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.

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.

regulated flow

Q1 = V * Q

Flow sensor 1

V ratio factor Q

unregulated flow

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Flow controller

Flow sensor 2

Regulated flow Q

Flow Q2 (unregulated)

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

The Type 8623-B control unit is not included in the delivery of the Type 8623

compact flow controller

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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!

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).

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

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

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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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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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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

Change

Selection

Change

lower

limit

Change

upper

limit

Change

Set K factor 2

Set ratio

Change K factor

Change

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).

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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.

Q flow k K factor f Output frequency of the flow sensor

The K factor defines the number of pulses per volume unit:

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

Pulse

Impuls

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

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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

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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.

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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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

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.

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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

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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

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