Burkert 8630 User Manual
Operating Instructions
Bedienungsanleitung
Instructions de Service
Type 8630
TOP Control Continuous
We reserve the right to make technical changes without notice.
Technische Änderungen vorbehalten.
Sous resérve de modification techniques.
© 2001 Bürkert Werke GmbH & Co KG.
Operating Instructions 0507/11_EU-EN_00804575
Overall Operating Instructions
C
ONTENTS
TOP Control
Continuous 8630
GENERAL NOTES
Symbols.......................................................................................................................................................................................................................................................... 10
Intended use ............................................................................................................................................................................................................................................ 10
Safety notes .............................................................................................................................................................................................................................................. 10
Protection from damage by electrostatic charging ......................................................................................................................... 11
Scope of delivery .............................................................................................................................................................................................................................. 11
Warranty conditions ...................................................................................................................................................................................................................... 11
Master code .............................................................................................................................................................................................................................................. 12
Transport, storage ............................................................................................................................................................................................................................ 12
Disposal ......................................................................................................................................................................................................................................................... 12
SYSTEM DESCRIPTION
Valve types................................................................................................................................................................................................................................................. 14
Characteristics of the valve types
Construction of TOP Control Continuous ..................................................................................................................................................... 16
Illustrations (cover removed)
Design features
Functional diagram as a positioner with single-acting actuator
..................................................................................................................................................................................................................................... 17
Operation as a positioner ..................................................................................................................................................................................................... 19
Schematic representation of positioning control
Characteristics of the positioner software
...................................................................................................................................................................................... 15
................................................................................................................................................................................................... 16
............................................................................................................ 18
.................................................................................................................................................. 20
.................................................................................................................................................................. 21
*
Alternative chapters or functions depending on device configuration
8630 - 1
C
ONTENTS
*Operation as a process controller (option)............................................................................................................................................... 22
Example of process control: TOP Control Continuous with sensor
Schematic representation of process control
Characteristics of the process controller software
......................................................................................................................................................... 23
............................................................................................................................................. 24
................................................................................................... 22
* Operation as a flow rate controller (option).......................................................................................................................................... 25
Characteristics of the flow rate controller software
Schematic representation of process control with flow rate controller
......................................................................................................................................... 25
....................................................................................... 26
* Interfaces of the TOP Control Continuous in the multipole variant .................................................................. 27
* Interfaces of the TOP Control Continuous in the variants with
cable bushings
.................................................................................................................................................................................................................................. 28
Technical data........................................................................................................................................................................................................................................ 29
Safety settings on failure of auxiliary electrical or pneumatic energy
Factory settings on the TOP Control Continuous
Data of the TOP Control Continuous
............................................................................................................................................................................. 31
............................................................................................................................................. 30
......................................................................................... 29
FIRST COMMISSIONING
Fluidic installation............................................................................................................................................................................................................................. 34
*Electrical installation - multipole connector ............................................................................................................................................ 35
*Electrical installation - connection terminals for cable bushings............................................................................ 36
Basic settings of the TOP Control Continuous..................................................................................................................................... 37
Settings in the menu items
Entering the position setpoint in the AUTOMATIC mode
Manual opening and closing of the valve actuator in the MANUAL mode
....................................................................................................................................................................................................... 38
.......................................................................................................................... 38
............................................................................. 39
INSTALLATION
Installation of the valve ............................................................................................................................................................................................................ 42
Turning the TOP Control Continuous.................................................................................................................................................................. 42
Procedure
................................................................................................................................................................................................................................................... 42
Fluidic connection of the TOP Control Continuous....................................................................................................................... 43
*
Alternative chapters or functions depending on device configuration
2 - 8630
C
ONTENTS
*Electrical connection - multipole connectors ....................................................................................................................................... 44
Marking of the multipole plugs or sockets and the contacts
Output signals for SPS (circular plug M 16)
Operating voltage (circular plug M 12)
Inductive proximity switches (circular socket M 8)
Process value (circular plug M 8)
....................................................................................................................................................................................... 46
............................................................................................................................................................. 45
............................................................................................................................................................................ 45
........................................................................................................................................... 45
Process value with the option flow rate controller (2 circular plugs M 8)
Option: with temperature sensor input (3 circular plugs M 8)
................................................................................................................... 44
.............................................................................................................. 46
*Electrical connection - terminals for cable bushing.................................................................................................................... 47
Connection PCB of the TOP Control Continuous with screw terminals and jumpers ................................................ 47
Terminal configuration with cable bushings
Choice of binary outputs or process value input
............................................................................................................................................................ 47
............................................................................................................................................... 48
*Setting the inductive proximity switches (option)........................................................................................................................... 50
Opening the housing of the TOP Control Continuous
Positioning the inductive proximity switches
.......................................................................................................................................................... 50
................................................................................................................................. 50
OPERATION AND CONTROLLER FUNCTIONS
Operating and display elements ................................................................................................................................................................................ 52
Operating levels.................................................................................................................................................................................................................................. 52
Commissioning and set-up as a positioner............................................................................................................................................... 53
Procedure for specifying the basic settings
Main menu for the settings on commissioning
Description of the procedure
.................................................................................................................................................................................................. 55
Configuring the supplementary functions .................................................................................................................................................... 59
Keys in the configuration level
Configuration menu
.......................................................................................................................................................................................................................... 59
Supplementary functions
.............................................................................................................................................................................................. 59
........................................................................................................................................................................................................... 62
Operating the process............................................................................................................................................................................................................... 86
Changeover between operating modes
Operating mode AUTOMATIC....................................................................................................................................................................................... 87
Meaning of the keys in the AUTOMATIC mode
Display of the AUTOMATIC mode
..................................................................................................................................................................................... 87
............................................................................................................................................................ 53
.................................................................................................................................................... 54
...................................................................................................................................................................... 86
.................................................................................................................................................. 87
Operating mode MANUAL.................................................................................................................................................................................................. 88
Meaning of the keys in the MANUAL mode
Display of the MANUAL mode
*
Alternative chapters or functions depending on device configuration
.............................................................................................................................................................................................. 88
............................................................................................................................................................ 88
8630 - 3
C
ONTENTS
OPERATING THE PROCESS CONTROLLER
Factory settings on the process controller................................................................................................................................................... 90
Setting up a process control system .................................................................................................................................................................... 90
Self-parametrization of the positioner -
Supplementary function
Basic settings of the function
P.Q’LIN
P.CO TUNE -
P.CO LEAK -
- Starting the routine for linearization of the process curve ..................................................................... 105
Display during call-up and execution of the routine
Self-optimization of the process controller (process tune) ..................................................... 106
Leakage characteristic for flow rate control ................................................................................................... 110
P.CONTRL
P.CONTRL
X.TUNE
.................................................................................................................................................................... 91
................................................................................................................................................................... 92
............................................................................................................................... 91
.......................................................................................................................................... 105
Operating the process ............................................................................................................................................................................................................... 112
Changeover between the operating modes
................................................................................................................................................................ 112
Operating mode AUTOMATIC....................................................................................................................................................................................... 113
Meaning of the keys
Displays
........................................................................................................................................................................................................................................................ 113
Operating structure and procedures
......................................................................................................................................................................................................................... 113
.................................................................................................................................................................................. 113
Manually changing the process setpoint ...................................................................................................................................................... 114
Operating mode MANUAL.................................................................................................................................................................................................. 114
Meaning of the keys
Displays
........................................................................................................................................................................................................................................................ 115
Operating structure and procedures
......................................................................................................................................................................................................................... 114
.................................................................................................................................................................................. 115
PROFIBUS DP
General notes......................................................................................................................................................................................................................................... 118
Technical data ....................................................................................................................................................................................................................................... 118
Safety settings on bus failure ......................................................................................................................................................................................... 118
Interfaces....................................................................................................................................................................................................................................................... 119
Electrical connections ............................................................................................................................................................................................................... 119
Connection with one plugged bus connector
Connection with 2 plugged bus connectors
Operating voltage (circular plug M12)
Bus connection (circular socket M12)
........................................................................................................................................................... 119
.............................................................................................................................................................. 120
............................................................................................................................................................................. 120
............................................................................................................................................................................ 120
4 - 8630
C
ONTENTS
Inductive proximity switches (circular socket M8)............................................................................................................................................. 121
Process value (circular plug M8)
Termination connection for PROFIBUS systems
......................................................................................................................................................................................... 121
................................................................................................................................................ 122
Settings on the TOP Control Continuous ..................................................................................................................................................... 123
Explanation of the menu items .............................................................................................................................................................................................. 124
Functional deviations from the standard version.............................................................................................................................. 124
Configuration in the Profibus DP master ...................................................................................................................................................... 125
Configuration of the process values
................................................................................................................................................................................. 125
Bus status display ........................................................................................................................................................................................................................... 127
Example 1 with COM-Profibus V3.3 .................................................................................................................................................................... 128
Example for a positioner
............................................................................................................................................................................................................... 128
Example 2 with COM-Profibus V3.3 .................................................................................................................................................................... 131
Example for a process controller
......................................................................................................................................................................................... 131
DEVICE NET
General notes......................................................................................................................................................................................................................................... 134
Explanation of terms .................................................................................................................................................................................................................... 134
Technical data ....................................................................................................................................................................................................................................... 135
Safety settings on bus failure ......................................................................................................................................................................................... 135
Interfaces....................................................................................................................................................................................................................................................... 136
Electrical connection................................................................................................................................................................................................................... 136
Operating voltage (4-pole M12 circular plug)
Bus connection (4-pole M12 circular plug)
Inductive proximity switches (4-pole M8 circular socket)
Process value (circular plug M8)
......................................................................................................................................................................................... 137
Termination connection for DeviceNet systems
Net topology of a DeviceNet system
............................................................................................................................................................................... 138
Settings on the TOP Control Continuous ..................................................................................................................................................... 139
Explanation of the menu items in the program run-off schematic
Settings in the main menu
......................................................................................................................................................................................................... 140
........................................................................................................................................................... 137
................................................................................................................................................................. 137
........................................................................................................................... 137
................................................................................................................................................... 138
...................................................................................................... 139
Configuring the process data ......................................................................................................................................................................................... 141
Static input assemblies
Static output assemblies
................................................................................................................................................................................................................. 141
............................................................................................................................................................................................................. 143
8630 - 5
C
ONTENTS
Bus status display ........................................................................................................................................................................................................................... 144
Configuration example 1 ....................................................................................................................................................................................................... 145
Installation of the EDS file
Address allocation
Offline parametrization of the device
Online parametrization of the device
.............................................................................................................................................................................................................................. 145
......................................................................................................................................................................................................... 145
............................................................................................................................................................................... 146
............................................................................................................................................................................... 147
Configuration example 2 ....................................................................................................................................................................................................... 148
Setting up the process map (mapping)
.......................................................................................................................................................................... 149
MAINTENANCE AND ERROR CORRECTION ON THE POSITIONER
Maintenance ............................................................................................................................................................................................................................................ 152
Error messages and malfunctions .......................................................................................................................................................................... 152
Error messages on the LC display
Other malfunctions
............................................................................................................................................................................................................................. 152
..................................................................................................................................................................................... 152
MAINTENANCE AND ERROR CORRETION ON THE
PROCESS CONTROLLER
Maintenance ............................................................................................................................................................................................................................................ 154
Error messages and malfunctions .......................................................................................................................................................................... 154
Error messages on the LC display
Other malfunctions
............................................................................................................................................................................................................................. 156
..................................................................................................................................................................................... 154
Appendix
6 - 8630
C
ONTENTS
GENERAL RULES
Selection criteria for continuous valves .......................................................................................................................................................... 158
Characteristics of PID controllers............................................................................................................................................................................. 160
P component
I component
D component
Superimposing the P, I and D components
Function of a real PID controller
Rules for setting PID controllers ................................................................................................................................................................................ 165
Setting rules of Ziegler and Nichols (oscillation method)
Setting rules of Chien, Hrones and Reswick (controller output step method)
............................................................................................................................................................................................................................................ 160
.............................................................................................................................................................................................................................................. 161
............................................................................................................................................................................................................................................ 162
............................................................................................................................................................... 163
........................................................................................................................................................................................... 164
............................................................................................................................ 165
........................................................................ 166
OPERATING STRUCTURE
Operating structure of the TOP Control Continuous..................................................................................................................... 170
TABLE FOR POSITIONER
Table for noting your settings on the positioner .................................................................................................................................. 178
TABLE FOR PROCESS CONTROLLER
Tables for noting your settings on the process controller ..................................................................................................... 180
MASTER CODE
Code number .......................................................................................................................................................................................................................................... 182
8630 - 7
C
ONTENTS
8 - 8630
G
ENERAL NOTES
GENERAL NOTES
Symbols.............................................................................................................................................................................................................................................................. 10
Intended use
Safety notes
Protection from damage by electrostatic charging
Scope of delivery
Warranty conditions
................................................................................................................................................................................................................................................ 10
.................................................................................................................................................................................................................................................. 10
............................................................................................................................. 11
.................................................................................................................................................................................................................................. 11
.......................................................................................................................................................................................................................... 11
Master code .................................................................................................................................................................................................................................................. 12
Transport, storage
................................................................................................................................................................................................................................ 12
Disposal ............................................................................................................................................................................................................................................................. 12
8630 - 9
GENERAL NOTES
Symbols
The following symbols are used in these operating instructions:
marks a work step that you must carry out.
ATTENTION!
NOTE
Intended use
In order for the device to function perfectly and have a long service life, you must observe the information
given in these operating instructions and comply with the operating conditions and the permissible data
for the TOP Control Continuous, in addition to the information for the respective pneumatically actuated
valve, which is specified in the „Technical Data“ chapter of these instructions and in the valve
instructions.
Please note that the Top control Continuous may not be used out-of-doors.
In view of the large number of possible applications and categories of use, you should check whether the
Top control Continuous is suitable for your specific application, and carry out tests where necessary.
Safety notes
marks notes on whose non-observance your health or the functioning of the device
will be endangered.
marks important additional information, tips and recommendations.
• Keep to standard engineering rules in planning the use of and operating the device!
• Installation and maintenance work are only allowed by specialist personnel using suitable tools!
• Observe the current regulations on accident prevention and safety during operation and maintenance
of the device!
• Switch off the supply voltage in all cases before intervening in the system!
• Note that in systems under pressure, piping and valves may not be loosened!
• Take suitable precautions to prevent inadvertent operation or damage by unauthorized action!
• Make sure that after an interruption to the electrical or pneumatic supply, the process starts up again in
a well-defined, controlled manner!
• On non-observance of these notes and unauthorized interference with the device, we will refuse all
liability and the warranty on device and accessories will become void!
10 - 8630
Protection from damage by electrostatic charging
This device contains electronic components that are sensitive to
electrostatic discharge (ESD). Contact to electrostatically charged
persons or objects will endanger these components. In the worst
case, they will be immediately destroyed or will fail after
commissioning.
GENERAL NOTES
ATTENTION
EXERCISE CAUTION ON HANDLING!
ELECTROSTATICALLY SENSITITVE
COMPONENTS/MODULES
Observe the requirements of EN 100 015 - 1 in order to minimize
the possibility of, or avoid, damage from instantaneous electrostatic
discharge. Also take care not to touch components that are under
supply voltage.
Scope of delivery
Immediately after receipt of a shipment, make sure that the contents are undamaged and match the
scope of delivery stated on the packing slip. In general this consists of:
• Pneumatically actuated valve of type 2652, 2655, 2672, 2700, 2712, 2730, 2731 or 2731K with attached
TOP Control
• Operating Instructions for the TOP Control
If there are discrepancies, please contact immediately our customer service:
Continuous,
Continuous and for the valve with pneumatic actuation.
Bürkert Fluid Control Systems
Chr.-Bürkert-Str. 13-17
Service Department
D-76453 Ingelfingen
Tel.: (07940) 10-111
Fax: (07940) 10-448
E-Mail: info@de.buerkert.com
NOTE
Suitable cable plugs for the multipole connection are available as accessoires.
Warranty conditions
This document contains no warranty promises. We refer in this connection to our General Conditions of
Sale and Business. The condition for the warranty is use of the unit for the intended purpose under the
specified application conditions.
ATTENTION!
The warranty covers only faultless condition of the TOP Control Continuous and the
attached valve with pneumatic actuation. No liability will be accepted for consequential
damage of any kind that may arise from failure or malfunctioning of the device.
8630 - 11
GENERAL NOTES
Master Code
Operation of this device can be locked by means of a freely selectable user code. Independent of this,
there exists an unchangeable master code with which you can execute all operative actions on the
device. This 4-digit code is to found on the last page of these operating instructions.
If required, cut out this code and keep it separate from these operating instructions.
Transport, storage
ATTENTION!
Transport and store the appliance in its original packing only.
Disposal
ATTENTION!
When disponsing of the appliance, observe the national standards for refuse disposal.
12 - 8630
SYSTEM DESCRIPTION
SYSTEM DESCRIPTION
Valve types ................................................................................................................................................................................................................................................ 14
Characteristics of the valve types .......................................................................................................................................................................... 15
Construction of TOP Control Continuous.................................................................................................................................................... 16
Illustrations (cover removed) ........................................................................................................................................................................................ 16
Design features
Functional diagram as a positioner with single-acting actuator
.............................................................................................................................................................................................................................. 17
....................................................................................... 18
Operation as a positioner.................................................................................................................................................................................................... 19
Schematic representation of positioning control ................................................................................................................................. 20
Characteristics of the positioner software
................................................................................................................................................... 21
* Operation as a process controller (option) .......................................................................................................................................... 22
Example of process control: TOP Control Continuous with sensor ............................................................................ 22
Schematic representation of process control
Characteristics of the process controller software
.......................................................................................................................................... 23
............................................................................................................................ 24
* Operation as a flow rate controller (option)......................................................................................................................................... 25
Characteristics of the flow rate controller software.......................................................................................................................... 25
Schematic representation of process control with flow rate controller
................................................................... 26
* Interfaces of the TOP Control Continuous in the multipole variant ................................................................. 27
* Interfaces of the TOP Control Continuous in the variants with cable bushings ........................... 28
Technical data
Safety settings on failure of auxiliary electrical or pneumatic energy ...................................................................... 29
Factory settings on the TOP Control Continuous
Data of the TOP Control Continuous
* Alternative chapters or functions depending on device configuration
....................................................................................................................................................................................................................................... 29
............................................................................................................................... 30
.................................................................................................................................................................. 31
8630 - 13
SYSTEM DESCRIPTION
By the combination of the TOP Control with pneumatically actuated process valves, the functionality of
the Bürkert process valve series is extended. These valves, in connection with the TOP Control, may
also be employed in those control applications requiring continuous behaviour of the actuator.
Valve types
The figure below gives an overview of the possible combinations of TOP Control and various
pneumatically actuated valves. For each type, various actuator sizes and valve sizes are available (not
shown). More detailled information is to be found on the respective data sheets. The product range is
being extended continually.
TOP Control
Continuous
Type 8630
with flat-seat valve
Type 2712
(here with flange connection)
TOP Control
Continuous
Type 8630
with ball valve
Type 2655
with Y-valve Type 2700
with butterfly valve
Type 2672
with diaphragm valve
Type 2730
Various process valves from the Bürkert range can be combined with the TOP Control to suit different
applications. Y-, diaphragm or ball valves with control cones are suitable.
14 - 8630
SYSTEM DESCRIPTION
Pneumatically driven piston and rotary actuators may be used to operate them. Both single-acting and doubleacting actuators are offered in combination with TOP Control Continuous.
With single-acting actuators, only one chamber in the actuator is pressurized and vented. The pressure
produced works against a spring. The piston moves until an equilibrium is set up between the pressure and the
spring force.
With double-acting actuators, the chambers on both sides of the piston are pressurized. When the one
chamber is pressurized, the other is vented and vice versa. No spring is installed in this actuator version.
Characteristics of the valve types
Typ es
Characteristic
Y-valves
Flat seat valves
• 2700
• 2712
• Inlet flow under seat
• Non-impact closure
• Straight flow of
medium
• Self-adjusting packed
gland for very tight seal
Diaphram valves Ball valves Flap valves
• 2730 (plastic)
• 2731 (metal)
• 2731K (pipe housing)
• Medium is hermeti cally separated from
actuator and the
ambient
• Self-draining housing
design without dead
spaces
• Either flow direction
with low turbulence
flow
• May be steam
sterilized
• CIP compatible
• Non-impact closure
• Actuator and dia phragm are de tachable with the
housing
• 2652 (2-part,VA)
• 2655 (3-part,VA)
• 2658 (plastic)
• Piggable
• Low and dead space
• insensitive to
contamination
• Lower pressure loss
than with other valve
types
• with 3-part ball valve,
seat and seal can be
exchaged while
installed
Note
Only usable as process
controller.
• 2672 (metal)
• 2675 (plastic)
• insusceptible to dirt
• less pressure loss
compared to other
valve types
• good value for money
• smaller volume
Typ ica l me dia
• Water, steam and
gases
• Alcohols, oils, fuels,
hydraulic fluides
• Salt solutions, lyes
(organic)
• Organic solvents
• Neutral gases and
liquids
• contaminated, ab rasive and aggressive
media
• high purity or sterile
media
• high viscosity media
• Neutral gases and
liquids
• pure water
• slightly aggressive
media
• Neutral gases and
fluides
• slightly aggressive
media
8630 - 15
SYSTEM DESCRIPTION
Construction of TOP Control Continuous
Illustrations (cover removed)
Positioning system
with 2, 3 or 4 solenoid valves
Screw for adjusting the lower proximity
switch
Screw for adjusting the upper proximity
switch
Pressure supply port
(marked: 1)
Control ports
(connected in the
factory)
Operating module with display and
keys
Exhaust air ports
(marked 3)
16 - 8630
Fixing screw for fixing the
TOP Control Continuous
on the drive
Max. torque 1.2 Nm
Electrical connection module,
here with multipole connectors
Design features
•
Versions
for single and double acting valve actuators
Position sensor
•
very high resolution conductive plastic potentiometer, coupled without play to the piston rod of the
pneumatic actuator
Microprocessor controlled electronics
•
for signal processing, control and driving the valve
Operating module
•
The device is operated via 3 keys. 8-digit, 16-segment LC display for showing the setpoint or actual
value and for configuration and parametrization via menu functions.
Positioning system
•
With single-acting actuators, the positioning system consists of 2 solenoid valves; with double-acting
actuators of four solenoid valves. With single-acting actuators, one valve serves to pressurize the
pneumatic piston drive and another to exhaust it. Double-acting actuators contain 2 valves for
pressurization and 2 for exhausting.The solenoid valves work on the rocker principle and are driven
via the controller with a PWM voltage. This enables great flexibility with regard to actuator volumes
and floating speed. For larger pneumatic actuators, the solenoid valve are equipped with diaphragm
boosters.
SYSTEM DESCRIPTION
As an option, with single-acting actuators, there are fast pressurizing/exhaust variants with an additional pressurizing valve and an additional exhaust valve. These enable the actuator to be completely
pressurized and exhausted more rapidly. This is used with the tight-closure function (see section
"
CUTOFF
Position repeater (optional)
•
2 inductive proximity switches (initiators) or mechanical limit switches.
Attainment of an upper or lower position of the valve can be relayed via binary outputs e.g. to a PLC.
The end settings on the initiators can be adjusted by the owner by means of setscrews.
") and on activation of a safety position of 0 or 100% (see section "
BIN-IN
").
•
Pneumatic interfaces
1/4’’- connectors in various threads
(G, NPT, RC)
•
Housing
The housing of the TOP Control is protected by a pressure relief valve from excessive internal
pressure, e.g. resulting from leaks.
The cover may be secured against unauthorized opening with a lead seal or with a self-tapping
screw.
•
Electrical interfaces
Multipole plug connector or cable bushing
8630 - 17
SYSTEM DESCRIPTION
Fuctional diagram as a positioner with single-acting actuator
Actual process value
Process
setpoint
external
position
setpoint
TOP Control Continuous
Process
controller
Actual
position
Position
sensor
Setpoint position
Positioner
Positioning
system
Positioning system
1: pressurizing valve
2: exhaust valve
Compressed air
supply
Pneumatic
actuator
(single-acting)
Valve
(actuator)
Exhaust air
Sensor
18 - 8630
Actual process value
(flow rate, pressure, level,
temperature etc.)
SYSTEM DESCRIPTION
Operating as a positioner
The actual position (POS) of the pneumatic actuator is measured via the position sensing system. The
controller compares this actual value of the position with the setpoint (CMD) , which can be specified as
a standard signal. If a control difference (Xd1) exists, a pulse-width modulated voltage signal is sent to
the positioning system as the correcting variable. With single-acting actuators, if the difference is positive, the pressurizing valve is driven via output B1; if it is negative, the exhaust valve is driven via output
E1. In this way, the position of the actuator is altered until the control difference is zero. Z1 represents a
disturbance.
Z1
CMD
Position setpoint Positioner
Xd1
Position control
loop
B1
E1
Positioning
system Solenoid
POS
Wegmeßsystem
Position sensor
P
K
Continious valve
Valve opening
8630 - 19
SYSTEM DESCRIPTION
POS
CMD
INP
X.CONTRL
DBDx
POS
X.LIMIT
DIR.ACT
CMD
X.TIME
CUTOFF
20 - 8630
Schematic representation of positioning control
4 … 20 mA
0 … 20 mA
0 … 10 V
0 … 5 V
DIR.CMD SPLTRNG CHARACT
INP
Characteristics of the positioner software
Supplementary function Effect
Positioner with supplementary functions
Valve closes tight outside control range. A value is
Tight-closing function
given (at %) from which the actuator is completely
exhausted (at 0%) or pressurized (at 100 %).
SYSTEM DESCRIPTION
Stroke limitation
Signal range splitting
Correction characteristic to match
the operating curve
Insensitivity range
Direction of action of the controller
setpoint
Safety position Valve moves to a specified safety position.
Hierarchical concept for simple operation with the following levels
Process operation
Configuration
Mech. valve piston movement only withhin a specified
stroke range.
Splitting of the standard signal range over two or more
TOP Control Continuous.
Linearization of the process characteristic can be
performed.
The positioner cuts in only above a specified control
difference.
Reversal of the setpoint action direction
In this level your switch between automatic and manual
operation.
In this level you specify on commissioning certain basic
functions and configure supplementary functions as
needed.
8630 - 21
SYSTEM DESCRIPTION
* Operation as a process controller (option)
On operation of the TOP Control Continuous as a process controller, the abovementioned position
control becomes a subordinate auxiliary control loop; the result is a cascade control. The process
controller in the main loop of the TOP Control Continuous has a PID function. The setpoint specified is
the process setpoint (SP) and it is compared with the process variable to be controlled. The actual
position (XPOS) of the pneumatic actuator is measured via the position sensing system. The controller
compares this actual value of the position with the setpoint (CMD) , which can be specified as a
standard signal. If a control difference (Xd1) exists, a pulse-width modulated voltage signal is sent to the
positioning system as the correcting variable. With single-acting actuators, if the difference is positive,
the pressurizing valve is driven via output B1. If it is negative, the exhaust valve is driven via output E1.
In this way, the position of the actuator is altered until the control difference is zero. Z2 represents a
disturbance.
Z1
Process
setpoint
Xd1
Positioner
XPOS
Position control loop
SP
Xd2
Process controller
B1
E1
Positioning
system Solenoid valves
Position sensor
Process
CMD
control
loop
PV
P
K
Continuous
Valve
Valve
opening
Valve
opening
Z2
Process variable
Process
Example of process control:
TOP Control Continuous with sensor
22 - 8630
Transmitter
SYSTEM DESCRIPTION
Schematic representation of process control
8630 - 23
SYSTEM DESCRIPTION
Characteristics of the process controller software
Supplementary function Effect
Positioner with supplementary functions
Valve closes tight outside control range. A value is
Tight-closing function
Stroke limitation
Signal range splitting
Correction characteristic to match
the operating curve
Insensitivity range
Direction of action of the controller
setpoint
Safety position Valve moves to a specified safety position
Analog feedback (option)
given (at %) from which the actuator is completely
exhausted (at 0%) or pressurized (at 100%).
Mech. valve piston movement only within a specified
stroke range.
Splitting of the standard signal range over two or more
TOP Control Continuous.
Linearization of the process characteristic can be
performed.
The positioner cuts in only after a specified control
difference.
Reserval of the setpoint action direction
Feedback of the position/process values
Binary outputs
Connectable process controller with the following characteristics (Option)
Controller structure PID
Parameters that can be set
Scalable input
Method of setpoint setting Setting either via standard signal input or via keys
Hierarchical concept for simple operation with the following levels
Process operation
Configuration
Proportional action factor, reset time, rate time and
operating point
Decimal point position, upper and lower sacle valures
of process value and setpoint
In this level your switch between automatic and manual
operation.
In this level you specify on commissioning certain basic
functions and configure supplementary functions as
needed.
24 - 8630
* Operation as a flow rate controller (option)
The flow rate controller is a special type of process controller. The process value (PV) is not measured
directly via an analog input but calculated in the device by the dp method. According to the algorithm,
the flow rate is dependent on the parameters
dium temperature
for 2 pressure transmitters and a temperature transmitter which can be optionally connected.
One pressure transmitter measures the pressure before the valve and a second one after the valve. The
temperature is either entered manually in the operating menu or is provided as a standard signal by a
temperature transmitter. The kv value is determined internally from the current position of the control
valve. For this purpose, a kv characteristic curve is provided in the control valve used.
The density of the medium is entered via the operating menu.
Temperature (optional)
(T) and the kv value. For this reason, the
pressure before valve
TOP Control Continuous FMR
SYSTEM DESCRIPTION
(p1),
pressure after valve
(p2),
me-
has inputs
Pressure
p1 p2
kv value
T
p1
In the case of the flow rate controller, the process parameters are either the volumetric flow rate or, for
special applications, the transport velocity at the end of a pumping section.
The volumetric flow rate is represented in m
gas pressure of 1013 mbar (abs).
There are special applications for flow rate controllers in which a pumping section is set up after the
valve, in which bulk goods enter via an airlock. These bulk goods are blown through the pumping
section by the pumping pressure that builds up behind the valve.
PV
8630
Flow rate
controller
e.g. valve
type 2712
3
/h STP, i.e. referred to 0 °C (medium temperature) and a
Pressure
p2
The transport velocity corresponds to the volumetric flow rate of the medium, referred to the piping
diameter of the pumping section. However, it is not specified for standard conditions, but reflects the
velocity of the gas particles at the existing medium temperature. The diameter is entered in the
operating menu.
Characteristics of the flow rate controller software
The flow rate controller offers the same functions as the process controller.
8630 - 25
SYSTEM DESCRIPTION
Schematic representation of process control with flow rate controller
26 - 8630
* Interfaces of the TOP Control Continuous
in the multipole variant
SYSTEM DESCRIPTION
Inputs for position or
process setpoint
4..20 mA
0..20 mA
0..10 V
0..5 V
Input for process setpoint
4..20 mA
Frequency
Pt 100
* Flow rate controller
Binary input
24 V DC
* Note:
Inputs for process value with flow rate controller (option): p1, p2, T (optional).
The standard process controller inputs (4 ... 20 mA, frequency, Pt 100) and the initiators cannot be used with this option.
Inputs
Sup-
ply
TOP Control
Continuous
(multipole - variant)
Operating unit
2 binary outputs
Analog position feedback
*Initiators 1 + 2
Outputs
NOTE
TOP Control Continuous Type 8630 is a 3-conductor device, i.e. the voltage supply (24 V
DC) is separate from the setpoint signal.
8630 - 27
SYSTEM DESCRIPTION
* Interface of the TOP Control Continuous in the variants with
cable bushings
Inputs for position or process
setpoint
4..20 mA
0..20 mA
0..10 V
0..5 V
Input for process setpoint*
4..20 mA
Frequency
Pt 100
(alternative to binary outputs)
Binary input
24 V DC
NOTE
TOP Control Continuous Type 8630 is a 3-conductor device, i.e. the voltage supply (24 V
DC) is separate from the setpoint signal.
Inputs
Sup-
ply
TOP Control
Continuous
(PG - variant)
Operating unit
2 binary outputs*
(alternative to input for process
setpoint)
Analog
position feedback
Outputs
*
Note:
The choice between a
process setpoint input and
two binary outputs is made
by positioning the jumper.
28 - 8630
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