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Operating Instructions

1. 8630 149 burkert DEvicENET 102 10 02 peiuud TH SNVIS M uoisJeA 7800100001 NVI 150 8630 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 b ur ke rt MAINTENANCE AND ERROR CORRECTION ON THE POSITIONER MAINTENANCE AND ERROR CORRECTION ON THE POSITIONER Maintenance 152 Error messages and Malfunctions i 152 Error messages on the display en 152 Other Malfunctions 152 8630 151 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 MAINTENANCE AND ERROR CORRECTION ON THE POSITIONER burkert Maintenance When operated according to these Operating Instructions the TOP Control Continuous is maintenance free Error messages and malfunctions Error messages on the LC display Error message on switching on CMD FAUL signal error check signal set value positioner EE FAULT EEPROM faulty none device faulty Error message on execution of the function X TUNE X ERH 1 No compressed air connected Connect compressed air X ERR 2 Compressed air failure during Check compressed air supply AUTOTUNE X ERH 38 Actuator or positioning system leaky None device faulty on exhaust side 4 Actuator system leaky on pressurized None device faulty side The end positions for POS MIN and Check whether the allocation of the end 5 are too near t
2. 145 Installation of the EDS tT 145 Address allocation 145 Offline parametrization of the device 146 Online parametrization of the device ttt 147 Configuration M 148 Setting up the process map mapping 149 8630 133 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 DEvicENET burkert General notes The following sections of the complete operating instructions are not applicable to the DeviceNet variant of the TOP Control Continuous 8630 Variants of the TOP Control Continuous First commissioning Electrical connection Defining the basic settings Function INPUT Function SPLTRNG Function BIN IN Function OUTPUT Function CAL USER CAL INP Function CAL USEH CAL OUT Function CAL USEH CAL SP Explanation of terms DeviceNet DeviceNet is a field bus system based on the CAN protocol Controller Area Network It permits the networking of actuators and sensors slaves with higher ranking control devices masters n the DeviceNet the TOP Control Continuous is a slave device according to the Predefined Master Slave Connection Set defined in the DeviceNet specification Polled 1 0 Strobed I O and Change of State COS are supported as I O connection variants With the DeviceNet a distinction is made between cyclic or event controlled transferred process messages of high priority I O Messages and acycl
3. 5 APPENDIX Function of a real PID controller D component with delay In the process controller of the positioner the D component is realized with a delay T dXd dY Function T a dt Superimposing the P and DT components Function of the real PID controller dY 1 dXd T S Y Kp Xd 7 J Xd dt Tv 9 Step response of the real PID controller Kp Xd 164 8630 bu rkert MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 burkert GENERAL RULES APPENDIX Rules for setting PID controllers The literature on control technology contains a number of rules by which a favourable setting of the controller parameters can be determined experimentally In order to avoid incorrect settings the conditions under which the rules were set up in each case must be kept in mind Apart from the characteristics of the controlled member and the controller itself it makes a difference whether a change in disturbance or a command variable is to be compensated Setting rules of Ziegler and Nichols oscillation method With this method the controller parameters are set on the basis of the behaviour of the control loop at the limit of stability These parameters are initially set such that the control loop begins to oscillate Critical characteristic values occurring allow one to deduce a favourable setting of the control parameters A prerequisite for usi
4. 162 Superimposing the P and D components 163 Function OF a real PID Controllek aceto tee ee ctu we ieh 164 Rules for setting PID controllers 165 Setting rules of Ziegler and Nichols oscillation method ttt 165 Setting rules of Chien Hrones and Reswick controller output step method 166 OPERATING STRUCTURE Operating structure of the TOP Control nuttin 170 TABLE FOR POSITIONER Table for noting your settings on the positioner e 178 TABLE FOR PROCESS CONTROLLER Tables for noting your settings on the process controller i 180 MASTER CODE Code AUM Dg j 182 8630 7 burkert CONTENTS SLOZ LO Oz peiuud 1H Snielg Y uols eA 780010000 NYIN 8 8630 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 burkert GENERAL 5 GENERAL NOTES 10 Intended use iiin 10 Safety notes 10 Protection from damage by electrostatic charging i 11 Scope of delivery 11 Warranty Conditions RM 11 Master code 12 ransport Storage 12 Bj 12 8630 9 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 GewmuNots 7 burkert Symbols The following symbol
5. 120 8630 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 burkert DP Inductive proximity switches circular socket M 8 in Allocation Signal level Proximity switch 1 NO 51 1 gt Open 24 V Proximity switch 1 GND SS GND Proximity switch 2 NO S2 3 gt Open 24 V 4 Proximity switch 2 GND 5 gt GND 4 20 24 V input transmitter internally output transmitter supplied GND bridge after GND 4 20 not assigned externally process actual supplied not assigned 4 GND process actual 2 9 4 20 mA Frequency 24 V sensor supply P internally clock input Eja 2 o clock supplied clock input GND not assigned 3 g clock Frequenz not assigned externally clock input supplied clock input 3 o clock not assigned 2 not assigned process actual 1 current supply process actual 3 GND process actual 2 compensation Adjustable via software see chapter Procedure for determining the basic settings The jumper is located on the connector board of the TOP Control Continuous gt NOTE For line compensation reasons connect sensor Pt 100 via 3 conductors PIN 3 and PIN 4 gt must be bridged at the sensor 8630 121 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2
6. E s ERS Pen ANCCMO LANL ODOA NORM CLS oS as BINISIG P OUT mum BIN DEV X DEVX EN OUT END NORM CLS Lema NORM CLS BIN2LIM X BIN2SPOS BIN2SIG burkert MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 burkert CAL USEH F OPERATING STRUCTURE APPENDIX POS MIN CAL INP INP ORA INP gt activated AMA INP 5 activated CALSP SP SP 20MA controller SP SP gy i CAL Process controller activated PV P 100 xxx 8630 175 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 OPERATING STRUCTURE APPENDIX Er SER I O ENDFUNCT X TUNE X TUNE x X TUNEEND P Q LIN P Q LIN x P Q LINEND 176 8630 burkert n printed 20 01 2015 leased freigegebe re HL K Status MAN 1000010084 EN Version burkert TABLES FOR POSITIONER APPENDIX TABLES FOR POSITIONER APPENDIX 8630 177 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 Tastes ror Posmonen Amex burkert Tables for noting your setting on the positioner Settings of the freely programmable characteristic Ref point Valve stroke 95 Set p
7. hed Limi f iti int CMD imits refer to position setpoint Valve stroke 96 POS Setting range 75 100 96 1 100 99 98 97 96 95 94 MN 554 Setpoint 96 rm CMD N OO D O Setting range 0 25 94 95 96 97 98 99 100 66 8630 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 b ur kert OPERATION AND CONTROLLER FUNCTIONS DIR CMD Sense of action or direction of the positioner setpoint Factory setting DIR CRISE With this supplementary function you can set the sense of action between the input signal INP and the setpoint position CMD of the actuator Direct sense of action CAG gt ER e g 4 mA or 0V 20 A 20 mA or 5 10 V gt 100 DIR CFRLL Inverse sense of action UIR LFRILL e g 4 mA orO V 100 20 mA or 5 10 V gt 0 Setpoint position CMD 100 Inputsignal INP 8630 67 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 OPERATION AND CONTROLLER FUNCTIONS b u rkert DIR ACT Sense of action or direction of the actuator Factory setting DIR ARISE With this supplementary function you can set the sense of action between the state of pressurization of the actuator and the actual position POS Direct sense of action LI RC 1 So DIR ARISE exhausted gt 0 pressurized gt 100 A 2 Inverse Wirkungsrichtung e
8. gt Apply the supply voltage to the circular connector M12 Configuration of the circular connector M 12 Pin Allocation External connection 24V not connected 1o 24 V DC 10 96 GND max residual ripple 10 96 3 not connected NOTE Further installation notes are to be found in the chapter nstallation gt After application of the supply voltage the TOP Control Continuous is in operation Carry out the necessary basic settings and initiate self parametrization of the TOP Control 8630 35 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 First Commssonng burkert Electrical installation connection terminals for cable bushings gt Remove the cover with the cable bushings to gain access to the terminals This is done by unscrewing the 4 self tapping screws gt Apply the setpoint signal and the supply 12 3 4 5 6 Screw terminals voltage to the respective terminals see Terminal configuration with cable bushings Terminal configuration with cable bushings Terminal Allocation External connection Setpoint 1 o 0 4 20 mA or 0 5 10 V Setpoint GND Do GND 5 Operating voltage a 24 V DC 10 9 Operating voltage GND 6 max residual ripple 10 96 NOTE Further installation notes are to be found in the chapter nstallation After application of the supply voltage the TOP Control Continuous is in operatio
9. 2 Inputs for process value 4 20 Frequency Pt 100 TOP Control Continuous DeviceNet m Operating unit qu Electrical connection For operation of the device it is absolutely necessary to connect the 5 pole bus and the 4 pole circular plugs M12 voltage supply Plug M12 1 1 Plug M12 Der 2 5 4 2 4 nee voltage 3 3 TE PlugM8 2 4 4 2 socket process value 3 71 Gate Voltage supply to the device is not from the DeviceNet voltage V and V m but from the electrically isolated operating voltage gt NOTE 136 8630 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 burkert DeviceNet Operating voltage 4 pole M12 circular plug 24 V max Residual ripple 10 Bus connection 4 pole M12 circular plug ____ screen not assigned Inductive proximity switches 4 pole M8 circular socket roximity switch 1 NO 51 proximity switch 1 GND GND EMEND T GND proximity switch 2 NO S2 7 3 gt Open 24 proximity switch 2 GND 4 gt GND Process value circular plug M8 24 V input transmitter output transmitter GND 4 20 mA internally supplied bridge after GND not assigned process actual not assigned process actual 4 20 mA externally supplied adjustable via software 8630 137 MAN 1000010084 EN Version K Status RL released freigegeben
10. LEAK IN Display of the momentarily running phase of leakage determination LEAK PO progress is indicated by a rotating beam at the left hand edge of the display LEAK OPN LEAK PAH LEAK END Display flashes Leakage determination successfully completed L ERRX Display on occurrence of an error display on the right error number see chapter Maintenance and Troubleshooting in the controller manual Press both buttons simultaneously to interrupt the determination of the characteristic and select LEAK BRK 110 8630 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 b u r ke rt OPERATING THE PROCESS CONTROLLER Program sequence The control valve is closed After 10 sec settling time the admission pressure at the controller unit FMR is registered NOTE Scaling of the x axis of the leakage characteristic is based upon this pressure value The upper limit is this value times a factor of 0 85 Up to 21 reference points are determined Example at an admission pressure of 2 0 bar the characteristic curve is obtained from O to 1 7 bar in 85 mbar steps The control valve is slowly opened in a ramp time of 60 sec Parallel to this the conveyance pressure pressure at the outlet side of the FMR is monitored For each reference point of the characteristic the conveyance pressure and the air flow are registered Reading in is complete when after 60 sec the conto
11. or Tight closing function Deactivate tight closing POS 100 with lt 100 CUTOFF has function PV 0 with SP gt 0 or been inadvertently activated PV PV with SP SP Only with devices with analog repeat red LED does light Binary output Check connection of Current 100 mA binary output Binary output does not switch short circuit Only with devices with process controller Device does not work as a Menu item PCONTRL stands in Hemove the menu item controller despite correctly main menu The device thus PCONTRL from the main executed settings works as a process controller menu and expects a process value at the corresponding input 156 8630 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 burkert GENERAL RULES APPENDIX GENERAL RULES APPENDIX Selection criteria for continuous valves 158 Characteristics of PID controllers 160 P ttt 160 COS Nem 161 EEG OMS 162 o perimbosing the P and D ttd een 163 Function of a real PID controller tct 164 Rules for setting PID controllers ernennen 165 Setting rules of Ziegler and Nichols oscillation method iisi 165 Setting rules of Chien Hrones and Reswick controller output step method 166 8630 157 MAN 10
12. 20 01 2015 burkert Data of the TOP Control Continuous System DESCRIPTION OPERATING CONDITIONS Permissible ambient temperature 10 50 C Protection type IP 65 to EN 60529 only with correctly connected cable or plug and socket ATTENTION The TOP Control Continuous is not suitable for outdoor use CONFORMITY TO THE FOLLOWING STANDARDS CE conformity wer EMC Guideline 89 336 EWG MECHANICAL DATA Dimensions see data sheet Housing material TOP Control Dichtmaterial ELECTRICAL DATA Connections Voltage supply Power consumption Housing internal temperature indication Input resistance for actual value signal Input resistance for setpoint signal Protection class Analog position feedback max current for voltage output O 5 10 V max burden for current output 0 4 20 mA Inductive proximity switch current limitation outer Noryl PPE PA PSU inner PA 6 NBR Choice between multipole connector or 3 bushings M 16 x 1 5 with screw terminals 0 14 1 5 mm 24 V DC 10 residual ripple 10 96 No industrial DC lt 5W 55 125 C accuracy 2 C 180 Q at 4 20 mA resolution 12 bit 17 at frequency 0 1000 Hz 1 of mean 300 V sinus square wave sawtooth PT 100 20 220 C resolution lt 0 1 C 180 Q at 0 4 20 mA resolution 12 bit 19 at 0 5 10 V resolution 12 bit 3 to VDE 0580 10mA 560 Q 100 mA 8630 31
13. BUS ADDR Entry of the device address default 3 ADDR xxx Values from O to 126 can be set with the arrow keys confirmation is done with the MANUAL AUTOMATIC key BUS PDI Selection of the process values that are to be transferred from the TOP Control Continuous to the control master PDI POS with the MANUAL AUTOMATIC key each process value can be either activated appears or deactivated no PDI ERR For significance of the process values see table PDI Process Data Input BUS PDO Selection of the process values that are to be transferred from the control master to the TOP Control Continuous PDO INP With the MANUAL AUTOMATIC key each process value can be either activated appears or deactivated no PDO ERR For significance of the process values see table PDO Process Data Output BUS FAIL Activation for movement to saftey position on bus communication failure SPOS OFF The actuator moves to the position corresponding to the setpoint last transmitted default setting SPOS ON With SPOS ON set the following configurations can occur Activated menu item SAFEPOS On error in bus communication the actuator moves to the position set under SAFEPOS Deactivated menu item SAFEPOS On error in bus communication the actuator moves to the end position it would occupy in the zero voltage condition Functional deviations from the standard version The operating mode can be switched between MANUAL and AUTOMATIC in
14. NO Proximity switch 2 GND 24 V DC 3 open 24 V GND GND 8630 45 burkert INSTALLATION Process value circular plug M 8 Input type Pin Allocation External connection MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 4 20 internal supply 4 20 external Frequency internal supply Frequency external supply 24 V supply transmitter Output Transmitter GND bridge to GND GND from 3 conductor transmitter not connected Process actual not connected Process actual 24 V supply sensor Clock input Clock input GND not connected not connected Clock input Clock input not connected not connected process actual 1 current supply process actual 3 GND process actual 2 compensation May be set via software section Procedure for specifying the basic settings 24 V Clock Clock Clock Clock The jumper is situated on the connection board of the TOP Control Continuous see next page NOTE For line compensation reasons connect sensor Pt 100 via 3 conductors PIN 3 and PIN 4 must be bridged at the sensor Process value with the option flow rate controller 2 circular plugs M8 Option with temperature sensor input 3 circular plugs M8 Input type No of Pin Configuration Jumper ext connection plugs internally 1 1 24 V supply t
15. System DESCRIPTION SINIL X J401ND LOVEVHO OSNuliIdS 1H1INOO X peal aura as u u u En A Buiuonisod uonejuesoaadai 2 lt 20 8630 SLOZ LO Oz peiuud ueqebebie 1H Snielg M uoisJeA 780010000 NYIN MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 burkert w w w SverewDescnrro Characteristics of the positioner software Positioner with supplementary functions Valve closes tight outside control range A value is Tight closing function given at 96 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 CU oplitting of the standard signal range over two or more 9 ge TOP Control Continuous Correction characteristic to match Linearization of the process characteristic can be the operating curve performed The positioner cuts in only above a specified control Insensitivity range difference ae Heversal of the setpoint action direction Safety position Valve moves to a specified safety position Hierarchical concept for simple operation with the following levels In this level your switch between automatic and manual Process operation operation In this level you specify on commissioning
16. aZ E e LLI O N LO wT e 102 10 02 TH SNVIS uoisJeA 7800100001 NVI The fixed points that were entered should be noted in the table in the Appendix NOTE Led 8630 65 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 OPERATION AND CONTROLLER FUNCTIONS b u rkert CUTOFF Tight closure function for positioners or process controllers Factory setting CUT 0 CUTY 100 This function causes the valve to close tightly outside the control range Enter here the limits in percent for the position setpoint CMD or with activated PID controller either for the position setpoint or for the process setpoint SP from which the actuator is to be completely vented or pressurized In the case of the fast pressurization venting version two valves are driven in each case in order to obtain complete venting more rapidly Opening or resumption of controlled operation is performed with a hysteresis of 1 If the process valve is in the region of tight closure there appears the display a flashing MIN MAX symbol Tight closing threshold exhaust 0 inactive setting range 0 25 97 Tight closing threshold pressurize 100 inactive AV setting range 75 100 Menu appears only with activated PID controller Limits refer to process setpoint SP
17. e Select Order no vast ue The Midi screen appears s Hn rn 2 i am b Thor 1 u an 3 E E IBS nm m RSE aSa Em i DP Here the process values are entered corresponding to the selection in the configuration menu of the TOP Control Continuous Important 1 Observe sequence of process values 2 Input before output e Select process value PDI POS e Select process value PDI MODE e Select process value PDO INP e Select process value PDO MODE Enter inputs and outputs in the process diagram 8630 129 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 DP burkert Final configuration screen jE E E i 1 4 E me E B E p a E m H k ix me ERE De m M ol es 130 8630 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 burkert Example 2 with COM Profibus V3 3 Example for a process controller Settings in the configuration menu of the TOP Control Continuous ADDR 3 PDI PDO e PDI PV e PDO SP Procedure as in Example 1 Final configuration screen 55 111 A een
18. 8630 53 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 54 OPERATION AND CONTROLLER FUNCTIONS burkert Main menu for the settings on commissioning MANUAL MODE 8630 FUNLSNGL AUTOMATIC a MODE T o P FS DEA ZA INP 0 208 LU eun ine 07100 INP ase oY Jump over on first commissioning RUDFUNLT INPLIT Ze y xmme E Lx Tune x 55 crane ro MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 b ur rkert OPERATION AND CONTROLLER FUNCTIONS Description of the procedure After the voltage supply has been switched on the positioner is in the process operating level in the AUTOMATIC mode To specify the basic settings switch to the configuration level Depress the MANU AL AUTOMATIC key for 5 seconds The display then shows ACTFUNCT the first item of the main menu To make a setting under the menu item ACTFUNC press the MANUAL AUTOMATIC key briefly Then one of the sub menu items appears on the display The arrow keys are used to switch between these sub items enabling the desired settings to be made The desired setting is confirmed after selection by pressing the MANUAL AUTOMATIC key The arrow keys are also used to switch between the items of the main menu ACTFUNCT INPUT NOTE At the level of the sub menu items the selected function is shown by the three or four characte
19. Control Continuous i 37 Settings in the mMenu itemS 38 Entering the position setpoint in the AUTOMATIC mode t 38 Manual opening and closing of the valve actuator in the MANUAL mode s 39 Alternative chapters or functions depending on device configuration 8630 33 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 First Commssionng burkert NOTE This section enable you to put the TOP Control Continuous rapidly into operation for a functional check Supplementary functions unnecessary for this purpose are not dealt with here gt Fluidic installation gt Install the valve according to operating instructions Connect supply pressure to connection 1 3 bar instrument air free from oil water and dust Attach the exhaust line or silencer to connection 3 Remove the protective caps from the valve and and the TOP Control Continuous b NOTE 34 8630 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 burkert kHmsrCowwssionwe Electrical installation multipole connector gt Apply the setpoint signal to the circular connector M16 Configuration of the circular connector M 16 Pin Allocation External connection Signal level B A Setpoint 0 4 20 mA Be 0 4 20 mA or 0 5 10 V 5 10 V GND Setpoint GND
20. Inverse equipercentile characteristic 50 1 FREE gt 0 5 User defined characteristic freely programmable via fixed points AJM 10 15 66 100 XXX 66 85 XXX AJ The flow characteristic f s describes the flow through a valve expressed by the value as a function of the stroke s of the actuator spindle It is determined by the shape of the valve seat and the seat seal In general two types of flow characteristic are realized the linear and the equipercentile With linear characteristics equal changes in stroke ds are allocated to equal changes in k value dk dk n ds V li With an equipercentile characteristic a change in stroke ds corresponds to an equipercentile change in value dk k n ds gleichpr The operating characteristic Q f s represents the relationship between the volumetric flow passing through a valve installed in a system and the stroke s This characteristic contains the properties of the piping pumps and consumers It hence has a different shape from the flow characteristic 8630 63 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 OPERATION AND CONTROLLER FUNCTIONS b u rkert Normalized valve stroke 96 POS For positioning applications of control systems special requirements are usually made on the shape of the characteristic e g linearity For this reason it is sometimes necessary to correct
21. MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 System DESCRIPTION Binary outputs current limitation Binary input PNEUMATIC DATA Control medium Dust content Water content Oil content Temperature range of compressed air Pressure range Supply pressure variation Air flow capacity of control valve Intrinsic air consumption with zero control output Connections 32 8630 burkert electrically isolated 100 mA output is clocked electrically isolated 0 5 V log 0 10 30V log 1 inverted output reversed accordingly Qualitiy Classes to DIN ISO 8573 1 Class 5 max particle size 40 um max particle density 10 mg m Class 3 max pressure dew point 20 C or min 10 deg below the lowest operating temperature Class 5 max 25 mg m 10 50 C 3 bar max 10 during operation 1001 min STP for pressurizing and exhausting Q value acc to definition on pressure drop from 7 to 6 bar abs 0 0 l min STP G 1 4 internal thread G NPT RC MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 burkert w w PesrCowwssionwe FIRST COMMISSIONING Fluidic installation RR 34 Electrical installation multipole connector e 35 Electrical installation connection terminals for cable bushings 36 Basic settings of the TOP
22. Menu point does not appear with selection of actual value frequency Storage of the minimum input signal 0 mA 4 mA 0 V Apply the minimum value of the standard signal to the input and confirm ist by pressing the MANUAL AUTOMATIC key Storage of the maximum input signal 20 mA 5 V 10 V Apply the maximum value of the standard signal to the input and confirm it by pressing the MANUAL AUTOMATIC key CAL PV Calibration of the process setpoint 4 20 mA Pt 100 This menu item does not appear on selection of frequency setpoint Select 4 20 mA Apply the minimum value of the process setpoint signal to the input and confirm the value by pressing the MANUAL AUTOMATIC key Apply the maximum value of the process setpoint signal to the input and confirm the value by pressing the MANUAL AUTOMATIC key Select Pt 100 Alter the value displayed using the arrow keys until thedisplay on the SIDE Control S HART agrees with that on the reference measuring instrument Then confirm the value by pressing the MANUAL AUTOMATIC key 8630 83 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 OPERATION AND CONTROLLER FUNCTIONS burkert CAL P1 CAL P2 CAL TEMP Calibrating the transmitter inputs at the flow rate controller 4 20 mA Apply 4 mA to the input to be calibrated p1 p2 temperature and confirm the value by pressing the MANU AL AUTOMATIC key Apply 20 mA to the input
23. 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 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 burkert gGSverewDescnrron 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 val
24. RL released freigegeben printed 20 01 2015 burkert CONTENTS Inductive proximity switches circular socket MB tabs 121 Process value irc lar plug ee nee 121 Termination connection for PROFIBUS systems 122 Settings on the TOP Control Continuous ii 123 Explanation of the menu items 124 Functional deviations from the standard version i 124 Configuration in the Profibus DP master tnt 125 Configuration of the process 125 Bus status display 127 Example 1 with COM Profibus V3 3 i 128 Example for a positioner 128 Example 2 with COM Profibus V3 8 131 Example for a process COM idet 131 DEVICE NET General notes i 134 Explanation of terms iii 134 Biz 135 Safety settings on bus failure 135 136 Electrical connection 136 Operating voltage 4 pole M12 circular plug 137 Bus CONNECTION 4 pole M12 137 Inductive proximity switches 4 pole M8 circular socket tts 137 Process value circular plug 8 137 Termination connection Tor DeviceNet systems ht rnnt ee 138 Net topology ora MM Mi I 138 Settings on the TOP Control Continuous ii 139 Explanation of t
25. and the valve opened or closed by hand MANUAL mode Changeover between operating modes Operate the MANUAL AUTOMATIC key to switch between the MANUAL and AUTOMATIC YO modes E Both in the MANUAL and the AUTOMATIC modes you can change to the configuration Q level by pressing the MANUAL AUTOMATIC key for longer than 5 seconds On switching back to the process operating level the operating mode is resumed that was set before switching over Operating mode yellow LED in the Display MANUAL AUTOMATIC key AUTOMATIC flashes zu jc An apostrophe runs continuously from left to right MANUAL 86 8630 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 b ur kert OPERATION AND CONTROLLER FUNCTIONS Operating mode AUTOMATIC yellow LED flashes In the AUTOMATIC mode normal controlled operation is executed and monitored Meaning of the keys in the AUTOMATIC mode or Switch over the display V Change the process setpoint i with configured supplementary functions PCONTRL PCO SETP SETP INT gt 35 and display to SP Display of the AUTOMATIC mode With regard to the positioner the following parameters can be displayed Actual position of valve actuator POS 0 100 96 Setpoint position of valve actuator after rescaling through optionally activated split range function or correction characteristic 0 100 Input signal for set
26. certain basic Configuration functions and configure supplementary functions as needed 8630 21 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 SvsrewDescmemw burkert 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 CMD 0 Positioner Positioning Continuous opening system Soleno Valve id valves Position sensor Position contro
27. continues with the setting of the positioning system and optimization of the positioner gt NOTE If manual presetting of the end positions by means of TUNE POS is necessary it must be done before execution of AUTOTUNE 8630 57 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 OPERATION AND CONTROLLER FUNCTIONS b u rkert 3 TUNE PWM Readjust minimum PWM pulse duty factor for driving the solenoid integrated in the TOP Control Continuous The AUTOTUNE function determines automatically the minimum PWM pulse duty factor necessary for driving the solenoid integrated in the TOP Control Continuous If the frictional characteristics of the positioning mechanism are unfavourable these values may deviate from the optimum By using TUNE PWM however they can be readjusted to obtain the lowest possible speed in both directions NOTE The function TUNE PWM must be executed after AUTOTUNE TUNE AIR Adapt the opening to the closing time of the process valve With spring closing process valves the opening speed may be varied within certain limits by changing the supply pressure The closing speed however is independent of the supply pressure and given by the spring force and the nominal diameter of the venting valve By using TUNE AIH the opening time may be adapted to the closing time This results in symmetrical motion which has a favourable effect on the process control NOTE T
28. determined using a pressure Identifiers HEX 41 40 08 transmitter Value range 1013 16000 PDI MTMP Medium temperature GSD file PDI MTMP Temperature of the medium in C The value will be predefined from the menu the bus or using a temperature transmitter Identifiers HEX 41 40 09 Value range 20 150 gt NOTE PDI PV and PDI SP only be selected if the process controller has been activated PDI P1 P2 MTMP can only be selected if the fluid flow controller option is active Finally the process data output from the controller to the TOP Control Continuous is entered gt NOTE In the same order as in the selection in the TOP Control Continuous and only process data PDI activated in the configuration menu may be entered The updating of the process data output only takes place in the MANUAL and AUTOMATIC modes 126 8630 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 burkert PnoriBus DP PDO Process Data Output from the control to TOP Control Continuous Name Description Identifiers PDO INP Set position Input GSD file PDO INP Set value positioner in o value range O 1000 In the pure positioner operation inanctive Identifiers HEX 81 40 14 the transmission of the set position NP is required as process controller PCONTRL active the transmission of INP is not possible If the value is too small or too large th
29. gt fa j IT Vi X CONTRL Parametrization of the PID controller CODE SA CE or ic L J A i J SIG ERR BIN IN OUTPUT CAL USER SE PL I ENDFUNCT 8630 91 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 OPERATING THE PROCESS CONTROLLER burkert Basic settings of the function PCONTRL 9 Parametrization of the process controller 92 8630 PCO INP SCAL PCO KV PCO END FILT PCO SCAL PCO TUNE PCO KV PCO LEAK PCO END Insensitivity range dead band of the PID process controller Parameters of the PID process controller Type of setpoint setting Specification of the signal type for process actual value Filtering of the process actual value input Scaling of the process controller Self optimization of the process controller process tune kv characteristic curve of process valve Leakage characteristic for flow rate control Storage of the new parameters End of the parametrization MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 burkert OPERATING THE PROCESS CONTROLLER P CO DBND Insensitivity range dead band of the process controller Factory setting 196 refers to the span of the process actual value scaled by means of SCAL PV and PV This function assures t
30. in the Established state I O data exchange An I O connection is in the TIME OUT state new establishmend of connection by Master ensure the I O data are transferred cyclically or with confirmed COS the corresponding Acknowledge Messages are sent by the Master Different device with same address in the network or BUS OFF due to communication problems change address of device and restart device error analysis in network with a bus monitor MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 burkert DeviceNet Configuration example 1 The example describes the basic procedure on configuring the device when using the software RSNetworx for DeviceNet Rev 2 11 51 0 Installation of the EDS file The installation of the EDS file on the supplied floppy takes place with the aid of the tool EDS nstallati on Wizard belonging to RSNetworx The Icon also supplied on floppy can also be assigned in the course of the installation procedure where this does not take place automatically Address allocation There are two possibilities for the assignment of addresses to the devices Firstly an address can be set to the desired value over the range O 63 via the keys at the device see chapter Settings at TOP Control Continuous secondly a change of address of connected devices can be carried out via the bus with the aid of the tool Node Commissioning belonging to RSNetworx Therefore th
31. its shape in a suitable manner For this purpose a transfer member is provided in the TOP Control Continuous which realizes different characteristics These are used to correct the operation characteristic The equipercentile characteristics 1 25 1 33 25 1 33 1 and 50 1 and a linear characteristic may be set Furthermore it is possible to freely program a 100 Normalized position eevee m m setpoint characteristic via fixed points or have it calibrated CMD automatically Entering the freely programmable characteristic The characteristic is defined via 21 fixed points distributed evenly over the 0 100 range of the position setpoint They are separated by 5 96 Each fixed point may be allocated to a freely selectable stroke setting range 0 100 The difference between two adjacent values of stroke may not exceed 20 To enter the point on the characteristic values of the function first select the menu item CHR FREE After pressing the MANUAL AUTOMATIC key the first fixed point is displayed 0 96 Next to it is the value of the function initially O 96 With the arrow keys set a value of the function between 0 and 100 96 After pressing the MANUAL AUTOMATIC key the next fixed point is displayed etc Finally press the MANUAL AUTOMATIC key to confirm the value of the function belonging to the last fixed point 100 96 The display returns to the menu item CHARACT 64 8630 OPERATION AND CONTROL
32. menu which can then be specified Addition of supplementary functions to the main menu gt Select in the main menu the item ADDFUNCT gt By pressing the MANUAL AUTOMATIC key enter the supplementary menu gt With the arrow keys select the desired supplementary function gt By pressing the MANUAL AUTOMATIC key confirm addition of the supplementary function to the main menu The function is automatically marked with an asterisk All marked functions are added to the main menu after confirmation of ENDFUNCT n the main menu enter the parameters for the supplementary functions Deletion of supplementary functions from the main menu NOTE By removing a function from the main menu the settings previously made under this function are again invalidated Select in the main menu the item ADDFUNCT gt By pressing the MANUAL AUTOMATIC key enter the supplementary menu gt With the arrow keys select a supplementary function marked with gt By pressing the MANUAL AUTOMATIC key confirm deletion of the supplementary function the asterisk marking is deleted After confirmation of ENDFUNCT the supplementary function is deactivated and deleted from the main menu Setting of numeric values Numeric values are set in the menu items provided by pressing the keys arrow up increment value arrow down decrement value one or more times In the case of 4 digit numbers only the flashing digit c
33. of the volume measured setting range O 3 VOL XXX Enter the volume measured setting range 0 9999 Unit as selected before under UNITXXXX XX XX Display of the calculated K factor 100 8630 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 b ur rkert OPERATING THE PROCESS CONTROLLER P CO SCAL Scaling the process controller on selection of Pt 100 input P CO INP PT100 Position of the decimal point PLU PED SEAL 26 E 96 Setting range 0 3 Lower scaling value for process actual value D the value is entered in the unit that is subeequently selected for the flow rate Upper scaling value for process actual value the value is entered in the unit that is subsequently selected for the flow rate AJ v Lower scaling value for external process setpoint the value is assigned to the minimum current or voltage value of the standard signal AJM Upper scaling value for process setpoint the value is assigned to the maximum current or voltage value of the standard signal AM Setting the desired unit of temperature UNIT C 9 Unit C 7 uw FEK Unit F This setting determines the reference span for the dead band of the process controller and the analog feedback of the process actual value option This setting is only active when PCO SETP SETP EXT is selecte
34. optimization of the PID parameters a setpoint modulator filter is calculated for the reduction of unwanted non linear effects Such effects may arise because of physical limitation of the correcting variables and the floating time of the control valve The setpoint modulator further improves the control behaviour It is activated as long as the PTUNE function is activated in the operating menu of the TOPControl Continuous P TUN ACT When the function P TUNE is deactivated in the operating menu P TUN D ACT after completion of self optimization the process is controlled with the optimized PID parameters and the setpoint modulator is deactivated Be sure to comply with the sequence on setting up the process control system 106 8630 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 b u r ke rt OPERATING THE PROCESS CONTROLLER Operation To carry out self optimization process tune on the process controller proceed as follows with the steps D described All operating steps for the execution of process tune are performed on the spot using the NOTE operating elements keypad and display of the TOP Control Continuous Step D Activate process tune You are in the menu item PCONTROL in the configuration level of the TOP Control Continuous Activate process tune on the process controller P TUN ACT and select the process type corresponding to your cont
35. printed 20 01 2015 DEvicENET burkert Process value circular plug M8 continuation nosttype PmJassionmen 1 1 24 V supply sensor clock input not assigned clock input GND Clock GND Frequency M internally supplied 0 Clock not assigned clock input not assigned Clock GND clock input Frequency o Clock externally supplied not assigned Pt 100 see process actual 1 current supply Note process actual 2 GND process actual 3 compensation adjustable via software NOTE For line compensation reasons connect sensor Pt 100 via three conductors PIN3 and 4 must be bridged at the sensor Actual process value for the fluid flow controller option 2 M8 round plugs or optionally with temperature sensor input 3 M8 round plugs internally 1 1 24 V transmitter supply p1 supplied 2 4 20 mA transmitter output p1 transmitter 3 4 not assigned 2 1 24 V transmitter supply p2 2 4 20 transmitter output p2 3 4 not assigned option 3 1 24 V transmitter supply temperature 3 4 20 mA output 3 10 ar transmitter transmitter temperature xm 2 4 not assigned With external supply of the sensors the mass of the standard signal must be connected with the mass of supply voltage Termination connection for DeviceNet systems On installing a DeviceNet system it is important to have the cor
36. printed 20 01 2015 burkerl MAINTENANCE AND ERROR CORRECTION ON THE PROCESS CONTROLLER Error messages on execution of the function P Q LIN Q ERH 1 No compressed air connected No change in process value Connect compressed air Check process switch on pump or open shut off valve if necessary Check pressure supply e execute AUTOTUNE Q ERR 2 Current fixed point of the valve stroke was not reached because Pressure supply failre during PQ LIN AUTOTUNE was executed Error message on execution of the function LEAK MEAS L ERH 1 No admission pressure at the controller unit gt 50 mbar Switch on compressor before start of leakage measurement 2 Control does not fully close Execute AUTOTUNE No leakage detectable the difference between admission pressure and conveying pressure is SO low even at slight valve opening that no air leak can be measured Whilst the valve is open the delivery pressure is not increased which means that no restart points for the characteristic can be recorded The leakage characteristic must be deactivated since the precision of air flow control cannot be raised Make sure that the conveying pipe is closed and the blocking air is open 8630 155 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 MAINTENANCE AND ERROR CORRECTION ON THE PROCESS CONTROLLER burkert Other malfunctions POS with gt 0
37. rt OPERATING THE PROCESS CONTROLLER P CO INP Specification of the signal type for process actual value Frequency signal flow rate O 1000 Hz Connection with Pt100 temperature 20 220 C Configuration for flow rate controller option standard signal current 4 20 mA flow rate pressure level P CO FILT Filtering of the process actual value input Factory setting O Valid for all types of process actual value Filter has low pass behavior PT1 Range 0 9 FILT XX Setting in 10 steps O 9 Setting in 10 steps Corresponds to limiting 2 10 minimum minimum filtering 4 EEE 8 82 _ _ 6 04 3 8 Q5 9 00 mama tering __ 8630 95 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 OPERATING THE PROCESS CONTROLLER P CO SCAL burkert Scaling the process controller on selection of analog input 4 20 mA P CO INP 4 20 A P scat 26 AD OE Ga 59 AWM 7 Position of the decimal point for process actual value and setpoint Setting range 0 3 Lower scaling value for process actual value process value the value is assigned to 4 mA Upper scaling value for process actual value process value the value is assigned to 20 mA Lower scaling value for process setpoint the value is assigned to the smalles
38. 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 p2 8630 Flow rate controller e g valve type 2712 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 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 secti
39. the inductive proximity switches gt The inductive proximity switches are positioned vertically with one adjusting screw each Turning clockwise causes upward adjustment Turning anticlockwise causes downward adjustment ATTENTION T mm On adjusting the height of the inductive proximity switches make sure that adjacent flexes are not pulled e g by getting hooked in the proximity switches If this is not adhered to plugged connections may be damaged or loosened Screw to adjust the lower proximity switch Screw to adjust the upper proximity switch bd 50 8630 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 b ur kert OPERATION AND CONTROLLER FUNCTIONS OPERATION AND CONTROLLER FUNCTION Operating and display elements 52 Operating levels 52 Commissioning and set up as a positioner iii 53 Procedure for specifying the basic settings ttt 53 Main menu Tor the SSI ON Ol nee 54 Description of the procedure 55 Configuring the supplementary functions 59 By SMM TOMI TONY OVS ee 59 Configuration menu ttis 59 S pplementary mre HOS 62 Operating the process 86 Changeover between operating modes ttti 86 Operating mode AU OMATIC 87 Meaning of the keys AUTOMATIC mode 87 Display of the A
40. the process operating level either with the keypad on the TOP Control Continuous or over the bus MANUAL AUTOMATIC switchover on the keypad is no longer possible when an operating mode under PDO MODE is transmitted to the TOP Control Continuous over the bus 124 8630 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 burkert PnoriBus DP Configuration in the PROFIBUS DP master User parameters hex paramaters are not required Configuration of the process values First the process data input are entered from the TOP Control Continuous to the control PDI Process Data Input In the same order as in the selection in the TOP Control Continuous and only process data PDI activated in the configuration menu may be entered from the TOP Control Continuous to the control PDI POS Actual position Position GSD file PDI POS Actual value of positioner in o Range of values 0 1000 Values 0 or 1000 are possible when e g Identifiers HEX 41 40 00 AUTOTUNE was not run throug properly PDI CMD Setpoint position Command GSD file PDI CMD Positioner setpoint in o Range of values O 1000 Identifiers HEX 41 40 01 Process actual value Process Value GSD file PDI PV Actual value of process controller in physical units as set in menu PCO INP or RCO SCAL max range of values 999 9999 depending on internal Identifiers HEX 41
41. values can be entered for T OPN and T CLS that lie between the minimum values determined by X TUNE and 60 s Opening time for full stroke in seconds A v Closing time for full stroke in seconds AJ v Effect of limitation of the opening speed after a step in the setpoint Valve stroke 96 POS CMD 100 If positioning times lt 1 s are determined from the AUTOTUNE X is automatically copied to the main menu and the relevant value is set to 1 s gt NOTE 8630 71 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 OPERATION AND CONTROLLER FUNCTIONS b u rkert X CONTRL Parametrization of the positioner AM S para Ed aw qp Insensitivity range dead band of the positioner Entry of the dead band in 96 referred to the scaled stroke range i e minus LIM see function X LIMIT This function assures that the positioner cuts in only above a certain control difference The function reduces wear on the solenoid valves in the TOP Control Continuous and the pneumatic actuator gt NOTE lf during execution of X TUNE AUTOTUNE of the positioner the supplementary function X CONTRL is in the main menu the dead band X CO DBND is automatically determined in dependence on the frictional behaviour of the positioning mechanism The value resulting is a guide value It can be readjusted manually Positi
42. variant 14 27 Interfaces of the TOP Control Continuous in the variants with cable bushings 28 Technical tits 29 Safety settings on failure of auxiliary electrical or pneumatic energy 29 Factory settings on the TOP Control COntiNuUoUS cece nee emerit 30 Data of the TOP Control Continuous ken 31 Alternative chapters or functions depending on device configuration 8630 13 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 SvsrewDescmemw By the combination of the TOP Control with pneumatically actuated process valves the functionality of the B rkert 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 m 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 T
43. 00010084 EN Version K Status RL released freigegeben printed 20 01 2015 GENERAL RULES APPENDIX burkert Selection criteria for continuous valves The following criteria are of decisive importance for optimal control behaviour and attainment of the maximum flow rate through the valve Correct choice of flow coefficient which is defined essential by the size of the valve Good matching of the valve size to the pressure conditions taking into consideration the other flow resistances in the system Dimensioning guidelines can be given on the basis of the flow coefficient The value refers to the standardized conditions with respect to pressure temperature and media properties The value is defined as the flow rate in m h of wasser through a component at a pressure difference Dp of 1 bar and a temperature of 20 C With continuous valves the value is additionally used This specifies the value when the continuous valve is fully open Depending on the specified data the following cases must be distinguished on selection of a valve a The pressures before and after the valve p and p are known at which the desired maximum flow rate is to be attained ma The required k value is obtained from Q max gt 1 0 where ae is the flow coefficient of the continuous valve when fully open m h nax is the maximum volumetric flow rate m3 h Ap 1 bar the pressur
44. 015 DP burkert Termination connection for PROFIBUS systems On installation of a PROFIBUS system care must be taken to terminate the data lines correctly The termination generates a well defined potential state and avoids the occurrence of disturbances by signal reflections on the data lines For this purpose the data lines must be terminated at both ends by resistors as shown RxD TxD P Drop lines to the end devices 2 through n 1 122 8630 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 burkert DP Settings on the TOP Control Continuous In deviation from the details in the enclosed operating instructions the following settings must be made in the main menu of the device Operating mode AUTOMATIC 2 MANUAL M A MA MA 2 i BUS PDI POI POS POI PDI TEMP V A PDI MODE V 1 PDIP1 PDI P2 POL JE E 5 BUS POO INP _ IA PDO END on activation moves fo safety position SPOSON PEH SPOS OFF amp BUS FAIL z MIK BUS END Sue A EEPROM eH END 8630 123 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 DP burkert Explanation of the menu items
45. 015 burkert OPERATION AND CONTROLLER FUNCTIONS Commissioning and set up as a positioner Before commissioning execute the fluidic and electrical installations Procedure for specifying the basic settings On first commissioning of the TOP Control Continuous carry out the following basic settings e Specify the function of the pneumatic actuator used e Specify the standard signal input for setpoint setting 4 20 mA 0 20 mA 0 10 V or 0 5 V e Start the automatic adaptation of the positioner to the current operating conditions AUTOTUNE Configuration of the keys MANUAL AUTOMATIC key A Arrow keys Switch between main and sub menu items e g ACT FUNC FUNCSNGL Switch between eual ranking menu items e g ACTFUNC INPUT Factory setting of the positioner Function Factory setting ACTFUNC FUNCSNGL INPUT INP 420A CHARACT CHA LIN DIR CMD DIR CRISE CUTOFF CUT 0 CUTY 10096 DIR ACT DIR ARISE SPLTRNG SR 0 96 SRT 100 Function Factory setting OUTPUT OUT ANL OUT POS OUT BIN OUT DEV BIN IN B IN SPOS X CONTROL X CO DBND X LIMIT LIM 0 100 X CO PARA X T OPN Values determined by AUTOTUNE T CLS Values determined by AUTOTUNE After execution of SETFACT 1 s KX KX 1 CODE OUT 420A DEV 5 0 NO SPOS 000 NO 1 Values determined by AUTOTUNE Values determined by AUTOTUNE After execution of SETFACT 1 CODE 0000
46. 100 and the initiators cannot be used with this option gt 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 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 System DESCRIPTION burkert Interface of the TOP Control Continuous in the variants with cable bushings setpoint 4 20 mA 0 20 mA 0 10 V 0 5 V 4 20 mA Frequency Pt 100 puts 24 V DC gt NOTE 28 8630 Inputs for position or process Input for process setpoint alternative to binary out TOP Control Continuous PG variant 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 TOP Control Continuous Type 8630 is a 3 conductor device i e the voltage supply 24 V DC is separate from the setpoint signal MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 burkert Technical data System DESCRIPTION Safety settings on failure of auxiliary electrical or pneumatic energy Actuator type Designation Single acting SFA up down Single acting SFB up down Double acting SFI up down Safety position after failure of auxiliary energy Electrical Pneumatic do
47. 15 b ur kert OPERATION AND CONTROLLER FUNCTIONS During execution of the AUTOTUNE function the valve moves its own away from its current position For this reason never execute AUTOTUNE while the process is running MANUAL TUNE FUNCTIONS Access to the manual TUNE functions is obtained by selection X TUNE in the main menu and briefly pressing the MANUAL AUTOMATIC key or on abortion of countdown by releasing the MANUAL AUTOMATIC key AUTOTUNE MANUAL TUNE release X TUNE TUNE END D EN 5S gt TUNE 4 ty 3 A LIM YES EN aes TUNE POS A LIM NO POS MAX POS MIN move to max move to min TUNE 2 position position A TUNE 1 E TUNE PWM YE TUNE 0 9 change min PWM T V change min PWM T V for for pressurizing valve venting valve display of opening time s X T XXX TUNE AIR T OPN XX 4 LCLS XX display of closing time s The following parameters which are automatically determined during X TUNE may be manually present or adjusted afterwards D TUNE END Return to main menu 2 TUNE POS Present end position The AUTOTUNE function determines the end positions of the control armature from the physically stops Certain armatures e g rotating vanes have no physically stops so that the end positions must be manually present using TUNE POS When executed immediately afterwards AUTOTUNE assumes the manual end settings and
48. 2 T kys is the pressure drop over the fully opened valve and Ap is the pressure drop over the entire system gt NOTE With a valve authority Y lt 0 3 the continuous valve is overdimensioned With the valve fully open in this case the flow resistance is significantly smaller than that of the other fluidic components in the system This means that only in the lower opening range is the valve position dominant in the operating characteristic For this reason the operating characteristic is strongly deformed By selection of a progressive equiprocentile characteristic between position setpoint and valve stroke this can be partially compensated and the operating characteristic linearized within certain limits However the valve authority Y should be gt 0 1 even when using a corrected characteristic The control behaviour control performance settling time when using a corrected characteristic is strongly dependent on the operating point 8630 159 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 GENERAL RULES APPENDIX burkert Characteristics of PID controllers A PID controller has a proportional an integral and a differential component P and D components P component Function Y 2 Kp Xd Where Kp is the proportional action factor amplification factor It is given by the ratio of the correcting range AY to the proportional range AXd Characteristic
49. 40 02 scaling Process setpoint Setpoint GSD file PDI SP Setpoint of value of process controller in physical units as set in menu PCO INP or PCO SCAL max range of values 999 9999 depending on internal scaling PDI TEMP Device temperature Temperature GSD file PDI TEMP Temperature in 0 1 C is measured on the CPU board with a sensor range of values 550 55 C 1250 125 C Identifiers HEX 41 40 04 Identifiers HEX 41 40 03 PDI MODE Operation mode Operation Mode GSD file PDI Mode Operation mode AUTO 10 PTUNE HAND 123 BUSSAFEPOS XTUNE Identifiers HEX 41 00 05 MENUE PQLIN PDI ERR Error Error GSD file PDI ERR States the number of the process value output that was not written The value is retained until deleted with PD O ERR HEX Identifiers HEX 41 00 06 14 PD O CMD 15 PD O SP 16 PD O MODE 8630 125 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 DP burkert Process Data Input continued from the TOP Control Continuous to the controller Forward pressure p1 GSD file PDI P1 Pressure in mbar rel that is present in front of the process valve The value will be determined using a pressure Identifiers HEX 41 40 07 transmitter Value range 1013 16000 Back pressure p2 GSD file PDI P2 Pressure in mbar rel that is present behind the process valve The value will be
50. C Normally Closed output in switched state low V a NO Normally Open output in switched state high 24 V 8 8630 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 b ur rkert OPERATION AND CONTROLLER FUNCTIONS D BIN1 DEV X Selection alarm output for too great an actuation signal from the positioner The permissible actuating signal DEV X XXX shall not be smaller than dead band BIN1 LIM X Selection binary position output LIM X XXX limit position OUT BIN1 NORM OPN NORM CLS BIN1 SPOS Selection actuator in safety position O BIN1 SIG Selection error message setpoint signal amp BIN1 SIG P Selection error message process value signal BIN1 RMOT Selection operating mode AUTOMATIC and EXTERNAL Setpoint activated OUT BIN1 NORM OPN NORM CLS Operating mode 24 Aue 3 AUTO 4 External set value Operating mode MANUAL or 999 internal set value 8630 79 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 OPERATION AND CONTROLLER FUNCTIONS b u rkert e OUT BIN2 Configuring binary output 2 Permissible actuating signal D Limit position Q NORM CLS Eg 4 5 6 d NOTE NORM CLS NC Normally Closed output in switched state low 0 V NO Normally Open output in switched state high 24 V 80 8630 MAN 1000010084 EN
51. Characteristics and step response of the D component of a PID controller Step response Rise response Characteristic A controller with a D component reacts to changes in the controlled variable and can thus reduce more quidckly any control differences that occur 162 8630 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 burkert GENERAL RULES APPENDIX Superimposing the P and D components Function Y Kp Xd J Xd dt d Xd dt Substituting Kp Ti Tn and Kd Kp Tv we obtain for the function on the PID controller Y Kp Xd J Xd dt dXd dt Kp isthe proportional action factor amplification factor Tn is the reset time the time required to obtain the same change in correcting variable as was caused by the P component and Tv is the rate time the time by which a certain change in correcting variable is obtained earlier with the D component than t would have been with a pure P controller Step response and rise response of the PID controller Xd bes D Component KpeXd c M M E ee ey gt Reset time Tn Step response of the PID controller I Component P Component t I Component D Component P Component t i AE Derivative action time Tv Rise response of the PID controller 8630 163 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 GENERAL
52. D DBND xx x Y X CO END X CONTRL 8630 171 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 structure PCONTRL P CO DBND DBND xx x P CO PARA xxx o Lr a PCOS SEIP NT SETP EXT PGO IMP SP only with external setpoint selected via PCO SETP SETPEXT wE with PCO INP 420A BENS xoa DIAM can be entered only if VELO has been selected 172 8630 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 burkert ENSE BIN IN B IN SPOS then SPOS 000 PCOTUNE Fr Lm LKVUSER 9 DPKVX PCO LEAK P CODEKEY Kl OPERATING STRUCTURE APPENDIX ey ut PTYPPRES l CODEMENU CODE GLOB ERAP INP PINP OFF ON INP OFF LEAK MEAS LEAK CHAR CODE xxxx TUNES SPOSXXX If SAFEPOS is deactivated then SPOS 000 SPOS OFF _ E SPOS OFF SPOS ON If SAFEPOS is deactivated 8630 173 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 OPERATING STRUCTURE APPENDIX 174 8630 OUTPUT
53. EOS TETTE cnm LR t 1 nauns s E ee X TEED ET ra m E 1 zl Seance ana rmm m emm DP 8630 131 burkert DP 132 8630 102 10 02 paud 1H snielS uOISJIOA 7800100001 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 burkerl DEVICE NET General dudum E 134 Explanation of terms __ 6_6 6_ __ _ 6 134 Technical data 135 Safety settings on bus failure i 135 Ine 136 Electrical connection 136 Operating voltage 4 pole M12 circular plug tt 137 Bus connection 4 pole 12 circular plug nee 137 Inductive proximity switches 4 pole M8 circular socket 137 Process value circular plug 8 11siri 137 Termination connection for DeviceNet systems ttt 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 2 2 2 11 1 139 Setting in the 140 Configuring the process data omnia 141 Static input assemblies ttt 141 Static output assemblies ttc 143 BUS Salis CIS DIG V ee 144 Configuration
54. LER FUNCTIONS burkert Example of a programmed characteristic Valve stroke 96 POS T 855 o lt nal o E lt o um l n Ngee eee es ee ree i a i ee ee ee gt Sy es pee ae 5 al a FF SER EN FEDER FAT ee ee EM a ee a et ee a I iis 1 1 1 en ei iem N jos c paa 777777575505 A c a o 2 ios l i 2222222 9 9 1 2 LLL MM ee i E N i RN i MEL ecc i i l D l ra L Ms ae nn gt ga l tee 1 12 1 4 1 q Po plo 5 odd 22 7 Y XY a ee ee se ee eo 3 8 SE g part 1 N i NOLL L UO LO on 5 ____ oat d i TLL e gt V S i 1 Fog gt O 2 lt MEM 1 PS 1 1 i 11
55. MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 Operating Instructions Bedienungsanleitung Instructions de Service Type 8630 TOP Control Continuous burkert MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 We reserve the right to make technical changes without notice Technische Anderungen vorbehalten Sous res rve de modification techniques 2001 Burkert Werke GmbH amp Co KG Operating Instructions 0507 11 EU EN 00804575 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 burkert CONTENTS Overall Operating Instructions TOP Control Continuous 8630 GENERAL NOTES e eM 10 Intended use iii 10 10 Protection from damage by electrostatic charging s 11 Scope of delivery 11 Warranty Conditions mm 11 12 ransport StOrage T 12 Disposal 12 SYSTEM DESCRIPTION Valve types 14 Characteristics of the valve types 15 Construction of TOP Control Continuous 16 cover removed RR e 16 ERR ee 17 Functional diagram as a positioner with single acting actuator ette 18 Operation as a positioner 19 Schematic representation of positioning cont
56. N Version K Status RL released freigegeben printed 20 01 2015 DEvicENET burkert The adresses given in the table Static Input Assemblies can be used as path statement for the attribute Produced Connection Path of I O connection whereby the attributes described in more detail in the following table can be transferred as Input Process Data via this I O connection Independently from thsi however it is also possible to acyclically access the attributes combined in the Assemblies via Explicit Messages Description of the Data Attributes Attribute address Class Instance Attribute data type length POS Actual Position Actual Position 111 1 59 Actual value of position controller in o Value range O 1000 However values lt 0 respectively 21000 are also possible if INT 2 Byte e g AUTOTUNE has not run correctly CMD Position Setpoint Position Setpoint 111 1 58 Setpoint value of position controller in o Value range O 1000 UINT 2 Byte Media temperature value range 20 150 120 1 9 Temperature of the medium in C The value will be predefined from the menu the bus or using a temperature INT 2 Byte transmitter Back pressure P2 120 1 8 Pressure in mbar rel that is present behind the process valve The value will be determined using a pressure transmitter INT 2 Byte Value range 1013 16000 Forward pressure P1 120 1 7 Pressure in mbar rel that is present in front of the proc
57. Output signals for SPS circular plug 16 45 Operating voltage circular plug M 12 45 Inductive proximity switches circular socket M 8 45 Process value circular plug 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 with cable bushing i 47 Connection PCB of the TOP Control Continuous with screw terminals and jumpers 47 Terminal configuration with cable bushings ee een 47 Choice of binary outputs or process value input 48 Setting the inductive proximity switches option 50 Opening the housing of the TOP Control opm oS 50 Positioning the inductive proximity switches 50 Alternative chapters or functions depending on device configuration 8630 41 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 smuaw gt NOTE See data sheet for dimensions of TOP Control and the variants of the complete device consisting of TOP Control Continuous pneumatic actuator and valve Installation of the valve The actuator must not connected For dimensions and threads see data sheet for the process valve Turning the TOP Control Continuous If after installation of the continuous valve the display of the TOP Control Continuous is poorly visible or it is difficult t
58. UTOMATIC Mode ttti 87 Operating mode MANUAL 88 Meaning of the keys in the MANUAL mode ttes 88 Display of the MANUAL ttis 88 8630 51 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 OPERATION AND CONTROLLER FUNCTIONS b u rkert Operating and display elements The TOP Control Continuous is equipped with a 3 key operating and display element with LC display The functions of the keys are described in the following sections Br Tta MANUAL AUTOMATIC KEY LED yellow in the MANUAL AUTOMATIC key see chapter Operating the process controller Arrow key up Arrow key down Operating levels Operation of the TOP Control Continuous is done via two operating levels Process operating level After the device is switched on the process operating level is active In this level you can switch between the operating modes AUTOMATIC and MANUAL In the AUTOMATIC mode position or process control only for the process controller option runs In the MANUAL mode the valve can be manually opened and closed Configuration level In the configuration level you can specify on first commissioning the basic functions and configure supplementary functions if needed Process operating level i i p g 5 sec Configuration level MANUAL AUTO Supplemen MATIC tary End functions o2 8630 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2
59. V 8630 97 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 OPERATING THE PROCESS CONTROLLER burkert P CO SCAL Scaling the process controller on selection of the frequency input P CO INP FREQ On entry into this menu the valve is closed in order to have a well defined starting conditions for execution of the teach in function gt Je UNIT LAS Unit I s UNIT LAF Unit l min NIT S T Unit m3 min UNIT Unit m3 h UNIT Ub S Unit gal US s NIT nit gal US min 5 AD AJ v 5P 000 AM C UNIT UG H Sr T KX XX Unit gal US h UNIT 16 5 Unit gal Imperial s NIT Ib TI nit gal Imperial min UNIT Unit gal Imperial h ec A y 5 ma OR 98 8630 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 bu rkert ex unis meno A OPERATING THE PROCESS CONTROLLER Position of the decimal point for process actual value and setpoint Setting range O 3 Lower scaling value for process actual value the value is entered in the unit that subsequently selected for the flow rate This setting determines the reference span for the dead band of the process controller and the analog feedback of the process actual valu
60. Version K Status RL released freigegeben printed 20 01 2015 b ur rkert OPERATION AND CONTROLLER FUNCTIONS D BIN2 DEV X Selection alarm output for too great an actuation signal from the positioner he permissible actuating signal DEV X XXX shall not be smaller than dead band BIN2 LIM X Selection binary position output LIM X XXX limit position OUT BIN2 NORM OPN NORM CLS BIN2 SPOS Selection actuator in safety position BIN2 SIG Selection error message setpoint signal 6 BIN2 SIG P Selection error message process value signal BIN2 RMOT Selection operating mode AUTOMATIC and EXTERNAL Setpoint activated OUT BIN2 NORM OPN NORM CLS Operating mode 0 24 3 AUTO 4 external set value Operating mode MANUAL or T mo internal set value 8630 81 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 OPERATION AND CONTROLLER FUNCTIONS b u rkert CAL USER Calibration of the actual value display the inputs for position setpoint process setpoint process actual value and of the K factor for the valve EJ Eros d E 5 T uw __ gt E3 1 20 ape JEJ 2 w Eg 2 zoma E3 Xxx ea Pax FO u car TEMP JEA reve TEMP 20 mo AKO Excr
61. Version K Status RL released freigegeben printed 20 01 2015 e Actual position of valve actuator e Setpoint position of valve actuator Input signal for setpoint position here identical to setpoint position e Temperature inside TOP Control Continuous housing 38 8630 POS 0 100 CMD__XXX 0 100 0 5 10 V or 0 4 20 mA TEMP XX X C MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 burkert Manual opening and closing of the valve actuator in the MANUAL mode Open valve actuator Close valve actuator Display the display set in the AUTOMATIK mode is retained gt NOTE Select the display POS XXX in this case the actual position of the valve actuator can 8630 39 burkert FIRST COMMISSIONING SLOZ LO Oz peiuud 1H Snielg Y uols eA 780010000 NYIN 40 8630 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 burkerE INSTALLATION Installation of the valve ii 42 Turning the TOP Control Continuous 42 en ee ee TE ne nee ee nenne 42 Fluidic connection of the TOP Control Continuous i 43 Electrical connection multipole connectors i 44 Marking of the multipole plugs or sockets and the contacts sel 44
62. 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 Neutral gases and liquids contaminated ab rasive and aggressive media high purity or sterile media high viscosity media Ball valves 2652 2 part VA 2655 3 part VA 2658 plastic Piggable Low and dead space e 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 Neutral gases and liquids pure water slightly aggressive media Flap valves 2672 metal 2675 plastic insusceptible to dirt less pressure loss compared to other valve types good value for money e smaller volume Neutral gases and fluides slightly aggressive media 8630 15 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 System DESCRIPTION burkert Construction of TOP Control Continuous Illustrations cover removed ocrew for adjusting the lower proximity switch Screw for adjusting the upper proximity switch Positioning system with 2 3 or 4 soleno id valves Operating module with display and keys
63. an be set with the arrow keys By pressing the MANUAL AUTOMATIC key you can switch to the next digit 60 8630 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 b ur kert OPERATION AND CONTROLLER FUNCTIONS Principle of adding supplementary functions to the main menu Main menu ACTFUNC stots mne INPLIT menu tem menu Select menu tem rum e ri gt CHARACT V7 CUTOFF DIR CMD DIR ACT SPLTRNG X LIMIT X TIME Y CONTRL CODE SAFEPOS SIG ERR BIN IN CAL USER Return to augmented SETFA CT main menu SER IO ENDFUNCT Confer selected aupgliemeniary lungen and add to main menu ACTFUNC INPUT Augment CHARACT 4 main menu X CONTRL ADDFUNCT X TUNE END 8630 61 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 OPERATION AND CONTROLLER FUNCTIONS b u rkert Supplementary Functions ADDFUNCT gt Select the transfer characteristic between input signal ans stroke correction characteristic Tight closure function for positioners or process controllers if activated CUTOFF DIR CMD Sense of action between input signal ans setpoint position Allocation of state of pressurization of actuator chamber Port 2 to actual position DIR ACT SPLTRNG Signal range splitting input signal in for which the valvetra
64. and step response of the P component of a PID controller E a Y Kp Xd 8 t Xd Proportional range AXd Characteristic line Step response Characteristics A pure P controller works theoretically undamped i e it is fast and dynamically favourable It has a residual control difference i e it does not completely eliminate the effects of disturbances and is thus relatively unfavourable from a static viewpoint 160 8630 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 burkert GENERAL RULES APPENDIX component Function Y Ff Xd dt Ti is the integration or floating time It is the time that expires until the controller output has run through the entire correcting range Characteristic and step response of the component of a PID controller Control range AXc Floating time Ti Characteristic line Step response Characteristics A purely controller completely eliminates the effects of disturbances It thus has a favourable static behaviour Because of its finite correcting speed it works more slowly than a P controller and tends to oscillation It is hence dynamically relatively unfavourable 8630 161 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 GENERAL RULES APPENDIX burkert D component Function Y Kd d Xd dt The higher Kd is the stronger the D influence is
65. atus RL released freigegeben printed 20 01 2015 burkert DP Interfaces Bus Initiators 1 2 Inputs for process actual value 4 20 mA Frequency Pt 100 Top Control Continuous PROFIBUS DP DY Electrical connections For operating the device it is imperative to connect the 5 pole inverse coded M12 circular socket connector and the 4 pole M12 circular plug connector voltage supply Connection with one plugged bus connector M8 plug 2 1 M12 plug 4 pole 4 2 T 4 pole process value operating voltage M12 socket 3 4 2 socket 5 pole 5 3 P s 4 pole inverse coded 2 4 initiators Profibus DP 1 8630 119 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 DP burkert Connection with 2 plugged bus connectors 1 M12 plug 2e 20 4 5 pole inverse coded Profibus DP We M12 socket 3 1 M12 plug o pole 5 f 4 pole inverse coded 7 i i operating Profibus DP 1 3 voltage Operating voltage circular plug M12 4 pole Pin Allocation 7 External connection 1 not connected l 24V DC 10 T max Residual ripple 10 not connected Bus connection circular socket plug M12 5 pole RxD TxD N Received transmitted data minus Data transmission potential mass to 5 V RxD TxD P Received transmitted data plus Screen Screen protective earth ground
66. ble and simultaneously freedom from overshoot Start AUTOTUNE by calling up X TUNE in the main menu Then depress the MANUAL AUTOMATIC key for 5 seconds NOTE To cancel AUTOTUNE operate both arrow keys at the same time and select X TUN BRK Start the automatic adaptation of the positioner to the current operating conditions Display Description TUNE 5 Countdown from 5 to O start of AUTOTUNE TUNE 4 TUNE O X T INIT Display of the autotune phase in progress at the moment X T A1 P continuation is indicated by a rotating bar to the left of the X T TOPN display TCLS TUNE END Flashing display gt end of AUTOTUNE X ERR X Message on occurrence of an error Indication right Error number see chapter Maintenance and controller fault rectification The basic settings onthe TOP Control Continuous are made in the factory commissioning nevertheless execution of X TUNE is absolutely necessary TOP Control Continuous then determines automatically the optimum settings for the current operating conditions If the supplementary function X CONTRL is present in the main menu during execution of X TUNE the positioner dead band X CO DBND is additionally determined automatically as a function of the frictional behaviour of the positioning mechanism see chapter Supplementary Functions X CONTROL 56 8630 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 20
67. bus standard is indicated on the display Display message Device status Explanation problem elimination BUS OFFL offline Device is no connection to the bus alternates with the bus connection incl plug configuration correct display value set voltage supple and bus connection of the other subscribers correct 4 dots online Device is engaged in cyclic data exchange to the left beneath the active display value set connection 8630 127 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 PnoriBus DP burkert Example 1 with COM Profibus V3 3 Example for a positioner Settings in the configuration menu of the TOP Control Continuous ADDR 3 PDI PDO e PDI POS e PDO INP e PDI MODE e PDO MODE After starting COM Profibus and the setting of master and SPS information one gets the following screen __ m di imama D Gm ite e Select CONTROLLER e Setan element under the control Setthe 3rd address in the menu address without image Confirm with OK Select CONTROLLER family e Select Type 8630 Select Configuration 128 8630 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 burkert The following screen appears DEn abe n secossa sess Ax 49 4
68. cess operating level normal controlled operation is executed and monitored in the AUTOMATIC mode and the valve opened or closed by hand MANUAL mode Switching between the operating modes gt Operate the MANUAL AUTOMATIC key to switch between the MANUAL Q AUTOMATIC modes Both in the MANUAL and the AUTOMATIC modes you can change to the configuration C level by pressing the MANUAL AUTOMATIC key for longer than 5 seconds On switching back to the process operating level the operating mode is resumed that was set before AREE switching over Operating mode Yellow LED in the Display MANUAL AUTOMATIC key AUTOMATIC flashes SE An apostrophe runs continuously 7 from left to right MANUAL 112 8630 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 b u r ke rt OPERATING THE PROCESS CONTROLLER Operating mode AUTOMATIC In the AUTOMATIC mode normal controlled operation is executed and monitored Switch over the display or V Change the process setpoint gt 3 sec With configured supplementary functions PCONTRL P CO SETP SETP INT and SP display set Make P TUNE process tune ready for start With PID self optimization activated PCONTRL BCO TUNE P TUN ACT Displays With the process controller activated the following parameters can be displayed Actual value of process variable process value PV 999 9999 Setpoint of process variable p
69. d 8630 101 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 7 7 102 8630 PCO SCAL 66 OPERATING THE PROCESS CONTROLLER b ur ke rt P CO SCAL Scaling the process controller on selection of the p p input P CO INP P1 P2 Position of the decimal point Setting range O 3 Lower scaling value for process value The value is entered in the unit that is subsequently selected for the flow rate Upper scaling value for process value The value is entered in the unit that is subsequently selected for the flow rate Lower scaling value for external process setpoint The value is assigned to the minimum current or voltage value of the standard signal Upper scaling value for process setpoint The value is assigned to the maximum current or voltage value of the standard signal VELO 2 FLOW Display of the flow rate As a transport velocity in m s e g with bulk goods or as a volumetric flow rate in h Temperature of the medium Activate the temperature transmitter optional or enter the temperature value TEMP SENS TEMP MAN TEMP BUS lt paa Temperature default value from the Master as process data output for PROFIBUS DP or DeviceNet Medium density kg m under standard conditions Diameter of piping in the pumpin
70. d 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 B rkert Fluid Control Systems Chr B rkert Str 13 17 Service Department D 76453 Ingelfingen Tel 07940 10 1 11 Fax 07940 10 448 E Mail info de buerkert com gt 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 Hi tenor 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 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 GeneraL Nores 7 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
71. dust Attach the exhaust line or silencer to connection 3 Maintain the applied supply pressure without fail at least 0 5 1 bar over that required to bring the pneumatic actuator into the end position This assures that the control behaviour in the upper region of the stroke will not be significantly affected negatively if the pressure difference is too small Keep variations in the supply pressure as low as possible during operation max 10 26 With larger variations the controller parameters calibrated with the AUTOTUNE function will not be optimal Remove the protective caps from the valve and the TOP Control Continuous 8630 43 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 Electrical connection multipole connectors ATTENTION Hi gt For connection to the technical earth ground TE athreaded stud with nut is provided on the connection module To assure electromagnetic compatibility EMC connect this stud to a suitable earthing grounding point using as short a cable as possible max 30 cm gt NOTE Use of the 4 20 mA setpoint input If the voltage supply of a TOP Control device fails in a row of such devices connected in series the input of the failed device will become high impedance This will cause the 4 20 mA standard signal to fail If this occurs please contact Burkert Service directly With P
72. e option Upper scaling value for process actual value the value is entered in the unit that is subsequently selected for the flow rate This setting determines the reference span for the dead band of the process controller and the analog feedback of the process actual value option Lower scaling value for process setpoint the value is assigned to the minimum current or voltage value of the standard signal This setting is active only when PCO SETP SETP EXT has been selected Upper scaling value for process setpoint the value is assigned to the maximum current or voltage value of the standard signal This setting is active only when SETP SETP EXT has been selected Setting the desired unit of the flow rate Manual entry of the K factor for the flow rate sensor e g from the data sheet for the flow rate sensor Position of the decimal point for the K factor setting range O 2 K factor setting range O 9999 8630 99 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 OPERATING THE PROCESS CONTROLLER burkert mc rn Teach In funktion Calibration of the k factor by measurement of a certain quantity of fluid START Start of measurement Open the valve Close the valve when the tank is filled Use the arrow keys for opening and closing the valve For this the valve must not be fully open End of measurement Position of the decimal point for entry
73. e piping and valves may not be loosened ake 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 e 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 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 burker oGewsa Protection from damage by electrostatic charging electrostatic discharge ESD Contact to electrostatically charged persons or objects will endanger these components In the worst 4 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 This device contains electronic components that are sensitive to ATTENTION EXERCISE CAUTION ON HANDLING ELECTROSTATICALLY SENSITITVE COMPONENTS MODULES 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 actuate
74. e positioner SP FAULT signal error check signal set value process controller PV FAULT signal error check signal actual value process controller PT FAULT signal error check signal actual value Pt 100 FAULT signal error check signal actual value P1 fluid flow controller P2 FAULT signal error check signal actual value P2 fluid flow controller TMP FAUL signal error check signal actual value temperature fluid flow controller EE FAULT EEPROM faulty none device faulty MFI FAUL Fieldbus board faulty Error messages on execution of the function X TUNE X ERR 1 No compressed air connected Connect compressed air X ERH 2 Compressed air failure during Check compressed air supply AUTOTUNE X ERR 3 Actuator or positioning system leaky None device faulty on exhaust side 4 Actuator system leaky on pressurized None device faulty side X ERR 6 The end positions for POS MIN and Check whether the allocation of the end POS MAX are too near to each other positions to POS MIN and POS MAX via the function TUNE POS is correct If incorrect Execution TUNE POS again If correct TUNE POS with this arrangement of the end positions is not possible since they are too close together X ERR 7 False allocation of POS MIN and POS determine POS MIN and POS MAX MAX move the actuator in each case in the direction shown on the display 154 8630 MAN 1000010084 EN Version K Status RL released freigegeben
75. e drop over the valve as in the definintion of k 1000 kg m the density of water as in the definition of k Ap is the pressure drop over the valve bar and r is the density of the medium kg m b The pressures at the inlet and outlet of the overall system p and p are known at which the desired maximum flow rate is to be attained X Step 1 Calculate the flow coefficient of the overall system k __ from equation 1 Vges otep 2 Measure the flow rate through the system without the continuous valve e g by short circuiting the piping where the vale is installed Step 3 Calculate the flow coefficient of the system without the continuous valve k from equation 1 Step 4 Calculate the required value of the continuous valve from equation 2 158 8630 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 burkert GENERAL RULES APPENDIX The of the continuous valve should have at least the value valculated from the equation 1 or 2 relevant to the application but under no circumstances be very much greater The rule of thumb often used with switching valves somewhat larger never hurts can be strongly detrimental to the control behaviour of continuous valves Determination in practice of the upper limit to the value of the continuous valve is possible by means of the so called valve authority 4 2 ky 3 2
76. e last valid value will be used and will be displayed in ERR with HEX 14 PDO SP Process set value Set point GSD file PDO SP Set value process controller in physical unit as set up in the INP or PCO SCAL menu max value range Identifiers HEX 81 40 15 999 9999 depending on the internal scaling If the value is too small or too large the last valid value will be used and will be displayed in ERR with HEX 15 PDO MODE Operation Mode GSD file PDO MODE Value range 0 AUTO 1 MANUAL 12 BUSSAFEPOS Identifiers HEX 81 00 16 Operation mode 0 AUTO 12 BUSSAFEPOS 1 HAND If the value is too small or too large the last valid value will be used and will be displayed in ERR with HEX 16 PDO ERR Reset of error message GSD file PDO ERR If the value gt 0 ERR is reset Identifiers HEX 81 00 17 PDO MTMP Medium temperature GSD file PDO MTMP Temperature of the medium in C The value will be predefined from the menu the bus or using a Identifiers HEX 81 40 18 temperature transmitter Value range 20 150 If the value is too small or too large the last valid value will be used and will be displayed in ERR with HEX 18 PDO INP is always active with the positioner not present with process conroller PDO SP can only be selected if the process controller is activated PDO MTMP can only be selected if the fluid flow controller option is active gt NOTE Bus status display The
77. e mode for changing the process setpoint can be activated After release of the key the first digit of the process setpoint flashes The first digit of the process setpoint can be set After confirmation with the MANUAL AUTOMATIC key the set value is stored In the same manner the other digits are set After confirmation of the last digit the display returns to the previous mode Operating mode MANUAL yellow LED off In the manual mode the valve can be opened and closed by hand Meaning of the keys in the MANUAL mode P K 4 de 4 SFI 114 8630 Press the A key in the MANUAL mode Pressurization of the actuator SFA valve opens SFB valve closes SFI port 2 1 pressurized Press the Y key in the MANUAL mode Venting of the actuator SFA valve closes SFB valve opens SFI port 2 2 pressurized Hold down the key and simultaneously press the y Fast pressurization Hold down the key and simultaneously press the A Fast venting SFA actuator closing by spring force SFA actuator opening by spring force actuator with double action MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 burkert OPERATING THE PROCESS CONTROLLER Displays The last display set in the AUTOMATIC mode is shown By selecting PV the actual value of the process variable can be checked To display the actual position of the valve actuator durin
78. e sequential addition in an existing network of devices with the default address 63 is a simple matter The figure shows how the new address 2 is assigned to a device with the address 63 Node Lomms issioning Current Device 5 8630 145 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 DEvicENET burkert Offline parametrization of the device After the addition of a device in the DeviceNet configuration of RSNetworx the device can be parametrized offline The figures shows by way of example how an Input Assembly Input Process data transferable via I O connection at variance with the factory setting can be selected Note however that the length of the process data must be appropriately adapted with a following configuration of the DeviceNet Masters Scanners see chapter Configuration Example 2 All parameter changes carried out offline must be rendered effective for the real device by a Download Procedure LL B Ed Mee ee a s uarary NIS 0067 War Tores Tie CLOSE 10009 Tre Time 0010 Chs aciei Cure DHARACT 0611 Peu Aucune X TUNE Mo Function 123 Prospero Fen L 146 8630 MAN 1000010084 EN Version K Status RL relea
79. eactivate leakage characteristic LEAK ACT Activate leakage characteristic A Helease LEAK MEAS TUNE 5 Start automatic determination of e the leakage 55 TUNE 4 characteristic zu LEAK CHAR 3 Show the a leakage Q characteristic display TUNE 1 TUNE O LEAK XXX Reference points are displayed alternately as conveyance pressure in mbar and air flow or conveyance speed in m h or m s respectively To interrupt the leakage determination press both arrow buttons simultaneously and select LEAK BRK 104 8630 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 b u r ke rt OPERATING THE PROCESS CONTROLLER P Q LIN Starting the routine for linearization of the process curve This function makes sense only when flow control is to be carried out You start the routine for linearization of the process characteristic by calling up the menu item PQ LIN in the main menu and pressing the MANUAL AUTOMATIC key for 5 seconds The function PQ LIN can only be started when the menu item PCONTRL PCOINP INP FREQ item PCOINP INP420 has been selected With the activation of the function PCONTRL the functions PQ LIN which are required for process control are copied into the main menu Via these functions the program is started for autonomous determination of the fixed points for a correction characteristic The prog
80. egeben printed 20 01 2015 OPERATION AND CONTROLLER FUNCTIONS b u rkert X LIMIT Limitation of the mechanical stroke range Factory setting LIM 0 10096 This supplementary function limits the physical stroke to preset values minimum and maximum The range of the limited stroke is thereby set to 100 If the limited stroke range is left during operation negative or positive POS values greater than 100 are displayed 50 of the overall stroke Entering the start value of the stroke range in Entering the end value of the stroke rage in LUT XXX 50 100 of the overall stroke minimum separation between L M is 5O 96 Limited Physical stroke stroke 96 POS POS 160 unlimited stroke 9 100 5 S Gu S o D p BE e ez limited 5 E stroke ES 9 40 4 8 12 16 20 Setpoint mA INP 70 8630 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 b ur kert OPERATION AND CONTROLLER FUNCTIONS X TIME Limitation of the correcting speed Factory setting 1 s oe NOTE When executing the function X TUNE the minimum opening and closing time for and T CLS is automatically entered for the full stroke In this way it is possible to traverse at maximum speed If the correcting speed is to be limited
81. er 91 Supplementary function 91 Basic setings ol the tuncion uu ee ee 92 P Q LIN Starting the routine for linearization of the process Curve i 105 Display during call up and execution of the routine 105 PCO TUNE Self optimization of the process controller process tune 106 PCO LEAK Leakage characteristic for flow rate control i 110 Operating the 5 com gie 112 Changeover between the operating TOUS essen ee 112 Operating mode AUTOMATIC 113 Meaning of the Keys RR 113 DI D 113 Operating structure and procedures 113 Manually changing the process setpoint iiini 114 Operating mode MANUAL 114 Meaning of the Keys PERREXIT 114 DID 115 Operating structure and procedures 115 PROFIBUS DP General notes t 118 Technical data 11111011111 118 Safety settings on bus failure 118 119 Electrical CONNECTIONS 119 Connection with one plugged DUS 119 OPIS CTI Fi plugged DUSCOFTIBCIOIS et 120 Operating voltage circular plug M12 eier 120 sbrreoqaeueuee cesin 120 4 8630 MAN 1000010084 EN Version K Status
82. erl Configuration the process data 5 static input and 2 static output assemblies are available for the transmission of process data via an connection Select attributes for transmission jointly as process data via an I O connection are combiened in an object in these Assemblies Selection of the process data takes place by setting the device parameters Active Input Assembly and Active Output Assembly or where supported by the DevicNet Master Scanner by setting the Produced Connection Path and Consumed Connection Path on initializing an I O connection corresponding to the DeviceNet specification Static input assemblies Adress Data Attribute of ther Assemblies Format of the Data for Read access Class Instance Attribute Attribute Pos ERR factory setting POS low POS high ERR POS CMD ERR 4 2 3 POS low POS high CMD low CMD high ERR PV ERR 4 3 3 PV low PV high ERR PV SP ERR 4 4 3 PV low PV high SP low SP high ERR 4 1 3 PV SP CMD ERR 4 5 3 PV low PV high SP low SP high CMD low CMD high ERR PV P1 P2 MTMP ERR 4 6 3 PV low PV high P1 low P1 high P2 low P2 high MTMP low MTMP high ERR PV SP CMD P1 P2 MTMP ERR 4 7 3 Byte 0 PV low Byte 1 PV high Byte 2 SP low Byte 3 SP high Byte 4 CMD low Byte 5 CMD high Byte 6 P1 low Byte 7 P1 high Byte 8 P2 low Byte 9 P2 high Byte 10 MTMP low Byte 11 MTMP high Byte 12 ERR 8630 141 MAN 1000010084 E
83. ess valve The value will be determined using a pressure transmitter INT 2 Byte Value range 1013 16000 lt 1 U Do Process actual value Process Value 120 1 3 Actual value of process controller in physical unit as set in the menu P CO INP respectively SCAL max value INT 2 Byte range 999 9999 depending on the internal scaling Process Setpoint Process Setpoint 120 1 2 Setpoint value of process controller in physical unit as set in the menu INP respectively RCO SCAL max value INT 2 Byte range 999 9999 depending on the internal scaling m JJ JJ Error Error 100 1 1 Gives the number of the process value output which has not USINT 1Byte been entered The value is retained until deleted by the acyclic writing of the attribute Error with O access via Explicit Message Set Attribut Single HEX OX14 INP OX15 SP 0 18 MTMP 142 8630 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 bu rkert DeviceNet Static Output Assemblies Address Data Attribute of the assemblies for Format of the Data Write Read access Class Instance Attribute Attribute INP factory setting 4 21 3 Byte 0 INP low Byte 1 INP high SP 4 22 3 Byte 0 SP low Byte 1 SP high MTMP 4 23 3 Byte 0 MTMP low Byte 1 MTMP high SP MTMP 4 24 3 Byte 0 SP low Byte 1 SP high Byte 2 MTMP low Byte 3 MTMP high The addresses gi
84. g section mm A dialog appears only when transport velocity Velocity has been selected as a process parameter DIAM This setting specifies the reference range for the deadband of the process controller and for the analog display of the process value option This setting is active only when PCO SETP SETP EXT has been selected MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 burkert OPERATING THE PROCESS CONTROLLER P CO TUNE Activating the self optimization of the process controller process tune Activate Select controlled process tune member Controlled member unknown Pronar i LV Prien JES Flow rate control Temperature control Pressure control Filling level control A NOTE Process tune is started in the operating mode AUTOMATIC P CO KV Display or enter kv characteristic curve of the process valve option flow rate controller Enter user defined kv curve No of places after the decimal point for KV USEH DPKV X ZA entry of kv curve 5 KV FACT i Display enter value in m h Display factory set kv curve Display enter kv curve in 96 referred to the kvs value 8630 103 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 OPERATING THE PROCESS CONTROLLER b u 4 P CO LEAK Reading in of the leakage characteristic Flow rate control option PCO LEAK LEAK D ACT D
85. g MANUAL operation change to the display POS XXX in advance in the AUTOMATIC mode Operating structure and procedures AUTOMATIC mode MANUAL mode Valve closed at No operating action Valve opens at normal speed normal speed Release key Release key Av I release release Menu item Valve closes Valve opens fast fast Configuration 8630 115 burkert OPERATING THE PROCESS CONTROLLER SLOZ LO Oz peiuud 1H Snielg Y uols eA 780010000 NYIN 116 8630 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 burkert DP PROFIBUS DP General notes iea 118 1 1 data 118 Safety settings on bus failure omnia 118 Interfaces 119 Electrical CONNECTIONS ent 119 Connection with one plugged DUS Connector iiir 119 Connection with 2 plugged bus connectors 120 Operating voltage circular plug M12 110111101 120 Bus connection circular socket M12 cst 120 Inductive proximity switches circular socket 8 121 Process value circular plug M8 ttti 121 Termination connection for Profibus Systems a neuen aetema 122 Settings on the TOP Control Continuous 123 Explanation of the menu 124 Functional deviations from the standard version 124 Configuration in the PROFIBUS DP
86. g the housing of the TOP Control tan edite 50 Positioning the inductive proximity SWItONOS uccidere Deua Latus eee eee aedem 50 OPERATION AND CONTROLLER FUNCTIONS Operating and display elements 52 Operating levels eese ore temet deutet ratum 52 Commissioning and set up as a positioner te 53 Procedure for specifying the basic settings ee nenne ee 53 Main menu for the settings on commissioning 54 Description of the procedure RE 55 Configuring the supplementary 5 59 Keys in the configuration level 59 Coni guration RU MERO 59 Supplementary functions 62 Operating the trs 86 Changeover between operating modes ttt ttt ttt ttt ttt ttti ttti 86 Operating mode AUTOMATIC 87 Meaning of the keys the AUTOMATIC mode 87 Display of the AUTOMATIC mode ttt ttt ttt itti ttt ttti ttti 87 Operating mode MANUAL s 88 Meaning of the keys in the MANUAL mode 88 Display of the MANUAL Mode RR TES 88 Alternative chapters or functions depending on device configuration 8630 3 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 CONTENTS burkert OPERATING THE PROCESS CONTROLLER Factory settings on the process controller 90 Setting up a process control system 90 Self parametrization of the position
87. gle acting actuator Actual process value Process Setpoint position controller Positioner Positioning system 1 pressurizing valve Actual 2 exhaust valve position passa Compressed air Position supply sensor Exhaust air Sensor VA Actual process value flow rate pressure level temperature etc MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 burkert w Jw 5 Desorirrion 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 positi ve 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 disturbance Valve opening CMD Position setpoint Positioner Positioning Continious valve system Sole noid Position control Position sensor loop Ll e 8630 19 burkert
88. hat the process controller cuts in only above a certain control difference The function reduces wear on the solenoid valves in the TOP Control Continuous and the pneumatic actuator J v Entering the dead band in 96 Insensitivity range with process control Process setpoint Control SP difference to controller Xd2 Dead band Process actual value PV 8630 93 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 OPERATING THE PROCESS CONTROLLER P CO PARA burkert Parameters of the PID process controller v AD au AJM Gain factor of the process controller 99 99 factory setting 1 00 Heset time 0 5 s 999 9 s factory setting 999 9 s Rate time 0 s 999 9 s factory setting 0 s Operating point 0 0 100 96 factory setting 0 96 gt self optimization of the PID parameters see Step B The parameters entered should be noted in the table in the Appendix Tables for process controller For definition of the parameters of a PID controllers see Appendix General rules P CO SETP Type of setpoint setting internal external 94 8630 SETP INT seTPEXT 96 Setpoint setting internally via the keys on the TOP Control Continuous Setpoint setting externally via the standard signal input MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 b u r rkert
89. he actual value of the controlled variable Curve of the controlled variable after a step in controller output AY Controller output Y 2 Actual value Ks AY Lee Controlled variable AX Procedure e Switch controller to MANUAL Deliver a step in controller output and register the controlled variable with a chart recorder e With critical runs e g on risk of overheating switch off in good time NOTE It should be observed that with thermally sluggish systems the axtual value of the controlled variable may continue to rise after switching off In the following table the setting values are given for the controller parameters as a function of Tu Tg and Ks for command and disturbance behaviour as well as for an aperiodic control event and a control event with 20 overswing They apply for members with P behaviour with dead time and with first order delay 166 8630 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 burkert GENERAL RULES APPENDIX Parameter setting according to Chien Hrones and Reswick Controlle type Parameter setting with aperiodic control event 0 96 overswing Command Tg poste Tu Ks _ Tg puce Tu Ks Tn 1 2 Tg 0 6 ues Tg Tv 0 5 Disturbance Tg pice Tu Ks 06 19 Tu Ks 4 Tu Tg Tu Ks Tn 2 4 Tu Tv 0 42 Tu Kp 0 95 with control event with 20 overs
90. he function TUNE AIR must be executed after AUTOTUNE Avoid faulty adaptation of the controller by executing X TUNE in all cases at the supply pressure pneumatic auxiliary energy that will exist in later operation The function X TUNE should preferably be executed without operating medium pressure to avoid disturbing influences from flow forces END Quitting the main menu and display of the software version gt To quit the main menu select the item END with the arrow keys To the right of the display the software version is shown END XX If the MANUAL AUTOMATIC key is pressed EEPROM appears on the display until the changes have been saved After that the device returns to the mode in which it was before switching over to the main menu MANUAL or AUTOMATIC 58 8630 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 Configuring the supplementary functions b ur OPERATION AND CONTROLLER FUNCTIONS gt NOTE The operating concept for the TOP Control Continuous is based on a strict separation between the basic and supplementary functions In the delivered state only the basic functions are activated These suffice for normal operation For more demanding control applications you can select and specify supplementary functions in the configuration level Keys in the configuration level Press key in Menu in a selected and confirmed menu item Scroll up Increme
91. he menu items in the program run off schematic es 139 IH MAIN MEn et ee ee ee 140 Configuring the process data 141 Se ea E AEE ee 141 Static u tput assemblies 143 8630 5 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 CONTENTS burkert Bus status display mm 144 Configuration example tti 145 Installation of the EDS file 145 Padrosa C WON estime E MM MU MIEL MD M 145 COHineparameltizauomoPIDe tV DO mo suu E 146 OnlhiecparametuzZation or he C6 VID 147 Configuration example 2 148 Setting up the process map Em 149 MAINTENANCE AND ERROR CORRECTION ON THE POSITIONER 152 Error messages and Malfunctions iii 152 EHermessadesohme LO espace MP uM lee 152 Other 13 AU UEC ONS 152 MAINTENANCE AND ERROR CORRETION ON THE PROCESS CONTROLLER 154 Error messages and Malfunctions it 154 Error messages on the EG et ue 154 Other MallUNCHONS 156 Appendix 6 8630 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 burkert CONTENTS GENERAL RULES Selection criteria for continuous valves 158 Characteristics of PID controllers 160 160 161
92. ic management messages of low priority Explicit Messages The protocol sequence corresponds to DeviceNet Specification Release 2 0 134 8630 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 burkerl Technical data EDS file BUER8630 EDS Icons BUER8630 ICO Baud rate 125 kBit s 250 kBit s 500 kBit s adjustable via keys at the device or via network Factory setting 125 kBit s Adress 0 63 adjustable via keys at the device or via network Factory setting 63 Process data 7 static Input Assemblies Input from TOP Control Continuous to DeviceNet Master Scanner 4 static Output Assemblies Total line length according to DeviceNet specification Total line length 2 sum of all mein and drop lines Maximum total line length Thick Cable Thin Cable 125 kBaud 500m 250 kBaud 100 m for all baud rates Drop line length Drop Lines Baud rate Length of drop lines Maximum length Maximum total length of drop lines in network 125 kBaud 6 m for all baud rates 250 kBaud 500 kBaud Safety settings on bus failure The actuator moves to the position corresponding to the setpoint last transmitted default setting For other setting options see the chapter Settings on the TOP Control Continuous 8630 135 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 DEvicENET burkert Interfaces Bus Initiators 1
93. itioner controls the position of the process valve to the desired setpoint and is automatically parametrized and optimized by the X TUNE function The superimposed process controller which together with a sensor forms a process control loop can control any process parameter It has a PID structure whose components may be combined in various ways P PI PD PID and freely parametrized KP TN TV In order to obtain good control behaviour the structure of the controller must be adapted to the characteristics of the process controlled member The parameters must be chosen to obtain a short setting time a small overshoot width and good damping Parametrization demands experience in control tecnique measuring equipment and is time consuming For this reason TOP Control Continuous has a self optimization function TUNE This function provides an unique direct determination of the parameters The results may be read out as needed and modified in any way desired METHOD OF OPERATION During commissioning of the control system the process is excited by a step in the setpoint in a closed control loop This step is carried out within the future working range of the process control system and serves to determine characteristic variables of the process Calculation of the PID controller parameters is carried out on the basis of these characteristic variables by use of a modified Ziegler Nichols procedure SETPOINT MODULATOR In addition to
94. l loop Valve Xd2 CMD Process Y opening control poop __ Jg Process controller SP Process variable Process Process setpoint Transmitter Example of process control TOP Control Continuous with sensor 22 8630 System DESCRIPTION burkert 1 45 HLNOY d 1114 1725 3WLL X AsOLND LOVHVHO S9NHIl1IdS QWO Hla TH1NOOX T EJ 7 N 247 N F ds p _ LWITX 504 P N 043u09 sseooud jo lt SLOZ LO Oz peiuud ueqebebie 1H 5 M uoisJeA 780010000 NYIN 23 8630 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 System DESCRIPTION burkert Characteristics of the process controller software Supplementary function Positioner with supplementary functions 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 Analog feedback option Valve closes tight outside control range A value is given at 96 from which the actuator is completely exhausted at 096 or pressurized at 100 Mech valve piston movement only within a specified stroke range oplitting of the standard signal range over two o
95. l valve is fully open or the conveyance pressure previously reaches the uper limit of the scaling Airleakage compensation is now activated The process value is now obtained from the difference between the measured air flow and the air leak rate calculated from the characteristic Q Q Q conv pipe FMR air leak PCONTRL PCO DBND LEAK Deactivate leakage characteristic P CO PARA LEAK ACT Activate leakage characteristic PCO SETP LA Helease LEAK MEAS TUNE 5 P CO INP Start automatic determination of the leakage P CO FILT characteristic PCO SCAL LEAK CHAR Show the charateristic display TUNE 2 P CO KV TUNE 1 P CO LEAK o 5 Countdown P CO END TUNE 0 Reference points are displayed alternately as conveyance pressure in mbar and air flow or conveyance speed in m h or m s respectively LEAK XXX Deactivation of the characteristic curve The leakage characteristic that has been read in can be deactivated using the function LEAK D ACT in the PCO LEAK menu 8630 111 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 OPERATING THE PROCESS CONTROLLER burkert Operating the process Each time after switching on the voltage supply the TOP Control Continuous is automatically in the process operating level To change to the process operating level from the configuration level confirm the menu item END by pressing the MANUAL AUTOMATIC key In the pro
96. lids there arises at a cellular wheel sliuce an air leakage dependent on the pressure The air flow through the controller unit is the sum of this leakage and the air flow of the conveying pipe QFMR air leak conv pipe To achieve an air leakage compensation an air leakage characteristic must be read in once with the conveying pipe closed Reading in of the leakage characteristic Boundary conditions For exact measurement of the leakage the system should be started up in the normal mode However the following exceptions apply The conveying pipe must be closed off behind the components causing the leak The material to be transported is omitted ATTENTION In the case of pneumatic conveying of pourable solids with a rotary valve the following must be observed The conveying pipe must be closed off behind the rotary valve The rotary valve must be empty and run at the nominal rpm Measures for sealing the system e g blocking air that enters from above into the rotary valve must be connected The compressor must be switched on Measurement and reading in of the leakage characteristic gt Select program to initiate automatic recording of leakage characteristic using PCONTRL gt PCO LEAK gt PCO MEAS menu gt Press and hold the button for 5 seconds The leakage characteristic is now automatically captured and read in Display Countdown from 5 to O to the start of leakage determination
97. master i 125 Configuration of the process values 125 Bus status display uo t ttim tetuer te mittat 127 Example 1 with COM Profibus V3 3 128 Example for a positioner iiini 128 Example 2 with COM Profibus V3 3 t 131 Example for a proc ss controll end eier 131 8630 117 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 DP burkert General notes he following functions are invalid for the TOP Control Continuous with PROFIBUS DP INPUT CAL USEH CAL INP CAL USEH CAL OUT e CAL USEH CAL SP Technical data The protocol sequence corresponds to DIN 19245 Part 3 GSD file BUERC630 GSD Bitmap files BUEC630 DIB BUEC630N BMP for Siemens COM PROFIBUS BUEC630D BMP for Siemens COM PROFIBUS PNO ID C630 Hex Baud rate max 1 5 Mbaud automatically set by TOP Control Continuous Sync and freeze mode not supported Diagnosis telegram no device specific diagnosis Parameter telegram no user parameters Configuration of the process data is performed in the TOP Control and in the PROFIBUS Master A maximum of 10 process values Sum of input and output can be transferred Safety settings on bus failure The actuator moves to the position corresponding to the setpoint last transmitted default setting For other setting options see the chapter Settings on the TOP Control Continuous 118 8630 MAN 1000010084 EN Version K St
98. n Carry out the necessary basic settings and initiate self parametrization of the TOP Control 36 8630 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 burkert Basic settings of the Control Continuous Configuration of the keys MANUAL AUTOMATIC key Switch between main and subitems e g ACT FUNC FUNCSNGL Arrow keys owitch between equal ranking menu items e g ACTFUNC INPUT RN N ACT FUNC K INPUT Eg 7 727 MANUAL INP MODE INP 5 Ne DW KE 3 Jump over on first commissioning 8630 37 burkert First COMMISSIONING Settings in the menu items 1 ACTFUNC Actuator function FUNC SNGL single acting FUNC DOUB double acting Standard signal 2 INPUT INP 420 Current 4 20 mA INP 0 20A Current O 20 mA INP 0 10V Voltage O 10V INP 05V Voltage 0 5V 3 ADDFUNCT Jump over 4 X TUNE Initiate self parametrization 5 END XX Return to AUTOMATIC mode the display EEPROM appears until the settings have been in the memory Entering the position setpoint in the AUTOMATIC mode After selection of the basic settings and return to the AUTOMATIC mode the TOP Control Continuous works as a positioner Enter the position setpoint via the signal Switching between the ee display options PUS 50 Mapay CAD 50 MAN 1000010084 EN
99. n configuration the function PRCONTRL PCO SETP SETP EXT setpoint setting via analog input is specified In this case the external setpoint setting is reactivated only after completion of process tune Self optimization of the process controller now runs automatically The display shows a rotating bar and the message P TUNE After completion of process tune the device is in the AUTO mode The process controller works from this point on with the optimized PID parameters and controls to the current internal or external setpoint SP To execute a new optimization cycle repeat Steps 2 4 NOTE The Process Tune in the conrol menu of the TOP Control Continuous remains active so that op the process control takes place with the Set value Modulation Filer for the reduction of unwanted non linear effects If the control will be carried out without the Set value Modulator the process tune in the control menu must be deactivated PCONTRL PCO TUNE P TUN D ACT To stop the self optimization press both arrow keys at the same time and select P TUN 8630 109 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 OPERATING THE PROCESS CONTROLLER burkert P COLEAK Leakage characteristic for flow rate control Flow rate control option The program function PCO LEAK enables air leakage compensation which increases the accuracy of the flow rate control Background during transport of pourable so
100. ncy 24 V supply sensor 7 24 internal Clock input 8 Clock 4 supply not connected Clock input GND 10 o Clock GND 4 20 MA not connected external Process actual supply Process actual not connected Frequency not connected external Clock input 8 o Clock supply not connected 10 o Clock Clock input Pt 100 not connected see Process actual 1 current supply Note Process actual 2 compensation below Process actual 3 GND to bridge terminals 9 and 10 at the sensor gt NOTE For reasons of line compensation connect the Pt 100 sensor over 3 conductors sure 48 8630 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 burkerE InsraLLarion Terminal allocation with binary outputs Terminal Allocation External connection 11 Binary input 12 Binary input GND 8630 49 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 namen Setting the inductive proximity switches Option v In order to set the inductive proximity switches the housing of the Control Continuous must opened Switch off the operating voltage before making this intervention Opening the housing of the TOP Control Continuous gt Remove any lead seals or fastenings present between cover and housing Turn the cover anticlockwise and lift it off Positioning
101. ng force SFI actuator with double action Displays of the MANUAL mode The last display set in the AUTOMATIC mode is shown By selecting POS XXX the actual position of the valve actuator can be checked AUTOMATIC mode MANUAL mode Valve closes No Valve opens at normal Release key operating Release key at normal speed action speed SM KH A ID release 5 sec release Menu item uration Valve closes Valve opens fast fast Confi 88 8630 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 b u r ke rt OPERATING THE PROCESS CONTROLLER OPERATING THE PROCESS CONTROLLER Factory settings on the process controller 90 Setting up a process control 90 Self parametrization for positioner X TUNE 91 Supplementary function P CONTHRL t 91 Basic settings of the function ttt 92 P Q LIN Starting the routine for linearization of the process Curve 105 Display during call up and execution of the routine 105 PCO TUNE Self optimization of the process controller process tune 106 PCO LEAK Leakage characteristic for flow rate contro 110 Operating the process 112 Changeover between the operating modes 112 Operating mode AUTOMATIC 113 Meaning of the Ke
102. ng this method is naturally that the control loop is permitted to oscillate Procedure Set the controller to P control i e Tn 999 Tv 0 Kp initially small e Set the desired set point Increase Kp until the controlled variable executes continuous undamped oscillation The proportional action factor amplifucatuib factor set at the limit of stability is designated The resulting oscillation period is designated Curve of controller output at the limit of stability Actual value X Time From K the controller parameters can then be calculated using the following table crit crit Parameter setting according to Ziegler and Nichols Contr type Einstellung der Parameter PID Kp 0 6 K Tn 0 5T Tv 0 12T crit crit crit The adjustment rules of Ziegler and Nichols have been determined for P members with first order time increase and dead time However they apply only for controllers with disturbance behaviour and not for those with command behaviour 8630 165 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 GENERAL RULES APPENDIX burkert Setting rules of Chien Hrones and Reswick controller output step method With this method the controller parameters are set on the basis of the transient behaviour of the controlled member step in the controller output of 100 96 is delivered The times Tu and Tg are derived from the curve of t
103. nsverses the entire stroke X LIMIT Limitation of mechanical stroke range X Limitation of correcting speed X CONTRL Parametrization of positioner Parametrization of the PID process controller RCONTRL Without function in the version as positioner CODE Code protection for settings SAFEPOS Enter safety position SIG ERR Configure error recognition signal level BIN IN Activation of binary input Configuration of the outputs only with supplementary OUTPUT board for analog feedback or binary outputs CAL USER Calibration SETFACT Reset to factory settings SER I O Configuration of the serial interface ENDFUNCT 62 8630 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 b ur kert OPERATION AND CONTROLLER FUNCTIONS CHARACT Selection of the transfer characteristic between input signal position setpoint and stroke correction curve Customized characteristic Factory setting CHA LIN With this function you can select a transfer characteristic with respect to setpoint position setpoint position CMD and valve stroke POS to correct the flow or operating curve LHARALT 166 CHA LIN Linear characteristic CHE 1725 Equipercentile characteristic 1 25 CH9 1 33 Equipercentile characteristic 1 33 EHR 1 50 Equipercentile characteristic 1 50 CHa 25 1 Inverse equipercentile characteristic 25 1 CHR 33 1 Inverse equipercentile characteristic 33 1 tun 5n
104. nt increase numeric value select Scroll down Decrement decrease numeric value select Press key in Menu in menu ADDFUNCT E confirm selected menu item Confirm selected menu item of supplementary Q menu to add it to the main menu The menu item is marked with an asterisk in the supplementary menu Confirm set values The menu item appears int he main menu and can be selected and edited there Confirm the menu item selected and marked with asterisk in the supplementary menu for deletion from the main menu Configuration menu Switching between the process operating level and the configuration level Process operating level Configuration level MANUAL AUTO m END 8630 59 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 OPERATION AND CONTROLLER FUNCTIONS b u rkert gt 55 To activate the configuration menu press in the process operating level the MANUAL AUTOMATIC key for 5 seconds The configuration menu consists of a main and a supplementary menu The main menu contains initially the basic functions which are specified during first commissioning The supplementary menu comprises supplementary functions which may be reached via the menu item ADDFUNCT of the main menu Specification of device functions and parameters is possible only within the main menu If needed the main menu may be augmented by additional functions and parameters from the supplementary
105. ntl ftet gt 100 96 bel ftet gt 0 96 Actual position POS 100 Exhausted Pressurized State of pressurization 68 8630 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 b ur kert OPERATION AND CONTROLLER FUNCTIONS SPLTRNG Split range Split range min and max values of the input signal in for which the valve traverses the entire stroke Factory setting SR 0 96 SR 100 96 gt NOTE This function is only effective when operating as a positioner This supplementary function limits the Position setpoint range of the TOP Control Continuous by specifying a minimum and maximum values In this way it is possible to distribute the standard signal range used 4 20 mA 0 20 mA 0 10 V or 0 5 V over several TOP Control Continuous with or without overlap Several valves can thus be used as final control elements either alternating or if the setpoint ranges overlap simultaneously Entering the minimum value of the input signal in 75 96 of the standard signal range AJ Entering the maximum value of the input signal in 96 25 100 96 of the standard signal rage AM Splitting the standard signal range into tow setpoint ranges Valve stroke 76 POS Setpoint range mA INP Setpoint range Setpoint range TOP Control TOP Control Continuous 1 Continuous 2 8630 69 MAN 1000010084 EN Version K Status RL released freig
106. o attach the cable or hoses the TOP Control Continuous may be rotated relative to the pneumatic actuator Procedure gt Disconnect the fluidic connection between TOP Control Continuous and pneumatic actuator gt Loosen the fixing screws recessed into the side of the housing hex socket SW3 see chapter System description Construction of the TOP Control Continuous Rotate the TOP Control Continuous clockwise without lifting into the desired position gt Retighten the fixing screw with 1 2 Nm moderate torque gt Remarke the fluidic connection between TOP Control Continuous and pneumatic actuator using longer hoses if necessary ATTENTION wer Hl If theTOP Control Continuous is lifted during rotation axially displaced the mechanical coupling to the position sensor mechanism may be damaged By turning in the wrong direction anticlockwise there is a risk of unhooking the position sensor mechanism This can be reconnected only with a special tool Hl To assure leak tightness of the device 65 the screw for connecting TOP Control Continuous and process valve shall be tightened with a torque not exceeding 1 2 Nm 42 8630 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 burkerE NSUN Fluidic connection of the TOP Control Continuous gt Apply the supply pressure to connection 1 3 7 bar instrument air free from oil water and
107. o each other positions to POS MIN and POS MAX via the function TUNE POS is correct If incorrect Execution TUNE POS again If correct TUNE POS with this arrangement of the end positions is not possible since they are too close together False allocation of POS MIN and POS To determine POS MIN and POS MAX MAX move the actuator in each case in the direction shown on the display Other malfunctions POS 0 with gt 0 or Tight closing function Deactivate tight closing POS 100 by 100 CUTOFF function has been inadvertently activated 152 8630 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 burkerl MAINTENANCE AND ERROR CORRECTION ON THE PROCESS CONTROLLER MAINTENANCE AND ERROR CORRECTION ON THE PROCESS CONTROLLER DA AU SI nee 154 Error messages and Malfunctions i 154 Error messages on the LC display 11iiiiiiiiiiisissssssssssstsssssssstittttittstsiitiii 154 VNR MM VG WS 156 8630 153 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 MAINTENANCE AND ERROR CORRECTION ON THE PROCESS CONTROLLER burkert Maintenance When operated according to these Operating Instructions the TOP Control Continuous is maintenance free Error messages and malfunctions Error messages on the LC display General error messages CMD FAUL signal error check signal set valu
108. o transmitter p1 VOX supplied 2 4 20 mA output from transmitter p1 1 1 transmitter 3 4 12 2 1 24 supply to transmitter p2 oe 2 14 20 mA output from transmitter p2 M ux 3 4 Option 3 1 24 V supply to transmitter 24 2 4 20 mA output from temperature transmitter transmitter o 3 4 With external supply of the sensors the mass of the standard signal must connected to the mass of the supply voltage Circular plug M12 46 8630 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 burkerE NSUN Electrical connection terminals for cable bushing ATTENTION For connection to the technical earth ground TE a threaded stud with nut is provided on the connection module To assure electromagnetic compatibility EMC connect this stud to a suitable earthing grounding point using as short a cable as possible max 30 cm gt NOTE Use of the 4 20 mA setpoint input If the voltage supply of a TOP Control Continuous device fails in a row of such devices connected in series the input of the failed device will become high impedance This will cause the 4 20 mA standard signal to fail If this occurs please contact B rkert Service directly Connection PCB of the TOP Control Continuous with screw terminals and jumpers Jumper 1 gt Remove the cove
109. oint of position in 96 6 5h 1 178 8630 n printed 20 01 2015 leased freigegebe K Status RL re MAN 1000010084 EN Version burkert TABLES FOR PROCESS CONTROLLER APPENDIX TABLES FOR PROCESS CONTROLLER APPENDIX 8630 179 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 Tastes ron Process Appenox 7 burkert Tables for noting your settings on the process controller Settings of the freely programmable characteristic Ref point Valve stroke 95 Set point of 180 8630 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 bu rkert MASTERCODE APPENDIX MASTERCODE APPENDIX 8630 181 burkert MASTERCODE 7175 MASTERCODE APPENDIX 182 8630 GLOZ LO Oz peiuud 1H Snielg M uoisJeA 780010000 NYIN MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 Contact addresses Kontaktadressen Germany Deutschland Allemange B rkert Fluid Control System Sales Centre Chr B rkert Str 13 17 D 74653 Ingelfingen Tel 49 0 7940 10 91 111 Fax 49 0 7940 10 91 448 E mail info de buerkert com International Contact addresses can be found on the internet at Die Kontaktadressen finden Sie im Internet unter Les adresses se trouvent sur internet sous www burkert com gt B
110. on 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 burkert System DESCRIPTION 3Nn L i dS AOL vos VHVd gt T8H LNOO 1115 094 1 25 diN3 L dS Ad OW SOd N X mx Liz N OJ1UOO SS9901d uonejuesaJdaiJ SLOZ LO Oz peiuud ueqebebie 1H Snielg M uoisJeA 7800100001 NYIN 8630 26 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 burkerlL w Jw 99 SverwDescnrro Interfaces of the TOP Control Continuous in the multipole variant Inputs for position or process setpoint 4 20 mA 0 20 mA 0 10 V 0 5 V 2 binary outputs Analog position feedback TOP Control Continuous multipole variant Input for process setpoint Initiators 1 2 4 20 mA Frequency Pt 100 Flow rate controller Operating unit tt Inputs for process value with flow rate controller option p T optional Note The standard process controller inputs 4 20 mA frequency Pt
111. on setpoint Control CMD difference Xd1 Position Dead band actual value POS 2 Parameters of the positioner XX X Gain factor of the positioner to close the valve Gain factor of the positioner to open the valve e End of parametrization of positioner Jump back to X CONTRL 72 8630 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 b ur kert OPERATION AND CONTROLLER FUNCTIONS CODE Code protection for the settings Factory setting CODE 0000 Locking of all functions that cloud change the operating status of the device The display on the display unit can be switched over gt Locking of the entry into the configuration level Locking of all actions including bus para meterd and binary input that change the operating status of the device The display on the display unit can be switched over Entry of the 4 digit code If the code protection is activated entry of the code will be demanded on every protected operative manipulation Change the flasching digit BE Confirm the digit and switch to next digit 8630 73 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 OPERATION AND CONTROLLER FUNCTIONS b u rkert SAFEPOS Entering the safety position Factory setting O 96 abes gt OSE Enter safety position 0 100 When the safety p
112. osition is O or 100 the actuator will be fully vented or pressurized as soon as the safety position is activated int he supplementary function S G ERH or BIN IN ATTENTION The safety position set is only moved to when a corresponding signal is present at the binary input for configuration see B N N or on occurrence of a signal error for configuration see SIG ERR This function is executed only in the AUTOMATIC mode With the fast pressurize fast vent variant two valves are driven in each case to obtain faster pressurizing and venting 74 8630 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 b ur kert OPERATION AND CONTROLLER FUNCTIONS SIG ERR Configuration of error recognition signal level Activate signal error Activate move to safety recognition position Configure error recognition of SIG ERR amp o gt ERR INP INPON gt SPOS ON Move to safety position if INP OFF SPOS OFF signal in error Configure error recognition of LA process value ERR PINP FS PINPON 6 SPOS signal A Move to safety position if When signal error recognition is activated the error is displayed see chapter Maintenance and Error Correction gt Error recognition Error recognition can be selected only with 4 20 mA Pt100 and P1 P2 signals 4 20 mA Error in input signal 3 5 mA
113. played in ERA with HEX 18 8630 143 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 Bus status display burkert The bus standard is indicated on the display Display Device status Explanation problem elimination message BUS OFFL alternates with the display value set BUS NOCO alternates with the set indication value 2 dots left under the set indication value 4 dots left under the set indication value BUS TIME alternates with the set indication value BUS CRIT alternates with the set indication value 144 8630 offline online no connection to Master online Explicit Messaging only online active connection connection Timeout critical bus error Device is not connected to the bus the network access procedure Duplicate MAC ID Test duration 2 s has not yet ended or the device is the sole active network subscriber s the baud rate correctly set throughout the network s the bus connection incl plug in assignment correct s the voltage supply and bus connection of the other subscribers correct Device is correctly connected to the bus the network access procedure has been completed without error but no connection is established with the Master Messaging connection with Master is established No I O connection is in the Established state no I O data exchange An I O connection is
114. point position INP XXX 0 5 10 V or 0 4 20 mA Temperature inside housing of TOP Control Continuous TEMP XX X in C By pressing the arrow keys you can switch between these 4 display options AUTOMATIC mode Configuration 5 sec Ale v No operating Switch over action display Release key MANUAL mode NOTE If the device is in the safety position for the relevant configuration see menu item B N N or SIG ERR SAFE XXX appears in the display If the menu item CUTOFF is activated and the process is in the tight closing range a flashing MIN or MAX symbol appears in the display 8630 87 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 OPERATION AND CONTROLLER FUNCTIONS b u rkert Operating mode MANUAL yellow LED off In the manual mode the valve can be opened and closed by hand Meaning of the keys in the MANUAL mode Press the A key in the MANUAL mode Pressurization of the actuator SFA valve opens SFB valve closes SFI port 2 1 pressurized gt gt D Press the key in the MANUAL mode Venting of the actuator SFA valve closes SFB valve opens SFI port 2 2 pressurized lt Hold down the A key and simultaneously press the y Fast pressurization Hold down the key and simultaneously press the A Fast venting EID Pid SFA actuator closing by spring force SFA actuator opening by spri
115. r more TOP Control Continuous Linearization of the process characteristic can be performed The positioner cuts in only after a specified control difference Heserval of the setpoint action direction Valve moves to a specified safety position Feedback of the position process values Binary outputs Connectable process controller with the following characteristics Option Proportional action factor reset time rate time and Parameters that can be set 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 Configuration 24 8630 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 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 burkerl 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 me dium
116. r value will be matched to ist The process will be cancelled with the message P1P2 ERR if the pressure lies between 10 and 55 of the des sensor measurement range or if the difference between p1 and p2 gt 1 5 CAL FACT Reset the settings under CAL USER to the factory settings Hold down the MANUAL AUTOMATIC key until the countdown has expired 84 8630 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 b ur kert OPERATION AND CONTROLLER FUNCTIONS SETFACT Resetting to the factory settings Using this function all settings made by the user can be reset to the status existing on delivery All EEPROM parameters with the exception of the calibration values are reset to the default values Following this a hardware reset is executed To initiate the function hold the MANU AL AUTOMATIC key depressed for ca _ 96 5 s until the countdown has finished 55 8630 85 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 OPERATION AND CONTROLLER FUNCTIONS b u rkert Operating the process Each time after switching on the voltage supply the TOP Control Continuous is automatically in the process operating level To get there from the configuration level confirm the menu item END by pressing the MANUAL AUTOMATIC key In the process operating level the normal controlled operation is executed and monitored in the AUTOMATIC mode
117. r with the cable bushings to gain access to the screw terminals This is done by S S S S S s unscrewing the 4 self tapping screws 12 3 4 5 6 terminals 11 12 7 8 9 10 Setpoint 0 4 20 mA or 0 5 10 V Setpoint GND GND Analog position feedback C completely isolated electrically Analog position feedback GND gt GND Allocation 1 2 3 4 24 V DC 10 mie ra ENG T max residual ripple 10 8630 47 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 Wsmuaw burkert Choice of binary outputs or process value input Select using the jumpers 2 binary outputs see terminal Allocation when binary outputs selected or Process value input see terminal Allocation when process value input selected Terminals 7 to 10 are connected to the corresponding signals Terminal Allocation External connection 7 24 0 Binary output 1 Binary output 1 8 GND Binary output 2 9 24 0 NC NO Binary output 2 10 0 GND Terminal allocation on selection of process value input The input type is set via the configuration menu see Procedure for specifying the basic settings Input type 4 20 24 V input transmitter 7 __ gt internal Output transmitter 8 supply Bridge to GND GND from GND 3 conductor transmitter GND Freque
118. ram increases in 20 steps the valve stroke from 0 to 100 and measures the associated process variables The pairs of values of the correction characteristic are stored as a freely programmable characteristic under the menu item CHARACT CHAFREE and may be viewed under this menu item If the menu item CHARACT was not transferred under the menu item ADDFUNCT to the main menu this is done automatically on execution of the function PQ LIN At the same time the menu item is activated Display during call up and execution of the routine 5 Countdown from 5 to 0 for starting PQ LIN 4 der Routine 0 PQ LIN O Display of the fixed point that is being approached at the moment PQLIN 1 der Fortgang wird durch einen sich drehenden Balken am linken PQLIN2 Rand des Displays angezeigt PQ LIN PQ LIN END flashing End of routine Q ERR X X Message on occurrence of an error shown on the right is the error number see chapter Maintenance process controller 8630 105 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 OPERATING THE PROCESS CONTROLLER burkert P CO TUNE Self optimization of the process controller process tune e The control system TOP Control Continuous is equipped with a positioner which if required can be supplemented by a superimposed process controller see chapter Operation as a Process Controller The pos
119. rect termination circuit for the data lines The circuit avoids the occurrence of faults through signal reflections on the data lines For this purpose the main line is to be terminated at both ends with resistors of respectively 120 Q and 1 4 W power loss 138 8630 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 burkert DeviceNet Net topology of a DeviceNet system Comprises a trunk line and several drop lines Trunk and drop lines are composed of identical material See drawing Trunk Line DeviceNet cable V Ma CAN_H CAN_L og Terminating Terminating resistor resistor 120 Ohm 120 Ohm 1 1 en Drop Lines N DeviceNet cable max length 6 m Subscriber 1 node 1 Subscriber n node n Settings on the TOP Control Continuous Explanations of the menu items in the program run off schematic BUS ADDR Input of the device address factory setting 63 The address can be changed via the keys at the device or via the bus After each change all Connection Objects are deleted followed by the execution of the normal Start Up procedure for network access by a subscriber as after a Reset or Power Up ADDR XXX Values from O 63 can be set via the arrow keys confirmation takes place with the MANUAL AUTOMATIC key BUS RATE The baud rate can be changed via the keys at the device or via the bus In each case a change has no effect until a Reset transmission of a Reset message
120. rocess setpoint SP 999 9999 Setpoint position of valve actuator after rescaling through optionally activated split range function or correction curve CMD XXX 0 100 96 Temperature inside housing of the TOP Control Continuous TEMP C By pressing the arrow keys you can switch between these display options Operating structure and procedures AUTOMATIC mode process tune Configuration ready for start PV and SP POS XXX Switch over Set the P TUNE mE display i process process tune CMD XXX A or setpoint MANUAL mode NOTE If the device is in the safety position for the relevant configuration see menu item BIN IN or SIG ERR SAFE XXX appears in the display If the menu item CUTOFF is activated and the process vave is in the tight closing range a flashing MIN or MAX symbol appears in the display If the process value PV is above or below the measurement range a flashing bar appears in the display 8630 113 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 OPERATING THE PROCESS CONTROLLER Manually changing the process setpoint gt AM burkert If the supplementary function PCONTRL PCO SETP SETP INT setting of the setpoint via keys was specified on configuration then with the display SP set setpoint and on pressing one of the arrow keys for longer than 3 seconds th
121. rofibus DP or DeviceNet The markings of the multipole plugs and sockets and the contacts are to be found in the respective chapters Marking of the multipole plugs or sockets and the contacts F Do Mo oy Output signals to 5 Operating voltage 20 OL AK 3 2_ 4 2 00 3 5 Process value Initiators inductive proximity switches 44 8630 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 4 ANS Output signals for SPS circular plug M16 Allocation External connection signal level Setpoint GND 0 4 20 mA 0 5 10 V completely isolated electrically Setpoint 0 4 20 mA 0 5 10 V GND 0 4 20 mA 0 5 10 V Analog position feedback completely isolated electrically Analog position feedback GND GND Binary output 1 E 24V 0V Binary output 2 24V 0V Binary output GND GND Binary input 0 5 log 0 Binary input GND 10 30 log 1 not connected not connected not connected Operating voltage circular plug M 12 Pin Allocation External connection 24V i ted 7 NOL COMNEEIE 24 V DC 10 GND T max residual ripple 10 3 not connected Inductive proximity switches circular socket M 8 Pin Allocation Signal level Proximity switch 1 NO 24 V DC open 24 V Proximity switch 1 GND GND GND Proximity switch 2
122. rol ttt ttc 20 Characteristics of the positioner software 21 Alternative chapters or functions depending on device configuration 8630 1 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 CONTENTS burkert 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 ttt ttt 24 Operation as a flow rate controller option 25 Characteristics of the flow rate controller software ttt 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 DuUSNINGS 28 Technical 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 oe 31 FIRST COMMISSIONING nee ae 34 Electrical installation multipole connector 35 Electrical installation connection terminals for cable DUSNINGS 36 Basic settings of the TOP Control Continuous 37 Settings in the menu i
123. rol job If the process is unknown enter P N DEF not defined PCO FILT PCO SCAL Select the controlled Activate process tune member Controlled member unknown Temperature control PTYPTEMP l Pressure control Change to the process operation level by leaving the configuration level via the menu item END X XX and switching the device to the operating mode AUTOMATIC yellow LED in the MANUAL AUTOMATIC key flashes 8630 107 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 OPERATING THE PROCESS CONTROLLER burkert Step Process tune ready to start You are in the process operating level in the AUTOMATIC mode yellow LED in the MANUAL AUTOMATIC key flashes Make ready process tune by the following operating procedure Make ready PTUNE process tune process tune ready ily g E SP EXXX 4 X process tune not ready The next setpoint step entered via the keypad see Step is now used for parameter optimization The setpoint SP is set equal to the actual sensor value PV and is the starting value for the optimization step Adaptation modification of this starting value is described in Step Readiness of process tune is symbolized int he display by three horizontal bars behind the flashing setpoint symbol SP Step Adaptation of the starting value for the optimization step optional If required yo
124. rs at the right of the 8 digit display These characters flash on the display ACTFUNC Function of actuator Enter under this menu item the function of the pneumatic actuator used in combination with the Control This function is marked on the rating plate of the actuator FUNCSNGL single acting A ACT FUNC V double acting INPUT Selected standard signal Enter under this menu item the standard signal used for the setpoint eur INP 4 208 c Current 4 20 mA INP 0 208 U eu H Current O 20 mA o 1ov Voltage 0 10 V 0 5 Voltage 0 5 8630 55 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 OPERATION AND CONTROLLER FUNCTIONS b u rkert ADDFUNCT See section Configuring the supplementary functions gt Jump over this menu item on first commissioning X TUNE Autotune for positioner gt Start the program for automatic parametrization of the TOP Control Continuous the menu item X TUNE The following functions are initiated automatically e Adaptation of the sensor signal to the physical stroke of the valve used Determination of parameters of the PWM signals for driving the solenoid valves integrated in the TOP Control Continuous e Setting of the controller parameters of the positioner Optimization is done according to the criteria as short a correcting time as possi
125. s are used in these operating instructions gt marks a work step that you must carry out v ATTENTION marks notes on whose non observance your health or the functioning of the device will be endangered gt 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 H 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 pressur
126. sed freigegeben printed 20 01 2015 burkerl DEvicENET Online parametrization of the device Devices can also be parameterized online Here it can be selected whether only a single parameter or all parameters of a group are to be uploaded from the device or downloaded to the device The facility also exists for cyclically transferring single parameters or all the parameters of a group in monitor mode This can be useful especially for commissioning purposes Shown in the figure is the group of process values respectively Diagnostic information If the button Start Monitor is pressed these values are cyclically updated However Explicit Messages are also used for this cyclic access no I O connections 8630 147 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 DEvicENET burkert Configuration example 2 This example describes the basic procedure for setting up the process mapping of a DeviceNet Master Scanner using the software RSNetworx for DeviceNet Rev 2 11 51 0 Setting up the Scanlist and setting the I O parameters First of all the Scanlist of the DeviceNet Master Scanner is set up For this the devices listed in the left hand part of the associated window are transferred to the right hand part of the window Then a change of the I O parameters can be carried out for each device transferred to the Scanlist This is necessary when on configuring the rele
127. t current or voltage value of the standard signal Upper scaling value for process setpoint the value is assigned to the largest current or voltage value of the standard signal This setting determines the reference span for the dead band of the process controller and the analog feedback of the process actual value option This setting is only active when PCO SETP SETP EXT is selected 96 8630 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 b u r ke rt OPERATING THE PROCESS CONTROLLER Example of scaling for 4 20 mA input Process actual value from transmitter 4 20 mA corresponds 0 10 l min Process setpoint from SPS 4 20 mA corresponds 0 8 l min Scaling value Process Example for entering scaling values l min actual value ee ee te ee Variant 3 Process setpoint 0 4 20 Input signal mA On entering small scaling values decimal places are automatically added to increase the precision of display such that the maximum possible digit range is given between the lower and upper scaling values in each case The amplification factor KP of the process controller refers to the scaling values set With PCO SETP SETP INT setpoint entry via the arrow keys scaling of the setpoint via and SP is not possible The setpoint may be entered directly corresponding to the scaled process variable PV P
128. ted menu item SAFEPOS The actuator moves to the end position which it would assume in the zero voltage state Switching over the operating mode M A owitching over the operating mode into MANUAL or AUTOMATIC Binary input 0 Operating mode AUTOMATIC Binary input 1 gt Operating mode MANUAL If the operating mode switchover has been selected you can then no longer switch over the operating mode using the MANUAL AUTOMATIC key 76 8630 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 b ur kert OPERATION AND CONTROLLER FUNCTIONS OUTPUT Option Configuration of the outputs Configure the analog output Configure binary output 1 Configure binary output 2 o End of configuration of the outputs ap OUT ANL Standard signal for the analog position output Selection of the desired output Selection of the desired standard signal ANL POS 55 ANL 4 20A ANL 0 204 16 ANL O 10V ANL O 5V gt NOTE The signal types shown in gray only selectable with active process controller 8630 77 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 OPERATION AND CONTROLLER FUNCTIONS b u rkert B OUT BIN1 Configuring binary output 1 Permissible actuating signal DEVX NoRMOPN E D Limit position 2 NORM CLS Eg 4 5 dr 6 NORM CLS NOTE NORM CLS N
129. tems ttti 38 Entering the position Setpoint in the AUTOMATIC Mode ttt ttti 38 Manual opening and closing of the valve actuator in the MANUAL mode 39 INSTALLATION Installation of the valve iiie 42 Turning the Control CONt NUOUS cert 42 42 Fluidic connection of the TOP Control COntiNuUoUS 43 Alternative chapters or functions depending on device configuration 2 8630 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 burkert CONTENTS Electrical connection multipole connectors i 44 Marking of the multipole plugs or sockets and the contacts e 44 Output signals for SPS circular plug M 16 acit ete iato 45 Operating voltage circular plug M 12 45 Inductive proximity switches circular socket 8 45 Process value tEmcular Bling N O __________ 46 Process value with the option flow rate controller 2 circular plugs M 8 Option with temperature sensor input 3 circular plugs 8 tte 46 Electrical connection terminals for cable 47 Connection PCB of the TOP Control Continuous with screw terminals and jumpers 47 Terminal contiguration With cable DUSRINGS eost certe in maman ee 47 Choice of binary outputs or process value input ttt ttt 48 Setting the inductive proximity switches Option e 50 Openin
130. the function PCONTRL the function PQ LIN is also inserted into the main menu gt Call up the basic settings for the process controller under PCONTRL Linearization of the process characteristic If you are dealing with a flow control system the process characteristic can be linearized automatically Initiate the function P Q LIN Self optimization of the process controller gt Activate the function PCO TUNE and initiate self optimization of the PID parameters of the process controller Activate valve characteristic curve Initiate the function PCO KV to activate the valve characteristic Read in leakage characteristic gt Initiate automatic determination of the leakage characteristic using the functions PCO LEAK gt PCO MEAS ATTENTION In all cases keep to the following sequence X gt P Q LIN gt TUNE 90 8630 o 0000 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 b u r ke rt OPERATING THE PROCESS CONTROLLER Self parametrization of the positioner TUNE The description of the self optimization of controllers is to be found in the chapter Operating and Controller Functions Commissioning and Setting Up as a Positioner Main Menu for the Settings on Commissioning 4 X TUNE Supplementary function CONTRL e see also the section Operating the positioner configuring the supplementary functions ADDFUNCT
131. 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 When disponsing of the appliance observe the national standards for refuse disposal 12 8630 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 burkert SverewDescnrron SYSTEM DESCRIPTION Valve types 14 Characteristics of the valve types ttt ttis 15 Construction of TOP Control Continuous 16 Illustrations cover removed iiinis 16 17 Functional diagram as a positioner with single acting actuator es 18 Operation as a positioner 19 Schematic representation of positioning control 20 Characteristics of the positioner software 21 Operation as a process controller Option iii 22 Example of process control TOP Control Continuous with sensor 22 Schematic representation of process control ttt 23 Characteristics of the process controller software ttt 24 Operation as a flow rate controller option 25 Characteristics of the flow rate controller software ees 25 Schematic representation of process control with flow rate controller 26 Interfaces of the TOP Control Continuous in the multipole
132. to be calibrated p1 p2 temperature and confirm the value by pressing the MANUAL AUTOMATIC key At the inputs p1 p2 4 mA corresponds to a pressure of 0 0 bar rel 20 mA corresponds to a pressure of 10 0 bar rel or the end value set under CAL PLIM At the temperature input 4 mA correspond to a temperature of 0 C 20 mA correspond to a temperature of 150 C or the end value set under CAL 6 9 CAL PLIM CAL Setting up the sensor measurement range First enter the lower pressure temperature value that corresponds to the 4 mA transmitter signal Then enter the upper pressure temperature value that corresponds to the 20 mA transmitter signal PMIN must be within the range 1 01 15 0 bar rel PMAX in the range 0 0 16 0 bar rel TMIN and TMAX must be within the O 150 C range CAL P1P2 Balancing the pressure transmitters The pressure transmitters p1 and p2 can be balanced in order to increase the measurement accuracy at small pressure differences To do this the feed line behind process valve must be closed and a constant pressure must be applied to the controller unit With a pressure lt 10 of the sensor measurement range the zero point can be balanced with a pressure gt 55 of the sensor measurement range the upper calibration value Change the display between p1 and p2 using the arrow keys If you press the MANUAL AUTOMATIC key the displayed value will be confirmed and the othe
133. to the Identity Object or a Power Up is performed That is to say if the changed attribute baud rate is accessed before a Reset or Power Up the entered changed value does not agree with the still current to be changed baud rate of the network KBD XXX Selection of 125kbit s 250 kbit s or 5OOkbit s BUS FAIL Activation for movement to saftey position on bus communication failure SPOS OFF The actuator moves to the position corresponding to the setpoint last transmitted default setting SPOS ON With SPOS ON set the following configurations can occur Activated menu item SAFEPOS On error in bus communication the actuator moves to the position set under SAFEPOS Deactivated menu item SAFEPOS On error in bus communication the actuator moves to the end position it would occupy in the zero voltage condition 8630 139 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 DEvicENET burkert Settings in the main menu The following settings are to be made in the main menu of the device at variance with the statements in these operating instructions Operating BG I MANUAL iv IV V D MIA On activation moves to safety position Dim RN BUS END n 5 Sec EV TAI 9 END 140 8630 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 burk
134. u can carry out an adaptation of the starting value for the optimization step Switch the device to the MANUAL mode LED in the MANUAL AUTOMATIC key is off By pressing the arrow keys open or close the process valve which causes a corresponding change in the process value PV As soon as the desired starting value is set switch the device back to the AUTOMATIC mode Step 4 Initiate process tune You are in the process operating level in the AUTOMATIC mode yellow LED in the MANUAL AUTOMATIC key flashes Process tune is now initiated by entering via the keypad a setpoint step This step should take place in the future working range of the process control system The procedure is as follows SE With the display SP setpoint set press one of the arrow keys for longer than 3 us V seconds to activate the mode for changing the process setpoint After release of the key the first digit of the process setpoint flashes Set the value of the flashing digit of the process setpoint SP DB dg Confirm the value set and move to the next digit After confirmation of the fourth 96 digit the process setpoint set is stored as the end value of the process setpoint step 108 8630 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 b u r ke rt OPERATING THE PROCESS CONTROLLER NOTE setpoint step for parameter optimization must always be entered the operating keypad This also applies when o
135. urkert gt Company gt Locations MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 The smart choice of Fluid Control Systems www buerkert com burkert Fluid Control Systems
136. uw E3 1 End of calibration V eimo B With the removal of the additional function CALUSER the factory calibration will be NOTE re established 82 8630 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 bu rkerL OPERATION AND CONTROLLER FUNCTIONS NOTE The signal types shown in grey can be selected only with the process controller activated The signal surrounded by a dotted line can be selected only with the process controller deactivated The signal types in brackets are only shown in this menu they cannot be changed here The type of signal shown is that which you have selected in the associated menus CAL INP CAL SP Display of the selection in the menu NPUT CAL PV Display of the selection in the menu PCO INP The signal types over a grey background can be selected only with the option flow rate controller Calibration of the position display 0 100 96 Storage of the minimum position Move to minimum position via arrow keys and confirm by pressing the MANUAL AUTOMATIC key Storage of the maximum position Move to maximum position via arrow keys and confirm by pressing the MANUAL AUTOMATIC key CAL INP Calibration of the position setpoint 4 20 mA 0 20 0 5 V 0 10 V CAL SP Calibration of the process setpoint 4 20 mA 0 20 0 5 V 0 10V
137. vant TOP Control Continuous Assemblies have been selected which differ from the default settings Shown in the figure is the setting of the I O parameters with selected Input Assembly POS CMD ERR 5 bytes long and selected Output Assembly INP 2 bytes long default Assembly no change required Be Ed Mee Bence loc Heb 86m 8 i m w GQitasz ae Haben 4 zi tue 4 ih T mm Toston Tee 8230 Talore 8 0 148 8630 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 burkerl DEvicENET Setting up the process mapp mapping Using the function AUTOMAP it is possible to assign the input data of the devices listed in the Scanlist to the process mapping of the DeviceNet Master Scanner In our example this resulted in the assignment shown in the figure For example the Input Process values of the TOP Control Continuous with the address 4 are assigned to the internal addresses of the scanner in the following manner Actual position 1 Setpoint position 1 1 Error 6 N Therefore if the actual position of the TOP Control Continuous with the address 4 is to be read from a control program this takes place via an access to 1 1 6 M 02 Pole 1110 FT EY LPs
138. ve are equipped with diaphragm boosters As an option with single acting actuators there are fast pressurizing exhaust variants with an additio nal 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 and on activation of a safety position of 0 or 100 see section B N 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 T 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 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 System DESCRIPTION Fuctional diagram Process setpoint external position setpoint TOP Control Continuous Pneumatic actuator single acting Valve actuator M 18 8630 burkert as a positioner with sin
139. ven in the table Static Output Assemblies can be used as path statement for the attribute Consumed Connection Path of an I O connection whereby the attributes described in more detail in the following table can be transferred as Output Process Data via this I O connection Independently from this however it is also possible to acyclically access the attributes combined in the Assemblies via Explicit Messages Description of the Output Data Attributes Attribute address Class Instance Attribute data type length Position setpoint 111 1 58 Setpoint of position controller in o Value range 0 1000 UINT 2 Byte In purely position controller operation PCONTRL inactiv transmission of the setpoint position NP is necessary as process controller PCONTRL activ the transmission of NP is not possible In the case of too small or too large a value the last valid is used and indicated in ERA with HEX 14 Process set value Process Setpoint 120 1 2 Set value process controller in physical unit as set up in the PCO INP or RCO SCAL menu max value INT 2 Byte range 999 9999 depending on the internal scaling If the value is too small or too large the last valid value will be used and will be displayed in ERR with HEX 15 Medium temperature 120 1 9 Temperature of the medium in C Value range 20 150 INT 2 Byte If the value is too small or too large the last valid value will be used and will be dis
140. wing Command _ Tg Tu Ks Tg De Tu Ks Tg Tg Kp 0 99 Tu Ks Tn 1 35 Tg Tv 0 47 Tu Disturbance Tg Tu Ks Kp 0 7 Ko 20 7 9 Tu Ks Tn 2 3 Tu The proportional action factor Ks of the controlled member is obtained according from x A A Ks lt 8630 167 burkert GENERAL 5 APPENDIX 168 8630 GLOZ LO Oz peiuud ueqebebie y 1H Snielg Y uols eA 780010000 NYIN n printed 20 01 2015 leased freigegebe re HL K Status MAN 1000010084 EN Version burkert OPERATING STRUCTURE APPENDIX OPERATING STRUCTURE APPENDIX 8630 169 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 structure Appenox Operating structure of the TOP Control Continuous On activation moves to safety position V 170 8630 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 burkert ADDFUNCT OPERATING STRUCTURE APPENDIX CHA LIN Hr 33 1 B CHA 50 1 Menu appears only with activated PID controller CUTOFF TYPE ROO CMD DIR CRISE DIR CFALL DIR ACT T DIR ARISE DIR AFALL SPLTRNG 58 xx X LIMIT LIM xx uM T xxx X TIME T OPN xxx EM T CLS xxx X CO DBN
141. wn up undefined depending on connection of control conductors 8630 29 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 System DESCRIPTION Factory settings on the TOP Control Continuous burkert Function Factory setting Function Factory setting ACTFUNC FUNCSNGL X CONTHL X CO DBND 1 INPUT INP 4 20 A Ar Ann KX Values calculated by AUTOTUNE CHA LIN KX Values calculated by AUTOTUNE After execution of SETFACT 1 DIR CMD DIR CRISE PCONTRL PCO DBND 1 CUTOFF CUT 0 0 7100 FARA KP 1 00 TN 999 9 DIR ACT DIR ARISE TV 0 0 XO 0 SPLTRNG SR 0 96 587 100 96 PCOSETP P CO INP INP 4 20 A PCO 0 X LIMIT LIM 0 100 PCO SCAL PV 000 0 PV 100 0 PCOTUNE X TIME PCOKV FACT T OPN Values calculated by AUTOTUNE 25 7 PCONTRL with flow rate controller TCLS Values calculated by AUTOTUNE PCODBND 1 After execution of SETFACT 1s PCO PARA KP 1 0 OUTPUT TN 999 9 OUT ANL TV 0 0 OUT POS OUT 420A XO 0 PCOSETP SETP INT OUT BIN P CO INP INP P1 P2 OUT DEV DEV 5 0 NO PCO FILT 0 T BIN IN c ML 0 PV 100 0 B IN SPOS SPOS 000 NO UNIT M3 H TEMP MAN DENS 1 293 DIAM 0025 PCOTUNE PCOKV FACT CODE CODE 0000 The functions and factory settings shown in grey valid for the optional flow rate control 30 8630 MAN 1000010084 EN Version K Status RL released freigegeben printed
142. x 0 5 of end value hysteresis 0 5 of end value Pt100 Error in input signal gt 225 C x 0 5 96 of end value hysteresis 0 5 96 of end value P1 P2 Error in input signal 3 5 mA x 0 5 of end value hysteresis 0 5 of end value If other types of signal are selected or if the process controller is unactivated the respective branch of menu will be faded out If because of this configuration neither of the error recognition modes is possible the message NOT AVAIL is displayed in the selection menu Safety position SPOS ON If SPOS ON is set the following configurations may occur Activated menu item SAFEPOS On error recognition the actuatur moves to the position set under SAFEPOS Deactivated menu item SAFEPOS On error recognition the actuator moves to the end position which it would assume in the zero voltage state 8630 75 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 OPERATION AND CONTROLLER FUNCTIONS b u rkert BIN IN Activating the binary input Select the function of the binary input Type of binary input BINSPOS Safety position Type of binary input LA 56 normally closed 0 5V 1 10 30V 0 normally open NORM amp 0 5V 0 10 30V 1 Operating mode changeover LA Safety position B IN SPOS Moving to a safety position Activated menu item SAFEPOS The actuator moves to the position set under SAFEPOS Deactiva
143. ype 2730 Various process valves from the B rkert range can be combined with the TOP Control to suit different applications Y diaphragm or ball valves with control cones are suitable 14 8630 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 burkert System DESCRIPTION Pneumatically driven piston and rotary actuators may be used to operate them Both single acting and double acting 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 Characteristic Typical media Y valves Flat seat valves nlet flow under seat Non impact closure Straight flow of medium Self adjusting packed gland for very tight seal Water steam and gases Alcohols oils fuels hydraulic fluides Salt solutions lyes organic Organic solvents Diaphram valves 2730 plastic 2731 metal 2731 pipe housing Medium is hermeti cally separated from actuator and the
144. ys 113 ee 113 Operating structure and procedures 113 Manually changing the process setpoint te 114 Operating mode MANUAL 114 Meaning of the d c NR IEEE 114 BIOL PEE 115 Operating structure and procedures 115 8630 89 MAN 1000010084 EN Version K Status RL released freigegeben printed 20 01 2015 OPERATING THE PROCESS CONTROLLER burkert Factory settings on the process controller Function Factory setting Function Factory setting PCONTRL PCONTRL with flow rate controller PCO DBND 1 PCO DBND 1 PCO PARA PCO PARA KP 1 00 KP 1 0 TN 999 9 TN 999 9 TV 0 0 TV 0 0 XO XO 0 PCO SETP SETP INT PCO SETP SETP INT PCO INP INP 420A PCO INP INP P1 P2 PCO FILT 0 FILT 0 SCAL PV 000 0 PCO SCAL 000 0 PV 100 0 100 0 RTYP FLOW PCOTUNE D ACT UNIT DENS 1 293 DIAM 0025 D ACT PCO KV FACT The functions and factory settings shown in grey are valid for the optional flow rate control Setting up a process control system In order to be able to operate the TOP Control Continuous as a process controller you must execute the following steps n all cases carry out the self parametrization for positioners X TUNE gt Via the configuration menu add the supplementary function PCONTHRL to the main menu With

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