Burkert 8620 User Manual
mxCONTROL Type 8620
Type 8620
mxCONTROL
Multifunction
Water Treatment
Controller
Operating Instructions
Page 1
mxCONTROL Type 8620
We reserve the right to make changes without notice!
© 2009 - 2010 Bürkert Werke GmbH & Co. KG
Operating instructions 1007/03_EU_EN_00805853
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mxCONTROL Type 8620
Contents
CONTENTS 3
1 THE OPERATING INSTRUCTIONS 6
2 INTENDED USE 7
2.1 Restrictions 7
2.2 Anticipated misuse 7
3 GENERAL SAFETY INSTRUCTIONS 8
4 GENERAL INFORMATION 10
4.1 Scope of Delivery 10
4.2 Warranty Regulations 10
4.3 Certifications 10
4.4 Information in the Internet 10
5 ABBREVIATIONS 11
5.1 Abbreviations in Software and Documentation 11
5.2 Display of the units 15
6 TECHNICAL DATA 17
6.1 Technical Specifications 17
6.2 Type Plate – Example 20
6.3 Hardware Structure 21
6.4 Module Overview 22
7 INSTALLATION 23
7.1 Safety Notes 23
7.2 Quick Start Guide 23
7.3 Mechanical Installation 24
7.4 Electrical Connections 24
7.5 Terminal Strip Pin Assignment 26
7.5.1 Power Supply (PS) 26
7.5.2 Instrumentation Supply (IS) 27
7.6 Download of a Configuration and Parameter File 27
8 DESCRIPTION OF HUMAN-MACHINE INTERFACE 28
8.1 Safety Notes 28
8.2 Operating and Display Elements 28
8.3 Operation Mode 29
8.3.1 Automatic & Manual Mode Key 29
8.3.2 Automatic Mode (LED on) 29
8.3.3 Manual Mode (LED off) 29
8.4 Layout of Menu Screens 30
9 MENU STRUCTURE 31
9.1 Principle of Menu Tree Structure 31
9.2 Setting Numeric Values 33
10 PASSWORD PROTECTION 34
11 GENERAL SOFTWARE CONCEPT AND FUNCTIONS 36
11.1 Functional Overview 36
11.2 Up- and Downloading of Configuration/Parameter Files 37
11.2.1 Download 37
11.2.2 Upload 38
11.3 Data Logging 39
11.3.1 Selection of SD card size for Data Logging purposes 42
11.3.2 Start of Data Logging (enabling) 43
11.3.3 Stop of Data Logging (disabling) 44
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mxCONTROL Type 8620
11.4 Configuration and Parameterization 45
11.4.1 Preface about Configuration/Parameterisation 45
11.4.2 Operating Language 45
11.4.3 Factory Setting of Parameters and Factory Reset 45
11.5 Communication 46
11.5.1 USB 46
11.5.2 Ethernet (only devices with Ethernet option) 46
11.5.3 (Remote) Device access via PC-Tool 52
12 INPUTS 55
12.1 Digital Inputs 55
12.1.1 Binary Inputs 56
12.1.2 Frequency Inputs 57
12.1.3 Pulse Counter Inputs 62
12.2 Analog Inputs 62
12.2.1 4…20 mA Inputs 62
12.2.2 Pt100 Inputs 69
13 OUTPUTS 72
13.1 Relay Outputs 72
13.1.1 Relay as Binary Output (On/Off) 73
13.1.2 Relay as PFM Output 73
13.1.3 Relay as PWM Output 74
13.1.4 Configuration (CodeLevel: Specialist) 74
13.2 Analog 4...20 mA Outputs (Option) 75
13.3 Transistor Outputs (Option) 77
13.3.1 Transistor output as On/Off-Output 77
13.3.2 Transistor output as PFM Output 77
13.3.3 Transistor output as PWM Output 77
13.3.4 Transistor output as fast PWM Output 78
13.3.5 Configuration (Code Level: Specialist) 79
14 CONTROLLER MODULES 80
14.1 Common Settings 80
14.1.1 Automatic and Manual Mode 80
14.1.2 Definitions for “Inversion” and “All Timers” 80
14.1.3 System Switch override function (Specialist level) 81
14.1.4 Flow Switch override function (Specialist level) 82
14.1.5 Maximum Output Timer (MOT) 84
14.2 General PID controller (COMMON_PID) 85
14.3 Conductivity Control Modules 94
14.3.1 On-/Off-Control (COND_CONTROL) 95
14.3.2 PI-Control (COND_PI) 99
14.3.3 On-/Off-Ratio Control (COND_CONTROL_RATIO) 103
14.3.4 PI-Ratio Control (COND_PI_RATIO) 106
14.4 Corrosion Display (CORROSION-DISPLAY) 109
14.5 pH Controller Modules (PH_ACID_CAUS) and (PH_ACID_OR_CAUS) 110
14.5.1 pH-Control (PH_ACID_CAUS) 110
14.5.2 pH Control (PH_ ACID_OR_CAUS) 115
14.6 Dosing of oxygen absorption media 119
14.6.1 Flow and temperature-based dosing (O2_SCAV_CTRL_RATIO) 119
14.6.2 Process-value-proportional dosing (OPEN_PROP) 123
14.7 Chlorine / Redox Control (CL_ORP) 125
14.8 Batch Dosing (BATCH) 128
14.9 Time scheduled Biocide Dosing (BIOCIDE_DOSING) 131
14.10 Monitoring Process Values (MONITOR_PV) 137
14.11 Dual Channel Totalizer (TOTALIZER) 139
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mxCONTROL Type 8620
15 ALARM AND ERROR MESSAGES 142
15.1 Alarm function 142
15.2 Displaying (Input-) Alarms and different (Output-) States 144
15.3 Error Messages and Warnings 145
16 MAINTENANCE AND TROUBLESHO OTING 153
16.1 Safety Notes 153
16.2 Maintenance work 153
16.3 Malfunctions 153
17 SPARE PARTS 154
18 PACKING AND TRANSPORT 154
19 STORAGE 154
20 DISPOSAL 154
21 APPENDICES 155
21.1 Project (for example "BW 06") 155
21.1.1 Input/Output Assignment – project "BW 06" 155
21.1.2 Wiring Diagram Example for Project "BW 06" 155
21.2 Power Supply of Actuators/Sensors 156
21.2.1 Power Supply out of the mxCONTROL 156
21.2.2 Separate Power Supply 156
21.3 Hardware Version 1 157
21.3.1 PIN Assignment for Power Supply Level (Power Supply) 157
21.3.2 PIN Assignment for Low Voltage Level (Instrumentation Supply) 158
21.3.3 Connection Examples for Inputs and Outputs 159
21.4 Hardware version 2 162
21.4.1 PIN assignment for power supply level (power supply) 162
21.4.2 PIN Assignment for Low Voltage Level (Instrumentation Supply) 163
21.4.3 Connection Examples for Inputs and Outputs 164
21.5 Main Menu Structure – Menu Tree (Example for Project "BW 06T") 168
21.5.1 Processdata – Inputs – Outputs 168
21.5.2 Processdata – Cond Control 169
21.5.3 Configuration of Inputs 170
21.5.4 Configuration of the Codes 171
21.5.5 System Settings 172
21.5.6 Up-/Download - Download 173
21.5.7 Up-/Download – Upload 174
21.5.8 Data Logging / Calibration / Clock 175
21.6 Data Logging File – Example 176
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mxCONTROL Type 8620
1 The operating instructions
WARNING!
The operating instructions must be read and understood.
Read the operating instructions carefully.
Note the chapters Intended Use and General Safety Instructions!
Presentation elements
DANGER!
Mains voltage! Immediate danger!
Death or serious injuries are the result of non-compliance with the safety instructions.
DANGER!
Immediate danger!
Death or serious injuries are the result of non-compliance with the safety instructions.
WARNING!
Potentially dangerous situation!
Serious injuries or death may result from non-compliance with the safety instructions.
CAUTION!
Potentially dangerous situation!
Medium or light injuries may result from non-compliance with the safety instructions.
CAUTION!
Potentially dangerous situation!
Likely property damages in case of non-compliance.
Designates important additional information, tips and recommendations important for your
safety and the flawless function of the device.
Refers to information in these operating instructions or other documentation.
→ Marks a section you have to carry out.
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mxCONTROL Type 8620
2 Intended Use
WARNING!
Hazards to persons, equipment in the vicinity and the environment may result when not using
the „Type 8620 mxCONTROL“ as intended.
The „Type 8620 mxCONTROL“ may not be used in explosion-hazard rooms.
The „Type 8620 mxCONTROL“ may only be used at temperatures from 0 °C.
The permissible data and operating conditions specified in the operating instructions as well
as the application areas described in chapter 6.1 must be followed. The customer is responsible for choosing the device suitable for his application.
Proper transport, proper storage and installation as well as careful operation and service are
the prerequisites for safe and flawless operation.
Use the „Type 8620 mxCONTROL“ only as intended.
The „Type 8620 mxCONTROL“ is a multifunction controller. This multifunction controller was
developed to automate the control and process variables in a water treatment system (e.g.
boiler, cooling tower or Reverse Osmosis system).
Sophisticated electronics and state of the art control algorithms ensure that optimum process control is
maintained at all times, with minimal operator intervention.
Depending on the hardware version, the „Type 8620 mxCONTROL“ is capable of processing several
analog and digital inputs as well as several relay, transistor and analog outputs at the same time.
Combined with an easy to read display in three languages: English, German and French (other
languages on request), the device offers nearly unlimited options for process automation systems.
The „Type 8620 mxCONTROL“ functions are highly software-based. All configuration and
parameter files can be created in a quick and unsophisticated manner with the help of a PC Tool
and downloaded in the „Type 8620 mxCONTROL“ via SD card or USB. Alternatively, the optional
Ethernet interface can be used to configure and parameterize the device. The operator can then enter
and display all important variables and parameters using five soft-touch keys.
The „Type 8620 mxCONTROL“ is supplied with an SD card containing not only the configuration and
parameter files but also the operating instructions.
Three authorization levels (code level) allow for the safe operation of the „Type 8620 mxCONTROL“:
Open access, access only for instructed operators, access for specialists.
2.1 Restrictions
Note possibly existing restrictions when exporting the device.
2.2 Anticipated misuse
• The „Type 8620 mxCONTROL“ may not be used in explosion-hazard areas!
• Do not put mechanical stress on the unit (e.g. by storing heavy objects on it or using it as a
step).
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mxCONTROL Type 8620
3 General Safety Instructions
These safety instructions do not take any
• Incidents and occurrences into account which may occur during assembly, operation and
maintenance of the devices.
• Local safety regulations where the operating party is responsible for its compliance, also in
Danger from electrical voltage
Reaching into the system presents an acute risk of injury.
Always switch off the power before beginning with the work activities and secure it against being
switched back on inadvertently! Obey the applicable accident prevention and safety regulations for
electrical devices!
Inadvertent operation or impermissible restrictions may cause general danger situations
through the downstream actuators, including physical injuries.
regard to the installation staff.
DANGER!
WARNING!
Take proper precautions to prevent accidental actuation or inadmissible impeding.
Dangerous situations may develop during installation and repair activities. This type of work may only
be carried out by authorized technical personnel and with suitable tools!
After an interruption of the electric supply, ensure a defined and controlled restart of the processes!
WARNING!
Personal injuries and damage to the system may occur following a system interruption or after
manual operation through unwanted operation of output devices.
Before changing the mode of operation (Manual or Automatic), appropriate measures must be
taken to prevent harm to personnel and the system due to unwanted actuation of an output device
(e.g. biocide pump).
CAUTION!
The general engineering rules apply to the deployment planning and operation of the device!
Disregarding these rules may result in injuries and/or damages to the device and possibly its
environment.
Follow the general rules of engineering!
CAUTION!
Electrostatically endangered components/modules
The device contains electronic components which may react sensitively against electrostatic
discharges (ESD). Touching electrostatically charged persons or objects puts these components at
risk. In the worst case, they will be destroyed or fail after startup.
Follow the requirements according to DIN EN 61340-5 to minimize or prevent the possibility of
damage due to sudden electrostatic discharge!
Make also sure not to touch the electronic components if supply voltage is supplied!
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mxCONTROL Type 8620
CAUTION!
Hardware and Software modifications and changes
For safety reasons unauthorised modifications and changes of hardware and software are not allowed.
Make sure to comply with the notes, thresholds, operating modes and safety instructions given in this
manual.
Non-compliance with this manual and operating sequence will void any liability claims.
CAUTION!
Temporary protection against overload and short circuit
Instrumentation Supply part (24 V DC): the device is protected against destruction by overload and
short circuit. No safe function is ensured for the duration of such disturbance. After such a disturbance,
the „Type 8620 mxCONTROL“ automatically continues its normal operation.
The plant must be dimensioned so that the sum of extracted current of all actuators/sen¬sors
connected at the Instrumentation Supply side never exceeds the value of 1.04 A.
The „Type 8620 mxCONTROL“ was developed on the basis of recognized technical safety
rules and corresponds to the state of technology. Hazards may nonetheless develop.
Operate the „Type 8620 mxCONTROL“ only in flawless condition and in compliance with the
operating instructions. Also make sure to comply with the conditions of use according to
the specifications in chapter 6.1 „Technical Specifications“ and on the type plate of the
device.
Non-compliance with these instructions and unauthorized tampering with „Type 8620
mxCONTROL“ voids any liability by us; the warranty for the device and accessories also
becomes void!
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mxCONTROL Type 8620
4 General Information
4.1 Scope of Delivery
Verify immediately after receiving the shipment that the contents are not damaged and agrees with the
specified scope of delivery as stated on the enclosed "Delivery instructions"; also make sure that the
details on the type plate match the conditions of use.
Please contact our sales centre immediately in case of disagreements:
Bürkert Fluid Control Systems
Sales Center
Christian-Bürkert-Str. 13-17
D-74653 Ingelfingen
Germany
or your Bürkert distribution centre.
Phone: +49 (0)7940 - 10 111
Fax: +49 (0)7940 - 10 448
Email: info@de.buerkert.com
4.2 Warranty Regulations
This document contains no promise of guarantee. Please refer to our terms of sales and delivery. The
warranty is only valid if the device is used as authorized in accordance with the specified application
conditions.
The warranty extends only to defects of the „Type 8620 mxCONTROL“ and its components.
We accept no liability for any kind of collateral damage which can occur due to failure or
malfunction of the device.
4.3 Certifications
The certification designation on the Bürkert type plates refers to the Bürkert products.
More information on the certifications can be found in the chapter
6.1 “Technical Specifications“.
4.4 Information in the Internet
You can find operating instructions and data sheets on type 8620 in the Internet at:
www.buerkert.de → Technical Data → Operating instructions → Data sheets → Type 8620.
The complete documentation is supplied on the SD card.
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mxCONTROL Type 8620
5 Abbreviations
5.1 Abbreviations in Software and Documentation
Further abbreviations (Error messages) can be found in chapter 15.3.
Abbreviation Explanation
+Tm Maximum output time
+TmPB Maximum pre-bleed duration
AH Higher Alarm Process Value
AL Lower Alarm Process Value
Alarm- Lower alarm limit
Alarm+ Upper alarm limit
AlarmHys Alarm hysteresis in % of process value range
Alarm H Upper Process Value Alarm
Alarm L Lower Process Value Alarm
AnalogIn 1 to 4 Analog input 1 … 4
ASL Acid (pump) stop limit (Acid Stop Limit)
ASL PumpStop Pump Stop due to the ASL alarm
Au Automatic Mode
BATCH (or Batch Dosing) Batch Module (dosing by batches)
Binary Binary input (digital: 0 / 24 VDC)
BIOCIDE_DOSING Biocide dosing module
BioDos Biocide dosing module (abbrev.)
Cd Conductivity module (On/Off control) - abbrev.
Cd-PI
Cd-PIr
Cd r
CL Chlorine
CL/ORP Chlorine/Oxidising Redox Potential PI-Control Module - abbrev.
CL_ORP Chlorine/Oxidising Redox Potential-PI-Control Module
CM Calibration mode: 4-20mA input or output is currently calibrated
CMD Module output (command) to actuator (%) - proportional/integral
CMD A Module output (Acid) - acid pump
CMD C Module output (Caustic) - caustic pump
CMD on Output value at module output e.g. during dosing
CMDsafe
CMD 1, CMD 2 Module output for channel 1, module output for channel 2 (at BIOCIDE_DOSING)
Cond Conductivity
COND_CONTROL Conductivity module (On/Off control)
COND_CONTROL_RATIO
COND_PI
COND_PI_RATIO
Cor Corrosion
CorroD Corrosion Display Module (short name)
Conductivity module (PI control) - abbrev.
(in part with 3-point step output)
Conductivity module (PI-Ratio-Control) - abbrev., set point depending on MakeUp-Channel ratio
Conductivity module (On/Off Ratio-Control) - abbrev., set point depending on
Make-Up-Channel ratio
Safety output value, it is active if
- on the 4…20 mA input less than 3.5 mA or more than 20.5 mA are applied,
- on the Pt100 input, a temperature outside of the measuring range is applied
Conductivity module (On/Off Ratio-Control), set point depending on Make-UpChannel ratio
Conductivity module (PI control)
(in part with 3-point step output)
Conductivity module (PI-Ratio-Control), set point depending on Make-Up-Channel
ratio
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Abbreviation Explanation
CORROSION_DISPLAY Corrosion Display Module
Cut- Lower CutOff threshold (Module "COMMON_PID")
Cut+ Upper CutOff threshold (Module "COMMON_PID")
D- Max. negative set point change per minute, falling (Delta-)
D+ Max. positive set point change per minute, rising (Delta+)
Dbnd Deadband - to prevent vibration of the actuator
DigIn 1 … 4 Digital input 1 … 4
Dos1 … Dos8 Biocide timer settings (8 per day per channel)
FA AD-Fault
Fc Calibration Data Fault
FC Configuration Fault
fF Flow switch: “No Flow”
FI Input Fault
Filter Filter stage (for Low Pass Filter)
Fmax Maximum actuator output pulse rate per minute or per hour
fo forced by other modules
Freq- Lower frequency value of a frequency range
Freq+ Upper frequency value of a frequency range
Fr Friday
fS System switch: “Stand-by”
FS Sensor Fault; Full scale (in connection with Technical Specification)
FSOR Flow switch override
Hyst Switching hysteresis set in engineering units
HO Process Value state, Value Hold during User Calibration of 4-20mA inputs
Inv Inversion of the sense of action of a module/signal
IS Instrumentation Supply
Kp Gain/amplification factor (in [% control output/PV unit])
Kx Ratio factor for internal set point calculation
Lim- Lower output limit in %
Lim+ Upper output limit in %
Ma Manual (operation) mode
Mo Monday
MONITOR_PV Module - monitoring only a Process Value PV (data logging)
Mon PV Module - monitoring only a Process Value (data logging) - short name
MOT Maximum Output Timer
MPY Mils Per Year
MTPB Maximum pre-bleed timer
µMPY Micro Mils Per Year
nA Input not active
O2_SCAV_CTRL_RATIO Dosing of O2-absorption media based on flow and temperature
O2SCR Dosing of O2-absorption media based on flow and temperature - abbrev.
OF Output fault of the 4…20 mA outputs
OPEN_PROP Dosing proportionally to process value
OpProp Dosing proportionally to process value - abbrev.
ORP Oxidising Redox Potential (Redox)
PB
PB ratio
PFM Pulse Frequency Modulation
pH-AC
pH-A/C
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Pre-Bleed Limit of biocide dosing module in connection with the
COND_CONTROL and COND_PI modules
Pre-Bleed Ratio Limit of biocide dosing module - only in connection with the
modules COND_CONTROL_RATIO and COND_PI_RATIO
pH PI Module with selection of acid and caustic pump (abbrev.)
pH PI Module with selection of acid or caustic pump (abbrev.)
mxCONTROL Type 8620
mxCONTROL Type 8620
Abbreviation Explanation
PH_ACID_CAUS
PH_ACID_OR_CAUS
pH PI Module with selection of acid and caustic pump
pH PI Module with selection of acid or caustic pump
ptf.binary Binary input (digital, potential-free)
PS Power Supply
Psd Process switching difference
PumpStop Pump stopped because corrosion limit exceeded
PV Process value
PV BSi Process value of Batch size
PV cal Conductivity value (for TDS-calibration)
PWM Pulse Width Modulation
r read (access via configuration menu or via XML-configuration or parameter file)
Ref.Date Week1 Reference Date for week 1
rw read and write (access via configuration menu or via XML-config. / parameter file)
Sa Saturday
Scal- Minimum value of sensor range (in engineering units)
Scal+ Maximum value of sensor range (in engineering units)
SP Set point
SP BSi Set point of Batch size
SpecFunc Special input function for 4…20 mA inputs
SPLim Set point minimum (internal calculation for conductivity)
SPLim- Lower set point limit for pH measurement
SPLim+ Upper set point limit for pH measurement
SP Limit Set point Limiter
SP Ramp Set point ramp
SSOR System switch override
State Current state of dosing process in batch module
Su Sunday
Tco cl Time for complete closing: 100% Æ 0%)
Tco op Time for complete opening: 0% Æ 100%)
Tdose (Total) Biocide dosing time; Batch dosing time
TDS Total Dissolved Solids
TDS cal TDS-value (Total Dissolved Solids value)
Th Thursday
+Tm Maximum output time
+TmPB Maximum pre-bleed duration
Tm1 Interval between main biocide dosing & post dosing
Tm2 Delay after post-dosing before conductivity control resumes
Tn Reset time in seconds
Tperiod period duration
Tpuls Pulse duration of the actuator output in milliseconds or seconds
Tsample Sample time of the respective control loop; sample time with data logging
Tu Tuesday
Tv Rate time
w write (access via configuration menu or via XML-configuration or parameter file)
Warn- Lower warning limit
Warn+ Upper warning limit
WarnHys Warning hysteresis in % of process value range (AwHyst)
WH Upper warning process value
We Wednesday
WL Lower warning process value
YA Abbreviation in the alarm display for ASL-pump-stop
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Abbreviation Explanation
YF Out fails (MOT is expired)
YS Safety output value is active (due to input/sensor fault)
mxCONTROL Type 8620
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mxCONTROL Type 8620
5.2 Display of the units
Because of the limited display, there is not always sufficient room available for the detailed display of
the unit. Depending on the available positions, 3 or 6 positions are shown in the display; the
equivalents as well as the output during data logging are listed in the following table, arranged by
groups.
Display
max. 3 characters
Volume units
L L L Litre
hL hL hL Hectolitre
m3 m3 m3 Cubic metre
Gal Gal US Gal US U.S. liq. Gallon
bbl bbl US bbl US U.S. Barrel
gal gal Im gal Imp Imperial Gallon
ft3 ft3 ft3 Cubic Foot
yd3 yd3 yd3 Cubic Yard
Flow units
L/s L/s L/s Litre per second
L/m L/min L/min Litres per minute
L/h L/h L/h Litre per hour
m3M m3/min m3/min Cubic metre per minute
m3H m3/h m3/h Cubic metres per hour
G/s Gal/s Gal/s US U.S. liq. Gallons per second
G/m Gal/m Gal/m US U.S. liq. Gallons per minute
G/h Gal/h Gal/h US U.S. liq. Gallons per hour
g/s gal/s gal/s Imp Imperial gallons per second
g/m gal/m gal/m Imp Imperial gallons per minute
g/h gal/h gal/h Imp Imperial gallons per hour
bbS bbl/s bbl/s US U.S. Barrel per second
bbM bbl/m bbl/m US U.S. Barrel per minute
bbH bbl/h bbl/h US U.S. Barrel per hour
f3S ft3/s ft3/s Cubic Feet per second
f3M ft3 /m ft3 /min Cubic Feet per minute
f3H ft3/h ft3/h Cubic Feet per hour
P/s Pul/s Pul/s Pulses per second
P/m Pul/m Pul/m Pulses per minute
Units for chemical analysis
µS µS/cm µS/cm Microsiemens per centimetre
mS mS/cm mS/cm Millisiemens per centimetre
MPY MPY MPY Mils per year
µMY µMPY µMPY Micromils per year
mV mV mV Millivolt
mgL mg/L mg/L Milligrams per litre
%Sa %Sat %Sat Percent of saturation
pH pH pH pH
Temperature units
°C °C °C Degree Centigrade
°F °F °F Degree Fahrenheit
°Ra °Rank °Rank Degree Rankine
K K K Kelvin
Display
max. 6
characters
Display of the unit
selection as well as
data logging
Page 15
unit
Display
max. 3 characters
Display
max. 6
characters
Display of the unit
selection as well as
data logging
mxCONTROL Type 8620
unit
Pressure units
bar bar bar Bar
mba mbar mbar Millibar
psi psi psi psi
Various units
ppm ppm ppm Parts per million
V V V Volt
mA mA mA Milliamps
Pul Pulse Pulse Pulse
Hz Hz Hz Hertz
% % % Percent
Other parameter units
ms ms ms Milliseconds
s s s Seconds
min min min Minutes
h h h Hours
/m /min /min Per minute
/h /h /h Per hour
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mxCONTROL Type 8620
6 Technical Data
6.1 Technical Specifications
These operating instructions are valid from Firmware revision: C.00.00.00
General Details of the Device
Enclosure with sealed keypad and display
Enclosure outer dimensions L x W x H 230 x 204 x 119 mm (without cable glands)
Enclosure material PC (UL94) with transparent door and key
Weight 1.8 kg
Degree of protection
Graphic display, large and backlighted 128 x 64 dots, two colored (blue and white)
Keypads for manual operation 5 keys for user inputs
Operating temperature 0 … +50 °C
Storage temperature -20 … +60 °C
Electrical Details
Mains voltage (power supply) 100 … 240 V AC, 50/60 Hz, no adjustment necessary
Power consumption (of mxCONTROL device) max. 35 W (incl. sensor supply at Instrumentation Supply part)
Total power consumption
(using the internal power distribution)
Total input current I
Total output current I
(using internal power distr.) max. 10 A
in
out
(using the internal power distribution)
Instrumentation supply for sensors / transistor
outputs
Fuse for device protection
(Instrumentation)
Fuse for Relays outputs
Inrush current (typ.) Cold start: 30 A / 230 V AC
Electrical Connections
Electrical connection Power Supply Hardware version 1: Screw terminals, grid 5.08 mm,
Electrical connection Instrumentation Supply Hardware version 1: Screw terminals, grid 3.81 mm,
Cable glands and cables
IP 65 and NEMA/UL 50, Type No. 4X, with door closed and
properly sealed cable glands,
additional cover of USB port and SD card slot
max. 2400 W (at 240 V AC) or max. 1100 W (at 110 V AC)
incl. connected actuators at Power Supply part
<10 A (incl. device power consumption of 35 W)
24 V DC (±5 %), max. 1.04 A (25 W),
short circuit and overload protected
internal: electronic fuse, recovers automatically after fault
condition is removed
Relay outputs to be fused in external installation according to
actuators
for wire gauges 0.14 … 1.5/2.5 mm
Hardware version 2: Spring type terminal, grid 5.0 mm,
for wire gauges 0.2 … 2.5/4.0 mm
for wire gauges 0.14 … 1.0/1.5 mm
Hardware version 2: Spring type terminal, grid 3.5 mm,
for wire gauges 0.2 … 1.5 mm
2
(AWG 26…14)
2
(AWG 24…12)
2
(AWG 26…16)
2
(AWG 24…16)
Hardware version 1:
9 x M16 (PG9) 5 ... 6.5 mm cable
1 x M32 (PG21) 5 mm cable (5x)
Hardware version 2:
4 x M16 (PG9) 5 ... 6.5 mm cable
2 x M16 (PG9) 6 ... 9.5 mm cable
3 x M20 (PG13) 9 ... 13.5 mm cable
1 x M32 (PG21) 5 mm cable (5x)
(cable = outer diameter of cable)
Not used cable glands have to be sealed with appropriate
sealing bolts to guarantee the Degree of protection IP65.
Thermal stability (cable material):
105 °C for cables at Power Supply part
80 °C for cables at Instrumentation Supply part
Page 17
mxCONTROL Type 8620
Internal Equipment – Inputs
Inputs Hardware version 1:
4 Analog inputs (4 … 20 mA or Pt100; software-
configurable) +
4 digital (On/Off or Freq) inputs
Hardware version 2:
4 Analog inputs 4 … 20 mA +
2 Pt100 +
4 Digital (On/Off or Freq) inputs +
4 digital (On/Off) inputs
Analog inputs – Characteristics
Input resistance of 4…20 mA inputs
max. 300 Ω
Measuring error of 4…20 mA inputs < 0.2 % FS
Range of Pt100 inputs -20 … +150 °C
Measuring error Pt100 inputs
max. ±0.25 K
3 wire connection; software compensated wire resistance
required
Digital Inputs - Characteristics
Logical values binary inputs 1 or HIGH: 13 ... 35 V; 0 or LOW: 0 … 4.5 V
Input resistance of binary inputs
≥ 20 kΩ
Max. frequency 2 kHz
Duty factor frequency 1 : 1
Measuring error frequency max. 0.2 % FS
Input accepts signals from
open collector; open emitter; push-pull output; hall effect; reed
switch; micro switch
Internal Equipment - Outputs
Outputs Hardware version 1:
5 Relay outputs +
4 Analog outputs 4 … 20 mA (optional) +
4 Transistor outputs (optional)
Hardware version 2:
5 Relay outputs +
2 Analog outputs 4 … 20 mA +
2 Transistor outputs
4…20 mA Analog outputs - Characteristics
Relay outputs - Characteristics
max. 500 Ohmic load, output resolution 10 bit (effective >9 bit)
max. 250 V AC/DC, max. 10 A, potential-free, two-way
contacts,
max. 2500 VA (AC), max. 40 W Ohmic load (DC),
3 million switching cycles at 1 A, 10 million switching cycles at
0 A
Transistor outputs - Characteristics
24 V DC, switching capacity each max. 16 W, pnp, max. 2200
Hz
Further internal Equipment
Micro-controller core 32 bit with integrated flash memory
Slot for SD card (memory card)
Can be used for data logging, up- and download of
configuration and parameter files
Clock real-time clock with calendar
Battery back-up for real-time clock
Lithium battery CR2032, exchangeable, approx. 10 years
service life
Continuation next page
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mxCONTROL Type 8620
Communication
SD card
SD card capacity: minimum 64 MB, maximum 2 GB,
formatted with FAT16 file system
Up-/download of configuration data
via USB or SD card
and parameters
Data-logging on SD card
Firmware update via USB
USB slave interface standard USB interface for PC communication
Ethernet interface
optional: Ethernet interface for easy diagnosis including Web
Server and email option
Extension bus interface
CAN-based bus for connection of extension units
(e.g. I/O extensions)
Controller structure
Number of control loops max. 8 active control loops
Controller outputs/Module outputs 1) On/Off
2) Pulse frequency modulated (PFM)
3) Pulse width modulated (PWM)
4) Analog
Sample period
approx. 50 ms (with 1…4 active control loops);
approx. 100 ms (with more than 4 active control loops)
User configuration
Cascade control possible; inputs, outputs and control function
designations can be changed via configuration file
Characteristics of modules
General PID control
PID process controller for fixed value, subsequent value or
cascade control
Conductivity control
On/Off or PI control - continuous dosing through PFM, PWM or
4…20 mA analog output,
automatic or manual drain
Corrosion display
No controller function, only display of measuring values;
impact on general alarm output
pH control
PI control - continuous dosing through PFM, PWM or 4…20
mA analog output
Module for dosing of oxygen scavenger media
Proportional dosing for flow and oxygen content depending on
flow with or without temperature input
Chlorine / Redox Control
PI control - continuous dosing through PFM, PWM or 4…20
mA analog output
Batch-Dosing
Allows batching of a chemical based on volume of water
added
Biocide dosing
14-day program, 8 dosing events per channel/per day; Prebleed function to optimize biocide kill time
Monitor module Display of process values
Totalizer function
Single or dual channel flow totalizer (each having two
manually resetable totalizers)
Further functionalities
Password protection, filter; selection of engineering units,
alarm; inverse function
Norms and standards
Environment standards IEC/ DIN IEC 60068
EMC standards EN 61000, EN 55011
Continuation next page
Page 19
CE mark applicable tests resulting in CE mark
UL/CSA (for UL/CSA approved versions)
conform to Std. UL61010-1 Second Edition “Process Control
Equipment” and to the appropriate
CSA standard C22.2 No. 61010-1 Second Edition
mxCONTROL Type 8620
Table 1: Technical Specifications
6.2 Type Plate – Example
Device designation (multi function controller)
Type
Specifical Configuration of the device
Voltage and Frequency range, admissible Current
Serial Number and
Order Number and Production Code
The UL Mark is necessary for marketing at the US and
Canadian market.
Attention! Consider the manual!
This UL Mark certifies that the appropriate safety
requirements are observed (for UL approved versions
only.)
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mxCONTROL Type 8620
6.3 Hardware Structure
This simplified block diagram shows the main hardware components of „Type 8620 mxCONTROL“.
Figure 1: Block diagram - Hardware structure
The number of the in- and outputs of the several hardware versions is listed in the following
Table 2:
Inputs
Outputs
Analog 4 … 20 mA - 4
Analog Pt100 - 2
Analog 4 … 20 mA or Pt100 4 -
Digital (Binary) - 4
Digital (Binary or Frequency) 4 4
Analog 4 … 20 mA 4 (optional) 2
Relay 5 5
Transistor 4 (optional) 2
Table 2: Number of inputs and outputs of the hardware versions
Hardware version 1 Hardware version 2
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mxCONTROL Type 8620
6.4 Module Overview
This table shows the available standard modules which can be combined specifically for the
application. They can function either as process or control or merely as display module.
The module names as used in the configuration files and the short designations for the menu are
listed as well as a short explanation of the module type.
Module-name for XMLconfiguration-file
NONE -- --
BATCH Batch Batch-Dosing
BIOCIDE_DOSING BioDos Biocide-Dosing
CL_ORP CL/ORP Chlorine/Redox-PI-Control
COMMON_PID PID General PID controller
COND_CONTROL Cd Conductivity On/Off control
COND_CONTROL_RATIO Cd r
COND_PI Cd-PI Conductivity PI-Control
COND_PI_RATIO Cd-PIr
CORROSION_DISPLAY CorroD Corrosion-Display
MONITOR_PV Mon PV
O2_SCAV_CTRL_RATIO O2SCR
OPEN_PROP OpProp Dosing (proportionally to process value)
PH_ACID_CAUS pH-AC pH PI-Control with outputs for acid and caustic pumps
PH_ ACID_OR_CAUS pH-A/C pH PI-Control with output for acid (or caustic) pump
TOTALIZER Total 2-channel totalizer
Short name in
menu
Module type
Conductivity On/Off control, set point via ratio from Make-Up
Channel
Conductivity PI-Control,
set point via ratio from Make-Up-Channel
Monitoring only up to two process values (data logging) and
optionally output
Dosing of oxygen absorption media based on flow rate and
temperature of the feed water
Table 3: Module designations and types
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mxCONTROL Type 8620
7 Installation
7.1 Safety Notes
DANGER!
Danger from electrical voltage!
Reaching into the system presents an acute risk of injury.
Always switch off the power before beginning with the work activities and secure it against being
switched back on inadvertently!
Obey the applicable accident prevention and safety regulations for electrical devices! Please, compare
the DANGER and UL indications in chapter 7.4 “Electrical Connections”!
WARNING!
Danger from improper installation!
Improper installations may result in injuries as well as damages on the device and its environment.
This type of work may only be carried out by authorized technical personnel and with suitable tools!
Danger from unintentional operation!
Dangerous situations may develop from unintentional operation of the plant.
Prevent the possibility of unintentional operation of the plant through suitable measures.
7.2 Quick Start Guide
Install the „Type 8620 mxCONTROL“ in a plant or
mounted on a backboard as shown in figure 2
Figure 2:
→ Install the required sensors and other equipment, according to the separate operating
instructions.
→ Make the wiring connections according to the specifications in chapter
→
Switch on the operating voltage.
→ Load the configuration file and the parameter file from an SD card (see chapter
→ Chec
→ Set
k/edit parameters and values in the operating menu according to the menu description
(see Chapter
9) and module description (chapter 14).
the date and time in the corresponding menu (refer to chapter
„Type 8620 mxCONTROL“ - Installation example
7.4.
11.2).
21.5.8).
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mxCONTROL Type 8620
7.3 Mechanical Installation
Direct sunlight will reduce the viewing contrast at the display – although it is harmless to the
display. Therefore find a suitable, protected location for the installation.
The „Type 8620 mxCONTROL“ is not designed for ambient temperatures below.0 °C.
If this cannot be avoided, the „Type 8620 mxCONTROL“ must be installed in a
thermostatically controlled cabinet to maintain a normal ambient temperature.
In North America, the device must not be installed directly at building walls! In this case use
always appropriate backboards or switchboards/switching cabinets for mounting the device.
→ Open the cover (unlock it if a key is supplied) by pressing the snap lock with both thums.
For closing the cover press it down until a “click” is to be heard (and lock it with the key).
→ The „Type 8620 mxCONTROL“ is designed for wall mounting (exception: North America – see
information frame above).
Figure 2 shows the preferred mountin
g position.
Drill 4 holes (according to
the used screws) according
to the dimension shown.
Mount the device with 4 appropriate screws
(recommended screws:
M4.5 or M5,
screw head: ≤ 9.5 mm).
Figure 3: Dimensions for mounting
4 Mounting holes
→ Wall mounting with screws is made possible by 4 openings located in each corner of the
enclosure (see
Figure 3). Access to these openings is obtained by opening the cover.
7.4 Electrical Connections
DANGER!
Danger from electrical voltage
Reaching into the system presents an acute risk of injury.
Make sure that no supply voltage is present on the device when working on it! Obey the applicable
accident prevention and ensure that all electrical connections comply with local and plant regulations!
Pay attention to correct design of the fuse and/or the line safety switch in the power supply
line.
For dimensioning and installation of disconnecting switch, fuses etc. necessarily refer to further
information below!
In North America, devices with UL certification have to be used for these purposes.
Page 24
mxCONTROL Type 8620
Dimensioning of fuses, line safety switches, overcurrent protection devices
Pay attention to correct design of the fuse and/or the line safety switch in the power supply line.
The L- and N-conductors have to be protected with overcurrent protection devices (max. 10 A) as e.g.
fuses, line safety switch etc.
Also install an equipment for the disconnection of L- and N-conductors from the power supply
near the „Type 8620 mxCONTROL“. Therefor e.g. the above-mentioned overcurrent protection
device or an appropriate disconnecting switch (110/240 V and with at least the size of current of the
overcurrent protection device) can be used.
If the sum of extracted current of all connected actuators at the Power Supply part exceeds the
value of 10 A, the actuators can be connected with a separate voltage supply for those actuators -
please refer to the schemata in appendix
21.2 „Power Supply of Actuators/Sensors“.
Electrical Connections
The preferred mounting position for the „Type 8620 mxCONTROL“ is with the cable glands facing
downward, i.e. all cable glands are located at the bottom of the device.
→ The electrical connections can be accessed by loosening the screws that hold the lower cover
plate in place. You can then lift the cover plate by the black handle.
→ The terminal strips for the mains voltage level (power supply) and the low-voltage level
(instrumentation supply) are separated by an isolating plate (see
Mains voltage level
(Power supply PS)
(Hardware version 1)
Figure 4).
Low-voltage level
(Instrumentation
supply IS)
Isolating plate
(Hardware version 2)
Figure 4: Viewing the inside of the terminal strip compartment (with the cover plate removed) of the
„Type 8620 mxCONTROL“:
top: Hardware version 1: Screw terminals
bottom: Hardware version 2: Spring type terminals
→ Use suitable cables (for wire gauges/cross sections see chapter 7.5) for the passage through the
cable glands (for outside cable diameters and thermal stability of cable material refer to chapter
6.1, paragraph “Electrical connections”).
→
Unscrew the nut of cable gland and remove the seal.
→ First push the cable through the nut of the cable gland and the seal insert and then prepare each
wire of the cable with a cable end sleeve (see
(cable for Power Supply: sleeve length: 7 mm,
Figure 5) of the recommended length:
cable for Instrumentation Supply: sleeve length: 5 mm).
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mxCONTROL Type 8620
Figure 5:
Cable with cable end sleeves
→ Then guide the prepared cable through the cable gland opening into the device and attach the
wires to the terminal strip.
→ Now screw the cable gland nut tight until the cable is securely attached
(tightening torque for cable gland M16: max. 6 Nm
(tightening torque for M20 cable gland: max. 8 Nm
(tightening torque for M20 cable gland: max. 10 Nm)
→ After clamping all required connections re-attach the plate and tighten the screws.
Important! Seal unused cable glands with sealing bolts – protection class IP65 is otherwise
not guaranteed.
7.5 Terminal Strip Pin Assignment
7.5.1 Power Supply (PS)
Connect the cables as shown in the PIN tables in the appendix (21.3.1 and 21.4.1).
The respective terminal assignment plans are created with the PC Tool according to the “project”.
They serve as basis for wiring diagrams and the input/output assignment as shown in the example in
the appendix
Hardware version 1
Figure 6: Terminal strips for the mains voltage level, with PIN numbers
21.1
Hardware version 2
Hardware version 1 Hardware version 2
PIN numbering 1 to 48 1 to 36
Terminal strips Screw terminals Spring type terminals
Terminal grid 5.08 mm, AWG 26 … 14 5.0 mm, AWG 24 … 12
Wire gauges - rigid wires 0.14 … 2.5 mm² 0.2 … 4.0 mm²
Wire gauges - flexible wires 0.14 … 1.5 mm² 0.2 … 2.5 mm²
Tightening torque for screws 0.5 … 0.6 Nm (4.5 … 5.3 lb in) --
PIN table Table in appendix 21.3.1 Table in appendix 21.4.1
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mxCONTROL Type 8620
7.5.2 Instrumentation Supply (IS)
Connect the cables as shown in the PIN tables in the appendix (21.3.2 and 21.4.2).
The respective terminal assignment plans are created with the PC Tool according to the “project”.
They serve as basis for wiring diagrams and the input/output assignment as shown in the example in
the appendix
Hardware version 1
Figure 7: Terminal strips for the low voltage level, with PIN numbers
21.1
For sensor inputs and analog 4…20 mA outputs shielded cables are recommended for best
EMC. Connect the cable shields with the respective Pin “GND” for EMC.
Hardware version 2
Hardware version 1 Hardware version 2
PIN numbering 49 to 111 37 to 96
Terminal strips Screw terminals Spring type terminals
Terminal grid 3.81 mm, AWG 26 … 16 3.5 mm, AWG 24 … 16
Wire gauges - rigid wires 0.14 … 1.5 mm² 0.2 … 1.5 mm²
Wire gauges - flexible wires 0.14 … 1.0 mm² 0.2 … 1.5 mm²
Tightening torque for screws 0.22 … 0.25 Nm (2 … 2.2 lb in) --
PIN table Table in appendix 21.3.2 Table in appendix 21.4.2
7.6 Download of a Configuration and Parameter File
A configuration file must be downloaded to the „Type 8620 mxCONTROL“ before it can be effectively
used in an automation system. Downloading of configuration files is for the Specialist Level only!
After successful download of the configuration file the parameters will be set back to the default
values. With the download of the corresponding parameter file the default values will be overwritten
with these values.
Read chapter
8 and especially chapter 11.2 before.
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mxCONTROL Type 8620
8 Description of Human-Machine Interface
8.1 Safety Notes
WARNING!
Danger from improper operation!
Improper operation may result in injuries as well as damages on the device and its environment.
The device may only be operated by authorized technical personnel!
The persons operating the device must be familiar with the content of the operating instructions and
have understood the same. The safety instructions and intended use require special consideration.
8.2 Operating and Display Elements
Hinged lid protection for
the USB-Interface and
SD card-slot
(SD card will be ejected
by pressing it)
A/M-Key - switches
between automatic and
manual mode, with
flashing alarm-LED
Display
4 soft keys.
(the functions change as
shown in the lowest line
of the respective
display)
handle for lifting the
cover plate
Figure 8: View on the panel of „Type 8620 mxCONTROL“
The „Type 8620 mxCONTROL“ is operated with 4 soft keys below the display (with alternating
functions) and an A/M key to switch between automatic and manual mode.
The brightness of the display can be changed. The brightness can be adjusted in 10 brightness
levels under the main menu item "System settings"; refer to
The default setting is brig
htness level 5 to ensure a long service life of the display.
Table 4 in chapter 9.1.
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mxCONTROL Type 8620
8.3 Operation Mode
8.3.1 Automatic & Manual Mode Key
A/M key with
yellow LED
In case of alarm, follow the descriptions in chapter 15 “Alarm and Error Messages”.
8.3.2 Automatic Mode (LED on)
The „Type 8620 mxCONTROL“ starts in automatic mode after powering up. The LED is on; a "running
bar" in the top line of the display also indicates the Automatic Mode.
The A/M key switches between the Automatic and Manual Mode;
the A/M key includes a yellow LED:
LED on Æ Automatic Mode
LED off Æ Manual Mode
LED flashing Æ ALARM (at least one alarm) both in
automatic and manual mode
8.3.3 Manual Mode (LED off)
The operating mode for all modules can be changed directly by pressing the separate A/M-Key.
Attention: All dosing processes of the Batch- and Biocide-Dosing-Modules are cancelled
in Manual Mode!
(The next dosing process will start at its programmed time when returning to Automatic Mode.)
In manual operation, the control of the process values is transferred from the device to the user. The
user now controls the process values manually with the soft keys of the „Type 8620 mxCONTROL“
whereby the connected actuators are operated. For this purpose, the values in the main menu
"Process data" need to be changed under the corresponding module.
Switching from Automatic to Manual Mode is “changeless”, except for the "Biocide-Dosing" and
"Batch" modules. “Changeless switching” means that the last output value in Automatic Mode is the
current output value in Manual Mode as long as the operator does not change the output value
manually.
If the system switch override function or the flow switch override function or the
safety output value is activated the manual output value will be reset to “0”!
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mxCONTROL Type 8620
8.4 Layout of Menu Screens
Running bar directly below the upper horizontal screen border, running
from the left to the right – indicates the Automatic Mode
Cursor bar
Menu items
Current position inside
the whole menu tree
4 Soft keys
Menu title - indicates the (self selected) designation for the
BW 06
Processdata
Parameter
Configuration
System settings
1
ENTER
“project” (module combination)
(or "No Config. loaded", if no
configuration file is
downloaded)
Current cursor position within
the current menu (slide bar)
The soft keys at the device have no symbols. Their function is defined
in the bottom screen line, where the current function of each key is
displayed as a text string or as a symbol.
The keys have symbols to explain the possible actions, in the above
example:
no function, up-arrow, down-arrow, Enter
The current position inside the menu tree is shown in the middle of the
bottom screen line.
You can scroll through the menu with the "up-arrow" and "down-arrow"
soft keys.
The menu position/numbering is indicated by the main menu and max.
4 submenus, i.e. it is a max. 5-character alphanumeric combination and
is shown in the following format: "4-A-3-1-2".
(the numbering of the menu items within the menu goes from 1 to 9,
higher positions are continued with capital letters because of the limited
space in the display:
from "A" (=10), "B" (=11) to "Z" (=35).
The font size of the current position string depends on the number of
submenus to be displayed.
Cond Control
The trend of the process value PV from standard (4...20 mA) and
frequency signal inputs is shown as chart and regularly updated.
The example shows a trend chart of set point SP and process value PV -
EXIT HOLD
SP/PV
the inscription ("SP/PV") only names the trend chart without identifying
any soft key.
“HOLD“ freezes the display (“CONT” continues displaying the trend.)
Page 30
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