Burkert 8623 User Manual [en, de, fr]
Operating Instructions
Bedienungsanleitung
Instructions de Service
Type 8623
Compact Flow Controller
used together with the Control Unit Type 8623-B
Kompakter Durchflußregler
in Verbindung mit der Bedieneinheit Type 8623-B
Régulateur compact de débit
en relation avec l’unité de commande Type 8623-B
We reserve the right to make technical changes without notice.
Technische Änderungen vorbehalten.
Sous resérve de modification techniques.
© 2002 Bürkert Werke GmbH & Co. KG
Operating Instructions 0507/07_EU-ML_00800222
CONTENTS:
1 GENERAL SAFETY INSTRUCTIONS ................................................................................... 1
2 FUNCTION.............................................................................................................................................. 2
3 APPLICATION AREAS.................................................................................................................... 3
3.1 Control and display of flows in pipe runs................................................................................ 3
3.2 Ratio Control............................................................................................................................................ 3
4 TECHNICAL DATA............................................................................................................................. 4
5 COMMISSIONING .............................................................................................................................. 7
6 OPERATION WITHOUT THE TYPE 8623-B CONTROL UNIT............................. 8
7 OPERATION WITH THE TYPE 8623-B CONTROL UNIT ......................................... 8
7.1 Display and Bargraph display ....................................................................................................... 9
7.2 Standard Mode.................................................................................................................................... 11
7.2.1 Bargraph display in the standard mode ............................................................................... 11
7.3 Programming mode.......................................................................................................................... 12
7.3.1 Setting in the Programming mode............................................................................................ 13
7.3.2 Multiplier of the K Factor................................................................................................................ 14
7.3.3 K Factor of the 1st flow sensor ................................................................................................. 15
7.3.4 Selecting the type of default Set-value ................................................................................. 15
7.3.5 Internal default set-value (C.01) .............................................................................................. 16
7.3.6 External default set-value (C.02)............................................................................................. 17
7.3.7 Ratio Control (C.03) ......................................................................................................................... 19
7.3.8 Amplification factor KP .................................................................................................................... 20
7.3.9 Integral action time TN.................................................................................................................... 21
7.4 Manual mode ........................................................................................................................................ 22
7.5 Set-up mode ......................................................................................................................................... 22
8 BRIEF INSTRUCTIONS ............................................................................................................... 24
8.1 Summary of the various operating levels ........................................................................... 24
8.2 Programming mode (the grey values blink) ...................................................................... 25
8.3 Manual mode ........................................................................................................................................ 26
8.4 Set-up mode ......................................................................................................................................... 26
9 APPENDIX ............................................................................................................................................ 27
9.1 Error messages ................................................................................................................................. 27
9.2 Specific Fitting factors according to DN and Material ................................................. 28
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SYMBOLS USED
In these Operating Instructions, the following symbols are used:
Indicates a working step that you have to carry on.
ATTENTION!
NOTE
Indicates information which must be followed. Failure to do
this could endanger your health or the functionality of the
device.
Indicates important additional information, tips and
recommendations.
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1 GENERAL SAFETY INSTRUCTIONS
To ensure that the device functions correctly, and will have a long service life,
please comply with the information in these Operating Instructions, as well as
the application conditions and permissible data specified in the data sheets of
the proportional valves used and of the Type 8623 regulator:
• When planning the application of the device, and during its operation,
observe the general technical rules!
• Work on the device should only be carried out by specialist staff using the
correct tools!
• Observe the relevant accident prevention and safety regulations applicable
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for electrical equipment throughout the operation, maintenance and repair of
the device!
• Always switch off the voltage supply before working on the system!
• Take suitable measures to prevent unintentional operation or impermissible
impairment!
• If these instructions are ignored, no liability will be accepted from our side,
and the guarantee on the device and on accessories will become invalid!
NOTE
Approvals such as Ex, UL, UR, CSA, DVGW etc., will be
indicated on the rating plate, or by a special label.
2 FUNCTION
The Type 8623 Flow Controller is used in conjunction with proportional valves to
control liquid flows in pipe runs. The compact construction of the device makes
direct installation on the proportional valve possible.
• Suitable for valve types: 6022, 6023, 6223, 2832 and 2834
• Flow controller with adjustable PI regulation
• Measurement of the flow over a flow sensor with a frequency output (flowproportional frequency signal)
• For flow sensors with frequency output up to a frequency of max. 625 Hz
• Direct control of a proportional valve
• Calibration
• Default set-value for standard 4-20 mA signal
• Ratio control
NOTE
The Type 8623 Flow Controller can be operated with or without
the Type 8623-B Control Unit.
The Control Unit is used for displays and for programming the
flow controller.
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3 APPLICATION AREAS
3.1 Control and display of flows in pipe runs
Standard
signal input
Flow sensor
Flow controller
Fig. 1: Layout of a
control system using the
Regulated flow
Proportional valve
Type 8623 compact flow
controller (circuit)
3.2 Ratio Control
• Mixing of two liquids
• Control of a liquid flow above a second liquid flow
In ratio control, the flow in one pipe run is fed into the flow in a second pipe run
at a certain ratio. The ratio is adjustable between 0.01 and 9.99. The two flow
rates are measured using two flow sensors with frequency outputs.
Q
regulated flow
1
Q1 = V * Q
2
Flow sensor 1
V ratio factor
Q
unregulated flow
2
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Flow controller
Flow sensor 2
Regulated flow Q
Flow Q2 (unregulated)
1
Proportional valve
Fig. 2: Layout of a ratio control using the Type 8623 compact flow controller
(circuit)
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4 TECHNICAL DATA
Operating voltage 24 V DC
Power consumption max. 1,5 W
Output current max. 1,0 A
Operating temperature -10 to + 60 °C
Noise resistance to EN50082-2
Noise emission to EN50081-2
Inputs:
Signal inputs 2 frequency inputs 2 to 625 Hz
Accuracy ±1%
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Type of signal Sinusoidal, square wave, triangular
1 Standard signal input 4 - 20 mA
Connection in unit: 7-pole terminal + PE
Outputs:
Cable outlet can be turned in 90° steps
Number of terminals 2 poles and earth
Type of contact Surface contact, similar to a flat plug
Controller:
Control algorithm PI-Controller
Sampling time TA 40 ms
Amplification factor KP 0 ... 99,99
Integral action time TN 0,1 ... 199,99 s
Integral action time 2 0,0 ... 1999,9
Ratio 0,01 ... 9,99
Calibration 0 ... 199,99
( ≥ 300 mVss)
Wire cross-section max. 0,5 mm²
PG 9 fitting;
Cable φ 6 - 7 mm
(DIN 46 247/48)
Housing:
Degree of protection IP 65
Material / Mounting Polyamide / M3 x 45 mm cheesehead screws
Dimensions / Weight 32 x 90 x 41,5 mm / approx. 50g
Order No. 134 072 K
Control unit Type 8623-B for compact flow controller
Order No. 134 052 P
1)
The Type 8623-B control unit is not included in the delivery of the Type 8623
compact flow controller
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1)
Settings of the compact flow controller at delivery
K-Factor 1 46,60
K-Factor 2 46,60
Selection internal set-value (C.01)
Lower limit value 0,00
Upper limit value 180,00
Set-value 0,00
Ratio 1,00
KP 1,00
TN 0,50
Wiring connections
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not used
Fig. 3: Wiring connections
ATTENTION!
PE
Valve output
Do not connect any voltages to Terminal 5!
Terminal 5 is a 24V output for supplying the flow sensor
(e.g., Bürkert Type 8020 with Hall sensor).
PE
GND
24 V DC
24 V output
Frequency input 1
GND
Frequency input 2
Standard signal input 4 - 20 mA
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Flow sensor with coil
Wiring connections
Type 8020 flow sensor with
coil
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Fig. 4: Connection of the Type 8020 flow sensor with coil
NOTE
Flow sensor with Hall sensor
Wiring connections
Type 8020 flow sensor with Hall
sensor
For the connection of the Type 8020 flow sensor with coil to the
Type 8623 controller, no supply voltage is necessary!
Type 8623 flow
controller
Type 8623 flow controller
Fig. 5: Connection of the Type 8020 flow sensor with Hall sensor
NOTE For the connection of the Type 8020 flow sensor with Hall sensor
6 - 8623
to the Type 8623 controller, a supply voltage is necessary!
5 INITIALISATION
NOTE
Î Connect the cable (Fig. 3).
Î Put on the lid or the control unit !
Î Insert the flow controller onto the proportional valve (suitable valve types:
6022, 6023, 6223, 2832 and 2834)
Î Screw the flow controller tightly!
Work on the device should only be carried out by specialist staff
using the correct tools!
Switch off all voltages to the flow controller before working on it!
ATTENTION!
When screwing the flow controller to the proportional valve,
ensure that the seal is properly seated!
The apparatus socket may only be pushed onto the
connector flags with the fixing screw assembled.
Changing the direction of the cable outlet
Î Carefully underlay the manifold with the screwdriver blade and
lever it out (Fig. 6).
Î Turn the manifold into the desired position (max. 2 x 90°).
Î Press the manifold into the housing until it latches in.
Fig. 6: Turning the manfold
ATTENTION!
Do not twist off the cable ends!
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8623 - 7
6 OPERATION WITHOUT THE TYPE 8623-B CONTROL
UNIT
After switching on the operational voltage, the controller works with the preset
parameters (Page 33).
NOTE
Changing the parameters or re-configuring the inputs is only
possible with the Type 8623-B control unit.
7 OPERATION WITH THE TYPE 8623-B CONTROL UNIT
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NOTE
ATTENTION!
When operating with the control unit, four modes are possible:
• Standard mode
• Programming mode
• Manual mode
• Set-up mode
Measure: Result:
Î Switch off the supply voltage: the parameters last set will be saved.
Î Insert the Type 8623-B all necessary data will be transferred from
control unit. the flow controller into the control unit and
You can install the Type 8623-B control unit onto the Type 8623
compact flow controller in place of the lid, turned by 180°.
When installing the Type 8623-B control unit, the supply
voltage must be switched off, as otherwise a re-programming
and thereby a loss of function of the Type 8623 flow controller
can take place.
be stored.
Î Switch on the supply voltage: the Standard mode is activated (see 7.2).
Î Selected the required mode: Programming, Manual or Set-up mode will
Î Close the current mode: the data that has been set up will be
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be activated (see 7.3 to 7.5)
transferred from the Type 8623-B control
unit to the Type 8623 flow controller.
7.1 Display and Bargraph display
Upper bar row:
display of the multipliers,
units and selections
not used
4 1/2 digit display for the
actual flow rate value. In
the Programming mode,
the values that can be
currently set are displayed.
Bar graph: Displays the deviation between the set value and
the actual value.
Fig. 7: Display of the Type 8623-B Control Unit
not used
Indicates the
Programming mode
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8623 - 9
Bargraph displays in the different modes
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Standard mode
Programming
mode
Bargraph Setting / display
Display of the set-value
Actual value
Agreement of set and actual values
Actual value
Deviation from set value: -2 %
Actual value
Deviation from set value: +4 %
K-factor of the 1st flow sensor
Type of default set-value
Internal default set-value
External default set-value - lower limit
External default set-value - upper limit
Ratio control -K-factor of the 2nd flow sensor
Ratio control - ratio factor
Amplification factor KP
Manual Mode
Positioning mode
Fig. 8: Bargraph displays
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Integral action time TN
Current opening level of the valve
Minimum opening level of the valve
7.2 Standard Mode
Î Switch the operating voltage on.
After switching on the operating voltage, all the segments of the control unit
light up for about 2 seconds (display test).
The current flow rate will then be displayed.
Display of the actual value Display of the set-value
Fig. 9: Displays in the standard mode
7.2.1 Bargraph display in the standard mode
The bar graph indicates the current deviation of the actual value from the setvalue. If both values are the same, only one bar will be indicated in the middle.
For each 2 % of deviation, one additional bar will be displayed in the
corresponding direction.
Example:
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Actual and set-values identical
Deviationoftheactualvaluefromtheset-value = -2 %
Deviationoftheactualvaluefromtheset-value = +4%
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7.3 Programming mode
NOTE:
As only the control unit Type 8623-B is in the Programming
mode, the flow controller continues to work with the old values
until the Programming mode is exited.
Î Hold the key down for 2 seconds.
The control unit is now in the programming mode.
Each position can be individually adjusted in the sequence of
Paragraphs 7.3.2 to 7.3.9.
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NOTE:
Î Change the currently-adjusted value (blinks).
Î Move to the next position.
Î After reaching the last value, exit the programming mode:
You will return to the Standard mode.
When you leave the Programming mode, the currently-set
values will be saved, and a Reset carried out.
Attention: any current control function will be interrupted!
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7.3.1 Setting in the Programming mode
Set up
K Factor 1
Set up
Selection
Internal set-value (C.01) External set-value (C.02) Ratio control (C.03)
Set up
set-value
Change
set-value
Set lower
limit
Set upper
limit
Set KP
Set TN
Change
K Factor
1
Change
Selection
Change
lower
limit
Change
upper
limit
Change
KP
Change
TN
Set
K factor 2
Set ratio
Change
K factor
2
Change
Change
ratio
ratio
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Return to Standard mode
Fig. 10: Setting the parameters
NOTE The lower 7 bars indicate which parameter is being set up (see
front of folded page).
8623 - 13
7.3.2 Multiplier of the K Factor
NOTE: The K factor makes it possible to standardise the output
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frequency of the floe sensor to the flow.
1
Q
Q flow
k K factor
f Output frequency of the flow sensor
The K factor defines the number of pulses per volume unit:
k
You can find the K factor in the data sheet of the flow sensor
being used.
The volume unit of the K factor determines the flow unit, e.g.,
Type 8020 with DN 25 PVC fitting (see Table 2, Page 24)
k 46,60
gives the flow value in litres per time unit
k
Pulse
Impuls
f
V
Pulse
Impulse
Litre
Liter
The display only displays values in the range from 0 to 199,99. With the multiplier
(upper row of bars), you can extend the display by a factor of 10.
Multiplier = 1
Multiplier = 10
Change the multiplier
proceed to set the K factor
Fig. 11: Multiplier of the K Factor
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7.3.3 K Factor of the 1st flow sensor
Setting the pre-comma value of the 1st K factor
Increase of the pre-comma value
Proceed to set the post-comma
value
Setting the post-comma value of the 1st K factor
Increase of the post-comma value
Continue from 8.3.4
7.3.4 Selecting the type of default Set-value
Î Select here whether the unit should work with an internal or an external
default set-value, or with ratio control.
The selection will be indicated in the upper row of bars.
Internal set-value
selected
(see 7.3.5)
Fig. 12: Selection of the default set value
External set-value
selected (standard
signal) (see 7.3.6)
Ratio control selected
(see 7.3.7)
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Î Continue from 7.3.5, 7.3.6 or 7.3.7, depending on the selected
default set-value
8623 - 15
7.3.5 Internal default set-value (C.01)
With the internal set-value default, the set-value is entered and stored as a flow
rate (with time units: h, min, sec). The controller will make use of these set flow
rates.
7.3.5.1 Time units of the Set-values
Î Set up the time units in hours, minutes or seconds using the upper row of
bars.
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Fig. 13: Time units of the set-value
7.3.5.2 Internal set-value
Setting the pre-comma value of the internal set-value
Setting the post-comma value of the internal set-value
Time unit = h volume units / h
Time unit = min volume units / min
Time unit = s volume units / s
Change the time units
Continue from 7.3.5.2
Increase of the pre-comma value
Proceed to set the post-comma
value
Increase of the post-comma value
NOTE:
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Continue from 7.3.8
The setting-up of a set-value can only take place to a value
which corresponds to 625 Hz. Setting a set-value outside of this
limit is not possible.
Example:
Set K Factor: 4 pulses /l
gewünschter Sollwert: 199,99 l / s
=> Frequency of the flow sensor:
f = Q * K f frequenz
= 199.99 l/s * 4 pulse / l Q Flow rate
= 800 Hz K K Factor
=> f > 625 Hz, i.e., cannot be read in
=> Set values that can be set: 0 - 156.25 l/s (corresponds to the
frequencies 0 - 625 Hz)
=> For higher set-values, a sensor with a lower K factor must be
selected.
7.3.6 External default set-value (C.02)
For external default set-values, enter a scale limit with time units (see 7.3.5.1).
The flow range corresponding to the standard signal (4-20 mA) must be set.
I.e., the input of the flow at 4 mA (lower limit value) and at 20 mA (upper limit
value) takes place.
Example: Lower limit value 0 l/min 4 mA
Upper limit value 180 l/min 20 mA
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7.3.6.1 Lower limit value
Î Limit the lowest control range using the lower limit value
NOTE:
Setting the pre-comma value of the lower limit value
With external set-values (standard signals) the error message
E.06 appears as soon as a signal less than 4 mA is read in.
Increase of the pre-comma value
Proceed to set the post-comma
value
8623 - 17
Setting the post-comma value of the lower limit value
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7.3.6.2 Upper limit value
Î Limit the upper control range using the upper limit value
Increase of the post-comma value
Continue from
7.3.6.2
NOTE:
Setting the pre-comma value of the upper limit value
Setting the post-comma value of the upper limit value
With external set-values (standard signals) the error message
E.06 appears as soon as a signal larger than 20 mA is read in.
Increase of the pre-comma value
Proceed to set the post-comma
value
Increase of the post-comma value
Continue from 7.3.8
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7.3.7 Ratio Control (C.03)
In ratio control, the flow Q1 (regulated flow) will track so that it corresponds to the
defined ratio to a flow Q2 (unregulated flow).
Q1 = ratio factor * Q
Example:
You set up a ratio of 1:4: 4.00
Flow rate Q2: 20 l/h
Regulation of the flow rate Q1: 20*4 = 80 l/h
Î Set the ratio to your own requirements.
NOTE
If the ratio is set so high that the flow Q1 corresponds to a
frequency greater than 625 Hz, error message E.07 appears on
the display.
2
7.3.7.1 Multiplier of the K factor
Multiplikator = 1
Multiplikator = 10
Ändern des Multiplikators
Weiter zur Einstellung des 2.
K-Faktors
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Fig. 14: Multiplier of the
K factor
7.3.7.2 K Factor of the 2nd flow sensor
Î Set the K Factor of the 2nd flow sensor analogously to the setting of the K
Factor of the 1st flow sensor(see 8.3.3)
Setting the pre-comma value of the 2nd K factor
Increase of the pre-comma value
Proceed to set the post-comma
value
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Setting the post-comma value of the 2nd K factor
7.3.7.3 Ratio factor
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Î Select a ratio factor between 0.01 and 9.99
Setting the pre-comma value of the ratio factor
Setting the post-comma value of the ratio factor
Increase of the post-comma value
Continue from
7.3.7.2
Increase of the pre-comma value
Proceed to set the post-comma
value
Increase of the post-comma value
Continue from 7.3.8
7.3.8 Amplification factor KP
Î Select an amplification factor KP in the setting range between 0 and 99.99.
Setting the pre-comma value of the amplification factor
Increase of the pre-comma value
Proceed to set the post-comma
value
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Setting the post-comma value of the amplification factor
Increase of the post-comma value
Continue from 7.3.9
7.3.9 Integral action time TN
Î For the integral action time TN, select a value between 0.1 and 199.99 sec.
Setting the pre-comma value of the integral action time TN
Increase of the pre-comma value
Proceed to set the post-comma
value
Setting the post-comma value of the integral action time TN
End of the programming mode
Change to standard
mode
After setting the integral action time TN, the parameters are accepted
and the return to the standard mode takes place.
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8623 - 21
7.4 Manual mode
NOTE
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7.5 Set-up mode
In this mode, you can set up the minimum opening angle of the proportional
valve. Below this limit, the proportional valve remains closed. This limit is
dependant on the pressure difference and the temperature. Define this lower
limit in order to keep the resolution loss in the drive low.
In the Manual mode, there is no regulation, and the
proportional valve remains in the set position.
Î In the Standard mode, hold down both keys simultaneously to
change to the Manual mode. The current opening angle of the
valve will be displayed in % (see 8.3).
Î Increase the opening angle of the proportional valve with this
key, i.e., with the key held down, the valve increasingly opens
up to a max. of 100%.
Î Using this key, decrease the opening angle of the proportional
valve, down to the minimum opening angle set in the Set-up
mode(see 7.5).
Î To exit the Manual mode, press down both keys at the same
time;
the unit changes into the Standard mode.
ATTENTION!
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Î Always set the minimum opening angle when first
initialising the unit!
Î In principle, always set the minimum opening angle at the
maximum pressure!
Î In the Standard mode, hold down this key for about 2
seconds. You will come into the Programming mode.
Î Hold down this key for a further 2 seconds.
You will come into the Set-up mode, and the programming
symbol and the minimum opening angle last set will be
displayed.
Î Set the minimum opening angle between 0 and 100%.
=> You open the proportional valve
=> You close the proportional valve (cf. 7.4
Manual mode)
NOTE
NOTE
ATTENTION!
The minimum opening angle has been reached at the last
moment before the valve opens, i.e., immediately before the
start of the flow.
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Î To exit the Set-up mode, press down both keys at the same
time.
The unit saves the set values, and changes to the Standard
mode, i.e., the Programming mode is also exited.
You can remove the control unit from the compact flow controller, e.g., after programming, without affecting the set process.
The programmed values remain stored in the flow controller.
Protection class IP65 is only guaranteed with the housing
closed.
Î For this reason, always replace the housing lid and
screw it down tightly.
8623 - 23
8 BRIEF INSTRUCTIONS
8.1 Summary of the various operating levels
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Display of the values to be set up,
positions that can
be changed blink.
Standard mode
Control of the proportional valve according to the programmed conditions
2 sec.
After last
value -> return
Programming
mode
Increase of
the blinking
values
Next position
or next value
Fig. 15: Summary of the various operating levels.
2 sec.
Manual Mode
Adjustment of
the opening angle of the proportional valve from
MIN to 100%
Set-up mode
Set up the minimum opening
angle of the proportional valve
24 - 8623
8.2 Programming mode (the grey values blink)
Set the multiplier of K
Factor 1
Selecting the default setvalue
Setting up all the following parameters
Setting the multiplier or
the unit, if present
Setting the figures before
the decimal point for K
Factor 1
Setting the figures before
the decimal point for the
corresponding parameter
Setting the figures after the
decimal point for K Factor 1
Setting the figures after
the decimal point for the
corresponding parameter
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Fig. 16 Programming mode
Return to standard mode
8623 - 25
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