 + 2

Operating unit

Electrical connection

For operation of the device, it is absolutely necessary to connect the 5-pole (bus) and the 4-pole circular plugs M12 (voltage supply).

NOTE Voltage supply to the device is not from the DeviceNet voltage V+ and V-m but from the electrically isolated operating voltage.

136 - 8630

Operating voltage (4-pole M12 circular plug)

Pin

Assignment

+24 V not assigned

GND not assigned external circuit

Bus connection (4-pole M12 circular plug)

Pin

Signal screen

V+

V-

CAN H

CAN L

Color not assigned red black white blue

Inductive proximity switches (4-pole M8 circular socket)

Pin

Assignment proximity switch 1 + (NO) proximity switch 1 GND proximity switch 2 + (NO) proximity switch 2 GND

Signal level

Process value (circular plug M8)

Input type *

4...20 mA internally supplied

4...20 mA externally supplied

Pin Assignment

+ 24 V input transmitter output transmitter

GND bridge after GND

2 not assigned process actual + not assigned process actual -

* adjustable via software

Jumper external circuit

EVICE

8630 - 137

EVICE

Process value (circular plug M8, continuation)

Input type * Pin Assignment

Frequency internally supplied

+ 24 V supply sensor clock input + not assigned clock input - / GND

Frequency externally supplied

Pt-100 (see

Note) 3

2 not assigned clock input + not assigned clock input not assigned process actual 1 (current supply) process actual 2 (GND) process actual 3 (compensation)

Jumper

* adjustable via software external circuit

Pt100

NOTE For line compensation reasons, connect sensor Pt-100 via three conductors. PIN3 and 4 must be bridged at the sensor.

Actual process value for the fluid flow controller option (2 M8 round plugs), or optionally: with temperature sensor input (3 M8 round plugs)

Input type internally supplied transmitter * option: temperature transmitter*

Plug

Pin Assignment

3 + 4

+ 24 V transmitter supply p1

4 ... 20 mA - transmitter output p1 not assigned

3 + 4

+ 24 V - transmitter supply p2

4 ... 20 mA - transmitter output p2 not assigned

2 + 4

+ 24 V transmitter supply

4 ... 20 mA - output transmitter temperature not assigned

* With external supply of the sensors the mass of the standard signal must be connected with the mass of supply voltage.

Jumper external circuit

Termination connection for DeviceNet systems

On installing a DeviceNet system, it is important to have the correct termination circuit for the data lines.

The circuit avoids the occurrence of faults through signal reflections on the data lines. For this purpose the main line is to be terminated at both ends with resistors of respectively 120 Ω and 1 / 4 W power loss.

138 - 8630

Net topology of a DeviceNet system

Comprises a trunk line and several drop lines.

Trunk and drop lines are composed of identical material (see drawing).

EVICE

Settings on the TOP Control Continuous

Explanations of the menu items in the program run-off schematic

BUS ADDR

ADDR XXX

Input of the device address (factory setting: 63)

The address can be changed via the keys at the device or via the bus. After each change, all Connection Objects are deleted followed by the execution of the normal

Start-Up procedure for network access by a subscriber (as after a Reset or Power-

Up).

Values from 0 .. 63 can be set via the arrow keys; confirmation takes place with the

MANUAL/AUTOMATIC key.

BUS RATE

KBD XXX

The baud rate can be changed via the keys at the device or via the bus. In each case a change has no effect until a Reset (transmission of a Reset message to the

Identity Object) or a Power-Up is performed. That is to say, if the changed attribute baud rate is accessed before a Reset or Power-Up, the entered (changed) value does not agree with the still current (to be changed) baud rate of the network.

Selection of 125kbit/s, 250 kbit/s or 500kbit/s.

BUS FAIL

SPOS OFF

SPOS ON

Activation for movement to saftey position on bus communication failure

The actuator moves to the position corresponding to the setpoint last transmitted

(default setting).

With SPOS ON set, the following configurations can occur:

Activated menu item SAFEPOS

On error in bus communication, the actuator moves to the position set under

SAFEPOS.

Deactivated menu item SAFEPOS

On error in bus communication, the actuator moves to the end position it would occupy in the zero voltage condition.

8630 - 139

EVICE

Settings in the main menu

The following settings are to be made in the main menu of the device, at variance with the statements in these operating instructions:

Operating status

AUTOMATIC or

MANUAL

5 sec.

On activation, moves to,

safety position

140 - 8630

5 sec.

EVICE

Configuration the process data

5 static input and 2 static output assemblies are available for the transmission of process data via an

I/O connection. Select attributes for transmission jointly as process data via an I/O connection are combiened in an object in these Assemblies.

Selection of the process data takes place by setting the device parameters Active Input Assembly and

Active Output Assembly, or where supported by the DevicNet Master/Scanner, by setting the Produced

Connection Path and Consumed Connection Path on initializing an I/O connection corresponding to the

DeviceNet specification.

Static input assemblies

Name

Pos+ERR (factory setting)

POS+CMD+ERR

PV+ERR

PV+SP+ERR

PV+SP+CMD+ERR

PV+P1+P2+MTMP+ERR

PV+SP+CMD+P1+P2+MTMP+ERR

Adress Data Attribute of ther Assemblies for Read access, Class, Instance, Attribute

Format of the Data

Attribute

4, 1, 3 Byte 0: POS low

Byte 1: POS high

Byte 2: ERR

4, 2, 3

4, 3, 3

4, 4, 3

4, 5, 3

4, 6 , 3

Byte 0: POS low

Byte 1: POS high

Byte 2: CMD low

Byte 3: CMD high

Byte 4: ERR

Byte 0: PV low

Byte 1: PV high

Byte 2: ERR

Byte 0: PV low

Byte 1: PV high

Byte 2: SP low

Byte 3: SP high

Byte 4: ERR

Byte 0: PV low

Byte 1: PV high

Byte 2: SP low

Byte 3: SP high

Byte 4: CMD low

Byte 5: CMD high

Byte 6: ERR

Byte 0: PV low

Byte 1: PV high

Byte 2: P1 low

Byte 3: P1 high

Byte 4: P2 low

Byte 5: P2 high

Byte 6: MTMP low

Byte 7: MTMP high

Byte 8: ERR

4, 7, 3 Byte 0: PV low

Byte 1: PV high

Byte 2: SP low

Byte 3: SP high

Byte 4: CMD low

Byte 5: CMD high

Byte 6: P1 low

Byte 7: P1 high

Byte 8: P2 low

Byte 9: P2 high

Byte 10: MTMP low

Byte 11: MTMP high

Byte 12: ERR

8630 - 141

EVICE

The adresses given in the table Static Input Assemblies can be used as path statement for the attribute

Produced Connection Path of an I/O connection, whereby the attributes described in more detail in the following table can be transferred as Input Process Data via this I/O connection. Independently from thsi however, it is also possible to acyclically access the attributes combined in the Assemblies via Explicit

Messages.

Name

POS

CMD

MTMP

ERR

Description of the Data Attributes Attribute address

Class, Instance,

Attribute; data type, length

111, 1, 59; Actual Position (Actual Position)

Actual value of position controller in ‰. Value range 0...1000.

However values <0 respectively >1000 are also possible if e.g. AUTOTUNE has not run correctly.

Position Setpoint (Position Setpoint)

Setpoint value of position controller in ‰.

Value range 0...1000.

INT, 2 Byte

111, 1, 58;

UINT, 2 Byte

Media temperature value range -20 ... 150

Temperature of the medium in °C. The value will be predefined from the menu, the bus, or using a temperature transmitter.

Back pressure P2

Pressure in mbar (rel) that is present behind the process valve. The value will be determined using a pressure transmitter.

Value range -1013 ... 16000

120, 1, 9;

INT, 2 Byte

120, 1, 8;

INT, 2 Byte

Forward pressure P1

Pressure in mbar (rel) that is present in front of the process valve. The value will be determined using a pressure transmitter.

Value range -1013 ... 16000

Process actual value (Process Value)

Actual value of process controller in physical unit (as set in the menu P.CO INP respectively P.CO SCAL), max. value range –999...9999, depending on the internal scaling.

120, 1, 7;

INT, 2 Byte

120, 1, 3;

INT, 2 Byte

Process Setpoint (Process Setpoint)

Setpoint value of process controller in physical unit (as set in the menu P.CO INP respectively P.CO SCAL), max. value range –999...9999, depending on the internal scaling.

120, 1, 2;

INT, 2 Byte

Error (Error)

Gives the number of the process value (output) which has not been entered. The value is retained until deleted by the acyclic writing of the attribute „Error“ with „0“(access via

Explicit Message – Set Attribut Single).

HEX

0X14 INP

0X15 SP

0X18 MTMP

100, 1, 1;

USINT, 1Byte

142 - 8630

EVICE

Static Output Assemblies

Name

INP (factory setting)

MTMP

SP+MTMP

Address Data Attribute of the assemblies for

Write/Read access Class, Instance, Attribute

4, 21, 3

4, 22, 3

4, 23, 3

4, 24, 3

Format of the Data

Attribute

Byte 0: INP low

Byte 1: INP high

Byte 0: SP low

Byte 1: SP high

Byte 0: MTMP low

Byte 1: MTMP high

Byte 0: SP low

Byte 1: SP high

Byte 2: MTMP low

Byte 3: MTMP high

The addresses given in the table Static Output Assemblies can be used as path statement for the attribute Consumed Connection Path of an I/O connection, whereby the attributes described in more detail in the following table can be transferred as Output Process Data via this I/O connection.

Independently from this however, it is also possible to acyclically access the attributes combined in the

Assemblies via Explicit Messages.

Name

INP

MTMP

Description of the Output Data Attributes Attribute address,

Class, Instance,

Attribute; data type, length

111, 1, 58; Position setpoint

Setpoint of position controller in ‰.

Value range 0...1000.

In "purely" position controller operation ( PCONTRL inactiv) transmission of the setpoint position INP is necessary; as process controller ( PCONTRL activ) the transmission of INP is not possible. In the case of too small or too large a value, the last valid is used and indicated in ERR with HEX 14.

UINT, 2 Byte

Process-set-value (Process Setpoint)

Set-value process controller in physical unit (as set up in the P.CO INP or P.CO SCAL menu), max. value range –999...9999, depending on the internal scaling.

If the value is too small or too large, the last valid value will be used and will be displayed in ERR with

HEX 15.

120, 1, 2;

INT, 2 Byte

Medium temperature

Temperature of the medium in °C.

Value range -20 ... 150.

If the value is too small or too large, the last valid value will be used and will be displayed in ERR with

HEX 18.

120, 1, 9;

INT, 2 Byte

8630 - 143

EVICE

Bus status display

The bus standard is indicated on the display.

Display message

BUS OFFL alternates with the display value set

Device status offline

BUS NOCO alternates with the set indication value online, no connection to

Master

2 dots left, under the set indication value online,

Explicit Messaging only

4 dots left, under the set indication value

BUS TIME alternates with the set indication value online, active I/O connection

I/O connection

Timeout

BUS CRIT alternates with the set indication value critical bus error

Explanation/problem elimination

Device is not connected to the bus; the network access procedure (Duplicate MAC-ID-Test, duration 2 s) has not yet ended or the device is the sole active network subscriber.

- Is the baud rate correctly set throughout the network?

- Is the bus connection incl. plug in assignment correct?

- Is the voltage supply and bus connection of the other

subscribers correct?

Device is correctly connected to the bus, the network access procedure has been completed without error, but no connection is established with the Master.

Messaging connection with Master is established. No I/O connection is in the Established state (no I/O data exchange).

An I/O connection is in the Established state (I/O data exchange).

An I/O connection is in the TIME OUT state.

- new establishmend of connection by Master; ensure the

I/O data are transferred cyclically, or with confirmed COS,

the corresponding Acknowledge Messages are sent by the

Master.

Different device with same address in the network, or BUS

OFF due to communication problems:

- change address of device and restart device.

- error analysis in network with a bus monitor.

144 - 8630

EVICE

Configuration example 1

The example describes the basic procedure on configuring the device when using the software

RSNetworx for DeviceNet (Rev. 2.11.51.0).

Installation of the EDS file

The installation of the EDS file on the supplied floppy takes place with the aid of the tool EDS Installation Wizard belonging to RSNetworx.

The Icon, also supplied on floppy can also be assigned in the course of the installation procedure

(where this does not take place automatically).

Address allocation

There are two possibilities for the assignment of addresses to the devices.

Firstly an address can be set to the desired value over the range 0 … 63 via the keys at the device (see chapter Settings at TOP Control Continuous); secondly a change of address of connected devices can be carried out via the bus with the aid of the tool Node Commissioning belonging to RSNetworx.

Therefore, the sequential addition in an existing network of devices with the default address 63 is a simple matter.

The figure shows how the new address 2 is assigned to a device with the address 63.

8630 - 145

EVICE

Offline parametrization of the device

After the addition of a device in the DeviceNet configuration of RSNetworx, the device can be parametrized offline.

The figures shows by way of example, how an Input Assembly (Input Process data transferable via I/O connection) at variance with the factory setting can be selected. Note however that the length of the process data must be appropriately adapted with a following configuration of the DeviceNet Masters/

Scanners (see chapter Configuration, Example 2).

All parameter changes carried out offline must be rendered effective for the real device by a Download

Procedure.

146 - 8630

EVICE

Online parametrization of the device

Devices can also be parameterized online. Here it can be selected whether only a single parameter or all parameters of a group are to be uploaded from the device or downloaded to the device.

The facility also exists for cyclically transferring single parameters or all the parameters of a group in monitor mode. This can be useful, especially for commissioning purposes.

Shown in the figure is the group of process values, respectively Diagnostic information. If the button

Start Monitor is pressed, these values are cyclically updated. However, Explicit Messages are also used for this cyclic access (no I/O connections).

8630 - 147

EVICE

Configuration example 2

This example describes the basic procedure for setting-up the process mapping of a DeviceNet Master /

Scanner, using the software RSNetworx for DeviceNet (Rev. 2.11.51.0).

Setting-up the Scanlist and setting the I/O parameters

First of all the Scanlist of the DeviceNet Master / Scanner is set-up. For this the devices listed in the left hand part of the associated window are transferred to the right hand part of the window. Then a change of the I/O parameters can be carried out for each device transferred to the Scanlist. This is necessary when, on configuring the relevant TOP Control Continuous, Assemblies have been selected which differ from the default settings.

Shown in the figure is the setting of the I/O parameters with selected

Input-Assembly

Output-Assembly

POS+CMD+ERR (5 bytes long) and selected

INP (2 bytes long; default-Assembly - no change required).

148 - 8630

EVICE

Setting up the process mapp (mapping)

Using the function AUTOMAP it is possible to assign the input data of the devices listed in the Scanlist to the process mapping of the DeviceNet Master / Scanner.

In our example this resulted in the assignment shown in the figure .

For example, the Input Process values of the TOP Control Continuous with the address 4 are assigned to the internal addresses of the scanner in the following manner:

Actual position:

Setpoint position:

Error:

I:1.6

I:1.7

I:1.8

Therefore if the actual position of the TOP Control Continuous with the address 4 is to be read from a control program, this takes place via an access to 1:1.6.

8630 - 149

EVICE

150 - 8630

AINTENANCE AND ERROR CORRECTION ON THE POSITIONER

MAINTENANCE AND ERROR

CORRECTION ON THE

POSITIONER

Maintenance

152 Error messages and malfunctions

......................................................................................................................................................................

152

Error messages on the LC display

.....................................................................................................................................................................

152

Other malfunctions

152

8630 - 151

AINTENANCE AND ERROR CORRECTION ON THE POSITIONER

Maintenance

When operated according to these Operating Instructions, the TOP Control Continuous is maintenance free.

Error messages and malfunctions

Error messages on the LC display

Error message on switching on

Display

CMD FAUL

EE FAULT

Causes of error signal error set-value positioner

EEPROM faulty

Remedy check signal none, device faulty

Error message on execution of the function X.TUNE

Display

X.ERR 1

X.ERR 2

X.ERR 3

X.ERR 4

X.ERR 6

X.ERR 7

Causes of error

No compressed air connected

Remedy

Connect compressed air

Compressed air failure during

AUTOTUNE

Actuator or positioning system leaky on exhaust side

Check compressed air supply

None, device faulty

Actuator system leaky on pressurized side

The end positions for

POS-MAX

POS-MIN and

are too near to each other

None, device faulty

Check whether the allocation of the end positions to POS-MIN and POS-MAX via the function TUNE-POS is correct.

If incorrect:

Execution TUNE-POS again.

If correct:

TUNE-POS with this arrangement of the end positions is not possible since they are too close together.

False allocation of POS-MIN and POS-

MAX

To determine POS-MIN and POS-MAX , move the actuator in each case in the direction shown on the display.

Other malfunctions

Problem Possible causes

POS = 0 (with CMD > 0 %) or Tight-closing function

POS = 100 %, (by CMD < 100 %) (CUTOFF) has been inadvertently activated

Remedy

Deactivate tight-closing function

152 - 8630

AINTENANCE AND ERROR CORRECTION ON THE PROCESS CONTROLLER

MAINTENANCE AND ERROR

CORRECTION ON THE

PROCESS CONTROLLER

Maintenance

154 Error messages and malfunctions

......................................................................................................................................................................

154

Error messages on the LC display

.........................................................................................................................................................................

154

Other malfunctions

156

8630 - 153

AINTENANCE AND ERROR CORRECTION ON THE PROCESS CONTROLLER

Maintenance

When operated according to these Operating Instructions, the TOP Control Continuous is maintenance free.

Error messages and malfunctions

Error messages on the LC display

General error messages

Display

CMD FAUL

SP FAULT

PV FAULT

PT FAULT

P1 FAULT

P2 FAULT

TMP FAUL

EE FAULT

MFI FAUL

Causes of error signal error set-value, positioner signal error set-value, process controller signal error actual value, process controller signal error actual value, Pt-100 signal error actual value, P1 fluid flow controller signal error actual value, P2 fluid flow controller signal error actual value, temperature, fluid flow controller

EEPROM faulty

Fieldbus board faulty

Remedy check signal check signal check signal check signal check signal check signal check signal none, device faulty

Error messages on execution of the function X.TUNE

Display

X.ERR 1

X.ERR 2

X.ERR 3

X.ERR 4

X.ERR 6

X.ERR 7

Causes of error

No compressed air connected

Compressed air failure during

AUTOTUNE

Actuator or positioning system leaky on exhaust side

Actuator system leaky on pressurized side

Remedy

Connect compressed air

Check compressed air supply

None, device faulty

The end positions for

POS-MAX

POS-MIN and

are too near to each other

Check whether the allocation of the end positions to POS-MIN and POS-MAX via the function TUNE-POS is correct.

If incorrect:

Execution TUNE-POS again.

If correct:

TUNE-POS with this arrangement of the end positions is not possible since they are too close together.

False allocation of POS-MIN and POS-

MAX

To determine POS-MIN and POS-MAX , move the actuator in each case in the direction shown on the display.

154 - 8630

AINTENANCE AND ERROR CORRECTION ON THE PROCESS CONTROLLER

Error messages on execution of the function P.Q'LIN

Display

Q.ERR 1

Causes of error

No compressed air connected

No change in process value

Remedy

Connect compressed air

Check process, switch on pump or open shut-off valve if necessary

Q.ERR 2 Current fixed point of the valve stroke was not reached because

• Pressure supply failre

during P.Q’LIN

• No AUTOTUNE was executed

• Check pressure supply

• execute AUTOTUNE

Error message on execution of the function LEAK MEAS

Display

L.ERR 1

L.ERR 2

L.ERR 3

Cause of error

No admission pressure at the controller unit (> 50 mbar).

Control does not fully close.

No leakage detectable: the difference between admission pressure and conveying pressure is so low, even at slight valve opening, that no air leak can be measured.

Whilst the valve is open the delivery pressure is not increased, which means that no restart points for the characteristic can be recorded.

Remedy

Switch on compressor before start of leakage measurement.

Execute AUTOTUNE.

The leakage characteristic must be deactivated since the precision of air flow control cannot be raised.

Make sure that the conveying pipe is closed and the blocking air is open.

8630 - 155

AINTENANCE AND ERROR CORRECTION ON THE PROCESS CONTROLLER

Other malfunctions

Problem Possible causes

POS = 0 (with CMD > 0%) or Tight-closing function

POS = 100%,(with CMD < 100%) (CUTOFF) has

PV = 0 (with SP > 0) or

PV = PV (with SP > SP ) been inadvertently activated

Only with devices with analog

repeat: red LED does light

Binary output does not switch

Only with devices with process controller:

Device does not work as a controller despite correctly executed settings.

Binary output:

Current > 100 mA short circuit

Menu item P.CONTRL stands in main menu. The device thus works as a process controller and expects a process value at the corresponding input.

Remedy

Deactivate tight-closing function

Check connection of binary output

Remove the menu item

P.CONTRL from the main menu.

156 - 8630

ENERAL

ULES

PPENDIX

)

GENERAL RULES

(APPENDIX)

Selection criteria for continuous valves

.................................................................................................................................................................

158 Characteristics of PID controllers

...................................................................................................................................................................................

160

P component

160

I component

161

D component

162

Superimposing the P, I and D components

........................................................................................................................................................

163

Function of a real PID controller

.......................................................................................................................................................................................

164

Rules for setting PID controllers

.......................................................................................................................................................................................

165

Setting rules of Ziegler and Nichols (oscillation method)

.................................................................................................................

165

Setting rules of Chien, Hrones and Reswick (controller output step method)

......................................................

166

8630 - 157

ENERAL

ULES

PPENDIX

)

Selection criteria for continuous valves

The following criteria are of decisive importance for optimal control behaviour and attainment of the maximum flow rate through the valve:

• Correct choice of flow coefficient, which is defined essential by the size of the valve;

• Good matching of the valve size to the pressure conditions, taking into consideration the other flow resistances in the system.

Dimensioning guidelines can be given on the basis of the flow coefficient (k v

). The k v

value refers to the standardized conditions with respect to pressure, temperature and media properties.

The k v

value is defined as the flow rate in m 3 /h of wasser through a component at a pressure difference

Dp of 1 bar and a temperature of 20°C.

With continuous valves the “ k vs continuous valve is fully open.

value” is additionally used. This specifies the k v

value when the

Depending on the specified data, the following cases must be distinguished on selection of a valve: a) The pressures before and after the valve p

Q max

is to be attained:

and p

are known at which the desired maximum flow rate

The required k vs value is obtained from: k

= Q max

⋅

∆ p

⋅

ρ

(1)

where: k

Q max

∆ p

0 r

∆ p r is the flow coefficient of the continuous valve when fully open [m³/h] is the maximum volumetric flow rate [m³/h]

= 1 bar; the pressure drop over the valve as in the definintion of k

= 1000 kg/m³; the density of water as in the definition of k

V is the pressure drop over the valve [bar] and is the density of the medium [kg/m³] b) The pressures at the inlet and outlet of the overall system (p

1 desired maximum flow rate Q max

is to be attained:

and p

), are known at which the

Step 1:

Step 2:

Step 3:

Step 4:

Calculate the flow coefficient of the overall system k

Vges

from equation (1).

Measure the flow rate through the system without the continuous valve

(e.g. by short-circuiting the piping where the vale is installed).

Calculate the flow coefficient of the system without the continuous valve (k

Va equation (1).

) from

Calculate the required k

value of the continuous valve ( k

) from equation (2).

1 k

Vges

−

1 k

(2)

158 - 8630

ENERAL

ULES

PPENDIX

)

NOTE The k

of the continuous valve should have at least the value valculated from the equation

(1 or 2) relevant to the application, but under no circumstances be very much greater.

The rule of thumb often used with switching valves, "somewhat larger never hurts", can be strongly detrimental to the control behaviour of continuous valves!

Determination in practice of the upper limit to the k

value of the continuous valve is possible by means of the so-called "valve authority"

Ψ:

Ψ =

( )

0 = k

2 k

+ k

(3)

(

∆ p)

( ∆ p)

0 is the pressure drop over the fully opened valve and is the pressure drop over the entire system.

NOTE With a valve authority Y < 0.3 the continuous valve is overdimensioned.

With the valve fully open, in this case the flow resistance is significantly smaller than that of the other fluidic components in the system. This means that only in the lower opening range is the valve position dominant in the operating characteristic. For this reason, the operating characteristic is strongly deformed.

By selection of a progressive (equiprocentile) characteristic between position setpoint and valve stroke, this can be partially compensated and the operating characteristic linearized within certain limits. However, the valve authority Y should be > 0.1, even when using a corrected characteristic.

The control behaviour (control performance, settling time) when using a corrected characteristic is strongly dependent on the operating point.

8630 - 159

ENERAL

ULES

PPENDIX

)

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

Where Kp is the proportional action factor (amplification factor). It is given by the ratio of the correcting range ∆ Y to the proportional range ∆ Xd.

Characteristic and step response of the P component of a PID controller

Proportional range

Characteristic line Step response

Characteristics

A pure P controller works theoretically undamped, i.e. it is fast and dynamically favourable. It has a residual control difference, i.e. it does not completely eliminate the effects of disturbances and is thus relatively unfavourable from a static viewpoint.

160 - 8630

ENERAL

ULES

PPENDIX

)

I component

Function: Y = ∫ Xd dt

Ti is the integration or floating time. It is the time that expires until the controller output has run through the entire correcting range.

Characteristic and step response of the I component of a PID controller

Control range ∆ Xc

Characteristic line

Floating time

Step response

Correcting range

Characteristics

A purely I controller completely eliminates the effects of disturbances. It thus has a favourable static behaviour. Because of its finite correcting speed, it works more slowly than a P controller and tends to oscillation. It is hence dynamically relatively unfavourable.

8630 - 161

ENERAL

ULES

PPENDIX

)

D component

Function: Y = Kd d Xd/dt

The higher Kd is, the stronger the D influence is.

Characteristics and step response of the D component of a PID controller

Step response Rise response

Characteristic

A controller with a D component reacts to changes in the controlled variable and can thus reduce more quidckly any control differences that occur.

162 - 8630

ENERAL

ULES

PPENDIX

)

Superimposing the P, I and D components

Function: Y = Kp Xd +

∫∫∫∫∫ Xd dt + d Xd/dt

Substituting Kp · Ti = Tn and Kd/Kp = Tv we obtain for the function on the PID controller:

Y = Kp (Xd +

∫∫∫∫∫ Xd dt + Tv dXd/dt)

Kp is the proportional action factor/amplification factor

Tn is the reset time

(the time required to obtain the same change in correcting variable as was caused by the P component) and

Tv is the rate time

(the time by which a certain change in correcting variable is obtained earlier with the D component than t would have been with a pure P controller).

Step response and rise response of the PID controller

Y t

Kp•Xd

Step response of the PID controller t t

Rise response of the PID controller

8630 - 163

ENERAL

ULES

PPENDIX

)

Function of a real PID controller

D component with delay

In the process controller of the positioner, the D component is realized with a delay T.

Function T + Y = Kd dXd dt

Superimposing the P, I and DT components

Xd t

T t

Function of the real PID controller

T + Y = Kp (Xd + dt Tn

∫∫∫∫∫ Xd dt + Tv ) dt

Step response of the real PID controller

Xd t

Kp Xd t

164 - 8630

ENERAL

ULES

PPENDIX

)

Rules for setting PID controllers

The literature on control technology contains a number of rules by which a favourable setting of the controller parameters can be determined experimentally. In order to avoid incorrect settings, the conditions under which the rules were set up in each case must be kept in mind. Apart from the characteristics of the controlled member and the controller itself, it makes a difference whether a change in disturbance or a command variable is to be compensated.

Setting rules of Ziegler and Nichols (oscillation method)

With this method, the controller parameters are set on the basis of the behaviour of the control loop at the limit of stability. These parameters are initially set such that the control loop begins to oscillate.

Critical characteristic values occurring allow one to deduce a favourable setting of the control parameters. A prerequisite for using this method is naturally that the control loop is permitted to oscillate.

Procedure

• Set the controller to P control (i.e. Tn = 999, Tv = 0), Kp initially small.

• Set the desired set point.

• Increase Kp until the controlled variable executes continuous, undamped oscillation.

The proportional action factor (amplifucatuib factor) set at the limit of stability is designated K crit resulting oscillation period is designated T krit

. The

Curve of controller output at the limit of stability

Actual value

Istwert

From K crit

and T crit

the controller parameters can then be calculated using the following table.

Parameter setting according to Ziegler and Nichols

Contr. type Einstellung der Parameter

PID

Kp = 0.5 K crit

Kp = 0.45 K crit

Kp = 0.6 K crit

Tn = 0.85 T

Tn = 0.5 T crit crit

Tv = 0.12 T crit

The adjustment rules of Ziegler and Nichols have been determined for P members with first order time increase and dead time. However, they apply only for controllers with disturbance behaviour and not for those with command behaviour.

8630 - 165

ENERAL

ULES

PPENDIX

)

Setting rules of Chien, Hrones and Reswick

(controller output step method)

With this method the controller parameters are set on the basis of the transient behaviour of the controlled member. A step in the controller output of 100 % is delivered. The times Tu and Tg are derived from the curve of the actual value of the controlled variable.

Curve of the controlled variable after a step in controller output

∆∆∆∆∆

Y

Controller output Y t

Actual value

Ks * ∆ Y

Controlled variable t

Tu Tg

Procedure

• Switch controller to MANUAL.

• Deliver a step in controller output and register the controlled variable with a chart recorder.

• With critical runs (e.g. on risk of overheating), switch off in good time.

NOTE It should be observed that with thermally sluggish systems, the axtual value of the controlled variable may continue to rise after switching off.

In the following table, the setting values are given for the controller parameters as a function of Tu, Tg and Ks for command and disturbance behaviour, as well as for an aperiodic control event and a control event with 20% overswing. They apply for members with P behaviour, with dead time and with first-order delay.

166 - 8630

ENERAL

ULES

PPENDIX

)

Parameter setting according to Chien, Hrones and Reswick

Controlle type

Parameter setting with aperiodic control event

(0 % overswing) with control event

(with 20 % overswing)

Command

Kp = 0,3

Tu*Ks

Disturbance

Kp = 0,3

Tu*Ks

Command

Kp = 0,7

Tu*Ks

Disturbance

Kp = 0,7

Tu*Ks

PID

Kp = 0,35

Tu*Ks

Tn = 1,2 Tg

Kp = 0,6

Tu*Ks

Tn = 4 · Tu

Kp = 0,6

Tu*Ks

Tn = Tg

Tv = 0,5 · Tu

Kp = 0,95

Tu*Ks

Tn = 2,4 · Tu

Tv = 0,42 · Tu

Kp = 0,6

Tu*Ks

Tn = Tg

Kp = 0,7

Tu*Ks

Tn = 2,3 · Tu

Kp = 0,95

Tu*Ks

Tn = 1,35 ·Tg

Tv = 0,47 · Tu

Kp = 1,2

Tu*Ks

Tn = 2 · Tu

Tv = 0,42 · Tu

The proportional action factor Ks of the controlled member is obtained according from:

Ks =

∆

∆ Y

8630 - 167

ENERAL

ULES

PPENDIX

)

168 - 8630

PERATING STRUCTURE

PPENDIX

)

OPERATING STRUCTURE

(APPENDIX)

8630 - 169

PERATING STRUCTURE

PPENDIX

)

Operating structure of the TOP Control Continuous

170 - 8630

On activation, moves to, safety position

PERATING STRUCTURE

PPENDIX

)

Menu appears only with activated PID controller

8630 - 171

PERATING STRUCTURE

PPENDIX

)

172 - 8630 with PCO INP = 4´20A with PCO INP = FREQ

SP: only with external setpoint

(selected via PCO SETP / SETPEXT) with PCO INP = P´100 with PCO INP = P1´P2

DIAM can be entered only if,

P.TYP VELO has been selected!

PERATING STRUCTURE

PPENDIX

)

If SAFEPOS is deactivated, then SPOS = 000

8630 - 173

PERATING STRUCTURE

PPENDIX

)

174 - 8630

Controller activated

Process controller activated

PERATING STRUCTURE

PPENDIX

)

8630 - 175

PERATING STRUCTURE

PPENDIX

)

176 - 8630

ABLES FOR

OSITIONER

PPENDIX

)

TABLES FOR

POSITIONER

(APPENDIX)

8630 - 177

ABLES FOR

OSITIONER

PPENDIX

)

Tables for noting your setting on the positioner

Settings of the freely programmable characteristic

Ref. point

(Set point of position in %)

100

Date: Date:

Valve stroke [%]

Date: Date:

178 - 8630

ABLES FOR

ROCESS

ONTROLLER

PPENDIX

)

TABLES FOR

PROCESS CONTROLLER

(APPENDIX)

8630 - 179

ABLES FOR

ROCESS

ONTROLLER

PPENDIX

)

Tables for noting your settings on the process controller

Settings of the freely programmable characteristic

Ref. point

(Set point of position in %)

100

Date: Date:

Valve stroke [%]

Date: Date:

Parameters set on the process controller

Date: Date: Date:

DBND

UNIT

KFAC

FILT

INP

Date:

180 - 8630

ASTERCODE

PPENDIX

)

MASTERCODE

(APPENDIX)

8630 - 181

ASTERCODE

PPENDIX

)

182 - 8630

MASTERCODE

7175

Addresses of BC offices/Adressliste BC Länder Europe/Europa

BC-A Austria, Österreich

Bürkert-Contromatic G.m.b.H.

Diefenbachgasse 1-3

A-1150 Wien

Phone: Int. (+43 1)894 13 33, Nat. (01)894 13 33

Fax: Int. (+43 1)894 13 00, Nat. (01)894 13 00

E-mail: [email protected]

BC-B Belgium, Belgien

Bürkert Contromatic NV/SA

Bijkhoevelaan 3

B-2110 Wijnegem

Phone: Int. (+32 3)325 89 00, Nat. (03)325 89 00

Fax: Int. (+32 3)325 61 61, Nat. (03)325 61 61

E-mail: [email protected]

BC-CZ Czech Rep., Tschechische Rep.

Bürkert-Contromatic G.m.b.H. organizacni slozka

Krenova 35

CZ-602 00 Brno

Phone: Int. (+420 543)25 25 05, Nat. (543)25 25 05

Fax: Int. (+420 543)25 25 06, Nat. (543)25 25 06

E-mail: [email protected]

BC-DK Denmark, Dänemark

Bürkert-Contromatic A/S

Hørkær 24

DK-2730 Herlev

Phone: Int. (+45 44)50 75 00, Nat. 44-50 75 00

Fax: Int. (+45 44)50 75 75, Nat. 44-50 75 75

E-mail: [email protected]

BC-EST

Bürkert Oy Eesti

Laki 11 E

EE-12915 Tallin

Estonia, Estland

Phone: Int. (+3 72)6440 698, Nat. (372)6440 698

Fax: Int. (+3 72)6313 759, Nat. (372)6313 759

E-mail: [email protected]

BC-SF

Bürkert Oy

Finland, Finnland

Atomitie 5

FI-00370 Helsinki

Phone: Int. (+358 9)549 706 00, Nat. (09)549 706 00

Fax: Int. (+358 9)503 12 75, Nat. (09)503 12 75

E-mail: [email protected]

BC-F France, Frankreich

Burkert Contromatic SARL

Rue du Giessen

FR-67220 Triembach au Val

Phone: Int. (+33 388)58 91 11, Nat. (0388)58 91 11

Fax: Int. (+33 388)57 20 08, Nat. (0388)57 20 08

E-mail: [email protected]

BC-I Italy, Italien

Burkert Contromatic Italiana S.p.A.

Centro Direzionale „Colombirolo“

Via Roma, 74

IT-20060 Cassina De’ Pecchi (Mi)

Phone: Int. (+39 02)959 071, Nat. (02)959 071

Fax: Int. (+39 02)959 072 51, Nat. (02)959 072 51

E-mail: [email protected]

BC-N Norway, Norwegen

Bürkert-Contromatic A/S

Hvamstubben 17

NO-2013 Skjetten

Phone: Int. (+47 63)84 44 10, Nat. (63)84 44 10

Fax: Int. (+47 63)84 44 55, Nat. (63)84 44 55

E-mail: [email protected]

BC-NL Netherlands, Niederlande

Bürkert Contromatic BV

Computerweg 9

NL-3542 DP Utrecht

Phone: Int. (+31 346)58 10 10, Nat. (0346)58 10 10

Fax: Int. (+31 346)56 37 17, Nat. (0346)56 37 17

E-mail: [email protected]

BC-P Portugal, Portugal

Phone: Int. (+351 21)21 28 490, Nat. (21)21 28 490

Fax: Int. (+351 21)21 28 491, Nat. (21)21 28 491

E-mail: [email protected]

BC-PL Poland, Polen

Burkert-Contromatic GmbH

Oddzial w Polsce

Bernardynska street 14 a

PL-02-904 Warszawa

Phone: Int. (+48 22)840 60 10, Nat. (022)840 60 10

Fax: Int. (+48 22)840 60 11, Nat. (022)840 60 11

E-mail: [email protected]

BC-E Spain, Spanien

Bürkert Contromatic S.A.

Avda. Barcelona, 40

ES-08970 Sant Joan Despi, Barcelona

Phone: Int. (+34 93)477 79 80, Nat. (93)477 79 80

Fax: Int. (+34 93)477 79 81, Nat. (93)477 79 81

E-mail: [email protected]

BC-S Sweden, Schweden

Bürkert-Contromatic AB

Skeppsbron 13 B

SE-211 20 Malmö

Phone: Int. (+46 40)664 51 00, Nat. (040)664 51 00

Fax: Int. (+46 40)664 51 01, Nat. (040)664 51 01

E-mail: [email protected]

BC-CH Switzerland, Schweiz

Bürkert-Contromatic AG Schweiz

Bösch 71

CH-6331 Hünenberg ZG

Phone: Int. (+41 41)785 66 66, Nat. (041)785 66 66

Fax: Int. (+41 41)785 66 33, Nat. (041)785 66 33

E-mail: [email protected]

BC-TR Turkey, Türkei

Burkert Contromatic Akiskan

Kontrol Sistemleri Ticaret A.S.

1203/8 Sok. No2-E

TR-Yenisehir, Izmir

Phone: Int. (+90 232)459 53 95, Nat. (0232)459 53 95

Fax: Int. (+90 232)459 76 94, Nat. (0232)459 76 94

E-mail: [email protected]

BC-UK United Kingdom,

Vereinigtes Königreich

Burkert Contromatic Limited

Brimscombe Port Business Park

Brimscombe, Stroud

Glos, GL5 2QF / UNITED KINGDOM

Phone: Int. (+44 1453)73 13 53, Nat. (01453)73 13 53

Fax: Int. (+44 1453)73 13 43, Nat. (01453)73 13 43

E-mail: [email protected]

Addresses of BC offices/Adressliste BC Länder APAC

BC-AUS Australia, Australien

BURKERT CONTROMATIC AUSTRALIA PTY, LIMITED

2 Welder Road

Seven Hills, NSW 2147

AUSTRALIA

Phone: Int. (+61 2)1300 888 868, Nat.(02)1300 888 868

Fax: Int. (+61 2)1300 888 076, Nat.(02)1300 888 076

E-mail: [email protected]

Victoria

BURKERT CONTROMATIC AUSTRALIA PTY, LIMITED

Unit 11/26-30 Howleys Road

Notting Hill Victoria 2168

Phone: Int. (+61 3)85459700, Nat. (03)85459700

Fax: Int. (+61 3)95626599, Nat. (03)95626599

Queensland

BURKERT CONTROMATIC AUSTRALIA PTY, LIMITED

Unit 4/43 Sandgate Road

Albion Queensland 4010

Phone: Int. (+61 7)33269600, Nat. (07)33269600

Fax: Int. (+61 7)32628801, Nat. (07)32628801

Western Australia

BURKERT CONTROMATIC AUSTRALIA PTY. LIMITED

104 Westpoint, 396 Scarborough Beach Road

Osborn Park Western Australia 6017

Phone: Int. (+61 8)94443980, Nat. (08)94443980

Fax: Int. (+61 8)94449353, Nat. (08)94449353

BC-CN China, China

Burkert Contromatic (Shanghai), Co.,Ltd.

Room J1, 3rd floor

207 Tai Gu Road

Wai Gao Qiao Free Trade Zone

Shanghai 200131

P. R. China

Phone: Int. (+86 21)5868 21 19, Nat. (21)5868 21 19

Fax: Int. (+86 21)5868 21 20, Nat. (21)5868 21 20

E-mail: [email protected]

Beijing

Burkert Contromatic (Shanghai), Co., Ltd.

Room 808, Jingtai Building

No. 24, Jian Guo Men Wai Da Jie

Beijing P. R. China, 100022

Phone: Int. (+8610)6515 6508, Nat. (10)6515 6508

Fax: Int. (+8610)6515 6507, Nat. (10)6515 6507

Chengdu

Burkert Contromatic (Shanghai), Co., Ltd.

Room 603-604, Fuji Building

26 Dongfeng Road, Shudu Dadao

Chengdu P. R. China, 610061

Phone: Int. (+8628)84439064, Nat. (28)84439064

Fax: Int. (+8628)84451341, Nat. (28)84451341

Guangzhou

Burkert Contromatic (Shanghai), Co., Ltd.

Room 1502, Tower 4, Dong Jun Plaza

828 - 836 Dong Feng Road East

Guangzhou P. R. China, 510080

Phone: Int. (+8620)87698379, Nat. (20)87698379

Fax: Int. (+8620)87671131, Nat. (20)87671131

Shanghai

Burkert Contromatic (Shanghai), Co., Ltd.

Room 27E, Shanghai Industry Building

No. 18 Caoxi Bai Road

Shanghai P. R. China, 200030

Phone: Int. (+8621)64865110, Nat. (21)64865110

Fax: Int. (+8621)64874815, Nat. (21)64874815

Suzhou

Burkert Contromatic (Shanghai), Co., Ltd.

Room 5, #06-06

Block A, No. 5 Xinghan Street

SIP Suzhou P. R. China, 215021

Phone: Int. (+86512)67611916, Nat. (512)67611916

Fax: Int. (+86512)67611120, Nat. (512)67611120

BC-HKG (China) Hong Kong, Hongkong

Burkert Contromatic (China/HK) Ltd.

Unit 708 Prosperity Centre,

77 - 81, Container Port Road

Kwai Chung, N.T., HONG KONG

Phone: Int. (+852)248 012 02, Nat. 248 012 02

Fax: Int. (+852)241 819 45, Nat. 241 819 45

E-mail: [email protected]

BC-IND India, Indien

Burkert Contromatic PVT Ltd.

Apex Towers

1st Floor, No. 54 II Main Rd

RA Puram

Chennai 600 028

INDIA

Phone: Int. (+91 044)52303456, Nat. (044)52303456

Fax: Int. (+91 044)52303232, Nat. (044)52303232

E-mail: [email protected]

BC-J

Burkert Ltd.

Japan, Japan

1-8-5 Asagaya Minami

Suginami-ku

Tokyo 166-0004

JAPAN

Phone: Int. (+81 3)5305 3610, Nat. (03)5305 3610

Fax: Int. (+81 3)5305 3611, Nat. (03)5305 3611

E-mail: [email protected]

BC-KOR Korea, Korea

Burkert Contromatic Korea Co., Ltd.

C-401, Micro Office Bldg. 554-2

Gasan-Dong, Keumcheon-Gu

Seoul 153-803

KOREA

Phone: Int. (+82 2)3462 5592, Nat. (02)3462 5592

Fax: Int. (+82 2)3462 5594, Nat. (02)3462 5594

E-mail: [email protected]

BC-TT Malaysia, Malaysia

BURKERT CONTROMATIC SINGAPORE PTE. LTD.

2F-1, Tingkat Kenari 6

Sungai Ara

11960 Penang

MALAYSIA

Phone: Int. (+60 4)643 5008, Nat. (04)643 5008

Fax: Int. (+60 4)643 7010, Nat. (04)643 7010

E-mail: [email protected]

BC-NZ New Zealand, Neuseeland

BURKERT CONTROMATIC NEW ZEALAND LIMITED

2A, Unit L, Edinburgh Street

Penrose, Auckland

NEW ZEALAND

Phone: Int. (+64 9)622 28 40, Nat. (09)622 28 40

Fax: Int. (+64 9)622 28 47, Nat. (09)622 28 47

E-mail: [email protected]

Addresses of BC offices/Adressliste BC Länder APAC

BC-RP Philippines, Philippinen

BURKERT CONTROMATIC PHILIPPINES, INC.

8467, West Service Road Km 14

South Superhighway, Sunvalley

Paranaque City, Metro Manila

PHILIPPINES

Phone: Int. (+63 2)776 43 84, Nat. (02)776 43 84

Fax: Int. (+63 2)776 43 82, Nat. (02)776 43 82

E-mail: [email protected]

BC-SIN Singapore, Singapur

BURKERT CONTROMATIC SINGAPORE PTE. LTD.

51 Ubi Avenue 1, #03-14

Paya Ubi Industrial Park

Singapore 408933

SINGAPORE

Phone: Int. (+65)6844 2233, Nat. 6844 2233

Fax: Int. (+65)6844 3532, Nat. 6844 3532

E-mail: [email protected]

BC-RC Taiwan, Taiwan

Burkert Contromatic Taiwan Ltd.

9F, No. 32, Chenggong Road, Sec. 1,

Nangang District

Taipei

TAIWAN 115, R.O.C

Phone: Int. (+886 2)2653 7868, Nat. (02)2653 7868

Fax: Int. (+886 2)2653 7968, Nat. (02)2653 7968

E-mail: [email protected]

Addresses of BC offices/Adressliste BC Länder NAFTA

BC-BRA Brazil, Brasilien

Bürkert-Contromatic Brasil Ltda.

Rua Américo Brasiliense, 2171 cj.1007

04715-005 São Paulo - SP

BRAZIL

Phone: Int. (+55 11)5182 0011, Nat. (011)5182 0011

Fax: Int. (+55 11)5182 8899, Nat. (011)5182 8899

E-mail: [email protected]

BC-CDN

Bürkert Contromatic Inc.

760 Pacific Road, Unit 3

Oakville, Ontario L6L 6M5

Canada, Kanada

CANADA

Phone: Int. (+1 905)847 55 66, Nat. (905)847 55 66

Fax: Int. (+1 905)847 90 06, Nat. (905)847 90 06

E-mail: [email protected]

BC-USA

BURKERT CONTROMATIC CORP.

2602 McGaw Avenue

USA, USA

Irvine, CA 92614

USA

Phone: Int. (+1 949)223 31 00, Nat. (949)223 31 00

Fax: Int. (+1 949)223 31 98, Nat. (949)223 31 98

E-mail: [email protected]

Addresses of BC offices/Adressliste BC Länder AFRICA/AFRIKA

BC-SA South Africa, Südafrika

Bürkert Contromatic Pty. Ltd.

P.O. Box 26260

East Rand

1462

Phone: Int. (+27 11)574 60 00, Nat. (011)574 60 00

Fax: Int. (+27 11)454 14 77, Nat. (011)454 14 77

E-mail: [email protected]

Adressliste Bürkert Fluid Control Systems Deutschland

Headquarter and Service Center,

Stammsitz und Service-Center

Ingelfingen

Bürkert GmbH & Co. KG

Christian-Bürkert-Straße 13 - 17

74653 Ingelfingen

Telefon: Int. (+497940)10-111, Nat. (07940)10-111

Fax: Int. (+497940)10-448, Nat. (07940)10-448

E-mail: [email protected]

Distribution Center, Vertriebs-Center

Berlin

Bürkert GmbH & Co. KG

Paradiesstraße 206 b

DE-12526 Berlin

Telefon: Int. (+4930)6797170, Nat. (030)6797170

Fax: Int. (+4930)67971766, Nat. (030)67971766

Hannover

Bürkert GmbH & Co. KG

Rendsburger Straße 12

DE-30659 Hannover

Telefon: Int. (+49511)902760, Nat. (0511)902760

Fax: Int. (+49511)9027666, Nat. (0511)9027666

Dortmund

Bürkert GmbH & Co. KG

Holzener Straße 70

DE-58708 Menden

Telefon: Int. (+492373)96810, Nat. (02373)96810

Fax: Int. (+492373)968150, Nat. (02373)968150

Frankfurt

Bürkert GmbH & Co. KG

Am Flugplatz 27

DE-63329 Egelsbach

Telefon: Int. (+496103)94140, Nat. (06103)94140

Fax: Int. (+496103)941466, Nat. (06103)941466

Stuttgart

Bürkert GmbH & Co. KG

Karl-Benz-Straße 19

DE-70794 Filderstadt-Bernhausen

Telefon: Int. (+49711)451100, Nat. (0711)451100

Fax: Int. (+49711)4511066, Nat. (0711)4511066

München

Bürkert GmbH & Co. KG

Paul-Gerhardt-Allee 24

DE-81245 München

Telefon: Int. (+4989)8292280, Nat. (089)8292280

Fax: Int. (+4989)82922850, Nat. (089)82922850

Service Center, Dienstleistungs-Center

Dortmund

Bürkert GmbH & Co. KG

Holzener Straße 70

DE-58708 Menden

Telefon: Int. (+492373)968134, Nat. (02373)968134

Fax: Int. (+492373)968132, Nat. (02373)968132

Dresden

Bürkert GmbH & Co. KG

Christian-Bürkert-Straße 2

DE-01900 Großröhrsdorf

Telefon: Int. (+4935952)36-300, Nat. (035952)36-300

Fax: Int. (+4935952)36-551, Nat. (035952)36-551

www.buerkert.com

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