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

CONTENTS

Overall Operating Instructions

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 ......................................................................................................................................................................................	15
Construction of TOP Control Continuous .....................................................................................................................................................	16
Illustrations (cover removed) ...................................................................................................................................................................................................	16
Design features .....................................................................................................................................................................................................................................	17
Functional diagram as a positioner with single-acting actuator ............................................................................................................	18
Operation as a positioner .....................................................................................................................................................................................................	19
Schematic representation of positioning control ..................................................................................................................................................	20
Characteristics of the positioner software ..................................................................................................................................................................	21

* Alternative chapters or functions depending on device configuration

8630 - 1

CONTENTS

*Operation as a process controller (option)...............................................................................................................................................	22
Example of process control: TOP Control Continuous with sensor ...................................................................................................	22
Schematic representation of process control .........................................................................................................................................................	23
Characteristics of the process controller software .............................................................................................................................................	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 ........................................................................................................................................................................................................................................	29
Safety settings on failure of auxiliary electrical or pneumatic energy .........................................................................................	29
Factory settings on the TOP Control Continuous .............................................................................................................................................	30
Data of the TOP Control Continuous .............................................................................................................................................................................	31

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 .......................................................................................................................................................................................................	38
Entering the position setpoint in the AUTOMATIC mode ..........................................................................................................................	38
Manual opening and closing of the valve actuator in the MANUAL mode .............................................................................	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

CONTENTS

*Electrical connection - multipole connectors .......................................................................................................................................	44
Marking of the multipole plugs or sockets and the contacts ...................................................................................................................	44
Output signals for SPS (circular plug M 16) .............................................................................................................................................................	45
Operating voltage (circular plug M 12) ............................................................................................................................................................................	45
Inductive proximity switches (circular socket M 8) ...........................................................................................................................................	45
Process value (circular plug M 8) .......................................................................................................................................................................................	46
Process value with the option flow rate controller (2 circular plugs M 8)
Option: with temperature sensor input (3 circular plugs M 8) ..............................................................................................................	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 ............................................................................................................................................................	47
Choice of binary outputs or process value input ...............................................................................................................................................	48
*Setting the inductive proximity switches (option) ...........................................................................................................................	50
Opening the housing of the TOP Control Continuous .................................................................................................................................	50
Positioning the inductive proximity switches ..........................................................................................................................................................	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 ............................................................................................................................................................	53
Main menu for the settings on commissioning ....................................................................................................................................................	54
Description of the procedure ..................................................................................................................................................................................................	55
Configuring the supplementary functions ....................................................................................................................................................	59
Keys in the configuration level ..............................................................................................................................................................................................	59
Configuration menu ..........................................................................................................................................................................................................................	59
Supplementary functions ...........................................................................................................................................................................................................	62
Operating the process...............................................................................................................................................................................................................	86
Changeover between operating modes ......................................................................................................................................................................	86
Operating mode AUTOMATIC.......................................................................................................................................................................................	87
Meaning of the keys in the AUTOMATIC mode ..................................................................................................................................................	87
Display of the AUTOMATIC mode .....................................................................................................................................................................................	87
Operating mode MANUAL ..................................................................................................................................................................................................	88
Meaning of the keys in the MANUAL mode ............................................................................................................................................................	88
Display of the MANUAL mode ..............................................................................................................................................................................................	88

* Alternative chapters or functions depending on device configuration

8630 - 3

CONTENTS

OPERATING THE PROCESS CONTROLLER

Factory settings on the process controller...................................................................................................................................................	90
Setting up a process control system ....................................................................................................................................................................	90
Self-parametrization of the positioner - X.TUNE...............................................................................................................................	91
Supplementary function P.CONTRL ....................................................................................................................................................................	91
Basic settings of the function P.CONTRL...................................................................................................................................................................	92
P.Q’LIN - Starting the routine for linearization of the process curve .....................................................................	105
Display during call-up and execution of the routine ..........................................................................................................................................	105
P.CO TUNE - Self-optimization of the process controller (process tune) .....................................................	106
P.CO LEAK - Leakage characteristic for flow rate control ...................................................................................................	110
Operating the process ...............................................................................................................................................................................................................	112
Changeover between the operating modes ................................................................................................................................................................	112
Operating mode AUTOMATIC .......................................................................................................................................................................................	113
Meaning of the keys .........................................................................................................................................................................................................................	113
Displays ........................................................................................................................................................................................................................................................	113
Operating structure and procedures ..................................................................................................................................................................................	113
Manually changing the process setpoint ......................................................................................................................................................	114
Operating mode MANUAL ..................................................................................................................................................................................................	114
Meaning of the keys .........................................................................................................................................................................................................................	114
Displays ........................................................................................................................................................................................................................................................	115
Operating structure and procedures ..................................................................................................................................................................................	115

PROFIBUS DP

General notes.........................................................................................................................................................................................................................................	118
Technical data .......................................................................................................................................................................................................................................	118
Safety settings on bus failure .........................................................................................................................................................................................	118
Interfaces.......................................................................................................................................................................................................................................................	119
Electrical connections ...............................................................................................................................................................................................................	119
Connection with one plugged bus connector ...........................................................................................................................................................	119
Connection with 2 plugged bus connectors ..............................................................................................................................................................	120
Operating voltage (circular plug M12) .............................................................................................................................................................................	120
Bus connection (circular socket M12) ............................................................................................................................................................................	120

4 - 8630

	CONTENTS
Inductive proximity switches (circular socket M8) .............................................................................................................................................	121
Process value (circular plug M8) .........................................................................................................................................................................................	121
Termination connection for PROFIBUS systems ................................................................................................................................................	122
Settings on the TOP Control Continuous .....................................................................................................................................................	123
Explanation of the menu items ..............................................................................................................................................................................................	124
Functional deviations from the standard version ..............................................................................................................................	124
Configuration in the Profibus DP master ......................................................................................................................................................	125
Configuration of the process values .................................................................................................................................................................................	125
Bus status display ...........................................................................................................................................................................................................................	127
Example 1 with COM-Profibus V3.3 ....................................................................................................................................................................	128
Example for a positioner ...............................................................................................................................................................................................................	128
Example 2 with COM-Profibus V3.3 ....................................................................................................................................................................	131
Example for a process controller .........................................................................................................................................................................................	131
DEVICE NET
General notes.........................................................................................................................................................................................................................................	134
Explanation of terms ....................................................................................................................................................................................................................	134
Technical data .......................................................................................................................................................................................................................................	135
Safety settings on bus failure .........................................................................................................................................................................................	135
Interfaces.......................................................................................................................................................................................................................................................	136
Electrical connection ...................................................................................................................................................................................................................	136
Operating voltage (4-pole M12 circular plug) ...........................................................................................................................................................	137
Bus connection (4-pole M12 circular plug) .................................................................................................................................................................	137
Inductive proximity switches (4-pole M8 circular socket) ...........................................................................................................................	137
Process value (circular plug M8) .........................................................................................................................................................................................	137
Termination connection for DeviceNet systems ...................................................................................................................................................	138
Net topology of a DeviceNet system ...............................................................................................................................................................................	138
Settings on the TOP Control Continuous .....................................................................................................................................................	139
Explanation of the menu items in the program run-off schematic ......................................................................................................	139
Settings in the main menu .........................................................................................................................................................................................................	140
Configuring the process data .........................................................................................................................................................................................	141
Static input assemblies .................................................................................................................................................................................................................	141
Static output assemblies .............................................................................................................................................................................................................	143
	8630 - 5

CONTENTS

Bus status display ...........................................................................................................................................................................................................................	144
Configuration example 1 .......................................................................................................................................................................................................	145
Installation of the EDS file .........................................................................................................................................................................................................	145
Address allocation ..............................................................................................................................................................................................................................	145
Offline parametrization of the device ...............................................................................................................................................................................	146
Online parametrization of the device ...............................................................................................................................................................................	147
Configuration example 2 .......................................................................................................................................................................................................	148
Setting up the process map (mapping) ..........................................................................................................................................................................	149

MAINTENANCE AND ERROR CORRECTION ON THE POSITIONER
Maintenance ............................................................................................................................................................................................................................................	152
Error messages and malfunctions ..........................................................................................................................................................................	152
Error messages on the LC display .....................................................................................................................................................................................	152
Other malfunctions .............................................................................................................................................................................................................................	152

MAINTENANCE AND ERROR CORRETION ON THE
PROCESS CONTROLLER
Maintenance ............................................................................................................................................................................................................................................	154
Error messages and malfunctions ..........................................................................................................................................................................	154
Error messages on the LC display .....................................................................................................................................................................................	154
Other malfunctions .............................................................................................................................................................................................................................	156

Appendix

6 - 8630

CONTENTS

GENERAL RULES
Selection criteria for continuous valves ..........................................................................................................................................................	158
Characteristics of PID controllers.............................................................................................................................................................................	160
P component ............................................................................................................................................................................................................................................	160
I component ..............................................................................................................................................................................................................................................	161
D component ............................................................................................................................................................................................................................................	162
Superimposing the P, I and D components ...............................................................................................................................................................	163
Function of a real PID controller ...........................................................................................................................................................................................	164
Rules for setting PID controllers ................................................................................................................................................................................	165
Setting rules of Ziegler and Nichols (oscillation method) ............................................................................................................................	165
Setting rules of Chien, Hrones and Reswick (controller output step method) ........................................................................	166

OPERATING STRUCTURE

Operating structure of the TOP Control Continuous.....................................................................................................................

170

TABLE FOR POSITIONER

Table for noting your settings on the positioner ..................................................................................................................................

178

TABLE FOR PROCESS CONTROLLER

Tables for noting your settings on the process controller .....................................................................................................

180

MASTER CODE

Code number ..........................................................................................................................................................................................................................................

182

8630 - 7

CONTENTS

8 - 8630

GENERAL NOTES

GENERAL NOTES

Symbols..............................................................................................................................................................................................................................................................	10
Intended use ................................................................................................................................................................................................................................................	10
Safety notes ..................................................................................................................................................................................................................................................	10
Protection from damage by electrostatic charging .............................................................................................................................	11
Scope of delivery ..................................................................................................................................................................................................................................	11
Warranty conditions ..........................................................................................................................................................................................................................	11
Master code ..................................................................................................................................................................................................................................................	12
Transport, storage ................................................................................................................................................................................................................................	12
Disposal .............................................................................................................................................................................................................................................................	12

8630 - 9

GENERAL NOTES

Symbols

The following symbols are used in these operating instructions:

marks a work step that you must carry out.

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

NOTE		marks important additional information, tips and recommendations.

Intended use

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

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

In view of the large number of possible applications and categories of use, you should check whether the Top control Continuous is suitable for your specific application, and carry out tests where necessary.

Safety notes

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

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

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

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

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

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

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

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

10 - 8630

GENERAL NOTES

Protection from damage by electrostatic charging

ATTENTION

EXERCISE CAUTION ON HANDLING!

ELECTROSTATICALLY SENSITITVE

COMPONENTS/MODULES

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

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

Scope of delivery

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

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

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

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

Bürkert Fluid Control Systems

Chr.-Bürkert-Str. 13-17

Service Department

D-76453 Ingelfingen

Tel.: [phone]

Fax: [phone]

E-Mail: [e-mail]

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

MasterCode

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

SYSTEMDESCRIPTION

Valve types ................................................................................................................................................................................................................................................	14
Characteristics of the valve types ..........................................................................................................................................................................	15
Construction of TOP Control Continuous....................................................................................................................................................	16
Illustrations (cover removed) ........................................................................................................................................................................................	16
Design features ..............................................................................................................................................................................................................................	17
Functional diagram as a positioner with single-acting actuator .......................................................................................	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 ..........................................................................................................................................	23
Characteristics of the process controller software............................................................................................................................	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.......................................................................................................................................................................................................................................	29
Safety settings on failure of auxiliary electrical or pneumatic energy ......................................................................	29
Factory settings on the TOP Control Continuous...............................................................................................................................	30
Data of the TOP Control Continuous..................................................................................................................................................................	31

* Alternative chapters or functions depending on device configuration

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	with Y-valve Type 2700
Type 2712
(here with flange connection)

TOP Control
Continuous	with butterfly valve
Type 8630	Type 2672

with ball valve	with diaphragm valve
Type 2655	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

	Y-valves	Diaphram valves	Ball valves	Flap valves
	Flat seat valves
Types	• 2700	• 2730 (plastic)	• 2652 (2-part,VA)	• 2672 (metal)
	• 2712	• 2731 (metal)	• 2655 (3-part,VA)	• 2675 (plastic)
		• 2731K (pipe housing)	• 2658 (plastic)
Characteristic	• Inlet flow under seat	• Medium is hermeti-	• Piggable	• insusceptible to dirt
		cally separated from
	• Non-impact closure	actuator and the	• Low and dead space	• less pressure loss
		ambient		compared to other
	• Straight flow of		• insensitive to	valve types
	medium	• Self-draining housing	contamination
		design without dead		• good value for money
	• Self-adjusting packed	spaces	• Lower pressure loss
	gland for very tight seal		than with other valve	• smaller volume
		• Either flow direction	types
		with low turbulence
		flow	• with 3-part ball valve,
			seat and seal can be
		• May be steam	exchaged while
		sterilized	installed
		• CIP compatible	Note
			Only usable as process
		• Non-impact closure	controller.
		• Actuator and dia-
		phragm are de-
		tachable with the
		housing
Typical media	• Water, steam and	• Neutral gases and	• Neutral gases and	• Neutral gases and
	gases	liquids	liquids	fluides
	• Alcohols, oils, fuels,	• contaminated, ab-	• pure water	• slightly aggressive
	hydraulic fluides	rasive and aggressive		media
		media	• slightly aggressive
	• Salt solutions, lyes		media
	(organic)	• high purity or sterile
		media
	• Organic solvents
		• high viscosity media

8630 - 15

SYSTEM DESCRIPTION

ConstructionofTOPControlContinuous

Illustrations (cover removed)

Screw for adjusting the lower proximity switch

Screw for adjusting the upper proximity

switch

Positioning system with 2, 3 or 4 solenoid valves

Operating module with display and

keys

Pressure supply port (marked: 1)

Control ports	Exhaust air ports
(connected in the	(marked 3)
factory)

Fixing screw for fixing the	Electrical connection module,
TOP Control Continuous	here with multipole connectors
on the drive
Max. torque 1.2 Nm

16 - 8630

SYSTEM DESCRIPTION

Design features

• Versions

for single and double acting valve actuators

• Position sensor

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

• Microprocessor controlled electronics

for signal processing, control and driving the valve

• Operating module

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

• Positioning system

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

As an option, with single-acting actuators, there are fast pressurizing/exhaust variants with an additional pressurizing valve and an additional exhaust valve. These enable the actuator to be completely pressurized and exhausted more rapidly. This is used with the tight-closure function (see section "CUTOFF") and on activation of a safety position of 0 or 100% (see section "BIN-IN").

• Position repeater (optional)

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

Attainment of an upper or lower position of the valve can be relayed via binary outputs e.g. to a PLC. The end settings on the initiators can be adjusted by the owner by means of setscrews.

• Pneumatic interfaces
			• Electrical interfaces
1/4’’- connectors in various threads				Multipole plug connector or cable bushing
(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.

8630 - 17

SYSTEM DESCRIPTION

Fuctional diagram as a positioner with single-acting actuator

Actual process value

Process
setpoint	Process	Setpoint position
external	controller
position
setpoint		Positioner
			Positioning system
	Actual		1: pressurizing valve
			2: exhaust valve
	position
		Positioning
TOP Control Continuous		system
	Position		Compressed air
			supply
	sensor
			Exhaust air
Pneumatic
actuator
(single-acting)
Valve
(actuator)
			Sensor

Actual process value (flow rate, pressure, level, temperatureetc.)

18 - 8630

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
		B1
CMD	Xd1	PK	Valve opening
		E1
Position setpoint	Positioner	Positioning	Continious valve
		system Sole-
		noid
		POS
	Position control	PositionWegmeßsystemsensor
	loop

8630 - 19

SYSTEM DESCRIPTION

Schematicrepresentationofpositioningcontrol

CMD

POS

POS

X.LIMIT

DIR.ACT

20mA	20mA	10V	5V
4…	0…	0…	0…

INP

X.CONTRL	DBDx
	CMD
	X.TIME
	CUTOFF
	CHARACT
	SPLTRNG
INP	DIR.CMD

20 - 8630

			SYSTEM DESCRIPTION
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 %).
		Stroke limitation	Mech. valve piston movement only withhin a specified
			stroke range.
		Signal range splitting	Splitting of the standard signal range over two or more
			TOP Control Continuous.
		Correction characteristic to match	Linearization of the process characteristic can be
		the operating curve	performed.
		Insensitivity range	The positioner cuts in only above a specified control
			difference.
		Direction of action of the controller	Reversal of the setpoint action direction
		setpoint
		Safety position	Valve moves to a specified safety position.

Hierarchical concept for simple operation with the following levels

Process operation

In this level your switch between automatic and manual operation.

In this level you specify on commissioning certain basic Configuration 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
	B1
Xd1	PK
	E1		Valve
Positioner	Positioning	Continuous	opening
	system Soleno-	Valve
	id valves
	XPOS
	Position sensor
Position control loop

						Z2
				Process	Valve
	SP	Xd2	CMD		opening	Process variable
				control
				loop

Process Process controller Process setpoint

PV

Transmitter

Example of process control:

TOP Control Continuous with sensor

22 - 8630

SYSTEM DESCRIPTION

Schematicrepresentationofprocesscontrol

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	given (at %) from which the actuator is completely
		exhausted (at 0%) or pressurized (at 100%).
	Stroke limitation	Mech. valve piston movement only within a specified
		stroke range.
	Signal range splitting	Splitting of the standard signal range over two or more
		TOP Control Continuous.
	Correction characteristic to match	Linearization of the process characteristic can be
	the operating curve	performed.
	Insensitivity range	The positioner cuts in only after a specified control
		difference.
	Direction of action of the controller	Reserval of the setpoint action direction
	setpoint
	Safety position	Valve moves to a specified safety position
	Analog feedback (option)	Feedback of the position/process values
		Binary outputs
	Connectable process controller with the following characteristics (Option)
	Controller structure	PID
	Parameters that can be set	Proportional action factor, reset time, rate time and
		operating point
	Scalable input	Decimal point position, upper and lower sacle valures
		of process value and setpoint
	Method of setpoint setting	Setting either via standard signal input or via keys

Hierarchical concept for simple operation with the following levels

Process operation

In this level your switch between automatic and manual operation.

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

needed.

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SYSTEM DESCRIPTION

* Operation as a flow rate controller (option)

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

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

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

Temperature (optional)

Pressure	Pressure
p1	PV
	p2

8630 Flowrate controller

	e.g.valve
	type	2712
T	kv value
p1		p2

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

The volumetric flow rate is represented in m3/h STP, i.e. referred to 0 °C (medium temperature) and a gas pressure of 1013 mbar (abs).

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

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

Characteristics of the flow rate controller software

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

8630 - 25

SYSTEM DESCRIPTION

Schematicrepresentationofprocesscontrolwithflowratecontroller

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SYSTEM DESCRIPTION

*Interfaces of theTOP Control Continuous in the multipole variant

Inputs for position or process setpoint

4..20 mA

0..20 mA 0..10 V

0..5 V

Input for process setpoint

4..20 mA

Frequency Pt 100

* Flow rate controller

Binary input

24 V DC

Inputs

Supply

TOPControl	Outputs
Continuous

(multipole - variant)

Operating unit

2 binary outputs

Analog position feedback

*Initiators 1 + 2

* 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.

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 theTOP 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

Inputs

Supply

TOPControl Continuous

(PG - variant)

Operating unit

Outputs

2 binary outputs*

(alternative to input for process setpoint)

Analog

position feedback

* Note:

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

NOTE		TOP Control Continuous Type 8630 is a 3-conductor device, i.e. the voltage supply (24 V
		DC) is separate from the setpoint signal.

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